Genie S-65 Service Manual
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Genie S-65 Service Manual

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Download this manual See also: Service & Repair Manual, Service Manual
800-610-4101
ActionRental.com
Second Edition, First Printing
Part No. 48412 (Rev A1)
July 2008
Technical
Publications
S-60
®
S-65
®
Service
Manual

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  • Page 1 800-610-4101 ActionRental.com Technical Publications S-60 ® S-65 ® Service Manual Second Edition, First Printing Part No. 48412 (Rev A1) July 2008...

  • Page 2: Introduction

    However, "Genie" and "S" are Registered Trademarks continuous improvement of our products is a of Genie Industries in the USA and many other countries. Genie policy. Therefore product specifications are subject to change without notice.
  • Page 3 ActionRental.com 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 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. Genie S-60 & Genie S-65 Part No. 48412...

  • Page 5: Table Of Contents

    Check the Engine Coolant Level - Gasoline/LPG Models ....... 4 - 3 Check for Fuel Leaks ..................4 - 3 Check the Hydraulic Oil Level ................. 4 - 4 Check for Hydraulic Leaks ................4 - 4 Part No. 48412 Genie S-60 & Genie S-65...
  • Page 6 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 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 7 Check the Toothed Belt - Deutz Diesel Models ..........4 - 43 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...
  • Page 8 Platform Rotate Left Function Inoperative ............ 5 - 55 Platform Rotate Right Function Inoperative ..........5 - 58 Jib Boom Up Inoperative, S-65 Models ............5 - 61 Jib Boom Down Inoperative, S-65 Models ............ 5 - 63 Genie S-60 & Genie S-65 Part No.
  • Page 9 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...
  • Page 10 Jib Boom, S-65 Models ................. 7 - 15 Jib Boom Lift Cylinder, S-65 Models ............. 7 - 16 Jib Boom / Platform Rotate Manifold Components, S-65 Models ....7 - 17 Boom Components Boom Cable Track ..................7 - 18 Boom ......................
  • Page 11 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...
  • Page 12 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 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 13: Specifications

    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...

  • Page 14: Performance Specifications

    130 to 160 seconds Platform rotate - 160° 10 to 20 seconds Gradeability (boom stowed) Platform level up 35 to 65 seconds Rough terrain Platform level down 25 to 55 seconds 2 - 2 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 15: Hydraulic Specifications

    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...

  • Page 16: Ford Lrg 423 Engine Specifications

    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...
  • Page 17 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...

  • Page 18: Deutz F4L 1011F Engine Specifications

    (M-8 x 50 Torx, 8.8) Units ship with 10W-40 SG/CC. V-belt pulley bolts 28 to 34 38 to 46 Injection system (M-10 x 16, 8.8) Injection pump make OMAP 2 - 6 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 19 Crankshaft/central bolt 210° (M-12 x 28, 8.8) Oil pan bolts 15 to 18 20 to 24 (M-8 x 16 Torx, 8.8) Oil drain bolts 37 to 44 50 to 60 Part No. 48412 Genie S-60 & Genie S-65 2 - 7...

  • Page 20: Hydraulic Hose And Fitting Torque Specifications

    SAE size O- 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.

  • Page 21: Bolt Torque Specifications

    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...

  • Page 22: Part

    Section 2 - Specifications Service Manual - Second Edition 800-610-4101 ActionRental.com This page intentionally left blank. 2 - 10 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 23: Scheduled Maintenance Inspections

    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...
  • Page 24 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...
  • Page 25 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...
  • Page 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...
  • Page 27 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...
  • Page 28 - Deutz Diesel Models Check the Toothed Belt - Deutz Diesel Models 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...

  • Page 29: Maintenance Inspection Report

    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...
  • Page 30 Section 3 - Scheduled Maintenance Inspections Service Manual - Second Edition 800-610-4101 ActionRental.com Warm Cold Dealer Tools are New parts engine engine service required required required required suggested This page intentionally left blank. 3 - 8 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 31: Scheduled Maintenance Procedures

    · Turntable rotated with the boom between the non-steering wheels · Turntable secured with the turntable rotation lock pin · Key switch in the position with the key removed · Wheels chocked Part No. 48412 Genie S-60 & Genie S-65 4 - 1...

