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Genie S-60 S-65 S-60 HC Service Manual 77828 – PDF DOWNLOAD
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Description
Genie S-60 S-65 S-60 HC Service Manual 77828 – PDF DOWNLOAD
Language : English
Pages : 407
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-60 S-65 S-60 HC Service Manual 77828 – PDF DOWNLOAD
Cover........................................................................................................................ 1 Introduction................................................................................................................. 2 Revision History............................................................................................................. 3 Serial Number Legend......................................................................................................... 5 Safety Rules................................................................................................................. 6 Table of Contents............................................................................................................ 8 Specifications............................................................................................................... 21 Machine Specifications................................................................................................... 21 Performance Specifications............................................................................................... 22 Hydraulic Specifications................................................................................................. 23 Manifold Component Specifications........................................................................................ 24 GM 3.0L Engine........................................................................................................... 25 Ford LRG-425 EFI Engine.................................................................................................. 26 Ford DSG-423 EFI Engine.................................................................................................. 27 Deutz F3L 2011 Engine.................................................................................................... 28 Perkins 404-22 Engine.................................................................................................... 30 Machine Torque Specifications............................................................................................ 31 Hydraulic Hose and Fitting Torque Specifications......................................................................... 32 SAE and Metric Fastener Torque Chart..................................................................................... 33 Scheduled Maintenance Procedures............................................................................................. 35 Pre-Delivery Preparation................................................................................................. 37 Maintenance Inspection Report............................................................................................ 39 Checklist A Procedures................................................................................................... 41 A-1 Inspect the Manuals and Decals................................................................................... 41 A-2 Perform Pre-operation Inspection................................................................................. 42 A-3 Perform Function Tests........................................................................................... 42 A-4 Perform Engine Maintenance....................................................................................... 43 A-5 Check the High Pressure Hydraulic Filter Condition Indicator..................................................... 43 A-6 Test the Oscillate Axle (if equipped)............................................................................ 44 A-7 Perform 30 Day Service........................................................................................... 44 A-8 Inspect the Engine Air Filter - GM Models........................................................................ 45 A-9 Perform Engine Maintenance - GM, Ford and Perkins Models......................................................... 45 A-10 Inspect the Fuel Filter/Water Separator - Diesel Models......................................................... 46 A-11 Check and Adjust the Engine RPM - Perkins Models................................................................ 48 A-12 Grease the Turntable Rotation Bearing and Rotate Gear........................................................... 49 A-13 Replace the Drive Hub Oil....................................................................................... 49 A-14 Perform Engine Maintenance - GM and Ford Models................................................................. 50 A-15 Perform Engine Maintenance - Perkins Models..................................................................... 50 Checklist B Procedures................................................................................................... 51 B-1 Inspect the Battery.............................................................................................. 51 B-2 Inpect the Electrical Wiring..................................................................................... 52 B-3 Check the Exhaust System......................................................................................... 53 B-4 Inspect the Engine Air Filter - Ford, Deutz and Perkins Models................................................... 54 B-5 Check the Oil Cooler and Cooling Fins - Deutz Models............................................................. 54 B-6 Inspect the Tires, Wheels and Lug Nut Torque..................................................................... 55 B-7 Confirm the Proper Brake Configuration........................................................................... 56 B-8 Check the Drive Hub Oil and Fastener Torque...................................................................... 56 B-9 Check and Adjust the Engine RPM - Ford and Deutz Models.......................................................... 58 B-10 Test the Ground Control Override................................................................................ 59 B-11 Check the Oscillate Directional Valve Linkage................................................................... 60 B-12 Test the Platform Self-leveling................................................................................. 60 B-13 Test the Engine Idle Select..................................................................................... 61 B-14 Test the Fuel Select Operation - GM and Ford Models............................................................. 62 B-15 Test the Drive Brakes........................................................................................... 63 B-16 Test the Drive Speed - Stowed Position.......................................................................... 