Manual de Servicios S-60 139188 PDF

Service Manual
Serial Number Range
from S6007-14782
S-60 to S6010-20420
S-65
S-60 HC
S-60 TRAX
S-65 TRAX
Part No. 139188

Rev B
January 2010
Introduction January 2010
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie Industries offers the following Service
operating instructions in the Genie S-60 and Genie Manuals for these models:
S-65 Operator's Manual or the Genie S-60 HC
Operator's Manual or the Genie S-60 TRAX and Title Part No.
Genie S-65 TRAX Operator's Manual before
S-60 and S-65 Service Manual
attempting any maintenance or repair procedure. (before serial number 2575) ................................ 34476
This manual provides detailed scheduled
maintenance information for the machine owner and S-60 and S-65 Service Manual
(from serial number 2575 to 6623) ....................... 48412
user. It also provides troubleshooting fault codes
and repair procedures for qualified service
S-60 and S-65 Service Manual
professionals. (from serial number 6624 to 9153) ....................... 65196
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However, S-60, S-65 and S-60 HC Service Manual
(from serial number 9154 to 14781) .................... 77828
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are subject
to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us: Copyright © 1995 by Genie Industries
http://www.genieindustries.com 139188 Rev B January 2010

Fith Edition, Second Printing
e-mail: techpub@terex.com
"Genie" and "S" are registered trademarks of
Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.
ii S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
January 2010
INTRODUCTION
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
Genie Industries
18340 NE 76th Street Serial label
Redmond, WA 98052 (located under cover)
USA Serial number
stamped on chassis
PN - 77055
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX iii
January 2010
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iv S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
January 2010 Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-60 and Genie S-65
Operator's Manual or the Genie S-60 HC Operator's
Manual or the Genie S-60 TRAX and Genie S-65
TRAX Operator's Manual will result in death or
serious injury.
Many of the hazards identified in the operator's

manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX v
Section 1 • Safety Rules January 2010
SAFETY RULES
Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.
Read each procedure thoroughly. This
manual and the decals on the machine, Be sure that all tools and working areas
use signal words to identify the following: are properly maintained and ready for use.
Keep work surfaces clean and free of
Safety alert symbol—used to alert debris that could get into machine components and
personnel to potential personal cause damage.
injury hazards. Obey all safety
messages that follow this symbol Be sure any forklift, overhead crane or
to avoid possible injury or death. other lifting or supporting device is fully
capable of supporting and stabilizing the
Indicates an imminently hazardous
weight to be lifted. Use only chains or straps that
situation which, if not avoided, will
are in good condition and of ample capacity.
result in death or serious injury.
Be sure that fasteners intended for one
Indicates a potentially hazardous
situation which, if not avoided, time use (i.e., cotter pins and self-locking
could result in death or serious nuts) are not reused. These components
injury. may fail if they are used a second time.
Indicates a potentially hazardous Be sure to properly dispose of old oil or

situation which, if not avoided, other fluids. Use an approved container.
may cause minor or moderate Please be environmentally safe.
injury. Be sure that your workshop or work area is
Indicates a potentially hazardous properly ventilated and well lit.
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 • S-60 TRAX • S-65 TRAX Part No. 139188
January 2010
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Serial Number Legend ................................................................................................. iii
Section 1 Safety Rules

General Safety Rules .................................................................................................. v
Section 2 Rev Specifications

B Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................ 2 - 3
Manifold Component Specifications ....................................................................... 2 - 4
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 5
Deutz F3L-2011 / Deutz D2011 L03i Engine Specifications .................................... 2 - 6
Perkins 404-22 Engine Specifications .................................................................... 2 - 8
Machine Torque Specifications .............................................................................. 2 - 9
Trax Torque Specifications .................................................................................. 2 - 10
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 11
SAE and Metric Fasteners Torque Charts ............................................................ 2 - 12
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX vii
January 2010
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
C 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 Inspect the Track Components and Fastener Torque,
S-60 TRAX and S-65 TRAX ....................................................................... 3 - 10
A-8 Perform 30 Day Service ............................................................................. 3 - 11
A-9 Check the Track Tension, S-60 TRAX and S-65 TRAX .............................. 3 - 11
A-10 Perform Engine Maintenance - Ford and Perkins Models ........................... 3 - 13
A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 13
A-12 Check and Adjust the Engine RPM - Perkins Models ................................. 3 - 15
A-13 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 16
A-14 Replace the Drive Hub Oil .......................................................................... 3 - 17
A-15 Perform Engine Maintenance - Ford Models ............................................... 3 - 19
A-16 Perform Engine Maintenance - Perkins Models .......................................... 3 - 19
viii S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
January 2010
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

C Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 20
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 21
B-3 Check the Exhaust System ....................................................................... 3 - 22
B-4 Inspect the Engine Air Filter - Ford, Deutz and Perkins Models .................. 3 - 23
B-5 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 23
B-6 Inspect the Tires, Wheels and Lug Nut Torque,
S-60, S-65 and S-60 HC ............................................................................. 3 - 24
B-7 Confirm the Proper Brake Configuration ...................................................... 3 - 25
B-8 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 25
B-9 Check and Adjust the Engine RPM - Ford and Deutz Models ..................... 3 - 28
B-10 Test the Ground Control Override ............................................................... 3 - 29
B-11 Check the Oscillate Directional Valve Linkage ........................................... 3 - 29
B-12 Test the Platform Self-leveling ................................................................... 3 - 30
B-13 Test the Engine Idle Select ........................................................................ 3 - 30
B-14 Test the Fuel Select Operation - Ford Models ............................................ 3 - 31
B-15 Test the Drive Brakes ................................................................................ 3 - 32
B-16 Test the Drive Speed - Stowed Position ..................................................... 3 - 32
B-17 Test the Drive Speed - Raised or Extended Position .................................. 3 - 33
B-18 Test the Alarm Package - Optional Equipment ........................................... 3 - 34
B-19 Perform Hydraulic Oil Analysis ................................................................... 3 - 35
B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 35
B-21 Replace the Fuel Filter Element - Perkins Models ...................................... 3 - 36
B-22 Inspect the Boom Extend/Retract Cables ................................................... 3 - 38
B-23 Perform Engine Maintenance - Deutz Models ............................................. 3 - 39
B-24 Perform Engine Maintenance - Ford models ............................................... 3 - 40
B-25 Replace the Engine Air Filter Element - Ford Models ................................. 3 - 40
B-26 Perform Engine Maintenance - Perkins Models .......................................... 3 - 41
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX ix
January 2010
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

B Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models ............................................. 3 - 42
C-2 Grease the Platform Overload Mechanism (if equipped),
S-60, S-65, S-60 TRAX and S-65 TRAX .................................................... 3 - 42
C-3 Test the Platform Overload System, S-60 and S-65 (if equipped),
S-60, S-65, S-60 TRAX and S-65 TRAX .................................................... 3 - 43
C-4 Test the Platform Load Sense System, S60 HC ........................................ 3 - 46
C-5 Replace the Fuel Filter/Water Separator Element - Perkins Models ............ 3 - 48
C-6 Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 50
C-7 Perform Engine Maintenance - Perkins Models .......................................... 3 - 50
C-8 Perform Engine Maintenance - Ford Models ............................................... 3 - 51
B Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 52
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 53
D-3 Inspect for Turntable Bearing Wear ............................................................ 3 - 54
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 55
D-5 Check the Free-wheel Configuration ........................................................... 3 - 57
D-6 Replace the Hydraulic Filters ...................................................................... 3 - 59
D-7 Perform Engine Maintenance - Deutz Models ............................................. 3 - 61
B Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 62
E-2 Perform Engine Maintenance - Deutz Models ............................................. 3 - 64
E-3 Perform Engine Maintenance - Deutz Models ............................................. 3 - 64
E-4 Remove and Inspect the Boom Extend/Retract Cables .............................. 3 - 65
x S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
January 2010
TABLE OF CONTENTS
Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1
B Platform Controls
1-1 ALC-500 Circuit Board .................................................................................. 4 - 2
1-2 Joysticks ..................................................................................................... 4 - 3
A Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 8
2-2 Platform Rotator ........................................................................................... 4 - 9
2-3 Platform Overload System, S-60, S-65, S-60 TRAX and
S-65 TRAX (if equipped) ............................................................................. 4 - 11
2-4 Platform Load Sense System, S-60 HC ..................................................... 4 - 13
A Jib Boom Components, S-65 and S-65 TRAX
3-1 Jib Boom .................................................................................................... 4 - 17
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 18
A Boom Components
4-1 Cable Track ................................................................................................ 4 - 19
4-2 Boom ......................................................................................................... 4 - 24
4-3 Boom Lift Cylinder ...................................................................................... 4 - 27
4-4 Boom Extension Cylinder ........................................................................... 4 - 28
4-5 Boom Extend/Retract Cables ..................................................................... 4 - 31
4-6 Platform Leveling Master Cylinder .............................................................. 4 - 34
A Engines
5-1 RPM Adjustment - Ford and Deutz Models ................................................ 4 - 35
5-2 RPM Adjustment - Perkins Models ............................................................. 4 - 35
5-3 Flex Plate ................................................................................................... 4 - 35
5-4 Engine Fault Codes - Ford Models ............................................................. 4 - 40
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX xi
January 2010
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

A Hydraulic Pumps
6-1 Function Pump ........................................................................................... 4 - 41
6-2 Drive Pump ................................................................................................ 4 - 42
A Manifolds
7-1 Function Manifold Components .................................................................. 4 - 45
7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 49
7-3 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 50
7-4 Brake/Two-speed Manifold Components .................................................... 4 - 51
7-5 Turntable Rotation Manifold Components ................................................... 4 - 52
7-6 Oscillate Directional Valve Components ..................................................... 4 - 53
7-7 Valve Adjustments - Oscillate Relief Valve ................................................ 4 - 55
7-8 Drive Oil Diverter Manifold (welder option) .................................................. 4 - 56
7-9 Traction Manifold Components, 2WD ......................................................... 4 - 57
7-10 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 59
7-11 Traction Manifold Components, 4WD ......................................................... 4 - 61
7-12 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 63
7-13 Valve Coils ................................................................................................. 4 - 64
A Turntable Rotation Components
8-1 Turntable Rotation Assembly ..................................................................... 4 - 66
A Axle Components
9-1 Oscillate Axle Cylinders ............................................................................. 4 - 68
A Track Components
10-1 Track Assembly, S-60 TRAX and S-65 TRAX ............................................ 4 - 69
xii S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
January 2010
TABLE OF CONTENTS
Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1
A Fault Codes - Control System ................................................................................ 5 - 2
B Fault Codes - Ford DSG-423 EFI Engine ............................................................... 5 - 6
A Fault Codes - Platform Load Sense System, S-60 HC ......................................... 5 - 10
Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
A Electrical Symbols Legend .................................................................................... 6 - 2
A Hydraulic Symbols Legend .................................................................................... 6 - 3
A Ford Engine Relay Layout ...................................................................................... 6 - 4
A Limit Switch Location Legend ................................................................................ 6 - 5
B Electrical Schematic, S-60 HC
(before serial number 19039) ........................................................................ 6 - 8
B Chassis Wiring Diagram, S-60 HC
(before serial number 19039) ........................................................................ 6 - 9
B Ground Control Box Terminal Strip Wiring Diagram, S-60 HC
(before serial number 19039) ...................................................................... 6 - 12
B Platform Control Box Wiring Diagram, S-60 HC
A Electrical Schematic, S-60 HC
(after serial number 19038) ......................................................................... 6 - 16
A Chassis Wiring Diagram, S-60 HC
A Ground Control Box Terminal Strip Wiring Diagram, S-60 HC
A Platform Control Box Wiring Diagram, S-60 HC
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX xiii
January 2010
TABLE OF CONTENTS
Section 6 Rev Schematics, continued

A Ford DSG-423 EFI Engine Harness ..................................................................... 6 - 23
A Electrical Schematic,
S-60 and S-60 TRAX, Ford DSG-423 EFI Models ...................................... 6 - 26
A Ground Control Box Terminal Strip Wiring Diagram,
A Ground Control Box Switch Panel Wiring Diagram,
A Platform Control Box Wiring Diagram,
A Platform Control Box Switch Panel Wiring Diagram,
A Electrical Schematic,
A Ground Control Box Terminal Strip Wiring Diagram,
S-65 and S-65 TRAX, Ford DSG-423 EFI Models
xiv S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
January 2010
TABLE OF CONTENTS

B Electrical Schematic,
S-60 and S-60 TRAX, Deutz F3L-2011/Deutz D2011L03i Models ............... 6 - 54
B Electrical Schematic, CE Models
B Ground Control Box Terminal Strip Wiring Diagram,
B Ground Control Box Terminal Strip Wiring Diagram, CE Models,
A Ground Control Box Switch Panel Wiring Diagram, CE Models,
A Platform Control Box Terminal Strip Wiring Diagram,
B Electrical Schematic, CE Models
B Ground Control Box Terminal Strip Wiring Diagram, CE Models
A Ground Control Box Switch Panel Wiring Diagram, CE Models
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX xv
January 2010
TABLE OF CONTENTS

S-65 and S-65 TRAX, Deutz F3L-2011/Deutz D2011L03i Models
S-60 and S-60 TRAX, Perkins 404-22 Models ............................................ 6 - 98
S-60 and S-60 TRAX, Perkins 404-22 Models ........................................... 6 - 102
xvi S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
January 2010
TABLE OF CONTENTS

S-65 and S-65 TRAX, Perkins 404-22 Models
(before serial number 16734) ..................................................................... 6 - 118
(after serial number 16733) ........................................................................ 6 - 122
A Belt Driven Generator Wiring Diagram ................................................................. 6 - 125
A 12kW Hydraulic Generator Option Wiring Diagram ............................................... 6 - 128
A Hydraulic Schematic, 12kW Hydraulic Generator Option
A Hydraulic Schematic, 12kW Hydraulic Generator Option
A Hydraulic Schematic, 2WD Models ..................................................................... 6 - 133
A Hydraulic Schematic, 4WD Models ..................................................................... 6 - 135
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX xvii
January 2010
xviii S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
January 2010 Section 2 • Specifications
REV C
Specifications
Machine Specifications Track Components, S-60 TRAX and S-65 TRAX
Tires and wheels, S-60, S-65 and S-60 HC Track material Rubber
Tensioning system Pressurized grease

Tire size
(Rough terrain, low profile) 355/55D625 Weight (each) 1,500 lbs
680 kg
Tire size
(Rough terrain, tall) 385-19.5
Tire size Fluid capacities

(Hi-flotation) 41/18LL x 22.5
Fuel tank 35 gallons
Tire ply rating 151 liters
(Rough terrain, low profile and Hi-flotation) 14
LPG tank 33.5 pounds
Tire ply rating 15.2 kg
(Rough terrain, tall) 16
Hydraulic tank 45 gallons
Wheel lugs 9 @ 5/8 -18 170 liters
Lug nut torque, dry 240 ft-lbs Hydraulic system 55 gallons

325 Nm (including tank) 208 liters
Drive hubs 20 fl oz
Lug nut torque, lubricated 180 ft-lbs 0.6 liters
244 Nm
Turntable rotation drive hub 40 fl oz
Overall tire diameter 36.9 in (before serial number 20367) 1.2 liters
(Rough terrain, low profile tires) 93.7 cm
(after serial number 20366) 43 oz
Overall tire diameter 40.1 in 1.3 liters
(Rough terrain, tall tires) 102 cm
Drive hub oil type:
Overall tire diameter 40.3 in SAE 90 multipurpose hypoid gear oil API service
(Hi-flotation tires) 102.4 cm classification GL5
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. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 2-1
Section 2 • Specifications January 2010
SPECIFICATIONS REV C
Performance Specifications Drive speed, maximum

stowed position
Boom function speeds, maximum
from platform controls 2WD models 40 ft / 6.2 sec
12.2 m / 6.2 sec
Jib boom up, S-65 60 to 70 seconds
4WD models 40 ft / 7.2 sec
Jib boom down, S-65 40 to 50 seconds 12.2 m / 7.2 sec
Boom up 60 to 70 seconds S-60 TRAX and S-65 TRAX 40 ft / 12 sec

12.2 m / 12 sec
Boom down 60 to 70 seconds
Drive speed, maximum
Boom extend 58 to 66 seconds raised or extended position
Boom retract 53 to 62 seconds S-60, S-65 and S-60 HC 40 ft / 40 sec
12.2 m / 40 sec
Turntable rotate, 360° 78 to 86 seconds
boom stowed S-60 TRAX and S-65 TRAX 40 ft / 57 sec
12.2 m / 57 sec
Turntable rotate, 360° 125 to 165 seconds
boom raised or extended Gradeability See Operator's Manual
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

Genie policy. Product specifications are subject
2-2 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
REV C SPECIFICATIONS
Hydraulic Specifications Drive pump
Hydraulic Oil Specifications Type: bi-directional, variable

displacement piston pump
Hydraulic oil type Chevron Rando HD 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 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
exceed 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 fluid when ambient
temperatures are consistently Auxiliary pump
above 32°F / 0°C may result in
Type: gear, fixed displacement
component damage.
Displacement 1.75 gpm
Note: Use Chevron Aviation A hydraulic fluid when 2.8 L/min
ambient temperatures are 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
Industries Service Department before use. to change without notice.
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

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
27 Hz Spark plug gap 0.049 to 0.053 inches
High function idle (computer controlled) 2500 rpm 1.244 to 1.346 mm
42 Hz Engine coolant
Compression ratio 9.7:1 Capacity 10 quarts
Compression pressure (approx.) 9.5 liters
Pressure (psi or bar) of lowest cylinder must be Cylinder head temperature sending unit
at least 75% of highest cylinder
Fault code set temperature 280°F
Lubrication system 138°C
Oil pressure 29 to 39 psi Engine shut-down temperature 300°F
(at operating temperature @ 2500 rpm) 2 to 2.7 bar 149°C
Oil capacity 4 quarts Starter motor
(including filter) 3.8 liters
Normal engine cranking speed 200 to 250 rpm
Oil pressure switch
Current draw, normal load 140-200A
Oil pressure switch point 7.5 psi
0.51 bar Current draw, maximum load 800A
Oil viscosity requirements Alternator
Extreme operating temperatures may require the use of Output 95A, 13.8V DC
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine. Battery
Type 12V DC, Group 31
Quantity 1
Cold cranking ampere @ 0°F 1000A
Reserve capacity @ 25A rate 200 minutes

Deutz F3L2011 Engine Lubrication system

Deutz D2011L03i Engine Oil pressure 40 to 60 psi
(@ 2000 rpm) 1.4 to 3 bar
Displacement 142 cu in
2.33 liters Oil capacity 8.5 quarts
(including filter) 8 liters
Number of cylinders 3 (Deutz F3L2011 Engine)
Bore and stroke 3.7 x 4.4 inches Oil capacity 9.5 quarts
94 x 112 mm (including filter) 9 liters
(Deutz D2011L03i Engine)
Horsepower 48 @ 2800 rpm
36 kW @ 2800 rpm Oil viscosity requirements
Firing order 1-2-3 -22° F to 86° F/ -30° C to 30° C 5W-30

(synthetic)
Low idle 1500 rpm
313 Hz -4° F to 90° F / -20° C to 32° C 10W-40
High idle 2500 rpm Above 23° F / -5° C 20W-50

522 Hz
Units ship with 15W-40.
Compression ratio 19:1 Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Compression pressure 362 to 435 psi Engine Operator Handbook on your machine.
25 to 30 bar
Oil temperature switch
Governor centrifugal mechanical
Temperature switch point 220°F
Valve clearance, cold 104°C
Intake 0.012 in Oil pressure switch
0.3 mm
Oil pressure switch point 7 psi
Exhaust 0.020 in (Deutz F3L2011 Engine) 0.5 bar
0.5 mm
Oil pressure switch point 22 psi
(Deutz D2011L03i Engine) 1.5 bar

Fuel injection system
Injection pump make Bosch
Injection pump pressure, maximum 15000 psi

1034 bar
Injector opening pressure 3046 psi

210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's

Manual on your machine.
Starter motor
Current draw, normal load 140A to 200A
Brush length, new 0.72 in

18.5 mm
Brush length, minimum 0.27 in

7 mm
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
Reserve capacity @ 25A rate 200 minutes
Alternator output 60A @ 14V DC
Fan belt deflection 3/8to 1/2 inch

9 to 12 mm
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

(including filter) 8.8 liters
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.
22 Hz Extreme operating temperatures may require the use of
High idle 2500 rpm alternative engine oils. For oil requirements, refer to the
42 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
Alternator output 55A @ 12V DC
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

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

TRAX Torque Specifications

Sprocket to hub adapter fasteners
3 /4 -10 nuts, GR 8, dry 375 ft-lbs
508 Nm
3 /4 -10 nuts, GR 8, lubricated 281 ft-lbs
381 Nm
1 /2 -13 FHS screws, dry 80 ft-lbs
108 Nm
1 /2 -13 FHS screws, lubricated 60 ft-lbs
81 Nm
Hub adapter to drive hub fasteners
Lug nut torque, dry 240 ft-lbs

325 Nm
Lug nut torque, lubricated 180 ft-lbs

244 Nm
Sprocket bearing hub fasteners
1-14 bolts, GR 8, dry 650 ft-lbs

881 Nm
1-14 bolts, GR 8, lubricated 488 ft-lbs

662 Nm
Idler and bogey wheel fasteners

3 /4 -10 bolts, GR 8, dry 375 ft-lbs
508 Nm
3 /4 -10 bolts, GR 8, lubricated 281 ft-lbs
381 Nm

2 - 10 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX Part No. 139188
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. The O-ring
Your machine is equipped with Parker Seal-Lok® cannot be re-used if the fitting or hose end has
fittings and hose ends. Genie specifications require been tightened beyond finger tight.
that fittings and hose ends be torqued to
specification when they are removed and installed Note: The O-rings used in the Parker Seal Lok®
or when new hoses or fittings are installed. fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
SAE O-ring Boss Port number 49612).
(tube fitting - installed into Aluminum)
2 Lubricate the O-ring before installation.
SAE Dash size Torque
3 Be sure that the face seal O-ring is seated and
-4 11 ft-lbs / 14.9 Nm retained properly.
-6 23 ft-lbs / 31.2 Nm 4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
-8 40 ft-lbs / 54.2 Nm tight.
-10 69 ft-lbs / 93.6 Nm 5 Tighten the nut or fitting to the appropriate
-12 93 ft-lbs / 126.1 Nm torque per given size as shown in the table.
-16 139 ft-lbs / 188.5 Nm

6 Operate all machine functions and inspect the
hoses and fittings and related components to
-20 172 ft-lbs / 233.2 Nm confirm that there are no leaks.
-24 208 ft-lbs / 282 Nm
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
Part No. 139188 S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX 2 - 11
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
January 2010 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,
Used to indicate the presence of
annually and every 2 years as specified on the
an imminently hazardous situation
Maintenance Inspection Report.
which, if not avoided, will result in
Failure to perform each procedure death or serious injury.
as presented and scheduled may
Used to indicate the presence of a
cause death, serious injury or
potentially hazardous situation
substantial damage.
which, if not avoided, could result
Immediately tag and remove from service a in death or serious injury.
damaged or malfunctioning machine.
Repair any machine damage or malfunction potentially hazardous situation
before operating machine. which, if not avoided, may cause
minor or moderate injury.
Use only Genie approved replacement parts.
Unless otherwise specified, perform each potentially hazardous situation
maintenance procedure with the machine in the which, if not avoided, may result in
following configuration: property damage.
• Machine parked on a firm, level surface Indicates that a specific result is expected after
• Boom in stowed position performing a series of steps.
• Turntable rotated with the boom between Indicates that an incorrect result has occurred
the non-steer wheels after performing a series of steps.
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Section 3 • Scheduled Maintenance Procedures January 2010
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in this The pre-delivery preparation report contains
manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation Report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annual and
two years. The Scheduled Maintenance Procedures
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
have been divided into five subsections—A, B, C,
D and E. Use the following chart to determine which
group(s) of procedures are required to perform a
Indicates that a cold engine will be scheduled inspection.
required to perform this procedure.
Inspection Checklist
Indicates that a warm engine will be Daily or every 8 hours A

required to perform this procedure.
Quarterly or every 250 hours A+B
Semi-annually or every 500 hours A+B+C

Indicates that dealer service is required
to perform this procedure. Annual or every 1000 hours A+B+C+D
Two years or every 2000 hours A+B+C+D+E
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.
Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing the
The Pre-delivery Preparation is performed prior to each Pre-operation Inspection, the Maintenance items and the
delivery. The inspection is designed to discover if anything Function Tests.
is apparently wrong with a machine before it is put into
service. Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
A damaged or modified machine must never be used. If instructions in the operator’s manual.
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed from If any inspection receives an N, remove the machine from
service. service, repair and re-inspect it. After repair, place a check
in the R box.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's Legend
specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed by N = no, unable to complete
qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements listed in Comments
the responsibilities manual.
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
Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
(425) 881-1800 (44) 1476-584333
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.

Rev B
Maintenance Inspection Report

Model Checklist A - Rev B Y N R Checklist B - Rev C 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) A-7 Inspect tracks,
Deutz models
S-60 TRAX and
Inspector signature S-65 TRAX B-6 Tires and wheels,
S-60, S-65 and
Perform after 40 hours:
S-60 HC
Inspector title A-8 30 day service
B-7 Brake configuration
Inspector company Perform every 30 days:
B-8 Drive hub oil level
A-9 Check track tension,
B-9 Engine RPM -
Instructions S-60 TRAX and
Ford and Deutz models
• Make copies of this report to use for S-65 TRAX
B-10 Ground control override
each inspection. Perform every 100 hours:
B-11 Directional valve
• Select the appropriate checklist(s) for A-10 Engine maintenance -
the type of inspection to be Ford and Perkins B-12 Platform leveling
performed. models B-13 Engine idle select
A-11 Fuel filter/separator - B-14 Fuel select -
Daily or 8 hour Diesel models Ford models
Inspection: A
A-12 Check engine RPM- B-15 Drive brakes
Quarterly or 250 hour Perkins models B-16 Drive speed -
Inspection: A+B
A-13 Rotation bearing stowed position
Semi-annual or 500 hour
Perform after 150 hours: B-17 Drive speed -
Inspection: A+B+C
A-14 Drive hub oil raised position
Annual or 1000 hours B-18 Alarm package
Inspection: A+B+C+D Perform every 200 hours:
A-15 Engine maintenance - B-19 Hydraulic oil analysis
2 Year or 2000 hour
Ford models B-20 Fuel and hydraulic
Inspection: A+B+C+D+E
A-16 Engine maintenance - tank cap venting
• Place a check in the appropriate box Perkins models B-21 Fuel filter element -
after each inspection procedure is Perkins models
completed. B-22 Inspect the Boom
• Use the step-by-step procedures in extend/retract cables
this section to learn how to perform
these inspections.
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend Comments
Y = yes, acceptable
N = no, remove from service
R = repaired
MAINTENANCE INSPECTION REPORT
Model Checklist B (cont) - Rev C Y N R Checklist D - Rev B Y N R

Perform every 400 hours: D-1 Boom wear pads
Serial number
B-23 Engine maintenance - D-2 Turntable bearing bolts
Date Deutz models D-3 Turntable bearing
B-24 Engine maintenance - wear
Hour meter Ford models D-4 Drive hub oil
B-25 Replace air filter - D-5 Free-wheel
Machine owner Ford models configuration
B-26 Engine maintenance - D-6 Hydraulic filters
Inspected by (print) Perkins models
D-7 Engine maintenance -
Inspector signature Deutz models
Checklist C - Rev B Y N R
Inspector title C-1 Engine maintenance - Checklist E - Rev B Y N R
Deutz models
Inspector company E-1 Hydraulic oil
C-2 Grease platform
Perform every 3000 hours:
overload (if equipped)
Instructions E-2 Engine maintenance -
C-3 Test platform overload,
• Make copies of this report to use for Deutz models
S-60, S-65,
each inspection. Perform every 12,000 hours:
S-60 TRAX and
• Select the appropriate checklist(s) for S-65 TRAX E-3 Engine maintenance -
the type of inspection to be (if equipped) Deutz models
performed. C-4 Test load sense, Perform every 7 years:
S-60 HC E-4 Replace the Boom
Daily or 8 hour
Inspection: A C-5 Fuel filter/separator - Extend/Retract cables
Perkins models
Quarterly or 250 hour
Inspection: A+B C-6 Replace air filter -
Deutz and Perkins
Semi-annual or 500 hour models
Inspection: A+B+C
Annual or 1000 hours
C-7 Engine maintenance -
Inspection: A+B+C+D
Perkins models
2 Year or 2000 hour
Inspection: A+B+C+D+E
C-8 Engine maintenance -
• Place a check in the appropriate box Ford models
after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections. Comments
• If any inspection receives an “N”, tag
and remove the machine from
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
REV B
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 Industries if replacement manuals or decals
associated with using this machine. They also are 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.
CHECKLIST A PROCEDURES REV B
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.
REV B CHECKLIST A PROCEDURES
A-4 A-5
Perform Engine Maintenance Check the High Pressure
Hydraulic Filter Condition
Indicator
Note: Engine specifications require that this Note: Genie specifications require that this
procedure be performed daily or every 8 hours, procedure be performed daily or every 8 hours,
whichever comes first. whichever comes first.
Proper engine maintenance, following the engine Maintaining the high pressure hydraulic filter in
manufacturer's maintenance schedule, is essential good condition is essential to good system
to good engine performance and service life. Failure performance and safe machine operation. The filter
to perform the maintenance procedures can lead to condition indicator will show when the hydraulic flow
poor engine performance and component damage. is bypassing a clogged filter. If the filter is not
frequently checked and replaced, impurities will
Required maintenance procedures and additional remain in the hydraulic system and cause
engine information are available in the component damage.
Deutz FL 2011 Operation Manual
(Deutz part number 0297-9929) OR the 1 Open the engine side turntable cover.
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020) OR the 2 Start the engine from the ground controls.
Perkins 400 Series Operation Manual 3 Change the engine idle to high rpm (rabbit
(Perkins part number TPD 1443S). symbol).
4 Visually inspect the filter condition indicator.
Genie part number 84794 Result: The filter condition indicator should be
operating with the plunger in the green area.
Ford DSG 423 EFI Operator Handbook
Genie part number 119488 Result: If the indicator displays the plunger in
the red area, this indicates that the hydraulic
Perkins 400 Series Operation Manual filter is being bypassed and the filter should be
Genie part number 94890 replaced. See D-6, Replace the Hydraulic
Filters.
A-6 A-7
Test the Oscillate Axle Inspect the Track Components,
(if equipped) S-60 TRAX and S-65 TRAX
Note: Genie specifications require that this Note: Genie specifications require that this
procedure be performed daily or every 8 hours, procedure be performed daily or every 8 hours,
whichever comes first. whichever comes first.
Proper axle oscillation is essential to safe machine Maintaining tracks and track assembly components
operation. If the axle oscillation system is not is essential to safe operation and good
operating correctly, the stability of the machine is performance. A track assembly failure could result
compromised and it may tip over. in a machine tip-over. Component damage may
also result if problems are not discovered and
1 Start the engine from the platform controls. repaired in a timely fashion.
2 Drive the right steer tire or track (if equipped) up 1 Thoroughly clean the track assembly of any dirt,
onto a 6 inch / 15 cm block or curb. rocks, clay, etc.
Result: The three remaining tires or tracks (if 2 Inspect the following areas for damaged,
equipped) should stay in firm contact with the cracked, loose or missing parts and fasteners:
ground and the chassis should remain level at
all times. • Track
3 Drive the left steer tire or track (if equipped) up • Idler wheels
onto a 6 inch / 15 cm block or curb. • Drive sprocket and hub
Result: The three remaining tires or tracks (if • Bogey wheels
equipped) should stay in firm contact with the • Undercarriage
ground and the chassis should remain level at
• Rotation limiter brackets attached to axles
all times.
• Track assembly fasteners
4 Drive both steer tires or tracks (if equipped) up
onto a 6 inch / 15 cm block or curb.
Result: The non-steer tires or tracks (if
equipped) should stay in firm contact with the
ground.
Note: If the chassis does not remain level during
test, refer to Repair Procedure 7-6, How to Set Up
the Oscillate Directional Valve.
A-8 A-9
Perform 30 Day Service Check the Track Tension and
Fastener Torque, S-60 TRAX and
S-65 TRAX
The 30 day maintenance procedure is a one time
sequence of procedures to be performed after the
first 30 days or 40 hours of usage, whichever
comes first. After this interval, refer to the Note: Manufacturer specifications require that this
maintenance tables for continued scheduled procedure be performed every 30 days.
maintenance.
Maintaining proper track tension and properly
1 Perform the following maintenance procedures: torqued fasteners is essential to good machine
performance and service life. The machine will not
• A-10 Perform Engine Maintenance - operate properly with a track that is incorrectly
Ford and Perkins Models tensioned. Continued use of a machine with
• A-13 Grease the Turntable Bearing and incorrectly tensioned tracks may cause component
Rotate Gear damage.
• B-6 Inspect the Tires, Wheels and 1 Thoroughly clean the track assembly of any dirt,
Lug Nut Torque, S-60, S-65 and rocks, clay, etc.
S-60 HC
2 Chock the tracks at one end of the machine to
• B-8 Check the Drive Hub Oil Level and prevent the machine from rolling.
Fastener Torque
3 Center a lifting jack of ample capacity
• C-1 Perform Engine Maintenance -
(20,000 lbs / 10,000 kg) under the drive chassis
Deutz Models
between the tracks at the other end of the
• D-2 Check the Turnable Rotation machine.
Bearing Bolts
4 Lift the machine until the tracks are off the
• D-6 Replace the Hydraulic Filters ground and then place jack stands under the
drive chassis for support.
5 Visually inspect the section of track under the 7 Locate the grease zerk fitting on the other side
bogey wheels. of the track tension cylinder.
Result: There should be less than 1 inch / 8 Pump grease into the grease zerk fitting until
2.5 cm of gap between the bogey wheels and grease, free from air, comes out of the grease
the inside surface of the track. Proceed to step plug. Securely tighten the grease plug. Do not
12. overtighten.
Result: There is 1 inch / 2.5 cm or more of gap 9 Continue to pump grease into the grease zerk
between the bogey wheels and the inside fitting just until the idler wheel moves. Check
surface of the track. Proceed to step 6. the track tension.
10 If necessary, continue to pump grease into the
cylinder until the track has proper tension.
Component damage hazard.
Do not over tighten the track.
Overtightening the track will cause
the machine to lose power during
operation.
Note: If the track becomes too tight, loosen the
grease plug on the cylinder to remove grease and
loosen the track.
11 Clean up any grease that may have spilled.
a 12 Check the torque of the track assembly

fasteners. Refer to Section 2, Specifications.
a bogey wheels
13 Raise the machine, remove the jack stands and
6 Locate the grease plug on the track tension lower the machine.
cylinder. Loosen the plug, but do not remove it.
14 Repeat this procedure for each track assembly.
Outside Inside
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent.
a b
a grease zerk
b grease plug
A-10 A-11
Perform Engine Maintenance - Inspect the Fuel Filter/Water
Ford and Perkins Models Separator - Diesel Models
Note: Engine specifications require that this Note: Genie specifications require that this
procedure be performed every 100 hours. Perform procedure be performed every 100 hours or
this procedure more often if dusty conditions exist monthly, whichever comes first.
or the machine is subjected to extended low idle
operation. Proper maintenance of the fuel filter/water separator
is essential for good engine performance. Failure to
Proper engine maintenance, following the engine perform this procedure can lead to poor engine
manufacturer's maintenance schedule, is essential performance and/or hard starting, and continued
to good engine performance and service life. Failure use may result in component damge. Extremely
to perform the maintenance procedures can lead to dirty conditions may require this procedure be
poor engine performance and component damage. performed more often.
Required maintenance procedures and additional Explosion and fire hazard. Engine
engine information are available in the fuels are combustible. Perform this
Ford DSG-423 EFI Operator Handbook procedure in an open, well-
(EDI part number 1060020) OR the ventilated area away from heaters,
Perkins 400 Series Operation Manual sparks, flames and lighted
(Perkins part number TPD 1443S) . tobacco. Always have an approved
fire extinguisher within easy reach.
Ford DSG 423 EFI Operator Handbook Note: Perform this procedure with the engine off.
Genie part number 119488
Perkins Models:
Perkins 400 Series Operation Manual
Genie part number 94890 1 Put on protective clothing and eye wear.
2 Open the engine side turntable cover and locate
the fuel filter/water separator next to the
hydraulic return filter on the bulkhead.
3 Inspect the filter bowl for water buildup.
Result: If water is present in the filter bowl
continue with steps 4 through 8.
4 Loosen the vent plug located on the fuel filter/ 8 Start the engine from the ground controls and
water separator head. check the fuel filter/water separator and vent
plug for leaks.
Explosion and fire hazard. If a fuel
a
leak is discovered, keep any
d additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
c
Deutz Models:
b
1 Put on protective clothing and eye wear.
2 Remove the engine tray retaining fastener
located under the engine tray.Swing the engine
tray out and away from the machine.
a vent plug
b drain plug 3 Install the fastener that was just removed
c filter bowl through the engine tray and into the engine tray
d separator head
anchor hole in the turntable.
5 Loosen the drain plug located at the bottom of
Crushing hazard. Failure to install
the bowl. Allow the water to drain into a suitable
the fastener into the engine tray
container until fuel starts to come out.
anchor hole to secure the engine
Immediately tighten the drain plug.
tray from moving could result in
6 Tighten the vent plug. death or serious injury.
Note: If the fuel filter/water separator is completely 4 Locate the fuel filter/water separator next to the
drained, you must prime the fuel filter/water oil filter.
separator before starting the engine. See C-6,
Replace The Fuel Filter/Water Separator Element -
Perkins Models, for instructions on how to prime
the fuel filter/water separator.
7 Clean up any fuel that may have spilled.
5 Loosen the drain plug located at the bottom of A-12

the filter. Allow the water to drain into a suitable
container until fuel starts to come out. Check and Adjust the
Immediately tighten the drain plug. Engine RPM - Perkins Models
Note: Do not completely drain the filter.
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
a performance and service life. The machine will not
operate properly if the rpm is incorrect and
b continued use may cause component damage.
Note: This procedure will require two people.
1 Connect a tachometer to the engine. Start the

a fuel filter/water separator engine from the ground controls and check the
b drain valve rpm. Refer to Section 2, Specifications.
6 Clean up any fuel that may have spilled. Skip to step 3 if the low idle rpm is correct.
7 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
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.
8 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener.
2 Loosen the low idle lock nut and turn the low idle A-13
adjustment screw clockwise to increase the
rpm, or counterclockwise to decrease the rpm. Grease the Turntable Rotation
Tighten the low idle lock nut and confirm the Bearing and Rotate Gear
rpm.
Note: Genie specifications require that this

procedure be performed every 100 hours of
operation. Perform this procedure more often if
dusty conditions exist.
Frequent application of lubrication to the turntable
bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.
1 Locate the grease fitting on the front turntable

cover.
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of 4 to 5
a b c d inches / 10 to 13 cm at a time and repeat this
a solenoid boot step until the entire bearing has been greased.
b high idle adjustment nut
c yoke
3 Apply grease to each tooth of the drive gear,
d low idle lock nut and adjustment located under the turntable.
screw
3 Move the function enable toggle switch to the
high idle (rabbit symbol) position and note the
rpm. Refer to Section 2, Specifications.
or equivalent
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.
A-14 S-60 TRAX and S-65 TRAX:

