Genie s60

Introduction February 2012
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie offers the following Service Manuals for
operating instructions in the Genie S-60 and Genie these models:
S-65 Operator's Manual or the Genie S-60 HC
Operator's Manual before attempting any Title Part No.
maintenance or repair procedure.
S-60 and S-65 Service Manual
This manual provides detailed scheduled
(before serial number 2575) ................................. 34476
maintenance information for the machine owner
and user. It also provides troubleshooting fault S-60 and S-65 Service Manual
codes and repair procedures for qualified service (from serial number 2575 to 6623) ....................... 48412
professionals.
S-60 and S-65 Service Manual
Basic mechanical, hydraulic and electrical skills are (from serial number 6624 to 9153) ....................... 65196
required to perform most procedures. However,
several procedures require specialized skills, tools, S-60 and S-65 Service Manual
lifting equipment and a suitable workshop. In these (from serial number 14782 to 21000) ................ 139188
instances, we strongly recommend that
maintenance and repair be performed at an S-60, S-65, S60 HC and TRAX Service Manual
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 Copyright © 2011 Terex Corporation
and send in suggestions for improvement. All
77828 Rev E February 2012
communications will be carefully considered for Fourth Edition, Fifth Printing
future printings of this and all other manuals.
"Genie" and "S" are registered trademarks of
Terex South Dakota, Inc. in the USA and many
Contact Us: other countries.
Printed on recycled paper

http://www.genielift.com
e-mail: awp.techpub@terex.com Printed in U.S.A.
ii S-60 • S-65 • S-60 HC Part No. 77828

February 2012
Revision History
Revision Date Section Procedure / Schematic Page / Description
E 2/2012 Introduction Revision History Added
3 - Maint. 3-1
E1 1/2013 3 - maint. 3-6, E-4
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications. Electronic Version

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

February 2012
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications. Electronic Version

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

February 2012
Serial Number Legend
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
Rated work load (including occupants): 500 lb / 227 kg

Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
Air Tires 2 deg / Foam Tires 4.5 deg S60 05 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 60 ft 2 in/ 18.3 m
Model Sequence
Maximum platform reach : 50 ft 4 in/ 15.3 m
number
Gradeability: 45%
Country of manufacture: USA Model year
This machine complies with:
ANSI A92.5
CAN B.354.4
Terex South Dakota, Inc.

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

Failure to obey the instructions and safety rules in manual and the decals on the machine
this manual, and the Genie S-60 and Genie S-65 use signal words to identify the following:
Operator's Manual or the Genie S-60 HC
Safety alert symbol—used to alert
Operator's Manual will result in death or serious
personnel to potential personal
injury.
injury hazards. Obey all safety
Many of the hazards identified in the operator's messages that follow this symbol
manual are also safety hazards when maintenance to avoid possible injury or death.
and repair procedures are performed.
Indicates an imminently hazardous
situation which, if not avoided, will
Do Not Perform Maintenance result in death or serious injury.
Unless:
Indicates a potentially hazardous
You are trained and qualified to perform situation which, if not avoided,
maintenance on this machine. could result in death or serious
injury.
You read, understand and obey:
- manufacturer’s instructions and safety rules Indicates a potentially hazardous
- employer’s safety rules and worksite situation which, if not avoided,
regulations may result in minor or moderate
- applicable governmental regulations injury.
You have the appropriate tools, lifting Indicates a potentially hazardous

equipment and a suitable workshop. situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
vi S-60 • S-65 • S-60 HC Part No. 77828

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.
Be sure that all tools and working areas

are properly maintained and ready for use.
Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area is

properly ventilated and well lit.
Part No. 77828 S-60 • S-65 • S-60 HC vii

February 2012
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Revision History .......................................................................................................... iii
Serial Number Legend ................................................................................................. v
Section 1 Safety Rules

General Safety Rules .................................................................................................. vi
Section 2 Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................ 2 - 3
Manifold Component Specifications ....................................................................... 2 - 4
GM 3.0L Engine Specifications .............................................................................. 2 - 5
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7
Deutz F3L-2011 Engine Specifications ................................................................... 2 - 8
Perkins 404-22 Engine Specifications .................................................................. 2 - 10
Machine Torque Specifications ............................................................................ 2 - 11
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 12
SAE and Metric Fasteners Torque Charts ............................................................ 2 - 13
viii S-60 • S-65 • S-60 HC Part No. 77828

February 2012
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................. 3 - 8
A-3 Perform Function Tests ................................................................................ 3 - 8
A-4 Perform Engine Maintenance ....................................................................... 3 - 9
A-5 Check the High Pressure Hydraulic Filter Condition Indicator ....................... 3 - 9
A-6 Test the Oscillate Axle (if equipped) ........................................................... 3 - 10
A-7 Perform 30 Day Service ............................................................................. 3 - 10
A-8 Inspect the Engine Air Filter - GM Models .................................................. 3 - 11
A-9 Perform Engine Maintenance - GM, Ford and Perkins Models .................... 3 - 11
A-10 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12
A-11 Check and Adjust the Engine RPM - Perkins Models ................................. 3 - 14
A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 15
A-13 Replace the Drive Hub Oil .......................................................................... 3 - 15
A-14 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 16
A-15 Perform Engine Maintenance - Perkins Models .......................................... 3 - 16
Part No. 77828 S-60 • S-65 • S-60 HC ix

February 2012
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued

Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 17
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 18
B-3 Check the Exhaust System ....................................................................... 3 - 19
B-4 Inspect the Engine Air Filter - Ford, Deutz and Perkins Models .................. 3 - 20
B-5 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 20
B-6 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 21
B-7 Confirm the Proper Brake Configuration ...................................................... 3 - 22
B-8 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 22
B-9 Check and Adjust the Engine RPM - Ford and Deutz Models ..................... 3 - 24
B-10 Test the Ground Control Override ............................................................... 3 - 25
B-11 Check the Oscillate Directional Valve Linkage ........................................... 3 - 26
B-12 Test the Platform Self-leveling ................................................................... 3 - 26
B-13 Test the Engine Idle Select ........................................................................ 3 - 27
B-14 Test the Fuel Select Operation - GM and Ford Models ............................... 3 - 28
B-15 Test the Drive Brakes ................................................................................ 3 - 29
B-16 Test the Drive Speed - Stowed Position ..................................................... 3 - 30
B-17 Test the Drive Speed - Raised or Extended Position .................................. 3 - 30
B-18 Test the Alarm Package - Optional Equipment ........................................... 3 - 31
B-19 Perform Hydraulic Oil Analysis ................................................................... 3 - 32
B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 33
B-21 Replace the Fuel Filter Element - Perkins Models ...................................... 3 - 34
B-22 Inspect the Boom Extend/Retract Cables ................................................... 3 - 35
B-23 Perform Engine Maintenance - Deutz Models ............................................. 3 - 37
B-24 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 37
B-25 Replace the Engine Air Filter Element - GM and Ford models .................... 3 - 38
B-26 Perform Engine Maintenance - Perkins Models .......................................... 3 - 38
x S-60 • S-65 • S-60 HC Part No. 77828

February 2012
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued

Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models ............................................. 3 - 39
C-2 Grease the Platform Overload Mechanism, S-60 and S-65 (if equipped) ..... 3 - 39
C-3 Test the Platform Overload System, S-60 and S-65 (if equipped) ............... 3 - 40
C-4 Test the Platform Load Sense System, S60 HC ........................................ 3 - 43
C-5 Replace the Fuel Filter/Water Separator Element - Perkins Models ............ 3 - 45
C-6 Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 47
C-7 Perform Engine Maintenance - Perkins Models .......................................... 3 - 47
C-8 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 48
Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 49
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 50
D-3 Inspect for Turntable Bearing Wear ............................................................ 3 - 51
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 52
D-5 Check the Free-wheel Configuration ........................................................... 3 - 53
D-6 Replace the Hydraulic Filters ...................................................................... 3 - 54
D-7 Check and Adjust the Air/LPG Mixture - GM Models .................................. 3 - 56
D-8 Perform Engine Maintenance - Deutz Models ............................................. 3 - 57
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 58
E-2 Perform Engine Maintenance - Deutz Models ............................................. 3 - 60
E-3 Perform Engine Maintenance - Deutz Models ............................................. 3 - 60
E-4 Remove and Inspect the Boom Extend/Retract Cables .............................. 3 - 61
Part No. 77828 S-60 • S-65 • S-60 HC xi

February 2012
TABLE OF CONTENTS
Section 4 Repair Procedures

Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1 ALC-500 Circuit Board .................................................................................. 4 - 2
1-2 Joysticks ..................................................................................................... 4 - 3
Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 8
2-2 Platform Rotator ........................................................................................... 4 - 9
2-3 Platform Overload System, S-60 and S-65 (if equipped) ............................. 4 - 12
2-4 Platform Load Sense System, S-60 HC ..................................................... 4 - 14
Jib Boom Components, S-65
3-1 Jib Boom .................................................................................................... 4 - 18
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 19
Boom Components
4-1 Cable Track ................................................................................................ 4 - 20
4-2 Boom ......................................................................................................... 4 - 26
4-3 Boom Lift Cylinder ...................................................................................... 4 - 28
4-4 Boom Extension Cylinder ........................................................................... 4 - 29
4-5 Boom Extend/Retract Cables ..................................................................... 4 - 32
4-6 Platform Leveling Master Cylinder .............................................................. 4 - 35
xii S-60 • S-65 • S-60 HC Part No. 77828

February 2012
TABLE OF CONTENTS
Section 4 Repair Procedures, continued

Engines
5-1 RPM Adjustment - Ford and Deutz Models ................................................ 4 - 36
5-2 RPM Adjustment - Perkins Models ............................................................. 4 - 36
5-3 Flex Plate ................................................................................................... 4 - 36
5-4 Engine Fault Codes - GM and Ford Models ................................................ 4 - 43
Hydraulic Pumps
6-1 Function Pump ........................................................................................... 4 - 44
6-2 Drive Pump ................................................................................................ 4 - 45
Manifolds
7-1 Function Manifold Components .................................................................. 4 - 49
7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 53
7-3 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 54
7-4 Brake/Two-speed Manifold Components .................................................... 4 - 55
7-5 Turntable Rotation Manifold Components ................................................... 4 - 56
7-6 Oscillate Directional Valve Components ..................................................... 4 - 57
7-7 Valve Adjustments - Oscillate Relief Valve ................................................ 4 - 59
7-8 Drive Oil Diverter Manifold Components (welder option) ............................. 4 - 60
7-9 Traction Manifold Components, 2WD ......................................................... 4 - 61
7-10 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 63
7-11 Traction Manifold Components, 4WD ......................................................... 4 - 65
7-12 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 67
7-13 Valve Coils ................................................................................................. 4 - 68
Turntable Rotation Components
8-1 Turntable Rotation Assembly ..................................................................... 4 - 70
Axle Components
9-1 Oscillate Axle Cylinders ............................................................................. 4 - 72
Part No. 77828 S-60 • S-65 • S-60 HC xiii

February 2012
TABLE OF CONTENTS
Section 5 Fault Codes

Introduction ............................................................................................................ 5 - 1
Fault Codes - Control System ................................................................................ 5 - 2
Fault Codes - Ford LRG-425 EFI Engine ................................................................ 5 - 6
Fault Codes - Ford DSG-423 EFI Engine ............................................................. 5 - 12
Fault Codes - Platform Load Sense System, S-60 HC ......................................... 5 - 16
Section 6 Schematics
Introduction ............................................................................................................ 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 (from serial number 12800) ............................................................. 6 - 7
Chassis Wiring Diagram,
Ground Control Box Terminal Strip Wiring Diagram,
Platform Control Box Wiring Diagram,
S-60 HC (from serial number 12800) ........................................................... 6 - 10
GM 3.0L Engine Harness ..................................................................................... 6 - 11
Ford LRG-425 EFI Engine Harness ...................................................................... 6 - 12
Ford DSG-423 EFI Engine Harness ..................................................................... 6 - 13
xiv S-60 • S-65 • S-60 HC Part No. 77828

February 2012
TABLE OF CONTENTS
Section 6 Schematics, continued

Electrical Schematic, S-60, GM 3.0L Models ....................................................... 6 - 14
S-60, GM 3.0L Models ............................................................................... 6 - 16
Ground Control Box Switch Panel Wiring Diagram,
S-60, GM 3.0L Models ............................................................................... 6 - 17
Platform Control Box Terminal Strip Wiring Diagram,
S-60, GM 3.0L Models ............................................................................... 6 - 18
Platform Control Box Switch Panel Wiring Diagram,
S-60, GM 3.0L Models ............................................................................... 6 - 19
Electrical Schematic, S-65, GM 3.0L Models ....................................................... 6 - 20
S-65, GM 3.0L Models ............................................................................... 6 - 22
S-65, GM 3.0L Models ............................................................................... 6 - 23
S-65, GM 3.0L Models ............................................................................... 6 - 24
S-65, GM 3.0L Models ............................................................................... 6 - 25
Electrical Schematic, S-60, Ford LRG-425 EFI Models
(before serial number 11880) ...................................................................... 6 - 26
(from serial number 11880 to 14053) .......................................................... 6 - 28
Electrical Schematic, S-60, Ford DSG-423 EFI Models
(after serial number 14053) ......................................................................... 6 - 30
S-60, Ford LRG-425 EFI Models (before serial number 11880) ................... 6 - 32
Part No. 77828 S-60 • S-65 • S-60 HC xv

February 2012
TABLE OF CONTENTS

S-60, Ford Models (after serial number 11879) ........................................... 6 - 34
S-60, Ford Models ...................................................................................... 6 - 36
S-60, Ford Models ...................................................................................... 6 - 37
(from serial number 11880 to 14053) .......................................................... 6 - 40
Electrical Schematic, S-65, Ford DSG-423 EFI Models
S-65, Ford Models ...................................................................................... 6 - 48
S-65, Ford Models ...................................................................................... 6 - 49
xvi S-60 • S-65 • S-60 HC Part No. 77828

February 2012
TABLE OF CONTENTS

Electrical Schematic, S-60, Deutz F3L-2011 Models
Electrical Schematic, S-60, CE Models, Deutz F3L-2011 Models
S-60, Deutz F3L-2011 Models (before serial number 11880) ....................... 6 - 58
S-60, Deutz F3L-2011 Models (after serial number 11879) ......................... 6 - 60
S-60, CE Models, Deutz F3L-2011 Models
S-60, Deutz F3L-2011 Models .................................................................... 6 - 66
S-60, Deutz F3L-2011 Models .................................................................... 6 - 67
Part No. 77828 S-60 • S-65 • S-60 HC xvii

February 2012
TABLE OF CONTENTS

xviii S-60 • S-65 • S-60 HC Part No. 77828

February 2012
TABLE OF CONTENTS

S-65, Deutz F3L-2011 Models .................................................................... 6 - 84
S-65, Deutz F3L-2011 Models .................................................................... 6 - 85
Electrical Schematic, S-60, Perkins 404-22 Models
S-60, Perkins 404-22 Models (before serial number 11880) ........................ 6 - 90
S-60, Perkins 404-22 Models (before serial number 11880) ........................ 6 - 91
S-60, Perkins 404-22 Models (after serial number 11879) ........................... 6 - 92
S-60, Perkins 404-22 Models (after serial number 11879) ........................... 6 - 93
S-60, Perkins 404-22 Models ..................................................................... 6 - 94
S-60, Perkins 404-22 Models ..................................................................... 6 - 95
S-65, Perkins 404-22 Models (before serial number 11880) ....................... 6 - 100
S-65, Perkins 404-22 Models (before serial number 11880) ....................... 6 - 101
Part No. 77828 S-60 • S-65 • S-60 HC xix

February 2012
TABLE OF CONTENTS

S-65, Perkins 404-22 Models (after serial number 11879) .......................... 6 - 102
S-65, Perkins 404-22 Models (after serial number 11879) .......................... 6 - 103
S-65, Perkins 404-22 Models .................................................................... 6 - 104
S-65, Perkins 404-22 Models .................................................................... 6 - 105
Belt Driven Generator Wiring Diagram ................................................................. 6 - 106
12kW Hydraulic Generator Option Wiring Diagram .............................................. 6 - 107
Hydraulic Schematic, 12kW Hydraulic Generator Option ..................................... 6 - 108
Hydraulic Schematic, 2WD Models ..................................................................... 6 - 109
Hydraulic Schematic, 4WD Models ..................................................................... 6 - 110
xx S-60 • S-65 • S-60 HC Part No. 77828

February 2012 Section 2 • Specifications
Specifications
Machine Specifications Fluid capacities
Fuel tank 35 gallons
Tires and wheels
151 liters
Tire size LPG tank 33.5 pounds
(Rough terrain, low profile) 355/55D625 15.2 kg
Tire size Hydraulic tank 45 gallons
(Rough terrain, tall) 385-19.5 170 liters
Tire size Hydraulic system 55 gallons
(Hi-flotation) 41/18LL x 22.5 (including tank) 208 liters
Tire ply rating Drive hubs 20 fl oz
(Rough terrain, low profile and Hi-flotation) 14 0.6 liters
Tire ply rating Turntable rotation drive hub 40 fl oz

(Rough terrain, tall) 16 1.19 liters
Drive hub oil type:
Wheel lugs 9 @ 5/8 -18 SAE 90 multipurpose hypoid gear oil API service
classification GL5
Lug nut torque, dry 240 ft-lbs
325 Nm
Lug nut torque, lubricated 180 ft-lbs

244 Nm
Overall tire diameter 36.9 in

(Rough terrain, low profile tires) 93.7 cm

(Rough terrain, tall tires) 102 cm

(Hi-flotation tires) 102.4 cm
Tire pressure 70 psi

(Rough terrain, low profile tires) 4.92 bar

(Rough terrain, tall tires) 5.9 bar

(Hi-flotation tires) 4.13 bar
For operational specifications, refer to the

Operator's Manual.
Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.
Part No. 77828 S-60 • S-65 • S-60 HC 2-1

Section 2 • Specifications February 2012
SPECIFICATIONS
Performance Specifications
Boom function speeds, maximum
from platform controls
Jib boom up, S-65 60 to 70 seconds
Jib boom down, S-65 40 to 50 seconds
Boom up 60 to 70 seconds
Boom down 60 to 70 seconds
Boom extend 58 to 66 seconds
Boom retract 53 to 62 seconds
Turntable rotate, 360° 78 to 86 seconds

boom stowed
Turntable rotate, 360° 125 to 165 seconds

boom raised or extended
Platform rotate, 160° 8 to 12 seconds
Braking distance, maximum
High range on paved surface 3 to 6 ft

0.9 to 1.8 m
Drive speed, maximum

stowed position
2WD models 40 ft / 6.2 sec

12.2 m / 6.2 sec
4WD models 40 ft / 7.6 sec

12.2 m / 7.6 sec
Drive speed, maximum

raised or extended position
All models 40 ft / 40 sec

12.2 m / 40 sec
Gradeability See Operator's Manual

Genie policy. Product specifications are subject
to change without notice.
2-2 S-60 • S-65 • S-60 HC Part No. 77828

SPECIFICATIONS
Hydraulic Specifications Drive pump
Hydraulic Oil Specifications Type: bi-directional, variable

displacement piston pump
Hydraulic oil type Chevron Rando HD MV equivalent
Viscosity grade Multi-viscosity Flow rate @ 2500 rpm 32.4 gpm
Viscosity index 200 122.6 L/min
Cleanliness level, minimum 15/13 Drive pressure, maximum 3750 psi

259 bar
Water content, maximum 200 ppm
Charge pump
Chevron Rando HD MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils. Type: gerotor
Genie specifications require hydraulic oils which are Displacement 0.85 cu in
designed to give maximum protection to hydraulic 13.9 cc
systems, have the ability to perform over a wide
temperature range, and the viscosity index should Flow rate @ 2500 rpm 9.2 gpm
exeed 140. They should provide excellent antiwear, 34.8 L/min
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties. Charge pressure @ 2500 rpm 310 psi
21.4 bar
Optional fluids
Function pump
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32 Type: 2 section tandem gear pump
BP Biohyd SE-S
Displacement - Pump 1 (inner) 1.4 cu in
Fire resistant UCON Hydrolube HP-5046 23 cc
Quintolubric 822
Flow rate @ 2500 rpm 15.3 gpm
Mineral based Shell Tellus T32 58 L/min
Shell Tellus T46
Chevron Aviation A Displacement - Pump 2 (outer) 0.24 cu in
(oscillate models) 4 cc
Flow rate @ 2500 rpm 2 gpm

Continued use of Chevron Aviation 7.6 L/min
A hydraulic oil when in ambient
temperatures consistently below Auxiliary pump
0°F / -18°C may result in
Type: gear, fixed displacement
component damage.
Displacement 1.75 gpm
Note: Use Chevron Aviation A hydraulic oil when in 2.8 L/min
ambient temperatures consistently below 0°F / -
18°C.
Note: Use Shell Tellus T46 hydraulic oil when oil

temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for Continuous improvement of our products is a
the approved optional fluids. Consult the Genie Genie policy. Product specifications are subject
Service Department before use. to change without notice.
Part No. 77828 S-60 • S-65 • S-60 HC 2-3

SPECIFICATIONS
Function manifold Manifold Component

System relief valve pressure 3000 psi Specifications
207 bar
Plug torque
Steer flow regulator 3.5 gpm
13.2 L/min SAE No. 2 36 in-lbs / 4 Nm
Jib boom / platform rotate 0.6 gpm SAE No. 4 10 ft-lbs / 13 Nm

flow regulator 2.27 L/min
SAE No. 6 14 ft-lbs / 19 Nm
Oscillate relief valve pressure (@ 2500 rpm) 800 psi
55 bar SAE No. 8 38 ft-lbs / 51 Nm
Drive manifold SAE No. 10 41 ft-lbs / 55 Nm
Hot oil relief valve pressure 280 psi SAE No. 12 56 ft-lbs / 76 Nm
19.3 bar
Drive motors, 4WD models Valve coil resistance specifications

Displacement per revolution, 0.79 cu in Solenoid valve, 3 position 4 way, 10V DC 5 to 7Ω
high speed 13 cc (schematic items D, V and Y)
Displacement per revolution, 1.83 cu in Solenoid valve, 3 position 4 way, 10V DC 4 to 6Ω
low speed 30 cc (schematic item BB)
Drive motors, 2WD models Solenoid valve, 2 position 3 way, 10V DC 5 to 7Ω
Displacement per revolution, 1.28 cu in (schematic items B, C, E, F and FF)
high speed 20.9 cc Solenoid valve, 2 position 3 way, 10V DC 5.5 to 7.5Ω
Displacement per revolution, 2.14 cu in (schematic items KK and LL)
low speed 35 cc Proportional solenoid valve, 12V DC 4 to 6Ω
Hydraulic filters (schematic items M and T)
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
Medium pressure filter Beta 3 ≥ 200
Medium pressure filter 51 psi

bypass pressure 3.5 bar
Hydraulic return filter 10 micron with

25 psi / 1.7 bar bypass

2-4 S-60 • S-65 • S-60 HC Part No. 77828

SPECIFICATIONS
GM 3.0L EFI Engine Starter motor
Displacement 181 cu in Normal engine cranking speed 350 rpm

3 liters Current draw, normal load 400A
Number of cylinders 4 Current draw, maximum load 600A
Bore & stroke 4 x 3.6 inches Current draw, minimum 100A
101.6 x 91.44 mm
Battery
Horsepower
Intermittent 67 @ 2300 rpm Type 12V DC
50 kW @ 2300 rpm
Group 31
Continuous 60 @ 2300 rpm
45 kW @ 2300 rpm Quantity 1
Firing order 1-3-4-2 Cold cranking ampere @ 0°F 1000A
Low idle 1650 rpm Reserve capacity @ 25A rate 200 minutes
386 Hz
Electronic fuel pump
High idle 2500 rpm
585 Hz Fuel pressure, static 9 to 11 psi
0.6 to 0.76 bar
Compression ratio 9.25:1
Fuel flow rate 0.3 gpm
Compression pressure - minimum 100 psi 1.14 L/min
Pressure (psi or bar) of lowest cylinder 6.9 bar
must be at least 75% of highest cylinder Fuel requirement
Valve clearances Zero lash + 1 full turn For fuel requirements, refer to the engine Operator's
Manual on your machine.
Lubrication system
Ignition system
Oil pressure, minimum 18 psi
(operating temp. @ 2000 rpm) 1.24 bar Spark plug type AC ACMR-43-LTS
Oil capacity 5 quarts Spark plug gap 0.040 inches

(including filter) 4.7 liters 1.01 mm
Oil viscosity requirements Engine coolant
Below 0° F / -17.8° C 5W-30 Capacity 12 quarts

11.4 liters
Above 0° F / -17.8° C 10W-30
Alternator output 66A @ 12V DC
Extreme operating temperatures may require the use of
Fan belt deflection 1/2inch
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine. 12 mm

Part No. 77828 S-60 • S-65 • S-60 HC 2-5

SPECIFICATIONS
Ford LRG-425 EFI Engine Electronic fuel pump
Displacement 153 cu in Fuel pressure, static 63 psi

2.5 liters 4.3 bar
Number of cylinders 4 Fuel flow rate 0.58 gpm

2.2 L/min
Bore & stroke 3.78 x 3.4 inches
96.01 x 86.36 mm
Horsepower 70 @ 2500 rpm Fuel requirement

52 kW @ 2500 rpm For fuel requirements, refer to the engine Operator's
Firing order 1-3-4-2 Manual on your machine.
Low function idle (computer controlled) 1600 rpm Ignition system

395 Hz Spark plug type Motorcraft AGSF-32-FM
High function idle (computer controlled) 2500 rpm Spark plug gap 0.042 to 0.046 inches
620 Hz 1.07 to 1.17 mm
Compression ratio 9.4:1 Engine coolant
Compression pressure (approx.) Capacity 11.5 quarts
Pressure (psi or bar) of lowest cylinder must be 10.9 liters
at least 75% of highest cylinder
Coolant temperature switch
Valve clearances - 0.035 to 0.055 inches
collapsed tappet 0.889 to 1.397 mm Temperature switch point 230°F
110°C
Lubrication system
Starter motor
Oil pressure 40 to 60 psi
(operating temperature @ 2500 rpm) 2.75 to 4.1 bar Normal engine cranking speed 200 to 250 rpm
Oil capacity 4.5 quarts Current draw, normal load 140-200A
(including filter) 4.3 liters
Current draw, maximum load 800A
Oil pressure switch
Alternator
Oil pressure switch point 7.5 psi
0.51 bar Output 95A, 14.5V DC
Oil viscosity requirements Battery
Extreme operating temperatures may require the use of Type 12V DC, Group 31
Engine Operator Handbook on your machine. Quantity 1
Cold cranking ampere @ 0°F 1000A
Reserve capacity @ 25A rate 200 minutes

2-6 S-60 • S-65 • S-60 HC Part No. 77828

SPECIFICATIONS
Ford DSG-423 EFI Engine Electronic fuel pump
Displacement 140.4 cu in Fuel pressure, static 64 psi

2.3 liters 4.4 bar
Number of cylinders 4 Fuel flow rate 0.43 gpm

1.6 L/min
Bore & stroke 3.44 x 3.7 inches
87.5 x 94 mm Fuel requirement
Horsepower 59 @ 2500 rpm For fuel requirements, refer to the engine Operator's
44 kW @ 2500 rpm Manual on your machine.
Firing order 1-3-4-2 Ignition system
Low function idle (computer controlled) 1600 rpm Spark plug type Motorcraft AGSF-32-FEC
53 Hz Spark plug gap 0.049 to 0.053 inches
High function idle (computer controlled) 2500 rpm 1.244 to 1.346 mm
83 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
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
Engine Operator Handbook on your machine. Battery
Type 12V DC, Group 31
Quantity 1
Cold cranking ampere @ 0°F 1000A

Part No. 77828 S-60 • S-65 • S-60 HC 2-7

SPECIFICATIONS
Deutz F3L 2011 Engine Oil viscosity requirements
Displacement 142 cu in -22° F to 86° F/ -30° C to 30° C 5W-30

2.33 liters (synthetic)
Number of cylinders 3 -4° F to 90° F / -20° C to 32° C 10W-40
Bore and stroke 3.7 x 4.4 inches Above 23° F / -5° C 20W-50
94 x 112 mm Units ship with 15W-40.
Horsepower 48 @ 2800 rpm Extreme operating temperatures may require the use of
36 kW @ 2800 rpm alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Firing order 1-2-3
Oil temperature switch
Low idle 1500 rpm
313 Hz Temperature switch point 300°F
149°C
High idle 2500 rpm
522 Hz Oil pressure switch
Compression ratio 19:1 Oil pressure switch point 7 psi

0.48 bar
Compression pressure 362 to 435 psi
25 to 30 bar Fuel injection system
Injection pump make Bosch

Governor centrifugal mechanical
Injection pump pressure, maximum 15000 psi
Valve clearance, cold
1034 bar
Intake 0.012 in
Injector opening pressure 3046 psi
0.3 mm
210 bar
Exhaust 0.020 in
Fuel requirement
0.5 mm
For fuel requirements, refer to the engine Operator's
Lubrication system
Manual on your machine.
Oil pressure 20 to 44 psi
Starter motor
1.4 to 3 bar
Current draw, no load 90A
Oil capacity 8.5 quarts
(including filter) 8 liters Brush length, new 0.72 in
18.5 mm
Brush length, minimum 0.27 in

7 mm

2-8 S-60 • S-65 • S-60 HC Part No. 77828

SPECIFICATIONS
Battery
Type 12V DC
Size 13 x 613/16 x 93/8 inches

33 x 17.3 x 23.8 cm
Quantity 1
Cold cranking ampere 1000A
Fan belt deflection 3/8 to 1/2 inch

9 to 12 mm
Part No. 77828 S-60 • S-65 • S-60 HC 2-9

SPECIFICATIONS
Perkins 404-22 Engine Lubrication system
Displacement 134 cu in Oil pressure, cold 60 psi

2.2 liters (at 2500 rpm) 4.1 bar
Number of cylinders 4 Oil capacity 9.3 quarts

Bore and stroke 3.31 x 3.94 inches
84 x 100 mm Oil viscosity requirements
Horsepower 51 @ 2500 rpm Below 86°F / 30°C 5W-20

38 kW @ 2500 rpm -4°F to 104°F / -20°C to 40°C 10W-30
Firing order 1-3-4-2 Above 14°F / -10°C 15W-40
Low idle 1300 rpm Units ship with 15W-40.
201 Hz Extreme operating temperatures may require the use of
High idle 2500 rpm alternative engine oils. For oil requirements, refer to the
231 Hz Engine Operator Handbook on your machine.
Compression ratio 23.3:1 Oil pressure sending unit
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
Fan belt deflection 3/8 in

10 mm
Starter motor
Current draw, no load 90A
Brush length, new 0.7480 in

19 mm
Brush length, minimum 0.5 in

12.7 mm

2 - 10 S-60 • S-65 • S-60 HC Part No. 77828

SPECIFICATIONS
Battery Machine Torque Specifications

Type 12V DC Platform rotator
Size 13 x 613/16 x 93/8 inches 1-8 center bolt, GR 8 480 ft-lbs
33 x 17.3 x 23.8 cm 651 Nm
Quantity 1 3/8 -16 bolts, GR 8 44 ft-lbs
Cold cranking ampere 1000A 60 Nm
Reserve capacity @ 25A rate 200 minutes Drive motor and hubs
Engine coolant Drive hub mounting bolts, lubricated 160 ft-lbs

217 Nm
Capacity 7.7 quarts
7.3 liters Drive motor mounting bolts, lubricated 55 ft-lbs
75 Nm
Coolant temperature sending unit
Turntable bearing
Temperature switch point 221° F
105° C Rotate bearing mounting bolts, lubricated 180 ft-lbs
244 Nm
Turntable rotation assembly
Backlash pivot plate, lubricated 320 ft-lbs

433 Nm

Part No. 77828 S-60 • S-65 • S-60 HC 2 - 11

SPECIFICATIONS
Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
Your machine is equipped with Parker Seal-Lok® The O-ring cannot be re-used if the fitting or
fittings and hose ends. Genie specifications require hose end has been tightened beyond finger
that fittings and hose ends be torqued to tight.
specification when they are removed and installed
or when new hoses or fittings are installed. The O-rings used in the Parker
Seal Lok® fittings and hose ends
are custom-size O-rings. They are
SAE O-ring Boss Port not standard SAE size O-rings.
(tube fitting - installed into Aluminum) They are available in the O-ring
field service kit (Genie part
SAE Dash size Torque
number 49612).
-4 11 ft-lbs / 14.9 Nm 2 Lubricate the O-ring before installation.
-6 23 ft-lbs / 31.2 Nm 3 Be sure that the face seal O-ring is seated and
retained properly.
-8 40 ft-lbs / 54.2 Nm
4 Position the tube and nut squarely on the face
-10 69 ft-lbs / 93.6 Nm
seal end of the fitting and tighten the nut finger
-12 93 ft-lbs / 126.1 Nm tight.
-16 139 ft-lbs / 188.5 Nm 5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
-20 172 ft-lbs / 233.2 Nm
6 Operate all machine functions and inspect the
-24 208 ft-lbs / 282 Nm hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port Seal-Lok Fittings

®
(tube fitting - installed into Steel) (hose end)
SAE Dash size Torque SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 25 Nm
-6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40 Nm
-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 55 Nm
-10 105 ft-lbs / 142.4 Nm -10 60 ft-lbs / 80 Nm
-12 140 ft-lbs / 190 Nm -12 85 ft-lbs / 115 Nm
-16 210 ft-lbs / 284.7 Nm -16 110 ft-lbs / 150 Nm
-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm
-24 315 ft-lbs / 427.1 Nm -24 180 ft-lbs / 245 Nm
2 - 12 S-60 • S-65 • S-60 HC Part No. 77828

SPECIFICATIONS
SAE FAST ENER T ORQUE CHART

• This chart is to be used as a guide only unless noted elsew here in this manual •
A574 High Stre ngth
SIZE THREAD Grade 5 Gra de 8
Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in - lb s Nm in - lb s Nm in - lb s Nm in - lb s Nm in - lb s Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7

28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
f t - lb s Nm f t - lb s Nm f t - lb s Nm f t - lb s Nm f t - lb s Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4

24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 1/8
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in- lbs Nm in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
f t - lbs Nm f t -lbs Nm f t - lbs Nm f t - lbs Nm f t - lbs Nm ft - lbs Nm f t - lbs Nm f t - lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
Part No. 77828 S-60 • S-65 • S-60 HC 2 - 13

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2 - 14 S-60 • S-65 • S-60 HC Part No. 77828

February 2012 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

information and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, semi-annually,
Indicate, an imminently hazardous
annually and every 2 years as specified on the
Maintenance Inspection Report. The frequency
result in death or serious injury.
and extent of periodic examinations and tests
may also depend on national regulations. Indicates a potentially hazardous
situation which, if not avoided,
Failure to perform each procedure
could result in death or serious
as presented and scheduled may
injury.
cause death, serious injury or
substantial damage. Indicates a potentially hazardous
Immediately tag and remove from service a
may cause minor or moderate
damaged or malfunctioning machine.
injury.
Repair any machine damage or malfunction
before operating machine. situation which, if not avoided,
Use only Genie approved replacement parts. may result in property damage.
Unless otherwise specified, perform each Indicates that a specific result is expected after
maintenance procedure with the machine in the performing a series of steps.
following configuration: Indicates that an incorrect result has occurred
• Machine parked on a firm, level surface after performing a series of steps.
• Boom in stowed position
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power disconnected
from the machine
Part No. 77828 S-60 • S-65 • S-60 HC 3-1

Section 3 • Scheduled Maintenance Procedures February 2012
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

The following symbols have been The pre-delivery preparation report contains
used in this manual to help checklists for each type of scheduled inspection.
communicate the intent of the
instructions. When one or more of Make copies of the Pre-delivery Preparation Report
the symbols appear at the to use for each inspection. Store completed forms
beginning of a maintenance as required.
procedure, it conveys the meaning Maintenance Schedule
below.
There are five types of maintenance inspections
that must be performed according to a schedule—
Indicates that tools will be required to daily, quarterly, semi-annually, annual and
perform this procedure. two years. The Scheduled Maintenance Procedures
Section and the Maintenance Inspection Report
have been divided into five subsections—A, B, C,
D and E. Use the following chart to determine which
Indicates that new parts will be required
group(s) of procedures are required to perform a
to perform this procedure.
scheduled inspection.
Indicates that a cold engine will be Inspection Checklist

required to perform this procedure.
Daily or every 8 hours A
Quarterly or every 250 hours A+B

Indicates that a warm engine will be
required to perform this procedure. Semi-annually or every 500 hours A+B+C
Annual or every 1000 hours A+B+C+D
Indicates that dealer service is required Two years or every 2000 hours A+B+C+D+E
to perform this procedure.
Maintenance Inspection Report
The maintenance inspection report contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and governmental regulations
and requirements.
3-2 S-60 • S-65 • S-60 HC Part No. 77828

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.
Scheduled maintenance inspections shall be performed Legend

by qualified service technicians, according to the Y = yes, completed
manufacturer's specifications and the requirements N = no, unable to complete
listed in the responsibilities manual. R = repaired
Comments
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
Terex South Dakota, Inc USA Genie UK

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

Maintenance Inspection Report

Model Checklist A Y N R Checklist B Y N R
A-1 Manuals and decals B-1 Inspect battery
Serial number
A-2 Pre-operation B-2 Inspect electrical
Date inspection wiring
A-3 Functions tests B-3 Exhaust system
Hour meter A-4 Engine maintenance B-4 Inspect air filter -
A-5 Filter condition indicator Ford, Deutz and
Machine owner Perkins models
A-6 Oscillate axle
B-5 Oil cooler and fins-
Inspected by (print) Perform after 40 hours:
Deutz models
A-7 30 day service
Inspector signature B-6 Tires and wheels
Perform every 100 hours:
B-7 Brake configuration
Inspector title A-8 Inspect air filter -
B-8 Hub oil and Torque
GM models
B-9 Engine RPM -
Inspector company A-9 Engine maintenance -
Ford and Deutz models
GM, Ford and
Perkins models B-10 Ground control override
Instructions
• Make copies of this report to use for A-10 Fuel filter/separator - B-11 Directional valve
each inspection. Diesel models B-12 Platform leveling
• Select the appropriate checklist(s) for A-11 Check engine RPM- B-13 Engine idle select
the type of inspection to be Perkins models B-14 Fuel select -
performed. A-12 Rotation bearing GM and Ford models
Daily or 8 hour Perform after 150 hours: B-15 Drive brakes

Inspection: A A-13 Drive hub oil B-16 Drive speed -
Perform every 200 hours: stowed position
Quarterly or 250 hour
Inspection: A+B A-14 Engine maintenance - B-17 Drive speed -
GM and Ford models raised position
Semi-annual or 500 hour
Inspection: A+B+C A-15 Engine maintenance - B-18 Alarm package
Annual or 1000 hours Perkins models B-19 Hydraulic oil analysis

Inspection: A+B+C+D B-20 Fuel and hydraulic
tank cap venting
2 Year or 2000 hour
Inspection: A+B+C+D+E B-21 Fuel filter element -
Perkins models
• Place a check in the appropriate box B-22 Boom extend/retract
after each inspection procedure is cables
completed.
Perform every 400 hours:
• Use the step-by-step procedures in
this section to learn how to perform B-23 Engine maintenance -
these inspections. Deutz models
• If any inspection receives an “N”, tag B-24 Engine maintenance -
and remove the machine from GM and Ford models
service, repair and re-inspect it. After B-25 Replace air filter -
repair, place a check in the “R” box. GM and Ford models
Legend B-26 Engine maintenance -
Y = yes, acceptable Perkins models
N = no, remove from service
R = repaired
Comments
Part No. 77828 S-60 • S-65 • S-60 HC 3-5

MAINTENANCE INSPECTION REPORT
Model Checklist C Y N R Checklist E Y N R

C-1 Engine maintenance - E-1 Hydraulic oil
Serial number Deutz models Perform every 3000 hours:
Date C-2 Grease platform E-2 Engine maintenance -
overload, S-60 and Deutz models
Hour meter S-65 (if equipped)
Perform every 12,000 hours:
C-3 Test platform overload,
E-3 Engine maintenance -
Machine owner S-60 and S-65
Deutz models
(if equipped)
Inspected by (print) Perform every 10 years:
C-4 Test load sense,
S-60 HC E-4 Replace the Boom
Inspector signature Extend/Retract cables
C-5 Fuel filter/separator -
Perkins models
Inspector title
C-6 Replace air filter -
Deutz and Perkins
Inspector company
models
Instructions Perform every 600 hours:
• Make copies of this report to use for C-7 Engine maintenance -
each inspection. Perkins models
• Select the appropriate checklist(s) for Perform every 800 hours:
the type of inspection to be C-8 Engine maintenance -
performed. GM and Ford models
Daily or 8 hour
Inspection: A Checklist D Y N R
Quarterly or 250 hour D-1 Boom wear pads
Inspection: A+B D-2 Turntable bearing bolts
Semi-annual or 500 hour D-3 Turntable bearing
Inspection: A+B+C wear
Annual or 1000 hours D-4 Drive hub oil
Inspection: A+B+C+D D-5 Free-wheel
2 Year or 2000 hour configuration
Inspection: A+B+C+D+E D-6 Hydraulic filters
D-7 Air/LPG mixture -
• Place a check in the appropriate box
GM models
after each inspection procedure is
completed. D-8 Engine maintenance -
• Use the step-by-step procedures in Deutz models
this section to learn how to perform
these inspections.
• If any inspection receives an “N”, tag
and remove the machine from Comments
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6 S-60 • S-65 • S-60 HC Part No. 77828

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.
1 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not appropriate
for the machine or all manuals are not in good
condition or are illegible. Remove the machine
from service until the manual is replaced.
Part No. 77828 S-60 • S-65 • S-60 HC 3-7

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 Part No. 77828

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.
GM 3.0L Operator Handbook
(GM part number 36100007) OR the 2 Start the engine from the ground controls.
Ford LRG-425 EFI Operator Handbook 3 Change the engine idle to high rpm (rabbit
(Ford part number FPP 194-302) OR the symbol).
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020) OR the 4 Visually inspect the filter condition indicator.
Perkins 400 Series Operation Manual Result: The filter condition indicator should be
(Perkins part number TPD 1443S). operating with the plunger in the green area.
Result: If the indicator displays the plunger in
the red area, this indicates that the hydraulic
Genie part number 84794
filter is being bypassed and the filter should be
GM 3.0L Operator Handbook replaced. See D-6, Replace the Hydraulic
Genie part number 101095 Filters.
Ford LRG 425 EFI Operator Handbook

Ford DSG 423 EFI Operator Handbook

Perkins 400 Series Operation Manual

Part No. 77828 S-60 • S-65 • S-60 HC 3-9

A-6 A-7
Test the Oscillate Axle Perform 30 Day Service
(if equipped)
The 30 day maintenance procedure is a one time

sequence of procedures to be performed after the
Note: Genie specifications require that this
first 30 days or 40 hours of usage, whichever
procedure be performed daily or every 8 hours,
comes first. After this interval, refer to the
whichever comes first.
maintenance tables for continued scheduled
Proper axle oscillation is essential to safe machine maintenance.
operation. If the axle oscillation system is not
1 Perform the following maintenance procedures:
operating correctly, the stability of the machine is
compromised and it may tip over.
• A-9 Perform Engine Maintenance -
1 Start the engine from the platform controls. GM, Ford and Perkins Models
2 Drive the right steer tire up onto a • A-12 Grease the Turntable Bearing and
6 inch / 15 cm block or curb. Rotate Gear
Result: The three remaining tires should stay in • B-6 Inspect the Tires, Wheels and
firm contact with the ground and the chassis Lug Nut Torque
should remain level at all times. • B-8 Check the Drive Hub Oil Level and
Fastener Torque
3 Drive the left steer tire up onto a
6 inch / 15 cm block or curb. • C-1 Perform Engine Maintenance -
Deutz Models
Result: The three remaining tires should stay in
firm contact with the ground and the chassis • D-2 Check the Turnable Rotation
should remain level at all times. Bearing Bolts
• D-6 Replace the Hydraulic Filters
4 Drive both steer tires up onto a
6 inch / 15 cm block or curb.
Result: The non-steer tires should stay in firm
contact with the ground.
Note: If the chassis does not remain level during
test, refer to Repair Procedure 7-6, How to Set Up
the Oscillate Directional Valve.
3 - 10 S-60 • S-65 • S-60 HC Part No. 77828

A-8 A-9
Inspect the Engine Air Filter - Perform Engine Maintenance -
GM Models GM, Ford and Perkins Models
Note: Engine specifications require that this Note: Engine specifications require that this
procedure be performed weekly or every 40 hours, procedure be performed every 100 hours. Perform
whichever comes first. Perform this procedure more this procedure more often if dusty conditions exist
often if dusty conditions exist. or the machine is subjected to extended low idle
operation.
Maintaining the engine air filter in good condition is
essential to good engine performance and service Proper engine maintenance, following the engine
life. Failure to perform this procedure can lead to manufacturer's maintenance schedule, is essential
poor engine performance and component damage. to good engine performance and service life. Failure
to perform the maintenance procedures can lead to
Note: Perform this procedure with the engine off. poor engine performance and component damage.
1 Locate the engine air filter assembly. Required maintenance procedures and additional
engine information are available in the
2 Release the latches from the air cleaner canister
end cap. Remove the end cap.
(GM part number 36100007) OR the
3 Remove the filter element. Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) OR the
4 Clean the inside of the canister and the end cap Ford DSG-423 EFI Operator Handbook
with a damp cloth. (EDI part number 1060020) OR the
5 Inspect the air filter element. If needed, blow Perkins 400 Series Operation Manual
from the inside out using low pressure dry (Perkins part number TPD 1443S) .
compressed air, or carefully tap out dust.
Replace the filter if needed. GM 3.0L Operator Handbook
6 Install the filter element.
7 Install the air filter canister end cap and secure Ford LRG 425 EFI Operator Handbook
the end cap latches. Genie part number 84792
Note: Be sure the discharge valve is pointing down Ford DSG 423 EFI Operator Handbook
when the cap is instaled. Genie part number 119488

Part No. 77828 S-60 • S-65 • S-60 HC 3 - 11

A-10 3 Inspect the filter bowl for water buildup.

