Genie S-65 XC Service And Repair Manual
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Genie S-65 XC Service And Repair Manual

Serial number range from s65xcm-101
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See also: Operator's Manual
Service and Repair Manual
S
-65 XC
®
Serial Number Range
™
from S65XCM-101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1288652GT
Rev B
September 2018

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Questions and answers

Jr
March 17, 2025

Error code 33. Id12. Won’t let the boom go up or down or ret/ext. until shutoff and restarted

1
1 comments:
Mr. Anderson
May 14, 2025

Error code 33 for the Genie S-65 XC indicates that the boom raise and extend functions should not operate. This condition occurs when the machine is on a slope or not on level ground. To resolve it:

1. Lower the boom to the stowed position.
2. Return the machine to level ground.
3. Stow the boom.

Once on level ground with the boom stowed, the drive function should operate.

This answer is automatically generated

0
CM Chris Moesta
April 25, 2025

How do you start S-65 XC that has no electrical power?

0
1 comments:
Mr. Anderson
May 12, 2025

The Genie S-65 XC drive function will not operate with emergency power, and the standard start procedure requires electrical power. Therefore, it cannot be started with no electrical power.

This answer is automatically generated

0
wilber ferrera
March 5, 2025

no arranca ni hace nada esta bloqueado

0
1 comments:
Mr. Anderson
March 5, 2025

The Genie S-65 XC may not start or respond due to several possible reasons:

1. Engine Fault Codes – The document lists potential engine issues such as:
- Engine Speed Sensor #2 voltage abnormalities (SPN 723, FMI 3, 4, 8, 10).
- Accelerator Pedal Position voltage issues (SPN 29, FMI 3, 4; SPN 91, FMI 3, 4).
- Engine Rack Position Sensor voltage issues (SPN 733, FMI 3, 4).

2. Electrical Issues – The manual advises ensuring:
- All external AC power supply is disconnected.
- Necessary tools and parts are available for troubleshooting.
- Only Genie-approved replacement parts are used.

3. Safety Lockouts – The machine may not operate if:
- The boom is not in the stowed position.
- The turntable is not secured with the rotation lock.
- Wheels are not properly chocked.

To resolve the issue, check for fault codes, inspect electrical connections, secure all safety locks, and ensure proper machine positioning.

This answer is automatically generated

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Summary of Contents for Genie S-65 XC

  • Page 1 Service and Repair Manual Serial Number Range -65 XC ® ™ This manual includes: from S65XCM-101 Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1288652GT Rev B September 2018...

  • Page 2: Find A Manual For This Model

    Copyright © 2015 by Terex Corporation 1288652GT Rev B, September 2018 First Edition, First Printing Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "XC" and "TRAX" are trademarks of Terex South Dakota, Inc.
  • Page 3 September 2018 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 7/2018 New Release 9/2018 Specifications Oscillate valve relief pressure Repair Display menu Schematics Update hydraulic and electrical schematics Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual September 2018 Introduction Serial Number Legend 1 Model 1 Serial label (located under cover) 2 Facility code 2 Serial number (stamped on drive chassis) 3 Sequence number ® ™ ® ™ -60 XC • S -65 XC Part No.

  • Page 5: Safety Rules

    September 2018 Service and Repair Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine 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 Service and Repair Manual September 2018 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    September 2018 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
  • Page 8 4-1 Cable Track ....................44 How to Remove the Cable Track, S-60 XC and S-60 TRAX ......44 How to Remove the Cable Track, S-65 XC and S-65 XC TRAX ....45 How to Repair the Cable Track ............... 47 4-2 Boom ......................
  • Page 9 September 2018 Table of Contents Engines ........................ 65 5-1 RPM Adjustment - Ford and Deutz Models ........... 65 5-2 RPM Adjustment - Perkins 404D-22 Models ..........65 5-3 Flex Plate - Removal ..................65 How to Install a Type "A" Flex Plate..............67 How to Install a Type "B"...
  • Page 10 September 2018 Table of Contents Axle Components ....................96 9-1 Oscillating Axle Cylinders ................96 Section 4 Fault Codes ......................97 Introduction ......................97 Control System Fault Codes ................98 How to Retrieve Control System Fault Codes ..........98 Control System Fault Codes ................99 Engine Fault Codes ..................

  • Page 11: Specifications

    Specifications Section 2 Specific ati ons Performance Specifications Machine Specifications Boom function speeds, maximum from platform Tires and wheels, S-60 XC, S-65 XC controls Tire size (Rough terrain) 355/55D625 Jib boom up (S-65 XC models) 48 to 53 seconds Tire weight, new foam-filled (minimum)

  • Page 12: Hydraulic Oil Specifications

    Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
  • Page 13 September 2018 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...
  • Page 14 Service and Repair Manual September 2018 Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade Viscosity index ISO Grade Kinematic Viscosity Viscosity index cSt @ 200°F / 100°C Kinematic Viscosity cSt @ 104°F / 40°C 44.4 cSt @ 149°F / 65°C Flash point...

  • Page 15: Hydraulic Component Specifications

    September 2018 Service and Repair Manual Specifications Hydraulic Component Auxiliary pump Specifications Type: gear, fixed displacement Displacement 1.75 gpm Drive pump 2.8 L/min Type: bi-directional, variable displacement piston pump Function manifold Flow rate @ 2500 rpm 30.3 gpm System relief valve pressure 3000 psi 115 L/min 207 bar...

  • Page 16: Ford Msg-425 Efi Engine Specifications

    Service and Repair Manual September 2018 Specifications Ford MSG-425 EFI Engine Electronic fuel pump Fuel pressure, static 60 psi Displacement 153 cu in 4.1 bar 2.5 liters Fuel flow rate 0.43 gpm Number of cylinders 1.6 L/min Bore and Stroke 3.5 x 3.9 inches Fuel requirement 89 x 100 mm...

