Genie S-60 Service Manual
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Genie S-60 Service Manual

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Service Manual
Third Edition
First Printing
Part No. 65196

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Summary of Contents for Genie S-60

  • Page 1 Service Manual Third Edition First Printing Part No. 65196...
  • Page 2 Readers are encouraged to notify Genie of errors "Genie" and "S" are Registered Trademarks and send in suggestions for improvement. All of Genie Industries in the USA and many other countries. communications will be carefully considered for future printings of this and other manuals. Please...
  • Page 3 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.
  • Page 4 Be sure that your workshop or work area hazardous situation which, if not is properly ventilated and well lit. avoided, may result in property damage. Green—used to indicate operation or maintenance information. Genie S-60 & Genie S-65 Part No. 65196...

  • Page 5: Table Of Contents

    Theory of Operation Power Source ......................3 - 1 Hydraulic System ...................... 3 - 1 Electrical System ...................... 3 - 1 Limit Switches ......................3 - 2 Machine Controls ...................... 3 - 2 Part No. 65196 Genie S-60 & Genie S-65...
  • Page 6 A-22 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ...... 4 - 25 A-23 Check the Engine Belt - Gasoline/LPG and Perkins Diesel Models ....4 - 26 A-24 Replace the Fuel Filters - Gasoline/LPG Models ........... 4 - 28 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 7 B-23 Inspect the Fuel Tank Cap Venting System ..........4 - 49 B-24 Replace the Engine Air Filter Element ............4 - 50 B-25 Replace the Spark Plugs - Gasoline/LPG Models ......... 4 - 51 Part No. 65196 Genie S-60 & Genie S-65...
  • Page 8 Replace the Engine Air Breather - Perkins Diesel Models ......4 - 78 Grease the Steer Axle Wheel Bearings, 2WD Models ........4 - 78 Check the Fuel Injectors - Perkins Diesel Models ......... 4 - 80 Genie S-60 & Genie S-65 Part No. 65196 viii...
  • Page 9 Boom Extend Function Inoperative ............... 5 - 34 Boom Retract Function Inoperative ............... 5 - 36 Turntable Rotate Left Function Inoperative ........... 5 - 38 Turntable Rotate Right Function Inoperative ..........5 - 42 Part No. 65196 Genie S-60 & Genie S-65...
  • Page 10 Machine Will Not Drive At Full Speed ............5 - 69 Machine Drives At Full Speed With Platform Raised or Extended ....5 - 70 Drive Enable System Is Malfunctioning ............5 - 71 Auxiliary Functions Inoperative ..............5 - 72 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 11 2WD Hydraulic Schematic - Non-oscillating axle ............. 6 - 22 2WD Hydraulic Schematic - Oscillating axle ............6 - 23 4WD Hydraulic Schematic - Non-oscillating axle ............. 6 - 24 4WD Hydraulic Schematic - Oscillating axle ............6 - 25 Part No. 65196 Genie S-60 & Genie S-65...
  • Page 12 Boom ......................7 - 23 Boom Lift Cylinder ..................7 - 26 Extension Cylinders ..................7 - 27 Platform Leveling Master Cylinder ..............7 - 29 Turntable Covers Turntable Covers ..................7 - 30 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 13 Components ..................7 - 39 Engine Fault Codes - Ford Models ..............7 - 39 Hydraulic Pumps 10-1 Lift/Steer Pump ..................... 7 - 41 10-2 Drive Pump ....................7 - 42 xiii Part No. 65196 Genie S-60 & Genie S-65...
  • Page 14 11-13 Jib Boom/Platform Rotate Manifold Components, S-65 Models ....7 - 63 Fuel and Hydraulic Tanks 12-1 Fuel Tank ...................... 7 - 64 12-2 Hydraulic Tank ....................7 - 65 Turntable Rotation Components 13-1 Rotation Hydraulic Motor ................7 - 68 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 15 16-1 Oscillating Axle Lock-out Cylinders ............... 7 - 77 Non-steering Axle Components 17-1 Drive Motor ....................7 - 78 17-2 Drive Hub ...................... 7 - 79 17-3 Wheel Brake ....................7 - 80 Part No. 65196 Genie S-60 & Genie S-65...
  • Page 16 Third Edition • First Printing This page intentionally left blank. Genie S-60 & Genie S-65 Part No. 65196...

  • Page 17: Specifications

    0.5 liters ANSI and CSA 150 lbs 150 lbs 667 N 667 N Continuous improvement of our products is a Genie 90 lbs 90lbs policy. Product specifications are subject to change 400N 400N without notice. Part No. 65196 Genie S-60 &...

  • Page 18: Performance Specifications

    Gradeability (boom stowed) Platform level down 25 to 55 seconds Rough terrain Jib boom up, S-65 models 40 to 60 seconds Jib boom down, S-65 models 50 to 80 seconds 2 - 2 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 19: Hydraulic Specifications

    0.152 cu in 2.5 cc Displacement per revolution, variable 1.12 to 2.8 cu in 18.4 to 45.9 cc Displacement 1.4 gpm 5.3 l/min Auxiliary pump 2500 psi relief pressure 172 bar Part No. 65196 Genie S-60 & Genie S-65 2 - 3...

  • Page 20: Ford Engine Lrg 425 Efi Specifications

    Use oils meeting API classification SG (labeled SG/CC Capacity quarts or SG/CD) as they offer improved wear protection. 10.9 liters Units ship with 10W-40 SG/CC. Alternator Output 95A, 14.5VDC 2 - 4 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 21: Deutz Engine F4L 1011F Specifications

    -10°F to 90°F / -23°C to 32°C 10W-40 Temperature above -4°F / -34°C 15W-40 Engine oil should have properties of API classification SG/CC or CD/SG grades. Units ship with 10W-40 SG/CC. Part No. 65196 Genie S-60 & Genie S-65 2 - 5...

  • Page 22: Perkins Engine

    Engine oil should have properties of API classification CC/SE. API classification CD/SE or CCMC D4 can be used, but is not recommended during the first 50 hours or for light load applications. 2 - 6 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    6 Operate all machine functions and inspect the O-ring field service kit hoses and fittings and related components to (Genie part number 49612). be sure that there are no leaks. 2 Lubricate the O-ring before installation. Part No. 65196 Genie S-60 & Genie S-65 2 - 7...
  • Page 24 Section 2 • Specifications Third Edition • First Printing This page intentionally left blank. 2 - 8 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 25: Theory Of Operation

    Section 3 • Theory of Operation Theory Of Operation Power Source Electrical System The Genie S-60 and Genie S-65 are powered by Boom/Steer functions are accomplished by either a Gasoline/LPG engine or one of two diesel moving a toggle switch or a controller, which engines.

  • Page 26: Limit Switches

    Limit switches Machine Controls There are two types of limit switches which are The Genie S-60 and Genie S-65 machines are found in various locations on the machine: drive equipped with operational controls which are found speed limit switches and a drive enable limit in two locations: the ground controls, located on switch.
  • Page 27 · Key switch in the position with the Indicates that a specific result is expected after key removed performing a series of steps. · Wheels chocked Part No. 65196 Genie S-60 & Genie S-65 4 - 1...
  • Page 28 Make copies of the Maintenance Inspection Report Indicates that dealer service is required to use for each inspection. Store completed forms to perform this procedure. for three years. 4 - 2 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 29: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 65196 Genie S-60 & Genie S-65 4 - 3...
  • Page 30 Y = yes, acceptable separator-Deutz models N = no, remove from service D-10 Change fuel lines- R = repaired Deutz models D-11 Valves-Deutz models Comments D-12 Clean engine breather- Perkins models 4 - 4 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 31: Inspect The Operators And Safety Manuals

    1 Check to be sure that the storage container is present and in good condition. 1 Refer to the Decals section in the Genie S-60 & Genie S-65 Operator's Manual and use the 2 Check to make sure that the operator's,...

  • Page 32: Inspect For Damage And Loose Or Missing Parts

    · Boom wear pads · Tires and wheels · Engine and related components · Limit switches, alarms, horn and beacon · Nuts, bolts and other fasteners · Platform entry mid-rail or gate 4 - 6 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 33: Check The Engine Oil Level

    -10° to 90°F / -23° to 32°C 5W-30 above -10°F / -23°C 5W-30 above 25°F / -4°C 10W-30 Use oils meeting API classification SH or SG grade. Units ship with 10-40 CC/SG. Part No. 65196 Genie S-60 & Genie S-65 4 - 7...

