Professional Documents
Culture Documents
Genie S-60 TRAX
Genie S-60 TRAX
Introduction
This manual provides detailed scheduled S-60 and S-65 Service Manual
maintenance information for the machine owner and (before serial number 3090) ................................ 34476
user. It also provides troubleshooting fault codes
S-60 and S-65 Service Manual
and repair procedures for qualified service
(from serial number 3090 to 5388) ....................... 48412
professionals.
Basic mechanical, hydraulic and electrical skills are S-60 and S-65 Service Manual
required to perform most procedures. However, (from serial number 5389 to 9153) ....................... 65196
several procedures require specialized skills, tools,
S-60, S-65 and S-60 HC Service Manual
lifting equipment and a suitable workshop. In these
(from serial number 9154 to 14781) .................... 77828
instances, we strongly recommend that
maintenance and repair be performed at an S-60, S-65, S-60X, S-60XC, S-60 HC and TRAX
authorized Genie dealer service center. (from serial number 21001) ................................ 147753
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All Copyright © 2011 Terex Corporation
communications will be carefully considered for
139188 Rev D February 2012
future printings of this and all other manuals. Fith Edition, Fourth Printing
ii S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012
Revision History
Revision Date Section Procedure / Schematic Page / Description
D 2/2012 Introduction Revision History Added
3 - Maint. 3-1
D1 1/2013 3 - Maint. 3-6, 3-65
REFERENCE EXAMPLES:
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX iii
February 2012
REFERENCE EXAMPLES:
iv S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012
Model: S-60
Serial number: S6005-12345
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: E0186
Machine unladen weight: 20,736lbs / 9,406kg
Foam Tires add 764 lbs/347 kg to weight
PN - 77055
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX v
Section 1 • Safety Rules February 2012
Safety Rules
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
vi S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 1 • Safety Rules
SAFETY RULES
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX vii
February 2012
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Revision History .......................................................................................................... iii
Serial Number Legend ................................................................................................. v
Section 2 Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................ 2 - 3
Manifold Component Specifications ....................................................................... 2 - 4
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 5
Deutz F3L-2011 / Deutz D2011 L03i Engine Specifications .................................... 2 - 6
Perkins 404-22 Engine Specifications .................................................................... 2 - 8
Machine Torque Specifications .............................................................................. 2 - 9
Trax Torque Specifications .................................................................................. 2 - 10
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 11
SAE and Metric Fasteners Torque Charts ............................................................ 2 - 12
viii S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012
TABLE OF CONTENTS
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February 2012
TABLE OF CONTENTS
x S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012
TABLE OF CONTENTS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX xi
February 2012
TABLE OF CONTENTS
xii S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012
TABLE OF CONTENTS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX xiii
February 2012
TABLE OF CONTENTS
Section 6 Schematics
Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend .................................................................................... 6 - 2
Hydraulic Symbols Legend .................................................................................... 6 - 3
Ford Engine Relay Layout ...................................................................................... 6 - 4
Limit Switch Location Legend ................................................................................ 6 - 5
Electrical Schematic, S-60 HC
(before serial number 19039) ........................................................................ 6 - 8
Chassis Wiring Diagram, S-60 HC
(before serial number 19039) ........................................................................ 6 - 9
Ground Control Box Terminal Strip Wiring Diagram, S-60 HC
(before serial number 19039) ...................................................................... 6 - 12
Platform Control Box Wiring Diagram, S-60 HC
(before serial number 19039) ...................................................................... 6 - 13
Electrical Schematic, S-60 HC
(after serial number 19038) ......................................................................... 6 - 16
Chassis Wiring Diagram, S-60 HC
(after serial number 19038) ......................................................................... 6 - 17
Ground Control Box Terminal Strip Wiring Diagram, S-60 HC
(after serial number 19038) ......................................................................... 6 - 20
Platform Control Box Wiring Diagram, S-60 HC
(after serial number 19038) ......................................................................... 6 - 21
xiv S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012
TABLE OF CONTENTS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX xv
February 2012
TABLE OF CONTENTS
xvi S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012
TABLE OF CONTENTS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX xvii
February 2012
TABLE OF CONTENTS
xviii S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 2 • Specifications
Specifications
Machine Specifications Track Components, S-60 TRAX and S-65 TRAX
Tires and wheels, S-60, S-65 and S-60 HC Track material Rubber
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 2-1
Section 2 • Specifications February 2012
SPECIFICATIONS
2-2 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 2 • Specifications
SPECIFICATIONS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 2-3
Section 2 • Specifications February 2012
SPECIFICATIONS
Hot oil relief valve pressure 280 psi SAE No. 12 56 ft-lbs / 76 Nm
19.3 bar
High pressure filter Beta 3 ≥ 200 Proportional solenoid valve, 12V DC 3.7 to 5.7Ω
(schematic item Q)
High pressure filter 51 psi
bypass pressure 3.5 bar
2-4 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 2 • Specifications
SPECIFICATIONS
Horsepower 59 @ 2500 rpm For fuel requirements, refer to the engine Operator's
44 kW @ 2500 rpm Manual on your machine.
Low function idle (computer controlled) 1600 rpm Spark plug type Motorcraft AGSF-32-FEC
27 Hz Spark plug gap 0.049 to 0.053 inches
High function idle (computer controlled) 2500 rpm 1.244 to 1.346 mm
42 Hz Engine coolant
Compression ratio 9.7:1 Capacity 10 quarts
Compression pressure (approx.) 9.5 liters
Pressure (psi or bar) of lowest cylinder must be Cylinder head temperature sending unit
at least 75% of highest cylinder
Fault code set temperature 280°F
Lubrication system 138°C
Oil pressure 29 to 39 psi Engine shut-down temperature 300°F
(at operating temperature @ 2500 rpm) 2 to 2.7 bar 149°C
Oil capacity 4 quarts Starter motor
(including filter) 3.8 liters
Normal engine cranking speed 200 to 250 rpm
Oil pressure switch
Current draw, normal load 140-200A
Oil pressure switch point 7.5 psi
0.51 bar Current draw, maximum load 800A
Oil viscosity requirements Alternator
Extreme operating temperatures may require the use of Output 95A, 13.8V DC
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine. Battery
Quantity 1
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 2-5
Section 2 • Specifications February 2012
SPECIFICATIONS
Bore and stroke 3.7 x 4.4 inches Oil capacity 9.5 quarts
94 x 112 mm (including filter) 9 liters
(Deutz D2011L03i Engine)
Horsepower 48 @ 2800 rpm
36 kW @ 2800 rpm Oil viscosity requirements
2-6 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 2 • Specifications
SPECIFICATIONS
Fuel requirement
Starter motor
Battery
Type 12V DC
Quantity 1
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 2-7
Section 2 • Specifications February 2012
SPECIFICATIONS
Compression pressure 426 psi Oil pressure switch point 14.2 psi
29.4 bar 1 bar
Pressure (psi) of lowest cylinder must Fuel injection system
be within 50 psi / 3.45 bar of highest cylinder
Injection pump make Zexel
Governor centrifugal mechanical
Injection pressure 2133 psi
Valve clearance, cold 147 bar
Intake 0.008 in Fuel requirement
0.2 mm
For fuel requirements, refer to the engine Operator's
Exhaust 0.008 in Manual on your machine.
0.2 mm
Alternator output 55A @ 12V DC
Starter motor
2-8 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 2 • Specifications
SPECIFICATIONS
Reserve capacity @ 25A rate 200 minutes Drive motor and hubs
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 2-9
Section 2 • Specifications February 2012
SPECIFICATIONS
2 - 10 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 2 • Specifications
SPECIFICATIONS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 2 - 11
Section 2 • Specifications February 2012
SPECIFICATIONS
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
2 - 12 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3-1
Section 3 • Scheduled Maintenance Procedures February 2012
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annual and
two years. The Scheduled Maintenance Procedures
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
have been divided into five subsections—A, B, C,
D and E. Use the following chart to determine which
group(s) of procedures are required to perform a
Indicates that a cold engine will be scheduled inspection.
required to perform this procedure.
Inspection Checklist
3-2 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
Pre-Delivery Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Make copies of this form to use for each Pre-Delivery
Pre-delivery Preparation. Preparation.
The Pre-delivery Preparation is performed prior to each Use the operator’s manual on your machine.
delivery. The inspection is designed to discover if
anything is apparently wrong with a machine before it is The Pre-delivery Preparation consists of completing
put into service. the Pre-operation Inspection, the Maintenance items
and the Function Tests.
A damaged or modified machine must never be used.
If damage or any variation from factory delivered Use this form to record the results. Place a check in
condition is discovered, the machine must be tagged the appropriate box after each part is completed.
and removed from service. Follow the instructions in the operator’s manual.
Repairs to the machine may only be made by a If any inspection receives an N, remove the machine
qualified service technician, according to the from service, repair and re-inspect it. After repair, place
manufacturer's specifications. a check in the R box.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
3-4 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3-5
Section 3 • Scheduled Maintenance Procedures February 2012
3-6 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Note: Genie specifications require that this and damage.
procedure be performed daily or every 8 hours, Result: The machine is equipped with all
whichever comes first. required decals, and all decals are legible and in
Maintaining the operator’s and safety manuals in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each machine required decals, or one or more decals are
and should be stored in the container provided in illegible or in poor condition. Remove the
the platform. An illegible or missing manual will not machine from service until the decals are
provide safety and operational information replaced.
necessary for a safe operating condition.
4 Always return the manuals to the storage
In addition, maintaining all of the safety and container after use.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators Note: Contact your authorized Genie distributor or
and personnel to the many possible hazards Genie if replacement manuals or decals are
associated with using this machine. They also needed.
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could result
in unsafe operating conditions.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3-7
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
A-2 A-3
Perform Pre-operation Perform Function Tests
Inspection Completing the function tests is essential to safe
Completing a Pre-operation Inspection is essential machine operation. Function tests are designed to
to safe machine operation. The Pre-operation discover any malfunctions before the machine is
Inspection is a visual inspection performed by the put into service. A malfunctioning machine must
operator prior to each work shift. The inspection is never be used. If malfunctions are discovered, the
designed to discover if anything is apparently wrong machine must be tagged and removed from
with a machine before the operator performs the service.
function tests. The Pre-operation Inspection also Complete information to perform this procedure is
serves to determine if routine maintenance available in the appropriate operator's manual. Refer
procedures are required. to the Operator's Manual on your machine.
Complete information to perform this procedure is
available in the appropriate operator's manual. Refer
to the Operator's Manual on your machine.
3-8 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-4 A-5
Perform Engine Maintenance Check the High Pressure
Hydraulic Filter Condition
Indicator
Note: Engine specifications require that this Note: Genie specifications require that this
procedure be performed daily or every 8 hours, procedure be performed daily or every 8 hours,
whichever comes first. whichever comes first.
Proper engine maintenance, following the engine Maintaining the high pressure hydraulic filter in
manufacturer's maintenance schedule, is essential good condition is essential to good system
to good engine performance and service life. Failure performance and safe machine operation. The filter
to perform the maintenance procedures can lead to condition indicator will show when the hydraulic flow
poor engine performance and component damage. is bypassing a clogged filter. If the filter is not
frequently checked and replaced, impurities will
Required maintenance procedures and additional remain in the hydraulic system and cause
engine information are available in the component damage.
Deutz FL 2011 Operation Manual
(Deutz part number 0297-9929) OR the 1 Open the engine side turntable cover.
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020) OR the 2 Start the engine from the ground controls.
Perkins 400 Series Operation Manual 3 Change the engine idle to high rpm (rabbit
(Perkins part number TPD 1443S). symbol).
4 Visually inspect the filter condition indicator.
Deutz FL 2011 Operation Manual
Genie part number 84794 Result: The filter condition indicator should be
operating with the plunger in the green area.
Ford DSG 423 EFI Operator Handbook
Genie part number 119488 Result: If the indicator displays the plunger in
the red area, this indicates that the hydraulic
Perkins 400 Series Operation Manual filter is being bypassed and the filter should be
Genie part number 94890 replaced. See D-6, Replace the Hydraulic
Filters.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3-9
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
A-6 A-7
Test the Oscillate Axle Inspect the Track Components,
(if equipped) S-60 TRAX and S-65 TRAX
Note: Genie specifications require that this Note: Genie specifications require that this
procedure be performed daily or every 8 hours, procedure be performed daily or every 8 hours,
whichever comes first. whichever comes first.
Proper axle oscillation is essential to safe machine Maintaining tracks and track assembly components
operation. If the axle oscillation system is not is essential to safe operation and good
operating correctly, the stability of the machine is performance. A track assembly failure could result
compromised and it may tip over. in a machine tip-over. Component damage may
also result if problems are not discovered and
1 Start the engine from the platform controls. repaired in a timely fashion.
2 Drive the right steer tire or track (if equipped) up 1 Thoroughly clean the track assembly of any dirt,
onto a 6 inch / 15 cm block or curb. rocks, clay, etc.
Result: The three remaining tires or tracks (if 2 Inspect the following areas for damaged,
equipped) should stay in firm contact with the cracked, loose or missing parts and fasteners:
ground and the chassis should remain level at
all times. • Track
3 Drive the left steer tire or track (if equipped) up • Idler wheels
onto a 6 inch / 15 cm block or curb. • Drive sprocket and hub
Result: The three remaining tires or tracks (if • Bogey wheels
equipped) should stay in firm contact with the • Undercarriage
ground and the chassis should remain level at
• Rotation limiter brackets attached to axles
all times.
• Track assembly fasteners
4 Drive both steer tires or tracks (if equipped) up
onto a 6 inch / 15 cm block or curb.
Result: The non-steer tires or tracks (if
equipped) should stay in firm contact with the
ground.
Note: If the chassis does not remain level during
test, refer to Repair Procedure 7-6, How to Set Up
the Oscillate Directional Valve.
3 - 10 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-8 A-9
Perform 30 Day Service Check the Track Tension and
Fastener Torque, S-60 TRAX and
S-65 TRAX
The 30 day maintenance procedure is a one time
sequence of procedures to be performed after the
first 30 days or 40 hours of usage, whichever
comes first. After this interval, refer to the Note: Manufacturer specifications require that this
maintenance tables for continued scheduled procedure be performed every 30 days.
maintenance.
Maintaining proper track tension and properly
1 Perform the following maintenance procedures: torqued fasteners is essential to good machine
performance and service life. The machine will not
• A-10 Perform Engine Maintenance - operate properly with a track that is incorrectly
Ford and Perkins Models tensioned. Continued use of a machine with
• A-13 Grease the Turntable Bearing and incorrectly tensioned tracks may cause component
Rotate Gear damage.
• B-6 Inspect the Tires, Wheels and 1 Thoroughly clean the track assembly of any dirt,
Lug Nut Torque, S-60, S-65 and rocks, clay, etc.
S-60 HC
2 Chock the tracks at one end of the machine to
• B-8 Check the Drive Hub Oil Level and prevent the machine from rolling.
Fastener Torque
3 Center a lifting jack of ample capacity
• C-1 Perform Engine Maintenance -
(20,000 lbs / 10,000 kg) under the drive chassis
Deutz Models
between the tracks at the other end of the
• D-2 Check the Turnable Rotation machine.
Bearing Bolts
4 Lift the machine until the tracks are off the
• D-6 Replace the Hydraulic Filters ground and then place jack stands under the
drive chassis for support.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 11
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
5 Visually inspect the section of track under the 7 Locate the grease zerk fitting on the other side
bogey wheels. of the track tension cylinder.
Result: There should be less than 1 inch / 8 Pump grease into the grease zerk fitting until
2.5 cm of gap between the bogey wheels and grease, free from air, comes out of the grease
the inside surface of the track. Proceed to step plug. Securely tighten the grease plug. Do not
12. overtighten.
Result: There is 1 inch / 2.5 cm or more of gap 9 Continue to pump grease into the grease zerk
between the bogey wheels and the inside fitting just until the idler wheel moves. Check
surface of the track. Proceed to step 6. the track tension.
10 If necessary, continue to pump grease into the
cylinder until the track has proper tension.
Component damage hazard.
Do not over tighten the track.
Overtightening the track will cause
the machine to lose power during
operation.
Note: If the track becomes too tight, loosen the
grease plug on the cylinder to remove grease and
loosen the track.
a b
a grease zerk
b grease plug
3 - 12 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-10 A-11
Perform Engine Maintenance - Inspect the Fuel Filter/Water
Ford and Perkins Models Separator - Diesel Models
Note: Engine specifications require that this Note: Genie specifications require that this
procedure be performed every 100 hours. Perform procedure be performed every 100 hours or
this procedure more often if dusty conditions exist monthly, whichever comes first.
or the machine is subjected to extended low idle
operation. Proper maintenance of the fuel filter/water separator
is essential for good engine performance. Failure to
Proper engine maintenance, following the engine perform this procedure can lead to poor engine
manufacturer's maintenance schedule, is essential performance and/or hard starting, and continued
to good engine performance and service life. Failure use may result in component damge. Extremely
to perform the maintenance procedures can lead to dirty conditions may require this procedure be
poor engine performance and component damage. performed more often.
Required maintenance procedures and additional Explosion and fire hazard. Engine
engine information are available in the fuels are combustible. Perform this
Ford DSG-423 EFI Operator Handbook procedure in an open, well-
(EDI part number 1060020) OR the ventilated area away from heaters,
Perkins 400 Series Operation Manual sparks, flames and lighted
(Perkins part number TPD 1443S) . tobacco. Always have an approved
fire extinguisher within easy reach.
Ford DSG 423 EFI Operator Handbook Note: Perform this procedure with the engine off.
Genie part number 119488
Perkins Models:
Perkins 400 Series Operation Manual
Genie part number 94890 1 Put on protective clothing and eye wear.
2 Open the engine side turntable cover and locate
the fuel filter/water separator next to the
hydraulic return filter on the bulkhead.
3 Inspect the filter bowl for water buildup.
Result: If water is present in the filter bowl
continue with steps 4 through 8.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 13
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
4 Loosen the vent plug located on the fuel filter/ 8 Start the engine from the ground controls and
water separator head. check the fuel filter/water separator and vent
plug for leaks.
Explosion and fire hazard. If a fuel
a
leak is discovered, keep any
d additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
c
Deutz Models:
b
1 Put on protective clothing and eye wear.
2 Remove the engine tray retaining fastener
located under the engine tray.Swing the engine
tray out and away from the machine.
a vent plug
b drain plug 3 Install the fastener that was just removed
c filter bowl through the engine tray and into the engine tray
d separator head
anchor hole in the turntable.
5 Loosen the drain plug located at the bottom of
Crushing hazard. Failure to install
the bowl. Allow the water to drain into a suitable
the fastener into the engine tray
container until fuel starts to come out.
anchor hole to secure the engine
Immediately tighten the drain plug.
tray from moving could result in
6 Tighten the vent plug. death or serious injury.
Note: If the fuel filter/water separator is completely 4 Locate the fuel filter/water separator next to the
drained, you must prime the fuel filter/water oil filter.
separator before starting the engine. See C-6,
Replace The Fuel Filter/Water Separator Element -
Perkins Models, for instructions on how to prime
the fuel filter/water separator.
7 Clean up any fuel that may have spilled.
3 - 14 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 15
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
2 Loosen the low idle lock nut and turn the low idle A-13
adjustment screw clockwise to increase the
rpm, or counterclockwise to decrease the rpm. Grease the Turntable Rotation
Tighten the low idle lock nut and confirm the Bearing and Rotate Gear
rpm.
3 - 16 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
4 Fill the hub until the oil level is even with the
bottom of the plug hole. Refer to Section 2,
Specifications.
5 Install the plugs into the drive hub.
6 Repeat this procedure for the other drive hub.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 17
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST A PROCEDURES
9 Locate the hub disconnect pin in the center of 16 Raise the machine, remove the jack stands and
the drive hub. Manually depress the pin and lower the machine.
rotate the drive hub until one of the two plugs is
17 Drive the machine in either direction just until
at the lowest point.
the remaining sprocket retaining fasteners can
be installed onto the drive hub adapter. Turn the
machine off.
18 Install the remaining sprocket retaining fasteners
to the drive hub adapter and torque to
specification. Refer to Section 2, Specifications.
19 Repeat this procedure for each drive hub.
a
a drive hub plugs
3 - 18 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-15 A-16
Perform Engine Maintenance - Perform Engine Maintenance -
Ford Models Perkins Models
Note: Engine specifications require that this Note: Engine specifications require that this
procedure be performed every 200 hours. procedure be performed every 200 hours.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure to good engine performance and service life. Failure
to perform the maintenance procedures can lead to to perform the maintenance procedures can lead to
poor engine performance and component damage. poor engine performance and component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
Ford DSG-423 EFI Operator Handbook Perkins 400 Series Operation Manual
(EDI part number 1060020). (Perkins part number TPD 1443S).
Ford DSG 423 EFI Operator Handbook Perkins 400 Series Operation Manual
Genie part number 119488 Genie part number 94890
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 19
Section 3 • Scheduled Maintenance Procedures February 2012
Checklist B Procedures
B-1 4 Be sure that the battery separator wire
connections are tight (if equipped).
Inspect the Battery
5 Fully charge the battery(s) and allow the
battery(s) to rest at least 6 hours.
6 Remove the battery vent caps and check the
Note: Genie specifications require that this specific gravity of each battery cell with a
procedure be performed every 250 hours or hydrometer. Note the results.
quarterly, whichever comes first. 7 Check the ambient air temperature and adjust
Proper battery condition is essential to good engine the specific gravity reading for each cell as
performance and operational safety. Improper fluid follows:
levels or damaged cables and connections can • Add 0.004 to the reading of each cell for
result in engine component damage and hazardous every 10° / 5.5° C above 80° F / 26.7° C.
conditions.
• Subtract 0.004 from the reading of each cell for
Electrocution/burn hazard. Contact every 10° / 5.5° C below 80° F / 26.7° C.
with hot or live circuits could result
in death or serious injury. Remove Result: All battery cells display an adjusted
all rings, watches and other specific gravity of 1.277 or higher. The battery
jewelry. is fully charged. Proceed to step 11.
Bodily injury hazard. Batteries Result: One or more battery cells display a
contain acid. Avoid spilling or specific gravity of 1.217 or below. Proceed to
contacting battery acid. Neutralize step 8.
battery acid spills with baking soda 8 Perform an equalizing charge OR fully charge
and water. the battery(s) and allow the battery(s) to rest at
1 Put on protective clothing and eye wear. least 6 hours.
2 Be sure that the battery cable connections are 9 Remove the battery vent caps and check the
free of corrosion. specific gravity of each battery cell with a
hydrometer. Note the results.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion on
the battery terminals and cables.
3 - 20 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 21
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
3 - 22 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-4 B-5
Inspect the Engine Air Filter - Check the Oil Cooler and
Ford, Deutz and Perkins Models Cooling Fins - Deutz Models
Note: Genie specifications require that this Note: Genie specifications require that this
procedure be performed every 250 hours or procedure be performed every 250 hours or
quarterly, whichever comes first. quarterly, whichever comes first.
Maintaining the engine air filter in good condition is Maintaining the oil cooler in good condition is
essential to good engine performance and service essential for good engine performance. Operating a
life. Failure to perform this procedure can lead to machine with a damaged oil cooler may result in
poor engine performance and component damage. engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
Note: Perform this procedure with the engine off. cooling system.
1 Locate the engine air filter assembly. Bodily injury hazard. Do not
2 Release the latches from the air cleaner canister inspect while the engine
end cap. Remove the end cap. is running. Remove the key to
secure from operation.
3 Remove the filter element.
Burn hazard. Beware of hot engine
4 Clean the inside of the canister and the end cap components. Contact with hot
with a damp cloth. engine components may result in
5 Inspect the air filter element. If needed, blow severe burns.
from the inside out using low pressure dry Oil cooler:
compressed air, or carefully tap out dust.
Replace the filter if needed. 1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
6 Install the filter element. tray out and away from the machine.
7 Install the air filter canister end cap and secure 2 Install the fastener that was just removed
the end cap latches. through the engine tray and into the engine tray
Note: Be sure the discharge valve is pointing down anchor hole in the turntable.
when the cap is instaled. 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. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 23
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
3 - 24 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-7 B-8
Confirm the Proper Check the Drive Hub Oil Level
Brake Configuration and Fastener Torque
Note: Genie specifications require that this Note: Genie specifications require that this
procedure be performed every 250 hours or procedure be performed every 250 hours or
quarterly, whichever comes first. quarterly, whichever comes first.
Proper brake configuration is essential to safe Failure to maintain proper drive hub oil levels may
operation and good machine performance. cause the machine to perform poorly and continued
Hydrostatic brakes and hydraulically-released, use may cause component damage.
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully S-60, S-65 and S-60 HC:
operational. 1 Drive the machine to rotate the hub until the
1 Locate the drive hub disconnect cap. plugs are both horizontal.
a
S-60, S-65, S-60 HC S-60 TRAX, S-65 TRAX
brake disengaged position 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.
brake engaged position
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 25
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
S-60 TRAX and S-65 TRAX: 9 Locate the hub disconnect pin in the center of
the drive hub. Manually depress the pin and
1 Select the drive hub to be serviced. Loosen and rotate the drive hub until the plugs are both
remove as many sprocket retaining fasteners as horizontal.
possible from the hub adapter.
2 Drive the machine in either direction just enough
to access the remaining fasteners. Do not
remove the retaining fasteners.
3 Chock the tracks at the opposite end of the
machine to prevent the machine from rolling.
4 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the tracks.
5 Lift the machine until the tracks are off the
a
ground and then place jack stands under the
drive chassis for support. a drive hub plugs
6 Attach a lifting strap from an overhead crane to 10 Remove one plug and check the oil level.
the center-point of the track assembly, above
Result: The oil level should be even with the
the sprocket.
bottom of the plug hole.
7 Remove the remaining sprocket retaining
fasteners from the hub adapter. 11 If necessary, remove the other plug and add oil
until the oil level is even with the bottom of the
8 Carefully remove the track assembly from the plug hole. Refer to Section 2, Specifications.
drive hub and set aside.
12 Install the plug(s) into the drive hub.
Crushing hazard. The track
13 Check the torque of the drive hub mounting
assembly could become
bolts. Refer to Section 2, Specifications.
unbalanced and fall when removed
from the machine if not properly 14 Attach a lifting strap from an overhead crane to
supported by the overhead crane. the center-point of the track assembly, above
the sprocket.
3 - 26 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
15 Install the track assembly onto the drive hub Turntable rotate drive hub
adapter while guiding the hub adapter studs into
the sprocket of the track assembly. Install as 1 Remove the plug located on the side of the hub
many sprocket retaining fasteners as possible and check the oil level.
to the hub adapter and torque to specification. Result: The oil level should be even with the
Refer to Section 2, Specifications. bottom of the plug hole.
16 Raise the machine, remove the jack stands and
lower the machine.
17 Drive the machine in either direction just until
the remaining sprocket retaining fasteners can
be installed onto the drive hub adapter. Turn the
machine off.
18 Install the remaining sprocket retaining fasteners
a
to the drive hub adapter and torque to
specification. Refer to Section 2, Specifications.
19 Repeat this procedure for each drive hub.
b
a drain/fill plug
b mounting fasteners
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 27
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
3 - 28 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-10 B-11
Test the Ground Control Check the Oscillate Directional
Override Valve Linkage
Note: Genie specifications require that this
procedure be performed every 250 hours or
quarterly, whichever comes first.
Note: Genie specifications require that this
A properly functioning ground control override is procedure be performed every 250 hours or
essential to safe machine operation. The ground quarterly, whichever comes first.
control override function is intended to allow ground
personnel to operate the machine from the ground Note: Perform this test only on models equipped
controls whether or not the Emergency Stop button with a oscillating axle.
on the platform controls is in the on or off position. Proper axle oscillation is essential to safe machine
This function is particularly useful if the operator at operation. If the oscillate directional valve linkage is
the platform controls cannot return the boom to the not operating correctly, the stability of the machine
stowed position. is compromised and it may tip over.
1 Push in the platform red Emergency Stop button 1 Remove the drive chassis cover from the
to the off position. non-steer end of the machine.
2 Start the engine from the ground controls. 2 Locate the oscillate directional valve inside of
3 At the ground controls, operate each boom the non-steer axle and inspect the linkage for
function through a partial cycle. the following:
Result: All boom functions should operate. • Lock nut is tight against yoke
• Yoke clevis pins are installed
• Cotter pins are installed through clevis pins
• Linkage is properly attached to
directional valve
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 29
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-12 B-13
Test the Platform Self-leveling Test the Engine Idle Select
Note: Genie specifications require that this
procedure be performed every 250 hours or
quarterly, whichever comes first.
Note: Genie specifications require that this
procedure be performed every 250 hours or A properly operating engine idle select switch
quarterly, whichever comes first. is essential to good engine performance and safe
machine operation. There are two settings.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is Foot switch activated low idle (turtle symbol)
essential for safe machine operation. The allows the operator to control individual boom
platform is maintained at level by the platform functions.
leveling slave cylinder which operates in a closed
loop hydraulic circuit with the master cylinder Foot switch activated high idle (rabbit symbol)
located at the base of the boom. should be used for normal machine operation. This
A platform self-leveling failure creates an unsafe selection activates high idle only when the foot
working condition for platform and ground switch is pressed down.
personnel. 1 Pull out the red Emergency Stop button to the
1 Start the engine from the ground controls and on position at both the ground and platform
lower the boom into the stowed position. controls.
2 Hold the function enable/rpm select toggle 2 Start the engine from the ground controls then
switch to either side and adjust the platform to a move and hold the function enable/rpm select
level position using the platform level toggle toggle switch to the high idle (rabbit symbol).
switch. Result: The engine should change to high idle.
3 Raise and lower the primary boom through 3 Release the function enable/rpm select toggle
a full cycle. switch.
Result: The platform should remain level at Result: The engine should return to low idle.
all times to within ±5 degrees.
4 Turn the key switch to platform controls.
5 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Result: The engine should not change to
high idle.
6 Press down the foot switch.
Result: The engine should change to high idle.
7 Move the engine idle control switch to foot
switch activated low idle (turtle symbol).
Result: The engine should change to low idle.
3 - 30 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-14 4 Release the foot switch and shut the engine off
by pushing in the red Emergency Stop button in
Test the Fuel Select Operation - to the off position.
Ford Models 5 Move the fuel select switch to LPG.
6 Restart the engine and allow it to run at
low idle.
Note: Genie specifications require that this 7 Press down the foot switch to allow the engine
procedure be performed every 250 hours or to run at high idle.
quarterly, whichever comes first.
Result: The engine should start promptly and
The ability to select and switch between operate smoothly in low and high idle.
gasoline and LPG fuels as needed is essential to
Note: The engine may hesitate momentarily and
safe machine operation. A fuel selection can be
then continue to run on the selected fuel if the fuel
made when the engine is running or not.
source is switched while the engine is running.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate fuel
system problems that could develop into a
hazardous situation.
Note: Perform this test after checking the gasoline
and LPG fuel levels, and warming the engine to
normal operating temperature.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 31
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-15 B-16
Test the Drive Brakes Test the Drive Speed -
Stowed Position
3 - 32 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 33
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
Note: Genie specifications require that this Result: The descent alarm should sound when
procedure be performed every 250 hours or the switch is held down.
quarterly, whichever comes first. 4 Turn the key switch to platform control.
The alarm package includes: Result: The flashing beacon should be on
• Travel alarm and flashing.
• Flashing beacon 5 Press down the foot switch. Move the boom
control handle to the down position, hold for a
Note: The descent alarm is standard equipment on
moment and then release it.
all models after serial number 15908.
Result: The descent alarm should sound when
Alarms and a beacon are installed to alert operators the control handle is held down.
and ground personnel of machine proximity and
motion. The alarm package is installed on the 6 S-65 and S-65 TRAX: Press down the foot
turntable covers. switch. Move the jib boom toggle switch to the
down position, hold for a moment and then
Note: The alarms and beacon will operate with the release it.
engine running or not running.
Result: The descent alarm should sound when
1 Turn the key switch to ground control and pull the control handle is held down.
out the red Emergency Stop button to the on
position at both the ground and platform 7 Press down the foot switch. Move the drive
controls. control handle off center, hold for a moment and
then release it. Move the drive control handle off
Result: The flashing beacon should be on and center in the opposite direction, hold for a
flashing. moment and then release it.
2 Move the function enable/rpm select toggle Result: The travel alarm should sound when the
switch to either side and activate the boom drive control handle is moved off center in either
toggle switch in the down position, hold for a direction.
moment and then release it.
Result: The descent alarm should sound when
the switch is held down.
3 - 34 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-19 B-20
Perform Hydraulic Oil Analysis Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 35
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
7 Using a mild solvent, carefully wash the cap Explosion and fire hazard. Engine
venting system. Dry using low pressure fuels are combustible. Perform this
compressed air. Repeat this procedure procedure in an open, well-
beginning with step 6. ventilated area away from heaters,
sparks, flames and lighted
8 Install the breather cap onto the hydraulic tank. tobacco. Always have an approved
fire extinguisher within easy reach.
Note: Perform this procedure with the engine off.
3 - 36 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
3 Thoroughly clean the outside surfaces of the Bleed the fuel system:
fuel filter assembly.
10 Loosen the vent plug on top of the fuel injection
4 Place a suitable container under the fuel filter pump.
element.
5 Disconnect and plug the fuel line from the fuel
pump to the fuel filter element.
a
c b
a
a vent plug
b fuel injection pump
c fuel lift pump
a fuel line
b filter head
c fuel filter element 11 Operate the priming lever or priming bulb (if
equipped) of the fuel lift pump until fuel, free
6 Remove the fuel filter element with a filter from air, comes from the vent plug. Tighten the
wrench. vent plug.
7 Apply a thin layer of fuel to the new fuel filter 12 Clean up any fuel that may have spilled during
element O-ring. this procedure.
8 Install the new fuel filter element and tighten it 13 Operate the starter motor for intervals of 15
securely by hand. Clean up any fuel that may seconds until the engine starts.
have spilled during the installation procedure.
14 Swing the engine back to its original position
9 Use a permanent ink marker to write the date and install the engine pivot plate retaining
and number of hours from the hour meter on the fastener.
oil filter housing.
