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Service Manual - Genie Industries

1. a BLK 22 5 WHT 23 i O BLK 26 5 NC k RO NC eo ER BE 502 2 9 2 BLK WHT 34 Ore CR14 WHT 1 H P L GRN TO GRD 19 GRN WHT 8 7 6 5 4 38 2 1 gs khi BLU BLK 37 i BLU 436 WHT BLK 31 f hi WHT 30 9 E WHT RED 32 o x BLK RED 35 GENERATOR 45 GRN WHT 1 E SPARE 44 GRN BLK 1 a HORN 43 GRN 1 c BLU RED 13 Mr LL TURN ROT HI 42 ORG RED 1 BLISS 41 40 GRN 25 L P 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 PEERS m STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 O GLOW PLG OPT 34 BLK WHT 1 START 33 BLK 1 32 WHT RED 1 RED 10 HPL E D C 31 WHT BLK 1 RED WHT 29 E D C 30 WHT 1 BLKWHTES mme 2WD AWD 29 RED WHT 1 Dray O 28 f f AUX PWR 27 RED 1 2 PWR TO FS 26 5 BLK 7 UE PWR START 25 RED 5 FS x PWR CONT 24 WHT F S BLK RED 9 PWR FRM PLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 OPTION WIRE 21 WHT Gris lo 20 LL JIB VALVE 19 GRN WHT 3 JIB p PLAT ROT R 18 GRN BLK 3 ML RE
2. M L K J H G F E D C B A JIB BOOM PLATFORM ROTATE 1 SLAVE TURNTABLE BOOM UP DOWN ROTATE BOOM EXTENSION CYLINDER PRIMARY ies EE SECONDARY EM Td e tL S T 1200 L I FEC BRAKE esee dd i 2 XZ JIBBOOM s N MANIFOLD MASTER CYLINDER TWO SPEED 1025 _ y aceon bem ee MANIFOLD 250PSI E ed OPTIONAL WJ A 1 MOTOR GEN FUNCTION 3 MANIFOLD 290 Fe an G qur S7 iMEDIUM ke 1 PRESSURE rri t RYSY FILTER TEST 3500 b PSI 071 PRESS EF jj GENERATOR BES FUNCTION SELECT 4 E PUMP PRESS l TAGEM 5 60 Models 2600 psi Y S 65 Models 2900 psi I DRIVE PUMP ac mj 2500 OPTIONAL m f de LC J OIL p l p l dad nn gt 2 5 COOLER 5 AL eo T SECOND COUNTERBALANCE VALVE ADDED RESERVOIR AUX PUMP AFTER SERIAL NUMBER 4862 amp OSCILLATE CYLINDERS puc HYDRAULIC l eee
3. Service Manual Electrical Schematic Gasoline LPG Models Section 6 Schematics BLK RED 1 HIGH RPM io 1 ENGINE SPEED amp i z E 1 FUNCTION ENABLE z E HIGH RPM BLK RED o 1 T x RED WHT E H 95 52 BLU BLK EH j 165 BLK RED R4 E H cod a E gt pere 5 Use 8 3 RED WHT R3 E H lee HTASHSSNS E 2G 5 gt 4 m Z amp ojd sin RED WHT 23 E H RED BLK R6 E HO 5 EIS o a g o I M4 GENERATOR 4 m GRN WHT 1 GRN WHT 4 DE A Ed 4 o amp 8 E BLU RED 1 F BLU RED R7 EH LF LP H FUEL GAS BLU WHT 1 oz BLU WHT R6 E H p x 8 fo 7 E 5 E ox BLU WHT R6 E H p 4 FUEL GAS ORG RED 1 BLK Z RED 7 4 3 J 8 E gt 3 zo g os E BLK 1 x EE z SES 89H n u u ENGINE Eg START 5 EDS E ENGINE WHT 24 oz C START BLK 1 g WHT e 1 5 Veo ye Sz IN ILL iod gt dla 000001 WHT 21
4. P2 NC EMERGENCY STOP TS3 DP1 GLOW PLUG OPTION 8 7l6 5 4 38 2 1 TS4 o HIGH O RPM L1 LED TS9 GENERATOR OPTION TS8 DRIVE ENABLE oo 2WD 4WD SELECT jej EXTEND RETRACT BP2 R xI T A TS6 JIB enta OPTION LOCKOUT RELAY TS5 O o gt PLATFORM 559 ROTATE 57 PLATFORM LEVEL pqA Rpl P3 NO HORN Part No 48412 Genie 5 60 amp Genie 5 65 Service Manual Second Edition Section 6 Schematics Platform Control Box Wiring Diagram Diesel Models
5. HORSE POWER LIMITER HPL 1 2 31415 6 7 8 910 ORG BLK 1 ORG 1 2 GROUND STUD GEN OPTION 45 GRN WHT 1 SPARE 44 GRN BLK 1 HORN 43 GRN 1 TURN ROT HI 42 ORG RED 1 4 40 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 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 4WD 29 RED WHT 1 28 AUX PWR 27 RED 1 PWR TO F S 26 BLK ES PWR START 25 RED F S F S PWR CONT 24 WHT H P L PWR FRM PLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 21 20 JIB VALVE 19 GRN WHT 3 PLAT ROT R 18 GRN BLK 3 PLAT ROT L 17 GRN 3 PLAT LVL 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 3 110 SEC BOOM DN 11 BLU BLK 3 SEC BOOM UP 10 BLU 3 EXT RET F C 9 BLK RED 3 RETRACT 8 BLK WHT 3 EXTEND 7 BLK 3 CABLE TURN EXT 6 WHT RED 3 1 TURN ROT R 5 WHT BLK 3 TURN ROT L 4 WHT 3 PRIMARY F C 3 RED WHT 3 PRIMARY DN 2_ RED BLK 3 PRIMARY UP 1 RED 3 CABLE 2 CABLE Platform Control Box Legend Diesel Models RED BLK 1 TILT ALARM
6. CASE DRAINS eec se ind loch eee iem etie M J H G E JIB BOOM PT R 527 i g ATFORM ROTATE TURNTABLE SLAVE ROTATE BOOM UP DOWN ro sy TWO SPEED Eh SS gt FET BRAKE MANIFOLD mi gt p rd MANIFOLD d pom 3 pe arc IAS E ZR R gt 2 MASTER S PLATFORM Il p gt EXTEND RETRACT PTIONAL eee 2 OTOR GENERATOR ZH 2100 P18 m ol 2 eee Le Fare pte TEST Ee PK ar ex ad sS X 6 o du PRESS n Je SELECT _____ GPM KF op Xp Sn Psi rat p DRIVE PUMP u p poses 1 pee T OPTIONAL ps m SSS SSS SS SS SS SS SS SS SS 3 25 p 1 COOLER PSI 9 12900 PSI WITH JiB SECOND COUNTERBALANCE VALVE ADDED 1 AFTER SERIAL NUMBER 4862 RESERVOIR AUXILIARY PUMP HYDRAULIC COUPLER l e STEER MANIFOLD DRIVE MANIFOLD Nu 250 ET VES M7 REAR RIGHT AE PH alei ma LE STEERING 070 Wr REAR by A LEFT LH 8i SMAR LJ m i 5 1 1 RB
7. 2 8 Bolt Torque Specifications ana tegi Tegel e gn edt eee rales 2 9 Section Three Scheduled Maintenance Inspections Introduction i at i em co A arteries 3 1 Tid DIG A rm epe e ec te bo eere rg 3 2 Table B Beate ela e ed pede e blade 3 3 Table s 3 5 Table Doo zza leet a ERR RR ia Eo ten dea Hebe E ie IRE nds 3 6 Maintenance Inspection Report 3 7 Section Four Scheduled Maintenance Procedures 4 ann tia iti bete ir eb ede 4 1 A l I spectthe Manuals ee aii dea eo 4 2 A 2 Inspectthe Decals and Placards 4 2 A 3 Inspect for Damage Loose or Missing 4 2 A 4 Check the Engine Oil Level mme 4 3 A 5 Check the Engine Coolant Level Gasoline LP G Models 4 3 A 6 Check Tor Fuel leaks nadie e cie o te etae 4 3 A 7 Check the Hydraulic Oil Level oo eect meme 4 4 A 8 Check for Hydraulic Leaks 10 aaa 4 4 lt Part No 48412 Genie S 60 amp Genie S 65 Service Manual Second Edition Te 9 TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 9 Check the Tire Pressure 222 11 nennen 4 5 10
8. D B A 1 BOOM EXTENSION CYLINDER PRIMARY gt S SECONDARY t a 1200 LT 1207 2 3 PRESS 4 TANK 5 6 7 8 Part No 48412 Genie S 60 amp Genie S 65 6 23 Section 6 Schematics Oscillating Axle 4WD Hydraulic Schematic Service Manual JIB BOOM PLATFORM ROTATE o lt LO N gt tr lt a z Q m o oj pei
9. 4 41 D 4 Check the Engine Valve Clearance Gasoline LP G Models 4 42 D 5 Check the Engine Cylinder Compression Gasoline LP G Models 4 42 D 6 Clean the PCV Hoses and Fittings Gasoline LP G Models 4 42 D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models 4 43 D 8 Check the Toothed Belt Deutz Diesel Models 4 43 D 9 Replace the Timing Belt Gasoline LPG 4 43 D 10 Grease the Steer Axle Wheel Bearings 2WD Models 4 44 48412 Genie 5 60 amp Genie 5 65 vii Service Manual Second Edition Te 9 TABLE OF CONTENTS Section Five Troubleshooting Flow Charts Introduce ood i Lene s eae A 5 1 1 Engine Will Not Crank mmm 5 3 2 Engine Cranks Over But Will Not Start Gasoline LP G Models 5 5 2A Engine Cranks Over But Will Not Start OR Engine Runs While Cranking The Dies Gasoline LPG Models 5 8 2B Engine Runs While Cranking Then Dies 5 11 3 Engine Cranks Over But Will Not Start Deutz Diesel Models 5 12 4 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LP G 5 15 5 Engine Will Not Start O
10. RED 7 27 e 218 L S POWER Q GR WT 4 GRN WHT i 45 GENERATOR OPTION 44 DUMP VALVES GRN CR5 GRN 1 43 HORN BLK 7 ORG RED 1 42 WHT RED 26A am N TURNTABLE ROT HIGH CABLE OG BK EH ORG BLK 1 41 OG BK zISM PULSE PICKUP BRN GROUND 47 WHT 6 ORG 1 40 WHT 7 LIMIT SWITCH BLU RED 1 39 BU RD S P LP WHT 21A BU WT CR6__ BLU WHT 1__ 38 IBU WT S P GAS BU BK EH BLU BLK 1 37 BL BK D B STEER LEFT WHTIBLK 25A BLU E H BLU 1 36 BLU D B STEER RIGHT BLK 22A BLK RED 1 35 BK RD CR4 BK RD S P RPM WHT 23A CABLE BLKIWHT 1__ 34 GLOW PLUG b NC BK 3 ISM___ BLK i 33 BLK CRS BLK S P START N E WI RD E H WHT RED 1 32 WT RD D B BRAKE WT BK I WHT BLK 1 31 E D C p NCA NO NO t RED 5 WHT 1 30 E D C ho ad RD WT E H R W 1 29 RD WT D B 2WD 4WD N A RD BK E H RED BLK 1 28 TILT ALARM j CABLE RED EH RED 1 27 RD 4 ISM AUX PWR WTIRD E H 26 WATER TEMP SENDER WT BK E H 25 OIL PRESSURE SENDER BLKIWHT SA 1045 WHTEH 24 WARNING SENDER RD WT E H WHT 2 23 KEYSWITCH PWR BLK CR5 BLK 2 22 POWER TO PLATFORM WHT CR2 WHT E H 21 WHT 43A WHT SP DB IGNITION POWER 4 RED BLK 2A RED EH RED CR 7 20 RED S P 12V BATTERY SUPPLY GRN WHT 3 19 GRWT S P JIB VALVE GRN BLK 4 _ GRN BLK 3 18 GR BK DB GR BK S P PLATFORM ROTATE RIGHT HM RED WHT 3A GRN 4 GRN 3 17 GRN D B GRN S P PLATFORM ROTATE LEFT m US CABLE ORG RED R8 ORG RED 3 16 OG
11. 5 50 21 Platform Level Up Function Inoperative 2 2 2 5 5 22 Platform Level Down Function Inoperative 5 53 23 Platform Rotate Left Function Inoperative 5 55 24 Platform Rotate Right Function Inoperative 5 58 25 Jib Boom Up Inoperative 5 65 Models 5 61 26 Jib Boom Down Inoperative 5 65 5 63 viii Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition _ d m Section Five Section Six TABLE OF CONTENTS Troubleshooting Flow Charts continued 27 Oscillate Function Inoperative seseseeeeeenneeennn eene 5 65 28 Steer Left Function aea 5 66 29 Steer Right Function Inoperative 5 68 30 A All Drive Functions Inoperative All Other Functions Operate Normally 5 70 31 Drive Forward Or Reverse Function Inoperative 5 73 32 2 5 74 33 Machine Will Not Drive At Full 5 75 34 Machin
12. REDBLKS 2 RDPKSP PRI BOOM DOWN i REDA RED IEEE AED SP PRL BOOM UP GRNUWHT 19A i D B A ORGIBLK 15B ik ORG RED 168 i onG 148 2 4 um GRN 178 dinis let MES Oi RED WHT 298 Ot BLK R1 87 H i BLKWHT BB 19 BRN GROUND i CABLE Ha H1 BLK7B ce WHT 2IA i 3 WHTIBLK 58 2 BLU 368 WHT 4B f 4 BLU BLK 37B i i RED BLK 2B EM 5 WHTIRED 32B H RED 1B Ss Pe BRN GROUND BLK 33A i EM FO smarren i ORGBLK lt AB IGN START BLKWHT 24A i i i 2 smarneur MODULE i RED 20A i i CADIE RED 27B LO aux on RED R1 30 4 HO 5 GROUND amp Amar LO e semen i LO 7 Kev ewe i O s kevaveass i i annee s IGN FUELON i mm eve ORG RED 16 TB16D 10 RED 6 ISM BLK 6 i Waris BLK RED R4 E H j RED 6 i RED CB1 i i 1 2 s n PLATFORM LEVEL DISABLE 8 d i HYDRAUIC OIL COOLER ORG RED 4 i BLK 1 ISM 1 p OPTION RELAYS el F i j BLK R1 E H 2 BLK D B WHT 21D i BLK RS AH ij WHT R17 E H i 5 i ENGINE f HARNEss BRN GRD ORG R17 E H NI i i GRN 43D O i 6 16 Genie 5 60 amp Genie 5 65 Part No 48412 Section 6 Schematics Service Manual Second Edition JIB DELAY CAPACITOR CR14 PLATFORM ROTATOR RELAY IT
13. Activate footswitch and Continued from the jib boom toggle switch Replace CR13 previous page TS6 in the down direction and check voltage on the red and black wires at the jib platform rotate select valves item AM Install a 0 to 5000 psi 0 Exchange jib boom to 345 bar pressure 2500 psi platform rotate select uncaon gauge atthe quick or more valves item AM operates disconnect coupling on Activate footswitch and the function manifold jib boom down function and activate the jib boom down function Replace defective valve function inoperative Check for mechanical restrictions keeping jib boom down function from operating OR repair or replace jib m cylinder replace counterbalance less than 2500 psi valve OR 0 035 orifice may be plugged OR jib boom platform rotate select manifold has an internal defect OR consult Genie Industries Service Department function Exchange jib boom operates Replace defective counterbalance valves counterbalance valve and activate jib boom down function function inoperative Consult Genie Industries Service Department 5 64 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Oscillate Function Inoperative Be sure all other function operate normally Remove the chassis cover atthe non steer end Check the linkage f
14. sse Testing Plug Torque Specifications Description Hex size Torque SAE No 8 5 16 50 ft lbs 68 Nm SAE No 2 1 8 50 in lbs 6 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 12 5 8 75 ft lbs 102 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 52 Genie S 60 amp Genie S 65 Part No 48412 Section 7 Repair Procedures Service Manual Second Edition J gt gt Z AA MANIFOLDS 10 9 Valve Adjustments 2WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connecta 0 to 600 psi 0 to 41 bar pressure gauge to the test port located on the drive manifold 2 Startthe engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turnthe engine off Hold the charge pressure relief valve and remove the cap item 1 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restartthe engine Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off then remove the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 7 54 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures gt gt Ri ZZ ZL MANIFOLDS This page int
15. 2 Connect leads from an ohmmeter to the valve coil terminals Valve coil specification 2 position 3 way valve 5 90 schematic item AM Part No 48412 Genie S 60 amp Genie S 65 7 17 Section 7 Repair Procedures Service Manual Second Edition Boom Components 4 1 Boom Cable Track The boom cable track guides cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire boom cable track is necessary when performing major repairs that involve removing the boom How to Remove the Boom Cable Track When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Referto Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Open the platform control box and remove the platform control box mounting fasteners 2 Separate the footswitch quick disconnect then lower the platform control box and lay it off to the side 3 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on the counterbalance valve manifold located near the platform rotator Cap the fittings on the manifold Bodily injury hazard S praying 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 squi
16. D 4 Check the Engine Valve Clearance Gasoline LPG Models D 5 Check the Engine Cylinder Compression Gasoline LPG Models D 6 Clean the PCV Hoses and Fittings Gasoline LPG Models D 7 Check the Fuel Injection Pumps and Injectors Deutz Diesel Models D 8 Check the Toothed Belt Deutz Diesel Models D 9 Replace the Timing Belt Gasoline LP G Models D 10 Grease the Steer Axle Wheel Bearings 2WD Models ra Pa ra ra ra ra ra ra ra r2 3 6 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second 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 Make copies ofthis page to use for eachinspection Select the appropriate checklist s for the type ofinspection 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 an tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y x yes acceptable 2 no
17. MANIFOLDS 5 6 lt 475 gt s WEE D qp 9 Sa L 2 9 oe T Part No 48412 Genie S 60 amp Genie S 65 7 39 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS Function Manifold Components continued Index Schematic No Description Item Function Torque 18 Proportional solenoid valve ASTA Turntable rotate left right 10 12 ft Ibs 14 16 Nm 19 Solenoid valve Poppet Platform level up 25 30 ft Ibs 34 41 Nm 20 Flow regulator valve 0 6 2 27 Tei Platform level 10 12 65 14 16 Nm 21 Solenoid valve Poppet Platform level down 25 30 ft lbs 34 41 Nm 22 Differential sensing valve Mp Meters flow to functions 10 12 ft lbs 14 16 Nm 23 Relief valve 2600 psi 179 bar 5 60 models 2900 psi 200 bar 5 65 models Was System 35 40 ft lbs 47 54 Nm 24 Diagnostic Testing 25 Check valve seess Differential sensing circuit Platform rotate left
18. E X T ces i i 9 CT 9 I a BLI 7 1 5 LINY d 5 s ge gt PA BEEN E AL PEN apo a E 1 ipo EEE WENN E AE ON i umi 7 1 1 EM 1 ERY X LIEN 20 I HOMI 1 Ll NU g u a K poc B m gt Seed eee 1 jx E a 5 t 5 WA 50 TO a x T a LR zm m aa 1 851 La gt 221 25 OES e I i Dx PSY EI L2 MES T r KO n_j OSes eu uel dek INI s qe ee 415 t Fal SLA 98 ez oo 2 am N SAI 88 Lo 8212 1 a a i EE i S La s s al Pj RI g AE OLH Tek ef 9 m ez ti 5 mo s i 9 6 14 5 oi 88 poe cese I SE ER i I zu t uj ee B gt Z w zt fu EE 1 SZ WONNA mil xm Be ZE LY A 1 a 5 s 50 I TAX PIEJ Bo ge 1 Qu Ls szl Gb r z SF ps Dj E SUM IA ZE NEUEM Soy sea mcg logo RH SC PSY 27 eJ 1 a lEs 88 A H Ela SE s 1 k 5 sa ex io 1 76 BI poned 9 i a pas d A T kie ES ev 1 1 EB lt ox EJO g w H a
19. Result The drive enable indicator light should come on 6 Repeatsteps 3 and 4 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 when 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 a testline on the ground for reference 2 Startthe engine from the platform controls Part No 48412 Genie S 60 amp Genie S 65 4 25 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 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 pointon 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 2
20. gg en l A aj N e BLK 3 BLK WHT 3 a JE BLK 4 7 EXTEND BooM BLK WHT RETRACT BLK WHT 4 B LL EH 1 BLK RED BLK RED 4 7 n Fr BLK RED 3 n E WHT BLK 3 e WHT 3 i WHT 4 x WHT 4 z 1 E RIGHT TURNTABLE WHT BLK d rA w ROTATE zz WHT BLK 4 E BELLE P 8 o zl E a 1 m i E WHT RED 4 2 LE WHT RED 3 q I 1 1 Run RED 4 PRIMARY a RED BLK N DOWN BOOM KE RED BLK 4 BLEEE I 2 d EREN c E Tf 100 RED WHT 4 a X RED 3 RED BLK 3 p sA E RED WHT 3 p e x E ORG 3 UP PLATFORM LEVEL z LDOWN ORG BLK 3 m ORG O Ir m Eg 2 E ORG 4 7 i E UP PLATFORM LEVEL ORG BLK 1 DOWN ORG BLK 4 7 ee c tpm p ORG RED 4 I 7 n gt ORG RED 3 5 BLK 6 RED 6 7 D amp gt sa X DE RA AI AEA EG GRN 3 oz UP LS JIB BOOM m E 1 DOWN A GRN BLK 3 5 GRN e 2 GRN 4 E UP GRN BLK JIB BOOM DOWN GRN BLK 4 7 o x ieee RIGHT PLATFORM E RIGHT PLATFORM LEFT ROTATE LLeFT__ROTATE D 1 1 H 1 1 __ 02 L BRN YEL GRNWHT E GRNWHTS m 9 tr 7 RED JIB VALVES E 5 E58 bene G S I 500 i NR GROUND DRIVE ENABLE LIMIT SWITCH DRIVE BRAKE VALVE TRAVEL ALARM STEER RIGHT STEER L
21. Replace the EDC Adjust the drive pump Defective Sundstrand null neutral Consult no improvement drive pump contact Genie Industries Service Sundstrand authorized Department repair facility symptoms improve Re adjust drive joystick controller OR if problem still persists consult Genie Industries Service Department PartNo 48412 Genie 5 60 amp Genie 5 65 5 73 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 32 Traction Any type of traction Function desee Inoperative RER Be sure all other functions operate normally 5 74 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Machine Will Not Drive At Full Speed Be sure all other functions operate normally Be sure the machine is not raised above or extended beyond the drive limit switches Be sure the boom drive limit switch is clear of any debris and is not activated when the boom is in the stowed position Be sure thatthe boom extend drive limit switch arm is being held down when the boom is retracted Be sure the wiring to limit switches is intact and show no sign of damage or corrosion 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 the boom in the stowed position check continuity from TB40 to
22. item A 2 5 to 3 5 ohms function Move function enable operates Replace defective Switch to either side and directional valve hold the turntable rotate left right toggle switch at the ground controls in the left direction Manually override the directional valve by pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI 345 bar pressure 2600 gauge at the quick PS or Exchange flow regulator function disconnect coupling on more valve item I with a like operates Replace defective flow the boom function valve item H Check regulator valve manifold and start the turntable rotate left engine Move the function function enable switch to either side and hold the turntable rotate left toggle switch at the function inoperative ground controls in the left direction and check the pressure less than 2600 PSI Continued on the next page Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department 5 44 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Plumb a 0 to 5000 psi lessthan Function manifold could 0 to 345 bar pressure 250 psi have an internal defect gauge into the hose Consult Genie Industries from the function Service Department manifold to the turntabl
23. CHART 19 Disconnect wires to 0 or turntable rotate right infinite directional valve coil ohms item A and test the resistance of the valve Coil See Repair Section Continued from the previous page Replace turntable rotate right directional valve coil item A 2 5 to 3 5 ohms function Move function enable operates Replace defective directional valve Switch to either side and hold the turntable rotate left right toggle switch at the ground controls in the right direction Manually override the directional valve by pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI 345 bar pressure 2600 gauge at the quick PS or Exchange flow regulator function disconnect coupling on more valve item I with a like operates Replace defective flow the boom function valve item H Check regulator valve manifold and start the turntable rotate right engine Move the function function enable switch to either side and hold the turntable rotate right toggle switch at the ground controls in the right direction and check the pressure less than 2600 PSI Continued on the next page function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Se
24. M 10 x 16 8 8 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition ee IM MUMMI Section 2 Specifications SPECIFICATIONS Bolt tightening specifications continued peine a torque torque 98 Bolt description size grade ft lbs Nm Gil thermostat housing screw 37 to 44 50 to 60 Idler pulley V belt pulley bolt 27 to 32 36to44 Plug M 38 x 15 M 10 x 25 8 8 Oil thermostat housing bolts 5 5 to 7 7 5to 9 Idler pulley for toothed belt 300 36 41049 M 6 x 35 Torx 8 8 M 10 x 50 8 8 Oil thermostat housing bolts 5 5 to 7 7 5 to 9 Oil pump bolts 15 to 18 20 to 24 M 6 x 80 Torx 8 8 M 8 x 35 Torx Oil thermostat housing bolts 14 to 16 19 to 22 Oil filter bracket bolts 7 to 8 9 to 11 6 105 8 8 8 x 20 Torx 8 8 Valve plunger housing bolts 14 to 16 19 to 22 Oil intake housing bolts 15 to 18 20 to 24 8 30 Torx 8 8 M 8 x 75 Torx Alternator nuts M 5 3 4 PUS pump noS 151018 2004 Fuel bracket bolts M 8 x 20 8 8 15 20 Injection pump bolts 15 to 18 201024 Adapter housing bolts 70 to 77 95 to 105 Injector cap nut 30 to 37 40 to 50 M 12 x 35 10 9 or M 12 x 75 10 9 Injector fastening bolt 15 to 18 20 to 24 first step second step tightening tightening Injection line 10012 13 5 to 16 5 torque angles ft l N 1st 2 Air intake manifold bolts 15 to 18 20 to 24 i i d ue M 8 x 30 8 8
25. Part No 48412 Genie S 60 amp Genie S 65 Service Manual Second Edition eMM TABLE OF CONTENTS Section Seven Repair Procedures continued Turntable Rotation Components 12 1 Rotation Hydraulic 2 ete aaa memes 7 62 2WD Steering Axle Components 13 1 Yoke and Hub ette He etie bett AWA rope e eb decis 7 65 13 2 Steering C ylifiders ente tee te Re Pete 7 66 13 3 TH RO uii rece 7 67 4WD Steering Axle Components 14 1 Yoke a d Hub aa DO Dee ed 7 68 14 2 Steering Cylinders ae wait eth redo ri dL y ee eges 7 69 14 3 NIE ROd dae eine eee 7 69 Oscillating Axle Components 15 1 Oscillating Axle Lock out Cylinders 2 mm 7 70 Non steering Axle Components 16 1 Drive MOTOT erred iren ed e e Pr eva Ur a ea gs 7 71 16 2 Torque H bner ai eee c A YA 7 71 Xii Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 2 Specifications Specifications Machine Specifications Platform dimensions 6 ft 8ft Standard Optional Stowed dimensions S 60 S 65 Length 6f 8 ft Length 27 ft2in 3010 1 83 m 2 44 m 8 3 m 9 4m width 30 in 36 in 2 43 m 2 43 Tires and wheels Height 9 ft 9 ft Tire size 15 19 5 NHS eum id Tire ply rating 12 Wei
26. 11 13 ft lbs 15 18 Nm 26 Check valve p Differential sensing circuit Platform rotate right 11 13 ft lbs 15 18 Nm 27 Priority flow regulator valve Steering ai eden 10 12 ft lbs 14 16 Nm 3 5 13 2 l min without oscillate axle 5 gpm 18 9 l min with oscillate axle 28 Solenoid valve N O Poppet 452 Platform rotate left ib boom up 25 30 ft Ibs 34 41 Nm 29 Solenoid valve Poppet CC asus Platform rotate right ib boom down 25 30 ft lbs 34 41 Nm 30 Flow regulator valve 0 6 2 27 MIn DD Platform rotate 10 12 ft lbs 14 16 Nm 31 Counterbalance valve BEGA R Platform level 35 40 ft lbs 47 54 Nm 32 Counterbalance valve FF uus Platform level down 35 40 ft lbs 47 54 Nm 33 Check valve GG Boom extend retract circuit 11 13 ft lbs 15 18 Nm Plug Torque Specifications Description Hex size Torque SAE No 8 5 16 50 ft lbs 68 Nm SAE No 2 1 8 50 in lbs 6 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 40 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Proc
27. Continued from the previous page Replace boom up directional valve coil item B 2 5 to 3 5 ohms function Move function enable operates Replace defective Switch to either side and directional valve hold the boom up toggle switch at the ground controls in the up direction Manually override the directional valve by pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from moving OR disconnect coupling on repair cylinder or the boom function cylinder counterbalance manifold and start the valve OR consult Genie engine Move the Industries Service function enable switch to Department either side and hold the boom up toggle switch atthe ground controls in the up direction and check the pressure less than 2500 PSI Exchange flow regulator function valve item H with a like operates valve item G Check boom up function Replace defective flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR boom function manifold could have an internal defect Consult Genie Industries Service Department 5 32 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Boom Down Function Inoperative Be sure all other functions oper
28. Diode Battery 15AMP Circuit breaker Solenoid or relay coil TILT ALARM Horn nol Light U 07 Resistor AE Tilt sensor gt Spark plug Glow plug 181 NO Limit switch normally open held closed 17 b ym Ground supression circuit 5 S LHM NC NO p LS3 s g Limit switch Ag NC 1 Limit switch normally closed held open VAC Vacuum switch O N 1590 Oil pressure switch normally closed Auxiliary pump 4 Water temperature switch normally open ON ISIM Foot switch PLAT KSI GRND Key switch HORN Horn button normally open P1 A Emergency Stop button normally closed Relay contact normally open Relay panel contactor CES RIES CDE EI Horsepower limiter board DP1 ey ood o A Single axis drive controller LG LHM 3 Time delay relay TS3 an Az m Toggle switch SPDT 1 Naj Toggle switch DPDT JH9IH BP2 PWM X Single axis proportional controller START RELAY TACHOMETER START INPUT AUX ON GROUND BATTERY KEY PWR KEY BYPASS IGN FUEL ON EN
29. PartNo 48412 Genie 5 60 amp Genie 5 65 Section 6 Schematics Service Manual Second Edition Ground Control Box Wiring Diagram Diesel Models RED 7 45 27A R zB LS POWER Q i i GRWT 4 GANWHTT 45 GEN OPTION i f 44 DUMP VALVES GAN CRS GANT 45 HORN i ORGREDI 42 TURNTABLE ROT HIGH WHTIRED 26A CABLE OGIBK E H ORG BLK 1 41 OG BK ZISM PULSE PICKUP BRN GROUND i 47 WHT 6 086 1 40 WHT LIMIT SWITCH i BLUED 39 BUIRD SP Le WERDE i BLUWHT 98 cas i BUBKEH BLUBLK1 37 BUBKDB STEER LEFT WHTIBLK 26A i BLU EH BLU 1 36 BLU D B STEER RIGHT i ALL BLK 224 i BLK RED 1 35 BKIRD CRa BKiDS P RPM i i BLKWHTEH BLKWHT 1 34 BKAT S P nom i CABLE GLOW PLUG i lt 6 ISM BLK SP START j i WURDEH WHURED 82 WIRDOB BRAKE wreken WHTBLK1 9r i H RED 5 WHT 1 30 E D C H I i NO NO i i RDWEEH fw 29 REDWH
30. S 9 gel a 1 80 o 9 i 3 5 59 S Lie E 5 S Bc lE Eu 95 E 2 14 23 5 lt Mz gt E wn z E B a mm E BN a 55 7 H sj CE BN A s fc ic E i I 9 gt Ca z GED 280 i 59 i TEO eum BEM p Eo wih os _ ge I a 85 a S X a 3 a HE 1 X ed gt I I lt m I 5 _ 98 R 5259 LLGL az B gz lt 2 lx ul 1 22 ox ES o cx x 5 zc tr eo 5 01 5 22 Ds 1 1 1 aj H H f I 5 gt 24 CUM RANK REPE EE i A 59 irt CH I gs 56 c c o9 6 24 Genie 5 60 amp Genie 5 65 Part No 48412 CASE DRAINS Service Manual Second Edition Section 7 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair ofthis machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start M Read understand and obe
31. 0v 12V or Activate footswitch and more boom extend retract proportional controller BP2 on platform control panel in extend direction and check voltage TP7 0v Activate footswitch and check voltage at terminal on 2 12V or more Re adjust controller see Repair Section OR replace controller BP2 OR consult Genie Industries Service Department CHART 16 Repair open in blk wire circuit from TB7 to boom extend function directional valve coil item C OR repair open in brown ground wire circuit to valve coil Troubleshoot boom extend retract function toggle switch TS19 on ground control panel OR repair open in blk wire circuit from 7519 to TB7 OR consult Genie Industries Service Department Repair open in blk wire from TP7 to TB7 Repair open in power supply circuit from TP 24 to to BP2 OR repair open in brown ground wire circuit from ground to BP2 PartNo 48412 Genie S 60 amp Genie S 65 5 37 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 16 Disconnect wires to boom extend directional valve coil item C and testthe resistance of the valve coil See Repair Section Continued from the previous page Move function enable Switch to either side and hold the boom extend toggle switch atthe ground controls in the extend direction Manually override the directional valve by pushing in on the end of the
32. Hydraulic Tank Filter Condition Indicator B 7 Inspect the Electrical Wiring B 8 Inspect the Tires and Wheels 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 LP G Models B 12 Check and Adjust the Engine RPM Part No 48412 Genie S 60 amp Genie S 65 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition MAINTENANCE TABLES Table B continued R 2 bon pen ools are New parts engine engine service 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 ra ra B 18 Test the 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 B 24 the Drive Speed Stowed Position B 25 Test the Alarm Package n Optional Equipment B 26 Perform Hydraulic Oil Anaysis 5 See D 1 Test or Replace the Hydraulic Oil Every 500 hours perform the following engine maintenance procedure B 27 Replace the Engine Oil and Filter Deutz Diesel Models 3 4 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual S
33. 4 Disengage the torque hubs by turning over the torque hub disconnect caps on each non steering wheel hub ho o disengage position S mj 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 Liftthe machine and remove the jack stands MM AWARNING llsion hazard Failure to re engage the torque hubs may cause death or serious injury and property damage Steer wheels 4WD models 7 Chock the non steering wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 Ibs 9072 kg under the drive chassis between the non steer tires 9 Liftthe 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 disengage position engage position 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 12 Re engage the torque hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Liftthe machine and remove the jack stands AWARNING Collision hazard Failure t
34. A 1 Inspect the Manuals Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition 1 Check to be sure thatthe storage container is present and in good condition 2 Check to make sure thatthe 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 Referto 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 p
35. CHART 15 Continued from the previous page With key switch in ground position and both E mergency Stop buttons pulled out to the oN position move the function enable switch to either side and hold the boom down toggle switch TS17 on ground panel in down direction and check voltage on red blk 2 wire on boom function directional valve coil item B 20V or more Continued on the next page Service Manual Second Edition Move the function enable switch to either side and hold the boom down toggle switch TS17 on ground panel in down direction and check voltage at TB2 With key switch in platform position and both E mergency Stop buttons pulled out to the oN position activate footswitch and boom function controller BP 1 on platform control panel in down direction and check voltage TB2 Activate footswitch and boom function controller BP 1 on platform control panel in down direction and check voltage TP2 0v Activate footswitch and check voltage at terminal on BP 1 12V or more Re adjust controller see Repair Section OR replace controller BP 1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more Repair open in red blk 32 wire circuit from TB2 to boom down function directional valve coil item B OR repair open in brown ground wire circuit to valve coil Troubleshoot boom down function toggle Switch TS17 on gr
36. During removal the overhead crane strap will need to be carefully adjusted for proper balancing 13 Remove the external snap 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 of the number 3 boom tube Place the extension cylinder on blocks for support hing hazard AWARNING Crushing hazard The extension cylinder may become unbalanced and fall when itis removed from the number 3 boom tube if itis not properly supported 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 7 22 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section T
37. Function manifold Function relief valve pressure S60 2600 psi 179 bar Drive pump S65 2900 psi 200 bar Type bi directional variable displacement piston pump Boom down 2100 psi relief valve pressure 145 bar Displacement 2500 rpm 0 to 30 3 gallons per minute 0 to 114 7 liters per minute Boom extend 2500 psi 172 bar Maximum drive pressure 3500 psi 241 3 bar Oscillate axle 950 psi 65 bar Charge pressure neutral position 290 psi 20bar Steer regulator drive position 250 psi 17 bar Oscillate models 5gpm 18 9 liters min Non oscillate models 3 5 gom 13 2 liters min Medium pressure filter 3 micron Auxiliary pump Medium pressure filter 50 psi bypass pressure 3 4bar fixed displacement gear pump Drive manifold Displacement static 0 152 cu in 2 5 cc Brake 250 psi relief pressure 17 2 bar Displacement 1 4 gallons per minute 5 3 liters per minute Steer end drive motors 4WD models Auxiliary pump 2500 psi Displacement 1 52 relief pressure 172 bar per revolution 25 cc Non steer end drive motors Displacement per revolution variable 0 16 to 2 8 cu in 4WD 2 speed motor 2 62 to 45 9 cc Displacement per revolution variable 1 12 to 2 8 cu in 2WD 18 4 to 45 9 cc Function pump Type pressure balanced gear Displacement static 1 14 cu in 19 cc Displacement 2500 rpm Oto 12 3 gallons per minute 0 to 46 6 liters per minute Hydraulic tank circuit 10 micron with 25 psi return line filter 1 7
38. HYDRAULIC OIL TEMP SWITCH COOLING FAN OPTION BATTERY Part No 48412 Genie S 60 amp Genie S 65 6 7 Section 6 Schematics Service Manual Electrical Schematic Gasoline LPG Models REV B N LO N BRN 2 m e NL 9 T BLU RED 3 EO WHS 9 A BRN 5 4 m I WHT 1 RED 5 BLK 5 Q J W I Ew 5 B A DRIVE ENABLE E BLU WHT 3 E 8 5 Eo E WHT BLK 1 E WHT BLK 31 E H jr S e 3 A WHT RED 1 WHT RED 32 E H 7 5 o e FL BLU BLK 1 ZA BLU BLK 37 E H 7 BLU 1 BLU 36 E H aS PN SEIEN JL ZEE gc RENEE z 2 3 z ORG 1 E WHT 6 BRN 6 Ei FAE EEREBEJ WHT 7 BRN 7 gibe get E laste 1 z igozo o 2458 A A a B REDWHT E RED WHT 1 zz HIGH co E D LOW zz T KE 55 al a 8
39. PLUG a GLOW 5 PLUG e BLK WHT 34 E H z Eu 23 S amp WHT g sA SES sa ENGINE SERERE START 5 A t ENGINE HMEEEBEEBEEE WHT 24 E H 2 START 9 9 Bo zz N 5 N N WHT 21 E H 7 o 5 9 ORG RED 1 BLK 7 7 F 24 E 5 Orr z d BLK R1 E H i zo I 52 I LEJ Sil ME a 1 P AUXILIARY 0 L PUMP pu RED RED27EH PUMP 1 Bx RED 1 Fl NE A o 5 t 8 S x s7 F RED BLK 1 gt RED BLK 28 E H x a RED WHT 2 RED WHT 23 E H x 5 Q m z m R x F gt i E 9 a n a 4 GRN 1 GRN e 7 o q 3 e m fp S BLK 2 9 BLK E H o EO tr WHT OZ WHT R17 E H rid 2506 gt Mn 5 5 WERKE 52 ORG R17 E a iv ML MET R a ORG BLK 1 ORG BLK 41 E H a a E 2 DE S 1408 9 a iq t ow o t mi A O 8 34 a a a RED RED 20 E H m st Ln HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID GENERATOR OPTION GLOW PLUG OPTION HOUR METER OIL PRESSURE SENDER WATER TEMP SENDER FUEL SOLENOID STARTER MOTOR AUXILIARY P
40. Service Manual Section 6 Schematics 2WD Hydraulic Schematic Non Oscillating Axle M L K F E D C B A JIB BOOM PLATFORM ROTATE 1 SLAVE TURNTABLE BOOM UP DOWN rh CYLINDER BOTATE 1 d BOOM EXTENSION CYLINDER CAPE MT MICRON EN PRIMARY NS SECONDARY ros EA Om I NEST 1200 L BRAKE _ 25 eo me PSI 2 XZ JIB BOOM BI MANIFOLD MASTER RM PS amp CYLINDER TWO SPEED e Ed BRAKE MANIFOLD SS CE CREE OPTIONAL E Se i 1 GENERATOR d 3 290 Li i i G PSI i 2500 ROBIE iMEDIUM n PSL Ll IPRESSURE 1 a FILTER 21 els A pr BB 00 Ds i i poe duse press LE GENERATOR EH Ea FUNCTION SELE
41. TS9 to either side and check the voltage at the blu wht wire on TS9 0v With the footswitch activated and the drive joystick in the full forward position check the voltage on the center terminal of the drive enable toggle switch TS9 9 to 12V Replace drive enable toggle switch TS9 9 to 12V Repair open in wht wire from terminal 4 on drive joystick to TS9 to TP30 to TB30 through drive enable limit switch 153 to TB12 to wht 12 wire on EDC quick disconnect plug Repair open in blu wht wire from TS9 to TP 12 to TB12 Repair open in wire from terminal 4 from drive joystick DP1 OR replace drive joystick controller OR consult Genie Industries Service Department Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 31 Drive Forward Disconnectthe EDC voltage readings different wire connector from the rive controller Or Reverse drive pump start i engine move the drive Function controller to full forward Inoperative position and note the Be sure all other Reverse the volt meter functions operate leads and move the normally including drive controller to full drives it reverse position and rive In opposite note the voltage direction of malfunction voltage readings the same Check the resistance of the EDC 20 to 24 ohms 0 or infinite ohms