  • Page 17: Deutz D2011 L03I Engine Specifications

    September 2018 Service and Repair Manual Specifications Deutz D2011 L03i Engine Deutz D2011 L03i Engine, continued Fuel injection system Displacement 142 cu in Injection pump make Bosch 2.33 liters Injection pump pressure, 15000 psi Number of cylinders maximum 1034 bar Bore and Stroke 3.7 x 4.4 inches Injector opening pressure...

  • Page 18: Deutz Td2011L04I Engine Specifications

    Service and Repair Manual September 2018 Specifications Deutz TD2011L04i Engine Lubrication system 40 to 60 psi Oil pressure, hot(at 2000 rpm) Displacement 220.9 cu in 2.8 to 4.1 bar 3.62 liters Oil capacity(including filter) 12.8 quarts Number of cylinders 12.1 liters Bore and stroke 3.78 x 4.92 inches Oil viscosity requirements 96 x 125 mm -22°F to 86°F / -30°C to 30°C...
  • Page 19 September 2018 Service and Repair Manual Specifications Deutz TD2011L04i Engine, continued Fuel injection system Injection pump make Motorpal Injection pump pressure, maximum 15,000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine.

  • Page 20: Deutz D 2.9 L4 Engine Specifications

    Service and Repair Manual September 2018 Specifications Deutz D 2.9 L4 Engine Oil viscosity requirements -22° F to 86° F/ -30° C to 30° C 5W-30 (synthetic) Displacement 177 cu in -4° F to 90° F / -20° C to 32° C 10W-40 2.9 liters Above 23°...

  • Page 21: Perkins 404D-22 Engine Specifications

    September 2018 Service and Repair Manual Specifications Perkins 404D-22 Engine Oil pressure sending unit Oil pressure switch point 14.2 psi Displacement 134 cu in 1 bar 2.2 liters Fuel injection system Number of cylinders Injection pump make Zexel Bore and Stroke 3.31 x 3.94 inches Injection pressure 2133 psi...

  • Page 22: Machine Torque Specifications

    Service and Repair Manual September 2018 Specifications Machine Torque Specifications TRAX Torque Specifications Platform rotator 1-8 center bolt, GR 5 500 ft-lbs Sprocket to hub adapter fasteners 678 Nm 3/4 -10 nuts, GR 8, dry 317 ft-lbs 1/2 -13 bolts, GR 8 90 ft-lbs 430 Nm 122 Nm...

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends be...

  • Page 24: Torque Procedure

    Refer to Illustration 1. hose end are custom-size O-rings. They are not standard size O-rings. They are available in the O-ring field service kit (Genie part number 49612). Lubricate the O-ring before installation. Be sure the O-ring face seal is seated and retained properly.
  • Page 25 September 2018 Service and Repair Manual Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.

  • Page 26: Repair Procedures

    Be sure that all necessary tools and parts are available and ready for use. Use only Genie approved replacement parts. Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.
  • Page 27 September 2018 Service and Repair Manual Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.

  • Page 28: Control System

    Service and Repair Manual September 2018 Control System ALC-600 Control Module Platform Controls The platform control box contains the ALC-600 platform Control Module. The platform Control Module receives all signals from the platform switches, joysticks and foot switch, and provides operator feedback through an Indicator Module.

  • Page 29: Service Mode

    September 2018 Service and Repair Manual Control System The Control System on this machine allows access to calibrations through the Service Mode. The How to Enter ALC-600 Service procedures that follow may require the operator to Mode already be in the Service Mode. The Service Mode can only be entered at machine start up and requires a special code.

  • Page 30: How To Use The Recovery Mode

    Service and Repair Manual September 2018 Control System While pressing the ground function enable button, push and hold the recovery toggle How to Use the Recovery Mode switch in the recovery position. Recovery is only to be used as a last attempt to Result: The auxiliary power unit will turn on lower the platform when the operator in the platform and the boom will begin the following recovery...

  • Page 31: Full Machine Calibration

    Calibration procedures shall only be completed by maximum speed setting should be adjusted to qualified technicians that have Genie factory maintain optimum performance. The maximum service training. speed settings on the joystick can be changed to compensate for hydraulic pump wear to maintain Tip-over hazard.

  • Page 32: How To Adjust The Joystick Ramp Rate Setting

    Service and Repair Manual September 2018 Control System How to Adj ust the Joystic k Ramp R ate Setting Start a timer and activate the machine function How to Adjust the Joystick Ramp that needs to be adjusted. Using the ground Rate Setting control functions is the same as asking for full joystick deflection at the platform.

  • Page 33: How To Adjust The Joystick Threshold Setting

    September 2018 Service and Repair Manual Control System How to Adj ust the Joystic k Thr eshol d Setting Start the engine from the ground controls. How to Adjust the Joystick Start a timer and activate the machine function Threshold Setting that needs to be adjusted.

