Genie S-65 User manual

Service
Manual
Technical
Publications
Second Edition, First Printing
Part No. 48412 (Rev A1)
July 2008
S-60
®
S-65
®
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Genie S-60 & Genie S-65 Part No. 48412
Service Manual - Second Edition
ii
Introduction
®
Copyright©1998byGenieIndustries
SecondEdition:FirstPrinting, June1998
"Genie" and "S" are Registered Trademarks
of Genie Industries in the USA and many other
countries.
Thesemachinescomplywith
ANSI/SIA92.5-1992.
Printedonrecycledpaper
PrintedinU.S.A.
Genie North America
Telephone [phone]
Toll Free 800 536-1800 in U.S.A.
Toll Free 800 426-8089 in Canada
Fax [phone]
Genie Europe
Office Telephone [phone]
Office FaxFax (44) 01636-611090
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®
®
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate
Genie S-60 & Genie S-65 Operator's Manual
before attempting any maintenance or repair
procedure.
This service manual covers the Genie S-60 and
Genie S-65 2WD and 4WD models.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at a Genie dealer service center.
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a
Genie policy. Therefore product specifications are
subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and other manuals. Please
write to the technical publications team in care of
Genie Industries, PO Box 69, Redmond WA
98073-0069 U.S.A.
If you have any questions, please call Genie
Industries.
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Part No. 48412 Genie S-60 & Genie S-65
Service Manual - Second Edition
iii
Safety Rules
Section 1 - 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.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
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Genie S-60 & Genie S-65 Part No. 48412
Service Manual - Second Edition
SAFETY RULES
iv
Section 1 - Safety Rules
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure that your workshop or work area
is properly ventilated and well lit.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals, on the machine,
use signal words to identify the following:
Indicates the presence of
a hazard that will cause
death or serious injury.
Indicates the presence of
a hazard that may cause
death or serious injury.
Indicates the presence of
a hazard that will or may
cause serious injury or
damage to the machine.
Indicates special
operation or maintenance
information.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components, and lifting or
placing loads. Always wear approved steel-toed
shoes.
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Part No. 48412 Genie S-60 & Genie S-65
Service Manual - Second Edition
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 LRG 423 Engine Specifications ....................................................................... 2 - 4
Deutz F4L 1011F Engine Specifications .................................................................. 2 - 6
Hydraulic Hose and Fitting Torque Specifications .................................................... 2 - 8
Bolt Torque Specifications........................................................................................ 2 - 9
Section Three Scheduled Maintenance Inspections
Introduction............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 3
Table C..................................................................................................................... 3 - 5
Table D..................................................................................................................... 3 - 6
Maintenance Inspection Report................................................................................ 3 - 7
Section Four Scheduled Maintenance Procedures
Introduction............................................................................................................... 4 - 1
A-1 Inspect the Manuals........................................................................................ 4 - 2
A-2 Inspect the Decals and Placards .................................................................... 4 - 2
A-3 Inspect for Damage, Loose or Missing Parts.................................................. 4 - 2
A-4 Check the Engine Oil Level............................................................................. 4 - 3
A-5 Check the Engine Coolant Level - Gasoline/LPG Models............................... 4 - 3
A-6 Check for Fuel Leaks...................................................................................... 4 - 3
A-7 Check the Hydraulic Oil Level......................................................................... 4 - 4
A-8 Check for Hydraulic Leaks.............................................................................. 4 - 4
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Genie S-60 & Genie S-65 Part No. 48412
Service Manual - Second Edition
TABLE OF CONTENTS
vi
Section Four Scheduled Maintenance Procedures, continued
A-9 Check the Tire Pressure ................................................................................. 4 - 5