42. direction and check the pressure less than 2100 PSI Reset boom down relief valve item F pressure see Repair Section OR replace boom down relief valve OR repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 5 35 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 16 Boom Extend Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled outto the ON position move the function enable switch to either side and hold the boom extend toggle Switch TS 19 on ground panel in extend direction and check voltage on blk red wire on boom extend retract proportional valve coil item M 20V or more Continued on the next page Move the function enable switch to either side and hold the boom extend toggle switch 7519 on ground panel in the extend direction and check voltage at TB9 With keyswitch in platform position and both Emergency Stop buttons pulled out to the on position activate footswitch and boom extend retract proportional controller BP2 on platform control panel in extend direction and check voltage at TP9 0v Activate footswitch and check voltage at terminal on BP2 12V or more Re adjust controller se
43. on ground panel in the right direction and check voltage at TB4 With key switch in platform position and both E mergency Stop buttons pulled out to the oN position activate footswitch and turntable rotate left right proportional controller BP 1 on platform control panel in the right direction and check voltage TB4 0v Activate footswitch and turntable rotate left right proportional controller BP 1 on platform control panel in the right direction and check voltage TP4 0v Activate footswitch and check voltage at terminal on BP 1 12V or more Re adjust controller see Repair Section OR replace controller BP 1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 19 Repair open in wht wire circuit from TB4 to turntable rotate right function directional valve coil item A OR repair open in brown ground wire circuit to valve coil Troubleshoot turntable rotate left right function toggle switch TS18 on ground control panel OR repair open in wht wire circuit from TS18 to TB4 OR consult Genie Industries Service Department Repair open in wht blk wire from to TB4 Repair open in power supply circuit from TP 24 to BP1 OR repair open in brown ground wire circuit from ground to BP1 PartNo 48412 Genie S 60 amp Genie S 65 5 47 Section 5 Troubleshooting Flow Charts Service Manual Second Edition
44. service is strongly recommended Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 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 S 65 Models Remove the jib boom See 3 1 How to Remove the Jib Boom 3 Remove the mounting fasteners from the jib boom jib rotate valve manifold on the end of the boom Then remove the manifold and set it aside 4 Remove the fasteners from the drive speed limit switch mounted on the side ofthe cable track Do not disconnectthe wiring 5 Supportthe cable track with an overhead crane 6 Remove the hose cable clamp from the pivot end ofthe boom 7 Remove the hose and cable clamp atthe platform end of the cable track 8 Remove the fasteners from the large cable track guide atthe platfrom end of the cable track Remove the guide 7 20 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 9 Remove the cotter pin from the clevis pin at the platform end ofthe cable track and remove the clevis pin 10 Remove the fasteners from the side panel on the cable track to access the cab
45. toggle switch Repair open in blk red wire circuit from toggle Switch to TP 35 to TB35 Repair open in blk red wire circuit from TB35 to CR4 Repair open in brown ground wire circuit to terminal 86 on CR4 Repair open in white 321 power wire from terminal 87 on CR2 to CR3 to CR4 Replace CR4 relay Repair short in blk red R 4 wire to terminal 7 on precision governor PartNo 48412 Genie 5 60 amp Genie 5 65 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 6 Continued from the previous page Check voltage at OV terminal 30 on CR3 12V Check voltage at 0v terminal 486 on CR3 12V n X continuity Check continuity from ground to brown wire on terminal 485 of CR3 continuity Check voltage to ov terminal 87 on CR3 12V Check voltage at terminal 1 red wht wire on electronic governor 12V Check voltage at terminal 1 red wht wire on governor actuator 12V Check continuity from terminal 6 on precision continui governor to blu blk terminal 2 on governor actuator full continuity Continued on the next page Repair open in wht wire circuit from CR2 terminal 87 to CR3 30 Repair open in rd blk R6 wire circuit from vacuumn switch to CR6 to CR7 to terminal 86 on CR3 Repair open in ground wire to terminal 85 on CR3 Replace CR3 relay Repair open in red wht wire c
46. 12 Check and Adjust the Engine RPM Maintaining the engine rpm atthe proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Gasoline LPG Models Perform this procedure in gasoline mode with the engine at normal operating temperature 1 Disconnectthe blue black wire from the governor actuator 2 Connectan 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 Tum the idle adjustment screw on the carburetor clockwise to increase rpm or counterclockwise to decrease rpm a carburetor b adjustment screw 4 Tum the engine off and reconnect the blue black wire to the governor actuator 5 Startthe engine from the ground controls O Result Electronic governor low idle should be 1600 rpm Part No 48412 Genie S 60 amp Genie S 65 4 19 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 6 Move the function enable toggle switch to the high idle rabbit symbol atthe ground controls Result High idle should be 2500 rpm 7 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
47. 20 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 4 Loosen the yoke lock nut then turn the high idle adjustment solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle Deutz Diesel models Low idle 1300 rpm High idle 2300 rpm B 13 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure ofthe key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull outthe 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 3 Check any machine function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check any machine function from the platform controls Result The machine functions should not operate TABLE B PROCEDURES 6 Turn the key switch to the orr position O Result The engine should stop and no functions should operate Deutz Diese
48. 4 29 C 2 Check the Turntable Rotation Bearing amp 4 29 C 3 Check the Free wheel Configuration eesriie 4 30 C 4 Grease the Turntable Rotation Bearing and Rotate Gear 4 31 C 5 Replace the Torque Hub meme 4 31 C 6 Replace the Hydraulic Tank 32 4 33 C 7 Replace the Drive Loop Hydraulic Filter sse 4 33 C 8 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models 4 34 C 9 Replace the Gasoline Fuel Filter Gasoline LP G Models 4 34 C 10 Replace the PCV Valve Gasoline LPG 5 4 36 C 11 Replace the Spark Plugs Gasoline LPG Models 4 37 C 12 Check and Adjust the Air LPG Mixture Gasoline LP G Models 4 37 C 13 Check and Adjust the Ignition Timing Gasoline LP G Models 4 38 C 14 Check the Engine Valve Clearances Deutz Diesel Models 4 38 C 15 Check the Turntable Rotation Gear 4 38 D 1 Testor Replace the Hydraulic Oil sssem m 4 39 D 2 Change or Recondition the Engine Coolant Gasoline LPG Models 4 39 D 3 Change the
49. Contact with AWARNING 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 Retum to Perform Service problem repair Solved Part No 48412 Genie S 60 amp Genie S 65 6 1 Section 6 Schematics Service Manual Second Edition x E Mn Electrical Components Item Description Genie Manufacturer Manufacturer Qty Part Number Part Number nune Battery 1000 CCA 12V DC 30143 nemus pe ER 1 2 1 BP unies J oystick controller Single axis up down 24495 OEM Controls EMS4M6883 1 BP2 cess J oystick controller Dual axis Swing extend 40613 OEM Controls EJ 55 10089 1 CB1 CB2 Circuit breaker 24018 ETA stadiis 45 700 IG 1 P 10 2 CR1 through Relay SPDT 12V DC 340
50. E H Lyd 2 Ld i ea u ids zu 5 IO 8 0 125 SIE WATER TEMP al SENDER Loos 5 lt HR E a BLK R1 E H lp m xix 1 go 1 FE S at A P p REA a F i AUXILIARY i amp fk AUXILIARY PUMP y neci cn PUMP RED RED 27 E H 7 a n Qa RED 1 Te P OVE a m Za 1 OG Vui 4 t 2 E 5 E RED RED BLK 1 RED BLK 28 E H 1 a 4 gt WHT 2 RED WHT 23 E H r a g g NERIS Mr E gt x pu m E q t IT GRN GRN 1 GRN p 2 E N BLK 2 F 02 BLK R5 EH E Bo WHT OZ WHT R17 E H 95 9 4 a gt 256 RENEE ORG R17 E H oz a I ul ERROR zi WHT 21 E H 3 500 a RED E H TM ORG BLK 1 ORG BLK 41 E H a 5 c c g eet ee I a 1 PEE 2 Z PCs ui Bc 5 Bal lt a c a RED F RED 20 E H N LO N HIGH IDLE RELAY FLASHING BEACONS PRECISION GOVERNOR RELAY FUEL RELAY FUEL RELAY GENERATOR OPTION LPG SOLENOID ANTI DIESEL VALVE FUEL PUMP WATER TEMP SENDER OIL PRESSURE SENDER HOUR METER AUTOMATIC CHOKE SPARK PLUG SPARK PLUG IGNITION SYSTEM SPARK PLUG SPARK PLUG PULSE GENERATOR STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN
51. Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 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 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 Inspectfor 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 underside of the drive chassis Ground area under the machine Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures A 9 Check the Tire Pressure This procedure
52. Main bearing bolts 37 50 60 45 Air intake manifold 3 hole 15 to 18 20 to 24 Big end bolts 22 30 60 60 flange bolts M 8 35 Torx 8 8 Flywheel bolts 22 30 60 30 Exhaust manifold bolts 27 to 32 36 to 44 M 10 x 30 Torx 10 9 Cylinder head step 1 22 30 studs step 2 59 80 Starter fastening bolts 28 to 34 38 to 46 step 3 118 160 120 NA M 10 x 28 8 8 Camshaft central bolt 22 30 150 NA Starter carrier bolts 50 to 60 68 to 82 M 12 x 28 8 8 Crankshaft central bolt 96 130 210 NA 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 Part No 48412 Genie 5 60 amp Genie 5 65 2 7 Section 2 Specifications Service Manual Second Edition H SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker S eal Loke O ring face seal fittings and hose ends Machines that utilize Parker Seal Loke O ring face seal fittings and hose ends require thatthe fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Hydraulic Hose and Fitting Torque Specifications SAE O ring Boss Port tube fitting SAE Dash Installing SAE Dash sea e 27 e 27 399 6 mnm 8 8 40 52 sea 359 45 wo es 84 8 mnm 40 842 gt 90 12 tea 60 6 wwo 197 9 Aummm 66 pea 4 es 2397 126 1 19
53. No 2 1 8 50 in Ibs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 46 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 10 5 Valve Adjustments Oscillate Manifold How to Adjust the Oscillate Sequencing Valve Pressure When removing a hose assembly or fitting the O ring on the fitting and or hose end mustbe replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Connecta 0 to 2000 psi 0 to 138 bar pressure gauge to the test port located on the oscillate manifold Bodily injury hazard S praying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Disconnectthe directional valve linkage by removing the clevis yoke from the drive chassis 3 Startthe 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 unloader valve and remove the cap item 4 6 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap ip Do not adjust th AWARNING 170 07 hazard Do not adjust the relief valve
54. ON position check voltage at TB39 With keyswitch on and both Ss aa Stop buttons pulled out to the ON position check voltage at terminal 430 on CR7 Crank engine for 15 seconds and check voltage at terminal 486 on CR7 Check continuity from ground to brown wire on terminal 485 on CR7 good Continued on the next page Replace fuel select switch Repair open in blu red wire circuit from fuel select switch to TP 39 to TB39 Repair open in blu red wire circuit from TB39 to terminal 30 on CR7 Repair open in red blk wire circuit from vacuum switch to CR6 to CR7 Repair open in brown ground wire circuit to terminal 85 on CR7 Chart 4 PartNo 48412 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 4 Continued from the Hold the start switch to Replace CR7 relay ravioli page either side and check p page voltage at terminal 87 on CR7 Hold the start switch to Repair open in blu red either side and check wire circuit from CR7 voltage at blu red wire terminal 87 to LPG on LPG solenoid solenoid 0 or 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 5 16 Genie 5 60 amp Genie 5 65 Part No 48412 Service Ma
55. 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 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance 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 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 equivalent hydraulic oil Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Perform this procedure with the boom in the stowed position 1 Remove the hydraulic tank See Repair Procedure 11 2 How to Remove the Hyaraulic Tank The pump needs to primed before starting the engine See R
56. SWITCH RELAY CUTOUT CUTOUT TS18 TURNTABLE ROTATE SWITCH RELAY BELAY TS19 BOOM EXTEND RETRACT SWITCH CB1 CIRCUIT BREAKER CONTROLS 15A CB2_ _CIRCUIT BREAKER ENGINE 15 HM HOUR METER R2 RESISTOR 10 OHM BOOM FUNCTIONS G1 VOLT METER GAGE G2 OIL PRESSURE GAGE G3 WATER TEMP GAGE Part No 48412 Genie S 60 amp Genie S 65 6 9 Section 6 Schematics Service Manual Second Edition l Ground Control Box Wiring Diagram Gasoline LPG Models STACKED CONTACTS
57. Service Manual Ford number P P D 194 287 Genie part number 33907 Part No 48412 Genie S 60 amp Genie S 65 4 43 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE D PROCEDURES D 10 Grease the Steer Axle Wheel Bearings 2WD Models Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Blockthe non steering wheels then center a lifting jack under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support 4 Remove the lug nuts then remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There should not be any side to side or up and down movement Skip to step 10 if there is no movement 6 Remove the dustcap from the hub then remove the cotter pin from the castle nut 7 Tighten the castle nut to 35 foot pounds 47 Nm to seatthe bearings 8 Loosen the castle nut then re tighten to 8 foot pounds 11 Nm 9 Checkfor wheel bearing wear
58. TP 22 to Emergency Stop button P2 With the key switch turned to platform controls and both Emergency Stop buttons pulled outto the on position check the voltage on the output side of the platform Emergency Stop button contact 12V Check voltage atTP23 0 12V Repair open in blk wire circuit from platform Emergency Stop button to TP 26 to foot switch OR replace foot switch OR consult Genie Industries Service Department Check if Emergency yes Stop switch the contact Replace contact on Emergency Stop button P2 Replace the platform Emergency Stop button Repair open in blk wire with diode from Emergency Stop button to TP23 PartNo 48412 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 14 Boom Up Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled outto the ON position move the function enable switch to either side and hold the boom up toggle switch 7517 on ground panel in up direction and check voltage on red wht wire on boom up down proportional valve coil item O 20V or more Continued on the next page Move the function enable switch to either side and hold the boom up toggle switch TS17 on ground panel in the up direction and check voltage at TB3 With the keyswitc
59. Yoke and Hub drive motor Bodily injury hazard S praying How to Remove the Yoke AWARNING 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 3 Loosen the wheel lug nuts Do not When removing a hose assembly remove them or fitting the O ring on the fitting and or hose end must be replaced 4 Blockthe non steering wheels and then and then torqued to specification center a lifting jack of ample capacity under the during installation steering axle dde 2 aa Hydraulic 5 Raisethe machine 6 inches 15 2 cm and Hong doque place blocks under the chassis for support Specifications 6 Remove the lug nuts then remove the tire and 1 Remove the pin retaining fasteners from both wheel assembly the steering cylinder and the tie rod pivot pins Remove the pins 7 Remove the hydraulic hose clamp retaining fastener from the top of the yoke 8 Remove the drive motor mounting fasteners 9 Slide the drive motor shaft out of the torque hub and then remove the drive motor from the machine 10 Remove the pin retaining fasteners from the upper and lower yoke pivot pins 12 Support the yoke torque hub assembly with a lifting jack Secu
60. and scheduled may cause death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years M 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 Indicates the presence of a hazard that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific resultis expected after performing a step Part No 48412 Genie S 60 amp Genie S 65 4 1 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition Table A Procedures
61. bar bypass Part No 48412 Genie S 60 amp Genie 5 65 2 3 Section 2 Specifications SPECIFICATIONS 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 0 035 to 0 055 inches Service Manual Second Edition Starter motor 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 bolt 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 75 to 4 1 bar Type 12V Group 31 Oil capacity 5 quarts including filter 4 7 liters Quantity 1 Cil viscosity requ
62. circuit 10 12 ft Ibs 14 16 Nm 3 Orifice Plug 0 025 inch 0 635 mm UU Priority flow regulator circuit 4 Priority flow regulator valve 3 5 13 2 l min VV Regulates flow to oscillate 10 12 ft Ibs 14 16 Nm 7 50 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures gt gt Oi Z ZZL This page intentionally left blank Part No 48412 Genie S 60 amp Genie S 65 7 51 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 10 8 2WD Drive Manifold Components The drive manifold is mounted inside the drive chassis atthe non steerend Index Schematic No Description Item Function Torque 1 Relief valve 250 psi 17 2 bar WW Charge pressure circult 10 12 ft lbs 14 16 Nm 2 Flow divider combiner valve NX ias Controls flow to drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 3 Orifice 0 070 in 1 78 mm NY s Drive circuit 4 Shuttle valve 3 position 3 way ZZ xis Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor 15 18 ft lbs 20 24 Nm 5 Diagnostic fitting
63. circuit from key switch to function enable toggle Switch to each function toggle switch 12V Troubleshoot each function individually Repair open in red wire circuit from emergency stop button to the key switch Check if key switch internal cam is activating Replace key switch contact for ground ground contact controls no Replace key switch KS1 5 28 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Controls Inoperative Ground Controls Operate Normally Does engine startfrom yes the platform controls Be sure all cables from chassis through the cable Check voltage at TB22 UN track are in good condition with no 12V kinks or abrasions Check voltage at TP 22 0v 12V Check voltage at blk wire on input side of platform Emergency Stop button contact P2 Chart 13 Start engine from the platform controls then press down the foot Test or replace foot switch see Repair Section OR repair open in wht wire circuit from foot switch to 24 switch and check voltage at TP24 12V Repair open in wht wire circuit from TP 24 to function toggle switches and function controllers Repair open in red wire circuit from key switch to TB22 OR Replace the platform controls contact atthe key switch Repair open in blk 2 wire circuit from TB22 TP22 Repair open in blk wire from
64. controls 6 Inspectthe filter and related components to be sure that there are no leaks 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 thatthe filter be replaced more often ACAUTION P re of hot oil Contact with hot oil may cause severe burns Perform this procedure with the engine off 1 Openthe engine side turntable cover and locate the drive loop hydraulic filter mounted on the engine near the main pump 2 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing 3 Remove the filter element from the housing 4 Inspect the housing seal and replace it if necessary 5 Install the new filter Genie part no 20880 and hand tighten the housing onto the filter head Clean up any oil that may have spilled during the installation procedure 6 Startthe engine from the ground controls 7 Inspect the filter assembly to be sure that there are no leaks 8 Clean up any oil that may have spilled Part No 48412 Genie S 60 amp Genie S 65 4 33 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE C PROCEDURES C 8 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models Replacing
65. does notneed to be performed on machines equipped with the foam filled tire option An 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 itis 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 if equipped Proper axle oscillation is essential to safe machine operation If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over 1 Startthe engine from the platform controls 2 Drive the right steer tire up onto a 6 inch 15 2 cm block or curb Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 3 Drive the left steer tire up onto a 6 inch 15 2 cm block or curb Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level atall times 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 If the chassis does not remain level during test see Repair Procedure 10 6 How to Set Up the Directional Valve Linkage
66. down direction and check voltage at TB18 12V Continued on the next page Chart 26 Move the function enable switch to either side and activate the jib boom toggle switch TS15 in the down direction and check voltage at TB18 Repair open in grn blk wire from TB18 to jib boom down directional valve OR repair open in brown ground wire circuit to directional valve Repair open in grn blk wire from TS6 to TP18 Repair open in red power wire circuit from keyswitch to 7515 OR replace toggle switch 1915 Activate the footswitch and the jib boom toggle switch TS6 in the down direction and check voltage at TP18 Repair open in grn blk wire from TP 18 to TB18 With the keyswitch turned to platform control and both Emergency Stop buttons pulled outto the ON position activate the footswitch and check the voltage on the center terminal of the jib boom toggle switch TS6 OR replace jib boom toggle switch TS6 Check the voltage at OV Repair open in red wire terminal 30 on CR13 from to CR13 OR repair open in brown i ground wire circuit to R13 12V Check the voltage at Replace CR13 terminal 287a on CR13 12V Repair open in red wire from terminal 87a on CR13 to T56 OR consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 5 63 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 26
67. fasteners from the fuel tank hold down straps Remove the straps from the fuel tank Supportthe fuel tank with 2 lifting straps Place one lifting strap at each end of tank and attach the lifting straps to an overhead crane Remove the fuel tank from the machine i tank AWARNING Crushing hazard The fueltan may become unbalanced and fall if itis not properly supported and secured to the overhead crane Clean the fuel tank and inspect for rust and corrosion before installing 11 2 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply lines and has an external return line filter with a filter 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the fuel tank See 11 1 How to Remove the Fuel Tank Part No 48412 Genie S 60 amp Genie S 65 7 59 Section 7 Repair Procedures Service Manual Second Edition FUEL AND HYDRAULIC TANKS 2 Close the two hyd
68. from keyswitch KS1 to auxiliary toggle switch TS10 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 36 Check continuity from Replace negative cable negative terminal on from auxiliary pump to auxiliary power unit to ground ground Replace auxiliary pump motor Continued from the previous page PartNo 48412 Genie 5 60 amp Genie 5 65 5 79 Section 5 Troubleshooting Flow Charts Service Manual Second Edition p Z ZZA ee This page intentionally left blank 5 80 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 6 Schematics Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair ofthis machine Immediately tag and remove from service damaged 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 and 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 Electrocution hazard
69. fuel speed solenoid injection system is binding or defective solenoid Check if 2 speed binds Check linkage or solenoid moves in and replace solenoid out freely 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 PartNo 48412 Genie S 60 amp Genie S 65 5 25 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 10 Functions Inoperative Engine Starts and Runs Check hydraulic Fill with Dexron fluid level ES hydraulic UIQ Do the pumps feel excessively hot If engine has been run Check pump suction line closed shutoff valves In the with valves closed it open position the valve may have damaged one handles should be or both pumps Please parallel with hose contact the Genie Industries Service Department Open valves and start the engine Check all machine functions for correct operation Disconnect ignition coil spline Troubleshoot connector plug from turns inoperative boom n an op pele functions ut iesel models ho inoperative drive manual fuel shutoff lever functions separately to the closed position clockwise Remove function pump from main pump but leave all hoses connected Hold start switch and crank engine over while observing Spline drive a
70. higher than specified MANIFOLDS 7 Repeatsteps 3 through 6 and 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 Sequencing valve specifications Pressure 950 psi 65 5 bar Part No 48412 Genie S 60 amp Genie S 65 7 47 Section 7 Repair Procedures Service Manual Second Edition Pv Z 1 MANIFOLDS 10 6 Directional Valve Manifold Components The directional valve manifold is mounted inside the drive chassis atthe non steerend Index No Description Function Torque 1 Caban wia owi od eb tertius Breather a a da tts 20 25 ftlbs 27 33Nm 2 Spool valve eet EE A Directional control 7 48 Genie 5 60 6 Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 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 S replaced 1 Lowerthe 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 Check the tire pressure in all four tires and add CZ air if needed to meet specification 4 Remove the drive chassis cover f
71. horsepower limiter board 7to 8V Replace horsepower limiter board 0v With the drive speed selector toggle switch TS8 in the high 7 to 8V position activate the Repair open in org blk wire from alternator to TB41 to TP41 to terminal 43 on horsepower limiter board footswitch and check the voltage on the org blk wire on the alterator 0v Repair or replace alternator Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Activate the footswitch and hold the drive joystick in the full forward position and Continued from the previous page check the voltage at terminal 6 on the joystick controller 9 to 12V Connect the positve lead from a voltmeter to terminal 4 on the joystick and the negative lead to terminal 5 on the joystick Activate the footswitch and hold the drive joystick in the full forward position and check the voltage across the and 5 terminals on the drive joystick controller Connect the positve lead from a voltmeter to terminal 45 on the joystick and the negative lead to terminal 4 on the joystick Activate the footswitch and hold the drive joystick in the full reverse position and check the voltage across the 5 and 4 terminals on the drive joystick controller 2V Continued on the next page CHART 30 Repair open in wire from terminal 10 on horsepower limit
72. in blk wht wire circuit from 151910 TB8 OR consult Genie Industries Service Department Repair open in blk wht wire from TP8 to TB8 Repair open in power supply circuit from TP 24 to BP1to BP2 OR repair open in brown ground wire circuit from ground to BP2 5 40 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 17 Disconnect wires to 0 or Continued from the ARR infini infinit previous page pom SEMC a hme Replace boom retract test the resistance of the arka valve coil valve coil See Repair Section 2 5 to 3 5 ohms function Move function enable operates Replace defective Switch to either side and directional valve hold the boom retract toggle switch atthe ground controls in the retract direction Manually override the directional valve by pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from retracting disconnect coupling on OR repair cylinder or the boom function cylinder counterbalance manifold and start the valves OR consult engine Move the Genie Industries Service function enable switch to Department either side and hold the boom retract toggle switch at the ground controls in the retract direction and check the pressure less than 2500 PSI
73. 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 B 27 Replace the Engine Oil and Filter Deutz Diesel Models Engine specifications require thatthis procedure be performed every 500 hours Perform this procedure more often if dusty 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 againstthe 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 oil ACAUTION Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the filler cap located above the dipstick Part No 48412 Genie S 60 amp Genie S 65 4 27 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 2 Pullthe end ofthe drain hose outfrom under the engine 3 Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a suitable container See capacity specifications below 4
74. platform level function up and down directional operates valves items S and U and activate the platform level up function Replace the defective directional valve function inoperative Exchange platform level function up and down operates counterbalance valves items EE and FF and activate the platform level up function Replace the defective counterbalance valve function inoperative Install a 0 to 3000 Check for mechanical 0 to 207 bar pressure 600 psi restrictions keeping gauge at the quick ormore Platform level up disconnect coupling on function from operating the function manifold OR replace slave and activate the platform cylinder OR replace level up function slave cylinder counterbalance valves OR consult Genie Industries Service Department less than 2600 psi Test master cylinder see Chart 16 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR function manifold may have an internal defect Consult Genie Industries Service Department 5 52 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Level Down Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the position move the function enable Switch to either side and activate the
75. push the rotation gear into the rotation bearing 3 Loosenthe lock nuton the adjustment bolt 4 Tum the adjustment bolt clockwise until it contacts the pivot plate 5 Turn the adjustment bolt 1 2 turn counterclockwise Then tighten the lock nut on the adjustment bolt 7 64 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 2WD Steering Axle Components 13 1 Yoke and Hub How to Remove the Yoke and Hub 1 Removethe pin retaining fasteners from both the steering cylinder and the tie rod pivot pins Remove the pins tie rod axle yoke pivot pin yoke hub pivot pin g steering cylinder 0 w 2 Loosen wheel lug nuts Do not remove them 3 Blockthe non steering wheels and then center a lifting jack of ample capacity under the steering axle 4 Raisethe machine 6 inches 15 cm and place blocks under the chassis for support 5 Remove the lug nuts Then remove the tire and wheel assembly Remove the pin retaining fasteners from the yoke pivot pins S upportthe yoke hub assembly with a lifting jack Use a slide hammer to remove the upper yoke pivot pin then use a soft metal driftto drive the lower yoke pivot pin down and out AWARNING Crushing hazard The yoke hub assembly may become unbalanced and fall when the yoke pivot pins are removed if itis not properly secured and supported by the lifting jack Torq
76. refer to Chart 30 OR consult Genie Industries Service Department Hold the drive enable switch TS 9 to either side and activate the footswitch and drive forward function Will unit drive Repair open in blu wht wire from drive enable toggle switch TS9 to TP12 to TB12 OR replace drive enable toggle switch TS9 Activate limit switch by hand and check continuity from TB30 to TB12 continui no continuity Please begin troubleshooting from beginning of chart OR consult Genie Industries Service Department Chart 35 Repair open in power supply circuit from TP24 The machine is operating correctly If machine does not operate properly consult Genie Industries Service Department Replace drive enable limit switch contact OR replace drive enable limit switch 153 PartNo 48412 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 36 Auxiliary it the red auxilary ump switch cover Functions th cover hol H auxiliary switch an Inoperative listen sound of auxiliary pump motor operating Be sure all other functions operate normally Be sure key switch is in the appropriate position and the Emergency Stop buttons are pulled out to the on RE motor does position not operate Be sure engine is notrunning when using auxiliary power Note Operating auxiliary power with the engine running should i
77. remove from service R repaired Comments Checklist A YN Referto Table A A 1Manuals A 2 Decals and placards A 3 Damage loose or missing parts A 4 Engine oil level 5 Engine coolant Gas LPG A 6 Fuel leaks A 7 Hydraulic oil level A 8 Hydraulic leaks A 9 Tire pressure A 10 Oscillate axle A 11 Platform and ground controls A 12 Auxiliary power A 13 Tiltsensor A 14 Limit switches Perform every 100 hours A 15 Replace engine oil and filter Gas LP G Models A 16 Drain filter separator Deutz Diesel A 17 Replace air filter Checklist B YN Referto Table B B 1 Engine belt B 2 Engine radiator Gas LPG B 3 Oil cooler and fins Diesel B 4 Exhaustsystem 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 Gas LP G B 12 Engine RPM B 13 Key switch B 14 Emergency Stop B 15 Ground control override B 16 Directional valve B 17 Platformleveling B 22 Drive enable system B 23 Drive brakes B 24 Drive speed stowed B 25 Alarm package B 18 Horn B 19 Footswitch B 20 Engine idle select B 21Fuelselect Gas LP G B 26 Hydraulic oil analysis Perform every 500 hours B 27 engine oil Diesel Checklist Ref
78. 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 B 22 Test the Drive Enable System Proper drive enable system operation is essential to safe machine operation When the boom is pastthe non steering wheels drive movement is stopped and the indicator light turns on The drive enable switch must be to either side to reactivate the drive function and should inform the operator that the machine will move in the opposite direction that the drive and steer controls are moved An improperly functioning drive enable system may allow the machine to be moved into an unsafe position 1 Startthe engine from the platform controls 2 Rotate the turntable to the right until the boom is pastthe 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 TABLE B PROCEDURES 4 Hold the drive enable toggle switch to either side and slowly move the drive control handle off center LLI 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 Result The drive function should operate 5 Rotate the turntable to the left until the boom is past the left non steering wheel
