Genie S-60 HC Service Manual Download Page 358

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December 2013

Section 6 • Schematics

6 - 150

S-60 • S-65 • S-60 TRAX • S-65 TRAX

Part No. 147753

S-60 HC • S-60X • S-60XC

Ground Control Box Terminal Strip Wiring Diagram
S-60/S-65/S60 TRAX/S65 TRAX

Perkins Engine Models (CE)

Perkins 404-22 Engine

PRIMAR

BOOM UP

PRIMAR

BOOM DOWN

PRIMAR

BOOM UP/DOWN FUNC CTRL

TURNT

ABLE ROT

ATE RIGHT

TURNT

ABLE ROT

ATE FUNC CONTROL

PRIMAR

BOOM EXTEND

PRIMAR

BOOM RETRACT

PRIMAR

BOOM EXT/RET

FUNC. CTRL

PLA

TFORM LEVEL

+12 VOL

TO PLA

TFORM (1)

IGNITION POWER (1)

JIB SELECT

VAL

VE (S-65 OPTION)

PLA

TFORM ROT

ATE RIGHT/JIB DOWN

PLA

TFORM ROT

ATE LEFT/JIB UP

PLA

TFORM LEVEL

DOWN

ENGINE

AUXILAR

PUMP

+12 VOL

TO PLA

TFORM (2)

HIGH FUNCTION SPEED

GLOW PLUG

JIB DOWN DESCENT

ALARM

TERMINAL

BASE (TB)

RELA

TACHOMETER

INPUT

AUX PWR UNIT

GROUND

TTER

TO KEY

SW (DIESEL

ONL

JUMP

TO 7 (GAS ONL

IGN OR FUEL

TEMP

OR PRESS F

AUL

12/24 V

olt IGNIT

ON/ST

MODULE P/N 56057

Genie Industries

TO REMOVE: PUSH GENTL

AND LIFT

(UNUSED)

BK-CR1

OR/BK-41C

BK-33C

RD-CR19

BRN

WH-23C

WH-U34-9

RD-24C

BK C5-5

GROUND BOL

ENGINE

HARNESS

BRAKE

TERNA

TOR PULS PICKUP

CR4

CR2

CR1

CR5

WH-21B (1)

BRN

KEYSWITCH POWER (2)

BK-22C1

CB7 BK/RD

BRN

BK/RD-35C

FUNCTION

HARNESS

CABLE #1

18/22

HARNESS TO

SWITCH PANEL

C8PBR BK/WH C3B-8

C7PBE BK-LS5 C6-7

C7PBE BK C3B-7

C9PER BK/RD C3B-9

C14PLU OR C4B-2

C15PLD OR/BK C4B-3

C17JU GR C4B-5

C18JD GR/BK C4B-6

C27AUX RD C1B-1

RD-TS51

WH-KS1-3

BK-KS1-1

WH-HM

GR/WH-TS57

GR/BK-TS57

GR-TS57

OR/BK-TS59

OR-TS59

BK/RD-TS63

BK/WH-TS63

BK-TS63

WH/RD-CR19

WH/BK-TS62

RD/WH-CR34

RD/BK-TS61

BK-TS52

BK/WH-TS56

CR45

C21IGN WH

OR/RD

C6TRF WH/RD C6-6

C5TRR WH/BK C6-5

C3PBF RD/WH C6-3

C2PBD RD/BK C6-2

C9PER BK/RD C6-9

C14PLU OR C6-14

C15PLD OR/BK C6-15

C17JU GR C6-17

C18JD GR/BK C6-18

BK-ISM3

C19JSV GR/WH C4B-7

OIL

PRESSURE SWITCH

OIL

TEMPERA

TURE SWITCH

WH/RD-L2-

WH-25D

C25PS WH/BK C5-16

C26TS WH/RD C5-14

C35RPM BK/RD C1B-9

C41RPM OR/BK C2B-3

C34SA

BK/WH C1B-8

WH-ISM10

C34SA

BK/WH C5-22

C41RPM OR/BK C5-2

RD/BK-ALARM C6-19

C8PBR BK/WH C6-8

BRN-<GND>

BRN C7B-3

GR C2B-5

P23BA

WH C7B-2

P22BA

BK C6-22

BK/RD-CR4

WH-ISM7

C32BRK WH/RD C5-23

C27AUX RD C6-27

C129JDA

C3B-10

C2PBD RD/BK C3B-2

C32BRK WH/RD C1B-6

BATTERY POWER

12V DC

RETRACT

BOOM LED

BL-TS58

134

LOAD WEIGHING LIM. SW

. +12V (1)

RD-H6+

C59CNK BL/BK C3B-1

C59CNK BL/BK C6-1

BL/BK-L46+

RD-CB1

RD-CB2

P20BA

+12 VOL

POWER (1)

BOOM ST

OWED

C40LS1 OR C2B-2

C40LS1 OR C6-40

C6TRF WH/RD C3B-6

C5TRR WH/BK C3B-5

C3PBF RD/WH C3B-3

C1PBU RD C3B-1

RD-TS61

CIRCUIT

BREAKER POWER

MOT

OR STROKE

C29MS RD/WH C1B-3

C29MS RD/WH C5-24

PROPEL

FOR

ARD

C30FWD WH C1B-4

C30FWD WH C5-21

PROPEL

REVERSE

C31REV WH/BK C1B-5

C31REV WH/BK C5-20

C21IGN2 WH C5-3

RD-CR19#86

WH/RD-C6-32

P134FB RD C6-23

C33STR BK C1B-7

C39LP

BL/RD C2B-1

U33

C32

BK-22D
BL/WH-C1B-12
BK C7B-1

RD-ISM6

TURNT

ABLE ROT

ATE LEFT

WH-TS62

C4TRL

WH C6-4

C4TRL

WH C3B-4

C1PBU RD C6-1

BRN

C21IGN WH CR2

BRN

P20BA

BRN

GR/BK H6

P134PWR RD-134-2D

RD H6

BRN

RD-TS51

C132PLI2 BL/WH C1B-12

134

LOAD WEIGHING LIM. SW

. +12V (2)

RD-KS

P134BA

RD C6-24

P134BA

BK C6-25

BRN

BRN-GND

OR C38-2

GR/BK-L45

OR/BK-ISM2

C21IGN WH C5-11

BK C6-10

RD-CR2

RD-24B

BK-CR5

BK C32-4

RD-TS52

RD/BK-ALARM

P134PWR RD C2B-6

D30

D52

D29

4
3
5

6
7

CR17

OR C5-1

C21IGN WH

WH C5-4

RD-CB3

RD-27C

RD-CB1

BK-ISM1

WH U34-8

BRN

RD CB3-2

WH/RD-6D

RD/WH-3D

RD-ISM4

BRN

WH/RD-R2

WH/RD-R4

RD/WH-R16

RD/WH-TS61

RD/WH-R16

WH/RD-R4

WH/RD-R2

CR34

CR19

CB7

C5-18

BK/RD-CR4

AUX

BAT

BK/RD

U34

8
9

WH - ISM#9

BR - GND

GR/RD C4B-10

C6-19

WH U34-2

C1B

(GREY)

C2B

(BLACK)

C3B

(GREEN)

C4B

(BROWN)

C45GEN GR/WH C2B-7

GENERA

TOR OPTION

C45GEN GR/WH C5-12

C133PLA GR/BK C3B-12

C46HRN GR CR5#86

C46HRN GR C2B-5

POWER TO PLATFORM

12V DC

P20BA

WH - CR2

C6-13 C13DE BL/RD C4B-1

C6-34 SNSR BR C4B-4

C6-33 C123PBS RD/BK C4B-8

C6-20 P109ANG GR/WH C4B-9

C1B-10 C36SCC BL C6-36

C1B-11 C37SCW BL/BK C6-37

C1B-2 C28TTA RD/B C6-28

C2B-4 C42LS OR/RD C6-31

210

LOAD WEIGHING LIM. SW

. +12V (3)

134

KEYSWITCH POWER (1)

IGNITION POWER (2)

+12 VOL

POWER (2)

CABLE #2

18/19

C7P

BRN

ES0193U

RD - TB134-3D

P134TTS RD C6-26

NOTE: DASHED LINES INDICATE OPTIONS.

(UNUSED)

BRN

P134FB WH-C6-23

C5-7

WH TB21

OPT

GND BRN

P48PWR WH C45-87

C32

Summary of Contents for S-60 HC

Page 1: ......

Page 2: ...r 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 http www genielift com e...

Page 3: ...2011L04i 4 Repair 7 12 7 13 7 15 5 Faults UpdatedFaultCodes 6 Schem 6 1 Revised all schematics and grouped by Markets ANSI CSA CE AS Added Options Section C1 12 2012 2 Spec Machine Torque Spec 5 Faults SeparatedFordFaultCodes UpdatedFordDSG 423FaultCodes Updated Ford MSG 425 Fault Codes C2 1 2013 3 Maint 3 6 E 4 D 12 2013 4 Repair 7 4 7 5 6 Schem 6 25 6 29 REFERENCEEXAMPLES KubotaEngine_Section2_S...

Page 4: ... Procedure Schematic Page Description REFERENCEEXAMPLES KubotaEngine_Section2_Specifications A 6 B 3 C 7_Section3_MaintenanceProcedure 3 2 6 4 9 1_Section4_RepairProcedure Fault Codes_Section 5 6 35 6 56 6 104_Section 6_Schematic Page ElectronicVersion Click on any procedure or page number highlighted in blue to view the update ...

Page 5: ...chassis Air Tires 2 deg Foam Tires 4 5 deg Gradeability 45 Maximum allowable side force 150 lb 670 N Maximum number of platfrm occupants 2 Model year Manufacture date 04 12 05 2010 Maximum wind speed 28 mph 12 5 m s Maximum platform height 60 ft 2 in 18 3 m Maximum platform reach 50 ft 4 in 15 3 m Machine unladen weight 20 736lbs 9 406kg Foam Tires add 764 lbs 347 kg to weight Terex South Dakota 5...

Page 6: ... moderate injury Indicates a potentially hazardous 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 Safety Rules Section 1 Safe...

Page 7: ...ee of debris that could get into machine components and causedamage Be sure any forklift overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These comp...

Page 8: ...ecifications 2 1 PerformanceSpecifications 2 2 Hydraulic Specifications 2 3 ManifoldComponentSpecifications 2 4 Ford DSG 423 EFI Engine Specifications 2 5 Ford MSG 425 EFI Engine Specifications 2 6 Deutz D2011L03i Engine Specifications 2 7 Deutz TD2011L04i Engine Specifications 2 9 Perkins 404 22 Engine Specifications 2 11 Machine Torque Specifications 2 12 Trax Torque Specifications 2 13 Hydrauli...

Page 9: ...er 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...

Page 10: ... 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 Pack...

Page 11: ...nt Deutz and Perkins Models 3 50 C 7 Check the Safety Envelope Limit Switches and Angle Sensor S 60X and S 60XC 3 50 C 8 Perform Engine Maintenance Perkins Models 3 53 C 9 Perform Engine Maintenance Ford Models 3 53 ChecklistDProcedures D 1 Check the Boom Wear Pads 3 54 D 2 Check the Turntable Rotation Bearing Bolts 3 55 D 3 Inspect for Turntable Bearing Wear 3 56 D 4 Replace the Drive Hub Oil 3 5...

Page 12: ...2 2 4 Platform Load Sense System S 60 HC 4 14 Jib Boom Components S 65 and S 65 TRAX 3 1 Jib Boom 4 18 3 2 Jib Boom Lift Cylinder 4 19 BoomComponents 4 1 CableTrack 4 20 4 2 Boom 4 25 4 3 Boom Lift Cylinder 4 28 4 4 Boom Extension Cylinder 4 29 4 5 Boom Extend Retract Cables 4 32 4 6 Platform Leveling Master Cylinder 4 35 4 7 Primary Boom Angle Sensor S 60X and S 60XC 4 36 Engines 5 1 RPM Adjustme...

Page 13: ... 7 7 Oscillate Directional Valve Components 4 54 7 8 Valve Adjustments Oscillate Relief Valve 4 56 7 9 Drive Oil Diverter Manifold welder option 4 57 7 10 TractionManifoldComponents 2WD 4 58 7 11 Valve Adjustments 2WD Traction Manifold 4 59 7 12 Traction Manifold Components 4WD from SN 21001 to 21231 4 60 7 13 Traction Manifold Components 4WD after SN 21231 4 62 7 14 Valve Adjustments 4WD Traction...

Page 14: ...ineWireHarness 6 8 Ford MSG 425 Engine Wire Harness 6 9 Electrical Schematic Options All Models 6 12 WiringDiagram BeltDrivenGenerator 6 13 WiringDiagram 3kWHydraulicGenerator 6 16 Wiring Diagram 12kW Hydraulic Generator Welder Option 6 17 Electrical Schematic 12kW Hydraulic Generator Welder Option 6 20 Hydraulic Schematic 12kW Hydraulic Generator Welder Option 6 21 Hydraulic Schematic 2WD Models ...

Page 15: ... 6 48 Ground Control Box Terminal Strip Wiring Diagram S 65 S60 TRAX S65 TRAX Deutz Engine Models ANSI CSA 6 52 Ground Control Box Switch Panel Wiring Diagram S 65 S60 TRAX S65 TRAX Deutz Engine Models ANSI CSA 6 53 Platform Control Box Wiring Diagram S 65 S60 TRAX S65 TRAX Deutz Engine Models ANSI CSA 6 56 Platform Control Box Switch Panel Wiring Diagram S 65 S60 TRAX S65 TRAX Deutz Engine Models...

Page 16: ...S 60X and S 60XC DeutzTD2011L04iModels ANSI CSA 6 88 Ground Control Box Terminal Strip Wiring Diagram S 60X and S 60XC Deutz Engine Models ANSI CSA 6 92 Ground Control Box Switch Panel Wiring Diagram S 60X and S 60XC Deutz Engine Models ANSI CSA 6 93 Platform Control Box Wiring Diagram S 60X and S 60XC Deutz Engine Models ANSI CSA 6 96 Platform Control Box Switch Panel Wiring Diagram S 60X and S 6...

Page 17: ...ram S 60 S 65 Ford Engine Models CE 6 124 Platform Control Box Wiring Diagram S 60 S 65 Ford Engine Models CE 6 125 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 Ford Engine Models CE 6 128 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX DeutzD2011L03iModels CE 6 130 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX DeutzTD2011L04iModels CE 6 134 Ground Control Box Terminal Strip Wiri...

Page 18: ...60 HC CE 6 158 Chassis Wiring Diagram S 60 HC CE 6 159 Ground Control Box Terminal Strip Wiring Diagram S 60 HC CE from SN 21001 to 21287 6 162 Ground Control Box Terminal Strip Wiring Diagram S 60 HC CE after SN 21287 6 163 Platform Control Box Wiring Diagram S 60 HC CE 6 166 Electrical Schematics AS From SN 21001 to 21629 Electrical Schematic S 60 S 65 Ford Engine Models AS from SN 21001 to 2162...

Page 19: ...iring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models AS from SN 21001 to 21629 6 192 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models AS from SN 21001 to 21629 6 193 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS from SN 21001 to 21629 6 196 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 S60 TRAX S65 TR...

Page 20: ...Control Box Wiring Diagram S 60 S 65 Ford Engine Models AS after SN 21629 6 221 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 Ford Engine Models AS after SN 21629 6 224 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz D2011L03i Models AS after SN 21629 6 226 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz TD2011L04i Models AS after SN 21629 6 230 Ground Control Box Termin...

Page 21: ...am S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS after SN 21629 6 246 Ground Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS after SN 21629 6 247 Platform Control Box Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS after SN 21629 6 250 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine ...

Page 22: ...S 60 S 65 S 60 TRAX S 65 TRAX PartNo 147753 S 60 HC S 60X S 60XC December2013 This page intentionally left blank TABLE OF CONTENTS xxii ...

Page 23: ...low profile tires 4 92 bar Tire pressure 60 psi Hi flotation tires 4 13 bar Track Components S 60 TRAX and S 65 TRAX Track material Rubber Tensioning system Pressurized grease Weight each 1 500 lbs 680 kg Fluid capacities Fuel tank 35 gallons Deutz and Perkins Models 132 5 liters Ford models 30 gallons 113 5 liters LPG tank 33 5 pounds 15 2 kg Hydraulic tank 45 gallons 170 liters Hydraulic system ...

Page 24: ...te 360 125 to 165 seconds boom extended Platform rotate 160 8 to 12 seconds Braking distance maximum High range on paved surface 3 to 6 ft 0 9 to 1 8 m SPECIFICATIONS Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Drive speed maximum stowed position 2WD models 40 ft 6 2 sec 12 2 m 6 2 sec 4WD models 40 ft 7 2 sec 12 2 m 7 2 sec ...

Page 25: ...Shell Tellus S2 V 46 Chevron Aviation A ARNICA 32 Continued use of Chevron Aviation A hydraulic oil when ambient temperatures are consistently above 32 F 0 C may result in componentdamage Note Use Chevron Aviation A hydraulic oil when ambient temperatures consistently below 0 F 18 C Note Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Note Genie specificatio...

Page 26: ...per revolution 1 83 cu in low speed 30 cc Drive motors 2WD models Displacement per revolution 1 28 cu in high speed 20 9 cc Displacement per revolution 2 14 cu in low speed 35 cc Hydraulic filters High pressure filter Beta 3 200 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 micr...