Inspect the Fuel Filter/Water Result: If water is present in the filter bowl
continue with steps 4 through 8.
Separator - Diesel Models
4 Loosen the vent plug located on the fuel filter/
water separator head.

a
procedure be performed every 100 hours or
monthly, whichever comes first. d
Proper maintenance of the fuel filter/water separator

is essential for good engine performance. Failure to
perform this procedure can lead to poor engine c
performance and/or hard starting, and continued
use may result in component damge. Extremely b
dirty conditions may require this procedure be
performed more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this a vent plug
procedure in an open, well- b drain plug
ventilated area away from heaters, c filter bowl
d separator head
sparks, flames and lighted
tobacco. Always have an approved 5 Loosen the drain plug located at the bottom of
fire extinguisher within easy reach. the bowl. Allow the water to drain into a suitable
Note: Perform this procedure with the engine off. container until fuel starts to come out.
Immediately tighten the drain plug.
Perkins Models:
6 Tighten the vent plug.
1 Put on protective clothing and eye wear. Note: If the fuel filter/water separator is completely
2 Open the engine side turntable cover and locate drained, you must prime the fuel filter/water
the fuel filter/water separator next to the separator before starting the engine.
hydraulic return filter on the bulkhead. See C-6, Replace The Fuel Filter/Water Separator
Element - Perkins Models, for instructions on how
to prime the fuel filter/water separator.
3 - 12 S-60 • S-65 • S-60 HC Part No. 77828

7 Clean up any fuel that may have spilled. 5 Loosen the drain plug located at the bottom of
the filter. Allow the water to drain into a suitable
8 Start the engine from the ground controls and
container until fuel starts to come out.
check the fuel filter/water separator and vent
Immediately tighten the drain plug.
plug for leaks.
Note: Do not completely drain the filter.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
Deutz Models:
a
1 Put on protective clothing and eye wear.
2 Remove the engine tray retaining fastener b
located under the engine tray.Swing the engine
tray out and away from the machine.
3 Install the fastener that was just removed a fuel filter/water separator
through the engine tray and into the engine tray b drain valve
anchor hole in the turntable.
6 Clean up any fuel that may have spilled.
Crushing hazard. Failure to install
the fastener into the engine tray 7 Start the engine from the ground controls and
anchor hole to secure the engine check the fuel filter/water separator for leaks.
tray from moving could result in Explosion and fire hazard. If a fuel
death or serious injury. leak is discovered, keep any
4 Locate the fuel filter/water separator next to the additional personnel from entering
oil filter. the area and do not operate the
machine. Repair the leak
immediately.
8 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 13

A-11 2 Loosen the low idle lock nut and turn the low idle
adjustment screw clockwise to increase the
Check and Adjust the rpm, or counterclockwise to decrease the rpm.
Engine RPM - Perkins Models Tighten the low idle lock nut and confirm the
rpm.
Note: Engine specifications require that this

procedure be performed every 100 hours.
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.
Note: This procedure will require two people.
1 Connect a tachometer to the engine. Start the

engine from the ground controls and check the
rpm. Refer to Section 2, Specifications.
Skip to step 3 if the low idle rpm is correct.
a b c d
a solenoid boot
b high idle adjustment nut
c yoke
d low idle lock nut and adjustment
screw
3 Move the function enable toggle switch to the

high idle (rabbit symbol) position and note the
rpm. Refer to Section 2, Specifications.
If high idle rpm is correct, disregard adjustment
step 4.
4 Loosen the yoke lock nut, then turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
3 - 14 S-60 • S-65 • S-60 HC Part No. 77828

A-12 A-13
Grease the Turntable Rotation Replace the Drive Hub Oil
Bearing and Rotate Gear
Note: Manufacturer drive hub specifications require

that this one-time procedure be performed after the
first 150 hours.
procedure be performed every 100 hours of
operation. Perform this procedure more often if Replacing the drive hub oil is essential for good
dusty conditions exist. machine performance and service life. Failure to
replace the drive hub oil after the first 150 hours of
Frequent application of lubrication to the turntable
use may cause the machine to perform poorly and
bearing and rotate gear is essential to good
continued use may cause component damage.
machine performance and service life. Continued
use of an improperly greased bearing and gear will 1 Select the drive hub to be serviced. Drive the
result in component damage. machine until one of the two plugs is at the
lowest point.
1 Locate the grease fitting on the front turntable
cover. 2 Remove both plugs and drain the oil into a
suitable container.
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of 4 to 5 3 Drive the machine until one plug is at the top
inches / 10 to 13 cm at a time and repeat this and the other is at 90 degrees.
step until the entire bearing has been greased.
a
3 Apply grease to each tooth of the drive gear,
located under the turntable.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent
a drive hub plugs
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side 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. 77828 S-60 • S-65 • S-60 HC 3 - 15

A-14 A-15
Perform Engine Maintenance - Perform Engine Maintenance -
GM and Ford Models Perkins Models
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
GM 3.0L Operator Handbook Perkins 400 Series Operation Manual
(GM part number 36100007) OR the (Perkins part number TPD 1443S).
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) OR the Perkins 400 Series Operation Manual
Ford DSG-423 EFI Operator Handbook Genie part number 94890
(EDI part number 1060020).
GM 3.0L Operator Handbook To access the engine:

1 Remove the engine tray retaining fastener
Ford LRG 425 EFI Operator Handbook located under the engine tray. Swing the engine
Genie part number 84792 tray out and away from the machine.
Ford DSG 423 EFI Operator Handbook 2 Install the fastener that was just removed
Genie part number 119488 through the engine tray and into the engine tray
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
3 - 16 S-60 • S-65 • S-60 HC Part No. 77828

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 Be sure that the battery hold downs and cable

connections are tight.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 17

CHECKLIST B PROCEDURES
10 Check the ambient air temperature and adjust B-2

the specific gravity reading for each cell as
follows: Inspect the Electrical Wiring
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for Note: Genie specifications require that this
every 10° / 5.5° C below 80° F / 26.7° C. procedure be performed every 250 hours or
Result: All battery cells display a specific quarterly, whichever comes first.
gravity of 1.277 or greater. The battery is fully Maintaining electrical wiring in good condition is
charged. Proceed to step 13. essential to safe operation and good machine
Result: The difference in specific gravity performance. Failure to find and replace burnt,
readings between cells is greater than 0.1 OR chafed, corroded or pinched wires could result in
the specific gravity of one or more cells is less unsafe operating conditions and may cause
than 1.177. Replace the battery. component damage.
11 Check the battery acid level. If needed, Electrocution/burn hazard. Contact

replenish with distilled water to 1/8 inch / 3 mm with hot or live circuits could result
below the bottom of the battery fill tube. Do not in death or serious injury. Remove
overfill. all rings, watches and other
jewelry.
12 Install the vent caps and neutralize any
electrolyte that may have spilled. 1 Open the engine side turntable cover.
located under the engine tray. Swing the engine
3 Install the fastener that was just removed
through the engine tray and into the engine tray
3 - 18 S-60 • S-65 • S-60 HC Part No. 77828

4 Inspect the following areas for burnt, chafed, B-3

corroded and loose wires:
Check the Exhaust System
• Engine wiring harness
• Hydraulic manifold wiring
5 Open the ground controls side turntable cover.
6 Inspect the following areas for burnt, chafed, procedure be performed every 250 hours or
corroded and loose wires: quarterly, whichever comes first.
• Inside of the ground control box Maintaining the exhaust system is essential to
• Hydraulic manifold wiring good engine performance and service life. Running
7 Inspect for a liberal coating of dielectric grease the engine with a damaged or leaking exhaust
at the following location: system can cause component damage and unsafe
operating conditions.
• All wire harnesses connectors to the
ground control box Bodily injury hazard. Do not
inspect while the engine is running.
Remove the key to secure from
raise the boom above the turntable covers.
operation.
9 Inspect the turntable area for burnt, chafed and
Burn hazard. Beware of hot engine
pinched cables.
components. Contact with hot
10 Lower the boom to the stowed position and turn engine components may result in
the engine off. severe burns.
11 Inspect the following areas for burnt, chafed, 1 Remove the engine tray retaining fastener
corroded, pinched and loose wires: located under the engine tray.Swing the engine
• Cable track on the primary boom
• Cables on the primary, and jib booms
• Jib boom/Platform rotate manifold anchor hole in the turntable.
• Inside of the platform control box Crushing hazard. Failure to install
12 Inspect for a liberal coating of dielectric grease the fastener into the engine tray
at the following location: anchor hole to secure the engine
• All wire harnesses connectors to the
platform control box
13 Swing the engine back to its original position 3 Be sure that all nuts and bolts are tight.
and install the engine tray retaining fastener. 4 Inspect all welds for cracks.
5 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
and install the engine tray retaining fastener.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 19

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
inspect while the engine
is running. Remove the key to
end cap. Remove the end cap.
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
severe burns.
5 Inspect the air filter element. If needed, blow
from the inside out using low pressure dry Oil cooler:
compressed air, or carefully tap out dust.
Replace the filter if needed.
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
when the cap is instaled. Crushing hazard. Failure to install
3 - 20 S-60 • S-65 • S-60 HC Part No. 77828

3 Remove the fasteners from the engine side B-6

cover, then remove the cover.
Inspect the Tires, Wheels and
4 Inspect the oil cooler for leaks and physical
damage.
Lug Nut Torque
a b c

quarterly, whichever comes first.
Maintaining the tires and wheels, including proper

wheel fastener torque, is essential to safe operation
and good performance. Tire and/or wheel failure
could result in a machine tip-over. Component
damage may also result if problems are not
discovered and repaired in a timely fashion.
Bodily injury hazard. An over-
a oil cooler inflated tire can explode and could
b cylinder head cooling fins
c fan blower fins cause death or serious injury.
5 Clean the oil cooler of debris and foreign Tip-over hazard. Do not use
material. temporary flat tire repair products.
Cooling and fan blower fins: Note: The tires on some machines are foam-filled
and do not need air added to them.
6 Inspect the fan blower fins for physical damage.
1 Check all tire treads and sidewalls for cuts,
7 Clean the fan blower fins of debris and foreign cracks, punctures and unusual wear.
material.
2 Check each wheel for damage, bends and
8 Inspect the head cooling passages and fins for cracked welds.
physical damage or foreign material, using a
flashlight. 3 Check each lug nut for proper torque.
Refer to Section 2, Specifications.
9 Clean the cylinder head cooling passages of
debris and foreign material. 4 Check the pressure in each air-filled tire.
Refer to Section 2, Specifications.
10 Install the engine side cover.
and install the engine pivot plate retaining
fastener.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 21

B-7 B-8
Confirm the Proper Check the Drive Hub Oil Level
Brake Configuration and Fastener Torque
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 1 Drive the machine to rotate the hub until the
operational. plugs are located one on top and the other at
90 degrees.
1 Check each drive hub disconnect cap to be sure
it is in the engaged position.
brake disengaged position a
brake engaged position
a drive hub plugs
2 Remove the plug located at 90 degrees and

check the oil level.
Result: The oil level should be even with the
bottom of the side plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
4 Install the plug(s) into the drive hub.
5 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
6 Repeat this procedure for each drive hub.
3 - 22 S-60 • S-65 • S-60 HC Part No. 77828

Turntable rotate drive hub

1 Remove the plug located on the side of the hub
and check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
a drain/fill plug
b mounting fasteners
2 If necessary, add oil until the oil level is even

with the bottom of the plug hole.
3 Apply pipe thread sealant to the plug, and
install the plug in the drive hub.
4 Check the torque of the turntable drive hub
mounting fasteners. Refer to Section 2,
Specifications.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 23

B-9 2 Install the fastener that was just removed

Check and Adjust the anchor hole in the turntable.
Engine RPM - Ford and Deutz Crushing hazard. Failure to install
Models the fastener into the engine tray
Note: Genie specifications require that this 3 Connect a tachometer to the engine, and then
procedure be performed every 250 hours or start the engine from the ground controls and
quarterly, whichever comes first. check the rpm. Refer to Section 2,
Specifications.
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine Skip to step 5 if the low idle rpm is correct.
performance and service life. The machine will not
operate properly if the rpm is incorrect and 4 Loosen the low idle lock nut, then turn the low
continued use may cause component damage. idle adjustment screw clockwise to increase the
rpm or counterclockwise to decrease the rpm.
Ford models: Tighten the low idle lock nut and recheck the
rpm.
Note: The engine rpm is controlled by the ECM and
can only be adjusted by re-programming the ECM.
If rpm adjustment or service is required, please
contact Genie Service Department OR your local
Ford dealer.
f
Deutz models:
e
Note: This procedure will require two people.

a b c d
a solenoid boot
b high idle adjustment nut
c yoke lock nut
d yoke
e low idle adjustment screw
f low idle lock nut
3 - 24 S-60 • S-65 • S-60 HC Part No. 77828

5 Move the function enable/rpm select toggle B-10

switch to the high idle (rabbit symbol) position at
the ground controls and check the rpm. Refer to Test the Ground Control
Section 2, Specifications. Override
If high idle rpm is correct, disregard adjustment Note: Genie specifications require that this
step 6. procedure be performed every 250 hours or
6 Loosen the yoke lock nut, then turn the high idle
adjustment nut and solenoid boot A properly functioning ground control override is
counterclockwise to increase the rpm or essential to safe machine operation. The ground
clockwise to decrease the rpm. Tighten the control override function is intended to allow ground
yoke lock nut and recheck the rpm. personnel to operate the machine from the ground
Note: Be sure the solenoid fully retracts when controls whether or not the Emergency Stop button
activating high idle. on the platform controls is in the on or off position.
This function is particularly useful if the operator at
7 Swing the engine back to its original position the platform controls cannot return the boom to the
and install the engine pivot plate retaining stowed position.
fastener.
1 Push in the platform red Emergency Stop button
to the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boom
function through a partial cycle.
Result: All boom functions should operate.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 25

B-11 B-12
Check the Oscillate Directional Test the Platform Self-leveling
Valve Linkage

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. Automatic platform self-leveling throughout
Note: Perform this test only on models equipped the full cycle of boom raising and lowering is
with a oscillating axle. essential for safe machine operation. The
platform is maintained at level by the platform
Proper axle oscillation is essential to safe machine leveling slave cylinder which operates in a closed
operation. If the oscillate directional valve linkage is loop hydraulic circuit with the master cylinder
not operating correctly, the stability of the machine located at the base of the boom.
is compromised and it may tip over. A platform self-leveling failure creates an unsafe
working condition for platform and ground
1 Remove the drive chassis cover from the personnel.
non-steer end of the machine.
2 Locate the oscillate directional valve inside of lower the boom into the stowed position.
the non-steer axle and inspect the linkage for
the following: 2 Hold the function enable/rpm select toggle
switch to either side and adjust the platform to a
• Lock nut is tight against yoke level position using the platform level toggle
• Yoke clevis pins are installed switch.
• Cotter pins are installed through clevis pins 3 Raise and lower the primary boom through
• Linkage is properly attached to a full cycle.
directional valve Result: The platform should remain level at
all times to within ±5 degrees.
3 - 26 S-60 • S-65 • S-60 HC Part No. 77828

B-13 2 Start the engine from the ground controls then

move and hold the function enable/rpm select
Test the Engine Idle Select toggle switch to the high idle (rabbit symbol).
Note: Genie specifications require that this Result: The engine should change to high idle.
quarterly, whichever comes first. 3 Release the function enable/rpm select toggle
switch.
A properly operating engine idle select switch
is essential to good engine performance and safe Result: The engine should return to low idle.
machine operation. There are two settings. 4 Turn the key switch to platform controls.
Foot switch activated low idle (turtle symbol) 5 Move the engine idle control switch to foot
allows the operator to control individual boom switch activated high idle (rabbit and foot switch
functions. symbol).
Foot switch activated high idle (rabbit symbol) Result: The engine should not change to
should be used for normal machine operation. This high idle.
selection activates high idle only when the foot
6 Press down the foot switch.
switch is pressed down.
Result: The engine should change to high idle.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform 7 Move the engine idle control switch to foot
controls. switch activated low idle (turtle symbol).
Result: The engine should change to low idle.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 27

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.
GM and 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.
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.
1 At the platform controls, move the fuel select

switch to gasoline and then move the engine
idle control switch to foot switch activated high
idle (rabbit and foot switch symbol).
2 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
3 - 28 S-60 • S-65 • S-60 HC Part No. 77828

B-15 4 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use
Test the Drive Brakes when crossing the test line.
5 Bring the machine to top drive speed before
reaching the test line. Release the drive joystick
when your reference point on the machine
crosses the test line.
quarterly, whichever comes first. 6 Measure the distance between the test line and
your machine reference point. Refer to
Proper brake action is essential to safe machine Section 2, Specifications.
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual Note: The brakes must be able to hold the machine
noise. Hydrostatic brakes and hydraulically- on any slope it is able to climb.
released individual wheel brakes can appear to
operate normally when they are actually not fully
operational.
Collision hazard. Be sure that the
machine is not in free-wheel or
partial free-wheel configuration.
See B-7, Confirm the Proper Brake
Configuration.
Note: Select a test area that is firm, level and free
of obstructions.
1 Mark a test line on the ground for reference.

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

B-16 B-17
Test the Drive Speed - Test the Drive Speed -
Stowed Position Raised or Extended Position
Proper drive function movement is essential to safe Proper drive function movement is essential to safe
machine operation. The drive function should machine operation. The drive function should
respond quickly and smoothly to operator control. respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation, Drive performance should also be free of hesitation,
jerking and unusual noise over the entire jerking and unusual noise over the entire
proportionally controlled speed range. proportionally controlled speed range.
Note: Select a test area that is firm, level and free Note: Select a test area that is firm, level and free
of obstructions. of obstructions.
1 Create start and finish lines by marking two lines 1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart. on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls. 2 Start the engine from the platform controls.
3 Move the engine idle control switch to 3 Move the engine idle select switch to foot switch
foot switch activated high idle (rabbit and foot activated high idle (rabbit and foot switch
switch symbol), then lower the boom into the symbol).
stowed position.
4 Press down the foot switch and raise the
4 Choose a point on the machine; i.e., contact primary boom above horizontal.
5 Choose a point on the machine; i.e., contact
when crossing the start and finish lines.
5 Bring the machine to top drive speed before when crossing the start and finish lines.
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
6 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Specifications.
3 - 30 S-60 • S-65 • S-60 HC Part No. 77828

6 Bring the machine to top drive speed before B-18

reaching the start line. Begin timing when your
reference point on the machine crosses the Test the Alarm Package -
start line. Optional Equipment
7 Continue at full speed and note the time when Note: Genie specifications require that this
the machine reference point crosses the finish procedure be performed every 250 hours or
line. Refer to Section 2, Specifications. quarterly, whichever comes first.
8 Lower the boom to the stowed position and The alarm package includes:
extend the boom 1 foot / 30 cm.
• Travel alarm
9 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use • Descent alarm
when crossing the start and finish lines. • Flashing beacon
10 Bring the machine to top drive speed before Alarms and a beacon are installed to alert operators
reaching the start line. Begin timing when your and ground personnel of machine proximity and
reference point on the machine crosses the motion. The alarm package is installed on the
start line. turntable covers.
11 Continue at top speed and note the time when Note: The alarms and beacon will operate with the
the machine reference point crosses the finish engine running or not running.
line. Refer to Section 2, Specifications.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
Result: The flashing beacon should be on and
flashing.
2 Move the function enable/rpm select toggle
switch to either side and activate the boom
toggle switch in the down position, hold for a
moment and then release it.
Result: The descent alarm should sound when
the switch is held down.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 31

3 S-65: Move the function enable/rpm select B-19

toggle switch to either side and activate the jib
boom toggle switch in the down position, hold Perform Hydraulic Oil Analysis
for a moment and then release it.
the switch is held down. Note: Genie specifications require that this
4 Turn the key switch to platform control. procedure be performed every 250 hours or
Result: The flashing beacon should be on
and flashing. Replacement or testing of the hydraulic oil is
essential for good machine performance and
5 Press down the foot switch. Move the boom service life. Dirty oil and a clogged suction strainer
control handle to the down position, hold for a may cause the machine to perform poorly and
moment and then release it. continued use may cause component damage.
Result: The descent alarm should sound when Extremely dirty conditions may require oil changes
the control handle is held down. to be performed more often. For hydraulic oil
specifications, refer to Section 2, Specifications.
6 S-65: Press down the foot switch. Move the jib
boom toggle switch to the down position, hold Note: Before replacing the hydraulic oil, the oil may
for a moment and then release it. be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the control handle is held down. the two year inspection, test the oil quarterly.
7 Press down the foot switch. Move the drive Replace the oil when it fails the test.
control handle off center, hold for a moment and See E-1, Test or Replace the Hydraulic Oil.
then release it. Move the drive control handle off
center in the opposite direction, hold for a
moment and then release it.
Result: The travel alarm should sound when the
drive control handle is moved off center in either
direction.
3 - 32 S-60 • S-65 • S-60 HC Part No. 77828

B-20 3 Using a mild solvent, carefully wash the cap

venting system. Dry using low pressure
Inspect the Fuel and Hydraulic compressed air. Repeat this procedure
Tank Cap Venting Systems beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
Note: Genie requires that this procedure be tank.
performed every 250 hours or quarterly, whichever 6 Check for proper venting.
comes first. Perform this procedure more often if
dusty conditions exist. Result: Air passes through the fuel tank cap.
Proceed to step 8.
Free-breathing fuel and hydraulic tank caps are
essential for good machine performance and Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 7.
service life. A dirty or clogged tank cap may cause
the machine to perform poorly and continued use Note: When checking for positive tank cap venting,
may cause component damage. Extremely dirty air should pass freely through the cap.
conditions may require that the caps be inspected
more often. 7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
Note: Explosion and fire hazard. Engine fuels are compressed air. Repeat this procedure
combustible. Perform this procedure in an open, beginning with step 6.
well-ventilated area away from heaters, sparks,
flames and lighted tobacco. Always have an 8 Install the breather cap onto the hydraulic tank.
approved fire extinguisher within easy reach.
Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.

2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Proceed to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 33

B-21 3 Thoroughly clean the outside surfaces of the

fuel filter assembly.
Replace the Fuel Filter Element -
4 Place a suitable container under the fuel filter
Perkins Models element.
5 Disconnect and plug the fuel line from the fuel
pump to the fuel filter element.
quarterly, whichever comes first. a
Replacing the diesel fuel filter element is essential b

for good engine performance and service life. A
dirty or clogged filter may cause the engine to c
perform poorly and continued use may cause
component damage. Extremely dirty conditions
may required that the filter be replaced more often.
Note: Explosion and fire hazard. Engine fuels are
combustible. Perform this procedure in an open,
a fuel line
well-ventilated area away from heaters, sparks, b filter head
flames and lighted tobacco. Always have an c fuel filter element
approved fire extinguisher within easy reach.
6 Remove the fuel filter element with a filter
Note: Perform this procedure with the engine off. wrench.
1 Remove the engine tray retaining fastener 7 Apply a thin layer of fuel to the new fuel filter
located under the engine tray. Swing the engine element O-ring.
8 Install the new fuel filter element and tighten it
2 Install the fastener that was just removed securely by hand. Clean up any fuel that may
through the engine tray and into the engine tray have spilled during the installation procedure.
9 Use a permanent ink marker to write the date
Crushing hazard. Failure to install and number of hours from the hour meter on the
the fastener into the engine tray oil filter housing.
3 - 34 S-60 • S-65 • S-60 HC Part No. 77828

Bleed the fuel system: B-22

10 Loosen the vent plug on top of the fuel injection Inspect the Boom
pump. Extend/Retract Cables
a
c b procedure be performed every 250 hours or
The boom extend/retract cables are responsible for
the extension and retraction of the number 3 boom
tube. Inspecting for foreign objects, damage and/or
improper adjustment of the boom extend/retract
cables and related components on a regular basis
is essential to good machine performance and safe
a vent plug machine operation. The boom extend and retract
b fuel injection pump functions should operate smoothly and be free of
c fuel lift pump
hesitation, jerking and unusual noise.
11 Operate the priming lever or priming bulb (if 1 Raise the boom to horizontal and fully extend
equipped) of the fuel lift pump until fuel, free the boom.
from air, comes from the vent plug. Tighten the
vent plug. 2 After the boom is fully extended, lower the boom
until the platform is at chest height. Turn the
12 Clean up any fuel that may have spilled during machine off.
this procedure.
3 S-60 and S-65: Remove the boom end cover
13 Operate the starter motor for intervals of 15 retaining fasteners and remove the cover.
seconds until the engine starts.
S-60 HC: Remove the boom end cover from the
14 Swing the engine back to its original position pivot end of the boom while guiding the small
and install the engine pivot plate retaining cable from the string potentiometer out of the
fastener. slot of the cover. Rest the cover and string
Note: It is important to allow the starter motor to potentiometer on the counterweight.
cool for 30 seconds between each 15 second Component damage hazard. The
interval of operation. cable from the string potentiometer
Note: If the engine runs correctly for a short time can become damaged if it is
and then stops or runs roughly, check for air in the kinked or pinched.
fuel system. If there is air in the fuel system, there
is probably a leak in the low pressure side of the
system.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 35

4 Remove the retaining fasteners from the access 6 S-60 and S-65: Install the cover at the pivot end
covers located on the side of the boom at the of the boom.
platform end of the machine. Remove the
S-60 HC: Install the boom end cover at the pivot
covers.
end of the boom while guiding the small cable
5 Visually inspect the cables and components from the string potentiometer into the slot of the
through both inspection holes for the following: cover.
• Frayed or broken wire strands Component damage hazard. The
• Kinks in the cables cable from the string potentiometer
can become damaged if it is
• Corrosion kinked or pinched.
• Paint or foreign materials on the cable
Note: Be sure the cable from the string
• Split or cracked cable ends potentiometer is correctly routed around the small
• Cables are on all pulleys pulley before installing the boom end cover.
• Extend cable break limit switch arm is 7 Install the access panels on the sides of the
centered in the pivot plate boom.
• Cables have equal tension 8 Start the engine from the ground controls and
• Cables at end of adjustment range fully retract and lower the boom to the stowed
position.
• No broken or damaged pulleys
• No unusual or excessive pulley wear 9 Turn the key switch to the platform controls.
• All fasteners in place and secure 10 Extend the boom approximately 2 feet / 0.6 m.
• S-60 HC: String potentiometer cable break 11 Retract the boom. While retracting the boom,
limit switch arm is securely attached to end visually inspect the number 2 and number 3
of cable boom tubes.
Note: A flashlight and inspection mirror may be Result: The number 2 boom tube should not
necessary to thoroughly inspect the above items. move more than 1/2 inch / 13 mm before the
Note: A pulley groove gauge should be used to number 3 boom tube begins to retract.
check the condition of the pulleys. Note: If the number 2 boom tube moves more than
1
/2 inch / 13 mm before the number 3 boom tube
begins to retract, the boom extend/retract cables
need to be adjusted. See Repair Procedure 4-5,
How to Adjust the Boom Extend/Retract Cables.
3 - 36 S-60 • S-65 • S-60 HC Part No. 77828

B-23 B-24
Deutz Models GM and Ford Models
Deutz FL 2011 Operation Manual GM 3.0L Operator Handbook
(Deutz part number 0297-9929). (GM part number 36100007) OR the
Deutz FL 2011 Operation Manual (Ford part number FPP 194-302) OR the
Genie part number 84794 Ford DSG-423 EFI Operator Handbook
To access the engine: GM 3.0L Operator Handbook

located under the engine tray. Swing the engine Ford LRG 425 EFI Operator Handbook
tray out and away from the machine. Genie part number 84792
2 Install the fastener that was just removed Ford DSG 423 EFI Operator Handbook
through the engine tray and into the engine tray Genie part number 119488
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 37

B-25 B-26
Replace the Engine Air Filter Perform Engine Maintenance -
Element - GM and Ford Models Perkins Models
Maintaining the engine air filter in good condition is Proper engine maintenance, following the engine
essential to good engine performance and service manufacturer's maintenance schedule, is essential
life. Failure to perform this procedure can lead to to good engine performance and service life. Failure
poor engine performance and component damage. to perform the maintenance procedures can lead to
poor engine performance and component damage.
Required maintenance procedures and additional
1 Locate the engine air filter assembly. engine information are available in the
2 Release the latches from the air cleaner canister Perkins 400 Series Operation Manual
end cap. Remove the end cap. (Perkins part number TPD 1443S).
3 Remove and discard the filter element.

4 Clean the inside of the canister and the end cap Genie part number 94890
with a damp cloth.
5 Install the new filter element.
To access the engine:
6 Install the air filter canister end cap and secure
the end cap latches. 1 Remove the engine tray retaining fastener
Note: Be sure the discharge valve is pointing down tray out and away from the machine.
when the cap is instaled.
3 - 38 S-60 • S-65 • S-60 HC Part No. 77828

Checklist C Procedures
C-1 C-2
Perform Engine Maintenance - Grease the Platform Overload
Deutz Models Mechanism, S-60 and S-65
(if equipped)

Proper engine maintenance, following the engine procedure be performed every 500 hours or six
manufacturer's maintenance schedule, is essential months, whichever comes first. Perform this
to good engine performance and service life. Failure procedure more often if dusty conditions exist.
Application of lubrication to the platform overload
mechanism is essential to safe machine operation.
Required maintenance procedures and additional Continued use of an improperly greased platform
engine information are available in the overload mechanism could result in the system not
Deutz FL 2011 Operation Manual sensing an overloaded platform condition and will
(Deutz part number 0297-9929). result in component damage.
1 Locate the grease fittings on each pivot pin of

Deutz FL 2011 Operation Manual the platform overload assembly.
2 Thoroughly pump grease into each grease
fitting.
Grease Specification
located under the engine tray. Swing the engine Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
tray out and away from the machine. or equivalent

Part No. 77828 S-60 • S-65 • S-60 HC 3 - 39

CHECKLIST C PROCEDURES
C-3 The platform support subassembly utilizes two load

support arms that are opposed in a full
Test the Platform Overload parallelogram link. This isolates platform loads into
System, S-60 and S-65 a shear or vertical state, which translates into a
compressive load. A spring in the parallelogram link
(if equipped) supports this purely compressive load regardless of
where the load is placed in the platform.
As weight is added to the platform, the spring will
Note: Genie specifications require that this compress until, when the platform is overloaded,
procedure be performed every 500 hours or six the lower arm contacts a limit switch and thereby
months, whichever comes first. activating the overload signal. When adjusted
correctly, the platform overload system will
Testing the platform overload system regularly is deactivate normal boom operation at platform
essential to safe machine operation. Continued use capacity.
of an improperly operating platform overload
system could result in the system not sensing an Note: Perform this procedure with the boom fully
overloaded platform condition. Machine stablity retracted and in the stowed position and with the
could be compromised resulting in the machine machine on a firm, level surface.
tipping over. 1 Remove all weight, tools and equipment from
The platform overload system is designed to detect the platform.
an overloaded platform and prevent machine Note: Failure to remove all weight, tools and
operation anytime the machine is turned on. When accessories from the platform will result in an
activated, the system halts all normal boom inaccurate test.
operation, giving visual and audible warning to the
operator. 2 Turn the key switch to ground control and pull
Models equipped with the platform overload option position at both the ground and platform
are provided with additional machine components: controls. Start the engine from the ground
an adjustable spring-loaded platform support controls and level the platform. Do not turn the
subassembly, a limit switch, an electronic module engine off.
which receives the overload signal and interrupts
power, and an audio/visual warning indication to 3 Determine the maximum platform capacity.
alert the operator of the overload. Refer to the machine serial plate.
3 - 40 S-60 • S-65 • S-60 HC Part No. 77828

4 Using a suitable lifting device, place a test 6 Using a suitable lifting device, place an
weight equal to that of the available capacity additional 50 lbs / 23 kg of weight onto the
one of the locations shown. platform.
Refer to Illustration 1.
Result: The alarm should sound.
Result: The platform overload indicator lights The platform overload indicator lights should be
should be off at both the ground and platform flashing at both the ground and platform
controls and the alarm should not sound. controls.
Result: The platform overload indicator lights are Result: The alarm does not sound and the
on and the alarm is sounding. Calibrate the platform overload indicator lights are not
platform overload system. Refer to Repair flashing. Calibrate the platform overload
Proceedure 2-3, How to Calibrate the Platform system. Refer to Repair Proceedure 2-3,
Overload System, S-60 and S-65 (if equipped). How to Calibrate the Platform Overload System,
S-60 and S-65 (if equipped).
5 Carefully move the test weight to each
remaining location. Refer to Illustration 1. Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
Result: The platform overload indicator lights
sounds.
should be off at both the ground and platform
controls and the alarm should not sound. 7 Carefully move the test weights to each
remaining location on the platform.
Result: The platform overload indicator lights are
Refer to Illustration 1.
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair Result: The alarm should sound.
Proceedure 2-3, How to Calibrate the Platform The platform overload indicator lights should be
Overload System, S-60 and S-65 (if equipped). flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Proceedure 2-3,
How to Calibrate the Platform Overload System,
S-60 and S-65 (if equipped).
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
Illustration 1
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 41

8 Test all machine functions from the platform 16 Test all machine functions from the platform
controls. controls.
Result: All platform control functions should not Result: All platform control functions should
operate. operate.
9 Turn the key switch to ground control. Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-3,
10 Test all machine functions from the ground
How to Calibrate the Platform Overload System, S-
controls.
60 and S-65
Result: All ground control functions should not (if equipped).
operate.
17 Using a suitable lifting device, remove the
11 Activate the auxiliary power toggle switch. remaining test weights from the platform.
Note: The engine will turn off when the auxiliary
power is activated.
12 Using auxiliary power, test all machine functions

from the ground controls.
Result: All ground control functions should
operate.
13 Using a suitable lifting device, lift the additional
test weight from the platform.
Result: The platform overload indicator lights
should turn off at both the ground and platform
controls and the alarm should not sound.
Note: There may be an 2 second delay before the
overload indicator lights and alarm turn off.
14 Start the engine and test all machine functions

from the ground controls.
operate normally.
15 Turn the key switch to platform control.
3 - 42 S-60 • S-65 • S-60 HC Part No. 77828

C-4 The platform support subassembly utilizes two load

support arms that are opposed in a full
Test the Platform Load Sense parallelogram link. This isolates platform loads into
System, S-60 HC a shear or vertical state, which translates into a
compressive load. A spring in the parallelogram link
supports this purely compressive load regardless of
where the load is placed in the platform.
Note: Genie specifications require that this As weight is added to the platform, the spring will
procedure be performed every 500 hours or six compress until, when the platform is overloaded,
months, whichever comes first. the lower arm contacts a limit switch and thereby
activating the overload signal. When adjusted
Testing the platform load sense system regularly is correctly, the platform overload system will
essential to safe machine operation. Continued use deactivate normal boom operation at platform
of an improperly operating platform load sense capacity.
system could result in the system not sensing an
overloaded platform condition. Machine stablity Note: Perform this procedure with the boom fully
could be compromised resulting in the machine retracted and in the stowed position and with the
tipping over. machine on a firm, level surface.
The platform overload system is designed to detect Note: Be sure that no load sense system faults
an overloaded platform and prevent machine exist prior to performing this procedure.
operation anytime the machine is turned on. When
activated, the system halts all normal boom Note: On a properly functioning machine, the LEDs
operation, giving visual and audible warning to the on both control modules, located next to the ground
operator. control box, should be off.
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.
2 Turn the key switch to ground control and pull
position at both the ground and platform
controls.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 43

3 Start the engine from the ground controls. 6 Using a suitable lifting device, remove the test
Do not turn the engine off. weights from the platform.
4 Using a suitable lifting device, place an 7 Push in the ground controls red Emergency Stop
appropriate test weight equal to 750 lbs / button to the off position, then pull the red
340.2 kg on to the center of the platform floor. Emergency Stop button out to the on position to
reset the control system.
Result: The amber restricted range of motion
LED at the platform controls should come on Recovery process from the platform controls:
and the engine should continue to run.
Note: This procedure only operates if the platform
Result: If the amber restricted range of motion is overloaded or enters the safety envelope.
LED at the platform controls does not come on,
there is no alarm and the engine continues to 1 With the key switch turned to platform controls,
run, the platform load sense system needs to activate the auxiliary power toggle switch.
be calibrated. See Repair Procedure 2-4, Result: The boom will automatically retract until
How to Calibrate the Platform Load Sense it is in the unrestricted zone.
System, S-60 HC.
2 Push in the platform controls red Emergency
5 Using a suitable lifting device, place an Stop button to the off position, then pull out the
additional appropriate test weight equal to red Emergency Stop button to the on position to
501 to 510 lbs / 227.2 to 231.3 kg on to the reset the system.
center of the platform floor. The total weight in
the platform must equal 1251 to 1260 lbs / 3 Start the engine and lower the boom to the
567.4 to 571.5 kg. stowed position.
Result: The alarm should sound and the engine Recovery process from the ground controls:
should turn off. The platform overload indicator
Note: This procedure only operates if the platform
light should be on at both the ground and
is overloaded or enters the safety envelope.
platform controls. The platform load sense
system is functioning properly. 1 Turn the key switch to ground controls.
Result: If the alarm does not sound, the engine 2 Locate the recovery toggle switch on the side of
does not turn off or the platform indicator light the ground control box. Activate the recovery
does not come on at both the ground and toggle switch and the auxiliary power toggle
platform controls, see Repair Procedure 2-4, switch at the same time.
How to Calibrate the Platform Load Sense
System, S-60 HC. Result: The boom will automatically fully retract
and then lower to the stowed position.
Note: The weight in the platform must be 1200 lbs /
544.3 or less before the engine can be restarted. 3 Push in the ground controls red Emergency Stop
button to the off position, then pull out the red
Emergency Stop button to the on position to
reset the system.
3 - 44 S-60 • S-65 • S-60 HC Part No. 77828

C-5 3 Loosen the vent plug located on the fuel filter/

water separator head.
Replace the Fuel Filter/Water
Separator - Perkins Models
a
e b
procedure be performed every 500 hours or six
months, whichever comes first. d
Regular replacement of the fuel filter/water c

separator is essential for good engine performance.
Failure to perform this procedure can lead to poor
engine performance and/or hard starting, and
continued use may result in component damge.
Extremely dirty conditions may require this a vent plug
b main fuel line
procedure be performed more often. c drain plug
d filter bowl
Explosion and fire hazard. Engine e filter element
fuels are combustible. Perform this f separator head
procedure in an open, well-
ventilated area away from heaters, 4 Place a suitable container under the filter bowl.
sparks, flames and lighted Loosen the drain plug located at the bottom of
tobacco. Always have an approved the bowl. Completely drain the fuel.
fire extinguisher within easy reach. 5 Rotate the filter bowl counterclockwise and
Note: Perform this procedure with the engine off. remove it from the element.
6 Rotate the filter element counterclockwise and
1 Open the engine side turntable cover and locate
remove it from the filter head.
the fuel filter/water separator on the bulkhead.
7 Install the bowl onto the new filter element.
2 Disconnect and plug the fuel supply hose from
the fuel tank to the fuel filter/water separator. 8 Apply a thin layer of oil onto the element gasket.
Install the filter/bowl assembly onto the filter
head. Tighten the drain plug and vent plug.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 45

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.
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
fuel system. If there is air in the fuel system, there
is probably a leak in the low pressure side of the
system.
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.
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
3 - 46 S-60 • S-65 • S-60 HC Part No. 77828

C-6 C-7
Replace the Engine Air Filter Perform Engine Maintenance -
Element - Deutz and Perkins Perkins Models
Models

Note: Engine specifications require that this procedure be performed every 600 hours.
procedure be performed every 500 hours or every Proper engine maintenance, following the engine
six months, whichever comes first. manufacturer's maintenance schedule, is essential
Maintaining the engine air filter in good condition is to good engine performance and service life. Failure
essential to good engine performance and service to perform the maintenance procedures can lead to
life. Failure to perform this procedure can lead to poor engine performance and component damage.
poor engine performance and component damage. Required maintenance procedures and additional
Note: Perform this procedure with the engine off. engine information are available in the
1 Locate the engine air filter assembly. (Perkins part number TPD 1443S).
end cap. Remove the end cap. Perkins 400 Series Operation Manual
3 Remove and discard the filter element.
4 Clean the inside of the canister and the end cap
with a damp cloth.
5 Install the new filter element.
6 Install the air filter canister end cap and secure
the end cap latches.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 47

C-8
Perform Engine Maintenance -
GM and Ford Models

Proper engine maintenance, following the engine

manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
(GM part number 36100007) OR the
(Ford part number FPP 194-302) OR the
Ford DSG-423 EFI Operator Handbook

Ford LRG 425 EFI Operator Handbook


3 - 48 S-60 • S-65 • S-60 HC Part No. 77828

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.
annually, whichever comes first. Wear pad specifications Minimum
Top and side wear pads 1/2 inch

Maintaining the boom wear pads in good condition
is essential to safe machine operation. Wear pads (platform end of boom) 12.7 mm
are placed on boom tube surfaces to provide a low
Bottom wear pads 5/8 inch
friction, replaceable wear pad between moving
(platform end of boom) 15.9 mm
parts. Improperly shimmed wear pads or continued
use of worn out wear pads may result in component 1/2 inch
Top and side wear pads
damage and unsafe operating conditions.
(pivot end of boom) 12.7 mm
Bottom wear pads 5/8 inch
2 Raise the end of the primary boom to a (pivot end of boom) 15.9 mm
comfortable working height (chest high), then
extend the boom 1 foot / 30 cm.
3 Measure each wear pad. Replace the wear pad
once it reaches the minimum allowable
thickness. If the wear pad is still within
specification, shim as necessary to obtain
minimum clearance with zero binding.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 49

CHECKLIST D PROCEDURES
D-2 4 Start the engine form the ground controls.

Check the Turntable Rotation 5 Raise the boom and remove the safety chock.
Bearing Bolts 6 Lower the boom to the stowed position.
7 Remove drive chassis covers from both the
steer end and the non-steer end of the machine.
8 Check to ensure that each lower bearing
mounting bolt under the drive chassis is torqued
in sequence to specifications. Refer to
annually, whichever comes first.
Section 2, Specifications.
Maintaining proper torque on the turntable bearing
bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
1 Raise the boom and place a safety chock on the

lift cylinder rod. Carefully lower the boom onto
the lift cylinder safety chock.
Crushing hazard. Keep hands
away from cylinders and all moving
parts when lowering the boom.
Note: The lift cylinder safety chock is available
through Genie Bolt torque sequence
(Genie part number 75097).
2 Turn the engine off.

3 Be sure that each turntable mounting bolt is
torqued in sequence to specifications. Refer to
1 19
13 15
10 7
22 12
6
24
18
4
3
17
23
5
11 21
8 9
16 14
20 2
Bolt torque sequence
3 - 50 S-60 • S-65 • S-60 HC Part No. 77828

D-3 4 Place a dial indicator between the drive chassis

and the turntable at a point that is directly
Inspect for Turntable Bearing under, or inline with, the boom and no more than
Wear 1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, place
the dial indicator no more than 1 inch / 2.5 cm from
the turntable rotation bearing.
annually, whichever comes first. a
Periodic inspection of turntable bearing wear is

essential to safe machine operation, good machine
performance and service life. Continued use of a
b
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious
injury and component damage.
c
Note: Perform this procedure with the machine on a
firm, level surface and the boom in the stowed
position. d
1 Grease the turntable bearing. See A-12, Grease a turntable

the Turntable Bearing and Rotate Gear. b dial indicator
c drive chassis
2 Torque the turntable bearing bolts to d turntable rotation bearing
specification. See D-2, Check the Turntable
Rotation Bearing Bolts. 5 At the dial indicator, adjust it to "zero" the
indicator.
3 Start the machine from the ground controls and
raise the boom to full height. Do not extend the 6 Fully extend the boom and lower to a horizontal
boom. position.
7 Note the reading on the dial indicator.
Result: The measurement is less than
0.063 inch / 1.6 mm. The bearing is good.
Result: The measurement is more than
0.063 inch / 1.6 mm. The bearing is worn and
needs to be replaced.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 51

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.
1 Select the drive hub to be serviced. Then drive

the machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
a drive hub plugs
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side 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.
3 - 52 S-60 • S-65 • S-60 HC Part No. 77828

D-5 4 Disengage the drive hubs by turning over the

drive hub disconnect caps on each
Check the Free-wheel non-steer wheel hub.
Configuration disengaged position
Note: Genie specifications require that this engaged position

annually, whichever comes first. 5 Manually rotate each non-steer wheel.
Proper use of the free-wheel configuration is Result: Each non-steer wheel should rotate with
essential to safe machine operation. The minimum effort.
free-wheel configuration is used primarily for towing.
6 Re-engage the drive hubs by turning over
A machine configured to free-wheel without operator
the hub disconnect caps. Rotate each wheel to
knowledge may cause death or serious injury and
check for engagement. Lift the machine and
property damage.
remove the jack stands.
Collision hazard. Select a work site Collision hazard. Failure to
that is firm and level. re-engage the drive hubs may
Component damage hazard. If the cause death or serious injury and
machine must be towed, do not property damage.
exceed 2 mph / 3.2 km/h. Steer Wheels: 4WD Models
Non-steer Wheels: All Models
7 Chock the non-steer wheels to prevent the
1 Chock the steer wheels to prevent the machine machine from rolling.
from rolling. 8 Center a lifting jack of ample capacity
2 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis
(20,000 lbs / 10,000 kg) under the drive chassis between the steer tires.
between the non-steer tires. 9 Lift the wheels off the ground and then place
3 Lift the wheels off the ground and then place jack stands under the drive chassis for support.
jack stands under the drive chassis for support. 10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
steer wheel hub.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 53

11 Manually rotate each steer wheel. D-6

Result: Each steer wheel should rotate with Replace the Hydraulic Filters
minimum effort.
12 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Raise the machine, Note: Genie requires that this procedure be
remove the jack stands and lower the machine. performed every 1000 hours or annually, whichever
comes first. Perform this procedure more often if
Collision hazard. Failure to
dusty conditions exist.
re-engage the drive hubs may
cause death or serious injury and Replacement of the hydraulic filters is essential for
property damage. good machine performance and service life. A dirty
or clogged filter may cause the machine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filters be replaced more often.
Bodily injury hazard. Beware of hot
oil. Contact with hot oil may cause
severe burns.
Hydraulic return filter:
1 Open the ground controls side turntable cover

and locate the hydraulic return filter housing on
top of the hydraulic tank.
2 Remove the cap from the filter housing.
3 Lift the handle on the filter element and rotate
the element counterclockwise to release the
element from the housing.
4 Remove the filter element from the filter
housing.
5 Install the new filter element into the filter
housing.
3 - 54 S-60 • S-65 • S-60 HC Part No. 77828

6 Push the filter element down to be sure the 15 Install the new filter elements into the housings
O-ring on the element is fully seated into the and tighten them securely.
housing.
Note: The medium and high pressure filters use the
7 Rotate the filter element clockwise to lock it in same elements.
place.
16 Clean up any oil that may have spilled during the
8 Install the filter housing cap. installation procedure.
9 Use a permanent ink marker to write the date 17 Use a permanent ink marker to write the date
and number of hours from the hour meter on the and number of hours from the hour meter on the
oil filter housing. oil filter housings.
Medium and high pressure filters: 18 Start the engine from the ground controls.
Note: The medium pressure filter is for the charge 19 Inspect the filter housings and related
pump and the high pressure filter is for all machine components to be sure that there are no leaks.
functions except the drive circuit and oscillating
axle circuit.
10 Open the engine side turntable cover and locate

the medium and high pressure filters near the
pump.
Note: The medium pressure filter is located on the
right. The high pressure filter, with filter condition
indicator, is located on the left.
11 Place a suitable container under each filter.
12 Remove the filter housings by using a wrench on
the nut provided on the bottom of the housings.
13 Remove the filter elements from the housings.
14 Inspect the housing seals and replace them if
necessary.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 55

D-7 5 Adjust the high idle adjustment screw to obtain

an air-to-fuel mixture ratio of 13.0:1 to 13.2:1,
Check and Adjust the Air/LPG using an exhaust gas analyzer.
Mixture - GM Models Note: Preliminary setting is 1/4 inch / 6.4 mm of
threads showing. Measure from top of lock nut to
top of adjustment screw.
Note: Genie specifications require that this Note: If an exhaust gas analyzer is not available,
procedure be performed every 1000 hours or adjust to obtain peak or optimum rpm.
annually, whichever comes first. 6 Hold the adjustment screw and tighten the
Maintaining the proper air-to-fuel mixture during lock nut.
LPG operation is essential to good engine 7 Return the function enable toggle switch to the
performance. center position.
Explosion and fire hazard. Engine 8 Locate the low idle mixture adjustment screw on
fuels are combustible. Perform this the LPG regulator.
procedure in an open, well-
9 Adjust the low idle mixture adjustment screw to
ventilated area away from heaters,
obtain an air-to-fuel mixture ratio of 13.0:1 to
sparks, flames and lighted
13.2:1.
tobacco. Always have an approved
fire extinguisher within easy reach. Note: Preliminary setting: turn low idle adjustment
screw clockwise all the way in. Turn low idle
Note: The engine should be warmed to normal
adjustment screw counterclockwise 2 3/4 turns.
operating temperature before performing this
procedure.
1 Move the fuel select toggle switch to LPG fuel

and start the engine from the ground controls.
2 Locate the high idle mixture adjustment
screw on the LPG venturi that attaches to the
air cleaner air cleaner hose.
3 Loosen the lock nut on the high idle mixture
adjustment screw.
4 Load the system by activating the primary boom
retract function, then move the function enable
toggle switch to the high idle (rabbit symbol)
position.
3 - 56 S-60 • S-65 • S-60 HC Part No. 77828

D-8
Perform Engine Maintenance -
Deutz Models

Proper engine maintenance, following the engine

manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
(Deutz part number 0297-9929).


