Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 11
All Lift and Install a 0 to 5000 PSI 2600 Troubleshoot each
(345 bar) pressure psi or function individually or
Steer Functions gauge on the function more consult Genie Industries
manifold. Start engine, Service Department.
Inoperative, move the function
Drive Functions enable toggle switch to
either side and hold the
Operational boom retract function
and check the hydraulic
pressure.
Be sure the hydraulic
suction line shutoff less than
valve for the lift/steer 2600 psi
pump is in the open Adjust the function Move the function
position. manifold system relief 2600 enable switch to either
valve (item W) all the psi or side and hold the boom
Be sure all grounding way in (clockwise) more retract switch and
counting the number of readjust the relief
wires for the hydraulic turns. Move the function pressure to 2600 psi for
manifold valves are free enable switch to either S-60 or 2900 psi for
side and hold the boom S-65 .
of corrosion and have retract switch and
full continuity to ground. recheck the pressure.
less than
2600 psi
steering
Check steer functions. operates Repair or replace
differential sensing valve
(item V) OR repair or
replace flow regulator
valve (item AA) OR
manifold has an internal
defect, consult Genie
steering inoperative Industries Service
Department.

Check the function ok Replace the relief valve

pump, see Repair (item W) OR manifold
section. has an internal defect.
Consult the Genie
Industries Service
Department.
bad

Replace the function

pump.

Part No. 48412 Genie S-60 & Genie S-65 5 - 27

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 12
Ground Does the engine start yes Start the engine from Repair open in red wire
from the ground the ground controls. circuit from key switch to
Controls controls? Move the function
0V
function enable toggle
enable toggle switch to switch to each function
Inoperative, either side and check toggle switch.
Platform the voltage on the
center terminal of the
Controls platform level toggle
switch TS16.
Operate
no 12V
Normally
Be sure all other Troubleshoot each
function individually.
functions operate
normally, including
the platform
controls. With both Emergency Repair open in red wire
Stop buttons pulled out 0V circuit from emergency
to the ON position, check stop button to the
voltage at red wire on key switch.
the input side of the
ground controls contact
of the key switch KS1
(the red wire checked
should originate from
the Emergency Stop
button).

12V

With the keyswitch 0V Check if key switch yes Replace key switch
turned to ground internal cam is activating contact for ground
controls and both ground contact. controls.
Emergency Stop buttons
are pulled out to the ON
no
position, check voltage
at red wire at the output
side of the ground Replace key switch
controls contact on the KS1.
key switch.

12V

Repair open in red wire

circuit from key switch to
function enable toggle
switch to each function
toggle switch.

5 - 28 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 13
Platform Does engine start from yes Start engine from the Test or replace foot
the platform controls? platform controls, then switch (see Repair
Controls press down the foot
0V
Section) OR repair open
switch and check in wht wire circuit from
Inoperative, voltage at TP24. foot switch to TP24.
Ground
12V
Controls
no
Operate Repair open in wht wire
circuit from TP24 to
Normally function toggle switches
and function controllers.
Be sure all
cables from chassis 0V
Check voltage at TB22. Repair open in red wire
through the cable circuit from key switch to
track are in good TB22 OR Replace the
condition with no platform controls contact
12V at the key switch.
kinks or abrasions.

0V
Check voltage at TP22. Repair open in blk-2
wire circuit from TB22
TP22.
12V

Check voltage at blk Repair open in blk wire

wire on input side of 0V from TP22 to
platform Emergency Emergency Stop button
Stop button contact P2. P2.

12V

With the key switch 0V Check if Emergency yes Replace contact on

turned to platform Stop switch the contact. Emergency Stop button
controls and both P2.
Emergency Stop buttons no
pulled out to the on
position, check the
voltage on the output Replace the platform
side of the platform Emergency Stop button.
Emergency Stop button
contact.

12V
0V
Check voltage at TP23. Repair open in blk wire
with diode from
Emergency Stop button
12V to TP23.

Repair open in blk wire

circuit from platform
Emergency Stop button
to TP26 to foot switch
OR replace foot switch
OR consult Genie
Industries Service
Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 29

Section 5 - Troubleshooting Flow Charts
Chart 14
Boom Up With key switch in
ground position and
Function both Emergency Stop
0V
buttons pulled out to the
Inoperative ON position, move the
function enable switch to
Be sure all other either side and hold the
functions operate boom up toggle switch
normally. (TS17) on ground panel
in up direction and
check voltage on red/
wht wire on boom up/
down proportional valve
coil (item O).
20V or more
Continued on the next
page.
5 - 30 Genie S-60 & Genie S-65
Service Manual - Second Edition
Move the function Repair open in red/wht
enable switch to either wire circuit from TB3 to
side and hold the boom boom up/down
8 to 9V
up toggle switch (TS17) proportional valve coil
on ground panel in the (item O) OR repair open
up direction and check in brown ground wire
voltage at TB3. circuit to valve coil.
0V
With the keyswitch in 8 to 9V Repair open in red/wht
platform position and wire from TP3 to TB3.
both Emergency Stop
buttons pulled out to the
ON position, activate
footswitch and boom
function controller (BP1)
on platform control
panel in up direction and
check voltage at TP3.
0V
Activate footswitch and 0V Repair open in power
check voltage at "+" supply circuit from TP24
terminal on BP1. to BP1 OR repair open
in brown ground wire
circuit from ground to
12V or more BP1.
Re-adjust controller (see
Repair Section) OR
replace controller BP1
OR consult Genie
Industries Service
Department.
Part No. 48412
Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 14

Continued from the With key switch in
ground position and
previous page. both Emergency Stop
0V
buttons pulled out to the
ON position, move the
function enable switch to
either side and hold the
boom up toggle switch
(TS17) on ground panel
in up direction and
check voltage on red #1
wire on boom up/down
directional valve coil
(item B).
Move the function
enable switch to either 12V or
side and hold the boom
more
up toggle switch (TS17)
on ground panel in up
direction and check
voltage at TB1.
0V
With key switch in
platform position and
both Emergency Stop 12V or
buttons pulled out to the more
ON position, activate
footswitch and boom
function controller (BP1)
on platform control
panel in up direction and
check voltage TB1.
Repair open in red #1
wire circuit from TB1 to
boom up function
directional valve coil
(item B) OR repair open
in brown ground wire
circuit to valve coil.
Troubleshoot boom up
function toggle switch
(TS17) on ground
control panel OR repair
open in red #1 wire
circuit from TS17 to TB1
OR consult Genie
Industries Service
Department.

0V
12V or
Activate footswitch and more Repair open in red wire
boom function controller from TP1 to TB1.
(BP1) on platform
control panel in up
direction and check
voltage TP1.

0V

Activate footswitch and 0V Repair open in power

20V or more check voltage at "+" supply circuit from TP24
terminal on BP1. to BP1 OR repair open
in brown ground wire
circuit from ground to
12V or more BP1.

Re-adjust controller (see

Repair Section) OR
replace controller BP1
OR consult Genie
Industries Service
Department.

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 31

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 14

Disconnect wires to 0 or
Continued from the boom up directional infinite
previous page. valve coil (item B) and ohms Replace boom up
directional valve coil
test the resistance of the
(item B).
valve coil. See Repair
Section.

2.5 to 3.5 ohms

function
Move function enable operates Replace defective
switch to either side and directional valve.
hold the boom up toggle
switch at the ground
controls in the up
direction. Manually
override the directional
valve by pushing in on
the end of the valve
spool.

function inoperative

Install a 0 to 5000 PSI Check for mechanical

(345 bar) pressure 2500 restrictions keeping
gauge at the quick PSI or boom from moving OR
disconnect coupling on more repair cylinder or
the boom function cylinder counterbalance
manifold and start the valve OR consult Genie
engine. Move the Industries Service
function enable switch to Department.
either side and hold the
boom up toggle switch
at the ground controls in
the up direction and
check the pressure.

less than 2500 PSI

Exchange flow regulator function

valve (item H) with a like operates Replace defective flow
valve (item G). Check regulator valve.
boom up function.

function inoperative

Repair cylinder or
cylinder counterbalance
valve OR boom function
manifold could have an
internal defect. Consult
Genie Industries Service
Department.

