Technical Publications

® S-60

® S-65 Service Manual

Second Edition, First Printing Part No. 48412 (Rev A1) July 2008 Introduction Service Manual - Second Edition

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®

Genie North America Important Telephone (425) 881-1800 Read, understand and obey the safety rules and Toll Free 800 536-1800 in U.S.A. operating instructions in the appropriate Toll Free 800 426-8089 in Canada Genie S-60 & Genie S-65 Operator's Manual Fax (425) 556-8649 before attempting any maintenance or repair procedure. Genie Europe This service manual covers the Genie S-60 and Genie S-65 2WD and 4WD models. Office Telephone (44) 01636-605030 Office FaxFax (44) 01636-611090 This manual provides detailed scheduled Parts Telephone (44) 01636-605002 maintenance information for the machine owner Parts Fax (44) 01636-611091 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. Copyright © 1998 by Genie Industries Genie Industries has endeavored to deliver the Second Edition: First Printing, June 1998 highest degree of accuracy possible. However, "Genie" and "S" are Registered Trademarks continuous improvement of our products is a of Genie Industries in the USA and many other Genie policy. Therefore product specifications are countries. subject to change without notice. These machines comply with ANSI/SIA 92.5-1992. Readers are encouraged to notify Genie of errors Printed on recycled paper and send in suggestions for improvement. All communications will be carefully considered for Printed in U.S.A. future printings of this and other manuals. Please write to the technical publications team in care of Genie Industries, PO Box 69, Redmond WA 98073-0069 U.S.A. If you have any questions, please call Genie Industries. ii Genie S-60 & 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 & Genie S-65 Operator's Manual will result in death or serious injury.

Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed. Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop.

Part No. 48412 Genie S-60 & Genie S-65 iii Section 1 - Safety Rules Service Manual - Second Edition

SAFETY RULES

Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, flames and be aware of all known safety hazards. Personal lighted tobacco away from flammable and safety and the continued safe operation of the combustible materials like battery gases machine should be your top priority. and engine fuels. Always have an approved fire extinguisher within easy reach.

Read each procedure thoroughly. This manual and the decals, on the machine, Be sure that all tools and working areas use signal words to identify the following: are properly maintained and ready for use. Keep work surfaces clean and free Indicates the presence of of debris that could get into machine components a hazard that will cause and cause damage. death or serious injury. Indicates the presence of a hazard that may cause Be sure that your workshop or work area death or serious injury. is properly ventilated and well lit. Indicates the presence of a hazard that will or may cause serious injury or Be sure any forklift, overhead crane or damage to the machine. other lifting or supporting device is fully capable of supporting and stabilizing the Indicates special weight to be lifted. Use only chains or straps that operation or maintenance are in good condition and of ample capacity. information.

Be sure that fasteners intended for one Be sure to wear protective eye wear and time use (i.e., cotter pins and self-locking other protective clothing if the situation nuts) are not reused. These components warrants it. may fail if they are used a second time.

Be aware of potential crushing hazards Be sure to properly dispose of old oil or such as moving parts, free swinging or other fluids. Use an approved container. unsecured components, and lifting or Please be environmentally safe. placing loads. Always wear approved steel-toed shoes.

iv Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Table of Contents

Introduction Important Information ...... ii

Section One Safety Rules General Safety Rules ...... iii

Section Two Specifications Machine Specifications ...... 2 - 1 Performance Specifications ...... 2 - 2 Hydraulic Specifications ...... 2 - 3 Ford LRG 423 Engine Specifications ...... 2 - 4 Deutz F4L 1011F Engine Specifications ...... 2 - 6 Hydraulic Hose and Fitting Torque Specifications ...... 2 - 8 Bolt Torque Specifications ...... 2 - 9

Section Three Scheduled Maintenance Inspections Introduction...... 3 - 1 Table A ...... 3 - 2 Table B ...... 3 - 3 Table C ...... 3 - 5 Table D ...... 3 - 6 Maintenance Inspection Report ...... 3 - 7

Section Four Scheduled Maintenance Procedures Introduction...... 4 - 1 A-1 Inspect the Manuals...... 4 - 2 A-2 Inspect the Decals and Placards ...... 4 - 2 A-3 Inspect for Damage, Loose or Missing Parts ...... 4 - 2 A-4 Check the Engine Oil Level...... 4 - 3 A-5 Check the Engine Coolant Level - Gasoline/LPG Models ...... 4 - 3 A-6 Check for Fuel Leaks ...... 4 - 3 A-7 Check the Hydraulic Oil Level ...... 4 - 4 A-8 Check for Hydraulic Leaks ...... 4 - 4

Part No. 48412 Genie S-60 & Genie S-65 v Service Manual - Second Edition

TABLE OF CONTENTS

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

TABLE OF CONTENTS

Section Four Scheduled Maintenance Procedures, continued B-23 Test the Drive Brakes ...... 4 - 25 B-24 Test the Drive Speed - Stowed Position ...... 4 - 26 B-25 Test the Alarm Package - Optional Equipment ...... 4 - 27 B-26 Perform Hydraulic Oil Analysis ...... 4 - 27 B-27 Replace the Engine Oil and Filter - Deutz Diesel Models ...... 4 - 27 C-1 Check the Boom Wear Pads ...... 4 - 29 C-2 Check the Turntable Rotation Bearing Bolts ...... 4 - 29 C-3 Check the Free-wheel Configuration ...... 4 - 30 C-4 Grease the Turntable Rotation Bearing and Rotate ...... 4 - 31 C-5 Replace the Torque Hub Oil ...... 4 - 31 C-6 Replace the Hydraulic Tank Filter ...... 4 - 33 C-7 Replace the Drive Loop Hydraulic Filter ...... 4 - 33 C-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models ...... 4 - 34 C-9 Replace the Gasoline Fuel Filter - Gasoline/LPG Models...... 4 - 34 C-10 Replace the PCV Valve - Gasoline/LPG Models ...... 4 - 36 C-11 Replace the Spark Plugs - Gasoline/LPG Models ...... 4 - 37 C-12 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models ...... 4 - 37 C-13 Check and Adjust the Ignition Timing - Gasoline/LPG Models ...... 4 - 38 C-14 Check the Engine Valve Clearances - Deutz Diesel Models ...... 4 - 38 C-15 Check the Turntable Rotation Gear Backlash ...... 4 - 38 D-1 Test or Replace the Hydraulic Oil ...... 4 - 39 D-2 Change or Recondition the Engine Coolant - Gasoline/LPG Models ...... 4 - 39 D-3 Change the Fuel Lines ...... 4 - 41 D-4 Check the Engine Valve Clearance - Gasoline/LPG Models ...... 4 - 42 D-5 Check the Engine Cylinder Compression - Gasoline/LPG Models ...... 4 - 42 D-6 Clean the PCV Hoses and Fittings - Gasoline/LPG Models ...... 4 - 42 D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models...... 4 - 43 D-8 Check the Toothed Belt - Deutz Diesel Models ...... 4 - 43 D-9 Replace the Timing Belt - Gasoline/LPG Models ...... 4 - 43 D-10 Grease the Steer Axle Wheel Bearings - 2WD Models ...... 4 - 44

Part No. 48412 Genie S-60 & Genie S-65 vii Service Manual - Second Edition

TABLE OF CONTENTS

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

TABLE OF CONTENTS

Section Five Troubleshooting Flow Charts, continued 27 Oscillate Function Inoperative ...... 5 - 65 28 Steer Left Function Inoperative ...... 5 - 66 29 Steer Right Function Inoperative ...... 5 - 68 30 All Drive Functions Inoperative, All Other Functions Operate Normally ...... 5 - 70 31 Drive Forward Or Reverse Function Inoperative ...... 5 - 73 32 Traction Function Inoperative ...... 5 - 74 33 Machine Will Not Drive At Full Speed ...... 5 - 75 34 Machine Drives At Full Speed With Platform Raised or Extended ...... 5 - 76 35 Drive Enable System Is Malfunctioning ...... 5 - 77 36 Auxiliary Functions Inoperative ...... 5 - 78

Section Six Schematics Introduction ...... 6 - 1 Electrical Components ...... 6 - 2 Electrical Symbols Legend ...... 6 - 4 Abbreviation Legend ...... 6 - 5 Electrical Schematic - Gasoline/LPG Models (Rev B) ...... 6 - 7 Ground Control Box Legend - Gasoline/LPG Models ...... 6 - 9 Ground Control Box Wiring Diagram - Gasoline/LPG Models ...... 6 - 10 Platform Control Box Legend - Gasoline/LPG Models ...... 6 - 11 Platform Control Box Wiring Diagram - Gasoline/LPG Models ...... 6 - 12 Electrical Schematic - Deutz Diesel Models ...... 6 - 13 Ground Control Box Legend - Deutz Diesel Models ...... 6 - 15 Ground Control Box Wiring Diagram - Deutz Diesel Models ...... 6 - 16 Platform Control Box Legend - Deutz Diesel Models ...... 6 - 17 Platform Control Box Wiring Diagram - Deutz Diesel Models ...... 6 - 18 Hydraulic Symbols Legend ...... 6 - 20 2WD Hydraulic Schematic - Non-oscillating axle ...... 6 - 21 2WD Hydraulic Schematic - Oscillating axle ...... 6 - 22 4WD Hydraulic Schematic - Non-oscillating axle ...... 6 - 23 4WD Hydraulic Schematic - Oscillating axle ...... 6 - 24

Part No. 48412 Genie S-60 & Genie S-65 ix Service Manual - Second Edition

TABLE OF CONTENTS

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

TABLE OF CONTENTS

Section Seven Repair Procedures, Ford LRG-423 Engine, continued 7-3 Timing Adjustment ...... 7 - 30 7-4 Adjustment ...... 7 - 30 7-5 RPM Adjustment ...... 7 - 30 7-6 Flex Plate ...... 7 - 30 7-7 Water Temperature and Oil Pressure Gauges ...... 7 - 31 7-8 Vacuum Switch ...... 7 - 32 Ground Controls 8-1 Control Relays ...... 7 - 33 8-2 Toggle Switches, See 1-5, Toggle Switches...... 7 - 9 8-3 Wago® Components ...... 7 - 33 8-4 Resistors ...... 7 - 33 8-5 Power Relay ...... 7 - 34 Hydraulic Pumps 9-1 Lift/Steer Pump ...... 7 - 35 9-2 Drive Pump ...... 7 - 35 Manifolds 10-1 Function Manifold Components ...... 7 - 38 10-2 Valve Adjustments - Function Manifold...... 7 - 42 10-3 Turntable Rotation Manifold Components...... 7 - 45 10-4 Oscillate Manifold Components ...... 7 - 46 10-5 Valve Adjustments - Oscillate Manifold...... 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 Components...... 7 - 52 10-9 Valve Adjustments, 2WD Drive Manifold ...... 7 - 54 10-10 4WD Drive Manifold Components...... 7 - 56 10-11 Valve Adjustments, 4WD Drive Manifold ...... 7 - 58 . Fuel and Hydraulic Tanks 11-1 Fuel Tank ...... 7 - 59 11-2 Hydraulic Tank ...... 7 - 59

Part No. 48412 Genie S-60 & Genie S-65 xi Service Manual - Second Edition

TABLE OF CONTENTS

Section Seven Repair Procedures, continued Turntable Rotation Components 12-1 Rotation Hydraulic Motor ...... 7 - 62 2WD Steering Axle Components 13-1 Yoke and Hub ...... 7 - 65 13-2 Steering Cylinders ...... 7 - 66 13-3 Tie Rod ...... 7 - 67 4WD Steering Axle Components 14-1 Yoke and Hub ...... 7 - 68 14-2 Steering Cylinders ...... 7 - 69 14-3 Tie Rod ...... 7 - 69 Oscillating Axle Components 15-1 Oscillating Axle Lock-out Cylinders ...... 7 - 70 Non-steering Axle Components 16-1 Drive Motor ...... 7 - 71 16-2 Torque Hub ...... 7 - 71

xii Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 2 - Specifications Specifications

Machine Specifications Platform dimensions 6 ft 8 ft (Standard) (Optional) Stowed dimensions S-60 S-65 Length 6 ft 8 ft Length 27 ft 2 in 30 ft 10 in 1.83 m 2.44 m 8.3 m 9.4 m Width 30 in 36 in Width 8 ft 8 ft 76.2 cm 91.4 cm 2.43 m 2.43 m Tires and wheels Height 9 ft 9 ft Tire size 15-19.5 NHS 2.74 m 2.74 m Tire ply rating 12 Weight 26,060 lbs 28,400 lbs Tire contact area 71 sq in 11,821 kg 12,882 kg 458 sq cm Ground clearance 12 in 12 in 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 18.3 m 19.8 m Wheel diameter 191/2 in 49.5 cm Maximum horizontal reach 51 ft 3 in 56 ft 4 in Wheel width 121/4 in 15.6 m 17.2 m 31 cm Maximum turntable tailswing 3 ft 31/2 in 3 ft 31/2 in Wheel lugs 10 @ 3/4 -16 100 cm 100 cm Lug nut torque, dry bolts 420 ft-lbs Wheelbase 9 ft 0 in 9 ft 0 in 569.5 Nm 2.7 m 2.7 m Lug nut torque, lubricated bolts 320 ft-lbs Minimum turning radius, 12 ft 1 in 12 ft 1 in 433.9 Nm inside 3.7 m 3.7 m Fluid capacities Minimum turning radius, 22 ft 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 15.2 kg Platform rotation 160° 160° Hydraulic tank 45 gallons Maximum capacity 600 lbs 500 lbs 170 liters 6 foot platform 272 kg 227 kg Hydraulic system 55 gallons Maximum capacity 500 lbs 500 lbs (including tank) 208 liters 8 foot platform 227 kg 227 kg Drive torque hubs 44 fl oz Maximum allowable 1.30 liters side force (ANSI and CSA) 150 lbs 150 lbs 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 S-60 & Genie S-65 2 - 1 Section 2 - Specifications Service Manual - Second Edition

SPECIFICATIONS

Performance Specifications Boom function speeds, maximum from platform controls Drive speeds, maximum 2WD 4WD Jib boom up 40 to 60 seconds Drive speed, stowed 4.4 mph 3.0 mph Gasoline/LPG models 7.1 km/h 4.8 km/h Jib boom down 50 to 80 seconds 40 ft/6.2 sec 40 ft/9.1 sec Boom up 55 to 85 seconds 12.2 m/6.2 sec 12.2 m/9.1 sec Boom down 90 to 120 seconds Drive speed, stowed 4.0 mph 2.8 mph Deutz Diesel models 6.4 km/h 4.5 km/h Boom extend 60 to 80 seconds 40 ft/6.8 sec 40 ft/9.7 sec 12.2 m/6.8 sec12.2 m/9.7 sec Boom retract 55 to 85 seconds

Drive speed, 0.6 mph 0.6 mph Turntable rotate - 360° raised or extended 1.0 km/h 1.0 km/h boom fully stowed 80 to 100 seconds - all models 40 ft/40 sec 40 ft/40 sec 12.2 m/40 sec 12.2 m/40 sec Turntable rotate - 360° boom extended 130 to 160 seconds

Platform rotate - 160° 10 to 20 seconds Gradeability (boom stowed) 2WD 4WD Platform level up 35 to 65 seconds Rough terrain 28% 40% Platform level down 25 to 55 seconds

2 - 2 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 2 - Specifications

SPECIFICATIONS

Hydraulic Specifications Function manifold

Hydraulic fluid Dexron equivalent Function relief valve pressure S60 2600 psi 179 bar Drive pump S65 2900 psi 200 bar

Type: bi-directional variable displacement 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 20 bar Steer regulator drive position 250 psi 17 bar Oscillate models 5 gpm 18.9 liters/min Non-oscillate models 3.5 gpm 13.2 liters/min Medium pressure filter 3 micron Auxiliary pump Medium pressure filter 50 psi bypass pressure 3.4 bar Type: 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 cu in 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 0 to 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 bar) bypass

Part No. 48412 Genie S-60 & Genie S-65 2 - 3 Section 2 - Specifications Service Manual - Second Edition

SPECIFICATIONS

Ford Engine LRG-423

Displacement 140 cu in motor 2.3 liters Normal engine cranking speed 200 to 250 rpm Number of cylinders 4 Current draw, normal load 170A & 3.781 x 3.126 inches 96.04 x 79.4 mm Current draw, maximum load 200A

Horsepower 63 @ 4000 rpm Current draw, minimum 140A

Firing order 1 - 3 - 4 - 2 Maximum circuit voltage drop 0.5V DC while starting (normal temperature) Low idle - carburetor 900 rpm Brush length, new 0.66 in Low idle - electronic governor 1600 rpm 16.8 mm

High idle 2500 rpm Brush length wear limit 0.25 in 6.35 mm Governor electronic Brush spring tension 64 ounces Compression ratio 9.4:1 18 Newtons

Compression pressure (approx.) Bolt torque 45 to 84 inch-pounds Pressure (psi) of lowest cylinder must be through brush 5.08 to 9.5 Nm at least 75% of highest cylinder Brush mounting 15 to 20 foot-pounds Valve clearances - 0.035 to 0.055 inches 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

Oil viscosity requirements Cold cranking ampere 1000A

Temperature below 60°F / 15.5°C 5W-30 Reserve capacity @ 25A rate 200 minutes

-10°F to 90°F / -23°C to 32°C 10W-30 Fuel pump

Temperature above 10W-40 to 10W-50 Electronic solenoid 7 psi -10°F / -23°C 0.48 bar

Temperature above 20W-40 or 20W-50 20°F / -6.6°C

Use oils meeting API classification SG (labeled SG/CC or SG/CD) as they offer improved wear protection. Units ship with 10W-40 SG/CC.

2 - 4 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 2 - Specifications

SPECIFICATIONS

Ignition System Bolt torque specifications torque torque Spark plug type Motorcraft AWSF-52C Bolt description (size) ft-lbs Nm

Spark plug gap 0.042 to 0.046 inches Exhaust manifold to cylinder head bolt or nut (M-10): 1.07 to 1.18 mm torque in sequence first step 14 to 19 19 to 26 Engine coolant second step 35 to 50 47 to 68 Capacity 111/2 quarts to 54 to 64 73 to 87 10.9 liters bolt (M-10) Alternator Intake manifold to 15 to 22 20 to 30 Output 95A, 14.5V cylinder head bolt or nut (M-8)

Bolt torque specifications Oil pressure sending unit to block 8 to 18 11 to 24 torque torque Oil pan drain plug to pan (M-14) 15 to 25 20 to 34 Bolt description (size) ft-lbs Nm Oil pan to block (M-6) 10 to 13.5 14 to 18 Timing belt tensioner 29 to 40 40 to 55 pivot bolt (M-10) Oil filter insert to block 21 to 26 28 to 35

Timing belt tensioner 25 to 29 35 to 40 Rocker arm cover to 7 to 10 9 to 13 adjusting bolt (M-8) cylinder head (M-6)

Camshaft gear bolt (M-12) 52 to 66 70 to 90 Spark plug to cylinder 7 to 15 9 to 20 head (M-14) Camshaft thrust plate bolt (M-6) 6 to 9 8 to 12 Temperature sending 8 to 18 11 to 24 Carburetor to spacer stud (M-8) 7.5 to 15 10 to 20 unit to block (M-14) Carburetor spacer to 10 to 14 14 to 19 Water jacket drain plug to block 12 to 18 16 to 24 manifold bolt (M-8) Water pump to block bolt (M-8) 15 to 22 20 to 30 Crankshaft damper 92 to 122 125 to 165 bolt (M-14) Water outlet connection 15 to 22 20 to 30 bolt (M-8) Cylinder head bolt (M-12): torque in sequence first step 50 to 60 68 to 81 Cylinder front cover bolt (M-6) 10 to 12 13 to 16 second step 80 to 90 108 to 122 Inner timing belt cover 15 to 22 20 to 30 stud (M-8)

Outer timing belt cover 6 to 9 8 to 12 bolt (M-6)

Part No. 48412 Genie S-60 & Genie S-65 2 - 5 Section 2 - Specifications Service Manual - Second Edition

SPECIFICATIONS

Deutz Engine F4L 1011F Injection pump pressure 4351 psi 300 bar Displacement 166.7 cu in 2.732 liters Injector opening pressure 3626 psi 250 bar Number of cylinders 4 Fuel requirement diesel number 2-D Bore and stroke 3.58 x 4.13 inches 91 x 105 mm Alternator output 55A, 14V

Horsepower 56 @ 3000 rpm Starter motor

Firing order 1 - 3 - 4 - 2 Current draw, no load 90A

Compression ratio 18.5:1 Brush length, new 0.7480 in 19 mm Compression pressure 362 to 435 psi 25 to 30 bar Brush length, minimum 0.5 in 12.7 mm Low idle 1300 rpm Battery High idle 2300 rpm Type 12V, Group 31 Governor centrifugal mechanical Quantity 1 Valve clearance, cold Cold cranking ampere 1000A Intake 0.012 in 0.3 mm Reserve capacity @ 25A rate 200 minutes 3 1 Exhaust 0.020 in Fan belt deflection /8 to /2 inch 0.5 mm 9 to 12 mm

Lubrication system Bolt tightening specifications torque torque Oil pressure 26 to 87 psi Bolt description (size, grade) ft-lbs Nm 1.8 to 6.0 bar Camshaft/thrust bearing bolt 15 to 18 20 to 24 Oil capacity 11 quarts (M-8 x 35, 8.8) (including filter) 10.5 liters Rocker arm bolts 15 to 18 20 to 24 Oil viscosity requirements (M-8 x 45, 8.8)

Temperature below 60°F / 15.5°C (synthetic) 5W-30 Rocker arm set screw nut 15 to 18 20 to 24

-10°F to 90°F / -23°C to 32°C 10W-40 Cylinder head cover 6 to 7 8 to 10

Temperature above -4°F / -34°C 15W-40 Blower rotor nut 33 to 41 45 to 55 (M-17 Valeo or M-18 Bosch) Engine oil should have properties of API classification CC/SG or CD/SG grades. Blower carrier bolts 15 to 18 20 to 24 Units ship with 10W-40 SG/CC. (M-8 x 50 Torx, 8.8)

Injection system V-belt pulley bolts 28 to 34 38 to 46 (M-10 x 16, 8.8) Injection pump make OMAP

2 - 6 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 2 - Specifications

SPECIFICATIONS

torque torque Bolt tightening specifications, continued ft-lbs Nm torque torque Bolt description (size, grade) ft-lbs Nm Oil thermostat housing screw 37 to 44 50 to 60 plug (M-38 x 1.5) Idler pulley/V-belt pulley bolt 27 to 32 36 to 44 (M-10 x 25, 8.8) Oil thermostat housing bolts 5.5 to 7 7.5 to 9 (M-6 x 35 Torx, 8.8) Idler pulley for toothed belt 30 to 36 41 to 49 (M-10 x 50, 8.8) Oil thermostat housing bolts 5.5 to 7 7.5 to 9 (M-6 x 80 Torx, 8.8) Oil pump bolts 15 to 18 20 to 24 (M-8 x 35 Torx) Oil thermostat housing bolts 14 to 16 19 to 22 (M-6 x 105 Torx, 8.8) Oil filter bracket bolts 7 to 8 9 to 11 (M-8 x 20 Torx, 8.8) Valve plunger housing bolts 14 to 16 19 to 22 (M-8 x 30 Torx, 8.8) Oil intake housing bolts 15 to 18 20 to 24 (M-8 x 75 Torx) Alternator nuts (M-5) 3 4

Fuel pump bolts 15 to 18 20 to 24 Fuel bracket bolts (M-8 x 20, 8.8) 15 20

Injection pump bolts 15 to 18 20 to 24 Adapter housing bolts 70 to 77 95 to 105 (M-12 x 35, 10.9 or M-12 x 75, 10.9) Injector cap nut 30 to 37 40 to 50 first step second step Injector fastening bolt 15 to 18 20 to 24 tightening tightening Injection line 10 to 12 13.5 to 16.5 torque angles ft-lbs Nm 1st 2nd Air intake manifold bolts 15 to 18 20 to 24 (M-8 x 30, 8.8) 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 x 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 S-60 & Genie S-65 2 - 7 Section 2 - Specifications Service Manual - Second Edition

SPECIFICATIONS

Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal-Lok® O-ring face seal fittings and hose ends. Machines that utilize Parker Seal-Lok® O-ring face seal fittings and hose ends require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.

Hydraulic Hose and Fitting Torque Specifications SAE O-ring Boss Port - tube fitting Seal-Lok® - hose end SAE Dash Installing SAE Dash Size into... ft. lbs. Nm Size ft. lbs. Nm -4 Aluminum 11 14.9 -4 18 24.4 Steel 16 21.7 -6 27 36.6 -6 Aluminum 23 31.2 -8 40 54.2 Steel 35 47.5 -10 63 85.4 -8 Aluminum 40 54.2 -12 90 122 Steel 60 81.3 -16 120 162.7 -10 Aluminum 69 93.6 -20 140 190 Steel 105 142.4 -24 165 223.7 -12 Aluminum 93 126.1 Steel 140 190 -16 Aluminum 139 188.5 Steel 210 284.7 -20 Aluminum 172 233.2 Steel 260 352.5 -24 Aluminum 208 282 Steel 315 427.1

Torque Procedure 1 Replace the O-ring. The O-ring must be 3 Be sure that the 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 4 Position the tube and nut squarely on the face hose end has been tightened beyond finger seal end of the fitting and tighten the nut finger tight. tight. The O-rings used in the Parker Seal Lok® 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 not a 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 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 2 - Specifications

SPECIFICATIONS

Bolt Torque Specifications

Size Threads SAE Grade 5 Bolts 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

1/4 inch 20 96 11 144 16

28 120 14 168 19

5/16 inch 18 17 23 25 34

24 19 28 25 34

3/8 inch 16 30 41 45 61

24 35 48 50 68

7/16 inch 14 50 68 70 95

20 55 75 80 109

1/2 inch 13 75 102 110 149

20 90 122 120 163

9/16 inch 12 110 149 150 204

18 120 163 170 231

5/8 inch 11 150 204 220 298

18 170 231 240 326

3/4 inch 10 260 353 380 515

16 300 407 420 570

7/8 inch 9 430 583 600 814

14 470 637 660 895

1 inch 8 640 868 900 1221

12 700 949 1000 1356

Torque specifications for lubricated bolts are 25% less than dry torque specifications for each bolt size.

These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.

Part No. 48412 Genie S-60 & Genie S-65 2 - 9 Section 2 - Specifications Service Manual - Second Edition

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2 - 10 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 3 - Scheduled Maintenance Inspections Scheduled Maintenance Inspections

About This SectionWarm Cold Dealer Tools are New parts engine engine service Therequired Schedulerequired required required suggested

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 Observe and Obey: the Maintenance Inspection Report have been divided into four subsections—A, B, C, D. Use the Maintenance inspections shall be completed by following chart to determine which group(s) of a person trained and qualified on the procedures are required to perform a scheduled maintenance of this machine. inspection. Scheduled maintenance inspections shall be completed daily, quarterly, annually and every Inspection Table or Checklist 2 years as specified on the Maintenance Inspection Report. Daily A Failure to properly complete each Quarterly A + B inspection when required may cause death, serious injury or Annual A + B + C substantial damage. Two year A + B + C + D Immediately tag and remove from service a damaged or malfunctioning machine. Maintenance Tables Repair any machine damage or malfunction before operating machine. The maintenance tables contained in this section provide summary information on the specific Keep records on all inspections for three years. physical requirements for each inspection.

Machines that have been out of service for a Complete step-by-step instructions for each period longer than 3 months must complete the scheduled maintenance procedure are provided in quarterly inspection. 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 & Genie S-65 3 - 1 Section 3 - Scheduled Maintenance Inspections Service Manual - Second Edition Maintenance Tables

Warm Cold Dealer Table A Tools are New parts engine engine service required required required required suggested

A-1 Inspect the Manuals

A-2 Inspect the Decals and Placards

A-3 Inspect for Damage, Loose or Missing Parts

A-4 Check the Engine Oil Level

A-5 Check the Engine Coolant Level - Gasoline/LPG Models

A-6 Check for Fuel Leaks

A-7 Check the Hydraulic Oil Level

A-8 Check for Hydraulic Leaks

A-9 Check the Tire Pressure

A-10 Test the Oscillate Axle (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 Switches

Every 100 hours, perform the following three engine maintenance procedures.

A-15 Replace the Engine Oil and Filter Gasoline/LPG Models

3 - 2 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 3 - Scheduled Maintenance Inspections

MAINTENANCE TABLES

Warm Cold Dealer Table A, continued Tools are New parts engine engine service required required required required suggested

A-16 Drain the Fuel Filter/Water Separator - Deutz Diesel Models

A-17 Replace the Engine Air Filter

Table B

B-1 Check the Engine Belt

B-2 Check the Radiator - Gasoline/LPG Models

B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models

B-4 Check the Exhaust System

B-5 Check the Battery

B-6 Check the Hydraulic Tank Filter Condition Indicator

B-7 Inspect the Electrical Wiring

B-8 Inspect the Tires and Wheels (including lug nut torque)

B-9 Confirm the Proper Brake Configuration

B-10 Check the Oil Level in the Torque Hubs

B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models

B-12 Check and Adjust the Engine RPM

Part No. 48412 Genie S-60 & Genie S-65 3 - 3 Section 3 - Scheduled Maintenance Inspections Service Manual - Second Edition

MAINTENANCE TABLES

Warm Cold Dealer Table B, continued Tools 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

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 Test the Drive Speed - Stowed Position

B-25 Test the Alarm Package - Optional Equipment

B-26 Perform Hydraulic Oil Anaysis 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 S-60 & Genie S-65 Part No. 48412 Service Manual - Second 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

C-2 Check the Turntable Rotation Bearing Bolts

C-3 Check the Free-wheel Configuration

C-4 Grease the Turntable Rotation Bearing and Rotate Gear

C-5 Replace the Torque Hub Oil

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/LPG Models

C-10 Replace the PCV Valve - Gasoline/LPG Models

C-11 Replace the Spark Plugs - Gasoline/LPG Models

C-12 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models

C-13 Check and Adjust the Ignition Timing - Gasoline/LPG Models

C-14 Check the Engine Valve Clearances - Deutz Diesel Models

C-15 Check the Turntable Rotation Gear Backlash

Part No. 48412 Genie S-60 & Genie S-65 3 - 5 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

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/LPG Models

D-10 Grease the Steer Axle Wheel Bearings - 2WD Models

3 - 6 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 3 - Scheduled Maintenance Inspections Maintenance Inspection Report

Model Checklist A Y N R B-18 HornWarm Cold Dealer Refer to Table A Tools are New parts B-19 Footengine switch engine service Serial number required required required required suggested A-1 Manuals B-20 Engine idle select Date A-2 Decals and placards B-21 Fuel select-Gas/LPG A-3 Damage, loose or B-22 Drive enable system Hour meter missing parts B-23 Drive brakes Machine owner A-4 Engine oil level B-24 Drive speed-stowed A-5 Engine coolant-Gas/LPG B-25 Alarm package Inspected by (print) A-6 Fuel leaks B-26 Hydraulic oil analysis A-7 Hydraulic oil level Inspector signature Perform every 500 hours: A-8 Hydraulic leaks B-27 Replace engine oil Inspector title A-9 Tire pressure and filter-Deutz Diesel A-10 Oscillate axle Inspector company A-11 Platform and Checklist C Y N R Instructions ground controls Refer to Table C · Make copies of this page to use for A-12 Auxiliary power C-1 Boom wear pads each inspection. A-13 Tilt sensor C-2 Turntable bearing bolts · Select the appropriate checklist(s) for A-14 Limit switches the type of inspection to be performed. C-3 Free-wheel configuration Perform every 100 hours: C-4 Grease rotation bearing Daily Inspection: A A-15 Replace engine oil C-5 Torque hub oil Quarterly Inspection: A+B and filter-Gas/LPG Models C-6 Hydraulic tank filter Annual Inspection: A+B+C A-16 Drain filter/separator Deutz Diesel C-7 Drive loop hydraulic filter 2 Year Inspection: A+B+C+D A-17 Replace air filter C-8 Fuel filter-Deutz Diesel · Place a check in the appropriate box C-9 Fuel filter-Gas/LPG after each inspection procedure is Checklist B Y N R C-10 PCV valve-Gas/LPG completed. · Use the maintenance tables in this Refer to Table B C-11 Spark plugs-Gas/LPG section and the step-by-step B-1 Engine belt C-12 Air/LPG mixture procedures in section 4 to learn how to C-13 Ignition timing-Gas/LPG B-2 Engine radiator-Gas/LPG perform these inspections. C-14 Valves-Deutz Diesel B-3 Oil cooler and fins-Diesel · If any inspection receives an “N”, tag C-15 Turntable backlash and remove the machine from service, B-4 Exhaust system repair and re-inspect it. After repair, B-5 Battery Checklist D Y N R place a check in the “R” box. B-6 Hydraulic tank filter Refer to Table D Legend B-7 Electrical wiring Y = yes, acceptable D-1 Hydraulic oil B-8 Tires and wheels N = no, remove from service D-2 Engine coolant-Gas/LPG B-9 Brake configuration R = repaired D-3 Change fuel lines B-10 Torque hub oil level Comments D-4 Valves-Gas/LPG B-11 Idle mixture-Gas/LPG D-5 Compression-Gas/LPG B-12 Engine RPM D-6 PCV hoses-Gas/LPG B-13 Key switch D-7 Fuel injection-Diesel B-14 Emergency Stop D-8 Toothed belt-Diesel B-15 Ground control override D-9 Timing belt-Gas/LPG B-16 Directional valve D-10 Wheel bearings B-17 Platform leveling

Part No. 48412 Genie S-60 & Genie S-65 3 - 7 Section 3 - Scheduled Maintenance Inspections Service Manual - Second Edition

Warm Cold Dealer Tools are New parts engine engine service required required required required suggested

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3 - 8 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures Scheduled Maintenance Procedures

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. Observe and Obey: Symbols Legend

Maintenance inspections shall be completed by Indicates the presence of a hazard a person trained and qualified on the that will cause death or serious maintenance of this machine. injury. Scheduled maintenance inspections shall be Indicates the presence of a hazard that may cause death or serious completed daily, quarterly, annually and every 2 injury. years as specified on the Maintenance Inspection Report. Indicates the presence of a hazard that will or may cause serious Failure to perform each procedure injury or damage to the machine. as presented and scheduled may cause death, serious injury or Indicates special operation or substantial damage. maintenance information. Immediately tag and remove from service a Indicates that a specific result is expected after damaged or malfunctioning machine. performing a step. Repair any machine damage or malfunction before operating machine. Keep records on all inspections for three years. Unless otherwise specified, perform each maintenance procedure with the machine in the following configuration: · Machine parked on a flat, level surface · Boom in stowed position · Turntable rotated with the boom between the non-steering wheels · Turntable secured with the turntable rotation lock pin

· Key switch in the OFF position with the key removed · Wheels chocked

Part No. 48412 Genie S-60 & Genie S-65 4 - 1 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition Table A Procedures

A-1 2 Inspect all decals for legibility and damage. Replace any damaged or illegible decal Inspect the Manuals immediately. Maintaining the operator’s and safety manuals in Contact your authorized Genie good condition is essential to safe machine distributor or Genie Industries if operation. Manuals are included with each replacement decals are needed. 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 A-3 condition. Inspect for Damage, Loose or 1 Check to be sure that the storage container is Missing Parts present and in good condition. Daily machine condition inspections are essential 2 Check to make sure that the operator's, to safe machine operation and good machine responsibilities and safety manual are present performance. Failure to locate and repair damage, and complete in the storage container in the and discover loose or missing parts may result in platform. an unsafe operating condition. 3 Examine the pages of each manual to be sure 1 Inspect the entire machine for damage and that they are legible and in good condition. improperly installed or missing parts including: 4 Always return the manuals to the storage · Electrical components, wiring and electrical container after use. cables Contact your authorized Genie · Hydraulic hoses, fittings, cylinders and distributor or Genie Industries if manifolds replacement manuals are needed. · Fuel and hydraulic tanks · Drive and turntable rotation motors and A-2 torque hubs Inspect the · Axle components Decals and Placards · Boom components and wear pads Maintaining all of the safety and instructional · Dents or damage to machine decals and placards in good condition is mandatory for safe machine operation. Decals · Tires and wheels alert operators and personnel to the many possible · Engine and related components hazards associated with using this machine. They also provide users with operation and maintenance · Limit switches information. An illegible decal will fail to alert personnel of a procedure or hazard and could · Alarms, horn and beacon (if equipped) result in unsafe operating conditions. · Nuts, bolts and other fasteners 1 Refer to the Decals section in the · Platform entry mid-rail or gate Genie S-60 & Genie S-65 Operator's Manual · Cracks in welds or structural components and use the decal list and illustrations to determine that all decals and placards are in · Compartment covers and latches place. 4 - 2 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

A-4 A-5 Check the Engine Oil Level Check the Engine Coolant Level Maintaining the proper engine oil level is essential - Gasoline/LPG Models to good engine performance and service life. Maintaining the engine coolant at the proper level Operating the machine with an improper oil level is essential to engine service life. Improper coolant can damage engine components. level will affect the engine's cooling capability and Check the oil level with the damage engine components. Daily checks will engine off. allow the inspector to identify changes in coolant level that might indicate cooling system problems. 1 Check the oil dipstick. Add oil as needed. 1 Check the fluid level in the coolant recovery Result: The oil level should be in the "safe" tank. Add fluid as needed. zone. Result: The fluid level should be in the Ford LRG-423 Engine 5 quarts NORMAL range. Oil capacity (including filter) 4.7 liters Fluids in the radiator are under pressure and extremely hot. Use Ford LRG-423 Engine caution when removing cap and Oil viscosity requirements adding fluids. below 60°F / 15.5°C 5W-30

-10° to 90°F / -23° to 32°C 10W-30 A-6 above -10°F / -23°C 10W-40 or 10W-50 Check for Fuel Leaks above 25°F / -4°C 20W-40 or 20W-50 Failure to detect and correct fuel leaks will result in an unsafe condition. An explosion or fuel fire may Use oils meeting API classification SF (labeled SF/CC cause death or serious injury. or SF/CD) as they offer improved wear protection. Engine fuels are combustible. Deutz Engine F4L 1011F 11 quarts Inspect the machine in an open, Oil capacity (including filter) 10.5 liters well-ventilated area away from heaters, sparks, flames and Deutz Engine F4L 1011F Oil viscosity requirements lighted tobacco. Always have an approved fire extinguisher within below 60°F / 15.5°C (synthetic) 5W-30 easy reach.

