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6. LO C7P 3 BATGND C7B 3 _ GROUND z C2P 3 C41RPM C2B 3 EA s lt e 3 m 2 I o a 01 4 C30FWD WH C1B 4 2 C5 21 WH RD 4 DRIVE FORWARD 2 15 01 5 C31REV WH BK C1B 5 5 20 WH BK DRIVE REVERSE Pl 4 4 4 DRIVE C130TA WH RD X TRAVEL ALARM OPTION Meee ee oR 0 cate 9 8 C264 C26 2 C32BRK WH RD f CIPS 6 5 23 _ 2 WH RD BRAKE RELEASE gt m 9 281 28 2 5 C29MS RDWH C29MS RD WH f oz 204 CIPS mE 1 MOTOR STROKE 55 8 5 2 CDESBURD ss I 2 eu 5 5 C253 C252 8 19 CDE2 BL BK 1 11 C37SCW BL BK C1B 11
7. 29099 N d FINGOW LYVLS NOLINDI HOA 72 21 dWal OF C4 SZAVAM 151 NO EHLUO NOI 8 26027 e 25 SVD 201 8 0000000 e O est60 139310 MS AB4OL 2 1 zi 9 9 G s s G4 AND HMdXDY v INANI HVIS wn pue e osea Z lt que z Q4 6 olya OL t O 10548 uo L seujsnpu z 5 2 151 5 5 9 58 v 0 O 558 WHv1v GVOTH3AO WHOd1V1d EEL Coo 51 959 9H2ig H9 zc C 281 QH 5 lt ZVALO 5 20 O NOILONGSY 3385 LAN CH CHO
8. N LO C7P 3 BATGND C7B 3 GROUND E 2 3 C41RPM OR BK C2B 3 m 8 5 a B 8 01 4 C30FWD WH 1 4 521_ WH RD 4 DRIVE FORWARD 7715 5 meg CIPS C31REV WH BK C1B 5 _ 5 20 _ C31REV WH BK DRIVE REVERSE P Pl BB M 4 DRIVE WH RD TRAVELALARM 1 OPTION Q T E EE 9 264 C262 I ave CIPS C32BRK WH RD 6 C5 23 _ 2 WH RD 6 RELEASE x z Q C28 1 C282 z C29MS C29MS RD WH 4 o 202 CIPS CIB3 8526 1 MOTOR STROKE e e E 8 ODES BUD s 5 E 5 5 C25 1 C252 _ CDE2BLBK 7 1 11 C37SCW C1B 11 C37SCW P SIEER RIGHT he L LEFT 2 i aiant ENABLE C36STCC BL C36SCC BL
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11. 29099 N d FINGOW LYVLS NOLINDI 2 21 JNV SS3ud HO 01 o CH 2 1904 9 6 z 60027 EL 99 201400 8 AINO 136310 MS A34 OL 2 L G a 9 9 OF s s G4 zu v 9 G Oo In ANANILHVLS pue el G4 H3l3WOHOVL 2 lt z G Suomi O I 191 OL G seujsnpu lt lt lt z gt T 5 LL 58 5 850 Z1ST CH HO 514 2 8 0 7151 80 mz AORA WHY TV QVOTH3AO WHOd1V1d G4 V ET 1 GVOTHSAO zer C4 m wn G H3MOd AV HH NHOH uer C4 Suo d S 9 GH 8 5 1 820 N39SvO E 21 90 HWHO vel MS WI1GVOTH3AO
12. 2 gg E S og 5 2 a sz E ER a gt BK RD C1B 9 8 FOOTSW HIGH FOOTSW Low a zB D x Su 8 LOW RPM Hic Rem A BK RD BRN t bie d HIGH IDLE RELAY 8 BKRD 08 18 HIGH RPM SOLENOID 2 cz Se T at 4 e N 5 E 5 C2P 7 GR WH C2B 7 z C45GEN GR WH 5 12 il V GENERATOR ORTION IGC IOL lt II IE gt I2 EI a8aY yEVK I6 K MII I II I9 I I IG 2L III II I EV L9II NYEY I I III lt IIIIIIN IIT IAAIIIAIIEI5II AIIIAINT TD SSS i 1 1 g x 2 DLITE BLWH C3B 12 l i DRIVE LIGHT work HTS DRIVE LIGHT OPTION i ala o 9 E 3 RD WORK LIGHTS OPTION c E 2 12_ C2P 10 8 e EC is i 4
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15. Perkins 404 22 Models before serial number 11880 Electrical Schematic S 60 Section 6 Schematics z ge 5 x 55 2 elo GE zu E E ES y C35RPM BK RD C1B 9 8 amp FOOTSW HIGH a S 5 FOOTSW LOW E x x ow b gt 26 LOW RPM z RPM FUNCTION ENA 25 C35RPM BK RD BRN t 095 HIGH IDLE RELAY 8 5 8 BIRD 63 18 HIGH RPM SOLENOID cz Pile a aM MD CE Ga X 22 Not C2P 7 GR WH C2B 7 GR WH C5 12 DGENERATOBOBTION i 3 is 4 12 DLITE BLWH C3B 12 o 4 DRIVELIGHT WORK LIGHT RD CO DRIVE LIGHT OPTION 8 9 ig glg 9 10 m v i amp WORK LIGHTS OPTION 8 2 12 C2P 10 e 6 ORK LIGHTS Q
16. N LO C7P 8 BATGND C7B 3 ROUND C2P 3 OR BK C2B 3 9 5 lt 8 5 7 T 5 a Haze C30FWD WH C1B 4 5 21 __ WH BK 0D DRIVE FORWARD gt 15 gt o 2 CIPS WH BK C1B 5 C5 20 _ C31REV WH BK DRIVE REVERSE Pi c A 2 DRIVE MODE C130TA WH RD i7 TRAVELALARM z gt LI OPTION 8 9 8 261 C26 2 ave C32BRK WH RD C1B 6 Fd 5 23 _ C32BRK WH RD il BRAKE RELEASE gt x z 5 8 C283 C282 56 7 o C29MS RDWH C1B 3 C524 __ C29MS RD WH MOTORSTRORE 2 5 8 95 BL RD gt 16 e 5 5 C251 025 2 CDE2BL BK 1 11 C37SCW BL BK 1 11 C37SCW 0 gt 7 18 lt lt lt lt lt gt gt STEER RIGHT ko DRIVE ENABLE zu t RIGHT x1 010 C36STCC BL C1B 10 C36SCC BL IA 255 x CDE1 BLWH 2 0 E C244 C242 Dac z a FREIE sconces E E 9 Z 220 7 lt 1 BL 1 6 lt
17. Perkins 404 22 Models after serial number 11879 Electrical Schematic S 60 Section 6 Schematics gg E 8802 SE g zc a y CIP 9 C35RPM BK RD 9 5 EE FOOTSW HIGH e e 9 o FOOTSW LOW E 28 x ow b 25 LOW RPM x o FUNCTION HIGH RPM gt BK RD a BAN GH IDLE RELAY 2 a i 65 18 HIGH RPM SOLENOID cz 4 C2P 7 GR WH 2 7 C45GEN GR WH C5 12 I GENEBATOB OPTION ee ee E s e 12 DLITE BLWH C3B 12 1 DRIVE LIGHT GHT IGHTS WORK LIGHT RD QUO DRIVE LIGHT OPTION a 3 ge Aa BD X WORK LIGHTS OPTION Lu b C2P 12 T C2P 10 v ae 26 3 o 1 gt 4 2 11 C C2P 9
18. Perkins 404 22 Models after serial number 11879 Electrical Schematic S 65 Section 6 Schematics e amp 25 5 SE g gt a y CIP 9 C35RPM BK RD C1B 9 FOOTSW HIGH FooTsw Low FE x s b LOW RPM HIGH Rpm FUNCTION ENA 5 C35RPM BK RD BRN THIGH RP gt i e HIGH IDLE RELAY 8 BKRD 65 18 45 HIGH RPM SOLENOID 2 cz o 114 1 UE UTERE ORI 4 5 C2P7 GR WH C2B 7 s C45GEN GR WH 5 12 Hl A GENERATOR OPTI N i n 1 ji i 12 DLITE BLWH DRIVELIGHT ars 4 s i WORK LIGHT BD M DRIVE LIGHT OPTION oe E 10 ye F 3 Hn RD WORK LIGHTS iy 2 C2P 10 a gt K as Q mmn mnm me
19. P22LS BK gt ROCKER STEER OPTION ONLY N c C7P 8 BATGND GROUND z E 3 hze 23 C41RPM OR BK 3 8 4 C30FWD WH 5 21 C30FWD WH BR RD DRIVE FORWARD 215 i heze CIPS C31REV WH BK C520 C31REV WH BK RD p BK BRIVE REVERSE e z 35 Pi gt DRIVEMODE s C130TA WH RD i TRAVEL ALARM s OPTION 5 a E 9 C264 C262 C32BRK WH RD z 4 lt 5 23 C32BRK WH RD lj RELEASE x z 9 8 28 1 C282 a 29 5 RD WH 29MS RD WH o C1P 3 C29MS C524 29 5 RD WI heron STROKE 2 5 a e E s 5 O7 9 5 3 C253 C252 CDE2 BLBK 1 11 C37SCW BUBK C37SCW STEER RIGHT LEFT 2 a DRIVE ENABLE t RIGHT 10 C36STCC BL C36SCC BL STEER LEFT 2 9o x GDENBEWH g C244 0242 SEE ies 55 gale m i BL 9 ig 6 lt lt lt
20. TWR Fel ORANGE BLUE 16 1 211 PC 56 28 0 009 CONNECTOR EHOWN BLUE T A 211 A56 7007 LOCKING CAM B 211 56 0008 COVER EL 211 CC 28 1120 TERM WHITE RED 18 MTRTWR8 PINK TAN 18 18 ORANGE BLUE 16 RED WHITE 18 NA 16 BROWN BLUE 16 17 BROWNIGREEN 16 30 LT BLUE WHITE 18 AUXOUT2 gt 35 TAN DK GREEN 18 AUX ANA PD1 lt DKBLUE TE Re 32 TAN 18 31 YELLOWIGRAY 18 COOLANT 38 PURPLE YELLOW 18 3 TEMPERATURE SKANK PUT 36 DK BLUE YELLOW 18 19 BLACK 16 SENDER 2 GROUND Bd ae 75 49 BLACKILT GREEN 18 YELLOWGRAY 18 svo mer gt 50 LT GREEN RED 18 SV 21 __ 18 GREEN 18 B 55 DK GREENIORANGE 18 ines 5 TWIST WIRES 10 TURNS 860 DEGJFOOT FULL LENGTH i lt gt 3 GRAY BROWN 18 CAMS 14 PURPLE ORANGE 18 TWIST WIRES 10 T RNS 350 FULL LENGTH LTGREEN 18 rag CRANE 1 PURPLEWHITE 18 LTGREEN RED 18 RANK S512 WHITE PURPLE 18 TANE 8 22 RED TAN 16 BLACKILT GREEN 18 VBAT a VAT 02 GRAVORANGETE STARTER LOCKOUT FUELLOCKOFF gt MAP SEN
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22. Electrical Schematic S 60 CE Models Deutz F3L 201 1 Models after serial number 11879 Section 6 Schematics x I gg E m s ER p CIP 9 BK RD C1B 9 o 8 FOOTSW HIGH e FOOTSW LOW E 2 b 25 LOW RPM z FUNCTION ENA HIGH RPM __ BK RD gp BAN iGHIDLE RELAY I 5 65 19 HIGH RPM SOLENOID e C2P 7 GR WH C2B 7 GR WH 5 12 3 s GENERATOR OPTION RHENUM eres NE 12 DLITE BLWH C3B 12 On i DRIVE LIGHT H LIGHTS RD WORK LIGH DRIVE LIGHT OPTION l 1 Ss 8 gg 9 rS 5 i WORK LIGHTS OPTION ru 2 12 C2P 10 a Or ig N 9 M Ls tr VEIA E A EAE C2P 11 C2P 9 5 x 9 gi
23. OR J1 18 C134PWR RD L4 BRN 1 14 15 RD PDLITE RD un QN CA5GENGR WHC2P7 0 c oe 3 556 56 uk T m Wok ee ME 27 CO 2 2 5 5 RD P24FS WH C9 2 ga BK C35HS BK RD 9 4 a 5 Les RDBK HI _ C133PLA GR BK D39 az 5 ort Qaik e tan i 139 WO V o 1 58 66 ______ L 1 4 RD E STOP g NE 212 C134PWR RD _ C33STR C1P 7 LR m P25FS RD C9 3 F zb BL RD DE3 J1 16 gt LS _ 258 naa Ni 3 BL DE1 J1 6 EIFE BK BK C34SA C1P 8 rz BUBK DE2 J1 7 B YL Ji 8 OR J1 9 BRN J1 10 C29MS RD WH 1 8 Pe 8 oO O O Q WH CR30 C27AUX RD C1P 1 gt 5 lt EC E EE Tz 85 z lt 5 9 mae I 2
24. a m o 515 a 9 zu A 8 518 1 9 BK RD 9 E 4 FOOTSW HIGH e FOOTSW LOW n B 5 e B LOW RPM 8 FUNCTIONENABLE4 5 8 HIGH RPM w MM EL c x 1 GENERATOR 5 e ON C2P 7 GR WH C2B 7 z C5 12 C45GEN GR WH GENERATOR OPTION gms II s raat m s II a n c c Ic o sss Seno c di r D C Er a i c Rc E cain rk cR et ees geet gee CC Cof mr Sisi C C d c sts T 1 5 2 a C2P 6 DLITE GF BK C2B 6 9 m DRIVE LIGHT 9 ee LIGHTS eur Sj WORK LIGHT ___ Cf DRIVE LIGHT OPTION 1 lt E N 21 S C4B 11 RD 4 2 12_ 77 2 10 5 85 WORK LIGHTS OPTION 3 Dd 5 a 1 o a
25. HOLIMS OL SS3NHvH WH TB21 OPTIONS WH OPTIONS Part No 77828 NOTE DASHED LINES INDICATE OPTION WIRES A DWG 5 60 5 65 5 60 HC G 6 46 Section 6 Schematics Ford Models after serial number 11879 Ground Control Box Switch Panel Wiring Diagram S 65 February 2012 6 47 A DANO 5 60 5 65 5 60 HC G Part No 77828 5 z 2565 o r o gt o am 8 5 4285506 ni j u up xxu 2186 iueoooosoz9S9s9mutssxE S E E gt gt TE gt
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30. 1 i l i i i a i 1 9 C2P 4 DLITE OR RD C2B 4 I g I lt DRIVELIGHT 1 RD DRIVE LIGHT g z ii 8 C OPTION Pu 5 ig i 25 WORKLIGHT 9 z o s T A 207 4 gt 196 SN WORK LIGHTS A 5 9 x 8 kisi usu a SS ws SSS cs w SSO J 2 WH H 1 l l ea i C21IGN WH HOUR METER y Ln BL WH CHECK ENGINE LED 4 g 6 5 I RUN TEST SWITCH s 7 88 o 1 8 C2P 1 C39LP BL RD C2B 1 Qo 8 FUEL C5 19 P23BAT WH FEH 16 PIN1 SELECT 3 ro FUEL C5 11 C21IGN WH FEH 71 PIN21 SELECT i E a o 8 C5 9 C128RPM OR RD FEH 306 PIN24 C41RPM OR BK sy 6283 So C108ESL BL WH FEH 658 PING oz C127TSW GR FEH 458 PIN18 5 5 a z2 C5 10 C39LP BL RD FEH 72 55 4 5 18 C35RPM BK RD FEH 307A PIN23 29 Sx 8 P20BAT RD FEH 361 7 C33STRBK C1B 7 GND 570 PIN34 ENG
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32. 1 AME MEE C2P 4 DLITE OR RD C2B 4 4 DRIVELIGHT aN e S DRIVE LIGHT 3 AA PTION E 4 05 1c A ig WORKLIGHT 8 2 8 v 8 2 55 e RD 4 gt mi un 5 C 195 WORK LIGHTS E OPTION o8 m n a SE 8 3 C21IGN WH t HOUR METER A GY RD B Gy YL u GASOLINE SENSOR RD gt 58 BK BL ae RD GN Ta N or LPG LOCKOUT WH BK D BLWH CHECK ENGINE LED n BR n 8 e I RUN TEST SWITCH E 5 P 8 8 o wo 5 C2P 1 C39LP BL RD C2B 1 So 8 521 C5 19 P23BAT WH 16 FUEL 7 E 16 _ f SELECT 8 e a 5 8 LS FUEL C5 11 C21IGN WH FEH 71 PIN16 gt SELECT n B C5 9 C128RPM OR RD FEH 306 PIN24 C41RPM OR BK C2B 3 N C108ESL BL WH FEH 658 PING 5 C127TSW GR FEH 458 PIN3 a E o m z C5 10 C39LP BL RD FEH 72 7 BE u C5 18 C35RPM BK RD FEH 307A PIN23 o 5 59 9 C1P 7 C33STRBK CiB 7 GND BR FEH 570 PIN34 a 5 ENGINE 5 2 OR BK FEH 11 8 START ip C55 R33STR BK FEH 32 PI
33. TB20 EE ale 8 z Ez s e C35RPM BK RD C1B 9 m ENGINE 5 OIL PRESSURE SPEED 25PSR WH BK 3 8 SENDER OPTION 3 VOLT METER OPTION I LOWRPM L NCTION ENABLE C26TSR WH RD WATER TEMPERATURE 1 HIGH RPM SENDER OPTION i cp ecce ey 2 n GENERATOR i uu C45GEN GR WH C2B 7 GR WH Itl iar lt a Irrr mn 1 fo fn nn nn nn nn nn rn nn i 9 DLITE OR RD C2B 4 g FE Cd RD DRIVELIGHT 3 i 8 ig 5 95 9 g WORKLIGHT ze 4 9 RD i gt CO 4 I 5 196 d WORK LIGHTS 5 i Sx LAO S 4 i C21IGN WH t HOUR METER 5 w BL WH CHECK ENGINE LED 9 i BR 4 8 g z RUN TEST SWITCH 5 T 5 m 5 a e amp 8 8 2 C39LP BL RD C2B 1 9 8 C5 19 P23BAT WH FEH 16 PIN1 Es SELECT e 5 8 eisai FUEL C5 11 C21IGN WH FEH 71 PIN21 gt SELECT 7 5 B C5 9 C128RPM OR RD FEH 306 PIN24 C41RPM OR BK C2B 3 gt
34. 29099 N d FINGOW LYVLS NOLINDI HOA 72 21 INYA HO dWal OF C4 151 78 26027 s es no CINO 579 04 dWnr O est KINO 195310 MS AIM OL 2 EAN s s s G4 HMdXDY v H G 5 wn pue id i Z lt ue z la OL t O oa 1895 L seujsnpu z 3 151 PES 5 9 2 v 8 5 558 WHv1v GVOTH3AO WHOd1V1d EEL OH 7 21 80 HW18 VIdEEH 9HO8 H9 lt 21 810 om SION NSQNE GRE i 5 20 HWE lt GH QH HO HST8LLO ME QH s QH a x 829 N39SrO 51 89 8 5 s E veh 9 MS WIONHOMavoT vet Q GH 5 5 Je E269 9138 H3 HM Gavel vel L WI QVO1 PEL Qd ZISTQH HMdfELd 9H H 9 22 65 6 O GH 280 561 8 18 060 erena 8 2652 9 8 9
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36. Ii Platform Control Box Wiring Diagram S 65 Perkins 404 22 Models February 2012 Section 6 Schematics Platform Control Box Wiring Diagram S 65 Perkins 404 22 Models TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOTSWITCH CONNECTOR ALC 500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH ITEM DESCRIPTION H1 C9 C1P C4P 48 PIN CONNECTOR BLOCK U13 J1 42 J3 CR27 CR30 LS18 C134PWR RD H1 C32BRK WH RD C1P 6 C32BRK WH RD J2 19 C40LS OR C2P 2 P24FS WH C9P 2 P23BAT WH C7P 2 BK C1P 12 P22BAT BK C7P 1 C19JSV GRANH C4P 7 C18PRR GR BK C4P 6 C17PRL GR C4P 5 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C129JDA BL C3P 10 TS8 C59CHK BL BK C3P 11 L47 C59CNK BL BK C3P 11 P26BAT BK C9 1 P2 CWLITE WH TS49 oruz 55502 TOTES C19JSV GR WH TS7 3 WH C19JSV GRAWH C4P 7 BRN JC3 GND RDE STOP mf CI34PWRRDLSIB _________ JIB OPT RD 1518 CABLE LS18 CE M OPTION N P25FS RD C9 3 TS2
37. ALC 500 circuit board drive steer joystick controller extend retract joystick controller d primary boom up down and turntable rotate left right joystick controller A TEREX COMPANY 4 2 5 60 5 65 5 60 HC 1 1 ALC 500 Circuit Board AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note When the ALC 500 circuit board is replaced the joystick controllers will need to be calibrated See 1 2 How to Calibrate a Joystick How to Remove the ALC 500 Circuit Board 1 Push the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid 3 Locate the ALC 500 circuit board mounted to the inside of the platform control box AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 77828 February 2012 Section 4 Repair Procedures 4 Attach a grounded wrist strap to the ground screw inside the platform control box 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
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42. razza 4 4 e 22 04 2 HOLIMS A ROG TREO HM Auvnixnv 2 1961 HOLIMS 4015 AON3OH3W3 Id 28760 QH HM Z8 61HO QH HM 8 61 QH HM LLL WUO SZ 1 uuo OL Gu HM HOLSISAH HOLSISAHY INOZ H3ddn 3naviNunL WOOS AHVWWIHd vH 1 WYO 9 IVA HOLSIS3H 314109 HOLSISSY woog bly Yl uuo MSZ Sc H8 February 2012 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram S 60 CE Models Deutz F3L 201 1 Models before serial number 11880 Section 6 Schematics February2012 EE E EI EEEEEi ZS EE S I iswas a asa a Ground Control Box Terminal Strip Wiring Diagram S 60 CE Models Deutz F3L 2011 Models after serial number 11879 February 2012 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 60 CE Models Deutz F3L 2011 Models after serial number 11879 1108
43. t a solenoid boot b high idle adjustment nut d low idle lock nut and adjustment Screw 3 Move the function enable toggle switch to the high idle rabbit symbol position and note the rpm Refer to Section 2 Specifications If high idle rpm is correct disregard adjustment step 4 4 Loosen the yoke lock nut then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Note Be sure the solenoid fully retracts when activating high idle 3 14 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures A 12 Grease the Turntable Rotation Bearing and Rotate Gear Note Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease fitting on the front turntable cover 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased
44. 6 107 Hydraulic Schematic 12kW Hydraulic Generator Option 6 108 Hydraulic Schematic 2WD 6 109 Hydraulic Schematic 4WD 6 110 Genie 5 60 5 65 5 60 HC Part 77828 February 2012 Section 2 Specifications Machine Specifications Specifications Fluid capacities Fuel tank 35 gallons Tires and wheels 181 liters Tire size LPG tank 33 5 pounds Rough terrain low profile 355 55D625 15 2 kg Tire size Hydraulic tank 45 gallons Rough terrain tall 385 19 5 170 liters Tire size Hydraulic system 55 gallons Hi flotation 41 18LL x 22 5 including tank 208 liters Tire ply rating Drive hubs 20 fl oz Rough terrain low profile and Hi flotation 14 0 6 liters Tire ply rating Turntable rotation drive hub i i 07 Rough terrain tall 16 19 liters Drive hub oil type Wheel lugs 9 5 8 18 SAE 90 multipurpose hypoid gear oil API service Lug nut torque dry 240 ft Ibs classification 325 Nm Lug nut torque lubricated 180 ft Ibs 244 Nm Overall tire diameter 36 9 in Rough terrain low profile tires 93 7 cm Overall tire diameter 40 1 in Rough terrain tall tires 102 cm Overall tire diameter 40 3 in Hi flotation tires 102 4 cm Tire pressure 70 psi Rough terrain low profile tir
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60. AP Non steer end drive motor circuit 60 70 ft lbs 81 95 Nm Orifice 0 040 inch 1 mm Equalizes pressure on both sides of flow divider combiner valve 3 6 Orifice 0 040 inch 1 mm AE Equalizes pressure on both sides of flow divider combiner valve 11 7 Orifice 0 040 inch 1 mm WW Equalizes pressure on both sides of flow divider combiner valve 13 Check Steer end drive motor circuit 60 70 ft lbs 81 95 Nm Check valve ete poo Steer end drive motor circuit 35 40 ft lbs 14 16 Nm 10 Shuttle valve position way Charge pressure circuit that directs hot oil out of low pressure side of drive pump 80 90 ft lbs 108 122 Nm 11 Flow divider combiner valve AD au Controls flow to steer end drive motors in forward and reverse 80 90 ft lbs 108 122 Nm 12 Check ns Y Y xs Non steer end drive motor circuit 35 40 ft lbs 14 16 Nm 13 Flow divider combiner valve XX Controls flow to non steer end drive motors in forward and reverse 80 90 ft lbs 108 122 Nm 14 Relief valve 280 psi 19 3 bar UU Charge pressure circuit 35 40 ft lbs 14 16 Nm Genio
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65. 4 28 4 4 Extension 4 29 45 4 32 46 Platform Leveling Master 4 35 xii S 60 5 65 S 60 Part No 77828 February 2012 TABLE CONTENTS Section 4 Repair Procedures continued Engines 5 1 RPM Adjustment Ford and Deutz Models 4 36 5 2 RPM Adjustment Perkins 4 36 5 3 Flex Plate eu oie mo edet emm etin Ea 4 36 5 4 Engine Fault Codes GM and Ford Models 4 43 Hydraulic Pumps 6 1 Function pumpu uu Q Ere LUE 4 44 6 2 drive Pump icit ED 4 45 Manifolds 7 1 Function Manifold Components 4 49 7 2 Valve Adjustments Function Manifold 4 53 7 3 Jib Boom Platform Rotate Manifold Components 4 54 7 4 Brake Two speed Manifold Components 2 4 55 7 5 Turntable Rotation Manifold Components 4 56 7 6 Oscillate Directional Valve 4 57 7 Valve Adjustments Oscillate Relief Valve 4 59 7 8 Drive Oil Diverter Manifold Components w
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70. 2 11 C2P 9 E E A x fn 9 P134FB WH gt t FLASHING BEACONS m Pod EN OPTION IET D Ed yO C21HM WH fs i 3 HOUR METER E DONDE ES RUN TEST SWITCH 5 a C5 8 C127SW GR CONN 5 18 C35HRPM BK RD lt lt GM CONNG D BRN lt lt GM CONN6 E 8 C135FP BLWH D lt GM 9 C2P 1 C39LP BL RD C2B 1 5 11 C21IGN WH F lt GM CONN6 LP pie FUEL SELECT GAS 9 g as SELECT GAS 4 gt 128 OR RD lt lt CONNS 5 6510 C39LP BL RD D 22 GMCONN8 C41RPM OR BK C2B 3 5 2 C 22 GM CONN8 5 6 C27AUX RD 22 GM CONNS CHECK ENGINE LED C5 13 C108ESL BLWH lt lt GMCONN10 N 9 5 C33STRBK J C1B 7 i SANE 8 CES C33STR BK lt lt GM CONN10 i S 8 C5 19 P23BAT WH lt lt GM CONNIO ENGINE 7 START e az E GM HARNESS 0 eo RS 1 2 e 1 2b BUE ala i 88 18 1 9 STARTER MOTOR 9 19 a NA o i 2 I M eal N AUXILIARY a as 1 G2ZAUX RD n AUXILIARY POWER RELAY o C27AUX RD 1 1 lt
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72. GR SELECT dy 22 Ur e gcc ES A LL 1 2 P2 J TS8 O RR EMERGENCY P3 Ts7 i J TS14 TS2 TS4 STOP HORN PLATFORM JIB TS1 HIGH LOW TS47 ENGINE HIGH LOW PLATFORM ROTATE GR BK BOOM AUXILIARY 2WD 4WD GENERATOR START RPM LEVEL lt PUMP OPTION 027 WH 24 RD RD RD RD NOTE DASHED LINES INDICATE OPTION WIRES CE LIFT DRIVE OPTION REPLACE WIRE WITH CR27 amp CR30 Genie A TEREX Part No 77828 S 60 5 65 5 60 6 25 February 2012 Section 6 Schematics JEE Ea Platform Control Box Switch Panel Wiring Diagram S 65 GM 3 0L Models Section 6 Schematics February 2012 Electrical Schematic S 60 Ford LRG 425 EFI Models before serial number 11880 February 2012 Section 6 Schematics Electrical Schematic 5 60 Ford LRG 425 EFI Models before serial number 11880
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74. pee DES i i P22LS BK C3P 11 _ C59CNK BL BK C3B 11 BL BK d 3 BK 37 3 4 Z C37 4 LS5 CABLE TENSION LED 8 3 5 o P134 RD E RD C38 1 gt RD A BR C38 2 1517 UP DOWN 5 a SPEED REDUCTION LIMIT SWITCH 2 B 92 _ 4 OR lt go E PLATFORM LEVEL 5 t DOWN C4P 3 C15PLD OR BK C4B 3 5 20 1 20 2 2 ru i GIAPEUOR D PLATFORM LEVEL UP PLATFORM LEVEL TIDOWN 1 PLATFORM LEVEL DOWN E C214 C21 2 a 5 C4P 6 C18JD PRR GR BK C4B 6 E IRIGHT PLATFORM ROTATE LEFT C17JU PRL GR C4B 5 TEE m C23 1 8 C18JD PRR GR BK 5 3 pE i A gt gt PLATFORM ROTATE RIGHT FRIGHT PLATFORM g LEER ROTATE GH D PLATFORM ROTATE LEFT 224 C222 Sd i C120 RD BK DESCENTALARMOPTION i i ER AE EE OPER 1 xum x ag 2 n 2 ale 5 enie G S 60 5 65 S 60 HC 6 53 Part No 77828 February 2012 Section 6 Schematics Electrical 5 60 Deutz F3L 2011 Models after serial number 11879 Section 6 Schematics February2012 J H J H po A e s c Electrical Schematic S 60 CE Models Deutz F3L 201 1 Mode
75. 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 Turntable rotation brake release 10 13 ft Ibs 14 18 Nm 4 Orifice 0 030 inch 0 76 mm release circuit located inside port A TEREX COMPANY 4 56 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures 7 6 MANIFOLDS Oscillate Directional Valve Components The oscillate directional valve is mounted inside the drive chassis at the non steer end Index No Description 1 Gaps tenes 2 Spool valve Function Torque ORE Breather 20 25 ft lbs 27 33 Nm Part No 77828 A TEREX COMPANY 5 60 5 65 5 60 HC 4 57 Section 4 Repair Procedures February 2012 MANIFOLDS How to Set Up the Oscillate Directional Valve Note Adjustment of the oscillate directional valve linkage is only necessary when the linkage or valve has been replaced 1 Lowerthe boom to the stowed position 2 Use a bubble type level to be sure the floor is completely level Tip over hazard Failure to perform AWARNING this procedure on a level floor could compromise the stability of the machine resulting in the machine tipping over 3 Checkthe tire pressure in all
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87. 25 Proportional solenoid valve Qus 26 Flow control valve 0 6 2 27 L MIN 27 Check valve 30 psi 2 EE uu 28 Differential sensing valve 110 psi 7 6 bar Ls 29 Needle valve 30 Solenoid valve 3 position 4 31 Solenoid valve 3 position 4 Part 77828 A TEF S 60 5 65 S 60 HC COMPANY Function Section 4 Repair Procedures 1 Blocks flow from auxiliary pump to function pump System relief Bleeds off differential sensing valves to tank Differential sensing circuit meters flow to functions Differential sensing circuit platform level up Differential sensing circuit platform level down Turntable rotate left right Platform rotate and jib boom S 65 Platform rotate and jib boom circuit S 65 prevents hydraulic hoses from draining back to tank Boom extend retract circuit Platform level circuit Platform level up down Platform rotate and jib boom up down S 65 MANIFOLDS Torque 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 20 25 ft lbs 27 34 Nm 30 35 ft lbs 41 47 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 20 25 f