Page 27: ...eme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Electronic fuel pump Fuel pressure static 64 psi 4 4 bar Fuel flow rate 0 43 gpm 1 6 L min Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Ignition system Spark plug type Motorcraft AGSF 32 FEC Spark plug g...

Page 28: ...ents Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Electronic fuel pump Fuel pressure static 60 psi 4 1 bar Fuel flow rate 0 43 gpm 1 6 L min Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Ignition system Spark plug type Motorcraft AYFS 32Y R Spar...

Page 29: ... to the Engine Operator Handbook on your machine Oil temperature switch Temperature switch point 220 F 104 C Oil pressure switch Oil pressure switch point 22 psi 1 5 bar Deutz D2011L03i Engine Displacement 142 cu in 2 33 liters Number of cylinders 3 Bore and stroke 3 7 x 4 4 inches 94 x 112 mm Horsepower 48 2800 rpm 36 kW 2800 rpm Firing order 1 2 3 Lowidle 1500 rpm 313 Hz Highidle 2500 rpm 521 7 ...

Page 30: ...fer 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 8 to 1 2 inch 9 to 12 mm SPECIF...

Page 31: ... 11 24 Nm Oil temperature switch point 275 F 135 C Oil pressure switch Installation torque 8 18 ft lbs 11 24 Nm Oil pressure switch point 22 psi 1 5 bar Deutz TD2011L04i Engine Displacement 220 9 cu in 3 62 liters Number of cylinders 4 Bore and stroke 3 78 x 4 92 inches 96 x 125 mm Horsepower Net intermittent 2400 rpm 74 55 kW Inductionsystem turbocharged Firingorder 1 3 4 2 Low idle 1500 rpm 450 ...

Page 32: ... For fuel requirements refer to the engine Operator s Manual on your machine Starter motor Current draw normal load 140 200A Cranking speed 250 350 rpm 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 Alternatoroutput 80A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm SPECIFICATIONS Continuous ...

Page 33: ...y 9 3 quarts including filter 8 8 liters Oil viscosity requirements Below 86 F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil pressure sending unit Oil pressure switch point 14 2 psi 1 bar Fuel inject...

Page 34: ...CIFICATIONS Machine Torque Specifications Platform rotator 1 8 center bolt GR 5 640 ft lbs 867 Nm 3 8 16 bolts GR 8 33 ft lbs 45 Nm use a removable thread locking compound 1 2 13 bolts GR 8 80 ft lbs 108 Nm Drive motor and hubs Drive hub mounting bolts lubricated 160 ft lbs 217 Nm Drive motor mounting bolts lubricated 55 ft lbs 75 Nm Turntable bearing Rotate bearing mounting bolts lubricated 180 f...

Page 35: ...ws 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 SPECIFICATIONS Contin...

Page 36: ... 20 2 6 9 16 18 1 1 4 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAEO ringBossPort tube fitting installed into Aluminum all types SAE Dash size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm SAEO ringBossPort tube fitting installed into...

Page 37: ...gs 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in lbs 3 4 Nm 2 Make a reference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 Figure 1 a hex nut b reference mark c body hex fitting 3 Working clockw...

Page 38: ...2 16 S 60 S 65 S 60 TRAX S 65 TRAX PartNo 147753 S 60 HC S 60X S 60XC Section 2 Specifications December2013 SPECIFICATIONS 10 9 12 9 8 8 4 6 ...

Page 39: ... the boom between thenon steerwheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheelschocked All external AC power supply disconnected from the machine About This Section This section contains detailed procedures for each scheduledmaintenanceinspection Each procedure includes a description safety information and step by step instructions...

Page 40: ...delivery Preparation Report to use for each inspection Store completed forms asrequired MaintenanceSchedule 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 Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the f...

Page 41: ... R repaired Comments Fundamentals It is the responsibility of the dealer to perform the Pre deliveryPreparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered conditio...

Page 42: ...3 4 S 60 S 65 S 60 TRAX S 65 TRAX PartNo 147753 S 60 HC S 60X S 60XC December2013 Section 3 Scheduled Maintenance Procedures This page intentionally left blank ...

Page 43: ...d Deutz models B 10 Ground control override B 11 Directional valve B 12 Platform leveling B 13 Engine idle select B 14 Fuel select Ford models B 15 Drive brakes B 16 Drive speed stowed position B 17 Drive speed raised position B 18 Alarm package B 19 Hydraulic oil analysis B 20 Fuel and hydraulic tank cap venting B 21 Fuel filter element Perkins models B 22 Inspect the Boom extend retract cables M...

Page 44: ...tion D 6 Hydraulic filters D 7 Engine maintenance Deutz models Checklist E Y N R E 1 Hydraulic oil Perform every 3000 hours E 2 Engine maintenance Deutz models Perform every 12 000 hours E 3 Engine maintenance Deutz models Perform every 10 years E 4 Replace the Boom Extend Retract cables Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the t...

Page 45: ... 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 goodcondition Result The operator s manual i...

Page 46: ...e Pre operation Inspection also serves to determine if routine maintenance proceduresarerequired Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before...

Page 47: ...Handbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 Perkins 400 Series Operation Manual Genie part number 94890 A 5 Check the High Pressure Hydraulic Filter Condition Indicator Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining the high pressure hydraulic filter in good condition is essent...

Page 48: ...he ground and the chassis should remain level at all times 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 7 Inspect the Track Components S...

Page 49: ... Turnable Rotation Bearing Bolts D 6 Replace the Hydraulic Filters A 9 Check the Track Tension and Fastener Torque S 60 TRAX and S 65 TRAX Manufacturer specifications require that this procedure be performed every 30 days Maintaining proper track tension and properly torqued fasteners is essential to good machine performance and service life The machine will not operate properly with a track that ...

Page 50: ...rk fitting until grease free from air comes out of the grease plug Securely tighten the grease plug Do not overtighten 9 Continue to pump grease into the grease zerk fitting just until the idler wheel moves Check the track tension 10 If necessary continue to pump grease into the cylinder until the track has proper tension Componentdamagehazard Do not over tighten the track Overtightening the track...

Page 51: ...d MSG 425 EFI Operator Handbook Genie part number 215322 Perkins 400 Series Operation Manual Genie part number 94890 A 11 Inspect the Fuel Filter Water Separator Diesel Models Genie specifications require that this procedure be performed every 100 hours or monthly whichever comes first Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform...

Page 52: ...on how to prime the fuel filter water separator 7 Clean up any fuel that may have spilled 8 Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks Explosion and fire hazard If a fuel leak is discovered keep any additionalpersonnelfromentering the area and do not operate the machine Repair the leak immediately DeutzModels 1 Put on protective clot...

Page 53: ...nelfromentering 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 CHECKLIST A PROCEDURES A 12 Check and Adjust the Engine RPM Perkins Models Engine specifications require that this procedure be performed every 100 hours Maintaining the engine rpm at the proper setting for both l...

Page 54: ...e lock nut and recheck the rpm Note Be sure the solenoid fully retracts when activating high idle CHECKLIST A PROCEDURES A 13 Grease the Turntable Rotation Bearing and Rotate Gear 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 rota...

Page 55: ...ction 2 Specifications 5 Install the plugs into the drive hub 6 Repeat this procedure for the other drive hub S 60 TRAX and S 65 TRAX 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 to access the remaining fasteners Do not remove the retaining fasteners 3 Chock the trac...

Page 56: ...e hub 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 CHECKLIST A P...

Page 57: ...ok EDI part number 1060020 OR the Ford MSG 425 EFI Operator Handbook EDIpartnumber1020010 FordDSG423EFIOperatorHandbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 A 16 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 200 hours Properenginemaintenance followingtheengine manufacturer s maintenance...

Page 58: ...l help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery hold downs and cable connections are tight Checklist B Procedures 4 Be sure that the battery separator wire connections are tight if equipped 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 specific gravity of each battery cell with a ...

Page 59: ...utralize any electrolyte that may have spilled B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operatin...

Page 60: ...ox 13 Swing the engine back to its original position and install the engine tray retaining fastener B 3 Check the Exhaust System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause ...

Page 61: ...nd cap and secure the end cap latches Note Be sure the discharge valve is pointing down when the cap is installed B 5 Check the Oil Cooler and Cooling Fins Deutz Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the oil cooler in good condition is essential for good engine performance Operating a machine with a damag...

Page 62: ...spect the Tires Wheels and Lug Nut Torque S 60 S 65 S 60 HC S60X and S 60XC Genie specifications require that this 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 ...

Page 63: ...l and Fastener Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage S 60 S 65 S 60 HC S 60X and S 60XC 1 Drive the machine to rotate the hub until the plugs are both horizontal a drive hub plugs 2 Rem...

Page 64: ...embly above the sprocket 7 Remove the remaining sprocket retaining fasteners from the hub adapter 8 Carefully remove the track assembly from the drive hub and set aside Crushing hazard The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 9 Locate the hub disconnect pin in the center of the drive hub Manually depress the p...

Page 65: ...asteners 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 Turntable rotate drive hub 1 Remove the plug located on the side of the hub and check the oil level Result The oil level should be even with ...

Page 66: ...azard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury 3 Connect a tachometer to the engine and then start the engine from the ground controls and check the rpm Refer to Section 2 Specifications Skip to step 5 if the low idle rpm is correct 4 Loosen the low idle lock nut then turn the low idle adjustment ...

Page 67: ... position 2 Start the engine from the ground controls 3 At the ground controls operate each boom function through a partial cycle Result All boom functions should operate B 11 Check the Oscillate Directional Valve Linkage Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Note Perform this test only on models equipped with a oscillating...

Page 68: ...ions require that this procedure be performed every 250 hours or quarterly whichever comes first A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are two settings Foot switch activated low idle turtle symbol allows the operator to control individual boom functions Foot switch activated high idle rabbit symbol should be used for...

Page 69: ...e to normaloperatingtemperature 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 ...

Page 70: ...e point on the machine 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 16 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper...

Page 71: ...high idle rabbit and foot switch symbol 4 Press down the foot switch and raise the primary boom above horizontal 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continu...

Page 72: ...hold for a moment and then release it Result The descent alarm should sound when the switch is held down 3 S 65 and S 65 TRAX Move the function enable rpm select toggle switch to either side and activate the jib boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the switch is held down 4 Turn the key switch to platform control R...

Page 73: ... E 1 Test or Replace the Hydraulic Oil B 20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Free breathing fuel and hydraulic tank caps are essential for good machine performance and service life A dirty or clogged tank cap may cause...

Page 74: ...cifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacing the diesel fuel filter element is essential for good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may required that the filter be replaced more often Explosio...

Page 75: ... meter on the oil filter housing CHECKLIST B PROCEDURES Bleed the fuel system 10 Loosen the vent plug on top of the fuel injection pump a vent plug b fuel injection pump c fuel lift pump 11 Operate the priming lever or priming bulb if equipped of the fuel lift pump until fuel free from air comes from the vent plug Tighten the vent plug 12 Clean up any fuel that may have spilled during thisprocedur...

Page 76: ...the boom end cover from the pivot end of the boom while guiding the small cable from the string potentiometer out of the slot of the cover Rest the cover and string potentiometeronthecounterweight Componentdamagehazard The cable from the string potentiometer can become damaged if it is kinked or pinched 4 Remove the retaining fasteners from the access covers located on the side of the boom at the ...

Page 77: ...end 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 ...

Page 78: ...tor Handbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 CHECKLIST B PROCEDURES B 25 Replace the Engine Air Filter Element Ford Models Engine specifications require that this procedure be performed every 400 hours Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure ca...

Page 79: ...enginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poorengineperformanceandcomponentdamage Requiredmaintenanceproceduresandadditional engine information are available in the Perkins 400 Series Operation Manual Perkins part number TPD 1443S Perkins 400 Series Oper...

Page 80: ... 2011 Series Operation Manual Genie part number 139320 Checklist C Procedures C 2 Grease the Platform Overload Mechanism if equipped S 60 S 65 S 60 TRAX and S 65 TRAX Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechani...

Page 81: ...ignal and interrupts power and an audio visual warning indication to alert the operator of the overload The platform support subassembly utilizes two load support arms that are opposed in a full parallelogram link This isolates platform loads into a shear or vertical state which translates into a compressive load A spring in the parallelogram link supports this purely compressive load regardless o...

Page 82: ...How to Calibrate the Platform Overload System if equipped S 60 S 65 S 60 TRAX and S 65 TRAX Illustration 1 6 Using a suitable lifting device place an additional 50 lbs 23 kg of weight onto the platform Result The alarm should sound The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound and the platform overload indicator l...

Page 83: ...vice lift the additional test weight from the platform Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound Note There may be an 2 second delay before the overload indicator lights and alarm turn off 14 Start the engine and test all machine functions from the ground controls Result All ground control functions should ...

Page 84: ...ly utilizes two load support arms that are opposed in a full parallelogram link This isolates platform loads into 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 As weight is added to the platform the spring will compress until when the platform is over...

Page 85: ...does not come on at both the ground and platform controls see Repair Procedure 2 4 How to Calibrate the Platform Load Sense System S 60 HC Note The weight in the platform must be 1200 lbs 544 3 kg or less before the engine can berestarted 6 Using a suitable lifting device remove the test weights from the platform 7 Push in the ground controls red Emergency Stop button to the off position then pull...

Page 86: ...ways have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Open the engine side turntable cover and locate the fuel filter water separator on the bulkhead 2 Disconnect and plug the fuel supply hose from the fuel tank to the fuel filter water separator 3 Loosen the vent plug located on the fuel filter waterseparatorhead CHECKLIST C PROCEDURES a vent ...

Page 87: ...y anchor hole to secure the engine tray from moving could result in death or serious injury 14 Loosen the vent plug on top of the fuel injection pump a vent plug b fuel injection pump c fuel lift pump CHECKLIST C PROCEDURES 15 Operate the priming lever or priming bulb if equipped of the fuel lift pump until fuel free from air comes from the vent plug Tighten the vent plug 16 Clean up any fuel that...

Page 88: ...loth 5 Install the new filter element 6 Install the air filter canister end cap and secure the end cap latches CHECKLIST C PROCEDURES C 7 Check the Safety Envelope Limit Switches and Angle Sensor S 60X and S 60XC Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Testing the safety envelope system regularly is essential to safe machine...

Page 89: ... does not stop after 10 degrees Check limit switches LST3O and LST3S 6 Turn the key switch to the off position and push in the red Emergency Stop button Note The following step can be done using a measuring tape or a digital protractor Genie part number58377 7 MeasuringTape Measure the distance between the center of the pivot pins as shown 171 inches 434 cm 2 0 inch 5 cm DigitalProtractor Place th...

Page 90: ... the unrestricted platform capacity light will flash Result The primary boom does not stop after 10 degrees Calibrate the boom angle sensor Refer to Repair Procedure 1 2 How to Calibrate the Boom angle Sensor 6 Move the primary boom down joystick off center and retract the primary boom until the unrestricted platform capacity light stops flashing Result Primary boom down should return to normalope...

Page 91: ... Manual Perkins part number TPD 1443S Perkins 400 Series Operation Manual Genie part number 94890 CHECKLIST C PROCEDURES C 9 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 800 hours Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform th...

Page 92: ...rt the engine from the ground controls 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 4 Extend and retract the primary boom through...

Page 93: ...d Keephands away from cylinders and all moving parts when lowering the boom Note The lift cylinder safety chock is available throughGenie Geniepartnumber75097 2 Turn the engine off 3 Be sure that each turntable mounting bolt is torqued in sequence to specifications Refer to Section 2 Specifications Bolt torque sequence 4 Start the engine form the ground controls 5 Raise the boom and remove the saf...

Page 94: ...2 Torque the turntable bearing bolts to specification See D 2 Check the Turntable Rotation Bearing Bolts 3 Start the machine from the ground controls and raise the boom to full height Do not extend the boom 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an ...

Page 95: ...ery 1000 hours or annually whichever comes first Replacing the drive hub oil is essential for good machine performance and service life Failure to 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 S 60 HC S 60X and S 60XC 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is a...

Page 96: ...sprocket 7 Remove the remaining sprocket retaining fasteners from the hub adapter 8 Carefully remove the track assembly from the drive hub and set aside Crushing hazard The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 9 Locate the hub disconnect pin in the center of the drive hub Manually depress the pin and rotate th...

Page 97: ...tions 20 Repeat this procedure for each drive hub CHECKLIST D PROCEDURES D 5 Check the Free wheel Configuration Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel ...

Page 98: ...rd Failure to re engage the drive hubs could result in death or serious injury and propertydamage Steer end 4WD Models 7 Chock the non steer wheels or tracks to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 lbs 10 000 kg under the drive chassis between the steer tires or tracks 9 Lift the wheels or tracks off the ground and then place jack stands under the drive...

Page 99: ...f 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 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 severeburns Note Perform this procedure with the engine o...

Page 100: ...ocate 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 th...

Page 101: ...renginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poorengineperformanceandcomponentdamage Requiredmaintenanceproceduresandadditional engine information are available in the Deutz 2011 Series Operation Manual Deutzpartnumber0312 3547 Deutz 2011 Series Operation ...

Page 102: ...ions E 1 Test or Replace the Hydraulic Oil Genie requires that this procedure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued us...

Page 103: ...g 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 18 Install the hydraulic return filter...