64 B-17 Test the Drive Speed - Raised or Extended Position.............................................................. 64 B-18 Test the Alarm Package - Optional Equipment..................................................................... 65 B-19 Perform Hydraulic Oil Analysis.................................................................................. 66 B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems......................................................... 67 B-21 Replace the Fuel Filter Element - Perkins Models................................................................ 68 B-22 Inspect the Boom Extend/Retract Cables.......................................................................... 69 B-23 Perform Engine Maintenance - Deutz Models....................................................................... 71 B-24 Perform Engine Maintenance - GM and Ford Models................................................................. 71 B-25 Replace the Engine Air Filter Element - GM and Ford Models...................................................... 72 B-26 Perform Engine Maintenance - Perkins Models..................................................................... 72 Checklist C Procedures................................................................................................... 73 C-1 Perform Engine Maintenance - Deutz Models........................................................................ 73 C-2 Grease the Platform Overload Mechanism, S-60 and S-65 (if equipped).............................................. 73 C-3 Test the Platform Overload System, S-60 and S-65 (if equipped)................................................... 74 C-4 Test the Platform Load Sense System, S-60 HC..................................................................... 77 C-5 Replace the Fuel Filter/Water Separator - Perkins Models......................................................... 79 C-6 Replace the Engine Air Filter Element - Deutz and Perkins Models................................................. 81 C-7 Perform Engine Maintenance - Perkins Models...................................................................... 81 C-8 Perform Engine Maintenance - GM and Ford Models.................................................................. 82 Checklist D Procedures................................................................................................... 83 D-1 Check the Boom Wear Pads......................................................................................... 83 D-2 Check the Turntable Rotation Bearing Bolts....................................................................... 84 D-3 Inspect for Turntable Bearing Wear............................................................................... 85 D-4 Replace the Drive Hub Oil........................................................................................ 86 D-5 Check the Free-wheel Configuration............................................................................... 87 D-6 Replace the Hydraulic Filters.................................................................................... 88 D-7 Check and Adjust the Air/LPG Mixture - GM Models................................................................. 90 D-8 Perform Engine Maintenance - Deutz Models........................................................................ 91 Checklist E Procedures................................................................................................... 92 E-1 Test or Replace the Hydraulic Oil................................................................................ 92 E-2 Perform Engine Maintenance - Deutz Models........................................................................ 94 E-3 Perform Engine Maintenance - Deutz Models........................................................................ 94 E-4 Replace the Boom Extend/Retract Cables........................................................................... 95 Repair Procedures............................................................................................................ 97 Platform Controls........................................................................................................ 98 1-1 ALC-500 Circuit Board............................................................................................ 98 1-2 Joysticks........................................................................................................ 99 Platform Components......................................................................................................104 2-1 Platform Leveling Slave Cylinder.................................................................................104 2-2 Platform Rotator.................................................................................................105 2-3 Platform Overload System, S-60 and S-65 (if equipped)............................................................108 2-4 Platform Load Sense System, S-60 HC..............................................................................110 Jib Boom Components, S-65................................................................................................114 3-1 Jib Boom.........................................................................................................114 3-2 Jib Boom Lift Cylinder...........................................................................................115 Boom Components..........................................................................................................116 4-1 Cable Track......................................................................................................116 Boom Components......................................................................................................121 4-2 Boom.............................................................................................................122 4-3 Boom Lift Cylinder...............................................................................................124 4-4 Boom Extension Cylinder..........................................................................................125 4-5 Boom Extend/Retract Cables.......................................................................................128 4-6 Platform Leveling Master Cylinder................................................................................131 Engines..................................................................................................................132 5-1 RPM Adjustment - Ford and Deutz Models...........................................................................132 5-2 RPM Adjustment - Perkins Models..................................................................................132 5-3 Flex Plate.......................................................................................................132 5-4 Engine Fault Codes - GM and Ford Models..........................................................................139 Hydraulic Pumps..........................................................................................................140 