-10°F to 90°F / -23°C to 32°C 10W-40 1 Open the shutoff valve on the liquid petroleum gas (LPG) tank by turning it counterclockwise. above -4°F / -34°C 15W-40 2 Perform a visual inspection around the following areas. (An LPG detector may be necessary to Engine oil should have properties of API classification locate LPG leaks.) CC/SE, CD/SE, SF/CC or SF/CD grades.

Part No. 48412 Genie S-60 & Genie S-65 4 - 3 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE A PROCEDURES

Gasoline/LPG models: A-8 · LPG tank, hoses and fittings, solenoid shutoff Check for Hydraulic Leaks valve, LPG regulator and carburetor Detecting hydraulic fluid leaks is essential to · Gasoline tank, manual shutoff valve, fuel operational safety and good machine performance. pump solenoid shutoff valve, hoses and Undiscovered leaks can develop into hazardous fittings and carburetor situations, impair machine functions and damage machine components. Deutz Diesel models: 1 Inspect for hydraulic oil puddles, dripping or · Fuel tank, shutoff valve, hoses and fittings, residue on or around the following areas: fuel pump, fuel filter, fuel injection pumps and · Hydraulic tank—filter, fittings, hoses, auxiliary fuel injectors power unit and turntable surface If a fuel leak is discovered, keep · Engine compartment—fittings, hoses, any additional personnel from pumps, filter and turntable surface entering the area and do not operate the machine. Repair the · All hydraulic cylinders leak immediately. · All hydraulic manifolds · Boom(s) · The underside of the turntable A-7 · The underside of the drive chassis Check the Hydraulic Oil Level · Ground area under the machine Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic oil levels can damage hydraulic components. Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems. 1 Be sure that the boom is in the stowed position, then visually inspect the sight gauge located on the side of the hydraulic 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

4 - 4 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

A-9 A-10 Check the Tire Pressure Test the Oscillate Axle This procedure does not need (if equipped) to be performed on machines Proper axle oscillation is essential to safe machine equipped with the foam-filled operation. If the axle oscillation system is not tire option. operating correctly, the stability of the machine is An over-inflated tire can explode compromised and it may tip over. and may cause death or serious 1 Start the engine from the platform controls. injury. 2 Drive the right steer tire up onto a 6 inch To safeguard maximum stability, achieve (15.2 cm) block or curb. optimum machine handling and minimize tire wear, it is essential to maintain proper pressure Result: The three remaining tires should stay in in all air-filled tires. firm contact with the ground and the chassis should remain level at all times. 1 Check each tire with an air pressure gauge and add air as needed. 3 Drive the left steer tire up onto a 6 inch (15.2 cm) block or curb. Tire specifications Result: The three remaining tires should stay in firm contact with the ground and the chassis Tire size 15-19.5 NHS should remain level at all times. Pressure 85 psi 4 Drive both steer tires up onto a 6 inch 5.86 bar (15.2 cm) block or curb. 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 OR see Repair Procedure 10-5, How to Adjust the Sequence Valve Pressure.

Part No. 48412 Genie S-60 & Genie S-65 4 - 5 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE A PROCEDURES

A-11 6 Start the engine from the platform controls. Test the Platform and 7 Do not press down on the footswitch. Ground Controls 8 Attempt to operate all machine functions. Testing the machine functions and the Emergency Result: All machine functions should not Stop buttons for malfunctions is essential for safe operate. machine operation. An unsafe working condition 9 Press down on the footswitch and activate each exists if any function fails to operate properly or machine function. either Emergency Stop button fails to stop all the machine functions and shut off the engine. Each Result: All machine functions should operate function should activate, operate smoothly and be through a full cycle. free of hesitation, jerking and unusual noise. 10 Push in the Emergency Stop button to the OFF 1 Pull out the Emergency Stop button at the position at the platform controls. ground controls to the ON position. Result: No function should operate, the engine 2 Start the engine from the ground controls. should stop. 3 Do not hold the function enable switch to either As a safety feature, selecting side. Attempt to activate each boom and and operating the ground platform function toggle switch. controls will override the platform controls, including Result: All boom and platform functions should the Emergency Stop switch. not operate. Deutz Diesel models: 4 Hold the function enable switch to either side All functions should stop and activate each boom and platform function immediately. The engine will toggle switch. shut off after 2 to 3 seconds. Result: All boom and platform functions should operate through a full cycle. Descent alarm (if equipped) should sound while the boom is lowering. A-12 Test the Auxiliary Power 5 Push in the Emergency Stop button to the OFF position. Operation Result: No function should operate, the engine Detection of auxiliary power system malfunctions is should stop. essential for safe machine operation. An unsafe working condition exists if the auxiliary powered Machines equipped with Platform functions do not operate in the event of a main Level Control Disable Function: power loss. When operating the machine on The platform level function will not engine power, selecting auxiliary power will stop operate when the boom is raised the engine immediately. Auxiliary power is or extended past the drive speed designed for short term emergency use only, limit switches. and excessive use will result in battery drain Deutz Diesel models: and component damage. All functions should stop immediately. The engine will 1 Turn the key switch to ground control and pull shut off after 2 to 3 seconds. out the Emergency Stop button to the ON position at the ground controls.

4 - 6 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

2 Lift the red auxiliary power switch cover. A-13 3 Simultaneously hold the auxiliary power switch Test the Tilt Sensor ON and activate each boom function toggle switch. 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 not be sounding prior to the test. 1 Start the engine from the platform controls. 2 Open the tank side turntable cover and press down on one side of the tilt sensor. To conserve battery power, test Result: After a 1.5 second delay, the alarm in each function through a partial the platform should sound. cycle. Tip-over hazard. The alarm should Result: All boom functions should operate. be audible at the ground controls. 4 Turn the key switch to platform control. If the alarm is not audible at the ground controls, replace the 5 Pull out the Emergency Stop switch to the ON alarm. position at the platform controls, then press down the foot switch. 6 Lift the red auxiliary power switch cover. 7 Simultaneously hold the auxiliary power switch ON and activate each function control handle or toggle switch

a b c

a fuel tank To conserve battery power, test b tilt sensor c ground control box each function through a partial cycle. Result: All boom and steer functions should operate. Drive functions should not operate with auxiliary power.

Part No. 48412 Genie S-60 & Genie S-65 4 - 7 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE A PROCEDURES

A-14 3 Visually inspect the boom extend drive limit switch located on the end of the cable track on Test the Limit Switches the boom. Inspect for the following: Drive Limit Switches · Broken or missing roller or arm Detecting limit switch malfunctions is essential to · Missing fasteners safe machine operation. The drive limit switches · Loose wiring 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 at an unsafe drive speed. 1 Remove the cover from the rear of the turntable to access the drive limit switch. 2 Visually inspect the drive limit switch mounted to the turntable side plate at the pivot end of the boom. Inspect for the following: · Broken or missing roller or roller head a b · Missing fasteners

· Loose wiring a boom extend drive limit switch b cable track a b 4 Start the engine from the ground controls. 5 Extend the boom approximately 3 feet (0.9 m). 6 Manually activate the boom extend drive limit switch. Result: The boom extend drive limit switch arm should move freely and spring return to center. A distinct click should be felt and heard. 7 Turn the keyswitch to platform control. 8 Fully retract the 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. c 11 Slowly move the drive control handle off center.

a turntable riser Result: The machine should move at a reduced b boom drive speed. c boom drive limit switch

4 - 8 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

12 Lower the boom to the stowed position, then 3 Start the engine from the platform controls and extend the boom 3 feet (91 cm). rotate the turntable so the boom is between the non-steer tires. 13 Slowly move the drive control handle off center. 4 Rotate the turntable to the left until the boom is Result: The machine should move at a reduced past the left non-steer wheel. drive speed. Result: The drive enable indicator light should Drive speed, maximum, be on. Drive function should not operate until raised or extended the drive enable toggle switch is activated.

All models 1 foot per second 5 Rotate the turntable to the right until the boom is 0.31 meter per second past the right non-steer wheel. Result: The drive enable indicator light should be on. Drive function should not operate until Drive Enable Limit Switch the drive enable toggle switch is activated. 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

c b

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 felt and heard.

Part No. 48412 Genie S-60 & Genie S-65 4 - 9 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE A PROCEDURES

A-15 2 Place a suitable container under the engine Replace the Engine Oil and pivot plate directly below the oil pan drain plug. Filter - Gasoline/LPG Models Ford engine specifications require that this procedure be performed every 100 hours. Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation. Periodic replacement of the engine oil and filter is essential to good engine performance. Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components. A daily check of elapsed machine hours against the hours noted a b c on the oil filter will allow the inspector to anticipate b and perform oil and filter changes at the 100 hour a engine pivot plate interval. b pivot plate retaining bolts c oil drain hose Perform this procedure after warming the engine to normal 3 Remove the plug from the oil pan and allow all operating temperature. of the oil from the engine to drain into a suitable Beware of hot engine parts and oil. container. See capacity specifications below. Contact with hot engine oil and/or 4 Install the plug into the oil pan. engine parts may cause severe burns. 5 Remove the 2 engine pivot plate retaining bolts from under the engine pivot plate. Swing the 1 Remove the oil filler cap located on the engine pivot plate away from the machine to valve cover. 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 Fill the engine with new oil per specifications and install the filler cap. See capacity specifications below. 10 Start the engine from the ground controls. Allow the engine to run for 30 seconds, then turn the engine off.

4 - 10 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE A PROCEDURES

11 Check the oil filter and the oil pan drain plug for A-16 leaks. Drain the Fuel Filter/ Water 12 Swing the engine pivot plate back to its original Separator - Deutz Diesel Models position and replace the two pivot plate retaining bolts. Engine specifications require that 13 Check the engine oil level dipstick. Add oil this procedure be performed every if needed. 100 hours. Poor fuel quality or very wet conditions may necessitate performing this Ford LRG-423 Engine 5 quarts procedure more often. Oil capacity (including filter) 4.7 liters Proper maintenance of the fuel filter/water Ford LRG-423 Engine separator is essential for good engine Oil viscosity requirements performance. Failure to perform this procedure can lead to poor engine performance and component below 60°F / 15.5°C 5W-30 damage.

-10° to 90°F / -23° to 32°C 10W-30 Engine fuels are combustible. Perform this procedure in an open, above -10°F / -23°C 10W-40 or 10W-50 well-ventilated area away from heaters, sparks, flames and above 25°F / -4°C 20W-40 or 20W-50 lighted tobacco. Always have an approved fire extinguisher within Use oils meeting API classification SF (labeled SF/CC easy reach. or SF/CD) as they offer improved wear protection. Perform this procedure with the engine off. 1 Loosen the drain plug located at the bottom of the filter. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug.

a

b

a fuel filter b drain plug

Part No. 48412 Genie S-60 & 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. 6 Replace the end cap on the canister, then replace the retaining ring. If the fuel filter is completely drained, you must prime the fuel filter/water separator before Air filters - Genie part numbers Ford LRG-423 Engine 27916 starting the engine. Refer to C-8 in Deutz F4L 1011F Engine 27916 this section, Replace The Diesel Fuel Filter/Water Separator, for instructions on how to prime the fuel filter/water separator. 3 Start the 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 Clean the inside of the canister and the gasket with a damp cloth. 5 Insert the new filter and replace the mounting fastener.

4 - 12 Genie S-60 & 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.

Do not inspect while the engine is running. Remove the key to secure from operation. Deutz Diesel engine Beware of hot engine components. Contact with hot engine components may cause Ford LRG-423 engines are severe burns. equipped with a serpentine belt and incorporate a self adjusting 1 Deutz Diesel models: Remove the 2 bolts from pulley tensioner. No adjustment is under the engine pivot plate. Swing the engine required. pivot plate away from the machine to access the front engine access cover mounting Belt deflection - 3/8 inch to 1/2 inch fasteners. 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.

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TABLE B PROCEDURES

B-2 B-3 Check the Radiator Check the Oil Cooler and Cooling - Gasoline/LPG Models Fins - Deutz Diesel Models Maintaining the radiator in good condition is Maintaining the oil cooler in good condition is essential for good engine performance. Operating essential for good engine performance. Operating a machine with a damaged or leaking radiator may a machine with a damaged oil cooler may result in result in engine damage. Also, restricting air flow engine damage. Also, restricting air flow through through the radiator (i.e., dirt or debris) will affect the oil cooler will affect the performance of the the performance of the cooling system. A frequent cooling system. check allows the inspector to identify changes in the condition of the radiator that might indicate Do not inspect while the engine cooling system problems. is running. Remove the key to secure from operation. Do not inspect while the engine Beware of hot engine is running. Remove the key to components. Contact with hot secure from operation. engine components may cause Beware of hot engine parts and severe burns. coolant. Contact with hot engine Oil Cooler parts and/or coolant may cause severe burns. 1 Remove the fasteners from the engine side 1 Remove the 2 engine pivot plate retaining bolts cover, then remove the cover. from under the engine pivot plate. Swing the 2 Inspect the oil cooler for leaks and physical engine pivot plate away from the machine to damage. access the radiator. a b c 2 Inspect the radiator for leaks and physical damage. 3 Clean the radiator fins of debris and foreign materials.

a oil cooler b cylinder head cooling fins c fan blower fins 3 Clean the oil cooler of debris and foreign material.

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TABLE B PROCEDURES

Cooling and Fan Blower Fins B-4 4 Inspect the fan blower fins for physical damage. Check the Exhaust System 5 Clean the fan blower fins of debris and foreign Maintaining the exhaust system is essential to material. good engine performance and service life. Running 6 Inspect the head cooling passages and fins for the engine with a damaged or leaking exhaust physical damage or foreign material, using a system can cause component damage and unsafe flashlight. operating conditions. 7 Clean the cylinder head cooling passages of Do not inspect while the engine debris and foreign material. is running. Remove the key to secure from operation. Beware of hot engine 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 system.

a b b

a engine pivot plate b pivot plate retaining bolts 2 All models: Be sure that all nuts and bolts are tight. 3 Inspect all welds for cracks. 4 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints.

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TABLE B PROCEDURES

B-5 B-6 Check the Battery Check the Hydraulic Tank Filter Proper battery condition is essential to good Condition Indicator engine performance and operational safety. Maintaining the hydraulic tank filter in good Improper fluid levels or damaged cables and condition is essential to good system performance connections can result in engine component and safe machine operation. The filter condition damage and hazardous conditions. indicator will show when the hydraulic flow is Electrocution hazard. Contact with bypassing a clogged filter. If the filter is not hot or live circuits may result in frequently checked and replaced, impurities death or serious injury. Remove all will remain in the hydraulic system and cause rings, watches and other jewelry. component damage. Batteries contain acid. Avoid 1 Start the engine from the platform controls. spilling or contacting battery acid. 2 Move the engine speed control switch to high Neutralize battery acid spills with idle (rabbit symbol). baking soda and water. 3 Inspect the filter condition indicator. 1 Put on protective clothing and eye wear. 2 Be sure that the battery cable connections are free of corrosion. a 3 Be sure that the battery hold downs and cable connections are tight. 4 Remove the battery vent caps and check the specific gravity with a hydrometer. b c 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 a filter condition indicator corrosion preventative sealant will b filter help eliminate corrosion on the c hydraulic tank battery terminals and cables. 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.

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TABLE B PROCEDURES

B-7 B-8 Inspect the Electrical Wiring Inspect the Tires and Wheels Maintaining electrical wiring in good condition is (including lug nut torque) essential to safe operation and good machine Maintaining the tires and wheels in good performance. Failure to find and replace burnt, condition is essential to safe operation and good chafed, corroded or pinched wires could result in performance. Tire and/or wheel failure could result unsafe operating conditions and may cause in a machine tip-over. Component damage may component damage. also result if problems are not discovered and Electrocution hazard. Contact with repaired in a timely fashion. hot or live circuits may result in An over-inflated tire can death or serious injury. Remove all explode and may cause death rings, watches and other jewelry. or serious injury. 1 Inspect the following areas for burnt, chafed, Tip-over hazard. Do not use corroded and loose wires: temporary flat tire repair products. · Engine compartment electrical panel 1 Check all tire treads and sidewalls for cuts, (Gasoline/LPG models) cracks, punctures and unusual wear. · Engine wiring harness 2 Check each wheel for damage, bends and · Inside of the ground control box cracked welds. · Turntable manifold wiring 3 Check each lug nut for proper torque. 2 Start the engine from the ground controls and raise the boom above the turntable covers. 4 Check the pressure in each air-filled tire.

3 Inspect the turntable area for burnt, chafed and Tires and wheels pinched cables. 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 Inspect the following areas for burnt, chafed, 5.86 bar corroded, pinched and loose wires: Wheel lugs 10 @ 3/4 -16 · Cable track on the boom Lug nut torque, dry 420 ft-lbs · 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 & Genie S-65 4 - 17 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE B PROCEDURES

B-9 B-10 Confirm the Proper Check the Oil Level Brake Configuration in the Torque Hubs Proper brake configuration is essential to safe Failure to maintain proper torque hub oil levels operation and good machine performance. may cause the machine to perform poorly and Hydrostatic brakes and hydraulically-released, continued use may cause component damage. spring-applied individual wheel brakes can appear to operate normally when they are actually not fully Drive Torque Hubs operational. 1 Drive the machine to rotate the hub until the 1 Check each torque hub disconnect cap to be plugs are located one on top and the other at sure it is in the engaged position. 90 degrees.

brake disengage position

brake engage position

2 Be sure the free-wheel valve on the drive pump is closed (clockwise).

The free-wheel valve is located on 2 Remove the plug located at 90 degrees and the bottom of the drive pump. check the oil level. Result: The oil level should be even with the bottom of the plug hole.

d 3 If necessary, remove the top plug and add oil until the oil level is even with the bottom of the a c side plug hole. b 4 Apply pipe thread sealant to the plug, and then install it in the torque hub. 5 Repeat this procedure for each drive torque hub. a drive pump b free-wheel valve c lift pump Drive torque hub oil d screwdriver Capacity 44 fl oz The free-wheel valve should 1.30 liters always remain closed. Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5

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TABLE B PROCEDURES

Turntable Rotate Torque Hub B-12 1 Remove the plug located on the side of the hub Check and Adjust the and check the oil level. Engine RPM Result: The oil level should be even with the Maintaining the engine rpm at the proper setting for bottom of the plug hole. 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 a operating temperature. b 1 Disconnect the blue/black wire from the governor actuator. 2 Connect an rpm gauge to the engine, then start the engine from the ground controls. a torque hub b plug Result: Carburetor low idle should be 900 rpm. Skip to step 4 if the low idle rpm is correct. 2 If necessary, add oil until the oil level is even with the bottom of the side plug hole. 3 Turn the idle adjustment screw on the carburetor clockwise to increase rpm or 3 Apply pipe thread sealant to the plug, and then counterclockwise to decrease rpm. install it in the torque hub.

Turntable rotate torque hub oil

Capacity 17 fluid ounces 0.51 liters a

Type SAE 90 multipurpose hypoid gear oil - API service b classification GL5

a carburetor b adjustment screw B-11 4 Turn the engine off and reconnect the Check and Adjust the Engine Idle blue/black wire to the governor actuator. Mixture - Gasoline/LPG Models 5 Start the engine from the ground controls. Complete information to perform this procedure is Result: Electronic governor low idle should available in the Ford LRG-423 2.3 Liter Industrial be 1600 rpm. Engine Service Manual (Ford number: PPD-194- 287). Genie part number 33907.

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TABLE B PROCEDURES

6 Move the function enable toggle switch to the Deutz Diesel models: high idle (rabbit symbol) at the ground controls. 1 Connect an rpm gauge to the engine, and then Result: High idle should be 2500 rpm. start the engine from the ground controls. 7 Turn the engine off. Result: Low idle should be 1300 rpm. If low and high idle rpm’s are correct, Skip to step 3 if the low idle rpm is correct. disregard adjustment steps 8 and 9. 2 Loosen the low idle lock nut, then turn the low 8 Remove the mounting fasteners from the idle adjustment screw clockwise to increase the electronic governor located on the engine rpm or counterclockwise to decrease the rpm. side bulkhead, then remove the back panel Tighten the low idle lock nut and recheck the from the governor. rpm. 9 Restart the engine, turn the low or high speed trimpot screw clockwise to increase the rpm or counterclockwise to decrease the rpm.

Do not adjust any trimpot other f than specified in this procedure. e

a

a b c d b a solenoid boot b high idle adjustment nut a low idle adjustment c yoke lock nut b high idle adjustment d yoke e low idle adjustment screw 10 Apply a drop of silicone to the top of the trimpot f low idle lock nut screw. Apply a bead of silicone to the surface of the back panel prior to re-assembly. 3 Move the function enable toggle switch to the high idle (rabbit symbol) position at the ground 11 Re-assemble the governor and recheck low and controls. high idle. Result: High idle should be 2300 rpm. Gasoline/LPG models 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

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TABLE B PROCEDURES

4 Loosen the yoke lock nut, then turn the high idle 6 Turn the key switch to the OFF position. adjustment nut and solenoid boot Result: The engine should stop and no counterclockwise to increase the rpm or functions should operate. clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. Deutz Diesel models: All functions should stop immediately. The Be sure the solenoid fully retracts engine will shut off after 2 to 3 when activating high idle. seconds.

Deutz Diesel models

Low idle 1300 rpm B-14

High idle 2300 rpm Test the Emergency Stop Buttons Properly functioning Emergency Stop buttons B-13 are essential for safe machine operation. An Test the Key Switch improperly operating Emergency Stop button will fail to shut off power and stop all machine Proper key switch action and response is essential functions, resulting in a hazardous situation for to safe machine operation. The machine can be ground and platform personnel. operated from the ground or platform controls and the activation of one or the other is accomplished As a safety feature, selecting with the key switch. Failure of the key switch to and operating the ground controls activate the appropriate control panel could cause will override the platform controls, a hazardous operating situation. including the Emergency Stop button. 1 Pull out the Emergency Stop button to the ON position at both the ground and platform 1 Start the engine from the ground controls. controls. 2 Push down the Emergency Stop button to the 2 Turn the key switch to ground control, start the OFF position. engine and then turn the key switch to platform Result: The engine should shut off and no control. machine functions should operate. 3 Check any machine function from the ground Deutz Diesel models: All controls. functions should stop immediately. The engine will shut off after 2 to 3 Result: The machine functions should not seconds. operate. 3 Start the engine from the platform controls. 4 Turn the key switch to ground control. 4 Push down the Emergency Stop button to the 5 Check any machine function from the platform OFF position. controls. Result: The engine should shut off and no Result: The machine functions should not machine functions should operate. 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 & Genie S-65 4 - 21 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE B PROCEDURES

B-15 B-16 Test the Ground Control Override Check the Directional Valve A properly functioning ground control override is Linkage essential to safe machine operation. The ground Perform this test only on models control override function is intended to allow equipped with a oscillating axle. ground personnel to operate the machine from the ground controls whether or not the Emergency Proper axle oscillation is essential to safe machine Stop button on the platform controls is in the ON or operation. If the directional valve linkage is not OFF position. This function is particularly useful if operating correctly, the stability of the machine is the operator at the platform controls cannot return compromised and it may tip over. the boom to the stowed position. 1 Remove the drive chassis cover from the 1 Push in the platform Emergency Stop button non-steer end. to the OFF position. 2 Inspect the linkage for the following: 2 Start the engine from the ground controls. · Lock nut is tight against yoke 3 Operate each boom function through a · Yoke clevis pins are installed partial cycle. · Cotter pins are installed through clevis pins Result: All boom functions should operate. · Linkage is properly attached to directional valve

a

b

c

d

a directional valve b clevis pin with cotter pin (hidden) c yoke d lock nut

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TABLE B PROCEDURES

B-17 2 Push down the horn button at the platform Test the Platform Self-leveling controls. Result: The horn should sound. Automatic platform self-leveling throughout the full cycle of boom raising and lowering is If necessary, the horn can be essential for safe machine operation. The adjusted to obtain the loudest platform is maintained at level by the platform volume by turning the adjustment leveling slave cylinder which operates in a closed screw near the wire terminals on loop hydraulic circuit with the master cylinder the horn. located at the base of the boom. A platform self- leveling failure creates an unsafe working condition for platform and ground personnel. B-19 1 Start the engine from the ground controls and Test the Foot Switch lower the boom into the stowed position. A properly functioning foot switch is essential to 2 Hold the function enable toggle switch to either safe machine operation. Machine functions should side and adjust the platform to a level position activate and operate smoothly as long as the foot using the platform level toggle switch. switch is pressed down, and promptly stop when 3 Raise and lower the boom through the foot switch is released. The foot switch will also a full cycle. shift the engine into high idle if the idle select is switched to the rabbit and foot switch symbol. An Result: The platform should remain level at improperly functioning foot switch can cause an all times to within ±5 degrees. unsafe working condition and endanger platform and ground personnel.

The engine should not start if the B-18 foot switch is pressed down. Test the Horn 1 Turn the keyswitch to platform controls and pull A functional horn is essential to safe machine out the Emergency Stop button to the ON operation. The horn is activated at the platform position at both the ground and platform controls and sounds at the ground as a warning to controls. ground personnel. An improperly functioning horn 2 Press down the footswitch and attempt to start will prevent the operator from alerting ground the engine by moving the start toggle switch to personnel of hazards or unsafe conditions. either side. 1 Turn the key switch to platform control and Result: The engine should not start. pull out the Emergency Stop button to the 3 Do not press down the footswitch and start the ON position at both the ground and engine. platform controls. 4 Do not press 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. Result: The machine functions should operate.

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TABLE B PROCEDURES

B-20 7 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch Test the Engine Idle Select symbol). A properly operating engine idle select switch Result: The engine should not change to is essential to good engine performance and safe high idle. machine operation. There are three settings. 8 Press down the foot switch. Low idle (turtle symbol) allows the operator to control individual boom functions only. Drive Result: The engine should change to high idle. functions do not operate at low idle. High idle (rabbit symbol) allows the operator to control multiple boom and/or drive functions B-21 simultaneously. This setting maintains a Test the Fuel Select Operation consistent high idle and is usually selected only when the generator option is being used. - Gasoline/LPG Models

Foot switch activated high idle (rabbit and foot The ability to select and switch between switch symbols) should be used for normal gasoline and LPG fuels as needed is essential to machine operation. This selection activates high safe machine operation. A fuel selection can be idle only when the foot switch is pressed down. made when the engine is running or not. Switching malfunctions and/or the failure of the 1 Pull out the Emergency Stop button to the engine to start and run properly in both fuel ON position at both the ground and platform modes and through all idle speeds can indicate controls. fuel system problems that could develop into a hazardous situation. 2 Start the engine from the ground controls. Then move the function enable toggle switch to the Perform this test after checking high idle (rabbit symbol) position and hold in the the gasoline and LPG fuel levels, ON position. and warming the engine to normal Result: The engine should change to high idle. operating temperature. 3 Release the function enable toggle switch. 1 Move the fuel select switch to gasoline and then move the engine idle control switch to foot Result: The engine should return to low idle. switch activated high idle (rabbit and foot switch symbol). 4 Turn the key switch to platform controls. 2 Start the engine from the platform controls and 5 At the platform controls, move the engine idle allow it to run at low idle. control switch to high idle (rabbit symbol). 3 Press down the foot switch to allow the engine Result: The engine should change to high idle. to run at high idle. 6 Move the engine idle control switch to low idle Result: The engine should start promptly and (turtle symbol). operate smoothly in low and high idle. Result: The engine should change to low 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.

4 - 24 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE B PROCEDURES

6 Restart the engine and allow it to run at 4 Hold the drive enable toggle switch to either low idle. side and slowly move the drive control handle off center. 7 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. The engine may hesitate momentarily and then continue to run on the selected fuel if the Always use the color-coded fuel source is switched while direction arrows on the the engine is running. platform control panel and the drive chassis to identify which direction the machine will travel. B-22 Result: The drive function should operate. Test the Drive Enable System 5 Rotate the turntable to the left until the boom is past the left non-steering wheel. Proper drive enable system operation is essential to safe machine operation. When the Result: The drive enable indicator light should boom is past the non-steering wheels, drive come on. movement is stopped and the indicator light turns 6 Repeat steps 3 and 4. 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 B-23 are moved. An improperly functioning drive enable system may allow the machine to be moved into Test the Drive Brakes an unsafe position. Proper brake action is essential to safe machine 1 Start the engine from the platform controls. operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual 2 Rotate the turntable to the right until the boom is noise. Hydrostatic brakes and hydraulically- past the right non-steering wheel. released individual wheel brakes can appear to operate normally when they are actually not fully Result: The drive enable indicator light should operational. turn on. 3 Slowly move the drive control handle off center. Be sure that the machine is not in free-wheel or partial free-wheel Result: The drive function should not operate. 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 test line on the ground for reference. 2 Start the engine from the platform controls.

Part No. 48412 Genie S-60 & 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 B-24 foot switch activated high idle (rabbit and foot switch), then lower the boom into the Test the Drive Speed stowed position. - Stowed Position 4 Choose a point on the machine; i.e., contact Proper drive function movement is essential to patch of a tire, as a visual reference for use safe machine operation. The drive function should when crossing the test line. respond quickly and smoothly to operator control. 5 Bring the machine to top drive speed before Drive performance should also be free of reaching the test line. Release the drive joystick hesitation, jerking and unusual noise over the when your reference point on the machine entire proportionally controlled speed range. crosses the test line. Select a test area that is firm, level 6 Measure the distance between the test line and and free of obstructions. your machine reference point. 1 Create start and finish lines by marking two lines on the ground 40 feet (12.2 m) apart. Braking: paved surface 2WD 4WD 2 Start the engine from the platform controls. 3 Move the engine idle control switch to Stopping distance 3 to 5 ft 3 to 5 ft foot switch activated high idle (rabbit and foot 0.9 to 1.5 m 0.9 to 1.5 m switch), then lower the boom into the stowed position.

The brakes must be able to hold 4 Choose a point on the machine; i.e., contact the machine on any slope it is able patch of a tire, as a visual reference for use to climb. when crossing the start and finish lines. 5 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 6 Continue at full speed and note the time when the machine reference point crosses the finish line.