79. the relief valve and remove the cap item 5 function manifold 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeatsteps 2 through 5 and recheck relief valve pressure Boom extend relief valve specifications Pressure 2500 psi 172 bar MANIFOLDS How to Override a Valve A hydraulic valve may need to be manually overridden to troubleshoota 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 uses a three position valve The platform level uses a three position and a two position valve The three position valves and the proportional valves can be manually overridden To identify the manifold valves see 10 1 Function Manifold in this section 1 Push the button on the end of the valve in 14 inch 6 mm 2 Hold the function enable switch to either side and move the ground control function switch for the function being overridden to operate function llisi AWARNING Collision hazard Impact with moving boom components may cause death or serious injury Use extreme cauti
80. the brake and motor onto the torque hub Fill the hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealantto the plugs and then install the plugs Adjust turntable rotation gear backlash See Repair P rocedure 18 1 How to Adjust the Turntable Rotation Gear Backlash Turntable rotate torque hub Capacity 17 fluid ounces 0 51 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 48412 Genie S 60 amp Genie S 65 7 63 Section 7 Repair Procedures Service Manual Second Edition See eee a O I TURNTABLE ROTATION COMPONENTS How to Adjust the 6 Rotate the torque hub pivot plate away from the turntable until it contacts adjustment bolt Turntable Rotation Gear Backlash Then tighten the mounting fasteners on the The tumtable rotation torque hub is mounted on a torque hub pivot plate adjustable plate that controls the gap betweenthe 7 Rotate the turntable through an entire rotation rotation motor gear and the turntable bearing Check for tight spots that could cause binding Be sure to check the backlash Readjustif necessary 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 Pushthe torque hub pivot plate towards the turntable as far as possible this will
81. tighten the drain plug QEO a fuel filter b drain plug Part No 48412 Genie S 60 amp Genie S 65 4 11 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES 2 Clean up any fuel that may have spilled If the fuel filter is completely drained you must prime the fuel filter water separator before starting the engine R efer to C 8 in this section Replace The Diesel Fuel Filter Water Separator for instructions on how to prime the fuel filter water separator 3 Startthe engine from the ground controls and check the fuel filter water separator for leaks A 17 Replace the Engine Air Filter Engine specifications require that this procedure be performed every 100 hours Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off 1 Remove the retaining ring from the end cap of the air filter canister 2 Remove the end cap from the air cleaner canister 3 Remove the air filter retaining fastener then remove the filter 4 Cleanthe inside ofthe canister and the gasket with a damp cloth 5 Insertthe new filter and replace the mounting fastener 6 Replace the end cap on the canister then replace the retain
82. to decrease the voltage 8 Setthe lo range Press down the foot switch then move the control handle all the way to the pown position Adjust the voltage to 6 2V DC Tum the dual range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 9 Startthe engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Lower the boom to the stowed position Engine should be at normal operating temperature 10 Start a timer and record how long ittakes for the boom to fully raise Adjustthe 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 outthe Emergency Stop button to the position 14 Press down the foot switch and then move the control handle all the way to the ue position Record the maximum voltage reading 15 Startthe engine PLATFORM CONTROLS 16 Start a timer and simultaneously move the control handle all the way to the up position Note how long ittakes to reach the maximum voltage recorded in step 14 This is the ramp rate 17 Setthe ramp rate turn the trimpot to ob
83. together the cable track may become unbalanced and fall when itis removed from the machine Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 12 Remove the mounting fasteners from the large cable track guide atthe platform end ofthe cable track Remove the guide 13 Remove the hose and cable clamp atthe platform end of the cable track 14 Attach a lifting strap from an overhead crane to the cable track 15 Remove the cotter pin and clevis pin from the upper cable track atthe platform end 16 Remove the cable track mounting fasteners that attach the lower cable track to the boom 17 Remove the cable track from the machine and place it on a structure capable of supporting it Crushing hazard The cable track AWARNING may become unbalanced and fall if it is not properly attached to the overhead crane ACAUTION Component damage hazard Cables and hoses can be damaged ifthey are kinked or pinched How to Repair the Boom Cable Track Component damage hazard ACAUTION The boom cable track can be damaged if it is twisted A cable track repair kitis available through the Genie Industries Service Parts Department Part no 46677 The kit includes a 4 link section of cable track fasteners other miscellaneous parts and detailed instructions 1 Remove the boom cable track See 4 1 How to Remove the Boom Cable Track 2 Visually inspect the cable tra
84. toggle switch TS19 on ground panel in the retract direction and check voltage on blk red wire on boom extend retract proportional valve coil item M 20V or more Continued on the next page Move the function enable switch to either side and hold the boom retract toggle switch 7519 on ground panel in the retract direction and check voltage at TB9 With keyswitch in platform position and both Emergency Stop buttons pulled out to the on position activate footswitch and boom extend retract proportional controller BP2 on platform control panel in the retract direction and check voltage at TP9 0v Activate footswitch and check voltage at terminal on BP2 12V or more Re adjust controller see Repair Section OR replace controller BP2 OR consult Genie Industries Service Department Chart 17 9 to 9 5V Repair open in blk red wire circuit from TB9 to boom extend retract proportional valve coil item M OR repair open in brown ground wire circuit to valve coil 9 to 9 5V Repair open in blk red wire from TP9 to TB9 Repair open in power supply circuit from TP 24 to BP1to BP2 OR repair open in brown ground wire circuit from ground to BP2 PartNo 48412 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts CHART 17 Continued from the previous page With key switch in ground position and both E mergency Stop switches pulled o
85. until the platform is resting on the blocks just enough to support the platform Do not restthe entire weight of the boom on the blocks Part No 48412 Genie S 60 amp Genie S 65 7 11 Section 7 Repair Procedures Service Manual Second Edition PLATFORM COMPONENTS 4 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the platform rotate counterbalance valve manifold and connect them together using a connector Cap the fittings on the cylinder AWARNING Bodily injury hazard S praying 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 Pullthe slave cylinder hoses through the platform rotator 6 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin 7 Remove the external retaining ring from the barrel end pivot pin 8 Use a soft metal drift to drive the rod end pivot pin out 9 Use a soft metal drift and drive the barrel end pin out 10 Carefully pull the cylinder out of the boom Component damage hazard ACAUTION 2 3 Hoses can be damaged if they are kinked or pinched How to Bleed the Slave Cylinder Do notstartthe 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 tw
86. valve spool Install a 0 to 5000 PSI 345 bar pressure gauge at the quick disconnect coupling on the boom function manifold and start the engine Move the function enable switch to either side and hold the boom extend toggle switch at the ground controls in the extend direction and check the pressure Exchange flow regulator valve item H with a like valve item G Check boom extend function Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department function inoperative 0 or infinite ohms 2 5 to 3 5 ohms function operates less than 2500 PSI function operates function inoperative Replace boom extend directional valve coil item C Replace defective directional valve Check for mechanical restrictions keeping boom from extending OR repair cylinder or cylinder counterbalance valves OR consult Genie Industries Service Department Replace defective flow regulator valve Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Boom Retract Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom retract
87. 0 188 5 284 7 233 2 352 5 282 427 1 wi 4 Torque Procedure 1 Replace the O ring The O ring must be 3 Be sure thatthe face seal O ring is seated and replaced anytime the seal has been broken retained properly The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight R Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight The O rings used in the Parker m Seal Lok6 fittings and hose ends 5 Tighten the nut or fitting to the appropriate are a custom size O ring They torque per given size as shown in the table are nota standard SAE size O above ring They are available in the O 6 Operate all machine functions and inspect the ring field service kit Genie pn hoses and fittings and related components to 49612 be sure that there are no leaks 2 Lubricate the O ring before installation 2 8 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 2 Specifications SPECIFICATIONS Bolt Torque Specifications Size Threads SAE Grade 5 Bolts lt gt SAE Grade 8 Bolts 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 32 49 6 68 8 14 inch 20 96 11 144 16 28 120 14 168 19 5he inch
88. 1 Control Relays beo ap e ct eite ile o Eo pes 7 33 8 2 Toggle Switches See 1 5 Toggle Switches sss 7 9 8 3 Wago Components 7 33 9 4 RGSISTOMS c ai et abet edita ee B ER e 7 33 9 5 Power Relay uide Esq t ete een Ga Ud lan 7 34 Hydraulic Pumps 9 1 LTS teer Pump cec rrt er erede E a Cod edge 7 35 9 2 Drive ioo oti ire t tet cec dad en 7 35 Manifolds 10 1 Function Manifold Components 2 7 38 10 2 Valve Adjustments Function Manifold eect 7 42 10 3 Turntable Rotation Manifold amp 7 45 10 4 Oscillate Manifold Components 22 memes 7 46 10 5 Valve Adjustments Oscillate Manifold ses 7 47 10 6 Directional Valve Manifold Components 7 48 10 7 Steer Manifold Components S 60 65 Oscillating Models 7 50 10 8 2WD Drive Manifold 3 22 memes 7 52 10 9 Valve Adjustments 2WD Drive 7 54 10 10 4WD Drive Manifold 22 memes 7 56 10 11 Valve Adjustments 4WD Drive Manifold eseese 7 58 Fuel and Hydraulic Tanks Tiel Fuel anka ode i 7 59 11 2 Hydraulic RANK e wio e ite i tia 7 59
89. 13 Install the suction strainers using a thread sealant on the threads 14 Install the drain plug using a thread sealanton the threads 15 Install the hydraulic tank onto the machine 16 Install the two suction hoses and the supply hose forthe auxiliary power unit 17 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 18 Clean up any oil that may have spilled and open the hydraulic tank valves Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the hydraulic tank Always use pipe thread sealant when installing the drain plug Use only Dexron II equivalent hydraulic fluid Hydraulic system Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 55 gallons capacity including tank 208 liters Hydraulic fluid Dexron equivalent Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures How to Prime the Pump ACAUTION Component damage hazard Be sure thatthe hydraulic tank shutoff valves in the position before priming the pump The 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 1 Connect
90. 18 17 23 25 34 24 19 28 25 34 3 8 inch 16 30 41 45 61 24 35 48 50 68 7he 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 inch 9 430 583 600 814 14 470 637 660 895 Linch 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 application of bolt Part No 48412 Genie S 60 amp Genie S 65 2 9 Section 2 Specifications Service Manual Second Edition EE This page intentionally leftblank 2 10 Genie 5 60 6 Genie 5 65 Part No 48412 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections 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 properly complete each AWARNING inspection when required may cause death serious injury or substantial damage Immediately tag and remove from service damaged or malfunctioning
91. 20 foot pounds 569 5 Nm Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second 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 ofthis machine Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the orr position with the key removed Wheels chocked Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie S 60 amp Genie S 65 Operator s Manual Be sure thatall necessary tools and test equipment are available and ready for use M Read each appropiate flow chartthoroughly Attempting shortcuts may produce hazardous conditions Be aware ofthe following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocu
92. 26 to 87 psi 1 8 to 6 0 bar Oil capacity 11 quarts including filter 10 5 liters Oil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SG or CD SG grades Units ship with 10W 40 SG CC Injection system Injection pump make OMAP Service Manual Second Edition ELEC RC I A SU Injection pump pressure 4351 psi 300 bar Injector opening pressure 3626 psi 250 bar Fuel requirement diesel number 2 D Alternator output 55A 14V Starter motor Current draw no load 90A Brush length new 0 7480 in 19 mm Brush length minimum 0 5 in 12 7 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Fan belt deflection 3 8 to 1 2 inch 9to 12 mm Bolt tightening specifications torque torque Bolt description size grade ft lbs Nm Camshaft thrust bearing bolt 15 to 18 20 to 24 M 8 x 35 8 8 Rocker arm bolts 15 to 18 20 to 24 M 8 x 45 8 8 Rocker arm set screw nut 15 to 18 20 to 24 Cylinder head cover 6 to 7 8 to 10 Blower rotor nut 33 to 41 45 to 55 M 17 Valeo or M 18 Bosch Blower carrier bolts 15 to 18 20 to 24 M 8 x 50 Torx 8 8 V belt pulley bolts 28 to 34 38 to 46
93. 413 211 CR14 PLATFORM ROTATOR TS4 RELAY O O HGH O RPM GEN OPTION 45 GRN WHT 1 SPARE 44 GRN BLK 1 TS2 HORN 43 GRN 1 TURN ROT 42 ORG RED 1 41 40 L1 LED START LP 39 BLU RED 1 GAS 38 BLU WHT 1 STEER LEFT 37 BLU BLK 1 TS20 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 GLOW PLUG 34 BLK WHT 1 TS9 START 33 BLK 1 GENERATOR BRAKE 32 wHT RED 1 OPTION E D C si WHT BLK 1 TS8 E D C WHT 1 2WD 4WD 29 RED WHT 1 DRIVE ENABLE 28 O AUX PWR 27 RED 1 PWR F S 26 BLK FS 2WD 4WD PWR START 25 RED ES ge SELECT PWR CONT 24 WHT H P L 181 PWR FRM PLAT 23 WHT 2 PWR TO PLAT 22 BLK 2 21 20 EXTEND JIB VALVE 19 GRN WHT 3 JIB RETRACT AUXILIARY PLAT ROT R 18 GRN BLK 3 E POWER PLAT ROT L 17 GRN 3 PLAT LVL 16 ORG RED 3 BP2 R X A TS6 PLAT LVL DN 15 ORG BLK 3 JIB PLAT LVL UP 14 oRG 3 pec BOOM DRV ENA LT 18 BLU RED 3 110 CR13 OPTION DRV ENA 12 BLUWHT 3 SEC BOOM DN 11 BLU BLK 3 RELAY SEC BOOM UP 10 BLU 3 TS5 EXT RET F C 9 BLK RED 3 8 BLK WHT 3 5 o PLATFORM EXTEND 7 BLK 3 CABLE 09 ROTATE TURN EXT 6 WHT RED 3 1 TURN ROT R 5 WHT BLK 3 D1R A D2 TURN ROT L 4 WHT 3 PRIMARY F C 3 RED WHT 3 PRIMARY DN 2 RED BLK 3 PRIMARY UP 1 RED 3 GABLE BP1 2 HORSE POWER LIMITER p2 A R pi HPL 12 3 4 5 6 7 8 910
94. 5 watt 34798 Dale verte ones RH25 150 1 1 ZETOR Resistor 100 25 watt 27287 RH25 10R 1 1 TS1 TS10 Toggle switch DPST 2 position momentary 13480 Microswitch Control Inc 2 1 8 2 TS2 6 9 11 13 15 2 n Toggle switch SPDT 3 position momentary 13037 Microswitch Control Inc INTI T Lise 6 TS3 8 125220 i seis Toggle switch DPST 2 position maintained 27378 Microswitch Control Inc ANT TES 4 TS4 Toggle switch DPDT 3 position maintained 13038 Microswitch Control Inc ONT del sues 1 TS5 7 14 16 17 18 19 Toggle switch DPDT 3 position momentary 16397 Microswitch Control Inc 2NTT 7 i iiiter 7 iei Vacuum switch 22278 Peterson Industrial 1504 54 nette te 1 Part No 48412 Genie S 60 amp Genie S 65 6 3 Section 6 Schematics Service Manual Second Edition Electrical Symbols Legend I HIB DHO Wire color with cable number TB20 Terminal TB Terminal base TP Terminal platform Quick disconnect terminal BLK 21 TB21 T circuits connect at terminal _ T circuits connect Connection no terminal Circuits crossing no connection
95. 52 Potter Brumfield VF4 15F11 CO5 6 CR13 14 17 and 18 Relay SPDT 12V DC 19274 Potter Brumfield VF4 45F11 CO5 4 Diode Diode 6 amp 200 PIV 45782 Motorola MOTMR752 43 J oystick controller Drive 20424 OEM Controls MCH1159AD1386 1 EB Flashing beacon 20189 ECCO Electronic Controls 6400X 2 2 224 13482 Linemaster Switch Corp 632 5 aaa ann 1 CU Gauge Voltage 30789 MD OE 332 5025 wi 1 62 nasse Gauge Oil Pressure 30786 VDO icri nhe 350 516 inea 1 Ganin Gauge Water Temp 30787 V DO RE 310 502 1 FH uta Alarm Warble tone 19270 Floyd Bell Inc MW 09 616 Q 1 Horn 12V DC 130 GB 19145 Sparton Engineered Prod 7431 24823 5 1 H3 itt Alarm intermittent 18963 Floyd Bell Inc XB 09 630 Q 1 NA asso Alarm chime tone 45462 Floyd B
96. 6 18 Hydraulic Symbols 6 20 2WD Hydraulic Schematic Non oscillating axle 6 21 2WD Hydraulic Schematic Oscillating 6 22 AWD Hydraulic Schematic Non oscillating axle 6 23 AWD Hydraulic Schematic Oscillating axle 6 24 Part No 48412 Genie S 60 8 Genie S 65 ix Service Manual Second Edition A TABLE OF CONTENTS Section Seven Repair Procedures Intro duGtio n e 7 1 Platform Controls 1 1 J oystick Controllers i iride Pd te RR CH Rr 7 2 1 2 Horsepower Limiter 7 6 1 3 EGOGOWIIE dn re t ree te tec ettet Pe Lets 7 8 1 4 Resistors A eap p te c be are E PASE 7 9 1 5 Toggle WitchES 2 35 oh oce apa pte ER dO ERO RECO anes 7 9 1 6 be ae e bec rette d 7 10 Platform Components 2 1 Platform tee e o eb gs 7 11 2 2 Platform Leveling Slave 7 11 2 3 Platform Rotator i ite Late Ua eie Ra ene t tende 7 12 Jib Boom Components S 65 Models 3 1 Jib Boom 5 65 Models eee nennen 7 15 3 2 J ib Boom Lift Cylinder 5 65 5 7 16 3 3 J ib Boom Platform Rotate Manifold Components 5 65
97. 7 BU RD S P L P BU WT CR6 BLU WHT 1 38 IBUWT S P GAS i G1 G2 G3 BU BK E H BLU BLK 1 37 BL BK D B STEER LEFT BLU E H _ BLU 1 36 BLU D B STEER RIGHT BLK RED 1 35 BK RD S P RPM i CABLE BLK WHT 1 34 GLOW PLUG i P1 KS1 e BK 3 ISM BLK 1 BLK CR8__ BLK S P START olo TS10 WT RD E H WHT RED 1 32 WT RD D B BRAKE ONCO WT BK E H WHT BLK 1 31 E D C __ NO NO WHT 1 30 RED 5 E D C i ONCO olo RIW 1 29 2WD 4WD i RD BK E H RED BLK 1 28 TILT ALARM CABLE pep EH RED 1 27 4 RD 4 ISM RED S P AUX PWR i 5 WT RD E H 26 WT RD S P WATER TEMP SENDER WT BK E H 25 WT BK S P OIL PRESSURE SENDER WT 10P ISM WHT EH 24 WARNING SENDER WHT EH _ WHT 2 23 WHT S P KEYSWITCH PWR i BLK CR5 BLK2 22 BLK S P PWR TO PLAT i WHT E H WHT CR2 21 WHT 43A WHT SP DB IGNITION PWR RED E H 20 RED S P 12V BATT SUPPLY GRN WHT 4 GRN WHT 3 19 GR WT S P JIB VALVE HM GRN BLK 4 GRN BLK 3 18 GR BK D B GR BK S P PLAT ROT TS19 TS17 GRN 4 GRN 3 17 GRN D B GRN S P PLAT ROT L ORG RED R8 ORG RED 3 16 OG RD D B OG RD S P PLAT LEVEL F C 1 ORG BLK 4 ORG BLK S 15 OG BK D B OG BK S P PLAT LEVEL DN ORG 4 ORG 3 14 ORG D B ORG S P PLAT LEVEL UP WHTS BLURED S 18 DRV ENA LT WHT EH BLUMHT 3 12 BLK 5 DRV ENA TS12 TS15 BLU BLK 3 11 BU BK D B BU BK S P SEC BOOM DN TS18 BLU 3 10 BLU D B
98. 8 Upa 8 B M e BLK 3 BLK WHT 3 5 JE BLK 4 EXTEND BOOM BLK WHT nga RETRACT nm BLK WHT 4 522 a gt 58 _ 8 8 8 BLK RED E BLK RED 4 8 2 BLK RED 3 wo a WHT BLK 3 MIES WHT x WHT 4 URNTABLE ROTATE WHTBER E 7 m co LEFT lae WHT BLK 4 BI 8 wz i ta E WHT RED 4 amp WHT RED 3 Eug m ERE RED 4 29 UP p RED BLK 4 PE PRIMARY BOOM 9 n DOWN RED BLK 4 1 al lt e a 1 e le E 1 e RED WHT 4 T n m T XP RED 3 RED BLK 3 e BR E RED WHT 3 p LI A ORG 3 PLATFORM LEVEL z R LDOWN ORG BLK 3 E ORG o l Z 5 ORG 4 n TUP UP PLATFORM LEVEL ORG BLK DOWN ZZA ORG BLK 4 o n 1 in aS E o 1 ORG RED 4 z E ORG RED 3 go gt E BLK 6 QZ RED 6 g M E 7 A I 8 RUG BE EG GRN 3 oz UP S k JIB BOOM DOWN GRN BLK 3 GRN i p 5 GRN 4 n R UP E ie BOOK GRN BLK DOWN ud GRN BLK 4 7 2 x RIGHT P RIGHT PLATFORM ROTATE PLATFORM ROTATE w LLEFT LEFT Bo d _ 2 a BRN YEL GRNWHT F GRN WHT 3 i m HH i 2 c 2 RED JIB VALVES 4 CR14 LIFT DRIVE SELECTOR OPTION GROUND D
99. ATFORM LEVEL DISABLE CR17 COOLING FAN RELAY SECTION A A Ground Control Box Legend Diesel Models O RED 7 45 4 27A e 218 GRMT 4___ GRNIWHT 1 45 44 IGRN CR amp GRN i 43 BLK 6 ORG RED 1 42 CABLE oRG BLK 1 OG BK 2ISM 7 WHT 6 ORG 1 40 WHT 7 BLU RED 1 BU RD CR7 BU RD S P BU WT GR6_ BLU WHT 1 38 BUWT S P BU BK E H BLU BLK 1 37 BUBK D B BLU EH _ BLU 1 36 BLU D B BLK RED 1 35 BK RD S P CABLE BLK WHT 1 34 46 BLK 3 1SM BLK t BLK CR8 BLK S P WTJRD E H WHT RED 1 32 wr RD D B WI BK EH WHT BLK 1 31 WHT 1 30 RED 5 RW 1 28 RED BLK 1 28 CABLE reve RED 27 RD 4 1SM RED S P 5 WT RD E H 26 WT RD S P WTIBK E H 25 WT BK S P WT 1O ISM WHT E H 24 WHT EH _ WHT 2 23 WHT S P BLK 2 22 BLK CR5___ BLK S P WHTEH WHT GR2 21 WHT 43A__ WHT SP DB RED EH 20 RED S P GRN WHT 3 19 GRN BLK 4__ GRN BLK 3 18 GR BK D B GR BK S P GRN 4 GRN 3 17 GRN D B GRN S P CABLE ORG RED R8 ORG RED 3 16 OG RD D B OG RD S P 1 ORG BLK 4_ 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 WHTEH BLU WHT 3 12 BLK 5 BL
100. CABLE 3 N 3 P3 HORN x c a RED BLK 1 5 5 GROUND TILT STUD ALARM gt Part No 48412 Genie 5 60 amp Genie 5 65 Service Manual Second Edition Section 6 Schematics Platform Control Box Wiring Diagram Gasoline LPG Models BLK 22 a gt WHT 23 E o BLK 26 2 OJ 6 9g E E N a E c EE z o T BLU RED 39 Y UL Sac BLU WHT 38 wi
101. CAUTION Beware of hot engine components Contact with hot engine components may cause severe burns Oil Cooler 1 Remove the fasteners from the engine side cover then remove the cover 2 Inspectthe oil cooler for leaks and physical damage a oil cooler b cylinder head cooling fins C fan blower fins 3 Clean the oil cooler of debris and foreign material Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Cooling and Fan Blower Fins 4 5 Inspect the fan blower fins for physical damage Clean the fan blower fins of debris and foreign material Inspectthe head cooling passages and fins for physical damage or foreign material using a flashlight Clean the cylinder head cooling passages of debris and foreign material Section 4 Scheduled Maintenance Procedures 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 ACAUTION components Contact with hot engine components may cause severe 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 syste
102. CHART 2A Hold the start switch to either side and check voltage at blu wht wire Continued from the previous page on anti diesel valve on engine carburetor 12V Hold the start switch to either side and check voltage at blu wht 438 wire on fuel pump 12V Hold the start switch to either side and check voltage at blu wht 438 wire on gasoline Solenoid at gasoline tank 12V Hold the start switch to either side does engine start yes Go to chart 2B Repair open in blu wht 338 wire circuit CR6 to anti diesel valve no Check continuity from continuity brown ground wire on fuel pump to ground Repair open in brown ground wire circuit to fuel pump continuity Repair open in blu wht 338 wire circuit from anti diesel valve to fuel pump BT in blu wht 38 wire circuit from fuel pump to gasoline solenoid Reconnect the two wires to vacuum switch and check for fuel line blockage OR replace anti diesel valve OR see Ford service manual for troubleshooting fuel pump and or carburetor OR Consult Genie Industries Service Department 5 10 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Engine Runs While Cranking Then Dies Hold start switch to either side and check voltage at terminal 2 on start lockout module 6 to 7V While cranking engine for 15 seconds check continuity to ground on terminal 10 start loc
103. CT GPM 4 2 PRESS L 14 GPM 5 60 Models 2600 psi r1 psi DRIVE PUMP 5 65 Models 2900 psi Qt gt a LH l 2 2900 57 OPTIONAL ld Ec imr W Z RZ OIL 3 3 PSI COOLER m gt 5 Sk 5 M SECOND COUNTERBALANCE VALVE ADDED RESERVOIR AUX PUMP AFTER SERIAL NUMBER 4862 den 68 1 HYDRAULIC i ROTARY 6 COUPLER M CE STEER MANIFOLD DRIVE MANIFOLD MR 7 REAR 1 RIGHT STEERING CYLINDER 8 REAR f LEFT i CASEDRAINS 0 Part No 48412 Genie S 60 8 Genie S 65 6 21 Service Manual Section 6 Schematics r ss ee 2WD Hydraulic Schematic Oscillating Axle
104. EFT BOOM UP LIMIT SWITCH BOOM EXTEND LIMIT SWITCH MOTOR STROKE BOOM EXTEND BOOM RETRACT BOOM EXTEND RETRACT FLOW CONTROL TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN DESCENT ALARM PRIMARY BOOM FLOW CONTROL PLATFORM LEVEL UP PLATFORM LEVEL DOWN PLAT LEVEL F C CE PLATFORM LEVEL DISABLE OPTION PLATFORM ROTATE LEFT JIB UP PLATFORM ROTATE RIGHT JIB DOWN Genie 5 60 6 Genie 5 65 6 14 Part No 48412 Section 6 Schematics Service Manual Second Edition em G1 G2 P1 KS1 ONCO ojo NO NO ONCO olo TS11 O 6 TS13 CB1 CB2 1211 a d C2 STACKED CONTACTS LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH TS10 AUXILIARY SWITCH TS11 ENGINE START SWITCH TS13 FUNCTION ENABLE 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 CB1 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 G3 WATER TEMP GAGE TS19 515 G3 TS10 TS17 7518 7514 CR18 PL
105. ETRACT 8 BLKWHT 3 REDWHT S lo al EXTEND 7 BLK 3 ul RED BLK 2 Ite al TURN ROT 6 WHT RED 3 2x I TURN ROT R 5 WHT BLK 3 J R TURN ROT L WHT 3 7 X AD2 PRIMARY 3 RED WHT 3 PRIMARY DN 2 RED BLK 3 1 os PRIMARY UP 1 RED 3 WHT BLK 5 a T E m 9 E WHT 4 4 1 1 x h c z D2 A X ui vit 5 1234 56 7 8 9 10 ORG RED 42 a ag WHT RED 6 9 a R n 5 S ORG RED 16 m 9 RED BLK 1 ORG Ha 5 o NI z 8 EE ORG BLK 15 lt ES CO lt GRN 43 6 12 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Section 6 Schematics Electrical Schematic Diesel Models A HIGH RPM e x ENGINESPEED BLED im i o FUNCTION ENABLE A HIGH RPM BLK RED o p D o e 8 se 8 BLK RED R4 E H o 52 OFF f GENERATOR o LON ES GRN WHT 1 GRN WHT 4 E H 7 za B M BLK WHT 1 b p GLOW ENGINE
106. Edition TABLE D PROCEDURES 4 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate S wing the engine pivot plate away from the machine to access the radiator drain valve A 24 NI VII B Za LN a _ pivot plate retaining bolts b engine pivot plate 5 Open the drain valve on the radiator and allow all the coolantto drain into a suitable container 6 After all the coolant has drained close the drain valve Connect the coolant return hose to the radiator 7 Openthe drain valve on the engine block and allow the coolantto drain into a container After the fluid is drained close the drain valve 8 Replace all coolanthoses and clamps 9 Pourthe proper coolant mixture anti freeze and water for your climate into the radiator until itis full 10 Disconnectthe hose coupler atthe fan end from the tube that is connected to the water pump and hold it until coolant starts to come out of the open hose Then immediately reconnectthe hose a tube connected to water pump b hose coupler 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 Startthe 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 Startthe engine from the ground controls and run itunt
107. G FAULT o x o o s o v Ignition start module BP1 RENDER EELA Dual axis Ramp up and down proportional controller Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 6 Schematics Abbreviation Legend LABEL DESCRIPTION BAT aeui Battery BP ossia Proportional controller woe Circuit breaker CR nos haven Control relay DP used Drive proportional controller EB duis Flashing beacon ES uti uenis Foot switch C Gauge Horn or Alarm Hour meter KO wa enia Keyswitch I So dete oon LED IS isis Limit switch Power switch Power relay Baden Resistor NB asco Terminal base location WP iania Terminal platform location ROEE Toggle switch Vacuum switch Part No 48412 Genie 5 60 amp Genie 5 65 6 5 Section 6 Schematics Service Manual Second Edition e O M ee 6 6 Genie 5 60 amp Genie 5 65 Part No 48412 REV B NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION
108. Genie Industries Technical Publications Genie 5 60 Genie 5 65 _____ Service Manual Second Edition First Printing 1 Part 48412 Rev 1 July 2008 Introduction Service Manual Second Edition Genie 5 60 Genie 65 Important Read understand and obey the safety rules and operating instructions in the appropriate 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 5 65 2WD and 4WD models This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at a Genie dealer service center Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and other
109. Goes 09 ROTARY 8 6 COUPLER EE GENERE STEER MANIFOLD Z AZER 1 L eil a _ Jd OSCILLATE MANIFOLD no E no MANIFOLD 3 Tap SS eS ud ER as a 4 250 d RSSSF EG RRR OGR NEJ L 7 9 REAR i z RIGHT LA e M5 e E 4 ma STEERING 070 5c 8 REAR E LEFT 1 I 1 I m 1 1 1 n CET BE 1 CASE DRAINS Part No 48412 Genie S 60 8 Genie S 65 6 22 Service Manual Section 6 Schematics 4WD Hydraulic Schematic Non Oscillating Axle
110. IONS 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 sec 12 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 40 sec 40 40 sec 12 2 m 40 sec 12 2 m 40 sec Gradeability boom stowed 2WD 4WD Rough terrain 2896 4096 Service Manual Second Edition MIENNE O QX QQ Boom function speeds maximum from platform controls J ib boom up 40 to 60 seconds J ib boom down 50 to 80 seconds Boom up 55 to 85 seconds Boom down 90 to 120 seconds Boom extend 60 to 80 seconds Boom retract 55 to 85 seconds Turntable rotate 360 boom fully stowed 80 to 100 seconds Turntable rotate 360 boom extended 130 to 160 seconds Platform rotate 160 10 to 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 48412 Service Manual Second Edition Section 2 Specifications Hydraulic Specifications Hydraulic fluid Dexron equivalent SPECIFICATIONS
111. Install the plug into the drain hose 5 Usean oil wrench and remove the oil filter a engine oil level dipstick b fuel filter c oil filter 6 Apply a thin layer of oil to the new filter gasket Genie partno 49924 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 Fillthe engine with new oil per specifications and install the oil filler cap 9 Startthe engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 10 Check the oil filter and oil drain hose for leaks 11 Check the engine oil level dipstick Add oil if needed Deutz Engine F4L 1011F Oil capacity including filter 11 quarts 10 5 liters Deutz Engine F4L 1011F Oil viscosity requirements Temperature below 60 F 15 5 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 2 Clean up any fuel that may have spilled Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second 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
112. LAY PLAT ROT L 17 GRN 3 PLAT LVL 16 ORG RED 3 PLAT LVL DN 15 ORG BLK 3 PLAT LVL UP 14 ORG 3 CKE DRV ENA LT 13 BLU RED 3 110 GRN 17 DRV ENA 12 BLU WHT 3 GRN BLK He SEC BOOM 11 BLU BLK 3 SEC BOOM UP 10 BLU 3 a EXT RET 9 BLK RED 3 BED m 14 RETRACT 8 BLK WHT 3 U EXTEND 7 BLK 3 eh TURN 6 WHT RED 3 Ho SOS TURN ROT R 5 WHT BLK 3 7 f TURN ROT L 4 WHT 3 DiR x A PRIMARY 3 RED WHT 3 PRIMARY DN 2 RED BLK 3 La aes PRIMARY UP 1 RED 3 WHT BLK 45 ae 4 BP1 L 2 WHT 4 Mn 7 y HORSE POWER LIMITER D2A X R pi 4 2 3 4 5 6 94 ORG RED 42 Y e WHT RED 46 NOG 3 GROUND B ORG RED 16 STUD RED BLK 1 OnG His S TILT ORG BLK 15 O ALARM RED GRN 43 NOTE RESISTOR IS MOUNTED TO EXT RET CONTROLLER USE 100 OHM RES FOR 4WD AND 150 OHM RES FOR 2WD 6 18 Genie 5 60 amp Genie 5 65 Part No 48412 Section 6 Schematics Service Manual Second Edition e O M ee Part No 48412 Genie 5 60 amp Genie 5 65 6 19 Service Manual Second Edition Section 6 Schematics Hydraulic Symbols Legend 2 Pressure gauge a Filter Fixed displacement pump Bi directional variable displacement pump d Bi directional motor 2 2 speed bi directional
113. Models 1 17 Boom Components 4 1 Boom Cable tene EA A TE p 7 18 4 2 BOOM zatai Re wia AA dE ats 7 20 4 3 Boom Lift ylirider ici d ie dE ce Ec dde 7 23 4 4 Extension Cylinder iarrann i ri sw 7 24 4 5 Platform Leveling Master me 7 25 Turntable Covers 5 1 Turntable Covers s eR NIE p metas 7 26 Deutz Engine F4L 1011F 6 1 RPM Adjustment cece ssa nennen nnne nenne nennen 7 27 6 2 Flex P late etd teet d a O EE en AR 7 27 6 3 Oil Temperature and Oil Pressure 7 27 Ford LRG 423 Engine Fel GovernorAGtUator saa intr 7 28 J 2 Choke Adjustments ree e ceed daa AR 7 29 X Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section Seven TABLE OF CONTENTS Repair Procedures Ford LRG 423 Engine continued 7 3 Timing Adjustment a 7 30 7 4 Carburetor ee eene 7 30 7 5 RPM AdjJustment 3 iere Bee td RO Ee Oe EH Ede 7 30 7 6 Flex Plate cep e ER b AL GA ries tla 7 30 7 7 Water Temperature and Oil Pressure Gauges 7 31 7 8 VacullmiS WII hrs cet e cete re d e ala re ates 7 32 Ground Controls 8
114. OR see Repair P rocedure 10 5 How to Adjust the Sequence Valve Pressure Part No 48412 Genie S 60 amp Genie S 65 4 5 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES A 11 Test the Platform and Ground Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions and shut off the engine Each function should activate operate smoothly and be free of hesitation jerking and unusual noise 1 Pulloutthe Emergency Stop button atthe ground controls to the ow position 2 Startthe engine from the ground controls 3 Do nothold the function enable switch to either side Attempt to activate each boom and platform function toggle switch Result All boom and platform functions should not operate 4 Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while the boom is lowering 5 Push in the Emergency Stop button to the orr position Result No function should operate the engine should stop Machines equipped with Platform Level Control Disable Function The platform level f
115. OWER RELAY AUXILIARY PUMP FLASHING BEACONS LEVEL SENSOR SERVICE HORN RELAY SERVICE HORN HYDRAULIC OIL TEMP SWITCH COOLING FAN OPTION BATTERY PartNo 48412 Genie 5 60 amp Genie 5 65 6 13 Section 6 Schematics Service Manual Electrical Schematic Diesel Models A m st LN BRN 2 e E b 8 VAN amp BLU RED 3 F WHS o 9 4 S 2 24 0 I WHT 1 RED 5 BLK 5 I DRIVE EN fo u ENABLE EL BLU WHT 3 t 5 5 EL WHT BLK 1 B WHT BLK 31 E H AY TA S E WHT RED 1 E WHT RED 32 E H SU a BLU BLK 1 E BLU BLK 37 E H 7 BLU 1 BLU 36 E H 7 RE E i 39 ORG 1 WHT6 BRN 6 3 a m WHT 7 BRN 7 a no z o 22 A m REDWHT E RED WHT 1 R HIGH 99 o m 8 LLow ss LE
116. RD D B OG RD S P PLATFORM LEVEL eS UA ORG BLK 4__ ORG BLK 3 15 OG BK D B oG Bk s P PLATFORM LEVEL DOWN O ORG 4 ORG 3 14 ORG D B ORG PLATFORM LEVEL UP NT G WHT 5 BLU RED 3__ 18 DRIVE ENABLE LIGHT A WHTIBLK 5A WHT E H BLU WHT 3 12 BLK 5 DRIVE ENABLE WATA BLUBLK3 11 BU BK S P SECONDARY BOOM DOWN BLU 3 10 BLU S P SECONDARY BOOM UP BLKRED 4 BLKRED 3 9 BK RD S P EXTEND RETRACT FC L Q4 BLKWHT 4 8 BK WT D B BK WT S P BOOM RETRACT BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND R WIR 4 WHTIRED 3_ 6 WT RD S P TURNTABLE ROTATE F C CABLE WHT BLK4 3 5 WT BK D B WT BK S P TURNTABLE ROTATE LEFT WHT 4 WHT 3 4 WHT D B WHT S P TURNTABLE ROTATE RIGHT R W 4 RED WHT 3 3 RD WT S P PRIMARY BOOM F C 1 GRNIBLK 18A RED BLK 4 _ RED BLK 3 2 RD BK D B RD BK S P PRIMARY BOOM DOWN A RED 4 RED 3 1 RED D B RED S P PRIMARY BOOM UP to Hj e A 5 GRN WHT 19A D C B A AC ORG BLK 15B ET GI ORG RED 16B ORG 14B 24 Z GRN 17B O ORG BLK 15A 85 GRN BLK 18B Y RED WHT 29B 54 95 BLK R1 87 ORGREDAGA a R BLK WHT 8B 5 4 10 BRN GROUND i c gt WHT RED 6A CABLE BLK 7B JT a ES WHT 21A BLKIREDB NEJ WHT BLK 5B Zy NIEZ BLU 36B WHT 4B gt BLU BLK 37B RED BLK 2B 4 gt 9 WHT RED 32B RED 1B Ba 10 BRN GROUND o CS 3 BUCRESS TT STARTRELAY BLKIRED 95A QBGIELKAB IGNITION START mm
117. RIVE 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 EXTEND RETRACT FLOW CONTROL TURNTABLE ROTATE R TURNTABLE ROTATE L TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN DESCENT ALARM PRIMARY BOOM FLOW CONTROL PLAT LEVEL UP PLAT LEVEL DN PLAT LEVEL F C CE PLATFORM LEVEL DISABLE OPTION PLATFORM ROTATE LEFT JIB UP PLATFORM ROTATE RIGHT JIB DOWN 6 8 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 6 Schematics Ground Control Box Legend Gasoline LPG Models RED 7 46 27A oe 21B L S POWER O i GRWT 4 GRNWHT 1 45 GEN OPTION 44 DUMP VALVES i gt GRN GR5_ GRN 1 43 HORN BLK 7 ORG RED 1 42 TURNTABLE ROT HIGH CABLE ORG BLK 1 41 OG BK 2ISM PULSE PICKUP i 7 WHT 6 ORG 1 40 WHT 7 LIMIT SWITCH m BLU RED 1 39 BU RD CR
118. S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Rotate Left Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the position move the function enable Switch to either side and activate the platform rotate toggle switch 514 the left direction and check voltage at grn wht wire atTP19 at the platform controls With keyswitch turned to control and oth Emergency Stop buttons pulled out to the on position activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at the grn wht wire at the jib delay capacitor 12V Continued on the next page Repair open in grn wht wire from TS 14 to TB19 to TP19 OR test toggle switch See Repair Section 0v Check voltage on center 0V terminal of TS5 12V With keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at TP 19 0v Activate footswitch and platform rotate toggle Switch TS5 in the left direction and check voltage at the grn wht wire on TS5 0v Test toggle switch See Repair Section OR replace platform rotate toggle switch TS5 Chart 23 Repai