Part No. 77828 S-60 • S-65 • S-60 HC 3 - 57

Checklist E Procedures
E-1 1 GM and Ford models: Turn the valve on the
LPG tank clockwise to the off position (if
Test or Replace the Hydraulic Oil equipped). Then slowly disconnect the hose
from the LPG tank.
2 GM and Ford models: Open the clamps from
the LPG tank straps and remove the LPG tank
Note: Genie requires that this procedure be from the machine (if equipped).
performed every 2000 hours or every two years,
whichever comes first. Perform this procedure more 3 Models with hydraulic tank shut-off valves:
often if dusty conditions exist. Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
Replacement or testing of the hydraulic oil is underneath the turntable. Close the valves.
essential for good machine performance and
service life. Dirty oil and suction strainers may Component damage hazard. The
cause the machine to perform poorly and continued engine must not be started with the
use may cause component damage. Extremely hydraulic tank shut-off valves in
dirty conditions may require oil changes to be the closed position or component
performed more often. damage will occur. If the tank
valves are closed, remove the key
Note: Before replacing the hydraulic oil, the oil may from the key switch and tag the
be tested by an oil distributor for specific levels of machine to inform personnel of the
contamination to verify that changing the oil is condition.
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
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 open closed
Torque Specifications.
4 Place a suitable container underneath the
Note: Perform this procedure with the boom in the
hydraulic tank.
stowed position.
5 Remove the drain plug from the hydraulic tank.
6 Completely drain the tank into a suitable
container. See capacity specifications.
3 - 58 S-60 • S-65 • S-60 HC Part No. 77828

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 Models with hydraulic tank shut-off valves:
9 Remove the ground controls side turntable Open the two hydraulic tank valves at the
cover. hydraulic tank.
10 Support the hydraulic tank with an appropriate
23 Fill the tank with hydraulic oil until the level is
lifting device.
within the top 2 inches / 5 cm of the sight
11 Remove the hydraulic tank mounting fasteners. gauge. Do not overfill.
12 Remove the hydraulic tank from the machine. 24 Clean up any oil that may have spilled.
Crushing hazard. The hydraulic 25 Prime the pump. Refer to Repair Procedure 6-2,
tank could become unbalanced How to Prime the Pump.
and fall if not properly supported
Note: Always use pipe thread sealant when
when removed from the machine.
installing the suction hose fittings and the drain
13 Remove the hydraulic return filter housing plug.
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. 77828 S-60 • S-65 • S-60 HC 3 - 59

E-2 E-3
Deutz Models Deutz Models
procedure be performed every 3000 hours. procedure be performed every 12,000 hours.
Deutz FL 2011 Operation Manual Deutz FL 2011 Operation Manual
(Deutz part number 0297-9929). (Deutz part number 0297-9929).
Deutz FL 2011 Operation Manual Deutz FL 2011 Operation Manual

Genie part number 84794 Genie part number 84794
To access the engine: To access the engine:
1 Remove the engine tray retaining fastener 1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine located under the engine tray. Swing the engine
tray out and away from the machine. tray out and away from the machine.
2 Install the fastener that was just removed 2 Install the fastener that was just removed
through the engine tray and into the engine tray through the engine tray and into the engine tray
anchor hole in the turntable. anchor hole in the turntable.
Crushing hazard. Failure to install Crushing hazard. Failure to install
the fastener into the engine tray the fastener into the engine tray
anchor hole to secure the engine anchor hole to secure the engine
tray from moving could result in tray from moving could result in
death or serious injury. death or serious injury.
3 - 60 S-60 • S-65 • S-60 HC Part No. 77828

E-4
Replace the Boom Extend/
Retract Cables

procedure be performed every 10 years.
The boom extend/retract cables are responsible for

the extension and retraction of the number 3 boom
tube. Replacement of the boom extend/retract
cables is essential to good machine performance
and safe machine operation. The boom extend/
retract functions should operate smoothly and be
free of hesitation, jerking and unusual noise.
1 Replace the boom extend/retract cables. See
Repair Procedure 4-5, How to Adjust the Boom
Extend/Retract Cables.
Part No. 77828 S-60 • S-65 • S-60 HC 3 - 61

3 - 62 S-60 • S-65 • S-60 HC Part No. 77828

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: Indicates an imminently hazardous
Read, understand and obey the safety rules and result in death or serious injury.
operating instructions in the appropriate
Operator's Manual on your machine. Indicates a potentially hazardous
Be sure that all necessary tools and parts are could result in death or serious
available and ready for use. injury.
Use only Genie approved replacement parts. Indicates the presence of a
potentially hazardous situation
Read each procedure completely and adhere
which, if not avoided, may cause
to the instructions. Attempting shortcuts may minor or moderate injury.
produce hazardous conditions.
Unless otherwise specified, perform each situation which, if not avoided,
repair procedure with the machine in the may result in property damage.
following configuration:
• Machine parked on a firm, level surface Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
• Turntable rotated with the boom between
after performing a series of steps.
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
from the machine
Part No. 77828 S-60 • S-65 • S-60 HC 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
injury. Remove all rings, watches
and other jewelry.
d c b
a ALC-500 circuit board

b drive/steer joystick controller
c boom extend/retract
joystick controller
d primary boom up/down and
turntable rotate left/right
joystick controller
4-2 S-60 • S-65 • S-60 HC Part No. 77828

PLATFORM CONTROLS
4 Attach a grounded wrist strap to the ground 1-2

screw inside the platform control box.
Joysticks
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
How to Calibrate a Joystick
components. Maintain firm contact The joysticks on this machine utilize digital Hall
with a metal part of the machine Effect technology for proportional control. If a
that is grounded at all times when joystick is disconnected or replaced, it must be
handling printed circuit boards OR calibrated before that particular machine function
use a grounded wrist strap. will operate.
5 Carefully disconnect the wire connectors from Note: The joystick must be calibrated before the
the circuit board. threshold, max-out or ramping can be set.
6 Remove the ALC-500 circuit board mounting
fasteners.
1 Open the platform control box.
7 Carefully remove the ALC-500 circuit board from
the platform control box. 2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
3 Turn the key switch to platform control. Do not
start the engine.
4 Select a joystick to calibrate.
5 Disconnect the wire harness connector from the
joystick for approximately 10 seconds or until
the alarm sounds. Connect the wire harness
connector to the joystick.
6 Move the joystick full stroke in either direction
and hold for 5 seconds.
7 Return the joystick to the neutral position, pause
for a moment, then move the joystick full stroke
in the opposite direction. Hold for 5 seconds and
return the joystick to the neutral position.
Result: The alarm should sound indicating
successful joystick calibration.
8 Repeat this procedure for each joystick
controlled machine function including the thumb
rocker steer switch.
Note: No machine function should operate while
performing the joystick calibration procedure.
Part No. 77828 S-60 • S-65 • S-60 HC 4-3

PLATFORM CONTROLS
How to Adjust the Joystick 10 Slowly move the joystick off center in either
direction just until the function begins to move.
Threshold Setting
11 Slowly move the joystick back to the neutral
The threshold setting of a joystick is the minimum position. Just before the function stops moving,
output at which a function proportional valve can move the drive enable toggle switch to either
open and allow the function to operate. side to set the threshold.
Note: Perform this procedure with the boom in the Result: The alarm should sound indicating a
stowed position. successful calibration.
1 Pull out the red Emergency Stop button to the 12 Repeat steps 9 through 11 for each boom
on position at both the ground and platform joystick controlled machine function (boom up/
controls. down, boom extend/retract and turntable rotate).
2 Turn the key switch to platform control. Do not 13 Return the joystick to the neutral position and
start the engine. wait for approximately 10 seconds to allow the
settings to be saved.
Stop button to the off position. Result: The alarm should sound indicating that
the settings have been saved in memory.
4 Do not press down the foot switch.
Note: Do not operate any machine function during
5 Move and hold the drive enable toggle switch in
the 10 second waiting time.
the right position and pull out the red
Emergency Stop button to the on position. 14 Cycle the red Emergency Stop button off, then
back on.
6 When the alarm sounds, release the drive
enable toggle switch.
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.
8 Start the engine from the platform controls and
press down the foot switch.
9 Select a boom function joystick to set the
threshold.
4-4 S-60 • S-65 • S-60 HC Part No. 77828

PLATFORM CONTROLS
How to Adjust the Joystick 8 Start the engine from the platform controls and
Max-out Setting
9 Start a timer and activate the machine function
The max-out setting of a joystick controls the that needs to be adjusted. Record the time it
maximum speed of a joystick-controlled machine takes for that function to complete a full cycle
function. Whenever a hydraulic cylinder, drive (ie; boom up).
motor or hydraulic pump is replaced, the max-out
setting should be adjusted to maintain optimum 10 Compare the machine function time with the
performance. The max-out settings on the joystick function times listed in Section 2,
can be changed to compensate for hydraulic pump Specifications. Determine whether the function
wear to maintain peak performance from the time needs to increase or decrease.
machine. 11 While the joystick is activated, adjust the max-
Note: Perform this procedure with the boom in the out setting to achieve the proper function cycle
stowed position. time. Momentarily move the drive enable toggle
switch in the right direction to increase the
1 Pull out the red Emergency Stop button to the function speed or momentarily move the drive
on position at both the ground and platform enable toggle switch in the left direction to
controls. decrease the function speed.
2 Turn the key switch to platform control. Do not Note: Each time the drive enable toggle switch is
start the engine. momentarily moved, the function speed will change
in 2% increments.
Stop button to the off position. 12 Repeat steps 9 through 11 for each joystick
controlled machine function.
13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
Emergency Stop button to the on position.
Result: The alarm should sound indicating that
Result: There should be a pause and the alarm 14 Cycle the red Emergency Stop button off, then
should sound 4 times indicating that the back on.
machine is in max-out calibration mode.
Part No. 77828 S-60 • S-65 • S-60 HC 4-5

PLATFORM CONTROLS
How to Adjust the Joystick 8 Start the engine from the platform controls and
Ramp Rate Setting
9 Start a timer and simultaneously move the
The ramp rate setting of a joystick controls the time joystick in either direction full stroke. Note how
at which it takes for the joystick to reach maximum long it takes the function to reach maximum
output, when moved out of the neutral position. The speed. This is the ramp rate.
ramp rate settings of a joystick can be changed to
compensate for hydraulic pump wear to maintain 10 Compare the function ramp rate time with the
peak performance from the machine. table and determine whether the ramp rate time
needs to increase or decrease.
stowed position. 11 Release the foot switch.
12 Activate the joystick and adjust the ramp rate.
1 Pull out the red Emergency Stop button to the
Momentarily move the drive enable toggle
on position at both the ground and platform
switch in the right direction to increase the time
controls.
or momentarily move the drive enable toggle
2 Turn the key switch to platform control. Do not switch in the left direction to decrease the time.
start the engine.
Note: Each time the drive enable toggle switch is
3 Push in the platform controls red Emergency momentarily moved, the time will change in 5%
Stop button to the off position. increments from a default of 100%, with a minimum
of 50% and a maximum of 150%.
13 Repeat steps 9 through 11 for each joystick
controlled machine function.
Emergency Stop button to the on position. 14 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
Result: The alarm should sound indicating that
Result: The alarm does not sound. The
Result: There should be a pause and the alarm
minimum or maximum adjustment has been
should sound 6 times indicating that the
obtained. No changes can be saved.
machine is in ramp rate calibration mode.
Result: The alarm does not sound. Repeat steps
3 through 7.
15 Cycle the red Emergency Stop button off, then
back on.
4-6 S-60 • S-65 • S-60 HC Part No. 77828

PLATFORM CONTROLS
Ramp rate (factory settings)
Boom up/down
transition accelerate 1 second
transition decelerate 10 seconds
S ramp accelerate 1 second
S ramp decelerate 0.45 second
Boom extend/retract
accelerate 2 seconds
decelerate 0.5 second
Turntable rotate
decelerate 0.75 second
Drive
decelerate to neutral 0.5 second
decelerate, change of direction 0.5 second
decelerate, coasting 0.75 second
decelerate, braking 1 second
decelerate, shift from low to high speed 1 second
decelerate, shift from high to low speed 4 seconds
Part No. 77828 S-60 • S-65 • S-60 HC 4-7

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: The jib
two primary supports for the platform. The slave boom could fall when the slave
cylinder keeps the platform level through the cylinder rod-end pivot pin is
entire range of boom motion. It operates in a removed if not properly supported.
closed-circuit hydraulic loop with the master 5 Remove the external snap rings from the barrel-
cylinder. The slave cylinder is equipped with end pivot pin.
counterbalance valves to prevent movement in
the event of a hydraulic line failure. 6 Use a soft metal drift to drive the barrel-end
pivot pin out.
How to Remove the Platform 7 Carefully pull the cylinder out of the boom to
Leveling Slave Cylinder access the hydraulic hoses.
Note: Before cylinder removal is considered, bleed 8 Tag, disconnect and plug the hydraulic hoses
the slave cylinder to be sure there is no from the slave cylinder. Cap the fittings on the
air in the closed loop. cylinder.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or the hydraulic oil can penetrate and
hose end must be replaced. All connections must burn skin. Loosen hydraulic
be torqued to specification during installation. Refer connections very slowly to allow
to the oil pressure to dissipate
Section 2, Hydraulic Hose and Fitting Torque gradually. Do not allow oil to
Specifications. squirt or spray.
1 Extend the boom until the slave cylinder barrel- How to Bleed the Slave Cylinder
end pivot pin is accessible.
Note: Do not start the engine. Use auxiliary power
2 Raise the boom slightly and place blocks under for this procedure.
the platform for support.
1 Simultaneously activate the boom up function
3 Lower the boom until the platform is resting on and the platform level up function until the boom
the blocks just enough to support the platform. is fully raised.
Note: Do not rest the entire weight of the boom on 2 Simultaneously activate the boom down function
the blocks. and the platform level down function until the
boom is fully lowered.
4-8 S-60 • S-65 • S-60 HC Part No. 77828

PLATFORM COMPONENTS
2-2 2 S-60 HC: Tag and disconnect the electrical

connector from the platform load sense module.
Platform Rotator
3 Tag, disconnect and plug the hydraulic hoses
The platform rotator is a hydraulically activated from the platform rotator manifold. Cap the
helical gear assembly used to rotate the platform fittings on the rotator.
160 degrees. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove the burn skin. Loosen hydraulic
Platform Rotator connections very slowly to allow
the oil pressure to dissipate
Component damage hazard. Mark gradually. Do not allow oil to squirt
the platform mounting weldment or spray.
and the rotator flange before
removing the platform mounting 4 S-65: Support the jib boom leveling arms and
weldment. The platform mounting the platform mounting weldment with an
weldment must be replaced in the appropriate lifting device. Do not apply any
exact same position on the rotator lifting pressure.
flange as it was before removal. If 5 Remove the mounting bolts from the platform
a new rotator is installed or the mounting weldment. Remove the center bolt and
rotator is disassembled, proper slide the platform mounting weldment off of the
alignment can be achieved by platform rotator.
rotating the rotator all the way to
the left and then installing the Crushing hazard. The platform
platform mounting weldment all the mounting weldment could become
way in the left position. unbalanced and fall if not properly
supported when removed from the
Note: When removing a hose assembly or fitting, machine.
hose end must be replaced. All connections must 6 Support the platform rotator with an appropriate
be torqued to specification during installation. Refer lifting device. Do not apply any lifting pressure.
to
S-60:
Section 2, Hydraulic Hose and Fitting Torque
Specifications. 7 Support the rod end of the platform leveling
slave cylinder. Protect the cylinder rod from
1 Remove the platform and platform support.
damage.
Note: S-60 HC: If the load sense components are
disassembled and/or removed from the platform
support, the platform load sense system will need
to be calibrated. See 2-4, How to Calibrate the
Platform Load Sense System,
S-60 HC.
Part No. 77828 S-60 • S-65 • S-60 HC 4-9

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
S-65: rotated to the right.
7 Remove the pin retaining fasteners from the jib Before serial number 9154:
boom and jib boom leveling arms to platform 2 Connect a clear hose to the top bleed valve.
rotator pivot pins. Do not remove the pins. Place the other end of the hose in a container to
8 Support the jib boom leveling arms. collect any drainage. Secure the container to
the boom.
9 Use a soft metal drift to drive both pins out, then
remove the platform rotator from the machine. 3 Open the top bleed valve on the rotator, but do
not remove it.
Bodily injury hazard. The jib boom
leveling arms may fall if not a
properly supported.
10 Lower the jib boom leveling arms.
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.
d c b
a top bleed valve
b bottom bleed valve
c container
d clear hose
4 - 10 S-60 • S-65 • S-60 HC Part No. 77828

PLATFORM COMPONENTS
4 Move the function enable toggle switch to either 4 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch side and hold the platform rotate toggle switch
to the left position until the platform is fully to the left position until the platform is fully
rotated to the left. Continue holding the toggle rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed switch until air stops coming out of the bleed
valve. Close the bleed valve. screw. Close the bleed screw.
Crushing hazard. Keep clear of the Crushing hazard. Keep clear of the
platform during rotation. platform during rotation.
5 Connect the clear hose to the bottom bleed 5 Open the bottom bleed screw on the rotator, but
valve and open the valve. Do not remove the do not remove it.
bleed valve.
Bodily injury hazard. Spraying
6 Move the function enable toggle switch to either hydraulic oil can penetrate and
side and hold the platform rotate toggle switch burn skin. Loosen hydraulic
to the right position until the platform is fully connections very slowly to allow
rotated to the right. Continue holding the toggle the oil pressure to dissipate
switch until air stops coming out of the bleed gradually. Do not allow oil to
valve. Close the bleed valve. squirt or spray.
Crushing hazard. Keep clear of the 6 Move the function enable toggle switch to either
platform during rotation. side and hold the platform rotate toggle switch
to the right position until the platform is fully
7 Remove the hose from the bleed valve and
rotated to the right. Continue holding the toggle
clean up any hydraulic oil that may have spilled.
switch until air stops coming out of the bleed
8 Rotate the platform fully in both directions and screw. Close the bleed screw.
inspect the bleed valves for leaks.
Crushing hazard. Keep clear of the
After serial number 9153: platform during rotation.
2 Place a suitable container underneath the 7 Clean up any hydraulic oil that may have spilled.
platform rotator. 8 Rotate the platform fully in both directions and
3 Open the top bleed screw on the rotator, but do inspect the bleed screws for leaks.
not remove it.
burn skin. Loosen hydraulic
connections very slowly to allow
gradually. Do not allow oil to
squirt or spray.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 11

PLATFORM COMPONENTS
2-3 5 Move the platform up and down by hand, so it

bounces approximately 2.5 to 5 cm / 1 to 2
Platform Overload System, inches. Allow the platform to settle.
S-60 and S-65 (if equipped) Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6.
How to Calibrate the Platform
Result: The overload indicator lights are flashing
Overload System at the platform and ground controls, and the
alarm is sounding. Slowly tighten the load spring
Calibration of the platform overload system is
adjustment nut in a clockwise direction in 10°
essential to safe machine operation. Continued use
increments until the overload indicator light
of an improperly calibrated platform overload
turns off, and the alarm does not sound.
system could result in the system failing to sense
Proceed to step 8.
an overloaded platform. The stability of the
machine is compromised and it could tip over. Note: The platform will need to be moved up and
down and allowed to settle between each
Note: For S-60 HC models, refer to Repair
adjustment.
Procedure 2-4, Platform Load Sense System, S-60
HC. Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
firm, level surface.
6 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
1 Turn the key switch to platform control. Start the
inches. Allow the platform to settle.
engine and level the platform.
Result: The overload indicator lights are off at
2 Determine the maximum platform capacity.
the platform and ground controls, and the alarm
Refer to the machine serial plate.
does not sound. Slowly loosen the load spring
3 Remove all weight, tools and accessories from adjustment nut in a counterclockwise direction
the platform. in 10° increments until the overload indicator
light flashes at both the platform and ground
Note: Failure to remove all weight, tools and controls, and the alarm sounds.
accessories from the platform will result in an Proceed to step 7.
incorrect calibration.
Result: The overload indicator lights are flashing
4 Using a suitable lifting device, place a test at the platform and ground controls, and the
weight equal to the maximum platform capacity alarm is sounding. Repeat this procedure
at the center of the platform floor. beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
platform overload indicator lights and alarm
responds.
4 - 12 S-60 • S-65 • S-60 HC Part No. 77828

PLATFORM COMPONENTS
7 Move the platform up and down by hand, so it 11 Test all machine functions from the ground
bounces approximately 2.5 to 5 cm / 1 to 2 controls.
inches. Allow the platform to settle.
Result: All ground control functions should not
Result: The overload indicator lights are off and operate.
the alarm does not sound. Proceed to step 8.
12 Using a suitable lifting device, lift the test weight
Result: The overload indicator lights are flashing off the platform floor.
at the platform and ground controls, and the
Result: The platform overload indicator light
alarm is sounding. Repeat this procedure
should be off at both the ground and platform
beginning with step 5.
controls and the alarm should not sound.
overload indicator lights and alarm turn off.
responds.
13 Test all machine functions from the ground
8 Add an additional 10 lb / 4.5 kg test weight to
controls.
the platform.
Result: The overload indicator light is flashing at
operate normally.
both the ground and platform controls, and the
alarm is sounding. Proceed to step 9. 14 Turn the key switch to platform control.
Result: The overload indicator light is off at both 15 Test all machine functions from the platform
the ground and platform controls, and the alarm controls.
does not sound. Remove the additional 10 lb /
4.5 kg test weight. Repeat this procedure Result: All platform control functions should
beginning with step 6. operate normally.

responds.
9 Test all machine functions from the platform

controls.
Result: All platform control functions should not
operate.
10 Turn the key switch to ground control.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 13

PLATFORM COMPONENTS
2-4 3 Open the ground control box and locate the

calibration toggle switch near the relays.
Platform Load Sense System,
Note: If either the operational and/or safety
S-60 HC controller has been replaced or if the software has
been updated, restore the system to the default
How to Calibrate the Platform settings and then continue to step 4. See How to
Load Sense System Restore the Default Settings. Otherwise, continue
to step 4 to enter calibration mode.
Proper calibration of the load sense system is
essential to safe machine operation. Continued use 4 Turn the key switch to ground control and pull
of an improperly calibrated load sense system out the red Emergency Stop button to the on
could result in the system failing to sense an position.
overloaded platform. The stability of the machine is Result: The alarm sound for approximately
compromised and it could tip over. 2 seconds.
Note: For S-60 and S-65 models, refer to Repair
Procedure 2-3, Platform Overload System, S-60
and S-65 (if equipped).
Note: Perform this procedure with the boom fully
retracted and in the stowed position and with the
machine on a firm, level surface.
Note: The platform overload system will not allow
partial calibration and must be completed in its
entirety.
1 At the ground controls, turn the key switch to

the off position and push in the red Emergency
Stop button to the off position. Pull out the red
Emergency Stop button to the on postion at the
platform controls.
2 Remove all weight, tools and equipment from
the platform. How to Restore the System
Tip-over hazard. Failure to remove
Default Settings
all weight, options, accessories 1 Turn the key switch to ground control and
and/or tools from the platform or pull out the red Emergency Stop button to
subtracting the weight of those the on position.
items from the test weights, will
result in the platform load sense Result: The alarm should sound a long tone.
system not calibrating correctly. 2 Activate and hold the calibration toggle
This will allow too much weight to switch for 5 seconds.
be added to the platform which will
result in the machine tipping over. Result: The alarm should sound a tone for
1 second.
3 Push in the red Emergency Stop button to
the off position.
4 - 14 S-60 • S-65 • S-60 HC Part No. 77828

PLATFORM COMPONENTS
5 Activate and release the calibration toggle

switch 3 times within 2 seconds after the alarm
sounds to enter calibration mode.
Result: The alarm should sound for 1 second
indicating the first calibration step was f a
accepted. The green LED on the operational
controller should be blinking fast and the red e b
LED should be blinking twice indicating that
step 2 of calibration is next.
Result: The alarm did not sound and the green
LED on the operational controller is not blinking
fast. Repeat this procedure beginning with
step 1.
Note: Once calibration mode is entered and begun,
there is a 8 minute time limit between each
calibration step. If any one step passes the 8
minute time limit, the system will time out and the
calibration process will need to be repeated d c
beginning with step 1.
a green LED (operational control module)
b red LED (operational control module)
c operational control module
d safety control module
e red LED (safety control module)
f green LED (safety control module)
Operational Control Module LED Status

Description Definition
Green and red LEDs not f lashing System is calibrated
Green LED f lashing rapidly System is in calibration mode
Red LED f lashing w ith pauses Indicates next calibration step (ie; 2, 3, etc
Safety Control Module LED Status

Description Definition
Green and red LEDs not f lashing System is calibrated
Green and red LEDs f lashing alternately System is not calibrated
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 15

PLATFORM COMPONENTS
7 Raise the boom until the distance, when 9 Raise the boom until the distance, when
measured between the centers of the pivot pins measured between the centers of the pivot pins
shown, equals 108.75 inches / 276 cm shown, equals 167.25 inches / 424.8 cm
± 0.75 inch / 19 mm. ± 0.75 inch / 19 mm.
Crushing hazard. Keep clear of all Crushing hazard. Keep clear of all
moving parts of the boom while the moving parts of the boom while the
boom is raising. Do not attempt to boom is raising. Do not attempt to
measure between the pivot pins measure between the pivot pins
while the boom is moving. while the boom is moving.
switch inside the ground control box 1 time.
indicating the third calibration step was
Measure between controller should be blinking fast and the red
the centers of these LED should be blinking four times indicating that
pivot pins
11 Fully raise and extend the boom.
indicating the fourth calibration step was
controller should be blinking fast and the red
LED should be blinking five times indicating that
8 Activate the calibration toggle switch inside the step 5 of calibration is next.
ground control box 1 time. 13 Fully retract and lower the boom to the stowed
Result: The alarm should sound for 1 second position.
indicating the second calibration step was 14 Using a suitable lifting device, place an
accepted. The green LED on the operational appropriate test weight equal to
controller should be blinking fast and the red 750 lbs / 340.2 kg on to the center of the
LED should be blinking three times indicating platform floor.
that step 3 of calibration is next.
Note: If your machine is equipped with any platform
accessories or options, they must be removed from
the platform OR the weights of those options or
accessories must be subtracted from the test
weights to accurately calibrate the platform load
sense system.
4 - 16 S-60 • S-65 • S-60 HC Part No. 77828

PLATFORM COMPONENTS
15 Activate and release the calibration toggle 20 Using a suitable lifting device, remove the test
switch inside the ground control box 1 time. weights from the platform.
Result: The alarm should sound for 1 second 21 Pull out the red Emergency Stop button to the
indicating the fifth calibration step was on position at the ground controls and visually
accepted. The green LED on the operational inspect the LEDs on the operational and safety
controller should be blinking fast and the red controllers.
LED should be blinking six times indicating that
Result: Both the green and red LEDs on both
controllers should be off indicating the system
16 Using a suitable lifting device, place an is calibrated.
additional test weight equal to 510 lbs / 231.3 kg
Note: If an LED is blinking on either controller, the
on to the center of the platform floor. The total
load sense system is not calibrated correctly or a
weight in the platform must equal
fault may exist. Refer to Section 5, Fault Codes to
1260 lbs / 571.5 kg.
determine the system fault.
indicating the sixth calibration step was
accepted. The engine may turn off and the
alarm may sound indicating an overloaded
platform.
18 At the ground controls, push in the red
Emergency Stop button to the off position, then
pull out the red Emergency Stop button to the
on position to reset the system.
19 Visually inspect the LEDs on the controllers.
Result: All LEDs on both controllers should be
off indicating the platform load sense system is
calibrated.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 17

Jib Boom Components, S-65

3-1 6 Attach a lifting strap from an overhead crane to
the jib boom assembly.
Jib Boom
7 Place blocks under the platform leveling cylinder
for support. Protect the cylinder rod from
How to Remove the Jib Boom damage.
Note: Perform this procedure with the boom in the 8 Remove the pin retaining fastener from the slave
stowed position. cylinder rod-end pivot pin. Use a soft metal drift
Note: When removing a hose assembly or fitting, to remove the pin.
the O-ring (if equipped) on the fitting and/or the Crushing hazard. The jib boom
hose end must be replaced. All connections must could fall when the slave cylinder
be torqued to specification during installation. Refer rod-end pivot pin is removed if not
to Section 2, Hydraulic Hose and Fitting Torque properly attached to the overhead
Specifications. crane.
1 Remove the platform. 9 Remove the pin retaining fastener from the jib
boom bellcrank to primary boom pivot pin.
2 Remove the platform mounting weldment.
10 Use a soft metal drift to remove the pin and
3 Remove the hose and cable cover from the side
carefully remove the jib boom assembly from
of the jib boom.
the primary boom.
4 Remove the hose and cable clamp from the jib
Crushing hazard. The jib boom
boom pivot pin. Lay all hoses and cables to the
could become unbalanced and fall
side.
when removed from the machine if
Component damage hazard. Hoses not properly attached to the
and cables can become damaged overhead crane.
if they are kinked or pinched.
5 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
squirt or spray.
4 - 18 S-60 • S-65 • S-60 HC Part No. 77828

JIB BOOM COMPONENTS, S-65
3-2 3 Remove the pin retaining fasteners from the jib

boom lift cylinder rod-end pivot pin. Do not
Jib Boom Lift Cylinder remove the pin.
4 Use a soft metal drift to tap the jib boom lift
How to Remove the Jib Boom cylinder rod-end pivot pin half way out. Then
Lift Cylinder lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
stowed position.
5 Support the jib boom lift cylinder with a lifting
Note: When removing a hose assembly or fitting, device.
hose end must be replaced. All connections must 6 Remove the pin retaining fastener from the jib
be torqued to specification during installation. Refer boom lift cylinder barrel-end pivot pin. Use a
to Section 2, Hydraulic Hose and Fitting Torque soft metal drift to remove the barrel-end pin and
Specifications. let the cylinder hang down.
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.
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.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 19

Boom Components
4-1 5 Remove the hose and cable clamp from the
platform support.
Cable Track
The primary boom cable track guides the cables from the counterbalance valve manifold located
and hoses running up the boom. It can be repaired on the platform rotator. Cap the fittings on the
link by link without removing the cables and hoses manifold.
that run through it. Removing the entire primary Bodily injury hazard. Spraying
boom cable track is only necessary when hydraulic oil can penetrate and
performing major repairs that involve removing the burn skin. Loosen hydraulic
primary boom. connections very slowly to allow
How to Remove the Cable Track, gradually. Do not allow oil to
S-60 squirt or spray.
Note: When removing a hose assembly or fitting, 7 Tag, disconnect and plug the platform leveling
the O-ring (if equipped) on the fitting and/or the slave cylinder hydraulic hoses from the
hose end must be replaced. All connections must bulkhead fittings on the side of the primary
be torqued to specification during installation. Refer boom. Cap the bulkhead fittings.
to Section 2, Hydraulic Hose and Fitting Torque Bodily injury hazard. Spraying
Specifications. hydraulic oil can penetrate and
1 Raise the boom to a horizontal position. burn skin. Loosen hydraulic
2 Locate the cables from the boom cable track to the oil pressure to dissipate
the platform control box. Number each cable gradually. Do not allow oil to
and its entry location at the platform control squirt or spray.
box.
8 Locate all electrical cables under the boom at
3 Disconnect the cables from the platform control the pivot end that enter the cable track.
box.
9 Tag and disconnect the electrical connectors for
4 Remove the electrical outlet box bracket all cables that enter the cable track.
mounting fasteners. Remove the outlet box and
lay it to the side. 10 Remove the retaining fasteners from the
electrical connector receptacles for the cables
that enter the cable track.
4 - 20 S-60 • S-65 • S-60 HC Part No. 77828

BOOM COMPONENTS
11 Carefully pull the cables and connector 17 Remove the cable track pull tube guide
receptacles out of the primary boom. fasteners from the cable track guide at the
platform end of the boom. Remove the cable
12 Tag, disconnect and plug all hydraulic hoses
track guide from the boom.
that enter the cable track from the bulkhead
fittings at the pivot end of the boom. 18 Remove the cable track mounting fasteners that
attach the lower cable track to the primary
boom.
burn skin. Loosen hydraulic 19 Carefully remove the cable track from the
connections very slowly to allow machine and place it on a structure capable of
the oil pressure to dissipate supporting it.
Crushing hazard. The cable track
squirt or spray.
13 Pull the hydraulic hoses out of the primary if not properly attached to the
boom. overhead crane.
14 Place blocks in between the upper and lower Component damage hazard.
cable tracks and secure the upper and lower Cables and hoses can be damaged
tracks together. if they are kinked or pinched.
Crushing hazard. If the upper and Component damage hazard. The
lower cable tracks are not properly cable track can be damaged if it is
secured together, the cable track twisted.
15 Attach a strap from an overhead crane to the
cable track.
16 Remove the cotter pin from the cable track pull
tube at the platform end of the boom.
Note: Always replace the cotter pin with a new one.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 21

BOOM COMPONENTS
How to Remove the Cable Track, 7 Tag, disconnect and plug the platform leveling
slave cylinder hydraulic hoses from the
S-65 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 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
1 Open the platform control box.
squirt or spray.
2 Tag and disconnect the foot switch wiring from
the terminal strip inside the platform control box.
from the "V1" and "V2" ports of the jib boom/
Pull the wiring out of the platform control box.
platform rotate manifold. Cap the fittings on the
3 Raise the boom to a horizontal position. manifold.
4 Disconnect the wire connectors from the bottom Bodily injury hazard. Spraying
of the platform control box. hydraulic oil can penetrate and
Note: When installing the wire connectors to the
bottom of the platform control box, match the color
of the connectors to those on the control box to be
sure they are installed in the correct location.
squirt or spray.
5 Remove the mounting fasteners from the power 9 Remove the hose and cable cover from the side
to platform outlet box bracket. Lay the outlet of the jib boom.
box and bracket assembly off to the side.
10 Locate all electrical cables under the boom at
6 Remove the hose and cable clamps from the the pivot end that enter the cable track.
platform support and jib boom.
11 Tag and disconnect the electrical connectors for
all cables that enter the cable track.
12 Remove the retaining fasteners from the
electrical connector receptacles for the cables
that enter the cable track.
4 - 22 S-60 • S-65 • S-60 HC Part No. 77828

BOOM COMPONENTS
13 Carefully pull the cables and connector 19 Attach a lifting strap from an overhead crane to
receptacles out of the primary boom. the cable track.
14 Tag, disconnect and plug all hydraulic hoses 20 Remove the mounting fasteners that attach the
that enter the cable track from the bulkhead lower cable track to the boom.
fittings at the pivot end of the boom.
21 Carefully remove the cable track from the
Bodily injury hazard. Spraying machine and place it on a structure capable of
hydraulic oil can penetrate and supporting it.
Crushing hazard. The cable track
if not properly attached to the
overhead crane.
squirt or spray.
15 Pull the hydraulic hoses out of the primary
Cables and hoses can be damaged
boom.
16 Remove the cotter pin from the upper cable
Component damage hazard. The
track at the platform end of the boom.
cable track can be damaged if it is
Note: Always replace the cotter pin with a new one. twisted.
17 Remove the cable track pull tube guide
fasteners from the cable track guide at the
platform end of the boom. Remove the cable
track guide from the boom.
18 Place blocks in between the upper and lower
cable tracks and secure the upper and lower
tracks together.
Crushing hazard. If the upper and
lower cable tracks are not properly
secured together, the cable track
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 23

BOOM COMPONENTS
How to Repair the Cable Track 7 Connect the ends of the replacement cable track
section to the existing cable track using the
Component damage hazard. snap rings.
The boom cable track can be
damaged if it is twisted. 8 Install the rollers onto the new section of cable
track.
Note: A cable track repair kit is available through
the Genie Parts Department, part no. 77896. The 9 Operate the boom extend/retract function
kit includes a 4 link section of cable track. through a full cycle to ensure smooth operation
of the new section of cable track.
1 Visually inspect the cable track and determine
which 4 link section needs to be replaced.
2 Carefully remove the snap rings from each end
of the damaged section of cable track.
3 Remove the retaining fasteners from the upper
black rollers from the 4 link section of cable
track to be replaced. Remove the rollers.
4 Lift up the hoses and cables and carefully
remove the damaged 4 link section of cable
track.
Component damage hazard. Hoses
and cables can be damaged if they
are kinked or pinched.
5 Remove the upper rollers from the replacement
section of cable track.
6 Lift up the hoses and cables and carefully insert
the new 4 link section of cable track.
Hoses and cables can be damaged
4 - 24 S-60 • S-65 • S-60 HC Part No. 77828

BOOM COMPONENTS
a b
k c
f
j
a short link arm to boom pivot pin

b boom
c boom lift cylinder rod-end pivot pin
d boom lift cylinder
e long link arm (ground controls side)
f long link arm (engine side)
g long link arm to turntable pivot pin
h master cylinder cam
i master cylinder cam link
j short link arm to turntable pivot pin
k long link arm to boom pivot pin
l master platform level cylinder
i m short link arm weldment
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 25

BOOM COMPONENTS
4-2 5 Slowly lower the boom until the long link arm
contacts the wood block. Do not rest the entire
Boom weight of the boom on the block. Turn the
machine off.
How to Remove the Boom Component damage hazard. The
Bodily injury hazard. This turntable covers can become
procedure requires specific repair damaged if the weight of the boom
skills, lifting equipment and a is allowed to rest on the block.
suitable workshop. Attempting this 6 Place wood blocks between the short link arm
procedure without these skills and and the turntable weldment for support.
tools could result in death or
serious injury and significant 7 Attach lifting straps from a 5 ton / 5000 kg
component damage. Dealer overhead crane to each end of the boom.
service is strongly recommended. Support the boom. Do not apply any lifting
pressure.
the O-ring (if equipped) on the fitting and/or the 8 Support and secure the rod end of the boom lift
hose end must be replaced. All connections must cylinder to a second overhead crane or similar
be torqued to specification during installation. Refer lifting device.
to Section 2, Hydraulic Hose and Fitting Torque
9 Remove the lift cylinder rod-end pivot pin
Specifications.
retaining fasteners. Use a soft metal drift to
1 Remove the jib boom. See 3-1, How to Remove remove the pin.
the Jib Boom. The boom could fall if not properly
2 Remove the cable track. See 4-1, How to supported when the lift cylinder
Remove the Cable Track. rod-end pivot pin is removed.
3 Raise the boom until the short and long link arm 10 Using auxiliary power, activate the boom down
to boom pivot pins are above the turntable function so the cylinder will retract. Retract the
covers. cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
4 Place a block of wood measuring boom. Turn the machine off.
4 x 4 x 60 inches / 10 x 10 x 152 cm under the
long link arm, across the turntable covers. Crushing hazard. The boom lift
cylinder could fall if not properly
supported and secured to the lifting
device.
4 - 26 S-60 • S-65 • S-60 HC Part No. 77828

BOOM COMPONENTS
11 Using the overhead crane, carefully lower the 16 Tag and disconnect the electrical connector for
boom lift cylinder and allow it to rest on the the cable break limit switch.
boom rest pad. Protect the cylinder rod from
17 Tag and disconnect all boom wire harness
damage.
electrical connectors located at the pivot end of
12 S-60 and S-65: Remove the boom end cover the boom.
retaining fasteners and remove the cover.
18 Support the platform leveling master cylinder.
S-60 HC: Remove the boom end cover from the Remove the master cylinder rod-end pivot pin
pivot end of the boom while guiding the small retaining fasteners. Place a rod through the pin
cable from the string potentiometer out of the and twist to remove. Carefully lower the master
slot of the cover. Rest the cover and string cylinder down.
potentiometer on the counterweight.
Component damage hazard. The from the bulkhead fittings at the pivot end of the
cable from the string potentiometer boom. Cap the bulkhead fittings.
can become damaged if it is
kinked or pinched.
13 S-60 HC: Remove the string potentiometer cable burn skin. Loosen hydraulic
break limit switch mounting fasteners. connections very slowly to allow
14 S-60 HC:Remove the pulley retaining plate from
the string potentiometer pulley bracket.
squirt or spray.
Carefully remove the string potentiometer cable
and limit switch assembly from the boom. 20 Remove the external snap rings from both boom
pivot pins at the short and long link arms. Do
15 Tag, disconnect and plug the boom extension
not remove the pins.
cylinder. 21 Using the overhead crane, adjust the boom as
necessary to relieve pressure from the pivot
pins.
burn skin. Loosen hydraulic 22 Use a soft metal drift to remove each boom
connections very slowly to allow pivot pin. Carefully remove the boom assembly
the oil pressure to dissipate from the machine and place it on a structure
gradually. Do not allow oil to capable of supporting it.
squirt or spray.
Crushing hazard. The boom could
fall if not properly supported by the
overhead crane when each boom
pivot pin is removed.
Crushing hazard. The long and
short link arms may fall if not
properly supported when the boom
pivot pins are removed.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 27

BOOM COMPONENTS
4-3 4 Remove the pin retaining fastener from the

boom lift cylinder rod-end pivot pin. Use a soft
Boom Lift Cylinder metal drift to remove the pin.
The boom lift cylinder raises and lowers the boom. Crushing hazard. The boom will fall
The boom lift cylinder is equipped with if not properly supported when the
counterbalance valves to prevent movement in the primary boom rod-end pivot pin is
event of a hydraulic line failure. removed.
5 Using auxiliary power, activate the boom down
How to Remove the Boom function so the cylinder will retract. Retract the
Lift Cylinder cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
Bodily injury hazard. This boom. Turn the machine off.
procedure requires specific repair
skills, lifting equipment and a 6 Tag, disconnect and plug the boom lift cylinder
suitable workshop. Attempting this hydraulic hoses. Cap the fittings on the cylinder.
procedure without these skills and Bodily injury hazard. Spraying
tools could result in death or hydraulic oil can penetrate and
serious injury and significant burn skin. Loosen hydraulic
component damage. Dealer connections very slowly to allow
service is strongly recommended. 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 7 Remove the pin retaining fasteners from the
be torqued to specification during installation. Refer boom lift cylinder barrel-end pivot pins. Do not
to Section 2, Hydraulic Hose and Fitting Torque remove the pins.
Specifications.
8 Use a slide hammer to remove the barrel-end
1 Raise the boom to a horizontal position. pivot pins.
2 Attach a 5 ton / 5000 kg overhead crane to the Crushing hazard. The boom lift
boom at the platform end for support. Do not lift cylinder could become unbalanced
the boom. and fall if not properly supported
3 Support and secure both ends of the boom lift and secured to the lifting device.
cylinder to a second overhead crane or similar 9 Move the boom lift cylinder towards the
lifting device. counterweight end of the machine. Rotate the
boom lift cylinder until the barrel-end pivot pin
bores will clear the boom linkage.
10 Carefully remove the boom lift cylinder from the
machine.
Crushing hazard. The boom lift
cylinder could become unbalanced
and fall if not properly supported
and secured to the lifting device.
4 - 28 S-60 • S-65 • S-60 HC Part No. 77828

BOOM COMPONENTS
4-4 2 S-60 and S-65: Remove the boom end cover

retaining fasteners and remove the cover.
Boom Extension Cylinder
S-60 HC: Remove the boom end cover from the
The boom extension cylinder is located inside the pivot end of the boom while guiding the small
boom assembly and incorporates cables and cable from the string potentiometer out of the
pulleys that are responsible for extending the slot of the cover. Rest the cover and string
number 3 boom tube. The primary boom extension potentiometer on the counterweight.
cylinder is equipped with counterbalance valves to Component damage hazard. The
prevent movement in the event of a hydraulic line cable from the string potentiometer
failure. can become damaged if it is
kinked or pinched.
How to Remove the Boom
3 S-60 HC: Remove the string potentiometer cable
Extension Cylinder break limit switch mounting fasteners.
Bodily injury hazard. This 4 S-60 HC:Remove the pulley retaining plate from
procedure requires specific repair the string potentiometer pulley bracket.
skills, lifting equipment and a Carefully remove the string potentiometer cable
suitable workshop. Attempting this and limit switch assembly from the boom.
procedure without these skills and
tools could result in death or 5 Remove the access covers from both sides of
serious injury and significant the boom at the pivot end.
component damage. Dealer
6 Fully loosen the lock nuts on the extend cables.
service is strongly recommended.
Do not remove the nuts.
7 Loosen the retract cable nut at the platform end
of the boom. Pull the cable rod from the support
and let it hang down.
be torqued to specification during installation. Refer
Specifications.
Note: Perform this procedure with the boom fully
retracted.
1 Raise the boom to a horizontal position.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 29

BOOM COMPONENTS
8 Remove the cable guard fasteners and remove 11 Remove the fasteners from the retaining blocks
the cable guard. 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.
12 Disconnect the wire connector to the extend

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
b retaining block
9 Locate the retaining plates that secure the

retract cables to the inside of the number 3
boom tube.
10 Remove the cable retaining plates and pull the a b c d
retract cables off of the pulleys. Lay the cables
flat and out of the way. a extend cable lock nuts
b extend cable mounting plate
c extend cable mounting plate fastener
d extend cable bracket
4 - 30 S-60 • S-65 • S-60 HC Part No. 77828

BOOM COMPONENTS
14 Pull back on the extend cable mounting plate 23 Attach a lifting strap from a 5 ton / 5000 kg
until it clears the blocks welded to the inside of overhead crane to the lug at the rod end of the
the number 1 boom tube. boom extension cylinder.
15 Lift up the extend cable mounting plate and push 24 Lift the boom extension cylinder with the crane
the extend cables towards the platform to create until it clears the cylinder saddle inside the
slack in the cables. Rest the cable and bracket number 2 boom tube.
assembly on top of the extend cylinder.
25 Carefully support and slide the extension
16 Locate the lower extend cable bracket on the cylinder out of the boom.
bottom of the number 3 boom tube.
Crushing hazard. The extension
17 Remove the lower extend cable bracket cylinder could fall when removed
mounting fasteners and pull back on the bracket from the boom if not properly
to release it from the number 3 boom tube. supported.
18 While pushing the lower extend cable bracket Component damage hazard. Be
towards the platform, pull the extend cable careful not to damage the cable
mounting plate towards the pivot end of the break limit switch.
boom.
Component damage hazard. Be
19 Secure the extend cable bracket and cables to careful not to damage the
the cylinder to prevent them from falling off counterbalance valves on the
when removing the cylinder. primary boom extension cylinder
when removing the cylinder from
20 Remove the external snap rings from the
the boom.
extension cylinder pin at the pivot end of the
boom. Note: During removal of the extension cylinder, the
overhead crane strap will need to be carefully
21 Use a soft metal drift to remove the pin.
adjusted for proper balancing.
22 Tag, disconnect and plug the boom extension
cylinder.
squirt or spray.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 31