  • Page 34: How To Enter Alc600 Software Update Mode

    1-6 H ow to Enter ALC 600 Software U pdate Mode How to Enter ALC600 Software Update Mode Go to the Genie website http://firmware.genielift.com, select your machine and ALC600 controller type. Enter the machine serial number and part number for the software.
  • Page 35 September 2018 Service and Repair Manual Control System Display Module Menus Screen or Menu Item Default Display Settings Backlight 0 - 100% Contrast 0 - 100% Display Inversion On / Off Item Selections Default Screen or Menu Models & Options Model S80XC / S85XC / S60XC / S65XC <select model>...
  • Page 36 Service and Repair Manual September 2018 Control System Screen or Menu Item Default Sensor Calibrations Universal Tilt Sensor Calibrate Load Sense Calibrate Boom Angle Sensor Calibrate Boom Length Sensor Calibrate Screen or Menu Item Default Auto Threshold Boom Up / Down Threshold select OK to Calibrate Calibration Screen or Menu...
  • Page 37 September 2018 Service and Repair Manual Control System Screen or Menu Item Default Deutz TD2011 Threshold default = 2350 rpm Anti-Stall Drive Minimum default = 50% Range default = 100 rpm Hysteresis default = 125 rpm Screen or Menu Item Default Perkins 404D Threshold...
  • Page 38 Service and Repair Manual September 2018 Control System Screen or Menu Item Default Primary Lift Speeds Extend Thresholds 190% max, 50% min, 100% = 506 mA (default) Retract Threshold 251% max, 50% min, 100% = 329 mA (default) Up Threshold 195% max, 50% min, 100% = 620 mA(default) Down Threshold 196% max, 50% min, 100% = 616 mA (default)
  • Page 39 September 2018 Service and Repair Manual Control System Screen or Menu Item Default Turntable Ramps CW Accelerating 5000 ms max, 1000 ms min, 3000 ms (default) CW Decelerating 5000 ms max, 500 ms min, 2000 ms (default) CCW Accelerating 5000 ms max, 1000 ms min, 3000 ms (default) CCW Decelerating 5000 ms max, 500 ms min, 2000 ms (default) Screen or Menu...

  • Page 40: How To Replace The Display Controller (Discon) Module

    Service and Repair Manual September 2018 Repair Procedures Open the ground box lid (1) and disconnect the wire harness going to the display controller How to Replace the Display (DISCON). Controller (DISCON) Module Remove the DISCON door from the back by loosening the four Torx head screws (8) and Push in the red Emergency Stop button to the remove the two ribbon cables (6) connecting...

  • Page 41: How To Replace The Ground Control Overlay

    September 2018 Service and Repair Manual Repair Procedures Evenly tighten the nuts, beginning with the lower center nut, working out and then up. How to Replace the Ground Box Install the new ribbon cables, connecting the Control Overlay ground box overlay to the DISCON and reinstall the DISCON door, using the Torx Push in the red Emergency Stop button to the head screws removed in step 4.
  • Page 42 Service and Repair Manual September 2018 Repair Procedures Disconnect the wire harness connected to the Remove the DISCON door (4) and disconnect DISCON and cut the zip ties securing the the ribbon cables (3) from the Display harness to the ground box lid. Do not remove Controller (DISCON) (2).
  • Page 43 September 2018 Service and Repair Manual Repair Procedures 13 Reinstall the DISCON door using the Torx head screws. Tighten, but do not overtighten. 14 Reinstall the ground box door to the ground box, using the fasteners removed in step 7. Tighten the fasteners securely.

  • Page 44: Platform Components

    Service and Repair Manual September 2018 Platform Components Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft Platform Leveling Slave Cylinder metal drift to drive the rod-end pivot pin out. The slave cylinder and the rotator pivot are thetwo Crushing hazard.

  • Page 45: Platform Rotator

    Do not allow oil to Mark the platform mounting squirt or spray. weldment and the rotator flange before removing the platform S-65 XC: mounting weldment. The platform mounting weldment Support the jib boom leveling arms and the must be replaced in the exact...
  • Page 46 Service and Repair Manual September 2018 Platform Components S-60 XC: S-65 XC: Support the rod end of the platform leveling 11 Remove the pin retaining fasteners from the jib slave cylinder. Protect the cylinder rod from boom and jib boom leveling arms to platform damage.
  • Page 47 September 2018 Service and Repair Manual Platform Components Move the function enable toggle switch to How to Bleed the Platform Rotator either side and hold the platform rotate toggle Note: This procedure will require two people. Do not switch to the right position until the platform is start the engine.

  • Page 48: Platform Overload System

    Service and Repair Manual September 2018 Platform Components 10 Place a 1,000 lb / 454 kg test weight on the platform floor using a suitable lifting device. Platform Overload System Place the weight near the center entry point of the platform, as far away from the operator Proper calibration of the platform overload system controls as possible, as shown in Illustration 1.

  • Page 49: How To Perform Zero Load Platform Overload Calibration

    September 2018 Service and Repair Manual Platform Components 17 Test all machine functions from the ground How to Perform Zero Load controls. Platform Calibration Result: All ground control functions should not Perform this procedure when the required weight operate. The engine should not start or run. for full load calibration is not available.

  • Page 50: How To Replace The Platform Overload Load Cell

    Service and Repair Manual September 2018 Platform Components How to R eplac e the Platfor m Overload Load C ell Assemble the load cell and foot assembly to How to Replace the Load Cell the platform and securely tighten the two Sensor mounting screws.
  • Page 51 September 2018 Service and Repair Manual Platform Components Support and secure the platform to an appropriate lifting device. Platform Remove the platform mounting fasteners and remove the platform from the machine. How to Remove the Platform Crushing hazard. The platform Remove the cable clamp from the top of the could become unstable and fall platform mounting weldment.

  • Page 52: Jib Boom Components

    Service and Repair Manual September 2018 Jib Boom Components Attach a lifting strap from an overhead crane to the jib boom assembly. Jib Boom Place blocks under the platform leveling cylinder for support. Protect the cylinder rod How to Remove the Jib Boom from damage.

  • Page 53: Jib Boom Lift Cylinder

    September 2018 Service and Repair Manual Jib Boom Components Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then Jib Boom Lift Cylinder lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm.

  • Page 54: Boom Components

    Service and Repair Manual September 2018 Boom Components Tag, disconnect and plug the platform leveling slave cylinder hydraulic hoses from the Cable Track bulkhead fittings on the side of the primary boom. Cap the bulkhead fittings. The primary boom cable track guides the cables Bodily injury hazard.

  • Page 55: How To Remove The Cable Track, S-65 Xc And S-65 Xc Trax

    September 2018 Service and Repair Manual Boom Components How to R emove the C able Trac k, S-65 XC and S-65 XC TR AX How to Remove the Cable Track, 14 Place blocks in between the upper and lower cable tracks and secure the upper and lower S-65 XC and S-65 XC TRAX tracks together.
  • Page 56 Service and Repair Manual September 2018 Boom Components Tag, disconnect and plug the hydraulic hoses 18 Remove the cable track pull tube guide from the "V1" and "V2" ports of the jib fasteners from the cable track guide at the boom/platform rotate manifold.