119. Service Manual Second Edition TABLE B PROCEDURES 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 AWARNING Do not inspect while the engine is running Remove the key to secure from operation Beware of hot engine parts and ACAUTION coolant Contact with hot engine parts and or coolant may cause severe bums 1 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate S wing the engine pivot plate away from the machine to access the radiator 2 Inspectthe radiator for leaks and physical damage 3 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 performance of the cooling system Do not inspect while the engine AWARNING is running Remove the key to secure from operation A
120. T D ZWDIAWD i RDBKEH REDBLK1 28 TILT ALARM 0 Fi i CABLE RED ER RED 1 27 RD ISM 9 RED SP AUX PWR i i 5 WIRD EH 26 WIRDSE WATER TEMP SENDER j RED ZT i WIBKEH 25 WIBKSP OIL PRESSURE SENDER i En am WARNING SENDER RDWTEH WHT2 wrrrsr ISM HTSR KEYSWITCH PWR STACKED CONTACT GONTAGTS i BLK CRS BLK2 22 BLK SPP PWR TO PLAT i RED 1A i WHT CR2 WHT EH 21 WHT 43A WHT SP DB IGNITION PWR i BED BLK 2A 1 RED EH REDRI7W30 20 RED S P 12V SUPPLY i i GRNWHT3 19 GRWT SP JIB VALVE i i GRN BLK 4 GRN BLK 3 18 GRBKD B S P PLAT ROT R RED WHT SA i GANA GANS 17 GAN D B GAN S P PLAT ROT L CABLE ORGREDFG ORGREDS 16 OGRDOB oomp SP PLAT LEVEL FC i 1 ORGIBLK 4 ORGIBLK 3 15 OGIBKD B OG BK S P PLAT LEVEL DN i i ORG 4 ORG ORG pa ORG SP PLAT LEVEL UP WHES BLUREDS 15 DAV ENA LT i i WHER BLUWHTS 12 BIS DRY ENA j BLUBLKS i SEC BOOM DN i WHT 4A i BLU G 10 BLU S P SEC BOOM UP i i BLK RED 4___ BLKIRED 3 s BKIRD S P EXT RET i f Bewara BlkWHTS 8 BKWTSP BOOM RETRACT j i BLK 7 BLK S P BOOM EXTEND i WIR A WHT RED 3 6 WIRD S P TURN ROT i ___ ___ 5 WTBKDB __ 5 TURN ROT i i 2 WHT 4 WHT 3 wHTD B WHT S P TURN ROT R i AWA REDWHTS 3 ROMTS P PRI BOOM FC i
121. Testthe Oscillate Axle if equipped ooo etter tier 4 5 11 Testthe Platform and Ground 5 4 6 A 12 Test the Auxiliary Power Operation 4 6 213 Test the TIIES E SOF wyzywa O Re e Ec ue ede abe Pee abe Ede od 4 7 A 14 Test the Limit S aaa nemen 4 8 A 15 Replace the Engine Oil and Filter Gasoline LP G Models 4 10 16 Drain the Fuel Filter Water Separator Deutz Diesel Models 4 11 A 17 Replace the Engine Air mme 4 12 Bel Check the Engine eoe epo te es 4 13 B 2 Check the Radiator Gasoline LP G 4 14 B 3 Check the Oil Cooler and Cooling Fins Deutz Diesel Models 4 14 B 4 Check the Exhaust System 000 4 15 B 5 Check the Battery eec edet lh 4 16 B 6 Check the Hydraulic Tank Filter Condition 4 16 B 7 Inspect the Electrical Wiring 2 2 22 4 17 B 8 Inspect the Tires and Wheels including lug nut torque 4 17 B 9 Confirm the Proper Brake 4 18 B 10 Check the Oil Level in the Torque Hubs ss e 4 18 B 11 Check and Adjust the Engine Idle Mixtur
122. U BLK 3 11 BU BK D B BU BK S P BLU 3 10 BLU D B BLU S BLKRED 4 BLK RED 3 8 BK RD S P BLKIWHT 4__ BLK WHT 3 BK WT D B BKIWT S P BLK 4 BLK 3 7 BLK D B BL S P WIR 4 WHT RED 3 6 WI RD S P CABLE 5 wT BK D B WT BK S P 2 WHT 4 WHT 3 WHT D B WHT S P RW RED WHT 3 3 RD WT S P RED BLK 4__ RED BLK 3 2_ RD BK D B RD BK S P RED 4 RED 3 1 RED D B RED S P D DIODE BLOCKS CABLE 3 1 sTART RELAY 2 TACHOMETER IGN START O STARTINPUT MODULE 4 AUX ON O 5 aRouND 6 BATTERY CABLE 7 key POWER 4 KEY ByPass 9 IGN FUELON 10 ENG FAULT CR1 CR2 CR4 START FUEL RPM RPM RELAY RELAY CUTOUT RELAY RELAY I 1 CR5 HORN RELAY L S POWER O i GEN OPTION DUMP VALVE S HORN TURN ROT HI PULSE PICKUP LIMIT SWITCH LP 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 PLAT LEVEL DN PLAT LEVEL UP DRV ENA LT DRV ENA SEC BOOM DN SEC BOOM UP EXT RET FC BOOM RETRACT BOOM EXTEND TURN ROT TURN ROT L TURN ROT R PRI BOOM F C PRI BOOM DOWN PRI BOOM UP
123. V lu position and oth Emergency Stop buttons pulled out to the on position activate footswitch and turntable rotate proportional controller BP1 on platform control panel in the right direction and check voltage at TP6 0v Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP 1 OR consult Genie Industries Service Department Repair open in wht red wire circuit from TB6 to turntable rotate left right proportional valve coil item R OR repair open in brown ground wire circuit to valve coil Repair open in wht red wire from TP6 to TB6 Repair open in power supply circuit from TP 24 to BP1 OR repair open in brown ground wire circuit from ground to 1 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the turntable rotate left right toggle switch TS18 on ground panel in the right direction and check voltage on wht wire on boom function directional valve coil item A 20V or more Continued on the next page Section 5 Troubleshooting Flow Charts Move the function enable switch to either side and hold the turntable rotate left right toggle switch TS18
124. WARNING Bodily injury hazard Spraying rotator may become unbalanced hydraulic oil can penetrate and and fall ifitis not properly burn skin Loosen hydraulic supported connections very slowly to allow the oil pressure to dissipate 5 65 Models gradually Do not allow oilto squirt 6 Remove the pin retaining fasteners from the jib or spray boom and jib boom leveling arms to platform S 65 models Tag disconnect and plug the rotator pivot pins Do not remove the pins hydraulic hoses from the V1 and V2 ports 7 Support the jib boom and leveling arms platform rotator manifold Cap the fittings on the manifold 8 Usea soft metal drift to drive both pins out then Bodily injury hazard S prayi remove the platform rotator from the machine AWARNING odily injury hazard 5praying hydraulic oil can penetrate and Crushing hazard The platform bus skin ipea hydraulic rotator may become unbalanced connections very slowly to allow and fall if itis not properly the oil pressure to dissipate supported gradually Do not allow oil to squirt or spray 3 Supportthe 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 Crushing hazard The platform AWARNING mounting weldment may become unbalanced and fall if itis not properly supported 5 Supportth
125. WD 4WD Stopping distance 3to5ft 3 to 5 ft 0 9to 1 5m 0 9to1 5m The brakes must be able to hold the machine on any slope itis 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 obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe 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 atfull speed and note the time when the machine reference point crosses the finish line Drive speed stowed position 2WD 4WD Gasoline LP G models 40 ft 6 2 sec 40 ft 9 1 sec 12 2 m 6 2 sec 12 2 m 9 1 sec 40 ft 6 8 sec 40 ft 9 1 sec 12 2 m 6 8 sec 12 2 m 9 1 sec Deutz Diesel models Genie 5 60 amp Geni
126. WHT 1 EE 1 as BRN TO GRD T o Lo zo 98 19 GRN WHT 8 17 6 5141 31 1211 ks a M BLU BLK 37 gt i BLU 36 S E WHT BLK 31 we WHT 30 US ad WHT RED 32 i O a ul BLK RED 35 _ E 9 a ra GENERATOR 45 GRN WHT 1 5 a SPARE 44 GRN BLK 1 5 HORN 43 GRN 1 53 BLU RED 13 TURN ROT 42 ORG RED 1 x E 41 m T 40 GRN 425 59 LP 39 BLU RED 1 fr GAS 38 BLU WHT 1 gt STEER LEFT 37 BLU BLK 1 STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 O lt GLOW PLG 34 BLK WHT 1 START 33 BLK 1 BRAKE 32 WHT RED 1 RED 10 H PL E D C 31 WHT BLK 1 RED WHT 29 E D C 30 WHT 1 BLK WHT 8 2WD 4WD 29 RED WHT 1 1 Nupgum 28 r f AUX PWR 27 RED 1 R X A 09 PWR ES 26 BLK FS fw BLK 7 i PWR START 25 RED FS 2 v PWR CONT 24 WHT F S yey BLK RED 9 PWR FRM PLAT 23 WHT 2 ae PWR PLAT 22 BLK 2 o 21 7 OPTION WIRE 21 WHT A CHI 000 JIB VALVE 19 GRN WHT 3 a UT PLAT ROT R 18 GRN BLK 3 R RELAY PLAT ROT L 17 GRN 3 PLAT LVL F C 16 ORG RED 3 PLAT LVL DN 15 ORG BLK 3 ooh PLAT LVL UP 14 ORG 3 p DRV ENA LT 13 BLU RED 3 e GRN 17 L DRV ENA 12 BLU WHT 3 NE GRNBLK 18 SEC BOOM DN 14 BLU BLK 3 GRN WHT 19 SEC BOOM UP 10 BLU 3 EXT RET 9 BLK RED 3 Z E R
127. _ BLU S P SEC BOOM UP OOG BLK RED 4 BLK RED 3 9 BK RD S P EXT RET F C BLKIWHT 4_ BLK WHT 3 8 BKWT D B BKWT S P BOOM RETRACT BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND WIR 4 WHT RED 3 6 WT RD S P TURN ROT F C CABLE WHT BLK 4 WHT BLK 3 5 WT BK D B WT BK S P TURN ROT L TS16 TS14 WHT 4 WHT 3 4 WHT D B WHT S P TURN ROT R i TS13 CB2 RIW 4 RED WHT 3 3 RDWT S P PRI BOOM i RED BLK 4 RED BLK 3 2 RD BK D B RD BK S P PRI BOOM DOWN E RED 4 RED 3 1 RED D B RED S P PRI BOOM UP 2 00 D C B A yet TERR DIODE d BLOCKS Pa KS1 V l olo 1 CABLE NO NO ojo O 1 stant RELAY O 2 GNITION START lou O 3 STARTINPUT MODULE N 4 AUX ON STACKED CONTACTS i O CR18 5 PLAT 6 LEVEL DISABLE i NR 7 kevewn i 4 8 key Bypass 9 IGN FUELON 10 ENG FAULT CR1 CR2 CR3 CR4 START IGNITION RPM RPM RELAY RELAY CUTOUT RELAY LABEL DESCRIPTION BELAY P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH NI NI TS10 AUXILIARY SWITCH 1 TS11 ENGINE START SWITCH i TS12 ENGINE FUEL SELECT SWITCH i TS13 FUNCTION ENABLE TS14 PLATFORM ROTATE SWITCH i TS15 JIB BOOM UP DOWN SWITCH CR5 CR6 CR7 TS16 PLATFORM LEVEL SWITCH SECTION A A HORN FUEL FUEL TS17 PRIMARY BOOM UP DOWN
128. a 0 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 atthe ignition coils The ignition coils are located above the alternator AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry FUEL AND HYDRAULIC TANKS Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the cLosEp position a manual fuel shutoff valve 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 Connect the wiring and start the engine from the ground controls Check for hydraulic leaks Part No 48412 Genie S 60 amp Genie S 65 7 61 Section 7 Repair Procedures Service Manual Second Edition Turntable Rotation Components 12 1 Rotation Hydraulic Motor How to Remove the Rotation Hydraulic Motor When removing a hose assembly or fitting the O ring on the fitting and or hose end mustbe replaced and then torqued to specification during installation R efer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin Emm Unlocked position Locked position 2 Tag disconnect and plug the hydraulic ho
129. able track Part No 48412 Genie S 60 amp Genie S 65 7 19 Section 7 Repair Procedures Service Manual Second Edition BOOM COMPONENTS 9 Install the black rollers onto the new section of cable track 10 Install cable track onto the machine and operate the boom extend function fully to ensure smooth operation ofthe new section of cable track 4 2 Boom How to Shim the Boom 1 Measure each top wear pad Replace the pad if it is less than 9 16 inch 14 3 mm thick If the pad is more than 9 16 inch 14 3 mm thick perform the following procedure 2 Measure each bottom and side wear pad Replace the pad if itis less than 11 16 inch 17 5 mm thick If the pad is more than 11 16 inch 17 5 mm thick perform the following procedure 3 Extend the boom until the wear pads are accessible 4 Loosen the wear pad mounting fasteners 5 Install the new shims under wear pad to obtain zero clearance and zero drag 6 Tighten the mounting fasteners 7 Extend and retract the boom through an entire cycle Check for tight spots that may cause binding or scraping of the boom Always maintain squareness between the outer and inner boom tubes How to Remove the Boom AWARNING This procedure requires specific 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
130. ace start toggle Switch TS11 Repair blk wire circuit from start switch TS11 to TB33 Repair blk wire circuit from TB33 to terminal 3 on ignition start module Repair open in red power supply wire circuit from CB1 to CR1to CR2 then to terminal 6 to On ignition start module PartNo 48412 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 1 Hold the start switch to Check ground wire to either side and check terminal 5 on start voltage at terminal 1 on lockout module ignition start module Continued from the previous page Repair open in ground wire Consult Genie Industries Service Department Hold the start switch to Repair open in blk wire either side and check from terminal 1 on voltage at terminal 86 ignition start module to Check voltage at terminal 430 on CR1 Repair open in red wire circuit from battery to CB1 to CR1 terminal 330 Hold the start switch to Check brown ground Repair open in brown either side and check wire to terminal 85 on ground wire circuit to voltage at terminal 487 CR1 on Replace CR1 relay Hold the start switch to Repair open in blk wire either side and check circuit from CR1 to voltage at the black wire starter solenoid on the starter solenoid Check voltage at starter cable 12V Repair open in battery cable to starter Repair
131. adiator are under pressure and extremely hot Use caution when removing cap and adding fluids A 6 Check for Fuel Leaks Failure to detect and correct fuel leaks will result in an unsafe condition An explosion or fuel fire may cause death or serious injury Engine fuels are combustible 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 2 Perform a visual inspection around the following areas An LPG detector may be necessary to locate LPG leaks Part No 48412 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES Gasoline LPG models LPG tank hoses and fittings solenoid shutoff valve LP G 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 If a fuel leak is discovered keep 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
132. aged 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 1479 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 outto 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 48412 Genie S 60 amp Genie S 65 7 27 Section 7 Repair Procedures Service Manual Second Edition Ford LRG 423 Engine 7 1 Governor actuator and linkage a yoke Governor Actuator b linkage rod c carburetor d throttle plate shaft How to Set Up the Governor e governor actuator f actuator shaft Actuator and Linkage g actuator arm Adjustment of the governor 4 Position the linkage rod so that t
133. al 3 to 4 5 amp 6 no continuity are single pole double throw SPDT switches Dual function switching requires a double pole terminal 4 to 5 amp 6 no continuity double throw DP DT switch terminal 5 to 6 continuity Center position There are no terminal combinations How to Test a Toggle Switch that will produce continuity Continuity is the equivalent of 0 to infinite 3 ohms A simple continuity tester Right position may not accurately test the switch terminal 1 to 2 continuity This procedure covers fundamental switch testing zero Q n not ificall ly to all varieties of ia d 2 terminal 1 to 3 4 5 amp 6 no continuity 99 infinite 1 Tum the key switch to the OFF position Tag terminal 2 to 3 4 5 amp 6 no continuity and disconnect all wiring from the toggle switch to be tested terminal 3 to 4 5 amp 6 no continuity 2 Connect the leads of an ohmmeterto the switch terminal 4 to 5 continuity terminals in the following combinations listed terminal 4 to 6 no continuity below to check for continuity terminal 5 to 6 no continuity Part No 48412 Genie S 60 amp Genie S 65 7 9 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 1 6 Control Relays Relays used for single function switching are single pole double throw SP DT relays How to Test a Single Pole Double Throw Relay AWARNING Electrocution hazard Contact with electrically charged circuits m
134. alve OR replace CR6 PartNo 48412 Genie S 60 amp Genie S 65 5 17 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 5 Hold the start switch to either side and check Continued from the previous page voltage at blu wht wire on the fuel pump 12V Hold the start switch to either side and check voltage at blu wht wire on gasoline solenoid at fuel tank 12V 0 or infinite Check resistance of ohms gasoline solenoid 18 to 19 ohms 0 or infinite Check resistance of ohms anti diesel valve 24 to 25 ohms Install a pressure gauge to the fuel pump Hold 7 psi start switch to either side and observe the pressure on the gauge more than 7 psi Reconnect starter and see Ford service manual for carburetor troubleshooting OR consult Genie Industries Service Department less than no Check continuity from continuity aroung to brown wire at uel pump Repair open in brown wire circuit to the uel pump continuity Repair open in blu wht wire from anti diesel solenoid to fuel pump OR replace fuel pump no Check continuity from ontinui ground to brown wire at gasoline solenoid Repair open in brown ground wire circuit to the gasoline solenoid continuity Repair open in blu wht wire from fuel pump to gasoline solenoid OR replace gasoline solenoid Replace gasoline solenoid Replac
135. and open the valve Do not remove the bleed valve Move the function enable toggle switch to either side and activate and hold the platform rotate switch to the nicur position until the platform is fully rotated Continue holding the switch until air stops coming out of the bleed valve Then close the bleed valve hi AWARNING Crushing hazard Keep clear of 7 the platform during rotation Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled Rotate the platform full right then left and inspectthe bleed valves for leaks 7 14 Genie 5 60 6 Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end mustbe replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform mounting weldment and the platform rotator See 2 3 How to Remove the Platform Rotator 3 Remove the cable tray from the side of the jib boom 4 Supportthe jib boom with a lifting device 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cyli
136. ar pressure gauge to the test port item 23 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the boom down switch with the boom fully lowered 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 6 function manifold 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do notadjust AWARNING the relief valves higher than specified 6 Repeatsteps 2 through 5 and recheck relief valve pressure Boom down relief valve specifications Pressure 2100 psi 145 bar Pressure 5 60 models 2600 psi 179 3 bar 5 65 models 2900 psi 200 bar 7 42 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures How to Adjust the Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 Connecta 0 to 3000 psi 0 to 207 bar pressure gauge to the test port item 23 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the extend switch with the boom fully extended Observe the pressure reading on the pressure gauge 4 Turn the engine off Use a wrench to hold
137. art switch and check voltage at terminal 9 on ignition start module Check voltage at terminal 6 on ignition start module 12V Check continuity from ground wire at terminal 35 on start lockout module to ground continuity Consult Genie Industries Service Department Repair open in blk wire from terminal 86 on CR2 to terminal 9 on ignition start module Repair open in power supply wires from CB1 to CR1 to CR2 to terminal 6 on ignition start module Repair open in brown ground wire to start lockout module 5 6 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 2 noo continuity Check continuity from ground to terminal 85 on CR2 Repair open in brown ground wire circuit to C Continued from the previous page continuity If weak spark still exists consult Ford engine service manual for troubleshooting engine with weak spark OR consult Genie Industries Service PartNo 48412 Genie S 60 amp Genie S 65 5 7 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 2A Engine Cranks Over But Will Not Start Gasoline LPG Models or Engine Runs While Cranking Then Dies Perform these tests in gasoline mode only Hold the start switch to either side and check the voltage atthe white wire on the choke while cra
138. ate normally With key switch in ground position and both Emergency Stop buttons pulled outto the ON position move the function enable switch to either side and hold the boom down toggle switch TS17 on ground panel in down direction and check voltage on red wht wire on boom up down proportional valve coil item O 20V or more Continued on the next page Move the function MEE ja side and hold the boom down toggle switch 517 on ground panel in the down direction and check voltage at TB3 With the keyswitch in Chart 15 Repair open in red wht wire circuit from TB3 to boom up down proportional valve coil item O OR repair open in brown ground wire circuit to valve coil 6 to 7V Repair open in red wht the platform position and wire from TP3 to TB3 both Emergency Stop buttons pulled out to the ON position activate footswitch and boom function controller BP 1 on platform control panel in down direction and check voltage at TP3 0v Activate footswitch and check voltage at terminal on BP 1 12V or more Re adjust controller see Repair Section OR replace controller BP 1 OR consult Genie Industries Service Department Repair open in power supply circuit from TP 24 to BP1 OR repair open in brown ground wire circuit from ground to BP1 PartNo 48412 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts
139. ay cause death or serious injury Remove all rings watches and other jewelry Direct Connection Relay 1 Labeland then disconnect all the wiring from the relay to be tested 2 Connectthe leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 representthe coil and should not be tested in any other combination Test Desired result terminal 85 to 86 without resistor 85 to 950 terminal 85 to 86 with resistor 75 to 85Q terminal 87 to 87a 6 30 no continuity infinite Q terminal 87a to 30 continuity zero Q 3 Connect12V DC to terminal 85 and a ground wire to terminal 86 then test the following terminal combinations Test Desired result terminal 87 to 87a amp 30 no continuity infinite Q terminal 87 to 30 continuity zero Q 87 5 sk g 30 terminal no 87a terminal no 85 ground terminal no 30 common terminal no 86 coil terminal no 87 N O Control Relay Schematic without resistor 85 87 87a G 0 86 30 Control Relay Schematic with resistor Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures Platform Components 2 1 Platform How to Remove the Platform 1 Separate the foot switch quick disconnect plug 2 Supportthe platform support weldment with a app
140. 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 701090 Spark plug to cylinder 7 to 15 9 to 20 Camshaft thrust plate bolt M 6 6to9 8 to 12 head M 14 Carburetor to spacer stud M 8 7 5 to 15 10 to 20 ne ciet 8 to 18 O Carburetor spacer to 10 to 14 14 to 19 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 50 to 60 68 081 Cylingerfrontcoverbolt 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 6to 9 8 to 12 bolt M 6 Part No 48412 Genie 5 60 amp Genie 5 65 2 5 Section 2 Specifications SPECIFICATIONS Deutz Engine F4L 1011F Displacement 166 7 cu in 2 732 liters Number of cylinders 4 Bore and stroke 3 58 x 4 13 inches 91 x 105 mm Horsepower 56 3000 rpm Firing order 1 3 4 2 Compression ratio 18 5 1 Compression pressure 362 to 435 psi 25 to 30 bar Low idle 1300 rpm High idle 2300 rpm Governor centrifugal mechanical Valve clearance cold Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure
141. by attempting to move the wheel hub side to side then up and down Result If there is side to side or up and down movement proceed to step 10 to replace the wheel bearings with new ones When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced O Result If there is no side to side or up and down movement grease the wheel bearings 10 Remove the castle nut 11 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 13 Pack both bearings with clean fresh grease 14 Place the large inner bearing into the rear of the hub 15 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub 16 Slide the hub onto the yoke spindle Component damage Do not ACAUTION 2 71 apply excessive force or damage to the lip of the seal may occur 17 Place the outer bearing into the hub 18 Install the washer and slotted nut 19 Tighten the slotted nutto 35 foot pounds 47 Nm to seatthe bearings 20 Loosen the slotted nut then re tighten to 8 foot pounds 11 Nm 21 Install a new cotter pin Bend the cotter pin to lock it in 22 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to 4
142. ck and determine which 4 link section needs to be replaced BOOM COMPONENTS 3 Drill outthe 4 spot welds on each side of the cable track using a 17 64 drill bit Repeat this step for the other end of the 4 link section of cable track ACAUTION Component damage hazard Cables and hoses can be damaged if the drill bit comes in contact with them Protect the hoses and cables with a block of wood to prevent drilling into the hoses and cables 4 Remove the retaining fasteners from upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 5 Liftup the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard ACAUTION Hoses and cables can be damaged if they are kinked or pinched 6 Remove the upper rollers from the replacement section of cable track 7 Liftup the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard ACAUTION Hoses and cables can be damaged if they are kinked or pinched 8 Connect the ends of the replacement cable track section to the existing cable track using the fasteners provided in the kit Do not overtighten the fasteners ACAUTION Component damage hazard Over tightening the fasteners will result in the cable track not rotating and may bind during operation Be sure that the fasteners are installed from the inside out so the nuts are on the outside of the c
143. ck for mechanical 0 to 345 bar pressure restrictions OR replace gauge into master the slave cylinder cylinder rod end counterbalance valves hydraulic hose hose connected to port PL2 using a tee fitting Activate boom up function and check the pressure less than 2000 PSI Install a 0 to 5000 psi less than 0 to 345 bar pressure 2000PSl gauge into the barrel end hydraulic hose from the master cylinder and raise the primary boom one inch ata time Continually monitor the pressure gauge during boom up Do notallow the pressure to exceed 2500 PSI Repair or replace the master cylinder 2000 PSI or more Repair or replace the slave cylinder Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Platform Level Up Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the position move the function enable Switch to either side and activate the platform level toggle switch TS16 in the up direction and check the voltage at org wire on platform level up function directional valve item S Continued on the next page 12V or more With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the on position move the function enable Switch to eit
144. color to identify which wire to use for testing 3 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity Test Desired result red to black no continuity infinite red to white no continuity black to white continuity zero Q Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures PLATFORM CONTROLS 1 4 Center Right 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 doubie throw OA 0019 SPDT Grez 4 5 6 1 Turn the key switch to the orr position 2 Disconnecteither end of one of the wires 4 222 1 u w ILLI connected to the resistor to be tested DPDT 101010 3 Connectthe leads from an ohmmeter to each end or wiring of the resistor being tested ZE Test Desired result 4 Compare the ohmmeter reading with the 22 5 5 resistance rating printed on the resistor Left position terminal 1 to 2 3 4 5 amp 6 no continuity infinite 1 5 terminal 2 to 3 continuity zero Toggle Switches LLL terminal2t04 5 amp 6 no continuity Toggle switches used for single function switching termin
145. ction 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE C PROCEDURES 3 Load the system by activating the boom retract function then move the function enable toggle switch to the high idle rabbit symbol position 4 Adjustthe 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 1 4 inch of threads showing Measure from top of lock nutto top of adjustment screw If an exhaust gas analyzer is not available adjustto obtain peak or optimum rpm 5 Hold the adjustment screw and tighten the lock nut 6 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 low idle mixture adjustment screw Preliminary setting turn low idle adjustment screw clockwise all the way in Turn low idle adjustment screw counterclockwise 2 3 4 turns 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 P P D 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 1011F Workshop Manual Deutz Number 0297 7195 Genie partnumber 52229 C 15 Check the Turntable
146. ction 5 Troubleshooting Flow Charts CHART 19 Plumb a 0 to 5000 psi lessthan Function manifold could 0 to 345 bar pressure 250 psi have an internal defect gauge into the hose Consult Genie Industries from the function Service Department manifold to the turntable rotation brake Move the function enable switch to either side and activate the turntable rotate right function Continued from the previous page 250 psi or more Exchange turntable rotate right and left function counterbalance valves operates items JJ and Il Activate turntable rotate right function Replace defective counterbalance valve function inoperative Check for mechanical restrictions keeping turntable rotate right function from operating OR replace shuttle valve item HH OR consult Genie Industries Service Department Part No 48412 Genie S 60 amp Genie S 65 5 49 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 20 All Platform Leveling Functions Inoperative Be sure all other functions operate normally Remove both hydraulic Replace the hoses from the manifold counterbalance valves TuS PL1 amp PL2 Plug on function manifold e hoses and cap the items A amp B manifold fittings Move the function enable switch to either side and activate the boom up function and check to see if platform levels Plumb a 0 to 5000 psi Che
147. d be used when removing a Wago component This screwdriver is located in the operator s manual storage box in the platform 1 Label the wiring from the component to be removed 2 Locate the removal tab on the bottom or top side ofthe component 3 Use a small narrow flat blade screwdriver to push in and release the wire from the component 4 Use the small narrow flat blade screwdriver to gently pry up on the tab ofthe componentand remove it Part No 48412 Genie S 60 amp Genie S 65 7 33 Section 7 Repair Procedures Service Manual Second Edition GROUND CONTROLS 8 5 Power Relay Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry The power relay is mounted on the backside of the ground control box How to Test the Power Relay Electrocution hazard Disconnect AWARNING the ground cable from the battery before performing this procedure 1 Connectthe leads from an ohmmeter to each terminal combination and check for continuity Test Desired result 2 small posts 12 to 160 2 large posts no continuity infinite Any small post to no continuity any large post infinite Q 2 Connect 12V DC to one of the small posts and a ground wire to the other small post then test the following terminal combination Test Desired result 2 large posts continuity zero Q a high amp p
148. e Gasoline LPG Models 4 19 B 12 Check and Adjust Engine 4 19 B 13 Test the Key SWIECh siete a ert O AE 4 21 B 14 Test the Emergency Stop 2 emen 4 21 B 15 Testthe Ground Control Override 2 mene 4 22 B 16 Check the Directional Valve Linkage 2 4 22 B 17 Testthe Platform ee 4 23 B 18 Testthie Horn hte eei dae p Ree e qe e 4 23 B 19 Testthe FoOt SWIECH AN a re AE A GA eee 4 23 B 20 Testthe Engine Idle 4 24 B 21 Testthe Fuel Select Operation Gasoline LPG Models 4 24 B 22 Test the Drive Enable System 2 2 4 25 vi Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section Four TABLE OF CONTENTS Scheduled Maintenance Procedures continued B 23 Test the Drive Brakes aa wia A A died cr ade nated 4 25 24 Testthe Drive Speed Stowed 5 cca 4 26 B 25 Testthe Alarm Package Optional 4 27 B 26 Perform Hydraulic Oil Analysis 3 4 27 B 27 Replace the Engine Oil and Filter Deutz Diesel Models 4 27 C 1 Check the Boom Wear Pads 3 3 meme
149. e rotation brake Move the function enable switch to either side and activate the turntable rotate left function Continued from the previous page 250 psi or more Exchange turntable rotate leftand right function counterbalance valves operates items and JJ Activate turntable rotate left function Replace defective counterbalance valve function inoperative Check for mechanical restrictions keeping turntable rotate left function from operating OR replace shuttle valve item HH OR consult Genie Industries Service Department CHART 18 Part No 48412 Genie S 60 amp Genie S 65 5 45 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 19 Turntable Rotate Right Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled outto the ON position move the function enable switch to either side and hold the turntable rotate toggle Switch TS18 on ground panel in the right direction and check voltage on wht red wire on turntable rotate left right proportional valve coil item R 20V or more Continued on the next page Move the function enable switch to either side and hold the turntable rotate toggle TUO Switch TS18 on ground panel in the right direction and check voltage at TB6 0v With keyswitch in 4 to 6
150. e Repair Section OR replace controller BP2 OR consult Genie Industries Service Department 9 to 10V Repair open in blk red wire circuit from TB9 to boom extend retract proportional valve coil item M OR repair open in brown ground wire circuit to valve coil 9 to 10V Repair open in blk red wire from TP9 to TB9 Repair open in power supply circuit from TP 24 to BP1to BP2 OR repair open in brown ground wire circuit from ground to BP2 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom extend retract toggle switch TS19 on ground panel in the extend direction and check voltage on blk wire on boom function directional valve coil item C 20V or more Continued on the next page Section 5 Troubleshooting Flow Charts Move the function enable switch to either yoy an side and hold the boom more extend toggle switch 7519 on ground panel in the extend direction and check voltage at 7 With key switch in position a oth Emergency Stop buttons pulled out to the ON position activate footswitch and boom extend retract proportional controller BP2 on platform control panel in extend direction and check voltage TB7
151. e displacement piston pump The pump outputis controlled by the electronic displacement controller EDC located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Sundstrand S auer service center Call Genie Industries Service Departmentto 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Disconnectthe electrical connection atthe electronic displacement controller EDC located on the drive pump Part No 48412 Genie S 60 amp Genie S 65 7 35 Section 7 Repair Procedures Service Manual Second Edition HYDRAULIC PUMPS 2 Close the two hydraulic tank valves located at How to Prime the Pump the hydraulic tank 1 Connecta 0 to 600 psi 0 to 41 bar pressure open closed Component damage hazard The ACAUTION engine must not be started with the hydraulic tank shutoff valves in the cLosED positi
152. e 5 65 Part No 48412 Service Manual Second 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 Turn the key switch to ground control and pull out the Emergency Stop button to the position at both the ground and platform controls Result The flashing beacon should be on and flashing 2 Move the function enable toggle switch to either side and activate the boom toggle switch in the pown position hold for a moment and then release it Result The descent alarm should sound when the switch is held down 3 Turn the key switch to platform control Result The flashing beacon should be on and flashing 4 Press down the foot switch Move the boom control handle to the position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down TABLE B PROCEDURES 5 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 momentand then release
153. e Drives At Full Speed With Platform Raised or Extended 5 76 35 Drive Enable System Is Malfunctioning 5 77 36 X Auxiliary Functions 5 78 Schematics lalce Seve ER EE 6 1 Electrical COmporients oio etr See aed pex pete toten s beet esu th auae 6 2 Electrical Symbols Legend ssssssssssseeeeneeeeene ener nnns 6 4 Abbreviation begend cuite iei tete wady iaa 6 5 Electrical Schematic Gasoline LPG Models Rev B 6 7 Ground Control Box Legend Gasoline LPG 6 9 Ground Control Box Wiring Diagram Gasoline LPG Models 6 10 Platform Control Box Legend Gasoline LPG 6 11 Platform Control Box Wiring Diagram Gasoline LPG Models 6 12 Electrical Schematic Deutz Diesel 6 13 Ground Control Box Legend Deutz Diesel Models 6 15 Ground Control Box Wiring Diagram Deutz Diesel 6 16 Platform Control Box Legend Deutz Diesel 6 17 Platform Control Box Wiring Diagram Deutz Diesel Models
