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Service Manual - Genie Industries

1. N N GRN 2 m n m o BLU RED 3 E o 4 o GRN 5 amp WHT 1 I RED 5 a BLK 5 2 g 92 aj ui R 2 a X DRIVE ENABLE R E BLU WHT 3 5 8 5 gt E WHT BLK 1 E WHT BLK 31 E H w 58 8 8 E WHT RED 1 E WHT RED 32 E H m m BLU BLK 1 BLU BLK437 E H T BLU 1 BLU 36 E H 8 g 8 L z L a UL 8 i 3 89 ORG 1 E WHT 6 GRN 6 E m Ut n RESEEREEH E WHT 7 GRN 7 a d ou e oo CZ Az 95 5 o D o N aa a p sz RED WHT E RED WHT 1 7 TN HIGH 00 aD 2 EE oo 88 rr AO a CZ E BLK 3 a BLK WHT 3 m BLK 4 7 a R e EXTEND BOOM 5 BLK WHT g a RETRACT mn BLK WHT 4 7 Be _ m 2 i BLK RED 4 o n E WHT RED 3 1 E WHT BLK 3 e
2. N LO N GRN 2 m e a m e E BLU RED 3 WHT 5 o GRN 5 WHT 1 RED T BLK 5 2 S 9 4 ui u p A DRIVE ENABLE EE x E BLU WHT 3 E E WHT BLK 1 WHT BLK 31 E H gr 58 S E WHT RED 1 E WHT RED 32 E H E M i 5 2 m BLU BLK 1 BLU BLK 37 E H BLU 1 BLU 36 E H z e 8 B E 8 E 8 Y E 3 8o ORG 1 E GRN 6 i Fs WHT 7 GRN 7 49 2 ES co m L zz RED WHT E RED WHT 1 E p TN RR HIGH 4 p ow __ gt gt oo amp 88 19 cO a GZ BLK 3 i BLK WHT 3 M m z BLK 4 Tej EXTEND BOOM BLK WHT x Ew o RETRACT np BLK WHT 4 5 m 5 5 D a La o _ BLK RED 4 y E WHT RED 3 1 E WHT BLK 3 He gt WHT ET 3 i WHT x WHT 4 RIGHT WHT BLK z pel TURNTABLE ROTATE WHT BLK 4 I 5 28 sm 5 LT 8 Y B WHT RED 4 m Sa RED 4 UP
3. HI SPEED DIVIDER BY PASS M L K J H G F E D C B A JIB BOOM PLATFORM ROTATE F 6 SR SLAVE 1 E i BOOM UP DOWN E A TI PODR de a TURNTABLE ABE ROTATE BOOM EXTENSION J i PRIMARY em us SECONDARY Jk i 5 zt A n uel lm un BH H1 PIE Hes poc di e i p LIED ME awe 2 JIB BOOM 0 be lt 4 7 cf MANIFOLD MASTER B A tS POPE nell ei Sins i H PLATFORM BRAKE F4 025 BOOM T gt lt mila LEVEL ua TURNTABLE RETRACT ne 300 FUNCTION 2 STROKE 1 MANIFOLD LE MOTOR GEN 2100 3 50 IE zab W i rS pal 3 L gt 1 I J ae TAI m TEST A idem PRESS amp nm PPM Owe TE DEM Hs mene FILTER M t 77 50 TEEN DER 3 1 278 L I Fa PRESS at is OLE exitii E
4. o LOT RED BLK 1 RED BLK 28 E H 7 N 3 HIGH RPM ENGINE SPEED 5 BLK RED 1 m e n 2 ni F HIGH RPM ENGINE SPEED BLK RED E 3 26 RED WHT E H F 20 Fi 52 BLU BLK E H GS gt Z _BLK RED R4 E H 9 s 5 p 9 GR RED WHT R3 E H EZ gt lt 5 JO GZ luc A N e Sr R gd RED WHT 23 E H RED BLK R6 E H O n c 8 8 8 e E BLU RED 1 BLU RED R7 E H a FUEL Eo GAS BLU WHT 1 oz BLU WHT R6 E H g 8 fo BLU WHT R6 E H m N a 52 x BLU WHTsR6 E H 5 po LP FUEL 4 GAS ORG RED 1 BLK 7 g d g m fr a EJ EE 5o zz 8 E E BLK 1 EE g ls 5 5 _ START 59 Basis 5 5 p 55 5 ea s START oops WHT 424 2 ENGINE BLK ES l g WHT m E 94 Z N A 52 2 X zi LES o WHT 21 E H e 1 eH T 59 WATER TEMP gel SENDER n MM bs 5 t p S E 5 lt zt 1 HE AE BLK RI1 E H g To M Ww a p
5. TABLE C PROCEDURES C 11 Replace the Spark Plugs Gasoline LPG Models 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 Label then disconnect the plug wires from the spark plugs by grasping the molded 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 a R Install the new spark plugs then connect the wires Be sure that each spark plug wire is attached to the correct spark plug 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 to 10 foot pounds 7 to 14 Nm Part No 34476 Genie S 60 Genie S 65 4 35 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES C 12 Check and Adjust the Air LPG Mixture Gasoline LPG Models Maintaining the proper air to fuel mixture during LPG operation is essential to good engine performance Engine fuels are combustible Perform this procedure in an open well ventilated area away from heat
6. Machine Specifications Platform dimensions 6ft 8ft Standard Optional Stowed dimensions WU iid S09 Length 6 ft 8 ft Length 27 ft 2 in 30 ft 10 in 1 83 m 2 44 m 83m 9 4m width 30 in 36 in Width 8ft 8ft 76 2 cm 91 4 cm 2 43 2 43 Tires and wheels Height 9 ft 9 ft Tire size 15 19 5 NHS 2 74m 2 74m i Tire ply rating 12 Weight 26 060 lbs 28 400 lbs Tire contact area 71 sq in 11 821 kg 12 882 kg 458 sq cm Ground clearance 12 in 12 Overall tire diameter 40 in 30 cm 30 cm 102 cm Operational dimensions Tire pressure 85 psi 5 86 bar Maximum platform height 60 ft 65 ft 183m 19 8m Wheel diameter 191 2 in 49 5 cm Maxi horizontal h 51ft3i 56 ft 4 i aximum horizontal reac ie i Ps Wheel width 1214 in 31 cm Maximum turntable tailswing ft 31 2 in 3 ft 31 2 in Wheel lugs 10 3 4 16 100 cm 100 cm Lug nut torque dry bolts 420 ft lbs Wheelbase 9 ft 0 in 9 ft 0 in 569 5 Nm 2 7m 2 7m Lug nut torque wet bolts 320 ft lbs Minimum turning circle 12 ft 1 in 12 ft 1 in 433 9 Nm inside 3 7m 3 7m E Fluid capacities Turntable rotation continuous continuous Fuel tank 30 gallons Platform rotation 160 160 114 liters LPG tank 33 5 d Maximum capacity 600 Ibs 500 Ibs an 152 kg 6 foot platform 272 kg 227 kg Hydraulic tank 45 gallons Maximum capacity 500 Ibs 500 Ibs 170 liters 8 foot platform 227 kg 227 kg LU Hydraulic system 55 gallons Continuous improvement of our p
7. ZZA CHART 5 Hold start switch and Repair open in blu wht Continued from the check voltage at blu wht wire circuit from CR6 previous page wire on gasoline to fuel solenoid solenoid at fuel tank 12V 0 or Check resistance of MAE Replace gasoline gasoline solenoid solenoid 18 to 19 ohms kran wire to pad Repair ground wire good 00 infinite Check resistance of ohms Replace anti diesel anti diesel valve valve 24 to 25 ohms Hold start switch and Repair open in blu wht check voltage at blu wht wire between fuel on fuel pump next to solenoid and fuel pump fuel tank 12V ne EUER und wire to 8 Repair ground wire good less than Install a pressure gauge 7 psi to the fuel pump Replace fuel pump more tnan 7 psi Reconnect starter check anti diesel and fuel valve for defects OR see Ford service manual for carburetor troubleshooting Part No 34476 Genie 5 60 amp Genie 5 65 5 17 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 6 Engine High Idle Inoperative Gasoline LPG Models If high idle operates on LPG but not on gasoline see Ford service manual for carburetor troubleshooting If high idle operates on gasoline but not on LPG see Repair section for LPG regulator adjustments Be sure throttle linkage from governor to carburetor is not binding see Repair section Be sure high
8. 5 44 26 Jib Boom Up Inoperative S 65 Models 5 46 27 Jib Boom Down Inoperalive 5 65 5 48 28 Oscillate Function 5 50 29 Steer Left Function 5 51 30 Steer Right Function Inoperative sse 5 52 31 All Drive Functions Inoperative All Other Functions Operate Normally 5 53 32 Drive Forward Or Reverse Function Inoperative 5 56 33 Traction Function Inoperative eicito en eka een 5 57 34 Machine Will Not Drive At Full 5 58 35 Machine Drives At Full Speed With Platform Raised or Extended 5 59 36 Drive Enable System Is Malfunctioning 2 2 5 60 37 Auxiliary Functions 2 5 61 Section Six Schematics Introduction oce dn eerte eae dae ee dde e d reto aed de Aa 6 1 Electrical Symbols Legend sA odka tie dad A t tee etes 6 2 Electrical Schematic Gasoline LPG Models 6 3 Ground Control Box Legend Gasoline LPG 6 5 Relay Panel Legend Gasoline LPG Models s 6 6 Platform Control Box Leg
9. BLK A1 E H CR1 NO STARTER MOTOR AUXILIARY PUMP TS10 AUXILIARY PUMP RED TS1 TB27 RED 27 E H AUXILIARY POWER GRN TP25 TP24 je FS1 GRN BLK BLK Ux TP27 RELAY PRI RED 1 AUXILIARY PUMP PR1 NO m FLASHING BEACONS TP28 TB28 RED BLK 1 RED BLK 28 E H TP26 N A RD WHT 2 RED WHTHAS E HI L gt LEVEL SENSOR BLK P2 s TP9 TB23 BLK RED 3 BLK RED SERVICE HORN RELAY TB22 BLK 2 TP22 Service Manual TB9 CR5 NO BLK6 Lj SERVICE HORN KS1 PLAT GRND RED P1 TB41 ORG BLK 1 ORG BLK 41 E H Electrical Schematic Diesel Models Section 6 Schematics RED RED STA 00000 CB2 CB1 15AMP r REGULATOR IND 15AMP k d ALTERNATOR BAT E 1 20 RED RED 20 E H id lili ili j Part No 34476 Genie S 60 amp Genie S 65 6 8 Section 6 Schematics Service Manual Electrical Schematic Diesel Models
10. Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures S 2WD DRIVE MANIFOLD Plug Torque Specifications 18 2 Torie Valve Adjustments SAE No 2 1 8 50 in lbs 6Nm Howto Adjust the Charge SAE No 4 3 16 13ftlbs 18Nm Pressure Relief Valve SAE No 6 1 4 18 ft lbs 24 Nm 1 Connect a 0 to 600 psi 0 to 41 bar pressure SAE No 8 5 16 50 ft lbs 68 Nm 5 the test port located on the drive SAE No 10 9 16 55 ft lbs 7 5 Nm ACAUTION Bodily injury hazard Spraying SAE No 12 5 8 75 ft lbs 102 Nm 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 Start the engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turn the engine off Hold the relief valve 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 Then install the valve cap 6 Restart the engine Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off then remove the pressure gauge Relief valve specifications Pressure 250 psi 17 b
11. 2 222 2 0 0 4 20 B 16 Check the Directional Valve Linkage sss 4 21 B 17 Test the Platform Self leveling 2 000 eee aaa aaa 4 21 B 18 Test the Service 4 21 B 19 Test the Foot Switch 42 4 aaa enses 4 22 B 20 Test the Engine Idle 4 22 B 21 Test the Fuel Select Operation Gasoline LPG Models 4 23 B 22 Test the Drive Enable System sse 4 23 B 23 Test the Drive Brakes 4 24 vi Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition 2 TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued B 24 Test the Drive Speed Stowed Position sss 4 24 B 25 Test the Alarm Package Optional 4 25 B 26 Perform Hydraulic Oil Analysis 4 25 B 27 Replace the Engine Oil and Filter Deutz Diesel Models 4 26 C 1 Check the Boom Wear aaa aaa aaa 4 27 C 2 Check the Turntable Rotation Bearing 4 27 C 3 Check the Free wheel Configuration 2 4 28 C 4 Grease the Turntable Rotation Bearing and Rotate 4 29 C 5
12. Crank engine and check py voltage at org blk 41 wire on alternator 610 7V Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on start lockout module Disconnect wht 24 wire from oil pressure sender and check continuity to yes ground on signal post of sender while cranking the engine Is continuity maintained no Repair short to ground wht 24 wire from sender to TB24 to start terminal 10 on lockout module Disconnect red wire from terminal 4 on start 12V lockout module and check voltage at terminal 4 Repair positive short in red wire circuit from TB27 Repair or replace alternator OR contact Genie Industries Service Department Check oil level OR replace oil pressure sending unit OR refer to Deutz service manual for troubleshooting low oil pressure Replace start lockout module OR consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 4 Engine Will Not Disconnect LPG suppl line from tank an Start On LPG bleed pressure from But Will Start ing On Gasoline Gasoline LPG With keyswitch on and oV Replace fuel select Models both mushroom switch switches pulled out check voltage at LPG Be sure fuel select side blu red wire of switch is switched fuel select swit
13. Repair open in wht wire circuit from terminal 487 on CR2 to CR4 terminal 30 Replace CR4 relay Repair open in blk red wire circuit from CR4 terminal 87A to electronic governor terminal 7 Repair open in brown wire circuit from ignition module to electronic governor Recheck throttle linkage see Repair section OR check and or replace governor actuator OR see Ford service manual for carburetor troubleshooting Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine High Idle Inoperative Deutz 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 workshop Start engine switch rpm select switch to high idle rabbit symbol and check if GSR solenoid pulls in solenoid pulls in manual to troubleshoot fuel injection system solenoid does not pull in Check voltage on red Check voltage at blk red gy wire at center terminal wire on rpm select switch of rpm select switch Replace toggle switch Repair open in blk red wire circuit from toggle switch to TP35 to TB35 Check voltage at TB35 12 Repair open in blk red wire circuit from TB35 to terminal 30 on CR3 V
14. v MOTOR GEN ra 2100 3 Psi 91 634 i ma LS I 2 MED A TEST PRESS PAN EMEN Sa FILTER e a DOS al Z 3 5 EE ES PRESS GPM P w PEL o GEN TR FUNCTION SELECT aa 4 X PUMP i RZ i 14 GPM tmu MET Se ete neuer eet ee t 1 DRIVE PUMP XX I T TANK T rx 2500 es 2 22 7 2 err 25 R SEC REG 3 PSI PSI PSI i amp o 1 340 2900 WITH la i 5 RESERVOIR AUX PUMP SL MES DAS HYDRAULIC ROTARY COUPLER EEEE 1 STEER MANIFOLD 6 DRIVE MANIFOLD T wi M8 REAR 4 RIGHT RIGHT 7 M6 a El STEERING gt REAR Ry I FRONT LEFT J 1 2 8 5 ns HI SPEED DIVIDER 5 4 4 E BY PASS Part No 34476 Genie S 60 8 Genie S 65 6 15 Service Manual Section 6 Schematics OH semet 4WD Hydraulic Schematic Oscillating Axle
15. GEN T 106 06 E KA W n GPI GPM MH M q 1 FUNCTION SELECT m DX KISZ T 4 PUMP IHE IRE NIME PSI 1 r 1 14 GPM i I 2 ZSEE T xc RO AG K DRIVE PUMP XX m s to crm mak Ir 2500 o PSI 25 4 SEC REG 3 3 PSI i PSI PSI BE 2600 W O JIB 2900 WITH JIB X 5 RESERVOIR AUX PUMP SEEDS 3 5 HYDRAULIC n ROTARY COUPLER Lo o oa 6 a a a 1 STEER MANIFOLD DRIVE MANIFOLD 1 250 5 JW PSI 1 d TI X NN 4 FRONT 7 i RIGHT I M6 1 i A VALVE X STEERING B VALVE 12 052 Part No 34476 Genie 5 60 8 Genie 5 65 6 16 Service Manual First Edition Section 7 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Repairs Start M Read understand and obey the safety rules and operating instructions in the Genie S 60 amp Genie S 65 Operator s Manual MI Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcut
16. Perform these tests in gasoline mode only Chart 2A Crank engine and check Repair open in white voltage at automatic 21 wire circuit from choke gt ignition plug to automatic choke 12V Check automatic choke bad Adjust or replace for proper adjustment or automatic choke OR internal damage consult Genie Industries Service Department good With keyswitch on and Repair open in red wht both mushroom V 23 wire circuit from switches pulled out 0 TB23 to vacuum switch check voltage at red wht 23 wire on vacuum switch 12V R a oV bad emove the blk wire Turn machine off See Replace vacuum switch with diode from terminal Repair section for 86 on CR3 crank the vacuum switch check engine over for 15 seconds and check ok voltage at ODE AI bad on vacuum switc a reconnect blk wire after Check vacuum line for Replace vacuum line test restrictions 12V See Ford service manual to troubleshoot low manifold vacuum With keyswitch on and both mushroom switches pulled out disconnect wires from oV Repair open in red blk vacuum switch and I wire circuit from vacuum connect the wires switch to CR6 together Check the voltage at terminal 86 on CR6 Continued on the next page Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshootin
17. pump does not run Hold the auxiliary power switch and check the voltage at terminal TB27 Hold the auxiliary power switch and check the voltage at initiate terminal red wire on PR1 motor start solenoid Hold the auxiliary power switch and check the voltage at positive power cable on auxiliary power unit Check auxiliary power unit grounding cable OR repair or replace electric motor Chart 37 Deadhead a pressure _ less than Hold auxiliary switch gauge into the pressure 2000 psi and adjust pump relief line of the auxiliary valve or replace pump pump and hold the auxiliary power switch 2000 psi Reconnect pressure line and check battery condition There is possibly not enough battery capacity to Operate both aux pump and function valves Replace defective auxiliary power toggle switch Repair open in red wire circuit from TB27 to PR1 Replace PR1 relay Part No 34476 Genie S 60 amp Genie S 65 5 61 Section 5 Troubleshooting Flow Charts Service Manual First Edition gt gt gt _ This page intentionally left blank 5 62 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 6 Schematics Observe and Obey M Troubleshooting and 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 da
18. 2 5 Deutz F4L Engine 2 4 aaa aaa aaa aaa 2 7 Scheduled Maintenance Inspections I trodUCUON zn ee oet AE ad rei eo geste dea eda 3 1 c C o 3 2 Table Bes aT I A 3 3 Table G 3 5 3 6 Maintenance Inspection 3 7 Scheduled Maintenance Procedures ITO CUCU Ent 4 1 A 1 Inspect the 4 2 A 2 Inspect the Decals and Placards 4 2 Inspect for Damage Loose or Missing 00042422022222 4 2 A 4 Check the Engine Oil Level eseee eee aaa 4 3 A 5 Check the Engine Coolant Level Gasoline LPG Models 4 3 A 6 Check for Fuel Leaks eeeu aaa aaa aaa aaa aaa aaa 4 3 A 7 Check the Hydraulic Oil 4 4 A 8 Check for Hydraulic 4 4 Part No 34476 Genie S 60 amp Genie S 65 Service Manual First Edition 2 2 TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 9 Check the Tire Pressure 4 4 40000 nennen tennis 4 5 A 10 Test the Ogcillate Axle 2 RR erc re Rn akit 4 5 A 1
19. 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations PLATFORM CONTROLS Left Center Right came 01010 0019 Grez SPDT 8751 298 POT 21212 listed below to check for continuity Test Desired result Left position 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 terminal 3 to 4 5 amp 6 terminal 4 to 5 amp 6 no continuity no continuity no continuity terminal 5 to 6 continuity There are no terminal combinations that will produce continuity Center position infinite Right position terminal 1 to 2 continuity zero Q terminal 1 to 3 4 54 6 no continuity infinite terminal 2 to 3 4 5 amp 6 terminal 3 to 4 5 amp 6 no continuity no continuity terminal 4 to 5 continuity terminal 4 to 6 no continuity terminal 5 to 6 no continuity Part No 34476 Genie S 60 amp Genie S 65 7 9 Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS 1 6 Control Relays Relays used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Direct C
20. 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 7 60 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures EEN Part No 34476 Genie S 60 amp Genie S 65 7 61 Distributed By E Genie North America 18340 NE 76th Street P O Box 97030 Redmond Washington 98073 9730 Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England
21. Re adjust or replace horsepower limiter board See Repair section OR consult Genie Industries Service Department Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Machine Drives At Full Speed With Platform Raised or Extended Remove machine from service immediately Be sure boom lift drive limit switch or boom extend drive limit switch is not being held down or up Be sure wiring to limit switches is intact and shows no sign of tampering Be sure orange wire cable 1 is properly attached to horsepower limiter Raise boom off drive full limit switch turn machine off and check continuity between ground and terminal 6 on horsepower limiter board no continuity Check continuity full between ground and TB40 no continuity Repair limit switch wiring OR replace boom lift drive limit switch OR replace boom extend drive limit switch continuity paromo controller E continuity Chart 35 Defective Sundstrand drive pump Replace or C wires on drive repair at authorized pump move drive Sundstrand repair controller to full forward facility position and check voltage between terminals 4 and 5 on drive controller Disconnect electronic Replace horsepower limiter board Repair open in org wire circuit from TB40 to horsepower limiter board terminal 6 Part No 34476 Genie S 60
22. Service Manual First Edition 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 Be sure that engine choke is operating properly With keyswitch on and both mushroom switches pulled out check voltage at gasoline side blu wht wire of fuel select Switch 12V With keyswitch on and both mushroom switches pulled out check voltage at TB38 12V With keyswitch on and both mushroom switches pulled out check voltage at terminal 30 on CR6 12V Crank engine for 15 seconds and check voltage at terminal 86 on CR6 while cranking 12V Check ground wire to terminal 85 on CRG good Hold start switch and check voltage at blu wht wire on anti diesel valve on carburetor Continued on the next page Replace fuel select switch Repair open in blu wht wire circuit from fuel select switch to TP38 to TB38 Repair open in blu wht wire circuit from TB38 to terminal 30 on CR6 Repair open in red blk wire circuit from vacuum switch to CR6 Repair open in ground wire to terminal 85 on CR6 Repair open in blu wht wire circuit from CR6 terminal 487 to anti diesel valve OR replace CR6 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts mom c
23. C 7 Drive loop hydraulic filter C 8 Fuel filter diesel C 9 Fuel filter gasoline C 10 PCV valve gasoline C 11 Spark plugs gasoline C 12 Air LPG mixture C 13 Ignition timing gasoline C 14 Valves Deutz C 15 Turntable backlash Checklist D Y NR Refer to Table D D 1 Hydraulic oil D 2 Engine coolant gasoline D 3 Change fuel lines D 4 Valves gasoline D 5 Compression gasoline D 6 PCV hoses gasoline D 7 Fuel injection Deutz D 8 Toothed belt Deutz D 9 Timing belt Ford Part No 34476 Genie S 60 amp Genie S 65 Section 3 Scheduled Maintenance Inspections Service Manual First Edition pm ZZ 00000 This page intentionally left blank 3 8 Genie S 60 8 Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine 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 damage Immediately tag and remove from service a damag
24. Check voltage at terminal 30 on CR3 12V Check voltage to Repair open in wht wire terminal 486 on CR3 circuit from terminal 87 on CR2 to terminal 86 12V on CR3 Repair open in ground wire to terminal 85 on Check ground wire to terminal 85 on CR3 Check voltage to terminal 87 on CR3 Replace CR3 relay 12V Repair open in blk red wire circuit from CR3 to CR4 Check voltage at initiate OV terminal 86 on CR4 Continued on next page Chart 8 Repair open in circuit supplying 12V to center terminal of switch Part No 34476 Genie 5 60 amp Genie 5 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 8 Check ground wire to terminal 85 on CR4 Repair ground wire to terminal 85 on Continued from the previous page Check voltage to Repair open in wht wire terminal 30 on CR4 circuit from CR2 to CR3 to CR4 Check voltage at the Replace CR4 relay blk red wire on the OR repair open in 2 speed solenoid blk red wire circuit from terminal 87 on CR4 to 2 speed solenoid Check if 2 speed solenoid Check linkage or solenoid moves in and replace solenoid out freely moves freely Replace 2 speed solenoid Note resistance across solenoid terminals should be approximately 0 3 ohms 5 22 Genie 5 60 amp Genie 5 65 Part No 34476 Serv
25. amp Genie S 65 5 59 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 36 Drive Enable Do not hold the drive Wil holding the drive Troubleshoot enable switch and enable switch allow horsepower limit board System Is check if machine will boom to drive in drive ae or i i drive in the stowed stowed position over drive pump See chart Malfunctioning position with boom over non steer wheels 30 non steer wheels Repair or replace drive enable limit switch Do not hold the drive enable switch and check if machine will drive in the stowed position with boom over the steer wheels Repair or replace drive enable limit switch Will holding the drive enable switch allow boom to drive in stowed position over steer wheels Repair or replace drive enable toggle switch 5 60 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Auxiliary Functions Inoperative Be sure all other functions operate normally Be sure key switch is in the appropriate position and the emergency stop buttons are pulled up into the on position Be sure engine is not running when using auxiliary power Note Operating auxiliary power with the engine running should immediately kill the engine With engine not running pump lift switch cover hold runs auxiliary switch and listen for sound of auxiliary pump running
26. and the alternator is operating properly with 12 5 to 14 5V DC output Gasoline LPG models Perform this procedure in gasoline mode 7 6 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 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 may result in death or serious injury Remove all rings watches and other jewelry Platform control box a horsepower limiter board 3 Connect the black lead from a DC volt meter to the no 2 terminal and the red lead to the no 10 terminal L 12V DC 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 016 8 9 S e 2 Horsepower limiter board a A potentiometer maximum voltage output to the controller in the stowed position b B potentiometer maximum voltage output to the drive controller in the boom raised position potentiometer reaction rate or how fastthe voltage output reacts to the change in engine rpm PLATFORM CONTROLS Start the engine from the platform controls Move the engine idle control switch to foot switch activated
27. drive speed 8 Lower the boom to the stowed position then extend the boom 1 foot 30 cm 9 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed Drive speed maximum raised or extended a drive limit switch b boom c extension cylinder All models 1 foot per second d master cylinder 0 31 meter per second 4 8 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Drive Enable Limit Switch 1 With the engine off and the boom in the stowed position 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 c turntable rotation bearing TABLE A PROCEDURES Manually activate the drive enable limit switch Result The drive enable limit switch roller should move freely and spring return to center A distinct click should be felt and heard 3 Start the engine from the platform controls 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 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 shou
28. irection o malfunction voltage readings the same Adjust the drive pump Defective Sundstrand null neutral See no improvement drive pump contact Sundstrand Series 40 Sundstrand authorized Service Manual repair facility symptoms improve Check all drive speeds and monitor for recurring symptoms Possible contamination in hydraulic system 5 56 Genie 5 60 amp Genie 5 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 33 Traction Any type of traction roblem consult Genie Function ndustries Service Inoperative Department Be sure all other functions operate normally Part No 34476 Genie 5 60 amp Genie 5 65 5 57 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 34 Machine Will Not Drive At Full Speed Be sure all other functions operate normally Be sure the free wheel valve is closed on the drive pump Be sure the drive speed select switch is on high range machine on level surface symbol With boom fully stowed check TB40 for Repair or replace boom lift drive limit switch or boom extend limit continuity to ground switch no continuity full Orange wire shorted to ground repair orange wire circuit from TB40 to horsepower limiter board With boom fully stowed check horsepower continuity limiter board terminal 6 for continuity to ground no continuity
29. side plug hole 4 Apply pipe thread sealant to the plug and then install it in the torque hub 5 Repeat this procedure for each drive torque hub Drive torque hub oil 44 fl oz 1 30 liters Capacity Type SAE 90 multipurpose hypoid gear oil APIservice classification GL5 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures J JJ P r nn g TABLE B PROCEDURES Turntable Rotate Torque Hub B 11 1 Remove the plug located on the side ofthe hub Check and Adjust the Engine Idle Mi M MUN Mixture Gasoline LPG Models Result The oil level should be even with the bottom of the plug hole Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 B 12 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 a torque hub will not operate properly if the rpm is incorrect and b continued use may cause component damage Gasoline LPG Models 2 f necessary add oil until the oil level is even with the bottom of the side plug hole Perform this procedure in gasoline mode with the engine at normal 3 Appl
30. torque torque 4 Bolt description size ft lbs Nm Oil pan drain plug to pan M 14 15 to 25 20 to 34 Timing belt tensioner 29 to 40 40 to 55 Oil pan to block M 6 TOGO dao Tote pivot bolt M 10 Oil filter insert to block 21 to 26 28 to 35 Timing belt tensioner 25 to 29 35 to 40 Rocker arm cover to 7 to 10 9 to 13 adjusting bolt M 8 cylinder head M 6 Camshaft gear bolt M 12 52 to 66 70 to 90 Spark plug to cylinder 7 to 15 9 to 20 Camshaft thrust plate bolt M 6 6109 8to12 head M 14 Carburetor to spacer stud M 8 7 5 to 15 10 to 20 AOI Carburetor spacer to 10 to 14 14 to 19 3 5 manifold bolt M 8 Water jacket drain plug to block 12 to 18 16 to 24 Crankshaft damper 92 to 122 125 to 165 Water pump to block bolt M 8 15 to 22 20 to 30 bolt M 14 Water outlet connection 15 to 22 20 to 30 Cylinder head bolt M 12 torque in sequence bolt M 8 first step 90 to 60 681081 Cylinder front cover bolt M 6 10 to 12 13 to 16 second step 80 to 90 108 to 122 Inner timing belt cover 15 to 22 20 to 30 stud M 8 Outer timing belt cover 6 to 9 8 to 12 bolt M 6 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 2 Specifications eee DEUTZ ENGINE F4L 1011 SPECIFICATIONS Deutz Engine FAL 1011 Injection pump pressure 4351 psi 300 bar Displacement 166 7 cu in 2 732 liters Injector opening pr
31. 200 bar 7 36 Genie S 60 8 Genie S 65 Part No 34476 Service Manual First Edition 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 test port item 23 on the function manifold 2 Start the engine from the ground controls Hold the extend switch with the boom fully extended and observe the pressure reading on the pressure gauge 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 13 function 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 AWARNING Tip over hazard Do not adjust the relief valves higher than recommended 6 Restart the engine Hold the extend switch with the boom fully extended and recheck the valve pressure Boom extend relief valve specifications Pressure 2100 psi 145 bar FUNCTION MANIFOLD How to Override a Valve A hydraulic valve may need to be manually overridden to troubleshoot a malfunction The proportional boom functions boom 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 u
32. 21 on terminal 87 of CR2 Repair open in wht 21 wire to ignition coil Continued from the previous page Check voltage at red wire on terminal 30 of CR2 Repair open in red wire circuit from battery to CB1 to CR1 to CR2 Hold start switch and check voltage at terminal 9 on start lockout module Hold start switch and check voltage at terminal 86 of CR2 oV Check voltage at terminal 6 and 7 on start lockout module 12V Check ground wire 12V terminal 5 on start lockout module Repair open in blk wire from terminal 86 on CR2 to terminal 9 on start lockout module Repair open in power supply wires to terminal 6 and 7 on start lockout module Repair open in ground circuit to start lockout module good Check the 3 amp fuse on ignition module OR replace the start lockout module OR consult Genie Industries Service Department Check ground to no good Repair open in ground terminal 85 on CR2 wire to CR2 good If weak spark still exists contact Genie Industries Service Department OR consult Ford engine service manual for troubleshooting engine with weak spark 5 6 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Cranks Over But Will Not Start Gasoline LPG Models or Engine Runs While Cranking Then Dies Continuation of good spark fault path