5 - 32 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition
Boom Down With key switch in
ground position and
Function both Emergency Stop
0V
buttons pulled out to the
Inoperative ON position, move the
function enable switch to
Be sure all other either side and hold the
functions operate boom down toggle
normally. switch (TS17) on ground
panel in down direction
and check voltage on
red/wht wire on boom
up/down proportional
valve coil (item O).
20V or more
Continued on the next
page.
Part No. 48412 Genie S-60 & Genie S-65
Section 5 - Troubleshooting Flow Charts
Chart 15
Move the function Repair open in red/wht
enable switch to either wire circuit from TB3 to
side and hold the boom boom up/down
6 to 7V
down toggle switch proportional valve coil
(TS17) on ground panel (item O) OR repair open
in the down direction in brown ground wire
and check voltage at circuit to valve coil.
TB3.
0V
With the keyswitch in 6 to 7V Repair open in red/wht
the platform position and wire from TP3 to TB3.
both Emergency Stop
buttons pulled out to the
ON position, activate
footswitch and boom
function controller (BP1)
on platform control
panel in down direction
and check voltage at
TP3.
0V
Activate footswitch and 0V Repair open in power
check voltage at "+" supply circuit from TP24
terminal on BP1. to BP1 OR repair open
in brown ground wire
circuit from ground to
12V or more BP1.
Re-adjust controller (see
Repair Section) OR
replace controller BP1
OR consult Genie
Industries Service
Department.
5 - 33
Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 15

Continued from the With key switch in
ground position and
previous page. both Emergency Stop
0V
buttons pulled out to the
ON position, move the
function enable switch to
either side and hold the
boom down toggle
switch (TS17) on ground
panel in down direction
and check voltage on
red/blk #2 wire on boom
function directional valve
coil (item B).
Move the function
enable switch to either 12V or
side and hold the boom
more
down toggle switch
(TS17) on ground panel
in down direction and
check voltage at TB2.
0V
With key switch in
platform position and
both Emergency Stop 12V or
buttons pulled out to the more
ON position, activate
footswitch and boom
function controller (BP1)
on platform control
panel in down direction
and check voltage TB2.
Repair open in red/blk
#2 wire circuit from TB2
to boom down function
directional valve coil
(item B) OR repair open
in brown ground wire
circuit to valve coil.
Troubleshoot boom
down function toggle
switch (TS17) on ground
control panel OR repair
open in red/blk #2 wire
circuit from TS17 to TB2
OR consult Genie
Industries Service
Department.

0V
12V or
Activate footswitch and more Repair open in red/blk
boom function controller wire from TP2 to TB2.
(BP1) on platform
control panel in down
direction and check
voltage TP2.

0V

Activate footswitch and 0V Repair open in power

20V or more check voltage at "+" supply circuit from TP24
terminal on BP1. to BP1 OR repair open
in brown ground wire
circuit from ground to
12V or more BP1.

Re-adjust controller (see

Repair Section) OR
replace controller BP1
OR consult Genie
Industries Service
Department.

Continued on the next

page.

5 - 34 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 15

Disconnect wires to 0 or
Continued from the boom down directional infinite
previous page. valve coil (item B) and ohms Replace boom down
test the resistance of the directional valve coil
(item B).
valve coil. See Repair
Section.

2.5 to 3.5 ohms

function
Move function enable operates Replace defective
switch to either side and directional valve.
hold the boom down
toggle switch at the
ground controls in the
down direction.
Manually override the
directional valve by
pushing in on the end of
the valve spool.

function inoperative

Install a 0 to 5000 PSI Check for mechanical

(345 bar) pressure restrictions keeping
gauge at the quick 2100 boom from moving OR
disconnect coupling on PSI repair cylinder or
the boom function cylinder counterbalance
manifold and start the valve OR consult Genie
engine. Move the Industries Service
function enable switch to Department.
either side and hold the
boom down toggle
switch at the ground
controls in the down
direction and check the
pressure.

less than 2100 PSI

Reset boom down relief

valve (item F) pressure
(see Repair Section) OR
replace boom down
relief valve OR repair
cylinder or cylinder
counterbalance valve
OR function manifold
could have an internal
defect. Consult Genie
Industries Service
Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 35

Section 5 - Troubleshooting Flow Charts
Chart 16
Boom Extend With key switch in
ground position and
Function both Emergency Stop
0V
buttons pulled out to the
Inoperative ON position, move the
function enable switch to
Be sure all other either side and hold the
functions operate boom extend toggle
normally. switch (TS19) on ground
panel in extend direction
and check voltage on
blk/red wire on boom
extend/retract
proportional valve coil
(item M).
20V or more
Continued on the next
page.
5 - 36 Genie S-60 & Genie S-65
Service Manual - Second Edition
Move the function Repair open in blk/red
enable switch to either wire circuit from TB9 to
side and hold the boom boom extend/retract
9 to 10V
extend toggle switch proportional valve coil
(TS19) on ground panel (item M) OR repair open
in the extend direction in brown ground wire
and check voltage at circuit to valve coil.
TB9.
0V
With keyswitch in 9 to 10V Repair open in blk/red
platform position and wire from TP9 to TB9.
both Emergency Stop
buttons pulled out to the
on position, activate
footswitch and boom
extend/retract
proportional controller
(BP2) on platform
control panel in extend
direction and check
voltage at TP9.
0V
Activate footswitch and 0V Repair open in power
check voltage at "+" supply circuit from TP24
terminal on BP2. to BP1 to BP2 OR repair
open in brown ground
wire circuit from ground
12V or more to BP2.
Re-adjust controller (see
Repair Section) OR
replace controller BP2
OR consult Genie
Industries Service
Department.
Part No. 48412
Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 16

Continued from the With key switch in
ground position and
previous page. both Emergency Stop
0V
buttons pulled out to the
ON position, move the
function enable switch to
either side and hold the
boom extend/retract
toggle switch (TS19) on
ground panel in the
extend direction and
check voltage on blk
wire on boom function
directional valve coil
(item C).
Move the function
enable switch to either 12V or
side and hold the boom
more
extend toggle switch
(TS19) on ground panel
in the extend direction
and check voltage at
TB7.
0V
With key switch in
platform position and
both Emergency Stop 12V or
buttons pulled out to the more
ON position, activate
footswitch and boom
extend/retract
proportional controller
(BP2) on platform
control panel in extend
direction and check
voltage TB7.
Repair open in blk wire
circuit from TB7 to boom
extend function
directional valve coil
(item C) OR repair open
in brown ground wire
circuit to valve coil.
Troubleshoot boom
extend/retract function
toggle switch (TS19) on
ground control panel OR
repair open in blk wire
circuit from TS19 to TB7
OR consult Genie
Industries Service
Department.

0V
12V or
Activate footswitch and more Repair open in blk wire
boom extend/retract from TP7 to TB7.
proportional controller
(BP2) on platform
control panel in extend
direction and check
voltage TP7.
20V or more 0V

Activate footswitch and 0V Repair open in power

check voltage at "+" supply circuit from TP24
terminal on BP2. to BP1 to BP2 OR repair
open in brown ground
12V or more wire circuit from ground
to BP2.
Re-adjust controller (see
Repair Section) OR
replace controller BP2
OR consult Genie
Industries Service
Department.