154. e Rod lubricated 56 ft lbs 76 Nm 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 Part No 48412 Genie S 60 amp Genie S 65 7 69 Section 7 Repair Procedures Service Manual Second Edition Oscillating Axle Components 15 1 Oscillating Axle Lock out Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the oscillating axle The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure The valves are not adjustable How to Remove an Oscillating Axle Cylinder This procedure requires specific AWARNING repair skills and a suitable workshop Attempting this procedure withoutthese 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Referto Section Two Hydraulic Hose and Fitting Torque Specifications 1 Rotate the boom until the boom is between the steer tires 2 Remove the fasteners from drive chassis cover atthe steer end Remove the cover 3 Tag disconnect and plug the oscillating axle cyli
155. e anti diesel valve Replace fuel pump OR check anti diesel and fuel valve for defects 5 18 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine High Idle Inoperative Gasoline LPG Models If high idle operates on LPG butnoton 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 Be sure high idle can be achieved by grasping the governor actuator arm and momentarily pulling to throttle the carburetor Start engine and move the rpm select to high idle rabbit symbol for following checks Check voltage at blk red wire on rpm select switch TS4 and TS13 12V Check voltage at TB35 NN 12V Check voltage at terminal 85 blk red on 12V Check continuity from ground to the brown wire on terminal 486 of continuity Check voltage at OV terminal 30 on CR4 12V Check voltage at 12V terminal 87A on CR4 Check voltage at terminal 7 on electronic governor Continued on the next page continuity Chart 6 Check voltage at center terminal on rpm select Repair open in power supply circuit to center switch TS4 and TS13 terminal of switch 12V Replace rpm select
156. e boom The lift cylinder safety chock is available through Genie part no 33484 2 Besurethateach tumtable mounting bolt is torqued in sequence to 210 foot pounds 285 Newton meters 28 1 2 00 09 16_ 13 12 0 17 so o 25 30 29 26 e 22 o 7 18 9 o 1476 15 Bolt torque sequence Part No 48412 Genie 5 60 amp Genie 5 65 4 29 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE C PROCEDURES 3 Lowerthe boom to the stowed position 4 Checkto ensure that each bearing mounting bolt under the drive chassis is torqued in sequence to 210 foot pounds 285 Newton meters Q 18 4 30 8 14 2 9 Bolt torque sequence C 3 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 Ibs 9072 kg under the drive chassis between the non steer tires 3 wheels off the ground and then place jack stands under the drive chassis for support
157. e circuit that runs from TB37 to steer right directional valve coil on steer manifold Replace steer right directional valve coil item SS OR repair open in brown ground M to steer right valve coil Repair open in blu blk 37 wire circuit from drive controller DP 1 to TP37 then to TB37 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 29 Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keeping gauge at the quick steer right function from disconnect coupling on operating OR repair or the boom function replace steer cylinder manifold and activate OR consult Genie the steer right function Industries Service Department Continued from the previous page less than 2600 PSI Repair or replace steer cylinder OR steer manifold could have an internal defect Consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 5 69 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 30 All Drive Functions Inoperative All Other Functions Operate Normally Be sure the rpm toggle switch is in the footswitch activated high idle position Be sure the hydraulic tank shut off valves are in the open position Be sure machine is not in the free wheel configuration With the keyswitch less turned to platform
158. e engine components Check the oil level with the engine off 1 Checkthe oil dipstick Add oil as needed Result The oil level should be in the safe zone Ford LRG 423 Engine 5 quarts Oil capacity including filter 4 7 liters Ford LRG 423 Engine Oil viscosity requirements below 60 F 15 5 5W 30 10 to 90 F 23 to 32 C 10W 30 above 10 F 23 10W 40 or 10W 50 above 25 F 4 C 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 1011F Oil capacity including filter 11 quarts 10 5 liters Deutz Engine F4L 1011F Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE 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 AWARNING Fluids in the r
159. e hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters 6 Install the brake and motor onto the torque hub 7 Fillthe hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealantto the plugs and then install the plugs 8 Adjustturntable rotation gear backlash See Repair P rocedure 12 1 How to Adjust the Turntable Rotation Gear Backlash Turntable rotate torque hub Oil capacity 17 fluid ounces 0 51 liters 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 off 1 Remove the filter with an oil filter wrench 2 Applya thin layer of oil to the new oil filter gasket 3 Install the new filter Genie part no 46014 and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure TABLE C PROCEDURES 4 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 5 Startthe engine from the ground
160. e oil pan drain plug for leaks 12 Swing the engine pivot plate back to its original position and replace the two pivot plate retaining bolts 13 Check the engine oil level dipstick Add oil if needed Ford LRG 423 Engine 5 quarts Cil capacity including filter 4 7 liters Ford LRG 423 Engine Oil viscosity requirements below 60 F 15 5 5W 30 10 to 90 F 23 to 32 C 10W 30 above 10 F 23 10W 40 or 10W 50 above 25 F 4 C 20W 40 or 20W 50 Use oils meeting API classification SF labeled SF CC or SF CD as they offer improved wear protection TABLE A PROCEDURES A 16 Drain the Fuel Filter Water Separator Deutz Diesel Models Engine specifications require that this procedure be performed every 100 hours Poor fuel quality or very wet conditions may necessitate performing this procedure more often Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and component damage Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Loosenthe drain plug located atthe bottom of the filter Allow the water to drain into a suitable container until fuel starts to come out Immediately
161. e platform rotator Do notapply any lifting pressure S 60 Models 6 Supportthe rod end ofthe platform leveling slave cylinder 7 Remove the pin retainer from the slave cylinder rod end pivot pin and the rotator pivot pin Part No 48412 Genie S 60 amp Genie S 65 7 13 Section 7 Repair Procedures Service Manual Second Edition PLATFORM COMPONENTS How to Bleed the Platform Rotator Do notstartthe engine Use auxiliary power for all machine functions in this procedure 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles then hold the switch to the nicur position until the platform is fully rotated to the right 2 Connecta clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Secure the container to the boom 3 Open the top bleed valve on the rotator but do not remove it a top bleed valve b X bottom bleed valve c clear hose d container 4 Move the function enable toggle switch to either side and activate and hold the platform rotate switch to the Lert position until the platform is fully rotated Continue holding the switch until air stops coming out of the bleed valve Then close the bleed valve hi AWARNING Crushing hazard Keep clear of the platform during rotation 5 Connectthe clear hose to the bottom bleed valve
162. e slotted nutto 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 420 foot pounds 569 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 ofthe same hydraulic circuit but move in opposite directions The tie rod maintains equal movement of the tires When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder Bodily injury hazard S praying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the pin retaining fasteners Then remove the pivot pin from each end of the steering cylinder 3 Remove the steering cylinder from the machine 7 66 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 13 3 Tie Rod How to Remove the Tie Rod 1 Remove the pin reta
163. e wires Wheel lugs 10 3 4 16 UP NAS Onah bogi Lug nut torque dry 420 ft Ibs Boom to platform cable harness 569 5 Nm Inside of the platform control box Lug nut torque lubricated 320 ft lbs Jib boom cable cover S 65 models 433 9 Nm Part No 48412 Genie S 60 amp Genie S 65 4 17 Section 4 Scheduled Maintenance Procedures Service Manual Second 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 notfully operational 1 Check each torque hub disconnect cap to be sure it is in the engaged position i brake disengage position gt mj brake engage position 2 Be sure the free wheel valve on the drive pump is closed clockwise The free wheel valve is located on the bottom of the drive pump a drive pump b free wheel valve c lift pump d screwdriver 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 l
164. e with raised spline flywheel 1 4 inch gap a b c d e f Flex Plate Removal 1 Disconnectand remove the hose between the carburetor venturi and the air cleaner 2 Disconnectthe linkage from the governor then remove the governor linkage from the carburetor Do not alter the length of the linkage 3 Disconnectthe wiring plug atthe 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 Supportthe 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 7 30 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 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 coupler onto the pump shaft with the set screw towards the pump Leave a 1 4inch 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 Ibs 61 Nm Component damage ha
165. econd Edition Section 3 Scheduled Maintenance Inspections MAINTENANCE TABLES Warm Cold Dealer Table C Tools are New parts engine engine service required required required required suggested C 1 Check the Boom Wear Pads EE C 2 Check the Turntable Rotation Bearing Bolts MI C 3 Check the Free wheel Configuration C 4 Grease the Turntable Rotation Bearing and Rotate Gear C 5 Replace the Torque Hub Oil C 6 Replace the Hydraulic Tank Filter C 7 Replace the Drive Loop Hydraulic Filter C 8 Replace the Diesel Fuel Filter Water Separator Deutz Diesel Models C 9 Replace the Gasoline Fuel Filter Gasoline LP G Models C 10 Replace the PCV Valve 52 Gasoline LPG Models C 11 Replace the Spark Plugs Gasoline LP G Models M C 12 Check and Adjust the Air LP G Mixture Gasoline LP G Models C 13 Check and Adjust the Ignition Timing Gasoline LP G Models C 14 Check the Engine Valve Clearances FA Deutz Diesel Models C 15 Check the Turntable Rotation Gear Backlash Part No 48412 Genie 5 60 amp Genie 5 65 Section 3 Scheduled Maintenance Inspections Service Manual Second 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 D 2 Change or Recondition the Engine Coolant Gasoline LPG Models D 3 Change the Fuel Lines
166. ection 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 22 Disconnect the wires 0 or from the platform level infinite down directional valve ohms coil item U and test the A ali ofthe valve coil Continued from the previous page Replace the platform level down directional valve coil item U 6 to 7 ohms Exchange platform level function down and up directional operates valves items U and S and activate the platform level down function Replace the defective directional valve function inoperative Exchange platform level function down and up operates counterbalance valves items FF and EE and activate the platform level down function Replace the defective counterbalance valve function inoperative Install a 0 to 3000 Check for mechanical 0 to 207 bar pressure 2600 psi restrictions keeping gauge at the quick or RES platform level down disconnect coupling on function from operating the function manifold OR replace slave and activate the platform cylinder OR replace level down function slave cylinder counterbalance valves OR consult Genie Industries Service Department less than 2600 psi Test master cylinder see Chart 16 OR repair or replace slave cylinder or slave cylinder counterbalance valves OR function manifold may have an internal defect Consult Genie Industries Service Department 5 54 Genie
167. edures MANIFOLDS A lt 475 gt s WEE D qp D Sa L i 2 9 oe A 8 Part No 48412 Genie S 60 amp Genie S 65 7 41 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 10 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Connecta 0 to 5000 psi 0 to 345 bar pressure gauge to the test port item 23 on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the retract switch with the boom fully retracted Observe the pressure reading on the pressure gauge 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap item 23 function manifold 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeatsteps 2 through 5 and recheck relief valve pressure System relief valve specifications How to Adjust the Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connecta 0 to 5000 psi 0 to 345 b
168. ell Inc CH 09 525 Q 1 Hourmeter eee 19506 ENM Corporation T40A4508 1 KS uet Contact Keyswitch N O 45081 Telemecanique ZB2 BE101 2 LED Red 12V DC 32335 Arctolectric Corp LE177C39007 1 51 22 es Contact Limit switch NiC HiO ace O 19491 Telemecanique XESP 2051 3 Level sensor Level sensor 4 5 44586 Power Comp of Midwest 15 36 1 This list continues on the next page 6 2 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 6 Schematics i J 0 OO CJ ELECTRICAL COMPONENTS Item Description Genie Manufacturer Manufacturer Qty Part Number Part Number PD Contact 29732 Telemecanique ZB2 BE102 4 Contact 45081 Telemecanique 2 2 101 1 PRISES Relay 12V DC continuous 27155 Sta 70 902 1 Rl ese Resistor 1000 25 watt 27116 Dale RH25 100R 1 1 Resistor 1500 2
169. en in grn wire from TS6 to TP17 OR Repair open in red power wire circuit from keyswitch to 7515 OR replace toggle switch 1915 Activate the footswitch and the jib boom toggle switch TS6 in the up direction and check voltage at TP 17 Repair open in grn wire from TP17 to TB17 With the keyswitch turned to platform control and both Emergency Stop buttons pulled outto the ON position activate the footswitch and check the voltage on the center terminal of the jib boom toggle switch TS6 replace jib boom toggle Switch TS6 Check the voltage at 0v Repair open in red wire terminal 30 on CR 13 from BP1to CR13 OR repair open in brown i ground wire circuit to R13 12V Check the voltage at Replace CR13 terminal 287a on CR13 12V Repair open in red wire from terminal 87a on CR13 to T56 OR consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 5 61 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 25 f Activate footswitch and CI the jib boom toggle switch Replace CR13 p page TS6 in the up direction and check voltage on the red and black wires at the jib platform rotate select valves item AM Install a 0 to 5000 psi 0 Exchange jib boom to 345 bar pressure 2500 psi platform rotate select gauge atthe quick or more valves item AM disconnect coupling on Activate footswi
170. ending unit no continuity Remove wht wire from continuity Repair short in wht wire TB24 circuit from TB24 to temperature sender no continuity Repair short in wht wire circuit from ignition start module to TB24 OR consult Genie Industries Service Department 0 or Turn the machine off infinite Replace the fuel and isolate the fuel ohms solenoid solenoid Check the resistance of the solenoid 3 50 ohms See Deut service manual for troubleshooting fuel System 5 12 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 3 Hold start switch and Repair open in wht 421 Continued from the check voltage at wht wire from CR2 to fuel previous page 21 wire on terminal 87 solenoid of CR2 Check voltage at red Repair open in red wire wire on terminal 30 of circuit from battery to CR2 CB1 to CR1 to CR2 Hold the start switch to Hold the start switch to Repair open in blk wire either side and check either side and check from terminal 86 on voltage at terminal 86 voltage at terminal 9 on CR2 to terminal 9 on of CR2 the ignition start module the ignition start module Check voltage at Repair open in power terminal 6 and 7 on supply wires to terminal ignition start module 6 and 7 on ignition start module Check continuity from no Repair open in brown ground to brown wire at continuity ground wire c
171. enie S 60 amp Genie S 65 7 7 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 13 Raise the boom above horizontal 14 Drive the machine for 40 feet 12 m and record the elapsed time Repeatthis 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 distance 40 ft 12 m 2WD 4WD Gasoline LP G models 40 6 2 sec 40 ft 9 1 sec 12 2 m 6 2 sec 12 2 m 9 1 sec Deutz Diesel models 40ft 6 8 sec 40 ft 9 1 sec 12 2 m 6 8 sec 12 2 m 9 1 sec distance 40 ft 12 m 1 foot per second 30 5 cm per second Boom raised or extended All models 1 3 Foot Switch How to Test the Foot Switch 1 Turnthe key switch to the orr position and separate the wiring quick disconnect plug from the platform toe board 2 Donotpress down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity Test Desired result red to black continuity zero Q red 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
172. enie S 65 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 8 Continued from the previous page Check voltage at OV Repair open in blk red terminal 86 on CR4 wire circuit from CR3 to CR4 12V Check continuity from ground to brown wire at Repair open in brown ground wire circuit to terminal 485 on CR4 terminal 485 on CR4 good Check voltage to OV Repair open in wht wire terminal 30 on CR4 circuit from CR2 to CR3 to CR4 12V Check voltage at the Replace CR4 relay blk red wire on the OR repair open in blk red wire circuit from terminal 487 on CR4 to 2 speed solenoid 2 speed solenoid 12V solenoid Check if 2 speed binds 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 24 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Chart 9 Engi ne At platform controls koee ie p and start engine and switch ground rpm switches Low Idle rpm ES to e an i maintained low idle replace defective switch Inoperative turtle symbol Check Deutz Diesel voltage at blk red wire on rpm select switch Models Check if mechanical linkage Check voltage at the Replace CR4 relay red wire on the from 2 speed i 2 solenoid to
173. entionally left blank Part No 48412 Genie S 60 amp Genie S 65 7 55 Section 7 Repair Procedures Service Manual Second Edition MANIFOLDS 10 10 4WD Drive Manifold Components The drive manifold is mounted inside the drive chassis atthe non steerend Index Schematic No Description Item Function Torque 1 Directional valve 2 position 2 way AB High speed divider bypass N C Pilot to 25 30 ft lbs 34 41 Nm 2 Flow divider combiner valve AC aas Controls flow to flow divider combiner valves 6 and 7 25 30 ft lbs 34 41 Nm 3 Relief valve 250 psi 17 2 bar AD Charge pressure circuit 10 12 ft lbs 14 16 Nm 4 Check valve pilot to close AE Works in conjunction with Index no 12 in the high speed divider bypass circuit 10 12 ft lbs 14 16 Nm 5 Orifice plug 0 052 inch 1 32 mm AF Front drive motor circuit 6 Flow divider combiner valve AG Controls flow to steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 7 Flow divider combiner valve AH Controls flow to non steer end drive motors in forward and reverse 2 0 25 30 ft lbs 34 41 Nm 8 Orifice 0 070 in 1 78 mm usus Rear drive motor circuit 9 Or
174. epair Procedure 11 2 How to Remove the Hydraulic Tank Component damage hazard Be ACAUTION sure thatthe hydraulic tank shutoff valves in the position before priming the pump The 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 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 coolantto 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 Disconnectthe coolant return hose atthe radiator and drain the coolant return tank into a suitable container 3 Slowly remove the radiator cap from the radiator Bodily injury hazard Allow any ACAUTION pressure to dissipate gradually before removing the radiator cap Part No 48412 Genie S 60 amp Genie S 65 4 39 Section 4 Scheduled Maintenance P rocedures Service Manual Second
175. er board to terminal 6 on drive joystick no Check continuity from continuity terminal 3 on drive joystick to ground Repair open in brown ground wire circuit from terminal 3 on drive joystick to ground continuity Replace drive joystick controller OR consult Genie Industries Service Department no Check continuity from continuity terminal 3 on drive joystick to ground Repair open in brown ground wire circuit from terminal 3 on drive joystick to ground continuity Replace drive joystick controller OR consult Genie Industries Service Department Part No 48412 Genie S 60 amp Genie S 65 5 71 Section 5 Troubleshooting Flow Charts CHART 30 Continued from the previous page Activate the footswitch and hold the drive joystick in the full forward position and check the voltage across the wht 12 wire and the wht blk 31 wire on EDC 2V Troubleshoot drive forward and drive reverse functions separately OR replace pump OR consult Genie Industries Service Department Service Manual Second Edition With the footswitch activated and the drive joystick in the full forward position move the drive enable toggle switch TS9 to either side and check the voltage across the wht 12 wire and the wht blk 31on EDC 0V With the footswitch activated and the drive joystick in the full forward position move the drive enable toggle switch
176. erto Table C C 1Boom 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 C 7 Drive loop hydraulic filter C 8 Fuel filter Deutz Diesel C 9 Fuel filter Gas LPG C 10 PCV valve Gas LPG C 11 Spark plugs Gas LPG C 12 Air LPG mixture C 13 Ignition timing G as LP G C 14 Valves Deut Diesel C 15 Turntable backlash Checklist D Y NR Referto Table D D 1 Hydraulic oil D 2Engine coolant Gas LP G D 4Valves Gas LPG D 3 Change fuel lines D 5 Compression G as LP G D 6 PCV hoses Gas LP G D 7 Fuelinjection Diesel D 8Toothedbelt Diesel D 9 Timing belt Gas LP G D 10 Wheel bearings Part No 48412 Genie S 60 amp Genie S 65 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition This page intentionally left blank 3 8 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second 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
177. full throttle the engine will over rev Choke adjustments are affected and cause component damage by climate Richer adjustment will be necessary in colder climates leaner adjustment in warmer climates The linkage must be free of friction and obstruction Do not let it rub againstthe engine brackets or hoses Automatic Choke with Poppet Valve 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 48412 Genie S 60 amp Genie S 65 7 29 Section 7 Repair Procedures Service Manual Second Edition FORD LRG 423 ENGINE 7 3 Timing Adjustment Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual F ord number P P D 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 Manual F ord number P P D 194 287 Genie part number 33907 7 5 RPM Adjustment Referto Maintenance P rocedures 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 plat
178. function Exchange flow regulator operates Replace defective flow valve item G with a like regulator valve valve item H Check boom retract function function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect Consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 5 41 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 18 Turntable Rotate Left Function Inoperative Be sure all other functions operate normally With key switch in ground position and both Emergency Stop buttons pulled outto the ON position move the function enable switch to either side and hold the turntable rotate toggle switch 75 18 on ground panel in the left direction and check voltage on wht red wire on turntable rotate left right proportional valve coil item R 20V or more Continued on the next page Move the function enable switch to either side and hold the turntable rotate toggle Switch 7518 on ground panel in the left direction and check voltage at TB6 0v With keyswitch in platform position and both Emergency Stop buttons pulled outto the on position activate footswitch and turntable rotate left right proportional controller BP 1 on platform control panel in the left direction and check voltage at TP 6 0v Activate footswitch and check voltage at termi
179. ge terminal DL directional output ramp rate adjustable trimpot lo range adjustable trimpot threshold adjustable trimpot hi range adjustable trimpot ra oO ow 4 Setthe preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click 5 Connectthe red lead from a volt meter to the A terminal on the controller printed circuit board Connectthe black lead to ground 6 Setthe threshold Press down the foot switch then slowly move the control handle off center until the momenta 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 leftor right Adjust the voltage to 5 5V DC Turn the max outtrimpot 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 leftor 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 Startthe engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Engine should be a
180. ght 26 060 Ibs 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 198m Wheel diameter 191 2 in 49 5 cm Maximum horizontal reach s pue Wheel width 121 4 in 31 cm Maximum turntable tailswing 3 ft 31 2 in 3 ft 31 2 in Wheel 1 3 4 1 100 cm 100 cm SDS Lug nut torque dry bolts 420 ft lbs Wheelbase 9 ft 0 in 9 ft 0 in 569 5 Nm 2 7 m 2 7 m Lug nut torque lubricated bolts 320 ft lbs Minimum turning radius 12 ft1in 12 ft 1 in 433 9 Nm inside 3 7m 3 7m 22 Fluid capacities Minimum turning radius 22ft 2 in 22 ft 2 in Fuel tank 30 gallons outside 6 76 m 6 76 m 114 liters Turntable rotation continuous continuous LPG tank 33 5 pounds Platform rotation 160 160 RAKI Hydraulic tank 45 gallons Maximum capacity 600 Ibs 500 Ibs 170 liters 6 foot platform 272 kg 227 kg Hydraulic system 55 gallons Maximum capacity 500 Ibs 500 Ibs including tank 208 liters ZAT KO 221254 Drive torque hubs 44 fl oz Maximum allowable 1 30 liters side force ANSI and CSA 150 Ibs 150 Ibs Turntable rotation 17 fl oz 68 kg 68 kg torque hub 0 51 liters Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 48412 Genie 5 60 amp Genie 5 65 2 1 Section 2 Specifications SPECIFICAT
181. ground no continuity With the boom in the stowed position check terminal on horsepower limiter board for continuity to ground Re adjust or replace horsepower limiter board OR check for misalignment of limit switches LS1 and LS2 OR consult Genie Industries Service Department Chart 33 Check for correct wiring of limit switches LS1 and LS2 OR repair or replace boom lift drive limit switch or boom extend limit switch Repair shortto ground in orange wire shorted to ground from 40 to TP40 to terminal 46 on horsepower limiter circuit board PartNo 48412 Genie S 60 amp Genie S 65 5 75 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 34 Machine Drives At Full Speed With Platform Raised or Extended Be sure boom drive limit switch is being activated by the cam on the boom when the boom is raised Be sure thatthe boom extend drive limit switch is not being held down or being activated when the boom is extended Be sure the wiring to limit switches is intact and show no sign of damage or corrosion Extend the boom past the drive limit switch and check continuity from ground to terminal on the horsepower limiter board Test limit switches See procedure A 14 in the Maintenance Section Repair open from wht wires at TB40 to drive limit switches LS1 and LS2 then from brown ground wires to ground Replace horsepower
182. ground Specifications Tap the pin the other direction and lower the ite leveli D t the pin 1 Raise the jib boom slightly and place blocks ZE QU under the platform mounting weldment Then 5 Supportthe jib boom lift cylinder with a lifting lower the jib boom until the platform is resting device ON Ule PIPERS Stene UON 6 Remove the pin retaining fastener from the jib platform boom lift cylinder barrel end pivot pin Use a Do notrestthe entire weight of the soft metal drift to remove the barrel end pin boom on the blocks 7 Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the cylinder from the machine Crushing hazard The jib boom lift AWARNING cylinder may become unbalanced and fall when itis removed from the machine if itis not properly supported 7 16 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures gt ZAIN E JIB BOOM COMPONENTS S 65 MODELS 3 3 Jib Boom Platform Rotate Manifold Components S 65 Models 1 2 position 3 way valve AM Platform rotate jib boom select 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 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
183. h in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and boom function controller BP 1 on platform control panel in up direction and check voltage at TP3 0v Activate footswitch and check voltage at terminal on BP 1 12V or more Re adjust controller see Repair Section OR replace controller BP1 OR consult Genie Industries Service Department 8 to 9V Repair open in red wht wire circuit from TB3 to boom up down proportional valve coil item O OR repair open in brown ground wire circuit to valve coil 8to9V Repair open in red wht wire from TP3 to TB3 Repair open in power supply circuit from TP 24 to BP1 OR repair open in brown ground wire circuit from ground to BP1 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the boom up toggle switch 7517 on ground panel in up direction and check voltage on red 1 wire on boom up down directional valve coil item B 20V or more Continued on the next page Section 5 Troubleshooting Flow Charts Move the function enable switch to either side and hold the boom up toggle switch TS17 on ground panel in up direction and check voltage a
184. h is essential to safe machine operation Machine functions should activate and operate smoothly as long as the foot switch is pressed down and promptly stop when the footswitch is released The footswitch will also shiftthe engine into high idle if the idle selectis switched to the rabbit and foot switch symbol An improperly functioning foot switch can cause an unsafe working condition and endanger platform and ground personnel The engine should not start if the foot switch is pressed down 1 Turn the keyswitch to platform controls and pull out the Emergency Stop button to the position at both the ground and platform controls 2 Press down the footswitch and attemptto start the engine by moving the start toggle switch to either side Result The engine should not start 3 Do not press down the footswitch and start the engine 4 Do notpress down the footswitch Check the machine functions Result The machine functions should not operate 5 Press down the foot switch and operate the machine functions O Result The machine functions should operate Part No 48412 Genie S 60 amp Genie S 65 4 23 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 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 allow
185. he lifting device Part No 48412 Genie S 60 amp Genie S 65 Section 7 Repair Procedures Service Manual Second 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 AWARNING weight do not attemptto support the cover by hand Component damage hazard ACAUTION Protectthe cover from damage by using carpet or padding on the crane or forklift forks 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 P rotect the strut cylinder rod from damage Mark the location of the hinge support bracket on the bulkhead to ensure proper cover alignment during installation 4 Remove the cover hinge bolts that fasten the hinge support bracket to the bulkhead 5 Carefully lift and remove the cover from the machine Crushing hazard The turntable AWARNING cover may become unbalanced and fall if itis not properly supported and secured to a appropriate lifting device AWARNING If a turntable cover must be 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 26 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edit
186. he throttle is in actuator is only necessary when the idle position Then adjust the clevis yoke on the governor actuator or the the linkage rod to obtain the proper length linkage has been replaced Install the yoke onto the actuator arm 1 Connectthe linkage rod to the throttle plate 5 With the throttle in the idle position and the shaft then tighten the lock nut actuator arm ata 110 degree angle to the linkage rotate the clevis yoke on the linkage rod two turns counterclockwise to pre load the spring Tighten the lock nut on the linkage rod 2 Fasten the lock nut and clevis yoke to the linkage rod Do not tighten the lock nut against the clevis yoke 3 Loosen the fastener on the actuator arm Rotate the actuator arm until itis ata 110 degree angle to the linkage rod Then tighten the actuator arm fastener 7 28 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures gt Kii 2 H J FORD LRG 423 ENGINE 6 Manually pull the actuator arm through a full 7 2 cycle to be sure thatthe linkage moves freely Be sure thatthe linkage activates the throttle Choke Adjustments shaft to approximately half throttle ee TE OOOO This engine is equipped with an electrically heated ACAUTION Component damage hazard automatic choke The choke has a poppet valve to If the throttle linkage is improperly enhance cold starting ability on LPG fuel adjusted and allowed to reach
187. her side and activate the platform level toggle switch TS16 in the up direction and check the voltage at TB14 With the keyswitch turned to platform control and both Emergency Stop buttons pulled outto the on position activate the footswitch and the platform level toggle Switch TS7 in the up direction and check the voltage at TB14 Troubleshoot platform level toggle switch 516 on ground control panel OR repair open in red power wire circuit to 1516 OR repair open in org wire circuit from 1516 to TB14 OR consult Genie Industries Service Department 12V or more Chart 21 Repair open in org wire from TB14 to platform level up directional valve Coil item S OR repair open in brown ground wire circuit to valve coil Troubleshoot platform level toggle switches 7516 and TS7 on ground and platform control panels OR repair open in red power wire circuit to T516 and 57 OR repair open in org wire circuit from TS 16 and TS7 to TB14 OR consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 21 Disconnect the wires 0 or from the platform level infinite up directional valve coil ohms item S and test the eae of the valve coil Continued from the previous page Replace the platform level up directional valve coil item S 6 to 7 ohms Exchange
188. ice 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 thatthe 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 Perform this procedure with the engine off 4 34 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 1 Remove the 2 bolts from under the engine pivot plate S wing the engine pivot plate away from the machine to access the fuel filter located nearthe carburetor a pivotplate retaining bolts b engine pivot plate 2 Disconnectthe fuel hose from the filter then remove the filter from the fitting a fuel filter b hose from the fuel pump to the fuel filter 3 TABLE C PROCEDURES Install the new fuel filter Genie part no 33971 into the fitting on the carburetor Connect the fuel hose to the filter Clean up any fuel that may have spilled during the installation procedure Start the machine from the ground controls then inspect the fuel filter and hose for leaks If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Swing the engine piv
