Genie S-65 Service Manual
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Genie S-65 Service Manual

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Download this manual See also: Service & Repair Manual, Maintenance Manual
Part No. 77828
Service Manual
Rev B1
December 2005
Refer to inside cover for additional serial number information
(from serial number 9154)

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Do you have a question about the S-65 and is the answer not in the manual?

Questions and answers

Floyd churchwell
January 24, 2025

es65d where is the 2 speed motor and how to test the functions

0
1 comments:
Mr. Anderson
May 14, 2025

The two-speed motor on the Genie S-65 is part of the drive system. It is located inside the drive chassis, connected to the drive motor circuits at the steer and non-steer ends.

To test its functions:
1. Perform the drive speed test in both the stowed and raised or extended positions.
2. Ensure the engine idle control switch is set to foot switch activated high idle (rabbit and foot switch symbol).
3. Check that the drive function responds quickly and smoothly to operator control.
4. Drive performance should be free of hesitation, jerking, or unusual noise across the full speed range.

This test should be done every 250 hours or quarterly, whichever comes first.

This answer is automatically generated

0

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Summary of Contents for Genie S-65

  • Page 1 Part No. 77828 Service Manual Rev B1 December 2005 Refer to inside cover for additional serial number information (from serial number 9154)

  • Page 2: Introduction

    Important Serial Number Information Read, understand and obey the safety rules and Genie Industries offers the following Service operating instructions in the Genie S-60 and Genie Manuals for these models: S-65 Operator's Manual before attempting any maintenance or repair procedure.
  • Page 3 Maximum platform reach : 50 ft 4 in/ 15.3 m number Gradeability: 45% Model year Country of manufacture: USA This machine complies with: ANSI A92.5 CAN B.354.4 Genie Industries 18340 NE 76th Street Redmond, WA 98052 PN - 77055 Part No. 77828 S-60 • S-65...
  • Page 4 July 2005 This page intentionally left blank. S-60 • S-65 Part No. 77828...
  • Page 5 Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-60 and Genie S-65 Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 6 Please be environmentally safe. property damage. Be sure that your workshop or work area Used to indicate operation or is properly ventilated and well lit. maintenance information. S-60 • S-65 Part No. 77828...

  • Page 7: Table Of Contents

    Maintenance Inspection Report ................3 - 5 Checklist A Procedures Perform Pre-operation Inspection ..............3 - 7 Perform Function Tests ................3 - 7 Perform Engine Maintenance - Deutz Models ..........3 - 8 Part No. 77828 S-60 • S-65...

  • Page 8: Table Of Contents

    Check and Adjust the Engine RPM - Deutz Models ........3 - 20 Test the Ground Control Override .............. 3 - 22 B-10 Check the Oscillate Directional Valve Linkage ........... 3 - 22 B-11 Test the Platform Self-leveling ..............3 - 23 viii S-60 • S-65 Part No. 77828...

  • Page 9: Table Of Contents

    Test the Platform Overload System (if equipped) ........3 - 35 Inspect the Boom Extend/Retract Cables ..........3 - 37 Perform Engine Maintenance - Perkins Models ......... 3 - 38 Perform Engine Maintenance - GM and Ford Models ........ 3 - 39 Part No. 77828 S-60 • S-65...

  • Page 10: Table Of Contents

    Introduction ......................4 - 1 Platform Controls ALC-500 Circuit Board ................. 4 - 2 Joysticks ...................... 4 - 3 Platform Components Platform Leveling Slave Cylinder ..............4 - 7 Platform Rotator ................... 4 - 8 S-60 • S-65 Part No. 77828...

  • Page 11: Table Of Contents

    July 2005 TABLE OF CONTENTS Section 4 Repair Procedures, continued Jib Boom Components, S-65 Jib Boom ....................4 - 11 Jib Boom Lift Cylinder ................4 - 12 Boom Components Cable Track ....................4 - 13 Boom ......................4 - 18 Boom Lift Cylinder ..................

  • Page 12: Table Of Contents

    Oscillate Axle Cylinders ................4 - 59 Section 5 Fault Codes Introduction ......................5 - 1 Fault Codes - Control System ................5 - 2 Fault Codes - Ford Engine ..................5 - 6 S-60 • S-65 Part No. 77828...
  • Page 13 Platform Control Box Switch Panel Wiring Diagram, S-60, GM 3.0L Models ................6 - 12 Electrical Schematic, S-65, GM 3.0L Models ............6 - 13 Ground Control Box Terminal Strip Wiring Diagram, S-65, GM 3.0L Models ................6 - 15 Ground Control Box Switch Panel Wiring Diagram, S-65, GM 3.0L Models ................
  • Page 14 (after serial number 11879) ................ 6 - 31 Ground Control Box Terminal Strip Wiring Diagram, S-65, Ford LRG-425 EFI Models (before serial number 11880) ....6 - 33 Ground Control Box Switch Panel Wiring Diagram, S-65, Ford LRG-425 EFI Models (before serial number 11880) ....6 - 34 Ground Control Box Terminal Strip Wiring Diagram, S-65, Ford LRG-425 EFI Models (after serial number 11879) ....
  • Page 15 (after serial number 11879) ................ 6 - 54 Platform Control Box Terminal Strip Wiring Diagram, S-60, Deutz F3L-2011 Models ..............6 - 55 Platform Control Box Switch Panel Wiring Diagram, S-60, Deutz F3L-2011 Models ..............6 - 56 Part No. 77828 S-60 • S-65...
  • Page 16 (after serial number 11879) ................ 6 - 63 Ground Control Box Terminal Strip Wiring Diagram, S-65, Deutz F3L-2011 Models (before serial number 11880) ....6 - 65 Ground Control Box Switch Panel Wiring Diagram, S-65, Deutz F3L-2011 Models (before serial number 11880) ....6 - 66 Ground Control Box Terminal Strip Wiring Diagram, S-65, Deutz F3L-2011 Models (after serial number 11879) .......
  • Page 17 (after serial number 11879) ................ 6 - 87 Ground Control Box Terminal Strip Wiring Diagram, S-65, Perkins 404-22 Models (before serial number 11880) ...... 6 - 89 Ground Control Box Switch Panel Wiring Diagram, S-65, Perkins 404-22 Models (before serial number 11880) ...... 6 - 90 Ground Control Box Terminal Strip Wiring Diagram, S-65, Perkins 404-22 Models (after serial number 11879) ......
  • Page 18 July 2005 This page intentionally left blank. xviii S-60 • S-65 Part No. 77828...