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91. 1 OD 2295 5 Part No 77828 A DWG 5 60 5 65 5 60 HC 6 30 Section 6 Schematics February2012 Electrical Schematic 5 60 Ford DSG 423 EFI Models after serial number 14053 A P22LS BK N LO C7P 3 BATGND C7B 3 GROUND gt lt G2P33 C41RPM C2B 3 m 8 5 X Q haze CIP4 C30FWD WH 1 4 z 60521 C3OFWD WH BK PD DRIVE FORWARD gt 15 Y M H 3 CIPS C31REV WH BK C1B 5 _ 5 20__ C31REV WH BK POp 8K REVERSE e DRIVE C130TA WH RD TRAVELALARM een OPTION Jan Ge toad meen sacs a 8 C26 1 C26 2 C32BRK WH RD T E CI 6 i 5 23 _ 2 WH RD esse gt
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95. Section 6 Schematics Electrical Schematic 60 CE Models Deutz F3L 2011 Models before serialnumber 11880 February2012 gt ROCKER STEER OPTION ONLY P22LS BK N c LO C7P 3 BATGND C7B 3 eRouNp s G2P 3 C41RPM C2B 3 8 E lt 8 gt a B 5 o a 154 4 C30FWD WH C1B 4 s C5 21 C30FWD WH BK 82 DRIVE FORWARD 215 CIPS C31REV WH BK 1 5 C520 C3IREVWHBK ARH BK DRIVE REVERSE 4 1 t DRIVE MODE XI C130TA WH RD TRAVEL ALARM 5 e TON a 8 C2631 26 2 E haze SIPS C32BRK WH RD C1B 6 C523 _ C32BRKWH RD Il BRAKE RELEASE x z 8 28 1 28 2 T 29 5 RD WH 29MS RD WH zaz G1P 3 C29MS RD WI C1B 3 C524
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97. M E Electrical Schematic S 65 Ford DSG 423 EFI Models after serial number 14053 Section 6 Schematics February 2012 Ground Control Box Terminal Strip Wiring Diagram S 65 Ford LRG 425 EFI Models before serial number 11880 1108 February 2012 C Ground Control Box Terminal Strip Wiring Diagram S 65 Ford LRG 425 EFI Models before serial number 11880 Section 6 Schematics 969 157 zs gs 60 e zoe 42 E 52 tc 2 q 5 X 51 69 18 1538010 zrHw1g T 5 S 8 9 2157 40 s 2 80 1STHO v g vEHO HO r4 eer WHOALVId 581 O EEL ZEL S1 WHOd1V1d
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106. I M ALARM T P134TTSR RD RD 5 gt BRN LEVEL SENSOR T Lf C3B 12 LoS apd 5 C3P 12 C133PLA BLWH e gt 3 E C46HRN GR si a gt ott Bes C 2SHBN GR 1 4 HORN RELAY Bo GRBK 11 a C7P 1 P22BAT BK C7B 1 E OF 5 9 5 P22BAT BK FHBK gt 5 8 3 CiPi2 CIS2PLIBUWH 12 S EE z 2 i a S esu Le P134FB WH 2 6 PI34PWR GR BK C2B 6 gt FLASHING BEACONS gt i le gt T 5 RD 1 51 Bk amp oz C21IGNWH__ 80 8 R21IGN WH s C5 4 HYDRAULIC OIL TEMPERATURE 8 gt T SWITCH OPTION 1 81 J 55 7 6 nne 0R sy C54 127 COOLING FAN 5 D eu Ad t OPTION Le g eje E 4 8 m 4 8 C41RPM OR BK C2B 3 C41RPM OR BK C5 2 gt 2 T us C21IGN WH 9 E lt 7 4 pox lt R K 118 bp fezi T 5 IE E m 5 gt z a a 25 BUSY Yt m so 5 lt 5 918 i Es i a Q A XE CO 54 8 RD i C7B 4 X P20BATRD 4 i o S S a e e Part No 77828 5 60 5 65 5 60 HC 6 98 Section 6 Schematics February 2012 Elec
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109. t Ese di TEN c e SIS m ms u t 15 o on lt lt gt 1 4 i 5 ws ee 4 8 5 RD C7B 4 P20BAT RD 2 i i S m e e LO Part No 77828 gt CE AND PLATFORM OVERLOAD OPTION ONLY NOTES S 60 S 65 S 60 HC G 6 72 Section 6 Schematics February 2012 Electrical Schematic S 65 CE Models Deutz F3L 201 1 Models before serial number 11880 P22LS BK N e C7P 3 BATGND C7B 3 GROUND 4 2 3 C41RPM C2B 3 5 lt lt gt gt lt 8 5 9 152 4 C30FWD WH C1B 4 Fe 5 21 C30FWD WH X BK RD DRIVE FORWARD Q Se 15 LIPS C31REV WH BK C1B 5 0520 COIREVWHEK 7 BK DRIVE REVERSE
110. 0839 it 19 o 2215 P C3P M 59 BL BK C3B 11 e 15 5 5 BK 037 3 42 WH C37 4 5 gt LS5 CABLE TENSION LED EE 8 5 o P134 RD RD C381 RD G BR C38 2 _ 5 LS17 BOOM UP DOWN a Ny a SPEED REDUCTION LIMIT SWITCH 2 uu yy OR lt 6482 99 ee PLATFORM LEVEL 4 t DOWN 3 C15PLD C4B 3 5 20 1 20 2 2 i GIPEU OR Inl PLATFORM LEVEL UP PLATFORM LEVEL igs GABE t DOWN DM 4 PLATFORM LEVEL DOWN X C214 C21 2 8 10 C129JDA BL C3B 10 52 8 5 6 C18JD PRR GR BK C4B 6 Jig 1 UP C17JU PRL GR C4B 5 C283 C23 2 8 8 IA 8 8 C18JD PRR GR BK 8 i lt PLATFORM ROTATE RIGHT RIGHT PLATFORM LEFT ROTATE C17JU PRL GR D Siar OAM HOTATELEET 224 C222 i 5 B RIGHT PLATFORM pes LEFT ROTATE 2 gt it 4 C120 RD BK DESCENT ALARM OPTION t PECES F L a 7 C19JSV GR WH C4B 7 1 2 2 m o 5 3 a 5 I Im ES JIB VALVE JIB VALVE a 9 n x tr u K 8 8 m P22LS BK gt ROCKER STEER OPTION ONLY A TEREX DWG 5 60 5 65 5 60 HC 6 43 Part No 77828 February 2012 Section 6 Schematics
111. 5 W IIAL gt s ui o is E t CE 3 lel E 5 9 i T I co a T 22 fr QE gt a 79 he Sess M ta RN 1 E 8 m s i H lig I 3 amp 8 Dow lt 205 2 Zr gt lt gt 5 1t 1 s d 7 IE t o Y 944 1 ag 1 gat a P a i Sq su MESE 2 X 89 Mer 1 55 c lt des tr m I 4 a fr eo o lt 52 m NE 9 c 8 8 Eee KER o H iW 1 E 5 Eds E 5 iu dE we 78 E Pa d E CR s pog wd amp E zz m M lt lt dps litre i it H d iud cc gt I 6 109 BRAN 5 60 5 65 5 60 G Part No 77828 February 2012 Section 6 Schematics s Hydraulic
112. 515 SIF E L io o v 5 2 i S E 8 i B8 BE ge sev 58 zh v v 2 2 gt 1O m a lA 0 gt e 2 D o m o ido 1001 2 gt gt 5 lt P 5 2 im z Mole 6 u gt 9 2 8 8 15 8 5 35 gs pm 806 5 E 9 39 8 88 96 8 E 5 E I o EIN 0 9 2 2 E HT 9 i a Q a Q P 1 Es m 5 8 2 bu 1 1 WH WH 1 1 012 TS3 7 i FUEL SELECT 1 L l OBIS we CM E OW p2 SPEED 969 ne ARa stor V TS14 TS4 2 P3 59 WH TS1 HIGH LOW TS47 NONE HIGH LOW Dii d HORN gt PLATFORM AUXILIARY 2WD 4WD GENERATOR RPM o OPTION i LEVEL TS7 PUMP BK WH RD ROTATE RD RD RD 8 NOTE DASHED LINES INDICATE OPTION WIRES CE LIFT DRIVE OPTION REPLACE WIRE WITH CR27 amp CR30 Genie TEREX DWG Part No 77828 5 60 5 65 5 60 6 37 February 2012 Section 6 Schematics H H M s Platform Control Box Switch Panel Wiring Diagram S 60 Ford Models Section 6 Schematics February2012 Electrical Schematic S 65 Ford LRG 425 EFI Models before serial number 11880 February 2012 Sec
113. 6 93 Platform Control Box Terminal Strip Wiring Diagram 5 60 Perkins 404 22 Models arrsa 6 94 Platform Control Box Switch Panel Wiring Diagram 5 60 Perkins 404 22 Models 6 95 Electrical Schematic S 65 Perkins 404 22 Models before serial number 11880 6 96 Electrical Schematic S 65 Perkins 404 22 Models after serial number 11879 6 98 Ground Control Terminal Strip Wiring Diagram 5 65 Perkins 404 22 Models before serial number 11880 6 100 Ground Control Box Switch Panel Wiring Diagram 5 65 Perkins 404 22 Models before serial number 11880 6 101 Genie Part No 77828 S 60 5 65 5 60 2012 TABLE CONTENTS Section 6 Schematics continued Ground Control Box Terminal Strip Wiring Diagram 5 65 Perkins 404 22 Models after serial number 11879 6 102 Ground Control Box Switch Panel Wiring Diagram 5 65 Perkins 404 22 Models after serial number 11879 6 103 Platform Control Box Terminal Strip Wiring Diagram 5 65 Perkins 404 22 5 2 6 104 Platform Control Switch Panel Wiring Diagram 5 65 Perkins 404 22 2 6 105 Belt Driven Generator Wiring 6 106 12kW Hydraulic Generator Option Wiring Diagram
114. 77828 February 2012 Section 5 Fault Codes Condition Error Type String Potentiometer Safety Sensor C166PSL Sensor tolerance fault Power relays disengaged Power relays disengaged String potentiometer wiring open or shorted to voltage Output short high Value too high Power relays disengaged String potentiometer wiring open or shorted to voltage Power relays disengaged String potentiometer wiring open or shorted to ground OR string potentiometer is faulty Power relays disengaged String potentiometer wiring open or shorted to ground Output short low FAULT CODES Repair wiring and or connections OR replace string potentiometer and calibrate overload system Repair wiring and or connections OR replace string potentiometer and calibrate overload system Repair wiring and or connections OR replace string potentiometer and calibrate overload system Repair wiring and or connections OR replace string potentiometer and calibrate overload system Repair wiring and or connections OR replace string potentiometer and calibrate overload system Not calibrated Boom range of motion is Calibrate the platform load sense orga limited system Used to clear diagnostic Just calibrated Self clearing Checks operational and safety sensor values against each other Value too low Inconsistent Genie Repair wiring and or connections OR replace string pote
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117. Wen Gh a TS2 ENGINE START TOGGLE SWITCH bg CR13 E m 1B TS3 FUEL SELECT TOGGLE SWITCH Li pg bd 754 HI LOW RPM TOGGLE SWITCH BRN 1 chante 1 E tnb P TS7 PLATFORM ROTATE TOGGLE SWITCH a ped 1 15 758 JIB BOOM UP DOWN TOGGLE SWITCH BAN BAN BEN BAN F18 FUSE 10 19 TS9 PLATFORM LEVEL TOGGLE SWITCH bd a bi WORKLIGHTONLY E TS14 DRIVE SPEED TOGGLE SWITCH 9 p NN ig TS15 DRIVE ENABLE TOGGLE SWITCH 3 ig eue Rio 7547 GENERATOR TOGGLE SWITCH ri m 23 2 7548 DRIVE LIGHT WORK LIGHT TOGGLE SWITCH OPTION ji E E BK ele E 9 p 8 12 HE 15 5 gu 1912 3o 1512 9 m imim Sio i 2o 18 zz x gt 5 2 lt m m imin gi i 2 5 Sielei im e igim I JE E EIE 19 Iz iz zs Igio IB 112 ojo A 1910 Blo B 1 9 oso o w Om wijs oos 595 5 a 5 8 E 8 285 ES 70 m gt c lt 2 ce 2 m mm im IU Oo 9 e 19 FETPESEJ 5 25 9 9 7 ms gt gt 2 9 2 5 E 8 z iz 5 me 55 0 s 9 gf 2 3 g 8 9 gs 33 gs B Jg Q o i o 58 Oo go 59 x 5 loj
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119. 9 9 gt lt gt BIB a g 9 e a EN s iQ A o v 5 5 2 iS T pop Ln 1 WH WH 1 012 D r FUEL SELECT GR sG SC P2 9 EMERGENCY TS14 TS4 59 WH TS8 TS1 HIGH LOW TS47 ENGINE HIGH LOW KORN 2 PLATFORM GR BK JIB AUXILIARY 2WD AWD GENERATOR RPM 5 LEVEL 4 Boom PUMP OPTION Bk H PLATFORM Daz WH RD ROTATE RD RD RD Arts S 60 S 65 S 60 HC February 2012 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram S 65 Ford Models Section 6 Schematics February2012 c Electrical Schematic S 60 Deutz F3L 201 1 Models before serial number 11880 2215 February 2012 C
120. E 1 2 4 8 RD BK _ g 228 1 ibe C28TTA RD BK 8 fo 1 5885 Pet ALARM 4 En P134TTSR RD RD BK Lhe 5 e LEVEL SENSOR x C3B 12 L l 8011 ZZ woo BY C133PLA BUWH gt gt amgk d o il as E C2B 5 la m C2P 5 C46HRN GR 2 C46HRN GR HOBN RELAY 414 Ro GRBK 7 1 P22BAT 7 1 8 I 5 P22BAT BK BK 7 l 5 HORN 1 12 C132PLIBLWH _ C1B 12 5 s 5 5 i V P134FB WH u 2 6 __ 1 4 __ 2 6 s re gt FLASHING BEACONS gt 5 RD 5 oz z C21IGN WH E R21IGNWH C94 HYDHAULIO EHRERATURE e _ 8 5 i 15 sc 5 R116 OR 654 COOLING FAN 256 gt amp JI f OPTION Y Oz x E m C41RPM OR BK C2B 3 wi C41RPM OR BK 5 2 kaz sc S T C21IGN WH a 5 a w ptox Je 1 91 K 2 om oF 221 5 x t 14 5 e lt 2 lt 5 mis B o mm 5 C C lt l E 8 5 8 s RD E C7B 4 P20BAT RD 4 S n m e e Part No 77828 gt CE AND PLATFORM OVERLOAD OPTION ONLY NOTES 5 60 5 65 5 60 G 6 54
121. Low C3P 12 DLITE BLWH 638 12 i DRIVE LIGHT o t LIGHTS LVN WORK LIGHT RD C DRIVE LIGHT OPTION 5 8 lt Mo 15 ee s Z S E 2 gt WORKLIGHTSOPTION pa cap 12 YY C2P 10 i NA Qype eases 3 Soe aan Se oe ees Bae eee A s uu l s s 1 C2P 11 C2P 9 gt 8 8 e RIT hi 5 hs 8 a 2 8 C34SA BKWH 4 C34SA 5 22 4 4 GLOW PLUG 9 E Glow T PLUG 7 000 a gt A 26 5 WH RD OIL TEMPERATURE LED KS n Y 28 2 u BES 258 2 Q 558 2 gt o oz 285 7 C33STRBK 7 22 0 56 3 3 C5 14 Ego au OIL TEMPERATURE SWITCH 4 ENGINE ES START 5 ai e x Ci S 4 ENGINE Seloso seose 65 16 OIL PRESSURE SWITCH Y START 000 C25PSR WH BK E 8 ne E E tc o g A POWER RELAY Q gt BE C21IGN2 WH 5 11 ofa FUEL SOLENOID a aja N PUMP lt 0 C27AUX RD C1B 1 4 o Geren we HOUR METER 8 8 IGN START RELAY ge 5 R33STR C5 5 B 4 STARTER MOTOR Di S AUXILIARY A m PUMP Roe C27AUX RD x AUXILIARY POWER RELAY 2 C7B 2 a E bo us P2SBAT WH AUXILIARY PUMP
122. N LO enie G A TEREX DWG 5 60 S 65 S 60 HC Part No 77828 6 32 Section 6 Schematics February 2012 Ground Control Box Switch Panel Wiring Diagram S 60 A Ford LRG 425 EFI Models before serial number 11880 N LO lt 5 gt 54 s geso 5 7 8 x EEG a m 8 484 EEE 8 5 2 21825 25 ez gt 119055 5a gg 5 5555 212 EE 258 886 z lt Sur am Eu 883356 5 _ z 5 2 2 2 2 Elk 2 9 G 5 5 oo ze 85262 2 5
123. P 1 i 5 C2P 7 GR WH C2B 7 z C45GEN GR WH 65 12 Itl 1 GENERATOR OPTION D I CECI DOE LEE IE NEM LIE NO ce 1 g amp C3P 12 DLITE BLWH C3B 12 o 1 DRIVE LIGHT URS ee WORK LIGHT RO lt DRIVE LIGHT OPTION 8 l 5 m YW al WORK LIGHTS OPTION 2 42 C2P 10 ay O ER Si D A 5 i S s 1 C2P 11 a C2P 9 2 x 8 8 8 5 hs 8 a 9 8 BK WH 4 C34SA BK WH 5 22 4 i e GLOW PLUG oO E 5 e e na D 000 C26TSR WH RD OIL TEMPERATURE LED c E 55 gt 3 558 5 2 ots EI lolz oz 9 CSASTRBK 4401B7 Foe gt 65 14 OIL TEMPERATURE SWITCH ENGINE B 85945855529 START 5 So lt 6 s lt S pieisisisisieciele 65 16 OIL PRESSURE SWITCH START e a t C25PSR WH BK BK 9 E 3 ne e a d POWER RELAY E 1 Em n gt CE e a C2TIGN2 WH Cot FUEL SOLENOID amp RE AUX So 3 PUMP 1 C27AUX RD 1 1 P 4 HEN WH HOUR METER 1 IGN START RELAY mM MES er 8 22 G s Z a s T gg 5 R33STRBK C55 zi S
124. lt q o 8 eo i so lt a 30 du AA 9 WHOsLWId __ 3NION3 E t MO03HO T Q65 48 18 2 9 25 GLZ HM 2 r e i Sl 5 a 1 va D a o 12 Qd 2 HOLIMS qu E HM HM A3 Ie AIG HA O 2 C s 1551 HOLIMS 401 1 QH HM 21886190 QH HM i 28 6 L49 z Yl uuo GL 1 WYO 01 Gu HM MSZ HOISIS3H HOISIS3H 31v10H INOZ H3ddn qaviNunL WOOS AHVWIHd vH l Yok WYO S MSZ lt 2 HOLSISSHY 1 HO1SIS3H STaVLNYNL ed woog viH WYO S QH HM NYA February 2012 Section 6 Schematics Ground Control Switch Panel Wiring Diagram 5 60 Perkins 404 22 Models after serial number 11879 Section 6 Schematics February 2012 sss Ts W uaEUIEIAO Platform Control Box Wiring Diagram S 60 Perkins 404 22 Models February 2012 Section 6 Schematics Platform Control Box Wiring Diagram S
125. 2215 P134PWR RD February2012 NOTES Ford DSG 423 EFI Models after serial number 14053 Electrical Schematic 5 60 Section 6 Schematics 26 2 i B 9 BK RD C1B 9 o ENGINE 5 OIL PRESSURE SPEED 25258 WH BK E C25PSR WH 1 SENDER OPTION 2 5 1 VOLT METER f e L LOWRPM L C26TSR WH RD FEH PIN 39 WATER TEMPERATURE t HIGH RPM 5 gt i SENDER OPTION P iya SBS COCCO EE Nea i a a iar ET EE aa E E ET DE TAE Seb ee ERES Cu ENT ra Re E rer ini i GENERATOR 5 Ro C2P 7 C45GEN GR WH C2B 7 5 12 C SGENGRWH D GENERATOR b OPTION rr mmm s Ia rv I y m m a II VV WVqY Y 1 g C2P 4 DLITE OR RD C2B 4 1
126. 334S NIMS a SHO 9 8 91 9 a 5 N 3 X z m Pa f to 200 x m 99 8 i ET 2158 E 255 z al al s 218 2 8 21215 62255 gia 3 9 3 z 8 Sim g zo i i 9 WoW 2j 952 i 81 Naa zeo 8 EI 3 l 5 968 HM 91 B 9 595 1 a 5 8328 insa Sade SAC Lis mA Y N LO N 10 DRIVE LIGHT ONLY HOLIMS OL SS3NHVH NOTE DASHED LINES INDICATE OPTION WIRES A TEREX BRAND S 60 5 65 5 60 HC Part No 77828 6 64 Section 6 Schematics Deutz F3L 2011 Models after serial number 11879 Ground Control Box Switch Panel Wiring Diagram S 60 CE Models February2012 6 65 w S 60 S 65 S 60 HC G Part 77828
127. 34 32 ANAAUX PD1 4 361R 16 150 DG W 18 150 DG W 18 VBAT 37 ANA AUX PU1 5 361 16 361 14 114 LB Y 18 114 LB Y 18 392 RLG 352 BR LG 18 352 BR LG 18 EGO2 40 EGR PWM 74 GY LB 18 360 18 360 BR PK 18 s O2 SENSOR 41 S KNK Sor 33 ANA RTN KNK 351 BR W 18 ST VREF 16 R LG 18 32 R LB 16 J1 BLACK XN e 13 STARTER CONTROL FUEL PUMP 361AR 16 XY 1 SENSOR STARTER lease Ws 74 GY LB 18 392 R LG 18 151 LB BK 18 4 m 359 GY R 18 O 359 GY R 18 317 GY O 18 317 GY O 18 4 Eme J2 GREY 570 BK W 16 342 LG P 18 342 LG P 18 SPK PWR GROUND 850 Y BK 18 COIL 1 COIL2 16 359 GY R 18 COIL 3 351 BR W 18 1 SOLENOID 669 DG W 18 COIL 5 458 O BK 18 COIL6 32 16 32 R LB 16 15 STARTER INTERUPT 39 STARTER IN AUTOCRANK 361A 16 787A PK BK 16 5 FUEL PUMP 342 LG P 18 2 STARTER LOCKOUT 28 242 DG 18 pu FUEL LOCKOFF 926A LB O 18 926A L8 O 18 FUEL PUMP S SRY 18 _ _ _ ER PEE RELAY CONTROL TPS1 TPS2 DBW DBW 30 355 GY W 18 357 Y W 18 28 151 LB BK 18 29 317 GY O 18 Th OIL PRESSURE BRAKE SWITCH 6 511 LG R 18 511 LG R 18 511
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129. Note When checking for positive tank cap venting air should pass freely through the cap 7 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeatthis procedure beginning with step 6 8 Install the breather cap onto the hydraulic tank Section Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 21 Replace the Fuel Filter Element Perkins Models Note Engine specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacing the diesel fuel filter element is essential for good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may required that the filter be replaced more often Note Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Removethe engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fa
130. OSE lox a 2 2202 MER o pv gt 9 EZ 8 i i 2 x i ATERE DWG S 60 S 65 S 60 Part No 77828 February 2012 Section 6 Schematics RE SEE EI EE Chassis Wiring Diagram S 60 HC from serial number 12800 Section 6 Schematics February 2012 mr mque Ground Control Box Terminal Strip Wiring Diagram S 60 HC from serial number 12800 February 2012 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 60 HC from serial number 12800 45095 Nid FINGON LYVLS NOLINDI 92 21 Inva SS3Hd HO dL OF NO NOI Sv9 os dWnr 2 60 2 799310 MS OL 4 aava 9 annos s INDEMdXDV v indviMvis WxISWOHOVL 2 1 n 0000000 wy pue Anua OL L WtiVTv WHO41V1d EEL 55 L S1GvOTd3AO ZEL 83395 L47 H3MOd AV BH NHOH Sr NOILdO HO1VH3N39 Sr H3MOd
131. a RD BK L48 NON CE rhc C134PWR RD C2P 6 C134PWR RD 1518 RD TILT lt CWLITE BK BRN Q E E T yin e CWLITE WH TS49 T N Part No 77828 enie S 60 S 65 S 60 6 36 February 2012 Section 6 Schematics uw M A Platform Control Box Switch Panel Wiring Diagram S 60 Ford Models N M L K J H G F E D C B A PLATFORM CONTROL HARNESS TO CONTROL BOX DRIVE LIGHTS WORK LIGHTS DLITE RD RD __ __ _________________________________________________________________________89__ JC2 OPTION TILT ALARM LED JC3 OPTION PRIMARY BOOM DRIVE UP DOWN 7 i 7 pem Des FORWARD REVERSE 7 amp TURNTABLE ROTATE TS15 E LEFT RIGHT ae EXTEND RETRACT DRIVE 148 6 6 ENABLE 6 INDEX i i bg m JC2 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE 3
132. lt MN FLOW CONTROL 8 BK WH C3B 8 a 184 7 lt BO lt 12 7 7 C3B 7 49 135 CABLE LIMIT SWITCH IE 5 YEL 3 15 RD mp amp C7PBE BK 5 4 EXTEND Sig lt on 5 C37 1 e C372 Ci amp 1 16 2 ig Pwrls 9 g t RETRACT i 1 GND 2 10 a g Corer BKM BOOM RETRACT g lt lt E T 5 nee 1 n C17 1 C17 2 HOO 8 42 9 22 1 E prze 118 58 4 4 _ OR RD C38 3 WH C38 4 LS17 BOOM UP DOWN P24FS WH 6 Ur 5 REDUCTION LIMIT SWITCH Pus 8 z x P24FS WH x 890 a t 2458 B Dx E OP C13DE BURD BL RD C91 WH C92 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK T x gt 3 5 2 taze G2P 2 592 2 CH 2 WH BK LS1 PRIMARY BOOM 5 stus DRIVE LIMIT SWITCH 9 J1 F H WH 0104 WH C10 2 LS2 PRIMARY BOOM UP LIMIT SWITCH C40LS C2B 2 OR x Se i989 SEES o 2215 11 C59CNK BL BK C3B 11 BL BK 9 s lt BK C37 3 42 wH C37 4 3 gt 1 gt LS5 CABLE TENSION LED eve g E 3 in o m P134 RD RD C8
133. zo WH JIB WH JIB C129JDA BL C3P 10 a o Peg s ge ee 1 ITE WH dha _________ 2 4 _ J Bo 5 9656 114 5 82 HASE z I i 50 25 59 11 w CI7PRLGR C4P 5 C19JSV GR WH CR27 Oi C19JSV GR WH 7 5 FEO BK J1 2 RD J1 1 C18PRR GRIBK C4P 6 OR 11 BRN 1 12 P24FS stc QN e C14PLU OR C4P 2 5 BEz EG a C15PLD 3 5 60 5 65 5 60 HC Part No 77828 RD RD NOTE DASHED LINES INDICATE OPTION WIRES RD 3 TURNTABLE ROTATE LEFT RIGHT JC2 BOOM UP DOWN amp C46HRN GR C2P 5 P3 HORN February 2012 Section 6 Schematics JEE E E el Platform Control Box Switch Panel Wiring Diagram S 65 Deutz F3L 2011 Models Section 6 Schematics February 2012 EZ2iiiui iii iiiiiiuiiia U D z I ZXD KI KWwr Electrical Schematic S 60 Perkins 404 22 Models before serial number 11880 C22LS 2012
134. 11 C59CNK BL BK C3B 11 BL BK o 5 37 3 BK Vy 2 wH C37 4 ime 1 LS5 CABLE TENSION LED eve g m 3 i 5 m P134 RD RD C38 1 RD 3852 7 LS17 BOOM UP DOWN m SPEED REDUCTION LIMIT SWITCH 2 C14PLU OR C4B 2 F UP LEVEL M DOWN 3 CI5PLD OR BK C4B 3 20 1 20 2 2 8 ET i IA PLATFORM LEVEL UP PLATFORM LEVEL DOWN CASPLD OH BK Ini PLATFORM LEVEL DOWN E E C212 10 C129JDA BL C3B 10 5 S g gt 4 6 C18JD PRR GR BK C4B 6 E DOWN UP BOOM C17JU PRL GR C4B 5 C233 C23 2 8 gt CIBIDEBHGHE PLATFORM ROTATE RIGHT iE RIGHT PLATFORM EEEEE BOIAIE CI7JU PRLGR PLATFORM ROTATE LEFT i 6224 C22 2 5 RIGHT PLATFORM p CN LEFT 1 HDI alae erat See jit 11 1 1 64 C129 RD BK pee e DESCENT ALARM OPTION 1 4 2 C4P 7 C19JSV GR WH 4 7 A 8 d 9 2 5 5 5 JIB VALVE JIB VALVE S 6 5 I tazi 0 5959 asaya gt ROCKER STEER OPTION ONLY 6 39 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 6 Schematics Electrical Schematic 5 65 Ford LRG 425 EFI Models before serial number 11880 S
135. 3 C15PLD OR BK C4B 3 20 1 C20 2 8 c C14PLU OR 4 PLATFORM LEVEL UP PLATFORM LEVEL t DOWN CISREDIOR BK il PLATFORM LEVEL DOWN 5 E eit C21 2 8 5 C4P 6 C18JD PRR GR BK C4B 6 FRIGHT I LEFT C17JU PRL GR C4B 5 1 5 8 023 1 C23 2 5 C18JD PRR GR BK 5 gt Q PLATFORM ROTATE RIGHT FRIGHT PLATFORM lt 2 ROTATE C17JU PRL GR D PLATFORM ROTATE LEFT 224 C222 25 lt n o B S 8 s Qa 6 55 A TEREX DWG 5 60 5 65 5 60 HC G PartNo 77828 February 2012 Section 6 Schematics pum M Electrical Schematic 5 60 Models Deutz F3L 2011 Models before serial number 11880 Section 6 Schematics February 2012 am MH P Q a Electrical Schematic S 60 CE Models Deutz F3L 201 1 Models after serial number 11879 2215 February 2012
136. 8 Removethe cable guard fasteners and remove the cable guard a cable guard b retaining block 9 Locate the retaining plates that secure the retract cables to the inside of the number 3 boomtube 10 Remove the cable retaining plates and pull the retract cables off of the pulleys Lay the cables flat and out of the way Genie 11 Remove the fasteners from the retaining blocks from the extension cylinder saddle Remove the blocks Note Access the fasteners through the access hole in the outer boom tube at the pivot end 12 Disconnect the wire connector to the extend cable break limit switch 13 Remove the retaining fasteners that secure the extend cable mounting plates to the inside of the number 1 boom tube extend cable lock nuts extend cable mounting plate extend cable mounting plate fastener extend cable bracket a b 4 30 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures 14 Pull back on the extend cable mounting plate until it clears the blocks welded to the inside of the number 1 boom tube 15 Lift up the extend cable mounting plate and push the extend cables towards the platform to create slack in the cables Rest the cable and bracket assembly on top of the extend cylinder 16 Locate the lower extend cable bracket on the bottom of the number 3 boom tube 17 Remove the lower extend cable bracket mounting fasteners and pull back on the