189. id and locate the boom up down controller terminal D2 directional output terminal A proportional output terminal ground terminal positive terminal R activates max out range terminal DL directional output ramp rate adjustable trimpot lo range adjustable trimpot threshold adjustable trimpot hi range adjustable trimpot a b C d e f g h i J Set the preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click Connect the red lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground Set the threshold Press down the foot switch then slowly move the control handle off center until the momenta voltage reading appears Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to i i the voltage or counterclockwise to AWARNING Electrocution hazard Contact Increase with electrically charged circuits decrease the voltage may result in death or serious injury Remove all rings watches and other jewelry 7 2 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 7 Setthe hi range Press down the footswitch 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
190. ifice 0 070 in 1 78 mm A Equalizes pressure on both sides of flow divider combiner valve Index no 2 10 Shuttle valve 3 position 3 way AK Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 15 18 ft Ibs 20 24 Nm 11 Diagnostic fitting sene Testing 12 Check valve see Al unos Works in conjunction with Index no 4 in the high speed divider bypass circuit 10 12 ft lbs 14 16 Nm Plug Torque Specifications Description Hex size Torque SAE No 8 5 16 50 ft lbs 68 Nm SAE No 2 1 8 50 in Ibs 6 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 12 5 8 75 ft lbs 102 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 56 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures MANIFOLDS 2 Part No 48412 Genie S 60 amp Genie S 65 7 5 Section 7 Repair Procedures Service Manual Second Edition J gt gt Z AA MANIFOLDS 10 11 Valve Adjustments 4WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connecta 0 to 600 psi 0 to 41 bar pressure gauge to the test port located on the drive manifold 2 Startthe engine from the platform controls 3 Drive the
191. il 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 48412 Service Manual Second 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 Engine fuels are combustible Replace the fuel lines in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Close the manual fuel shutoff valve located nextto the fuel tank 2 Remove andreplace 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 j CE E M CEA A DA ILE 1 OOOO Deutz Diesel models a hose from the injector to the fuel tank b hoses connecting injectors c hose from the fuel shutoff valve to the fuel pump d hose from the fuel pump to the fuel fil
192. ing ring Air filters Genie part numbers Ford LRG 423 Engine Deutz FAL 1011F Engine 27916 27916 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Table B Procedures B 1 5 Check the engine belt for proper tension Check the Engine Belt 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 AWARNING P ot inspect while the engine is running Remove the key to secure from operation ACAUTION 72212 of hotengine components Contact with hot engine components may cause severe 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 front engine access cover mounting fasteners Belt deflection Deut Diesel engine Ford LRG 423 engines are equipped with a serpentine belt and incorporate a self adjusting pulley tensioner No adjustment is required 3 8 inch to 1 2 inch Deutz Diesel models 9 mm to 12 mm 2 Remove the front engine access cover mounting fasteners 3 All models Inspect the engine belt for Cracking Glazing Separation Breaks 4 Replace belt if any damage is found Part No 48412 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance Procedures
193. ining fasteners then remove the pivot pin from each end ofthe 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 3 Center a lifting jack of ample capacity under the steering axle then raise the machine 4 Loosen the jam nuton the adjustable end ofthe tie rod 5 Remove the pin retaining fasteners then remove the pivot pin from the adjustable end of the tie rod 2WD STEERING AXLE COMPONENTS 6 Slide the tie rod off the yoke and adjust it by turning the end One half turn on the adjustable end equals approximately 1 4 inch 6 4 mm change in the front and rear measurements 7 Slide the tie rod onto the yoke Install the pivot pin then install the retaining bolt 8 Tighten the jam nutagainstthe tie rod 9 Lowerthe machine and recheck the frontand back measurements step 2 If further adjustment is needed repeat steps 3 through 8 Toe in specification 0 1 8 inch 6 35 mm Part No 48412 Genie S 60 amp Genie S 65 7 67 Section 7 Repair Procedures Service Manual Second Edition 4WD Steering Axle Components 14 1 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittngs on the
194. inite valve coil item SS on ohms steer manifold and test the resistance of the valve coil 5 to 6 ohms Continued on the next page With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP 1 in left direction and check voltage at the controller terminal with the blu wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department Repair open in blu 436 wire circuit that runs from TB36 to steer left directional valve coil on steer manifold Replace steer left directional valve coil item SS OR repair open in brown ground to steer left valve coil Repair open in blu 436 wire circuit from drive controller DP 1 to TP 36 then to TB36 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 28 Install a 0 to 5000 PSI Check for mechanical 0 to 345 bar pressure restrictions keeping gauge at the quick steer left function from disconnect coupling on operating OR repair or the boom function replace steer cylinder manifold and activate OR consult Genie the steer left function Industries Service Department Continued from the previous page less than 2600 PSI Repair or replace steer cylinder OR steer manifold could have an inter
195. ion Section 7 Repair Procedures Deutz Engine F4L 1011F 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 OO pump pump shaft coupler flex plate with raised spline flywheel 1 2 inch gap a b d e f How to Remove the Flex Plate 1 Disconnectthe wiring plug atthe electronic displacement controller EDC located on the drive pump 2 Supportthe drive pump with an appropriate lifting device Then remove all ofthe 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 flywheel 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 lbs 46 Nm 2 Install the coupler onto the pump shaft with the set screw toward the pump Leave a 1 2 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 dam
196. ircuit from terminal 87 on CR3 to terminal 1 on electronic governor Repair open in red wht wire circuit from electronic governor terminal 5 to governor actuator terminal 1 Repair open in blu blk wire circuit from governor actuator to electronic governor 5 20 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 6 Check voltage on red Repair open in red wht o ed fom the wht wire on governor wire from governor p page actuator controller to governor actuator Turn machine off 0 or remove both wires infinite from governor actuator ohms and check resistance across governor actuator terminals Replace governor actuator 2to 3 ohms Reconnect governor Repair open in brown wires and restart engine wire circuit from ignition and check voltage at coil plug to electronic electronic governor governor terminal 3 and 4 brown wires See Maintenance section for governor adjustments OR replace electronic governor PartNo 48412 Genie S 60 amp Genie S 65 5 21 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 7 Engine Low Idle Inoperative Gasoline LPG Models If low idle operates on LPG butnoton gasoline see Ford service manual for carburetor troubleshooting If low idle operates on gasoline but not on LPG see Repair section for LPG
197. ircuit to 12V terminal 5 on ignition terminal 5 on ignition start module start module continuity Replace the ignition start module OR consult Genie Industries Service Department no continuity Check continuity from ground to terminal 85 Repair open in brown ground wire circuit to CR2 on CR2 good Continued on the next page PartNo 48412 Genie S 60 amp Genie S 65 5 13 Section 5 Troubleshooting Flow Charts CHART 3 Crank engine and check gy voltage at terminal 2 on start lockout module Continued from the previous page 6to 7V While cranking engine for 15 seconds check continuity to ground on yes terminal 10 on start lockout module Is continuity maintained no Check voltage at 12V terminal 4 on ignition start module 0v Replace ignition start module OR consult Genie Industries Service Department Service Manual Second Edition MIENNE C _ ___ _ _ Crank engine and check ov voltage at org blk 41 wire on alternator 6 to 7V Repair open in org blk 341 wire circuit from alternator to TB41 to terminal 42 on start lockout module Disconnect wht 424 wire from oil pressure sender and check continuity to yes ground on signal post of sender while cranking the engine Is continuity maintained Disconnect wht 424 wire from engine temperature sender and check continuity t
198. irements Cold cranking ampere 1000A Temperature below 60 F 15 5 5W 30 Reserve capacity 25A rate 200 minutes 10 F to 90 F 23 C to 32 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 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 2 Specifications Ignition System Spark plug type Motorcraft AWSF 52C 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug gap SPECIFICATIONS Bolt torque specifications torque torque Bolt description size ft lbs Nm Exhaust manifold to cylinder head bolt or nut M 10 torque in sequence Enai lant first step 14 to 19 19 to 26 second step 35 to 50 47 to 68 i 1 Capacity a Flywheel to crankshaft 54 to 64 73 to 87 bolt M 10 Alternator Intake manifold to 15 to 22 20 to 30 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 torque torque 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 to55 Oll pan to block M 6 108438 Ao pivot
199. ivate the boom extend drive limit switch Result The boom extend drive limit switch arm should move freely and spring retum to center A distinct click should be felt and heard 7 Turn the keyswitch to platform control 8 Fully retractthe boom 9 Slowly move the drive control handle off center Result The machine should move at normal drive speeds 10 Raise the boom to just above horizontal 11 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 12 Lower the boom to the stowed position then extend the boom 3 feet 91 cm 13 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed Drive speed maximum raised or extended All models 1 foot per second 0 31 meter per second Drive Enable Limit Switch 1 With the engine off and the boom in between the steer and non steer tires 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 2 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 fel
200. jury Remove all rings watches and other jewelry 1 Inspectthe following areas for burnt chafed corroded and loose wires Engine compartment electrical panel Gasoline LP G models Engine wiring harness Inside of the ground control box Turntable manifold wiring 2 Startthe engine from the ground controls and raise the boom above the turntable covers 3 Inspectthe tumtable area for burnt chafed and pinched cables 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 ip D t AWARNING Tip over hazard Do not use temporary flat tire repair products 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 Tire size 15 19 5 NHS 4 Lower the boom into the stowed position and Tire ply rating 12 turn the engine off Tire pressure 85 psi 5 Inspectthe following areas for burnt chafed 5 86 bar corroded pinched and loos
201. kout module Is continuity maintained no Check voltage at terminal 4 on ignition start module 0v Replace start lockout module OR consult Genie Industries Service Department 12V Section 5 Troubleshooting Flow Charts Crank engine and check voltage at org blk 41 wire on alternator 6 to 7V Repair open in org blk 341 wire circuit from alternator to TB41 to terminal 42 on start lockout module Disconnect wht 424 wire from oil pressure sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained Disconnect wht 424 wire from water temperature sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained no Repair short to gound in wht 24 wire from sending units to TB24 to terminal 10 on ignition start module Disconnect red wire from terminal 4 on ignition start module and check voltage at terminal 4 0v Test auxiliary power toggle switches TS1 and 1510 See Repair Section 0V yes yes 12V Chart 2B Check alternator wiring OR repair or replace alternator OR contact Genie Industries Service Department Check oil level OR replace oil pressure sending unit OR refer to Ford service manual for troubleshooting low oil pressure Check coolant level OR replace water temperature sending unit OR refer to Ford service manua
202. l for troubleshooting a overheated engine Replace ignition start module OR consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 5 11 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 3 Engine Cranks Hold the start switch to H either side and check Over But Will AD while Not Start engine is cranking Deutz Diesel 11V or more Models Check if engine over Be sure to check the temperature sending engine oil level and fill as needed signal post has continuity to ground Be sure to check fuel level Be sure the diesel fuel shut off valve is in the on position Be sure thatthe battery is fully charged no continuity Disable the starter by removing the blk wire at the starter solenoid Hold the start switch to either side and check the voltage at positive terminal on fuel Solenoid Continued on the next page Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery Check if oil cooler and or engine block feels excessively hot Check engine oil level OR oil cooler fins for clogging OR check engine fan belts OR see Deutz service manual for troubleshooting an not hot overheating engine Remove wht wire from continuity Replace temperature temperature sending Switch sending unit unit check continuity to ground on s
203. l models All functions should stop immediately The engine will shut off after 2 to 3 seconds 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 Startthe 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 Startthe 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 Part No 48412 Genie S 60 amp Genie S 65 4 21 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES B 15 Test the Ground Control Override A properly functioning ground control override is essential to safe machine operation The ground contro
204. l override function is intended to allow ground personnel to operate the machine from the ground controls whether or notthe Emergency Stop button on the platform controls is in the or orr position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Pushin the platform Emergency Stop button to the orr position 2 Startthe engine from the ground controls 3 Operate each boom function through a partial cycle Result All boom functions should operate B 16 Check the Directional Valve Linkage Perform this test only on models equipped with a oscillating axle Proper axle oscillation is essential to safe machine operation If the directional valve linkage is not operating correctly the stability of the machine is compromised and it may tip over 1 Remove the drive chassis cover from the non steer end 2 Inspectthe linkage for the following Lock nut is tight against yoke Yoke clevis pins are installed Cotter pins are installed through clevis pins Linkage is properly attached to directional valve a directional valve b clevis pin with cotter pin hidden c yoke d lock nut Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures B 17 Test the Platform Self leveling Automatic platform self leveling throughout the full cycle of boom raising and lowe
205. lacards are in place 2 Inspectall decals for legibility and damage Replace any damaged or illegible 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 Inspectthe 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 48412 Service Manual Second 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 improperoil level can damag
206. lations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Part No 48412 Genie S 60 amp Genie S 65 lii Section 1 Safety Rules Service Manual Second Edition SAFETY RULES Personal Safety Any person working on or around a machine must be aware ofall 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 hazard that will cause death or serious injury AWARNING Indicates the presence of a hazard that may cause death or serious injury ACAUTION 7icetss the presence of a hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 3 such as moving parts free swinging or unsecured components and lifting or placing loads Always wear approved steel toed shoes 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 u
207. le track mounting fasteners 11 Remove the cable track mounting fasteners then remove the cable track from the boom and lay itoff to the side Component damage hazard ACAUTION The boom cable track can be damaged if itis twisted Component damage hazard ACAUTION Hoses can be damaged if they are kinked or pinched 12 Remove the turntable end cover 13 Remove the retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Pull the cylinder back and secure it from moving ACAUTION Component damage hazard When pulling the master cylinder back be sure not to damage the master cylinder hoses or fittings 14 Remove the fasteners from the drive speed limit switch mounted to the turntable riser at the pivot end of the boom Do not disconnect the wiring 15 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard S praying 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 16 Attach an overhead 5 ton 4536 kg crane to the center point of the boom 17 Attach a similar lifting device to the lift cylinder BOOM COMPONENTS 18 Use the crane to lift the boom to a horizontal position 19 Place support blocks underthe lift cylinder across the turntable 20 Remove the pin retaini
208. lift cylinder rod end pivot pin then remove the jib boom lift cylinder from the jib boom mounting weldment AWARNING Crushing hazard If the overhead crane is not properly attached the jib boom lift cylinder may become unbalanced and fall when it is removed from the machine Part No 48412 Genie S 60 amp Genie S 65 7 15 Section 7 Repair Procedures Service Manual Second Edition JIB BOOM COMPONENTS S 65 MODELS 3 2 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses fittings on the Jib Boom Lift Cylinder ir S 65 Models AWARNING Bodily injury hazard S praying hydraulic oil can penetrate and How to Remove the Jib Boom burn skin Loosen hydraulic Lift Cylinder connections very slowly to allow the oil pressure to dissipate Perform this procedure with the gradually Do not allow oil to boom in the stowed position squirt or spray When removing a hose assembly 3 Remove the pin retaining fasteners from the jib or fitting the O ring on the fitting boom lift cylinder rod end pivot pin Do not and or hose end must be replaced remove the pin and then torqued to specification during installation 4 Use a soft metal driftto tap the jib boom lift Refer to Section Two Hydraulic cylinder rod end pivot pin half way out Then Hose and Fitting Torque lower one of the leveling arms to the
209. limiter board OR re adjust horsepower limiter board OR consult Genie Industries Service Department Repair open in org wire circuit from TB40 to TP40 to terminal 6 on horsepower limiter circuit board Replace defective limit Switch contact OR replace limit switch Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Drive Enable System Is Malfunctioning Be sure the boom is in the stowed position With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position and the boom rotated between the non steer tires activate footswitch and drive controller in forward direction Will unit drive yes With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position and the boom rotated between the steer end tires activate footswitch and drive controller in forward direction Will unit drive yes Check for continuity continui from TB30 to TB12 no continuity Repair open from TB30 through red wire to LS3 then from LS3 through blk wire to TB12 With keyswitch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and drive controller in forward direction and check voltage at terminal 2 on drive controller DP 1 12V or more Repair open from terminal 4 on DP1 to center terminal on TS9 OR
210. lug Torque Specifications 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 Part No 48412 Genie S 60 amp Genie S 65 7 45 Section 7 Repair Procedures MANIFOLDS 10 4 Oscillate Manifold Components Service Manual Second Edition En c Q ue Z L L CN The oscillate manifold is mounted inside the drive chassis atthe non steer end Index Schematic No Description Item Function Torque 1 Orifice Plug 0 052 inch 1 32 mm KK Differential sensing circuit 2 Differential sensing valve ELE sies Differential sensing 10 12 ft lbs 14 16 Nm 3 Check 42 MM Oscillate check left 35 40 ft lbs 47 54 Nm 4 Pilot operated unloader valve 950 psi 65 bar NN Sequencing eit AAAA 10 12 ft Ibs 14 16 Nm 5 Shuttle valve 2 position 3 way OO PIE uie eere sec 10 12 ft lbs 14 16 Nm 6 Lj Check valve circuit the piston is located between index numbers 3 and 7 7 Check valve seeeeeee PPS Oscillate check right 35 40 ft lbs 47 54 Nm 8 Shuttle valve 2 position 3 way QQ Unloading ii tnr 35 40 ft lbs 47 54 Nm 9 Diagnostic fitting sse Testing Description Hex size Torque SAE
211. m RE W a engine pivot plate b pivot plate retaining bolts 2 All models Be sure that all nuts and bolts are tight 3 Inspectall welds for cracks 4 Inspectfor exhaust leaks i e carbon buildup around seams and joints Part No 48412 Genie S 60 amp Genie S 65 4 15 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE B PROCEDURES 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 Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Batteries contain acid Avoid AWARNING 22 87 spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Besurethatthe battery cable connections are free of corrosion 3 Be sure that 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 will help eliminate corrosion on
212. machine M Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years 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 48412 Genie S 60 amp Genie S 65 3 1 Section 3 Scheduled Maintenance Inspections Service Manual Second Edition Mainte
213. machine slowly in either direction and observe the pressure reading on the pressure gauge 4 Turnthe engine off Hold the charge pressure relief valve and remove the cap index 3 5 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the valve cap 6 Restartthe engine Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off then remove the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 7 58 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures Fuel and Hydraulic Tanks 11 1 Fuel Tank How to Remove the Fuel Tank 6 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 a grounding wire between the machine and pump or container Turn the manual fuel shutoff valve to the CLOSED position Remove the tank side turntable cover See 5 1 How to Remove a Turntable Cover Gasoline LPG models Disconnect drain and plug the fuel hose Deutz Diesel models Disconnect drain and plug the supply and return fuel lines Cap the fuel return fitting on the fuel tank Remove the retaining
214. manuals Please write to the technical publications team in care of Genie Industries PO Box 69 Redmond WA 98073 0069 U S A Ifyou have any questions please call Genie Industries Genie North America Telephone 425 881 1800 Toll Free 800 536 1800 in U S A Toll Free 800 426 8089 in Canada Fax 425 556 8649 Genie Europe Office Telephone 44 01636 605030 Office FaxFax 44 01636 611090 Parts Telephone 44 01636 605002 Parts Fax 44 01636 611091 Genie Industries Copyright 1998 by Genie Industries Second Edition F irstP rinting J une 1998 Genie and S are Registered Trademarks of Genie Industries in the USA and many other countries These machines comply with ANSI SIA 92 5 1992 Mag Printed on recycled paper Printed inU S A ij Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second 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 You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regu
215. ming the engine to normal operating temperature Beware of hot engine parts and oil ACAUTION Contact with hot engine oil and or engine parts may cause severe burns 1 Remove the filler cap located on the valve cover 2 Place a suitable container under the engine pivot plate directly below the oil pan drain plug Z A V a engine pivot plate b pivot plate retaining bolts c oil drain hose 3 Remove the plug from the oil pan and allow all of the oil from the engine to drain into a suitable container See capacity specifications below 4 Install the plug into the oil pan 5 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the oil filter 6 Use an oil filter wrench and remove the filter 7 Apply a thin layer of oil to the new oil filter gasket Genie part no 28656 Then install the filter and tighten it securely by hand 8 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 9 Fillthe engine with new oil per specifications and install the filler cap See capacity specifications below 10 Startthe engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 11 Check the oil filter and th
216. mmediately kill the engine With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position activate the auxiliary pump toggle switch and check the voltage on the red cable on the auxiliary power unit 12V Continued on the next page Install a 0 to 5000 psi 0 to 345 bar pressure gauge into the pressure port of the auxiliary pump and hold the auxiliary power toggle switch and note the pressure less than 2500 psi Check for a positive connection between electric motor and the pump by removing the pump from the motor but leave all the hoses connected Visually check coupling connection bad Replace the auxiliary power unit Test PR1 See Repair Procedure 8 5 good Activate the auxiliary pump toggle switch and check the voltage at TB27 0v Activate the auxiliary pump toggle switch and check the voltage at the center terminal of TS 10 12V or more Repair open in red 427 wire from 7510 to TB27 OR replace 1510 OR repair open in brown ground wire to 1 Reconnect pressure 2500 psi line and check battery condition There is possibly not enough battery capacity to operate both aux pump and function valves Repair or replace pump OR relief valve is out of adjustment Consult good Genie Industries Service Department bad Replace PR1 12V or more Repair open from TB27 to PR1 Repair open
217. motor Om Pump prime mover engine or motor Cylinder MANNWAN Accumulator 4 0 035 Orifice with size A Variable orifice or shut off valve n x Check valve E A Relief valve Priority flow divider olf Wy m Solenoid operated dump valve L a Differential sensing valve Solenoid operated proportional valve Solenoid operated 2 pos 3 way directional valve 9 M duo LEA 6 4 Pilot operated flow control valve Solenoid operated 2 pos 4 way directional valve Solenoid operated 3 pos 4 way directional valve DO1 d 2 pos 3 way shuttle valve mom E u 3 pos 4 way directional valve Sequencing valve ril gt ren 00 1 Unloader valve Pressure compensating valve Genie 5 60 amp Genie 5 65 Part No 48412
218. n BLKSSD STARTINPUT MODULE A ee RED 27B 4 AUX oN RED 20A 4 BEN GRD LE s GROUND BLU WHT 38A RED R2 30 LLE 6 BATTERY RED R1 30 lt 7 KEY PWR 8 KEY BYPASS WHT R2 86 PLATFORM LEVEL DISABLE amp IGN FUEEON HYD OIL COOLER v WHT24D vo ENG FAULT OPTION RELAYS RED 6 ISM a E R WHT BISM RED WHT R3 E H RED CB1 BLK 33B ORG RED416 TB16D A 1 2 s 4 E BLK 1 ISM 18 l eil BLK Ri E H WHT 2iD ORG RED 4 m BLK D B BLU WHT R6 A H FUSE 5 BLU WHT R6 E H BLU RED R7 E H INLINE H 5 6 7 WHT R17 EH h OR amp RITEH BLK 22D BLU WHT 38D GRN 43D RED BLK R6 E H BLU RED 39B SECTION A A 6 10 Genie 5 60 amp Genie 5 65 Part No 48412 Section 6 Schematics Service Manual Second Edition Platform Control Box Legend Gasoline LPG Models P2 EMERGENCY STOP TS3 i UB DELAY LAY CAPACITOR DP1 8 7 6 5
219. n Gasoline But Will Start On LPG Gasoline LP G 4 emen 5 17 6 Engine High Idle Inoperative Gasoline LPG Models 5 19 7 Engine Low Idle Inoperative Gasoline LP G 5 22 8 Engine High Idle Inoperative Deutz Diesel 5 23 9 Engine Low Idle Inoperative Deutz Diesel 5 25 10 All Functions Inoperative Engine Starts and 5 26 11 AllLiftand Steer Functions Inoperative Drive Functions Operational 5 27 12 Ground Controls Inoperative Platform Controls Operate Normally 5 28 13 Platform Controls Inoperative Ground Controls Operate Normally 5 29 14 Boom Up Function Inoperative 2222 mmm 5 30 15 Down Function Inoperative 0 5 33 16 Extend Function Inoperative 10 1 5 36 17 Boom Retract Function Inoperative 5 39 18 Turntable Rotate Left Function 5 42 19 Turntable Rotate Right Function Inoperative 5 46 20 AllPlatform Leveling Functions
220. n in brown rotate p ak MS circuit to valves item AM valve coils Activate footswitch and platform rotate right function function inoperative Repair or replace platform rotator OR 0 030 orifice fitting in jib manifold are plugged OR jib manifold may have an internal defect Consult Genie Industries Service Department 5 60 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Jib Boom Up Function Inoperative S 65 Models Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the jib boom toggle switch TS15 in the up direction and check voltage at the grn wire on the jib boom up directional valve item BB With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate the footswitch and the jib boom toggle switch TS6 in the up direction and check voltage at TB17 12V Continued on the next page Chart 25 Move the function enable switch to either side and activate the jib boom toggle switch TS15 in the up direction and check voltage at TB17 Repair open in grn wire from TB17 to jib boom up directional valve OR repair open in brown ground wire circuit to directional valve Repair op
221. n in brown ground wire to CR14 Repair open in cable containing red and black wires from CR14 to jib boom platform rotate select valves Replace defective valve coil 5 56 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 23 Check continuity from Repair open in brown brown ground wires on ground wire circuit to valve coils to ground valve coils Continued from the previous page Exchange jib boom uroen Repair open in brown platform rotate select ground wire circuit to valves item valve coils Activate footswitch and platform rotate left function function inoperative Repair or replace platform rotator OR 0 030 orifice fittings in jib manifold are plugged OR jib manifold may have an internal defect Consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 5 57 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 24 Platform Rotate Right Function Inoperative Be sure all other functions operate normally With the keyswitch turned to ground control ov and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and activate the platform rotate toggle switch TS14 in the right direction and check voltage at grn wht wire at TP 19 at the platform controls With key
222. nal defect Consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 5 67 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 29 Steer Right Function Inoperative Be sure all other functions operate normally With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP 1 in right direction and check voltage on TB37 12V or more With key switch in perm position and oth Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP 1 in right direction and check voltage on blu blk 437 Wire on steer right directional valve coil item SS on steer manifold 12V or more Disconnect wires to 0 or steer right directional infinite valve coil item SS on ohms steer manifold and test the resistance of the valve coil 5 to 6 ohms Continued on the next page With key switch in platform position and both Emergency Stop buttons pulled out to the ON position activate footswitch and steer rocker switch on drive controller DP 1 in right direction and check voltage at the controller terminal with the blu blk wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department Repair open in blu blk 37 wir
223. nal on BP 1 12V or more Re adjust controller see Repair Section OR replace controller BP 1 OR consult Genie Industries Service Department Repair open in wht red wire circuit from TB6 to turntable rotate left right proportional valve coil item R OR repair open in brown ground wire circuit to valve coil 440 6V Repair open in wht red wire from TP6 to TB6 Repair open in power supply circuit from TP 24 to BP1 OR repair open in brown ground wire circuit from ground to BP1 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Continued from the previous page With key switch in ground position and both Emergency Stop buttons pulled out to the ON position move the function enable switch to either side and hold the turntable rotate left right toggle switch TS18 on ground panel in the left direction and check voltage on wht blk wire on boom function directional valve coil item A 20V or more Continued on the next page Section 5 Troubleshooting Flow Charts Move the function enable switch to either side and hold the turntable rotate left right toggle switch TS18 on ground panel in the left direction and check voltage at TB5 With key switch in platform position and both E mergency Stop buttons pulled out to the oN position activate footswitch and turntable rotate left right proportional controller BP 1 on platform control
224. nance Tables Table A 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 Oil Level A 5 Check the Engine Coolant Level Gasoline LPG Models OS 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 the Oscillate Axle if equipped 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 S witches Every 100 hours perform the following three engine maintenance procedures A 15 Replace the Engine Oil and Filter Gasoline LP G Models Part No 48412 3 2 Genie S 60 amp Genie S 65 Service Manual Second Edition Section 3 Scheduled Maintenance Inspections n MM MAINTENANCE TABLES 1 w Cold Deal Table A continued Tools are New parts RA A ae senie required required required required suggested A 16 Drain the Fuel Filter Water Separator Deutz Diesel Models A 17 Replace the Engine Air Filter N B 1 Check the Engine Belt B 2 Check the Radiator HE Gasoline LP G Models B 3 Check the Oil Cooler and Cooling Fins m Deutz Diesel Models B 4 Check the Exhaust S ystem SCR B 5 Check the Battery 6 Check
225. nd pivot pin and Platform Leveling Master Cylinder The master cylinder acts as a pump for the 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 atthe base ofthe boom How to Remove the Platform Leveling Master Cylinder twistto remove the pin 6 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder When removing a hose assembly 7 Remove the pin retaining fastener from the rod or fitting the O ring on the fitting end pivot pin and or hose end must be replaced and then torqued to specification 8 Use a soft metal drift to remove the pin during installation Referto Section Two Hyaraulic AWARNING Hose and Fitting Torque Specifications 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 S praying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin Crushing hazard The master cylinder may become unbalanced and fall if itis not properly supported by t
226. nder Bodily injury hazard S praying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Support the barrel end of the cylinder with a lifting device 7 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin 8 Use a soft metal drift to remove the pin and lay the cylinder onto the ground 9 Tag disconnect and plug all the hydraulic hoses from the jib boom manifold Bodily injury hazard S praying 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 10 Attach a lifting strap from an overhead crane to the jib boom 11 Remove the pin retaining fastener from 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 If the overhead crane is not properly attached the jib boom may become unbalanced and fall when itis removed from the machine 12 Remove the pin retaining fastener from the jib boom lift cylinder rod end pivot pin Do not remove the pin 13 Slide both of the jib boom leveling arms off of the jib boom pivot pin 14 Support the rod end of the jib boom lift cylinder with a lifting device 15 Use a soft metal drift to remove the jib boom