Note: It is important to allow the starter motor to
cool for 30 seconds between each 15 second
interval of operation.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 37
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
S-60 HC: Remove the boom end cover from the Note: A pulley groove gauge should be used to
pivot end of the boom while guiding the small check the condition of the pulleys.
cable from the string potentiometer out of the
slot of the cover. Rest the cover and string
potentiometer on the counterweight.
Component damage hazard. The
cable from the string potentiometer
can become damaged if it is
kinked or pinched.
3 - 38 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 39
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST B PROCEDURES
B-24 B-25
Perform Engine Maintenance - Replace the Engine Air Filter
Ford Models Element - Ford Models
Note: Engine specifications require that this Note: Engine specifications require that this
procedure be performed every 400 hours. procedure be performed every 400 hours.
Proper engine maintenance, following the engine Maintaining the engine air filter in good condition is
manufacturer's maintenance schedule, is essential essential to good engine performance and service
to good engine performance and service life. Failure life. Failure to perform this procedure can lead to
to perform the maintenance procedures can lead to poor engine performance and component damage.
poor engine performance and component damage.
Note: Perform this procedure with the engine off.
Required maintenance procedures and additional
engine information are available in the 1 Locate the engine air filter assembly.
Ford DSG-423 EFI Operator Handbook 2 Release the latches from the air cleaner canister
(EDI part number 1060020). end cap. Remove the end cap.
3 Remove and discard the filter element.
Ford DSG 423 EFI Operator Handbook
Genie part number 119488 4 Clean the inside of the canister and the end cap
with a damp cloth.
5 Install the new filter element.
6 Install the air filter canister end cap and secure
the end cap latches.
Note: Be sure the discharge valve is pointing down
when the cap is instaled.
3 - 40 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-26
Perform Engine Maintenance -
Perkins Models
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 41
Section 3 • Scheduled Maintenance Procedures February 2012
Checklist C Procedures
C-1 C-2
Perform Engine Maintenance - Grease the Platform Overload
Deutz Models Mechanism (if equipped), S-60,
S-65, S-60 TRAX and S-65 TRAX
Grease Specification
3 - 42 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 43
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST C PROCEDURES
3 Start the engine from the ground controls and 7 Using a suitable lifting device, place an
level the platform. Do not turn the engine off. additional 50 lbs / 23 kg of weight onto the
platform.
4 Determine the maximum platform capacity.
Refer to the machine serial plate. Result: The alarm should sound.
The platform overload indicator lights should be
5 Using a suitable lifting device, place a test
flashing at both the ground and platform
weight equal to that of the available capacity in
controls.
one of the locations shown.
Refer to Illustration 1. Result: The alarm does not sound and the
platform overload indicator lights are not
Result: The platform overload indicator lights
flashing. Calibrate the platform overload
should be off at both the ground and platform
system. Refer to Repair Proceedure 2-3,
controls and the alarm should not sound.
How to Calibrate the Platform Overload System
Result: The platform overload indicator lights are (if equipped), S-60, S-65, S-60 TRAX and
on and the alarm is sounding. Calibrate the S-65 TRAX.
platform overload system. Refer to Repair
Note: There may be a 2 second delay before the
Proceedure 2-3, How to Calibrate the Platform
overload indicator lights flash and the alarm
Overload System (if equipped), S-60, S-65,
sounds.
S-60 TRAX and S-65 TRAX.
6 Carefully move the test weight to each 8 Carefully move the test weights to each
remaining location. Refer to Illustration 1. remaining location on the platform.
Refer to Illustration 1.
Result: The platform overload indicator lights
Result: The alarm should sound.
should be off at both the ground and platform
controls and the alarm should not sound. The platform overload indicator lights should be
flashing at both the ground and platform
Result: The platform overload indicator lights are controls.
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair Result: The alarm does not sound and the
Proceedure 2-3, How to Calibrate the Platform platform overload indicator lights are not
Overload System (if equipped), S-60, S-65, flashing. Calibrate the platform overload
S-60 TRAX and S-65 TRAX. system. Refer to Repair Proceedure 2-3,
How to Calibrate the Platform Overload System
(if equipped), S-60, S-65, S-60 TRAX and
S-65 TRAX.
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
Illustration 1
3 - 44 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
9 Test all machine functions from the platform 17 Test all machine functions from the platform
controls. controls.
Result: All platform control functions should not Result: All platform control functions should
operate. operate.
10 Turn the key switch to ground control. Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-3,
11 Test all machine functions from the ground
How to Calibrate the Platform Overload System (if
controls.
equipped), S-60, S-65, S-60 TRAX and S-65 TRAX.
Result: All ground control functions should not
18 Using a suitable lifting device, remove the
operate.
remaining test weights from the platform.
12 Activate the auxiliary power toggle switch.
Note: The engine will turn off when the auxiliary
power is activated.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 45
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST C PROCEDURES
Models equipped with the platform overload option Note: If your machine is equipped with any platform
are provided with additional machine components: accessories or options, they must be removed from
an adjustable spring-loaded platform support the platform OR the weights of those options or
subassembly, a limit switch, an electronic module accessories must be subtracted from the test
which receives the overload signal and interrupts weights to accurately calibrate the platform load
power, and an audio/visual warning indication to sense system.
alert the operator of the overload. 1 Remove all weight, tools and equipment from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.
3 - 46 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
2 Turn the key switch to ground control and pull 6 Using a suitable lifting device, remove the test
out the red Emergency Stop button to the on weights from the platform.
position at both the ground and platform
7 Push in the ground controls red Emergency Stop
controls.
button to the off position, then pull the red
3 Start the engine from the ground controls. Emergency Stop button out to the on position to
Do not turn the engine off. reset the control system.
4 Using a suitable lifting device, place an Recovery process from the platform controls:
appropriate test weight equal to 750 lbs /
340.2 kg on to the center of the platform floor. Note: This procedure only operates if the platform
is overloaded or enters the safety envelope.
Result: The amber restricted range of motion
LED at the platform controls should come on 1 With the key switch turned to platform controls,
and the engine should continue to run. activate the auxiliary power toggle switch.
Result: If the amber restricted range of motion Result: The boom will automatically retract until
LED at the platform controls does not come on, it is in the unrestricted zone.
there is no alarm and the engine continues to 2 Push in the platform controls red Emergency
run, the platform load sense system needs to Stop button to the off position, then pull out the
be calibrated. See Repair Procedure 2-4, red Emergency Stop button to the on position to
How to Calibrate the Platform Load Sense reset the system.
System, S-60 HC.
3 Start the engine and lower the boom to the
5 Using a suitable lifting device, place an stowed position.
additional appropriate test weight equal to
501 to 510 lbs / 227.2 to 231.3 kg on to the Recovery process from the ground controls:
center of the platform floor. The total weight in
Note: This procedure only operates if the platform
the platform must equal 1251 to 1260 lbs /
is overloaded or enters the safety envelope.
567.4 to 571.5 kg.
Result: The alarm should sound and the engine 1 Turn the key switch to ground controls.
should turn off. The platform overload indicator 2 Locate the recovery toggle switch on the side of
light should be on at both the ground and the ground control box. Activate the recovery
platform controls. The platform load sense toggle switch and the auxiliary power toggle
system is functioning properly. switch at the same time.
Result: If the alarm does not sound, the engine Result: The boom will automatically fully retract
does not turn off or the platform indicator light and then lower to the stowed position.
does not come on at both the ground and
platform controls, see Repair Procedure 2-4, 3 Push in the ground controls red Emergency Stop
How to Calibrate the Platform Load Sense button to the off position, then pull out the red
System, S-60 HC. Emergency Stop button to the on position to
reset the system.
Note: The weight in the platform must be
1200 lbs / 544.3 kg or less before the engine can
be restarted.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 47
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST C PROCEDURES
C-5
a
Replace the Fuel Filter/Water
Separator - Perkins Models f
e b
d
Note: Genie specifications require that this
procedure be performed every 500 hours or six c
months, whichever comes first.
1 Open the engine side turntable cover and locate 7 Install the bowl onto the new filter element.
the fuel filter/water separator on the bulkhead. 8 Apply a thin layer of oil onto the element gasket.
2 Disconnect and plug the fuel supply hose from Install the filter/bowl assembly onto the filter
the fuel tank to the fuel filter/water separator. head. Tighten the drain plug and vent plug.
3 - 48 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
9 Clean up any diesel fuel that may have spilled 15 Operate the priming lever or priming bulb (if
during the installation procedure. equipped) of the fuel lift pump until fuel, free
from air, comes from the vent plug. Tighten the
10 Install the fuel supply hose from the fuel tank to
vent plug.
the fuel filter/water separator. Tighten the
clamp. 16 Clean up any fuel that may have spilled during
this procedure.
11 Use a permanent ink marker to write the date
and number of hours from the hour meter on the 17 Operate the starter motor for intervals of 15
oil filter housing. seconds until the engine starts.
Bleed the system: Note: It is important to allow the starter motor to
cool for 30 seconds between each 15 second
12 Remove the engine tray retaining fastener interval of operation.
located under the engine tray. Swing the engine
tray out and away from the machine. Note: If the engine runs correctly for a short time
and then stops or runs roughly, check for air in the
13 Install the fastener that was just removed
fuel system. If there is air in the fuel system, there
through the engine tray and into the engine tray
is probably a leak in the low pressure side of the
anchor hole in the turntable.
system.
Crushing hazard. Failure to install
the fastener into the engine tray 18 Swing the engine back to its original position
anchor hole to secure the engine and install the engine pivot plate retaining
fastener.
tray from moving could result in
death or serious injury.
14 Loosen the vent plug on top of the fuel injection
pump.
c b
a vent plug
b fuel injection pump
c fuel lift pump
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 49
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST C PROCEDURES
C-6 C-7
Replace the Engine Air Filter Perform Engine Maintenance -
Element - Deutz and Perkins Perkins Models
Models
3 - 50 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-8
Perform Engine Maintenance -
Ford Models
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 51
Section 3 • Scheduled Maintenance Procedures February 2012
Checklist D Procedures
D-1 4 Extend and retract the primary boom through the
entire range of motion to check for tight spots
Check the Boom Wear Pads that may cause binding or scraping of the boom.
Note: Always maintain squareness between the
outer and inner boom tubes.
3 - 52 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
1 19
13 15
10 7
22 12
6
24
18
4
3
17
23
5
11 21
8 9
16 14
20 2
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 53
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST D PROCEDURES
3 - 54 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
8 Fully retract the boom and raise the boom to full D-4
height. Visually inspect the the dial indicator to
be sure the needle returns to the "zero" position. Replace the Drive Hub Oil
9 Remove the dial indicator and rotate the
turntable 90°.
10 Repeat steps 4 through 9 until the rotation Note: Genie specifications require that this
bearing has been checked in at least four procedure be performed every 1000 hours or
equally spaced areas 90° apart. annually, whichever comes first.
11 Lower the boom to the stowed position and turn Replacing the drive hub oil is essential for good
the machine off. machine performance and service life. Failure to
12 Remove the dial indicator from the machine. replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and continued
use may cause component damage.
4 Fill the hub until the oil level is even with the
bottom of the plug hole. Refer to Section 2,
Specifications.
5 Install the plugs into the drive hub.
6 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
7 Repeat this procedure for each drive hub.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 55
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST D PROCEDURES
S-60 TRAX and S-65 TRAX: 9 Locate the hub disconnect pin in the center of
the drive hub. Manually depress the pin and
1 Select the drive hub to be serviced. Loosen and rotate the drive hub until one of the two plugs is
remove as many sprocket retaining fasteners as at the lowest point.
possible from the hub adapter.
2 Drive the machine in either direction just enough
to access the remaining fasteners. Do not
remove the retaining fasteners.
3 Chock the tracks at the opposite end of the
machine to prevent the machine from rolling.
4 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the tracks.
5 Lift the machine until the tracks are off the a
a drive hub plugs
ground and then place jack stands under the
drive chassis for support. 10 Remove both plugs and drain the oil into a
suitable container.
6 Attach a lifting strap from an overhead crane to
the center-point of the track assembly, above 11 Manually depress the hub disconnect pin and
the sprocket. rotate the drive hub until both plugs are
horizontal.
7 Remove the remaining sprocket retaining
fasteners from the hub adapter. 12 Fill the hub until the oil level is even with the
bottom of the plug hole. Refer to Section 2,
8 Carefully remove the track assembly from the
Specifications.
drive hub and set aside.
13 Install the plugs into the drive hub.
Crushing hazard. The track
assembly could become 14 Check the torque of the drive hub mounting
unbalanced and fall when removed bolts. Refer to Section 2, Specifications.
from the machine if not properly
15 Attach a lifting strap from an overhead crane to
supported by the overhead crane.
the center-point of the track assembly, above
the sprocket.
3 - 56 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 57
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST D PROCEDURES
4 Disengage the drive hubs by turning over the Steer end: 4WD Models
drive hub disconnect caps on each
non-steer end drive hub. 7 Chock the non-steer wheels or tracks to prevent
the machine from rolling.
S-60, S-65, S-60 HC S-60 TRAX, S-65 TRAX 8 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the steer tires or tracks.
9 Lift the wheels or tracks off the ground and then
place jack stands under the drive chassis for
support.
10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
steer end drive hub.
engaged position
3 - 58 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 59
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST D PROCEDURES
5 Install the new filter element into the filter 15 Install the new filter elements into the housings
housing. and tighten them securely.
6 Push the filter element down to be sure the Note: The medium and high pressure filters use the
O-ring on the element is fully seated into the same elements.
housing.
16 Clean up any oil that may have spilled during the
7 Rotate the filter element clockwise to lock it in installation procedure.
place.
17 Use a permanent ink marker to write the date
8 Install the filter housing cap. and number of hours from the hour meter on the
9 Use a permanent ink marker to write the date oil filter housings.
and number of hours from the hour meter on the 18 Start the engine from the ground controls.
oil filter housing.
19 Inspect the filter housings and related
Medium and high pressure filters: components to be sure that there are no leaks.
Note: The medium pressure filter is for the charge
pump and the high pressure filter is for all machine
functions except the drive circuit and oscillating
axle circuit.
3 - 60 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-7
Perform Engine Maintenance -
Deutz Models
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 61
Section 3 • Scheduled Maintenance Procedures February 2012
Checklist E Procedures
E-1 1 Ford models: Turn the valve on the LPG tank
clockwise to the off position (if equipped). Then
Test or Replace the Hydraulic Oil slowly disconnect the hose from the LPG tank.
2 Ford models: Open the clamps from the LPG
tank straps and remove the LPG tank from the
machine (if equipped).
Note: Genie requires that this procedure be
performed every 2000 hours or every two years, 3 Open the ground controls side turntable cover
whichever comes first. Perform this procedure more and locate the two hydraulic tank valves at the
often if dusty conditions exist. hydraulic tank. Close the valves.
3 - 62 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
7 Tag, disconnect and plug the two suction hoses 18 Install the hydraulic return filter housing onto the
and supply hose for the auxiliary pump from the hydraulic tank.
hydraulic tank. Cap the fittings on the tank.
19 Install the hydraulic tank onto the machine.
Note: The hoses can be accessed through the
20 Install the two suction hoses to the suction
access hole under the turntable.
strainers.
8 Disconnect and plug the return filter hydraulic 21 Install the supply hose for the auxiliary power
hose at the return filter. Cap the fitting on the unit and the return filter hose.
filter housing.
22 Open the two hydraulic tank valves at the
9 Remove the ground controls side turntable hydraulic tank.
cover.
23 Fill the tank with hydraulic oil until the level is
10 Support the hydraulic tank with an appropriate
within the top 2 inches / 5 cm of the sight
lifting device.
gauge. Do not overfill.
11 Remove the hydraulic tank mounting fasteners.
24 Clean up any oil that may have spilled.
12 Remove the hydraulic tank from the machine.
25 Prime the pump. Refer to Repair Procedure 6-2,
Crushing hazard. The hydraulic How to Prime the Pump.
tank could become unbalanced
Note: Always use pipe thread sealant when
and fall if not properly supported
installing the suction hose fittings and the drain
when removed from the machine.
plug.
13 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic
return filter housing from the hydraulic tank.
14 Remove the suction strainers from the tank and
clean them using a mild solvent.
15 Rinse out the inside of the tank using a mild
solvent.
16 Install the suction strainers using a thread
sealant on the threads.
17 Install the drain plug using a thread sealant on
the threads.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 63
Section 3 • Scheduled Maintenance Procedures February 2012
CHECKLIST E PROCEDURES
E-2 E-3
Perform Engine Maintenance - Perform Engine Maintenance -
Deutz Models Deutz Models
Note: Engine specifications require that this Note: Engine specifications require that this
procedure be performed every 3000 hours. procedure be performed every 12,000 hours.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure to good engine performance and service life. Failure
to perform the maintenance procedures can lead to to perform the maintenance procedures can lead to
poor engine performance and component damage. poor engine performance and component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
Deutz FL 2011 Operation Manual Deutz FL 2011 Operation Manual
(Deutz part number 0297-9929). (Deutz part number 0297-9929).
3 - 64 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-4
Replace the Boom Extend/
Retract Cables
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 3 - 65
Section 3 • Scheduled Maintenance Procedures February 2012
3 - 66 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point where
repairs can be completed. To re-assemble, perform
Repair procedures shall be completed by a
the disassembly steps in reverse order.
person trained and qualified on the repair of this
machine. Symbols Legend
Immediately tag and remove from service a Safety alert symbol—used to alert
damaged or malfunctioning machine. personnel to potential personal
injury hazards. Obey all safety
Repair any machine damage or malfunction
messages that follow this symbol
before operating the machine.
to avoid possible injury or death.
Before Repairs Start: Used to indicate the presence of
an imminently hazardous situation
Read, understand and obey the safety rules and which, if not avoided, will result in
operating instructions in the appropriate death or serious injury.
Operator's Manual on your machine.
Used to indicate the presence of a
Be sure that all necessary tools and parts are potentially hazardous situation
available and ready for use. which, if not avoided, could result
in death or serious injury.
Use only Genie approved replacement parts.
Used to indicate the presence of a
Read each procedure completely and adhere
potentially hazardous situation
to the instructions. Attempting shortcuts may which, if not avoided, may cause
produce hazardous conditions. minor or moderate injury.
Unless otherwise specified, perform each Used to indicate the presence of a
repair procedure with the machine in the potentially hazardous situation
following configuration: which, if not avoided, may result in
• Machine parked on a firm, level surface property damage.
• Boom in stowed position Indicates that a specific result is expected after
• Turntable rotated with the boom between performing a series of steps.
the non-steer wheels
Indicates that an incorrect result has occurred
• Turntable secured with the turntable after performing a series of steps.
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power disconnected
from the machine
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4-1
Section 4 • Repair Procedures February 2012
Platform Controls
The platform control box contains one printed 1-1
circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional ALC-500 Circuit Board
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall Electrocution/burn hazard. Contact
Effect technology and require no adjustment. The with electrically charged circuits
operating parameters of the joysticks are stored in could result in death or serious
memory at the ECM circuit board at the platform injury. Remove all rings, watches
controls. If a joystick error occurs or if a joystick is and other jewelry.
replaced, it will need to be calibrated before that Note: When the ALC-500 circuit board is replaced,
particular machine function will operate. See 1-2, the joystick controllers will need to be calibrated.
How to Calibrate a Joystick. See 1-2, How to Calibrate a Joystick.
Each joystick controller should operate smoothly
and provide proportional speed control over its How to Remove the ALC-500
entire range of motion. Circuit Board
1 Push in the red Emergency Stop button to the
a
off position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to the
inside of the platform control box.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
d c b
4-2 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
PLATFORM CONTROLS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4-3
Section 4 • Repair Procedures February 2012
PLATFORM CONTROLS
How to Adjust the Joystick 8 Start the engine from the platform controls and
press down the foot switch.
Threshold Setting
9 Select a boom function joystick to set the
The threshold setting of a joystick is the minimum threshold.
output at which a function proportional valve can
open and allow the function to operate. 10 Slowly move the joystick off center in either
direction just until the function begins to move.
Note: Perform this procedure with the boom in the
stowed position. 11 Slowly move the joystick back to the neutral
position. Just before the function stops moving,
1 Pull out the red Emergency Stop button to the move the drive enable toggle switch to either
on position at both the ground and platform side to set the threshold.
controls.
12 Repeat steps 9 through 11 for each boom
2 Turn the key switch to platform control. Do not joystick controlled machine function (boom up/
start the engine. down, boom extend/retract and turntable rotate).
3 Push in the platform controls red Emergency 13 Return the joystick to the neutral position and
Stop button to the off position. wait for approximately 10 seconds to allow the
settings to be saved.
4 Do not press down the foot switch.
Result: The alarm should sound indicating that
5 Move and hold the drive enable toggle switch in
the settings have been saved in memory.
the right position and pull out the red
Emergency Stop button to the on position. Note: Do not operate any machine function during
the 10 second waiting time.
6 As soon as the alarm sounds, release the drive
enable toggle switch. 14 Cycle the red Emergency Stop button off, then
back on.
7 Momentarily activate the drive enable toggle
switch in the right direction 8 times.
Result: There should be a pause and the alarm
should sound 8 times indicating that the
machine is in threshold calibration mode.
Result: The alarm does not sound. Repeat steps
3 through 7.
4-4 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
PLATFORM CONTROLS
How to Adjust the Joystick Result: There should be a pause and the alarm
should sound 4 times indicating that the
Max-out Setting machine is in max-out calibration mode.
The max-out setting of a joystick controls the Result: The alarm does not sound. Repeat steps
maximum speed of a joystick-controlled machine 3 through 7.
function. Whenever a hydraulic cylinder, drive
motor or hydraulic pump is replaced, the max-out 8 Start the engine from the platform controls and
setting should be adjusted to maintain optimum press down the foot switch.
performance. The max-out settings on the joystick 9 Start a timer and activate the machine function
can be changed to compensate for hydraulic pump that needs to be adjusted. Record the time it
wear to maintain peak performance from the takes for that function to complete a full cycle
machine. (ie; boom up).
Note: Perform this procedure with the boom in the 10 Compare the machine function time with the
stowed position. function times listed in Section 2,
Specifications. Determine whether the function
1 Pull out the red Emergency Stop button to the
time needs to increase or decrease.
on position at both the ground and platform
controls. 11 While the joystick is activated, adjust the max-
out setting to achieve the proper function cycle
2 Turn the key switch to platform control. Do not
time. Momentarily move the drive enable toggle
start the engine.
switch in the right direction to increase the
3 Push in the platform controls red Emergency function speed or momentarily move the drive
Stop button to the off position. enable toggle switch in the left direction to
decrease the function speed.
4 Do not press down the foot switch.
Note: Each time the drive enable toggle switch is
5 Move and hold the drive enable toggle switch in momentarily moved, the function speed will change
the right position and pull out the red in 2% increments from a default of 100%, with a
Emergency Stop button to the on position. minimum of 60% and a maximum of 120%.
6 When the alarm sounds, release the drive
enable toggle switch.
7 Momentarily activate the drive enable toggle
switch in the right direction 4 times.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4-5
Section 4 • Repair Procedures February 2012
PLATFORM CONTROLS
12 Repeat steps 9 through 11 for each joystick How to Adjust the Joystick
controlled machine function.
Ramp Rate Setting
13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the The ramp rate setting of a joystick controls the time
settings to be saved. at which it takes for the joystick to reach maximum
output, when moved out of the neutral position. The
Result: The alarm should sound indicating that ramp rate settings of a joystick can be changed to
the settings have been saved in memory. compensate for hydraulic pump wear to maintain
Result: The alarm does not sound. The peak performance from the machine.
minimum or maximum adjustment has been Note: Perform this procedure with the boom in the
obtained. No changes can be saved. stowed position.
Note: Do not operate any machine function during
1 Pull out the red Emergency Stop button to the
the 10 second waiting time.
on position at both the ground and platform
14 Cycle the red Emergency Stop button off, then controls.
back on. 2 Turn the key switch to platform control. Do not
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Emergency Stop button to the on position.
6 When the alarm sounds, release the drive
enable toggle switch.
7 Momentarily activate the drive enable toggle
switch in the right direction 6 times.
Result: There should be a pause and the alarm
should sound 6 times indicating that the
machine is in ramp rate calibration mode.
Result: The alarm does not sound. Repeat steps
3 through 7.
4-6 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
PLATFORM CONTROLS
8 Start the engine from the platform controls and Ramp rate (factory settings)
press down the foot switch.
9 Start a timer and simultaneously move the Boom up/down
transition accelerate 1 second
joystick in either direction full stroke. Note how
transition decelerate 10 seconds
long it takes the function to reach maximum
S ramp accelerate 1 second
speed. This is the ramp rate. S ramp decelerate 0.45 second
10 Compare the function ramp rate time with the
table and determine whether the ramp rate time Boom extend/retract
needs to increase or decrease. accelerate 2 seconds
decelerate 0.5 second
11 Release the foot switch.
Turntable rotate
12 Activate the joystick and adjust the ramp rate. accelerate 2 seconds
Momentarily move the drive enable toggle decelerate 0.75 second
switch in the right direction to increase the time
or momentarily move the drive enable toggle Drive
switch in the left direction to decrease the time. accelerate 2 seconds
decelerate to neutral 0.5 second
Note: Each time the drive enable toggle switch is decelerate, change of direction 0.5 second
momentarily moved, the time will change in 5% decelerate, coasting 0.75 second
increments from a default of 100%, with a minimum decelerate, braking 1 second
of 50% and a maximum of 150%. decelerate, shift from low to high speed 1 second
decelerate, shift from high to low speed 4 seconds
13 Repeat steps 9 through 11 for each joystick
controlled machine function.
14 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
settings to be saved.
Result: The alarm should sound indicating that
the settings have been saved in memory.
Result: The alarm does not sound. The
minimum or maximum adjustment has been
obtained. No changes can be saved.
Note: Do not operate any machine function during
the 10 second waiting time.
15 Cycle the red Emergency Stop button off, then
back on.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4-7
Section 4 • Repair Procedures February 2012
Platform Components
2-1 4 Remove the pin retaining fastener from the slave
cylinder rod-end pivot pin. Use a soft metal drift
Platform Leveling Slave Cylinder to drive the rod-end pivot pin out.
The slave cylinder and the rotator pivot are the Crushing hazard. S-65 and
two primary supports for the platform. The slave S-65 TRAX: The jib boom could
cylinder keeps the platform level through the fall when the slave cylinder rod-end
entire range of boom motion. It operates in a pivot pin is removed if not properly
closed-circuit hydraulic loop with the master supported.
cylinder. The slave cylinder is equipped with 5 Remove the external snap rings from the barrel-
counterbalance valves to prevent movement in end pivot pin.
the event of a hydraulic line failure.
6 Use a soft metal drift to drive the barrel-end
How to Remove the Platform pivot pin out.
Leveling Slave Cylinder 7 Carefully pull the cylinder out of the boom to
access the hydraulic hoses.
Note: Before cylinder removal is considered, bleed
the slave cylinder to be sure there is no air in the 8 Tag, disconnect and plug the hydraulic hoses
closed loop. from the slave cylinder. Cap the fittings on the
cylinder.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the Bodily injury hazard. Spraying
hose end must be replaced. All connections must hydraulic oil can penetrate and
be torqued to specification during installation. Refer burn skin. Loosen hydraulic
to Section 2, Hydraulic Hose and Fitting Torque connections very slowly to allow
Specifications. the oil pressure to dissipate
gradually. Do not allow oil to
1 Extend the boom until the slave cylinder barrel- squirt or spray.
end pivot pin is accessible.
How to Bleed the Slave Cylinder
2 Raise the boom slightly and place blocks under
the platform for support. Note: Do not start the engine. Use auxiliary power
for this procedure.
3 Lower the boom until the platform is resting on
the blocks just enough to support the platform. 1 Simultaneously activate the boom up function
Note: Do not rest the entire weight of the boom on and the platform level up function until the boom
the blocks. is fully raised.
2 Simultaneously activate the boom down function
and the platform level down function until the
boom is fully lowered.
4-8 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
PLATFORM COMPONENTS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4-9
Section 4 • Repair Procedures February 2012
PLATFORM COMPONENTS
8 Remove the pivot pin retaining fasteners from How to Bleed the Platform
both the slave cylinder rod-end pivot pin and the
rotator pivot pin. Rotator
9 Use a soft metal drift to remove both pivot pins. Note: This procedure will require two people. Do not
Remove the platform rotator from the machine. start the engine. Use auxiliary power for this
procedure.
Crushing hazard. The platform
rotator may become unbalanced 1 Move the function enable toggle switch to either
and fall if not properly supported. side and activate the platform rotate toggle
switch to the right then the left through two
Note: When installing the platform rotator fasteners, platform rotation cycles, then hold the switch to
torque the fasteners to specifications. the right position until the platform is fully
10 Lower the jib boom leveling arms. rotated to the right.
10 Lower the jib boom leveling arms. Crushing hazard. Keep clear of the
platform during rotation.
Crushing hazard. The platform
rotator may become unbalanced
and fall if not properly supported.
Note: When installing the platform rotator fasteners,
torque the fasteners to specifications.
4 - 10 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
PLATFORM COMPONENTS
Crushing hazard. Keep clear of the Note: For S-60 HC models, refer to Repair
platform during rotation. Procedure 2-4, Platform Load Sense System,
S-60 HC.
7 Clean up any hydraulic oil that may have spilled.
Note: Perform this procedure with the machine on a
8 Rotate the platform fully in both directions and
firm, level surface.
inspect the bleed screws for leaks.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 11
Section 4 • Repair Procedures February 2012
PLATFORM COMPONENTS
5 Move the platform up and down by hand, so it 7 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2 bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle. inches. Allow the platform to settle.
Result: The overload indicator lights are off and Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6. the alarm does not sound. Proceed to step 8.
Result: The overload indicator lights are flashing Result: The overload indicator lights are flashing
at the platform and ground controls, and the at the platform and ground controls, and the
alarm is sounding. Slowly tighten the load spring alarm is sounding. Repeat this procedure
adjustment nut in a clockwise direction in 10° beginning with step 5.
increments until the overload indicator light
Note: There may be a 2 second delay before the
turns off, and the alarm does not sound.
platform overload indicator light and alarm
Proceed to step 8.
responds.
Note: The platform will need to be moved up and
down and allowed to settle between each 8 Add an additional 10 lb / 4.5 kg test weight to
adjustment. the platform.
Result: The overload indicator light is flashing at
Note: There may be a 2 second delay before the
both the ground and platform controls, and the
platform overload indicator light and alarm
alarm is sounding. Proceed to step 9.
responds.
Result: The overload indicator light is off at both
6 Move the platform up and down by hand, so it
the ground and platform controls, and the alarm
bounces approximately 2.5 to 5 cm / 1 to 2
does not sound. Remove the additional 10 lb /
inches. Allow the platform to settle.
4.5 kg test weight. Repeat this procedure
Result: The overload indicator lights are off at beginning with step 6.
the platform and ground controls, and the alarm
Note: There may be a 2 second delay before the
does not sound. Slowly loosen the load spring
platform overload indicator light and alarm
adjustment nut in a counterclockwise direction
responds.
in 10° increments until the overload indicator
light flashes at both the platform and ground 9 Test all machine functions from the platform
controls, and the alarm sounds. controls.
Proceed to step 7.
Result: All platform control functions should not
Result: The overload indicator lights are flashing operate.
at the platform and ground controls, and the
alarm is sounding. Repeat this procedure 10 Turn the key switch to ground control.
beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator lights and alarm
responds.
4 - 12 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
PLATFORM COMPONENTS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 13
Section 4 • Repair Procedures February 2012
PLATFORM COMPONENTS
2 Remove all weight, tools and equipment from 5 Activate and release the calibration toggle
the platform. switch 3 times within 2 seconds after the alarm
sounds to enter calibration mode.
Tip-over hazard. Failure to remove
all weight, options, accessories Result: The alarm should sound for 1 second
and/or tools from the platform or indicating the first calibration step was
subtracting the weight of those accepted. The green LED on the operational
items from the test weights, will controller should be blinking fast and the red
result in the platform load sense LED should be blinking twice indicating that
system not calibrating correctly. step 2 of calibration is next.
This will allow too much weight to
Result: The alarm did not sound and the green
be added to the platform which will
LED on the operational controller is not blinking
result in the machine tipping over.
fast. Repeat this procedure beginning with
3 Open the ground control box and locate the step 1.
calibration toggle switch near the relays.
Note: Once calibration mode is entered and begun,
Note: If either the operational and/or safety there is a 8 minute time limit between each
controller has been replaced or if the software has calibration step. If any one step passes the 8
been updated, restore the system to the default minute time limit, the system will time out and the
settings and then continue to step 4. See How to calibration process will need to be repeated
Restore the Default Settings. Otherwise, continue beginning with step 1.
to step 4 to enter calibration mode.
4 - 14 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
PLATFORM COMPONENTS
6 Start the engine from the ground controls. 8 Activate the calibration toggle switch inside the
ground control box 1 time.
7 Raise the boom until the distance, when
measured between the centers of the pivot pins Result: The alarm should sound for 1 second
shown, equals 108.75 inches / 276 cm indicating the second calibration step was
± 0.75 inch / 19 mm. accepted. The green LED on the operational
controller should be blinking fast and the red
Crushing hazard. Keep clear of all
LED should be blinking three times indicating
moving parts of the boom while the
that step 3 of calibration is next.
boom is raising. Do not attempt to
measure between the pivot pins 9 Raise the boom until the distance, when
while the boom is moving. measured between the centers of the pivot pins
shown, equals 167.25 inches / 424.8 cm
± 0.75 inch / 19 mm.
Crushing hazard. Keep clear of all
moving parts of the boom while the
boom is raising. Do not attempt to
Measure between measure between the pivot pins
the centers of these
while the boom is moving.
pivot pins
10 Activate and release the calibration toggle
switch inside the ground control box 1 time.
Result: The alarm should sound for 1 second
indicating the third calibration step was
accepted. The green LED on the operational
controller should be blinking fast and the red
LED should be blinking four times indicating that
step 4 of calibration is next.
11 Fully raise and extend the boom.
Red LED f lashing w ith pauses Indicates next calibration step (ie; 2, 3, etc
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 15
Section 4 • Repair Procedures February 2012
PLATFORM COMPONENTS
12 Activate and release the calibration toggle 17 Activate and release the calibration toggle
switch inside the ground control box 1 time. switch inside the ground control box 1 time.