BOOM COMPONENTS
4-5 4 Adjust the extend cable adjustment nuts until

approximately 1.5 inches / 4 cm of threads are
Boom Extend/Retract Cables visible past the nylock nut.
Note: If the cables have been replaced, be sure the
How to Adjust the Boom Extend/ adjustment nuts have been replaced. Do not re-use
Retract Cables the existing nuts.
The boom extend/retract cables are responsible for 5 Extend the boom until there is approximately 3
the extension and retraction of the number 3 boom feet / 1 m of travel left. Do not fully extend the
tube. Proper adjustment of the boom extend/retract boom.
cables and related components on a regular basis
is essential to good machine performance and safe 6 Locate the retract cable adjustment nut on the
machine operation. The boom extend and retract bottom of the number 1 boom tube at the
functions should operate smoothly and be free of platform end of the boom.
hesitation, jerking and unusual noise. 7 Using a dial type torque wrench, torque the
retract cable adjustment nut to 32-36 ft lbs /
Note: Perform this procedure with the boom in a
43-49 Nm using gentle and steady torque.
horizontal position.
8 Retract and extend the boom approximately
1 Fully retract the boom. 3 feet / 1 m two times and stop during the
2 S-60 and S-65: Remove the boom end cover extension cycle. This will create slack in the
retaining fasteners and remove the cover. retract cables.
S-60 HC: Remove the boom end cover from the Note:Be sure to not fully extend the boom. Stop
pivot end of the boom while guiding the small when there is approximately 3 feet / 1 m of
cable from the string potentiometer out of the travel left.
slot of the cover. Rest the cover and string
9 Repeat steps 7 and 8 two to three times.
potentiometer on the counterweight.
10 Fully extend the boom then retract the boom
Component damage hazard. The
approximately 12 inches / 30 cm.
cable from the string potentiometer
can become damaged if it is 11 At the pivot end of the boom, visually inspect
kinked or pinched. the boom extend cables for even cable droop or
sag.
3 Inspect the threaded ends of the boom extend
cables. The threads must be clean and in good Note: If the boom extend cables are uneven,
condition with no damaged threads. tighten the boom extend cable adjustment nut at
the pivot end of the boom for the appropriate cable.
4 - 32 S-60 • S-65 • S-60 HC Part No. 77828

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.
b c
6 Route the new boom extend cables through the
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.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 33

BOOM COMPONENTS
Boom retract cables: 17 Remove the rope from the old cable and
securely attach the rope to the same end of the
10 Remove the cotter pins and clevis pins from the new boom retract cable.
boom retract cables at the platform end of the
boom. 18 At the pivot end of the boom, carefully pull the
rope with the new retract cable attached.
Note: Always use a new cotter pin when installing a
clevis pin. 19 Pull the new cable towards the pivot end of the
boom until the end of the cable is at the end of
11 Remove the wear pad fasteners from the upper the boom tube. Remove the rope.
wear pads on the number 1 boom tube. Remove
the wear pads. 20 Repeat steps 14 through 19 for the other boom
retract cable.
Note: Pay attention to the location of each wear
pad and the quantity of shims for each one. 21 At the platform end of the boom, install the
retract cables, clevis pins and new cotter pins
12 Attach a lifting strap from an overhead crane to to the adjustment plate.
the platform end of the boom.
22 Remove and discard the old boom retract
13 Raise the boom using the overhead crane and pulleys from the pivot end of the boom
place a wood block under the number 2 boom extension cylinder.
tube between the number 1 and number 2 boom
tubes for support. This will create clearance 23 Install the new boom retract pulleys to the pivot
between the boom tubes to remove the retract end of the boom extension cylinder.
cables. 24 Install the boom extension cylinder assembly
14 Attach the cable pulling tool or a rope to one of into the boom.
the boom retract cables at the pivot end of the Note: Before lowering the extension cylinder into
boom. the saddles of the number 1 boom tube, wrap the
Note: A cable pulling tool is available through Genie boom retract cables around the pulleys.
Parts Department (Genie part no. 94510) 25 Adjust the boom extend/retract cables.
15 At the platform end of the boom, pull on the See 4-5, How to Adjust the Boom Extend/
boom retract cable that has the rope attached Retract Cables.
to it.
16 Pull the old cable completely out of the boom
tube. Discard the old boom retract cable.
4 - 34 S-60 • S-65 • S-60 HC Part No. 77828

BOOM COMPONENTS
4-6 5 Place a rod through the rod-end pivot pin and

twist to remove the pin. Lower the rod end of the
Platform Leveling master cylinder onto the block.
Master Cylinder 6 Remove the pin retaining fastener from the
barrel-end pivot pin.
The master cylinder acts as a pump for the slave
cylinder. It’s part of the closed circuit hydraulic loop 7 Place a rod through the barrel-end pivot pin and
that keeps the platform level through the entire twist to remove the pin.
range of boom motion. The master cylinder is
8 Remove the master cylinder from the machine.
located at the pivot end of the boom.
How to Remove the Platform

Leveling Master Cylinder
Specifications.
1 Raise the boom until the master cylinder is
above the turntable covers.
2 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the cylinder.
squirt or spray.
3 Place a 2 x 4 x 48 inches / 5 x 10 x 120 cm
block of wood across the turntable covers.
Position the block under the master cylinder.
4 Remove the pin retaining fastener from the
master cylinder rod-end pivot pin.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 35

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.
Two different styles of flex plates have been used

in the production of your machine model.
Type "A" flex plates utilize a flex plate installed
5-2 onto the flywheel of the engine and a separate
RPM Adjustment - Perkins coupler installed onto the pump splined shaft.
Models Type "B" flex plates combines the pump coupler,
as part of the flex plate, which is installed onto the
Refer to Maintenance Procedure A-11, Check and engine flywheel.
Adjust the Engine RPM - Perkins Models.
Type "A" Type "B"

(flexplate with (flexplate with
separate coupler) coupler combined)
4 - 36 S-60 • S-65 • S-60 HC Part No. 77828

ENGINES
How to Remove the Flex Plate GM models:
Deutz models: 1 Remove the muffler clamp at the exhaust pipe.
1 Remove the tailpipe bracket mounting fasteners 2 Remove the muffler bracket to bell housing
from the engine bell housing. fasteners. Remove the muffler and bracket
assembly.
2 Support the drive pump assembly with an
appropriate lifting device. 3 Disconnect the electrical connector for the
crankshaft position sensor located at the bottom
3 Remove all of the engine bell housing fasteners. of the bell housing.
4 Carefully pull the pump and bell housing 4 Support the engine with a suitable lifting device.
assembly away from the engine and secure it Do not lift it.
from moving.
5 Remove the engine plate to vibration isolator
Component damage hazard. Hoses fasteners.
can be damaged if they are kinked
or pinched. 6 Remove the engine mounting plate to bell
housing fasteners.
5 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel. Component damage hazard. The
engine could fall and the
crankshaft position sensor can
become damaged if the engine is
not properly supported when the
fasteners are removed.
7 Slide the engine mounting plate towards the
pump as far as it will go.
appropriate lifting device.
9 Remove all of the engine bell housing fasteners.
10 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
or pinched.
Remove the flex plate from the flywheel.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 37

ENGINES
Ford LRG-425 EFI models: Ford DSG-423 EFI models:

1 Disconnect the electrical connector for the 1 Disconnect the electrical connectors from both
oxygen sensor at the tailpipe. Do not remove oxygen sensors at the tailpipe and exhaust
the oxygen sensor. manifold. Do not remove the oxygen sensors.
2 Remove the engine oil dipstick fasteners from 2 Remove the exhaust pipe fasteners at the
the muffler bracket. Remove the dipstick from muffler.
the engine.
3 Support the muffler and bracket assembly with a
3 Remove the muffler retaining fasteners from the suitable lifting device.
exhaust pipe.
4 Remove the muffler bracket mounting fasteners
4 Support the muffler and bracket assembly with from the bell housing. Carefully remove the
an overhead crane or other suitable lifting muffler and bracket assembly from the engine.
device.
5 Support the engine with an overhead crane or
5 Remove the muffler bracket mounting fasteners. other suitable lifting device. Do not lift it.
Carefully remove the muffler and bracket
6 Remove the engine mounting plate to bell
assembly from the engine.
housing fasteners.
6 Support the engine with a suitable lifting device.
7 Raise the engine slightly using the overhead
Do not lift it.
crane and place a block of wood under the oil
7 Remove the engine plate to vibration isolator pan for support.
fasteners.
8 Remove the engine mounting plate to bell overhead crane or other suitable lifting device.
housing fasteners. Do not apply any lifting pressure.
9 Raise the engine slightly to take the weight off 9 Remove all of the engine bell housing retaining
of the engine mounting plate. fasteners.
10 Slide the engine mounting plate towards the 10 Carefully pull the pump and bell housing
pump as far as it will go. assembly away from the engine and secure it
from moving.
appropriate lifting device. Component damage hazard. Hoses
or pinched.
13 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
or pinched.
4 - 38 S-60 • S-65 • S-60 HC Part No. 77828

ENGINES
Perkins models: 1
1 Remove the fuel filter/water separator mounting

fasteners. 6 3
2 Remove the fuel filter/water separator and lay it

to the side. Do not disconnect the hoses.
appropriate lifting device. 4 5

5 Carefully pull the pump and bell housing 2
assembly away from the engine and secure it Ford and Deutz models
from moving.
can be damaged if they are kinked 1
or pinched.
How to Install a Type "A"

Flex Plate
2 3
1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
2 Ford models: Torque the flex plate mounting Perkins models
bolts in sequence to 14 ft-lbs / 19 Nm.
1
Then torque the flex plate mounting bolts in
sequence to 20 ft-lbs / 27 Nm.
GM models: Torque the flex plate mounting 6 1 3
bolts in sequence to 22 ft-lbs / 30 Nm. Then
torque the flex plate mounting bolts in sequence 4 3
to 31 ft-lbs / 42 Nm.
Deutz models: Torque the flex plate mounting 2 5
bolts in sequence to 28 ft-lbs / 38 Nm. 4 5
sequence to 40 ft-lbs / 54 Nm. 2
Perkins models: Torque the flex plate mounting GM models
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 39

ENGINES
3 Install the pump coupler onto the pump shaft How to Install a Type "B"
with the set screw toward the pump. Leave the
appropriate gap between coupler and pump end Flex Plate
plate for your engine. 1 Install the flex plate onto the engine flywheel
with the rubber vibration isolators towards the
a b c d e
pump.
2 Apply Loctite® removable thread sealant to the
flex plate fasteners and loosely install the
fasteners.
3 Deutz models: Torque the flex plate mounting
f Then torque the flex plate mounting bolts in
a pump
b pump shaft Ford and Perkins models: Torque the flex
c pump coupler
d flex plate with raised spline plate mounting bolts in sequence to
e engine flywheel 14 ft-lbs / 19 Nm. Then torque the flex plate
f 3/16 inch / 4.8 mm gap - Diesel Models mounting bolts in sequence to 20 ft-lbs / 27 Nm.
1/16 inch / 1.5 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423 4 Apply a high viscosity coupling grease
5/32 inch / 3.8 mm gap - GM Models
(Genie part number 128025) to the splines of the
4 Apply Loctite® removable thread sealant to the pump shaft and flex plate.
pump coupler set screw. Torque the set screw
to 61 ft-lbs / 83 Nm. Grease Specification
5 Proceed to Repair Procedure, How to Install the Shell Alvania® Grease CG, NLGI 0/1 or equivalent.
Pump and Bell Housing Assembly.
4 - 40 S-60 • S-65 • S-60 HC Part No. 77828

ENGINES
1 How to Install the Pump and Bell

Housing Assembly
6 3 1 Install the pump and bell housing assembly.
Ford LRG-425 and Deutz models: Torque the
bell housing mounting bolts labeled "C" in
sequence to 28 ft-lbs / 38 Nm. Then torque the
bell housing mounting bolts labeled "C" in
4 5
Ford DSG-423 models: Torque the bell housing
mounting bolts labeled "A" and "B" in sequence
2 to 28 ft-lbs / 38 Nm and the mounting bolts
Ford models labeled "C" to 49 ft-lbs / 66 Nm. Then torque the
bell housing mounting bolts labeled "A" and "B"
in sequence to 40 ft-lbs / 54 Nm and the
6 1 mounting bolts labeled "C" to 70 ft-lbs / 95 Nm.
Perkins models: Torque the bell housing
mounting bolts labeled "B" in sequence to
28 ft-lbs / 38 Nm and the mounting bolts labeled
"A" to 49 ft-lbs / 66 Nm. Then torque the bell
4 3 housing mounting bolts labeled "B" in sequence
to 40 ft-lbs / 54 Nm and the mounting bolts
labeled "A" to 70 ft-lbs / 95 Nm.
GM models:Torque the bellhousing mounting
2 5 bolts in sequence to 28 ft-lbs / 38 Nm. Then
torque the bell housing mounting bolts in
Deutz models sequence to 40 ft-lbs / 54 Nm.
Type "A" flexplate: When
1 installing the pump, do not force
the pump coupler into the flexplate
or damage to the pump shaft seal
6 3 may occur.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
4 5
2
Perkins models
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 41

ENGINES
1 6 6 1
C C
A A
7 8
C C
C 4
3 C
9
B
B
C 4 5
C C B
9
5 2 B B
8 B B 7
Ford LRG-425 EFI models
2 3
6
1 B Perkins models
B
3
A
6 1
10 8
A
4
4 3
C C
7 B 5
11 12
2
Ford DSG-423 EFI models 7 5
6 1 2 9
10 C C 8 GM models
C C
4 3
C C
C C
11 12
C C
7 C C 5
2 9
Deutz models
4 - 42 S-60 • S-65 • S-60 HC Part No. 77828

ENGINES
5-4
Engine Fault Codes -
GM and Ford Models
How to Retrieve Engine Fault

Codes
GM models:
When an engine malfunction is detected by the

Electronic Control Module (ECM), a fault code is
recorded and the check engine light will turn on at
the ground controls. Special equipment is required
to retrieve fault codes stored within the ECM.
Contact the Genie Service Department for
assistance in retrieving fault codes.
Note: If the check engine light is on and the engine

is stopped, tag the machine and remove from
service. Contact service personnel immediately.
Note: If the check engine light is on and the engine
is still running, contact service personnel within 24
hours.
Ford models:
The ECM constantly monitors the engine by the

use of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel
injection and make constant and instantaneous
changes to ignition timing, fuel delivery and throttle
position to maintain the engine's running condition
at its highest efficiency while at the same time
keeping exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of
set parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor and
will turn on the Check Engine Light.
Refer to Section 5, How to Retrieve Engine Fault
Codes for your specific model of engine. Use the
Fault Code Chart within Section 5 to aid in
identifying the fault.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 43

Hydraulic Pumps
6-1 2 Tag, disconnect and plug the function pump
hydraulic hoses. Cap the fittings on the pump.
Function Pump
How to Remove the burn skin. Loosen hydraulic
Function Pump connections very slowly to allow
squirt or spray.
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.
Models without hydraulic tank shut-off valves:
1 Models without hydraulic tank shut-off
valves: Remove the drain plug from the
sure to fill the hydraulic tank to
hydraulic tank and completely drain the tank
specification and prime the pump
into a suitable container. See capacity
after installing the pump.
specifications.
Models with hydraulic tank shut-off valves:
Models with hydraulic tank shut-off valves:
Locate the two hydraulic tank valves at the Component damage hazard. Be
hydraulic tank through the access hole sure to open the two hydraulic tank
underneath the turntable. Close the valves. valves and prime the pump after
Component damage hazard. The installing the pump.
engine must not be started with the
hydraulic tank shut-off valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
open closed
4 - 44 S-60 • S-65 • S-60 HC Part No. 77828

HYDRAULIC PUMPS
6-2 2 Models without hydraulic tank shut-off

valves: Remove the drain plug from the
Drive Pump hydraulic tank and completely drain the tank
into a suitable container. See capacity
The drive pump is a bi-directional variable specifications.
displacement piston pump. The pump output is
controlled by the electro-proportional controller, Models with hydraulic tank shut-off valves:
located on the pump. The only adjustment that can Locate the two hydraulic tank valves at the
be made to the pump is the neutral or null hydraulic tank through the access hole
adjustment. Any internal service to the pump underneath the turntable. Close the valves.
should only be performed at an authorized Eaton Component damage hazard. The
Hydraulics center. Call Genie Industries Service engine must not be started with the
Department to locate your local authorized service hydraulic tank shut-off valves in
center. the closed position or component
damage will occur. If the tank
How to Remove the Drive Pump valves are closed, remove the key
Component damage hazard. The from the key switch and tag the
work area and surfaces where this machine to inform personnel of the
procedure will be performed must condition.
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
hose end must be replaced. All connections must open closed
to Section 2, Hydraulic Hose and Fitting Torque 3 Tag and disconnect and plug the hydraulic
Specifications. hoses from the drive and function pumps.
Cap the fittings on the pumps.
1 Disconnect the electrical connection at the
electro-proportional controller located on the Bodily injury hazard. Spraying
drive pump. hydraulic oil can penetrate and
squirt or spray.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 45

HYDRAULIC PUMPS
4 Support the pump with a lifting device and How to Prime the Pump
remove the two drive pump mounting fasteners.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure
5 Carefully pull the drive pump out until the pump gauge to the test port on the drive pump.
coupler separates from the flex plate.
2 Remove the safety pin (if equipped) from the
6 Remove the drive pump from the machine. engine pivot plate latch.
Component damage hazard. The Note: The engine pivot plate latch is located under
hydraulic pump may become the engine turntable pivot plate at the counterweight
unbalanced and fall if not properly end of the machine.
supported.
3 Open the engine pivot plate latch and swing the
Component damage hazard. When
engine pivot plate out and away from the
installing the pump, do not force
machine.
the pump coupler into the flexplate
or damage to the pump shaft seal 4 GM and Ford models: Close the valve on the
may occur. LPG tank then disconnect the hose from the
tank. Move the fuel select switch to the LPG
Models without hydraulic tank shut-off valves:
position.
Component damage hazard. Be Perkins models: Disconnect the engine wiring
sure to fill the hydraulic tank to harness from the fuel solenoid at the injector
specification and prime the pump pump.
after installing the pump.
Deutz models: Hold the manual fuel shutoff
Models with hydraulic tank shut-off valves: valve clockwise to the closed position.
sure to open the two hydraulic tank a
valves and prime the pump after
installing the pump.
a manual fuel shutoff valve
4 - 46 S-60 • S-65 • S-60 HC Part No. 77828

HYDRAULIC PUMPS
5 Have another person crank the engine with the

starter motor for 15 seconds, wait 15 seconds,
then crank the engine an additional 15 seconds
or until the pressure reaches 320 psi / 22 bar.
6 GM and Ford models: Connect the LPG hose
to the LPG tank and open the valve on the tank.
Move the fuel select switch to the gasoline
position.
Perkins models: Connect the engine wiring
harness to the fuel solenoid.
Deutz models: Release the manual fuel shutoff
valve.
check for hydraulic leaks.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 47

4 - 48 S-60 • S-65 • S-60 HC Part No. 77828

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) ............................ 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) ....................... 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
150 psi / 10.3 bar .............................. P ........... Turntable rotate circuit ...................... 30-35 ft-lbs / 41-47 Nm
This list continues. Please turn the page
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 49

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 - 50 S-60 • S-65 • S-60 HC Part No. 77828

MANIFOLDS
Function Manifold Components, continued

Index Schematic
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
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) ................................. 20-25 ft-lbs / 27-34 Nm
27 Check valve, 30 psi / 2 bar ................ EE ......... Platform rotate and jib
boom circuit (S-65)
(prevents hydraulic hoses
from draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
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) ................................. 20-25 ft-lbs / 27-34 Nm
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 51

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

MANIFOLDS
7-2
Valve Adjustments -
Function Manifold
How to Adjust the System

Relief Valve
stowed position.

gauge to the PTEST port on the function manifold.
3 Hold the function enable/rpm select toggle
switch to the high idle position. Activate and
hold the boom retract toggle switch with the
boom fully retracted.
4 Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item K).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 5 and recheck relief
valve pressure.
8 Remove the pressure gauge.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 53

MANIFOLDS
7-3
Jib Boom / Platform Rotate Manifold Components
Index Schematic
1 Solenoid valve, 2 position 3 way ..... FF ......... Platform rotate/jib boom select ......... 20-25 ft-lbs / 27-34 Nm
FF
4 - 54 S-60 • S-65 • S-60 HC Part No. 77828

MANIFOLDS
7-4
Brake/Two-Speed Manifold Components
The brake/two-speed manifold is mounted near the turntable rotator.
Index Schematic
1 Orifice, 0.025 inch / 0.64 mm .......... JJ .............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. 77828 S-60 • S-65 • S-60 HC 4 - 55

MANIFOLDS
7-5
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor.
Index Schematic
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 - 56 S-60 • S-65 • S-60 HC Part No. 77828

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. 77828 S-60 • S-65 • S-60 HC 4 - 57

MANIFOLDS
How to Set Up the Oscillate 7 To level the drive chassis, start the engine and
push up or pull down on the threaded rod until
Directional Valve the machine is completely level.
Note: Adjustment of the oscillate directional valve 8 Verify that the ground and drive chassis are
linkage is only necessary when the linkage or valve completely level.
has been replaced.
9 Adjust the heim joint until the hole lines up with
1 Lower the boom to the stowed position. the retaining fastener hole in the axle.
2 Use a "bubble type" level to be sure the floor is 10 Install the heim joint to the axle and tighten the
completely level. jam nut.
Tip-over hazard. Failure to perform 11 Check to be sure the drive chassis is
this procedure on a level floor completely level.
could compromise the stability of
the machine resulting in the 12 Measure the distance between the drive chassis
machine tipping over. and the non-steer axle on both sides (from the
inside of the drive chassis).
3 Check the tire pressure in all four tires and add
air if needed to meet specification. Note: If the distance is not equal and the
adjustment to the linkage was completed with the
Note: The tires on some machines are foam-filled ground and drive chassis level, repeat steps 6
and do not need air added to them. through 11 OR consult the Genie Service
Department.
4 Remove the drive chassis cover and the non-
steer axle covers.
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
6 Remove the heim joint retaining fastener from
the axle.
4 - 58 S-60 • S-65 • S-60 HC Part No. 77828

MANIFOLDS
7-7
Valve Adjustments - Oscillate
Relief Valve
How to Adjust the Oscillate

Relief Valve Pressure
1 Remove the drive chassis cover from the non-
steer end of the machine.
gauge to the diagnostic nipple located near the
oscillate directional valve.
3 Disconnect the directional valve linkage, by
removing the heim joint and retaining fastener
from the axle.
Move the engine idle toggle switch to the
maintained high idle position.
5 With the engine running in high rpm, manually
activate the valve and observe the pressure
reading on the pressure gauge. Refer to
7 Locate the relief valve on the directional valve
and remove the cap.
8 Adjust the internal screw. Turn it clockwise to
increase the pressure or counterclockwise to
decrease the pressure. Install the valve cap.
Tip-over hazard. Do not adjust the
relief valve higher than specified.
9 Repeat steps 4 through 7 and manually activate
the valve to confirm the valve pressure.
10 Turn the engine off, remove the pressure gauge
and assemble the directional valve linkage.
11 Install the cover on the non-steer end of the
drive chassis.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 59

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
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 - 60 S-60 • S-65 • S-60 HC Part No. 77828

MANIFOLDS
7-9
Traction Manifold Components, 2WD
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
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. 77828 S-60 • S-65 • S-60 HC 4 - 61

MANIFOLDS
1 2
TT WW
VV UU XX SS
6 5 4 3
4 - 62 S-60 • S-65 • S-60 HC Part No. 77828

MANIFOLDS
7-10 9 Adjust the internal hex socket until the pressure

reading on the gauge is 30 psi / 2 bar less than
Valve Adjustments, 2WD the pressure reading on the pump. Turn it
Traction Manifold clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the valve cap.
How to Adjust the Charge
Pressure Relief Valve 10 Repeat steps 7 through 9 until the pressure
reading at the drive manifold is 30 psi / 2 bar
1 Connect a 0 to 600 psi / 0 to 50 bar pressure less than the pressure reading at the pump.
gauge to the test port on the drive pump.
11 Turn the engine off and remove the pressure
2 Hold the charge pressure relief valve and gauge.
remove the cap (item TT).
3 Turn the internal hex socket clockwise fully until
it stops. Install the cap.
4 Start the engine and move and hold the function
enable/rpm select toggle switch to the high rpm
(rabbit symbol) position. Note the reading on the
pressure gauge.
6 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the traction manifold.
Press down the foot switch and slowly move the
drive control handle off center just until the
machine begines to move. Note the reading on
the pressure gauge. Turn the machine off.
8 Hold the charge pressure relief valve and
remove the cap (item TT).
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 63

MANIFOLDS
4 - 64 S-60 • S-65 • S-60 HC Part No. 77828

MANIFOLDS
7-11
Traction Manifold Components, 4WD
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
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
7 Orifice, 0.040 inch / 1 mm .................. WW ....... Equalizes pressure on both sides
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. 77828 S-60 • S-65 • S-60 HC 4 - 65

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 - 66 S-60 • S-65 • S-60 HC Part No. 77828

MANIFOLDS
7-12 9 Adjust the internal hex socket until the pressure

reading on the gauge is 30 psi / 2 bar less than
Valve Adjustments, 4WD the pressure reading on the pump. Turn it
Traction Manifold clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the valve cap.
How to Adjust the Charge
Pressure Relief Valve 10 Repeat steps 7 through 9 until the pressure
reading at the drive manifold is 30 psi / 2 bar
1 Connect a 0 to 600 psi / 0 to 50 bar pressure less than the pressure reading at the pump.
gauge to the test port on the drive pump.
11 Turn the engine off and remove the pressure
2 Hold the charge pressure relief valve and gauge.
remove the cap (item UU).
3 Turn the internal hex socket clockwise fully until
it stops. Install the cap.
4 Start the engine and move and hold the function
enable/rpm select toggle switch to the high rpm
(rabbit symbol) position. Note the reading on the
pressure gauge.
6 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the traction manifold.
Press down the foot switch and slowly move the
drive control handle off center just until the
machine begines to move. Note the reading on
the pressure gauge. Turn the machine off.
8 Hold the charge pressure relief valve and
remove the cap (item UU).
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 67

MANIFOLDS
7-13 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C.
A properly functioning coil provides an As valve coil resistance is sensitive to changes in
electromotive force which operates the solenoid air temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / 10°C
within the coil. Zero resistance indicates the coil that your air temperature increases or decreases
has failed. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Valve Coil Resistance Specification

resistance values outside specification can produce
erratic operation. When coil resistance decreases Description Specification
below specification, amperage increases. As
resistance rises above specification, voltage Solenoid valve, 3 position 4 way, 10V DC 5 to 7Ω
increases. (schematic items D, V and Y)
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)
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)
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)
Result: The resistance should be within

specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
4 - 68 S-60 • S-65 • S-60 HC Part No. 77828

MANIFOLDS
How to Test a Coil Diode

a
Genie incorporates spike suppressing diodes in all COIL AMMETER
of its directional valve coils except proportional d

valves and those coils with a metal case. Properly
functioning coil diodes protect the electrical circuit
by suppressing voltage spikes. Voltage spikes c - b
naturally occur within a function circuit following the
+
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 -
a multimeter
b 9V DC battery
injury. Remove all rings, watches c 10Ω resistor
and other jewelry. d coil
1 Test the coil for resistance. See, How to Test a Note: Dotted lines in illustration indicate a
Coil. reversed connection as specified in
step 6
2 Connect a 10Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the 4 Connect the negative lead to the other terminal
other end of the resistor to a terminal on the on the coil.
coil. Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
Ω
Resistor, 10Ω end of the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
Note: The battery should read 9V DC or more when battery. Note and record the current reading.
measured across the terminals. 6 At the battery or coil terminals, reverse the
connections. Note and record the current
3 Set a multimeter to read DC current.
reading.
Note: The multimeter, when set to read DC current,
Result: Both current readings are greater than
should be capable of reading up to 800 mA.
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. 77828 S-60 • S-65 • S-60 HC 4 - 69

Turntable Rotation Components

8-1 3 Loosen the backlash pivot plate and adjustment
bolts.
Turntable Rotation Assembly
How to Remove the Turntable

Rotation Assembly
Specifications.
firm and level surface.
1 Secure the turntable from rotating with the

turntable rotation lock pin. a b c
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
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.
Crushing hazard. The turntable
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 - 70 S-60 • S-65 • S-60 HC Part No. 77828

TURNTABLE ROTATION COMPONENTS
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.
How to Adjust the Turntable

Rotation Gear Backlash
The turntable rotation drive hub is mounted on an
adjustable plate that controls the gap between the
rotation motor pinion gear and the turntable bearing
ring gear.
Note: Perform this procedure with the boom

between the non-steer end tires and with the a b c
machine on a firm and level surface.
1 Secure the turntable from rotating with the a backlash pivot plate
b adjustment bolt with lock nut
turntable rotation lock pin. c backlash pivot plate mounting bolts
Note: The turntable rotation lock pin is located next 3 Push the backlash pivot plate towards the
to the boom rest pad. turntable as far as possible (this will push the
rotation gear into the turntable bearing ring
gear).
4 Loosen the lock nut on the adjustment bolt.
5 Turn the adjustment bolt clockwise until it
contacts the backlash pivot plate.
6 Turn the adjustment bolt 1/2 turn
counterclockwise. Tighten the lock nut on the
adjustment bolt.
7 Rotate the backlash pivot plate away from the
turntable until it contacts the adjustment bolt.
Then torque the mounting fasteners on the
backlash pivot plate to specification. Refer to
8 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.
Part No. 77828 S-60 • S-65 • S-60 HC 4 - 71

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.
Specifications.
1 Rotate the turntable until the boom is between
the steer tires.
2 Tag, disconnect and plug the oscillating axle
cylinder.
or spray.
4 - 72 S-60 • S-65 • S-60 HC Part No. 77828

February 2012 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Genie S-60 and S-65 Operator’s Manual or the
Genie S-60 HC Operator's Manual on your
machine.
Observe and Obey: Be sure that all necessary tools and test
Troubleshooting and repair procedures shall be equipment are available and ready for use.
completed by a person trained and qualified on Read each appropiate fault code thoroughly.
the repair of this machine. Attempting shortcuts may produce hazardous
Immediately tag and remove from service a conditions.
damaged or malfunctioning machine. Be aware of the following hazards and follow
Repair any machine damage or malfunction generally accepted safe workshop practices.
before operating the machine. Crushing hazard. When testing
or replacing any hydraulic
Unless otherwise specified, perform each
component, always support
repair procedure with the machine in the
the structure and secure it
following configuration:
from movement.
• Machine parked on a firm, level surface
• Turntable rotated with the boom between could result in death or serious
the non-steer wheels injury. Remove all rings, watches
• Turntable secured with the turntable and other jewelry.
rotation lock Bodily injury hazard. Spraying
• Key switch in the off position with the hydraulic oil can penetrate and
key removed burn skin. Loosen hydraulic
• Wheels chocked connections very slowly to allow
from the machine
squirt or spray.
Note: Perform all troubleshooting on a firm level
surface.
Note: Two persons will be required to safely
perform some troubleshooting procedures.
Part No. 77828 S-60 • S-65 • S-60 HC 5-1

Section 5 • Fault Codes February 2012
FAULT CODES
Fault Code Chart - 3 Determine the error source: The red LED
indicates the error source and will flash two
Control System separate codes. The first code will indicate the
first digit of the two digit code, flashing once per
How to Retrieve Control System second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Fault Codes
Note: When the red LED is flashing the code, the
Note: At least one fault code is present when the
yellow LED will be on solid.
alarm at the platform controls produces two short
beeps every 30 seconds for 10 minutes. 4 Determine the error type: The yellow LED
indidates the error type and will flash two
Note: Perform this procedure with the engine off,
separate codes. The first code will indicate the
the key switch turned to platform controls and the
first digit of the two digit code, flashing once per
red Emergency Stop button pulled out to the on
second. It will then pause for 1.5 seconds and
position at both the ground and platform controls.
flash the second digit once per 0.5 second.
1 Open the platform control box lid. Note: When the yellow LED is flashing the code,
Electrocution/burn hazard. Contact the red LED will be on solid.
with electrically charged circuits 5 Use the fault code table on the following pages
could result in death or serious to aid in troubleshooting the machine by
injury. Remove all rings, watches pinpointing the area or component affected.
and other jewelry.
2 Locate the red and yellow fault LEDs on the
ALC-500 circuit board inside the platform control
box. Do not touch the circuit board.
Electrostatic discharge (ESD) can
damage printed circuit board
components. If the circuit board
does need to be handled, maintain
firm contact with a metal part of
the machine that is grounded at all
times when handling the printed
circuit board OR use a grounded
wrist strap.
5-2 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES
Error Source Error Type Condition Solution

ID Name ID Name
21 Boom 1 Joystick 11 Function is inoperative
Value at 5V Cycle power off,
(primary boom up/ 12 until joystick is
Value too high then on and
down) 15 calibrated. Alarm
Value too low problem should be
16 sounds indicating
Value at 0V corrected.
fault.
Function is inoperative
17 Not calibrated until joystick is Calibrate joystick
calibrated.
Initiate 1-second beep Self-clearing.
18 Just calibrated
of alarm. (transient)
22 Boom 1 directional Valve is operating Cycle power off,
valves outside of operational then on and
21 Fault
limits. Alarm sounds problem should be
indicating fault. corrected.
23 Boom 1 flow Valve is operating Cycle power off,
control valve 12 Value too high outside of operational then on and
15 Value too low limits. Alarm sounds problem should be
Normal function Calibrate valve
17 Not calibrated
except threshold for thresholds
one or both directions Self-clearing.
18 Just calibrated
is zero. (transient)
31 Boom 2 Joystick 11 Value at 5V Joystick is operating Cycle power off,
(secondary boom 12 Value too high outside of operational then on and
up/down or 15 Value too low limits. Alarm sounds problem should be
primary boom 16 Value at 0V indicating fault. corrected.
extend/retract) Function is inoperative
calibrated.
Initiate 1 second beep Self-clearing.
18 Just calibrated
32 Boom 2 directional Valve is operating Cycle power off,
valves outside of operational then on and
21 Fault
Continued on next page
Part No. 77828 S-60 • S-65 • S-60 HC 5-3

FAULT CODES

ID Name ID Name
33 Boom 2 flow Valve is operating Cycle power off,
control valve 12 Value too high outside of operational then on and
Normal function
except threshold for Calibrate valve
17 Not calibrated
one or both directions thresholds
is zero.
Self-clearing.
18 Just calibrated
(transient)
41 Turntable rotate 11 Value at 5V Joystick is operating Cycle power off,
joystick 12 Value too high outside of operational then on and
16 Value at 0V indicating fault. corrected.
Function is inoperative
calibrated.
18 Just calibrated
42 Turntable rotate Valve is operating Cycle power off,
directional valves outside of operational then on and
21 Fault
43 Turntable rotate Valve is operating Cycle power off,
flow control valve 12 Value too high outside of operational then on and
17 Not calibrated
except threshold for thresholds.
18 Just calibrated
44 Drive enable Drive enable function Cycle power off,
toggle switch is inoperative. then on and
21 Fault
problem should be
corrected.
5-4 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES

ID Name ID Name
51 Drive joystick 11 Value at 5V Limited speed and
12 Value too high direction frozen at Power up
15 Value too low zero and neutral. controller with
16 Value at 0V Alarm sounds problem corrected.
indicating fault.
Joystick speed and
17 Not calibrated direction frozen at Calibrate joystick
zero and neutral.
18 Just calibrated
53 Drive flow valve Limited speed and
(EDC) direction frozen at Power up
12 Value too high
zero and neutral. controller with
15 Value too low
Alarm sounds problem corrected.
indicating fault.
17 Not calibrated
except threshold for thresholds
18 Just calibrated
54 Drive brake valve Limited speed and
direction frozen at Power up
21 Fault zero and neutral. controller with
indicating fault.
55 High speed drive Motor speed frozen in
Power up
motor Valve the low state. Alarm
21 Fault controller with
sounds indicating
problem corrected.
fault.
61 Steer joystick 11 Value at 5V Limited speed and
12 Value too high direction frozen at Power up
15 Value too low zero and neutral. controller with
16 Value at 0V Alarm sounds problem corrected.
indicating fault.
Joystick speed and
17 Not calibrated direction frozen at Calibrate Joystick
zero and neutral.
18 Just calibrated
62 Steer directional Limited speed and
valves direction frozen at Power up
21 Fault zero and neutral. controller with
indicating fault.
Part No. 77828 S-60 • S-65 • S-60 HC 5-5

FAULT CODES
Ford LRG-425 EFI Engine 5 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
Fault Codes times. After the fault codes, the check engine
The ECM constantly monitors the engine by the light will blink a code 123 three times again
use of sensors on the engine. The ECM also indicating the end of the stored codes.
uses signals from the sensors to initiate
Note: If any fault codes are present, the ECM will
sequential fuel injection and make constant and
blink a three digit code three times for each code
instantaneous changes to ignition timing, fuel
stored in memory. It will blink the first digit of a
delivery and throttle position to maintain the
three digit code, pause, blink the second digit,
engine's running condition at its highest efficiency
pause, and then blink the third digit. For example:
while at the same time keeping exhaust
the check engine light blinks 5 consecutive
emissions to a minimum. When a sensor fails or
times, blinks 3 times and then 1 time. That would
returns signals that are outside of set
indicate code 531.
parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor Note: Once a fault code has been retrieved and
and will turn on the Check Engine Light. the repair has been completed, the ECM memory
must be reset to clear the fault code from the
Note: Perform this procedure with the key switch
ECM. See How to Clear Engine Fault Codes from
in the off position.
the ECM.
1 Open the ground controls side cover and
locate the run/test toggle switch on the side of How to Clear Engine Fault
the 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
3 Quickly activate and release the start toggle
locate the battery.
switch/button. Do not start the engine.
2 Disconnect the negative battery cable from
4 Move and hold the run/test toggle switch to
the battery for a minimum of 5 minutes.
the test position.
Electrocution/burn hazard.
Result: The check engine light should turn on.
Contact with electrically charged
The check engine light should begin to blink.
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
3 Connect the negative battery cable to the
battery.
5-6 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES
Code Problem Cause Solution
Closed Loop Multiplier Heated Oxygen Sensor wiring and/or

111
Repair wiring and/or connections OR replace
High (LPG) connections open or shorted OR sensor is faulty sensor OR repair vacuum and exhaust leaks.
OR there are vacuum leaks or exhaust leaks.
112
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections
(Bank 1) open or shorted OR sensor is faulty.
Repair wiring and/or connections OR
replace sensor.
113
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections
(Bank 2) open or shorted OR sensor is faulty.
The post cat Heated Oxygen Sensor wiring

Post-cat oxygen and/or connections are open or shorted OR Repair wiring and/or connections OR replace
114 sensor open sensor is cold, non-responsive or inactive for the post cat oxygen sensor.
60 seconds or longer.
Heated Oxygen Sensor wiring and/or Repair wiring and/or connections OR replace
connections open or shorted OR sensor is sensor OR repair any vacuum and exhaust leaks
Closed Loop Multiplier
121 High (Gasoline)
faulty OR there are vacuum leaks or exhaust
leaks OR fuel pressure is low OR the fuel
OR test the fuel pressure OR clean or replace the
fuel injectors.
injectors need cleaning or replacing.
MAP, IAT or ECT sensors not in correct position

OR wiring and/or connections for sensors open
122
Closed Loop Multiplier or shorted OR sensor is faulty OR one or more Adjust or replace sensors OR clean or repair
Low (Gasoline) fuel injectors are stuck open OR there is fuel injectors.
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.
Heated Oxygen Sensor wiring and/or

connections open or shorted OR sensor is
124
Closed Loop Multiplier
sensor OR replace fuel OR test and repair the
Low (LPG) faulty OR fuel quality is poor OR fuel system
fuel system components.
components may be faulty.
133 Gasoline cat monitor
Repair exhaust leaks OR there is an emissions

134
There are exhaust leaks OR the catalyst system
LPG cat monitor efficiency is below the acceptable level. compliance issue. Contact Ford Power Products
for assistance.
135 NG cat monitor

connections open or shorted OR sensor is Repair heated oxygen sensor wiring and/or
Adaptive Lean Fault -
141
faulty OR there are vacuum or exhaust leaks connections OR replace sensor OR repair
High Limit (Gasoline) OR one or more fuel injectors faulty or stuck vacuum and exhaust leaks OR test the fuel
closed OR fuel quality is poor OR fuel pressure OR clean or replace the fuel injectors.
pressure is too low.
MAP, IAT or ECT sensors not in correct position

OR wiring and/or connections for sensors open
Adaptive Rich Fault -
142
or shorted OR sensor is faulty OR one or more Adjust or replace sensors OR clean or repair
Low Limit (Gasoline) fuel injectors are stuck closed OR there is fuel injectors.
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.

connections open or shorted OR sensor is
143
Adaptive Learn High sensor OR repair any vacuum and exhaust
faulty OR there are vacuum leaks or exhaust
(LPG) leaks OR replace fuel OR test and repair the
leaks OR fuel quality is poor OR fuel system
fuel system components.
Engine wire harness may have an intermittent Repair short in engine wire harness
Adaptive Learn Low
144 (LPG)
short to 5V DC or 12V DC OR fuel system
OR test and repair the fuel system
components.
Part No. 77828 S-60 • S-65 • S-60 HC 5-7

FAULT CODES
161
Battery is faulty OR alternator is not charging OR Replace battery OR repair alternator OR repair
System Voltage Low
battery supply wiring to ECM is open or shorted. battery supply wiring to ECM.
162
Alternator is overcharging the battery when
System Voltage High Repair or replace the alternator.
engine RPM is greater than 1500 rpm.
IAT sensor wiring and/or connections are open or

211 IAT High Voltage shorted OR sensor is faulty OR engine intake air
temperature is too cold.
sensor OR direct warmer air into air intake.
IAT sensor wiring and/or connections are open or

212 IAT Low Voltage shorted OR sensor is faulty OR engine intake air
temperature is too hot.
sensor OR direct cooler air into air intake.
Air intake temperature is greater than 200° F with

213
IAT Higher Than
the engine greater than 1000 rpm OR air intake
Expected (1)
system has leaks OR IAT sensor is faulty. Check air intake system for damage and proper
routing of air intake components OR replace the
Air intake temperature is greater than 210° F with IAT sensor.
IAT Higher Than
214 Expected (2)
the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.
Faulty oil pressure sensor OR sensor wiring Replace oil pressure sensor OR repair sensor
215 Oil Pressure Low and/or connections open or shorted OR engine wiring and/or connections OR fill engine oil level
to specification.
oil level too low.
Engine cooling system is malfunctioning OR Repair engine cooling system problems OR

221 CHT/ECT High Voltage sensor wires and/or connections open or shorted
OR sensor is faulty.
repair open or shorted wiring to sensor OR
replace sensor.
Engine cooling system is malfunctioning and
222 CHT/ECT Low Voltage overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.
Coolant temperature at the cylinder head is 240° F. Repair engine cooling system problems OR
223
CHT Higher Than repair open or shorted wiring to sensor OR
Expected (1) overheating the engine OR sensor wires and/or replace sensor OR fill engine coolant level to
connections open or shorted OR sensor is faulty specification.
Coolant temperature at the cylinder head is 250° F.

224
CHT Higher Than
Expected (2) overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
231
Open or shorted wiring and/or connections to MAP
MAP High Pressure
sensor OR sensor is faulty.
Repair wiring and/or connections to sensor OR
replace MAP sensor.
232
Open or shorted wiring and/or connections to MAP
MAP Low Voltage
sensor OR sensor is faulty.
234 BP High Pressure MAP sensor is faulty OR ECM is faulty.