Drive speed: stowed position 2WD 4WD

Gasoline/LPG models 40 ft/6.2 sec 40 ft/9.1 sec 12.2 m/6.2 sec 12.2 m/9.1 sec

Deutz Diesel models 40 ft/6.8 sec 40 ft/9.1 sec 12.2 m/6.8 sec 12.2 m/9.1 sec

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TABLE B PROCEDURES

B-25 5 Press down the foot switch. Move the drive control handle off center, hold for a moment Test the Alarm Package and then release it. Move the drive control - Optional Equipment handle off center in the opposite direction, hold for a moment and then release it. The alarm package includes: Result: The travel alarm should sound when the · Travel alarm drive control handle is moved off center in · Descent alarm either direction. · Flashing beacon Alarms and a beacon are installed to alert B-26 operators and ground personnel of machine proximity and motion. The alarm package is Perform Hydraulic Oil Analysis installed on the turntable covers. See D-1, Test or Replace the Hydraulic Oil. The alarms and beacon will operate with the engine running or not running. B-27 1 Turn the key switch to ground control and pull Replace the Engine Oil and out the Emergency Stop button to the ON position at both the ground and platform Filter - Deutz Diesel Models controls. Engine specifications require Result: The flashing beacon should be on and that this procedure be performed flashing. every 500 hours. Perform this procedure more often if dusty 2 Move the function enable toggle switch to either conditions exist. side and activate the boom toggle switch in the DOWN position, hold for a moment and then Periodic replacement of the engine oil and release it. filter is essential to good engine performance. Operating the machine with an improper oil level or Result: The descent alarm should sound when neglecting periodic oil and filter changes can the switch is held down. damage engine components. A frequent check 3 Turn the key switch to platform control. of elapsed machine hours against the hours noted on the oil filter will allow the inspector to Result: The flashing beacon should be on anticipate and perform oil and filter changes at and flashing. the 500 hour interval. 4 Press down the foot switch. Move the boom Perform this procedure after control handle to the DOWN position, hold for a warming the engine to normal moment and then release it. operating temperature. Result: The descent alarm should sound when Beware of hot engine parts and oil. the control handle is held down. Contact with hot engine oil and/or engine parts may cause severe burns. 1 Remove the oil filler cap located above the dipstick.

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TABLE B PROCEDURES

2 Pull the end of the drain hose out from under 10 Check the oil filter and oil drain hose for leaks. the engine. 11 Check the engine oil level dipstick. Add oil if 3 Remove the plug from the end of the drain hose needed. and allow all of the oil from the engine to drain into a suitable container. See capacity Deutz Engine F4L 1011F 11 quarts specifications below. Oil capacity (including filter) 10.5 liters

4 Install the plug into the drain hose. Deutz Engine F4L 1011F Oil viscosity requirements 5 Use an oil wrench and remove the oil filter. Temperature below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40 a 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. c b 2 Clean up any fuel that may have spilled.

a engine oil level dipstick b fuel filter c oil filter 6 Apply a thin layer of oil to the new filter gasket (Genie part no. 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 Fill the engine with new oil per specifications and install the oil filler cap. 9 Start the engine from the ground controls. Allow the engine to run for 30 seconds then turn the engine off.

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C-1 C-2 Check the Boom Check the Turntable Rotation Wear Pads Bearing Bolts Maintaining the boom wear pads in good condition Maintaining proper torque on the turntable bearing is essential to safe machine operation. Wear pads bolts is essential to safe machine operation. are placed on boom tube surfaces to provide a low Improper bolt torque could result in an unsafe friction, replaceable wear pad between moving operating condition and component damage. parts. Improperly shimmed wear pads or continued use of worn out wear pads may result in 1 Raise the boom and place a safety chock on component damage and unsafe operating the lift cylinder rod. Carefully lower the boom conditions. onto the lift cylinder safety chock. Crushing hazard. Keep hands If the wear pads are not worn away from cylinder and all moving below specification but are still parts when lowering the boom. within specification, see Repair Procedure 4-2, How to Shim the The lift cylinder safety chock is Boom. available through Genie (part no. 33484). 1 Start the engine from the ground controls. 2 Be sure that each turntable mounting bolt is 2 Raise the end of the boom to a comfortable torqued in sequence to 210 foot-pounds working height (chest high), then extend the (285 Newton meters). boom 1 foot (30 cm).

28 1 3 Measure each wear pad. Replace the wear pad 24 5 20 9 if it is less than specification. If the wear pad is 16 13 not less than specification, shim as necessary 12 17 to obtain zero clearance and zero drag. 8 21 4 25 4 Extend and retract the boom through the entire 30 29 range of motion to check for tight spots that 26 3 may cause binding or scraping of the boom. 22 7 18 11 Always maintain squareness 14 15 between the boom outer and inner 10 19 6 23 tubes. 2 27

Bolt torque sequence Wear pad specifications

Upper wear pads 9/16 inch 14.3 mm Bottom and side wear pads 11/16 inch 17.5 mm

Part No. 48412 Genie S-60 & Genie S-65 4 - 29 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE C PROCEDURES

3 Lower the boom to the stowed position. 4 Disengage the torque hubs by turning over the torque hub disconnect caps on each 4 Check to ensure that each bearing mounting non-steering wheel hub. bolt under the drive chassis is torqued in sequence to 210 foot-pounds disengage position (285 Newton meters).

1 10 15 13 7

6 12 engage position

18 4 5 Manually rotate each non-steering wheel.

3 17 Result: Each non-steering wheel should rotate with minimum effort. 11 5 6 Re-engage the torque hubs by turning over 8 14 16 9 the hub disconnect caps. Rotate each wheel to 2 check for engagement. Lift the machine and Bolt torque sequence remove the jack stands. Collision hazard. Failure to re-engage the torque hubs may C-3 cause death or serious injury and property damage. Check the Free-wheel Steer wheels: 4WD models Configuration 7 Chock the non-steering wheels to prevent the Proper use of the free-wheel configuration is machine from rolling. essential to safe machine operation. The free-wheel configuration is used primarily for 8 Center a lifting jack of ample capacity towing. A machine configured to free-wheel without (20,000 lbs/9072 kg) under the drive chassis operator knowledge may cause death or serious between the non-steer tires. injury and property damage. 9 Lift the wheels off the ground and then place Collision hazard. Select a work jack stands under the drive chassis for support. site that is firm and level. 10 Disengage the torque hubs by turning over the Non-steering wheels: All models torque hub disconnect caps on each steer wheel hub. 1 Chock the steer wheels to prevent the machine from rolling. disengage position 2 Center a lifting jack of ample capacity (20,000 lbs/9072 kg) under the drive chassis between the non-steer tires.

3 Lift the wheels off the ground and then place engage position jack stands under the drive chassis for support. 11 Manually rotate each steer wheel. Result: Each steer wheel should rotate with minimum effort.

4 - 30 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE C PROCEDURES

12 Re-engage the torque hubs by turning over C-4 the hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and Grease the Turntable Rotation remove the jack stands. Bearing and Rotate Gear Collision hazard. Failure to Yearly application of lubrication to the turntable re-engage the torque hubs may bearing and rotate gear is essential to good cause death or serious injury and machine performance and service life. Continued property damage. use of an improperly greased bearing and gear will All models: result in component damage.

13 Be sure the free-wheel valve on the drive pump 1 Locate the grease fitting on the platform end of is closed (clockwise). the tank side bulkhead. The free-wheel valve is located on 2 Pump grease into the turntable rotation bearing. the bottom of the drive pump. Rotate the turntable in increments of 4 to 5 inches (10 to 13 cm) at a time and repeat this step until the entire bearing has been greased. 3 Apply grease to each tooth of the drive gear, d located under the turntable. a c Grease type Multipurpose grease b

a drive pump b free-wheel valve C-5 c lift pump d screwdriver Replace the Torque Hub Oil The free-wheel valve should Replacing the torque hub oil is essential for good always remain closed. machine performance and service life. Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage. Drive Torque Hubs:

1 Select the torque hub to be serviced. Then drive the machine until one of the two plugs is at the lowest point. 2 Remove both plugs and drain the oil.

Part No. 48412 Genie S-60 & Genie S-65 4 - 31 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE C PROCEDURES

3 Drive the machine until one plug is at the top Turntable Rotate Torque Hub: and the other is at 90 degrees. 1 Secure the turntable from rotating with the turntable rotation lock pin.

4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole. unlocked locked Apply pipe thread sealant to the plugs, and then 2 Remove the motor/brake mounting bolts, and install the plugs. then remove the motor and brake from the 5 Repeat steps 1 through 4 for all the other drive torque hub and set them to the side. torque hubs. Component damage hazard. Hoses can be damaged if they are Oil capacity per hub 44 fl oz kinked or pinched. 1.30 liters a b Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5

f c

d e

a motor/brake mounting bolt b motor c torque hub d torque hub mounting bolt e plug f 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 S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE C PROCEDURES

4 Remove the plug from the side of the torque 4 Use a permanent ink marker to write the date hub. Then drain the oil from the hub. and number of hours from the hour meter on the oil filter. 5 Install the torque hub. Torque the hub mounting bolts to 180 foot-pounds (244 Newton meters). 5 Start the engine from the ground controls. 6 Install the brake and motor onto the torque hub. 6 Inspect the filter and related components to 7 Fill the hub with oil from the side hole until the be sure that there are no leaks. oil level is even with the bottom of the hole. Apply pipe thread sealant to the plugs, and then install the plugs. C-7 8 Adjust turntable rotation gear backlash. See Replace the Drive Loop Repair Procedure 12-1, How to Adjust the Turntable Rotation Gear Backlash. Hydraulic Filter Replacing the drive loop hydraulic filter is essential Turntable rotate torque hub to good machine performance and service life. A dirty or clogged filter may cause the machine to Oil capacity 17 fluid ounces 0.51 liters perform poorly and continued use may cause component damage. Extremely dirty conditions Type: SAE 90 multipurpose hypoid gear oil - API may require that the filter be replaced more often. service classification GL5 Beware of hot oil. Contact with hot oil may cause severe burns. Perform this procedure with the C-6 engine off. Replace the Hydraulic Tank Filter 1 Open the engine side turntable cover and locate the drive loop hydraulic filter mounted on the Replacement of the hydraulic tank filter is engine near the main pump. essential for good machine performance and 2 Remove the filter housing by using a wrench on service life. A dirty or clogged filter may cause the the nut provided on the bottom of the housing. machine to perform poorly and continued use may cause component damage. Extremely dirty 3 Remove the filter element from the housing. conditions may require that the filter be replaced 4 Inspect the housing seal and replace it if more often. necessary. Beware of hot oil. Contact with 5 Install the new filter (Genie part no. 20880) and hot oil may cause severe burns. hand tighten the housing onto the filter head. Perform this procedure with the Clean up any oil that may have spilled during engine off. the installation procedure. 1 Remove the filter with an oil filter wrench. 6 Start the engine from the ground controls. 2 Apply a thin layer of oil to the new oil filter 7 Inspect the filter assembly to be sure that there gasket. are no leaks. 3 Install the new filter (Genie part no. 46014) and 8 Clean up any oil that may have spilled. tighten it securely by hand. Clean up any oil that may have spilled during the installation procedure. Part No. 48412 Genie S-60 & Genie S-65 4 - 33 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE C PROCEDURES

C-8 3 Fill the new filter (Genie part no. 29560) with fresh diesel fuel and apply a thin layer of oil or Replace the Diesel Fuel diesel fuel to the new fuel filter gasket. Filter/Water Separator - Deutz 4 Install the new filter and tighten it securely by Diesel Models hand. Clean up any diesel fuel that might have spilled during the procedure. Replacing the diesel fuel filter is essential to good engine performance and service life. A dirty or 5 Turn the manual fuel shutoff valve, located at clogged filter may cause the engine to perform the fuel tank, to the OPEN position. poorly and continued use may cause component 6 Start the engine from the ground controls, then damage. Extremely dirty conditions may require inspect the fuel filter for leaks. that the filter be replaced more often. If a fuel leak is discovered, keep Engine fuels are combustible. any additional personnel from Replace the fuel filter in an open, entering the area and do not well-ventilated area away from operate the machine. Repair heaters, sparks, flames and the leak immediately. lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the C-9 engine off. Replace the Gasoline Fuel 1 Turn the manual fuel shutoff valve, located at Filter - Gasoline/LPG Models the fuel tank, to the CLOSED position. Replacing the gasoline fuel filter is essential to 2 Remove the fuel filter with a filter wrench. good engine performance and service life. A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Engine fuels are combustible. Replace the fuel filter in an open, well-ventilated area away from a heaters, sparks, flames and b lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off. a oil filter b fuel filter/water separator

4 - 34 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE C PROCEDURES

1 Remove the 2 bolts from under the engine pivot 3 Install the new fuel filter (Genie part no. 33971) plate. Swing the engine pivot plate away from into the fitting on the carburetor. the machine to access the fuel filter, located 4 Connect the fuel hose to the filter. near the carburetor. 5 Clean up any fuel that may have spilled during the installation procedure. 6 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. 7 Swing the engine pivot plate back to its original position and replace the two retaining bolts.

a b a

a pivot plate retaining bolts b engine pivot plate 2 Disconnect the fuel hose from the filter, then remove the filter from the fitting.

a b

a fuel filter b hose from the fuel pump to the fuel filter

Part No. 48412 Genie S-60 & Genie S-65 4 - 35 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE C PROCEDURES

C-10 2 Remove the hose from the PCV valve, then Replace the PCV Valve remove the valve. - Gasoline/LPG Models Yearly replacement of the PCV valve is essential to good engine performance. A malfunctioning PCV 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. Swing the engine pivot plate away from the machine to access the PCV valve.

a

a PCV valve 3 Install the new PCV valve. Connect the hoses. 4 Swing the engine pivot plate back to its original position and replace the two retaining bolts.

a b a

a pivot plate retaining bolts b engine pivot plate

4 - 36 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE C PROCEDURES

C-11 C-12 Replace the Spark Plugs Check and Adjust the Air/LPG - Gasoline/LPG Models Mixture - Gasoline/LPG Models Periodic replacement of the spark plugs is Maintaining the proper air-to-fuel mixture during essential to good engine performance and LPG operation is essential to good engine service life. Worn, loose or corroded spark plugs performance. will cause the engine to perform poorly and may result in component damage. Engine fuels are combustible. Perform this procedure in an open, Perform this procedure with the well-ventilated area away from engine off. heaters, sparks, flames and lighted tobacco. Always have an 1 Label, then disconnect the plug wires from the approved fire extinguisher within spark plugs by grasping the molded boot. Do easy reach. not pull on the plug wire. The engine rpm needs to be 2 Blow out any debris around spark plugs. preset for gasoline fuel operation 3 Remove all the spark plugs from the engine. before adjusting the LPG idle mixture. Refer to B-12, Check and 4 Adjust the gap on each new spark plug. Adjust the Engine RPM. 5 Install the new spark plugs, then connect the The engine should be warmed to wires. Be sure that each spark plug wire is normal operating temperature attached to the correct spark plug. before performing this procedure.

Spark plug specifications 1 Move the fuel select switch to LPG fuel and start the engine from the ground controls. Spark plug type Motorcraft AWSF-52C 2 Loosen the high idle mixture adjustment lock nut. Spark plug gap 0.042 to 0.046 inches 1.07 to 1.18 mm a

Spark plug torque 5 to 10 foot-pounds 7 to 14 Nm

a high idle mixture adjustment screw

Part No. 48412 Genie S-60 & Genie S-65 4 - 37 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE C PROCEDURES

3 Load the system by activating the boom retract C-13 function, then move the function enable toggle switch to the high idle (rabbit symbol) position. Check and Adjust the Ignition Timing - Gasoline/LPG Models 4 Adjust the high idle adjustment screw to obtain an air-to-fuel mixture ratio of 13.0:1 to 13.2:1, Complete information to perform this procedure is using an exhaust gas analyzer. available in the Ford LRG-423 2.3 Liter Industrial Engine Service Manual (Ford number: PPD-194- Preliminary setting is 1/4 inch of threads showing. Measure from 287). Genie part number 33907. top of lock nut to top of adjustment screw. If an exhaust gas analyzer is not C-14 available, adjust to obtain peak or optimum rpm. Check the Engine Valve Clearances - Deutz Diesel Models 5 Hold the adjustment screw and tighten the lock nut. Complete information to perform this procedure is available in the Deutz FL 1011F Workshop 6 Move the engine idle control switch to low idle Manual (Deutz Number 0297 7195). (turtle symbol) and adjust the low idle screw to Genie part number 52229. obtain an air-to-fuel mixture ratio of 13.0:1 to 13.2:1.

C-15 Check the Turntable Rotation Gear Backlash The turntable rotation torque hub is mounted on an adjustable plate that controls the gap between the rotation motor gear and the turntable bearing. Maintaining proper backlash of the turntable bearing is essential to safe machine operation. Improper backlash could result in an unsafe operating condition and component damage.

See 12-1, How to Adjust the Turntable Rotation Gear Backlash.

a

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.

4 - 38 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures Table D Procedures

D-1 D-2 Test or Replace the Hydraulic Oil Change or Recondition the Replacement or testing of the hydraulic oil is Engine Coolant essential for good machine performance and - Gasoline/LPG Models service life. Dirty oil and suction strainers may cause the machine to perform poorly and Replacing or reconditioning the engine coolant is continued use may cause component damage. essential to good engine performance and service Extremely dirty conditions may require oil changes life. Old or dirty coolant may cause the engine to to be performed more often. perform poorly and continued use may cause engine damage. Extremely dirty conditions may The machine uses Dexron require coolant to be changed more frequently. equivalent hydraulic oil. Before replacing the hydraulic oil, the oil Beware of hot engine parts and may be tested by an oil distributor coolant. Contact with hot engine for specific levels of contamination parts and/or coolant will cause to verify that changing the oil is severe burns. necessary. If the hydraulic oil is Perform this procedure with the not replaced at the two year engine off and cooled. inspection, test the oil quarterly. Replace the oil when it fails the 1 Put on protective clothing and eye wear. test. 2 Disconnect the coolant return hose at the Perform this procedure with the radiator and drain the coolant return tank into a boom in the stowed position. suitable container. 1 Remove the hydraulic tank. See Repair 3 Slowly remove the radiator cap from the Procedure 11-2, How to Remove the Hydraulic radiator. Tank. Bodily injury hazard. Allow any The pump needs to primed before pressure to dissipate gradually starting the engine. See Repair before removing the radiator cap. Procedure 11-2, How to Remove the Hydraulic Tank. Component damage hazard. Be sure that the hydraulic tank shutoff valves are in the OPEN 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.

Part No. 48412 Genie S-60 & Genie S-65 4 - 39 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE D PROCEDURES

4 Remove the 2 engine pivot plate retaining bolts 10 Disconnect the hose coupler at the fan end from from under the engine pivot plate. Swing the the tube that is connected to the water pump engine pivot plate away from the machine to and hold it until coolant starts to come out of the access the radiator drain valve. open hose. Then immediately reconnect the hose.

b a

a b a a tube connected to water pump b hose coupler a pivot plate retaining bolts b engine pivot plate 11 Fill the radiator and then fill the coolant recovery 5 Open the drain valve on the radiator and allow tank to the NORMAL range. all the coolant to drain into a suitable container. 12 Clean up any coolant spilled during this 6 After all the coolant has drained, close the drain procedure. valve. Connect the coolant return hose to 13 Start the engine from the ground controls, the radiator. run it for 30 seconds, and then turn it off. 7 Open the drain valve on the engine block and 14 Inspect for leaks and then check the fluid allow the coolant to drain into a container. level in the coolant recovery tank. Add After the fluid is drained, close the drain valve. water if needed. 8 Replace all coolant hoses and clamps. 15 Start the engine from the ground controls 9 Pour the proper coolant mixture (anti-freeze and and run it until reaching normal operating water) for your climate into the radiator until it is temperature. full. 16 Allow engine to cool and check the fluid level in the coolant recovery tank. Add water if needed.

Ford Engine 11.5 quarts Coolant capacity 10.9 liters

4 - 40 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE D PROCEDURES

D-3 a b b bbb b b 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 next to the fuel tank. 2 Remove and replace the fuel line hoses and clamps according to the following illustrations: Fuel may be expelled under f e d c pressure. Wrap a cloth around fuel hoses to absorb leaking fuel Deutz Diesel models before disconnecting them. 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 filter 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 & Genie S-65 4 - 41 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE D PROCEDURES

a b c D-4 Check the Engine Valve Clearance - Gasoline/LPG Models Complete information to perform this procedure is available in the Ford LRG-423 2.3 Liter Industrial Engine Service Manual (Ford number: PPD-194- 287). Genie part number 33907.

D-5 Check the Engine Cylinder Compression - Gasoline/LPG Models Complete information to perform this procedure is available in the Ford LRG-423 2.3 Liter Industrial d Engine Service Manual (Ford number: PPD-194- Gasoline/LPG 287). Genie part number 33907. a carburetor b fuel filter c hose from the fuel filter to the fuel pump d hose from the fuel pump D-6 to the fuel tank (not shown) Clean the PCV Hoses and 3 Clean up any fuel that may have spilled during Fittings - Gasoline/LPG Models this procedure. Maintaining PCV hoses is essential to good engine 4 Start the engine from the ground controls, then performance. Improperly functioning PCV hoses inspect the fuel filter and hoses for leaks. will fail to ventilate the crankcase and continued If a fuel leak is discovered, keep use of neglected hoses could result in component any additional personnel from damage. entering the area and do not operate the machine. Repair Perform this procedure with the the leak immediately. engine off.

4 - 42 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE D PROCEDURES

1 Remove the 2 engine pivot plate retaining bolts 5 Dry both hoses and inspect them for cracks and from under the engine pivot plate. Swing the damage. Replace the hoses if they are engine pivot plate away from the machine to damaged. access the PCV hoses.

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 part number 52229.

a b a D-8 Check the Toothed Belt a pivot plate retaining bolts b engine pivot plate - Deutz Diesel Models 2 Disconnect the hose from the PCV valve, then Complete information to perform this procedure is disconnect the hose from the engine. available in the Deutz FL 1011 Operation Manual (Deutz number: 0297 4706 EN). a Genie part number 29790.

D-9 Replace the Timing Belt

c - Gasoline/LPG Models Complete information to perform this procedure is available in the Ford LRG-423 2.3 Liter Industrial Engine Service Manual (Ford number: PPD-194- b 287). Genie part number 33907.

a carburetor to valve cover hose b PCV valve c PCV valve to carburetor hose 3 Disconnect the hose from the carburetor, then disconnect the hose from the valve cover. 4 Clean the hoses with a mild cleaning solvent.

Part No. 48412 Genie S-60 & Genie S-65 4 - 43 Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE D PROCEDURES

D-10 9 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and Grease the Steer Axle down. Wheel Bearings - 2WD Models Result: If there is side to side or up and down Maintaining the steer axle wheel bearings is movement, proceed to step 10 to replace the essential for safe machine operation and service wheel bearings with new ones. life. Operating the machine with loose or worn When replacing a wheel bearing, wheel bearings may cause an unsafe operating both the inner and outer bearings, condition and continued use may result in including the pressed-in races, component damage. Extremely wet or dirty must be replaced. conditions or regular steam cleaning and pressure washing of the machine may require that this Result: If there is no side to side or up and procedure be performed more often. down movement, grease the wheel bearings. 10 Remove the castle nut. 1 Loosen the wheel lug nuts. Do not remove them. 11 Pull the hub off of the spindle. The washer and outer bearing should fall loose from the hub. 2 Block the non-steering wheels, then center a lifting jack under the steer axle. 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the 3 Raise the machine 6 inches (15 cm) and place rear bearing. blocks under the drive chassis for support. 13 Pack both bearings with clean, fresh grease. 4 Remove the lug nuts, then remove the tire and wheel assembly. 14 Place the large inner bearing into the rear of the hub. 5 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and 15 Install a new bearing grease seal into the hub down. by pressing it evenly into the hub until it is flush. Result: There should not be any side to side or Always replace the bearing grease up and down movement. seal when removing the hub. Skip to step 10 if there is no movement. 16 Slide the hub onto the yoke spindle. Component damage. Do not 6 Remove the dust cap from the hub, then apply excessive force or damage remove the cotter pin from the castle nut. to the lip of the seal may occur. 7 Tighten the castle nut to 35 foot-pounds 17 Place the outer bearing into the hub. (47 Nm) to seat the bearings. 18 Install the washer and slotted nut. 8 Loosen the castle nut, then re-tighten to 8 foot-pounds (11 Nm). 19 Tighten the slotted nut to 35 foot-pounds (47 Nm) to seat the 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 420 foot-pounds (569.5 Nm). 4 - 44 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Troubleshooting Flow Charts

Before Troubleshooting:

Read, understand and obey the safety rules and operating instructions printed in the Genie S-60 & Genie S-65 Operator’s Manual. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Read each appropiate flow chart thoroughly. Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous completed by a person trained and qualified on conditions. the repair of this machine. Be aware of the following hazards and follow Immediately tag and remove from service a generally accepted safe workshop practices. damaged or malfunctioning machine. Crushing hazard. When testing Repair any machine damage or malfunction or replacing any hydraulic before operating the machine. component, always support the structure and secure it Unless otherwise specified, perform each from movement. repair procedure with the machine in the following configuration: Electrocution hazard. Contact with electrically charged circuits · Machine parked on a flat level surface may result in death or serious · Boom in stowed position injury. Remove all rings, watches · Turntable rotated with the boom between and other jewelry. the non-steering wheels Bodily injury hazard. Spraying · Turntable secured with the turntable hydraulic oil can penetrate and rotation lock pin burn skin. Loosen hydraulic · Key switch in the OFF position with the connections very slowly to allow key removed the oil pressure to dissipate gradually. Do not allow oil to · Wheels chocked squirt or spray. Perform all troubleshooting on a firm level surface. Two persons will be required to safely perform some troubleshooting procedures.

Part No. 48412 Genie S-60 & Genie S-65 5 - 1 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

TROUBLESHOOTING FLOW CHARTS

About This Section General Repair Process When a malfunction is discovered, the flow charts in this section will help a service professional Malfunction Identify Troubleshoot pinpoint the cause of the problem. To use this discovered symptoms section, basic hand tools and certain pieces of test equipment are required—voltmeter, ohmmeter, pressure gauges. problem still exists The location of terminals mentioned in this section can be found on the appropriate electrical or Return to Inspect Perform hydraulic schematics provided in Section 6, service problem and test repair Schematics. solved 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.

5 - 2 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 1

Engine Will Not less than Check battery condition Check battery voltage. 12V OR check alternator Crank Over OR check battery cables OR replace the battery. Be sure the key switch 12V or more is in the appropriate position. With the keyswitch Trace circuit back Be sure that both turned to ground 0V through the key switch, Emergency Stop controls and both emergency stop button Emergency Stop buttons and CB2, repair open. buttons are pulled out to are pulled out to the ON the ON position. position, check the voltage at the center Be sure the circuit terminal on the start toggle switch TS11. breakers are not tripped. 12V Be sure the battery is Hold the start toggle Repair open in jumper fully charged. switch to either side and 0V wire from one side of the check the voltage at switch to the other OR either side terminal on replace start toggle start switch. switch TS11.

12V

Hold the start switch to 0V Repair blk wire circuit either side and check from start switch TS11 voltage at terminal to TB33. TB33.

12V

Hold the start switch to Repair blk wire circuit either side and check 0V from TB33 to terminal voltage at terminal #3 on #3 on ignition/start ignition/start module. module.

12V

Hold the start switch to Repair open in red either side and check 0V power supply wire circuit voltage at terminal #6 on from CB1 to CR1 to CR2 the ignition/start module. then to terminal #6 to on ignition/start module.

12V

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 3 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 1

Hold the start switch to 0V Check ground wire to bad Continued from the either side and check terminal #5 on start Repair open in ground previous page. voltage at terminal #1 on lockout module. wire. ignition/start module. good

Consult Genie Industries 12V Service Department.

Hold the start switch to Repair open in blk wire either side and check 0V from terminal #1 on voltage at terminal #86 ignition/start module to on CR1. CR1.

12V

Check voltage at 0V Repair open in red wire terminal #30 on CR1. circuit from battery to CB1 to CR1 terminal #30. 12V

Hold the start switch to 0V Check brown ground bad Repair open in brown either side and check wire to terminal #85 on ground wire circuit to voltage at terminal #87 CR1. CR1. on CR1. good

Replace CR1 relay. 12V

Hold the start switch to 0V Repair open in blk wire either side and check circuit from CR1 to voltage at the black wire starter solenoid. on the starter solenoid.

12V

Check voltage at starter 0V Repair open in battery cable. cable to starter.

12V

Repair or replace starter or starter solenoid.

5 - 4 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 2

Engine Cranks less With the keyswitch than Check battery condition turned to ground 11V OR check alternator OR Over But Will controls and both check for short circuits Emergency Stop buttons OR check battery cables Not Start - pulled out to the on OR replace the battery. Gasoline/LPG position, hold start switch to either side and Models check battery voltage while engine is cranking. Be sure to check the engine oil level and fill more than 11V as needed. Check if engine coolant continuity Check if radiator and/or hot Check engine coolant temperature sending engine block feels level OR check radiator Be sure to check fuel unit signal post has excessively hot. fins for clogging OR levels and engine continuity to ground. check engine fan belts coolant level. OR see Ford service manual for Be sure the gasoline troubleshooting an not hot overheating engine. shut-off valve is in the ON or OPEN position.

Be sure that automatic Remove wht wire from continuity Replace temperature choke is not sticking temperature sending switch sender. closed. unit, check continuity to ground on temperature Perform following tests sending unit. in gasoline mode only. no continuity Be sure that the water no continuity temperature gauge Remove wht wire from continuity Repair short in wht wire TB24 and check circuit from TB24 to does not show an continuity to ground. temperature sender. overheated condition. no continuity

Repair short in wht wire circuit from terminal #10 on ignition/start module to TB24 OR consult Genie Industries Service Department.

good Remove #1 spark plug spark and ground spark plug Go to Chart 2A. body. Crank engine and observe spark.

weak or no spark

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 5 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 2

Disable starter by See Ford service Continued from the removing blk wire at the 12V manual for previous page. starter solenoid, hold the troubleshooting ignition start switch to either system. side and check voltage at the white wire on the ignition coil plug.

less than 12V

Hold the start switch to 12V Repair open in wht #21 either side and check wire from CR2 to ignition voltage at wht #21 on coil. terminal #87 of CR2.

0V

Check voltage at red 0V Repair open in red wire wire on terminal #30 of circuit from battery to CR2. TB20 to CB1 to CR1 to CR2. 12V

Hold the start switch to Hold start switch and Repair open in blk wire either side and check 0V check voltage at 12V from terminal #86 on voltage at terminal #86 terminal #9 on ignition/ CR2 to terminal #9 on of CR2. start module. ignition/start module.

0V

Check voltage at 0V Repair open in power terminal #6 on ignition/ supply wires from CB1 start module. to CR1 to CR2 to terminal #6 on ignition/ start module. 12V

no Check continuity from continuity Repair open in brown 12V ground wire at terminal ground wire to start #5 on start lockout lockout module. module to ground.

continuity

Consult Genie Industries Service Department.

Continued on the next page.

5 - 6 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 2

no Check continuity from continuity Repair open in brown Continued from the ground to terminal #85 ground wire circuit to previous page. on CR2. CR2.

continuity

If weak spark still exists, consult Ford engine service manual for troubleshooting engine with weak spark OR consult Genie Industries Service.

Part No. 48412 Genie S-60 & Genie S-65 5 - 7 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 2A

Engine Cranks Hold the start switch to Repair open in white either side and check #21 wire circuit from the Over But Will the voltage at the white 0V ignition coil plug to the wire on the choke while automatic choke. Not Start - cranking the engine. Gasoline/LPG Models 12V

Check automatic choke bad Adjust or replace or for proper adjustment or automatic choke OR internal damage. consult Genie Industries Engine Runs Service Department. While Cranking good Then Dies With keyswitch on and 0V Repair open in red/wht both Emergency Stop #23 wire circuit from buttons pulled out to the TB23 to vacuum switch. Perform these tests in ON position, check gasoline mode only. voltage at red/wht #23 wire on vacuum switch.

12V bad Remove the blk wire Turn machine off. See Replace vacuum switch. with diode from terminal 0V Repair section for how #86 on CR3, hold the the test the vacuum start switch to either switch. side and crank the engine over for 15 seconds and check ok voltage at red/blk wire bad on vacuum switch Check vacuum line for Replace vacuum line. (reconnect blk wire after restrictions or damage. test). ok

12V See Ford service manual to troubleshoot low manifold vacuum. With keyswitch on and both Emergency Stop buttons pulled out to the Repair open in red/blk ON position, disconnect 0V wire circuit from vacuum wires from vacuum switch to CR6. switch and connect the wires together. Check the voltage at terminal #86 on CR6.

12V

Continued on the next page.

5 - 8 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 2A

With keyswitch on and Repair open in red Continued from the both Emergency Stop 0V power wire circuit with previous page. buttons pulled out to the diode to fuel select ON position, crank toggle switch TS3. engine and check voltage at center terminal on fuel select switch TS3 in platform control box.

12V 0V With keyswitch on and Replace toggle switch. 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 Repair open in blu/wht both Emergency Stop 0V wire circuit from toggle buttons pulled out to the TS3 toggle switch to on position, crank TP38 to TB38. engine and check voltage at terminal TB38.

12V

With keyswitch on and 0V Repair open in blu/wht both Emergency Stop wire circuit from TB38 to buttons pulled out to the terminal #30 on CR6. ON position, crank engine and check voltage at blu/wht wire at terminal #30 on CR6.

12V

With keyswitch on and 0V Check brown ground no good Repair open in brown both Emergency Stop wire on terminal #85 of ground wire circuit to buttons pulled out to the CR6. CR6. ON position, crank the engine and check voltage at terminal #87 good on CR6. Replace CR6. 12V

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 9 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 2A

Hold the start switch to 0V Repair open in blu/wht Continued from the either side and check #38 wire circuit CR6 to previous page. voltage at blu/wht wire anti-diesel valve. on anti-diesel valve (on engine carburetor).

12V no Hold the start switch to 0V Check continuity from continuity Repair open in brown either side and check brown ground wire on ground wire circuit to voltage at blu/wht #38 fuel pump to ground. fuel pump. wire on fuel pump. continuity

Repair open in blu/wht #38 wire circuit from 12V anti-diesel valve to fuel pump.

Hold the start switch to Repair open in blu/wht either side and check 0V #38 wire circuit from fuel voltage at blu/wht #38 pump to gasoline wire on gasoline solenoid. solenoid (at gasoline tank).

12V

Hold the start switch to no Reconnect the two wires either side, does engine to vacuum switch and start? check for fuel line blockage OR replace anti-diesel valve OR see yes Ford service manual for troubleshooting fuel Go to chart 2B. pump and/or carburetor OR Consult Genie Industries Service Department.

