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

Part No. 65196 Genie S-60 & Genie S-65
Third Edition •First Printing
TABLE OF CONTENTS
ix
Section Five Troubleshooting Flow Charts
Introduction ............................................................................................................... 5 - 1
Fault Code Chart ...................................................................................................... 5 - 3
1 Engine Will Not Crank Over ............................................................................ 5 - 8
2 Engine Cranks Over But Will Not Start - Gasoline/LPG Models .................... 5 - 10
2A Engine Runs While Cranking then Dies- Gasoline/LPG Models .................... 5 - 12
3 Engine Cranks Over But Will Not Start - Diesel Models ................................ 5 - 13
4 Engine Will Not Start On LPG, But Will Start On Gasoline
- Gasoline/LPG Models ................................................................................. 5 - 16
5 Engine Will Not Start On Gasoline, But Will Start On LPG
- Gasoline/LPG Models ................................................................................. 5 - 18
6 Engine High Idle Inoperative - Gasoline/LPG Models.................................... 5 - 19
7 Engine Low Idle Inoperative - Gasoline/LPG Models .................................... 5 - 20
8 Engine High Idle Inoperative - Diesel Models ................................................ 5 - 21
9 Engine Low Idle Inoperative - Diesel Models................................................. 5 - 23
10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 24
11 All Lift and Steer Functions Inoperative, Drive Functions Operational ........... 5 - 25
12 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 26
13 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 27
14 Boom Up Function Inoperative ...................................................................... 5 - 28
15 Boom Down Function Inoperative ................................................................. 5 - 31
16 Boom Extend Function Inoperative ............................................................... 5 - 34
17 Boom Retract Function Inoperative ............................................................... 5 - 36
18 Turntable Rotate Left Function Inoperative ................................................... 5 - 38
19 Turntable Rotate Right Function Inoperative ................................................. 5 - 42

Genie S-60 & Genie S-65 Part No. 65196
Third Edition •First Printing
TABLE OF CONTENTS
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Section Five Troubleshooting Flow Charts, continued
20 All Platform Leveling Functions Inoperative .................................................. 5 - 46
21 Platform Level Up Function Inoperative ........................................................ 5 - 47
22 Platform Level Down Function Inoperative .................................................... 5 - 49
23 Platform Rotate Left Function Inoperative ..................................................... 5 - 51
24 Platform Rotate Right Function Inoperative ................................................... 5 - 53
25 Oscillate Function Inoperative ....................................................................... 5 - 55
26 Jib Boom Up Function Inoperative ................................................................ 5 - 56
27 Jib Boom Down Function Inoperative ............................................................ 5 - 58
28 Steer Left Function Inoperative ..................................................................... 5 - 60
29 Steer Right Function Inoperative ................................................................... 5 - 62
30 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 64
31 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 67
32 Traction Function Inoperative ........................................................................ 5 - 68
33 Machine Will Not Drive At Full Speed............................................................ 5 - 69
34 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 70
35 Drive Enable System Is Malfunctioning ......................................................... 5 - 71
36 Auxiliary Functions Inoperative ..................................................................... 5 - 72

Part No. 65196 Genie S-60 & Genie S-65
Third Edition • First Printing
TABLE OF CONTENTS
xi
Section Six Schematics
Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Electrical Symbols Legend ........................................................................................ 6 - 4
Abbreviation Legend .................................................................................................. 6 - 5
Engine Wire Harness - Gasoline/LPG Models ........................................................... 6 - 7
Electrical Schematic - Gasoline/LPG Models - Rev B ............................................... 6 - 8
Ground Control Box Wiring Diagram - Gasoline/LPG Models ................................... 6 - 10
Platform Control Box Wiring Diagram - Gasoline/LPG Models ................................. 6 - 11
Electrical Schematic - Deutz Diesel Models ............................................................ 6 - 12
Ground Control Box Wiring Diagram - Deutz Diesel Models ..................................... 6 - 14
Platform Control Box Wiring Diagram - Deutz Diesel Models ................................... 6 - 15
Electrical Schematic - Perkins Diesel Models ......................................................... 6 - 16
Ground Control Box Wiring Diagram - Perkins Diesel Models .................................. 6 - 18
Platform Control Box Wiring Diagram - Perkins Diesel Models ................................ 6 - 19
Hydraulic Symbols Legend ...................................................................................... 6 - 21
2WD Hydraulic Schematic - Non-oscillating axle ..................................................... 6 - 22
2WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 23
4WD Hydraulic Schematic - Non-oscillating axle ..................................................... 6 - 24
4WD Hydraulic Schematic - Oscillating axle ........................................................... 6 - 25