Replace MAP sensor OR replace the ECM.
235 BP Low Pressure MAP sensor is faulty OR ECM is faulty.
Crankshaft position sensor wiring and/or

242 Crank Sync Noise connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.
Crankshaft position sensor wiring and/or Be sure system ground connections are in place
243 Never Crank Synced
At Start
connections open or shorted OR there is a poor
and secure OR repair wiring and/or connections
to sensor OR replace sensor.
Crankshaft position sensor wiring and/or

244 Camshaft Sensor Loss connections open or shorted OR there is a poor
5-8 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES

Camshaft position sensor wiring and/or Be sure system ground connections are in place
245 Camshaft Sensor Noise connections open or shorted OR there is a poor and secure OR repair wiring and/or connections
system ground connection OR sensor is faulty. to sensor OR replace sensor.
253
Knock sensor wiring and/or connections open or Repair wiring and/or connections to knock sensor
Knock Sensor Open
shorted OR sensor is faulty. OR replace knock sensor.
Knock sensor wiring and/or connections open or Check for excessive engine vibration OR repair
254 Excessive Knock Signal shorted OR there is excessive engine vibration
OR sensor is faulty.
wiring and/or connections to knock sensor OR
replace knock sensor.
311
Open wiring and/or connections to fuel injector #1
Injector Driver #1 Open
OR fuel injector #1 is faulty OR ECM is faulty. Repair wiring and/or connections to fuel injector #1
Wiring and/or connections to fuel injector #1 is OR replace fuel injector #1 OR replace the ECM.
312 Injector Driver #1 Shorted shorted OR fuel injector #1 is faulty OR
ECM is faulty.
313
ECM is faulty.
315
ECM is faulty.
321
ECM is faulty.
Open wiring and/or connections to fuel pump OR

351
Fuel Pump Loop Open or
fuel pump power shorted to ground OR fuel pump
High Side Short to Ground
is faulty. Repair wiring and/or connections to fuel pump OR
replace fuel pump.
352
Fuel Pump High Side Wiring and/or connections to fuel pump shorted to
Shorted to Power power OR fuel pump is faulty.
Fuel pressure too high OR LPG lockoff not opening

MegaJector Delivery completely OR the line between the MegaJector
353 Pressure Higher Than
Expected
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly Check fuel pressure OR repair LPG lockoff OR
OR MegaJector is faulty. repair the line between the MegaJector and
Fuel pressure too low OR LPG lockoff not opening carburetor OR repair engine cooling system OR
MegaJector Delivery completely OR the line between the MegaJector replace the MegaJector.
354 Pressure Lower Than
Expected
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly
OR MegaJector is faulty.
The ECM doesn't get any response from the Check CAN circuits for continuity and shorts to
355 MegaJector
Communication Lost
MegaJector, or an incorrect response for 500ms
period or longer.
power or ground and for continuity and repair as
necessary OR replace the MegaJector.
The MegaJector detects voltage greater than 18
361 MegaJector Voltage
Supply High
volts for 5 seconds anytime the engine is cranking
Repair charging system OR replace the
MegaJector.
or running.
The MegaJector detects voltage less than 9.5 volts Repair VBAT power or ground circuit to ECM and
362
MegaJector Voltage
for 5 seconds anytime the engine is cranking or MegaJector OR replace battery OR repair
Supply Low
running. charging system OR replace the MegaJector.
Part No. 77828 S-60 • S-65 • S-60 HC 5-9

FAULT CODES
363 MegaJector Internal The MegaJector detects an internal fault. Open or

Actuator Fault Detection short in power, ground or CAN circuits.
Check Power, Ground and CAN circuits at
MegaJector and all connections and repair as
364 MegaJector Internal The MegaJector detects an internal circuitry failure.
Circuitry Fault Detection Open or short in power, ground or CAN circuits. necessary OR MegaJector has an internal fault.
Contact Ford Power Products for assistance.
MegaJector Internal The MegaJector detects an internal
365 Communication Fault communications failure. Open or short in power,
ground or CAN circuits.
Detection
411
Open wiring and/or connections to ignition
Coil Driver #1 Open
coil #1 OR ignition coil #1 is faulty. Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
412
Wiring and/or connections to ignition coil #1
Coil Driver #1 Shorted
shorted OR ignition coil #1 is faulty
413
Open wiring and/or connections to ignition
Coil Driver #2 Open
coil #2 OR ignition coil #2 is faulty. Repair wiring and/or connections to ignition
coil #2 OR replace ignition coil #2.
414
Wiring and/or connections to ignition coil #2
Coil Driver #2 Shorted
shorted OR ignition coil #2 is faulty
511 FPP1 High Voltage
512 FPP1 Low Voltage
513 FPP1 Higher than IVS Limit

If this fault appears on your machine, contact
Not used.
the Genie Industries Service Department.
514 FPP1 Lower than IVS Limit
531 TPS1 (Signal Voltage) High The #1 throttle position sensor wiring and/or
Be sure system ground connections are in place
system ground connection OR throttle position
532 TPS1 (Signal Voltage) Low sensor #1 is faulty.
to sensor OR replace throttle position sensor #1.
533 TPS2 (Signal Voltage) High The #2 throttle position sensor wiring and/or
Be sure system ground connections are in place
system ground connection OR throttle position
534 TPS2 (Signal Voltage) Low sensor #2 is faulty.
to sensor OR replace throttle position sensor #2.
The throttle position sensor wiring and/or

535 TPS1 Higher than TPS2 connections for either TPS1 or TPS2 open or
Be sure engine harness wiring and connections
are in place and secure OR repair wiring and/or
shorted OR there is a poor system ground
connections to one or both TPS sensors OR
536 TPS1 Lower than TPS2 connection OR one or both throttle position
sensors are faulty.
replace one or both TPS sensors.
Governor actuator is stuck closed OR wiring

537 Throttle Unable to Open and/or connections open or shorted OR
governor actuator is faulty. Repair wiring and/or connections to governor
actuator OR replace the governor actuator.
Governor actuator is stuck open OR wiring
538 Throttle Unable to Close and/or connections open or shorted OR
governor actuator is faulty.
Engine harness wiring and/or connections open

545
Repair wiring and/or connections in engine
Governor Interlock Failure or shorted OR there is a poor system ground
harness OR replace the ECM.
connection OR ECM is faulty.
5 - 10 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES
551 Max Governor Speed

Override
ECM needs to be re-programmed OR throttle is Re-program ECM OR repair binding throttle
552 FPP1 Low Voltage sticking open OR there are air leaks between the
throttle body and cylinder head.
operation OR repair any air leaks between the
throttle body and cylinder head.
553 FPP1 Higher than IVS Limit
611 COP Failure
612 Invalid Interrupt
613 A/D Loss

Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is faulty. damage or shorts to ECM to be sure they are
614 RTI 1 Loss secure OR replace ECM.
615 Flash Checksum Invalid
616 RAM Failure
631
External 5V DC Ref
Lower than Expected Engine harness wiring and/or connections open Locate and repair any engine harness wiring
or shorted to ground OR there is a faulty engine damage or shorts OR locate and troubleshoot or
632
External 5V DC Ref sensor OR ECM is faulty. repair faulty engine sensor OR replace ECM.
Higher than Expected
655 RTI2 Loss Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is faulty. damage or shorts to ECM to be sure they are
656 RTI3 Loss
secure OR replace ECM.
Part No. 77828 S-60 • S-65 • S-60 HC 5 - 11

FAULT CODES
Ford DSG-423 EFI Engine 5 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
Fault Codes times. After the fault codes, the check engine
The ECM constantly monitors the engine by the light will blink a code 123 three times again
use of sensors on the engine. The ECM also indicating the end of the stored codes.
uses signals from the sensors to initiate
Note: If any fault codes are present, the ECM will
sequential fuel injection and make constant and
blink a three digit code three times for each code
instantaneous changes to ignition timing, fuel
stored in memory. It will blink the first digit of a
delivery and throttle position to maintain the
three digit code, pause, blink the second digit,
engine's running condition at its highest efficiency
pause, and then blink the third digit. For example:
while at the same time keeping exhaust
the check engine light blinks 5 consecutive
emissions to a minimum. When a sensor fails or
times, blinks 3 times and then 1 time. That would
returns signals that are outside of set
indicate code 531.
parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor Note: Once a fault code has been retrieved and
and will turn on the Check Engine Light. the repair has been completed, the ECM memory
must be reset to clear the fault code from the
Note: Perform this procedure with the key switch
ECM. See How to Clear Engine Fault Codes from
in the off position.
the ECM.
1 Open the ground controls side cover and
locate the run/test toggle switch on the side of How to Clear Engine Fault
the 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
3 Quickly activate and release the start toggle
locate the battery.
switch/button. Do not start the engine.
2 Disconnect the negative battery cable from
4 Move and hold the run/test toggle switch to
the battery for a minimum of 5 minutes.
the test position.
Electrocution/burn hazard.
Result: The check engine light should turn on.
Contact with electrically charged
The check engine light should begin to blink.
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
3 Connect the negative battery cable to the
battery.
5 - 12 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES
Code Description Code Description
111 CL (closed loop) high LPG 212 IAT (intake air temperature) low voltage
112 EGO open / lazy pre-cat 1 213 IAT (intake air temperature) higher than expected 1
113 EGO open / lazy pre-cat 2/post-cat 1 214 IAT (intake air temperature) higher than expected 2
114 EGO open / lazy post-cat 1 215 Oil pressure low
115 EGO open / lazy post-cat 2 221 ECT/CHT (engine/cylinder head temp) high voltage
121 CL (closed loop) high gasoline bank 1 222 ECT/CHT (engine/cylinder head temp) low voltage
122 CL (closed loop) low gasoline bank 1 223 CHT higher than expected 1
124 CL (closed loop) low LPG 224 CHT higher than expected 2
133 Gasoline catalyst monitor 1 225 ECT higher than expected 1
134 LPG catalyst monitor 226 ECT higher than expected 2
141 AL (adaptive learning) high gasoline bank 1 231 MAP (manifold absolute pressure) high pressure
142 AL (adaptive learning) low gasoline bank 1 232 MAP (manifold absolute pressure) low pressure
143 AL (adaptive learning) high LPG 234 BP (barometric pressure) high pressure
144 AL (adaptive learning) low LPG 235 BP (barometric pressure) low pressure
161 Battery voltage high 242 Crank sync noise
162 Battery voltage low 243 Never crank synced at start
163 AUX analog PD1 high 244 Cam loss
164 AUX analog PD1 low 245 Cam sync noise
165 AUX analog PU3 high 246 Crank loss
166 AUX analog PU3 low 253 Knock 1-2 sensor open 1
167 AUX analog PUD1 high 254 Knock 1-2 excessive signal 1
168 AUX analog PUD1 low
171 AUX analog PUD2 high
173 AUX analog PUD3 high
181 AUX DIG1 high
182 AUX DIG1 low
183 AUX DIG2 high
184 AUX DIG2 low
185 AUX DIG3 high
186 AUX DIG3 low
211 IAT (intake air temperature) high voltage
Part No. 77828 S-60 • S-65 • S-60 HC 5 - 13

FAULT CODES
261 FP (fuel pressure) high voltage 531 TPS1 (throttle position sensor) high voltage
262 FP (fuel pressure) low voltage 532 TPS1 (throttle position sensor) low voltage
271 FT (fuel temperature) gasoline high voltage 533 TPS2 (throttle position sensor) high voltage
272 FT (fuel temperature) gasoline low voltage 534 TPS2 (throttle position sensor) low voltage
273 FT (fuel temperature) gaseous fuel high voltage 535 TPS1 (throttle position sensor) higher than TPS2
274 FT (fuel temperature) gaseous fuel low voltage 536 TPS1 (throttle position sensor) lower than TPS2
311 Injector loop open OR low-side short to ground 1 537 Unable to reach higher TPS (throttle position sensor)
312 Injector coil shorted 1 538 Unable to reach lower TPS (throttle position sensor)
313 Injector loop open OR low-side short to ground 2 539 TPS 1-2 simultaneous voltages
314 Injector coil shorted 2 541 AUX analog PU1 high
315 Injector loop open OR low-side short to ground 3 542 AUX analog PU1 low
316 Injector coil shorted 3 543 AUX analog PU2 high
321 Injector loop open OR low-side short to ground 4 544 AUX analog PU2 low
322 Injector coil shorted 4 551 Max govern speed override
351 FPump motor loop open OR high-side shorted to ground 552 Fuel rev limit
352 Fpump motor high-side shorted to power 553 Spark rev limit
353 EPR delivery pressure higher than expected 611 COP failure
354 EPR delivery pressure lower than expected 612 Invalid interrupt
355 EPR comm lost 613 A/D loss
359 Fuel run-out longer than expected 614 RTI 1 loss
361 EPR voltage supply high 615 Flash checksum invalid
362 EPR voltage supply low
363 EPR internal actuator fault detection
364 EPR internal circuitry fault detection
365 EPR internal comm fault detection
411 Primary loop open OR low-side short to ground 1
412 Primary coil shorted 1
5 - 14 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES
616 RAM failure 744 PWM5 short to power
631 5VE1 low voltage 761 MIL (malfunction indicator light) control ground short
632 5VE1 high voltage 762 MIL (malfunction indicator light) open
633 5VE2 high voltage 763 MIL (malfunction indicator light) control short to power
634 5VE2 low voltage 771 Tach output ground short
635 5VE1-5VE2 simultaneous out-of-range 772 Tach output short to power
641 Rx inactive 1629 J1939 TSC1 message receipt lost
642 Rx noise 1630 J1939 ETC message receipt lost
643 Invalid packet format
644 Shutdown request
646 CAN Tx failure
647 CAN Rx failure
648 CAN address conflict failure
655 RTI 2 loss
656 RTI 3 loss
711 Relay control ground short
712 Relay coil open
713 Relay coil short to power
714 Fpump relay control ground short
715 Fpump relay coil open
716 Fpump relay coil short to power
721 Start relay control ground short
722 Start relay coil open
723 Start relay coil short to power
731 PWM1-gauge1 open / ground short
732 PWM1-gauge1 short to power
733 PWM2-gauge2 open / ground short
735 PWM3-gauge3 open / ground short For further engine fault code troubleshooting and
diagnostic information, refer to the Ford DSG-423
EFI Service Manual (EDI part number 1060040).
741 PWM4 open / ground short Genie part number 119494.
742 PWM4 short to power
743 PWM5 open / ground short
Part No. 77828 S-60 • S-65 • S-60 HC 5 - 15

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.
4 Determine the error source: The red LED

indicates the error source and will flash two
separate codes. The first code will indicate
the first digit of the two digit code, flashing
once per second. It will then pause for 1.5
seconds and flash the second digit once per
0.5 second.
d c
a green LED (operational control

module)
b red LED (operational control module)
c operational control module
d safety control module
e red LED (safety control module)
f green LED (safety control module)
5 - 16 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES
Error Source Error Type

Condition Solution
ID Name ID Name
Use recovery switch and APU
from the ground controls to
Safety envelope Power relays
12 System Checks 11
reached disengaged.
recover the machine to stowed
position or within the operating
envelope.
Remove weight from platform

Platform load greater Power relays
12 until load is 1200 lbs / 544 kg or
than 1250 pounds disengaged.
less.
CAN communication Power relays Repair CAN bus wiring and/or
13
failure disengaged. connections.
Use recovery switch and APU
from the ground controls to
Power relays
14 Sensor power failure recover the machine to stowed
disengaged.
position or within the operating
envelope.
Inspect boom angle sensor for

Power relays proper operation and be sure it is
21 Angle sensor not active
disengaged. connected to boom properly OR
replace boom angle sensor.
Inspect string potentiometer for

String potentiometer Power relays proper operation and be sure it is
22
not active disengaged. connected to boom properly OR
replace string potentiometer.
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.
Boom up/down and

extend/retract
Repair system wiring and/or
26 Output short low inoperative. Relay wiring
connections.
open or shorted to
ground.
Part No. 77828 S-60 • S-65 • S-60 HC 5 - 17

FAULT CODES

Condition Solution
ID Name ID Name
String
Repair wiring and/or connections
Potentiometer Power relays
21 Operational sensor
5 Sensor tolerance fault
disengaged.
OR replace string potentiometer
and calibrate overload system.
(C167PSL)
Power relays
disengaged. String Repair wiring and/or connections
11 Output short high potentiometer wiring OR replace string potentiometer
open or shorted to and calibrate overload system.
voltage.
Power relays
12 Value too high potentiometer wiring OR replace string potentiometer
voltage.
Power relays
15 Value too low potentiometer wiring OR replace string potentiometer
ground.
Power relays
16 Output short low potentiometer wiring OR replace string potentiometer
ground.
Boom range of motion is Calibrate the platform load sense
17 Not calibrated
limited. system.
18 Just calibrated used to clear diagnostic Self-clearing.
5 - 18 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES

Condition Solution
ID Name ID Name
String
Potentiometer
22 Safety Sensor
5 Sensor tolerance fault Power relays disengaged OR replace string potentiometer
(C166PSL)
Power relays
11 Output short high potentiometer wiring OR replace string potentiometer
voltage.
Power relays
12 Value too high potentiometer wiring OR replace string potentiometer
voltage.
Power relays
disengaged. String
potentiometer wiring
15 Value too low OR replace string potentiometer
open or shorted to
ground OR string
potentiometer is faulty.
Power relays
16 Output short low potentiometer wiring OR replace string potentiometer
ground.
17 Not calibrated
limited. system.
Used to clear diagnostic
18 Just calibrated Self-clearing.
codes.
Checks operational and Repair wiring and/or connections

21 Inconsistent safety sensor values OR replace string potentiometer
against each other. and calibrate overload system.
Part No. 77828 S-60 • S-65 • S-60 HC 5 - 19

FAULT CODES

Condition Solution
ID Name ID Name
Boom Angle Repair wiring and/or connections
Power relays
31 Operational 5 Sensor tolerance fault
disengaged.
OR replace boom angle sensor
Sensor (C123PBS) and calibrate overload system.
Power relays
disengaged. Boom angle
11 Output short high OR replace boom angle sensor
sensor wiring open or
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
15 Value too low
shorted to ground OR sensor and calibrate overload
range.
Power relays
16 Output short low OR replace boom angle sensor
shorted to ground.

17 Not calibrated
limited. system.
codes.
5 - 20 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES

Condition Solution
ID Name ID Name
Boom Angle Safety Power relays
32 Sensor (C141PBS)
disengaged.
OR replace boom angle sensor
Power relays
11 Output short high OR replace boom angle sensor
shorted to voltage.
Power relays
12 Value too high
shorted to voltage OR sensor and calibrate overload
range.
Power relays
15 Value too low
shorted to ground OR sensor and calibrate overload
range.
Power relays
16 Output short low OR replace boom angle sensor
shorted to ground.

17 Not calibrated
limited. system.
codes.

21 Inconsistent safety sensor values OR replace boom angle sensor
Part No. 77828 S-60 • S-65 • S-60 HC 5 - 21

FAULT CODES

Condition Solution
ID Name ID Name
Load Cell Repair wiring and/or connections
Power relays
41 Operational 5 Sensor tolerance fault
disengaged.
OR replace platform load cell
(C175LDS) and calibrate overload system.
Power relays
disengaged. Load cell
11 Output short high OR replace platform load cell
wiring open or shorted to
voltage.
Power relays Repair wiring and/or connections

disengaged. Load cell OR replace platform load cell
12 Value too high wiring open or shorted to and calibrate overload system
voltage. Platform may be OR remove excess weight from
overloaded. platform.

Power relays
Check for binding of the overload
15 Value too low wiring open or shorted to
component linkage and be sure
ground. Platform may be
platform is not touching the
reverse loaded.
ground or being supported from
underneath.
Power relays
16 Output short low OR replace platform load cell
ground.
17 Not calibrated
limited. system.
codes.
5 - 22 S-60 • S-65 • S-60 HC Part No. 77828

FAULT CODES

Condition Solution
ID Name ID Name
Load Cell Safety Power relays
42 (C94LDS)
disengaged.
Power relays
11 Output short high OR replace platform load cell
voltage.
Power relays Repair wiring and/or connections

disengaged. Load cell OR replace platform load cell
12 Value too high wiring open or shorted to and calibrate overload system
voltage. Platform may be OR remove excess weight from
overloaded. platform.

Power relays
Check for binding of the overload
15 Value too low wiring open or shorted to
component linkage and be sure
ground. Platform may be
platform is not touching the
reverse loaded.
ground or being supported from
underneath.
Power relays
16 Output short low OR replace platform load cell
ground.
17 Not calibrated
limited. system.
codes.

21 Inconsistent safety sensor values OR replace platform load cell
Part No. 77828 S-60 • S-65 • S-60 HC 5 - 23

5 - 24 S-60 • S-65 • S-60 HC Part No. 77828

February 2012 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
Observe and Obey: could result in death or serious
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
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
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
Malfunction Identify Troubleshoot
equipment are available and ready for use. discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 77828 S-60 • S-65 • S-60 HC 6-1

Section 6 • Schematics February 2012
Electrical Symbols Legend
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
Gauge Auxiliary pump

OPS1
Circuits crossing N.C.
no connection
510
HM Toggle switch SPDT Oil pressure switch
normally closed Resistor with
ohm value
Diode Hour meter

TS6
DOWN
UP
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 Part No. 77828

Hydraulic Symbols Legend
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
Pump Solenoid operated 2 position,

bi-directional, 3 way, directional valve
variable displacement Directional valve
(mechanically activated)
3000 psi
(206.8 bar)
3:1
Needle valve
50% 50%
Flow divider/combiner valve

Motor with pressure balancing orifice
bi-directional Counterbalance valve
and flow percentages with pressure and pilot ratio
Shut off valve
Pilot operated 3 position,

3 way, shuttle valve
Motor
2-speed,
bi-directional
2 position, 2 way
solenoid valve
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. 77828 S-60 • S-65 • S-60 HC 6-3

Ford Engine Relay Layout
Ford LRG-425 EFI (before serial number 14054)
F5-15A
Power
F4-15A F3-20A
Relay
F2-5A F1-30A
Starter Fuel Pump

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

Limit Switch Location Legend
Boom Extend Boom Speed

Limit Switch Reduction
(LS2) Limit Switch
(LS17)
Cable Tension
Limit Switch
(LS5)
Drive Enable Boom Angle

Limit Switch Limit Switch
(LS3) (LS1)
Part No. 77828 S-60 • S-65 • S-60 HC 6-5

6-6 S-60 • S-65 • S-60 HC Part No. 77828

Electrical Schematic, S-60 HC

(from serial number 12800)
Electrical Schematic, S-60 HC

A B C D E F G H I J K L M N
1 STRING POTENTIOMETER
LS19
S22
STRING TENSION
S23
LIMIT SWITCH
23 24
OR
RD
BN
BK
YL
BL
NO HC
PLATFORM BOX
2
PLATFORM SUPPORT
C44-4
C44-5
C44-6
C44-1
C44-2
C44-3
C45-2
C45-4
C45-3
C45-1
C9P-2
P24FS WH
SAFETY CONTROLLER OPERATIONAL CONTROLLER PLATFORM LOAD SENSOR TS1
2 5
AUXILIARY
C1P-1
PUMP
S24 C27AUX RD
C183RCV
C169ENV
V183RCV
GROUND
GROUND
P109SEN
P1-10 C123PBS
C141PBS
P1-12 C175LDS
C177ERL
C133LDS
S140CAL
C167PSL
C173PEL
C166PSL
S170ENL
S171ENL
R134BAT
P110RET
P174BAT
1 3 4 6
P63SEN
C94LDS
P20BAT
P26BAT
P20BAT
P20BAT
C172PL
C168PL
P63SEN OR/RD
CAN +
CAN +
CAN -
S25
CAN -
RET
3
N/C
N/C
P109SEN GR/WH
WH - CH1 RETURN
P109PSL GR/WH
GR - CH1 OUTPUT
D63
P1-11
BL - CH2 RETURN
OR - CH2 OUTPUT
P1-10
P1-12
P2-10
P2-12
P1-11
P2-11
P63PSL OR/RD
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
C53 C41 C42
RD - PWR
BK - GND
+
L4
H1 PLATFORM
120
OVERLOAD
C183RCV BL
P23BAT WH
120
C133PLA GR/BK
C3P-12
1 1
4 C166PSL OR
C46-2
C46-1
C175LDS WH/BK
C94LDS WH
C5-4
C5-3
C5-1
C134PWR RD
C4P-12 C134PWR RD 2 2
P110RET BR C46-3 P110RET BK C5-2

3 3
P23BAT WH
C167PSL OR/BK C46-4 C169ENV GR C4P-11
P2
EMERGENCY STOP
C123PBS RD/BK C46-5 C183RCV BL C4P-10
C141PBS RD C46-6 P23BAT YL C4P-9 P23BAT WH

L50
C40B-10
C40B-12
C40B-11
BOOM EXTEND/RETRACT F.C.
C40B-6
C40B-1
C40B-8
C40B-9
C40B-2
C40B-3
C40B-4
C40B-5
ACTIVE ENVELOPE
C40B-7
COM PORT A D82CAN+ YL
C30-2 C30-1
COM PORT B D82CAN- GR C173PEL BK
TB9
5
BOOM UP/DOWN F.C.
S145CAL RD/WH
C133PLA GR/BK
C177ERL BL/BK
C29-2 C29-1
C168PL BL/RD
S170ENL WH/RD
S171ENL WH/BK
C172PL BL
P174BAT WH
V183RCV BL
TB3
P23BAT WH
P26BAT BK
R134BAT RD
C7PBE BK TS73
GROUND BOX
GND BR
CALIBRATION LS2 TS49

C37-1
TB2A TB7A SWITCH

NO HC C10-1B C11-2 BK C11-1
RECOVERY
WH
P109ANG GR/WH
SWITCH D48
P63ANG OR/RD
1 TB134
13 14 4 5 C3FC RD/WH TB3
R2PBD RD/BK
RD TB23 TB-0 3 2
CR52 LS1 NO HC
6 21
LS5
BOOM
TB27
30
R2PBD RD/BK C2PBD RD/BK
C7PBE BK
CABLE CR53 C10-2 C27AUX RD 6 D49

NC C10-1A WH TB40
TENSION DOWN BOOM
BK
NO HC
D47
22 CUTOUT EXTEND 13 14 1
BR 30 30 C8RET BK/WH TB8
86 CUTOUT 86
87A 87
NO HC 3 2
CR59 86 85 C9FC BK/WH TB9
C37-2
CR56
RD/BK POWER ON P22LS WH R8PBR BK/WH D46
30
RECOVERY
C7PBE BK
86
C2PB
87 87A 85 87 87A 85 DUAL CAPACITY

30 85 30 85
V183RCV BL
C114-5
C114-6
C114-4
C114-2
C114-1
C114-3
R2PBD RD/BK
85 87A 87 R134BAT RD 1 1 R134BAT RD

C7PBE BK
C13-1
C16-1
7 87 87A 86 87 87A
86 P174BAT WH
R174BAT RD
6
7
6
7 H6
C32
L45
OR
RD
BN
BK
YL
BL
C133PLA GR/BK 8 8 +
R22BAT BK 5 PLATFORM
R18 R17
5
P22BAT BK OVERLOAD
5 5 4 4
CR54 CR55
LOAD SENSE LOAD SENSE
C16-2
C13-2
CUTOUT PLATFORM CUTOUT GROUND TB134 C133PLA GR/BK

S17 S18
C2PBD RD/BK
B00M ANGLE SENSOR

NOTES:
8
B00M DOWN
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.

B00M EXTEND
SWING/
LOWER LINK
6-7 S-60 • S-65 • S-60 HC Part No. 77828

N
23
NO
LS19
HC
STRING
24
LIMIT SWITCH
POTENTIOMETER
C45-2
C45-4
C45-3
C45-1
M
P63PSL OR/RD
P109PSL GR/WH
P63SEN OR/RD C53-6
P109SEN GR/WH C41-8

S22
L
C167PSL OR/BK C42-2 C44-4 OR
P109PSL GR/WH C44-5 BN

P110RET BR C41-9 C44-6 YL
P110RET BR C53-7 C44-1 RD

STRING
P63PSL OR/RD C44-2 BK

C166PSL OR C53-9 C44-3 BL
POTENTIOMETER
S23
K
S17
P110RET BR C41-9 C114-5 OR
P109ANG GR/WH C41-8 C114-6 BN

C123PBS RD/BK C41-10 C114-4 YL
P110RET BR C53-7 C114-2 RD
P63ANG OR/RD C53-6 C114-1 BK

C141PBS RD C53-8 C114-3 BL
R134BAT RD C41-2 C42-11,12
S18
J
P23BAT WH C46-6
BOOM ANGLE SENSOR
1 2 S170ENL WH/RD C53-11

S171ENL WH/BK C53-12
3 4
C177ERL BL/BK C42-3

5
GND BR C41-1 C53-1

6
C168PL BL/RD C42-10

7
C40
P174BAT WH C41-6
8
P26BAT BK C41-7
9
120
C133PLA GR/BK C42-5

V183RCV BL C42-7
10 11
RTESISTOR
TERMINATING
I
C145CAL OR/RD C41-11

12
C53
GRAY
GND BR C40-6
P1-1 GROUND
R134BAT RD C40-1
P1-2 P20BAT
D82CAN+ YL
P1-3 CAN +
D82CAN- GR
P1-4 CAN -
P1-5 N/C
P63SEN OR/RD C45-1
P1-6 P63SEN
P110RET BR C114-2 C44-1

P1-7 RET
H
C141PBS RD C114-3
P1-8 C141PBS
C166PSL OR C44-3
P1-9 C166PSL
C94LDS WH C46-1 C5-3

P1-10 C94LDS
SAFETY MODULE
S170ENL WH/RD C40-3

P1-11 S170ENL
S171ENL WH/BK C40-4

P1-12 S171ENL
D82CAN+ YL COM PORT A

120
D82CAN- GR COM PORT B

TO PC
G
CONNECTS
RTESISTOR
TERMINATING
C41
GRAY
GND BR C40-6
P1-1 GROUND
R134BAT RD C40-1
P1-2 P20BAT
D82CAN+ YL
P1-3 CAN +
D82CAN- GR
P1-4 CAN -
P1-5 N/C
P174BAT WH C40-8
P1-6 P174BAT
P26BAT BK C40-9
F
P1-7 P26BAT
P109SEN GR/WH LS19-3

P1-8 P109SEN
P110RET BR C46-3 C114 C44
P1-9 RET
C123PBS RD/BK C114-4

P1-10 C123PBS
C145CAL RD/WH C40-12
P1-11 S140CAL
C175LDS WH/BK C46-2

FLOW
BOOM
P1-12 C175LDS
UP/DWN
CONTROL
C183RCV BL C46-5
P2-1 C183RCV
February 2012
Part No. 77828
C167PSL OR/BK C44-4

P2-2 C167PSL
C177ERL BL/BK C40-5

P2-3 C177ERL
E
Y12
C169ENV GR C46-4 C4-11

P2-4 C169ENV
C133PLA GR/BK C40-10

P2-5 C133LDS
OPERATIONAL MODULE
P2-6 N/C
V183RCV BL C40-11
P2-7 V183RCV
C172PL BL
P2-8 C172PL
C173PEL BK
P2-9 C173PEL
Y15
C168PL BL/RD C40-7

P2-10 C168PL
R134BAT RD C40-1
P2-11 P20BAT
R134BAT RD C40-1
FUNCTION MANIFOLD
P2-12 P20BAT
D
FLOW
BOOM
C42
BLACK
EXTEND/
RETRACT
CONTROL
C46
BL - CH2 RETURN
C175LDS WH/BK C5-4 C46-2 OR - CH2 OUTPUT
WH - CH1 RETURN
C
C94LDS WH C5-3 C46-1

GR - CH1 OUTPUT
P110RET BR C5-2 C46-3

BK - GND
S25
S24
C134PWR RD C5-1 C4-1

RD - PWR
S-60 • S-65 • S-60 HC
C5
LOAD
B
SENSOR
PLATFORM
P23BAT WH C46-6
C134PWR RD C5-1
C183RCV BL C46-5
C169ENV GR C46-4
9
11
10
12
A
C4P
8
7
6
5
4
3
2
1
6-8
Chassis Wiring Diagram, S-60 HC
Section 6 • Schematics
Chassis Wiring Diagram, S-60 HC

Ground Control Box Terminal Strip Wiring Diagram, S-60 HC

8
7
6
5
4
3
2
1
6-9
CR52 CR53 CR54 CR55
BOOM DOWN BOOM EXTEND LOAD SENSE LOAD SENSE
CUTOUT CUTOUT CUTOUT PLATFORM CUTOUT GROUND
30
30
30
30
87A
87A
86
86
85
86
85
85
86
85
87
87
A
87
87
P22BAT BK C32-4
R2PBD RD/BK
C2PBD RD/BK TB2A

C7PBE BK TB7A
C168PL BL/RD C40-7

S171ENL WH/BK C40-4
R174BAT RD C32-7
S171ENL WH/BK C40-4
GND BR
R7PBE BK R18
GND BR
S170ENL WH/RD C40-3
P174BAT WH CR59-87A C32-6
S170ENL WH/RD C40-3
C177ERL BL/BK C40-5

C7PBE BK C37-1 TS49-5
CR59
R22BAT BK C32-5
C2PBD RD/BK C13-1

B
R134BAT RD CR59-30
P23BAT WH CR59-86
S170ENL WH/RD CR54/55
1 2 3
S171ENL WH/BK CR54/55

C177ERL BL/BK CR53
4 5
GND BR
6
C168PL BL/RD CR52
R17
BOOM
DOWN
C40
TS73
BYPASS
P174BAT WH TS73-1
7 8
PRIMARY
SWITCH
C23PWR WH TB0B
CALIBRATION
C133PLA GR/BK C32-8
C
R7PBE BK CR53
1 2 3 V183RCV BL TS49-3
P23BAT WH C40-2
S145CAL RD/WH TS73-5
9 10 11 12
P134PWR RD TB134
S-60 • S-65 • S-60 HC

P174BAT WH CR55-30 P174BAT WH C40-8
4 5 6
D49
R134BAT RD C40-1 C32-1

R2PBD RD/BK TS49 C2PBD RD/BK CR53-87
C3FC RD/WH TB3C
D48
R8PBR BK/WH TS49

R2PBD RD/BK CR56
TS49
1
SWITCH
R8PBR BK/WH CR56

RECOVERY
87
87
5
C8RET BK/WH TB8C

R22LS WH C10
D47
86
85
85
86
3
6
87A
87A
C27AUX RD TB27C C9FC BK/WH TB9C
D46
30
30
V183RCV BL C40-11
D
R134BAT RD CR59-30
R18
BOOM
P22BAT BK
BYPASS
EXTEND
GND BR
CR59
PRIMARY
HIGH
CR56
POWER
MODULE
R22BAT BK
CAPACITY
HI-CAPACITY
RECOVERY
GND BR P174BAT WH
R174BAT RD
CR54-30
CR54-87
C133PLA
CR55-87
CR55-30 CR59-87A
GR/BK C40-10
E
TERMINAL BASE (TB)

8
7
6
5
4
1
D C B A C23PWR WH C40-9
KEYSWITCH POWER
0 SPARE 0
C32
C32 CONNECTOR
8
7
6
5
1
4
3
RD/BK-ALARM
PLUG ANSI/CSA ONLY
1 PRIMARY BOOM UP 1
BRN
D29
C2PBD RD/BK CR52
2 PRIMARY BOOM DOWN 2
Ground Control Box Terminal Strip Wiring Diagram, S-60 HC
BK-22D2
RD-TS52
RD-TS51
C3FC RD/WH TS49

BK C7B-1
BL/WH-132B
3 PRIMARY BOOM FUNCTION CONTROL 3

R134BAT RD H6
C133PLA GR/BK H6
Part No. 77828

February 2012
4 TURNTABLE ROTATE LEFT 4
5 TURNTABLE ROTATE RIGHT 5

F
6 TURNTABLE ROTATE FUNCTION CTRL 6

GR/BK-133B
C7PBE BK CR53
7 PRIMARY BOOM EXTEND 7
C8RET BK/WH TS49
C133LDS GR/BK-L45
+
8 PRIMARY BOOM RETRACT 8

C9FC BK/WH TS49 P134BAT RD+L45
H6
9 PRIM. BOOM EXT/RET FUNC. CTRL 9

CE ONLY
44 JIB DOWN DESCENT ALARM 44
RD/BK-ALARM
13 DRIVE ENABLE 13
G
+12 VOLT
D30
14 PLATFORM LEVEL UP 14
PLATFORM
C7
15 PLATFORM LEVEL DOWN 15
17 PLATFORM ROTATE LEFT/JIB UP 17

C7PBE BK CR53
P22LS WH CR56
18 PLATFORM ROTATE RIGHT/JIB DOWN 18

18/19 #1
19 JIB SELECT VALVE 19 C3 & C4
C2PBD RD/BK CR52 TS49-5
20 +12 VOLT POWER 20

H
21 IGNITION POWER 21
18/19 #2
C1 & C2
RD
22 +12 VOLT TO PLATFORM (1) 22

RD/BK
D45
22 +12 VOLT TO PLATFORM (2) 22 P23BAT WH
23 KEYSWITCH POWER 23
C11-2
KEYSWITCH POWER
BOOM
24 CIRCUIT BREAKER POWER 24 WH
EXTEND
LIMIT SWITCH
25 OIL PRESSURE SWITCH 25 C11 (LS1)
I
26 OIL TEMPERATURE SWITCH 26

C27AUX RD CR56
C10-1
27 AUXILIARY PUMP 27
CABLE
TENSION
WH
28 TILT ALARM 28 LIMIT SWITCH

C37 (LS5)
29 MOTOR STROKE 29
30 PROPEL FORWARD 30
31 PROPEL REVERSE 31
+12V POWER
32 BRAKE 32
J
33 START ENGINE 33
34 GLOW PLUG 34
35 HIGH FUNCTION SPEED 35
36 STEER LEFT 36
37 STEER RIGHT 37
C5
39 (UNUSED) 39
K
40 BOOM STOWED 40
ENGINE HARNESS
41 ALTERNATOR PULSE PICKUP 41
46 SERVICE HORN 46
59 RETRACT BOOM LED 59

P134PWR RD CR59-87
134 LOAD WEIGHING LIM. SW. +12V (1) 134
R134BAT RD H6+
L
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
Genie Industries
HARNESS
FUNCTION
1 TO REMOVE: 1 START RELAY

2 Push gently 2 TACHOMETER
3 U1 C9 (LS3)
and lift 3 START INPUT
4
M
4 AUX PWR UNIT C11 (LS2)

5 5 GROUND LS17 (C38)
6 6 BATTERY
7 7 TO KEY SW (DIESEL ONLY)
8 8 JUMP TO 7 (GAS ONLY)
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
10 10 TEMP OR PRESS FAULT
12/24 Volt IGNITON/START MODULE P/N 56057
GROUND BOLT
N
Platform Control Box Wiring Diagram, S-60 HC

N M L K J I H G F E D C B A
P23BAT WH H1+
7 6
8 5
P23BAT WH E-STOP PLATFORM CONTROL BOX

9 4
CONNECTOR C4
C183RCV BL CR59
10 3
C169ENV GR L50
11 2 2
C134PWR RD E-STOP
12 1
PLATFORM CONTROL
HARNESS
(TO CONTROL BOX)
L48
TILT ALARM LED MOUNT AT BOTTOM OF PBOX
(ANSI/CSA OPT.)
JC1 TS15 + JC3

JC2 7 PRIMARY BOOM 7 DRIVE ENABLE DRIVE
7
PRIMARY BOOM UP/DOWN FORWARD/REVERSE
& TURNTABLE ROTATE LEFT/RIGHT
EXTEND/RETRACT
& STEER LEFT/RIGHT 3
6 6 6
COMPONENT INDEX
CR13 JIB RELAY ( JIB OPTION ONLY )
5 5 5
JC2 BOOM PROPORTIONAL JOYSTICK:
PRIMARY BOOM UP/DOWN AND TURNTABLE ROTATE
BOOM PROPORTIONAL JOYSTICK:
4 4 4 JC1
PRIMARY BOOM EXTEND/RETRACT
JC3 DRIVE/STEER PROPORTIONAL JOYSTICK
3 L47 3 L4
PLATFORM
3 L1 DRIVE ENABLE LED
RETRACT
BOOM
OVERLOAD
(CE OPTION)
L4 PLATFORM OVERLOAD LED 4
LED L47 LOWER/RETRACT BOOM LED
2 +
2 L1 +
2 L48 BOOM TILTED LED
DRIVE ENABLE L?? OUT OF ENVELOPE LED
LED
1 1 1 P2 EMERGENCY STOP BUTTON
P3 HORN BUTTON
+ TS1 AUXILIARY POWER TOGGLE SWITCH
TS2 ENGINE START TOGGLE SWITCH
TS3 FUEL SELECT TOGGLE SWITCH (GAS/LPG)
TS4 HI/LOW RPM TOGGLE SWITCH
TS6 GLOW PLUG TOGGLE SWITCH 5

TS7 PLATFORM ROTATE TOGGLE SWITCH (JIB OPTION ONLY)
P23BAT WH E-STOP, TS1-2

TS8 JIB BOOM UP/DOWN TOGGLE SWITCH
TS9 PLATFORM LEVEL TOGGLE SWITCH
C134PWR RD E-STOP
C133PLA GR/BK D39
C28TTA RD/BK H1-

TS14 DRIVE SPEED TOGGLE SWITCH
TS15 DRIVE ENABLE TOGGLE SWITCH
TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS48 DRIVE LIGHT/WORK LIGHT SWITCH (OPTION)

CR57 RECOVERY ENABLE RELAY
CR58 RECOVERY ACTIVATE RELAY
P23BAT WH H1+, C4-9
C134PWR RD C4-12
C134PWR RD L48+
C169ENV GR C4-11
C183RCV BL C4-10
P23BAT WH C7-12
C27AUX RD C1-1
P23BAT WH L4+
P23BAT WH L4+
D63
7
WH WH
TS9 TS7 TS47
PLATFORM PLATFORM TS14 GENERATOR
P3 LEVEL ROTATE DRIVE SPEED
TS6 TS2 TS4 (OPTION)
HORN HIGH/LOW
GLOW PLUG START HIGH/LOW RPM 1 1 1
(2WD/4WD)
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. 77828 S-60 • S-65 • S-60 HC 6 - 10

Platform Control Box Wiring Diagram, S-60 HC

GM 3.0L Engine Wire Harness

GM 3.0L Engine Wire Harness
A B C D E F G H I J K L M N
TWR
FCI ORANGE/BLUE 16
1 211 PC 56 2S 0 009 CONNECTOR

211 A 56 7007 LOCKING CAM
211 A 56 0008 COVER
BROWN/BLUE 16
BROWN/GREEN 16
A
B
C
WHITE/BLACK 18
211 CC 2S 1120 TERM D MTRTWR8
WHITE/RED 18
E
PINK/TAN 18
F
ECM 18 ORANGE/BLUE 16 RED/WHITE 18 G
INJ +
16 BROWN/BLUE 16 H
INJ 1
17 BROWN/GREEN 16
INJ 2
30 LT BLUE/WHITE 18
AUX OUT 2
35 TAN/DK GREEN 18
AUX ANA PD1
33 LT GRN 18
MAP
38 DK BLUE 18
FPP ENGINE
32 TAN 18
IAT
ECT
31 YELLOW/GRAY 18 COOLANT
39 PURPLE/YELLOW 18
IVS
36 DK BLUE/YELLOW 18 TEMPERATURE
AUX ANA PU1
19 BLACK 16 SENDER
2 POWER GROUND
POWER GROUND
ANA_RTN
20
49
BLACK 16
BLACK/LT GREEN 18 YELLOW GRAY 18 A
50 LT GREEN/RED 18
5 VOLT REF
21 PINK/TAN 18 BLACK/LT GREEN 18 B
VSW
55 DK GREEN/ORANGE 18
EGO 1
41 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
KNK +
42
KNK - GRAY/BROWN 18
13
CAM + LT GREEN 18
14 PURPLE/ORANGE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
CAM - 4
11 PURPLE/WHITE 18 LT GREEN/RED 18
CRANK + 3
12 WHITE/PURPLE 18 TAN 18
CRANK - 2
22 RED/TAN 16 BLACK/LT GREEN 18
VBAT 1
23 RED/TAN 16
VBAT
9 GRAY/ORANGE 18
STARTER LOCKOUT MAP SENSOR
8 WHITE/BLACK 18
FUEL LOCKOFF TAN/BLACK 18
7
FUEL PUMP
10 WHITE/LT BLUE 18
RELAY CONTROL BLACK 16
53 PURPLE/LT BLUE 18
3 TPS1
TPS2
54
24
LT BLUE/DK BLUE 18
PINK/WHITE 18
BLACK 16 BLACK 12
DBW +
25 TAN/ORANGE 18
DBW -
37 LT GREEN/BLACK 18 RED/TAN 16
OIL PRESSURE
56 YELLOW/LT GREEN 18 RED/TAN 16
TACH
MIL
26 LT BLUE/BLACK 18 GROUND
47 BLACK/WHITE 18
AUX ANA PD2
29 PURPLE/DK BLUE 18
AUX OUT 1
40 TAN/BROWN 18
FUEL SELECT YELLOW/DK BLUE 18
48
AUX ANA PU2
34 GRAY/DK BLUE 18 PINK/TAN 18 F1
GOV SELECT
15 WHITE/RED 18
GASEOUS TRIM 5A
43 BLUE/PINK 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
CAN +
44 BLUE/WHITE 18
CAN - DK GREEN 18 1
51
RS 232 TX
52 ORANGE 18
RS 232 RX
27 YELLOW 18
OIL PRESSURE TWR
COIL 1
4 INJ 3
INJ 4
29
30
SENSOR PINK 18
DK BLUE 18
PURPLE/YELLOW 18
A
B
VSW- P23BAT
FPP1
28
INJ 5 C IVS
1 BLACK/LT GREEN 18
INJ 6 D ANA RTN
2 RED/WHITE 18
INJ 7 E
7 LT BLUE/BLK 18 MIL - C108ESL
INJ 8 F
6 LT GREEN/RED 18 LT GREEN/RED 18 VREF
AUX OUT 3 G
H
LT BLUE/PINK 16
J START IN (INTERUPT TYPE) - C33STR
PINK/BLACK 16
K START IN (AUTOCRANKING)
BLK/LT GREEN 18
TWR MTRTWR10
BLK/LT GREEN 18
A
DK GREEN/ORANGE 18
B
PINK/DK GREEN 16
BLK/LT GREEN 18 TWR C
D BLACK 18
RTN D
5 LT GREEN/RED 18 C
5V
TWR 1
DK GREEN 18 B
TX MTRTWR4_EGO
LT BLUE/WHITE 18 AUX OUT 2
ORANGE 18 A
A TAN/DK GREEN 18 AUX IN PD1
RX ENGINE TEST SWITCH B
YELLOW/LT GREEN 18 TACH - C41RPM
C
TAN/BROWN 18 FUEL SELECT - C39LP
COMM D
GRAY/DK BLUE 18 GOV SELECT - C128LPRM
E
BLUE/PINK 18 CAN +
STARTER F
1 BLUE/WHITE 18
G CAN -
RELAY PURPLE/DK BLUE 18
H AUX OUT 1
87A LT BLUE/PINK 16
WPTWR1 WHITE 16 30 MTRTWR8
87 PINK/BLACK 16
TWR
STARTER PINK/TAN 18 86
6 SOLENOID
GRAY/ORANGE 18 85
YELLOW 18
D
RED/TAN 14
F2 RED 14 RED 12
GRAY/BROWN 18 C
SHD 1
LT GREEN/RED 20A
B TWR
BLACK/WHITE 18
PURPLE/ORANGE 18
BATT+ 1 YELLOW/DK BLUE 18
A AUX IN PD2 - C27AUX
A B AUX IN PU2 - C35HRPM
DK BLUE/YELLOW 18
WPSHD1 THIS JUNCTION TO PINK/YELLOW 16
C AUX IN PU1
D FUEL PUMP - C135FP
PINK/YELLOW 16
BE WITHIN 3-6 INCHES DISTRIBUTOR BLACK 16
E GROUND - GND
OF CONNECTOR PINK/DK GREEN 16
CONNECTOR F RELAY FUSED POWER - C21IGN
SPLICE TO ASSEMBLY
SEAL END OF OPEN WIRE
MTRTWR6
7 RED 14 30
87 PINK/YELLOW 16
F4
WHITE/PURPLE 18 TWR
CRANKSHAFT PINK/TAN 18 86 15A
B
FUEL
PURPLE/WHITE 18
POSITION
A PUMP BATT+ 2
IGNITION SENSOR TAN/BLACK 18 85 ALTERNATOR
RELAY
COIL RED 12 RED 12
RED 16
BLK/LT GREEN 18 2
LT GREEN/RED 18
3 RED 16 A
PURPLE/LT BLUE 18
6
BOSCH RED 14 30
LT BLUE/DK BLUE 18
5 THROTTLE 87 PINK/DK GREEN 16
F3 PINK/DK GREEN 16 PINK/DK GREEN 16 B
ALTERNATOR
PINK/WHITE 18
4
TAN/ORANGE 18
1 RED/TAN 14 86 15A
8 WHITE/BLUE 18 85
POWER
RELAY
1 THESE CONNECTORS ARE CONNECTED TO GENIE HARNESS #88833
6 - 11 S-60 • S-65 • S-60 HC Part No. 77828

