Genie S-60 HC Service Manual
  1. Manuals
  2. Brands
  3. Genie Manuals
  4. Lifting Systems
  5. S-60 HC
  6. Service manual

Genie S-60 HC Service Manual

Hide thumbs Also See for S-60 HC:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
Table of Contents

Advertisement

Quick Links

See also: Operator's Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the S-60 HC and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Genie S-60 HC

Summary of Contents for Genie S-60 HC

  • Page 2: Introduction

    Read, understand and obey the safety rules and Genie offers the following Service Manuals for operating instructions in the Genie S-60 and Genie these models: S-65 Operator's Manual or the Genie S-60 HC Operator's Manual before attempting any Title Part No.

  • Page 3: Revision History

    A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. Part No. 77828 S-60 • S-65 • S-60 HC...
  • Page 4 A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5. 6-35, 6-56, 6-104_Section 6_Schematic Page #. S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 5: Serial Number Legend

    500 Oak Wood Road PO Box 1150 PO Box 1150 Watertown, SD 57201 Watertown, SD 57201 Serial label (located under cover) Serial number tam ed on c a i PN - 77055 Part No. 77828 S-60 • S-65 • S-60 HC...

  • Page 6: Safety Rules

    Failure to obey the instructions and safety rules in use signal words to identify the following: this manual, and the Genie S-60 and Genie S-65 Operator's Manual or the Genie S-60 HC Safety alert symbol—used to alert...
  • Page 7 Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. Part No. 77828 S-60 • S-65 • S-60 HC...

  • Page 8: Table Of Contents

    Perkins 404-22 Engine Specifications ..............2 - 10 Machine Torque Specifications ................2 - 11 Hydraulic Hose and Fitting Torque Specifications ..........2 - 12 SAE and Metric Fasteners Torque Charts ............2 - 13 viii S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 9 A-13 Replace the Drive Hub Oil ................3 - 15 A-14 Perform Engine Maintenance - GM and Ford Models ......... 3 - 16 A-15 Perform Engine Maintenance - Perkins Models .......... 3 - 16 Part No. 77828 S-60 • S-65 • S-60 HC...
  • Page 10 B-24 Perform Engine Maintenance - GM and Ford Models ......... 3 - 37 B-25 Replace the Engine Air Filter Element - GM and Ford models ....3 - 38 B-26 Perform Engine Maintenance - Perkins Models .......... 3 - 38 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 11 Perform Engine Maintenance - Deutz Models ..........3 - 60 Perform Engine Maintenance - Deutz Models ..........3 - 60 Remove and Inspect the Boom Extend/Retract Cables ......3 - 61 Part No. 77828 S-60 • S-65 • S-60 HC...
  • Page 12 Platform Leveling Slave Cylinder ..............4 - 8 Platform Rotator ................... 4 - 9 Platform Overload System, S-60 and S-65 (if equipped) ......4 - 12 Platform Load Sense System, S-60 HC ............. 4 - 14 Jib Boom Components, S-65 Jib Boom ....................4 - 18 Jib Boom Lift Cylinder ................
  • Page 13 7-12 Valve Adjustments, 4WD Traction Manifold ..........4 - 67 7-13 Valve Coils ....................4 - 68 Turntable Rotation Components Turntable Rotation Assembly ..............4 - 70 Axle Components Oscillate Axle Cylinders ................4 - 72 xiii Part No. 77828 S-60 • S-65 • S-60 HC...
  • Page 14 Fault Codes - Control System ................5 - 2 Fault Codes - Ford LRG-425 EFI Engine ..............5 - 6 Fault Codes - Ford DSG-423 EFI Engine ............. 5 - 12 Fault Codes - Platform Load Sense System, S-60 HC ......... 5 - 16 Section 6 Schematics Introduction ......................
  • Page 15 S-60, Ford LRG-425 EFI Models (before serial number 11880) ....6 - 32 Ground Control Box Switch Panel Wiring Diagram, S-60, Ford LRG-425 EFI Models (before serial number 11880) ....6 - 33 Part No. 77828 S-60 • S-65 • S-60 HC...
  • Page 16 S-65, Ford Models (after serial number 11879) ........... 6 - 47 Platform Control Box Terminal Strip Wiring Diagram, S-65, Ford Models ..................6 - 48 Platform Control Box Switch Panel Wiring Diagram, S-65, Ford Models ..................6 - 49 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 17 Platform Control Box Terminal Strip Wiring Diagram, S-60, Deutz F3L-2011 Models ..............6 - 66 Platform Control Box Switch Panel Wiring Diagram, S-60, Deutz F3L-2011 Models ..............6 - 67 xvii Part No. 77828 S-60 • S-65 • S-60 HC...
  • Page 18 S-65, CE Models, Deutz F3L-2011 Models (after serial number 11879) ................. 6 - 82 Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models, Deutz F3L-2011 Models (after serial number 11879) ................. 6 - 83 xviii S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 19 S-65, Perkins 404-22 Models (before serial number 11880) ....... 6 - 100 Ground Control Box Switch Panel Wiring Diagram, S-65, Perkins 404-22 Models (before serial number 11880) ....... 6 - 101 Part No. 77828 S-60 • S-65 • S-60 HC...
  • Page 20 12kW Hydraulic Generator Option Wiring Diagram ..........6 - 107 Hydraulic Schematic, 12kW Hydraulic Generator Option ........6 - 108 Hydraulic Schematic, 2WD Models ..............6 - 109 Hydraulic Schematic, 4WD Models ..............6 - 110 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 21: Specifications

    (Hi-flotation tires) 4.13 bar For operational specifications, refer to the Operator's Manual. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 77828 S-60 • S-65 • S-60 HC 2 - 1...

  • Page 22: Performance Specifications

    40 ft / 40 sec 12.2 m / 40 sec Gradeability See Operator's Manual Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 2 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 23: Hydraulic Specifications

    Charge pump Chevron Rando HD MV oil is fully compatible and Type: gerotor mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are Displacement 0.85 cu in designed to give maximum protection to hydraulic 13.9 cc...

  • Page 24: Manifold Component Specifications

    Hydraulic return filter 10 micron with 25 psi / 1.7 bar bypass Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 25 For oil requirements, refer to the 12 mm Engine Operator Handbook on your machine. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 77828 S-60 • S-65 • S-60 HC 2 - 5...

  • Page 26: Ford Lrg-425 Efi Engine Specifications

    Cold cranking ampere @ 0°F 1000A Reserve capacity @ 25A rate 200 minutes Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 6 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 27: Ford Dsg-423 Efi Engine Specifications

    Cold cranking ampere @ 0°F 1000A Reserve capacity @ 25A rate 200 minutes Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 77828 S-60 • S-65 • S-60 HC 2 - 7...

  • Page 28: Deutz F3L-2011 Engine Specifications

    0.72 in 18.5 mm Brush length, minimum 0.27 in 7 mm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 8 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 29 33 x 17.3 x 23.8 cm Quantity Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes Alternator output 60A @ 14V DC Fan belt deflection inch 9 to 12 mm Part No. 77828 S-60 • S-65 • S-60 HC 2 - 9...

  • Page 30: Perkins 404-22 Engine Specifications

    0.7480 in 19 mm Brush length, minimum 0.5 in 12.7 mm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 10 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 31: Machine Torque Specifications

    Turntable rotation assembly Backlash pivot plate, lubricated 320 ft-lbs 433 Nm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 77828 S-60 • S-65 • S-60 HC 2 - 11...

  • Page 32: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok ® The O-ring cannot be re-used if the fitting or fittings and hose ends. Genie specifications require hose end has been tightened beyond finger that fittings and hose ends be torqued to tight.
  • Page 33 53.2 72.2 46.7 63.3 62.3 84.4 18.9 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 Part No. 77828 S-60 • S-65 • S-60 HC 2 - 13...
  • Page 34 Section 2 • Specifications February 2012 This page intentionally left blank. 2 - 14 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 35: Scheduled Maintenance Procedures

    • Turntable secured with the turntable rotation lock • Key switch in the off position with the key removed • Wheels chocked • All external AC power disconnected from the machine Part No. 77828 S-60 • S-65 • S-60 HC 3 - 1...
  • Page 36 Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements. 3 - 2 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 37: Pre-Delivery Preparation

    500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D...
  • Page 38 Section 3 • Scheduled Maintenance Procedures February 2012 This page intentionally left blank. 3 - 4 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 39: Maintenance Inspection Report

    “R” box. GM and Ford models B-26 Engine maintenance - Legend Perkins models Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 77828 S-60 • S-65 • S-60 HC 3 - 5...
  • Page 40 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 3 - 6 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 41: Checklist A Procedures

    In addition, maintaining all of the safety and container after use. instructional decals in good condition is mandatory Note: Contact your authorized Genie distributor or for safe machine operation. Decals alert operators Genie if replacement manuals or decals are and personnel to the many possible hazards needed.