A-10 Test the Oscillate Axle (if equipped) ............................................................... 4 - 5
A-11 Test the Platform and Ground Controls .......................................................... 4 - 6
A-12 Test the Auxiliary Power Operation ................................................................ 4 - 6
A-13 Test the Tilt Sensor ........................................................................................ 4 - 7
A-14 Test the Limit Switches................................................................................... 4 - 8
A-15 Replace the Engine Oil and Filter - Gasoline/LPG Models ........................... 4 - 10
A-16 Drain the Fuel Filter/Water Separator - Deutz Diesel Models....................... 4 - 11
A-17 Replace the Engine Air Filter ........................................................................ 4 - 12
B-1 Check the Engine Belt .................................................................................. 4 - 13
B-2 Check the Radiator - Gasoline/LPG Models ................................................. 4 - 14
B-3 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models..................... 4 - 14
B-4 Check the Exhaust System .......................................................................... 4 - 15
B-5 Check the Battery ......................................................................................... 4 - 16
B-6 Check the Hydraulic Tank Filter Condition Indicator ..................................... 4 - 16
B-7 Inspect the Electrical Wiring ......................................................................... 4 - 17
B-8 Inspect the Tires and Wheels (including lug nut torque) ............................... 4 - 17
B-9 Confirm the Proper Brake Configuration....................................................... 4 - 18
B-10 Check the Oil Level in the Torque Hubs ....................................................... 4 - 18
B-11 Check and Adjust the Engine Idle Mixture - Gasoline/LPG Models .............. 4 - 19
B-12 Check and Adjust the Engine RPM............................................................... 4 - 19
B-13 Test the Key Switch...................................................................................... 4 - 21
B-14 Test the Emergency Stop Buttons................................................................ 4 - 21
B-15 Test the Ground Control Override ................................................................ 4 - 22
B-16 Check the Directional Valve Linkage ............................................................ 4 - 22
B-17 Test the Platform Self-leveling...................................................................... 4 - 23
B-18 Test the Horn................................................................................................ 4 - 23
B-19 Test the Foot Switch..................................................................................... 4 - 23
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
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Part No. 48412 Genie S-60 & Genie S-65
Service Manual - Second Edition
TABLE OF CONTENTS
vii
Section Four Scheduled Maintenance Procedures,continued
B-23 Test the Drive Brakes ................................................................................... 4 - 25
B-24 Test the Drive Speed - Stowed Position ....................................................... 4 - 26
B-25 Test the Alarm Package - Optional Equipment............................................. 4 - 27
B-26 Perform Hydraulic Oil Analysis ..................................................................... 4 - 27
B-27 Replace the Engine Oil and Filter - Deutz Diesel Models ............................. 4 - 27
C-1 Check the Boom Wear Pads ........................................................................ 4 - 29
C-2 Check the Turntable Rotation Bearing Bolts................................................. 4 - 29
C-3 Check the Free-wheel Configuration ............................................................ 4 - 30
C-4 Grease the Turntable Rotation Bearing and Rotate Gear............................. 4 - 31
C-5 Replace the Torque Hub Oil ......................................................................... 4 - 31
C-6 Replace the Hydraulic Tank Filter................................................................. 4 - 33
C-7 Replace the Drive Loop Hydraulic Filter ....................................................... 4 - 33
C-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models ....... 4 - 34
C-9 Replace the Gasoline Fuel Filter - Gasoline/LPG Models............................. 4 - 34
C-10 Replace the PCV Valve - Gasoline/LPG Models .......................................... 4 - 36
C-11 Replace the Spark Plugs - Gasoline/LPG Models ........................................ 4 - 37
C-12 Check and Adjust the Air/LPG Mixture - Gasoline/LPG Models ................... 4 - 37
C-13 Check and Adjust the Ignition Timing - Gasoline/LPG Models ..................... 4 - 38
