Genie S-65 - Service Manual

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Table of Contents

Introduction2
- Serial Number Information2
- Revision History3
- Serial Number Legend5
Safety Rules6
- Personal Safety6
- Table of Contents8
Specifications23
- Machine Specifications23
- Performance Specifications24
- Hydraulic Specifications25
- Manifold Component Specifications26
- Ford DSG-423 EFI Engine Specifications27
- Ford MSG-425 EFI Engine Specifications28
- Deutz D2011L03I Engine Specifications29
- Deutz Td2011L04I Engine Specifications31
- Perkins 404-22 Engine Specifications33
- Machine Torque Specifications34
- Trax Torque Specifications35
- Hydraulic Hose and Fitting Torque Specifications36
Scheduled Maintenance Procedures39
- About this Section39
- Pre-Delivery Preparation41
- Maintenance Inspection Report43
Checklist a Procedures45
- Inspect the Manuals and Decals45
- Perform Pre-Operation Inspection46
- Perform Function Tests46
- Perform Engine Maintenance47
- Check the High Pressure Hydraulic Filter Condition Indicator47
- Test the Oscillate Axle (if Equipped)48
  - S-60 TRAX and S-65 TRAX48
- Perform 30 Day Service49
- Perform Engine Maintenance - Ford and Perkins Models51
- Inspect the Fuel Filter/Water Separator - Diesel Models51
- Check and Adjust the Engine RPM - Perkins Models53
- Grease the Turntable Rotation Bearing and Rotate Gear54
- Replace the Drive Hub Oil55
- Perform Engine Maintenance - Ford Models57
- Perform Engine Maintenance - Perkins Models57
Checklist B Procedures58
- Inspect the Battery58
- Inspect the Electrical Wiring59
- Check the Exhaust System60
- Inspect the Engine Air Filter - Ford, Deutz and Perkins Models61
- Check the Oil Cooler and Cooling Fins - Deutz Models61
- Inspect the Tires, Wheels and Lug Nut Torque62
  - S-60 HC, S60X and S-60XC62
- Confirm the Proper Brake Configuration63
- Check the Drive Hub Oil Level and Fastener Torque63
- Check and Adjust the Engine RPM - Ford and Deutz Models66
- Test the Ground Control Override67
- Check the Oscillate Directional Valve Linkage67
- Test the Platform Self-Leveling68
- Test the Engine Idle Select68
- Test the Fuel Select Operation - Ford Models69
- Test the Drive Brakes70
- Test the Drive Speed - Stowed Position70
- Test the Drive Speed - Raised or Extended Position71
- Test the Alarm Package - Optional Equipment72
- Perform Hydraulic Oil Analysis73
- Inspect the Fuel and Hydraulic Tank Cap Venting Systems73
- Replace the Fuel Filter Element - Perkins Models74
- Inspect the Boom Extend/Retract Cables76
- Perform Engine Maintenance - Deutz Models77
- Perform Engine Maintenance - Ford Models78
- Replace the Engine Air Filter Element - Ford Models78
- Perform Engine Maintenance - Perkins Models79
Checklist C Procedures80
- Perform Engine Maintenance - Deutz Models80
- Grease the Platform Overload Mechanism (if Equipped80
  - S-65, S-60 TRAX and S-65 TRAX80
- Test the Platform Overload System, S-60 and S-65 (if Equipped)81
  - S-60 TRAX and S-65 TRAX81
- Test the Platform Load Sense System, S60 HC84
- Replace the Fuel Filter/Water Separator Element - Perkins Models86
- Replace the Engine Air Filter Element - Deutz and Perkins Models88
- Check the Safety Envelope Limit Switches and Angle Sensor, S-60X and S-60XC88
- Perform Engine Maintenance - Perkins Models91
- Perform Engine Maintenance - Ford Models91
Checklist D Procedures92
- Check the Boom Wear Pads92
- Check the Turntable Rotation Bearing Bolts93
- Inspect for Turntable Bearing Wear94
- Replace the Drive Hub Oil95