Result: The alarm should sound for 1 second Result: The alarm should sound for 1 second
indicating the fourth calibration step was indicating the sixth calibration step was
accepted. The green LED on the operational accepted. The engine may turn off and the
controller should be blinking fast and the red alarm may sound indicating an overloaded
LED should be blinking five times indicating that platform.
step 5 of calibration is next.
18 At the ground controls, push in the red
13 Fully retract and lower the boom to the stowed Emergency Stop button to the off position, then
position. pull out the red Emergency Stop button to the
on position to reset the system.
14 Using a suitable lifting device, place an
appropriate test weight equal to 19 Visually inspect the LEDs on the controllers.
750 lbs / 340.2 kg on to the center of the
Result: All LEDs on both controllers should be
platform floor.
off indicating the platform load sense system is
Note: If your machine is equipped with any platform calibrated.
accessories or options, they must be removed from
20 At the ground controls, push in the red
the platform OR the weights of those options or
Emergency Stop button to the off position.
accessories must be subtracted from the test
weights to accurately calibrate the platform load 21 Using a suitable lifting device, remove the test
sense system. weights from the platform.
15 Activate and release the calibration toggle 22 Pull out the red Emergency Stop button to the
switch inside the ground control box 1 time. on position at the ground controls and visually
inspect the LEDs on the operational and safety
Result: The alarm should sound for 1 second
controllers.
indicating the fifth calibration step was
accepted. The green LED on the operational Result: Both the green and red LEDs on both
controller should be blinking fast and the red controllers should be off indicating the system
LED should be blinking six times indicating that is calibrated.
step 6 of calibration is next.
Note: If an LED is blinking on either controller, the
16 Using a suitable lifting device, place an load sense system is not calibrated correctly or a
additional test weight equal to 510 lbs / 231.3 kg fault may exist. Refer to Section 5, Fault Codes to
on to the center of the platform floor. The total determine the system fault.
weight in the platform must equal
1260 lbs / 571.5 kg.
4 - 16 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 17
Section 4 • Repair Procedures February 2012
1 Raise the jib boom slightly and place blocks Crushing hazard. The platform and
under the platform mounting weldment. Then jib boom could become unbalanced
lower the jib boom until the platform is resting and fall when the jib boom barrel-
on the blocks just enough to support the end pivot pin is removed if not
platform. properly supported.
Note: Do not rest the entire weight of the boom on 7 Attach a lifting strap from an overhead crane to
the blocks. the lug on the rod end of the jib boom lift
cylinder.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the 8 Use a soft metal drift to remove the jib boom lift
cylinder. cylinder rod-end pin. Remove the cylinder from
the machine.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and Crushing hazard. The jib boom lift
burn skin. Loosen hydraulic cylinder could become unbalanced
connections very slowly to allow and fall when removed from the
the oil pressure to dissipate machine if not properly attached to
gradually. Do not allow oil to the overhead crane.
squirt or spray.
4 - 18 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
Boom Components
4-1 6 Tag, disconnect and plug the hydraulic hoses
from the counterbalance valve manifold located
Cable Track on the platform rotator. Cap the fittings on the
manifold.
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire primary burn skin. Loosen hydraulic
boom cable track is only necessary when connections very slowly to allow
performing major repairs that involve removing the the oil pressure to dissipate
primary boom. gradually. Do not allow oil to
squirt or spray.
How to Remove the Cable Track, 7 Tag, disconnect and plug the platform leveling
S-60, S-60 HC and S-60 TRAX slave cylinder hydraulic hoses from the
bulkhead fittings on the side of the primary
Note: When removing a hose assembly or fitting, boom. Cap the bulkhead fittings.
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must Bodily injury hazard. Spraying
be torqued to specification during installation. Refer hydraulic oil can penetrate and
to Section 2, Hydraulic Hose and Fitting Torque burn skin. Loosen hydraulic
Specifications. connections very slowly to allow
the oil pressure to dissipate
1 Raise the boom to a horizontal position. gradually. Do not allow oil to
2 Locate the cables from the boom cable track to squirt or spray.
the platform control box. Number each cable 8 Locate all electrical cables under the boom at
and its entry location at the platform control the pivot end that enter the cable track.
box.
9 Tag and disconnect the electrical connectors for
3 Disconnect the cables from the platform control all cables that enter the cable track.
box.
10 Remove the retaining fasteners from the
4 Remove the electrical outlet box bracket electrical connector receptacles for the cables
mounting fasteners. Remove the outlet box and that enter the cable track.
lay it to the side.
11 Carefully pull the cables and connector
5 Remove the hose and cable clamp from the receptacles out of the primary boom.
platform support.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 19
Section 4 • Repair Procedures February 2012
BOOM COMPONENTS
12 Tag, disconnect and plug all hydraulic hoses 18 Remove the cable track mounting fasteners that
that enter the cable track from the bulkhead attach the lower cable track to the primary
fittings at the pivot end of the boom. boom.
Bodily injury hazard. Spraying 19 Carefully remove the cable track from the
hydraulic oil can penetrate and machine and place it on a structure capable of
burn skin. Loosen hydraulic supporting it.
connections very slowly to allow
Crushing hazard. The cable track
the oil pressure to dissipate
could become unbalanced and fall
gradually. Do not allow oil to
if not properly attached to the
squirt or spray.
overhead crane.
13 Pull the hydraulic hoses out of the primary
Component damage hazard.
boom.
Cables and hoses can be damaged
14 Place blocks in between the upper and lower if they are kinked or pinched.
cable tracks and secure the upper and lower
Component damage hazard. The
tracks together.
cable track can be damaged if it is
Crushing hazard. If the upper and twisted.
lower cable tracks are not properly
secured together, the cable track How to Remove the Cable Track,
could become unbalanced and fall S-65 and S-65 TRAX
when removed from the machine.
Note: When removing a hose assembly or fitting,
15 Attach a strap from an overhead crane to the the O-ring (if equipped) on the fitting and/or the
cable track. hose end must be replaced. All connections must
16 Remove the cotter pin from the cable track pull be torqued to specification during installation. Refer
tube at the platform end of the boom. to Section 2, Hydraulic Hose and Fitting Torque
Specifications.
Note: Always replace the cotter pin with a new one.
1 Open the platform control box.
17 Remove the cable track pull tube guide
fasteners from the cable track guide at the 2 Tag and disconnect the foot switch wiring from
platform end of the boom. Remove the cable the terminal strip inside the platform control box.
track guide from the boom. Pull the wiring out of the platform control box.
3 Raise the boom to a horizontal position.
4 - 20 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
BOOM COMPONENTS
4 Disconnect the wire connectors from the bottom 9 Remove the hose and cable cover from the side
of the platform control box. of the jib boom.
Note: When installing the wire connectors to the 10 Locate all electrical cables under the boom at
bottom of the platform control box, match the color the pivot end that enter the cable track.
of the connectors to those on the control box to be
11 Tag and disconnect the electrical connectors for
sure they are installed in the correct location.
all cables that enter the cable track.
5 Remove the mounting fasteners from the power 12 Remove the retaining fasteners from the
to platform outlet box bracket. Lay the outlet electrical connector receptacles for the cables
box and bracket assembly off to the side. that enter the cable track.
6 Remove the hose and cable clamps from the 13 Carefully pull the cables and connector
platform support and jib boom. receptacles out of the primary boom.
7 Tag, disconnect and plug the platform leveling
14 Tag, disconnect and plug all hydraulic hoses
slave cylinder hydraulic hoses from the
that enter the cable track from the bulkhead
bulkhead fittings on the side of the primary
fittings at the pivot end of the boom.
boom. Cap the bulkhead fittings.
Bodily injury hazard. Spraying
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
burn skin. Loosen hydraulic
connections very slowly to allow
connections very slowly to allow
the oil pressure to dissipate
the oil pressure to dissipate
gradually. Do not allow oil to
gradually. Do not allow oil to
squirt or spray.
squirt or spray.
15 Pull the hydraulic hoses out of the primary
8 Tag, disconnect and plug the hydraulic hoses
boom.
from the "V1" and "V2" ports of the jib boom/
platform rotate manifold. Cap the fittings on the 16 Remove the cotter pin from the upper cable
manifold. track at the platform end of the boom.
Bodily injury hazard. Spraying Note: Always replace the cotter pin with a new one.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic 17 Remove the cable track pull tube guide
connections very slowly to allow fasteners from the cable track guide at the
the oil pressure to dissipate platform end of the boom. Remove the cable
gradually. Do not allow oil to track guide from the boom.
squirt or spray.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 21
Section 4 • Repair Procedures February 2012
BOOM COMPONENTS
18 Place blocks in between the upper and lower How to Repair the Cable Track
cable tracks and secure the upper and lower
tracks together. Component damage hazard.
The boom cable track can be
Crushing hazard. If the upper and damaged if it is twisted.
lower cable tracks are not properly
secured together, the cable track Note: A cable track repair kit is available through
could become unbalanced and fall the Genie Industries Service Parts Department,
when removed from the machine. part no. 77896. The kit includes a 4 link section of
cable track.
19 Attach a lifting strap from an overhead crane to
the cable track. 1 Visually inspect the cable track and determine
which 4 link section needs to be replaced.
20 Remove the mounting fasteners that attach the
lower cable track to the boom. 2 Carefully remove the snap rings from each end
of the damaged section of cable track.
21 Carefully remove the cable track from the
machine and place it on a structure capable of 3 Remove the retaining fasteners from the upper
supporting it. black rollers from the 4 link section of cable
track to be replaced. Remove the rollers.
Crushing hazard. The cable track
could become unbalanced and fall 4 Lift up the hoses and cables and carefully
if not properly attached to the remove the damaged 4 link section of cable
overhead crane. track.
Component damage hazard. Component damage hazard. Hoses
Cables and hoses can be damaged and cables can be damaged if they
if they are kinked or pinched. are kinked or pinched.
Component damage hazard. The 5 Remove the upper rollers from the replacement
cable track can be damaged if it is section of cable track.
twisted.
6 Lift up the hoses and cables and carefully insert
the new 4 link section of cable track.
Component damage hazard.
Hoses and cables can be damaged
if they are kinked or pinched.
7 Connect the ends of the replacement cable track
section to the existing cable track using the
snap rings.
8 Install the rollers onto the new section of cable
track.
9 Operate the boom extend/retract function
through a full cycle to ensure smooth operation
of the new section of cable track.
4 - 22 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
BOOM COMPONENTS
a b
k c
f
j
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 23
Section 4 • Repair Procedures February 2012
BOOM COMPONENTS
4 - 24 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
BOOM COMPONENTS
9 Slowly operate the overhead crane to apply 14 Using auxiliary power, activate the boom down
tension to the lifting straps. Do not attempt to function so the cylinder will retract. Retract the
lift the machine with the overhead crane. cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
10 Locate and remove the counterweight retaining
boom. Turn the machine off.
fastener at the center of the counterweight.
Carefully lift the counterweight upwards and Crushing hazard. The boom lift
remove the counterweight from the machine. cylinder could fall if not properly
Set the counterweight on the ground. Do not supported and secured to the lifting
leave the counterweight suspended above the device.
ground.
15 Using the overhead crane, carefully lower the
Crushing hazard. The turntable boom lift cylinder and allow it to rest on the
counterweight will fall if not boom rest pad. Protect the cylinder rod from
properly supported by the overhead damage.
crane resulting in death or serious
16 S-60, S-65, S-60 TRAX and S-65 TRAX:
injury. Keep personnel away from
Remove the boom end cover retaining fasteners
the area when removing the
and remove the cover.
counterweight.
S-60 HC: Remove the boom end cover from the
11 Attach lifting straps from a 5 ton / 5000 kg
pivot end of the boom while guiding the small
overhead crane to each end of the boom.
cable from the string potentiometer out of the
Support the boom. Do not apply any lifting
slot of the cover. Rest the cover and string
pressure.
potentiometer on the counterweight.
12 Support and secure the rod end of the boom lift
Component damage hazard. The
cylinder to a second overhead crane or similar
cable from the string potentiometer
lifting device.
can become damaged if it is
13 Remove the lift cylinder rod-end pivot pin kinked or pinched.
retaining fasteners. Use a soft metal drift to
17 S-60 HC: Remove the string potentiometer cable
remove the pin.
break limit switch mounting fasteners.
Crushing hazard. The boom could
18 S-60 HC:Remove the pulley retaining plate from
fall if not properly supported when
the string potentiometer pulley bracket.
the lift cylinder rod-end pivot pin is
Carefully remove the string potentiometer cable
removed.
and limit switch assembly from the boom.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 25
Section 4 • Repair Procedures February 2012
BOOM COMPONENTS
19 Tag, disconnect and plug the boom extension 25 Using the overhead crane, adjust the boom as
cylinder hydraulic hoses. Cap the fittings on the necessary to relieve pressure from the pivot
cylinder. pins.
Bodily injury hazard. Spraying 26 Use a soft metal drift to remove each boom
hydraulic oil can penetrate and pivot pin. Carefully remove the boom assembly
burn skin. Loosen hydraulic from the machine and place it on a structure
connections very slowly to allow capable of supporting it.
the oil pressure to dissipate
Crushing hazard. The boom could
gradually. Do not allow oil to
fall if not properly supported by the
squirt or spray.
overhead crane when each boom
20 Tag and disconnect the electrical connector for pivot pin is removed.
the cable break limit switch.
Crushing hazard. The long and
21 Tag and disconnect all boom wire harness short link arms may fall if not
electrical connectors located at the pivot end of properly supported when the boom
the boom. pivot pins are removed.
22 Support the platform leveling master cylinder.
Remove the master cylinder rod-end pivot pin
retaining fasteners. Place a rod through the pin
and twist to remove. Carefully lower the master
cylinder down.
23 Tag, disconnect and plug the hydraulic hoses
from the bulkhead fittings at the pivot end of the
boom. Cap the bulkhead fittings.
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.
24 Remove the external snap rings from both boom
pivot pins at the short and long link arms. Do
not remove the pins.
4 - 26 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
BOOM COMPONENTS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 27
Section 4 • Repair Procedures February 2012
BOOM COMPONENTS
The boom extension cylinder is located inside the S-60 HC: Remove the boom end cover from the
boom assembly and incorporates cables and pivot end of the boom while guiding the small
pulleys that are responsible for extending the cable from the string potentiometer out of the
number 3 boom tube. The primary boom extension slot of the cover. Rest the cover and string
cylinder is equipped with counterbalance valves to potentiometer on the counterweight.
prevent movement in the event of a hydraulic line Component damage hazard. The
failure. cable from the string potentiometer
can become damaged if it is
How to Remove the Boom kinked or pinched.
Extension Cylinder 3 S-60 HC: Remove the string potentiometer cable
Bodily injury hazard. This break limit switch mounting fasteners.
procedure requires specific repair 4 S-60 HC:Remove the pulley retaining plate from
skills, lifting equipment and a the string potentiometer pulley bracket.
suitable workshop. Attempting this Carefully remove the string potentiometer cable
procedure without these skills and and limit switch assembly from the boom.
tools could result in death or
serious injury and significant 5 Remove the access covers from both sides of
component damage. Dealer the boom at the pivot end.
service is strongly recommended.
6 Fully loosen the lock nuts on the extend cables.
Note: When removing a hose assembly or fitting, Do not remove the nuts.
the O-ring (if equipped) on the fitting and/or the
7 Loosen the retract cable nut at the platform end
hose end must be replaced. All connections must
of the boom. Pull the cable rod from the support
be torqued to specification during installation. Refer
and let it hang down.
to Section 2, Hydraulic Hose and Fitting Torque
Specifications.
Note: Perform this procedure with the boom fully
retracted.
1 Raise the boom to a horizontal position.
4 - 28 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
BOOM COMPONENTS
8 Remove the cable guard fasteners and remove 12 Disconnect the wire connector to the extend
the cable guard. cable break limit switch.
13 Remove the retaining fasteners that secure the
extend cable mounting plates to the inside of
the number 1 boom tube.
a b
a cable guard a b c d
b retaining block
a extend cable lock nuts
9 Locate the retaining plates that secure the b extend cable mounting plate
retract cables to the inside of the number 3 c extend cable mounting plate fastener
boom tube. d extend cable bracket
10 Remove the cable retaining plates and pull the 14 Pull back on the extend cable mounting plate
retract cables off of the pulleys. Lay the cables until it clears the blocks welded to the inside of
flat and out of the way. the number 1 boom tube.
11 Remove the fasteners from the retaining blocks
from the extension cylinder saddle. Remove the
blocks.
Note: Access the fasteners through the access
hole in the outer boom tube at the pivot end.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 29
Section 4 • Repair Procedures February 2012
BOOM COMPONENTS
15 Lift up the extend cable mounting plate and push 23 Attach a lifting strap from a 5 ton / 5000 kg
the extend cables towards the platform to create overhead crane to the lug at the rod end of the
slack in the cables. Rest the cable and bracket boom extension cylinder.
assembly on top of the extend cylinder.
24 Lift the boom extension cylinder with the crane
16 Locate the lower extend cable bracket on the until it clears the cylinder saddle inside the
bottom of the number 3 boom tube. number 2 boom tube.
17 Remove the lower extend cable bracket 25 Carefully support and slide the extension
mounting fasteners and pull back on the bracket cylinder out of the boom.
to release it from the number 3 boom tube.
Crushing hazard. The extension
18 While pushing the lower extend cable bracket cylinder could fall when removed
towards the platform, pull the extend cable from the boom if not properly
mounting plate towards the pivot end of the supported.
boom.
Component damage hazard. Be
19 Secure the extend cable bracket and cables to careful not to damage the cable
the cylinder to prevent them from falling off break limit switch.
when removing the cylinder.
Component damage hazard. Be
20 Remove the external snap rings from the careful not to damage the
extension cylinder pin at the pivot end of the counterbalance valves on the
boom. primary boom extension cylinder
when removing the cylinder from
21 Use a soft metal drift to remove the pin.
the boom.
22 Tag, disconnect and plug the boom extension
Note: During removal of the extension cylinder, the
cylinder hydraulic hoses. Cap the fittings on the
overhead crane strap will need to be carefully
cylinder.
adjusted for proper balancing.
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 - 30 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
BOOM COMPONENTS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 31
Section 4 • Repair Procedures February 2012
BOOM COMPONENTS
12 Visually inspect the cable break limit switch arm How to Replace the Boom
to be sure the wheel of the limit switch arm is
centered in the notch of the pivot plate. Extend/Retract Cables
Note: If the boom extend cables are adjusted Note: The cable pulleys must also be replaced
evenly, the wheel of the limit switch arm should be when replacing the cables.
centered in the notch of the pivot plate.
1 Remove the boom extension cylinder. See 4-4,
How to Remove the Boom Extension Cylinder.
Boom extend cables:
2 Remove the cables from the lower boom extend
a cable bracket that attaches to the number 3
boom tube.
3 Remove the rue rings and clevis pins from the
boom extend cables located near the extend
cable break limit switch.
4 Remove the external snap rings from the boom
extend cable pulley pivot pin. Use a soft metal
drift to remove the pin.
Note: When driving the pivot pin out, be sure to
drive it from the shaped end of the pin.
5 Remove the pulley and boom extend cables
from the extension cylinder assembly. Discard
the old cables and pulleys.
6 Route the new boom extend cables through the
b c
boom extend pulley bracket.
a cable break limit switch 7 Install the new boom extend cable pulley, pivot
b extend cable adjustment nut pin and snap rings.
c extend cable pivot plate
Note: Be sure the boom extend cables are routed
13 Install the boom end cover at the pivot end of through the grooves of the pulley and the upper
the boom. wear pad on the extension cylinder.
14 Fully retract and lower the boom to the stowed 8 Install the boom extend cable clevis pins and
position. rue rings to the pivot plate near the cable break
limit switch.
9 Install the boom extend cables to the lower
extend cable bracket that mounts to the number
3 boom tube.
4 - 32 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
BOOM COMPONENTS
Boom retract cables: 17 Securely attach the rope to the same end of the
new boom retract cable.
10 Remove the cotter pins and clevis pins from the
boom retract cables at the platform end of the 18 At the pivot end of the boom, carefully pull the
boom. rope with the new retract cable attached.
Note: Always use a new cotter pin when installing a 19 Pull the new cable towards the pivot end of the
clevis pin. boom until the end of the cable is at the end of
the boom tube. Remove the rope.
11 Remove the wear pad fasteners from the upper
wear pads on the number 1 boom tube. Remove 20 Repeat steps 14 through 19 for the other boom
the wear pads. retract cable.
Note: Pay attention to the location of each wear 21 At the platform end of the boom, install the
pad and the quantity of shims for each one. retract cables, clevis pins and new cotter pins
to the adjustment plate.
12 Attach a lifting strap from an overhead crane to
the platform end of the boom. 22 Remove and discard the old boom retract
pulleys from the pivot end of the boom
13 Raise the boom using the overhead crane and extension cylinder.
place a wood block under the number 2 boom
tube between the number 1 and number 2 boom 23 Install the new boom retract pulleys to the pivot
tubes for support. This will create clearance end of the boom extension cylinder.
between the boom tubes to remove the retract 24 Install the boom extension cylinder assembly
cables. into the boom.
14 Attach the cable pulling tool or a rope to one of Note: Before lowering the extension cylinder into
the boom retract cables at the pivot end of the the saddles of the number 1 boom tube, wrap the
boom. boom retract cables around the pulleys.
Note: A cable pulling tool is available through Genie 25 Adjust the boom extend/retract cables.
Service Parts Department (Genie part no. 94510) See 4-5, How to Adjust the Boom Extend/
15 At the platform end of the boom, pull on the Retract Cables.
boom retract cable that has the rope attached
to it.
16 Pull the old cable completely out of the boom
tube. Remove the rope. Discard the old boom
retract cable.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 33
Section 4 • Repair Procedures February 2012
BOOM COMPONENTS
4 - 34 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
Engines
5-1 5-3
RPM Adjustment - Ford and Flex Plate
Deutz Models
The flex plate acts as a coupler between the engine
Refer to Maintenance Procedure B-9, Check and and the pump. It is bolted to the engine flywheel
Adjust the Engine RPM - Ford and Deutz Models. and has a splined center to drive the pump.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 35
Section 4 • Repair Procedures February 2012
ENGINES
How to Remove the Flex Plate 6 Remove the engine mounting plate to bell
housing fasteners.
Deutz models:
7 Raise the engine slightly using the overhead
1 Remove the tailpipe bracket mounting fasteners crane and place a block of wood under the oil
from the engine bell housing. pan for support.
2 Support the drive pump assembly with an 8 Support the drive pump assembly with an
appropriate lifting device. overhead crane or other suitable lifting device.
Do not apply any lifting pressure.
3 Remove all of the engine bell housing fasteners.
9 Remove all of the engine bell housing retaining
4 Carefully pull the pump and bell housing fasteners.
assembly away from the engine and secure it
from moving. 10 Carefully pull the pump and bell housing
assembly away from the engine and secure it
Component damage hazard. Hoses from moving.
can be damaged if they are kinked
or pinched. Component damage hazard. Hoses
can be damaged if they are kinked
5 Remove the flex plate mounting fasteners. or pinched.
Remove the flex plate from the flywheel.
11 Remove the flex plate mounting fasteners.
Ford models: Remove the flex plate from the flywheel.
1 Disconnect the electrical connectors from both Perkins models:
oxygen sensors at the tailpipe and exhaust
manifold. Do not remove the oxygen sensors. 1 Remove the fuel filter/water separator mounting
fasteners.
2 Remove the exhaust pipe fasteners at the
muffler. 2 Remove the fuel filter/water separator and lay it
to the side. Do not disconnect the hoses.
3 Support the muffler and bracket assembly with a
suitable lifting device. 3 Support the drive pump assembly with an
appropriate lifting device.
4 Remove the muffler bracket mounting fasteners
from the bell housing. Carefully remove the 4 Remove all of the engine bell housing fasteners.
muffler and bracket assembly from the engine.
5 Carefully pull the pump and bell housing
5 Support the engine with an overhead crane or assembly away from the engine and secure it
other suitable lifting device. Do not lift it. from moving.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
6 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
4 - 36 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
ENGINES
How to Install a Type "A" 3 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
Flex Plate appropriate gap between coupler and pump end
1 Install the flex plate onto the engine flywheel plate for your engine.
with the raised spline towards the pump.
a b c d e
2 Ford models: Torque the flex plate mounting
bolts in sequence to 14 ft-lbs / 19 Nm.
Then torque the flex plate mounting bolts in
sequence to 20 ft-lbs / 27 Nm.
Deutz models: Torque the flex plate mounting
bolts in sequence to 28 ft-lbs / 38 Nm.
Then torque the flex plate mounting bolts in f
sequence to 40 ft-lbs / 54 Nm.
a pump
Perkins models: Torque the flex plate mounting b pump shaft
c pump coupler
bolts in sequence to 49 ft-lbs / 66 Nm. d flex plate with raised spline
Then torque the flex plate mounting bolts in e engine flywheel
sequence to 70 ft-lbs / 95 Nm. f 3/16 inch / 4.8 mm gap - Diesel Models
0.080 inch / 2 mm gap - Ford Models
1
4 Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
6 3 to 61 ft-lbs / 83 Nm.
5 Proceed to Repair Procedure, How to Install the
Pump and Bell Housing Assembly.
4 5
2
Ford and Deutz models
2 3
Perkins models
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 37
Section 4 • Repair Procedures February 2012
ENGINES
Grease Specification
4 5
Shell Alvania® Grease CG, NLGI 0/1 or equivalent.
2
Ford models
6 3
4 5
Perkins models
4 - 38 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
ENGINES
9
B
B
4 5
B
B B
8 B B 7
2 3
Perkins models
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 39
Section 4 • Repair Procedures February 2012
ENGINES
5-4
Engine Fault Codes -
Ford Models
4 - 40 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
Hydraulic Pumps
6-1 2 Tag, disconnect and plug the function pump
hydraulic hoses. Cap the fittings on the pump.
Function Pump
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove the burn skin. Loosen hydraulic
Function Pump connections very slowly to allow
the oil pressure to dissipate
Note: When removing a hose assembly or fitting,
gradually. Do not allow oil to
the O-ring (if equipped) on the fitting and/or the
squirt or spray.
hose end must be replaced. All connections must
be torqued to specification during installation. Refer 3 Remove the pump mounting bolts. Carefully
to Section 2, Hydraulic Hose and Fitting Torque remove the pump.
Specifications.
Component damage hazard. Be
1 Locate the two hydraulic tank valves at the sure to open the two hydraulic tank
hydraulic tank through the access hole valves and prime the pump after
underneath the turntable. Close the valves. installing the pump.
open closed
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 41
Section 4 • Repair Procedures February 2012
HYDRAULIC PUMPS
4 - 42 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
HYDRAULIC PUMPS
5 Carefully pull the drive pump out until the pump 4 Ford models: Close the valve on the LPG tank
coupler separates from the flex plate. then disconnect the hose from the tank. Move
the fuel select switch to the LPG position.
6 Remove the drive pump from the machine.
Perkins models: Disconnect the engine wiring
Component damage hazard. The
harness from the fuel solenoid at the injector
hydraulic pump may become
pump.
unbalanced and fall if not properly
supported. Deutz models: Hold the manual fuel shutoff
valve clockwise to the closed position.
Component damage hazard. When
installing the pump, do not force a
the pump coupler into the flexplate
or damage to the pump shaft seal
may occur.
Component damage hazard. Be
sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 43
Section 4 • Repair Procedures February 2012
4 - 44 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
Manifolds
7-1
Function Manifold Components
The function manifold is located underneath the ground controls side turntable cover.
Index Schematic
No. Description Item Function Torque
1 Counterbalance valve ....................... H ........... Platform level down .......................... 30-35 ft-lbs / 41-47 Nm
2 Counterbalance valve ....................... G ........... Platform level up ............................... 30-35 ft-lbs / 41-47 Nm
3 Proportional solenoid valve .............. M .......... Boom extend/retract ......................... 30-35 ft-lbs / 41-47 Nm
4 Solenoid valve, 2 position 3 way ...... C ........... Boom retract ..................................... 30-35 ft-lbs / 41-47 Nm
5 Solenoid valve, 2 position 3 way ...... B ........... Boom extend .................................... 30-35 ft-lbs / 41-47 Nm
6 Solenoid valve, 3 position 4 way ...... D ........... Turntable rotate ................................ 20-25 ft-lbs / 27-34 Nm
7 Proportional solenoid valve .............. T ........... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
8 Solenoid valve, 3 position 4 way ...... BB ......... Steer left/right .................................... 20-25 ft-lbs / 27-34 Nm
9 Check valve, 30 psi / 2 bar ................ I ............ Differential sensing circuit,
platform rotate left and
jib boom up (S-65, S-65 TRAX) ........ 20-25 ft-lbs / 27-34 Nm
10 Check valve, 30 psi / 2 bar ................ J ............ Differential sensing circuit,
platform rotate right and
jib boom down (S-65, S-65 TRAX) ... 20-25 ft-lbs / 27-34 Nm
11 Check valve ....................................... N ........... Differential sensing circuit,
boom extend/retract .......................... 10-12 ft-lbs / 14-16 Nm
12 Solenoid valve, 2 position 3 way ...... F ........... Boom down ....................................... 30-35 ft-lbs / 41-47 Nm
13 Solenoid valve, 2 position 3 way ...... E ........... Boom up ........................................... 30-35 ft-lbs / 41-47 Nm
14 Check valve ....................................... O ........... Differential sensing circuit,
turntable rotate ................................. 10-12 ft-lbs / 14-16 Nm
15 Check valve ....................................... R ........... Differential sensing circuit,
boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
16 Priority flow regulator valve,
3.5 gpm / 13.2 L/min .......................... AA ......... Steer left/right circuit ......................... 30-35 ft-lbs / 41-47 Nm
17 Differential sensing valve,
110 psi / 7.6 bar ................................. S ........... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
18 Differential sensing valve,
150 psi / 10.3 bar .............................. P ........... Turntable rotate circuit ...................... 30-35 ft-lbs / 41-47 Nm
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 45
Section 4 • Repair Procedures February 2012
MANIFOLDS
1 2 3 4 5 6 7 8
H G M C B D T BB
I
9
J
Y 10
31
N
11
V F
30 12
E
13
O
14
U
29
R
L 15
28
EE AA
27 16
Z
26
Q
25
S
17
X P
24 18
W
23
CC DD K A
22 21 20 19
4 - 46 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
MANIFODLS
19 Check valve, 5 psi / 0.3 bar ............... A ........... Blocks flow from auxiliary pump
to function pump ............................... 30-35 ft-lbs / 41-47 Nm
20 Relief valve, 3000 psi / 206.8 bar ..... K ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
21 Flow control valve,
0.1 gpm / 0.38 L/min .......................... DD ........ Bleeds off differential sensing
valves to tank .................................... 20-25 ft-lbs / 27-34 Nm
22 Differential sensing valve,
150 psi / 10.3 bar .............................. CC ........ Differential sensing circuit,
meters flow to functions .................... 30-35 ft-lbs / 41-47 Nm
23 Check valve ....................................... W .......... Differential sensing circuit,
platform level up ............................... 10-12 ft-lbs / 14-16 Nm
24 Check valve ....................................... X ........... Differential sensing circuit,
platform level down .......................... 10-12 ft-lbs / 14-16 Nm
25 Proportional solenoid valve .............. Q ........... Turntable rotate left/right .................. 20-25 ft-lbs / 27-34 Nm
26 Flow control valve,
0.6 gpm / 2.27 L/min .......................... Z ........... Platform rotate and
jib boom (S-65, S-65 TRAX) ............. 20-25 ft-lbs / 27-34 Nm
27 Check valve, 30 psi / 2 bar ................ EE ......... Platform rotate and jib
boom circuit (S-65, S-65 TRAX)
(prevents hydraulic hoses
from draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
28 Differential sensing valve,
110 psi / 7.6 bar ................................. L ........... Boom extend/retract circuit ............... 30-35 ft-lbs / 41-47 Nm
29 Needle valve ..................................... U ........... Platform level circuit ......................... 30-35 ft-lbs / 41-47 Nm
30 Solenoid valve, 3 position 4 way ...... V ........... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
31 Solenoid valve, 3 position 4 way ...... Y ........... Platform rotate and jib boom
up/down (S-65, S-65 TRAX) ............. 20-25 ft-lbs / 27-34 Nm
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 47
Section 4 • Repair Procedures February 2012
MANIFOLDS
1 2 3 4 5 6 7 8
H G M C B D T BB
I
9
J
Y 10
31
N
11
V F
30 12
E
13
O
14
U
29
R
L 15
28
EE AA
27 16
Z
26
Q
25
S
17
X P
24 18
W
23
CC DD K A
22 21 20 19
4 - 48 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
MANIFOLDS
7-2
Valve Adjustments -
Function Manifold
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 49
Section 4 • Repair Procedures February 2012
MANIFOLDS
7-3
Jib Boom / Platform Rotate Manifold Components
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 3 way ..... FF ......... Platform rotate/jib boom select ......... 20-25 ft-lbs / 27-34 Nm
FF
4 - 50 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
MANIFOLDS
7-4
Brake/Two-Speed Manifold Components
The brake/two-speed manifold is mounted near the turntable rotator.
Index Schematic
No. Description Item Function Torque
1 Orifice, 0.025 inch / 0.64 mm .......... JJ ............ Turntable rotation brake release
2 Solenoid valve, 2 position 3 way ... KK ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
3 Solenoid valve, 2 position 3 way .... LL ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm
4 Check valve ...................................... II ............ Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm
1 2 3
JJ KK LL
II
4
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 51
Section 4 • Repair Procedures February 2012
MANIFOLDS
7-5
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor.
Index Schematic
No. Description Item Function Torque
1 Counterbalance valve .................... MM .......... Turntable rotate right ....................... 35-40 ft-lbs / 47-54 Nm
2 Counterbalance valve .................... NN ........... Turntable rotate left .......................... 35-40 ft-lbs / 47-54 Nm
3 Shuttle valve, 2 position 3 way ...... OO ........... Turntable rotation brake release ..... 10-13 ft-lbs / 14-18 Nm
4 Orifice, 0.030 inch / 0.76 mm ......... PP ........... Brake release circuit
(located inside port)
1 2
MM NN
PP
4
OO
3
4 - 52 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
MANIFOLDS
7-6
Oscillate Directional Valve Components
The oscillate directional valve is mounted inside the drive chassis at the non-steer end.
