Telehandler 5

Service Manual - Second Edition Section 7 - Repair Procedures
BOOM COMPONENTS
4-3 5 Tag, disconnect and plug the boom lift cylinder

hydraulic hoses. Cap the fittings on the
Boom Lift Cylinder cylinder.
Bodily injury hazard. Spraying
How to Remove the Boom hydraulic oil can penetrate and
Lift Cylinder burn skin. Loosen hydraulic
connections very slowly to allow
This procedure requires specific the oil pressure to dissipate
repair skills, lifting equipment and gradually. Do not allow oil to
a suitable workshop. Attempting squirt or spray.
this procedure without these skills
and tools may result in death or 6 Remove the pin retaining fastener from the lift
serious injury and significant cylinder rod-end pivot pin. Use a soft metal drift
component damage. Dealer to remove the pin, then lower the lift cylinder
service is strongly recommended. onto the blocks. Protect the cylinder rod from
damage.
When removing a hose assembly
or fitting, the O-ring on the fitting Crushing hazard. The lift cylinder
and/or hose end must be replaced may become unbalanced and fall
and then torqued to specification if it is not properly supported.
during installation.
7 Remove the mounting fasteners from the barrel-
Refer to Section Two, Hydraulic
end cylinder pin retaining plates.
Hose and Fitting Torque
Specifications. 8 With the lift cylinder being supported by the
1 Raise the boom until the boom is horizontal. overhead crane, pull the cylinder toward the
platform until it is out.
2 Place support blocks under the cylinder across
the turntable. Crushing hazard. The lift cylinder
may become unbalanced and fall
3 Attach an overhead 5 ton (4536 kg) crane to the if it is not properly supported.
boom. Do not lift the boom.
Component damage hazard. The
4 Support the rod end of the boom lift cylinder cables and hydraulic hoses can be
with an overhead crane or similar lifting device. damaged if the lift cylinder is
Crushing hazard. If the overhead pulled across them.
crane is not properly attached,
the lift cylinder may become
unbalanced and fall when it is
disconnected from the machine.
Part No. 48412 Genie S-60 & Genie S-65 7 - 23

Section 7 - Repair Procedures Service Manual - Second Edition
BOOM COMPONENTS
4-4 6 Remove the turntable end cover.

Extension Cylinders 7 Tag, disconnect and plug the extension cylinder
The extension cylinder consists of two cylinders cylinder.
that are fastened together. The first cylinder Bodily injury hazard. Spraying
extends and retracts the number 2 boom tube. The hydraulic oil can penetrate and
second cylinder extends and retracts the number 3 burn skin. Loosen hydraulic
boom tube.The extension cylinders are equipped connections very slowly to allow
with counterbalance valves to prevent movement the oil pressure to dissipate
in the event of a hydraulic line failure. gradually. Do not allow oil to
squirt or spray.
How to Remove the
8 Remove the trunnion pin covers from both sides
Extension Cylinders of the number 1 boom tube at the pivot end of
This procedure requires specific the boom.
repair skills, lifting equipment and 9 Remove the trunnion pin retaining fastener and
a suitable workshop. Attempting use a slide hammer to remove the pins.
this procedure without these skills
and tools may cause death or 10 Remove the pin retaining fasteners from both
serious injury and significant sides of the extension cylinder at the pivot end
component damage. Dealer of the boom.
service is strongly recommended.
11 Use a slide hammer to remove the pins.
12 Support and slide the extension cylinder out of
or fitting, the O-ring on the fitting
the pivot end of the boom.
and/or hose end must be replaced
and then torqued to specification Crushing hazard. The extension
during installation. cylinder will fall when it is removed
Refer to Section Two, Hydraulic from the extension boom if it is not
Hose and Fitting Torque properly supported.
Specifications.
Note the length of the cylinder
1 Extend the boom until the extension cylinder after removal. The cylinder must
rod-end pin is accessible in the number 3 boom be at the same length for
tube. installation.
2 Remove the platform. See 2-1, How to Remove
the Platform.
3 Remove the platform leveling slave cylinder.
See 2-2, How to Remove the Slave Cylinder.
S-65 Models: Remove the jib boom. See 3-1, How
to Remove the Jib Boom.
4 Raise the boom to a horizontal position.
5 Remove the external snap rings from the
extension cylinder rod-end pin (at the platform
end). Use a soft metal drift to remove the pin.
7 - 24 Genie S-60 & Genie S-65 Part No. 48412

BOOM COMPONENTS
4-5 5 Place a rod through the barel-end pivot pin and

twist to remove the pin.
Platform Leveling
Master Cylinder
The master cylinder acts as a pump for the slave
cylinder. It’s part of the closed circuit hydraulic loop
that keeps the platform level through the entire
range of boom motion. The master cylinder is
located at the base of the boom.
How to Remove the Platform

6 Attach a lifting strap from an overhead crane to
Leveling Master Cylinder the lug on the rod end of the master cylinder.
When removing a hose assembly 7 Remove the pin retaining fastener from the rod-
or fitting, the O-ring on the fitting end pivot pin.
and then torqued to specification 8 Use a soft metal drift to remove the pin.
during installation. Crushing hazard. The master
Refer to Section Two, Hydraulic cylinder may become unbalanced
Hose and Fitting Torque and fall if it is not properly
Specifications. supported by the lifting device.
1 Raise the boom until the rod-end pivot pin is
accessible.
2 Remove the turntable end cover to access the
master cylinder.
3 Tag, disconnect and plug the master cylinder
cylinder.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 Remove the pin retaining fasteners from the
master cylinder barrel-end pivot pin.

Turntable Covers
5-1
Turntable Covers
How to Remove a
Turntable Cover
1 Raise the turntable cover. Support the open
cover with an overhead crane or forklift.
Do not lift it.
Crushing hazard. Due to its heavy
weight, do not attempt to support
the cover by hand.
Component damage hazard.
Protect the cover from damage by
using carpet or padding on the
crane or forklift forks.
2 Remove the upper and lower retaining clips
from the gas strut.
3 Gently pry the strut pivot sockets off of the ball
studs and remove the strut. Protect the strut
cylinder rod from damage.
Mark the location of the hinge
support bracket on the bulkhead to
ensure proper cover alignment
4 Remove the cover hinge bolts, that fasten the
hinge support bracket to the bulkhead.
5 Carefully lift and remove the cover from
the machine.
Crushing hazard. The turntable
cover may become unbalanced
and fall if it is not properly
supported and secured to a
appropriate lifting device.
If a turntable cover must be
replaced, be sure that all
appropriate safety and
instructional decals are
applied to the new cover.
Alignment adjustments may be
necessary when a new cover
is installed.

Deutz Engine F4L 1011F

6-1 How to Install the Flex Plate
RPM Adjustment 1 Install the flex plate onto the flywheel with the
raised spline towards the pump. Torque the flex
Refer to Maintenance Procedures, B-12, plate mounting bolts to 34 ft-lbs (46 Nm).
Check and Adjust the Engine RPM.
2 Install the coupler onto the pump shaft with the
set screw toward the pump. Leave a 1/2 inch
(12.7 mm) gap between the coupler and pump
end plate.
6-2
3 Apply Loctite® removable thread sealant to the
Flex Plate coupler set screw. Torque the set screw to
45 ft-lbs (61 Nm).
The flex plate acts as a coupler between the
engine and the pump. It is bolted to the engine Component damage hazard. Do
flywheel and has a splined center to drive not force the drive pump during
the pump. installation or the flex plate teeth
may become damaged.
a b c d e
4 Install the pump and torque the pump mounting
plate fasteners to 34 ft-lbs (46 Nm).
6-3
Oil Temperature and Pressure
f Gauges
a pump
The oil temperature gauge is an electrical gauge.
b pump shaft
c coupler The sending unit has limit contacts that are factory
d flex plate with raised spline set. The contacts will close at 300o F (147o C).
e flywheel When the contacts close, the engine will shut off to
f 1/2 inch gap
prevent damage and will not start until the
temperature drops below the contact point.
How to Remove the Flex Plate Temperature will be indicated when the key is on
1 Disconnect the wiring plug at the electronic and the Emergency Stop Button is pulled out to the
displacement controller (EDC), located on ON position.
the drive pump. Component damage hazard.