C-14 Check the Engine Valve Clearances - Deutz Diesel Models ........................ 4 - 38
C-15 Check the Turntable Rotation Gear Backlash............................................... 4 - 38
D-1 Test or Replace the Hydraulic Oil ................................................................. 4 - 39
D-2 Change or Recondition the Engine Coolant - Gasoline/LPG Models............ 4 - 39
D-3 Change the Fuel Lines.................................................................................. 4 - 41
D-4 Check the Engine Valve Clearance - Gasoline/LPG Models ........................ 4 - 42
D-5 Check the Engine Cylinder Compression - Gasoline/LPG Models ............... 4 - 42
D-6 Clean the PCV Hoses and Fittings - Gasoline/LPG Models ......................... 4 - 42
D-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models.......... 4 - 43
D-8 Check the Toothed Belt - Deutz Diesel Models ............................................ 4 - 43
D-9 Replace the Timing Belt - Gasoline/LPG Models.......................................... 4 - 43
D-10 Grease the Steer Axle Wheel Bearings - 2WD Models ................................ 4 - 44
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Genie S-60 & Genie S-65 Part No. 48412
Service Manual - Second Edition
TABLE OF CONTENTS
viii
Section Five Troubleshooting Flow Charts
Introduction............................................................................................................... 5 - 1
1 Engine Will Not Crank Over ............................................................................ 5 - 3
2 Engine Cranks Over But Will Not Start - Gasoline/LPG Models ..................... 5 - 5
2A Engine Cranks Over But Will Not Start OR Engine Runs
While Cranking The Dies- Gasoline/LPG Models ........................................... 5 - 8
2B Engine Runs While Cranking Then Dies....................................................... 5 - 11
3 Engine Cranks Over But Will Not Start - Deutz Diesel Models ..................... 5 - 12
4 Engine Will Not Start On LPG, But Will Start On Gasoline
- Gasoline/LPG Models................................................................................. 5 - 15
5 Engine Will Not Start On Gasoline, But Will Start On LPG
- Gasoline/LPG Models................................................................................. 5 - 17
6 Engine High Idle Inoperative - Gasoline/LPG Models ................................... 5 - 19
7 Engine Low Idle Inoperative - Gasoline/LPG Models.................................... 5 - 22
8 Engine High Idle Inoperative - Deutz Diesel Models ..................................... 5 - 23
9 Engine Low Idle Inoperative - Deutz Diesel Models...................................... 5 - 25
10 All Functions Inoperative, Engine Starts and Runs....................................... 5 - 26
11 All Lift and Steer Functions Inoperative, Drive Functions Operational.......... 5 - 27
12 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 28
13 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 29
14 Boom Up Function Inoperative ..................................................................... 5 - 30
15 Boom Down Function Inoperative................................................................. 5 - 33
16 Boom Extend Function Inoperative............................................................... 5 - 36
17 Boom Retract Function Inoperative .............................................................. 5 - 39
18 Turntable Rotate Left Function Inoperative................................................... 5 - 42
19 Turntable Rotate Right Function Inoperative ................................................ 5 - 46
20 All Platform Leveling Functions Inoperative.................................................. 5 - 50
21 Platform Level Up Function Inoperative........................................................ 5 - 51
22 Platform Level Down Function Inoperative ................................................... 5 - 53
23 Platform Rotate Left Function Inoperative .................................................... 5 - 55
24 Platform Rotate Right Function Inoperative .................................................. 5 - 58
25 Jib Boom Up Inoperative, S-65 Models ........................................................ 5 - 61
26 Jib Boom Down Inoperative, S-65 Models.................................................... 5 - 63
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Part No. 48412 Genie S-60 & Genie S-65
Service Manual - Second Edition
TABLE OF CONTENTS
ix
Section Five Troubleshooting Flow Charts, continued
27 Oscillate Function Inoperative ....................................................................... 5 - 65
28 Steer Left Function Inoperative ...................................................................... 5 - 66
29 Steer Right Function Inoperative ................................................................... 5 - 68
30 All Drive Functions Inoperative, All Other Functions Operate Normally .......... 5 - 70
31 Drive Forward Or Reverse Function Inoperative ............................................. 5 - 73