  • Page 42: Perform Pre-Operation Inspection

    Operator's Manual on your machine. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. 3 - 8 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 43: Perform Engine Maintenance

    Ford LRG 425 EFI Operator Handbook Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Perkins 400 Series Operation Manual Genie part number 94890 Part No. 77828 S-60 • S-65 • S-60 HC 3 - 9...

  • Page 44: Test The Oscillate Axle (If Equipped)

    Result: The non-steer tires should stay in firm contact with the ground. Note: If the chassis does not remain level during test, refer to Repair Procedure 7-6, How to Set Up the Oscillate Directional Valve. 3 - 10 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 45: Inspect The Engine Air Filter - Gm Models

    Note: Be sure the discharge valve is pointing down Ford DSG 423 EFI Operator Handbook when the cap is instaled. Genie part number 119488 Perkins 400 Series Operation Manual Genie part number 94890 Part No. 77828 S-60 • S-65 • S-60 HC 3 - 11...

  • Page 46: Inspect The Fuel Filter/Water Separator - Diesel Models

    See C-6, Replace The Fuel Filter/Water Separator hydraulic return filter on the bulkhead. Element - Perkins Models, for instructions on how to prime the fuel filter/water separator. 3 - 12 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 47 Repair the leak immediately. 8 Swing the engine back to its original position and install the engine pivot plate retaining fastener. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 13...

  • Page 48: Check And Adjust The Engine Rpm - Perkins Models

    Tighten the yoke lock nut and recheck the rpm. Note: Be sure the solenoid fully retracts when activating high idle. 3 - 14 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 49: Grease The Turntable Rotation Bearing And Rotate Gear

    Refer to Section 2, Specifications. 5 Install the plugs into the drive hub. 6 Repeat this procedure for the other drive hub. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 15...

  • Page 50: Perform Engine Maintenance - Gm And Ford Models

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 16 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 51: Checklist B Procedures

    Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. 3 Be sure that the battery hold downs and cable connections are tight. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 17...

  • Page 52: Inspect The Electrical Wiring

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 18 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 53: Check The Exhaust System

    5 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints. 6 Swing the engine back to its original position and install the engine tray retaining fastener. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 19...

  • Page 54: Inspect The Engine Air Filter - Ford, Deutz And Perkins Models

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 20 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 55: Inspect The Tires, Wheels And Lug Nut Torque

    Refer to Section 2, Specifications . 10 Install the engine side cover. 11 Swing the engine back to its original position and install the engine pivot plate retaining fastener. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 21...

  • Page 56: Confirm The Proper Brake Configuration

    4 Install the plug(s) into the drive hub. 5 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications . 6 Repeat this procedure for each drive hub. 3 - 22 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 57 3 Apply pipe thread sealant to the plug, and install the plug in the drive hub. 4 Check the torque of the turntable drive hub mounting fasteners. Refer to Section 2, Specifications . Part No. 77828 S-60 • S-65 • S-60 HC 3 - 23...

  • Page 58: Check And Adjust The Engine Rpm - Ford And Deutz Models

    Note: The engine rpm is controlled by the ECM and can only be adjusted by re-programming the ECM. If rpm adjustment or service is required, please contact Genie Service Department OR your local Ford dealer. Deutz models: Note: This procedure will require two people.

  • Page 59: Test The Ground Control Override

    2 Start the engine from the ground controls. 3 At the ground controls, operate each boom function through a partial cycle. Result: All boom functions should operate. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 25...

  • Page 60: Check The Oscillate Directional Valve Linkage

    3 Raise and lower the primary boom through a full cycle. • Linkage is properly attached to directional valve Result: The platform should remain level at all times to within ±5 degrees. 3 - 26 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 61: Test The Engine Idle Select

    7 Move the engine idle control switch to foot on position at both the ground and platform switch activated low idle (turtle symbol). controls. Result: The engine should change to low idle. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 27...

  • Page 62: Test The Fuel Select Operation - Gm And Ford Models

    3 Press down the foot switch to allow the engine to run at high idle. Result: The engine should start promptly and operate smoothly in low and high idle. 3 - 28 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 63: Test The Drive Brakes

    2 Start the engine from the platform controls. 3 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol), then lower the boom into the stowed position. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 29...

  • Page 64: Test The Drive Speed - Stowed Position

    6 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Specifications. 3 - 30 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 65: Test The Alarm Package - Optional Equipment

    Result: The descent alarm should sound when the switch is held down. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 31...

  • Page 66: Perform Hydraulic Oil Analysis

    Result: The travel alarm should sound when the drive control handle is moved off center in either direction. 3 - 32 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 67: Inspect The Fuel And Hydraulic Tank Cap Venting Systems

    4 Install the fuel tank cap onto the fuel tank. 5 Remove the breather cap from the hydraulic tank. Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever 6 Check for proper venting. comes first. Perform this procedure more often if Result: Air passes through the fuel tank cap.

  • Page 68: Replace The Fuel Filter Element - Perkins Models

    Crushing hazard. Failure to install oil filter housing. the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 34 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 69: Inspect The Boom Extend/Retract Cables

    13 Operate the starter motor for intervals of 15 retaining fasteners and remove the cover. seconds until the engine starts. S-60 HC: Remove the boom end cover from the 14 Swing the engine back to its original position pivot end of the boom while guiding the small...
  • Page 70 Remove the S-60 HC: Install the boom end cover at the pivot covers. end of the boom while guiding the small cable...

  • Page 71: Perform Engine Maintenance - Deutz Models

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 37...

  • Page 72: Replace The Engine Air Filter Element - Gm And Ford Models

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. 3 - 38 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 73: Checklist C Procedures

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 39...

  • Page 74: Test The Platform Overload System, S-60 And S-65 (If Equipped)

    3 Determine the maximum platform capacity. power, and an audio/visual warning indication to Refer to the machine serial plate. alert the operator of the overload. 3 - 40 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 75 How to Calibrate the Platform Overload System, S-60 and S-65 (if equipped). Note: There may be a 2 second delay before the overload indicator lights flash and the alarm sounds. Illustration 1 Part No. 77828 S-60 • S-65 • S-60 HC 3 - 41...
  • Page 76 14 Start the engine and test all machine functions from the ground controls. Result: All ground control functions should operate normally. 15 Turn the key switch to platform control. 3 - 42 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 77: Test The Platform Load Sense System, S60 Hc

    2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 43...
  • Page 78 544.3 or less before the engine can be restarted. button to the off position, then pull out the red Emergency Stop button to the on position to reset the system. 3 - 44 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 79: Replace The Fuel Filter/Water Separator Element - Perkins Models

    8 Apply a thin layer of oil onto the element gasket. Install the filter/bowl assembly onto the filter head. Tighten the drain plug and vent plug. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 45...
  • Page 80 14 Loosen the vent plug on top of the fuel injection pump. vent plug fuel injection pump fuel lift pump 3 - 46 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 81: Replace The Engine Air Filter Element - Deutz And Perkins Models

    4 Clean the inside of the canister and the end cap with a damp cloth. 5 Install the new filter element. 6 Install the air filter canister end cap and secure the end cap latches. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 47...

  • Page 82: Perform Engine Maintenance - Gm And Ford Models

    GM 3.0L Operator Handbook Genie part number 101095 Ford LRG 425 EFI Operator Handbook Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 3 - 48 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 83: Checklist D Procedures

    3 Measure each wear pad. Replace the wear pad once it reaches the minimum allowable thickness. If the wear pad is still within specification, shim as necessary to obtain minimum clearance with zero binding. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 49...

  • Page 84: Check The Turntable Rotation Bearing Bolts

    (Genie part number 75097). 2 Turn the engine off. 3 Be sure that each turntable mounting bolt is torqued in sequence to specifications. Refer to Section 2, Specifications. Bolt torque sequence 3 - 50 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 85: Inspect For Turntable Bearing Wear

    0.063 inch / 1.6 mm. The bearing is good. Result: The measurement is more than 0.063 inch / 1.6 mm. The bearing is worn and needs to be replaced. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 51...

  • Page 86: Replace The Drive Hub Oil

    5 Install the plugs into the drive hub. 6 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications . 7 Repeat this procedure for each drive hub. 3 - 52 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 87: Check The Free-Wheel Configuration

    3 Lift the wheels off the ground and then place jack stands under the drive chassis for support. 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 53...

  • Page 88: Replace The Hydraulic Filters

    12 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel to Note: Genie requires that this procedure be check for engagement. Raise the machine, remove the jack stands and lower the machine. performed every 1000 hours or annually, whichever comes first.
  • Page 89 12 Remove the filter housings by using a wrench on the nut provided on the bottom of the housings. 13 Remove the filter elements from the housings. 14 Inspect the housing seals and replace them if necessary. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 55...

