Genie S-65 Manuale utente

ServiceManual

PartNo.77828

RevB1

December2005

Refertoinsidecoverforadditionalserialnumberinformation

(fromserialnumber9154)

S-60 • S-65 Part No. 77828

July 2005

Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the

Genie S-60 and Genie

S-65 Operator's Manual

before attempting any

maintenance or repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting fault

codes 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 an

authorized Genie dealer service center.

Technical Publications

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 all other manuals.

http://www.genieindustries.com

e-mail: [email protected]

Serial Number Information

Genie Industries offers the following Service

Manuals for these models:

Title Part No.

S-60 and S-65 Service Manual

(before serial number 2575) ................................. 34476

S-60 and S-65 Service Manual

(from serial number 2575 to 6623) ....................... 48412

S-60 and S-65 Service Manual

(from serial number 6624 to 9153) ....................... 65196

77828 Rev B July 2005

Fourth Edition, Second Printing

"Genie" and "S" are registered trademarks of

Genie Industries in the USA and many other

countries.

Printed on recycled paper

Printed in U.S.A.

Introduction

Part No. 77828 S-60 • S-65

July 2005

S6005 05 - 12345

Model

Model year

Sequence

number

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5

CAN B.354.4

Model: S-60

Serial number: S6005-12345

Electrical schematic number: E0186

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

Air Tires 2 deg / Foam Tires 4.5 deg

Gradeability: 45%

Maximum allowable side force : 150 lb / 670 N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 04/12/05

2005

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 60 ft 2 in/ 18.3 m

Maximum platform reach : 50 ft 4 in/ 15.3 m

Machine unladen weight: 20,736lbs / 9,406kg

Foam Tires add 764 lbs/347 kg to weight

Serial Number Legend

INTRODUCTION

iii

S-60 • S-65 Part No. 77828

July 2005

This page intentionally left blank.

Part No. 77828 S-60 • S-65

July 2005

Safety Rules

Section 1 • 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.

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.

S-60 • S-65 Part No. 77828

July 2005

SAFETY RULES

Section 1 • Safety Rules

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:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Used to indicate the presence of

an imminently hazardous situation

which, if not avoided, will result in

death or serious injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, could result

in death or serious injury.

With safety alert symbol—used to

indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

minor or moderate injury.

Without safety alert symbol—used

to indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

property damage.

Used to indicate 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 when lifting or

placing loads. Always wear approved steel-toed

shoes.

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 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.

Be sure that your workshop or work area

is properly ventilated and well lit.

Part No. 77828 S-60 • S-65

December 2005

Table of Contents

vii

Introduction

ImportantInformation ..................................................................................................

Serial Number Information...........................................................................................

Serial Number Legend................................................................................................

iii

Section 1 Safety Rules

General Safety Rules .................................................................................................

iii

Section 2 Rev Specifications

A Machine Specifications.......................................................................................... 2 - 1

A Performance Specifications................................................................................... 2 - 1

B Hydraulic Specifications ........................................................................................ 2 - 2

B Manifold Component Specifications ...................................................................... 2 - 3

A GM 3.0L Engine Specifications.............................................................................. 2 - 4

A Ford LRG-425 EFI Engine Specifications.............................................................. 2 - 5

B Deutz F3L-2011 Engine Specifications.................................................................. 2 - 6

B Perkins 404-22 Engine Specifications ................................................................... 2 - 7

C Machine Torque Specifications.............................................................................. 2 - 8

C Hydraulic Hose and Fitting Torque Specifications ................................................. 2 - 9

A SAE and Metric Fasteners Torque Charts........................................................... 2 - 10

Section 3 Rev Scheduled Maintenance Procedures

Introduction ........................................................................................................... 3 - 1

Pre-Delivery Preparation ....................................................................................... 3 - 3

Maintenance Inspection Report ............................................................................. 3 - 5

CChecklist A Procedures

A-1 Perform Pre-operation Inspection ................................................................ 3 - 7

A-2 Perform Function Tests ............................................................................... 3 - 7

A-3 Perform Engine Maintenance - Deutz Models.............................................. 3 - 8

S-60 • S-65 Part No. 77828

July 2005

TABLE OF CONTENTS

viii

Section 3 Rev Scheduled Maintenance Procedures, continued

A-4 Perform Engine Maintenance - GM and Ford Models .................................. 3 - 8

A-5 Perform Engine Maintenance - Perkins Models ........................................... 3 - 9

A-6 Check the High Pressure Hydraulic Filter Condition Indicator ...................... 3 - 9