Index
No. Description Function Torque
1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm
2 Spool valve ...................................................... Directional control
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 53
Section 4 • Repair Procedures February 2012
MANIFOLDS
How to Set Up the Oscillate 8 Verify that the ground and drive chassis are
completely level.
Directional Valve
9 Adjust the heim joint until the hole lines up with
Note:Adjustment of the oscillate directional valve the retaining fastener hole in the axle.
linkage is only necessary when the linkage or valve
has been replaced. 10 Install the heim joint to the axle and tighten the
jam nut.
1 Lower the boom to the stowed position.
11 Check to be sure the drive chassis is
2 Use a "bubble type" level to be sure the floor is completely level.
completely level.
12 Measure the distance between the drive chassis
Tip-over hazard. Failure to perform and the non-steer axle on both sides (from the
this procedure on a level floor inside of the drive chassis).
could compromise the stability of
the machine resulting in the Note: If the distance is not equal and the
machine tipping over. adjustment to the linkage was completed with the
ground and drive chassis level, repeat steps 6
3 Check the tire pressure in all four tires and add through 11 OR consult Genie Industries Service
air if needed to meet specification. Department.
Note: The tires on some machines are foam-filled
and do not need air added to them.
4 - 54 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
MANIFOLDS
7-7
Valve Adjustments - Oscillate
Relief Valve
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 55
Section 4 • Repair Procedures February 2012
MANIFOLDS
7-8
Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
No. Description Item Function Torque
1 Directional valve ............................ CU ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm
2 Orifice disc, 0.030 inch / 0.080 cm . CV ........... Delays shift to drive
3 Solenoid valve ............................... CW .......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
4 Relief valve .................................... CX ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm
5 Check valve .................................... CY ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm
CY
5
CU
1
CV
2
CW
3
CX
4
4 - 56 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
MANIFOLDS
7-9
Traction Manifold Components, 2WD
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
No. Description Item Function Torque
1 Relief valve, 280 psi / 19.3 bar ......... TT ......... Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
2 Flow divider/combiner valve ............. WW ....... Controls flow to drive motors
in forward and reverse ............... 90-100 ft-lbs / 122-136 Nm
3 Check valve ....................................... SS ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
4 Check valve ....................................... XX ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
5 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
6 Orifice, 0.070 inch / 1.78 mm ............ VV ......... Drive motor circuit
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 57
Section 4 • Repair Procedures February 2012
MANIFOLDS
1 2
TT WW
VV UU XX SS
6 5 4 3
4 - 58 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
MANIFOLDS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 59
Section 4 • Repair Procedures February 2012
MANIFOLDS
4 - 60 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
MANIFOLDS
7-11
Traction Manifold Components, 4WD
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
No. Description Item Function Torque
1 Check valve ....................................... TT ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 14-16 Nm
2 Check valve ....................................... SS ......... Non-steer end drive motor circuit ..... 35-40 ft-lbs / 14-16 Nm
3 Flow divider/combiner valve ............. AB ......... Controls flow to flow
divider/combiner valves
11 and 13 ...................................... 80-90 ft-lbs / 108-122 Nm
4 Check valve ....................................... AF ......... Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm
5 Orifice, 0.040 inch / 1 mm .................. AC ........ Equalizes pressure on both sides
of flow divider/combiner valve 3
6 Orifice, 0.040 inch / 1 mm .................. AE ......... Equalizes pressure on both sides
of flow divider/combiner valve 11
7 Orifice, 0.040 inch / 1 mm .................. WW ....... Equalizes pressure on both sides
of flow divider/combiner valve 13
8 Check valve ....................................... AG ........ Steer end drive motor circuit ............ 60-70 ft-lbs / 81-95 Nm
9 Check valve ....................................... ZZ ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 14-16 Nm
10 Shuttle valve, 3 position 3 way ......... VV ......... Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
11 Flow divider/combiner valve ............. AD ........ Controls flow to steer end
drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
12 Check valve ....................................... YY ......... Non-steer end drive motor circuit ..... 35-40 ft-lbs / 14-16 Nm
13 Flow divider/combiner valve ............. XX ......... Controls flow to non-steer end
drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
14 Relief valve, 280 psi / 19.3 bar ......... UU ........ Charge pressure circuit .................... 35-40 ft-lbs / 14-16 Nm
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 61
Section 4 • Repair Procedures February 2012
MANIFOLDS
1 2
TT SS
UU
14
XX
13
YY
12
AD
11
AB
3
AF
4
VV
10
ZZ
9
AG
8
WW
7
AE
6
AC
4 - 62 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
MANIFOLDS
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 63
Section 4 • Repair Procedures February 2012
MANIFOLDS
While valves may operate when coil resistance is Solenoid valve, 3 position 4 way, 10V DC 4 to 6Ω
outside specification, maintaining coils within (schematic item BB)
specification will help ensure proper valve function
over a wide range of operating temperatures. Solenoid valve, 2 position 3 way, 10V DC 5 to 7Ω
(schematic items B, C, E, F and FF)
Electrocution/burn hazard. Contact
with electrically charged circuits Solenoid valve, 2 position 3 way, 10V DC 5.5 to 7.5Ω
could result in death or serious (schematic items KK and LL)
injury. Remove all rings, watches
and other jewelry. Proportional solenoid valve, 12V DC 4 to 6Ω
(schematic items M and T)
1 Tag and disconnect the wiring from the coil to be
tested. Proportional solenoid valve, 12V DC 3.7 to 5.7Ω
2 Test the coil resistance. (schematic item Q)
4 - 64 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
MANIFOLDS
+
interruption of electrical current to a coil. Faulty
10 W 9V
diodes can fail to protect the electrical system, RESISTOR BATTERY
resulting in a tripped circuit breaker or component
c
damage. b
+
Electrocution/burn hazard. Contact -
with electrically charged circuits a multimeter
b 9V DC battery
could result in death or serious
c 10Ω resistor
injury. Remove all rings, watches d coil
and other jewelry.
Note: Dotted lines in illustration indicate a
1 Test the coil for resistance. See, How to Test a reversed connection as specified in
Coil. step 6
2 Connect a 10Ω resistor to the negative terminal 3 Set a multimeter to read DC current.
of a known good 9V DC battery. Connect the Note: The multimeter, when set to read DC current,
other end of the resistor to a terminal on the should be capable of reading up to 800 mA.
coil.
4 Connect the negative lead to the other terminal
Ω
Resistor, 10Ω on the coil.
Genie part number 27287
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
Note: The battery should read 9V DC or more when
measured across the terminals. 5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 65
Section 4 • Repair Procedures February 2012
Note: The turntable rotation lock pin is located next a backlash pivot plate
to the boom rest pad. b adjustment bolt with lock nut
c backlash pivot plate mounting bolts
2 Tag, disconnect and plug the hydraulic hoses
from the turntable rotation drive motor. Cap the 4 Attach a suitable lifting device to the lifting eyes
fittings on the drive motor. on the drive hub assembly.
Bodily injury hazard. Spraying 5 Remove the backlash pivot plate mounting
hydraulic oil can penetrate and bolts. Carefully remove the drive hub assembly
burn skin. Loosen hydraulic from the machine.
connections very slowly to allow
Crushing hazard. The turntable
the oil pressure to dissipate
could rotate unexpectedly when
gradually. Do not allow oil to squirt
the rotation drive hub assembly is
or spray.
removed if the turntable is not
secured with the turntable rotation
lock pin.
Crushing hazard. The turntable
rotation drive hub assembly could
become unbalanced and fall when
removed from the machine if not
properly supported.
4 - 66 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
When installing the drive hub assembly: 2 Loosen the backlash pivot plate mounting
fasteners.
6 Install the drive hub. Torque the back lash pivot
plate to specification. Refer to Section 2,
Specifications.
7 Adjust turntable rotation gear backlash.
See How to Adjust the Turntable Rotation Gear
Backlash.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 67
Section 4 • Repair Procedures February 2012
Axle Components
9-1 3 Remove the pin retaining fasteners from the rod-
end pivot pin. Use a soft metal drift to remove
Oscillating Axle Cylinders the pin.
The oscillating axle cylinders extend and retract 4 Attach a lifting strap from an overhead crane to
between the drive chassis and the axle to maintain the barrel end of the oscillating cylinder.
a level chassis while driving over uneven terrain. 5 Remove the pin retaining fasteners from the
The cylinders are equipped with counterbalance barrel-end pivot pin. Use a soft metal drift to
valves to prevent movement in the event of a remove the pin.
hydraulic hose failure.
6 Remove the cylinder from the machine.
How to Remove an Oscillate Crushing hazard. The oscillate
Axle Cylinder cylinder could become unbalanced
and fall if not properly attached to
Note: Perform this procedure on firm, level surface the overhead crane when removed
with the boom in the stowed position. from the machine.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must
be torqued to specification during installation. Refer
to Section 2, Hydraulic Hose and Fitting Torque
Specifications.
1 Rotate the turntable until the boom is between
the steer tires or tracks.
2 Tag, disconnect and plug the oscillating axle
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
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 - 68 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
Track Components
10-1 How to Replace the Track
Track Assembly, 1 Remove the track assembly from the machine.
S-60 TRAX and S-65 TRAX See How to Remove a Track Assembly.
Note: The sprocket is comprised of two halves.
How to Remove a Track Before removing the track assembly from the
Assembly machine and to ease the removal of the sprocket,
drive the machine until one complete half of the
Note: Perform this procedure on a firm, level sprocket is located above the undercarriage of the
surface with the boom in the stowed position. track assembly.
1 Select a track assembly to remove. Loosen and 2 Loosen the grease plug on the track tension
remove as many sprocket retaining fasteners as cylinder to relieve the track tension. Clean up
possible from the hub adapter. any grease that has spilled.
2 Drive the machine in either direction just enough 3 Remove the 2 sprocket retaining fasteners.
to access the remaining fasteners. Do not Remove the sprocket half from the track
remove the retaining fasteners. assembly.
3 Chock the tracks at the opposite end of the 4 Carefully remove the track from the
machine to prevent the machine from rolling. undercarriage.
4 Center a lifting jack of ample capacity 5 Use an overhead crane to lay the undercarriage
(20,000 lbs / 10,000 kg) under the drive chassis on its side with the drive sprocket bearing
between the tracks. assembly facing upward and the track tension
cylinder towards the ground.
5 Lift the machine until the tracks are off the
ground and then place jack stands under the
drive chassis for support.
6 Attach a lifting strap from an overhead crane to
the center-point of the track assembly, above
the sprocket.
7 Remove the remaining sprocket retaining
fasteners from the hub adapter.
8 Carefully remove the track assembly from the
drive hub and set aside.
Crushing hazard. The track
assembly could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 69
Section 4 • Repair Procedures February 2012
TRACK COMPONENTS
6 Install the new track onto the undercarriage. 9 Rotate the sprocket half until the split tooth of
the sprocket is lower than the other side.
7 Attach a lifting strap from an overhead crane to
the center-point of the track, above the a
sprocket.
8 Use the overhead crane to raise the track
assembly to an upright position. Rest the
assembly on the floor or ground to remove any
slack in the lower portion of the track.
Note: Be sure the idler and bogey wheels are
aligned with the inside surface of the track.
a split tooth
4 - 70 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 4 • Repair Procedures
TRACK COMPONENTS
14 Using the pry bars, lift the sprocket half into 19 Pump grease into the grease zerk fitting until
position. Install the 2 sprocket retaining grease, free from air, comes out of the grease
fasteners and torque to specification. Refer to plug. Securely tighten the grease plug. Do not
Section 2, Specifications. overtighten.
15 Attach a lifting strap from an overhead crane to 20 Continue to pump grease into the grease fitting
the center-point of the track assembly, above just until the idler wheel moves. Check the track
the sprocket. tension.
16 Install the track assembly onto the drive hub Result: There should be less than 1 inch /
adapter while guiding the hub adapter studs into 2.5 cm of gap between the bogey wheels and
the sprocket of the track assembly. Install as the inside surface of the track.
many sprocket retaining fasteners as possible Proceed to step 22.
to the hub adapter and torque to specification.
Result: There is 1 inch / 2.5 cm or more of gap
Refer to Section 2, Specifications.
between the bogey wheels and the inside
Crushing hazard. The track surface of the track. Proceed to step 21.
assembly could become
unbalanced and fall when installed
onto the machine if not properly
supported by the overhead crane.
17 Adjust the track tension. Locate the grease plug
on the track tension cylinder. Loosen the plug,
but do not remove it.
18 Locate the grease zerk fitting on the other side
of the track tension cylinder.
Outside Inside
a bogey wheels
a b
a grease zerk
b grease plug
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 4 - 71
Section 4 • Repair Procedures February 2012
TRACK COMPONENTS
Grease Specification
4 - 72 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the Operator's
Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropriate fault code thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Electrocution/burn hazard. Contact
Repair any machine damage or malfunction with electrically charged circuits
before operating the machine. could result in death or serious
injury. Remove all rings, watches
Unless otherwise specified, perform each repair and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Machine parked on a firm, level surface
• Boom in stowed position
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Welder disconnected from the machine (if
equipped with the weld cable to platform
option)
• Wheels chocked
• All external AC power disconnected from the
machine
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 5-1
Section 5 • Fault Codes February 2012
FAULT CODES
5-2 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 5 • Fault Codes
FAULT CODES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 5-3
Section 5 • Fault Codes February 2012
FAULT CODES
5-4 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 5 • Fault Codes
FAULT CODES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 5-5
Section 5 • Fault Codes February 2012
FAULT CODES
Ford DSG-423 EFI Engine 4 Continue to hold the run/test toggle switch in the
test position and count the blinks.
How to Retrieve Ford Engine Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three times.
Fault Codes After the fault codes, the check engine light will
The ECM constantly monitors the engine by the blink a code 123 three times again indicating the
use of sensors on the engine. The ECM also uses end of the stored codes.
signals from the sensors to initiate sequential fuel
Note: If any fault codes are present, the ECM will
injection and make constant and instantaneous
blink a three digit code three times for each code
changes to ignition timing, fuel delivery and throttle
stored in memory. It will blink the first digit of a
position to maintain the engine's running condition
three digit code, pause, blink the second digit,
at its highest efficiency while at the same time
pause, and then blink the third digit. For example:
keeping exhaust emissions to a minimum. When a
the check engine light blinks 5 consecutive times,
sensor fails or returns signals that are outside of
blinks 3 times and then 1 time. That would indicate
set parameters, the ECM will store a fault code in
code 531.
memory that relates to the appropriate sensor and
will turn on the Check Engine Light. Note: Once a fault code has been retrieved and the
repair has been completed, the ECM memory must
Note: Perform this procedure with the key switch in
be reset to clear the fault code from the ECM. See
the off position.
How to Clear Engine Fault Codes from the ECM.
1 Open the ground controls side cover and locate
the run/test toggle switch on the side of the How to Clear Engine Fault
ground control box. Codes from the ECM
2 Pull out the red Emergency Stop button to the Note: Perform this procedure with the engine off
on position at both the ground and platform and the key switch in the off position.
controls.
1 Open the engine side turntable cover and locate
3 Move and hold the run/test toggle switch to the
the battery.
test position.
2 Disconnect the negative battery cable from the
Result: The check engine light should turn on.
battery for a minimum of 5 minutes.
The check engine light should begin to blink.
Electrocution/burn 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.
5-6 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 5 • Fault Codes
FAULT CODES
143 AL (Adaptive Learn) high LPG 226 ECT higher than expected 2
MAP (Manifold Absolute Pressure) high
144 AL (Adaptive Learn) low LPG 231 pressure
161 Battery Voltage high MAP (Manifold Absolute Pressure) low
232 voltage
162 Battery Voltage low
AUX analog PD1 high BP (Barometric Pressure) high
163 234 pressure
164 AUX analog PD1 low
235 BP (Barometric Pressure) low pressure
165 AUX analog PU3 high
166 AUX analog PU3 low 242 Crank sync noise
167 AUX analog PUD1 high 243 Never crank synced at start
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 5-7
Section 5 • Fault Codes February 2012
FAULT CODES
359 Fuel run-out longer than expected 551 Max govern speed override
5-8 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 5 • Fault Codes
FAULT CODES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 5-9
Section 5 • Fault Codes February 2012
FAULT CODES
Platform Load Sense System, 5 Determine the error type: The green LED
indicates the error type and will flash two
S-60 HC separate codes. The first code will indicate
the first digit of the two digit code, flashing
How to Retrieve Platform Load once per second. It will then pause for 1.5
seconds and flash the second digit once per
Sense System Fault Codes 0.5 second.
Note: Perform this procedure with the engine off,
6 Use the fault code table on the following
the key switch turned to ground controls and the
pages to aid in troubleshooting the machine
red Emergency Stop buttons pulled out to the on
by pinpointing the area or component
position at both the ground and platform controls.
affected.
1 Open the ground controls side turntable cover.
2 Locate the operational and safety controllers
near the ground control box.
3 Determine whether a safety or operational fault
exists by visually inspecting which controller f a
has flashing LEDs.
e b
Note: If the LEDs are flashing on both controllers,
determine the fault code on one controller at a
time.
5 - 10 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 5 • Fault Codes
FAULT CODES
Power relays
Power relay output disengaged. Relay wiring Repair system wiring and/or
23
short high open or shorted to connections.
voltage.
Power relays
disengaged. Relay wiring Repair system wiring and/or
24 Power relay output
open or shorted to connections.
short low
ground.
Boom up/down and
extend/retract
Directional relay output Repair system wiring and/or
25 inoperative. Relay wiring
short high connections.
open or shorted to
voltage.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 5 - 11
Section 5 • Fault Codes February 2012
FAULT CODES
5 - 12 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 5 • Fault Codes
FAULT CODES
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 5 - 13
Section 5 • Fault Codes February 2012
FAULT CODES
Power relays
Repair wiring and/or connections
disengaged. Boom angle
11 Output short high OR replace boom angle sensor
sensor wiring open or
and calibrate overload system.
shorted to voltage.
Power relays
disengaged. Boom angle Repair wiring and/or connections
sensor wiring open or OR adjust or replace boom angle
12 Value too high
shorted to voltage OR sensor and calibrate overload
sensor is out of operating system.
range.
Power relays
disengaged. Boom angle Repair wiring and/or connections
sensor wiring open or OR adjust or replace boom angle
15 Value too low
shorted to ground OR sensor and calibrate overload
sensor is out of operating system.
range.
Power relays
Repair wiring and/or connections
disengaged. Boom angle
16 Output short low OR replace boom angle sensor
sensor wiring open or
and calibrate overload system.
shorted to ground.
5 - 14 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 5 • Fault Codes
FAULT CODES
Power relays
Repair wiring and/or connections
disengaged. Boom angle
11 Output short high OR replace boom angle sensor
sensor wiring open or
and calibrate overload system.
shorted to voltage.
Power relays
disengaged. Boom angle Repair wiring and/or connections
sensor wiring open or OR adjust or replace boom angle
12 Value too high
shorted to voltage OR sensor and calibrate overload
sensor is out of operating system.
range.
Power relays
disengaged. Boom angle Repair wiring and/or connections
sensor wiring open or OR adjust or replace boom angle
15 Value too low
shorted to ground OR sensor and calibrate overload
sensor is out of operating system.
range.
Power relays
Repair wiring and/or connections
disengaged. Boom angle
16 Output short low OR replace boom angle sensor
sensor wiring open or
and calibrate overload system.
shorted to ground.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 5 - 15
Section 5 • Fault Codes February 2012
FAULT CODES
Power relays
Repair wiring and/or connections
disengaged. Load cell
11 Output short high OR replace platform load cell
wiring open or shorted to
and calibrate overload system.
voltage.
Power relays
Repair wiring and/or connections
disengaged. Load cell
16 Output short low OR replace platform load cell
wiring open or shorted to
and calibrate overload system.
ground.
Boom range of motion is Calibrate the platform load sense
17 Not calibrated
limited. system.
Used to clear diagnostic
18 Just calibrated Self-clearing.
codes.
5 - 16 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 5 • Fault Codes
FAULT CODES
Power relays
Repair wiring and/or connections
disengaged. Load cell
11 Output short high OR replace platform load cell
wiring open or shorted to
and calibrate overload system.
voltage.
Power relays
Repair wiring and/or connections
disengaged. Load cell
16 Output short low OR replace platform load cell
wiring open or shorted to
and calibrate overload system.
ground.
Boom range of motion is Calibrate the platform load sense
17 Not calibrated
limited. system.
Used to clear diagnostic
18 Just calibrated Self-clearing.
codes.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 5 - 17
Section 5 • Fault Codes February 2012
5 - 18 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
Electrocution/burn hazard. Contact
with electrically charged circuits
Observe and Obey: could result in death or serious
injury. Remove all rings, watches
Troubleshooting and repair procedures shall be and other jewelry.
completed by a person trained and qualified on
the repair of this machine. Hydraulic Schematics
Immediately tag and remove from service a Bodily injury hazard. Spraying
damaged or malfunctioning machine. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
Before Troubleshooting: or spray.
Read, understand and obey the safety rules and General Repair Process
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.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6-1
Section 6 • Schematics February 2012
FS1
BLK
BLK
P3
WHT LS3 Foot switch
N.O.H.C N.C.H.O
Quick disconnect
terminal Limit switch Horn button
Coil normally open
solenoid or relay
P1
KS1
WHT #21 TB21
PLATFORM
OTS2
GROUND N.O.
T-circuits connect H1 Emergency Stop
at terminal button normally
Oil temperature
switch closed
Horn or alarm Key switch normally open
(before serial number 22051)
T-circuits
connect FAN
FB PR1
CTS1
N.O.
Hydraulic oil
Flashing beacon Power relay cooling fan
Connection Coolant temperature
no terminal switch
normally open Aux
G1 TS2 Pump
ENGINE
START
L3
PLATFORM LEVEL
-
Gauge sending unit Tilt sensor
LED
Battery
Toggle switch DPDT
F1
KS1
25A A B C
CB1
PULL IN
Fuse
HOLD
CR4
15A with amperage N.O. Key switch
(after serial number 22050)
Circuit breaker
with amperage
Control relay contact Fuel or RPM
normally open solenoid
Starting aid:
glow plug or
flame ignitor
Coil
6-2 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 6 • Schematics
25 psi
(1.7 bar) .035"
(0.89 mm)
Orifice with size
Solenoid operated
Solenoid operated 3 position, 3 position, 4 way,
Filter with 4 way, directional valve proportional directional valve
bypass valve
relief setting
Check valve
200 psi
(13.8 bar)
2 position, 3 way, shuttle valve
Pump
fixed displacement Relief valve Priority
with pressure setting flow regulator valve
o
Brake
Needle valve
50% 50%
E
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. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6-3
Section 6 • Schematics February 2012
Starter Empty
Relay
F1-10A F2-5A
Fuel Power
Pump Relay F3-10A F4-15A
Relay
F5-15A F6-10A
6-4 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
February 2012 Section 6 • Schematics
Cable Tension
Limit Switch
(LS5)
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6-5
Section 6 • Schematics February 2012
6-6 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
Section 6 • Schematics February 2012
6-7 6-8
Section 6 • Schematics February 2012
1 STRING POTENTIOMETER
LS19
STRING TENSION
S22 S23 LIMIT SWITCH
14 13
NO HC
OR
RD
BN
BK
YL
BL
24 23
PLATFORM BOX
2
C45-4 WH
C45-1 RD
C45-2 BN
C45-3 BK
C44-4
C44-5
C44-6
C44-1
C44-2
C44-3
PLATFORM SUPPORT
C9P-2
P24FS WH
SAFETY CONTROLLER OPERATIONAL CONTROLLER
TS1
AUXILIARY 5
NOT USED
NOT USED
NOT USED
2
C183RCV
C169ENV
V183RCV
GROUND
GROUND
P109SEN
P1-10 C123PBS
C141PBS
C177ERL
P1-11 C145CAL
P1-12 C175LDS
C167PSL
C133PLA
C173PEL
P2-11 R134BAT
P2-12 R134BAT
C166PSL
P1-11 S170ENL
P1-12 S171ENL
R134BAT
P110RET
R134BAT
P110RET
P174BAT
PUMP
P63SEN
P1-10 C94LDS
P26BAT
C172PL
P2-10 C168PL
CAN +
CAN +
CAN -
CAN -
PLATFORM LOAD CELL C1P-1
C27AUX RD
1 3 4 6
P63SEN OR/RD
P2-1
P2-2
P2-3
P2-4
P2-5
P2-6
P2-7
P2-8
P2-9
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
3
P109SEN GR/WH
P109PSL GR/WH
D63
WH - CH1 RETURN
P63PSL OR/RD
OR - CH2 OUTPUT
GR - CH1 OUTPUT
BL - CH2 RETURN
C53 C41 C42
RD - PWR
BK - GND
+
H1
120W L4
PLATFORM
C183RCV BL
C134BAT RD
120W OVERLOAD
C133PLA GR/BK
C3P-12
1 1
C46-2 C175LDS WH/BK C5-4
4 C166PSL OR C46-1 C94LDS WH C5-3 C5-1 C134PWR RD
C4P-12 C134PWR RD 2 2
C40B-10
C40B-12
C40B-11
BOOM EXTEND/RETRACT F.C.
C40B-7
C40B-6
C40B-1
C40B-8
C40B-9
C40B-2
ACTIVE ENVELOPE
C40B-3
C40B-4
C40B-5
COM PORT A D82CAN+ YL
C30-2 C30-1
COM PORT B D82CAN- GR C173PEL BK
TB9
5
BOOM UP/DOWN F.C.
C145CAL RD/WH
GROUND BOX
C133PLA GR/BK
C177ERL BL/BK
C29-2 C29-1
C168PL BL/RD
S170ENL WH/RD
S171ENL WH/BK
C134PBAT RD
C172PL BL
P174BAT WH
V183RCV BL
TB3
P23BAT WK
R134BAT RD
R7PBE BK
TB7A
GND BR
TB2A TS73
C7PBE BK
1 2
13 14 SWITCH C3PUD RD/WH TB3
LS2
C2PBD RD/BK
RD TB23A TB-0A
NO/HC 4 5
21 3 R2PBD RD/BK C2PBD RD/BK
6 LS5
CABLE NC
C10-1 C10-2 TB40A
TB27C
C27AUX RD 30 D49
TENSION 6
BK WH OR
22 CR52 CR53 D47
BR BOOM BOOM 13 LS1 14 1 2
CR56 C8PBR BK/WH TB8
DOWN EXTEND NO/HC
C37-2
30 86 30 86 RECOVERY 87A 87
CUTOUT CUTOUT DUAL CAPACITY C9PER BK/WH TB9
86 85 3
CR59 C134LS WH R8PBR BK/WH D46
RD/BK
87 87A 85 87 87A 85 POWER ON
R7PBE BK
86 30
C2PBD
30 85 30 85
C114-5
C114-6
C114-4
C114-2
C114-1
C114-3
V183RCV BL
C2PBD RD/BK
85 87A 87
R134BAT RD 1 1 R134BAT RD
C7PBE BK
C13-1
C16-1
87 87A 86 87 87A 86
P174BAT WH 6 6
7 R174BAT RD 7 7
C32
OR
RD
BN
BK
YL
BL
C13-2
LOAD SENSE LOAD SENSE 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
CUTOUT PLATFORM CUTOUT GROUND TB134C C133PLA GR/BK
S17 S18
C2PBD RD/BK
8
B00M DOWN
B00M EXTEND
6-8 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
N
14
24
LS19
NO HC
STRING
23
LIMIT SWITCH
POTENTIOMETER
C45-2 BK
C45-3 BR
C45-4 RD
13 C45-1 WH
M
P63PSL OR/RD
P109PSL GR/WH
P63SEN OR/RD (C53-6)
S23
K
S17
1
J
C134BAT RD (C46-6)
BOOM ANGLE SENSOR
C40
P174BAT WH (C41-6)
8
P23BAT WH (C41-7)
9
120W
TERMINATING
GND BR (C40-6)
P1-1 GROUND
R134BAT RD (C40-1)
P1-2 P20BAT
D82CAN+ YL
P1-3 CAN +
D81CAN- GR
P1-4 CAN -
C141PBS RD (C114-3)
P1-8 C141PBS
C166PSL OR (C44-3)
P1-9 C166PSL
TO PC
CONNECTS
RTESISTOR
TERMINATING
C41
GRAY
GND BR (C40-6)
P1-1 GROUND
R134BAT RD (C40-1)
P1-2 P20BAT
D82CAN+ YL CAN +
P1-3
D81CAN- GR
P1-4 CAN -
P174BAT WH (C40-8)
P1-6 P174BAT
F
P23BAT WH (C40-9)
P1-7 P26BAT
P1-12 C175LDS
BOOM
UP/DWN
CONTROL
C183RCV BL (C46-6)
February 2012
P2-1 C183RCV
Part No. 139188
V183RCV BL (C40-11)
P2-7 V183RCV
C172PL BL (C29-2)
P2-8 C172PL
C173PEL BK (C30-2)
P2-9 C173PEL
Y15
R134BAT RD (C40-1)
P2-11 P20BAT
R134BAT RD (C40-1)
FUNCTION MANIFOLD
D
P2-12 P20BAT
FLOW
BOOM
C42
EXTEND/
BLACK
RETRACT
CONTROL
C46
BL - CH2 RETURN
C175LDS WH/BK (C51-4, C46-2) OR - CH2 OUTPUT
C
WH - CH1 RETURN
C94LDS WH (C51-3, C46-1)
GR - CH1 OUTPUT
SENSOR
PLATFORM
C134BAT RD (C46-6)
C169ENV GR (C46-4)
C134PWR RD (C51-1)
ES0390D
9
11
10
12
A
C4P
Chassis Wiring Diagram, S-60 HC
6-9
Section 6 • Schematics
8
7
6
5
4
3
2
1
February 2012 Section 6 • Schematics
6-9 6 - 10
Section 6 • Schematics February 2012
6 - 11 6 - 12
8
7
6
5
4
3
2
1
6 - 12
CR52 CR53 CR54 CR55
BOOM DOWN BOOM EXTEND LOAD SENSE LOAD SENSE
CUTOUT CUTOUT CUTOUT PLATFORM CUTOUT GROUND
30 30 30 30
86 87 85 86 87 85 86 87 85 86 87 85 A
Section 6 • Schematics
C2PBD RD/BK
GND BR
GND BR
C7PBE BK (TB7A)
(C13-1 / TS49-5)
S170ENL WH/RD (C40-3)
R174BAT RD (C32-7)
B
R134BAT RD CR59-30
C134BAT RD (CR59-86)
S170ENL WH/RD (CR54-86/CR55-86)
S171ENL WH/BK (CR54-85/CR5585)
1 2 3 4
R18
C177ERL BL/BK (CR53-86)
5
BOOM
DOWN
BYPASS
PRIMARY
GND BR
6
C40
TS73
P174BAT WH (TS73-1)
8
SWITCH
P23BAT WH (TB0B)
CALIBRATION
C133PLA GR/BK (C32-8)
C7PBE BK (CR53)
1 2 3 V183RCV BL (TS49-3)
C
C134BAT RD (C40-2)
C145CAL RD/WH (TS73-2)
9 10 11 12
P134PWR RD (TB134C)
P174BAT WH (CR55-30) P174BAT WH (C40-8)
4 5 6
R134BAT RD (C40-1 / C32-1)
R2PBD RD/BK (TS49-4) C2PBD RD/BK (CR52-87)
R8PBR BK/WH (TS49-1) C3PUD RD/WH (TB3C)
D48
4
SWITCH
1 2
R17
BOOM
87A 87A
BYPASS
EXTEND
3
PRIMARY
6
30 30 V183RCV BL (C40-11)
R134BAT RD (CR59-30)
P22BAT BK (CR54-30)
GND BR
CR59
HIGH
CR56
POWER
MODULE
R22PWR BK (CR54-87)
CAPACITY
HI-CAPACITY
RECOVERY
GND BR P174BAT WH
R174BAT RD
C133PLA
(CR55-87)
(CR55-30 / CR59-87A)
GR/BK (C40-10)
BRN
D C B A P23BAT WH (C40-9)
12
E
KEYSWITCH POWER
0 SPARE 0
C32
8
7
5
6
1
12
4
3
RD/BK-ALARM
C32 CONNECTOR
1 PRIMARY BOOM UP 1
BRN
D29
C2PBD RD/BK (CR52-30)
2 PRIMARY BOOM DOWN 2
BK-22D2
RD-TS52
RD-TS51
BK C7B-1
R134BAT RD (H6)
(H6)
GR/BK-133B
C7PBE BK (CR53-30)
7 PRIMARY BOOM EXTEND 7
C8PBR BK/WH (TS49-2)
C133LDS GR/BK (L45)
+
RD/BK-ALARM
13 DRIVE ENABLE 13
G
PLATFORM
C7
15 PLATFORM LEVEL DOWN 15
C134LS WH (CR56)
21 IGNITION POWER 21
C37-1
C13-1
H
18/19 #2
C1 & C2
RD
D45
23 KEYSWITCH POWER 23
KEYSWITCH POWER
C11-2
BOOM
24 CIRCUIT BREAKER POWER 24 WH
EXTEND
LIMIT SWITCH
25 OIL PRESSURE SWITCH 25 C11 (LS1)
C10-1
27 AUXILIARY PUMP 27
CABLE
TENSION
WH
30 PROPEL FORWARD 30
31 PROPEL REVERSE 31
+12V POWER
32 BRAKE 32
J
33 START ENGINE 33
34 GLOW PLUG 34
36 STEER LEFT 36
37 STEER RIGHT 37
C5
39 (UNUSED) 39
K
40 BOOM STOWED 40
ENGINE HARNESS
46 SERVICE HORN 46
45 GENERATOR OPTION 45
L
B A
Genie Industries
HARNESS
FUNCTION
GROUND BOLT
N
February 2012 Section 6 • Schematics
P23BAT WH H1+
7 6
8 5
P23BAT WH (P2)
9 4
C183RCV BL CR59
C4P
10 3
C169ENV GR L50
11 2
C134PWR RD (P2)
12 1
2
PLATFORM CONTROL
HARNESS
L48
TILT ALARM LED
TS48 (ANSI/CSA OPT.)