32 Traction Function Inoperative ........................................................................ 5 - 74
33 Machine Will Not Drive At Full Speed ............................................................ 5 - 75
34 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 76
35 Drive Enable System Is Malfunctioning ......................................................... 5 - 77
36 Auxiliary Functions Inoperative ...................................................................... 5 - 78
Section Six Schematics
Introduction ............................................................................................................... 6 - 1
Electrical Components .............................................................................................. 6 - 2
Electrical Symbols Legend ........................................................................................ 6 - 4
Abbreviation Legend .................................................................................................. 6 - 5
Electrical Schematic - Gasoline/LPG Models (Rev B) ............................................... 6 - 7
Ground Control Box Legend - Gasoline/LPG Models ................................................. 6 - 9
Ground Control Box Wiring Diagram - Gasoline/LPG Models ................................... 6 - 10
Platform Control Box Legend - Gasoline/LPG Models ............................................. 6 - 11
Platform Control Box Wiring Diagram - Gasoline/LPG Models ................................. 6 - 12
Electrical Schematic - Deutz Diesel Models ............................................................ 6 - 13
Ground Control Box Legend - Deutz Diesel Models ................................................. 6 - 15
Ground Control Box Wiring Diagram - Deutz Diesel Models ..................................... 6 - 16
Platform Control Box Legend - Deutz Diesel Models ............................................... 6 - 17
Platform Control Box Wiring Diagram - Deutz Diesel Models ................................... 6 - 18
Hydraulic Symbols Legend ...................................................................................... 6 - 20
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
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Genie S-60 & Genie S-65 Part No. 48412
Service Manual - Second Edition
TABLE OF CONTENTS
x
Section Seven Repair Procedures
Introduction............................................................................................................... 7 - 1
Platform Controls
1-1 Joystick Controllers......................................................................................... 7 - 2
1-2 Horsepower Limiter Board .............................................................................. 7 - 6
1-3 Foot Switch..................................................................................................... 7 - 8
1-4 Resistors......................................................................................................... 7 - 9
1-5 Toggle Switches ............................................................................................. 7 - 9
1-6 Control Relays .............................................................................................. 7 - 10
Platform Components
2-1 Platform ........................................................................................................ 7 - 11
2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 11
2-3 Platform Rotator ........................................................................................... 7 - 12
Jib Boom Components, S-65 Models
3-1 Jib Boom, S-65 Models................................................................................. 7 - 15
3-2 Jib Boom Lift Cylinder, S-65 Models............................................................. 7 - 16
3-3 Jib Boom / Platform Rotate Manifold Components, S-65 Models ................. 7 - 17
Boom Components
4-1 Boom Cable Track ........................................................................................ 7 - 18
4-2 Boom ............................................................................................................ 7 - 20
4-3 Boom Lift Cylinder ........................................................................................ 7 - 23
4-4 Extension Cylinders ...................................................................................... 7 - 24
4-5 Platform Leveling Master Cylinder ................................................................ 7 - 25
Turntable Covers
5-1 Turntable Covers .......................................................................................... 7 - 26
Deutz Engine F4L 1011F
6-1 RPM Adjustment........................................................................................... 7 - 27
6-2 Flex Plate...................................................................................................... 7 - 27
6-3 Oil Temperature and Oil Pressure Gauges................................................... 7 - 27