  • Page 19: A Machine Specifications

    Machine Specifications Performance Specifications Tires and wheels Boom function speeds, maximum from platform controls Wheel lugs Jib boom up, S-65 60 to 70 seconds Lug nut torque, dry 170 ft-lbs 225 Nm Jib boom down, S-65 40 to 50 seconds...
  • Page 20 Charge pump Chevron Rykon 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 21 3.5 bar ³ 200 Medium pressure filter Beta Medium pressure filter 51 psi bypass pressure 3.5 bar Hydraulic return filter 10 micron with 25 psi / 1.7 bar bypass Part No. 77828 S-60 • S-65 2 - 3...
  • Page 22 Above 0° F / -17.8° C 10W-30 11.4 liters Only use engine oils labeled "For Gasoline Engines" Alternator output 66A @ 12V DC by the American Petroleum Institute (API). Fan belt deflection inch 12 mm 2 - 4 S-60 • S-65 Part No. 77828...
  • Page 23 Use oils meeting API classification SJ or SH. Reserve capacity @ 25A rate 200 minutes Units ship with 15W-40 SJ. Ignition system Spark plug type Motorcraft AGSF-32-FM Spark plug gap 0.042 to 0.046 inches 1.07 to 1.17 mm Part No. 77828 S-60 • S-65 2 - 5...
  • Page 24 Engine oil should have minimum properties of API Alternator output 60A @ 14V DC classification CC/SG or CD/SG grades. Units ship with 10W-40 CH-4 Fan belt deflection inch 9 to 12 mm 2 - 6 S-60 • S-65 Part No. 77828...
  • Page 25 55A @ 12V DC 0.2 mm Fan belt deflection 10 mm Starter motor Current draw, no load Brush length, new 0.7480 in 19 mm Brush length, minimum 0.5 in 12.7 mm Part No. 77828 S-60 • S-65 2 - 7...
  • Page 26 Torque 8-18 ft-lbs Rotate bearing mounting bolts, lubricated 180 ft-lbs 11-24 Nm 244 Nm Temperature switch point 221° F Turntable rotation assembly 105° C Backlash pivot plate 260 ft-lbs 352.5 Nm 2 - 8 S-60 • S-65 Part No. 77828...

  • Page 27: C 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 28 50.5 39.9 54.1 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 2 - 10 S-60 • S-65 Part No. 77828...
  • Page 29 · Key switch in the off position with the Indicates that an incorrect result has occurred key removed after performing a series of steps. · Wheels chocked · All external AC power disconnected from the machine Part No. 77828 S-60 • S-65 3 - 1...
  • Page 30 Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. 3 - 2 S-60 • S-65 Part No. 77828...

  • Page 31: Pre-Delivery Preparation

    PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Part No. 77828 S-60 • S-65 3 - 3 Rev B...
  • Page 32 Section 3 • Scheduled Maintenance Procedures July 2005 This page intentionally left blank. 3 - 4 S-60 • S-65 Part No. 77828...

  • Page 33: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 77828 S-60 • S-65 3 - 5...
  • Page 34 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments 3 - 6 S-60 • S-65 Part No. 77828...

  • Page 35: A-1 Perform Pre-Operation Inspection

    The Pre-operation Inspection also Complete information to perform this procedure is serves to determine if routine maintenance available in the Genie S-60 and Genie S-65 procedures are required. Operator's Manual on your machine. Complete information to perform this procedure is available in the Genie S-60 and Genie S-65 Operator's Manual on your machine.

  • Page 36: A-3 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. 3 - 8 S-60 • S-65 Part No. 77828...

  • Page 37: A-5 Perform Engine Maintenance - 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. Part No. 77828 S-60 • S-65 3 - 9...

  • Page 38: A-7 Test The Oscillate Axle (If Equipped)

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

  • Page 39: A-9 Perform Engine Maintenance - Gm, Ford And Perkins Models

    3 Inspect the filter bowl for water buildup. Genie part number 84792 Result: If water is present in the filter bowl Perkins 400 Series Operation Manual continue with steps 4 through 8. Genie part number 94890 Part No. 77828 S-60 • S-65 3 - 11...
  • Page 40 See B-20, Replace The Fuel Filter Element - Perkins Models, for instructions on how to prime the fuel filter/water separator. 7 Clean up any fuel that may have spilled. 3 - 12 S-60 • S-65 Part No. 77828...

  • Page 41: A-11 Check And Adjust The Engine Rpm - Perkins Models

    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 3 - 13...

  • Page 42: A-12 Grease The Turntable Rotation Bearing And Rotate Gear

    Bearing and Rotate Gear Tighten the low idle lock nut and confirm the rpm. Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist.

  • Page 43: A-13 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. Part No. 77828 S-60 • S-65 3 - 15...

  • Page 44: B-1 Inspect The Battery

    · Engine wiring harness battery terminals and cables. · Hydraulic manifold wiring 5 Open the ground controls side turntable cover. 3 - 16 S-60 • S-65 Part No. 77828...

  • Page 45: B-3 Check The Exhaust System

    4 Inspect all welds for cracks. fastener. 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 pivot plate retaining fastener. Part No. 77828 S-60 • S-65 3 - 17...

  • Page 46: B-4 Check The Oil Cooler And Cooling Fins - Deutz Models

    10 Install the engine side cover. death or serious injury. 11 Swing the engine back to its original position and install the engine pivot plate retaining fastener. 3 - 18 S-60 • S-65 Part No. 77828...

  • Page 47: B-5 Check The Lug Nut Torque (Including The Tires And Wheels)

    4 Check the pressure in each air-filled tire. drive pump free-wheel valve lift pump screwdriver The free-wheel valve is located on the side of the drive pump. The free-wheel valve should always remain closed. Part No. 77828 S-60 • S-65 3 - 19...

  • Page 48: B-7 Check The Oil Level In The Drive Hubs

    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 - 20 S-60 • S-65 Part No. 77828...
  • Page 49 5 Move the function enable/rpm select toggle switch to the high idle (rabbit symbol) position at the ground controls. Result: High idle should be 2500 rpm. If high idle rpm is correct, disregard adjustment step 6. Part No. 77828 S-60 • S-65 3 - 21...

  • Page 50: B-9 Test The Ground Control Override

    · Lock nut is tight against yoke Result: All boom functions should operate. · Yoke clevis pins are installed · Cotter pins are installed through clevis pins · Linkage is properly attached to directional valve 3 - 22 S-60 • S-65 Part No. 77828...

  • Page 51: B-11 Test The Platform Self-Leveling

    Result: The engine should change to high idle. 6 Move the engine idle control switch to foot switch activated low idle (turtle symbol). Result: The engine should change to low idle. Part No. 77828 S-60 • S-65 3 - 23...

  • Page 52: B-13 Test The Fuel Select Operation - Gm And Ford Models

    4 Release the foot switch and shut the engine off by pushing in the red Emergency Stop button in to the off position. 5 Move the fuel select switch to LPG. 3 - 24 S-60 • S-65 Part No. 77828...

  • Page 53: B-14 Test The Drive Brakes

    4 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the test line. Part No. 77828 S-60 • S-65 3 - 25...

  • Page 54: B-15 Test The Drive Speed - Stowed Position

    7 Continue at full speed and note the time when the machine reference point crosses the finish the machine reference point crosses the finish line. Refer to Section 2, Specifications. line. Refer to Section 2, Specifications. 3 - 26 S-60 • S-65 Part No. 77828...

  • Page 55: B-17 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 3 - 27...

  • Page 56: B-18 Perform Hydraulic Oil Analysis

    6 S-65: Press down the foot switch. Move the jib changing the oil is necessary. If boom toggle switch to the down position, hold the hydraulic oil is not replaced for a moment and then release it.

  • Page 57: B-19 Replace The Fuel Filter/Water Separator Element - Perkins Models

    7 Install the bowl onto the new filter element. 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 3 - 29...
  • Page 58 14 Loosen the vent plug on top of the fuel injection pump. vent plug fuel injection pump fuel lift pump 3 - 30 S-60 • S-65 Part No. 77828...

