Do you have a question about the S-65 and is the answer not in the manual?
Questions and answers
Floyd churchwell
January 24, 2025
es65d where is the 2 speed motor and how to test the functions
1 comments:
Mr. Anderson
May 14, 2025
The two-speed motor on the Genie S-65 is part of the drive system. It is located inside the drive chassis, connected to the drive motor circuits at the steer and non-steer ends.
To test its functions: 1. Perform the drive speed test in both the stowed and raised or extended positions. 2. Ensure the engine idle control switch is set to foot switch activated high idle (rabbit and foot switch symbol). 3. Check that the drive function responds quickly and smoothly to operator control. 4. Drive performance should be free of hesitation, jerking, or unusual noise across the full speed range.
This test should be done every 250 hours or quarterly, whichever comes first.
Important Serial Number Information Read, understand and obey the safety rules and Genie Industries offers the following Service operating instructions in the Genie S-60 and Genie Manuals for these models: S-65 Operator's Manual before attempting any maintenance or repair procedure.
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Maximum platform reach : 50 ft 4 in/ 15.3 m number Gradeability: 45% Model year Country of manufacture: USA This machine complies with: ANSI A92.5 CAN B.354.4 Genie Industries 18340 NE 76th Street Redmond, WA 98052 PN - 77055 Part No. 77828 S-60 • S-65...
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July 2005 This page intentionally left blank. S-60 • S-65 Part No. 77828...
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Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-60 and 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.
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Please be environmentally safe. property damage. Be sure that your workshop or work area Used to indicate operation or is properly ventilated and well lit. maintenance information. S-60 • S-65 Part No. 77828...
Check and Adjust the Engine RPM - Deutz Models ........3 - 20 Test the Ground Control Override .............. 3 - 22 B-10 Check the Oscillate Directional Valve Linkage ........... 3 - 22 B-11 Test the Platform Self-leveling ..............3 - 23 viii S-60 • S-65 Part No. 77828...
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(after serial number 11879) ................ 6 - 31 Ground Control Box Terminal Strip Wiring Diagram, S-65, Ford LRG-425 EFI Models (before serial number 11880) ....6 - 33 Ground Control Box Switch Panel Wiring Diagram, S-65, Ford LRG-425 EFI Models (before serial number 11880) ....6 - 34 Ground Control Box Terminal Strip Wiring Diagram, S-65, Ford LRG-425 EFI Models (after serial number 11879) ....
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(after serial number 11879) ................ 6 - 54 Platform Control Box Terminal Strip Wiring Diagram, S-60, Deutz F3L-2011 Models ..............6 - 55 Platform Control Box Switch Panel Wiring Diagram, S-60, Deutz F3L-2011 Models ..............6 - 56 Part No. 77828 S-60 • S-65...
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(after serial number 11879) ................ 6 - 63 Ground Control Box Terminal Strip Wiring Diagram, S-65, Deutz F3L-2011 Models (before serial number 11880) ....6 - 65 Ground Control Box Switch Panel Wiring Diagram, S-65, Deutz F3L-2011 Models (before serial number 11880) ....6 - 66 Ground Control Box Terminal Strip Wiring Diagram, S-65, Deutz F3L-2011 Models (after serial number 11879) .......
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(after serial number 11879) ................ 6 - 87 Ground Control Box Terminal Strip Wiring Diagram, S-65, Perkins 404-22 Models (before serial number 11880) ...... 6 - 89 Ground Control Box Switch Panel Wiring Diagram, S-65, Perkins 404-22 Models (before serial number 11880) ...... 6 - 90 Ground Control Box Terminal Strip Wiring Diagram, S-65, Perkins 404-22 Models (after serial number 11879) ......
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July 2005 This page intentionally left blank. xviii S-60 • S-65 Part No. 77828...
Machine Specifications Performance Specifications Tires and wheels Boom function speeds, maximum from platform controls Wheel lugs Jib boom up, S-65 60 to 70 seconds Lug nut torque, dry 170 ft-lbs 225 Nm Jib boom down, S-65 40 to 50 seconds...
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Charge pump Chevron Rykon MV oil is fully compatible and Type: gerotor mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are Displacement 0.85 cu in designed to give maximum protection to hydraulic 13.9 cc...
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3.5 bar ³ 200 Medium pressure filter Beta Medium pressure filter 51 psi bypass pressure 3.5 bar Hydraulic return filter 10 micron with 25 psi / 1.7 bar bypass Part No. 77828 S-60 • S-65 2 - 3...
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Above 0° F / -17.8° C 10W-30 11.4 liters Only use engine oils labeled "For Gasoline Engines" Alternator output 66A @ 12V DC by the American Petroleum Institute (API). Fan belt deflection inch 12 mm 2 - 4 S-60 • S-65 Part No. 77828...