  • Page 90: Check And Adjust The Air/Lpg Mixture - Gm Models

    3 Loosen the lock nut on the high idle mixture adjustment screw. 4 Load the system by activating the primary boom retract function, then move the function enable toggle switch to the high idle (rabbit symbol) position. 3 - 56 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 91: Perform Engine Maintenance - Deutz Models

    Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 57...

  • Page 92: Checklist E Procedures

    LPG tank. 2 GM and Ford models: Open the clamps from the LPG tank straps and remove the LPG tank Note: Genie requires that this procedure be from the machine (if equipped). performed every 2000 hours or every two years, 3 Models with hydraulic tank shut-off valves: whichever comes first.
  • Page 93 15 Rinse out the inside of the tank using a mild solvent. 16 Install the suction strainers using a thread sealant on the threads. 17 Install the drain plug using a thread sealant on the threads. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 59...

  • Page 94: E-2 Perform Engine Maintenance - Deutz Models

    3 - 60 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 95 1 Replace the boom extend/retract cables. See Repair Procedure 4-5, How to Adjust the Boom Extend/Retract Cables. Part No. 77828 S-60 • S-65 • S-60 HC 3 - 61...
  • Page 96 Section 3 • Scheduled Maintenance Procedures February 2012 This page intentionally left blank. 3 - 62 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 97 • Turntable secured with the turntable rotation lock • Key switch in the off position with the key removed • Wheels chocked • All external AC power disconnected from the machine Part No. 77828 S-60 • S-65 • S-60 HC 4 - 1...

  • Page 98: Platform Controls

    Remove all rings, watches and other jewelry. ALC-500 circuit board drive/steer joystick controller boom extend/retract joystick controller primary boom up/down and turntable rotate left/right joystick controller 4 - 2 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 99: Joysticks

    8 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch. Note: No machine function should operate while performing the joystick calibration procedure. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 3...
  • Page 100 8 Start the engine from the platform controls and press down the foot switch. 9 Select a boom function joystick to set the threshold. 4 - 4 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 101 14 Cycle the red Emergency Stop button off, then Result: There should be a pause and the alarm back on. should sound 4 times indicating that the machine is in max-out calibration mode. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 5...
  • Page 102 Note: Do not operate any machine function during Result: The alarm does not sound. Repeat steps the 10 second waiting time. 3 through 7. 15 Cycle the red Emergency Stop button off, then back on. 4 - 6 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 103 0.5 second decelerate, coasting 0.75 second decelerate, braking 1 second decelerate, shift from low to high speed 1 second decelerate, shift from high to low speed 4 seconds Part No. 77828 S-60 • S-65 • S-60 HC 4 - 7...

  • Page 104: Platform Components

    Note: Do not rest the entire weight of the boom on 2 Simultaneously activate the boom down function the blocks. and the platform level down function until the boom is fully lowered. 4 - 8 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 105: Platform Rotator

    Protect the cylinder rod from 1 Remove the platform and platform support. damage. Note: S-60 HC: If the load sense components are disassembled and/or removed from the platform support, the platform load sense system will need to be calibrated. See 2-4, How to Calibrate the Platform Load Sense System, S-60 HC.
  • Page 106 Note: When installing the platform rotator fasteners, torque the fasteners to specifications. top bleed valve bottom bleed valve container clear hose 4 - 10 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 107 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 11...

  • Page 108: Platform Overload System, S-60 And S-65 (If Equipped)

    Note: The platform will need to be moved up and down and allowed to settle between each Note: For S-60 HC models, refer to Repair adjustment. Procedure 2-4, Platform Load Sense System, S-60...
  • Page 109 9 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 10 Turn the key switch to ground control. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 13...

  • Page 110: Platform Load Sense System, S-60 Hc

    Result: The alarm should sound a tone for result in the machine tipping over. 1 second. 3 Push in the red Emergency Stop button to the off position. 4 - 14 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 111 Safety Control Module LED Status Description Definition Green and red LEDs not f lashing System is calibrated Green and red LEDs f lashing alternately System is not calibrated Part No. 77828 S-60 • S-65 • S-60 HC 4 - 15...
  • Page 112 OR the weights of those options or accessories must be subtracted from the test weights to accurately calibrate the platform load sense system. 4 - 16 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 113 19 Visually inspect the LEDs on the controllers. Result: All LEDs on both controllers should be off indicating the platform load sense system is calibrated. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 17...

  • Page 114: Jib Boom Components

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 18 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 115: Jib Boom Lift Cylinder

    Do not allow oil to squirt or spray. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 19...

  • Page 116: Boom Components

    Remove the outlet box and 10 Remove the retaining fasteners from the lay it to the side. electrical connector receptacles for the cables that enter the cable track. 4 - 20 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 117 16 Remove the cotter pin from the cable track pull tube at the platform end of the boom. Note: Always replace the cotter pin with a new one. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 21...
  • Page 118 11 Tag and disconnect the electrical connectors for all cables that enter the cable track. 12 Remove the retaining fasteners from the electrical connector receptacles for the cables that enter the cable track. 4 - 22 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 119 Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 23...
  • Page 120 Note: A cable track repair kit is available through 9 Operate the boom extend/retract function the Genie Parts Department, part no. 77896. The through a full cycle to ensure smooth operation kit includes a 4 link section of cable track.
  • Page 121 Part No. 77828 S-60 • S-65 • S-60 HC 4 - 25...

  • Page 122: Boom

    4 x 4 x 60 inches / 10 x 10 x 152 cm under the Crushing hazard. The boom lift long link arm, across the turntable covers. cylinder could fall if not properly supported and secured to the lifting device. 4 - 26 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 123 18 Support the platform leveling master cylinder. S-60 HC: Remove the boom end cover from the Remove the master cylinder rod-end pivot pin pivot end of the boom while guiding the small retaining fasteners.

  • Page 124: Boom Lift Cylinder

    10 Carefully remove the boom lift cylinder from the machine. Crushing hazard. The boom lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device. 4 - 28 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 125: Boom Extension Cylinder

    2 S-60 and S-65: Remove the boom end cover retaining fasteners and remove the cover. Boom Extension Cylinder S-60 HC: Remove the boom end cover from the pivot end of the boom while guiding the small The boom extension cylinder is located inside the...
  • Page 126 Lay the cables flat and out of the way. extend cable lock nuts extend cable mounting plate extend cable mounting plate fastener extend cable bracket 4 - 30 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 127 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 31...

  • Page 128: Boom Extend/Retract Cables

    Note:Be sure to not fully extend the boom. Stop S-60 HC: Remove the boom end cover from the when there is approximately 3 feet / 1 m of pivot end of the boom while guiding the small travel left.
  • Page 129 9 Install the boom extend cables to the lower extend cable bracket that mounts to the number 3 boom tube. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 33...
  • Page 130 1 boom tube, wrap the boom retract cables around the pulleys. Note: A cable pulling tool is available through Genie Parts Department (Genie part no. 94510) 25 Adjust the boom extend/retract cables. See 4-5, How to Adjust the Boom Extend/ 15 At the platform end of the boom, pull on the Retract Cables.

  • Page 131: Platform Leveling Master Cylinder

    3 Place a 2 x 4 x 48 inches / 5 x 10 x 120 cm block of wood across the turntable covers. Position the block under the master cylinder. 4 Remove the pin retaining fastener from the master cylinder rod-end pivot pin. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 35...

  • Page 132: Rpm Adjustment - Ford And Deutz Models

    Refer to Maintenance Procedure A-11, Check and engine flywheel. Adjust the Engine RPM - Perkins Models. Type "A" Type "B" (flexplate with (flexplate with separate coupler) coupler combined) 4 - 36 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 133 Component damage hazard. Hoses can be damaged if they are kinked or pinched. 11 Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 37...
  • Page 134 Component damage hazard. Hoses can be damaged if they are kinked or pinched. 14 Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel. 4 - 38 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 135 Perkins models: Torque the flex plate mounting GM models bolts in sequence to 49 ft-lbs / 66 Nm. Then torque the flex plate mounting bolts in sequence to 70 ft-lbs / 95 Nm. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 39...
  • Page 136 4 Apply a high viscosity coupling grease 0.080 inch / 2 mm gap - Ford DSG-423 inch / 3.8 mm gap - GM Models (Genie part number 128025) to the splines of the pump shaft and flex plate. ® 4 Apply Loctite removable thread sealant to the pump coupler set screw.
  • Page 137 Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. Perkins models Part No. 77828 S-60 • S-65 • S-60 HC 4 - 41...
  • Page 138 Section 4 • Repair Procedures February 2012 ENGINES Ford LRG-425 EFI models Perkins models Ford DSG-423 EFI models GM models Deutz models 4 - 42 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 139: Engine Fault Codes - Gm And Ford Models

    Refer to Section 5, How to Retrieve Engine Fault Codes for your specific model of engine. Use the Fault Code Chart within Section 5 to aid in identifying the fault. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 43...