  • Page 57: How To Repair The Cable Track

    The boom cable track can be damaged if it is twisted. Note: A 4 link repair section of cable track is available through the Genie Service Parts Department. Visually inspect the cable track and determine which 4 link section needs to be replaced.
  • Page 58 Service and Repair Manual September 2018 Boom Components Boom components 1 short link arm to boom pivot pin 2 boom 3 boom lift cylinder rod-end pivot pin 4 boom lift cylinder 5 long link arm (ground controls side) 6 long link arm (engine side) 7 long link arm to turntable pivot pin 8 master cylinder cam 9 master cylinder cam link...

  • Page 59: Boom

    September 2018 Service and Repair Manual Boom Components Boom How to R emove the Boom Remove the jib boom. Refer to Repair Procedure, How to Remove the Jib Boom. How to Remove the Boom Remove the cable track. Refer to Repair Procedure, How to Remove the Cable Track.
  • Page 60 Service and Repair Manual September 2018 Repair Procedures 15 Remove the hose and cable guide fasteners at Slowly operate the overhead crane to apply the primary boom pivot pin. Remove the hose tension to the lifting straps. Do not attempt to and cable guide.
  • Page 61 September 2018 Service and Repair Manual Repair Procedures 19 Using auxiliary power, activate the boom down 25 Support the platform leveling master cylinder. function so the cylinder will retract. Retract the Remove the master cylinder rod-end pivot pin cylinder just enough until the rod end of the retaining fasteners.

  • Page 62: Boom Lift Cylinder

    Service and Repair Manual September 2018 Repair Procedures Support and secure both ends of the boom lift cylinder to a second overhead crane or similar Boom Lift Cylinder lifting device. The boom lift cylinder raises and lowers the boom. Remove the pin retaining fastener from the The boom lift cylinder is equipped with boom lift cylinder rod-end pivot pin.

  • Page 63: Boom Extension Cylinder

    September 2018 Service and Repair Manual Repair Procedures Use a slide hammer to remove the barrel-end pivot pins. Boom Extension Cylinder Crushing hazard. The lift cylinder The boom extension cylinder is located inside the could become unbalanced and boom assembly and incorporates cables and fall if not properly supported and pulleys that are responsible for extending the secured to the lifting device.
  • Page 64 Service and Repair Manual September 2018 Repair Procedures Remove the string potentiometer cable break 11 Remove the fasteners from the retaining limit switch mounting fasteners. blocks from the extension cylinder saddle. Remove the blocks. Remove the pulley retaining plate from the string potentiometer pulley bracket.
  • Page 65 September 2018 Service and Repair Manual Repair Procedures 17 Remove the lower extend cable bracket 24 Lift the boom extension cylinder with the crane mounting fasteners and pull back on the until it clears the cylinder saddle inside the bracket to release it from the number 3 boom number 2 boom tube.

  • Page 66: Boom Extend/Retract Cables

    Service and Repair Manual September 2018 Repair Procedures Adjust the extend cable adjustment nuts until approximately 1.5 inches / 4 cm of threads are Boom Extend/Retract Cables visible past the nylock nut. Note: If the cables have been replaced, be sure the How to Adjust the Boom adjustment nuts have been replaced.
  • Page 67 September 2018 Service and Repair Manual Repair Procedures How to Replace the Boom 12 Visually inspect the cable break limit switch arm to be sure the wheel of the limit switch arm Extend/Retract Cables is centered in the notch of the pivot plate. Note: The cable pulleys must also be replaced Note: If the boom extend cables are adjusted when replacing the cables.
  • Page 68 Repair Procedure, How to Adjust the Boom Extend/Retract Cables. Note: A cable pulling tool is available through Genie Service Parts Department (Genie part no. 94510) 15 At the platform end of the boom, pull on the boom retract cable that has the rope attached to it.

  • Page 69: Platform Leveling Master Cylinder

    September 2018 Service and Repair Manual Repair Procedures Place a 2 x 4 x 48 inches / 5 x 10 x 120 cm block of wood across the turntable covers. Platform Leveling Master Cylinder Position the block under the master cylinder. The master cylinder acts as a pump for the slave Remove the pin retaining fastener from the cylinder.

  • Page 70: Primary Boom Angle Sensor Calibration

    Service and Repair Manual September 2018 Repair Procedures When the display prompts the operator to lower the boom, press and hold the function Primary Boom Angle Sensor enable button and the boom down buttons until the display indicates that the lower calibration The primary boom angle sensor is used to limit the point has been obtained.

  • Page 71: Primary Boom Angle Sensor Replacement, Xc

    September 2018 Service and Repair Manual Repair Procedures How to Replace the Primary Boom Angle Sensor From the ground controls raise the primary boom until the sensor assembly is above the counterweight. Push in the red Emergency Stop button to the off position and turn the key switch to the off position.
  • Page 72 Service and Repair Manual September 2018 Repair Procedures Referring to Illustration 2, locate the sensor 11 Remove any old blue thread locker, dirt or oils carrier plate (7) and remove the three phillips from the threaded holes in the pin-guide head screws (8) securing the bracket.

  • Page 73: Boom Length Sensor Calibration

    September 2018 Service and Repair Manual Repair Procedures 14 Apply blue thread locker into the sensor housing threaded holes and insert the sensor Boom Length Sensor carrier plate guiding "finger" into the sensor retainer bracket. Be sure the sensor faces the magnet and the notch on the carrier plate How to Calibrate the Primary aligns with the sensor housing (illustration 1,...
  • Page 74 Service and Repair Manual September 2018 Repair Procedures Press the OK button to continue to capture the maximum extension point. Press the function enable and boom extend buttons until the boom reaches its maximum extension. Continue holding the buttons for several seconds after the boom reaches its maximum extension until the display indicates the calibration point has been captured.