33. 38 wire circuit CR6 to wire on anti diesel valve anti diesel valve on engine carburetor Hold start switch and oV Repair open in blu wht check voltage at blu wht 38 wire circuit from 38 wire on gasoline anti diesel valve to solenoid at gasoline gasoline solenoid tank Hold start switch does Reconnect the two engine fire wires to vacuum switch and check for fuel line blockage OR replace anti diesel valve OR see Ford service manual for Go to chart 2B troubleshooting fuel page 5 10 pump and or carburetor OR Consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 5 9 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 2B Engine Runs Crank engine and check gy Crank engine and check oy Check alternator wiring i i voltage at terminal 2 voltage at org blk 41 OR repair or replace While Cranki ng on start lockout module wire on alternator alternator OR contact i Genie Industries Then Dies 6 to 7V Service Department Repair open in org blk 6 to 7V 41 wire circuit from alternator to TB41 to terminal 2 on start lockout module While cranking engine yes Disconnect wht 24 wire Check oil level OR for 15 seconds check from oil pressure sender replace oil pressure continuity to ground on and check continuity to yes sending unit OR refer to terminal 10 start ground on signal pos
34. 5 a 5 AUXILIARY PUMP 7 AUXILIARY RED RED 27 E H 7 Zu PUMP RED 1 G E AN EE A Wes xa 9 ro AT Te e o n m ws RED RED BLK 1 RED BLK 28 E H a A Ly WHT 2 RED WHT 23 E H n 5 a e e amp a gt 9 x ale S e e Aa amp I BLK RED 3 BLK RED 9 P A a a 9 BLK 2 o BLK RED R5 E H e Q ast Yao a EM tc a WHT 21 E H RED E H ORG BLK 1 ORG BLK 41 E H ul a mj 5 aL ll 1 E Heej o 4 ER T 2 4474 BIS NE ee la amp c 5C E a iu i i O F O lt lt a6 A RED RED 20 E H th T N gt LO N GENERATOR OPTION HIGH IDLE RELAY FLASHING BEACONS PRECISION GOVERNOR RELAY FUEL RELAY FUEL RELAY LPG SOLENOID ANTI DIESEL VALVE GASOLINE SOLENOID FUEL PUMP WATER TEMP SENDER OIL PRESSURE SENDER HOUR METER AUTOMATIC CHOKE IGNITION SYSTEM PULSE GENERATOR STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN Part No 34476 Genie S 60 amp Genie S 65 6 3 Section 6 Schematics Service Manual Electrical Schematic Gasoline LPG Models
35. 7 26 7 4 Carburetor 442224440 0 00 00 7 26 7 5 RPM Adjustment orea a e a 7 26 7 65 FleGPIAIS naa OMA GAM ale fhe tice AB RE Es 7 26 7 7 Water Temperature and Oil Pressure 7 27 7 8 VACUUNNSWIICH oot atate ettet s 7 27 Ground Controls 8 1 Control Relays a aaa snnt 7 28 8 2 Toggle Switches See 1 5 Toggle 7 9 8 3 rettet namen ck REM Ta Pp 7 29 MIO CD E 7 29 9 5 Power Relay zana RO ROAR AO 7 30 Hydraulic Pumps 9 1 Lift Steer Pump une tore tente Pte geist Dee eth e risen 7 31 9 2 Drive FUMI 52 eo atest anette 7 31 Function Manifolds 10 1 Function aanita 7 34 10 2 Valve Adjustments Function 0 22 44 7 36 Fuel and Hydraulic Tanks 11 1 Hydraulic L nk uiii Er eee e te e 7 39 T1 2 Fuel Tank Asa eee age env ened reagent A 7 40 Turntable Rotation Components 12 1 Rotation Hydraulic 7 41 12 2 Turntable Rotation Manifold Components 7 43 2WD Steering Axle Components 13 11 Xoke and UD 3 3 retreat et tnt pret 7 44 13 2 Steering Cylinders eeeeeees eee aaa a
36. 7 47 Section 7 Repair Procedures Service Manual First Edition 4WD STEERING AXLE COMPONENTS 14 Use a slide hammer to remove the upper king pin then use a soft metal drift to drive the lower king pin down and out Crushing hazard The yoke torque AWARNING hub assembly will fall when the lower king pin is removed if it is not properly supported 15 Place the yoke torque hub assembly on a flat surface with the torque hub down Remove the bolts that secure the yoke to the torque hub Torque specifications Lug nut dry bolts 420 ft Ibs 569 5 Nm Lug nut lubricated bolts 320 ft lbs 433 9 Nm Torque hub mounting bolts 120 ft lbs 163 Nm Drive motor mounting bolts 75 ft lbs 102 Nm 14 2 Steering Cylinders How to Remove a Steering Cylinder This procedure is the same as the 2WD procedure See repair procedure 13 2 How to Remove a Steering Cylinder 14 3 Tie Rod How to Remove the Tie Rod This procedure is the same as the 2WD procedure See Repair Procedure 13 3 How to Remove the Tie Rod How to Perform the Toe in Adjustment This procedure is the same as the 2WD procedure See Repair Procedure 13 3 How to Perform the Toe in Adjustment Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 15 1 Oscillating Axle Components Oscillating Axle Lock out Cylinders The oscillating axle cylinders extend and retract bet
37. 75 to 4 1 bar Type 12V Group 31 Oil capacity 5 quarts including filter 4 7 liters Quantity 1 Oil viscosity requirements Cold cranking ampere 1000A Temperature below 60 F 15 5 C 5W 30 Reserve capacity 25A rate 200 minutes 10 F to 90 F 23 C to 32 C 10W 30 Fuel pump Temperature above 10W 40 to 10W 50 Electronic solenoid 7 psi 10 F 23 C 0 48 bar 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 Part No 34476 Genie S 60 amp Genie S 65 2 5 Section 2 Specifications Service Manual First Edition 8 sr FORD ENGINE LRG 423 SPECIFICATIONS Ignition System Bolt torque specifications Spark plug type Motorcraft AWSF 52C torque Bolt description size ft Ibs Spark plug gap 0 042 to 0 046 inches 1 07 to 1 18 mm torque Nm torque in sequence Exhaust manifold to cylinder head bolt or nut M 10 Enalne coolant first step 14 to 19 19 to 26 9 second step 35 to 50 47 to 68 i 1 Capacity 11 A is Flywheel to crankshaft 54 to 64 73 to 87 bolt M 10 Alemator Intake manifold to 15022 201030 Output 95A 14 50 Cylinder head bolt or nut M 8 Bolt torque specifications Oil pressure sending unit to block 8 to 18 11 to 24
38. 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 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 lbs 9072 kg under the drive chassis between the non steer tires 3 Lift the wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the torque hubs by turning over the torque hub disconnect caps on each non steering wheel hub ho disengage position S mj a engage position 5 Manually rotate each non steering wheel Result Each non steering wheel should rotate with minimum effort 6 Re engage the torque hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the jack stands AWARNING Collision hazard Failure to re engage the torque hubs may cause 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 1bs 9072 kg under the drive chassis between the non ste
39. Genie 5 60 8 Genie 5 65 6 14 Service Manual Section 6 Schematics gt JI 4WD Hydraulic Schematic Non Oscillating Axle M L K J G F E D C B A JIB BOOM PLATFORM ROTATE pO INN p SLAVE 1 17 P H BOOM UP DOWN d ROTATE BOOM EXTENSION E a 3 PRIMARY am a SECONDARY i At Ex a tid a Mp ue L ie 03 28 gt lt i cL 2 JIB BOOM ef MANIFOLD MASTER B A NN PLATFORM BRAKE F4 025 1 BOOM 3 pai ene vue LEVEL TURNTABLE EXTEND RETRACT m Pill FUNCTION gt lt ee S 2 STROKE OPTIONAL Mi MANIFOLD
40. Interchange the 2400 level up and down peer counterbalance valves More items B amp C function operates Replace defective counterbalance valve Disconnecting hydraulic lines or adjusting the cylinder counterbalance valves in this situation can be very dangerous Please consult Genie Industries Service Department Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Platform Level Down Function Inoperative Be sure all other functions operate normally If platform level down function operates normally from the ground controls but not from the platform controls troubleshoot the platform control toggle switch See Repair section If platform level down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check voltage at org blk wire on platform level down function directional valve 0 or Remove both wires from infinite valve coil and check ohms resistance across the coil terminals 4 to 5 ohms Hold toggle switch and manually override the level down directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item O with a like valve item N
41. JIB BOOM COMPONENTS S 65 MODELS Remove the pin retainers from the jib boom lift cylinder rod end pivot pin Do not remove the pin Use a soft metal drift to tap the rod end pivot pin half way out Then lower the leveling link to the ground Tap the pin the other direction and lower the opposite leveling link Do not remove the pin Support the jib boom lift cylinder with an overhead crane Remove the pin retainer from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pin Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder will fall when it is removed if it is not properly supported Part No 34476 Genie S 60 amp Genie S 65 7 15 Section 7 Repair Procedures JIB BOOM COMPONENTS S 65 MODELS Service Manual First Edition 2222 2 22 22H 8 10 ft lbs 11 14 Nm 3 3 Jib Boom Platform Rotate Manifold Components S 65 Models 1 2 position way valve A Platform rotate select 2 2 position way valve Platform rotate select Y 8 10 ft lbs 11 14 Nm Plug Torque Specifications Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm 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 SAE N
42. PLUG 34 BLK WHT 1 START 33 BLK 1 BRAKE 32 WHT RED 1 ED C 31 WHT BLK 1 E D C 30 WHT 1 2WD AWD 29 RED WHT 1 TILT ALARM 28 RED BLK 1 AUX PWR 27 RED 1 PWR TO ES 26 BLK FS PWR START 25 GREEN FS PWR CONT 24 WHT H P L PWR FRMPLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 21 20 JIB VALVE 19 GRN WHT 3 a PLAT ROT R 18 GRN BLK 3 Xe PLAT ROT L 17 GRN 3 PLAT LVL F C 16 ORG RED 3 PLAT LVL DN 15 ORG BLK 3 PLAT LVL UP 14 ORG 3 DRV ENA LT 13 BLU RED 3 93 DRV 12 BLU WHT 3 Wu SEC BOOM DN 11 BLU BLK 3 SEC BOOM UP 10 BLU 3 HORN 9 BLK RED 3 RETRACT 8 BLK WHT 3 EXTEND 7 BLK 3 DON TURN EXT F C 6 WHT RED 3 GABLE TURN ROT R 5_ WHT BLK 3 KY TURN ROT L 4 WHT 3 PRIMARY EC 3 REDWHT 3 PRIMARY DN 2 RED BLK 3 PRIMARY UP 1 RED 3 7 CABLE SZ HORSE POWER LIMITER GRN 2 ac mo m ALARM NC P2 STOP NC O M 8 7 6 5 4 3 2 1 DP1 a O un Ts4 O O RPM e o MF la Ts2 START L1 7 LED 060 r O GENERATOR 1520 OPTION gt O 99 O DRIVE ENABLE O TS8 O 2WD 4WD SELECT TS1 AUX aka PE BP2 JIB TSe BOOM R X A OPTION EXTEND RETRA
43. Replace the Torque Hub 4 29 C 6 Replace the Hydraulic Tank 4 31 C 7 Replace the Drive Loop Hydraulic Filter 4 31 C 8 Replace the Diesel Fuel Filter Deutz Diesel Models 4 32 C 9 Replace the Gasoline Fuel Filter Gasoline LPG Models 4 32 C 10 Replace the PCV Valve Gasoline LPG Models 4 34 C 11 Replace the Spark Plugs Gasoline LPG Models 4 35 C 12 Check and Adjust the Air LPG Mixture Gasoline LPG Models 4 36 C 13 Check and Adjust the Ignition Timing Gasoline LPG Models 4 37 C 14 Check the Engine Valve Clearances Deutz Diesel Models 4 37 C 15 Check the Turntable Rotation Gear 4 37 D 1 Test or Replace the Hydraulic 4 38 D 2 Change or Recondition the Engine Coolant Gasoline LPG Models 4 39 D 3 Change the Fuel 01401100 aaa 4 41 D 4 Check the Engine Valve Clearance Gasoline LPG Models 4 42 D 5 Check the Engine Cylinder Compression Gasoline LPG Models 4 42 D 6 Clean the PCV Hoses and Fittings Gasoline LPG Models 4 43 D 7 Check the Fuel In
44. a series of steps Part No 34476 Genie S 60 amp Genie S 65 7 1 Section 7 Repair Procedures Service Manual First Edition 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 ERR CET Platform control box horsepower limiter board terminals drive proportional controller extend retract proportional controller boom proportional controller turntable rotate proportional controller Boom Up Down Controller Adjustments 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 Electrocution hazard Contact AWARNING with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 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 Open the platform control box lid and locate the boom up down controller terminal D2 directional output termina
45. 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 a hazardous operating situation 1 Pull out the Emergency Stop button to the oN position at both the ground and platform controls 2 Turn the key switch to ground control start the engine and then turn the key switch to platform control a solenoidboot 3 Check any machine function from the ground b highidle adjustment nut controls lock nut d yoke Result The machine functions should not e lowidle adjustment screw operate f lock nut 4 Turn the key switch to ground control 3 Move the engine idle control switch to high idle y 9 rabbit symbol from the ground controls 5 Check any machine function from the platform EN controls Result High idle should be 2300 rpm Result The machine functions should not If high idle rpm is correct disregard operate adjustment step 4 6 Turn the key switch to the orr position 4 Loosen the yoke lock nut then turn the adjustment nut and solenoid boot O Result The engine should stop and no counterclockwise to increase the rpm or functions should operate clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds De
46. at the platform end of the boom Crushing hazard The boom tubes ACAUTION will fall when they are removed from the boom if they are not properly supported 7 Support and slide the number 2 and 3 boom tubes out of the number 1 boom tube Place the 2 and 3 boom tubes on blocks for support During removal the overhead crane strap will need to be carefully adjusted for proper balancing 8 Remove and label the wear pads from the top side of the number 2 boom tube at the platform end of the boom 9 Remove the trunnion cap mounting fasteners at the base of the number 2 boom tube Then use a slide hammer to remove the trunnion caps 10 Carefully rotate the the base end of the extension cylinder until the pin mounting bore is in a vertical position BOOM COMPONENTS 11 Support the number 3 boom tube with an overhead crane at the platform end of the boom Crushing hazard The boom tubes ACAUTION will fall when they are removed from the boom if they are not properly supported 12 Support and slide the number 3 boom tube out of the number 2 boom tube Place the 3 boom tube on blocks for support During removal the overhead crane strap will need to be carefully adjusted for proper balancing 13 Remove the retaining rings from the extension cylinder rod end pivot pin at the platform end of the number 3 boom tube Use a soft metal drift to remove the pin 14 Support and slide the extension cylinder out of the base end o
47. boom 433 9 Nm boom to platform cable harness inside of the platform control box jib boom cable track S 65 models Part No 34476 Genie S 60 amp Genie S 65 4 15 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 9 Confirm 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 torque hub disconnect cap to be sure it is in the engaged position brake disengage position brake engage position 2 Be sure the free wheel valve on the drive pump is closed clockwise a drive pump b free wheelvalve c screwdriver d liftpump The free wheel valve should always remain closed B 10 Check the Oil Level in the Torque Hubs Failure to maintain proper torque hub oil levels may cause the machine to perform poorly and continued use may cause component damage Drive Torque 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
48. button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item N with a like valve item O function inoperative function Install a pressure gauge Interchange pressure operates Replace defective flow atthe quick disconnect compensating flow control valve coupling on the function control valve item U manifold and hold the with like valve item V function switch function inoperative less than 2600 psi Replace jib boom directional valve function Interchange check Replace defective tem with like valve 9P9rates item L function inoperative Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 5 47 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 27 Jib Boom Down Function Inoperative S65 Models Be sure all other functions operate normally If jib boom down function operates normally from the ground controls but not from the platform controls troubleshoot the platform control toggle switch or CR13 See Repair section If jib boom down function operates normally from the platform controls but not from the ground controls troubleshoot the
49. button to the oN position and turn the key switch to ground control O Result The flashing beacon should be on and flashing 2 Move the boom switch to the pown position hold for a moment and then release it O Result The descent alarm should sound when the switch is held down 3 Turn the key switch to platform control 4 Atthe platform controls pull out the Emergency Stop button to the oN position Result The flashing beacon should be on and flashing TABLE B PROCEDURES 5 Press down the foot switch Move the boom control handle to the pown position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down 6 Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction B 26 Perform Hydraulic Oil Analysis See D 1 Test or Replace the Hydraulic Oil Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 27 Replace the Engine Oil and Filter Deutz Diesel Models Engine specifications require that this procedure be performed every 500 hours Perform this procedure more often if dusty
50. conditions exist 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 Perform this procedure after warming the engine to normal operating temperature Beware of hot engine parts and ACAUTION oil Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the oil filler cap located on the valve cover 2 Pullthe end of the 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 4 Install the plug into the drain hose Use an oil wrench and remove the oil filter a engine oil level dipstick b oilfilter c fuelfilter 6 Apply athin layer of oil to the new filter gasket filter part no 29561 Then install the filter and tighten it securely by hand 7 Use a 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 replace the oil filler cap 9 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine
51. controls troubleshoot jib boom up the platform control inoperative toggle switch See Repair section If platform rotate left function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check voltage at grn blk wire on platform rotate left function directional valve Hold platform rotate left function switch and check voltage at grn wht Repair open in grn wht wire circuit from CR14 to jib boom manifold valves OR replace wire on both valves on jib boom manifold CR14 or TR2 time delay relay OR consult Genie 12V Industries Service Department Remove both wires from oor infinite valve coil and check resistance across the ohms Replace the coil coil terminals 4 to 8 ohms Repair OR replace the defective valve OR check for mechanical restrictions keeping platform from rotating OR repair hydraulic rotator Repair open in grn blk wire circuit from TB18 to directional valve 0 or Remove both wires from infinite valve coil and check ohms f resistance across the Replace the coil coil terminals 4 to 5 ohms Continued on the next page 5 42 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 24 Hold toggle switch left function and manu
52. drive chassis 9 Install the clevis yoke pin then the cotter pin Be sure to bend the cotter pin 10 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 Part No 34476 Genie S 60 amp Genie S 65 7 53 Section 7 Repair Procedures Service Manual First Edition gt gt gt gt gt gt STEER AND OSCILLATE MANIFOLDS 16 4 Steer Manifold Components The steer manifold is mounted to the engine side tray Index Schematic No Description Item Function Torque 1 3 position 4 way 003 valve Steering 3 etre Rede rs 30 35 in lbs 3 4 Nm 2 Priority flow regulator valve 3 gpm 13 2 l min Bas ait OSCIIAIE bers aston dite reist 10 12 ft Ibs 14 16 Nm W e 2 Plug Torque Specifications Description Hex size Torque Description Hex size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm 7 54 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition S
53. engine belt s for cracking glazing separation breaks 3 Check the engine belt s for proper tension Deutz Diesel engine Ford LRG 423 engines are equipped with a serpentine belt and incorporate a self adjusting pulley tensioner No adjustment is required Belt deflection Deutz Diesel models 3 8 inch to 1 2 inch 9 mm to 12 mm B 2 Check the Radiator Gasoline LPG Models 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 Do not inspect while the engine AWARNING is running Remove the key to secure from operation Beware of hot engine ACAUTION components Contact with hot engine components may cause severe burns 1 Inspect the radiator for leaks and physical damage 2 Clean the radiator fins of debris and foreign materials B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models Maintaining the oil cooler in good condition 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 performanc
54. fe STEERING i 07 1 REAR ES LEFT 1 Part No 34476 Genie 5 60 8 Genie 5 65 6 13 Service Manual Section 6 Schematics 2 2 2WD Hydraulic Schematic Oscilating Axle JIB BOOM PLATFORM ROTATE AF 1 dod SLAVE NK UT BOOM UP DOWN 9 LIE M E 1 1 TURNTABLE T ROTATE BOOM EXTENSION T lt PRIMARY ES SECONDARY el rx LE i i 2 03 03 JIB BOOM a NB AN MANIFOLD MASTER B A AL PLATFORM r BRAKE N 025 LEVEL TURNTABLE BOOM PR1 PR2 PL1 PL2 51 5
55. function inoperative Interchange check valve item L with like valve item K function inoperative 2400 Install a pressure gauge psi or at the quick disconnect more coupling on the function manifold and hold the function switch less than 2400 psi Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department function operates function operates Repair open in org blk wire circuit from TB15 to directional valve Replace the coil Replace the platform leveling directional valve Replace defective check valve Interchange the level up 2400 and down psi or counterbalance valves More items B amp C function operates Replace defective counterbalance valve Chart 23 Disconnecting hydraulic lines or adjusting the cylinder counterbalance valves in this situation can be very dangerous Please consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 24 Platform Rotate Check if jib Left Function perdona 60 models proceed Inoperative um to next Stop Be sure all other functions operate normally If platform rotate left function operates normally from the ground controls but not from the platform
56. ground control toggle switch See Repair section Check if platform rotate Repair OR replace rotate right is right defective valve s OR operational operates check jib boom for mechanical restrictions OR repair jib boom cylinder OR replace rotate right jib boom cylinder inoperative counterbalance valves Hold ground control function switch and check voltage at grn blk wire on jib boom down function directional valve Repair open in grn blk wire circuit from TB17 to directional valve 00r Remove both wires from infinite valve coil and check ohms resistance across the coil terminals Replace the coil 4 to 5 ohms Hold toggle switch and manually override the jib boom down directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item N with a like valve item O function operates Replace the jib boom directional valve function inoperative Continued on the next page Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Install a pressure gauge at the quick disconnect coupling on the rotate function manifold and hold the function switch Continued from the previous page 2600 psi or more Replace the jib boom directional valve less than 2600 p
57. handle 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 EXTEND position Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp speed 17 Set the ramp rate turn the trimpot to obtain a 3 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Boom up down specifications Threshold 3 5V DC 9 75V DC 100 to 130 seconds Boom extend Max out Cycle time Boom retract Dual lo range 9 2V DC Cycle time 55 to 85 seconds Ramp rate 3 seconds 1 2 Horsepower Limiter Board The horsepower limiter board is responsible for governing drive pump output It senses engine rpm from the alternator The horsepower limiter board senses drops in rom normally due to increased drive resistance rough terrain or incline and decreases voltage to the drive controller which in turn decreases voltage to the drive pump thereby reducing pump output to maintain optimum engine rpm and horsepower Three adjustments are required for optimum performance How to Adjust the Horsepower Limiter Board The engine rpm must be correct before performing this procedure See Maintenance Procedure B 12 Check and Adjust the Engine RPM Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC
58. high idle rabbit and foot switch symbol Press down the foot switch and adjust the A potentiometer counterclockwise to increase voltage or clockwise to decrease voltage A potentiometer specifications all models Voltage setting 10 5 to 11 5V DC Move the engine idle control switch to low idle turtle symbol Press down the foot switch and then adjust the C potentiometer to obtain a 0 01V DC to 0 03V DC voltage reading Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 10 Press down the foot switch and re adjust the A potentiometer 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 control handle movement If the engine surges or hunts adjust the C potentiometer counterclockwise until surging is minimized Under an extreme load an excessive counterclockwise adjustment to the C potentiometer will cause the engine to stall The C potentiometer adjustment is a compromise between engine stability surging and engine rpm droop Part No 34476 Genie S 60 amp Genie S 65 7 7 Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS 12 Disconnect the volt meter 13 Raise the boom above the drive limit switch a drive limit switch b boomextension cylinder 14 Drive the mac
59. idle can be achieved by grasping the governor actuator arm and momentarily pulling to throttle the carburetor Start engine and switch rpm select to un idle rabbit symbol 10 lime checks Check voltage at blk red wire on rpm switch good 12V _ Check voltage at terminal 87A on CR4 oV _ Yy Check voltage at terminal 7 on electronic governor oV E WE Check voltage at terminal 30 on CR3 12V y Continued on the next page 12 Repair short in blk rd OV Repair open in wht wire gt 0 Check voltage at center terminal on rpm select switch 12 Replace rpm select 12V toggle switch oV Repair open in blk red Check voltage at TB35 wire circuit from toggle switch to TP35 to TB35 12V Check voltage at ov Repair open in blk red terminal 86 blk red of wire circuit from TB35 to 12V Check ground wire to bad Repair open in ground terminal 85 on CR4 a to terminal 85 on 4 Check voltage at OV Repair open in power terminal 30 on CR4 wire from terminal 87 on CR2 to CR4 12V Replace CR4 relay wire to terminal 7 on precision governor circuit from CR2 terminal 487 to CR3 30 Repair open in circuit supplying 12V to center terminal of switch Genie S 60 am
60. including tank 208 liters Hydraulic fluid Dexron Il equivalent TABLE D PROCEDURES D 2 Change or Recondition the Engine Coolant Gasoline LPG 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 Beware of hot engine parts and ACAUTION coolant Contact with hot engine parts and or coolant will cause severe burns Perform this procedure with the engine off and cooled 1 Puton protective clothing and eye wear 2 Disconnect the coolant return hose at the radiator and drain the coolant return tank 3 Remove the radiator cap from the radiator Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE D PROCEDURES 4 Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the radiator drain valve 10 Disconnect the upper hose at the top and hold it until coolant starts to pour out of the open hose Then immediately reconnect the hose a pivotplate retaining bolts b enginepivotplate 5 Open the drain valve on the radiator and allow all the coolant to drain into a suitable container After all the coolant has drained clos
61. lines Cap the fuel return fitting on the fuel tank 3 Remove the mounting fasteners from the bottom of the tank 4 Use an appropriate lifting device to remove the tank from the machine Clean the fuel tank and inspect for rust and corrosion before installing 7 40 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures Turntable Rotation Components 12 1 Rotation Hydraulic Motor How to Remove the Rotation Hydraulic Motor 1 Secure the turntable from rotating with the turntable rotation lock pin UI m Locked position 2 Tag and disconnect the hydraulic hoses from the motor brake and manifold then plug them ACAUTION POTY 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 mounting bolts then remove the motor from the brake motor brake mounting bolts motor brake torque hub mounting bolts torque hub plug How to Remove the Turntable Rotation Brake or Torque Hub Refer to Maintenance Procedures 5 How to Replace the Torque Hub Oil Part No 34476 Genie S 60 amp Genie S 65 7 41 Section 7 Repair Procedures Service Manual First Edition TURNTABLE ROTATION COMPONENTS How to Adjust the Turntable Rotation Gear Backlash The turn
62. off 10 Check the oil filter and oil pan for leaks 11 Check the engine oil level dipstick Add oil if needed Deutz Engine F4L 1011 Cil capacity including filter 11 quarts 10 5 liters Deutz Engine F4L 1011 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 CC SE CD SE CC SF or CD SF grades 4 26 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures C 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 worn out wear pads may result in component damage and unsafe operating conditions 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 not less than 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 could cause binding or