137. A 5 Check the High Pressure Hydraulic Filter Condition Indicator Note Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining the high pressure hydraulic filter in good condition is essential to good system performance and safe machine operation The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage 1 Openthe engine side turntable cover 2 Startthe engine from the ground controls 3 Change the engine idle to high rpm rabbit symbol 4 Visually inspect the filter condition indicator O Result The filter condition indicator should be operating with the plunger in the green area Result If the indicator displays the plunger in the red area this indicates that the hydraulic Genie part number 84794 Tessa filter is being bypassed and the filter should be GM 3 0L Operator Handbook replaced See D 6 Replace the Hydraulic Genie part number 101095 Filters Ford LRG 425 EFI Operator Handbook Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Perkins 400 Series Operation Manual Genie part number 94890 Genie Part No 77828 5 60 5 65 S 60 HC Section Scheduled Maintenance Procedures February 2012 CHECKLIST A PROCEDURES A
138. B IE 2 11 C2P 9 I C x 91 I a a apa Cr s hal aa Za cet Sl N 5 tr o g e C34SA 4 C34SA BK WH 5 22 2 GLOW PLUG 8 GLOW 7 PLUG BE oU GLOW PLUGS al Q 27000 C26TSR WH RD 0 LED XsgB lt 22 258 gt 549 I N 25 8 z D 1 7 C33STRBK 7 Bee oR C5 14 P E ESE SS gt E 4 COOLANT TEMPERATURE SWITCH I G e X 6 T START a 65504588905 8 e ENGINE ciele gt gt 65 16 e OIL PRESSURE SWITCH S t s C25PSR WH BK a 1 8 9 Nz f d A POWER RELAY m oaz B C21IGN2 WH 5 11 ss i gt FUEL SOLENOID a l N 62 C27AUX RD C1B 1 ae WH HOUR METER 88 D IGN START RELAY aS opi o i ge m R33STRBK C55 az E ai Q c 1 1 8 ESE EN L STARTER MOTOR Ad u B AUXILIARY a pi C27AUX RD x PUMP RD AUXILIARY POWER RELAY i 2 7 2 2 r 9 CIE 5 L 4 PUMP rex s 8 f gt as RD BK Ba 1 2 WH n
139. B i HRe DES 2 P22LS C3P 11 59 BL BK C3B 11 BL BK g 4 BK 037 3 42 WH 37 4 gt 1 LS5 CABLE TENSION LED oem g 5 134 RD RD C381 y RD A C382 _ 5 LS17 BOOM UP DOWN amp s SPEED REDUCTION LIMIT SWITCH 2 4 2 _ C14PLU OR lt C482 2 PLATFORM LEVEL 3 t DOWN C4P 3 C15PLD OR BK C4B 3 z 20 1 C20 2 2 op i CIAEEULOR n PLATFORM LEVEL UP _ PLATFORM LEVEL t DOWN Il 1 PLATFORM LEVEL DOWN 5 E E C213 C212 5 8 10 C129JDA BL C3B 10 C4P 6 C18JD PRR GR BK C4B 6 JIB BOOM C17JU PRL GR C4B 5 5 E 23 1 023 2 TS 8 5 E C18JD PRR GR BK 8 8 RIGHT RIGHT PLATFORM lt gt ROTATE IA PLATFORM ROTATE LEFT C224 C22 2 m 5 PLATFORM 8 5 i BDB 4 DESCENT ALARM OPTION i 4 7 C19JSV GR WH C4B 7 ees E 2 m JIB VALVE JIB VALVE x Sola m o r s a 2 ge 5 a gt ROCKER STEER OPTION ONLY enie G S 60 S 65 S 60 HC 6 41 Part No 77828 February 2012 Section 6 Schematics Electrical Schematic S 65 Ford LRG 425 EFI Models from serial number 11880 to 14053 Secti
140. G Platform Control Box Wiring Diagram S 60 Section 6 Schematics Ford Models aa 1 C39LP BL RD C2P 1 4 o 26 og A 1 E C118LSR OR RD 4 ax WH RD C3P 6 gt m 4 7 1 LLI e C13DE BURD C4P 1 pg a C8PBR BK WH C3P 8 It gt P24FS WH C40LSS 2 2 4 m a C9PER BK RD C3P 9 P24FS WH e CA1RPM OR BK C2P 3 a C30FWD WH 4 Q C1PBU C3P 1 gt C31REV WH BK 5 a N e C2PBD RD BK C3P 2 o C36SCC BL 10 C3P 3 i a C37SCW C1P 11 5 C5TRR WH BK 5 1 4 C32BRK WH RD 6 e e CATRL WH 4 Sa C29MS RD WH C1P 3 5 e C3P GR 6 we C35RPM BK RD 9 Q C33STR BK 1 7 C27AUX RD 1 1 C2P BK 6 2 5 9 E o s gt JC1 3 OR le JC2 4 RD of JC1 2 P 55 C1P GY JC2 5 BK z JC2 3 OR Vai os JC1 5 YEL 59 JC2 2 BRN le 2 JC3 5 WH A gu ioe JC3 3 OR le E Uo JC3 4 BL grg JC3 2 BRN 1515 BUWH C28TTA RD BK C1P 2 5 TS15 BUBK DRE LED BURD le y TS14 RD WH A E a 5 5 lt 5 8 GR BK C133TTA C3P 12 GRUB 4 k
141. GO 2 Suo u9 4 95 820 H9 61 HOLWNYALIV 250 8 40 Wald HO QNONu8 820 Wd tro or ZNSI A8 40 ov 5 WOO8 2 010 HO 151075 V2 2820 15105 Jp 6 1 820 9160 ze maas O 1 929 38 18 MOSZED iraro 22 x z 1759718 595955 Je O 01 810 18 00590 Je se NOILONNJ HOH Q 34 6 810 WdHSEO vt omamo O Qd 22 50 HWDI8 VStEO 9551 8 819 HWE 5 Jp ee 3NION3 LYVLS Q4 21 810 48 HLSEED ENSIS ee 24 62 30 22 WHTW CH HM HOLIMS OL SS3NuvH 9 910 QU HM 5 e i 3SH3A3H T3dOHd I 812 14 02 80 M8 HM AH IED 5 810 A3HIEO 05 T3dOHd 05 z 12 50 GM40FO rz z 62 BOULSHOLON O 9 30 SWezo Nua 810 5620 21 1v80zd VL182O JP bata eed 2 z Qd 1951 09 mou xnv zo 98 61 0 O HOLIMS 1491009 O 2 8 8 92 HOLIMS aunssatid 10 2 Q4 91 50 1920 OLNSPIS HM 5 4 ol 8 a Eo E E O ve ve Coo O V2 ez H3MOd
142. P24FS WH 9 2 TS4 i i 1 1 1 i 1 1 1 1 1 1 1 1 C46HRN GR C2P 5 1 i 1 1 1 L CDLITE OR RD C2P 4 C45GEN GR WH C2P 7 C46HRN GR C2P 5 P26ESTP BK C118LSR OR RD C4P 4 6 WH RD 6 e e C8PBR BK WH C3P 8 C16DRE BL RD 1 C7PBE BK C3P 7 24FS WH i i i i i i T C40LSS OR C2P 2 C9PER BK RD C3P 9 24FS WH C41RPM OR BK C2P 3 C30FWD WH 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 P C2PBD RD BK C3P 2 C36STCC 10 RD WH C3P 3 C37STC BL BK C1P 11 C5TRR WH BK C3P 5 C32BRK WH RD C1P 6 C4TRL WH C3P 4 9 9 C29MS RD WH C1P 3 U13 ALC 500 J2 C35RPM BK RD C1P 9 C34SA BK WH C1P 8 C33STR BK C1P 7 C27AUX RD C1P 1 J1 o JC1 3 OR e JC2 4 RD JC1 2 BRN JC2 5 BK JC2 3 OR JC1 5 YEL JC2 2 BRN JC3 5 WH JC3 3 OR JC3 4 BL JC3 2 BRN TS15 BL WH C28TTA RD BK C1P 2 1515 BL BK DRE LED BL RD TS14 RD WH RD BK L4 C28TTA RD BK C1P 2 C7P 3 ES C9
143. S 60 HC Part No 77828 February 2012 Section 5 Fault Codes Condition Error Type Boom Angle Safety 141 5 Power relays Sensor tolerance fault disengaged Power relays disengaged Boom angle sensor wiring open or shorted to voltage Output short high Value too high Power relays disengaged Boom angle sensor wiring open or shorted to OR sensor is out of operating range Power relays disengaged Boom angle sensor wiring open or shorted to ground OR sensor is out of operating range Power relays disengaged Boom angle sensor wiring open or shorted to ground Output short low FAULT CODES Repair wiring and or connections OR replace boom angle sensor and calibrate overload system Repair wiring and or connections OR replace boom angle sensor and calibrate overload system Repair wiring and or connections OR adjust or replace boom angle sensor and calibrate overload system Repair wiring and or connections OR adjust or replace boom angle sensor and calibrate overload system Repair wiring and or connections OR replace boom angle sensor and calibrate overload system Boom range of motion is Calibrate the platform load sense Not calibrated FA limited system N Just calibrated Used ito clear diagnostic Self clearing codes Checks operational and safety sensor values against each other Value too lo
144. Schematics nm PH H e Belt Driven Generator Wiring Diagram F E D C B A 1 120V AC W O REGULATOR 87a 3 m 30A aj 89 r 4 87 2 WT e e 2 86 85 5 BRN 5 3 m WHT NEUTRAL 120 E AUTO C e RESET CB 4 BLK 120VAC e e 15A 5 6 7 8 Genie Part No 77828 5 60 5 65 5 60 HC 6 106 February 2012 Section 6 Schematics E Belt Driven Generator Wiring Diagram Section 6 Schematics February2012 me eee 12kW Hydraulic Generator Option Wiring Diagram Section 6 Schematics saah avesT srsaa r 12kW Hydraulic Generator Option Wiring Diagram A C 12 5 KW HYDRAULIC GENERATOR NEUTRAL BUSS BAR XO 3XO Q Q Q 6 12 L3 D February 2012 NEMA 4 CONTROL CN 50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI m Y x 8 GA 4 CONDUCTOR BREAKER NY WI m OUTLET z BLACK 12GA on RAIL GROUND STUD ON 8 4 CONDUCTOR 12 RED F RED WHITE N L3 W
145. T lt i EN de 1 8 58 E 1 aa 1 1 lt P 59 LI RY 4 ea 4 JH t RBL 32 4 E SA 148 gt EN Ed 8 217 83 8 E 1 1 tI Le k 2 5 u ME EE t T 7 bd Kau g 3 x E 1 i MES Da E i ES oe lt 52 se pi E ERE se gm B 1 L NE BP N I n FIG 5 pa iB Boii milia m gus L 8 15 7 sss jq lt m lt n iad Oz iy E a lt i u lt i Itc I jj ik Pe B 54 5 bd IN ji HEN I gt La Y ture d po 6 110 r S 60 S 65 S 60 HC G Part No 77828 February 2012 Section 6 Schematics Hydraulic Schematic 4WD Models Genie Sweden Phone 0046 3157 5101 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 900 808 110 Fax 0034 935 725 080 Genie Germany P
146. TEREX COMPANY Part No 77828 5 60 5 65 5 60 HC 4 65 Section 4 Repair Procedures February 2012 MANIFOLDS TT ss UU Genie 4 66 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures 7 12 Valve Adjustments 4WD Traction Manifold How to Adjust the Charge Pressure Relief Valve 1 Connecta 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump 2 Holdthe charge pressure relief valve and remove the cap item UU 3 Turn the internal hex socket clockwise fully until it stops Install the cap 4 Startthe engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position Note the reading on the pressure gauge 5 Turnthe engine off 6 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold 7 Startthe engine from the platform controls Press down the foot switch and slowly move the drive control handle off center just until the machine begines to move Note the reading on the pressure gauge Turn the machine off 8 Hold the charge pressure relief valve and remove the cap item UU Part No 77828 A TEREX 5 60 5 65 5 60 HC MANIFOLDS 9 Adjust the internal hex socket until the pressure reading on the gauge is 30 psi 2 bar less than the pressure reading
147. a 28 1 28 2 5 a T C29MS RD WH C29MS RD WH oz 61 3 C1B 3 C5 24 il MOTOR STROKE s Y 5 se Eu 2 8 25 1 C252 CDE2BLBK C1P 11 C37SCW BL BK C1B 11 C37SCW nn 7 18 STEER RIGHT ko DRIVE ENABLE su t RIGHT 10 C36STCC BL C1B 10 C36SCC BL D STEERER PEE x COEHBDMN g C241 C242 9 IL A SSA o 7 SEE 8 s g RKOUT Bk 6 WH RD C3B 6 IE T lt YOUT 5 4 a 42 8 15555 4 C4TRL WH C3B 4 C4TRL WH TURNTABLE ROTATE LEFT i OR 1 13 14 1 14 2 1 BRN 2 lt 7 5 C5TRR WH BK 5 WH BK TATE RIGHT 15 n 15 1 15 2 RIGHT 8 15 C15 s d m TURNTABLE ROTATE LEFT 8 28 o 1 d z i 6314 C312 WH RD lt lt gt gt TURNTABLE ROTATE FLOW CONTROL 12 1 12 2 CERM Ibi PRIMARY BOOM UP C2PBD RD BK a PRIMARY BOOM DOWN C13 1 C13 2 7 lt x m E E k HE C3PBF 9 Your 5 2 BOOM FLOW CONTROL B 29 1 29 2 SIE XMAS n C3P 1 C1PBU RD C3B 1 13 pwr 3 11 6 y m a 5 2 BRN y ze C3P 2 C2PBD RD BK C3B 2 E lt s 6323 RD WH C3B 3 2 30 1 30 2 a ce G3P 9 C9PER BK RD C3B
148. m e 8 133 oz 5 gt 3 5 5 x g o gt 5 515 X Q 9 o 88 25 DO 159 5 S 5 m a E Q Q a m T A 5 5 b v 191 e o M RD RD bd xai DE Cu co PEL WH WH RD 5 012 I Gy pe O QOD Peace EMERGENCY e qq STOP Em eee TS14 TS6 TS2 TS4 2 HORN 159 WH TS7 HIGH LOW GLOW PLUG ENGINE HIGH LOW TS47 3 PLATFORM PLATFORM AUXILIARY 2WD AWD START RPM GENERATOR LEVEL ROTATE PUMP OPTION WH 24 RD RD RD RD NOTE DASHED LINES INDICATE OPTION WIRES Genie Part No 77828 tnt wO S 60 S 65 S 60 HC February 2012 Section 6 Schematics p eee Platform Control Box Switch Panel Wiring Diagram S 60 Perkins 404 22 Models Section 6 Schematics February2012 Electrical Schematic S 65 Perkins 404 22 Models before serialnumber 11880 February 2012 Section 6 Schematics Electrical Schematic S 65 Perkins 404 22 Models before serialnumber 11880 C22LS BK
149. poe 9B5ig HS tu H313W o Sz QU HM x 30 woog z N E 5 g WHOdlVld __ oppor t 65 Me 9 260 GIZ HM a z amp m c 2 Lazz ea G B Fa 2288 HOLIMS au ay A33 O OJ 1 59 5 pu ORIG 1951 HOLIMS 8015 Nua 9L8 HIWGH x 2115140 6 WYO OL MSZ Sc Hd 998 1951 HO1SIS3H 3NOZ uaddn 43345 WOOS AHVWIHd Woog 919 L WYO S qu qu qu Ms ava HOLSISSY 31V1OH HOISIS3H 3aviNunL woog viH WYO s 6 81 5 60 5 65 5 60 HC Part 77828 February 2012 Section 6 Schematics E Ground Control Box Switch Panel Wiring Diagram S 65 CE Models Deutz F3L 2011 Models before serial number 11880 Section 6 Schematics February2012 EE EE E EFFEEF E R R EE E ui gt asa s s cry lt a 8
150. rec GBP 6 WH RD C3B 6 vour s WH git 42 85 1955 C3P 4 WH C3B 4 iz CATRL WH TURNTABLE ROTATE LEFT pwR S Ss 18 C14 1 C14 2 u 5 C5TRR WH BK C3B 5 5 WH BK 4 TURNTABLE ROTATE RIGHT E 15 C154 15 2 lt SRIGHT TURNTABLE ee 1 LEFT 8 zc Fd C6TRF WH RD TURNTABLE ROTATE i M FLOW CONTROL W C31 1 C31 2 C12 1 C12 2 LE Ibl PRIMARY BOOM UP PRIMARY BOOM tDOWN C2PBD RD BK DM PRESE PRIMARY BOOM DOWN i _ 5 C134 C182 lt 3 ES Bi ip s lt we d 8 E BK gt p Ee F RD WH vour s 2 PRIMARY BOOM FLOW CONTROL a BD C29 1 29 2 6 C3P 1 C1PBU RD C3B 1 1 pwr 3 KI 8 lt ig ano 2 BAN C92 C2PBD RD BK C3B 2 Ft E lt 8 C3B 3 8 30 1 C302 03 9 C9PER BK RD C3B 9 C9PER BK RD PRIMARY BOOM EXTEND RETRACT Hu FLOW CONTROL 62 8 5 C8PBR BKWH C3B 8 E lt s lt ma 7 C3B 7 x 49 155 CABLE LIMIT SWITCH m our sz YE 3 4 I i RD RD BR C7PBE BK BOOM EXTEND Sig an 5 BOOM 37 1 C372 Ci 1 162 PWG gt gt 9 lt t RETRACT i E CPER BKWH IM BOOM RETRACT lt lt ma s Ci71 CI72 m 2 t E A BRN ss Q 299 8 2 E rz CH8LSROR
151. 1 T mz C aa 8 a STARTER MOTOR T 151 x m 0 AUXILIARY 8 PUMP RD C27AUX RD x a AUXILIARY POWER RELAY E 2 1 N IO 2 7 2 B pes Wet AUXILIARY PUMP ru E s Not 2 1 2 WH 4 8 RD BK 3 2 8 pete 855 C28TTA RD BK WH 1 iH C28TTA RD BK z TW TLFALARM J M P134TTSR RD RD IBK pe xc Ye LEVEL SENSOR A w 3 C3B 12 l 12 C133PLA BLWH Q C2B 5 2 PE C2P 5 C46HRN GR gt C46HRN GR MOAN RELAY 13 e GRBK ffoi a C7P 1 P22BAT C7B 1 E I L B P22BAT BK FH BK E d aaa 2321212 C1P 12_ C132PLI BLWH 1 12 s 5 o m 6 g P134FB WH u FLASHING BEACONS 2 6 P134PWR GR BK 2 6 os 5 lt gt OPTION r OE PER MEET 1 5 4 BK Hz y C C2NGNWH E R21IGN WH 05 4 HYDRAULIC OIL TEMPERATURE 8 A SWITCH OPTION PH6HYDRD gi 8 lt G g E 56 s 1 OR _ i COOLING FAN Ad OPTION lee le x 5 C41RPM C2B 3 wi C41RPM OR BK C52 A inset AG e e C21IGN WH 5 k 1 ag og 5 lt
152. 610 678 922 1016 990 1342 5840 1139 1315 1464 1844 2074 2047 2304 3213 3620 3620 4067 LUBED lt Nm 100 110 12 4 120 120 13 5 LUBED 10 1 LUBED lt 23 25 7 42 47 4 66 4 74 5 101 6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 2643 2969 18 20 33 37 50 24 27 1 44 7 50 1 67 8 17 6 19 31 2 35 2 50 1 55 5 77 3 86 7 108 4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223 17 19 31 35 49 55 75 85 110 120 150 170 270 300 430 470 640 710 790 890 1120 1240 1950 2190 5 16 3 N 7 1 ar 13 14 23 26 57 CO of Or Co NIN oo 108 4 122 162 176 217 244 379 120 130 160 180 280 310 450 500 680 750 970 1080 1360 1510 2370 2670 Bri o N _ 110 18 130 18 16 14 13 18 10 200 16 14 12 7 12 7 A2 220 320 350 1 4 8 1 2 8 14 16 9 14 8 480 12 7 12 7 5 3 7 530 590 670 840 12 930 6 1460 1640 CHART This chart is to be used as a guide only unless noted elsewhere this manual Class 4 6 Class 8 8 Class 10 9 03 Class 12 9 DRY Y DR DRY in ibs 54 68 775 91 1021 DRY DRY 600 458 622 612 830 536 727 715 970 20 5
153. AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures 4 Inspect the following areas for burnt chafed corroded and loose wires Engine wiringharness Hydraulic manifold wiring 5 Open the ground controls side turntable cover 6 Inspect the following areas for burnt chafed corroded and loose wires Inside of the ground control box Hydraulic manifold wiring 7 Inspect for a liberal coating of dielectric grease atthe following location All wire harnesses connectors to the ground control box 8 Startthe engine from the ground controls and raise the boom above the turntable covers 9 Inspectthe turntable area for burnt chafed and pinched cables 10 Lower the boom to the stowed position and turn the engine off 11 Inspect the following areas for burnt chafed corroded pinched and loose wires Cabletrack on the primary boom Cables on the primary and jib booms Jib boom Platform rotate manifold Inside of the platform control box 12 Inspect for a liberal coating of dielectric grease atthe following location All wire harnesses connectors to the platform control box 13 Swing the engine back to its original position and install the engine tray retaining fastener Part No 77828 Genie
154. C6TRF WH RD 6 C8PBR BK WH C3P 8 C16DRE BL RD C4P 1 C7PBE BK C3P 7 WH 401 55 OR C2P 2 WH C9PER BK RD C3P 9 C41RPM 2 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK 5 C2PBD RD BK C3P 2 C2P C3P C36STCC BL C1P 10 RD WH C3P 3 C37STC BL BK C1P 11 C5TRR WH BK C3P 5 C32BRK WH RD C1P 6 C4TRL WH C3P 4 99 J2 C29MS RDANH C1P 3 U13 ALC 500 C35RPM BK RD C1P 9 C34SA BK WH C1P 8 C33STR BK C1P 7 C27AUX RD C1P 1 J1 JC1 3 OR JC2 4 RD JC1 2 BRN JC2 5 BK JC2 3 OR JC1 5 YEL JC2 2 BRN JC3 5 WH JC3 3 OR JC3 4 BL JC3 2 BRN TS15 BLWH C28TTA RD BK C1P 2 1815 DRE LED BL RD TS14 RD WH e 9 Ne eye C134PWR 1518 C28TTA 2 BATGRN C7P 3 OPTION FOOT SWITCH 12V DC BATTERY C4P BR C3P GR C2P BK C1P GY GR BK C133TTA 12 RD BK L48 NON CE p C134PWR RD C2P 6 RD TILT CWLITE BK BRN BRN TILT ALARM 19 18 CONTROL CABLE a cm pec rM RD BK 2
155. C8PBR BK WH C3P 8 C16DRE BL RD C4P 1 C7PBE BK C3P 7 24FS WH C40LSS OR C2P 2 C9PER BK RD C3P 9 24FS WH C41RPM C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 C2PBD RD BK C3P 2 C2P C36STCC BL 10 RD WH C3P 3 C37STC BL BK C1P 11 C5TRR WH BK C3P 5 C32BRK WH RD 6 C4TRL WH 4 C29MS RD WH C1P 3 U13 J2 ALC 500 C35RPM BK RD C1P 9 C34SA BK WH C1P 8 C33STR BK C1P 7 C27AUX RD 1 1 J1 JC1 3 OR JC2 4 RD JC1 2 BRN JC2 5 BK JC2 3 OR JC1 5 YEL JC2 2 BRN JC3 5 WH JC3 3 OR JC3 4 BL JC3 2 BRN TS15 BL WH C28TTA RD BK C1P 2 1815 DRE LED BL RD TS14 RD WH RD BK L4 C134PWR RD LS18 CWLITE BK BRN C28TTA RD BK C1P 2 C4P C7P C7P C9 JIB BATGRN 7 3 C4P BR C3P GR C2P BK C1P GY 2 z t m 19 18 CONTROL CABLE FOOT SWITCH 12V DC BATTERY RD BK 28 BRN BRN SN SCS RD BK L48 NON CE C134PWR RD C2P 6 RD TILT H1 TILT ALARM CWLITE WH TS49 enie G A TEREX DANO S 60 S 65 S 6
156. Ld 18 19 u FUSE 10 WORKLIGHT ONLY E p N A 1 128 I S 18 i 1 IJ 212 iQ 109 1 ME m 2 c na c 3 55 d BK 19 5 RE P 5 m 0 io iz 3 5 5 515 419 295 ce iE 210 x m m Bu im im Su 21210152 gt Ho lod m mn 1D 10 DIES 09 IQ Im lt 2 N 28121 IX IX lt 9 IN ez EE ig jel Z 10 Al x Lm io X 2 iD N J2 a 2 o I o g os o m gt mos s S 52 5 2 S E 8 SBA uU 5 5 cole 0 gt 10 a cla mo 99 60 E mo sS3zx gt 2 9 gt lt r gw x iz 2 ais nm o o gt e 8 io AI 95 25 gt 2 2 2 g 2 2 g o E iD gt Slo I 0 6 Q 8 eg 8 9 9 5 oy 88 3 5 o 5 s 9 T x RE L3 cn e a 5 5 0 m 9 2 o 2 1 iN WH WH L TS3 012 FUEL 7
157. SA WHOd1V1d 4 Lag 7991 12217 EM 1 280 VSI 3NION3 Q41 H5 180 1 1 902 4 1 YSL SNOILdO ee g Smid oe 3gviNunL ES Tia au C iim cadi ego SIg HM GS Ig HM T HM 259 ez8 peHO HAWdH LOVHLSY o aN31X3 Lu a noos ra 4 2951 z woog N wi 1951 2 oe 5 u HWGH o lt y T co o i 1 poem Pop _ I 4313W lt 30 Ki s i WuO31V1d 3NION3 A d MO3HO 6 9 20 GIZ HM 2 i z _____ ___ ____ ______________ _ 5 Lazza za Q Q HOLIMS AJA 9 159 2 HM 2 Auvnixnv 1991 HOLIMS 4015 AON3OH3W3 28 7280 QH HM 21886190 i 2 8 6 149 m 1 uuo SL cc
158. SRI 250 So tn 8 5 ri 4 9 amp Rd alg 8 z 259 m gai 58955 2 5 Nua aa amp GIONS10s HM e EZ HOIH o E 29 52 55 HM 65 AvT3H 141 a Nua Nua euo N LO N enie G Part No 77828 A TEREX DWG S 60 S 65 S 60 6 90 Section 6 Schematics February2012 Ground Control Box Switch Panel Wiring Diagram S 60 Perkins 404 22 Models before serialnumber 11880 2 a 5 k 5 5 Oz 6 2 lt gt 255 2 4 1716 gt lt ul Sam 02025 256 19 5 216
159. SS TAANE Noso P 65 O 0 5 2652 9v NHOH 9 Jp SUO HO o 5 820 ly 2 Jp 35109 820 IWdH HO 201080151072 2 GaMOLSWOOd O 282080 151070 65 d1 3NvdOHd AINON 6 Ww 01 52 160 em 9 2 1 820 41659 76 5 1 20 MOSZ O gt L 8LO MOSZEO 9 133199315 1 720 18 995969 Jp 01 810 18 205980 s130 dua nauso Jp SE Se GH 6 910 WdHSE 9 ve aasann 8 1 P 1HVIS3NION3 t G4 QA 2951 8 12 810 15559 ze 26 52 59 GH HM Jp 9 9910 QU HM HOLIMS OL 02 50 X8 HM 38 2 20 SS3NuvH S 8LO TES 2 0 06 O 7 810 HM 0 ESO SWGEO Jp 62 62 O A 8 EE HAGE Sees rH 82 8 VLL82O Jp 2 10 v11820 2 dWndAHvnixnv 22 Q Gt ISI 20 eg uasna O O 9 O 8 se O O 9 9 O 2 ve
160. deo 1 P 8 WHOSIWId 81 0 gus 9 drO x8 H9 Ar819 2 14 24 G4 5 8 Es Fizoxguodidsio Je i 6 lt 51 48 6 8 14510 Je P 6951 30 2 80 Polo aundauacio 9 yo EF o Wuvivxgwau 80 vv 053 Gd 01 80 18 6 7819 NOLLONNS 138 1X3 O OA 6 9 Tao HMA Jp 0 951 8 8 48980 2 2 344 95 Jp 951 1 38 38925 9 9 Pi duHwduiso yo 7819 1 1 J19VLNYNL C T dssrawum 9 8 O Qu HM 38199 5 S Qd 2 Je 2951 5 99159 v v LoM wL O Je 1431 1 1 318V1NunL Qd T8E0 HM 19170 Qd H5 8 50 rezo V2 NGONOLLONIHUROOR 9LH8 HWGH x 2 2 Qd Avoa Oog 8 gt 961 2 Wuvivoig au Alt dn Wood L9S1 QH 1 869 v g 91 0
161. o m a I A NJA c a aja ne z 1 S A N amp 9 STARTER MOTOR 919 8 8 8 mur St gt B SE AUXILIARY SPEED REDUCTION RELAY gt a ala TRUMP GETAUX RD 1 AUXILIARY POWER RELAY u 8 1 1 C27AUX RD 1 1 4 AUXILIARY PUMP 5 C28TTA RD BK u g G28TTA beet ALARM 1 1 RD BK x WH C7P 2 P23BAT WH C7B 2 LL P134TTS RD 7 X 1 Keven SENSOR lt 4 52 S gt 8 a NX RD 1 2 C28TTA RD BK C1P 2 5 ENER Lj PIS4FBWH FLASHING eu PE BEACONS OPTION BK C2P 5 C46HRN GR C2B 5 C46HRN GR HORN RELAY 1 a l P 7 1 P22BATBK C7B 1 P22HRNBK 7 P46HRN BK C6 9 5 2 5 P134PWR GR BK 82 HYDRAULIC OIL C2P 6 C2B 6 R21IGN WH C5 4 TEMPERATURE SWITCH P134PWR RD C A EA 8 P22LS d C116 OR 65 1 gt COOLING FAN 9 ad PHeHvDRD 80 5 i OPTION 9 s x 2 5 5 6 9 Le je ALTERNATOR FIELD FORD ENGINE HARNESS T 8 58 3m E at T T a8 5 ae 85 2 pti 154 2 ME 5 2 40 C Mm E 2 Oc l 5 e 8556 Seg 1 RIG lt lt u 14 Eg oS 859 ERI u x Fuss a 20 P20BAT RD C7B 4 ae
162. 3 gt 11 N 1 a 18 8 55 12 6322 C2PBD RD BK coe _ lt TL NBN C3P 3 C3PBF RD WH C3B 3 C30 1 C302 Face CPI C9PER BK RD C3B 9 um C9PER BK RD Je PRIMARY BOOM EXTEND RETRACT FLOW CONTROL C3P 8 C8PBR BK WH C3B 8 13 lt lt C3P 7 C7PBE BK C3B 7 BO s lt 12 12 155 CABLE TENSION LIMIT SWITCH m aurpe 3 D iu RD RD BR C7PBE BK 4 BOOM EXTEND 5 4 1 EXTEND Sig lt os 5 i C37 2 C164 162 mE t RETRACT i 8 C8PBR BK WH GND 10 Q g 1 n E 5 t C17 1 C17 2 BRN ss Q 8 89 5 lt CAP CH8LSROR RD C4B 4 _ OR RD C38 3 BK WH C384 LS17 BOOM UP DOWN PAAFSWH gt gt 5 SPEED REDUCTION LIMIT SWITCH gt tn 2 e 2 Pears WH o B 99 E C13DE BL RD C4B 1 BL RD C9 1 BK WH C92 du LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK PLE gt 3 gt 8 9 89e B CPP zr o CH 2 WH cna LS1 PRIMARY BOOM EXTEND 5 SUE DRIVE LIMIT SWITCH E J1 FH WH C10 1 BK WH 10 2 LS2 PRIMARY BOOM UP ey x DRIVE LIMIT SWITCH 9 Ulster Y C40LS OR C2B 2 x PF m i 1 uo DES I o 2215 11 C59CNK BL BK C3B 11 BL BK A 3 BK C37 3 BK 9 2 wH 74 v i gt 4 LS5 CABLE TENSION L
163. 3 C15PLD C4B 3 20 1 C20 2 8 c oe i CTAPEULOR Inl 1 PLATFORM LEVEL UP PLATFORM LEVEL t DOWN 1 LEVEL DOWN E i E C214 C212 B 26 8 10 C129JDA BL C3B 10 EZ 8 6 C18JD PRR GR BK C4B 6 DOWN s te __ BOOM C17JU PRL GR C4B 5 ASTE c23 1 C23 2 8 I 8 8 C18JD PRR GR BK i gt PLATFORM ROTATE RIGHT RIGHT PLATFORM p LEFT ROTATE C17JU PRL GR D BLATEORM ROTATE LEFT C223 C222 li 5 RIGHT PLATFORM LEFT ROTATE 2 7 C129 RD BK l 1 DESCENTALARMOPTION 1 2 7 C19JSV GR WH C4B 7 d osSLLIKRGIUUSVGRANC c cA Tar 3 5 m o n 6 5 JIB VALVE 58 JIB VALVE x go s z o 21 R z 42958 3 aja 6 99 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 6 Schematics Electrical Schematic S 65 Perkins 404 22 Models after serial number 11879 Section 6 Schematics February2012 iii r_s I IIIIIISKS O I IE a w acaUlDe hohyraD asx F 3 Ground Control Box Terminal Strip Wiring Diagram S 65 Perkins 404 22 Models before serial number 11880 February 2012 Section 6 Schematics Ground Control Box Terminal Str