6-1 Function Pump....................................................................................................140 6-2 Drive Pump.......................................................................................................141 Manifolds................................................................................................................145 7-1 Function Manifold Components.....................................................................................145 7-2 Valve Adjustments - Function Manifold............................................................................149 7-3 Jib Boom / Platform Rotate Manifold Components...................................................................150 7-4 Brake/Two-speed Manifold Components..............................................................................151 7-5 Turntable Rotation Manifold Components...........................................................................152 7-6 Oscillate Directional Valve Components...........................................................................153 7-7 Valve Adjustments - Oscillate Relief Valve.......................................................................155 7-8 Drive Oil Diverter Manifold Components (welder option)...........................................................156 7-9 Traction Manifold Components, 2WD................................................................................157 7-10 Valve Adjustments, 2WD Traction Manifold........................................................................159 7-11 Traction Manifold Components, 4WD...............................................................................161 7-12 Valve Adjustments, 4WD Traction Manifold........................................................................163 7-13 Valve Coils.....................................................................................................164 Turntable Rotation Components............................................................................................166 8-1 Turntable Rotation Assembly......................................................................................166 Axle Components..........................................................................................................168 9-1 Oscillating Axle Cylinders.......................................................................................168 Fault Codes..................................................................................................................169 Fault Codes - Control System.............................................................................................170 Fault Codes - Ford LRG-425 EFI Engine....................................................................................174 Fault Codes - Ford DSG-423 EFI Engine....................................................................................180 Fault Codes - Platform Load Sense System, S-60 HC........................................................................184 Schematics...................................................................................................................193 Electrical Symbols Legend................................................................................................194 Hydraulic Symbols Legend.................................................................................................195 Ford Engine Relay Layout.................................................................................................196 Limit Switch Location Legend.............................................................................................197 Electrical Schematic, S-60 HC (from serial number 12800).................................................................200 Chassis Wiring Diagram, S-60 HC (from serial number 12800)...............................................................201 Ground Control Box Terminal Strip Wiring Diagram, S-60 HC (from serial number 12800).....................................204 Plaform Control Box Wiring Diagram, S-60 HC (from serial number 12800)...................................................205 GM 3.0L Engine Wire Harness..............................................................................................208 Ford LRG-425 EFI Engine Harness..........................................................................................209 Ford DSG-423 EFI Engine Harness..........................................................................................211 Electrical Schematic, S-60, GM 3.0L Models...............................................................................214 Ground Control Box Terminal Strip Wiring Diagram, S-60, GM 3.0L Models...................................................218 Ground Control Box Switch Panel Wiring Diagram, S-60, GM 3.0L Models.....................................................219 Platform Control Box Wiring Diagram, S-60, GM 3.0L Models................................................................222 Platform Control Box Switch Panel Wiring Diagram, S-60, GM 3.0L Models...................................................223 Electrical Schematic, S-65, GM 3.0L Models...............................................................................226 Ground Control Box Terminal Strip Wiring Diagram, S-65, GM 3.0L Models...................................................230 Ground Control Box Switch Panel Wiring Diagram, S-65, GM 3.0L Models.....................................................231 Platform Control Box Wiring Diagram, S-65, GM 3.0L Models................................................................234 Platform Control Box Switch Panel Wiring Diagram, S-65, GM 3.0L Models...................................................235 Electrical Schematic, S-60, Ford LRG-425 EFI Models (before serial number 11880).........................................238 Electrical Schematic, S-60, Ford LRG-425 EFI Models (from serial number 11880 to 14053)..................................242 Electrical Schematic, S-60, Ford DSG-423 EFI Models (after serial number 14053)..........................................246 Ground Control Box Terminal Strip Wiring Diagram, S-60, Ford LRG-425 EFI Models (before serial number 11880).............250 Ground Control Box Switch Panel Wiring Diagram, S-60, Ford LRG-425 EFI Models (before serial number 11880)...............251 Ground Control Box Terminal Strip Wiring Diagram, S-60, Ford Models (after serial number 11879)..........................254 Ground Control Box Switch Panel Wiring Diagram, S-60, Ford Models (after serial number 11879)............................255 Platform Control Box Wiring Diagram, S-60, Ford Models...................................................................258 Platform Control Box Switch Panel Wiring Diagram, S-60, Ford Models......................................................259 Electrical Schematic, S-65, Ford LRG-425 EFI Models (before serial number 11880).........................................262 Electrical Schematic, S-65, Ford LRG-425 EFI Models (from serial number 