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Terex Genie Lift Guard S-60, Service Manual

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Terex Genie Lift Guard S-60 Service Manual Download Page 114

Service Manual

 

February 2015

 

Platform Controls 

 

 

92 

S-

60 • S

-

65 • S

-60 TRAX 

• S

-

65 TRAX • S

-

60 HC • S

-

60X • S

-60XC  Part No. 825591 

 

 

How t o Adj ust  t he Joystick  Max- out Set ting 

How to Adjust the Joystick 

Max-out Setting 

The max-out setting of a joystick controls the 
maximum speed of a joystick-controlled machine 
function. Whenever a hydraulic cylinder, drive 
motor or hydraulic pump is replaced, the max-out 
setting should be adjusted to maintain optimum 
performance. The max-out settings on the joystick 
can be changed to compensate for hydraulic pump 
wear to maintain peak performance from the 
machine. 

Note: Perform this procedure with the boom in the 
stowed position. 

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 the engine. 

3 

Push in the platform controls red Emergency 
Stop button to the off position. 

4 

Do not press down the foot switch. 

5 

Move and hold the drive enable toggle switch 
in the right position and pull out the red 
Emergency Stop button to the on position. 

6 

When the alarm sounds, release the drive 
enable toggle switch. 

7 

Momentarily activate the drive enable toggle 
switch in the right direction 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. 

9 

Start a timer and activate the machine 
function that needs to be adjusted. Record the 
time it takes for that function to complete a full 
cycle (ie; boom up). 

10  Compare the machine function time with the 

function times listed in Refer to Specifications,

 

Performance Specifications

. Determine 

whether the function time needs to increase or 
decrease. 

11  While the joystick is activated, adjust the 

max-out setting to achieve the proper function 
cycle time. Momentarily move the drive 
enable toggle switch in the right direction to 
increase the function speed or momentarily 
move the drive enable toggle switch in the left 
direction to decrease the function speed. 

Note: Each time the drive enable toggle switch is 
momentarily moved, the function speed will 
change in 2% increments from a default of 100%, 
with a minimum of 60% and a maximum of 120%. 

12  Repeat steps 9 through 11 for each joystick 

controlled machine function. 

13  Return the joystick to the neutral position and 

wait for approximately 10 seconds to allow the 
settings to be saved. 

 

Result: The alarm should sound indicating 
that the settings have been saved in memory. 

Note: Do not operate any machine function during 
the 10 second waiting time. 

Summary of Contents for Genie Lift Guard S-60

Page 1: ...mber Range S 60 from S6013 26296 S 65 from S6013 26296 S 60X from S60X13 26296 S 60XC from S60XC13 26296 S 60 HC from S60HC13 26296 S 60 TraX from S60TX13 26296 S 65 TraX from S65TX13 26296 Part No 825591 Rev A1 February 2015 ...

Page 2: ...ice center Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without n...

Page 3: ...rocedure Page Description A 12 2013 New Release A1 2 2015 Maintenance Added B 22 Test the Emergency Power System Reference Examples Section Maintenance B 3 Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...91 Revision History Revision Date Section Procedure Page Description Reference Examples Section Maintenance B 3 Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 5: ...2015 Service Manual Introduction Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC v Serial Number Legend 1 Model 2 Model year 3 Sequence number 4 Serial number stamped on chassis 5 Serial label ...

Page 6: ...t in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable g...

Page 7: ... of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco...

Page 8: ...on 2 Specifications 1 Machine Specifications 1 Performance Specifications 2 Hydraulic Specification 3 Hydraulic Component Specifications 5 Ford MSG 425 EFI Engine Specifications 7 Deutz D2011 L03i Engine Specifications 8 Deutz TD2011L04i Engine Specifications 10 Deutz D 2 9 L4 Engine Specifications 12 Perkins 404D 22 Engine Specifications 14 Perkins 404F 22 Engine Specifications 15 Machine Torque ...

Page 9: ...rm Engine Maintenance Perkins Models 30 A 7 Check the High Pressure Hydraulic Filter Condition Indicator 30 A 8 Test the Oscillate Axle 31 A 9 Inspect the Track Components S 60 TRAX and S 65 TRAX 31 A 10 Perform 30 Day Service 32 A 11 Check the Track Tension and Fastener Torque S 60 TRAX and S 65 TRAX 32 A 12 Perform Engine Maintenance Ford Models 34 A 13 Perform Engine Maintenance Ford Models 34 ...

Page 10: ...er Torque 45 B 9 Check and Adjust the Engine RPM Deutz D2011 L03i and TD2011L04i 47 B 10 Test the Ground Control Override 48 B 11 Check the Oscillate Directional Valve Linkage 49 B 12 Test the Platform Self leveling 49 B 13 Test the Engine Idle Select 50 B 14 Test the Fuel Select Operation Ford Models 51 B 15 Test the Drive Brakes 52 B 16 Test the Drive Speed Stowed Position 52 B 17 Test the Drive...

Page 11: ... 62 C 6 Test the Platform Load Sense System S 60 HC 64 C 7 Replace the Fuel Filter Water Separator Perkins Models 66 C 8 Check the Safety Envelope Limit Switches and Angle Sensor S 60X and S 60XC 68 C 9 Perform Engine Maintenance Ford Models 70 Checklist D Procedures 71 D 1 Check the Boom Wear Pads 71 D 2 Check the Turntable Rotation Bearing Bolts 72 D 3 Inspect for Turntable Bearing Wear 73 D 4 R...

Page 12: ...ce Perkins 404D 22 Models 85 E 9 Perform Engine Maintenance Perkins Models 86 E 10 Replace the Boom Extend and Retract Cables 86 Section 4 Repair Procedures 87 Introduction 87 Platform Controls 89 1 1 ALC 500 Circuit Board 89 1 2 Joysticks 90 How to Adjust the Joystick Threshold Setting 91 How to Adjust the Joystick Max out Setting 92 How to Adjust the Joystick Ramp Rate Setting 93 How to Calibrat...

Page 13: ...Cylinder 116 4 4 Boom Extension Cylinder 117 4 5 Boom Extend Retract Cables 120 4 6 Platform Leveling Master Cylinder 123 4 7 Primary Boom Angle Sensor S 60X and S 60XC 124 Engines 126 5 1 RPM Adjustment Ford and Deutz Models 126 5 2 RPM Adjustment Perkins 404D 22 Models 126 5 3 Flex Plate Removal 126 How to Install a Type A Flex Plate 128 How to Install a Type B Flex Plate 129 How to install the ...

Page 14: ...ate Directional Valve 149 7 7 Valve Adjustments Oscillate Relief Valve 150 7 8 Drive Oil Diverter Manifold Components welder option 151 7 9 Traction Manifold Components 2WD 152 7 10 Valve Adjustments 2WD Traction Manifold 153 7 11 Traction Manifold Components 4WD 154 7 12 Valve Adjustments 4WD Traction Manifold 156 7 13 Hydraulic Generator Manifold Components 3kW 157 7 14 Valve Coils 158 How to Te...

Page 15: ...nd Perkins 404F 22 Models 175 Fault Code Display Flashing and Solid LED s Deutz D 2 9 L4 and Perkins 404F 22 Models 176 Soft Key Functions and Icons Deutz D 2 9 L4 and Perkins 404F 22 Models 177 Main Menu Structure Deutz D 2 9 L4 Models 178 Main Menu Structure Perkins 404F 22 Models 179 Deutz D 2 9 L4 Engine Fault Codes 180 Perkins 404F 22 Engine Fault Codes 191 Ford MSG 425 Engine Fault Codes 193...

Page 16: ...arness 214 Deutz D 2 9 L4 Engine Wire Harness 215 Perkins 404F 22 Engine Wire Harness 218 Electrical Schematic Options Deutz D2011L03i TD2011L04i and Perkins 404D 22 219 Electrical Schematic Options Deutz D 2 9 L4 222 Electrical Schematic Options Perkins 404F 22 223 Wiring Diagram 3kW Hydraulic Generator 226 Wiring Diagram 12kW Hydraulic Generator Welder Option 227 Electrical Schematic 12kW Hydrau...

Page 17: ...trical Schematic Deutz TD2011L04i Models ANSI CSA 254 Ground Control Box Terminal Strip Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA 258 Ground Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA 259 Platform Control Box Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA 262 Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L0...

Page 18: ...x Terminal Strip Wiring Diagram Perkins 404F 22 Models ANSI CSA 294 Ground Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA 295 Platform Control Box Wiring Diagram Perkins 404F 22 Models ANSI CSA 298 Platform Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA 299 Electrical Schematic S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA 302 Ground Control Box Te...

Page 19: ...323 Platform Control Box Wiring Diagram S 60X S 60XC Deutz D2011L03i TD2011L04i Models ANSI CSA 326 Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Deutz D2011L03i TD2011L04i Models ANSI CSA 327 Electrical Schematic S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA 330 Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA 334 Ground Control Box Switch...

Page 20: ...gram S 60X S 60XC Perkins 404D 22 Models ANSI CSA 350 Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Perkins 404D 22 Models ANSI CSA 351 Electrical Schematic S 60X S 60XC Perkins 404F 22 Models ANSI CSA 354 Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Perkins 404F 22 Models ANSI CSA 358 Ground Control Box Switch Panel Wiring Diagram S 60X S 60XC Perkins 404F 22 Mode...

Page 21: ...Electrical Schematic Deutz TD2011L04i Models CE 382 Ground Control Box Terminal Strip Wiring Diagram Deutz D2011L03i TD2011L04i Models CE 386 Ground Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models CE 387 Platform Control Box Wiring Diagram Deutz D2011L03i TD2011L04i Models CE 390 Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models CE 391 Ele...

Page 22: ...ring Diagram Ford MSG 425 EFI Models AS 423 Electrical Schematic Deutz D2011L03i Models AS 426 Electrical Schematic Deutz TD2011L04i Models AS 430 Ground Control Box Terminal Strip Wiring Diagram Deutz D2011L03i TD2011L04i Models AS 434 Ground Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models AS 435 Platform Control Box Wiring Diagram Deutz D2011L03i TD2011L04i Models AS 43...

Page 23: ...rrain low profile tires 70 psi 4 92 bar Tire pressure Hi flotation tires 60 psi 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 Deutz and Perkins Models 35 gallons 132 5 liters Ford models 30 gallons 113 5 liters LPG tank 33 5 pounds 15 2 kg Hydraulic tank 45 gallons 170 liters Hydr...

Page 24: ...tended 125 to 165 seconds Platform rotate 160 8 to 12 seconds Braking distance maximum High range on paved surface 3 to 6 ft 0 9 to 1 8 m Drive speed maximum stowed position 2WD models 40 ft 6 2 sec 12 2 m 6 2 sec 4WD models 40 ft 7 2 sec 12 2 m 7 2 sec S 60 TRAX and S 65 TRAX 40 ft 12 sec 12 2 m 12 sec Drive speed maximum raised or extended position S 60 S 65 S 60 HC S 60X and S 60XC 40 ft 40 sec...

Page 25: ...e HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the hy...

Page 26: ...0 F 82 C Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro...

Page 27: ...ow rate 2500 rpm 15 3 gpm 58 L min Displacement Pump 2 outer oscillate models 0 24 cu in 4 cc Flow rate 2500 rpm 2 gpm 7 6 L min Auxiliary pump Type gear fixed displacement Displacement 1 75 gpm 2 8 L min Function manifold System relief valve pressure 3000 psi 207 bar Steer flow regulator 3 5 gpm 13 2 L min Jib boom platform rotate flow regulator 0 6 gpm 2 27 L min Oscillate relief valve pressure ...