5 - 10 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 2B

Engine Runs Hold start switch to 0V Crank engine and check 0V Check alternator wiring either side and check voltage at org/blk #41 OR repair or replace While Cranking voltage at terminal #2 on wire on alternator. alternator OR contact start lockout module. Genie Industries Service Then Dies Department. 6 to 7V

Repair open in org/blk #41 wire circuit from alternator to TB41 to 6 to 7V terminal #2 on start lockout module.

While cranking engine Disconnect wht #24 wire Check oil level OR for 15 seconds, check from oil pressure sender replace oil pressure continuity to ground on yes and check continuity to yes sending unit OR refer to terminal #10 start ground on signal post of Ford service manual for lockout module. Is sender, while cranking troubleshooting low oil continuity maintained? the engine. Is continuity pressure. maintained?

no

Disconnect wht #24 wire Check coolant level OR from water temperature replace water sender and check yes temperature sending continuity to ground on unit OR refer to Ford signal post of sender, service manual for while cranking the troubleshooting a engine. Is continuity overheated engine. maintained? no

no

Repair short to ground in wht #24 wire from sending units to TB24 to terminal #10 on ignition/ start module.

Check voltage at 12V Disconnect red wire Replace ignition/start terminal #4 on ignition/ from terminal #4 on 12V module OR consult start module. ignition/start module and Genie Industries Service check voltage at Department. terminal #4.

0V 0V

Test auxiliary power toggle switches TS1 and Replace start lockout TS10. See Repair module OR consult Section. Genie Industries Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 11 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 3

Engine Cranks less Hold the start switch to than Check battery condition either side and check 11V OR check alternator OR Over But Will battery voltage while check for short circuits engine is cranking. OR check battery cables Not Start - OR replace the battery. Deutz Diesel 11V or more Models

Check if engine over- continuity Check if oil cooler hot Check engine oil level Be sure to check the temperature sending and/or engine block OR oil cooler fins for engine oil level and fill signal post has feels excessively hot. clogging OR check as needed. continuity to ground. engine fan belts OR see Deutz service manual for troubleshooting an Be sure to check overheating engine. fuel level. not hot Be sure the diesel fuel shut-off valve is in Remove wht wire from continuity Replace temperature the on position. temperature sending switch sending unit. unit, check continuity to Be sure that the battery ground (on sending is fully charged. unit).

no continuity 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 Disable the starter by Turn the machine off infinite Replace the fuel ohms removing the blk wire at 12V and isolate the fuel solenoid. the starter solenoid. solenoid. Check the Hold the start switch to resistance of the either side and check solenoid. the voltage at positive terminal on fuel 3.50 ohms solenoid.

See Deutz service manual for 0V troubleshooting fuel system.

Continued on the next page.

5 - 12 Genie S-60 & 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 #21 Continued from the check voltage at wht 12V wire from CR2 to fuel previous page. #21 wire on terminal #87 solenoid. of CR2.

0V

Check voltage at red 0V Repair open in red wire wire on terminal #30 of circuit from battery to CR2. CB1 to CR1 to CR2.

12V

Hold the start switch to Repair open in blk wire Hold the start switch to 0V either side and check either side and check 12V 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.

0V

Check voltage at 0V Repair open in power terminal #6 and 7 on supply wires to terminal ignition/start module. #6 and 7 on ignition/start module. 12V

Check continuity from no Repair open in brown ground to brown wire at continuity ground wire circuit 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.

Check continuity from no Repair open in brown ground to terminal #85 continuity ground wire circuit to on CR2. CR2.

good

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 13 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 3

Crank engine and check 0V Crank engine and check 0V Repair or replace Continued from the voltage at org/blk #41 alternator OR contact previous page. voltage at terminal #2 on start lockout module. wire on alternator. Genie Industries Service Department. 6 to 7V

Repair open in org/blk #41 wire circuit from 6 to 7V alternator to TB41 to terminal #2 on start lockout module.

While cranking engine Disconnect wht #24 wire Check oil level OR for 15 seconds, check from oil pressure sender replace oil pressure continuity to ground on yes and check continuity to yes sending unit OR refer to terminal #10 on start ground on signal post of Deutz service manual lockout module. Is sender, while cranking for troubleshooting low continuity maintained? the engine. Is continuity oil pressure. maintained?

no

Disconnect wht #24 wire Check oil level OR from engine temperature replace engine sender and check yes temperature sending continuity to ground on unit OR refer to Deutz signal post of sender, service manual for while cranking the troubleshooting a engine. Is continuity overheated engine. no maintained?

no

Repair short to ground in wht #24 wire from sending units to TB24 to terminal #10 on ignition/ start module.

Check voltage at 12V Disconnect red wire Replace ignition/start terminal #4 on ignition/ from terminal #4 on 12V module OR consult start module. ignition/start module and Genie Industries Service check voltage at Department. terminal #4.

0V 0V

Test auxiliary power toggle switches TS1 and Replace ignition/start TS10. See Repair module OR consult Section. Genie Industries Service Department.

5 - 14 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 4

Engine Will Not Disconnect LPG supply line from LPG tank and Start On LPG, bleed pressure from But Will Start line. On Gasoline -

Gasoline/LPG With keyswitch on and 0V Replace fuel select Models both Emergency Stop switch. buttons pulled out to the ON position, check Be sure fuel select voltage at LPG side switch is switched (blu/red wire) of fuel to LPG. select switch.

Be sure to check 12V LPG fuel level. With keyswitch on and Repair open in blu/red both Emergency Stop 0V wire circuit from fuel buttons pulled out to the select switch to TP39 to ON position, check TB39. voltage at TB39.

12V

With keyswitch on and 0V Repair open in blu/red both Emergency Stop wire circuit from TB39 to buttons pulled out to the terminal #30 on CR7. ON position, check voltage at terminal #30 on CR7.

12V

Crank engine for 15 0V Repair open in red/blk seconds and check wire circuit from vacuum voltage at terminal #86 switch to CR6 to CR7. on CR7.

12V

Check continuity from bad Repair open in brown ground to brown wire on ground wire circuit to terminal #85 on CR7. terminal #85 on CR7.

good

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 15 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 4

0V Hold the start switch to Replace CR7 relay. Continued from the either side and check previous page. voltage at terminal #87 on CR7.

12V

Hold the start switch to Repair open in blu/red either side and check 0V wire circuit from CR7 voltage at blu/red wire terminal #87 to LPG on LPG solenoid. solenoid.

12V 0 or infinite Check resistance of ohms Replace LPG solenoid. 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 S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 5

Engine Will With keyswitch on and 0V Replace fuel select both Emergency Stop switch. Not Start On switches pulled out to the ON position, check Gasoline, voltage at gasoline side (blu/wht wire) of fuel But Will Start select switch. On LPG - Gasoline/LPG 12V Models With keyswitch on and Repair open in blu/wht both Emergency Stop 0V wire circuit from fuel Be sure fuel select buttons pulled out to the select switch to ON position, check TP38 to TB38. switch is switched voltage at TB38. to gasoline. 12V Be sure to check gasoline fuel level. With keyswitch on and 0V Repair open in blu/wht both Emergency Stop wire circuit from TB38 to Be sure that engine buttons pulled out to the terminal #30 on CR6. ON position, check choke is operating voltage at terminal #30 properly. on CR6.

12V

Crank engine for 15 0V Repair open in red/blk seconds and check wire circuit from vacuum voltage at terminal #86 switch to CR6. on CR6 while cranking.

12V no Check continuity from continuity Repair open in brown ground to brown wire at ground wire circuit to terminal #85 on CR6. terminal #85 on CR6.

continuity

Hold the start switch to Repair open in blu/wht either side and check 0V wire circuit from CR6 voltage at blu/wht wire terminal #87 on anti-diesel valve (on to anti-diesel valve OR carburetor). replace CR6.

12V

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 17 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 5

no Hold the start switch to 0V Check continuity from continuity Repair open in brown Continued from the either side and check ground to brown wire at ground wire circuit to the previous page. voltage at blu/wht wire fuel pump. fuel pump. on the fuel pump. continuity

Repair open in blu/wht wire from anti-diesel 12V solenoid to fuel pump OR replace fuel pump.

no Hold the start switch to Check continuity from continuity Repair open in brown either side and check 0V ground to brown wire at ground wire circuit to the voltage at blu/wht wire gasoline solenoid. gasoline solenoid. on gasoline solenoid (at fuel tank). continuity

Repair open in blu/wht wire from fuel pump to gasoline solenoid OR 12V replace gasoline solenoid.

0 or infinite Check resistance of ohms Replace gasoline gasoline solenoid. solenoid.

18 to 19 ohms 0 or infinite Check resistance of ohms Replace anti-diesel anti-diesel valve. valve.

24 to 25 ohms

less than Install a pressure gauge 7 psi Replace fuel pump OR to the fuel pump. Hold check anti-diesel and start switch to either fuel valve for defects 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.

5 - 18 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 6

Engine Start engine and move 0V Check voltage at center 0V Repair open in power the rpm select to high terminal on rpm select supply circuit to center High Idle idle (rabbit symbol) for switch TS4 and TS13. terminal of switch. Inoperative - following checks. Check voltage at blk/red wire 12V Gasoline/LPG on rpm select switch TS4 and TS13. Models Replace rpm select toggle switch. If high idle operates 12V on LPG but not on gasoline, see Ford 0V Check voltage at TB35. Repair open in blk/red service manual for wire circuit from toggle carburetor switch to TP35 to TB35. troubleshooting. 12V If high idle operates on gasoline but not Check voltage at 0V Repair open in blk/red on LPG, see Repair terminal #85 (blk/red) on wire circuit from section for LPG CR4. TB35 to CR4. regulator adjustments. 12V Be sure no Check continuity from continuity Repair open in brown linkage from governor ground to the brown ground wire circuit to to carburetor is not wire on terminal #86 of terminal #86 on CR4. binding. CR4.

Be sure high idle can continuity be achieved by grasping the governor actuator Check voltage at 0V Repair open in white terminal #30 on CR4. #21 power wire from arm and momentarily terminal 87 on CR2 to pulling to throttle the CR3 to CR4. carburetor. 12V

Check voltage at 12V Replace CR4 relay. terminal 87A on CR4.

0V

Check voltage at 12V Repair short in blk/red terminal 7 on electronic #R4 wire to terminal #7 governor. on precision governor.

0V

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 19 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 6

0V Repair open in wht wire Continued from the Check voltage at terminal #30 on CR3. circuit from CR2 previous page. terminal #87 to CR3 #30. 12V

Check voltage at 0V Repair open in rd/blk terminal #86 on CR3. #R6 wire circuit from vacuumn switch to CR6 to CR7 to terminal #86 on CR3. 12V

no Check continuity from continuity Repair open in ground ground to brown wire on wire to terminal #85 on terminal #85 of CR3. CR3.

continuity

0V Check voltage to Replace CR3 relay. terminal #87 on CR3.

12V

Check voltage at 0V Repair open in red/wht terminal 1 (red/wht wire) wire circuit from terminal on electronic governor. #87 on CR3 to terminal #1 on electronic governor. 12V

Check voltage at 0V Repair open in red/wht terminal 1 (red/wht wire) wire circuit from on governor actuator. electronic governor terminal #5 to governor actuator terminal #1. 12V

Check continuity from no Repair open in blu/blk terminal #6 on precision continuity wire circuit from governor to blu/blk governor actuator to terminal #2 on governor electronic governor. actuator.

full continuity

Continued on the next page.

5 - 20 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 6

Check voltage on red/ 0V Repair open in red/wht Continued from the wht wire on governor wire from governor previous page. actuator. controller to governor actuator. 12V

Turn machine off, 0 or remove both wires infinite from governor actuator ohms Replace governor and check resistance actuator. across governor actuator terminals.

2 to 3 ohms

Reconnect governor Repair open in brown wires and restart engine 0V wire circuit from ignition and check voltage at coil plug to electronic electronic governor governor. terminal 3 and 4 (brown wires).

12V

See Maintenance section for governor adjustments OR replace electronic governor.

Part No. 48412 Genie S-60 & Genie S-65 5 - 21 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 7

Engine Low Idle Start engine and switch Isolate the ground and rpm select to low idle 12V platform rpm toggle Inoperative - (turtle symbol). Check switches TS4 and TS13, voltage at terminal #86 check individually and Gasoline/LPG (blk/rd wire) on CR4. replace defective switch. Models 0V If low idle operates on LPG but not on Check voltage at 0V Repair open in wht wire gasoline, see Ford terminal #30 on CR4. circuit from terminal #87 on CR2 to CR4 terminal service manual for #30. carburetor 12V troubleshooting.

0V If low idle operates Check voltage at Replace CR4 relay. on gasoline but not terminal #87A on CR4. on LPG, see Repair section for LPG 12V regulator adjustments. Check voltage at 0V Repair open in blk/red Be sure throttle terminal #7 on wire circuit from CR4 electronic governor. terminal #87A to linkage from governor electronic governor to carburetor is not terminal #7. binding, see Repair 12V section.

Check voltage at Repair open in brown electronic governor 0V wire circuit from ignition terminal 3 and 4 (brown module to electronic wires). governor.

12V

Turn machine off, Recheck throttle linkage remove blu/blk wire from engine goes to high idle (see Repair section) OR terminal #6 on electronic check and/or replace governor and restart governor actuator OR engine. see Ford service manual for carburetor troubleshooting. engine goes to low idle

Recheck electronic governor adjustments OR replace electronic governor.

5 - 22 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 8

Engine Start engine, switch rpm Check high idle solenoid select switch to high idle adjustment (see pulls in High Idle (rabbit symbol) and Maintenance section) or check if 2-speed see Deutz workshop Inoperative - solenoid pulls in. manual to troubleshoot Deutz Diesel fuel injection system. solenoid does Models not pull in Be sure mechanical Check voltage at blk/red 0V Check voltage on red 0V Repair open in circuit linkage is not binding wire on rpm select wire at center terminal of supplying 12V to center or defective. switch TS4 and TS13. rpm select switch. terminal of switch.

Be sure 2-speed 12V solenoid grounding wires are free of 12V Replace toggle switch corrosion and have full continuity to ground. 0V Check voltage at TB35. Repair open in blk/red wire circuit from toggle switch to TP35 to TB35. 12V

Check voltage at 0V Repair open in blk/red terminal #30 on CR3. wire circuit from TB35 to terminal #30 on CR3. 12V

Check voltage to 0V Repair open in wht wire terminal #86 on CR3. circuit from terminal #87 on CR2 to terminal #86 on CR3. 12V

no Check continuity from continuity Repair open in brown ground to brown wire at ground wire circuit to terminal #85 on CR3. terminal #85 on CR3.

continuity

Check voltage to 0V terminal #87 on CR3. Replace CR3 relay.

12V

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 23 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 8

Continued from the Check voltage at 0V Repair open in blk/red previous page. terminal #86 on CR4. wire circuit from CR3 to CR4.

12V

Check continuity from bad Repair open in brown ground to brown wire at ground wire circuit to terminal #85 on CR4. terminal #85 on CR4.

good

Check voltage to 0V Repair open in wht wire terminal #30 on CR4. circuit from CR2 to CR3 to CR4. 12V

Check voltage at the 0V Replace CR4 relay blk/red wire on the OR repair open in 2-speed solenoid. blk/red wire circuit from terminal #87 on CR4 to 2-speed solenoid. 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 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 9

Engine At platform controls, Isolate the platform and start engine and switch 12V ground rpm switches, Low Idle rpm select switch TS4 to check individually and maintained low idle replace defective switch. Inoperative - (turtle symbol). Check voltage at blk/red wire Deutz Diesel on rpm select switch. Models 0V Check if 12V mechanical linkage Check voltage at the Replace CR4 relay. from 2-speed red wire on the 2-speed solenoid. solenoid to fuel injection system is 0V 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.

ok

See Deutz workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 25 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 10

All Functions Check hydraulic low Fill with Dexron fluid level. equivalent hydraulic Inoperative, fluid.

Engine Starts ok and Runs Check pump suction line closed Do the pumps feel yes If engine has been run shutoff valves. In the excessively hot? 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 no Department.

Open valves and start open the engine. Check all machine functions for correct operation.

Disconnect ignition coil spline Troubleshoot connector plug from turns inoperative boom ignition coils. On Deutz functions and diesel models, hold 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 at rear of main pump.

spline does not turn

Engine to pump flex plate coupling is defective OR main pump is defective. Consult Genie Industries Service Department.

5 - 26 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 11

All Lift and Install a 0 to 5000 PSI 2600 Troubleshoot each (345 bar) pressure psi or function individually or Steer Functions gauge on the function more consult Genie Industries manifold. Start engine, Service Department. Inoperative, move the function enable toggle switch to Drive Functions either side and hold the Operational boom retract function and check the hydraulic Be sure the hydraulic pressure. suction line shutoff less than valve for the lift/steer 2600 psi pump is in the open Adjust the function Move the function position. manifold system relief 2600 enable switch to either valve (item W) all the psi or side and hold the boom Be sure all grounding way in (clockwise) more retract switch and counting the number of readjust the relief wires for the hydraulic turns. Move the function pressure to 2600 psi for manifold valves are free enable switch to either S-60 or 2900 psi for side and hold the boom S-65 . of corrosion and have retract switch and full continuity to ground. recheck the pressure. less than 2600 psi steering Check steer functions. operates Repair or replace differential sensing valve (item V) OR repair or replace flow regulator valve (item AA) OR manifold has an internal defect, consult Genie steering inoperative Industries Service Department.

Check the function ok Replace the relief valve pump, see Repair (item W) OR manifold section. has an internal defect. Consult the Genie Industries Service Department. bad

Replace the function pump.

Part No. 48412 Genie S-60 & Genie S-65 5 - 27 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 12

Ground Does the engine start yes Start the engine from Repair open in red wire from the ground the ground controls. 0V circuit from key switch to Controls controls? Move the function function enable toggle enable toggle switch to switch to each function Inoperative, either side and check toggle switch. the voltage on the Platform center terminal of the Controls platform level toggle switch TS16. Operate Normally no 12V Be sure all other Troubleshoot each function individually. functions operate normally, including the platform controls. With both Emergency Repair open in red wire Stop buttons pulled out 0V circuit from emergency to the ON position, check stop button to the voltage at red wire on key switch. the input side of the ground controls contact of the key switch KS1 (the red wire checked should originate from the Emergency Stop button).

12V

With the keyswitch 0V Check if key switch yes Replace key switch turned to ground internal cam is activating contact for ground controls and both ground contact. controls. Emergency Stop buttons are pulled out to the ON no position, check voltage at red wire at the output side of the ground Replace key switch controls contact on the KS1. key switch.

12V

Repair open in red wire circuit from key switch to function enable toggle switch to each function toggle switch.

5 - 28 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 13

Platform Does engine start from yes Start engine from the Test or replace foot the platform controls? platform controls, then 0V switch (see Repair Controls press down the foot Section) OR repair open switch and check in wht wire circuit from Inoperative, voltage at TP24. foot switch to TP24. Ground Controls 12V no Operate Repair open in wht wire circuit from TP24 to Normally function toggle switches and function controllers. Be sure all cables from chassis 0V Check voltage at TB22. Repair open in red wire through the cable circuit from key switch to track are in good TB22 OR Replace the condition with no platform controls contact 12V at the key switch. kinks or abrasions.

0V Check voltage at TP22. Repair open in blk-2 wire circuit from TB22 TP22. 12V

Check voltage at blk Repair open in blk wire wire on input side of 0V from TP22 to platform Emergency Emergency Stop button Stop button contact P2. P2.

12V

With the key switch 0V Check if Emergency yes Replace contact on turned to platform Stop switch the contact. Emergency Stop button controls and both P2. Emergency Stop buttons no pulled out to the on position, check the voltage on the output Replace the platform side of the platform Emergency Stop button. Emergency Stop button contact.

12V 0V Check voltage at TP23. Repair open in blk wire with diode from Emergency Stop button 12V to TP23.

Repair open in blk wire circuit from platform Emergency Stop button to TP26 to foot switch OR replace foot switch OR consult Genie Industries Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 29 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 14

Boom Up With key switch in Move the function Repair open in red/wht Function ground position and enable switch to either wire circuit from TB3 to both Emergency Stop 0V side and hold the boom 8 to 9V boom up/down buttons pulled out to the up toggle switch (TS17) proportional valve coil Inoperative ON position, move the on ground panel in the (item O) OR repair open function enable switch to up direction and check in brown ground wire Be sure all other either side and hold the voltage at TB3. circuit to valve coil. functions operate boom up toggle switch (TS17) on ground panel normally. in up direction and 0V check voltage on red/ wht wire on boom up/ With the keyswitch in 8 to 9V Repair open in red/wht down proportional valve platform position and wire from TP3 to TB3. coil (item O). both Emergency Stop buttons pulled out to the ON position, activate footswitch and boom function controller (BP1) on platform control panel in up direction and check voltage at TP3.

0V

Activate footswitch and 0V Repair open in power check voltage at "+" supply circuit from TP24 terminal on BP1. to BP1 OR repair open in brown ground wire circuit from ground to 12V or more BP1.

Re-adjust controller (see Repair Section) OR replace controller BP1 OR consult Genie 20V or more Industries Service Department.

Continued on the next page.

5 - 30 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 14

With key switch in Move the function Repair open in red #1 Continued from the ground position and enable switch to either wire circuit from TB1 to previous page. 12V or both Emergency Stop 0V side and hold the boom more boom up function buttons pulled out to the up toggle switch (TS17) directional valve coil ON position, move the on ground panel in up (item B) OR repair open function enable switch to direction and check in brown ground wire either side and hold the voltage at TB1. circuit to valve coil. boom up toggle switch (TS17) on ground panel in up direction and 0V check voltage on red #1 wire on boom up/down With key switch in Troubleshoot boom up directional valve coil platform position and function toggle switch (item B). both Emergency Stop 12V or (TS17) on ground buttons pulled out to the more control panel OR repair ON position, activate open in red #1 wire footswitch and boom circuit from TS17 to TB1 function controller (BP1) OR consult Genie on platform control Industries Service panel in up direction and Department. check voltage TB1.

0V 12V or Activate footswitch and more Repair open in red wire boom function controller from TP1 to TB1. (BP1) on platform control panel in up direction and check voltage TP1.

0V

Activate footswitch and 0V Repair open in power 20V or more check voltage at "+" supply circuit from TP24 terminal on BP1. to BP1 OR repair open in brown ground wire circuit from ground to 12V or more BP1.

Re-adjust controller (see Repair Section) OR replace controller BP1 OR consult Genie Industries Service Department.

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 31 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 14

Disconnect wires to 0 or Continued from the boom up directional infinite previous page. valve coil (item B) and ohms Replace boom up directional valve coil test the resistance of the (item B). 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 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 2500 restrictions keeping gauge at the quick PSI or boom from moving OR disconnect coupling on more 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 at the 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 Replace defective flow valve (item G). Check regulator valve. boom up function.

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 S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 15

Boom Down With key switch in Move the function Repair open in red/wht Function ground position and enable switch to either wire circuit from TB3 to both Emergency Stop 0V side and hold the boom 6 to 7V boom up/down buttons pulled out to the down toggle switch proportional valve coil Inoperative ON position, move the (TS17) on ground panel (item O) OR repair open function enable switch to in the down direction in brown ground wire Be sure all other either side and hold the and check voltage at circuit to valve coil. functions operate boom down toggle TB3. switch (TS17) on ground normally. panel in down direction and check voltage on 0V red/wht wire on boom up/down proportional With the keyswitch in 6 to 7V Repair open in red/wht valve coil (item O). 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 (BP1) on platform control panel in down direction and check voltage at TP3.

0V

Activate footswitch and 0V Repair open in power check voltage at "+" supply circuit from TP24 terminal on BP1. to BP1 OR repair open in brown ground wire circuit from ground to 12V or more BP1.

Re-adjust controller (see Repair Section) OR 20V or more replace controller BP1 OR consult Genie Industries Service Department.

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 33 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 15

With key switch in Move the function Repair open in red/blk Continued from the ground position and enable switch to either #2 wire circuit from TB2 previous page. 12V or both Emergency Stop 0V side and hold the boom more to boom down function buttons pulled out to the down toggle switch directional valve coil ON position, move the (TS17) on ground panel (item B) OR repair open function enable switch to in down direction and in brown ground wire either side and hold the check voltage at TB2. circuit to valve coil. boom down toggle switch (TS17) on ground panel in down direction 0V and check voltage on red/blk #2 wire on boom With key switch in Troubleshoot boom function directional valve platform position and down function toggle coil (item B). both Emergency Stop 12V or switch (TS17) on ground buttons pulled out to the more control panel OR repair ON position, activate open in red/blk #2 wire footswitch and boom circuit from TS17 to TB2 function controller (BP1) OR consult Genie on platform control Industries Service panel in down direction Department. and check voltage TB2.

0V 12V or Activate footswitch and more Repair open in red/blk boom function controller wire from TP2 to TB2. (BP1) on platform control panel in down direction and check voltage TP2.

0V

Activate footswitch and 0V Repair open in power 20V or more check voltage at "+" supply circuit from TP24 terminal on BP1. to BP1 OR repair open in brown ground wire circuit from ground to 12V or more BP1.

Re-adjust controller (see Repair Section) OR replace controller BP1 OR consult Genie Industries Service Department.

Continued on the next page.

5 - 34 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 15

Disconnect wires to 0 or Continued from the boom down directional infinite previous page. valve coil (item B) and ohms Replace boom down test the resistance of the directional valve coil (item B). 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 down toggle switch at the ground controls in the down 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 2100 boom from moving OR disconnect coupling on PSI 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 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.

Part No. 48412 Genie S-60 & Genie S-65 5 - 35 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 16

Boom Extend With key switch in Move the function Repair open in blk/red Function ground position and enable switch to either wire circuit from TB9 to both Emergency Stop 0V side and hold the boom 9 to 10V boom extend/retract buttons pulled out to the extend toggle switch proportional valve coil Inoperative ON position, move the (TS19) on ground panel (item M) OR repair open function enable switch to in the extend direction in brown ground wire Be sure all other either side and hold the and check voltage at circuit to valve coil. functions operate boom extend toggle TB9. switch (TS19) on ground normally. panel in extend direction and check voltage on 0V blk/red wire on boom extend/retract With keyswitch in 9 to 10V Repair open in blk/red proportional valve coil platform position and wire from TP9 to TB9. (item M). 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 0V Repair open in power check voltage at "+" supply circuit from TP24 terminal on BP2. to BP1 to BP2 OR repair open in brown ground wire circuit from ground 12V or more to BP2.

Re-adjust controller (see 20V or more Repair Section) OR replace controller BP2 OR consult Genie Industries Service Department.

Continued on the next page.

5 - 36 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 16

With key switch in Move the function Repair open in blk wire Continued from the ground position and enable switch to either circuit from TB7 to boom previous page. 12V or both Emergency Stop 0V side and hold the boom more extend function buttons pulled out to the extend toggle switch directional valve coil ON position, move the (TS19) on ground panel (item C) OR repair open function enable switch to in the extend direction in brown ground wire either side and hold the and check voltage at circuit to valve coil. boom extend/retract TB7. toggle switch (TS19) on ground panel in the extend direction and 0V check voltage on blk wire on boom function With key switch in Troubleshoot boom directional valve coil platform position and extend/retract function (item C). both Emergency Stop 12V or toggle switch (TS19) on buttons pulled out to the more ground control panel OR ON position, activate repair open in blk wire footswitch and boom circuit from TS19 to TB7 extend/retract OR consult Genie proportional controller Industries Service (BP2) on platform Department. control panel in extend direction and check voltage TB7.

0V 12V or Activate footswitch and more Repair open in blk wire boom extend/retract from TP7 to TB7. proportional controller (BP2) on platform control panel in extend direction and check voltage TP7.

20V or more 0V

Activate footswitch and 0V Repair open in power check voltage at "+" supply circuit from TP24 terminal on BP2. to BP1 to BP2 OR repair open in brown ground wire circuit from ground 12V or more to BP2. Re-adjust controller (see Repair Section) OR replace controller BP2 OR consult Genie Industries Service Department.

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 37 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 16

Disconnect wires to 0 or Continued from the boom extend directional infinite previous page. valve coil (item C) and ohms Replace boom extend directional valve coil test the resistance of the (item C). 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 extend toggle switch at the ground controls in the extend 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 2500 restrictions keeping gauge at the quick PSI or boom from extending disconnect coupling on more 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 extend toggle switch at the ground controls in the extend direction and check the pressure.

less than 2500 PSI function Exchange flow regulator operates Replace defective flow valve (item H) with a like regulator valve. valve (item G). Check boom extend function.

function inoperative

Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal defect. Consult Genie Industries Service Department.

5 - 38 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 17

Boom Retract With key switch in Move the function Repair open in blk/red Function ground position and enable switch to either wire circuit from TB9 to both Emergency Stop 0V side and hold the boom 9 to 9.5V boom extend/retract buttons pulled out to the retract toggle switch proportional valve coil Inoperative ON position, move the (TS19) on ground panel (item M) OR repair open function enable switch to in the retract direction in brown ground wire Be sure all other either side and hold the and check voltage at circuit to valve coil. functions operate boom retract toggle TB9. switch (TS19) on ground normally. panel in the retract direction and check 0V voltage on blk/red wire on boom extend/retract With keyswitch in 9 to 9.5V Repair open in blk/red proportional valve coil platform position and wire from TP9 to TB9. (item M). 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 0V Repair open in power check voltage at "+" supply circuit from TP24 terminal on BP2. to BP1 to BP2 OR repair open in brown ground wire circuit from ground 12V or more to BP2.

Re-adjust controller (see 20V or more Repair Section) OR replace controller BP2 OR consult Genie Industries Service Department.

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 39 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 17

With key switch in Move the function Repair open in blk/wht Continued from the ground position and enable switch to either wire circuit from TB8 to previous page. 12V or both Emergency Stop 0V side and hold the boom more boom retract function switches pulled out to retract toggle switch directional valve coil the ON position, move (TS19) on ground panel (item C) OR repair open the function enable in the retract direction in brown ground wire switch to either side and and check voltage at circuit to valve coil. hold the boom extend/ TB8. retract toggle switch (TS19) on ground panel in the retract direction 0V and check voltage on blk/wht wire on boom With key switch in Troubleshoot boom function directional valve platform position and extend/retract function coil (item C). both Emergency Stop 12V or toggle switch (TS19) on switches pulled out to more ground control panel OR the ON position, activate repair open in blk/wht footswitch and boom wire circuit from TS19 to extend/retract TB8 OR consult Genie proportional controller Industries Service (BP2) on platform Department. control panel in the retract direction and check voltage TB8.

0V 12V or Activate footswitch and more Repair open in blk/wht boom extend/retract wire from TP8 to TB8. proportional controller (BP2) on platform control panel in the retract direction and check voltage TP8.

20V or more 0V

Activate footswitch and 0V Repair open in power check voltage at "+" supply circuit from TP24 terminal on BP2. to BP1 to BP2 OR repair open in brown ground wire circuit from ground 12V or more to BP2. Re-adjust controller (see Repair Section) OR replace controller BP2 OR consult Genie Industries Service Department.

Continued on the next page.

5 - 40 Genie S-60 & 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 boom retract directional infinite previous page. valve coil (item C) and ohms Replace boom retract directional valve coil test the resistance of the (item C). 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 at the 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 2500 restrictions keeping gauge at the quick PSI or boom from retracting disconnect coupling on more 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 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.

Part No. 48412 Genie S-60 & Genie S-65 5 - 41 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 18

Turntable With key switch in Move the function Repair open in wht/red Rotate Left ground position and enable switch to either wire circuit from TB6 to both Emergency Stop side and hold the 4 to 6V turntable rotate left/right buttons pulled out to the 0V turntable rotate toggle proportional valve coil Function ON position, move the switch (TS18) on ground (item R) OR repair open function enable switch to panel in the left direction in brown ground wire Inoperative either side and hold the and check voltage at circuit to valve coil. turntable rotate toggle TB6. Be sure all other switch (TS18) on ground functions operate panel in the left direction normally. and check voltage on wht/red wire on turntable rotate left/right proportional valve coil 0V (item R).

With keyswitch in 4 to 6V Repair open in wht/red platform position and wire from TP6 to TB6. both Emergency Stop buttons pulled out to the on position, activate footswitch and turntable rotate left/right proportional controller (BP1) on platform control panel in the left direction and check voltage at TP6.

0V

Activate footswitch and 0V Repair open in power 20V or more check voltage at "+" supply circuit from TP24 terminal on BP1. to BP1 OR repair open in brown ground wire circuit from ground to 12V or more BP1.

Re-adjust controller (see Repair Section) OR replace controller BP1 OR consult Genie Industries Service Department.

Continued on the next page.

5 - 42 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 18

With key switch in Move the function Repair open in wht/blk Continued from the ground position and enable switch to either wire circuit from TB5 to previous page. 12V or both Emergency Stop side and hold the more turntable rotate left buttons pulled out to the 0V turntable rotate left/right function directional valve ON position, move the toggle switch (TS18) on coil (item A) OR repair function enable switch to ground panel in the left open in brown ground either side and hold the direction and check wire circuit to valve coil. turntable rotate left/right voltage at TB5. toggle switch (TS18) on ground panel in the left direction and check 0V voltage on wht/blk wire on boom With key switch in Troubleshoot turntable function directional valve platform position and rotate left/right function coil (item A). both Emergency Stop 12V or toggle switch (TS18) on buttons pulled out to the more ground control panel OR ON position, activate repair open in wht/blk footswitch and turntable wire circuit from TS18 to rotate left/right TB5 OR consult Genie proportional controller Industries Service (BP1) on platform Department. control panel in the left direction and check voltage TB5.

0V 12V or Activate footswitch and more Repair open in wht/blk turntable rotate left/right wire from TP5 to TB5. proportional controller (BP1) on platform control panel in the left direction and check voltage TP5.

20V or more 0V

Activate footswitch and 0V Repair open in power check voltage at "+" supply circuit from TP24 terminal on BP1. to BP1 OR repair open in brown ground wire circuit from ground to 12V or more BP1. Re-adjust controller (see Repair Section) OR replace controller BP1 OR consult Genie Industries Service Department.

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 43 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 18

Disconnect wires to 0 or Continued from the turntable rotate left infinite previous page. directional valve coil ohms Replace turntable rotate (item A) and test the left directional valve coil resistance of the valve (item A). 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 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 PSI 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 function inoperative toggle switch at the ground controls in the Repair cylinder or left direction and check cylinder counterbalance the pressure. valve OR function manifold could have an internal defect. Consult Genie Industries Service Department.

less than 2600 PSI

Continued on the next page.