  • Page 34: Check The Engine Coolant Level - Liquid Cooled Models

    (LPG) tank by turning it counterclockwise tank. Add fluid as needed. (if equipped). Result: The fluid level should be at the mark. FULL Do not remove the radiator cap. 4 - 8 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 35: Check The Hydraulic Oil Level

    Hydraulic oil specifications machine. Repair the leak immediately. Hydraulic oil type Dexron equivalent Tank capacity 45 gallons 170 liters Hydraulic system 53 gallons (including tank) 200.6 liters Part No. 65196 Genie S-60 & Genie S-65 4 - 9...

  • Page 36: Check For Hydraulic Leaks

    · Primary, and jib booms Tire size 15-19.5 NHS · The underside of the turntable · The underside of the drive chassis Pressure 85 psi · Ground area under the machine 5.86 bar 4 - 10 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 37: Test The Oscillate Axle (If Equipped)

    If the chassis does not remain level during test, see Repair Procedure 11-6, How to Set Up the Directional Valve Linkage OR see Repair Procedure 11-5, How to Adjust the Oscillate Sequencing Valve Pressure. Part No. 65196 Genie S-60 & Genie S-65 4 - 11...

  • Page 38: Test The Platform And Ground Controls

    Emergency Stop switch. Diesel models: All functions should stop immediately. The engine will shut off after 2 to 3 seconds. 4 - 12 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 39: Test The Auxiliary Power Operation

    4 Turn the key switch to platform control. 5 Pull out the Emergency Stop button to the position at the platform controls, then press down the foot switch. Part No. 65196 Genie S-60 & Genie S-65 4 - 13...

  • Page 40: Test The Tilt Sensor

    · Broken or missing roller or arm · Missing fasteners · Loose wiring fuel tank tilt sensor ground control box turntable riser boom boom up drive limit switch (LS2) 4 - 14 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 41 All models 1 foot per second (0.6 mph) A distinct click should be felt and heard. 0.3 meter per second (0.97 km/h) Part No. 65196 Genie S-60 & Genie S-65 4 - 15...
  • Page 42 Result: The drive enable indicator light should be on. Drive function should not operate until the drive enable override toggle switch is activated. turntable drive enable limit switch (LS3) turntable rotation bearing 4 - 16 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 43: Drain The Fuel Filter/Water Separator - Diesel Models

    Refer to C-4 in this section, Replace The Fuel Filter Element - Perkins Diesel Models, for instructions on how to prime the fuel filter/water separator. Part No. 65196 Genie S-60 & Genie S-65 4 - 17...
  • Page 44 Allow the water to drain into a suitable machine. Repair the leak container until fuel starts to come out. immediately. Immediately tighten the drain plug. fuel filter drain plug 4 - 18 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 45: Inspect The Engine Air Filter

    7 Install the end cap onto the canister. Install and tighten the retaining ring. 7 Install the end cap onto the canister. Secure the retaining fasteners. Air filters - Genie part numbers Ford LRG-425 EFI Engine 27916 Deutz F4L 1011F Engine...

  • Page 46: Perform 30 Day Service

    Bodily injury hazard. Beware of hot engine parts and coolant. Contact with hot engine parts and/or coolant may cause severe burns. 1 Remove the air baffle retaining fasteners. Remove the air baffle. 4 - 20 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 47: Check The Battery

    3 Be sure that the battery hold downs and cable position and install the two engine pivot plate connections are tight. retaining bolts. 7 Replace the air baffle and install the air baffle retaining fasteners. Part No. 65196 Genie S-60 & Genie S-65 4 - 21...

  • Page 48: Replace The Engine Oil And Filter - Gasoline/Lpg Models

    1 Open the engine side turntable cover and remove the oil filler cap located on the valve cover. 4 - 22 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 49 7 Use an oil filter wrench and remove the filter. Use oils meeting API classification SH or SG grade. 8 Apply a thin layer of fresh oil on the gasket of Oil filter - Genie part number 52581 the new oil filter. Install the filter and tighten it securely by hand.

  • Page 50: Inspect The Electrical Wiring

    10 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts. engine pivot plate pivot plate retaining bolts air baffle 4 - 24 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 51: Check The Oil Cooler And Cooling Fins - Deutz Diesel Models

    3 Clean the oil cooler of debris and foreign Bodily injury hazard. Beware of material. hot engine components. Contact with hot engine components may cause severe burns. Part No. 65196 Genie S-60 & Genie S-65 4 - 25...

  • Page 52: Check The Engine Belt - Gasoline/Lpg And Perkins Diesel Models

    9 Install the engine side cover. 10 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts. 4 - 26 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 53 Perkins Diesel models inch to inch 2 Inspect the engine belt for: 9 mm to 12 mm · Cracking Engine belts - Genie part numbers · Glazing Ford models 52580 Perkins Diesel models 62423 · Separation · Breaks 3 Replace belt if any damage is found.

  • Page 54: Replace The Fuel Filters - Gasoline/Lpg Models

    4 Disconnect and plug the fuel hose from the fuel Gasoline/LPG Models pre-filter to the fuel pump, then remove the pre- filter. 5 Install the new fuel pre-filter (Genie part number 52179) and connect the fuel hoses to the filter. Engine specifications require that this procedure be performed every 6 Clean up any fuel that may have spilled during 200 hours.
  • Page 55 Third Edition • First Printing Section 4 • Scheduled Maintenance Procedures TABLE A PROCEDURES 11 Install the new fuel pressure regulator/filter (Genie part number 52567) onto the engine mounting leg and connect the hoses to the regulator/filter. Component damage hazard. Be...

  • Page 56: Check The Exhaust System

    1 Diesel models: Remove the 2 bolts from under the engine pivot plate. Swing the engine pivot plate away from the machine to access the exhaust system. engine pivot plate pivot plate retaining bolts air baffle 4 - 30 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 57: Check The Hydraulic Tank Return Filter Condition Indicator

    , this indicates that the hydraulic filter is being bypassed and the filter should be replaced. See B-22, Replace the Hydraulic Tank Return Filter. Part No. 65196 Genie S-60 & Genie S-65 4 - 31...

  • Page 58: Inspect The Tires And Wheels (Including Lug Nut Torque)

    1 Check all tire treads and sidewalls for cuts, cracks, punctures and unusual wear. 2 Check each wheel for damage, bends and cracked welds. 3 Check each lug nut for proper torque. 4 - 32 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 59: Confirm The Proper Brake Configuration

    1 Check each drive hub disconnect cap to be drive pump sure it is in the engaged position. free-wheel valve lift pump brake disengage position screwdriver The free-wheel valve should always remain closed. brake engage position Part No. 65196 Genie S-60 & Genie S-65 4 - 33...

  • Page 60: Check The Oil Level In The Drive Hubs

    3 If necessary, remove the top plug and add oil until the oil level is even with the bottom of the drive hub side plug hole. plug 4 - 34 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 61 Turntable rotate drive hub oil Capacity 17 fluid ounces 0.51 liters Type SAE 90 multipurpose hypoid gear oil - API service classification GL5 Part No. 65196 Genie S-60 & Genie S-65 4 - 35...

  • Page 62: Check And Adjust The Engine Rpm

    1 Connect a tachometer to the engine. Start the engine from the ground controls. Result: Low idle should be 1500 rpm for Deutz models, 1600 rpm for Perkins models. 4 - 36 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 63: Test The Key Switch

    6 Turn the key switch to the position. Result: The engine should stop and no functions should operate. Diesel models: All functions should stop immediately. The engine will shut off after 2 to 3 seconds. Part No. 65196 Genie S-60 & Genie S-65 4 - 37...

  • Page 64: Test The Emergency Stop Buttons

    Result: The engine should shut off and no machine functions should operate. The ground control Emergency Stop button will stop all machine operation, even if the key switch is switched to platform control. 4 - 38 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 65: Check The Directional Valve Linkage

    Result: The platform should remain level at · Linkage is properly attached to all times to within ±5 degrees. directional valve directional valve clevis pin with cotter pin (hidden) yoke lock nut Part No. 65196 Genie S-60 & Genie S-65 4 - 39...