DRIVE LIGHTS / WORK LIGHTS
(OPTION) +
JC2 7 JC1 7 JC3 7
PRIMARY BOOM UP/DOWN PRIMARY BOOM DRIVE FORWARD/REVERSE
& TURNTABLE ROTATE LEFT/RIGHT EXTEND/RETRACT & STEER LEFT/RIGHT
6 6 6
3
COMPONENT INDEX
5 5 5
JC2 BOOM PROPORTIONAL JOYSTICK:
PRIMARY BOOM UP/DOWN AND TURNTABLE ROTATE
P3 HORN BUTTON
+ TS1 AUXILIARY POWER TOGGLE SWITCH
C134PWR RD C4-12
C183RCV BL (C4-10)
C27AUX RD (C1-1)
P23BAT WH (C7-2)
C169ENV GR C4-11
C134BAT RD (L4+)
C134BAT RD (L4+)
D63
TS9
PLATFORM
TS7
PLATFORM
WH
TS14
TS47
GENERATOR
7
P3 LEVEL ROTATE DRIVE SPEED
TS6 TS2 TS4 (OPTION)
HORN HIGH / LOW
GLOW PLUG START HIGH/LOW RPM 1 1 1
P2
+ EMERGENCY
STOP
L50 2 2 2
WH OUT OF TS1
ENVELOPE LED AUXILIARY PUMP
8
CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 13
February 2012 Section 6 • Schematics
6 - 13 6 - 14
Section 6 • Schematics February 2012
6 - 15 6 - 16
Section 6 • Schematics February 2012
OR
RD
RD
BN
BN
BK
BK
YL
YL
BL
BL
PLATFORM BOX
2
C114-6
C114-1
C114-4
C114-5
C114-3
C114-2
C44-4
C44-1
C44-6
C44-5
C44-3
C44-2
PLATFORM SUPPORT
C9P-2
P24FS WH
SCON - SAFETY CONTROLLER TCON - OPERATIONAL CONTROLLER PLATFORM LOAD CELL
TS1
GROUND
GROUND
C183RCV
V183RCV
C141PBS
C169ENV
P109SEN
P1-10 C123PBS
C177ELO
C166PSL
P1-11 S170ENL
P1-12 S171ENL
P1-11 C145CAL
P1-12 C175LDS
C173PEL
R134BAT
P110RET
P2-11 R134BAT
P2-12 R134BAT
C167PSL
C133PLA
R134BAT
P110RET
P174BAT
P174BAT
AUXILIARY 5
P1-7 P23BAT
2
P63SEN
P1-10 C94LDS
C200PL
C172PL
P2-10 C168PL
C42LS
CAN +
CAN +
PUMP
CAN -
CAN -
N/C
C1P-1
P109SEN GR/WH
P109SEN GR/WH
C166PSL OR
C141PBS RD
P63SEN OR/RD
C167PSL OR/BK
P63SEN OR/RD
C123PBS RD/BK
C27AUX RD
1 3 4 6
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
P2-1
P2-2
P2-3
P2-4
P2-5
P2-6
P2-7
P2-8
P2-9
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
3 D63
WH - CH1 RETURN
C41
OR - CH2 OUTPUT
GR - CH1 OUTPUT
BL - CH2 RETURN
C53 C42
RD - PWR
BK - GND
+
H1
L4 P2
PLATFORM EMERGENCY
C183RCV BL
C134BAT RD
120W OVERLOAD STOP
120W
C133PLA GR/BK
C3P-12 1 1
4 C46-2
C46-1
C175LDS WH/BK
C94LDS WH
C51-4
C51-3 C51-1
C134PWR RD
C4P-12 C134PWR RD 2 2
C40B-10
C40B-12
C40B-11
C40B-1
C40B-3
C40B-4
C40B-6
C40B-8
C40B-9
C40B-5
C40B-7
C40B-2
BOOM EXTEND/RETRACT F.C. ACTIVE ENVELOPE
COM PORT B D81CAN- GR
C30-2 Y15 C30-1
C173PEL BK
C55-2
C55-1
TB9
5
BOOM UP/DWN FC
C29-2 GROUND BOX
C145CAL RD/WH
S171ENL WH/BK
C29-1
S170ENL WH/RD
Y12
C133PLA GR/BK
C177ELO BL/BK
C168PL BL/RD
C172PL BL
C42LS OR/RD
TB3
P174BAT WH
C134BAT RD
V183RCV BL
R134BAT RD
GND BR
C200PL BK/RD
P23BAT WH
C7PBE BK
TB1A TB2A TB7A TS73
RD/BK CALIBRATION
TS49
C37-1
TB23B TB-0B
BK
21 3 NO/HC 4 5
C1PBU RD
NO/HC 87A 87
30 86 30 86 30 86 RECOVERY
3 C9PER BK/RD TB9C
86 85 DUAL CAPACITY
C2PBD RD/BK
C1PBU RD
86 30
30 85 30 85 V183RCV BL
85 87A 87
R134BAT RD 1 1 R134BAT RD
C16-1
87 87A 86 87 87A 86
C13-1
C12-1
P174BAT WH 6 6
R2PBD RD/BK
7 R174BAT RD 7 7
R1PBU RD
R7PBE BK
C32
C133PLA GR/BK 8 8 + L45
R22BAT BK 5 5 H6 PLATFORM
OVERLOAD
P22BAT BK 4 4
CR54 CR55 NOTES:
R19 R18 R17
C16-2
GND BR 12 12
C12-2
C13-2
LOAD SENSE LOAD SENSE 1. ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN THE STOWED POSITION.
5W 5W 5W
PLATFORM CUTOUT GROUND CUTOUT TB134C C133PLA GR/BK
C2PBD RD/BK
8
B00M DOWN
BOOM EXTEND
B00M UP
ES0390E
6 - 16 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
S22
C167PSL OR/BK C42-2 C44-6
YL
P110RET BK C41-9 C44-5
N
OR
P109SEN GR/WH C114-6 C44-4
BN
BL
P110RET BK C53-7 C44-2
RD
P63SEN OR/RD C53-6 C44-1
BK
POTENTIONMETER
S23
M
S17
1
C134BAT RD (C46-6)
2
S170ENL WH/RD (C53-11)
3
S171ENL WH/BK (C53-12)
4
C177ELO BL/BK (C42-3)
5
C42LS OR/RD (C41-5)
6
C168PL BL/RD (C42-10)
K
C40
P174BAT WH (C41-6)
8
120W
P23BAT WH (C41-7)
9
RESISTOR
V183RCV BL (C42-7)
10 11
C145CAL RD/WH (C41-11)
12
C53
GRAY
GND BR (C41-1)
P1-1 GROUND
J
R134BAT RD (C40-1)
P1-2 R134BAT
D82CAN+ YL
P1-3 CAN+
D81CAN- GR
P1-4 CAN-
SAFETY MODULE
CONNECTS
RESISTOR
TERMINATING
H
C41
GRAY
P1-6 P174BAT
P23BAT WH (C40-9)
P1-7 P23BAT
P109SEN GR/WH (C114-6 / C44-4)
P1-8 P109SEN
P110RET BK (C46-3 / C114-2 / C44-5)
P1-9 P110RET
C123PBS RD/BK (C114-4)
P1-10 C123PBS
C145CAL RD/WH (C40-12)
P1-11 C145CAL
C175LDS WH/BK (C46-2 / C51-4)
P1-12 C175LDS
FLOW
BOOM
F
C183RCV BL (C46-5)
UP/DOWN
CONTROL
P2-1 C183RCV
C167PSL OR/BK (C44-6)
P2-2 C167PSL
TB3
P2-4 C169ENV
OPERATIONAL MODULE
P2-7 V183RCV
TB9
C172PL BL (Y12)
P2-8 C172PL
E
C173PEL BK (Y15)
P2-9 C173PEL
Y15
EXTEND/
RETRACT
CONTROL
BLACK
C46
FUNCTION MANIFOLD
D
R134BAT RD (C42-12)
GND BR (C41-1)
BL - CH2 RETURN
C175LDS WH/BK (C51-4 / C46-2)
OR - CH2 OUTPUT
WH - CH1 RETURN
C94LDS WH (C51-3 / C46-1)
GR - CH1 OUTPUT
C55-1
C55-2
BK - GND
C
ES0390E
C169ENV GR (C46-4)
C134PWR RD (C51-1)
9
10
12
11
A
C4P
6 - 17
Section 6 • Schematics
8
7
6
5
4
3
2
1
Chassis Wiring Diagram, S-60 HC
(after serial number 19038)
February 2012 Section 6 • Schematics
6 - 17 6 - 18
Section 6 • Schematics February 2012
6 - 19 6 - 20
8
7
6
5
4
3
2
1
6 - 20
CR52 CR53 CR54 CR55
BOOM DOWN BOOM EXTEND LOAD SENSE LOAD SENSE
CUTOUT CUTOUT PLATFORM CUTOUT GROUND CUTOUT
30 30 30 30
87A 87A
87 87 87 87
86 85 86 85 86 85 86 85
A
Section 6 • Schematics
GND BR
GND BR
C7PBE BK (C37-1)
S170ENL WH/RD (C40-3)
S170ENL WH/RD (C40-3)
B
CALIBRATION
P174BAT WH (TS73-1)
SWITCH
P23BAT WH (TB0B)
GND BR
C133PLA GR/BK (C32-8)
R7PBE BK (CR53) 1 2 3 V183RCV BL (TS49-3)
C134BAT RD (C40-2)
C145CAL RD/WH (TS73-5)
C
1 2 3 4 5 6 7 8 9 10 11 12
P134BAT RD (TB134-1C)
P174BAT WT (CR55-30) P174BAT WT (C40-8)
R134BAT RD (C32-1 / TB134) 4 5 6
R2PBD RD/BK (TS49-4) C2PBD RD/BK (CR52-87) TS49
R8PBR BK/WH (TS49-1) C3PUD RD/WH (TB3C) RECOVERY
D48
85 86
5
87A
6
30 30 V183RCV BL (C40-11)
R134BAT RD-FH
R134BAT RD (CR59-30)
CR56 CR59 P22BAT BK (CR54-30)
RECOVERY HI-CAPACITY
R22BAT BK (CR54-87)
UP CUTOUT
GND BR
R19
BRN
UP BYPASS
87A GND BR
5 ohms 1% 25W
8
7
6
5
4
1
12
86 87 85
C1PBU (C12-1) C32
12
6
8
7
5
1
4
3
C32 CONNECTOR
BK (C7B-1)
BL/WH (132B)
C133PLA GR/BK
R134BAT RD (H6 / L45)
Ground Control Box Terminal Strip Wiring Diagram, S-60 HC
KEYSWITCH POWER
GR/BK (133B)
0 SPARE 0
C1PBU RD (CR63-30)
1 PRIMARY BOOM UP 1
+
C7PBE BK (CR53-30)
7 PRIMARY BOOM EXTEND 7
C8PBR BK/WH (TS49-2)
C7PBE BK (CR53-87)
18/19 #1
9 PRIM. BOOM EXT/RET FUNC. CTRL 9
C3 & C4
13 DRIVE ENABLE 13
C13-1
C37-1
18/19 #2
14 PLATFORM LEVEL UP 14
C1 & C2
BOOM
H
21 IGNITION POWER 21
C10-1
CABLE
TENSION
22 +12 VOLT TO PLATFORM (1) 22 LIMIT SWITCH
C37 (LS5)
22 +12 VOLT TO PLATFORM (2) 22 D45
P23BAT WH (C7B-2)
KEYSWITCH POWER
23 KEYSWITCH POWER 23
I
27 AUXILARY PUMP 27
29 MOTOR STROKE 29
30 PROPEL FORWARD 30
J
31 PROPEL REVERSE 31
32 BRAKE 32
33 START ENGINE 33
34 GLOW PLUG 34
36 STEER LEFT 36
C5
37 STEER RIGHT 37
K
ENGINE HARNESS
39 (UNUSED) 39
40 BOOM STOWED 40
46 SERVICE HORN 46
45 GENERATOR OPTION 45
46R HORN RELAY POWER 46R
118 LIFT SPEED REDUCTION 118
132 PLATFORM OVERLOAD LS 132
133 PLATFORM OVERLOAD ALARM 133
R134BAT RD (L45)
B A
FUNCTION
U1 HARNESS
1 C9 (LS2)
FH
1 START RELAY
2 2 TACHOMETER C11 (LS2)
M
GROUND BOLT
N
February 2012 Section 6 • Schematics
C134BAT RD
L48 7 6
TILT ALARM LED
TS15
DRIVE ENABLE
+
C134BAT RD P2
8 5
2
9 4
C183RCV BL CR59 C4P
10 3
C169ENV GR L50
11 2
6 C134PWR RD P2
6 1 6 1 12 1
1
5 2 5 2
5 2
4 3 3 4 3
4
L4
PLATFORM
OVERLOAD
3
(CE OPTION)
L1
DRIVE ENABLE +
JC2 JC1 +
LED JC3 PLATFORM CONTROL
PRIMARY BOOM UP/DOWN PRIMARY BOOM DRIVE FORWARD/REVERSE HARNESS
& TURNTABLE ROTATE LEFT/RIGHT EXTEND/RETRACT & STEER LEFT/RIGHT
C134PWR RD E-STOP
SINGLE AXIS JOYSTICK
C134PWR RD C4-12
TS4 RPM SELECT TOGGLE SWITCH
C169ENV GR C4-11
C183RCV BL C4-10
C27AUX RD C1-1
C134PWR RD L48+
C134BAT RD L4+
P23BAT WH C7-2
C134BAT RD L4+
TS6 GLOW PLUG TOGGLE SWITCH (OPTION)
TS7 PLATFORM ROTATE TOGGLE SWITCH
TS9 PLATFORM LEVEL TOGGLE SWITCH
TS14 DRIVE SPEED SELECT TOGGLE SWITCH
D63
TS15 DRIVE ENABLE TOGGLE SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 21
February 2012 Section 6 • Schematics
6 - 21 6 - 22
February 2012 Section 6 • Schematics
N M L K J I H G F E D C B A
IGNITION COILS HO2S #1
R 16 R 16 R 16 HO2S #2
ENGINE ECM Y/BK 18
CONNECTOR
1
W/PK 18 BK/LG 18 GY/R 18 SHD
Y/RD 18 GY/LB 18 GY/YL 18 A
GY/LB 18
Y/BK 18 R 16 B
1 DG/P 18 GY/R 18
SPK_COIL1A W/PK 18 DB/O 18 BK/LB 18 C
2
SPK_COIL1B D
3 Y/RD 18
SPARK_COIL2A BK/W 16 GY/R 18 GY/Y 18
4
SPK_GND DG/P
5
SPK_COIL2B
6
SPK_COIL3A
7
SPK_COIL3B
UEGOS
8 CYL #2 CYL #3 CYL #4 CYL #1 GY/R 18 TWR GASOLINE
9 A
UEGOC
10 CAM
LG/W 18
B SENSOR
UEGOP BR/W 18
UEGPR
11
W/LG 18 W/LG 18 C INTERFACE
12 DG/O 18 D
AUX ANA PD1
(FRP) AUX ANA PD2
13 W/LG 18
FORD
14 DG/P 18 DG/P 18
CAN1 +
15 O/LG 18 O/LG 18
MTRTWR4 42 PIN
CAN1 - CONNECTOR
CAN2 -
CAN2 +
16
17
18
BR/W 18
LG/R 18 LG/R 18
2
AUX ANA PD3 BR/W 18
5V EXT 1
19
GY/R 18 GY/R 18 GY/R 18
GROUND BR 16 BR 16
20 34 GND
5V RTN GY/LB 18
21
EGO1 GY/Y 18 BK/W 12
22
EGO2
23 LG/BK 18 BOSCH RING
MAP
AUX ANA PUD3
24 TMAP
25 GY 18
CRANK + DBL 18
26 LG/BK 18
CRANK - GY/R 18 BR/W 18 4
27
CAM +
28 DB/O 18 GY 18
3 CHT
CAM - DG/BK GY/R 18 2
29
SPEED + LB/R 18 1
30
SPEED -
31 LG/W
5V EXT 2 DG/BK
32 LB/R 18 36 ROADSPEED -
5V RTN 2
PULSE IN
GOV 1
33
34
35
T/LB 18
DG/W 18
LB/R 18
T/LB 18
LG/BK 18
T/LB 18
35 ROADSPEED +
24 GOV SELECT 1 C128 RPM 3
OIL PRESS GY 18 BK/W 16
36
IAT LG/R 18 BK/W 16
37
ECT LG/W LB/BK 18 LB/BK 18
38 14 FPP1
(FRT) AUX ANA PU1 W/R 18 BK/LB 18
39
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
40 BK/O 18
F2
41 W/LB 18 R/LG 18 R/LG 18 R/LG 18 R/LG 18
(BRAKE) AUX DIG 3 1 VSW P23 BAT
42 BK/Y 18 BK/Y 18
(GOV2) AUX DIG 4
43 T/Y 18 5A VSW
TACH R/LG 18
44
VSW DB/W 18
45
AUX ANA PUD2
46 P/LB 18 F3
AUX ANA PUD1 GY/W 18 R/T 14
47 R/T 14 R 14
TPS 1 Y/W 18
48
TPS 2
49 Y/DB 18 10A ECM
(FUELSELECT)AUX DIG1
AUX DIG 2
KNOCK +
50
51
52
Y/R 18
DG/P 18
GY 18
BK/Y 18
23 GOV SELECT 2 C35 RPM 4
KNOCK - DBL 18 O/LG 18
LB/BK 18 29 CAN -
53 DG/P 18
FPP1 28 CAN +
54 LB/Y 18
(FPP2) FPP2-IVS DG/O 18 DG/O 18
55 DG 18 32 ANA AUX PD1
PC TX
56 O 18
PC RX DB/W 18 DB/W 18
57 37 AUX ANA PU2B
KNOCK 2+
KNOCK 2-
58 CRANK LB/Y 18 LB/Y 18
12 FPP2
59
VBAT PROT R/T 16 RD/T 14
60
VBAT BK/LB 18 GY/R 18 GY/R 18 GY/R 18
61 33 ANA RTN
EGOH 2 BK/LG 18 BR/W 18 BR/W 18 BR/W 18
62 31 VREF
EGOH 1
63 R 14
INJ HS T 16
64
INJ1 LS
65 BR/Y 16 BK/LG 18 BOSCH THROTTLE
INJ2 LS
66 BR/LB 16 BATT(+) R 12 R 12
ALTERNATOR
INJ3 LS
INJ4 LS
INJ5 LS
67
68
69
W 16
BK/W 16
GY/W 18
Y/W 18
LB/DG 18
GY/W 18
Y/W 18
LB/DG 18
6
5
RING R 16
3 5
GROUND 4 2
70 BR/W 18 BR/W 18 RED/TAN
INJ6 LS BK/W 16 GY/R 18 GY/R 18 3 1
71
AUX PWM8 LG/P 18 GY/O 18 GY/O 18 2
72
STARTER R/Y 18 1
73
RELAY PK/LG 18
74
MIL BK/R 16
75
UEGO H
76
AUX PWM7 W/BK 18
77
LOCKOFF LB/O 18 LG/P 18 DG/W 18
78
(FUEL PUMP) AUX PWM6 R/T 16 R/Y 18
79
VBAT LB/DG 18
80
DBW +
81 BK/W 16 OIL PRESSURE
GROUND GY/O 18
82
DBW - R/BK 18
83 R/BK 18 21 AUX PWM 5
AUX PWM5 REC
6
84 R/BK 18 R/W 18 R/W 18 16 AUX PWM 4
AUX PWM5 O/LG 18
85
AUX PWM1 R/W 18 BK/O 18
86 BK/O 18 25 IVS
AUX PWM4 T/GN 18 DG/W 18
87 DG/W 18 26 OIL PRES
AUX PWM2 T/Y 18
88 T/Y 18 2 TACH
AUX PWM4 REC C41 RPM
89 PK/LG 18 PK/LG 18 6 MIL
FP REC AUX PWM3 REC C10 BESL
90 BK/R 16 BK/R 16 BK/R 16
FUEL PUMP AUX PWM3 18 FUEL PUMP - C21 IGN
O/LG 18 O/LG 18
39 AUX OUT1 C135 FP
R 16 W 16 Y/DB 18 Y/DB 18
7 FUEL SELECT C39 LP
P/LB 18 P/LB 18
10 AUX ANA PD1B
T/GN 18 T/GN 18
27 AUX OUT 2
W/LB 18 W/LB 18
4 BRAKE
DG 18 DG 18 11 RS 232+
W/R 18 O 18 O 18 3 RS 232- C127 TSW
A
INJECTOR CYL #2 GY/R 18
FUEL PUMP
B LB/PK 16
F4 15 START IN INTERUPT R33 STR
LPG W/PK 16
R 16 BN/LB 16
TEMPERATURE
GY/R 18 1
PK/BK 16 PK/BK 16 PK/BK 16
19 START IN AUTOCRANK
5 FUEL PUMP + C135 FP+ 7
ANA RTN 15A
BR/W 18 2
TWR 5V REF
DG 18 3
PC TX
W/BK 18 O 18 4
PC RX
FUEL PUMP RELAY
INJECTOR CYL #4 R/LG 18 A
B
DG/P 18 5
6
UNUSED
LB/O 18 LB/O 18
STARTER STARTER RELAY CAN
85
LPG
Y/R 18
DG/P 18 7
UNUSED
R 16 30 SOLENOID 87A
TERMINATION
CAN + LB/PK 16
R 16 BR/Y 16
LOCKOFF O/LG 18 8 PK/BK 16 30 CONNECTOR
KNOCK CAN -
R/LG 18
87 LB/PK 16
87 W/PK 16
86
SENSOR DIAGNOSTIC CONNECTOR 87A RING W 18
SHD TWR
W 18 2
R/LG 18 R/LG 18 86 CAN + TERM
R 16 RELAY
OMRON DG/P 18 3
CAN +
INJECTOR CYL #3
LG/P 18 85
FPP O/LG 18 1
CAN -
R 16 T 16 PK/BK 16 PK/BK 16
BK/W 18 6
4
5
GROUND
UNUSED 8
UNUSED
8
UNUSED
F6 F1
R 16 R16 R/LB 16 7
POWER
POWER RELAY
R/Y 18 85 10A ALTERNATOR 10A EPR EPR
INJECTOR CYL #1 R 16
R 16 R 16 R 16
30
F5 R 16 CONNECTOR
87
R 16 R 16
R/T 18 86
87A
15A RELAYED POWER
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 23
February 2012 Section 6 • Schematics
6 - 23 6 - 24
Section 6 • Schematics February 2012
6 - 25 6 - 26
N
RD
RD
BRN
P134PWR RD
P22LS BK
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
P24FS WH
ENGINE
SPEED C25PSR WH/BK OIL PRESSURE
G2
SENDER (OPTION)
TS4
G1
WATER TEMPERATURE
G3
FUNCTION ENABLE
HIGH RPM SENDER (OPTION)
TS54
TB45
GENERATOR
C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH GENERATOR
TS47
OPTION
WH
RD
L
TS48
OPTION
NO
FUSE
10A
RD
L29
L30
BOX GROUND
WORKLIGHT RD
PLATFORM
RD
WH BK
FUSE 10A
WORK LIGHTS
OPTION
K
WH BK
L30
C21IGN WH
HM
HOUR METER
GY/RD
A
FORD ENGINE
RD
C
BK/BL
D
J
RD/GN
L2
LPG LOCKOUT
WH/BK
BL/WH CHECK ENGINE LED
BR
CR39
RD
RUN/TEST SWITCH
C5-13 BL/WH
C35RPM BK/RD
TS64
C5-8 GR
I
CR39
TS3
SELECT
D11
TS53
TB21
QUICK DISCONNECT
FORD 42 PIN
C5-10 C39LP BL/RD FEH(72) PIN7
TB41
C1P-7 C1B-7
ENGINE C5-2 C41RPM OR/BK FEH(11) PIN2
G
START
TS52
TB33
M4
PUMP
FUEL
C135FP BL/WH BK PIN 18
P26ESTP BK
P24FS WH
P25FS RD
START
(FORD ENGINE HARNESS)
C21IGN WH
P24BAT RD
F
STARTER
C9P-2
C9P-3
STARTER MOTOR
February 2012
CR19
D4
TS51
TB27
PUMP C27AUX RD
AUXILIARY POWER RELAY
WH(FS)
AUXILIARY
RD(FS)
PR1
PUMP
NO
C1P-1 C27AUX RD C1P-1
PUMP
AUX
AUXILIARY PUMP
E
FS1
C28TTA RD/BK
M2
BK(FS)
B
C28TTA RD/BK WH
TILT ALARM
TB23
WH C7P-2 P23BAT WH C7B-2 P134TTS RD RD BK BRN
LEVEL SENSOR
C9P-1 BK
C
D2
TB134
S8
H1
D
Electrical Schematic, S-60 and S-60 TRAX,
FB1
P2
P134FB WH FLASHING
BEACONS OPTION
L48
CR5
P3
H2
TB46
C7P-1 P22BAT BK C7B-1 P22HRN BK R46HRN BK C6-9
HORN
NO
TB134
TB46R
SW3
NO
P134PWR GR/BK
HYDRAULIC OIL
C
CR17
C2P-6 C2B-6 R21IGN WH C5-4 TEMPERATURE SWITCH
P134PWR RD (OPTION)
TB22
86
85
P22LS BK COOLING FAN
M1 FAN
C116 OR C5-1
87a 87
(OPTION)
30
P116HYD RD
KS1
GRND
PLAT
ALTERNATOR FIELD
(FORD ENGINE HARNESS)
C3B & C3P - GREEN; C4B & C4P - BROWN.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM
Ford DSG-423 EFI Models
P1
RD
RD
STA.
A
S
I
ALTERNATOR
REGULATOR
RD
FLD.
Section 6 • Schematics
IN STOWED POSITION.
CB1
15A
CB3
15A
GND.
BAT.
CB2
15A
FUSE
LINK
A
-
P20BAT RD C7B-4
NOTES:
12V DC
TB20
2
B1
6 - 26
1
8
1
8
Ford DSG-423 EFI Models
Section 6 • Schematics
6 - 27
Electrical Schematic, S-60 and S-60 TRAX,
16 DRIVE REVERSE
TS14
TB31
H4
TB32
C26-1 C26-2
C1P-6 C32BRK WH/RD C1B-6 C5-23 C32BRK WH/RD
ROCKER STEER OPTION ONLY.
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
C1P-3 C29MS RD/WH C1B-3 C5-24 C29MS RD/WH
20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
C
TS15
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
TB4
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
D
P162JPW OR
C15-1 C15-2
D9
DRIVE FORWARD/REVERSE &
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
GND 1
6
ROUT 5
XOUT 3
PWR 2
YOUT 4
TS62
R4
CR19
7.5
TB6
C31-1 C31-2
JC3
C12-1 C12-2
5
C1PBU RD
PRIMARY BOOM UP
UP
E
PRIMARY BOOM
2 DOWN C2PBD RD/BK
Part No. 139188
CR34
TS61
J2
R14
11
5
TB3
XOUT 3 C165TRS WH/RD
YOUT 4 C164PES RD/WH
R16
10
C3PBF RD/WH
P162JPW OR
6
BR
TURNTABLE ROTATE
TB2
BOOM UP/DOWN &
PWR 2
7
JC2
8
TB9
3 C30-1 C30-2
C3P-9 C9PER BK/RD C3B-9 C9PER BK/RD PRIMARY BOOM EXTEND/RETRACT
14
9 FLOW CONTROL
C163PLS BL/WH
10
21 LS5
NC
22
EXTEND/RETRACT
G
RD RD BR C7PBE BK
PRIMARY BOOM
BOOM EXTEND
GND 1
6
3
PWR 2
YOUT 4
EXTEND
J1
TS63
C8PBR BK/WH
U13 JOYSTICK CONTROL CARD
BOOM RETRACT
TB8
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
C4P-4 C118LSR OR/RD C4B-4 OR/RD C38-3 BK WH C38-4 LS17-BOOM UP/DOWN
1
SPEED REDUCTION LIMIT SWITCH
13
14
P24FS WH
TB118
BK
TB13
LS3
NO
H
HC
P24FS WH
J3
4
C4P-1 C13DE BL/RD C4B-1 BL/RD C9-1 BK WH C9-2 LS3-DRIVE ENABLE LIMIT SWITCH
3
13
14
P26ESTP BK
3
TB22
LS1
NO
HC
C2P-2
4
C11-2 WH BK C11-1 LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
13
14
LS2
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
C3P-11 C59CNK BL/BK C3B-11 BL/BK
L46
NO
LS5
J
BK C37-3 BK WH C37-4
L47
TB59
13
14
CR34
TB134
21
HO 22
SPEED REDUCTION LIMIT SWITCH
TS9
LS17
NC
UP
PLATFORM LEVEL
DOWN C4P-3 C15PLD OR/BK C4B-3
TB14
C20-1 C20-2
TS59
C14PLU OR
K
PLATFORM LEVEL UP
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
D27
TS7
TB18
C4P-5 C23-1 C23-2
D28
TS57
C18JD/PRR GR/BK PLATFORM ROTATE RIGHT
RIGHT PLATFORM
L
TB17
D29
C129 RD/BK
DESCENT ALARM OPTION
H3
D30
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD
February 2012 Section 6 • Schematics
6 - 27 6 - 28
Section 6 • Schematics February 2012
6 - 29 6 - 30
8
7
6
5
4
3
2
1
6 - 30
CR2 BRN
CR1 CR23
IGNITION POWER
RELAY DRIVE LIGHT
START RELAY OPTION
RD
A
BRN
BK-33C
BRN
WH-OPTIONS
Section 6 • Schematics
WH-ISM9
CR4
WH-C5-19
WH-23C
AUXILIARY
R43DLITE2 RD
R43DLITE1 RD
POWER RELAY
C2B-4 OR/RD
WH-C5-11
RD-24B
WH-21C
BK C5-5
BRN
C5
C32 C32
B
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
SWING SPEED PRIMARY BOOM
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
CR17
WH/RD-R2 HYDRAULIC
WH/RD-R4 OIL COOLER
OPTION
RD/WH-R16 OR-LS17 C38-2
RD/WH-TS61
RD-CB3
D29
C3PBF RD/WH C3B-3 SWITCH
BRN
RD/WH-CR34 C3PBF RD/WH C29-1 C5-8 GR
3 PRIMARY BOOM FUNCTION CONTROL 3
FUSE 10A
WH/BK-TS62 C5TRR WH/BK C14-1
5 TURNTABLE ROTATE RIGHT 5
C6TRF WH/RD C3B-6 +12 VOLT
C7PBE BK C3B-7 C7
WH-TB21 OPTIONS
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
D30
C14PLU OR C4B-2
LIMIT SWITCH
F.H.
P20BAT RD
20 +12 VOLT POWER 20
WH-CR2 #87 C128RPM OR/RD C5-9
21 IGNITION POWER 21
C11
WH-KS
23 KEYSWITCH POWER 23
RD-CR2 #86
RD-CB1
24 CIRCUIT BREAKER POWER 24
#2
#1
C5
F.H.
C37
25 (UNUSED) 25
H
26 (UNUSED) 26
RD-CR19#86 C27AUX RD C1B-1
C30FWD WH C5-21
30 PROPEL FORWARD 30
C31REV WH/BK C1B-5
RD/WH-R16
31 PROPEL REVERSE 31
RD/WH-TS61
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
34 (UNUSED) 34
C35RPM BK/RD C1B-9
C36SCC BL C24-1
36 STEER LEFT 36
J
C40LS1 OR C10-2
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C5
GR-CR5
46 SERVICE HORN 46
C59CNK BL/BK C3B-11
K
RD-KS P134TTS RD A
134 LOAD WEIGHING LIM. SW. +12V (2) 134
#2
F.H.
BRN-TS64
BRN C37-2
BRN C7B-3
B A
HARNESS
FUNCTION
BK C16-1
C9 (LS3)
C11 (LS2)
LS17 (C38)
GROUND BOLT
N
February 2012 Section 6 • Schematics
OVERLOAD LED
TURNTABLE
PLATFORM
UP/DOWN
(CE OPTION)
ROTATE
ROTATE
BOOM
TS61
TS57
TS62
RD
L45
D9
RD/WH WH/RD
RD RD
RD/BK-2 RD-1
+
-
WH/BK-5
RD
C19JSV GR/WH
WH-4
RD/WH
RD
2
GR/BK-18D
RD
RD
RD
GR-17D
RD
D3
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
WH/RD WH/RD
RD
RD
RD
WH/RD
3
RD-27
WH
PLATFORM
RD
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
GR-17D
OR-14D
RD-27D
RD/WH
WH-4D
RD-1D
BK-7D
WH
RD
4
TURNTABLE
RESISTOR
ROTATE
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
BK/RD C5-13
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK-33D
RD-20C
RD CR17
BRN-GND
BL/RD-39D
RD-20D
RD-24D
7.5 ohm 1%
BK/RD-35D
R2
5 ohm 1%
TURNTABLE
RESISTOR
RD
ROTATE
WH
ENGINE
R4
CHECK
L2
1
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
SELECT
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
FUEL
TS53
B
CB3
CB2
RD
-
5
3
4
WH
RD/WH
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
RD
RD
RD
6
LABEL DESCRIPTION
CB1 CIRCUIT BREAKER, ENGINE, 15A
DALE RH-25 25W
RD-20D
CB2 CIRCUIT BREAKER, CONTROLS, 15A
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RESISTOR
CB3
UP/DOWN
ENGINE
ENGINE 15A
R16
START
TS52
CR2 IGNITION POWER RELAY
BREAKER
CIRCUIT
CR4 HIGH IDLE RELAY
CB1
RD-24D
CR5 HORN RELAY
CR17 HYDRAULIC OIL COOLER FAN RELAY
BRN
RD
BRN HM HOUR METER
KS1 KEY SWITCH
L2 CHECK ENGINE LED
RD
RD
1 1
D13
R2 SPEED LIMITING RESISTOR 5 OHMS
R4 SPEED LIMITING RESISTOR 7.5 OHMS
P1
NC NC
RD R14 SPEED LIMITING RESISTOR 5 OHMS
D14
R16 SPEED LIMITING RESISTOR 10 OHMS
FUNCTION
2 2
ENABLE
TS51 AUXILIARY POWER TOGGLE SWITCH
TS54
RD
RD
TS52
TS53
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
8
TS54 FUNCTION ENABLE SWITCH
TS56 GLOW PLUG TOGGLE SWITCH
RD TS57 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. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 31
February 2012 Section 6 • Schematics
6 - 31 6 - 32
Section 6 • Schematics February 2012
6 - 33 6 - 34
N
CWLITE WH TS49
CONTROL RELAY (CE OPTION)
CONTROL RELAY (CE OPTION)
(TO SWITCH
PLATFORM
BRN GND
RD-E-STOP C134PWR RD LS18
Y
Y
C1P-C4P
C134PWR RD-H1+
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
OPT.