5 - 44 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 18

Plumb a 0 to 5000 psi lessthan Function manifold could Continued from the (0 to 345 bar) pressure 250 psi have an internal defect. previous page. 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 left function.

250 psi or more

Exchange turntable rotate left and right function counterbalance valves operates Replace defective (items II and JJ). counterbalance valve. Activate turntable rotate left function.

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.

Part No. 48412 Genie S-60 & Genie S-65 5 - 45 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 19

Turntable With key switch in Move the function Repair open in wht/red Rotate Right ground position and enable switch to either wire circuit from TB6 to both Emergency Stop side and hold the 4 to 6V turntable rotate left/right buttons pulled out to the 0V turntable rotate toggle proportional valve coil Function ON position, move the switch (TS18) on ground (item R) OR repair open function enable switch to panel in the right in brown ground wire Inoperative either side and hold the direction and check circuit to valve coil. turntable rotate toggle voltage at TB6. Be sure all other switch (TS18) on ground functions operate panel in the right normally. direction and check voltage on wht/red wire on turntable rotate left/ right proportional valve 0V coil (item R).

With keyswitch in 4 to 6V Repair open in wht/red platform position and wire from TP6 to TB6. both Emergency Stop buttons pulled out to the on position, activate footswitch and turntable rotate left/right proportional controller (BP1) on platform control panel in the right direction and check voltage at TP6.

0V

Activate footswitch and 0V Repair open in power 20V or more check voltage at "+" supply circuit from TP24 terminal on BP1. to BP1 OR repair open in brown ground wire circuit from ground to 12V or more BP1.

Re-adjust controller (see Repair Section) OR replace controller BP1 OR consult Genie Industries Service Department.

Continued on the next page.

5 - 46 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 19

With key switch in Move the function Repair open in wht wire Continued from the previous page. ground position and enable switch to either 12V or circuit from TB4 to both Emergency Stop side and hold the more turntable rotate right buttons pulled out to the 0V turntable rotate left/right function directional valve ON position, move the toggle switch (TS18) on coil (item A) OR repair function enable switch to ground panel in the right open in brown ground either side and hold the direction and check wire circuit to valve coil. turntable rotate left/right voltage at TB4. toggle switch (TS18) on ground panel in the right direction and check 0V voltage on wht wire on boom With key switch in Troubleshoot turntable function directional valve platform position and rotate left/right function coil (item A). both Emergency Stop 12V or toggle switch (TS18) on buttons pulled out to the more ground control panel OR ON position, activate repair open in wht wire footswitch and turntable circuit from TS18 to TB4 rotate left/right OR consult Genie proportional controller Industries Service (BP1) on platform Department. control panel in the right direction and check voltage TB4.

0V 12V or Activate footswitch and more Repair open in wht/blk turntable rotate left/right wire from TP4 to TB4. proportional controller (BP1) on platform control panel in the right direction and check voltage TP4.

20V or more 0V

Activate footswitch and 0V Repair open in power check voltage at "+" supply circuit from TP24 terminal on BP1. to BP1 OR repair open in brown ground wire circuit from ground to 12V or more BP1.

Re-adjust controller (see Repair Section) OR replace controller BP1 OR consult Genie Industries Service Department.

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 47 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 19

Disconnect wires to 0 or Continued from the turntable rotate right infinite previous page. directional valve coil ohms Replace turntable rotate (item A) and test the right directional valve resistance of the valve coil (item A). 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 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 PSI 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 function inoperative toggle switch at the ground controls in the Repair cylinder or right direction and check cylinder counterbalance the pressure. valve OR function manifold could have an internal defect. Consult Genie Industries Service Department.

less than 2600 PSI

Continued on the next page.

5 - 48 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 19

Plumb a 0 to 5000 psi lessthan Function manifold could Continued from the (0 to 345 bar) pressure 250 psi have an internal defect. previous page. 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.

250 psi or more

Exchange turntable rotate right and left function counterbalance valves operates Replace defective (items JJ and II). counterbalance valve. Activate turntable rotate right function.

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 & Genie S-65 5 - 49 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 20

All Platform Remove both hydraulic Replace the hoses from the manifold yes counterbalance valves Leveling (ports PL1 & PL2). Plug on function manifold the hoses and cap the (items A & B). Functions manifold fittings. Move the function enable Inoperative switch to either side and activate the boom up Be sure all other function and check to functions operate see if platform levels. normally. no

Plumb a 0 to 5000 psi 2000 Check for mechanical (0 to 345 bar) pressure PSI 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 2000 PSI Repair or replace the gauge into the barrel- master cylinder. end hydraulic hose from the master cylinder and raise the primary boom one inch at a time. Continually monitor the pressure gauge during boom up. Do not allow the pressure to exceed 2500 PSI.

2000 PSI or more

Repair or replace the slave cylinder.

5 - 50 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 21

Platform Level With the keyswitch With the keyswitch Repair open in org wire turned to ground control turned to ground control 12V or from TB14 to platform Up Function and both Emergency and both Emergency more level up directional valve Stop buttons pulled out Stop buttons pulled out coil (item S) OR repair Inoperative to the ON position, move to the on position, move open in brown ground the function enable 0V the function enable wire circuit to valve coil. Be sure all other switch to either side and switch to either side and functions operate activate the platform activate the platform level toggle switch TS16 level toggle switch TS16 normally. in the up direction and in the up direction and check the voltage at org check the voltage at wire on platform level up TB14. function directional valve (item S). 0V

With the keyswitch Troubleshoot platform turned to platform level toggle switches control and both TS16 and TS7 on Emergency Stop buttons ground and platform pulled out to the on 0V control panels OR repair position, activate the open in red power wire footswitch and the circuit to TS16 and TS7 platform level toggle OR repair open in org switch TS7 in the up wire circuit from TS16 direction and check the and TS7 to TB14 OR voltage at TB14. consult Genie Industries Service Department. 12V or more

Troubleshoot platform level toggle switch TS16 on ground control panel 12V or more OR repair open in red power wire circuit to TS16 OR repair open in org wire circuit from TS16 to TB14 OR consult Genie Industries Service Department.

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 51 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 21

Disconnect the wires 0 or Continued from the from the platform level infinite previous page. up directional valve coil ohms Replace the platform (item S) and test the level up directional valve coil (item S). resistance of the valve coil.

6 to 7 ohms

Exchange platform level function up and down directional operates Replace the defective valves (items S and U) directional valve. and activate the platform level up function.

function inoperative

Exchange platform level function up and down operates Replace the defective counterbalance valves counterbalance valve. (items EE and FF) and activate the platform level up function.

function inoperative

Install a 0 to 3000 Check for mechanical (0 to 207 bar) pressure 2600 psi restrictions keeping gauge at the quick or more 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 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 22

Platform Level With the keyswitch With the keyswitch Repair open in org/blk Down Function turned to ground control turned to ground control 12V or wire from TB15 to and both Emergency and both Emergency more platform level down Stop buttons pulled out Stop buttons pulled out directional valve coil Inoperative to the ON position, move to the on position, move (item U) OR repair open the function enable 0V the function enable in brown ground wire Be sure all other switch to either side and switch to either side and circuit to valve coil. functions operate activate the platform activate the platform level toggle switch TS16 level toggle switch TS16 normally. in the down direction in the down direction and check the voltage at and check the voltage at org/blk wire on platform TB15. level down function directional valve 0V (item U).

With the keyswitch Troubleshoot platform turned to platform level toggle switches control and both TS16 and TS7 on Emergency Stop buttons ground and platform pulled out to the on 0V control panels OR repair position, activate the open in red power wire footswitch and the circuit to TS16 and TS7 platform level toggle OR repair open in org/ switch TS7 in the down blk wire circuit from direction and check the TS16 and TS7 to TB15 voltage at TB15. OR consult Genie Industries Service Department. 12V or more

Troubleshoot platform level toggle switch TS16 on ground control panel 12V or more OR repair open in red power wire circuit to TS16 OR repair open in org/blk wire circuit from TS16 to TB15 OR consult Genie Industries Service Department.

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 53 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 22

Disconnect the wires 0 or Continued from the from the platform level infinite previous page. down directional valve ohms Replace the platform coil (item U) and test the level down directional valve coil (item U). resistance of the valve coil.

6 to 7 ohms

Exchange platform level function down and up directional operates Replace the defective valves (items U and S) directional valve. and activate the platform level down function.

function inoperative

Exchange platform level function down and up operates Replace the defective counterbalance valves counterbalance valve. (items FF and EE) and activate the platform level down function.

function inoperative

Install a 0 to 3000 Check for mechanical (0 to 207 bar) pressure 2600 psi restrictions keeping gauge at the quick or more 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 S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 23

Platform Rotate With the keyswitch Repair open in grn/wht turned to ground control 0V wire from TS14 to TB19 Left Function and both Emergency to TP19 OR test toggle Stop buttons pulled out switch. See Repair Inoperative to the ON position, move Section. the function enable Be sure all other switch to either side and functions operate activate the platform rotate toggle switch normally. TS14 in the left direction and check voltage at grn/wht wire at TP19 at the platform controls.

12V

With keyswitch turned to 0V Check voltage on center 0V Repair open in red platform control and terminal of TS5. power wire circuit both Emergency Stop through controllers and buttons pulled out to the function toggle switches on position, activate to TS5. footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at the grn/ 12V wht wire at the jib delay capacitor.

With keyswitch turned to 12V Repair open in grn/wht platform control and wire from TP19 to jib both Emergency Stop delay capacitor. buttons pulled out to the on position, activate footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at TP19.

12V 0V

Activate footswitch and 12V Repair open in grn/wht platform rotate toggle wire from TS5 to TP19. 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 Continued on the next toggle switch TS5. page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 55 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 23

With keyswitch turned to Replace the jib delay Continued from the platform control and 0V capacitor OR repair previous page. both Emergency Stop open in brown ground buttons pulled out to the wire from capacitor to on position, activate ground. footswitch and platform rotate toggle switch TS5 in the left direction and check voltage at the red wire at the jib delay capacitor.

12V

Activate footswitch and 0V Repair open in red wire platform rotate toggle from jib delay capacitor switch TS5 in the left 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 0V repair open in power switch TS5 in the left 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.

12V

Activate footswitch and Repair open in cable platform rotate toggle 0V containing red and black switch TS5 in the left wires from CR14 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 0 or infinite Test the resistance of ohms Replace defective valve the valve coils. coil.

5.5 to 6.5 ohms

Continued on the next page.

5 - 56 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 23

no Check continuity from Repair open in brown Continued from the continuity brown ground wires on ground wire circuit to previous page. valve coils to ground. valve coils.

continuity function Exchange jib boom/ operates Repair open in brown platform rotate select ground wire circuit to valves (item AM). 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.

Part No. 48412 Genie S-60 & Genie S-65 5 - 57 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 24

Platform Rotate With the keyswitch Repair open in grn/wht turned to ground control 0V wire from TS14 to TB19 Right Function and both Emergency to TP19 OR test toggle Stop buttons pulled out switch. See Repair Inoperative to the ON position, move Section. the function enable Be sure all other switch to either side and functions operate activate the platform rotate toggle switch normally. TS14 in the right direction and check voltage at grn/wht wire at TP19 at the platform controls.

12V

With keyswitch turned to 0V Check voltage on center 0V Repair open in red platform control and terminal of TS5. power wire circuit both Emergency Stop through controllers and buttons pulled out to the function toggle switches on position, activate to TS5. footswitch and platform rotate toggle switch TS5 in the right direction and check voltage at the grn/ 12V wht wire at the jib delay capacitor.

With keyswitch turned to 12V Repair open in grn/wht platform control and wire from TP19 to jib both Emergency Stop delay capacitor. buttons pulled out to the on position, activate footswitch and platform rotate toggle switch TS5 in the right direction and check voltage at TP19.

12V 0V

Activate footswitch and 12V Repair open in grn/wht platform rotate toggle wire from TS5 to TP19. switch TS5 in the right direction and check voltage at the grn/wht wire on TS5.

0V

Test toggle switch. See Repair Section OR Continued on the next replace platform rotate page. toggle switch TS5.

5 - 58 Genie S-60 & 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 Continued from the platform control and 0V capacitor OR repair previous page. both Emergency Stop open in brown ground buttons pulled 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.

12V

Activate footswitch and 0V 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 0V 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.

12V

Activate footswitch and Repair open in cable platform rotate toggle 0V containing red and black switch TS5 in the right wires from CR14 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 0 or infinite Test the resistance of ohms Replace defective valve the valve coils. coil.

5.5 to 6.5 ohms

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 59 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 24

no Check continuity from Repair open in brown Continued from the continuity brown ground wires on ground wire circuit to previous page. valve coils to ground. valve coils.

continuity function Exchange jib boom/ operates Repair open in brown platform rotate select ground wire 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 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 25

Jib Boom Up With the keyswitch Move the function Repair open in grn wire turned to ground control enable switch to either from TB17 to jib boom Function 12V and both Emergency 0V side and activate the jib up directional valve OR Stop buttons pulled out boom toggle switch repair open in brown Inoperative, to the ON position, move TS15 in the up direction ground wire circuit to the function enable and check voltage at directional valve. S-65 Models switch to either side and TB17. activate the jib boom Be sure all other toggle switch TS15 in functions operate the up direction and 0V normally. check voltage at the grn wire on the jib boom up Repair open in red directional valve power wire circuit from (item BB). keyswitch to TS15 OR replace toggle switch TS15. 12V

With the keyswitch Activate the footswitch 12V Repair open in grn wire turned to platform 0V and the jib boom toggle from TP17 to TB17. control and both switch TS6 in the up Emergency Stop buttons direction and check pulled out to the ON voltage at TP17. position, activate the footswitch and the jib boom toggle switch TS6 0V in the up direction and check voltage at TB17. With the keyswitch Repair open in grn wire turned to platform 12V from TS6 to TP17 OR control and both replace jib boom toggle Emergency Stop buttons switch TS6. pulled out to the ON position, activate the footswitch and check the voltage on the center terminal of the jib boom toggle switch TS6.

0V 12V Check the voltage at 0V Repair open in red wire terminal #30 on CR13. from BP1 to CR13 OR repair open in brown ground wire circuit to CR13. 12V

0V Check the voltage at Replace CR13. terminal #87a on CR13.

12V

Continued on the next Repair open in red wire page. from terminal#87a on CR13 to TS6 OR consult Genie Industries Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 61 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 25

Activate footswitch and 12V Continued from the jib boom toggle switch Replace CR13. previous page. TS6 in the up direction and check voltage on the red and black wires at the jib/platform rotate select valves (item AM).

0V

Install a 0 to 5000 psi (0 Exchange jib boom/ function to 345 bar) pressure 2500 psi platform rotate select operates gauge at the quick or more valves (item AM). Replace defective valve. disconnect coupling on Activate footswitch and the function manifold jib boom up function. and activate the jib boom up function. function inoperative

Check for mechanical restrictions keeping jib boom up function from operating OR repair or replace jib boom cylinder OR replace counterbalance valve OR 0.035" orifice may less than 2500 psi 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 up function.

function inoperative

Consult Genie Industries Service Department.

5 - 62 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 26

Jib Boom Down With the keyswitch Move the function Repair open in grn/blk Function turned to ground control enable switch to either wire from TB18 to jib and both Emergency 0V side and activate the jib 12V boom down directional Stop buttons pulled out boom toggle switch valve OR repair open in Inoperative, to the ON position, move TS15 in the down brown ground wire the function enable direction and check circuit to directional S-65 Models switch to either side and voltage at TB18. valve. activate the jib boom Be sure all other toggle switch TS15 in functions operate the down direction and 0V normally. check voltage at the grn/blk wire on the jib Repair open in red boom down directional power wire circuit from valve (item BB). keyswitch to TS15 OR replace toggle switch TS15. 12V

With the keyswitch Activate the footswitch 12V Repair open in grn/blk turned to platform 0V and the jib boom toggle wire from TP18 to TB18. control and both switch TS6 in the down Emergency Stop buttons direction and check pulled out to the ON voltage at TP18. position, activate the footswitch and the jib boom toggle switch TS6 0V in the down direction and check voltage at TB18. With the keyswitch Repair open in grn/blk turned to platform 12V wire from TS6 to TP18 control and both OR replace jib boom Emergency Stop buttons toggle switch TS6. pulled out to the ON position, activate the footswitch and check the voltage on the center terminal of the jib boom toggle switch TS6.

0V

12V Check the voltage at 0V Repair open in red wire terminal #30 on CR13. from BP1 to CR13 OR repair open in brown ground wire circuit to CR13. 12V

0V Check the voltage at Replace CR13. terminal #87a on CR13.

12V

Continued on the next Repair open in red wire page. from terminal#87a on CR13 to TS6 OR consult Genie Industries Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 63 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 26

Activate footswitch and 12V 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).

0V

Install a 0 to 5000 psi (0 Exchange jib boom/ to 345 bar) pressure 2500 psi platform rotate select function gauge at the quick or more valves (item AM). operates Replace defective valve. disconnect coupling on Activate footswitch and the function manifold jib boom down function. and activate the jib boom down function. function inoperative

Check for mechanical restrictions keeping jib boom down function from operating OR repair or replace jib boom cylinder OR 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 S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 27

Oscillate Remove the chassis bad Re-adjust or replace cover at the non-steer linkage. Function end. Check the linkage for damage or improper Inoperative linkage adjustment. See Repair section, 10-6 Be sure all other How to Set Up the function operate Directional Valve normally. Linkage. good

Install a 0 to 2000 psi Adjust the sequence (0 to 138 bar) pressure less valve. See Repair gauge at the quick than procedure 10-5, How to disconnect coupling on 950 psi Adjust the Oscillate the oscillate manifold. Sequencing Valve Disconnect the oscillate Pressure OR consult linkage from non-steer Genie Industries Service axle. Start the engine Department. and manually activate the directional valve. Check the pressure.

950 psi

Consult Genie Industries Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 65 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 28

Steer Left With key switch in With key switch in 12V or Repair open in blu #36 platform position and platform position and more wire circuit from drive Function both Emergency Stop both Emergency Stop controller (DP1) to TP36 buttons pulled out to the buttons pulled out to the then to TB36. Inoperative ON position, activate 0V ON position, activate footswitch and steer footswitch and steer Be sure all other rocker switch on drive rocker switch on drive functions operate controller (DP1) in left controller (DP1) in left direction and check direction and check normally. voltage on TB36. voltage at the controller terminal with the blu wire attached.

0V

Repair or replace steer 12V or more microswitch on drive controller. Consult Genie Industries Service Department.

With key switch in Repair open in blu #36 platform position and 0V wire circuit that runs both Emergency Stop from TB36 to steer left buttons pulled out to the directional valve coil on ON position, activate steer manifold. footswitch and steer rocker switch on drive controller (DP1) 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 Replace steer left steer left directional infinite directional valve coil valve coil (item SS) on ohms (item SS) OR repair steer manifold and test open in brown ground the resistance of the wire to steer left valve valve coil. coil.

5 to 6 ohms

Continued on the next page.

5 - 66 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 28

Install a 0 to 5000 PSI 2600 Check for mechanical Continued from the (0 to 345 bar) pressure restrictions keeping previous page. PSI or gauge at the quick more 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. less than 2600 PSI

Repair or replace steer cylinder OR steer manifold could have an internal defect. Consult Genie Industries Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 67 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 29

Steer Right With key switch in With key switch in 12V or Repair open in blu/blk platform position and platform position and more #37 wire circuit from Function both Emergency Stop both Emergency Stop drive controller (DP1) to buttons pulled out to the buttons pulled out to the TP37 then to TB37. Inoperative ON position, activate 0V ON position, activate footswitch and steer footswitch and steer Be sure all other rocker switch on drive rocker switch on drive functions operate controller (DP1) in right controller (DP1) in right direction and check direction and check normally. voltage on TB37. voltage at the controller terminal with the blu/blk wire attached.

0V

Repair or replace steer 12V or more microswitch on drive controller. Consult Genie Industries Service Department.

With key switch in Repair open in blu/blk platform position and 0V #37 wire circuit that runs both Emergency Stop from TB37 to steer right buttons pulled out to the directional valve coil on ON position, activate steer manifold. footswitch and steer rocker switch on drive controller (DP1) in right direction and check voltage on blu/blk #37 wire on steer right directional valve coil (item SS) on steer manifold.

12V or more

Disconnect wires to 0 or Replace steer right steer right directional infinite directional valve coil valve coil (item SS) on ohms (item SS) OR repair steer manifold and test open in brown ground the resistance of the wire to steer right valve valve coil. coil.

5 to 6 ohms

Continued on the next page.

5 - 68 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 29

Install a 0 to 5000 PSI 2600 Check for mechanical Continued from the (0 to 345 bar) pressure restrictions keeping previous page. PSI or gauge at the quick more 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. less than 2600 PSI

Repair or replace steer cylinder OR steer manifold could have an internal defect. Consult Genie Industries Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 69 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 30

All Drive With the keyswitch less turned to platform than Check continuity of Repair open in power Functions control and both 12V brown ground wire from continuity supply circuit from TP24 Emergency Stop buttons terminal #3 on DP1 to to terminal #2 on drive Inoperative, pulled out to the ON ground. joystick (DP1). position, activate the All Other footswitch and check the no continuity Functions voltage at terminal #2 on the drive joystick (DP1). Operate Repair open in brown ground wire circuit from Normally ground to DP1. 12V or more Be sure the rpm toggle switch is in the less footswitch activated With the keyswitch than Check continuity of Repair open in power high idle position. turned to platform 12V brown ground wire from continuity supply circuit from TP24 control and both terminal #2 on the to terminal #1 on the Emergency Stop buttons horsepower limiter horsepower limiter Be sure the hydraulic pulled out to the ON circuit board to ground. circuit board. tank shut off valves are position, activate the in the OPEN position. footswitch and check the voltage at terminal #1 on no continuity the horsepower limiter Be sure machine is circuit board. Repair open in brown not in the free wheel ground wire circuit from configuration. ground to the horsepower limiter circuit board. 12V or more

With the drive speed With the drive speed 7 to 8V Replace horsepower selector toggle switch selector toggle switch limiter board. (TS8) in the high (TS8) in the high position, activate the 0V position, activate the footswitch and hold the footswitch and check the drive joystick in the full voltage at terminal #3 on forward position and the horsepower limiter check the voltage at board. terminal #10 on the horsepower limiter 0V board.

With the drive speed Repair open in org/blk selector toggle switch wire from alternator to (TS8) in the high 7 to 8V TB41 to TP41 to position, activate the terminal #3 on footswitch and check the horsepower limiter 9 to 12V voltage on the org/blk board. wire on the alterator.

0V

Repair or replace Continued on the next alternator. page.

5 - 70 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 30

Activate the footswitch Repair open in wire from Continued from the and hold the drive 0V terminal #10 on previous page. joystick in the full horsepower limiter forward position and board to terminal #6 on check the voltage at drive joystick. terminal #6 on the joystick controller.

9 to 12V no Connect the positve 0V Check continuity from continuity Repair open in brown lead from a voltmeter to terminal #3 on drive ground wire circuit from terminal #4 on the joystick to ground. terminal #3 on drive joystick and the negative joystick to ground. lead to terminal #5 on the joystick. Activate the continuity footswitch and hold the drive joystick in the full Replace drive joystick forward position and controller OR consult check the voltage Genie Industries Service across the #4 and #5 Department. terminals on the drive joystick controller.

2V no Connect the positve 0V Check continuity from continuity Repair open in brown lead from a voltmeter to terminal #3 on drive ground wire circuit from terminal #5 on the joystick to ground. terminal #3 on drive joystick and the negative joystick to ground. lead to terminal #4 on the joystick. Activate the continuity footswitch and hold the drive joystick in the full Replace drive joystick reverse position and controller OR consult check the voltage Genie Industries Service across the #5 and #4 Department. terminals on the drive joystick controller.

2V

Continued on the next page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 71 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 30

Activate the footswitch With the footswitch Repair open in wht wire Continued from the and hold the drive activated and the drive from terminal #4 on previous page. joystick in the full joystick in the full drive joystick to TS9 to forward position and 0V forward position, move 2V TP30 to TB30 through check the voltage the drive enable toggle drive enable limit switch across the wht #12 wire switch (TS9) to either (LS3) to TB12 to wht and the wht/blk #31 wire side and check the #12 wire on EDC quick on EDC. voltage across the wht disconnect plug. #12 wire and the wht/blk #31on EDC.

0V

With the footswitch 9 to 12V Repair open in blu/wht activated and the drive wire from TS9 to TP12 joystick in the full to TB12. forward position, move the drive enable toggle switch (TS9) to either side and check the voltage at the blu/wht wire on TS9.

0V 2V With the footswitch Repair open in wire from activated and the drive terminal #4 from drive joystick in the full 0V joystick DP1 OR replace forward position, check drive joystick controller the voltage on the OR consult Genie center terminal of the Industries Service drive enable toggle Department. switch (TS9).

9 to 12V

Replace drive enable toggle switch TS9.

Troubleshoot drive forward and drive reverse functions separately OR replace pump OR consult Genie Industries Service Department.

5 - 72 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 31

Drive Forward Disconnect the EDC voltage readings different Repair or replace the wire connector from the drive controller. Or Reverse drive pump, start engine, move the drive Function controller to full forward Inoperative position and note the voltage across terminals TB30 and TB31. Be sure all other Reverse the volt meter functions operate leads and move the normally including drive controller to full reverse position and drive in opposite note the voltage. direction of malfunction. voltage readings the same 0 or infinite ohms Check the resistance of Replace the EDC. the EDC.

20 to 24 ohms

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.

Part No. 48412 Genie S-60 & Genie S-65 5 - 73 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 32

Traction Any type of traction problem, consult Genie Function Industries Service Inoperative Department. Be sure all other functions operate normally.

5 - 74 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 33

Machine Will With the boom in the Check for correct wiring stowed position, check continuity of limit switches Not Drive At continuity from TB40 to (LS1 and LS2) OR ground. repair or replace boom Full Speed lift drive limit switch or boom extend limit Be sure all other switch. functions operate no continuity normally.

Be sure the machine is With the boom in the Repair short to ground not raised above or stowed position, check in orange wire shorted terminal #6 on continuity to ground from TB40 to extended beyond the horsepower limiter TP40 to terminal #6 on drive limit switches. board for continuity to horsepower limiter ground. circuit board. Be sure the boom drive limit switch is clear of no continuity any debris and is not activated when the Re-adjust or replace horsepower limiter boom is in the stowed board OR check for position. misalignment of limit switches (LS1 and LS2) Be sure that the boom OR consult Genie Industries Service extend drive limit switch Department. 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).

Part No. 48412 Genie S-60 & Genie S-65 5 - 75 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 34

Machine Drives Extend the boom past Replace horsepower the drive limit switch and limiter board OR re- At Full Speed check continuity from continuity adjust horsepower ground to terminal #6 on limiter board OR consult With Platform the horsepower limiter Genie Industries Service Raised or board. Department. Extended no continuity

Be sure boom drive limit Check continuity from continuity Repair open in org wire switch is being activated ground to TB40. circuit from TB40 to by the cam on the boom TP40 to terminal #6 on horsepower limiter when the boom is circuit board. raised. no continuity

Be sure that the boom extend drive limit switch Test limit switches. See bad Replace defective limit is not being held down procedure A-14 in the switch contact OR or being activated when Maintenance Section. replace limit switch. the boom is extended. good Be sure the wiring to Repair open from wht limit switches is intact wires at TB40 to drive and show no sign of limit switches (LS1 and damage or corrosion. LS2), then from brown ground wires to ground.

5 - 76 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts Chart 35

Drive Enable With keyswitch in With keyswitch in 0V Repair open in power platform position and platform position and supply circuit from System Is both Emergency Stop both Emergency Stop TP24. buttons pulled out to the no buttons pulled out to the Malfunctioning ON position and the ON position, activate boom rotated between footswitch and drive Be sure the boom is in the non-steer tires, controller in forward the stowed position. activate footswitch and direction and check drive controller in voltage at terminal #2 on forward direction. Will drive controller (DP1). unit drive? 12V or more

Repair open from terminal #4 on DP1 to center terminal on TS9 yes OR refer to Chart 30 OR consult Genie Industries Service Department.

With keyswitch in Hold the drive enable The machine is platform position and switch (TS9) to either operating correctly. If both Emergency Stop no side and activate the yes machine does not buttons pulled out to the footswitch and drive operate properly, ON position and the forward function. Will consult Genie Industries boom rotated between unit drive? Service Department. the steer end tires, activate footswitch and drive controller in no forward direction. Will unit drive? Repair open in blu/wht wire from drive enable toggle switch (TS9) to TP12 to TB12 OR replace drive enable yes toggle switch (TS9).

Check for continuity continuity Activate limit switch by Replace drive enable from TB30 to TB12. hand and check continuity limit switch contact OR continuity from TB30 to replace drive enable TB12. limit switch (LS3). no continuity no continuity

Repair open from TB30 Please begin through red wire to LS3 troubleshooting from then from LS3 through beginning of chart OR blk wire to TB12. consult Genie Industries Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 77 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition Chart 36

Auxiliary Lift the red auxiliary motor Install a 0 to 5000 psi Reconnect pressure pump switch cover operates (0 to 345 bar) pressure 2500 psi line and check battery Functions switch cover, hold gauge into the pressure condition. There is auxiliary switch and port of the auxiliary possibly not enough Inoperative listen for sound of pump and hold the battery capacity to auxiliary pump motor auxiliary power toggle operate both aux. pump Be sure all other operating. switch and note the and function valves. functions operate pressure. normally. less than 2500 psi Be sure key switch is in the appropriate Check for a positive good Repair or replace pump position and the connection between OR relief valve is out of electric motor and the adjustment. Consult Emergency Stop pump by removing the Genie Industries Service buttons are pulled pump from the motor, Department. but leave all the hoses out to the ON motor does connected. Visually position. not operate check coupling connection. Be sure engine is not running when bad using auxiliary power. Replace the auxiliary power unit. Note: Operating auxiliary power with the engine running bad With the keyswitch 0V Test PR1. See Repair Replace PR1. should immediately turned to ground control Procedure 8-5. kill the engine. and both Emergency Stop buttons pulled out good to the ON position, activate the auxiliary pump toggle switch and Activate the auxiliary 12V or check the voltage on the pump toggle switch and more Repair open from TB27 red cable on the check the voltage at to PR1. auxiliary power unit. TB27.

0V

Activate the auxiliary Repair open from pump toggle switch and 0V keyswitch (KS1) to check the voltage at the auxiliary toggle switch center terminal of TS10. (TS10). 12V 12V or more

Repair open in red #27 wire from TS10 to TB27 OR replace TS10 OR repair open in brown ground wire to PR1. Continued on the next page.

5 - 78 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 36

Check continuity from bad Replace negative cable Continued from the negative terminal on from auxiliary pump to previous page. auxiliary power unit to ground. ground.

good

Replace auxiliary pump motor.

Part No. 48412 Genie S-60 & Genie S-65 5 - 79 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

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5 - 80 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 6 - Schematics Schematics

About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution hazard. Contact with electrically charged circuits may Troubleshooting and repair procedures shall be result in death or serious injury. completed by a person trained and qualified on Remove all rings, watches and the repair of this machine. other jewelry. Immediately tag and remove from service a Hydraulic Schematics damaged or malfunctioning machine. Bodily injury hazard. Spraying Repair any machine damage or malfunction hydraulic oil can penetrate and before operating the machine. burn skin. Loosen hydraulic connections very slowly to allow Before Troubleshooting: the oil pressure to dissipate Read, understand and obey the safety rules gradually. Do not allow oil to squirt and operating instructions printed in the or spray. Genie S-60 and Genie S-65 Operator's General Repair Process Manual. Be sure that all necessary tools and test Malfunction Identify Troubleshoot equipment are available and ready for use. discovered symptoms

problem still exists

Return to Inspect Perform service problem and test repair solved

Part No. 48412 Genie S-60 & Genie S-65 6 - 1 Section 6 - Schematics Service Manual - Second Edition

Electrical Components

Item Description Genie Manufacturer Manufacturer Qty Part Number Part Number BAT ...... Battery, 1000 CCA, 12V DC .. 30143 ...... Trojan ...... C31XH-2 ...... 1

BP1 ...... Joystick controller Single axis, up/down...... 24495 ...... OEM Controls ...... EMS4M6883 ...... 1

BP2 ...... Joystick controller Dual axis, Swing/extend ...... 40613 ...... OEM Controls ...... EJS5M10089 ...... 1

CB1, CB2 ...... Circuit breaker ...... 24018 ...... ETA ...... 45-700-IG1-P10 ...... 2

CR1 through CR7 ...... Relay, SPDT, 12V DC ...... 34052 ...... 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

DP1 ...... Joystick controller-Drive ...... 20424 ...... OEM Controls ...... MCH1159AD1386 ...... 1

FB ...... Flashing beacon ...... 20189 ...... ECCO Electronic Controls ... 6400X ...... 2

FS1 ...... Footswitch...... 13482 ...... Linemaster Switch Corp...... 632-S ...... 1

G1 ...... Gauge - Voltage ...... 30789 ...... VDO ...... 332-502 ...... 1

G2 ...... Gauge - Oil Pressure...... 30786 ...... VDO ...... 350-516 ...... 1

G3 ...... Gauge - Water Temp...... 30787 ...... VDO ...... 310-502 ...... 1

H1 ...... Alarm, Warble tone ...... 19270 ...... Floyd Bell Inc...... MW-09-616-Q ...... 1

H2 ...... Horn, 12V DC, 130 dB ...... 19145 ...... Sparton Engineered Prod. ... 7431A-24823-5 ...... 1

H3 ...... Alarm, intermittent ...... 18963 ...... Floyd Bell Inc...... XB-09-630-Q ...... 1

H4 ...... Alarm, chime tone ...... 45462 ...... Floyd Bell Inc...... CH-09-525-Q ...... 1

HM ...... Hourmeter ...... 19506 ...... ENM Corporation ...... T40A4508 ...... 1

KS1 ...... Contact - Keyswitch, N.O...... 45081 ...... Telemecanique ...... ZB2-BE101 ...... 2

L1 ...... LED - Red, 12V DC ...... 32335 ...... Arctolectric Corp...... LE177C39007 ...... 1

LS1, 2, 3 ...... Contact - Limit switch, N.C.H.O...... 19491 ...... Telemecanique ...... XESP2051 ...... 3

Level sensor .. Level sensor, 4.5° ...... 44586 ...... Power Comp. of Midwest .... LS36 ...... 1

This list continues on the next page.