227. nder hydraulic hoses Cap the fittings on the oscillate cylinder Bodily injury hazard S praying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the pin retaining fasteners from the rod end pivot pin Use a soft metal drift to remove the pin 5 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder 6 Remove the pin retaining fasteners from the barrel end pivot pin Use a soft metal drift to remove the pin Crushing hazard The oscillate AWARNING cylinder may become unbalanced and fall when itis removed from the machine if itis not properly attached to the overhead crane 7 Remove the cylinder from the machine 7 70 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures Non steering Axle Components 16 1 Drive Motor How to Remove a Drive Motor Component damage hazard ACAUTION Repairs to the motor should only be performed by an authorized Sundstrand S auer dealer 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 When removing a hose assembly or fitting the O ring on the fitti
228. ng and or hose end must be replaced and then torqued to specification during installation Referto Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Remove the fasteners from drive chassis cover atthe non steer end Remove the cover 2 Tag disconnectand plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor Bodily injury hazard S praying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the drive motor mounting fasteners 4 Slide the drive motor shaft out of the brake and then remove the drive motor from the machine Torque specifications Drive motor mounting bolts 75 ft lbs 102 Nm 16 2 Torque Hub How to Remove a Drive Torque Hub When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the drive motor See 22 1 How to Remove a Drive Motor 2 Tag disconnect and plug the hydraulic hose from the brake Then remove the hydraulic fitting and the bleed valve 3 Loosen the wheel lug nuts Do not remove them 4 Center a lifting jack of ample capacity under the non steering axle Raise the machine and place blocks under the drive chassis for
229. ng fastener from the boom lift cylinder rod end pin Use a soft metal drift to remove the pin Crushing hazard The boom Iift AWARNING cylinder will fall unless itis properly supported 21 Lowerthe rod end ofthe lift cylinder onto support blocks P rotectthe cylinder rod from damage 22 Remove the pin retaining fastener from the boom pivot pin 23 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 ifthe outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 How to Remove the Extension Cylinder 1 Remove the boom See 4 2 How to Remove the Boom 2 Place blocks under the extension cylinder for support 3 Remove the external snap 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 Part No 48412 Genie S 60 amp Genie S 65 7 21 Section 7 Repair Procedures Service Manual Second Edition BOOM COMPONENTS 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
230. nking the engine Check automatic choke for proper adjustment or internal damage good With keyswitch on and both Emergency Stop buttons pulled out to the ON position check voltage at red wht 23 wire on vacuum switch 12V Remove the blk wire with diode from terminal 386 on CR3 hold the start switch to either side and crank the engine over for 15 seconds and check voltage at red blk wire on vacuum switch reconnect blk wire after test With keyswitch on and both Emergency Stop buttons pulled out to the ON position disconnect wires from vacuum switch and connect the wires together Check the voltage at terminal 86 on CR6 12V Continued on the next page Repair open in white 21 wire circuit from the ignition coil plug to the automatic choke Adjust or replace automatic choke OR consult Genie Industries Service Department Repair open in red wht 323 wire circuit from TB23 to vacuum switch Turn machine off See bad Replace vacuum switch Repair section for how the testthe vacuum switch ok bad Check vacuum line for Replace vacuum line restrictions or damage ok See Ford service manual to troubleshoot low manifold vacuum Repair open in red blk wire circuit from vacuum switch to CR6 Genie S 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition i ee BG ee Continued from the previous page With keyswitch on and both Eme
231. nual Second Edition Section 5 Troubleshooting Flow Charts 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 Emergency Stop switches pulled out to the position check voltage at gasoline side blu wht wire of fuel Select switch 12V With keyswitch on and both S de Stop buttons pulled out to the ON position check voltage at TB38 With keyswitch on and both AU a Stop buttons pulled out to the ON position check voltage at terminal 430 on CR6 Crank engine for 15 seconds and check voltage at terminal 486 on CR6 while cranking no Check continuity from continuity ground to brown wire at terminal 485 on CR6 continuity Hold the start switch to either side and check voltage at blu wht wire on anti diesel valve on carburetor Continued on the next page Chart 5 0v 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 CR 6 Repair open in red blk wire circuit from vacuum switch to CR 6 Repair open in brown ground wire circuit to terminal 85 on CR6 Repair open in blu wht wire circuit from CR6 terminal 87 to anti diesel v
232. o 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 The free wheel valve is located on the bottom of the drive pump a drive pump b free wheel valve c lift pump d screwdriver The free wheel valve should always remain closed TABLE C PROCEDURES C 4 Grease the Turntable Rotation Bearing and Rotate Gear Y early 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 turntable in increments of 4 to 5 inches 10 to 13 cm ata time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Grease type Multipurpose grease 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 poin
233. o ground on signal post of sender while cranking the engine Is continuity maintained yes no Repair short to ground in wht 424 wire from sending units to TB24 to terminal 10 on ignition start module Disconnect red wire from terminal 4 on 12V ignition start module and check voltage at terminal 4 0v Testauxiliary power toggle switches 51 and T 10 See Repair Section 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 Check oil level OR replace engine temperature sending unit OR refer to Deutz service manual for troubleshooting a overheated engine Replace ignition start module OR consult Genie Industries Service Department 5 14 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models Be sure fuel select switch is switched to LPG Be sure to check LPG fuel level Disconnect LPG supply line from LPG tank and bleed pressure from line With keyswitch on and both Stop buttons pulled out to the ON position check voltage at LPG side blu red wire of fuel select switch With keyswitch on and both Emergency Stop buttons pulled out to the
234. o 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 CAUTION the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 2 4 PLATFORM COMPONENTS 2 S 60 models Tag disconnect and plug the 8 Use a soft metal drift to drive both pins out then hydraulic hoses from the platform rotator remove the platform rotator from the machine manifold Cap the fittings on the rotator AWARNING Crushing hazard The platform A
235. ocated at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole 3 Ifnecessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Apply pipe thread sealantto the plug and then install itin the torque hub 5 Repeatthis procedure for each drive torque hub Drive torque hub oil 44 fl oz 1 30 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures Turntable Rotate Torque Hub 1 Removethe plug located on the side ofthe hub and check the oil level Result The oil level should be even with the bottom ofthe plug hole a torque hub b plug 2 Ifnecessary add oil until the oil level is even with the bottom ofthe side plug hole 3 Apply pipe thread sealantto the plug and then install itin the torque hub Turntable rotate torque hub oil 17 fluid ounces 0 51 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 B 11 Check and Adjust the Engine Idle Mixture Gasoline LPG Models Complete information to perform this procedure is available in the Ford LRG 423 2 3 Liter Industrial Engine Service Manual F ord number P P D 194 287 Genie part number 33907 TABLE B PROCEDURES B
236. odels Remove the jib boom See 3 1 How to Remove the Jib Boom 4 Raise the boom to a horizontal position 5 Remove the external snap rings from the extension cylinder rod end pin atthe platform end Use a soft metal driftto 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 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 8 Remove the trunnion pin covers from both sides of the number 1 boom tube atthe pivot end of the boom 9 Remove the trunnion pin retaining fastener and use a slide hammer to remove the pins 10 Remove the pin retaining fasteners from both sides of the extension cylinder at the pivot end of the boom 11 Use a slide hammer to remove the pins 12 Support and slide the extension cylinder out of the pivot end of the boom Crushing hazard The extension AWARNING cylinder will fall when itis removed from the extension boom if itis not properly supported Note the length of the cylinder after removal The cylinder must be atthe same length for installation 7 24 Genie 5 60 amp Genie 5 65 Part 48412 Service Manual Second Edition Section 7 Repair Procedures BOOM COMPONENTS 4 5 5 Place a rod through the barel e
237. 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 a lifting strap attached to an overhead crane at the platform end ofthe boom 7 Supportand 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 Crushing hazard The number 2 AWARNING and 3 boom tubes may become unbalanced and fall when they are removed from the number 1 boom tube if they are not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 8 Remove and label the wear pads from the top side of the number 2 boom tube atthe 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 11 Support the number 3 boom tube with a lifting strap attached to an overhead crane at the platform end of the boom 12 Support and slide the number 3 boom tube out ofthe number 2 boom tube Place the number 3 boom tube on blocks for support AWARNING Crushing hazard The number 3 boom tube may become unbalanced and fall when it is removed from the number 2 boom tube if itis not properly supported
238. on 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 3 Tagand disconnect and plug the hydraulic hoses from the drive and lift steer pumps Cap the fittings on the pumps Bodily injury hazard S praying 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 Supportthe pump with a lifting device and remove the two drive pump mounting fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump from the machine Component damage hazard ACAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump gauge to the test port on the drive pump Gasoline LPG models Disconnectthe electrical connector atthe ignition coils The ignition coils are located above the alternator 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 clockwise to the cLosEp position a manual fuel shutoff valve 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
239. on the engine side bulkhead then remove the back panel from the governor 9 Restartthe engine turn the low or high speed trimpot screw clockwise to increase the rpm or counterclockwise to decrease the rpm Do notadjust any trimpot other than specified in this procedure clic MONON 2 s 00 a low idle adjustment b high idle 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 Deutz Diesel models 1 Connectan 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 2 Loosen the low idle lock nut then tum the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and recheck the solenoid boot high idle adjustment nut yoke lock nut yoke low idle adjustment screw low idle lock nut 3 Move the function enable toggle switch to the high idle rabbit symbol position atthe ground controls Result High idle should be 2300 rpm If high idle rpm is correct disregard adjustment step 4 Low idle carburetor 900 rpm Low idle electronic governor 1600 rpm High idle 2500 rpm 4
240. on when overriding a machine function Identify the direction of machine movement before overriding a valve Part No 48412 Genie 5 60 amp Genie 5 65 7 43 Section 7 Repair Procedures Service Manual Second Edition J gt gt Z AA MANIFOLDS How to Check the Resistance of a Valve Coil 1 Turnthe key switch to the orr position and disconnect the wires from the valve coil to be tested 2 Connectthe leads from an ohmmeter to the valve coil terminals Valve coil specifications Proportional solenoid valve 12V 8 60 schematic items M O and R 3 position 4 way directional valve 10V 3 20 schematic items A B and C Normally open poppet valve 6 40 schematic item S U BB and CC 7 44 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 10 3 MANIFOLDS Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor on the tank side ofthe turntable Index No Schematic Description Item Function Torque Shuttle valve 2 position 3 way Turntable rotation brake release 10 13 ft lbs 14 18 Nm Counterbalance valve ll ies Turntable rotate right 35 40 ft lbs 47 54 Nm Counterbalance valve Turntable rotate left 35 40 ft lbs 47 54 Nm P
241. operative 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 Start engine switch rpm select switch to high idle rabbit symbol and solenoid pulls in check if 2 speed solenoid pulls in solenoid does not pull in Check voltage at blk red Wire on rpm select switch 754 and TS13 12V Check voltage at TB35 ov 12V Check voltage at OV terminal 30 on CR3 12V Check voltage to 0v terminal 486 on CR3 12V continuity Check continuity from ground to brown wire at terminal 485 on CR3 continuity Check voltage to OV terminal 87 on CR3 12V Continued on the next page Check high idle adjustment see Maintenance section or see Deutz workshop manual to troubleshoot fuel injection system Check voltage on red ov wire at center terminal of rpm select switch 12V Replace toggle switch Repair open in blk red wire circuit from toggle switch to TP35 to TB35 Repair open in blk red wire circuit from TB35 to terminal 430 on CR3 Repair open in wht wire circuit from terminal 87 on CR2 to terminal 486 on CR3 Repair open in brown ground wire circuit to terminal 85 on Replace CR3 relay Chart 8 Repair open in circuit supplying 12V to center terminal of switch PartNo 48412 Genie S 60 amp G
242. or troubleshooting an nothot overheating engine Remove wht wire from continui temperature sending unit check continuity to ground on temperature sending unit Replace temperature switch sender no continuity Remove wht wire from TB24 and check continuity to ground Repair short in wht wire continui circuit from TB24 to temperature sender no continuity Repair short in wht wire circuit from terminal 10 on ignition start module to TB24 OR consult Genie Industries Service Department Spark Go to Chart 2A PartNo 48412 Genie S 60 amp Genie S 65 5 5 Section 5 Troubleshooting Flow Charts CHART 2 Disable starter by removing blk wire at the starter solenoid hold the start switch to either Continued from the previous page side and check voltage at the white wire on the ignition coil plug less than 12V Hold the start switch to either side and check voltage at wht 21 on terminal 87 of CR2 Check voltage at red wire on terminal 30 of CR2 12V Hold the start switch to either side and check voltage at terminal 86 of CR2 12V Continued on the next page Service Manual Second Edition _ _ __ _ See Ford service manual for troubleshooting ignition system Repair open in wht 421 wire from CR2 to ignition coil Repair open in red wire circuit from battery to TB20 to CB1 to CR1 to CR2 Hold st
243. or damage or improper linkage adjustment See Repair section 10 6 How to Set Up the Directional Valve Linkage Install a 0 to 2000 psi 0 to 138 bar pressure gauge atthe quick disconnect coupling on the oscillate manifold Disconnect the oscillate linkage from non steer axle Start the engine and manually activate the directional valve Check the pressure Consult Genie Industries Service Department Chart 27 Re adjust or replace linkage Adjust the sequence valve See Repair procedure 10 5 How to Adjust the Oscillate Sequencing Valve Pressure OR consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 5 65 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 28 Steer Left Function Inoperative Be sure all other functions operate normally With key switch in platform position and both Emergency Stop buttons pulled outto the ON position activate footswitch and steer rocker switch on drive controller DP 1 in left direction and check voltage on TB36 12V or more With key switch in platform position and both Emergency Stop buttons pulled outto the ON position activate footswitch and steer rocker switch on drive controller DP 1 in left direction and check voltage on blu 36 wire on steer left directional valve coil item SS on steer manifold 12V or more Disconnect wires to 0 or steer left directional inf
244. or replace starter or starter solenoid 5 4 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second 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 Or OPEN position Be sure that automatic choke is not sticking closed Perform following tests in gasoline mode only Be sure that the water temperature gauge does not show an overheated condition less With the keyswitch turned to ground controls and both Emergency Stop buttons pulled out to the on position hold start switch to either side and check battery voltage while engine is cranking more than 11V Check if engine coolant temperature sending 10100 unit signal post has continuity to ground no continuity good Remove 1 spark plug and ground spark plug body Crank engine and observe spark weak or no spark Continued on the next page Chart 2 Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery Check if radiator and or engine block feels excessively hot Check engine coolant level OR check radiator fins for clogging OR check engine fan belts OR see Ford service manual f
245. ot 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 Checkthe 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 outthe Emergency Stop button to the ON position at both the ground and platform controls Do notstartthe engine PLATFORM CONTROLS 3 Openthe platform control box lid and locate the boom extend retract controller Pn COA E ramp rate adjustable trimpot dual lo range adjustable trimpot terminal R activates max out range terminal unused terminal X auxiliary terminal ground terminal battery positive terminal A proportional output threshold adjustable trimpot max out adjustable trimpot a b C d e f 0 i J Set the preliminary ramp rate Turn the trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click Connect the red lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground Set the threshold Press down the foot switch then slowly move the control handle off center
246. ot plate back to its original position and replace the two retaining bolts Part No 48412 Genie S 60 amp Genie S 65 4 35 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE C PROCEDURES C 10 Replace the PCV Valve Gasoline LPG Models Yearly replacement of the P CV valve is essential to good engine performance A malfunctioning P CV valve can impair crankcase ventilation and may cause engine damage Perform this procedure with the engine off 1 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate S wing the engine pivot plate away from the machine to access the PCV valve umi TIP US Al epi a pivotplate retaining bolts b engine pivot plate 2 Remove the hose from the PCV valve then remove the valve a PCV valve 3 Install the new PCV valve Connectthe hoses 4 Swingthe engine pivot plate back to its original position and replace the two retaining bolts 4 36 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance 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 di
247. oubleshoot discovered symptoms problem still exists Retum to Perform Service repair problem Solved 5 2 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine Will Not Crank Over Be sure the key switch is in the appropriate position Be sure that both Emergency Stop buttons are pulled out to the position Be sure the circuit breakers are not tripped Be sure the battery is fully charged less than Check battery voltage 12V or more With the keyswitch turned to ground controls and both Emergency Stop buttons are pulled outto the ON position check the voltage at the center terminal on the start toggle switch TS11 Hold the start toggle Switch to either side and check the voltage at either side terminal on start switch Hold the start switch to either side and check voltage at terminal TB33 Hold the start switch to either side and check voltage at terminal 3 on ignition start module Hold the start switch to either side and check voltage at terminal 6 on the ignition start 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 Repair open in jumper wire from one side ofthe Switch to the other OR repl
248. ound control panel OR repair open in red blk 32 wire circuit from TS17 to TB2 OR consult Genie Industries Service Department Repair open in red blk wire from TP2 to TB2 Repair open in power supply circuit from TP 24 to BP1 OR repair open in brown ground wire circuit from ground to BP1 5 34 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 15 Disconnect wires to 001 boom down directional infinite valve coil item B and ohms coe ja sa test the resistance of the valve valve coil See Repair item B Section Continued from the previous page 2 5 to 3 5 ohms function Move function enable operates Switch to either side and hold the boom down toggle switch atthe ground controls in the down direction Manually override the directional valve by pushing in on the end of the valve spool Replace defective directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping gauge at the quick boom from moving OR disconnect coupling on repair cylinder or the boom function cylinder counterbalance manifold and start the valve OR consult Genie engine Move the Industries Service function enable switch to Department either side and hold the boom down toggle Switch at the ground controls in the down
249. ower contact terminal large post b solenoid activate coil terminal small post Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 9 1 Lift Steer Pump How to Remove the Lift Steer Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Close the two hydraulic tank valves located at the hydraulic tank open 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 ofthe condition 2 Tag disconnect and plug the lift steer pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard S praying 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 Hydraulic Pumps 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 9 2 Drive Pump The drive pump is a bi directional variabl
250. panel in the left direction and check voltage TBS 0v Activate footswitch and turntable rotate left right proportional controller BP 1 on platform control panel in the left direction and check voltage TP 5 0v Activate footswitch and check voltage at terminal on BP1 12V or more Re adjust controller see Repair Section OR replace controller BP 1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 18 Repair open in wht blk wire circuit from TB5 to turntable rotate left function directional valve coil item A OR repair open in brown ground wire circuit to valve coil Troubleshoot turntable rotate left right function toggle switch TS18 on ground control panel OR repair open in wht blk wire circuit from TS 18 to TB5 OR consult Genie Industries Service Department Repair open wht blk wire from TP5 to TB5 Repair open in power supply circuit from TP 24 to BP1 OR repair open in brown ground wire circuit from ground to PartNo 48412 Genie 5 60 amp Genie 5 65 5 43 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 18 Disconnect wires to 0 or turntable rotate left infinite directional valve coil ohms item A and test the resistance of the valve Coil See Repair Section Continued from the previous page Replace turntable rotate left directional valve coil
251. platform level toggle switch TS16 in the down direction and check the voltage at org blk wire on platform level down function directional valve item U 12V or more Continued on the next page With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the on position move the function enable Switch to either side and activate the platform level toggle switch 5 16 in the down direction and check the voltage at TB15 With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate the footswitch and the platform level toggle switch 57 in the down direction and check the voltage at TB15 Troubleshoot platform level toggle switch 516 on ground control panel OR repair open in red power wire circuit to 1516 OR repair open in org blk wire circuit from TS16 to TB15 OR consult Genie Industries Service Department 12V or more Chart 22 Repair open in org blk wire from TB15 to platform level down directional valve coil item U OR repair open in brown ground wire circuit to valve coil Troubleshoot platform level toggle switches 516 and TS7 on ground and platform control panels OR repair open in red power wire circuit to T516 and 57 OR repair open in org blk wire circuit from 1516 and TS7 to TB15 OR consult Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 S
252. r open in red power wire circuit through controllers and function toggle switches to T 5 Repair open in grn wht wire from TP 19 to jib delay capacitor Repair open in grn wht wire from 755 to TP 19 PartNo 48412 Genie S 60 amp Genie S 65 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 23 With keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at the red wire at the jib delay capacitor Continued from the previous page Activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage on the red wire at terminal 86 on Activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage on the red and black wires at terminal 387 on CR14 Activate footswitch and platform rotate toggle Switch TS5 in the left direction and check voltage on the red and black wires at the jib platform rotate select valves item 12V Test the resistance of the valve coils Continued on the next page Replace the jib delay capacitor OR repair open in brown ground wire from capacitor to ground Repair open in red wire from jib delay capacitor to CR14 Replace relay CR14 OR repair open in power supply from P2 to CR14 OR repair ope
253. raulic shutoff valves located atthe 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 3 Remove the drain plug from the hydraulic tank 4 Completely drain the tank into a suitable container See capacity specifications 5 Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves 6 Disconnect and plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter housing 7 Disconnectand plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank 8 Remove the retaining fasteners from the hydraulic tank hold down straps Remove the straps from the hydraulic tank 9 Supportthe hydraulic tank with 2 lifting straps Place one lifting strap at each end ofthe tank and attach the lifting straps to an overhead crane 10 Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING may become unbalanced and fall if itis not properly supported and secured to the overhead crane 11 Remove the suction strainers from the tank and clean them using a mild solvent 12 Rinse outthe inside of the tank using a mild Solvent
254. re the yoke torque hub assembly to the lifting jack 13 Use a slide hammer to remove the upper yoke pivot pin then use a soft metal driftto drive the lower yoke pivot pin down and out a EA AWARNING Cushing hazard The yoke hub c torque hub assembly may become d yoke unbalanced and fall when the yoke 8 pivot pins are removed if it is not le ro g steer cylinder properly secured and supported by the lifting jack 7 68 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 14 Place the yoke torque hub assembly on a flat surface with the torque hub facing down 15 Remove the torque hub mounting fasteners that attach the yoke to the torque hub Remove the yoke weldment from the torque hub Replace the thrust washer when installing the yoke torque hub assembly onto the axle Torque specifications 4WD STEERING AXLE COMPONENTS 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 Lug nut dry 420 ft lbs 569 5 14 3 lubri ubricated 320 ft Ibs 433 9 Nm Tie Rod Torque hub mounting bolts _ dry 120 ft lbs 163Nm Howto Remove the Tie Rod lubricated 90 ft lbs 122 Nm This procedure is the same as the 2WD procedure Drive motor mounting bolts See Repair Procedure 13 3 dry 75 ft lbs 102 Nm How to Remove the Ti
255. reaches 320 psi 22 bar Gasoline LPG models Connect the ignition coil wiring and startthe engine from the ground controls Check for hydraulic leaks 7 36 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures gt gt Oi Z ZZL This page intentionally left blank Part No 48412 Genie S 60 amp Genie S 65 7 37 Section 7 Repair Procedures Service Manual Second Edition Manifolds 10 1 Function Manifold Components The function manifold is located on the tank side tray behind the ground control box Index Schematic No Description Item 1 3 position 4 way 003 valve Anu 2 3 position 4 way 003 valve Bases 3 3 position 4 way 003 valve Qnm 4 Check valve pilot operated Dine 5 Relief valve 2500 psi 172 bar 6 Relief valve 2100 psi 145 bar Eas 7 Flow regulator valve 1 5 5 7 M N Gans 8 Flow regulator valve 1 5 gpm 5 7 l min 9 Flow regulator valve 1 5 5 7 10 Flow regulator valve 0 1 gpm 0 38 l min Jc zs 11 Check valve 0020 Kina 12 Check valve 0 1 LE ess 13 Proportional solenoid valve 14 Check valve 0 N 15 Proportional solenoid
256. 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 fk 12V Check voltage at terminal 487A on CR4 lt 12V Check voltage at terminal 7 on electronic governor Check voltage at electronic governor terminal 3 and 4 brown wires 12V Turn machine off remove blu blk wire from terminal 6 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 toggle switches TS4 and TS13 check individually and replace defective switch Repair open in wht wire circuit from terminal 87 on CR2 to CR4 terminal 30 Replace CR4 relay Repair open in blk red wire circuit from CR4 terminal 487A 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 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Engine High Idle In
257. replace differential sensing valve item V OR repair or replace flow regulator valve item AA OR manifold has an internal defect consult Genie Industries Service Department Replace the relief valve item W OR manifold has an internal defect Consult the Genie Industries Service Department PartNo 48412 Genie S 60 amp Genie S 65 5 27 Section 5 Troubleshooting Flow Charts Service Manual Second Edition Chart 12 Ground Controls Inoperative Platform Controls Operate Normally i Does the engine start from the ground controls Be sure all other functions operate normally including the platform controls With both Emergency Stop buttons pulled out to the position check voltage at red wire on the input side of the ground controls contact of the key switch KS1 the red wire checked should originate from the Emergency Stop button With the keyswitch turned to ground controls and both Emergency Stop buttons are pulled out to the ON position check voltage at red wire at the output side ofthe ground controls contact on the key switch Repair open in red wire circuit from key switch to function enable toggle Switch to each function toggle switch Startthe engine from the ground controls Move the function enable toggle switch to either side and check the voltage on the center terminal of the platform level toggle Switch TS 16 Repair open in red wire
258. rgency Stop buttons pulled out to the ON position crank engine and check voltage at center terminal on fuel select switch TS3 in platform control box 12V With keyswitch on and HY both Emergency Stop buttons pulled out to the ON position crank engine and check voltage on gasoline side blu wht wire of fuel select switch 12V With keyswitch on and both Emergency Stop buttons pulled outto the on position crank engine and check voltage at terminal TB38 12V With keyswitch on and both Stop buttons pulled out to the ON position crank engine and check voltage at blu wht wire at terminal 430 on CR6 12V With keyswitch on and both Emergency Stop buttons pulled out to the ON position crank the engine and check voltage at terminal 487 on CR6 12V Continued on the next page Section 5 Troubleshooting Flow Charts CHART 2A Repair open in power wire circuit with diode to fuel select toggle switch TS3 Replace toggle switch Repair open in blu wht wire circuit from toggle TS3 toggle switch to TP38 to TB38 Repair open in blu wht wire circuit from TB38 to terminal 30 on CR6 Check brown ground wire on terminal 85 of CR6 Repair open in brown ground wire circuit to CR6 no good good Replace CR6 PartNo 48412 Genie S 60 amp Genie S 65 5 9 Section 5 Troubleshooting Flow Charts Service Manual Second Edition
259. ring is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located atthe base ofthe boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Startthe engine from the ground controls and lower the boom into the stowed position 2 Hold the function enable toggle switch to either side and adjustthe platform to a level position using the platform level toggle switch 3 Raise and lower the boom through a full cycle O Result The platform should remain level at all times to within 5 degrees B 18 Test the Horn A functional horn is essential to safe machine operation The horn is activated atthe platform controls and sounds atthe ground as a warning to ground personnel An improperly functioning horn will preventthe operator from alerting ground personnel of hazards or unsafe conditions 1 Tum the key switch to platform control and pull outthe Emergency Stop button to the ON position at both the ground and platform controls TABLE B PROCEDURES 2 Push down the horn button at the platform controls Result The horn should sound If necessary the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn B 19 Test the Foot Switch A properly functioning foot switc
260. rom the non steerend 5 Disconnectthe linkage clevis yoke from the drive chassis if not already disconnected 6 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 7 To level the drive chassis startthe engine and push up or pull down on the linkage adjustment rod until the machine is completely level 8 Verify thatthe ground and drive chassis are completely level 9 Adjustthe length ofthe rod by turning the clevis yoke until the clevis yoke can be pinned to the drive chassis 10 Install the clevis yoke pin then the cotter pin Be sure to bend the cotter pin 11 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level consult Genie Industries Service Department Part No 48412 Genie S 60 amp Genie S 65 7 49 Section 7 Repair Procedures Service Manual Second Edition M HP M MANIFOLDS 10 7 Steer Manifold Components S 60 65 Oscillating Models The steer manifold is underneath the function manifold Index Schematic No Description Item Function Torque 1 3 position 4 way solenoid valve SS conis Steer left right 30 35 in lbs 3 4 Nm 2 Check valve sees Priority flow regulator
261. ropriate lifting device 3 Open the platform control box and remove the platform control box mounting fasteners 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 from the platform before removal 4 Remove the platform mounting fasteners and remove the platform from the machine Crushing hazard The platform AWARNING may become unstable and fall if it is not properly supported 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 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 Platform Leveling Slave Cylinder Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hose and Fitting Torque Specifications 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 3 Lowerthe boom