  • Page 32: Inspect The Manuals

    · 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 ·...

  • Page 33: Check The Engine Oil Level

    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...

  • Page 34: Check The Hydraulic Oil Level

    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...

  • Page 35: Check The Tire Pressure

    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...

  • Page 36: Test The Platform And Ground Controls

    1 Turn the key switch to ground control and pull immediately. The engine will out the Emergency Stop button to the shut off after 2 to 3 seconds. position at the ground controls. 4 - 6 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 37: Test The Tilt Sensor

    To conserve battery power, test 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...

  • Page 38: Test The Limit Switches

    10 Raise the boom to just above horizontal. 11 Slowly move the drive control handle off center. Result: The machine should move at a reduced turntable riser boom drive speed. boom drive limit switch 4 - 8 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 39 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...

  • Page 40: Replace The Engine Oil And Filter - Gasoline/Lpg Models

    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.

  • Page 41: Drain The Fuel Filter/Water Separator - Deutz Diesel Models

    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. fuel filter drain plug Part No. 48412 Genie S-60 & Genie S-65 4 - 11...

  • Page 42: Replace The Engine Air Filter

    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 Air filters - Genie part numbers filter/water separator before Ford LRG-423 Engine 27916 starting the engine. Refer to C-8 in...

  • Page 43: Check The Engine Belt

    2 Remove the front engine access cover mounting fasteners. 3 All models: Inspect the engine belt for: · Cracking · Glazing · Separation · Breaks 4 Replace belt if any damage is found. Part No. 48412 Genie S-60 & Genie S-65 4 - 13...

  • Page 44: Check The Radiator - Gasoline/Lpg Models

    3 Clean the radiator fins of debris and foreign materials. oil cooler cylinder head cooling fins fan blower fins 3 Clean the oil cooler of debris and foreign material. 4 - 14 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 45: Check The Exhaust System

    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. Part No. 48412 Genie S-60 & Genie S-65 4 - 15...

  • Page 46: Check The Battery

    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. 4 - 16 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 47: Inspect The Electrical Wiring

    · Boom to platform cable harness 569.5 Nm · Inside of the platform control box Lug nut torque, lubricated 320 ft-lbs 433.9 Nm · Jib boom cable cover (S-65 models) Part No. 48412 Genie S-60 & Genie S-65 4 - 17...

  • Page 48: Confirm The Proper Brake Configuration

    Drive torque hub oil 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 4 - 18 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 49: Check And Adjust The Engine Idle Mixture - Gasoline/Lpg Models

    Complete information to perform this procedure is be 1600 rpm. available in the Ford LRG-423 2.3 Liter Industrial Engine Service Manual (Ford number: PPD-194- 287). Genie part number 33907. Part No. 48412 Genie S-60 & Genie S-65 4 - 19...
  • Page 50 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 4 - 20 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 51: Test The Key Switch

    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...

  • Page 52: Test The Ground Control Override

    · Cotter pins are installed through clevis pins Result: All boom functions should operate. · Linkage is properly attached to directional valve directional valve clevis pin with cotter pin (hidden) yoke lock nut 4 - 22 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 53: Test The Platform Self-Leveling

    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. Part No. 48412 Genie S-60 & Genie S-65 4 - 23...

  • Page 54: Test The Engine Idle Select

    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 position. 5 Move the fuel select switch to LPG. 4 - 24 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 55: Test The Drive Enable System

    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...

  • Page 56: Test The Drive Speed - Stowed Position

    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 4 - 26 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 57: Test The Alarm Package - Optional Equipment

    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. Part No. 48412 Genie S-60 & Genie S-65 4 - 27...
  • Page 58 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.

  • Page 59: Check The Boom Wear Pads

    Always maintain squareness between the boom outer and inner tubes. Bolt torque sequence Wear pad specifications Upper wear pads inch 14.3 mm Bottom and side wear pads inch 17.5 mm Part No. 48412 Genie S-60 & Genie S-65 4 - 29...

  • Page 60: Check The Free-Wheel Configuration

    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...

  • Page 61: Grease The Turntable Rotation Bearing And Rotate Gear

    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...
  • Page 62 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...