63. over inflated tire can explode AWARNING and may cause death or serious injury 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 and add air as needed Tire specifications Tire size 15 19 5 NHS Pressure 85 psi 5 86 bar TABLE A PROCEDURES A 10 Test the Oscillate Axle oscillating axle equipped models 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 2 cm block or curb O Result The three remaining tires should stay in firm contact with the ground 3 Drive the left steer tire up onto a 6 inch 15 2 cm block or curb O Result The three remaining tires should stay in firm contact with the ground 4 Drive both steer tires up onto a 6 inch 15 2 cm block or curb O Result The non steer tires should stay in firm contact with the ground Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 11 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is e
64. red wire circuit from key switch to function switches 5 26 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 13 Platform Does engine startfrom yes Start engine from the ov Test and replace foot Controls the platform controls gt platform then press switch OR repair open down the foot switch in wht wire circuit from Inoperative 10 lad voltage at foot switch to TP24 Ground 12V Controls no Operate Repair open in wht wire circuit from TP24 to Normal ly function controllers y Be sure all Check voltage at TB22 y Check for open in red cables are in good wire circuit trom key condition with no switch to TB22 OR kinks Grabrasion 12V Replace the key switch platform contacts ov Check voltage at TP22 Repair open in blk 2 wire circuit from TB22 TP22 12V uo LLL LL Check voltage at blk ov Replace contact on wire on platform emergency stop button emergency stop button 12V oV Check voltage at 23 Repair open in blk wire circui from emergency 12V stop button to TP23 Repair open in blk wire circuit from platform emergency stop switch to TP26 to foot switch OR replace foot switch OR consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 5 27 Section 5 Troubleshooting Flow C
65. 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 manual 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 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 S 60 amp Genie S 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 legibility and damage Replace any damaged or illegib
66. slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion The master cylinder is located at the base of the boom How to Remove the Platform Leveling Master Cylinder 1 Raise the boom until the 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 ACAUTION 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 both master cylinder pins 5 Use a soft metal drift to remove the pins Part No 34476 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Service Manual First Edition Turntable Covers 5 1 Turntable Covers How to Remove a Turntable Cover 1 Raise the turntable cover Support the open cover with an overhead crane or forklift Do not lift it Crushing hazard Due to its heavy ACAUTION weight do not attempt to support the cover by hand 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 4 Remove the cover hinge bolts that fasten the hinge su
67. 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 OFF position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push in the platform Emergency Stop button to the orr position 2 Start the engine from the ground controls 3 Operate each boom function through a partial cycle Result All boom functions should operate Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 16 Check the Directional Valve Linkage 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 directionalvalve b clevis pin with cotter pin hidden c yoke d locknut TABLE B PROCEDURES B 17 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
68. to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Remove the pin retaining fastener from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin then allow the lift cylinder to rest on the blocks Protect the cylinder rod from damage Crushing hazard The lift ACAUTION cylinder will fall unless it is properly supported 7 Remove the mounting fasteners from the barrel end cylinder pin mounting plates 8 With the lift cylinder being supported by the overhead crane pull the cylinder toward the platform until it is out Component damage hazard The ACAUTION cables and hydraulic hoses can be damaged if the lift cylinder is pulled across them 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 may cause death or serious injury and significant component damage Dealer service is strongly recommended 1 Extend the boom until the cylinder rod end pin is accessible in t
69. 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 control handle 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 7 Setthe hi range Press down the foot switch fully retract the boom then move the control handle all the way to the left or right Adjust the voltage to 5 5V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Setthe lo range Press down the foot switch extend the boom 3 feet then move the control handle all the way to the left or right Adjust the voltage to 4 5V DC Turn the lo range trimpot adjustment screw clockwise to increase 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 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 120 second cycle time Extend the boom t
70. up on the tab of the component and remove it GROUND CONTROLS 8 4 Resistors How to Test the Resistor The resistor is used to maintain proper control of boom function speeds A 10 ohm resistor reduces voltage to all the boom function switches Refer to the schematic legends for resistor locations and values 1 Turn the key switch to the orr position 2 Disconnect either end of one of the wires connected to the resistor to be tested 3 Connect the leads from an ohmmeter to each end or wiring of the resistor being tested 4 Compare the ohmmeter reading with the resistance rating printed on the resistor Part No 34476 Genie S 60 amp Genie S 65 7 29 Section 7 Repair Procedures Service Manual First Edition GROUND CONTROLS 8 5 Power Relay The power relay is mounted on the backside of the ground control box Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry How to Test the Power Relay Electrocution hazard Disconnect AWARNING the ground cable from the battery before performing this procedure 1 Connect the leads from an ohmmeter to each terminal combination and check for continuity Test Desired result 2 small posts 13 to 170 2 large posts no continuity infinite Any small post to no continuity any large post infinite 2 Connect 12V DC to one of the sma
71. 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 Close the manual fuel shutoff valve located next to the fuel tank 2 Remove and replace the fuel line hoses and clamps according to the following illustrations Fuel may be expelled under pressure Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them TABLE D PROCEDURES OURS E 1 3 lt Ce am KS s 03 ZA gl al FA Q K 0 5 Deutz Diesel models a hosefromthe injector to the fuel tank b hoses connecting injectors c hose from the fuel shutoff valve to the fuel pump d hosefromthe fuel pump to the fuel filter e hosefrom the fuel filter to the injection pump f hose from the injection pump to the injectors Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE D PROCEDURES a carburetor b fuelfilter hose from the fuel filter to the fuel pump d hosefromthe fuel pump to the fuel tank not shown 3 Clean up any fuel that may have spilled during this procedure 4 Start the engine from the ground controls then inspect the fuel filter and hoses for leaks lf a fuel leak is discovered keep ALLS any addi
72. wire on extend retract function valve function oor Hold toggle switch down operates Check the resistance infinite and manually override of the retract directional ohms Replace the coil the retract directional valve coil valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item S with a like valve item P 4 to 5 ohms Replace the valve function inoperative Check for mechanical restrictions keeping boom from retracting OR repair cylinder OR replace cylinder counterbalance valve Install a 0 to 3000 psi pressure gauge at the quick disconnect coupling on the function manifold and hold the function switch less than 2400 psi Repair cylinder OR replace cylinder counterbalance valve OR manifold has internal defect consult Genie Industries Service Department Genie 5 60 amp Genie 5 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Turntable Rotate Function Inoperative Be sure all other functions operate normally If turntable rotate function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If turntable rotate function operates normally from the platform controls but not from the ground controls troubleshoot the ground
73. 0 seconds Boom down lo range Cycle time Ramp rate 3 to 4 seconds Turntable Rotation Controller Adjustments 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 Electrocution hazard Contact AWARNING with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 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 Part No 34476 Genie S 60 amp Genie S 65 7 8 Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS 3 Open the platform control box lid and locate the turntable rotation controller Refer to the platform control box illustration page 7 2 Lo Fo eo terminal D2 directional output terminal proportional output terminal ground terminal positive terminal R activates max out range terminal D1 directional output ramprate adjustable trimpot lo range adjustable trimpot threshold adjustable trimpot hirange adjustable trimpot F O O Q O000 4 Set the preliminary ramp rate Turn the trimpot adjustment screw clockwise 15 turns or
74. 1 d LE NER 3 pos 4 way directional valve Unloader valve EM M 9 Pressure compensating valve Part No 34476 Genie S 60 amp Genie S 65 Service Manual Section 6 Schematics 2 2 2WD Hydraulic Schematic Non Oscillating Axle JIB BOOM PLATFORM ROTATE re E 212 L4 SLAVE 5o BOOM UP DOWN 9 LIE EM d M pod TURNTABLE I 7 gt ps ROTATE BOOM EXTENSION 085 PRIMARY B SECONDARY ja Z LA io za EE IL SE I ak D 03 z gt LI i 2 03 a SS z JIB BOOM lt e INE M
75. 1 Manuals B 21 Fuel select gasoline A 2 Decals and placards B 22 Drive enable system A 3 Damage loose or missing parts A 4 Engine oil level A 5 Engine coolant gasoline A 6 Fuel leaks A 7 Hydraulic oil level A 8 Hydraulic leaks A 9 Tire pressure A 10 Oscillate axle B 23 Drive brakes B 24 Drive speed stowed B 25 Alarm package B 19 Foot switch B 26 Hydraulic oil analysis Perform every 500 hours B 27 Replace engine oil and filter Deutz Checklist C YN R A 11 Platform and ground controls A 12 Auxiliary power A 13 Tilt sensor A 14 Limit switches Perform every 100 hours A 15 Replace engine oil and filter gasoline A 16 Replace air filter Checklist B Y N R Refer to Table B B 1 Engine belt s B 2 Engine radiator B 3 Oil cooler and fins Deutz B 4 Exhaust system B 5 Battery B 6 Hydraulic tank filter B 7 Electrical wiring B 8 Tires and wheels B 9 Brake configuration B 10 Torque hub oil level B 11 Idle mixture gasoline B 12 Engine RPM B 13 Key switch B 14 Emergency Stop B 15 Ground control override B 16 Directional valve B 17 Platform leveling B 18 Service horn Refer to Table C C 1 Boom wear pads C 2 Turntable bearing bolts C 3 Free wheel configuration C 4 Grease rotation bearing C 5 Torque hub oil C 6 Hydraulic tank filter
76. 1 Test the Platform and Ground Controls 4 6 A 12 Test the Auxiliary Power Operation 4 6 13 Test the Tilt Senisor z nc eire eee A deem AA 4 7 A 14 Test the Limit 4 8 A 15 Replace the Engine Oil and Filter Gasoline LPG Models 4 10 A 16 Replace the Engine Air 4 4 11 B 1 Check the Engine Belt s sese 4 12 B 2 Check the Radiator Gasoline LPG 4 12 B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models 4 12 B 4 Check the Exhaust System sess 4 13 B 5 Check the Battery cadet dude eae eae 4 14 B 6 Check the Hydraulic Tank Filter Condition Indicator 4 14 B 7 Inspect the Electrical 0 4 15 B 8 Inspect the Tires and Wheels 4 15 B 9 Confirm the Proper Brake Configuration 2 4 16 B 10 Check the Oil Level in the Torque 4 16 B 11 Check and Adjust the Engine Idle Mixture Gasoline LPG Models 4 17 B 12 Check and Adjust the Engine 4 17 B 13 Test the Key Switch iaa aaa nennen enne 4 19 B 14 Test the Emergency Stop 4 20 B 15 Test the Ground Control
77. 2 EXTEND RETRACT R1 R2 P1 P2 i MOTOR 3 24 FUNCTION I STROKE OPTIONAL L 4 2500 2100 MANIFOLD B t 4PSIr 4 C D PSI MOTOR GEN ra 2100 ZF o PS pum Li BE i gt 4 M T EB TEST H fs L PRESS E Nn n TH H t t tj FILTER TEJ DAS ep ARISE Lan i 1 B Or o s REECE 27 SE GPM OF je M PRESS x8 R L ba HM ape 4 350 L K bae Y a 110 6 130 6 Li Ki M H MEN GPI 1 H i 1 taga FUNCTION P CBRCECT ZEM AB 7 A i 24 i J PRESS PUMP 1 1 PSI I m 1 1 1 14 GPM i SENS NN SM OSEEEEE queen cec 6 T wj 0 1 DRIVE PUMP Cx GPM Tank 2500 I og PSI 25 4 SEQ REG 5 3 3 PSI PSI PSI Q E 2600 W O JIB 5 2900 WITH JIB mn kj e RESERVOIR AUX PUMP we ES D i 185 6 HYDRAULIC AL ROTARY COUPLER 1 STEER MANIFOLD DRIVE MANIFOLD pia 250 Sw TIAL iw 7 PSI icis t p o Lad MA 1 I I M5 1 a 4 E T A VALVE E D E lee AA A C B I 8 1 1 M3 STEERING B VALVE 2 ae 07 X L 1 Part No 34476
78. 20 seconds Platform level up 35 to 65 seconds Platform level down 25 to 55 seconds 2 2 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 2 Specifications Hydraulic Specifications Hydraulic fluid Dexron II equivalent Drive pump HYDRAULIC SPECIFICATIONS Function pump Type pressure balanced gear Type bi directional variable displacement piston pump Displacement 2500 rpm to 30 3 gallons per minute 0 to 114 7 liters per minute Maximum drive pressure 3500 psi 241 3 bar Charge pressure neutral position 340 psi 24 bar drive position 250 psi 17 bar Medium pressure filter 3 micron Medium pressure filter 50 psi bypass pressure 3 4 bar Drive manifold Brake 250 psi relief pressure 17 2 bar Steer end drive motors 4WD models Displacement 1 52 cu in per revolution 25 cc Non steer end drive motors 0 16 to 2 8 cu in 2 62 to 45 9 cc Displacement per revolution variable 4WD 2 speed motor 1 12 to 2 8 cu in 18 4 to 45 9 cc Displacement per revolution variable 2WD 1 14 cu in 19 cc Displacement static Displacement 2500 rpm Oto 12 3 gallons per minute 0 to 46 6 liters per minute Hydraulic tank circuit return line filter 10 micron with 25 psi 1 7 bar bypass Function manifold Function relief valve pressure S60 2600 psi 179 bar S65 2900 psi 200 bar Boom down 2100 psi relief valve pressure 145 b
79. 476 Genie S 60 amp Genie S 65 iii Section 1 Safety Rules Service Manual First Edition 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 should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following y Indicates the presence of a hazard that will cause death or serious injury AWARNING Indicates the presence of a hazard that may cause death or serious injury Indicates the presence of ACAUTION a hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Be sure to wear protective eye wear and other protective clothing if the situation warrants it such as moving parts free swinging or unsecured components and lifting or placing loads Always wear approved steel toed shoes 3j Be aware of potential crushing hazards zl Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage 1 Be sure that all too
80. 5 GROUND TS18 ENGINE RPM SWITCH BATTERY TS14 PLATFORM ROTATE SWITCH TS15 OPTION JIB BOOM UP DOWN SWITCH CABLE O 7 TS16 PLATFORM LEVEL SWITCH 4 Key Bypass TS17 PRIMARY BOOM UP DOWN SWITCH o IGN FUELON TS18 TURNTABLE ROTATE SWITCH TS19 BOOM EXTEND RETRACT SWITCH O to ena CIRCUIT BREAKER CONTROLS 16 CRI CR2 GRA CB2 CIRCUIT BREAKER ENGINE 15A krak Kus ne NEM EM HOUR METER RELAY RELAY CUTOUT RELAY R2 RESISTOR 10 OHM BOOM FUNCTIONS RELAY Gt VOLT METER GAGE G oL paessuae case i f G3 WATER TEMP GAGE CR5 HORN RELAY Part No 34476 Genie S 60 amp Genie S 65 6 10 Section 6 Schematics Service Manual Platform Control Box Legend Diesel Models CR15 EXT RET LOCKOUT RELAY CR13 JIB LOCKOUT RELAY CR14 PLATFORM ROTATOR RELAY oj JIB DELAY TR2 TIMER RELAY OPTION le GEN OPTION 45 GRNWHT 1 SPARE 44 GRN BLK 1 SPARE 43 GRN 1 TURN ROT 42 ORG RED 1 PULSE PICKUP 41 ORG BLK 1 LIMIT SWITCH 40 ORG 1 L P 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 GLOW
81. 7 Repair Procedures Service Manual First Edition Ford LRG 423 Engine 7 1 Governor actuator and linkage a clevis yoke Governor Actuator b linkagerod c carburetor d throttle plate shaft How to Set Up the Governor e governoractuator f tuator shaft Actuator and Linkage mim Adjustment of the governor actuator is only necessary when the governor actuator or the 4 Position the linkage rod so that the throttle is in linkage has been replaced the idle position Then adjust the clevis yoke on 1 Connect the linkage rod to the throttle plate the linkage rod to obtain the proper length shaft then tighten the lock nut Install the yoke onto the actuator arm 2 Fasten the lock nut and clevis yoke to the 5 With the throttle in the idle position and the linkage rod Do not tighten the lock nut actuator arm at a 110 degree angle to the against the clevis yoke linkage rotate the clevis yoke on the linkage rod two turns counterclockwise to pre load the 3 Loosen the fastener on the actuator arm spring Tighten the lock nut on the linkage rod Rotate the actuator arm until it is at a 110 degree angle to the linkage rod Then tighten the actuator arm fastener 7 24 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures M Ha j FORD LRG 423 ENGINE 6 Manually pull the actuator arm through a full T 2 cycle to be sure
82. ANIFOLD MASTER B A i AL PLATFORM I BRAKE N 025 LEVEL TURNTABLE BOOM PR1 PR2 PL1 PL2 51 52 EXTEND RETRACT R1 R2 1 P2 E MOTOR FUNCTION STROKE OPTIONAL 2500 2100 3 Oo MANIFOLD B t 3PSIr 1 C D PSI MOTOR GEN Bigo DE oto 50 G H a Ps E RJ 9 N E MED TEST H PRESS ro cae R E d L 1 L FILTER Du ep eee eet 80 pomo ND I 1 A PRESS CAM JUOD NIET 3500 o T y 4 Du PSE GEN 406 14 Li Ki Li d yl GP y GPM o o E FUNCTION SELECT X X Zh AAL PRES ez aS MEE uU ee ne I I I 5 psi EN 14 GPM HT y E l AI AC wj 1 04 I DRIVE PUMP T1 GPM TANK 1 2500 PSI 25 4 SEQ REG 5 PSI a 5 3 2600 W O JIB NZ 2900 WITH JIB soli e RESERVOIR AUX PUMP GAUDI HYDRAULIC 6 ROTARY COUPLER 1 STEER MANIFOLD 2 ZEE EC DRIVE I MANIFOLD 4 850 s S 7 7 4 1 RIGHT L Ms EE EM ER 4 RE 1 8 m y
83. C M 8 x 50 Torx 8 8 Injection system V belt pulley bolts 28 to 34 38 to 46 M 10 x 16 8 8 Injection pump make OMAP Part No 34476 Genie S 60 amp Genie S 65 2 7 Section 2 Specifications DEUTZ ENGINE F4L 1011 SPECIFICATIONS Bolt tightening specifications continued torque torque Bolt description size grade ft lbs Nm Idler pulley V belt pulley bolt 27 to 32 36 to 44 M 10 x 25 8 8 Idler pulley for toothed belt 30 to 36 41 to 49 M 10 x 50 8 8 Oil pump bolts 15 to 18 20 to 24 M 8 x 35 Torx Oil filter bracket bolts 7 to8 9 to 11 M 8 x 20 Torx 8 8 Oil intake housing bolts 15 to 18 20 to 24 M 8 x 75 Torx Fuel pump bolts 15 to 18 20 to 24 Injection pump bolts 15 to 18 20 to 24 Injector cap nut 30 to 37 40 to 50 Injector fastening bolt 15 to 18 20 to 24 Injection line 10to 12 13 5 16 5 Air intake manifold bolts 15 to 18 20 to 24 M 8 x 30 8 8 Air intake manifold 3 hole 15 to 18 20 to 24 flange bolts M 8 x 35 Torx 8 8 Exhaust manifold bolts 27 to 32 36 to 44 M 10 x 30 Torx 10 9 Starter fastening bolts 28 to 34 38 to 46 M 10 x 28 8 8 Starter carrier bolts 50 to 60 68 to 82 M 12 x 28 8 8 Oil pan bolts 15 to 18 20 to 24 M 8 x 16 Torx 8 8 Oil drain bolts 37 to 44 50 to 60 Service Manual First Edition 22 torque torque ft Ibs Nm Oil thermostat housing screw 37 to 44 50 to 60 plug M 38 x 1 5 Oil thermostat
84. CT pLATFORM 785 rotate O O DI R A D2 O O O PLATFORM BP1 TS7 LEVEL z a o NO P3 HORN 6 11 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 6 Schematics Pressure gauge O Filter Fixed displacement pump ki Bi directional variable displacement pump d Bi directional motor T 2 speed bi directional motor Pump prime mover engine or motor Cylinder WW Accumulator TT 0 035 Orifice with size at Variable orifice or shut off valve gt Check valve a Ia Relief valve Priority flow divider Solenoid operated dump valve Hydraulic Symbols Legend LT EW al Differenti sensing valve Solenoid operated proportional valve CX z F Flow regulator valve 47 Solenoid operated 2 pos 3 way directional valve 4 9 HAN Counterbalance valve Y Pilot operated flow control valve M Solenoid operated 2 pos 4 way directional valve S EDO Solenoid operated 3 pos 4 way directional valve DO1 gt 2 pos 3 way shuttle valve
85. EL DESCRIPTION P1 EMERGENCY STOP BUTTON KEY SWITCH TS10 AUXILIARY SWITCH TS ENGINE START SWITCH Ts12 ENGINE FUEL SELECT SWITCH Ts18 ENGINE RPM SWITCH TS14 PLATFORM ROTATE SWITCH TS15 OPTION JIB BOOM UP DOWN SWITCH TS16 PLATFORM LEVEL SWITCH TS17 PRIMARY BOOM UP DOWN SWITCH TS18 TURNTABLE ROTATE SWITCH TS19 BOOM EXTEND RETRACT SWITCH CIRCUIT BREAKER CONTROLS 15A CB2 CIRCUIT BREAKER ENGINE 15A HM HOUR METER R2 RESISTOR 10 OHM BOOM FUNCTIONS G1 VOLT METER GAGE G2 OIL PRESSURE GAGE Ga WATER TEMP GAGE 62 TS10 TS19 CR16 TURNTABLE ROTATE CUTOUT RELAY in Section 6 Schematics p Ground Control Box Legend Gasoline LPG Models GR WT 4__ GRNWHT 1 45 RED 6 GRN BLK 44 RED 7 GRN 1 RED 27 WHT 21 BLK 6 ORG RED 1 42 BLK 6 CABLE ORG BLK 1 41 OG BK 2ISM 7 WHT 6 ORG 1 40 WHT 7 BLU RED 1 39 BU RD CRT BU RD S P BU WT CR6_ BLU WHT 1 38 BU WT S P BU BKE H BLU BLK 1 37 BUBK D B BLUEH BLU t 36 BLU D B BLK RED 1 35 BK RD S P CABLE BLK WHT 1 34 6 BLK 3 ISM BLK 1 BLKCR8__ BLK
86. Edition Steer and Oscillate Manifolds 16 1 Oscillate Manifold Components The oscillate manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function 1 Diagnostic 2 Testing 2 Differential sensing valve Differential sensing 3 Check valve Dusk Oscillate check left 4 Pilot operated unloader valve 950 psi 65 Sequencing 5 Shuttle valve 2 position 3 way O uen tS ES 6 PISTON ise ne Gusts Check valve circuit 7 Check valve Eus Oscillate check right 8 Shuttle valve 2 position way Funes Unloading Plug Torque Specifications Torque 10 12 ft lbs 14 16 Nm 35 40 ft lbs 47 54 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 35 40 ft lbs 47 54 Nm 35 40 ft lbs 47 54 Nm Description Hex size Torque Description Hex size Torque SAE No 2 1 3 50 5 6 No 8 5 16 50 ft lbs 68 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm 7 50 Genie S 60 8 Genie S 65 Part No 34476 Service Manual First Edition Sec
87. KCR5__ BLKS P PWR TO PLAT WHTEH WHTCR2 21 WHTD B WHT S P IGNITION PWR RED EH 20 RED S P 12V SUPPLY GRN WHT 3 19 JIB VALVE GRN BLK 4_ GRN BLK 3 18 GR BKD B GR BKS P PLAT ROT R TS19 TS17 GRN 4 GRN 3 17 GRND B GPN S P PLAT ROT L CABLE ORG RED 4 ORG RED 3 16 OG RDD B OG RD S P PLAT LEVEL o0 1 ORG BLK 4_ ORG BLK 3 15 OG BKD B OG BKS P PLAT LEVEL DN ORG 4 ORG 3 14 ORGD B __ ORG SP PLAT LEVEL UP WHT 5 BLU RED 3 18 ENA LT WHTEH BLU WHT 3 12 BLK 5 DRV ENA TS15 TS18 BLUBLK4 BLUBLK 3 11 BU BKD B BU BKS SEC BOOM DN BLU 4 BLU 3 10 BLU D B BLU S P SEC BOOM UP TS11 BK RD CR amp BLK RED 3 8 HORN BLK WHT 4_ BLK WHT 3 8 BKIWTD B BKWT S P BOOM RETRACT O o BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND WIR 4 WHT RED 3 6 WT RD 8 P TURN ROT F C CABLE wHr Btk4_ WHTBLK 3 5 wT BKD B WT BK S P TURN ROT L TS16 TS14 2 WHT 4 WHT 3 WHTD B WHTS P TURN ROT R TS13 CB1 CB2 REDIBLES 2 nomtoa RDBKSR Pai soom DOWN RED 4 RED 3 1 REDDB RED SP PRI BOOM UP u i s 6 D 6 B A DIODE GA BLOCKS TURNTABLE ROTATE CABLE ae LABEL DESCRIPTION O 1 STARTRELAY Pi EMERGENCY STOP BUTTON TACHOMETER IGN START KS1 KEY SWITCH Ols START INPUT MODULE TS10 AUXILIARY SWITCH 911 ENGINE START SWITCH O 4 Aux
88. Manifold 10 1 Function Manifold The function manifold is located on the tank side tray behind the ground control box Index Schematic No Description Item Function Torque 1 3 position 4 way 003 valve pom Platform rotate 30 35 in lbs 3 4 Nm 2 Counterbalance valve Bu Platform level 35 40 ft lbs 47 54 Nm 3 Sandwich valve manifold B ans Platform level 4 3 position 4 way 003 valve o Platform 30 35 in lbs 3 4 Nm 5 3 position 4 way 003 valve P eon Turntable rotate 30 35 in lbs 3 4 Nm 6 Cover plate TN 30 35 in lbs 3 4 Nm 7 3 position 4 way 003 valve Bus Boom up down 30 35 in lbs 3 4 Nm 8 3 position 4 way 003 valve Boom extend retract 30 35 in lbs 3 4 Nm 9 Counterbalance valve Platform level down 35 40 ft lbs 47 54 Nm 10 Check Turntable rotate differential sensing 11 13 ft lbs 15 18 Nm 11 Check valve ores Mi aiiis Boom up down differential sensing 11 13 ft Ibs 15 18 Nm 12 Flow regulator valve Y xoi B
89. N BLK 1 SPARE 43 GRN 1 TURN ROT HI 42 ORG RED 1 PULSE PICKUP 41 ORG BLK 1 LIMIT SWITCH 40 ORG 1 LP 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 GLOW PLUG 34 BLK WHT 1 START 33 BLK 1 BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 E D C 30 WHT 1 2WD AWD 29 RED WHT 1 TILT ALARM 28 RED BLK 1 AUX PWR 27 RED 1 PWR TO F S 26 BLK F S PWR START 25 GREEN F S PWR CONT 24 WHT H P L PWR FRMPLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 21 20 JIB VALVE 19 GRNWHT 3 PLAT ROT R 18 GRN BLK 3 PLAT ROT L 17 GRN 3 PLAT LVL F C 16 ORG RED 3 PLAT LVL DN 15 ORG BLK 3 PLAT LVL UP 14 ORG 3 DRV ENA LT 13 BLU RED 3 DRV ENA 12 BLU WHT 3 SEC BOOM DN 11 BLU BLK 3 SEC BOOM UP 10 BLU 3 HORN 9 BLK RED 3 RETRACT 8 BLK WHT 3 EXTEND 7 BLK 3 TURN EXT 6 WHT RED 3 TURN ROT R 5 WHT BLI 3 TURN ROT L 4 WHT 3 PRIMARY F C 3 REDAWHT 3 PRIMARY DN 2 RED BLK 3 PRIMARY UP 1 RED 3 HORSE POWER LIMITER GRN 2 GRD STUD NC P2 STOP NC 2 2 FUEL Ts3 O SELECT O O 817 6 5 4 3 2 1 DP1 1 20 HIGH Ts4 O O RPM J FEM O TS2 START O L1 7 LED SJ T
90. N position at both the ground and platform controls Do not start the engine 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller Part No 34476 Genie S 60 amp Genie S 65 7 5 Section 7 Repair Procedures Service Manual First Edition PLATFORM CONTROLS 8 Set the dual lo range Press down the foot switch then move the control handle all the way to the RETRACT position Adjust the voltage to 9 2V DC Turn the dual range trimpot adjustment screw clockwise to increase 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 AWARNING 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 100 to 130 second cycle time 11 Start a timer and record how long it takes for the boom to fully retract Adjust the dual range trimpot to achieve an 55 to 85 second cycle time If the function cycle time is not AWARNING A achievable check the relief valve pressure See 10 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 then move the control
91. OUT CUTOUT RELAY RELAY GEN OPTION DUMP VALVE S L S POWER TURN ROT HI PULSE PICKUP LIMIT SWITCH L P GAS STEER LEFT STEER RIGHT RPM GLOW PLUG START BRAKE E D C E D C 2WD AWD TILT ALARM AUX PWR TEMP SENDER OIL PRESSURE SENDER WARNING SENDER KEYSWITCH PWR PWR TO PLAT IGNITION PWR 12V BATT SUPPLY JIB VALVE PLAT ROT R PLAT ROT L PLAT LEVEL F C PLAT LEVEL DN PLAT LEVEL UP DRV ENA LT DRV ENA SEC BOOM DN SEC BOOM UP HORN BOOM RETRACT BOOM EXTEND TURN ROT F C TURN ROT L TURN ROT R PRI BOOM PRI BOOM DOWN PRI BOOM UP O 5 Part No 34476 Genie S 60 amp Genie S 65 6 5 Section 6 Schematics Service Manual LL OCZ Relay Panel Legend Gasoline LPG Models IGNITION MODULE GOVERNOR 6 6 Genie S 60 amp Genie S 65 Part No 34476 Service Manual Section 6 Schematics Platform Control Box Legend Gasoline LPG Models CR15 EXT RET LOCKOUT RELAY CR13 JIB LOCKOUT RELAY CR14 PLATFORM ROTATOR RELAY JIB DELAY TR2 TIMER RELAY OPTION lon GEN OPTION 45 GRN WHT 1 SPARE 44 GR
92. RED BLK PRIMARY BOOM DOW p RED BLK 4 n BITTER 2 mA Xf 100i L RED WHT 4 5 2 R RED 3 E 5 RED BLK 3 e A kb t RED WHT 3 a E ORG 3 UP PLATFORM LEVEL z OWN ORG BLK 3 5 ORG o o If e 5 ORG 4 7 ip ORG BLK powy PLATFORM LEVEL ORG BLK 4 n a 4 B Ra ORG RED 4 7 n ORG RED 3 m E n e IS GRN 3 oe UP LEE JIB BOOM DOWN GRN BLK 3 gt GRN A e 5 GRN 4 E E GRN BLK powy 8 BOOM 225 GRN BLK 4 7 2 x RIGHT P Dou p PLATFORM ROTATE Lepr PLATFORM ROTATE E E 2 sz sul n E GRN WHT 3 a 2 s m e t aa m O rid d UN JIB VALVES GROUND DRIVE ENABLE LIMIT SWITCH DRIVE BRAKE VALVE TRAVEL ALARM STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH MOTOR STROKE BOOM EXTEND BOOM RETRACT TURNTABLE ROTATE R TURNTABLE ROTATE L TURNTABLE ROTATE amp EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN DESCENT ALARM PRIMARY BOOM FLOW CONTROL PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL F C PLATFORM ROTATE LEFT JIB UP PLATFORM ROTATE RIGHT JIB DOWN Genie S 60 amp Genie S 65 6 4 Part No 34476 Service Manual e NO NO 7512 CB2 LAB
93. Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires engine compartment electrical panel engine wiring harness inside of the ground control box turntable manifold wiring 2 Start the engine from the ground controls and TABLE B PROCEDURES B 8 Inspect the Tires and Wheels including lug nut torque Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion An over inflated tire can AWARNING explode and may cause death or serious injury 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 Check the pressure in each air filled tire Tires and wheels raise the boom above the turntable covers Tire size 15 19 5 NHS 3 Inspect the turntable area for burnt chafed and lire ply rating 12 pinched cables Tire pressure 85 psi 4 Lower the boom into the stowed position and SARA turn the engine off Wheel lugs 10 3 4 16 5 Inspect the following areas for burnt chafed Lug nut torque dry 420 ft lbs corroded pinched and loose wires 569 5 Nm Lug nut torque wet 320 ft Ibs cable track on the
94. S GENERATOR 20 OPTION ie 159 O DRIVE ENABLE O O O SELECT f TS1 AUX 2 JIB Tse OO O BOOM OPTION EXTEND RETRACT pLATFORM 788 O RoTATE AD2 O PLATFORM BP1 TS7 LEVEL NO P3 HORN O Part No 34476 Genie S 60 amp Genie S 65 6 7 OFF TP28 on GENERATOR RED BLK 1 RED BLK 28 E H GENERATOR VALVE OPTION TS20 TB28 HIGH RPM BLK RED 1 ENGINE SPEED 2 TS4 TP35 ENGINE SPEED HIGH RPM BLK RED NO CR4 Ux HIGH IDLE RELAY CR3 CR3 TB35 HIGH IDLE CUTOUT RELAY ES BLK RED R4 E H RPM SOLENOID CR4 NO IGN START MODULE WHT gt TP33 HOUR METER BLK 1 TS2 START OIL PRESSURE SENDER WATER TEMP o SENDER z ENGINE 10 ENG FAULT TB24 START WHT 24 E H ENGINE 1 START RELAY 2 TACHOMETER 8 KEY BYPASS r 10 9 IGN FUEL ON CR2 WTS 6 BATTERY 0 7 KEY PWR TS11 3 START INPUT 4 AUX ON 710 5 GROUND TB21 WHT 21 E H FUEL SOLENOID CR2 NO ORG RED 1 BLK 7 RED 7 GRN WHT TB42 LS1 TB43 o z CR1