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Use oils meeting API classification SJ or SH. Reserve capacity @ 25A rate 200 minutes Units ship with 15W-40 SJ. Ignition system Spark plug type Motorcraft AGSF-32-FM Spark plug gap 0.042 to 0.046 inches 1.07 to 1.17 mm Part No. 77828 S-60 • S-65 2 - 5...
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Engine oil should have minimum properties of API Alternator output 60A @ 14V DC classification CC/SG or CD/SG grades. Units ship with 10W-40 CH-4 Fan belt deflection inch 9 to 12 mm 2 - 6 S-60 • S-65 Part No. 77828...
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55A @ 12V DC 0.2 mm Fan belt deflection 10 mm Starter motor Current draw, no load Brush length, new 0.7480 in 19 mm Brush length, minimum 0.5 in 12.7 mm Part No. 77828 S-60 • S-65 2 - 7...
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Torque 8-18 ft-lbs Rotate bearing mounting bolts, lubricated 180 ft-lbs 11-24 Nm 244 Nm Temperature switch point 221° F Turntable rotation assembly 105° C Backlash pivot plate 260 ft-lbs 352.5 Nm 2 - 8 S-60 • S-65 Part No. 77828...
Your machine is equipped with Parker Seal-Lok ® The O-ring cannot be re-used if the fitting or fittings and hose ends. Genie specifications require hose end has been tightened beyond finger that fittings and hose ends be torqued to tight.
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· Key switch in the off position with the Indicates that an incorrect result has occurred key removed after performing a series of steps. · Wheels chocked · All external AC power disconnected from the machine Part No. 77828 S-60 • S-65 3 - 1...
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Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. 3 - 2 S-60 • S-65 Part No. 77828...
After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 77828 S-60 • S-65 3 - 5...
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After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments 3 - 6 S-60 • S-65 Part No. 77828...
The Pre-operation Inspection also Complete information to perform this procedure is serves to determine if routine maintenance available in the Genie S-60 and Genie S-65 procedures are required. Operator's Manual on your machine. Complete information to perform this procedure is available in the Genie S-60 and Genie S-65 Operator's Manual on your machine.
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 8 S-60 • S-65 Part No. 77828...
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 77828 S-60 • S-65 3 - 9...
Result: The non-steer tires should stay in firm contact with the ground. If the chassis does not remain level during test, see Repair Procedure 7-6, How to Set Up the Oscillate Directional Valve. 3 - 10 S-60 • S-65 Part No. 77828...
3 Inspect the filter bowl for water buildup. Genie part number 84792 Result: If water is present in the filter bowl Perkins 400 Series Operation Manual continue with steps 4 through 8. Genie part number 94890 Part No. 77828 S-60 • S-65 3 - 11...
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See B-20, Replace The Fuel Filter Element - Perkins Models, for instructions on how to prime the fuel filter/water separator. 7 Clean up any fuel that may have spilled. 3 - 12 S-60 • S-65 Part No. 77828...
Repair the leak immediately. 8 Swing the engine back to its original position and install the engine pivot plate retaining fastener. Part No. 77828 S-60 • S-65 3 - 13...
Bearing and Rotate Gear Tighten the low idle lock nut and confirm the rpm. Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist.
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 77828 S-60 • S-65 3 - 15...
4 Inspect all welds for cracks. fastener. 5 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints. 6 Swing the engine back to its original position and install the engine pivot plate retaining fastener. Part No. 77828 S-60 • S-65 3 - 17...
10 Install the engine side cover. death or serious injury. 11 Swing the engine back to its original position and install the engine pivot plate retaining fastener. 3 - 18 S-60 • S-65 Part No. 77828...
4 Check the pressure in each air-filled tire. drive pump free-wheel valve lift pump screwdriver The free-wheel valve is located on the side of the drive pump. The free-wheel valve should always remain closed. Part No. 77828 S-60 • S-65 3 - 19...
4 Install the plug(s) into the drive hub. 5 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications . 6 Repeat this procedure for each drive hub. 3 - 20 S-60 • S-65 Part No. 77828...
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5 Move the function enable/rpm select toggle switch to the high idle (rabbit symbol) position at the ground controls. Result: High idle should be 2500 rpm. If high idle rpm is correct, disregard adjustment step 6. Part No. 77828 S-60 • S-65 3 - 21...
· Lock nut is tight against yoke Result: All boom functions should operate. · Yoke clevis pins are installed · Cotter pins are installed through clevis pins · Linkage is properly attached to directional valve 3 - 22 S-60 • S-65 Part No. 77828...