6 - 2 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 6 - Schematics

ELECTRICAL COMPONENTS

Item Description Genie Manufacturer Manufacturer Qty Part Number Part Number P1, P2 ...... Contact, N.C...... 29732 ...... Telemecanique ...... ZB2-BE102 ...... 4

P3 ...... Contact, N.O...... 45081 ...... Telemecanique ...... ZB2-BE101 ...... 1

PR1 ...... Relay, 12V DC continuous .... 27155 ...... Stancor ...... 70-902 ...... 1

R1 ...... Resistor, 100Ω 25 watt ...... 27116 ...... Dale ...... RH25-100R-1% ...... 1 Resistor, 150Ω 25 watt ...... 34798 ...... Dale ...... RH25-150-1% ...... 1

R2 ...... Resistor, 10Ω 25 watt ...... 27287 ...... Dale ...... RH25-10R-1% ...... 1

TS1, TS10 ...... Toggle switch, DPST 2 position momentary ...... 13480 ...... Microswitch Control Inc...... 2NT1-8 ...... 2

TS2, 6, 9, 11, 13, 15 ...... Toggle switch, SPDT 3 position momentary ...... 13037 ...... Microswitch Control Inc...... 1NT1-7 ...... 6

TS3, 8, 12, 20 ...... Toggle switch, DPST 2 position maintained ...... 27378 ...... Microswitch Control Inc...... 2NT1-3 ...... 4

TS4 ...... Toggle switch, DPDT 3 position maintained ...... 13038 ...... Microswitch Control Inc...... 2NT1-1 ...... 1

TS5,7,14,16, 17,18, 19 ...... Toggle switch, DPDT 3 position momentary ...... 16397 ...... Microswitch Control Inc...... 2NT1-7 ...... 7

VAC ...... Vacuum switch ...... 22278 ...... Peterson Industrial ...... 1501-L ...... 1

Part No. 48412 Genie S-60 & Genie S-65 6 - 3 Section 6 - Schematics Service Manual - Second Edition

Electrical Symbols Legend

TB17

15AMP. DP1

T1N.O. WTS1 BLK 1

2 GRN/BLK ORG/BLK-1 Circuit breaker 3 4 5 6 Water temperature 7 switch 8 normally open Wire color with cable Single axis FS1 number RED drive controller BLK Solenoid or Ground #51 WHT relay coil supression Foot switch TB20 circuit TR2 2

1 T 6

PLAT RED-5

WHT-5 3 TILT KS1 Terminal ALARM TB=Terminal base GRND Time delay relay TP=Terminal platform Key switch Horn NC NO TS3

TP29 LS3

START

ENGINE

BLK-5 GRN-5

Quick disconnect L4 OP HORN P4 Toggle switch SPDT terminal Limit switch Light Horn button BLK #21 TB21 normally open TS6

LS2 LEFT T-circuits connect NC RIGHT at terminal 10 Limit switch P1 normally closed Toggle switch DPDT Resistor held open Emergency Stop button BP2 T-circuits normally closed PWM A connect + - VAC X R

Vacuum switch CR4 Single axis Tilt sensor Connection proportional no terminal controller

P1N.C. OPS1 Relay contact normally open 1 START RELAY 2 TACHOMETER 3 START INPUT Spark plug 4 AUX. ON 5 GROUND PR4 Oil pressure 6 BATTERY Circuits crossing 7 KEY PWR. switch 8 KEY BYPASS no connection 9 IGN./FUEL ON normally closed 10 ENG. FAULT Relay panel contactor Ignition start module Glow plug BP1 Diode AUX. PUMP 1 D2 D1 2 A R 3 4 - + LS1 5 + - 6 R A

NO + 7 D1 D2 Auxiliary pump 8 9 10 Limit switch normally open Horsepower Dual axis

- held closed limiter board Ramp up and down proportional controller Battery

6 - 4 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 6 - Schematics

Abbreviation Legend

LABEL DESCRIPTION BAT ...... Battery BP ...... Proportional controller CB ...... Circuit breaker CR ...... Control relay DP ...... Drive proportional controller FB...... Flashing beacon FS...... Foot switch G ...... Gauge H...... Horn or Alarm HM...... Hour meter KS ...... Keyswitch L ...... LED LS ...... Limit switch P ...... Power switch PR ...... Power relay R...... Resistor TB...... Terminal base location TP...... Terminal platform location TS...... Toggle switch VAC ...... Vacuum switch

Part No. 48412 Genie S-60 & Genie S-65 6 - 5 Section 6 - Schematics Service Manual - Second Edition

6 - 6 Genie S-60 & Genie S-65 Part No. 48412 Section 6 - Schematics Service Manual

Electrical Schematic- REV B Gasoline/LPG Models AB C D E F G H I J K L M N

1

2

3

4

5

6

7

8

6 - 7 Genie S-60 & Genie S-65 Part No. 48412 Service Manual Section 6 - Schematics

REV B Electrical Schematic- Gasoline/LPG Models NM L K J I H G F E D C B A

1

2

3

4

5

6

7

8

Part No. 48412 Genie S-60 & Genie S-65 6 - 8 Service Manual - Second Edition Section 6 - Schematics

Ground Control Box Legend- Gasoline/LPG Models

Part No. 48412 Genie S-60 & Genie S-65 6 - 9 Section 6 - Schematics Service Manual - Second Edition

Ground Control Box Wiring Diagram- Gasoline/LPG Models

6 - 10 Genie S-60 & Genie S-65 Part No. 48412 Section 6 - Schematics Service Manual - Second Edition

Platform Control Box Legend- Gasoline/LPG Models

Part No. 48412 Genie S-60 & Genie S-65 6 - 11 Service Manual - Second Edition Section 6 - Schematics

Platform Control Box Wiring Diagram- Gasoline/LPG Models

6 - 12 Genie S-60 & Genie S-65 Part No. 48412 Section 6 - Schematics Service Manual

Electrical Schematic- Diesel Models AB C D E F G H I J K L M N

1

2

3

4

5

6

7

8

6 - 13 Genie S-60 & Genie S-65 Part No. 48412 Service Manual Section 6 - Schematics

Electrical Schematic- Diesel Models NM L K J I H G F E D C B A

1

2

3

4

5

6

7

8

Part No. 48412 Genie S-60 & Genie S-65 6 - 14 Section 6 - Schematics Service Manual - Second Edition

Ground Control Box Legend- Diesel Models

Part No. 48412 Genie S-60 & Genie S-65 6 - 15 Section 6 - Schematics Service Manual - Second Edition

Ground Control Box Wiring Diagram- Diesel Models

6 - 16 Genie S-60 & Genie S-65 Part No. 48412 Section 6 - Schematics Service Manual - Second Edition

Platform Control Box Legend- Diesel Models

Part No. 48412 Genie S-60 & Genie S-65 6 - 17 Service Manual - Second Edition Section 6 - Schematics

Platform Control Box Wiring Diagram- Diesel Models

6 - 18 Genie S-60 & Genie S-65 Part No. 48412 Section 6 - Schematics Service Manual - Second Edition

Part No. 48412 Genie S-60 & Genie S-65 6 - 19 Service Manual - Second Edition Section 6 - Schematics

Hydraulic Symbols Legend

Cylinder Pressure gauge Solenoid operated 2 pos., 4 way, directional valve Differential sensing valve

Accumulator Filter Solenoid operated 3 pos., 4 way, directional valve (DO1) 0.035 Orifice with size Solenoid operated proportional valve

2 pos., 3 way, shuttle valve Fixed displacement pump Variable orifice or shut-off valve

Flow regulator valve Bi-directional, Check valve 3 pos., 4 way, directional valve variable displacement pump

Solenoid operated 2 pos., Relief valve 3 way, directional valve Sequencing valve Bi-directional motor

Priority flow divider

Counterbalance valve 2-speed, Unloader valve bi-directional motor

E

Pump prime mover (engine or motor) Solenoid operated dump valve Pilot operated flow control valve Pressure compensating valve

6 - 20 Genie S-60 & Genie S-65 Part No. 48412 Service Manual Section 6 - Schematics

2WD Hydraulic Schematic Non-Oscillating Axle NM L K J I H G F E D C B A

JIB BOOM PLATFORM ROTATE 1 SLAVE TURNTABLE CYLINDER BOOM UP/DOWN X ROTATE

BOOM EXTENSION CYLINDER

X .035” 1 PRIMARY SECONDARY

II JJ AN 1200 BRAKE 2 SPEED .030” PSI 2 .030” AN JIB BOOM HH MANIFOLD MASTER

AM AM CYLINDER TWO SPEED/ .025” ACCUM. BRAKE MANIFOLD 250 PSI

PR1 PR2 PL1 PL2 S1 S2 P1 P2 OPTIONAL FUNCTION 3500 GENERATOR FF PSI EE 50 MANIFOLD 3 PSI 290 D PSI 2500 MEDIUM 2100 PSI PSI Y Z F PRESSURE GG X Q FILTER TEST P A B C E BB S

3500 CC U PSI AA I H G PRESS. GENERATOR 3.5 FUNCTION 0.6 SELECT GPM 0.6 N L K 4 E PUMP GPM DD T GPM R O M 14 GPM. PRESS. * S-60 Models = 2600 psi * PSI S-65 Models = 2900 psi DRIVE PUMP V W J 0.1 T1 GPM TANK 2500 PSI OPTIONAL 25 SEC REG OIL 3 3 PSI PSI PSI COOLER 5

SECOND COUNTERBALANCE VALVE ADDED M 1 AFTER SERIAL NUMBER 4862 RESERVOIR AUX. PUMP

RR

HYDRAULIC ROTARY 6 COUPLER STEER MANIFOLD

DRIVE MANIFOLD

250 PSI

M7 VV 7 REAR RIGHT M5 YY

WW M3 STEERING .070” CYLINDER 8 REAR XX LEFT M1

CASE DRAINS

Part No. 48412 Genie S-60 & Genie S-65 6 - 21 Service Manual Section 6 - Schematics

2WD Hydraulic Schematic Oscillating Axle NM L K J I H G F E D C B A

JIB BOOM PLATFORM ROTATE 1 SLAVE TURNTABLE BOOM UP/DOWN X ROTATE BOOM EXTENSION CYLINDER X .035” 1 PRIMARY SECONDARY

II JJ 1200 PSI BRAKE 2 SPEED .030” 2 .030” JIB BOOM MANIFOLD MASTER T CYLINDER HH .025” TWO SPEED/ ACCUM. BRAKE MANIFOLD 250 PSI P PR1 PR2 PL1 PL2 P1S1 S2 P2 OPTIONAL FUNCTION 2500 MOTOR/GEN. FF PSI EE 50 MANIFOLD 3 PSI 290 D PSI MEDIUM 2100 2500 Y Z PSI F PSI PRESSURE X GG Q P FILTER A C TEST BB B E S 3500 CC U I H PSI PRESS. AA G GENERATOR 5.0 FUNCTION SELECT 0.6 0.6 GPM N L K 4 E PUMP GPM T GPM DD R O M 14 GPM. * PRESS. * S-60 Models = 2600 psi PSI S-65 Models = 2900 psi DRIVE PUMP W V J 0.1 T1 GPM TANK 2500 PSI OPTIONAL 25 SEC REG 3 3 PSI OIL PSI PSI COOLER 5

SECOND COUNTERBALANCE VALVE ADDED M 1 AFTER SERIAL NUMBER 4862 RESERVOIR AUX. PUMP

RR OSCILLATE CYLINDERS

3.5 gpm HYDRAULIC TT UU ROTARY .025” SS 6 COUPLER STEER MANIFOLD OSCILLATE MANIFOLD DRIVE MANIFOLD LL KK P .052” P8 250 950 PSI PSI M7 VV 7 NN PP REAR A VALVE A CYL RIGHT QQ M5 YY B VALVE OO B CYL

WW MM

XX M3 STEERING .070” 8 REAR LEFT M1

CASE DRAINS Part No. 48412 Genie S-60 & Genie S-65 6 - 22 Service Manual Section 6 - Schematics

4WD Hydraulic Schematic Non-Oscillating Axle NM L K J I H G F E D C B A

JIB BOOM PLATFORM ROTATE 1 TURNTABLE SLAVE BOOM UP/DOWN X ROTATE BOOM EXTENSION CYLINDER X 1 PRIMARY SECONDARY TWO SPEED/ 0.035” BRAKE MANIFOLD JIB BOOM 0.030” II JJ 1200 1200 MANIFOLD PSI PSI BRAKE 2 SPEED 0.030” HH 2 AM AM

T MASTER 0.025” ACCUM. 250 PSI PLATFORM TURNTABLE P LEVEL BOOM PR1 PR2 PL1 PL2 S1 S2 P1 P2 EXTEND RETRACT OPTIONAL FUNCTION 3500 MOTOR/GENERATOR PSI 50 MANIFOLD EE FF PSI D 3 290 GG 2500 PSI MED. 2100 PSI Z Y PSI PRESS. X P Q F

FILTER TEST A B C E

BB 3500 CC S U PSI I H G PRESS. AA GENERATOR FUNCTION 3.5 0.6 0.6 SELECT GPM N L K E PUMP GPM DD T GPM R O M 14 GPM. W PRESS. *PSI 4 DRIVE PUMP J 0.1 V GPM T1 TANK 2500 OPTIONAL PSI SEC REG OIL 3 25 3 PSI PSI * 2600 PSI W/O JIB COOLER PSI * 2900 PSI WITH JIB

SECOND COUNTERBALANCE VALVE ADDED 1 M AFTER SERIAL NUMBER 4862 RESERVOIR AUXILIARY PUMP 5

SS

HYDRAULIC ROTARY COUPLER STEER MANIFOLD

DRIVE 6 MANIFOLD A T 250 PSI B AD M7 M8 REAR AK RIGHT FRONT RIGHT M5 M6 7

AC AI AF M3 M4 STEERING .070” .052” REAR FRONT AJ .070” LEFT AH AG LEFT M1 M2 8

AE

AB P AL

CASE DRAINS Part No. 48412 Genie S-60 & Genie S-65 6 - 23 Service Manual Section 6 - Schematics

4WD Hydraulic Schematic Oscillating Axle NM L K J I H G F E D C B A

JIB BOOM PLATFORM ROTATE 1

SLAVE TURNTABLE BOOM UP/DOWN X ROTATE

BOOM EXTENSION X 1 PRIMARY SECONDARY TWO SPEED/ 0.035” BRAKE MANIFOLD 0.030” II JJ 1200 PSI BRAKE 2 SPEED 2 0.030” HH AM AM JIB BOOM

T MANIFOLD MASTER 0.025” ACCUM. PLATFORM 250 PSI LEVEL TURNTABLE BOOM P PR1 PR2 PL1 PL2 ROTATE S1 S2 P1 P2 EXTEND RETRACT OPTIONAL FUNCTION 3500 MOTOR/GEN. PSI 50 MANIFOLD EE FF PSI 3 D 290 2500 MED. 2100 GG PSI PSI PSI Z Y PRESS. X P Q F

FILTER TEST A B C E

BB CC S U 3500 5.0 I H G PSI PRESS. GPM GENERATOR FUNCTION AA SELECT 0.6 0.6 N L K E PUMP GPM DD GPM T R O M W PRESS. 4 14 GPM. * X PSI DRIVE PUMP V J 0.1 T1 GPM TANK 2500 PSI OPTIONAL SEC REG OIL COOLER 3 3 25 PSI PSI PSI * 2600 W/O JIB * 2900 WITH JIB

SECOND COUNTERBALANCE VALVE ADDED M 1 5 RESERVOIR AUX. PUMP AFTER SERIAL NUMBER 4862

SS

VV 3.5 HYDRAULIC GPM ROTARY 0.025” COUPLER UU TT STEER MANIFOLD 6 DRIVE MANIFOLD A KK LL T P 0.052” P8 X 250 950 PSI NN B PSI M7 AD M8 X

AK REAR FRONT A VALVE OO A CYL RIGHT RIGHT MM QQ M5 M6 B VALVE PP B CYL 7

AC AI AF M3 M4 STEERING 0.070” 0.052” REAR FRONT AJ 0.070” LEFT AH AG LEFT M1 M2 8

AE

AB P AL

CASE DRAINS Part No. 48412 Genie S-60 & Genie S-65 6 - 24 Service Manual - Second Edition Section 7 - Repair Procedures Repair Procedures

About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

Observe and Obey: Perform disassembly procedures to the point where repairs can be completed. Then to Repair procedures shall be completed by a re-assemble, perform the disassembly steps in person trained and qualified on the repair of this reverse order. machine. General Repair Process Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction Malfunction Identify Troubleshoot discovered symptoms before operating the machine. Before Repairs Start: problem still exists Read, understand and obey the safety rules and operating instructions in the Genie S-60 & Genie S-65 Operator’s Manual. Return to Inspect Perform service problem and test repair Be sure that all necessary tools and parts are solved available and ready for use. Symbols Legend Read each procedure completely and adhere to the instructions. Attempting shortcuts may Indicates the presence of a hazard produce hazardous conditions. that will cause death or serious injury. Unless otherwise specified, perform each repair procedure with the machine in the Indicates the presence of a hazard following configuration: that may cause death or serious injury. · Machine parked on a flat, level surface · Boom in stowed position Indicates the presence of a hazard that will or may cause serious · Turntable rotated with the boom between personal injury or the non-steering wheels damage to the machine. · Turntable secured with the turntable Indicates special operation or rotation lock pin maintenance information. · Key switch in the OFF position with the key removed Indicates that a specific result is expected after performing a series of steps. · Wheels chocked

Part No. 48412 Genie S-60 & Genie S-65 7 - 1 Section 7 - Repair Procedures Service Manual - Second Edition Platform Controls

1-1 1 Check the battery condition with a volt meter. The reading should be 12V DC or more to Joystick Controllers accurately adjust the controller.

Maintaining joystick controllers at the proper 2 Turn the key switch to platform control and settings is essential to safe machine operation. pull out the Emergency Stop button to the Every joystick controller should operate smoothly ON position at both the ground and platform and provide proportional speed control over its controls. Do not start the engine. entire range of motion. 3 Open the platform control box lid and locate the boom up/down controller. a b a b c d e f g h i j

a terminal "D2" directional output b terminal "A" proportional output f e d c c terminal "-" ground d terminal "+" positive Platform control box e terminal "R" activates max-out range a horsepower limiter board f terminal "D1" directional output b terminals g ramp rate adjustable trimpot c drive proportional controller h lo range adjustable trimpot d extend/retract proportional controller i threshold adjustable trimpot e boom proportional controller j hi range adjustable trimpot f turntable rotate proportional controller 4 Set the preliminary ramp rate: Turn the trimpot adjustment screw counterclockwise 15 turns or Boom Up/Down Controller until you hear a repeated click. Adjustments 5 Connect the red(+) lead from a volt meter to the “A” terminal on the controller printed circuit Do not adjust the joystick board. Connect the black(-) lead to ground. controllers unless the static battery 6 Set the threshold: Press down the foot switch, voltage is above then slowly move the control handle off center 12V DC and the alternator until the moment a voltage reading appears. is operating properly with Adjust the voltage to 3.5V DC. Turn the 13.6 to 14.5V DC output. threshold trimpot adjustment screw clockwise to Electrocution hazard. Contact increase the voltage or counterclockwise to 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 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

PLATFORM CONTROLS

7 Set the hi range: Press down the foot switch, 16 Start a timer and simultaneously move the then move the control handle all the way to control handle all the way to the UP position. the UP position. Adjust the voltage to 8.5V DC. Note how long it takes to reach the maximum Turn the max-out trimpot adjustment screw voltage recorded in step 14. This is the clockwise to increase the voltage or ramp rate. counterclockwise to decrease the voltage. 17 Set the ramp rate: turn the trimpot to obtain 8 Set the lo range: Press down the foot switch, a 3 to 4 second ramp speed. Turn the then move the control handle all the way to the trimpot clockwise to increase the time or DOWN position. Adjust the voltage counterclockwise to decrease the time. to 6.2V DC. Turn the dual range trimpot adjustment screw clockwise to increase the Boom up/down specifications voltage or counterclockwise to decrease the voltage. Threshold 3.5V DC 9 Start the engine and move the engine idle Boom up - hi range 8.5V DC control switch to foot switch activated high Cycle time 55 to 85 seconds idle (rabbit and foot switch symbol). Lower the boom to the stowed position. Boom down - lo range 6.2V DC Engine should be at normal Cycle time 90 to 120 seconds operating temperature. Ramp rate 3 to 4 seconds 10 Start a timer and record how long it takes for the boom to fully raise. Adjust the max-out trimpot to achieve a 55 to 85 second Turntable Rotation Controller cycle time. Adjustments 11 Start a timer and record how long it takes for the boom to fully lower. Adjust the dual range Do not adjust the joystick trimpot to achieve an 90 to 120 second cycle controllers unless the static battery time. voltage is above 12V DC and the alternator is If the function cycle time is not operating properly with achievable, check the relief valve 13.6 to 14.5V DC output. pressure. See 10-2, Valve Adjustments - Function Manifold. Electrocution hazard. Contact with electrically charged circuits 12 Turn the engine off and re-connect the may result in death or serious volt meter. injury. Remove all rings, watches 13 Pull out the Emergency Stop button to and other jewelry. the ON position. 1 Check the battery condition with a volt meter. 14 Press down the foot switch and then move the The reading should be 12V DC or more to control handle all the way to the UP position. accurately adjust the controller. Record the maximum voltage reading. 2 Turn the key switch to platform control and 15 Start the engine. pull out the Emergency Stop button to the ON position at both the ground and platform controls. Do not start the engine.

Part No. 48412 Genie S-60 & Genie S-65 7 - 3 Section 7 - Repair Procedures Service Manual - Second Edition

PLATFORM CONTROLS

3 Open the platform control box lid and locate 7 Set the hi range: Press down the foot switch, the turntable rotation controller. Refer to the fully retract the boom, then move the control platform control box illustration, page 7-2. handle all the way to the left or right. Adjust the voltage to 5.5V DC. Turn the max-out trimpot adjustment screw clockwise to increase the a b c d e f g h i j voltage or counterclockwise to decrease the voltage. 8 Set the lo range: Press down the foot switch, extend the boom 3 feet, then move the control handle all the way to the left or right. Adjust the voltage to 4.5V DC. Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 9 Start the engine and move the engine idle control switch to foot switch activated high idle a terminal "D2" directional output (rabbit and foot switch symbol). b terminal "A" proportional output c terminal "-" ground Engine should be at normal d terminal "+" positive operating temperature. e terminal "R" activates max-out range f terminal "D1" directional output 10 Fully retract the boom, then start a timer and g ramp rate adjustable trimpot record how long it takes the turntable to rotate h lo range adjustable trimpot through a complete circle. Adjust the max-out i threshold adjustable trimpot j hi range adjustable trimpot trimpot to achieve a 80 to 100 second cycle time. 4 Set the preliminary ramp rate: Turn the trimpot adjustment screw counterclockwise 15 turns or 11 Extend the boom, then start a timer and record until you hear a repeated click. how long it takes the turntable to rotate through a complete circle. Adjust the lo range trimpot to 5 Connect the red(+) lead from a volt meter to the achieve a 130 to 160 second cycle time. “A” terminal on the controller printed circuit board. Connect the black(-) lead to ground. 12 Turn the engine off and re-connect the volt meter. 6 Set the threshold: Press down the foot switch, then slowly move the control handle off center 13 Pull out the Emergency Stop button to until the moment a voltage reading appears. the ON position. Adjust the voltage to 3.5V DC. Turn the 14 Press down the foot switch and then move the threshold trimpot adjustment screw clockwise to control handle all the way to the left or right. increase the voltage or counterclockwise Record the maximum voltage reading. to decrease the voltage. 15 Start the engine.

7 - 4 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

PLATFORM CONTROLS

16 Start a timer and simultaneously move the 3 Open the platform control box lid and locate control handle all the way to the left or right. the boom extend/retract controller. Note how long it takes to reach the maximum voltage recorded in step 14. This is the a b c d e f g h i j ramp rate. 17 Set the ramp rate: Turn the trimpot to obtain a 5 second ramp speed. Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time.

Turntable rotation specifications

Threshold 3.5V DC

Turntable rotation - a ramp rate adjustable trimpot hi range (boom retracted) 5.5V DC b dual (lo) range adjustable trimpot c terminal "R", activates max-out range Cycle time 80 to 100 seconds d terminal unused lo range (boom extended) 4.5V DC e terminal "X", auxiliary Cycle time 130 to 160 seconds f terminal "-", ground g terminal "+", battery, positive Ramp rate 5 seconds h terminal "A", proportional output i threshold adjustable trimpot j max-out adjustable trimpot Boom Extend/Retract Controller 4 Set the preliminary ramp rate: Turn the trimpot adjustment screw counterclockwise 15 turns or Adjustments until you hear a repeated click. Do not adjust the joystick 5 Connect the red(+) lead from a volt meter to controllers unless the static battery the “A” terminal on the controller printed circuit voltage is above board. Connect the black(-) lead to ground. 12V DC and the alternator is operating properly with 6 Set the threshold: Press down the foot switch, 13.6 to 14.5V DC output. then slowly move the control handle off center until the moment a voltage reading appears. Electrocution hazard. Contact Adjust the voltage to 3.5V DC. Turn the with electrically charged circuits threshold trimpot adjustment screw clockwise to may result in death or serious increase the voltage or counterclockwise to injury. Remove all rings, watches decrease the voltage. and other jewelry. 7 Set the max-out: Press down the foot switch, 1 Check the battery condition with a volt meter. then move the control handle all the way to The reading should be 12V DC or more to the EXTEND position. Adjust the voltage to accurately adjust the controller. 9.75V DC. Turn the max-out trimpot adjustment screw clockwise to increase the voltage or 2 Turn the key switch to platform control and counterclockwise to decrease the voltage. pull out the Emergency Stop button to the ON position at both the ground and platform controls. Do not start the engine.

Part No. 48412 Genie S-60 & Genie S-65 7 - 5 Section 7 - Repair Procedures Service Manual - Second Edition

PLATFORM CONTROLS

8 Set the dual (lo) range: Press down the foot Boom extend/retract specifications switch, then move the control handle all the way to the RETRACT position. Adjust the voltage Threshold 3.5V DC to 9.2V DC. Turn the dual range trimpot adjustment screw clockwise to increase the Boom extend - Max-out 9.75V DC voltage or counterclockwise to decrease Cycle time 60 to 80 seconds the voltage. Boom retract - Dual (lo) range 9.2V DC 9 Start the engine and move the engine idle Cycle time 55 to 85 seconds control switch to foot switch activated high idle (rabbit and foot switch symbol). Lower Ramp rate 3 seconds the boom to the stowed position. Engine should be at normal operating temperature. 10 Start a timer and record how long it takes for the boom to fully extend. Adjust the 1-2 max-out trimpot to achieve a 60 to 80 second Horsepower Limiter Board cycle time. 11 Start a timer and record how long it takes for The horsepower limiter board is responsible for the boom to fully retract. Adjust the dual range governing drive pump output. It senses engine rpm trimpot to achieve an 55 to 85 second cycle from the alternator. The horsepower limiter board time. senses drops in rpm normally due to increased drive resistance (rough terrain or incline), and If the function cycle time is not decreases voltage to the drive controller which in achievable, check the relief valve turn decreases voltage to the drive pump, thereby pressure. See 10-2, Valve reducing pump output to maintain optimum engine Adjustments - Function Manifold. rpm and horsepower. Three adjustments are required for optimum performance. 12 Turn the engine off and re-connect the volt meter. How to Adjust the Horsepower 13 Pull out the Emergency Stop button to Limiter Board the ON position. The engine rpm must be 14 Press down the foot switch and then move the correct before performing this control handle all the way to the EXTEND position. procedure. See Maintenance Record the maximum voltage reading. Procedure B-12, Check and 15 Start the engine. Adjust the Engine RPM. 16 Start a timer and simultaneously move the Do not adjust the horsepower control handle all the way to the EXTEND position. limiter board unless the static Note how long it takes to reach the maximum battery voltage is above 12V DC voltage recorded in step 14. This is the ramp and the alternator is operating speed. properly with 12.5 to 14.5V DC output. 17 Set the ramp rate: turn the trimpot to obtain a 3 second ramp speed. Turn the Gasoline/LPG models: Perform trimpot clockwise to increase the time or this procedure in gasoline mode. counterclockwise to decrease the time.

7 - 6 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

PLATFORM CONTROLS

1 Remove the fasteners from the platform 4 Start the engine from the platform controls. control box lid. 5 Move the engine idle control switch to foot 2 Open the control box lid and locate the switch activated high idle (rabbit and foot switch horsepower limiter board. symbol). Electrocution hazard. Contact 6 Press down the foot switch and adjust the with electrically charged circuits "A" potentiometer counterclockwise to increase may result in death or serious voltage or clockwise to decrease voltage. injury. Remove all rings, watches and other jewelry. "A" potentiometer specifications - all models

a 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. Platform control box 9 Move the engine idle control switch to foot a horsepower limiter board switch activated high idle (rabbit and foot switch symbol). 3 Connect the black(-) lead from a DC volt meter to the no. 2 terminal, and the red(+) lead to the 10 Press down the foot switch and re-adjust the no. 10 terminal. "A" potentiometer to the previous voltage setting in step 6. 11 Be sure that the boom is in the stowed position, a 12V DC or greater then drive the machine and observe how the ground b engine rpm reacts to drive control handle engine rpm sensor not used movement. If the engine surges or hunts, adjust not used the "C" potentiometer counterclockwise until low drive speed limit switch not used surging is minimized. not used not used Under an extreme load, an output to drive controller c excessive counterclockwise adjustment to the "C" Horsepower limiter board potentiometer will cause the engine to stall. The "C" a "A" potentiometer maximum voltage output to the controller in the stowed potentiometer adjustment is a position compromise between engine stability (surging) and engine b "B" potentiometer maximum voltage output to the drive controller in the rpm droop. boom raised position 12 Disconnect the volt meter. c "C" potentiometer reaction rate or how fast the voltage output reacts to the change in engine rpm

Part No. 48412 Genie S-60 & Genie S-65 7 - 7 Section 7 - Repair Procedures Service Manual - Second Edition

PLATFORM CONTROLS

13 Raise the boom above horizontal. 1-3 14 Drive the machine for 40 feet (12 m) and Foot Switch record the elapsed time. Repeat this step in the opposite drive direction. How to Test the Foot Switch 15 Adjust the "B" potentiometer to obtain the correct raised drive speed of 1 foot per second 1 Turn the key switch to the OFF position and (0.31 m per second). Turn the "B" separate the wiring quick disconnect plug from potentiometer counterclockwise to increase the platform toe board. voltage or clockwise to decrease voltage. 2 Do not press down the foot switch. Connect the 16 Close the platform control box lid and install leads from an ohmmeter or continuity tester to the fasteners. each wire combination listed below and check for continuity.

Drive speed specifications Test Desired result Stowed position distance: 40 ft / 12 m red to black continuity 2WD 4WD (zero Ω) Gasoline/LPG models 40 ft/6.2 sec 40 ft/9.1 sec 12.2 m/6.2 sec 12.2 m/9.1 sec red to white no continuity Ω Deutz Diesel models 40 ft/6.8 sec 40 ft/9.1 sec (infinite ) 12.2 m/6.8 sec 12.2 m/9.1 sec black to white no continuity Boom raised or distance: 40 ft / 12 m extended 1 foot per second All models 30.5 cm per second Do not use the color of the connector as a guide for these tests. Use the actual wire 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 Ω)

red to white no continuity

black to white continuity (zero Ω)

7 - 8 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

PLATFORM CONTROLS

1-4 LeftCenter 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 1 3 1 3 1 3 for resistor locations and values. 2 2 2 Single pole How to Test the Resistors double throw (SPDT) 12 3 12 3 12 3 1 Turn the key switch to the OFF position. 45 6 45 6 45 6 2 Disconnect either end of one of the wires Double pole double throw connected to the resistor to be tested. (DPDT) 3 Connect the leads from an ohmmeter to each 12 3 12 3 12 3 end or wiring of the resistor being tested. Test Desired result 4 Compare the ohmmeter reading with the resistance rating printed on the resistor. Left position terminal 1 to 2, 3, 4, 5 & 6 no continuity (infinite Š) 1-5 terminal 2 to 3 continuity Š Toggle Switches (zero ) terminal 2 to 4, 5 & 6 no continuity Toggle switches used for single function switching terminal 3 to 4, 5 & 6 no continuity are single pole double throw (SPDT) switches. Dual function switching requires a double pole terminal 4 to 5 & 6 no continuity double throw (DPDT) switch. terminal 5 to 6 continuity Center position There are no terminal combinations How to Test a Toggle Switch that will produce continuity Š 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 Š) and does not specifically apply to all varieties of toggle switches. terminal 1 to 3, 4, 5 & 6 no continuity (infinite Š) 1 Turn the key switch to the OFF position. Tag terminal 2 to 3, 4, 5 & 6 no continuity and disconnect all wiring from the toggle switch to be tested. terminal 3 to 4, 5 & 6 no continuity 2 Connect the leads of an ohmmeter to 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 & 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 (SPDT) relays. How to Test a Single Pole Double Throw Relay terminal no. 87a - N.C. Electrocution hazard. terminal no. 85 - ground terminal no. 30 - common Contact with electrically charged terminal no. 86 - coil circuits may cause death or terminal no. 87 - N.O. serious injury. Remove all rings, watches and other jewelry. Direct Connection Relay Control Relay Schematic - without resistor

1 Label and then disconnect all the wiring from the relay to be tested. 2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity. Terminals 85 and 86 represent the coil and should not be tested in any other combination.

Test Desired result terminal 85 to 86 without resistor 85 to 95Ω terminal 85 to 86 with resistor 75 to 85Ω terminal 87 to 87a & 30 no continuity (infinite Ω) Control Relay Schematic - with resistor terminal 87a to 30 continuity (zero Ω)

3 Connect 12V DC to terminal 85 and a ground wire to terminal 86, then test the following terminal combinations.

Test Desired result terminal 87 to 87a & 30 no continuity (infinite Ω) terminal 87 to 30 continuity (zero Ω)

7 - 10 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures Platform Components

2-1 2-2 Platform Platform Leveling Slave Cylinder

How to Remove the Platform The slave cylinder and the rotator pivot are the two primary supports for the platform. The slave 1 Separate the foot switch quick disconnect plug. cylinder keeps the platform level through the entire range of boom motion. It operates in a 2 Support the platform support weldment with a closed-circuit hydraulic loop with the master appropriate lifting device. cylinder. The slave cylinder is equipped with 3 Open the platform control box and remove the counterbalance valves to prevent movement in platform control box mounting fasteners. Then the event of a hydraulic line failure. lower the control box and set it aside. How to Remove the Platform If your machine is equipped with an airline to platform option, the Leveling Slave Cylinder airline must be disconnected from Before cylinder removal is the platform before removal. considered, bleed the slave 4 Remove the platform mounting fasteners and cylinder to be sure there is no remove the platform from the machine. air in the closed loop. Crushing hazard. The platform When removing a hose assembly may become unstable and fall if it or fitting, the O-ring on the fitting is not properly supported. and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Extend the boom until the slave cylinder barrel-end pivot pin is accessible. 2 Raise the boom slightly and place blocks under the platform. 3 Lower the boom until the platform is resting on the blocks just enough to support the platform. Do not rest the entire weight of the boom on the blocks.