Replace the Drive Hub Oil 1 Select the drive hub to be serviced. Loosen and
remove as many sprocket retaining fasteners as
possible from the hub adapter.
2 Drive the machine in either direction just enough
Note: Manufacturer drive hub specifications require to access the remaining fasteners. Do not
that this one-time procedure be performed after the remove the retaining fasteners.
first 150 hours.
3 Chock the tracks at the opposite end of the
Replacing the drive hub oil is essential for good machine to prevent the machine from rolling.
machine performance and service life. Failure to
replace the drive hub oil after the first 150 hours of
use may cause the machine to perform poorly and
between the tracks.
continued use may cause component damage.
S-60, S-65 and S-60 HC:
ground and then place jack stands under the
1 Select the drive hub to be serviced. Drive the drive chassis for support.
machine until one of the two plugs is at the 6 Attach a lifting strap from an overhead crane to
lowest point. the center-point of the track assembly, above
2 Remove both plugs and drain the oil into a the sprocket.
suitable container. 7 Remove the remaining sprocket retaining
3 Drive the machine until both plugs are fasteners from the hub adapter.
horizontal. 8 Carefully remove the track assembly from the
drive hub and set aside.
a
Crushing hazard. The track
assembly could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.
a drive hub plugs
4 Fill the hub until the oil level is even with the
bottom of the plug hole. Refer to Section 2,
Specifications.
5 Install the plugs into the drive hub.
6 Repeat this procedure for the other drive hub.
9 Locate the hub disconnect pin in the center of 16 Raise the machine, remove the jack stands and
the drive hub. Manually depress the pin and lower the machine.
rotate the drive hub until one of the two plugs is
17 Drive the machine in either direction just until
at the lowest point.
the remaining sprocket retaining fasteners can
be installed onto the drive hub adapter. Turn the
machine off.
18 Install the remaining sprocket retaining fasteners
to the drive hub adapter and torque to
specification. Refer to Section 2, Specifications.
19 Repeat this procedure for each drive hub.
a
a drive hub plugs
10 Remove both plugs and drain the oil into a

suitable container.
11 Manually depress the hub disconnect pin and
rotate the drive hub until both plugs are
hoizontal.
bottom of the side plug hole. Refer to Section 2,
Specifications.
14 Attach a lifting strap from an overhead crane to
the center-point of the track assembly, above
the sprocket.
15 Install the track assembly onto the drive hub
adapter while guiding the hub adapter studs into
the sprocket of the track assembly. Install as
many sprocket retaining fasteners as possible
to the hub adapter and torque to specification.
Refer to Section 2, Specifications.
A-15 A-16
Perform Engine Maintenance - Perform Engine Maintenance -
Ford Models Perkins Models
Note: Engine specifications require that this Note: Engine specifications require that this
procedure be performed every 200 hours. procedure be performed every 200 hours.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure to good engine performance and service life. Failure
to perform the maintenance procedures can lead to to perform the maintenance procedures can lead to
poor engine performance and component damage. poor engine performance and component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
Ford DSG-423 EFI Operator Handbook Perkins 400 Series Operation Manual
(EDI part number 1060020). (Perkins part number TPD 1443S).
Ford DSG 423 EFI Operator Handbook Perkins 400 Series Operation Manual
Genie part number 119488 Genie part number 94890
Checklist B Procedures REV C
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.
REV C 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
death or serious injury.
CHECKLIST B PROCEDURES REV C
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.
B-4 B-5
Inspect the Engine Air Filter - Check the Oil Cooler and
Ford, Deutz and Perkins Models Cooling Fins - Deutz Models
procedure be performed every 250 hours or procedure be performed every 250 hours or
quarterly, whichever comes first. quarterly, whichever comes first.
Maintaining the engine air filter in good condition is Maintaining the oil cooler in good condition is
essential to good engine performance and service essential for good engine performance. Operating a
life. Failure to perform this procedure can lead to machine with a damaged oil cooler may result in
poor engine performance and component damage. engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
Note: Perform this procedure with the engine off. cooling system.
1 Locate the engine air filter assembly. Bodily injury hazard. Do not
2 Release the latches from the air cleaner canister inspect while the engine
end cap. Remove the end cap. is running. Remove the key to
secure from operation.
3 Remove the filter element.
Burn hazard. Beware of hot engine
4 Clean the inside of the canister and the end cap components. Contact with hot
with a damp cloth. engine components may result in
5 Inspect the air filter element. If needed, blow severe burns.
from the inside out using low pressure dry Oil cooler:
compressed air, or carefully tap out dust.
Replace the filter if needed. 1 Remove the engine tray retaining fastener
6 Install the filter element. tray out and away from the machine.
7 Install the air filter canister end cap and secure 2 Install the fastener that was just removed
the end cap latches. through the engine tray and into the engine tray
Note: Be sure the discharge valve is pointing down anchor hole in the turntable.
when the cap is instaled. Crushing hazard. Failure to install
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, S-60, S-65 and
S-60 HC
a b c

procedure be performed every 250 hours or
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.
a oil cooler
b cylinder head cooling fins Bodily injury hazard. An over-
c fan blower fins inflated tire can explode and could
cause death or serious injury.
5 Clean the oil cooler of debris and foreign
material. Tip-over hazard. Do not use
temporary flat tire repair products.
Cooling and fan blower fins:
Note: The tires on some machines are foam-filled
6 Inspect the fan blower fins for physical damage. and do not need air added to them.
7 Clean the fan blower fins of debris and foreign
1 Check all tire treads and sidewalls for cuts,
material.
cracks, punctures and unusual wear.
8 Inspect the head cooling passages and fins for
2 Check each wheel for damage, bends and
physical damage or foreign material, using a
cracked welds.
flashlight.
3 Check each lug nut for proper torque.
9 Clean the cylinder head cooling passages of
debris and foreign material.
4 Check the pressure in each air-filled tire.
10 Install the engine side cover.
and install the engine pivot plate retaining
fastener.
B-7 B-8
Confirm the Proper Check the Drive Hub Oil Level
Brake Configuration and Fastener Torque
procedure be performed every 250 hours or procedure be performed every 250 hours or
quarterly, whichever comes first. quarterly, whichever comes first.
Proper brake configuration is essential to safe Failure to maintain proper drive hub oil levels may
operation and good machine performance. cause the machine to perform poorly and continued
Hydrostatic brakes and hydraulically-released, use may cause component damage.
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully S-60, S-65 and S-60 HC:
operational. 1 Drive the machine to rotate the hub until the
1 Locate the drive hub disconnect cap. plugs are both horizontal.
a
S-60, S-65, S-60 HC S-60 TRAX, S-65 TRAX
a drive hub plugs
2 Remove one plug and check the oil level.

a
Result: The oil level should be even with the
a drive hub disconnect cap bottom of the plug hole.
2 Check each drive hub disconnect cap to be sure 3 If necessary, remove the other plug and add oil
it is in the engaged position. until the oil level is even with the bottom of the
plug hole.
brake disengaged position 4 Install the plug(s) into the drive hub.
5 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
brake engaged position
S-60 TRAX and S-65 TRAX: 9 Locate the hub disconnect pin in the center of
the drive hub. Manually depress the pin and
1 Select the drive hub to be serviced. Loosen and rotate the drive hub until the plugs are both
remove as many sprocket retaining fasteners as horizontal.
to access the remaining fasteners. Do not
remove the retaining fasteners.
machine to prevent the machine from rolling.
between the tracks.
a
drive chassis for support. a drive hub plugs
6 Attach a lifting strap from an overhead crane to 10 Remove one plug and check the oil level.
Result: The oil level should be even with the
the sprocket.
bottom of the plug hole.
7 Remove the remaining sprocket retaining
fasteners from the hub adapter. 11 If necessary, remove the other plug and add oil
until the oil level is even with the bottom of the
8 Carefully remove the track assembly from the plug hole. Refer to Section 2, Specifications.
12 Install the plug(s) into the drive hub.
from the machine if not properly 14 Attach a lifting strap from an overhead crane to
supported by the overhead crane. the center-point of the track assembly, above
the sprocket.
15 Install the track assembly onto the drive hub Turntable rotate drive hub
the sprocket of the track assembly. Install as 1 Remove the plug located on the side of the hub
many sprocket retaining fasteners as possible and check the oil level.
to the hub adapter and torque to specification. Result: The oil level should be even with the
Refer to Section 2, Specifications. bottom of the plug hole.
lower the machine.
machine off.
a
b
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.
B-9 Skip to step 5 if the low idle rpm is correct.

Check and Adjust the 4 Loosen the low idle lock nut, then turn the low
Engine RPM - Ford and Deutz idle adjustment screw clockwise to increase the
rpm or counterclockwise to decrease the rpm.
Models Tighten the low idle lock nut and recheck the
rpm.

f
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine e
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.
Ford models:
a b c d
Note: The engine rpm is controlled by the ECM and
can only be adjusted by re-programming the ECM. a solenoid boot
b high idle adjustment nut
If rpm adjustment or service is required, please c yoke lock nut
contact Genie Industries Service Department OR d yoke
your local Ford dealer. e low idle adjustment screw
f low idle lock nut
Deutz models:
5 Move the function enable/rpm select toggle
Note: This procedure will require two people. switch to the high idle (rabbit symbol) position at
the ground controls and check the rpm. Refer to
1 Remove the engine tray retaining fastener Section 2, Specifications.
tray out and away from the machine. If high idle rpm is correct, disregard adjustment
step 6.
through the engine tray and into the engine tray 6 Loosen the yoke lock nut, then turn the high idle
anchor hole in the turntable. 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.
tray from moving could result in Note: Be sure the solenoid fully retracts when
death or serious injury. activating high idle.
3 Connect a tachometer to the engine, and then 7 Swing the engine back to its original position
start the engine from the ground controls and and install the engine pivot plate retaining
check the rpm. Refer to Section 2, fastener.
Specifications.
B-10 B-11
Test the Ground Control Check the Oscillate Directional
Override Valve Linkage
A properly functioning ground control override is procedure be performed every 250 hours or
essential to safe machine operation. The ground quarterly, whichever comes first.
control override function is intended to allow ground
personnel to operate the machine from the ground Note: Perform this test only on models equipped
controls whether or not the Emergency Stop button with a oscillating axle.
on the platform controls is in the on or off position. Proper axle oscillation is essential to safe machine
This function is particularly useful if the operator at operation. If the oscillate directional valve linkage is
the platform controls cannot return the boom to the not operating correctly, the stability of the machine
stowed position. is compromised and it may tip over.
1 Push in the platform red Emergency Stop button 1 Remove the drive chassis cover from the
to the off position. non-steer end of the machine.
2 Start the engine from the ground controls. 2 Locate the oscillate directional valve inside of
3 At the ground controls, operate each boom the non-steer axle and inspect the linkage for
function through a partial cycle. the following:
Result: All boom functions should operate. • Lock nut is tight against yoke
• Yoke clevis pins are installed
• Cotter pins are installed through clevis pins
• Linkage is properly attached to
directional valve
B-12 B-13
Test the Platform Self-leveling Test the Engine Idle Select
procedure be performed every 250 hours or A properly operating engine idle select switch
quarterly, whichever comes first. is essential to good engine performance and safe
machine operation. There are two settings.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is Foot switch activated low idle (turtle symbol)
essential for safe machine operation. The allows the operator to control individual boom
platform is maintained at level by the platform functions.
leveling slave cylinder which operates in a closed
loop hydraulic circuit with the master cylinder Foot switch activated high idle (rabbit symbol)
located at the base of the boom. should be used for normal machine operation. This
A platform self-leveling failure creates an unsafe selection activates high idle only when the foot
working condition for platform and ground switch is pressed down.
personnel. 1 Pull out the red Emergency Stop button to the
1 Start the engine from the ground controls and on position at both the ground and platform
lower the boom into the stowed position. controls.
2 Hold the function enable/rpm select toggle 2 Start the engine from the ground controls then
switch to either side and adjust the platform to a move and hold the function enable/rpm select
level position using the platform level toggle toggle switch to the high idle (rabbit symbol).
switch. Result: The engine should change to high idle.
3 Raise and lower the primary boom through 3 Release the function enable/rpm select toggle
a full cycle. switch.
Result: The platform should remain level at Result: The engine should return to low idle.
all times to within ±5 degrees.
4 Turn the key switch to platform controls.
5 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Result: The engine should not change to
high idle.
6 Press down the foot switch.
Result: The engine should change to high idle.
7 Move the engine idle control switch to foot
switch activated low idle (turtle symbol).
Result: The engine should change to low idle.
B-14 4 Release the foot switch and shut the engine off
by pushing in the red Emergency Stop button in
Test the Fuel Select Operation - to the off position.
Ford Models 5 Move the fuel select switch to LPG.
6 Restart the engine and allow it to run at
low idle.
Note: Genie specifications require that this 7 Press down the foot switch to allow the engine
procedure be performed every 250 hours or to run at high idle.
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.
B-15 B-16
Test the Drive Brakes Test the Drive Speed -
Stowed Position

Proper brake action is essential to safe machine quarterly, whichever comes first.
operation. The drive brake function should operate
Proper drive function movement is essential to safe
smoothly, free of hesitation, jerking and unusual
machine operation. The drive function should
noise. Hydrostatic brakes and hydraulically-
respond quickly and smoothly to operator control.
released individual wheel brakes can appear to
Drive performance should also be free of hesitation,
operate normally when they are actually not fully
jerking and unusual noise over the entire
operational.
proportionally controlled speed range.
Collision hazard. Be sure that the
Note: Select a test area that is firm, level and free
machine is not in free-wheel or
of obstructions.
partial free-wheel configuration.
See B-7, Confirm the Proper Brake 1 Create start and finish lines by marking two lines
Configuration. on the ground 40 feet / 12.2 m apart.
Note: Select a test area that is firm, level and free 2 Start the engine from the platform controls.
of obstructions.
3 Move the engine idle control switch to
1 Mark a test line on the ground for reference. foot switch activated high idle (rabbit and foot
switch symbol), then lower the boom into the
2 Start the engine from the platform controls.
stowed position.
3 Move the engine idle control switch to
4 Choose a point on the machine; i.e., contact
foot switch activated high idle (rabbit and
patch of a tire, as a visual reference for use
foot switch symbol), then lower the boom into
when crossing the start and finish lines.
the stowed position.
5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
when crossing the test line.
start line.
6 Continue at full speed and note the time when
reaching the test line. Release the drive joystick
the machine reference point crosses the finish
when your reference point on the machine
line. Refer to Section 2, Specifications.
crosses the test line.
6 Measure the distance between the test line and
your machine reference point. Refer to
Section 2, Specifications.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
B-17 7 Continue at full speed and note the time when

the machine reference point crosses the finish
Test the Drive Speed - line. Refer to Section 2, Specifications.
Raised or Extended Position 8 Lower the boom to the stowed position and
extend the boom 1 foot / 30 cm.
quarterly, whichever comes first. 10 Bring the machine to top drive speed before
Proper drive function movement is essential to safe reference point on the machine crosses the
machine operation. The drive function should start line.
respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation, 11 Continue at top speed and note the time when
jerking and unusual noise over the entire the machine reference point crosses the finish
proportionally controlled speed range. line. Refer to Section 2, Specifications.
Note: Select a test area that is firm, level and free

of obstructions.
1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
3 Move the engine idle select switch to foot switch
activated high idle (rabbit and foot switch
symbol).
4 Press down the foot switch and raise the
primary boom above horizontal.
reference point on the machine crosses the
start line.
B-18 3 S-65 and S-65 TRAX: Move the function enable/

rpm select toggle switch to either side and
Test the Alarm Package - activate the jib boom toggle switch in the down
Optional Equipment position, hold for a moment and then release it.
Note: Genie specifications require that this Result: The descent alarm should sound when
procedure be performed every 250 hours or the switch is held down.
quarterly, whichever comes first. 4 Turn the key switch to platform control.
The alarm package includes: Result: The flashing beacon should be on
• Travel alarm and flashing.
• Flashing beacon 5 Press down the foot switch. Move the boom
control handle to the down position, hold for a
Note: The descent alarm is standard equipment on
moment and then release it.
all models after serial number 15908.
Result: The descent alarm should sound when
Alarms and a beacon are installed to alert operators the control handle is held down.
and ground personnel of machine proximity and
motion. The alarm package is installed on the 6 S-65 and S-65 TRAX: Press down the foot
turntable covers. switch. Move the jib boom toggle switch to the
down position, hold for a moment and then
Note: The alarms and beacon will operate with the release it.
engine running or not running.
1 Turn the key switch to ground control and pull the control handle is held down.
out the red Emergency Stop button to the on
position at both the ground and platform 7 Press down the foot switch. Move the drive
controls. control handle off center, hold for a moment and
then release it. Move the drive control handle off
Result: The flashing beacon should be on and center in the opposite direction, hold for a
flashing. moment and then release it.
2 Move the function enable/rpm select toggle Result: The travel alarm should sound when the
switch to either side and activate the boom drive control handle is moved off center in either
toggle switch in the down position, hold for a direction.
moment and then release it.
the switch is held down.
B-19 B-20
Perform Hydraulic Oil Analysis Inspect the Fuel and Hydraulic
Tank Cap Venting Systems

Note: Genie requires that this procedure be
performed every 250 hours or quarterly, whichever
Replacement or testing of the hydraulic oil is comes first. Perform this procedure more often if
essential for good machine performance and dusty conditions exist.
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and Free-breathing fuel and hydraulic tank caps are
continued use may cause component damage. essential for good machine performance and
Extremely dirty conditions may require oil changes service life. A dirty or clogged tank cap may cause
to be performed more often. For hydraulic oil the machine to perform poorly and continued use
specifications, refer to Section 2, Specifications. may cause component damage. Extremely dirty
conditions may require that the caps be inspected
Note: Before replacing the hydraulic oil, the oil may more often.
be tested by an oil distributor for specific levels of
Explosion and fire hazard. Engine
contamination to verify that changing the oil is
fuels are combustible. Perform this
necessary. If the hydraulic oil is not replaced at
procedure in an open, well-
the two year inspection, test the oil quarterly.
ventilated area away from heaters,
Replace the oil when it fails the test.
sparks, flames and lighted
See E-1, Test or Replace the Hydraulic Oil.
tobacco. Always have an approved
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.
3 Using a mild solvent, carefully wash the cap B-21

venting system. Dry using low pressure
compressed air. Repeat this procedure Replace the Fuel Filter Element -
beginning with step 2. Perkins Models
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank. Note: Engine specifications require that this
6 Check for proper venting. procedure be performed every 250 hours or
Result: Air passes through the fuel tank cap.
Proceed to step 8. Replacing the diesel fuel filter element is essential
for good engine performance and service life. A
Result: If air does not pass through the cap, dirty or clogged filter may cause the engine to
clean or replace the cap. Proceed to step 7. perform poorly and continued use may cause
Note: When checking for positive tank cap venting, component damage. Extremely dirty conditions
air should pass freely through the cap. may required that the filter be replaced more often.
7 Using a mild solvent, carefully wash the cap Explosion and fire hazard. Engine
venting system. Dry using low pressure fuels are combustible. Perform this
compressed air. Repeat this procedure procedure in an open, well-
beginning with step 6. ventilated area away from heaters,
sparks, flames and lighted
8 Install the breather cap onto the hydraulic tank. tobacco. Always have an approved

3 Thoroughly clean the outside surfaces of the Bleed the fuel system:
fuel filter assembly.
10 Loosen the vent plug on top of the fuel injection
4 Place a suitable container under the fuel filter pump.
element.
5 Disconnect and plug the fuel line from the fuel
pump to the fuel filter element.
a
c b
a
a vent plug
b fuel injection pump
c fuel lift pump
a fuel line
b filter head
c fuel filter element 11 Operate the priming lever or priming bulb (if
equipped) of the fuel lift pump until fuel, free
6 Remove the fuel filter element with a filter from air, comes from the vent plug. Tighten the
wrench. vent plug.
7 Apply a thin layer of fuel to the new fuel filter 12 Clean up any fuel that may have spilled during
element O-ring. this procedure.
8 Install the new fuel filter element and tighten it 13 Operate the starter motor for intervals of 15
securely by hand. Clean up any fuel that may seconds until the engine starts.
have spilled during the installation procedure.
9 Use a permanent ink marker to write the date and install the engine pivot plate retaining
and number of hours from the hour meter on the fastener.
oil filter housing.
Note: It is important to allow the starter motor to
cool for 30 seconds between each 15 second
interval of operation.
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.
B-22 4 Remove the retaining fasteners from the access

covers located on the side of the boom at the
Inspect the Boom platform end of the machine. Remove the
Extend/Retract Cables covers.
5 Visually inspect the cables and components
through both inspection holes for the following:
• Frayed or broken wire strands
procedure be performed every 250 hours or • Kinks in the cables
quarterly, whichever comes first. • Corrosion
The boom extend/retract cables are responsible for • Paint or foreign materials on the cable
the extension and retraction of the number 3 boom • Split or cracked cable ends
tube. Inspecting for foreign objects, damage and/or
improper adjustment of the boom extend/retract • Cables are on all pulleys
cables and related components on a regular basis • Extend cable break limit switch arm is
is essential to good machine performance and safe centered in the pivot plate
machine operation. The boom extend and retract • Cables have equal tension
functions should operate smoothly and be free of
hesitation, jerking and unusual noise. • Cables at end of adjustment range
• No broken or damaged pulleys
1 Raise the boom to horizontal and fully extend
the boom. • No unusual or excessive pulley wear
• All fasteners in place and secure
2 After the boom is fully extended, lower the boom
until the platform is at chest height. Turn the • S-60 HC: String potentiometer cable break
machine off. limit switch arm is securely attached to end
of cable
3 S-60, S-65, S-60 TRAX and S-65 TRAX:
Remove the boom end cover retaining fasteners Note: A flashlight and inspection mirror may be
and remove the cover. necessary to thoroughly inspect the above items.
S-60 HC: Remove the boom end cover from the Note: A pulley groove gauge should be used to
pivot end of the boom while guiding the small check the condition of the pulleys.
cable from the string potentiometer out of the
slot of the cover. Rest the cover and string
potentiometer on the counterweight.
Component damage hazard. The
cable from the string potentiometer
can become damaged if it is
kinked or pinched.
6 S-60, S-65, S-60 TRAX and S-65 TRAX: Install B-23

the cover at the pivot end of the boom.
Perform Engine Maintenance -
S-60 HC: Install the boom end cover at the pivot
end of the boom while guiding the small cable
Deutz Models
from the string potentiometer into the slot of the
cover.
Component damage hazard. The Note: Engine specifications require that this
cable from the string potentiometer procedure be performed every 400 hours.
kinked or pinched. Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
Note: Be sure the cable from the string
to good engine performance and service life. Failure
potentiometer is correctly routed around the small
to perform the maintenance procedures can lead to
pulley before installing the boom end cover.
poor engine performance and component damage.
7 Install the access panels on the sides of the
Required maintenance procedures and additional
boom.
engine information are available in the
8 Start the engine from the ground controls and Deutz FL 2011 Operation Manual
fully retract and lower the boom to the stowed (Deutz part number 0297-9929).
position.
9 Turn the key switch to the platform controls. Deutz FL 2011 Operation Manual
10 Extend the boom approximately 2 feet / 0.6 m.
11 Retract the boom. While retracting the boom,
visually inspect the number 2 and number 3
boom tubes.
Result: The number 2 boom tube should not
move more than 1/2 inch / 13 mm before the
number 3 boom tube begins to retract.
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.
B-24 B-25
Perform Engine Maintenance - Replace the Engine Air Filter
Ford Models Element - Ford Models
procedure be performed every 400 hours. procedure be performed every 400 hours.
Proper engine maintenance, following the engine Maintaining the engine air filter in good condition is
manufacturer's maintenance schedule, is essential essential to good engine performance and service
to good engine performance and service life. Failure life. Failure to perform this procedure can lead to
to perform the maintenance procedures can lead to poor engine performance and component damage.
engine information are available in the 1 Locate the engine air filter assembly.
Ford DSG-423 EFI Operator Handbook 2 Release the latches from the air cleaner canister
(EDI part number 1060020). end cap. Remove the end cap.
3 Remove and discard the filter element.
Genie part number 119488 4 Clean the inside of the canister and the end cap
with a damp cloth.
5 Install the new filter element.
6 Install the air filter canister end cap and secure
the end cap latches.
Note: Be sure the discharge valve is pointing down
when the cap is instaled.
B-26
Perkins Models

Proper engine maintenance, following the engine

(Perkins part number TPD 1443S).

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

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.

or equivalent
REV B CHECKLIST C PROCEDURES
C-3 Models equipped with the platform overload option

are provided with additional machine components:
Test the Platform Overload an adjustable spring-loaded platform support
System (if equipped), S-60, S-65, subassembly, a limit switch, an electronic module
which receives the overload signal and interrupts
S-60 TRAX and S-65 TRAX power, and an audio/visual warning indication to
alert the operator of the overload.
The platform support subassembly utilizes two load
Note: Genie specifications require that this support arms that are opposed in a full
procedure be performed every 500 hours or six parallelogram link. This isolates platform loads into
months, whichever comes first. a shear or vertical state, which translates into a
compressive load. A spring in the parallelogram link
Testing the platform overload system regularly is supports this purely compressive load regardless of
essential to safe machine operation. Continued use where the load is placed in the platform.
of an improperly operating platform overload
system could result in the system not sensing an As weight is added to the platform, the spring will
overloaded platform condition. Machine stablity compress until, when the platform is overloaded,
could be compromised resulting in the machine the lower arm contacts a limit switch and thereby
tipping over. activating the overload signal. When adjusted
correctly, the platform overload system will
The platform overload system is designed to detect deactivate normal boom operation at platform
an overloaded platform and prevent machine capacity.
operation anytime the machine is turned on. When
activated, the system halts all normal boom Note: Perform this procedure with the boom fully
operation, giving visual and audible warning to the retracted and in the stowed position and with the
operator. machine on a firm, level surface.
1 Remove all weight, tools and equipment from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.
2 Turn the key switch to ground control and pull

position at both the ground and platform
controls. Start the engine from the ground
controls and level the platform. Do not turn the
engine off.
CHECKLIST C PROCEDURES REV B
3 Start the engine from the ground controls and 7 Using a suitable lifting device, place an
level the platform. Do not turn the engine off. additional 50 lbs / 23 kg of weight onto the
platform.
4 Determine the maximum platform capacity.
Refer to the machine serial plate. Result: The alarm should sound.
The platform overload indicator lights should be
5 Using a suitable lifting device, place a test
flashing at both the ground and platform
weight equal to that of the available capacity in
controls.
one of the locations shown.
Refer to Illustration 1. Result: The alarm does not sound and the
platform overload indicator lights are not
Result: The platform overload indicator lights
flashing. Calibrate the platform overload
should be off at both the ground and platform
system. Refer to Repair Proceedure 2-3,
controls and the alarm should not sound.
How to Calibrate the Platform Overload System
Result: The platform overload indicator lights are (if equipped), S-60, S-65, S-60 TRAX and
on and the alarm is sounding. Calibrate the S-65 TRAX.
platform overload system. Refer to Repair
Note: There may be a 2 second delay before the
Proceedure 2-3, How to Calibrate the Platform
overload indicator lights flash and the alarm
Overload System (if equipped), S-60, S-65,
sounds.
S-60 TRAX and S-65 TRAX.
6 Carefully move the test weight to each 8 Carefully move the test weights to each
remaining location. Refer to Illustration 1. remaining location on the platform.
Refer to Illustration 1.
Result: The alarm should sound.
should be off at both the ground and platform
controls and the alarm should not sound. The platform overload indicator lights should be
flashing at both the ground and platform
Result: The platform overload indicator lights are controls.
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair Result: The alarm does not sound and the
Proceedure 2-3, How to Calibrate the Platform platform overload indicator lights are not
Overload System (if equipped), S-60, S-65, flashing. Calibrate the platform overload
S-60 TRAX and S-65 TRAX. system. Refer to Repair Proceedure 2-3,
How to Calibrate the Platform Overload System
(if equipped), S-60, S-65, S-60 TRAX and
S-65 TRAX.
overload indicator lights flash and the alarm
sounds.
Illustration 1
9 Test all machine functions from the platform 17 Test all machine functions from the platform
controls. controls.
Result: All platform control functions should not Result: All platform control functions should
operate. operate.
10 Turn the key switch to ground control. Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-3,
11 Test all machine functions from the ground
How to Calibrate the Platform Overload System (if
controls.
equipped), S-60, S-65, S-60 TRAX and S-65 TRAX.
Result: All ground control functions should not
18 Using a suitable lifting device, remove the
operate.
remaining test weights from the platform.
12 Activate the auxiliary power toggle switch.
Note: The engine will turn off when the auxiliary
power is activated.
13 Using auxiliary power, test all machine functions

from the ground controls.
Result: All ground control functions should
operate.
14 Using a suitable lifting device, lift the additional
test weight from the platform.
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.
15 Start the engine and test all machine functions

from the ground controls.
Result: All ground control functions should
operate normally.
16 Turn the key switch to platform control.
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 overload 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 overload 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.
inaccurate test.
2 Turn the key switch to ground control and pull 6 Using a suitable lifting device, remove the test
out the red Emergency Stop button to the on weights from the platform.
position at both the ground and platform
7 Push in the ground controls red Emergency Stop
controls.
button to the off position, then pull the red
3 Start the engine from the ground controls. Emergency Stop button out to the on position to
Do not turn the engine off. reset the control system.
4 Using a suitable lifting device, place an Recovery process from the platform controls:
appropriate test weight equal to 750 lbs /
340.2 kg on to the center of the platform floor. Note: This procedure only operates if the platform
is overloaded or enters the safety envelope.
Result: The amber restricted range of motion
LED at the platform controls should come on 1 With the key switch turned to platform controls,
and the engine should continue to run. activate the auxiliary power toggle switch.
Result: If the amber restricted range of motion Result: The boom will automatically retract until
LED at the platform controls does not come on, it is in the unrestricted zone.
there is no alarm and the engine continues to 2 Push in the platform controls red Emergency
run, the platform load sense system needs to Stop button to the off position, then pull out the
be calibrated. See Repair Procedure 2-4, red Emergency Stop button to the on position to
How to Calibrate the Platform Load Sense reset the system.
System, S-60 HC.
3 Start the engine and lower the boom to the
5 Using a suitable lifting device, place an stowed position.
additional appropriate test weight equal to
501 to 510 lbs / 227.2 to 231.3 kg on to the Recovery process from the ground controls:
center of the platform floor. The total weight in
Note: This procedure only operates if the platform
the platform must equal 1251 to 1260 lbs /
is overloaded or enters the safety envelope.
567.4 to 571.5 kg.
Result: The alarm should sound and the engine 1 Turn the key switch to ground controls.
should turn off. The platform overload indicator 2 Locate the recovery toggle switch on the side of
light should be on at both the ground and the ground control box. Activate the recovery
platform controls. The platform load sense toggle switch and the auxiliary power toggle
system is functioning properly. switch at the same time.
Result: If the alarm does not sound, the engine Result: The boom will automatically fully retract
does not turn off or the platform indicator light and then lower to the stowed position.
does not come on at both the ground and
platform controls, see Repair Procedure 2-4, 3 Push in the ground controls red Emergency Stop
How to Calibrate the Platform Load Sense button to the off position, then pull out the red
System, S-60 HC. Emergency Stop button to the on position to
reset the system.
Note: The weight in the platform must be
1200 lbs / 544.3 kg or less before the engine can
be restarted.
C-5
a
Replace the Fuel Filter/Water
Separator - Perkins Models f
e b
d
procedure be performed every 500 hours or six c
months, whichever comes first.
Regular replacement of the fuel filter/water

separator is essential for good engine performance.
Failure to perform this procedure can lead to poor a vent plug
engine performance and/or hard starting, and b main fuel line
continued use may result in component damge. c drain plug
Extremely dirty conditions may require this d filter bowl
e filter element
procedure be performed more often. f separator head
Explosion and fire hazard. Engine 4 Place a suitable container under the filter bowl.
fuels are combustible. Perform this Loosen the drain plug located at the bottom of
procedure in an open, well- the bowl. Completely drain the fuel.
ventilated area away from heaters,
sparks, flames and lighted 5 Rotate the filter bowl counterclockwise and
tobacco. Always have an approved remove it from the element.
fire extinguisher within easy reach. 6 Rotate the filter element counterclockwise and
Note: Perform this procedure with the engine off. remove it from the filter head.
1 Open the engine side turntable cover and locate 7 Install the bowl onto the new filter element.
the fuel filter/water separator on the bulkhead. 8 Apply a thin layer of oil onto the element gasket.
2 Disconnect and plug the fuel supply hose from Install the filter/bowl assembly onto the filter
the fuel tank to the fuel filter/water separator. head. Tighten the drain plug and vent plug.
3 Loosen the vent plug located on the fuel filter/

water separator head.
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
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).
2 Release the latches from the air cleaner canister
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.
C-8
Ford Models


Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).

Checklist D Procedures REV B
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.

procedure be performed every 1000 hours or Wear pad specifications Minimum
annually, whichever comes first. 1/2 inch
Top and side wear pads
Maintaining the boom wear pads in good condition (platform end of boom) 12.7 mm
is essential to safe machine operation. Wear pads
Bottom wear pads 5/8 inch
are placed on boom tube surfaces to provide a low
(platform end of boom) 15.9 mm
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued 1/2 inch
Top and side wear pads
use of worn out wear pads may result in component
(pivot end of boom) 12.7 mm
damage and unsafe operating conditions.
Bottom wear pads 5/8 inch
1 Start the engine from the ground controls.
(pivot end of boom) 15.9 mm
2 Raise the end of the primary boom to a
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.
REV B 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.
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 (Genie part number 75097). Bolt torque sequence
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
CHECKLIST D PROCEDURES REV B
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-13, 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.
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.
S-60, S-65 and S-60 HC:
1 Select the drive hub to be serviced. Drive the

machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until both plugs are
horizontal.
a drive hub plugs
Specifications.
S-60 TRAX and S-65 TRAX: 9 Locate the hub disconnect pin in the center of
the drive hub. Manually depress the pin and
1 Select the drive hub to be serviced. Loosen and rotate the drive hub until one of the two plugs is
remove as many sprocket retaining fasteners as at the lowest point.
to access the remaining fasteners. Do not
remove the retaining fasteners.
machine to prevent the machine from rolling.
between the tracks.
5 Lift the machine until the tracks are off the a
a drive hub plugs
drive chassis for support. 10 Remove both plugs and drain the oil into a
suitable container.
the center-point of the track assembly, above 11 Manually depress the hub disconnect pin and
the sprocket. rotate the drive hub until both plugs are
horizontal.
fasteners from the hub adapter. 12 Fill the hub until the oil level is even with the
8 Carefully remove the track assembly from the
Specifications.
assembly could become 14 Check the torque of the drive hub mounting
unbalanced and fall when removed bolts. Refer to Section 2, Specifications.
the sprocket.
16 Install the track assembly onto the drive hub D-5

the sprocket of the track assembly. Install as Check the Free-wheel
many sprocket retaining fasteners as possible Configuration
lower the machine. Note: Genie specifications require that this
annually, whichever comes first.
be installed onto the drive hub adapter. Turn the Proper use of the free-wheel configuration is
machine off. essential to safe machine operation. The
19 Install the remaining sprocket retaining fasteners free-wheel configuration is used primarily for towing.
to the drive hub adapter and torque to A machine configured to free-wheel without operator
specification. Refer to Section 2, Specifications. knowledge may cause death or serious injury and
property damage.
Collision hazard. Select a work site
that is firm and level.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
Non-steer end: All Models
1 Chock the steer wheels or tracks (if equipped) to

prevent the machine from rolling.
between the non-steer tires or tracks.
3 Lift the wheels or tracks off the ground and then
place jack stands under the drive chassis for
support.
4 Disengage the drive hubs by turning over the Steer end: 4WD Models
drive hub disconnect caps on each
non-steer end drive hub. 7 Chock the non-steer wheels or tracks to prevent
the machine from rolling.
S-60, S-65, S-60 HC S-60 TRAX, S-65 TRAX 8 Center a lifting jack of ample capacity
between the steer tires or tracks.
9 Lift the wheels or tracks off the ground and then
place jack stands under the drive chassis for
support.
10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
steer end drive hub.
a S-60, S-65, S-60 HC S-60 TRAX, S-65 TRAX
a drive hub disconnect cap
5 Manually rotate each non-steer wheel or track.