Result: The engine should change to high idle. 6 Move the engine idle control switch to foot switch activated low idle (turtle symbol). Result: The engine should change to low idle. Part No. 77828 S-60 • S-65 3 - 23...
4 Release the foot switch and shut the engine off by pushing in the red Emergency Stop button in to the off position. 5 Move the fuel select switch to LPG. 3 - 24 S-60 • S-65 Part No. 77828...
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. Part No. 77828 S-60 • S-65 3 - 25...
7 Continue at full speed and note the time when the machine reference point crosses the finish the machine reference point crosses the finish line. Refer to Section 2, Specifications. line. Refer to Section 2, Specifications. 3 - 26 S-60 • S-65 Part No. 77828...
6 S-65: Press down the foot switch. Move the jib changing the oil is necessary. If boom toggle switch to the down position, hold the hydraulic oil is not replaced for a moment and then release it.
7 Install the bowl onto the new filter element. 8 Apply a thin layer of oil onto the element gasket. Install the filter/bowl assembly onto the filter head. Tighten the drain plug and vent plug. Part No. 77828 S-60 • S-65 3 - 29...
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14 Loosen the vent plug on top of the fuel injection pump. vent plug fuel injection pump fuel lift pump 3 - 30 S-60 • S-65 Part No. 77828...
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 77828 S-60 • S-65 3 - 33...
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 34 S-60 • S-65 Part No. 77828...
Test the Platform Overload platform capacity in one of the locations shown. System (if equipped) Genie specifications require that this procedure be performed every 500 hours or six months. Testing the platform overload system regularly is essential to safe machine operation.
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System (if equipped). 10 Test all machine functions from the ground controls. Result: All ground control functions should not operate. Machine functions should still operate with auxiliary power at the ground controls. 3 - 36 S-60 • S-65 Part No. 77828...
Remove the and the access panels on the sides of the covers. boom. 7 Start the engine from the ground controls and fully retract and lower the boom to the stowed position. Part No. 77828 S-60 • S-65 3 - 37...
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 38 S-60 • S-65 Part No. 77828...
Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 77828 S-60 • S-65 3 - 39...
The lift cylinder safety chock is once it reaches the minimum allowable available through Genie thickness. If the wear pad is still within (Genie part number 75097). specification, shim as necessary to obtain 2 Turn the engine off. minimum clearance with zero binding.
See D-2, Check the Turntable Rotation Bearing Bolts. Bolt torque sequence 3 Start the machine from the ground controls and raise the boom to full height. Do not extend the boom. Part No. 77828 S-60 • S-65 3 - 41...
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12 Remove the dial indicator from the machine. turntable dial indicator drive chassis turntable rotation bearing 5 At the dial indicator, adjust it to "zero" the indicator. 6 Fully extend the boom and lower to a horizontal position. 3 - 42 S-60 • S-65 Part No. 77828...
Install the plugs into the drive hub. Refer to disengaged position Section 2, Specifications . 5 Repeat steps 1 through 4 for all the other drive hubs. engaged position Part No. 77828 S-60 • S-65 3 - 43...
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The free-wheel valve is located on the side of the drive pump. The free-wheel valve should always remain closed. engaged position 11 Manually rotate each steer wheel. Result: Each steer wheel should rotate with minimum effort. 3 - 44 S-60 • S-65 Part No. 77828...
3 Loosen the lock nut on the high idle mixture adjustment screw. 4 Load the system by activating the primary boom retract function, then move the function enable toggle switch to the high idle (rabbit symbol) position. 3 - 46 S-60 • S-65 Part No. 77828...
9 Adjust the low idle mixture adjustment screw to obtain an air-to-fuel mixture ratio of 13.0:1 to 13.2:1. Preliminary setting: turn low idle adjustment screw clockwise all the way in. Turn low idle adjustment screw counterclockwise 2 turns. Part No. 77828 S-60 • S-65 3 - 47...
Result: The overload indicator light and the alarm is on. Slowly tighten the load spring adjustment nut by turning it clockwise just until Genie specifications require that the overload indicator light and alarm turns off. this procedure be performed every 1000 hours of operation or yearly.
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11 Test all machine functions from the ground controls. Result: All ground control functions should not operate. If the platform overload system is not operating properly, repeat steps 1 through 4. Part No. 77828 S-60 • S-65 3 - 49...
The hoses can be accessed through the access hole under the turntable. 7 Disconnect and plug the return filter hydraulic hose at the return filter. Cap the fitting on the filter housing. 3 - 50 S-60 • S-65 Part No. 77828...