Page 28: ...Medium pressure filter bypass pressure 51 psi 3 5 bar Hydraulic return filter 10 micron with 25 psi 1 7 bar bypass Manifold Component Specifications Plug torque SAE No 2 36 in lbs 4 Nm SAE No 4 10 ft lbs 13 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft lbs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft lbs 76 Nm Continuous improvement of our products is a Genie policy Product specifications are subj...

Page 29: ...atures 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 Manual for your engine Ignition system Spark plug type Motorcraft AYFS 32Y R Spark plug gap 0 049 to 0 053 inche...

Page 30: ...e cold Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure 40 to 60 psi 1 4 to 3 bar Oil capacity including filter 9 5 quarts 9 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requir...

Page 31: ...For fuel requirements refer to the engine Operator Manual for your engine 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 Group 34 78 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 Continuous improvement ...

Page 32: ...ld Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure hot at 2000 rpm 40 to 60 psi 2 8 to 4 1 bar Oil capacity including filter 12 8 quarts 12 1 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine ...

Page 33: ...ent 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 Alternator output 80A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Continuous improvement...

Page 34: ... requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Temperature switch point 257 F 125 C Oil Pressure switch Oil pressure switch point 20 psi 1 4...

Page 35: ...d 250A to 400A Brush length new 0 72 in 18 5 mm Brush length minimum 0 27 in 7 mm Battery Type 12V DC Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Alternator output 95A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation ...

Page 36: ... F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil pressure sending unit Oil pressure switch point 14 2 psi 1 bar Fuel injection system Injection pump make Zexel Injection pressure 2133 psi 147 bar Fuel ...

Page 37: ...ar Oil capacity including filter 9 4 11 2 quarts 8 9 10 6 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 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil pressure sending unit Oil pressure switch point 14 2...

Page 38: ...inued Battery Type 12V DC Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Engine coolant Capacity 7 7 quarts 7 3 liters Coolant temperature switch Temperature switch point 221 F 105 C Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation ...

Page 39: ...ssembly Backlash pivot plate lubricated 320 ft lbs 433 Nm TRAX Torque Specifications Sprocket to hub adapter fasteners 3 4 10 nuts GR 8 dry 317 ft lbs 430 Nm 3 4 10 nuts GR 8 lubricated 281 ft lbs 381 Nm 1 2 13 FHS screws dry 80 ft lbs 108 Nm 1 2 13 FHS screws lubricated 60 ft lbs 81 Nm Hub adapter to drive hub fasteners Lug nut torque dry 240 ft lbs 325 Nm Lug nut torque lubricated 180 ft lbs 244...

Page 40: ... Thread Size Flats 4 7 16 20 2 6 9 16 18 1 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 SAE O ring Boss Port 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 Adjustable Fitting No...

Page 41: ...ring face seal is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align...

Page 42: ...ne the correct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the...

Page 43: ...nd scheduled may cause death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Machine Configuration Unless other...

Page 44: ...messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially h...

Page 45: ...n Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into subsections Use the following chart to determine which group s of procedures are required to perform a s...

Page 46: ...performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate b...

Page 47: ...aintenance Ford Models A 5 Engine maintenance Deutz models A 6 Engine maintenance Perkins models A 7 Filter condition indicator A 8 Oscillate axle A 9 Inspect tracks S 60 TRAX and S 65 TRAX Perform after 40 hours A 10 30 day service Perform every 30 days A 11 Inspect track tension S 60 TRAX and S 65 TRAX Perform after 50 hours A 12 Engine maintenance Ford Models Perform every 100 hours A 13 Engine...

Page 48: ...service R repaired Checklist C Y N R C 1 Engine maintenance Deutz models C 2 Engine maintenance Perkins models C 3 Engine maintenance Perkins models C 4 Grease platform overload if equipped C 5 Test platform overload if equipped C 6 Test load sense S 60 HC C 7 Fuel filter separator Perkins models C 8 Safety envelope S 60X S 60XC Perform every 800 hours C 9 Engine maintenance Ford Models Checklist ...

Page 49: ...personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good c...

Page 50: ...ation Inspection also serves to determine if routine maintenance procedures are required 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 Per form Functi on Tests A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Comp...

Page 51: ...G 425 EFI Operator Handbook Genie part number 215322 A 5 Per form Engi ne M ai ntenance Deutz Models A 5 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first All Models Oil level Coolant level Oil fuel and coolant leaks Air filter D 2 9 L4 Models Fuel filter separator Exhaust system Required maintenance ...

Page 52: ...dicator A 7 Check the High Pressure Hydraulic Filter Condition Indicator Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the high pressure hydraulic filter in good condition is essential to good system performance and safe machine operation The filter condition indicator will show when the hydraulic flow is bypassing a clogged ...

Page 53: ...hould remain level at all times 4 Drive both steer tires up onto a 6 inch 15 cm block or curb Result The non steer tires should stay in firm contact with the ground Note If the chassis does not remain level during test refer to Repair Procedure How to Set Up the Directional Valve Linkage A 9 Inspect the Tr ack Com ponents S 60 TR AX and S 65 TR AX A 9 Inspect the Track Components S 60 TRAX and S 6...

Page 54: ...eck the Track Tensi on and Fastener Torque S 60 TR AX and S 65 TR AX A 11 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 th...

Page 55: ...ing 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 Component damage hazard Do not over tighten the track Overtightening the track will...

Page 56: ... Required maintenance procedures and additional engine information are available in the Ford MSG 425 EFI Operator Handbook EDI part number 1020010 Ford MSG 425 EFI Operator Handbook Genie part number 215322 A 13 Perform Engine M aintenance Ford Models A 13 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 100 hours Perform this procedure mo...

Page 57: ...able cover and locate the fuel filter water separator next to the hydraulic return filter on the bulkhead 3 Visually inspect the filter bowl for water buildup Result If water is present in the filter bowl continue with steps 4 through 8 4 Loosen the vent plug located on the fuel filter water separator head 1 vent plug 2 main fuel line 3 drain plug 4 filter bowl 5 filter element 6 separator head 5 ...

Page 58: ...ground controls and check the rpm Refer to Specifications Engine Specifications Skip to step 3 if the low idle rpm is correct 2 Loosen the low idle lock nut and turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and confirm the rpm 1 solenoid boot 2 high idle adjustment nut 3 yoke 4 low idle lock nut and adjustment...

Page 59: ...o 13 cm at a time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent A 17 R epl ace the Drive H ub Oil A 17 Replace the Drive Hub Oil Drive hub specifications require that this one time procedure be performed after the first 150...

Page 60: ...ks 5 Lift the machine until the tracks are off the ground and then place jack stands under the drive chassis for support 6 Attach a lifting strap from an overhead crane to the center point of the track assembly above the sprocket 7 Remove the remaining sprocket retaining fasteners from the hub adapter 8 Carefully remove the track assembly from the drive hub and set aside Crushing hazard The track ...

Page 61: ...her direction just until the remaining sprocket retaining fasteners can be installed onto the drive hub adapter Turn the machine off 18 Install the remaining sprocket retaining fasteners to the drive hub adapter and torque to specification Refer to Specifications Machine Torque Specifications 19 Repeat this procedure for each drive hub A 18 Perform Engine M aintenance Ford Models A 18 Perform Engi...

Page 62: ...at the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery retainers and cable connections are tight 4 Be sure that the battery separator wire connections are tight if equipped 5 Put on protective clothing and eye wear 6 Remove the battery ve...

Page 63: ...ery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled B 2 Inspect the Electrical Wiring B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintainin...

Page 64: ...tform control box 13 Swing the engine back to its original position and install the engine tray retaining fastener B 3 C heck the Exhaust System 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 Operating the engine with...

Page 65: ...ine 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 damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the performance of the cooling system Bodily injury hazard Do not in...

Page 66: ...r es Wheels and Lug N ut Torque S 60 S 65 S 60 HC S60X and S 60XC B 6 Inspect 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 whe...

Page 67: ... C heck the Drive H ub Oil Level and Fastener Tor que B 8 Check the Drive Hub Oil Level 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...

Page 68: ...plugs are both horizontal 1 drive hub plugs 10 Remove one plug and check the oil level Result The oil level should be even with the bottom of the plug hole 11 If necessary remove the other plug and add oil until the oil level is even with the bottom of the plug hole Refer to Specifications Machine Specifications 12 Install the plug s into the drive hub 13 Check the torque of the drive hub mounting...

Page 69: ...edure be performed every 250 hours or quarterly whichever comes first Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Deutz models Note Two people will be required to perform this procedure 1 Remove the engin...

Page 70: ...and recheck the rpm Note Be sure the solenoid fully retracts when activating high idle 7 Swing the engine back to its original position and install the engine pivot plate retaining fastener B 10 Test the Ground C ontrol Override B 10 Test the Ground Control Override Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioni...

Page 71: ...s are installed Cotter pins are installed through clevis pins Linkage is properly attached to directional valve B 12 Test the Platform Self leveling B 12 Test the Platform Self leveling Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential ...

Page 72: ...mal machine operation This selection activates high idle only when the foot switch is pressed down 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Start the engine from the ground controls 3 Move the rpm select toggle switch to the high idle rabbit symbol position and push in the function enable button position Result The engine should change ...

Page 73: ...LPG fuel levels and warming the engine to normal operating temperature 1 At the platform controls move the fuel select switch to gasoline and then move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 2 Start the engine from the platform controls and allow it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle Resul...

Page 74: ...the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Refer to Specifications Performance 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 Stow ed Positi on B 16 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 2...

Page 75: ...switch activated 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 sta...

Page 76: ...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 Result The flashing...

Page 77: ...ng Systems B 20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie specifications require 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 the machine t...

Page 78: ...he boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Inspecting for foreign objects damage and or improper adjustment of the boom extend retract cables and related components on a regular basis is essential to good machine performance and safe machine operation The boom extend and retract functions should operate smoothly and be free of hesitatio...

Page 79: ...pulleys 6 S 60 S 65 S 60X S 60XC S 60 TRAX and S 65 TRAX Install the cover at the pivot end of the boom S 60 HC Install the boom end cover at the pivot end of the boom while guiding the small cable from the string potentiometer into the slot of the cover Component damage hazard The cable from the string potentiometer can become damaged if it is kinked or pinched Note Be sure the cable from the str...

Page 80: ... break the security tie and lift the emergency power switch cover if equipped 3 Simultaneously hold the emergency power switch on and activate each boom function toggle switch Note To conserve battery power test each function through a partial cycle Result All boom functions operate 4 Close the emergency power switch cover and secure the cover with a security tie if equipped 5 Turn the key switch ...

Page 81: ...his procedure be performed every 400 hours Engine oil Oil filter Coolant level Oil fuel and coolant leaks Hoses and pipes for leaks and damage Electrical wiring damage Engine belts Fuel filter Air filter Spark plugs Loose or missing fasteners Required maintenance procedures and additional engine information are available in the Ford MSG 425 EFI Operator Handbook EDI part number 1020010 Ford MSG 42...