  • Page 66: Test The Horn

    4 Do not press down the foot switch and operate the machine functions. Result: The machine functions should not operate. 5 Press down the foot switch and operate the machine functions. Result: The machine functions should operate. 4 - 40 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 67: Test The Engine Idle Select Operation

    (rabbit symbol) position. Result: The engine RPM should change to high idle. 3 Release the function enable toggle switch. Result: The engine RPM should change to low idle. Part No. 65196 Genie S-60 & Genie S-65 4 - 41...

  • Page 68: Test The Fuel Select Operation - Gasoline/Lpg Models

    3 Press down the foot switch to allow the engine to run at high idle. Result: The engine should start promptly and operate smoothly in low and high idle. 4 - 42 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 69: Test The Drive Enable System

    5 Move the lift/drive select toggle switch to the drive position (if equipped). 6 Slowly move the drive control handle off center. Result: The drive function should not operate. Part No. 65196 Genie S-60 & Genie S-65 4 - 43...

  • Page 70: Test The Drive Brakes

    3 Move the lift/drive select switch to the drive position (if equipped). 4 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the test line. 4 - 44 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 71: Test The Drive Speed - Stowed Position

    (if equipped). 4 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. Part No. 65196 Genie S-60 & Genie S-65 4 - 45...

  • Page 72: Test The Drive Speed - Raised Or Extended Position

    All models 1 foot per second (0.6 mph) when crossing the start and finish lines. 0.3 meter per second (0.97 km/h) 4 - 46 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 73: Test The Alarm Package (If Equipped)

    Result: The descent alarm should sound when the toggle switch is held down. 3 Turn the key switch to platform controls. Result: The flashing beacons should be and flashing. Part No. 65196 Genie S-60 & Genie S-65 4 - 47...

  • Page 74: Perform Hydraulic Oil Analysis

    1 Place a suitable container under the hydraulic tank return filter. 2 Remove the filter with an oil filter wrench. 3 Apply a thin layer of fresh oil to the new oil filter gasket. 4 - 48 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 75: Inspect The Fuel Tank Cap Venting System

    Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off. 1 Remove the cap from the fuel tank. Part No. 65196 Genie S-60 & Genie S-65 4 - 49...

  • Page 76: Replace The Engine Air Filter Element

    2 Remove the end cap from the air cleaner canister. 3 Remove the air filter retaining fastener. Remove the filter element. 4 Clean the inside of the canister and the gasket with a damp cloth. 4 - 50 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 77 6 Install the end cap onto the canister. Secure the 6 Install the end cap onto the canister. Install and retaining fasteners. tighten the retaining ring. Air filters - Genie part numbers Perkins Diesel models: Ford LRG-425 EFI Engine 27916...

  • Page 78: Replace The Spark Plugs - Gasoline/Lpg Models

    0.042 to 0.046 inches machine to access the spark plugs. 1.07 to 1.18 mm Spark plug torque 5-10 ft-lbs 7-14 Nm engine pivot plate pivot plate retaining bolts air baffle 4 - 52 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 79: Check The Engine Belt - Deutz Diesel Models

    Belt deflection - Deutz Diesel models inch to inch 9 mm to 12 mm Engine belt - Genie part number 32698 engine pivot plate pivot plate retaining bolts air baffle Part No. 65196 Genie S-60 & Genie S-65...

  • Page 80: Check The Engine Valve Clearances - Deutz Diesel Models

    Complete information to perform this procedure is more often. available in the Deutz F4L 1011F Operation Manual , Deutz part number 0297 7343 (Genie part Explosion and fire hazard. Engine number 52883). fuels are combustible. Perform this...
  • Page 81 18 Start the engine from ground controls and 7 Install the bowl onto the new filter element check for leaks. (Genie part number 22942). Part No. 65196 Genie S-60 & Genie S-65 4 - 55...

  • Page 82: Replace The Fuel Filter Element - Perkins Diesel Models

    1 Open the engine side turntable cover and locate the fuel filter. 7 Lightly lubricate the upper seal and the o-ring with clean diesel fuel and install them into the filter head. 4 - 56 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 83: Replace The Engine Oil And Filter - Perkins Diesel Models

    See capacity specifications. Do not remove the drain plug located on the side of the oil pan. 4 Install and tighten the plug in the drain hose. Part No. 65196 Genie S-60 & Genie S-65 4 - 57...

  • Page 84: Check The Glow Plugs - Perkins Diesel Models

    Perkins 700 Series Workshop the oil filter. Manual , Perkins part number TPD 1359E (Genie part number 62424). 8 Fill the engine with new oil per specifications and install the oil filler cap.

  • Page 85: Check The Specific Gravity Of Engine Coolant - Liquid Cooled Models

    4 Allow the engine to cool until the temperature of the coolant is below 140° F (60° C). Burn hazard. Beware of hot coolant. Contact with hot coolant may cause severe burns. Part No. 65196 Genie S-60 & Genie S-65 4 - 59...

  • Page 86: Replace The Pcv Valve - Gasoline/Lpg Models

    6 Install the new PCV valve and connect the hose. 7 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts. PCV Valve - Genie part number 33957 engine pivot plate pivot plate retaining bolts air baffle 4 - 60 Genie S-60 &...

  • Page 87: Check The Boom Wear Pads

    Wear pad specifications engage position Upper and side wear pads inch 14.3 mm Bottom wear pads inch 17.5 mm Part No. 65196 Genie S-60 & Genie S-65 4 - 61...
  • Page 88 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub. disengage position engage position drive pump free-wheel valve lift pump screwdriver 4 - 62 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 89: Check The Turntable Rotation Bearing Bolts

    The lift cylinder safety chock is sequence to 210 ft-lbs (285 Nm). available through Genie (part number 33484). Bolt torque sequence Part No. 65196 Genie S-60 & Genie S-65 4 - 63...

  • Page 90: Grease The Turntable Rotation Bearing And Rotate Gear

    5 Repeat steps 1 through 4 for all the other drive hubs. Oil capacity per hub 44 fl oz 1.30 liters Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5 4 - 64 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 91 Oil capacity 17 fluid ounces 0.51 liters Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5 motor motor/brake mounting bolts brake drive hub drive hub mounting bolts Part No. 65196 Genie S-60 & Genie S-65 4 - 65...

  • Page 92: Replace The Drive Loop Hydraulic Filter

    2 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing. 3 Remove the filter element from the housing. 4 - 66 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 93: Replace The Engine Oil And Filter-Deutz Diesel Models

    7 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter. Part No. 65196 Genie S-60 & Genie S-65 4 - 67...

  • Page 94: Clean The Fuel Pump Strainer - Deutz Diesel Models

    Always have an Engine oil should have properties of API classification approved fire extinguisher within CC/SE or CC/SF grades. easy reach. Oil filter - Genie part number 49924 Perform this procedure with the engine off. Immediately clean up any fuel that may have spilled during this procedure.

  • Page 95: Replace The Diesel Fuel Filter/Water Separator - Deutz Diesel Models

    Perform this procedure with the engine off. 1 Turn the manual fuel shutoff valve, located at the fuel tank, to the position. CLOSED Part No. 65196 Genie S-60 & Genie S-65 4 - 69...

  • Page 96: Change The Fuel Hoses - Deutz Diesel Models

    Repair the leak immediately. engine pivot plate pivot plate retaining bolts oil drain hose air baffle 4 - 70 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 97 Part No. 65196 Genie S-60 & Genie S-65 4 - 71...

  • Page 98: Check The Engine Valve Clearances - Perkins Diesel Models

    Complete information to perform this procedure is Complete information to perform this procedure is available in the Perkins Workshop Manual , available in the Perkins Workshop Manual , (Perkins part number TPD 1359E) Genie part (Perkins part number TPD 1359E) Genie part number 62424. number 62424).

  • Page 99: Test Or Replace The Hydraulic Oil

    Remove the 1 Remove the fuel tank. See Repair Section 12-1, hold down straps from the hydraulic tank. How to Remove the Fuel Tank. Part No. 65196 Genie S-60 & Genie S-65 4 - 73...
  • Page 100 Hydraulic fluid Dexron equivalent 17 Fill the tank with hydraulic oil until the level is within the top 2 inches (5 cm) of the sight gauge. Do not overfill. 4 - 74 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 101: Change Or Recondition The Engine Coolant - Liquid Cooled Models

    12 Start the engine from the ground controls and let it run for 30 seconds. Turn the engine off and inspect for leaks. engine pivot plate pivot plate retaining bolts air baffle Part No. 65196 Genie S-60 & Genie S-65 4 - 75...