2 Support the drive pump with an appropriate Do not crank the engine with
lifting device. Then remove all of the pump the over-temperature light on.
mounting plate to engine bell housing bolts. The oil pressure gauge is an electrical gauge. The
3 Carefully pull the pump away from the engine sending unit has limit contacts that are factory set.
and secure it from moving. The contacts will close at 7 psi (0.48 bar). When
the contacts close, the engine will shut off to
4 Remove the flex plate mounting fasteners, prevent damage. Oil pressure will be indicated
then remove the flex plate from the flywheel. when the engine is running.
Do not crank the engine with the
low oil pressure light on.
Ford LRG-423 Engine
a b c d
g
110°
Governor actuator and linkage

7-1 a clevis yoke
Governor Actuator b linkage rod
c carburetor
d throttle plate shaft
How to Set Up the Governor e governor actuator
f actuator shaft
Actuator and Linkage g actuator arm
Adjustment of the governor 4 Position the linkage rod so that the throttle is in
actuator is only necessary when the idle position. Then adjust the clevis yoke on
the governor actuator or the the linkage rod to obtain the proper length.
linkage has been replaced. Install the yoke onto the actuator arm.
1 Connect the linkage rod to the throttle plate 5 With the throttle in the idle position and the
shaft, then tighten the lock nut. actuator arm at a 110 degree angle to the
linkage, rotate the clevis yoke on the linkage
2 Fasten the lock nut and clevis yoke to the
rod two turns counterclockwise to pre-load the
linkage rod. Do not tighten the lock nut
spring. Tighten the lock nut on the linkage rod.
against the clevis yoke.
3 Loosen the fastener on the actuator arm. Rotate
the actuator arm until it is at a 110 degree angle
to the linkage rod. Then tighten the actuator
arm fastener.

FORD LRG-423 ENGINE
6 Manually pull the actuator arm through a full 7-2

cycle to be sure that the linkage moves freely.
Be sure that the linkage activates the throttle Choke Adjustments
shaft to approximately half throttle.
This engine is equipped with an electrically heated
Component damage hazard. automatic choke. The choke has a poppet valve to
If the throttle linkage is improperly enhance cold starting ability on LPG fuel.
adjusted and allowed to reach full
throttle, the engine will over-rev Choke adjustments are affected
and cause component damage. by climate. Richer adjustment
will be necessary in colder
The linkage must be free of friction climates, leaner adjustment
and obstruction. Do not in warmer climates.
let it rub against the engine,
brackets or hoses. Automatic Choke with
Poppet Valve
The choke functions in both gasoline and LPG
mode. The choke butterfly may be adjusted to a
fully closed (rich) position for colder climates and
the poppet valve will provide a flow path during
LPG fueled operation.
rich lean

FORD LRG-423 ENGINE
7-3 7-6
Timing Adjustment Flex Plate
Complete information to perform this procedure is The flex plate acts as a coupler between the
available in the Ford LRG-423 2.3 Liter Industrial engine and the pump. It is bolted to the engine
Engine Service Manual (Ford number: PPD-194- flywheel and has a splined center to drive
287). Genie part number 33907. the pump.
a b c d e
7-4
Carburetor Adjustment
Complete information to perform this procedure is
available in the Ford LRG-423 2.3 Liter Industrial f
Engine Service Manual (Ford number: PPD-194- a pump
287). Genie part number 33907. b pump shaft
c coupler
d flex plate with raised spline
e flywheel
f 1/4 inch gap
7-5
RPM Adjustment Flex Plate Removal
1 Disconnect and remove the hose between
Refer to Maintenance Procedures, B-12, Check the carburetor venturi and the air cleaner.
and Adjust the Engine RPM.
2 Disconnect the linkage from the governor,
then remove the governor linkage from
the carburetor. Do not alter the length of
the linkage.
3 Disconnect the wiring plug at the electronic
displacement controller (EDC), located on
the drive pump.
4 Remove the mounting fasteners from the
regulator mounting bracket, then pull the
bracket up past the bell housing. Secure
the bracket before continuing.
5 Support the drive pump with an appropriate
lifting device. Then remove all of the pump
mounting plate to engine bell housing bolts.
6 Carefully pull the pump away from the
engine and secure it from moving.
7 Remove the flex plate mounting fasteners,
then remove the flex plate from the fly wheel.

FORD LRG-423 ENGINE
How to Install the Flex Plate 7-7

1 Install the flex plate onto the flywheel with the Water Temperature and Oil
raised spline towards the pump. Torque the flex Pressure Gauges
plate mounting bolts to 34 ft-lbs (46 Nm).
2 Install the coupler onto the pump shaft with the The water temperature gauge is an electrical
set screw towards the pump. Leave a 1/4 inch gauge. The sending unit has limit contacts that are
(6.35 mm) gap between the coupler and pump factory set. The contacts will close at 230°F
end plate. (109° C). When the contacts close, the engine will
shut off to prevent damage and will not start until
3 Apply Loctite® removable thread sealant to the the temperature drops below the contact point.
coupler set screw. Torque the set screw to Temperature will be indicated when the key is on
45 ft-lbs (61 Nm). and the Emergency Stop Button is pulled out to the
ON position.
Component damage hazard. Do
not force the drive pump during Component damage hazard.
installation or the flex plate teeth Do not crank the engine with
may become damaged. the over-temperature light on.
4 Install the pump and torque the pump mounting The oil pressure gauge is an electrical gauge. The
plate fasteners to 34 ft-lbs (46 Nm). sending unit has limit contacts that are factory set.
The contacts will close at 8 psi (0.55 bar). When
the contacts close, the engine will shut off to
prevent damage. Oil pressure will be indicated
when the engine is running.

Do not crank the engine with the
low oil pressure light on.

FORD LRG-423 ENGINE
7-8
Vacuum Switch
How to Test the Vacuum Switch

a b
d c
a ohmmeter
b common terminal (SOL.)
c vacuum switch
d normally open terminal (ING.)
1 Connect the leads from an ohmmeter or

continuity tester to the common and normally
open terminals.
Result: There should be no continuity
(infinite Ω).
2 Apply mild suction to the vacuum port.
Result: The switch should close and show full
continuity (zero Ω).
Do not short the vacuum switch
terminals to ground.

Ground Controls
8-1 8-4
Control Relays Resistors
See 1-6, Control Relays How to Test the Resistor
The resistor is used to maintain proper control of
boom function speeds. A 10 ohm resistor reduces
8-2 voltage to all the boom function switches at the
ground controls.
Toggle Switches
Refer to the schematic legends for
See 1-5, Toggle Switches. resistor locations and values.
1 Turn the key switch to the OFF position.
2 Disconnect either end of one of the wires
8-3 connected to the resistor to be tested.
Wago® Components 3 Connect the leads from an ohmmeter to each
end or wiring of the resistor being tested.
How to Remove a Wago® 4 Compare the ohmmeter reading with the
Component resistance rating printed on the resistor.
Electrocution hazard.
Contact with electrically charged
circuits may cause death or
serious injury. Remove all rings,
watches and other jewelry.
A small screwdriver is provided
and should be used when
removing a Wago® component.
This screwdriver is located in the
operator’s manual storage box in
the platform.
1 Label the wiring from the component to be
removed.
2 Locate the removal tab on the bottom or top
side of the component.
3 Use a small narrow flat blade screwdriver to
push in and release the wire from the
component.
4 Use the small narrow flat blade screwdriver to
gently pry up on the tab of the component and
remove it.