  • Page 59: B-20 Replace The Fuel Filter Element - Perkins Models

    Part No. 77828 S-60 • S-65 3 - 31...

  • Page 60: B-21 Perform Engine Maintenance - Deutz Models

    If there is air in the fuel system, there is probably a leak in the low pressure side of the system. 3 - 32 S-60 • S-65 Part No. 77828...

  • Page 61: B-22 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. Part No. 77828 S-60 • S-65 3 - 33...

  • Page 62: C-1 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. 3 - 34 S-60 • S-65 Part No. 77828...

  • Page 63: C-3 Test The Platform Overload System (If Equipped)

    Test the Platform Overload platform capacity in one of the locations shown. System (if equipped) Genie specifications require that this procedure be performed every 500 hours or six months. Testing the platform overload system regularly is essential to safe machine operation.
  • Page 64 System (if equipped). 10 Test all machine functions from the ground controls. Result: All ground control functions should not operate. Machine functions should still operate with auxiliary power at the ground controls. 3 - 36 S-60 • S-65 Part No. 77828...

  • Page 65: C-4 Inspect The Boom Extend/Retract Cables

    Remove the and the access panels on the sides of the covers. boom. 7 Start the engine from the ground controls and fully retract and lower the boom to the stowed position. Part No. 77828 S-60 • S-65 3 - 37...

  • Page 66: C-5 Perform Engine Maintenance - 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 - 38 S-60 • S-65 Part No. 77828...

  • Page 67: C-6 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. Part No. 77828 S-60 • S-65 3 - 39...

  • Page 68: D-1 Check The Boom Wear Pads

    The lift cylinder safety chock is once it reaches the minimum allowable available through Genie thickness. If the wear pad is still within (Genie part number 75097). specification, shim as necessary to obtain 2 Turn the engine off. minimum clearance with zero binding.

  • Page 69: D-3 Inspect For Turntable Bearing Wear

    See D-2, Check the Turntable Rotation Bearing Bolts. Bolt torque sequence 3 Start the machine from the ground controls and raise the boom to full height. Do not extend the boom. Part No. 77828 S-60 • S-65 3 - 41...
  • Page 70 12 Remove the dial indicator from the machine. turntable dial indicator drive chassis turntable rotation bearing 5 At the dial indicator, adjust it to "zero" the indicator. 6 Fully extend the boom and lower to a horizontal position. 3 - 42 S-60 • S-65 Part No. 77828...

  • Page 71: D-4 Replace The Drive Hub Oil

    Install the plugs into the drive hub. Refer to disengaged position Section 2, Specifications . 5 Repeat steps 1 through 4 for all the other drive hubs. engaged position Part No. 77828 S-60 • S-65 3 - 43...
  • Page 72 The free-wheel valve is located on the side of the drive pump. The free-wheel valve should always remain closed. engaged position 11 Manually rotate each steer wheel. Result: Each steer wheel should rotate with minimum effort. 3 - 44 S-60 • S-65 Part No. 77828...

  • Page 73: D-6 Replace The Hydraulic Filters

    December 2005 Section 3 • Scheduled Maintenance Procedures REV E Replace the Hydraulic Filters Part No. 77828 S-60 • S-65 3 - 45...

  • Page 74: D-7 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 - 46 S-60 • S-65 Part No. 77828...

  • Page 75: D-8 Perform Engine Maintenance - Deutz Models

    9 Adjust the low idle mixture adjustment screw to obtain an air-to-fuel mixture ratio of 13.0:1 to 13.2:1. Preliminary setting: turn low idle adjustment screw clockwise all the way in. Turn low idle adjustment screw counterclockwise 2 turns. Part No. 77828 S-60 • S-65 3 - 47...

  • Page 76: D-9 Calibrate The Platform Overload System (If Equipped)

    Result: The overload indicator light and the alarm is on. Slowly tighten the load spring adjustment nut by turning it clockwise just until Genie specifications require that the overload indicator light and alarm turns off. this procedure be performed every 1000 hours of operation or yearly.
  • Page 77 11 Test all machine functions from the ground controls. Result: All ground control functions should not operate. If the platform overload system is not operating properly, repeat steps 1 through 4. Part No. 77828 S-60 • S-65 3 - 49...

  • Page 78: E-1 Test Or Replace The Hydraulic Oil

    The hoses can be accessed through the access hole under the turntable. 7 Disconnect and plug the return filter hydraulic hose at the return filter. Cap the fitting on the filter housing. 3 - 50 S-60 • S-65 Part No. 77828...
  • Page 79 18 Install the hydraulic tank onto the machine. 19 Install the two suction hoses to the suction strainers. 20 Install the supply hose for the auxiliary power unit and the return filter hose. Part No. 77828 S-60 • S-65 3 - 51...

  • Page 80: E-2 Perform Engine Maintenance - Deutz Models

    3 - 52 S-60 • S-65 Part No. 77828...

  • Page 81: E-4 Remove And Inspect The Boom Extend/Retract Cables

    If the cables are replaced, the cable sheaves or pulleys should also be replaced. Genie specifications require that this procedure be performed at 5 Remove the cotter pins and clevis pins from the 5 years or 5000 hours, whichever...
  • Page 82 16 Install the boom extension cylinder assembly into the boom. 17 Adjust the boom extend/retract cables. See Repair Procedure 4-5, How to Adjust the Boom Extend/Retract Cables. 3 - 54 S-60 • S-65 Part No. 77828...
  • Page 83 Read, understand and obey the safety rules and which, if not avoided, will result in operating instructions in the Genie S-60 and death or serious injury. Genie S-65 Operator’s Manual. Used to indicate the presence of a...

  • Page 84: Alc-500 Circuit Board

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

  • Page 85: Joysticks

    Result: The alarm should sound indicating successful joystick calibration. 6 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch. No machine fuction should operate while performing the joystick calibration procedure. Part No. 77828 S-60 • S-65 4 - 3...
  • Page 86 4 times. Result: There should be a pause and the alarm should sound 4 times indicating that the machine is in max-out calibration mode. 4 - 4 S-60 • S-65 Part No. 77828...
  • Page 87 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 4 - 5...
  • Page 88 8 times indicating that the machine is in threshold calibration mode. 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 - 6 S-60 • S-65 Part No. 77828...

  • Page 89: Platform Leveling Slave Cylinder

    Do not rest the entire weight of the boom on the blocks. Part No. 77828 S-60 • S-65 4 - 7...

  • Page 90: Platform Rotator

    Do not allow oil to squirt Platform Rotator or spray. Component damage hazard. Mark 3 S-65: Support the jib boom leveling arms and the platform mounting weldment the platform mounting weldment with an and the rotator flange before appropriate lifting device. Do not apply any removing the platform mounting lifting pressure.
  • Page 91 Crushing hazard. The platform rotator may become unbalanced and fall if not properly supported. When installing the platform rotator fasteners, torque the fasteners to specifications. top bleed valve bottom bleed valve container clear hose Part No. 77828 S-60 • S-65 4 - 9...
  • Page 92 Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 10 S-60 • S-65 Part No. 77828...