  • Page 63: Replace The Hydraulic Tank Filter

    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. Clean up any oil that may have spilled during Perform this procedure with the the installation procedure.

  • Page 64: Replace The Diesel Fuel Filter/Water Separator - Deutz Diesel Models

    Service Manual - Second Edition 800-610-4101 ActionRental.com TABLE C PROCEDURES 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.
  • Page 65 ActionRental.com 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.

  • Page 66: Replace The Pcv Valve - Gasoline/Lpg Models

    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. pivot plate retaining bolts engine pivot plate 4 - 36 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 67: Replace The Spark Plugs - Gasoline/Lpg Models

    Spark plug gap 0.042 to 0.046 inches 1.07 to 1.18 mm Spark plug torque 5 to 10 foot-pounds 7 to 14 Nm high idle mixture adjustment screw Part No. 48412 Genie S-60 & Genie S-65 4 - 37...

  • Page 68: Check And Adjust The Ignition Timing - Gasoline/Lpg Models

    Turntable Rotation Gear Backlash. low idle mixture adjustment screw Preliminary setting: turn low idle adjustment screw clockwise all the way in. Turn low idle adjustment screw counterclockwise 2 turns. 4 - 38 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 69: Test Or Replace The Hydraulic Oil

    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. 48412 Genie S-60 & Genie S-65 4 - 39...
  • Page 70 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...

  • Page 71: Change The Fuel Lines

    Part No. 48412 Genie S-60 & Genie S-65 4 - 41...

  • Page 72: Check The Engine Valve Clearance - Gasoline/Lpg Models

    Perform this procedure with the operate the machine. Repair engine off. the leak immediately. 4 - 42 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 73: Check The Fuel Injection Pumps And Injectors - Deutz Diesel Models

    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...

  • Page 74: Grease The Steer Axle Wheel Bearings - 2Wd Models

    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...

  • Page 75: 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.
  • Page 76 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...

  • Page 77: Engine Will Not Crank Over

    #6 on from CB1 to CR1 to CR2 the ignition/start module. then to terminal #6 to on ignition/start module. Continued on the next page. Part No. 48412 Genie S-60 & Genie S-65 5 - 3...
  • Page 78 Check voltage at starter Repair open in battery cable. cable to starter. Repair or replace starter or starter solenoid. 5 - 4 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 79 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...
  • Page 80 Repair open in brown 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...
  • Page 81 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...

  • Page 82: Engine Cranks Over But Will Not Start - Gasoline/Lpg Models

    CR6. switch and connect the wires together. Check the voltage at terminal #86 on CR6. Continued on the next page. 5 - 8 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 83 CR6. CR6. position, crank the engine and check good voltage at terminal #87 on CR6. Replace CR6. Continued on the next page. Part No. 48412 Genie S-60 & Genie S-65 5 - 9...
  • Page 84 OR replace anti-diesel valve OR see 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...
  • Page 85 Genie Industries Service check voltage at Department. terminal #4. 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...

  • Page 86: Engine Cranks Over But Will Not Start - Deutz Diesel Models

    3.50 ohms solenoid. See Deutz service manual for troubleshooting fuel system. Continued on the next page. 5 - 12 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 87 Genie Industries Service Department. Check continuity from Repair open in brown continuity ground to terminal #85 ground wire circuit to on CR2. CR2. good Continued on the next page. Part No. 48412 Genie S-60 & Genie S-65 5 - 13...
  • Page 88 Genie Industries Service check voltage at Department. terminal #4. 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...

  • Page 89: Engine Will Not Start On Lpg, But Will Start On Gasoline - Gasoline/Lpg Models

    Check continuity from 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...
  • Page 90 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. 5 - 16 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 91: Engine Will Not Start On Gasoline, But Will Start On Lpg

    CR6 voltage at blu/wht wire terminal #87 on anti-diesel valve (on to anti-diesel valve OR carburetor). replace CR6. Continued on the next page. Part No. 48412 Genie S-60 & Genie S-65 5 - 17...
  • Page 92 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...