GROUND CONTROLS
8-5 2 Connect 12V DC to one of the small posts and

a ground wire to the other small post, then test
Power Relay the following terminal combination.
Electrocution hazard. Contact with Test Desired result

electrically charged circuits may
result in death or serious injury. 2 large posts continuity (zero Ω)
Remove all rings, watches and
other jewelry.
a b b a
The power relay is mounted on the
backside of the ground control
box.
How to Test the Power Relay

Electrocution hazard. Disconnect
the ground cable from the battery
before performing this procedure.
1 Connect the leads from an ohmmeter to each
terminal combination and check for continuity.
Test Desired result

a high amp power contact terminal
(large post)
2 small posts 12 to 16Ω
b solenoid activate coil terminal
2 large posts no continuity (small post)
(infinite Ω)
Any small post to no continuity

any large post (infinite Ω)

Hydraulic Pumps
9-1 3 Remove the pump mounting bolts. Carefully
remove the pump.
Lift/Steer Pump
Be sure to open the two hydraulic
How to Remove the tank valves and prime the pump
Lift/Steer Pump after installing the pump.
and/or hose end must be replaced 9-2
and then torqued to specification
during installation. Drive Pump
Hose and Fitting Torque The drive pump is a bi-directional variable
Specifications. displacement piston pump. The pump output is
controlled by the electronic displacement controller
1 Close the two hydraulic tank valves located at (EDC), located on the pump. The only adjustment
the hydraulic tank. that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized
Sundstrand-Sauer service center. Call Genie
Industries Service Department to locate your local
authorized service center.
How to Remove the Drive Pump

open closed Component damage hazard. The
work area and surfaces where this
Component damage hazard. The procedure will be performed must
engine must not be started with be clean and free of debris that
the hydraulic tank shutoff valves in could get into the hydraulic system
the CLOSED position or component and cause severe component
damage will occur. damage. Dealer service is
If the tank valves are closed, recommended.
remove the key from the key
switch and tag the machine to When removing a hose assembly
inform personnel of the condition. or fitting, the O-ring on the fitting
2 Tag, disconnect and plug the lift/steer pump and then torqued to specification
hydraulic hoses. Cap the fittings on the pump. during installation.
Specifications.
connections very slowly to allow 1 Disconnect the electrical connection at the
the oil pressure to dissipate electronic displacement controller (EDC)
gradually. Do not allow oil to located on the drive pump.
squirt or spray.

HYDRAULIC PUMPS
2 Close the two hydraulic tank valves located at How to Prime the Pump
the hydraulic tank.
1 Connect a 0 to 600 psi (0 to 41 bar) pressure
gauge to the test port on the drive pump.
2 Gasoline/LPG models: Disconnect the
electrical connector at the ignition coils. The
ignition coils are located above the alternator.
Electrocution hazard.
open closed
circuits may cause death or
Component damage hazard. The serious injury. Remove all rings,
engine must not be started with watches and other jewelry.
the hydraulic tank shutoff valves in Deutz Diesel models: Hold the manual fuel
the CLOSED position or component shutoff valve clockwise to the CLOSED position.
damage will occur. If the tank
valves are closed, remove the key a
from the key switch and tag the
machine to inform personnel of the
condition.
3 Tag and disconnect and plug the hydraulic
hoses from the drive and lift/steer pumps. Cap
the fittings on the pumps.
a manual fuel shutoff valve
squirt or spray.
4 Support the pump with a lifting device and 3 Crank the engine with the starter motor for
remove the two drive pump mounting fasteners. 15 seconds, wait 15 seconds, then crank the
engine an additional 15 seconds or until the
5 Carefully pull the drive pump out until the pump pressure reaches 320 psi (22 bar).
coupler separates from the flex plate.
4 Gasoline/LPG models: Connect the ignition
6 Remove the drive pump from the machine. coil wiring and start the engine from the ground
controls. Check for hydraulic leaks.
Be sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.

This page intentionally left blank.

Manifolds
10-1
Function Manifold Components
The function manifold is located on the tank side tray, behind the ground control box.
Index Schematic
No. Description Item Function Torque
1 3 position 4 way D03 valve ................ A ........... Turntable rotate left/right ....................... 30-35 in-lbs / 3-4 Nm
2 3 position 4 way D03 valve ................ B ........... Boom up/down ...................................... 30-35 in-lbs / 3-4 Nm
3 3 position 4 way D03 valve ................ C ........... Boom extend/retract .............................. 30-35 in-lbs / 3-4 Nm
4 Check valve, pilot operated ............... D ........... Boom extend/retract circuit ................ 11-13 ft-lbs / 15-18 Nm
5 Relief valve, 2500 psi (172 bar) ........ E ........... Boom extend ...................................... 25-30 ft-lbs / 34-41 Nm
6 Relief valve, 2100 psi (145 bar) ........ F ........... Boom down ........................................ 25-30 ft-lbs / 34-41 Nm
7 Flow regulator valve,
1.5 gpm (5.7 l/min) ............................. G ........... Boom extend/retract circuit
(prevents over flowing
the proportional valve) ...................... 10-12 ft-lbs / 14-16 Nm
1.5 gpm (5.7 l/min) ............................. H ........... Boom up/down circuit
the proportional valve) ...................... 10-12 ft-lbs / 14-16 Nm
1.5 gpm (5.7 l/min) ............................. I ............ Turntable rotate left/right
the proportional valve) ........................ 10-12 ft-lbs / 14-6 Nm
0.1 gpm (0.38 l/min) ........................... J ............ Bleeds off differential
sensing valves to tank ...................... 10-12 ft-lbs / 14-16 Nm
11 Check valve ....................................... K ........... Differential sensing circuit,
boom extend/retract .......................... 11-13 ft-lbs / 15-18 Nm
12 Check valve ....................................... L ........... Differential sensing circuit,
boom up/down .................................. 11-13 ft-lbs / 15-18 Nm
13 Proportional solenoid valve ............... M .......... Boom extend/retract .......................... 10-12 ft-lbs / 14-16 Nm
14 Check valve ....................................... N ........... Differential sensing circuit,
turntable rotate left/right .................... 11-13 ft-lbs / 15-18 Nm
15 Proportional solenoid valve ............... O ........... Boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
16 Check valve ....................................... P ........... Differential sensing circuit,
platform level up ............................... 11-13 ft-lbs / 15-18 Nm
17 Check valve ....................................... Q ........... Differential sensing circuit,
platform level down ........................... 11-13 ft-lbs / 15-18 Nm
This list continues. Please turn the page