95. S P WT RD EH WHT RED 1 32 WT RD D B WI BK EH WHT BLK 1 31 WHT 1 30 RED 5 RM 1 29 RD BK RED BLK 1 28 CABLE RED EH _ RED 1 27 RD 4 ISM gt RED S P 5 WT RD E H 26 WT RD S P WTIBK 25 WT BK S P WTIHOISM WHT 24 wurEH wure 28 WHT S P BLK 88 BLK 2 22 BLK S P WHTE H WHTCR2 21 WHTD B WHTS P RED 20 RED S P GRN WHT GRN WHT 3 19 GRWT S P GRN BLK 4_ GRN BLK 3 18 GR BKD B GR BK S P GRN 4 GRN 3 17 GRN D B _ GRN S P CABLE ORG RED 4 ORG RED 3 16 OG RD D B OG RD S P 1 ORG BLK4 ORG BLK 3 15 OG BK D B OG BK S P ORG 4 ORG 3 14 ORG D B ORG S P WHT 5 BLU RED 3 13 WHT E H BLUWHT 3 12 BLK 5 BLU BLK 4 BLU BLK 3 11 BU BKD B BU BK S P BLU 4 BLU 3 10 BLUD B BLU S P BK RD CR5_ BLK RED 3 9 BLKWHT BLK WHT 8 BKWTD B BKWT S P BLK 4 BLK 3 7 BLKD B BLK S P WIR 4 WHT RED 8 6 WTIRD S P CABLE wHr BLk4 WHTIBLK 3 5 WT BKD B WT BK S P 2 WHT 4 WHT 3 WHTD B WHTS P RANA RED WHT 3 3 RDMT S P RED BLK 4__ RED BLK 3 2 RD BKD B RD BK S P RED 4 RED 3 1 REDDB RED S P D DIODE a BLOCKS CABLE 3 O 1 stant RELAY 2 TACHOMETER IGN START STARTINPUT MODULE 4 AUX ON O GROUND O BATTERY O 7 KEY PWR CABLE 4 KEY BYPASS O 9 IGN FUELON 10 ENG FAULT CR1 CR2 CR3 CR4 START IGNITION RPM RPM RELAY RELAY CUTOUT RELAY RELAY CR5 CR6 CR7 HORN FUEL FUEL RELAY CUT
96. Slave 7 11 2 3 Platform Rotator ce tak APG Ee ER tenis 7 12 Jib Boom Components S 65 Models 3 1 Jib Boom 5 65 Models esssssssssseeeesee nennen nnne 7 14 3 2 Jib Boom Lift Cylinder S 65 Models sse 7 15 3 3 Jib Boom Platform Rotate Manifold Components 5 65 Models 7 16 Boom Components 4 1 Plastic Cable iir P 7 17 425 AN AA Mim Ue ee 7 17 4 3 Lift Cylinder 222 4 00 7 20 4 4 Extension Cylinders 7 20 4 5 Platform Leveling Master Cylinder sese 7 21 Turntable Covers 5 1 Turntable Covers 0001 0 anawa entes snnt 7 22 Deutz Engine FAL 1011 6 1 BPM Adjustment E Ead t Ped 7 23 622 Elex Plate tette mite aite ite LEE 7 23 6 3 Oil Temperature and Oil Pressure 7 23 Ford LRG 423 Engine FAT Governor Actuator wem ai GA A 7 24 7 2 Choke 7 25 X Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition E O OOO TABLE OF CONTENTS Section Seven Repair Procedures Ford LRG 423 Engine continued 7 3 Timing Adjustment riii iie iaaiiai aata
97. V Genie Industries Genie 60 Genie 65 _ J 2 Service Manual First Edition First Printing Part No 34476 Introduction Service Manual First Edition Genie 5 60 Genie 65 Important Read understand and obey the safety rules and operating instructions in the Genie S 60 amp Genie S 65 Operator s Manual before attempting any maintenance or repair procedure This service manual covers the Genie S 60 and Genie S 65 2WD and 4WD models introduced in 1995 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 publ
98. aa aaa nennen 7 45 B29 Tie AZ ODER assets ee aah ak AA tu tides 7 46 Part No 34476 Genie S 60 8 Genie S 65 xi Service Manual First Edition TABLE OF CONTENTS Section Seven Repair Procedures continued 4WD Steering Axle Components 14 1 Xoke and HUD t Fc rt re et s 7 47 14 2 Steering Cylinders 002042 00 aaa 7 48 1453 Tie O teal ZBIERA 7 48 Oscillating Axle Components 15 1 Oscillating Axle Lock out Cylinder 2 0 1 7 49 Steer Oscillate Manifolds 16 1 Oscillate Manifold Components 0 0 000 7 50 16 2 Valve 7 51 16 3 Directional Valve Manifold Components 7 52 16 4 Steer Manifold Components ccccccceeeeeeeeeeeeeeeecaeeeeeeeeeeeaeeseeeeeeeeeeeeee 7 54 Non steering Axle Components 17 1 Drive Motor aie see ted ne uc ea i 7 55 1 22 Torque HUD Eee tite AE o i t ee uen 7 55 2WD Drive Manifold 18 1 2WD Drive Manifold 7 56 18 2 Valve Adjustments 7 57 4WD Drive Manifold 19 1 4WD Drive Manifold 2 2 40 7 58 19 2 Valve AdjUStMents E 7 60 xii Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 2 Specifications Specifications
99. able 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 Oil type Multipurpose grease C 5 Replace the Torque Hub Oil Replacing the torque hub oil is essential for good machine performance and service life Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Torque Hubs 1 Select the torque hub to be serviced Then drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES 3 Drive the machine until one plug is at the top Turntable Rotate Torque Hub and the other is at 90 degrees 1 Secure the turntable from rotating with the turntable rotation lock pin 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole unlocked locked Apply pipe thread sealant to the plugs and 2 Remove the motor brake mounting bolts and then install the plugs then remove the motor and brake from the 5 Repeat steps 1 through 4 for all the other drive torque hub and set them to the side torque hubs Oil capacity per hub Non steer 44 fl oz 1 30 lit
100. ace the valve Counting the turns adjust the boom down relief valve item F in all the way Then operate the function down With boom fully lowered hold the function down switch Adjust the relief valve to function Operates read 2100 PSI and replace the cylinder counterbalance valve function inoperative Check for mechanical restrictions and or a condition exists in which the cylinder counterbalance valve is not allowing the cylinder to retract or the cylinder has internal defects Disconnecting hydraulic lines or adjusting the cylinder counterbalance valve in this situation can be very dangerous Please consult Genie Industries Service Department Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts omm c AZ H P M r CHART 15 Adjust the boom down With boom fully relief valve item F lowered hold the in one turn clockwise function down switch Then with pressure Adjust the relief valve to gauge still attached read 1800 psi operate the function down Continued from the previous page less than 2100 psi Remove the boom down 1 high pressure line from 2100 psi the manifold and cap the port Hold down function and recheck pressure Repair the boom lift cylinder less than 2100 psi Internal defect in manifo
101. al First Edition Section 4 Scheduled Maintenance Procedures C 13 Check and Adjust the Ignition Timing Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 C 14 Check the Engine Valve Clearances Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Workshop Manual Deutz Number 02611642 Genie part number 29789 C 15 Check the Turntable Rotation Gear Backlash The turntable rotation torque hub is mounted on an adjustable plate that controls the gap between the rotation motor gear and the turntable bearing Maintaining proper backlash of the turntable bearing is essential to safe machine operation Improper backlash could result in an unsafe operating condition and component damage See 12 1 How to Adjust the Turntable Rotation Gear Backlash TABLE C PROCEDURES Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table D Procedures D 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
102. ally override operates the rotate left directional valve po in button on end of valve spool Note overriding the valve will require two people If a helper is not avallable interchange the valve item N with a like valve item O Continued from the previous page Replace the platform rotate directional valve function inoperative Install a pressure gauge 2600 psi Interchange pressure function at the quick disconnect gr more compensating flow operates Replace defective flow coupling on the rotate control valve item U control valve function manifold and with like valve item V hold the function switch function inoperative function 2600 psi Replace rotate left directional valve Replace defective check valve Interchange check item H with like valve item L function operates function inoperative Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 5 43 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 25 Platform Rotate Right Function Inoperative Be sure all other functions operate normally If platform rotate right function operates normally from the ground controls but not from the platfor
103. anual Section 6 Schematics gt gt Ground Control Box Legend Diesel Models GRWT 4 __ GRNWHT 1 45 GEN OPTION RED 6 GRN BLK E H 44 DUMP VALVE S RED 7 GRN 1 RED 27 wHrW21 L S POWER BLK 6 ORGIRED 1 42 BLK 7 TURN ROT HI G1 CABLE gG BKEH ORG BLK 1 4 OG BKHZISM PULSE PICKUP 7 WHT 6 ORG 1 40 WHT 7 LIMIT SWITCH BLU RED 1 39 BUIRDCR7 BURDSP Lj IBUWT CRS BLUWHT 1 38 BUWTSP GAS BLU BLK 1 37 BUBK D B STEER LEFT BLUEH _ BLU 1 36 BLU D B STEER RIGHT BLKIRED 1 35 BK RDSP RPM CABLE BLK WHT 1 34 GLOW PLUG P1 KS 1 6 BLK 3 ISM _ BLK 1 33 BLK CR8 BLK S P START TS1 0 WT RD E H WHT RED 1 32 WT RD D B BRAKE ONCO WT BKE H WHT BLK 1 31 E D C NO NO WHT 1 30 RED 5 ED C RM 1 29 2WD AWD RED BLK 1 28 TILT ALARM CABLE RED EH _ RED 1 27 RD 4 ISM gt RED S P AUX PWR 5 WT RD 26 WT RD S P TEMP SENDER WTIBK E H 25 S P OIL PRESSURE SENDER WT 101SM_ WHT E H 24 WARNING SENDER WHT 2 23 WHT S P KEYSWITCH PWR BLK 2 22 BL
104. ar Part No 34476 Genie S 60 amp Genie S 65 7 57 Section 7 Repair Procedures Service Manual First Edition 4WD Drive Manifold 19 1 4WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Shuttle valve 3 position way Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path or brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm 2 Relief valve 250 psi 17 bar Charge pressure circuit 15 18 ft lbs 20 24 Nm 3 Orifice 0 052 in 1 32 mm bus Drive circuit non steer end 4 Flow divider combiner valve C RS Controls flow to steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 5 Flow divider combiner valve A idea Controls flow to non steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 6 Orifice 0 070 in 1 78 mm E ue Drive circuit steer end 7 Orifice 0 070 in 1 78 mm Gay Drive circuit non steer end 8 Flow divider combiner valve Ba Controls flow to flow divider combiner valves 4 and 5 25 30 ft lbs 34 41 Nm 9 Diagnostic T
105. ar S 60 models 2900 psi 200 bar S 65 models AB System relief 35 40 ft lbs 47 54 Nm 25 Priority flow regulator valve Trees Steering eee 10 12 ft Ibs 14 16 Nm 26 Check valve orzeka Platform rotate right differential sensing 11 13 ft lbs 15 18 Nm 27 Check valve Platform rotate left differential sensing 11 13 ft lbs 15 18 Nm 28 Check valve eese Louie Platform level differential sensing 11 13 ft lbs 15 18 Nm 7 34 Genie 5 60 amp Genie 5 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures FUNCTION MANIFOLD 6909 9 Part No 34476 Genie S 60 Genie S 65 7 35 Section 7 Repair Procedures Service Manual First Edition FUNCTION MANIFOLD 10 2 Valve Adjustments Function Manifold How to Adjust the Main 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 test port item 23 on the function manifold 2 Start the engine from the ground controls 3 Hold the retract switch with the boom fully retracted and observe the pressure reading on the pressure gauge 4 Turn the engine o
106. ar Boom extend 2100 psi 145 bar Oscillate axle 950 psi 65 bar Steer regulator 3 5 gallons per minute 13 2 liters per minute Auxiliary pump Type fixed displacement gear pump 0 152 cu in 2 5 cc Displacement static Displacement 1 4 gallons per minute 5 3 liters per minute Auxiliary pump 3000 psi relief pressure 207 bar Part No 34476 Genie S 60 amp Genie S 65 2 3 Section 2 Specifications Service Manual First Edition BOLT TORQUE SPECIFICATIONS Bolt Torque Specifications Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry inch pounds foot pounds Newton meters inch pounds foot pounds Newton meters No 10 24 43 5 60 7 2 49 6 68 8 1 4 inch 20 96 11 144 16 28 120 14 168 19 5 16 inch 18 17 23 25 34 24 19 28 25 34 3 8 inch 16 30 41 45 61 24 35 48 50 68 7 16 inch 14 50 68 70 95 20 55 75 80 109 1 2 inch 13 75 102 110 149 20 90 122 120 163 9 16 inch 12 110 149 150 204 18 120 163 170 231 5 8 inch 11 150 204 220 298 18 170 231 240 326 3 4 inch 10 260 353 380 515 16 300 407 420 570 7 8 inch 9 430 583 600 814 14 470 637 660 895 1 inch 8 640 868 900 1221 12 700 949 1000 1356 Torque specifications for lubricated bolts are 25 less than dry torque specifications for each bolt size These bolt torque specifications are for general use only Specification may vary depending on a
107. aulic hoses from the manifold ports PL1 amp PL2 Plug the hoses and cap the manifold fittings Operate boom up function and check if platform levels m into the master cylinder PSI barrel end hydraulic hose using a tee fitting Operate boom up function and read the pressure less than 2400 psi Deadhead the pressure gauge into the barrel end hydraulic hose from legs the master cylinder and than gauge during boom up o not allow the pressure to exceed 2500 psi 2400 psi or more Repair or replace the slave cylinder Chart 21 Repair org red wire circuit from TB16 to flow control valve infinite Remove both wires from ohms valve coil and check ams Replace the coil Plumb a pressure gauge 2400 Replace the counterbalance valves items B amp C or valve block A Check for mechanical restrictions OR replace the slave cylinder counterbalance valves raise the boom one inch at a time Continually 2400 psi monitor the pressure Repair or replace the master cylinder Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 22 Platform Level Up Function Inoperative Be sure all other functions operate normally If platform level up function operates normally from the ground controls but not from the platform controls troubleshoot the pla
108. auxiliary Ramp rate 5 seconds f terminal ground g terminal battery positive h terminal A proportional output i threshold adjustable trimpot j max out adjustable trimpot 4 Setthe preliminary ramp rate Turn the trimpot adjustment screw clockwise 15 turns or until Boom Extend Retract Controller you hear a repeated click Adjustments 5 Connect the red lead from a volt meter to the A terminal on the controller printed circuit Pe nob board Connect the black lead to ground controllers unless the static battery voltage is above 6 Set the threshold Press down the foot switch 12V DC and the alternator then slowly move the control handle off center is operating properly with until the moment a voltage reading appears 13 6 to 14 5V DC output Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Electrocution hazard Contact AWARNING with electrically charged circuits may result in death or serious injury Remove all rings watches 7 Set the max out Press down the foot switch and other jewelry then move the control handle 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 2 Turn the key switch to platform control and voltage pull out the Emergency Stop button to the O
109. auxiliary power will stop the engine immediately Auxiliary power is designed for short term emergency 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 oN position 2 Simultaneously hold the auxiliary power switch ON while activating the following functions through a partial cycle jib boom up down S 65 models boom up down extend and retract turntable rotate right left Result Each function should operate smoothly 4 6 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 3 Turn the key switch to platform control 4 Atthe platform controls pull out the Emergency Stop button to the oN position then press down the foot switch 5 Simultaneously hold the auxiliary power switch on while activating the following functions through a partial cycle jib boom up down S 65 models boom up down extend and retract turntable rotate right left steer right left Result Each function should operate smoothly TABLE A PROCEDURES A 13 Test the Tilt Sensor The tilt sensor sounds an alarm in the platform when the incline of the turntable exceeds 4 5 degrees Select a level test area The tilt alarm should not be sounding prior to test 1 Start the engine from the platform controls 2 Ope
110. blu blk wire circuit from steer Switch to TP37 to TB37 Repair open in blu blk wire circuit from TB37 lo steer valve 0 or infinite ohms Replace steer right valve coil Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts All Drive Functions inoperative All Other Functions Operate Normally Be sure the hydraulic suction line valve is in the open position Be sure machine is not in the free wheel configuration Start engine from ground controls and standing clear of the tires momentarily move pump control override lever in each direction machine moves Move to platform ress down foot switch old drive enable switch to either side and try to drive machine drives no drive Disconnect drive pump electronic displacement controller EDC wires Check resistance across both wires on EDC side of quick disconnect Oor infinite 20 to 24 ohms Press down foot switch and check voltage at horsepower limiter board terminal 1 12V or more Continued on the next page machine does not move Place a jumper wire between TB30 and TB12 and test drive without holding drive enable switch Chart 31 Repair or replace the drive pump Repair open in no drive dc Bk wht wire circuit from TP30 to TB30 machine drives Replace drive enable limit switch OR repair open in wire c
111. brake release 2 Counterbalance valve A us Turntable rotate right 3 Counterbalance valve Bau Turntable rotate left 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 SAE No 8 5 16 50 ft lbs 68 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm 10 13 ft lbs 14 18 Nm 35 40 ft lbs 47 54 Nm 35 40 ft lbs 47 54 Nm Part No 34476 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Service Manual First Edition 2WD Steering Axle Components 13 1 Yoke and Hub How to Remove the Yoke and Hub 1 Remove the retaining bolt then the pivot pin from both the steering cylinder and the tie rod tie rod axle king pin retaining bolt yoke hub pivot pin retaining bolt steering cylinder 2 Loosen the wheel lug nuts Do not remove them 3 Block the non steering wheels and then center a lifting jack of ample capacity under the steering axle 4 Raise the machine 6 inches 15 cm and place blocks under the chassis for support 5 Remove the lug nuts then the tire and wheel assembly Remove the retaining bolts from the king pins 7 Attach a strap from a lifting device to the yoke hub assembly for support 8 Use a slide hammer to remove the upper king pin then use a sof
112. cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often The machine uses Dexron II 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 quarterly testing B 26 thereafter should be completed Perform this procedure with the boom in the stowed position 1 Close the two hydraulic shutoff valves located at the hydraulic tank closed Component damage hazard The ACAUTION engine must not be started with the hydraulic tank shutoff valves in the CLOSED 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 2 Remove the drain plug from the hydraulic tank 3 Completely drain the tank into a suitable container See capacity specifications listed below 4 Disconnect and cap the two suction hoses that are attached to the hydraulic tank shutoff valves 5 Remove the strainer assemblies from the tank 6 Carefully clean any foreign material from the strainers Clean the strainers from the inside out 7 Apply pipe thread sealant to the strainer mounting threads and then install them 8 Apply pipe th
113. ch to LPG 12V Be sure to check LPG fuel level With keyswitch on and Repair open in blu red both mushroom oV wire circuit from fuel switches pulled out select switch to TP39 to check voltage at TB39 TB39 12V With keyswitch on and 0 Repair open blu red both mushroom wire circuit from TB39 to switches pulled out terminal 30 on CR7 check voltage at terminal 30 on CR7 12V Crank engine for 15 0 Repair open red blk seconds and check wire circuit from vacuum voltage at terminal 86 switch to CR6 to CR7 on CR7 12V Check ground wire to bad Repair open in ground terminal 85 on CR7 to terminal 85 on CR7 good Continued on the next page NSE A 5 14 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 4 Continued from the Hold start switch and Replace CR7 relay check voltage at previous Pads terminal 87 on CR7 Hold start switch and Repair open in blu red check voltage at blu red wire circuit from CR7 wire on LPG solenoid terminal 87 to LPG solenoid Oor infinite ohms Check resistance of LPG solenoid 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 34476 Genie S 60 amp Genie S 65 5 15 Section 5 Troubleshooting Flow Charts
114. consult Genie Industries Service Department 2100 CHART 16 Counting the turns adjust the boom extend relief valve item D in all the way Then operate the extend function With boom fully extended hold the extend function switch Adjust the relief valve to read 2100 PSI and replace the cylinder counterbalance valve function operates function inoperative Check for mechanical restrictions and or the cylinder has internal defects Please consult Genie Industries Service Department With boom fully extended hold the extend function switch Adjust the relief valve to read 1200 psi Repair the cylinder and or replace cylinder counterbalance valves Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 17 Boom Retract Function Inoperative Be sure all other functions operate normally including boom extend function If boom retract function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom retract function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch or CR16 relay See Repair section Repair open in blk wht wire circuit from TB8 to directional valve Hold ground control function switch and check volts at blk wht
115. control toggle switch or CR16 relay See Repair section Chart 18 Hold ground control function switch and check volts at wht red Repair open in wht red wire circuit from TB6 to proportional valve OR wire on turntable rotate function proportional valve replace 10 ohm resistor at ground control box 4to 7V Oor Remove both wires infinite from valve coil and ohms 3 check resistance across Replace the coil the coil terminals 4 5 to 5 5 ohms Hold toggle switch and function Replace defective manually override operates proportional valve proportional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item Z with a like valve item AA function inoperative Interchange rotation function operates Replace defective flow regulator valve function flow regulator valve item X with a like valve item Y function inoperative 0 or Hold toggle switch to function Check the resistance hare Replace the defective left and manually operates of the directional ONMS__ valve coil s override rotate left valve coils directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item P with a like valve item S 4 to 5 ohms Replace the valve function inoperati
116. ctions 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 engine idle control switch to foot switch activated high idle rabbit and foot switch then lower the boom into the stowed position 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 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 Gasoline LPG models 40 f 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 1 sec 12 2 m 6 8 sec 12 2 m 9 1 sec Deutz Diesel models Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 25 Test the Alarm Package Optional Equipment The alarm package includes travel alarm descent alarm flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable covers The alarms and beacon will operate with the engine running or not running 1 Atthe ground controls pull out the Emergency Stop
117. 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 raise Adjust the max out trimpot to achieve a 55 to 85 second cycle time 11 Start a timer and record how long it takes for the boom to fully lower Adjust the dual range trimpot to achieve an 90 to 120 second cycle time If the function cycle time is not achievable check the relief valve pressure See 10 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 then move the control handle all the way to the uP position Record the maximum voltage reading 15 Start the engine PLATFORM CONTROLS 16 Start a timer and simultaneously move the control handle all the way to the uP position Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp speed 17 Set the ramp rate turn the trimpot to obtain a 3 to 4 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Boom up down specifications Threshold 3 5V DC 8 5V DC 55 to 85 seconds Boom up hi range Cycle time 6 2V DC 90 to 12
118. e less than 2600 psi Check steer functions steering operates steering inoperative Check the function pump see Repair section Replace the relief valve OR manifold has internal defects consult Genie Industries Service Department Replace the pump Chart 11 Repair or replace differential sensing valve item AC OR repair or replace flow regulator valve item W OR manifold has internal defect consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 12 Ground Does the engine start Start the engine from Repair open in red wire from the ground the ground controls and circuit from key switch Controls controls check the voltage on to function switches the center pole red Inoperative wire of the platform Platform level switch Controls Operate Troubleshoot the Normally functions individually Be sure all other Check voltage at red functions operate wire on ground controls Repair open in red wire normally including R A ja circuit fon emergency platform controls checked should stop button to the originate at the key switch emergency stop button Check voltage at red Check if key switch Replace key switch wire at ground controls internal cam is contact for ground contact on the key activating ground controls switch contact Replace key switch Repair open in
119. e Yoke ACAUTION hydraulic oil can penetrate and and Hub burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray The yoke installation utilizes bushings and a thrust washer that may require periodic replacement The yoke must be removed before the torque hub can be removed 4 Loosen the wheel lug nuts Do not 1 Start the engine from the ground controls remove them Rotate the turntable until the platform is between the steer tires 5 Block the non steering wheels and then 2 center a lifting jack of ample capacity under the 2 Remove the pin retaining fasteners then steering axle remove the pivot pin from both the steering cylinder and the tie rod 6 Raise the machine 15 inches 38 cm and place blocks under the chassis for support 7 Remove the lug nuts then remove the tire and wheel assembly 8 Remove the hydraulic hose mounting bracket from the top of the yoke 9 Remove the roll pin from the upper king pin 10 Remove the retaining bolts from the upper and lower king pins 11 Remove the drive motor mounting fasteners 12 Slide the drive motor shaft out of the brake and then remove it 13 Attach a strap from a lifting device to the yoke torque hub assembly for support oscillate cylinder king pin torque hub yoke pivot pin tie rod steer cylinder 34476 Genie 5 60 Genie 5 65
120. e directional valve OR the manifold has internal defects OR Consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 20 Turntable Rotate Right Function Inoperative Be sure all other functions operate normally including turntable rotate left function If turntable rotate right function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If turntable rotate right function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check volts at wht wire on rotate function directional valve 12V 0 or Remove both wires from infinite rotate right valve coil and check resistance across the coil terminals ohms 4 to 5 ohms Hold toggle switch right and manually override rotate right directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item P with a like valve item S function inoperative 2400 Install a pressure gauge psi at the quick disconnect coupling on the function manifold and hold the function switch less than 2400 psi R
121. e engine from the ground controls 7 Inspect the filter assembly to be sure that there are no leaks Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES C 8 Replace the Diesel Fuel Filter Deutz Diesel Models Replacing the diesel 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 Engine fuels are combustible 1 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 Turn the manual fuel shutoff valve located at the fuel tank to the cLosep position 2 Remove the fuel filter with a filter wrench fuel filter oil filter o m 3 Apply a thin layer of oil or diesel fuel to the new fuel filter gasket 4 Install the new filter part no 29560 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 then inspect the fuel filter for leaks If a fuel leak is discov
122. e filter then remove the fitting from the filter 7 Start the machine from the ground controls then inspect the fuel filter and hose for leaks 3 Remove the filter from the carburetor If a fuel leak is discovered keep 1217 any additional personnel from entering the area and do not operate the machine Repair the leak immediately 8 Swing the engine pivot plate back to its original position and replace the two retaining bolts Part No 34476 Genie S 60 amp Genie S 65 4 33 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES C 10 2 Remove the hose from the PCV valve then the valve Replace the PCV Valve Gasoline LPG Models Yearly replacement of the PCV valve is essential to good engine performance A malfunctioning valve can impair crankcase ventilation and may cause engine damage Perform this procedure with the engine off 1 Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV valve PCV valve SA 3 Install the new PCV valve Connect the hoses 4 Swing the engine pivot plate back to its original IT JM UJ EFA N position and replace the two retaining bolts a pivotplate retaining bolts b engine pivot plate 4 34 Genie 5 60 amp Genie 5 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures
123. e of the cooling system Do not inspect while the engine AWARNING is running Remove the key to secure from operation ACAUTION Beware of hot engine components Contact with hot engine components may cause severe burns 4 12 Genie 5 60 8 Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Oil Cooler 1 Remove the cover from the side of the engine then remove the oil cooler top cover 2 Inspect the oil cooler for leaks and physical damage D Ir A 4 ioe a oilcooler b cylinder head cooling fins c blowerfins 3 Clean the oil cooler of debris and foreign material Cooling and Blower Fins 4 Inspect the blower fins for physical damage 5 Clean the blower fins of debris and foreign material 6 Inspect the head cooling passages and fins for physical damage or foreign material using a flashlight 7 Clean the cylinder head cooling passages of debris and foreign material TABLE B PROCEDURES B 4 Check the Exhaust System Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions Do not inspect while the engine AWARNING is running Remove the key to secure from operation Beware of hot engine CAUTION components Contact with hot engine components may cause se
