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Genie S-60 S-65 Service Manual 65196 – PDF DOWNLOAD
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Description
Genie S-60 S-65 Service Manual 65196 – PDF DOWNLOAD
Language : English
Pages : 284
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-60 S-65 Service Manual 65196 – PDF DOWNLOAD
Front Cover............................................................................ 1 Safety Rules........................................................................... 3 Table of Contents...................................................................... 5 Section Two Specifications............................................................. 17 Machine Specifications............................................................. 17 Performance Specifications......................................................... 18 Hydraulic Specifications........................................................... 19 Ford LRG-425 EFI Engine............................................................ 20 Deutz F4L 1011F Engine............................................................. 21 Perkins 704-30 Engine.............................................................. 22 Hydraulic Hose and Fitting Torque Specification.................................... 23 Section Three Theory of Operation...................................................... 25 Power Source....................................................................... 25 Hydraulic System................................................................... 25 Electrical System.................................................................. 25 Limit Switches..................................................................... 26 Machine Controls................................................................... 26 Section Four Scheduled Maintenance Procedures.......................................... 27 Maintenance Inspection Report...................................................... 29 Table A Procedures................................................................. 31 A-1 Inspect the Operators and Safety Manuals................................... 31 A-2 Inspect the Decals and Placards............................................ 31 A-3 Inspect for Damage and Loose and Missing Parts............................. 32 A-4 Check the Engine Oil Level................................................. 33 A-5 Check the Engine Coolant Level - Liquid Cooled Models...................... 34 A-6 Check for Fuel Leaks....................................................... 34 A-7 Check the Hydraulic Oil Level.............................................. 35 A-8 Check for Hydraulic Leaks.................................................. 36 A-9 Check the Tire Pressure.................................................... 36 A-10 Test the Oscillate Axle (if equipped)..................................... 37 A-11 Test the Platform and Ground Controls..................................... 38 A-12 Test the Auxiliary Power Operation........................................ 39 A-13 Test the Tilt Sensor...................................................... 40 A-14 Test the Limit Switches................................................... 40 A-15 Drain the Fuel Filter/Water Separator - Diesel Models..................... 43 A-16 Inspect the Engine Air Filter............................................. 45 A-17 Perform 30 Day Service.................................................... 46 A-18 Inspect the Radiator - Liquid Cooled Models............................... 46 A-19 Check the Battery......................................................... 47 A-20 Replace the Engine Oil and Filter - Gasoline/LPG Models................... 48 A-21 Inspect the Electrical Wiring............................................. 50 A-22 Check the Oil Cooler and Cooling Fins - Deutz Models...................... 51 A-23 Check the Engine Belt - Ford and Perkins Models........................... 52 A-24 Replace the Fuel Filters - Ford Models.................................... 54 Table B Procedures................................................................. 56 B-1 Check the Exhaust System................................................... 56 B-2 Check the Hydraulic Tank Return Filter Condition Indicator................. 57 B-3 Inspect the Tires and Wheels (including lug nut torque).................... 58 B-4 Confirm the Proper Brake Configuration..................................... 59 B-5 Check the Oil Level in the Drive Hubs...................................... 60 B-6 Check and Adjust the Engine RPM............................................ 62 B-7 Test the Key Switch........................................................ 63 B-8 Test the Emergency Stop Buttons............................................ 64 B-9 Test the Ground Control Override........................................... 64 B-10 Check the Directional Valve Linkage....................................... 65 B-11 Test the Platform Self-leveling........................................... 65 B-12 Test the Horn............................................................. 66 B-13 Test the Foot Switch...................................................... 66 B-14 Test the Engine Idle Select Operation..................................... 67 B-15 Test the Fuel Select Operation - Ford Models.............................. 68 B-16 Test the Drive Enable System.............................................. 69 B-17 Test the Drive Brakes..................................................... 70 B-18 Test the Drive Speed - Stowed Position.................................... 71 B-19 Test the Drive Speed - Raised or Extended Position........................ 72 B-20 Test the Alarm Package (if equipped)...................................... 73 B-21 Perform Hydraulic Oil Analysis............................................ 74 B-22 Replace the Hydraulic tank Return Filter.................................. 74 B-23 Inspect the Fuel Tank Cap Venting System.................................. 75 B-24 Replace the Engine Air Filter Element..................................... 76 B-25 Replace the Spark Plugs - Ford Models..................................... 78 Table C Procedures................................................................. 79 C-1 Check the Engine Belt - Deutz Models....................................... 79 C-2 Check the Engine Valve Clearances - Deutz Models........................... 80 C-3 Replace the Fuel Filter/Water Separator Element - Perkins Models........... 80 C-4 Replace the Fuel Filter Element - Perkins Models........................... 