Ford LRG-423 Engine
7-1 Governor Actuator ........................................................................................ 7 - 28
7-2 Choke Adjustments....................................................................................... 7 - 29
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Part No. 48412 Genie S-60 & Genie S-65
Service Manual - Second Edition
TABLE OF CONTENTS
xi
Section Seven Repair Procedures, Ford LRG-423 Engine, continued
7-3 Timing Adjustment ........................................................................................ 7 - 30
7-4 Carburetor Adjustment.................................................................................. 7 - 30
7-5 RPM Adjustment........................................................................................... 7 - 30
7-6 Flex Plate...................................................................................................... 7 - 30
7-7 Water Temperature and Oil Pressure Gauges ............................................. 7 - 31
7-8 Vacuum Switch ............................................................................................. 7 - 32
Ground Controls
8-1 Control Relays .............................................................................................. 7 - 33
8-2 Toggle Switches, See 1-5, Toggle Switches................................................... 7 - 9
8-3 Wago®Components ..................................................................................... 7 - 33
8-4 Resistors....................................................................................................... 7 - 33
8-5 Power Relay ................................................................................................. 7 - 34
Hydraulic Pumps
9-1 Lift/Steer Pump............................................................................................. 7 - 35
9-2 Drive Pump ................................................................................................... 7 - 35
Manifolds
10-1 Function Manifold Components .................................................................... 7 - 38
10-2 Valve Adjustments - Function Manifold......................................................... 7 - 42
10-3 Turntable Rotation Manifold Components..................................................... 7 - 45
10-4 Oscillate Manifold Components .................................................................... 7 - 46
10-5 Valve Adjustments - Oscillate Manifold......................................................... 7 - 47
10-6 Directional Valve Manifold Components ....................................................... 7 - 48
10-7 Steer Manifold Components, S-60/65 Oscillating Models............................. 7 - 50
10-8 2WD Drive Manifold Components................................................................. 7 - 52
10-9 Valve Adjustments, 2WD Drive Manifold ...................................................... 7 - 54
10-104WD Drive Manifold Components................................................................. 7 - 56
10-11Valve Adjustments, 4WD Drive Manifold ...................................................... 7 - 58
.Fuel and Hydraulic Tanks
11-1 Fuel Tank...................................................................................................... 7 - 59
11-2 Hydraulic Tank.............................................................................................. 7 - 59
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Genie S-60 & Genie S-65 Part No. 48412
Service Manual - Second Edition
TABLE OF CONTENTS
xii
Section Seven Repair Procedures, continued
Turntable Rotation Components
12-1 Rotation Hydraulic Motor .............................................................................. 7 - 62
2WD Steering Axle Components
13-1 Yoke and Hub ............................................................................................... 7 - 65
13-2 Steering Cylinders ........................................................................................ 7 - 66
13-3 Tie Rod ......................................................................................................... 7 - 67
4WD Steering Axle Components
14-1 Yoke and Hub ............................................................................................... 7 - 68
14-2 Steering Cylinders ........................................................................................ 7 - 69
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
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Part No. 48412 Genie S-60 & Genie S-65 2 - 1
Section 2 - SpecificationsService Manual - Second Edition
Specifications
MachineSpecifications
Stowed dimensions S-60 S-65
Length 27 ft 2 in 30 ft 10 in
8.3 m 9.4 m
Width 8 ft 8 ft
2.43 m 2.43 m
Height 9 ft 9 ft
2.74 m 2.74 m
Weight 26,060 lbs 28,400 lbs
11,821 kg 12,882 kg
Ground clearance 12 in 12 in
30 cm 30 cm
Operational dimensions
Maximum platform height 60 ft 65 ft
18.3 m 19.8 m
Maximum horizontal reach 51 ft 3 in 56 ft 4 in