  • Page 140: Hydraulic Pumps

    If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. open closed 4 - 44 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 141: Drive Pump

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 45...
  • Page 142 Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump. manual fuel shutoff valve 4 - 46 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 143 Perkins models: Connect the engine wiring harness to the fuel solenoid. Deutz models: Release the manual fuel shutoff valve. 7 Start the engine from the ground controls and check for hydraulic leaks. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 47...
  • Page 144 Section 4 • Repair Procedures February 2012 This page intentionally left blank. 4 - 48 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 145: Function Manifold Components

    110 psi / 7.6 bar ......... S ... Boom up/down circuit ....... 30-35 ft-lbs / 41-47 Nm Differential sensing valve, 150 psi / 10.3 bar ......P ... Turntable rotate circuit ...... 30-35 ft-lbs / 41-47 Nm This list continues. Please turn the page Part No. 77828 S-60 • S-65 • S-60 HC 4 - 49...
  • Page 146 Section 4 • Repair Procedures February 2012 MANIFOLDS 4 - 50 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 147 Solenoid valve, 3 position 4 way ..V ... Platform level up/down ..... 20-25 ft-lbs / 27-34 Nm Solenoid valve, 3 position 4 way ..Y ... Platform rotate and jib boom up/down (S-65) ......... 20-25 ft-lbs / 27-34 Nm Part No. 77828 S-60 • S-65 • S-60 HC 4 - 51...
  • Page 148 Section 4 • Repair Procedures February 2012 MANIFOLDS 4 - 52 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 149: Valve Adjustments - Function Manifold

    Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 53...

  • Page 150: Jib Boom / Platform Rotate Manifold Components

    Jib Boom / Platform Rotate Manifold Components Index Schematic Description Item Function Torque Solenoid valve, 2 position 3 way ..FF ..Platform rotate/jib boom select ..20-25 ft-lbs / 27-34 Nm 4 - 54 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 151: Brake/Two-Speed Manifold Components

    Solenoid valve, 2 position 3 way ..LL ... Two-speed motor shift ..... 20-25 ft-lbs / 27-34 Nm Check valve ........II .... Brake release circuit ......20-25 ft-lbs / 27-34 Nm Part No. 77828 S-60 • S-65 • S-60 HC 4 - 55...

  • Page 152: Turntable Rotation Manifold Components

    Shuttle valve, 2 position 3 way ..OO ... Turntable rotation brake release ..10-13 ft-lbs / 14-18 Nm Orifice, 0.030 inch / 0.76 mm ..PP ... Brake release circuit (located inside port) 4 - 56 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 153: Oscillate Directional Valve Components

    The oscillate directional valve is mounted inside the drive chassis at the non-steer end. Index Description Function Torque Cap ..............Breather ..........20-25 ft-lbs / 27-33 Nm Spool valve ............Directional control Part No. 77828 S-60 • S-65 • S-60 HC 4 - 57...
  • Page 154 Note: The tires on some machines are foam-filled ground and drive chassis level, repeat steps 6 and do not need air added to them. through 11 OR consult the Genie Service Department. 4 Remove the drive chassis cover and the non- steer axle covers.

  • Page 155: Valve Adjustments - Oscillate Relief Valve

    10 Turn the engine off, remove the pressure gauge and assemble the directional valve linkage. 11 Install the cover on the non-steer end of the drive chassis. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 59...

  • Page 156: Drive Oil Diverter Manifold Components (Welder Option)

    Relief valve ........CX ... Charge pressure circuit ....35-40 ft-lbs / 47-54 Nm Check valve ........CY ... Prevents oil to generator ....35-40 ft-lbs / 47-54 Nm 4 - 60 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 157: Traction Manifold Components, 2Wd

    ......50-55 ft-lbs / 68-75 Nm Orifice, 0.070 inch / 1.78 mm .... VV ..Drive motor circuit Part No. 77828 S-60 • S-65 • S-60 HC 4 - 61...
  • Page 158 Section 4 • Repair Procedures February 2012 MANIFOLDS 4 - 62 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 159: Valve Adjustments, 2Wd Traction Manifold

    Note the reading on the pressure gauge. Turn the machine off. 8 Hold the charge pressure relief valve and remove the cap (item TT). Part No. 77828 S-60 • S-65 • S-60 HC 4 - 63...
  • Page 160 Section 4 • Repair Procedures February 2012 MANIFOLDS This page intentionally left blank. 4 - 64 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 161: Traction Manifold Components, 4Wd

    ........80-90 ft-lbs / 108-122 Nm Relief valve, 280 psi / 19.3 bar ..UU ..Charge pressure circuit ....35-40 ft-lbs / 14-16 Nm Part No. 77828 S-60 • S-65 • S-60 HC 4 - 65...
  • Page 162 Section 4 • Repair Procedures February 2012 MANIFOLDS 4 - 66 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 163: Valve Adjustments, 4Wd Traction Manifold

    Note the reading on the pressure gauge. Turn the machine off. 8 Hold the charge pressure relief valve and remove the cap (item UU). Part No. 77828 S-60 • S-65 • S-60 HC 4 - 67...

  • Page 164: Valve Coils

    2 Test the coil resistance. Result: The resistance should be within specification, plus or minus 30%. Result: If the resistance is not within specification, plus or minus 30%, replace the coil. 4 - 68 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 165 Section 4 • Repair Procedures MANIFOLDS How to Test a Coil Diode AMMETER Genie incorporates spike suppressing diodes in all COIL of its directional valve coils except proportional valves and those coils with a metal case. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes.

  • Page 166: Turntable Rotation Components

    Crushing hazard. The turntable rotation drive hub assembly could become unbalanced and fall when removed from the machine if not properly supported. 4 - 70 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 167 Refer to Section 2, Specifications . 8 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary. Part No. 77828 S-60 • S-65 • S-60 HC 4 - 71...

  • Page 168: Oscillate Axle Cylinders

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 72 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 169 Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie S-60 and S-65 Operator’s Manual or the Genie S-60 HC Operator's Manual on your machine. Observe and Obey: Be sure that all necessary tools and test equipment are available and ready for use.
  • Page 170 OR use a grounded wrist strap. 5 - 2 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 171 Boom 2 directional Valve is operating Cycle power off, valves outside of operational then on and Fault limits. Alarm sounds problem should be indicating fault. corrected. Continued on next page Part No. 77828 S-60 • S-65 • S-60 HC 5 - 3...
  • Page 172 Self-clearing. Just calibrated is zero. (transient) Drive enable Drive enable function Cycle power off, toggle switch is inoperative. then on and Fault problem should be corrected. 5 - 4 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 173 Just calibrated of alarm. (transient) Steer directional Limited speed and valves direction frozen at Power up Fault zero and neutral. controller with Alarm sounds problem corrected. indicating fault. Part No. 77828 S-60 • S-65 • S-60 HC 5 - 5...
  • Page 174 The check engine light should begin to blink. circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. 5 - 6 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 175 Repair short in engine wire harness Adaptive Learn Low short to 5V DC or 12V DC OR fuel system OR test and repair the fuel system (LPG) components may be faulty. components. Part No. 77828 S-60 • S-65 • S-60 HC 5 - 7...
  • Page 176 OR replace sensor. Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor Camshaft Sensor Loss system ground connection OR sensor is faulty. 5 - 8 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 177 Repair VBAT power or ground circuit to ECM and MegaJector Voltage for 5 seconds anytime the engine is cranking or MegaJector OR replace battery OR repair Supply Low running. charging system OR replace the MegaJector. Part No. 77828 S-60 • S-65 • S-60 HC 5 - 9...
  • Page 178 Repair wiring and/or connections in engine Governor Interlock Failure or shorted OR there is a poor system ground harness OR replace the ECM. connection OR ECM is faulty. 5 - 10 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 179 Locate and repair any engine harness wiring Loose wire connections to ECM OR ECM is faulty. damage or shorts to ECM to be sure they are secure OR replace ECM. RTI3 Loss Part No. 77828 S-60 • S-65 • S-60 HC 5 - 11...
  • Page 180 The check engine light should begin to blink. circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. 5 - 12 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 181 AUX analog PUD3 low AUX DIG1 high AUX DIG1 low AUX DIG2 high AUX DIG2 low AUX DIG3 high AUX DIG3 low IAT (intake air temperature) high voltage Part No. 77828 S-60 • S-65 • S-60 HC 5 - 13...
  • Page 182 Primary coil shorted 2 Primary loop open OR low-side short to ground 3 Primary coil shorted 3 Primary loop open OR low-side short to ground 4 Primary coil shorted 4 5 - 14 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 183 PWM4 open / ground short Genie part number 119494. PWM4 short to power Ford DSG 423 EFI Operator Handbook PWM5 open / ground short Genie part number 119488 Part No. 77828 S-60 • S-65 • S-60 HC 5 - 15...
  • Page 184 0.5 second. green LED (operational control module) red LED (operational control module) operational control module safety control module red LED (safety control module) green LED (safety control module) 5 - 16 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 185 Boom up/down and extend/retract Repair system wiring and/or Output short low inoperative. Relay wiring connections. open or shorted to ground. Part No. 77828 S-60 • S-65 • S-60 HC 5 - 17...
  • Page 186 Boom range of motion is Calibrate the platform load sense Not calibrated limited. system. Just calibrated used to clear diagnostic Self-clearing. 5 - 18 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 187 Used to clear diagnostic Just calibrated Self-clearing. codes. Checks operational and Repair wiring and/or connections Inconsistent safety sensor values OR replace string potentiometer against each other. and calibrate overload system. Part No. 77828 S-60 • S-65 • S-60 HC 5 - 19...
  • Page 188 Boom range of motion is Calibrate the platform load sense Not calibrated limited. system. Used to clear diagnostic Just calibrated Self-clearing. codes. 5 - 20 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 189 Used to clear diagnostic Just calibrated Self-clearing. codes. Checks operational and Repair wiring and/or connections Inconsistent safety sensor values OR replace boom angle sensor against each other. and calibrate overload system. Part No. 77828 S-60 • S-65 • S-60 HC 5 - 21...
  • Page 190 Boom range of motion is Calibrate the platform load sense Not calibrated limited. system. Used to clear diagnostic Just calibrated Self-clearing. codes. 5 - 22 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 191 Used to clear diagnostic Just calibrated Self-clearing. codes. Checks operational and Repair wiring and/or connections Inconsistent safety sensor values OR replace platform load cell against each other. and calibrate overload system. Part No. 77828 S-60 • S-65 • S-60 HC 5 - 23...
  • Page 192 Section 5 • Fault Codes February 2012 This page intentionally left blank. 5 - 24 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 193 Be sure that all necessary tools and test Identify Malfunction Troubleshoot equipment are available and ready for use. discovered symptoms problem still exists Return to Inspect Perform service and test repair problem solved Part No. 77828 S-60 • S-65 • S-60 HC 6 - 1...