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 37

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 16

Disconnect wires to 0 or
Continued from the boom extend directional infinite
previous page. valve coil (item C) and ohms Replace boom extend
directional valve coil
test the resistance of the
(item C).
valve coil. See Repair
Section.

2.5 to 3.5 ohms

function
Move function enable operates Replace defective
switch to either side and directional valve.
hold the boom extend
toggle switch at the
ground controls in the
extend direction.
Manually override the
directional valve by
pushing in on the end of
the valve spool.

function inoperative

Install a 0 to 5000 PSI Check for mechanical

(345 bar) pressure 2500 restrictions keeping
gauge at the quick PSI or boom from extending
disconnect coupling on more OR repair cylinder or
the boom function cylinder counterbalance
manifold and start the valves OR consult
engine. Move the Genie Industries Service
function enable switch to Department.
either side and hold the
boom extend toggle
switch at the ground
controls in the extend
direction and check the
pressure.

less than 2500 PSI

function
Exchange flow regulator operates Replace defective flow
valve (item H) with a like regulator valve.
valve (item G). Check
boom extend function.

function inoperative

Repair cylinder or
cylinder counterbalance
valve OR function
manifold could have an
internal defect. Consult
Genie Industries Service
Department.

5 - 38 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition
Boom Retract With key switch in
ground position and
Function both Emergency Stop
0V
buttons pulled out to the
Inoperative ON position, move the
function enable switch to
Be sure all other either side and hold the
functions operate boom retract toggle
normally. switch (TS19) on ground
panel in the retract
direction and check
voltage on blk/red wire
on boom extend/retract
proportional valve coil
(item M).
20V or more
Continued on the next
page.
Part No. 48412 Genie S-60 & Genie S-65
Section 5 - Troubleshooting Flow Charts
Chart 17
Move the function Repair open in blk/red
enable switch to either wire circuit from TB9 to
side and hold the boom
9 to 9.5V boom extend/retract
retract toggle switch proportional valve coil
(TS19) on ground panel (item M) OR repair open
in the retract direction in brown ground wire
and check voltage at circuit to valve coil.
TB9.
0V
With keyswitch in 9 to 9.5V Repair open in blk/red
platform position and wire from TP9 to TB9.
both Emergency Stop
buttons pulled out to the
on position, activate
footswitch and boom
extend/retract
proportional controller
(BP2) on platform
control panel in the
retract direction and
check voltage at TP9.
0V
Activate footswitch and 0V Repair open in power
check voltage at "+" supply circuit from TP24
terminal on BP2. to BP1 to BP2 OR repair
open in brown ground
wire circuit from ground
12V or more to BP2.
Re-adjust controller (see
Repair Section) OR
replace controller BP2
OR consult Genie
Industries Service
Department.
5 - 39
Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 17

Continued from the With key switch in
ground position and
previous page. both Emergency Stop
0V
switches pulled out to
the ON position, move
the function enable
switch to either side and
hold the boom extend/
retract toggle switch
(TS19) on ground panel
in the retract direction
and check voltage on
blk/wht wire on boom
function directional valve
coil (item C).
Move the function
enable switch to either 12V or
side and hold the boom
more
retract toggle switch
(TS19) on ground panel
in the retract direction
and check voltage at
TB8.
0V
With key switch in
platform position and
both Emergency Stop 12V or
switches pulled out to more
the ON position, activate
footswitch and boom
extend/retract
proportional controller
(BP2) on platform
control panel in the
retract direction and
check voltage TB8.
Repair open in blk/wht
wire circuit from TB8 to
boom retract function
directional valve coil
(item C) OR repair open
in brown ground wire
circuit to valve coil.
Troubleshoot boom
extend/retract function
toggle switch (TS19) on
ground control panel OR
repair open in blk/wht
wire circuit from TS19 to
TB8 OR consult Genie
Industries Service
Department.

0V
12V or
Activate footswitch and more Repair open in blk/wht
boom extend/retract wire from TP8 to TB8.
proportional controller
(BP2) on platform
control panel in the
retract direction and
check voltage TP8.
20V or more 0V

Activate footswitch and 0V Repair open in power

check voltage at "+" supply circuit from TP24
terminal on BP2. to BP1 to BP2 OR repair
open in brown ground
12V or more wire circuit from ground
to BP2.
Re-adjust controller (see
Repair Section) OR
replace controller BP2
OR consult Genie
Industries Service
Department.

Continued on the next

page.

5 - 40 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 17

Disconnect wires to 0 or
Continued from the boom retract directional infinite
previous page. valve coil (item C) and ohms Replace boom retract
directional valve coil
test the resistance of the
(item C).
valve coil. See Repair
Section.

2.5 to 3.5 ohms

function
Move function enable operates Replace defective
switch to either side and directional valve.
hold the boom retract
toggle switch at the
ground controls in the
retract direction.
Manually override the
directional valve by
pushing in on the end of
the valve spool.

function inoperative

Install a 0 to 5000 PSI Check for mechanical

(345 bar) pressure 2500 restrictions keeping
gauge at the quick PSI or boom from retracting
disconnect coupling on more OR repair cylinder or
the boom function cylinder counterbalance
manifold and start the valves OR consult
engine. Move the Genie Industries Service
function enable switch to Department.
either side and hold the
boom retract toggle
switch at the ground
controls in the retract
direction and check the
pressure.

less than 2500 PSI

function
Exchange flow regulator operates Replace defective flow
valve (item G) with a like regulator valve.
valve (item H). Check
boom retract function.

function inoperative

Repair cylinder or
cylinder counterbalance
valve OR function
manifold could have an
internal defect. Consult
Genie Industries Service
Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 41

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 18
Turntable With key switch in Move the function Repair open in wht/red
ground position and enable switch to either wire circuit from TB6 to
Rotate Left both Emergency Stop side and hold the turntable rotate left/right
0V 4 to 6V
buttons pulled out to the turntable rotate toggle proportional valve coil
Function ON position, move the switch (TS18) on ground (item R) OR repair open
Inoperative function enable switch to panel in the left direction in brown ground wire
either side and hold the and check voltage at circuit to valve coil.
turntable rotate toggle TB6.
Be sure all other switch (TS18) on ground
functions operate panel in the left direction
normally. and check voltage on
wht/red wire on turntable
rotate left/right
proportional valve coil 0V
(item R).

With keyswitch in 4 to 6V Repair open in wht/red

platform position and wire from TP6 to TB6.
both Emergency Stop
buttons pulled out to the
on position, activate
footswitch and turntable
rotate left/right
proportional controller
(BP1) on platform
control panel in the left
direction and check
voltage at TP6.

0V

Activate footswitch and 0V Repair open in power

20V or more check voltage at "+" supply circuit from TP24
terminal on BP1. to BP1 OR repair open
in brown ground wire
circuit from ground to
12V or more BP1.

Re-adjust controller (see

Repair Section) OR
replace controller BP1
OR consult Genie
Industries Service
Department.

Continued on the next

page.

5 - 42 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 18

Continued from the With key switch in
ground position and
previous page. both Emergency Stop
buttons pulled out to the
ON position, move the
function enable switch to
either side and hold the
turntable rotate left/right
toggle switch (TS18) on
ground panel in the left
direction and check
voltage on
wht/blk wire on boom
function directional valve
coil (item A).
Move the function
enable switch to either
side and hold the
0V turntable rotate left/right
toggle switch (TS18) on
ground panel in the left
direction and check
voltage at TB5.
0V
With key switch in
platform position and
both Emergency Stop
buttons pulled out to the
ON position, activate
footswitch and turntable
rotate left/right
proportional controller
(BP1) on platform
control panel in the left
direction and check
voltage TB5.
Repair open in wht/blk
12V or wire circuit from TB5 to
turntable rotate left
more
function directional valve
coil (item A) OR repair
open in brown ground
wire circuit to valve coil.
Troubleshoot turntable
rotate left/right function
12V or toggle switch (TS18) on
more ground control panel OR
repair open in wht/blk
wire circuit from TS18 to
TB5 OR consult Genie
Industries Service
Department.