  • Page 93: Engine High Idle Inoperative - Gasoline/Lpg Models

    87A on CR4. Check voltage at Repair short in blk/red terminal 7 on electronic #R4 wire to terminal #7 governor. on precision governor. Continued on the next page. Part No. 48412 Genie S-60 & Genie S-65 5 - 19...
  • Page 94 Repair open in blu/blk continuity terminal #6 on precision 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...
  • Page 95 3 and 4 (brown wires). See Maintenance section for governor adjustments OR replace electronic governor. Part No. 48412 Genie S-60 & Genie S-65 5 - 21...

  • Page 96: Engine Low Idle Inoperative - Gasoline/Lpg Models

    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...

  • Page 97: Engine High Idle Inoperative - Deutz 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. 48412 Genie S-60 & Genie S-65 5 - 23...
  • Page 98 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 - 24 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 99: Engine Low Idle Inoperative - Deutz Diesel Models

    Check adjustment of linkage and fuel injection system low idle. See Maintenance section. See Deutz workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department. Part No. 48412 Genie S-60 & Genie S-65 5 - 25...

  • Page 100: All Functions Inoperative, Engine Starts And Runs

    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...

  • Page 101: All Lift And Steer Functions Inoperative, Drive Functions Operational

    Check the function Replace the relief valve pump, see Repair (item W) OR manifold section. has an internal defect. Consult the Genie Industries Service Department. Replace the function pump. Part No. 48412 Genie S-60 & Genie S-65 5 - 27...

  • Page 102: Ground Controls Inoperative, Platform Controls Operate Normally

    Replace key switch controls contact on the KS1. key switch. 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...

  • Page 103: 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. 48412 Genie S-60 & Genie S-65 5 - 29...

  • Page 104: Boom Up Function Inoperative

    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...
  • Page 105 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...
  • Page 106 (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...

  • Page 107: Boom Down Function Inoperative

    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...
  • Page 108 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...
  • Page 109 (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...

  • Page 110: Boom Extend Function Inoperative

    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...
  • Page 111 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...
  • Page 112 (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...

  • Page 113: Boom Retract Function Inoperative

    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...
  • Page 114 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...
  • Page 115 (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...

  • Page 116: Turntable Rotate Left Function Inoperative

    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...
  • Page 117 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...
  • Page 118 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...
  • Page 119 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...

  • Page 120: Turntable Rotate Right Function Inoperative

    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...
  • Page 121 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...
  • Page 122 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...
  • Page 123 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...

  • Page 124: All Platform Leveling Functions Inoperative

    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...

  • Page 125: Platform Level Up Function Inoperative

    12V or more 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...
  • Page 126 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...

  • Page 127: Platform Level Down Function Inoperative

    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...
  • Page 128 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...

  • Page 129: Platform Rotate Left Function Inoperative

    TS5 in the left direction and check voltage at the grn/wht wire on TS5. Test toggle switch. See Repair Section OR replace platform rotate toggle switch TS5. Continued on the next page. Part No. 48412 Genie S-60 & Genie S-65 5 - 55...
  • Page 130 (item AM). 0 or infinite ohms Test the resistance of 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...
  • Page 131 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...

  • Page 132: Platform Rotate Right Function Inoperative

    TS5 in the right direction and check voltage at the grn/wht wire on TS5. Test toggle switch. See Repair Section OR replace platform rotate Continued on the next toggle switch TS5. page. 5 - 58 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 133 (item AM). 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...
  • Page 134 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...
  • Page 135 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 TS6 OR consult Genie Industries Service Department. Part No. 48412 Genie S-60 & Genie S-65 5 - 61...
  • Page 136 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...
  • Page 137 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 TS6 OR consult Genie Industries Service Department. Part No. 48412 Genie S-60 & Genie S-65 5 - 63...
  • Page 138 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...

  • Page 139: 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. 48412 Genie S-60 & Genie S-65 5 - 65...

  • Page 140: Steer Left Function Inoperative

    5 to 6 ohms Continued on the next page. 5 - 66 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 141 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...

  • Page 142: Steer Right Function Inoperative

    5 to 6 ohms Continued on the next page. 5 - 68 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 143 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...

  • Page 144: All Drive Functions Inoperative, All Other Functions Operate Normally

    #3 on footswitch and check the horsepower limiter 9 to 12V voltage on the org/blk board. wire on the alterator. Repair or replace alternator. Continued on the next page. 5 - 70 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 145 OR consult check the voltage Genie Industries Service across the #5 and #4 Department. terminals on the drive joystick controller. Continued on the next page. Part No. 48412 Genie S-60 & Genie S-65 5 - 71...
  • Page 146 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...