CE LIFT/DRIVE OPTION
L
TS7 WH
JIB
RD LS18 CABLE
CR27
BRN
LS18
(CE)
BRN
CR30
BK C1P-12
C40LS OR C2P-2
C40LS OR J2-4
TS1 WH
P23BAT WH C7P-2
J
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
BOOM
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129DA BL C3P-10 TS8
C46HRN GR C2P-5
I
C7P
C3P
F.S.
C46HRN GR C2P-5
F.S.
C9
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C7PBE BK C3P-7
C13DE BL/RD C4P-1
C8PBR BK/WH C3P-8
C7P
P24FS WH C40LSS OR C2P-2
C9PER BK/RD C3P-9
P24FS WH C41RPM OR/BK C2P-3
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
F
C3P
C3P(GR)
C35RPM BK/RD C1P-9
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
FOR STEER ROCKER SWITCH OPTION.
D
P162JPW OR
C1P
C165TRS WH/RD
WIRE CONNECTS TO JC3-5
GND BRN
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS BL/WH
C7P
GND BRN
C160JPL WH/RD
P162JPW OR
C
C159STC BL/WH
GND BRN
C144DER BL/WH C28TTA RD/BK C1P-2
C143DEL BL/BK
BATGRN C7P-3
Ford DSG-423 EFI Models
B
D39
ALARM
Section 6 • Schematics
TILT
RD/BK-L48 RD/BK-L48- (NON-CE)
H1
C134PWR RD C2P-6
C134PWR RD LS18 RD-TILT
+
CWLITE BK
BRN
A BRN
BRN BRN
CWLITE WH TS49
6 - 34
1
8
February 2012 Section 6 • Schematics
1
PLATFORM CONTROL
HARNESS
(TO CONTROL BOX)
COMPONENT INDEX
JC2 BOOM PROPORTIONAL JOYSTICK:
BOOM UP/DOWN , TURNTABLE ROTATE
JC1 BOOM PROPORTIONAL JOYSTICK:
BOOM EXTEND/RETRACT
JC3 DRIVE/STEER PROPORTIONAL JOYSTICK 2
L1 DRIVE ENABLE LED
DLITE RD RD
L4 PLATFORM OVERLOAD LED
L47 LOWER/RETRACT BOOM LED
BK
L48 BOOM TILTED LED
+
P2 EMERGENCY STOP BUTTON
JC2 JC1
PRIMARY BOOM P3 HORN SWITCH
PRIMARY BOOM TS15
UP/DOWN
& TURNTABLE ROTATE
EXTEND/RETRACT DRIVE L48 TS1 AUXILIARY POWER TOGGLE SWITCH
LEFT/RIGHT TS48/TS49 ENABLE TILT ALARM LED TS2 ENGINE START TOGGLE SWITCH
DRIVE LIGHTS/ (ANSI/CSA OPTION)
WORK LIGHTS
TS3 FUEL SELECT TOGGLE SWITCH
(OPTION) TS4 HI/LOW RPM TOGGLE SWITCH 3
JC3
BK
BK
TS7 PLATFORM ROTATE TOGGLE SWITCH
BK
RD
6 1 DRIVE TS9 PLATFORM LEVEL TOGGLE SWITCH
6 1 FORWARD/REVERSE 6 1
& STEER LEFT/RIGHT TS14 DRIVE SPEED TOGGLE SWITCH
5 2 TS15 DRIVE ENABLE TOGGLE SWITCH
5 2 5 2 TS47 GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT
4 3 BRN TS48
TOGGLE SWITCH (OPTION)
4 3 4 3
ROCKER OPT.
4
BRN
L47 L4
RETRACT + PLATFORM
BOOM OVERLOAD
RD
L1 (CE OPTION)
BK
DRIVE ENABLE
BRN
BK
BK
OPTION ONLY)
5
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
P162JPW OR
P162JPW OR
P162JPW OR
BL-DE1 J1-6
WLITE WH
WLITE WH
GND BR
GND BR
GND BR
BRN
RD
BK
BK
6
C46HRN GR C2P-5
C14PLU OR C4P-2
WH CR27
C17PRL GR C4P-5
C27AUX RD C1P-1
WH CR30
BK
P25FS RD C9-3
C33STR BK C1P-7
P24FS WH C9-2
PDLITE RD
C39LP BL/RD C2P-1
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
WH WH
7
D12 TS3
FUEL SELECT
TS2 TS4
ENGINE HIGH/LOW P2
START RPM EMERGENCY
STOP
TS7 TS14
PLATFORM HIGH/LOW
P3 WH TS1 TS47
TS9 ROTATE DRIVE SPEED
HORN GENERATOR D11
PLATFORM AUXILIARY (2WD/4WD)
RD
(OPTION)
LEVEL PUMP
BK
8
WH
RD RD RD RD
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 35
February 2012 Section 6 • Schematics
6 - 35 6 - 36
Section 6 • Schematics February 2012
6 - 37 6 - 38
N
RD
RD
BRN
P134PWR RD
P22LS BK
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
P24FS WH
ENGINE
SPEED C25PSR WH/BK OIL PRESSURE
G2
SENDER (OPTION)
TS4
G1
WATER TEMPERATURE
G3
FUNCTION ENABLE
HIGH RPM SENDER (OPTION)
TS54
TB45
GENERATOR
C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH GENERATOR
TS47
OPTION
WH
RD
L
TS48
OPTION
NO
FUSE
10A
RD
L29
L30
BOX GROUND
WORKLIGHT RD
PLATFORM
RD
WH BK
FUSE 10A
WORK LIGHTS
OPTION
K
WH BK
L30
C21IGN WH
HM
HOUR METER
GY/RD
A
FORD ENGINE
RD
C
BK/BL
D
J
RD/GN
L2
LPG LOCKOUT
WH/BK
BL/WH CHECK ENGINE LED
BR
CR39
RD
RUN/TEST SWITCH
C5-13 BL/WH
C35RPM BK/RD
TS64
C5-8 GR
I
CR39
TS3
SELECT
D11
TS53
TB21
QUICK DISCONNECT
FORD 42 PIN
C5-10 C39LP BL/RD FEH(72) PIN7
TB41
C1P-7 C1B-7
ENGINE C5-2 C41RPM OR/BK FEH(11) PIN2
G
START
TS52
TB33
M4
PUMP
FUEL
C135FP BL/WH BK PIN 18
P26ESTP BK
P24FS WH
P25FS RD
START
(FORD ENGINE HARNESS)
C21IGN WH
P24BAT RD
F
STARTER
C9P-2
C9P-3
STARTER MOTOR
February 2012
CR19
D4
TS51
TB27
PUMP C27AUX RD
AUXILIARY POWER RELAY
WH(FS)
AUXILIARY
RD(FS)
PR1
PUMP
NO
C1P-1 C27AUX RD C1P-1
PUMP
AUX
AUXILIARY PUMP
E
FS1
C28TTA RD/BK
M2
BK(FS)
B
C28TTA RD/BK WH
TILT ALARM
TB23
WH C7P-2 P23BAT WH C7B-2 P134TTS RD RD BK BRN
LEVEL SENSOR
C9P-1 BK
C
D2
TB134
S8
H1
D
Electrical Schematic, S-65 and S-65 TRAX,
FB1
P2
P134FB WH FLASHING
BEACONS OPTION
L48
CR5
P3
H2
TB46
C7P-1 P22BAT BK C7B-1 P22HRN BK R46HRN BK C6-9
HORN
NO
TB134
TB46R
SW3
NO
P134PWR GR/BK
HYDRAULIC OIL
C
CR17
C2P-6 C2B-6 R21IGN WH C5-4 TEMPERATURE SWITCH
P134PWR RD (OPTION)
TB22
86
85
P22LS BK COOLING FAN
M1 FAN
C116 OR C5-1
87a 87
(OPTION)
30
P116HYD RD
KS1
GRND
PLAT
ALTERNATOR FIELD
(FORD ENGINE HARNESS)
C3B & C3P - GREEN; C4B & C4P - BROWN.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM
Ford DSG-423 EFI Models
P1
RD
RD
STA.
A
S
I
ALTERNATOR
REGULATOR
RD
FLD.
Section 6 • Schematics
IN STOWED POSITION.
CB1
15A
CB3
15A
GND.
BAT.
CB2
15A
FUSE
LINK
A
-
P20BAT RD C7B-4
NOTES:
12V DC
TB20
2
B1
6 - 38
1
8
1
8
Ford DSG-423 EFI Models
Section 6 • Schematics
6 - 39
Electrical Schematic, S-65 and S-65 TRAX,
16 DRIVE REVERSE
TS14
TB31
H4
TB32
C26-1 C26-2
C1P-6 C32BRK WH/RD C1B-6 C5-23 C32BRK WH/RD
ROCKER STEER OPTION ONLY.
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
C1P-3 C29MS RD/WH C1B-3 C5-24 C29MS RD/WH
20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
C
TS15
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
D
C15-1 C15-2
D9
DRIVE FORWARD/REVERSE &
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
TS62
GND 1
6
ROUT 5
XOUT 3
PWR 2
YOUT 4
R4
CR19
7.5
TB6
C31-1 C31-2
C6TRF WH/RD
JC3
TURNTABLE ROTATE
FLOW CONTROL
TB1
R2
C12-1 C12-2
5
C1PBU RD
PRIMARY BOOM UP
UP
E
PRIMARY BOOM
DOWN C2PBD RD/BK
Part No. 139188
2
PRIMARY BOOM DOWN
C13-1 C13-2
February 2012
CR34
1
TS61
J2
R14
5
11
TB3
R16
XOUT 3 C165TRS WH/RD
YOUT 4 C164PES RD/WH
10
C3PBF RD/WH
PWR 2 P162JPW OR
6
BR
TB2
TURNTABLE ROTATE
BOOM UP/DOWN &
7
JC2
8
TB9
3 C30-1 C30-2
C3P-9 C9PER BK/RD C3B-9 C9PER BK/RD PRIMARY BOOM EXTEND/RETRACT
14
9 FLOW CONTROL
C163PLS BL/WH
21 LS5
10
NC
22
EXTEND/RETRACT
G
RD RD BR C7PBE BK
BOOM EXTEND
PRIMARY BOOM
GND 1
6
3
YOUT 4
EXTEND
BOOM C37-1 C37-2 C16-1 C16-2
RETRACT
JC1
TS63
C8PBR BK/WH
U13 JOYSTICK CONTROL CARD
BOOM RETRACT
TB8
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
C4P-4 C118LSR OR/RD C4B-4 OR/RD C38-3 BK WH C38-4 LS17-BOOM UP/DOWN
1
SPEED REDUCTION LIMIT SWITCH
13
14
P24FS WH
TB118
BK
TB13
LS3
NO
H
HC
P24FS WH
J3
4
C4P-1 C13DE BL/RD C4B-1 BL/RD C9-1 BK WH C9-2 LS3-DRIVE ENABLE LIMIT SWITCH
3
13
14
P26ESTP BK
3
TB22
LS1
NO
HC
C2P-2
4
C11-2 WH BK C11-1 LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
13
14
LS2
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
C3P-11 C59CNK BL/BK C3B-11 BL/BK
L46
NO
LS5
J
BK C37-3 BK WH C37-4
L47
TB59
13
14
CR34
TB134
21
HO 22
SPEED REDUCTION LIMIT SWITCH
TS9
LS17
NC
UP
PLATFORM LEVEL
DOWN C4P-3 C15PLD OR/BK C4B-3
TB14
C20-1 C20-2
TS59
C14PLU OR
K
PLATFORM LEVEL UP
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
D27
TS8
TB18
C4P-5 C23-1 C23-2
D28
TS58
C18JD/PRR GR/BK PLATFORM ROTATE RIGHT
RIGHT PLATFORM
L
TB17
TS57
RIGHT PLATFORM
D29
LEFT ROTATE
TS7
WH
C129 RD/BK
BRN
H3
D30
C4P-7 C19JSV GR/WH C4B-7
TB19
M
P24FS WH
P26ESTP BK
NO
P22LS BK
P134 RD
CR14
GR/WH
N
BRN
RD
RD
February 2012 Section 6 • Schematics
6 - 39 6 - 40
Section 6 • Schematics February 2012
6 - 41 6 - 42
8
7
6
5
4
3
2
1
6 - 42
CR2 BRN
CR1 CR23
IGNITION POWER
RELAY DRIVE LIGHT
START RELAY OPTION
RD
A
BRN
BK-33C
BRN
WH-OPTIONS
Section 6 • Schematics
WH-ISM9
CR4
WH-C5-19
WH-23C
AUXILIARY
R43DLITE2 RD
R43DLITE1 RD
POWER RELAY
C2B-4 OR/RD
WH-C5-11
RD-24B
WH-21C
BK C5-5
BRN
C5
C32 C32
B
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
SWING SPEED PRIMARY BOOM
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
CR17
WH/RD-R2 HYDRAULIC
WH/RD-R4 OIL COOLER
OPTION
RD/WH-R16 OR-LS17 C38-2
RD/WH-TS61
RD-CB3
D29
C3PBF RD/WH C3B-3 SWITCH
BRN
RD/WH-CR34 C3PBF RD/WH C29-1 C5-8 GR
3 PRIMARY BOOM FUNCTION CONTROL 3
FUSE 10A
WH/BK-TS62 C5TRR WH/BK C14-1
5 TURNTABLE ROTATE RIGHT 5
C6TRF WH/RD C3B-6 +12 VOLT
C7PBE BK C3B-7 C7
WH-TB21 OPTIONS
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
D30
C14PLU OR C4B-2
LIMIT SWITCH
F.H.
P20BAT RD
20 +12 VOLT POWER 20
WH-CR2 #87 C128RPM OR/RD C5-9
21 IGNITION POWER 21
C11
WH-KS
23 KEYSWITCH POWER 23
RD-CR2 #86
RD-CB1
24 CIRCUIT BREAKER POWER 24
#2
#1
C5
F.H.
C37
25 (UNUSED) 25
H
26 (UNUSED) 26
RD-CR19#86 C27AUX RD C1B-1
C30FWD WH C5-21
30 PROPEL FORWARD 30
C31REV WH/BK C1B-5
RD/WH-R16
31 PROPEL REVERSE 31
RD/WH-TS61
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
34 (UNUSED) 34
C35RPM BK/RD C1B-9
C36SCC BL C24-1
36 STEER LEFT 36
J
C40LS1 OR C10-2
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C5
GR-CR5
46 SERVICE HORN 46
C59CNK BL/BK C3B-11
K
RD-KS P134TTS RD A
134 LOAD WEIGHING LIM. SW. +12V (2) 134
#2
F.H.
BRN-TS64
BRN C37-2
BRN C7B-3
B A
HARNESS
FUNCTION
BK C16-1
C9 (LS3)
C11 (LS2)
LS17 (C38)
GROUND BOLT
N
February 2012 Section 6 • Schematics
OVERLOAD LED
TURNTABLE
PLATFORM
UP/DOWN
(CE OPTION)
ROTATE
ROTATE
BOOM
TS61
TS57
TS62
RD GR/BK
L45
D9
RD/WH WH/RD
RD RD
RD/BK-2 RD-1
+
-
WH/BK-5
RD
C19JSV GR/WH
WH-4
RD/WH
RD
2
GR/BK-18D
RD
RD
RD
GR-17D
RD
D3
GR/BK
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
GR
WH/RD WH/RD GR/BK
RD
D28
GR
RD
RD
WH/RD RD 3
RD-27
WH
UP/DOWN
JIB BOOM
PLATFORM
RD
TS58
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
GR-17D
OR-14D
RD-27D
RD/WH
BL-44D
WH-4D
RD-1D
BK-7D
WH
RD
4
TURNTABLE
RESISTOR
ROTATE
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
BK/RD C5-13
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK-33D
RD-20C
RD CR17
BRN-GND
BL/RD-39D
RD-20D
RD-24D
7.5 ohm 1%
BK/RD-35D
R2
5 ohm 1%
TURNTABLE
RESISTOR
RD
ROTATE
WH
ENGINE
R4
CHECK
L2
1
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
SELECT
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
FUEL
TS53
B
CB3
CB2
RD
-
5
3
4
WH
RD/WH
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
RD
RD
RD
LABEL DESCRIPTION 6
CB1 CIRCUIT BREAKER, ENGINE, 15A
CB2 CIRCUIT BREAKER, CONTROLS, 15A
DALE RH-25 25W
RD-20D
CB3 CIRCUIT BREAKER, OPTIONS, 15A
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RESISTOR
UP/DOWN
ENGINE
ENGINE 15A
R16
START
TS52
BREAKER
CR4 HIGH IDLE RELAY
CIRCUIT
CR5 HORN RELAY
CB1
RD-24D
CR17 HYDRAULIC OIL COOLER FAN RELAY
CR22 DRIVE LIGHT RELAY (OPTION)
BRN
HM HOUR METER
WH-21D
RD
BRN KS1 KEY SWITCH
L2 CHECK ENGINE LED
L46 LOWER/RETRACT BOOM LED
RD
RD
1 1
D13
R4 SPEED LIMITING RESISTOR 7.5 OHMS
R14 SPEED LIMITING RESISTOR 5 OHMS
P1
NC NC
RD R16 SPEED LIMITING RESISTOR 10 OHMS
D14
TS51 AUXILIARY POWER TOGGLE SWITCH
FUNCTION
2 2
ENABLE
TS52 ENGINE START TOGGLE SWITCH
TS54
RD
RD
TS53
TS54
FUEL SELECT TOGGLE SWITCH
FUNCTION ENABLE SWITCH
8
TS56 GLOW PLUG TOGGLE SWITCH
TS57 PLATFORM ROTATE TOGGLE SWITCH
RD TS58 JIB BOOM UP/DOWN TOGGLE SWITCH
TS59 PLATFORM LEVEL TOGGLE SWITCH
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH
TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 43
February 2012 Section 6 • Schematics
6 - 43 6 - 44
Section 6 • Schematics February 2012
6 - 45 6 - 46
N
CWLITE WH TS49
CONTROL RELAY (CE OPTION)
CONTROL RELAY (CE OPTION)
(TO SWITCH
PLATFORM
BRN GND
RD-E-STOP C134PWR RD LS18
Y
Y
C1P-C4P
C134PWR RD-H1+
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
OPT.
CE LIFT/DRIVE OPTION
L
TS7 WH
JIB
RD LS18 CABLE
CR27
BRN
LS18
(CE)
BRN
CR30
BK C1P-12
C40LS OR C2P-2
C40LS OR J2-4
TS1 WH
P23BAT WH C7P-2
J
P22BAT BK C7P-1
JIB
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129DA BL C3P-10 TS8
C46HRN GR C2P-5
I
C7P
C3P
F.S.
C46HRN GR C2P-5
F.S.
C9
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C7PBE BK C3P-7
C13DE BL/RD C4P-1
C8PBR BK/WH C3P-8
C7P
P24FS WH C40LSS OR C2P-2
C9PER BK/RD C3P-9
P24FS WH C41RPM OR/BK C2P-3
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
F
C3P
C3P(GR)
C35RPM BK/RD C1P-9
C2P
Ford DSG-423 EFI Models (before serial number 16734)
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
FOR STEER ROCKER SWITCH OPTION.
D
P162JPW OR
C1P
C165TRS WH/RD
WIRE CONNECTS TO JC3-6
GND BRN
C164PES RD/WH C1P(GY)
P162JPW OR
C163PLS BL/WH
GND BRN
C7P
C160JPL WH/RD
* NOTE:
P162JPW OR
C
C159STC BL/WH*
GND BRN
C144DER BL/WH C28TTA RD/BK C1P-2
C143DEL BL/BK
C13DE BL/RD
BATGRN C7P-3
B
D39
ALARM
Section 6 • Schematics
TILT
RD/BK-L48 RD/BK-L48- (NON-CE)
H1
C134PWR RD C2P-6
C134PWR RD LS18 RD-TILT
+
CWLITE BK
BRN
A BRN
BRN BRN
CWLITE WH TS49
6 - 46
1
8
February 2012 Section 6 • Schematics
1
PLATFORM CONTROL
HARNESS
(TO CONTROL BOX) COMPONENT INDEX
BK
BK
TS7 PLATFORM ROTATE TOGGLE SWITCH
BK
RD
6 1 DRIVE TS9 PLATFORM LEVEL TOGGLE SWITCH
6 1 FORWARD/REVERSE 6 1
& STEER LEFT/RIGHT TS14 DRIVE SPEED TOGGLE SWITCH
5 2 TS15 DRIVE ENABLE TOGGLE SWITCH
5 2 5 2 TS47 GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT
4 3 BRN TS48
TOGGLE SWITCH (OPTION)
4 3 4 3
ROCKER OPT.
BRN
BRN
L47 L4
RETRACT + PLATFORM
BOOM CR13 OVERLOAD
RD
L1 (CE OPTION)
BK
DRIVE ENABLE
BRN
BK
BK
OPTION ONLY)
5
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
P162JPW OR
P162JPW OR
P162JPW OR
BL-DE1 J1-6
WLITE WH
WLITE WH
GND BR
GND BR
GND BR
WH-JIB
BRN
RD
BK
BK
C129JDA BL C3P-10
6
C19JSV GR/WH
P24FS WH
C46HRN GR C2P-5
C14PLU OR C4P-2
WH CR27
C17PRL GR C4P-5
WH-JIB
C27AUX RD C1P-1
WH CR30
BK
P25FS RD C9-3
C33STR BK C1P-7
P24FS WH C9-2
PDLITE RD
C39LP BL/RD C2P-1
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
7
WH WH
RD RD RD RD
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 47
February 2012 Section 6 • Schematics
6 - 47 6 - 48
Section 6 • Schematics February 2012
6 - 49 6 - 50
N
(TO SWITCH
PLATFORM
CONTROL
HARNESS
WH
Y
B
BRN JC3 BR
Y
BRN GND
M
Y
Y
C134PWR RD-H1+
CWLITE WH TS49
GR/WH
BR
ITEM
CR13#86 GR/WH
CR14
CR27
CR30
J1
J2
J3
OPT.
C1
R
CE LIFT/DRIVE OPTION
RD OUTPUT
L
TS7 WH
GR/WH +
CR14
R
C134PWR RD
GR/WH
BRN -
RD LS18 CABLE
JIB
BRN
GR/WH RD
R
B
LS18
(CE)
BRN
TILT ALARM
CR30
BK C1P-12
C40LS OR C2P-2
C1P-C4P
ITEM
C40LS OR J2-4
LS18
C7P
U13
H1
C1
C9
TS1 WH
P23BAT WH C7P-2
J
P22BAT BK C7P-1
JIB
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129DA BL C3P-10 TS8
C46HRN GR C2P-5
I
C7P
C3P
F.S.
C46HRN GR C2P-5
F.S.
C9
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C7PBE BK C3P-7
C13DE BL/RD C4P-1
C8PBR BK/WH C3P-8
C7P
P24FS WH C40LSS OR C2P-2
C9PER BK/RD C3P-9
P24FS WH C41RPM OR/BK C2P-3
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
F
C3P
C3P(GR)
C35RPM BK/RD C1P-9
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
Ford DSG-423 EFI Models (after serial number 16733)
P162JPW OR
C1P
C165TRS WH/RD
WIRE CONNECTS TO JC3-5
GND BRN
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS BL/WH
C7P
GND BRN
C160JPL WH/RD
P162JPW OR
C
C159STC BL/WH
GND BRN
C144DER BL/WH C28TTA RD/BK C1P-2
C143DEL BL/BK
BATGRN C7P-3
B
D39
ALARM
Section 6 • Schematics
TILT
RD/BK-L48 RD/BK-L48- (NON-CE)
H1
C134PWR RD C2P-6
C134PWR RD LS18 RD-TILT
+
CWLITE BK
BRN
A BRN
BRN BRN
CWLITE WH TS49
6 - 50
1
8
February 2012 Section 6 • Schematics
1
PLATFORM CONTROL
HARNESS
(TO CONTROL BOX) COMPONENT INDEX
BK
BK
TS7 PLATFORM ROTATE TOGGLE SWITCH
BK
RD
6 1 DRIVE TS9 PLATFORM LEVEL TOGGLE SWITCH
6 1 FORWARD/REVERSE 6 1
& STEER LEFT/RIGHT TS14 DRIVE SPEED TOGGLE SWITCH
5 2 TS15 DRIVE ENABLE TOGGLE SWITCH
5 2 5 2 TS47 GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT
4 3 BRN TS48
TOGGLE SWITCH (OPTION)
4 3 4 3
ROCKER OPT.
BRN
4
BRN
L47 L4
RETRACT + PLATFORM
BOOM CR13 OVERLOAD
RD
L1 (CE OPTION)
BK
DRIVE ENABLE
BRN
BK
BK
OPTION ONLY)
5
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
P162JPW OR
CR14-#86 RD
P162JPW OR
P162JPW OR
BL-DE1 J1-6
WLITE WH
WLITE WH
GND BR
GND BR
GND BR
WH-JIB
BRN
RD
BK
BK
C129JDA BL C3P-10
6
P24FS WH
C46HRN GR C2P-5
C14PLU OR C4P-2
WH CR27
C17PRL GR C4P-5
WH-JIB
C27AUX RD C1P-1
WH CR30
BK
P25FS RD C9-3
C33STR BK C1P-7
P24FS WH C9-2
PDLITE RD
C39LP BL/RD C2P-1
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
WH WH
7
TS8 D12 TS3
FUEL SELECT
GR
TS2 TS4
ENGINE HIGH/LOW P2
START RPM EMERGENCY
STOP
TS7 TS14
PLATFORM HIGH/LOW
P3 WH JIB TS47
TS9 ROTATE TS1 DRIVE SPEED
HORN GENERATOR D11
PLATFORM AUXILIARY (2WD/4WD)
RD
GR/BK (OPTION)
LEVEL PUMP
BK
8
D27
WH
RD RD RD RD
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 51
February 2012 Section 6 • Schematics
6 - 51 6 - 52
Section 6 • Schematics February 2012
6 - 53 6 - 54
Circuit breaker
RD
RD
BRN
serial number
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
ES0192G
added after
CR4
N
D12
19405
CB7
10A
TS4
FOOTSW. LOW
CR4
Q3
ENGINE
BK/RD
TS54
SPEED
C5-18
HIGH RPM SOLENOID
NO
D14
LOW RPM
FUNCTION ENA.
HIGH RPM C26PSR WH/BK OIL PRESSURE
G2
G1
CR23
TS48
DRIVE LIGHT
LIGHTS
FUSE 10A
WORK LIGHT RD
DRIVE LIGHT L29
F19
(OPTION)
L29
L30
RD
RD
RD
FUSE 10A
TB21
C2P-12 C2P-10
CR23
(OPTION)
NO
PBOX GND
C2P-11 C2P-9
K
L30
PR2
TB34
TS6
PLUG
GLOW
J
GLOW PLUG
PLUG
FUSE 70A
PR2
NO
F22
number 16733
L2
D64
MODULE
START
U1
I
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
8 KEY BYPASS
10 ENG. FAULT
TS2
7 KEY PWR.
6 BATTERY
5 GROUND
C33STR BK
4 AUX. ON
D33
TB25
START
ENGINE C5-16 C25PS WH/BK OIL PRESSURE SWITCH
C28TTA RD/BK
START
SW2
BK
NC
TB33
CR2
H
POWER RELAY
P26ESTP BK
TB21
P24FS WH
P25FS RD
C21IGN2 WH C5-11
TS1
FUEL SOLENOID
CR2
AUX
NO
HM
C9P-2
HOUR METER
G
_
IGN./START RELAY
CR1
NO
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
D3
STARTER
STARTER MOTOR
FS1
D4
BK-(FS)
TS51
CR19
F
EMISSIOIN CONTROL
February 2012
AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK
M2
TB23
PR1
NO
P2
D2
PUMP
L48
AUX
AUXILIARY PUMP
C5-3
RD/BK C1P-2 WH
TB28
D40
E
Overload
RD/BK
Platform
B
C1B-2
Option
C28TTA RD/BK WH
H1
C28TTA RD/BK
TILT ALARM
P134TTSR RD RD BK BRN
LEVEL SENSOR
C3B-12
C
A
C3P-12 C133PLA BL/WH
S8
TB46
RD
C2B-5
C2P-5 C46HRN GR C46HRN GR HORN RELAY
P3
CR5
Electrical Schematic, S-60 and S-60 TRAX,
H2
NO
C7P-1 P22BAT BK C7B-1
TB133
P22BAT BK F.H. BK
D
HORN
C32-8
TB132
7
5
TB134
C1P-12 C132PLI BL/WH C1B-12
FB1
3
U33
P134FB WH FLASHING BEACONS
C2P-6 P134PWR GR/BK C2B-6
(OPTION)
1
Deutz F3L-2011/Deutz D2011L03i Models
12
4
6
TB134
RD
SW4
NO
BK
C
HYDRAULIC OIL
86
85
C21IGN WH R21IGN WH C5-4 TEMPERATURE
TB22
WH
RD
SWITCH (OPTION)
87a 87
30
P116HYD RD
PLAT
GRD
C41RPM OR/BK
CR17
FAN
R116 OR C5-1 COOLING FAN
KS1
(OPTION)
M1
3MF
C3
+
TB41
C41RPM OR/BK C2B-3 C41RPM OR/BK C5-2
B
D22
RD
EXCT.
STA.
C21IGN WH
BAT.
IND.
P1
RD
RD
-
Section 6 • Schematics
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
D1
TB20
A
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 54
1
8
1
8
Deutz F3L-2011/Deutz D2011L03i Models
Section 6 • Schematics
6 - 55
Electrical Schematic, S-60 and S-60 TRAX,
TB31
LOW DRIVE
(HIGH TORQUE)
H4
8
MODE
(OPTION)
HIGH DRIVE
(LOW TORQUE)
B
TB32
C26-1 C26-2
C1P-6 C32BRK WH/RD C1B-6 C5-23 C32BRK WH/RD
ROCKER STEER OPTION ONLY.
19 BRAKE RELEASE
TB29
C28-1 C28-2
C1P-3 C29MS RD/WH C1B-3 C5-24 C29MS RD/WH
20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
TS15
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
RIGHT C1P-10 C36STCC BL C1B-10 C36SCC BL
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
C28TTA RD/BK
TB36
P26ESTP BK
P24FS WH
TB4
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
P162JPW OR
D
C15-1 C15-2
D9
DRIVE FORWARD/REVERSE &
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
GND 1
6
R OUT 5
X OUT 3
PWR 2
Y OUT 4
TS62
7.5W
R4
CR19
TB6
C31-1 C31-2
JC3
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
1 C13-1 C13-2
CR34
J2
R14
February 2012
5W
11
TB3
C164PES RD/WH
C165TRS WH/RD
R16
10W
P162JPW OR
C3PBF RD/WH
PRIMARY BOOM FLOW CONTROL
12
C29-1 C29-2
C3P-1 C1PBU RD C3B-1
J1
6
BR
TURNTABLE ROTATE
TB2
BOOM UP/DOWN &
X OUT 3
PWR 2
Y OUT 4
7
JC2
TB9
3 C30-1 C30-2
C3P-9 C9PER BK/RD C3B-9 C9PER BK/RD PRIMARY BOOM EXTEND/RETRACT
14
9 FLOW CONTROL
C163PLS BL/WH
13
10
C3P-7 C7PBE BK C3B-7 LS5 CABLE TENSION LIMIT SWITCH
12
NC
TB7
BR
21
22
EXTEND/RETRACT
RD RD BR C7PBE BK
PRIMARY BOOM
G
BOOM EXTEND
GND 1
6
PWR 2
Y OUT 4
EXTEND
J1
RETRACT
JC1
TS63
C8PBR BK/WH
U13 JOYSTICK CONTROL CARD
BOOM RETRACT
TB8
C17-1 C17-2
BRN
NO
HC
1
C4P-4 C118LSR OR/RD C4B-4 OR/RD C38-3 BK WH C38-4 LS17-BOOM UP/DOWN
1
SPEED REDUCTION LIMIT SWITCH
13
14
P24FS WH
TB118
2
LS17
BK
TB13
P24FS WH
H
NO
J3
HC
4
C4P-1 C13DE BL/RD C4B-1 BL/RD C9-1 BK WH C9-2 LS3-DRIVE ENABLE LIMIT SWITCH
3
13
14
P26ESTP BK
3
TB22
LS3
C2P-2
NO
HC
4
C11-2 WH BK C11-1 LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
13
14
LS1
NO
HC
14
LS2
C40LS OR C2B-2 F.H. OR
BK
I
TB40
OPTION
CR30
CR27
DRIVE
NO
NC
LIFT/
CE
P22LS BK
C3P-11 C59CNK BL/BK C3B-11 BL/BK
L46
NO
BK C37-3 BK WH C37-4
L47
J
TB59
13
14
CR34
LS5
TB134
NC
HO
P134 RD RD C38-1 RD BR C38-2 LS17-BOOM UP/DOWN
21
22
SPEED REDUCTION LIMIT SWITCH
LS17
TS9
TB14
C20-1 C20-2
TS59
C14PLU OR
PLATFORM LEVEL UP
K
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
D27
TS7
TB18
C4P-5 C23-1 C23-2
D28
TS57
C18JD/PRR GR/BK PLATFORM ROTATE RIGHT
RIGHT PLATFORM
LEFT ROTATE C17JU/PRL GR
L
TB17
D29
C129 RD/BK
DESCENT ALARM
H3
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD
February 2012 Section 6 • Schematics
6 - 55 6 - 56
Section 6 • Schematics February 2012
6 - 57 6 - 58
Circuit breaker
RD
RD
BRN
ES0192G
serial number
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
added after
CR4
N
D12
19405
C35RPM BK/RD
C1P-9 C35RPM BK/RD C1B-9 BRN
HIGH IDLE RELAY
FOOTSW. HIGH
CB7
10A
TS4
FOOTSW. LOW
CR4
Q3
ENGINE
BK/RD
TS54
SPEED
C5-18
HIGH RPM SOLENOID
NO
D14
LOW RPM
FUNCTION ENA.