  • Page 102: Change The Fuel Hoses - Gasoline/Lpg Models

    Perform this procedure with the engine off and cooled. 1 Tag, disconnec and plug the fuel hose from the fuel tank at the manual shutoff valve. 4 - 76 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 103 9 Swing the engine pivot plate back to its original before disconnecting them. position and install the two engine pivot plate retaining bolts. Part No. 65196 Genie S-60 & Genie S-65 4 - 77...

  • Page 104: Replace The Engine Air Breather - Perkins Diesel Models

    Maintaining the steer axle wheel bearings is available in the Perkins 700 Series Workshop essential for safe machine operation and service Manual , Perkins part number TPD 1359E (Genie life. Operating the machine with loose or worn part number 62424).
  • Page 105 (15 cm). Remove the blocks from under the the bearing seal out of the hub. Remove the drive chassis. inner bearing. 26 Lower the machine. 13 Pack both bearings with clean, fresh grease. Part No. 65196 Genie S-60 & Genie S-65 4 - 79...

  • Page 106: Check The Fuel Injectors - Perkins Diesel Models

    3000 hours or 18 months, whichever comes first. Complete information to perform this procedure is available in the Perkins 700 Series Workshop Manual , Perkins part number TPD 1359E (Genie part number 62424). 4 - 80 Genie S-60 & Genie S-65...
  • Page 107 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.
  • Page 108 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. 65196...

  • Page 109: Fault Code Chart

    Pressure shorted wires from the MAP sensor to the ground OR poor (MAP) sensor ECM to ground OR replace MAP sensor. terminal connection. high voltage. Part No. 65196 Genie S-60 & Genie S-65 5 - 3...
  • Page 110 Section OR check for poor terminal is not sending the high voltage. connection from the fuel pump relay to fuel signal to the fuel pump pump OR replace the ECM. to turn ON. 5 - 4 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 111 ECM OR engine oil. replace the oil pressure switch Part No. 65196 Genie S-60 & Genie S-65 5 - 5...
  • Page 112 ECM Fault - from one or more of the Illegal sensors and has gone Replace the ECM. Operation. into a default program and then return to normal operation 5 - 6 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 113 Check battery and/or alternator condition System to the ECM is 18V DC OR check for shorted wires or poor terminal voltage high. or more. connections from the battery to the ECM. Part No. 65196 Genie S-60 & Genie S-65 5 - 7...

  • Page 114: Engine Will Not Crank Over

    #6 on the power supply wire circuit ignition/start module. from CB1 to CR1 to CR2 then to terminal #6 to on ignition/start module. Continued on the next page. 5 - 8 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 115 Check voltage at starter Repair open in battery cable. cable to starter. Repair or replace starter or starter solenoid. Part No. 65196 Genie S-60 & Genie S-65 5 - 9...

  • Page 116: Engine Cranks Over But Will Not Start - Gasoline/Lpg Models

    Remove #1 spark plug spark and ground spark plug Consult Genie Industries body. Crank engine and Service Department. observe spark. weak or no spark Continued on the next page. 5 - 10 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 117 ECM to ignition coil OR check for loose or bad connections from the ECM to the ignition coil OR replace the ignition coil OR consult Genie Industries Service Department. Part No. 65196 Genie S-60 & Genie S-65 5 - 11...

  • Page 118: Engine Runs While Cranking Then Dies- Gasoline/Lpg Models

    Genie Industries Service check voltage at Department. terminal #4. Test auxiliary power toggle switches TS1 and TS9. See Repair Section. Replace ignition/start module OR consult Genie Industries Service Department. 5 - 12 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 119: Engine Cranks Over But Will Not Start - Diesel Models

    Check voltage at red Repair open in red wire wire on terminal #30 of circuit from battery to CR2. CB1 to CR1 to CR2. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 13...
  • Page 120 6 to 7V Repair open in org/blk #41 wire circuit from alternator to TB41 to terminal #2 on ignition/ 6 to 7V start module. Continued on the next page. 5 - 14 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 121 Genie Industries Service check voltage at Department. terminal #4. Test auxiliary power toggle switches TS1 and TS9. See Repair Section. Replace ignition/start module OR consult Genie Industries Service Department. Part No. 65196 Genie S-60 & Genie S-65 5 - 15...

  • Page 122: Engine Will Not Start On Lpg, But Will Start On Gasoline - Gasoline/Lpg Models

    ECM to both Emergency Stop terminal #85 on CR3 OR buttons pulled out to the replace ECM. position, check voltage at terminal #85 on CR3. Continued on the next page. 5 - 16 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 123 Check resistance of 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. Part No. 65196 Genie S-60 & Genie S-65 5 - 17...

  • Page 124: Engine Will Not Start On Gasoline, But Will Start On Lpg Gasoline/Lpg Models

    2 seconds. Did the fuel pump turn on? See Ford LRG-425 EFI service manual for fuel system troubleshooting OR consult Genie Industries Service Department. 5 - 18 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 125: Engine High Idle Inoperative - Gasoline/Lpg Models

    Check voltage at TB35. Repair open in blk/red wire circuit from toggle switch to TB35. Repair open in tan/blu wire from TB35 to ECM OR consult Genie Industries Service Department. Part No. 65196 Genie S-60 & Genie S-65 5 - 19...

  • Page 126: Engine Low Idle Inoperative - Gasoline/Lpg Models

    LPG, see Repair section for LPG Replace ECM or consult regulator adjustments. Genie Industries Service Department. Be sure throttle linkage from governor to carburetor is not binding, see Repair section. 5 - 20 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 127: Engine High Idle Inoperative - Diesel Models

    #85 on CR3. terminal #85 on CR3. continuity Check voltage to Replace CR3 relay. terminal #87 on CR3. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 21...
  • Page 128 Check if 2-speed Check linkage or solenoid moves in and replace solenoid. out freely. moves freely Replace 2-speed solenoid. Note: resistance across solenoid terminals should be approximately 0.3 ohms. 5 - 22 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 129: Engine Low Idle Inoperative - Diesel Models

    Check adjustment of linkage and fuel injection system low idle. See Maintenance section. See Deutz OR Perkins workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department. Part No. 65196 Genie S-60 & Genie S-65 5 - 23...

  • Page 130: All Functions Inoperative, Engine Starts And Runs

    Engine to pump flex plate coupling is faulty OR main pump is faulty. Consult Genie Industries Service Department. 5 - 24 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 131: All Lift And Steer Functions Inoperative, Drive Functions Operational

    (item X) OR manifold section. has an internal fault. Consult the Genie Industries Service Department. *NOTE 1 S-60: 2600 PSI or more S-65: 2900 PSI or more Replace the function pump. *NOTE 2 S-60: Less than 2600 PSI S-65: Less than 2900 PSI Part No.

  • Page 132: Ground Controls Inoperative, Platform Controls Operate Normally

    Replace key switch. controls contact on the key switch. Repair open in red wire circuit from key switch to function enable toggle switch to each function toggle switch. 5 - 26 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 133: Platform Controls Inoperative, Ground Controls Operate Normally

    Emergency Stop button 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. 65196 Genie S-60 & Genie S-65 5 - 27...

  • Page 134: Boom Up Function Inoperative

    12V or more ground. Re-adjust controller (see Repair Section) OR 20V or more replace controller OR consult Genie Industries Service Department. Continued on the next page. 5 - 28 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 135 12V or more controller. Re-adjust controller (see Repair Section) OR replace controller OR consult Genie Industries Service Department. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 29...
  • Page 136 Repair cylinder or cylinder counterbalance valve OR boom function *NOTE 1 manifold could have an S-60: 2600 PSI or more internal fault. Consult S-65: 2900 PSI or more Genie Industries Service Department. *NOTE 2 S-60: Less than...

  • Page 137: Boom Down Function Inoperative

    12V or more controller. Re-adjust boom controller (see Repair 20V or more Section) OR replace boom controller OR consult Genie Industries Service Department. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 31...
  • Page 138 12V or more controller. Re-adjust boom controller (see Repair Section) OR replace boom controller OR consult Genie Industries Service Department. Continued on the next page. 5 - 32 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 139 Consult Genie Industries Service Department. * NOTE 1 S-60: 2600 PSI S-65: 2900 PSI * NOTE 2 S-60: Less than 2600 PSI S-65: Less than 2900 PSI Part No. 65196 Genie S-60 & Genie S-65 5 - 33...