124. e the coil Replace the platform rotate directional valve Repair open in grn wht wire circuit from CR14 to jib boom manifold valves OR replace CR14 or TR2 time delay relay OR consult Genie Industries Service Department ohms Replace the coil Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Install a pressure gauge at the quick disconnect coupling on the rotate function manifold and hold the function switch Continued from the previous page Replace the platform rotate directional valve less than 2600 psi Interchange check valve function item with like valve operates item L function inoperative Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department CHART 25 Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 26 Jib Boom Up Function Inoperative S65 Models Be sure all other functions operate normally If jib boom up function operates normally from the ground controls but not from the platform controls troubleshoot the platform control toggle switch or CR13 See Repair section If jib boom up function operates normally fro
125. e the drain valve Connect the coolant return hose to the radiator 7 Open the drain valve on the engine block and allow the coolant to drain into a container After the fluid is drained close the drain valve Replace all coolant hoses and clamps Pour the proper coolant mixture anti freeze and water for your climate into the radiator until it is full a upperhose b lowerhose 11 Fill the radiator and then fill the coolant recovery tank to the NORMAL range 12 Clean up any coolant spilled during this procedure 13 Start the engine from the ground controls run it for 30 seconds and then turn it off 14 Inspect for leaks and then check the fluid level in the coolant recovery tank Add water if needed 15 Start the engine from the ground controls and run it until reaching normal operating temperature 16 Allow engine to cool and check the fluid level in the coolant recovery tank Add water if needed Ford Engine Coolant capacity 11 5 quarts 10 9 liters Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures D 3 Change the Fuel Lines Maintaining the fuel lines in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel line may cause an unsafe operating condition ADANGER Engine fuels are combustible BLAA Replace the fuel lines an open
126. each wire combination listed below and check for continuity Test Desired result green to black no continuity infinite green to white no continuity black to white continuity zero Q 7 8 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 1 4 Resistors The resistors are used on 4WD machines to maintain low range drive speed The resistors are located in the platform control box Refer to the schematic legends for resistor locations and values How to Test the Resistors 1 Turn the key switch to the orr position 2 Disconnect either end of one of the wires connected to the resistor to be tested 3 Connect the leads from an ohmmeter to each end or wiring of the resistor being tested 4 Compare the ohmmeter reading with the resistance rating printed on the resistor 1 5 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
127. ealer Table A Tools are New parts engine engine service required required required required suggested A 1 Inspect the Manuals A 2 Inspect the Decals and Placards A 3 Inspect for Damage Loose or Missing Parts LOS A 4 Check the Engine Cil Level A 5 Check the Engine Coolant Level Gasoline LPG Models ZS A 6 Check for Fuel Leaks A 7 Check the Hydraulic Oil Level A 8 Check for Hydraulic Leaks A 9 Check the Tire Pressure A 10 Test the Oscillate Axle A 11 Test the Platform and Ground Controls A 12 Test the Auxiliary Power Operation A 13 Test the Tilt Sensor A 14 Test the Limit Switches 3 2 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Table A continued Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES Warm Gold Dealer engine engine service required required suggested Every 100 hours perform the following two engine maintenance procedures A 15 Replace the Engine Oil and Filter U Gasoline LPG Models A 16 Replace the Engine Air Filter 1 Check the Engine Belt s B 2 Check the Radiator m Gasoline LPG Models B 3 Check the Oil Cooler and Cooling Fins w T Deutz Diesel Models B 4 Check the Exhaust System B 5 Check the Battery B 6 Check the Hydraulic Tank Filter Condition Indicator B 7 Inspect the Electrical Wiring B 8 Inspect the Tires and Wh
128. ection 7 Repair Procedures Non steering Axle Components 17 1 Drive Motor Component damage hazard Repairs to the motor should only be performed by an authorized Sundstrand Sauer dealer How to Remove a Drive Motor ACAUTION A drive motor can only be removed from the inside of the chassis Component damage hazard The ACAUTION 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 1 Disconnect the hydraulic hoses from the drive motor and plug them Bodily injury hazard Spraying ACAUTION 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 drive motor mounting bolts 3 Slide the drive motor shaft out of the brake and 17 2 Torque Hub How to Remove a Drive Torque Hub 1 Remove the drive motor See 17 1 How to Remove a Drive Motor 2 Disconnect the hydraulic hose from the brake and plug it Then remove the hydraulic fitting and the bleed valve 3 Loosen the wheel lug nuts Do not remove them 4 Center a lifting jack under the non steering axle Raise the machine and place blocks under the drive chassis to support it 5 Remove the wheel lug nuts then the tire and wheel assembly 6 Place a second lifting jack und
129. ed 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 Start the engine from the platform controls 2 Without pressing down the foot switch check the machine functions Result The machine functions should not operate 3 Press down the foot switch and operate the machine functions Result The machine functions should operate B 20 Test the Engine Idle Select 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 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 selection activates high idle only when the foot switch is pressed down 1 Pull out the Emergency Stop button to the ON position at both t
130. ed 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 maintenance 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 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety information and step by step instructions Symbols Legend revs Indicates the presence of a 421114023 hazard that will cause death or serious injury Indicates the presence of a AWARNING P hazard that may cause death or serious injury Indicates the presence of a ACAUTION s hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information O Indicates that a specific result is expected after performing a step Part No 34476 Genie S 60 8 Genie S 65 4 1 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table A Procedures A 1 Inspect the Manuals Maintaining the operators and safety manuals in good condition is essential to
131. eels U including lug nut torque B 9 Confirm the Proper Brake Configuration B 10 Check the Oil Level in the Torque Hubs B 11 Check and Adjust the Engine Idle Mixture Gasoline LPG Models B 12 Check and Adjust the Engine RPM Part No 34476 Genie S 60 amp Genie S 65 Section 3 Scheduled Maintenance Inspections Service Manual First Edition _ _ MAINTENANCE TABLES 1 W Cold Dealer Table B continued Tools are New parts ma engine rni required required required required suggested B 13 Test the Key Switch B 14 Test the Emergency Stop Buttons B 15 Test the Ground Control Override B 16 Check the Directional Valve Linkage B 17 Test the Platform Self leveling B 18 Test the Service Horn B 19 Test the Foot Switch B 20 Test the Engine Idle Select B 21 Test the Fuel Select Operation Gasoline LPG Models B 22 Test the Drive Enable System B 23 Test the Drive Brakes ra B 24 Test the Drive Speed Stowed Position B 25 Test the Alarm Package n Optional Equipment B 26 Perform Hydraulic Oil Anaysis See D 1 Test or Replace the Hyaraulic Oil Every 500 hours perform the following engine maintenance procedure B 27 Replace the Engine Oil and Filter Deutz Diesel Models 3 4 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES N
132. emove the pivot pin from each end of the tie rod 2 Remove the tie rod How to Perform the Toe in Adjustment Perform this procedure on a firm level surface Block the non steering tires and be sure that the machine is in the stowed position 1 Straighten the steer wheels 2 Measure the steer tires front to front and back to back using a measuring fixture Toe in specification Center a lifting jack of ample capacity under the steering axle then raise the machine Loosen the jam nut on the adjustable end of the tie rod Remove the pin retaining fasteners then remove the pivot pin from the adjustable end of the tie rod Slide the tie rod off the yoke and adjust it by turning the end One turn on the adjustable end equals approximately 1 8 inch 3 2 mm change in the front and rear measurements Slide the tie rod onto the yoke Install the pivot pin then install the retaining bolt Tighten the jam nut against the tie rod Lower the machine and recheck the front and back measurements step 2 If further adjustment is needed repeat steps 3 through 8 0 1 8 inch 6 35 mm 7 46 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 4WD Steering Axle Components 14 1 3 Disconnect and plug the hydraulic hoses from the wheel motor Cap the wheel motor Yoke and Hub hydraulic fittings Bodily injury hazard Spraying How to Remove th
133. emove the rotate right function pressure line from the manifold and cap the port S1 2400 Then with pressure psi gauge still attached Operate the function less than 2400 psi Replace the directional valve OR the manifold has internal defects function operates Repair open in wht wire circuit from TB4 to directional valve Replace the valve coil Replace the rotate directional valve Interchange the rotate right and left counterbalance valves Replace defective P counterbalance valve item A and item B on turntable rotation motor function inoperative Check for mechanical restrictions keeping turntable from rotating right OR replace directional valve OR repair rotation motor Repair rotation motor Consult Genie Industries Service Department Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts All Platform Leveling Functions Inoperative Be sure all other functions operate normally Be sure both automatic and manual platform leveling do not operate If automatic leveling operates but manual leveling does not troubleshoot Platform Leveling Up Function Inoperative Hold ground control oV function switch and check voltage at org red wire on platform level flow control valve item J 12V Oor resistance across coil terminals 4 to 8 ohms Remove both hydr
134. end Gasoline LPG Models 6 7 Electrical Schematic Diesel Models 8 6 8 Ground Control Box Legend Diesel Models 6 10 Platform Control Box Legend Diesel 6 11 Hydraulic Symbols enne enne 6 12 2WD Hydraulic Schematic Non oscillating axle 6 13 2WD Hydraulic Schematic Oscillating axle sees 6 14 4WD Hydraulic Schematic Non oscillating 6 15 4WD Hydraulic Schematic Oscillating 2 6 16 Part No 34476 Genie S 60 amp Genie S 65 ix Service Manual First Edition 222 TABLE OF CONTENTS Section Seven Repair Procedures Intro QUGllOn u EEA n RENEE 7 1 Platform Controls 1 1 Joystick Controllers esistente 7 2 1 2 Horsepower Limiter enn 7 6 1 3 7 8 1 4 3BOSISIOIS i eet een eed Akai At A te edes 7 9 1 5 gt Toggle ae sai ali O tec Lb snae dene 7 9 1156 2 2G ontrol HelayS stat 7 10 Platform Components 2517 Platform ot E 7 11 2 2 Platform Leveling
135. epair open in wht blk function switch and wire circuit from TBS to check volts at wht blk directional valve wire on rotate function directional valve 0 or Remove both wires from infinite rotate left valve coil and ohms check resistance across Replace the valve coil the coil terminals 4 to 5 ohms function Hold toggle switch left Replace the rotate and manually override Per2teS directional valve rotate left directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item P with a like valve item S function inoperative Install 2400 nstall a pressure gauge psj at the quick disconnect coupling on the function manifold and hold the function switch function operates Interchange the rotate left and right counterbalance valves item A and item B on turntable rotation motor Replace defective counterbalance valve function inoperative less than 2400 psi Check for mechanical restrictions keeping turntable from rotating left OR replace directional valve OR repair rotation motor Repair rotation motor Remove the rotate left function pressure line from the manifold and cap the port S2 Then with pressure gauge still attached operate the function less than 2400 psi Replace th
136. er the torque hub for support 7 Remove the bolts that attach the torque hub to the chassis then remove the torque hub Crushing hazard The torque ACAUTION hub will fall if it is not properly supported when the mounting bolts are removed Torque specifications Lug nut dry 420 ft Ibs then remove it 569 5 Nm Lug nut lubricated 320 ft lbs Torque specifications 433 9 Nm Drive motor mounting bolts 75 ft lbs Drive torque hub mounting bolts 120 ft lbs 102 Nm 163 Nm Drive motor mounting bolts 75 ft lbs 102 Nm Part No 34476 Genie S 60 amp Genie S 65 7 55 Section 7 Repair Procedures Service Manual First Edition 2WD Drive Manifold 18 1 2WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item 1 Relief valve 250 psi 17 bar Bes 2 Shuttle valve 3 position way 3 Orifice 0 070 in 1 78 mm Dui 4 Flow divider combiner valve Gie 5 Diagnostic 000 11 Function Torque Charge pressure circuit 15 18 ft lbs 20 24 Nm Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path or brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm Drive circuit Controls flow to drive motors in forward and reverse 25 30 ft Ibs 34 41 Nm Testing
137. er tires 9 Lift the wheels off the ground and then place jack stands under the drive chassis for support 10 Disengage the torque hubs by turning over the torque hub disconnect caps on each steer wheel hub TEE disengage position A rz X 2 engage position Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the torque hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the jack stands Collision hazard Failure to AWARNING re engage the torque hubs may cause death or serious injury and property damage All models 13 Be sure the free wheel valve on the drive pump is closed clockwise a drive pump b free wheelvalve screwdriver d liftpump The free wheel valve should always remain closed TABLE C PROCEDURES C 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 improperly 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 turnt
138. erchange flow regulator valve item X with a like valve item Y function Replace defective flow operates regulator valve function inoperative 0 or Check the resistance of infinit function reet iniinite Replace the defective operates neon vave ohms valve coil Hold toggle switch and manually override extend directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item S with a like valve item P 4 to 5 ohms Replace the valve function inoperative Continued on the next page Genie 5 60 amp Genie 5 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Continued from the previous page Install a 0 to 3000 PSI pressure gauge at the quick disconnect coupling on the function manifold and hold the function switch less than 2100 psi Adjust the boom extend relief valve item D in one turn clockwise Then with pressure gauge still attached operate the function less than 2100 psi Remove the extend function pressure line from the manifold and cap the port Then with pressure gauge still attached operate the function psi less than 2100 psi Internal defect in manifold OR one of the previous tests involving the pump or manifold components was possibly overlooked or diagnosed incorrectly Recheck and or
139. ered keep 3 any additional personnel from entering the area and do not operate the machine Repair the leak immediately C 9 Replace the Gasoline Fuel Filter Gasoline LPG Models 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 Engine 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 gt a Perform this procedure with the engine off Genie S 60 8 Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures TABLE C PROCEDURES Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the fuel filter located near the carburetor Aa d T Du sig fuel filter hose from the fuel pump to the fuel filter om 4 Install the fitting into the new fuel filter then install the fiter into the carburetor 5 Connect the fuel hose to the filter a pivotplate retaining bolts b engine pivot plate 6 Clean up any fuel that may have spilled during the installation procedure 2 Disconnect the fuel hose from th
140. ers Steer 44 fl oz 1 30 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 motor brake mounting bolt motor torque hub torque hub mounting bolt plug brake 3 Remove the torque hub mounting bolts then use a lifting device to remove the torque hub from the machine 4 Remove the plug from the side of the torque hub Then drain the oil from the hub 5 Install the torque hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters 4 30 Genie S 60 8 Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 6 Install the brake and motor onto the torque hub 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 plugs and then install the plugs 17 fluid ounces 0 51 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 C 6 Replace the Hydraulic Tank Filter Replacement of the hydraulic tank 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 Beware of hot oil Contact with ACAUTION hot oil may cause severe burns Perform this procedure with the engine of
141. ers sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach The engine rpm needs to be preset for gasoline fuel operation before adjusting the LPG idle mixture Refer to B 12 Check and Adjust the Engine RPM The engine should be warmed to normal operating temperature before performing this procedure 1 Move the fuel select switch to LPG fuel and start the engine from the ground controls 2 Loosen the high idle mixture adjustment lock nut a highidle mixture adjustment screw Load the system by pressing the boom retract switch then move the engine idle control switch to high idle rabbit symbol Adjust the high idle adjustment screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 using an exhaust gas analyzer Preliminary setting is inch of threads showing Measure from top of lock nut to top of adjustment screw If an exhaust gas analyzer is not available adjust to obtain peak or optimum rpm Hold the adjustment screw and tighten the lock nut Move the engine idle control switch to low idle turtle symbol and adjust the low idle screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 a lowidle mixture adjustment screw Preliminary setting turn low idle adjustment screw clockwise all the way in Turn low idle adjustment screw counterclockwise 2 turns 4 36 Genie S 60 amp Genie S 65 Part No 34476 Service Manu
142. ery to GR2 CB1 to CR1 to CR2 g Hold start switch and 0 check voltage at terminal 486 of CR2 Hold start switch and check voltage at terminal 9 on start lockout module Repair open in blk wire from terminal 486 on CR2 to terminal 9 on start lockout module Check voltage at Repair open in power terminal 6 and 7 on supply wires to terminal start lockout module 6 and 7 on start lockout module Check ground wire Repair open in ground 12V terminal 5 on start circuit to terminal 5 on lockout module start lockout module Check 3 amp fuse on ignition module OR replace the start lockout module OR consult Genie Industries Service Department w Check ground to no good Repair open in ground terminal 485 on CR2 wire to CR2 good Continued on the next page RET di 5 12 Genie 5 60 amp Genie 5 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts eo CHART 3 Continued from the previous page Crank engine and check gy voltage at terminal 2 on start lockout module 6 to 7V While cranking engine for 15 seconds check yes continuity to ground on terminal 10 on start lockout module Is continuity maintained no Check voltage at 12V terminal 4 on start lockout module Replace start lockout module OR consult Genie Industries Service Department
143. essure 3626 psi 250 bar Number of cylinders 4 1 Fuel requirement diesel number 2 D Bore and stroke 3 58 x 4 13 inches 91 x 105 mm Alternator output 55A 14V Horsepower 56 3000rpm Starter motor Firing order 1 3 4 2 Current draw no load 90A Compression ratio 18 5 1 Brush length new 0 7480 in 19mm Compression pressure 362 to 435 psi 25 to 30 bar Brush length minimum 0 5 in 12 7 mm Low idle 1300 rpm Battery High idle 2300 rpm g P Type 12V Group 31 Governor centrifugal mechanical Quantity 1 Valve clearance cold 7 Cold cranking ampere 1000A Intake 0 012 in 0 3 mm Reserve capacity 25A rate 200 minutes Exhaust 0 020 in Fan belt deflection 3 8 to 1 2 inch 0 5 mm 9 to 12 mm Lubrication system Bolt tightening specifications torque torque Oil pressure 26 to 87 psi Bolt description size grade ft lbs Nm 1 8 to 6 0 bar Camshaft thrust bearing bolt 15 to 18 20 to 24 Oil capacity 11 quarts 8 x 35 8 8 including filter 10 5 liters Rocker arm bolts 15 to 18 20 to 24 Oil viscosity requirements M 8 x 45 8 8 Temperature below 60 F 15 5 C synthetic 5W 30 Rocker arm set screw nut 15 to 18 20 to 24 10 F to 90 F 23 C to 32 C 10W 40 Cylinder head cover 6 to 7 8 to 10 Temperature above 4 F 34 C 15W 40 Blower rotor nut 33 to 41 45 to 55 M 17 Valeo or M 18 Bosch Engine oil should have properties of API classification CC SG or CD SG grades Blower carrier bolts 15 to 18 20 to 24 Units ship with 10W 40 SG C
144. essure to dissipate gradually Do not allow oil to squirt or spray Part No 34476 Genie S 60 amp Genie S 65 7 11 Section 7 Repair Procedures Service Manual First Edition PLATFORM COMPONENTS 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 switch up and down through two platform leveling cycles to remove any air that might be in the system 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator Component damage hazard Mark ACAUTION 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 1 Remove the platform See 2 1 How to Remove the Platform 2 Disconnect and plug the hydraulic hoses from the platform rotator manifold Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to a
145. esting 7 58 Genie 5 60 amp Genie 5 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 4WD DRIVE MANIFOLD o C gt 34476 Genie 5 60 amp Genie 5 65 7 59 Section 7 Repair Procedures Service Manual First Edition 4WD DRIVE MANIFOLD Plug Torque Specifications 6 Restart the engine Drive the machine in either direction and recheck the valve pressure Description Hex size Torque 7 Turn the engine off then remove the SAE No 2 1 8 50 in lbs 6 Nm pressure gauge SAE No 4 3 16 13 ft Ibs 18 Nm Relief valve specifications SAE No 6 1 4 18 ft Ibs 24 Nm Pressure 250 psi SAE No 8 5 16 50 ft lbs 68 Nm En SAE No 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm 19 2 Valve Adjustments How to Adjust the Charge Pressure Relief Valve 1 Connect a O to 600 psi 0 to 41 bar pressure gauge to the test port located on the drive manifold ACAUTION 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 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 4 Turn the engine off Hold the relief valve and remove the cap index 2
146. ew parts engine engine service required required required suggested C 1 Check the Boom Wear Pads C 2 Check the Turntable Rotation Bearing Bolts C 3 Check the Free wheel Configuration C 4 Grease the Turntable Rotation Bearing and Rotate Gear C 5 Replace the Torque Hub Oil gt FA C 6 Replace the Hydraulic Tank Filter Le C 7 Replace the Drive Loop Hydraulic Filter Le C 8 Replace the Diesel Fuel Filter Deutz Diesel Models C 9 Replace the Gasoline Fuel Filter Gasoline LPG Models Le C 10 Replace the PCV Valve Gasoline LPG Models Le C 11 Replace the Spark Plugs Gasoline LPG Models o C 12 Check and Adjust the Air LPG Mixture Gasoline LPG Models C 13 Check and Adjust the Ignition Timing Gasoline LPG Models E C 14 Check the Engine Valve Clearances Deutz Diesel Models Dd a C 15 Check the Turntable Rotation Gear Backlash Pa ra Ea pa pa Fa ra AAA EEEEEREE Part No 34476 Genie S 60 8 Genie S 65 3 5 Section 3 Scheduled Maintenance Inspections Service Manual First Edition MAINTENANCE TABLES Warm Cold Dealer Table D Tools are New parts engine engine service required required required required suggested D 1 Test or Replace the Hydraulic Oil Ur D 2 Change or Recondition the Engine Coolant z Gasoline LPG Models D 3 Change the Fuel Lines D 4 Check the En
147. f 1 Remove the filter with an oil filter wrench 2 Apply a thin layer of oil to the new oil filter gasket 3 Install the new filter part no 20293 and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 4 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 5 Start the engine from the ground controls 6 Inspect the filter and related components to be sure that there are no leaks TABLE C PROCEDURES C 7 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 Beware of hot oil Contact with ACAUTION hot oil may cause severe burns Perform this procedure with the engine off 1 Open the engine side turntable cover and locate the drive loop hydraulic filter mounted on the engine near the main pump 2 Rotate the filter housing counterclockwise and remove the housing Remove the filter element from the housing Inspect the housing seal and replace it if necessary 5 Install the new filter part no 20880 and hand tighten the housing onto the filter head Clean up any oil that may have spilled during the installation procedure Start th
148. f the number 3 boom tube Place the extension cylinder on blocks for support During removal the overhead crane strap will need to be carefully adjusted for proper balancing 15 Remove and label the wear pads from the extension cylinder Pay careful attention to the location of each wear pad Part No 34476 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Service Manual First Edition BOOM COMPONENTS 4 3 Boom Lift Cylinder How to Remove the Boom Lift Cylinder This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Raise the boom until the boom is horizontal 2 Place support blocks under the cylinder across the turntable 3 Support the boom with an overhead crane Do not lift the boom 4 Support the balance point of the boom lift cylinder with an overhead crane or similar lifting device Crushing hazard If the overhead AWARNING crane is not properly attached the lift cylinder may become unbalanced and fall when it is disconnected from the machine 5 Tag disconnect and plug the boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly
149. ff Use a wrench to hold the relief valve and remove the cap item 24 function 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 AWARNING Tip over hazard Do not adjust the relief valves higher than recommended 6 Restart the engine Hold the retract switch with the boom fully retracted and recheck the valve pressure Main relief valve specifications How to Adjust the Boom Down 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 test port item 23 on the function manifold 2 Start the engine from the ground controls Hold the boom down switch with the boom fully lowered and observe the pressure reading on the pressure gauge 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 14 function 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 AWARNING Tip over hazard Do not adjust the relief valves higher than recommended 6 Restart the engine Hold the boom down switch with the boom fully lowered and recheck the valve pressure Boom down relief valve specifications Pressure 2100 psi 145 bar Pressure S 60 S 65 2600 psi 2900 psi 179 bar
150. g Flow Charts Service Manual First Edition CHART 2A Continued from the previous page With keyswitch on and both mushroom switches pulled out check voltage at center terminal on fuel select switch in platform control box g both mushroom switches pulled out check voltage on gasoline side blu wht wire of fuel select switch 12V With keyswitch on and both mushroom switches pulled out check voltage at terminal TB38 12V With keyswitch on and both mushroom switches pulled out check voltage at blu wht wire at terminal 30 on CR6 12V With keyswitch on and both mushroom switches pulled out crank engine and check voltage at terminal 87 on CRG 12V Continued on the next page N M oV Repair open in red power wire circuit with diode With keyswitch on and az Replace toggle switch Repair open in blu wht wire circuit from toggle switch to TP38 to TB38 ov Repair open in blu wht wire circuit from TB38 to terminal 30 on CR6 no good Check ground wire on Repair open in ground terminal 85 of CR6 wire Replace CR6 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Continued from the previous page CHART 2A Hold start switch and oV Repair open in blu wht check voltage at blu wht
151. ge or malfunction before operating machine Keep records on all inspections for three years MI Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection About This Section The Schedule There are four types of maintenance inspections that must be performed according to a schedule daily quarterly annual two year To account for repeated procedures the Maintenance Tables and the Maintenance Inspection Report have been divided into four subsections A B C D Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Table or Checklist Daily A Quarterly A B Annual A B C Two year A B C D Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure are provided in section 4 Scheduled Maintenance Procedures 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 Part No 34476 Genie S 60 amp Genie S 65 3 1 Section 3 Scheduled Maintenance Inspections Service Manual First Edition Maintenance Tables Warm Gold D