  • Page 194: Electrical Symbols Legend

    Key switch N.O. (after serial number 22050) Circuit breaker with amperage Fuel or RPM Control relay contact solenoid normally open Starting aid: glow plug or flame ignitor Coil 6 - 2 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 195: Hydraulic Symbols Legend

    2 position, 2 way solenoid valve Pump prime mover (engine or motor) Differential sensing valve Directional valve pilot operated 2 position, 2 way Double acting cylinder Solenoid operated proportional valve Part No. 77828 S-60 • S-65 • S-60 HC 6 - 3...

  • Page 196: Ford Engine Relay Layout

    Relay F2-5A F1-30A Starter Fuel Pump Relay Relay Ford DSG-423 EFI (after serial number 14053) Starter Empty Relay F1-10A F2-5A Fuel Power Pump F3-10A F4-15A Relay Relay F5-15A 6 - 4 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 197: Limit Switch Location Legend

    Limit Switch Location Legend Boom Extend Boom Speed Limit Switch Reduction (LS2) Limit Switch (LS17) Cable Tension Limit Switch (LS5) Drive Enable Boom Angle Limit Switch Limit Switch (LS3) (LS1) Part No. 77828 S-60 • S-65 • S-60 HC 6 - 5...
  • Page 198 Section 6 • Schematics February 2012 6 - 6 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 199: Electrical Schematic, S-60 Hc (From Serial Number 12800)

    Section 6 • Schematics February 2012 Electrical Schematic, S-60 HC (from serial number 12800)
  • Page 200 LOAD SENSE CUTOUT GROUND CUTOUT PLATFORM TB134 C133PLA GR/BK C2PBD RD/BK B00M ANGLE SENSOR NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. SWING/ LOWER LINK 6 - 7 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 201: Chassis Wiring Diagram, S-60 Hc (From Serial Number 12800)

    C169ENV GR C46-4 C45-1 P63SEN OR/RD C53-6 C183RCV BL C46-5 P23BAT WH C46-6 C45-3 P109SEN GR/WH C41-8 C45-4 P109PSL GR/WH C45-2 P63PSL OR/RD 10 11 FUNCTION MANIFOLD CONNECTS TO PC Part No. 77828 S-60 • S-65 • S-60 HC 6 - 8...
  • Page 202 February 2012 Section 6 • Schematics Chassis Wiring Diagram, S-60 HC (from serial number 12800)

  • Page 203: Ground Control Box Terminal Strip Wiring Diagram, S-60 Hc (From Serial Number 12800)

    Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60 HC (from serial number 12800)

  • Page 204: Ground Control Box Terminal Strip Wiring Diagram

    Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60 HC (from serial number 12800) TS49 ENGINE HARNESS RECOVERY FUNCTION SWITCH HARNESS CE ONLY R134BAT RD H6 BL/WH-132B CR54-30 BK-22D2 GR/BK-133B C133LDS GR/BK-L45 C11-2 BK C7B-1...
  • Page 205 February 2012 Section 6 • Schematics Platform Control Box Wiring Diagram, S-60 HC (from serial number 12800) PLATFORM CONTROL BOX P23BAT WH E-STOP CONNECTOR C4 C183RCV BL CR59 C169ENV GR L50 C134PWR RD E-STOP PLATFORM CONTROL HARNESS (TO CONTROL BOX)
  • Page 206 February 2012 Section 6 • Schematics Platform Control Box Wiring Diagram, S-60 HC (from serial number 12800)
  • Page 207 Section 6 • Schematics February 2012 GM 3.0L Engine Wire Harness...
  • Page 208 THROTTLE PINK/DK GREEN 16 PINK/DK GREEN 16 PINK/DK GREEN 16 PINK/WHITE 18 TAN/ORANGE 18 RED/TAN 14 POWER RELAY WHITE/BLUE 18 THESE CONNECTORS ARE CONNECTED TO GENIE HARNESS #88833 6 - 11 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 209 361A R 16 77 DB-Y 18 PLUG (RELAY POWER) 459 O-LG 18 PLUG (CAN -) 361A R 16 361A R 16 662 DG-P 18 PLUG (CAN +) WPTWR2_GY MTRTWR4 MTRSHD4 Part No. 77828 S-60 • S-65 • S-60 HC 6 - 12...
  • Page 210 February 2012 Section 6 • Schematics Ford LRG-425 EFI Engine Wire Harness...
  • Page 211 POWER POWER RELAY ALTERNATOR R/Y 18 INJECTOR CYL #1 R 16 CONNECTOR R 16 R 16 R 16 R 16 R 16 R 16 R/T 18 RELAYED POWER Part No. 77828 S-60 • S-65 • S-60 HC 6 - 13...
  • Page 212 February 2012 Section 6 • Schematics Ford DSG-423 EFI Engine Wire Harness...

  • Page 213: Electrical Schematic, S-60 Gm 3.0L Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-60 GM 3.0L Models...
  • Page 214 TB45 TB27 P134PWR TB39 P134PWR TB35 TB24 TB21 CR23 CR23 ALTERNATOR TS64 FUSE LINK BAT. GND. CR17 87a 87 STA. FUEL FLD. PUMP REGULATOR 12V DC STARTER PUMP 6 - 14 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 215 TB18 TB14 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 15...
  • Page 216 February 2012 Section 6 • Schematics Electrical Schematic, S-60 GM 3.0L Models...

  • Page 217: Ground Control Box Terminal Strip Wiring Diagram

    Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60 GM 3.0L Models...
  • Page 218 WH C11-2 WH LS2 C10-2 BRN-GND BRN-TS64 BRN C7B-3 F.H. F.H. F.H. F.H. R43DLITE1 RD R43DLITE2 RD BK-22C1 BK C5-5 BK-33D BK-33D RD-24C NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 16 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 219: Ground Control Box Switch Panel Wiring Diagram

    PLATFORM LEVEL TOGGLE SWITCH TS61 BOOM UP/DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS64 RUN/TEST TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 17...
  • Page 220 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 GM 3.0L Models...

  • Page 221: S-60, Gm 3.0L Models

    Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-60 GM 3.0L Models...
  • Page 222 PANEL) C28TTA RD/BK C1P-2 WH/RD C1P-6 BATGRN C7P-3 BK C1P-12 RD LS18 CABLE F.S. LS18 OPT. (CE) FOOT OPTION 12V DC SWITCH BATTERY TILT 19/18 CONTROL CABLE ALARM 6 - 18 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 223 (WORKLIGHT ONLY) FUEL SELECT EMERGENCY TS14 STOP TS47 ENGINE HIGH/LOW HIGH/LOW PLATFORM HORN GENERATOR START PLATFORM AUXILIARY (2WD/4WD) ROTATE (OPTION) LEVEL PUMP WH-24 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77828 S-60 • S-65 • S-60 HC 6 - 19...
  • Page 224 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-60 GM 3.0L Models...

