Genie S-60 User manual

Service Manual Third Edition
First Printing
Part No. 65196

Part No. 65196 Genie S-60 & Genie S-65
Third Edition •First Printing
Table of Contents
v
Introduction
Important Information...................................................................................................... ii
Section One Safety Rules
General Safety Rules..................................................................................................... iii
Section Two Specifications
Machine Specifications ............................................................................................. 2 - 1
Performance Specifications ...................................................................................... 2 - 2
Hydraulic Specifications............................................................................................ 2 - 3
Ford Engine LRG 425 EFI Specifications ................................................................. 2 - 4
Deutz Engine F4L 1011F Specifications ................................................................... 2 - 5
Perkins Engine 704-30 Specifications....................................................................... 2 - 6
Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 7
Section Three Theory of Operation
Power Source ........................................................................................................... 3 - 1
Hydraulic System...................................................................................................... 3 - 1
Electrical System ...................................................................................................... 3 - 1
Limit Switches ........................................................................................................... 3 - 2
Machine Controls ...................................................................................................... 3 - 2

Genie S-60 & Genie S-65 Part No. 65196
Third Edition •First Printing
TABLE OF CONTENTS
vi
Section Four Scheduled Maintenance Procedures
Introduction ............................................................................................................... 4 - 1
Maintenance Inspection Report ................................................................................ 4 - 3
A-1 Inspect the Operator's and Safety Manuals .................................................... 4 - 5
A-2 Inspect the Decals and Placards ..................................................................... 4 - 5
A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6
A-4 Check the Engine Oil Level ............................................................................. 4 - 7
A-5 Check the Engine Coolant Level - Liquid Cooled Models ................................ 4 - 8
A-6 Check for Fuel Leaks ...................................................................................... 4 - 8
A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 9
A-8 Check for Hydraulic Leaks ............................................................................ 4 - 10
A-9 Check the Tire Pressure ............................................................................... 4 - 10
A-10 Test the Oscillate Axle (if equipped) .............................................................. 4 - 11
A-11 Test the Platform and Ground Controls ......................................................... 4 - 12
A-12 Test the Auxiliary Power Operation ............................................................... 4 - 13
A-13 Test the Tilt Sensor ....................................................................................... 4 - 14
A-14 Test the Limit Switches ................................................................................. 4 - 14
A-15 Drain the Fuel Filter/Water Separator - Diesel Models .................................. 4 - 17
A-16 Inspect the Engine Air Filter .......................................................................... 4 - 19
A-17 Perform 30 Day Service ................................................................................ 4 - 20
A-18 Inspect the Radiator - Liquid Cooled Models ................................................. 4 - 20
A-19 Check the Battery ......................................................................................... 4 - 21
A-20 Replace the Engine Oil and Filter - Gasoline/LPG Models ............................ 4 - 22
A-21 Inspect the Electrical Wiring .......................................................................... 4 - 24
A-22 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ...................... 4 - 25
A-23 Check the Engine Belt - Gasoline/LPG and Perkins Diesel Models .............. 4 - 26
A-24 Replace the Fuel Filters - Gasoline/LPG Models........................................... 4 - 28

Part No. 65196 Genie S-60 & Genie S-65
Third Edition •First Printing
TABLE OF CONTENTS
vii
Section Four Scheduled Maintenance Procedures, continued
B-1 Check the Exhaust System ........................................................................... 4 - 30
B-2 Check the Hydraulic Tank Return Filter Condition Indicator .......................... 4 - 31
B-3 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 32
B-4 Confirm the Proper Brake Configuration ....................................................... 4 - 33
B-5 Check the Oil Level in the Drive Hubs ........................................................... 4 - 34
B-6 Check and Adjust the Engine RPM ............................................................... 4 - 36
B-7 Test the Key Switch ...................................................................................... 4 - 37
B-8 Test the Emergency Stop Buttons ................................................................. 4 - 38
B-9 Test the Ground Control Override ................................................................. 4 - 38
B-10 Check the Directional Valve Linkage ............................................................. 4 - 39
B-11 Test the Platform Self-leveling ...................................................................... 4 - 39
B-12 Test the Horn ................................................................................................ 4 - 40
B-13 Test the Foot Switch ..................................................................................... 4 - 40
B-14 Test the Engine Idle Select Operation ........................................................... 4 - 41
B-15 Test the Fuel Select Operation - Gasoline/LPG Models ................................ 4 - 42
B-16 Test the Drive Enable System ....................................................................... 4 - 43
B-17 Test the Drive Brakes ................................................................................... 4 - 44
B-18 Test the Drive Speed - Stowed Position ........................................................ 4 - 45
B-19 Test the Drive Speed - Raised or Extended Position .................................... 4 - 46
B-20 Test the Alarm Package (if equipped) ........................................................... 4 - 47
B-21 Perform Hydraulic Oil Analysis ...................................................................... 4 - 48
B-22 Replace the Hydraulic Tank Return Filter...................................................... 4 - 48
B-23 Inspect the Fuel Tank Cap Venting System .................................................. 4 - 49
B-24 Replace the Engine Air Filter Element ........................................................... 4 - 50
B-25 Replace the Spark Plugs - Gasoline/LPG Models ......................................... 4 - 51

Genie S-60 & Genie S-65 Part No. 65196
Third Edition •First Printing
TABLE OF CONTENTS
viii
Section Four Scheduled Maintenance Procedures, continued
C-1 Check the Engine Belt - Deutz Diesel Models ............................................... 4 - 52
C-2 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 53
C-3 Replace the Fuel Filter/Water Separator Element - Perkins Diesel Models ... 4 - 53
C-4 Replace the Fuel Filter Element - Perkins Diesel Models .............................. 4 - 55
C-5 Replace the Engine Oil and Filter - Perkins Diesel Models ........................... 4 - 57
C-6 Check the Glow Plugs - Perkins Diesel Models ............................................ 4 - 58
C-7 Check the Specific Gravity of Engine Coolant - Liquid Cooled Models .......... 4 - 59
C-8 Replace the PCV Valve - Gasoline/LPG Models ........................................... 4 - 60
D-1 Check the Boom Wear Pads ......................................................................... 4 - 61
D-2 Check the Free-wheel Configuration ............................................................. 4 - 61
D-3 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 63
D-4 Grease the Turntable Rotation Bearing and Rotate Gear.............................. 4 - 64
D-5 Replace the Drive Hub Oil ............................................................................. 4 - 64
D-6 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 66
D-7 Replace the Engine Oil and Filter - Deutz Diesel Models .............................. 4 - 67
D-8 Clean the Fuel Pump Strainer - Deutz Diesel Models ................................... 4 - 68
D-9 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models......... 4 - 69
D-10 Change the Fuel Hoses - Deutz Diesel Models ............................................. 4 - 70
D-11 Check the Engine Valve Clearances - Perkins Diesel Models ....................... 4 - 72
D-12 Clean the Engine Breather Assembly - Perkins Diesel Models ..................... 4 - 72
E-1 Test or Replace the Hydraulic Oil.................................................................. 4 - 73
E-2 Change or Recondition the Engine Coolant - Liquid Cooled Models ............. 4 - 75
E-3 Change the Fuel Hoses - Gasoline/LPG Models ........................................... 4 - 76
E-4 Replace the Engine Air Breather - Perkins Diesel Models ............................. 4 - 78
E-5 Grease the Steer Axle Wheel Bearings, 2WD Models .................................. 4 - 78
E-6 Check the Fuel Injectors - Perkins Diesel Models ......................................... 4 - 80