164. 3 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures 4 Perform Engine Maintenance Note Engine specifications require that this procedure be performed daily or every 8 hours whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual Deutz part number 0297 9929 OR the GM 3 0L Operator Handbook GM part number 36100007 OR the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 OR the Perkins 400 Series Operation Manual Perkins part number TPD 14435 Deutz FL 2011 Operation Manual CHECKLIST A PROCEDURES
165. 3 n g BRN B 5 ono 2 12 bree 6322 RD BK C3B 2 i E lt 5 lt lt 6363 RDWH C3B 3 2 m ke 9 C9PER BK RD C3B 9 C9PER BK RD C901 6302 PRIMARY BOOM EXTEND RETRACT lt lt gt lt lt lt gt FLOW CONTROL 22 S Haze 03 8 C8PBR BK WH C3B 8 z lt 8 s lt lt lt 7 7 C3B 7 498 1155 CABLE TENSION LIMIT SWITCH YEL 18 3 T RD A gn C7PBE BK s sc DEED i s BOOM EXTEND 51 5 37 1 37 2 Ci 1 16 2 2 pwr s 9 t RETRACT n ewp N55 19 8 IA BOOM RETRACT lt T ___ _ x 5 6172 E n E 2 899 8 2 E CH8LSROR RD C4B 4 OR RD C38 3 BK C38 4 LS17 BOOM UP DOWN P24FS WH J E stus SPEED REDUCTION LIMIT SWITCH 2 a 9909 P24FS WH ds 42 gt E s lt BL RD 1 BURD yy BK _ WH C9 2 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTPBK PX 3 gt y N 9 999 4 lt C2P 2 gt lt WH LS1 PRIMARY BOOM 5 SUE 1 DRIVE LIMIT SWITCH n E J1 WH C10 1 BK WH C10 2 LS2 PRIMARY BOOM UP DRIVE LIMIT SWITCH E C40LS OR C2B 2 OR x E T 5 go PEERS PES pee P 19 2215
166. 5 60 5 65 5 60 HC HYDRAULIC PUMPS 2 Models without hydraulic tank shut off valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container See capacity specifications Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valves Component damage hazard 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 3 Tagand disconnect and plug the hydraulic hoses from the drive and function pumps Cap the fittings on the pumps AWARNING 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 Section 4 Repair Procedures February 2012 HYDRAULIC PUMPS 4 Supportthe pump with a lifting device and remove the two drive pump mounting fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump from the machine Component damage hazard The hydraulic pump may become unbalanced and fall if not properly supported Component damage hazard When
167. 5 60 5 65 S 60 HC 4 Adjust the extend cable adjustment nuts until approximately 1 5 inches 4 cm of threads are visible past the nylock nut Note If the cables have been replaced be sure the adjustment nuts have been replaced Do not re use the existing nuts 5 Extend the boom until there is approximately feet 1 m of travel left Do not fully extend the boom 6 Locate the retract cable adjustment nut on the bottom of the number 1 boom tube at the platform end of the boom 7 Usinga dialtype torque wrench torque the retract cable adjustment nut to 32 36 ft Ibs 43 49 Nm using gentle and steady torque 8 Retract and extend the boom approximately 3 feet 1 m two times and stop during the extension cycle This will create slack in the retract cables Note Be sure to not fully extend the boom Stop when there is approximately 3 feet 1 m of travel left 9 Repeat steps 7 and 8 two to three times 10 Fully extend the boom then retract the boom approximately 12 inches 30 cm 11 At the pivot end of the boom visually inspect the boom extend cables for even cable droop or sag Note If the boom extend cables are uneven tighten the boom extend cable adjustment nut at the pivot end of the boom for the appropriate cable Part No 77828 February 2012 Section 4 Repair Procedures 12 Visually inspect the cable break limit switch arm to be sure the wheel of the limit switch arm is centered in the notch of
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170. 55 a aye 2 C33STR In 0 1 m z I s a n 8 8 8 4 ma 14 STARTER MOTOR 9 511 eo QO i d AUXILIARY a PUMP u Hj AUXILIARY POWER RELAY 1 1 C27AUX RD 1 1 Eg xxxn a x cz I pa 5 L 4 AUXILIARY PUMP 4 i 5 A C28TTA RD BK ES gt g 28 EDIB m ALARM AN 1 1 2 2 RD BK BRN x WH C7P 2 P23BAT WH C7B 2 hin P134TTS RD n 4 SENSOR lt 3 o 1 a e d i m 8 8 m RD CIP 2 C28TTA RD BK C1P 2 vz 84 _ LJ 134 WH FLASHING BEACONS OPTION M C2P 5 C46HRN GR C2B 5 C46HRN GR pe BI g a C7P i P22BATBK C7B 1 P22HRNBK P46HRN BK C6 9 9 P134PWR GR BK 2 HYDRAULIC OIL o C2P 6 C2B 6 r R21IGN WH C5 4 TEMPERATURE SWITCH Ne P134PWR RD i OPTION T 8 o P22LS BK C116 05 1 Z V COOLING FAN 9 P116HYD RD A EHI T OPTION S LO ja 5 gt 6 02 C107AF WH 510 i A 4 96 T r 36 0 E m s zi 2k 5 z NO T 1 c e EN ET e 2o ME Ti 3 BNO Ei E 2282 854
171. 612 Invalid Interrupt 613 O Loose wire connections to ECM OR ECM is faulty 614 RTI 1 Loss 615 Flash Invalid 616 RAM Failure External 5V DC Ref Lower than Expected Engine harness wiring and or connections open or shorted to ground OR there is a faulty engine External 5V DC Ref sensor OR ECM is faulty Higher than Expected 655 2 Loss Loose wire connections to is faulty 656 Loss Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM Genie S 60 5 65 5 60 Part No 77828 Section 5 Fault Codes February 2012 FAULT CODES Ford DSG 423 EFI Engine How to Retrieve Ford Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highes
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174. CDE3 BL RD 5 5 5 C254 C25 2 CDE2 1 11 C37SCW 1 11 C37SCW BL BK nn 2 gt T 18 47 STEER RIGHT t DRIVE ENABLE Caes TCOBE C36SCC BL gt t RIGHT X zoo CIP 10 3i C1B 10 gis x CDE Bue g C24 1 C24 2 e sS A f lt BL 64 6 C6TRF WH RD C3B 6 Wi 15577 ur 8 H 3c BL 1 5 5 70 4 C4TRL WH C3B 4 C4TRL WH 1 TURNTABLE ROTATE LEFT 4 Pwa s lt Pu 8 a C14 1 4 14 2 2 gno 2z 14 lt lt 6325 CSTAR WH BK UOS C5TRR WH BK lt lt IA ss 4 TURNTABLE ROTATE RIGHT 16 n 2 2 C151 C15 2 a TURNTABLE ROTATE E amp LEFT 8 d 6 WH RD xD TURNTABLE ROTATE 4 FLOW CONTROL C31 1 C31 2 a 12 1 ace TUE PRIMARY BOOM UP PRIMARY BOOM t DOWN C2PBD RD BK T i 4 BOOM DOWN i x C134 13 2 us 8 zs Bi 5 Bi 2 ig lt S B 15 vourg 2 C3PBF RD WH lt 4 PRIMARY BOOM FLOW CONTROL a BD C29 1 C29 2 8 6 veris us eoo 1 C1PBU RD C3B 1 14 pwr 3 KI y 18 1g 2 12 5 lt 2 C2PBD RD BK C3B 2 E lt p NE sz t 033 5 C3PBF RD WH C3B 3 a 1 2 03 9 C9PER BK RD C3B 9 BK RD pd 2 5 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL CP s BK WH C3B 8 lt E iu EZ E 7 7 C3B 7 49 1
175. FOOT SWITCH C7P 12V DC BATTERY C2P BK C1P GY GR BK C133TTA C3P 12 GR BK L4 CE RD BK 28 RD BK L48 NON CE C134PWR RD LS18 C134PWR RD C2P 6 RD TILT CWLITE BK BRN BRN BRN Lo 19 18 CONTROL CABLE CWLITE WH TS49 enie G A TEREX DWG S 60 5 65 S 60 HC Part No 77828 6 104 February 2012 D Section 6 Schematics n Platform Control Box Switch Panel Wiring Diagram S 65 Perkins 404 22 Models C B A PLATFORM CONTROL HARNESS TO CONTROL BOX COMPONENT INDEX 13 JIB BOOM CUTOUT RELAY 2 DHIVELIGHTS JC2 BOOM PROPORTIONAL JOYSTICK WOBICLIGHTS ene ES BOOM UP DOWN TURNTABLE ROTATE OPTION ucc DUC EO E REC MC ECC CD ECC D nC CIRCE D CO C MOD LEE JC1 BOOM PROPORTIONAL JOYSTICK JC2 463
176. Function Pump How to Remove the Function Pump Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Models without hydraulic tank shut off valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container See capacity specifications Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable 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 TEREX COMPANY 5 60 5 65 S 60 HC 2 Tag disconnect and plug the function pump hydraulic hoses Cap the fittings on the pump AWARNING 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 Remove the pump mounting bolts Carefully remove the pump Models without hydraulic tank shut off valves Component damage hazard Be
177. GLOW PLUG 9 GLOW PLUG 000 C26TSR WH RD OIL TEMPERATURE LED o Ag 2 83 258 gt 2 595 gt rl o o g lt BIS A D C33STR BK BUS E 7 5187 E et Ge OIL TEMPERATURE SWITCH 4 ENGINE g 55858252224 8 START 95525488706 9 1 x ENGINE 5 16 q OIL PRESSURE SWITCH a C25PSR WH BK s 5 x 8 ne E 8 a 9 a d POWER RELAY a 0 o eet p FUEL SOLENOID RE y c 9 C27AUX C1B 1 S ola C21IGN WH ae HOUR METER S S G 1 1 IGN START RELAY ec 4 eres ae Shs R33STRBK C5 5 BGs 3 1 mx ae QR E Ni STARTER MOTOR a cei 8 151 x 2 AUXILIARY 5 q PUMP RD C27AUX RD x aq AUXILIARY POWER RELAY 3 2 EO iocum 7 2 e CP P2SBATWII S5 1 _ AUXILIARY pump i 4 lt e s Ree A ga o Vy CIP 2 X WH 4 me OA RD BK 3 C1B 2 8 532 E C28TTA RD BK WH C28TTA RD BK lt Le e i TILT ALARM 4 ____ ____ ue M P134TTSR RD RD BK BRN Lie LEVEL SENSOR C3B 12 ee GsP 12 C133PLA BLWH e F3 5 C2P 5 C46HRN GR dd gh C46HRN GR i HORN RELAY GR BK 2 i
178. Ground Control Box Terminal Strip Wiring Diagram 5 60 HC from serial number 12800 Platform Control Box Wiring Diagram 5 60 HC from serial number 12800 GM 3 0L Engine Harness Ford LRG 425 EFI Engine Harness Ford DSG 423 EFI Engine Harness Genie xiv S 60 5 65 S 60 Part No 77828 February 2012 TABLE CONTENTS Section 6 Schematics continued Electrical Schematic 5 60 GM 3 0L 6 14 Ground Control Box Terminal Strip Wiring Diagram 5 60 GM 302 Models i e d EP ra a re upas 6 16 Ground Control Box Switch Panel Wiring Diagram 5 60 GM 3 0L Models a 6 17 Platform Control Terminal Strip Wiring Diagram S60 GM 302 6 18 Platform Control Switch Panel Wiring Diagram 5 60 GM 3 01 5 6 19 Electrical Schematic 5 65 GM 3 0L 6 20 Ground Control Box Terminal Strip Wiring Diagram 5 65 GM 3 0L Models 6 22 Ground Control Switch Panel Wiring Diagram 5 65 GM 3 0L Models 40 0 6 23 Pla
179. I E z 5 DL E Q 219 O Ea gt ic uli ES m u E 2 d C32BRK WH RD C1P 6 s _________________ 2 __ ______________ E C32BRK WH RD J2 19 NE E a 5 i i i TE oH NEM i 00 5 x n 5 Q t USE CAOLSORC2P2 1 L CAOLS OR J24 Pod P24FS WH C9P 2 bog i l 1 1 1 I P23BAT WH C7P 2 11 22 7 1 1 1 1 T ji I 1 1 C19JSV GR WH 7 C18PRR GR BK C4P 6 NE C17PRL GR 5 m C15PLD OR BK C4P 3 bog 5 C14PLU 2 C129JDA BL C3P 10 TS8 C46HRN GR C2P 5 n I C59CHK BL BK C3P 11 L47 1 C59CNK BUBK C3P 11 1 EN P26BAT BK 9 1 P2 ME P25FS 9 3 52 r3 T P24FS WH C9 2 TS4 i 1 i 1 1 1 1 l 1 CDLITE OR RD C2P 4 120 pred AME MMC cc D NM NM CN Sta M MM P eee qp M bg bg s St GR WH 2 7 pog 6 C46HRN 2 5 N C39LP BL RD C2P 1 pog Q E O O l P26ESTP BK bg oe i it Mil i E As e 115 _ 5 dL Um 225 C118LSR OR RD 4 1 i e e gt C6TRF WH RD C3P 6 1 gt 1 1 Fog C8PBR BK
180. If the wear pad is still within specification shim as necessary to obtain minimum clearance with zero binding Part No 77828 Genie S 60 5 65 5 60 HC 4 Extend and retract the primary boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Note Always maintain squareness between the outer and inner boom tubes Wear pad specifications Minimum Top and side wear pads 1 2 inch platform end of boom 12 7 mm Bottom wear pads 5 8 inch platform end of boom 15 9 mm Top and side wear pads 1 2 inch pivot end of boom 12 7 mm Bottom wear pads 5 8 inch pivot end of boom 15 9 mm Section Scheduled Maintenance Procedures February 2012 CHECKLIST D PROCEDURES D 2 Check the Turntable Rotation Bearing Bolts Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the boom and place a safety chock on the lift cylinder rod Carefully lower the boom onto the lift cylinder safety chock AWARNING Crushing hazard Keep hands away from cylinders and all moving parts when lowering the boom Note The lift cylinder safety chock is available through Genie Genie partnumber 750
181. Lr LEVEL SENSOR C3B 12 P 12 C133PLA BL WH g 2 C2B 5 e SSGHRNIGRE lt CAGBRN GR b HORN RELAY gv GRBK 4 a 7 1 22 C7B 1 2 oz I 5 22 s x HORN 5 K 2 4 C1P 12 CIB I2 b E u x 9 P134FB WH FLASHING BEACONS 2 6 PIS4PWR GR BK 2 6 MESI 5 gt O h fife m IEEE PRIORA ERES T 5 RD i M m e s tc i BK 52 C21IGN WH R21IGN WH gt gt 05 4 T q HYDRAULIC OIL TEMPERATURE 2 d SWITCH OPTION i a PH6HYDRD 8115 B lt 85 5 IRH6OR 05 1 M Z4 COOLING FAN 5 ae mu AE OPTION o 8 x m C41RPM OR BK C2B 3 OR BK 5 2 Tw 96554 s C21IGN WH b 1 s 71 90 od c T 200 8 Xi E Y m q Eq st i Olet oleh EN E ERI MS m lt E 53 8 5 RD P20BAT RD i m e e Part No 77828 gt CE AND PLATFORM OVERLOAD OPTION ONLY NOTES A TEREX 5 60 5 65 5 60 HC G 6 88 Section 6 Schematics Electrical Schematic S 60 Perki
182. Push in the ground controls red Emergency Stop button to the off position then pull the red Emergency Stop button out to the on position to reset the control system Recovery process from the platform controls Note This procedure only operates if the platform is overloaded or enters the safety envelope 1 With the key switch turned to platform controls activate the auxiliary power toggle switch Result The boom will automatically retract until it is in the unrestricted zone Push in the platform 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 Start the engine and lower the boom to the stowed position Recovery process from the ground controls Note This procedure only operates if the platform is overloaded or enters the safety envelope 1 Result If the alarm does not sound the engine 2 does not turn off or the platform indicator light does not come on at both the ground and platform controls see Repair Procedure 2 4 How to Calibrate the Platform Load Sense System S 60 HC Note weight in the platform must 1200 16 544 3 less before the engine can be restarted 3 Genie Turn the key switch to ground controls Locate the recovery toggle switch on the side of the ground control box Activate the recovery toggle switch and the auxiliary power toggle switch at the same time R
183. S 60 S 65 S 60 HC 3 19 CHECKLIST B PROCEDURES B 3 Check the Exhaust System Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Burn hazard Beware of hot engine ACAUTION components Contact with hot engine components may result in severe burns 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury 3 Be sure that all nuts and bolts are tight 4 Inspect all welds for cracks Inspect for exhaust leaks i e carbon buildup around seams and joints 6 Swing the engine back to its original position and install the engine tray retaining fastener Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 4 Inspect the En
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185. end pivot pin is removed if not properly supported 7 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder 8 Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Section 4 Repair Procedures February 2012 Boom Components 4 1 Cable Track The primary boom cable track guides the cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom How to Remove the Cable Track S 60 Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raisethe boom to a horizontal position 2 Locate the cables from the boom cable track to the platform control box Number each cable and its entry location at the platform control box 3 Disconnect the cables from the platform control box 4 Remove the electrical outlet box bracket mounting fasteners Remov
186. flashing Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System S 60and S 65 if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Genie S 60 S 65 S 60 HC Section Scheduled Maintenance Procedures February 2012 CHECKLIST C PROCEDURES 8 Testall machine functions from the platform controls O Result All platform control functions should not operate 9 Turn the key switch to ground control 10 Test all machine functions from the ground controls O Result All ground control functions should not operate 11 Activate the auxiliary power toggle switch Note The engine will turn off when the auxiliary power is activated 12 Using auxiliary power test all machine functions from the ground controls O Result All ground control functions should operate 13 Using a suitable lifting device lift the additional test weight from the platform O Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound Note There may be an 2 second delay before the overload indicator lights and alarm turn off 14 Start the engine and test all machine functions from the ground controls O Result All ground control functions should operate normally 15 Turn the key switch to platform control Genie
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189. lt 39 2 m 3NION3 5 i WHO4LW1d o Nag lt 9 50 E l a ERE Ji ros Sel peu 1 5 oo E za a o 22 04 HOLIMS AIA 5 O O LSY 1 2 u3MOd HM 1561 HOLIMS 4018 ZISTHO Nua g souls dy 21580 Sc HH 9IH HWQH L9S L HWQH 8015 538 INOZ H3ddN 43885 WOO8 woog 91H O 2 1 s qu qu qu MSZ 52 HOLSISSY 1 HO1SIS3H 318v1NHn1L NAGI ta woog viH 1 uuo s Sc Hd du enie G A TEREX S 60 S 65 S 60 6 59 Part No 77828 February 2012 Section 6 Schematics EE EE EE EE Ground Control Box Switch Panel Wiring Diagram S 60 Deutz F3L 2011 Models before serial number 11880 Section 6 Schematics February2012 ma 25 Ground Control Box Terminal Strip Wiring Diagram S 60 Deutz F3L 201 1 Models after serial number 11879 February 2012 Ground Control Terminal Strip Wiring Diagram 5 60 Deutz F3L 2011 Models
190. lt insa NOILdO AYTAY LUVLS Aray N Nua uSMOd NOLLINSI idu zuo HOLIMS OL SS3NHVH WH TB21 OPTIONS FUSE 10A DRIVE LIGHT ONLY NOTE DASHED LINES INDICATE OPTION WIRES enie G Part No 77828 A TEREX DWG 5 60 5 65 5 60 HC 6 102 Section 6 Schematics Perkins 404 22 Models after serial number 11879 Ground Control Box Switch Panel Wiring Diagram S 65 February 2012 6 103 A TEREK DWG S 60 S 65 S 60 HC G Part No 77828 gt or T o5 8 4 518 2 25 usu lt 0 S zu t T O x Ei E 8 x 2556 9 m ez es e 2 21065151556 2 515 2 ol E E gt gt TE 5 2 Z 85 z s 5 5
191. lt s lt 02 kS Elaes amp Gm mmo Qc orco SEIS E Qu Be ela ag als bie 28 3ER g 55 2 5 5 5 259 54256 00 O lt u slo 91915 TVNINH31 OL 259 2 2 888 8 8 8885 SS3NHVH 5 3 O6 6 6 6 6 6 6 G O ZI Y PP IP IP as aunia ASf6LO T3A31 461 VSL STOHLNOO 7351 WHOALWId rapi 3iviou SA 1900 1581 sid 49 zao 3NION3 LINHO 2 2 G8L58 H5 G8 eee ee YSL SNOILdO uaxvaua 1 SOS nouo Peas ew 9551 J 2951 o0z du ego qu qu Q 9 QU HM deduHM arc Hw a SI8 HM SHH Gi HM 2 269 qi qu o aN31X3 Lu woog c 5951 woog Q 1951 96 od O E 5 H lt S o 5 2 o E poo 000g o p po I H313N 92 CH HM
192. lu ig lt 5 C3PBF RD WH 19 vour s 2 t BOOM FLOW CONTROL w C29 1 C29 2 S xus C3P 1 C1PBU RD C3B 1 55 6 iz PWR 3 11 amp 2 lt BAN 55 1 2 C2PBD RD BK C3B 2 F z X 1 s zc RD WH C3B 3 a C30 1 30 2 haze 9 C9PER BK RD C3B 9 C9PER BK RD PRIMARY BOOM EXTEND RETRACT Uu FLOW CONTROL 5 098 C8PBR BKWH 988 8 ee m lt s lt CSP C7PBE BK C3B 7 59 155 CABLE TENSION LIMIT SWITCH 15 8 I 1 i RD RD S BR C7PBE BK Ble ie LEXTENB on 5 BOOM C37 1 C37 2 Ci 1 16 2 12 9 11 RETRACT 8 8 COPERBKWH IA gt gt BOOM RETRACT lt lt Ta us gt MEE 5 I C17 2 BRN SS 9 829 E lt CHI8LSROR RD C4B 4 _ OR RD C38 3 BK WH C38 4 LS17 BOOM UP DOWN P24FS WH 5 a UE SPEED REDUCTION LIMIT SWITCH eee x m 2 e e 2 Pasw amp 422 BL RD C4B 1 BL RD C9 1 BK WH co2 H LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK o stUx gt 3 gt 599 Haze 022 92 2 2 WH BK LS1 PRIMARY BOOM 5 Sve DRIVE LIMIT SWITCH 8 J1 F H WH C104 BK gt MH 10 2 LS2 PRIMARY BOOM UP a Ue DRIVE LIMIT SWITCH a C40LS OR 2 2 x
193. pause and then blink the third digit For example the check engine light blinks 5 consecutive times blinks 3 times and then 1 time That would indicate code 531 Note Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See How to Clear Engine Fault Codes from the ECM How to Clear Engine Fault Codes from the ECM Note Perform this procedure with the engine off and the key switch in the off position 1 Openthe engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Connectthe negative battery cable to the battery Part No 77828 February 2012 Section 5 Fault Codes Code Closed Loop Multiplier High LPG 25 Open Inactive Bank 1 25 Open Inactive Bank 2 Post cat oxygen sensor open Closed Loop Multiplier High Gasoline Closed Loop Multiplier Low Gasoline Closed Loop Multiplier Low LPG Gasoline cat monitor LPG cat monitor NG cat monitor Adaptive Lean Fault High Limit Gasoline Adaptive Rich Fault Low Limit Gasoline Adaptive Learn High LPG Adaptive Learn Low LPG Heated Oxygen Sensor wiring and or connections ope
194. s lt N 16 vour pe 2 BED Je PRIMARY BOOM FLOW CONTROL w 29 1 29 2 Sie 1 C1PBU RD C3B 1 pwr gt 5 y BRN ig 2 12 2 C2PBD RD BK C3B 2 7 lt E P lt s lt lt 08 3 RD WH C3B 3 8 30 1 C30 2 Fa ce 3 9 C9PER BK RD C3B 9 C9PER BK RD Jp PRIMARY BOOM EXTEND RETRACT FLOW CONTROL C3P 8 C8PBR BK WH C3B 8 i s lt n eee iE lt ac s lt 122 lt 7 C7PBE BK C3B 7 u 49 1 55 CABLE TENSION LIMIT SWITCH ES E or 5 YEL B i RD RD BR C7PBE BK BOOWERTEND Sig an 5 C37 1 C37 2 16 1 C16 2 9 1 RETRACT BRN 3 BK WH r ele 8 LOPBRBKWH e Inl BOOM RETRACT Po x lt 5 t 5 C17 2 5 BRN 9 39 8 E lt lt CHB8LSROR RD C4B 4 I OR RD C38 3 BK WH C38 4 LS17 BOOM UP DOWN 2 SPEED REDUCTION LIMIT SWITCH Ded s o 2 P2FSWH 5 B 99 E cart C13DE BL RD C4B 1 BL RD COM SS BK C92 LS3 DRIVE ENABLE LIMIT SWITCH sits 26 3 S 2 U2 A gt 6 8 CPP 499 e lt CH 2 WH BK LS1 PRIMARY BOOM 5 DRIVE LIMIT SWITCH 8 J1 EH WH 10 1 BK Mi C10 2 LS2 PRIMARY BOOM UP SUS DRIVE LIMIT SWITCH a A C40LS OR C2B 2 x 3
195. sure to fill the hydraulic tank to specification and prime the pump after installing the pump Models with hydraulic tank shut off valves Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Part No 77828 February 2012 Section 4 Repair Procedures 6 2 Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electro proportional controller located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Eaton Hydraulics center Call Genie Industries Service Department to locate your local authorized service center How to Remove the Drive Pump Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connection at the electro proportional controller located on the drive pump Part No 77828 A TEREX