  • Page 147: Drive Forward Or Reverse Function Inoperative

    (neutral). Consult 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...

  • Page 148: Traction Function Inoperative

    Service Manual - Second Edition 800-610-4101 ActionRental.com Chart 32 Traction Any type of traction problem, consult Genie Function Industries Service Department. Inoperative Be sure all other functions operate normally. 5 - 74 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 149: Machine Will Not Drive At Full Speed

    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...

  • Page 150: Machine Drives At Full Speed With Platform Raised Or Extended

    TB40 to drive and show no sign of limit switches (LS1 and LS2), then from brown damage or corrosion. ground wires to ground. 5 - 76 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 151: Drive Enable System Is Malfunctioning

    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...

  • Page 152: Auxiliary Functions Inoperative

    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...
  • Page 153 Check continuity from 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...
  • Page 154 Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition 800-610-4101 ActionRental.com This page intentionally left blank. 5 - 80 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 155 Do not allow oil to squirt Read, understand and obey the safety rules or spray. and operating instructions printed in the Genie S-60 and Genie S-65 Operator's General Repair Process Manual. Be sure that all necessary tools and test...

  • Page 156: Electrical Components

    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...
  • Page 157 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...

  • Page 158: Electrical Symbols Legend

    Ignition start contactor module Glow plug Diode AUX. PUMP Auxiliary pump Limit switch Horsepower Dual axis normally open limiter board Ramp up and down held closed proportional controller Battery 6 - 4 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 159: Abbreviation Legend

    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...
  • Page 160 Section 6 - Schematics Service Manual - Second Edition 800-610-4101 ActionRental.com 6 - 6 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 161 Section 6 - Schematics Service Manual REV B Electrical Schematic- Gasoline/LPG Models 800-610-4101 ActionRental.com 6 - 7 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 162 Service Manual Section 6 - Schematics REV B Electrical Schematic- Gasoline/LPG Models 800-610-4101 ActionRental.com Part No. 48412 Genie S-60 & Genie S-65 6 - 8...

  • Page 163: Ground Control Box Legend - Gasoline/Lpg Models

    Service Manual - Second Edition Section 6 - Schematics 800-610-4101 ActionRental.com Ground Control Box Legend- Gasoline/LPG Models Part No. 48412 Genie S-60 & Genie S-65 6 - 9...

  • Page 164: Ground Control Box Wiring Diagram-Gasoline/Lpg Models

    Section 6 - Schematics Service Manual - Second Edition 800-610-4101 ActionRental.com Ground Control Box Wiring Diagram- Gasoline/LPG Models 6 - 10 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 165: Platform Control Box Legend - Gasoline/Lpg Models

    Section 6 - Schematics Service Manual - Second Edition 800-610-4101 ActionRental.com Platform Control Box Legend- Gasoline/LPG Models Part No. 48412 Genie S-60 & Genie S-65 6 - 11...

  • Page 166: Platform Control Box Wiring Diagram - Gasoline/Lpg Models

    Service Manual - Second Edition Section 6 - Schematics 800-610-4101 ActionRental.com Platform Control Box Wiring Diagram- Gasoline/LPG Models 6 - 12 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 167 Section 6 - Schematics Service Manual Electrical Schematic- Diesel Models 800-610-4101 ActionRental.com 6 - 13 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 168 Service Manual Section 6 - Schematics Electrical Schematic- Diesel Models 800-610-4101 ActionRental.com Part No. 48412 Genie S-60 & Genie S-65 6 - 14...
  • Page 169 Section 6 - Schematics Service Manual - Second Edition 800-610-4101 ActionRental.com Ground Control Box Legend- Diesel Models Part No. 48412 Genie S-60 & Genie S-65 6 - 15...
  • Page 170 Section 6 - Schematics Service Manual - Second Edition 800-610-4101 ActionRental.com Ground Control Box Wiring Diagram- Diesel Models 6 - 16 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 171 Section 6 - Schematics Service Manual - Second Edition 800-610-4101 ActionRental.com Platform Control Box Legend- Diesel Models Part No. 48412 Genie S-60 & Genie S-65 6 - 17...
  • Page 172 Service Manual - Second Edition Section 6 - Schematics 800-610-4101 ActionRental.com Platform Control Box Wiring Diagram- Diesel Models 6 - 18 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 173 Section 6 - Schematics Service Manual - Second Edition 800-610-4101 ActionRental.com Part No. 48412 Genie S-60 & Genie S-65 6 - 19...