Genie S-60 & Genie S-65 Part No. 65196
Third Edition •First Printing
TABLE OF CONTENTS
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Section Seven Repair Procedures
Introduction ............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controllers ......................................................................................... 7 - 2
1-2 Horsepower Limiter Board .............................................................................. 7 - 9
1-3 Foot Switch ................................................................................................... 7 - 11
1-4 Toggle Switches ............................................................................................ 7 - 12
Platform Components
2-1 Platform ........................................................................................................ 7 - 13
2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 13
2-3 Platform Rotator ............................................................................................ 7 - 15
Jib Boom Components, S-65 Models
3-1 Jib Boom ....................................................................................................... 7 - 18
3-2 Jib Boom Lift Cylinder ................................................................................... 7 - 19
Boom Components
4-1 Cable Track .................................................................................................. 7 - 20
4-2 Boom ............................................................................................................ 7 - 23
4-3 Boom Lift Cylinder ......................................................................................... 7 - 26
4-4 Extension Cylinders ...................................................................................... 7 - 27
4-5 Platform Leveling Master Cylinder ................................................................ 7 - 29
Turntable Covers
5-1 Turntable Covers .......................................................................................... 7 - 30

Part No. 65196 Genie S-60 & Genie S-65
Third Edition •First Printing
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TABLE OF CONTENTS
Section Seven Repair Procedures, continued
Deutz Engine F4L 1011F
6-1 RPM Adjustment ........................................................................................... 7 - 31
6-2 Flex Plate ...................................................................................................... 7 - 31
6-3 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 32
Perkins Engine 704-30
7-1 RPM Adjustment ........................................................................................... 7 - 33
7-2 Flex Plate ...................................................................................................... 7 - 33
7-3 Coolant Temperature and Oil Pressure Gauges ........................................... 7 - 34
Ford Engine LRG-425 EFI
8-1 Timing Adjustment ........................................................................................ 7 - 35
8-2 Flex Plate ...................................................................................................... 7 - 35
8-3 Coolant Temperature and Oil Pressure Gauges ........................................... 7 - 36
Ground Controls
9-1 Control Relays .............................................................................................. 7 - 38
9-2 Toggle Switches, See 1-4, Toggle Switches ................................................. 7 - 39
9-3 Wago®Components ...................................................................................... 7 - 39
9-4 Engine Fault Codes - Ford Models ................................................................ 7 - 39
Hydraulic Pumps
10-1 Lift/Steer Pump ............................................................................................. 7 - 41
10-2 Drive Pump ................................................................................................... 7 - 42

Genie S-60 & Genie S-65 Part No. 65196
Third Edition •First Printing
Section Seven Repair Procedures, continued
Manifolds
11-1 Function Manifold Components..................................................................... 7 - 44
11-2 Valve Adjustments - Function Manifold ......................................................... 7 - 48
11-3 Turntable Rotation Manifold Components ..................................................... 7 - 50
11-4 Oscillate Manifold Components..................................................................... 7 - 51
11-5 Valve Adjustments - Oscillate Manifold ......................................................... 7 - 52
11-6 Directional Valve Manifold Components ........................................................ 7 - 53
11-7 Steer Manifold Components, Oscillating Models ........................................... 7 - 55
11-8 Steer Manifold Components, Non-oscillating Models .................................... 7 - 56
11-9 2WD Drive Manifold Components ................................................................. 7 - 57
11-10 Valve Adjustments, 2WD Drive Manifold ....................................................... 7 - 58
11-11 4WD Drive Manifold Components ................................................................. 7 - 60
11-12 Valve Adjustments, 4WD Drive Manifold ....................................................... 7 - 62
11-13 Jib Boom/Platform Rotate Manifold Components, S-65 Models .................... 7 - 63
Fuel and Hydraulic Tanks
12-1 Fuel Tank ...................................................................................................... 7 - 64
12-2 Hydraulic Tank .............................................................................................. 7 - 65
Turntable Rotation Components
13-1 Rotation Hydraulic Motor............................................................................... 7 - 68
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Part No. 65196 Genie S-60 & Genie S-65
Third Edition •First Printing
Section Seven Repair Procedures, continued
2WD Steering Axle Components
14-1 Yoke and Hub ............................................................................................... 7 - 71
14-2 Steering Cylinders ......................................................................................... 7 - 73
14-3 Tie Rod ......................................................................................................... 7 - 74
4WD Steering Axle Components
15-1 Yoke and Hub ............................................................................................... 7 - 75
15-2 Steering Cylinders, See 14-2, Steering Cylinders ......................................... 7 - 76
15-3 Tie Rod, See 14-3, Tie Rod .......................................................................... 7 - 76
Oscillating Axle Components
16-1 Oscillating Axle Lock-out Cylinders ............................................................... 7 - 77
Non-steering Axle Components
17-1 Drive Motor ................................................................................................... 7 - 78
17-2 Drive Hub ...................................................................................................... 7 - 79
17-3 Wheel Brake ................................................................................................. 7 - 80
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TABLE OF CONTENTS