82 C-5 Replace the Engine Oil and Filter - Perkins Models......................... 83 C-6 Check the Glow Plugs - Perkins Models...................................... 84 C-7 Check the Specific Gravity of the Engine Coolant - Liquid Cooled Models.... 85 C-8 Replace the PCV Valve - Ford Models........................................ 86 Table D Procedures................................................................. 27 D-1 Check the Boom Wear Pads................................................... 87 D-2 Check the Free-wheel Configuration......................................... 87 D-3 Check the Turntable Rotation Bearing Bolts................................. 89 D-4 Grease the Turntable Rotation Bearing and Rotate Gear...................... 90 D-5 Replace the Drive Hub Oil.................................................. 90 D-6 Replace the Drive Loop Hydraulic Filter.................................... 92 D-7 Replace the Engine Oil and Filter - Deutz Models........................... 93 D-8 Clean the Fuel Pump Strainer - Deutz Models................................ 94 D-9 Replace the Diesel Fuel Filter/Water Separator - Deutz Models.............. 95 D-10 Change the Fuel Hoses - Deutz Models...................................... 96 D-11 Check the Engine Valve Clearances - Perkins Models........................ 98 D-12 Clean the Engine Breather Assembly - Perkins Models....................... 98 Table E Procedures................................................................. 99 E-1 Test or Replace the Hydraulic Oil.......................................... 99 E-2 Change or Recondition the Engine Coolant - Liquid Cooled Models............101 E-3 Change the Fuel Hoses - Ford Models........................................102 E-4 Replace the Engine Air Breather - Perkins Models...........................104 E-5 Grease the Steer Axle Wheel Bearings - 2WD Models..........................104 E-6 Check the Fuel Injectors - Perkins Diesel Models...........................106 Section Five Troubleshooting Flowcharts................................................107 Fault Code Chart...................................................................109 Chart 1 Engine Will Not Crank Over.................................................114 Chart 2 Engine Cranks Over But Will Not Start - Ford Models........................116 Chart 2A Engine Runs While Cranking Then Dies - Ford Models........................118 Chart 3 Engine Cranks Over But Will Not Start - Diesel Models......................119 Chart 4 Engine Will Not Start On LPG, But Will Start On Gasoline - Ford Models.....122 Chart 5 Engine Will Not Start On Gasoline, But Will Start On LPG - Ford Models.....124 Chart 6 Engine High Idle Inoperative - Ford Models.................................125 Chart 7 Engine Low Idle Inoperative - Ford Models..................................126 Chart 8 Engine High Idle Inoperative - Diesel Models...............................127 Chart 9 Engine Low Idle Inoperative - Diesel Models................................129 Chart 10 All Functions Inoperative, Engine Starts and Runs.........................130 Chart 11 All Lift and Steer Functions Inoperative, Drive Functions Operational.....131 Chart 12 Ground Controls Inoperative, Platform Controls Operate Normally...........132 Chart 13 Platform Controls Inoperative, Ground Controls Operate Normally...........133 Chart 14 Boom Up Function Inoperative..............................................134 Chart 15 Boom Down Function Inoperative............................................137 Chart 16 Boom Extend Function Inoperative..........................................140 Chart 17 Boom Retract Function Inoperative.........................................142 Chart 18 Turntable Rotate Left Function Inoperative................................144 Chart 19 Turntable Rotate Right Function Inoperative...............................148 Chart 20 All Platform Leveling Functions Inoperative...............................152 Chart 21 Platform Level Up Function Inoperative....................................153 Chart 22 Platform Level Down Function Inoperative..................................155 Chart 23 Platform Rotate Left Function Inoperative.................................157 Chart 24 Platform Rotate Right Function Inoperative................................159 Chart 25 Oscillate Function Inoperative............................................161 Chart 26 Jib Boom Up Function Inoperative, S-65 Models.............................162 Chart 27 Jib Boom Down Function Inoperative, S-65 Models...........................164 Chart 28 Steer Left Function Inoperative...........................................166 Chart 29 Steer Right Function Inoperative..........................................168 Chart 30 All Drive Functions Inoperative, All Other Functions Operate Normally.....170 Chart 31 Drive Forward or Reverse Function Inoperative.............................173 Chart 32 Traction Function Inoperative.............................................174 Chart 33 Machine Will Not Drive At Full Speed......................................175 Chart 34 Machine Drives At Full Speed With Platform Raised or Extended.............176 Chart 35 Drive Enable System is Malfunctioning.....................................177 Chart 36 Auxiliary Functions Inoperative...........................................178 Section Six Schematics.................................................................181 Electrical Components..............................................................182 Electrical Symbols Legend..........................................................184 Abbreviation Legend................................................................185 Ford LRG-425 EFI Engine Wiring Harness.............................................186 Electrical Schematic - Ford Models.................................................187 Ground Control Box Wiring Diagram - Ford Models....................................189 Platform Control Box Wiring Diagram - Ford Models..................................190 Electrical Schematic - Deutz Models................................................191 Ground Control Box Wiring Diagram - Deutz Models...................................193 Platform Control Box Wiring Diagram - Deutz Models.................................194 Electrical Schematic - Perkins Models..............................................195 Ground Control Box Wiring Diagram - Perkins Models.................................197 Platform Control Box Wiring Diagram - Perkins Models...............................198 Hydraulic Symbols Legend...........................................................199 