Page 82: ... 3547 OR the Deutz D 2 9 L4 Series Operation Manual Deutz part number 0312 3893 Deutz 2011 Series Operation Manual Genie part number 139320 Deutz D 2 9 L4 Series Operation Manual Genie part number 1251561 C 2 Perform Engine M aintenance Perki ns M odels C 2 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 500 hours All Models Fuel filte...

Page 83: ...890 Perkins 404F Series Operation Manual Genie part number 1251562 C 4 Gr ease the Platform Overload Mechanism if equipped S 60 S 65 S 60 TRAX and S 65 TR AX C 4 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 du...

Page 84: ...d 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 overloaded the lower ar...

Page 85: ...Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 7 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 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 an...

Page 86: ... machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over The platform overload system is designed to detect an overloaded platform and prevent machine operation anytime the machine is turned on When activated the system hal...

Page 87: ... Result The amber restricted range of motion LED at the platform controls should come on and the engine should continue to run Result If the amber restricted range of motion LED at the platform controls does not come on there is no alarm and the engine continues to run the platform load sense system needs to be calibrated Refer to Repair Procedure How to Calibrate the Platform Load Sense System S ...

Page 88: ...to the stowed position 3 Push in the ground controls red Emergency Stop button to the off position then pull out the red Emergency Stop button to the on position to reset the system C 7 Repl ace the Fuel Filter Water Separator Perkins M odels C 7 Replace the Fuel Filter Water Separator Perkins Models Genie specifications require that this procedure be performed every 500 hours or six months whiche...

Page 89: ...ey are overtightened 11 Clean up any diesel fuel that may have spilled during the installation procedure 12 Install the fuel supply hose from the fuel tank to the fuel filter water separator Tighten the clamp 13 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter element housing Prime the fuel system 14 Loosen the vent plug on top of the fuel injectio...

Page 90: ...l weight tools and equipment removed from the platform Note Start this procedure with the boom fully retracted and in the stowed position Ground controls 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 2 Start the engine from the ground controls 3 Turn and hold the function enable switch to the restricted maximum platform capacity and raise the...

Page 91: ...ivot pins Platform controls Note Start this procedure with the boom fully retracted and in the stowed position 1 Pull out the red Emergency Stop button to the on position and start the engine 2 Select the restricted maximum platform capacity with the toggle switch 1 restricted maximum platform capacity 2 unrestricted maximum platform capacity 3 Raise the primary boom until it is fully elevated 4 E...

Page 92: ...ricted platform capacity light stops flashing Result Primary boom extend should return to normal operation 9 Return the machine to the fully stowed position C 9 Perform Engine M aintenance Ford M odels C 9 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 800 hours Engine oil Oil filter Coolant level Oil fuel and coolant leaks Hoses and pip...

Page 93: ...ng conditions 1 Start 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 b...

Page 94: ...inder rod Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands away from the cylinder and all moving parts when lowering the boom Note The lift cylinder safety chock is available through Genie After Market Support 2 Turn the engine off 3 Confirm that each turntable mounting bolt is torqued in sequence to specification Refer to Specifications Machine Torque Specif...

Page 95: ...the boom in the stowed position 1 Grease the turntable bearing Refer to Maintenance Procedure Grease the Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification Refer to Maintenance Procedure 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 betwee...

Page 96: ...Repl ace the Drive H ub Oil D 4 Replace the Drive Hub Oil Genie specifications require that this procedure be performed every 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 result in component dam...

Page 97: ...ket 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 the dri...

Page 98: ...ue Specifications 20 Repeat this procedure for each drive hub D 5 Check the Free wheel Confi gur ation 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 mac...

Page 99: ...llision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage 1 brake disengaged position 2 brake engaged position Steer wheels 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 9 Lift the wheels or track...

Page 100: ...ment of the hydraulic filters is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns Note Perform this procedure with the en...

Page 101: ...ngs and tighten them securely Note The medium and high pressure filters use the same elements 16 Clean up any oil that may have spilled during the installation procedure 17 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings 18 Start the engine from the ground controls 19 Inspect the filter housings and related components to be sure that ...

Page 102: ...erformed every 1000 hours All Models Alternator Fan belts Engine valve lash 404F 22 Models Air pump belt Crankcase breather Required maintenance procedures and additional engine information are available in the Perkins 400 Series Operation Manual Perkins part number TPD 1443S OR the Perkins 404F Series Operation Manual Perkins part number SEBU8609 Perkins 400 Series Operation Manual Genie part num...

Page 103: ...g installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the boom in the stowed position 1 Ford models Turn the valve on the LPG tank clockwise to the off position if equipped Then slowly disconnect the hose from the LPG tank 2 Ford models Open the clamps from the LPG tank straps and remove the LPG tank from the machine if equipped 3 ...

Page 104: ...y power unit and the return filter hose 20 Open the two hydraulic tank shut off valves at the hydraulic tank 21 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill Refer to Specifications Machine Specifications 22 Clean up any oil that may have spilled during the installation procedure 23 Prime the pump Refer to Repair Procedure How t...

Page 105: ... in the Deutz 2011 Series Operation Manual Deutz part number 0312 3547 OR the Deutz D 2 9 L4 Series Operation Manual Deutz part number 0312 3893 Deutz 2011 Series Operation Manual Genie part number 139320 Deutz D 2 9 L4 Series Operation Manual Genie part number 1251561 E 4 Per form Engi ne M ai ntenance Perkins 404D 22 M odels E 4 Perform Engine Maintenance Perkins 404D 22 Models Engine specificat...

Page 106: ...s 404F Series Operation Manual Perkins part number SEBU8609 Perkins 404F Series Operation Manual Genie part number 1251562 E 6 Per form Engi ne M ai ntenance Perkins Models E 6 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 3 000 hours or 2 years whichever comes first All models Engine coolant Required maintenance procedures and addit...

Page 107: ...able in the Deutz D 2 9 L4 Series Operation Manual Deutz part number 3012 3893 Deutz D 2 9 L4 Series Operation Manual Genie part number 1251561 E 8 Per form Engi ne M ai ntenance Perkins 404D 22 M odels E 8 Perform Engine Maintenance Perkins 404D 22 Models Engine specifications require that this procedure be performed every 6 000 hours or 3 years whichever comes first Engine coolant extender Requi...

Page 108: ...s part number SEBU8609 Perkins 400 Series Operation Manual Genie part number 94890 Perkins 404F Series Operation Manual Genie part number 1251562 E 10 R epl ace the Boom Extend and R etr act C ables E 10 Replace the Boom Extend Retract Cables Genie specifications require that this procedure be performed every 10 years The boom extend retract cables are responsible for the extension and retraction ...

Page 109: ...iate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration M...

Page 110: ...ol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation w...

Page 111: ...nal speed control over its entire range of motion 1 ALC 500 circuit board 2 drive steer joystick controller 3 primary boom up down extend retract and turntable rotate right left joystick controller 1 1 ALC 500 Circuit Boar d 1 1 ALC 500 Circuit Board Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewel...

Page 112: ...tion will operate Note The joystick must be calibrated before the threshold max out or ramp rate can be set Note Perform this procedure with the engine off 1 Open the platform control box 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Turn the key switch to platform control Do not start the engine 4 Select a joystick to calibrate 5 Disconnect...

Page 113: ...e 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 direction just until the function begins to move 11 Slow...

Page 114: ...uld 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 9 Start a timer and activate the machine function that needs to be adjusted Record the time it takes for that function to complete a full cycle ie boom up 10...

Page 115: ...times indicating that the machine is in ramp rate 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 Start a timer and simultaneously move the joystick in either direction full stroke Note how long it takes the function to reach maximum speed This is the ramp rate 10 Compare the function ramp rate...

Page 116: ... 1 second decelerate shift from high to low speed 4 seconds How to C alibr ate the Boom Angle Sensor How to Calibrate the Boom Angle Sensor The boom angle sensor controls the maximum angle that the boom can attain Note Perform this procedure on a firm level surface 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Turn the key switch to platform controls 3 Move a...

Page 117: ...nually reduce the boom speed as it reaches the fully elevated position 9 Momentarily activate the drive enable toggle switch to the right 1 time to set the elevated position Result The alarm will sound indicating that the angle sensor has been calibrated 10 Release the joystick and the foot switch and wait for 10 seconds Result The alarm will sound indicating that the settings have been saved and ...

Page 118: ...lace blocks under the platform 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...

Page 119: ...itting Torque Specifications 1 Remove the platform and platform support Note S 60 HC If the load sense components are disassembled and or removed from the platform support the platform load sense system will need to be calibrated Refer to Repair Procedure 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 an...

Page 120: ...fications 10 Lower the jib boom leveling arms Crushing hazard The platform rotator may become unbalanced and fall if not properly supported Note When installing the platform rotator fasteners torque the fasteners to specifications S 65 and S 65 TRAX 11 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins Do not remove the pins 12 Support th...

Page 121: ... function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw Crushing hazard Keep clear of the platform during rotation 5 Open the bottom bleed screw on the rotator but do not remove it Bodily injury ...

Page 122: ...latform capacity at the center of the platform floor 5 Move the platform up and down by hand so it bounces approximately 2 5 to 5 cm 1 to 2 inches Allow the platform to settle Result The overload indicator lights are off and the alarm does not sound Proceed to step 6 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Slowly tighten the l...

Page 123: ... Proceed to step 9 Result The overload indicator light is off at both the ground and platform controls and the alarm does not sound Remove the additional 10 lb 4 5 kg test weight Repeat this procedure beginning with step 6 Note There may be a 2 second delay before the platform overload indicator light and alarm responds 9 Test all machine functions from the platform controls Result All platform co...

Page 124: ...ntrols turn the key switch to the off position and push in the red Emergency Stop button to the off position Pull out the red Emergency Stop button to the on position at the platform controls 2 Remove all weight tools and equipment from the platform Tip over hazard Failure to remove all weight options accessories and or tools from the platform or subtracting the weight of those items from the test...

Page 125: ...re beginning with step 1 Note Once calibration mode is entered and begun there is a 8 minute time limit between each calibration step If any one step passes the 8 minute time limit the system will time out and the calibration process will need to be repeated beginning with step 1 1 green LED operational control module 2 red LED operational control module 3 operational control module 4 safety contr...

Page 126: ...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 calibration step was accepted The green LED on the operational controller should be blinking fast and the red LED should be blinking four times indicat...

Page 127: ...top button to the on position to reset the system 19 Visually inspect the LEDs on the controllers Result All LEDs on both controllers should be off indicating the platform load sense system is calibrated 20 At the ground controls push in the red Emergency Stop button to the off position 21 Using a suitable lifting device remove the test weights from the platform 22 Pull out the red Emergency Stop ...

Page 128: ...b boom lift 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 6 Attach a lifting strap from an overhead crane to the jib boom assembly 7 Place blocks under the platform leveling cylinder for sup...

Page 129: ...ry 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 opposite l...

Page 130: ...g 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 burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Tag disconnect and plug the platform leveling slave cylinder hydraulic hos...

Page 131: ... R emove the C able Track S 65 and S 65 TR AX How to Remove the Cable Track S 65 and S 65 TRAX Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Open the platform control box 2 Tag and disc...

Page 132: ...netrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 15 Pull the hydraulic hoses out of the primary boom 16 Remove the cotter pin from the upper cable track at the platform end of the boom Note Always replace the cotter pin with a new one 17 Remove the cable track pull tube guide fasteners from the cable...