Part No. 48412 Genie S-60 & Genie S-65 7 - 11 Section 7 - Repair Procedures Service Manual - Second Edition

PLATFORM COMPONENTS

4 Tag, disconnect and plug the hydraulic hoses 2-3 from the slave cylinder at the union located near the platform rotate counterbalance valve Platform Rotator manifold and connect them together using a connector. Cap the fittings on the cylinder. The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform Bodily injury hazard. Spraying 160 degrees. hydraulic oil can penetrate and burn skin. Loosen hydraulic How to Remove the connections very slowly to allow the oil pressure to dissipate Platform Rotator gradually. Do not allow oil to Component damage hazard. Mark squirt or spray. the platform mounting weldment 5 Pull the slave cylinder hoses through the and the rotator flange before platform rotator. removing the platform mounting weldment. The platform mounting 6 Remove the pin retaining fastener from weldment must be replaced in the the slave cylinder rod-end pivot pin. Do not exact same position on the rotator remove the pin. flange as it was before removal. If 7 Remove the external retaining ring from the a new rotator is installed or the barrel-end pivot pin. rotator is disassembled, proper alignment can be achieved by 8 Use a soft metal drift to drive the rod-end pivot rotating the rotator all the way to pin out. the left and then installing the platform mounting weldment all 9 Use a soft metal drift and drive the barrel-end the way in the left position. pin out. When removing a hose assembly 10 Carefully pull the cylinder out of the boom. or fitting, the O-ring on the fitting Component damage hazard. and/or hose end must be replaced Hoses can be damaged if they are and then torqued to specification kinked or pinched. during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. How to Bleed the Slave Cylinder 1 Remove the platform. See 2-1, How to Remove the Platform. Do not start the engine. Use auxiliary power for all machine functions in this procedure. 1 Raise the boom to a horizontal position. 2 Move the platform level switch up and down through two platform leveling cycles to remove any air that might be in the system.

7 - 12 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

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. Crushing hazard. The platform Bodily injury hazard. Spraying rotator may become unbalanced hydraulic oil can penetrate and and fall if it is not properly burn skin. Loosen hydraulic supported. connections very slowly to allow S-65 Models: the oil pressure to dissipate gradually. Do not allow oil to 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 on 7 Support the jib boom and leveling arms. platform rotator manifold. Cap the fittings on the manifold. 8 Use a soft metal drift to drive both pins out, then remove the platform rotator from the machine. Bodily injury hazard. Spraying hydraulic oil can penetrate and Crushing hazard. The platform burn skin. Loosen hydraulic rotator may become unbalanced connections very slowly to allow and fall if it is not properly the oil pressure to dissipate supported. gradually. Do not allow oil to squirt or spray. 3 Support the platform mounting weldment, but do not apply any lifting pressure. 4 Remove the six mounting bolts from the platform mounting weldment, then remove the center bolt and slide the platform mounting weldment off of the platform rotator. Crushing hazard. The platform mounting weldment may become unbalanced and fall if it is not properly supported. 5 Support the platform rotator. Do not apply any lifting pressure. S-60 Models:

6 Support the rod end of the 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 & Genie S-65 7 - 13 Section 7 - Repair Procedures Service Manual - Second Edition

PLATFORM COMPONENTS

How to Bleed the Platform 4 Move the function enable toggle switch to either side and activate and hold the platform rotate Rotator switch to the LEFT position until the platform is Do not start the engine. Use fully rotated. Continue holding the switch until auxiliary power for all machine air stops coming out of the bleed valve. Then functions in this procedure. close the bleed valve. 1 Move the function enable toggle switch to either side and activate the platform rotate toggle Crushing hazard. Keep clear of switch to the right then the left through two the platform during rotation. platform rotation cycles, then hold the switch to 5 Connect the clear hose to the bottom bleed the RIGHT position until the platform is fully valve and open the valve. Do not remove the rotated to the right. bleed valve. 2 Connect a clear hose to the top bleed valve. 6 Move the function enable toggle switch to either Place the other end of the hose in a container side and activate and hold the platform rotate to collect any drainage. Secure the container to switch to the RIGHT position until the platform is the boom. fully rotated. Continue holding the switch until 3 Open the top bleed valve on the rotator, but do air stops coming out of the bleed valve. Then not remove it. close the bleed valve. a Crushing hazard. Keep clear of the platform during rotation. 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform full right then left and inspect the bleed valves for leaks.

d c b

a top bleed valve b bottom bleed valve c clear hose d container

7 - 14 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures Jib Boom Components, S-65 Models

3-1 9 Tag, disconnect and plug all the hydraulic Jib Boom, S-65 Models hoses from the jib boom manifold. Bodily injury hazard. Spraying How to Remove the Jib Boom hydraulic oil can penetrate and burn skin. Loosen hydraulic Perform this procedure with the connections very slowly to allow boom in the stowed position. the oil pressure to dissipate gradually. Do not allow oil to When removing a hose assembly squirt or spray. or fitting, the O-ring on the fitting and/or hose end must be replaced 10 Attach a lifting strap from an overhead crane to and then torqued to specification the jib boom. during installation. 11 Remove the pin retaining fastener from the jib Refer to Section Two, Hydraulic boom pivot pin. Use a soft metal drift to remove Hose and Fitting Torque the pin, then remove the jib boom from the Specifications. primary boom. 1 Remove the platform. See 2-1, Crushing hazard. If the overhead How to Remove the Platform. crane is not properly attached, the 2 Remove the platform mounting weldment jib boom may become unbalanced and the platform rotator. See 2-3, How to and fall when it is removed from Remove the Platform Rotator. the machine. 3 Remove the cable tray from the side of the 12 Remove the pin retaining fastener from the jib jib boom. boom lift cylinder rod-end pivot pin. Do not remove the pin. 4 Support the jib boom with a lifting device. 13 Slide both of the jib boom leveling arms off of 5 Tag, disconnect and plug the jib boom lift the jib boom pivot pin. cylinder hydraulic hoses. Cap the fittings on the cylinder. 14 Support the rod end of the jib boom lift cylinder with a lifting device. Bodily injury hazard. Spraying hydraulic oil can penetrate and 15 Use a soft metal drift to remove the jib boom lift burn skin. Loosen hydraulic cylinder rod-end pivot pin, then remove the jib connections very slowly to allow boom lift cylinder from the jib boom mounting the oil pressure to dissipate weldment. gradually. Do not allow oil to Crushing hazard. If the overhead squirt or spray. crane is not properly attached, the 6 Support the barrel end of the cylinder with a jib boom lift cylinder may become lifting device. unbalanced and fall when it is removed from the machine. 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.

Part No. 48412 Genie S-60 & 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. Cap the fittings on the Jib Boom Lift Cylinder, cylinder. S-65 Models Bodily injury hazard. Spraying 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 drift to 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 ground. Specifications. Tap the pin the other direction and lower the opposite leveling arm. Do not remove the pin. 1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Then 5 Support the jib boom lift cylinder with a lifting lower the jib boom until the platform is resting device. on the blocks just enough to support the 6 Remove the pin retaining fastener from the jib platform. boom lift cylinder barrel-end pivot pin. Use a Do not rest the 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 cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported.

7 - 16 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

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 OFF position and disconnect the wires from the valve coil to be tested. 2 Connect the leads from an ohmmeter to the valve coil terminals.

1 1 Valve coil specification

2 position 3 way valve 5.9Ω AM (schematic item AM)

AM

Part No. 48412 Genie S-60 & Genie S-65 7 - 17 Section 7 - Repair Procedures Service Manual - Second Edition Boom Components

4-1 4 Tag, disconnect and plug the hydraulic hoses from the platform leveling cylinder at the union Boom Cable Track and connect the hoses from the cylinder together using a connector. The boom cable track guides cables and hoses running up the boom. It can be repaired link by link Bodily injury hazard. Spraying without removing the cables and hoses that run hydraulic oil can penetrate and through it. Removing the entire boom cable track is burn skin. Loosen hydraulic necessary when performing major repairs that connections very slowly to allow involve removing the boom. the oil pressure to dissipate gradually. Do not allow oil to How to Remove the Boom squirt or spray. Cable Track 5 S-65 Models: Remove the hose and cable cover from the side of the jib boom. When removing a hose assembly or fitting, the O-ring on the fitting 6 S-65 Models: Remove the jib/rotate manifold and/or hose end must be replaced mounting fasteners. Do not disconnect any of and then torqued to specification the hoses. during installation. 7 S-65 Models: Tag, disconnect and plug the Refer to Section Two, Hydraulic hydraulic hoses from the jib boom lift cylinder. Hose and Fitting Torque Cap the fittings on the cylinder. Specifications. Bodily injury hazard. Spraying 1 Open the platform control box and remove the hydraulic oil can penetrate and platform control box mounting fasteners. burn skin. Loosen hydraulic 2 Separate the footswitch quick disconnect then connections very slowly to allow lower the platform control box and lay it off to the oil pressure to dissipate the side. gradually. Do not allow oil to squirt or spray. 3 Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports on the 8 Raise the boom to a horizontal position. counterbalance valve manifold located near the 9 Remove the fasteners from the drive speed limit platform rotator. Cap the fittings on the switch mounted on the side of the cable track at manifold. the pivot end of the boom. Do not disconnect Bodily injury hazard. Spraying the wiring. hydraulic oil can penetrate and 10 Remove the fasteners from the side panel on burn skin. Loosen hydraulic the lower cable track, then remove the panel. connections very slowly to allow Pull all of the cables out of the channel. the oil pressure to dissipate gradually. Do not allow oil to 11 Place blocks in between the upper and lower squirt or spray. cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track may become unbalanced and fall when it is removed from the machine.

7 - 18 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

BOOM COMPONENTS

12 Remove the mounting fasteners from the large 3 Drill out the 4 spot welds on each side of the cable track guide at the platform end of the cable track using a 17/64" drill bit. Repeat this cable track. Remove the guide. step for the other end of the 4 link section of cable track. 13 Remove the hose and cable clamp at the platform end of the cable track. Component damage hazard. Cables and hoses can be 14 Attach a lifting strap from an overhead crane to damaged if the drill bit comes in the cable track. contact with them. Protect the 15 Remove the cotter pin and clevis pin from the hoses and cables with a block of upper cable track at the platform end. wood to prevent drilling into the hoses and cables. 16 Remove the cable track mounting fasteners that attach the lower cable track to the boom. 4 Remove the retaining fasteners from upper black rollers from the 4 link section of cable 17 Remove the cable track from the machine and track to be replaced. Remove the rollers. place it on a structure capable of supporting it. 5 Lift up the hoses and cables and carefully Crushing hazard. The cable track remove the damaged 4 link section of cable may become unbalanced and fall track. if it is not properly attached to the overhead crane. Component damage hazard. Hoses and cables can be Component damage hazard. damaged if they are kinked or Cables and hoses can be pinched. damaged if they are kinked or pinched. 6 Remove the upper rollers from the replacement section of cable track. How to Repair the Boom 7 Lift up the hoses and cables and carefully insert Cable Track the new 4 link section of cable track. Component damage hazard. Component damage hazard. The boom cable track can be Hoses and cables can be damaged if it is twisted. damaged if they are kinked or pinched. A cable track repair kit is available through the Genie Industries 8 Connect the ends of the replacement cable Service Parts Department, track section to the existing cable track using Part no. 46677. The kit includes a the fasteners provided in the kit. Do not 4 link section of cable track, overtighten the fasteners. fasteners, other miscellaneous parts and detailed instructions. Component damage hazard. Over tightening the fasteners will 1 Remove the boom cable track. See 4-1, How to result in the cable track not Remove the Boom Cable Track. rotating and may bind during operation. 2 Visually inspect the cable track and determine which 4 link section needs to be replaced. Be sure that the fasteners are installed from the inside out so the nuts are on the outside of the cable track.

Part No. 48412 Genie S-60 & 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 How to Remove the Boom cable track. This procedure requires specific 10 Install cable track onto the machine and operate repair skills, lifting equipment and the boom/extend function fully to ensure a suitable workshop. Attempting smooth operation of the new section of cable this procedure without these skills track. and tools may cause death or serious injury and significant component damage. Dealer 4-2 service is strongly recommended. Boom Perform this procedure with the boom in the stowed position. How to Shim the Boom When removing a hose assembly or fitting, the O-ring on the fitting 1 Measure each top wear pad. and/or hose end must be replaced and then torqued to specification Replace the pad if it is less than during installation. 9/16 inch (14.3 mm) thick. If the Refer to Section Two, Hydraulic pad is more than 9/16 inch Hose and Fitting Torque (14.3 mm) thick, perform the Specifications. following procedure. 1 Remove the platform. See 2-1, 2 Measure each bottom and side wear pad. How to Remove the Platform. Replace the pad if it is less than 2 Remove the platform rotator and leveling slave 11/16 inch (17.5 mm) thick. If the cylinder. See 2-3, How to Remove the Platform pad is more than 11/16 inch Rotator. (17.5 mm) thick, perform the following procedure. S-65 Models: Remove the jib boom. See 3-1, How to Remove the Jib Boom 3 Extend the boom until the wear pads are . accessible. 3 Remove the mounting fasteners from the jib 4 Loosen the wear pad mounting fasteners. boom/jib rotate valve manifold on the end of the boom. Then remove the manifold and set it 5 Install the new shims under the wear pad to aside. obtain zero clearance and zero drag. 4 Remove the fasteners from the drive speed limit 6 Tighten the mounting fasteners. switch mounted on the side of the cable track. Do not disconnect the wiring. 7 Extend and retract the boom through an entire cycle. Check for tight spots that may cause 5 Support the cable track with an overhead crane. binding or scraping of the boom. 6 Remove the hose/cable clamp from the pivot Always maintain squareness end of the boom. between the outer and inner boom 7 Remove the hose and cable clamp at the tubes. platform end of the cable track. 8 Remove the fasteners from the large cable track guide at the platfrom end of the cable track. Remove the guide.

7 - 20 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

BOOM COMPONENTS

9 Remove the cotter pin from the clevis pin at the 18 Use the crane to lift the boom to a horizontal platform end of the cable track and remove the position. clevis pin. 19 Place support blocks under the lift cylinder, 10 Remove the fasteners from the side panel on across the turntable. the cable track to access the cable track 20 Remove the pin retaining fastener from the mounting fasteners. boom lift cylinder rod-end pin. Use a soft metal 11 Remove the cable track mounting fasteners, drift to remove the pin. then remove the cable track from the Crushing hazard. The boom lift boom and lay it off to the side. cylinder will fall unless it is Component damage hazard. properly supported. The boom cable track 21 Lower the rod end of the lift cylinder onto can be damaged if it is twisted. support blocks. Protect the cylinder rod from Component damage hazard. damage. Hoses can be damaged if they are 22 Remove the pin retaining fastener from the kinked or pinched. boom pivot pin. 12 Remove the turntable end cover. 23 Remove the boom pivot pin with a soft metal 13 Remove the retaining fastener from the master drift, then carefully remove the boom from the cylinder rod-end pivot pin. Use a soft metal drift machine. to remove the pin. Pull the cylinder back and Crushing hazard. If the overhead secure it from moving. crane is not properly attached, Component damage hazard. the boom may become When pulling the master cylinder unbalanced and fall when it is back, be sure not to damage the removed from the machine. master cylinder hoses or fittings. How to Disassemble the Boom 14 Remove the fasteners from the drive speed limit switch mounted to the turntable riser at the Complete disassembly of the pivot end of the boom. Do not disconnect the boom is only necessary wiring. if the outer or inner boom tubes must be replaced. The extension 15 Tag, disconnect and plug the extension cylinder cylinder can be removed without hydraulic hoses. Cap the fittings on the completely disassembling the cylinder. boom. See 4-4, How to Remove Bodily injury hazard. Spraying the Extension Cylinder. hydraulic oil can penetrate and 1 Remove the boom. See 4-2, burn skin. Loosen hydraulic How to Remove the Boom. connections very slowly to allow the oil pressure to dissipate 2 Place blocks under the extension cylinder for gradually. Do not allow oil to support. squirt or spray. 3 Remove the external snap rings from the 16 Attach an overhead 5 ton (4536 kg) crane to the extension cylinder barrel-end pivot pin at the center point of the boom. base of the number 1 boom tube. Use a soft metal drift to remove the pin. 17 Attach a similar lifting device to the lift cylinder.

Part No. 48412 Genie S-60 & 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 12 Support and slide the number 3 boom tube out side of the number 1 boom tube at the platform of the number 2 boom tube. Place the number 3 end of the boom. boom tube on blocks for support. Pay careful attention to the Crushing hazard. The number 3 location and amount of shims boom tube may become used with each wear pad. unbalanced and fall when it is removed from the number 2 boom 5 Remove the two wear pad stop bolts from each tube if it is not properly supported. side of the number 1 boom tube (located on the outside). During removal, the overhead crane strap will need to be 6 Support the number 2 and 3 boom tubes with a carefully adjusted for proper lifting strap attached to an overhead crane at balancing. the platform end of the boom. 13 Remove the external snap rings from the 7 Support and slide the number 2 and 3 boom extension cylinder rod-end pivot pin at the tubes out of the number 1 boom tube. Place the platform end of the number 3 boom tube. Use a 2 and 3 boom tubes on blocks for support. soft metal drift to remove the pin. Crushing hazard. The number 2 14 Support and slide the extension cylinder out of and 3 boom tubes may become the base end of the number 3 boom tube. Place unbalanced and fall when they are the extension cylinder on blocks for support. removed from the number 1 boom tube if they are not properly Crushing hazard. The extension supported. cylinder may become unbalanced and fall when it is removed from During removal, the overhead the number 3 boom tube if it is not crane strap will need to be properly supported. carefully adjusted for proper balancing. During removal, the overhead crane strap will need to be 8 Remove and label the wear pads from the top carefully adjusted for proper side of the number 2 boom tube at the platform balancing. end of the boom. 15 Remove and label the wear pads from the 9 Remove the trunnion cap mounting fasteners at extension cylinder. the base of the number 2 boom tube. Then use a slide hammer to remove the trunnion caps. Pay careful attention to the location of each wear pad. 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.

7 - 22 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

BOOM COMPONENTS

4-3 5 Tag, disconnect and plug the boom lift cylinder hydraulic hoses. Cap the fittings on the Boom Lift Cylinder cylinder. Bodily injury hazard. Spraying How to Remove the Boom hydraulic oil can penetrate and Lift Cylinder burn skin. Loosen hydraulic connections very slowly to allow This procedure requires specific the oil pressure to dissipate repair skills, lifting equipment and gradually. Do not allow oil to a suitable workshop. Attempting squirt or spray. this procedure without these skills and tools may result in death or 6 Remove the pin retaining fastener from the lift serious injury and significant cylinder rod-end pivot pin. Use a soft metal drift component damage. Dealer to remove the pin, then lower the lift cylinder service is strongly recommended. onto the blocks. Protect the cylinder rod from damage. When removing a hose assembly or fitting, the O-ring on the fitting Crushing hazard. The lift cylinder and/or hose end must be replaced may become unbalanced and fall and then torqued to specification if it is not properly supported. during installation. 7 Remove the mounting fasteners from the barrel- Refer to Section Two, Hydraulic end cylinder pin retaining plates. Hose and Fitting Torque Specifications. 8 With the lift cylinder being supported by the 1 Raise the boom until the boom is horizontal. overhead crane, pull the cylinder toward the platform until it is out. 2 Place support blocks under the cylinder across the turntable. Crushing hazard. The lift cylinder may become unbalanced and fall 3 Attach an overhead 5 ton (4536 kg) crane to the if it is not properly supported. boom. Do not lift the boom. Component damage hazard. The 4 Support the rod end of the boom lift cylinder cables and hydraulic hoses can be with an overhead crane or similar lifting device. damaged if the lift cylinder is Crushing hazard. If the overhead pulled across them. crane is not properly attached, the lift cylinder may become unbalanced and fall when it is disconnected from the machine.

Part No. 48412 Genie S-60 & Genie S-65 7 - 23 Section 7 - Repair Procedures Service Manual - Second Edition

BOOM COMPONENTS

4-4 6 Remove the turntable end cover. Extension Cylinders 7 Tag, disconnect and plug the extension cylinder hydraulic hoses. Cap the fittings on the The extension cylinder consists of two cylinders cylinder. that are fastened together. The first cylinder Bodily injury hazard. Spraying extends and retracts the number 2 boom tube. The hydraulic oil can penetrate and second cylinder extends and retracts the number 3 burn skin. Loosen hydraulic boom tube.The extension cylinders are equipped connections very slowly to allow with counterbalance valves to prevent movement the oil pressure to dissipate in the event of a hydraulic line failure. gradually. Do not allow oil to How to Remove the squirt or spray. Extension Cylinders 8 Remove the trunnion pin covers from both sides of the number 1 boom tube at the pivot end of This procedure requires specific the boom. repair skills, lifting equipment and 9 Remove the trunnion pin retaining fastener and a suitable workshop. Attempting use a slide hammer to remove the pins. this procedure without these skills and tools may cause death or 10 Remove the pin retaining fasteners from both serious injury and significant sides of the extension cylinder at the pivot end component damage. Dealer of the boom. service is strongly recommended. 11 Use a slide hammer to remove the pins. When removing a hose assembly 12 Support and slide the extension cylinder out of or fitting, the O-ring on the fitting the pivot end of the boom. and/or hose end must be replaced and then torqued to specification Crushing hazard. The extension during installation. cylinder will fall when it is removed Refer to Section Two, Hydraulic from the extension boom if it is not Hose and Fitting Torque properly supported. Specifications. Note the length of the cylinder 1 Extend the boom until the extension cylinder after removal. The cylinder must rod-end pin is accessible in the number 3 boom be at the same length for tube. installation. 2 Remove the platform. See 2-1, How to Remove the Platform. 3 Remove the platform leveling slave cylinder. See 2-2, How to Remove the Slave Cylinder. S-65 Models: Remove the jib boom. See 3-1, How to 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 (at the platform end). Use a soft metal drift to remove the pin.

7 - 24 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

BOOM COMPONENTS

4-5 5 Place a rod through the barel-end pivot pin and Platform Leveling twist to remove the pin. 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 at the base of the boom. How to Remove the Platform 6 Attach a lifting strap from an overhead crane to Leveling Master Cylinder 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. Crushing hazard. The master Refer to Section Two, Hydraulic cylinder may become unbalanced Hose and Fitting Torque and fall if it is not properly Specifications. supported by the lifting device. 1 Raise the boom until the rod-end pivot pin is accessible. 2 Remove the turntable end cover to access the master cylinder. 3 Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying 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.

Part No. 48412 Genie S-60 & Genie S-65 7 - 25 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 weight, do not attempt to support the cover by hand. Component damage hazard. Protect the cover from damage by using carpet or padding on the crane or 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. Protect the strut cylinder rod from damage. Mark the location of the hinge support bracket on the bulkhead to ensure proper cover alignment during installation. 4 Remove the cover hinge bolts, that fasten the hinge support bracket to the bulkhead. 5 Carefully lift and remove the cover from the machine. Crushing hazard. The turntable cover may become unbalanced and fall if it is not properly supported and secured to a appropriate lifting device. 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 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures Deutz Engine F4L 1011F

6-1 How to Install the Flex Plate RPM Adjustment 1 Install the flex plate onto the flywheel with the raised spline towards the pump. Torque the flex Refer to Maintenance Procedures, B-12, plate mounting bolts to 34 ft-lbs (46 Nm). Check and Adjust the Engine RPM. 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 6-2 end plate. 3 Apply Loctite® removable thread sealant to the Flex Plate coupler set screw. Torque the set screw to 45 ft-lbs (61 Nm). The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine Component damage hazard. Do flywheel and has a splined center to drive not force the drive pump during the pump. installation or the flex plate teeth may become damaged. a b c d e 4 Install the pump and torque the pump mounting plate fasteners to 34 ft-lbs (46 Nm).

6-3 Oil Temperature and Pressure

f Gauges

a pump The oil temperature gauge is an electrical gauge. b pump shaft c coupler The sending unit has limit contacts that are factory d flex plate with raised spline set. The contacts will close at 300o F (147o C). e flywheel When the contacts close, the engine will shut off to 1 f /2 inch gap prevent damage and will not start until the How to Remove the Flex Plate temperature drops below the contact point. Temperature will be indicated when the key is on 1 Disconnect the wiring plug at the electronic and the Emergency Stop Button is pulled out to the displacement controller (EDC), located on ON position. the drive pump. Component damage hazard. 2 Support the drive pump with an appropriate Do not crank the engine with lifting device. Then remove all of the pump the over-temperature light on. mounting plate to engine bell housing bolts. The oil pressure gauge is an electrical gauge. The 3 Carefully pull the pump away from the engine sending unit has limit contacts that are factory set. and secure it from moving. The contacts will close at 7 psi (0.48 bar). When the contacts close, the engine will shut off to 4 Remove the flex plate mounting fasteners, prevent damage. Oil pressure will be indicated then remove the flex plate from the flywheel. when the engine is running. Component damage hazard. Do not crank the engine with the low oil pressure light on. Part No. 48412 Genie S-60 & Genie S-65 7 - 27 Section 7 - Repair Procedures Service Manual - Second Edition Ford LRG-423 Engine

a b c d

g 110°

f

e

7-1 Governor actuator and linkage a clevis 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 the 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 Connect the linkage rod to the throttle plate 5 With the throttle in the idle position and the shaft, then tighten the lock nut. actuator arm at a 110 degree angle to the linkage, rotate the clevis yoke on the linkage 2 Fasten the lock nut and clevis yoke to the rod two turns counterclockwise to pre-load the linkage rod. Do not tighten the lock nut spring. Tighten the lock nut on the linkage rod. against the clevis yoke. 3 Loosen the fastener on the actuator arm. Rotate the actuator arm until it is at a 110 degree angle to the linkage rod. Then tighten the actuator arm fastener.

7 - 28 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

FORD LRG-423 ENGINE

6 Manually pull the actuator arm through a full 7-2 cycle to be sure that the linkage moves freely. Be sure that the linkage activates the throttle Choke Adjustments shaft to approximately half throttle. This engine is equipped with an electrically heated 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 full throttle, the engine will over-rev Choke adjustments are affected and cause component damage. by climate. Richer adjustment will be necessary in colder The linkage must be free of friction climates, leaner adjustment and obstruction. Do not in warmer climates. let it rub against the 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.

rich lean

Part No. 48412 Genie S-60 & Genie S-65 7 - 29 Section 7 - Repair Procedures Service Manual - Second Edition

FORD LRG-423 ENGINE

7-3 7-6 Timing Adjustment Flex Plate

Complete information to perform this procedure is The flex plate acts as a coupler between the available in the Ford LRG-423 2.3 Liter Industrial engine and the pump. It is bolted to the engine Engine Service Manual (Ford number: PPD-194- flywheel and has a splined center to drive 287). Genie part number 33907. the pump.

a b c d e

7-4 Carburetor Adjustment

Complete information to perform this procedure is available in the Ford LRG-423 2.3 Liter Industrial f Engine Service Manual (Ford number: PPD-194- a pump 287). Genie part number 33907. b pump shaft c coupler d flex plate with raised spline e flywheel 1 7-5 f /4 inch gap RPM Adjustment Flex Plate Removal 1 Disconnect and remove the hose between Refer to Maintenance Procedures, B-12, Check the carburetor venturi and the air cleaner. and Adjust the Engine RPM. 2 Disconnect the linkage from the governor, then remove the governor linkage from the carburetor. Do not alter the length of the linkage. 3 Disconnect the wiring plug at the electronic displacement controller (EDC), located on the drive pump. 4 Remove the mounting fasteners from the regulator mounting bracket, then pull the bracket up past the bell housing. Secure the bracket before continuing. 5 Support the drive pump with an appropriate lifting device. Then remove all of the pump mounting plate to engine bell housing bolts. 6 Carefully pull the pump away from the engine and secure it from moving. 7 Remove the flex plate mounting fasteners, then remove the flex plate from the fly wheel.

7 - 30 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

FORD LRG-423 ENGINE

How to Install the Flex Plate 7-7 1 Install the flex plate onto the flywheel with the Water Temperature and Oil raised spline towards the pump. Torque the flex Pressure Gauges plate mounting bolts to 34 ft-lbs (46 Nm). 2 Install the coupler onto the pump shaft with the The water temperature gauge is an electrical set screw towards the pump. Leave a 1/4 inch gauge. The sending unit has limit contacts that are (6.35 mm) gap between the coupler and pump factory set. The contacts will close at 230°F end plate. (109° C). When the contacts close, the engine will shut off to prevent damage and will not start until 3 Apply Loctite® removable thread sealant to the the temperature drops below the contact point. coupler set screw. Torque the set screw to Temperature will be indicated when the key is on 45 ft-lbs (61 Nm). and the Emergency Stop Button is pulled out to the Component damage hazard. Do ON position. not force the drive pump during Component damage hazard. installation or the flex plate teeth Do not crank the engine with may become damaged. the over-temperature light on. 4 Install the pump and torque the pump mounting The oil pressure gauge is an electrical gauge. The plate fasteners to 34 ft-lbs (46 Nm). 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. Do not crank the engine with the low oil pressure light on.

Part No. 48412 Genie S-60 & 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

a b

d c

a ohmmeter b common terminal (SOL.) c vacuum switch d normally open terminal (ING.) 1 Connect the leads from an ohmmeter or continuity tester to the common and normally open terminals. Result: There should be no continuity (infinite Ω). 2 Apply mild suction to the vacuum port. Result: The switch should close and show full continuity (zero Ω). Component damage hazard. Do not short the vacuum switch terminals to ground.

7 - 32 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures Ground Controls

8-1 8-4 Control Relays Resistors

See 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 Turn the key switch to the OFF position. 2 Disconnect either end of one of the wires 8-3 connected to the resistor to be tested. ® Wago Components 3 Connect the leads from an ohmmeter to each end or wiring of the resistor being tested. ® How to Remove a Wago 4 Compare the ohmmeter reading with the Component resistance rating printed on the resistor. 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 should 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 of the 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 of the component and remove it.

Part No. 48412 Genie S-60 & Genie S-65 7 - 33 Section 7 - Repair Procedures Service Manual - Second Edition

GROUND CONTROLS

8-5 2 Connect 12V DC to one of the small posts and a ground wire to the other small post, then test Power Relay the following terminal combination.

Electrocution hazard. Contact with Test Desired result electrically charged circuits may result in death or serious injury. 2 large posts continuity (zero Ω) Remove all rings, watches and other jewelry. a b b a The power relay is mounted on the backside of the ground control box. How to Test the Power Relay Electrocution hazard. Disconnect the ground cable from the battery before performing this procedure. 1 Connect the leads from an ohmmeter to each terminal combination and check for continuity.

Test Desired result a high amp power contact terminal (large post) 2 small posts 12 to 16Ω b solenoid activate coil terminal 2 large posts no continuity (small post) (infinite Ω)

Any small post to no continuity any large post (infinite Ω)

7 - 34 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures Hydraulic Pumps

9-1 3 Remove the pump mounting bolts. Carefully Lift/Steer Pump remove the pump. Component damage hazard. How to Remove the Be sure to open the two hydraulic tank valves and prime the pump Lift/Steer Pump after installing the pump. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced 9-2 and then torqued to specification during installation. Drive Pump Refer to Section Two, Hydraulic Hose and Fitting Torque The drive pump is a bi-directional variable Specifications. displacement piston pump. The pump output is controlled by the electronic displacement controller 1 Close the two hydraulic tank valves located at (EDC), located on the pump. The only adjustment the hydraulic tank. that can be made to the pump is the neutral or null adjustment. Any internal service to the pump should only be performed at an authorized Sundstrand-Sauer service center. Call Genie Industries Service Department to locate your local authorized service center. How to Remove the Drive Pump open closed Component damage hazard. The work area and surfaces where this Component damage hazard. The procedure will be performed must engine must not be started with be clean and free of debris that the hydraulic tank shutoff valves in could get into the hydraulic system the CLOSED position or component and cause severe component damage will occur. damage. Dealer service is If the tank valves are closed, recommended. remove the key from the key switch and tag the machine to When removing a hose assembly inform personnel of the condition. or fitting, the O-ring on the fitting and/or hose end must be replaced 2 Tag, disconnect and plug the lift/steer pump and then torqued to specification hydraulic hoses. Cap the fittings on the pump. during installation. Refer to Section Two, Hydraulic Bodily injury hazard. Spraying Hose and Fitting Torque hydraulic oil can penetrate and Specifications. burn skin. Loosen hydraulic connections very slowly to allow 1 Disconnect the electrical connection at the the oil pressure to dissipate electronic displacement controller (EDC) gradually. Do not allow oil to located on the drive pump. squirt or spray.

Part No. 48412 Genie S-60 & 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 Connect 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 at the ignition coils. The ignition coils are located above the alternator. Electrocution hazard. Contact with electrically charged open closed circuits may cause death or Component damage hazard. The serious injury. Remove all rings, engine must not be started with watches and other jewelry. the hydraulic tank shutoff valves in Deutz Diesel models: Hold the manual fuel the CLOSED position or component shutoff valve clockwise to the CLOSED position. damage will occur. If the tank valves are closed, remove the key a from the key switch and tag the machine to inform personnel of the condition. 3 Tag and disconnect and plug the hydraulic hoses from the drive and lift/steer pumps. Cap the fittings on the pumps. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. a manual fuel shutoff valve 4 Support the pump with a lifting device and 3 Crank the engine with the starter motor for remove the two drive pump mounting fasteners. 15 seconds, wait 15 seconds, then crank the engine an additional 15 seconds or until the 5 Carefully pull the drive pump out until the pump pressure reaches 320 psi (22 bar). coupler separates from the flex plate. 4 Gasoline/LPG models: Connect the ignition 6 Remove the drive pump from the machine. coil wiring and start the engine from the ground controls. Check for hydraulic leaks. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump.