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18 Install the hydraulic tank onto the machine. 19 Install the two suction hoses to the suction strainers. 20 Install the supply hose for the auxiliary power unit and the return filter hose. Part No. 77828 S-60 • S-65 3 - 51...
If the cables are replaced, the cable sheaves or pulleys should also be replaced. Genie specifications require that this procedure be performed at 5 Remove the cotter pins and clevis pins from the 5 years or 5000 hours, whichever...
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16 Install the boom extension cylinder assembly into the boom. 17 Adjust the boom extend/retract cables. See Repair Procedure 4-5, How to Adjust the Boom Extend/Retract Cables. 3 - 54 S-60 • S-65 Part No. 77828...
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Read, understand and obey the safety rules and which, if not avoided, will result in operating instructions in the Genie S-60 and death or serious injury. Genie S-65 Operator’s Manual. Used to indicate the presence of a...
Result: The alarm should sound indicating successful joystick calibration. 6 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch. No machine fuction should operate while performing the joystick calibration procedure. Part No. 77828 S-60 • S-65 4 - 3...
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4 times. Result: There should be a pause and the alarm should sound 4 times indicating that the machine is in max-out calibration mode. 4 - 4 S-60 • S-65 Part No. 77828...
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0.5 second decelerate, coasting 0.75 second decelerate, braking 1 second decelerate, shift from low to high speed 1 second decelerate, shift from high to low speed 4 seconds Part No. 77828 S-60 • S-65 4 - 5...
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8 times indicating that the machine is in threshold calibration mode. 8 Start the engine from the platform controls and press down the foot switch. 9 Select a boom function joystick to set the threshold. 4 - 6 S-60 • S-65 Part No. 77828...
Do not allow oil to squirt Platform Rotator or spray. Component damage hazard. Mark 3 S-65: Support the jib boom leveling arms and the platform mounting weldment the platform mounting weldment with an and the rotator flange before appropriate lifting device. Do not apply any removing the platform mounting lifting pressure.
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Crushing hazard. The platform rotator may become unbalanced and fall if not properly supported. When installing the platform rotator fasteners, torque the fasteners to specifications. top bleed valve bottom bleed valve container clear hose Part No. 77828 S-60 • S-65 4 - 9...
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Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 10 S-60 • S-65 Part No. 77828...
July 2005 Section 4 • Repair Procedures Jib Boom Components, S-65 REV A 6 Attach a lifting strap from an overhead crane to the jib boom assembly. Jib Boom 7 Place blocks under the platform leveling cylinder for support. Protect the cylinder rod from How to Remove the Jib Boom damage.
Section 4 • Repair Procedures July 2005 JIB BOOM COMPONENTS, S-65 REV A 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not Jib Boom Lift Cylinder remove the pin. 4 Use a soft metal drift to tap the jib boom lift How to Remove the Jib Boom cylinder rod-end pivot pin half way out.
4 Remove the electrical outlet box bracket 10 Remove the retaining fasteners from the mounting fasteners. Remove the outlet box and electrical connector receptacles for the cables lay it to the side. that enter the cable track. Part No. 77828 S-60 • S-65 4 - 13...
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15 Attach a strap from an overhead crane to the cable track. 16 Remove the cotter pin from the cable track pull tube at the platform end of the boom. Always replace the cotter pin with a new one. 4 - 14 S-60 • S-65 Part No. 77828...
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6 Remove the hose and cable clamps from the all cables that enter the cable track. platform support and jib boom. 12 Remove the retaining fasteners from the electrical connector receptacles for the cables that enter the cable track. Part No. 77828 S-60 • S-65 4 - 15...
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Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine. 4 - 16 S-60 • S-65 Part No. 77828...
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A cable track repair kit is available 9 Operate the boom extend/retract function through the Genie Industries through a full cycle to ensure smooth operation Service Parts Department, of the new section of cable track.
How to Remove the Boom Perform this procedure with the boom in the stowed position. Consult the Genie Industries Service Department for instructions on how to safely remove the boom When removing a hose assembly assembly from the machine. Failure to read and...
10 Carefully remove the boom lift cylinder from the machine. Crushing hazard. The boom lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device. Part No. 77828 S-60 • S-65 4 - 19...
Perform this procedure with the boom fully retracted. cable guard 1 Raise the boom to a horizontal position. retaining block 2 Remove the access covers from both sides of the boom at the pivot end. 4 - 20 S-60 • S-65 Part No. 77828...
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Do not allow oil to squirt or spray. extend cable lock nuts extend cable mounting plate extend cable mounting plate fastener extend cable bracket Part No. 77828 S-60 • S-65 4 - 21...
During removal of the extension 3 Remove the boom cover at the pivot end of the cylinder, the overhead crane strap boom. will need to be carefully adjusted for proper balancing. 4 - 22 S-60 • S-65 Part No. 77828...