0V
12V or
Activate footswitch and more Repair open in wht/blk
turntable rotate left/right wire from TP5 to TB5.
proportional controller
(BP1) on platform
control panel in the left
direction and check
voltage TP5.
20V or more 0V

Activate footswitch and 0V Repair open in power

check voltage at "+" supply circuit from TP24
terminal on BP1. to BP1 OR repair open
in brown ground wire
12V or more circuit from ground to
BP1.
Re-adjust controller (see
Repair Section) OR
replace controller BP1
OR consult Genie
Industries Service
Department.

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 43

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 18

Disconnect wires to 0 or
Continued from the turntable rotate left infinite
previous page. directional valve coil ohms Replace turntable rotate
(item A) and test the left directional valve coil
resistance of the valve (item A).
coil. See Repair Section.

2.5 to 3.5 ohms

function
Move function enable operates Replace defective
switch to either side and directional valve.
hold the turntable rotate
left/right toggle switch at
the ground controls in
the left direction.
Manually override the
directional valve by
pushing in on the end of
the valve spool.

function inoperative

Install a 0 to 5000 PSI

(345 bar) pressure 2600
gauge at the quick PSI or Exchange flow regulator function
disconnect coupling on more valve (item I) with a like operates Replace defective flow
the boom function valve (item H). Check regulator valve.
manifold and start the turntable rotate left
engine. Move the function.
function enable switch to
either side and hold the function inoperative
turntable rotate left
toggle switch at the
ground controls in the Repair cylinder or
left direction and check cylinder counterbalance
the pressure. valve OR function
manifold could have an
internal defect. Consult
Genie Industries Service
Department.

less than 2600 PSI

Continued on the next

page.

5 - 44 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 18

Plumb a 0 to 5000 psi lessthan Function manifold could

Continued from the (0 to 345 bar) pressure 250 psi have an internal defect.
previous page. gauge into the hose Consult Genie Industries
from the function Service Department.
manifold to the turntable
rotation brake. Move the
function enable switch to
either side and activate
the turntable rotate left
function.

250 psi or more

Exchange turntable
rotate left and right function
counterbalance valves operates Replace defective
(items II and JJ). counterbalance valve.
Activate turntable rotate
left function.

function inoperative

Check for mechanical

restrictions keeping
turntable rotate left
function from operating
OR replace shuttle valve
(item HH) OR consult
Genie Industries Service
Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 45

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 19
Turntable With key switch in Move the function Repair open in wht/red
ground position and enable switch to either wire circuit from TB6 to
Rotate Right both Emergency Stop side and hold the 4 to 6V turntable rotate left/right
buttons pulled out to the 0V turntable rotate toggle proportional valve coil
Function ON position, move the switch (TS18) on ground (item R) OR repair open
Inoperative function enable switch to panel in the right in brown ground wire
either side and hold the direction and check circuit to valve coil.
turntable rotate toggle voltage at TB6.
Be sure all other switch (TS18) on ground
functions operate panel in the right
normally. direction and check
voltage on wht/red wire
on turntable rotate left/
right proportional valve 0V
coil (item R).

With keyswitch in 4 to 6V Repair open in wht/red

platform position and wire from TP6 to TB6.
both Emergency Stop
buttons pulled out to the
on position, activate
footswitch and turntable
rotate left/right
proportional controller
(BP1) on platform
control panel in the right
direction and check
voltage at TP6.

0V

Activate footswitch and 0V Repair open in power

20V or more check voltage at "+" supply circuit from TP24
terminal on BP1. to BP1 OR repair open
in brown ground wire
circuit from ground to
12V or more BP1.

Re-adjust controller (see

Repair Section) OR
replace controller BP1
OR consult Genie
Industries Service
Department.

Continued on the next

page.

5 - 46 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 19

With key switch in
Continued from the ground position and
previous page.
both Emergency Stop
buttons pulled out to the
ON position, move the
function enable switch to
either side and hold the
turntable rotate left/right
toggle switch (TS18) on
ground panel in the right
direction and check
voltage on
wht wire on boom
function directional valve
coil (item A).
Move the function
enable switch to either
side and hold the
0V turntable rotate left/right
toggle switch (TS18) on
ground panel in the right
direction and check
voltage at TB4.
0V
With key switch in
platform position and
both Emergency Stop
buttons pulled out to the
ON position, activate
footswitch and turntable
rotate left/right
proportional controller
(BP1) on platform
control panel in the right
direction and check
voltage TB4.
Repair open in wht wire
circuit from TB4 to
12V or
more turntable rotate right
function directional valve
coil (item A) OR repair
open in brown ground
wire circuit to valve coil.
Troubleshoot turntable
rotate left/right function
12V or toggle switch (TS18) on
more ground control panel OR
repair open in wht wire
circuit from TS18 to TB4
OR consult Genie
Industries Service
Department.

0V
12V or
Activate footswitch and more Repair open in wht/blk
turntable rotate left/right wire from TP4 to TB4.
proportional controller
(BP1) on platform
control panel in the right
direction and check
voltage TP4.

20V or more 0V

Activate footswitch and 0V Repair open in power

check voltage at "+" supply circuit from TP24
terminal on BP1. to BP1 OR repair open
in brown ground wire
circuit from ground to
12V or more BP1.

Re-adjust controller (see

Repair Section) OR
replace controller BP1
OR consult Genie
Industries Service
Department.

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 47

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 19

Disconnect wires to 0 or
Continued from the turntable rotate right infinite
previous page. directional valve coil ohms Replace turntable rotate
(item A) and test the right directional valve
resistance of the valve coil (item A).
coil. See Repair Section.

2.5 to 3.5 ohms

function
Move function enable operates Replace defective
switch to either side and directional valve.
hold the turntable rotate
left/right toggle switch at
the ground controls in
the right direction.
Manually override the
directional valve by
pushing in on the end of
the valve spool.

function inoperative

Install a 0 to 5000 PSI

(345 bar) pressure 2600
gauge at the quick PSI or Exchange flow regulator function
disconnect coupling on more valve (item I) with a like operates Replace defective flow
the boom function valve (item H). Check regulator valve.
manifold and start the turntable rotate right
engine. Move the function.
function enable switch to
either side and hold the function inoperative
turntable rotate right
toggle switch at the
ground controls in the Repair cylinder or
right direction and check cylinder counterbalance
the pressure. valve OR function
manifold could have an
internal defect. Consult
Genie Industries Service
Department.

less than 2600 PSI

Continued on the next

page.

5 - 48 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 19

Plumb a 0 to 5000 psi lessthan Function manifold could

Continued from the (0 to 345 bar) pressure 250 psi have an internal defect.
previous page. gauge into the hose Consult Genie Industries
from the function Service Department.
manifold to the turntable
rotation brake. Move the
function enable switch to
either side and activate
the turntable rotate right
function.

250 psi or more

Exchange turntable
rotate right and left function
counterbalance valves operates Replace defective
(items JJ and II). counterbalance valve.
Activate turntable rotate
right function.

function inoperative

Check for mechanical

restrictions keeping
turntable rotate right
function from operating
OR replace shuttle valve
(item HH) OR consult
Genie Industries Service
Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 49

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 20
All Platform Remove both hydraulic Replace the
hoses from the manifold yes counterbalance valves
Leveling (ports PL1 & PL2). Plug on function manifold
the hoses and cap the (items A & B).
Functions manifold fittings. Move
Inoperative the function enable
switch to either side and
activate the boom up
Be sure all other function and check to
functions operate see if platform levels.
normally.
no

Plumb a 0 to 5000 psi 2000 Check for mechanical

(0 to 345 bar) pressure PSI restrictions OR replace
gauge into master the slave cylinder
cylinder rod-end counterbalance valves.
hydraulic hose (hose
connected to port PL2)
using a tee fitting.
Activate boom up
function and check the
pressure.

less than 2000 PSI

Install a 0 to 5000 psi less than

(0 to 345 bar) pressure 2000 PSI Repair or replace the
gauge into the barrel- master cylinder.
end hydraulic hose from
the master cylinder and
raise the primary boom
one inch at a time.
Continually monitor the
pressure gauge during
boom up. Do not allow
the pressure to exceed
2500 PSI.