Ford LRG-425 EFI Engine Wire Harness
INJ +
6
7
361 R 16
555 T 16
361 R 16
555 T 16
361 R 16 361 R 16 361 R 16
FORD 1
INJ 1
8 557 BR-Y 16 557 BR-Y 16
INJ 3
INJ 4
9 558 BR-LB 16 558 BR-LB 16 42 PIN
10 556 W 16 556 W 16
INJ 2
INJ 5
11 743 GY 18 INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2
570 BK-W 16 39 R-W 18
CONNECTOR
12 359 GY-R 18 16 WATER TEMP
INJ 6
31
AUX OUT 2
EGR
21 18 O-Y 18 WATER
19 198 DG-O 18 ACT TEMP
AUX ANA PD1
20 358 LG-BK 18
MAP
FPP 1
15
27
151 LB-BK 18
743 GY 18
151 LB-BK
307 BK-Y 18
151 LB-BK
307 BK-Y 18
14 FPP1 2
IAT 25 IVS
28 354 LG-R 18 354 LG-R 18 359 GY-R 18
ECT
17 307 BK-Y 18 570 BK-W 16
IVS F1 30A
18 150 DG-W 18 570 BK-W 16 570 BK-W 12 570 BK-W 12 34 GROUND
AUX ANA PU1
16 114 LB-Y 18
ECT 570 BK-W 16
FPP 2
22 352 BR-LG 18 F2 5A
EGR PWM 16 R-LG 18 16 R-LG 18
23 360 BR-PK 18 1 VSW
EGR RECIRC
1 570 BK-W 16 570 BK-W 16
POWER GROUND
2 570 BK-W 16 570 BK-W 16 MAP_CONN
POWER GROUND F3 20A
13 359 GY-R 18 570 BK-W 16 361 R 14 361 R 14 361 R 12
ANA_RTN
5 VOLT REF
14 351 BR-W 18 351 BR-W 18
16 R-LG 18
351 BR-W 18
C
TWR
9 VBATT
3
3 16 R-LG 18 361 R 14
VSW
33 350 GY 18 358 LG-BK 18 358 LG-BK 18
CRANK - B
32 349 DB 18 359 GY-R 18 359 GY-R 18
CRANK + A
35 452 GY-R 18 18 O-Y 18 18 O-Y 18
CAM - 38 EGR ANA IN
34 282 DB-O 18 198 DG-O 18 198 DG-O 18
CAM + 32 ANA AUX PD1
4 361 R 16 150 DG-W 18 150 DG-W 18
VBAT CAM CRANK 37 ANA AUX PU1
5 361 R 16 361 R 14 114 LB-Y 18 114 LB-Y 18
VBAT 12 FPP2
25 392 R-LG 18 352 BR-LG 18 352 BR-LG 18
EGO 2 40 EGR PWM
24 74 GY-LB 18 360 BR-PK 18 360 BR-PK 18
EGO 1 41 EGR REC
EGO 3
26 O2 SENSOR 361 R 14
KNK +
29
359 GY-R 18 359 GY-R 18
33 ANA RTN
4
30
KNK - 351 BR-W 18 351 BR-W 18
31 VREF
J1 BLACK 361A R 16 361A R 16 O2 MTRTWR6 MTRSHD6

TWR SHD
THROTTLE
FUEL PUMP
16 R-LG 18 32 R-LB 16
13 STARTER CONTROL
570 BK-W 16 570 BK-W 16 SENSOR 355 GY-W 18
A A
355 GY-W 18
6
86 30 STARTER
357 Y-W 18 357 Y-W 18 RELAY RELAY
74 GY-LB 18 392 R-LG 18 B B 5
151 LB-BK 18 151 LB-BK 18
C C 4 85 87 87A
359 GY-R 18 359 GY-R 18 317 GY-O 18 317 GY-O 18 86 30 32 R-LB 16
D D 1 15 STARTER IN (INTERUPT)
359 GY-R 18 351 BR-W 18 32 R-LB 16
E E 3 39 STARTER IN (AUTOCRANK)
J2 GREY 342 LG-P 18
351 BR-W 18
F F
359 GY-R 18
2
85 87 87A
342 LG-P 18
SPK PWR GROUND
4
1
570 BK-W 16
850 Y-BK 18 1 2 3
TWR
A
242 DG 18 5
COIL 1 1 COIL 1
2 851 Y-R 18 361A R 16
2 VBAT 361A R 16 FPP_COMM F4 15A
COIL 2 B 359 GY-R 18 D 787A PK-BK 16 787A PK-BK 16
3 RTN 5 FUEL PUMP
COIL 3 3 COIL 2 351 BR-W 18 C
13 5V
COIL 4 LOCKOFF SOLENOID 669 DG-W 18 B
24 TX
COIL 5 458 O-BK 18 A
25 RX 86 30 POWER
COIL 6 TWR
STARTER LOCKOUT
22 342 LG-P 18 RELAY
23 242 DG 18
FUEL LOCKOFF 85 87 87A
9 926A LB-O 18 926A LB-O 18
FUEL PUMP F5 15A
32 15 R-Y 18 15 R-Y 18 361 R 16 361 R 16
RELAY CONTROL
TPS1
30
31
355 GY-W 18 6
357 Y-W 18
TPS2 253 DG-W 18
28 151 LB-BK 18 OIL PRESSURE
DBW +
29 317 GY-O 18
DBW -
6 511 LG-R 18 511 LG-R 18 511 LG-R 18
BRAKE SWITCH 4 BRAKE
7 253 DG-W 18 253 DG-W 18 253 DG-W 18
OIL PRESSURE 26 OIL PRES
8 11 T-Y 18 11 T-Y 18 11 T-Y 18
TACH 2 TACH
27 658 PK-LG 18 658 PK-LG 18 658 PK-LG 18
MIL 6 MIL
10 238 DG-Y 18 238 DG-Y 18
FUEL PUMP MON
5 71 O-LG 18 71 O-LG 18 71 O-LG 18
AUX OUT 1 21 AUX OUT1
14 72 Y-BK 18 72 Y-BK 18 72 Y-BK 18
FUEL SELECT 7 FUEL SELECT
AUX ANA PU2
15 148 Y-R 18
306 T-LB 18
148 Y-R 18
306 T-LB 18
148 Y-R 18
10 AUX ANA PU2 7
16 306 T-LB 18
GOV SELECT 1 24 GOV SELECT 1
17 307 BK-Y 18 307 BK-Y 18 307 BK-Y 18
GOV SELECT 2 23 GOV SELECT 2
11 169 LG-BK 18 169 LG-BK 18 169 LG-BK 18
ROAD SPEED + 35 ROADSPEED +
12 172 LB-R 18 172 LB-R 18 172 LB-R 18
ROAD SPEED - 36 ROADSPEED -
26 77 DB-Y 18
GASEOUS TRIM
33 349A DB 18 349A DB 18 349A DB 18
OVERSPEED 30 OVERSPEED
18 662 DG-P 18 662 DG-P 18 662 DG-P 18
CAN + 28 CAN +
19 459 O-LG 18 459 O-LG 18 459 O-LG 18
CAN - 29 CAN -
20 642 DG-O 18 642 DG-O 18 642 DG-O 18
RS 485 + 11 RS 485+
21 461 O 18 461 O 18 461 O 18
3 RS 485-
RS 485 -
RS 232 TX
34 669 DG-W 18 669 DG-W 18 669 DG-W 18
458 O-BK 18
20 RS 232+ 8
35 458 O-BK 18 458 O-BK 18
RS 232 RX 18 RS 232-
TWR SHD
570 BK-W 16
TRIM VALVE A A PLUG (GROUND)
TWR 361A R 16
77 DB-Y 18 B B PLUG (RELAY POWER)
A 459 O-LG 18
361A R 16 361A R 16 C C PLUG (CAN -)
B 662 DG-P 18
D D PLUG (CAN +)
WPTWR2_GY MTRTWR4 MTRSHD4
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 12

Ford LRG-425 EFI Engine Wire Harness

Ford DSG-423 EFI Engine Wire Harness
IGNITION COILS HO2S #1
HO2S #2
ENGINE ECM Y/BK 18
R 16 R 16 R 16
1
CONNECTOR 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 GY/R 18 GY/Y 18
4 BK/W 16
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
CAN1 +
CAN1 -
14
15
DG/P 18
O/LG 18
DG/P 18
O/LG 18
MTRTWR4 42 PIN
CONNECTOR
2
16
CAN2 - BR/W 18
17
CAN2 + LG/R 18 LG/R 18
18
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 -
5V EXT 2
5V RTN 2
31
32
33
LG/W
DG/BK
LB/R 18
LB/R 18
LG/BK 18
36 ROADSPEED -
3
PULSE IN 35 ROADSPEED +
34 T/LB 18 T/LB 18 T/LB 18
GOV 1 24 GOV SELECT 1 C128 RPM
35 DG/W 18
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
(FUELSELECT)AUX DIG1
TPS 2
48
49
50
Y/W 18
Y/DB 18 10A ECM 4
AUX DIG 2 BK/Y 18
51 Y/R 18 23 GOV SELECT 2 C35 RPM
KNOCK + GY 18
52 DG/P 18
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
BOSCH THROTTLE
INJ2 LS
INJ3 LS
65
66
67
BR/Y 16
BR/LB 16
W 16
BK/LG 18
GY/W 18 GY/W 18
BATT(+) R 12 R 12
ALTERNATOR 5
INJ4 LS
68 Y/W 18 Y/W 18 6 RING R 16
INJ5 LS 5 3
69 BK/W 16 LB/DG 18 LB/DG 18
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
AUX PWM5 REC

DBW -
82
83
84
GY/O 18
R/BK 18
R/BK 18
R/W 18
R/BK 18
R/W 18
21 AUX PWM 5 6
AUX PWM5 16 AUX PWM 4
85 O/LG 18
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 FUEL PUMP
GY/R 18
B
F4
LB/PK 16 15 START IN INTERUPT R33 STR 7
R 16 BN/LB 16 LPG PK/BK 16 PK/BK 16
W/PK 16 19 START IN AUTOCRANK
PK/BK 16
TEMPERATURE 5 FUEL PUMP + C135 FP+
GY/R 18 1
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
INJECTOR CYL #3
LG/P 18 85
FPP
DG/P 18
O/LG 18
BK/W 18
3
1
6
CAN +
CAN - 8
GROUND
PK/BK 16 PK/BK 16 4
R 16 T 16 UNUSED
5
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. 77828 S-60 • S-65 • S-60 HC 6 - 13

Ford DSG-423 EFI Engine Wire Harness

Electrical Schematic, S-60

GM 3.0L Models
N
RD
RD
BRN
C22LS RD
P24FS WH
P26ESTP BK
C41RPM OR/BK
C28TTA RD/BK
D12
C1P-9 C35RPM BK/RD C1B-9

FOOTSW. HIGH
FOOTSW. LOW
ENGINE
TS54
SPEED
TS4
TB35
D13
D14
M
LOW RPM
FUNCTION ENABLE
HIGH RPM
TB45
GENERATOR
ON
TS47
C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH

GENERATOR OPTION
WH
RD
L
CR23
TS48
C2P-6 DLITE GR/BK C2B-6

L29
DRIVE LIGHT
LIGHTS
WORK LIGHT C4B-12 RD DRIVE LIGHT OPTION
L29
L30
RD
RD
FUSE 10A
C4B-11 RD
C2P-12 C2P-10
CR23
WORK LIGHTS OPTION

NO
K
PBOX GND
C2P-11 C2P-9
FB1
L30
P134FB WH FLASHING BEACONS

OPTION
C21HM WH
HM
HOUR METER
J
_
P134PWR
RUN/TEST SWITCH
C5-8 C127SW GR A
TS64
GM CONN4
C5-18 C35HRPM BK/RD B GM CONN6
M4
PUMP
FUEL
BRN
+
E
I
GM CONN6
TB21
C135FP BL/WH D GM CONN6

TS3
C2P-1 C39LP BL/RD C2B-1 C5-11 C21IGN WH F GM CONN6

LP
FUEL SELECT
GAS
TS53
D11
TB39
LP
FUEL SELECT
GAS C5-9 C128LRPM OR/RD E
D10
GM CONN8
C5-10 C39LP BL/RD D GM CONN8
C41RPM OR/BK C2B-3 C5-2 C41RPM OR/BK C GM CONN8
H
C5-6 C27AUX RD B
TB41
GM CONN8
L2
CHECK ENGINE LED

C28TTA RD/BK
C5-13 C108ESL BL/WH F GM CONN10

TS2
CR1
C1P-7 C33STR BK C1B-7

ENGINE C5-5 C33STR BK J GM CONN10
TB33
G
TB24
START
TS52
NO
C5-19 P23BAT WH A GM CONN10

ENGINE
START
P134PWR
P26ESTP BK
P24FS WH
P25FS RD
R33STR BK
GM HARNESS
F
C9P-2
C9P-3
STARTER
February 2012
Part No. 77828

D3
STARTER MOTOR
D4
TS51
TB27
AUXILIARY
TS1
PUMP C27AUX RD
AUXILIARY POWER RELAY
WH(FS)
RD(FS)
AUXILIARY
PR1
NO
PUMP 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
WH C7P-2 P23BAT WH C7B-2 P134TTSR RD RD BK BRN
LEVEL SENSOR
C9P-1 BK
C
D2
A
TB23
S8
D
RD C1P-2 C28TTA RD/BK C1P-2

P2
H1
HORN
P3
BK C2P-5 C46HRN GR C2B-5 C46HRN GR

HORN RELAY
H2
CR5
TB46
TB22
C7P-1 P22BAT BK C7B-1 P22HRN BK R46HRN BK C6-9
HORN
NO
S-60 • S-65 • S-60 HC

TB134
RD
SW3
NO
C2P-6 P134PWR C2B-6
HYDRAULIC OIL
CR17
C
R21IGN WH C5-4 TEMPERATURE SWITCH

(OPTION)
86
C21IGN WH
85
GRND
COOLING FAN
M1 FAN
PLAT
C116 OR
KS1
C5-1
(OPTION)
87a 87
30
P116HYD RD
GM HARNESS
P1
GM HARNESS
B
RD
STA.
RD
A
S
I
ALTERNATOR
REGULATOR
FLD.
CB2
CB3
15A
15A
D1
GND.
BAT.
GM 3.0L Models
FUSE
LINK
A
TB20
-
P20BAT RD C7B-4
12V DC
B2
6 - 14
1
8
1
8
6 - 15
GM 3.0L Models
C7P-3 BATGND C7B-3

GROUND
A
C2P-3 C41RPM OR/BK C2B-3

5
U4
TB30
C1P-4 C30FWD WH C1B-4 C5-21 C30FWD WH BK RD

15 DRIVE FORWARD
15
C31REV WH/BK
1
C1P-5 C1B-5 C5-20 C31REV WH/BK RD BK

16 DRIVE REVERSE
TS14
TB31
H4
DRIVE MODE C130TA WH/RD TRAVEL ALARM

8
OPTION
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
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC
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
CDE2 BL/BK C37SCW BL/BK C37SCW BL/BK

C
C1P-11 C1B-11
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
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
RKOUT 6 C3P-6 C6TRF WH/RD C3B-6
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3
C3P-4 C4TRL WH C3B-4 C4TRL WH

J1
4 5 10 TURNTABLE ROTATE LEFT

TB4
OR
PWR 3 13 C14-1 C14-2
D
BRN C5TRR WH/BK C5TRR WH/BK

C3P-5 C3B-5 TURNTABLE ROTATE RIGHT
GND 2 14 9
TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
TB6
LEFT
TS62
C6TRF WH/RD TURNTABLE ROTATE

5
R4
FLOW CONTROL
C31-1 C31-2
TB1
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
DOWN C2PBD RD/BK

PRIMARY BOOM DOWN
C13-1 C13-2
CR34
Part No. 77828

TS61
J2
R14
February 2012
7
5
TB3
PRI UP/DN & TT ROTATE
R16
6
10
BK C3PBF RD/WH
YOUT 5 2 PRIMARY BOOM FLOW CONTROL
RD
JC2
XOUT 4 1 C29-1 C29-2

C3P-1 C1PBU RD C3B-1
J1
OR 6
PWR 3 11
TB2
BRN
GND 2 12 C3P-2 C2PBD RD/BK C3B-2
7
1
C3P-3 C3PBF RD/WH C3B-3
F
8
TB9
C30-1 C30-2
C3P-9 C9PER BK/RD C3B-9 C9PER BK/RD PRIMARY BOOM EXTEND/RETRACT
14
FLOW CONTROL
C3P-8 C8PBR BK/WH C3B-8
13
7
21 LS5
PRIMARY EXT/RET
NC
C3P-7 C7PBE BK C3B-7 LS5 CABLE TENSION LIMIT SWITCH

6 12
TB7
YEL
22
OUT 5 3
RD RD BR C7PBE BK
G
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH

U13 JOYSTICK CONTROL CARD
GND 2 10 BOOM RETRACT

TB8
1
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
2
BK
TB13
LS3
NO
HC
H
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
LS2
NO
HC
C2P-2
4
C11-2 WH BK C11-1 LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
13
14
LS1
J1 F.H. WH C10-1 BK WH C10-2 LS2-PRIMARY BOOM UP

DRIVE LIMIT SWITCH
13
14
NO
HC
I
C40LS OR C2B-2 F.H. OR
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
LS5-CABLE TENSION LED
TB59
13
14
CR34
TB134
P134 RD RD C38-1 RD BR C38-2 LS17-BOOM UP/DOWN
21
HO 22
TS9
C4P-2 C14PLU OR C4B-2
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
C4P-6 C18JD/PRR GR/BK C4B-6

RIGHT
PLATFORM ROTATE
LEFT C17JU/PRL GR C4B-5
TB18
C4P-5 C23-1 C23-2
D28
TS57
C18JD/PRR GR/BK PLATFORM ROTATE RIGHT
RIGHT PLATFORM
L
LEFT ROTATE C17JU/PRL GR

PLATFORM ROTATE LEFT
C22-1 C22-2
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

GM 3.0L Models
Ground Control Box Terminal Strip Wiring Diagram, S-60

GM 3.0L Models
8
7
6
5
4
3
2
1
6 - 16
CR1
IGNITION
START RELAY
A
GM 3.0L Models
BRN
BK-33D
BK-33D
RD-24C
BK C5-5
C5
B
F.H.
BRN
BK-46R
BK-22C1
CR5 OR C5-1
R43DLITE2 RD
R43DLITE1 RD
HORN
RELAY
C2B-5 GR C21IGN WH
BRN
C
CR22 CR17
DRIVE LIGHT
C5
HYDRAULIC
F.H.
OPTION OIL COOLER
S-60 • S-65 • S-60 HC

GR-46D BRN OPTION
RD-CB3 OPTIONS RD-CB3
D C TERMINAL BASE (TB) B A C1PBU RD C3B-1

RD-TS61 C1PBU RD C12-1
1 BOOM UP 1
RD/BK-ALARM C2PBD RD/BK C3B-2
TS64
RD/BK-TS61 C2PBD RD/BK C13-1 RUN/TEST
#1
2 BOOM DOWN 2
D29
C3PBF RD/WH C3B-3 BRN SWITCH
D
RD/WH-R16 C3PBF RD/WH C29-1 C5-8 GR

3 BOOM FUNCTION CONTROL 3
C4TRL WH C3B-4
WH-TS62 C4TRL WH C15-1
C5TRR WH/BK C3B-5
WH/BK-TS62 C5TRR WH/BK C14-1
BRN-GND

C6TRF WH/RD C3B-6 +12V DC
WH/RD-TS62 C6TRF WH/RD C31-1 POWER TO
6 TURNTABLE ROTATE FUNCTION CTRL 6 PLATFORM
C7PBE BK C3B-7
C7
BK-TS63 C7PBE RD-LS5 C37-1
7 BOOM EXTEND 7
C8PBR BK/WH C3B-8
E
BK/WH-TS63 C8PBR BK/WH C17-1

8 BOOM RETRACT 8
C9PER BK/RD C3B-9
BK/RD-TS63 C9PER BK/RD C30-1 18/19 #1
9 BOOM EXT/RET FUNCTION CTRL 9 C3 & C4

JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
44 JIB BBOM DOWN DESCENT ALARM 44
D30
C13DRE BL/RD C4B-1

C13DRE BL/RD C10-1
13 DRIVE ENABLE 13
C14PLU OR C4B-2
Part No. 77828

February 2012
OR-TS59 C14PLU OR C20-1 18/19 #2

14 PLATFORM LEVEL UP 14 C1 & C2
C15PLD OR/BK C4B-3
OR/BK-TS59 C15PLD OR/BK C21-1
#2
#1

F
C17JU GR C4B-5
GR-TS57 C17JU GR C22-1
C18JD GR/BK C4B-6
GR/BK-TS57 C18JD GR/BK C23-1 BOOM
C19JSV GR/WH C4B-7 EXTEND
GR/WH-TS57 LIMIT SWITCH
#2
C5
19 JIB BOOM SELECT VALVE 19 LS1

F.H.
RD-CB2 P20BAT RD
P20BAT RD
20 +12V DC POWER 20
WH-HM C21IGN2 WH C5-11

BK-CR5 P22BAT BK C7B-1 CABLE
C11
G
BK-KS C22LS17 BK C10-2 TENSION

22 +12V DC TO PLATFORM (1) 22 LIMIT SWITCH
P22BAT BK C11-1
LS5
P22BAT BK C9-2
22 +12V DC TO PLATFORM (2) 22
P23BAT WH C7B-2
WH-KS
23 KEY SWITCH POWER 23
RD-CR1
RD-134D
24 CIRCUIT BREAKER POWER 24
#2
#1
C5
F.H.
C37
25 (UNUSED) 25
H
26 (UNUSED) 26
C5-6 RD C27AUX RD C1B-1
RD-TS51 C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B P20BAT RD +12V DC
28 TILT ALARM 28 POWER
C29MS RD/WH C1B-3 BRN
C29MS RD/WH C5-24
29 MOTOR STROKE 29
C30FWD WH C1B-4
C30FWD WH C5-21
30 DRIVE FORWARD 30
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
31 DRIVE REVERSE 31
I
C32BRK WH/RD C1B-6

GROUND HARNESS
TO SWITCH PANEL WH/RD-ALRM C32BRK WH/RD C5-23
32 BRAKE 32
C33STR BK C1B-7
BK-TS52
33 ENGINE START 33
C34SA BK/WH C1B-8
34 (UNUSED) 34
C35HS BK/RD C1B-9
RD-TS54 C35HS BK/RD C5-18
C36STCC BL C1B-10
C36STCC BL C24-1
36 STEER RIGHT 36
C37STC BL/BK C1B-11
J
C37STC BL/BK C25-1

C5
37 STEER LEFT 37
C39LP BL/RD C2B-1
ENGINE
BL/RD-TS53 C39LP BL/RD C5-10

39 LIQUID PROPANE FUEL 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C5
C41RPM OR/BK C5-2

C46HRN GR C2B-5
GR-CR5
WH C11-2
46 HORN 46
C59CNK BL/BK C3B-11
WH-L46+ C59CNK WH-LS5 C37-4
K

C134PWR GR/BK C2B-6
RD-24D C134PWR RD-LS17 C38-1
134 PLAT. OVERLOAD LIM. SW. +12V (1) 134
P134FB WH-FH C134PWR BK-LS5 C37-3
RD-KS P134TTSR RD A
#2
F.H.
GR/WH C5-12 C45GEN GR/WH C2B-7

BRN-TS64
BRN C37-2
BRN C7B-3
BK-CR5 R46HRN BK
OR/RD-FH C38-3 C118BSR OR/RD C4B-4
BRN

C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
NOTE: DASHED LINES INDICATE OPTION WIRES

L
B A
OR-CR34 OR-LS17 C38-2
BK C16-1
OR/RD-118B OR/RD-LS17 C38-3

WH LS2 C10-2
F.H.
HARNESS
FUNCTION
M
GROUND BOLT
N
Ground Control Box Switch Panel Wiring Diagram, S-60

GM 3.0L Models
OVERLOAD LED
TURNTABLE
PLATFORM
(CE OPTION)
UP/DOWN
PLATFORM
ROTATE
ROTATE
(TO TERMINAL STRIP)

BASE BOX HARNESS
RD
BOOM
TS57
TS62
TS61
RD
L45
D9
RD RD
RD/BK-2 RD-1
-
RD 2
C19JSV GR/WH
RD/WH
RD
RD
GR/BK-18D
RD RD
RD
WH/RD-6
WH/BK-5
GR-17D
RD
D3
WH-4
RD
AUXILIARY
RD RD
POWER
TS51
RD
D4
RD
RD
RD RD
PLATFORM
RD
3
LEVEL
RD
TS59
BRN
RD-27
WH
+
LOWER/ -
BOOM EXTEND/
RETRACT
RETRACT
BOOM
C134PWR RD
RD/WH-CR34
RD
LED
L46
TS63
GR/WH-19D
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
WH/RD-6D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
WH-4D
TURNTABLE ROTATE
RD-1D
BK-7D
WH
RD
4
RESISTOR
R4
DALE RH-25 25W

DALE RH-25 25W
RD-20C
BK-22D1
RD-134D2
BRN-GND
BK-33D
WH-21D
WH-23D
OR-LS17
RD CR22
RD CR17
BL/RD-39D
10 ohm 1%
BK/RD-35D
BL/WH-38
5 ohm 1%
BOOM UPPER ZONE
RD C32-7
RD
WH
RESISTOR
ENGINE
CHECK
LED
L2
R16
KEY SWITCH
1
RD/WH-TB3D
RD
FUEL SELECT
OPTIONS 15A
2
CONTROLS 15A
BREAKER
CIRCUIT
KS1
B1
BREAKER
TS53
CIRCUIT
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
OR
RD
RD
RD RD RD LABEL DESCRIPTION
CB2 CIRCUIT BREAKER, CONTROLS, 15A 6
CB3 CIRCUIT BREAKER, OPTIONS, 15A
CR1 IGNITION / START RELAY
DALE RH-25 25W
CR5 SERVICE HORN RELAY

5 ohm 1%
RD
CR17 HYDRAULIC OIL COOLER RELAY
RESISTOR
UP/DOWN
CR22 DRIVE LIGHT RELAY (OPTION)

R14
RD/WH-TS61
RD/WH-R16
CR34 BOOM SPEED REDUCTION RELAY

OR-LS17
RD/WH-R16
HM HOUR METER
BRN
KS1 KEY SWITCH
ENGINE
L2 CHECK ENGINE LED
START
BRN
BRN
BRN
WH-21D
TS52
L46 LOWER/RETRACT BOOM LED
REDUCTION
L45 PLATFORM OVERLOAD LED (CE OPTION)

SPEED
BOOM
CR34
P1 EMERGENCY STOP BUTTON

RD
RD
R4 SPEED LIMITING RESISTOR 5 OHMS

HOUR METER
RD
1 1 R16 SPEED LIMITING RESISTOR 10 OHMS
D13
STOP SWITCH
EMERGENCY
TS51 AUXILIARY POWER TOGGLE SWITCH

NC NC
RD TS52 ENGINE START TOGGLE SWITCH
D14
TS53 FUEL SELECT TOGGLE SWITCH
FUNCTION
2 2
ENABLE
TS54 FUNCTION ENABLE TOGGLE SWITCH
TS54
P1
RD TS57 PLATFORM ROTATE TOGGLE SWITCH 8

RD
TS61 BOOM UP/DOWN TOGGLE SWITCH

RD TS62 TURNTABLE ROTATE TOGGLE SWITCH
TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH
NOTE: DASHED LINES INDICATE OPTION WIRES TS64 RUN/TEST TOGGLE SWITCH
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 17


GM 3.0L Models
Platform Control Box Wiring Diagram, S-60

GM 3.0L Models
N
12V DC PLATFORM POWER CONNECTOR
CONTROL BOARD OUTPUT CONNECTOR

CONTROL BOARD POWER CONNECTOR
CONTROL BOARD INPUT CONNECTOR
CWLITE WH TS49
(TO SWITCH
PLATFORM
CONTROL RELAY (CE OPTION)
CONTROL
HARNESS
LOAD SENSE LIMIT SWITCH
FOOTSWITCH CONNECTOR
48 PIN CONNECTOR BLOCK
PANEL)
ALC-500 CONTROL BOARD
DESCRIPTION
TILT ALARM
M
C19JSV GR/WH TS7

C19JSV GR/WH C4P-7
BRN JC3
BRN GND
RD-E-STOP C134PWR RD LS18
C1P-C4P
ITEM
C134PWR RD-H1+
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
OPT.
CE LIFT/DRIVE OPTION
L
TS7 WH
RD LS18 CABLE
CR27
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
OPTION
K
LS18
(CE)
BRN
BK C1P-12
CR30
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
TS1 WH
P23BAT WH C7P-2
J
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
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+
I
C59CNK BL/BK C3P-11

P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
CDLITE OR/RD C2P-4
C4P
C7P
C3P
F.S.
SWITCH
C45GEN GR/WH C2P-7
FOOT
H
C46HRN GR C2P-5 C9
C39LP BL/RD C2P-1
P26ESTP BK
WH/RD C1P-6
11
3
C118LSR OR/RD C4P-4

G
C6TRF WH/RD C3P-6

J3
C8PBR BK/WH C3P-8
BATTERY
C16DRE BL/RD C4P-1
12V DC
C7PBE BK C3P-7
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
C31REV WH/BK C1P-5
C2P
C3P
C4P
C7P
C2PBD RD/BK C3P-2
February 2012
Part No. 77828

C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6 C4P(BR)
C4TRL WH C3P-4
ALC-500
19/18 CONTROL CABLE

U13
C29MS RD/WH C1P-3

J2
E
C3P(GR)
C35RPM BK/RD C1P-9
C33STR BK C1P-7
* NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
C27AUX RD C1P-1
C2P(BK)
D
J1
C1P
9
1
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
C7P
JC2-2 BRN
S-60 • S-65 • S-60 HC

JC3-5 WH
JC3-3 OR
C
JC3-4 BL *
JC3-2 BRN
TS15 BL/WH C28TTA RD/BK C1P-2
TS15 B BL/BK
C28TTA RD/BK C1P-2

DRE LED BL/RD
TS14 RD/WH
BATGRN C7P-3
B
GR/BK C133TTA C3P-12

GR/BK-L4- (CE)
D39
RD/BK-28
ALARM
TILT
RD/BK-L4- RD/BK-L48- (NON-CE)
H1
GM 3.0L Models
C134PWR RD C2P-6
C134PWR RD LS18 RD-TILT
+
CWLITE BK
BRN
A BRN
BRN BRN
CWLITE WH TS49
6 - 18
1
8
Platform Control Box Switch Panel Wiring Diagram, S-60

GM 3.0L Models
PLATFORM
COMPONENT INDEX 1
CONTROL JC2 BOOM PROPORTIONAL JOYSTICK:
HARNESS BOOM UP/DOWN , TURNTABLE ROTATE
(TO CONTROL BOX) JC1 BOOM PROPORTIONAL JOYSTICK:
BOOM EXTEND/RETRACT
L1 DRIVE ENABLE LED
L4 PLATFORM OVERLOAD LED
TS48
L48 BOOM TILTED LED
DRIVE LIGHTS/
WORK LIGHTS P2 EMERGENCY STOP BUTTON
2
DLITE RD RD
(OPTION) P3 HORN SWITCH
JC2 BK
JC3 TS1 AUXILIARY TOGGLE SWITCH
DRIVE TS2 ENGINE START TOGGLE SWITCH
BOOM UP/DOWN
7 JC1 7
+
FORWARD/REVERSE
7 TS3 FUEL SELECT TOGGLE SWITCH
& TURNTABLE ROTATE BOOM & STEER
LEFT/RIGHT TS15 LEFT/RIGHT TS4 HI/LOW RPM TOGGLE SWITCH
EXTEND/RETRACT L48
DRIVE TS7 PLATFORM ROTATE TOGGLE SWITCH
6 6 ENABLE TILT ALARM LED
(ANSI/CSA OPT.)
6 TS9 PLATFORM LEVEL TOGGLE SWITCH
TS14 DRIVE SPEED TOGGLE SWITCH
5 5 5 TS15 DRIVE ENABLE TOGGLE SWITCH
3
BK
BK
BK
RD
TS48 DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)
4 4 4
L4
3 BRN 3 PLATFORM 3
OVERLOAD
(CE OPTION)
2 +
2 L1
DRIVE +
2
ENABLE
BRN
1 L47
1 1 4
BL J1-5 (ROCKER SWITCH OPTION ONLY)

RETRACT
+
RD
BOOM
BK
BRN
BK
BRN BRN BRN BRN F18
FUSE 10A
BK
(WORKLIGHT ONLY)
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
C133PLA GR/BK D39

DLITE OR/RD C2P-4
C28TTA RD/BK H1-

5
BL/RD-DE3 J1-16
BL/BK-DE2 J1-7
BK
BL-DE1 J1-6
WLITE WH
WLITE WH
BRN J1-14
BRN J1-10
BRN J1-12
OR J1-13
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
YL J1-3
BL J1-5
BRN
BK
RD
BK
BK
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
C46HRN GR C2P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C18PRR GR/BK C4P-6
C19JSV GR/WH C4P-7

WH CR27
C17PRL GR C4P-5
C27AUX RD C1P-1
WH CR30
C29MS RD/WH J1-8
C45GEN GR/WH C2P-7
P25FS RD C9-3
C33STR BK C1P-7
C35HS BK/RD C1P-9

P24FS WH C9-2
6
WH WH
TS3
D12 FUEL
SELECT 1 1 1
7
4 3
NO
NC NC NC
P2
TS2 TS4 2 2 2 EMERGENCY
P3 TS7 TS14
ENGINE HIGH/LOW STOP
TS9 WH PLATFORM TS1 HIGH/LOW TS47
HORN START RPM D11
PLATFORM AUXILIARY (2WD/4WD) GENERATOR
RD
ROTATE
LEVEL PUMP (OPTION)
BK
WH-24
RD RD RD RD
8
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 19


GM 3.0L Models

GM 3.0L Models
N
RD
RD
BRN
C22LS RD
P24FS WH
P26ESTP BK
C41RPM OR/BK
C28TTA RD/BK
D12

FOOTSW. HIGH
FOOTSW. LOW
ENGINE
TS54
SPEED
TS4
TB35
D13
D14
M
LOW RPM
FUNCTION ENABLE
HIGH RPM
TB45
GENERATOR
ON
TS47

GENERATOR OPTION
WH
RD
L
CR23
TS48
C2P-6 DLITE GR/BK C2B-6

L29
DRIVE LIGHT
LIGHTS
WORK LIGHT C4B-12 RD DRIVE LIGHT OPTION
L29
L30
RD
RD
FUSE 10A
C4B-11 RD
C2P-12 C2P-10
CR23
WORK LIGHTS OPTION

NO
K
PBOX GND
C2P-11 C2P-9
FB1
L30

OPTION
C21HM WH
HM
HOUR METER
J
_
P134PWR
RUN/TEST SWITCH
C5-8 C127SW GR A
TS64
GM CONN4
C5-18 C35HRPM BK/RD B GM CONN6
M4
PUMP
FUEL
BRN
+
E
I
GM CONN6
TB21
C135FP BL/WH D GM CONN6

TS3
C2P-1 C39LP BL/RD C2B-1 C5-11 C21IGN WH F GM CONN6

LP
FUEL SELECT
GAS
TS53
D11
TB39
LP
FUEL SELECT
GAS C5-9 C128LRPM OR/RD E
D10
GM CONN8
C5-10 C39LP BL/RD D GM CONN8
C41RPM OR/BK C2B-3 C5-2 C41RPM OR/BK C GM CONN8
H
C5-6 C27AUX RD B
TB41
GM CONN8
L2
CHECK ENGINE LED

C28TTA RD/BK
C5-13 C108ESL BL/WH F GM CONN10

TS2
CR1
C1P-7 C33STR BK C1B-7

ENGINE C5-5 C33STR BK J GM CONN10
TB33
G
TB24
START
TS52
NO
C5-19 P23BAT WH A GM CONN10

ENGINE
START
P134PWR
P26ESTP BK
P24FS WH
P25FS RD
R33STR BK
GM HARNESS
F
C9P-2
C9P-3
STARTER
February 2012
Part No. 77828

D3
STARTER MOTOR
D4
TS51
TB27
AUXILIARY
TS1
PUMP C27AUX RD
WH(FS)
RD(FS)
AUXILIARY
PR1
NO
PUMP 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
WH C7P-2 P23BAT WH C7B-2 P134TTSR RD RD BK BRN
LEVEL SENSOR
C9P-1 BK
C
D2
A
TB23
S8
D

P2
H1
HORN
P3

HORN RELAY
H2
CR5
TB46
TB22
HORN
NO
S-60 • S-65 • S-60 HC

TB134
RD
SW3
NO
C2P-6 P134PWR C2B-6
HYDRAULIC OIL
CR17
C
R21IGN WH C5-4 TEMPERATURE SWITCH

(OPTION)
86
C21IGN WH
85
GRND
COOLING FAN
M1 FAN
PLAT
C116 OR
KS1
C5-1
(OPTION)
87a 87
30
P116HYD RD
GM HARNESS
P1
GM HARNESS
B
RD
STA.
RD
A
S
I
ALTERNATOR
REGULATOR
FLD.
CB2
CB3
15A
15A
D1
GND.
BAT.
GM 3.0L Models
FUSE
LINK
A
TB20
-
P20BAT RD C7B-4
12V DC
B2
6 - 20
1
8
1
8
6 - 21
GM 3.0L Models
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC
20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
TS15
CDE2 BL/BK C1P-11 C37SCW BL/BK C1B-11 C37SCW BL/BK

C
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
PWR 3 13 C14-1 C14-2
C3P-5 C3B-5
D
GND 2 14 9 TURNTABLE ROTATE RIGHT

TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
TB6
LEFT
TS62

R4
5
FLOW CONTROL
C31-1 C31-2
TB1
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
DOWN C2PBD RD/BK

PRIMARY BOOM DOWN
C13-1 C13-2
CR34
TS61
J2
R14
Part No. 77828
7
February 2012
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
8
F
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
OUT 5 3
RD RD BR C7PBE BK
G
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
2
BK
TB13
LS3
NO
HC
P24FS WH
H
J3
4
3
13
14
P26ESTP BK
3
TB22
LS2
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS1

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
CR30
NC
LIFT/
CE
P22LS BK
L46
NO
LS5
J
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
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
C3P-10 C129JDA BL C3B-10

CR13
NC
TS8

DOWN JIB
UP BOOM C17JU/PRL GR C4B-5
TB18
C4P-5 C23-1 C23-2
D28
TS58
RIGHT PLATFORM
L

C22-1 C22-2
TB17
TS57
RIGHT PLATFORM
D29
LEFT ROTATE
TS7
WH
C129 RD/BK
H3
D30
C4P-7 C19JSV GR/WH C4B-7
M
CR13
TB19
C19JSV GR/WH
BRN
C41RPM OR/BK
JIB VALVE
C28TTA RD/BK
P26ESTP BK JIB VALVE
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD

GM 3.0L Models

GM 3.0L Models
8
7
6
5
4
3
2
1
6 - 22
CR1
IGNITION
START RELAY
A
GM 3.0L Models
BRN
BK-33D
BK-33D
RD-24C
BK C5-5
C5
B
F.H.
BRN
BK-46R
BK-22C1
CR5 OR C5-1
R43DLITE2 RD
R43DLITE1 RD
HORN
RELAY
C2B-5 GR C21IGN WH
BRN
C
CR22 CR17
DRIVE LIGHT
C5
HYDRAULIC
F.H.
OPTION OIL COOLER
S-60 • S-65 • S-60 HC

GR-46D BRN OPTION

1 BOOM UP 1
TS64
#1
2 BOOM DOWN 2
D29
D

C4TRL WH C3B-4
C5TRR WH/BK C3B-5
BRN-GND

C6TRF WH/RD C3B-6 +12V DC
WH/RD-TS62 C6TRF WH/RD C31-1 POWER TO
6 TURNTABLE ROTATE FUNCTION CTRL 6 PLATFORM
C7PBE BK C3B-7
C7
7 BOOM EXTEND 7
C8PBR BK/WH C3B-8
E

8 BOOM RETRACT 8
C9PER BK/RD C3B-9
9 BOOM EXT/RET FUNCTION CTRL 9 C3 & C4

JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
44 JIB BBOM DOWN DESCENT ALARM 44
D30
C13DRE BL/RD C4B-1

C13DRE BL/RD C10-1
13 DRIVE ENABLE 13
C14PLU OR C4B-2
Part No. 77828

February 2012
OR-TS59 C14PLU OR C20-1 18/19 #2

C15PLD OR/BK C4B-3
#2
#1

F
C17JU GR C4B-5
C18JD GR/BK C4B-6
#2
C5

F.H.
RD-CB2 P20BAT RD
P20BAT RD
20 +12V DC POWER 20

C11
G

P22BAT BK C11-1
LS5
P22BAT BK C9-2
P23BAT WH C7B-2
WH-KS
RD-CR1
RD-134D
#2
#1
C5
F.H.
C37
25 (UNUSED) 25
H
26 (UNUSED) 26
C5-6 RD C27AUX RD C1B-1
C28TTA RD/BK C1B-2
C29MS RD/WH C5-24
29 MOTOR STROKE 29
C30FWD WH C1B-4
C30FWD WH C5-21
30 DRIVE FORWARD 30
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
31 DRIVE REVERSE 31
I
C32BRK WH/RD C1B-6

GROUND HARNESS
32 BRAKE 32
C33STR BK C1B-7
BK-TS52
33 ENGINE START 33
C34SA BK/WH C1B-8
34 (UNUSED) 34
C35HS BK/RD C1B-9
RD-TS54 C35HS BK/RD C5-18
C36STCC BL C1B-10
C36STCC BL C24-1
36 STEER RIGHT 36
C37STC BL/BK C1B-11
J
C37STC BL/BK C25-1

C5
37 STEER LEFT 37
C39LP BL/RD C2B-1
ENGINE

C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C5
C41RPM OR/BK C5-2

C46HRN GR C2B-5
GR-CR5
WH C11-2
46 HORN 46
C59CNK BL/BK C3B-11
K

C134PWR GR/BK C2B-6
RD-24D C134PWR RD-LS17 C38-1
RD-KS P134TTSR RD A
#2
F.H.