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3 Remove the rue rings and clevis pins from the boom extend cables located near the cable break limit switch. cable break limit switch extend cable adjustment nut extend cable pivot plate Part No. 77828 S-60 • S-65 4 - 23...
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A cable pulling tool is available 7 Install the new boom extend cable pulley, pivot through Genie Service Parts pin and snap rings. Department, part no. 94510. Be sure the boom extend cables 15 At the platform end of the boom, pull on the...
Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the boom until the master cylinder is above the turntable covers. Part No. 77828 S-60 • S-65 4 - 25...
0.15 inch / 3.8 mm gap - GM Models crankshaft position sensor can inch / 1.5 mm gap - Ford Models become damaged if the engine is not properly supported when the fasteners are removed. 4 - 26 S-60 • S-65 Part No. 77828...
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7 Remove the engine plate to vibration isolator or pinched. fasteners. 6 Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel. Part No. 77828 S-60 • S-65 4 - 27...
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/ 3.8 mm gap - GM Models ® 5 Apply Loctite removable thread sealant to the pump coupler set screw. Torque the set screw to 61 ft-lbs / 83 Nm. Ford and Deutz models 4 - 28 S-60 • S-65 Part No. 77828...
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Perkins models: Torque the bell housing mounting bolts labeled "B" in sequence to 40 ft-lbs / 54 Nm and the mounting bolts labeled "A" to 70 ft-lbs / 95 Nm. Deutz models Perkins models Part No. 77828 S-60 • S-65 4 - 29...
ECM. It will blink the first digit of a three Contact Genie Industries Service Department for digit code, pause, blink the second assistance in retrieving fault codes.
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5 minutes. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. Part No. 77828 S-60 • S-65 4 - 31...
If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 4 - 32 S-60 • S-65 Part No. 77828...
Any internal service to the pump should only be performed at an authorized Eaton Hydraulics center. Call Genie Industries Service Department to locate your local authorized service open closed center.
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Deutz models: Hold the manual fuel shutoff valve clockwise to the closed position. Component damage hazard. Be sure to fill the hydraulic tank to specification and prime the pump after installing the pump. manual fuel shutoff valve 4 - 34 S-60 • S-65 Part No. 77828...
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Perkins models: Connect the engine wiring harness to the fuel solenoid. Deutz models: Release the manual fuel shutoff valve. 7 Start the engine from the ground controls and check for hydraulic leaks. Part No. 77828 S-60 • S-65 4 - 35...
Install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. 4 - 40 S-60 • S-65 Part No. 77828...
The oscillate directional valve is mounted inside the drive chassis at the non-steer end. Index Description Function Torque Cap ..............Breather ..........20-25 ft-lbs / 27-33 Nm Spool valve ............Directional control 4 - 44 S-60 • S-65 Part No. 77828...
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The tires on some machines are drive chassis level, repeat steps 6 foam-filled and do not need air through 11 OR consult Genie added to them. Industries Service Department. 4 Remove the drive chassis cover and the non- steer axle covers.
10 Turn the engine off, remove the pressure gauge and assemble the directional valve linkage. 11 Install the cover on the non-steer end of the drive chassis. 4 - 46 S-60 • S-65 Part No. 77828...
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July 2005 Section 4 • Repair Procedures REV D MANIFOLDS This page intentionally left blank. Part No. 77828 S-60 • S-65 4 - 47...
Shuttle valve, 3 position 3 way ..UU ..Charge pressure circuit that directs hot oil out of low pressure side of drive pump ......50-55 ft-lbs / 68-75 Nm Orifice, 0.070 inch / 1.78 mm .... VV ..Drive motor circuit 4 - 48 S-60 • S-65 Part No. 77828...
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July 2005 Section 4 • Repair Procedures REV D MANIFOLDS Part No. 77828 S-60 • S-65 4 - 49...
Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap. 10 Turn the engine off and remove the pressure gauge. 4 - 50 S-60 • S-65 Part No. 77828...
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July 2005 Section 4 • Repair Procedures REV D MANIFOLDS This page intentionally left blank. Part No. 77828 S-60 • S-65 4 - 51...
Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap. 10 Turn the engine off and remove the pressure gauge. 4 - 54 S-60 • S-65 Part No. 77828...
MANIFOLDS 7-12 How to Test a Coil Diode Valve Coils Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional How to Test a Coil valves and those coils with a metal case. Properly functioning coil diodes protect the electrical circuit A properly functioning coil provides an by suppressing voltage spikes.
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9V DC battery 10Ω resistor coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6 4 - 56 S-60 • S-65 Part No. 77828...