HIGH RPM C26PSR WH/BK OIL PRESSURE
G2
TB35
M
G1
CR23
TS48
DRIVE LIGHT
LIGHTS
FUSE 10A
WORK LIGHT RD
DRIVE LIGHT (OPTION)
F19
L29
L30
RD
RD
RD
FUSE 10A
TB21
C2P-12 C2P-10
CR23
NO
PBOX GND
C2P-11 C2P-9
K
L30
PR2
TB34
TS6
C1P-8 C34SA BK/WH C1B-8 C34SA BK/WH C5-22 GLOW PLUG RELAY
GLOW
TS56
PLUG
GLOW
J
GLOW PLUG
PLUG
FUSE 70A
PR2
NO
number 16733
ENGINE
D64
FAULT
L2
3 START INPUT IGNITION/
MODULE
START
U1
I
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
8 KEY BYPASS
10 ENG. FAULT
TS2
7 KEY PWR.
6 BATTERY
5 GROUND
C33STR BK
4 AUX. ON
D33
TB25
START
ENGINE C5-16 C25PS WH/BK OIL PRESSURE SWITCH
C28TTA RD/BK
START
SW2
BK
NC
TB33
H
POWER RELAY
P26ESTP BK
TB21
CR2
P24FS WH
P25FS RD
C21IGN2 WH C5-11
TS1
FUEL SOLENOID
NO
AUX
PUMP
C1P-1 C27AUX RD C1B-1
C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
G
_
IGN./START RELAY
CR1
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
NO
D3
STARTER
STARTER MOTOR
FS1
D4
BK-(FS)
TS51
CR19
EMISSION CONTROL
F
February 2012
AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK
M2
C7P-2 P23BAT WH
PR1
TB23
NO
P2
D2
PUMP
AUX
AUXILIARY PUMP
Electrical Schematic, S-60 and S-60 TRAX, CE Models
C5-3
C1P-2 WH
TB28
D40
RD/BK
E
B
C1B-2
C28TTA RD/BK WH
H1
C28TTA RD/BK
TILT ALARM
P134TTSR RD RD BK BRN
LEVEL SENSOR
L4
D39
C3B-12
C
A
C3P-12 C133PLA BL/WH
S8
TB46
GR/BK
RD
C2B-5
C2P-5 C46HRN GR C46HRN GR HORN RELAY
NC
P3
H2
C7P-1 P22BAT BK C7B-1
TB133
NO
P22BAT BK F.H. BK
D
C32-8
HORN
TB132
L45
8
7
C1P-12 C132PLI BL/WH C1B-12 5
TB134
FB1
3
U33
P134FB WH FLASHING BEACONS
C2P-6 P134PWR GR/BK C2B-6
H6
OPTION
1
Deutz F3L-2011/Deutz D2011L03i Models
6
4
12
TB134
RD
SW4
BK
NO
C
HYDRAULIC OIL
86
85
C21IGN WH R21IGN WH C5-4
TB22
TEMPERATURE
WH
RD
SWITCH (OPTION)
87a 87
30
P116HYD RD
PLAT
GRD
C41RPM OR/BK
FAN
COOLING FAN
CR17
R116 OR C5-1
KS1
(OPTION)
M1
3MF
C3
+
TB41
C41RPM OR/BK C2B-3 C41RPM OR/BK C5-2
D22
B
RD
EXCT.
STA.
C21IGN WH
BAT.
IND.
P1
RD
RD
-
Section 6 • Schematics
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
D1
TB20
A
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 58
1
8
1
8
Deutz F3L-2011/Deutz D2011L03i Models
Section 6 • Schematics
6 - 59
Electrical Schematic, S-60 and S-60 TRAX, CE Models
TB31
LOW DRIVE
(HIGH TORQUE)
H4
8
MODE
(OPTION)
HIGH DRIVE
(LOW TORQUE)
B
TB32
C26-1 C26-2
C1P-6 C32BRK WH/RD C1B-6 C5-23 C32BRK WH/RD
ROCKER STEER OPTION ONLY.
19 BRAKE RELEASE
TB29
C28-1 C28-2
C1P-3 C29MS RD/WH C1B-3 C5-24 C29MS RD/WH
20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
TS15
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
RIGHT C1P-10 C36STCC BL C1B-10 C36SCC BL
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
C28TTA RD/BK
TB36
P26ESTP BK
P24FS WH
TB4
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
P162JPW OR
D
C15-1 C15-2
D9
DRIVE FORWARD/REVERSE &
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
GND 1
6
R OUT 5
X OUT 3
PWR 2
Y OUT 4
TS62
7.5W
R4
CR19
TB6
C31-1 C31-2
JC3
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
1 C13-1 C13-2
CR34
February 2012
J2
R14
5W
11
TB3
C164PES RD/WH
C165TRS WH/RD
R16
10W
P162JPW OR
C3PBF RD/WH
PRIMARY BOOM FLOW CONTROL
12
C29-1 C29-2
C3P-1 C1PBU RD C3B-1
J1
6
BR
TURNTABLE ROTATE
TB2
BOOM UP/DOWN &
X OUT 3
PWR 2
Y OUT 4
7
JC2
TB9
3 C30-1 C30-2
C3P-9 C9PER BK/RD C3B-9 C9PER BK/RD PRIMARY BOOM EXTEND/RETRACT
14
9 FLOW CONTROL
C163PLS BL/WH
13
10
C3P-7 C7PBE BK C3B-7 LS5 CABLE TENSION LIMIT SWITCH
12
NC
TB7
BR
21
22
EXTEND/RETRACT
RD RD BR C7PBE BK
G
PRIMARY BOOM
BOOM EXTEND
GND 1
6
PWR 2
Y OUT 4
EXTEND
J1
RETRACT
JC1
TS63
C8PBR BK/WH
U13 JOYSTICK CONTROL CARD
BOOM RETRACT
TB8
C17-1 C17-2
BRN
NO
HC
1
C4P-4 C118LSR OR/RD C4B-4 OR/RD C38-3 BK WH C38-4 LS17-BOOM UP/DOWN
1
SPEED REDUCTION LIMIT SWITCH
13
14
P24FS WH
TB118
2
LS17
BK
TB13
P24FS WH
H
NO
J3
HC
4
C4P-1 C13DE BL/RD C4B-1 BL/RD C9-1 BK WH C9-2 LS3-DRIVE ENABLE LIMIT SWITCH
3
13
14
P26ESTP BK
3
TB22
LS3
C2P-2
NO
HC
4
C11-2 WH BK C11-1 LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
13
14
LS1
NO
HC
14
LS2
I
BK
TB40
OPTION
CR30
CR27
DRIVE
NO
NC
LIFT/
CE
P22LS BK
C3P-11 C59CNK BL/BK C3B-11 BL/BK
L46
NO
J
BK C37-3 BK WH C37-4
L47
TB59
13
14
CR34
LS5
TB134
NC
HO
P134 RD RD C38-1 RD BR C38-2 LS17-BOOM UP/DOWN
21
22
SPEED REDUCTION LIMIT SWITCH
LS17
TS9
TB14
C20-1 C20-2
TS59
C14PLU OR
PLATFORM LEVEL UP
K
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
D27
TS7
TB18
C4P-5 C23-1 C23-2
D28
TS57
C18JD/PRR GR/BK PLATFORM ROTATE RIGHT
RIGHT PLATFORM
L
TB17
D29
C129 RD/BK
DESCENT ALARM
H3
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD
February 2012 Section 6 • Schematics
6 - 59 6 - 60
Section 6 • Schematics February 2012
6 - 61 6 - 62
8
7
6
5
4
3
2
1
6 - 62
RD
CR1 CR2
POWER BRN CR23
IGNITION DRIVE LIGHT
START RELAY RELAY
(OPTION)
RD
BK-ISM1 A
BRN
number 19405
Circuit breaker
WH
BRN
C32
8
7
5
6
1
4
3
12
WH-OPTIONS
WH-ISM9
CR4
Section 6 • Schematics
C5-18 BK/RD
R43DLITE2 RD
R43DLITE1 RD
C21IGN WH C5-11
BAT
HIGH RPM
AUX
BK/RD-35C
C2B-4 OR/RD
RD-24B
SOLENOID RELAY
WH-21B
BRN
BK
BK C5-5
WH
RD H6
BRN
BK-22D2
RD-TS52
RD-TS51
BK/RD-CR4
BK C7B-1
GR/BK H6
B
BL/WH-132B
C5
10A
CB7
C5-18 C32 C32
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
SWING SPEED PRIMARY BOOM
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
GR/BK-L45
RD-ISM4
GR/BK-133B
CR17
WH/RD-R2 HYDRAULIC
OIL COOLER
P134PWR RD-134C
WH/RD-R4
(OPTION)
RD/WH-R16 OR-LS17 C38-2
RD/WH-TS61
+
RD-CB3
H6
D C B A
RD-TS61 C1PBU RD C12-1
D
1 PRIMARY BOOM UP 1
RD/BK-ALARM C2PBD RD/BK C3B-2
FUSE 10A
WH/BK-TS62 C5TRR WH/BK C14-1
5 TURNTABLE ROTATE RIGHT 5 +12 VOLT
C6TRF WH/RD C3B-6 POWER TO
BK
RD
WH
6 TURNTABLE ROTATE FUNCTION CTRL 6
E
C7PBE BK C3B-7
Ground Control Box Terminal Strip Wiring Diagram,
WH-TB21 OPTIONS
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
D30
C11 (LS1)
F.H.
RD-CB1 P20BAT RD
20 +12 VOLT POWER 20
G
D52
BK-CR5
CABLE
BK-KS P22LS17 BK C38-4 TENSION
22 +12 VOLT TO PLATFORM (1) 22 LIMIT SWITCH
P22BAT BK C11-1 C37 (LS5)
BK C32-4 P22BAT BK C9-2
22 +12 VOLT TO PLATFORM (2) 22
WH-ISM7 P23BAT WH C7B-2
WH-KS
23 KEYSWITCH POWER 23
RD-ISM6 RD-CR2
RD-CB1
24 CIRCUIT BREAKER POWER 24
#2
#1
C5
F.H.
C37
H
27 AUXILARY PUMP 27
C28TTA RD/BK C1B-2
C30FWD WH C5-21
I
30 PROPEL FORWARD 30
C31REV WH/BK C1B-5
31 PROPEL REVERSE 31
RD/WH-TS61
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
TO SWITCH PANEL
GROUND HARNESS
RD-TS54
35 HIGH FUNCTION SPEED 35
J
C36SCC BL C1B-10
C36SCC BL C24-1
36 STEER LEFT 36
C37SCW BL/BK C1B-11
C5
39 (UNUSED) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
OR/BK-ISM2 C41RPM OR/BK C2B-3
C5
GR-CR5
46 SERVICE HORN 46
C59CNK BL/BK C3B-11
RD-KS P134TTS RD A
134 LOAD WEIGHING LIM. SW. +12V (2) 134
#2
F.H.
BRN C37-2
BRN C7B-3
B A
HARNESS
FUNCTION
BK C16-1
BK
RD
WH
BK-CR1
Genie Industries U1
1 TO REMOVE: 1 START RELAY
OR/BK-41C
F.H.
2 Push gently
2 TACHOMETER
BK-33C and lift.
M
3 3 START INPUT
RD-CR19
4 4 AUX PWR UNIT
BRN
5 5 GROUND
RD-24C
6 6 BATTERY
WH-23C
7 7 TO KEY SW (DIESEL ONLY) C9 (LS3)
ES0192G (DEUTZ)
ES0194H (PERKINS)
GROUND BOLT
February 2012 Section 6 • Schematics
OVERLOAD LED
TURNTABLE
1
PLATFORM
UP/DOWN
(CE OPTION)
ROTATE
ROTATE
BOOM
TS61
TS57
TS62
RD
L45
D9
RD/WH WH/RD
RD RD
RD/BK-2 RD-1
+
-
WH/BK-5
C19JSV GR/WH
WH-4
RD/WH
RD
GR/BK-18D
RD
RD
RD
2
GR-17D
RD
D3
RD
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
WH/RD WH/RD
RD
RD
RD
WH/RD
3
RD-27
WH
PLATFORM
RD
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
RD/WH
WH-4D
RD-1D
BK-7D
WH
RD
4
TURNTABLE
RESISTOR
ROTATE
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK/WH-34D
BK-33D
RD-20C
WH/RD-26
RD C32-7
RD CR17
BRN-GND
RD-20D
RD-24D
7.5 ohm 1%
BK/RD-35D
R2
5 ohm 1%
TURNTABLE
RESISTOR
ROTATE
WH
ENGINE
R4
CHECK
L2
1
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
B
CB3
CB2
RD
-
3
4
WH
RD/WH
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
RD
RD
RD
RD
6
LABEL DESCRIPTION
DALE RH-25 25W
RD-20D
CB1 CIRCUIT BREAKER, ENGINE, 15A
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RD
RESISTOR
UP/DOWN
ENGINE
ENGINE 15A
R16
START
TS52
BREAKER
CR1 IGNITION / START RELAY
CIRCUIT
CR2 IGNITION POWER RELAY
CB1
BK/WH-34D
RD-24D
BRN CR4 HIGH IDLE RELAY
CR5 HORN RELAY
BRN
RD
CR22 DRIVE LIGHT RELAY (OPTION)
HM HOUR METER 7
After serial KS1 KEY SWITCH
RD
RD
1 1
D13
P1 EMERGENCY STOP BUTTON
GLOW
PLUG
TS56
R2 SPEED LIMITING RESISTOR 5 OHMS
P1
NC NC
RD R4 SPEED LIMITING RESISTOR 7.5 OHMS
D14
R14 SPEED LIMITING RESISTOR 5 OHMS
FUNCTION
2 2
ENABLE
R16 SPEED LIMITING RESISTOR 10 OHMS
TS54
RD
TS51 AUXILIARY POWER TOGGLE SWITCH
RD
TS52
TS54
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
8
TS56 GLOW PLUG TOGGLE SWITCH
RD TS57 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. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 63
February 2012 Section 6 • Schematics
6 - 63 6 - 64
Section 6 • Schematics February 2012
6 - 65 6 - 66
8
7
6
5
4
3
2
1
6 - 66
RD
CR1 CR2
POWER BRN CR23
IGNITION DRIVE LIGHT
START RELAY RELAY
OPTION
RD
BK-ISM1 A
U33
BRN
PLATFORM
OVER LOAD
number 19405
Circuit breaker
WH
BRN
C32
8
7
5
6
1
4
3
12
WH-OPTIONS
WH-ISM9
CR4
C5-18 BK/RD
Section 6 • Schematics
R43DLITE2 RD
R43DLITE1 RD
C21IGN WH C5-11
BAT
HIGH RPM
AUX
BK/RD-35C
C2B-4 OR/RD
RD-24B
SOLENOID RELAY
WH-21B
BRN
BK C5-5
RD H6
BRN
BK/RD-CR4
BK-22D2
RD-TS52
RD-TS51
BK C7B-1
GR/BK H6
BL/WH-132B
B
C5
10A
CB7
C5-18 C32 C32
BK
WH
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
SWING SPEED PRIMARY BOOM
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
GR/BK-L45
RD-ISM4
GR/BK-133B
CR17
WH/RD-R2 HYDRAULIC
P134PWR RD-134C
RD-CB3
H6
1 PRIMARY BOOM UP 1
RD/BK-ALARM C2PBD RD/BK C3B-2
RD/BK-TS61 C2PBD RD/BK C13-1
#1
D29
FUSE 10A
WH/BK-TS62 C5TRR WH/BK C14-1
5 TURNTABLE ROTATE RIGHT 5
C6TRF WH/RD C3B-6 +12 VOLT
BK
RD
WH
6 TURNTABLE ROTATE FUNCTION CTRL 6
C7PBE BK C3B-7 C7
E
WH-TB21 OPTIONS
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
D30
LIMIT SWITCH
F.H.
RD-CB1 P20BAT RD
D52
BK-CR5
BK-KS P22LS17 BK C38-4 CABLE
22 +12 VOLT TO PLATFORM (1) 22 TENSION
P22BAT BK C11-1 LIMIT SWITCH
BK C32-4 P22BAT BK C9-2 C37 (LS5)
22 +12 VOLT TO PLATFORM (2) 22
WH-ISM7 P23BAT WH C7B-2
WH-KS
23 KEYSWITCH POWER 23
RD-ISM6 RD-CR2
RD-CB1
24 CIRCUIT BREAKER POWER 24
#2
#1
C5
F.H.
C37
H
27 AUXILIARY PUMP 27
C28TTA RD/BK C1B-2
C30FWD WH C5-21
I
30 PROPEL FORWARD 30
C31REV WH/BK C1B-5
31 PROPEL REVERSE 31
RD/WH-TS61
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
TO SWITCH PANEL
GROUND HARNESS
RD-TS54
35 HIGH FUNCTION SPEED 35
J
C36SCC BL C1B-10
C36SCC BL C24-1
36 STEER LEFT 36
C37SCW BL/BK C1B-11
C5
39 (UNUSED) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
OR/BK-ISM2 C41RPM OR/BK C2B-3
C5
+
K
GR-CR5
46 SERVICE HORN 46
C59CNK BL/BK C3B-11
C3
RD-KS P134TTS RD A
134 LOAD WEIGHING LIM. SW. +12V (2) 134
#2
F.H.
BRN C37-2
BRN C7B-3
B A
HARNESS
FUNCTION
BK C16-1
BK
RD
WH
BRN
BK-CR1
Genie Industries
1 TO REMOVE: 1 START RELAY
F.H.
OR/BK-41C
2 Push gently 2 TACHOMETER
BK-33C U1
3
M
ES0192G
GROUND BOLT
February 2012 Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60 and S-60 TRAX,
CE Models Deutz F3L-2011/Deutz D2011L03i Models
N M L K J I H G F E D C B A
OVERLOAD LED
1
TURNTABLE
PLATFORM
UP/DOWN
(CE OPTION)
ROTATE
ROTATE
BOOM
TS61
TS57
TS62
RD
L45
D9
RD/WH WH/RD
RD RD
RD/BK-2 RD-1
+
-
WH/BK-5
C19JSV GR/WH
WH-4
RD/WH
RD
GR/BK-18D
RD
RD
RD 2
GR-17D
RD
D3
RD
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
WH/RD WH/RD
RD
RD
RD
WH/RD
3
RD-27
WH
PLATFORM
RD
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
RD/WH
WH-4D
RD-1D
BK-7D
WH
RD
4
TURNTABLE
RESISTOR
ROTATE
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK/WH-34D
BK-33D
RD-20C
WH/RD-26
RD C32-7
RD CR17
BRN-GND
RD-20D
RD-24D
7.5 ohm 1%
BK/RD-35D
R2
5 ohm 1%
TURNTABLE
RESISTOR
ROTATE
WH
ENGINE
R4
CHECK
L2
1
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
B
CB3
CB2
RD
-
3
5
4
WH
RD/WH
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
RD
RD
RD
RD
6
LABEL DESCRIPTION
DALE RH-25 25W
RD-20D
CB1 CIRCUIT BREAKER, ENGINE, 15A
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RD
RESISTOR
UP/DOWN
ENGINE
ENGINE 15A
R16
START
TS52
BREAKER
CR1 IGNITION / START RELAY
CIRCUIT
CR2 IGNITION POWER RELAY
CB1
BK/WH-34D
RD-24D
BRN CR4 HIGH IDLE RELAY
CR5 HORN RELAY
BRN
RD
CR22 DRIVE LIGHT RELAY (OPTION)
HM HOUR METER
7
After serial KS1 KEY SWITCH
RD
RD
1 1
D13
P1 EMERGENCY STOP BUTTON
GLOW
PLUG
TS56
R2 SPEED LIMITING RESISTOR 5 OHMS
P1
NC NC
RD R4 SPEED LIMITING RESISTOR 7.5 OHMS
D14
R14 SPEED LIMITING RESISTOR 5 OHMS
FUNCTION
2 2
ENABLE
R16 SPEED LIMITING RESISTOR 10 OHMS
TS54
RD
TS51 AUXILIARY POWER TOGGLE SWITCH
RD
TS52 ENGINE START TOGGLE SWITCH 8
TS54 FUNCTION ENABLE SWITCH
TS56 GLOW PLUG TOGGLE SWITCH
RD TS57 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. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 67
February 2012 Section 6 • Schematics
6 - 67 6 - 68
Section 6 • Schematics February 2012
6 - 69 6 - 70
12V DC PLATFORM POWER CONNECTOR
CWLITE WH TS49
(TO SWITCH
PLATFORM
CONTROL RELAY (CE OPTION)
CONTROL RELAY (CE OPTION)
CONTROL
HARNESS
FOOT SWITCH CONNECTOR
PANEL)
ALC-500 CONTROL BOARD
DESCRIPTION
TILT ALARM
BRN JC3
BRN GND
RD-E-STOP C134PWR RD LS18
C1P-C4P
C134PWR RD-H1+
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
OPT.
CE LIFT/DRIVE OPTION
TS7 WH
L
RD LS18 CABLE
CR27
BRN
CR30
BK C1P-12
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
TS1 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
J
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129JDA BL C3P-10 TS8
C46HRN GR C2P-5
C59CHK BL/BK C3P-11 L47+
C59CNK BL/BK C3P-11
P26BAT BK C9-1 P2
I
FOOT SWITCH
C4P
C7P
C3P
F.S.
P26ESTP BK
WH/RD C1P-6
11
3
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
G
C7P
P24FS WH C40LSS OR C2P-2
C9PER BK/RD C3P-9
P24FS WH C41RPM OR/BK C2P-3
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C7P
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
F
February 2012
C4P
Platform Control Box Wiring Diagram, S-60 and S-60 TRAX,
C3P
C3P(GR)
E
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
C1P
9
1
P162JPW OR
D
C165TRS WH/RD
C7P
GND BRN
C160JPL WH/RD
* NOTE:
P162JPW OR
C159STC BL/WH*
GND BRN
C
BATGRN C7P-3
GR/BK C133TTA C3P-12
B
GR/BK-L4- (CE)
D39
RD/BK-28
ALARM
Section 6 • Schematics
TILT
RD/BK-L4- RD/BK-L48- (NON-CE)
H1
C134PWR RD C2P-6
C134PWR RD LS18 RD-TILT
+
CWLITE BK
BRN
BRN
BRN BRN
A
CWLITE WH TS49
6 - 70
1
8
February 2012 Section 6 • Schematics
1
PLATFORM CONTROL
HARNESS (TO CONTROL BOX)
JC2 JC3
DRIVE
BOOM UP/DOWN & FORWARD/REVERSE
TURNTABLE ROTATE & STEER
LEFT/RIGHT TS48 LEFT/RIGHT
DRIVE LIGHTS/
WORK LIGHTS
(OPTION)
DLITE RD RD 2
TS15
DRIVE +
ENABLE
JC1 L48
TILT ALARM LED
BOOM (ANSI/CSA OPT.)
EXTEND/RETRACT
6 1 6 1 6 1
BK
BK
3
RD
5 2 5 2 5 2
4 3 4 3 4 3
+
L47
RETRACT + 4
BOOM
RD
LED
BK
BRN
BK
BRN BRN BRN BRN F18 FUSE 10A
(WORK LIGHT ONLY)
BK
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
C165TRS WH/RD
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
BK
5
P162JPW OR
P162JPW OR
P162JPW OR
BL-DE1 J1-6
WLITE WH
WLITE WH
GND BRN
GND-BR
GND BR
BRN
RD
BK
PDLITE RD
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
C46HRN GR C2P-5
C14PLU OR C4P-2
C17PRL GR C4P-5
C27AUX RD C1P-1
WH CR30
P25FS RD C9-3
C33STR BK C1P-7
RD RD COMPONENT INDEX
JC2 BOOM PROPORTIONAL JOYSTICK:
WH WH
BOOM UP/DOWN , TURNTABLE ROTATE
JC1 BOOM PROPORTIONAL JOYSTICK:
RD
RD D12
BOOM EXTEND/RETRACT
4 NO
3
1 1 1
JC3 DRIVE/STEER PROPORTIONAL JOYSTICK
7
NC NC NC L1 DRIVE ENABLE LED
L4 PLATFORM OVERLOAD LED
TS6 TS2 TS4 2 22
TS14 L47 LOWER/RETRACT BOOM LED
P3 WH GLOW PLUG ENGINE HIGH/LOW
TS1 HIGH/LOW TS47
HORN TS9 START RPM L48 BOOM TILTED LED
AUXILIARY (2WD/4WD) GENERATOR
RD
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 71
February 2012 Section 6 • Schematics
6 - 71 6 - 72
Section 6 • Schematics February 2012
6 - 73 6 - 74
Circuit breaker
RD
RD
BRN
serial number
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
ES0192G
added after
CR4
N
D12
19405
CB7
10A
TS4
FOOTSW. LOW
CR4
Q3
ENGINE
BK/RD
TS54
SPEED
C5-18
HIGH RPM SOLENOID
NO
D14
LOW RPM
FUNCTION ENA.
HIGH RPM C26PSR WH/BK OIL PRESSURE
G2
G1
CR23
TS48
DRIVE LIGHT
LIGHTS
FUSE 10A
WORK LIGHT RD
DRIVE LIGHT L29
F19
(OPTION)
L29
L30
RD
RD
RD
FUSE 10A
TB21
C2P-12 C2P-10
CR23
(OPTION)
NO
PBOX GND
C2P-11 C2P-9
K
L30
PR2
TB34
TS6
PLUG
GLOW
J
GLOW PLUG
PLUG
FUSE 70A
PR2
NO
F22
number 16733
L2
D64
MODULE
START
U1
I
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
8 KEY BYPASS
10 ENG. FAULT
TS2
7 KEY PWR.
6 BATTERY
5 GROUND
C33STR BK
4 AUX. ON
D33
TB25
START
ENGINE C5-16 C25PS WH/BK OIL PRESSURE SWITCH
C28TTA RD/BK
START
SW2
BK
NC
TB33
CR2
H
POWER RELAY
P26ESTP BK
TB21
P24FS WH
P25FS RD
C21IGN2 WH C5-11
TS1
FUEL SOLENOID
CR2
AUX
NO
HM
C9P-2
HOUR METER
G
_
IGN./START RELAY
CR1
NO
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
D3
STARTER
STARTER MOTOR
FS1
D4
BK-(FS)
TS51
CR19
F
EMISSIOIN CONTROL
February 2012
AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK
M2
TB23
PR1
NO
P2
D2
PUMP
L48
AUX
AUXILIARY PUMP
C5-3
RD/BK C1P-2 WH
TB28
D40
E
Overload
RD/BK
Platform
B
C1B-2
Option
C28TTA RD/BK WH
H1
C28TTA RD/BK
TILT ALARM
P134TTSR RD RD BK BRN
LEVEL SENSOR
C3B-12
C
A
C3P-12 C133PLA BL/WH
S8
TB46
RD
C2B-5
C2P-5 C46HRN GR C46HRN GR HORN RELAY
P3
CR5
Electrical Schematic, S-65 and S-65 TRAX,
H2
NO
C7P-1 P22BAT BK C7B-1
TB133
P22BAT BK F.H. BK
D
HORN
C32-8
TB132
7
5
TB134
C1P-12 C132PLI BL/WH C1B-12
FB1
3
U33
P134FB WH FLASHING BEACONS
C2P-6 P134PWR GR/BK C2B-6
(OPTION)
1
Deutz F3L-2011/Deutz D2011L03i Models
12
4
6
TB134
RD
SW4
NO
BK
C
HYDRAULIC OIL
86
85
C21IGN WH R21IGN WH C5-4 TEMPERATURE
TB22
WH
RD
SWITCH (OPTION)
87a 87
30
P116HYD RD
PLAT
GRD
C41RPM OR/BK
CR17
FAN
R116 OR C5-1 COOLING FAN
KS1
(OPTION)
M1
3MF
C3
+
TB41
C41RPM OR/BK C2B-3 C41RPM OR/BK C5-2
B
D22
RD
EXCT.
STA.
C21IGN WH
BAT.
IND.
P1
RD
RD
-
Section 6 • Schematics
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
D1
TB20
A
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 74
1
8
1
8
Deutz F3L-2011/Deutz D2011L03i Models
Section 6 • Schematics
6 - 75
Electrical Schematic, S-65 and S-65 TRAX,
TB31
LOW DRIVE
(HIGH TORQUE)
H4
TB32
C26-1 C26-2
C1P-6 C32BRK WH/RD C1B-6 C5-23 C32BRK WH/RD
ROCKER STEER OPTION ONLY.
19 BRAKE RELEASE
TB29
C28-1 C28-2
C1P-3 C29MS RD/WH C1B-3 C5-24 C29MS RD/WH
20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
TS15
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
RIGHT C1P-10 C36STCC BL C1B-10 C36SCC BL
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C28TTA RD/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
2
2
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
D
C15-1 C15-2
D9
DRIVE FORWARD/REVERSE &
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
7.5W
TS62
GND 1
6
R OUT 5
X OUT 3
PWR 2
Y OUT 4
R4
CR19
TB6
C31-1 C31-2
C6TRF WH/RD
JC3
TURNTABLE ROTATE
FLOW CONTROL
TB1
R2
5W
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
C13-1 C13-2
CR34
1
R14
TS61
February 2012
J2
5W
11
TB3
C165TRS WH/RD
C164PES RD/WH
C3PBF RD/WH
P162JPW OR
6
BR
TB2
TURNTABLE ROTATE
BOOM UP/DOWN &
X OUT 3
PWR 2
Y OUT 4
7
JC2
TB9
3 C30-1 C30-2
C3P-9 C9PER BK/RD C3B-9 C9PER BK/RD PRIMARY BOOM EXTEND/RETRACT
14
9 FLOW CONTROL
C163PLS BL/WH
21 LS5
10
NC
22
EXTEND/RETRACT
RD RD BR C7PBE BK
G
BOOM EXTEND
PRIMARY BOOM
GND 1
6
PWR 2
Y OUT 4
EXTEND
BOOM C37-1 C37-2 C16-1 C16-2
RETRACT
JC1
TS63
C8PBR BK/WH
U13 JOYSTICK CONTROL CARD
BOOM RETRACT
TB8
C17-1 C17-2
LS17
NO
HC
BRN
1
C4P-4 C118LSR OR/RD C4B-4 OR/RD C38-3 BK WH C38-4 LS17-BOOM UP/DOWN
1
SPEED REDUCTION LIMIT SWITCH
13
14
P24FS WH
TB118
BK
TB13
LS3
NO
HC
P24FS WH
H
J3
4
C4P-1 C13DE BL/RD C4B-1 BL/RD C9-1 BK WH C9-2 LS3-DRIVE ENABLE LIMIT SWITCH
3
13
14
P26ESTP BK
TB22
3
LS1
NO
HC
C2P-2
4
C11-2 WH BK C11-1 LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
13
14
LS2
14
NO
HC
I
BK
TB40
OPTION
CR27
CR30
DRIVE
NO
NC
LIFT/
CE
P22LS BK
C3P-11 C59CNK BL/BK C3B-11 BL/BK
L46
NO
LS5
J
BK C37-3 BK WH C37-4
L47
TB59
13
14
CR34
TB134
21
HO 22
SPEED REDUCTION LIMIT SWITCH
TS9
LS17
NC
UP
PLATFORM LEVEL
DOWN C4P-3 C15PLD OR/BK C4B-3
TB14
C20-1 C20-2
TS59
C14PLU OR
PLATFORM LEVEL UP
K
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
D27
TS8
TB18
C4P-5 C23-1 C23-2
D28
TS58
C18JD/PRR GR/BK PLATFORM ROTATE RIGHT
RIGHT PLATFORM
L
TB17
RIGHT
D29
PLATFORM
LEFT ROTATE
TS7
WH
TS57
C129 RD/BK
BRN
DESCENT ALARM
D30
H3
C4P-7 C19JSV GR/WH C4B-7
TB19
M
P24FS WH
P26ESTP BK
NO
P22LS BK
P134 RD
CR14
GR/WH
N
BRN
RD
RD
February 2012 Section 6 • Schematics
6 - 75 6 - 76
Section 6 • Schematics February 2012
6 - 77 6 - 78
Circuit breaker
RD
RD
BRN
ES0192G
serial number
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
added after
CR4
N
D12
19405
C35RPM BK/RD
C1P-9 C35RPM BK/RD C1B-9 BRN
HIGH IDLE RELAY
FOOTSW. HIGH
CB7
10A
TS4
FOOTSW. LOW
CR4
Q3
ENGINE
BK/RD
TS54
SPEED
C5-18
HIGH RPM SOLENOID
NO
D14
LOW RPM
FUNCTION ENA.