152. gine Valve Clearance n Gasoline LPG Models D 5 Check the Engine Cylinder Compression n Gasoline LPG Models D 6 Clean the PCV Hoses and Fittings u Gasoline LPG Models D 7 Check the Fuel Injection Pumps and Injectors n Deutz Diesel Models D 8 Check the Toothed Belt n Deutz Diesel Models D 9 Replace the Timing Belt Gasoline LPG Models LOS Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 3 Scheduled Maintenance Inspections Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions copies of this page to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily Inspection A Quarterly Inspection A B Annual Inspection A B C 2 Year Inspection A B C D Place a check in the appropriate box after each inspection procedure is completed Use the maintenance tables in this section and the step by step procedures in section 4 to learn how to perform these inspections If any inspection receives 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 N no remove from service R repaired Comments Checklist A YN R Refer to Table A B 20 Engine idle select A
153. gt Lig WHT 3 x WHT x 1 17 WHT 4 n E RIGHT WHT BLK H LEFT TURNTABLE ROTATE WHT BLK 4 5 tr Z E g 5 m Y B WHT RED 4 B RED 4 5 UP RED BLK PRIMARY BOOM A DOWN B RED BLK 4 z p URZ 10 RED WHT 4 e RED 3 gt RED BLK 3 Bog uu RED WHT 3 n E ORG 3 UP PLATFORM LEVEL x Down ORG BLK 3 ORG 7 0 5 ORG 4 i saa PLATFORM LEVEL a DOWN ORG BLK 4 2 a p o a ORG RED 4 5 n ORG RED 3 4 m z n e F GRN 3 oz L 0 JIBBOOM M DOWN GRN BLK 3 GRN e o a GRN 4 a p j 1 GRN BLK 4 DOWN GRN BLK 4 E x R RIGHT P PLATFORM ROTATE Lepr PLATFORM ROTATE i e 2 n E GRN WHT 3 B 5 JIB VALVES o GROUND DRIVE ENABLE LIMIT SWITCH DRIVE BRAKE VALVE TRAVEL ALARM STEER RIGHT STEER LEFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH MOTOR STROKE BOOM EXTEND BOOM RETRACT TURNTABLE ROTATE R TURNTABLE ROTATE L TURNTABLE ROTATE 8 EXTEND RETRACT FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN DESCENT ALARM PRIMARY BOOM FLOW CONTROL PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL F C PLATFORM ROTATE LEFT JIB UP Genie S 60 amp Genie S 65 6 9 Part No 34476 PLATFORM ROTATE RIGHT JIB DOWN Service M
154. h in down foot switch hold controller handle the steer switch left and check voltage at terminal 8 on the drive controller blu wire Hold the steer switch Repair open in blu wire left and check voltage circuit from steer switch at TB36 to TP36 to TB36 Hold the steer switch Repair open in blu wire left and check voltage at circuit from TB36 to blu wire on steer valve steer valve 0 or Remove both wires from infinite steer left coil and check ohms resistance across coil terminals Replace steer left valve coil 4 to 8 ohms Replace steer valve OR consult Genie Industries Service Department Chart 29 Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 30 Steer Right Function Inoperative Be sure all other functions operate normally Start the engine from the platform press down foot switch hold the steer switch right and check voltage at terminal 7 on the drive controller blu blk wire Hold the steer switch right and check voltage at TB37 Hold the steer switch right and check voltage at blu blk wire on steer valve Remove both wires from steer right coil and check resistance across coil terminals Replace steer valve OR consult Genie Industries Service Department 4 to 8 ohms Repair or replace the steer microswitch in controller handle Repair open in
155. harts Service Manual First Edition Chart 14 Boom Up Function Inoperative Be sure all other functions operate normally If boom up function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom up function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch or replace resistor See Repair section Hold ground control Repair open in red wht function switch up and oV wire circuit with diode check volts at red wht from TB3 to proportional wire on boom function valve proportional valve Remove both wires from valve coil and check resistance across the coil terminals 0 or infinite ohms Replace coil 4 5 to 5 5 ohms Hold toggle switch up function operates and manually override proportional valve push In button on end of valve spool Note Overriding the valve will require two people If a helper is not available interchange the valve item AA with a like valve item Z Replace defective proportional valve function inoperative Hold ground control function switch up Check volts at red wire on boom function directional valve Repair open circuit in red wire from TB1 to boom function directional valve Remove both wires from valve coil Check resistance acros
156. he directional valve manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Rants aee on veu Breathe zwa emite 20 25 ft lbs 27 33Nm 2 inei Directional control 7 52 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures STEER AND OSCILLATE 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 Failure to perform this procedure AWARNING on a level floor will compromise the stability of the machine and may result in the machine tipping over 3 Remove the drive chassis cover from the non steer end 4 Disconnect the linkage clevis yoke from the drive chassis if not already disconnected 5 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 6 To level the drive chassis start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level 7 Verify that the ground and drive chassis are completely level 8 Adjust the length of the rod by turning the clevis yoke until the clevis yoke can be pinned to the
157. he ground and platform controls 2 Start the engine from the ground controls Then move the engine idle control switch to high idle rabbit symbol and hold in the ow position Result The engine should change to high idle Release the engine idle control switch Result The engine should return to low idle Turn the key switch to platform controls a At the platform controls move the engine idle control switch to high idle rabbit symbol Result The engine should change to high idle 6 Move the engine idle control switch to low idle turtle symbol Result The engine should change to low idle 7 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol O Result The engine should not change to high idle 8 Press down the foot switch O Result The engine should change to high idle Gasoline LPG models Low idle 1600 rpm High idle 2500 rpm Deutz Diesel models Low idle 1300 rpm High idle 2300 rpm Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 21 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 when the engine is running or not Switching malfunctions and or the failure of the engine to start and
158. he number 3 boom tube 2 Remove the platform See 2 1 How to Hemove the Platform Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 3 Remove the platform leveling slave cylinder See 2 2 How to Remove the Slave Cylinder S 65 Models Remove the jib boom See 3 1 How to Hemove the Jib Boom 4 Raise the boom to a horizontal position Remove the snap rings from the extension cylinder rod end pin at the platform end Use a soft metal drift to remove the pin 6 Remove the turntable end cover 7 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying ACAUTION 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 8 Remove the pin retaining fasteners from both sides of the extension cylinder at the base end of the boom 9 Use a slide hammer to remove the pins 10 Support and slide the extension cylinder out of the boom Crushing hazard The extension ACAUTION cylinder will fall when it is removed from the extension boom if it is not properly supported Note the length of the cylinder after removal The cylinder must be at the same length for installation BOOM COMPONENTS 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the
159. hen 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 120 to 150 second cycle time 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 then move the control handle all the way to the left or right Record the maximum voltage reading 15 Start the engine 7 4 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures PLATFORM CONTROLS 16 Start a timer and simultaneously move the 3 Open the platform control box lid and locate control handle all the way to the left or right the boom extend retract controller 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 trimpot to obtain a 5 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time m wa 7 gt ee oo Ua Turntable rotation specifications Threshold 3 5V DC Turntable rotation hi range boom retracted 5 5V DC a ramprate adjustable trimpot Cycle time 80 to 120 seconds b dual lo range adjustable trimpot lo range boom extended 4 5V DC c terminal activates max out range Cycle time 120 to 150 seconds d terminalunused e
160. hen they are actually not fully operational Be sure that the machine is not in AWARNING free wheel or partial free wheel configuration Refer to B 9 in this section Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark atest line on the ground for reference 2 Start the engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch then lower the boom into the stowed position 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 joystick when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Braking paved surface 2WD 4WD Stopping distance 3 to 5 ft 5 to 7 ft 0 9110 1 5m 1 5t02 1m The brakes must be able to hold the machine on any slope it is able to climb B 24 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 obstru
161. hine for 40 feet 12 m and record the elapsed time Repeat this step in the opposite drive direction 15 Adjust the B potentiometer to obtain the correct raised drive speed of 1 foot per second 0 31 m per second Turn the B potentiometer counterclockwise to increase voltage or clockwise to decrease voltage 16 Close the platform control box lid and install the fasteners Drive speed specifications Stowed position Gasoline LPG models 40 ft 6 2 sec Deutz Diesel models 40 ft 6 8 sec distance 40 ft 12 m 2WD 4WD 40 ft 9 1 sec 12 2 m 6 2 sec 12 2 m 9 1 sec 40 ft 9 1 sec 12 2 m 6 8 sec 12 2 m 9 1 sec Boom raised or extended All models distance 40 ft 12 m 1 foot per second 30 5 cm per second 1 3 Foot Switch How to Test the Foot Switch 1 Turn the key switch to the orr position and separate the wiring quick disconnect plug from the platform toe board Do not 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 green to black continuity zero Q green to white no continuity infinite black to white no continuity Do not use the color of the connector as a guide for these tests Use the actual wire color to identify which connector to use for testing Press down the foot switch Connect the leads from an ohmmeter or continuity tester to
162. housing bolts 5 5 to 7 7 5 to 9 M 6 x 35 Torx 8 8 Oil thermostat housing bolts 5 5 to 7 7 5 to 9 M 6 x 80 Torx 8 8 Oil thermostat housing bolts 14 to 16 19 to 22 M 6 x 105 Torx 8 8 Valve plunger housing bolts 14 to 16 19 to 22 M 8 x 30 Torx 8 8 Alternator nuts M 5 3 4 Fuel bracket bolts M 8 x 20 8 8 15 20 Adapter housing bolts 70 to 77 95 to 105 M 12 x 35 10 9 or M 12 x 75 10 9 first step second step tightening tightening torque angles ft los Nm ist 2nd Main bearing bolts 37 50 60 45 Big end bolts 22 30 60 60 Flywheel bolts 22 30 60 30 Cylinder head step 1 22 30 studs step 2 59 80 step 3 118 160 1209 NA Camshaft central bolt 22 30 150 NA Crankshaft central bolt 96 130 210 NA 2 8 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may cause death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine dama
163. ic 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 Component damage hazard The ACAUTION 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 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 ACAUTION engine must not be started with the hydraulic tank shutoff valves in the CLOSED 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 Part No 34476 Genie S 60 amp Genie S 65 7 31 Section 7 Repair Procedures Service Manual First Edition OOOO HY HYDRAULIC PUMPS 3 Tag and disconnect the hydraulic hoses from the pumps and plug them Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow
164. ications team in care of Genie Industries PO Box 69 Redmond WA 98073 0069 U S A If you have any questions call Genie Industries Genie North America Telephone 206 881 1800 Toll Free in U S A 800 536 1800 Toll Free in Canada 800 426 8089 Fax 206 883 3475 Genie Europe Telephone 44 01636 605030 Fax 44 01636 611090 Genie Industries Copyright 1995 by Genie Industries First Edition First Printing January 1995 GenieQ is a registered trademark of Genie Industries Registered 2009987 These machines comply with ANSI SIA 92 5 1992 _ 2 Printed on recycled paper Patents Pending Printed in U S A ii Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition 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 M You are trained and qualified to perform maintenance on this machine M 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 34
165. ice Manual First Edition Section 5 Troubleshooting Flow Charts Chart 9 Engine At platform controls the PIO and start engine and switch ground rpm switches Low Idle rpm select switch to m and i a maintained low idle replace defective Inope rative turtle symbol Check switch Deutz Diesel volts at blk red wire on Models rpm select switch Check if mechanical linkage Check voltage at the Replace relay from 2 speed red wire on the solenoid to fuel 2 speed solenoid injection system is binding or defective solenoid Check if 2 speed binds solenoid moves in and out freely Check linkage or replace solenoid moves freely Check adjustment of linkage and fuel injection system low idle See Maintenance section See Deutz workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 5 23 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 10 All Functions Inoperative Engine Starts and Runs ok Check pump suction line shutoff valves Valve handles should be parallel with hose Disconnect center coil wire from distributor cap and isolate from grounding Deutz models hold manual fuel shutoff lever counterclockwise Remove function pump from main pump but leave all hoses connected Hold start switch and crank engine over wh
166. ies Service Department Part No 34476 Genie S 60 amp Genie S 65 5 29 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 15 Boom Down Function Inoperative Be sure all other functions operate normally including boom up function If boom down function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom down function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch or replace resistor See Repair section Hold ground control function switch and check volts at red blk wire on boom function directional valve Hold toggle switch down and manually override the down directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item R with a like valve item S function operates function inoperative Install a 0 to 3000 PSI pressure gauge atthe 2100 quick disconnect psi coupling on the function manifold and hold the function switch less than 1800 psi Continued on the next page Repair open in red blk wire circuit from TB2 to directional valve 00 infinite ohms Replace the coil Check the resistance of the down directional valve coil 4 to 5 ohms Repl
167. ift 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 30 16 Extend Function Inoperative en 5 32 17 Boom Retract Function Inoperative 5 34 18 Turntable Rotate Function Inoperative 2 5 35 19 Turntable Rotate Left Function Inoperative 5 37 20 Turntable Rotate Right Function Inoperative 5 38 21 All Platform Leveling Functions Inoperative 5 39 22 Platform Level Up Function 5 40 23 Platform Level Down Function Inoperative 5 41 viii Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition P r nsq TABLE OF CONTENTS Section Five Troubleshooting Flow Charts continued 24 Platform Rotate Left Function Inoperative 5 42 25 Platform Rotate Right Function Inoperative
168. ile observing spline drive at rear of main pump Engine to pump flex plate coupling 15 defective See Repair section Check hydraulic fluid level spline does not turn Fill with Dexron II equivalent hydraulic fluid Open valves If engine has been run with valves closed it may have damaged one or both pumps Troubleshoot inoperative boom functions and inoperative drive functions separately 5 24 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts All Lift and Steer Functions Inoperative Drive Functions Operational 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 Be sure axles are fully extended Troubleshoot each function individually or consult Genie Industries Service Department Install a 0 to 3000 PSI pressure gauge on the function manifold Start engine hold the boom retract function and check the hydraulic pressure less than 2600 psi 2600 psi or more Hold the boom retract switch and readjust the relief pressure to 2600 psi for S 60 or 3000 psi for S 65 Adjust the function manifold relief valve item AB all the way in clockwise counting the number of turns Hold the boom retract switch and recheck the pressur
169. in hose Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the oil filter Use an oil filter wrench and remove the filter N Apply a thin layer of oil to the new oil filter gasket filter part no 28656 Then install the filter and tighten it securely by hand Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 8 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 9 Fill the engine with new oil per specifications and install the filler cap 10 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 11 Check the oil filter and the oil drain hose for leaks 12 Swing the engine pivot plate back to its original position and replace the two retaining bolts 13 Check the engine oil level dipstick Add oil if needed Ford LRG 423 Engine 5 quarts Oil capacity including filter 4 7 liters Ford LRG 423 Engine Oil viscosity requirements below 60F 15 50 5W 30 10 to 90F 23 to 32C 10W 30 above 10F 23C 10W 40 or 10W 50 above 25F 4C 20W 40 or 20W 50 TABLE A PROCEDURES A 16 Replace the Engine Air Filter Engine specifications require that this procedure be performed every 100 hours Perform this procedure more often if dusty conditi
170. ine turn the low or high speed set screw clockwise to increase the rpm or counterclockwise to decrease the rpm Do not adjust any trimpot other than specified in this procedure lt gt CJ union s 5 20 gt Qus 25a Gasoline LPG idle adjustment a lowidle adjustment b highidle adjustment 10 Apply a drop of silicone to the top of the trimpot screw Apply a bead of silicone to the surface of the back panel prior to re assembly 11 Re assemble the governor and recheck low and high idle Gasoline LPG models Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm Deutz Diesel models 1 Connect an rpm gauge to the engine and then start the engine from the ground controls Result Low idle should be 1300 rpm Skip to step 3 if the low idle rpm is correct Genie S 60 8 Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures J JJ P r nn g TABLE B PROCEDURES 2 Loosen the lock nut then turn the adjustment B 13 screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the lock nut and recheck the rpm 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
171. ing bolts at the platform end of the boom 8 Remove the side panel from the cable track to access the cable track mounting bolts 9 Remove the cable track mounting fasteners then remove the cable track from the boom and lay it off to the side Component damage hazard ACAUTION The boom cable track can be damaged if it is twisted 10 Remove the turntable end cover 11 Remove the retaining bolt 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 12 Remove the drive speed limit switch mounted on the inside of the pivot end of the boom Do not disconnect the wiring 13 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying ACAUTION 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 14 Attach an overhead 5 ton 4536 kg crane to the center point of the boom 15 Attach a similar lifting device to the lift cylinder 16 Use the crane to lift the boom to a horizontal position 17 Place support blocks under the cylinder across the turntable 18 Remove the pin retaining fastener from the boom lift cylinder rod end pin Use a soft metal drift to remove the pin Crushing hazard The boom lift ACAUTION cylinder will fall unless it is properly s
172. ircuits from terminal TB30 to limit switch and from limit switch to TB12 oe Replace EDC less than 12V Correct insufficient voltage supply alternator or battery OR repair open in wht wire circuit supplying 12V to terminal 1 Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 31 Switch rpm select Check voltage at TB41 Repair open in org blk switch to rabbit with foot wire circuit from TB4 to p page switch press down foot horsepower limiter switch and check terminal 3 voltage at terminal 3 on horsepower limiter Check voltage at Repair open in org blk org blk wire on engine wire circuit from alternator alternator to TB41 Repair or replace alternator Press down foot switch and check voltage at terminal 10 on horsepower limiter Replace horsepower limiter board 9 to 12V Press down foot switch Repair open in red wire and check voltage at circuit from horse power terminal 6 on drive limiter board to drive controller control terminal 6 9 to 12V Continued on the next page 5 54 Genie 5 60 amp Genie 5 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 31 Disconnect drive pump Repair or replace drive d m the EDC wires press down controller p page foot switch hold drive controller in full forward p
173. jection Pumps and Injectors Deutz Diesel Models 4 44 D 8 Check the Toothed Belt Deutz Diesel Models 4 44 D 9 Replace the Timing Belt Gasoline LPG 4 44 Part No 34476 Genie S 60 8 Genie S 65 Vii Service Manual First Edition TABLE OF CONTENTS Section Five Troubleshooting Flow Charts Introd ction Pa AAAA LA A ea o aed 5 1 1 Engine Will Not Crank 5 3 2 Engine Cranks Over But Will Not Start Gasoline LPG Models 5 5 3 Engine Cranks Over But Will Not Start Deutz Diesel Models 5 11 4 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG 5 14 5 Engine Will Not Start On Gasoline But Will Start On LPG Gasoline EPG Models etie intct iei e ni D iride te eat 5 16 6 Engine High Idle Inoperative Gasoline LPG Models 5 18 7 Engine Low Idle Inoperative Gasoline LPG Models 5 20 8 Engine High Idle Inoperative Deutz Diesel Models 5 21 9 Engine Low Idle Inoperative Deutz Diesel 5 23 10 All Functions Inoperative Engine Starts and 5 24 11 All L
174. l A proportional output terminal ground terminal positive terminal R activates max out range terminal D1 directional output ramp rate adjustable trimpot lo range adjustable trimpot threshold adjustable trimpot hi range adjustable trimpot 725070000 Set the preliminary ramp rate Turn the trimpot adjustment screw clockwise 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 control handle 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 7 2 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 7 Set the hi range Press down the foot switch then move the control handle all the way to the up position Adjust the voltage to 8 5V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 8 Setthe lo range Press down the foot switch then move the control handle all the way to the DOWN position Adjust the voltage to 6 2V DC Turn the dual range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to
175. l clean and deaerate the hydraulic fluid during operation This tank has a 45 gallon 170 liter capacity and an oil level gauge with a temperature indicator It utilizes internal suction strainers for the pump supply lines and has an external return line filter with a condition indicator How to Remove the Hydraulic Tank Component damage hazard ACAUTION 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 1 Remove the fuel tank See 11 2 How to Remove the Fuel Tank 2 Close the two hydraulic tank valves located at the hydraulic tank open closed 3 Completely drain the oil from the tank by removing the drain plug located in the bottom of the tank ACAUTION Burn hazard Contact with hot oil may cause severe burns Disconnect the hydraulic hoses from the tank Remove the mounting fasteners from the bottom of the tank Use an appropriate lifting device to remove the tank from the machine Always use pipe thread sealant when installing the drain plug Use only Dexron II equivalent hydraulic fluid Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the hydraulic tank How to Prime the Pump 1 2 Connect a O to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump Gasoline LPG models Disconnect the electrical connector in the e
176. l 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 1 Engine fuels are combustible i Inspect the machine in an open well ventilated area away from heaters sparks flames and lighted tobacco 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 Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES 2 Perform a visual inspection around the following areas An LPG detector may be necessary to locate LPG leaks Gasoline LPG models LPG tank hoses and fittings solenoid shutoff valve LPG regulator and carburetor gasoline tank manual shutoff valve fuel pump solenoid shutoff valve hoses and fittings and carburetor Deutz Diesel models fuel tank shutoff valve hoses and fittings fuel pump fuel filter fuel injection pumps and fuel injectors z If a fuel leak is discovered keep 3 any additional personnel from entering the area and do not operate the machine Repair the leak immediately 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
177. l as needed Result The oil level should be in the safe zone Ford LRG 423 Engine 5 quarts Cil capacity including filter 4 7 liters Ford LRG 423 Engine Oil viscosity requirements below 60F 15 5C 5W 30 10 to 90F 23 to 32C 10W 30 above 10F 23C 10W 40 or 10W 50 above 25F 4C 20W 40 or 20W 50 Use oils meeting API classification SF labeled SF CC or SF CD as they offer improved wear protection Deutz Engine F4L 1011 Oil capacity including filter 11 quarts 10 5 liters Deutz Engine F4L 1011 Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10F 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 CD SE SF CC or SF CD grades TABLE A PROCEDURES A 5 Check the Engine Coolant Level Gasoline LPG 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 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be in the NORMAL range Fluids in the radiator are under AWARNING pressure and extremely hot Use caution when removing cap and adding fluids A 6 Check for Fue
178. ld OR one of the previous tests involving the pump or manifold components was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 5 31 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 16 Boom Extend Function Inoperative Be sure all other functions operate normally If boom extend function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If boom extend function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch or CR16 relay See Repair section Hold ground control function switch and check volts at wht red wire on proportional valve Repair open in wht red wire circuit from TB6 to proportional valve 12V 0 or Remove both wires from Mnie valve coil and check ohms resistance across the Replace coil coil terminals 4 5 to 5 5 ohms function Replace the defective Hold toggle switch in operates proportional valve extend position and manually override proportional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item Z with a like valve item AA function inoperative Int
179. ld not operate until the drive enable switch is activated Part No 34476 Genie S 60 amp Genie S 65 4 9 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 15 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 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 100 hour interval Perform this procedure after warming the engine to normal operating temperature Beware of hot engine parts and ACAUTION oil Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the oil filler cap located on the valve cover 2 Pull the end of the oil drain hose out from under the engine a engine pivot plate b pivot plate retaining bolts c oildrain hose W 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 A Install the plug into the dra
180. le decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed A 3 Inspect for Damage 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 fittings cylinders and manifolds fuel and hydraulic tanks drive and turntable rotation motors and torque hubs axle components boom components and wear pads dents or damage to machine tires and wheels engine and related components limit switches alarms horn and beacon if equipped nuts bolts and other fasteners platform entry mid rail or gate cracks in welds or structural components compartment covers and latches 4 2 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition 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 oil dipstick Add oi
181. level by the platform leveling slave cylinder which is controlled by the master cylinder located at the base of the boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Start the engine from the ground controls and lower the boom into the stowed position 2 Adjust the platform to a level position using the platform leveling switch 3 Raise and lower the boom through a full cycle Result The platform should remain level at all times to within 5 degrees B 18 Test the Service Horn A functional service horn is essential to safe machine operation The service 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 control and pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 Push down the service horn button at the platform controls Result The service horn should sound Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 19 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 the foot switch is press
182. ll posts and a ground wire to the other small post then test the following terminal combination Test Desired result high amp power contact terminal large post Solenoid activate coil terminal small post 2 large posts continuity zero Q 7 30 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 9 1 Lift Steer Pump How to Remove the Lift Steer Pump 1 Close the two hydraulic tank valves located at the hydraulic tank s open closed Component damage hazard The ACAUTION 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 2 Disconnect and plug the lift steer pump hydraulic hoses Cap the fittings Bodily injury hazard Spraying A CAUTION 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 Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Hydraulic Pumps 9 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electron