Page 133: ... black rollers from the 4 link section of cable track to be replaced Remove the rollers 4 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Hoses can be damaged if they are kinked or pinched 5 Remove the upper rollers from the replacement section of cable track 6 Lift up the hoses and cables and carefully insert the new 4 link secti...

Page 134: ...t pin 2 boom 3 boom lift cylinder rod end pivot pin 4 boom lift cylinder 5 long link arm ground controls side 6 long link arm engine side 7 long link arm to turntable pivot pin 8 master cylinder cam 9 master cylinder cam link 10 short link arm to turntable pivot pin 11 long link arm to boom pivot pin 12 master platform level cylinder 13 short link arm weldment ...

Page 135: ... skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specificat...

Page 136: ... 5 ton 5000 kg overhead crane to each end of the boom Support the boom Do not apply any lifting pressure 12 Support and secure the rod end of the boom lift cylinder to a second overhead crane or similar lifting device 13 Remove the lift cylinder rod end pivot pin retaining fasteners Use a soft metal drift to remove the pin Crushing hazard The boom could fall if not properly supported when the lift...

Page 137: ...ster cylinder Remove the master cylinder rod end pivot pin retaining fasteners Place a rod through the pin and twist to remove Carefully lower the master cylinder down 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 ve...

Page 138: ...Raise the boom to a horizontal position 2 Attach a 5 ton 5000 kg overhead crane to the boom at the platform end for support Do not lift the boom 3 Support and secure both ends of the boom lift cylinder to a second overhead crane or similar lifting device 4 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The bo...

Page 139: ...nt in the event of a hydraulic line failure How to Remove the Boom Extension Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly ...

Page 140: ... 3 boom tube 10 Remove the cable retaining plates and pull the retract cables off of the pulleys Lay the cables flat and out of the 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...

Page 141: ...zard 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 the lug at the rod end of the boom extension cylinder 24 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside the n...

Page 142: ... or pinched 3 Inspect the threaded 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 ...

Page 143: ...cables 2 Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boom tube 3 Remove the rue rings and clevis pins from the boom extend cables located near the extend cable break limit switch 4 Remove the external snap rings from the boom extend cable pulley pivot pin Use a soft metal drift to remove the pin Note When driving the pivot pin out be sure to drive it fr...

Page 144: ...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 145: ...ng Torque Specifications 1 Raise the boom until the master cylinder is above the turntable covers 2 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder 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...

Page 146: ...he red Emergency Stop button to the off position and turn the key switch to the off position 3 Locate the primary boom angle sensor mounted on the ground control side long link arm 4 Cut and discard the two button cable ties securing the angle sensor harness to the gusset plate 5 Locate and disconnect the angle sensor harness connector 6 Remove the angle sensor retaining fasteners and set aside Re...

Page 147: ... and platform controls to the on position 12 Using a volt meter set to DC volts back probe the angle sensor harness connector Insert the negative lead into terminal 2 the positive lead into terminal 3 13 Adjust the angle sensor until the volt meter reads 3 8V dc to 4 2V dc and securely tighten the fasteners 14 Calibrate the boom angle sensor Refer to Repair Procedure How to Calibrate the Boom Angl...

Page 148: ...Perkins 404D 22 Models 5 3 Fl ex Plate Rem oval 5 3 Flex Plate The 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 coupl...

Page 149: ... engine with an overhead crane or other suitable lifting device Do not lift it 6 Remove the engine mounting plate to bell housing fasteners 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 engine ...

Page 150: ...ing bolts in sequence to 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 appropriate gap between coupler and pump end plate for your engine 1 pump ...

Page 151: ...nstall the fasteners 3 Deutz models Torque 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...

Page 152: ... labeled C to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled A and B in sequence to 40 ft lbs 54 Nm and the 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 5...

Page 153: ...el injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor an...

Page 154: ... 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 One or more fault LED s will illuminate on the display located at the ground control box The active fault code wi...

Page 155: ...table Close the valves Component damage hazard 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 open closed 2 Tag disconnect and plug the function pump hydraulic hoses Cap the fittings on the pum Bodily...

Page 156: ...he fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connectors at the electrical proportional controller located on the drive pump 2 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntab...

Page 157: ...table 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 4 Ford models Close the valve on the LPG tank then disconnect the hose from the tank Then move the fuel select switch to the LPG position Perkins 404D 22 models Disconnect the engine wiring harness from the fuel solenoid at the injector pump D...

Page 158: ...t 30 35 ft lbs 41 47 Nm 8 Solenoid valve 3 position 4 way BB Steer left right 20 25 ft lbs 27 34 Nm 9 Check valve 30 psi 2 bar I Differential sensing circuit platform rotate left and jib boom up S 65 S 65 TRAX 20 25 ft lbs 27 34 Nm 10 Check valve 30 psi 2 bar J Differential sensing circuit platform rotate right and jib boom down S 65 S 65 TRAX 20 25 ft lbs 27 34 Nm 11 Check valve N Differential se...

Page 159: ...February 2015 Service Manual Manifolds Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 137 ...

Page 160: ...fferential sensing circuit platform level up 10 12 ft lbs 14 16 Nm 24 Check valve X Differential sensing circuit platform level down 10 12 ft lbs 14 16 Nm 25 Proportional solenoid valve Q Turntable rotate left right 20 25 ft lbs 27 34 Nm 26 Flow control valve 0 6 gpm 2 27 L min Z Platform rotate and jib boom S 65 S 65 TRAX 20 25 ft lbs 27 34 Nm 27 Check valve 30 psi 2 bar EE Platform rotate and ji...

Page 161: ...February 2015 Service Manual Manifolds Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 139 Function M ani fol d C omponents from serial number 26515 ...

Page 162: ...valve 3 position 4 way BB Steer left right 20 25 ft lbs 27 34 Nm 9 Check valve 30 psi 2 bar I Differential sensing circuit platform rotate left andjib 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 andjib 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 ...

Page 163: ...February 2015 Service Manual Manifolds Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 141 ...

Page 164: ...ifferential sensing circuit platform level up 10 12 ft lbs 14 16 Nm 24 Check valve X Differential sensing circuit platform level down 10 12 ft lbs 14 16 Nm 25 Proportional solenoid valve Q Turntable rotate left right 20 25 ft lbs 27 34 Nm 26 Flow control valve 0 6 gpm 2 27 L min Z Platform rotate and jib boom S 65 S 65 TRAX 20 25 ft lbs 27 34 Nm 27 Check valve 30 psi 2 bar EE Platform rotate and j...

Page 165: ...February 2015 Service Manual Manifolds Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 143 ...

Page 166: ...he function enable rpm select toggle switch to the high idle position Activate and hold the boom retract toggle switch with the boom fully retracted 4 Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic 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 ...

Page 167: ...Jib Boom Platform R otate M ani fol d C omponents 7 3 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to the platform support Index No Description Schematic Item Function Torque 1 Solenoid valve 2 position 3 way FF Platform rotate jib boom select 20 25 ft lbs 27 34 Nm ...

Page 168: ...ponents The brake two speed manifold is mounted near the turntable rotator Index No Description Schematic Item Function Torque 1 Solenoid valve 2 position 3 way KK Brake release 20 25 ft lbs 27 34 Nm Orifice 0 025 inch 0 64 mm JJ Brake release 2 Solenoid valve 2 position 3 way LL Two speed motor shift 20 25 ft lbs 27 34 Nm 3 Check valve II Brake release circuit 20 25 ft lbs 27 34 Nm ...

Page 169: ...rotation manifold is mounted to the turntable rotation motor Index No Description Schematic 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 l...

Page 170: ... C om ponents 7 6 Oscillate Directional Valve Components The oscillate directional valve is mounted inside the drive chassis at the non steer end Index No Description Schematic 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 ...

Page 171: ...4 Remove the drive chassis cover and the non steer axle covers 5 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 6 Remove the heim joint retaining fastener from the axle 7 To level the drive chassis start the engine and push up or pull down on the threaded rod until the machine is completely level 8 Verify that the ground and ...

Page 172: ...ontrols Move the engine idle toggle switch to the maintained high idle position 5 With the engine running in high rpm manually activate the valve and observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic 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 ...

Page 173: ...the engine compartment Index No Description Schematic 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...

Page 174: ...nction Torque 1 Relief valve 280 psi 19 3 bar TT Charge pressure circuit 30 35 ft lbs 41 47 Nm 2 Flow divider combiner valve WW Controls flow to drive motors in forward and reverse 90 100 ft lbs 122 136 Nm 3 Check valve SS Drive circuit 30 35 ft lbs 41 47 Nm 4 Check valve XX Drive circuit 30 35 ft lbs 41 47 Nm 5 Shuttle valve 3 position 3 way UU Charge pressure circuit tha tdirects hot oil out of ...

Page 175: ...he engine off 6 Remove 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 re...

Page 176: ...Orifice 0 040 inch 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 ...

Page 177: ...February 2015 Service Manual Manifolds Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 155 ...

Page 178: ...he engine off 6 Remove 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 re...

Page 179: ...nents 3kW 7 13 Hydraulic Generator Manifold Components 3kW The generator manifold is mounted to the hydraulic generator located in the engine compartment Index No Description Schematic Item Function Torque 1 Proportional solenoid valve HH Generator speed 33 37 ft lbs 45 50 Nm 2 Relief valve 3000 psi 207 bar GG Generator circuit 20 25 ft lbs 27 34 Nm ...

Page 180: ...us injury Remove all rings 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 ...

Page 181: ...f the resistor to a terminal on the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9V DC battery 3 10Ω resistor 4 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 o...

Page 182: ...procedure with the machine on a firm and level surface 1 Secure the turntable from rotating with the turntable rotation lock pin Note The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the turntable rotation drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loo...

Page 183: ...cification Refer to Specifications Machine Torque Specifications 7 Adjust turntable rotation gear backlash Refer to Repair Procedure How to Adjust the Turntable Rotation Gear Backlash How to Adj ust the Tur ntabl e R otati on Gear Backlash How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation...

Page 184: ...urn the adjustment bolt clockwise until it contacts the backlash pivot plate 6 Turn the adjustment bolt 1 2 turn counterclockwise Tighten the lock nut on the adjustment bolt 7 Rotate the backlash pivot plate away from the turntable until it contacts the adjustment bolt Then torque the mounting fasteners on the backlash pivot plate to specification Refer to Specifications Machine Torque Specificati...

Page 185: ...ng installation Refer to Specifications 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 p...

Page 186: ...move 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 R eplace a Tr ack How to Replace a Track Assembly Note Perform this procedure on firm level surface with th...

Page 187: ...wheels 2 bogey wheels 9 Rotate the sprocket half until the split tooth of the sprocket is lower than the other side 1 split tooth 10 Using an overhead crane or other suitable lifting device lift up on the rubber track to create enough room to install the other sprocket half 11 Install the sprocket half removed in step 3 while engaging the sprocket teeth with the rubber track Note Be sure to align ...

Page 188: ...ng hazard The track assembly could become unbalanced and fall when installed onto the machine if not properly supported by the overhead crane 17 Adjust the track tension Locate the grease plug on the track tension cylinder Loosen the plug but do not remove it 18 Locate the grease zerk fitting on the other side of the track tension cylinder 1 grease zerk 2 grease plug 19 Pump grease into the grease...

Page 189: ... too 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 tor...