Page 104: ...nformation are available in the Deutz 2011 Series Operation Manual Deutzpartnumber0312 3547 Deutz 2011 Series Operation Manual Genie part number 139320 CHECKLIST E PROCEDURES E 3 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performedevery12 000hours Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good en...

Page 105: ...rs 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 RepairProcedure4 5 Boo...

Page 106: ...3 68 S 60 S 65 S 60 TRAX S 65 TRAX PartNo 147753 S 60 HC S 60X S 60XC December2013 Section 3 Scheduled Maintenance Procedures This page intentionally left blank ...

Page 107: ...the key removed Wheelschocked All external AC power disconnected from the machine 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 appropriaterepairprocedureaftertroubleshooting theproblem Perform disassembly procedures to the point where repairs can be completed To re assemble perform th...

Page 108: ...ver its entire range of motion a ALC 500 circuit board b drive steer joystick controller c primary boom up down extend retract and turntable rotate right left joystick controller 1 1 ALC 500 Circuit Board Electrocution burnhazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note When the ALC 500 circuit board is repla...

Page 109: ...stick 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...

Page 110: ... 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 9 Select a boom function joystick to set the threshold 10 Slowly move the joystick off center in either dir...

Page 111: ... the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle switch in the right direction 4 times Result There should be a pause and the alarm should sound 4 times indicating that the machine is in max out calibration mode 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...

Page 112: ...h maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Perform this procedure on a firm level surface 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start ...

Page 113: ...nimum of 50 and a maximum of 150 13 Repeat steps 9 through 11 for each joystick controlled machine function 14 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved Result The alarm should sound indicating that the settings have been saved in memory Result The alarm does not sound The minimum or maximum adjustment has been obtained No c...

Page 114: ...d 12 times indicating that the machine is in Angle Sensor calibration mode 6 Start the engine from the platform controls and press down the foot switch 7 Momentarily activate the drive enable toggle switch to the right 1 time to set the stowed position Note The alarm will not sound indicating the setting 8 Raise the primary boom to the fully elevated position Note Manually reduce the boom speed as...

Page 115: ...latform for support 3 Lower the boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 4 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Use a soft metal drift to drive the rod end pivot pin out Crushing hazard S 65 and S 65 TRAX The jib boom could fall when the slave cylinder rod...

Page 116: ...te S 60 HC If the load sense components are disassembled and or removed from the platform support the platform load sense system will need to be calibrated See 2 4 Platform Load Sense System S 60 HC 2 S 60 HC Tag and disconnect the electrical connector from the platform load sense module 3 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the rotato...

Page 117: ...orted 10 Lower the jib boom leveling arms Crushing hazard The platform rotatormaybecomeunbalanced and fall if not properly supported Note When installing the platform rotator fasteners torque the fasteners to specifications How to Bleed the Platform Rotator Note This procedure will require two people Do not start the engine Use auxiliary power for this procedure 1 Move the function enable toggle s...

Page 118: ...s PLATFORMCOMPONENTS 2 3 Platform Overload System S 60 S 65 S 60 TRAX and S 65 TRAX if equipped How to Calibrate the Platform Overload System Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromis...

Page 119: ...erload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator lights and alarm responds 7 Move the platform up and down by hand so it bounces appro...

Page 120: ...enormally PLATFORMCOMPONENTS 2 4 Platform Load Sense System S 60 HC How to Calibrate the Platform Load Sense System Proper calibration of the load sense system is essential to safe machine operation Continued use of an improperly calibrated load sense system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note For...

Page 121: ...ch 3 times within 2 seconds after the alarm sounds to enter calibration mode Result The alarm should sound for 1 second indicating the first calibration step was accepted The green LED on the operational controller should be blinking fast and the red LED should be blinking twice indicating that step 2 of calibration is next Result The alarm did not sound and the green LED on the operational contro...

Page 122: ...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 the pivot pins while the boom is moving 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 calibrat...

Page 123: ... of calibration is next 16 Using a suitable lifting device place an additional test weight equal to 510 lbs 231 3 kg on to the center of the platform floor The total weight in the platform must equal 1260 lbs 571 5 kg PLATFORMCOMPONENTS 17 Activate and release the calibration toggle switch inside the ground control box 1 time Result The alarm should sound for 1 second indicating the sixth calibrat...

Page 124: ...ic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Attach a lifting strap from an overhead crane to the jib boom assembly 7 Place blocks under the platform leveling cylinder for support Protect the cylinder ro...

Page 125: ...tions very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the op...

Page 126: ...ox 4 Remove the electrical outlet box bracket mounting fasteners Remove the outlet box and lay it to the side Boom Components 5 Remove the hose and cable clamp from the platformsupport 6 Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and bur...

Page 127: ...m Note Always replace the cotter pin with a new one 17 Remove the cable track pull tube guide fasteners from the cable track guide at the platform end of the boom Remove the cable track guide from the boom 18 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom 19 Carefully remove the cable track from the machine and place it on a structure capable of sup...

Page 128: ...jury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Remove the hose and cable cover from the side of the jib boom 10 Locate all electrical cables under the boom at the pivot end that enter the cable track 11 Tag and disconnect the electrical connectors for all ...

Page 129: ...ted Note A cable track repair kit is available through the Genie Industries Service Parts Department part no 77896 The kit includes a 4 link section of cable track 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Carefully remove the snap rings from each end of the damaged section of cable track 3 Remove the retaining fasteners from the upper black rolle...

Page 130: ...in 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 m short link arm weldment BOOMCOMPONENTS ...

Page 131: ...ignificant componentdamage Dealer service is strongly recommended 1 Remove the jib boom See 3 1 How to Remove the Jib Boom 2 Remove the cable track See 4 1 How to Remove the Cable Track Note S 60X and S 60XC Disconnect the two limit switch connectors at the platform end of the cable track 3 Raise the boom until the short and long link arm to boom pivot pins are above the turntable covers 4 Place a...

Page 132: ...in Crushing hazard The boom could fall if not properly supported when the lift cylinder rod end pivot pin is removed 14 Using auxiliary power activate the boom down function so the cylinder will retract Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom Turn the machine off Crushing hazard The boom lift cylinder could fall if not properly...

Page 133: ...gh the pin and twist to remove Carefully lower the master cylinderdown 24 Tag disconnect and plug the hydraulic hoses from the bulkhead fittings at the pivot end of the boom Cap the bulkhead fittings Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 25...

Page 134: ... 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 BOOMCOMPONENTS 5 Using auxiliary power activate the boom down function so the cylinder will retract Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boo...

Page 135: ...fer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the boom fully retracted 1 Raise the boom to a horizontal position 2 S 60 S 60X S 60XC S 65 S 60 TRAX and S 65 TRAX Remove the boom end cover retaining fasteners and remove the cover S 60 HC Remove the boom end cover from the pivot end of the boom while guiding the small cable from the string potenti...

Page 136: ... way 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 12 Disconnect the wire connector to the extend cable break limit switch 13 Remove the retaining fasteners that secure the extend cable mounting plates to the inside of the number 1 boom tube a extend ca...

Page 137: ...t metal drift to remove the pin 22 Tag disconnect and plug the boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 23 Attach a lifting strap from a 5 ton 5000 kg overhead crane to t...

Page 138: ...eaded ends of the boom extend cables The threads must be clean and in good condition with no damaged threads 4 Adjust the extend cable adjustment nuts until approximately 1 5 inches 4 cm of threads are visible past the nylock nut Note If the cables have been replaced be sure the adjustment nuts have been replaced Do not re use the existing nuts 5 Extend the boom until there is approximately 3 feet...

Page 139: ...2 Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boomtube 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 s...

Page 140: ...nie part no 94510 15 At the platform end of the boom pull on the 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 17 Securely attach the rope to the same end of the new boom retract cable 18 At the pivot end of the boom carefully pull the rope with the new retract cable attached 19 Pull the ...

Page 141: ...ise 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 Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Place a 2 x 4 x 48 inches 5 x 10 x 1...

Page 142: ...d disconnect the angle sensor harness connector 6 Remove the angle sensor retaining fasteners and set aside Remove the angle sensor BOOMCOMPONENTS a button cable ties b start orientation c finish orientation d gusset plate 8 Install the angle sensor retaining fastners Do not tighten at this time 9 Route the angle sensor harness through the gusset plate and secure using two button cable ties 10 Sec...

Page 143: ...he flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel 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 onto the flywheel of the engine and a separate coupler installed onto the pump splined shaft Type B flex plates comb...

Page 144: ...the engine with an overhead crane or other suitable lifting device Do not lift it 6 Remove the engine mounting plate to bell housingfasteners 7 Raise the engine slightly using the overhead crane and place a block of wood under the oil pan for support 8 Support the drive pump assembly with an overhead crane or other suitable lifting device Do not apply any lifting pressure 9 Remove all of the engin...

Page 145: ... 40 ft lbs 54 Nm Perkins models Torque the flex plate mounting bolts in sequence to 49 ft lbs 66 Nm Then torque the flex plate mounting bolts in sequence to 70 ft lbs 95 Nm Ford and Deutz models Perkins models 3 Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriategapbetweencouplerandpumpend plate for your engine a pump b pump shaft c pump coupler d ...

Page 146: ...orque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Then torque the flex plate mounting bolts in sequence to 40 ft lbs 54 Nm Ford and Perkins 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 4 Apply a high viscosity coupling grease Genie part number 128025 to the splines of the pump sh...

Page 147: ...n sequence to 40 ft lbs 54 Nm and the mounting bolts labeled C to 70 ft lbs 95 Nm Perkins models Torque the bell housing mounting bolts labeled B in sequence to 28 ft lbs 38 Nm and the mounting bolts labeled A to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled B in sequence to 40 ft lbs 54 Nm and the mounting bolts labeled A to 70 ft lbs 95 Nm Componentdamagehazard Type A flexp...

Page 148: ...d 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 L...

Page 149: ... the valves Componentdamagehazard The 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 2 Tag disconnect and plug the function pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying ...

Page 150: ...he fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connection at the electro proportionalcontrollerlocatedonthe drive pump 2 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close...

Page 151: ...ine turntable pivot plate at the counterweight end of the machine 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine HYDRAULICPUMPS 4 Ford models Close the valve on the LPG tank then disconnect the hose from the tank Move the fuel select switch to the LPG position Perkins models Disconnect the engine wiring harness from the fuel solenoid at the injec...

Page 152: ... 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 ...

Page 153: ... 65 TRAX 4 47 S 60 HC S 60X S 60XC December2013 Section 4 Repair Procedures MANIFOLDS H G M C D T I J N F E O R AA S P Y V U L EE Z Q X W CC DD K A B BB 21 22 20 19 5 4 3 1 2 6 7 8 23 24 25 26 27 28 29 30 31 18 17 16 14 15 11 12 13 10 9 ...

Page 154: ...ing 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 ...

Page 155: ...tion 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 counte...

Page 156: ... 60X S 60XC December2013 Section 4 Repair Procedures 7 3 Jib Boom Platform Rotate Manifold Components Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way FF Platform rotate jib boom select 20 25 ft lbs 27 34 Nm MANIFOLDS FF 1 ...

Page 157: ...mounted near the turntable rotator Index Schematic No Description Item Function Torque 1 Orifice 0 025 inch 0 64 mm JJ Turntable rotation brake release 2 Solenoid valve 2 position 3 way KK Brake release 20 25 ft lbs 27 34 Nm 3 Solenoid valve 2 position 3 way LL Two speed motor shift 20 25 ft lbs 27 34 Nm 4 Check valve II Brake release circuit 20 25 ft lbs 27 34 Nm MANIFOLDS JJ KK LL II 1 4 2 3 ...

Page 158: ... mounted near the turntable rotator Index Schematic No Description Item Function Torque 1 Orifice 0 025 inch 0 64 mm JJ Turntable rotation brake release 2 Solenoid valve 2 position 3 way KK Brake release 20 25 ft lbs 27 34 Nm 3 Solenoid valve 2 position 3 way LL Two speed motor shift 20 25 ft lbs 27 34 Nm 4 Check valve II Brake release circuit 20 25 ft lbs 27 34 Nm KK LL II JJ 1 4 2 3 MANIFOLDS ...

Page 159: ...ntable rotation motor Index Schematic No Description Item Function Torque 1 Counterbalance valve MM Turntable rotate right 35 40 ft lbs 47 54 Nm 2 Counterbalance valve NN Turntable rotate left 35 40 ft lbs 47 54 Nm 3 Shuttle valve 2 position 3 way OO Turntable rotation brake release 10 13 ft lbs 14 18 Nm 4 Orifice 0 030 inch 0 76 mm PP Brake release circuit located inside port MANIFOLDS 1 2 4 3 MM...

Page 160: ...tional Valve Components The oscillate directional valve is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Cap Breather 20 25 ft lbs 27 33 Nm 2 Spool valve JJ Directional control 3 Relief valve 800 psi 55 bar LL Oscillate relief 30 35 ft lbs 41 47 Nm MANIFOLDS JJ LL 1 2 3 ...

Page 161: ...nd 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 MANIFOLDS 8 Verify that the ground and drive chassis are comple...

Page 162: ...gine 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 Section 2 Specifications 6 Turn the engine off 7 Locate the relief valve on the directional valve and loosen the jamb nut 8 Adjust the hex screw Turn it clockwise to increase the pressure or counterclockwise t...

Page 163: ... Description Item Function Torque 1 Directional valve CU Diverter valve 80 90 ft lbs 108 122 Nm 2 Orifice disc 0 030 inch 0 080 cm CV Delays shift to drive 3 Solenoid valve CW Pilot valve to diverter 35 40 ft lbs 47 54 Nm 4 Relief valve CX Charge pressure circuit 35 40 ft lbs 47 54 Nm 5 Pressure switch 200 psi 18 6 bar CZ Generator relay switch 16 ft lbs 22 Nm 6 Connector fitting 11 ft lbs 15 Nm 7...

Page 164: ... 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 f...

Page 165: ...essure gauge from the drive pump Connect the gauge to the test port located on the traction manifold 7 Start the engine from the platform controls 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 9 Adjust...

Page 166: ...der combiner valve 3 6 Orifice 0 040 inch 1 mm AE Equalizes pressure on both sides of flow divider combiner valve 11 7 Orifice 0 040 inch 1 mm WW Equalizes pressure on both sides of flow divider combiner valve 13 8 Check valve AG Steer end drive motor circuit 60 70 ft lbs 81 95 Nm 9 Check valve ZZ Steer end drive motor circuit 35 40 ft lbs 14 16 Nm 10 Shuttle valve 3 position 3 way VV Charge press...

Page 167: ...PartNo 147753 S 60 S 65 S 60 TRAX S 65 TRAX 4 61 S 60 HC S 60X S 60XC December2013 Section 4 Repair Procedures MANIFOLDS TT SS AB AF AC AE WW AG ZZ VV AD YY XX UU 5 6 7 9 10 8 12 13 14 1 2 11 3 4 ...

Page 168: ...h 1 mm WW Equalizes pressure on both sides of flow divider combiner valve 1 6 Orifice 0 040 inch 1 mm AE Equalizes pressure on both sides of flow divider combiner valve 13 7 Orifice 0 040 inch 1 mm AC Equalizes pressure on both sides of flow divider combiner valve 4 8 Check valve SS Non steer end drive motor circuit 35 40 ft lbs 14 16 Nm 9 Check valve AF Non steer end drive motor circuit 60 70 ft ...

Page 169: ...PartNo 147753 S 60 S 65 S 60 TRAX S 65 TRAX 4 63 S 60 HC S 60X S 60XC December2013 Section 4 Repair Procedures MANIFOLDS XX UU TT AB WW AE AC SS AF ZZ AG VV AD YY 5 3 14 1 13 12 11 10 6 7 9 8 4 2 ...

Page 170: ...ove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold 7 Start the engine from the platform controls 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 U...

Page 171: ...d Components 3kW after SN 21396 The generator manifold is mounted to the hydraulic generator located in the engine compartment Index Schematic No Description Item Function Torque 1 Proportional solenoid valve HH Generator speed 33 37 ft lbs 45 50 Nm 2 Relief valve 2700 psi 186 bar GG Generator circuit 20 25 ft lbs 27 34 Nm MANIFOLDS 2 1 HH GG ...

Page 172: ...ngs watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance 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 Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 ...

Page 173: ... 10Ω Ω Ω Ω Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals a multimeter b 9V DC battery c 10Ω resistor d coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the nega...

Page 174: ...if not properlysupported Turntable Rotation Components 8 1 Turntable Rotation Assembly How to Remove the Turntable Rotation Assembly Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perf...

Page 175: ... lock pin Note The turntable rotation lock pin is located next to the boom rest pad 2 Loosen the backlash pivot plate mounting fasteners a backlash pivot plate b adjustment bolt with lock nut c backlash pivot plate mounting bolts 3 Push the backlash pivot plate towards the turntable as far as possible this will push the rotation gear into the turntable bearing ring gear 4 Loosen the lock nut on th...

Page 176: ...ion Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable until the boom is between the steer tires or tracks 2 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissip...

Page 177: ...t of the track assembly above the sprocket 7 Remove the remaining sprocket retaining fasteners from the hub adapter 8 Carefully remove the track assembly from the drive hub and set aside Crushing hazard The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane How to Replace the Track 1 Remove the track assembly from the machi...

Page 178: ... wheels TRACKCOMPONENTS b a a a 9 Rotate the sprocket half until the split tooth of the sprocket is lower than the other side 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 rubbertrack Note Be sure ...