- Check the Free-Wheel Configuration97
- Replace the Hydraulic Filters99
- Perform Engine Maintenance - Deutz Models101
Checklist E Procedures102
- Test or Replace the Hydraulic Oil102
- Perform Engine Maintenance - Deutz Models104
- Replace the Boom Extend/Retract Cables105
Repair Procedures107
Platform Controls108
- Circuit Board108
- Remove ALC-500 Circuit Board108
- Joysticks109
- How to Calibrate Joystick109
Platform Components115
- Platform Leveling Slave Cylinder115
- Platform Rotator116
- Platform Overload System, S-60, S-65, S-60 TRAX and S-65 TRAX (if Equipped)118
- Platform Load Sense System, S-60 HC120
- Jib Boom124
- Jib Boom Lift Cylinder125
Boom Components126
- Cable Track126
- Boom131
- Boom Lift Cylinder134
- Boom Extension Cylinder135
- Boom Extend/Retract Cables138
- Platform Leveling Master Cylinder141
- Primary Boom Angle Sensor S-60X and S-60XC142
Engines143
- RPM Adjustment - Ford and Deutz Models143
- RPM Adjustment - Perkins Models143
- Flex Plate143
- Engine Fault Codes - Ford Models148
Hydraulic Pumps149
- Function Pump149
- Drive Pump150
Manifolds152
- Function Manifold Components152
- Valve Adjustments - Function Manifold155
- Jib Boom / Platform Rotate Manifold Components156
- Brake/Two-Speed Manifold Components (to SN 25201)157
- Brake/Two-Speed Manifold Components (from SN 25202)158
- Turntable Rotation Manifold Components159
- Oscillate Directional Valve Components160
- Valve Adjustments - Oscillate Relief Valve162
- Drive Oil Diverter Manifold (Welder Option)163
- Traction Manifold Components, 2WD164
- Valve Adjustments, 2WD Traction Manifold165
- Traction Manifold Components, 4WD (from SN 21001 to 21231)166
- Traction Manifold Components, 4WD (after SN 21231)168
- Valve Adjustments, 4WD Traction Manifold170
- Hydraulic Generator Manifold Components, 3Kw (after SN 21396)171
- Valve Coils172
Turntable Rotation Components174
- Turntable Rotation Assembly174
Axle Components176
Track Components177
Fault Codes181
- Electrical Symbols Legend210
- Hydraulic Symbols Legend211
- Limit Switch Location Legend212
- Ford Engine Relay Layout213
- Ford DSG-423 Engine Wire Harness215
- Ford MSG-425 Engine Wire Harness217
- Electrical Schematic, Options (All Models)219
- Wiring Diagram, Belt Driven Generator221
- Wiring Diagram, 3Kw Hydraulic Generator223
- Wiring Diagram, 12Kw Hydraulic Generator - Welder Option225
- Electrical Schematic, 12Kw Hydraulic Generator Welder Option227
- Hydraulic Schematic, 2WD Models (from SN 21001 to 21396)231
- Hydraulic Schematic, 2WD Models (after SN 21396)233
- Hydraulic Schematic, 4WD Models (from SN 21001 to 21396)235
- Hydraulic Schematic, 4WD Models (after SN 21396)237
Electrical Schematics - ANSI/CSA239
- Electrical Schematic, S-65 Ford Engine Models (ANSI / CSA)239
- Ground Control Box Terminal Strip Wiring Diagram243
  - Ford Engine Models (ANSI / CSA)245
- Ground Control Box Switch Panel Wiring Diagram245
  - Ford Engine Models (ANSI / CSA)246
- Platform Control Box Wiring Diagram247
  - Ford Engine Models (ANSI/CSA)249
- Platform Control Box Switch Panel Wiring Diagram249
  - Ford Engine Models (ANSI / CSA)250
- Electrical Schematic, S-65/S60 TRAX/S65 TRAX Deutz D2011L03I Models (ANSI / CSA)251
- Electrical Schematic, S-65/S60 TRAX/S65 TRAX Deutz Td2011L04I Models (ANSI / CSA)255
- Electrical Schematic, S-65/S60 TRAX/S65 TRAX267
Electrical Schematics - ANSI/CSA279
- Electrical Schematic, S-60X and S-60XC279
- Ground Control Box Terminal Strip Wiring Diagram, S-60X and S-60XC283