15.6 m 17.2 m
Maximum turntable tailswing 3 ft 31/2in 3 ft 31/2in
100 cm 100 cm
Wheelbase 9 ft 0 in 9 ft 0 in
2.7 m 2.7 m
Minimum turning radius, 12 ft 1 in 12 ft 1 in
inside 3.7 m 3.7 m
Minimum turning radius, 22 ft 2 in 22 ft 2 in
outside 6.76 m 6.76 m
Turntable rotation continuous continuous
Platform rotation 160° 160°
Maximum capacity 600 lbs 500 lbs
6 foot platform 272 kg 227 kg
Maximum capacity 500 lbs 500 lbs
8 foot platform 227 kg 227 kg
Maximum allowable
side force (ANSI and CSA) 150 lbs 150 lbs
68 kg 68 kg
Continuous improvement of our products is a
Genie policy. Product specifications are subject to
change without notice.
Platform dimensions 6 ft 8 ft
(Standard) (Optional)
Length 6 ft 8 ft
1.83 m 2.44 m
Width 30 in 36 in
76.2 cm 91.4 cm
Tires and wheels
Tire size 15-19.5 NHS
Tire ply rating 12
Tire contact area 71 sq in
458 sq cm
Overall tire diameter 40 in
102 cm
Tire pressure 85 psi
5.86 bar
Wheel diameter 191/2in
49.5 cm
Wheel width 121/4in
31 cm
Wheel lugs 10 @ 3/4 -16
Lug nut torque, dry bolts 420 ft-lbs
569.5 Nm
Lug nut torque, lubricated bolts 320 ft-lbs
433.9 Nm
Fluid capacities
Fuel tank 30 gallons
114 liters
LPG tank 33.5 pounds
15.2 kg
Hydraulic tank 45 gallons
170 liters
Hydraulic system 55 gallons
(including tank) 208 liters
Drive torque hubs 44 fl oz
1.30 liters
Turntable rotation 17 fl oz
torque hub 0.51 liters
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2 - 2 Genie S-60 & Genie S-65 Part No. 48412
Section 2 - Specifications Service Manual - Second Edition
SPECIFICATIONS
Boom function speeds, maximum
from platform controls
Jib boom up 40 to 60 seconds
Jib boom down 50 to 80 seconds
Boom up 55 to 85 seconds
Boom down 90 to 120 seconds
Boom extend 60 to 80 seconds
Boom retract 55 to 85 seconds
Turntable rotate - 360°
boom fully stowed 80 to 100 seconds
Turntable rotate - 360°
boom extended 130 to 160 seconds
Platform rotate - 160° 10 to 20 seconds
Platform level up 35 to 65 seconds
Platform level down 25 to 55 seconds
PerformanceSpecifications
Drive speeds, maximum 2WD 4WD
Drive speed, stowed 4.4 mph 3.0 mph
Gasoline/LPG models 7.1 km/h 4.8 km/h
40 ft/6.2 sec 40 ft/9.1 sec
12.2 m/6.2 sec 12.2 m/9.1 sec
Drive speed, stowed 4.0 mph 2.8 mph
Deutz Diesel models 6.4 km/h 4.5 km/h
40 ft/6.8 sec 40 ft/9.7 sec
12.2 m/6.8 sec12.2 m/9.7 sec
Drive speed, 0.6 mph 0.6 mph
raised or extended 1.0 km/h 1.0 km/h
- all models 40 ft/40 sec 40 ft/40 sec
12.2 m/40 sec 12.2 m/40 sec
Gradeability (boom stowed) 2WD 4WD
Rough terrain 28% 40%
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Part No. 48412 Genie S-60 & Genie S-65 2 - 3
Section 2 - SpecificationsService Manual - Second Edition
SPECIFICATIONS
HydraulicSpecifications
Hydraulic fluid Dexron equivalent
Drive pump
Type: bi-directional variable displacement piston pump
Displacement - 2500 rpm 0 to 30.3 gallons per minute
0 to 114.7 liters per minute
Maximum drive pressure 3500 psi
241.3 bar
Charge pressure
neutral position 290 psi 20 bar
drive position 250 psi 17 bar
Medium pressure filter 3 micron
Medium pressure filter 50 psi
bypass pressure 3.4 bar
Drive manifold
Brake 250 psi
relief pressure 17.2 bar
Steer end drive motors 4WD models
Displacement 1.52 cu in
per revolution 25 cc
Non-steer end drive motors
Displacement per revolution, variable 0.16 to 2.8 cu in
4WD (2 speed motor) 2.62 to 45.9 cc
Displacement per revolution, variable 1.12 to 2.8 cu in
2WD 18.4 to 45.9 cc
Function pump
Type: pressure balanced gear
Displacement - static 1.14 cu in
19 cc
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
Function manifold
Function relief valve pressure
S60 2600 psi 179 bar
S65 2900 psi 200 bar
Boom down 2100 psi
relief valve pressure 145 bar
Boom extend 2500 psi
172 bar
Oscillate axle 950 psi
65 bar
Steer regulator
Oscillate models 5 gpm 18.9 liters/min
Non-oscillate models 3.5 gpm 13.2 liters/min
Auxiliary pump
Type: fixed displacement gear pump
Displacement - static 0.152 cu in
2.5 cc
Displacement 1.4 gallons per minute
5.3 liters per minute
Auxiliary pump 2500 psi
relief pressure 172 bar
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2 - 4 Genie S-60 & Genie S-65 Part No. 48412
Section 2 - Specifications Service Manual - Second Edition
SPECIFICATIONS
Ford Engine LRG-423
Displacement 140 cu in
2.3 liters
Number of cylinders 4
Bore & stroke 3.781 x 3.126 inches
96.04 x 79.4 mm
Horsepower 63 @ 4000 rpm
Firing order 1 - 3 - 4 - 2
Low idle - carburetor 900 rpm
Low idle - electronic governor 1600 rpm
High idle 2500 rpm
Governor electronic
Compression ratio 9.4:1
Compression pressure (approx.)
Pressure (psi) of lowest cylinder must be
at least 75% of highest cylinder
Valve clearances - 0.035 to 0.055 inches
collapsed tappet 0.889 to 1.397 mm
Lubrication system
Oil pressure 40 to 60 psi
(operating temp. @ 2000 rpm) 2.75 to 4.1 bar
Oil capacity 5 quarts
(including filter) 4.7 liters
Oil viscosity requirements
Temperature below 60°F / 15.5°C 5W-30
-10°F to 90°F / -23°C to 32°C 10W-30
Temperature above 10W-40 to 10W-50
-10°F / -23°C
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.