Page 179: ...ome unbalanced and fall when installed onto the machine if not properly supported by the overhead crane 17 Adjust the track tension Locate the grease plug on the track tension cylinder Loosen the plug but do not remove it 18 Locate the grease zerk fitting on the other side of the track tension cylinder a grease zerk b grease plug TRACKCOMPONENTS 19 Pump grease into the grease zerk fitting until gr...

Page 180: ...o tight loosen the grease plug on the cylinder to remove grease and loosen the track 22 Raise the machine remove the jack stands and lower the machine 23 Drive the machine in either direction just until the remaining sprocket retaining fasteners can be installed onto the drive hub adapter Turn the machine off 24 Install the remaining sprocket retaining fasteners to the drive hub adapter and torque...

Page 181: ...th or serious injury Remove all rings watches and other jewelry Note Two persons will be required to safely performsometroubleshootingprocedures Fault Codes Observe and Obey Troubleshootingandrepairproceduresshallbe completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damagedormalfunctioningmachine Repair any machine damage or malfunct...

Page 182: ...ircuit 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 3 Determine the error source The red LED indicates the error source and will flash two separate codes The first code will indicate the first digit of the two digit code flashin...

Page 183: ...after Directional Alarm sounds problemhasbeen Valves indicating a fault corrected 23 Primary 12 Value too high Valve is operating Cycle power off Up Down 15 Value too low outside of limits then on after Flow Valve Alarm sounds problemhasbeen indicating a fault corrected 17 Notcalibrated Normalfunction Calibratevalve exceptthreshold threshold for one or both directions is zero 24 Anglesensor 11 Val...

Page 184: ...ry 21 Fault Valve is operating Cycle power off Ext Ret outside of limits then on after Directional Alarm sounds problemhasbeen Valves indicating a fault corrected 33 Primary 12 Value too high Valve is operating Cycle power off Ext Ret 15 Value too low outside of limits then on after Flow Valve Alarm sounds problemhasbeen indicating a fault corrected 17 Notcalibrated Normalfunction Calibratevalve e...

Page 185: ... Fault Limiteddirection Cycle power off Rotate Frozen at zero then on after Directional andneutral problemhasbeen Valves Alarm sounds corrected indicating a fault 43 Turntable 12 Value too high Limitedspeed Cycle power off Rotate 15 Value too low anddirection then on after Flow Valve Frozen at zero problemhasbeen andneutral corrected Alarm sounds indicating a fault 17 Notcalibrated Normalfunction ...

Page 186: ... 51 Drive Joystick 11 Value at 5V Limitedspeed Cycle power off 12 Value too high anddirection then on after 15 Value too low Frozen at zero problemhasbeen 16 Value at 0V andneutral corrected Alarm sounds indicating a fault 17 Notcalibrated Calibrate joystick 53 DriveFlow 12 Value too high Limitedspeed Cycle power off Valve EDC 15 Value too low anddirection then on after Frozen at zero problemhasbe...

Page 187: ...ult Direction frozen at Power up controller with zero and neutral AB problemcorrected 57 Foot switch ECU 12 Value too high Direction frozen at Power up controller with PowerCrosscheck 15 Value too low zero and neutral AB problemcorrected 61 Steer Joystick 11 Value at 5V Limitedspeed Cycle power off 12 Value too high anddirection then on after 15 Value too low Frozen at zero problemhasbeen 16 Value...

Page 188: ...ink 4 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 1 2 3 three times After the fault codes the check engine light will blink a code 1 2 3 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a three digit code three t...

Page 189: ...21 TPS1 lower than TPS2 122 TPS1 low voltage 123 TPS1 high voltage 127 IAT higher than expected 2 129 BP low pressure 134 EGO open lazy pre cat 1 140 EGO open lazy post cat 1 154 EGO open lazy pre cat 2 post cat 1 160 EGO open lazy post cat 2 Code Description 171 AL high gasoline bank1 172 AL low gasoline bank1 174 AL high gasoline bank2 175 AL low gasoline bank2 182 FT Gasoline Low Voltage 183 FT...

Page 190: ... damaging misfire 302 Emissions catalyst damaging misfire 303 Emissions catalyst damaging misfire Code Description 304 Emissions catalyst damaging misfire 305 Emissions catalyst damaging misfire 306 Emissions catalyst damaging misfire 307 Emissions catalyst damaging misfire 308 Emissions catalyst damaging misfire 326 Knock 1 Excessive Signal 327 Knock 1 sensor Open 331 Knock 2 Excessive Signal 332...

Page 191: ...S 1151 CL high LPG 1152 CL low LPG 1153 CL high NG Code Description 1154 CL low NG 1155 CL high gasoline bank1 1156 CL low gasoline bank1 1157 CL high gasoline bank2 1158 CL low gasoline bank2 1161 AL high LPG 1162 AL low LPG 1163 AL high NG 1164 AL low NG 1165 LPG cat monitor 1166 NG cat monitor 1171 Megajectordeliverypressure higherthanexpected 1172 Megajectordeliverypressure lower than expected...

Page 192: ...cted 2 1531 IVS Brake Trans Park interlock failure 1541 AUX analog PUD1 high 1542 AUX analog PUD1 low Code Description 1543 AUX analog PUD2 high 1544 AUX analog PUD2 low 1545 AUX analog PUD3 high 1546 AUX analog PUD3 low 1547 AUX analog PUD4 high 1548 AUX analog PUD4 low 1551 AUX DIG1 high 1552 AUX DIG1 low 1553 AUX DIG2 high 1554 AUX DIG2 low 1555 AUX DIG3 high 1556 AUX DIG3 low 1561 AUX analog P...

Page 193: ...eropen 1643 Buzzer control short to power Code Description 1644 MIL control ground short 1645 MIL control short to power 1661 PWM6 open ground short 1662 PWM6 short to power 1663 PWM7 open ground short 1664 PWM7 short to power 1665 PWM8 open ground short 1666 PWM8 short to power 1669 PWM9 open ground short 1670 PWM9 short to power 2111 Unable to reach lower TPS 2112 Unable to reach higher TPS 2115...

Page 194: ...Open or Low side Short to Ground 2310 Primary Coil Shorted 2312 Primary Loop Open or Low side Short to Ground 2313 Primary Coil Shorted 2315 Primary Loop Open or Low side Short to Ground Code Description 2316 Primary Coil Shorted 2318 Primary Loop Open or Low side Short to Ground 2319 Primary Coil Shorted 2321 Primary Loop Open or Low side Short to Ground 2322 Primary Coil Shorted 2324 Primary Loo...

Page 195: ...nk 4 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 1 6 5 4 three times After the fault codes the check engine light will blink a code 1 6 5 4 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a three digit code thre...

Page 196: ...ank2 175 AL low gasoline bank2 Code Description 182 FT Gasoline Low Voltage 183 FT Gasoline High Voltage 187 FT Gaseaous fuel low voltage 188 FT Gaseaous fuel high voltage 217 ECT higher than expected 2 219 Max govern speed override 221 TPS1 higher than TPS2 222 TPS2 low voltage 223 TPS2 high voltage 236 TIP Active 237 TIP Low Voltage 238 TIP High Voltage 261 Injector Loop Open or Low side short t...

Page 197: ... 306 Emissions catalyst damaging misfire 307 Emissions catalyst damaging misfire 308 Emissions catalyst damaging misfire Code Description 326 Knock 1 Excessive Signal 327 Knock 1 sensor Open 331 Knock 2 Excessive Signal 332 Knock 2 sensor Open 336 Crank sync noise 337 Crank loss 341 Cam sync noise 342 Cam loss 420 Gasoline cat monitor 430 Gasoline cat monitor 524 Oil pressure low 562 Battery Volta...

Page 198: ... 1162 AL low LPG Code Description 1163 AL high NG 1164 AL low NG 1165 LPG cat monitor 1166 NG cat monitor 1171 Megajectordeliverypressure higherthanexpected 1172 Megajectordeliverypressure lower than expected 1173 Megajector comm lost 1174 Megajector voltage supply high 1175 Megajector voltage supply low 1176 Megajector internal actuator fault detection 1177 Megajector internal circuitry fault det...

Page 199: ... high 1562 AUX analog PD2 low 1563 AUX analog PD3 high Code Description 1564 AUX analog PD3 low 1611 5VE 1 2 simultaneous out of range 1612 RTI 1 loss 1613 RTI 2 loss 1614 RTI 3 loss 1615 A D loss 1616 Invalidinterrupt 1621 Rx Inactive 1622 Rx Noise 1623 Invalid Packet Format 1624 ShutdownRequest 1625 ShutdownRequest 1626 CAN Tx failure 1627 CAN Rx failure 1628 CAN addresss conflict failure 1629 J...

Page 200: ...e 2139 FPP1 lower than IVS limit 2140 FPP2 lower than IVS limit Code Description 2229 BP high pressure 2300 Primary Loop Open or Low side Short to Ground 2301 Primary Coil Shorted 2303 Primary Loop Open or Low side Short to Ground 2304 Primary Coil Shorted 2306 Primary Loop Open or Low side Short to Ground 2307 Primary Coil Shorted 2309 Primary Loop Open or Low side Short to Ground 2310 Primary Co...

Page 201: ...a time 4 Determine the error source The red LED indicates the error source and will flash two separate codes The first code will indicate the first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second 5 Determine the error type The green LED indicates the error type and will flash two separate codes The first code wi...

Page 202: ...Anglesensor Powerrelaysdisengaged Inspect boom angle sensor for not active proper operation and be sure it is connected to boom properly OR replace boom angle sensor 22 Stringpotentiometer Powerrelaysdisengaged Inspect string potentiometer for proper not active operation and be sure it is connected to boom properly OR replace string potentiometer 23 Power relay output Powerrelaysdisengaged Repair ...

Page 203: ...12 Value too high Powerrelaysdisengaged Repair wiring and or connections OR Stringpotentiometerwiring replacestringpotentiometer open or shorted to voltage and calibrate overload system 15 Value too low Powerrelaysdisengaged Repair wiring and or connections OR Stringpotentiometerwiring replacestringpotentiometer open or shorted to ground and calibrate overload system 16 Output short low Powerrelay...

Page 204: ...tringpotentiometerand wiring open or shorted calibrate overload system to voltage 15 Value too low Powerrelaysdisengaged Repair wiring and or connections OR Stringpotentiometer replacestringpotentiometerand wiringopenOR calibrate overload system shorted to ground OR string potentiometer is faulty 16 Output short low Powerrelaysdisengaged Repair wiring and or connections OR Stringpotentiometer repl...

Page 205: ...iringand orconnections Boom angle sensor wiring OR adjust or replace boom angle sensor open or shorted to voltage and calibrate overload system OR sensor is out of operatingrange 15 Value too low Powerrelaysdisengaged Repairwiringand orconnections Boom angle sensor wiring OR adjust or replace boom angle sensor open OR shorted to ground and calibrate overload system OR sensor is out of operatingran...

Page 206: ...ensor open or shorted to voltage and calibrate overload system OR sensor is out of operatingrange 15 Value too low Powerrelaysdisengaged Repairwiringand orconnections Boom angle sensor wiring OR adjust or replace boom angle sensor open OR shorted to ground and calibrate overload system OR sensor is out of operatingrange 16 Output short low Powerrelaysdisengaged Repairwiringand orconnections Boom a...

Page 207: ... OR replace platform load cell OR remove shorted to voltage excess weight from platform Platform may be overloaded 15 Value too low Powerrelaysdisengaged Repair wiring and or connections OR Load cell wiring open OR replace platform load cell and shorted to ground calibrate overload system Platform may be reverse Check for binding of the overload loaded component linkage and be sure platform is NOT...

Page 208: ... be overloaded excess weight from platform 15 Value too low Powerrelaysdisengaged Repair wiring and or connections OR Load cell wiring open OR replace platform load cell and shorted to ground calibrate overload system Platform may be reverse Check for binding of the overload loaded component linkage and be sure platform is NOT on the ground OR supported from underneath 16 Output short low Powerrel...

Page 209: ... maintenance or repair procedure Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burnhazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry HydraulicSchematics Bodily injury hazard...

Page 210: ...itch Key switch Power relay Toggle switch SPDT Toggle switch DPDT Control relay contact normally open NO Horn button normally open Oil temperature switch normally open Coolant temperature switch normally open Oil pressure switch normally closed Gauge sending unit Fuel or RPM soleniod Coil with suppresion Key switch Tilt sensor Resistor with ohm value Auxiliary pump Hydraulic oil cooling fan Emerga...

Page 211: ...ed 3 position 3 way shuttle valve Flow divider combiner valve Directional valve mechanically activated Reilief valve with pressure setting Check valve Orifice with size Solenoid operated 3 position 4 way directional valve Priority flow regulator valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid operated 3 position 4 way proportio...

Page 212: ...imit Switch Location Legend LSB2S LSB1RO LST3O LST2O LST1O LS18 LS18A CE MODELS PRIMARY BOOM ANGLE SENSOR EXCLUDES THE S 60 HC ALL MODELS EXCEPT AS NOTED S 60 HC S 60X AND S 60XC AS NOTED STRING POT S 60 HC MODELS LSB1ES S 60X S 60XC LSB1EO S 60X S 60XC LST3S S 60X S 60XC PRIMARY BOOM ANGLE SENSOR S 60 HC ...

Page 213: ...6 Schematics December2013 Ford Engine Relay Layout Ford DSG 423 EFI Power Relay Starter Relay Fuel Pump Relay F5 15A F4 15A F3 10A F2 5A F1 10A Empty F6 10A Power Relay Fuel Pump Relay F5 15A F4 15A F3 10A F2 5A F1 10A Starter Relay Ford MSG 425 EFI EMPTY Starter 20A Empty Empty ...

Page 214: ...6 6 S 60 S 65 S 60 TRAX S 65 TRAX PartNo 147753 S 60 HC S 60X S 60XC December2013 Section 6 Schematics ...

Page 215: ...Section 6 Schematics December2013 6 7 Ford DSG 423 Engine Wire Harness 6 8 ...

Page 216: ...GY Y 18 BR W 18 W LG 18 GY LB 18 BK W 16 Y BK 18 Y RD 18 RD T 14 DG 18 O 18 GY R 18 GY 18 BR W 18 FP REC LB DG 18 DG P 18 R LG 18 Y BK 18 O LG 18 FUEL PUMP LG P 18 FUEL PUMP DG P 18 Y DB 18 DB O 18 DG O 18 O LG 18 W BK 18 R 16 Y RD 18 GY R 18 8 CAN 5 UNUSED 2 5V REF 1 ANA RTN 3 PC TX 4 PC RX 6 UNUSED 7 CAN DIAGNOSTIC CONNECTOR 82 DBW 79 VBAT 73 RELAY 70 INJ6 LS 67 INJ4 LS 64 INJ1 LS 61 EGOH 2 55 P...

Page 217: ...EN PURPLE 18 ORANGE LT GREEN 18 18 AUX ANAPD3 6 SPK_COIL3A 42 GOV2 AUX DIG 4 54 90 78 5 SPK_COIL2B 3 SPARK_COIL2A 2 SPK_COIL1B 12 AUX ANAPD1 24 AUX ANAPUD3 41 BRAKE AUX DIG 3 39 LPTEMP AUX ANAPU2 38 FRT AUX ANAPU1 35 OILPRESS 50 AUX DIG 2 45 AUX ANAPUD2 57 KNOCK 2 59 VBAT PROT 71 AUX PWM8 89 86 AUX PWM4 84 AUX PWM5 83 AUX PWM5 REC 87 AUX PWM2 1 SPK_COIL1A 4 SPK_GND 7 SPK_COIL3B 13 FRP AUX ANAPD2 4...

Page 218: ...December2013 Section 6 Schematics 6 10 Ford MSG 425 Engine Wire Harness 6 9 ...

Page 219: ...Section 6 Schematics December2013 6 11 Electrical Schematic Options All Models 6 12 ...

Page 220: ... OPTION CR46 BELT DRIVEN GENERATOR OPTION G2 G1 G3 VOLT METER OIL PRESSURE GAUGE C26TSR WH RD WORK LIGHTS DRIVE LIGHTS ES0396R ES0186U ES0193U ES0390J C25PSR WH BK COOLANT TEMP GAUGE MAIN AUX REGULATOR IND BAT STA BAT EXCT 12VDC B1 B2 ALTERNATOR BATTERY SEPERATOR START BATTERY CONTROL BATTERY J144 2 12VDC STARTER AUXILIARY PUMP PR1 NO CR1 NO D51 PR2 BAT2 APU B1BAT RD M3 M2 TB21 SECOND BATTERY OPTI...

Page 221: ...EGULATOR BK WH BK RD WH BK BRN RED 110V AC REGULATOR BLK 120VAC 15A WHT NEUTRAL AUTO 120V AC RESET CB 87a 87 5 85 4 3 2 86 1 30 30A CB RD WT BRN WHT NEUTRAL BLK 220VAC 5 87a 87 1 2 86 30 4 85 3 5 87a 87 1 2 86 30 4 85 3 BLK 120VAC 15A AUTO RESET CB 120V AC 30A WHT NEUTRAL GR 120V AC W O REGULATOR CB RD BRN WT 30A BK RED 12V WH BRN BK WH BK RD 12 5A 220V AC RESET CB AUTO 220V AC REGULATOR BK WH BK ...