  • Page 140: Boom Extend Function Inoperative

    Test toggle switch TS7, Replace toggle switch see Repair Section. TS7. 20V or more good Repair open in blk/red wire circuit from TS7 to TP9. Continued on the next page. 5 - 34 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 141 (item H). Check boom extend function. function inoperative Repair the cylinder or cylinder counterbalance valve OR function manifold could have an internal fault. Consult Genie Industries Service Department. Part No. 65196 Genie S-60 & Genie S-65 5 - 35...

  • Page 142: Boom Retract Function Inoperative

    Test extend/retract Replace extend/retract toggle switch, see toggle switch. 12V or more Repair Section. good Repair open in blk/red wire circuit from TS7 to TP9. Continued on the next page. 5 - 36 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 143 (item H). Check boom retract function. function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal fault. Consult Genie Industries Service Department. Part No. 65196 Genie S-60 & Genie S-65 5 - 37...

  • Page 144: Turntable Rotate Left Function Inoperative

    12V or more Re-adjust controller (see Repair Section) OR replace controller OR consult Genie Industries Service Department. Continued on the next page. 5 - 38 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 145 12V or more Re-adjust controller (see Repair Section) OR replace controller OR consult Genie Industries Service Department. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 39...
  • Page 146 Consult Genie Industries Service Department. *SEE NOTE 2 *NOTE 1 S-60: 2600 PSI or more S-65: 2900 PSI or more *NOTE 2 Continued on the next S-60: Less than page. 2600 PSI S-65: Less than...
  • Page 147 Activate turntable rotate left function. function inoperative Check for mechanical restrictions keeping turntable rotate left from operating OR replace shuttle valve (item II) OR consult Genie Industries Service Department. Part No. 65196 Genie S-60 & Genie S-65 5 - 41...

  • Page 148: Turntable Rotate Right Function Inoperative

    12V or more Re-adjust controller (see Repair Section) OR replace controller OR consult Genie Industries Service Department. Continued on the next page. 5 - 42 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 149 12V or more Re-adjust controller (see Repair Section) OR replace controller OR consult Genie Industries Service Department. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 43...
  • Page 150 Consult Genie Industries Service Department. *SEE NOTE 2 *NOTE 1 S-60: 2600 PSI or more S-65: 2900 PSI or more *NOTE 2 Continued on the next S-60: Less than page. 2600 PSI S-65: Less than...
  • Page 151 Activate turntable rotate right function. function inoperative Check for mechanical restrictions keeping turntable rotate right function from operating OR replace shuttle valve (item II) OR consult Genie Industries Service Department. Part No. 65196 Genie S-60 & Genie S-65 5 - 45...

  • Page 152: All Platform Leveling Functions Inoperative

    Continually monitor the pressure gauge during boom up. Do not allow the pressure to exceed 2600 PSI. *NOTE 1 S-60: 2600 PSI or more S-65: 2900 PSI or more *SEE NOTE 1 *NOTE 2 S-60: Less than 2600 PSI S-65: Less than...

  • Page 153: Platform Level Up Function Inoperative

    TS14 OR repair open in 12V or more org-4 wire circuit from TS14 to TB14 OR consult Genie Industries Service Department. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 47...
  • Page 154 (item DD) and activate the platform level up function. function inoperative *NOTE 1 S-60: 2600 PSI or more Test master cylinder S-65: 2900 PSI or more (see Chart 20) OR repair or replace slave cylinder or slave...

  • Page 155: Platform Level Down Function Inoperative

    TS14 OR repair open in org/blk wire circuit from 12V or more TS14 to TB15 OR consult Genie Industries Service Department. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 49...
  • Page 156 (item DD) and activate the platform level down function. function inoperative *NOTE 1 S-60: 2600 PSI or more Test master cylinder S-65: 2900 PSI or more (see Chart 20) OR repair or replace slave cylinder or slave...

  • Page 157: Platform Rotate Left Function Inoperative

    TS13 OR repair open in 12V or more grn wire circuit from TS13 to TB17 OR consult Genie Industries Service Department. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 51...
  • Page 158 (item T) and activate the platform *NOTE 1 rotate left function. S-60: 2600 PSI or more S-65: 2900 PSI or more function inoperative Consult Genie Industries Service Department. *NOTE 2 S-60: Less than...

  • Page 159: Platform Rotate Right Function Inoperative

    TS13 OR repair open in grn/blk wire circuit from 12V or more TS13 to TB18 OR consult Genie Industries Service Department. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 53...
  • Page 160 (item DD) with platform level flow regulator valve (item T) and activate the platform *NOTE 1 rotate right function. S-60: 2600 PSI or more S-65: 2900 PSI or more function inoperative Consult Genie Industries Service Department. *NOTE 2 S-60: Less than...

  • Page 161: Oscillate Function Inoperative

    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. 65196 Genie S-60 & Genie S-65 5 - 55...

  • Page 162: Jib Boom Up Function Inoperative

    Check the voltage at Replace CR13. terminal #87a on CR13. Repair open in red wire Continued on the next from terminal#87a on page. CR13 to TS8 OR consult Genie Industries Service Department. 5 - 56 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 163 OR consult Genie Industries Service Department. function Exchange jib boom Replace faulty operates counterbalance valves counterbalance valve. and activate jib boom up function. function inoperative Consult Genie Industries Service Department. Part No. 65196 Genie S-60 & Genie S-65 5 - 57...

  • Page 164: Jib Boom Down Function Inoperative

    Check the voltage at Replace CR13. terminal #87a on CR13. Repair open in red wire from terminal#87a on Continued on the next CR13 to TS8 OR page. consult Genie Industries Service Department. 5 - 58 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 165 Consult Genie Industries Service Department. *NOTE 1 S-60: 2600 PSI S-65: 2900 PSI *NOTE 2 S-60: Less than 2600 PSI S-65: Less than 2900 PSI Part No. 65196 Genie S-60 & Genie S-65 5 - 59...

  • Page 166: Steer Left Function Inoperative

    5 to 6 ohms Continued on the next page. 5 - 60 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 167 Repair or replace steer cylinder OR steer manifold could have an internal defect. Consult Genie Industries Service Department. *NOTE 1 S-60: 2600 PSI or more S-65: 2900 PSI or more *NOTE 2 S-60: Less than 2600 PSI S-65: Less than 2900 PSI Part No.

  • Page 168: Steer Right Function Inoperative

    5 to 6 ohms Continued on the next page. 5 - 62 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 169 Repair or replace steer cylinder OR steer manifold could have an internal fault. Consult Genie Industries Service Department. *NOTE 1 S-60: 2600 PSI or more S-65: 2900 PSI or more *NOTE 2 S-60: Less than 2600 PSI S-65: Less than 2900 PSI Part No.

  • Page 170: All Drive Functions Inoperative, All Other Functions Operate Normally

    TB41 and org/blk-1 9 to 12V #41wire on the alterator. wire from TP41 to terminal #3 on horsepower limiter board. Repair or replace alternator. Continued on the next page. 5 - 64 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 171 OR consult Genie full reverse position. Industries Service Check voltage across Department. the terminals #5 and #4 on the drive controller. Continued on the next page. Part No. 65196 Genie S-60 & Genie S-65 5 - 65...
  • Page 172 Replace drive enable toggle switch TS8. Troubleshoot drive forward and drive reverse functions separately OR replace pump OR consult Genie Industries Service Department. 5 - 66 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 173: Drive Forward Or Reverse Function Inoperative

    20 to 24 ohms improve Faulty drive pump, Adjust the drive pump ment contact authorized null (neutral). repair facility. symptoms improve Re-adjust horsepower limiter board OR consult Genie Industries Service Department. Part No. 65196 Genie S-60 & Genie S-65 5 - 67...

  • Page 174: Traction Function Inoperative

    Section 5 • Troubleshooting Flow Charts Third Edition • First Printing Chart 32 Traction Any type of traction problem, consult Genie Function Industries Service Department. Inoperative Be sure that all other functions operate normally. 5 - 68 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 175: Machine Will Not Drive At Full Speed

    Be sure the wiring to Industries Service limit switches is intact Department. and show no signs of damage or corrosion. Be sure the free-wheel valve is closed on the drive pump. Part No. 65196 Genie S-60 & Genie S-65 5 - 69...