MANIFOLDS

MANIFOLDS
Function Manifold Components, continued

Index Schematic
18 Proportional solenoid valve ............... R ........... Turntable rotate left/right ................... 10-12 ft-lbs / 14-16 Nm
19 Solenoid valve - N.O. Poppet ............ S ........... Platform level up ............................... 25-30 ft-lbs / 34-41 Nm
0.6 gpm (2.27 l/min) ........................... T ........... Platform level circuit .......................... 10-12 ft-lbs / 14-16 Nm
21 Solenoid valve - N.O. Poppet ............ U ........... Platform level down .......................... 25-30 ft-lbs / 34-41 Nm
22 Differential sensing valve .................. V ........... Meters flow to functions .................... 10-12 ft-lbs / 14-16 Nm
23 Relief valve,
2600 psi (179 bar), S-60 models
2900 psi (200 bar), S-65 models ....... W .......... System relief ..................................... 35-40 ft-lbs / 47-54 Nm
24 Diagnostic nipple ............................... X ........... Testing
25 Check valve ....................................... Y ........... Differential sensing circuit
Platform rotate left ............................. 11-13 ft-lbs / 15-18 Nm
26 Check valve ....................................... Z ........... Differential sensing circuit
Platform rotate right .......................... 11-13 ft-lbs / 15-18 Nm
27 Priority flow regulator valve, .............. AA ......... Steering ............................................. 10-12 ft-lbs / 14-16 Nm
3.5 gpm (13.2 l/min), without oscillate axle
5 gpm (18.9 l/min), with oscillate axle
28 Solenoid valve - N.O. Poppet ........... BB ......... Platform rotate left/Jib boom up ........ 25-30 ft-lbs / 34-41 Nm
29 Solenoid valve - N.O. Poppet ........... CC ........ Platform rotate right/Jib boom down . 25-30 ft-lbs / 34-41 Nm
0.6 gpm (2.27 l/min) ........................... DD ........ Platform rotate .................................. 10-12 ft-lbs / 14-16 Nm
31 Counterbalance valve ........................ EE ......... Platform level up ............................... 35-40 ft-lbs / 47-54 Nm
32 Counterbalance valve ........................ FF ......... Platform level down .......................... 35-40 ft-lbs / 47-54 Nm
33 Check valve ....................................... GG ........ Boom extend/retract circuit ............... 11-13 ft-lbs / 15-18 Nm
Plug Torque Specifications

Description Hex size Torque SAE No. 8 5/16 50 ft-lbs / 68 Nm
SAE No. 2 1/8 50 in-lbs / 6 Nm SAE No. 10 9/16 55 ft-lbs / 75 Nm
SAE No. 4 3/16 13 ft-lbs / 18 Nm
SAE No. 6 1/4 18 ft-lbs / 24 Nm

MANIFOLDS

MANIFOLDS
10-2 How to Adjust the Boom Down

Valve Adjustments - Relief Valve
Function Manifold Perform this procedure with the
boom in the stowed position.
How to Adjust the System 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure
Relief Valve gauge to the test port (item 23) on the function
manifold.
Perform this procedure with the
boom in the stowed position. 2 Start the engine from the ground controls.
1 Connect a 0 to 5000 psi (0 to 345 bar) pressure 3 Hold the function enable switch to either side
gauge to the test port (item 23) on the function and activate and hold the boom down switch
manifold. with the boom fully lowered. Observe the
pressure reading on the pressure gauge.
2 Start the engine from the ground controls.
4 Turn the engine off. Use a wrench to hold the
3 Hold the function enable switch to either side relief valve and remove the cap
and activate and hold the retract switch with the (item 6, function manifold).
boom fully retracted. Observe the pressure
reading on the pressure gauge. 5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
4 Turn the engine off. Use a wrench to hold the decrease the pressure. Then install the relief
relief valve and remove the cap valve cap.
(item 23, function manifold).
Tip-over hazard. Do not adjust
5 Adjust the internal hex socket. Turn it clockwise the relief valves higher than
to increase the pressure or counterclockwise to specified.
decrease the pressure. Then install the relief
valve cap. 6 Repeat steps 2 through 5 and recheck relief
valve pressure.
the relief valves higher than
Boom down relief valve specifications
specified.
6 Repeat steps 2 through 5 and recheck relief Pressure 2100 psi
valve pressure. 145 bar
System relief valve specifications
Pressure
S-60 models 2600 psi 179.3 bar
S-65 models 2900 psi 200 bar

MANIFOLDS
How to Adjust the Boom Extend How to Override a Valve

Relief Valve A hydraulic valve may need to be manually
Perform this procedure with the overridden to troubleshoot a malfunction. The
boom in the stowed position. proportional boom functions (boom up/down,
extend/retract and turntable rotate) use a variable
1 Connect a 0 to 3000 psi (0 to 207 bar) pressure position proportional valve and a three position
gauge to the test port (item 23) on the function directional valve. Example: one position for boom
manifold. up, one position for neutral and one position for
boom down. The platform rotate function uses a
2 Start the engine from the ground controls.
three position valve. The platform level uses a
3 Hold the function enable switch to either side three position and a two position valve. The three
and activate and hold the extend switch with the position valves and the proportional valves can be
boom fully extended. Observe the pressure manually overridden. To identify the manifold
reading on the pressure gauge. valves see 10-1, Function Manifold, in this section.
4 Turn the engine off. Use a wrench to hold the 1 Push the button on the end of the valve in
relief valve and remove the cap ¼ inch (6 mm).
(item 5, function manifold).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Then install the relief
valve cap.
the relief valves higher than
specified.
6 Repeat steps 2 through 5 and recheck relief
valve pressure.
2 Hold the function enable switch to either side
Boom extend relief valve specifications and move the ground control function switch for
the function being overridden to operate
Pressure 2500 psi function.
172 bar Collision hazard. Impact with
moving boom components may
cause death or serious injury. Use
extreme caution when overriding a
machine function. Identify the
direction of machine movement
before overriding a valve.

MANIFOLDS
How to Check the Resistance

of a Valve Coil
1 Turn the key switch to the OFF position and
disconnect the wires from the valve coil to be
tested.
2 Connect the leads from an ohmmeter to the
valve coil terminals.
Valve coil specifications
Proportional solenoid valve, 12V 8.6Ω

(schematic items M, O and R)
3 position 4 way directional valve, 10V 3.2Ω

(schematic items A, B and C)
Normally open poppet valve 6.4Ω

(schematic item S, U, BB and CC)

MANIFOLDS
10-3
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor on the tank side of the turntable.
Index Schematic
1 Shuttle valve 2 position 3 way ........... HH ........ Turntable rotation brake release ....... 10-13 ft-lbs / 14-18 Nm
2 Counterbalance valve ........................ II ........... Turntable rotate right ........................ 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ........................ JJ .......... Turntable rotate left ........................... 35-40 ft-lbs / 47-54 Nm
1 2 3
II
JJ
HH

Description Hex size Torque
SAE No. 2 1/ 8 50 in-lbs / 6 Nm
SAE No. 4 3/16 13 ft-lbs / 18 Nm
SAE No. 6 1/ 4 18 ft-lbs / 24 Nm

MANIFOLDS
10-4
Oscillate Manifold Components
The oscillate manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Orifice Plug, 0.052 inch (1.32 mm) .... KK ......... Differential sensing circuit
2 Differential sensing valve .................. LL ......... Differential sensing ........................... 10-12 ft-lbs / 14-16 Nm
3 Check valve ....................................... MM ....... Oscillate check - left .......................... 35-40 ft-lbs / 47-54 Nm
4 Pilot operated unloader valve
950 psi (65 bar) ................................. NN ........ Sequencing ....................................... 10-12 ft-lbs / 14-16 Nm
5 Shuttle valve 2 position 3 way ........... OO ........ Pilot ................................................... 10-12 ft-lbs / 14-16 Nm
6 Piston ................................................................ Check valve circuit
(the piston is located between
index numbers 3 and 7)
7 Check valve ....................................... PP ......... Oscillate check - right ....................... 35-40 ft-lbs / 47-54 Nm
8 Shuttle valve 2 position 3 way ........... QQ ........ Unloading .......................................... 35-40 ft-lbs / 47-54 Nm
9 Diagnostic fitting ............................................... Testing
1 2
KK
LL
MM
3
QQ NN
8 4
7
OO
PP
6 5
Description Hex size Torque
SAE No. 2 1/8 50 in-lbs / 6 Nm
SAE No. 4 3/16 13 ft-lbs / 18 Nm
SAE No. 6 1/4 18 ft-lbs / 24 Nm