BRN-TS64
BRN C37-2
BRN C7B-3
BK-CR5 R46HRN BK
BRN


L
B A
BK C16-1

WH LS2 C10-2
F.H.
HARNESS
FUNCTION
M
GROUND BOLT
N

GM 3.0L Models
OVERLOAD LED
TURNTABLE
PLATFORM
(CE OPTION)
UP/DOWN
PLATFORM
ROTATE
ROTATE
(TO TERMINAL STRIP)

BASE BOX HARNESS
RD
BOOM
TS57
TS62
TS61
RD GR/BK
L45
D9
RD RD
RD/BK-2 RD-1
-
RD
C19JSV GR/WH
RD/WH
RD
2
RD
GR/BK-18D
RD RD
RD
WH/RD-6
WH/BK-5
GR-17D
RD
D3
GR/BK
WH-4
RD
GR
AUXILIARY
RD RD
POWER
TS51
RD
D4
RD
RD
PLATFORM
RD RD GR/BK
RD
LEVEL
TS59
D28
GR
RD
BRN
RD
3
RD-27
UP/DOWN
WH
JIB BOOM
TS58
+
LOWER/ -
BOOM EXTEND/
RETRACT
RETRACT
BOOM
C134PWR RD
RD/WH-CR34
RD
LED
L46
TS63
GR/WH-19D
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
WH/RD-6D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
BL-44D
WH-4D
TURNTABLE ROTATE
RD-1D
BK-7D
WH
RD
RESISTOR
4
R4
DALE RH-25 25W

DALE RH-25 25W
RD-20C
BK-22D1
RD-134D2
BRN-GND
BK-33D
WH-21D
WH-23D
OR-LS17
RD CR22
RD CR17
BL/RD-39D
10 ohm 1%
BK/RD-35D
BL/WH-38
5 ohm 1%
BOOM UPPER ZONE
RD C32-7
RD
WH
RESISTOR
ENGINE
CHECK
LED
L2
R16
KEY SWITCH
1
RD/WH-TB3D
RD
FUEL SELECT
OPTIONS 15A
2
CONTROLS 15A
BREAKER
CIRCUIT
KS1
B1
BREAKER
TS53
CIRCUIT
B
CB3
CB2
RD
-
3
4
5
WH
RD/WH
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
RD
RD
OR
RD
RD LABEL DESCRIPTION
RD RD RD CB2 CIRCUIT BREAKER, CONTROLS, 15A
CR1 IGNITION / START RELAY 6
CR5 SERVICE HORN RELAY
DALE RH-25 25W
CR17 HYDRAULIC OIL COOLER RELAY

5 ohm 1%
RD
RESISTOR
UP/DOWN

R14
RD/WH-TS61
RD/WH-R16
HM HOUR METER
OR-LS17
RD/WH-R16
KS1 KEY SWITCH

BRN
L2 CHECK ENGINE LED
ENGINE
START
BRN
BRN
BRN
WH-21D
TS52
REDUCTION
P1 EMERGENCY STOP BUTTON 7

SPEED
BOOM
CR34

RD
RD

HOUR METER
RD
1 1 TS51 AUXILIARY POWER TOGGLE SWITCH
D13
STOP SWITCH
EMERGENCY

NC NC
RD TS53 FUEL SELECT TOGGLE SWITCH
D14
FUNCTION
2 2
ENABLE
TS57 PLATFORM ROTATE TOGGLE SWITCH
TS54
P1
RD TS58 JIB BOOM UP/DOWN TOGGLE SWITCH

TS59 PLATFORM LEVEL TOGGLE SWITCH 8
RD
TS61 BOOM UP/DOWN TOGGLE SWITCH

RD TS62 TURNTABLE ROTATE TOGGLE SWITCH
NOTE: DASHED LINES INDICATE OPTION WIRES TS64 RUN/TEST TOGGLE SWITCH
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 23


GM 3.0L Models

GM 3.0L Models
N

CWLITE WH TS49
(TO SWITCH
PLATFORM
CONTROL
HARNESS
FOOTSWITCH CONNECTOR
PANEL)
DESCRIPTION
TILT ALARM
M
C19JSV GR/WH TS7 WH

C19JSV GR/WH C4P-7
BRN JC3 BK
BRN GND
C1P-C4P
ITEM
C134PWR RD-H1+
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
OPT.
L
TS7 WH
JIB
RD LS18 CABLE
CR27
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
OPTION
K
LS18
(CE)
BRN
BK C1P-12
CR30
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
TS1 WH
P23BAT WH C7P-2
J
P22BAT BK C7P-1
JIB
C19JSV GR/WH C4P-7

C18PRR GR/BK C4P-6
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+
I
C59CNK BL/BK C3P-11

P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
CDLITE OR/RD C2P-4
C4P
C7P
C3P
F.S.
SWITCH
C45GEN GR/WH C2P-7
FOOT
H
C46HRN GR C2P-5
C9
C39LP BL/RD C2P-1
P26ESTP BK
WH/RD C1P-6
11
3
C118LSR OR/RD C4P-4

G
C6TRF WH/RD C3P-6

J3
C8PBR BK/WH C3P-8
BATTERY
C16DRE BL/RD C4P-1
12V DC
C7PBE BK C3P-7
C7P
C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
F
C31REV WH/BK C1P-5
C2P
C3P
C4P
C7P
C2PBD RD/BK C3P-2
February 2012
Part No. 77828

C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6 C4P(BR)
C4TRL WH C3P-4
ALC-500
19/18 CONTROL CABLE

U13
C29MS RD/WH C1P-3

J2
E
C3P(GR)
C35RPM BK/RD C1P-9
C33STR BK C1P-7
* NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
C27AUX RD C1P-1
C2P(BK)
D
J1
C1P
9
1
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK C1P(GY)
JC2-3 OR
JC1-5 YEL
C7P
JC2-2 BRN
S-60 • S-65 • S-60 HC

JC3-5 WH
JC3-3 OR
C
JC3-4 BL *
JC3-2 BRN
TS15 B BL/BK
C28TTA RD/BK C1P-2

DRE LED BL/RD
TS14 RD/WH
BATGRN C7P-3
B

GR/BK-L4- (CE)
D39
RD/BK-28
ALARM
TILT
RD/BK-L4- RD/BK-L48- (NON-CE)
H1
GM 3.0L Models
C134PWR RD C2P-6
+
CWLITE BK
BRN
A BRN
BRN BRN
CWLITE WH TS49
6 - 24
1
8

GM 3.0L Models
COMPONENT INDEX
PLATFORM 1
CONTROL CR13 JIB BOOM CUTOUT RELAY
HARNESS JC2 BOOM PROPORTIONAL JOYSTICK:
(TO CONTROL BOX) BOOM UP/DOWN , TURNTABLE ROTATE
BOOM EXTEND/RETRACT
L1 DRIVE ENABLE LED
L4 PLATFORM OVERLOAD LED
TS48
DRIVE LIGHTS/ L47 LOWER/RETRACT BOOM LED
WORK LIGHTS
DLITE RD RD
L48 BOOM TILTED LED 2
(OPTION) P2 EMERGENCY STOP BUTTON
JC2 BK
JC3 P3 HORN SWITCH
DRIVE
BOOM UP/DOWN
7 JC1 7
+
FORWARD/REVERSE
7
TS1
TS2
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
& TURNTABLE ROTATE BOOM & STEER
LEFT/RIGHT TS15 LEFT/RIGHT TS3 FUEL SELECT TOGGLE SWITCH
EXTEND/RETRACT L48
DRIVE
TS4 HI/LOW RPM TOGGLE SWITCH
6 6 ENABLE TILT ALARM LED
(ANSI/CSA OPT.)
6 TS7 PLATFORM ROTATE TOGGLE SWITCH
5 5 5 TS9 PLATFORM LEVEL TOGGLE SWITCH
BK
BK
TS14 DRIVE SPEED TOGGLE SWITCH 3
BK
RD
4 4 4 TS47 GENERATOR TOGGLE SWITCH (OPTION)
L4 TS48 DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)
3 BRN 3 PLATFORM 3
OVERLOAD
(CE OPTION)
2 +
2 L1
DRIVE +
2
BRN
ENABLE
BRN
1 1 1 4
L47 CR13

RETRACT JIB BOOM +
RD
BOOM CUTOUT
BK
BRN
BK
BRN BRN BRN BRN F18
FUSE 10A
BK
(WORKLIGHT ONLY)
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
C133PLA GR/BK D39

DLITE OR/RD C2P-4
C28TTA RD/BK H1-

BL/RD-DE3 J1-16
BL/BK-DE2 J1-7
BK 5
BL-DE1 J1-6
WLITE WH
WLITE WH
BRN J1-14
BRN J1-10
BRN J1-12
OR J1-13
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
YL J1-3
BL J1-5
WH-JIB
BRN
BK
RD
BK
BK
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
C46HRN GR C2P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C18PRR GR/BK C4P-6
C19JSV GR/WH C4P-7

WH CR27
C17PRL GR C4P-5
C27AUX RD C1P-1
WH CR30
C29MS RD/WH J1-8
C45GEN GR/WH C2P-7
P25FS RD C9-3
C33STR BK C1P-7
C35HS BK/RD C1P-9

P24FS WH C9-2
C19JSV GR/WH
P24FS WH
C129JDA BL C3P-10
WH-JIB
WH WH
TS3
D12 FUEL
4 NO
3 GR SELECT 1 1 1
7
NC NC NC
P2
TS7 TS8 TS2 TS4 2 2 2 EMERGENCY
P3 TS14
PLATFORM JIB ENGINE HIGH/LOW STOP
TS9 WH TS1 HIGH/LOW TS47
HORN ROTATE GR/BK BOOM START RPM D11
PLATFORM AUXILIARY (2WD/4WD) GENERATOR
RD
LEVEL PUMP (OPTION)

BK
D27
WH-24
RD RD RD RD
8
CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 25


GM 3.0L Models

Ford LRG-425 EFI Models (before serial number 11880)
N
RD
RD
BRN
P134PWR RD
P22LS BK
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
P24FS WH

D12
ENGINE
SPEED C25PSR WH/BK OIL PRESSURE
G2
SENDER (OPTION)
TS4
G1
VOLT METER (OPTION)

TB35
D13
D14
LOW RPM C26TSR WH/RD

M
WATER TEMPERATURE
G3
FUNCTION ENABLE
HIGH RPM SENDER (OPTION)
TS54
TB45
GENERATOR
HYDRAULIC
TS47
GENERATOR
WH
RD
OPTION
L
TS48
C2P-4 DLITE OR/RD C2B-4

L29
C21IGN WH
DRIVELIGHT RD DRIVE LIGHT

CR23
TS49
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
+
_
J
L2
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
C2P-1 C39LP BL/RD C2B-1

NC
FUEL C5-19 P23BAT WH FEH(16) PIN1

TB39
SELECT
D11
TS53
FUEL C5-11 C21IGN WH FEH(71) PIN21

SELECT
CR2
D10
TB21
C5-9 C128RPM OR/RD FEH(306) PIN24

C41RPM OR/BK C2B-3
H
C108ESL BL/WH FEH(658) PIN6

CR2
NO
C127TSW GR FEH(458) PIN18

BL/RD
QUICK DISCONNECT
FORD 42 PIN
C5-10 C39LP BL/RD FEH(72) PIN7
TB41
C5-18 C35RPM BK/RD FEH(307A) PIN23

C28TTA RD/BK
P20BAT RD FEH(361) PIN9

C33STR BK (GND) BR FEH(570) PIN34
TS2
C1P-7 C1B-7
ENGINE C5-2 C41RPM OR/BK FEH(11) PIN2
START
G
TS52
TB33
ENGINE C5-5 R33STR BK FEH(32) PIN15 IGN./START RELAY

START C33STR BK FEH(32) PIN13
CR1
NO
TB24
BL/WH FEH(787A) PIN5
M4
PUMP
FUEL
C135FP BL/WH BK
P26ESTP BK
P24FS WH
P25FS RD
C21IGN WH
P24BAT RD
C33STR BK
F
C9P-2
C9P-3
STARTER
February 2012
Part No. 77828

D3
STARTER MOTOR
D4
TS51
TB27
AUXILIARY
TS1
PUMP C27AUX RD
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
FB1
P2
P134FB WH FLASHING
BEACONS OPTION
L48

HORN RELAY
RD
CR5
P3
H2
TB46
HORN
NO
S-60 • S-65 • S-60 HC

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
R6
C107AF WH
510
C5-3
C3B & C3P - GREEN; C4B & C4P - BROWN.
1. ALL LIMIT SWITCHES SHOWN WITH BOOM
C1B & C1P - GRAY; C2B & C2P - BLACK;

B
P1
RD
RD
STA.
A
S
I
ALTERNATOR
REGULATOR
RD
FLD.
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
6 - 27
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
TS15
CDE2 BL/BK C37SCW BL/BK C37SCW BL/BK

C
C1P-11 C1B-11
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
PWR 3 13 C14-1 C14-2
D

GND 2 14 9
TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
TB6
LEFT
TS62

5
R4
FLOW CONTROL
C31-1 C31-2
TB1
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
DOWN C2PBD RD/BK

PRIMARY BOOM DOWN
C13-1 C13-2
CR34
Part No. 77828

TS61
J2
R14
February 2012
7
5
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
F
8
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
OUT 5 3
RD RD BR C7PBE BK
G
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
BK
TB13
LS3
NO
HC
H
P24FS WH
J3
4
3
13
14
P26ESTP BK
3
TB22
LS2
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS1

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
L46
NO
LS5
J
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
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

RIGHT
PLATFORM ROTATE
TB18
C4P-5 C23-1 C23-2
D28
TS57
RIGHT PLATFORM
L

C22-1 C22-2
TB17
D29
C129 RD/BK
H3
D30
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD


Ford LRG-425 EFI Models (from serial number 11880 to 14053)
N
RD
RD
BRN
P134PWR RD
P22LS BK
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
P24FS WH

D12
ENGINE
G2
SENDER (OPTION)
TS4
G1
VOLT METER (OPTION)

TB35
D13
D14

M
WATER TEMPERATURE
G3
FUNCTION ENABLE
TS54
TB45
GENERATOR
HYDRAULIC
TS47
GENERATOR
WH
RD
OPTION
L
TS48

L29
C21IGN WH

CR23
TS49
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
+
_
J
L2

BR
CR39
RD
RUN/TEST SWITCH
C5-13 BL/WH
C35RPM BK/RD
TS64
C5-8 GR
I
CR39
TS3

NC

TB39
SELECT
D11
TS53

SELECT
CR2
D10
TB21

C41RPM OR/BK C2B-3
H

CR2
NO

BL/RD
QUICK DISCONNECT
FORD 42 PIN
TB41

C28TTA RD/BK

TS2
C1P-7 C1B-7
START
G
TS52
TB33

CR1
NO
TB24
M4
PUMP
FUEL
C135FP BL/WH BK
P26ESTP BK
P24FS WH
P25FS RD
C21IGN WH
P24BAT RD
C33STR BK
F
STARTER
C9P-2
C9P-3
STARTER MOTOR
February 2012
Part No. 77828

D3
CR19
D4
TS51
TB27
SPEED REDUCTION RELAY

AUXILIARY
TS1
PUMP C27AUX RD
WH(FS)
AUXILIARY
RD(FS)
PR1
PUMP
NO
PUMP
AUX
AUXILIARY PUMP
E
FS1
C28TTA RD/BK
M2
BK(FS)
B
C28TTA RD/BK WH
TILT ALARM
TB23
LEVEL SENSOR
C9P-1 BK
C
D2
TB134
S8
H1
D
FB1
P2
P134FB WH FLASHING
BEACONS OPTION
L48

HORN RELAY
RD
CR5
P3
H2
TB46
HORN
NO
S-60 • S-65 • S-60 HC

TB134
TB46R
SW3
NO
P134PWR GR/BK
HYDRAULIC OIL
C
CR17
P134PWR RD (OPTION)
TB22
86
85
M1 FAN
C116 OR C5-1
87a 87
(OPTION)
30
P116HYD RD
KS1
GRND
PLAT
R6
C107AF WH
510
C5-3

B
P1
RD
RD
STA.
A
S
I
ALTERNATOR
REGULATOR
RD
FLD.
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 - 28
1
8
1
8
6 - 29
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
C
TS15

7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
D
PWR 3 13 C14-1 C14-2

GND 2 14 9
TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
LEFT
TS62
R4
CR19
7.5
TB6
C31-1 C31-2
FLOW CONTROL
TB1
R2
C12-1 C12-2
5
C1PBU RD
PRIMARY BOOM UP
UP
E
PRIMARY BOOM
DOWN C2PBD RD/BK
PRIMARY BOOM DOWN
Part No. 77828
C13-1 C13-2
February 2012
CR34
TS61
J2
R14
7
5
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
F

8
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
G
OUT 5 3
RD RD BR C7PBE BK
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
BK
TB13
H
LS3
NO
HC
P24FS WH
J3
4
3
13
14
P26ESTP BK
3
TB22
LS1
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS2

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
L46
J
NO
LS5
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
K
C14PLU OR
PLATFORM LEVEL UP
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
D27
TS7

RIGHT
PLATFORM ROTATE
TB18
C4P-5 C23-1 C23-2
D28
TS57
RIGHT PLATFORM
L

C22-1 C22-2
TB17
D29
C129 RD/BK
H3
D30
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD


Ford DSG-423 EFI Models (after serial number 14053)
N
RD
RD
BRN
P134PWR RD
P22LS BK
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
P24FS WH

D12
ENGINE
G2
SENDER (OPTION)
TS4
G1
VOLT METER (OPTION)

TB35
D13
D14
LOW RPM C26TSR WH/RD (FEH PIN 39)

M
WATER TEMPERATURE
G3
FUNCTION ENABLE
TS54
TB45
GENERATOR
C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH GENERATOR
TS47
OPTION
WH
RD
L
TS48

L29
C21IGN WH

CR23
TS49
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
GY/YL GASOLINE SENSOR

B
HARNESS
RD
C
BK/BL
D
J
RD/GN
L2
LPG LOCKOUT
WH/BK
BR
CR39
RD
RUN/TEST SWITCH
C5-13 BL/WH
C35RPM BK/RD
TS64
C5-8 GR
I
CR39
TS3

NC

TB39
SELECT
D11
TS53

SELECT
CR2
D10
TB21

C41RPM OR/BK C2B-3
H

CR2
NO

BL/RD
QUICK DISCONNECT
FORD 42 PIN
TB41

C28TTA RD/BK

TS2
C1P-7 C1B-7
START
G
TS52
TB33

START
CR1
NO
TB24
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
Part No. 77828

D3
CR19
D4
TS51
TB27

AUXILIARY
TS1
PUMP C27AUX RD
WH(FS)
AUXILIARY
RD(FS)
PR1
PUMP
NO
PUMP
AUX
AUXILIARY PUMP
E
FS1
C28TTA RD/BK
M2
BK(FS)
B
C28TTA RD/BK WH
TILT ALARM
TB23
LEVEL SENSOR
C9P-1 BK
C
D2
TB134
S8
H1
D
FB1
P2
P134FB WH FLASHING
BEACONS OPTION
L48

HORN RELAY
RD
CR5
P3
H2
TB46
HORN
NO
S-60 • S-65 • S-60 HC

TB134
TB46R
SW3
NO
P134PWR GR/BK
HYDRAULIC OIL
C
CR17
P134PWR RD (OPTION)
TB22
86
85
M1 FAN
C116 OR C5-1
87a 87
(OPTION)
30
P116HYD RD
KS1
GRND
PLAT
ALTERNATOR FIELD

B
P1
RD
RD
STA.
A
S
I
ALTERNATOR
REGULATOR
RD
FLD.
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 - 30
1
8
8
6 - 31
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
C
TS15

7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
D
PWR 3 13 C14-1 C14-2

GND 2 14 9
TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
LEFT
TS62
R4
CR19
7.5
TB6
C31-1 C31-2
FLOW CONTROL
TB1
R2
C12-1 C12-2
5
C1PBU RD
PRIMARY BOOM UP
UP
E
PRIMARY BOOM
DOWN C2PBD RD/BK
PRIMARY BOOM DOWN
Part No. 77828
C13-1 C13-2
February 2012
CR34
TS61
J2
R14
7
5
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
F

8
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
G
OUT 5 3
RD RD BR C7PBE BK
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
BK
TB13
H
LS3
NO
HC
P24FS WH
J3
4
3
13
14
P26ESTP BK
3
TB22
LS1
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS2

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
L46
J
NO
LS5
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
K
C14PLU OR
PLATFORM LEVEL UP
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
C21-1 C21-2
D27
TS7

RIGHT
PLATFORM ROTATE
TB18
C4P-5 C23-1 C23-2
D28
TS57
RIGHT PLATFORM
L

C22-1 C22-2
TB17
D29
C129 RD/BK
H3
D30
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD


8
7
6
5
4
3
2
1
6 - 32
BRN
IGNITION AUXILIARY
START RELAY POWER RELAY POWER RELAY
CR1
A
BRN CR2 CR39

WH-21C
RD-24B
RD-27C
WH-C5-11
BK-33C
WH-C5-19
RD-24C
BK C5-5
WH-23C
C5
B
F.H.
BRN
BK-46R WH C5-4
BK-22C1
OR C5-1
R43DLITE2 RD
R43DLITE1 RD
HORN
RELAY CR5 CR23 CR17
C2B-4 OR/RD C21IGN WH

BRN
C

DRIVE LIGHT
C5
F.H.
OPTION RELAY
S-60 • S-65 • S-60 HC

GR-46D HYDRAULIC OIL
WH-OPTIONS COOLER OPTION
RD-CB3

1 PRIMARY BOOM UP 1
D
TS64
#1
D29
C4TRL WH C3B-4

C5TRR WH/BK C3B-5
BRN-GND
FUSE 10A
5 TURNTABLE ROTATE RIGHT 5 +12 V DC
C6TRF WH/RD C3B-6
POWER TO
WH/RD-TS62 C6TRF WH/RD C31-1
(DRIVE LIGHT ONLY)

6 TURNTABLE ROTATE FLOW CONTROL 6 PLATFORM
C7PBE BK C3B-7 C7
E

C8PBR BK/WH C3B-8

C9PER BK/RD C3B-9
9 PRIM. BOOM EXT/RET FLOW CONTROL 9 C3 & C4
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
WH-TB21 OPTIONS
D30
C13DE BL/RD C4B-1

C13DE BL/RD C10-1
Part No. 77828

February 2012
13 DRIVE ENABLE 13
C14PLU OR C4B-2
OR-TS59 C14PLU OR C20-1 18/19 #2
C15PLD OR/BK C4B-3
F

#2
#1

C17JU GR C4B-5
17 PLATFORM ROTATE LEFT/JIB BOOM UP 17
C18JD GR/BK C4B-6
#2
C5
19 JIB SELECT VALVE 19

F.H.
RD-CB2 P20BAT RD C11 (LS1)

P20BAT RD
20 +12 V DC POWER 20
WH-CR2#87 C128RPM OR/RD C5-9
G
C11
BK-KS P22LS17 BK C38-4 TENSION

22 +12 V DC TO PLATFORM (1) 22 LIMIT SWITCH
P22BAT BK C11-1
C37 (LS5)
P22BAT BK C9-2
22 +12 V DC TO PLATFORM (2) 22
WH-CR39#30 P23BAT WH C7B-2
WH-KS
RD-CR2#86
RD-CB1
#2
#1
C5
F.H.
C37
25 (UNUSED) 25
H
26 (UNUSED) 26
RD-CR39#86 C27AUX RD C1B-1
C28TTA RD/BK C1B-2
C29MS RD/WH C5-24
29 MOTOR STROKE 29
C30FWD WH C1B-4
C30FWD WH C5-21
30 DRIVE FORWARD 30
C31REV WH/BK C1B-5
I
GROUND HARNESS C31REV WH/BK C5-20

31 DRIVE REVERSE 31
TO SWITCH PANEL C32BRK WH/RD C1B-6
WH/RD-ALRM C32BRK WH/RD C5-23
32 BRAKE 32
BK-CR1#86 C33STR BK C1B-7
BK-TS52
33 ENGINE START 33
C34SA BK/WH C1B-8
34 (UNUSED) 34
C35RPM BK/RD C1B-9
RD-TS54 C35RPM BK/RD C5-18
C36SCC BL C1B-10
C36SCC BL C24-1
36 STEER LEFT 36
J
C37SCW BL/BK C1B-11

C37SCW BL/BK C25-1
C5
37 STEER RIGHT 37
C39LP BL/RD C2B-1
ENGINE

39 LIQUID PROPANE FUEL (LPG) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C5
C41RPM OR/BK C5-2

C46HRN GR C2B-5
GR-CR5
WH C10-2
46 HORN 46
C59CNK BL/BK C3B-11
K
BL/BK-L46+ C59CNK BL/BK-LS5 C37-4

P134PWR GR/BK C2B-6
P134PWR RD-LS17 C38-1
134 PLAT. OVERLOAD LIM. SW. +12V DC (1) 134
P134FB WH-FH P134PWR BK-LS5 C37-3
RD-KS P134TTS RD A
#2
F.H.

BRN-TS64
BRN C37-2
BRN C7B-3
BK-CR5 R46HRN BK
OR/RD-FH C38-3 C118LSR OR/RD C4B-4
BRN

L
B A
BK C16-1

BL/WH-L2- C108ESL BL/WH C5-13
WH LS2 C11-2
F.H.
HARNESS
FUNCTIONS
M
C9 (LS3)
C11 (LS2)
LS17 (C38)
GROUND BOLT
N

UP/DOWN
PRIMARY
OVERLOAD LED
BOOM
GROUND CONTROL BOX HARNESS

TS61
(CE OPTION)
PLATFORM
PLATFORM
TURNTABLE
RD
ROTATE
TS57
RD
ROTATE
L45
TS62
D9
(TO TERMINAL STRIP)

RD RD
RD/BK-2 RD-1
-
RD
2
C19JSV GR/WH
RD/WH
RD
RD
GR/BK-18D
RD
RD
WH/RD-6
WH/BK-5
GR-17D
RD
D3
WH-4
AUXILIARY
RD RD
POWER
TS51
RD
D4
RD
RD
RD RD
PLATFORM
3
LEVEL
RD
TS59
BRN
RD-27
WH
TS63
BOOM EXTEND/
RETRACT
L46 +
RETRACT -
LOWER/
BOOM
C134PWR RD
RD/WH-CR34
RD
GR/WH-19D
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
WH/RD-6D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
GR-17D
OR-14D
RD-27D
WH-4D
RD-1D
BK-7D
TURNTABLE ROTATE
WH
RD
4
RESISTOR
R4
DALE RH-25 25W
DALE RH-25 25W
RD-20C
BK-22D1
RD-134D2
BRN-GND
BK-33D
RD-20D
WH-21D
WH-23D
RD-24D
OR-LS17
RD CR17
BK/RD C5-13
BL/RD-39D
BK/RD-35D
10 ohm 1%
5 ohm 1%
PRIMARY BOOM
RD
UPPER ZONE
RESISTOR
WH
ENGINE
CHECK
R16
L2
CONTROLS 15A
1
KEY SWITCH
RD/WH-TB3D
RD
OPTIONS 15A
2
BREAKER
BREAKER
CIRCUIT
SELECT
CIRCUIT
B1
FUEL
CB2
TS53
KS1
CB3
B
RD
5
-
3
4
WH
RD/WH
RD-20C
RD-20C
WH-23
RD-20C
NOTE:
RD
D2
RD/WH RD/WH DASHED LINES INDICATE

OPTION WIRES
RD
OR
RD
LABEL DESCRIPTION
CB1 CIRCUIT BREAKER, ENGINE, 15A
RD RD
CB2 CIRCUIT BREAKER, CONTROLS, 15A
CB3 CIRCUIT BREAKER, OPTIONS, 15A 6
CR5 HORN RELAY
ENGINE
RD-20D
DALE RH-25 25W
START
CR17 HYDRAULIC OIL COOLER FAN RELAY
TS52
ENGINE 15A
5 ohm 1%
PRIMARY UP/DOWN
BREAKER
CIRCUIT
RD/WH-TS61
RESISTOR
RD/WH-R16
RD CR39 AUXILIARY POWER RELAY

R14
OR-LS17
HM HOUR METER
RD/WH-R16
CB1
RD-24D
BRN KS1 KEY SWITCH
L2 CHECK ENGINE LED
BRN
BRN
BRN
SPEED REDUCTION
WH-21D

PRIMARY BOOM
RD
RELAY
CR34

RD
RD

HOUR METER

RD
1 1
D13
EMERGENCY

H.M.
NC NC TS53 FUEL SELECT TOGGLE SWITCH

STOP
RD
P1
D14
TS54
FUNCTION
2 2 TS57 PLATFORM ROTATE TOGGLE SWITCH
ENABLE
RD TS59 PLATFORM LEVEL TOGGLE SWITCH
RD TS61
TS62
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
8
RD

RD TS64 RUN/TEST TOGGLE SWITCH
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 33



Ford Models (after serial number 11879)
8
7
6
5
4
3
2
1
6 - 34
CR2 BRN
CR1 CR23
IGNITION POWER
RELAY DRIVE LIGHT
START RELAY OPTION
RD
A
BRN
BK-33C
BRN
WH-OPTIONS
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
S-60 • S-65 • S-60 HC

HYDRAULIC
WH/RD-R4 OIL COOLER

OPTION
RD/WH-R16 OR-LS17 C38-2
RD/WH-TS61
RD-CB3

1 PRIMARY BOOM UP 1
TS64
D

#1
D29
C3PBF RD/WH C3B-3 SWITCH
BRN
RD/WH-CR34 C3PBF RD/WH C29-1 C5-8 GR

C4TRL WH C3B-4

C5TRR WH/BK C3B-5
BRN-GND
FUSE 10A
C6TRF WH/RD C3B-6 +12 VOLT
(DRIVE LIGHT ONLY)

POWER TO
WH/RD-CR19 C6TRF WH/RD C31-1 PLATFORM
C7PBE BK C3B-7 C7

E
C8PBR BK/WH C3B-8

C9PER BK/RD C3B-9

9 PRIM. BOOM EXT/RET FUNC. CTRL 9 C3 & C4
WH-TB21 OPTIONS
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
D30

C13DE BL/RD C4B-1
C13DE BL/RD C10-1

13 DRIVE ENABLE 13
Part No. 77828

February 2012
C14PLU OR C4B-2
OR-TS59 C14PLU OR C20-1 18/19 #2
C15PLD OR/BK C4B-3
F

#2
#1

C17JU GR C4B-5
C18JD GR/BK C4B-6
GR/BK-TS57 C18JD GR/BK C23-1
C19JSV GR/WH C4B-7 BOOM
EXTEND
GR/WH-TS57
#2
C5
LIMIT SWITCH
F.H.

P20BAT RD
WH-CR2 #87 C128RPM OR/RD C5-9

G
C11
BK-CR5 P22BAT BK C7B-1

BK-KS P22LS17 BK C38-4 CABLE
22 +12 VOLT TO PLATFORM (1) 22 TENSION
P22BAT BK C11-1 LIMIT SWITCH
P22BAT BK C9-2 C37 (LS5)
WH-CR39 #30 P23BAT WH C7B-2
WH-KS
RD-CR2 #86
RD-CB1
#2
#1
C5
F.H.
C37
25 (UNUSED) 25
H
26 (UNUSED) 26

C28TTA RD/BK C1B-2
C28TTA RD/BK B P20BAT RD +12V POWER

28 TILT ALARM 28
C29MS RD/WH C5-24

29 MOTOR STROKE 29
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20

WH/RD-R2
WH/RD-R4
I
RD/WH-R16
RD/WH-TS61
C32BRK WH/RD C1B-6

GROUND HARNESS
32 BRAKE 32
BK-CR1 #86 C33STR BK C1B-7
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
34 (UNUSED) 34
C35RPM BK/RD C1B-9
C36SCC BL C1B-10
C36SCC BL C24-1
36 STEER LEFT 36
C37SCW BL/BK C1B-11
J
C5
C37SCW BL/BK C25-1

37 STEER RIGHT 37
ENGINE
C39LP BL/RD C2B-1

BL/RD TS53 C39LP BL/RD C5-10
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C5
C41RPM OR/BK C5-2

C46HRN GR C2B-5
WH C11-2
GR-CR5
46 SERVICE HORN 46
C59CNK BL/BK C3B-11
K

P134PWR GR/BK C2B-6

RD-KS P134TTS RD A
#2
F.H.
BRN-TS64
BRN C37-2
BRN C7B-3

BK-CR5 R46HRN BK
BRN

L
B A
HARNESS
FUNCTION
BK C16-1

WH LS2 C10-2
BL/WH -L2- C108ESL BL/WH C5-13

F.H.
M
C9 (LS3)
C11 (LS2)
LS17 (C38)
GROUND BOLT
N

OVERLOAD LED
TURNTABLE
PLATFORM
UP/DOWN
(CE OPTION)
(TO TERMINAL STRIP)

PLATFORM
ROTATE
ROTATE
BASE BOX HARNESS

RD
BOOM
TS61
TS57
TS62
RD
L45
D9
RD/WH WH/RD
RD RD
RD/BK-2 RD-1
+
-
WH/BK-5
RD
2
C19JSV GR/WH
WH-4
RD/WH
RD
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
RD-27
WH
PLATFORM
RD
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
BRN
TS63
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
DALE RH-25 25W

DALE RH-25 25W
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
DALE RH-25 25W
DALE RH-25 25W
RD-20D
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RESISTOR
CB3
UP/DOWN
CIRCUIT BREAKER, OPTIONS, 15A

RESISTOR
BOOM

R14
ENGINE
ENGINE 15A
R16
START
TS52
CR2 IGNITION POWER RELAY
BREAKER
CIRCUIT
CR4 HIGH IDLE RELAY
CB1
RD-24D
CR5 HORN RELAY
7
BRN

WH-21D
RD
BRN HM HOUR METER
KS1 KEY SWITCH
L2 CHECK ENGINE LED
RD

HOUR METER

STOP SWITCH
EMERGENCY
RD
1 1
D13
R4 SPEED LIMITING RESISTOR 7.5 OHMS
P1
NC NC
RD R14 SPEED LIMITING RESISTOR 5 OHMS
D14
FUNCTION
2 2
ENABLE
8
TS54
RD
RD TS53 FUEL SELECT TOGGLE SWITCH
TS54 FUNCTION ENABLE SWITCH
TS56 GLOW PLUG TOGGLE SWITCH
RD TS57 PLATFORM ROTATE TOGGLE SWITCH
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
NOTE: DASHED LINES INDICATE OPTION WIRES TS62 TURNTABLE ROTATE TOGGLE SWITCH
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 35



Ford Models
N

CWLITE WH TS49
(TO SWITCH
PLATFORM
FOOT SWITCH CONNECTOR

CONTROL
HARNESS

PANEL)

DESCRIPTION
M
C19JSV GR/WH TS7

TILT ALARM
Y
C19JSV GR/WH C4P-7

BRN JC3
Y
BRN GND
Y
Y
C1P-C4P
C134PWR RD-H1+
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
OPT.
L
TS7 WH
JIB
RD LS18 CABLE
CR27
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
OPTION
K
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
C18PRR GR/BK C4P-6

JIB
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129DA BL C3P-10 TS8
C46HRN GR C2P-5
I
C59CNK BL/BK C3P-11 L47+

P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
CDLITE OR/RD C2P-4
C4P
C7P
C3P
F.S.
C45GEN GR/WH C2P-7

H
C46HRN GR C2P-5
F.S.
C9
C39LP BL/RD C2P-1

P26ESTP BK
11
3
C118LSR OR/RD C4P-4

G
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C7PBE BK C3P-7
C13DE BL/RD C4P-1
C8PBR BK/WH C3P-8
C7P
C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
F
C31REV WH/BK C1P-5

C7P
C2PBD RD/BK C3P-2

February 2012
Part No. 77828

C36SCC BL C1P-10
C3PBF RD/WH C3P-3
C4P
C37SCW BL/BK C1P-11

C5TRR WH/BK C3P-5
C4P(BR)
ALC-500
C32BRK WH/RD C1P-6

C4TRL WH C3P-4
U13
19/18 CONTROL CABLE

C29MS RD/WH C1P-3
J2
E
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
J1
JC1-3 OR
C1P
JC2-4 RD
WIRE CONNECTS TO JC3-6
JC1-2 BRN
JC2-5 BK
C1P(GY)
JC2-3 OR
JC1-5 YEL
C7P
JC2-2 BRN
S-60 • S-65 • S-60 HC

JC3-5 WH
* NOTE:
JC3-3 OR
C
JC3-4 BL *
JC3-2 BRN
TS15 B BL/BK
C28TTA RD/BK C1P-2

DRE LED BL/RD
TS14 RD/WH
BATGRN C7P-3
B

GR/BK-L4- (CE)
D39
ALARM
TILT
RD/BK-L48 RD/BK-L48- (NON-CE)
H1
C134PWR RD C2P-6
+
CWLITE BK
BRN
A
Ford Models
BRN
BRN BRN
CWLITE WH TS49
6 - 36
1
8

Ford Models
PLATFORM CONTROL
1
HARNESS
(TO CONTROL BOX)
DRIVE LIGHTS/
2
WORK LIGHTS DLITE RD RD
(OPTION)
JC2 BK
TILT ALARM LED
(ANSI/CSA OPTION)
JC3
PRIMARY BOOM + DRIVE
UP/DOWN 7 JC1 7 FORWARD/REVERSE
7
& TURNTABLE ROTATE BOOM TS15 & STEER
LEFT/RIGHT EXTEND/RETRACT DRIVE LEFT/RIGHT
L48 COMPONENT INDEX
6 TS48/
TS49
6 ENABLE 6
5 5 5
BOOM UP/DOWN , TURNTABLE ROTATE
3
BK
BK
BK
RD
BOOM EXTEND/RETRACT
4 4 4 JC3 DRIVE/STEER PROPORTIONAL JOYSTICK
L1 DRIVE ENABLE LED
L4 L4 PLATFORM OVERLOAD LED
3 BRN 3 PLATFORM 3 L47 LOWER/RETRACT BOOM LED
OVERLOAD
L48 BOOM TILTED LED
(CE OPTION)
2 +
2 +
2 P2 EMERGENCY STOP BUTTON
P3 HORN SWITCH
BRN
1 L47 1 1 TS1 AUXILIARY POWER TOGGLE SWITCH 4

RETRACT

BOOM +
RD
L1 TS4 HI/LOW RPM TOGGLE SWITCH
BK
BRN DRIVE
ENABLE
BK TS9 PLATFORM LEVEL TOGGLE SWITCH
BRN BRN BRN BRN F18 FUSE 10A TS14 DRIVE SPEED TOGGLE SWITCH
(WORKLIGHT ONLY) TS15 DRIVE ENABLE TOGGLE SWITCH
BK
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
C133PLA GR/BK D39

DLITE OR/RD C2P-4
C28TTA RD/BK H1-

5
BL/RD-DE3 J1-16
BL/BK-DE2 J1-7
BK
BL-DE1 J1-6
WLITE WH
WLITE WH
BRN J1-10
BRN J1-12
BRN J1-14
OR J1-13
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
YL J1-3
BL J1-5
BRN
RD
BK
BK
BK
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
C46HRN GR C2P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C18PRR GR/BK C4P-6
C19JSV GR/WH C4P-7

WH CR27
C17PRL GR C4P-5
C27AUX RD C1P-1
WH CR30
C29MS RD/WH J1-8
C45GEN GR/WH C2P-7
P25FS RD C9-3
C33STR BK C1P-7
C35RPM BK/RD C1P-9

P24FS WH C9-2
6
WH WH
D12 TS3
FUEL SELECT 1 1 1
7
3
NO
4
DRIVE P2
SPEED
NC NC NC EMERGENCY
STOP
TS14 TS2 TS4 2 2 2
P3 WH HIGH/LOW TS47 ENGINE HIGH/LOW
TS9 TS1 D11
HORN (2WD/4WD) GENERATOR START RPM
PLATFORM AUXILIARY
RD
LEVEL PUMP (OPTION)

TS7 BK
PLATFORM WH
RD ROTATE RD RD RD
8
NOTE: DASHED LINES INDICATE OPTION WIRES CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 37


Ford Models

N
RD
RD
BRN
P134PWR RD
P22LS BK
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
P24FS WH

D12
ENGINE
G2
SENDER (OPTION)
TS4
G1
VOLT METER (OPTION)

TB35
D13
D14

M
WATER TEMPERATURE
G3
FUNCTION ENABLE
TS54
TB45
GENERATOR
HYDRAULIC
TS47
GENERATOR
WH
RD
OPTION
L
TS48

L29
C21IGN WH

CR23
TS49
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
+
_
J
L2

BR
CR39
RD
RUN/TEST SWITCH
C5-13 BL/WH
C35RPM BK/RD
TS64
C5-8 GR
I
CR39
TS3

NC

TB39
SELECT
D11
TS53

SELECT
CR2
D10
TB21

C41RPM OR/BK C2B-3
H

CR2
NO

BL/RD
QUICK DISCONNECT
FORD 42 PIN
TB41

C28TTA RD/BK

TS2
C1P-7 C1B-7
START
G
TS52
TB33

CR1
NO
TB24
M4
PUMP
FUEL
C135FP BL/WH BK
P26ESTP BK
P24FS WH
P25FS RD
C21IGN WH
P24BAT RD
C33STR BK
F
C9P-2
C9P-3
STARTER
February 2012
Part No. 77828

D3
STARTER MOTOR
D4
TS51
TB27
AUXILIARY
TS1
PUMP C27AUX RD
WH(FS)
AUXILIARY
RD(FS)
PR1
PUMP
NO
PUMP
AUX
AUXILIARY PUMP
E
FS1
C28TTA RD/BK
M2
BK(FS)
B
C28TTA RD/BK WH
TILT ALARM
TB23

LEVEL SENSOR
C9P-1 BK
C
D2
TB134
S8
H1
D
FB1
P2
P134FB WH FLASHING
BEACONS OPTION
L48

HORN RELAY
RD
CR5
P3
H2
TB46
HORN
NO
S-60 • S-65 • S-60 HC

TB134
TB46R
SW3
NO
P134PWR GR/BK
HYDRAULIC OIL
C
CR17
P134PWR RD (OPTION)
TB22
86
85
M1 FAN
C116 OR C5-1
87a 87
(OPTION)
30
P116HYD RD
KS1
GRND
PLAT
R6
C107AF WH
510
C5-3

B
P1
RD
RD
STA.
A
S
I
ALTERNATOR
REGULATOR
RD
FLD.
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
6 - 39
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
C29MS RD/WH C29MS RD/WH
S-60 • S-65 • S-60 HC
C1P-3 C1B-3 C5-24

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
TS15

C
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
PWR 3 13 C14-1 C14-2
BRN
D
C3P-5 C5TRR WH/BK C3B-5 C5TRR WH/BK

TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
TB6
LEFT
TS62

R4
5
FLOW CONTROL
C31-1 C31-2
TB1
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
DOWN C2PBD RD/BK

PRIMARY BOOM DOWN
C13-1 C13-2
CR34
TS61
J2
R14
Part No. 77828

February 2012
7
5
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
F
8
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
OUT 5 3
RD RD BR C7PBE BK
G
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
2
BK
TB13
LS3
NO
HC
H
P24FS WH
J3
4
3
13
14
P26ESTP BK
3
TB22
LS2
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS1

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
L46
NO
LS5
J
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
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

CR13
NC
TS8

DOWN JIB
TB18
C4P-5 C23-1 C23-2
D28
TS58
RIGHT PLATFORM
L

C22-1 C22-2
TB17
TS57
RIGHT PLATFORM
D29
LEFT ROTATE
TS7
WH
C129 RD/BK
H3
D30
M
CR13
TB19
C19JSV GR/WH
BRN
C41RPM OR/BK
JIB VALVE
C28TTA RD/BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD


N
RD
RD
BRN
P134PWR RD
P22LS BK
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
P24FS WH

D12
ENGINE
G2
SENDER (OPTION)
TS4
G1
VOLT METER (OPTION)

M
TB35
D13
D14
LOW RPM C26TSR WH/RD WATER TEMPERATURE

G3
FUNCTION ENABLE
TS54
TB45
GENERATOR
HYDRAULIC
TS47
GENERATOR
WH
RD
OPTION
L
TS48

L29
C21IGN WH

CR23
TS49
OPTION
NO
FUSE
10A
RD
L29
L30
BOX GROUND
WORKLIGHT RD
PLATFORM
RD
WH BK
K
FUSE 10A
WORK LIGHTS
OPTION
WH BK
L30
C21IGN WH
HM
HOUR METER
+
_
J
L2

BR
CR39
RD
RUN/TEST SWITCH
C5-13 BL/WH
C35RPM BK/RD
I
TS64
C5-8 GR
CR39
TS3

NC

TB39
SELECT
D11
TS53

SELECT
CR2
D10
TB21

H
C41RPM OR/BK C2B-3

CR2
NO

BL/RD
QUICK DISCONNECT
FORD 42 PIN
TB41

C28TTA RD/BK

TS2
C1P-7 C1B-7
G

START
TS52
TB33

CR1
NO
TB24
M4
PUMP
FUEL
C135FP BL/WH BK
P26ESTP BK
P24FS WH
P25FS RD
C21IGN WH
P24BAT RD
F
C33STR BK
February 2012
Part No. 77828

STARTER
C9P-2
C9P-3
STARTER MOTOR
D3
CR19
D4
TS51
TB27

AUXILIARY
TS1
PUMP C27AUX RD
WH(FS)
AUXILIARY
RD(FS)
PR1
PUMP
NO
E
PUMP
AUX
AUXILIARY PUMP
FS1
C28TTA RD/BK
M2
BK(FS)
B
C28TTA RD/BK WH
TILT ALARM
TB23
LEVEL SENSOR
C9P-1 BK
C
D2
TB134
S8
H1
D
FB1
P2
P134FB WH FLASHING
BEACONS OPTION
L48

HORN RELAY
RD
CR5
P3
H2
TB46
S-60 • S-65 • S-60 HC

HORN
NO
TB134
TB46R
SW3
C
NO
P134PWR GR/BK
HYDRAULIC OIL
CR17
P134PWR RD (OPTION)
TB22
86
85
M1 FAN
C116 OR C5-1
87a 87
(OPTION)
30
P116HYD RD
KS1
GRND
PLAT
R6
C107AF WH
510
C5-3
B
P1
RD
RD
STA.
A
S
I
ALTERNATOR
REGULATOR
RD
FLD.
IN STOWED POSITION.
CB1
15A
CB3
15A
GND.
BAT.
CB2
15A
A
FUSE
LINK
-
P20BAT RD C7B-4
NOTES:
12V DC
TB20
2
B1
6 - 40
1
8
1
8
6 - 41
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
C
TS15

7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
D
PWR 3 13 C14-1 C14-2

GND 2 14 9
TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
LEFT
TS62
R4
CR19
7.5
TB6
C31-1 C31-2
FLOW CONTROL
TB1
R2
C12-1 C12-2
5
C1PBU RD
PRIMARY BOOM UP
UP
E
PRIMARY BOOM
DOWN C2PBD RD/BK
PRIMARY BOOM DOWN
Part No. 77828
C13-1 C13-2
February 2012
CR34
TS61
J2
R14
7
5
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
F

8
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
G
OUT 5 3
RD RD BR C7PBE BK
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
2
BK
TB13
H
LS3
NO
HC
P24FS WH
J3
4
3
13
14
P26ESTP BK
3
TB22
LS1
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS2

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
L46
J
NO
LS5
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
K
C14PLU OR
PLATFORM LEVEL UP
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
D27

CR13
NC
TS8

DOWN JIB
TB18
C4P-5 C23-1 C23-2
D28
TS58
RIGHT PLATFORM
L

C22-1 C22-2
TB17
TS57
RIGHT PLATFORM
D29
LEFT ROTATE
TS7
WH
C129 RD/BK
H3
D30
M
CR13
TB19
C19JSV GR/WH
BRN
C41RPM OR/BK
JIB VALVE
C28TTA RD/BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD


N
RD
RD
BRN
P134PWR RD
P22LS BK
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
P24FS WH

D12
ENGINE
G2
SENDER (OPTION)
TS4
G1
VOLT METER (OPTION)

TB35
D13
D14
LOW RPM C26TSR WH/RD (FEH PIN 39)

M
WATER TEMPERATURE
G3
FUNCTION ENABLE
TS54
TB45
GENERATOR
C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH GENERATOR
TS47
OPTION
WH
RD
L
TS48

L29
C21IGN WH

CR23
TS49
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
GY/YL GASOLINE SENSOR

B
HARNESS
RD
C
BK/BL
D
J
RD/GN
L2
LPG LOCKOUT
WH/BK
BR
CR39
RD
RUN/TEST SWITCH
C5-13 BL/WH
C35RPM BK/RD
TS64
C5-8 GR
I
CR39
TS3

NC

TB39
SELECT
D11
TS53

SELECT
CR2
D10
TB21

C41RPM OR/BK C2B-3
H

CR2
NO

BL/RD
QUICK DISCONNECT
FORD 42 PIN
TB41

C28TTA RD/BK

TS2
C1P-7 C1B-7
START
G
TS52
TB33

START
CR1
NO
TB24
M4
PUMP
FUEL
C135FP BL/WH BK PIN 18
P26ESTP BK
P24FS WH
P25FS RD
START
C21IGN WH
P24BAT RD
F
STARTER
C9P-2
C9P-3
STARTER MOTOR
February 2012
Part No. 77828

D3
CR19
D4
TS51
TB27

AUXILIARY
TS1
PUMP C27AUX RD
WH(FS)
AUXILIARY
RD(FS)
PR1
PUMP
NO
PUMP
AUX
AUXILIARY PUMP
E
FS1
C28TTA RD/BK
M2
BK(FS)
B
C28TTA RD/BK WH
TILT ALARM
TB23
LEVEL SENSOR
C9P-1 BK
C
D2
TB134
S8
H1
D
FB1
P2
P134FB WH FLASHING
BEACONS OPTION
L48

HORN RELAY
RD
CR5
P3
H2
TB46
HORN
NO
S-60 • S-65 • S-60 HC

TB134
TB46R
SW3
NO
P134PWR GR/BK
HYDRAULIC OIL
C
CR17
P134PWR RD (OPTION)
TB22
86
85
M1 FAN
C116 OR C5-1
87a 87
(OPTION)
30
P116HYD RD
KS1
GRND
PLAT
ALTERNATOR FIELD

B
P1
RD
RD
STA.
A
S
I
ALTERNATOR
REGULATOR
RD
FLD.
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 - 42
1
8
8
6 - 43
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
C
TS15

7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
D
PWR 3 13 C14-1 C14-2

GND 2 14 9
TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
LEFT
TS62
R4
CR19
7.5
TB6
C31-1 C31-2
FLOW CONTROL
TB1
R2
C12-1 C12-2
5
C1PBU RD
PRIMARY BOOM UP
UP
E
PRIMARY BOOM
DOWN C2PBD RD/BK
PRIMARY BOOM DOWN
Part No. 77828
C13-1 C13-2
February 2012
CR34
TS61
J2
R14
7
5
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
F

8
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
G
OUT 5 3
RD RD BR C7PBE BK
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
2
BK
TB13
H
LS3
NO
HC
P24FS WH
J3
4
3
13
14
P26ESTP BK
3
TB22
LS1
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS2

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
L46
J
NO
LS5
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
K
C14PLU OR
PLATFORM LEVEL UP
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
D27

CR13
NC
TS8

DOWN JIB
TB18
C4P-5 C23-1 C23-2
D28
TS58
RIGHT PLATFORM
L

C22-1 C22-2
TB17
TS57
RIGHT PLATFORM
D29
LEFT ROTATE
TS7
WH
C129 RD/BK
H3
D30
M
CR13
TB19
C19JSV GR/WH
BRN
C41RPM OR/BK
JIB VALVE
C28TTA RD/BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD


8
7
6
5
4
3
2
1
6 - 44
BRN
IGNITION AUXILIARY
START RELAY POWER RELAY POWER RELAY
CR1
A
BRN CR2 CR39

WH-21C
RD-24B
RD-27C
WH-C5-11
BK-33C
WH-C5-19
RD-24C
BK C5-5
WH-23C
C5
B
F.H.
BRN
BK-46R WH C5-4
BK-22C1
OR C5-1
R43DLITE2 RD
R43DLITE1 RD
HORN
RELAY CR5 CR23 CR17
C2B-4 OR/RD C21IGN WH

C
BRN

DRIVE LIGHT
C5
F.H.
OPTION RELAY
S-60 • S-65 • S-60 HC

GR-46D HYDRAULIC OIL
WH-OPTIONS COOLER OPTION
RD-CB3

1 PRIMARY BOOM UP 1
D
TS64
#1
D29
C4TRL WH C3B-4

C5TRR WH/BK C3B-5
BRN-GND
FUSE 10A
5 TURNTABLE ROTATE RIGHT 5 +12 V DC
C6TRF WH/RD C3B-6
POWER TO
WH/RD-TS62 C6TRF WH/RD C31-1
(DRIVE LIGHT ONLY)

6 TURNTABLE ROTATE FLOW CONTROL 6 PLATFORM
C7PBE BK C3B-7 C7
E

C8PBR BK/WH C3B-8

C9PER BK/RD C3B-9
9 PRIM. BOOM EXT/RET FLOW CONTROL 9 C3 & C4
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
WH-TB21 OPTIONS
D30
C13DE BL/RD C4B-1

C13DE BL/RD C10-1
Part No. 77828

February 2012
13 DRIVE ENABLE 13
C14PLU OR C4B-2
OR-TS59 C14PLU OR C20-1 18/19 #2
C15PLD OR/BK C4B-3
F

#2
#1

C17JU GR C4B-5
17 PLATFORM ROTATE LEFT/JIB BOOM UP 17
C18JD GR/BK C4B-6
#2
C5

F.H.