196. t 5 0 10 _ 6 Inl STEER LEFT ls BLWH 5 C244 C242 3 6 lt bx A e 1 BL g 6 _ lt 096 C6TRF WH RD C3B 6 vour s WH 4 git 22 i o CATRL WH C3B 4 C4TRL WH TURNTABLE ROTATE LEFT iS s 18 lt 92 0325 CSTFIFEWPUBK g OBS CSTRR WH BK TURNTABLE ROTATE RIGHT B R lt RIGHT gt t TURNTABLE ROTATE E Ie 3 8 Fd WH RD it 4 FLOW CONTROL C31 1 C31 2 B 1PBU RD CIPRU 1 PRIMARY BOOM UP c o PRIMARY BOOM DOWN C2PBD RD BK XR T PRIMARY BOOM DOWN 1 t j a G gi 9 7 s z 5 amp E E 15 5 2 2 t I lt lt 4 PRIMARY BOOM FLOW CONTROL a RD 6291 292 Sik WU a 5 eg C1PBU RD C3B 1 l 3 11 18 BRN 2 12 746 082 C2PBD RD BK C3B 2 E P lt 94 083 C3B 3 o C30 _ C302 9 C9PER BK RD C3B 9 C9PER BK RD Jp PRIMARY BOOM EXTEND RETRACT FLOW CONTROL mes C8PBR BK WH C3B 8 i 76 19 i m lt E 7 C3B 7 5 49 155 CABLE TENSION LIMIT SWITCH 5 YEL 8 3 IF RD N C7PBE bil BOOWEXTEND 5 4 EXTEND 1 Sis lt 5 E BOOM 37 1 37 2 cie 1 162 12 pwr s 9 t RETRACT i 15 Q 81 C8PBR BK
197. 1515 DRE LED ey 1514 RD WH RD BK L4 C134PWR RD LS18 CWLITE BK BRN BRN C28TTA RD BK C1P 2 BATGRN C7P 3 OPT CE OPTION FOOT SWITCH 12V DC BATTERY C4P BR C3P GR C2P BK C1P GY 19 18 CONTROL CABLE LLL el RD BK 28 z BRN SN llI c _ __ RD BK L48 C134PWR RD C2P 6 RD TILT CWLITE WH TS49 ATEREX BRAND 5 60 5 65 5 60 HC Part No 77828 6 66 Section 6 Schematics Deutz F3L 2011 Models Platform Control Box Switch Panel Wiring Diagram S 60 February 2012 6 67 A TEREX DWG 9 5 9 5 E Ed 5 ku ES x 152 5 S 1 z o Gs z S Z S 54 5 5 E 5 212812 Z2 z 6 5 2 ss gt 21 51 85 a8 5 5495 see as Sr Sh _ Q Ez 5 5 55 E lt m 6 rx F 2
198. 180 4 5 04474044 es SATA 123135 WOO8 Ir 9 amp O oa 1 AST619 O 2 8L 3IVIOH WHOSIVId 81 O jssisgius 9 8 0 m dn 8171337 1 10 WHOd1V Id m rezono 2 eae 1951 90 59 NIO m 3 31 WHOSLV ld SL Fizoxguodusio Je 6 lt 51 8 014910 149 vL 34 SN SAS 6951 50 2 80 HO dro EL t Foroduns3udeio aro v Wuvivogau 8 WHVIVIN3OS33NMOGWOOS88IF w O G 01 80 6 6 P EA 9S1 QU id 6 60 GHA 8 WOO 8 TZIO 2 eo 8 HW 2 GN31X3 WOO8 2 5 28420 V2 951 1 90 X8 38920 5 9 9 IPS qunwdureo gt Jp 1812 19 CPG a EUM 9 9 GH HM 38190 lH SLVLOY STAVINENL 5 3 2991 S 8 O tHISO v SIO HM TEP O v 1431 318VINUnL 1 860 HM 19170 625 38460 Jp TOHLNOO NOILONMAINOOJ 9LH HWQH 39480 g 2 WOO8 2 1 810 Qs gt 1981 2
199. 2012 Section 6 Schematics SEES ESS Ground Control Box Switch Panel Wiring Diagram S 60 GM 3 0L Models Section 6 Schematics February 2012 pm UU ER Platform Control Box Wiring Diagram S 60 GM 3 0L Models February 2012 Section 6 Schematics Platform Control Box Wiring Diagram S 60 GM 3 0L Models DESCRIPTION TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOTSWITCH CONNECTOR ALC 500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH ITEM H1 C7P C9 48 PIN CONNECTOR BLOCK U13 J1 J2 CR27 CR30 LS18 NOTE WIRE CONNECTS TO JC3 6 FOR STEER ROCKER SWITCH OPTION CWLITE WH TS49 pu z 59 0 ocuz4 46502 TOTES C19JSV GR WH TS7 C19JSV GR WH 7 BRN JC3 sf s BRN GND L RD E STOP B X Ci34PWRADLSIB 0 0 C134PWR 1
200. 21 1 PAL lt gi 5 y s a a 9 C34SA BK WH C1B 8 C34SA BKWH C5 22 4 GLOW t PLUG B pret md lt gt ete 000 GLOW PLUGS PLUG HU 000 y R a 000 00 C26TSR WH RD COOLANT TEMPERATURE LED TN 555 2 EA gus 8 ng k cxe2orztu E 5 mE CSSSTAIBK g CIB E E gt colt COOLANT TEMPERATURE SWITCH EY REO 5 START b 55652588966 8 F ENGINE E se seem C5 16 5 OIL PRESSURE SWITCH 5 L G C25PSR WH BK REN 25 lt 8 E 8 9 s o 5 POWER RELAY a ar B C21GN2 WH c5 11 8 8 e Jt FUEL SOLENOID a N 4 1 1 C27AUX RD 1 1 5 S WH METER E IGN START RELAY ae po x R33STRBK C55 e zs 5 2 SA S La STARTER MOTOR 42 Key 5 AUXILIARY 5 5 x PUMP C27AUX RD x SPEED REDUCTION RELAY a C27AUX RD 8 C7P 2 P23BAT WH cee Z a AUXILIARY POWER RELAY gt af el N 1 8 AUXILIARY PUMP 2 SE 1 2 WH EET RD BK ER g 858 QIB C28TTA RD BK 1272 7 75 1 BERE C28TTA RD BK lt ALARM Yus sa P134TTSR RD RD BK BRN
201. 3 Apply grease to each tooth of the drive gear located underthe turntable Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Part No 77828 Genie S 60 S 65 S 60 HC 3 15 CHECKLIST A PROCEDURES A 13 Replace the Drive Hub Oil Note Manufacturer drive hub specifications require that this one time procedure be performed after the first 150 hours Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil after the first 150 hours of use may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees a drive hub plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole Refer to Section 2 Specifications 5 Install the plugs into the drive hub 6 Repeatthis procedure for the other drive hub Section Scheduled Maintenance Procedures February 2012 CHECKLIST A PROCEDURES A 14 Perform Engine Maintenance GM and Ford Models Note Engine specifications require that this procedure be performed every 200 hours Proper engine maintenance following
202. 32 8 C6TRF WH RD o 5 4 Sig ag 5 5 2 4 C4TRL WH C4TRL WH TURNTABLE ROTATE LEFT 1a PWR 3 amp 13 m 1 BRN TEM 77 0395 C5TRR WH BK C5TRR WH BK TURNTABLE RIGHT R lt RIGHT J gt TURNTABLE ROTATE m 8 C6TRF WH RD TURNTABLE 4 FLOW CONTROL C314 031 2 B 1PBU RD iia 1 PRIMARY BOOM PRIMARY BOOM t DOWN C2PBD RD BK PATE 2 PRIMARY BOOM DOWN 1 1 X 7 lt s S 2 ig e Sy dee P RD WH 9 Your 5 2 lt lt 4 5 gt PRIMARY BOOM FLOW CONTROL BD 291 C292 8 6 verre 1 C1PBU RD 14 pwr 3 1 amp 22 BAN S12 2 C2PBD RD BK 15 7 lt E lt s lt lt 6323 RD WH o C30 1 30 2 haze 9 C9PER BK RD BK RD Jp PRIMARY BOOM EXTEND RETRACT FLOW CONTROL az C3P 8 C8PBR BK WH T lt ig s lt 2 7 7 49 135 CABLE LIMIT SWITCH 5 YEL os 5 amp C7PBE D BOOM EXTEND 5 4 1 EXTEND q ME 5 C37 1 C37 2 C 64 C16 2 9 t RETRACT eop 8 E COPBRIBIWH 1 BOOM RETRACT x EK lt F Ci74 17 2 d t E 5909 8 42 9 2 E 6424 C118LSR OR RD C4B 4 _ C38 3 WH C38 4 LS17 BOOM UP DOWN PMFSWH gt x
203. 5 5 z z JC1 BOOM PROPORTIONAL JOYSTICK Pn 8 BOOM EXTEND RETRACT 4 E 4 JC3 DRIVE STEER PROPORTIONAL JOYSTICK L1 DRIVE ENABLE LED 3 3 14 14 PLATFORM OVERLOAD LED t E 1 PLATFORM 147 LOWER RETRACT BOOM LED ra L48 BOOM TILTED LED 2 a 2 I A P2 EMERGENCY STOP BUTTON Pu DS _ HORN SWITCH 1 1 TS1 AUXILIARY POWER TOGGLE SWITCH 4 d Gh N TS2 ENGINE START TOGGLE SWITCH bag Rs ig 753 FUEL SELECT TOGGLE SWITCH ws B ie iS 754 HILOW RPM TOGGLE SWITCH BRN lou ENABLE bd rj NE c 757 TOGGLE SWITCH pd BK i 7509 PLATFORM LEVEL TOGGLE SWITCH BRN BRN BRN f F18 FUSE 10A E TS14 DRIVE SPEED TOGGLE SWITCH F E WORKLIGHT ONLY ES TS15 DRIVE ENABLE TOGGLE SWITCH jo olo b ig TS47 GENERATOR TOGGLE SWITCH OPTION 19 igo I 7548 DRIVE LIGHT WORK LIGHT TOGGLE SWITCH OPTION i 19 ic Ris 121Q 19 M IE m 1919 1815 5 igi E 1515 gt id BK 19 5 E gt gt 125 2 iz g JE 25 5 E 35 m rir 19 zx s ia 25 lt m m 1010 zm lt lt 9 im c c 1010 IDIA i cle o EIE Sis 6 S JIT xx EJE So V
204. 5 60 5 65 S 60 HC 16 Test machine functions from the platform controls Result All platform control functions should operate Note If the platform overload system is not operating properly Referto Repair Procedure 2 3 How to Calibrate the Platform Overload System S 60and S 65 ifequipped 17 Using a suitable lifting device remove the remaining test weights from the platform Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures C 4 Test the Platform Load Sense System S 60 HC Note Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Testing the platform load sense system regularly is essential to safe machine operation Continued use of an improperly operating platform load sense System could result in the system not sensing an overloaded platform condition Machine stablity 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 halts all normal boom operation giving visual and audible warning to the operator Models equipped with the platform overload option are provided with additional machine components an adjustable spring loaded platform support subassembly a limit switch an electronic module which receives the overload signal
205. 5 65 5 60 HC 6 86 Section 6 Schematics February2012 Electrical Schematic S 60 Perkins 404 22 Models before serialnumber 11880 P22LS BK N c LO 7 3 BATGND C7B 3 GROUND 2 lt 6273 C2B 3 5 9 gt e a Haze 01 4 C30FWD WH C1B 4 C521 _ C3OFWD WH BK U RD 4 DRIVE FORWARD 25 CIPS C31REV WH BK C1B 5 5 20 WH BK RD BK e 5 DRIVE C130TA WH RD TRAVELALARM OPTION Q ENE ATENI E erc E 9 8 C264 C26 2 C32BRK WH RD 1 I hace lt C1B 6 5 23 __ C32BRK WH RD RAKE RELEASE gt x z 3 8 C28 1 C282 z T 29MS RD WH 3 MS RD WH o lt IPS C29MS RD WI 3 2
206. 5 80 5 59 asc gat 8522 Oey 1 RTI PE EA AIG 996 1 HABE C UNC n P20BAT RD C7B 4 wane BI E2206 S a N LO enie G S 60 S 65 S 60 HC Part No 77828 6 40 Section 6 Schematics 2012 Electrical Schematic 5 65 Ford LRG 425 EFI Models from serial number 11880 to 14053 N LO C7P 8 BATGND C7B 3 GROUND z E ls ce 3 OR BK C2B 3 8 m a CIP4 C30FWD WH 4 05 21 C30FWD WH BK DRIVE FORWARD n 15 y 3 e o 25 Hee OPS C31REV WH BK 5 C5 20 C31REV WH BK __ DRIVE REVERSE P 8 rm Rc
207. 52 135 CABLE TENSION LIMIT SWITCH ES YEL RD C7PBE BK nl 50 lt EXTEND 4 BOOM EXTEND o 5 BOOM C37 1 C37 2 C16 1 C16 2 9 o 1 RETRACT i BRN 8 BK WH po GNo 2 7 7210 Q 2 E COPEN BRWH 4g iil BOOM RETRACT x lt E E t a 4 1 c 8 2 P4 CH8LSROR RD C4B 4 OR RD C38 3 BK gt WH C38 4 LS17 BOOM UP DOWN 5 eve SPEED REDUCTION LIMIT SWITCH 9 22 o amp P24FS WH x 499 24 9 BL RD BURD lt 1 13DE BL I 4 1 E 9 2 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK 9 gt C2P 2 599 B zs WH BK LS1 PRIMARY BOOM 5 SUE DRIVE LIMIT SWITCH uo J1 EH WH BK w C10 2 LS2 PRIMARY BOOM UP stUx DRIVE LIMIT SWITCH E C40LS OR C2B 2 ZI FH OR x S 2 m i 1 no 7 Quo uo 9382 EE 1 1 29 o s E 2215 BK 1 P 11 59 BL BK C3B 11 5 g EI DM BK 037 3 BK 4 2 wH C37 4 3 x LS5 CABLE TENSION LED ove 8 m P134 RD RD C381 RD C38 2 _ 71 LS17 BOOM UP DOWN amp NN a SPEED REDUCTION LIMIT SWITCH 2 2 CI4PLU OR C4B 2 8 oo Up gt lt 299 PLATFORM LEVEL 8 t DOWN
208. 55 CABLE TENSION LIMIT SWITCH 1 3 aq i RD RD BR C7PBE BK BOO EXTEND Sig 5 BOOM C37 1 C37 2 C16 1 162 9 1 RETRACT RN 0 1 22 8 10 Bi E x P lt lt T3 17 2 m 1 oo BRN ss Q 422 8 2 CaP CH8LSROR RD C4B4 OR RD C38 3 WH C38 4 LS17 BOOM UP DOWN z SPEED REDUCTION LIMIT SWITCH PMFSWH gt stus P24FS WH sas B C4P 1 C13DE BURD C4B 1 BL RD C91 BK WH 9 2 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTPBK 2 lt i 2 StUx 3 N N 9 8 99 B qz C2P 2 42 46 CH 2 WH LS1 PRIMARY BOOM EXTEND 5 stus DRIVE LIMIT SWITCH o g J1 WH C101 BK WH C10 2 LS2 PRIMARY BOOM UP LIMIT SWITCH C40LS 2 2 OR x z 1 UO m o 2215 P 11 C59CNK BL BK C3B 11 BL BK e BK C37 3 BK 8 Z WH C37 4 3 LS5 CABLE TENSION LED eve 2 134 RD F RD 38 1 y RD BR C38 2 4 LS17 BOOM UP DOWN SN a SPEED REDUCTION LIMIT SWITCH E 2 _ OR C4B 2 Noo F zr pown ATFORM LEVEL 3 5 OR BK C4B 3 L gt lt 20 1 C20 2 I UP
209. 6 Test the Oscillate Axle if equipped Note Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Proper axle oscillation is essential to safe machine operation If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over 1 Startthe engine from the platform controls 2 Drive the right steer tire up onto 6 inch 15 cm block or curb O Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 3 Drive the left steer tire up onto a 6 inch 15 cm block or curb O Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 4 Drive both steer tires up onto a 6 inch 15 cm block or curb O Result The non steer tires should stay in firm contact with the ground Note If the chassis does not remain level during test refer to Repair Procedure 7 6 How to Set Up the Oscillate Directional Valve Genie 5 60 5 65 S 60 HC 7 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage whichever comes first After this interval refer to the maintenance tables for continued scheduled maintenance 1 Performthefollowing maintenance procedures 9 Perfo
210. 60 Perkins 404 22 Models TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOTSWITCH CONNECTOR ALC 500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH ITEM DESCRIPTION H1 C9 48 PIN CONNECTOR BLOCK U13 J1 J2 27 CR30 LS18 CWLITE WH TS49 TO SWITCH PLATFORM CONTROL PANEL HARNESS C19JSV GR WH TS7 C19JSV GR WH C4P 7 JC3 BRN GND RD E STOP C134PWR RD H1 C32BRK WH RD C1P 6 C32BRK WH RD J2 19 C40LS OR C2P 2 P24FS WH C9P 2 P23BAT WH C7P 2 C134PWR RD LS18 BK C1P 12 P22BAT BK C7P 1 C19JSV GR WH C4P 7 C18PRR GR BK C4P 6 C17PRL GR C4P 5 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C129JDA BL C3P 10 TS8 C59CHK BL BK C3P 11 L47 C59CNK BL BK C3P 11 P26BAT BK C9 1 P2 P25FS RD C9 3 TS2 P24FS WH 9 2 TS4 i i i i i I I GR C2P 5 I I H i L CDLITE OR RD C2P 4 C45GEN GRANH C2P 7 C46HRN 2 5 P26ESTP BK C118LSR OR RD C4P 4 WH RD C1P 6
211. 60 HC Part No 77828 February 2012 Section 6 Schematics pn Ground Control Box Switch Panel Wiring Diagram S 60 Perkins 404 22 Models before serial number 11880 Section 6 Schematics February2012 2 2 sraOrrrm mm Arm Ground Control Box Terminal Strip Wiring Diagram S 60 Perkins 404 22 Models after serial number 11879 February 2012 Ground Control Terminal Strip Wiring Diagram 5 60 Perkins 404 22 Models after serial number 11879 Section 6 Schematics 1108
212. 7 BRN JC3 m BRN GND gt lt a RD E STOP 1518 C134PWR RD H1 4 CE LIFT DRIVE OPTION JIB CR27 RD 1518 CABLE C32BRK WH RD 1 6 LS18 CE CR30 BK C1P 12 C40LS OR C2P 2 P23BAT WH C7P 2 P22BAT BK C7P 1 T C19JSV GR WH 7 C18PRR GR BK 6 C17PRL GR 5 C15PLD OR BK CAP 3 C14PLU 2 T 1 m C129DA BL C3P 10 TS8 C46HRN GR C2P 5 F C59CNK BL BK C3P 11 L47 P26BAT 9 1 P2 P25FS RD C9 3 TS2 P24FS WH 9 2 TS4 A BOOM CDLITE OR RD C2P 4 C45GEN GR WH 2 7 GR C2P 5 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL BOARD INPUT CONNECTOR CONTROL RELAY CE OPTION ALC 500 CONTROL BOARD CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH DESCRIPTION TILT ALARM 48 PIN CONNECTOR BLOCK ITEM H1 C9 U13 J1 J2 J3 CR27 CR30 LS18 OPTION February 2012
213. 8 I y DRIVELIGHT RD lt lt DRIVELIGHT D 5 u 8o pees OPTION g 28 7 4 WORKLIGHT 8 S ze 2 G M one 25 i wld lt WH BK 158 s 1185 WORK LIGHTS ES OPTION 9 E S M eee RET E e M PER NU E NODE irt o a ue Pein ms A NI TE NUR RET S RE csi Nee DEDE e reb M ane ee a 1 2 Sy WH 2 l e T d i M ERES MES C21IGN WH n gt HOUR METER y BLWH CHECK ENGINE LED QU ij BR n o 2 I RUN TEST SWITCH s T P 8 8 o 8 2 1 C39LP BL RD C2B 1 S8 62 FUEL ei C5 19 2 WH FEH 16 PIN1 SELECT 5 8 FUEL C5 11 C21IGN WH FEH 71 PIN21 gt SELECT att _ 2 5 65 9 C128RPM OR RD FEH 306 24 41 C2B 3 2 hH N C108ESL BL WH FEH 658 PING 5 C127TSW GR FEH 458 PIN18 a m C5 10 C39LP BL RD FEH 72 PIN7 5 B C5 18 BK RD FEH 307A PIN23 59 5 j 5 8 2 RD FEH 361 PIN9 5 9 7 C33STRBK CIB7 GND BR 570 3 5 ENGINE 5 2 OR BK FEH 11 START R AAA 11 is R33STR BK FEH 32 PIN15 IGN START RELAY START C33STR FEH 32 PIN13 amp gt BL WH FEH 787A PINS e a P
214. 850 55 lt 1 Lege eS e 5899 nata PUER T SO 2 RD C7B 4 1588 o 22 00 8 1 9 A E a co e 1 T N LO Section 6 Schematics February 2012 Electrical Schematic S 65 Ford LRG 425 EFI Models before serial number 11880 A P22LS N LO C7P 3 BATGND GROUND C2P 3 C41RPM C2B 3 g EKS 8 5 sz 01 4 C30FWD WH 4 E 6521 C30FWD WH DRIVE FORWARD gt 15 g CI PS 2 C31REV WH BK lt 0185 Sy 05 20 __ WH BK FAK DRIVE REVERSE 5 5 s S S a 3 z m xt t DRIVE MODE C130TA WH RD
215. 9 C9PER BK RD Jp PRIMARY BOOM EXTEND RETRACT FLOW CONTROL aps e C3P 8 C8PBR BKWH C3B 8 i ix 18 gt USES bx 7 ig sc G3P 7 3 7 ag LS5 CABLE TENSION LIMIT SWITCH iB l m N RD RD v BR C7PBE BK BODMIEXTEND n 5 BOOM C371 C372 Ci 1 C16 2 12 9 t RETRACT anoa CGPBRBKWH IA S gt BOOMRETRACT x lt lt i EEA 4 t BRN 42 tc 21 E lt CHBLSROR RD C4B 4 OR RD C38 3 BK WH C384 LS17 BOOM UP DOWN P24FSWH 5 SPEED REDUCTION LIMIT SWITCH 2 x P24FS WH 5 899 a Ll sas 5 zz BL RD C4B 1 5 BL RD 9 1 BK C92 d LS3 DRIVE ENABLE LIMIT SWITCH awa P26ESTP BK 4 92 ave 235 Ss 8 5 D E 2 2 9 gt Cii WH BK LS1 PRIMARY BOOM 5 ave DRIVE LIMIT SWITCH 8 J1 F H WH 10 1 BK C10 2 LS2 PRIMARY BOOM UP a UE DRIVE LIMIT SWITCH 99 i C40LS OR 2 2 _ OR x I t no 1 uo EE iy L S P22LS 11____ 59 BL BK C3B 11 BL BK 9 mI BK 373 4 Z wH C37 4 k 3 135 LED ove 8 8 m P134 RD RD C881 y RD C38 2 _ 5 LS17 BOOM UP DOWN Ya a SPEED REDUCTION LIMIT SWITCH
216. 9 n 3 m 8 9 3 9 5 Eg z a a 5 gt zuo Nus T un gt i h AYAY H3MOd AV BH H3MOd Av 3H 1HVIS z Auvnixnv NOILINDI Part No 77828 A TEREX DWG S 60 S 65 S 60 G 6 44 Section 6 Schematics February 2012 Ground Control Box Switch Panel Wiring Diagram S 65 e T 5 lt E B g o 2 5 gt 50 5 3 p 8 548 ELS 88928 88598 E 8 5955 555 65 2858 5 lt glS zeleru SE lt 9 5 SM ES 2528 Sx 5 200 8 WIS E Q 52852 34658 Z
217. B 9 Check and Adjust Engine RPM Ford and Deutz Models 3 24 B 10 Testthe Ground Control Override 3 25 B 11 Check the Oscillate Directional Valve Linkage 3 26 B 12 Testthe Platform Self leveling 2 2 2 0001 3 26 B 13 Test the Engine Idle 3 27 B 14 Test the Fuel Select Operation GM and Ford Models 3 28 B 15 Test the Drive Brakes enne 3 29 B 16 Test the Drive Speed Stowed Position 3 30 17 Testthe Drive Speed Raised or Extended Position 3 30 B 18 Testthe Alarm Package Optional Equipment 3 31 B 19 Perform Hydraulic 3 32 B 20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 3 33 B 21 Replace the Fuel Filter Element Perkins Models 3 34 B 22 Inspect the Boom Extend Retract 3 35 B 23 Perform Engine Maintenance Deutz 3 37 B 24 Perform Engine Maintenance GM and Ford Models 3 37 B 25 Replace the Engine Air Filter Element GM and Fo
218. 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 TEREX COMPANY 5 60 5 65 S 60 HC 6 Attach a lifting strap from an overhead crane to the jib boom assembly 7 Place blocks under the platform leveling cylinder for support Protect the cylinder rod from damage 8 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING hazard The jib boom could fall when the slave cylinder rod end pivot pin is removed if not properly attached to the overhead crane 9 Remove the pin retaining fastener from the jib boom bellcrank to primary boom pivot pin 10 Use a soft metal drift to remove the pin and carefully remove the jib boom assembly from the primary boom AWARNING Crushing hazard The jib boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Part No 77828 February 2012 Section 4 Repair Procedures 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder 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 the hose end must be replaced All connections must be torqued to specification
219. DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS14 DRIVE SPEED TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS47 GENERATOR TOGGLE SWITCH OPTION T848 DRIVE LIGHT WORK LIGHT SWITCH OPTION CR57 RECOVERY ENABLE RELAY CR58 RECOVERY ACTIVATE RELAY a ird e x 5 MESES g sk E amp 99 gt NI P2 EMERGENCY STOP 2 212 Part No 77828 A TEREX 5 60 5 65 S 60 6 10 February 2012 Section 6 Schematics snIWIrr nurcVO rr mmm Platform Control Box Wiring Diagram S 60 HC from serial number 12800 Section 6 Schematics February 2012 re M M GM 3 0L Engine Wire Harness Section 6 Schematics February 2012 SSS 3 01 Engine Wire Harness
220. E STOP TS1 2 C133PLA GR BK 039 C28TTA RD BK H1 February 2012 Section 6 Schematics DRIVE FORWARD REVERSE amp STEER LEFT RIGHT TS4 HIGH LOW RPM TS47 GENERATOR OPTION C134PWR RD L48 C Platform Control Box Wiring Diagram S 60 HC from serial number 12800 B A Genie i 0 I 0 I I I a 1 P23BAT WH E STOP PLATFORM CONTROL BOX CONNECTOR C4 C183RCV BL CR59 SOO I C169ENV GR 150 t C134PWR RD E STOP D 1 PLATFORM CONTROL HARNESS CONTROL BOX I 1 MOUNT BOTTOM CR13 JIB RELAY OPTION ONLY 362 BOOM PROPORTIONAL JOYSTICK PRIMARY BOOM UP DOWN AND TURNTABLE ROTATE Jct BOOM PROPORTIONAL JOYSTICK PRIMARY BOOM EXTEND RETRACT Joa DRIVE STEER PROPORTIONAL JOYSTICK DRIVE ENABLE LED 4 PLATFORM OVERLOAD LED 147 LOWER RETRACT BOOM LED 148 BOOM TILTED LED 17 OUT OF ENVELOPE LED P2 EMERGENCY STOP BUTTON P3 HORN BUTTON TS AUXILIARY POWER TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH 53 FUEL SELECT TOGGLE SWITCH GAS LPG TS4 HI LOW RPM TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH JIB OPTION ONLY TS8 JIB BOOM UP
221. Fitting open closed Torque Specifications 4 Place a suitable container underneath the Note Perform this procedure with the boom in the hydraulic tank stowed position Remove the drain plug from the hydraulic tank 6 Completely drain the tank into a suitable container See capacity specifications Genie 3 58 5 60 S 65 5 60 HC Part 77828 February 2012 Section 3 Scheduled Maintenance Procedures 7 disconnect and plug the two suction hoses and supply hose for the auxiliary pump from the hydraulic tank Cap the fittings on the tank Note The hoses can be accessed through the access hole under the turntable 8 Disconnect and plug the return filter hydraulic hose at the return filter Cap the fitting on the filter housing 9 Remove the ground controls side turntable cover 10 Supportthe hydraulic tank with an appropriate lifting device 11 Remove the hydraulic tank mounting fasteners 12 Remove the hydraulic tank from the machine AWARNING Crushing hazard The hydraulic tank couldbecome unbalanced and fall if not properly supported when removed from the machine 13 Remove the hydraulic return filter housing mounting fasteners Remove the hydraulic return filter housing from the hydraulic tank 14 Remove the suction strainers from the tank and clean them using a mild solvent 15 Rinse out the inside of the tank using a mild solvent 16 Install the suction strainers using a t
222. Fuel pressure static 63 psi 4 3 bar Fuel flow rate 0 58 gpm 2 2 L min Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Ignition system Spark plug type Motorcraft AGSF 32 FM 0 042 to 0 046 inches 1 07 to 1 17 mm Spark plug gap Engine coolant Capacity 11 5 quarts 10 9 liters Coolant temperature switch Temperature switch point 230 F 110 Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140 200A Current draw maximum load 800A Alternator Output 95A 14 5V Battery Type 12V DC Group 31 Quantity 1 Cold cranking ampere 0 F 1000A Reserve capacity 25A rate 200 minutes Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 77828 February 2012 Section 2 Specifications DSG 423 EFI Engine Displacement 140 4 cu in 2 3 liters Number of cylinders 4 Bore amp stroke 3 44 x 3 7 inches 87 5 x 94 mm Horsepower 59 2500 rpm 44 kW 2500 rpm Firing order 1 3 4 2 Low function idle computer controlled 1600 rpm 53 Hz High function idle computer controlled 2500 rpm 83 Hz Compression ratio 9 7 1 Compression pressure approx Pressure psi or bar of lowest cylinder must be at least 75 of highest cylinder Lubrication system Oil pressure 29 to 39 psi at o