Page 222: ...December2013 Section 6 Schematics 6 14 Wiring Diagram Belt Driven Generator 6 13 ...

Page 223: ...Section 6 Schematics December2013 6 15 Wiring Diagram 3kW Hydraulic Generator 6 16 ...

Page 224: ...L2 RED CAPACITOR 120V AC 60HZ T1 T2 T3 T4 5 8 GND RED YELLOW BLACK L1 1 2 3 4 1 2 3 4 DIAGNOSTIC 12VDC PURGE 12VDC 12VDC GEN OFF ON DTP06 4S DTP04 4P CB BLACK WHITE GREEN RED BLACK BLUE YELLOW YELLOW BLUE BLACK RED WHITE WHITE WHITE BLACK GREEN BLACK BLACK BLACK GROUND GREEN WHITE L2 BLACK CAPACITOR 120V AC 50HZ T1 T2 T3 T4 5 8 GND RED YELLOW BLACK L2 1 2 3 4 1 2 3 4 DIAGNOSTIC 12VDC PURGE 12VDC 1...

Page 225: ...D 8 GA 4 CONDUCTOR 208 VAC OUTLET L1 L2 L3 NEUTRAL BUSS BAR NEMA 4 CONTROL BOX PLATFORM 50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI BRASS SILVER 120V AC GFI GREEN 12GA BLACK 12GA X Y Z 8 GA 5 CONDUCTOR 20 AMP CIRCUIT BREAKER GROUND STUD ON DIN RAIL 1 2 3 N 5 4 6 BLACK 12GA ENCLOSURE TURNTABLE SILVER GREEN 110 VAC GFI PLATFORM BRASS BLACK GREEN WHITE 12 GA 3 CONDUCTOR 110 VAC PLUG TURNTABLE GEN...

Page 226: ...December2013 Section 6 Schematics 6 18 Wiring Diagram 12kW Hydraulic Generator Welder Option 6 17 ...

Page 227: ...Section 6 Schematics December2013 6 19 Electrical Schematic 12kW Hydraulic Generator Welder Option 6 20 ...

Page 228: ...4 HIGH IDLE RELAY V151HG GR 20 P26BAT BK C1P 3 BYPASS COIL MOTOR STROKE VALVE SX CONTROLLER CR50 OMRON RELAY P22BAT DIVERTER MANIFOLD PRESSURE SWITCH 200 PSI RD 1 TS47 GENERATOR ON C57 1 Y75 1 Y75 2 C1P 6 BRAKE RELEASE RD 16 4 GR WH WH 16 4 BR 16 4 GR WH CR66 OMRON RELAY U36 7 5 3 1 8 6 4 2 TB24 TIME DELAY MODULE 4 SECOND 8 N C 2 COM 1 N O 3 GND 5 SW INPUT C2B 7 C45GEN GR WH TB45 TB35 C35RPM BK RD...

Page 229: ...c 12kW Hydraulic Generator Option CY CW CX CV CU FUNCTION MANIFOLD 0 031 inch 0 79 mm WELDER MANIFOLD DRIVE PUMP B A 3 5 GPM 13 25 L min PMP B CLR PMP A 270 PSI 18 6 BAR 3 5 GPM 13 25 L min MTR B MTR A 21 GPM 79 5 L min G1 G2 21 GPM 79 5 L min G2 G1 24CC 1 3 GENERATOR 12 5 KW HYDRAULIC ROTARY COUPLER PRESSURE SWITCH 200 PSI 13 8 BAR N O 0 047 inch 1 2 mm CZ HS0078K ...

Page 230: ...December2013 Section 6 Schematics 6 22 Hydraulic Schematic 12kW Hydraulic Generator Option 6 21 ...

Page 231: ...Section 6 Schematics December2013 6 23 Hydraulic Schematic 2WD Models from SN 21001 to 21396 6 24 ...

Page 232: ...PRIMARY BOOM EXTENSION CYLINDER 7 gpm 26 5 L min TURNTABLE ROTATE 2 8 gpm 10 6 L min PRIMARY BOOM LIFT CYLINDER 8 gpm 30 3 L min P1 P2 ACCUM ACCUMULATOR 1000 psi 69 bar MASTER SLAVE PL1 PL2 PLATFORM LEVEL CYLINDERS L R PLATFORM ROTATE PR2 PR1 PR2 PR1 V2 V1 J1 J2 JIB BOOM CYLINDER S 65 MODELS 30 psi 2 1 bar 30 psi 2 1 bar 0 6 gpm 2 27 L min 30 psi 2 1 bar 0 1 gpm 0 38 L min FUNCTION MANIFOLD SWV ST...

Page 233: ...5 L min TURNTABLE ROTATE 2 8 gpm 10 6 L min PRIMARY BOOM LIFT CYLINDER 8 gpm 30 3 L min P1 P2 ACCUM ACCUMULATOR 1000 psi 69 bar MASTER SLAVE PL1 PL2 PLATFORM LEVEL CYLINDERS L R PLATFORM ROTATE PR2 PR1 PR2 PR1 V2 V1 J1 J2 JIB BOOM CYLINDER S 65 MODELS 30 psi 2 1 bar 30 psi 2 1 bar 0 6 gpm 2 27 L min 30 psi 2 1 bar 0 1 gpm 0 38 L min FUNCTION MANIFOLD SWV ST1 ST2 5 5 4 4 2 7 7 2B 2C 2A 1 1 3 3 25 p...

Page 234: ...December2013 Section 6 Schematics 6 26 Hydraulic Schematic 2WD Models after SN 21396 6 25 ...

Page 235: ...Section 6 Schematics December2013 6 27 Hydraulic Schematic 4WD Models from SN 21001 to 21396 6 28 ...

Page 236: ...R OPTION HS0078J P2 P1 PRIMARY LIFT CYLINDER S60 HC MODELS FUNCTION MANIFOLD TANK SWV ST1 ST2 PRESS PTEST J I Y Z DD EE 30 psi 2 1 bar 30 psi 2 1 bar 0 6 gpm 2 27 L min 30 psi 2 1 bar 0 1 gpm 0 38 L min PR2 PR1 V2 V1 JIB BOOM CYLINDER S 65 MODELS JIB SELECT MANIFOLD S 65 MOD FF J1 J2 PR2 PR1 RR QQ L R PLATFORM ROTATE U V X W G H MASTER SLAVE PL1 PL2 PLATFORM LEVEL CYLINDERS ACCUM ACCUMULATOR 1000 ...

Page 237: ...r 30 psi 2 1 bar 0 6 gpm 2 27 L min 30 psi 2 1 bar 0 1 gpm 0 38 L min PR2 PR1 V2 V1 JIB BOOM CYLINDER S 65 MODELS JIB SELECT MANIFOLD S 65 MOD FF J1 J2 PR2 PR1 RR QQ L R PLATFORM ROTATE U V X W G H MASTER SLAVE PL1 PL2 PLATFORM LEVEL CYLINDERS ACCUM ACCUMULATOR 1000 psi 69 bar R E T S F P1 P2 TURNTABLE ROTATE 2 8 gpm 10 6 L min PRIMARY BOOM LIFT CYLINDER 8 gpm 30 3 L min PP NN MM OO V2 S1 0 030 in...

Page 238: ...December2013 Section 6 Schematics 6 30 Hydraulic Schematic 4WD Models after SN 21396 6 29 ...

Page 239: ...Section 6 Schematics December2013 6 31 Electrical Schematic S 65 Ford Engine Models ANSI CSA 6 32 ...

Page 240: ...16 OR M1 S8 M2 C7B 1 C2B 5 C7B 2 C1B 1 C6 10 AUXILIARY PUMP C1B 7 C2B 1 C1B 9 C28TTA RD BK C28TTA RD BK C7P 1 C9P 3 C9P 2 P24FS WH P25FS RD P26ESTP BK C46HRN GR C2P 5 P23BAT WH C7P 2 C28TTA RD BK C27AUX RD C1P 1 C33STR BK C1P 7 C39LP BL RD C2P 1 BRN RD RD P22LS BK C41RPM OR BK P26ESTP BK P24FS WH TS4 ENGINE RPM TS54 ENGINE RPM C35RPM RD BK C1P 9 H1 H2 WH P2 BK BRN WH RD P22HRN BK 12V DC TS3 FUEL S...

Page 241: ...RD WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM RO...

Page 242: ...December2013 Section 6 Schematics 6 34 6 33 Electrical Schematic S 65 Ford Engine Models ANSI CSA ...

Page 243: ...Section 6 Schematics December2013 6 35 Ground Control Box Terminal Strip Wiring Diagram S 65 Ford Engine Models ANSI CSA 6 36 ...

Page 244: ... C6 2 C1PBU RD C6 1 C1PBU RD C3B 1 C3PBF RD WH C3B 3 C2PBD RD BK C3B 2 1 A B 2 C9PER BK RD C6 9 C3PBF RD WH C6 3 C5TRR WH BK C6 5 C6TRF WH RD C6 6 C9PER BK RD C3B 9 C7PBE BK C3B 7 C7PBE RD C6 7 C8PBR BK WH C3B 8 C4TRL WH C3B 4 C4TRL WH C6 4 C5TRR WH BK C3B 5 C6TRF WH RD C3B 6 C8PBR BK WH C6 8 3 4 5 7 6 8 C5 8 GR BRN TS64 ENGINE FAULT TOGGLE SWITCH D30 RD BK ALARM C6 19 C18JD GR BK C6 18 C17JU GR C...

Page 245: ...GGLE SWITCH S 65 OPTION TS51 TS52 TS53 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD C134D 2 P1 NC NC 1A 1B 2A ...

Page 246: ...December2013 Section 6 Schematics 6 38 Ground Control Box Switch Panel Wiring Diagram S 65 Ford Engine Models ANSI CSA 6 37 ...

Page 247: ...Section 6 Schematics December2013 6 39 Platform Control Box Wiring Diagram S 65 Ford Engine Models ANSI CSA 6 40 ...

Page 248: ...TRR WH BK C3P 5 C29MS RD WH C1P 3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH OPT JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P134PWR RD H1 RD E STOP BRN JC...

Page 249: ...L BK C3P 11 1 1 ROCKER STEER OPTION WH RD RELAY BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH CIRCUIT LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65 OPTION JIB VALVE RELAY S 65 OPTION L...

Page 250: ...December2013 Section 6 Schematics 6 42 Platform Control Box Switch Panel Wiring Diagram S 65 Ford Engine Models ANSI CSA 6 41 ...

Page 251: ...Section 6 Schematics December2013 6 43 Electrical Schematic S 65 S60 TRAX S65 TRAX Deutz D2011L03i Models ANSI CSA 6 44 ...

Page 252: ...ILT ALARM NO CR15 TS6 GLOW PLUG C34SA BK WH TS56 GLOW PLUG TB34 OIL TEMPERATURE SWITCH SW3 NO SW2 NC L2 C26TS WH RD FUEL SOLENOID EXCT BAT STA BAT IND REGULATOR C9P 2 12V DC P26ESTP BK P24FS WH P22LS BK RD AUX FE BRN TS4 ENGINE RPM TS54 ENGINE RPM FS1 RD C9P 3 P24FS WH C33STR BK FB1 C21IGN WH P134FB WH 3 TB33 2 1 BK TS52 ENGINE START TS1 AUXILIARY PUMP RD TB27 C28TTA RD BK TS51 CR2 9 10 5 6 7 8 NO...

Page 253: ...ELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE LEFT JIB...

Page 254: ...December2013 Section 6 Schematics 6 46 Electrical Schematic S 65 S60 TRAX S65 TRAX Deutz D2011L03i Models ANSI CSA 6 45 ...

Page 255: ...Section 6 Schematics December2013 6 47 Electrical Schematic S 65 S60 TRAX S65 TRAX Deutz TD2011L04i Models ANSI CSA 6 48 ...

Page 256: ... 14 C5 22 C1B 7 PUMP AUXILIARY ENGINE START START ENGINE ON G PLUG C1B 8 ON GLO PLUG SPEED ENGINE C41RPM OR BK P134 RD P134 RD C41RPM OR BK C1P 9 C1P 8 C1P 7 C7P 1 C27AUX RD C1P 1 C1P 2 C7P 2 P26ESTP BK P25FS RD C41RPM OR BK _ HM HM H2 C2P 5 BK BRN WH RD H1 WH FS P22BAT BK TILT ALARM HIGH IDLE RELAY HIGH RPM SOLENOID OPTION NO PR2 PR2 TS6 TS56 TB34 SWITCH SWITCH OIL TEMPERATURE OIL PRESSURE NO SW3...

Page 257: ...ELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE LEFT JIB...

Page 258: ...December2013 Section 6 Schematics 6 50 Electrical Schematic S 65 S60 TRAX S65 TRAX DeutzTD2011L04i Models ANSI CSA 6 49 ...

Page 259: ...Section 6 Schematics December2013 6 51 Ground Control Box Terminal Strip Wiring Diagram S 65 S60 TRAX S65 TRAX Deutz Engine Models ANSI CSA 6 52 ...

Page 260: ...H RD C5 14 C35RPM BK RD C1B 9 C41RPM OR BK C2B 3 C34SA BK WH C1B 8 WH ISM10 C34SA BK WH C5 22 C41RPM OR BK C5 2 RD BK ALARM C6 19 C8PBR BK WH C6 8 BRN GND BRN C7B 3 GR C2B 5 P23BAT WH C7B 2 P22BAT BK C6 22 BK RD CR4 WH ISM7 C32BRK WH RD C5 23 C27AUX RD C6 27 C129JDA BL C3B 10 C2PBD RD BK C3B 2 C32BRK WH RD C1B 6 BATTERY POWER 12V DC 59 59 RETRACT BOOM LED BL TS58 134 134 LOAD WEIGHING LIM SW 12V 1...

Page 261: ...S 65 OPTION TS51 TS52 TS54 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D P1 NC NC 1A 1B 2A 2B D2 K...

Page 262: ...December2013 Section 6 Schematics 6 54 Ground Control Box Switch Panel Wiring Diagram S 65 S60 TRAX S65 TRAX Deutz Engine Models ANSI CSA 6 53 ...

Page 263: ...Section 6 Schematics December2013 6 55 Platform Control Box Wiring Diagram S 65 S60 TRAX S65 TRAX Deutz Engine Models ANSI CSA 6 56 ...

Page 264: ...C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH OPT JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P13...

Page 265: ...C7 GR BK C4P 6 BL BK C3P 11 1 1 ROCKER STEER OPTION WH RD RELAY BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH CIRCUIT LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65 OPTION JIB VALVE REL...

Page 266: ...December2013 Section 6 Schematics 6 58 Platform Control Box Switch Panel Wiring Diagram S 65 S60 TRAX S65 TRAX Deutz Engine Models ANSI CSA 6 57 ...

Page 267: ...Section 6 Schematics December2013 6 59 Electrical Schematic S 65 S60 TRAX S65 TRAX Perkins Engine Models ANSI CSA 6 60 ...

Page 268: ...T BK TILT ALARM NO CR15 TS6 GLOW PLUG C34SA BK WH TS56 GLOW PLUG TB34 WATER TEMPERATURE SWITCH SW3 NO SW2 NC L2 C26TS WH RD FUEL SOLENOID EXCT BAT STA BAT IND REGULATOR C9P 2 12V DC P26ESTP BK P24FS WH P22LS BK RD AUX FE BRN TS4 ENGINE RPM TS54 ENGINE RPM FS1 RD C9P 3 P24FS WH C33STR BK FB1 C21IGN WH P134FB WH 3 TB33 2 1 BK TS52 ENGINE START TS1 AUXILIARY PUMP RD TB27 C28TTA RD BK TS51 CR2 9 10 5 ...

Page 269: ...R STROKE C29MS RD WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL...

Page 270: ...December2013 Section 6 Schematics 6 62 Electrical Schematic S 65 S60 TRAX S65 TRAX Perkins Engine Models ANSI CSA 6 61 ...

Page 271: ...Section 6 Schematics December2013 6 63 Ground Control Box Terminal Strip Wiring Diagram S 65 S60 TRAX S65 TRAX Perkins Engine Models ANSI CSA 6 64 ...

Page 272: ... RD C1B 9 C41RPM OR BK C2B 3 C34SA BK WH C1B 8 WH ISM10 C34SA BK WH C5 22 C41RPM OR BK C5 2 RD BK ALARM C6 19 C8PBR BK WH C6 8 BRN GND BRN C7B 3 GR C2B 5 P23BAT WH C7B 2 P22BAT BK C6 22 BK RD CR4 WH ISM7 C32BRK WH RD C5 23 C27AUX RD C6 27 C129JDA BL C3B 10 C2PBD RD BK C3B 2 C32BRK WH RD C1B 6 BATTERY POWER 12V DC 59 59 RETRACT BOOM LED BL TS58 134 134 LOAD WEIGHING LIM SW 12V 1 C59CNK BL BK C3B 11...

Page 273: ... TS51 TS52 TS54 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D P1 NC NC 1A 1B 2A 2B D2 KS1 B1 B 1 2...

Page 274: ...December2013 Section 6 Schematics 6 66 Ground Control Box Switch Panel Wiring Diagram S 65 S60 TRAX S65 TRAX Perkins Engine Models ANSI CSA 6 65 ...

Page 275: ...Section 6 Schematics December2013 6 67 Platform Control Box Wiring Diagram S 65 S60 TRAX S65 TRAX Perkins Engine Models ANSI CSA 6 68 ...