262. round control and pull out the Emergency Stop button to the position at the ground controls 4 6 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 2 Liftthe red auxiliary power switch cover 3 Simultaneously hold the auxiliary power switch oN and activate each boom function toggle switch To conserve battery power test each function through a partial cycle Result All boom functions should operate 4 Turn the key switch to platform control 5 Pull outthe Emergency Stop switch to the position at the platform controls then press down the foot switch 6 Liftthe red auxiliary power switch cover 7 Simultaneously hold the auxiliary power switch oN and activate each function control handle or toggle switch To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate Drive functions should not operate with auxiliary power TABLE A PROCEDURES A 13 Test the Tilt Sensor The tilt sensor sounds an alarm located in the platform when the incline of the turntable exceeds 4 5 degrees Select a level test area The tilt alarm should notbe sounding prior to the test 1 Startthe engine from the platform controls 2 Openthe tank side turntable cover and press down on one side ofthe tilt sensor O Result Aftera 1 5 second delay the alarm in
263. rsepower 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 and the alternator is operating properly with 12 5 to 14 5V DC output Gasoline LPG models P erform this procedure in gasoline mode 7 6 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Remove the fasteners from the platform control box lid 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 EH gm nm EB U Platform control box a horsepower limiter board Connect the black lead from a DC volt meter to the no 2 terminal and the red lead to the no 10 terminal 12V DC or greater ground engine rpm sensor notused notused low drive speed limit switch notused notused notused outputto drive controller L elejelelEIEIEFEIFIS 06 8 9 S 6 2 Horsepower limiter board a A potentiometer maximum voltage output to the controller in the stowed position b potentiometer maximum voltage output to the drive controller in the boom raised position c potentiome
264. rt or spray 4 Tag disconnect and plug the hydraulic hoses from the platform leveling cylinder atthe union and connectthe hoses from the cylinder together using a connector Bodily injury hazard S praying 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 5 5 65 Models Remove the hose and cable cover from the side of the jib boom 6 S 65 Models Remove the jib rotate manifold mounting fasteners Do not disconnect any of the hoses 7 5 65 Models Tag disconnect and plug the hydraulic hoses from the jib boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard S praying 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 8 Raise the boom to a horizontal position 9 Remove the fasteners from the drive speed limit switch mounted on the side of the cable track at the pivot end of the boom Do not disconnect the wiring 10 Remove the fasteners from the side panel on the lower cable track then remove the panel Pull all ofthe cables out of the channel 11 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and AWARNING lower cable tracks are not properly secured
265. s 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 Pulloutthe Emergency Stop button to the ON position at both the ground and platform controls 2 Startthe engine from the ground controls Then move the function enable toggle switch to the high idle rabbit symbol position and hold in the oN position Result The engine should change to high idle Release the function enable toggle switch Result The engine should return to low idle Turn the key switch to platform controls u R w Atthe 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 Result The engine sho
266. sconnectthe 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 Adjustthe gap on each new spark plug Install the new spark plugs then connect the wires Be sure that each spark plug wire is attached to the correct spark plug Spark plug specifications S park plug type Motorcraft AWSF 52C 0 042 to 0 046 inches 1 07 to 1 18 mm S park plug gap S park plug torque 5 to 10 foot pounds 7to 14 Nm 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 heaters 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 startthe engine from the ground controls 2 Loosen the high idle mixture adjustment lock nut a high idle mixture adjustment screw Part No 48412 Genie S 60 amp Genie S 65 4 37 Se
267. se Keep work surfaces clean and free of debris that could get into machine components and cause damage U Be sure thatall tools 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 Be sure forklift overhead crane or 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 ue other fluids Use an approved container Please be environmentally safe iv Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Table of Contents Introduction Important Information onda code ee deban te aed eae eel de ii Section One Safety Rules General Safety R A OR De ERE edd a t ad dia edet lii Section Two Specifications Machine 5 lt 2 1 Performance 5 22 aaa aaa 2 2 Hydraulic S pecifications u e pce pe iain 2 3 Ford LRG 423 Engine Specifications 2 4 Deutz FAL 1011F Engine Specifications 2 2 6 Hydraulic Hose and Fitting Torque Specifications
268. ses from the motor brake and manifold Cap the fittings on the motor brake and torque hub AWARNING 2odily injury hazard S praying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the motor brake mounting fasteners then remove the motor from the brake motor brake mounting bolts motor brake torque hub mounting bolts torque hub plug 7 62 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures How to Remove the Turntable Rotation Brake or Torque Hub 1 Secure the turntable from rotating with the turntable rotation lock pin unlocked locked 2 Remove the motor brake mounting bolts and then remove the motor and brake from the torque hub and setthem to the side ACAUTION Component damage hazard Hoses can be damaged if they are kinked or pinched motor brake mounting bolt motor torque hub torque hub mounting bolt plug brake 3 Remove the torque hub mounting bolts and then use a lifting device to remove the torque hub from the machine TURNTABLE ROTATION COMPONENTS Remove the plug from the side ofthe torque hub Then drain the oil from the hub Install the torque hub Torque the hub mounting bolts to 180 foot pounds 244 Newton meters Install
269. support 5 Remove the wheel lug nuts then the tire and wheel assembly 6 Place a second lifting jack under the torque hub for support and secure the torque hub to the lifting jack Part No 48412 Genie S 60 amp Genie S 65 7 71 Section 7 Repair Procedures Service Manual Second Edition NON STEERING AXLE COMPONENTS 7 Remove the torque hub mounting bolts that attach the torque hub to the chassis Remove the torque hub Crushing hazard The torque AWARNING hub may become unbalanced and fall if itis not properly supported and secured to the lifting jack Torque specifications 569 5 Nm 433 9 Nm 163 Nm 122Nm Lug nut dry 420 ft lbs lubricated 320 ft lbs Torque hub mounting bolts dry 120 ft lbs lubricated 90 ft Ibs Drive motor mounting bolts dry 75 ft lbs lubricated 56 ft lbs 102 Nm 76 Nm Genie S 60 amp Genie S 65 Part No 48412 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
270. switch turned to 0V Check voltage on center 0V platform control and terminal of 155 both Emergency Stop buttons pulled out to the on position activate footswitch and platform rotate toggle switch TS5 in the right direction and check voltage at the grn wht wire at the jib delay capacitor 12V Continued on the next page Repair open in grn wht wire from TS14 to TB19 to TP19 OR test toggle switch See Repair Section Repair open in red power wire circuit through controllers and function toggle switches to T 5 12V With keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate footswitch and platform rotate toggle switch TS5 in the right direction and check voltage at TP 19 Repair open in grn wht wire from TP 19 to jib delay capacitor 0v Activate footswitch and platform rotate toggle Switch TS5 in the right direction and check voltage at the grn wht wire on TS5 Repair open in grn wht wire from TS5 to TP19 0v Test toggle switch See Repair Section OR replace platform rotate toggle switch TS5 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts CHART 24 With keyswitch turned to Replace the jib delay sonnet fon the platform control and capacitor OR repair previous page both Emergency Stop open in brown ground buttons p
271. t 2 Remove both plugs and drain the oil Part No 48412 Genie S 60 amp Genie S 65 4 31 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE C PROCEDURES 3 Drive the machine until one plug is atthe 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 Fillthe 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 then 2 Remove the motor brake mounting bolts and install the plugs then remove the motor and brake from the 5 Repeatsteps 1 through 4 for all the other drive torque hub and set them to the side torque hubs ACAUTION Componentdamage hazard Hoses be damaged if they are Oil capacity per hub 44 fl oz kinked or pinched 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 and then use a lifting device to remove the torque hub from the machine 4 32 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 4 Remove the plug from the side of the torque hub Then drain the oil from the hub 5 Install the torqu
272. t TB1 With key switch in platform position and both E mergency Stop buttons pulled out to the oN position activate footswitch and boom function controller BP 1 on platform control panel in up direction and check voltage TB1 Activate footswitch and boom function controller BP 1 on platform control panel in up direction and check voltage TP 1 0v Activate footswitch and check voltage at terminal on BP 1 12V or more Re adjust controller see Repair Section OR replace controller BP 1 OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 14 Repair open in red 1 wire circuit from TB1 to boom up function directional valve coil item B OR repair open in brown ground wire circuit to valve coil Troubleshoot boom up function toggle switch 7517 on ground control panel OR repair open in red 1 wire circuit from TS17 to TB1 OR consult Genie Industries Service Department Repair open in red wire from TP1 to TB1 Repair open in power supply circuit from TP 24 to BP1 OR repair open in brown ground wire circuit from ground to BP1 PartNo 48412 Genie S 60 amp Genie S 65 5 31 Section 5 Troubleshooting Flow Charts Service Manual Second Edition CHART 14 Disconnect wires to 0 or boom up directional infinite valve coil item B and ohms test the resistance of the valve coil See Repair Section
273. t and heard TABLE A PROCEDURES Start the engine from the platform controls and rotate the turntable so the boom is between the non steer tires Rotate the turntable to the left until the boom is pastthe left non steer wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable toggle switch is activated Rotate the turntable to the right until the boom is pastthe right non steer wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable toggle switch is activated Part No 48412 Genie S 60 amp Genie S 65 4 9 Section 4 Scheduled Maintenance Procedures Service Manual Second Edition TABLE A PROCEDURES A 15 Replace the Engine Oil and Filter Gasoline LPG Models Ford engine specifications require thatthis 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 againstthe hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes atthe 100 hour interval Perform this procedure after war
274. t normal operating temperature 10 Fully retract the boom then start a timer and record how long ittakes the turntable to rotate through a complete circle Adjust the max out trimpot to achieve a 80 to 100 second cycle time 11 Extend the boom then starta timer and record how long it takes the turntable to rotate through a complete circle Adjustthe lo range trimpot to achieve a 130 to 160 second cycle time 12 Turn the engine off and re connect the volt meter 13 Pull outthe Emergency Stop button to the 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 Startthe engine 7 4 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures 16 Start a timer and simultaneously move the control handle all the way to the left or right Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp rate 17 Setthe ramp rate Turn the trimpot to obtain 5 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Turntable rotation specifications Threshold 3 5V DC Turntable rotation hi range boom retracted 5 5V DC Cycle time 80 to 100 seconds lo range boom extended 4 5V DC Cycle time 130 to 160 seconds Ramp rate 5 seconds Boom Extend Retract Controller Adjustments Do n
275. t rear of main pump Spline does not turn Engine to pump flex plate coupling 15 defective OR main pump is defective Consult Genie Industries Service Department 5 26 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second 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 Install a 0 to 5000 PSI 345 bar pressure gauge on the function manifold Start engine move the function enable toggle switch to either side and hold the boom retract function and check the hydraulic pressure less than 2600 psi Adjust the function manifold system relief valve item W all the way in clockwise counting the number of turns Move the function enable switch to either side and hold the boom retract switch and recheck the pressure Check the function pump see Repair section steering inoperative Replace the function pump Chart 11 Troubleshoot each function individually or consult Genie Industries Service Department Move the function enable switch to either side and hold the boom retract switch and readjust the relief pressure to 2600 psi for S 60 or 2900 psi for 5 65 Repair or
276. tain 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 120 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 adjustthe controller 2 Turnthe key switch to platform control and pull outthe Emergency Stop button to the position at both the ground and platform controls Do not start the engine Part No 48412 Genie S 60 amp Genie S 65 7 3 Section 7 Repair Procedures Service Manual Second 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 dj terminal D2 directional output terminal A proportional output terminal ground terminal positive terminal R activates max out ran
277. tch and the function manifold jib boom up function and activate the jib boom up function function operates Replace defective valve function inoperative Check for mechanical restrictions keeping jib boom up function from operating OR repair or replace jib boom cylinder OR replace counterbalance valve OR 0 035 orifice may be plugged OR jib boom platform rotate select manifold has an internal defect OR consult Genie Industries Service Department less than 2500 psi function Exchange jib boom operates counterbalance valves and activate jib boom up function Replace defective counterbalance valve function inoperative Consult Genie Industries Service Department 5 62 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 5 Troubleshooting Flow Charts Jib Boom Down Function Inoperative S 65 Models Be sure all other functions operate normally With the keyswitch turned to ground control and both Emergency Stop buttons pulled out to the ON position move the function enable Switch to either side and activate the jib boom toggle switch TS15 in the down direction and check voltage at the grn blk wire on the jib boom down directional valve item BB With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate the footswitch and the jib boom toggle switch TS6 in the
278. ter e hose from the fuel filter to the injection pump f hose from the injection pump to the injectors Part No 48412 Genie S 60 amp Genie S 65 Section 4 Scheduled Maintenance P rocedures Service Manual Second Edition TABLE D PROCEDURES Gasoline LPG a carburetor b fuel filter C hose from the fuel filter to the fuel pump d hose from the fuel pump to the fuel tank not shown 3 Clean up any fuel that may have spilled during this procedure 4 Startthe engine from the ground controls then inspectthe fuel filter and hoses for leaks If a fuel leak is discovered keep any additional 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 P P D 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 P P D 194 287 Genie part number 33907 D 6 Clean the PCV Hoses and Fittings Gasoline LPG Models Maintaining P CV hoses is essential to good engine performance Improperly functioning PCV hoses will fail to ventilate the crankcase and continued use of neglected hoses could res
279. ter reaction rate or how fast the voltage output reacts to the change in engine rpm Section 7 Repair Procedures PLATFORM CONTROLS 4 Startthe engine from the platform controls 5 Move the engine idle control switch to foot Switch activated high idle rabbit and foot switch symbol 6 Press down the foot switch and adjustthe A potentiometer counterclockwise to increase voltage or clockwise to decrease voltage A potentiometer specifications all models Voltage setting 10 5 to 11 5V DC 7 Move the engine idle control switch to low idle turtle symbol 8 Press down the foot switch and then adjust the C potentiometer to obtain a 0 01V DC to 0 03V DC voltage reading 9 Movethe engine idle control switch to foot Switch activated high idle rabbit and foot switch symbol 10 Press down the foot switch and re adjustthe 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 12 Disconnectthe volt meter Part No 48412 G
280. tes the presence of a hazard CAUTION that will or may cause serious personal injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 48412 Genie S 60 amp Genie S 65 7 1 Section 7 Repair Procedures Service Manual Second Edition Platform Controls 1 1 Joystick Controllers Maintaining joystick controllers atthe 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 COCO Platform control box horsepower limiter board terminals drive proportional controller extend retract proportional controller boom proportional controller turntable rotate proportional controller Dow Boom Up Down Controller Adjustments Do notadjustthe joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjustthe 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 Open the platform control box l
281. than control and both 12V Emergency Stop buttons pulled outto the ON position activate the footswitch and check the voltage at terminal 42 on the drive joystick DP 1 12V or more With the keyswitch turned to platform control and both Emergency Stop buttons pulled out to the on position activate the footswitch and check the voltage at terminal 1 on the horsepower limiter circuit board 12V or more With the drive speed selector toggle switch TS8 in the high po ten activate the ootswitch and hold the drive joystick in the full forward position and check the voltage at terminal 10 on the horsepower limiter board 9 to 12V Continued on the next page Check continuity of Repair open in power brown ground wire from continuity supply circuit from TP 24 terminal 3 on DP1 to to terminal 2 on drive ground joystick DP1 no continuity Repair open in brown ground wire circuit from ground to DP1 Check continuity of brown ground wire from terminal 42 on the horsepower limiter circuit board to ground Repair open in power supply circuit from TP 24 continuity to terminal 1 on the horsepower limiter circuit board no continuity Repair open in brown ground wire circuit from ground to the horsepower limiter circuit board With the drive speed selector toggle switch TS8 in the high pesman activate the ootswitch and check the voltage at terminal 3 on the
282. the battery 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 a filter condition indicator b filter c hydraulic tank O Result The filter should be operating with the plunger in the green area If the display shows the plunger in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See C 6 Replace the Hydraulic Tank Filter Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second 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 hotor live circuits may result in death or serious in
283. 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 thatthe 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 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 oil filter b fuel filter water separator w 3 Fill the new filter Genie part no 29560 with fresh diesel fuel and apply a thin layer of oil or diesel fuel to the new fuel filter gasket 4 Install the new filter and tighten it securely by hand Clean up any diesel fuel that might have spilled during the procedure 5 Turn the manual fuel shutoff valve located at the fuel tank to the position 6 Startthe engine from the ground controls then inspect the fuel filter for leaks If a fuel leak is discovered keep 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 serv
284. the leads from an ohmmeter or continuity tester to the common and normally open terminals Result There should be no continuity infinite 2 Apply mild suction to the vacuum port Result The switch should close and show full continuity zero Q Component damage hazard A CAUTION Do not shortthe vacuum switch terminals to ground 7 32 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures Ground Controls 8 1 8 4 Control Relays Resistors 5ee 1 6 Control Relays How to Test the Resistor The resistor is used to maintain proper control of boom function speeds A 10 ohm resistor reduces 8 2 voltage to all the boom function switches at the Toggle Switches ground controls Refer to the schematic legends for See 1 5 Toggle Switches resistor locations and values 1 Turnthe key switch to the orr position 2 Disconnecteither end of one ofthe wires 8 3 connected to the resistor to be tested Wago Components 3 Connectthe leads from an ohmmeter to each C end or wiring of the resistor being tested amp How to Remove a Wago 4 Compare the ohmmeter reading with the Component resistance rating printed on the resistor AWARNING Electrocution hazard Contact with electrically charged circuits may cause death or serious injury Remove all rings watches and other jewelry A small screwdriver is provided and shoul
285. the platform should sound Tip over hazard The alarm should AWARNING be audible atthe ground controls If the alarm is not audible at the ground controls replace the alarm a fueltank b tilt sensor c ground control box Part No 48412 Genie S 60 amp Genie S 65 4 7 Section 4 Scheduled Maintenance Procedures Service Manual Second 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 atan unsafe drive speed 1 Remove the cover from the rear of the turntable to access the drive limit switch 2 Visually inspectthe drive limit switch mounted to the turntable side plate atthe pivot end of the boom Inspect for the following Broken or missing roller or roller head Missing fasteners Loose wiring a turntable riser b boom C boom drive limit switch 3 Visually inspectthe boom extend 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 a boom extend drive limit switch b cable track 4 Startthe engine from the ground controls 5 Extend the boom approximately 3 feet 0 9 m 6 Manually act
286. the relief valve pressure See 10 2 Valve Adjustments Function Manifold 12 Turn the engine off and re connect the volt meter 13 Pull outthe Emergency Stop button to the position 14 Press down the foot switch and then move the control handle all the way to the ExTEnb position Record the maximum voltage reading 15 Startthe engine 16 Start a timer and simultaneously move the control handle all the way to the ExTEnb position Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp speed 17 Setthe 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 extend retract specifications Threshold 3 5V DC 9 75V DC 60 to 80 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 rpm 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 Ho
287. tion hazard Contact 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 required to safely perform some troubleshooting procedures PartNo 48412 Genie S 60 amp Genie S 65 5 1 Section 5 Troubleshooting Flow Charts Service Manual Second 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 Tr
288. tis not properly supported Component damage hazard The ACAUTION cables and hydraulic hoses can be damaged if the lift cylinder is pulled across them Part No 48412 Genie S 60 amp Genie S 65 7 23 Section 7 Repair Procedures Service Manual Second Edition BOOM COMPONENTS 4 4 Extension Cylinders The extension cylinder consists of two cylinders that are fastened together The first cylinder extends and retracts the number 2 boom tube The second cylinder extends and retracts the number 3 boom tube The extension cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Extension Cylinders This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure withoutthese skills and tools may cause death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Referto Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Extend the boom until the extension cylinder rod end pin is accessible in the number 3 boom tube 2 Remove the platform See 2 1 How to Remove the Platform 3 Remove the platform leveling slave cylinder See 2 2 How to Hemove the Slave Cylinder S 65 M
289. ue specifications Lug nut torque dry 420 ft lbs 569 5 Nm Lug nut torque lubricated 320 ft Ibs 433 9 Nm How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them Block the non steering wheels and place a lifting jack of ample capacity under the steering axle Raise the machine 6 inches 15 cm and place blocks under the chassis for support Remove the lug nuts Then remove the tire and wheel assembly Remove the dust cap cotter pin and slotted nut Pull the hub off the spindle The washer and outer bearing should fall loose from the hub Place the hub on a flatsurface and gently pry the bearing seal out of the hub Remove the rear bearing Part No 48412 Genie S 60 amp Genie S 65 7 65 Section 7 Repair Procedures Service Manual Second Edition 2WD STEERING AXLE COMPONENTS How to Install the Hub and Bearings When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Placethe large inner bearing into the rear of the hub 3 Press the bearing seal evenly into the hub until itis flush 4 Slide the hub onto the yoke spindle Component damage Do not ACAUTION J apply excessive force or damage to the lip of the seal may occur 5 Place the outer bearing into the hub 6 Install the washer and slotted nut 7 Tighten th
290. uld change to high idle 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 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 selectswitch to gasoline and then move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 2 Startthe engine from the platform controls and allow itto run atlow idle 3 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle 4 Release the foot switch and shut the engine off by pushing the Emergency Stop button in to the OFF position 5 Move the fuel select switch to LPG Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 6 Restartthe engine and allow itto runat low idle 7 Press down the foot switch to allow the engine to run athigh idle Result The engine should start promptly and operate
291. ulled out to the wire from capacitor to on position activate ground footswitch and platform rotate toggle switch TS5 in the right direction and check voltage at the red wire at the jib delay capacitor Activate footswitch and Repair open in red wire platform rotate toggle from jib delay capacitor Switch TS5 in the right to CR14 direction and check voltage on the red wire at terminal 86 on CR14 12V Activate footswitch and Replace relay CR14 OR platform rotate toggle repair open in power Switch TS5 in the right supply from P2 to CR14 direction and check OR repair open in brown voltage on the red and ground wire to CR14 black wires at terminal 87 on CR14 Activate footswitch and Repair open in cable platform rotate toggle containing red and black switch TS5 in the right wires from CR 14 to jib direction and check boom platform rotate voltage on the red and select valves black wires at the jib platform rotate select valves item AM 12V Testthe resistance of Replace defective valve the valve coils coil 5 5 to 6 5 ohms Continued on the next page PartNo 48412 Genie 5 60 amp Genie 5 65 5 59 Section 5 Troubleshooting Flow Charts Service Manual Second Edition gt _ CHART 24 Check continuity from Repair open in brown brown ground wires on ground wire circuit to valve coils to ground valve coils Continued from the previous page Exchange jib boom Repair ope
292. ult in component damage Perform this procedure with the engine off 4 42 Genie S 60 amp Genie S 65 Part No 48412 Service Manual Second Edition Section 4 Scheduled Maintenance Procedures 1 Removethe 2 engine pivot plate retaining bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the PCV hoses a _ pivot plate retaining bolts b engine pivot plate 2 Disconnectthe hose from the PCV valve then disconnectthe hose from the engine a carburetor to valve cover hose b PCV valve C PCV valve to carburetor hose 3 Disconnectthe hose from the carburetor then disconnect the hose from the valve cover 4 Clean the hoses with a mild cleaning solvent TABLE D PROCEDURES 5 Dry both hoses and inspectthem for cracks and damage Replace the hoses if they are damaged D 7 Check the Fuel Injection Pump and Injectors Deutz Diesel Models Complete information to perform this procedure is available in the Deutz FL 1011F Workshop Manual Deutz number 0297 7195 Genie partnumber 52229 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 partnumber 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
293. unction will not operate when the boom is raised or extended pastthe drive speed limit switches Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds Start the engine from the platform controls Do not press down on the footswitch Attemptto operate all machine functions O an o Result All machine functions should not operate 9 Press down on the footswitch and activate each machine function Result All machine functions should operate through a full cycle 10 Push in the Emergency Stop button to the orr position at the platform controls 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 switch Deutz Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds 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 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 g
294. until the momenta 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 Set the max out Press down the foot switch then move the control handle all the way to the position Adjust the voltage to 9 75V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Part No 48412 Genie S 60 amp Genie S 65 7 5 Section 7 Repair Procedures Service Manual Second Edition PLATFORM CONTROLS 8 Setthe dual lo range Press down the foot switch then move the control handle all the way to the RETRACT position Adjust voltage to 9 2V DC Turn the dual range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage 9 Startthe engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Lower the boom to the stowed position Engine should be at normal AWARNING operating temperature 10 Start a timer and record how long ittakes for the boom to fully extend Adjustthe max out trimpot to achieve a 60 to 80 second cycle time 11 Start a timer and record how long ittakes 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 achievable check
295. ut to the oN position move the function enable switch to either side and hold the boom extend retract toggle switch TS19 on ground panel in the retract direction and check voltage on blk wht wire on boom function directional valve coil item C 20V or more Continued on the next page Service Manual Second Edition Move the function enable switch to either yoy an side and hold the boom more retract toggle switch TS19 on ground panel in the retract direction and check voltage at 8 With key switch in platform position and both Emergency Stop 12V or switches pulled out to more the ON position activate footswitch and boom extend retract proportional controller BP2 on platform control panel in the retract direction and check voltage TB8 0v 12V or Activate footswitch and more boom extend retract proportional controller BP2 on platform control panel in the retract direction and check voltage TP8 0v Activate footswitch and check voltage at terminal on 2 12V or more Re adjust controller see Repair Section OR replace controller BP2 OR consult Genie Industries Service Department Repair open in blk wht wire circuit from TB8 to boom retract function directional valve coil item C OR repair open in brown ground wire circuit to valve coil Troubleshoot boom extend retract function toggle switch TS19 on ground control panel OR repair open
296. valve o 16 Check valve 0 0 17 Check This list continues Please turn the page Function Turntable rotate left right Boom up down Boom extend retract Boom extend retract circuit Boom extend Boom down Boom extend retract circuit prevents over flowing the proportional valve Boom up down circuit prevents over flowing the proportional valve Turntable rotate left right prevents over flowing the proportional valve Bleeds off differential sensing valves to tank Differential sensing circuit boom extend retract Differential sensing circuit boom up down Boom extend retract Differential sensing circuit turntable rotate left right Boom up down Differential sensing circuit platform level up Differential sensing circuit platform level down Torque 30 35 in lbs 3 4 Nm 30 35 in lbs 3 4 Nm 30 35 in Ibs 3 4 Nm 11 13 ftlbs 15 18 Nm 25 30 ft lbs 34 41 Nm 25 30 ft lbs 34 41 Nm 10 12 ftlbs 14 16 Nm 10 12 ftlbs 14 16 Nm 10 12 ftlbs 14 6 Nm 10 12 ftlbs 14 16 Nm 11 13 ftlbs 15 18 Nm 11 13 ftlbs 15 18 Nm 10 12 ftlbs 14 16 Nm 11 13 ftlbs 15 18 Nm 10 12 ftlbs 14 16 Nm 11 13 ftlbs 15 18 Nm 11 13 ftlbs 15 18 Nm 7 38 Genie 5 60 amp Genie 5 65 Part No 48412 Service Manual Second Edition Section 7 Repair Procedures
297. 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 If the wear pads are not worn below specification but are still within specification see Repair Procedure 4 2 How to Shim the Boom 1 Startthe engine from the ground controls 2 Raise the end ofthe 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 it is less than specification If the wear pad is notless than specification shim as necessary to obtain zero clearance and zero drag 4 Extend and retractthe boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Always maintain squareness between the boom outer and inner tubes Wear pad specifications 14 3 mm 17 5 mm 9 16 inch 11 16 inch Upper wear pads Bottom and side wear pads 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 th
298. wo Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom until the boom is horizontal 2 Place support blocks under the cylinder across the turntable 3 Attach an overhead 5 ton 4536 kg crane to the boom Do not lift the boom 4 Supportthe rod end 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 BOOM COMPONENTS 5 Tag disconnect and plug the boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Remove the pin retaining fastener from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin then lower the lift cylinder onto the blocks Protect the cylinder rod from damage Crushing hazard The lift cylinder AWARNING may become unbalanced and fall if itis not properly supported 7 Remove the mounting fasteners from the barrel end cylinder pin retaining plates 8 With the lift cylinder being supported by the overhead crane pull the cylinder toward the platform until it is out Crushing hazard The lift cylinder AWARNING may become unbalanced and fall if i
299. y the safety rules and operating instructions in the Genie S 60 amp Genie S 65 Operator s Manual Be sure that all necessary tools and parts are available and ready for use M Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface 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 Selectthe 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 Retum to Perform service problem repair solved Symbols Legend Indicates the presence of a hazard that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indica
300. zard 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 FORD LRG 423 ENGINE 7 7 Water Temperature and Oil Pressure Gauges 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 outto 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 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 48412 Genie S 60 amp Genie S 65 7 31 Section 7 Repair Procedures Service Manual Second Edition FORD LRG 423 ENGINE 7 8 Vacuum Switch How to Test the Vacuum Switch ohmmeter common terminal SOL vacuum switch normally open terminal ING O w 1 Connect

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