  • Page 93: Jib Boom

    July 2005 Section 4 • Repair Procedures Jib Boom Components, S-65 REV A 6 Attach a lifting strap from an overhead crane to the jib boom assembly. Jib Boom 7 Place blocks under the platform leveling cylinder for support. Protect the cylinder rod from How to Remove the Jib Boom damage.

  • Page 94: Jib Boom Lift Cylinder

    Section 4 • Repair Procedures July 2005 JIB BOOM COMPONENTS, S-65 REV A 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not Jib Boom Lift Cylinder remove the pin. 4 Use a soft metal drift to tap the jib boom lift How to Remove the Jib Boom cylinder rod-end pivot pin half way out.

  • Page 95: Cable Track

    4 Remove the electrical outlet box bracket 10 Remove the retaining fasteners from the mounting fasteners. Remove the outlet box and electrical connector receptacles for the cables lay it to the side. that enter the cable track. Part No. 77828 S-60 • S-65 4 - 13...
  • Page 96 15 Attach a strap from an overhead crane to the cable track. 16 Remove the cotter pin from the cable track pull tube at the platform end of the boom. Always replace the cotter pin with a new one. 4 - 14 S-60 • S-65 Part No. 77828...
  • Page 97 6 Remove the hose and cable clamps from the all cables that enter the cable track. platform support and jib boom. 12 Remove the retaining fasteners from the electrical connector receptacles for the cables that enter the cable track. Part No. 77828 S-60 • S-65 4 - 15...
  • Page 98 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. 4 - 16 S-60 • S-65 Part No. 77828...
  • Page 99 A cable track repair kit is available 9 Operate the boom extend/retract function through the Genie Industries through a full cycle to ensure smooth operation Service Parts Department, of the new section of cable track.

  • Page 100: Boom

    How to Remove the Boom Perform this procedure with the boom in the stowed position. Consult the Genie Industries Service Department for instructions on how to safely remove the boom When removing a hose assembly assembly from the machine. Failure to read and...

  • Page 101: 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. Part No. 77828 S-60 • S-65 4 - 19...

  • Page 102: Boom Extension Cylinder

    Perform this procedure with the boom fully retracted. cable guard 1 Raise the boom to a horizontal position. retaining block 2 Remove the access covers from both sides of the boom at the pivot end. 4 - 20 S-60 • S-65 Part No. 77828...
  • Page 103 Do not allow oil to squirt or spray. extend cable lock nuts extend cable mounting plate extend cable mounting plate fastener extend cable bracket Part No. 77828 S-60 • S-65 4 - 21...

  • Page 104: Boom Extend/Retract Cables

    During removal of the extension 3 Remove the boom cover at the pivot end of the cylinder, the overhead crane strap boom. will need to be carefully adjusted for proper balancing. 4 - 22 S-60 • S-65 Part No. 77828...
  • Page 105 3 Remove the rue rings and clevis pins from the boom extend cables located near the cable break limit switch. cable break limit switch extend cable adjustment nut extend cable pivot plate Part No. 77828 S-60 • S-65 4 - 23...
  • Page 106 A cable pulling tool is available 7 Install the new boom extend cable pulley, pivot through Genie Service Parts pin and snap rings. Department, part no. 94510. Be sure the boom extend cables 15 At the platform end of the boom, pull on the...

  • Page 107: Platform Leveling Master Cylinder

    Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the boom until the master cylinder is above the turntable covers. Part No. 77828 S-60 • S-65 4 - 25...

  • Page 108: Rpm Adjustment - Deutz Models

    0.15 inch / 3.8 mm gap - GM Models crankshaft position sensor can inch / 1.5 mm gap - Ford Models become damaged if the engine is not properly supported when the fasteners are removed. 4 - 26 S-60 • S-65 Part No. 77828...
  • Page 109 7 Remove the engine plate to vibration isolator or pinched. fasteners. 6 Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel. Part No. 77828 S-60 • S-65 4 - 27...
  • Page 110 / 3.8 mm gap - GM Models ® 5 Apply Loctite removable thread sealant to the pump coupler set screw. Torque the set screw to 61 ft-lbs / 83 Nm. Ford and Deutz models 4 - 28 S-60 • S-65 Part No. 77828...
  • Page 111 Perkins models: Torque the bell housing mounting bolts labeled "B" in sequence to 40 ft-lbs / 54 Nm and the mounting bolts labeled "A" to 70 ft-lbs / 95 Nm. Deutz models Perkins models Part No. 77828 S-60 • S-65 4 - 29...

  • Page 112: Engine Fault Codes - Gm And Ford Models

    ECM. It will blink the first digit of a three Contact Genie Industries Service Department for digit code, pause, blink the second assistance in retrieving fault codes.
  • Page 113 5 minutes. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. Part No. 77828 S-60 • S-65 4 - 31...

  • Page 114: Function Pump

    If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 4 - 32 S-60 • S-65 Part No. 77828...

  • Page 115: Drive Pump

    Any internal service to the pump should only be performed at an authorized Eaton Hydraulics center. Call Genie Industries Service Department to locate your local authorized service open closed center.
  • Page 116 Deutz models: Hold the manual fuel shutoff valve clockwise to the closed position. Component damage hazard. Be sure to fill the hydraulic tank to specification and prime the pump after installing the pump. manual fuel shutoff valve 4 - 34 S-60 • S-65 Part No. 77828...
  • Page 117 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 4 - 35...

  • Page 118: Function Manifold Components

    Check valve, 30 psi / 2 bar ....I .... Differential sensing circuit, platform rotate left and jib boom up (S-65) ......20-25 ft-lbs / 27-34 Nm Check valve, 30 psi / 2 bar ....J .... Differential sensing circuit, platform rotate right and jib boom down (S-65) .......
  • Page 119 July 2005 Section 4 • Repair Procedures REV D MANIFOLDS Part No. 77828 S-60 • S-65 4 - 37...
  • Page 120 Flow control valve, 0.6 gpm / 2.27 L/min ......Z ... Platform rotate and jib boom (S-65) ......... 20-25 ft-lbs / 27-34 Nm Check valve, 30 psi / 2 bar ....EE ..Platform rotate and jib boom circuit (S-65) (prevents hydraulic hoses from draining back to tank) ....
  • Page 121 July 2005 Section 4 • Repair Procedures REV D MANIFOLDS Part No. 77828 S-60 • S-65 4 - 39...

  • Page 122: Valve Adjustments - Function Manifold

    Install the relief valve cap. 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. 4 - 40 S-60 • S-65 Part No. 77828...

  • Page 123: 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 Part No. 77828 S-60 • S-65 4 - 41...

  • Page 124: 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 4 - 42 S-60 • S-65 Part No. 77828...

  • Page 125: Turntable Rotation Manifold Components

    Counterbalance valve ....MM ..Turntable rotate right ....... 35-40 ft-lbs / 47-54 Nm Counterbalance valve ....NN ... Turntable rotate left ......35-40 ft-lbs / 47-54 Nm Orifice, 0.030 inch / 0.76 mm ..PP ... Brake release circuit (located inside port) Part No. 77828 S-60 • S-65 4 - 43...