2000 PSI or more

Repair or replace the

slave cylinder.

5 - 50 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Platform Level With the keyswitch
turned to ground control
Up Function and both Emergency
Stop buttons pulled out
Inoperative to the ON position, move
the function enable 0V
Be sure all other switch to either side and
functions operate activate the platform
normally. level toggle switch TS16
in the up direction and
check the voltage at org
wire on platform level up
function directional valve
(item S).
Chart 21
With the keyswitch Repair open in org wire
turned to ground control 12V or from TB14 to platform
and both Emergency more level up directional valve
Stop buttons pulled out coil (item S) OR repair
to the on position, move open in brown ground
the function enable wire circuit to valve coil.
switch to either side and
activate the platform
level toggle switch TS16
in the up direction and
check the voltage at
TB14.
0V

With the keyswitch Troubleshoot platform

turned to platform
control and both
Emergency Stop buttons
pulled out to the on 0V
position, activate the
footswitch and the
platform level toggle
switch TS7 in the up
direction and check the
voltage at TB14.
12V or more
level toggle switches
TS16 and TS7 on
ground and platform
control panels OR repair
open in red power wire
circuit to TS16 and TS7
OR repair open in org
wire circuit from TS16
and TS7 to TB14 OR
consult Genie Industries
Service Department.

Troubleshoot platform
level toggle switch TS16
on ground control panel
12V or more OR repair open in red
power wire circuit to
TS16 OR repair open in
org wire circuit from
TS16 to TB14 OR
consult Genie Industries
Service Department.

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 51

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 21

Disconnect the wires 0 or

Continued from the from the platform level infinite
previous page. up directional valve coil ohms Replace the platform
(item S) and test the level up directional valve
coil (item S).
resistance of the valve
coil.

6 to 7 ohms

Exchange platform level function

up and down directional operates Replace the defective
valves (items S and U) directional valve.
and activate the platform
level up function.

function inoperative

Exchange platform level function

up and down operates Replace the defective
counterbalance valves counterbalance valve.
(items EE and FF) and
activate the platform
level up function.

function inoperative

Install a 0 to 3000 Check for mechanical

(0 to 207 bar) pressure 2600 psi restrictions keeping
gauge at the quick or more platform level up
disconnect coupling on function from operating
the function manifold OR replace slave
and activate the platform cylinder OR replace
level up function. slave cylinder
counterbalance valves
OR consult Genie
Industries Service
Department.
less than 2600 psi

Test master cylinder

(see Chart 16) OR
repair or replace slave
cylinder or slave
cylinder counterbalance
valves OR function
manifold may have an
internal defect. Consult
Genie Industries Service
Department.

5 - 52 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Platform Level With the keyswitch
turned to ground control
Down Function and both Emergency
Stop buttons pulled out
Inoperative to the ON position, move
the function enable 0V
Be sure all other switch to either side and
functions operate activate the platform
normally. level toggle switch TS16
in the down direction
and check the voltage at
org/blk wire on platform
level down function
directional valve
(item U).
Chart 22
With the keyswitch Repair open in org/blk
turned to ground control wire from TB15 to
and both Emergency
12V or
platform level down
more
Stop buttons pulled out directional valve coil
to the on position, move (item U) OR repair open
the function enable in brown ground wire
switch to either side and circuit to valve coil.
activate the platform
level toggle switch TS16
in the down direction
and check the voltage at
TB15.
0V

With the keyswitch Troubleshoot platform

turned to platform
control and both
Emergency Stop buttons
pulled out to the on 0V
position, activate the
footswitch and the
platform level toggle
switch TS7 in the down
direction and check the
voltage at TB15.
12V or more
level toggle switches
TS16 and TS7 on
ground and platform
control panels OR repair
open in red power wire
circuit to TS16 and TS7
OR repair open in org/
blk wire circuit from
TS16 and TS7 to TB15
OR consult Genie
Industries Service
Department.

Troubleshoot platform
level toggle switch TS16
on ground control panel
12V or more OR repair open in red
power wire circuit to
TS16 OR repair open in
org/blk wire circuit from
TS16 to TB15 OR
consult Genie Industries
Service Department.

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 53

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 22

Disconnect the wires 0 or

Continued from the from the platform level infinite
previous page. down directional valve ohms Replace the platform
coil (item U) and test the level down directional
valve coil (item U).
resistance of the valve
coil.

6 to 7 ohms

Exchange platform level function

down and up directional operates Replace the defective
valves (items U and S) directional valve.
and activate the platform
level down function.

function inoperative

Exchange platform level function

down and up operates Replace the defective
counterbalance valves counterbalance valve.
(items FF and EE) and
activate the platform
level down function.

function inoperative

Install a 0 to 3000 Check for mechanical

(0 to 207 bar) pressure 2600 psi restrictions keeping
gauge at the quick or more platform level down
disconnect coupling on function from operating
the function manifold OR replace slave
and activate the platform cylinder OR replace
level down function. slave cylinder
counterbalance valves
OR consult Genie
Industries Service
Department.
less than 2600 psi

Test master cylinder

(see Chart 16) OR
repair or replace slave
cylinder or slave
cylinder counterbalance
valves OR function
manifold may have an
internal defect. Consult
Genie Industries Service
Department.

5 - 54 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 23
Platform Rotate With the keyswitch Repair open in grn/wht
turned to ground control wire from TS14 to TB19
Left Function and both Emergency
0V
to TP19 OR test toggle
Stop buttons pulled out switch. See Repair
Inoperative to the ON position, move Section.
the function enable
Be sure all other switch to either side and
functions operate activate the platform
normally. rotate toggle switch
TS14 in the left direction
and check voltage at
grn/wht wire at TP19 at
the platform controls.

12V

With keyswitch turned to 0V Check voltage on center 0V Repair open in red

platform control and terminal of TS5. power wire circuit
both Emergency Stop through controllers and
buttons pulled out to the function toggle switches
on position, activate to TS5.
footswitch and platform
rotate toggle switch TS5
in the left direction and
check voltage at the grn/ 12V
wht wire at the jib delay
capacitor.

With keyswitch turned to 12V Repair open in grn/wht

platform control and wire from TP19 to jib
both Emergency Stop delay capacitor.
buttons pulled out to the
on position, activate
footswitch and platform
rotate toggle switch TS5
in the left direction and
check voltage at TP19.

12V 0V

Activate footswitch and 12V Repair open in grn/wht

platform rotate toggle wire from TS5 to TP19.
switch TS5 in the left
direction and check
voltage at the grn/wht
wire on TS5.

0V

Test toggle switch. See

Repair Section OR
replace platform rotate
Continued on the next toggle switch TS5.
page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 55

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 23

With keyswitch turned to Replace the jib delay

Continued from the platform control and capacitor OR repair
previous page. 0V
both Emergency Stop open in brown ground
buttons pulled out to the wire from capacitor to
on position, activate ground.
footswitch and platform
rotate toggle switch TS5
in the left direction and
check voltage at the red
wire at the jib delay
capacitor.

12V

Activate footswitch and 0V Repair open in red wire

platform rotate toggle from jib delay capacitor
switch TS5 in the left to CR14.
direction and check
voltage on the red wire
at terminal #86 on
CR14.