223. Function 5 inoperative Cycle power off primary boom up 12 Value too hiqh until joystick is down 15 calibrated Alarm En oma alue too low aa problem should be 16 V sounds indicating alue at fault corrected Function is inoperative 17 Not calibrated until joystick is Calibrate joystick calibrated 18 Just calibrated Initiate 1 second beep Self clearing of alarm transient 22 Boom 1 directional Valve is operating Cycle power off valves 21 Fault outside of operational then on and limits Alarm sounds problem should be indicating fault corrected 23 Boom 1 flow Valve is operating Cycle power off control valve 12 Value too high outside of operational then on and 15 Value too low limits Alarm sounds problem should be indicating fault corrected 4 Normal function Calibrate valve pr except threshold for thresholds one or both directions Self clearing is zero transient 31 Boom 2 Joystick 11 Value at 5V Joystick is operating Cycle power off secondary boom 12 Value too high outside of operational then on and up down or 15 Value too low limits Alarm sounds problem should be primary boom 16 Value at OV indicating fault corrected extend retract Function is inoperative 17 Not calibrated until joystick is Calibrate joystick calibrated 18 Just calibrated Initiate 1 second beep Self clearing of alarm transient 32 Boom2 directional Valve is opera
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225. HOLIMSA34 C4 DHM 5 80 HM WSI HA O zz WHOAIWId z O 653 eO 2 60 1vgzzd 1 10 a zz D OL 21 Q Qd 859 LIS Teed sg NOLLINSI te 5 39 HM WH HM lt gt 02 20 1 180 s uo J Lvaoed HOLIMS 2 anasomas air C 58 woos 2 879 ASr 619 8r 8IP LHOIH 31vLOH WHOL Td 8r 3 4 Y 1 820 Qr810 P O 16SL38 00 9 892 x8 H9 Orso ab 817 137 31vLOH WHOALW Td ab 1 220 V2 2951 39 S grO H9 e s NMOGT3A31WHOdlYid SL C C4 J 129 8 80 65S158 HO 8 8rO 01990 20919 Ey 8 dn3A31WHOdlVid Qd 22 15 12 1020 6sS1 HO Z 8r HO c r 318vVN33AMG eL Q Q 1 019 qu 18 WHYIVIN3OSSQNMOQGI Qd M 8 0 O 8951 18 01 859 18 vo RED 6 Wd 6 O 5 1 00 CHING 43460 g 6 860 Quia 4360 8 1 woog awid 8 O GH 5 g9SL HW1Y8 8 860 HWE 49485 4 GN31X3 WOO8 AHVWIHd Q4 1 10 95 389 0 89S 48 J L 8ED 394 9 2 9 Wo noona
226. I rt ss lt wTrussasi Platform Control Box Switch Panel Wiring Diagram S 60 3 0L Models B A COMPONENT INDEX JC2 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE JC1 BOOM PROPORTIONAL JOYSTICK BOOM EXTEND RETRACT JC3 DRIVE STEER PROPORTIONAL JOYSTICK L1 DRIVE ENABLE LED L4 PLATFORM OVERLOAD LED L47 LOWER RETRACT BOOM LED L48 BOOM TILTED LED P2 EMERGENCY STOP BUTTON P3 HORN SWITCH TS1 AUXILIARY TOGGLE SWITCH TS2 ENGINE START TOGGLE SWITCH TS3 FUEL SELECT TOGGLE SWITCH 54 HI LOW RPM TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH TS14 DRIVE SPEED TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TS47 GENERATOR TOGGLE SWITCH OPTION TS48 DRIVE LIGHT WORK LIGHT TOGGLE SWITCH OPTION P2 EMERGENCY STOP Genie 5 60 5 65 5 60 6 19 February 2012 Section 6 Schematics E Platform Control Box Switch Panel Wiring Diagram S 60 GM 3 0L Models Section 6 Schematics February 2012 Electrical Schematic 5 65 GM 3 0L Models February 2012 Section 6 Schematics Electrical Schematic 5 65 GM 3 0L Models C28TTA RD BK C28TTA RD BK
227. JP Z 81O 1820 E 20 Je CECI 1910 Xnvzzo Qe HOLIMS 1 92 G AOAR 8 8 91 80 N8 HM 61520 IMS SHEET USE G OLIWSXIS HM 5 zlslslz 5 E EE E P vz Q CH i nda ez GH x Q SHM al z O 2 60 LWazed ZO 1 10 w Inoa ai 850 X8 LISTZZd O 5 539 9120 WH HM HMNOIIZO x sz lt aN gt Nug Lvaozd 2 189 0H 1 103186 ar 61 O bate 8 V2 ss1 HwWu9 8rOHWH9 Teman 0715 Jp ALLOY O OH IS wo arzio yo m O sius SSI H s NMOQTRAHTWHOdIVid SL z gt 1 120 8 40 014910 O 6SS18 40 8 8rO 8 40 01480 1 020 HO Je 2 THE o 49 6951 30 2 80 lOljOUASHONS c gr amp 1 305304 NMOG EI vv Qd g nana 8 22 O 855118 01 960 18 Way var C 2 6 ECT 6 860 GUE 460 1210 HWIG V2
228. Jp 019910 rozo Honiaro 2 SNA AS EO 0 6951 2 80 rideo 01d Jp EL NAYNI o 5 E AOS 2 NOOS aI wO G 01 859 18 cua uade yo 6 7819 NOLLONN 13u 1X3 WOO 610 0 6 9 8 8 210 HM H8d80 Je MOOR 8 8 0 HMM 1260 981 04 38920 Jp 2 410 OF 2991 78 1 90 399 0 x z 9 9 UMMAH Jo 7819 NOLLONPH 31V10H 1 1 9 8 2 38199 10 JAHM uui Jp 5 1 31V1OH 3 18V S C 5 HH1SO Je v 1431 SLVLOY 318v1NunL O LOSTIN 1 860 19170 TOHIN ILONN WOO8 1 620 3890 2 CHINOS NOILONNAINOO GT suHW u 8E0 HWQH 38459 m aadzo PE 2 Q rera 2 Wuvivoig au nadio ei 1951 09 ME 4 occa ede Nua H31000 110 I g 8 eee a 5 5 HM NOIIZO I 6820 5 1 bd Te ura 5 x zz S i Sg
229. LG R 18 AWBHAKE 7 253 DG W 18 1 253 DG W 18 J j 253 DG W 18 26 OIL PRES 11 TY 18 2 OIL PRESSURE gt b 658 PK LG 18 6MIL s 27 ssa PKLG TS E 10 zea ted 238 DG Y 18 C FUEL PUMP MON s noce 7101518 14 72 VBK 18 72 18 lll j 72 Y BK 18 FUEL SELECT 15 MEYRIS L GOV SELECT 1 50071818 17 307 BKY 18 307 BK Y 18 _ 307 BK Y 18 GOV SELECT 2 Teo BATS 759108018 ROAD SPEED _________________________ _______ _________________ ___ _ _ _ __ ROAD SPEED 17218 818 DB Y 18 OVERSPEED Se os ee Oo 455 01618 ur Z LC 5205018 gt o J J P 1018 559061718 2s aeos J J 15808018 21 AUX OUT1 7 FUEL SELECT 10 AUX ANA PU2 24 GOV SELECT 1 23 GOV SELECT 2 35 ROADSPEED 36 ROADSPEED 30 OVERSPEED 28 29 CAN 11 RS 485 3 RS 485 20 RS 232 18 RS 232 RS 232 TX RS 232 RX 570 BK W 16 I HD TRIM VALVE GROUND mej 77 18 PLUG RELAY POWER e PLUS 361 n 16 361AR 16 manari D PLUG CAN WPTWR2_GY MTRTWR4 MTRSHD4 Genie xwe PartNo 77828 S 60 S 65 S 60 HC 6 12 February 2012 Section 6 Sche
230. LISTOY HMdteld 65 65 Qd 280 951 878 060 918 11 860 NO689 O 2 oF 6 m 93 920 HO 5 3519 250 30 40 Wad HO V2 9 820 NE HO WdH WO or GaMOLSWOOs Or 2 019 151070 Q4 oreo aura 2165 Jp ess ul ESSO nee 18 lHOlHH3HIS 18 D z 1 820 MOSLED Je MOSLO 120 18 20592 Je Se 3345 56 Qd 81 60 Wdsco JP 6 81O O Jp ve sw O 8 81O Jp 3 aonais Q 1810 X8 515550 98 LUONA ze avaa 26 et 62 30 QU HM V2 9 HOLIMS OL SS3NHvH Soe ig 16 Ble 02 50 ASHES 0 06 1250 HM 3060 Je 3MOHISHOLON 62 M 2 30 HWQH 620 Je d Nua 810 HWY 54620 85 VL182O JP Z Qd 20 P Q 1Ss1 qu 1910 qu Xnvzzo 9 61 0 0 Z O O aasnnn 5 5 5 EE E ve Gt P 9 180
231. Maintenance GM Ford and Perkins Models 3 11 10 Inspect the Fuel Filter Water Separator Diesel Models 3 12 A 11 Check and Adjust the Engine RPM Perkins Models 3 14 A 12 Grease the Turntable Rotation Bearing and Rotate Gear 3 15 A 13 Replace the Drive Hub Oil 3 15 A 14 Perform Engine Maintenance GM and Ford Models 3 16 A 15 Perform Engine Maintenance Perkins Models 3 16 Genie Part No 77828 S 60 S 65 S 60 HC Ix February 2012 TABLE CONTENTS Section 3 Scheduled Maintenance Procedures continued ChecklistB Procedures 1 Inspect the 0 8 0 0 3 17 B 2 Inspectthe Electrical Wiring 3 18 B 3 Check the Exhaust System 0 2 00000 3 19 4 Inspect the Engine Air Filter Ford Deutz and Perkins Models 3 20 B 5 Check the Cooler and Cooling Fins Deutz Models 3 20 B 6 Inspect the Tires Wheels and Lug Nut Torque 3 21 B 7 Confirmthe Proper Brake Configuration 22 3 22 B 8 Check the Drive Hub Oil Level and Fastener Torque 3 22
232. Manual Genie part number 84794 access the engine 1 Removethe engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 77828 Genie S 60 5 65 5 60 HC Grease the Platform Overload Mechanism S 60 and S 65 if equipped Note Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Section Scheduled Maintenance Procedures February 2012 CHECKLIST C PROCEDURES C 3 Test the Platform Overload System S 60 and
233. Q Saf O 2 x ae c _1 S80 54 t uio 225 Y 8 ha Sar o j MTS gt 3 285 4 i N 52 X z 58 8 SA 51 m B i fr zi a p oes 9 21 P x t lt i m i E z u LA t1 Ambro El ki NOS a LES 8 121 s E 8 14 5 MEUSE Ag gt IS T 125 1 o 1 9 i 15 819 r1 Ssg h eal qi 2020 L 1 zs oO d a iX s O _ EL a K hd 1 tr 5 rM a DEEST H x nd ERE x 1 lt spp eE 4 4 le 3 263 gu ix ui Ono s i gt Q Cao r Tt ag 5 J 8 o Eb gt o oe gt 1 E 3 E MELLE eee S i o0 o S z 8 i Has gt lt 2 amp ES S Wan IE kem T G i H a o0 m 5 ts 8 4 1 9 8 pra amp ED
234. Q 9 QH HM G9 QU HM lt GS Ig HM 1 20 az yg Q 8 aN31X3 woog woog 5951 1951 2 6 J J N gg z Q lt 9 Sous ONO NHA 39 N LOWHISY WHO lV1d I ao sn 9v1 Nu 9 50 GIZ HM GIZHM g ies c a i a zavera gt aja a 1z ad 2 2 2 Q O HOLIMS AS G Q z LS 27578 S am and HOLIMS 4015 ISTUD Nua Nua 1 i JO 6 a Yl WYO ZISTHO MSZ 52 9LH H WGH I981 HWQH HOLSIS3H 3385 INOZ WOOS WOO8 9 2 1 WYO s H HOLSIS3H 3ivioH NAVINYNAL 1 vH WOO8 I 1 Wyo S MSZ Sc HH enie G A TEREX DANO 6 91 S 60 S 65 S
235. QU t 2 RD BK Qeg 8 Y 8 555 2 Moe 522 E C28TTA RD BK WH 1 C28TTA RD BK T 1 TT P134TTSR RD RD i LEVEL SENSOR C3B 12 o Sp bart C133PLA ila a n e C2B 5 5 on C2P 5 C46HRN GR A C46HRN GR HORN RELAY gv GRBK C7P 1 P22BAT BK C7B 1 g P22BAT i 5 B EH BE HORN E 1 1 C1P 12 CIG2PLIBUWH 2 NE z 2 P134FB 2 6 P134PWRGR BK 2 6 gt Al ee BEAGCONS Pos gt I L RD e 2 Hz C2NGNWH R21IGNWH C amp 4 7 qHYDRAULIC OIL TEMPERATURE g 4 27 7 SWITCH OPTION PH6HYDRD 8115 8199 5 5 54 COOLING FAN r o gt lt jie 5 Q eje 95 225 27 8 5 C41RPM OR BK C2B 3 C41RPM OR BK C52 N e B re e C21IGN WH x 15 2 2 s t 5 0000 z II a a lt 2 5 2 i alec 89 0154 i alg m m lt 53 8 RD C7B 4 P20BATRD Hj Q a e LO Part No 77828 gt AND PLATFORM OVERLOAD OPTION ONLY NOTES 5 60
236. RD a OPTION S 9 P22LS CH6OR _ gt 051 COOLING P116HYD RD i OPTION g 9 9 107 m 510 gt gs 8 85 Xm E m at NO 5 Sm 1 T m 6 NO zx 5 ais lt u x 66 nooo EEG EO P20BAT RD C7B 4 Fam lt A Part No 77828 ATEREX BAAO 5 60 5 65 5 60 6 28 Section 6 Schematics February 2012 Electrical Schematic S 60 Ford LRG 425 EFI Models from serial number 11880 to 14053 N LO C7P 3 BATGND C7B 3 GROUND 2 E lt G2P33 C41RPM C2B 3 5 9 z X a haze 01 4 C30FWD WH C1B 4 s C521 C3OFWD WH BK RD DRIVE FORWARD 15 25 1 5 C31REV
237. RES ATUS EET vat EMEN T iL gt 1 e d C21IGN WH 4 1 HOUR METER I gt BLWH CHECK ENGINE LED m BR n 8 e s RUN TEST SWITCH 57 oa o 8 8 o I 8 2 1 C39LP BL RD C2B 1 62 FUEL RN C5 19 P23BAT WH FEH 16 PIN1 E SELECT 8 5 8 EI M FUEL C5 11 C21IGN WH FEH 71 PIN21 173 SELECT X 2 5 B C5 9 C128RPM OR RD FEH 306 PIN24 C41RPM OR BK C2B 8 N C108ESL FEH 658 PING 68 C127TSW GR FEH 458 PIN18 a m 5 10 C39LP BL RD FEH 72 PIN7 a3 T B C5 18 C35RPM BK RD FEH 307A PIN23 19 Sx P20BAT RD FEH 361 99 9 1 7 C33STRBK CiB 7 GND BR 570 PIN34 ENGINE 5 2 C41RPM OR BK FEH 11 PIN2 START e T bi R33STR FEH 32 15 IGN START RELAY 5 S s C33STR BK FEH 32 PIN13 gt BLAWH FEH 787A PINS x C135FP BL WH cz a eg o uox a N N A T m z C33STR BK 7 S lt 8 5 5 B 88 Bo amp STARTER MOTOR t ei E 1 sem AUXILIARY 8 C27AUXRD AUXILIARY POWER RELAY C27AUX RD 1 1 1 AUXILIARY PUMP 4 C28TTA RD BK u D L mauro x C28TTA RD BK I
238. Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 13 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery Check the battery acid level If needed replenish with distilled water to 1 8 inch 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 Genie 3 18 5 60 5 65 S 60 HC 2 Inspect the Electrical Wiring Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Openthe engine side turntable cover 2 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 3 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable
239. Schematic 2WD Models Section 6 Schematics Hydraulic Schematic 4WD Models February2012
240. Schematic S 65 Perkins 404 22 Models before serialnumber 11880 P22LS BK T e o C7P 3 BATGND C7B 3 GROUND 2 3 C41RPM C2B 3 5 4 C30FWD WH C1B 4 5 21 __ WH BK RD DRIVE FORWARD n 215 Hz 01 5 WH BK C1B 5 I C5 20 C31REV WH BK RD p ANE REVERSE s 2 Pl 1 DRIVE C130TA WH RD X TRAVELALARM z LM asa 9 26 1 C262 E ae T haze oP C32BRK WH RD C1B 6 C523 C32BRK WH RD Il BRAKE RELEASE gt x z g C28 1 C282 5 T 29MS RDWH 5 MS RD WH o lt IPS C29MS RD WI C1B 3 I 5 24 __ C29MS 4 MOTORSTROKE 2 e E ae
241. Sensor Open Knock sensor wiring and or connections open or Repair wiring and or connections to knock sensor P shorted OR sensor is faulty OR replace knock sensor Knock sensor wiring and or connections open or Check for excessive engine vibration OR repair Excessive Knock Signal shorted OR there is excessive engine vibration wiring and or connections to knock sensor OR OR sensor is faulty replace knock sensor Injector Driver 1 Open Open wiring and or connections to fuel injector 1 OR fuel injector 1 is faulty OR is faulty Repair wiring and or connections to fuel injector 1 Wiring and or connections to fuel injector 1 is OR replace fuel injector 1 OR replace the Injector Driver 1 Shorted shorted OR fuel injector 1 is faulty OR is faulty Injector Driver 2 Open Open wiring and or connections to fuel injector 2 OR fuel injector 2 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 2 Wiring and or connections to fuel injector 2 is OR replace fuel injector 2 OR replace the ECM Injector Driver 2 Shorted shorted OR fuel injector 2 is faulty OR ECM is faulty i Open wiring and or connections to fuel injector 3 Injector Driver 3 Open m mederi Open OR fuel injector 3 is faulty OR is faulty Repair wiring and or connections to fuel injector 3 Wiring and or connections to fuel injector 43 is OR replace fuel injector 3 OR replace the Injector Driver
242. TRAVELALARM 5 RS 9 C261 C26 2 C32BRK WH RD z 4 lt 1 6 5 23____ 2 BRAREBEIEASE x z a 8 C28 1 _ C282 C29MS RD WH F C29MS RD WH o 200 CIPS cies m 65 26 IM MOTOR STROKE e A 8 BL RD 5 oU 5 5 5 25 1 025 2 CDE2 BL BK 1 11 C37SCW BL BK 1 11 t C37SCW BL BK Prem _ 277 2 STEER RIGHT E P VE ENABLE C36STCC BL C36SCC BL t RIG C1P 10 6 C1B 10 36 STEER LEFT PE x CDE1 BUWH g 24 1 24 2 Eos 2211777 n hs 9 QE 7 lt lt ig wi hice 326 C6TRF WH RD C3B 6 t 5 T 4 lui gi 42 5 SS gis roce C3P 4 CATRL WH C3B 4 C4TRL WH TURNTABLE LEFT E gt ja 2213 C14 1 C14 2 u age CPP CSTAR WHIBK 0385 COTHRUWH BK lt 4 TURNTABLE ROTATE RIGHT je R lt 8 FRIGHT m em cto WEN 1 TURNTABLE ROTATE S 228 C6TRF WH RD De TURNTABLE ROTATE 4 FLOW CONTROL C31 1 C31 2 a C12 1 1PBU RD gt H PRIMARY BOOM UP PRIMARY BOOM t DOWN C2PBD E PRIMARY BOOM DOWN x C134 C13 2 a i lt S 81 amp i s lt at c 8 E ia C3PBF RD WH 19 vour s 2 lt lt PRIMARY BOOM FLOW CONTROL RD
243. Turntable Bearing and Rotate Gear 2 Torquethe turntable bearing bolts to specification See D 2 Check the Turntable Rotation Bearing Bolts 3 Startthe machine from the ground controls and raise the boom to full height Do not extend the boom Part No 77828 Genie S 60 S 65 S 60 HC CHECKLIST D PROCEDURES 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from theturntable rotation bearing turntable dial indicator drive chassis turntable rotation bearing 5 Atthe dial indicator adjust it to zero the indicator 6 Fully extend the boom and lower to a horizontal position 7 Notethe reading on the dial indicator O Result The measurement is less than 0 063 inch 1 6 mm The bearing is good Result The measurement is more than 0 063 inch 1 6 mm The bearing is worn and needs to be replaced Section Scheduled Maintenance Procedures February 2012 CHECKLIST D PROCEDURES 8 Fully retract the boom and raise the boom to full height Visually inspect the the dial indicator to be sure the needle returns to the zero position 9 Remove the dial indicator and rotate the turntable 909 10 R
244. WH BK C1B 5 C5 20 C3IREVWH BK J RD BK 16 lt i 1 DRIVE REVERSE E z 4 DRIVE C130TA WH RD TRAVELALARM Was S ae ee ced e m 8 C26 1 C26 2 C32BRK WH RD z I lt C1B 6 5 23 _ C32BRK WH RD BRAKE RELEASE 8 C28 1 _ C282 T E 7 o 01 C29MS RD WH C1B 3 C5 24 29 RDWH il MOTONSTBOKE E 55 OU 16 5 gt 5 C25 1 C252 2 _ CDE2BUBK uoo CP C37SCW BL BK C1B 11 E CETSCW BEBK STEER RIGHT 2 gt L LEFT DRIVE ENABLE t RIGHT s C1P 10 C36STCC BL C1B 10 C36SCC BL D USTEERTEET x CDE1 BLWH g CT ES a o 7 us BL g RKour ec Pb 6 C6TRF WH RD C3B 6 I vorpe WH 19574 lt ES 8 42 8 555 z 4 C4TRL WH C3B 4 C4TRL WH D TURNTABLE ROTATE LEFT 1 2213 C14 1 4 C14 2 ew z s lt lt G3P 5 WEEK 38 5 WH BK I TURNTABLE ROTATE RIGHT 15 15 1 15 2 RIGHT 8 15 C15 mE TURNTABLE ROTATE LEFT 8i PI 5 8 c31 1 C31 31 31 2 o SA C6TRF WH RD lt gt gt FLOW CONTROL C12 1 C12 2 5 omen Ibi PRIMARY BOOM UP C2PBD RD BK u PRIMARY BOOM DOWN x C13 1 1 2 7 lt aa
245. WYO 01 MSZ 52 NszSz Hi O 30191534 HOLSISSY 31vioH INOZ H3ddn 3aviNunL WOOS AHVWIHd vH 91H Yl wyo S MSZ HOLSISAHY 31v10H HO1SIS3H 1 NMOG dn ed woog blu o y 1 uuo S lt 2 February 2012 Section 6 Schematics sc lt r rm Ground Control Box Switch Panel Wiring Diagram S 60 Deutz F3L 2011 Models after serial number 11879 Section 6 Schematics February 2012 nmm 4 X Xwe n Ground Control Box Terminal Strip Wiring Diagram S 60 CE Models Deutz F3L 201 1 Models before serial number 11880 February 2012 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 60 CE Models Deutz F3L 2011 Models before serialnumber 11880 C FUNCTION HARNESS ENGINE C5 957 HOLIMS NOISN31L anayo 151 HOLINS woog 20810 Z 64 84 vO BED L 61 84 42 WHOdlV 1d OL H3MOd
246. __ C29MS I 2 0 8 CDE3BLRD s 5 5 C25 1 C25 2 2 CDE2 BL BK 11 C37SCW BL BK C1B 11 E C37SCW BL BK gt 7 18 1 5 RIGHT PHV ENABLE C36STCC BL C36SCC BL t RIGHT SIP AO 36 C1B 10 36 STEERTEFT 23 x CDE1 BLWH x 8 24 1 242 5 ic 2 Bele BL g RKOUT 64 lt 63 6 WH RD C3B 6 vour s WH ISS 4 a R 555 CPA CATRL WH C3B 4 C4TRL WH lt 1 gt gt 4 TURNTABLE ROTATE LEFT OR ig PWRLSS 7218 C3P 5 C5TRR WH BK C3B 5 CSTRR WH BK 12 2 14 9 t TURNTABLE ROTATE RIGHT 2 15 1 Ci52 lt 3 B Ven TURNTABLE ROTATE E po c EFT 8 C6TRF WH RD TURNTABLE E ad lt gt FLOW CONTROL WW C31 1 C31 2 12 1 122 7975 m lt lt 55 PRIMARY BOOM UP F s4A8 1 F k krseQa D gt PRIMARY BOOM t DOWN C2PBD RD BK gt os 1 m T 07 921 PRIMARY BOOM DOWN lt 3 EC Bj nr sc 5 8 15 vour s BK 2 ES RD WH 1 PRIMARY BOOM FLOW CONTROL RD 6294 C292 XU C3P 1 CIPBU RD C3B 1 Iz 3 11 ES amp pN gt CP C2PBD RD BK lt 6382 E 1 E lt X M s c 63 3 RD WH C3B 3 8 C30 1 C302 03 9 C9PER BK RD C3B 9 C9PER BK RD He PRIMARY BOOM EXTEND RETRACT FLOW
247. a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Test the coil for resistance See How to Test a Coil 2 Connecta 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Resistor 100 Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 3 Seta multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA Part No 77828 A TEREX COMI S 60 5 65 S 60 MANIFOLDS COIL of 4 100 9V RESISTOR BATTERY P gt i i T i lpi i tt LP Je i l l im multimeter 9V DC battery 100 resistor coil Dotted lines illustration indicate reversed connection as specified in step 6 4 Connectthe negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil 5 Momentaril
248. annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage AWARNING Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 3 2 km h Non steer Wheels All Models 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the non steer tires 3 Lift the wheels off the ground and then place jack stands under the drive chassis for support Part No 77828 Genie S 60 S 65 S 60 HC CHECKLIST D PROCEDURES 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub disengaged position arf arg engaged position 5 Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort 6 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the jack stands AWARNING Collision hazard Failure to re engage the drive hubs may cause death or serious injury and property damage Steer Wheels 4WD Models 7 Chockth
249. at all times when handling printed circuit boards OR use a grounded wrist strap 5 Carefully disconnect the wire connectors from the circuit board 6 Remove the ALC 500 circuit board mounting fasteners 7 Carefully remove the ALC 500 circuit board from the platform control box PLATFORM CONTROLS 1 2 Joysticks How to Calibrate a Joystick The joysticks on this machine utilize digital Hall Effect technology for proportional control If a joystick is disconnected or replaced it must be calibrated before that particular machine function will operate Note The joystick must be calibrated before the threshold max out or ramping can be set Note Perform this procedure with the engine off 1 Openthe platform control box 2 Pulloutthe 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 Disconnectthe wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds Connect the wire harness connector to the joystick 6 Move the joystick full stroke in either direction and hold for 5 seconds 7 Return the joystick to the neutral position pause for a moment then move the joystick full stroke in the opposite direction Hold for 5 seconds and return the joystick to the neutral position O Result The alarm should sound indicating successful joystic
250. before serial number 11880 6 81 Ground Control Box Terminal Strip Wiring Diagram 5 65 CE Models Deutz F3L 2011 Models 118790 6 82 Ground Control Switch Panel Wiring Diagram S 65 CE Models Deutz F3L 2011 Models afterserialnumber11879 a 6 83 Genie xviii S 60 S 65 S 60 Part No 77828 February 2012 TABLE CONTENTS Section 6 Schematics continued Platform Control Box Terminal Strip Wiring Diagram 5 65 Deutz F3L 2011 Models rr 6 84 Platform Control Switch Panel Wiring Diagram 5 65 Deutz F3L 201 1 6 85 Electrical Schematic S 60 Perkins 404 22 Models before serial number 11880 6 86 Electrical Schematic S 60 Perkins 404 22 Models after serial number 11879 6 88 Ground Control Box Terminal Strip Wiring Diagram 5 60 Perkins 404 22 Models before serial number 11880 6 90 Ground Control Box Switch Panel Wiring Diagram 5 60 Perkins 404 22 Models before serial number 11880 6 91 Ground Control Terminal Strip Wiring Diagram 5 60 Perkins 404 22 Models after serial number 11879 6 92 Ground Control Switch Panel Wiring Diagram 5 60 Perkins 404 22 Models after serial number 11879
251. boom lift cylinder long link arm ground controls side long link arm engine side long link arm to turntable pivot pin master cylinder cam master cylinder cam link short link arm to turntable pivot pin long link arm to boom pivot pin master platform level cylinder short link arm weldment S 60 5 65 S 60 Section 4 Repair Procedures February 2012 BOOM COMPONENTS 4 2 Boom How to Remove the Boom AWARNING 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 or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the jib boom See 3 1 How to Remove the Jib Boom 2 Remove cable track See 4 1 How to Remove the Cable Track 3 Raise the boom until the short and long link arm to boom pivot pins are above the turntable covers 4 Place a block of wood measuring 4 4 60 inches 10 x 10 x 152 cm under the long link arm across the turntable covers A TEREX COMPANY 5 60 5 65 5 60 HC 5 Slowly lower the boom until the long link arm contacts t