Page 190: ...Service Manual February 2015 168 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Section 5 Faul t Codes This page intentionally left blank ...

Page 191: ...eels chocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all...

Page 192: ...it board Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards 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 di...

Page 193: ...en on after problem has been corrected 15 Value too low Alarm sounds indicating a fault 17 Not calibrated Normal function except threshold for one or both directions is zero Calibrate valve threshold 24 Angle sensor 11 Value at 5V Reduced speed function Cycle power off then on after problem has been corrected 12 Value too high Alarm sounds indicating a fault 15 Value too low 16 Value at 0V 17 Not ...

Page 194: ...te before lowering Check and service ext ret and fully stowed switches 500lb Mode Operates normally 41 Turntable Rotate Joystick 11 Value at 5V Limited speed and direction frozen at zero and neutral Cycle power off then on after problem has been corrected 12 Value too high Alarm sounds indicating a fault 15 Value too low 16 Value at 0V 17 Not calibrated Calibrate joystick 42 Turntable Rotate Direc...

Page 195: ... problem corrected 51 Drive Joystick 11 Value at 5V Limited speed and direction Frozen at zero and neutral Alarm sounds indicating a fault Cycle power off then on after problem has been corrected 12 Value too high 15 Value too low 16 Value at 0V 17 Not calibrated Calibrate joystick 53 Drive Flow Valve EDC 12 Value too high Limited speed and direction Frozen at zero and neutral ALarm sounds indicat...

Page 196: ...orm Level Value 21 Fault Direction frozen at zero and neutral AB Power up controller with problem corrected 57 Foot switch ECU Power Crosscheck 12 Value too high Direction frozen at zero and neutral AB Power up controller with problem corrected 15 Value too low 61 Steer Joystick 11 Value at 5V Limited speed and direction Frozen at zero and neutral Alarm sounds indicating a fault Cycle power off th...

Page 197: ...The Perkins 404F 22 is equipped with an engine fault LED located at the platform control box If an engine fault occurs that does not result in an engine shutdown the engine rpm will go into limp home mode resulting in the loss of high rpm When operating from the platform if the red Emergency Stop button is pushed in the active fault code s will be erased from the display Start the engine from the ...

Page 198: ...d Contact service Flashing with right flashing amber LED engine soot level over 140 Engine shut down Contact service 4 Right green LED Flashing engine fault detected Contact service Solid fault acknowledged Contact service 5 Right amber LED Perkins models Solid with left amber LED on solid regeneration has been inhibited and engine soot level is between 80 100 Regeneration is required Flashing wit...

Page 199: ...22 M odels Soft Key Functions and Icons Deutz D 2 9 L4 and Perkins 404F 22 Models 1 Next menu Exit Back one screen Decrease brightness 2 Brightness Contrast Scroll up Increase Increase brightness 3 Regeneration forced Scroll down Decrease Decrease contrast 4 Regeneration inhibited Select Next Main menu Increase contarst Note Regeneration initiate inhibit and soot only apply to the Perkins 404F 22 ...

Page 200: ...l February 2015 Fault Code Display Deutz and Perkins Models 178 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Main M enu Str ucture Deutz D 2 9 L4 Models Main Menu Structure Deutz D 2 9 L4 Models ...

Page 201: ...ervice Manual Fault Code Display Deutz and Perkins Models Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 179 Main M enu Str ucture Perkins 404F 22 M odels Main Menu Structure Perkins 404F 22 Models ...

Page 202: ...ent 51 6 1230 Actuator error EGR Valve Overload by short circuit 51 7 1016 Actuator position for EGR Valve not plausible SPN FMI KWP Description 51 11 1231 Actuator error EGR Valve Power stage over temp due to high current 51 12 1018 Actuator EGR Valve powerstage over temperature 51 12 1021 Mechanical actuator defect EGR Valve 51 12 1225 Actuator EGR Valve over temperature 94 1 474 Low fuel pressu...

Page 203: ... flow sensor load correction factor exceeding the maximum drift limit 157 3 877 Sesnor error rail pressure signal range check high 157 4 878 Sensor error rail pressure signal range check low SPN FMI KWP Description 168 0 1180 Physical range check high for battery voltage 168 1 1181 Physical range check low for battery voltage 168 2 47 High battery voltage warning threshold exceeded 168 2 48 Low ba...

Page 204: ...e check high 411 4 381 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit EGR signal range check low SPN FMI KWP Description 412 3 1007 Sensor error EGR cooler downstream temperature signal range check high 412 4 1008 Sensor error EGR cooler downstream temperature signal range check low 520 9 306 Timeout Error of CAN Receive Frame TSC1TR...

Page 205: ...r 898 9 305 Timeout Error of CAN Receive Frame TSC1TE Setpoint 1079 13 946 Sensor supply voltage monitor 1 error ECU 1080 13 947 Sensor supply voltage monitor 2 error ECU SPN FMI KWP Description 1109 2 121 Engine shut off demand ignored 1136 0 1398 Physikal range check high for ECU temperature 1136 1 1399 Physikal range check low for ECU temperature 1136 3 1400 Sensor error ECU temperature signal ...

Page 206: ... flow 2659 1 1525 Physical range check low for EGR exhaust gas mass flow 2659 2 1523 Exhaust gas recirculation AGS sensor plausibility error SPN FMI KWP Description 2659 2 1527 AGS sensor temperature exhaust gas mass flow plausibility error 2659 12 1526 Exhaust gas recirculation AGS sensor has burn off not performed 2797 4 1337 Injector diagnostics timeout error of short circuit to ground measurem...

Page 207: ...tion control 523009 9 825 Pressure Relief Valve PRV reached maximun allowed opening count 523009 10 833 Pressure relief valve PRV reached maximun allowed open time SPN FMI KWP Description 523212 9 171 Timeout Error of CAN Receive Frame ComEngPrt Engine Protection 523216 9 198 Timeout Error of CAN Receive Frame PrHtEnCmd pre heat command engine command 523240 9 179 Timeout CAN message FunModCtl Fun...

Page 208: ... monitoring detection reported error 523612 12 628 Internal ECU monitoring detection reported error SPN FMI KWP Description 523612 12 637 Internal ECU monitoring detection reported error 523612 12 1170 Internal software error ECU 523612 14 973 Softwarereset CPU SWReset_0 523612 14 974 Softwarereset CPU SWReset_1 523612 14 975 Softwarereset CPU SWReset_2 523613 0 856 Maximum positive deviation of r...

Page 209: ...C1TR SPN FMI KWP Description 523788 12 299 Timeout Error of CAN Transmit Frame TrbCH Status Wastegate 523793 9 202 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 523794 9 203 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 523895 13 559 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 13 560 check of missing injector adjustm...

Page 210: ...d messages 523936 12 169 Timeout Error of CAN Transmit Frame EEC3VOL2 Engine send messages 523946 0 1158 Zero fuel calibration injector 1 in firing order maximum value exceeded SPN FMI KWP Description 523946 1 1164 Zero fuel calibration injector 1 in firing order minimum value exceeded 523947 0 1159 Zerofuel calibration injector 2 in firing order maximum value exceeded 523947 1 1165 Zerofuel calib...

Page 211: ...point to actual value downstream DOC too high 524028 2 1431 CAN message PROEGRActr plausibility error 524029 2 1432 Timeout Error of CAN Receive Frame ComEGRActr exhaust gas recirculation positioner 524030 7 1440 EGR actuator internal error 524031 13 1441 EGR actuator calibration error SPN FMI KWP Description 524032 2 1442 EGR actuator status message EGRCust is missing 524033 7 1443 EGR actuator d...

Page 212: ...110 9 1670 Timeout error of CAN Transmit Frame ComETVActr 524111 9 1680 Timeout error of CAN Receive Frame ComRxETVActr 524112 9 1671 Timeout ComITVActr 524113 9 1681 Timeout error of CAN Receive Frame ComRxITVActr SPN FMI KWP Description 524114 9 1659 Timeout error of CAN Transmit Frame A1DOC 524115 9 1660 Timeout error of CAN Transmit Frame AT1S 524116 9 1661 Timeout error of CAN Transmit Frame ...

Page 213: ...h Voltage Above Normal 558 4 Accelerator Pedal1 Low Idle Switch Voltage Below Normal 638 6 Engine Fuel Rack Actuator Current Above Normal 639 14 J1939 Network 1 Special Instruction SPN FMI Description 723 3 Engine Speed Sensor 2 Voltage Above Normal 723 4 Engine Speed Sensor 2 Voltage Below Normal 723 8 Engine Speed Sensor 2 Abnormal Frequency Pulse Width or Period 723 10 Engine Speed Sensor 2 Abn...

Page 214: ...d Due to System Timeout 3719 0 Particulate Trap 1 Soot Load Percent High most severe 3 3719 16 Particulate Trap 1 Soot Load Percent High moderate severity 2 4016 6 High Current Auxiliary Power Relay 1 Current Above Normal 4201 3 Engine Speed Sensor 1 Voltage Above Normal SPN FMI Description 4201 4 Engine Speed Sensor 1 Voltage Below Normal 4201 8 Engine Speed Sensor 1 Abnormal Frequency Pulse Nidt...

Page 215: ...n on The check engine light should begin to blink 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 pre...

Page 216: ...2 219 Max govern speed override 221 TPS1 higher than TPS2 222 TPS2 low voltage 223 TPS2 high voltage 236 TIP Active Code Description 237 TIP Low Voltage 238 TIP High Voltage 261 Injector Loop Open or Low side short to Ground 262 Injector Coil Shorted 264 Injector Loop Open or Low side short to Ground 265 Injector Coil Shorted 267 Injector Loop Open or Low side short to Ground 268 Injector Coil Sho...

Page 217: ...27 Fpump relay coil open 628 FPump motor loop open or high side shorted to ground 628 Fpump relay control ground short 629 FPump motor high side shorted to power 629 Fpump relay coil short to power Code Description 642 5VE1 low voltage 643 5VE1 high voltage 650 MIL open 652 5VE2 low voltage 653 5VE2 high voltage 685 Relay Coil Open 686 Relay Control ground short 687 Relay coil short to power 1111 ...

Page 218: ...521 CHT higher than expected 1 1522 CHT higher than expected 2 1531 IVS Brake Trans Park interlock failure 1541 AUX analog PUD1 high 1542 AUX analog PUD1 low 1543 AUX analog PUD2 high 1544 AUX analog PUD2 low 1545 AUX analog PUD3 high Code Description 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 PD2 high 1562 AUX ana...

Page 219: ...FPP1 invalid voltage and FPP2 disagrees with IVS 2121 FPP1 lower than FPP2 2122 FPP1 high voltage 2123 FPP1 low voltage 2125 FPP2 invalid voltage and FPP1 disagrees with IVS 2126 FPP1 higher than FPP2 2127 FPP2 low voltage 2128 FPP2 high voltage Code Description 2130 IVS stuck at idle FPP1 2 match 2131 IVS stuck off idle FPP1 2 match 2135 TPS1 2 simultaneous voltages out of range 2139 FPP1 lower t...

Page 220: ...ed 2315 Primary Loop Open or Low side Short to Ground 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 2618 Tach output ground short 2619 Tach output short to power For further engine fault code troubleshooting and diagnostic information refer to the Ford MSG 425 EFI D...