12V

Activate footswitch and Replace relay CR14 OR

platform rotate toggle 0V
switch TS5 in the left
direction and check
voltage on the red and
black wires at terminal
#87 on CR14.
repair open in power
supply from P2 to CR14
OR repair open in brown
ground wire to CR14.

12V

Activate footswitch and Repair open in cable

platform rotate toggle 0V containing red and black
switch TS5 in the left wires from CR14 to jib
direction and check boom/platform rotate
voltage on the red and select valves.
black wires at the jib/
platform rotate select
valves (item AM).

12V 0 or
infinite
Test the resistance of ohms Replace defective valve
the valve coils. coil.

5.5 to 6.5
ohms

Continued on the next

page.

5 - 56 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 23

no
Check continuity from continuity Repair open in brown
Continued from the
brown ground wires on ground wire circuit to
previous page.
valve coils to ground. valve coils.

continuity
function
Exchange jib boom/ operates Repair open in brown
platform rotate select ground wire circuit to
valves (item AM). valve coils.
Activate footswitch and
platform rotate left
function.

function inoperative

Repair or replace
platform rotator OR
0.030" orifice fittings in
jib manifold are plugged
OR jib manifold may
have an internal defect.
Consult Genie Industries
Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 57

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 24
Platform Rotate With the keyswitch Repair open in grn/wht
turned to ground control wire from TS14 to TB19
Right Function and both Emergency
0V
to TP19 OR test toggle
Stop buttons pulled out switch. See Repair
Inoperative to the ON position, move Section.
the function enable
Be sure all other switch to either side and
functions operate activate the platform
normally. rotate toggle switch
TS14 in the right
direction and check
voltage at grn/wht wire
at TP19 at the platform
controls.

12V

With keyswitch turned to 0V Check voltage on center 0V Repair open in red

platform control and terminal of TS5. power wire circuit
both Emergency Stop through controllers and
buttons pulled out to the function toggle switches
on position, activate to TS5.
footswitch and platform
rotate toggle switch TS5
in the right direction and
check voltage at the grn/ 12V
wht wire at the jib delay
capacitor.

With keyswitch turned to 12V Repair open in grn/wht

platform control and wire from TP19 to jib
both Emergency Stop delay capacitor.
buttons pulled out to the
on position, activate
footswitch and platform
rotate toggle switch TS5
in the right direction and
check voltage at TP19.

12V 0V

Activate footswitch and 12V Repair open in grn/wht

platform rotate toggle wire from TS5 to TP19.
switch TS5 in the right
direction and check
voltage at the grn/wht
wire on TS5.

0V

Test toggle switch. See

Repair Section OR
Continued on the next replace platform rotate
page. toggle switch TS5.

5 - 58 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 24

With keyswitch turned to Replace the jib delay

Continued from the platform control and capacitor OR repair
previous page. 0V
both Emergency Stop open in brown ground
buttons pulled out to the wire from capacitor to
on position, activate ground.
footswitch and platform
rotate toggle switch TS5
in the right direction and
check voltage at the red
wire at the jib delay
capacitor.

12V

Activate footswitch and 0V Repair open in red wire

platform rotate toggle from jib delay capacitor
switch TS5 in the right to CR14.
direction and check
voltage on the red wire
at terminal #86 on
CR14.

12V

Activate footswitch and Replace relay CR14 OR

platform rotate toggle 0V
switch TS5 in the right
direction and check
voltage on the red and
black wires at terminal
#87 on CR14.
repair open in power
supply from P2 to CR14
OR repair open in brown
ground wire to CR14.

12V

Activate footswitch and Repair open in cable

platform rotate toggle 0V containing red and black
switch TS5 in the right wires from CR14 to jib
direction and check boom/platform rotate
voltage on the red and select valves.
black wires at the jib/
platform rotate select
valves (item AM).

12V 0 or
infinite
Test the resistance of ohms Replace defective valve
the valve coils. coil.

5.5 to 6.5
ohms

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 59

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 24

Check continuity from
Continued from the
brown ground wires on
previous page.
valve coils to ground.
no
continuity Repair open in brown
ground wire circuit to
valve coils.

continuity
function
Exchange jib boom/ operates Repair open in brown
platform rotate select ground wire circuit to
valves (item AM). valve coils.
Activate footswitch and
platform rotate right
function.

function inoperative

Repair or replace
platform rotator OR
0.030" orifice fitting in jib
manifold are plugged
OR jib manifold may
have an internal defect.
Consult Genie Industries
Service Department.

5 - 60 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition
Jib Boom Up With the keyswitch
turned to ground control
Function and both Emergency
0V
Stop buttons pulled out
Inoperative, to the ON position, move
S-65 Models the function enable
switch to either side and
activate the jib boom
Be sure all other toggle switch TS15 in
functions operate the up direction and
normally. check voltage at the grn
wire on the jib boom up
directional valve
(item BB).
12V
With the keyswitch
turned to platform 0V
control and both
Emergency Stop buttons
pulled out to the ON
position, activate the
footswitch and the jib
boom toggle switch TS6
in the up direction and
check voltage at TB17.
12V
Continued on the next
page.
Part No. 48412 Genie S-60 & Genie S-65
Section 5 - Troubleshooting Flow Charts
Chart 25
Move the function Repair open in grn wire
enable switch to either from TB17 to jib boom
side and activate the jib 12V up directional valve OR
boom toggle switch repair open in brown
TS15 in the up direction ground wire circuit to
and check voltage at directional valve.
TB17.
0V
Repair open in red
power wire circuit from
keyswitch to TS15 OR
replace toggle switch
TS15.
Activate the footswitch 12V Repair open in grn wire
and the jib boom toggle from TP17 to TB17.
switch TS6 in the up
direction and check
voltage at TP17.
0V
With the keyswitch Repair open in grn wire
turned to platform 12V from TS6 to TP17 OR
control and both replace jib boom toggle
Emergency Stop buttons switch TS6.
pulled out to the ON
position, activate the
footswitch and check the
voltage on the center
terminal of the jib boom
toggle switch TS6.
0V
Check the voltage at 0V Repair open in red wire
terminal #30 on CR13. from BP1 to CR13 OR
repair open in brown
ground wire circuit to
CR13.
12V
0V
Check the voltage at Replace CR13.
terminal #87a on CR13.
12V
Repair open in red wire
from terminal#87a on
CR13 to TS6 OR
consult Genie Industries
Service Department.
5 - 61
Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 25

Activate footswitch and 12V

Continued from the jib boom toggle switch Replace CR13.
previous page. TS6 in the up direction
and check voltage on
the red and black wires
at the jib/platform rotate
select valves (item AM).

0V

Install a 0 to 5000 psi (0 Exchange jib boom/ function

to 345 bar) pressure 2500 psi platform rotate select operates
gauge at the quick or more valves (item AM). Replace defective valve.
disconnect coupling on Activate footswitch and
the function manifold jib boom up function.
and activate the jib
boom up function. function inoperative

Check for mechanical

restrictions keeping jib
boom up function from
operating OR repair or
replace jib boom
cylinder OR replace
counterbalance valve
OR 0.035" orifice may
less than 2500 psi be plugged OR jib
boom/platform rotate
select manifold has an
internal defect OR
consult Genie Industries
Service Department.

function
Exchange jib boom operates Replace defective
counterbalance valves counterbalance valve.
and activate jib boom up
function.

function inoperative

Consult Genie Industries

Service Department.