Page 276: ... WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH OPT JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P134PWR RD H1 R...

Page 277: ...4P 6 BL BK C3P 11 1 1 ROCKER STEER OPTION WH RD RELAY BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH CIRCUIT LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65 OPTION JIB VALVE RELAY S 65 OP...

Page 278: ...December2013 Section 6 Schematics 6 70 Platform Control Box Switch Panel Wiring Diagram S 65 S60 TRAX S65 TRAX Perkins Engine Models ANSI CSA 6 69 ...

Page 279: ...Section 6 Schematics December2013 6 71 Electrical Schematic S 60X and S 60XC Ford Engine Models ANSI CSA 6 72 ...

Page 280: ...AT WH C7P 2 C28TTA RD BK C27AUX RD C1P 1 C33STR BK C1P 7 C39LP BL RD C2P 1 BRN RD RD P22LS BK C41RPM OR BK P26ESTP BK P24FS WH TS4 ENGINE RPM TS54 ENGINE RPM C35RPM RD BK C1P 9 H1 H2 WH P2 BK BRN WH RD P22HRN BK 12V DC TS3 FUEL SELECT FS1 RD TS53 FUEL SELECT C21ING WH P134FB WH TB33 TS52 ENGINE START TS1 AUXILIARY PUMP TB27 TS51 C28TTA RD BK C27AUX RD PR1 NO TS2 ENGINE START TB35 HOUR METER P22BAT...

Page 281: ... PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT C15PLD OR BK P24FS WH P26ESTP BK P22LS BK RD AUX FE DESCENT ALRM BR PRIMARY BOOM RETRACT C165TRS WH RD P162JPW OR BR 1 5 4 2 3 6 C164PES RD WH C160JPL...

Page 282: ...December2013 Section 6 Schematics 6 74 Electrical Schematic S 60X and S 60XC Ford Engine Models ANSI CSA 6 73 ...

Page 283: ...Section 6 Schematics December2013 6 75 Ground Control Box Terminal Strip Wiring Diagram S 60X and S 60XC Ford Engine Models ANSI CSA 6 76 ...

Page 284: ...RD WH C6 3 C5TRR WH BK C6 5 C6TRF WH RD C6 6 C9PER BK RD C3B 9 C7PBE BK C3B 7 C7PBE RD C6 7 C8PBR BK WH C3B 8 C4TRL WH C3B 4 C4TRL WH C6 4 C5TRR WH BK C3B 5 C6TRF WH RD C3B 6 C8PBR BK WH C6 8 3 4 5 7 6 8 C5 8 GR BRN TS64 ENGINE FAULT TOGGLE SWITCH RD BK ALARM C6 19 C18JD GR BK C6 18 C17JU GR C6 17 C15PLD OR BK C6 15 C14PLU OR C6 14 C18JD GR BK C4B 6 C17JU GR C4B 5 C15PLD OR BK C4B 3 C14PLU OR C4B ...

Page 285: ...51 TS52 TS53 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD C134D 2 P1 NC NC 1A 1B 2A 2B D2 KS1 B1 B 1 2 4 3 G6 ...

Page 286: ...December2013 Section 6 Schematics 6 78 Ground Control Box Switch Panel Wiring Diagram S 60X and S 60XC Ford Engine Models ANSI CSA 6 77 ...

Page 287: ...Section 6 Schematics December2013 6 79 Platform Control Box Wiring Diagram S 60X and S 60XC Ford Engine Models ANSI CSA 6 80 ...

Page 288: ... BL BK C1P 11 C4TRL WH C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH OPT OPT CONTROL HARNESS TO PLATFORM SWITCH...

Page 289: ...R C4P 2 OR BK C4P 3 6 1 WH RD J1 1 WH BK J1 3 BR J1 12 OR J1 11 RD WH J1 2 JC7 GR BK C4P 6 BL BK C3P 11 1 1 ROCKER STEER OPTION WH BK BK BK RD BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM LIMIT SWITCH LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 L51 CAPACIT...

Page 290: ...December2013 Section 6 Schematics 6 82 Platform Control Box Switch Panel Wiring Diagram S 60X and S 60XC Ford Engine Models ANSI CSA 6 81 ...

Page 291: ...Section 6 Schematics December2013 6 83 Electrical Schematic S 60X and S 60XC DeutzD2011L03iModels ANSI CSA 6 84 ...

Page 292: ... PLUG C34SA BK WH TS56 GLOW PLUG TB34 OIL TEMPERATURE SWITCH SW3 NO SW2 NC L2 C26TS WH RD FUEL SOLENOID EXCT BAT STA BAT IND REGULATOR C9P 2 12V DC P26ESTP BK P24FS WH P22LS BK RD AUX FE BRN TS4 ENGINE RPM TS54 ENGINE RPM FS1 RD C9P 3 P24FS WH C33STR BK FB1 C21IGN WH P134FB WH 3 TB33 2 1 BK TS52 ENGINE START TS1 AUXILIARY PUMP RD TB27 C28TTA RD BK TS51 CR2 9 10 5 6 7 8 NO TB21 R33STR BK CR1 NO C28...

Page 293: ... DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE LEFT JIB BOOM UP S 65 OPTION PLATFORM ROTATE RIGHT JIB BOOM DOWN S 65 OPTION C15PLD OR BK P24FS WH P26ESTP BK P22LS BK RD AUX FE DESCENT ALRM BR PRIMARY BOOM RETRACT C165TRS WH RD P162JPW OR BR 1 5 4 2 3 6 C164PES RD WH C160...

Page 294: ...December2013 Section 6 Schematics 6 86 Electrical Schematic S 60X and S 60XC Deutz D2011L03i Models ANSI CSA 6 85 ...

Page 295: ...Section 6 Schematics December2013 6 87 Electrical Schematic S 60X and S 60XC DeutzTD2011L04iModels ANSI CSA 6 88 ...

Page 296: ...C5 22 C1B 7 PUMP AUXILIARY ENGINE START START ENGINE ON G PLUG C1B 8 ON GLO PLUG SPEED ENGINE C41RPM OR BK P134 RD P134 RD C41RPM OR BK C1P 9 C1P 8 C1P 7 C7P 1 C27AUX RD C1P 1 C1P 2 C7P 2 P26ESTP BK P25FS RD C41RPM OR BK _ HM HM H2 C2P 5 BK BRN WH RD H1 WH FS P22BAT BK TILT ALARM HIGH IDLE RELAY HIGH RPM SOLENOID OPTION NO PR2 PR2 TS6 TS56 TB34 SWITCH SWITCH OIL TEMPERATURE OIL PRESSURE NO SW3 NC ...

Page 297: ... DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE LEFT JIB BOOM UP S 65 OPTION PLATFORM ROTATE RIGHT JIB BOOM DOWN S 65 OPTION C15PLD OR BK P24FS WH P26ESTP BK P22LS BK RD AUX FE DESCENT ALRM BR PRIMARY BOOM RETRACT C165TRS WH RD P162JPW OR BR 1 5 4 2 3 6 C164PES RD WH C160...

Page 298: ...December2013 Section 6 Schematics 6 90 Electrical Schematic S 60X and S 60XC Deutz TD2011L04i Models ANSI CSA 6 89 ...

Page 299: ...Section 6 Schematics December2013 6 91 Ground Control Box Terminal Strip Wiring Diagram S 60X and S 60XC Deutz Engine Models ANSI CSA 6 92 ...

Page 300: ... C41RPM OR BK C5 2 RD BK ALARM C6 19 C8PBR BK WH C6 8 BRN GND BRN C7B 3 GR C2B 5 P23BAT WH C7B 2 P22BAT BK C6 22 BK RD CR4 WH ISM7 C32BRK WH RD C5 23 C27AUX RD C6 27 C2PBD RD BK C3B 2 C32BRK WH RD C1B 6 BATTERY POWER 12V DC 59 59 RETRACT BOOM LED 134 134 LOAD WEIGHING LIM SW 12V 1 C59CNK BL BK C3B 11 C59CNK BL BK C6 11 BL BK L46 RD CB1 RD CB2 P20BAT RD P20BAT RD 12 VOLT POWER 1 20 20 40 40 BOOM ST...

Page 301: ... TS52 TS54 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D P1 NC NC 1A 1B 2A 2B D2 KS1 B1 B 1 2 4 3 ...

Page 302: ...December2013 Section 6 Schematics 6 94 Ground Control Box Switch Panel Wiring Diagram S 60X and S 60XC Deutz Engine Models ANSI CSA 6 93 ...

Page 303: ...Section 6 Schematics December2013 6 95 Platform Control Box Wiring Diagram S 60X and S 60XC Deutz Engine Models ANSI CSA 6 96 ...

Page 304: ...RD WH C3P 3 C37SCW BL BK C1P 11 C4TRL WH C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH OPT OPT CONTROL HARNESS ...

Page 305: ...R J1 11 RD WH J1 2 JC7 GR BK C4P 6 BL BK C3P 11 1 1 ROCKER STEER OPTION WH BK BK BK RD BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM LIMIT SWITCH LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX GROUND CONTROLS C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 L51 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RE...

Page 306: ...December2013 Section 6 Schematics 6 98 Platform Control Box Switch Panel Wiring Diagram S 60X and S 60XC Deutz Engine Models ANSI CSA 6 97 ...

Page 307: ...Section 6 Schematics December2013 6 99 Electrical Schematic S 60X and S 60XC PerkinsEngineModels ANSI CSA 6 100 ...

Page 308: ...6 GLOW PLUG C34SA BK WH TS56 GLOW PLUG TB34 WATER TEMPERATURE SWITCH SW3 NO SW2 NC L2 C26TS WH RD FUEL SOLENOID EXCT BAT STA BAT IND REGULATOR C9P 2 12V DC P26ESTP BK P24FS WH P22LS BK RD AUX FE BRN TS4 ENGINE RPM TS54 ENGINE RPM FS1 RD C9P 3 P24FS WH C33STR BK FB1 C21IGN WH P134FB WH 3 TB33 2 1 BK TS52 ENGINE START TS1 AUXILIARY PUMP RD TB27 C28TTA RD BK TS51 CR2 9 10 5 6 7 8 NO TB21 R33STR BK CR...

Page 309: ...RIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE LEFT JIB BOOM UP S 65 OPTION PLATFORM ROTATE RIGHT JIB BOOM DOWN S 65 OPTION C15PLD OR BK P24FS WH P26ESTP BK P22LS BK RD AUX FE DESCENT ALRM BR PRIMARY BOOM RETRACT C165TRS WH RD P162JPW OR BR 1 5 4 2 3 6 C164PES...

Page 310: ...December2013 Section 6 Schematics 6 102 Electrical Schematic S 60X and S 60XC Perkins Engine Models ANSI CSA 6 101 ...

Page 311: ...Section 6 Schematics December2013 6 103 Ground Control Box Terminal Strip Wiring Diagram S 60X and S 60XC Perkins Engine Models ANSI CSA 6 104 ...

Page 312: ...2 C41RPM OR BK C5 2 RD BK ALARM C6 19 C8PBR BK WH C6 8 BRN GND BRN C7B 3 GR C2B 5 P23BAT WH C7B 2 P22BAT BK C6 22 BK RD CR4 WH ISM7 C32BRK WH RD C5 23 C27AUX RD C6 27 C2PBD RD BK C3B 2 C32BRK WH RD C1B 6 BATTERY POWER 12V DC 59 59 RETRACT BOOM LED 134 134 LOAD WEIGHING LIM SW 12V 1 C59CNK BL BK C3B 11 C59CNK BL BK C6 11 BL BK L46 RD CB1 RD CB2 P20BAT RD P20BAT RD 12 VOLT POWER 1 20 20 40 40 BOOM S...

Page 313: ...GGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D P1 NC NC 1A 1B 2A 2B D2 KS1 B1 B 1 2 4 3 G6 D64 3 2 1 TS52 TS56 1 2 3...

Page 314: ...December2013 Section 6 Schematics 6 106 Ground Control Box Switch Panel Wiring Diagram S 60X and S 60XC Perkins Engine Models ANSI CSA 6 105 ...

Page 315: ...Section 6 Schematics December2013 6 107 Platform Control Box Wiring Diagram S 60X and S 60XC Perkins Engine Models ANSI CSA 6 108 ...

Page 316: ... C37SCW BL BK C1P 11 C4TRL WH C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH OPT OPT CONTROL HARNESS TO PLATFORM...

Page 317: ...RD WH J1 2 JC7 GR BK C4P 6 BL BK C3P 11 1 1 ROCKER STEER OPTION WH BK BK BK RD BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM LIMIT SWITCH LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX GROUND CONTROLS C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 L51 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65...

Page 318: ...December2013 Section 6 Schematics 6 110 Platform Control Box Switch Panel Wiring Diagram S 60X and S 60XC Perkins Engine Models ANSI CSA 6 109 ...

Page 319: ...Section 6 Schematics December2013 6 111 Electrical Schematic S 60 S 65 Ford Engine Models CE from SN 21001 to 22516 6 112 ...

Page 320: ... BRN RD RD P22LS BK C41RPM OR BK P26ESTP BK P24FS WH TS4 ENGINE RPM TS54 ENGINE RPM C35RPM RD BK C1P 9 H1 H2 WH P2 BK BRN WH RD P22HRN BK 12V DC TS3 FUEL SELECT FS1 RD TS53 FUEL SELECT C21ING WH P134FB WH TB33 TS52 ENGINE START TS1 AUXILIARY PUMP TB27 TS51 C28TTA RD BK C27AUX RD PR1 NO TS2 ENGINE START TB35 HOUR METER P22BAT BK TB22 BK P3 P1 GND PLAT TB23 TB41 CB2 15A RD CB3 15A C46HRN GR CR5 NO R...

Page 321: ...TROKE C29MS RD WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP...

Page 322: ...December2013 Section 6 Schematics 6 114 Electrical Schematic S 60 S 65 Ford Engine Models CE from SN 21001 to 22516 6 113 ...

Page 323: ...Section 6 Schematics December2013 6 115 Electrical Schematic S 60 S 65 Ford Engine Models CE after SN 22516 6 116 ...

Page 324: ...PM OR BK P26ESTP BK P24FS WH TS4 ENGINE RPM TS54 ENGINE RPM C35RPM RD BK C1P 9 H1 H2 WH P2 BK BRN WH RD P22HRN BK 12V DC TS3 FUEL SELECT FS1 RD TS53 FUEL SELECT C21ING WH P134FB WH TB33 TS52 ENGINE START AUXILIARY PUMP TB27 TS51 C28TTA RD BK C27AUX RD PR1 NO TS2 ENGINE START TB35 HOUR METER P22BAT BK TB22 BK P3 P1 GND PLAT TB23 TB41 CB2 15A RD CB3 15A C46HRN GR CR5 NO R46HRN BK ALTERNATOR BAT BAT ...

Page 325: ...E C29MS RD WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLA...

Page 326: ...December2013 Section 6 Schematics 6 118 Electrical Schematic S 60 S 65 Ford Engine Models CE after SN 22516 6 117 ...

Page 327: ...Section 6 Schematics December2013 6 119 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 Ford Engine Models CE from SN 21001 to 22516 6 120 ...

Page 328: ... BK C3B 2 1 A B 2 C9PER BK RD C6 9 C3PBF RD WH C6 3 C5TRR WH BK C6 5 C6TRF WH RD C6 6 C9PER BK RD C3B 9 C7PBE BK C3B 7 C7PBE RD C6 7 C8PBR BK WH C3B 8 C4TRL WH C3B 4 C4TRL WH C6 4 C5TRR WH BK C3B 5 C6TRF WH RD C3B 6 C8PBR BK WH C6 8 3 4 5 7 6 8 C5 8 GR BRN TS64 ENGINE FAULT TOGGLE SWITCH D30 RD BK ALARM C6 19 C18JD GR BK C6 18 C17JU GR C6 17 C15PLD OR BK C6 15 C14PLU OR C6 14 C18JD GR BK C4B 6 C17...

Page 329: ...1 A B 2 C9PER BK RD C6 9 C3PBF RD WH C6 3 C5TRR WH BK C6 5 C6TRF WH RD C6 6 C9PER BK RD C3B 9 C7PBE BK C3B 7 C7PBE RD C6 7 C8PBR BK WH C3B 8 C4TRL WH C3B 4 C4TRL WH C6 4 C5TRR WH BK C3B 5 C6TRF WH RD C3B 6 C8PBR BK WH C6 8 3 4 5 7 6 8 C5 8 GR BRN TS64 ENGINE FAULT TOGGLE SWITCH D30 RD BK ALARM C6 19 C18JD GR BK C6 18 C17JU GR C6 17 C15PLD OR BK C6 15 C14PLU OR C6 14 C18JD GR BK C4B 6 C17JU GR C4B ...

Page 330: ...December2013 Section 6 Schematics 6 122 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 Ford Engine Models CE after SN 22516 6 121 ...

Page 331: ...Section 6 Schematics December2013 6 123 Ground Control Box Switch Panel Wiring Diagram S 60 S 65 Ford Engine Models CE 6 124 ...

Page 332: ...LIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D 2 P1 NC NC 1A 1B 2A 2B D2 KS1 B1 B 1 2 4 3 G6 D11 3 2 1 ...

Page 333: ... GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH LS18 JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P134PWR RD H1 RD E STOP BRN JC3 BRN GND C19JSV GR WH C4P 7 C19JSV GR WH TS7 C129JDA BL ...