  • Page 176: Machine Drives At Full Speed With Platform Raised Or Extended

    TB40 to drive and show no signs of limit switches (LS1 and LS2), then from brn damage or corrosion. ground wires to ground. 5 - 70 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 177: Drive Enable System Is Malfunctioning

    Please begin troubleshooting from beginning of chart OR consult Genie Industries Service Department. Repair open from TB30 through red-5 wire to LS3 then from LS3 through blk-5 wire to TB12. Part No. 65196 Genie S-60 & Genie S-65 5 - 71...

  • Page 178: Auxiliary Functions Inoperative

    Replace auxiliary pump auxiliary power unit. motor. Continued on the next page. 5 - 72 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 179 TS9. 12V or more Repair open in red #27 wire from TS9 to TB27 OR replace TS9. Part No. 65196 Genie S-60 & Genie S-65 5 - 73...
  • Page 180 Section 5 • Troubleshooting Flow Charts Third Edition • First Printing This page intentionally left blank. 5 - 74 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 181 Read, understand and obey the safety rules squirt or spray. and operating instructions printed in the Genie S-60 & Genie S-65 Operator's Manual. General Repair Process Be sure that all necessary tools and test equipment are available and ready for use.

  • Page 182: Electrical Components

    KS1 ....Contact - Key switch, N.O..45081 ... Telemecanique ....ZB2-BE101 ....2 L1 ....LED - Red, 12V DC ....32335 ... Arctolectric Corp....LE177C39007 ....1 This list continues on the next page. 6 - 2 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 183 2 position maintained .... 27378 ... Microswitch Control Inc..2NT1-3 ......2 TS3, TS11 (Diesel) ... Toggle switch, SPDT 3 position momentary .... 13037 ... Microswitch Control Inc..1NT1-7 ......2 Part No. 65196 Genie S-60 & Genie S-65 6 - 3...

  • Page 184: Electrical Symbols Legend

    Section 6 • Schematics Third Edition • First Printing Electrical Symbols Legend 6 - 4 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 185: Abbreviation Legend

    P ....Emergency Stop Button PR ....Power relay R ....Resistor TB ....Terminal base location TP ....Terminal platform location TS ....Toggle switch WTS .... Water temperature switch Part No. 65196 Genie S-60 & Genie S-65 6 - 5...
  • Page 186 Third Edition • First Printing Section 6 • Schematics Ford LRG-425 EFI Engine Wire Harness Part No. 65196 Genie S-60 & Genie S-65 6 - 7...
  • Page 187 3. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSISTION AND THE KEYSWITCH OFF. 4. R1: 100 OHMS FOR 4WD, R1: 150 OHMS FOR 2WD.. 6 - 8 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 188 Third Edition • First Printing Section 6 - Schematics Electrical Schematic- Gasoline/LPG Models Part No. 65196 Genie S-60 & Genie S-65 6 - 9...

  • Page 189: Ground Control Box Wiring Diagram-Gasoline/Lpg Models

    Section 6 • Schematics Third Edtion • First Printing Ground Control Box Wiring Diagram- Gasoline/LPG Models 6 - 10 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 190: Platform Control Box Wiring Diagram-Gasoline/Lpg Models

    Third Edition • First Printing Section 6 • Schematics Platform Control Box Wiring Diagram- Gasoline/LPG Models Part No. 65196 Genie S-60 & Genie S-65 6 - 11...

  • Page 191: Electrical Schematic-Deutz Diesel Models

    Section 6 • Schematics Third Edition • First Printing Electrical Schematic- Deutz Diesel Models 6 - 12 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 192 Third Edition • First Printing Section 6 • Schematics Electrical Schematic- Deutz Diesel Models Part No. 65196 Genie S-60 & Genie S-65 6 - 13...

  • Page 193: Ground Control Box Wiring Diagram-Deutz Diesel Models

    Section 6 • Schematics Third Edition • First Printing Ground Control Box Wiring Diagram- Deutz Diesel Models 6 - 14 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 194: Platform Control Box Wiring Diagram-Deutz Diesel Models

    Third Edition • First Printing Section 6 • Schematics Platform Control Box Wiring Diagram- Deutz Diesel Models Part No. 65196 Genie S-60 & Genie S-65 6 - 15...

  • Page 195: Electrical Schematic-Perkins Diesel Models

    Section 6 • Schematics Third Edition • First Printing Electrical Schematic- Perkins Diesel Models 6 - 16 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 196 Third Edition • First Printing Section 6 • Schematics Electrical Schematic- Perkins Diesel Models Part No. 65196 Genie S-60 & Genie S-65 6 - 17...

  • Page 197: Ground Control Box Wiring Diagram-Perkins Diesel Models

    Section 6 • Schematics Third Edition • First Printing Ground Control Box Wiring Diagram- Perkins Diesel Models 6 - 18 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 198: Platform Control Box Wiring Diagram-Perkins Diesel Models

    Third Edition • First Printing Section 6 • Schematics Platform Control Box Wiring Diagram- Perkins Diesel Models Part No. 65196 Genie S-60 & Genie S-65 6 - 19...

  • Page 199: Hydraulic Symbols Legend

    Section 6 • Schematics Third Edition • First Printing Hydraulic Symbols Legend 6 - 21 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 200: 2Wd Hydraulic Schematic Non-Oscillating Axle

    0.6GPM FUNCTION PUMP GENERATOR (2.3 L/min) (2.3 L/min) PRESSURE 14 GPM (53 L/min) MANIFOLD * S-60 Models = 2600 PSI S-65 Models = 2900 PSI DRIVE PUMP 0 TO 30 GPM (114.7 L/min) 0.1 GPM (0.4 L/min) TANK 2500 PSI...

  • Page 201: 2Wd Hydraulic Schematic Oscillating Axle

    0.6GPM FUNCTION PUMP GENERATOR (2.3 L/min) (2.3 L/min) PRESSURE 14 GPM (53 L/min) MANIFOLD * S-60 Models = 2600 PSI S-65 Models = 2900 PSI DRIVE PUMP 0 TO 30 GPM (114.7 L/min) 0.1 GPM (0.4 L/min) TANK 2500 PSI...

  • Page 202: 4Wd Hydraulic Schematic Non-Oscillating Axle

    0.6GPM FUNCTION PUMP GENERATOR (0.076 mm) (0.076 mm) PRESSURE 14 GPM (53 L/min) MANIFOLD S-60 Models = 2600 PSI S-65 Models = 2900 PSI DRIVE PUMP 0 TO 30 GPM (114.7 L/min) 0.1 GPM (0.4 L/min) TANK 2500 PSI OPTIONAL...

  • Page 203: 4Wd Hydraulic Schematic Oscillating Axle

    0.6GPM FUNCTION PUMP GENERATOR (0.076 mm) (0.076 mm) PRESSURE 14 GPM (53 L/min) MANIFOLD * S-60 Models = 2600 PSI S-65 Models = 2900 PSI DRIVE PUMP 0 TO 30 GPM (114.7 L/min) 0.1 GPM (0.4 L/min) TANK 2500 PSI...
  • Page 204 Red—used to indicate the Read, understand and obey the safety rules presence of an imminently and operating instructions in the Genie S-60 & hazardous situation which, if not Genie S-65 Operator’s Manual. avoided, will result in death or Be sure that all necessary tools and parts are serious injury.