  • Page 126: 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 4 - 44 S-60 • S-65 Part No. 77828...
  • Page 127 The tires on some machines are drive chassis level, repeat steps 6 foam-filled and do not need air through 11 OR consult Genie added to them. Industries Service Department. 4 Remove the drive chassis cover and the non- steer axle covers.

  • Page 128: 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. 4 - 46 S-60 • S-65 Part No. 77828...
  • Page 129 July 2005 Section 4 • Repair Procedures REV D MANIFOLDS This page intentionally left blank. Part No. 77828 S-60 • S-65 4 - 47...

  • Page 130: Traction Manifold Components, 2Wd

    Shuttle valve, 3 position 3 way ..UU ..Charge pressure circuit that directs hot oil out of low pressure side of drive pump ......50-55 ft-lbs / 68-75 Nm Orifice, 0.070 inch / 1.78 mm .... VV ..Drive motor circuit 4 - 48 S-60 • S-65 Part No. 77828...
  • Page 131 July 2005 Section 4 • Repair Procedures REV D MANIFOLDS Part No. 77828 S-60 • S-65 4 - 49...

  • Page 132: Valve Adjustments, 2Wd Traction Manifold

    Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap. 10 Turn the engine off and remove the pressure gauge. 4 - 50 S-60 • S-65 Part No. 77828...
  • Page 133 July 2005 Section 4 • Repair Procedures REV D MANIFOLDS This page intentionally left blank. Part No. 77828 S-60 • S-65 4 - 51...

  • Page 134: 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 4 - 52 S-60 • S-65 Part No. 77828...
  • Page 135 July 2005 Section 4 • Repair Procedures REV D MANIFOLDS Part No. 77828 S-60 • S-65 4 - 53...

  • Page 136: Valve Adjustments, 4Wd Traction Manifold

    Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap. 10 Turn the engine off and remove the pressure gauge. 4 - 54 S-60 • S-65 Part No. 77828...

  • Page 137: Valve Coils

    MANIFOLDS 7-12 How to Test a Coil Diode Valve Coils Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional How to Test a Coil valves and those coils with a metal case. Properly functioning coil diodes protect the electrical circuit A properly functioning coil provides an by suppressing voltage spikes.
  • Page 138 9V DC battery 10Ω resistor coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6 4 - 56 S-60 • S-65 Part No. 77828...

  • Page 139: Turntable Rotation Assembly

    Crushing hazard. The turntable rotation drive hub assembly could become unbalanced and fall when removed from the machine if not properly supported. Part No. 77828 S-60 • S-65 4 - 57...
  • Page 140 Then torque the mounting fasteners on the backlash pivot plate to 260 ft-lbs / 352.5 Nm. 7 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary. 4 - 58 S-60 • S-65 Part No. 77828...

  • Page 141: Oscillate Axle Cylinders

    Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 77828 S-60 • S-65 4 - 59...
  • Page 142 Section 4 • Repair Procedures July 2005 This page intentionally left blank. 4 - 60 S-60 • S-65 Part No. 77828...
  • Page 143 Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie S-60 and Genie S-65 Operator’s Manual. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Read each appropiate fault code thoroughly.
  • Page 144 OR use a grounded wrist strap. 5 - 2 S-60 • S-65 Part No. 77828...
  • Page 145 (transient) Boom 2 directional Limited speed and valves direction frozen at Power up Fault zero and neutral. controller with Alarm sounds problem corrected. indicating fault. Continued on next page Part No. 77828 S-60 • S-65 5 - 3...
  • Page 146 Self-clearing. Just calibrated is zero. (transient) Drive enable Enable override Power up override switches Fault direction is frozen at controller with neutral. problem corrected. 5 - 4 S-60 • S-65 Part No. 77828...
  • Page 147 Initiate 1-second beep Self-clearing. 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 5 - 5...