Crushing hazard. The turntable rotation drive hub assembly could become unbalanced and fall when removed from the machine if not properly supported. Part No. 77828 S-60 • S-65 4 - 57...
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Then torque the mounting fasteners on the backlash pivot plate to 260 ft-lbs / 352.5 Nm. 7 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary. 4 - 58 S-60 • S-65 Part No. 77828...
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. 77828 S-60 • S-65 4 - 59...
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Section 4 • Repair Procedures July 2005 This page intentionally left blank. 4 - 60 S-60 • S-65 Part No. 77828...
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Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie S-60 and Genie S-65 Operator’s Manual. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Read each appropiate fault code thoroughly.
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OR use a grounded wrist strap. 5 - 2 S-60 • S-65 Part No. 77828...
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(transient) Boom 2 directional Limited speed and valves direction frozen at Power up Fault zero and neutral. controller with Alarm sounds problem corrected. indicating fault. Continued on next page Part No. 77828 S-60 • S-65 5 - 3...
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Self-clearing. Just calibrated is zero. (transient) Drive enable Enable override Power up override switches Fault direction is frozen at controller with neutral. problem corrected. 5 - 4 S-60 • S-65 Part No. 77828...
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Initiate 1-second beep Self-clearing. Just calibrated of alarm. (transient) Steer directional Limited speed and valves direction frozen at Power up Fault zero and neutral. controller with Alarm sounds problem corrected. indicating fault. Part No. 77828 S-60 • S-65 5 - 5...
Check Engine Light. Refer to Repair Procedure 5-4, How to Retrieve Engine Fault Codes. Use the Fault Code Chart on the following pages to aid in identifying the fault. 5 - 6 S-60 • S-65 Part No. 77828...
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Repair wiring and/or connections OR replace IAT Low Voltage shorted OR sensor is faulty OR engine intake air sensor OR direct cooler air into air intake. temperature is too hot. Continued on next page Part No. 77828 S-60 • S-65 5 - 7...
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Repair wiring and/or connections to fuel Injector Driver #2 Shorted shorted OR fuel injector #2 is faulty OR ECM is injector #2 OR replace fuel injector #2 OR faulty. replace the ECM. 5 - 8 S-60 • S-65 Part No. 77828...
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Wiring and/or connections to ignition coil #2 Repair wiring and/or connections to ignition Coil Driver #2 Shorted shorted OR ignition coil #2 is faulty. coil #2 OR replace ignition coil #2. Continued on next page Part No. 77828 S-60 • S-65 5 - 9...
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Cause Solution If this fault appears on your machine, contact FPP1 High Voltage Not used. Genie Industries Service Department. If this fault appears on your machine, contact FPP1 Low Voltage Not used. Genie Industries Service Department. If this fault appears on your machine, contact FPP1 Higher than IVS Limit Not used.
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Locate and repair any engine harness wiring Loose wire connections to ECM OR ECM is RTI 3 Loss damage or shorts to ECM to be sure they are faulty.S secure OR replace ECM. Part No. 77828 S-60 • S-65 5 - 11...
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Section 5 • Fault Codes July 2005 This page intentionally left blank. 5 - 12 S-60 • S-65 Part No. 77828...
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Do not allow oil to squirt Read, understand and obey the safety rules or spray. and operating instructions printed in the Genie S-60 & Genie S-65 Operator's Manual on General Repair Process your machine. Be sure that all necessary tools and test...
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Fuse with amperage Key switch N.O. (after serial number 22050) Circuit breaker with amperage Fuel or RPM Control relay contact solenoid normally open Starting aid: glow plug or flame ignitor Coil 6 - 2 S-60 • S-65 Part No. 77828...
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2 position, 2 way solenoid valve Pump prime mover (engine or motor) Differential sensing valve Directional valve pilot operated 2 position, 2 way Double acting cylinder Solenoid operated proportional valve Part No. 77828 S-60 • S-65 6 - 3...
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Section 6 • Schematics July 2005 6 - 4 S-60 • S-65 Part No. 77828...
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LT BLUE/DK BLUE 18 THROTTLE PINK/DK GREEN 16 PINK/DK GREEN 16 PINK/DK GREEN 16 PINK/WHITE 18 TAN/ORANGE 18 RED/TAN 14 POWER RELAY WHITE/BLUE 18 THESE CONNECTORS ARE CONNECTED TO GENIE HARNESS #88833 Part No. 77828 S-60 • S-65 6 - 5...
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July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Ford LRG-425 EFI Models (after serial number 11879)
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Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-60 Ford LRG-425 EFI Models...