  • Page 205: Platform Controls

    2 Turn the key switch to platform control and pull out the Emergency Stop button to the position at both the ground and platform controls. Do not start the engine. 7 - 2 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 206 If the function cycle time is not the voltage or counterclockwise to decrease the achievable, check the relief valve voltage. pressure. See 11-2, Valve Adjustments - Function Manifold. Part No. 65196 Genie S-60 & Genie S-65 7 - 3...
  • Page 207 Refer to the Boom down - Lo range 6.5V DC platform control box illustration, page 7-2. Cycle time 90 to 94 seconds Ramp rate 3 to 4 seconds 7 - 4 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 208 Adjust the voltage to 3.5V DC. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. Part No. 65196 Genie S-60 & Genie S-65 7 - 5...
  • Page 209 16 Start a timer and simultaneously move the controller all the way to the left or right. Note how long it takes to reach the maximum voltage recorded in step 14. This is the ramp rate. 7 - 6 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 210 Adjust the voltage to 3.5V DC. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. Part No. 65196 Genie S-60 & Genie S-65 7 - 7...
  • Page 211 See 11-2, Valve Adjustments - Function Manifold. 12 Turn the engine off and re-connect the volt meter. 13 Pull out the Emergency Stop button to position. 7 - 8 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 212: Horsepower Limiter Board

    2 Open the control box lid and locate the horsepower limiter board. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Part No. 65196 Genie S-60 & Genie S-65 7 - 9...
  • Page 213 12.2 m/6.2 sec12.2 m/9.1 sec Diesel models 40 ft/6.8 sec 40 ft/9.7 sec 12.2 m/6.8 sec 12.2 m/9.7 sec Boom raised or extended 40 ft/40 sec all models 12.2m/40 sec 7 - 10 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 214: Foot Switch

    Test Desired result red to black continuity (zero Ω) red to white no continuity (infinite Ω) black to white no continuity (infinite Ω) Part No. 65196 Genie S-60 & Genie S-65 7 - 11...

  • Page 215: Toggle Switches

    4 to 5 continuity (zero 9) terminal 4 to 6 no continuity (infinite 9) Single pole double throw terminal 5 to 6 no continuity (infinite 9) (SPDT) Double pole double throw 7 - 12 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 216: Platform Components

    Hose and Fitting Torque supported. Specifications. 1 Adjust the platform to a level position. 2 Extend the boom until the slave cylinder barrel- end pivot pin is accessible. Part No. 65196 Genie S-60 & Genie S-65 7 - 13...
  • Page 217 10 Use a soft metal drift and remove the barrel-end damage. pivot pin. 6 S-60 models: Tag, disconnect and plug the 11 Carefully pull the cylinder out of the boom. hydraulic hoses from the slave cylinder at the Component damage hazard.

  • Page 218: Platform Rotator

    Third Edition • First Printing Section 7 • Repair Procedures PLATFORM COMPONENTS 2 S-60 models: Tag, disconnect and plug the hydraulic hoses from the platform rotator. Cap Platform Rotator the fittings on the rotator. Bodily injury hazard. Spraying The platform rotator is a hydraulically activated...
  • Page 219 2 Move the platform rotate toggle switch to the left and then to the right through two platform rotation cycles, continue holding the switch to until the platform is fully rotated to the RIGHT right. 7 - 16 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 220 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform full right, then full left and inspect the bleed valves for leaks. Part No. 65196 Genie S-60 & Genie S-65 7 - 17...

  • Page 221: Jib Boom Components, S-65 Models

    Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 - 18 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 222: Jib Boom Lift 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. Part No. 65196 Genie S-60 & Genie S-65 7 - 19...

  • Page 223: Boom Components

    Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 - 20 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 224 Always replace the cotter pin with a new one when removing a clevis pin. 16 Remove the mounting fasteners that attach the lower cable track to the boom. Part No. 65196 Genie S-60 & Genie S-65 7 - 21...
  • Page 225 7 Lift up the hoses and cables and carefully insert the new 4 link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 7 - 22 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 226: Boom

    4 Remove the mounting fasteners from the jib Always maintain squareness boom/platform rotate valve manifold on the end between the outer and inner boom of the boom. Remove the manifold and set it tubes. aside. Part No. 65196 Genie S-60 & Genie S-65 7 - 23...
  • Page 227 Component damage hazard. 20 Place support blocks under the boom lift Hoses can be damaged if they are cylinder, across the turntable. kinked or pinched. 13 Remove the turntable end cover. 7 - 24 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 228 2 tube. Use a slide support. hammer to remove the trunnion pins. 9 Carefully rotate the base end of the extension cylinder until the pin mounting bore is in a vertical position. Part No. 65196 Genie S-60 & Genie S-65 7 - 25...

  • Page 229: Boom Lift Cylinder

    14 Remove and label the wear pads from the and fall when it is disconnected extension cylinder. from the machine if it is not Pay careful attention to the properly supported. location of each wear pad. 7 - 26 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 230: Extension Cylinders

    3 damaged if the lift cylinder is boom tube. pulled across them. 2 Raise the boom to a horizontal position. Part No. 65196 Genie S-60 & Genie S-65 7 - 27...
  • Page 231 10 Remove the external snap rings from both sides of the extension cylinder pivot pin at the pivot end of the boom. 11 Use a soft metal drift to remove the extension cylinder pivot pin. 7 - 28 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 232: Platform Leveling Master 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. Part No. 65196 Genie S-60 & Genie S-65 7 - 29...

  • Page 233: Turntable Covers

    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. 7 - 30 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 234: Deutz Engine F4L 1011F

    4 Install the pump and torque the pump mounting plate fasteners to 34 ft-lbs (46 Nm). Part No. 65196 Genie S-60 & Genie S-65 7 - 31...

  • Page 235: Oil Temperature And Oil Pressure Gauges

    Temperature switch point 300° F 149° C Oil pressure sending unit specifications Torque 8-10 ft-lbs 11-14 Nm Hex size inch Oil pressure switch point 7 psi 0.48 bar 7 - 32 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 236: Perkins Engine

    4 Install the pump and torque the pump mounting plate fasteners to 34 ft-lbs (46 Nm). Part No. 65196 Genie S-60 & Genie S-65 7 - 33...

  • Page 237: Coolant Temperature And Oil Pressure Gauges

    Temperature switch point 221° F 105° C Oil pressure sending unit specifications Torque 8-10 ft-lbs 11-14 Nm Hex size inch Oil pressure switch point 4.2 psi 0.3 bar 7 - 34 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 238: Ford Engine Lrg-425 Efi

    4 Install the pump and torque the pump mounting plate fasteners to 34 ft-lbs (46 Nm). Part No. 65196 Genie S-60 & Genie S-65 7 - 35...

  • Page 239: Coolant Temperature And Oil Pressure Gauges

    Engine oil pressure will be indicated on the gauge when the engine is running. engine pivot plate pivot plate retaining bolts air baffle 7 - 36 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 240 Remove the sending unit from the engine block. Oil pressure switch point 8 psi 0.55 bar 4 Install the new sending unit. Do not over tighten. Part No. 65196 Genie S-60 & Genie S-65 7 - 37...

  • Page 241: Ground Controls

    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 - 38 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 242: Wago Components

    Result: The check engine light should turn on. The check engine light should begin to blink. 4 Use a small screwdriver to gently pry up on the tab of the component and remove it. Part No. 65196 Genie S-60 & Genie S-65 7 - 39...
  • Page 243 ECM memory must be reset to clear the fault code from the ECM. See 9-4, How to Clear Engine Fault Codes. 7 - 40 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 244: Hydraulic Pumps

    CLOSED 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. 65196 Genie S-60 & Genie S-65 7 - 41...

  • Page 245: Drive Pump

    1 Disconnect the electrical connection at the fasteners. electronic displacement controller (EDC) 5 Carefully pull the drive pump out until the pump located on the drive pump. coupler separates from the flex plate. 7 - 42 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 246 Deutz Diesel models: Release the manual shutoff valve. Perkins Diesel models: Connect the engine wiring harness to the fuel solenoid. 5 Start the engine from the ground controls and check for hydraulic leaks. Part No. 65196 Genie S-60 & Genie S-65 7 - 43...

  • Page 247: Function Manifold Components

    (schematic items A, B and C) SAE No. 6 18 ft-lbs / 24 Nm Proportional solenoid valve, 10V 7.5 to 10.5Ω SAE No. 8 50 ft-lbs / 68 Nm (schematic item M) 7 - 44 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 248 Third Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 65196 Genie S-60 & Genie S-65 7 - 45...
  • Page 249 Differential sensing valve ....V ... Meters flow to functions ....10-12 ft-lbs (14-16 Nm) 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) Diagnostic nipple ....... X ... Testing Check valve ........
  • Page 250 Third Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 65196 Genie S-60 & Genie S-65 7 - 47...