  • Page 75: Engines

    September 2018 Service and Repair Manual Engines Flex Plate RPM Adjustment - Ford and Deutz Models The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and Refer to Maintenance Procedure in the appropriate has a splined center to drive the pump.
  • Page 76 Service and Repair Manual September 2018 Engines How to Remove the Flex Plate Remove the engine mounting plate to bell housing fasteners. Deutz models: Raise the engine slightly using the overhead Remove the tailpipe bracket mounting crane and place a block of wood under the oil fasteners from the engine bell housing.

  • Page 77: How To Install A Type "A" Flex Plate

    September 2018 Service and Repair Manual Engines How to Ins tall a T ype " A" Flex Plate How to Install a Type "A" Flex Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the Plate appropriate gap between coupler and pump end plate for your engine.

  • Page 78: How To Install A Type "B" Flex Plate

    14 ft-lbs / 19 Nm. Then torque the flex plate mounting bolts in sequence to 20 ft-lbs / 27 Nm. Apply a high viscosity coupling grease (Genie part number 128025) to the splines of the pump shaft and flex plate.

  • Page 79: How To Install The Pump And Bell Housing Assembly

    September 2018 Service and Repair Manual Engines How to i nstall the Pump and Bell H ousing Ass embl y How to Install the Pump and Bell Housing Assembly Install the pump and bell housing assembly. Deutz models: Torque the bell housing mounting bolts labeled "C"...

  • Page 80: Ford Msg-425 Engine Fault Codes

    Service and Repair Manual September 2018 Engines Ford MSG-425 Engine Fault Codes How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle position to maintain the engine's running condition...

  • Page 81: Engine Fault Codes - Deutz D 2.9 L4 And Perkins 404F-22 Models

    September 2018 Service and Repair Manual Engines Engine Fault Codes - Deutz D 2.9 L4, D436 L3i and Perkins 404F-22 Models How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle...

  • Page 82: Hydraulic Pump

    Service and Repair Manual September 2018 Hydraulic Pump Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pum Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Function burn skin. Loosen hydraulic Pump connections very slowly to allow the oil pressure to dissipate...

  • Page 83: Drive Pump

    Eaton remove the key from the key Hydraulics center. Call Genie Industries Service switch and tag the machine to Department to locate your local authorized service inform personnel of the center.
  • Page 84 Service and Repair Manual September 2018 Hydraulic Pump Carefully pull the drive pump out until the pump Ford models: Close the valve on the LPG coupler separates from the flex plate. tank then disconnect the hose from the tank. Then move the fuel select switch to the LPG Remove the drive pump from the machine.
  • Page 85 September 2018 Service and Repair Manual This page intentionally left blank. ® ™ ® ™ Part No. 1288652GT -60 XC • S -65 XC...

  • Page 86: Manifolds

    Service and Repair Manual September 2018 Manifolds 7-1 Function Manifold Components The function manifold is located underneath the ground controls side turntable cover. Index Schematic Description Function Torque Item Solenoid valve, 2 position 2 way Boom up 33-37 ft-lbs / 45-50 Nm Solenoid valve, 2 position 2 way Boom down 33-37 ft-lbs / 45-50 Nm...
  • Page 87 September 2018 Service and Repair Manual Manifolds ® ™ ® ™ Part No. 1288652GT -60 XC • S -65 XC...
  • Page 88 Service and Repair Manual September 2018 Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Check valve, 30 psi / 2 bar Platform rotate tank line 20-25 ft-lbs / 27-34 Proportional directional valve Platform level up/down 33-37 ft-lbs / 45-50 Check valve Brake release circuit 8-10 ft-lbs / 10-15...
  • Page 89 September 2018 Service and Repair Manual Manifolds ® ™ ® ™ Part No. 1288652GT -60 XC • S -65 XC...

  • Page 90: Valve Adjustments - Function Manifold

    Service and Repair Manual September 2018 Manifolds How to Adjust the Boom Extend 7-2 Valve Adjustments - Function Relief Valve Manifold Note: Perform this procedure with the boom in the stowed position. How to Adjust the System Relief Valve Note: Refer to Function Manifold Component list to locate the boom extend relief valve.

  • Page 91: Jib Boom / Platform Rotate Manifold Components

    September 2018 Service and Repair Manual Manifolds Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid valve, 2 position 3 way Platform rotate/jib boom select 20-25 ft-lbs / 27-34 Nm ®...

  • Page 92: Turntable Rotation Manifold Components

    Service and Repair Manual September 2018 Manifolds Turntable Rotation Manifold Componentss The turntable rotation manifold is mounted to the turntable rotation motor. Index Schematic Description Function Torque Item Counterbalance valve Turntable rotate right 35-40 ft-lbs / 47-54 Nm Counterbalance valve Turntable rotate left 35-40 ft-lbs / 47-54 Nm Shuttle valve, 2 position 3 way...

  • Page 93: How To Set Up The Oscillate Directional Valve

    0.17in / 4.3mm and the adjustment to the linkage Tip-over hazard. Failure to was completed with the ground and drive chassis perform this procedure on a level level, repeat steps 6 through 11 OR consult Genie floor could compromise the Product Support. stability of the machine resulting in the machine tipping over.
  • Page 94 Service and Repair Manual September 2018 Manifolds Adjust the hex screw. Turn it clockwise to increase the pressure or counterclockwise to Valve Adjustments - Oscillate decrease the pressure. Tighten the jamb nut. Relief Valve Tip-over hazard. Do not adjust the relief valve higher than How to Adjust the Oscillate Relief specified.
  • Page 95 September 2018 Service and Repair Manual This page intentionally left blank. ® ™ ® ™ Part No. 1288652GT -60 XC • S -65 XC...