P20BAT RD
20 +12 V DC POWER 20
WH-CR2#87 C128RPM OR/RD C5-9
G

C11
BK-KS P22LS17 BK C38-4 TENSION

22 +12 V DC TO PLATFORM (1) 22 LIMIT SWITCH
P22BAT BK C11-1
C37 (LS5)
P22BAT BK C9-2
22 +12 V DC TO PLATFORM (2) 22
WH-CR39#30 P23BAT WH C7B-2
WH-KS
RD-CR2#86
RD-CB1
#2
#1
C5
F.H.
C37
25 (UNUSED) 25
H
26 (UNUSED) 26
27 AUXILARY PUMP 27
C28TTA RD/BK C1B-2
C29MS RD/WH C5-24
29 MOTOR STROKE 29
C30FWD WH C1B-4
C30FWD WH C5-21
30 DRIVE FORWARD 30
C31REV WH/BK C1B-5
I

31 DRIVE REVERSE 31
32 BRAKE 32
BK-CR1#86 C33STR BK C1B-7
BK-TS52
33 ENGINE START 33
C34SA BK/WH C1B-8
34 (UNUSED) 34
C35RPM BK/RD C1B-9
C36SCC BL C1B-10
C36SCC BL C24-1
36 STEER LEFT 36
J
C37SCW BL/BK C1B-11

C37SCW BL/BK C25-1
C5
37 STEER RIGHT 37
C39LP BL/RD C2B-1
ENGINE

39 LIQUID PROPANE FUEL (LPG) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C5
C41RPM OR/BK C5-2

C46HRN GR C2B-5
GR-CR5
WH C10-2
46 HORN 46
C59CNK BL/BK C3B-11
K

P134PWR GR/BK C2B-6
RD-KS P134TTS RD A
#2
F.H.

BRN-TS64
BRN C37-2
BRN C7B-3
BK-CR5 R46HRN BK
BRN

L
B A
BK C16-1

BL/WH-L2- C108ESL BL/WH C5-13
WH LS2 C11-2
F.H.
HARNESS
FUNCTIONS
M
C9 (LS3)
C11 (LS2)
LS17 (C38)
GROUND BOLT
N

UP/DOWN
PRIMARY
OVERLOAD LED
BOOM
GROUND CONTROL BOX HARNESS

TS61
(CE OPTION)
PLATFORM
PLATFORM
TURNTABLE
RD
ROTATE
TS57
RD GR/BK
ROTATE
L45
TS62
D9
(TO TERMINAL STRIP)

RD RD
RD/BK-2 RD-1
-
RD 2
C19JSV GR/WH
RD/WH
RD
RD
GR/BK-18D
RD
RD
WH/RD-6
WH/BK-5
GR-17D
RD
D3
GR/BK
WH-4
AUXILIARY
RD RD
POWER
TS51
RD
D4
RD
RD
PLATFORM
GR
RD RD GR/BK
LEVEL
TS59
D28
GR 3
RD
BRN
RD
RD-27
UP/DOWN
JIB BOOM
WH
TS58
TS63
BOOM EXTEND/
RETRACT
L46 +
RETRACT -
LOWER/
BOOM
C134PWR RD
RD/WH-CR34
RD
GR/WH-19D
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
WH/RD-6D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
GR-17D
OR-14D
RD-27D
BL-44D
WH-4D
RD-1D
BK-7D
TURNTABLE ROTATE
WH
RD
4
RESISTOR
R4
DALE RH-25 25W
DALE RH-25 25W
RD-20C
BK-22D1
RD-134D2
BRN-GND
BK-33D
RD-20D
WH-21D
WH-23D
RD-24D
OR-LS17
RD CR17
BK/RD C5-13
BL/RD-39D
BK/RD-35D
10 ohm 1%
5 ohm 1%
PRIMARY BOOM
RD
UPPER ZONE
RESISTOR
WH
ENGINE
CHECK
R16
L2
CONTROLS 15A
1
KEY SWITCH
RD/WH-TB3D
RD
OPTIONS 15A
2
BREAKER
BREAKER
CIRCUIT
SELECT
CIRCUIT
B1
FUEL
CB2
TS53
KS1
CB3
B
RD
-
3
4
WH
NOTE:
RD/WH
RD-20C
RD-20C
WH-23
DASHED LINES INDICATE
RD-20C
RD
D2
RD/WH RD/WH OPTION WIRES

RD
OR LABEL DESCRIPTION
RD

RD RD CB3 CIRCUIT BREAKER, OPTIONS, 15A
CR5 HORN RELAY 6
ENGINE
RD-20D
DALE RH-25 25W
START
TS52
ENGINE 15A
5 ohm 1%
PRIMARY UP/DOWN
CR39 AUXILIARY POWER RELAY
BREAKER
CIRCUIT
HM HOUR METER
RD/WH-TS61
RESISTOR
RD/WH-R16
RD KS1 KEY SWITCH

R14
OR-LS17
RD/WH-R16
L2 CHECK ENGINE LED
CB1
RD-24D
BRN L46 LOWER/RETRACT BOOM LED
BRN
BRN
BRN
SPEED REDUCTION
WH-21D

PRIMARY BOOM
RD
R4 SPEED LIMITING RESISTOR 5 OHMS 7
RELAY

CR34
RD
RD

HOUR METER

RD
1 1 TS53 FUEL SELECT TOGGLE SWITCH
D13
EMERGENCY
H.M.

NC NC TS57 PLATFORM ROTATE TOGGLE SWITCH
STOP
RD
P1
D14
TS54
FUNCTION
2 2
ENABLE
RD TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
RD TS62
TS63
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
8
RD
TS64 RUN/TEST TOGGLE SWITCH

RD
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 45



8
7
6
5
4
3
2
1
6 - 46
CR2 BRN
CR1 CR23
IGNITION POWER
RELAY DRIVE LIGHT
START RELAY OPTION
RD
A
BRN
BK-33C
BRN
WH-OPTIONS
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
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
CR17
WH/RD-R2
S-60 • S-65 • S-60 HC

HYDRAULIC
WH/RD-R4 OIL COOLER

OPTION
RD/WH-TS61
RD-CB3

1 PRIMARY BOOM UP 1
TS64
D

#1
D29
C3PBF RD/WH C3B-3 SWITCH
BRN
RD/WH-CR34 C3PBF RD/WH C29-1 C5-8 GR

C4TRL WH C3B-4

C5TRR WH/BK C3B-5
BRN-GND
FUSE 10A
(DRIVE LIGHT ONLY)

POWER TO
C7PBE BK C3B-7 C7

E
C8PBR BK/WH C3B-8

C9PER BK/RD C3B-9

WH-TB21 OPTIONS
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
D30

C13DE BL/RD C4B-1
C13DE BL/RD C10-1

13 DRIVE ENABLE 13
Part No. 77828

February 2012
C14PLU OR C4B-2
OR-TS59 C14PLU OR C20-1 18/19 #2
C15PLD OR/BK C4B-3
F

#2
#1

C17JU GR C4B-5
C18JD GR/BK C4B-6
EXTEND
GR/WH-TS57
#2
C5
LIMIT SWITCH
F.H.

P20BAT RD
WH-CR2 #87 C128RPM OR/RD C5-9

G
C11
BK-CR5 P22BAT BK C7B-1

BK-KS P22LS17 BK C38-4 CABLE
22 +12 VOLT TO PLATFORM (1) 22 TENSION
P22BAT BK C11-1 LIMIT SWITCH
P22BAT BK C9-2 C37 (LS5)
WH-CR39 #30 P23BAT WH C7B-2
WH-KS
RD-CR2 #86
RD-CB1
#2
#1
C5
F.H.
C37
25 (UNUSED) 25
H
26 (UNUSED) 26

C28TTA RD/BK C1B-2
C28TTA RD/BK B P20BAT RD +12V POWER

28 TILT ALARM 28
C29MS RD/WH C5-24

29 MOTOR STROKE 29
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20

WH/RD-R2
WH/RD-R4
I
RD/WH-R16
RD/WH-TS61
C32BRK WH/RD C1B-6

GROUND HARNESS
32 BRAKE 32
BK-CR1 #86 C33STR BK C1B-7
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
34 (UNUSED) 34
C35RPM BK/RD C1B-9
C36SCC BL C1B-10
C36SCC BL C24-1
36 STEER LEFT 36
C37SCW BL/BK C1B-11
J
C5
C37SCW BL/BK C25-1

37 STEER RIGHT 37
ENGINE
C39LP BL/RD C2B-1

BL/RD TS53 C39LP BL/RD C5-10
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C5
C41RPM OR/BK C5-2

C46HRN GR C2B-5
WH C11-2
GR-CR5
46 SERVICE HORN 46
C59CNK BL/BK C3B-11
K

P134PWR GR/BK C2B-6

RD-KS P134TTS RD A
#2
F.H.
BRN-TS64
BRN C37-2
BRN C7B-3

BK-CR5 R46HRN BK
BRN

L
B A
HARNESS
FUNCTION
BK C16-1

WH LS2 C10-2
BL/WH -L2- C108ESL BL/WH C5-13

F.H.
M
C9 (LS3)
C11 (LS2)
LS17 (C38)
GROUND BOLT
N

OVERLOAD LED
TURNTABLE
PLATFORM
UP/DOWN
(CE OPTION)
(TO TERMINAL STRIP)

PLATFORM
ROTATE
ROTATE
BASE BOX HARNESS

RD
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
2
RD/WH
RD
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 -
BRN
TS63
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
DALE RH-25 25W

DALE RH-25 25W
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
DALE RH-25 25W
DALE RH-25 25W
RD-20D
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RESISTOR
UP/DOWN

RESISTOR
BOOM

R14
ENGINE
ENGINE 15A
R16
START
TS52
BREAKER
CR4 HIGH IDLE RELAY
CIRCUIT
CR5 HORN RELAY
CB1
RD-24D
BRN
HM HOUR METER
WH-21D
RD
BRN KS1 KEY SWITCH
L2 CHECK ENGINE LED
RD

HOUR METER

STOP SWITCH
EMERGENCY
RD
1 1
D13
R4 SPEED LIMITING RESISTOR 7.5 OHMS
P1
NC NC
D14
FUNCTION
2 2
ENABLE
8
TS54
RD
RD TS54 FUNCTION ENABLE SWITCH
RD TS58 JIB BOOM UP/DOWN TOGGLE SWITCH
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 47



Ford Models
N

CWLITE WH TS49
(TO SWITCH
PLATFORM
FOOT SWITCH CONNECTOR

CONTROL
HARNESS

PANEL)

DESCRIPTION
M
C19JSV GR/WH TS7 WH

TILT ALARM
Y
Y
C19JSV GR/WH C4P-7

BRN JC3 BK
Y
BRN GND
Y
Y
C1P-C4P
C134PWR RD-H1+
ITEM
CR27
CR30
LS18
C7P
U13
H1
C9
J1
J2
J3
OPT.
L
TS7 WH
JIB
RD LS18 CABLE
CR27
BRN
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
OPTION
K
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
C19JSV GR/WH C4P-7

BOOM
C18PRR GR/BK C4P-6

JIB
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129DA BL C3P-10 TS8
C46HRN GR C2P-5
I
C59CNK BL/BK C3P-11 L47+

P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
CDLITE OR/RD C2P-4
C4P
C7P
C3P
F.S.
C45GEN GR/WH C2P-7

H
C46HRN GR C2P-5
F.S.
C9
C39LP BL/RD C2P-1

P26ESTP BK
11
3
C118LSR OR/RD C4P-4

G
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
C7PBE BK C3P-7
C13DE BL/RD C4P-1
C8PBR BK/WH C3P-8
C7P
C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
F
C31REV WH/BK C1P-5

C7P
C2PBD RD/BK C3P-2

February 2012
Part No. 77828

C36SCC BL C1P-10
C3PBF RD/WH C3P-3
C4P
C37SCW BL/BK C1P-11

C5TRR WH/BK C3P-5
C4P(BR)
ALC-500
C32BRK WH/RD C1P-6

C4TRL WH C3P-4
U13
19/18 CONTROL CABLE

C29MS RD/WH C1P-3
J2
E
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
J1
JC1-3 OR
C1P
JC2-4 RD
WIRE CONNECTS TO JC3-6
JC1-2 BRN
JC2-5 BK
C1P(GY)
JC2-3 OR
JC1-5 YEL
C7P
JC2-2 BRN
S-60 • S-65 • S-60 HC

JC3-5 WH
* NOTE:
JC3-3 OR
C
JC3-4 BL *
JC3-2 BRN
TS15 B BL/BK
C28TTA RD/BK C1P-2

DRE LED BL/RD
TS14 RD/WH
BATGRN C7P-3
B

GR/BK-L4- (CE)
D39
ALARM
TILT
RD/BK-L48 RD/BK-L48- (NON-CE)
H1
C134PWR RD C2P-6
+
CWLITE BK
BRN
A
Ford Models
BRN
BRN BRN
CWLITE WH TS49
6 - 48
1
8

Ford Models
PLATFORM CONTROL 1
HARNESS
(TO CONTROL BOX)
DRIVE LIGHTS/
WORK LIGHTS
2
DLITE RD RD
(OPTION)
JC2 BK
TILT ALARM LED
(ANSI/CSA OPTION)
JC3
PRIMARY BOOM + DRIVE
UP/DOWN 7 JC1 7 FORWARD/REVERSE
7
& TURNTABLE ROTATE BOOM TS15 & STEER
LEFT/RIGHT EXTEND/RETRACT LEFT/RIGHT COMPONENT INDEX
DRIVE L48
6 TS48/
TS49
6 ENABLE 6 CR13 JIB BOOM CUT OUT RELAY
BOOM UP/DOWN , TURNTABLE ROTATE
5 5 5 3
BK
BK
BK
RD
BOOM EXTEND/RETRACT
4 4 4 JC3 DRIVE/STEER PROPORTIONAL JOYSTICK
L1 DRIVE ENABLE LED
L4 L4 PLATFORM OVERLOAD LED
3 BRN 3 PLATFORM 3 L47 LOWER/RETRACT BOOM LED
OVERLOAD
L48 BOOM TILTED LED
(CE OPTION)
2 +
2 +
2 P2 EMERGENCY STOP BUTTON
BRN P3 HORN SWITCH
BRN
1 L47 1 1 TS1
TS2
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH 4
RETRACT

CR13 TS3 FUEL SELECT TOGGLE SWITCH
BOOM +
RD
L1 TS4 HI/LOW RPM TOGGLE SWITCH
BK
BRN DRIVE
ENABLE
BK TS8 JIB BOOM UP/DOWN TOGGLE SWITCH
BRN BRN BRN BRN F18 FUSE 10A TS9 PLATFORM LEVEL TOGGLE SWITCH
(WORKLIGHT ONLY) TS14 DRIVE SPEED TOGGLE SWITCH
BK
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
C133PLA GR/BK D39

DLITE OR/RD C2P-4
C28TTA RD/BK H1-

BL/RD-DE3 J1-16
5
BL/BK-DE2 J1-7
BK
BL-DE1 J1-6
WLITE WH
WLITE WH
BRN J1-10
BRN J1-12
BRN J1-14
OR J1-13
OR J1-11
WH J1-4
OR J1-9
BK J1-2
RD J1-1
WH-JIB
YL J1-3
BL J1-5
BRN
RD
BK
BK
BK
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
C46HRN GR C2P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
P24FS WH
C18PRR GR/BK C4P-6
C19JSV GR/WH C4P-7

WH CR27
C19JSV GR/WH
C17PRL GR C4P-5
C129JDA BL C3P-10
WH-JIB
C27AUX RD C1P-1
WH CR30
C29MS RD/WH J1-8
C45GEN GR/WH C2P-7
P25FS RD C9-3
C33STR BK C1P-7
C35RPM BK/RD C1P-9

P24FS WH C9-2
6
WH WH
D12 TS3
GR FUEL SELECT 1 1 1 7
3
NO
4
DRIVE P2
SPEED
NC NC NC EMERGENCY
STOP
TS14 TS2 TS4 2 2 2
P3 WH TS8 HIGH/LOW TS47 ENGINE HIGH/LOW
TS9 TS1 D11
HORN JIB (2WD/4WD) GENERATOR START RPM
PLATFORM GR/BK AUXILIARY
RD
LEVEL BOOM PUMP (OPTION)

TS7 BK
D27
PLATFORM WH
RD ROTATE RD RD RD
NOTE: DASHED LINES INDICATE OPTION WIRES CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 49


Ford Models

Deutz F3L-2011 Models (before serial number 11880)
N
RD
RD
BRN
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
D12

FOOTSW. HIGH
TS4
FOOTSW. LOW
ENGINE
TS54
SPEED
CR4
D14
LOW RPM
FUNCTION ENA.
HIGH RPM C35RPM BK/RD BRN
M
HIGH IDLE RELAY

D13
TB35
BK/RD C5-18
HIGH RPM SOLENOID
CR4
NO
Q3
TB45
TS47
C2P-7 C45GEN GR/WH C2B-7 C45GEN GR/WH C5-12

GENERATOR OPTION
L
CR23
TS48
C3P-12 DLITE BL/WH C3B-12

L29
DRIVE LIGHT
LIGHTS
WORK LIGHT RD
DRIVE LIGHT OPTION
FUSE
10A
L29
L30
RD
RD
FUSE 10A
RD
TB21
WORK LIGHTS OPTION

C2P-12 C2P-10
CR23
NO
K
PBOX GND
C2P-11 C2P-9
L30
PR2
TB34
TS6
C1P-8 C34SA BK/WH C1B-8 C34SA BK/WH C5-22

GLOW
TS56
J
PLUG
GLOW
PLUG
PR2
NO
C26TSR WH/RD OIL TEMPERATURE LED

TEMP.
L43
OIL
I
3 START INPUT IGNITION/
MODULE
START
U1
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
C1P-7 C1B-7 C5-14

OIL TEMPERATURE SWITCH
ENGINE
TS52
TB25
START
ENGINE C5-16 OIL PRESSURE SWITCH
C28TTA RD/BK
START
SW2
C25PSR WH/BK
BK
NC
TB33
H
CR2
POWER RELAY
P26ESTP BK
TB21
P24FS WH
P25FS RD
C21IGN2 WH C5-11
TS1
FUEL SOLENOID
CR2
AUX
NO
PUMP C1P-1 C27AUX RD C1B-1

G
C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
+
_
IGN./START RELAY
CR1
NO
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
D3
STARTER
STARTER MOTOR
FS1
F
CE AND PLATFORM OVERLOAD OPTION ONLY.

D4
BK-(FS)
TS51
February 2012
Part No. 77828

TB27
AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK
M2
PR1
TB23
NO
C7B-2
PUMP
C7P-2 P23BAT WH
AUX
AUXILIARY PUMP
P2
D2
L48
C5-3
RD/BK C1P-2 WH
E
TB28
Overload
D40
Platform
RD/BK
B
C1B-2
Option
C28TTA RD/BK WH
H1
C28TTA RD/BK
Only
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
NOTES:
CR5
GR/BK
H2
NO
D
C7P-1 P22BAT BK C7B-1
TB133
P22BAT BK F.H. BK
1
HORN
C32-8
TB132
8
7
5
TB134
C1P-12 C132PLI BL/WH C1B-12
FB1
3
U33
C2P-6 P134PWR GR/BK C2B-6
OPTION
12
S-60 • S-65 • S-60 HC

TB134
RD
CR17
C
SW3
NO
BK
HYDRAULIC OIL TEMPERATURE
86
85
C21IGN WH R21IGN WH C5-4
TB22
WH
SWITCH (OPTION)
RD
87a 87
30
P116HYD RD
PLAT
GRD
C41RPM OR/BK
FAN
COOLING FAN
R116 OR C5-1
KS1
(OPTION)
3MF
C3
M1
+
TB41
C41RPM OR/BK C2B-3 C41RPM OR/BK C5-2
B
D22
RD
EXCT.
STA.
C21IGN WH
BAT.
IND.
P1
RD
RD
-
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
A
D1
TB20
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 50
1
8

6 - 51
1
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
TS15

C
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
PWR 3 13 C14-1 C14-2
C3P-5 C3B-5
D

TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
TB6
LEFT
TS62

5
R4
FLOW CONTROL
C31-1 C31-2
TB1
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
DOWN C2PBD RD/BK

PRIMARY BOOM DOWN
C13-1 C13-2
CR34
Part No. 77828

TS61
J2
R14
February 2012
7
5
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
8
F
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
OUT 5 3
RD RD BR C7PBE BK
G
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
2
BK
TB13
LS3
NO
HC
P24FS WH
H
J3
4
3
13
14
P26ESTP BK
3
TB22
LS2
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS1

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
L46
NO
LS5
J
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
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

RIGHT
PLATFORM ROTATE
TB18
C4P-5 C23-1 C23-2
D28
TS57
RIGHT PLATFORM
L

C22-1 C22-2
TB17
D29
C129 RD/BK
H3
D30
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD


Deutz F3L-2011 Models (after serial number 11879)
N
RD
RD
BRN
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
D12

FOOTSW. HIGH
TS4
FOOTSW. LOW
ENGINE
TS54
SPEED
CR4
D14
LOW RPM
FUNCTION ENA.
M
HIGH IDLE RELAY

D13
TB35
BK/RD C5-18
HIGH RPM SOLENOID
CR4
NO
Q3
TB45
TS47

GENERATOR OPTION
L
CR23
TS48

L29
DRIVE LIGHT
LIGHTS
WORK LIGHT RD
DRIVE LIGHT OPTION
FUSE
10A
L29
L30
RD
RD
FUSE 10A
RD
TB21
WORK LIGHTS OPTION

C2P-12 C2P-10
CR23
NO
K
PBOX GND
C2P-11 C2P-9
L30
PR2
TB34
TS6

GLOW PLUG RELAY
GLOW
TS56
J
PLUG
GLOW
GLOW PLUG
PLUG
FUSE 70A
PR2
NO

TEMP.
L43
OIL
I
MODULE
START
U1
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
C1P-7 C1B-7 C5-14

ENGINE
TS52
TB25
START
C28TTA RD/BK
START
SW2
C25PSR WH/BK
BK
NC
TB33
H
CR2
POWER RELAY
P26ESTP BK
TB21
P24FS WH
P25FS RD
C21IGN2 WH C5-11
TS1
FUEL SOLENOID
CR2
AUX
NO
PUMP C1P-1 C27AUX RD C1B-1

G
C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
_
IGN./START RELAY
CR1
NO
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
D3
STARTER
STARTER MOTOR
FS1
F

D4
BK-(FS)
TS51
CR19
EMISSIOIN CONTROL
TB27
February 212
Part No. 77828

AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK

F.H. C27AUX RD
C7B-2 AUXILIARY POWER RELAY
C7P-2 P23BAT WH
M2
TB23
PR1
NO
P2
D2
PUMP
L48
AUX
AUXILIARY PUMP
C5-3
RD/BK C1P-2 WH
E
TB28
Overload
D40
Platform
RD/BK
B
C1B-2
Option
C28TTA RD/BK WH
H1
C28TTA RD/BK
Only
TILT ALARM
LEVEL SENSOR
C3B-12
C
A
S8
TB46
RD
C2B-5
P3
NOTES:
CR5
GR/BK
H2
NO
D
TB133
P22BAT BK F.H. BK
1
HORN
C32-8
TB132
8
7
5
TB134
FB1
3
U33
C2P-6 P134PWR GR/BK C2B-6
OPTION
12
S-60 • S-65 • S-60 HC

TB134
RD
CR17
SW3
C
NO
BK
86
85
TB22
WH
SWITCH (OPTION)
RD
87a 87
30
P116HYD RD
PLAT
GRD
C41RPM OR/BK
FAN
R116 OR C5-1 COOLING FAN
KS1
(OPTION)
3MF
C3
M1
+
TB41
B
D22
RD
EXCT.
STA.
C21IGN WH
BAT.
IND.
P1
RD
RD
-
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
A
D1
TB20
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 52
1
8
6 - 53
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
C
TS15

7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
PWR 3 13 C14-1 C14-2
D

GND 2 14 9
TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
LEFT
TS62
R4
CR19
7.5
TB6
C31-1 C31-2
FLOW CONTROL
TB1
R2
C12-1 C12-2
5
C1PBU RD
PRIMARY BOOM UP
UP
E
PRIMARY BOOM
DOWN C2PBD RD/BK
PRIMARY BOOM DOWN
Part No. 77828
C13-1 C13-2
February 2012
CR34
TS61
J2
R14
7
5
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
F
8
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
OUT 5 3
C7PBE BK
G
RD RD BR
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
BK
TB13
LS3
NO
HC
H
P24FS WH
J3
4
3
13
14
P26ESTP BK
3
TB22
LS1
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS2

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
L46
NO
LS5
J
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
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

RIGHT
PLATFORM ROTATE
TB18
C4P-5 C23-1 C23-2
D28
TS57
RIGHT PLATFORM
L

C22-1 C22-2
TB17
D29
C129 RD/BK
H3
D30
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD

Electrical Schematic, S-60, CE Models

N
RD
RD
BRN
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
D12

FOOTSW. HIGH
TS4
FOOTSW. LOW
ENGINE
TS54
SPEED
CR4
D14
LOW RPM
FUNCTION ENA.
M
HIGH IDLE RELAY

D13
TB35
BK/RD C5-18
HIGH RPM SOLENOID
CR4
NO
Q3
TB45
TS47

GENERATOR OPTION
L
CR23
TS48

L29
DRIVE LIGHT
LIGHTS
WORK LIGHT RD
DRIVE LIGHT OPTION
FUSE
10A
L29
L30
RD
RD
FUSE 10A
RD
TB21
WORK LIGHTS OPTION

C2P-12 C2P-10
CR23
NO
K
PBOX GND
C2P-11 C2P-9
L30
PR2
TB34
TS6

GLOW
TS56
J
PLUG
GLOW
PLUG
PR2
NO

TEMP.
L43
OIL
I
MODULE
START
U1
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
C1P-7 C1B-7 C5-14

ENGINE
TS52
TB25
START
C28TTA RD/BK
START
SW2
C25PSR WH/BK
BK
NC
TB33
H
CR2
POWER RELAY
P26ESTP BK
TB21
P24FS WH
P25FS RD
C21IGN2 WH C5-11
TS1
FUEL SOLENOID
AUX
CR2
NO
PUMP
C1P-1 C27AUX RD C1B-1
G
C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
+
_
IGN./START RELAY
CR1
NO
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
D3
STARTER
STARTER MOTOR
FS1
F

D4
BK-(FS)
TS51
February 2012
Part No. 77828

TB27
AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK
M2
PR1
TB23
NO
C7B-2
PUMP
C7P-2 P23BAT WH
AUX
AUXILIARY PUMP
P2
D2
C5-3
C1P-2 WH
E
TB28
Overload
D40
Platform
RD/BK
B
C1B-2
Option
C28TTA RD/BK WH
H1
C28TTA RD/BK
Only
TILT ALARM
LEVEL SENSOR
L4
D39
C3B-12
C
A
1
S8
TB46
GR/BK
RD
C2B-5
NC

LS18
P3
NOTES:
CR5
GR/BK
H2
NO
D
TB133
P22BAT BK F.H. BK
C32-8
1
HORN
TB132
8
7
5
L45
TB134
FB1
U33
P134PWR GR/BK C2B-6
H6
C2P-6 OPTION
1
6
4
12
S-60 • S-65 • S-60 HC

TB134
RD
CR17
C
SW3
NO
BK
86
85
TB22
WH
SWITCH (OPTION)
RD
87a 87
30
P116HYD RD
PLAT
GRD
C41RPM OR/BK
FAN
KS1
(OPTION)
3MF
C3
M1
+
TB41
B
D22
RD
EXCT.
STA.
C21IGN WH
BAT.
IND.
P1
RD
RD
-
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
A
D1
TB20
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 54
1
8

6 - 55
1
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
TS15

C
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
PWR 3 13 C14-1 C14-2
BRN
D
C3P-5 C5TRR WH/BK C3B-5 C5TRR WH/BK

TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
TB6
LEFT
TS62

5
R4
FLOW CONTROL
C31-1 C31-2
TB1
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
DOWN C2PBD RD/BK

PRIMARY BOOM DOWN
C13-1 C13-2
CR34
Part No. 77828

February 2012
TS61
J2
R14
7
5
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
F
8
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
OUT 5 3
RD RD BR C7PBE BK
G
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
2
BK
TB13
LS3
NO
HC
P24FS WH
H
J3
4
3
13
14
P26ESTP BK
3
TB22
LS2
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS1

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
L46
NO
LS5
J
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
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

RIGHT
PLATFORM ROTATE
TB18
C4P-5 C23-1 C23-2
D28
TS57
RIGHT PLATFORM
L

C22-1 C22-2
TB17
D29
C129 RD/BK
H3
D30
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD


N
RD
RD
BRN
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
D12

FOOTSW. HIGH
TS4
FOOTSW. LOW
ENGINE
TS54
SPEED
CR4
D14
LOW RPM
FUNCTION ENA.
M
HIGH IDLE RELAY

D13
TB35
BK/RD C5-18
HIGH RPM SOLENOID
CR4
NO
Q3
TB45
TS47

GENERATOR OPTION
L
CR23
TS48

L29
DRIVE LIGHT
LIGHTS
WORK LIGHT RD
DRIVE LIGHT OPTION
FUSE
10A
L29
L30
RD
RD
FUSE 10A
RD
TB21
WORK LIGHTS OPTION

C2P-12 C2P-10
CR23
NO
K
PBOX GND
C2P-11 C2P-9
L30
PR2
TB34
TS6
C1P-8 C34SA BK/WH C1B-8 C34SA BK/WH C5-22 GLOW PLUG RELAY
GLOW
TS56
J
PLUG
GLOW
GLOW PLUG
PLUG
FUSE 70A
PR2
NO

TEMP.
L43
OIL
I
MODULE
START
U1
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
C1P-7 C1B-7 C5-14

ENGINE
TS52
TB25
START
C28TTA RD/BK
START
SW2
C25PSR WH/BK
BK
NC
TB33
H
CR2
POWER RELAY
P26ESTP BK
TB21
P24FS WH
P25FS RD
C21IGN2 WH C5-11
TS1
FUEL SOLENOID
AUX
CR2
NO
PUMP
C1P-1 C27AUX RD C1B-1
G
C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
+
_
IGN./START RELAY
CR1
NO
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
D3
STARTER
STARTER MOTOR
FS1
F

D4
BK-(FS)
TS51
CR19
EMISSION CONTROL
TB27
February 2012
Part No. 77828

AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK

F.H. C27AUX RD
C7B-2 AUXILIARY POWER RELAY
M2
C7P-2 P23BAT WH
PR1
TB23
NO
P2
D2
PUMP
AUX
AUXILIARY PUMP
C5-3
C1P-2 WH
E
TB28
Overload
D40
Platform
RD/BK
B
C1B-2
Option
C28TTA RD/BK WH
H1
C28TTA RD/BK
Only
TILT ALARM
LEVEL SENSOR
L4
D39
C3B-12
C
A
1
S8
TB46
GR/BK
RD
C2B-5
NC

LS18
P3
NOTES:
CR5
GR/BK
H2
NO
D
TB133
P22BAT BK F.H. BK
C32-8
1
HORN
TB132
8
7
5
L45
TB134
FB1
U33
P134PWR GR/BK C2B-6
H6
C2P-6 OPTION
1
6
4
12
S-60 • S-65 • S-60 HC

TB134
RD
CR17
SW3
C
NO
BK
86
85
TB22
WH
SWITCH (OPTION)
RD
87a 87
30
P116HYD RD
PLAT
GRD
C41RPM OR/BK
FAN
KS1
(OPTION)
3MF
C3
M1
+
TB41
B
D22
RD
EXCT.
STA.
C21IGN WH
BAT.
IND.
P1
RD
RD
-
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
A
D1
TB20
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 56
1
8
6 - 57
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

15 DRIVE FORWARD
15
C31REV WH/BK
1

16 DRIVE REVERSE
TS14
TB31
H4

8
OPTION
B
TB32
C26-1 C26-2
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
S-60 • S-65 • S-60 HC

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
C
TS15

7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 STEER LEFT
NOTES:
17
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
TB36
P26ESTP BK
P24FS WH
3
3
7
BL
DRIVE & STEERING
WH 11
YOUT 5 4
BL
JC3

J1

TB4
OR
PWR 3 13 C14-1 C14-2
D

GND 2 14 9
TB5
C15-1 C15-2
D9
1 RIGHT
TURNTABLE ROTATE
LEFT
TS62
R4
CR19
7.5
TB6
C31-1 C31-2
FLOW CONTROL
TB1
R2
C12-1 C12-2
5
C1PBU RD
PRIMARY BOOM UP
UP
E
PRIMARY BOOM
DOWN C2PBD RD/BK
PRIMARY BOOM DOWN
Part No. 77828
C13-1 C13-2
February 2012
CR34
TS61
J2
R14
7
5
TB3
R16
6
10
BK C3PBF RD/WH
RD
JC2
XOUT 4 1 C29-1 C29-2

J1
OR 6
PWR 3 11
TB2
BRN
7
1
F
8
TB9
C30-1 C30-2
14
FLOW CONTROL
13
7
21 LS5
PRIMARY EXT/RET
NC

6 12
TB7
YEL
22
OUT 5 3
C7PBE BK
G
RD RD BR
BOOM EXTEND
JC1
4 EXTEND
J1
OR BOOM C37-1 C37-2 C16-1 C16-2

PWR 3 9 RETRACT
TS63
BRN C8PBR BK/WH


TB8
1
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
BK
TB13
LS3
NO
HC
H
P24FS WH
J3
4
3
13
14
P26ESTP BK
3
TB22
LS1
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS2

DRIVE LIMIT SWITCH
13
14
NO
HC
I
BK
TB40
OPTION
DRIVE
NO
CR27
NC
CR30
LIFT/
CE
P22LS BK
L46
NO
LS5
J
L47
TB59
13
14
CR34
TB134
21
HO 22
TS9
LS17
NC
UP
PLATFORM LEVEL
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

RIGHT
PLATFORM ROTATE
TB18
C4P-5 C23-1 C23-2
D28
TS57
RIGHT PLATFORM
L

C22-1 C22-2
TB17
D29
C129 RD/BK
H3
D30
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
N
BRN
RD
RD


8
7
6
5
4
3
2
1
6 - 58
CR1 CR2 RD
IGNITION/START POWER BRN BRN
RELAY RELAY
RD WH A
BK-ISM1
BRN
CR4
C32 CONNECTOR
C32
8
7
5
6
1
4
3
HIGH RPM
12
PLUG ANSI/CSA ONLY

WH SOLENOID
BRN BRN RELAY

WH-ISM9
BRN
RD H6
BK-22D2
RD-TS52
RD-TS51
C5-18 BK/RD
BK C7B-1
BK/RD-35C
C21IGN WH C5-3
GR/BK H6
WH-21B
RD-24B
BK C5-5
BK
BL/WH-132B
WH
C5
B
C32
F.H.
BRN
BK-46R
BK-22C1
CR5 CR22 OR C5-1
R43DLITE2 RD
R43DLITE1 RD
HORN DRIVE LIGHT
RELAY OPTION
C2B-5 GR C21IGN WH
C
BRN
GR/BK-L45
CR17
GR/BK-133B
C5
F.H.
HYDRAULIC
S-60 • S-65 • S-60 HC

OIL COOLER
GR-46D BRN OPTION
P134PWR RD-134C
+

H6
TERMINAL BASE (TB)

CE ONLY
D C B A C1PBU RD C3B-1
1 BOOM UP 1
RD/BK-TS61 C2PBD RD/BK C13-1
#1
2 BOOM DOWN 2
D
D29
C3PBF RD/WH C3B-3
RD/WH-R16 C3PBF RD/WH C29-1

C4TRL WH C3B-4
C5TRR WH/BK C3B-5
WH/BK-TS62 C5TRR WH/BK C14-1 +12V DC
C6TRF WH/RD C3B-6 POWER TO
WH/RD-TS62 C6TRF WH/RD C31-1 PLATFORM
BK
6 TURNTABLE ROTATE FUNCTION CTRL 6 C7
WH
C7PBE BK C3B-7
7 BOOM EXTEND 7
C8PBR BK/WH C3B-8
E

8 BOOM RETRACT 8
C9PER BK/RD C3B-9

9 BOOM EXT/RET FUNCTION CTRL 9
JDALARM BL C3B-10 C3 & C4

BL-TS58 RD/BK-ALARM
44 JIB BOOM DOWN DESCENT ALARM 44
D30
C13DRE BL/RD C4B-1

C13DRE BL/RD C10-1
13 DRIVE ENABLE 13
C14PLU OR C4B-2
Part No. 77828

February 2012
OR-TS59 C14PLU OR C20-1 18/19 #2

C15PLD OR/BK C4B-3
#2
#1
F

C17JU GR C4B-5
C18JD GR/BK C4B-6
18 PLATFORM ROTATE RIGHT/JIB DOWN 18 EXTEND
C19JSV GR/WH C4B-7
LIMIT SWITCH
GR/WH-TS57
#2
C5

F.H.
RD-CB2 P20BAT RD
RD-CB1 P20BAT RD
20 +12V DC POWER 20
D52
BRN-<GND> C21IGN WH CR2

BK-CR5
G
CABLE
C11

P22BAT BK C11-1
LS5
BK C32-4 P22BAT BK C9-2
WH-ISM7 P23BAT WH C7B-2
WH-KS
RD-ISM6 RD-CR2
RD-CB1
#2
#1
C5
F.H.
C37
WH/BK-ISM10 C25TSR WH/BK C5-16

25 OIL PRESSURE SWITCH 25
D33
H
WH/RD-L2- C26PSR WH/RD C5-14

26 OIL TEMPERATURE SWITCH 26
RD-ISM4 C27AUX RD C1B-1
BK
WH
C28TTA RD/BK C1B-2

28 TILT ALARM 28
C29MS RD/WH C1B-3 BRN POWER
C29MS RD/WH C5-24
29 MOTOR STROKE 29
C30FWD WH C1B-4
C30FWD WH C5-21
30 DRIVE FORWARD 30
C31REV WH/BK C1B-5
31 DRIVE REVERSE 31
I

32 BRAKE 32
BK-ISM3 C33STR BK C1B-7
BK-TS52
33 ENGINE START 33
C34SA BK/WH C1B-8
BK/WH-TS56 C34SA BK/WH C5-22
34 GLOW PLUG 34
BK/RD-CR4 C35HS BK/RD C1B-9
RD-TS54
C36STCC BL C1B-10
C36STCC BL C24-1
36 STEER RIGHT 36
C37STC BL/BK C1B-11
J
C37STC BL/BK C25-1

C5
37 STEER LEFT 37
C39LP BL/RD C2B-1
ENGINE
39 (UNUSED) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
OR/BK-ISM2 C41RPM OR/BK C2B-3
C5
BRN-GND C41RPM OR/BK C5-2

C46HRN GR C2B-5
+ C3
GR-CR5
WH C11-2
46 HORN 46
C59CNK BL/BK C3B-11
K

C134PWR GR/BK C2B-6
RD-H6+ C134PWR RD-LS17 C38-1
RD-KS P134TTSR RD A
#2
F.H.

BRN C37-2
BRN C7B-3
BK-CR5 R46HRN BK
BRN

BL/WH C32-3 C132PLI BL/WH C1B-12
GR/BK-H6- C133PLA BL/WH C3B-12
L
B A
BK C16-1

BK
WH
BRN
WH LS2 C10-2
BK-CR1
Genie Industries
1 TO REMOVE: 1 START RELAY
OR/BK-41C
F.H.
2 Push gently 2 TACHOMETER

BK-33C U1
3 and lift 3 START INPUT
RD-27C
4
HARNESS
4 AUX PWR UNIT

FUNCTION
BRN
5 5 GROUND
M
RD-24C
6 6 BATTERY
WH-23C
7 7 TO KEY SW (DIESEL ONLY)
8 8 JUMP TO 7 (GAS ONLY)
WH-CR2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH/BK-25D
10 10 TEMP OR PRESS FAULT
12/24 Volt IGNITON/START MODULE P/N 56057
GROUND BOLT
N

OVERLOAD LED
TURNTABLE
PLATFORM
UP/DOWN
(CE OPTION)
(TO TERMINAL STRIP)

PLATFORM
ROTATE
ROTATE
BASE BOX HARNESS

RD
BOOM
TS61
TS57
TS62
RD
L45
D9
RD RD
RD/BK-2 RD-1
+
2
C19JSV GR/WH
RD/WH
RD
RD
GR/BK-18D
RD
RD
WH/RD-6
WH/BK-5
GR-17D
RD
D3
WH-4
RD
AUXILIARY
RD RD
POWER
TS51
RD
D4
RD
RD RD
RD
3
RD
BRN
RD-27
WH
PLATFORM
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
TS59
LOWER/
BOOM
C134PWR RD
RD/WH-CR34
RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
WH/RD-6D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
WH-4D
RD-1D
BK-7D
4
WH
RD
TURNTABLE
RESISTOR
DALE RH-25 25W

DALE RH-25 25W
ROTATE
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK/WH-34D
BK-33D
RD-20C
WH/RD-26
OR-LS17
RD C32-7
RD CR17
BRN-GND
RD-20D
RD-24D
10 ohm 1%
BK/RD-35D
R4
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RESISTOR
WH
R16
ENGINE
CHECK
L2
1
RD/WH-TB3D
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
B
CB3
5
CB2
RD
-
3
4
WH
RD/WH
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
RD
OR
RD
RD
RD 6
LABEL DESCRIPTION
DALE RH-25 25W
RD-20D
5 ohm 1%
RD
RESISTOR
UP/DOWN

BOOM

R14
ENGINE
RD/WH-TS61
ENGINE 15A
START
RD/WH-R16
TS52
BREAKER
CIRCUIT
OR-LS17
CB1
RD/WH-R16
BK/WH-34D
RD-24D
BRN CR4 HIGH IDLE RELAY
CR5 HORN RELAY 7
BRN
BRN
BRN
WH-21D
RD
REDUCTION

SPEED
BOOM
CR34
HM HOUR METER
RD
RD
KS1 KEY SWITCH

L2 CHECK ENGINE LED
HOUR METER

STOP SWITCH
EMERGENCY
RD
1 1
D13
GLOW
PLUG
TS56
P1
NC NC
D14
8
FUNCTION
2 2
ENABLE
TS54
RD
RD
TS54 FUNCTION ENABLE SWITCH
RD

RD TS57 PLATFORM ROTATE TOGGLE SWITCH
Part No. 77828 S-60 • S-65 • S-60 HC 6 - 59



8
7
6
5
4
3
2
1
6 - 60
RD
CR1 CR2
POWER BRN CR23
IGNITION DRIVE LIGHT
START RELAY RELAY
OPTION
RD
BK-ISM1
A
U33
BRN
C32 CONNECTOR
(CE ONLY)
PLATFORM
OVER LOAD
WH
PLUG ANSI/CSA ONLY

BRN
C32
BRN
C32
8
7
6
5
1
4
3
12
WH-OPTIONS
WH-ISM9
CR4
C5-18 BK/RD
R43DLITE2 RD
R43DLITE1 RD
C21IGN WH C5-11
HIGH RPM
BK/RD-35C
C2B-4 OR/RD
RD-24B
SOLENOID RELAY
WH-21B
BRN
BK C5-5
RD H6
BRN
BK-22D2
RD-TS52
RD-TS51
BK C7B-1
GR/BK H6
BL/WH-132B
C5
BK
WH
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
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
S-60 • S-65 • S-60 HC

HYDRAULIC
P134PWR RD-134C
WH/RD-R4 OIL COOLER

OPTION
RD/WH-TS61
+
RD-CB3
H6
CE

OPTION ONLY

1 PRIMARY BOOM UP 1
D
RD/BK-TS61 C2PBD RD/BK C13-1

#1
D29
C3PBF RD/WH C3B-3
RD/WH-CR34 C3PBF RD/WH C29-1

C4TRL WH C3B-4

C5TRR WH/BK C3B-5
FUSE 10A
(DRIVE LIGHT ONLY)

POWER TO
BK
RD
WH
C7PBE BK C3B-7 C7

E
C8PBR BK/WH C3B-8

C9PER BK/RD C3B-9

WH-TB21 OPTIONS
JDALARM BL C3B-10
BL-TS58 RD/BK-ALARM
D30

C13DE BL/RD C4B-1
C13DE BL/RD C10-1

13 DRIVE ENABLE 13
Part No. 77828

February 2012
C14PLU OR C4B-2
OR-TS59 C14PLU OR C20-1 18/19 #2
C15PLD OR/BK C4B-3
F

#2
#1

C17JU GR C4B-5
C18JD GR/BK C4B-6
EXTEND
GR/WH-TS57
#2
C5
LIMIT SWITCH
F.H.

RD-CB1 P20BAT RD
D52

BRN-<GND> C21IGN WH CR2

G
C11
BK-CR5

Genie s60

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Introduction February 2012

Important Serial Number Information

Machine Design Life

Printed on recycled paper

ii S-60 • S-65 • S-60 HC Part No. 77828

E1 1/2013 3 - maint. 3-6, E-4

Kubota Engine_Section 2_Specifications. Electronic Version

Part No. 77828 S-60 • S-65 • S-60 HC iii

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

Kubota Engine_Section 2_Specifications. Electronic Version

iv S-60 • S-65 • S-60 HC Part No. 77828

Serial Number Legend

Rated work load (including occupants): 500 lb / 227 kg

Terex South Dakota, Inc.

Part No. 77828 S-60 • S-65 • S-60 HC v

Danger Read each procedure thoroughly. This

You have the appropriate tools, lifting Indicates a potentially hazardous

vi S-60 • S-65 • S-60 HC Part No. 77828

Be sure that all tools and working areas

Be sure that fasteners intended for one

Be sure that your workshop or work area is

Part No. 77828 S-60 • S-65 • S-60 HC vii

Section 1 Safety Rules

viii S-60 • S-65 • S-60 HC Part No. 77828

Section 3 Scheduled Maintenance Procedures

Part No. 77828 S-60 • S-65 • S-60 HC ix

Section 3 Scheduled Maintenance Procedures, continued

x S-60 • S-65 • S-60 HC Part No. 77828

Section 3 Scheduled Maintenance Procedures, continued

Part No. 77828 S-60 • S-65 • S-60 HC xi

Section 4 Repair Procedures

xii S-60 • S-65 • S-60 HC Part No. 77828

Section 4 Repair Procedures, continued

Part No. 77828 S-60 • S-65 • S-60 HC xiii

Section 5 Fault Codes

xiv S-60 • S-65 • S-60 HC Part No. 77828

Section 6 Schematics, continued

Part No. 77828 S-60 • S-65 • S-60 HC xv

Section 6 Schematics, continued

xvi S-60 • S-65 • S-60 HC Part No. 77828

Section 6 Schematics, continued

Part No. 77828 S-60 • S-65 • S-60 HC xvii

Section 6 Schematics, continued

xviii S-60 • S-65 • S-60 HC Part No. 77828

Section 6 Schematics, continued

Part No. 77828 S-60 • S-65 • S-60 HC xix

Section 6 Schematics, continued

xx S-60 • S-65 • S-60 HC Part No. 77828

Tire ply rating Turntable rotation drive hub 40 fl oz

Lug nut torque, lubricated 180 ft-lbs

Overall tire diameter 36.9 in

Overall tire diameter 40.1 in

Overall tire diameter 40.3 in

Tire pressure 70 psi

Tire pressure 85 psi

Tire pressure 60 psi

For operational specifications, refer to the

Continuous improvement of our products is a

Part No. 77828 S-60 • S-65 • S-60 HC 2-1

Jib boom up, S-65 60 to 70 seconds

Jib boom down, S-65 40 to 50 seconds

Boom down 60 to 70 seconds

Boom extend 58 to 66 seconds