252. component always support the structure and secure it from movement AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry AWARNING P dily 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 Note Perform all troubleshooting on a firm level surface Note Two persons will be required to safely perform some troubleshooting procedures Section 5 Fault Codes February 2012 FAULT CODES Fault Code Chart Control System How to Retrieve Control System Fault Codes Note At least one fault code is present when the alarm at the platform controls produces two short beeps every 30 seconds for 10 minutes Note Perform this procedure with the engine off the key switch turned to platform controls and the red Emergency Stop button pulled out to the on position at both the ground and platform controls 1 Openthe platform control box lid AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Locate the red and yellow fault LEDs on the ALC 500 circuit board inside the platform control box Do not touch the circuit board Component damage hazard Ele
253. during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib 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 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 Part No 77828 A TEREX 5 60 5 65 5 60 HC JIB BOOM COMPONENTS 65 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 leveling arm Do not remove the pin 5 Support the jib boom lift cylinder with a lifting device 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pin and let the cylinder hang down Crushing hazard The platform and AWARNING jib boom could become unbalanced and fall when the jib boom barrel
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257. faulty OR one or more fuel injectors are stuck closed OR there is electro magnetic interference from a faulty crankshaft and or camshaft position sensor Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel quality is poor OR fuel system components may be faulty Engine wire harness may have an intermittent short to 5V DC or 12V DC OR fuel system components may be faulty Genie Part No 77828 FAULT CODES Repair wiring and or connections OR replace sensor OR repair vacuum and exhaust leaks Repair wiring and or connections OR replace sensor Repair wiring and or connections OR replace the post cat oxygen sensor Repair wiring and or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors Adjust or replace sensors OR clean or repair fuel injectors Repair wiring and or connections OR replace sensor OR replace fuel OR test and repair the fuel system components Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance Repair heated oxygen sensor wiring and or connections OR replace sensor OR repair vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors Adjust or replace sensors OR clean or repair fuel injectors Repair wiring an
258. fluids Consult the Genie Service Department before use Part No 77828 Genie 5 60 5 65 S 60 SPECIFICATIONS Drive pump Type bi directional variable displacement piston pump Flow rate 2500 rpm 32 4 gpm 122 6 L min Drive pressure maximum 3750 psi 259 bar Charge pump Type gerotor Displacement 0 85 cu in 13 9 cc Flow rate 2500 rpm 9 2 gpm 34 8 L min Charge pressure 2500 rpm 310 psi 21 4 bar Function pump Type 2 section tandem gear pump Displacement Pump 1 inner 1 4 cu in 23 cc Flow rate 2500 rpm 15 3 gpm 58 L min Displacement Pump 2 outer 0 24 cu in oscillate models 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 Continuous improvement of our products is Genie policy Product specifications are subject to change without notice Section 2 Specifications February 2012 SPECIFICATIONS Function manifold System relief valve pressure 3000 psi 207 bar Steer flow regulator 3 5 gpm 13 2 L min Jib boom platform rotate 0 6 gpm flow regulator 2 27 L min Oscillate relief valve pressure 2500 rpm 800 psi 55 bar Drive manifold Hot oil relief valve pressure 280 psi 19 3 bar Drive motors 4WD models Displacement per revolution 0 79 cu in high speed 13 cc Displacement per revolution 1 83 cu in low
259. four tires and add air if needed to meet specification Note The tires on some machines are foam filled and do not need air added to them 4 Remove the drive chassis cover and the non steer axle covers 5 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 6 Remove the heim joint retaining fastener from the axle A TEREX COMPANY 5 60 5 65 5 60 HC 7 Tolevel 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 drive chassis are completely level 9 Adjust the heim joint until the hole lines up with the retaining fastener hole in the axle 10 Install the heim joint to the axle and tighten the jam nut 11 Check to be sure the drive chassis is completely level 12 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis Note If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level repeat steps 6 through 11 OR consult the Genie Service Department Part No 77828 February 2012 Section 4 Repair Procedures x Ma C MANIFOLDS 7 7 Valve Adjustments Oscillate Relief Valve How to Adjust the Oscillate Relief Valve Pressure 1 Remove the drive chassis cover from the non steer end of the machine 2 Co
260. gS 5i 59 gt i lt a zig us sa 8 ic lt u o S arl MEE 2056 ISA 4 6 ul Qoae EEE 7 ESOS gt P20BAT RD C7B 4 i J200 8 lt S 174 Part No 77828 5 60 5 65 5 60 G 6 42 Section 6 Schematics February 2012 Electrical Schematic S 65 Ford DSG 423 EFI Models after serial number 14053 A N LO C7P 3 BATGND C7B 3 GROUND C2P 3 C41RPM C2B 3 9 5 lt 8 5 9 z a haze 01 4 C30FWD WH C1B 4 5 21 _ WH BK BRIVE FORWARD gt 15 01 C31REV WH BK C1B 5 _ C5 20 C31REV WH BK AD BK DRUEREVERSE e gl
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264. installing the pump do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur Models without hydraulic tank shut off valves Component damage hazard Be sure to fill the hydraulic tank to specification and prime the pump after installing the pump Models with hydraulic tank shut off valves Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump How to Prime the Pump 1 Connecta 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump 2 Remove the safety pin if equipped from the engine pivot plate latch Note The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 3 Openthe engine pivot plate latch and swing the engine pivot plate out and away from the machine 4 GM and Ford models Close the valve on the LPG tank then disconnect the hose from the tank Move the fuel select switch to the LPG position Perkins models Disconnect the engine wiring harness from the fuel solenoid at the injector pump Deutz models Hold the manual fuel shutoff valve clockwise to the closed position a manual fuel shutoff valve A TEREX COMPANY 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures HYDRAULIC PUMPS 5 Have another person crank the engine with the starter motor for 15 se
265. its original position and install the engine pivot plate retaining fastener Part No 77828 Genie S 60 S 65 S 60 HC 3 21 CHECKLIST B PROCEDURES B 6 Inspect the Tires Wheels and Lug Nut Torque Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Checkeach wheelfor damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Section 2 Specifications 4 Checkthe pressure in each air filled tire Refer to Section 2 Specifications Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 7 Confirm the Proper Brake Configuration Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes
266. just removed Genie part number 119488 through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Genie S 60 5 65 S 60 HC Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures Checklist B Procedures B 1 Inspect the Battery Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions AWARNING Electrocution bu rn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Besurethatthe battery cable connections free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Besure that the battery hold downs and cable connections are tight Part No 77828
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269. not completely drain the filter a fuel filter water separator b drain valve 6 Clean up any fuel that may have spilled 7 Startthe engine from the ground controls and check the fuel filter water separator for leaks Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 8 Swing the engine back to its original position and install the engine pivot plate retaining fastener Section Scheduled Maintenance Procedures February 2012 CHECKLIST A PROCEDURES A 11 Check and Adjust the Engine RPM Perkins Models Note Engine specifications require that this procedure be performed every 100 hours Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will no operate properly if the rpm is incorrect and continued use may cause component damage Note This procedure will require two people 1 Connecta tachometer to the engine Start the engine from the ground controls and check the rpm Refer to Section 2 Specifications Skip to step 3 if the low idle rpm is correct 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 E
270. not within specification plus or minus 30 replace the coil TEREX COMPANY 5 60 5 65 S 60 HC Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 10 C that your air temperature increases or decreases from 68 F 20 C Valve Coil Resistance Specification Description Specification Solenoid valve 3 position 4 way 10V DC 5 to 70 schematic items D V and Y Solenoid valve 3 position 4 way 10V DC 4 to 60 schematic item BB Solenoid valve 2 position 3 way 10V DC 5 to 70 schematic items B C E F and FF Solenoid valve 2 position 3 way 10V DC 5 5 to 7 50 schematic items KK and LL Proportional solenoid valve 12V DC 4 to 60 schematic items M and T Proportional solenoid valve 12V DC 3 7 to 5 7Q schematic item Q Part No 77828 February 2012 Section 4 Repair Procedures How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional valves and those coils with a metal case Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to
271. o l l 8585 q a eise RA ed m lt 59 8 RD r C7B 4 P20BAT RD 4 q j e e LO Part No 77828 enie S 60 S 65 S 60 G 6 68 Section 6 Schematics February 2012 Electrical Schematic S 65 Deutz F3L 201 1 Models before serial number 11880 P22LS N c LO C7P 3 BATGND C7B 3 1 GROUND E C2P 3 C41RPM OR BK C2B 3 2 5 m x E e Q G1P 4 C30FWD WH C1B 4 C521 __ C30FWD WH BK RD GRIVEFORWAHD 2 15 CIPS WH BK C1B 5 s 5 20 C31REV WH BK PD jj BK e DHREREVERSE e m 4 4 z DRIVE MODE C130TA WH RD X
272. off 1 Locate the engine air filter assembly 2 Release the latches from the air cleaner canister end cap Remove the end cap 3 Remove and discard the filter element 4 Clean the inside of the canister and the end cap with a damp cloth 5 Install the new filter element 6 Install the air filter canister end cap and secure the end cap latches Part No 77828 Genie S 60 5 65 5 60 HC CHECKLIST C PROCEDURES 7 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 600 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Perkins 400 Series Operation Manual Perkins part number TPD 14435 Perkins 400 Series Operation Manual Genie part number 94890 Section Scheduled Maintenance Procedures February 2012 CHECKLIST C PROCEDURES C 8 Perform Engine Maintenance GM and Ford Models Note Engine specifications require that this procedure be performed every 800 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the
273. plug located on the fuel filter water separator head vent plug main fuel line drain plug filter bowl filter element separator head 4 Place a suitable container under the filter bowl Loosen the drain plug located at the bottom of the bowl Completely drain the fuel 5 Rotate the filter bowl counterclockwise and remove it from the element 6 Rotate the filter element counterclockwise and remove it from the filter head Install the bowl onto the new filter element 8 Apply a thin layer of oil onto the element gasket Install the filter bowl assembly onto the filter head Tighten the drain plug and vent plug Section Scheduled Maintenance Procedures February 2012 CHECKLIST C PROCEDURES 9 Clean up any diesel fuel that may have spilled during the installation procedure 10 Install the fuel supply hose from the fuel tank to the fuel filter water separator Tighten the clamp 11 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filer housing Bleedthe system 12 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 13 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could r
274. point 221 P P 105 C Rotate bearing mounting bolts lubricated 180 ft lbs 244 Nm Turntable rotation assembly Backlash pivot plate lubricated 320 ft lbs 433 Nm Continuous improvement of our products Genie policy Product specifications are subject to change without notice Genie Part No 77828 5 60 5 65 5 60 HC Section 2 Specifications February 2012 SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque 4 11 ft Ibs 14 9 Nm 6 23 ft Ibs 31 2 Nm 8 40 ft Ibs 54 2 Nm 10 69 ft Ibs 93 6 Nm 12 93 ft Ibs 126 1 Nm 16 139 ft Ibs 188 5 Nm 20 172 ft Ibs 233 2 Nm 24 208 ft Ibs 282 Nm SAE O ring Boss Port Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 2 Lubricate t
275. service until the manual is replaced Part No 77828 Genie S 60 S 65 S 60 HC 3 7 3 Openthe operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility anddamage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed Section Scheduled Maintenance Procedures February 2012 CHECKLIST A PROCEDURES A 2 Perform Pre operation Inspection Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation 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 Genie 5 60 5 65 S 60 HC
276. slave cylinder It s part of the closed circuit hydraulic loop 7 Place a through the barrel end pivot pin that keeps the platform level through the entire twist to remove the pin range of boom motion The master cylinder is 8 th i ine located at the pivot end of the boom emove the master cylinder from the machine How to Remove the Platform Leveling Master Cylinder Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 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 AWARNING 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 Placea2x4 x48 inches 5 x 10 x 120 cm block of wood across the turntable covers Position the block under the master cylinder 4 Remove the pin retaining fastener from the master cylinder rod end pivot pin A TEREX COMPANY Part No 77828 S 60 5 65 5 60 HC 4 35 Section 4 Repair Procedures February 2012 Engines 5 1 RPM Adjustment Ford and Deutz Models Referto Mainten
277. the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the GM 3 0L Operator Handbook GM part number 36100007 OR the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 GM 3 0L Operator Handbook A 15 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 200 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Perkins 400 Series Operation Manual Perkins part number TPD 14435 Perkins 400 Series Operation Manual Genie part number 94890 access the engine Genie number 101095 1 Removethe engine tray retaining fastener Ford LRG 425 EFI Operator Handbook located under the engine tray Swing the engine Genie part number 84792 tray out and away from the machine Ford DSG 423 EFI Operator Handbook 2 Install the fastener that was
278. the pivot plate Note If the boom extend cables are adjusted evenly the wheel of the limit switch arm should be centered in the notch of the pivot plate a cable break limit switch b extend cable adjustment nut extend cable pivot plate 13 Install the boom end cover at the pivot end of the boom 14 Fully retract and lower the boom to the stowed position BOOM COMPONENTS How to Replace the Boom Extend Retract Cables Note The cable pulleys must also be replaced when replacing the cables 1 Remove the boom extension cylinder See 4 4 How to Remove the Boom Extension Cylinder Boomextend cables 2 Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boomtube 3 Remove the rue rings and clevis pins from the boom extend cables located near the extend cable break limit switch 4 Remove the external snap rings from the boom extend cable pulley pivot pin Use a soft metal drift to remove the pin Note When driving the pivot pin out be sure to drive it from the shaped end of the pin 5 Remove the pulley and boom extend cables from the extension cylinder assembly Discard the old cables and pulleys 6 Route the new boom extend cables through the boom extend pulley bracket 7 Install the new boom extend cable pulley pivot pin and snap rings Note Be sure the boom extend cables are routed through the grooves of the pulley and the upper wear pad on the extension cyl
279. threshold A TEREX Ct 4 4 S 60 5 65 S 60 10 Slowly move the joystick off center in either direction just until the function begins to move 11 Slowly move the joystick back to the neutral position Just before the function stops moving move the drive enable toggle switch to either side to set the threshold Result The alarm should sound indicating a successful calibration 12 Repeat steps 9 through 11 for each boom joystick controlled machine function boom down boom extend retract and turntable rotate 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 14 Cycle the red Emergency Stop button off then back on Part No 77828 February 2012 mF cs Irmm 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
280. very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray A TEREX COMPANY 5 60 5 65 5 60 HC 3 Loosen the backlash pivot plate and adjustment bolts backlash pivot plate b adjustment bolt with lock nut backlash pivot plate mounting bolts 4 Attach a suitable lifting device to the lifting eyes on the drive hub assembly 5 Remove the backlash pivot plate mounting bolts Carefully remove the drive hub assembly from the machine AWARNING Crushing hazard The turntable could rotate unexpectedly when the rotation drive hub assembly is removed if the turntable is not secured with the turntable rotation lock pin AWARNING Crushing hazard The turntable rotation drive hub assembly could become unbalanced and fall when removed from the machine if not properly supported Part No 77828 February 2012 Section 4 Repair Procedures When installing the drive hub assembly 6 Install the drive hub Torque the back lash pivot plate to specification Refer to Section 2 Specifications 7 Adjustturntable rotation gear backlash See How Adjust the Turntable Rotation Gear Backlash How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing ring gear Note Perform this procedure with the boom between the non stee
281. whee P o i i I 2215 11_ 59 BL BK 11 15 5 BK 037 3 4 Z cor4 in 3 1 LS5 CABLE TENSION LED sU g E 5 8 m P134 RD F RD C881 RD BR C382 7 LS17 BOOM UP DOWN a SS SPEED REDUCTION LIMIT SWITCH 2 C4P 2 CI4PLU OR C4B 2 gt lt 29 ELTE e PLATFORM LEVEL 8 t DOWN 3 C15PLD 3 8 20 1 C20 2 c Ta i CI4PEU OR 1 1 PLATFORM LEVEL UP PLATFORM LEVEL t DOWN i CISPED OH BIK D PLATFORM LEVEL DOWN 5 E i C2t 1 C21 2 8 10 C129JDA BL C3B 10 8 R C4P 6 C18JD PRR GR BK C4B 6 DOWN BOOM C17JU PRL GR C4B 5 Cine C284 C23 2 8 8 C18JD PRR GR BK T 8 E i lt PLATFORM ROTATE RIGHT H RIGHT PLATFORM gt CIES GR D PLATFORM ROTATE LEFT C224 C222 RIGHT PLATFORM 2 ees LEFT ROTATE i 4 LE L Lp CI29 RD K DESCENTALARMOPTION t Pog 8 2 7 C19JSV GR WH C4B 7 ES CRTC 1 gt 5 5 JIB VALVE 8 JIB VALVE x go n n alg Elelu 2 ASRS Ex ale 5 S 60 5 65 5 60 HC 6 75 Part No 77828 February 2012 Section 6 Schematics Electrical Schematic S 65 Models Deutz F3L 2011 Models after serial n
282. x 9 GH HM 3919 5 ET a MEELIS 2 5 1 31VLOH STAVLINENL S SINE 5 959 N8 HM 4150 P r 1431 31V1Ot 318V1NH 01 T8E0 19170 28450 Jp 7031409 NOILONN WOO O Qd SHFHMGH 38469 aadeo Jp 5 5 1951 2 20 aadeo Wuv voig ad 1 210 Nadto oi Si ood 1951 09 gt ea v 8 al asya 2 A tec b SNOILdO 99 Q Y q9r u9 2 531009 110 wl E 8 uel o 4 Nua NOILZO amp co sd AV I3H 1H9N Gig NHOH 2280 Suo i g i m 5 497 38 om 220 C fre _ EE SO a xe S 5 2 L8 mol Su 9 Poor e i x SKRE z i i 6WSI HM An 8 z nua dioN310S Edd E 9 WdHH9IH p 6 I XINO 39 WHO41V1d AV13H een Nua Nua AHVLS NOLLINSI zuo 99 N LO N TANWd HOLIMS OL SSANYVH NOTE DASHED LINES INDICATE OPTION WIRES A TEREX DG 5 60 S 65 S 60 Part No 77828 6 62 Section 6 Schematics Deutz F3L 2011 Models before
283. 0 5 65 5 60 HC 3 1 About This Section This section contains detailed procedures for each scheduledmaintenance inspection Each procedure includes a description safety information and step by step instructions Symbols Legend Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicate an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures February 2012 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to performthis procedu
284. 0 Deutz F3L 2011 Models Section 6 Schematics February 2012 plum UU Electrical Schematic S 65 Deutz F3L 201 1 Models before serial number 11880 February 2012 Section 6 Schematics Electrical Schematic S 65 Deutz F3L 2011 Models before serialnumber 11880 C22LS BK E EE ge S ga E n OE amp E s 1 9 C35RPM BK RD C1B 9 FOOTSW HIGH Foorsw Low a zB 5 x Su zu P 5 GG LOW RPM z FUNCTION ENA HIGH RPM pi pa BK RD 4 LiGHIDLE RELAY 1 8 BKRD 0518 HIGH RPM SOLENOID 8 o ccc Add lE 8 e C2P 7 C45GEN GR WH C2B 7
285. 0 Ford Models nia CU Eu ee ERR GET 6 37 Electrical Schematic S 65 Ford LRG 425 EFI Models before serial number 11880 6 38 Electrical Schematic S 65 Ford LRG 425 EFI Models from serial number 11880 to 14053 6 40 Electrical Schematic 5 65 Ford DSG 423 EFI Models after serial number 14053 6 42 Ground Control Terminal Strip Wiring Diagram 5 65 Ford LRG 425 EFI Models before serial number 11880 6 44 Ground Control Box Switch Panel Wiring Diagram 5 65 Ford LRG 425 EFI Models before serial number 11880 6 45 Ground Control Box Terminal Strip Wiring Diagram 5 65 Ford Models after serial number 11879 6 46 Ground Control Box Switch Panel Wiring Diagram 5 65 Ford Models after serial number 11879 6 47 Platform Control Box Terminal Strip Wiring Diagram 6565 6 48 Platform Control Switch Panel Wiring Diagram 6 65 Ford u z S 6 49 Genie Xvi 5 60 S 65 5 60 HC Part No 77828 February 2012 TABLE CONTENTS Section 6 Schematics continued Electrical Schematic S 60 Deutz F3L 2011 Models before serial number 11880 6 50 Electrical Schematic S 60 Deutz F3L 2011 Models af