  • Page 96: Traction Manifold Components, 4Wd

    Service and Repair Manual September 2018 Manifolds Traction Manifold Components, 4WD The traction manifold is mounted inside the drive chassis at the non-steer end. Index Schematic Description Function Torque Item Flow divider/combiner valve Divides flow between diagonal pairs of 80-90 ft-lbs / 108-122 motors Check valve, 5 psi Prevents cavitation in LF motor...
  • Page 97 September 2018 Service and Repair Manual Manifolds ® ™ ® ™ Part No. 1288652GT -60 XC • S -65 XC...

  • Page 98: Valve Adjustments, 4Wd Traction Manifold

    Service and Repair Manual September 2018 Manifolds Hold the charge pressure relief valve and remove the cap (item DI). Valve Adjustments, 4WD Traction Adjust the internal hex socket until the Manifold pressure reading on the gauge is 30 psi / 2 bar less than the pressure reading on the pump.

  • Page 99: Generator Manifold Components

    September 2018 Service and Repair Manual Manifolds 7-10 12 Kw Generator Manifold The generator manifold is mounted on the turntable tray by the fuel tank. Index Schematic Description Function Torque Item Relief valve Generator relief valve 50 ft-lbs / 67 Nm Solenoid Valve Charge pressure circuit 60-65 ft lbs / 81-88 Nm...

  • Page 100: Valve Coils

    Service and Repair Manual September 2018 Manifolds 7-11 Valve Coil Resistance Valve Coils Specification How to Test a Coil Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As A properly functioning coil provides an valve coil resistance is sensitive to changes in air electromotive force which operates the solenoid temperature, the coil resistance will typically...

  • Page 101: How To Test A Coil Diode

    Manifolds How to T est a Coil Di ode How to Test a Coil Diode Genie incorporates spike suppressing diodes in all 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 102: Turntable Rotation Components

    Service and Repair Manual September 2018 Turntable Rotation Components Loosen the backlash pivot plate and adjustment bolts. Turntable Rotation Assembly How to Remove the Turntable Rotation Assembly Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced.

  • Page 103: How To Adjust The Turntable Rotation Gear Backlash

    September 2018 Service and Repair Manual Turntable Rotation Components How to Adj ust the Tur ntabl e R otati on Gear Bac klas h How to Adjust the Turntable Remove the backlash pivot plate mounting bolts. Carefully remove the drive hub assembly Rotation Gear Backlash from the machine.

  • Page 104: How To Calibrate The Turntable Tilt Sensor

    Service and Repair Manual September 2018 Turntable Rotation Components How to Calibrate the Turntable Tilt Push the backlash pivot plate towards the turntable as far as possible (this will push the Sensor rotation gear into the turntable bearing ring Note: Perform this procedure with the boom fully gear).

  • Page 105: September

    September 2018 Service and Repair Manual Turntable Rotation Components A graphic of the machine pitch will now be 13 A graphic of the machine roll will now be shown on the display. By pressing the UP or shown on the display. By pressing the UP and DOWN buttons, the graphic will change to DOWN buttons, the graphic will change to show the counterweight being uphill or...

  • Page 106: Axle Components

    Service and Repair Manual September 2018 Axle Components Tag, disconnect and plug the oscillating axle cylinder hydraulic hoses. Cap the fittings on Oscillating Axle Cylinders the cylinder. The oscillating axle cylinders extend and retract Bodily injury hazard. Spraying between the drive chassis and the axle to maintain hydraulic oil can penetrate and a level chassis while driving over uneven terrain.

  • Page 107: Fault Codes

    September 2018 Service and Repair Manual Fault Codes Section 4 Faul t Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use.

  • Page 108: Control System Fault Codes

    Service and Repair Manual September 2018 Control System Fault Codes How to R etrieve Contr ol System F ault Codes Control System How to Retrieve Control System Fault Codes The machine control system contains two different types of fault codes Active Faults: These faults have been detected in the current operating session.