MANIFOLDS
10-5 7 Repeat steps 3 through 6 and manually activate

the valve and recheck the valve pressure.
Valve Adjustments -
8 Turn the engine off, then remove the
Oscillate Manifold pressure gauge and assemble the directional
valve linkage.
How to Adjust the Oscillate
Sequencing Valve Pressure Sequencing valve specifications
When removing a hose assembly Pressure 950 psi

or fitting, the O-ring on the fitting 65.5 bar
Specifications.
gauge to the test port located on the oscillate
manifold.
squirt or spray.
2 Disconnect the directional valve linkage, by
removing the clevis yoke from the drive
chassis.
3 Start the engine from the platform controls.
4 With the engine running, manually activate the
valve and observe the pressure reading on the
pressure gauge.
5 Turn the engine off. Hold the unloader valve
and remove the cap (item 4).
to increase the pressure or counterclockwise
to decrease the pressure. Then install the
valve cap.
Tip-over hazard. Do not adjust the
relief valve higher than specified.

MANIFOLDS
10-6
Directional Valve Manifold Components
The directional valve manifold is mounted inside the drive chassis at the non-steer end.
Index
No. Description Function Torque
1 Cap ................................................................... Breather ............................................. 20-25 ft-lbs / 27-33Nm
2 Spool valve ....................................................... Directional control

MANIFOLDS
How to Set Up the Directional

Valve Linkage
Adjustment of the directional valve
linkage is only necessary when
the linkage or valve has been
replaced.
1 Lower the boom to the stowed position.
2 Use a "bubble type" level to be sure the floor is
completely level.
Failure to perform this procedure
on a level floor will compromise
the stability of the machine and
may result in the machine tipping
over.
3 Check the tire pressure in all four tires and add
air if needed to meet specification.
4 Remove the drive chassis cover from the
non-steer end.
5 Disconnect the linkage clevis yoke from the
drive chassis (if not already disconnected).
6 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
7 To level the drive chassis, start the engine and
push up or pull down on the linkage adjustment
rod until the machine is completely level.
8 Verify that the ground and drive chassis are
completely level.
9 Adjust the length of the rod by turning the clevis
yoke until the clevis yoke can be pinned to the
drive chassis.
10 Install the clevis yoke pin then the cotter pin. Be
sure to bend the cotter pin.
11 Measure the distance between the drive
chassis and the non-steer axle on both sides
(from the inside of the drive chassis).
If the distance is not equal and the
adjustment to the linkage was
completed with the ground and
drive chassis level, consult Genie
Industries Service Department.

MANIFOLDS
10-7
Steer Manifold Components, S-60/65 Oscillating Models
The steer manifold is underneath the function manifold.
Index Schematic
1 3 position 4 way solenoid valve ......... SS ......... Steer left/right ....................................... 30-35 in-lbs / 3-4 Nm
2 Check valve ....................................... TT ......... Priority flow regulator circuit .............. 10-12 ft-lbs / 14-16 Nm
3 Orifice Plug, 0.025 inch (0.635 mm) .. UU ........ Priority flow regulator circuit
4 Priority flow
regulator valve, 3.5 gpm (13.2 l/min) . VV ......... Regulates flow to
oscillate manifold .............................. 10-12 ft-lbs / 14-16 Nm
SS
TT
UU
4 2
VV
3


MANIFOLDS
10-8
2WD Drive Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Relief valve, 250 psi (17.2 bar) ......... WW ....... Charge pressure circuit ..................... 10-12 ft-lbs / 14-16 Nm
2 Flow divider/combiner valve .............. XX ......... Controls flow to drive motors
in forward and reverse ...................... 25-30 ft-lbs / 34-41 Nm
3 Orifice 0.070 in (1.78 mm) ................. YY ......... Drive circuit
4 Shuttle valve 3 position 3 way ........... ZZ ......... Charge pressure circuit that
gets hot oil out of low pressure
side of drive pump and allows
low pressure flow path for
brake release and 2-speed
motor shift ......................................... 15-18 ft-lbs / 20-24 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm SAE No. 12 5/8 75 ft-lbs / 102 Nm
SAE No. 6 1/4 18 ft-lbs / 24 Nm

MANIFOLDS

MANIFOLDS
10-9
Valve Adjustments, 2WD
Drive Manifold
How to Adjust the Charge

Pressure Relief Valve
gauge to the test port located on the drive
manifold.
3 Drive the machine slowly in either direction and
observe the pressure reading on the pressure
gauge.
4 Turn the engine off. Hold the charge pressure
relief valve and remove the cap (item 1).
valve cap.
6 Restart the engine. Drive the machine in either
direction and recheck the valve pressure.
pressure gauge.
Charge Pressure Relief valve specifications
Pressure 250 psi

17.2 bar

MANIFOLDS

MANIFOLDS
10-10
4WD Drive Manifold Components
The drive manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Directional valve, 2 position 2 way .... AB ......... High speed divider bypass
N.C. Pilot to open .............................. 25-30 ft-lbs / 34-41 Nm
2 Flow divider/combiner valve .............. AC ........ Controls flow to flow
divider/combiner valves 6 and 7 ....... 25-30 ft-lbs / 34-41 Nm
3 Relief valve, 250 psi (17.2 bar) ......... AD ........ Charge pressure circuit ..................... 10-12 ft-lbs / 14-16 Nm
4 Check valve, pilot to close ................. AE ......... Works in conjunction with
Index no.12 in the high speed
divider bypass circuit ........................ 10-12 ft-lbs / 14-16 Nm
5 Orifice - plug, 0.052 inch (1.32 mm) .. AF ......... Front drive motor circuit
6 Flow divider/combiner valve .............. AG ........ Controls flow to steer end
drive motors in forward
and reverse ....................................... 25-30 ft-lbs / 34-41 Nm
7 Flow divider/combiner valve .............. AH ........ Controls flow to non-steer end
drive motors in forward
and reverse ....................................... 25-30 ft-lbs / 34-41 Nm
8 Orifice 0.070 in (1.78 mm) ................. AI .......... Rear drive motor circuit
9 Orifice 0.070 in (1.78 mm) ................. AJ ......... Equalizes pressure on both sides
of flow divider combiner valve
Index no. 2
10 Shuttle valve, 3 position 3 way .......... AK ......... Charge pressure circuit
that gets hot oil out of low pressure
side of drive pump and allows low
pressure flow path for brake
release and 2-speed motor shift ....... 15-18 ft-lbs / 20-24 Nm
12 Check valve ....................................... AL ......... Works in conjunction with
Index no.4 in the high speed
divider bypass circuit ........................ 10-12 ft-lbs / 14-16 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm SAE No. 12 5/8 75 ft-lbs / 102 Nm
SAE No. 6 1/4 18 ft-lbs / 24 Nm

MANIFOLDS

MANIFOLDS
10-11
Valve Adjustments, 4WD
Drive Manifold
How to Adjust the Charge

Pressure Relief Valve
gauge to the test port located on the drive
manifold.
3 Drive the machine slowly in either direction and
observe the pressure reading on the pressure
gauge.
4 Turn the engine off. Hold the charge pressure
relief valve and remove the cap (index 3).
valve cap.
6 Restart the engine. Drive the machine in either
direction and recheck the valve pressure.
pressure gauge.
Charge Pressure Relief valve specifications
Pressure 250 psi