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48 PIN CONNECTOR BLOCK ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CR27 CONTROL RELAY (CE OPTION) CR30 CONTROL RELAY (CE OPTION) LS18 LOAD SENSE LIMIT SWITCH 6 - 27 S-60 • S-65 Part No. 77828...
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July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-60 Ford LRG-425 EFI Models...
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Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV B Ford LRG-425 EFI Models (before serial number 11880) P22LS BK NOTES: P134PWR RD 1. ALL LIMIT SWITCHES SHOWN WITH BOOM C28TTA RD/BK C28TTA RD/BK IN STOWED POSITION. C41RPM OR/BK C1B &...
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July 2005 Section 6 • Schematics REV B Electrical Schematic, S-65 Ford LRG-425 EFI Models (before serial number 11880) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15...
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July 2005 Section 6 • Schematics Electrical Schematic, S-65 Ford LRG-425 EFI Models (before serial number 11880)
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Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV A Ford LRG-425 EFI Models (after serial number 11879) P22LS BK NOTES: P134PWR RD 1. ALL LIMIT SWITCHES SHOWN WITH BOOM C28TTA RD/BK C28TTA RD/BK IN STOWED POSITION. C41RPM OR/BK C1B &...
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July 2005 Section 6 • Schematics REV A Electrical Schematic, S-65 Ford LRG-425 EFI Models (after serial number 11879) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15...
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July 2005 Section 6 • Schematics Electrical Schematic, S-65 Ford LRG-425 EFI Models (after serial number 11879)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 Ford LRG-425 EFI Models (before serial number 11880)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV A Ford LRG-425 EFI Models (before serial number 11880) ENGINE FUNCTIONS HARNESS F.H. BRN C37-2 BK C16-1 WH C10-2 WH LS2 C11-2 BRN-GND BRN-TS64 BRN C7B-3 F.H.
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July 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models (before serial number 11880) GR/BK RD/BK-2 RD-1 GR/BK NOTE: WH-23 DASHED LINES INDICATE OPTION WIRES RD/WH RD/WH LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A...
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July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models (before serial number 11880)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 Ford LRG-425 EFI Models (after serial number 11879)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV A Ford LRG-425 EFI Models (after serial number 11879) FUNCTION HARNESS ENGINE F.H. BRN C37-2 BK C16-1 WH C11-2 WH LS2 C10-2 BRN-GND BRN-TS64 BRN C7B-3 F.H.
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July 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models (after serial number 11879) GR/BK RD/WH WH/RD RD/BK-2 RD-1 WH/RD WH/RD WH/RD WH/RD GR/BK WH/RD WH-23 RD/WH RD/WH LABEL DESCRIPTION...
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July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models (after serial number 11879)
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Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-65 Ford LRG-425 EFI Models...
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Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-65 REV A Ford LRG-425 EFI Models CR30 CR27 ALC-500 PLATFORM CONTROL CE LIFT/DRIVE OPTION HARNESS (TO SWITCH PANEL) * NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
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July 2005 Section 6 • Schematics REV A Platform Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models PLATFORM CONTROL HARNESS (TO CONTROL BOX) DRIVE LIGHTS/ WORK LIGHTS DLITE RD (OPTION) TILT ALARM LED (ANSI/CSA OPTION) PRIMARY BOOM...
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July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models...
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ENG. FAULT TEMP. TB21 C5-3 TB21 FUSE CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 39 S-60 • S-65 Part No. 77828...
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July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Deutz F3L-2011 Models (after serial number 11879)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (before serial number 11880)
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July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (before serial number 11880)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (after serial number 11879)
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July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (after serial number 11879)
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Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-60 Deutz F3L-2011 Models...
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CE LIFT/DRIVE OPTION (TO SWITCH PANEL) C28TTA RD/BK C1P-2 WH/RD C1P-6 BATGRN C7P-3 BK C1P-12 RD LS18 CABLE F.S. LS18 OPT. (CE) OPTION TILT 19/18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH ALARM 6 - 55 S-60 • S-65 Part No. 77828...
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July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-60 Deutz F3L-2011 Models...
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Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV D Deutz F3L-2011 Models (before serial number 11880) C22LS BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD BK-(FS) WH-(FS)
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July 2005 Section 6 • Schematics REV D Electrical Schematic, S-65 Deutz F3L-2011 Models (before serial number 11880) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15 P24FS WH...
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July 2005 Section 6 • Schematics Electrical Schematic, S-65 Deutz F3L-2011 Models (before serial number 11880)
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Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV A Deutz F3L-2011 Models (after serial number 11879) C22LS BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD BK-(FS) WH-(FS)
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July 2005 Section 6 • Schematics REV A Electrical Schematic, S-65 Deutz F3L-2011 Models (after serial number 11879) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15 P24FS WH...