7 - 36 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

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Part No. 48412 Genie S-60 & 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 Function Torque

1 3 position 4 way D03 valve...... A ...... Turntable rotate left/right ...... 30-35 in-lbs / 3-4 Nm 2 3 position 4 way D03 valve...... B ...... Boom up/down ...... 30-35 in-lbs / 3-4 Nm 3 3 position 4 way D03 valve...... C ...... Boom extend/retract...... 30-35 in-lbs / 3-4 Nm 4 Check valve, pilot operated ...... D ...... Boom extend/retract circuit ...... 11-13 ft-lbs / 15-18 Nm 5 Relief valve, 2500 psi (172 bar) ...... E ...... Boom extend ...... 25-30 ft-lbs / 34-41 Nm 6 Relief valve, 2100 psi (145 bar) ...... F ...... Boom down ...... 25-30 ft-lbs / 34-41 Nm 7 Flow regulator valve, 1.5 gpm (5.7 l/min) ...... G ...... Boom extend/retract circuit (prevents over flowing the proportional valve) ...... 10-12 ft-lbs / 14-16 Nm 8 Flow regulator valve, 1.5 gpm (5.7 l/min) ...... H ...... Boom up/down circuit (prevents over flowing the proportional valve) ...... 10-12 ft-lbs / 14-16 Nm 9 Flow regulator valve, 1.5 gpm (5.7 l/min) ...... I ...... Turntable rotate left/right (prevents over flowing the proportional valve) ...... 10-12 ft-lbs / 14-6 Nm 10 Flow regulator valve, 0.1 gpm (0.38 l/min)...... J ...... Bleeds off differential sensing valves to tank ...... 10-12 ft-lbs / 14-16 Nm 11 Check valve ...... K ...... Differential sensing circuit, boom extend/retract ...... 11-13 ft-lbs / 15-18 Nm 12 Check valve ...... L ...... Differential sensing circuit, boom up/down ...... 11-13 ft-lbs / 15-18 Nm 13 Proportional solenoid valve ...... M ...... Boom extend/retract...... 10-12 ft-lbs / 14-16 Nm 14 Check valve ...... N ...... Differential sensing circuit, turntable rotate left/right ...... 11-13 ft-lbs / 15-18 Nm 15 Proportional solenoid valve ...... O ...... Boom up/down ...... 10-12 ft-lbs / 14-16 Nm 16 Check valve ...... P ...... Differential sensing circuit, platform level up ...... 11-13 ft-lbs / 15-18 Nm 17 Check valve ...... Q ...... Differential sensing circuit, platform level down ...... 11-13 ft-lbs / 15-18 Nm

This list continues. Please turn the page

7 - 38 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

MANIFOLDS

Part No. 48412 Genie S-60 & 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 ...... R ...... Turntable rotate left/right ...... 10-12 ft-lbs / 14-16 Nm 19 Solenoid valve - N.O. Poppet ...... S ...... Platform level up ...... 25-30 ft-lbs / 34-41 Nm 20 Flow regulator valve, 0.6 gpm (2.27 l/min)...... T ...... Platform level circuit ...... 10-12 ft-lbs / 14-16 Nm 21 Solenoid valve - N.O. Poppet ...... U ...... Platform level down ...... 25-30 ft-lbs / 34-41 Nm 22 Differential sensing valve ...... V ...... Meters flow to functions ...... 10-12 ft-lbs / 14-16 Nm 23 Relief valve, 2600 psi (179 bar), S-60 models 2900 psi (200 bar), S-65 models ...... W ...... System relief ...... 35-40 ft-lbs / 47-54 Nm 24 Diagnostic nipple ...... X ...... Testing 25 Check valve ...... Y ...... Differential sensing circuit Platform rotate left ...... 11-13 ft-lbs / 15-18 Nm 26 Check valve ...... Z ...... Differential sensing circuit Platform rotate right ...... 11-13 ft-lbs / 15-18 Nm 27 Priority flow regulator valve, ...... AA ...... Steering ...... 10-12 ft-lbs / 14-16 Nm 3.5 gpm (13.2 l/min), without oscillate axle 5 gpm (18.9 l/min), with oscillate axle 28 Solenoid valve - N.O. Poppet ...... BB ...... Platform rotate left/Jib boom up ...... 25-30 ft-lbs / 34-41 Nm 29 Solenoid valve - N.O. Poppet ...... CC ...... Platform rotate right/Jib boom down . 25-30 ft-lbs / 34-41 Nm 30 Flow regulator valve, 0.6 gpm (2.27 l/min)...... DD ...... Platform rotate ...... 10-12 ft-lbs / 14-16 Nm 31 Counterbalance valve ...... EE ...... Platform level up ...... 35-40 ft-lbs / 47-54 Nm 32 Counterbalance valve ...... FF ...... 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 S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

MANIFOLDS

Part No. 48412 Genie S-60 & Genie S-65 7 - 41 Section 7 - Repair Procedures Service Manual - Second Edition

MANIFOLDS

10-2 How to Adjust the Boom Down Valve Adjustments - Relief Valve Function Manifold Perform this procedure with the boom in the stowed position. How to Adjust the System 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure Relief Valve gauge to the test port (item 23) on the function manifold. Perform this procedure with the boom in the stowed position. 2 Start the engine from the ground controls. 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure 3 Hold the function enable switch to either side gauge to the test port (item 23) on the function and activate and hold the boom down switch manifold. with the boom fully lowered. Observe the pressure reading on the pressure gauge. 2 Start the engine from the ground controls. 4 Turn the engine off. Use a wrench to hold the 3 Hold the function enable switch to either side relief valve and remove the cap and activate and hold the retract switch with the (item 6, function manifold). boom fully retracted. Observe the pressure reading on the pressure gauge. 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to 4 Turn the engine off. Use a wrench to hold the decrease the pressure. Then install the relief relief valve and remove the cap valve cap. (item 23, function manifold). Tip-over hazard. Do not adjust 5 Adjust the internal hex socket. Turn it clockwise the relief valves higher than to increase the pressure or counterclockwise to specified. decrease the pressure. Then install the relief valve cap. 6 Repeat steps 2 through 5 and recheck relief valve pressure. Tip-over hazard. Do not adjust the relief valves higher than Boom down relief valve specifications specified. 6 Repeat steps 2 through 5 and recheck relief Pressure 2100 psi valve pressure. 145 bar

System relief valve specifications

Pressure S-60 models 2600 psi 179.3 bar S-65 models 2900 psi 200 bar

7 - 42 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

MANIFOLDS

How to Adjust the Boom Extend How to Override a Valve Relief Valve A hydraulic valve may need to be manually Perform this procedure with the overridden to troubleshoot a malfunction. The boom in the stowed position. proportional boom functions (boom up/down, extend/retract and turntable rotate) use a variable 1 Connect a 0 to 3000 psi (0 to 207 bar) pressure position proportional valve and a three position gauge to the test port (item 23) on the function directional valve. Example: one position for boom manifold. up, one position for neutral and one position for boom down. The platform rotate function uses a 2 Start the engine from the ground controls. three position valve. The platform level uses a 3 Hold the function enable switch to either side three position and a two position valve. The three and activate and hold the extend switch with the position valves and the proportional valves can be boom fully extended. Observe the pressure manually overridden. To identify the manifold reading on the pressure gauge. valves see 10-1, Function Manifold, in this section. 4 Turn the engine off. Use a wrench to hold the 1 Push the button on the end of the valve in relief valve and remove the cap ¼ inch (6 mm). (item 5, function manifold). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the relief valve cap. Tip-over hazard. Do not adjust the relief valves higher than specified. 6 Repeat steps 2 through 5 and recheck relief valve pressure. 2 Hold the function enable switch to either side Boom extend relief valve specifications and move the ground control function switch for the function being overridden to operate Pressure 2500 psi function. 172 bar Collision hazard. Impact with moving boom components may cause death or serious injury. Use extreme caution when overriding a machine function. Identify the direction of machine movement before overriding a valve.

Part No. 48412 Genie S-60 & Genie S-65 7 - 43 Section 7 - Repair Procedures Service Manual - Second Edition

MANIFOLDS

How to Check the Resistance of a Valve Coil

1 Turn the key switch to the OFF position and disconnect the wires from the valve coil to be tested. 2 Connect the leads from an ohmmeter to the valve coil terminals.

Valve coil specifications

Proportional solenoid valve, 12V 8.6Ω (schematic items M, O and R)

3 position 4 way directional valve, 10V 3.2Ω (schematic items A, B and C)

Normally open poppet valve 6.4Ω (schematic item S, U, BB and CC)

7 - 44 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

MANIFOLDS

10-3 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor on the tank side of the turntable.

Index Schematic No. Description Item Function Torque

1 Shuttle valve 2 position 3 way ...... HH ...... Turntable rotation brake release ...... 10-13 ft-lbs / 14-18 Nm 2 Counterbalance valve ...... II ...... Turntable rotate right ...... 35-40 ft-lbs / 47-54 Nm 3 Counterbalance valve ...... JJ ...... Turntable rotate left ...... 35-40 ft-lbs / 47-54 Nm

1 2 3

II

JJ

HH

Plug Torque Specifications

Description Hex size Torque

SAE No. 2 1/8 50 in-lbs / 6 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

Part No. 48412 Genie S-60 & Genie S-65 7 - 45 Section 7 - Repair Procedures Service Manual - Second Edition

MANIFOLDS

10-4 Oscillate Manifold Components

The oscillate manifold is mounted inside the drive chassis at the 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 ...... LL ...... Differential sensing ...... 10-12 ft-lbs / 14-16 Nm 3 Check valve ...... MM ...... Oscillate check - left ...... 35-40 ft-lbs / 47-54 Nm 4 Pilot operated unloader valve 950 psi (65 bar) ...... NN ...... Sequencing ...... 10-12 ft-lbs / 14-16 Nm 5 Shuttle valve 2 position 3 way ...... OO ...... Pilot ...... 10-12 ft-lbs / 14-16 Nm 6 Piston ...... Check valve circuit (the piston is located between index numbers 3 and 7) 7 Check valve ...... PP ...... Oscillate check - right ...... 35-40 ft-lbs / 47-54 Nm 8 Shuttle valve 2 position 3 way ...... QQ ...... Unloading ...... 35-40 ft-lbs / 47-54 Nm 9 Diagnostic fitting ...... Testing

1 2

KK

LL

9

MM 3

QQ NN

8 4

OO 7 Plug Torque Specifications PP 6 5 Description Hex size Torque

SAE No. 2 1/8 50 in-lbs / 6 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

7 - 46 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

MANIFOLDS

10-5 7 Repeat steps 3 through 6 and manually activate Valve Adjustments - the valve and recheck the valve pressure. Oscillate Manifold 8 Turn the engine off, then remove the pressure gauge and assemble the directional valve linkage. How to Adjust the Oscillate Sequencing Valve Pressure Sequencing valve specifications

When removing a hose assembly Pressure 950 psi or fitting, the O-ring on the fitting 65.5 bar and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Connect a 0 to 2000 psi (0 to 138 bar) pressure gauge to the test port located on the oscillate manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 2 Disconnect the directional valve linkage, by removing the clevis yoke from the drive chassis. 3 Start the engine from the platform controls. 4 With the engine running, manually activate the valve and observe the pressure reading on the pressure gauge. 5 Turn the engine off. Hold the unloader valve and remove the cap (item 4). 6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified.

Part No. 48412 Genie S-60 & Genie S-65 7 - 47 Section 7 - Repair Procedures Service Manual - Second Edition

MANIFOLDS

10-6 Directional Valve Manifold Components

The directional valve manifold is mounted inside the drive chassis at the non-steer end. Index No. Description Function Torque

1 Cap ...... Breather ...... 20-25 ft-lbs / 27-33Nm 2 Spool valve ...... Directional control

1

2

7 - 48 Genie S-60 & Genie S-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 replaced. 1 Lower the boom to the stowed position. 2 Use a "bubble type" level to be sure the floor is completely level. Failure to perform this procedure 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 air if needed to meet specification. 4 Remove the drive chassis cover from the non-steer end. 5 Disconnect the linkage clevis yoke from the drive chassis (if not already disconnected). 6 Place a "bubble type" level across the drive chassis non-steer end. Check to be sure the drive chassis is completely level. 7 To level the drive chassis, start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level. 8 Verify that the ground and drive chassis are completely level. 9 Adjust the length of the rod by turning the clevis yoke until the clevis yoke can be pinned to the drive chassis. 10 Install the clevis yoke pin 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 & Genie S-65 7 - 49 Section 7 - Repair Procedures Service Manual - Second Edition

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 ...... Steer left/right...... 30-35 in-lbs / 3-4 Nm 2 Check valve ...... TT ...... Priority flow regulator circuit ...... 10-12 ft-lbs / 14-16 Nm 3 Orifice Plug, 0.025 inch (0.635 mm) .. UU ...... Priority flow regulator circuit 4 Priority flow regulator valve, 3.5 gpm (13.2 l/min) . VV ...... Regulates flow to oscillate manifold ...... 10-12 ft-lbs / 14-16 Nm

SS

1

TT UU 4 2

VV 3

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Part No. 48412 Genie S-60 & 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 at the non-steer end. Index Schematic No. Description Item Function Torque

1 Relief valve, 250 psi (17.2 bar) ...... WW ...... Charge pressure circuit ...... 10-12 ft-lbs / 14-16 Nm 2 Flow divider/combiner valve ...... XX ...... Controls flow to drive motors in forward and reverse ...... 25-30 ft-lbs / 34-41 Nm 3 Orifice 0.070 in (1.78 mm) ...... YY ...... Drive circuit 4 Shuttle valve 3 position 3 way ...... ZZ ...... Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2-speed motor shift ...... 15-18 ft-lbs / 20-24 Nm 5 Diagnostic fitting ...... 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 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

MANIFOLDS

Part No. 48412 Genie S-60 & Genie S-65 7 - 53 Section 7 - Repair Procedures Service Manual - Second Edition

MANIFOLDS

10-9 Valve Adjustments, 2WD Drive Manifold

How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to the test port located on the drive manifold. 2 Start the engine from the platform controls. 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge. 4 Turn the engine off. Hold the charge pressure relief valve and remove the cap (item 1). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the valve cap. 6 Restart the engine. Drive the machine in either direction and recheck the valve pressure. 7 Turn the engine off, then remove the pressure gauge.

Charge Pressure Relief valve specifications

Pressure 250 psi 17.2 bar

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MANIFOLDS

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Part No. 48412 Genie S-60 & 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 at the non-steer end. Index Schematic No. Description Item Function Torque

1 Directional valve, 2 position 2 way .... AB ...... High speed divider bypass N.C. Pilot to open ...... 25-30 ft-lbs / 34-41 Nm 2 Flow divider/combiner valve ...... AC ...... 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 ...... 25-30 ft-lbs / 34-41 Nm 8 Orifice 0.070 in (1.78 mm) ...... AI ...... Rear drive motor circuit 9 Orifice 0.070 in (1.78 mm) ...... AJ ...... 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-lbs / 20-24 Nm 11 Diagnostic fitting ...... Testing 12 Check valve ...... AL ...... 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-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 - 56 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

MANIFOLDS

Part No. 48412 Genie S-60 & Genie S-65 7 - 57 Section 7 - Repair Procedures Service Manual - Second Edition

MANIFOLDS

10-11 Valve Adjustments, 4WD Drive Manifold

How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to the test port located on the drive manifold. 2 Start the engine from the platform controls. 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge. 4 Turn the engine off. Hold the charge pressure relief valve and remove the cap (index 3). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the valve cap. 6 Restart the engine. Drive the machine in either direction and recheck the valve pressure. 7 Turn the engine off, then remove the pressure gauge.

Charge Pressure Relief valve specifications

Pressure 250 psi 17.2 bar

7 - 58 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures Fuel and Hydraulic Tanks

11-1 11-2 Fuel Tank Hydraulic Tank

How to Remove the Fuel Tank The primary functions of the hydraulic tank are to cool, clean and deaerate the hydraulic fluid during Explosion hazard. Engine fuels operation. It utilizes internal suction strainers for are combustible. Remove the fuel the pump supply lines and has an external return tank in an open, well-ventilated line filter with a filter condition indicator. area away from heaters, sparks, flames and lighted tobacco. How to Remove the Always have an approved fire Hydraulic Tank extinguisher within easy reach. Component damage hazard. Explosion hazard. When The work area and surfaces transferring fuel, connect a where this procedure will be grounding wire between the performed must be clean and machine and pump or container. free of debris that could get 1 Turn the manual fuel shutoff valve to the into the hydraulic system. CLOSED position. When removing a hose assembly 2 Remove the tank side turntable cover. See 5-1, or fitting, the O-ring on the fitting How to Remove a Turntable Cover. and/or hose end must be replaced and then torqued to specification 3 Gasoline/LPG models: Disconnect, drain and during installation. plug the fuel hose. Refer to Section Two, Hydraulic Deutz Diesel models: Disconnect, drain and Hose and Fitting Torque plug the supply and return fuel lines. Cap the Specifications. fuel return fitting on the fuel tank. 1 Remove the fuel tank. See 11-1, How to 4 Remove the retaining fasteners from the fuel Remove the Fuel Tank. tank hold down straps. Remove the straps from the fuel tank. 5 Support the fuel tank with 2 lifting straps. Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane. 6 Remove the fuel tank from the machine. Crushing hazard. The fuel tank may become unbalanced and fall if it is not properly supported and secured to the overhead crane. Clean the fuel tank and inspect for rust and corrosion before installing.

Part No. 48412 Genie S-60 & Genie S-65 7 - 59 Section 7 - Repair Procedures Service Manual - Second Edition

FUEL AND HYDRAULIC TANKS

2 Close the two hydraulic shutoff valves located 10 Remove the hydraulic tank from the machine. at the hydraulic tank. Crushing hazard. The hydraulic may become unbalanced and fall if it is not properly supported and secured to the overhead crane. 11 Remove the suction strainers from the tank and clean them using a mild solvent. 12 Rinse out the inside of the tank using a mild solvent. open closed 13 Install the suction strainers using a thread Component damage hazard. The sealant on the threads. engine must not be started with 14 Install the drain plug using a thread sealant on the hydraulic tank shutoff valves in the threads. the CLOSED position or component damage will occur. If the tank 15 Install the hydraulic tank onto the machine. valves are closed, remove the key 16 Install the two suction hoses and the supply from the key switch and tag the hose for the auxiliary power unit. machine to inform personnel of the 17 Fill the tank with hydraulic oil until the level is condition. within the top 2 inches (5 cm) of the sight 3 Remove the drain plug from the hydraulic tank. gauge. Do not overfill. 4 Completely drain the tank into a suitable 18 Clean up any oil that may have spilled and open container. See capacity specifications. the hydraulic tank valves. 5 Tag, disconnect and plug the two suction hoses Component damage hazard. that are attached to the hydraulic tank Be sure to open the two hydraulic shutoff valves. tank valves and prime the pump after installing the hydraulic tank. 6 Disconnect and plug the T-fitting located at the return filter with the 2 hoses connected to it. Always use pipe thread sealant Cap the fitting on the return filter housing. when installing the drain plug. 7 Disconnect and plug the supply hose for the Use only Dexron II equivalent auxiliary power unit. Cap the fitting on the hydraulic fluid. hydraulic tank. Hydraulic system 8 Remove the retaining fasteners from the hydraulic tank hold down straps. Remove the Hydraulic tank capacity 45 gallons straps from the hydraulic tank. 170 liters 9 Support the hydraulic tank with 2 lifting straps. Place one lifting strap at each end of the tank Hydraulic system 55 gallons and attach the lifting straps to an overhead capacity (including tank) 208 liters crane. Hydraulic fluid Dexron equivalent

7 - 60 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

FUEL AND HYDRAULIC TANKS

How to Prime the Pump Deutz Diesel models: Hold the manual fuel shutoff valve clockwise to the CLOSED position. Component damage hazard. Be sure that the hydraulic tank shutoff a valves are in the OPEN 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 a 0 to 600 psi (0 to 41 bar) pressure gauge to the test port on the drive pump. a manual fuel shutoff valve 2 Gasoline/LPG models: Disconnect the electrical connector at the ignition coils. The 3 Crank the engine with the starter motor for ignition coils are located above the alternator. 15 seconds, wait 15 seconds, then crank the engine an additional 15 seconds or until the Electrocution hazard. pressure reaches 320 psi (22 bar). Contact with electrically charged circuits may cause death or 4 Connect the wiring and start the engine from serious injury. Remove all rings, the ground controls. Check for hydraulic leaks. watches and other jewelry.

Part No. 48412 Genie S-60 & Genie S-65 7 - 61 Section 7 - Repair Procedures Service Manual - Second Edition Turntable Rotation Components

12-1 2 Tag, disconnect and plug the hydraulic hoses from the motor, brake and manifold. Cap the Rotation Hydraulic Motor fittings on the motor, brake and torque hub. How to Remove the Rotation Bodily injury hazard. Spraying hydraulic oil can Hydraulic Motor penetrate and burn skin. Loosen hydraulic connections very slowly When removing a hose assembly to allow the oil pressure to or fitting, the O-ring on the fitting dissipate gradually. Do not and/or hose end must be replaced allow oil to squirt or spray. and then torqued to specification during installation. Refer to 3 Remove the motor/brake mounting fasteners, Section Two, Hydraulic Hose and then remove the motor from the brake. Fitting Torque Specifications. a b 1 Secure the turntable from rotating with the turntable rotation lock pin.

c

d f

Unlocked position e

a motor/brake mounting bolts b motor c brake d torque hub mounting bolts e torque hub f plug

Locked position

7 - 62 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

TURNTABLE ROTATION COMPONENTS

How to Remove the Turntable 4 Remove the plug from the side of the torque Rotation Brake or Torque Hub hub. Then drain the oil from the hub. 5 Install the torque hub. Torque the hub mounting 1 Secure the turntable from rotating with the bolts to 180 foot-pounds (244 Newton meters). turntable rotation lock pin. 6 Install the brake and motor onto the torque hub. 7 Fill the hub with oil from the side hole until the oil level is even with the bottom of the hole. Apply pipe thread sealant to the plugs, and then install the plugs. 8 Adjust turntable rotation gear backlash. See Repair Procedure 18-1, How to Adjust the Turntable Rotation Gear Backlash.

unlocked locked Turntable rotate torque hub

2 Remove the motor/brake mounting bolts, and Capacity 17 fluid ounces then remove the motor and brake from the 0.51 liters torque hub and set them to the side. Type: SAE 90 multipurpose hypoid gear oil - API Component damage hazard. service classification GL5 Hoses can be damaged if they are kinked or pinched.

a b

f c

d e

a motor/brake mounting bolt b motor c torque hub d torque hub mounting bolt e plug f brake 3 Remove the torque hub mounting bolts, and then use a lifting device to remove the torque hub from the machine.

Part No. 48412 Genie S-60 & Genie S-65 7 - 63 Section 7 - Repair Procedures Service Manual - Second Edition

TURNTABLE ROTATION COMPONENTS

How to Adjust the 6 Rotate the torque hub pivot plate away from the turntable until it contacts the adjustment bolt. Turntable Rotation Gear Backlash Then tighten the mounting fasteners on the The turntable rotation torque hub is mounted on a torque hub pivot plate. adjustable plate that controls the gap between the 7 Rotate the turntable through an entire rotation. rotation motor gear and the turntable bearing. Check for tight spots that could cause binding. Readjust if necessary. Be sure to check the backlash with the machine on a flat level surface. 1 Loosen the mounting fasteners on the torque hub pivot plate.

a

b

c

a pivot plate mounting bolts b adjustment bolt with lock nut c torque hub pivot plate 2 Push the torque hub pivot plate towards the turntable as far as possible (this will push the rotation gear into the rotation bearing). 3 Loosen the lock nut on the adjustment bolt. 4 Turn the adjustment bolt clockwise until it contacts the pivot plate.

5 Turn the adjustment bolt 1/2 turn counterclockwise. Then tighten the lock nut on the adjustment bolt.

7 - 64 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures 2WD Steering Axle Components

13-1 6 Remove the pin retaining fasteners from the Yoke and Hub yoke pivot pins. 7 Support the yoke/hub assembly with a lifting How to Remove the Yoke jack. and Hub 8 Use a slide hammer to remove the upper yoke pivot pin, then use a soft metal drift to drive the 1 Remove the pin retaining fasteners from both lower yoke pivot pin down and out. the steering cylinder and the tie rod pivot pins. Crushing hazard. The yoke/hub Remove the pins. assembly may become unbalanced and fall when the yoke a b c d pivot pins are removed if it is not properly secured and supported by the lifting jack.

Torque specifications

Lug nut torque, dry 420 ft-lbs 569.5 Nm

Lug nut torque, lubricated 320 ft-lbs 433.9 Nm

How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts. Do not remove g f f e them.

a tie rod 2 Block the non-steering wheels and place a b axle lifting jack of ample capacity under the steering c yoke pivot pin d yoke axle. e hub 3 Raise the machine 6 inches (15 cm) and place f pivot pin g steering cylinder blocks under the chassis for support. 2 Loosen the wheel lug nuts. Do not 4 Remove the lug nuts. Then remove the tire remove them. and wheel assembly. 3 Block the non-steering wheels, and then 5 Remove the dust cap, cotter pin and center a lifting jack of ample capacity under the slotted nut. steering axle. 6 Pull the hub off the spindle. The washer and 4 Raise the machine 6 inches (15 cm) and place outer bearing should fall loose from the hub. blocks under the chassis for support. 7 Place the hub on a flat surface and gently pry 5 Remove the lug nuts. Then remove the tire the bearing seal out of the hub. Remove the and wheel assembly. rear bearing.

Part No. 48412 Genie S-60 & Genie S-65 7 - 65 Section 7 - Repair Procedures Service Manual - Second Edition

2WD STEERING AXLE COMPONENTS

How to Install the 13-2 Hub and Bearings Steering Cylinders When replacing a wheel bearing, both the inner and outer bearings How to Remove a including the pressed-in races Steering Cylinder must be replaced. There are two identical steering cylinders that 1 Be sure that both bearings are packed work in parallel. They are part of the same with clean, fresh grease. hydraulic circuit, but move in opposite directions. 2 Place the large inner bearing into the rear The tie rod maintains equal movement of the tires. of the hub. When removing a hose assembly 3 Press the bearing seal evenly into the hub or fitting, the O-ring on the fitting until it is flush. and/or hose end must be replaced and then torqued to specification 4 Slide the hub onto the yoke spindle. during installation. Component damage. Do not Refer to Section Two, Hydraulic apply excessive force or damage Hose and Fitting Torque to the lip of the seal may occur. Specifications. 5 Place the outer bearing into the hub. 1 Tag, disconnect and plug the hydraulic hoses from the steering cylinder. Cap the fittings on 6 Install the washer and slotted nut. the cylinder. 7 Tighten the slotted nut to 35 foot-pounds Bodily injury hazard. Spraying (47 Nm). hydraulic oil can penetrate and 8 Loosen the slotted nut, then re-tighten to burn skin. Loosen hydraulic 8 foot-pounds (11 Nm). connections very slowly to allow the oil pressure to dissipate 9 Install a new cotter pin. Bend the cotter pin gradually. Do not allow oil to to lock it in. squirt or spray. 10 Install the dust cap, then the tire and wheel 2 Remove the pin retaining fasteners. Then assembly. Torque the wheel lug nuts to remove the pivot pin from each end of the 420 foot-pounds (569.5 Nm). steering cylinder. 3 Remove the steering cylinder from the machine.

7 - 66 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

2WD STEERING AXLE COMPONENTS

13-3 6 Slide the tie rod off the yoke and adjust it by Tie Rod turning the end. One half turn on the adjustable How to Remove the Tie Rod end equals approximately 1/4 inch (6.4 mm) change in the front 1 Remove the pin retaining fasteners, then and rear measurements. remove the pivot pin from each end of the tie 7 Slide the tie rod onto the yoke. Install the rod. pivot pin, then install the retaining bolt. 2 Remove the tie rod. 8 Tighten the jam nut against the tie rod. How to Perform the Toe-in 9 Lower the machine and recheck the Adjustment front and back measurements (step 2). If further adjustment is needed, repeat Perform this procedure on a steps 3 through 8. firm, level surface. Block the non-steering tires and be sure Toe-in specification 0 ± 1/8 inch (6.35 mm) 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 nut on the adjustable end of the tie rod. 5 Remove the pin retaining fasteners, then remove the pivot pin from the adjustable end of the tie rod.

Part No. 48412 Genie S-60 & 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 Yoke and Hub drive motor. How to Remove the Yoke Bodily injury hazard. Spraying hydraulic oil can penetrate and and Hub burn skin. Loosen hydraulic connections very slowly to allow The yoke installation utilizes bushings and a thrust the oil pressure to dissipate washer that may require periodic replacement. The gradually. Do not allow oil to yoke must be removed before the torque hub can squirt or spray. 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 Block the non-steering wheels, and then and then torqued to specification center a lifting jack of ample capacity under the during installation. steering axle. Refer to Section Two, Hydraulic 5 Raise the machine 6 inches (15.2 cm) and Hose and Fitting Torque 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 a 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 b 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. Secure the yoke/torque hub c assembly to the lifting jack. 13 Use a slide hammer to remove the upper yoke pivot pin, then use a soft metal drift to drive the g f e d lower yoke pivot pin down and out. a oscillate cylinder Crushing hazard. The yoke/hub b king pin c torque hub assembly may become d yoke unbalanced and fall when the yoke e pivot pin pivot pins are removed if it is not f tie rod properly secured and supported g steer cylinder by the lifting jack.

7 - 68 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures

4WD STEERING AXLE COMPONENTS

14 Place the yoke/torque hub assembly on a flat 14-2 surface with the torque hub facing down. Steering Cylinders 15 Remove the torque hub mounting fasteners that attach the yoke to the torque hub. Remove the How to Remove a yoke weldment from the torque hub. Steering Cylinder Replace the thrust washer when installing the yoke/torque hub This procedure is the same as the 2WD procedure. assembly onto the axle. See repair procedure 13-2, How to Remove a Steering Cylinder. Torque specifications

Lug nut, dry 420 ft-lbs 569.5 Nm 14-3 lubricated 320 ft-lbs 433.9 Nm Tie Rod Torque hub mounting bolts, dry 120 ft-lbs 163 Nm How to 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 Tie 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 & Genie S-65 7 - 69 Section 7 - Repair Procedures Service Manual - Second Edition Oscillating Axle Components

15-1 3 Tag, disconnect and plug the oscillating axle cylinder hydraulic hoses. Cap the fittings on the Oscillating Axle oscillate cylinder. Lock-out Cylinders Bodily injury hazard. Spraying hydraulic oil can penetrate and The oscillating axle cylinders extend and retract burn skin. Loosen hydraulic between the drive chassis and the oscillating axle. connections very slowly to allow The cylinders are equipped with counterbalance the oil pressure to dissipate valves to prevent movement in the event of a gradually. Do not allow oil to squirt hydraulic line failure. The valves are not or spray. adjustable. 4 Remove the pin retaining fasteners from the How to Remove an Oscillating rod-end pivot pin. Use a soft metal drift to Axle Cylinder remove the pin. 5 Attach a lifting strap from an overhead crane to This procedure requires specific the barrel end of the oscillating cylinder. repair skills and a suitable workshop. Attempting this 6 Remove the pin retaining fasteners from the procedure without these skills barrel-end pivot pin. Use a soft metal drift to and tools may result in death or remove the pin. serious injury and significant Crushing hazard. The oscillate component damage. Dealer cylinder may become unbalanced service is strongly recommended. and fall when it is removed from Perform this procedure on a firm, the machine if it is not properly level surface with the boom in attached to the overhead crane. the stowed position. 7 Remove the cylinder from the machine. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Rotate the boom until the boom is between the steer tires. 2 Remove the fasteners from drive chassis cover at the steer end. Remove the cover.

7 - 70 Genie S-60 & Genie S-65 Part No. 48412 Service Manual - Second Edition Section 7 - Repair Procedures Non-steering Axle Components

16-1 4 Slide the drive motor shaft out of the brake and Drive Motor then remove the drive motor from the machine. Torque specifications How to Remove a Drive Motor Drive motor mounting bolts 75 ft-lbs Component damage hazard. 102 Nm Repairs to the motor should only be performed by an authorized Sundstrand-Sauer dealer. Component damage hazard. The work area and surfaces where this 16-2 procedure will be performed must be clean and free of debris that Torque Hub could get into the hydraulic system and cause severe component How to Remove a Drive damage. Dealer service is recommended. Torque Hub When removing a hose assembly When removing a hose assembly or fitting, the O-ring on the fitting or fitting, the O-ring on the fitting and/or hose end must be replaced and/or hose end must be replaced and then torqued to specification and then torqued to specification during installation. during installation. Refer to Section Two, Hydraulic Refer to Section Two, Hydraulic Hose and Fitting Torque Hose and Fitting Torque Specifications. Specifications. 1 Remove the fasteners from drive chassis cover 1 Remove the drive motor. See 22-1, How to at the non-steer end. Remove the cover. Remove a Drive Motor. 2 Tag, disconnect and plug the hydraulic hoses 2 Tag, disconnect and plug the hydraulic hose from the drive motor. Cap the fittings on the from the brake. Then remove the hydraulic drive motor. fitting and the bleed valve. Bodily injury hazard. Spraying 3 Loosen the wheel lug nuts. Do not remove hydraulic oil can penetrate and them. burn skin. Loosen hydraulic connections very slowly to allow 4 Center a lifting jack of ample capacity under the the oil pressure to dissipate non-steering axle. Raise the machine and place gradually. Do not allow oil to squirt blocks under the drive chassis for support. or spray. 5 Remove the wheel lug nuts, then the tire and 3 Remove the drive motor mounting fasteners. 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 & 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 hub may become unbalanced and fall if it is not properly supported and secured to the lifting jack.

Torque specifications

Lug nut, dry 420 ft-lbs 569.5 Nm lubricated 320 ft-lbs 433.9 Nm

Torque hub mounting bolts, dry 120 ft-lbs 163 Nm lubricated 90 ft-lbs 122 Nm

Drive motor mounting bolts, dry 75 ft-lbs 102 Nm lubricated 56 ft-lbs 76 Nm

7 - 72 Genie S-60 & Genie S-65 Part No. 48412 Genie North America 18340 NE 76th Street P.O. Box 97030 Redmond, Washington 98073-9730

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