  • Page 148: A Fault Codes - Ford Engine

    Check Engine Light. Refer to Repair Procedure 5-4, How to Retrieve Engine Fault Codes. Use the Fault Code Chart on the following pages to aid in identifying the fault. 5 - 6 S-60 • S-65 Part No. 77828...
  • Page 149 Repair wiring and/or connections OR replace IAT Low Voltage shorted OR sensor is faulty OR engine intake air sensor OR direct cooler air into air intake. temperature is too hot. Continued on next page Part No. 77828 S-60 • S-65 5 - 7...
  • Page 150 Repair wiring and/or connections to fuel Injector Driver #2 Shorted shorted OR fuel injector #2 is faulty OR ECM is injector #2 OR replace fuel injector #2 OR faulty. replace the ECM. 5 - 8 S-60 • S-65 Part No. 77828...
  • Page 151 Wiring and/or connections to ignition coil #2 Repair wiring and/or connections to ignition Coil Driver #2 Shorted shorted OR ignition coil #2 is faulty. coil #2 OR replace ignition coil #2. Continued on next page Part No. 77828 S-60 • S-65 5 - 9...
  • Page 152 Cause Solution If this fault appears on your machine, contact FPP1 High Voltage Not used. Genie Industries Service Department. If this fault appears on your machine, contact FPP1 Low Voltage Not used. Genie Industries Service Department. If this fault appears on your machine, contact FPP1 Higher than IVS Limit Not used.
  • Page 153 Locate and repair any engine harness wiring Loose wire connections to ECM OR ECM is RTI 3 Loss damage or shorts to ECM to be sure they are faulty.S secure OR replace ECM. Part No. 77828 S-60 • S-65 5 - 11...
  • Page 154 Section 5 • Fault Codes July 2005 This page intentionally left blank. 5 - 12 S-60 • S-65 Part No. 77828...
  • Page 155 Do not allow oil to squirt Read, understand and obey the safety rules or spray. and operating instructions printed in the Genie S-60 & Genie S-65 Operator's Manual on General Repair Process your machine. Be sure that all necessary tools and test...
  • Page 156 Fuse with amperage 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 Part No. 77828...
  • Page 157 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 6 - 3...
  • Page 158 Section 6 • Schematics July 2005 6 - 4 S-60 • S-65 Part No. 77828...
  • Page 159 LT BLUE/DK BLUE 18 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 Part No. 77828 S-60 • S-65 6 - 5...
  • Page 160 July 2005 Section 6 • Schematics GM 3.0L Engine Wire Harness...
  • Page 161 PLUG (GROUND) 361A R 16 77 DB-Y 18 PLUG (RELAY POWER) 459 O-LG 18 361A R 16 PLUG (CAN -) 361A R 16 662 DG-P 18 PLUG (CAN +) WPTWR2_GY MTRTWR4 MTRSHD4 Part No. 77828 S-60 • S-65 6 - 6...
  • Page 162 July 2005 Section 6 • Schematics Ford LRG-425 EFI Engine Wire Harness...
  • Page 164 TB23 TB20 TB41 TB45 TB27 P134PWR TB39 P134PWR TB35 TB24 TB21 CR23 CR23 ALTERNATOR TS64 FUSE BAT. LINK GND. CR17 87a 87 STA. FLD. FUEL PUMP REGULATOR 12V DC STARTER PUMP 6 - 7 S-60 • S-65 Part No. 77828...
  • Page 165 TB17 TB15 TB40 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 6 - 8...
  • Page 166 July 2005 Section 6 • Schematics Electrical Schematic, S-60 GM 3.0L Models...
  • Page 167 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60 GM 3.0L Models...
  • Page 168 BK C16-1 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 - 9 S-60 • S-65 Part No. 77828...
  • Page 169 PLATFORM ROTATE TOGGLE SWITCH TS59 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 6 - 10...
  • Page 170 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 GM 3.0L Models...
  • Page 171 Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-60 GM 3.0L Models...
  • Page 172 HARNESS (TO SWITCH 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 - 11 S-60 • S-65 Part No. 77828...
  • Page 173 FUSE 10A (WORKLIGHT ONLY) FUEL SELECT EMERGENCY TS14 STOP TS47 ENGINE HIGH/LOW HIGH/LOW PLATFORM HORN GENERATOR START PLATFORM AUXILIARY (2WD/4WD) ROTATE PUMP (OPTION) LEVEL WH-24 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77828 S-60 • S-65 6 - 12...
  • Page 174 July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-60 GM 3.0L Models...
  • Page 176 Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV C GM 3.0L Models C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK P26ESTP BK P26ESTP BK RD(FS) C9P-3 P25FS RD C9P-1 BK BK(FS) WH(FS) C9P-2 P24FS WH P24FS WH FUSE 10A TS48...
  • Page 177 July 2005 Section 6 • Schematics REV C Electrical Schematic, S-65 GM 3.0L Models P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15 TS14 P24FS WH PRIMARY EXT/RET PRI UP/DN &...
  • Page 178 July 2005 Section 6 • Schematics Electrical Schematic, S-65 GM 3.0L Models...
  • Page 179 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 GM 3.0L Models...
  • Page 180 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV B GM 3.0L Models ENGINE FUNCTION HARNESS F.H. BRN C37-2 BK C16-1 WH C11-2 WH LS2 C10-2 BRN-GND BRN-TS64 BRN C7B-3 F.H. F.H. F.H. F.H.
  • Page 181 July 2005 Section 6 • Schematics REV B Ground Control Box Switch Panel Wiring Diagram, S-65 GM 3.0L Models GR/BK RD/BK-2 RD-1 GR/BK WH-23 RD/WH RD/WH LABEL DESCRIPTION CIRCUIT BREAKER, CONTROLS, 15A CIRCUIT BREAKER, OPTIONS, 15A IGNITION / START RELAY...
  • Page 182 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 GM 3.0L Models...
  • Page 183 Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-65 GM 3.0L Models...
  • Page 184 Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-65 REV B GM 3.0L Models ITEM DESCRIPTION TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOTSWITCH CONNECTOR C1P-C4P 48 PIN CONNECTOR BLOCK ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR...
  • Page 185 July 2005 Section 6 • Schematics REV B Platform Control Box Switch Panel Wiring Diagram, S-65 GM 3.0L Models COMPONENT INDEX PLATFORM CONTROL CR13 JIB BOOM CUTOUT RELAY HARNESS BOOM PROPORTIONAL JOYSTICK: (TO CONTROL BOX) BOOM UP/DOWN , TURNTABLE ROTATE...
  • Page 186 July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-65 GM 3.0L Models...
  • Page 188 C35RPM BK/RD ALTERNATOR TS64 FUSE FUSE BAT. 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 - 19 S-60 • S-65 Part No. 77828...
  • Page 189 TB17 TB15 TB40 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 6 - 20...
  • Page 190 July 2005 Section 6 • Schematics Electrical Schematic, S-60 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 192 ALTERNATOR TS64 FUSE 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 - 21 S-60 • S-65 Part No. 77828...
  • Page 193 TB17 TB15 TB40 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 6 - 22...
  • Page 194 July 2005 Section 6 • Schematics Electrical Schematic, S-60 Ford LRG-425 EFI Models (after serial number 11879)
  • Page 195 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 196 F.H. F.H. F.H. 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 - 23 S-60 • S-65 Part No. 77828...
  • Page 197 FUNCTION ENABLE TOGGLE SWITCH TS57 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 6 - 24...
  • Page 198 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 199 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60 Ford LRG-425 EFI Models (after serial number 11879)
  • Page 200 POWER RELAY WH-C5-11 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 - 25 S-60 • S-65 Part No. 77828...
  • Page 201 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 6 - 26...
  • Page 202 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Ford LRG-425 EFI Models (after serial number 11879)
  • Page 203 Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-60 Ford LRG-425 EFI Models...
  • Page 204 48 PIN CONNECTOR BLOCK 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 - 27 S-60 • S-65 Part No. 77828...
  • Page 205 TS14 ENGINE TS47 HIGH/LOW HIGH/LOW HORN START 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 6 - 28...
  • Page 206 July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-60 Ford LRG-425 EFI Models...
  • Page 208 Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV B Ford LRG-425 EFI Models (before serial number 11880) P22LS BK NOTES: P134PWR RD 1. ALL LIMIT SWITCHES SHOWN WITH BOOM C28TTA RD/BK C28TTA RD/BK IN STOWED POSITION. C41RPM OR/BK C1B &...
  • Page 209 July 2005 Section 6 • Schematics REV B Electrical Schematic, S-65 Ford LRG-425 EFI Models (before serial number 11880) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15...
  • Page 210 July 2005 Section 6 • Schematics Electrical Schematic, S-65 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 212 Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV A Ford LRG-425 EFI Models (after serial number 11879) P22LS BK NOTES: P134PWR RD 1. ALL LIMIT SWITCHES SHOWN WITH BOOM C28TTA RD/BK C28TTA RD/BK IN STOWED POSITION. C41RPM OR/BK C1B &...