A-7 Test the Oscillate Axle (if equipped) .......................................................... 3 - 10

A-8 Perform 30 Day Service ............................................................................. 3 - 10

A-9 Perform Engine Maintenance - GM, Ford and Perkins Models .................. 3 - 11

A-10 Inspect the Fuel Filter/Water Separator - Diesel Models ............................ 3 - 11

A-11 Check and Adjust the Engine RPM - Perkins Models ................................ 3 - 13

A-12 Grease the Turntable Rotation Bearing and Rotate Gear .......................... 3 - 14

A-13 Perform Engine Maintenance - GM and Ford Models ................................ 3 - 15

A-14 Perform Engine Maintenance - Perkins Models ......................................... 3 - 15

CChecklist B Procedures

B-1 Inspect the Battery ..................................................................................... 3 - 16

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 16

B-3 Check the Exhaust System ........................................................................ 3 - 17

B-4 Check the Oil Cooler and Cooling Fins - Deutz Models ............................. 3 - 18

B-5 Check the Lug Nut Torque (including the tires and wheels) ....................... 3 - 19

B-6 Confirm the Proper Brake Configuration .................................................... 3 - 19

B-7 Check the Oil Level in the Drive Hubs ....................................................... 3 - 20

B-8 Check and Adjust the Engine RPM - Deutz Models ................................... 3 - 20

B-9 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

Part No. 77828 S-60 • S-65

July 2005

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures,continued

B-12 Test the Engine Idle Select ........................................................................ 3 - 23

B-13 Test the Fuel Select Operation - GM and Ford Models .............................. 3 - 24

B-14 Test the Drive Brakes ................................................................................ 3 - 25

B-15 Test the Drive Speed - Stowed Position .................................................... 3 - 26

B-16 Test the Drive Speed - Raised or Extended Position ................................. 3 - 26

B-17 Test the Alarm Package - Optional Equipment .......................................... 3 - 27

B-18 Perform Hydraulic Oil Analysis .................................................................. 3 - 28

B-19 Replace the Fuel Filter/Water Separator Element - Perkins Models .......... 3 - 29

B-20 Replace the Fuel Filter Element - Perkins Models ..................................... 3 - 31

B-21 Perform Engine Maintenance - Deutz Models ............................................ 3 - 32

B-22 Perform Engine Maintenance - GM and Ford Models ................................ 3 - 33

B-23 Perform Engine Maintenance - Perkins Models ......................................... 3 - 33

DChecklist C Procedures

C-1 Perform Engine Maintenance - Deutz Models ............................................ 3 - 34

C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 34

C-3 Test the Platform Overload System (if equipped) ...................................... 3 - 35

C-4 Inspect the Boom Extend/Retract Cables .................................................. 3 - 37

C-5 Perform Engine Maintenance - Perkins Models ......................................... 3 - 38

C-6 Perform Engine Maintenance - GM and Ford Models ................................ 3 - 39

S-60 • S-65 Part No. 77828

December 2005

Section 3 Rev Scheduled Maintenance Procedures,continued

EChecklist D Procedures

D-1 Check the Boom Wear Pads ..................................................................... 3 - 40

D-2 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 40

D-3 Inspect for Turntable Bearing Wear ........................................................... 3 - 42

D-4 Replace the Drive Hub Oil ......................................................................... 3 - 43

D-5 Check the Free-wheel Configuration.......................................................... 3 - 43

D-6 Replace the Hydraulic Filters ..................................................................... 3 - 45

D-7 Check and Adjust the Air/LPG Mixture - GM Models ................................. 3 - 46

D-8 Perform Engine Maintenance - Deutz Models............................................ 3 - 47

D-9 Calibrate the Platform Overload System (if equipped) ............................... 3 - 48

DChecklist E Procedures

E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 50

E-2 Perform Engine Maintenance - Deutz Models............................................ 3 - 52

E-3 Perform Engine Maintenance - Deutz Models............................................ 3 - 52

E-4 Remove and Inspect the Boom Extend/Retract Cables ............................. 3 - 53

Section 4 Rev Repair Procedures

Introduction ........................................................................................................... 4 - 1

APlatform Controls

1-1 ALC-500 Circuit Board................................................................................. 4 - 2

1-2 Joysticks...................................................................................................... 4 - 3

BPlatform Components

2-1 Platform Leveling Slave Cylinder ................................................................. 4 - 7

2-2 Platform Rotator........................................................................................... 4 - 8

TABLE OF CONTENTS

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