Result: Each non-steer wheel or track should
rotate with minimum effort.
Note: S-60 TRAX and S-65 TRAX: Due to the
additional components of the track system, which
increase rotational friction, the track may not be
able to be rotated manually.
a
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel or a drive hub disconnect cap
track to check for engagement. Lift the machine
11 Manually rotate each steer wheel or track.
and remove the jack stands.
Result: Each steer wheel or track should rotate
Collision hazard. Failure to
with minimum effort.
re-engage the drive hubs could
result in death or serious injury and Note: S-60 TRAX and S-65 TRAX: Due to the
property damage. additional components of the track system, which
increase rotational friction, the track may not be
disengaged position able to be rotated manually.
engaged position
12 Re-engage the drive hubs by turning over D-6

the hub disconnect caps. Rotate each wheel or
track to check for engagement. Raise the Replace the Hydraulic Filters
machine, remove the jack stands and lower the
machine.
Collision hazard. Failure to
re-engage the drive hubs may
performed every 1000 hours or annually, whichever
cause death or serious injury and
comes first. Perform this procedure more often if
property damage.
dusty conditions exist.
disengaged position Replacement of the hydraulic filters is essential for
good machine performance and service life. A dirty
or clogged filter may cause the machine to perform
poorly and continued use may cause component
engaged position
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 15 Install the new filter elements into the housings
housing. and tighten them securely.
6 Push the filter element down to be sure the Note: The medium and high pressure filters use the
O-ring on the element is fully seated into the same elements.
housing.
16 Clean up any oil that may have spilled during the
7 Rotate the filter element clockwise to lock it in installation procedure.
place.
17 Use a permanent ink marker to write the date
8 Install the filter housing cap. and number of hours from the hour meter on the
9 Use a permanent ink marker to write the date oil filter housings.
and number of hours from the hour meter on the 18 Start the engine from the ground controls.
oil filter housing.
19 Inspect the filter housings and related
Medium and high pressure filters: components to be sure that there are no leaks.
Note: The medium pressure filter is for the charge
pump and the high pressure filter is for all machine
functions except the drive circuit and oscillating
axle circuit.

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.
D-7
Deutz Models


(Deutz part number 0297-9929).

Checklist E Procedures REV B
E-1 1 Ford models: Turn the valve on the LPG tank

clockwise to the off position (if equipped). Then
Test or Replace the Hydraulic Oil slowly disconnect the hose from the LPG tank.
2 Ford models: Open the clamps from the LPG
tank straps and remove the LPG tank from the
machine (if equipped).
performed every 2000 hours or every two years, 3 Open the ground controls side turntable cover
whichever comes first. Perform this procedure more and locate the two hydraulic tank valves at the
often if dusty conditions exist. hydraulic tank. Close the valves.
Replacement or testing of the hydraulic oil is Component damage hazard. The

essential for good machine performance and engine must not be started with the
service life. Dirty oil and suction strainers may hydraulic tank shut-off valves in
cause the machine to perform poorly and continued the closed position or component
use may cause component damage. Extremely damage will occur. If the tank
dirty conditions may require oil changes to be valves are closed, remove the key
performed more often. from the key switch and tag the
machine to inform personnel of the
Note: Before replacing the hydraulic oil, the oil may condition.
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 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 open closed
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting 4 Place a suitable container underneath the
Torque Specifications. hydraulic tank.
Note: Perform this procedure with the boom in the 5 Remove the drain plug from the hydraulic tank.
stowed position.
6 Completely drain the tank into a suitable
container. See capacity specifications.
REV B CHECKLIST E PROCEDURES
7 Tag, disconnect and plug the two suction hoses 18 Install the hydraulic return filter housing onto the
and supply hose for the auxiliary pump from the hydraulic tank.
hydraulic tank. Cap the fittings on the tank.
19 Install the hydraulic tank onto the machine.
Note: The hoses can be accessed through the
20 Install the two suction hoses to the suction
access hole under the turntable.
strainers.
8 Disconnect and plug the return filter hydraulic 21 Install the supply hose for the auxiliary power
hose at the return filter. Cap the fitting on the unit and the return filter hose.
filter housing.
22 Open the two hydraulic tank valves at the
9 Remove the ground controls side turntable hydraulic tank.
cover.
23 Fill the tank with hydraulic oil until the level is
10 Support the hydraulic tank with an appropriate
within the top 2 inches / 5 cm of the sight
lifting device.
gauge. Do not overfill.
11 Remove the hydraulic tank mounting fasteners.
24 Clean up any oil that may have spilled.
12 Remove the hydraulic tank from the machine.
25 Prime the pump. Refer to Repair Procedure 6-2,
Crushing hazard. The hydraulic How to Prime the Pump.
tank could become unbalanced
Note: Always use pipe thread sealant when
and fall if not properly supported
installing the suction hose fittings and the drain
when removed from the machine.
plug.
13 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic
return filter housing from the hydraulic tank.
14 Remove the suction strainers from the tank and
clean them using a mild solvent.
15 Rinse out the inside of the tank using a mild
solvent.
16 Install the suction strainers using a thread
sealant on the threads.
17 Install the drain plug using a thread sealant on
the threads.
CHECKLIST E PROCEDURES REV B
E-2 E-3
Perform Engine Maintenance - Perform Engine Maintenance -
Deutz Models Deutz Models
procedure be performed every 3000 hours. procedure be performed every 12,000 hours.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure to good engine performance and service life. Failure
to perform the maintenance procedures can lead to to perform the maintenance procedures can lead to
poor engine performance and component damage. poor engine performance and component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
Deutz FL 2011 Operation Manual Deutz FL 2011 Operation Manual
(Deutz part number 0297-9929). (Deutz part number 0297-9929).
Deutz FL 2011 Operation Manual Deutz FL 2011 Operation Manual

Genie part number 84794 Genie part number 84794
REV B CHECKLIST E PROCEDURES
E-4
Replace the Boom Extend/
Retract Cables

procedure be performed at 7 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.
January 2010 Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point where
repairs can be completed. To re-assemble, perform
Repair procedures shall be completed by a
the disassembly steps in reverse order.
person trained and qualified on the repair of this
machine. Symbols Legend
Immediately tag and remove from service a Safety alert symbol—used to alert
damaged or malfunctioning machine. personnel to potential personal
injury hazards. Obey all safety
Repair any machine damage or malfunction
messages that follow this symbol
before operating the machine.
to avoid possible injury or death.
Before Repairs Start: Used to indicate the presence of
an imminently hazardous situation
Read, understand and obey the safety rules and which, if not avoided, will result in
operating instructions in the appropriate death or serious injury.
Operator's Manual on your machine.
Be sure that all necessary tools and parts are potentially hazardous situation
available and ready for use. which, if not avoided, could result
in death or serious injury.
Use only Genie approved replacement parts.
Read each procedure completely and adhere
potentially hazardous situation
to the instructions. Attempting shortcuts may which, if not avoided, may cause
produce hazardous conditions. minor or moderate injury.
Unless otherwise specified, perform each Used to indicate the presence of a
repair procedure with the machine in the potentially hazardous situation
following configuration: which, if not avoided, may result in
• Machine parked on a firm, level surface property damage.
• Boom in stowed position Indicates that a specific result is expected after
• Turntable rotated with the boom between performing a series of steps.
the non-steer wheels
Indicates that an incorrect result has occurred
• Turntable secured with the turntable after performing a series of steps.
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power disconnected
from the machine
Section 4 • Repair Procedures January 2010
Platform Controls REV B
The platform control box contains one printed 1-1

circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional ALC-500 Circuit Board
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall Electrocution/burn hazard. Contact
Effect technology and require no adjustment. The with electrically charged circuits
operating parameters of the joysticks are stored in could result in death or serious
memory at the ECM circuit board at the platform injury. Remove all rings, watches
controls. If a joystick error occurs or if a joystick is and other jewelry.
replaced, it will need to be calibrated before that Note: When the ALC-500 circuit board is replaced,
particular machine function will operate. See 1-2, the joystick controllers will need to be calibrated.
How to Calibrate a Joystick. See 1-2, How to Calibrate a Joystick.
Each joystick controller should operate smoothly
and provide proportional speed control over its How to Remove the ALC-500
entire range of motion. Circuit Board
1 Push in the red Emergency Stop button to the
a
off position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to the
inside of the platform control box.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
d c b
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
REV B PLATFORM CONTROLS
4 Attach a grounded wrist strap to the ground 1-2

screw inside the platform control box.
Joysticks
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.
Result: The alarm should sound indicating
successful joystick calibration.
Result: The alarm does not sound. Check the
electrical connections or replace the joystick.
8 Repeat this procedure for each joystick
controlled machine function including the thumb
rocker steer switch.
Note: No machine fuction should operate while
performing the joystick calibration procedure.
PLATFORM CONTROLS REV B
How to Adjust the Joystick 9 Select a boom function joystick to set the
threshold.
Threshold Setting
10 Slowly move the joystick off center in either
The threshold setting of a joystick is the minimum direction just until the function begins to move.
output at which a function proportional valve can
open and allow the function to operate. 11 Slowly move the joystick back to the neutral
position. Just before the function stops moving,
Note: Perform this procedure with the boom in the move the drive enable toggle switch to either
stowed position. side to set the threshold.
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.
3 Push in the platform controls red Emergency
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.
6 As soon as 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.
Result: The alarm does not sound. Repeat steps
3 through 7.
8 Start the engine from the platform controls and
press down the foot switch.
How to Adjust the Function 8 Start the engine from the platform controls and
Speeds
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 from a default of 100%, with a
3 Push in the platform controls red Emergency minimum of 60% and a maximum of 120%.
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.
6 When the alarm sounds, release the drive
Result: The alarm should sound indicating that
Result: The alarm does not sound. The
minimum or maximum adjustment has been
Result: There should be a pause and the alarm obtained. No changes can be saved.
machine is in max-out calibration mode.
3 through 7.
PLATFORM CONTROLS REV B
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.
Note: Perform this procedure with the boom in the
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
6 When the alarm sounds, release the drive
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
obtained. No changes can be saved.
machine is in ramp rate calibration mode.
3 through 7.
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
Platform Components REV A
2-1 4 Remove the pin retaining fastener from the slave

cylinder rod-end pivot pin. Use a soft metal drift
Platform Leveling Slave Cylinder to drive the rod-end pivot pin out.
The slave cylinder and the rotator pivot are the Crushing hazard. S-65 and
two primary supports for the platform. The slave S-65 TRAX: The jib boom could
cylinder keeps the platform level through the fall when the slave cylinder rod-end
entire range of boom motion. It operates in a pivot pin is removed if not properly
closed-circuit hydraulic loop with the master supported.
cylinder. The slave cylinder is equipped with 5 Remove the external snap rings from the barrel-
counterbalance valves to prevent movement in end pivot pin.
the event of a hydraulic line failure.
6 Use a soft metal drift to drive the barrel-end
How to Remove the Platform pivot pin out.
Leveling Slave Cylinder 7 Carefully pull the cylinder out of the boom to
access the hydraulic hoses.
Note: Before cylinder removal is considered, bleed
the slave cylinder to be sure there is no air in the 8 Tag, disconnect and plug the hydraulic hoses
closed loop. from the slave cylinder. Cap the fittings on the
cylinder.
the O-ring (if equipped) on the fitting and/or the Bodily injury hazard. Spraying
hose end must be replaced. All connections must hydraulic oil can penetrate and
be torqued to specification during installation. Refer burn skin. Loosen hydraulic
to Section 2, Hydraulic Hose and Fitting Torque connections very slowly to allow
Specifications. the oil pressure to dissipate
gradually. Do not allow oil to
1 Extend the boom until the slave cylinder barrel- squirt or spray.
end pivot pin is accessible.
How to Bleed the Slave Cylinder
2 Raise the boom slightly and place blocks under
the platform for support. Note: Do not start the engine. Use auxiliary power
for this procedure.
3 Lower the boom until the platform is resting on
the blocks just enough to support the platform. 1 Simultaneously activate the boom up function
Note: Do not rest the entire weight of the boom on and the platform level up function until the boom
the blocks. is fully raised.
2 Simultaneously activate the boom down function
and the platform level down function until the
boom is fully lowered.
REV A 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 and S-65 TRAX: Support the jib boom
weldment. The platform mounting leveling arms and the platform mounting
weldment must be replaced in the weldment with an appropriate lifting device. Do
exact same position on the rotator not apply any 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 Section 2, Hydraulic Hose and Fitting Torque
S-60 and S-60 TRAX:
Specifications.
7 Support the rod end of the platform leveling
1 Remove the platform and platform support.
slave cylinder. Protect the cylinder rod from
Note: S-60 HC: If the load sense components are damage.
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.
PLATFORM COMPONENTS REV A
8 Remove the pivot pin retaining fasteners from How to Bleed the Platform
both the slave cylinder rod-end pivot pin and the
rotator pivot pin. Rotator
9 Use a soft metal drift to remove both pivot pins. Note: This procedure will require two people. Do not
Remove the platform rotator from the machine. start the engine. Use auxiliary power for this
procedure.
Crushing hazard. The platform
rotator may become unbalanced 1 Move the function enable toggle switch to either
and fall if not properly supported. side and activate the platform rotate toggle
switch to the right then the left through two
Note: When installing the platform rotator fasteners, platform rotation cycles, then hold the switch to
torque the fasteners to specifications. the right position until the platform is fully
10 Lower the jib boom leveling arms. rotated to the right.
Crushing hazard. The platform 2 Place a suitable container underneath the

rotator may become unbalanced platform rotator.
and fall if not properly supported. 3 Open the top bleed screw on the rotator, but do
Note: When installing the platform rotator fasteners, not remove it.
torque the fasteners to specifications. Bodily injury hazard. Spraying
S-65 and S-65 TRAX: hydraulic oil can penetrate and
burn skin. Loosen hydraulic
7 Remove the pin retaining fasteners from the jib connections very slowly to allow
boom and jib boom leveling arms to platform the oil pressure to dissipate
rotator pivot pins. Do not remove the pins. gradually. Do not allow oil to
squirt or spray.
8 Support the jib boom leveling arms.
4 Move the function enable toggle switch to either
9 Use a soft metal drift to drive both pins out, then side and hold the platform rotate toggle switch
remove the platform rotator from the machine. to the left position until the platform is fully
Bodily injury hazard. The jib boom rotated to the left. Continue holding the toggle
leveling arms may fall if not switch until air stops coming out of the bleed
properly supported. screw. Close the bleed screw.
10 Lower the jib boom leveling arms. Crushing hazard. Keep clear of the
platform during rotation.
Crushing hazard. The platform
rotator may become unbalanced
and fall if not properly supported.
Note: When installing the platform rotator fasteners,
torque the fasteners to specifications.
5 Open the bottom bleed screw on the rotator, but 2-3

do not remove it.
Platform Overload System,
Bodily injury hazard. Spraying
S-60, S-65, S-60 TRAX and
burn skin. Loosen hydraulic S-65 TRAX (if equipped)
connections very slowly to allow
the oil pressure to dissipate How to Calibrate the Platform
squirt or spray. Overload System
6 Move the function enable toggle switch to either Calibration of the platform overload system is
side and hold the platform rotate toggle switch essential to safe machine operation. Continued use
to the right position until the platform is fully of an improperly calibrated platform overload
rotated to the right. Continue holding the toggle system could result in the system failing to sense
switch until air stops coming out of the bleed an overloaded platform. The stability of the
screw. Close the bleed screw. machine is compromised and it could tip over.
Crushing hazard. Keep clear of the Note: For S-60 HC models, refer to Repair
platform during rotation. Procedure 2-4, Platform Load Sense System,
S-60 HC.
7 Clean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions and
firm, level surface.
inspect the bleed screws for leaks.
1 Turn the key switch to platform control. Start the

engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
incorrect calibration.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform capacity
at the center of the platform floor.
5 Move the platform up and down by hand, so it 7 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2 bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle. inches. Allow the platform to settle.
Result: The overload indicator lights are off and Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6. the alarm does not sound. Proceed to step 8.
Result: The overload indicator lights are flashing Result: The overload indicator lights are flashing
at the platform and ground controls, and the at the platform and ground controls, and the
alarm is sounding. Slowly tighten the load spring alarm is sounding. Repeat this procedure
adjustment nut in a clockwise direction in 10° beginning with step 5.
increments until the overload indicator light
turns off, and the alarm does not sound.
platform overload indicator light and alarm
Proceed to step 8.
responds.
Note: The platform will need to be moved up and
down and allowed to settle between each 8 Add an additional 10 lb / 4.5 kg test weight to
adjustment. the platform.
Result: The overload indicator light is flashing at
both the ground and platform controls, and the
alarm is sounding. Proceed to step 9.
responds.
Result: The overload indicator light is off at both
6 Move the platform up and down by hand, so it
the ground and platform controls, and the alarm
bounces approximately 2.5 to 5 cm / 1 to 2
does not sound. Remove the additional 10 lb /
inches. Allow the platform to settle.
4.5 kg test weight. Repeat this procedure
Result: The overload indicator lights are off at beginning with step 6.
the platform and ground controls, and the alarm
does not sound. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
responds.
in 10° increments until the overload indicator
light flashes at both the platform and ground 9 Test all machine functions from the platform
controls, and the alarm sounds. controls.
Proceed to step 7.
Result: All platform control functions should not
Result: The overload indicator lights are flashing operate.
at the platform and ground controls, and the
alarm is sounding. Repeat this procedure 10 Turn the key switch to ground control.
beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
platform overload indicator lights and alarm
responds.
11 Test all machine functions from the ground 2-4

controls.
Platform Load Sense System,
Result: All ground control functions should not
operate.
S-60 HC
12 Using a suitable lifting device, lift the test weight How to Calibrate the Platform
off the platform floor.
Load Sense System
Result: The platform overload indicator light
should be off at both the ground and platform Proper calibration of the load sense system is
controls and the alarm should not sound. essential to safe machine operation. Continued use
of an improperly calibrated load sense system
Note: There may be a 2 second delay before the could result in the system failing to sense an
overload indicator lights and alarm turn off. overloaded platform. The stability of the machine is
13 Test all machine functions from the ground compromised and it could tip over.
controls. Note: For S-60, S-65, S-60 TRAX and S-65 TRAX
Result: All ground control functions should models, refer to Repair Procedure 2-3, Platform
operate normally. Overload System, S-60, S-65, S-60 TRAX and
S-65 TRAX (if equipped).
14 Turn the key switch to platform control.
Note: Perform this procedure with the boom fully
15 Test all machine functions from the platform retracted and in the stowed position and with the
controls. machine on a firm, level surface.
Result: All platform control functions should
Note: The platform overload system will not allow
operate normally.
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 5 Activate and release the calibration toggle
the platform. switch 3 times within 2 seconds after the alarm
sounds to enter calibration mode.
Tip-over hazard. Failure to remove
all weight, options, accessories Result: The alarm should sound for 1 second
and/or tools from the platform or indicating the first calibration step was
subtracting the weight of those accepted. The green LED on the operational
items from the test weights, will controller should be blinking fast and the red
result in the platform load sense LED should be blinking twice indicating that
system not calibrating correctly. step 2 of calibration is next.
This will allow too much weight to
Result: The alarm did not sound and the green
be added to the platform which will
LED on the operational controller is not blinking
result in the machine tipping over.
fast. Repeat this procedure beginning with
3 Open the ground control box and locate the step 1.
calibration toggle switch near the relays.
Note: Once calibration mode is entered and begun,
Note: If either the operational and/or safety there is a 8 minute time limit between each
controller has been replaced or if the software has calibration step. If any one step passes the 8
been updated, restore the system to the default minute time limit, the system will time out and the
settings and then continue to step 4. See How to calibration process will need to be repeated
Restore the Default Settings. Otherwise, continue beginning with step 1.
to step 4 to enter calibration mode.
4 Turn the key switch to ground control and pull

position.
Result: The alarm sound for approximately f a
2 seconds. e b
How to Restore the System

Default Settings
1 Turn the key switch to ground control and
pull out the red Emergency Stop button to
the on position.
Result: The alarm should sound a long tone.
d c
2 Activate and hold the calibration toggle
switch for 5 seconds.
a green LED (operational control module)
Result: The alarm should sound a tone for b red LED (operational control module)
c operational control module
1 second. d safety control module
e red LED (safety control module)
3 Push in the red Emergency Stop button to f green LED (safety control module)
the off position.
6 Start the engine from the ground controls. 8 Activate the calibration toggle switch inside the
ground control box 1 time.
7 Raise the boom until the distance, when
measured between the centers of the pivot pins Result: The alarm should sound for 1 second
shown, equals 108.75 inches / 276 cm indicating the second calibration step was
± 0.75 inch / 19 mm. accepted. The green LED on the operational
controller should be blinking fast and the red
Crushing hazard. Keep clear of all
LED should be blinking three times indicating
moving parts of the boom while the
that step 3 of calibration is next.
boom is raising. Do not attempt to
measure between the pivot pins 9 Raise the boom until the distance, when
while the boom is moving. measured between the centers of the pivot pins
shown, equals 167.25 inches / 424.8 cm
± 0.75 inch / 19 mm.
Crushing hazard. Keep clear of all
moving parts of the boom while the
boom is raising. Do not attempt to
Measure between measure between the pivot pins
the centers of these
while the boom is moving.
pivot pins
10 Activate and release the calibration toggle
switch inside the ground control box 1 time.
Result: The alarm should sound for 1 second
indicating the third calibration step was
accepted. The green LED on the operational
controller should be blinking fast and the red
LED should be blinking four times indicating that
step 4 of calibration is next.
11 Fully raise and extend the boom.
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
12 Activate and release the calibration toggle 17 Activate and release the calibration toggle
switch inside the ground control box 1 time. switch inside the ground control box 1 time.
Result: The alarm should sound for 1 second Result: The alarm should sound for 1 second
indicating the fourth calibration step was indicating the sixth calibration step was
accepted. The green LED on the operational accepted. The engine may turn off and the
controller should be blinking fast and the red alarm may sound indicating an overloaded
LED should be blinking five times indicating that platform.
18 At the ground controls, push in the red
13 Fully retract and lower the boom to the stowed Emergency Stop button to the off position, then
position. pull out the red Emergency Stop button to the
on position to reset the system.
14 Using a suitable lifting device, place an
appropriate test weight equal to 19 Visually inspect the LEDs on the controllers.
750 lbs / 340.2 kg on to the center of the
Result: All LEDs on both controllers should be
platform floor.
off indicating the platform load sense system is
Note: If your machine is equipped with any platform calibrated.
accessories or options, they must be removed from
20 At the ground controls, push in the red
the platform OR the weights of those options or
Emergency Stop button to the off position.
accessories must be subtracted from the test
weights to accurately calibrate the platform load 21 Using a suitable lifting device, remove the test
sense system. weights from the platform.
15 Activate and release the calibration toggle 22 Pull out the red Emergency Stop button to the
switch inside the ground control box 1 time. on position at the ground controls and visually
inspect the LEDs on the operational and safety
Result: The alarm should sound for 1 second
controllers.
indicating the fifth calibration step was
accepted. The green LED on the operational Result: Both the green and red LEDs on both
controller should be blinking fast and the red controllers should be off indicating the system
LED should be blinking six times indicating that is calibrated.
Note: If an LED is blinking on either controller, the
16 Using a suitable lifting device, place an load sense system is not calibrated correctly or a
additional test weight equal to 510 lbs / 231.3 kg fault may exist. Refer to Section 5, Fault Codes to
on to the center of the platform floor. The total determine the system fault.
weight in the platform must equal
1260 lbs / 571.5 kg.
REV A
Jib Boom Components,
S-65 and S-65 TRAX
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.
JIB BOOM COMPONENTS, S-65 AND S-65 TRAX REV A
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.
REV A
Boom Components
4-1 6 Tag, disconnect and plug the hydraulic hoses
from the counterbalance valve manifold located
Cable Track on the platform rotator. Cap the fittings on the
manifold.
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire primary burn skin. Loosen hydraulic
boom cable track is only necessary when connections very slowly to allow
performing major repairs that involve removing the the oil pressure to dissipate
primary boom. gradually. Do not allow oil to
squirt or spray.
How to Remove the Cable Track, 7 Tag, disconnect and plug the platform leveling
S-60, S-60 HC and S-60 TRAX slave cylinder hydraulic hoses from the
bulkhead fittings on the side of the primary
Note: When removing a hose assembly or fitting, boom. Cap the bulkhead fittings.
hose end must be replaced. All connections must Bodily injury hazard. Spraying
be torqued to specification during installation. Refer hydraulic oil can penetrate and
to Section 2, Hydraulic Hose and Fitting Torque burn skin. Loosen hydraulic
Specifications. connections very slowly to allow
1 Raise the boom to a horizontal position. gradually. Do not allow oil to
2 Locate the cables from the boom cable track to squirt or spray.
the platform control box. Number each cable 8 Locate all electrical cables under the boom at
and its entry location at the platform control the pivot end that enter the cable track.
box.
9 Tag and disconnect the electrical connectors for
3 Disconnect the cables from the platform control all cables that enter the cable track.
box.
10 Remove the retaining fasteners from the
4 Remove the electrical outlet box bracket electrical connector receptacles for the cables
mounting fasteners. Remove the outlet box and that enter the cable track.
lay it to the side.
11 Carefully pull the cables and connector
5 Remove the hose and cable clamp from the receptacles out of the primary boom.
platform support.
BOOM COMPONENTS REV A
12 Tag, disconnect and plug all hydraulic hoses 18 Remove the cable track mounting fasteners that
that enter the cable track from the bulkhead attach the lower cable track to the primary
fittings at the pivot end of the boom. boom.
Bodily injury hazard. Spraying 19 Carefully remove the cable track from the
hydraulic oil can penetrate and machine and place it on a structure capable of
burn skin. Loosen hydraulic supporting it.
Crushing hazard. The cable track
could become unbalanced and fall
if not properly attached to the
squirt or spray.
overhead crane.
13 Pull the hydraulic hoses out of the primary
boom.
Cables and hoses can be damaged
14 Place blocks in between the upper and lower if they are kinked or pinched.
cable tracks and secure the upper and lower
tracks together.
cable track can be damaged if it is
Crushing hazard. If the upper and twisted.
lower cable tracks are not properly
secured together, the cable track How to Remove the Cable Track,
could become unbalanced and fall S-65 and S-65 TRAX
when removed from the machine.
15 Attach a strap from an overhead crane to the the O-ring (if equipped) on the fitting and/or the
cable track. hose end must be replaced. All connections must
16 Remove the cotter pin from the cable track pull be torqued to specification during installation. Refer
tube at the platform end of the boom. to Section 2, Hydraulic Hose and Fitting Torque
Specifications.
Note: Always replace the cotter pin with a new one.
1 Open the platform control box.
17 Remove the cable track pull tube guide
fasteners from the cable track guide at the 2 Tag and disconnect the foot switch wiring from
platform end of the boom. Remove the cable the terminal strip inside the platform control box.
track guide from the boom. Pull the wiring out of the platform control box.
3 Raise the boom to a horizontal position.
REV A BOOM COMPONENTS
4 Disconnect the wire connectors from the bottom 9 Remove the hose and cable cover from the side
of the platform control box. of the jib boom.
Note: When installing the wire connectors to the 10 Locate all electrical cables under the boom at
bottom of the platform control box, match the color the pivot end that enter the cable track.
of the connectors to those on the control box to be
11 Tag and disconnect the electrical connectors for
sure they are installed in the correct location.
all cables that enter the cable track.
5 Remove the mounting fasteners from the power 12 Remove the retaining fasteners from the
to platform outlet box bracket. Lay the outlet electrical connector receptacles for the cables
box and bracket assembly off to the side. that enter the cable track.
6 Remove the hose and cable clamps from the 13 Carefully pull the cables and connector
platform support and jib boom. receptacles out of the primary boom.
7 Tag, disconnect and plug the platform leveling
14 Tag, disconnect and plug all hydraulic hoses
slave cylinder hydraulic hoses from the
that enter the cable track from the bulkhead
bulkhead fittings on the side of the primary
fittings at the pivot end of the boom.
boom. Cap the bulkhead fittings.
squirt or spray.
squirt or spray.
15 Pull the hydraulic hoses out of the primary
boom.
from the "V1" and "V2" ports of the jib boom/
platform rotate manifold. Cap the fittings on the 16 Remove the cotter pin from the upper cable
manifold. track at the platform end of the boom.
Bodily injury hazard. Spraying Note: Always replace the cotter pin with a new one.
burn skin. Loosen hydraulic 17 Remove the cable track pull tube guide
connections very slowly to allow fasteners from the cable track guide at the
the oil pressure to dissipate platform end of the boom. Remove the cable
gradually. Do not allow oil to track guide from the boom.
squirt or spray.
18 Place blocks in between the upper and lower How to Repair the Cable Track
cable tracks and secure the upper and lower
tracks together. Component damage hazard.
The boom cable track can be
Crushing hazard. If the upper and damaged if it is twisted.
lower cable tracks are not properly
secured together, the cable track Note: A cable track repair kit is available through
could become unbalanced and fall the Genie Industries Service Parts Department,
when removed from the machine. part no. 77896. The kit includes a 4 link section of
cable track.
the cable track. 1 Visually inspect the cable track and determine
which 4 link section needs to be replaced.
20 Remove the mounting fasteners that attach the
lower cable track to the boom. 2 Carefully remove the snap rings from each end
of the damaged section of cable track.
21 Carefully remove the cable track from the
machine and place it on a structure capable of 3 Remove the retaining fasteners from the upper
supporting it. black rollers from the 4 link section of cable
track to be replaced. Remove the rollers.
Crushing hazard. The cable track
could become unbalanced and fall 4 Lift up the hoses and cables and carefully
if not properly attached to the remove the damaged 4 link section of cable
overhead crane. track.
Component damage hazard. Component damage hazard. Hoses
Cables and hoses can be damaged and cables can be damaged if they
if they are kinked or pinched. are kinked or pinched.
Component damage hazard. The 5 Remove the upper rollers from the replacement
cable track can be damaged if it is section of cable track.
twisted.
6 Lift up the hoses and cables and carefully insert
the new 4 link section of cable track.
Hoses and cables can be damaged
if they are kinked or pinched.
7 Connect the ends of the replacement cable track
section to the existing cable track using the
snap rings.
8 Install the rollers onto the new section of cable
track.
9 Operate the boom extend/retract function
through a full cycle to ensure smooth operation
of the new section of cable track.
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
4-2 1 Remove the jib boom. See 3-1, How to Remove

the Jib Boom.
Boom
2 Remove the cable track. See 4-1, How to
Remove the Cable Track.
How to Remove the Boom
3 Raise the boom until the short and long link arm
TIp-over hazard. This procedure to boom pivot pins are above the turntable
requires the removal of the covers.
turntable counterweight. Failure to
remove the counterweight before 4 Place a block of wood measuring
removing the boom assembly will 4 x 4 x 60 inches / 10 x 10 x 152 cm under the
result in the machine tipping over. long link arm, across the turntable covers.
Do not remove the boom without
5 Slowly lower the boom until the long link arm
first removing the counterweight.
contacts the wood block. Do not rest the entire
TIp-over hazard. When installing weight of the boom on the block. Turn the
the boom onto the machine, the machine off.
boom assembly must be first
installed prior to the installation of
turntable covers can become
the counterweight. If the
damaged if the weight of the boom
counterweight is installed before
is allowed to rest on the block.
the boom assembly, the machine
will tip over resulting in death or 6 Place wood blocks between the short link arm
serious injury. and the turntable weldment for support.
TIp-over hazard. The turntable 7 Insert a 1.125 x 12 inches / 32 x 300 mm
counterweight is essential for eye-bolt through each hole located on the top
machine stability. Failure to install surface of the counterweight. Secure the eye-
the counterweight after installing bolts in position with flat washers and nuts.
the boom assembly will
8 Securely attach lifting straps or chains with a
compromise machine stability
minimum rating of 5 tons / 5000 kg to the lifting
resulting in the machine tipping
points on the top of the turntable counterweight.
over. Death or serious injury will
Attach the lifting straps or chains to a
result.
5 ton / 5000 kg overhead crane.
Bodily injury hazard. This
Note: A spreader bar and other hardware may be
procedure requires specific repair
needed to safely remove the counterweight.
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
9 Slowly operate the overhead crane to apply 14 Using auxiliary power, activate the boom down
tension to the lifting straps. Do not attempt to function so the cylinder will retract. Retract the
lift the machine with the overhead crane. cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
10 Locate and remove the counterweight retaining
boom. Turn the machine off.
fastener at the center of the counterweight.
Carefully lift the counterweight upwards and Crushing hazard. The boom lift
remove the counterweight from the machine. cylinder could fall if not properly
Set the counterweight on the ground. Do not supported and secured to the lifting
leave the counterweight suspended above the device.
ground.
15 Using the overhead crane, carefully lower the
Crushing hazard. The turntable boom lift cylinder and allow it to rest on the
counterweight will fall if not boom rest pad. Protect the cylinder rod from
properly supported by the overhead damage.
crane resulting in death or serious
16 S-60, S-65, S-60 TRAX and S-65 TRAX:
injury. Keep personnel away from
Remove the boom end cover retaining fasteners
the area when removing the
and remove the cover.
counterweight.
S-60 HC: Remove the boom end cover from the
11 Attach lifting straps from a 5 ton / 5000 kg
pivot end of the boom while guiding the small
overhead crane to each end of the boom.
Support the boom. Do not apply any lifting
pressure.
potentiometer on the counterweight.
12 Support and secure the rod end of the boom lift
cylinder to a second overhead crane or similar
cable from the string potentiometer
lifting device.
13 Remove the lift cylinder rod-end pivot pin kinked or pinched.
retaining fasteners. Use a soft metal drift to
17 S-60 HC: Remove the string potentiometer cable
remove the pin.
break limit switch mounting fasteners.
Crushing hazard. The boom could
18 S-60 HC:Remove the pulley retaining plate from
fall if not properly supported when
the string potentiometer pulley bracket.
the lift cylinder rod-end pivot pin is
Carefully remove the string potentiometer cable
removed.
and limit switch assembly from the boom.
19 Tag, disconnect and plug the boom extension 25 Using the overhead crane, adjust the boom as
cylinder hydraulic hoses. Cap the fittings on the necessary to relieve pressure from the pivot
cylinder. pins.
Bodily injury hazard. Spraying 26 Use a soft metal drift to remove each boom
hydraulic oil can penetrate and pivot pin. Carefully remove the boom assembly
burn skin. Loosen hydraulic from the machine and place it on a structure
connections very slowly to allow capable of supporting it.
Crushing hazard. The boom could
fall if not properly supported by the
squirt or spray.
overhead crane when each boom
20 Tag and disconnect the electrical connector for pivot pin is removed.
the cable break limit switch.
Crushing hazard. The long and
21 Tag and disconnect all boom wire harness short link arms may fall if not
electrical connectors located at the pivot end of properly supported when the boom
the boom. pivot pins are removed.
22 Support the platform leveling master cylinder.
Remove the master cylinder rod-end pivot pin
retaining fasteners. Place a rod through the pin
and twist to remove. Carefully lower the master
cylinder down.
from the bulkhead fittings at the pivot end of the
boom. Cap the bulkhead fittings.
squirt or spray.
24 Remove the external snap rings from both boom
pivot pins at the short and long link arms. Do
not remove the pins.
4-3 5 Using auxiliary power, activate the boom down

function so the cylinder will retract. Retract the
Boom Lift Cylinder cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
The boom lift cylinder raises and lowers the boom. boom. Turn the machine off.
The boom lift cylinder is equipped with
counterbalance valves to prevent movement in the 6 Tag, disconnect and plug the boom lift cylinder
event of a hydraulic line failure. hydraulic hoses. Cap the fittings on the cylinder.
How to Remove the Boom hydraulic oil can penetrate and
Lift Cylinder burn skin. Loosen hydraulic
Bodily injury hazard. This the oil pressure to dissipate
procedure requires specific repair gradually. Do not allow oil to
skills, lifting equipment and a squirt or spray.
suitable workshop. Attempting this
procedure without these skills and 7 Remove the pin retaining fasteners from the
tools could result in death or boom lift cylinder barrel-end pivot pins. Do not
serious injury and significant remove the pins.
component damage. Dealer 8 Use a slide hammer to remove the barrel-end
service is strongly recommended. pivot pins.
Note: When removing a hose assembly or fitting, Crushing hazard. The boom lift
the O-ring (if equipped) on the fitting and/or the cylinder could become unbalanced
hose end must be replaced. All connections must and fall if not properly supported
be torqued to specification during installation. Refer and secured to the lifting device.
Specifications. 9 Move the boom lift cylinder towards the
counterweight end of the machine. Rotate the
1 Raise the boom to a horizontal position. boom lift cylinder until the barrel-end pivot pin
2 Attach a 5 ton / 5000 kg overhead crane to the bores will clear the boom linkage.
boom at the platform end for support. Do not lift 10 Carefully remove the boom lift cylinder from the
the boom. machine.
3 Support and secure both ends of the boom lift Crushing hazard. The boom lift
cylinder to a second overhead crane or similar cylinder could become unbalanced
lifting device. and fall if not properly supported
4 Remove the pin retaining fastener from the and secured to the lifting device.
boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
Crushing hazard. The boom will fall
if not properly supported when the
primary boom rod-end pivot pin is
removed.
4-4 2 S-60, S-65, S-60 TRAX and S-65 TRAX:

Remove the boom end cover retaining fasteners
Boom Extension Cylinder and remove the cover.
The boom extension cylinder is located inside the S-60 HC: Remove the boom end cover from the
boom assembly and incorporates cables and pivot end of the boom while guiding the small
pulleys that are responsible for extending the cable from the string potentiometer out of the
number 3 boom tube. The primary boom extension slot of the cover. Rest the cover and string
cylinder is equipped with counterbalance valves to potentiometer on the counterweight.
prevent movement in the event of a hydraulic line Component damage hazard. The
failure. cable from the string potentiometer
How to Remove the Boom kinked or pinched.
Extension Cylinder 3 S-60 HC: Remove the string potentiometer cable
Bodily injury hazard. This break limit switch mounting fasteners.
procedure requires specific repair 4 S-60 HC:Remove the pulley retaining plate from
skills, lifting equipment and a the string potentiometer pulley bracket.
suitable workshop. Attempting this Carefully remove the string potentiometer cable
procedure without these skills and and limit switch assembly from the boom.
tools could result in death or
serious injury and significant 5 Remove the access covers from both sides of
component damage. Dealer the boom at the pivot end.
service is strongly recommended.
6 Fully loosen the lock nuts on the extend cables.
Note: When removing a hose assembly or fitting, Do not remove the nuts.
7 Loosen the retract cable nut at the platform end
hose end must be replaced. All connections must
of the boom. Pull the cable rod from the support
be torqued to specification during installation. Refer
and let it hang down.
Specifications.
Note: Perform this procedure with the boom fully
retracted.
1 Raise the boom to a horizontal position.
8 Remove the cable guard fasteners and remove 12 Disconnect the wire connector to the extend
the cable guard. cable break limit switch.
13 Remove the retaining fasteners that secure the
extend cable mounting plates to the inside of
the number 1 boom tube.
a b
a cable guard a b c d
b retaining block
a extend cable lock nuts
9 Locate the retaining plates that secure the b extend cable mounting plate
retract cables to the inside of the number 3 c extend cable mounting plate fastener
boom tube. d extend cable bracket
10 Remove the cable retaining plates and pull the 14 Pull back on the extend cable mounting plate
retract cables off of the pulleys. Lay the cables until it clears the blocks welded to the inside of
flat and out of the way. the number 1 boom tube.
11 Remove the fasteners from the retaining blocks
from the extension cylinder saddle. Remove the
blocks.
Note: Access the fasteners through the access
hole in the outer boom tube at the pivot end.
15 Lift up the extend cable mounting plate and push 23 Attach a lifting strap from a 5 ton / 5000 kg
the extend cables towards the platform to create overhead crane to the lug at the rod end of the
slack in the cables. Rest the cable and bracket boom extension cylinder.
assembly on top of the extend cylinder.
24 Lift the boom extension cylinder with the crane
16 Locate the lower extend cable bracket on the until it clears the cylinder saddle inside the
bottom of the number 3 boom tube. number 2 boom tube.
17 Remove the lower extend cable bracket 25 Carefully support and slide the extension
mounting fasteners and pull back on the bracket cylinder out of the boom.
to release it from the number 3 boom tube.
Crushing hazard. The extension
18 While pushing the lower extend cable bracket cylinder could fall when removed
towards the platform, pull the extend cable from the boom if not properly
mounting plate towards the pivot end of the supported.
boom.
Component damage hazard. Be
19 Secure the extend cable bracket and cables to careful not to damage the cable
the cylinder to prevent them from falling off break limit switch.
when removing the cylinder.
20 Remove the external snap rings from the careful not to damage the
extension cylinder pin at the pivot end of the counterbalance valves on the
boom. primary boom extension cylinder
when removing the cylinder from
21 Use a soft metal drift to remove the pin.
the boom.
22 Tag, disconnect and plug the boom extension
Note: During removal of the extension cylinder, the
overhead crane strap will need to be carefully
cylinder.
adjusted for proper balancing.
squirt or spray.
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, S-65, S-60 TRAX and S-65 TRAX: extension cycle. This will create slack in the
Remove the boom end cover retaining fasteners retract cables.
and remove the cover. Note: Be sure to not fully extend the boom. Stop
S-60 HC: Remove the boom end cover from the when there is approximately 3 feet / 1 m of
pivot end of the boom while guiding the small travel left.
9 Repeat steps 7 and 8 two to three times.
potentiometer on the counterweight. 10 Fully extend the boom then retract the boom
approximately 12 inches / 30 cm.
cable from the string potentiometer 11 At the pivot end of the boom, visually inspect
can become damaged if it is the boom extend cables for even cable droop or
kinked or pinched. sag.
3 Inspect the threaded ends of the boom extend Note: If the boom extend cables are uneven,
cables. The threads must be clean and in good tighten the boom extend cable adjustment nut at
condition with no damaged threads. the pivot end of the boom for the appropriate cable.
12 Visually inspect the cable break limit switch arm How to Replace the Boom
to be sure the wheel of the limit switch arm is
centered in the notch of the pivot plate. Extend/Retract Cables
Note: If the boom extend cables are adjusted Note: The cable pulleys must also be replaced
evenly, the wheel of the limit switch arm should be when replacing the cables.
centered in the notch of the pivot plate.
1 Remove the boom extension cylinder. See 4-4,
How to Remove the Boom Extension Cylinder.
Boom extend cables:
2 Remove the cables from the lower boom extend
a cable bracket that attaches to the number 3
boom tube.
3 Remove the rue rings and clevis pins from the
boom extend cables located near the extend
cable break limit switch.
4 Remove the external snap rings from the boom
extend cable pulley pivot pin. Use a soft metal
drift to remove the pin.
Note: When driving the pivot pin out, be sure to
drive it from the shaped end of the pin.
5 Remove the pulley and boom extend cables
from the extension cylinder assembly. Discard
the old cables and pulleys.
6 Route the new boom extend cables through the
b c
boom extend pulley bracket.
a cable break limit switch 7 Install the new boom extend cable pulley, pivot
b extend cable adjustment nut pin and snap rings.
c extend cable pivot plate
Note: Be sure the boom extend cables are routed
13 Install the boom end cover at the pivot end of through the grooves of the pulley and the upper
the boom. wear pad on the extension cylinder.
14 Fully retract and lower the boom to the stowed 8 Install the boom extend cable clevis pins and
position. rue rings to the pivot plate near the cable break
limit switch.
9 Install the boom extend cables to the lower
extend cable bracket that mounts to the number
3 boom tube.
Boom retract cables: 17 Securely attach the rope to the same end of the
new boom retract cable.
10 Remove the cotter pins and clevis pins from the
boom retract cables at the platform end of the 18 At the pivot end of the boom, carefully pull the
boom. rope with the new retract cable attached.
Note: Always use a new cotter pin when installing a 19 Pull the new cable towards the pivot end of the
clevis pin. boom until the end of the cable is at the end of
the boom tube. Remove the rope.
11 Remove the wear pad fasteners from the upper
wear pads on the number 1 boom tube. Remove 20 Repeat steps 14 through 19 for the other boom
the wear pads. retract cable.
Note: Pay attention to the location of each wear 21 At the platform end of the boom, install the
pad and the quantity of shims for each one. retract cables, clevis pins and new cotter pins
to the adjustment plate.
the platform end of the boom. 22 Remove and discard the old boom retract
pulleys from the pivot end of the boom
13 Raise the boom using the overhead crane and extension cylinder.
place a wood block under the number 2 boom
tube between the number 1 and number 2 boom 23 Install the new boom retract pulleys to the pivot
tubes for support. This will create clearance end of the boom extension cylinder.
between the boom tubes to remove the retract 24 Install the boom extension cylinder assembly
cables. into the boom.
14 Attach the cable pulling tool or a rope to one of Note: Before lowering the extension cylinder into
the boom retract cables at the pivot end of the the saddles of the number 1 boom tube, wrap the
boom. boom retract cables around the pulleys.
Note: A cable pulling tool is available through Genie 25 Adjust the boom extend/retract cables.
Service Parts Department (Genie part no. 94510) See 4-5, How to Adjust the Boom Extend/
15 At the platform end of the boom, pull on the Retract Cables.
boom retract cable that has the rope attached
to it.
16 Pull the old cable completely out of the boom
tube. Remove the rope. Discard the old boom
retract cable.
4-6 4 Remove the pin retaining fastener from the

master cylinder rod-end pivot pin.
Platform Leveling
5 Place a rod through the rod-end pivot pin and
Master Cylinder twist to remove the pin. Lower the rod end of the
master cylinder onto the block.
The master cylinder acts as a pump for the slave
cylinder. It’s part of the closed circuit hydraulic loop 6 Remove the pin retaining fastener from the
that keeps the platform level through the entire barrel-end pivot pin.
range of boom motion. The master cylinder is
7 Place a rod through the barrel-end pivot pin and
located at the pivot end of the boom.
twist to remove the pin.
How to Remove the Platform 8 Remove the master cylinder from the machine.
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.
REV A
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-12, Check and engine flywheel.
Adjust the Engine RPM - Perkins Models.
Type "A" Type "B"

(flexplate with (flexplate with
separate coupler) coupler combined)
ENGINES REV A
How to Remove the Flex Plate 6 Remove the engine mounting plate to bell
housing fasteners.
Deutz models:
7 Raise the engine slightly using the overhead
1 Remove the tailpipe bracket mounting fasteners crane and place a block of wood under the oil
from the engine bell housing. pan for support.
2 Support the drive pump assembly with an 8 Support the drive pump assembly with an
appropriate lifting device. overhead crane or other suitable lifting device.
Do not apply any lifting pressure.
3 Remove all of the engine bell housing fasteners.
9 Remove all of the engine bell housing retaining
4 Carefully pull the pump and bell housing fasteners.
assembly away from the engine and secure it
from moving. 10 Carefully pull the pump and bell housing
assembly away from the engine and secure it
Component damage hazard. Hoses from moving.
can be damaged if they are kinked
or pinched. Component damage hazard. Hoses
5 Remove the flex plate mounting fasteners. or pinched.
Remove the flex plate from the flywheel.
11 Remove the flex plate mounting fasteners.
Ford models: Remove the flex plate from the flywheel.
1 Disconnect the electrical connectors from both Perkins models:
oxygen sensors at the tailpipe and exhaust
manifold. Do not remove the oxygen sensors. 1 Remove the fuel filter/water separator mounting
fasteners.
2 Remove the exhaust pipe fasteners at the
muffler. 2 Remove the fuel filter/water separator and lay it
to the side. Do not disconnect the hoses.
3 Support the muffler and bracket assembly with a
suitable lifting device. 3 Support the drive pump assembly with an
appropriate lifting device.
4 Remove the muffler bracket mounting fasteners
from the bell housing. Carefully remove the 4 Remove all of the engine bell housing fasteners.
muffler and bracket assembly from the engine.
5 Carefully pull the pump and bell housing
5 Support the engine with an overhead crane or assembly away from the engine and secure it
other suitable lifting device. Do not lift it. from moving.
Component damage hazard. Hoses
or pinched.
6 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
REV A ENGINES
How to Install a Type "A" 3 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
Flex Plate appropriate gap between coupler and pump end
1 Install the flex plate onto the engine flywheel plate for your engine.
with the raised spline towards the pump.
a b c d e
2 Ford models: Torque the flex plate mounting
bolts in sequence to 14 ft-lbs / 19 Nm.
Then torque the flex plate mounting bolts in
sequence to 20 ft-lbs / 27 Nm.
Deutz models: Torque the flex plate mounting
Then torque the flex plate mounting bolts in f
sequence to 40 ft-lbs / 54 Nm.
a pump
Perkins models: Torque the flex plate mounting b pump shaft
c pump coupler
bolts in sequence to 49 ft-lbs / 66 Nm. d flex plate with raised spline
Then torque the flex plate mounting bolts in e engine flywheel
sequence to 70 ft-lbs / 95 Nm. f 3/16 inch / 4.8 mm gap - Diesel Models
0.080 inch / 2 mm gap - Ford Models
1
4 Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
6 3 to 61 ft-lbs / 83 Nm.
5 Proceed to Repair Procedure, How to Install the
Pump and Bell Housing Assembly.
4 5
2
Ford and Deutz models
2 3
Perkins models
ENGINES REV A
How to Install a Type "B" 6 1

Flex Plate
1 Install the flex plate onto the engine flywheel
with the rubber vibration isolators towards the
pump. 4 3
2 Apply Loctite® removable thread sealant to the
flex plate fasteners and loosely install the
fasteners.
3 Deutz models: Torque the flex plate mounting
2 5
Then torque the flex plate mounting bolts in
sequence to 40 ft-lbs / 54 Nm. Deutz models
Ford and Perkins models: Torque the flex 1

plate mounting bolts in sequence to
14 ft-lbs / 19 Nm. Then torque the flex plate
mounting bolts in sequence to 20 ft-lbs / 27 Nm. 6 3
4 Apply a high viscosity coupling grease
(Genie part number 128025) to the splines of the
pump shaft and flex plate.
4 5
Shell Alvania® Grease CG, NLGI 0/1 or equivalent.
2
Ford models
6 3
4 5
Perkins models
REV A ENGINES
How to Install the Pump and Bell 6 1

Housing Assembly 10 C C 8
C C
1 Install the pump and bell housing assembly.
Deutz models: Torque the bell housing 4 3
C C
mounting bolts labeled "C" in sequence to 28 ft-
lbs / 38 Nm. Then torque the bell housing
mounting bolts labeled "C" in sequence to 40 ft- C C
11 12
lbs / 54 Nm.
Ford models: Torque the bell housing mounting C C
bolts labeled "A" and "B" in sequence to 28 ft- 7 C C 5
lbs / 38 Nm and the mounting bolts labeled "C"
to 49 ft-lbs / 66 Nm. Then torque the bell 2 9
housing mounting bolts labeled "A" and "B" in Deutz models
sequence to 40 ft-lbs / 54 Nm and the mounting
bolts labeled "C" to 70 ft-lbs / 95 Nm.
6
Perkins models: Torque the bell housing 1 B
B
mounting bolts labeled "B" in sequence to 3
A
28 ft-lbs / 38 Nm and the mounting bolts labeled
"A" to 49 ft-lbs / 66 Nm. Then torque the bell
housing mounting bolts labeled "B" in sequence
to 40 ft-lbs / 54 Nm and the mounting bolts 4 A
labeled "A" to 70 ft-lbs / 95 Nm.

Component damage hazard. C C
Type "A" flexplate: When 5
7 B
installing the pump, do not force 2
the pump coupler into the flexplate
or damage to the pump shaft seal Ford models
may occur.
Component damage hazard. Do 6 1
not force the drive pump during
A A
installation or the flex plate teeth
may become damaged.
9
B
B
4 5
B
B B
8 B B 7
2 3
Perkins models
ENGINES REV A
5-4
Engine Fault Codes -
Ford Models
How to Retrieve Engine Fault

Codes
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel
injection and make constant and instantaneous
changes to ignition timing, fuel delivery and throttle
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.
REV A
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.
1 Locate the two hydraulic tank valves at the sure to open the two hydraulic tank
hydraulic tank through the access hole valves and prime the pump after
underneath the turntable. Close the valves. installing the pump.

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
HYDRAULIC PUMPS REV A
6-2 2 Locate the two hydraulic tank valves at the

hydraulic tank through the access hole
Drive Pump underneath the turntable. Close the valves.
The drive pump is a bi-directional variable Component damage hazard. The

displacement piston pump. The pump output is engine must not be started with the
controlled by the electro-proportional controller, hydraulic tank shut-off valves in
located on the pump. The only adjustment that can the closed position or component
be made to the pump is the neutral or null damage will occur. If the tank
adjustment. Any internal service to the pump valves are closed, remove the key
should only be performed at an authorized Eaton from the key switch and tag the
Hydraulics center. Call Genie Industries Service machine to inform personnel of the
Department to locate your local authorized service condition.
center.
How to Remove the Drive Pump

work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system open closed
and cause severe component
damage. Dealer service is 3 Tag and disconnect and plug the hydraulic
recommended. hoses from the drive and function pumps.
Cap the fittings on the pumps.
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 Disconnect the electrical connection at the squirt or spray.
electro-proportional controller located on the
drive pump. 4 Support the pump with a lifting device and
remove the two drive pump mounting fasteners.
REV A HYDRAULIC PUMPS
5 Carefully pull the drive pump out until the pump 4 Ford models: Close the valve on the LPG tank
coupler separates from the flex plate. then disconnect the hose from the tank. Move
the fuel select switch to the LPG position.
6 Remove the drive pump from the machine.
Perkins models: Disconnect the engine wiring
harness from the fuel solenoid at the injector
hydraulic pump may become
pump.
unbalanced and fall if not properly
supported. Deutz models: Hold the manual fuel shutoff
valve clockwise to the closed position.
Component damage hazard. When
installing the pump, do not force a
the pump coupler into the flexplate
or damage to the pump shaft seal
may occur.
sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
How to Prime the Pump

1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the test port on the drive pump.
2 Remove the safety pin (if equipped) from the a manual fuel shutoff valve
engine pivot plate latch.
5 Have another person crank the engine with the
Note: The engine pivot plate latch is located under starter motor for 15 seconds, wait 15 seconds,
the engine turntable pivot plate at the counterweight then crank the engine an additional 15 seconds
end of the machine. or until the pressure reaches 320 psi / 22 bar.
3 Open the engine pivot plate latch and swing the 6 Ford models: Connect the LPG hose to the
engine pivot plate out and away from the LPG tank and open the valve on the tank. Move
machine. 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.
REV A
Manifolds
7-1
Function Manifold Components
The function manifold is located underneath the ground controls side turntable cover.
Index Schematic
No. Description Item Function Torque
1 Counterbalance valve ....................... H ........... Platform level down .......................... 30-35 ft-lbs / 41-47 Nm
2 Counterbalance valve ....................... G ........... Platform level up ............................... 30-35 ft-lbs / 41-47 Nm
3 Proportional solenoid valve .............. M .......... Boom extend/retract ......................... 30-35 ft-lbs / 41-47 Nm
4 Solenoid valve, 2 position 3 way ...... C ........... Boom retract ..................................... 30-35 ft-lbs / 41-47 Nm
5 Solenoid valve, 2 position 3 way ...... B ........... Boom extend .................................... 30-35 ft-lbs / 41-47 Nm
6 Solenoid valve, 3 position 4 way ...... D ........... Turntable rotate ................................ 20-25 ft-lbs / 27-34 Nm
7 Proportional solenoid valve .............. T ........... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
8 Solenoid valve, 3 position 4 way ...... BB ......... Steer left/right .................................... 20-25 ft-lbs / 27-34 Nm
9 Check valve, 30 psi / 2 bar ................ I ............ Differential sensing circuit,
platform rotate left and
jib boom up (S-65, S-65 TRAX) ........ 20-25 ft-lbs / 27-34 Nm
10 Check valve, 30 psi / 2 bar ................ J ............ Differential sensing circuit,
platform rotate right and
jib boom down (S-65, S-65 TRAX) ... 20-25 ft-lbs / 27-34 Nm
11 Check valve ....................................... N ........... Differential sensing circuit,
boom extend/retract .......................... 10-12 ft-lbs / 14-16 Nm
12 Solenoid valve, 2 position 3 way ...... F ........... Boom down ....................................... 30-35 ft-lbs / 41-47 Nm
13 Solenoid valve, 2 position 3 way ...... E ........... Boom up ........................................... 30-35 ft-lbs / 41-47 Nm
14 Check valve ....................................... O ........... Differential sensing circuit,
turntable rotate ................................. 10-12 ft-lbs / 14-16 Nm
15 Check valve ....................................... R ........... Differential sensing circuit,
boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
16 Priority flow regulator valve,
3.5 gpm / 13.2 L/min .......................... AA ......... Steer left/right circuit ......................... 30-35 ft-lbs / 41-47 Nm
17 Differential sensing valve,
110 psi / 7.6 bar ................................. S ........... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
150 psi / 10.3 bar .............................. P ........... Turntable rotate circuit ...................... 30-35 ft-lbs / 41-47 Nm
This list continues. Please turn the page
MANIFOLDS REV A
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
REV A MANIFODLS
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, S-65 TRAX) ............. 20-25 ft-lbs / 27-34 Nm
27 Check valve, 30 psi / 2 bar ................ EE ......... Platform rotate and jib
boom circuit (S-65, S-65 TRAX)
(prevents hydraulic hoses
from draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
110 psi / 7.6 bar ................................. L ........... Boom extend/retract circuit ............... 30-35 ft-lbs / 41-47 Nm
29 Needle valve ..................................... U ........... Platform level circuit ......................... 30-35 ft-lbs / 41-47 Nm
30 Solenoid valve, 3 position 4 way ...... V ........... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
31 Solenoid valve, 3 position 4 way ...... Y ........... Platform rotate and jib boom
up/down (S-65, S-65 TRAX) ............. 20-25 ft-lbs / 27-34 Nm
MANIFOLDS REV A
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
REV A 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.
2 Start the engine from the ground controls.
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.
MANIFOLDS REV A
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
REV A 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 ............ Turntable rotation brake release
2 Solenoid valve, 2 position 3 way ... KK ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
3 Solenoid valve, 2 position 3 way .... LL ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm
4 Check valve ...................................... II ............ Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm
1 2 3
JJ KK LL
II
4
MANIFOLDS REV A
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
REV A 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
MANIFOLDS REV A
How to Set Up the Oscillate 8 Verify that the ground and drive chassis are
completely level.
Directional Valve
9 Adjust the heim joint until the hole lines up with
Note:Adjustment of the oscillate directional valve the retaining fastener hole in the axle.
linkage is only necessary when the linkage or valve
has been replaced. 10 Install the heim joint to the axle and tighten the
jam nut.
1 Lower the boom to the stowed position.
11 Check to be sure the drive chassis is
2 Use a "bubble type" level to be sure the floor is completely level.
completely level.
12 Measure the distance between the drive chassis
Tip-over hazard. Failure to perform and the non-steer axle on both sides (from the
this procedure on a level floor inside of the drive chassis).
could compromise the stability of
the machine resulting in the Note: If the distance is not equal and the
machine tipping over. adjustment to the linkage was completed with the
ground and drive chassis level, repeat steps 6
3 Check the tire pressure in all four tires and add through 11 OR consult Genie Industries Service
air if needed to meet specification. Department.
Note: The tires on some machines are foam-filled
and do not need air added to them.
4 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.
7 To level the drive chassis, start the engine and
push up or pull down on the threaded rod until
the machine is completely level.
REV A 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.
MANIFOLDS REV A
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
REV A 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
MANIFOLDS REV A
1 2
TT WW
VV UU XX SS
6 5 4 3
REV A 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.
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).
MANIFOLDS REV A
REV A 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
MANIFOLDS REV A
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
REV A 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.
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).
MANIFOLDS REV A
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. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromotive force which operates the solenoid temperature, the coil resistance will typically
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.
REV A 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 -

with electrically charged circuits a multimeter
b 9V DC battery
c 10Ω resistor
injury. Remove all rings, watches d coil
and other jewelry.
Note: Dotted lines in illustration indicate a
1 Test the coil for resistance. See, How to Test a reversed connection as specified in
Coil. step 6
2 Connect a 10Ω resistor to the negative terminal 3 Set a multimeter to read DC current.
of a known good 9V DC battery. Connect the Note: The multimeter, when set to read DC current,
other end of the resistor to a terminal on the should be capable of reading up to 800 mA.
coil.
4 Connect the negative lead to the other terminal
Ω
Resistor, 10Ω on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
Note: The battery should read 9V DC or more when
measured across the terminals. 5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Turntable Rotation Components REV A
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.
REV A 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.
Axle Components REV A
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 or tracks.
2 Tag, disconnect and plug the oscillating axle
cylinder.
or spray.
REV A
Track Components
10-1 How to Replace the Track
Track Assembly, 1 Remove the track assembly from the machine.
S-60 TRAX and S-65 TRAX See How to Remove a Track Assembly.
Note: The sprocket is comprised of two halves.
How to Remove a Track Before removing the track assembly from the
Assembly machine and to ease the removal of the sprocket,
drive the machine until one complete half of the
Note: Perform this procedure on a firm, level sprocket is located above the undercarriage of the
surface with the boom in the stowed position. track assembly.
1 Select a track assembly to remove. Loosen and 2 Loosen the grease plug on the track tension
remove as many sprocket retaining fasteners as cylinder to relieve the track tension. Clean up
possible from the hub adapter. any grease that has spilled.
2 Drive the machine in either direction just enough 3 Remove the 2 sprocket retaining fasteners.
to access the remaining fasteners. Do not Remove the sprocket half from the track
remove the retaining fasteners. assembly.
3 Chock the tracks at the opposite end of the 4 Carefully remove the track from the
machine to prevent the machine from rolling. undercarriage.
4 Center a lifting jack of ample capacity 5 Use an overhead crane to lay the undercarriage
(20,000 lbs / 10,000 kg) under the drive chassis on its side with the drive sprocket bearing
between the tracks. assembly facing upward and the track tension
cylinder towards the ground.
drive chassis for support.
the sprocket.
fasteners from the hub adapter.
8 Carefully remove the track assembly from the
TRACK COMPONENTS REV A
6 Install the new track onto the undercarriage. 9 Rotate the sprocket half until the split tooth of
the sprocket is lower than the other side.
the center-point of the track, above the a
sprocket.
8 Use the overhead crane to raise the track
assembly to an upright position. Rest the
assembly on the floor or ground to remove any
slack in the lower portion of the track.
Note: Be sure the idler and bogey wheels are
aligned with the inside surface of the track.
a split tooth
10 Using an overhead crane or other suitable lifting

device, lift up on the rubber track to create
enough room to install the other sprocket half.
11 Install the sprocket half, removed in step 3,
while engaging the sprocket teeth with the
rubber track.
a b a
Note: Be sure to align the split tooth in both of the
a idler wheels sprocket halves.
b bogey wheels
12 Insert a pin or rod through the wheel stud hole
closest to the split tooth to hold the sprocket in
place.
13 Insert a pointed pry bar into the wheel stud hole
near the top of the sprocket. Insert another
pointed pry bar into the wheel stud hole at the
opposite side of the split tooth.
REV A TRACK COMPONENTS
14 Using the pry bars, lift the sprocket half into 19 Pump grease into the grease zerk fitting until
position. Install the 2 sprocket retaining grease, free from air, comes out of the grease
fasteners and torque to specification. Refer to plug. Securely tighten the grease plug. Do not
Section 2, Specifications. overtighten.
15 Attach a lifting strap from an overhead crane to 20 Continue to pump grease into the grease fitting
the center-point of the track assembly, above just until the idler wheel moves. Check the track
the sprocket. tension.
16 Install the track assembly onto the drive hub Result: There should be less than 1 inch /
adapter while guiding the hub adapter studs into 2.5 cm of gap between the bogey wheels and
the sprocket of the track assembly. Install as the inside surface of the track.
many sprocket retaining fasteners as possible Proceed to step 22.
Result: There is 1 inch / 2.5 cm or more of gap
between the bogey wheels and the inside
Crushing hazard. The track surface of the track. Proceed to step 21.
unbalanced and fall when installed
onto the machine if not properly
17 Adjust the track tension. Locate the grease plug
on the track tension cylinder. Loosen the plug,
but do not remove it.
18 Locate the grease zerk fitting on the other side
of the track tension cylinder.
Outside Inside
a bogey wheels
a b
a grease zerk
b grease plug
TRACK COMPONENTS REV A
21 Continue to pump grease into the cylinder until

the track has proper tension.
Do not over tighten the track.
Overtightening the track will cause
the machine to lose power during
operation.
Note: If the track becomes too tight, loosen the
grease plug on the cylinder to remove grease and
loosen the track.

lower the machine.
machine off.

or equivalent.
January 2010 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the Operator's
Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropriate fault code thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Repair any machine damage or malfunction with electrically charged circuits
before operating the machine. could result in death or serious
Unless otherwise specified, perform each repair and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Machine parked on a firm, level surface
• Boom in stowed position
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Welder disconnected from the machine (if
equipped with the weld cable to platform
option)
• Wheels chocked
• All external AC power disconnected from the
machine
Section 5 • Fault Codes January 2010
FAULT CODES REV A
Control System 3 Determine the error source: The red LED

indicates the error source and will flash two
separate codes. The first code will indicate the
How to Retrieve Control System first digit of the two digit code, flashing once per
Fault Codes second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Note: At least one fault code is present when the
alarm at the platform controls produces two short Note: When the red LED is flashing the code, the
beeps every 30 seconds for 10 minutes. yellow LED will be on solid.
Note: Perform this procedure with the engine off, 4 Determine the error type: The yellow LED
the key switch turned to platform controls and both indicates the error type and will flash two
red Emergency Stop button pulled out to the on separate codes. The first code will indicate the
position at both the ground and platform controls. first digit of the two digit code, flashing once per
second. It will then pause for 1.5 seconds and
1 Open the platform control box lid. flash the second digit once per 0.5 second.
Electrocution/burn hazard. Contact Note: When the yellow LED is flashing the code,
with electrically charged circuits the red LED will be on solid.
injury. Remove all rings, watches 5 Use the fault code table on the following pages
and other jewelry. to aid in troubleshooting the machine by
pinpointing the area or component affected.
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.
REV A 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,
21 Fault
Continued on next page
FAULT CODES REV A

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.
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.
REV A FAULT CODES

ID Name ID Name
51 Drive joystick 11 Value at 5V Joystick is operating Cycle power off,
12 Value too high outside of operational then on and
calibrated.
18 Just calibrated
53 Drive flow valve Valve is operating Cycle power off,
(EDC) 12 Value too high outside of operational then on and
17 Not calibrated
except threshold for thresholds
18 Just calibrated
54 Drive brake valve Valve is operating Cycle power off,
outside of operational then on and
21 Fault
55 High speed drive Motor speed frozen in Cycle power off,
motor Valve the low state. Alarm then on and
21 Fault
sounds indicating problem should be
fault. corrected.
61 Steer joystick 11 Value at 5V Joystick is operating Cycle power off,
12 Value too high outside of operational then on and
17 Not calibrated until joystick is Calibrate Joystick
calibrated.
18 Just calibrated
62 Steer directional Valve is operating Cycle power off,
21 Fault
FAULT CODES REV B
Ford DSG-423 EFI Engine 4 Continue to hold the run/test toggle switch in the
test position and count the blinks.
How to Retrieve Ford Engine Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three times.
Fault Codes After the fault codes, the check engine light will
The ECM constantly monitors the engine by the blink a code 123 three times again indicating the
use of sensors on the engine. The ECM also uses end of the stored codes.
signals from the sensors to initiate sequential fuel
Note: If any fault codes are present, the ECM will
injection and make constant and instantaneous
blink a three digit code three times for each code
changes to ignition timing, fuel delivery and throttle
stored in memory. It will blink the first digit of a
position to maintain the engine's running condition
three digit code, pause, blink the second digit,
at its highest efficiency while at the same time
pause, and then blink the third digit. For example:
keeping exhaust emissions to a minimum. When a
the check engine light blinks 5 consecutive times,
sensor fails or returns signals that are outside of
blinks 3 times and then 1 time. That would indicate
set parameters, the ECM will store a fault code in
code 531.
memory that relates to the appropriate sensor and
will turn on the Check Engine Light. Note: Once a fault code has been retrieved and the
repair has been completed, the ECM memory must
Note: Perform this procedure with the key switch in
be reset to clear the fault code from the ECM. See
the off position.
How to Clear Engine Fault Codes from the ECM.
1 Open the ground controls side cover and locate
the run/test toggle switch on the side of the How to Clear Engine Fault
ground control box. Codes from the ECM
2 Pull out the red Emergency Stop button to the Note: Perform this procedure with the engine off
on position at both the ground and platform and the key switch in the off position.
controls.
3 Move and hold the run/test toggle switch to the
the battery.
test position.
2 Disconnect the negative battery cable from the
Result: The check engine light should turn on.
battery for a minimum of 5 minutes.
The check engine light should begin to blink.
and other jewelry.
3 Connect the negative battery cable to the
battery.
REV B FAULT CODES
Code Description Code Description

111 CL (Closed Loop) high LPG IAT (Intake Air Temperature) high
211 voltage
112 EGO open / lazy pre-cat 1
IAT (Intake Air Temperature) low
113 EGO open / lazy pre-cat 2/post-cat 1 212 voltage
114 EGO open / lazy post-cat 1 IAT (Intake Air Temperature) higher
213 than expected 1
115 EGO open / lazy post-cat 2
IAT (Intake Air Temperature) higher
121 CL (Closed Loop) high gasoline bank 1 214 than expected 2
122 CL (Closed Loop) low gasoline bank 1 215 Oil pressure low
124 CL (Closed Loop) low LPG ECT / CHT (Engine/Cylinder Head
221 Coolant Temperature) high voltage
133 Gasoline catalyst monitor 1
ECT / CHT (Engine/Cylinder Head
134 LPG catalyst monitor 222 Coolant Temperature) low voltage
AL (Adaptive Learn) high gasoline bank 1 223 CHT higher than expected 1
141
224 CHT higher than expected 2
142 AL (Adaptive Learn) low gasoline bank 1 225 ECT higher than expected 1
143 AL (Adaptive Learn) high LPG 226 ECT higher than expected 2
MAP (Manifold Absolute Pressure) high
144 AL (Adaptive Learn) low LPG 231 pressure
161 Battery Voltage high MAP (Manifold Absolute Pressure) low
232 voltage
162 Battery Voltage low
AUX analog PD1 high BP (Barometric Pressure) high
163 234 pressure
164 AUX analog PD1 low
235 BP (Barometric Pressure) low pressure
165 AUX analog PU3 high
166 AUX analog PU3 low 242 Crank sync noise
167 AUX analog PUD1 high 243 Never crank synced at start
168 AUX analog PUD1 low 244 Cam loss
171 AUX analog PUD2 high 245 Cam sync noise
172 AUX analog PUD2 low 246 Crank loss
173 AUX analog PUD3 high 253 Knock1/2 sensor open 1
174 AUX analog PUD3 low 254 Knock1/2 excessive signal 1
181 AUX DIG1 high

182 AUX DIG1 low For further engine fault code troubleshooting and
183 AUX DIG2 high diagnostic information, refer to the Ford DSG-423
AUX DIG2 low EFI Service Manual (EDI part number 1060040).
184
185 AUX DIG3 high
Ford DSG 423 EFI Service Manual
186 AUX DIG3 low Genie part number 119494
FAULT CODES REV B

261 FP (Fuel Pressure) high voltage Primary Loop Open or Low-Side Short
413 to Ground 2
262 FP (Fuel Pressure) low voltage
FT (Fuel Temperature) gasoline high
414 Primary Coil Shorted 2
271 voltage Primary Loop Open or Low-Side Short
415 to Ground 3
FT (Fuel Temperature) gasoline low
272 voltage 416 Primary Coil Shorted 3
FT (Fuel Temperature) gaseous fuel Primary Loop Open or Low-Side Short
273 high voltage
421 to Ground 4
FT (Fuel Temperature) gaseous fuel 422 Primary Coil Shorted 4
274 low voltage TPS1 (Throttle Position Sensor) high
Injector Loop Open or Low-Side Short 531 voltage
311 to Ground 1 TPS1 (Throttle Position Sensor) Low
312 Injector Coil Shorted 1 532 voltage
Injector Loop Open or Low-Side Short TPS2 (Throttle Position Sensor) high
313 to Ground 2 533 voltage
314 Injector Coil Shorted 2 TPS2 (Throttle Position Sensor) low
534 voltage
Injector Loop Open or Low-Side Short
315 to Ground 3 TPS1 (Throttle Position Sensor) higher
535 than TPS2
316 Injector Coil Shorted 3
TPS1 (Throttle Position Sensor) lower
Injector Loop Open or Low-Side Short 536
321 to Ground 4
than TPS2
Unable to reach higher TPS (Throttle
322 Injector Coil Shorted 4 537 Position Sensor)
FPump motor loop open or high-side Unable to reach lower TPS (Throttle
351 shorted to ground 538 Position Sensor)
FPump motor high-side shorted to
352 power
539 TPS1/2 simultaneous voltages
EPR delivery pressure higher than 541 AUX analog PU1 high
353 expected 542 AUX analog PU1 low
EPR delivery pressure lower than
354 expected
543 AUX analog PU2 high
355 EPR comm lost 544 AUX analog PU2 low
359 Fuel run-out longer than expected 551 Max govern speed override
361 EPR voltage supply high 552 Fuel rev limit
362 EPR voltage supply low 553 Spark rev limit
363 EPR internal actuator fault detection For further engine fault code troubleshooting and
364 EPR internal circuitry fault detection diagnostic information, refer to the Ford DSG-423
EFI Service Manual (EDI part number 1060040).
365 EPR internal comm fault detection
Primary Loop Open or Low-Side Short
411 to Ground 1 Ford DSG 423 EFI Service Manual
412 Primary Coil Shorted 1
REV B FAULT CODES

611 COP failure 736 PWM3-Gauge3 short to power
612 Invalid interrupt 741 PWM4 open / ground short
613 A/D loss 742 PWM4 short to power
614 RTI 1 loss 743 PWM5 open / ground short
615 Flash checksum invalid 744 PWM5 short to power
616 RAM failure MIL (Malfunction Indicator Light) control
761 ground short
631 5VE1 low voltage
632 5VE1 high voltage 762 MIL (Malfunction Indicator Light) open
633 5VE2 high voltage MIL (Malfunction Indicator Light) control

763 short to power
634 5VE2 low voltage
771 Tach output ground short
635 5VE1/2 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 For further engine fault code troubleshooting and
646 CAN Tx failure diagnostic information, refer to the Ford DSG-423
EFI Service Manual (EDI part number 1060040).
647 CAN Rx failure
648 CAN address conflict failure
Ford DSG 423 EFI Service Manual
655 RTI 2 loss Genie part number 119494
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
734 PWM2-Gauge2 short to power
FAULT CODES REV A
Platform Load Sense System, 4 Determine the error source: The red LED
indicates the error source and will flash two
S-60 HC separate codes. The first code will indicate the
first digit of the two digit code, flashing once per
How to Retrieve Platform Load second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Sense System Fault Codes
5 Determine the error type: The green LED
Note: Perform this procedure with the engine off,
indicates the error type and will flash two
the key switch turned to ground controls and the
separate codes. The first code will indicate the
red Emergency Stop buttons pulled out to the on
first digit of the two digit code, flashing once per
position at both the ground and platform controls.
second. It will then pause for 1.5 seconds and
1 Open the ground controls side turntable cover. flash the second digit once per 0.5 second.
2 Locate the operational and safety controllers 6 Use the fault code table on the following pages
near the ground control box. to aid in troubleshooting the machine by
pinpointing the area or component affected.
3 Determine whether a safety or operational fault
exists by visually inspecting which controller
has flashing LEDs.
Note: If the LEDs are flashing on both controllers,
determine the fault code on one controller at a time.
f a
e b
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)
REV A 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.
FAULT CODES REV A