Page 334: ...December2013 Section 6 Schematics 6 126 Platform Control Box Wiring Diagram S 60 S 65 Ford Engine Models CE 6 125 ...

Page 335: ...Section 6 Schematics December2013 6 127 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 Ford Engine Models CE 6 128 ...

Page 336: ... LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65 OPTION JIB VALVE RELAY S 65 OPTION LED CABLE TENSION L47 P2 EMERGENCY STOP BUTTON HORN BUTTON P3 TS1 R20 ...

Page 337: ...Section 6 Schematics December2013 6 129 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX DeutzD2011L03iModels CE 6 130 ...

Page 338: ...56 GLOW PLUG TB34 OIL TEMPERATURE SWITCH SW3 NO SW2 NC L2 C26TS WH RD FUEL SOLENOID EXCT BAT STA BAT IND REGULATOR C9P 2 12V DC P26ESTP BK P24FS WH P22LS BK RD AUX FE BRN TS4 ENGINE RPM TS54 ENGINE RPM FS1 RD C9P 3 P24FS WH C33STR BK FB1 C21IGN WH P134FB WH 3 TB33 2 1 BK TS52 ENGINE START RD TB27 C28TTA RD BK TS51 CR2 9 10 5 6 7 8 NO TB21 R33STR BK CR1 NO C28TTA RD BK NO PR1 4 START RELAY START IN...

Page 339: ...ELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE LEFT JIB...

Page 340: ...December2013 Section 6 Schematics 6 132 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz D2011L03i Models CE 6 131 ...

Page 341: ...Section 6 Schematics December2013 6 133 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX DeutzTD2011L04iModels CE 6 134 ...

Page 342: ...B24 C1B 1 C27AUX RD B A C C7B 1 M2 M3 M3 PR2 NO S8 U1 C3 3MF B1 C1B 2 C7B 2 C5 3 C5 2 C2B 5 C5 5 C21IGN2 WH R46HRN BK C6 10 C5 11 C5 14 PUMP AUXILIARY ENGINE SPEED C41RPM OR BK P134 RD P134 RD C41RPM OR BK P25FS RD P26ESTP BK C7P 2 C1P 2 C1P 1 C27AUX RD C7P 1 C1P 9 _ C41RPM OR BK G6 C2P 5 H2 BRN BK WH FS H1 RD WH TILT ALARM P22BAT BK HIGH RPM SOLENOID HIGH IDLE RELAY OPTION SW2 NC SW3 NO OIL PRESS...

Page 343: ...ELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE LEFT JIB...

Page 344: ...December2013 Section 6 Schematics 6 136 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz TD2011L04i Models CE 6 135 ...

Page 345: ...Section 6 Schematics December2013 6 137 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models CE 6 138 ...

Page 346: ...K WH C5 22 C41RPM OR BK C5 2 RD BK ALARM C6 19 C8PBR BK WH C6 8 BRN GND BRN C7B 3 GR C2B 5 P23BAT WH C7B 2 P22BAT BK C6 22 BK RD CR4 WH ISM7 C32BRK WH RD C5 23 C27AUX RD C6 27 C129JDA BL C3B 10 C2PBD RD BK C3B 2 C32BRK WH RD C1B 6 BATTERY POWER 12V DC 59 59 RETRACT BOOM LED BL TS58 134 134 LOAD WEIGHING LIM SW 12V 1 RD H6 C59CNK BL BK C3B 11 C59CNK BL BK C6 11 BL BK L46 RD CB1 RD CB2 P20BAT RD P20...

Page 347: ...54 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D P1 NC NC 1A 1B 2A 2B D2 KS1 B1 B 1 2 4 3 G6 D64 3...

Page 348: ...December2013 Section 6 Schematics 6 140 Ground Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models CE 6 139 ...

Page 349: ...Section 6 Schematics December2013 6 141 Platform Control Box Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models CE 6 142 ...

Page 350: ...3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH LS18 JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P134PWR RD H1 RD E STOP BRN JC3 BRN GND C19JSV GR WH C4P 7 C1...

Page 351: ... WH RD RD COMPONENT INDEX ES0186U BK NOTE DASHED LINES INDICATE OPTIONS WH CR30 30 TS6 GLOW PLUG TOGGLE SWITCH RELAY BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RE...

Page 352: ...December2013 Section 6 Schematics 6 144 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models CE 6 143 ...

Page 353: ...Section 6 Schematics December2013 6 145 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models CE 6 146 ...

Page 354: ...K WH TS56 GLOW PLUG TB34 WATER TEMPERATURE SWITCH SW3 NO SW2 NC L2 C26TS WH RD FUEL SOLENOID EXCT BAT STA BAT IND REGULATOR C9P 2 12V DC P26ESTP BK P24FS WH P22LS BK RD AUX FE BRN TS4 ENGINE RPM TS54 ENGINE RPM FS1 RD C9P 3 P24FS WH C33STR BK FB1 C21IGN WH P134FB WH 3 TB33 2 1 BK TS52 ENGINE START RD TB27 C28TTA RD BK TS51 CR2 9 10 5 6 7 8 NO TB21 R33STR BK CR1 NO C28TTA RD BK NO PR1 4 START RELAY...

Page 355: ...WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTAT...

Page 356: ...December2013 Section 6 Schematics 6 148 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models CE 6 147 ...

Page 357: ...Section 6 Schematics December2013 6 149 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models CE 6 150 ...

Page 358: ...C41RPM OR BK C5 2 RD BK ALARM C6 19 C8PBR BK WH C6 8 BRN GND BRN C7B 3 GR C2B 5 P23BAT WH C7B 2 P22BAT BK C6 22 BK RD CR4 WH ISM7 C32BRK WH RD C5 23 C27AUX RD C6 27 C129JDA BL C3B 10 C2PBD RD BK C3B 2 C32BRK WH RD C1B 6 BATTERY POWER 12V DC 59 59 RETRACT BOOM LED BL TS58 134 134 LOAD WEIGHING LIM SW 12V 1 RD H6 C59CNK BL BK C3B 11 C59CNK BL BK C6 11 BL BK L46 RD CB1 RD CB2 P20BAT RD P20BAT RD 12 V...

Page 359: ... PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D P1 NC NC 1A 1B 2A 2B D2 KS1 B1 B 1 2 4 3 G6 D64 3 2 1 TS52 TS...

Page 360: ...December2013 Section 6 Schematics 6 152 Ground Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models CE 6 151 ...

Page 361: ...Section 6 Schematics December2013 6 153 Platform Control Box Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models CE 6 154 ...

Page 362: ...46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH LS18 JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P134PWR RD H1 RD E STOP BRN JC3 BRN GND C19JSV GR WH C4P 7 C19JSV GR WH TS7 C129JD...

Page 363: ...TS6 GLOW PLUG TOGGLE SWITCH ES0193U BK NOTE DASHED LINES INDICATE OPTIONS WH CR30 30 RELAY BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65 OPTION JIB VALVE ...

Page 364: ...December2013 Section 6 Schematics 6 156 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models CE 6 155 ...

Page 365: ...Section 6 Schematics December2013 6 157 Electrical Schematic S 60 HC CE 6 158 ...

Page 366: ...TEND RETRACT F C BOOM UP DWN FC 1 1 2 2 3 3 P2 EMERGENCY STOP L4 PLATFORM OVERLOAD C3P 12 C183RCV BL V183RCV BL TB8C TB9C D47 D46 C8PBR BK WH C9PER BK RD TB3C D48 D49 C2PBD RD BK C3PUD RD WH COM PORT B COM PORT A D81CAN GR D82CAN YL C2PBD RD BK P63SEN OR RD C53 C27AUX RD C1P 1 6 3 87 87A 85 86 CR59 POWER ON 30 TB134C C4P 9 C134BAT RD C4B 9 C134BAT RD V183RCV BL C2PBD RD BK C9P 2 P24FS WH C145CAL R...

Page 367: ... C53 7 C133PLA GR BK C40 10 STRING POTENTIONMETER BOOM ANGLE SENSOR C173PEL BK Y15 C172PL BL Y12 C134BAT RD 9 2 C183RCV BL C42 1 12 C145CAL RD WH C41 11 C53 GRAY C166PSL OR C44 3 C141PBS RD C114 3 C94LDS WH C46 1 C51 3 R134BAT RD C55 1 GND BR C41 1 P63SEN OR RD C114 1 C44 1 S170ENL WH RD C40 3 S171ENL WH BK C40 4 R134BAT RD C42 11 C55 1 R134BAT RD C41 2 C42 12 P110RET BK C114 2 C44 2 D81CAN GR D82...

Page 368: ...December2013 Section 6 Schematics 6 160 Chassis Wiring Diagram S 60 HC CE 6 159 ...

Page 369: ...Section 6 Schematics December2013 6 161 Ground Control Box Terminal Strip Wiring Diagram S 60 HC CE from SN 21001 to 21287 6 162 ...

Page 370: ...M LED 59 59 13 DRIVE ENABLE 13 TILT ALARM 28 28 OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH 18 19 1 18 22 3 23 23 KEYSWITCH POWER ALTERNATOR PULS PICKUP BRAKE C5 ENGINE HARNESS GROUND BOLT SERVICE HORN UNUSED 12 24 Volt IGNITON START MODULE P N 56057 2 9 10 7 4 3 1 TEMP OR PRESS FAULT IGN OR FUEL ON JUMP TO 7 GAS ONLY TO KEY SW DIESEL ONLY BATTERY GROUND AUX PWR UNIT START INPUT TACHOMETER START RE...

Page 371: ...SERVICE HORN UNUSED 12 24 Volt IGNITON START MODULE P N 56057 2 9 10 7 4 3 1 TEMP OR PRESS FAULT IGN OR FUEL ON JUMP TO 7 GAS ONLY TO KEY SW DIESEL ONLY BATTERY GROUND AUX PWR UNIT START INPUT TACHOMETER START RELAY 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 44 46 35 34 37 36 41 39 22 25 27 33 32 26 22 17 18 21 19 15 14 9 8 7 6 5 3 2 1 TERMINAL BASE TB A B 44 46 JIB DOWN DESCENT ALARM 34 36 35 39 3...

Page 372: ...December2013 Section 6 Schematics 6 164 Ground Control Box Terminal Strip Wiring Diagram S 60 HC CE after SN 21287 6 163 ...

Page 373: ...Section 6 Schematics December2013 6 165 Platform Control Box Wiring Diagram S 60 HC CE 6 166 ...

Page 374: ...R OPTION TS48 OPTION TS14 DRIVE SPEED TS1 AUXILIARY POWER TS9 PLATFORM LEVEL L48 TILT ALARM P2 ENERGENCY STOP ES0390J L4 PLATFORM OVERLOAD C134BAT RD P2 TS1 2 TS6 GLOW PLUG OPTION L50 OUT OF ENVELOPE P23BAT WH C7 2 NC NC C134BAT RD H1 C4P 9 C134PWR BK RD C4P 12 C134BAT RD L4 C134PWR RD L48 C169ENV GR C4P 11 C27AUX RD C1P 1 C183RCV BL C4P 10 C134BAT RD L4 C134PWR RD P2 C28TTA RD BK H1 1 6 1 6 TS7 P...

Page 375: ...Section 6 Schematics December2013 6 167 Electrical Schematic S 60 S 65 Ford Engine Models AS from SN 21001 to 21629 6 168 ...

Page 376: ...TP BK C46HRN GR C2P 5 P23BAT WH C7P 2 C28TTA RD BK C27AUX RD C1P 1 C33STR BK C1P 7 C39LP BL RD C2P 1 BRN RD RD P22LS BK C41RPM OR BK P26ESTP BK P24FS WH TS4 ENGINE RPM TS54 ENGINE RPM C35RPM RD BK C1P 9 H1 H2 WH P2 BK BRN WH RD P22HRN BK 12V DC TS3 FUEL SELECT FS1 RD TS53 FUEL SELECT C21ING WH P134FB WH TB33 TS52 ENGINE START TS1 AUXILIARY PUMP TB27 TS51 C28TTA RD BK C27AUX RD PR1 NO TS2 ENGINE ST...

Page 377: ...ROKE C29MS RD WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP ...

Page 378: ...December2013 Section 6 Schematics 6 170 Electrical Schematic S 60 S 65 Ford Engine Models AS from SN 21001 to 21629 6 169 ...

Page 379: ...Section 6 Schematics December2013 6 171 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 Ford Engine Models AS from SN 21001 to 21629 6 172 ...

Page 380: ...C2PBD RD BK C6 2 C1PBU RD C6 1 C1PBU RD C3B 1 C3PBF RD WH C3B 3 C2PBD RD BK C3B 2 1 A B 2 C9PER BK RD C6 9 C3PBF RD WH C6 3 C5TRR WH BK C6 5 C6TRF WH RD C6 6 C9PER BK RD C3B 9 C7PBE BK C3B 7 C7PBE RD C6 7 C8PBR BK WH C3B 8 C4TRL WH C3B 4 C4TRL WH C6 4 C5TRR WH BK C3B 5 C6TRF WH RD C3B 6 C8PBR BK WH C6 8 3 4 5 7 6 8 C5 8 GR BRN TS64 ENGINE FAULT TOGGLE SWITCH D30 RD BK ALARM C6 19 C18JD GR BK C6 18...

Page 381: ... UP DOWN TOGGLE SWITCH S 65 OPTION TS51 TS52 TS53 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD C134D 2 P1 NC N...

Page 382: ...December2013 Section 6 Schematics 6 174 Ground Control Box Switch Panel Wiring Diagram S 60 S 65 Ford Engine Models AS from SN 21001 to 21629 6 173 ...

Page 383: ...Section 6 Schematics December2013 6 175 Platform Control Box Wiring Diagram S 60 S 65 Ford Engine Models AS from SN 21001 to 21629 6 176 ...

Page 384: ...RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH OPT JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P134PWR RD H1 RD E ...

Page 385: ...GR BK C4P 6 BL BK C3P 11 1 1 ROCKER STEER OPTION WH RD RELAY BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH CIRCUIT LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65 OPTION JIB VALVE RELAY ...

Page 386: ...December2013 Section 6 Schematics 6 178 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 Ford Engine Models AS from SN 21001 to 21629 6 177 ...

Page 387: ...Section 6 Schematics December2013 6 179 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz D2011L03i Models AS from SN 21001 to 21629 6 180 ...

Page 388: ...P22BAT BK TILT ALARM NO CR15 TS6 GLOW PLUG C34SA BK WH TS56 GLOW PLUG TB34 OIL TEMPERATURE SWITCH SW3 NO SW2 NC L2 C26TS WH RD FUEL SOLENOID EXCT BAT STA BAT IND REGULATOR C9P 2 12V DC P26ESTP BK P24FS WH P22LS BK RD AUX FE BRN TS4 ENGINE RPM TS54 ENGINE RPM FS1 RD C9P 3 P24FS WH C33STR BK FB1 C21IGN WH P134FB WH 3 TB33 2 1 BK TS52 ENGINE START TS1 AUXILIARY PUMP RD TB27 C28TTA RD BK TS51 CR2 9 10...

Page 389: ... WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTA...

Page 390: ...December2013 Section 6 Schematics 6 182 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz D2011L03i Models AS from SN 21001 to 21629 6 181 ...

Page 391: ...Section 6 Schematics December2013 6 183 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz TD2011L04i Models AS from SN 21001 to 21629 6 184 ...

Page 392: ...10 C5 11 C5 14 C5 22 C1B 7 PUMP AUXILIARY ENGINE START START ENGINE ON G PLUG C1B 8 ON GLO PLUG SPEED ENGINE C41RPM OR BK P134 RD P134 RD C41RPM OR BK C1P 9 C1P 8 C1P 7 C7P 1 C27AUX RD C1P 1 C1P 2 C7P 2 P26ESTP BK P25FS RD C41RPM OR BK _ HM HM H2 C2P 5 BK BRN WH RD H1 WH FS P22BAT BK TILT ALARM HIGH IDLE RELAY HIGH RPM SOLENOID OPTION NO PR2 PR2 TS6 TS56 TB34 SWITCH SWITCH OIL TEMPERATURE OIL PRES...

Page 393: ...D WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROT...

Page 394: ...December2013 Section 6 Schematics 6 186 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz TD2011L04i Models AS from SN 21001 to 21629 6 185 ...

Page 395: ...Section 6 Schematics December2013 6 187 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models AS from SN 21001 to 21629 6 188 ...

Page 396: ... 16 C26TS WH RD C5 14 C35RPM BK RD C1B 9 C41RPM OR BK C2B 3 C34SA BK WH C1B 8 WH ISM10 C34SA BK WH C5 22 C41RPM OR BK C5 2 RD BK ALARM C6 19 C8PBR BK WH C6 8 BRN GND BRN C7B 3 GR C2B 5 P23BAT WH C7B 2 P22BAT BK C6 22 BK RD CR4 WH ISM7 C32BRK WH RD C5 23 C27AUX RD C6 27 C129JDA BL C3B 10 C2PBD RD BK C3B 2 C32BRK WH RD C1B 6 BATTERY POWER 12V DC 59 59 RETRACT BOOM LED BL TS58 134 134 LOAD WEIGHING L...

Page 397: ...GGLE SWITCH S 65 OPTION TS51 TS52 TS54 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D P1 NC NC 1A 1...