HIGH RPM C26PSR WH/BK OIL PRESSURE
G2
TB35
M
G1
CR23
TS48
DRIVE LIGHT
LIGHTS
FUSE 10A
WORK LIGHT RD
DRIVE LIGHT (OPTION)
F19
L29
L30
RD
RD
RD
FUSE 10A
TB21
C2P-12 C2P-10
CR23
NO
PBOX GND
C2P-11 C2P-9
K
L30
PR2
TB34
TS6
C1P-8 C34SA BK/WH C1B-8 C34SA BK/WH C5-22 GLOW PLUG RELAY
GLOW
TS56
PLUG
GLOW
J
GLOW PLUG
PLUG
FUSE 70A
PR2
NO
number 16733
ENGINE
D64
FAULT
L2
3 START INPUT IGNITION/
MODULE
START
U1
I
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
8 KEY BYPASS
10 ENG. FAULT
TS2
7 KEY PWR.
6 BATTERY
5 GROUND
C33STR BK
4 AUX. ON
D33
TB25
START
ENGINE C5-16 C25PS WH/BK OIL PRESSURE SWITCH
C28TTA RD/BK
START
SW2
BK
NC
TB33
H
POWER RELAY
P26ESTP BK
TB21
CR2
P24FS WH
P25FS RD
C21IGN2 WH C5-11
TS1
FUEL SOLENOID
NO
AUX
PUMP
C1P-1 C27AUX RD C1B-1
C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
G
_
IGN./START RELAY
CR1
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
NO
D3
STARTER
STARTER MOTOR
FS1
D4
BK-(FS)
TS51
CR19
F
EMISSION CONTROL
February 2012
AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK
M2
C7P-2 P23BAT WH
PR1
TB23
NO
P2
D2
PUMP
AUX
AUXILIARY PUMP
Electrical Schematic, S-65 and S-65 TRAX, CE Models
C5-3
C1P-2 WH
TB28
E
D40
RD/BK
B
C1B-2
C28TTA RD/BK WH
H1
C28TTA RD/BK
TILT ALARM
P134TTSR RD RD BK BRN
LEVEL SENSOR
L4
D39
C3B-12
C
A
C3P-12 C133PLA BL/WH
S8
TB46
GR/BK
RD
C2B-5
C2P-5 C46HRN GR C46HRN GR HORN RELAY
NC
P3
H2
C7P-1 P22BAT BK C7B-1
TB133
NO
P22BAT BK F.H. BK
D
C32-8
HORN
TB132
L45
8
7
5
C1P-12 C132PLI BL/WH C1B-12
TB134
FB1
3
U33
P134FB WH FLASHING BEACONS
C2P-6 P134PWR GR/BK C2B-6
H6
OPTION
1
Deutz F3L-2011/Deutz D2011L03i Models
6
4
12
TB134
RD
SW4
BK
NO
C
HYDRAULIC OIL
86
85
C21IGN WH R21IGN WH C5-4
TB22
TEMPERATURE
WH
RD
SWITCH (OPTION)
87a 87
30
P116HYD RD
PLAT
GRD
C41RPM OR/BK
FAN
COOLING FAN
CR17
R116 OR C5-1
KS1
(OPTION)
M1
3MF
C3
+
TB41
C41RPM OR/BK C2B-3 C41RPM OR/BK C5-2
B
D22
RD
EXCT.
STA.
C21IGN WH
BAT.
IND.
P1
RD
RD
-
Section 6 • Schematics
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
D1
TB20
A
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 78
1
8
1
8
Deutz F3L-2011/Deutz D2011L03i Models
Section 6 • Schematics
6 - 79
Electrical Schematic, S-65 and S-65 TRAX, CE Models
TB31
LOW DRIVE
(HIGH TORQUE)
H4
TB32
C26-1 C26-2
C1P-6 C32BRK WH/RD C1B-6 C5-23 C32BRK WH/RD
ROCKER STEER OPTION ONLY.
19 BRAKE RELEASE
TB29
C28-1 C28-2
C1P-3 C29MS RD/WH C1B-3 C5-24 C29MS RD/WH
20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
TS15
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
RIGHT C1P-10 C36STCC BL C1B-10 C36SCC BL
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C28TTA RD/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
2
2
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
D
C15-1 C15-2
D9
DRIVE FORWARD/REVERSE &
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
7.5W
TS62
GND 1
6
R OUT 5
X OUT 3
PWR 2
Y OUT 4
R4
CR19
TB6
C31-1 C31-2
C6TRF WH/RD
JC3
TURNTABLE ROTATE
FLOW CONTROL
TB1
R2
5W
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
C13-1 C13-2
CR34
1
R14
TS61
February 2012
J2
5W
11
TB3
C165TRS WH/RD
C164PES RD/WH
C3PBF RD/WH
P162JPW OR
6
BR
TB2
TURNTABLE ROTATE
BOOM UP/DOWN &
X OUT 3
PWR 2
Y OUT 4
7
JC2
TB9
3 C30-1 C30-2
C3P-9 C9PER BK/RD C3B-9 C9PER BK/RD PRIMARY BOOM EXTEND/RETRACT
14
9 FLOW CONTROL
C163PLS BL/WH
21 LS5
10
NC
22
EXTEND/RETRACT
RD RD BR C7PBE BK
G
BOOM EXTEND
PRIMARY BOOM
GND 1
6
PWR 2
Y OUT 4
EXTEND
BOOM C37-1 C37-2 C16-1 C16-2
RETRACT
JC1
TS63
C8PBR BK/WH
U13 JOYSTICK CONTROL CARD
BOOM RETRACT
TB8
C17-1 C17-2
LS17
NO
HC
BRN
1
C4P-4 C118LSR OR/RD C4B-4 OR/RD C38-3 BK WH C38-4 LS17-BOOM UP/DOWN
1
SPEED REDUCTION LIMIT SWITCH
13
14
P24FS WH
TB118
BK
TB13
LS3
NO
HC
P24FS WH
H
J3
4
C4P-1 C13DE BL/RD C4B-1 BL/RD C9-1 BK WH C9-2 LS3-DRIVE ENABLE LIMIT SWITCH
3
13
14
P26ESTP BK
TB22
3
LS1
NO
HC
C2P-2
4
C11-2 WH BK C11-1 LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
13
14
LS2
14
NO
HC
I
BK
TB40
OPTION
CR27
CR30
DRIVE
NO
NC
LIFT/
CE
P22LS BK
C3P-11 C59CNK BL/BK C3B-11 BL/BK
L46
NO
LS5
J
BK C37-3 BK WH C37-4
L47
TB59
13
14
CR34
TB134
21
HO 22
SPEED REDUCTION LIMIT SWITCH
TS9
LS17
NC
UP
PLATFORM LEVEL
DOWN C4P-3 C15PLD OR/BK C4B-3
TB14
C20-1 C20-2
TS59
C14PLU OR
PLATFORM LEVEL UP
K
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
D27
TS8
TB18
C4P-5 C23-1 C23-2
D28
TS58
C18JD/PRR GR/BK PLATFORM ROTATE RIGHT
RIGHT PLATFORM
L
TB17
RIGHT
D29
PLATFORM
LEFT ROTATE
TS7
WH
TS57
C129 RD/BK
BRN
DESCENT ALARM
D30
H3
C4P-7 C19JSV GR/WH C4B-7
TB19
M
P24FS WH
P26ESTP BK
NO
P22LS BK
P134 RD
CR14
GR/WH
N
BRN
RD
RD
February 2012 Section 6 • Schematics
6 - 79 6 - 80
Section 6 • Schematics February 2012
6 - 81 6 - 82
8
7
6
5
4
3
2
1
6 - 82
RD
CR1 CR2
POWER BRN CR23
IGNITION DRIVE LIGHT
START RELAY RELAY
(OPTION)
RD
BK-ISM1
A
BRN
number 19405
Circuit breaker
WH
BRN
C32
8
7
5
6
1
4
3
12
WH-OPTIONS
WH-ISM9
CR4
C5-18 BK/RD
R43DLITE2 RD
R43DLITE1 RD
C21IGN WH C5-11
BAT
HIGH RPM
Section 6 • Schematics
AUX
BK/RD-35C
C2B-4 OR/RD
RD-24B
SOLENOID RELAY
WH-21B
BRN
BK
BK C5-5
WH
RD H6
BRN
BK-22D2
RD-TS52
RD-TS51
BK/RD-CR4
BK C7B-1
GR/BK H6
BL/WH-132B
C5
10A
CB7
B
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
SWING SPEED PRIMARY BOOM
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
GR/BK-L45
RD-ISM4
GR/BK-133B
CR17
WH/RD-R2 HYDRAULIC
OIL COOLER
P134PWR RD-134C
WH/RD-R4
(OPTION)
RD/WH-R16 OR-LS17 C38-2
RD/WH-TS61
+
RD-CB3
H6
D C B A
RD-TS61 C1PBU RD C12-1
1 PRIMARY BOOM UP 1
D
D29
FUSE 10A
WH/BK-TS62 C5TRR WH/BK C14-1
5 TURNTABLE ROTATE RIGHT 5 +12 VOLT
C6TRF WH/RD C3B-6 POWER TO
BK
RD
WH
6 TURNTABLE ROTATE FUNCTION CTRL 6
C7PBE BK C3B-7
E
Ground Control Box Terminal Strip Wiring Diagram,
WH-TB21 OPTIONS
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
D30
18/19 #2
14 PLATFORM LEVEL UP 14 C1 & C2
C15PLD OR/BK C4B-3
C11 (LS1)
F.H.
RD-CB1 P20BAT RD
20 +12 VOLT POWER 20
D52
G
BK-CR5
CABLE
BK-KS P22LS17 BK C38-4 TENSION
22 +12 VOLT TO PLATFORM (1) 22 LIMIT SWITCH
P22BAT BK C11-1 C37 (LS5)
BK C32-4 P22BAT BK C9-2
22 +12 VOLT TO PLATFORM (2) 22
WH-ISM7 P23BAT WH C7B-2
WH-KS
23 KEYSWITCH POWER 23
RD-ISM6 RD-CR2
RD-CB1
24 CIRCUIT BREAKER POWER 24
#2
#1
C5
F.H.
C37
H
27 AUXILARY PUMP 27
C28TTA RD/BK C1B-2
C30FWD WH C5-21
I
30 PROPEL FORWARD 30
C31REV WH/BK C1B-5
31 PROPEL REVERSE 31
RD/WH-TS61
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
TO SWITCH PANEL
GROUND HARNESS
C36SCC BL C24-1
36 STEER LEFT 36
C37SCW BL/BK C1B-11
C5
39 (UNUSED) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
OR/BK-ISM2 C41RPM OR/BK C2B-3
C5
GR-CR5
46 SERVICE HORN 46
C59CNK BL/BK C3B-11
RD-KS P134TTS RD A
134 LOAD WEIGHING LIM. SW. +12V (2) 134
#2
F.H.
BRN C37-2
BRN C7B-3
B A
HARNESS
FUNCTION
BK C16-1
BK
RD
WH
BK-CR1
Genie Industries U1
1 TO REMOVE: 1 START RELAY
OR/BK-41C
F.H.
2 Push gently
2 TACHOMETER
BK-33C and lift.
3
M
3 START INPUT
RD-CR19
4 4 AUX PWR UNIT
BRN
5 5 GROUND
RD-24C
6 6 BATTERY
WH-23C
7 7 TO KEY SW (DIESEL ONLY) C9 (LS3)
ES0192G (DEUTZ)
ES0194H (PERKINS)
GROUND BOLT
February 2012 Section 6 • Schematics
OVERLOAD LED
TURNTABLE
PLATFORM
UP/DOWN
1
(CE OPTION)
ROTATE
ROTATE
BOOM
TS61
TS57
TS62
RD GR/BK
L45
D9
RD/WH WH/RD
RD RD
RD/BK-2 RD-1
+
-
WH/BK-5
C19JSV GR/WH
WH-4
RD/WH
RD
GR/BK-18D
RD
RD
RD
GR-17D
RD
2
D3
GR/BK
RD
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
GR
WH/RD WH/RD GR/BK
RD
D28
GR
RD
RD
WH/RD RD
RD-27
3
WH
PLATFORM
UP/DOWN
JIB BOOM
RD
TS58
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
RD/WH
BL-44D
WH-4D
RD-1D
BK-7D
WH
RD
TURNTABLE
RESISTOR
4
DALE RH-25 25W
DALE RH-25 25W
ROTATE
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK/WH-34D
BK-33D
RD-20C
WH/RD-26
RD C32-7
RD CR17
BRN-GND
RD-20D
RD-24D
7.5 ohm 1%
BK/RD-35D
R2
5 ohm 1%
TURNTABLE
RESISTOR
ROTATE
WH
ENGINE
R4
CHECK
L2
1
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
B
CB3
CB2
RD
-
3
4
WH
RD/WH
5
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
RD
RD
RD
RD
LABEL
CB1
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
6
DALE RH-25 25W
RD-20D
CB2 CIRCUIT BREAKER, CONTROLS, 15A
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RD
RESISTOR
UP/DOWN
ENGINE
ENGINE 15A
R16
START
TS52
BREAKER
CR2 IGNITION POWER RELAY
CIRCUIT
CR4 HIGH IDLE RELAY
CB1
BK/WH-34D
RD-24D
BRN CR5 HORN RELAY
CR17 HYDRAULIC OIL COOLER FAN RELAY
BRN
RD
HM HOUR METER
KS1 KEY SWITCH
After serial L2 CHECK ENGINE LED 7
RD
RD
1 1
D13
GLOW
R2 SPEED LIMITING RESISTOR 5 OHMS
PLUG
TS56
R4 SPEED LIMITING RESISTOR 7.5 OHMS
P1
NC NC
RD R14 SPEED LIMITING RESISTOR 5 OHMS
D14
R16 SPEED LIMITING RESISTOR 10 OHMS
FUNCTION
2 2
ENABLE
TS51 AUXILIARY POWER TOGGLE SWITCH
TS54
RD
TS52 ENGINE START TOGGLE SWITCH
RD TS54 FUNCTION ENABLE SWITCH
TS56 GLOW PLUG TOGGLE SWITCH 8
TS57 PLATFORM ROTATE TOGGLE SWITCH
RD TS58 JIB BOOM TOGGLE SWITCH
TS59 PLATFORM LEVEL TOGGLE SWITCH
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH
TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 83
February 2012 Section 6 • Schematics
6 - 83 6 - 84
Section 6 • Schematics February 2012
6 - 85 6 - 86
8
7
6
5
4
3
2
1
6 - 86
RD
CR1 CR2
POWER BRN CR23
IGNITION DRIVE LIGHT
START RELAY RELAY
OPTION
RD
BK-ISM1 A
U33
BRN
PLATFORM
OVER LOAD
number 19405
Circuit breaker
WH
BRN
C32
8
7
5
6
1
4
3
12
WH-OPTIONS
WH-ISM9
CR4
Section 6 • Schematics
C5-18 BK/RD
R43DLITE2 RD
R43DLITE1 RD
C21IGN WH C5-11
BAT
HIGH RPM
AUX
BK/RD-35C
C2B-4 OR/RD
RD-24B
SOLENOID RELAY
WH-21B
BRN
BK C5-5
RD H6
BRN
BK/RD-CR4
BK-22D2
RD-TS52
RD-TS51
BK C7B-1
GR/BK H6
B
BL/WH-132B
C5
10A
CB7
C5-18 C32 C32
BK
WH
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
SWING SPEED PRIMARY BOOM
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
GR/BK-L45
RD-ISM4
GR/BK-133B
CR17
WH/RD-R2 HYDRAULIC
P134PWR RD-134C
RD-CB3
H6
1 PRIMARY BOOM UP 1
RD/BK-ALARM C2PBD RD/BK C3B-2
FUSE 10A
WH/BK-TS62 C5TRR WH/BK C14-1
5 TURNTABLE ROTATE RIGHT 5
C6TRF WH/RD C3B-6 +12 VOLT
BK
RD
WH
6 TURNTABLE ROTATE FUNCTION CTRL 6
C7
E
C7PBE BK C3B-7
WH-TB21 OPTIONS
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
D30
LIMIT SWITCH
F.H.
RD-CB1 P20BAT RD
D52
BK-CR5
WH-KS
23 KEYSWITCH POWER 23
RD-ISM6 RD-CR2
RD-CB1
24 CIRCUIT BREAKER POWER 24
#2
#1
C5
F.H.
C37
H
27 AUXILIARY PUMP 27
C28TTA RD/BK C1B-2
C30FWD WH C5-21
I
30 PROPEL FORWARD 30
C31REV WH/BK C1B-5
31 PROPEL REVERSE 31
RD/WH-TS61
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
TO SWITCH PANEL
GROUND HARNESS
RD-TS54
35 HIGH FUNCTION SPEED 35
J
C36SCC BL C1B-10
C36SCC BL C24-1
36 STEER LEFT 36
C37SCW BL/BK C1B-11
C5
39 (UNUSED) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
OR/BK-ISM2 C41RPM OR/BK C2B-3
C5
+
K
GR-CR5
46 SERVICE HORN 46
C59CNK BL/BK C3B-11
C3
RD-KS P134TTS RD A
134 LOAD WEIGHING LIM. SW. +12V (2) 134
#2
F.H.
BRN C37-2
BRN C7B-3
B A
HARNESS
FUNCTION
BK C16-1
BK
RD
WH
BRN
BK-CR1
Genie Industries
1 TO REMOVE: 1 START RELAY
F.H.
OR/BK-41C
2 Push gently 2 TACHOMETER
BK-33C U1
M
ES0192G
GROUND BOLT
February 2012 Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX,
CE Models Deutz F3L-2011/Deutz D2011L03i Models
N M L K J I H G F E D C B A
OVERLOAD LED
TURNTABLE
1
PLATFORM
UP/DOWN
(CE OPTION)
ROTATE
ROTATE
BOOM
TS61
TS57
TS62
RD GR/BK
L45
D9
RD/WH WH/RD
RD RD
RD/BK-2 RD-1
+
-
WH/BK-5
C19JSV GR/WH
WH-4
RD/WH
RD
GR/BK-18D
RD
RD
RD
2
GR-17D
RD
D3
GR/BK
RD
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
GR
WH/RD WH/RD GR/BK
RD
D28
GR
RD
RD
WH/RD RD
RD-27
3
WH
PLATFORM
UP/DOWN
JIB BOOM
RD
TS58
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
RD/WH
BL-44D
WH-4D
RD-1D
BK-7D
WH
RD
4
TURNTABLE
RESISTOR
ROTATE
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK/WH-34D
BK-33D
RD-20C
WH/RD-26
RD C32-7
RD CR17
BRN-GND
RD-20D
RD-24D
7.5 ohm 1%
BK/RD-35D
R2
5 ohm 1%
TURNTABLE
RESISTOR
ROTATE
WH
ENGINE
R4
CHECK
L2
1
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
B
CB3
CB2
RD
-
3
4
WH
RD/WH
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
RD
RD
RD
RD
LABEL DESCRIPTION 6
CB1 CIRCUIT BREAKER, ENGINE, 15A
DALE RH-25 25W
RD-20D
CB2 CIRCUIT BREAKER, CONTROLS, 15A
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RD
RESISTOR
UP/DOWN
ENGINE
ENGINE 15A
R16
START
TS52
BREAKER
CR2 IGNITION POWER RELAY
CIRCUIT
CR4 HIGH IDLE RELAY
CB1
BK/WH-34D
RD-24D
BRN CR5 HORN RELAY
CR17 HYDRAULIC OIL COOLER FAN RELAY
BRN
RD
HM HOUR METER
KS1 KEY SWITCH 7
After serial L2 CHECK ENGINE LED
RD
RD
1 1
D13
GLOW
R2 SPEED LIMITING RESISTOR 5 OHMS
PLUG
TS56
R4 SPEED LIMITING RESISTOR 7.5 OHMS
P1
NC NC
RD R14 SPEED LIMITING RESISTOR 5 OHMS
D14
R16 SPEED LIMITING RESISTOR 10 OHMS
FUNCTION
2 2
ENABLE
TS51 AUXILIARY POWER TOGGLE SWITCH
TS54
RD
TS52 ENGINE START TOGGLE SWITCH
RD TS54
TS56
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
8
TS57 PLATFORM ROTATE TOGGLE SWITCH
RD TS58 JIB BOOM TOGGLE SWITCH
TS59 PLATFORM LEVEL TOGGLE SWITCH
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH
TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 87
February 2012 Section 6 • Schematics
6 - 87 6 - 88
Section 6 • Schematics February 2012
6 - 89 6 - 90
12V DC PLATFORM POWER CONNECTOR
CWLITE WH TS49
(TO SWITCH
PLATFORM
BRN JC3 BK
Y
BRN GND
RD-E-STOP C134PWR RD LS18
C1P-C4P
C134PWR RD-H1+
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
OPT.
CE LIFT/DRIVE OPTION
TS7 WH
JIB
L
RD LS18 CABLE
CR27
BRN
CR30
BK C1P-12
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
TS1 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
J
JIB
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129JDA BL C3P-10 TS8
C46HRN GR C2P-5
C59CHK BL/BK C3P-11 L47+
C59CNK BL/BK C3P-11
P26BAT BK C9-1 P2
I
C7P
C3P
F.S.
P26ESTP BK
WH/RD C1P-6
11
3
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
G
C7P
P24FS WH C40LSS OR C2P-2
C9PER BK/RD C3P-9
P24FS WH C41RPM OR/BK C2P-3
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C7P
C3P
C3P(GR)
E
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
FOR STEER ROCKER SWITCH OPTION.
C1P
9
P162JPW OR
D
C165TRS WH/RD
WIRE CONNECTS TO JC3-6
GND BRN
C164PES RD/WH C1P(GY)
P162JPW OR
C163PLS BL/WH
C7P
GND BRN
C160JPL WH/RD * NOTE:
P162JPW OR
C159STC BL/WH*
GND BRN
C
BATGRN C7P-3
GR/BK C133TTA C3P-12
B
GR/BK-L4- (CE)
D39
RD/BK-28
ALARM
Section 6 • Schematics
TILT
RD/BK-L4- RD/BK-L48- (NON-CE)
H1
C134PWR RD C2P-6
C134PWR RD LS18 RD-TILT
+
CWLITE BK
BRN
BRN
BRN BRN
A
CWLITE WH TS49
6 - 90
1
8
February 2012 Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX,
Deutz F3L-2011/Deutz D2011L03i Models (before serial number 16734)
N M L K J I H G F E D C B A
PLATFORM CONTROL
1
HARNESS (TO CONTROL BOX)
JC2 JC3
DRIVE
BOOM UP/DOWN & FORWARD/REVERSE
TURNTABLE ROTATE & STEER
LEFT/RIGHT TS48 LEFT/RIGHT
DRIVE LIGHTS/
WORK LIGHTS
DLITE RD RD
(OPTION) 2
TS15
DRIVE +
ENABLE
JC1 L48
TILT ALARM LED
BOOM (ANSI/CSA OPT.)
EXTEND/RETRACT
6 1 6 1 6 1
BK
BK
RD
5 2 5 2 5 2 3
4 3 4 3 4 3
+
L47
RETRACT CR13 +
BOOM JIB BOOM 4
RD
LED CUTOUT
BK
BRN
BK
BRN BRN BRN BRN F18 FUSE 10A
(WORK LIGHT ONLY)
BK
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
C165TRS WH/RD
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
BK
P162JPW OR
P162JPW OR
P162JPW OR
BL-DE1 J1-6
WLITE WH
WLITE WH
GND BRN
GND-BR
GND BR
WH-JIB
BRN
RD
BK
PDLITE RD
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
P24FS WH
C19JSV GR/WH
WH-JIB
C46HRN GR C2P-5
C14PLU OR C4P-2
C17PRL GR C4P-5
C129JDA BL C3P-10
C27AUX RD C1P-1
WH CR30
P25FS RD C9-3
C33STR BK C1P-7
RD
RD D12
GR 1 1 1 JC3 DRIVE/STEER PROPORTIONAL JOYSTICK
3
4 NO
NC NC NC
L1 DRIVE ENABLE LED 7
L4 PLATFORM OVERLOAD LED
TS2 L47 LOWER/RETRACT BOOM LED
TS8 TS6 TS4 2 22
TS14 L48 BOOM TILTED LED
P3 WH JIB GLOW PLUG ENGINE HIGH/LOW
TS1 HIGH/LOW TS47
HORN TS9 BOOM START RPM P2 EMERGENCY STOP BUTTON
GR/BK AUXILIARY (2WD/4WD) GENERATOR
RD
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 91
February 2012 Section 6 • Schematics
6 - 91 6 - 92
Section 6 • Schematics February 2012
6 - 93 6 - 94
(TO SWITCH
PLATFORM
CONTROL
HARNESS
WH
Y
B
BRN JC3 BR
Y
BRN GND
RD-E-STOP RD C134PWR RD LS18
B
Y
Y
Y
C134PWR RD-H1+
M
CWLITE WH TS49
GR/WH
BR
ITEM
CR13#86 GR/WH
CR14
CR27
CR30
J1
J2
J3
OPT.
C1
R
CE LIFT/DRIVE OPTION
RD OUTPUT
TS7 WH
GR/WH +
CR14
R
C134PWR RD
GR/WH
BRN -
L
RD LS18 CABLE
JIB
BRN
GR/WH RD
R
B
TILT ALARM
K
CR30
BK C1P-12
C40LS OR C2P-2
C1P-C4P
ITEM
C40LS OR J2-4
LS18
C7P
U13
H1
C1
C9
TS1 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
J
JIB
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129DA BL C3P-10 TS8
C46HRN GR C2P-5
C59CHK BL/BK C3P-11 L47+
C59CNK BL/BK C3P-11 L47+
P26BAT BK C9-1 P2
I
C7P
C3P
F.S.
P26ESTP BK
11
3
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
G
C7PBE BK C3P-7
C13DE BL/RD C4P-1
C8PBR BK/WH C3P-8
C7P
P24FS WH C40LSS OR C2P-2
C9PER BK/RD C3P-9
P24FS WH C41RPM OR/BK C2P-3
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C31REV WH/BK C1P-5
C7P
C3P
C3P(GR)
E
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
FOR STEER ROCKER SWITCH OPTION.
P162JPW OR
C1P
D
C165TRS WH/RD
WIRE CONNECTS TO JC3-5
GND BRN
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS BL/WH
C7P
GND BRN
C160JPL WH/RD
P162JPW OR
C159STC BL/WH
GND BRN
C
BATGRN C7P-3
GR/BK C133TTA C3P-12
B
GR/BK-L4- (CE)
D39
ALARM
Section 6 • Schematics
TILT
RD/BK-L48 RD/BK-L48- (NON-CE)
H1
C134PWR RD C2P-6
C134PWR RD LS18 RD-TILT
+
CWLITE BK
BRN
BRN
BRN BRN
A
CWLITE WH TS49
6 - 94
1
8
February 2012 Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX,
Deutz F3L-2011/Deutz D2011L03i Models (after serial number 16733)
N M L K J I H G F E D C B A
PLATFORM CONTROL 1
HARNESS (TO CONTROL BOX)
JC2 JC3
DRIVE
BOOM UP/DOWN & FORWARD/REVERSE
TURNTABLE ROTATE & STEER
LEFT/RIGHT TS48 LEFT/RIGHT
DRIVE LIGHTS/
WORK LIGHTS
DLITE RD RD
(OPTION)
2
TS15
+
DRIVE
ENABLE
JC1 L48
TILT ALARM LED
BOOM (ANSI/CSA OPT.)
EXTEND/RETRACT
6 1 6 1 6 1
BK
BK
RD
5 2 5
5 2 2
3
4 3 4 3 4 3
L47
RETRACT CR13
BOOM JIB BOOM + 4
RD
LED CUTOUT
BK
BRN
BK
BRN BRN BRN BRN F18 FUSE 10A
(WORK LIGHT ONLY)
BK
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
C165TRS WH/RD
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
BK
P162JPW OR
P162JPW OR
CR14-#86 RD
P162JPW OR
BL-DE1 J1-6
5
WLITE WH
WLITE WH
GND BRN
GND-BR
GND BR
WH-JIB
BRN
RD
BK
PDLITE RD
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
P24FS WH
WH-JIB
C46HRN GR C2P-5
C14PLU OR C4P-2
C17PRL GR C4P-5
C129JDA BL C3P-10
C27AUX RD C1P-1
WH CR30
P25FS RD C9-3
C33STR BK C1P-7
RD
RD D12
GR 1 1 1 JC3 DRIVE/STEER PROPORTIONAL JOYSTICK
4 3
NO
NC NC NC
L1
L4
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
7
TS2 L47 LOWER/RETRACT BOOM LED
TS8 TS6 TS4 2 22
TS14 L48 BOOM TILTED LED
P3 WH JIB GLOW PLUG ENGINE HIGH/LOW
TS1 HIGH/LOW TS47
HORN TS9 BOOM START RPM P2 EMERGENCY STOP BUTTON
GR/BK AUXILIARY (2WD/4WD) GENERATOR
RD
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 6 - 95
February 2012 Section 6 • Schematics
6 - 95 6 - 96
Section 6 • Schematics February 2012
6 - 97 6 - 98
Circuit breaker
BRN
RD
RD
P24FS WH
C28TTA RD/BK
serial number
C41RPM OR/BK
P134 RD
P26ESTP BK
P22LS BK
added after
CR4
N
TB35
ES0194H
19405
D12
FOOTSW. LOW
D13
BK/RD C5-18
HIGH RPM SOLENOID
ENGINE
D4
D3
TS54
SPEED
CR4
NO
Q3
D14
LOW RPM
HIGH RPM
FUNCTION
G1
GENERATOR
TS47
TS48
DRIVE LIGHT
CR23
RD
DRIVE LIGHT OPTION
FUSE
L29
10A
L30
WORK LIGHT
TS49
RD
TB21
PBOX GND
C2P-11 C2P-9
K
F18
L30
TB34
TS6
PLUG
NO
GLOW
J
GLOW PLUGS
PLUG
FUSE
70A
number 16733
ENGINE
FAULT
L2
3 START INPUT IGNITION/
MODULE
START
U1
I
SW3
2 TACHOMETER
NO
1 START RELAY
9 IGN./FUEL ON
TB26
8 KEY BYPASS
10 ENG. FAULT
TS2
7 KEY PWR.
6 BATTERY
5 GROUND
C33STR BK C1B-7
4 AUX. ON
D33
TB25
START
ENGINE C5-16 C25PS WH/BK OIL PRESSURE SWITCH
START BK
SW2
TB33
NC
H
POWER RELAY
TB21
CR2
P24FS WH
P25FS RD
C21IGN2 WH C5-11
TS1
FUEL SOLENOID
NO
AUX
PUMP C1P-1 C27AUX RD C1B-1
C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
G
_
IGN./START RELAY
CR1
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
NO
STARTER
STARTER MOTOR
FS1
AUXILIARY
POWER
BK-(FS)
TS51
CR19
F
February 2012
PUMP RD C27AUX RD
C9P-1 BK
PR1
NO
P2
D2
L48
PUMP
AUX
AUXILIARY PUMP
RD/BK C1P-2 WH
M2
number 16733
TB28
D40
E
RD/BK
C
After serial
C1B-2
C28TTA RD/BK WH
H1
C28TTA RD/BK
TILT ALARM
P134TTSR RD RD BK BRN
LEVEL SENSOR
C3B-12
B
RD
S8
TB46
C2B-5
C2P-5 C46HRN GR C46HRN GR HORN RELAY
P3
Electrical Schematic, S-60 and S-60 TRAX,
H2
NO
C7P-1 P22BAT BK C7B-1
TB133
P22BAT BK F.H. BK
D
HORN
TB132
8
C1P-12 C132PLI BL/WH C1B-12 5
TB134
FB1
3
C32
P134FB WH FLASHING BEACONS
C2P-6 P134PWR GR/BK C2B-6
OPTION
1
12
4
6
TB134
RD
CR17
SW4
NO
BK
C
86
85
C21IGN WH R21IGN WH C5-4
TB22
WH
SWITCH (OPTION)
RD
87a 87
30
P116HYD RD
C41RPM OR/BK
PLAT
GRD
FAN
R116 OR C5-1 COOLING FAN
KS1
(OPTION)
C5-3
M1
TB41
C41RPM OR/BK C2B-3 C41RPM OR/BK C5-2
Perkins 404-22 Models
W
B
D22
RD
EXCT.
STA.
C21IGN WH
BAT.
IND.
P1
RD
RD
-
Section 6 • Schematics
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
TB20
A
-
RD C7B-4 P20BAT RD
12V DC
B1
6 - 98
1
8
1
8
Section 6 • Schematics
6 - 99
Electrical Schematic, S-60 and S-60 TRAX,
TB31
LOW DRIVE
(HIGH TORQUE)
H4
8
MODE
(OPTION)
HIGH DRIVE
(LOW TORQUE)
B
TB32
C26-1 C26-2
C1P-6 C32BRK WH/RD C1B-6 C5-23 C32BRK WH/RD
ROCKER STEER OPTION ONLY.
19 BRAKE RELEASE
TB29
C28-1 C28-2
C1P-3 C29MS RD/WH C1B-3 C5-24 C29MS RD/WH
20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
TS15
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
RIGHT C1P-10 C36STCC BL C1B-10 C36SCC BL
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
C28TTA RD/BK
TB36
P26ESTP BK
P24FS WH
TB4
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
P162JPW OR
D
C15-1 C15-2
D9
DRIVE FORWARD/REVERSE &
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
1
6
R OUT 5
X OUT 3
PWR 2
Y OUT 4
TS62
7.5W
R4
CR19
GND
TB6
C31-1 C31-2
JC3
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
1 C13-1 C13-2
CR34
February 2012
J2
R14
5W
11
TB3
C164PES RD/WH
C165TRS WH/RD
R16
10W
P162JPW OR
C3PBF RD/WH
PRIMARY BOOM FLOW CONTROL
12
C29-1 C29-2
C3P-1 C1PBU RD C3B-1
J1
6
BR
TURNTABLE ROTATE
TB2
BOOM UP/DOWN &
X OUT 3
PWR 2
Y OUT 4
7
JC2
TB9
3 C30-1 C30-2
C3P-9 C9PER BK/RD C3B-9 C9PER BK/RD PRIMARY BOOM EXTEND/RETRACT
14
9 FLOW CONTROL
C163PLS BL/WH
13
10
C3P-7 C7PBE BK C3B-7 LS5 CABLE TENSION LIMIT SWITCH
12
NC
TB7
BR
21
22
EXTEND/RETRACT
RD RD BR C7PBE BK
G
PRIMARY BOOM
BOOM EXTEND
GND 1
6
PWR 2
Y OUT 4
EXTEND
J1
RETRACT
JC1
TS63
C8PBR BK/WH
U13 JOYSTICK CONTROL CARD
BOOM RETRACT
TB8
C17-1 C17-2
BRN
NO
HC
1
C4P-4 C118LSR OR/RD C4B-4 OR/RD C38-3 BK WH C38-4 LS17-BOOM UP/DOWN
1
SPEED REDUCTION LIMIT SWITCH
13
14
P24FS WH
TB118
2
LS17
BK
TB13
P24FS WH
H
NO
J3
HC
4
C4P-1 C13DE BL/RD C4B-1 BL/RD C9-1 BK WH C9-2 LS3-DRIVE ENABLE LIMIT SWITCH
3
13
14
P26ESTP BK
3
TB22
LS3
C2P-2
NO
HC
4
C11-2 WH BK C11-1 LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
13
14
LS1
NO
HC