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.
REV A 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.
FAULT CODES REV A

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.
REV A 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
FAULT CODES REV A

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.
REV A 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
January 2010 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
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Section 6 • Schematics January 2010
Electrical Symbols Legend

REV A
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
Hydraulic Symbols Legend

REV A
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
Ford Engine Relay Layout

REV A
Ford DSG-423 EFI
Starter Empty
Relay
F1-10A F2-5A
Fuel Power
Pump Relay F3-10A F4-15A
Relay
F5-15A
Limit Switch Location Legend

REV A
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)
Electrical Schematic, S-60 HC

6-7 6-8
Electrical Schematic, S-60 HC REV B

A B C D E F G H I J K L M N
1 STRING POTENTIOMETER
LS19
STRING TENSION
S22 S23 LIMIT SWITCH
14 13
NO HC
OR
RD
BN
BK
YL
BL
24 23
PLATFORM BOX
2
C45-4 WH
C45-1 RD
C45-2 BN
C45-3 BK
PLATFORM SUPPORT
C44-4
C44-5
C44-6
C44-1
C44-2
C44-3
C9P-2
P24FS WH
SAFETY CONTROLLER OPERATIONAL CONTROLLER
TS1
AUXILIARY 5
NOT USED
NOT USED
NOT USED
2
C183RCV
C169ENV
V183RCV
GROUND
GROUND
P109SEN
P1-10 C123PBS
C141PBS
C177ERL
P1-11 C145CAL
P1-12 C175LDS
PUMP
C167PSL
C133PLA
C173PEL
P2-11 R134BAT
P2-12 R134BAT
C166PSL
P1-11 S170ENL
P1-12 S171ENL
R134BAT
P110RET
R134BAT
P110RET
P174BAT
P63SEN
P1-10 C94LDS
P26BAT
C172PL
P2-10 C168PL
CAN +
CAN +
CAN -
CAN -
PLATFORM LOAD CELL C1P-1
C27AUX RD
1 3 4 6
P63SEN OR/RD
P2-1
P2-2
P2-3
P2-4
P2-5
P2-6
P2-7
P2-8
P2-9
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
3
P109SEN GR/WH
P109PSL GR/WH
D63
WH - CH1 RETURN
P63PSL OR/RD
OR - CH2 OUTPUT
GR - CH1 OUTPUT
C53
BL - CH2 RETURN
C41 C42
RD - PWR
BK - GND
+
H1
120W L4
PLATFORM
C183RCV BL
C134BAT RD
120W OVERLOAD
C133PLA GR/BK
C3P-12
1 1
C46-2 C175LDS WH/BK C5-4
4 C166PSL OR C46-1 C94LDS WH C5-3 C5-1 C134PWR RD
C4P-12 C134PWR RD 2 2
P110RET BK C46-3 P110RET BK C5-2

3 3
C134BAT RD
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 C134BAT RD C4P-9 C134BAT RD

L50
BOOM EXTEND/RETRACT F.C.
C40B-10
C40B-12
C40B-11
ACTIVE ENVELOPE
C40B-7
C40B-6
C40B-1
C40B-8
C40B-9
C40B-2
C40B-3
C40B-4
C40B-5
COM PORT A D82CAN+ YL
C30-2 C30-1
COM PORT B D82CAN- GR C173PEL BK
TB9
5
BOOM UP/DOWN F.C.
GROUND BOX
C145CAL RD/WH
C133PLA GR/BK
C29-2 C29-1
C177ERL BL/BK
C168PL BL/RD
S170ENL WH/RD
S171ENL WH/BK
C172PL BL
C134PBAT RD
P174BAT WH
TB3
V183RCV BL
P23BAT WK
R134BAT RD
R7PBE BK
TB7A
GND BR
TB2A TS73
C7PBE BK
CALIBRATION C11-2 C11-1 TB134 TS49

C37-1
SWITCH WH WH BK D48
P109SEN GR/WH
RECOVERY
1 2
P63SEN OR/RD
13 14 SWITCH C3PUD RD/WH TB3

LS2
TB23A TB-0A
C2PBD RD/BK
RD NO/HC 4 5
21 3 R2PBD RD/BK C2PBD RD/BK
6 LS5
CABLE NC
C10-1 C10-2 TB40A
TB27C
C27AUX RD 30 D49
TENSION 6
BK WH OR
22 CR52 CR53 D47
BR BOOM BOOM 13 LS1 14 1 2
CR56 C8PBR BK/WH TB8
DOWN EXTEND NO/HC RECOVERY 87A 87
C37-2
30 86 30 86
CUTOUT CUTOUT DUAL CAPACITY C9PER BK/WH TB9
86 85 3
CR59 C134LS WH R8PBR BK/WH D46
RD/BK
87 87A 85 87 87A 85 POWER ON
R7PBE BK
86 30
C2PBD
30 85 30 85 V183RCV BL
C114-5
C114-6
C114-4
C114-2
C114-1
C114-3
C2PBD RD/BK
85 87A 87
R134BAT RD 1 1 R134BAT RD
C7PBE BK
C13-1
C16-1
87 87A 86 87 87A 86
P174BAT WH 6 6
7 R174BAT RD 7 7
C32
OR
RD
BN
BK
YL
BL
C133PLA GR/BK 8 8 L45

+
R18 R22PWR BK 5 5 H6 PLATFORM
R17 OVERLOAD
5W 5W P22BAT BK 4 4
CR55 NOTES:
CR54
LOAD SENSE
C16-2
C13-2
LOAD SENSE 1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
CUTOUT PLATFORM CUTOUT GROUND TB134C C133PLA GR/BK
S17 S18
C2PBD RD/BK
B00M ANGLE SENSOR
8
B00M DOWN
B00M EXTEND
SWING / LOWER LINK ES0390D
N
REV B
14
24
LS19
NO HC
STRING
23
LIMIT SWITCH
POTENTIOMETER
C45-2 BK
C45-3 BR
C45-4 RD
13 C45-1 WH
M
P63PSL OR/RD
P109PSL GR/WH
P63SEN OR/RD (C53-6)
P109SEN GR/WH (C41-8)

S22
L
P110RET BR (C41-9) C44-4 OR
P109PSL GR/WH C44-5 BN

C167PSL OR/BK (C42-2) C44-6 YL
P110RET BK (C53-7) C44-1 RD

STRING
P63PSL OR/RD (C45-2) C44-2 BK

C166PSL OR (C53-9) C44-3 BL
POTENTIOMETER
S23
K
S17
P110RET BK (C41-9) C114-5 OR

P109ASEN GR/WH (C41-8) C114-6 BN
C123PBS RD/BK (C41-10) C114-4 YL
P110RET BK (C53-7) C114-2 RD
P63SEN OR/RD (C53-6) C114-1 BK

C141PBS RD (C53-8) C114-3 BL
R134BAT RD (C41-2 / C42-11,12)
S18
1
J
C134BAT RD (C46-6)
BOOM ANGLE SENSOR
S170ENL WH/RD (C53-11)

3
S171ENL WH/BK (C53-12)

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
P23BAT WH (C41-7)
9
120W
C133PLA GR/BK (C42-5)

V183RCV BL (C42-7)
RTESISTOR
I
TERMINATING
C145CAL RD/WH (C41-11)

10 11 12
C53
GRAY
GND BR (C40-6)
P1-1 GROUND
R134BAT RD (C40-1)
P1-2 P20BAT
D82CAN+ YL
P1-3 CAN +
D81CAN- GR
P1-4 CAN -
P1-5 NOT USED

P63SEN OR/RD (C45-1)
P1-6 P63SEN
P110RET BK (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, C51-3)

P1-10 C94LDS
SAFETY MODULE

P1-11 S170ENL

P1-12 S171ENL
D82CAN+ YL COM PORT A

120W
D81CAN- GR COM PORT B

G
TO PC
CONNECTS
RTESISTOR
TERMINATING
C41
GRAY
GND BR (C40-6)
P1-1 GROUND
R134BAT RD (C40-1)
P1-2 P20BAT
D82CAN+ YL CAN +
P1-3
D81CAN- GR
P1-4 CAN -
P1-5 NOT USED
P174BAT WH (C40-8)
P1-6 P174BAT
F
P23BAT WH (C40-9)
P1-7 P26BAT
P109SEN GR/WH (C45-3 / C114-6)

P1-8 P109SEN
P110RET BK (C46-3 / C114-5 / C44-4)

P1-9 RET
C123PBS RD/BK (C114-4)

P1-10 C123PBS
P1-11 S140CAL
C175LDS WH/BK (C46-2)

FLOW
P1-12 C175LDS
BOOM
UP/DWN
CONTROL
January 2010
C183RCV BL (C46-6)
P2-1 C183RCV
Part No. 139188
C167PSL OR/BK (C44-4)

P2-2 C167PSL
C29-2
E

P2-3 C177ERL
Y12
C169ENV GR (C46-4 / C4P-11)

P2-4 C169ENV

P2-5 C133LDS
OPERATIONAL MODULE
P2-6 NOT USED
V183RCV BL (C40-11)
P2-7 V183RCV
C172PL BL (C29-2)
P2-8 C172PL
C173PEL BK (C30-2)
P2-9 C173PEL
Y15
C168PL BL/RD (C40-7)

P2-10 C168PL
C30-2
R134BAT RD (C40-1)
P2-11 P20BAT
R134BAT RD (C40-1)
FUNCTION MANIFOLD
D
P2-12 P20BAT
FLOW
BOOM
C42
EXTEND/
BLACK
RETRACT
CONTROL
C46
BL - CH2 RETURN
C175LDS WH/BK (C51-4, C46-2) OR - CH2 OUTPUT
C
WH - CH1 RETURN
C94LDS WH (C51-3, C46-1)
GR - CH1 OUTPUT
P110RET BK (C51-2 / C46-3)

BK - GND
C134PWR RD (C51-1, C4P-12)
RD - PWR
C51
LOAD
B
SENSOR
PLATFORM
S-60 • S-65 • S-60 HC • S-60 TRAX • S-65 TRAX

C183RCV BL (C46-5)
C134BAT RD (C46-6)
C169ENV GR (C46-4)
C134PWR RD (C51-1)
ES0390D
9
11
10
12
A
C4P
Chassis Wiring Diagram, S-60 HC
6-9
Section 6 • Schematics
8
7
6
5
4
3
2
1

6-9 6 - 10
Ground Control Box Terminal Strip Wiring Diagram, S-60 HC

6 - 11 6 - 12
8
7
6
5
4
3
2
1
6 - 12
CR52 CR53 CR54 CR55
BOOM DOWN BOOM EXTEND LOAD SENSE LOAD SENSE
CUTOUT CUTOUT CUTOUT PLATFORM CUTOUT GROUND
30 30 30 30
87A 87A 87A 87A
86 87 85 86 87 85 86 87 85 86 87 85 A
C2PBD RD/BK
GND BR
GND BR
C7PBE BK (TB7A)
(C13-1 / TS49-5)
C2PBD RD/BK (TB2A)

R22PWR BK (C32-5)

R7PBE BK (C37-1)
R2PBD RD/BK (R18)

C7PBE BK (R17)
P22BAT BK (C32-4)
P174BAT WH (CR59-87A / C32-6)
R174BAT RD (C32-7)
B
R134BAT RD CR59-30
C134BAT RD (CR59-86)
S170ENL WH/RD (CR54-86/CR55-86)
S171ENL WH/BK (CR54-85/CR5585)
1 2 3 4
R18
C177ERL BL/BK (CR53-86)
5
BOOM
DOWN
BYPASS
PRIMARY
GND BR
6
C168PL BL/RD (CR52-86)

7
C40
TS73
P174BAT WH (TS73-1)
8
SWITCH
P23BAT WH (TB0B)
CALIBRATION
C7PBE BK (CR53)
1 2 3 V183RCV BL (TS49-3)
C
C134BAT RD (C40-2)
C145CAL RD/WH (TS73-2)
9 10 11 12
P134PWR RD (TB134C)
P174BAT WH (CR55-30) P174BAT WH (C40-8)
4 5 6
R134BAT RD (C40-1 / C32-1)
R2PBD RD/BK (TS49-4) C2PBD RD/BK (CR52-87)
R8PBR BK/WH (TS49-1) C3PUD RD/WH (TB3C)
D48
R2PBD RD/BK (CR56-87) D49

TS49
4
SWITCH
R8PBR BK/WH (CR56-87A)

RECOVERY
1 2
87 87 C8PBR BK/WH (TB8C)

5
C134LS WH (C10-1A) D47
R17
BOOM
87A 87A
BYPASS
EXTEND
3
PRIMARY
6
C27AUX RD (TB27C) 86 85 85 86 C9PER BK/WH (TB9C)

D46
30 30 V183RCV BL (C40-11)
R134BAT RD (CR59-30)

D
P22BAT BK (CR54-30)
GND BR
CR59
HIGH
CR56
POWER
MODULE
R22PWR BK (CR54-87)
CAPACITY
HI-CAPACITY
RECOVERY
GND BR P174BAT WH
R174BAT RD
C133PLA
(CR55-87)
(CR55-30 / CR59-87A)
GR/BK (C40-10)
BRN
TERMINAL BASE (TB)

8
7
6
5
4
1
D C B A P23BAT WH (C40-9)
12
E
KEYSWITCH POWER
0 SPARE 0
C32
8
7
5
6
1
12
4
3
RD/BK-ALARM
C32 CONNECTOR
1 PRIMARY BOOM UP 1
BRN
PLUG ANSI/CSA ONLY
D29
C2PBD RD/BK (CR52-30)
2 PRIMARY BOOM DOWN 2
BK-22D2
RD-TS52
RD-TS51
BK C7B-1
C3PUD RD/WH (TS49-5)

BL/WH-132B
3 PRIMARY BOOM FUNCTION CONTROL 3

C133PLA GR/BK
R134BAT RD (H6)
4 TURNTABLE ROTATE LEFT 4
Part No. 139188

January 2010
(H6)
5 TURNTABLE ROTATE RIGHT 5

F
GR/BK-133B
6 TURNTABLE ROTATE FUNCTION CTRL 6
C7PBE BK (CR53-30)
7 PRIMARY BOOM EXTEND 7
C8PBR BK/WH (TS49-2)
C133LDS GR/BK (L45)
+
8 PRIMARY BOOM RETRACT 8

C9PER BK/WH (TS49-2) R134BAT 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
14 PLATFORM LEVEL UP 14 +12 VOLT

D30
PLATFORM
C7
15 PLATFORM LEVEL DOWN 15
17 PLATFORM ROTATE LEFT/JIB UP 17

C7PBE BK (CR53)
C134LS WH (CR56)
18 PLATFORM ROTATE RIGHT/JIB DOWN 18

18/19 #1
C3 & C4
19 JIB SELECT VALVE 19
C2PBD RD/BK (CR52 / TS49-5)
20 +12 VOLT POWER 20
21 IGNITION POWER 21
C37-1
C13-1
H
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
KEYSWITCH POWER
C11-2
BOOM
24 CIRCUIT BREAKER POWER 24 WH
EXTEND
LIMIT SWITCH
25 OIL PRESSURE SWITCH 25 C11 (LS1)
26 OIL TEMPERATURE SWITCH 26

C27AUX RD (CR56-30)
I
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 / C32-1)
45 GENERATOR OPTION 45
L
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 C11 (LS2)
M
4 AUX PWR UNIT LS17 (C38)

5 5 GROUND
6 6 BATTERY
7 7 TO KEY SW (DIESEL ONLY)
8
ES0390D
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
REV B
N
REV B 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 (P2)
9 4
C183RCV BL CR59
C4P
10 3
C169ENV GR L50
11 2
C134PWR RD (P2)
12 1
2
PLATFORM CONTROL
HARNESS
L48
TILT ALARM LED
TS48 (ANSI/CSA OPT.)
DRIVE LIGHTS / WORK LIGHTS
(OPTION) +
JC2 7 JC1 7 JC3 7
PRIMARY BOOM UP/DOWN PRIMARY BOOM DRIVE FORWARD/REVERSE
& TURNTABLE ROTATE LEFT/RIGHT EXTEND/RETRACT & STEER LEFT/RIGHT
6 6 6
3
COMPONENT INDEX
5 5 5
JC2 BOOM PROPORTIONAL JOYSTICK:
PRIMARY BOOM UP/DOWN AND TURNTABLE ROTATE
4 4 4 JC1 BOOM PROPORTIONAL JOYSTICK:

PRIMARY BOOM EXTEND/RETRACT
JC3 DRIVE/STEER PROPORTIONAL JOYSTICK

3 L47
3 L4 3 L1 DRIVE ENABLE LED
PLATFORM
RETRACT L4 PLATFORM OVERLOAD LED
OVERLOAD
BOOM
(CE OPTION)
2 LED 2 2 L47 LOWER/RETRACT BOOM LED
+ L1
DRIVE ENABLE
+ L48 BOOM TILTED LED 4
L50 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
TS4 HI/LOW RPM TOGGLE SWITCH
TS6 GLOW PLUG TOGGLE SWITCH (OPTION)
TS7 PLATFORM ROTATE TOGGLE SWITCH

TS9 PLATFORM LEVEL TOGGLE SWITCH
C134BAT RD E-STOP (TS1-2)

TS14 DRIVE SPEED TOGGLE SWITCH
TS15 DRIVE ENABLE TOGGLE SWITCH
C133PLA GR/BK (D39)

TS47 GENERATOR TOGGLE SWITCH (OPTION)
TS48 DRIVE LIGHT/WORK LIGHT SWITCH (OPTION)
C134BAT RD (H1+, C4-9)
C134PWR RD C4-12
C183RCV BL (C4-10)
C27AUX RD (C1-1)
P23BAT WH (C7-2)
C169ENV GR C4-11
C134BAT RD (L4+)
C134BAT RD (L4+)
D63
WH
TS9
PLATFORM
TS7
PLATFORM TS14
TS47
GENERATOR
7
P3 LEVEL ROTATE DRIVE SPEED
TS6 TS2 TS4 (OPTION)
HORN HIGH / LOW
GLOW PLUG START HIGH/LOW RPM 1 1 1
P2
+ EMERGENCY
STOP
L50 2 2 2
WH OUT OF TS1
ENVELOPE LED AUXILIARY PUMP
8
CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30
Platform Control Box Wiring Diagram, S-60 HC

6 - 13 6 - 14
Electrical Schematic, S-60 HC

6 - 15 6 - 16
Electrical Schematic, S-60 HC REV A

A B C D E F G H I J K L M N
SWING / LOWER LINK BOOM COVER
1 B00M ANGLE SENSOR STRING POTENTIOMETER
S17 S18 S22 S23

OR
OR
RD
RD
BN
BN
BK
BK
YL
YL
BL
BL
PLATFORM BOX
2
C114-6
C114-1
C114-4
C114-5
C114-3
C114-2
C44-4
C44-1
C44-6
C44-5
C44-3
C44-2
PLATFORM SUPPORT
C9P-2
P24FS WH
SCON - SAFETY CONTROLLER TCON - OPERATIONAL CONTROLLER PLATFORM LOAD CELL
TS1
GROUND
GROUND
C183RCV
V183RCV
C141PBS
C169ENV
P109SEN
P1-10 C123PBS
C177ELO
C166PSL
P1-11 S170ENL
P1-12 S171ENL
P1-11 C145CAL
P1-12 C175LDS
C173PEL
R134BAT
P110RET
P2-11 R134BAT
P2-12 R134BAT
C167PSL
C133PLA
R134BAT
P110RET
AUXILIARY 5
P174BAT
P174BAT
2
P1-7 P23BAT
P63SEN
P1-10 C94LDS
C200PL
C172PL
P2-10 C168PL
C42LS
PUMP
CAN +
CAN +
CAN -
CAN -
N/C
C1P-1
C27AUX RD
P109SEN GR/WH
P109SEN GR/WH
C166PSL OR
C141PBS RD
P63SEN OR/RD
C167PSL OR/BK
P63SEN OR/RD
C123PBS RD/BK
1 3 4 6
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
P2-1
P2-2
P2-3
P2-4
P2-5
P2-6
P2-7
P2-8
P2-9
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
3 C41 D63
WH - CH1 RETURN
OR - CH2 OUTPUT
GR - CH1 OUTPUT
BL - CH2 RETURN
C53 C42
RD - PWR
BK - GND
+
H1
L4 P2
PLATFORM EMERGENCY
C183RCV BL
C134BAT RD
120W OVERLOAD STOP
120W
C133PLA GR/BK
C3P-12 1 1
C46-2 C175LDS WH/BK C51-4
4 C46-1 C94LDS WH C51-3 C51-1
C134PWR RD
C4P-12 C134PWR RD 2 2
P110RET BK C46-3 P110RET BK C51-2

3 3
C134BAT RD
C46-4 C169ENV GR C4P-11
C46-5 C183RCV BL C4P-10
C46-6 C134BAT RD C4P-9 C134BAT RD

COM PORT A D82CAN+ YL L50
C40B-10
C40B-12
C40B-11
BOOM EXTEND/RETRACT F.C.
C40B-1
C40B-3
C40B-4
C40B-6
C40B-8
C40B-9
C40B-5
C40B-7
C40B-2
D81CAN- GR ACTIVE ENVELOPE
COM PORT B
C30-2 Y15 C30-1
C173PEL BK
C55-2
C55-1
TB9
5
BOOM UP/DWN FC
C29-2 Y12 C29-1 GROUND BOX
C145CAL RD/WH
S171ENL WH/BK
S170ENL WH/RD
C133PLA GR/BK
C177ELO BL/BK
C168PL BL/RD
C172PL BL
TB3
C42LS OR/RD
P174BAT WH
C134BAT RD
V183RCV BL
R134BAT RD
C200PL BK/RD
GND BR
P23BAT WH
C7PBE BK
TB1A TB2A TB7A TS73
RD/BK CALIBRATION
C11-2 TB134 TS49
C37-1
SWITCH WH BK
1 RECOVERY D48
2
13 LS1 14 SWITCH C3PUD RD/WH TB3C
C2PBD RD/BK
C11-1
RD
21 TB23B TB-0B NO/HC 4 5

BK
3
C1PBU RD
R2PBD RD/BK C2PBD RD/BK

6 LS5
NC
TB27
C27AUX RD 30 D49
C7PBE
CABLE CR52 CR53 TB40

C10-1 C10-2 6
TENSION CR63 BOOM BOOM BK WH NO HC D47
22 BOOM UP DOWN EXTEND 13 14 1 2
BR
LS2 C8PBR BK/WH TB8C

CUTOUT CUTOUT CUTOUT CR56
NO/HC 87A 87
C37-2
30 86 30 86 30 86 RECOVERY
3 C9PER BK/RD TB9C
86 85 DUAL CAPACITY
C2PBD RD/BK
CR59 C42LS OR/RD R8PBR BK/WH D46

87 87A 85 87 87A 85 87 87A 85 POWER ON
C7PBE BK
C1PBU RD
86 30
30 85 30 85 V183RCV BL
85 87A 87
R134BAT RD 1 1 R134BAT RD
87 87A 86 87 87A 86
C16-1
C13-1
C12-1
P174BAT WH 6 6
R2PBD RD/BK
7 R174BAT RD 7 7
R1PBU RD
R7PBE BK
C133PLA GR/BK
C32
8 8 + L45
R22BAT BK 5 5 H6 PLATFORM
OVERLOAD
P22BAT BK 4 4
CR54 CR55 NOTES:
R19 R18 R17 GND BR 12 12 1. ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN THE STOWED POSITION.
C16-2
C12-2
C13-2
5W 5W 5W LOAD SENSE LOAD SENSE

PLATFORM CUTOUT GROUND CUTOUT TB134C C133PLA GR/BK
C2PBD RD/BK
8
B00M DOWN
BOOM EXTEND
B00M UP
ES0390E
S22
C167PSL OR/BK C42-2 C44-6
YL
P110RET BK C41-9 C44-5
N
OR
REV A
P109SEN GR/WH C114-6 C44-4

BN
C166PSL OR C53-9 C44-3

STRING
BL
P110RET BK C53-7 C44-2
RD
P63SEN OR/RD C53-6 C44-1
BK
POTENTIONMETER
S23
M
S17
C123PBS RD/BK C41-10 C114-4

YL
P110RET BK C41-9 C114-5
BN
P109SEN GR/WH C41-8 C114-6
OR
C141PBS RD C53-8 C114-3

BL
L
P110RET BK C53-7 C114-2

BK
P63SEN OR/RD C53-6 C114-1
RD
S18
BOOM ANGLE SENSOR
C200PL BK/RD (C42-6)
1
C134BAT RD (C46-6)
2
3
4
C177ELO BL/BK (C42-3)
5
C42LS OR/RD (C41-5)
6
C168PL BL/RD (C42-10)
K
C40
P174BAT WH (C41-6)
8
120W
P23BAT WH (C41-7)
9
RESISTOR

TERMINATING
V183RCV BL (C42-7)
10 11
12
C53
GRAY
GND BR (C41-1)
P1-1 GROUND
J
R134BAT RD (C40-1)
P1-2 R134BAT
D82CAN+ YL
P1-3 CAN+
D81CAN- GR
P1-4 CAN-
P1-5 NOT USED

P63SEN OR/RD (C114-1 / C44-1)
P1-6 P63SEN
P110RET BK (C114-2 / C44-1)
P1-7 P110RET
C141PBS RD (C114-3)
P1-8 C141PBS
C166PSL OR (C44-3)
P1-9 C166PSL
I
SAFETY MODULE
C94LDS WH (C46-1 / C51-3)

P1-10 C94LDS
P1-11 S170ENL
P1-12 S171ENL
D82CAN+ YL COM PORT A

D81CAN- GR COM PORT B
TO PC
120W
CONNECTS
RESISTOR
TERMINATING
H
C41
GRAY
GND BR (C53-1 / C55-2)

P1-1 GROUND
R134BAT RD (C42-11)
P1-2 R134BAT
D82CAN+ YL
P1-3 CAN+
D81CAN- GR
P1-4 CAN-
C42LS OR/RD (C40-6)
GND BR P1-5 C42LS
P174BAT WH (C40-8)
G
P1-6 P174BAT
P23BAT WH (C40-9)
P1-7 P23BAT
P109SEN GR/WH (C114-6 / C44-4)
P1-8 P109SEN
P110RET BK (C46-3 / C114-2 / C44-5)
P1-9 P110RET
C123PBS RD/BK (C114-4)
P1-10 C123PBS
P1-11 C145CAL
C175LDS WH/BK (C46-2 / C51-4)
P1-12 C175LDS
FLOW
BOOM
F
C183RCV BL (C46-5)
UP/DOWN
CONTROL
P2-1 C183RCV
C167PSL OR/BK (C44-6)
P2-2 C167PSL
TB3

P2-3 C177ELO
C169ENV GR (C46-4 / C4P-11)
Y12
P2-4 C169ENV
OPERATIONAL MODULE

P2-5 C133PLA
P2-6 C200PL
January 2010
V183RCV BL (C40-11)
P2-7 V183RCV
TB9
Part No. 139188
C172PL BL (Y12)
P2-8 C172PL
E
C173PEL BK (Y15)
P2-9 C173PEL
Y15

P2-10 C168PL
R134BAT RD (C41-2 / C42-12)
P2-11 R134BAT
R134BAT RD (C42-11 / C55-1)
P2-12 R134BAT
FLOW
BOOM
C42
EXTEND/
RETRACT
CONTROL
BLACK
C46
FUNCTION MANIFOLD
D
R134BAT RD (C42-12)
GND BR (C41-1)
BL - CH2 RETURN
C175LDS WH/BK (C51-4 / C46-2)
OR - CH2 OUTPUT
WH - CH1 RETURN
C94LDS WH (C51-3 / C46-1)
GR - CH1 OUTPUT
C55-1
C55-2
P110RET BK (C51-2 / C46-3)

PLATFORM
LOAD CELL
BK - GND
C
C134PWR RD (C51-1 / C4P-12)

RD - PWR
C51
B

C134BAT RD (C46-6)
C183RCV BL (C46-5)
ES0390E
C169ENV GR (C46-4)
C134PWR RD (C51-1)
9
10
12
11
A
C4P
6 - 17
8
7
6
5
4
3
2
1

6 - 17 6 - 18

6 - 19 6 - 20
8
7
6
5
4
3
2
1
6 - 20
CR52 CR53 CR54 CR55
BOOM DOWN BOOM EXTEND LOAD SENSE LOAD SENSE
CUTOUT CUTOUT PLATFORM CUTOUT GROUND CUTOUT
30 30 30 30
87A 87A
87 87 87 87
86 85 86 85 86 85 86 85
A
GND BR
GND BR
C2PBD RD/BK (TB2A)

R7PBE BK (R17)
P174BAT WH (CR59-87A / C32-6)

C7PBE BK (TB7A)
P22BAT BK (C32-4)
R22BAT BK (C32-5)
R2PBD RD/BK (R18)

C2PBD RD/BK (C13-1)
R174BAT RD (C32-7)
C7PBE BK (C37-1)
B
C200PL BK/RD (CR63-86)

P23BAT WT (CR59-86)
S170ENL WH/RD (CR54-86/CR55-86)
R18
S171ENL WH/BK (CR54-85/CR55-85)
PRIMARY BOOM
DOWN BYPASS C177ELO BL/BK (CR53-86)
5 ohms 1% 25W C42LS OR/RD (CR56-86)

TS73 C168PL BL/RD (CR52-86)
C40
CALIBRATION
P174BAT WH (TS73-1)
SWITCH
P23BAT WH (TB0B)
GND BR
R7PBE BK (CR53) 1 2 3 V183RCV BL (TS49-3)
C134BAT RD (C40-2)
C145CAL RD/WH (TS73-5)
C
1 2 3 4 5 6 7 8 9 10 11 12
P134BAT RD (TB134-1C)
P174BAT WT (CR55-30) P174BAT WT (C40-8)
R134BAT RD (C32-1 / TB134) 4 5 6
R2PBD RD/BK (TS49-4) C2PBD RD/BK (CR52-87) TS49
R8PBR BK/WH (TS49-1) C3PUD RD/WH (TB3C) RECOVERY
D48
R2PBD RD/BK (CR56-87) D49 SWITCH

4
R8PBR BK/WH (CR56-87A)

C42LS OR/RD (C40-6) 86 85 R17
1 2
85 86
5
87 87 C8PBR BK/WH (TB8C)

PRIMARY BOOM
C42LS OR/RD (C10-1) D47
87A EXTEND BYPASS
3
87A
6
C27AUX RD (TB27C) 5 ohms 1% 25W C9PER BK/WH (TB9C)

D46
30 30 V183RCV BL (C40-11)
R134BAT RD-FH
R134BAT RD (CR59-30)
CR56 CR59 P22BAT BK (CR54-30)
RECOVERY HI-CAPACITY
R22BAT BK (CR54-87)

D
DUAL CAPACITY MODULE POWER GND BR P174BAT WH

R174BAT RD
C133PLA
CR63
GND
PRIMARY BOOM C1PBU RD (TB1C)
(CR55-87)
UP CUTOUT
GND BR
R19
BRN
PRIMARY BOOM R1PBU RD 30

GR/BK (C40-10)
(CR55-30 / CR59-87A)
UP BYPASS
87A GND BR
5 ohms 1% 25W
8
7
6
5
4
1
12
86 87 85
C1PBU (C12-1) C32
12
6
8
7
5
1
4
3
C32 CONNECTOR

E
PLUG ANSI/CSA ONLY

BRN
RD (TS52)
RD (TS51)
BK (22-D2)
BK (C7B-1)
BL/WH (132B)
C133PLA GR/BK
R134BAT RD (H6 / L45)
D C TERMINAL BASE (TB) B A P23BAT WH (C40-9)
Part No. 139188

January 2010
KEYSWITCH POWER
GR/BK (133B)
0 SPARE 0
C1PBU RD (CR63-30)
1 PRIMARY BOOM UP 1
+
C133PLA GR/BK (L45)

F
C2PBD RD/BK (CR52-30)

H6
C3PUD RD/WH (TS49-5)

CE ONLY
5 TURNTABLE ROTATE RIGHT 5 +12 VOLT

PLATFORM
6 TURNTABLE ROTATE FUNCTION CTRL 6 C7
C7PBE BK (CR53-30)
C8PBR BK/WH (TS49-2)
C7PBE BK (CR53-87)

G
C9PER BK/RD (TS49-2)

C42LS OR/RD (CR56-86)
18/19 #1
9 PRIM. BOOM EXT/RET FUNC. CTRL 9
C3 & C4

C2PBD RD/BK (CR52-87 / TS49-5)
13 DRIVE ENABLE 13
C13-1
C37-1
18/19 #2
14 PLATFORM LEVEL UP 14
C1 & C2
BOOM
H
18 PLATFORM ROTATE RIGHT/JIB DOWN 18 C11-2

EXTEND
LIMIT SWITCH
19 JIB SELECT VALVE 19 C11 (LS1)
C10-1
CABLE
TENSION
22 +12 VOLT TO PLATFORM (1) 22 LIMIT SWITCH
C37 (LS5)
22 +12 VOLT TO PLATFORM (2) 22 D45
P23BAT WH (C7B-2)
KEYSWITCH POWER
I
24 CIRCUIT BREAKER POWER 24
25 OIL PRESSURE SWITCH 25

C27AUX RD (CR56-30)
27 AUXILARY PUMP 27
28 TILT ALARM 28 +12V POWER
29 MOTOR STROKE 29
J
32 BRAKE 32
33 START ENGINE 33
34 GLOW PLUG 34
36 STEER LEFT 36
C5
37 STEER RIGHT 37
K
ENGINE HARNESS
39 (UNUSED) 39
40 BOOM STOWED 40
41 ALTERNATOR PULS PICKUP 41
46 SERVICE HORN 46

P134PWR RD (CR59-87)
R134BAT RD (H6+)
L
R134BAT RD (L45)
B A
FUNCTION
U1 HARNESS
1 C9 (LS2)
FH
1 START RELAY
2 2 TACHOMETER C11 (LS2)
M
3 3 START INPUT C38 (LS17)

4 4 AUX PWR UNIT
5 5 GROUND
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
ES0390E

GROUND BOLT
N
REV A
REV A Platform Control Box Wiring Diagram, S-60 HC

C134BAT RD
L48 7 6
TILT ALARM LED
+ 8 5
TS15
DRIVE ENABLE C134BAT RD P2
2
9 4
C183RCV BL CR59 C4P
10 3
C169ENV GR L50
11 2
6 C134PWR RD P2
6 1 6 1 12 1
1
5 2 5 2
5 2
4 3 3 4 3
4
L4
PLATFORM
OVERLOAD
3
(CE OPTION)
L1
DRIVE ENABLE +
JC2 JC1 +
LED JC3 PLATFORM CONTROL
PRIMARY BOOM UP/DOWN PRIMARY BOOM DRIVE FORWARD/REVERSE HARNESS
& TURNTABLE ROTATE LEFT/RIGHT EXTEND/RETRACT & STEER LEFT/RIGHT
C134BAT RD E-STOP, TS1-2

COMPONENT INDEX
SINGLE AXIS JOYSTICK
C134PWR RD E-STOP
C133PLA GR/BK D39

JC1 PRIMARY BOOM EXTEND/RETRACT.
4
C28TTA RD/BK H1-

DUAL AXIS JOYSTICK
JC2 PRIMARY BOOM UP/DOWN, TURNTABLE JOYSTICK
L1 DRIVE ENABLE LED
L4 PLATFORM OVERLOAD LED
L47 LOWER/RETRACT BOOM LED
L48 BOOM TILTED LED
L50 OUT OF ENVELOPE LED
P2 EMERGENCY STOP BUTTON
P3 HORN SWITCH
TS1
TS2
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
5
TS3 FUEL SELECT TOGGLE SWITCH (FORD ONLY)
C134BAT RD H1+, C4-9

TS4 RPM SELECT TOGGLE SWITCH
C134PWR RD C4-12
C169ENV GR C4-11
C183RCV BL C4-10
C27AUX RD C1-1
C134PWR RD L48+
C134BAT RD L4+
TS6 GLOW PLUG TOGGLE SWITCH (OPTION)
P23BAT WH C7-2
C134BAT RD L4+
TS14 DRIVE SPEED SELECT TOGGLE SWITCH
D63
TS9 WH TS47 TS48 DRIVE LIGHT/WORK LGHT TOGGLE SWITCH (OPTION)

TS7
P3
HORN
PLATFORM
LEVEL
PLATFORM
ROTATE
TS14
DRIVE SPEED TS6 TS2 TS4
GENERATOR
(OPTION) 6
HIGH/LOW GLOW PLUG ENGINE START HIGH/LOW RPM 1 1 1
1 4
P2
5 NC NC NC EMERGENCY
+ 2
6 STOP
3 ES0390E
L50 2 2 2
WH OUT OF
TS1
ENVELOPE LED
AUXILIARY PUMP
CE LIFT/DRIVE OPTION. REPLACE WIRE WITH CR27 & CR30