  - Ford Engine Models (ANSI/CSA)283
- Ground Control Box Switch Panel Wiring Diagram S-60X and S-60XC285
- Ground Control Box Switch Panel Wiring Diagram285
- Platform Control Box Wiring Diagram, S-60X and S-60XC287
- Platform Control Box Switch Panel Wiring Diagram S-60X and S-60XC289
- Platform Control Box Switch Panel Wiring Diagram289
- Electrical Schematic, S-60X and S-60XC291
  - Deutz D2011L03I Models (ANSI/CSA)291
- Electrical Schematic, S-60X and S-60XC292
  - Deutz Td2011L04I Models (ANSI/CSA)295
- Ground Control Box Terminal Strip Wiring Diagram S-60X and S-60XC299
  - Deutz Engine Models (ANSI/CSA)299
- Ground Control Box Switch Panel Wiring Diagram S-60X and S-60XC301
- Platform Control Box Wiring Diagram, S-60X and S-60XC303
- Platform Control Box Switch Panel Wiring Diagram, S-60X and S-60XC305
- Electrical Schematic, S-60X and S-60XC307
  - Perkins Engine Models (ANSI/CSA)307
- Ground Control Box Terminal Strip Wiring Diagram S-60X and S-60XC311
- Ground Control Box Switch Panel Wiring Diagram, S-60X and S-60XC313
- Platform Control Box Wiring Diagram S-60X and S-60XC316
- Platform Control Box Switch Panel Wiring Diagram, S-60X and S-60XC317
Electrical Schematics - CE319
- Electrical Schematic319
  - Ford Engine Models (CE) (from SN 21001 to 22516)319
- Electrical Schematic320
  - Ford Engine Models (CE) (after SN 22516)323
- Ground Control Box Terminal Strip Wiring Diagram S-60/S-65 Ford Engine Models (CE) (from SN 21001 to 22516)327
- Ground Control Box Terminal Strip Wiring Diagram, S-60/S-65 Ford Engine Models, (CE) (after SN 22516)330
- Ground Control Box Switch Panel Wiring Diagram331
  - Ford Engine Models (CE)331
- Platform Control Box Wiring Diagram333
  - Ford Engine Models (CE)333
- Platform Control Box Switch Panel Wiring Diagram335
  - Ford Engine Models (CE)335
- Electrical Schematic, S-60/S-65/S60 TRAX/S65 TRAX337
  - Deutz D2011L03I Models (CE)337
- Electrical Schematic, S-60/S-65/S60 TRAX/S65 TRAX338
  - Deutz Td2011L04I Models (CE)341
- Ground Control Box Terminal Strip Wiring Diagram, S-60/S-65 S60 TRAX/S65 TRAX Deutz Engine Models (CE)345
- Ground Control Box Switch Panel Wiring Diagram S-60/S-65/S60 TRAX/S65 TRAX Deutz Engine Models (CE)347
- Platform Control Box Wiring Diagram S-60/S-65/S60 TRAX/S65 TRAX Deutz Engine Models (CE)349
- Platform Control Box Wiring Diagram, S-60/S-65/S60 TRAX/S65 TRAX349
- Platform Control Box Wiring Diagram, S-60/S-65/S60 TRAX/S65 TRAX350
- Platform Control Box Switch Panel Wiring Diagram S-60/S-65/S60 TRAX/S65 TRAX Deutz Engine Models (CE)351
Electrical Schematics - CE353
- Electrical Schematic, S-60/S-65/S60 TRAX/S65 TRAX353
  - Perkins Engine Models (CE)353
- Ground Control Box Terminal Strip Wiring Diagram S-60/S-65/S60 TRAX/S65 TRAX Perkins Engine Models (CE)357
- Ground Control Box Switch Panel Wiring Diagram S-60/S-65/S60 TRAX/S65 TRAX Perkins Engine Models (CE)359
- Platform Control Box Wiring Diagram S-60/S-65/S60 TRAX/S65 TRAX Perkins Engine Models (CE)361
  - S60 TRAX/S65 TRAX Perkins Engine Models (CE)361
- Electrical Schematic, S-60 HC (CE)365
- Chassis Wiring Diagram, S-60 HC (CE)367
- Ground Control Box Terminal Strip Wiring Diagram, S-60 HC (CE) (from SN 21001 to 21287)369
- Ground Control Box Terminal Strip Wiring Diagram S-60 HC369
  - (CE) (after SN 21287)371
- Platform Control Box Wiring Diagram, S-60 HC (CE)373
Electrical Schematics - AS, from SN 21001 to 21629375
- Electrical Schematic375
  - Ford Engine Models (AS) (from SN 21001 to 21629)375