17.2 bar

Fuel and Hydraulic Tanks

11-1 11-2
Fuel Tank Hydraulic Tank
How to Remove the Fuel Tank The primary functions of the hydraulic tank are to
cool, clean and deaerate the hydraulic fluid during
Explosion hazard. Engine fuels operation. It utilizes internal suction strainers for
are combustible. Remove the fuel the pump supply lines and has an external return
tank in an open, well-ventilated line filter with a filter condition indicator.
area away from heaters, sparks,
flames and lighted tobacco. How to Remove the
Always have an approved fire Hydraulic Tank
extinguisher within easy reach.
Explosion hazard. When
The work area and surfaces
transferring fuel, connect a
where this procedure will be
grounding wire between the
performed must be clean and
machine and pump or container.
free of debris that could get
1 Turn the manual fuel shutoff valve to the into the hydraulic system.
CLOSED position.
2 Remove the tank side turntable cover. See 5-1, or fitting, the O-ring on the fitting
How to Remove a Turntable Cover. and/or hose end must be replaced
3 Gasoline/LPG models: Disconnect, drain and
plug the fuel hose.
Deutz Diesel models: Disconnect, drain and Hose and Fitting Torque
plug the supply and return fuel lines. Cap the Specifications.
fuel return fitting on the fuel tank.
1 Remove the fuel tank. See 11-1, How to
4 Remove the retaining fasteners from the fuel Remove the Fuel Tank.
tank hold down straps. Remove the straps from
the fuel tank.
5 Support the fuel tank with 2 lifting straps. Place
one lifting strap at each end of the tank and
attach the lifting straps to an overhead crane.
6 Remove the fuel tank from the machine.
Crushing hazard. The fuel tank
if it is not properly supported and
secured to the overhead crane.
Clean the fuel tank and inspect
for rust and corrosion before
installing.

FUEL AND HYDRAULIC TANKS
2 Close the two hydraulic shutoff valves located 10 Remove the hydraulic tank from the machine.
at the hydraulic tank.
Crushing hazard. The hydraulic
if it is not properly supported and
secured to the overhead crane.
11 Remove the suction strainers from the tank and
clean them using a mild solvent.
12 Rinse out the inside of the tank using a mild
solvent.
open closed
13 Install the suction strainers using a thread
Component damage hazard. The sealant on the threads.
engine must not be started with 14 Install the drain plug using a thread sealant on
the hydraulic tank shutoff valves in the threads.
the CLOSED position or component
damage will occur. If the tank 15 Install the hydraulic tank onto the machine.
valves are closed, remove the key 16 Install the two suction hoses and the supply
from the key switch and tag the hose for the auxiliary power unit.
17 Fill the tank with hydraulic oil until the level is
condition.
within the top 2 inches (5 cm) of the sight
3 Remove the drain plug from the hydraulic tank. gauge. Do not overfill.
4 Completely drain the tank into a suitable 18 Clean up any oil that may have spilled and open
container. See capacity specifications. the hydraulic tank valves.
5 Tag, disconnect and plug the two suction hoses Component damage hazard.
that are attached to the hydraulic tank Be sure to open the two hydraulic
shutoff valves. tank valves and prime the pump
after installing the hydraulic tank.
6 Disconnect and plug the T-fitting located at the
return filter with the 2 hoses connected to it. Always use pipe thread sealant
Cap the fitting on the return filter housing. when installing the drain plug.
7 Disconnect and plug the supply hose for the Use only Dexron II equivalent
auxiliary power unit. Cap the fitting on the hydraulic fluid.
hydraulic tank.
Hydraulic system
8 Remove the retaining fasteners from the
hydraulic tank hold down straps. Remove the
Hydraulic tank capacity 45 gallons
straps from the hydraulic tank. 170 liters
9 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank Hydraulic system 55 gallons
and attach the lifting straps to an overhead capacity (including tank) 208 liters
crane.
Hydraulic fluid Dexron equivalent

FUEL AND HYDRAULIC TANKS
How to Prime the Pump Deutz Diesel models: Hold the manual fuel
shutoff valve clockwise to the CLOSED position.
Component damage hazard. Be
sure that the hydraulic tank shutoff a
valves are in the OPEN position
before priming the pump. The
engine must not be started with
the hydraulic tank shutoff valves in
the CLOSED position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
condition.
gauge to the test port on the drive pump.
a manual fuel shutoff valve
2 Gasoline/LPG models: Disconnect the
electrical connector at the ignition coils. The 3 Crank the engine with the starter motor for
ignition coils are located above the alternator. 15 seconds, wait 15 seconds, then crank the
engine an additional 15 seconds or until the
Electrocution hazard. pressure reaches 320 psi (22 bar).
circuits may cause death or 4 Connect the wiring and start the engine from
serious injury. Remove all rings, the ground controls. Check for hydraulic leaks.
watches and other jewelry.

Turntable Rotation Components

12-1 2 Tag, disconnect and plug the hydraulic hoses
from the motor, brake and manifold. Cap the
Rotation Hydraulic Motor fittings on the motor, brake and torque hub.
Bodily injury hazard.
How to Remove the Rotation Spraying hydraulic oil can
Hydraulic Motor penetrate and burn skin. Loosen
hydraulic connections very slowly
to allow the oil pressure to
dissipate gradually. Do not
allow oil to squirt or spray.
during installation. Refer to 3 Remove the motor/brake mounting fasteners,
Section Two, Hydraulic Hose and then remove the motor from the brake.
Fitting Torque Specifications.
a b
1 Secure the turntable from rotating with the
turntable rotation lock pin.
d
f
Unlocked position
e
a motor/brake mounting bolts

b motor
c brake
d torque hub mounting bolts
e torque hub
f plug
Locked position

TURNTABLE ROTATION COMPONENTS
How to Remove the Turntable 4 Remove the plug from the side of the torque
hub. Then drain the oil from the hub.
Rotation Brake or Torque Hub
5 Install the torque hub. Torque the hub mounting
1 Secure the turntable from rotating with the bolts to 180 foot-pounds (244 Newton meters).
turntable rotation lock pin.
6 Install the brake and motor onto the torque hub.
7 Fill the hub with oil from the side hole until the
oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plugs, and then
install the plugs.
8 Adjust turntable rotation gear backlash. See
Repair Procedure 18-1, How to Adjust the
Turntable Rotation Gear Backlash.
unlocked locked Turntable rotate torque hub

2 Remove the motor/brake mounting bolts, and Capacity 17 fluid ounces
then remove the motor and brake from the 0.51 liters
torque hub and set them to the side.
Type: SAE 90 multipurpose hypoid gear oil - API
Component damage hazard. service classification GL5
Hoses can be damaged if they are
kinked or pinched.
a b
f
c
d
e
a motor/brake mounting bolt

b motor
c torque hub
d torque hub mounting bolt
e plug
f brake
3 Remove the torque hub mounting bolts, and

then use a lifting device to remove the torque
hub from the machine.

TURNTABLE ROTATION COMPONENTS
How to Adjust the 6 Rotate the torque hub pivot plate away from the
turntable until it contacts the adjustment bolt.
Turntable Rotation Gear Backlash Then tighten the mounting fasteners on the
The turntable rotation torque hub is mounted on a torque hub pivot plate.
adjustable plate that controls the gap between the 7 Rotate the turntable through an entire rotation.
rotation motor gear and the turntable bearing. Check for tight spots that could cause binding.
Readjust if necessary.
Be sure to check the backlash
with the machine on a flat level
surface.
1 Loosen the mounting fasteners on the torque
hub pivot plate.
a pivot plate mounting bolts

b adjustment bolt with lock nut
c torque hub pivot plate
2 Push the torque hub pivot plate towards the

turntable as far as possible (this will push the
rotation gear into the rotation bearing).
3 Loosen the lock nut on the adjustment bolt.
4 Turn the adjustment bolt clockwise until it
contacts the pivot plate.
5 Turn the adjustment bolt 1/2 turn
counterclockwise. Then tighten the lock nut on
the adjustment bolt.