  • Page 174: Hydraulic Symbols Legend

    Bi-directional motor Priority flow divider Counterbalance valve 2-speed, Unloader valve bi-directional motor Pump prime mover (engine or motor) Solenoid operated Pilot operated flow dump valve Pressure compensating valve control valve 6 - 20 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 175: 2Wd Hydraulic Schematic - Non-Oscillating Axle

    FILTER TEST 3500 PRESS. GENERATOR FUNCTION SELECT PUMP PRESS. 14 GPM. * S-60 Models = 2600 psi S-65 Models = 2900 psi DRIVE PUMP TANK 2500 OPTIONAL COOLER SECOND COUNTERBALANCE VALVE ADDED AFTER SERIAL NUMBER 4862 RESERVOIR AUX. PUMP HYDRAULIC...

  • Page 176: 2Wd Hydraulic Schematic - Oscillating Axle

    FILTER TEST 3500 PRESS. GENERATOR FUNCTION SELECT PUMP PRESS. 14 GPM. S-60 Models = 2600 psi S-65 Models = 2900 psi DRIVE PUMP TANK 2500 OPTIONAL COOLER SECOND COUNTERBALANCE VALVE ADDED AFTER SERIAL NUMBER 4862 RESERVOIR AUX. PUMP OSCILLATE CYLINDERS 3.5 gpm...

  • Page 177: 4Wd Hydraulic Schematic - Non-Oscillating Axle

    SECOND COUNTERBALANCE VALVE ADDED AFTER SERIAL NUMBER 4862 RESERVOIR AUXILIARY PUMP HYDRAULIC ROTARY COUPLER STEER MANIFOLD DRIVE MANIFOLD REAR FRONT RIGHT RIGHT STEERING .052” .070” REAR FRONT .070” LEFT LEFT CASE DRAINS Part No. 48412 Genie S-60 & Genie S-65 6 - 23...

  • Page 178: 4Wd Hydraulic Schematic - Oscillating Axle

    ROTARY COUPLER STEER MANIFOLD DRIVE MANIFOLD 0.052” A CYL A VALVE REAR FRONT RIGHT RIGHT B CYL B VALVE STEERING 0.070” 0.052” REAR FRONT 0.070” LEFT LEFT CASE DRAINS Part No. 48412 Genie S-60 & Genie S-65 6 - 24...
  • Page 179 Read, understand and obey the safety rules and operating instructions in the Return to Perform Inspect Genie S-60 & Genie S-65 Operator’s Manual. service and test repair problem solved Be sure that all necessary tools and parts are available and ready for use.

  • Page 180: Platform Controls

    Electrocution hazard. Contact decrease the voltage. with electrically charged circuits 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...
  • Page 181 2 Turn the key switch to platform control and pull out the Emergency Stop button to 15 Start the engine. position at both the ground and platform controls. Do not start the engine. Part No. 48412 Genie S-60 & Genie S-65 7 - 3...
  • Page 182 Record the maximum voltage reading. to decrease the voltage. 15 Start the engine. 7 - 4 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 183 2 Turn the key switch to platform control and counterclockwise to decrease the voltage. pull out the Emergency Stop button to the position at both the ground and platform controls. Do not start the engine. Part No. 48412 Genie S-60 & Genie S-65 7 - 5...

  • Page 184: Horsepower Limiter Board

    17 Set the ramp rate: turn the trimpot to obtain a 3 second ramp speed. Turn the Gasoline/LPG models: Perform this procedure in gasoline mode. trimpot clockwise to increase the time or counterclockwise to decrease the time. 7 - 6 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 185 12 Disconnect the volt meter. "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...

  • Page 186: Foot Switch

    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...

  • Page 187: Resistors

    2 Connect the leads of an ohmmeter to the switch 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...

  • Page 188: Control Relays

    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...