7
Platform Control Box Wiring Diagram, S-60 HC

6 - 21 6 - 22
REV A Ford DSG-423 EFI Engine Wire Harness
IGNITION COILS HO2S #1
R 16 R 16 R 16 HO2S #2
ENGINE ECM Y/BK 18
CONNECTOR
1
W/PK 18 BK/LG 18 GY/R 18 SHD
Y/RD 18 GY/LB 18 GY/YL 18 A
GY/LB 18
Y/BK 18 R 16 B
1 DG/P 18 GY/R 18
SPK_COIL1A W/PK 18 DB/O 18 BK/LB 18 C
2
SPK_COIL1B D
3 Y/RD 18
SPARK_COIL2A BK/W 16 GY/R 18 GY/Y 18
4
SPK_GND DG/P
5
SPK_COIL2B
6
SPK_COIL3A
7
SPK_COIL3B
UEGOS
8 CYL #2 CYL #3 CYL #4 CYL #1 GY/R 18 TWR GASOLINE
9 A
UEGOC
10 CAM
LG/W 18
B SENSOR
UEGOP BR/W 18
UEGPR
11
W/LG 18 W/LG 18 C INTERFACE
12 DG/O 18 D
AUX ANA PD1
(FRP) AUX ANA PD2
13 W/LG 18
FORD
14 DG/P 18 DG/P 18
CAN1 +
15 O/LG 18 O/LG 18
MTRTWR4 42 PIN
CAN1 - CONNECTOR
CAN2 -
CAN2 +
16
17
18
BR/W 18
LG/R 18 LG/R 18
2
AUX ANA PD3 BR/W 18
5V EXT 1
19
GY/R 18 GY/R 18 GY/R 18
GROUND BR 16 BR 16
20 34 GND
5V RTN GY/LB 18
21
EGO1 GY/Y 18 BK/W 12
22
EGO2
23 LG/BK 18 BOSCH RING
MAP
AUX ANA PUD3
24 TMAP
25 GY 18
CRANK + DBL 18
26 LG/BK 18
CRANK - GY/R 18 BR/W 18 4
27
CAM +
28 DB/O 18 GY 18
3 CHT
CAM - DG/BK GY/R 18 2
29
SPEED + LB/R 18 1
30
SPEED -
31 LG/W
5V EXT 2 DG/BK
32 LB/R 18 36 ROADSPEED -
5V RTN 2
PULSE IN
GOV 1
33
34
35
T/LB 18
DG/W 18
LB/R 18
T/LB 18
LG/BK 18
T/LB 18
35 ROADSPEED +
24 GOV SELECT 1 C128 RPM 3
OIL PRESS GY 18 BK/W 16
36
IAT LG/R 18 BK/W 16
37
ECT LG/W LB/BK 18 LB/BK 18
38 14 FPP1
(FRT) AUX ANA PU1 W/R 18 BK/LB 18
39
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
40 BK/O 18
F2
41 W/LB 18 R/LG 18 R/LG 18 R/LG 18 R/LG 18
(BRAKE) AUX DIG 3 1 VSW P23 BAT
42 BK/Y 18 BK/Y 18
(GOV2) AUX DIG 4
43 T/Y 18 5A VSW
TACH R/LG 18
44
VSW DB/W 18
45
AUX ANA PUD2
46 P/LB 18 F3
AUX ANA PUD1 GY/W 18 R/T 14
47 R/T 14 R 14
TPS 1 Y/W 18
48
TPS 2
49 Y/DB 18 10A ECM
(FUELSELECT)AUX DIG1
AUX DIG 2
KNOCK +
50
51
52
Y/R 18
DG/P 18
GY 18
BK/Y 18
23 GOV SELECT 2 C35 RPM 4
KNOCK - DBL 18 O/LG 18
LB/BK 18 29 CAN -
53 DG/P 18
FPP1 28 CAN +
54 LB/Y 18
(FPP2) FPP2-IVS DG/O 18 DG/O 18
55 DG 18 32 ANA AUX PD1
PC TX
56 O 18
PC RX DB/W 18 DB/W 18
57 37 AUX ANA PU2B
KNOCK 2+
KNOCK 2-
58 CRANK LB/Y 18 LB/Y 18
12 FPP2
59
VBAT PROT R/T 16 RD/T 14
60
VBAT BK/LB 18 GY/R 18 GY/R 18 GY/R 18
61 33 ANA RTN
EGOH 2 BK/LG 18 BR/W 18 BR/W 18 BR/W 18
62 31 VREF
EGOH 1
63 R 14
INJ HS T 16
64
INJ1 LS
65 BR/Y 16 BK/LG 18 BOSCH THROTTLE
INJ2 LS
66 BR/LB 16 BATT(+) R 12 R 12
ALTERNATOR
INJ3 LS
INJ4 LS
INJ5 LS
67
68
69
W 16
BK/W 16
GY/W 18
Y/W 18
LB/DG 18
GY/W 18
Y/W 18
LB/DG 18
6
5
RING R 16
3 5
GROUND 4 2
70 BR/W 18 BR/W 18 RED/TAN
INJ6 LS BK/W 16 GY/R 18 GY/R 18 3 1
71
AUX PWM8 LG/P 18 GY/O 18 GY/O 18 2
72
STARTER R/Y 18 1
73
RELAY PK/LG 18
74
MIL BK/R 16
75
UEGO H
76
AUX PWM7 W/BK 18
77
LOCKOFF LB/O 18 LG/P 18 DG/W 18
78
(FUEL PUMP) AUX PWM6 R/T 16 R/Y 18
79
VBAT LB/DG 18
80
DBW +
81 BK/W 16 OIL PRESSURE
GROUND GY/O 18
82
DBW - R/BK 18
83 R/BK 18 21 AUX PWM 5
AUX PWM5 REC
6
84 R/BK 18 R/W 18 R/W 18 16 AUX PWM 4
AUX PWM5 O/LG 18
85
AUX PWM1 R/W 18 BK/O 18
86 BK/O 18 25 IVS
AUX PWM4 T/GN 18 DG/W 18
87 DG/W 18 26 OIL PRES
AUX PWM2 T/Y 18
88 T/Y 18 2 TACH
AUX PWM4 REC C41 RPM
89 PK/LG 18 PK/LG 18 6 MIL
FP REC AUX PWM3 REC C10 BESL
90 BK/R 16 BK/R 16 BK/R 16
FUEL PUMP AUX PWM3 18 FUEL PUMP - C21 IGN
O/LG 18 O/LG 18
39 AUX OUT1 C135 FP
R 16 W 16 Y/DB 18 Y/DB 18
7 FUEL SELECT C39 LP
P/LB 18 P/LB 18
10 AUX ANA PD1B
T/GN 18 T/GN 18
27 AUX OUT 2
W/LB 18 W/LB 18
4 BRAKE
DG 18 DG 18 11 RS 232+
W/R 18 O 18 O 18 3 RS 232- C127 TSW
A
INJECTOR CYL #2 GY/R 18
FUEL PUMP
B LB/PK 16
F4 15 START IN INTERUPT R33 STR
LPG W/PK 16
R 16 BN/LB 16
TEMPERATURE
GY/R 18 1
PK/BK 16 PK/BK 16 PK/BK 16
19 START IN AUTOCRANK
5 FUEL PUMP + C135 FP+ 7
ANA RTN 15A
BR/W 18 2
TWR 5V REF
DG 18 3
PC TX
W/BK 18 O 18 4
PC RX
FUEL PUMP RELAY
INJECTOR CYL #4 R/LG 18 A
B
DG/P 18 5
6
UNUSED
LB/O 18 LB/O 18
STARTER STARTER RELAY CAN
85
LPG
Y/R 18
DG/P 18 7
UNUSED
R 16 30 SOLENOID 87A
TERMINATION
CAN + LB/PK 16
R 16 BR/Y 16
LOCKOFF O/LG 18 8 PK/BK 16 30 CONNECTOR
KNOCK CAN -
R/LG 18
87 LB/PK 16
87 W/PK 16
86
SENSOR DIAGNOSTIC CONNECTOR 87A RING W 18
SHD TWR
W 18 2
R/LG 18 R/LG 18 86 CAN + TERM
R 16 RELAY
OMRON DG/P 18 3
CAN +
INJECTOR CYL #3
LG/P 18 85
FPP O/LG 18 1
CAN -
R 16 T 16 PK/BK 16 PK/BK 16
BK/W 18 6
4
5
GROUND
UNUSED 8
UNUSED
8
UNUSED
F6 F1
R 16 R16 R/LB 16 7
POWER
POWER RELAY
R/Y 18 85 10A ALTERNATOR 10A EPR EPR
INJECTOR CYL #1 R 16
R 16 R 16 R 16
30
F5 R 16 CONNECTOR
87
R 16 R 16
R/T 18 86
87A
15A RELAYED POWER
Ford DSG-423 EFI Engine Wire Harness
6 - 23 6 - 24
Electrical Schematic, S-60 and S-60 TRAX,

Ford DSG-423 EFI Models
6 - 25 6 - 26
N
REV A
RD
RD
BRN
P134PWR RD
P22LS BK
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
P24FS WH
C1P-9 C35RPM BK/RD C1B-9

D12
ENGINE
SPEED C25PSR WH/BK OIL PRESSURE
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
HIGH RPM SENDER (OPTION)
TS54
TB45
GENERATOR
C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH GENERATOR
TS47
OPTION
WH
RD
L
TS48
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
GY/RD
A
FORD ENGINE
GY/YL GASOLINE SENSOR

B
HARNESS
RD
C
BK/BL
D
J
RD/GN
L2
LPG LOCKOUT
WH/BK
BL/WH CHECK ENGINE LED
BR
CR39
RD
RUN/TEST SWITCH
C5-13 BL/WH
C35RPM BK/RD
TS64
C5-8 GR
I
CR39
TS3
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) PIN16

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) PIN3

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
C33STR BK (GND) BR FEH(570) PIN34

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

START
CR1
NO
TB24
BL/WH FEH(787A) PIN5
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
January 2010
Part No. 139188

D3
CR19
D4
TS51
TB27
SPEED REDUCTION RELAY

AUXILIARY
TS1
PUMP C27AUX RD
AUXILIARY POWER RELAY
WH(FS)
AUXILIARY
RD(FS)
PR1
PUMP
NO
C1P-1 C27AUX RD C1P-1
PUMP
AUX
AUXILIARY PUMP
E
FS1
C28TTA RD/BK
M2
BK(FS)
B
C28TTA RD/BK WH
TILT ALARM
TB23
WH C7P-2 P23BAT WH C7B-2 P134TTS RD RD BK BRN
LEVEL SENSOR
C9P-1 BK
C
D2
TB134
S8
H1
D

RD C1P-2 C28TTA RD/BK C1P-2
FB1
P2
P134FB WH FLASHING
BEACONS OPTION
L48
BK C2P-5 C46HRN GR C2B-5 C46HRN GR

HORN RELAY
RD
CR5
P3
H2
TB46
C7P-1 P22BAT BK C7B-1 P22HRN BK R46HRN BK C6-9
HORN
NO
TB134
TB46R
SW3
NO
P134PWR GR/BK
HYDRAULIC OIL
C
CR17
C2P-6 C2B-6 R21IGN WH C5-4 TEMPERATURE SWITCH
P134PWR RD (OPTION)
TB22
86
85
P22LS BK COOLING FAN
M1 FAN
C116 OR C5-1
87a 87
(OPTION)
30
P116HYD RD
KS1
GRND
PLAT
ALTERNATOR FIELD
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
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
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
C1P-3 C29MS RD/WH C1B-3 C5-24 C29MS RD/WH
20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
C
TS15
CDE2 BL/BK C1P-11 C37SCW BL/BK C1B-11 C37SCW BL/BK

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
4 C3P-6 C6TRF WH/RD C3B-6

11
5
C3P-4 C4TRL WH C3B-4 C4TRL WH
J1
13 10 TURNTABLE ROTATE LEFT

ROCKER OPTION
TB4
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
D
P162JPW OR
C3P-5 C5TRR WH/BK C3B-5 C5TRR WH/BK

9 TURNTABLE ROTATE RIGHT
14
TB5
C15-1 C15-2
D9
DRIVE FORWARD/REVERSE &
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
GND 1
6
ROUT 5
XOUT 3
PWR 2
YOUT 4
TS62
R4
CR19
7.5
TB6
C31-1 C31-2
JC3
C6TRF WH/RD TURNTABLE ROTATE

FLOW CONTROL
TB1
R2
C12-1 C12-2
5
C1PBU RD
PRIMARY BOOM UP
UP
E
PRIMARY BOOM
2 DOWN C2PBD RD/BK
Part No. 139188
PRIMARY BOOM DOWN

1 C13-1 C13-2
CR34
TS61
J2
R14
January 2010
11
5
TB3
XOUT 3 C165TRS WH/RD
YOUT 4 C164PES RD/WH
R16
10
C3PBF RD/WH
P162JPW OR
PRIMARY BOOM FLOW CONTROL

12
C29-1 C29-2
C3P-1 C1PBU RD C3B-1
J1
6
BR
TURNTABLE ROTATE
TB2
BOOM UP/DOWN &
C3P-2 C2PBD RD/BK C3B-2

GND 1
6
PWR 2
7
JC2
C3P-3 C3PBF RD/WH C3B-3

F
8
TB9
3 C30-1 C30-2
C3P-9 C9PER BK/RD C3B-9 C9PER BK/RD PRIMARY BOOM EXTEND/RETRACT
14
9 FLOW CONTROL
C163PLS BL/WH
C3P-8 C8PBR BK/WH C3B-8

13
P162JPW OR
10
21 LS5
NC
C3P-7 C7PBE BK C3B-7 LS5 CABLE TENSION LIMIT SWITCH

12
TB7
BR
22
EXTEND/RETRACT
G
RD RD BR C7PBE BK
PRIMARY BOOM
BOOM EXTEND
GND 1
6
3
PWR 2
YOUT 4
EXTEND
J1
BOOM C37-1 C37-2 C16-1 C16-2

RETRACT
JC1
TS63
C8PBR BK/WH
U13 JOYSTICK CONTROL CARD
BOOM RETRACT
TB8
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
C4P-4 C118LSR OR/RD C4B-4 OR/RD C38-3 BK WH C38-4 LS17-BOOM UP/DOWN
1
SPEED REDUCTION LIMIT SWITCH
13
14
P24FS WH
TB118
BK
TB13
LS3
NO
H
HC
P24FS WH
J3
4
C4P-1 C13DE BL/RD C4B-1 BL/RD C9-1 BK WH C9-2 LS3-DRIVE ENABLE LIMIT SWITCH
3
13
14
P26ESTP BK
3
TB22
LS1
NO
HC
C2P-2
4
C11-2 WH BK C11-1 LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
13
14
LS2
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
REV A
P134 RD
N
BRN
RD
RD

6 - 27 6 - 28
Ground Control Box Terminal Strip Wiring Diagram,

6 - 29 6 - 30
8
7
6
5
4
3
2
1
6 - 30
CR2 BRN
CR1 CR23
IGNITION POWER
RELAY DRIVE LIGHT
START RELAY OPTION
RD
A
BRN
BK-33C
BRN
WH-OPTIONS
WH-ISM9
CR4
WH-C5-19
WH-23C
AUXILIARY
R43DLITE2 RD
R43DLITE1 RD
POWER RELAY
C2B-4 OR/RD
WH-C5-11
RD-24B
WH-21C
BK C5-5
BRN
C5
C32 C32
B
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
SWING SPEED PRIMARY BOOM
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
CR17
WH/RD-R2 HYDRAULIC
WH/RD-R4 OIL COOLER
OPTION
RD/WH-R16 OR-LS17 C38-2
RD/WH-TS61
RD-CB3
D C TERMINAL BASE (TB) B A C1PBU RD C3B-1
RD-TS61 C1PBU RD C12-1

1 PRIMARY BOOM UP 1
RD/BK-ALARM C2PBD RD/BK C3B-2
TS64

D
RD/BK-TS61 C2PBD RD/BK C13-1 RUN/TEST

#1
D29
C3PBF RD/WH C3B-3 SWITCH
BRN
RD/WH-CR34 C3PBF RD/WH C29-1 C5-8 GR
NOTE: DASHED LINES INDICATE OPTION WIRES

C4TRL WH C3B-4
WH-TS62 C4TRL WH C15-1

C5TRR WH/BK C3B-5
BRN-GND
FUSE 10A
WH/BK-TS62 C5TRR WH/BK C14-1
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
BK-TS63 C7PBE RD-LS5 C37-1

E
C8PBR BK/WH C3B-8
BK/WH-TS63 C8PBR BK/WH C17-1

C9PER BK/RD C3B-9
BK/RD-TS63 C9PER BK/RD C30-1 18/19 #1

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. 139188

January 2010
C14PLU OR C4B-2
OR-TS59 C14PLU OR C20-1 18/19 #2

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

#2
#1

C17JU GR C4B-5
GR-TS57 C17JU GR C22-1

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.

RD-CB2 P20BAT RD C11 (LS1)
P20BAT RD
WH-CR2 #87 C128RPM OR/RD C5-9
WH-HM C21IGN2 WH C5-3

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
RD-CR19#86 C27AUX RD C1B-1
RD-TS51 C27AUX RD PR1

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

28 TILT ALARM 28
C29MS RD/WH C1B-3 BRN
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
TO SWITCH PANEL WH/RD-ALRM C32BRK WH/RD C5-23
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
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

C5
C37SCW BL/BK C25-1

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

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
WH C11-2
GR-CR5
46 SERVICE 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

P134FB WH-FH P134PWR BK-LS5 C37-3
RD-KS P134TTS RD A
#2
F.H.
BRN-TS64
BRN C37-2
BRN C7B-3
GR/WH C5-12 C45GEN GR/WH C2B-7

BK-CR5 R46HRN BK
BRN
OR/RD-FH C38-3 C118LSR OR/RD C4B-4

C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
L
B A
HARNESS
FUNCTION
BK C16-1
OR/RD-118B OR/RD-LS17 C38-3

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

F.H.
M
C9 (LS3)
C11 (LS2)
LS17 (C38)
GROUND BOLT
REV A
N
REV A Ground Control Box Switch Panel Wiring Diagram,

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
C19JSV GR/WH
WH-4
RD/WH
RD
2
GR/BK-18D
RD
RD
RD
GR-17D
RD
D3
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
WH/RD WH/RD
RD
RD
RD
WH/RD
3
RD-27
WH
PLATFORM
RD
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
GR-17D
OR-14D
RD-27D
RD/WH
WH-4D
RD-1D
BK-7D
WH
RD
4
TURNTABLE
RESISTOR
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
CB1 CIRCUIT BREAKER, ENGINE, 15A
DALE RH-25 25W
DALE RH-25 25W
RD-20D
CB2 CIRCUIT BREAKER, CONTROLS, 15A
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RESISTOR
CB3
UP/DOWN
CIRCUIT BREAKER, OPTIONS, 15A

RESISTOR
BOOM
CR1 IGNITION / START RELAY

R14
ENGINE
ENGINE 15A
R16
START
TS52
CR2 IGNITION POWER RELAY
BREAKER
CIRCUIT
CR4 HIGH IDLE RELAY
CB1
RD-24D
CR5 HORN RELAY
CR17 HYDRAULIC OIL COOLER FAN RELAY
BRN
CR22 DRIVE LIGHT RELAY (OPTION)

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

L45 PLATFORM OVERLOAD LED (CE OPTION)
HOUR METER

STOP SWITCH
EMERGENCY
RD
1 1
D13
R2 SPEED LIMITING RESISTOR 5 OHMS
R4 SPEED LIMITING RESISTOR 7.5 OHMS
P1
NC NC
RD R14 SPEED LIMITING RESISTOR 5 OHMS
D14
FUNCTION
2 2
ENABLE
TS51 AUXILIARY POWER TOGGLE SWITCH
TS54
RD
RD
TS52
TS53
FUEL SELECT TOGGLE SWITCH
8
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
TS63 BOOM EXTEND/RETRACT TOGGLE SWITCH
Ground Control Box Switch Panel Wiring Diagram,

6 - 31 6 - 32
Platform Control Box Wiring Diagram, S-60 and S-60 TRAX,

6 - 33 6 - 34
N
REV A
12V DC PLATFORM POWER CONNECTOR
CONTROL BOARD OUTPUT CONNECTOR

CONTROL BOARD POWER CONNECTOR
CONTROL BOARD INPUT CONNECTOR
CWLITE WH TS49
CONTROL RELAY (CE OPTION)
(TO SWITCH
PLATFORM
FOOT SWITCH CONNECTOR

CONTROL
HARNESS
LOAD SENSE LIMIT SWITCH

48 PIN CONNECTOR BLOCK
PANEL)
ALC-500 CONTROL BOARD

DESCRIPTION
M
C19JSV GR/WH TS7

TILT ALARM
Y
C19JSV GR/WH C4P-7

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

C7P
C2PBD RD/BK C3P-2
January 2010
Part No. 139188

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
P162JPW OR
C1P
C165TRS WH/RD
WIRE CONNECTS TO JC3-5
GND BRN
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS BL/WH
C7P
GND BRN
C160JPL WH/RD
P162JPW OR
C
C159STC BL/WH
GND BRN
C144DER BL/WH C28TTA RD/BK C1P-2
C143DEL BL/BK
C28TTA RD/BK C1P-2

C13DE BL/RD
C29MS RD/WH
BATGRN C7P-3
B
GR/BK C133TTA C3P-12

GR/BK-L4- (CE)
D39
ALARM
TILT
RD/BK-L48 RD/BK-L48- (NON-CE)
H1
C134PWR RD C2P-6
C134PWR RD LS18 RD-TILT
+
CWLITE BK
BRN
A BRN
BRN BRN
CWLITE WH TS49
6 - 34
1
8
REV A Platform Control Box Switch Panel Wiring Diagram,

1
PLATFORM CONTROL
HARNESS
(TO CONTROL BOX)
COMPONENT INDEX
BOOM UP/DOWN , TURNTABLE ROTATE
BOOM EXTEND/RETRACT
JC3 DRIVE/STEER PROPORTIONAL JOYSTICK 2
L1 DRIVE ENABLE LED
DLITE RD RD
BK
L48 BOOM TILTED LED
+
JC2 JC1
PRIMARY BOOM P3 HORN SWITCH
PRIMARY BOOM TS15
UP/DOWN
& TURNTABLE ROTATE
EXTEND/RETRACT DRIVE L48 TS1 AUXILIARY POWER TOGGLE SWITCH
LEFT/RIGHT TS48/TS49 ENABLE TILT ALARM LED TS2 ENGINE START TOGGLE SWITCH
DRIVE LIGHTS/ (ANSI/CSA OPTION)
WORK LIGHTS
TS3 FUEL SELECT TOGGLE SWITCH
(OPTION) TS4 HI/LOW RPM TOGGLE SWITCH 3
JC3
BK
BK
BK
RD
6 1 DRIVE TS9 PLATFORM LEVEL TOGGLE SWITCH
6 1 FORWARD/REVERSE 6 1
& STEER LEFT/RIGHT TS14 DRIVE SPEED TOGGLE SWITCH
5 2 TS15 DRIVE ENABLE TOGGLE SWITCH
5 2 5 2 TS47 GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT
4 3 BRN TS48
TOGGLE SWITCH (OPTION)
4 3 4 3
+ NOTE: DASHED LINES INDICATE OPTION WIRES

+
ROCKER OPT.
4
BRN
L47 L4
RETRACT + PLATFORM
BOOM OVERLOAD
RD
L1 (CE OPTION)
BK
DRIVE ENABLE
BRN
BK
BRN BRN BRN BRN F18

FUSE 10A
(WORKLIGHT
BK
OPTION ONLY)
5
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-

BK
C165TRS WH/RD
C164PES RD/WH
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
P162JPW OR
P162JPW OR
P162JPW OR
BL-DE1 J1-6
WLITE WH
WLITE WH
GND BR
GND BR
GND BR
BRN
RD
BK
BK
6
C46HRN GR C2P-5
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
BK
P25FS RD C9-3
C33STR BK C1P-7
C35RPM BK/RD C1P-9
P24FS WH C9-2
PDLITE RD
C39LP BL/RD C2P-1
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
WH WH
7
D12 TS3
FUEL SELECT
TS2 TS4
ENGINE HIGH/LOW P2
START RPM EMERGENCY
STOP
TS7 TS14
PLATFORM HIGH/LOW
P3 WH TS1 TS47
TS9 ROTATE DRIVE SPEED
HORN GENERATOR D11
PLATFORM AUXILIARY (2WD/4WD)
RD
(OPTION)
LEVEL PUMP
BK
8
WH
RD RD RD RD
Platform Control Box Switch Panel Wiring Diagram,

6 - 35 6 - 36

6 - 37 6 - 38
N
REV A
RD
RD
BRN
P134PWR RD
P22LS BK
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
P24FS WH
C1P-9 C35RPM BK/RD C1B-9

D12
ENGINE
SPEED C25PSR WH/BK OIL PRESSURE
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
HIGH RPM SENDER (OPTION)
TS54
TB45
GENERATOR
C2P-7 C45GEN GR/WH C2B-7 C5-12 C45GEN GR/WH GENERATOR
TS47
OPTION
WH
RD
L
TS48
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
GY/RD
A
FORD ENGINE
GY/YL GASOLINE SENSOR

B
HARNESS
RD
C
BK/BL
D
J
RD/GN
L2
LPG LOCKOUT
WH/BK
BL/WH CHECK ENGINE LED
BR
CR39
RD
RUN/TEST SWITCH
C5-13 BL/WH
C35RPM BK/RD
TS64
C5-8 GR
I
CR39
TS3
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) PIN16

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) PIN3

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
C33STR BK (GND) BR FEH(570) PIN34

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

START
CR1
NO
TB24
BL/WH FEH(787A) PIN5
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
January 2010
Part No. 139188

D3
CR19
D4
TS51
TB27

AUXILIARY
TS1
PUMP C27AUX RD
AUXILIARY POWER RELAY
WH(FS)
AUXILIARY
RD(FS)
PR1
PUMP
NO
C1P-1 C27AUX RD C1P-1
PUMP
AUX
AUXILIARY PUMP
E
FS1
C28TTA RD/BK
M2
BK(FS)
B
C28TTA RD/BK WH
TILT ALARM
TB23
WH C7P-2 P23BAT WH C7B-2 P134TTS RD RD BK BRN
LEVEL SENSOR
C9P-1 BK
C
D2
TB134
S8
H1
D

RD C1P-2 C28TTA RD/BK C1P-2
FB1
P2
P134FB WH FLASHING
BEACONS OPTION
L48
BK C2P-5 C46HRN GR C2B-5 C46HRN GR

HORN RELAY
RD
CR5
P3
H2
TB46
C7P-1 P22BAT BK C7B-1 P22HRN BK R46HRN BK C6-9
HORN
NO
TB134
TB46R
SW3
NO
P134PWR GR/BK
HYDRAULIC OIL
C
CR17
C2P-6 C2B-6 R21IGN WH C5-4 TEMPERATURE SWITCH
P134PWR RD (OPTION)
TB22
86
85
P22LS BK COOLING FAN
M1 FAN
C116 OR C5-1
87a 87
(OPTION)
30
P116HYD RD
KS1
GRND
PLAT
ALTERNATOR FIELD
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 - 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
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
19 BRAKE RELEASE
C28TTA RD/BK
TB29
C28-1 C28-2
20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
TB37
C25-1 C25-2
C
TS15
CDE2 BL/BK C1P-11 C37SCW BL/BK C1B-11 C37SCW BL/BK

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
C3P-6 C6TRF WH/RD C3B-6

4 11
5
C3P-4 C4TRL WH C3B-4 C4TRL WH
J1
10 TURNTABLE ROTATE LEFT

13
TB4
ROCKER OPTION
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
D

P162JPW OR

14
TB5
C15-1 C15-2
D9
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
TS62
GND 1
6
ROUT 5
XOUT 3
PWR 2
YOUT 4
R4
CR19
7.5
TB6
C31-1 C31-2
C6TRF WH/RD
JC3
TURNTABLE ROTATE
FLOW CONTROL
TB1
R2
C12-1 C12-2
5
C1PBU RD
PRIMARY BOOM UP
UP
E
PRIMARY BOOM
DOWN C2PBD RD/BK
Part No. 139188
2
PRIMARY BOOM DOWN
C13-1 C13-2
CR34
1
TS61
J2
R14
January 2010
11
TB3
R16
XOUT 3 C165TRS WH/RD
YOUT 4 C164PES RD/WH
10
C3PBF RD/WH
PWR 2 P162JPW OR

12 C29-1 C29-2
J1
6
BR
TB2
TURNTABLE ROTATE
BOOM UP/DOWN &

GND 1
6
7
JC2

F
8
TB9
3 C30-1 C30-2
14
9 FLOW CONTROL
C163PLS BL/WH

13
J1
PWR 2 P162JPW OR
21 LS5
10
NC

12
TB7
BR
22
EXTEND/RETRACT
G
RD RD BR C7PBE BK
BOOM EXTEND
PRIMARY BOOM
GND 1
6
3
YOUT 4
EXTEND
BOOM C37-1 C37-2 C16-1 C16-2
RETRACT
JC1
TS63
C8PBR BK/WH
BOOM RETRACT
TB8
P26ESTP BK
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
P24FS WH
TB118
BK
TB13
LS3
NO
H
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
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
BRN
DESCENT ALARM OPTION
H3
D30
C4P-7 C19JSV GR/WH C4B-7
JIB BOOM TIME DELAY CIRCUIT

CR13
TB19
M

C1
+
-
C41RPM OR/BK
JIB VALVE JIB VALVE
C28TTA RD/BK
P24FS WH
P26ESTP BK
NO
P22LS BK
REV A
P134 RD
CR14
GR/WH
N
BRN
RD
RD

6 - 39 6 - 40

6 - 41 6 - 42
8
7
6
5
4
3
2
1
6 - 42
CR2 BRN
CR1 CR23
IGNITION POWER
RELAY DRIVE LIGHT
START RELAY OPTION
RD
A
BRN
BK-33C
BRN
WH-OPTIONS
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 HYDRAULIC
WH/RD-R4 OIL COOLER
OPTION
RD/WH-TS61
RD-CB3

1 PRIMARY BOOM UP 1
TS64

D
RD/BK-TS61 C2PBD RD/BK C13-1 RUN/TEST

#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. 139188

January 2010
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

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

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
TO SWITCH PANEL WH/RD-ALRM C32BRK WH/RD C5-23
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
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

C5
C37SCW BL/BK C25-1

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

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

P134PWR GR/BK C2B-6
P134PWR RD-LS17 C38-1

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

BK-CR5 R46HRN BK
BRN

C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
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
REV A
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
RD/WH
RD
2
GR/BK-18D
RD
RD
RD
GR-17D
RD
D3
GR/BK
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
GR
WH/RD WH/RD GR/BK
RD
D28
GR
RD
RD
WH/RD RD 3
RD-27
WH
UP/DOWN
JIB BOOM
PLATFORM
RD
TS58
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
GR-17D
OR-14D
RD-27D
RD/WH
BL-44D
WH-4D
RD-1D
BK-7D
WH
RD
4
TURNTABLE
RESISTOR
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
CB3 CIRCUIT BREAKER, OPTIONS, 15A
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
P1
NC NC
D14
FUNCTION
2 2
ENABLE
TS54
RD
RD
TS53
TS54
FUEL SELECT TOGGLE SWITCH
FUNCTION ENABLE SWITCH
8
RD TS58 JIB BOOM UP/DOWN TOGGLE SWITCH

6 - 43 6 - 44

Ford DSG-423 EFI Models (before serial number 16734)
6 - 45 6 - 46
N
REV A

CWLITE WH TS49
(TO SWITCH
PLATFORM

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
C46HRN GR C2P-5
I

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
January 2010
Part No. 139188

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
Ford DSG-423 EFI Models (before serial number 16734)
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
D

J1
P162JPW OR
C1P
C165TRS WH/RD
GND BRN
C164PES RD/WH C1P(GY)
P162JPW OR
C163PLS BL/WH
GND BRN
C7P
C160JPL WH/RD
* NOTE:
P162JPW OR
C
C159STC BL/WH*
GND BRN
C143DEL BL/BK
C13DE BL/RD
C28TTA RD/BK C1P-2

C29MS RD/WH
BATGRN C7P-3
B

GR/BK-L4- (CE)
D39
ALARM
TILT
H1
C134PWR RD C2P-6
+
CWLITE BK
BRN
A BRN
BRN BRN
CWLITE WH TS49
6 - 46
1
8

S-65 and S-65 TRAX, Ford DSG-423 EFI Models (before serial number 16734)
1
PLATFORM CONTROL
HARNESS
(TO CONTROL BOX) COMPONENT INDEX
CR13 JIB RELAY ( JIB OPTION ONLY )

BOOM EXTEND/RETRACT
L1 DRIVE ENABLE LED
DLITE RD RD
BK
L48 BOOM TILTED LED
+
JC2 JC1
PRIMARY BOOM TS15
UP/DOWN
& TURNTABLE ROTATE
WORK LIGHTS
JC3
BK
BK
BK
RD
4 3 BRN TS48
4 3 4 3

+
4
ROCKER OPT.
BRN
BRN
L47 L4
RETRACT + PLATFORM
BOOM CR13 OVERLOAD
RD
L1 (CE OPTION)
BK
DRIVE ENABLE
BRN
BK
BRN BRN BRN BRN F18

FUSE 10A
(WORKLIGHT
BK
OPTION ONLY)
5
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-

BK
C165TRS WH/RD
C164PES RD/WH
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
P162JPW OR
P162JPW OR
P162JPW OR
BL-DE1 J1-6
WLITE WH
WLITE WH
GND BR
GND BR
GND BR
WH-JIB
BRN
RD
BK
BK
C129JDA BL C3P-10
6
C19JSV GR/WH
P24FS WH
C46HRN GR C2P-5
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
WH-JIB
C27AUX RD C1P-1
WH CR30
C29MS RD/WH J1-8
C45GEN GR/WH C2P-7
BK
P25FS RD C9-3
C33STR BK C1P-7
C35RPM BK/RD C1P-9
P24FS WH C9-2
PDLITE RD
C39LP BL/RD C2P-1
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
7
WH WH
TS8 D12 TS3

FUEL SELECT
GR
TS2 TS4
ENGINE HIGH/LOW P2
START RPM EMERGENCY
STOP
TS7 TS14
PLATFORM HIGH/LOW
P3 WH JIB TS47
TS9 ROTATE TS1 DRIVE SPEED
HORN GENERATOR D11
RD
LEVEL GR/BK PUMP (OPTION)

BK
8
D27
WH
RD RD RD RD

6 - 47 6 - 48

Ford DSG-423 EFI Models (after serial number 16733)
6 - 49 6 - 50
N
REV A
(TO SWITCH
PLATFORM
CONTROL
HARNESS

PANEL)
WH
Y
B

C19JSV GR/WH TS7

Y
C19JSV GR/WH C4P-7

BK
DESCRIPTION
BRN JC3 BR
Y
JIB DELAY RELAY

Y
BRN GND
M
RD-E-STOP RD C134PWR RD LS18

B
Y
Y
Y
C134PWR RD-H1+
CWLITE WH TS49
GR/WH
BR
ITEM
CR13#86 GR/WH
CR14
CR27
CR30
J1
J2
J3
OPT.
C1
R
RD OUTPUT
L
TS7 WH
GR/WH +
CR14
R
C134PWR RD
GR/WH
BRN -
RD LS18 CABLE
JIB

CR27
BRN
GR/WH RD
R
B

C32BRK WH/RD C1P-6

TIME DELAY CAPACITOR
C32BRK WH/RD J2-19

DESCRIPTION
OPTION
K
LS18
(CE)
BRN
TILT ALARM
CR30
BK C1P-12
C40LS OR C2P-2
C1P-C4P
ITEM
C40LS OR J2-4
LS18
C7P
U13
H1
C1
C9
TS1 WH
P23BAT WH C7P-2
J
P22BAT BK C7P-1
JIB
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
C46HRN GR C2P-5
I

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

January 2010
Part No. 139188

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)
Ford DSG-423 EFI Models (after serial number 16733)

D

J1
P162JPW OR
C1P
C165TRS WH/RD
GND BRN
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS BL/WH
C7P
GND BRN
C160JPL WH/RD
P162JPW OR
C
C159STC BL/WH
GND BRN
C143DEL BL/BK
C28TTA RD/BK C1P-2

C13DE BL/RD
C29MS RD/WH
BATGRN C7P-3
B

GR/BK-L4- (CE)
D39
ALARM
TILT
H1
C134PWR RD C2P-6
+
CWLITE BK
BRN
A BRN
BRN BRN
CWLITE WH TS49
6 - 50
1
8

S-65 and S-65 TRAX, Ford DSG-423 EFI Models (after serial number 16733)
1
PLATFORM CONTROL
HARNESS
(TO CONTROL BOX) COMPONENT INDEX
CR13 JIB RELAY ( JIB OPTION ONLY )

BOOM EXTEND/RETRACT
L1 DRIVE ENABLE LED
DLITE RD RD
BK
L48 BOOM TILTED LED
+
JC2 JC1
PRIMARY BOOM TS15
UP/DOWN
& TURNTABLE ROTATE
WORK LIGHTS
JC3
BK
BK
BK
RD
4 3 BRN TS48
4 3 4 3

+
ROCKER OPT.
BRN
4
BRN
L47 L4
RETRACT + PLATFORM
BOOM CR13 OVERLOAD
RD
L1 (CE OPTION)
BK
DRIVE ENABLE
BRN
BK
BRN BRN BRN BRN F18

FUSE 10A
(WORKLIGHT
BK
OPTION ONLY)
5
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-

BK
C165TRS WH/RD
C164PES RD/WH
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
P162JPW OR
CR14-#86 RD
P162JPW OR
P162JPW OR
BL-DE1 J1-6
WLITE WH
WLITE WH
GND BR
GND BR
GND BR
WH-JIB
BRN
RD
BK
BK
C129JDA BL C3P-10
6
P24FS WH
C46HRN GR C2P-5
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
WH-JIB
C27AUX RD C1P-1
WH CR30
C29MS RD/WH J1-8
C45GEN GR/WH C2P-7
BK
P25FS RD C9-3
C33STR BK C1P-7
C35RPM BK/RD C1P-9
P24FS WH C9-2
PDLITE RD
C39LP BL/RD C2P-1
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
WH WH
7
TS8 D12 TS3
FUEL SELECT
GR
TS2 TS4
ENGINE HIGH/LOW P2
START RPM EMERGENCY
STOP
TS7 TS14
PLATFORM HIGH/LOW
P3 WH JIB TS47
TS9 ROTATE TS1 DRIVE SPEED
HORN GENERATOR D11
RD
GR/BK (OPTION)
LEVEL PUMP
BK
8
D27
WH
RD RD RD RD

6 - 51 6 - 52

Deutz F3L-2011/Deutz D2011L03i Models
6 - 53 6 - 54
REV B
Circuit breaker
RD
RD
BRN
serial number
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
ES0192G
added after
CR4
N
D12
19405
C1P-9 C35RPM BK/RD C1B-9 C35RPM BK/RD BRN