2WD Steering Axle Components

13-1 6 Remove the pin retaining fasteners from the
yoke pivot pins.
Yoke and Hub
7 Support the yoke/hub assembly with a lifting
jack.
How to Remove the Yoke
and Hub 8 Use a slide hammer to remove the upper yoke
pivot pin, then use a soft metal drift to drive the
1 Remove the pin retaining fasteners from both lower yoke pivot pin down and out.
the steering cylinder and the tie rod pivot pins.
Crushing hazard. The yoke/hub
Remove the pins.
assembly may become
a b c d
unbalanced and fall when the yoke
pivot pins are removed if it is not
properly secured and supported
by the lifting jack.
Torque specifications
Lug nut torque, dry 420 ft-lbs

569.5 Nm
Lug nut torque, lubricated 320 ft-lbs

433.9 Nm
How to Remove the

Hub and Bearings
1 Loosen the wheel lug nuts. Do not remove
g f f e them.
a tie rod 2 Block the non-steering wheels and place a
b axle lifting jack of ample capacity under the steering
c yoke pivot pin
d yoke
axle.
e hub
3 Raise the machine 6 inches (15 cm) and place
f pivot pin
g steering cylinder blocks under the chassis for support.
2 Loosen the wheel lug nuts. Do not 4 Remove the lug nuts. Then remove the tire
remove them. and wheel assembly.
3 Block the non-steering wheels, and then 5 Remove the dust cap, cotter pin and
center a lifting jack of ample capacity under the slotted nut.
steering axle. 6 Pull the hub off the spindle. The washer and
4 Raise the machine 6 inches (15 cm) and place outer bearing should fall loose from the hub.
blocks under the chassis for support. 7 Place the hub on a flat surface and gently pry
5 Remove the lug nuts. Then remove the tire the bearing seal out of the hub. Remove the
and wheel assembly. rear bearing.

2WD STEERING AXLE COMPONENTS
How to Install the 13-2

Hub and Bearings Steering Cylinders
When replacing a wheel bearing,
both the inner and outer bearings How to Remove a
including the pressed-in races Steering Cylinder
must be replaced.
There are two identical steering cylinders that
1 Be sure that both bearings are packed work in parallel. They are part of the same
with clean, fresh grease. hydraulic circuit, but move in opposite directions.
2 Place the large inner bearing into the rear The tie rod maintains equal movement of the tires.
of the hub. When removing a hose assembly
3 Press the bearing seal evenly into the hub or fitting, the O-ring on the fitting
until it is flush. and/or hose end must be replaced
4 Slide the hub onto the yoke spindle. during installation.
Component damage. Do not Refer to Section Two, Hydraulic
apply excessive force or damage Hose and Fitting Torque
to the lip of the seal may occur. Specifications.
5 Place the outer bearing into the hub. 1 Tag, disconnect and plug the hydraulic hoses
from the steering cylinder. Cap the fittings on
6 Install the washer and slotted nut. the cylinder.
7 Tighten the slotted nut to 35 foot-pounds Bodily injury hazard. Spraying
(47 Nm). hydraulic oil can penetrate and
8 Loosen the slotted nut, then re-tighten to burn skin. Loosen hydraulic
8 foot-pounds (11 Nm). connections very slowly to allow
9 Install a new cotter pin. Bend the cotter pin gradually. Do not allow oil to
to lock it in. squirt or spray.
10 Install the dust cap, then the tire and wheel 2 Remove the pin retaining fasteners. Then
assembly. Torque the wheel lug nuts to remove the pivot pin from each end of the
420 foot-pounds (569.5 Nm). steering cylinder.
3 Remove the steering cylinder from the machine.

13-3 6 Slide the tie rod off the yoke and adjust it by
turning the end.
Tie Rod
One half turn on the adjustable
end equals approximately 1/4 inch
How to Remove the Tie Rod (6.4 mm) change in the front
1 Remove the pin retaining fasteners, then and rear measurements.
remove the pivot pin from each end of the tie 7 Slide the tie rod onto the yoke. Install the
rod. pivot pin, then install the retaining bolt.
2 Remove the tie rod. 8 Tighten the jam nut against the tie rod.
How to Perform the Toe-in 9 Lower the machine and recheck the
Adjustment front and back measurements (step 2).
If further adjustment is needed, repeat
Perform this procedure on a steps 3 through 8.
firm, level surface. Block the
non-steering tires and be sure Toe-in specification 0 ± 1/8 inch (6.35 mm)
that the machine is in the
stowed position.
1 Straighten the steer wheels.
2 Measure the steer tires, front to front and back
to back, using a measuring fixture.
3 Center a lifting jack of ample capacity under the

steering axle, then raise the machine.
4 Loosen the jam nut on the adjustable end
of the tie rod.
5 Remove the pin retaining fasteners, then
remove the pivot pin from the adjustable end of
the tie rod.

4WD Steering Axle Components

14-1 2 Tag, disconnect and plug the hydraulic hoses
from the drive motor. Cap the fittngs on the
Yoke and Hub drive motor.
How to Remove the Yoke hydraulic oil can penetrate and
and Hub burn skin. Loosen hydraulic
The yoke installation utilizes bushings and a thrust
washer that may require periodic replacement. The
yoke must be removed before the torque hub can
squirt or spray.
be removed.
3 Loosen the wheel lug nuts. Do not
When removing a hose assembly remove them.
and/or hose end must be replaced 4 Block the non-steering wheels, and then
and then torqued to specification center a lifting jack of ample capacity under the
during installation. steering axle.
Refer to Section Two, Hydraulic 5 Raise the machine 6 inches (15.2 cm) and
Hose and Fitting Torque place blocks under the chassis for support.
Specifications.
6 Remove the lug nuts, then remove the tire and
1 Remove the pin retaining fasteners from both wheel assembly.
the steering cylinder and the tie rod pivot pins.
Remove the pins. 7 Remove the hydraulic hose clamp retaining
a fastener from the top of the yoke.
8 Remove the drive motor mounting fasteners.
9 Slide the drive motor shaft out of the torque hub
and then remove the drive motor from the
b machine.
upper and lower yoke pivot pins.
12 Support the yoke/torque hub assembly with a
lifting jack. Secure the yoke/torque hub
c assembly to the lifting jack.
13 Use a slide hammer to remove the upper yoke
pivot pin, then use a soft metal drift to drive the
g f e d
lower yoke pivot pin down and out.
a oscillate cylinder
Crushing hazard. The yoke/hub
b king pin
c torque hub assembly may become
d yoke unbalanced and fall when the yoke
e pivot pin pivot pins are removed if it is not
f tie rod
properly secured and supported
g steer cylinder
by the lifting jack.

14 Place the yoke/torque hub assembly on a flat 14-2

surface with the torque hub facing down.
Steering Cylinders
15 Remove the torque hub mounting fasteners that
attach the yoke to the torque hub. Remove the
yoke weldment from the torque hub.
How to Remove a
Steering Cylinder
Replace the thrust washer when
installing the yoke/torque hub This procedure is the same as the 2WD procedure.
assembly onto the axle. See repair procedure 13-2,
How to Remove a Steering Cylinder.
Lug nut,
dry 420 ft-lbs 569.5 Nm 14-3
lubricated 320 ft-lbs 433.9 Nm
Tie Rod
Torque hub mounting bolts,
dry 120 ft-lbs 163 Nm How to Remove the Tie Rod
lubricated 90 ft-lbs 122 Nm
This procedure is the same as the 2WD procedure.
Drive motor mounting bolts, See Repair Procedure 13-3,
dry 75 ft-lbs 102 Nm How to Remove the Tie Rod.
How to Perform the Toe-in
Adjustment
This procedure is the same as the 2WD procedure.
See Repair Procedure 13-3,
How to Perform the Toe-in Adjustment.