183. llow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Support the platform mounting weldment but do not apply any lifting pressure 4 Remove the six mounting bolts from the platform mounting weldment then remove the center bolt and slide the platform mounting weldment off of the platform rotator Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures PLATFORM COMPONENTS 5 Support the platform rotator Do not apply any lifting pressure S 60 Models 6 Support the platform leveling slave cylinder 7 Remove the pin retainer from the slave cylinder rod end pivot pin and the rotator pivot pin 8 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine S 65 Models 6 Remove the pin retainers from the jib boom and leveling links to platform rotator pivot pins Do not remove the pins 7 Support the jib boom and leveling links 8 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine How to Bleed the Platform Rotator Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Move the platform rotate switch to the right then the left through two platform rotation cycles then hold the switch to the RIGHT position until the platform is fully rotated to the right 2 Connect a clear hose to the top bleed val
184. ls and working areas Be sure that your workshop or work area is properly ventilated and well lit 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 sure any forklift overhead F Be sure that fasteners intended for one Q time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or other fluids Use an approved container aw Please be environmentally safe iv Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Introduction Section One Section Two Section Three Section Four Table of Contents Important Information A AE EA PA LL ee EA d o ii Safety Rules General Safety iii Specifications Machine SpecifiCatlons ze tO Nz ir ote etr ada 2 1 Performance Specifications 2 2 Hydraulic Specifications 0 244 11 aaa aaa 2 3 Bolt Torque Specifications ae aaa 0 aaa aaa nennen nnn 2 4 Ford LRG 423 Engine 0 400 0 10 0
185. m controls troubleshoot the platform control toggle switch See Repair section If platform rotate right function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Check if jib I gom boom down is operates Operational 560 models proceed down to next step jib boom down inoperative Hold ground control function switch and check voltage at grn wire on platform rotate right function directional valve Remove both wires from 0 or valve coil and check infinite resistance across the h gt ohms coil terminals 4 to 5 ohms Hold toggle switch right and manually override the rotate right directional valve push in button on end of function valve spool Note operates overriding the valve will require two people If a helper is not available interchange the valve item N with a like valve item O function inoperative Continued on the next page Hold platform rotate left function switch and check voltage at grn wht wire on both valves on jib boom manifold Remove both wires from valve coil and check resistance across the coil terminals 4 to 8 ohms Repair OR replace defective valve s OR check for mechanical restrictions keeping platform from rotating OR repair hydraulic rotator Repair open in grn wire circuit from TB17 to directional valve Replac
186. m the platform before removal 3 Remove the platform mounting bolts and lift the platform off the mount 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 with 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 bleed the slave cylinder to be sure there is no air in the closed loop 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the boom slightly and place blocks under the platform Then lower the boom until the platform is resting on the blocks 3 Remove the pin retainer fastener from the rod end pin 4 Remove the external retaining ring from the barrel end pin 5 Use a soft metal drift to drive the rod end pin out 6 Use a soft metal drift and drive the barrel end pin out 7 Carefully pull the cylinder out of the boom 8 Disconnect the hydraulic hoses from the slave cylinder and connect them together with a connector Cap the fittings on the cylinder Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pr
187. m the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Step on foot switch and check voltage at Repair open in wht wire circuit from TP24 0 Check voltage at wht OV wire on CR13 relay center terminal of jib boom toggle switch 12V 12V to CR13 relay Replace CR13 relay Check voltage at grn OV wht wire on CR13 relay 12V Isolate ground and platform rotate toggle switches and test each switch Replace defective switch rotate left Check if platform rotate operates left is operational epair OR replace eve valve s OR ed jib boom for mechanical restrictions OR repair jib boom cylinder OR replace jib boom cylinder counterbalance valves rotate left inoperative Hold ground control function switch and check voltage at grn wire on jib boom up function directional valve Repair open in grn wire circuit from TB18 to directional valve Remove both wires from 0 or valve coil and check infinite resistance across the ohms Replace the coil coil terminals 4 to 5 ohms Continued on the next page Genie 5 60 amp Genie 5 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 26 function Hold toggle switch and Replace the jib boom up IM the manually override the operates page jib boom up directional valve push in
188. 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 Rotate the turntable to the right until the boom is past the right non steering wheel O Result The drive enable indicator light should turn on 3 Slowly move the drive control handle off center Result The drive function should not operate 4 Hold the drive enable toggle switch to either side and slowly move the drive control handle off center ttt 1 Always use the color coded ACAUTION 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 5 Rotate the turntable to the left until the boom is past the left non steering wheel Result The drive enable indicator light should come on 6 Repeat steps and 4 Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 23 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 w
189. maged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie S 60 8 Genie S 65 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics 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 General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform Service repair problem solved Part No 34476 Genie S 60 amp Genie S 65 6 1 Section 6 Schematics Service Manual First Edition Electrical Symbols Legend Wire color with cable number 82 29 Quick disconnect terminal BLK 421 TB21 T circuits connect at terminal T circuits connect Connec
190. n 11V Check if radiator and or engine block feels excessively hot Check if engine coolant continui over temperature y sending signal post has continuity to ground not hot Remove wht wire from temperature sending unit check continuity to ground on temperature sending unit no continuity no continuity Remove wht wire from TB24 and check continuity to ground no continuity Repair short in wht wire circuit from terminal 10 start lock out module to TB24 OR consult Genie Industries Service Department Go to Chart 2A page 5 7 See Ford service manual for troubleshooting ignition System Remove 1 spark plug and ground spark plug body Crank engine and observe spark weak or no spark Disable starter by removing blk wire at the starter solenoid hold start switch and check voltage at positive terminal of ignition plug less than 12V Continued on the next page Chart 2 Check engine coolant level OR check radiator fins for clogging OR check engine fan belts OR see Ford service manual for troubleshooting an overheating engine continuity Replace temperature switch sender Repair short in wht wire continuity circuit from TB24 to temperature sender Part No 34476 Genie 5 60 amp Genie 5 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 2 Hold start switch and check voltage at wht
191. n the tank side cover and press down on one side of the tilt sensor Result After a 1 5 second delay the alarm in the platform should sound a fueltank b tilt sensor c ground control box Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 14 Test the Limit Switches Drive Limit Switches Detecting limit switch malfunctions is essential to safe machine operation The drive limit switches are used to restrict drive speed when the boom is raised or extended An improperly functioning drive limit switch will allow the machine to operate in an unsafe position 1 Remove the cover from the base of the boom to access the limit switch 2 Visually inspect the drive limit switch located inside the pivot end of the boom Inspect for the following broken or missing actuator arm missing fasteners loose wiring 3 Visually inspect the drive limit switch located on the end of the cable track on the boom Inspect for the following broken or missing roller or arm missing fasteners loose wiring 4 Start the engine from the platform controls Slowly move the drive control handle off center Result The machine should move at normal drive speeds Raise the boom above the drive limit switch 7 Slowly move the drive control handle off center Result The machine should move at a reduced
192. ne A n belts OR see continuity to ground Deutz service manual for troubleshooting an not hot overheating engine Remove wht wire from l temperature sending continuity Replace temperature unit check continuity to switch sender ground on sending unit no continuity no continuity Remove wht wire from Repair short in wht wire continuity circuit from TB24 to E M temperature sender no continuity Repair short in wht wire circuit from start lock out module to TB24 OR consult Genie Industries Service Department 0 or Disable starter by Turn machine off and infinite Replace the fuel removing blk wire at the isolate the fuel solenoid ohms solenoid starter solenoid hold Check the resistance of start switch and check the solenoid voltage at positive terminal on fuel solenoid 3 50 ohms See Deutz service manual for troubleshooting fuel Continued on the next System page Part No 34476 Genie S 60 amp Genie S 65 5 11 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 3 Hold start switch and Repair open in wht 21 Continued from the check voltage at wht 12V wire from CR2 to fuel previous page 21 wire on terminal solenoid 87 of CR2 o oV n Check voltage at red Repair open in red wire wire on terminal 30 of circuit from batt
193. ngine wiring harness between the precision governor and the ignition coil The plug connector is located under the air cleaner Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Deutz Diesel models Hold the manual fuel shutoff valve counterclockwise to the cLosED position 3 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 320 psi 22 bar 4 Connect the wiring and start the engine from the ground controls Check for hydraulic leaks Part No 34476 Genie S 60 amp Genie S 65 7 39 Section 7 Repair Procedures Service Manual First Edition m sil FUEL AND HYDRAULIC TANKS 11 2 Fuel Tank How to Remove the Fuel Tank Explosion 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 hazard When transferring fuel connect grounding wire between the machine and pump or container 1 Turn the manual fuel shutoff valve to the CLOSED position 2 Gasoline LPG models Disconnect drain and plug the fuel hose Deutz Diesel models Disconnect drain and plug the supply and return fuel
194. nual First Edition CHART 1 Continued from the previous page Hold start switch and check voltage at terminal 86 on CR1 Repair open in blk wire from terminal 1 on start lockout module to CR1 Check voltage at terminal 30 on CR1 Repair red wire circuit from battery to CB1 to CR1 terminal 30 Hold start switch and check voltage at terminal 87 on CR1 Check ground to terminal 85 on CR1 Check voltage at initiate terminal starter solenoid Check repair or replace starter or starter solenoid good Replace CR1 relay Repair open in blk wire circuit from CR1 to starter solenoid bad cc Repair open in ground to CRI Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts 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 position Be sure that automatic choke is not sticking closed Perform following tests in gasoline mode only Hold start switch and less Check battery condition check battery voltage than OR check alternator OR while engine is 11V check for short circuits cranking OR check battery cables OR replace the battery more tha
195. nual Ford number PPD 194 287 Genie part number 33907 7 5 RPM Adjustment Refer to Maintenance Procedures B 12 Check and Adjust the Engine RPM 7 6 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 pump shaft coupler flex plate with raised spline flywheel 1 4inch gap a b f Flex Plate Removal 1 Disconnect and remove the hose between the carburetor venturi and the air cleaner 2 Disconnect the linkage from the governor then remove the governor linkage from the carburetor Do not alter the length of the linkage 3 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 4 Remove the mounting fasteners from the regulator mounting bracket then pull the bracket up past the bell housing Secure the bracket before continuing 5 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 6 Carefully pull the pump away from the engine and secure it from moving 7 Remove the flex plate mounting fasteners then remove the flex plate from the fly wheel How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft Ibs 46 Nm 2 Install the co
196. o 10 9 16 55 ft lbs 75 Nm SAE No 12 5 8 75 ft lbs 102 Nm How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and 2 disconnect the wires from the valve coil to be tested 2 Connect the leads from an ohmmeter to the valve coil terminals Valve coil specification 2 position 3 way valve 7 16 Genie S 60 8 Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 4 1 Plastic 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 only necessary when performing major repairs that involve removing the boom How to Repair the Plastic Cable Track Component damage hazard ACAUTION The boom cable track can be damaged if it is twisted a linkseparation point b lowerclip 1 Use a screwdriver to pry out and down on the lower clip 2 Repeat step 1 for each link 3 To remove a single link open the lower clip and then use a screwdriver to pry the link to the side Boom Components 4 2 Boom How to Shim the Boom Measure each wear pad Replace the pad if it is less than 7 16 inch 11 mm thick If the pad is more than 7 16 inch 11 mm thick perform the following procedure 1 Extend the boom until the wear pads are accessible 2 Loosen the wear pad m
197. o the lip of the seal may occur 2WD STEERING AXLE COMPONENTS 5 Place the outer bearing into the hub 6 Install the washer and slotted nut 7 Tighten the slotted nut to 35 foot pounds 47 Nm 8 Loosen the slotted nut then re tighten to 8 foot pounds 11 Nm 9 Install a new cotter pin Bend the cotter pin to lock it in 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 125 foot pounds 169 5 Nm 13 2 Steering Cylinders How to Remove a Steering Cylinder There are two identical steering cylinders that work in parallel They are part of the same hydraulic circuit but move in opposite directions The tie rod maintains equal movement of the tires Bushings are used at both ends of each steering cylinder clevis 1 Disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings Bodily injury hazard Spraying ACAUTION 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 fasteners Then remove the pivot pin from each end of the steering cylinder 3 Remove the steering cylinder Part No 34476 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Service Manual First Edition 2WD STEERING AXLE COMPONENTS 13 3 Tie Rod How to Remove the Tie Rod 1 Remove the pin retaining fasteners then r
198. on 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 M 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 y Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement m Electrocution hazard Contact 3 with electrically charged circuits may 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 on a firm level surface Two persons will be requi
199. onnection Relay 1 Label and then disconnect all the wiring from the relay to be tested 2 Connect the 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 without resistor 85 to 950 terminal 87 to 87a 8 30 no continuity infinite terminal 87a to 30 continuity zero 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 8 30 no continuity infinite terminal 87 to 30 continuity zero Q a terminal no 87a N C terminal no 85 coil terminal no 30 common terminal no 86 ground terminal no 87 N O 0OQo ow Control Relay Schematic without resistor 85 87 87A 30 Genie S 60 8 Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures Platform Components 2 1 Platform How to Remove the Platform 1 Remove the cable harness from the cable clamp located on the platform mounting bracket and separate the foot switch quick disconnect plug 2 Remove the platform control box mounting bolts then lower the control box and set it aside If your machine is equipped with an airline to platform option the airline must be disconnected fro
200. ons 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 1 Remove the end cap from the air cleaner canister 2 Remove the mounting fastener from the air filter then remove the filter 3 Clean the inside of the canister and the gasket with a dry cloth 4 Insert the new filter and replace the mounting fastener 5 Replace the end cap on the canister Air filters Genie part numbers Ford LRG 423 Engine 27916 Use oils meeting API classification SF labeled SF CC Deutz FAL 1011 Engine 27916 or SF CD as they offer improved wear protection Part No 34476 Genie S 60 amp Genie S 65 4 11 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table B Procedures B 1 Check the Engine Belt s Maintaining the engine belt s 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 Do not inspect while the engine AWARNING is running Remove the key to secure from operation ACAUTION of hot engine components Contact with hot engine components may cause severe burns 1 Deutz Diesel models Remove front engine cover to access belt 2 All models Inspect the
201. oom up down 10 12 ft Ibs 14 16 Nm 13 Relief valve 2100 psi 145 bar Dus Boom 25 30 ft lbs 34 41 Nm 14 Relief valve 2100 psi 145 bar E uie Boom down 25 30 ft lbs 34 41 Nm 15 Proportional solenoid valve AA BOOM atiende 10 12 ft Ibs 14 16 Nm 16 Flow regulator valve Turntable rotate boom 10 12 ft lbs 14 6 Nm 17 Normally closed poppet valve Wasz Platform level 25 30 ft lbs 34 41 Nm 18 Proportional solenoid valve Zi Turntable rotate boom 10 12 ft lbs 14 16 Nm 19 Flow regulator valve Platform 10 12 ft lbs 14 16 Nm 20 Differential sensing valve All functions seeeeeesss 10 12 ft lbs 14 16 Nm 21 Flow regulator valve Uu Platform rotate 10 12 ft lbs 14 16 Nm 22 Flow regulator valve Wiss Differential sensing circuit 10 12 ft lbs 14 16 Nm 23 Diagnostic 0 Testing 24 Relief valve 2600 psi 179 b
202. osition and check voltage across terminals 4 and 5 on drive controller Press down foot switch Repair open in either hold drive controller in wht or wht blk wire full forward position circuit from drive and check voltage controller to TP30 and across terminals TP31 respectively TP30 and TP31 Press down foot switch hold drive controller in UE full forward position Repair open in either wht or wht blk wire and check voltage ircuit from TB30 and across terminals 1831 rom five an TB30 and TB31 RODAN Press down foot switch Repair open in wht blk hold drive controller in wire circuit from TB31 to full forward position and EDC quick disconnect check voltage across OR repair open in wht the two wires at EDC wire circuit from TB30 to quick disconnect EDC quick disconnect Replace drive pump EDC OR consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 5 55 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 32 Drive Forward Disconnect the EDC voltage readings different pal or oae the wire connector from the rive controller Or Reverse drive pump start 1 engine move the drive Function controller to full forward Inoperative position and note the voltage across terminals TB30 and TB31 Be sure all other Reverse the volt meter functions operate leads and move the normally including drive controller to full SR reverse position and FU iacu note the voltage
203. ounting fasteners 3 Install the new shims under the wear pad to obtain zero clearance and zero drag 4 Tighten the mounting fasteners Extend and retract the boom through an entire cycle Check for tight spots that could cause scraping or binding Always maintain squareness between the outer and inner boom tubes How to Remove the Boom This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may cause death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure with the boom in the stowed position 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform rotator and leveling slave cylinder See 2 3 How to Remove the Platform Rotator Part No 34476 Genie S 60 amp Genie S 65 7 17 Section 7 Repair Procedures Service Manual First Edition BOOM COMPONENTS S 65 Models Remove the jib boom See 3 1 How to Remove the Jib Boom 3 Remove the mounting fasteners from the counterbalance valve manifold on the end of the boom Then remove the manifold and set it aside 4 Remove the drive speed limit switch mounted on the side of the cable track Do not disconnect the wiring 5 Support the cable track with an overhead crane 6 Remove the hose cable cover from the pivot end of the boom 7 Remove the cable track mount
204. own wires and restart engine wire circuit from ignition and check voltage at plug to electronic electronic governor governor terminal 3 and 4 brown See Maintenance section for governor adjustments OR replace electronic governor Part No 34476 Genie S 60 amp Genie S 65 5 19 Section 5 Troubleshooting Flow Charts Service Manual First Edition 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 to carburetor is not binding see Repair section Start engine and switch rpm select to low idle turtle symbol Check voltage at terminal 86 blk rd wire on CR4 Check voltage at oV terminal 30 on CR4 I 12V Check voltage at OV terminal 87A on CR4 12V Check voltage at terminal 7 on electronic governor 12V Check voltage at electronic governor terminal 3 and 4 brown wires Turn machine off remove blu blk wire from terminal 46 on electronic governor and restart engine engine goes to low idle Recheck electronic governor adjustments OR replace electronic governor engine goes to high idle Isolate the ground and platform rpm switches check individually and replace defective switch
205. p Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 6 Check voltage at Repair open in rd blk OWE terminal 86 on CR3 oV R6 wire circuit from previous page vacuumn switch to CR6 to CR7 to terminal 86 L 12V on CR3 Check ground wire to bad Repair open in ground terminal 85 on CR3 wire to terminal 85 on CR3 good Check voltage to ov Replace CR3 relay terminal 87 on CR3 Check voltage at terminal 1 red wht wire on electronic governor Check voltage at terminal 1 red wht wire on governor actuator V Repair open in red wht wire circuit from terminal 87 on CR3 to terminal 1 on electronic governor Repair open in red wht V wire circuit from electronic governor terminal 5 to governor actuator terminal 1 M E Check continuity from Repair open in blu blk terminal 46 on precision wire circuit from governor to blu blk governor actuator to terminal 2 on governor electronic governor OR actuator check and or replace governor actuator Replace governor actuator full continuity oor infinite ohms Turn machine off remove both wires from governor actuator and check resistance across governor actuator terminals 2 to 3 ohms Reconnect governor Repair open in br
206. pplication of bolt 2 4 Genie 5 60 8 Genie 5 65 Part No 34476 Service Manual First Edition Ford Engine LRG 423 Displacement 140 cu in 2 3 liters Number of cylinders 4 3 781 x 3 126 inches 96 04 x 79 4 mm Bore amp stroke Horsepower 63 4000 rpm Firing order 1 3 4 2 Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm Governor electronic Compression ratio 9 4 1 Compression pressure approx Pressure psi of lowest cylinder must be at least 75 of highest cylinder Section 2 Specifications H R o T FORD ENGINE LRG 423 Starter motor SPECIFICATIONS Normal engine cranking speed 200 to 250 rpm Current draw normal load 170A Current draw maximum load 200A Current draw minimum 140A 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 Brush spring tension 64 ounces 18 Newtons Bolt torque through brush 45 to 84 inch pounds 5 08 to 9 5 Nm Brush mounting 15 to 20 foot pounds Valve clearances 0 035 to 0 055 inches polt torque 20 to 27 Nm collapsed tappet 0 889 to 1 397 mm Maximum commutator 0 005 inches Lubrication system run out 0 127 mm Oil pressure 40 to 60 psi Battery operating temp 2000 rpm 2
207. pport bracket to the bulkhead 5 Carefully lift and remove the cover from the machine If a turntable cover must be AWARNING replaced be sure that all appropriate safety and instructional decals are applied to the new cover Alignment adjustments may be necessary when a new cover is installed 7 22 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures Deutz Engine F4L 1011 6 1 RPM Adjustment Refer to Maintenance Procedures B 12 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 p pum a b pumpshaft c coupler d flex plate with raised spline e flywheel f inch gap How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Support the 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 4 Remove the flex plate mounting fasteners then remove the flex plate from the fly wheel How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft Ibs 46 Nm 2 Install
208. r s are not tripped less than Check battery voltage 12V 12V or more ONA KA Check voltage at center terminal on start switch 12V ZEE Hold start switch and check voltage at either side terminal on start switch 12V Hold start switch and check voltage at terminal TB33 E Hold start switch and check voltage at terminal 3 on start lockout module ov oV oV E Hold start switch and check voltage at terminal 6 and 7 at start lockout module oV E Hold start switch and check voltage at terminal 1 on start lockout module Continued on the next page Chart 1 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 Repair blk wire circuit L from start switch to TB33 Repair blk wire circuit gt from TB33 to start lockout module terminal 3 Check repair open in power supply wire to terminal 6 and 7 on start lockout module Check ground wire to terminal 5 on start lockout module Repair open in ground wire Check 3 amp fuse on ignition module OR Consult Genie Industries Service Department Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Ma
209. read sealant to the drain plug and then install it in the tank 9 Install the two suction hoses 10 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 11 Clean up any oil that may have spilled and open the hydraulic tank valves 12 Prime the pump by doing the following Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump Gasoline LPG models Disconnect the electrical connector in the engine wiring harness between the precision governor and the ignition coil The plug connector is located under the air cleaner Electrocution hazard Contact with AWARNING electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Deutz Diesel models Hold the manual fuel shutoff valve counterclockwise to the CLOSED position a manualfuelshutoff valve All models 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 320 psi 22 bar 13 Connect the wiring and start the engine from the ground controls Check the hydraulic tank for leaks Hydraulic system Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 55 gallons capacity
210. red to safely perform some troubleshooting procedures Part No 34476 Genie S 60 amp Genie S 65 5 1 Section 5 Troubleshooting Flow Charts Service Manual First Edition 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 Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform Service repair problem Solved 5 2 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Will Not Crank Over Be sure the key switch is in the appropriate position Be sure the emergency stop buttons are pulled up into the on position Be sure the circuit breake
211. roducts is a Genie including tank 208 liters policy Product specifications are subject to change 7 without notice Drive torque hubs 44 fl oz 1 30 liters Turntable rotation 17 floz torque hub 0 51 liters Part No 34476 Genie S 60 amp Genie S 65 2 1 Section 2 Specifications PERFORMANCE SPECIFICATIONS Performance Specifications Drive speeds maximum 2WD 4WD Drive speed stowed 4 4 mph 3 0 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 sec12 2 m 9 1 sec Drive speed stowed 4 0 mph 2 8 mph Deutz Diesel models 6 4 km h 4 5 km h 40 ft 6 8 sec 40 ft 9 7 sec 12 2 m 6 8 sec12 2 m 9 7 sec Drive speed 0 6 mph 0 6 mph raised or extended 1 0 km h 1 0 km h all models 40 f 40 sec 40 ft 40 sec 12 2 m 40 sec 12 2 m 40 sec Service Manual First Edition pm s tr Boom function speeds maximum from platform controls Jib boom up 40 to 60 seconds Jib boom down 50 to 80 seconds Boom up 55 to 85 seconds Boom down 90 to 120 seconds Boom extend 100 to 130 seconds Boom retract 55 to 85 seconds Turntable rotate 360 boom fully stowed 80 to 120 seconds Turntable rotate 360 boom extended 120 to 150 seconds Gradeability boom stowed 2WD 4WD Rough terrain 28 40 Platform rotate 160 10 to
212. rom the jib boom pivot pin Use a soft metal drift to remove the pin then remove the jib boom from the primary boom AWARNING Crushing hazard The jib boom will fall when the pin is removed if it is not properly supported 10 Remove the pin retainers from the jib boom lift cylinder rod end pivot pin Do not remove the pin 11 Remove both of the jib boom leveling links from the primary boom 12 Support the jib boom lift cylinder with an overhead crane 13 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin then remove the jib boom lift cylinder from the primary boom AWARNING Crushing hazard The jib boom lift cylinder will fall when the pin is removed if it is not properly supported 7 14 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 3 2 Jib Boom Lift Cylinder S 65 Models How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib boom until the platform is resting on the blocks 2 Disconnect and plug the jib boom lift cylinder hydraulic hoses ACAUTION 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