- Ground Control Box Terminal Strip Wiring Diagram S-60/S-65 Ford Engine Models (AS) (from SN 21001 to 21629)379
AS, from SN 21001 to 21629381
- Ground Control Box Switch Panel Wiring Diagram S-60/S-65 Ford Engine Models (AS) (from SN 21001 to 21629)382
- Platform Control Box Wiring Diagram S-60/S-65 Ford Engine Models (AS) (from SN 21001 to 21629)383
- Platform Control Box Switch Panel Wiring Diagram S-60/S-65 Ford Engine Models (AS) (from SN 21001 to 21629)386
- Electrical Schematic, S-60/S-65/S60 TRAX/S65 TRAX Deutz D2011L03I Models (AS) (from SN 21001 to 21629)387
- Electrical Schematic, S-60/S-65/S60 TRAX/S65 TRAX Deutz Td2011L04I Models (AS) (from SN 21001 to 21629)391
- Ground Control Box Terminal Strip Wiring Diagram395
  - S60 TRAX/S65 TRAX Deutz Engine Models (AS) (from SN 21001 to 21629)397
- Ground Control Box Switch Panel Wiring Diagram398
  - S60 TRAX/S65 TRAX Deutz Engine Models (AS) (from SN 21001 to 21629)399
- Platform Control Box Wiring Diagram399
  - S60 TRAX/S65 TRAX Deutz Engine Models (AS) (from SN 21001 to 21629)401
- Platform Control Box Switch Panel Wiring Diagram402
- Electrical Schematic, S-60/S-65/S60 TRAX/S65 TRAX Perkins Engine Models (AS) (from SN 21001 to 21629)403
  - S60 TRAX/S65 TRAX Perkins Engine Models (AS) (from SN 21001 to 21629)404
  - Perkins Engine Models (AS) (from SN 21001 to 21629)405
- Platform Control Box Wiring Diagram411
  - S60 TRAX/S65 TRAX Perkins Engine Models (AS) (from SN 21001 to 21629)412
- Platform Control Box Switch Panel Wiring Diagram414
Electrical Schematics - AS, after SN 21629415
- Electrical Schematic415
  - Ford Engine Models (AS) (from SN 21630 to 22516)415
- Electrical Schematic416
  - Ford Engine Models (AS) (after SN 22516)419
- Ground Control Box Terminal Strip Wiring Diagram, S-60/S-65 Ford Engine Models (AS) (from SN 21630 to 22516)423
- Ground Control Box Terminal Strip Wiring Diagram, S-60/S-65 Ford Engine Models (AS) (after SN 22516))426
- Ground Control Box Switch Panel Wiring Diagram, S-60/S-65 Ford Engine Models (AS) (after SN 21629)427
- Platform Control Box Wiring Diagram429
  - Ford Engine Models (AS) (after SN 21629)430
- Platform Control Box Switch Panel Wiring Diagram, S-60/S-65 Ford Engine Models (AS) (after SN 21629)431
- Electrical Schematic, S-60/S-65/S60 TRAX/S65 TRAX Deutz D2011L03I Models (AS) (after SN 21629)433
- Electrical Schematic, S-60/S-65/S60 TRAX/S65 TRAX Deutz Td2011L04I Models (AS) (after SN 21629)437
- Ground Control Box Terminal Strip Wiring Diagram S-60/S-65/S60 TRAX/S65 TRAX Deutz Engine Models (AS) (after SN 21629)441
  - Deutz Engine Models (AS) (after SN 21629)441
- Platform Control Box Switch Panel Wiring Diagram448
- Electrical Schematic, S-60/S-65/S60 TRAX/S65 TRAX Perkins Engine Models (AS) (after SN 21629)449
- Ground Control Box Terminal Strip Wiring Diagram S-60/S-65/S60 TRAX/S65 TRAX Perkins Engine Models (AS) (after SN 21629)453
- Ground Control Box Switch Panel Wiring Diagram456
  - Perkins Engine Models (AS) (after SN 21629)456

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Service And Repair Manual402 pages

Operator's Manual60 pages

Maintenance Manual182 pages

Operator's Manual Supplement7 pages

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Genie S-65 Specifications

General

Lift Capacity	500 lbs
Machine Length	27 ft 9 in
Drive Speed - 4WD	3.5 mph
Gradeability - 4WD	45%
Fuel Type	Diesel
Outriggers	No
Steering	4-wheel
Max Travel Speed	3.5 mph
Platform Size	72 in x 30 in
Tire Type	Solid

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