2WD Hydraulic Schematic, Non-Oscillating Axle......................................200 2WD Hydraulic Schematic, Oscillating Axle..........................................201 4WD Hydraulic Schematic, Non-Oscillating Axle......................................202 4WD Hydraulic Schematic, Oscillating Axle..........................................203 Section Seven Repair Procedures........................................................204 Platform Controls..................................................................205 1-1 Joystick Controllers.......................................................205 1-2 Horsepower Limiter Board...................................................212 1-3 Foot Switch................................................................214 1-4 Toggle Switches............................................................215 Platform Components................................................................216 2-1 Platform...................................................................216 2-2 Platform Leveling Slave Cylinder...........................................216 2-3 Platform Rotator...........................................................218 Jib Boom Components, S-85 Models...................................................221 3-1 Jib Boom...................................................................221 3-2 Jib Boom Lift Cylinder.....................................................222 Boom Components....................................................................223 4-1 Cable Track................................................................223 4-2 Boom.......................................................................226 4-3 Boom Lift Cylinder.........................................................229 4-4 Extension Cylinders........................................................230 4-5 Platform Leveling Master Cylinder..........................................232 Turntable Covers...................................................................233 5-1 Turntable Covers...........................................................233 Deutz F4L 1011F Engine.............................................................234 6-1 RPM Adjustment.............................................................234 6-2 Flex Plate.................................................................234 6-3 Oil Temperature and Oil Pressure Gauges....................................235 Perkins 704-30 Engine..............................................................236 7-1 RPM Adjustment.............................................................236 7-2 Flex Plate.................................................................236 7-3 Coolant Temperature and Oil Pressure Gauges................................237 Ford LRG-425 EFI Engine............................................................238 8-1 Timing Adjustment..........................................................238 8-2 Flex Plate.................................................................238 8-3 Coolant Temperature and Oil Pressure Gauges................................239 Ground Controls....................................................................241 9-1 Control Relays.............................................................241 9-2 Toggle Switches............................................................242 9-3 Wago® Components...........................................................242 9-4 Engine Fault Codes - Ford Models...........................................242 Hydraulic Pumps....................................................................244 10-1 Lift/Steer Pump...........................................................244 10-2 Drive Pump................................................................245 Manifolds..........................................................................247 11-1 Function Manifold Components..............................................247 11-2 Valve Adjustments - Function Manifold.....................................251 11-3 Turntable Rotation Manifold Components....................................253 11-4 Oscillate Manifold Components.............................................254 11-5 Valve Adjustments - Oscillate Manifold....................................255 11-6 Directional Valve Manifold Components.....................................256 11-7 Steer Manifold Components, Oscillating Models.............................258 11-8 Steer Manifold Components, Non-oscillating Models.........................259 11-9 2WD Drive Manifold Components.............................................260 11-10 Valve Adjustments, 2WD Drive Manifold....................................261 11-11 4WD Drive Manifold Components............................................263 11-12 Valve Adjustments, 4WD Drive Manifold....................................265 11-13 Jib Boom / Platform Rotate Manifold Components, S-65 Models..............266 Fuel and Hydraulic Tanks...........................................................267 12-1 Fuel Tank.................................................................267 12-2 Hydraulic Tank............................................................268 Turntable Rotation Components......................................................271 13-1 Rotation Hydraulic Motor..................................................271 2WD Steering Axle Components.......................................................274 14-1 Yoke and Hub..............................................................274 14-2 Steering Cylinders........................................................276 14-3 Tie Rod...................................................................277 4WD Steering Axle Components.......................................................278 15-1 Yoke and Hub..............................................................278 15-2 Steering Cylinders........................................................279 15-3 Tie Rod...................................................................279 Oscillating Axle Components........................................................280 16-1 Oscillating Axle Lock-out Cylinders.......................................280 Non-steering Axle Components.......................................................281 17-1 Drive Motor...............................................................281 17-2 Drive Hub.................................................................282 17-3 Wheel Brake...............................................................283 Rear Cover.............................................................................284
S.S 05/24