Starter motor
Normal engine cranking speed 200 to 250 rpm
Current draw, normal load 170A
Current draw, maximum load 200A
Current draw, minimum 140A
Maximum circuit voltage drop 0.5V DC
while starting (normal temperature)
Brush length, new 0.66 in
16.8 mm
Brush length wear limit 0.25 in
6.35 mm
Brush spring tension 64 ounces
18 Newtons
Bolt torque 45 to 84 inch-pounds
through brush 5.08 to 9.5 Nm
Brush mounting 15 to 20 foot-pounds
bolt torque 20 to 27 Nm
Maximum commutator 0.005 inches
run-out 0.127 mm
Battery
Type 12V, Group 31
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Fuel pump
Electronic solenoid 7 psi
0.48 bar
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Part No. 48412 Genie S-60 & Genie S-65 2 - 5
Section 2 - SpecificationsService Manual - Second Edition
SPECIFICATIONS
Ignition System
Spark plug type Motorcraft AWSF-52C
Spark plug gap 0.042 to 0.046 inches
1.07 to 1.18 mm
Engine coolant
Capacity 111/2quarts
10.9 liters
Alternator
Output 95A, 14.5V
Bolt torque specifications torque torque
Bolt description (size) ft-lbs Nm
Timing belt tensioner 29 to 40 40 to 55
pivot bolt (M-10)
Timing belt tensioner 25 to 29 35 to 40
adjusting bolt (M-8)
Camshaft gear bolt (M-12) 52 to 66 70 to 90
Camshaft thrust plate bolt (M-6) 6 to 9 8 to 12
Carburetor to spacer stud (M-8) 7.5 to 15 10 to 20
Carburetor spacer to 10 to 14 14 to 19
manifold bolt (M-8)
Crankshaft damper 92 to 122 125 to 165
bolt (M-14)
Cylinder head bolt (M-12): torque in sequence
first step 50 to 60 68 to 81
second step 80 to 90 108 to 122
Bolt torque specifications torque torque
Bolt description (size) ft-lbs Nm
Exhaust manifold to cylinder head bolt or nut (M-10):
torque in sequence
first step 14 to 19 19 to 26
second step 35 to 50 47 to 68
Flywheel to crankshaft 54 to 64 73 to 87
bolt (M-10)
Intake manifold to 15 to 22 20 to 30
cylinder head bolt or nut (M-8)
Oil pressure sending unit to block 8 to 18 11 to 24
Oil pan drain plug to pan (M-14) 15 to 25 20 to 34
Oil pan to block (M-6) 10 to 13.5 14 to 18
Oil filter insert to block 21 to 26 28 to 35
Rocker arm cover to 7 to 10 9 to 13
cylinder head (M-6)
Spark plug to cylinder 7 to 15 9 to 20
head (M-14)
Temperature sending 8 to 18 11 to 24
unit to block (M-14)
Water jacket drain plug to block 12 to 18 16 to 24
Water pump to block bolt (M-8) 15 to 22 20 to 30
Water outlet connection 15 to 22 20 to 30
bolt (M-8)
Cylinder front cover bolt (M-6) 10 to 12 13 to 16
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)
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2 - 6 Genie S-60 & Genie S-65 Part No. 48412
Section 2 - Specifications Service Manual - Second Edition
SPECIFICATIONS
Injection pump pressure 4351 psi
300 bar
Injector opening pressure 3626 psi
250 bar
Fuel requirement diesel number 2-D
Alternator output 55A, 14V
Starter motor
Current draw, no load 90A
Brush length, new 0.7480 in
19 mm
Brush length, minimum 0.5 in
12.7 mm
Battery
Type 12V, Group 31
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Fan belt deflection 3/8to 1/2inch
9 to 12 mm
Bolt tightening specifications torque torque
Bolt description (size, grade) ft-lbs Nm
Camshaft/thrust bearing bolt 15 to 18 20 to 24
(M-8 x 35, 8.8)
Rocker arm bolts 15 to 18 20 to 24
(M-8 x 45, 8.8)
Rocker arm set screw nut 15 to 18 20 to 24
Cylinder head cover 6 to 7 8 to 10
Blower rotor nut 33 to 41 45 to 55
(M-17 Valeo or M-18 Bosch)
Blower carrier bolts 15 to 18 20 to 24
(M-8 x 50 Torx, 8.8)
V-belt pulley bolts 28 to 34 38 to 46
(M-10 x 16, 8.8)
Deutz Engine F4L 1011F
Displacement 166.7 cu in
2.732 liters
Number of cylinders 4
Bore and stroke 3.58 x 4.13 inches
91 x 105 mm
Horsepower 56 @ 3000 rpm
Firing order 1 - 3 - 4 - 2
Compression ratio 18.5:1
Compression pressure 362 to 435 psi
25 to 30 bar
Low idle 1300 rpm
High idle 2300 rpm
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in
0.3 mm
Exhaust 0.020 in
0.5 mm
Lubrication system
Oil pressure 26 to 87 psi
1.8 to 6.0 bar
Oil capacity 11 quarts
(including filter) 10.5 liters
Oil viscosity requirements
Temperature below 60°F / 15.5°C (synthetic) 5W-30
-10°F to 90°F / -23°C to 32°C 10W-40
Temperature above -4°F / -34°C 15W-40
Engine oil should have properties of API classification
CC/SG or CD/SG grades.
Units ship with 10W-40 SG/CC.