Page 221: ...n both controllers determine the fault code on one controller at a time 4 Determine the error source The red LED indicates the error source and will flash two separate codes The first code will indicate the first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second 5 Determine the error type The green LED indicates t...

Page 222: ...ating envelope 21 Angle sensor not active Power relays disengaged Inspect boom angle sensor for proper operation and be sure it is connected to boom properly OR replace boom angle sensor 22 String potentiometer not active Power relays disengaged Inspect string potentiometer for proper operation and be sure it is connected to boom properly OR replace string potentiometer 23 Power relay output short...

Page 223: ...load system 12 Value too high Power relays disengaged String potentiometer wiring open or shorted to voltage Repair wiring and or connections OR replace string potentiometer and calibrate overload system 15 Value too low Power relays disengaged String potentiometer wiring open or shorted to ground Repair wiring and or connections OR replace string potentiometer and calibrate overload system 16 Out...

Page 224: ...shorted to voltage Repair wiring and or connections OR replace string potentiometer and calibrate overload system 15 Value too low Power relays disengaged String potentiometer wiring open OR shorted to ground OR string potentiometer is faulty Repair wiring and or connections OR replace string potentiometer and calibrate overload system 16 Output short low Power relays disengaged String potentiomet...

Page 225: ...engaged Boom angle sensor wiring open or shorted to voltage OR sensor is out of operating range Repair wiring and or connections OR adjust or replace boom angle sensor and calibrate overload system 15 Value too low Power relays disengaged Boom angle sensor wiring open OR shorted to ground OR sensor is out of operating range Repair wiring and or connections OR adjust or replace boom angle sensor an...

Page 226: ... connections OR adjust or replace boom angle sensor and calibrate overload system 15 Value too low Power relays disengaged Boom angle sensor wiring open OR shorted to ground OR sensor is out of operating range Repair wiring and or connections OR adjust or replace boom angle sensor and calibrate overload system 16 Output short low Power relays disengaged Boom angle sensor wiring open OR shorted to ...

Page 227: ...wiring open OR shorted to voltage Platform may be reverse loaded Repair wiring and or connections OR replace platform load cell OR remove excess weight from platform 15 Value too low Power relays disengaged Load cell wiring open OR shorted to ground Repair wiring and or connections OR replace platform load cell and calibrate overload system Check for binding of the overload component linkage and b...

Page 228: ...ibrate overload system OR remove excess weight from platform 15 Value too low Power relays disengaged Load cell wiring open OR shorted to ground Platform may be reverse loaded Repair wiring and or connections OR replace platform load cell and calibrate overload system Check for binding of the overload component linkage and be sure platform is NOT on the ground OR supported from underneath 16 Outpu...

Page 229: ...nderstand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury...

Page 230: ... solenoid Connection no terminal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency stop button normally closed Resistor with ohm value Battery seperator Gauge sending unit Oil temperature switch normally open Coolant tem...

Page 231: ...motor Shuttle valve 2 position 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure...

Page 232: ...mit Swi tch Locati on Legend All models except as noted 1 LSB1RO 2 LSB2S 3 Primary boom angle sensor excludes the S 60 HC 1 LST3O 2 LST2O 3 LST1O S 60 HC S 60X and S 60XC as noted 1 String pot S 60 HC MODELS 2 LST3S S 60X S 60XC 3 LSB1ES S 60X S 60XC 1 LS18 LS18A CE MODELS 2 LSB1EO S 60X S 60XC 3 Primary boom angle sensor S 60 HC ...

Page 233: ...out Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 211 Ford Engi ne Rel ay Layout Ford MSG 425 EFI 1 Power Relay 2 Fuel Pump Relay 3 Starter Relay 4 Starter 20A 5 Empty 6 Fuse 1 10A 7 Fuse 2 5A 8 Fuse 3 10A 9 Fuse 4 15A 10 Fuse 5 15A ...

Page 234: ...ump Diode D22 6A Alternator Ext Relays CR2B Ignition on CR5B Horn CR6 Fuel pump CR17B Hydraulic oil cooler option CR23B Engine accessory CR39B Auxiliary pump Perkins 404F 22 Fuses F10 15A Relay power F11A 15A ARD Injector 1 F11B 15A ARD Injector 2 F11C 5A Linear solenoid F12 7 5A Engine start F17 10A Fuel Alternator Ext F22A 15A Glow plug 1 F22B 20A Glow plug 2 F22C 20A ARD Glow plug Diode D22 6A ...

Page 235: ...February 2015 Service Manual 213 Electrical Schematics Options Ford MSG 425 Engine Wire Harness ...

Page 236: ...Service Manual February 2015 214 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ford M SG 425 EFI Engine Wire H arness Ford MSG 425 EFI Engine Wire Harness ...

Page 237: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 215 Deutz D 2 9 L4 Engine Wire Har ness Deutz D 2 9 L4 Engine Wire Harness ...

Page 238: ...Service Manual February 2015 216 Deutz D 2 9 L4 Engine Wire Harness ...

Page 239: ...February 2015 Service Manual 217 Perkins 404F 22 Engine Wire Harness ...

Page 240: ...Service Manual February 2015 218 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Perki ns 404F 22 Engi ne Wire H arness Perkins 404F 22 Engine Wire Harness ...

Page 241: ...al Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 219 Electrical Schem atic Opti ons Deutz D2011L03i TD 2011L04i and Perkins 404D 22 Electrical Schematic Options Deutz D2011L03i TD2011L04i and Perkins 404D 22 ...

Page 242: ...Service Manual February 2015 220 Electrical Schematic Options Deutz D2011L03i TD2011L04i and Perkins 404D 22 ...

Page 243: ...February 2015 Service Manual 221 Electrical Schematic Options Deutz D 2 9 L4 ...

Page 244: ...Service Manual February 2015 222 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Opti ons Deutz D 2 9 L4 Electrical Schematic Options Deutz D 2 9 L4 ...

Page 245: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 223 Electrical Schem atic Opti ons Perkins 404F 22 Electrical Schematic Options Perkins 404F 22 ...

Page 246: ...Service Manual February 2015 224 Electrical Schematic Options Perkins 404F 22 ...

Page 247: ...February 2015 Service Manual 225 Wiring Diagram 3kW Hydraulic Generator ...

Page 248: ...Service Manual February 2015 226 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Wiring Diagram 3kW Hydraulic Gener ator Wiring Diagram 3kW Hydraulic Generator ...

Page 249: ...ruary 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 227 Wiring Diagram 12kW Hydr aulic Generator Wel der Option Wiring Diagram 12kW Hydraulic Generator Welder Option ...

Page 250: ...Service Manual February 2015 228 Wiring Diagram 12kW Hydraulic Generator Welder Option ...

Page 251: ...February 2015 Service Manual 229 Electrical Schematic 12kW Hydraulic Generator Welder Option ...

Page 252: ...nual February 2015 230 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic 12kW Hydraulic Generator W elder Opti on Electrical Schematic 12kW Hydraulic Generator Welder Option ...

Page 253: ...2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 231 Hydraulic Schem atic 12kW Hydraulic Generator W elder Opti on Hydraulic Schematic 12kW Hydraulic Generator Welder Option ...

Page 254: ...Service Manual February 2015 232 Hydraulic Schematic 12kW Hydraulic Generator Welder Option ...

Page 255: ...February 2015 Service Manual 233 Hydraulic Schematics Hydraulic Schematic 2WD Models ...

Page 256: ...Service Manual February 2015 234 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Hydraulic Schem atic 2WD M odels Hydraulic Schematic 2WD Models ...

Page 257: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 235 Hydraulic Schem atic 4WD M odels Hydraulic Schematic 4WD Models ...

Page 258: ...Service Manual February 2015 236 Hydraulic Schematic 4WD Models ...

Page 259: ...February 2015 Service Manual 237 Electrical Schematics AN SI and C SA Models Electrical Schematic Ford MSG 425 EFI Models ANSI CSA ...

Page 260: ...ce Manual February 2015 238 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic For d M SG 425 EFI M odels ANSI C SA Electrical Schematic Ford MSG 425 EFI Models ANSI CSA ...

Page 261: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 239 Electrical Schematic Ford MSG 425 EFI Models ANSI CSA ...

Page 262: ...Service Manual February 2015 240 Electrical Schematic Ford MSG 425 EFI Models ANSI CSA ...

Page 263: ...February 2015 Service Manual 241 Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 264: ... S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am Ford MSG 425 EFI Models AN SI CSA Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 265: ...rt No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 243 Ground C ontrol Box Switch Panel Wiring Di agr am For d MSG 425 EFI M odels ANSI C SA Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 266: ...Service Manual February 2015 244 Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 267: ...February 2015 Service Manual 245 Platform Control Box Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 268: ...uary 2015 246 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am Ford MSG 425 EFI Models AN SI CSA Platform Control Box Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 269: ... No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 247 Platform C ontrol Box Switch Panel Wiring Diagram For d M SG 425 EFI M odels ANSI C SA Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 270: ...Service Manual February 2015 248 Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 271: ...February 2015 Service Manual 249 Electrical Schematic Deutz D2011L03i Models ANSI CSA ...

Page 272: ...vice Manual February 2015 250 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Deutz D2011L03i M odels ANSI C SA Electrical Schematic Deutz D2011L03i Models ANSI CSA ...

Page 273: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 251 Electrical Schematic Deutz D2011L03i Models ANSI CSA ...

Page 274: ...Service Manual February 2015 252 Electrical Schematic Deutz D2011L03i Models ANSI CSA ...

Page 275: ...February 2015 Service Manual 253 Electrical Schematic Deutz TD2011L04i Models ANSI CSA ...

Page 276: ...ice Manual February 2015 254 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Deutz TD2011L04i M odels ANSI C SA Electrical Schematic Deutz TD2011L04i Models ANSI CSA ...

Page 277: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 255 Electrical Schematic Deutz TD2011L04i Models ANSI CSA ...

Page 278: ...Service Manual February 2015 256 Electrical Schematic Deutz TD2011L04i Models ANSI CSA ...

Page 279: ...February 2015 Service Manual 257 Ground Control Box Terminal Strip Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 280: ... 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am D eutz D 2011L03i TD 2011L04i Models AN SI CSA Ground Control Box Terminal Strip Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 281: ...1 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 259 Ground C ontrol Box Switch Panel Wiring Di agr am D eutz D2011L03i TD 2011L04i M odels ANSI C SA Ground Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 282: ...Service Manual February 2015 260 Ground Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 283: ...February 2015 Service Manual 261 Platform Control Box Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 284: ...2 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am D eutz D 2011L03i TD 2011L04i Models AN SI CSA Platform Control Box Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 285: ...1 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 263 Platform C ontrol Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i M odels ANSI C SA Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 286: ...Service Manual February 2015 264 Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 287: ...February 2015 Service Manual 265 Electrical Schematic Deutz D 2 9 L4 Models ANSI CSA ...

Page 288: ...rvice Manual February 2015 266 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Deutz D 2 9 L4 Models AN SI C SA Electrical Schematic Deutz D 2 9 L4 Models ANSI CSA ...

Page 289: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 267 Electrical Schematic Deutz D 2 9 L4 Models ANSI CSA ...

Page 290: ...Service Manual February 2015 268 Electrical Schematic Deutz D 2 9 L4 Models ANSI CSA ...