5 - 62 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition
Jib Boom Down With the keyswitch
turned to ground control
Function and both Emergency
0V
Stop buttons pulled out
Inoperative, to the ON position, move
S-65 Models the function enable
switch to either side and
activate the jib boom
Be sure all other toggle switch TS15 in
functions operate the down direction and
normally. check voltage at the
grn/blk wire on the jib
boom down directional
valve (item BB).
12V
With the keyswitch
turned to platform 0V
control and both
Emergency Stop buttons
pulled out to the ON
position, activate the
footswitch and the jib
boom toggle switch TS6
in the down direction
and check voltage at
TB18.
12V
Continued on the next
page.
Part No. 48412 Genie S-60 & Genie S-65
Section 5 - Troubleshooting Flow Charts
Chart 26
Move the function Repair open in grn/blk
enable switch to either wire from TB18 to jib
side and activate the jib 12V boom down directional
boom toggle switch valve OR repair open in
TS15 in the down brown ground wire
direction and check circuit to directional
voltage at TB18. valve.
0V
Repair open in red
power wire circuit from
keyswitch to TS15 OR
replace toggle switch
TS15.
Activate the footswitch 12V Repair open in grn/blk
and the jib boom toggle wire from TP18 to TB18.
switch TS6 in the down
direction and check
voltage at TP18.
0V
With the keyswitch Repair open in grn/blk
turned to platform 12V wire from TS6 to TP18
control and both OR replace jib boom
Emergency Stop buttons toggle switch TS6.
pulled out to the ON
position, activate the
footswitch and check the
voltage on the center
terminal of the jib boom
toggle switch TS6.
0V
Check the voltage at 0V Repair open in red wire
terminal #30 on CR13. from BP1 to CR13 OR
repair open in brown
ground wire circuit to
CR13.
12V
0V
Check the voltage at Replace CR13.
terminal #87a on CR13.
12V
Repair open in red wire
from terminal#87a on
CR13 to TS6 OR
consult Genie Industries
Service Department.
5 - 63
Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 26

Activate footswitch and 12V

Continued from the jib boom toggle switch Replace CR13.
previous page. TS6 in the down
direction and check
voltage on the red and
black wires at the jib/
platform rotate select
valves (item AM).

0V

Install a 0 to 5000 psi (0 Exchange jib boom/

to 345 bar) pressure 2500 psi platform rotate select function
gauge at the quick or more valves (item AM). operates Replace defective valve.
disconnect coupling on Activate footswitch and
the function manifold jib boom down function.
and activate the jib
boom down function.
function inoperative

Check for mechanical

restrictions keeping jib
boom down function
from operating OR
repair or replace jib
boom cylinder OR
replace counterbalance
less than 2500 psi valve OR 0.035" orifice
may be plugged OR jib
boom/platform rotate
select manifold has an
internal defect OR
consult Genie Industries
Service Department.

function
Exchange jib boom operates Replace defective
counterbalance valves counterbalance valve.
and activate jib boom
down function.

function inoperative

Consult Genie Industries

Service Department.

5 - 64 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 27
Oscillate Remove the chassis bad Re-adjust or replace
cover at the non-steer linkage.
Function end. Check the linkage
Inoperative for damage or improper
linkage adjustment. See
Repair section, 10-6
Be sure all other How to Set Up the
function operate Directional Valve
Linkage.
normally.
good

Install a 0 to 2000 psi Adjust the sequence

(0 to 138 bar) pressure less
gauge at the quick than
disconnect coupling on 950 psi
the oscillate manifold.
Disconnect the oscillate
linkage from non-steer
axle. Start the engine
and manually activate
the directional valve.
Check the pressure.
valve. See Repair
procedure 10-5, How to
Adjust the Oscillate
Sequencing Valve
Pressure OR consult
Genie Industries Service
Department.

950 psi

Consult Genie Industries

Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 65

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 28
Steer Left With key switch in With key switch in 12V or Repair open in blu #36
platform position and platform position and more wire circuit from drive
Function both Emergency Stop both Emergency Stop controller (DP1) to TP36
buttons pulled out to the buttons pulled out to the then to TB36.
Inoperative ON position, activate 0V ON position, activate
footswitch and steer footswitch and steer
Be sure all other rocker switch on drive rocker switch on drive
functions operate controller (DP1) in left controller (DP1) in left
normally. direction and check direction and check
voltage on TB36. voltage at the controller
terminal with the blu
wire attached.

0V

Repair or replace steer

12V or more
microswitch on drive
controller. Consult
Genie Industries Service
Department.

With key switch in Repair open in blu #36

platform position and 0V wire circuit that runs
both Emergency Stop from TB36 to steer left
buttons pulled out to the directional valve coil on
ON position, activate steer manifold.
footswitch and steer
rocker switch on drive
controller (DP1) in left
direction and check
voltage on blu #36 wire
on steer left directional
valve coil (item SS) on
steer manifold.

12V or more

Disconnect wires to 0 or Replace steer left

steer left directional infinite
valve coil (item SS) on ohms
steer manifold and test
the resistance of the
valve coil.
directional valve coil
(item SS) OR repair
open in brown ground
wire to steer left valve
coil.

5 to 6 ohms

Continued on the next

page.

5 - 66 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 28

Install a 0 to 5000 PSI 2600 Check for mechanical

Continued from the (0 to 345 bar) pressure
previous page. PSI or
gauge at the quick more
disconnect coupling on
the boom function
manifold and activate
the steer left function.
less than 2600 PSI
restrictions keeping
steer left function from
operating OR repair or
replace steer cylinder
OR consult Genie
Industries Service
Department.

Repair or replace steer

cylinder OR steer
manifold could have an
internal defect. Consult
Genie Industries Service
Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 67

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 29
Steer Right With key switch in With key switch in 12V or Repair open in blu/blk
platform position and platform position and more #37 wire circuit from
Function both Emergency Stop both Emergency Stop drive controller (DP1) to
buttons pulled out to the buttons pulled out to the TP37 then to TB37.
Inoperative ON position, activate 0V ON position, activate
footswitch and steer footswitch and steer
Be sure all other rocker switch on drive rocker switch on drive
functions operate controller (DP1) in right controller (DP1) in right
direction and check direction and check
normally. voltage on TB37. voltage at the controller
terminal with the blu/blk
wire attached.

0V

Repair or replace steer

12V or more microswitch on drive
controller. Consult
Genie Industries Service
Department.

With key switch in Repair open in blu/blk

platform position and 0V #37 wire circuit that runs
both Emergency Stop from TB37 to steer right
buttons pulled out to the directional valve coil on
ON position, activate steer manifold.
footswitch and steer
rocker switch on drive
controller (DP1) in right
direction and check
voltage on blu/blk #37
wire on steer right
directional valve coil
(item SS) on steer
manifold.

12V or more

Disconnect wires to 0 or Replace steer right

steer right directional infinite
valve coil (item SS) on ohms
steer manifold and test
the resistance of the
valve coil.
directional valve coil
(item SS) OR repair
open in brown ground
wire to steer right valve
coil.

5 to 6 ohms

Continued on the next

page.