Oscillating Axle Components

15-1 3 Tag, disconnect and plug the oscillating axle
cylinder hydraulic hoses. Cap the fittings on the
Oscillating Axle oscillate cylinder.
Lock-out Cylinders Bodily injury hazard. Spraying
The oscillating axle cylinders extend and retract burn skin. Loosen hydraulic
between the drive chassis and the oscillating axle. connections very slowly to allow
The cylinders are equipped with counterbalance the oil pressure to dissipate
valves to prevent movement in the event of a gradually. Do not allow oil to squirt
hydraulic line failure. The valves are not or spray.
adjustable.
How to Remove an Oscillating rod-end pivot pin. Use a soft metal drift to
remove the pin.
Axle Cylinder
5 Attach a lifting strap from an overhead crane to
This procedure requires specific
the barrel end of the oscillating cylinder.
repair skills and a suitable
workshop. Attempting this 6 Remove the pin retaining fasteners from the
procedure without these skills barrel-end pivot pin. Use a soft metal drift to
and tools may result in death or remove the pin.
serious injury and significant
Crushing hazard. The oscillate
component damage. Dealer
cylinder may become unbalanced
service is strongly recommended.
and fall when it is removed from
Perform this procedure on a firm, the machine if it is not properly
level surface with the boom in attached to the overhead crane.
the stowed position.
7 Remove the cylinder from the machine.
Specifications.
1 Rotate the boom until the boom is between the
steer tires.
2 Remove the fasteners from drive chassis cover
at the steer end. Remove the cover.

Non-steering Axle Components

16-1 4 Slide the drive motor shaft out of the brake and
then remove the drive motor from the machine.
Drive Motor
How to Remove a Drive Motor
Drive motor mounting bolts 75 ft-lbs
Component damage hazard. 102 Nm
Repairs to the motor should only
be performed by an authorized
Sundstrand-Sauer dealer.
Component damage hazard. The
work area and surfaces where this 16-2
procedure will be performed must
be clean and free of debris that Torque Hub
could get into the hydraulic system
and cause severe component How to Remove a Drive
damage. Dealer service is
recommended.
Torque Hub
When removing a hose assembly When removing a hose assembly
or fitting, the O-ring on the fitting or fitting, the O-ring on the fitting
and/or hose end must be replaced and/or hose end must be replaced
and then torqued to specification and then torqued to specification
during installation. during installation.
Refer to Section Two, Hydraulic Refer to Section Two, Hydraulic
Hose and Fitting Torque Hose and Fitting Torque
Specifications. Specifications.
1 Remove the fasteners from drive chassis cover 1 Remove the drive motor. See 22-1, How to
at the non-steer end. Remove the cover. Remove a Drive Motor.
2 Tag, disconnect and plug the hydraulic hoses 2 Tag, disconnect and plug the hydraulic hose
from the drive motor. Cap the fittings on the from the brake. Then remove the hydraulic
drive motor. fitting and the bleed valve.
Bodily injury hazard. Spraying 3 Loosen the wheel lug nuts. Do not remove
hydraulic oil can penetrate and them.
connections very slowly to allow 4 Center a lifting jack of ample capacity under the
the oil pressure to dissipate non-steering axle. Raise the machine and place
gradually. Do not allow oil to squirt blocks under the drive chassis for support.
or spray. 5 Remove the wheel lug nuts, then the tire and
3 Remove the drive motor mounting fasteners. wheel assembly.
6 Place a second lifting jack under the torque hub
for support and secure the torque hub to the
lifting jack.

NON-STEERING AXLE COMPONENTS
7 Remove the torque hub mounting bolts that

attach the torque hub to the chassis. Remove
the torque hub.
Crushing hazard. The torque
hub may become unbalanced and
fall if it is not properly supported
and secured to the lifting jack.
Lug nut,
dry 420 ft-lbs 569.5 Nm
lubricated 320 ft-lbs 433.9 Nm
Torque hub mounting bolts,

dry 120 ft-lbs 163 Nm
Drive motor mounting bolts,

dry 75 ft-lbs 102 Nm

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Service Manual - Second Edition Section 7 - Repair Procedures

4-3 5 Tag, disconnect and plug the boom lift cylinder

Part No. 48412 Genie S-60 & Genie S-65 7 - 23

4-4 6 Remove the turntable end cover.

7 - 24 Genie S-60 & Genie S-65 Part No. 48412

4-5 5 Place a rod through the barel-end pivot pin and

How to Remove the Platform

Part No. 48412 Genie S-60 & Genie S-65 7 - 25

7 - 26 Genie S-60 & Genie S-65 Part No. 48412

Deutz Engine F4L 1011F

the drive pump. Component damage hazard.

Ford LRG-423 Engine

Governor actuator and linkage

7 - 28 Genie S-60 & Genie S-65 Part No. 48412

FORD LRG-423 ENGINE

6 Manually pull the actuator arm through a full 7-2

Part No. 48412 Genie S-60 & Genie S-65 7 - 29

FORD LRG-423 ENGINE

7 - 30 Genie S-60 & Genie S-65 Part No. 48412

FORD LRG-423 ENGINE

How to Install the Flex Plate 7-7

Component damage hazard.

Part No. 48412 Genie S-60 & Genie S-65 7 - 31

FORD LRG-423 ENGINE

How to Test the Vacuum Switch

1 Connect the leads from an ohmmeter or

7 - 32 Genie S-60 & Genie S-65 Part No. 48412

Part No. 48412 Genie S-60 & Genie S-65 7 - 33

8-5 2 Connect 12V DC to one of the small posts and

Electrocution hazard. Contact with Test Desired result

How to Test the Power Relay

Test Desired result

Any small post to no continuity

7 - 34 Genie S-60 & Genie S-65 Part No. 48412

How to Remove the Drive Pump

Part No. 48412 Genie S-60 & Genie S-65 7 - 35

7 - 36 Genie S-60 & Genie S-65 Part No. 48412

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Part No. 48412 Genie S-60 & Genie S-65 7 - 37

This list continues. Please turn the page

7 - 38 Genie S-60 & Genie S-65 Part No. 48412

Part No. 48412 Genie S-60 & Genie S-65 7 - 39

Function Manifold Components, continued

Plug Torque Specifications

SAE No. 2 1/8 50 in-lbs / 6 Nm SAE No. 10 9/16 55 ft-lbs / 75 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm

SAE No. 6 1/4 18 ft-lbs / 24 Nm

7 - 40 Genie S-60 & Genie S-65 Part No. 48412

Part No. 48412 Genie S-60 & Genie S-65 7 - 41

10-2 How to Adjust the Boom Down

System relief valve specifications

7 - 42 Genie S-60 & Genie S-65 Part No. 48412

How to Adjust the Boom Extend How to Override a Valve

Part No. 48412 Genie S-60 & Genie S-65 7 - 43

How to Check the Resistance

Valve coil specifications

Proportional solenoid valve, 12V 8.6Ω

3 position 4 way directional valve, 10V 3.2Ω

Normally open poppet valve 6.4Ω

7 - 44 Genie S-60 & Genie S-65 Part No. 48412