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July 2005 Section 6 • Schematics Electrical Schematic, S-65 Deutz F3L-2011 Models (after serial number 11879)
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Section 6 • Schematics July 2005 Electrical Schematic, S-65, CE Models REV D Deutz F3L-2011 Models (before serial number 11880) C22LS BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD...
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July 2005 Section 6 • Schematics REV D Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH...
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July 2005 Section 6 • Schematics Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880)
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Section 6 • Schematics July 2005 Electrical Schematic, S-65, CE Models REV A Deutz F3L-2011 Models (after serial number 11879) C22LS BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD...
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July 2005 Section 6 • Schematics REV A Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH...
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July 2005 Section 6 • Schematics Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 Deutz F3L-2011 Models (before serial number 11880)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV B Deutz F3L-2011 Models (before serial number 11880) ENGINE FUNCTION HARNESS F.H. CE ONLY RD H6 BL/WH-132B P134PWR RD-134C BK-22D2 GR/BK-133B GR/BK-L45 BRN C37-2 BK C16-1...
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July 2005 Section 6 • Schematics REV B Ground Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models (before serial number 11880) GR/BK RD/BK-2 RD-1 GR/BK WH-23 RD/WH RD/WH LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A...
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July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models (before serial number 11880)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 Deutz F3L-2011 Models (after serial number 11879)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV A Deutz F3L-2011 Models (after serial number 11879) FUNCTION HARNESS ENGINE F.H. OPTION ONLY PLATFORM OVER LOAD (CE ONLY) RD H6 BL/WH-132B P134PWR RD-134C BK-22D2...
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July 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models (after serial number 11879) GR/BK RD/WH WH/RD RD/BK-2 RD-1 WH/RD WH/RD WH/RD WH/RD GR/BK WH/RD WH-23 RD/WH RD/WH LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A...
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July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models (after serial number 11879)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models REV B Deutz F3L-2011 Models (before serial number 11880) ENGINE FUNCTION HARNESS F.H. CE ONLY RD H6 P134PWR RD-134C BL/WH-132B BK-22D2 GR/BK-133B GR/BK-L45 BRN C37-2...
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July 2005 Section 6 • Schematics REV B Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880) GR/BK RD/BK-2 RD-1 GR/BK WH-23 RD/WH RD/WH LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A...
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July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879)
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Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models REV A Deutz F3L-2011 Models (after serial number 11879) FUNCTION HARNESS ENGINE F.H. RD H6 BL/WH-132B P134PWR RD-134C BK-22D2 GR/BK-133B GR/BK-L45 BRN C37-2 BK C16-1...
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July 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879) GR/BK RD/WH WH/RD RD/BK-2 RD-1 WH/RD WH/RD WH/RD WH/RD GR/BK WH/RD WH-23 RD/WH RD/WH LABEL...
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July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879)
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July 2005 Section 6 • Schematics Platform Control Box Wiring Diagram, S-65 Deutz F3L-2011 Models...
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Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-65 REV B Deutz F3L-2011 Models ITEM DESCRIPTION TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR C1P-C4P 48 PIN CONNECTOR BLOCK ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR...
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July 2005 Section 6 • Schematics REV B Platform Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models PLATFORM CONTROL HARNESS (TO CONTROL BOX) COMPONENT INDEX TS48 DRIVE LIGHTS/ CR13 JIB BOOM CUT OUT RELAY WORK LIGHTS DLITE RD...
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July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models...
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ENG. FAULT 15AMP. TEMP. TB21 C5-3 TB21 CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 75 S-60 • S-65 Part No. 77828...
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OIL COOLER MANIFOLD RETURN TANK FILTER FUNCTION 0.040 in MANIFOLD 1 mm 800 psi OSCILLATE CYLINDERS 55 bar HYDRAULIC ROTARY COUPLER OIL COOLER OPTION LEFT LEFT REAR FRONT OSCILLATE VALVE OSCILLATE AXLE Part No. 77828 S-60 • S-65 6 - 96...
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Questions and answers
es65d where is the 2 speed motor and how to test the functions
The two-speed motor on the Genie S-65 is part of the drive system. It is located inside the drive chassis, connected to the drive motor circuits at the steer and non-steer ends.
To test its functions:
1. Perform the drive speed test in both the stowed and raised or extended positions.
2. Ensure the engine idle control switch is set to foot switch activated high idle (rabbit and foot switch symbol).
3. Check that the drive function responds quickly and smoothly to operator control.
4. Drive performance should be free of hesitation, jerking, or unusual noise across the full speed range.
This test should be done every 250 hours or quarterly, whichever comes first.
This answer is automatically generated