  • Page 189: Platform Components

    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...

  • Page 190: Platform Rotator

    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...
  • Page 191 Do not remove the pins. S-65 models: Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports on 7 Support the jib boom and leveling arms.
  • Page 192 8 Rotate the platform full right then left and inspect the bleed valves for leaks. top bleed valve bottom bleed valve clear hose container 7 - 14 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 193: Jib Boom Components, S-65 Models

    Service Manual - Second Edition Section 7 - Repair Procedures 800-610-4101 ActionRental.com Jib Boom Components, S-65 Models 9 Tag, disconnect and plug all the hydraulic hoses from the jib boom manifold. Jib Boom, S-65 Models Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Jib Boom burn skin.
  • Page 194 Section 7 - Repair Procedures Service Manual - Second Edition 800-610-4101 ActionRental.com JIB BOOM COMPONENTS, S-65 MODELS 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.
  • Page 195 Section 7 - Repair Procedures 800-610-4101 ActionRental.com JIB BOOM COMPONENTS, S-65 MODELS Jib Boom / Platform Rotate Manifold Components, S-65 Models 2 position 3 way valve ....... AM ..Platform rotate/ jib boom select ..8-10 ft-lbs / 11-14 Nm Plug Torque Specifications Description...

  • Page 196: Boom Components

    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 6 S-65 Models: Remove the jib/rotate manifold or fitting, the O-ring on the fitting mounting fasteners.
  • Page 197 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...

  • Page 198: Boom

    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 boom/jib rotate valve manifold on the end of the 4 Loosen the wear pad mounting fasteners.
  • Page 199 1 boom tube. Use a soft center point of the boom. 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...
  • Page 200 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...

  • Page 201: Boom Lift Cylinder

    Crushing hazard. If the overhead 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...

  • Page 202: Extension Cylinders

    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).

  • Page 203: Platform Leveling Master Cylinder

    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...

  • Page 204: Turntable Covers

    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...

  • Page 205: Deutz Engine F4L 1011F

    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...

  • Page 206: Ford Lrg-423 Engine

    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...

  • Page 207: Choke Adjustments

    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...

  • Page 208: Timing Adjustment

    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...

  • Page 209: Water Temperature And Oil Pressure Gauges

    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...

  • Page 210: Vacuum Switch

    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...

  • Page 211: Ground Controls

    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...

  • Page 212: Power Relay

    2 small posts 12 to 16Ω solenoid activate coil terminal (small post) 2 large posts no continuity (infinite Ω) Any small post to no continuity (infinite Ω) any large post 7 - 34 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 213: Hydraulic Pumps

    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...
  • Page 214 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...
  • Page 215 Service Manual - Second Edition Section 7 - Repair Procedures 800-610-4101 ActionRental.com This page intentionally left blank. Part No. 48412 Genie S-60 & Genie S-65 7 - 37...

  • Page 216: Function Manifold Components

    ....... 11-13 ft-lbs / 15-18 Nm 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...
  • Page 217 Service Manual - Second Edition Section 7 - Repair Procedures 800-610-4101 ActionRental.com MANIFOLDS Part No. 48412 Genie S-60 & Genie S-65 7 - 39...
  • Page 218 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 ........Y ... Differential sensing circuit Platform rotate left ......
  • Page 219 Service Manual - Second Edition Section 7 - Repair Procedures 800-610-4101 ActionRental.com MANIFOLDS Part No. 48412 Genie S-60 & Genie S-65 7 - 41...

  • Page 220: Valve Adjustments - Function Manifold

    6 Repeat steps 2 through 5 and recheck relief Pressure 2100 psi 145 bar valve pressure. 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...
  • Page 221 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...
  • Page 222 (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...

  • Page 223: Turntable Rotation Manifold Components

    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. 48412 Genie S-60 & Genie S-65 7 - 45...

  • Page 224: Oscillate Manifold Components

    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 - 46 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 225: Valve Adjustments - Oscillate Manifold

    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...

  • Page 226: 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 7 - 48 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 227 (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...