  • Page 225: Electrical Schematic, S-65 Gm 3.0L Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-65 GM 3.0L Models...
  • Page 226 TB45 TB27 P134PWR TB39 P134PWR TB35 TB24 TB21 CR23 CR23 ALTERNATOR TS64 FUSE LINK BAT. GND. CR17 87a 87 STA. FUEL FLD. PUMP REGULATOR 12V DC STARTER PUMP 6 - 20 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 227 TB18 TB14 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 21...
  • Page 228 February 2012 Section 6 • Schematics Electrical Schematic, S-65 GM 3.0L Models...

  • Page 229: Ground Control Box Terminal Strip Wiring Diagram

    Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-65 GM 3.0L Models...
  • Page 230 WH C11-2 WH LS2 C10-2 BRN-GND BRN-TS64 BRN C7B-3 F.H. F.H. F.H. F.H. R43DLITE1 RD R43DLITE2 RD BK-22C1 BK C5-5 BK-33D BK-33D RD-24C NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 22 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 231 PLATFORM LEVEL TOGGLE SWITCH TS61 BOOM UP/DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS64 RUN/TEST TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 23...

  • Page 232: Ground Control Box Switch Panel Wiring Diagram

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 GM 3.0L Models...
  • Page 233 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-65 GM 3.0L Models...
  • Page 234 PANEL) C28TTA RD/BK C1P-2 WH/RD C1P-6 BK C1P-12 BATGRN C7P-3 RD LS18 CABLE F.S. LS18 OPT. (CE) FOOT OPTION 12V DC SWITCH BATTERY TILT 19/18 CONTROL CABLE ALARM 6 - 24 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 235 HORN ROTATE BOOM GENERATOR START PLATFORM AUXILIARY (2WD/4WD) GR/BK (OPTION) LEVEL PUMP WH-24 NOTE: DASHED LINES INDICATE OPTION WIRES CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30 Part No. 77828 S-60 • S-65 • S-60 HC 6 - 25...
  • Page 236 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-65 GM 3.0L Models...
  • Page 237 Section 6 • Schematics February 2012 Electrical Schematic, S-60 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 238 FUSE BAT. FUSE LINK GND. CR23 C5-8 GR CR17 87a 87 C5-13 BL/WH STA. FLD. REGULATOR 12V DC TB46R FUEL PUMP STARTER PUMP FORD 42 PIN QUICK DISCONNECT 6 - 26 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 239 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 27...
  • Page 240 February 2012 Section 6 • Schematics Electrical Schematic, S-60 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 241 Section 6 • Schematics February 2012 Electrical Schematic, S-60 Ford LRG-425 EFI Models (from serial number 11880 to 14053)
  • Page 242 BAT. FUSE LINK GND. CR23 C5-8 GR CR17 87a 87 C5-13 BL/WH STA. CR19 FLD. REGULATOR 12V DC TB46R FUEL PUMP STARTER PUMP FORD 42 PIN QUICK DISCONNECT 6 - 28 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 243 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 29...
  • Page 244 February 2012 Section 6 • Schematics Electrical Schematic, S-60 Ford LRG-425 EFI Models (from serial number 11880 to 14053)
  • Page 245 Section 6 • Schematics February 2012 Electrical Schematic, S-60 Ford DSG-423 EFI Models (after serial number 14053)
  • Page 246 GND. CR23 C5-8 GR CR17 87a 87 C5-13 BL/WH STA. CR19 FLD. REGULATOR 12V DC TB46R FUEL PUMP STARTER PUMP FORD ENGINE HARNESS FORD 42 PIN QUICK DISCONNECT 6 - 30 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 247 TB18 TB14 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 31...
  • Page 248 February 2012 Section 6 • Schematics Electrical Schematic, S-60 Ford DSG-423 EFI Models (after serial number 14053)
  • Page 249 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 250 WH-C5-19 RD-27C WH-C5-11 R43DLITE1 RD WH-21C R43DLITE2 RD RD-24B BK-22C1 BK C5-5 BK-33C RD-24C WH-23C WH-TB21 OPTIONS FUSE 10A NOTE: DASHED LINES INDICATE OPTION WIRES (DRIVE LIGHT ONLY) 6 - 32 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 251 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH TS64 RUN/TEST TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 33...

  • Page 252: Ground Control Box Switch Panel Wiring Diagram

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Ford LRG-425 EFI Models (before serial number 11880)

  • Page 253: S-60, Ford Models (After Serial Number 11879)

    Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60 Ford Models (after serial number 11879)
  • Page 254 RD-27C WH-21C RD-24B WH/RD-6D BK-22C1 GR-46D BK C5-5 BK-46R BK-33C RD/WH-TS61 RD/WH-R16 WH/RD-R4 WH/RD-R2 WH-OPTIONS WH-TB21 OPTIONS FUSE 10A (DRIVE LIGHT ONLY) NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 34 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 255 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 35...
  • Page 256 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Ford Models (after serial number 11879)
  • Page 257 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-60 Ford Models...
  • Page 258 ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CR27 CONTROL RELAY (CE OPTION) CR30 CONTROL RELAY (CE OPTION) LS18 LOAD SENSE LIMIT SWITCH 6 - 36 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 259 HIGH/LOW HIGH/LOW START HORN GENERATOR PLATFORM AUXILIARY (2WD/4WD) (OPTION) LEVEL PUMP PLATFORM ROTATE NOTE: DASHED LINES INDICATE OPTION WIRES CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30 Part No. 77828 S-60 • S-65 • S-60 HC 6 - 37...
  • Page 260 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-60 Ford Models...
  • Page 261 Section 6 • Schematics February 2012 Electrical Schematic, S-65 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 262 FUSE BAT. FUSE LINK GND. CR23 C5-8 GR CR17 87a 87 C5-13 BL/WH STA. FLD. REGULATOR 12V DC TB46R FUEL PUMP STARTER PUMP FORD 42 PIN QUICK DISCONNECT 6 - 38 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 263 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 39...
  • Page 264 February 2012 Section 6 • Schematics Electrical Schematic, S-65 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 265 Section 6 • Schematics February 2012 Electrical Schematic, S-65 Ford LRG-425 EFI Models (from serial number 11880 to 14053)
  • Page 266 BAT. FUSE LINK GND. CR23 C5-8 GR CR17 87a 87 C5-13 BL/WH STA. CR19 FLD. REGULATOR 12V DC TB46R FUEL PUMP STARTER PUMP FORD 42 PIN QUICK DISCONNECT 6 - 40 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 267 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 41...
  • Page 268 February 2012 Section 6 • Schematics Electrical Schematic, S-65 Ford LRG-425 EFI Models (from serial number 11880 to 14053)
  • Page 269 Section 6 • Schematics February 2012 Electrical Schematic, S-65 Ford DSG-423 EFI Models (after serial number 14053)
  • Page 270 GND. CR23 C5-8 GR CR17 87a 87 C5-13 BL/WH STA. CR19 FLD. REGULATOR 12V DC TB46R FUEL PUMP STARTER PUMP FORD ENGINE HARNESS FORD 42 PIN QUICK DISCONNECT 6 - 42 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 271 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 43...
  • Page 272 February 2012 Section 6 • Schematics Electrical Schematic, S-65 Ford DSG-423 EFI Models (after serial number 14053)
  • Page 273 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-65 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 274 WH-C5-19 RD-27C WH-C5-11 R43DLITE1 RD WH-21C R43DLITE2 RD RD-24B BK-22C1 BK C5-5 BK-33C RD-24C WH-23C WH-TB21 OPTIONS FUSE 10A NOTE: DASHED LINES INDICATE OPTION WIRES (DRIVE LIGHT ONLY) 6 - 44 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 275 JIB BOOM UP/DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH TS64 RUN/TEST TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 45...

  • Page 276: Ground Control Box Switch Panel Wiring Diagram

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 277 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-65 Ford Models (after serial number 11879)
  • Page 278 RD-27C WH-21C RD-24B WH/RD-6D BK-22C1 GR-46D BK C5-5 BK-46R BK-33C RD/WH-TS61 RD/WH-R16 WH/RD-R4 WH/RD-R2 WH-OPTIONS WH-TB21 OPTIONS FUSE 10A (DRIVE LIGHT ONLY) NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 46 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 279 JIB BOOM UP/DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 47...
  • Page 280 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Ford Models (after serial number 11879)
  • Page 281 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-65 Ford Models...
  • Page 282 ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CR27 CONTROL RELAY (CE OPTION) CR30 CONTROL RELAY (CE OPTION) LS18 LOAD SENSE LIMIT SWITCH 6 - 48 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 283 START HORN PLATFORM AUXILIARY (2WD/4WD) GENERATOR GR/BK BOOM LEVEL PUMP (OPTION) PLATFORM ROTATE NOTE: DASHED LINES INDICATE OPTION WIRES CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30 Part No. 77828 S-60 • S-65 • S-60 HC 6 - 49...
  • Page 284 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-65 Ford Models...