  • Page 109: Control System Fault Codes

    September 2018 Service and Repair Manual Control System Fault Codes Control System F ault C odes Component ID Name Cause Effect Solution Keyswitch 19 Fault Signals Machine will not Verify with a voltmeter that signals switch C134PLT be functional. properly. * With the keyswitch in the Ground C174GND position, C174GND (WH, TCON J5-12)
  • Page 110 Service and Repair Manual September 2018 Control System Fault Codes Component Name Cause Effect Solution Foot Switch 19 Stuck ON at Foot switch Machine will not * Release foot switch and cycle power. be functional. power up, input was * If problem persists, with a voltmeter verify or timeout detected as that C24FS (WH, PCON J12-2) is LOW...
  • Page 111 September 2018 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Primary 12 Joystick Circuit Boom Up and * Leave joystick in neutral position and cycle power. Boom Up / voltage too C164PUD is Down functions Down high.
  • Page 112 Service and Repair Manual September 2018 Control System Fault Codes Component Name Cause Effect Solution Boom Angle 13 No signal No CAN Boom Up, * Verify sensor power P85PWR (GR, Sensor messages have Extend and TCON J6-7) is at 12 V while the system is been received by Turntable running.
  • Page 113 September 2018 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution * Verify wiring for C7PBE (BK, TCON J4-7) 15 Circuit TCON detected and check for open or short circuits. shorted to that C7PBE circuit is shorted to GND.
  • Page 114 Service and Repair Manual September 2018 Control System Fault Codes Component Name Cause Effect Solution Turntable 12 Circuit TCON detected Turntable * With a voltmeter, measure Y24. Proper Rotate CW shorted to that C4TRL circuit Rotate resistance should be between 5 - 60 ohms. Valve is shorted to 12 V.
  • Page 115 September 2018 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution circuit is shorted to GND. Drive 12 Joystick Circuit C160DRV Drive * Leave joystick in neutral position and Forward / voltage too is above 4.5 V. Forward and cycle power.
  • Page 116 Service and Repair Manual September 2018 Control System Fault Codes Component Name Cause Effect Solution * Verify wiring for C29MS (RD/WH, TCON 15 Circuit TCON detected J2-8) and check for open or short circuits. shorted to that C29MS circuit is shorted to GND.
  • Page 117 September 2018 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution preventing the reaching the KS1 keyswitch contact ESTOP circuit blocks. from functioning. 21 ESTOP TCON detected * Check for open and short circuits in the Return that ESTOP boom cable.
  • Page 118 Service and Repair Manual September 2018 Control System Fault Codes Component Name Cause Effect Solution resistance is not between 55 and 65 ohms, check CAN wire harnesses. * Replace sensor if necessary. 15 Reverse The sensor has * Make sure the platform is not touching loading reported a the ground or an overhead obstruction.
  • Page 119 September 2018 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution voltmeter set to resistance verify that pins 3 and 4 on the harness connector measure between 110 and 130 Ohms. Check wiring and boom cable for open or short circuits if resistance check fails.
  • Page 120 Service and Repair Manual September 2018 Control System Fault Codes Component Name Cause Effect Solution short circuits if resistance check fails. * Replace TCON if necessary. 36 Incorrect TCON's Reprogram the machine with latest software secondary software. Check version processor http://firmware.genielift.com/ for the latest software version.
  • Page 121 September 2018 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution shorted to that C155PCE circuits. circuit is shorted to GND. Turntable 12 Circuit TCON detected Turntable * With a voltmeter, measure Y13. Proper Rotate Flow shorted to that C6TRF circuit Rotate...
  • Page 122 Service and Repair Manual September 2018 Control System Fault Codes Component Name Cause Effect Solution Engine Oil 21 Value too The engine oil Engine may * Stop engine as soon as possible. Pressure pressure is not attempt * Verify the engine oil level. measured as too to start until * Verify the engine oil pump.
  • Page 123 September 2018 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution 160 Steer Left 12 Circuit TCON detected Steer Left * With a voltmeter, measure Y3. Proper Valve shorted to that C37STL function will resistance should be between 5 - 60 ohms. circuit is shorted not operate.
  • Page 124 Service and Repair Manual September 2018 Control System Fault Codes Component Name Cause Effect Solution 178 Engine 21 Fault The engine has Machine will * Check the engine fault codes with an engine diagnostic tool. Warning triggered the function as Lamp Engine Warning normal.

  • Page 125: Engine Fault Codes

    September 2018 Service and Repair Manual Control System Fault Codes Engine F ault C odes Engine Fault Codes Some engine options have their own Electronic Control Module that contains more detailed fault information that is specific to the engine. This system can be accessed by using the engine's dedicated service tool.

  • Page 126: Deutz D 2.9 L4 Engine Fault Codes

    Service and Repair Manual September 2018 Deutz D 2.9 L4 Engine Fault Codes SPN FMI Description SPN = Suspect Parameter Number 1231 Actuator error EGR-Valve; Power FMI = Failure Mode Identifier stage over temp due to high KWP = Keyword Protocol current SPN FMI Description...
  • Page 127 September 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 Physical range check high for KWP = Keyword Protocol battery voltage SPN FMI Description 1181 Physical range check low for...
  • Page 128 Service and Repair Manual September 2018 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description 1008...
  • Page 129 September 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1109 2 Engine shut off demand ignored KWP = Keyword Protocol 1136 0 1398 Physikal range check high for SPN FMI Description...
  • Page 130 Service and Repair Manual September 2018 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2659 2 1527 AGS sensor temperature exhaust KWP = Keyword Protocol gas mass flow; plausibility error SPN FMI Description 2659 12...
  • Page 131 September 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523212 Timeout Error of KWP = Keyword Protocol CAN-Receive-Frame ComEngPrt; Engine Protection FMI KWP Description 523216 Timeout Error of 4766...
  • Page 132 Service and Repair Manual September 2018 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 1170 Internal software error ECU 523605...
  • Page 133 September 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523788 Timeout Error of KWP = Keyword Protocol CAN-Transmit-Frame TrbCH; Status Wastegate FMI KWP Description 523793 Timeout Error of 523717...
  • Page 134 Service and Repair Manual September 2018 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523946 1164 Zero fuel calibration injector 1 (in KWP = Keyword Protocol firing order); minimum value FMI KWP Description exceeded 523922...
  • Page 135 September 2018 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524032 1442 EGR actuator; status message KWP = Keyword Protocol EGRCust is missing FMI KWP Description 524033 1443 EGR actuator;...
  • Page 136 Service and Repair Manual September 2018 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524114 9 1659 Timeout error of KWP = Keyword Protocol CAN-Transmit-Frame A1DOC KWP Description 524115 9 1660 Timeout error of 524102 9 1674 Timeout error of...

  • Page 137: Perkins 404F-22 Engine Fault Codes

    September 2018 Service and Repair Manual Perkins 404F-22 Engine Fault Codes Description SPN = Suspect Parameter Number Engine Speed Sensor #2: Voltage FMI = Failure Mode Identifier Above Normal Description Engine Speed Sensor #2: Voltage Accelerator Pedal Position 2: Voltage Below Normal Above Normal Engine Speed Sensor#2: Abnormal...
  • Page 138 Service and Repair Manual September 2018 Perkins 404F-22 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 4201 Engine Speed Sensor #1: Voltage Description Below Normal 3251 Particulate Trap Differential Pressure: 4201 Engine Speed Sensor #1: Abnormal Voltage Above Normal Frequency, Pulse \Nidth, or Period 3251...

  • Page 139: Ford Msg-425 Engine Fault Codes

    September 2018 Service and Repair Manual Ford MSG-425 Engine Fault Codes How to R etrieve For d M SG-425 Engine F ault C odes How to Retrieve Ford Engine Note: Before the fault codes are displayed, the check engine light will blink a code 1-6-5-4 three Fault Codes times.