5 - 68 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 29

Install a 0 to 5000 PSI 2600 Check for mechanical

Continued from the (0 to 345 bar) pressure restrictions keeping
previous page. PSI or
gauge at the quick more steer right function from
disconnect coupling on operating OR repair or
the boom function replace steer cylinder
manifold and activate OR consult Genie
the steer right function. Industries Service
Department.
less than 2600 PSI

Repair or replace steer

cylinder OR steer
manifold could have an
internal defect. Consult
Genie Industries Service
Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 69

Section 5 - Troubleshooting Flow Charts
Chart 30
All Drive With the keyswitch less
turned to platform than
Functions control and both 12V
Emergency Stop buttons
Inoperative, pulled out to the ON
All Other position, activate the
footswitch and check the
Functions voltage at terminal #2 on
the drive joystick (DP1).
Operate
Normally
12V or more
Be sure the rpm toggle
switch is in the
less
footswitch activated With the keyswitch than
high idle position. turned to platform 12V
control and both
Emergency Stop buttons
Be sure the hydraulic pulled out to the ON
tank shut off valves are position, activate the
in the OPEN position. footswitch and check the
voltage at terminal #1 on
the horsepower limiter
Be sure machine is circuit board.
not in the free wheel
configuration.
12V or more
With the drive speed
selector toggle switch
(TS8) in the high
position, activate the 0V
footswitch and hold the
drive joystick in the full
forward position and
check the voltage at
terminal #10 on the
horsepower limiter
board.
9 to 12V
Continued on the next
page.
5 - 70 Genie S-60 & Genie S-65
Service Manual - Second Edition
Check continuity of Repair open in power
brown ground wire from continuity supply circuit from TP24
terminal #3 on DP1 to to terminal #2 on drive
ground. joystick (DP1).
no continuity
Repair open in brown
ground wire circuit from
ground to DP1.
Check continuity of Repair open in power
brown ground wire from continuity supply circuit from TP24
terminal #2 on the to terminal #1 on the
horsepower limiter horsepower limiter
circuit board to ground. circuit board.
no continuity
Repair open in brown
ground wire circuit from
ground to the
horsepower limiter
circuit board.
With the drive speed 7 to 8V Replace horsepower
selector toggle switch limiter board.
(TS8) in the high
position, activate the
footswitch and check the
voltage at terminal #3 on
the horsepower limiter
board.
0V
With the drive speed Repair open in org/blk
selector toggle switch wire from alternator to
(TS8) in the high 7 to 8V TB41 to TP41 to
position, activate the terminal #3 on
footswitch and check the horsepower limiter
voltage on the org/blk board.
wire on the alterator.
0V
Repair or replace
alternator.
Part No. 48412
Service Manual - Second Edition
Activate the footswitch
Continued from the and hold the drive
previous page. 0V
joystick in the full
forward position and
check the voltage at
terminal #6 on the
joystick controller.
9 to 12V
Connect the positve 0V
lead from a voltmeter to
terminal #4 on the
joystick and the negative
lead to terminal #5 on
the joystick. Activate the
footswitch and hold the
drive joystick in the full
forward position and
check the voltage
across the #4 and #5
terminals on the drive
joystick controller.
2V
Connect the positve 0V
lead from a voltmeter to
terminal #5 on the
joystick and the negative
lead to terminal #4 on
the joystick. Activate the
footswitch and hold the
drive joystick in the full
reverse position and
check the voltage
across the #5 and #4
terminals on the drive
joystick controller.
2V
Continued on the next
page.
Part No. 48412 Genie S-60 & Genie S-65
Section 5 - Troubleshooting Flow Charts
CHART 30
Repair open in wire from
terminal #10 on
horsepower limiter
board to terminal #6 on
drive joystick.
no
Check continuity from continuity Repair open in brown
terminal #3 on drive ground wire circuit from
joystick to ground. terminal #3 on drive
joystick to ground.
continuity
Replace drive joystick
controller OR consult
Genie Industries Service
Department.
no
Check continuity from continuity Repair open in brown
terminal #3 on drive ground wire circuit from
joystick to ground. terminal #3 on drive
joystick to ground.
continuity
Replace drive joystick
controller OR consult
Genie Industries Service
Department.
5 - 71
Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 30

Activate the footswitch
Continued from the and hold the drive
previous page. joystick in the full
forward position and 0V
check the voltage
across the wht #12 wire
and the wht/blk #31 wire
on EDC.
With the footswitch
activated and the drive
joystick in the full
forward position, move 2V
the drive enable toggle
switch (TS9) to either
side and check the
voltage across the wht
#12 wire and the wht/blk
#31on EDC.
Repair open in wht wire
from terminal #4 on
drive joystick to TS9 to
TP30 to TB30 through
drive enable limit switch
(LS3) to TB12 to wht
#12 wire on EDC quick
disconnect plug.

0V

With the footswitch 9 to 12V Repair open in blu/wht

activated and the drive wire from TS9 to TP12
joystick in the full to TB12.
forward position, move
the drive enable toggle
switch (TS9) to either
side and check the
voltage at the blu/wht
wire on TS9.

0V
2V
With the footswitch
activated and the drive
joystick in the full 0V
forward position, check
the voltage on the
center terminal of the
drive enable toggle
switch (TS9).
Repair open in wire from
terminal #4 from drive
joystick DP1 OR replace
drive joystick controller
OR consult Genie
Industries Service
Department.

9 to 12V

Replace drive enable

toggle switch TS9.

Troubleshoot drive
forward and drive
reverse functions
separately OR replace
pump OR consult Genie
Industries Service
Department.

5 - 72 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 31
Drive Forward Disconnect the EDC voltage readings different Repair or replace the
wire connector from the drive controller.
Or Reverse drive pump, start
Function engine, move the drive
controller to full forward
Inoperative position and note the
voltage across terminals
TB30 and TB31.
Be sure all other Reverse the volt meter
functions operate leads and move the
normally including drive controller to full
reverse position and
drive in opposite note the voltage.
direction of
malfunction.
voltage readings
the same
0 or
infinite
ohms
Check the resistance of Replace the EDC.
the EDC.

20 to 24 ohms

Adjust the drive pump Defective Sundstrand

null (neutral). Consult no improvement drive pump, contact
Genie Industries Service Sundstrand authorized
Department. repair facility.

symptoms improve

Re-adjust drive joystick

controller OR if problem
still persists, consult
Genie Industries Service
Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 73

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 32
Traction Any type of traction
problem, consult Genie
Function Industries Service
Department.
Inoperative
Be sure all other
functions operate
normally.

5 - 74 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 33
Machine Will With the boom in the Check for correct wiring
stowed position, check continuity of limit switches
Not Drive At continuity from TB40 to (LS1 and LS2) OR
ground. repair or replace boom
Full Speed lift drive limit switch or
boom extend limit
Be sure all other switch.
functions operate no continuity
normally.

Be sure the machine is With the boom in the Repair short to ground
not raised above or stowed position, check in orange wire shorted
terminal #6 on continuity to ground from TB40 to
extended beyond the horsepower limiter TP40 to terminal #6 on
drive limit switches. board for continuity to horsepower limiter
ground. circuit board.
Be sure the boom drive
limit switch is clear of no continuity
any debris and is not
activated when the Re-adjust or replace
horsepower limiter
boom is in the stowed board OR check for
position. misalignment of limit
switches (LS1 and LS2)
Be sure that the boom OR consult Genie
Industries Service
extend drive limit switch Department.
arm is being held down
when the boom is
retracted.
Be sure the wiring to
limit switches is intact
and show no sign of
damage or corrosion.

Be sure the free-wheel

valve is closed on the
drive pump.

Be sure the drive speed

select switch is on high
range (machine on level
surface symbol).

Part No. 48412 Genie S-60 & Genie S-65 5 - 75

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 34
Machine Drives Extend the boom past Replace horsepower
the drive limit switch and limiter board OR re-
At Full Speed check continuity from continuity adjust horsepower
ground to terminal #6 on limiter board OR consult
With Platform the horsepower limiter Genie Industries Service
Raised or board. Department.

Extended no continuity

Be sure boom drive limit Check continuity from continuity Repair open in org wire
switch is being activated ground to TB40. circuit from TB40 to
by the cam on the boom TP40 to terminal #6 on
horsepower limiter
when the boom is circuit board.
raised. no continuity

Be sure that the boom

extend drive limit switch Test limit switches. See Replace defective limit
bad
is not being held down procedure A-14 in the switch contact OR
Maintenance Section. replace limit switch.
or being activated when
the boom is extended.
good
Be sure the wiring to
Repair open from wht
limit switches is intact wires at TB40 to drive
and show no sign of limit switches (LS1 and
damage or corrosion. LS2), then from brown
ground wires to ground.

5 - 76 Genie S-60 & Genie S-65 Part No. 48412