Injection system
Injection pump make OMAP
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Part No. 48412 Genie S-60 & Genie S-65 2 - 7
Section 2 - SpecificationsService Manual - Second Edition
SPECIFICATIONS
Bolt tightening specifications, continued
torque torque
Bolt description (size, grade) ft-lbs Nm
Idler pulley/V-belt pulley bolt 27 to 32 36 to 44
(M-10 x 25, 8.8)
Idler pulley for toothed belt 30 to 36 41 to 49
(M-10 x 50, 8.8)
Oil pump bolts 15 to 18 20 to 24
(M-8 x 35 Torx)
Oil filter bracket bolts 7 to 8 9 to 11
(M-8 x 20 Torx, 8.8)
Oil intake housing bolts 15 to 18 20 to 24
(M-8 x 75 Torx)
Fuel pump bolts 15 to 18 20 to 24
Injection pump bolts 15 to 18 20 to 24
Injector cap nut 30 to 37 40 to 50
Injector fastening bolt 15 to 18 20 to 24
Injection line 10 to 12 13.5 to 16.5
Air intake manifold bolts 15 to 18 20 to 24
(M-8 x 30, 8.8)
Air intake manifold, 3-hole 15 to 18 20 to 24
flange bolts (M-8 x 35 Torx, 8.8)
Exhaust manifold bolts 27 to 32 36 to 44
(M-10 x 30 Torx, 10.9)
Starter fastening bolts 28 to 34 38 to 46
(M-10 x 28, 8.8)
Starter carrier bolts 50 to 60 68 to 82
(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
torque torque
ft-lbs Nm
Oil thermostat housing screw 37 to 44 50 to 60
plug (M-38 x 1.5)
Oil thermostat housing bolts 5.5 to 7 7.5 to 9
(M-6 x 35 Torx, 8.8)
Oil thermostat housing bolts 5.5 to 7 7.5 to 9
(M-6 x 80 Torx, 8.8)
Oil thermostat housing bolts 14 to 16 19 to 22
(M-6 x 105 Torx, 8.8)
Valve plunger housing bolts 14 to 16 19 to 22
(M-8 x 30 Torx, 8.8)
Alternator nuts (M-5) 3 4
Fuel bracket bolts (M-8 x 20, 8.8) 15 20
Adapter housing bolts 70 to 77 95 to 105
(M-12 x 35, 10.9 or M-12 x 75, 10.9)
first step second step
tightening tightening
torque angles
ft-lbs Nm 1st 2nd
Main bearing bolts 37 50 60° 45°
Big end bolts 22 30 60° 60°
Flywheel bolts 22 30 60° 30°
Cylinder head step 1 22 30
studs step 2 59 80
step 3 118 160 120° NA
Camshaft/central bolt 22 30 150° NA
Crankshaft/central bolt 96 130 210° NA
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2 - 8 Genie S-60 & Genie S-65 Part No. 48412
Section 2 - Specifications Service Manual - Second Edition
Hydraulic Hose and Fitting Torque Specifications
Your machine is equipped with Parker Seal-Lok®O-ring face seal fittings and hose ends. Machines that
utilize Parker Seal-Lok®O-ring face seal fittings and hose ends require that the fittings and hose ends be
torqued to specification when they are removed and installed or when new hoses or fittings are installed.
TorqueProcedure
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
The O-rings used in the Parker
Seal Lok® fittings and hose ends
are a custom-size O-ring. They
are not a standard SAE size O-
ring. They are available in the O-
ring field service kit (Genie pn.
49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table
above.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
be sure that there are no leaks.
Hydraulic Hose and Fitting Torque Specifications
SAE O-ring Boss Port - tube fitting Seal-Lok® - hose end
SAE Dash
Size Installing into... ft. lbs. Nm SAE Dash Size ft. lbs. Nm
-4 Aluminum 11 14.9 -4 18 24.4
Steel 16 21.7 -6 27 36.6
-6 Aluminum 23 31.2 -8 40 54.2
Steel 35 47.5 -10 63 85.4
-8 Aluminum 40 54.2 -12 90 122
Steel 60 81.3 -16 120 162.7
-10 Aluminum 69 93.6 -20 140 190
Steel 105 142.4 -24 165 223.7
-12 Aluminum 93 126.1
Steel 140 190
-16 Aluminum 139 188.5
Steel 210 284.7
-20 Aluminum 172 233.2
Steel 260 352.5
-24 Aluminum 208 282
Steel 315 427.1
SPECIFICATIONS
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