Page 398: ...December2013 Section 6 Schematics 6 190 Ground Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models AS from SN 21001 to 21629 6 189 ...

Page 399: ...Section 6 Schematics December2013 6 191 Platform Control Box Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models AS from SN 21001 to 21629 6 192 ...

Page 400: ...1 C4TRL WH C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH OPT JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITC...

Page 401: ...RD WH J1 2 JC7 GR BK C4P 6 BL BK C3P 11 1 1 ROCKER STEER OPTION WH RD RELAY BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH CIRCUIT LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65 OPTION J...

Page 402: ...December2013 Section 6 Schematics 6 194 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models AS from SN 21001 to 21629 6 193 ...

Page 403: ...Section 6 Schematics December2013 6 195 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS from SN 21001 to 21629 6 196 ...

Page 404: ...H1 WH P22BAT BK TILT ALARM NO CR15 TS6 GLOW PLUG C34SA BK WH TS56 GLOW PLUG TB34 WATER TEMPERATURE SWITCH SW3 NO SW2 NC L2 C26TS WH RD FUEL SOLENOID EXCT BAT STA BAT IND REGULATOR C9P 2 12V DC P26ESTP BK P24FS WH P22LS BK RD AUX FE BRN TS4 ENGINE RPM TS54 ENGINE RPM FS1 RD C9P 3 P24FS WH C33STR BK FB1 C21IGN WH P134FB WH 3 TB33 2 1 BK TS52 ENGINE START TS1 AUXILIARY PUMP RD TB27 C28TTA RD BK TS51 ...

Page 405: ... SPEED MOTOR STROKE C29MS RD WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLA...

Page 406: ...December2013 Section 6 Schematics 6 198 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS from SN 21001 to 21629 6 197 ...

Page 407: ...Section 6 Schematics December2013 6 199 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS from SN 21001 to 21629 6 200 ...

Page 408: ...14 C35RPM BK RD C1B 9 C41RPM OR BK C2B 3 C34SA BK WH C1B 8 WH ISM10 C34SA BK WH C5 22 C41RPM OR BK C5 2 RD BK ALARM C6 19 C8PBR BK WH C6 8 BRN GND BRN C7B 3 GR C2B 5 P23BAT WH C7B 2 P22BAT BK C6 22 BK RD CR4 WH ISM7 C32BRK WH RD C5 23 C27AUX RD C6 27 C129JDA BL C3B 10 C2PBD RD BK C3B 2 C32BRK WH RD C1B 6 BATTERY POWER 12V DC 59 59 RETRACT BOOM LED BL TS58 134 134 LOAD WEIGHING LIM SW 12V 1 C59CNK ...

Page 409: ...S 65 OPTION TS51 TS52 TS54 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D P1 NC NC 1A 1B 2A 2B D2 K...

Page 410: ...December2013 Section 6 Schematics 6 202 Ground Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS from SN 21001 to 21629 6 201 ...

Page 411: ...Section 6 Schematics December2013 6 203 Platform Control Box Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS from SN 21001 to 21629 6 204 ...

Page 412: ...C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH OPT JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P13...

Page 413: ... JC7 GR BK C4P 6 BL BK C3P 11 1 1 ROCKER STEER OPTION WH RD RELAY BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH CIRCUIT LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65 OPTION JIB VALVE R...

Page 414: ...December2013 Section 6 Schematics 6 206 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS from SN 21001 to 21629 6 205 ...

Page 415: ...Section 6 Schematics December2013 6 207 Electrical Schematic S 60 S 65 Ford Engine Models AS from SN 21630 to 22516 6 208 ...

Page 416: ... BRN RD RD P22LS BK C41RPM OR BK P26ESTP BK P24FS WH TS4 ENGINE RPM TS54 ENGINE RPM C35RPM RD BK C1P 9 H1 H2 WH P2 BK BRN WH RD P22HRN BK 12V DC TS3 FUEL SELECT FS1 RD TS53 FUEL SELECT C21ING WH P134FB WH TB33 TS52 ENGINE START TS1 AUXILIARY PUMP TB27 TS51 C28TTA RD BK C27AUX RD PR1 NO TS2 ENGINE START TB35 HOUR METER P22BAT BK TB22 BK P3 P1 GND PLAT TB23 TB41 CB2 15A RD CB3 15A C46HRN GR CR5 NO R...

Page 417: ...TROKE C29MS RD WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP...

Page 418: ...December2013 Section 6 Schematics 6 210 Electrical Schematic S 60 S 65 Ford Engine Models AS from SN 21630 to 22516 6 209 ...

Page 419: ...Section 6 Schematics December2013 6 211 Electrical Schematic S 60 S 65 Ford Engine Models AS after SN 22516 6 212 ...

Page 420: ...NGINE RPM C35RPM RD BK C1P 9 H1 H2 WH P2 BK BRN WH RD P22HRN BK 12V DC TS3 FUEL SELECT FS1 RD TS53 FUEL SELECT C21ING WH P134FB WH TB33 TS52 ENGINE START AUXILIARY PUMP TB27 TS51 C28TTA RD BK C27AUX RD PR1 NO TS2 ENGINE START TB35 HOUR METER P22BAT BK TB22 BK P3 P1 GND PLAT TB23 TB41 CB2 15A RD CB3 15A C46HRN GR CR5 NO R46HRN BK ALTERNATOR BAT BAT TB20 P20BAT RD RD REGULATOR FLD S I A STA P134TTS ...

Page 421: ...E C29MS RD WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLA...

Page 422: ...December2013 Section 6 Schematics 6 214 Electrical Schematic S 60 S 65 Ford Engine Models AS after SN 22516 6 213 ...

Page 423: ...Section 6 Schematics December2013 6 215 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 Ford Engine Models AS from SN 21630 to 22516 6 216 ...

Page 424: ...PBD RD BK C3B 2 1 A B 2 C9PER BK RD C6 9 C3PBF RD WH C6 3 C5TRR WH BK C6 5 C6TRF WH RD C6 6 C9PER BK RD C3B 9 C7PBE BK C3B 7 C7PBE RD C6 7 C8PBR BK WH C3B 8 C4TRL WH C3B 4 C4TRL WH C6 4 C5TRR WH BK C3B 5 C6TRF WH RD C3B 6 C8PBR BK WH C6 8 3 4 5 7 6 8 C5 8 GR BRN TS64 ENGINE FAULT TOGGLE SWITCH D30 RD BK ALARM C6 19 C18JD GR BK C6 18 C17JU GR C6 17 C15PLD OR BK C6 15 C14PLU OR C6 14 C18JD GR BK C4B...

Page 425: ...1 A B 2 C9PER BK RD C6 9 C3PBF RD WH C6 3 C5TRR WH BK C6 5 C6TRF WH RD C6 6 C9PER BK RD C3B 9 C7PBE BK C3B 7 C7PBE RD C6 7 C8PBR BK WH C3B 8 C4TRL WH C3B 4 C4TRL WH C6 4 C5TRR WH BK C3B 5 C6TRF WH RD C3B 6 C8PBR BK WH C6 8 3 4 5 7 6 8 C5 8 GR BRN TS64 ENGINE FAULT TOGGLE SWITCH D30 RD BK ALARM C6 19 C18JD GR BK C6 18 C17JU GR C6 17 C15PLD OR BK C6 15 C14PLU OR C6 14 C18JD GR BK C4B 6 C17JU GR C4B ...

Page 426: ...December2013 Section 6 Schematics 6 218 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 Ford Engine Models AS after SN 22516 6 217 ...

Page 427: ...Section 6 Schematics December2013 6 219 Ground Control Box Switch Panel Wiring Diagram S 60 S 65 Ford Engine Models AS after SN 21629 6 220 ...

Page 428: ...53 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D 2 P1 NC NC 1A 1B 2A 2B D2 KS1 B1 B 1 2 4 3 G6 D11...

Page 429: ...S OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH LS18 JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P134PWR RD H1 RD E STOP BRN JC3 BRN GND C19JSV GR WH C4P 7 C19JSV GR WH TS7 C129JDA BL C3P 10 TS8 P23...

Page 430: ...December2013 Section 6 Schematics 6 222 Platform Control Box Wiring Diagram S 60 S 65 Ford Engine Models AS after SN 21629 6 221 ...

Page 431: ...Section 6 Schematics December2013 6 223 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 Ford Engine Models AS after SN 21629 6 224 ...

Page 432: ...DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM COMPONENT INDEX C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65 OPTION JIB VALVE RELAY S 65 OPTION LED CABLE TENSION L47 P2 EMERGENCY STOP BUTTON HORN BUTTON P3 TS1 R20 RESISTOR 4700W AUXILIARY PUM...

Page 433: ...Section 6 Schematics December2013 6 225 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz D2011L03i Models AS after SN 21629 6 226 ...

Page 434: ...SW3 NO SW2 NC L2 C26TS WH RD FUEL SOLENOID EXCT BAT STA BAT IND REGULATOR C9P 2 12V DC P26ESTP BK P24FS WH P22LS BK RD AUX FE BRN TS4 ENGINE RPM TS54 ENGINE RPM FS1 RD C9P 3 P24FS WH C33STR BK FB1 C21IGN WH P134FB WH 3 TB33 2 1 BK TS52 ENGINE START RD TB27 C28TTA RD BK TS51 CR2 9 10 5 6 7 8 NO TB21 R33STR BK CR1 NO C28TTA RD BK NO PR1 4 START RELAY START INPUT KEY BYPASS ENGINE FAULT IGN FUEL ON T...

Page 435: ...BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE L...

Page 436: ...December2013 Section 6 Schematics 6 228 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz D2011L03i Models AS after SN 21629 6 227 ...

Page 437: ...Section 6 Schematics December2013 6 229 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX DeutzTD2011L04i Models AS after SN 21629 6 230 ...

Page 438: ...116 OR TB24 C1B 1 C27AUX RD B A C C7B 1 M2 M3 M3 PR2 NO S8 U1 C3 3MF B1 C1B 2 C7B 2 C5 3 C5 2 C2B 5 C5 5 C21IGN2 WH R46HRN BK C6 10 C5 11 C5 14 PUMP AUXILIARY ENGINE SPEED C41RPM OR BK P134 RD P134 RD C41RPM OR BK P25FS RD P26ESTP BK C7P 2 C1P 2 C1P 1 C27AUX RD C7P 1 C1P 9 _ C41RPM OR BK G6 C2P 5 H2 BRN BK WH FS H1 RD WH TILT ALARM P22BAT BK HIGH RPM SOLENOID HIGH IDLE RELAY OPTION SW2 NC SW3 NO O...

Page 439: ... BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFORM ROTATE ...

Page 440: ...December2013 Section 6 Schematics 6 232 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Deutz TD2011L04i Models AS after SN 21629 6 231 ...

Page 441: ...Section 6 Schematics December2013 6 233 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models AS after SN 21629 6 234 ...

Page 442: ...C34SA BK WH C5 22 C41RPM OR BK C5 2 RD BK ALARM C6 19 C8PBR BK WH C6 8 BRN GND BRN C7B 3 GR C2B 5 P23BAT WH C7B 2 P22BAT BK C6 22 BK RD CR4 WH ISM7 C32BRK WH RD C5 23 C27AUX RD C6 27 C129JDA BL C3B 10 C2PBD RD BK C3B 2 C32BRK WH RD C1B 6 BATTERY POWER 12V DC 59 59 RETRACT BOOM LED BL TS58 134 134 LOAD WEIGHING LIM SW 12V 1 RD H6 C59CNK BL BK C3B 11 C59CNK BL BK C6 11 BL BK L46 RD CB1 RD CB2 P20BAT...

Page 443: ...TS52 TS54 AUXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D P1 NC NC 1A 1B 2A 2B D2 KS1 B1 B 1 2 4 3 G...

Page 444: ...December2013 Section 6 Schematics 6 236 Ground Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models AS after SN 21629 6 235 ...

Page 445: ...Section 6 Schematics December2013 6 237 Platform Control Box Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models AS after SN 21629 6 238 ...

Page 446: ...1P 3 C1P C2P 1 J1 9 J2 C46HRN GR C2P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH LS18 JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P134PWR RD H1 RD E STOP BRN JC3 BRN GND C19JSV GR WH C4P 7...

Page 447: ...BK NOTE DASHED LINES INDICATE OPTIONS WH CR30 30 NC BL RD P22BAT C2 1 BK P22BAT C171LS WH RD TS6 GLOW PLUG TOGGLE SWITCH RELAY BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB...

Page 448: ...December2013 Section 6 Schematics 6 240 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Deutz Engine Models AS after SN 21629 6 239 ...

Page 449: ...Section 6 Schematics December2013 6 241 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS after SN 21629 6 242 ...

Page 450: ...W2 NC L2 C26TS WH RD FUEL SOLENOID EXCT BAT STA BAT IND REGULATOR C9P 2 12V DC P26ESTP BK P24FS WH P22LS BK RD AUX FE BRN TS4 ENGINE RPM TS54 ENGINE RPM FS1 RD C9P 3 P24FS WH C33STR BK FB1 C21IGN WH P134FB WH 3 TB33 2 1 BK TS52 ENGINE START RD TB27 C28TTA RD BK TS51 CR2 9 10 5 6 7 8 NO TB21 R33STR BK CR1 NO C28TTA RD BK NO PR1 4 START RELAY START INPUT KEY BYPASS ENGINE FAULT IGN FUEL ON TACHOMETE...

Page 451: ...29MS RD WH BRAKE RELEASE C8PBR BK WH C7PBE BK TB5 TS63 C5TRR WH BK C6TRF WH RD PRIMARY BOOM EXTEND TB1 TS62 TB3 C1PBU RD C2PBD RD BK TS61 TB2 TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM UP DOWN FLOW CONTROL PRIMARY BOOM DOWN TB7 C3PBF RD WH C9PER BK RD C14PLU OR TB8 TB9 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TB15 TB14 TS59 TS9 TB18 TB17 PLATFORM LEVEL DOWN PLATFORM LEVEL UP PLATFO...

Page 452: ...December2013 Section 6 Schematics 6 244 Electrical Schematic S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS after SN 21629 6 243 ...

Page 453: ...Section 6 Schematics December2013 6 245 Ground Control Box Terminal Strip Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS after SN 21629 6 246 ...

Page 454: ... C5 22 C41RPM OR BK C5 2 RD BK ALARM C6 19 C8PBR BK WH C6 8 BRN GND BRN C7B 3 GR C2B 5 P23BAT WH C7B 2 P22BAT BK C6 22 BK RD CR4 WH ISM7 C32BRK WH RD C5 23 C27AUX RD C6 27 C129JDA BL C3B 10 C2PBD RD BK C3B 2 C32BRK WH RD C1B 6 BATTERY POWER 12V DC 59 59 RETRACT BOOM LED BL TS58 134 134 LOAD WEIGHING LIM SW 12V 1 RD H6 C59CNK BL BK C3B 11 C59CNK BL BK C6 11 BL BK L46 RD CB1 RD CB2 P20BAT RD P20BAT ...

Page 455: ...UXILIARY PUMP TOGGLE SWITCH ENGINE START TOGGLE SWITCH HIGH IDLE RELAY HORN RELAY IGNITION FUEL RELAY START RELAY HYDRAULIC OIL COOLER RELAY OPTION TURNTABLE SPEED REDUCTION RELAY PRIMARY BOOM SPEED REDUCTION RELAY P1 EMERGENCY STOP BUTTON P4 R2 R4 RD WH CR34 87 RD TS61 2 WH RD CR19 87 WH RD CR19 87A NO 3 4 RD WH TS61 3 RD CB2 1 RD L45 RD C134D P1 NC NC 1A 1B 2A 2B D2 KS1 B1 B 1 2 4 3 G6 D64 3 2 1...

Page 456: ...December2013 Section 6 Schematics 6 248 Ground Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS after SN 21629 6 247 ...

Page 457: ...Section 6 Schematics December2013 6 249 Platform Control Box Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS after SN 21629 6 250 ...

Page 458: ...P 5 C42LS OR RD C2P 4 C45GEN GR WH C2P 7 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C13DE BL RD C4P 1 C7PBE BK C3P 7 C40LS OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 J3 1 11 1 P24FS WH BRN P24FS WH LS18 JIB S 65 OPT OPT CONTROL HARNESS TO PLATFORM SWITCH PANEL P134PWR RD H1 RD E STOP BRN JC3 BRN GND C19JSV GR WH C4P 7 C19JSV GR WH TS7 C129JDA BL C3P 10...

Page 459: ...0193U BK NOTE DASHED LINES INDICATE OPTIONS WH CR30 30 NC BL RD P22BAT C2 1 BK P22BAT RELAY BRAKE CIRCUIT LIFT DRIVE OPTION JOYSTICK DRIVE STEER JOYSTICK PRIMARY BOOM UP DOWN EXTEND RETRACT TURNTABLE ROTATE TILT ALARM RELAY LIMIT SWITCH LIFT DRIVE OPTION LED DRIVE ENABLE LED TILT ALARM C1 CR13 CR14 CR27 CR30 H1 JC3 JC7 L1 L48 CAPACITOR JIB CIRCUIT S 65 OPTION JIB SELECT RELAY S 65 OPTION JIB VALVE...

Page 460: ...December2013 Section 6 Schematics 6 252 Platform Control Box Switch Panel Wiring Diagram S 60 S 65 S60 TRAX S65 TRAX Perkins Engine Models AS after SN 21629 6 251 ...

Page 461: ......

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