Page 291: ...February 2015 Service Manual 269 Ground Control Box Terminal Strip Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 292: ...0 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am D eutz D 2 9 L4 M odels ANSI C SA Ground Control Box Terminal Strip Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 293: ...Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 271 Ground C ontrol Box Switch Panel Wiring Di agr am D eutz D 2 9 L4 M odels ANSI C SA Ground Control Box Switch Panel Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 294: ...Service Manual February 2015 272 Ground Control Box Switch Panel Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 295: ...February 2015 Service Manual 273 Platform Control Box Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 296: ...ruary 2015 274 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am D eutz D 2 9 L4 M odels ANSI C SA Platform Control Box Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 297: ...Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 275 Platform C ontrol Box Switch Panel Wiring Diagram Deutz D 2 9 L4 Models AN SI CSA Platform Control Box Switch Panel Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 298: ...Service Manual February 2015 276 Platform Control Box Switch Panel Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 299: ...February 2015 Service Manual 277 Electrical Schematic Perkins 404D 22 Models ANSI CSA ...

Page 300: ...vice Manual February 2015 278 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Perkins 404D 22 M odels ANSI C SA Electrical Schematic Perkins 404D 22 Models ANSI CSA ...

Page 301: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 279 Electrical Schematic Perkins 404D 22 Models ANSI CSA ...

Page 302: ...Service Manual February 2015 280 Electrical Schematic Perkins 404D 22 Models ANSI CSA ...

Page 303: ...February 2015 Service Manual 281 Ground Control Box Terminal Strip Wiring Diagram Perkins 404D 22 Models ANSI CSA ...

Page 304: ... S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am Perki ns 404D 22 Models AN SI C SA Ground Control Box Terminal Strip Wiring Diagram Perkins 404D 22 Models ANSI CSA ...

Page 305: ...Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 283 Ground C ontrol Box Switch Panel Wiring Di agr am Perkins 404D 22 Models AN SI CSA Ground Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models ANSI CSA ...

Page 306: ...Service Manual February 2015 284 Ground Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models ANSI CSA ...

Page 307: ...February 2015 Service Manual 285 Platform Control Box Wiring Diagram Perkins 404D 22 Models ANSI CSA ...

Page 308: ...uary 2015 286 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am Perki ns 404D 22 Models AN SI CSA Platform Control Box Wiring Diagram Perkins 404D 22 Models ANSI CSA ...

Page 309: ...rt No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 287 Platform C ontrol Box Switch Panel Wiring Diagram Perkins 404D 22 M odels ANSI C SA Platform Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models ANSI CSA ...

Page 310: ...Service Manual February 2015 288 Platform Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models ANSI CSA ...

Page 311: ...February 2015 Service Manual 289 Electrical Schematic Perkins 404F 22 Models ANSI CSA ...

Page 312: ...vice Manual February 2015 290 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Perkins 404F 22 M odels ANSI C SA Electrical Schematic Perkins 404F 22 Models ANSI CSA ...

Page 313: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 291 Electrical Schematic Perkins 404F 22 Models ANSI CSA ...

Page 314: ...Service Manual February 2015 292 Electrical Schematic Perkins 404F 22 Models ANSI CSA ...

Page 315: ...February 2015 Service Manual 293 Ground Control Box Terminal Strip Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 316: ... S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am Perki ns 404F 22 Models AN SI CSA Ground Control Box Terminal Strip Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 317: ...Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 295 Ground C ontrol Box Switch Panel Wiring Di agr am Perkins 404F 22 Models AN SI CSA Ground Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 318: ...Service Manual February 2015 296 Ground Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 319: ...February 2015 Service Manual 297 Platform Control Box Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 320: ...uary 2015 298 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am Perki ns 404F 22 Model s AN SI CSA Platform Control Box Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 321: ...rt No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 299 Platform C ontrol Box Switch Panel Wiring Diagram Perkins 404F 22 M odels ANSI C SA Platform Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 322: ...Service Manual February 2015 300 Platform Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 323: ...February 2015 Service Manual 301 Electrical Schematic S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 324: ...bruary 2015 302 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic S 60X S 60XC Ford M SG 425 EFI Models AN SI C SA Electrical Schematic S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 325: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 303 Electrical Schematic S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 326: ...Service Manual February 2015 304 Electrical Schematic S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 327: ...February 2015 Service Manual 305 Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 328: ... TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am S 60X S 60XC For d M SG 425 EFI M odels ANSI C SA Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 329: ...0 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 307 Ground C ontrol Box Terminal Strip Wiring Di agr am S 60X S 60XC For d M SG 425 EFI M odels ANSI C SA Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 330: ...Service Manual February 2015 308 Ground Control Box Switch Panel Wiring Diagram S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 331: ...February 2015 Service Manual 309 Platform Control Box Wiring Diagram S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 332: ... 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am S 60X S 60XC For d M SG 425 EFI M odels ANSI C SA Platform Control Box Wiring Diagram S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 333: ...S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 311 Platform C ontrol Box Switch Panel Wiring Diagram S 60X S 60XC Ford MSG 425 EFI Models AN SI CSA Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 334: ...Service Manual February 2015 312 Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Ford MSG 425 EFI Models ANSI CSA ...

Page 335: ...February 2015 Service Manual 313 Electrical Schematic S 60X S 60XC Deutz D2011L03i Models ANSI CSA ...

Page 336: ...ebruary 2015 314 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic S 60X S 60XC D eutz D 2011L03i Models AN SI CSA Electrical Schematic S 60X S 60XC Deutz D2011L03i Models ANSI CSA ...

Page 337: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 315 Electrical Schematic S 60X S 60XC Deutz D2011L03i Models ANSI CSA ...

Page 338: ...Service Manual February 2015 316 Electrical Schematic S 60X S 60XC Deutz D2011L03i Models ANSI CSA ...

Page 339: ...February 2015 Service Manual 317 Electrical Schematic S 60X S 60XC Deutz TD2011L04i Models ANSI CSA ...

Page 340: ...ruary 2015 318 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic S 60X S 60XC D eutz TD 2011L04i M odels AN SI CSA Electrical Schematic S 60X S 60XC Deutz TD2011L04i Models ANSI CSA ...

Page 341: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 319 Electrical Schematic S 60X S 60XC Deutz TD2011L04i Models ANSI CSA ...

Page 342: ...Service Manual February 2015 320 Electrical Schematic S 60X S 60XC Deutz TD2011L04i Models ANSI CSA ...

Page 343: ...February 2015 Service Manual 321 Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 344: ...AX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am D eutz D 2011L03i TD 2011L04i Models AN SI CSA Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 345: ... 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 323 Ground C ontrol Box Switch Panel Wiring Di agr am S 60X S 60XC D eutz D 2011L03i TD 2011L04i Models AN SI CSA Ground Control Box Switch Panel Wiring Diagram S 60X S 60XC Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 346: ...Service Manual February 2015 324 Ground Control Box Switch Panel Wiring Diagram S 60X S 60XC Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 347: ...February 2015 Service Manual 325 Platform Control Box Wiring Diagram S 60X S 60XC Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 348: ...S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am S 60X S 60XC Deutz D2011L03i TD2011L04i M odels ANSI C SA Platform Control Box Wiring Diagram S 60X S 60XC Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 349: ...60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 327 Platform C ontrol Box Switch Panel Wiring Diagram S 60X S 60XC D eutz D 2011L03i TD 2011L04i Models AN SI CSA Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 350: ...Service Manual February 2015 328 Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Deutz D2011L03i TD2011L04i Models ANSI CSA ...

Page 351: ...February 2015 Service Manual 329 Electrical Schematic S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA ...

Page 352: ...February 2015 330 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic S 60X S 60XC D eutz D 2 9 L4 M odels ANSI C SA Electrical Schematic S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA ...

Page 353: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 331 Electrical Schematic S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA ...

Page 354: ...Service Manual February 2015 332 Electrical Schematic S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA ...

Page 355: ...February 2015 Service Manual 333 Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA ...

Page 356: ... 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am S 60X S 60XC Deutz D 2 9 L4 Models AN SI C SA Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA ...

Page 357: ...No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 335 Ground C ontrol Box Switch Panel Wiring Di agr am S 60X S 60XC Deutz D 2 9 L4 ANSI C SA Ground Control Box Switch Panel Wiring Diagram S 60X S 60XC Deutz D 2 9 L4 ANSI CSA ...

Page 358: ...Service Manual February 2015 336 Ground Control Box Switch Panel Wiring Diagram S 60X S 60XC Deutz D 2 9 L4 ANSI CSA ...

Page 359: ...February 2015 Service Manual 337 Platform Control Box Wiring Diagram S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA ...

Page 360: ...38 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am S 60X S 60XC Deutz D 2 9 L4 Models AN SI CSA Platform Control Box Wiring Diagram S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA ...

Page 361: ... S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 339 Platform C ontrol Box Switch Panel Wiring Diagram S 60X S 60XC D eutz D 2 9 L4 M odels ANSI C SA Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA ...

Page 362: ...Service Manual February 2015 340 Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Deutz D 2 9 L4 Models ANSI CSA ...

Page 363: ...February 2015 Service Manual 341 Electrical Schematic S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 364: ...ebruary 2015 342 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic S 60X S 60XC Perki ns 404D 22 Models AN SI C SA Electrical Schematic S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 365: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 343 Electrical Schematic S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 366: ...Service Manual February 2015 344 Electrical Schematic S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 367: ...February 2015 Service Manual 345 Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 368: ...60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am S 60X S 60XC Perkins 404D 22 M odels ANSI C SA Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 369: ... S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 347 Ground C ontrol Box Switch Panel Wiring Di agr am S 60X S 60XC Perki ns 404D 22 M odels ANSI C SA Ground Control Box Switch Panel Wiring Diagram S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 370: ...Service Manual February 2015 348 Ground Control Box Switch Panel Wiring Diagram S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 371: ...February 2015 Service Manual 349 Platform Control Box Wiring Diagram S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 372: ... S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am S 60X S 60XC Perkins 404D 22 M odels ANSI C SA Platform Control Box Wiring Diagram S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 373: ...S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 351 Platform C ontrol Box Switch Panel Wiring Diagram S 60X S 60XC Perki ns 404D 22 Models AN SI CSA Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 374: ...Service Manual February 2015 352 Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Perkins 404D 22 Models ANSI CSA ...

Page 375: ...February 2015 Service Manual 353 Electrical Schematic S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 376: ...ebruary 2015 354 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic S 60X S 60XC Perki ns 404F 22 Models AN SI CSA Electrical Schematic S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 377: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 355 Electrical Schematic S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 378: ...Service Manual February 2015 356 Electrical Schematic S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 379: ...February 2015 Service Manual 357 Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 380: ...60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am S 60X S 60XC Perkins 404F 22 M odels ANSI C SA Ground Control Box Terminal Strip Wiring Diagram S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 381: ... S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 359 Ground C ontrol Box Switch Panel Wiring Di agr am S 60X S 60XC Perki ns 404F 22 M odels ANSI C SA Ground Control Box Switch Panel Wiring Diagram S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 382: ...Service Manual February 2015 360 Ground Control Box Switch Panel Wiring Diagram S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 383: ...February 2015 Service Manual 361 Platform Control Box Wiring Diagram S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 384: ... S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am S 60X S 60XC Perkins 404F 22 M odels ANSI C SA Platform Control Box Wiring Diagram S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 385: ...S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 363 Platform C ontrol Box Switch Panel Wiring Diagram S 60X S 60XC Perki ns 404F 22 Models AN SI CSA Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 386: ...Service Manual February 2015 364 Platform Control Box Switch Panel Wiring Diagram S 60X S 60XC Perkins 404F 22 Models ANSI CSA ...