HIGH IDLE RELAY
FOOTSW. HIGH
TB35
CB7
10A
FOOTSW. LOW
TS4
CR4
Q3
ENGINE
BK/RD C5-18
TS54
SPEED
HIGH RPM SOLENOID

NO
LOW RPM
D14
FUNCTION ENA.
HIGH RPM C26PSR WH/BK OIL PRESSURE
G2
SENDING UNIT (OPTION)

D13
M
G1
VOLT METER (OPTION)

C26TSR WH/RD WATER TEMPERATURE
G3

TB45
C2P-7 C45GEN GR/WH C2B-7 C45GEN GR/WH C5-12

TS47
GENERATOR (OPTION)
L
CR23
TS48
C3P-12 DLITE BL/WH C3B-12

DRIVE LIGHT
L29
LIGHTS
FUSE 10A
WORK LIGHT RD
DRIVE LIGHT L29
F19
(OPTION)
L29
L30
RD
RD
RD
FUSE 10A
WORK LIGHTS L30

TB21
C2P-12 C2P-10
F18
CR23
(OPTION)
NO
PBOX GND
C2P-11 C2P-9
K
L30
PR2
TB34
TS6
C1P-8 C34SA BK/WH C1B-8 C34SA BK/WH C5-22

GLOW PLUG RELAY
GLOW
TS56
PLUG
GLOW
GLOW PLUG
J
PLUG
FUSE 70A
PR2
NO
F22
number 16733
ENGINE FAULT LED

After serial
L2
D64
3 START INPUT IGNITION/
MODULE
START
U1
I
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
8 KEY BYPASS
10 ENG. FAULT
TS2
7 KEY PWR.
6 BATTERY
C33STR BK
5 GROUND
C1P-7 C1B-7 C5-14 C26TS WH/RD

4 AUX. ON
OIL TEMPERATURE SWITCH

ENGINE
TS52
D33
TB25
START
ENGINE C5-16 C25PS WH/BK OIL PRESSURE SWITCH
START
C28TTA RD/BK
SW2
BK
NC
TB33
CR2
H
POWER RELAY
P26ESTP BK
TB21
P24FS WH
P25FS RD
C21IGN2 WH C5-11
FUEL SOLENOID
TS1
CR2
AUX
NO
PUMP C1P-1 C27AUX RD C1B-1

C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
G
_
IGN./START RELAY
CR1
NO
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
D3
STARTER
STARTER MOTOR
FS1
D4
BK-(FS)
TS51
CR19
F
EMISSIOIN CONTROL
January 2010
Part No. 139188

TB27
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
TB28
RD/BK
D40
E
Overload
Platform
C1B-2
B
Option
C28TTA RD/BK C28TTA RD/BK WH

H1
TILT ALARM
P134TTSR RD RD BK BRN
LEVEL SENSOR
C3B-12
C
A
C3P-12 C133PLA BL/WH
S8
TB46
RD
C2B-5
C2P-5 C46HRN GR C46HRN GR HORN RELAY
P3
CR5

GR/BK
H2
NO
C7P-1 P22BAT BK C7B-1
TB133
P22BAT BK F.H. BK
D
HORN
C32-8
TB132
7
5
TB134
C1P-12 C132PLI BL/WH C1B-12
FB1
3
U33
P134FB WH FLASHING BEACONS
C2P-6 P134PWR GR/BK C2B-6
(OPTION)
1
12
4
6
TB134
RD
SW4
BK
NO
C
HYDRAULIC OIL
C21IGN WH R21IGN WH C5-4
86
85
TEMPERATURE
TB22
WH
RD
SWITCH (OPTION)
87a 87
P116HYD RD
30
PLAT
GRD
C41RPM OR/BK
R116 OR C5-1 COOLING FAN
CR17
FAN
KS1
(OPTION)
M1
3MF
C3
+
TB41
C41RPM OR/BK C2B-3 C41RPM OR/BK C5-2
B
D22
RD
EXCT.
C21IGN WH
STA.
BAT.
IND.
P1
RD
RD
-
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
D1
TB20
A
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 54
1
8
1
8
6 - 55
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

4
15 DRIVE FORWARD
15
C1P-5 C31REV WH/BK C1B-5 C5-20 C31REV WH/BK RD BK
1
16 DRIVE REVERSE
TS14
TB31
LOW DRIVE
(HIGH TORQUE)
H4
C130TA WH/RD TRAVEL ALARM

8
DRIVE
MODE
(OPTION)
HIGH DRIVE
(LOW TORQUE)
B
C26-1 C26-2
TB32

19 BRAKE RELEASE
C28-1 C28-2
TB29

20 MOTOR STROKE
L1
CDE3 BL/RD
16
J1
C25-1 C25-2
TB37
CDE2 BL/BK
TS15
C1P-11 C37SCW BL/BK C1B-11 C37SCW BL/BK

C
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 17 STEER LEFT
NOTES:
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
C28TTA RD/BK
TB36
P26ESTP BK
P24FS WH

11
5
C3P-4 C4TRL WH C3B-4 C4TRL WH TURNTABLE ROTATE LEFT
J1
13 10
ROCKER OPTION
TB4
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
P162JPW OR
D

14
C15-1 C15-2
TB5
D9
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
GND 1
6
R OUT 5
X OUT 3
PWR 2
Y OUT 4
TS62
7.5W
R4
CR19
TB6
C31-1 C31-2
C6TRF WH/RD
JC3
TURNTABLE ROTATE
FLOW CONTROL
TB1
R2
5W
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
C2PBD RD/BK
E
2 DOWN
PRIMARY BOOM DOWN
TS61
Part No. 139188
1 C13-1 C13-2
CR34
J2
R14
5W
January 2010
11
TB3
C164PES RD/WH
C165TRS WH/RD
R16
10W
C3PBF RD/WH
P162JPW OR

12
C29-1 C29-2
J1
6
BR
TURNTABLE ROTATE
TB2
BOOM UP/DOWN &

GND 1
6
X OUT 3
PWR 2
Y OUT 4
7
JC2

8
F
TB9
3 C30-1 C30-2
14
9 FLOW CONTROL
C163PLS BL/WH

13
P162JPW OR
10
12
NC
TB7
BR
21
22
EXTEND/RETRACT
RD RD BR C7PBE BK
BOOM EXTEND
PRIMARY BOOM
G
GND 1
6
PWR 2
Y OUT 4
EXTEND
BOOM C37-1 C37-2 C16-1 C16-2
J1
LS5
RETRACT
JC1
TS63
C8PBR BK/WH
BOOM RETRACT
TB8
C17-1 C17-2
BRN
NO
1
HC

1
P24FS WH SPEED REDUCTION LIMIT SWITCH
13
14
2
TB118
LS17
BK
TB13
P24FS WH
H
NO
J3
HC
4
3
P26ESTP BK
13
14
TB22
LS3
C2P-2
NO
4
HC

DRIVE LIMIT SWITCH
13
14
LS1
NO
HC

DRIVE LIMIT SWITCH
13
14
LS2
BK
I
TB40
OPTION
CR30
CR27
DRIVE
NO
NC
LIFT/
CE
P22LS BK
L46
NO
L47
J
TB59
13
14
CR34
LS5
TB134
NC
HO
21
22
LS17
TS9
UP
PLATFORM LEVEL
TB14
C20-1 C20-2
TS59
C14PLU OR
PLATFORM LEVEL UP
UP
K
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
DESCENT ALARM
H3
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
P134 RD
REV B
BRN
RD
RD

6 - 55 6 - 56
Electrical Schematic, S-60 and S-60 TRAX, CE Models

6 - 57 6 - 58
REV B
Circuit breaker
RD
RD
BRN
ES0192G
serial number
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
added after
CR4
N
D12
19405
C35RPM BK/RD
C1P-9 C35RPM BK/RD C1B-9 BRN
HIGH IDLE RELAY
FOOTSW. HIGH
CB7
10A
FOOTSW. LOW
TS4
CR4
Q3
ENGINE
BK/RD C5-18
TS54
SPEED
HIGH RPM SOLENOID

NO
LOW RPM
D14
FUNCTION ENA.
G2

D13
TB35
M
G1
VOLT METER (OPTION)

G3

TB45

TS47
GENERATOR (OPTION)
L
CR23
TS48

DRIVE LIGHT
L29
LIGHTS
FUSE 10A
WORK LIGHT RD
DRIVE LIGHT (OPTION)
F19
L29
L30
RD
RD
RD
FUSE 10A
WORK LIGHTS (OPTION)

TB21
C2P-12 C2P-10
F18
CR23
NO
PBOX GND
C2P-11 C2P-9
K
L30
PR2
TB34
TS6
C1P-8 C34SA BK/WH C1B-8 C34SA BK/WH C5-22 GLOW PLUG RELAY
GLOW
TS56
PLUG
GLOW
GLOW PLUG
J
PLUG
FUSE 70A
PR2
NO
number 16733
OIL TEMPERATURE LED

After serial
ENGINE
D64
FAULT
L2
MODULE
START
U1
I
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
8 KEY BYPASS
10 ENG. FAULT
TS2
7 KEY PWR.
6 BATTERY
C33STR BK
5 GROUND

4 AUX. ON

ENGINE
TS52
D33
TB25
START
START
C28TTA RD/BK
SW2
BK
NC
TB33
H
POWER RELAY
P26ESTP BK
TB21
CR2
P24FS WH
P25FS RD
C21IGN2 WH C5-11
FUEL SOLENOID
TS1
NO
AUX
PUMP
C1P-1 C27AUX RD C1B-1
C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
G
_
IGN./START RELAY
CR1
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
NO
D3
STARTER
STARTER MOTOR
FS1
D4
BK-(FS)
TS51
CR19
EMISSION CONTROL
F
January 2010
Part No. 139188

TB27
AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK
F.H. C27AUX RD
C7P-2 P23BAT WH
M2
PR1
TB23
NO
P2
D2
PUMP
AUX
AUXILIARY PUMP
C5-3
C1P-2 WH
RD/BK TB28
D40
E
C1B-2
B
H1
TILT ALARM
LEVEL SENSOR
L4
D39
C3B-12
C
A
S8
TB46
GR/BK
RD
C2B-5
NC
P3
GR/BK

CR5
LS18
H2
TB133
NO
P22BAT BK F.H. BK
D
HORN
C32-8
TB132
L45
8
7
C1P-12 C132PLI BL/WH C1B-12 5
TB134
FB1
3
U33
OPTION
H6
1
6
4
12
TB134
RD
SW4
BK
NO
C
HYDRAULIC OIL
86
85
TEMPERATURE
TB22
WH
RD
SWITCH (OPTION)
87a 87
P116HYD RD
30
PLAT
GRD
C41RPM OR/BK
FAN
CR17
KS1
(OPTION)
M1
3MF
C3
+
TB41
D22
B
RD
EXCT.
C21IGN WH
STA.
BAT.
IND.
P1
RD
RD
-
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
D1
TB20
A
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 58
1
8
1
8
6 - 59
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

4
15 DRIVE FORWARD
15
1
16 DRIVE REVERSE
TS14
TB31
LOW DRIVE
(HIGH TORQUE)
H4

8
DRIVE
MODE
(OPTION)
HIGH DRIVE
(LOW TORQUE)
B
C26-1 C26-2
TB32

19 BRAKE RELEASE
C28-1 C28-2
TB29

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

C
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 17 STEER LEFT
NOTES:
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
C28TTA RD/BK
TB36
P26ESTP BK
P24FS WH

11
5
J1
13 10
ROCKER OPTION
TB4
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
P162JPW OR
D

14
C15-1 C15-2
TB5
D9
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
GND 1
6
R OUT 5
X OUT 3
PWR 2
Y OUT 4
TS62
7.5W
R4
CR19
TB6
C31-1 C31-2
C6TRF WH/RD
JC3
TURNTABLE ROTATE
FLOW CONTROL
TB1
R2
5W
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
2 DOWN C2PBD RD/BK

PRIMARY BOOM DOWN
Part No. 139188
TS61
1 C13-1 C13-2
CR34
J2
R14
5W
January 2010
11
TB3
C164PES RD/WH
C165TRS WH/RD
R16
10W
C3PBF RD/WH
P162JPW OR

12
C29-1 C29-2
J1
6
BR
TURNTABLE ROTATE
TB2
BOOM UP/DOWN &

GND 1
6
X OUT 3
PWR 2
Y OUT 4
7
JC2

8
F
TB9
3 C30-1 C30-2
14
9 FLOW CONTROL
C163PLS BL/WH

13
P162JPW OR
10
12
NC
TB7
BR
21
22
EXTEND/RETRACT
RD RD BR C7PBE BK
G
BOOM EXTEND
PRIMARY BOOM
GND 1
6
PWR 2
Y OUT 4
EXTEND
BOOM C37-1 C37-2 C16-1 C16-2
J1
LS5
RETRACT
JC1
TS63
C8PBR BK/WH
BOOM RETRACT
TB8
C17-1 C17-2
BRN
NO
1
HC

1
13
14
2
TB118
LS17
BK
TB13
P24FS WH
H
NO
J3
HC
4
3
P26ESTP BK
13
14
TB22
LS3
C2P-2
NO
4
HC

DRIVE LIMIT SWITCH
13
14
LS1
NO
HC

DRIVE LIMIT SWITCH
13
14
C40LS OR C2B-2 LS2 F.H. OR
I
BK
TB40
OPTION
CR30
CR27
DRIVE
NO
NC
LIFT/
CE
P22LS BK
L46
NO
J
L47
TB59
13
14
CR34
LS5
TB134
NC
HO
21
22
LS17
TS9
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
ROTATE C17JU/PRL GR
L
LEFT
C22-1 C22-2
TB17
D29
C129 RD/BK
DESCENT ALARM
H3
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
REV B
P134 RD
N
BRN
RD
RD

6 - 59 6 - 60

6 - 61 6 - 62
8
7
6
5
4
3
2
1
6 - 62
RD
CR1 CR2
POWER BRN CR23
IGNITION DRIVE LIGHT
START RELAY RELAY
(OPTION)
RD
BK-ISM1 A
BRN
number 19405
Circuit breaker
WH
BRN
added after serial

BRN
C32
8
7
5
6
1
4
3
12
WH-OPTIONS
WH-ISM9
CR4
C5-18 BK/RD
R43DLITE2 RD
R43DLITE1 RD
C21IGN WH C5-11
BAT
HIGH RPM
AUX
BK/RD-35C
C2B-4 OR/RD
RD-24B
SOLENOID RELAY
WH-21B
BRN
BK
BK C5-5
WH
RD H6
BRN
BK-22D2
RD-TS52
RD-TS51
BK/RD-CR4
BK C7B-1
GR/BK H6
B
BL/WH-132B
C5
10A
CB7
C5-18 C32 C32
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
GR/BK-L45
RD-ISM4
GR/BK-133B
CR17
WH/RD-R2 HYDRAULIC
OIL COOLER
P134PWR RD-134C
WH/RD-R4
(OPTION)
RD/WH-TS61
+
RD-CB3
H6
TERMINAL BASE (TB) C1PBU RD C3B-1

(CE OPTION)
D C B A
D
1 PRIMARY BOOM UP 1
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
C6TRF WH/RD C3B-6 POWER TO
(DRIVE LIGHT OPTION)

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

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
C14PLU OR C4B-2
Part No. 139188

January 2010
OR-TS59 C14PLU OR C20-1 18/19 #2

C15PLD OR/BK C4B-3
#2
#1

C17JU GR C4B-5

C18JD GR/BK C4B-6

18 PLATFORM ROTATE RIGHT/JIB DOWN 18 BOOM
C19JSV GR/WH C4B-7 EXTEND
LIMIT SWITCH
GR/WH-TS57
#2
C5
C11 (LS1)
F.H.

RD-CB2 P20BAT RD
RD-CB1 P20BAT RD
G
D52
BRN-<GND> C21IGN WH CR2

C11
BK-CR5
CABLE
BK-KS P22LS17 BK C38-4 TENSION
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
H
WH/BK-ISM10 C25TS WH/BK C5-16

D33
WH/RD-L2- C26PS WH/RD C5-14

26 TEMPERATURE SWITCH 26

BK
RD
WH
27 AUXILARY PUMP 27
C28TTA RD/BK C1B-2
C28TTA RD/BK B P20BAT RD

C29MS RD/WH C5-24

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

WH/RD-R2
WH/RD-R4
RD/WH-R16
RD/WH-TS61
C32BRK WH/RD C1B-6
WH/RD-ALRM C32BRK WH/RD C5-23

32 BRAKE 32
BK-ISM3 C33STR BK C1B-7
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
TO SWITCH PANEL
GROUND HARNESS
BK/WH-TS56 C34SA BK/WH C5-22

34 GLOW PLUG 34
BK/RD-CB7 C35RPM BK/RD C1B-9
RD-TS54
J
C36SCC BL C1B-10
C36SCC BL C24-1
36 STEER LEFT 36
C37SCW BL/BK C1B-11
C5
C37SCW BL/BK C25-1

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

HARNESS
39 (UNUSED) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
OR/BK-ISM2 C41RPM OR/BK C2B-3
C5
C41RPM OR/BK C5-2

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

P134PWR GR/BK C2B-6
RD-H6+ P134PWR RD-LS17 C38-1

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

BK-CR5 R46HRN BK
BRN

L
BL/WH C32-3 C132PLI BL/WH C1B-12

GR/BK-H6- C133PLA BL/WH C3B-12
B A
HARNESS
FUNCTION
BK C16-1

WH LS2 C10-2
BK
RD
WH
BK-CR1
Genie Industries U1
OR/BK-41C
F.H.
2 Push gently
2 TACHOMETER
BK-33C and lift.
M
3 3 START INPUT
RD-CR19
4 4 AUX PWR UNIT
BRN
5 5 GROUND
RD-24C
6 6 BATTERY
WH-23C
7 7 TO KEY SW (DIESEL ONLY) C9 (LS3)
8 8 JUMP TO 7 (GAS ONLY) C11 (LS2)

WH-CR2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON LS17 (C38)
WH/BK-25D

N
ES0192G (DEUTZ)
ES0194H (PERKINS)
GROUND BOLT
REV B

OVERLOAD LED
TURNTABLE
1
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
C19JSV GR/WH
WH-4
RD/WH
RD
GR/BK-18D
RD
RD
RD
2
GR-17D
RD
D3
RD
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
WH/RD WH/RD
RD
RD
RD
WH/RD
3
RD-27
WH
PLATFORM
RD
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
RD/WH
WH-4D
RD-1D
BK-7D
WH
RD
4
TURNTABLE
RESISTOR
DALE RH-25 25W

DALE RH-25 25W
ROTATE
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK/WH-34D
BK-33D
RD-20C
WH/RD-26
RD C32-7
RD CR17
BRN-GND
RD-20D
RD-24D
7.5 ohm 1%
BK/RD-35D
R2
5 ohm 1%
TURNTABLE
RESISTOR
ROTATE
WH
ENGINE
R4
CHECK
L2
1
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
B
CB3
CB2
RD
-
3
4
WH
RD/WH
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
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
RD
RESISTOR
UP/DOWN

RESISTOR
BOOM

R14
ENGINE
ENGINE 15A
R16
START
TS52
BREAKER
CIRCUIT
CB1
BK/WH-34D
RD-24D
BRN CR4 HIGH IDLE RELAY
CR5 HORN RELAY
BRN

WH-21D
RD
HM HOUR METER 7
After serial KS1 KEY SWITCH
RD
number 16733 L2 CHECK ENGINE LED

HOUR METER

STOP SWITCH
EMERGENCY
RD
1 1
D13
GLOW
PLUG
TS56
P1
NC NC
RD R4 SPEED LIMITING RESISTOR 7.5 OHMS
D14
FUNCTION
2 2
ENABLE
TS54
RD
RD
TS52
TS54
8

6 - 63 6 - 64

S-60 and S-60 TRAX, CE Models
6 - 65 6 - 66
8
7
6
5
4
3
2
1
6 - 66
RD
CR1 CR2
POWER BRN CR23
START RELAY RELAY
OPTION
RD
BK-ISM1 A
U33
BRN
PLATFORM
OVER LOAD
number 19405
Circuit breaker
WH
BRN
added after serial

BRN
C32
8
7
5
6
1
4
3
12
WH-OPTIONS
WH-ISM9
CR4
C5-18 BK/RD
R43DLITE2 RD
R43DLITE1 RD
C21IGN WH C5-11
BAT
HIGH RPM
AUX
BK/RD-35C
C2B-4 OR/RD
RD-24B
SOLENOID RELAY
WH-21B
BRN
BK C5-5
RD H6
BRN
BK/RD-CR4
BK-22D2
RD-TS52
RD-TS51
BK C7B-1
GR/BK H6
BL/WH-132B
B
C5
10A
CB7
C5-18 C32 C32
BK
WH
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
GR/BK-L45
RD-ISM4
GR/BK-133B
CR17
WH/RD-R2 HYDRAULIC
P134PWR RD-134C
WH/RD-R4 OIL COOLER

OPTION
RD/WH-TS61
+
RD-CB3
H6

D
1 PRIMARY BOOM UP 1
#1
D29

C3PBF RD/WH C3B-3

C4TRL WH C3B-4

CE Models Deutz F3L-2011/Deutz D2011L03i Models

C5TRR WH/BK C3B-5
FUSE 10A

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
C14PLU OR C4B-2
Part No. 139188

January 2010
OR-TS59 C14PLU OR C20-1 18/19 #2

C15PLD OR/BK C4B-3
#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

G

Ground Control Box Terminal Strip Wiring Diagram, S-60 and S-60 TRAX,

C11
BK-CR5
BK C32-4 P22BAT BK C9-2 C37 (LS5)
WH-KS
RD-ISM6 RD-CR2
RD-CB1
#2
#1
C5
F.H.
C37
H

D33


BK
RD
WH
C28TTA RD/BK C1B-2

28 TILT ALARM 28
C29MS RD/WH C5-24

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

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

32 BRAKE 32
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
TO SWITCH PANEL
GROUND HARNESS

34 GLOW PLUG 34
BK/RD-CR4 C35RPM BK/RD C1B-9
RD-TS54
J
C36SCC BL C1B-10
C36SCC BL C24-1
36 STEER LEFT 36
C37SCW BL/BK C1B-11
C5
C37SCW BL/BK C25-1

37 STEER RIGHT 37
ENGINE
C39LP BL/RD C2B-1
39 (UNUSED) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
C5
BRN-GND C41RPM OR/BK C5-2

C46HRN GR C2B-5
WH C11-2
+
K
GR-CR5
46 SERVICE HORN 46
C59CNK BL/BK C3B-11
C3

P134PWR GR/BK C2B-6

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

BK-CR5 R46HRN BK
BRN

L

B A
HARNESS
FUNCTION
BK C16-1

WH LS2 C10-2
BK
RD
WH
BRN
BK-CR1
Genie Industries
F.H.
OR/BK-41C
BK-33C U1
3
M
and lift 3 START INPUT

RD-CR19
4 4 AUX PWR UNIT
BRN
5 5 GROUND
RD-24C
6 6 BATTERY
WH-23C

WH-CR2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON LS17 (C38)
WH/BK-25D

N
ES0192G
GROUND BOLT
REV B
REV A Ground Control Box Switch Panel Wiring Diagram, S-60 and S-60 TRAX,
OVERLOAD LED
1
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
C19JSV GR/WH
WH-4
RD/WH
RD
GR/BK-18D
RD
RD
RD 2
GR-17D
RD
D3
RD
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
WH/RD WH/RD
RD
RD
RD
WH/RD
3
RD-27
WH
PLATFORM
RD
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
RD/WH
WH-4D
RD-1D
BK-7D
WH
RD
4
TURNTABLE
RESISTOR
DALE RH-25 25W

DALE RH-25 25W
ROTATE
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK/WH-34D
BK-33D
RD-20C
WH/RD-26
RD C32-7
RD CR17
BRN-GND
RD-20D
RD-24D
7.5 ohm 1%
BK/RD-35D
R2
5 ohm 1%
TURNTABLE
RESISTOR
ROTATE
WH
ENGINE
R4
CHECK
L2
1
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
B
CB3
CB2
RD
-
3
5
4
WH
RD/WH
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
RD
RD
RD
RD
6
LABEL DESCRIPTION
DALE RH-25 25W
DALE RH-25 25W
RD-20D
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RD
RESISTOR
UP/DOWN

RESISTOR
BOOM

R14
ENGINE
ENGINE 15A
R16
START
TS52
BREAKER
CIRCUIT
CB1
BK/WH-34D
RD-24D
BRN CR4 HIGH IDLE RELAY
CR5 HORN RELAY
BRN

WH-21D
RD
HM HOUR METER
7
After serial KS1 KEY SWITCH
RD
number 16733 L2 CHECK ENGINE LED

HOUR METER

STOP SWITCH
EMERGENCY
RD
1 1
D13
GLOW
PLUG
TS56
P1
NC NC
RD R4 SPEED LIMITING RESISTOR 7.5 OHMS
D14
FUNCTION
2 2
ENABLE
TS54
RD
RD
TS52 ENGINE START TOGGLE SWITCH 8
TS54 FUNCTION ENABLE SWITCH

6 - 67 6 - 68

6 - 69 6 - 70
REV A

N
CWLITE WH TS49
(TO SWITCH
PLATFORM
CONTROL
HARNESS

PANEL)
DESCRIPTION
TILT ALARM
C19JSV GR/WH TS7

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

C32BRK WH/RD J2-19
OPTION
LS18
(CE)
BRN
K
CR30
BK C1P-12
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
TS1 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
J
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+
C59CNK BL/BK C3P-11
P26BAT BK C9-1 P2
I
P25FS RD C9-3 TS2

P24FS WH C9-2 TS4
CDLITE OR/RD C2P-4
FOOT SWITCH
C4P
C7P
C3P
F.S.
C45GEN GR/WH C2P-7

C46HRN GR C2P-5
C9
H
P26ESTP BK
WH/RD C1P-6
11
3
C118LSR OR/RD C4P-4
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
G
C8PBR BK/WH C3P-8

C16DRE BL/RD C4P-1
C7PBE BK C3P-7
C7P
C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C7P
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
F
January 2010
Part No. 139188

C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C4P
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
C3P
C3P(GR)
E
C35RPM BK/RD C1P-9

C34SA BK/WH C1P-8
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)

J1
C1P
9
1
P162JPW OR
D
C165TRS WH/RD

GND BRN
P162JPW OR
C163PLS BL/WH
C7P
GND BRN
C160JPL WH/RD
* NOTE:
P162JPW OR
C159STC BL/WH*
GND BRN
C

C143DEL BL/BK
C13DE BL/RD
C28TTA RD/BK C1P-2

C29MS 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
C134PWR RD C2P-6
+
CWLITE BK
BRN
BRN
BRN BRN
A
CWLITE WH TS49
6 - 70
1
8

1
PLATFORM CONTROL
HARNESS (TO CONTROL BOX)
JC2 JC3
DRIVE
BOOM UP/DOWN & FORWARD/REVERSE
TURNTABLE ROTATE & STEER
LEFT/RIGHT TS48 LEFT/RIGHT
DRIVE LIGHTS/
WORK LIGHTS
(OPTION)
DLITE RD RD 2
TS15
DRIVE +
ENABLE
JC1 L48
TILT ALARM LED
BOOM (ANSI/CSA OPT.)
EXTEND/RETRACT
6 1 6 1 6 1
BK
BK
3
RD
5 2 5 2 5 2
4 3 4 3 4 3
(ROCKER SWITCH OPTION)

L4
PLATFORM
BRN OVERLOAD
L1 (CE OPTION)
DRIVE
ENABLE
LED +
BRN
+
L47
RETRACT + 4
BOOM
RD
LED
BK
BRN
BK
BRN BRN BRN BRN F18 FUSE 10A
(WORK LIGHT ONLY)
BK
C59CNK BL/BK C3P-11
C134PWR RD E-STOP
C134PWR RD E-STOP
C133PLA GR/BK D39

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

C164PES RD/WH
C165TRS WH/RD
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
BK
5
P162JPW OR
P162JPW OR
P162JPW OR
BL-DE1 J1-6
WLITE WH
WLITE WH
GND BRN
GND-BR
GND BR
BRN
RD
BK
PDLITE RD
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
C46HRN GR C2P-5
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
C34SA BK/WH C1P-8
P25FS RD C9-3
C33STR BK C1P-7
C35HS BK/RD C1P-9

P24FS WH C9-2
C45GEN GR/WH C2P-7

6
RD RD COMPONENT INDEX
WH WH
RD
RD D12
BOOM EXTEND/RETRACT
4 NO
3
1 1 1
7
NC NC NC L1 DRIVE ENABLE LED
TS6 TS2 TS4 2 22
TS14 L47 LOWER/RETRACT BOOM LED
P3 WH GLOW PLUG ENGINE HIGH/LOW
TS1 HIGH/LOW TS47
HORN TS9 START RPM L48 BOOM TILTED LED
AUXILIARY (2WD/4WD) GENERATOR
RD
PLATFORM P2 P2 EMERGENCY STOP BUTTON

TS7 PUMP (OPTION)
LEVEL EMERGENCY
PLATFORM P3 HORN SWITCH
WH-24 STOP
ROTATE TS1 AUXILIARY POWER TOGGLE SWITCH
RD RD RD RD
TS4
TS6
HI/LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
8
NOTE: DASHED LINES INDICATE OPTION WIRES TS14 DRIVE SPEED TOGGLE SWITCH
TS48 DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)

6 - 71 6 - 72

6 - 73 6 - 74
REV B
Circuit breaker
RD
RD
BRN
serial number
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
ES0192G
added after
CR4
N
D12
19405

HIGH IDLE RELAY
FOOTSW. HIGH
TB35
CB7
10A
FOOTSW. LOW
TS4
CR4
Q3
ENGINE
BK/RD C5-18
TS54
SPEED
HIGH RPM SOLENOID

NO
LOW RPM
D14
FUNCTION ENA.
G2

D13
M
G1
VOLT METER (OPTION)

G3

TB45

TS47
GENERATOR (OPTION)
L
CR23
TS48

DRIVE LIGHT
L29
LIGHTS
FUSE 10A
WORK LIGHT RD
DRIVE LIGHT L29
F19
(OPTION)
L29
L30
RD
RD
RD
FUSE 10A
WORK LIGHTS L30

TB21
C2P-12 C2P-10
F18
CR23
(OPTION)
NO
PBOX GND
C2P-11 C2P-9
K
L30
PR2
TB34
TS6

GLOW PLUG RELAY
GLOW
TS56
PLUG
GLOW
GLOW PLUG
J
PLUG
FUSE 70A
PR2
NO
F22
number 16733
ENGINE FAULT LED

After serial
L2
D64
MODULE
START
U1
I
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
8 KEY BYPASS
10 ENG. FAULT
TS2
7 KEY PWR.
6 BATTERY
C33STR BK
5 GROUND

4 AUX. ON

ENGINE
TS52
D33
TB25
START
START
C28TTA RD/BK
SW2
BK
NC
TB33
CR2
H
POWER RELAY
P26ESTP BK
TB21
P24FS WH
P25FS RD
C21IGN2 WH C5-11
FUEL SOLENOID
TS1
CR2
AUX
NO

C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
G
_
IGN./START RELAY
CR1
NO
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
D3
STARTER
STARTER MOTOR
FS1
D4
BK-(FS)
TS51
CR19
F
EMISSIOIN CONTROL
January 2010
Part No. 139188

TB27
AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK
F.H. C27AUX RD
C7P-2 P23BAT WH
M2
TB23
PR1
NO
P2
D2
PUMP
L48
AUX
AUXILIARY PUMP
C5-3
RD/BK C1P-2 WH
RD/BK TB28
D40
E
Overload
Platform
C1B-2
B
Option

H1
TILT ALARM
LEVEL SENSOR
C3B-12
C
A
S8
TB46
RD
C2B-5
P3
CR5
GR/BK

H2
NO
TB133
P22BAT BK F.H. BK
D
HORN
C32-8
TB132
7
5
TB134
FB1
3
U33
(OPTION)
1
12
4
6
TB134
RD
SW4
BK
NO
C
HYDRAULIC OIL
86
85
TEMPERATURE
TB22
WH
RD
SWITCH (OPTION)
87a 87
P116HYD RD
30
PLAT
GRD
C41RPM OR/BK
CR17
FAN
KS1
(OPTION)
M1
3MF
C3
+
TB41
B
D22
RD
EXCT.
C21IGN WH
STA.
BAT.
IND.
P1
RD
RD
-
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
D1
TB20
A
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 74
1
8
1
8
6 - 75
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

4
15 DRIVE FORWARD
15
1
16 DRIVE REVERSE
TS14
TB31
LOW DRIVE
(HIGH TORQUE)
H4

8
(OPTION)
DRIVE
MODE
HIGH DRIVE
(LOW TORQUE)
B
C26-1 C26-2
TB32

19 BRAKE RELEASE
C28-1 C28-2
TB29

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

C
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 17 STEER LEFT
NOTES:
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
C28TTA RD/BK
TB36
P26ESTP BK
P24FS WH
2
2

4 11
5
J1
13 10
TB4
ROCKER OPTION
C159STC BL/WH
C14-1 C14-2
C160JPL WH/RD

D
P162JPW OR

14
C15-1 C15-2
TB5
D9
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
7.5W
TS62
GND 1
6
R OUT 5
X OUT 3
PWR 2
Y OUT 4
R4
CR19
TB6
C31-1 C31-2
JC3
FLOW CONTROL
TB1
R2
5W
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
DOWN C2PBD RD/BK

2
PRIMARY BOOM DOWN
Part No. 139188
R16
10W
1 C13-1 C13-2
CR34
R14
TS61
J2
5W
January 2010
11
TB3
C165TRS WH/RD
C164PES RD/WH
C3PBF RD/WH
P162JPW OR

12 C29-1 C29-2
J1
6
BR
TB2
TURNTABLE ROTATE
BOOM UP/DOWN &

GND 1
6
X OUT 3
PWR 2
Y OUT 4
7
JC2
8
F
TB9
3 C30-1 C30-2
14
9 FLOW CONTROL
C163PLS BL/WH
13
J1
P162JPW OR
21 LS5
10
C3P-7 C7PBE BK C3B-7
NC
12 LS5 CABLE TENSION LIMIT SWITCH

TB7
BR
22
C7PBE BK
EXTEND/RETRACT
RD RD BR
G
BOOM EXTEND
PRIMARY BOOM
EXTEND
GND 1
6
PWR 2
Y OUT 4
BOOM C37-1 C37-2 C16-1 C16-2

RETRACT
JC1
TS63
C8PBR BK/WH
BOOM RETRACT
TB8
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
2
TB118
BK
TB13
LS3
NO
HC
P24FS WH
H
J3
4
3
P26ESTP BK
13
14
TB22
3
LS1
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS2

DRIVE LIMIT SWITCH
13
14
NO
C40LS OR C2B-2 HC F.H. OR
I
BK
TB40
OPTION
CR27
CR30
DRIVE
NO
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
PLATFORM LEVEL UP
K
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
D27

CR13
NC
C4P-6 C4B-6
TS8
C18JD/PRR GR/BK
DOWN JIB
C23-1 C23-2
TB18
C4P-5
D28
TS58
RIGHT PLATFORM
ROTATE C17JU/PRL GR
L
LEFT
C22-1 C22-2
TB17
RIGHT PLATFORM
D29
LEFT ROTATE
TS7
WH
TS57
C129 RD/BK
DESCENT ALARM
BRN
D30
H3

CR13
TB19
M

C1
+
-
C41RPM OR/BK
JIB VALVE
C28TTA RD/BK
P24FS WH
P26ESTP BK
NO
P22LS BK
REV B
P134 RD
CR14
GR/WH
N
BRN
RD
RD

6 - 75 6 - 76

6 - 77 6 - 78
REV B
Circuit breaker
RD
RD
BRN
ES0192G
serial number
C41RPM OR/BK
C28TTA RD/BK
C22LS BK
P26ESTP BK
P24FS WH
added after
CR4
N
D12
19405
C35RPM BK/RD
C1P-9 C35RPM BK/RD C1B-9 BRN
HIGH IDLE RELAY
FOOTSW. HIGH
CB7
10A
FOOTSW. LOW
TS4
CR4
Q3
ENGINE
BK/RD C5-18
TS54
SPEED
HIGH RPM SOLENOID

NO
LOW RPM
D14
FUNCTION ENA.
G2

D13
TB35
M
G1
VOLT METER (OPTION)

G3

TB45

TS47
GENERATOR (OPTION)
L
CR23
TS48

DRIVE LIGHT
L29
LIGHTS
FUSE 10A
WORK LIGHT RD
DRIVE LIGHT (OPTION)
F19
L29
L30
RD
RD
RD
FUSE 10A
WORK LIGHTS (OPTION)

TB21
C2P-12 C2P-10
F18
CR23
NO
PBOX GND
C2P-11 C2P-9
K
L30
PR2
TB34
TS6
C1P-8 C34SA BK/WH C1B-8 C34SA BK/WH C5-22 GLOW PLUG RELAY
GLOW
TS56
PLUG
GLOW
GLOW PLUG
J
PLUG
FUSE 70A
PR2
NO
number 16733
OIL TEMPERATURE LED

After serial
ENGINE
D64
FAULT
L2
MODULE
START
U1
I
SW3
NO
2 TACHOMETER
1 START RELAY
9 IGN./FUEL ON
TB26
8 KEY BYPASS
10 ENG. FAULT
TS2
7 KEY PWR.
6 BATTERY
C33STR BK
5 GROUND

4 AUX. ON

ENGINE
TS52
D33
TB25
START
START
C28TTA RD/BK
SW2
BK
NC
TB33
H
POWER RELAY
P26ESTP BK
TB21
CR2
P24FS WH
P25FS RD
C21IGN2 WH C5-11
FUEL SOLENOID
TS1
NO
AUX
PUMP
C1P-1 C27AUX RD C1B-1
C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
G
_
IGN./START RELAY
CR1
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
NO
D3
STARTER
STARTER MOTOR
FS1
D4
BK-(FS)
TS51
CR19
EMISSION CONTROL
F
January 2010
Part No. 139188