  • Page 285: S-65, Deutz F3L-2011 Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-60 Deutz F3L-2011 Models (before serial number 11880)
  • Page 286 C5-3 TB21 FUSE CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 50 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 287 TB18 TB14 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 51...
  • Page 288 February 2012 Section 6 • Schematics Electrical Schematic, S-60 Deutz F3L-2011 Models (before serial number 11880)
  • Page 289 Section 6 • Schematics February 2012 Electrical Schematic, S-60 Deutz F3L-2011 Models (after serial number 11879)
  • Page 290 CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 FUSE 70A CR19 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 52 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 291 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 53...
  • Page 292 February 2012 Section 6 • Schematics Electrical Schematic, S-60 Deutz F3L-2011 Models (after serial number 11879)
  • Page 293 Section 6 • Schematics February 2012 Electrical Schematic, S-60, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 294 TB21 C5-3 FUSE CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 54 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 295 TB18 TB14 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 55...
  • Page 296 February 2012 Section 6 • Schematics Electrical Schematic, S-60, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 297 Section 6 • Schematics February 2012 Electrical Schematic, S-60, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 298 CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 FUSE 70A CR19 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 56 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 299 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 57...
  • Page 300 February 2012 Section 6 • Schematics Electrical Schematic, S-60, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 301 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60 Deutz F3L-2011 Models (before serial number 11880)
  • Page 302 F.H. F.H. F.H. F.H. PLUG ANSI/CSA ONLY RD-24B C21IGN WH C5-3 C5-18 BK/RD BK/RD-35C R43DLITE1 RD WH-21B R43DLITE2 RD BK-22C1 BK C5-5 NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 58 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 303 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 59...
  • Page 304 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Deutz F3L-2011 Models (before serial number 11880)
  • Page 305 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60 Deutz F3L-2011 Models (after serial number 11879)
  • Page 306 C5-18 BK/RD BK/RD-35C RD-27C WH-21B WH/RD-6D BK-22C1 GR-46D BK C5-5 BK-46R RD/WH-TS61 RD/WH-R16 WH/RD-R4 WH/RD-R2 WH-OPTIONS WH-TB21 OPTIONS FUSE 10A (DRIVE LIGHT ONLY) NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 60 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 307 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 61...
  • Page 308 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Deutz F3L-2011 Models (after serial number 11879)
  • Page 309 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (before serial number 11880)

  • Page 310: Ground Control Box Terminal Strip Wiring Diagram

    BRN C7B-3 GR/BK H6 F.H. F.H. F.H. F.H. RD-24B C21IGN WH C5-3 C5-18 BK/RD BK/RD-35C R43DLITE1 RD WH-21B R43DLITE2 RD BK-22C1 BK C5-5 NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 62 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 311: Ground Control Box Switch Panel Wiring Diagram

    PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 63...

  • Page 312: Ground Control Box Switch Panel Wiring Diagram

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 313 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models, Deutz F3L-2011 Models (after serial number 11879)
  • Page 314 C5-18 BK/RD BK/RD-35C RD-27C WH-21B WH/RD-6D BK-22C1 GR-46D BK C5-5 BK-46R RD/WH-TS61 RD/WH-R16 WH/RD-R4 WH/RD-R2 WH-OPTIONS WH-TB21 OPTIONS FUSE 10A (DRIVE LIGHT ONLY) NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 64 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 315: Ground Control Box Switch Panel Wiring Diagram

    PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 65...

  • Page 316: Ground Control Box Switch Panel Wiring Diagram

    February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 317 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-60 Deutz F3L-2011 Models...
  • Page 318 PANEL) C28TTA RD/BK C1P-2 WH/RD C1P-6 BATGRN C7P-3 BK C1P-12 RD LS18 CABLE F.S. LS18 OPT. (CE) OPTION TILT 19/18 CONTROL CABLE FOOT SWITCH 12V DC BATTERY ALARM 6 - 66 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 319 (WORK LIGHT ONLY) EMERGENCY TS14 STOP GLOW PLUG ENGINE HIGH/LOW HIGH/LOW TS47 PLATFORM HORN START AUXILIARY (2WD/4WD) GENERATOR ROTATE PLATFORM PUMP (OPTION) LEVEL WH-24 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77828 S-60 • S-65 • S-60 HC 6 - 67...
  • Page 320 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-60 Deutz F3L-2011 Models...

  • Page 321: Electrical Schematic, S-65, Deutz F3L-2011 Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-65 Deutz F3L-2011 Models (before serial number 11880)
  • Page 322 TB21 C5-3 FUSE CR23 CR23 TB25 CR17 TB26 ALTERNATOR 87a 87 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 68 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 323 TB18 TB14 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 69...
  • Page 324 February 2012 Section 6 • Schematics Electrical Schematic, S-65 Deutz F3L-2011 Models (before serial number 11880)

  • Page 325: Electrical Schematic, S-65, Deutz F3L-2011 Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-65 Deutz F3L-2011 Models (after serial number 11879)
  • Page 326 CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 FUSE 70A CR19 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 70 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 327 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 71...
  • Page 328 February 2012 Section 6 • Schematics Electrical Schematic, S-65 Deutz F3L-2011 Models (after serial number 11879)

  • Page 329: Electrical Schematic, S-65, Ce Models, Deutz F3L-2011 Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880)

  • Page 330: Electrical Schematic, S-65, Ce Models, Deutz F3L-2011 Models

    C5-3 TB21 FUSE CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 72 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 331 TB18 TB14 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 73...
  • Page 332 February 2012 Section 6 • Schematics Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 333 Section 6 • Schematics February 2012 Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 334 CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 FUSE 70A CR19 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 74 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 335 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 75...
  • Page 336 February 2012 Section 6 • Schematics Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 337 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-65 Deutz F3L-2011 Models (before serial number 11880)
  • Page 338 F.H. F.H. F.H. F.H. PLUG ANSI/CSA ONLY RD-24B C21IGN WH C5-3 C5-18 BK/RD BK/RD-35C R43DLITE1 RD WH-21B R43DLITE2 RD BK-22C1 BK C5-5 NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 76 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 339 JIB BOOM UP/DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 77...
  • Page 340 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models (before serial number 11880)
  • Page 341 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-65 Deutz F3L-2011 Models (after serial number 11879)
  • Page 342 C5-18 BK/RD BK/RD-35C RD-27C WH-21B WH/RD-6D BK-22C1 GR-46D BK C5-5 BK-46R RD/WH-TS61 RD/WH-R16 WH/RD-R4 WH/RD-R2 WH-OPTIONS WH-TB21 OPTIONS FUSE 10A (DRIVE LIGHT ONLY) NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 78 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 343 JIB BOOM TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 79...
  • Page 344 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models (after serial number 11879)

  • Page 345: Ground Control Box Terminal Strip Wiring Diagram, S-65, Ce Models, Deutz F3L-2011 Models

    Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models, Deutz F3L-2011 Models (before serial number 11880)

  • Page 346: Ground Control Box Terminal Strip Wiring Diagram, S-65, Ce Models, Deutz F3L-2011 Models

    BRN C7B-3 GR/BK H6 F.H. F.H. F.H. F.H. RD-24B C21IGN WH C5-3 C5-18 BK/RD BK/RD-35C R43DLITE1 RD WH-21B R43DLITE2 RD BK-22C1 BK C5-5 NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 80 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 347 JIB BOOM UP/DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 81...
  • Page 348 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 349 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models, Deutz F3L-2011 Models (after serial number 11879)
  • Page 350 C5-18 BK/RD BK/RD-35C RD-27C WH-21B WH/RD-6D BK-22C1 GR-46D BK C5-5 BK-46R RD/WH-TS61 RD/WH-R16 WH/RD-R4 WH/RD-R2 WH-OPTIONS WH-TB21 OPTIONS FUSE 10A (DRIVE LIGHT ONLY) NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 82 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 351 JIB BOOM TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 83...
  • Page 352 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 353 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-65 Deutz F3L-2011 Models...
  • Page 354 PANEL) C28TTA RD/BK C1P-2 WH/RD C1P-6 BATGRN C7P-3 BK C1P-12 RD LS18 CABLE F.S. LS18 OPT. (CE) OPTION TILT 19/18 CONTROL CABLE 12V DC BATTERY FOOT SWITCH ALARM 6 - 84 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 355 TS14 STOP GLOW PLUG ENGINE HIGH/LOW HIGH/LOW TS47 HORN START BOOM AUXILIARY (2WD/4WD) GENERATOR GR/BK PLATFORM PUMP (OPTION) LEVEL PLATFORM WH-24 ROTATE NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77828 S-60 • S-65 • S-60 HC 6 - 85...
  • Page 356 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models...