  • Page 213 July 2005 Section 6 • Schematics REV A Electrical Schematic, S-65 Ford LRG-425 EFI Models (after serial number 11879) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15...
  • Page 214 July 2005 Section 6 • Schematics Electrical Schematic, S-65 Ford LRG-425 EFI Models (after serial number 11879)
  • Page 215 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 216 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV A Ford LRG-425 EFI Models (before serial number 11880) ENGINE FUNCTIONS HARNESS F.H. BRN C37-2 BK C16-1 WH C10-2 WH LS2 C11-2 BRN-GND BRN-TS64 BRN C7B-3 F.H.
  • Page 217 July 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models (before serial number 11880) GR/BK RD/BK-2 RD-1 GR/BK NOTE: WH-23 DASHED LINES INDICATE OPTION WIRES RD/WH RD/WH LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A...
  • Page 218 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models (before serial number 11880)
  • Page 219 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 Ford LRG-425 EFI Models (after serial number 11879)
  • Page 220 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV A Ford LRG-425 EFI Models (after serial number 11879) FUNCTION HARNESS ENGINE F.H. BRN C37-2 BK C16-1 WH C11-2 WH LS2 C10-2 BRN-GND BRN-TS64 BRN C7B-3 F.H.
  • Page 221 July 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models (after serial number 11879) GR/BK RD/WH WH/RD RD/BK-2 RD-1 WH/RD WH/RD WH/RD WH/RD GR/BK WH/RD WH-23 RD/WH RD/WH LABEL DESCRIPTION...
  • Page 222 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models (after serial number 11879)
  • Page 223 Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-65 Ford LRG-425 EFI Models...
  • Page 224 Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-65 REV A Ford LRG-425 EFI Models CR30 CR27 ALC-500 PLATFORM CONTROL CE LIFT/DRIVE OPTION HARNESS (TO SWITCH PANEL) * NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
  • Page 225 July 2005 Section 6 • Schematics REV A Platform Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models PLATFORM CONTROL HARNESS (TO CONTROL BOX) DRIVE LIGHTS/ WORK LIGHTS DLITE RD (OPTION) TILT ALARM LED (ANSI/CSA OPTION) PRIMARY BOOM...
  • Page 226 July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-65 Ford LRG-425 EFI Models...
  • Page 228 ENG. FAULT TEMP. TB21 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 - 39 S-60 • S-65 Part No. 77828...
  • Page 229 TB17 TB15 TB40 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 6 - 40...
  • Page 230 July 2005 Section 6 • Schematics Electrical Schematic, S-60 Deutz F3L-2011 Models (before serial number 11880)
  • Page 232 C5-3 TB21 FUSE 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 - 41 S-60 • S-65 Part No. 77828...
  • Page 233 TB17 TB15 TB40 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 6 - 42...
  • Page 234 July 2005 Section 6 • Schematics Electrical Schematic, S-60 Deutz F3L-2011 Models (after serial number 11879)
  • Page 236 ENG. FAULT TEMP. TB21 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 - 43 S-60 • S-65 Part No. 77828...
  • Page 237 TB17 TB15 TB40 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 6 - 44...
  • Page 238 July 2005 Section 6 • Schematics Electrical Schematic, S-60, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 240 C5-3 TB21 FUSE 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 - 45 S-60 • S-65 Part No. 77828...
  • Page 241 TB17 TB15 TB40 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 6 - 46...
  • Page 242 July 2005 Section 6 • Schematics Electrical Schematic, S-60, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 243 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60 Deutz F3L-2011 Models (before serial number 11880)
  • Page 244 GR/BK H6 C32 CONNECTOR 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 - 47 S-60 • S-65 Part No. 77828...
  • Page 245 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 6 - 48...
  • Page 246 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Deutz F3L-2011 Models (before serial number 11880)
  • Page 247 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60 Deutz F3L-2011 Models (after serial number 11879)
  • Page 248 SOLENOID RELAY 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 - 49 S-60 • S-65 Part No. 77828...
  • Page 249 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 6 - 50...
  • Page 250 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Deutz F3L-2011 Models (after serial number 11879)
  • Page 251 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 252 RD-TS51 RD-TS52 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 - 51 S-60 • S-65 Part No. 77828...
  • Page 253 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 6 - 52...
  • Page 254 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 255 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 256 SOLENOID RELAY 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 - 53 S-60 • S-65 Part No. 77828...
  • Page 257 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 6 - 54...
  • Page 258 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 259 Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-60 Deutz F3L-2011 Models...
  • Page 260 CE LIFT/DRIVE OPTION (TO SWITCH 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 - 55 S-60 • S-65 Part No. 77828...
  • Page 261 FUSE 10A (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 6 - 56...
  • Page 262 July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-60 Deutz F3L-2011 Models...
  • Page 264 Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV D Deutz F3L-2011 Models (before serial number 11880) C22LS BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD BK-(FS) WH-(FS)
  • Page 265 July 2005 Section 6 • Schematics REV D Electrical Schematic, S-65 Deutz F3L-2011 Models (before serial number 11880) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15 P24FS WH...
  • Page 266 July 2005 Section 6 • Schematics Electrical Schematic, S-65 Deutz F3L-2011 Models (before serial number 11880)
  • Page 268 Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV A Deutz F3L-2011 Models (after serial number 11879) C22LS BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD BK-(FS) WH-(FS)
  • Page 269 July 2005 Section 6 • Schematics REV A Electrical Schematic, S-65 Deutz F3L-2011 Models (after serial number 11879) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15 P24FS WH...
  • Page 270 July 2005 Section 6 • Schematics Electrical Schematic, S-65 Deutz F3L-2011 Models (after serial number 11879)
  • Page 272 Section 6 • Schematics July 2005 Electrical Schematic, S-65, CE Models REV D Deutz F3L-2011 Models (before serial number 11880) C22LS BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD...
  • Page 273 July 2005 Section 6 • Schematics REV D Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH...
  • Page 274 July 2005 Section 6 • Schematics Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 276 Section 6 • Schematics July 2005 Electrical Schematic, S-65, CE Models REV A Deutz F3L-2011 Models (after serial number 11879) C22LS BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD...
  • Page 277 July 2005 Section 6 • Schematics REV A Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH...
  • Page 278 July 2005 Section 6 • Schematics Electrical Schematic, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 279 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 Deutz F3L-2011 Models (before serial number 11880)
  • Page 280 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV B Deutz F3L-2011 Models (before serial number 11880) ENGINE FUNCTION HARNESS F.H. CE ONLY RD H6 BL/WH-132B P134PWR RD-134C BK-22D2 GR/BK-133B GR/BK-L45 BRN C37-2 BK C16-1...
  • Page 281 July 2005 Section 6 • Schematics REV B Ground Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models (before serial number 11880) GR/BK RD/BK-2 RD-1 GR/BK WH-23 RD/WH RD/WH LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A...
  • Page 282 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models (before serial number 11880)
  • Page 283 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 Deutz F3L-2011 Models (after serial number 11879)
  • Page 284 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV A Deutz F3L-2011 Models (after serial number 11879) FUNCTION HARNESS ENGINE F.H. OPTION ONLY PLATFORM OVER LOAD (CE ONLY) RD H6 BL/WH-132B P134PWR RD-134C BK-22D2...