TB27
AUXILIARY
PUMP RD C27AUX RD
C9P-1 BK
F.H. C27AUX RD
C7P-2 P23BAT WH
M2
PR1
TB23
NO
P2
D2
PUMP
AUX
AUXILIARY PUMP
C5-3
C1P-2 WH
TB28
E
RD/BK
D40
C1B-2
B
H1
TILT ALARM
LEVEL SENSOR
L4
D39
C3B-12
C
A
S8
TB46
GR/BK
RD
C2B-5
NC
P3

GR/BK
CR5
LS18
H2
TB133
NO
P22BAT BK F.H. BK
D
HORN
C32-8
TB132
L45
8
7
5
TB134
FB1
3
U33
OPTION
H6
1
6
4
12
TB134
RD
SW4
BK
NO
C
HYDRAULIC OIL
86
85
TEMPERATURE
TB22
WH
RD
SWITCH (OPTION)
87a 87
P116HYD RD
30
PLAT
GRD
C41RPM OR/BK
FAN
CR17
KS1
(OPTION)
M1
3MF
C3
+
TB41
B
D22
RD
EXCT.
C21IGN WH
STA.
BAT.
IND.
P1
RD
RD
-
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
D1
TB20
A
-
RD C7B-4 P20BAT RD
12V DC
B2
6 - 78
1
8
1
8
6 - 79
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

4
15 DRIVE FORWARD
15
1
16 DRIVE REVERSE
TS14
TB31
LOW DRIVE
(HIGH TORQUE)
H4

8
(OPTION)
DRIVE
MODE
HIGH DRIVE
(LOW TORQUE)
B
C26-1 C26-2
TB32

19 BRAKE RELEASE
C28-1 C28-2
TB29

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

C
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 17 STEER LEFT
NOTES:
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
C28TTA RD/BK
TB36
P26ESTP BK
P24FS WH
2
2

4 11
5
J1
13 10
TB4
ROCKER OPTION
C159STC BL/WH
C14-1 C14-2
C160JPL WH/RD

D
P162JPW OR

14
C15-1 C15-2
TB5
D9
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
7.5W
TS62
GND 1
6
R OUT 5
X OUT 3
PWR 2
Y OUT 4
R4
CR19
TB6
C31-1 C31-2
JC3
FLOW CONTROL
TB1
R2
5W
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
DOWN C2PBD RD/BK

2
PRIMARY BOOM DOWN
Part No. 139188
R16
10W
1 C13-1 C13-2
CR34
R14
TS61
J2
5W
January 2010
11
TB3
C165TRS WH/RD
C164PES RD/WH
C3PBF RD/WH
P162JPW OR

12 C29-1 C29-2
J1
6
BR
TB2
TURNTABLE ROTATE
BOOM UP/DOWN &

GND 1
6
X OUT 3
PWR 2
Y OUT 4
7
JC2
8
F
TB9
3 C30-1 C30-2
14
9 FLOW CONTROL
C163PLS BL/WH
13
J1
P162JPW OR
21 LS5
10
C3P-7 C7PBE BK C3B-7
NC
12 LS5 CABLE TENSION LIMIT SWITCH

TB7
BR
22
C7PBE BK
EXTEND/RETRACT
RD RD BR
G
BOOM EXTEND
PRIMARY BOOM
EXTEND
GND 1
6
PWR 2
Y OUT 4
BOOM C37-1 C37-2 C16-1 C16-2

RETRACT
JC1
TS63
C8PBR BK/WH
BOOM RETRACT
TB8
C17-1 C17-2
LS17
NO
HC
BRN
1
1
13
14
2
TB118
BK
TB13
LS3
NO
HC
P24FS WH
H
J3
4
3
P26ESTP BK
13
14
TB22
3
LS1
NO
HC
C2P-2
4
DRIVE LIMIT SWITCH
13
14
LS2

DRIVE LIMIT SWITCH
13
14
NO
C40LS OR C2B-2 HC F.H. OR
I
BK
TB40
OPTION
CR27
CR30
DRIVE
NO
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
PLATFORM LEVEL UP
K
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
PLATFORM LEVEL DOWN
TB15
TB44
C21-1 C21-2
D27

CR13
NC
C4P-6 C4B-6
TS8
C18JD/PRR GR/BK
DOWN JIB
C23-1 C23-2
TB18
C4P-5
D28
TS58
RIGHT PLATFORM
ROTATE C17JU/PRL GR
L
LEFT
C22-1 C22-2
TB17
RIGHT PLATFORM
D29
LEFT ROTATE
TS7
WH
TS57
C129 RD/BK
DESCENT ALARM
BRN
D30
H3

CR13
TB19
M

C1
+
-
C41RPM OR/BK
JIB VALVE
C28TTA RD/BK
P24FS WH
P26ESTP BK
NO
P22LS BK
REV B
P134 RD
CR14
GR/WH
N
BRN
RD
RD

6 - 79 6 - 80

6 - 81 6 - 82
8
7
6
5
4
3
2
1
6 - 82
RD
CR1 CR2
POWER BRN CR23
START RELAY RELAY
(OPTION)
RD
BK-ISM1
A
BRN
number 19405
Circuit breaker
WH
BRN
added after serial

BRN
C32
8
7
5
6
1
4
3
12
WH-OPTIONS
WH-ISM9
CR4
C5-18 BK/RD
R43DLITE2 RD
R43DLITE1 RD
C21IGN WH C5-11
BAT
HIGH RPM
AUX
BK/RD-35C
C2B-4 OR/RD
RD-24B
SOLENOID RELAY
WH-21B
BRN
BK
BK C5-5
WH
RD H6
BRN
BK-22D2
RD-TS52
RD-TS51
BK/RD-CR4
BK C7B-1
GR/BK H6
BL/WH-132B
C5
10A
CB7
B
C5-18 C32 C32
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
GR/BK-L45
RD-ISM4
GR/BK-133B
CR17
WH/RD-R2 HYDRAULIC
OIL COOLER
P134PWR RD-134C
WH/RD-R4
(OPTION)
RD/WH-TS61
+
RD-CB3
H6
TERMINAL BASE (TB) C1PBU RD C3B-1

(CE OPTION)
D C B A
1 PRIMARY BOOM UP 1
D

#1
D29

C3PBF RD/WH C3B-3


C4TRL WH C3B-4

C5TRR WH/BK C3B-5
FUSE 10A
C6TRF WH/RD C3B-6 POWER TO

PLATFORM
WH/RD-CR19 C6TRF WH/RD C31-1
C7
BK
RD
WH
C7PBE BK C3B-7
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
C14PLU OR C4B-2
Part No. 139188

January 2010
OR-TS59 C14PLU OR C20-1

F
18/19 #2
C15PLD OR/BK C4B-3

#2
#1

C17JU GR C4B-5

C18JD GR/BK C4B-6

18 PLATFORM ROTATE RIGHT/JIB DOWN 18 BOOM
C19JSV GR/WH C4B-7 EXTEND
LIMIT SWITCH
GR/WH-TS57
#2
C5
C11 (LS1)
F.H.

RD-CB2 P20BAT RD
RD-CB1 P20BAT RD
D52
G

C11
BK-CR5
CABLE
BK-KS P22LS17 BK C38-4 TENSION
BK C32-4 P22BAT BK C9-2
WH-KS
RD-ISM6 RD-CR2
RD-CB1
#2
#1
C5
F.H.
C37
H

D33

26 TEMPERATURE SWITCH 26

BK
RD
WH
27 AUXILARY PUMP 27
C28TTA RD/BK C1B-2
C28TTA RD/BK B P20BAT RD

C29MS RD/WH C5-24

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

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

32 BRAKE 32
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
TO SWITCH PANEL
GROUND HARNESS

34 GLOW PLUG 34
BK/RD-CB7 C35RPM BK/RD C1B-9
RD-TS54
C36SCC BL C1B-10
J
C36SCC BL C24-1
36 STEER LEFT 36
C37SCW BL/BK C1B-11
C5
C37SCW BL/BK C25-1

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

HARNESS
39 (UNUSED) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
C5
C41RPM OR/BK C5-2

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

P134PWR GR/BK C2B-6

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

BK-CR5 R46HRN BK
BRN

L

B A
HARNESS
FUNCTION
BK C16-1

WH LS2 C10-2
BK
RD
WH
BK-CR1
Genie Industries U1
OR/BK-41C
F.H.
2 Push gently
2 TACHOMETER
BK-33C and lift.
3
M
3 START INPUT
RD-CR19
4 4 AUX PWR UNIT
BRN
5 5 GROUND
RD-24C
6 6 BATTERY
WH-23C

WH-CR2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON LS17 (C38)
WH/BK-25D

N
ES0192G (DEUTZ)
ES0194H (PERKINS)
GROUND BOLT
REV B

OVERLOAD LED
TURNTABLE
PLATFORM
UP/DOWN
1
(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
C19JSV GR/WH
WH-4
RD/WH
RD
GR/BK-18D
RD
RD
RD
GR-17D
RD
2
D3
GR/BK
RD
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
GR
WH/RD WH/RD GR/BK
RD
D28
GR
RD
RD
WH/RD RD
RD-27
3
WH
PLATFORM
UP/DOWN
JIB BOOM
RD
TS58
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
RD/WH
BL-44D
WH-4D
RD-1D
BK-7D
WH
RD
TURNTABLE
RESISTOR
4
DALE RH-25 25W
DALE RH-25 25W
ROTATE
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK/WH-34D
BK-33D
RD-20C
WH/RD-26
RD C32-7
RD CR17
BRN-GND
RD-20D
RD-24D
7.5 ohm 1%
BK/RD-35D
R2
5 ohm 1%
TURNTABLE
RESISTOR
ROTATE
WH
ENGINE
R4
CHECK
L2
1
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
B
CB3
CB2
RD
-
3
4
WH
RD/WH
5
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
RD
RD
RD
RD
LABEL
CB1
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
6
DALE RH-25 25W
DALE RH-25 25W
RD-20D
10 ohm 1%
PRIMARY BOOM
5 ohm 1%
UPPER ZONE
RD
RESISTOR
UP/DOWN

RESISTOR
BOOM

R14
ENGINE
ENGINE 15A
R16
START
TS52
BREAKER
CIRCUIT
CR4 HIGH IDLE RELAY
CB1
BK/WH-34D
RD-24D
BRN CR5 HORN RELAY
BRN

WH-21D
RD
HM HOUR METER
KS1 KEY SWITCH
After serial L2 CHECK ENGINE LED 7
RD
number 16733 L46 LOWER/RETRACT BOOM LED

HOUR METER

STOP SWITCH
EMERGENCY
RD
1 1
D13
GLOW
PLUG
TS56
P1
NC NC
D14
FUNCTION
2 2
ENABLE
TS54
RD
RD TS54 FUNCTION ENABLE SWITCH
TS56 GLOW PLUG TOGGLE SWITCH 8
RD TS58 JIB BOOM TOGGLE SWITCH

6 - 83 6 - 84

6 - 85 6 - 86
8
7
6
5
4
3
2
1
6 - 86
RD
CR1 CR2
POWER BRN CR23
START RELAY RELAY
OPTION
RD
BK-ISM1 A
U33
BRN
PLATFORM
OVER LOAD
number 19405
Circuit breaker
WH
BRN
added after serial

BRN
C32
8
7
5
6
1
4
3
12
WH-OPTIONS
WH-ISM9
CR4
C5-18 BK/RD
R43DLITE2 RD
R43DLITE1 RD
C21IGN WH C5-11
BAT
HIGH RPM
AUX
BK/RD-35C
C2B-4 OR/RD
RD-24B
SOLENOID RELAY
WH-21B
BRN
BK C5-5
RD H6
BRN
BK/RD-CR4
BK-22D2
RD-TS52
RD-TS51
BK C7B-1
GR/BK H6
B
BL/WH-132B
C5
10A
CB7
C5-18 C32 C32
BK
WH
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
HORN SELECT SPEED
RELAY OR C5-1
BRN RELAY REDUCTION
WH-OPTIONS
BRN
RELAY
C21IGN WH
C
C5
F.H.
GR/BK-L45
RD-ISM4
GR/BK-133B
CR17
WH/RD-R2 HYDRAULIC
P134PWR RD-134C
WH/RD-R4 OIL COOLER

OPTION
RD/WH-TS61
+
RD-CB3
H6

D
1 PRIMARY BOOM UP 1

#1

D29
C3PBF RD/WH C3B-3


C4TRL WH C3B-4


C5TRR WH/BK C3B-5
FUSE 10A

POWER TO
BK
RD
WH
C7
E
C7PBE BK C3B-7

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
C14PLU OR C4B-2
Part No. 139188

January 2010
OR-TS59 C14PLU OR C20-1 18/19 #2

C15PLD OR/BK C4B-3

#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

G

Ground Control Box Terminal Strip Wiring Diagram, S-65 and S-65 TRAX,

C11
BK-CR5

BK C32-4 P22BAT BK C9-2 C37 (LS5)
WH-KS
RD-ISM6 RD-CR2
RD-CB1
#2
#1
C5
F.H.
C37
H

D33


BK
RD
WH
C28TTA RD/BK C1B-2

28 TILT ALARM 28
C29MS RD/WH C5-24

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

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

32 BRAKE 32
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
TO SWITCH PANEL
GROUND HARNESS

34 GLOW PLUG 34
BK/RD-CR4 C35RPM BK/RD C1B-9
RD-TS54
J
C36SCC BL C1B-10
C36SCC BL C24-1
36 STEER LEFT 36
C37SCW BL/BK C1B-11
C5
C37SCW BL/BK C25-1

37 STEER RIGHT 37
ENGINE
C39LP BL/RD C2B-1
39 (UNUSED) 39
C40LS1 OR C2B-2
C40LS1 OR C10-2
40 BOOM STOWED 40
C5
BRN-GND C41RPM OR/BK C5-2

C46HRN GR C2B-5
WH C11-2
+
K
GR-CR5
46 SERVICE HORN 46
C59CNK BL/BK C3B-11
C3

P134PWR GR/BK C2B-6

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

BK-CR5 R46HRN BK
BRN

L

B A
HARNESS
FUNCTION
BK C16-1

WH LS2 C10-2
BK
RD
WH
BRN
BK-CR1
Genie Industries
F.H.
OR/BK-41C
BK-33C U1
M
3 and lift 3 START INPUT

RD-CR19
4 4 AUX PWR UNIT
BRN
5 5 GROUND
RD-24C
6 6 BATTERY
WH-23C

WH-CR2
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON LS17 (C38)
WH/BK-25D

N
ES0192G
GROUND BOLT
REV B
REV A Ground Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX,
OVERLOAD LED
TURNTABLE
1
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
C19JSV GR/WH
WH-4
RD/WH
RD
GR/BK-18D
RD
RD
RD
2
GR-17D
RD
D3
GR/BK
RD
AUXILIARY
RD RD
POWER
TS51
D4
WH/RD WH/RD
GR
WH/RD WH/RD GR/BK
RD
D28
GR
RD
RD
WH/RD RD
RD-27
3
WH
PLATFORM
UP/DOWN
JIB BOOM
RD
TS58
WH/RD
WH/RD
RETRACT
EXTEND/
GR/WH-19D LEVEL
BOOM
+
RETRACT -
TS63
BRN
RD/WH-CR34#87a
TS59
LOWER/
BOOM
C134PWR RD
L46
GR/BK-18D
OR/BK-15D
GR/BK-H6-
BL/BK-59D
BK/WH-8D
WH/BK-5D
BK/RD-9D
RD/BK-2D
RD C32-6
GR-17D
OR-14D
RD-27D
RD/WH
BL-44D
WH-4D
RD-1D
BK-7D
WH
RD
4
TURNTABLE
RESISTOR
DALE RH-25 25W

DALE RH-25 25W
ROTATE
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
BK-22D1
RD-134D2
RD CR22
WH-23D
WH-21D
BK/WH-34D
BK-33D
RD-20C
WH/RD-26
RD C32-7
RD CR17
BRN-GND
RD-20D
RD-24D
7.5 ohm 1%
BK/RD-35D
R2
5 ohm 1%
TURNTABLE
RESISTOR
ROTATE
WH
ENGINE
R4
CHECK
L2
1
RD
CONTROLS 15A
2
OPTIONS 15A
SWITCH
BREAKER
CIRCUIT
BREAKER
B1
KEY
KS1
CIRCUIT
B
CB3
CB2
RD
-
3
4
WH
RD/WH
RD-20C
WH-23
RD-20C
RD
D2
RD/WH RD/WH
RD
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
RD
RESISTOR
UP/DOWN

RESISTOR
BOOM

R14
ENGINE
ENGINE 15A
R16
START
TS52
BREAKER
CIRCUIT
CR4 HIGH IDLE RELAY
CB1
BK/WH-34D
RD-24D
BRN CR5 HORN RELAY
BRN

WH-21D
RD
HM HOUR METER
KS1 KEY SWITCH 7
After serial L2 CHECK ENGINE LED
RD
number 16733 L46 LOWER/RETRACT BOOM LED

HOUR METER

STOP SWITCH
EMERGENCY
RD
1 1
D13
GLOW
PLUG
TS56
P1
NC NC
D14
FUNCTION
2 2
ENABLE
TS54
RD
RD TS54
TS56
GLOW PLUG TOGGLE SWITCH
8
RD TS58 JIB BOOM TOGGLE SWITCH

6 - 87 6 - 88

Deutz F3L-2011/Deutz D2011L03i Models (before serial number 16734)
6 - 89 6 - 90
REV A

N
CWLITE WH TS49
(TO SWITCH
PLATFORM

CONTROL
HARNESS

PANEL)

DESCRIPTION
TILT ALARM
C19JSV GR/WH TS7 WH

Y
C19JSV GR/WH C4P-7

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

C32BRK WH/RD J2-19
OPTION
LS18
(CE)
BRN
K
CR30
BK C1P-12
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
TS1 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
J
JIB
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
C59CNK BL/BK C3P-11
P26BAT BK C9-1 P2
I
P25FS RD C9-3 TS2

P24FS WH C9-2 TS4
CDLITE OR/RD C2P-4
FOOT SWITCH
C4P
C7P
C3P
F.S.
C45GEN GR/WH C2P-7

C46HRN GR C2P-5
C9
H
P26ESTP BK
WH/RD C1P-6
11
3
C118LSR OR/RD C4P-4
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
G
C8PBR BK/WH C3P-8

C16DRE BL/RD C4P-1
C7PBE BK C3P-7
C7P
C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C7P
C31REV WH/BK C1P-5

C2PBD RD/BK C3P-2
F
January 2010
Part No. 139188

C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C4P
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
C3P
C3P(GR)
E
C35RPM BK/RD C1P-9

C34SA BK/WH C1P-8
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)

J1
C1P
9
P162JPW OR
D
C165TRS WH/RD
GND BRN
P162JPW OR
C163PLS BL/WH
C7P
GND BRN
C160JPL WH/RD * NOTE:
P162JPW OR
C159STC BL/WH*
GND BRN
C

C143DEL BL/BK
C13DE BL/RD
C28TTA RD/BK C1P-2

C29MS 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
C134PWR RD C2P-6
+
CWLITE BK
BRN
BRN
BRN BRN
A
CWLITE WH TS49
6 - 90
1
8
REV A Platform Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX,
PLATFORM CONTROL
1
JC2 JC3
DRIVE
DRIVE LIGHTS/
WORK LIGHTS
DLITE RD RD
(OPTION) 2
TS15
DRIVE +
ENABLE
JC1 L48
TILT ALARM LED
EXTEND/RETRACT
6 1 6 1 6 1
BK
BK
RD
5 2 5 2 5 2 3
4 3 4 3 4 3

L4
PLATFORM
BRN OVERLOAD
L1 (CE OPTION)
DRIVE
ENABLE
BRN LED +
BRN
+
L47
RETRACT CR13 +
BOOM JIB BOOM 4
RD
LED CUTOUT
BK
BRN
BK
(WORK LIGHT ONLY)
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-

C164PES RD/WH
C165TRS WH/RD
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
BK
P162JPW OR
P162JPW OR
P162JPW OR
BL-DE1 J1-6
WLITE WH
WLITE WH
GND BRN
GND-BR
GND BR
WH-JIB
BRN
RD
BK
PDLITE RD
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
P24FS WH
C19JSV GR/WH
WH-JIB
C46HRN GR C2P-5
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
C129JDA BL C3P-10
C27AUX RD C1P-1
WH CR30
C29MS RD/WH J1-8
C34SA BK/WH C1P-8
P25FS RD C9-3
C33STR BK C1P-7
C35HS BK/RD C1P-9

P24FS WH C9-2
C45GEN GR/WH C2P-7

6
COMPONENT INDEX
CR13 JIB BOOM CUT OUT RELAY
RD RD
WH WH
BOOM EXTEND/RETRACT
RD
RD D12
GR 1 1 1 JC3 DRIVE/STEER PROPORTIONAL JOYSTICK
3
4 NO
NC NC NC
L1 DRIVE ENABLE LED 7
TS8 TS6 TS4 2 22
TS14 L48 BOOM TILTED LED
P3 WH JIB GLOW PLUG ENGINE HIGH/LOW
TS1 HIGH/LOW TS47
HORN TS9 BOOM START RPM P2 EMERGENCY STOP BUTTON
GR/BK AUXILIARY (2WD/4WD) GENERATOR
RD
PLATFORM P2 P3 HORN SWITCH

TS7 PUMP (OPTION)
LEVEL EMERGENCY
PLATFORM D27 TS1 AUXILIARY POWER TOGGLE SWITCH
WH-24 STOP
ROTATE TS2 ENGINE START TOGGLE SWITCH
RD RD RD RD
TS7 PLATFORM ROTATE TOGGLE SWITCH 8
TS8 JIB BOOM UP/DOWN TOGGLE SWITCH
TS48 DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)

6 - 91 6 - 92

Deutz F3L-2011/Deutz D2011L03i Models (after serial number 16733)
6 - 93 6 - 94
REV A
(TO SWITCH
PLATFORM
CONTROL
HARNESS

N

PANEL)
WH
Y
B

C19JSV GR/WH TS7

Y
C19JSV GR/WH C4P-7

BK
DESCRIPTION
BRN JC3 BR
Y
JIB DELAY RELAY

Y
BRN GND
RD-E-STOP RD C134PWR RD LS18
B
Y
Y
Y
C134PWR RD-H1+
M
CWLITE WH TS49
GR/WH
BR
ITEM
CR13#86 GR/WH
CR14
CR27
CR30
J1
J2
J3
OPT.
C1
R
RD OUTPUT
TS7 WH
GR/WH +
CR14
R
C134PWR RD
GR/WH
BRN -
L
RD LS18 CABLE
JIB

CR27
BRN
GR/WH RD
R
B

C32BRK WH/RD C1P-6

TIME DELAY CAPACITOR
C32BRK WH/RD J2-19

DESCRIPTION
OPTION
LS18
(CE)
BRN
TILT ALARM
K
CR30
BK C1P-12
C40LS OR C2P-2
C1P-C4P
ITEM
C40LS OR J2-4
LS18
C7P
U13
H1
C1
C9
TS1 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
J
JIB
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
C46HRN GR C2P-5
P26BAT BK C9-1 P2
I
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

C46HRN GR C2P-5
F.S.
C9
H
P26ESTP BK
11
3
C118LSR OR/RD C4P-4
12V DC BATTERY
C6TRF WH/RD C3P-6
J3
G
C7PBE BK C3P-7
C13DE BL/RD C4P-1
C8PBR BK/WH C3P-8
C7P
C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C31REV WH/BK C1P-5
C7P
C2PBD RD/BK C3P-2

F
January 2010
Part No. 139188

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
C3P
C3P(GR)
E
C35RPM BK/RD C1P-9

C34SA BK/WH C1P-8
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)

J1
P162JPW OR
C1P
D
C165TRS WH/RD
GND BRN
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS BL/WH
C7P
GND BRN
C160JPL WH/RD
P162JPW OR
C159STC BL/WH
GND BRN
C

C143DEL BL/BK
C28TTA RD/BK C1P-2

C13DE BL/RD
C29MS RD/WH
BATGRN C7P-3
B
GR/BK-L4- (CE)
D39
ALARM
TILT
H1
C134PWR RD C2P-6
+
CWLITE BK
BRN
BRN
BRN BRN
A
CWLITE WH TS49
6 - 94
1
8
REV A Platform Control Box Switch Panel Wiring Diagram, S-65 and S-65 TRAX,
PLATFORM CONTROL 1
JC2 JC3
DRIVE
DRIVE LIGHTS/
WORK LIGHTS
DLITE RD RD
(OPTION)
2
TS15
+
DRIVE
ENABLE
JC1 L48
TILT ALARM LED
EXTEND/RETRACT
6 1 6 1 6 1
BK
BK
RD
5 2 5
5 2 2
3
4 3 4 3 4 3

L4
PLATFORM
BRN OVERLOAD
L1 (CE OPTION)
DRIVE
+ ENABLE
BRN +
LED
BRN
L47
RETRACT CR13
BOOM JIB BOOM + 4
RD
LED CUTOUT
BK
BRN
BK
(WORK LIGHT ONLY)
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-

C164PES RD/WH
C165TRS WH/RD
BL/RD-DE3 J1-16
C159STC BL/WH
C160JPL WH/RD
C163PLS BL/WH
BL/BK-DE2 J1-7
BK
P162JPW OR
P162JPW OR
CR14-#86 RD
P162JPW OR
BL-DE1 J1-6
5
WLITE WH
WLITE WH
GND BRN
GND-BR
GND BR
WH-JIB
BRN
RD
BK
PDLITE RD
BK TS15
C134PWR RD L4+
C134PWR RD L48+
RD-H1+
P26BAT BK C9-1
P23BAT WH C7P-2
P26BAT BK J3-3
P22BAT BK C7P-1
P24FS WH
WH-JIB
C46HRN GR C2P-5
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
C129JDA BL C3P-10
C27AUX RD C1P-1
WH CR30
C29MS RD/WH J1-8
C34SA BK/WH C1P-8
P25FS RD C9-3
C33STR BK C1P-7
C35HS BK/RD C1P-9

P24FS WH C9-2
C45GEN GR/WH C2P-7

6
COMPONENT INDEX
CR13 JIB BOOM CUT OUT RELAY
RD RD
WH WH
BOOM EXTEND/RETRACT
RD
RD D12
GR 1 1 1 JC3 DRIVE/STEER PROPORTIONAL JOYSTICK
4 3
NO
NC NC NC
L1
L4
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
7
TS8 TS6 TS4 2 22
TS14 L48 BOOM TILTED LED
P3 WH JIB GLOW PLUG ENGINE HIGH/LOW
TS1 HIGH/LOW TS47
HORN TS9 BOOM START RPM P2 EMERGENCY STOP BUTTON
GR/BK AUXILIARY (2WD/4WD) GENERATOR
RD
PLATFORM P2 P3 HORN SWITCH

TS7 PUMP (OPTION)
LEVEL EMERGENCY
PLATFORM D27 TS1 AUXILIARY POWER TOGGLE SWITCH
WH-24 STOP
ROTATE TS2 ENGINE START TOGGLE SWITCH
RD RD RD RD
TS7
TS8
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
8
CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30 TS9 PLATFORM LEVEL TOGGLE SWITCH
NOTE: DASHED LINES INDICATE OPTION WIRES TS48 DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)

6 - 95 6 - 96

Perkins 404-22 Models
6 - 97 6 - 98
REV B
Circuit breaker
BRN
RD
RD
P24FS WH
C28TTA RD/BK
serial number
C41RPM OR/BK
P134 RD
P26ESTP BK
P22LS BK
added after
CR4
N
TB35
ES0194H
19405
D12

HIGH IDLE RELAY
FOOTSW. HIGH
CB7
10A
FOOTSW. LOW
TS4
BK/RD C5-18
D13
HIGH RPM SOLENOID

ENGINE
D4
D3
TS54
SPEED
CR4
NO
Q3
LOW RPM
D14

FUNCTION
G2

ENABLE
M
G1
VOLT METER (OPTION)

G3

TB45
GENERATOR
TS47
GENERATOR OPTION
L
TS48

L29
DRIVE LIGHT
RD
CR23
DRIVE LIGHT OPTION

FUSE
L29
10A
L30
WORK LIGHT
RD
TS49
WORK LIGHTS OPTION

TB21
C2P-12 C2P-10
NO
WH
FUSE 10A
PBOX GND
C2P-11 C2P-9
K
F18
L30
TB34
TS6

GLOW
TS56
PLUG
NO
GLOW
GLOW PLUGS
J
PLUG
FUSE
70A
number 16733
COOLANT TEMPERATURE LED

U32
After serial
ENGINE
FAULT
L2
MODULE
START
U1
I
SW3
2 TACHOMETER
NO
1 START RELAY
9 IGN./FUEL ON
TB26
8 KEY BYPASS
10 ENG. FAULT
TS2
7 KEY PWR.
C1B-7
6 BATTERY
C33STR BK
5 GROUND
C1P-7 C5-14 C26TS WH/RD

4 AUX. ON
COOLANT TEMPERATURE SWITCH

ENGINE
TS52
D33
TB25
START
START BK
SW2
TB33
NC
H
POWER RELAY
TB21
CR2
P24FS WH
P25FS RD
C21IGN2 WH C5-11
FUEL SOLENOID
TS1
NO
AUX
C21IGN WH
C9P-3
HM
C9P-2
HOUR METER
G
_
IGN./START RELAY
CR1
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
M3
PR2
NO
NO
STARTER
STARTER MOTOR
FS1
AUXILIARY
POWER
BK-(FS)
TS51
CR19
F
January 2010
Part No. 139188

TB27
PUMP RD C27AUX RD
C9P-1 BK

C7B-2 F.H. C27AUX RD
C7P-2 P23BAT WH AUXILIARY POWER RELAY
TB23
PR1
NO
P2
D2
L48
PUMP
AUX
AUXILIARY PUMP
RD/BK C1P-2 WH
M2
number 16733
TB28
D40
RD/BK
E
C1B-2
C
After serial

H1
TILT ALARM
LEVEL SENSOR
C3B-12
B
RD
S8
TB46
C2B-5
P3

GR/BK
CR5
H2
NO
TB133
P22BAT BK F.H. BK
D
HORN
TB132
8
C1P-12 C132PLI BL/WH C1B-12 5
TB134
FB1
3
C32
OPTION
1
12
4
6
TB134
RD
CR17
SW4
NO
BK
C
C21IGN WH R21IGN WH C5-4 HYDRAULIC OIL TEMPERATURE
86
85
TB22
SWITCH (OPTION)
WH
RD
87a 87
P116HYD RD
30
C41RPM OR/BK
PLAT
COOLING FAN
GRD
R116 OR C5-1
FAN
KS1
(OPTION)
C5-3
M1
TB41
W
B
D22
RD
EXCT.
C21IGN WH
STA.
BAT.
IND.
P1
RD
RD
-
ALTERNATOR
REGULATOR
RD
CB1
CB3
15A
15A
BAT.
+
15AMP.
CB2
TB20
A
-
RD C7B-4 P20BAT RD
12V DC
B1
6 - 98
1
8
1
8
6 - 99
C7P-3 BATGND C7B-3

GROUND
A

5
U4
TB30

4
15 DRIVE FORWARD
15
1
16 DRIVE REVERSE
TS14
TB31
LOW DRIVE
(HIGH TORQUE)
H4

8
DRIVE
MODE
(OPTION)
HIGH DRIVE
(LOW TORQUE)
B
C26-1 C26-2
TB32

19 BRAKE RELEASE
C28-1 C28-2
TB29

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

C
7 18 STEER RIGHT
LEFT
DRIVE ENABLE
6 17 STEER LEFT
NOTES:
CDE1 BL/WH
C41RPM OR/BK
C24-1 C24-2
C28TTA RD/BK
TB36
P26ESTP BK
P24FS WH

11
5
J1
13 10
ROCKER OPTION
TB4
C159STC BL/WH
C160JPL WH/RD
C14-1 C14-2
P162JPW OR
D

14
C15-1 C15-2
TB5
D9
RIGHT
TURNTABLE ROTATE
BR
LEFT
STEER LEFT/RIGHT
1
6
R OUT 5
X OUT 3
PWR 2
Y OUT 4
TS62
7.5W
R4
CR19
GND
TB6
C31-1 C31-2
C6TRF WH/RD
JC3
TURNTABLE ROTATE
FLOW CONTROL
TB1
R2
5W
C12-1 C12-2
C1PBU RD
PRIMARY BOOM UP
UP
PRIMARY BOOM
E
2 DOWN C2PBD RD/BK

PRIMARY BOOM DOWN
Part No. 139188
TS61
1 C13-1 C13-2
CR34
J2
R14
5W
January 2010
11
TB3
C164PES RD/WH
C165TRS WH/RD
R16
10W
C3PBF RD/WH
P162JPW OR

12
C29-1 C29-2
J1
6
BR
TURNTABLE ROTATE
TB2
BOOM UP/DOWN &

GND 1
6
X OUT 3
PWR 2
Y OUT 4
7
JC2

8
F
TB9
3 C30-1 C30-2
14
9 FLOW CONTROL
C163PLS BL/WH

13
P162JPW OR
10
12
NC
TB7
BR
21
22
EXTEND/RETRACT
RD RD BR C7PBE BK
G
BOOM EXTEND
PRIMARY BOOM
GND 1
6
PWR 2
Y OUT 4
EXTEND
BOOM C37-1 C37-2 C16-1 C16-2
J1
LS5
RETRACT
JC1
TS63
C8PBR BK/WH
BOOM RETRACT
TB8
C17-1 C17-2
BRN
NO
1
HC

1
13
14
2
TB118
LS17
BK
TB13
P24FS WH
H
NO
J3
HC
4
3
P26ESTP BK
13
14
TB22
LS3
C2P-2
NO
4
HC

DRIVE LIMIT SWITCH
13
14
LS1
NO
HC

DRIVE LIMIT SWITCH
13
14
LS2
I
BK
TB40
OPTION
CR30
CR27
DRIVE
NO
NC
LIFT/
CE
P22LS BK
L46
NO
J
L47
TB59
13
14
CR34
LS5
TB134
NC
HO
21
22
LS17
TS9
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
ROTATE C17JU/PRL GR
L
LEFT
C22-1 C22-2
TB17
D29
C129 RD/BK
DESCENT ALARM
H3
M
C41RPM OR/BK
C28TTA RD/BK
P26ESTP BK
P24FS WH
P22LS BK
REV B
P134 RD
N
BRN
RD
RD

6 - 99 6 - 100
Ground Control Box Terminal Strip Wiring Diagram

6 - 101 6 - 102
8
7
6
5
4
3
2
1
6 - 102
RD
CR1 CR2
POWER BRN CR23
START RELAY RELAY
(OPTION)
RD
BK-ISM1 A
BRN
number 19405
Circuit breaker
WH
BRN
added after serial

BRN
C32
8
7
5
6
1
4
3
12
WH-OPTIONS
WH-ISM9
CR4
C5-18 BK/RD
R43DLITE2 RD
R43DLITE1 RD
C21IGN WH C5-11
BAT
HIGH RPM
AUX
BK/RD-35C
C2B-4 OR/RD
RD-24B
SOLENOID RELAY
WH-21B
BRN
BK
BK C5-5
WH
RD H6
BRN
BK-22D2
RD-TS52
RD-TS51
BK/RD-CR4
BK C7B-1
GR/BK H6
B
BL/WH-132B
C5
10A
CB7
C5-18 C32 C32
F.H.
BRN
RD-27C
BK-46R
GR-46D
BK-22C1
CR19 CR34
WH/RD-6D
RD/WH-3D
CR5 WH C5-4
HORN SELECT SPEED
RELAY OR C5-1

Manual de Servicios S-60 139188 PDF

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Service Manual

Serial Number Range

Part No. 139188

Important Serial Number Information

Contact Us: Copyright © 1995 by Genie Industries

http://www.genieindustries.com 139188 Rev B January 2010

Printed on recycled paper

Serial Number Legend

Rated work load (including occupants): 500 lb / 227 kg

This page intentionally left blank.

Many of the hazards identified in the operator's

Do Not Perform Maintenance

Personal Safety Workplace Safety

Indicates a potentially hazardous Be sure to properly dispose of old oil or

Be sure to wear protective eye wear and

Be aware of potential crushing hazards

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Section 3 Rev Scheduled Maintenance Procedures, continued

Section 3 Rev Scheduled Maintenance Procedures, continued

Section 4 Rev Repair Procedures

Section 4 Rev Repair Procedures, continued

Section 5 Rev Fault Codes

Section 6 Rev Schematics

Section 6 Rev Schematics, continued

Section 6 Rev Schematics, continued

Section 6 Rev Schematics, continued

Section 6 Rev Schematics, continued

This page intentionally left blank.

Tensioning system Pressurized grease

Tire size Fluid capacities

Lug nut torque, dry 240 ft-lbs Hydraulic system 55 gallons

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

Performance Specifications Drive speed, maximum

Boom up 60 to 70 seconds S-60 TRAX and S-65 TRAX 40 ft / 12 sec

Platform rotate, 160° 8 to 12 seconds

Braking distance, maximum

High range on paved surface 3 to 6 ft

Continuous improvement of our products is a

Hydraulic Specifications Drive pump

Hydraulic Oil Specifications Type: bi-directional, variable

Cleanliness level, minimum 15/13 Drive pressure, maximum 3750 psi

Flow rate @ 2500 rpm 2 gpm

Note: Use Shell Tellus T46 hydraulic oil when oil

Function manifold Manifold Component

Jib boom / platform rotate 0.6 gpm SAE No. 4 10 ft-lbs / 13 Nm

Drive manifold SAE No. 10 41 ft-lbs / 55 Nm

Drive motors, 4WD models Valve coil resistance specifications

Medium pressure filter Beta 3 ≥ 200

Medium pressure filter 51 psi

Hydraulic return filter 10 micron with

Continuous improvement of our products is a

Ford DSG-423 EFI Engine Electronic fuel pump

Displacement 140.4 cu in Fuel pressure, static 64 psi

Number of cylinders 4 Fuel flow rate 0.43 gpm

Firing order 1-3-4-2 Ignition system

Type 12V DC, Group 31

Cold cranking ampere @ 0°F 1000A