  • Page 357: Electrical Schematic, S-60, Perkins 404-22 Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-60 Perkins 404-22 Models (before serial number 11880)
  • Page 358 TB21 C5-3 TB21 CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 86 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 359 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 87...
  • Page 360 February 2012 Section 6 • Schematics Electrical Schematic, S-60 Perkins 404-22 Models (before serial number 11880)

  • Page 361: Electrical Schematic, S-60, Perkins 404-22 Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-60 Perkins 404-22 Models (after serial number 11879)
  • Page 362 CR23 CR23 TB25 TB26 CR17 ALTERNATOR 87a 87 CR19 FUSE 70A EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 88 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 363 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 89...
  • Page 364 February 2012 Section 6 • Schematics Electrical Schematic, S-60 Perkins 404-22 Models (after serial number 11879)
  • Page 365 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60 Perkins 404-22 Models (before serial number 11880)
  • Page 366 F.H. F.H. F.H. F.H. PLUG ANSI/CSA ONLY RD-24B C21IGN WH C5-3 C5-18 BK/RD BK/RD-35C R43DLITE1 RD WH-21B R43DLITE2 RD BK-22C1 BK C5-5 NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 90 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 367 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 BOOM UP/DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 91...
  • Page 368 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Perkins 404-22 Models (before serial number 11880)
  • Page 369 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-60 Perkins 404-22 Models (after serial number 11879)
  • Page 370 C5-18 BK/RD BK/RD-35C RD-27C WH-21B WH/RD-6D BK-22C1 GR-46D BK C5-5 BK-46R RD/WH-TS61 RD/WH-R16 WH/RD-R4 WH/RD-R2 WH-OPTIONS WH-TB21 OPTIONS FUSE 10A (DRIVE LIGHT ONLY) NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 92 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 371 PLATFORM ROTATE TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 93...
  • Page 372 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Perkins 404-22 Models (after serial number 11879)
  • Page 373 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-60 Perkins 404-22 Models...
  • Page 374 PANEL) C28TTA RD/BK C1P-2 WH/RD C1P-6 BATGRN C7P-3 BK C1P-12 RD LS18 CABLE F.S. LS18 OPT. (CE) 12V DC BATTERY FOOT SWITCH OPTION 19/18 CONTROL CABLE TILT ALARM 6 - 94 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 375 (WORKLIGHT ONLY) EMERGENCY STOP TS14 GLOW PLUG ENGINE HIGH/LOW HIGH/LOW TS47 HORN START PLATFORM (2WD/4WD) PLATFORM AUXILIARY GENERATOR LEVEL ROTATE PUMP (OPTION) WH-24 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77828 S-60 • S-65 • S-60 HC 6 - 95...
  • Page 376 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-60 Perkins 404-22 Models...

  • Page 377: Electrical Schematic, S-65, Perkins 404-22 Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-65 Perkins 404-22 Models (before serial number 11880)
  • Page 378 TB21 TB21 C5-3 CR23 CR23 TB25 CR17 TB26 ALTERNATOR 87a 87 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 96 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 379 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 97...
  • Page 380 February 2012 Section 6 • Schematics Electrical Schematic, S-65 Perkins 404-22 Models (before serial number 11880)

  • Page 381: Electrical Schematic, S-65, Perkins 404-22 Models

    Section 6 • Schematics February 2012 Electrical Schematic, S-65 Perkins 404-22 Models (after serial number 11879)
  • Page 382 CR23 CR23 TB25 CR17 TB26 ALTERNATOR 87a 87 FUSE 70A CR19 EXCT. BAT. BAT. 12V DC STA. STARTER PUMP REGULATOR IND. NOTES: CE AND PLATFORM OVERLOAD OPTION ONLY. 6 - 98 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 383 TB14 TB18 TB37 TB29 TB32 TB31 TB30 TB36 LS17 LS17 TB59 TB22 CR34 NOTES: 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION. ROCKER STEER OPTION ONLY. Part No. 77828 S-60 • S-65 • S-60 HC 6 - 99...
  • Page 384 February 2012 Section 6 • Schematics Electrical Schematic, S-65 Perkins 404-22 Models (after serial number 11879)
  • Page 385 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-65 Perkins 404-22 Models (before serial number 11880)
  • Page 386 F.H. F.H. F.H. F.H. PLUG ANSI/CSA ONLY RD-24B C21IGN WH C5-3 C5-18 BK/RD BK/RD-35C R43DLITE1 RD WH-21B R43DLITE2 RD BK-22C1 BK C5-5 NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 100 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 387 JIB BOOM UP/DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 BOOM UP/DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 101...
  • Page 388 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Perkins 404-22 Models (before serial number 11880)
  • Page 389 Section 6 • Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram, S-65 Perkins 404-22 Models (after serial number 11879)
  • Page 390 C5-18 BK/RD BK/RD-35C RD-27C WH-21B WH/RD-6D BK-22C1 GR-46D BK C5-5 BK-46R RD/WH-TS61 RD/WH-R16 WH/RD-R4 WH/RD-R2 WH-OPTIONS WH-TB21 OPTIONS FUSE 10A (DRIVE LIGHT ONLY) NOTE: DASHED LINES INDICATE OPTION WIRES 6 - 102 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 391 JIB BOOM TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH Part No. 77828 S-60 • S-65 • S-60 HC 6 - 103...
  • Page 392 February 2012 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Perkins 404-22 Models (after serial number 11879)
  • Page 393 Section 6 • Schematics February 2012 Platform Control Box Wiring Diagram, S-65 Perkins 404-22 Models...
  • Page 394 PANEL) C28TTA RD/BK C1P-2 WH/RD C1P-6 BATGRN C7P-3 BK C1P-12 RD LS18 CABLE F.S. LS18 OPT. (CE) OPTION 12V DC BATTERY FOOT SWITCH TILT 19/18 CONTROL CABLE ALARM 6 - 104 S-60 • S-65 • S-60 HC Part No. 77828...
  • Page 395 STOP TS14 GLOW PLUG ENGINE PLATFORM HIGH/LOW HIGH/LOW TS47 HORN START PLATFORM ROTATE BOOM AUXILIARY (2WD/4WD) GR/BK GENERATOR LEVEL PUMP (OPTION) WH-24 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77828 S-60 • S-65 • S-60 HC 6 - 105...
  • Page 396 February 2012 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-65 Perkins 404-22 Models...

  • Page 397: Belt Driven Generator Wiring Diagram

    120V AC 120V AC AUTO AUTO RESET CB RESET CB BLK-120VAC BLK-120VAC 220V AC W/REGULATOR RED/12V BK/WH BK/WH (BK/RD) (BK/RD) WHT-NEUTRAL 220V AC AUTO RESET CB BLK-220VAC 12.5A Part No. 77828 S-60 • S-65 • S-60 HC 6 - 106...
  • Page 398 February 2012 Section 6 • Schematics Belt Driven Generator Wiring Diagram...

  • Page 399: 12Kw Hydraulic Generator Option Wiring Diagram

    Section 6 • Schematics February 2012 12kW Hydraulic Generator Option Wiring Diagram...
  • Page 400 OR/RD relay. The EDC valve is switched over to the GR/WH C45GEN GR/WH output of the SX controller. GR/BK V150HG GR/BK C22PWR RD/WH 6 - 107 S-60 • S-65 • S-60 HC Part No. 77828...

  • Page 401: Hydraulic Schematic, 12Kw Hydraulic Generator Option

    Section 6 • Schematics Hydraulic Schematic, 12kW Hydraulic Generator Option DRIVE PUMP FUNCTION MANIFOLD PMP B PMP A DIVERTER MANIFOLD 0.031 280 psi MTR B MTR A 21CC HYDRAULIC GENERATOR Part No. 77828 S-60 • S-65 • S-60 HC 6 - 108...
  • Page 402 February 2012 Section 6 • Schematics Hydraulic Schematic, 12kW Hydraulic Generator Option...

  • Page 403: Hydraulic Schematic, 2Wd Models

    0.070 in 19.3 bar 1.78 mm RETURN TANK FILTER FUNCTION MANIFOLD 800 psi OSCILLATE CYLINDERS 55 bar HYDRAULIC ROTARY COUPLER OIL COOLER OPTION OSCILLATE VALVE LEFT OSCILLATE AXLE REAR Part No. 77828 S-60 • S-65 • S-60 HC 6 - 109...
  • Page 404 February 2012 Section 6 • Schematics Hydraulic Schematic, 2WD Models...

  • Page 405: Hydraulic Schematic, 4Wd Models

    TANK FILTER FUNCTION 0.040 in MANIFOLD 1 mm 800 psi OSCILLATE CYLINDERS 55 bar HYDRAULIC ROTARY COUPLER OIL COOLER OPTION LEFT LEFT REAR FRONT OSCILLATE VALVE OSCILLATE AXLE Part No. 77828 S-60 • S-65 • S-60 HC 6 - 110...
  • Page 406 February 2012 Section 6 • Schematics Hydraulic Schematic, 4WD Models...

This manual is also suitable for:

S-65

Table of Contents