213. 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 switch to gasoline and then move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 2 Start the 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 stop the engine Move the fuel select switch to LPG Restart the engine and allow it to run at low idle 7 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 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 TABLE B PROCEDURES B 22 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 used to reactivate the drive function and should inform the operator that the
214. s coil terminals 0 or infinite ohms Replace coil 4 to 5 ohms Interchange flow regulator valve item Y function operates Replace defective flow with a like valve regulator valve item X function inoperative Continued on the next page Genie 5 60 amp Genie 5 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 14 j 0 or Hold toggle switch up function Check the resistance az a the and manually override Operate of the directional Na Replace the defective p page directional valve push valve coils Onm j valve coil s in 0 of valve spool Note Qvoiriding the valvo ii 4105 ohms require two people If a helper is not available interchange the valve item R with a like valve item S Replace the valve function inoperative Interchange check valve function operates item M with a like valve item K Replace defective check valve function inoperative Install a 0 to 3000 PSI Check for mechanical pressure gauge at the restrictions keeping quick disconnect boom from moving coupling on the function OR repair cylinder manifold and hold the OR oylinder function switch counterbalance valve less than 2600 psi Repair cylinder OR replace cylinder counterbalance valve OR manifold has internal defect consult Genie Industr
215. s may produce hazardous conditions MI 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 Repair Procedures About 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 General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem Still exists Return to Perform service problem repair Solved Symbols Legend 73 Indicates the presence of a 3 hazard that will cause death or serious injury Indicates the presence of a AWARNING hazard that may cause death or serious injury Indicates the presence of a ACAUTION hazard that will or may cause serious personal injury or damage to the machine Indicates special operation or maintenance information O Indicates that a specific result is expected after performing
216. scraping Always maintain squareness between the boom outer and inner tubes Wear pad specifications 14 27 mm 11 mm Upper and side wear pads Lower wear pads 9 46 inch lig inch Table C Procedures C 2 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 no 33484 2 Be sure that each turntable mounting bolt is torqued in sequence to 210 foot pounds 285 Newton meters 5 20 9 167999 90g 17 2 40 25 300 29 26 0 o 22 7 186 o 1470 15 0 62 972 Bolt torque sequence Part No 34476 Genie S 60 Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES 3 Lower the boom to the stowed position 4 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in sequence to 210 foot pounds 285 Newton meters 6 12 18 ok 30 17 8 14 2 Bolt torque sequence C 3
217. ses 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 10 1 Function Manifold in this section 1 Push the button on the end of the valve in Y inch 6 mm 2 Move the ground control function switch for the function being overridden to operate function AWARNING Collision hazard Impact with moving boom components may cause death or serious injury Use extreme caution when overriding a machine function Identify the direction of machine movement before overriding a valve Part No 34476 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Service Manual First Edition gt gt gt gt gt PR JH 1 FUNCTION MANIFOLD How to Check the Resistance of a Valve Coil 1 Turn the key switch to the orr position and disconnect the wires from the valve coil to be tested 2 Connect the leads from an ohmmeter to the valve coil terminals Valve coil specifications Proportional solenoid valve 50 3 position 4 way directional valve 4 50 Normally closed poppet valve 70 7 38 Genie 5 60 8 Genie 5 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures Fuel and Hydraulic Tanks 11 1 Hydraulic Tank The primary functions of the hydraulic tank are to coo
218. si Interch heck function tem with like he operates Replace defective item L check valve function inoperative Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department CHART 27 Part No 34476 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 28 Oscillate Check for linkage Re adjust or replace Function damage or improper linkage linkage set up See i Repair section 16 3 Inoperative How to Set Up the Directional Valve Linkage Be sure all other function operate normally Install a pressure gauge Adjust the sequence atthe quick disconnect valve See Repair coupling on the oscillate procedure 16 3 How to manifold Disconnect Adjust the Oscillate linkage from drive Sequence Valve chassis and manually Pressure OR consult activate directional Genie Industries valve while engine is Service Department running Check the pressure 900 psi Consult Genie Industries Service Department 5 50 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Steer Left Function Inoperative Be sure all other functions operate normally Start the engine from Repair or replace the the platform press steer microswitc
219. ssential 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 Start the engine from the ground controls 2 Operate each machine function through a full cycle Result All machine functions should operate smoothly 3 Push in the Emergency Stop button to the position Result No function should operate the engine should stop Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds 4 Start the engine from the platform controls and then operate each machine function through a full cycle Result All machine functions should operate smoothly 5 Push in the Emergency Stop button to the position O 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 button 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 operating the machine on engine power selecting
220. t metal drift to drive the lower king pin down and out Crushing hazard The yoke hub AWARNING assembly will fall when the king pins are removed if it is not properly supported Torque specifications Lug nut torque dry 420 ft Ibs 569 5 Nm Lug nut torque wet 320 ft Ibs 433 9 Nm 7 44 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steering wheels and place a lifting jack of ample capacity under the steering axle 3 Raise the machine 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 slotted nut 6 Pull the hub off the 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 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 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 Component damage Do not ACAUTION apply excessive force or damage t
221. t of Ford service manual for lockout module Is sender while cranking troubleshooting low oil continuity maintained the engine Is continuity pressure maintained no 10 Repair short to ground in wht 24 wire from sender to TB24 to start lockout module terminal 10 Check voltage at Disconnect red wire Replace start lockout terminal 4 on start 12V from terminal 4 on start joy module OR consult lockout module lockout module and Genie Industries check voltage at Service Department terminal 4 Repair short to power in red wire circuit from TB27 Replace start lockout module OR consult Genie Industries Service Department 5 10 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Engine Cranks Over But Will Not Start Deutz Diesel Models Be sure to check the engine oil level and fill as needed Be sure to check fuel level Be sure the diesel shut off valve is in the on position Chart 3 Hold start switch and less Check battery condition check battery voltage than OR check alternator OR while engine is 11V check for short circuits cranking OR check battery cables OR replace the more than 11V battery anm V V Check engine oil level Check if engine coolant continuity Check if oil cooler hot oil cooler fins Tor over temperature and or engine block dogging OH check sending signal post has feels excessively hot na
222. table rotation torque hub is mounted on a adjustable plate that controls the gap between the rotation motor gear and the turntable bearing Be sure to check the backlash with the machine on a flat level surface 1 Loosen the mounting fasteners on the torque hub pivot plate a pivotplate mounting bolts b adjustment bolt with lock nut c torque hub pivot plate 2 Push the torque hub pivot plate towards the turntable as far as possible this will push the rotation gear into the rotation bearing 3 Loosen the lock nut on the adjustment bolt 4 Turn the adjustment bolt clockwise until it contacts the pivot plate 5 Turn the adjustment bolt turn counterclockwise Then tighten the lock nut on the adjustment bolt 6 Rotate the torque hub pivot plate away from the turntable until it contacts the adjustment bolt Then tighten the mounting fasteners on the torque hub pivot plate 7 Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures TURNTABLE ROTATION COMPONENTS 12 2 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 1 Shuttle valve 2 position way O uses Turntable rotation
223. terminals and cables B 6 Check the Hydraulic Tank Filter Condition Indicator Maintaining the hydraulic tank 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 1 Start the engine from the platform controls 2 Move the engine speed control switch to high idle rabbit symbol 3 Inspect the filter condition indicator filter condition indicator filter c hydraulictank om 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 filter should be replaced See C 6 Heplace the Hydraulic Tank Filter Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 7 Inspect the Electrical Wiring 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 may result in death or serious injury
224. tform control toggle switch See Repair section If platform level up function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Hold ground control function switch and check voltage at org wire on platform level up function directional valve 0 or Remove both wires from infinite valve coil and check ohms resistance across the coil terminals 4 to 5 ohms Hold toggle switch and manually override the level up directional valve push in button on end of valve spool Note overriding the valve will require two people If a helper is not available interchange the valve item O with a like valve item N function inoperative Interchange check valve item L with like valve item K function inoperative 2400 Install a pressure gauge psi or at the quick disconnect more coupling on the function manifold and hold the function switch less than 2400 psi Replace the directional valve OR the manifold has internal defects OR one of the previous tests was possibly overlooked or diagnosed incorrectly Recheck and or consult Genie Industries Service Department function operates function operates Repair open in org wire circuit from TB14 to directional valve Replace the coil Replace the platform leveling directional valve Replace defective check valve
225. that the linkage moves freely Be sure that the linkage activates the throttle Choke Adjustments shaft to approximately half throttle This engine is equipped with an electrically heated The linkage must be free of automatic choke The choke has a poppet valve to friction and obstruction Do not enhance cold starting ability on LPG fuel let it rub against the engine brackets or hoses Choke adjustments are affected by climate Richer adjustment A CAUTION Component damage hazard will be necessary in colder If the throttle linkage is improperly adjusted and allowed to reach full throttle the engine will over rev and cause component damage Automatic Choke with Poppet Valve climates leaner adjustment in warmer climates The choke functions in both gasoline and LPG mode The choke butterfly may be adjusted to a fully closed rich position for colder climates and the poppet valve will provide a flow path during LPG fueled operation Part No 34476 Genie S 60 amp Genie S 65 7 25 Section 7 Repair Procedures Service Manual First Edition FORD LRG 423 ENGINE 7 3 Timing Adjustment Complete informaiion to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 7 4 Carburetor Adjustment Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Ma
226. the coupler onto the pump shaft with the set screw toward the pump Leave a inch 12 7 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do ACAUTION 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 lbs 46 Nm 6 3 Oil Temperature and Pressure Gauges The oil temperature gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 300 F 147 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 Temperature will be indicated when the key is on and the Emergency Stop Button is pulled out to the on position Component damage hazard ACAUTION Do not crank the engine with the over temperature light on The oil pressure gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 7 psi 0 48 bar When the contacts close the engine will shut off to prevent damage Oil pressure will be indicated when the engine is running Component damage hazard ACAUTION Do not crank the engine with the low oil pressure light on Part No 34476 Genie S 60 amp Genie S 65 7 23 Section
227. the hoses with a mild cleaning solvent Dry both hoses and inspect them for cracks and damage Replace the hoses if they are damaged a pivotplate retaining bolts b enginepivotplate Part No 34476 Genie S 60 amp Genie S 65 4 43 Section 4 Scheduled Maintenance Procedures Service Manual First Edition IA TABLE D PROCEDURES D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Workshop Manual Deutz number 0291 1942 Genie part number 29789 D 8 Check the Toothed Belt Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011 Operation Manual Deutz number 0297 4706 EN Genie part number 29790 D 9 Replace the Timing Belt Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 4 44 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition 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 a damaged or malfunctioning machine Repair any machine damage or malfuncti
228. the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Support the pump and remove the two drive pump mounting bolts Carefully remove the pump Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump How to Prime the Pump 1 Connect a O to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Gasoline LPG models Disconnect the electrical connector in the engine wiring harness between the precision governor and the ignition coil The plug connector is located under the air cleaner Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Deutz Diesel models Hold the manual fuel shutoff valve counterclockwise to the CLOSED position 3 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 320 psi 22 bar 4 Connect the wiring and start the engine from the ground controls Check for hydraulic leaks 7 32 Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures _ mJ This page intentionally left blank Part No 34476 Genie S 60 amp Genie S 65 7 33 Section 7 Repair Procedures Service Manual First Edition Function
229. tion no terminal Circuits crossing no connection Diode Battery 15AMP TB Lo fol 5 Circuit breaker e E Water temperature switch di normally closed Solenoid or Ground CDM relay coil supression circuit Foot switch TILT ALARM 194 NC PLAT Hom Limit switch UZ GRND Key switch oO m Light Limit switch normally open HORN p P4 held closed P Horn button 3 normally open Resistor NC I Limit switch Pi normally closed held open Emergency Stop a button normally closed Tilt sensor Vacuum switch 1 Relay contact Spark plug normally open E Oil pressure switch Relay panel Glow plug normally closed contactor prs IT Starter motor relay Toggle switch SPDI dg Toggle switch DPDT L BP2 PWM n Single axis proportional controller Dual axis proportional controller Genie S 60 amp Genie S 65 Part No 34476 Service Manual Section 6 Schematics Electrical Schematic Gasoline LPG Models ON GENERATOR TP28
230. tion 7 Repair Procedures STEER AND OSCILLATE MANIFOLDS 16 2 Valve Adjustments How to Adjust the Sequencing Valve Pressure 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port located on the oscillate manifold Bodily injury hazard Spraying ACAUTION 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 Disconnect the directional valve linkage by removing the clevis yoke from the drive chassis 3 Start the engine from the platform controls 4 With the engine running manually activate the valve and observe the pressure reading on the pressure gauge 5 Turn the engine off Hold the valve and remove the cap index 4 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 7 Restart the engine manually activate the valve and recheck the valve pressure 8 Turn the engine off then remove the pressure gauge and assemble the directional valve linkage Unloader valve specifications Pressure 950 psi 65 bar Part No 34476 Genie S 60 amp Genie S 65 7 51 Section 7 Repair Procedures Service Manual First Edition gt gt Se STEER AND OSCILLATE MANIFOLDS 16 3 Directional Valve Manifold Components T
231. tional personnel from entering the area and do not operate the machine Repair the leak immediately D 4 Check the Engine Valve Clearance Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 D 5 Check the Engine Cylinder Compression Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual Ford number PPD 194 287 Genie part number 33907 Genie S 60 8 Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures TABLE D PROCEDURES D 6 2 Disconnect the hose from the PCV valve then Clean the PCV Hoses and disconnect the hose from the engine Fittings Gasoline LPG Models Maintaining PCV hoses is essential to good engine performance Improperly functioning PCV hoses will fail to ventilate the crankcase and continued use of neglected hoses could result in component damage Perform this procedure with the engine off 1 Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV hoses a hose carburetor to valve cover b PCV valve hose PCV valve to carburetor 3 Disconnect the hose from the carburetor then disconnect the hose from the valve cover 4 Clean
232. to 950 terminal 87 to 87a 8 30 no continuity infinite Q terminal 87a to 30 continuity zero 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 8 30 no continuity infinite Q terminal 87 to 30 continuity zero Q a terminal 87a N C terminal no 85 coil terminal no 30 common terminal no 86 ground terminal no 87 N O Control Relay Schematic with resistor 85 87 87A 86 30 Control Relay Schematic without resistor 85 87 87A 30 Genie S 60 8 Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 8 2 Toggle Switches See 1 5 Toggle Switches 8 3 Wago Components How to Remove a Wago Component Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry A small screwdriver is provided and should be used when removing a Wago component This screwdriver is located in the operators manual storage box in the platform 1 Label the wiring from the component to be removed 2 Use the provided screwdriver to push in and release the wire from the component 3 Locate the removal tab on the bottom or top side of the component 4 Use the provided screwdriver to gently pry
233. 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 oil tank Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge Hydraulic oil specifications Hydraulic oil type Dexron II equivalent Tank capacity 45 gallons 170 liters Hydraulic system 55 gallons including tank 208 liters 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 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas hydraulic tank filter fittings hoses auxiliary power unit and turntable surface engine compartment fittings hoses pumps filter and turntable surface all hydraulic cylinders all hydraulic manifolds boom s the underside of the turntable the underside of the drive chassis ground area under the machine Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 4 Scheduled Maintenance Procedures A 9 Check the Tire Pressure This procedure does not need to be performed on machines equipped with the foam filled tire option An
234. upler onto the pump shaft with the set screw towards the pump Leave 1 4 inch 6 35 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 45 ft lbs 61 Nm Component damage hazard Do ACAUTION 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 lbs 46 Nm Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures M Ha j FORD LRG 423 ENGINE 7 7 7 8 Water Temperature Oil Vacuum Switch Pressure Gauges How to Test the Vacuum Switch The water temperature gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 230 F 109 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 Temperature will be indicated when the key is on and the Emergency Stop Button is pulled out to the oN position Component damage hazard ACAUTION Do not crank the engine with the over temperature light on The oil pressure gauge is an electrical gauge The sending unit has limit contacts that are factory set The contacts will close at 8 psi 0 55 bar When the contacts close the engine will sh
235. upported 19 Lower the rod end of the lift cylinder onto support blocks Protect the cylinder rod from damage 20 Remove the pin retaining fastener from the boom pivot pin 21 Remove the boom pivot pin with a soft metal drift then carefully remove the boom from the machine Crushing hazard If the overhead AWARNING crane is not properly attached the boom may become unbalanced and fall when it is removed from the machine 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 Hemove the Extension Cylinder 1 Remove the boom See 4 2 How to Remove the Boom Genie S 60 amp Genie S 65 Part No 34476 Service Manual First Edition Section 7 Repair Procedures 2 Place blocks under the extension cylinder for support 3 Remove the retaining rings from the extension cylinder barrel end pivot pin at the base 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 Remove the two wear pad stop bolts from each side of the number 1 boom tube located on the outside 6 Support the number 2 and 3 boom tubes with an overhead crane
236. ut off to prevent damage Oil pressure will be indicated b sai when the engine is running 77 I inal ING ACAUTION Component damage hazard MR MdL Do not crank the engine with the 1 Connect the leads from an ohmmeter or low oil pressure light on continuity tester to the common and normally open terminals Result There should be no continuity infinite 2 2 Apply mild suction to the vacuum port Result The switch should close and show full continuity zero Q Component damage hazard ACAUTION Do not short the vacuum switch terminals to ground Part No 34476 Genie S 60 amp Genie S 65 7 27 Section 7 Repair Procedures Service Manual First Edition Ground Controls 8 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 Electrocution hazard AWARNING Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry Direct Connection Relay 1 Label and then disconnect all the wiring from the relay to be tested 2 Connect the 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 85 to 86 without resistor 85
237. utz Diesel models Low idle 1300 rpm High idle 2300 rpm Part No 34476 Genie S 60 amp Genie S 65 4 19 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 14 Test the Emergency Stop Buttons Properly 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 Emergency Stop button 1 Start the engine from the ground controls 2 Push down the Emergency Stop button to the OFF position Result The engine should shut off and no machine functions should operate Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds 3 Start the engine from the platform controls 4 Push down the Emergency Stop button to the OFF position O Result The engine should shut off and no machine functions should operate The ground Emergency Stop button will stop all machine operation even if the key switch is switched to platform control B 15 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation The ground control override function is intended
238. ve Continued on the next page Part No 34476 Genie S 60 amp Genie S 65 5 35 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 18 Interchange check valve function item K with a like valve operates item M Continued from the previous page Replace defective check valve Install a 0 to 3000 psi Check for mechanical pressure gauge at the restrictions keeping quick disconnect turntable from rotating coupling on the function OR check rotation motor manifold and hold the OR check rotation brake function switch OR check rotation torque hub function inoperative less than 2400 psi Repair rotation motor OR manifold has internal defect consult Genie Industries Service Department 5 36 Genie 5 60 Genie 5 65 34476 Service Manual First Edition Section 5 Troubleshooting Flow Charts Turntable Rotate Left Function Inoperative Be sure all other functions operate normally including turntable rotate right function If turntable rotate left function operates normally from the ground controls but not from the platform controls troubleshoot the platform controller See Repair section If turntable rotate left function operates normally from the platform controls but not from the ground controls troubleshoot the ground control toggle switch See Repair section Chart 19 Hold ground control oV R
239. ve Place the other end of the hose in a container to collect any drainage Secure the container to the boom Part No 34476 Genie S 60 amp Genie S 65 7 13 Section 7 Repair Procedures Service Manual First Edition Jib Boom Components S 65 Models 3 1 Jib Boom S 65 Models How to Remove the Jib Boom Perform this procedure with the boom in the stowed position 1 Remove the platform See 2 1 How to Hemove the Platform 2 Remove the platform mounting weldment and the platform rotator See 2 3 How to Remove the Platform Rotator 3 Support the platform pivot weldment with a lifting device 4 Disconnect and plug the jib boom lift cylinder hydraulic hoses ACAUTION 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 5 Remove the pin retainer from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin 6 Tag disconnect and plug all the hydraulic hoses from the jib boom manifold ACAUTION 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 Remove the cable tray from the side of the jib boom Support the jib boom with an overhead crane Remove the pin retainer f
240. vere burns 1 Deutz 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 enginepivotplate b pivotplateretaining bolts Part No 34476 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES 2 Be sure that all nuts and bolts are tight 3 Inspect all welds for cracks 4 Inspect for exhaust leaks i e carbon buildup around seams and joints B 5 Check the Battery 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 Batteries contain acid Avoid AWARNING spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion 3 Be sure that the battery hold downs and cable connections are tight 4 Remove the battery vent caps and check the specific gravity with a hydrometer 5 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Adding terminal protectors and a corrosion preventative sealant or goop will help eliminate corrosion on the battery
241. ween the drive chassis and the oscillating axle The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure The valves are not adjustable How to Remove an Oscillating Axle Cylinder AWARNING This procedure requires specific repair skills and a suitable workshop Attempting this procedure without these skills and tools may 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 1 Rotate the boom until the boom is between the steer tires 2 Block the non steering wheels then center a lifting jack between the steering wheels under the axle pivot pin 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis 4 Disconnect and plug the oscillating axle cylinder hydraulic hoses and cap the cylinder fittings ACAUTION 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 5 Remove the pin retaining fasteners from both pivot pins 6 Attach a strap from a lifting device to the cylinder for support 7 Use a soft metal drift to remove the pins Part No 34476 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Service Manual First
242. y pipe thread sealant to the plug and then operating temperature install it in the torque hub 1 Disconnect the blue black wire from the Turntable rotate torque hub oil governor actuator Capacity 17 fluid ounces 0 51 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 34476 Genie 5 60 amp Genie 5 65 4 17 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES 2 Connect an rpm gauge to the engine then start the engine from the ground controls Result Carburetor low idle should be 900 rpm Skip to step 4 if the low idle rpm is correct 3 Turn the idle adjustment screw on the carburetor clockwise to increase rpm or counterclockwise to decrease rpm Gasoline LPG low idle adjustment a carburetor b adjustmentscrew A Turn the engine off and reconnect the blue black wire to the governor actuator Start the engine from the ground controls Result Electronic governor low idle should be 1600 rpm Move the engine idle control switch to high idle rabbit symbol from the ground controls Result High idle should be 2500 rpm Turn the engine off If low and high idle rpm s are correct disregard adjustment steps 8 and 9 8 Remove the mounting fasteners from the electronic governor located on the engine side bulkhead then remove the back panel from the governor 9 Restart the eng

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