Page 387: ...February 2015 Service Manual 365 Electrical Schematics C E Models Electrical Schematic Ford MSG 425 EFI Models CE ...

Page 388: ...Service Manual February 2015 366 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic For d M SG 425 EFI M odels CE Electrical Schematic Ford MSG 425 EFI Models CE ...

Page 389: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 367 Electrical Schematic Ford MSG 425 EFI Models CE ...

Page 390: ...Service Manual February 2015 368 Electrical Schematic Ford MSG 425 EFI Models CE ...

Page 391: ...February 2015 Service Manual 369 Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models CE ...

Page 392: ...15 370 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am Ford MSG 425 EFI Models CE Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models CE ...

Page 393: ...ual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 371 Ground C ontrol Box Switch Panel Wiring Di agr am For d MSG 425 EFI M odels C E Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models CE ...

Page 394: ...Service Manual February 2015 372 Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models CE ...

Page 395: ...February 2015 Service Manual 373 Platform Control Box Wiring Diagram Ford MSG 425 EFI Models CE ...

Page 396: ...l February 2015 374 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am Ford MSG 425 EFI Models CE Platform Control Box Wiring Diagram Ford MSG 425 EFI Models CE ...

Page 397: ...al Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 375 Platform C ontrol Box Switch Panel Wiring Diagram For d M SG 425 EFI M odels CE Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models CE ...

Page 398: ...Service Manual February 2015 376 Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models CE ...

Page 399: ...February 2015 Service Manual 377 Electrical Schematic Deutz D2011L03i Models CE ...

Page 400: ...Service Manual February 2015 378 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Deutz D2011L03i M odels CE Electrical Schematic Deutz D2011L03i Models CE ...

Page 401: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 379 Electrical Schematic Deutz D2011L03i Models CE ...

Page 402: ...Service Manual February 2015 380 Electrical Schematic Deutz D2011L03i Models CE ...

Page 403: ...February 2015 Service Manual 381 Electrical Schematic Deutz TD2011L04i Models CE ...

Page 404: ...Service Manual February 2015 382 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Deutz TD2011L04i M odels CE Electrical Schematic Deutz TD2011L04i Models CE ...

Page 405: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 383 Electrical Schematic Deutz TD2011L04i Models CE ...

Page 406: ...Service Manual February 2015 384 Electrical Schematic Deutz TD2011L04i Models CE ...

Page 407: ...February 2015 Service Manual 385 Ground Control Box Terminal Strip Wiring Diagram Deutz D2011L03i TD2011L04i Models CE ...

Page 408: ... S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am D eutz D 2011L03i TD 2011L04i Models CE Ground Control Box Terminal Strip Wiring Diagram Deutz D2011L03i TD2011L04i Models CE ...

Page 409: ... 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 387 Ground C ontrol Box Switch Panel Wiring Di agr am D eutz D2011L03i TD 2011L04i M odels C E Ground Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models CE ...

Page 410: ...Service Manual February 2015 388 Ground Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models CE ...

Page 411: ...February 2015 Service Manual 389 Platform Control Box Wiring Diagram Deutz D2011L03i TD2011L04i Models CE ...

Page 412: ...2015 390 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am D eutz D 2011L03i TD 2011L04i Models CE Platform Control Box Wiring Diagram Deutz D2011L03i TD2011L04i Models CE ...

Page 413: ... 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 391 Platform C ontrol Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i M odels C E Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models CE ...

Page 414: ...Service Manual February 2015 392 Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models CE ...

Page 415: ...February 2015 Service Manual 393 Electrical Schematic Perkins 404D 22 Models CE ...

Page 416: ...Service Manual February 2015 394 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Perkins 404D 22 M odels C E Electrical Schematic Perkins 404D 22 Models CE ...

Page 417: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 395 Electrical Schematic Perkins 404D 22 Models CE ...

Page 418: ...Service Manual February 2015 396 Electrical Schematic Perkins 404D 22 Models CE ...

Page 419: ...February 2015 Service Manual 397 Ground Control Box Terminal Strip Wiring Diagram Perkins 404D 22 Models CE ...

Page 420: ...015 398 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am Perki ns 404D 22 Models CE Ground Control Box Terminal Strip Wiring Diagram Perkins 404D 22 Models CE ...

Page 421: ...anual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 399 Ground C ontrol Box Switch Panel Wiring Di agr am Perkins 404D 22 Models CE Ground Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models CE ...

Page 422: ...Service Manual February 2015 400 Ground Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models CE ...

Page 423: ...February 2015 Service Manual 401 Platform Control Box Wiring Diagram Perkins 404D 22 Models CE ...

Page 424: ...al February 2015 402 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am Perki ns 404D 22 Models CE Platform Control Box Wiring Diagram Perkins 404D 22 Models CE ...

Page 425: ...ual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 403 Platform C ontrol Box Switch Panel Wiring Diagram Perkins 404D 22 M odels C E Platform Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models CE ...

Page 426: ...Service Manual February 2015 404 Platform Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models CE ...

Page 427: ...February 2015 Service Manual 405 Electrical Schematic S 60 HC CE ...

Page 428: ...Service Manual February 2015 406 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic S 60 HC CE Electrical Schematic S 60 HC CE ...

Page 429: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 407 Chassis Wiring Diagram S 60 HC C E Chassis Wiring Diagram S 60 HC CE ...

Page 430: ...Service Manual February 2015 408 Chassis Wiring Diagram S 60 HC CE ...

Page 431: ...February 2015 Service Manual 409 Ground Control Box Terminal Strip Wiring Diagram S 60 HC CE ...

Page 432: ...nual February 2015 410 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am S 60 HC C E Ground Control Box Terminal Strip Wiring Diagram S 60 HC CE ...

Page 433: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 411 Platform C ontrol Box Wiring Di agr am S 60 HC C E Platform Control Box Wiring Diagram S 60 HC CE ...

Page 434: ...Service Manual February 2015 412 Platform Control Box Wiring Diagram S 60 HC CE ...

Page 435: ...February 2015 Service Manual 413 Electrical Schematics A S Models Electrical Schematic Ford MSG 425 EFI Models AS ...

Page 436: ...Service Manual February 2015 414 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic For d M SG 425 EFI M odels AS Electrical Schematic Ford MSG 425 EFI Models AS ...

Page 437: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 415 Electrical Schematic Ford MSG 425 EFI Models AS ...

Page 438: ...Service Manual February 2015 416 Electrical Schematic Ford MSG 425 EFI Models AS ...

Page 439: ...February 2015 Service Manual 417 Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models AS ...

Page 440: ...15 418 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am Ford MSG 425 EFI Models AS Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models AS ...

Page 441: ...ual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 419 Ground C ontrol Box Switch Panel Wiring Di agr am For d MSG 425 EFI M odels AS Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models AS ...

Page 442: ...Service Manual February 2015 420 Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models AS ...

Page 443: ...February 2015 Service Manual 421 Platform Control Box Wiring Diagram Ford MSG 425 EFI Models AS ...

Page 444: ...l February 2015 422 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am Ford MSG 425 EFI Models AS Platform Control Box Wiring Diagram Ford MSG 425 EFI Models AS ...

Page 445: ...al Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 423 Platform C ontrol Box Switch Panel Wiring Diagram For d M SG 425 EFI M odels AS Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models AS ...

Page 446: ...Service Manual February 2015 424 Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models AS ...

Page 447: ...February 2015 Service Manual 425 Electrical Schematic Deutz D2011L03i Models AS ...

Page 448: ...Service Manual February 2015 426 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Deutz D2011L03i M odels AS Electrical Schematic Deutz D2011L03i Models AS ...

Page 449: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 427 Electrical Schematic Deutz D2011L03i Models AS ...

Page 450: ...Service Manual February 2015 428 Electrical Schematic Deutz D2011L03i Models AS ...

Page 451: ...February 2015 Service Manual 429 Electrical Schematic Deutz TD2011L04i Models AS ...

Page 452: ...Service Manual February 2015 430 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Deutz TD2011L04i M odels AS Electrical Schematic Deutz TD2011L04i Models AS ...

Page 453: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 431 Electrical Schematic Deutz TD2011L04i Models AS ...

Page 454: ...Service Manual February 2015 432 Electrical Schematic Deutz TD2011L04i Models AS ...

Page 455: ...February 2015 Service Manual 433 Ground Control Box Terminal Strip Wiring Diagram Deutz D2011L03i TD2011L04i Models AS ...

Page 456: ... S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am D eutz D 2011L03i TD 2011L04i Models AS Ground Control Box Terminal Strip Wiring Diagram Deutz D2011L03i TD2011L04i Models AS ...

Page 457: ...o 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 435 Ground C ontrol Box Switch Panel Wiring Di agr am D eutz D2011L03i TD 2011L04i M odels AS Ground Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models AS ...

Page 458: ...Service Manual February 2015 436 Ground Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models AS ...

Page 459: ...February 2015 Service Manual 437 Platform Control Box Wiring Diagram Deutz D2011L03i TD2011L04i Models AS ...

Page 460: ...2015 438 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am D eutz D 2011L03i TD 2011L04i Models AS Platform Control Box Wiring Diagram Deutz D2011L03i TD2011L04i Models AS ...

Page 461: ...o 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 439 Platform C ontrol Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i M odels AS Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models AS ...

Page 462: ...Service Manual February 2015 440 Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i TD2011L04i Models AS ...

Page 463: ...February 2015 Service Manual 441 Electrical Schematic Perkins 404D 22 Models AS ...

Page 464: ...Service Manual February 2015 442 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Electrical Schem atic Perkins 404D 22 M odels AS Electrical Schematic Perkins 404D 22 Models AS ...

Page 465: ...February 2015 Service Manual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 443 Electrical Schematic Perkins 404D 22 Models CE ...

Page 466: ...Service Manual February 2015 444 Electrical Schematic Perkins 404D 22 Models AS ...

Page 467: ...February 2015 Service Manual 445 Ground Control Box Terminal Strip Wiring Diagram Perkins 404D 22 Models AS ...

Page 468: ...015 446 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Ground C ontrol Box Terminal Strip Wiring Di agr am Perki ns 404D 22 Models AS Ground Control Box Terminal Strip Wiring Diagram Perkins 404D 22 Models AS ...

Page 469: ...anual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 447 Ground C ontrol Box Switch Panel Wiring Di agr am Perkins 404D 22 Models AS Ground Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models AS ...

Page 470: ...Service Manual February 2015 448 Ground Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models AS ...

Page 471: ...February 2015 Service Manual 449 Platform Control Box Wiring Diagram Perkins 404D 22 Models AS ...

Page 472: ...al February 2015 450 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC Part No 825591 Platform C ontrol Box Wiring Di agr am Perki ns 404D 22 Models AS Platform Control Box Wiring Diagram Perkins 404D 22 Models AS ...

Page 473: ...nual Part No 825591 S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC 451 Platform C ontrol Box Switch Panel Wiring Diagram Perkins 404D 22 M odels AS Platform Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models AS ...

Page 474: ...rvice Manual February 2015 452 Platform Control Box Switch Panel Wiring Diagram Perkins 404D 22 Models AS S 60 S 65 S 60 TR AX S 65 TR AX S 60 HC S 60X S 60XC Part No 825591 Service M anual Febr uary 2015 ...

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