  • Page 285 July 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models (after serial number 11879) GR/BK RD/WH WH/RD RD/BK-2 RD-1 WH/RD WH/RD WH/RD WH/RD GR/BK WH/RD WH-23 RD/WH RD/WH LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A...
  • Page 286 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models (after serial number 11879)
  • Page 287 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 288 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models REV B Deutz F3L-2011 Models (before serial number 11880) ENGINE FUNCTION HARNESS F.H. CE ONLY RD H6 P134PWR RD-134C BL/WH-132B BK-22D2 GR/BK-133B GR/BK-L45 BRN C37-2...
  • Page 289 July 2005 Section 6 • Schematics REV B Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880) GR/BK RD/BK-2 RD-1 GR/BK WH-23 RD/WH RD/WH LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A...
  • Page 290 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (before serial number 11880)
  • Page 291 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 292 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models REV A Deutz F3L-2011 Models (after serial number 11879) FUNCTION HARNESS ENGINE F.H. RD H6 BL/WH-132B P134PWR RD-134C BK-22D2 GR/BK-133B GR/BK-L45 BRN C37-2 BK C16-1...
  • Page 293 July 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879) GR/BK RD/WH WH/RD RD/BK-2 RD-1 WH/RD WH/RD WH/RD WH/RD GR/BK WH/RD WH-23 RD/WH RD/WH LABEL...
  • Page 294 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models Deutz F3L-2011 Models (after serial number 11879)
  • Page 295 July 2005 Section 6 • Schematics Platform Control Box Wiring Diagram, S-65 Deutz F3L-2011 Models...
  • Page 296 Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-65 REV B Deutz F3L-2011 Models ITEM DESCRIPTION TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR C1P-C4P 48 PIN CONNECTOR BLOCK ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR...
  • Page 297 July 2005 Section 6 • Schematics REV B Platform Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models PLATFORM CONTROL HARNESS (TO CONTROL BOX) COMPONENT INDEX TS48 DRIVE LIGHTS/ CR13 JIB BOOM CUT OUT RELAY WORK LIGHTS DLITE RD...
  • Page 298 July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-65 Deutz F3L-2011 Models...
  • Page 300 ENG. FAULT 15AMP. TEMP. 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 - 75 S-60 • S-65 Part No. 77828...
  • Page 301 TB17 TB15 TB40 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 6 - 76...
  • Page 302 July 2005 Section 6 • Schematics Electrical Schematic, S-60 Perkins 404-22 Models (before serial number 11880)
  • Page 304 TB21 C5-3 TB21 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 - 77 S-60 • S-65 Part No. 77828...
  • Page 305 TB17 TB15 TB40 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 6 - 78...
  • Page 306 July 2005 Section 6 • Schematics Electrical Schematic, S-60 Perkins 404-22 Models (after serial number 11879)
  • Page 307 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60 Perkins 404-22 Models (before serial number 11880)
  • Page 308 GR/BK H6 C32 CONNECTOR 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 - 79 S-60 • S-65 Part No. 77828...
  • Page 309 TS57 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 6 - 80...
  • Page 310 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Perkins 404-22 Models (before serial number 11880)
  • Page 311 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-60 Perkins 404-22 Models (after serial number 11879)
  • Page 312 SOLENOID RELAY 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 - 81 S-60 • S-65 Part No. 77828...
  • Page 313 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 6 - 82...
  • Page 314 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-60 Perkins 404-22 Models (after serial number 11879)
  • Page 315 July 2005 Section 6 • Schematics Platform Control Box Wiring Diagram, S-60 Perkins 404-22 Models...
  • Page 316 CE LIFT/DRIVE OPTION (TO SWITCH 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 TILT 19/18 CONTROL CABLE ALARM 6 - 83 S-60 • S-65 Part No. 77828...
  • Page 317 FUSE 10A (WORKLIGHT ONLY) EMERGENCY STOP TS14 GLOW PLUG ENGINE HIGH/LOW HIGH/LOW TS47 HORN START PLATFORM PLATFORM AUXILIARY (2WD/4WD) GENERATOR LEVEL ROTATE PUMP (OPTION) WH-24 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 77828 S-60 • S-65 6 - 84...
  • Page 318 July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-60 Perkins 404-22 Models...
  • Page 320 Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV D Perkins 404-22 Models (before serial number 11880) C22LS BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD BK-(FS) WH-(FS)
  • Page 321 July 2005 Section 6 • Schematics REV D Electrical Schematic, S-65 Perkins 404-22 Models (before serial number 11880) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15 P24FS WH...
  • Page 322 July 2005 Section 6 • Schematics Electrical Schematic, S-65 Perkins 404-22 Models (before serial number 11880)
  • Page 324 Section 6 • Schematics July 2005 Electrical Schematic, S-65 REV A Perkins 404-22 Models (after serial number 11879) C22LS BK C28TTA RD/BK C28TTA RD/BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P26ESTP BK C9P-1 BK RD-(FS) C9P-3 P25FS RD BK-(FS) WH-(FS)
  • Page 325 July 2005 Section 6 • Schematics REV A Electrical Schematic, S-65 Perkins 404-22 Models (after serial number 11879) P22LS BK P134 RD C28TTA RD/BK C28TTA RD/BK P26ESTP BK P26ESTP BK C41RPM OR/BK C41RPM OR/BK P26ESTP BK P24FS WH TS15 P24FS WH...
  • Page 326 July 2005 Section 6 • Schematics Electrical Schematic, S-65 Perkins 404-22 Models (after serial number 11879)
  • Page 327 July 2005 Section 6 • Schematics Ground Control Box Terminal Strip Wiring Diagram, S-65 Perkins 404-22 Models (before serial number 11880)
  • Page 328 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV B Perkins 404-22 Models (before serial number 11880) ENGINE FUNCTIONS HARNESS F.H. H6 CE OPTION ONLY RD H6 BL/WH-132B P134PWR RD-134C BK-22D2 GR/BK-133B GR/BK-L45 BRN C37-2...
  • Page 329 July 2005 Section 6 • Schematics REV B Ground Control Box Switch Panel Wiring Diagram, S-65 Perkins 404-22 Models (before serial number 11880) GR/BK RD/BK-2 RD-1 GR/BK WH-23 LABEL DESCRIPTION RD/WH RD/WH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A...
  • Page 330 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Perkins 404-22 Models (before serial number 11880)
  • Page 331 July 2005 Section 6 • Schematics Ground Control Box Terminal Strip Wiring Diagram, S-65 Perkins 404-22 Models (after serial number 11879)
  • Page 332 Section 6 • Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram, S-65 REV A Perkins 404-22 Models (after serial number 11879) FUNCTION HARNESS ENGINE F.H. OPTION ONLY PLATFORM OVER LOAD (CE ONLY) RD H6 BL/WH-132B P134PWR RD-134C BK-22D2...
  • Page 333 July 2005 Section 6 • Schematics REV A Ground Control Box Switch Panel Wiring Diagram, S-65 Perkins 404-22 Models (after serial number 11879) GR/BK RD/WH WH/RD RD/BK-2 RD-1 WH/RD WH/RD WH/RD WH/RD GR/BK WH/RD WH-23 RD/WH RD/WH LABEL DESCRIPTION CIRCUIT BREAKER, ENGINE, 15A...
  • Page 334 July 2005 Section 6 • Schematics Ground Control Box Switch Panel Wiring Diagram, S-65 Perkins 404-22 Models (after serial number 11879)
  • Page 335 July 2005 Section 6 • Schematics Platform Control Box Wiring Diagram, S-65 Perkins 404-22 Models...
  • Page 336 Section 6 • Schematics July 2005 Platform Control Box Wiring Diagram, S-65 REV B Perkins 404-22 Models ITEM DESCRIPTION TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOTSWITCH CONNECTOR C1P-C4P 48 PIN CONNECTOR BLOCK ALC-500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR...
  • Page 337 July 2005 Section 6 • Schematics REV B Platform Control Box Switch Panel Wiring Diagram, S-65 Perkins 404-22 Models PLATFORM CONTROL HARNESS (TO CONTROL BOX) COMPONENT INDEX CR13 JIB BOOM CUTOUT RELAY TS48 BOOM PROPORTIONAL JOYSTICK: DRIVE LIGHTS/ BOOM UP/DOWN , TURNTABLE ROTATE...
  • Page 338 July 2005 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram, S-65 Perkins 404-22 Models...
  • Page 339 OIL COOLER 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 6 - 95...
  • Page 340 July 2005 Section 6 • Schematics Hydraulic Schematic, 2WD Models...
  • Page 341 OIL COOLER MANIFOLD RETURN 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 6 - 96...
  • Page 342 July 2005 Section 6 • Schematics Hydraulic Schematic, 4WD Models...
  • Page 343 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie China Genie Scandinavia Phone +86 21 53852570...

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