  • Page 140: Ford Msg-425 Engine Fault Codes

    Max govern speed override diagnostic information, refer to the Ford MSG-425 TPS1 higher than TPS2 EFI Diagnostic Manual (EDI part number 1080030). TPS2 low voltage Ford MSG-425 EFI Diagnostic Manual TPS2 high voltage Genie part number 162067 TIP Active ® ™ ® ™...
  • Page 141 Fpump relay control ground short diagnostic information, refer to the Ford MSG-425 FPump motor high-side shorted to power EFI Diagnostic Manual (EDI part number 1080030). Fpump relay coil short to power Ford MSG-425 EFI Diagnostic Manual Genie part number 162067 ® ™ ® ™...
  • Page 142 AUX analog PUD1 high EFI Diagnostic Manual (EDI part number 1080030). 1542 AUX analog PUD1 low 1543 AUX analog PUD2 high Ford MSG-425 EFI Diagnostic Manual Genie part number 162067 1544 AUX analog PUD2 low 1545 AUX analog PUD3 high ®...
  • Page 143 EFI Diagnostic Manual (EDI part number 1080030). 2116 FPP2 higher than IVS limit 2120 FPP1 invalid voltage and FPP2 disagrees Ford MSG-425 EFI Diagnostic Manual with IVS Genie part number 162067 2121 FPP1 lower than FPP2 2122 FPP1 high voltage 2123...
  • Page 144 2619 Tach output short to power For further engine fault code troubleshooting and diagnostic information, refer to the Ford MSG-425 EFI Diagnostic Manual (EDI part number 1080030). Ford MSG-425 EFI Diagnostic Manual Genie part number 162067 ® ™ ® ™...

  • Page 145: Schematics

    September 2018 Service and Repair Manual Schematics Section 5 Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, Troubleshooting and repair procedures shall be watches and other jewelry.

  • Page 146: Electrical Symbol Legend

    Service and Repair Manual September 2018 Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing no Quick disconnect...

  • Page 147: Hydraulic Symbols Legend

    September 2018 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve or motor) 3 way...

  • Page 148: Limit Switches And Angle Sensors

    Service and Repair Manual September 2018 Limit Switches and Angle Sensors Types of Limit Switches Numbering Legend There are two types of limit switches, found in Limit Front Circuit Load Operational various locations throughout the machine: Switch Axle Number moment mechanical-type operational/safety switches and Rear Stringpot...

  • Page 149: Limit Switch Location Legend

    September 2018 Service and Repair Manual Limit Switch Location Legend S-60 XC / S-65 XC 1 S24 1 Rotary Sensor 2 LSB1RS 2 LST3S 3 LSB2S 3 LST1O 4 String Potentiometer 4 UTS Limit Switches and Sensors Platform overload sensor...
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  • Page 151: Electrical Schematics

    September 2018 Service and Repair Manual Electrical Schematic- TCON...

  • Page 152: Electrical Schematic, Tcon

    Service and Repair Manual September 2018 Electrical Schematic- TCON ® ™ ® ™ -60 XC • S -65 XC Part No. 1288652GT...
  • Page 153 September 2018 Service and Repair Manual Electrical Schematic- PCON ® ™ ® ™ Part No. 1288652GT -60 XC • S -65 XC...
  • Page 154 Service and Repair Manual September 2018 Electrical Schematic- PCON...
  • Page 155 September 2018 Service and Repair Manual Electrical Schematic- Deutz 2.9L Models...

  • Page 156: Electrical Schematic, Deutz 2.9L Models

    Service and Repair Manual September 2018 Electrical Schematic- Deutz 2.9L Models ® ™ ® ™ -60 XC • S -65 XC Part No. 1288652GT...

  • Page 157: Electrical Schematic, Deutz 2011 Models

    September 2018 Service and Repair Manual Electrical Schematic- Deutz D2011 Models ® ™ ® ™ Part No. 1288652GT -60 XC • S -65 XC...
  • Page 158 Service and Repair Manual September 2018 Electrical Schematic- Deutz D2011 Models...
  • Page 159 September 2018 Service and Repair Manual Electrical Schematic- Perkins 404F Models...

  • Page 160: Electrical Schematic, Perkins 404F-E22Ta Models

    Service and Repair Manual September 2018 Electrical Schematic- Perkins 404F Models ® ™ ® ™ -60 XC • S -65 XC Part No. 1288652GT...

  • Page 161: Electrical Schematic, Perkins 404D-22 Models

    September 2018 Service and Repair Manual Electrical Schematic- Perkins 404D Models ® ™ ® ™ Part No. 1288652GT -60 XC • S -65 XC...
  • Page 162 Service and Repair Manual September 2018 Electrical Schematic- Perkins 404D Models...
  • Page 163 September 2018 Service and Repair Manual Electrical Schematic- Ford MSG425 Models...

  • Page 164: Electrical Schematic, Ford Msg425 Models

    Service and Repair Manual September 2018 Electrical Schematic- Ford MSG425 Models ® ™ ® ™ -60 XC • S -65 XC Part No. 1288652GT...
  • Page 165 September 2018 Service and Repair Manual Electrical Schematic- Generators ® ™ ® ™ Part No. 1288652GT -60 XC • S -65 XC...
  • Page 166 Service and Repair Manual September 2018 Electrical Schematic- Generators...

  • Page 167: Hydraulic Schematics

    September 2018 Service and Repair Manual Hydraulic Schematic, 4WD Models ® ™ ® ™ Part No. 1288652GT -60 XC • S -65 XC...
  • Page 168 Service and Repair Manual September 2018 Hydraulic Schematic, 4WD Models S®-60 XC™ • S®- 65 XC™ Part No. 1288652GT Ser vic e and R epair M anual September 2018...

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