  • Page 251: Valve Adjustments - Function Manifold

    Install the relief valve cap. valve pressure. Tip-over hazard. Do not adjust the relief valves higher than specified. 6 Repeat steps 2 through 5 to confirm relief valve pressure. 7 - 48 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 252 Use extreme caution when overriding a machine function. Identify the direction of machine movement before overriding a valve. Part No. 65196 Genie S-60 & Genie S-65 7 - 49...

  • Page 253: Turntable Rotation Manifold Components

    Counterbalance valve ......JJ ..Turntable rotate left ......35-40 ft-lbs (47-54 Nm) Plug Torque Specifications Description Hex size Torque SAE No. 2 50 in-lbs (6 Nm) SAE No. 4 13 ft-lbs (18 Nm) SAE No. 6 18 ft-lbs (24 Nm) 7 - 50 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 254: Oscillate Manifold Components

    Diagnostic fitting ..........Testing Plug Torque Specifications Description Hex size Torque SAE No. 2 50 in-lbs (6 Nm) SAE No. 4 13 ft-lbs (18 Nm) SAE No. 6 18 ft-lbs (24 Nm) Part No. 65196 Genie S-60 & Genie S-65 7 - 51...

  • Page 255: Valve Adjustments - Oscillate Manifold

    2 Remove the chassis cover from the non-steer end of the drive chassis. 3 Disconnect the directional valve linkage, by removing the clevis yoke from the drive chassis. 7 - 52 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 256: Directional Valve Manifold Components

    The directional valve manifold is mounted inside the drive chassis at the non-steer end. Index Description Function Torque Cap ..............Breather ..........20-25 ft-lbs (27-33Nm) Spool valve ............Directional control Part No. 65196 Genie S-60 & Genie S-65 7 - 53...
  • Page 257 10 Install the clevis yoke pin and the cotter pin. Be sure to bend the cotter pin. 7 - 54 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 258: Steer Manifold Components, Oscillating Models

    3.5 gpm (13.2 L/min) VV ..Regulates flow to oscillate manifold ......10-12 ft-lbs (14-16 Nm) Valve Coil Resistance Specifications Description Measurement Solenoid valve, 3 position 4 way, 10V 4.5 to 7.5Ω (schematic item SS) Part No. 65196 Genie S-60 & Genie S-65 7 - 55...

  • Page 259: Steer Manifold Components, Non-Oscillating Models

    The steer manifold is located underneath the function manifold. Index Schematic Description Item Function D03 valve, 3 position 4 way ....RR ..Steer left/right ........30-35 in-lbs (3-4 Nm) 7 - 56 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 260: 2Wd Drive Manifold Components

    Diagnostic fitting ..........Testing Plug Torque Specifications Description Hex size Torque SAE No. 4 13 ft-lbs (18 Nm) SAE No. 6 18 ft-lbs (24 Nm) SAE No. 8 50 ft-lbs (68 Nm) Part No. 65196 Genie S-60 & Genie S-65 7 - 57...

  • Page 261: Valve Adjustments, 2Wd Drive Manifold

    6 Start the engine from the platform controls. Drive the machine in either direction and confirm the valve pressure. 7 Turn the engine off, and remove the pressure gauge. 7 - 58 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 262 Third Edition • First Printing Section 7 • Repair Procedures MANIFOLDS This page intentionally left blank. Part No. 65196 Genie S-60 & Genie S-65 7 - 59...

  • Page 263: 4Wd Drive Manifold Components

    ....... 10-12 ft-lbs (14-16 Nm) Plug Torque Specifications Description Hex size Torque SAE No. 4 13 ft-lbs (18 Nm) SAE No. 6 18 ft-lbs (24 Nm) SAE No. 8 50 ft-lbs (68 Nm) 7 - 60 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 264 Third Edition • First Printing Section 7 • Repair Procedures MANIFOLDS Part No. 65196 Genie S-60 & Genie S-65 7 - 61...

  • Page 265: Valve Adjustments, 4Wd Drive Manifold

    6 Start the engine from the platform controls. Drive the machine in either direction and confirm the valve pressure. 7 Turn the engine off, and remove the pressure gauge. 7 - 62 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 266: Jib Boom/Platform Rotate Manifold Components, S-65 Models

    Orifice fitting, 0.030 inch (0.76 mm) .. AN ..Platform rotate circuit Valve Coil Resistance Specification 2 position 3 way solenoid valve, 10V 4.5 to 7.5Ω (schematic item AM) Part No. 65196 Genie S-60 & Genie S-65 7 - 63...

  • Page 267: Fuel And Hydraulic Tanks

    4 Metal tank: Remove the fuel tank hold down straps retaining fasteners. Remove the straps from the fuel tank. Plastic tank: Remove the fuel tank retaining fasteners. 7 - 64 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 268: Hydraulic Tank

    2 Remove the fuel tank. See 12-1, How to Remove the Fuel Tank. 8 Disconnect and plug the supply hose for the auxiliary power unit. Cap the fitting on the hydraulic tank. Part No. 65196 Genie S-60 & Genie S-65 7 - 65...
  • Page 269 18 Fill the tank with hydraulic oil until the level is within the top 2 inches (5 cm) of the sight gauge. Do not overfill. 7 - 66 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 270 5 Start the engine from the ground controls and LPG position. check for hydraulic leaks. Deutz Diesel models: Hold the manual fuel shutoff valve clockwise to the position. CLOSED Deutz model manual fuel shutoff valve Part No. 65196 Genie S-60 & Genie S-65 7 - 67...

  • Page 271: Turntable Rotation Components

    Fitting Torque Specifications. 1 Secure the turntable from rotating with the turntable rotation lock pin. Unlocked position motor motor/brake mounting bolts brake drive hub drive hub mounting bolts Locked position 7 - 68 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 272 Rotation Hydraulic Motor . Component damage hazard. Hoses can be damaged if they are kinked or pinched. motor motor/brake mounting bolts brake drive hub drive hub mounting bolts Part No. 65196 Genie S-60 & Genie S-65 7 - 69...
  • Page 273 7 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary. pivot plate mounting bolts adjustment bolt with lock nut drive hub pivot plate 7 - 70 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 274: 2Wd Steering Axle Components

    Torque specifications Lug nut torque, dry 420 ft-lbs tie rod 569.5 Nm axle Lug nut torque, lubricated 320 ft-lbs yoke pivot pin 434 Nm yoke clevis pin steering cylinder Part No. 65196 Genie S-60 & Genie S-65 7 - 71...
  • Page 275 Always use a new cotter pin when installing a castle nut. 10 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to 420 ft-lbs (569.5 Nm). 7 - 72 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 276: Steering Cylinders

    Do not allow oil to squirt or spray. 2 Remove the pin retaining fastener from the rod-end clevis pin of the steer cylinder. Remove the pin. Part No. 65196 Genie S-60 & Genie S-65 7 - 73...

  • Page 277: Tie Rod

    If further adjustment is needed, repeat 2 Measure the steer tires, front to front and back steps 3 through 8. to back, using a measuring fixture. Toe-in specification 0 ± inch (4 mm) 7 - 74 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 278: 4Wd Steering Axle Components

    11 Support and secure the yoke/drive hub assembly to a lifting jack. steer cylinder oscillate cylinder yoke pivot pin drive hub yoke clevis pin tie rod Part No. 65196 Genie S-60 & Genie S-65 7 - 75...
  • Page 279 420 ft-lbs See 14-3, How to Perform the Toe-in Adjustment. 569.5 Nm Lug nut torque, lubricated 320 ft-lbs 434 Nm Drive hub mounting bolts, lubricated 180 ft-lbs 122 Nm 7 - 76 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 280: Oscillating Axle Components

    Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Rotate the turntable until the boom is between the steer tires. Part No. 65196 Genie S-60 & Genie S-65 7 - 77...

  • Page 281: Non-Steering Axle Components

    Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the fasteners from the drive chassis cover on the non-steer axle. Remove the cover. 7 - 78 Genie S-60 & Genie S-65 Part No. 65196...

  • Page 282: Drive Hub

    5 Remove the wheel lug nuts, then the tire and wheel assembly. 6 Place a second lifting jack under the drive hub for support and secure the drive hub to the lifting jack. Part No. 65196 Genie S-60 & Genie S-65 7 - 79...

  • Page 283: Wheel Brake

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Remove the brake from the machine. 7 - 80 Genie S-60 & Genie S-65 Part No. 65196...
  • Page 284 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie Scandinavia Genie China Phone +46 31 575100...

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