  • Page 228: Steer Manifold Components, S-60/65 Oscillating Models

    Orifice Plug, 0.025 inch (0.635 mm) .. UU ..Priority flow regulator circuit Priority flow regulator valve, 3.5 gpm (13.2 l/min) . VV ..Regulates flow to oscillate manifold ......10-12 ft-lbs / 14-16 Nm 7 - 50 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 229 Service Manual - Second Edition Section 7 - Repair Procedures 800-610-4101 ActionRental.com This page intentionally left blank. Part No. 48412 Genie S-60 & Genie S-65 7 - 51...

  • Page 230: 2Wd Drive Manifold Components

    55 ft-lbs / 75 Nm SAE No. 4 13 ft-lbs / 18 Nm SAE No. 12 75 ft-lbs / 102 Nm SAE No. 6 18 ft-lbs / 24 Nm 7 - 52 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 231 Service Manual - Second Edition Section 7 - Repair Procedures 800-610-4101 ActionRental.com MANIFOLDS Part No. 48412 Genie S-60 & Genie S-65 7 - 53...

  • Page 232: Valve Adjustments, 2Wd Drive Manifold

    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 - 54 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 233 Service Manual - Second Edition Section 7 - Repair Procedures 800-610-4101 ActionRental.com MANIFOLDS This page intentionally left blank. Part No. 48412 Genie S-60 & Genie S-65 7 - 55...

  • Page 234: 4Wd Drive Manifold Components

    55 ft-lbs / 75 Nm SAE No. 4 13 ft-lbs / 18 Nm SAE No. 12 75 ft-lbs / 102 Nm SAE No. 6 18 ft-lbs / 24 Nm 7 - 56 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 235 Service Manual - Second Edition Section 7 - Repair Procedures 800-610-4101 ActionRental.com MANIFOLDS Part No. 48412 Genie S-60 & Genie S-65 7 - 57...

  • Page 236: Valve Adjustments, 4Wd Drive Manifold

    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...

  • Page 237: Fuel And Hydraulic Tanks

    Clean the fuel tank and inspect for rust and corrosion before installing. Part No. 48412 Genie S-60 & Genie S-65 7 - 59...
  • Page 238 55 gallons Place one lifting strap at each end of the tank capacity (including tank) 208 liters and attach the lifting straps to an overhead crane. Hydraulic fluid Dexron equivalent 7 - 60 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 239 4 Connect the wiring and start the engine from circuits may cause death or the ground controls. Check for hydraulic leaks. serious injury. Remove all rings, watches and other jewelry. Part No. 48412 Genie S-60 & Genie S-65 7 - 61...

  • Page 240: Turntable Rotation Components

    Fitting Torque Specifications. 1 Secure the turntable from rotating with the turntable rotation lock pin. Unlocked position motor/brake mounting bolts motor brake torque hub mounting bolts torque hub plug Locked position 7 - 62 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 241 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...
  • Page 242 3 Loosen the lock nut on the adjustment bolt. 4 Turn the adjustment bolt clockwise until it contacts the pivot plate. 5 Turn the adjustment bolt turn counterclockwise. Then tighten the lock nut on the adjustment bolt. 7 - 64 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 243: 2Wd Steering Axle Components

    7 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the 5 Remove the lug nuts. Then remove the tire rear bearing. and wheel assembly. Part No. 48412 Genie S-60 & Genie S-65 7 - 65...

  • Page 244: Steering Cylinders

    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...

  • Page 245: Tie Rod

    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...

  • Page 246: 4Wd Steering Axle Components

    7 - 68 Genie S-60 & Genie S-65 Part No. 48412...

  • Page 247: Steering Cylinders

    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...

  • Page 248: Oscillating Axle Components

    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...

  • Page 249: Non-Steering Axle Components

    3 Remove the drive motor mounting fasteners. 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...
  • Page 250 320 ft-lbs 433.9 Nm Torque hub mounting bolts, 120 ft-lbs 163 Nm lubricated 90 ft-lbs 122 Nm Drive motor mounting bolts, 75 ft-lbs 102 Nm lubricated 56 ft-lbs 76 Nm 7 - 72 Genie S-60 & Genie S-65 Part No. 48412...
  • Page 251 800-610-4101 ActionRental.com Genie North America 18340 NE 76th Street P.O. Box 97030 Redmond, Washington 98073-9730 Distributed By: Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England...

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