11880 to 14053)..................................266 Electrical Schematic, S-65, Ford DSG-423 EFI Models (after serial number 14053)..........................................270 Ground Control Box Terminal Strip Wiring Diagram, S-65, Ford LRG-425 EFI Models (before serial number 11880).............274 Ground Control Box Switch Panel Wiring Diagram, S-65, Ford LRG-425 EFI Models (before serial number 11880)...............275 Ground Control Box Terminal Strip Wiring Diagram, S-65, Ford Models (after serial number 11879)..........................278 Ground Control Box Switch Panel Wiring Diagram, S-65, Ford Models (after serial number 11879)............................279 Platform Control Box Wiring Diagram, S-65, Ford Models...................................................................282 Platform Control Box Switch Panel Wiring Diagram, S-65, Ford Models......................................................283 Electrical Schematic, S-60, Deutz F3L 2011 Models (before serial number 11880)...........................................286 Electrical Schematic, S-60, Deutz F3L 2011 Models (after serial number 11879)............................................290 Electrical Schematic, S-60, CE Models, Deutz F3L 2011 Models (before serial number 11880)................................294 Electrical Schematic, S-60, CE Models, Deutz F3L 2011 Models (after serial number 11879).................................298 Ground Control Box Terminal Strip Wiring Diagram, S-60, Deutz F3L 2011 Models (before serial number 11880)...............302 Ground Control Box Switch Panel Wiring Diagram, S-60, Deutz F3L 2011 Models (before serial number 11880).................303 Ground Control Box Terminal Strip Wiring Diagram, S-60, Deutz F3L 2011 Models (after serial number 11879)................306 Ground Control Box Switch Panel Wiring Diagram, S-60, Deutz F3L 2011 Models (after serial number 11879)..................307 Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models, Deutz F3L 2011 Models (before serial number 11880)....310 Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models, Deutz F3L 2011 Models (before serial number 11880)......311 Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models, Deutz F3L 2011 Models (after serial number 11879).....314 Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models, Deutz F3L 2011 Models (after serial number 11879).......315 Platform Control Box Wiring Diagram, S-60, Deutz F3L 2011 Models.........................................................318 Platform Control Box Switch Panel Wiring Diagram, S-60, Deutz F3L 2011 Models............................................319 Electrical Schematic, S-65, Deutz F3L 2011 Models (before serial number 11880)...........................................322 Electrical Schematic, S-65, Deutz F3L 2011 Models (after serial number 11879)............................................326 Electrical Schematic, S-65, CE Models, Deutz F3L 2011 Models (before serial number 11880)................................330 Electrical Schematic, S-65, CE Models, Deutz F3L 2011 Models (after serial number 11879).................................334 Ground Control Box Terminal Strip Wiring Diagram, S-65, Deutz F3L 2011 Models (before serial number 11880)...............338 Ground Control Box Switch Panel Wiring Diagram, S-65, Deutz F3L 2011 Models (before serial number 11880).................339 Ground Control Box Terminal Strip Wiring Diagram, S-65, Deutz F3L 2011 Models (after serial number 11879)................342 Ground Control Box Switch Panel Wiring Diagram, S-65, Deutz F3L 2011 Models (after serial number 11879)..................343 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models, Deutz F3L 2011 Models (before serial number 11880)....346 Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models, Deutz F3L 2011 Models (before serial number 11880)......347 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models, Deutz F3L 2011 Models (after serial number 11879).....350 Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models, Deutz F3L 2011 Models (after serial number 11879).......351 Platform Control Box Wiring Diagram, S-65, Deutz F3L 2011 Models.........................................................354 Platform Control Box Switch Panel Wiring Diagram, S-65, Deutz F3L 2011 Models............................................355 Electrical Schematic, S-60, Perkins 404-22 Models (before serial number 11880)...........................................358 Electrical Schematic, S-60, Perkins 404-22 Models (after serial number 11879)............................................362 Ground Control Box Terminal Strip Wiring Diagram, S-60, Perkins 404-22 Models (before serial number 11880)...............366 Ground Control Box Switch Panel Wiring Diagram, S-60, Perkins 404-22 Models (before serial number 11880).................367 Ground Control Box Terminal Strip Wiring Diagram, S-60, Perkins 404-22 Models (after serial number 11879)................370 Ground Control Box Switch Panel Wiring Diagram, S-60, Perkins 404-22 Models (after serial number 11879)..................371 Platform Control Box Wiring Diagram, S-60, Perkins 404-22 Models.........................................................374 Platform Control Box Switch Panel Wiring Diagram, S-60, Perkins 404-22 Models............................................375 Electrical Schematic, S-65, Perkins 404-22 Models (before serial number 11880)...........................................378 Electrical Schematic, S-65, Perkins 404-22 Models (after serial number 11879)............................................382 Ground Control Box Terminal Strip Wiring Diagram, S-65, Perkins 404-22 Models (before serial number 11880)...............386 Ground Control Box Switch Panel Wiring Diagram, S-65, Perkins 404-22 Models (before serial number 11880).................387 Ground Control Box Terminal Strip Wiring Diagram, S-65, Perkins 404-22 Models (after serial number 11879)................390 Ground Control Box Switch Panel Wiring Diagram, S-65, Perkins 404-22 Models (after serial number 11879)..................391 Platform Control Box Wiring Diagram, S-65, Perkins 404-22 Models.........................................................394 Platform Control Box Switch Panel Wiring Diagram, S-65, Perkins 404-22 Models............................................395 Belt Driven Generator Wiring Diagram.....................................................................................397 12kW Hydraulic Generator Option Wiring Diagram...........................................................................400 Hydraulic Schematic, 12kW Hydraulic Generator Option.....................................................................401 Hydraulic Schematic, 2WD Models..........................................................................................403 Hydraulic Schematic, 4WD Models..........................................................................................405 Back Cover...................................................................................................................407
S.S 05/24