286. 0 HC Part No 77828 6 84 Section 6 Schematics Deutz F3L 2011 Models Platform Control Box Switch Panel Wiring Diagram S 65 February 2012 6 85 A TEX G gt Q 5 x 2E g zz 52 2 Ser Flu volg e E i oco 5 BulB la 2 5 0 1560 a OE SSuuogEOS 2585 5 8 2 e lt 8 E 5 9455386458 Wess 52 Siaga S 5 8255 5 5 SESS 39592 48 5 4 n 8jssssbugiuBOEIEZSZI5iB3sr rx F T 55 EO 0 96 66 0 5 S9 5 lt 5 asss ig 585 8 58228 8 69 68 S 5 6 s lt o To uo 22 7 1 P26BAT 3 3 2 P23BAT C7P 2 BL J1 5 ROCKER SWITCH ONLY P26BAT BK C9 1 z9 wHJt4 RD Hi iHe BL 01 5 C134PWR 148 i i
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288. 1 5 C31REV WH BK C1B 5 C5 20 C31REV WH BK BK ORIVE BEVERSE gl 1 DRIVE C130TA WH RD TRAVEL ALARM 8 9 C26 1 26 2 T C32BRK WH RD Bi EK us C1B 6 5 23 __ C32BRK WH RD li BRAKE RELEASE gt 8 8 C28 1 C28 2 z T C29MS RDWH z C29MS RD WH z lt ace CIPS mE mE MOTOR STROKE aE 85 ka CDE3BLRD s 5 9 8 Eu E 3 C254 C252 2 CDE2 BL BK 1 11 C37SCW BL BK C1B 11 C37SCW BL BK t 18 STEER RIGHT Em RIGHT OTE ENABLE 10 C36STCC BL C1B 10 C36SCC BL LM ss 17 STEER LEFT GIR x CDE1 BLWH 8 24 1 C24 2 9 alo 5 zo gt gu 7 lt BL g lt lt C3P 6 WH RD C3B 6 9 2 vour s WH SS 4 8 42 815 uoc CP CATRL WH C3B 4 C4TRL WH TURNTABLE LEFT I pwr lt CSIRHWIBUK C141 142 lt lt 3 5 oes CSTRRIWHIBK TURNTABLE ROTATE RIGHT 15 15 1 15 2 lt 8 TRIGHT 8 C15 C15 r TURNTABLE ROTATE ccc LEFT 8i z l E E 8 C814 C312 5 WH RD lt lt gt TURNTABLE ROTATE ANC FLOW CONTROL 89 a 12 1 p 12 2 PRIMARY BOOM UP PRIMARY BOOM tDOWN C2PBD RD BK IA E T PRIMARY BOOM DOWN i z 13 1 2 lt 3 zo Bi i te Pir o c
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292. 16 N C108ESL BL WH FEH 658 PING 68 C127TSW GR FEH 458 PIN18 2 a 22 C5 10 C39LP BL RD FEH 72 PIN7 85 9 C5 18 C35RPM BK RD FEH 307A PIN23 59 8 55 8 P20BAT RD FEH 361 PIN9 r C33STRBK 7 GND BR 570 PIN34 8 ENGINE C52 C41RPM OR BK FEH 11 PIN2 START a 8 lj sal C55 R33STR BK FEH 32 PIN15 IGN START RELAY START sl to C33STR FEH 32 52 787 5 x x C135FP BL WH m I 55 cz eo e ss C33STR e E E NM g ul A N A 1 2 L 4 STARTER MOTOR 88 2 5 5 it 245 tote ol d SPEED REDUCTION RELAY 4 AUXILIARY a cea 1 AUXILIARY POWER RELAY az C27AUX RD 1 1 9 5 L 4 AUXILIARY PUMP 4 amp 1 5 C28TTARD BK ma u C28TTA W ooo o o 8 g rt ALARM l l 1 RD BK BRN x P23BAT WH 7 2 134 5 7 X YEVEP SENSOR y x 4 a gt g 8 N 28 RD BK 1 2 N Gases eee m 1 FLASHING BEACONS OPTION C46HRN GR C2B 5 C46HRN GR HORN RELAY RD w 9 5 x R46HRN 1 22 22 46 uon P134PWR GR BK 59 i HYDRAULIC OIL 2 6 R21IGN WH C5 4 4 TEMPERATURE SWITCH P134PWR
293. 2 BOOM FLOW CONTROL RD 29 1 C29 2 KOUE 1 C1PBU RD C3B 1 on 6 PWR 3 11 S Q 5 BRN 966 082 C2PBD RD BK C3B 2 F E P lt s lt 6923 C3B 3 2 C30 1 C30 2 C9PER BK RD C3B 9 E C9PER BK RD Jp PRIMARY BOOM EXTEND RETRACT FLOW CONTROL 8 C8PBR BK WH C3B 8 i 1 1 gt eae iG lt C3P 7 C7PBE BK C3B 7 TA 122 99 155 CABLE LIMIT SWITCH ours YE a IM RD RD N BR C7PBE BK IE lt LEXTENB e BOOM EXTEND 515 n 5 BOOM 637 037 2 Ci 1 C16 2 9 1 RETRACT BRN n 2 30 Q SPER BKM Ee Il gt gt BOOM RETRACT x lt 5 P 6174 C17 2 7 o 42 4 C118LSR OR RD C4B 4 OR RD C38 3 BK WH C38 4 LS17 BOOM UP DOWN P24FS WH 5 5 E stUx SPEED REDUCTION LIMIT SWITCH 222 x P24FS WH s 5 499 A E BL RD C4B 1 BL RD C9 1 BK MH C92 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP x S a 2 2 2 49 z 2 lt I CH 2 WH BK LSI PRIMARY BOOM EXTEND 5 sus DRIVE LIMIT SWITCH 8 JI EH WH BK gt C102 LS2 PRIMARY BOOM UP DRIVE LIMIT SWITCH 99 eme eee ees C40LS OR C2B 2 _ x HH 9 t mee T d Quo i x
294. 2 2 BL BK 1 11 C37SCW BL BK C1B 11 C37SCW BL BK tet Lo STEER RIGHT E DRIVE ENABLE t RIGHT CIP 10 C36STCC BL C1B 10 C36SCC til STEERIEET 5 x CDE1 BLWH 8 24 1 C242 t n 7 SN I BL SER g RKour s lt lt 03 6 C6TRF WH RD C3B 6 9 vorpe ssa lo T gift 42 8 uoc CP CATRL WH C3B 4 C4TRL WH I TURNTABLE ROTATE LEFT 51 14 pw BE C141 142 FEM e zz 5 WH BK C3B 5 WH BK SUHNTADLE ROTATE RIGHT E E 15 1 15 2 um a IRIGHT 8 C15 C15 RE d TURNTABLE LEFT 8 azg E 2 5 8 C812 WH RD Ke TURNTABLE ROTATE AW FLOW CONTROL ae B GIPBURB 12 1 4 12 2 PRIMARY BOOM UP E PRIMARY BOOM C2PBD RD BK T PRIMARY BOOM DOWN i ed gl 5 131 C132 lt 3 ko 8 PII g IE SC 1 prs yes EE RD WH 19 vour s 2 PRIMARY BOOM FLOW CONTROL g RD C29 1 C29 2 SiE xoi 1 C1PBU RD C3B 1 1 pwr 3 ER 6 iz a amp 2 lt 55 12 2 C2PBD RD BK C3B 2 X i 4 s 6323 RD WH C3B 3 8 30 1 C302 Haze C99 C9PER BK RD C3B 9 C9PER BK RD PRIMARY BOOM EXTEND RETRACT H FLOW CONTROL C3P 8 C8PBR BK WH C3B 8 MM 4 i 7 s lt face C9P7 C7PBE BK C3B 7 99 LS5 CABLE TENSION L
295. 2 P xs y 04P2 CiPLUOR lt 9g ss PLATFORM LEVEL 8 DOWN C4P 3 C15PLD OR BK C4B 3 C204 C20 2 8 c Ue i CTHPLU OR 1 PLATFORM LEVEL UP PLATFORM LEVEL t DOWN CISPEDIOR BKC D PLATFORM LEVEL DOWN E m C21 1 C21 2 5 C4P 6 C18JD PRR GR BK C4B 6 FRIGHT Tu aTFORM ROTATE LEFT C17JU PRL C4B 5 5 23 1 23 2 m TES 5 5 C18JD PRR GR BK 5 lt lt L gt gt PLATFORM ROTATE RIGHT T ROTATE o i CTTIUPREGR I 4 PLATFORM ROTATE LEFT 224 C222 DESCENT ALARM OPTIO 8 NM a xim Bx lt o ale K 8 8 amp aie enie G S 60 S 65 S 60 6 31 Part No 77828 February 2012 Section 6 Schematics Electrical Schematic 5 60 Ford DSG 423 EFI Models after serial number 14053 Section 6 Schematics February 2012 FEE EE KZ I Z I E ria sassa3x a IW IIIeIWIIIYIXQITGF GFTFdSZOISHz Ground Control Box Terminal Strip Wiring Diagram S 60 FordLRG 425 EFI Models before serialnumber 11880 February 2012 Section 6 Schematics Ground Control Terminal Strip Wiring Diagram 5 60 Ford LRG 425 EFI Models before serial number 11880
296. 2 4 8 i 8 01 ANALOG 0 JOYSTICK 8 4 8 02 ANALOG 1 NC V 1 l 03 DIG IN 3 NC m 41 T 6 7 1 E1 NOTUSED asam MES E2 NOT USED CR46 NOT USED F1 DIGINO F2 DIG IN 1 GENERATOR ON TB31 9 4 DIGIN2 SX Controller V R nMn O n TA T ca T L gi 4 o V V V m m 5 5 8 z 3 gt a 2 2 3 8 2 lt gt gt m 1 Turning on the Generator supplies current 3 When the AC generator is turned OFF the Inside to the high idle relay through the diode SX module will ramp the output to the EDC to Harness Enclosure switching the engine to high RPM In addition threshold preventing cavitation to the hydraulic PIN COLOR CKT COLOR the diode between TB45 and TB29 supplies motor powering the generator When threshold 1 BR GND WH RD power to the motor stroke valve switching is reached the bypass valve is turned OFF 2 C30EDC WH 3 WH BK C31EDC WH BK the motors to high speed low torque mode a BR GND BK RD 5 BR GND BURD 2 The SX controller is turned ON supplying 6 WH C30EDC A RD power to bypass valve and the change over 2 ra oo relay The EDC valve is switched over to the 9 GR WH C45GEN GR WH output of the SX controller 10 GR BK VIS0HG GR BK WH C22PWR RD WH 12 BR GND GR February 2012 Sec
297. 2011 Models after serial number 11879 N LO o 21512 gt 5 5 5 q 6 m 4 25466 EG 50525 x 6 S glaS Jols E Sul jaf mie 5 zu Solr GL 6 606 z E 5 5 us 59 9 005 6 oss lt Sx 9 5 2 8 88 2 2 83 8233588 2B 2 95 2 eo az Sm zz 5 usss mc Zx gt a lee ses gt S gt EG Z r z z 6 S Sjssssz rv 859255555 5 sss EP NIN dIHLS TVNINt31 2588808895893 55 3sva 3818855555523 5 Sja a zE Eeee eee ge NOILONNA AST
298. 3 gt 8884 28 RD BK ALARM 5 2 M u P134TTSR RD RD IBK BRN Le LEVEL SENSOR C3B 12 lt lt yy G3P 12 C133PLA BLWH g a la E C2P 5 C46HRN GR id Q tt C46HRN GR wt HORN RELAY os GR BK o mu tro C7P 1 P22BAT BK C7B 1 9 5 1 5 P22BAT BK FH dioni o 8 1 4 1 12 y C132PLIBLWH 1 12 y 5 m 9 gt Ur P134FB WH 2 FLASHING BEACONS 2 6 P134PWRGRIBK C2B 6 s ee gt gt S ea e E ERR ae ee eh n n s 8 RD 5 e is 4 BK oz y C2NGNWH R21IGNWH s 05 4 HYDRAULIC OIL TEMPERATURE 2 a c SWITCH OPTION x E e PH6HYD RD 8 5 8116 5 1 2 COOLING 5 2 25 option gt x j x x m C41RPM OR BK C2B 3 C41RPM OR BK C52 a 5 t n RM rg i ji _ 4 enen w S a eL T T zl as o o H 1 8 e m 1 5 1 msc 98 4 5 54 i a alg SE m lt 23 8 a i RD 4 C7B 4 2 RD i S m e e LO enie G A TEREX DANO S 60 S 65 S 60 HC Part No 77828 6 96 Section 6 Schematics February2012 Electrical
299. 3 DRIVE C130TA WH RD TRAVEL ALARM 5 9 8 C26 1 C26 2 lt Have CIPS C32BRK WH RD 6 C5 28 _ 2 WH RD sl BRAKE RELEASE E 8 28 1 28 2 C29MS RDWH C29MS RD WH o zo cc CIPS ces mE D MOTOR STROKE 5 A E BL RD 5 E 5 3 C25 1 C25 2 z 2 CDE2 i T C1P 11 C37SCW BL BK C1B 11 C37SCW BL BK STEER RIGHT 1 LEFT 2 Inl E N DRIVE ENABLE t RIGHT Sa C36STCC BL C1B 10 C36SCC BL STEERDEET 5 x CDE1 BLWH 9 24 1 C242 a 55 o 76 l SN l BL g amp 6 C6TRF WH RD C3B 6 5 ig WH o lt YOUT 5 T 4 ES git 46 8 555 uoc 4 C4TRL WH C3B 4 C4TRL WH I TURNTABLE ROTATE LEFT i OR 25 BAN 5 C5TRR WH BK C3B 5 WH BK TURNTABLE RIGHT 12 Gno 2 2214 9 1 15 1 15 2 1 RIGHT 8 C15 C15 T run 1 TURNTABLE ROTATE t LEFT 8i lt 9 Ej E m 5 C6TRF WH RD 6317 TURNTABLE FLOW CONTROL go GiPBUBD 12 1 MS 12 2 m PRIMARY BOOM UP PRIMARY BOOM t DOWN C2PBD RD BK IA ER T PRIMARY BOOM DOWN z y so gl gs dc 2 6 lt S ze 9 vour s BK 2 ER RD WI Je PRIMA
300. 3 5 C41RPM OR BK 5 2 Uu C21IGN WH E NT rat 00 ide Ww 5 T i 5 anni a lt clat lt 2 5 qii 5 4 C lt i B sind 1 54 8 RD 4 C7B 4 N P20BAT RD L Q a m e e LO Part No 77828 gt CE AND PLATFORM OVERLOAD OPTION ONLY NOTES 5 60 5 65 5 60 G 6 70 Section 6 Schematics February 2012 Electrical Schematic S 65 Deutz F3L 201 1 Models after serial number 11879 N c LO BATGND C7B 3 GROUND z C2P 3 C41RPM OR BK C2B 3 9 se g 3 2 x a CIP4 C30FWD WH 1 4 gt 60521 C30FWDWH BK PD DRIVE FORWARD gt 15 CIPS C31R
301. 3 Shorted shorted OR fuel injector 3 is faulty OR is faulty Open wiring and or connections to fuel injector 4 Injector Driver 4 Open s irector Driver 4 Open OR fuel injector 4 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 4 Wiring and or connections to fuel injector 4 is OR replace fuel injector 4 OR replace the ECM Injector Driver 4 Shorted shorted OR fuel injector 4 is faulty OR ECM is faulty Open wiring and or connections to fuel pump OR fuel pump power shorted to ground OR fuel pump is faulty Repair wiring and or connections to fuel pump OR Fuel Pump High Side Wiring and or connections to fuel pump shorted to replace fuel pump Shorted to Power power OR fuel pump is faulty Fuel pressure too high OR LPG lockoff not opening Megavector Delivery completely OR the line between the MegaJector Pressure Higher Than and carburetor is kinked or restricted or is leaking Expected OR engine cooling system is not operating properly Check fuel pressure OR repair LPG lockoff OR OR MegaJector is faulty repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace the MegaJector Fuel Pump Loop Open or High Side Short to Ground Fuel pressure too low OR LPG lockoff not opening Megavector Delivery completely OR the line between the MegaJector Pressure Lower Than and carburetor is kinked or restricted or is leaking Expected OR engine cooling system
302. 34PWR RD LS18 BK C1P 12 P22BAT BK C7P 1 C19JSV GR WH C4P 7 C18PRR GR BK C4P 6 C17PRL GR C4P 5 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C129JDA BL C3P 10 TS8 C46HRN GR C2P 5 C59CHK BL BK C3P 11 L47 C59CNK BL BK C3P 11 P26BAT BK C9 1 P2 18 _______________ 25 5 9 3 52 P24FS WH 9 2 TS4 CDLITE OR RD C2P 4 C45GEN GR WH C2P 7 3 C46HRN GR C2P 5 P26ESTP BK 24FS WH C118LSR OR RD C4P 4 WH RD C1P 6 C6TRF WH RD C3P 6 e e J3 C8PBR BK WH C3P 8 C16DRE BL RD 1 C7PBE BK C3P 7 24FS WH C40LSS OR C2P 2 C9PER BK RD C3P 9 C41RPM C2P 3 C30FWD WH C1P 4 LPS QU C1PBU RD C3P 1 C31REV WH BK C1P 5 C2PBD RD BK C3P 2 2 C36STCC BL 10 C3PBF RDANH C3P 3 C37STC BL BK C1P 11 C5TRR WH BK 5 C32BRK WH RD C1P 6 C4TRL WH C3P 4 C29MS RDANH C1P 3 U13 J2 ALC 500 C35RPM BK RD C1P 9 C34SA BK WH 1 8 C33STR BK C1P 7 C27AUX RD C1P 1 J1 JC1 3 OR JC2 4 RD JC1 2 BRN JC2 5 BK JC2 3 OR JC1 5 YEL JC2 2 BRN JC3 5 WH JC3 3 OR JC3 4 BL JC3 2 BRN TS15 BL WH C28TTA RD BK C1P 2
303. 3STRBK C55 i EY 5 8 mz iLig 8 2012 4 4 STARTER MOTOR en i E x EMISSIOIN CONTROL C27AUX RD amp REDUCTION RELAY C27AUX RD SE CBS BRSBAT Wil C7B 2 mI AUXILIARY POWER RELAY A E gt af FORO P 4 1 5 e 41133 JH AUXILIARY PUMP E acl 2 WH 1 RD BK m C28TTA RD BK 1277777777 1 C28TTA RD BK Les ALARM 1 mm I 1 1 P134TTSR RD RD s S sensor i C3B 12 lt gy 12 C133PLA gt o m 5 C46HRN GR bd gt ows C46tIRN GR 2 HORN RELAY 0 GRK a 7 1 P22BAT C7B 1 E r P22BAT BK F H BK Yt d HORN 8 8 to t cc der De Er redes 7 C1P 12 CIGPPLIBUWH CIB I2 az yt e P134FB WH 2 6 GR BK C2B 6 gt 9 A A gt FLASHING BEACONS gt F jo 5 2 M INS I MEETUPS EP 1 8 RD i M ol tr So i BK o 5 C2IGNWH R21IGN WH s gt C54 HYDRAULIC OIL TEMPERATURE 2 z d SWITCH OPTION T 1 z P116HYDRD_ 815 x e s 2 5 R116 OR C54 Z COOLING FAN 8 gt amp OPTION E le 9 Leje 8 E aa amp d 5 x m C41RPM OR BK C2B
304. 4 way Disan Turntable rotate 7 Proportional solenoid valve Boom up down circuit 8 Solenoid valve 3 position 4 way BB Steer left right 9 Check valve 30 psi 2 bar xii Differential sensing circuit platform rotate left and jib boom up S 65 10 Check valve 30 psi 2 bar Differential sensing circuit platform rotate right and jib boom down 65 11 Check valve Differential sensing circuit boom extend retract 12 Solenoid valve 2 position 3 way Boom down 13 Solenoid valve 2 position 3 way E uu Boom tute 1 14 Check Differential sensing circuit turntable rotate 15 Check R Differential sensing circuit boom up down 16 Priority flow regulator valve 3 5 13 2 L min IA Steer left right circuit 17 Differential sensing valve 110 psi 7 6 bar Oso Boom up down circuit 18 Differential sensing valve 1
305. 5 3 11 _ C59CNK C3B 11 BL BK 5 C37 3 BK 42 caz4 gt LS5 CABLE TENSION LED eve 8 5 o P134 RD E RD C38 1 RD BR C38 amp 2 _ 7 LS17 BOOM UP DOWN 5 ta a SPEED REDUCTION LIMIT SWITCH 8 2 14 OR C4B 2 rue 2 2 pown _ LEVEL 4 3 CI5PLD 3 7 t 15 gt Ks 20 1 C20 2 o 8 Lu CIAPEUIOR Il PLATFORM LEVEL UP Fr C PLATFORM LEVEL JEDOWN PLATFORM LEVEL DOWN 5 6214 C21 2 2 o a 10 C129JDA BL 10 gt 8 C4P 6 C18JD PRR GR BK C4B 6 DOWN jig UP BOOM C17JU PRL GR C4B 5 6231 C23 2 8 gt gt RIGHT F RIGHT PLATFORM ROTATE CUP GH 1 PLATFORM LEFT C22 1 2 2 RIGHT PLATFORM fo LEFT ROTATE it L C120 RD BK DESCENT ALARM OPTION _ ic 2 i 4 7 C19JSV GR WH C4B 7 _ _ _______________________________________________________________ tt m 3 5 x JIB VALVE 88 JIB VALVE 29 c EE u z a E gt ROCKER STEER OPTION ONLY 6 69 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 6 Schematics rc Elec
306. 5 1 uz lt 2 AE uz 515 95 1 z Ixo lt F POP lego assa EIS Nm 3888555555294 SS azke eee eee eee zoo 91915 TWNINYAL OL SS3NHVH TOHINOO 318vN3 ASr619 S10UINOO WHO41V1d Haxvaua SSL Sth G Op qri HO 4 undo au C 1 1 WuO41V1d 199 7951 6951 YSL 3NI9N3 Haxvaua ala x lt asrga G8L5g uo 31V1OH E 2981 SNOLLdO 55 i 181 3NION3 zd 2951 ido H g 9 QU HM G9 QH HM lt THM Gi HM lovulau 109135 5951 5981 QAO 2 E G6 Qu a woog OQ Noe ogo 65 AYYNIHd 5 1951 o aa y c x a Gg jj j TET pueris 21 50 NOudO 30 1 Nyg noon ANIONS 03H9 m q6S y8g 18 Nua i GLZ HM GIZ HM 8 i
307. 5 30 85 a eee V183RCV BL sii zi 5 555 GS 86 9 85 87 RD 1 1 R134BAT RD y 8 5 8 a 57 I ui sa 86 i I R174BAT RD H6 585 7 pi GR BK s 145 R18 R17 R22BAT BK 5 5 PLATFORM W H 50 55 22 4 OVERLOAD CR54 CR55 1 2 3 LOAD SENSE LOAD SENSE 4 5 5 CUTOUT PLATFORM CUTOUT GROUND TB134 ___ C133PLA GR BK r ez St C2PBD RD BK BOOM ANGLE SENSOR 8 5 4 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION S VEE eae en ee SWING E 8 m LOWER LINK Genie ATEREX BRAND 6 7 5 60 5 65 S 60 Part No 77828 Section 6 Schematics February 2012 Chassis Wiring Diagram 5 60 from serial number 12800 STRING POTENTIOMETER BOOM ANGLE SENSOR FUNCTION MANIFOLD CONNECTS TO PC C40 e 6 I S ou E gs 3
308. 50 psi 10 3 bar phus Turntable rotate circuit This list continues Please turn the page Torque 30 35 ft Ibs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 20 25 ft lbs 27 34 Nm 30 35 ft lbs 41 47 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs 27 34 Nm 10 12 ft lbs 14 16 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 10 12 ft lbs 14 16 Nm 10 12 ft lbs 14 16 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm TEREX COMPANY Part No 77828 5 60 5 65 5 60 HC February 2012 Section 4 Repair Procedures MANIFOLDS D 000000 G M C B H 7 re lt S 60 S 65 S 60 HC Part No 77828 50 February 2012 Function Manifold Components continued Index Schematic No Description Item 19 Check valve 5 psi 0 3 bar 20 Relief valve 3000 psi 206 8 bar IK uon 21 Flow control valve 0 1 0 38 L MIN DD 22 Differential sensing valve 150 psi 10 3 bar C Gus 23 Check valve Wiss 24 Check valve
309. 53 D 6 Replace the Hydraulic 3 54 D 7 Check and Adjust the Air LPG Mixture GM Models 3 56 D 8 Perform Engine Maintenance Deutz 3 57 Checklist E Procedures E 1 Testor Replace the Hydraulic Oil 3 58 E 2 Perform Engine Maintenance Deutz 3 60 E 3 Perform Engine Maintenance Deutz Models 3 60 E 4 Remove and Inspect the Boom Extend Retract Cables 3 61 Genie Part No 77828 S 60 5 65 S 60 HC xi February 2012 I S n1 TABLE OF CONTENTS Section 4 Repair Procedures lero 4 1 Platform Controls 1 1 ALC 500 Circuit Board sse nennen nennen 4 2 1 22 Joysticks tice e 4 3 Platform Components 21 Platform Leveling Slave 4 8 2 2 Platform Rotator 4 9 2 8 Platform Overload System 5 60 and S 65 if equipped 4 12 2 4 Platform Load Sense System S 60 sse 4 14 Jib Boom Components 5 65 2 1 BOOM sn un huie 4 18 3 2 Jib Boom Lift Cylinder nnne 4 19 Boom Components 4 4 OCable Tracks acea tette m edes 4 20 D Mie ME mE 4 26 4 3 Boom Lift Cylinder
310. 55 CABLE TENSION LIMIT SWITCH 5 YEL 8 3 RD N C7PBE BK bil B DWEXTEND 5 4 1 EXTEND Sis lt 5 BOOM 37 1 C372 C164 162 pwp s RETRACT i g amp an pemn o P E Il BOOM RETRACT LI x lt 5 E C17 2 E Do 8 BRN 9 499 gt re oa CH8LSROR D C4B4 _ OR RD C38 3 WH C38 4 LS17 BOOM UP DOWN PHESWH gt SPEED REDUCTION SWITCH 551820 E BL RD C4B 1 BL RD C9 1 BK WH C9 2 LS3 DRIVE ENABLE LIMIT SWITCH 13 lt lt lt gt 26 5 9 u 9 oo CPP 999 B ge lt Cit2 WH BK LSIPRIMARY BOOM EXTEND 5 stus DRIVE LIMIT SWITCH 58 J1 EH WH 0101 BK WH C102 LS2 PRIMARY BOOM UP LIMIT SWITCH 1 C40LS OR C2B 2 SE OR x 9 lape TEC NO so Fee x 15 115 8555 pec 4 2215 4 1 C59CNK BL BK C3B 11 BL BK o lt 5 BK 37 3 BK G 2 WH C37 4 3 e 4 LS5 CABLE TENSION LED 8 5 o P134 RD E RD C38 1 gt RD A BR 38 2 E LS17 BOOM UP DOWN 5 8 SPEED REDUCTION LIMIT SWITCH 2 8 2 _ C4B 2 GO DZ pown ATFORM LEVEL 3 C15PLD OR BK C4B 3 t 15 gt lt 20 1 C202 8
311. 551 8 810 5 ee 3NION3 1415 ee 21 810 515555 ENSIS zE ava amp 09 TANVd HOLIMS OL 62 52 QH HM HEED P otis 9 81 XH82EO i 3SH3A3H T3dOHd le O O e 02 50 A3HIEO TEE IWA3NIEO of GHVMHOd oc 5 9 12 59 AM20 9 810 HM 3080 mosson g O O 9 30 SW6ZO Nua EALO HWQH 5620 O O 179024 vLISZO Jp 2 810 vLISZO 1g dWndAdvuxnv zz Qd Xnvzzo ISS1 QH t 8L9 98 61 40 HOLIMS 1 52 Gd PISO QU HM 54920 8 8 HOLIMS 52 91 50 51820 OLASIIS HM h 8 8 2 ve 1InOHIO ve Co Je H3MOd ez C4 DHM Z 8L9 HM ZWSI HM P zz 01 Z O 34 ss 220 2 60 1Vgzzd HOLIMS 1 10 x8 NOISNAL Ol MWH ze Gt mavo M v 860 38 2157224 sg gt 5 z 4 12 5 59 ZN ILZO WH HM ZHO HM QN9 NH8 02 21 02 8G 1 8 80 1 02 10313687 61 eo HO LIMS sf s 2 Op SSI HWH9 OUR 4 82 HWH9 5 6 ne
312. 57 8585 i i 2215 11 C59CNK BL BK C3B 11 BL BK BK 037 3 4 Z cor4 in 3 1 LS5 CABLE TENSION LED sU g 5 o P134 RD F RD C881 RD BR C382 7 LS17 BOOM UP DOWN a SS SPEED REDUCTION LIMIT SWITCH 2 C4P 2 CI4PLU OR C4B 2 m gt lt E 29 ELTE e PLATFORM LEVEL 8 t DOWN 3 C15PLD 3 5 C20 1 C202 o c Ta i CI4PEU OR 1 1 PLATFORM LEVEL UP PLATFORM LEVEL t DOWN D 1 PLATFORM LEVEL DOWN E i T 21 1 C21 2 8 10 C129JDA BL C3B 10 8 R C4P 6 C18JD PRR GR BK C4B 6 DOWN UP BOOM C17JU PRL GR C4B 5 Caps C284 C23 2 8 8 C18JD PRR GR BK T 8 E i lt PLATFORM ROTATE RIGHT H RIGHT PLATFORM gt PEERI CIES GR D PLATFORM ROTATE LEFT C224 C222 RIGHT PLATFORM s it LEFT ROTATE d aM 51 it I mE C DESCENT ALARM OPTION 1 une l o 1 18 7 C19JSV GR WH C4B 7 ES CRTC 1 2 2 3 n o 5 JIB VALVE JIB VALVE x go n n alg Elelu 2 5 m enie G A TEPEX WG 5 60 5 65 5 60 HC 6 71 Part No 77828 February 2012 Section 6 Schematics JEE EE EEEEEE E E ZIZI Electrical Schematic S 65 Deutz F3L 2011 Models after ser
313. 6 8 58469 8 1 1 10 HWE 99480 295 8 860 HWE 1 WOO8 Qd 1 60 85 38429 2 951 98 12860 84 0 9 NOWONNS 9 O 1 1 0 38190 9860 QUHM 38120 6 SION S O 1910 8 HH1SO 2951 5 1 lgm3ivioHsBvINunL Qd 1 819 HM Td1rO Je Z9SI HM 1860 TOHINOO O GH 30830 1 620 HG 38469 E 860 48460 g 2 NMOGWOOS lt LELO 4 19S1 48 dU Wuvivoig du gi 1 O 1 20 nadio 1981 17960 nadio 8 asva TWNINYAL Drd Oso te tat Ye 19S1 HWdH 2 80 LISTHO 31000 10 8 lt J ae AWTS NUS Aay Nm 109135 NHOH PORES E rir EE CLE WOOS 93345 ONIMS 8 veuo 3 6149 8 a 83 z 5 E I M z 5 2 m ee P 252 E e g g el 2 i 3 ir 5 2 lt 5 Nua 9 8 z NOLLdO wee Nua 299
314. 60 4190 170 21 9 860 QU HM 39199 5 6 S 5 r4 N8 HM HH 190 2951 sc TE 8 1991 311 C 25 2 Qd 2 FSIOHM THII O 2951 uu 1 860 HM HLO WOOS O GH 398 59 1 620 38960 Nua 860 38469 HOMS g 2 WOOB 2 bebo Je Qs 1951 2 860 8420 T soe A gt Wav e a 9 O G 1 860 nadio 59 81 asva WNINYAL 9 ng mey NOTI RA ac NES E 0r 8 LIS THO Nolo 431000 10 Jes Tes 8 APR EESE AES od rH HMNOIIZO AVIS NUS anay p d 09395 103146 NYOH 0099 4 WOO8 9339 ONIMS l Suo veuo T B 5 5 sz 5e E Du TE ii 200 m 52 pog 12 I I 1 o 5 aal gt 5 z x ee 3 g 8 gigi i 3 za 25 2i 2 535 2 gg E 5 2 Nua i 9 8 i i n 8 J NOILdO
315. 60 5 65 5 60 HC Part No 77828 February 2012 Section 6 Schematics Limit Switch Location Legend Boom Extend Boom Speed Limit Switch Reduction LS2 Limit Switch LS17 Cable Tension Limit Switch LS5 Drive Enable Boom Angle Limit Switch Limit Switch LS3 LS1 Genie Part No 77828 S 60 5 65 5 60 HC Section 6 Schematics February 2012 ___ Genie 6 6 S 60 S 65 S 60 Part No 77828 Section 6 Schematics February 2012 Electrical Schematic S 60 HC from serial number 12800 Section 6 Schematics February 2012 Electrical Schematic 5 60 HC from serial number 12800
316. 6LO 78437 06 L HMH9 YSL STOHLNOO 7351 WHO41V1d 31V1OH 6951 WHOd1V1d x3 m 2951 Lj 10 zgo ANISNA 5 Q4L H9 QZL H9 c 185 m G8158 u5 1 8 e e Er I wood air 202 1 1 16 esst YSL SNOLLdO ANONA 5 O avang ond 31V1OH a LINDHID angviNunL T g eq Pw 2951 5 lt 74 E PEE 9551 eza qrr 18 902 280 e S HS HA GS HTg HA THM 1 20 8 azja lovulau o QN31X3 woog NMOG dn ES 5981 woog 1981 e 8 5 H lt Q a o mn Mna te e RT en 9 8 HnOH 77 i lt i A 30 Br 1 e s i WHOSLWId 3NION3 Sp lt 9 260 GLZ HM e g 9 z azas
317. 70 562 752 583 791 778 1055 682 925 909 1233 Genie Part No 77828 S 60 5 65 5 60 HC 2 13 _ N A A 1 N 1 r c i 4 N gt On CO ol BA NJ Oo al age 2 o oj 1 o O Go C2 NI N co exl Has a O1 o oA i zi a 00 8 g lt 0 8 lt 0 8 1 oo T col m Oj ala NI OW oN n LS w Oo A Af NN EN aM ai G olL AAL aol Of ml eun 9 N OER a col oO Of cl aja 15 Po O Q A gt Q N Ss D o gt os a A 4 N N N A a N do IN un AR N O 5 OJN O Po 285 Section 2 Specifica
318. 8 CWLITE WH TS49 Part No 77828 5 60 5 65 5 60 HC 6 94 February 2012 Section 6 Schematics ime M Platform Control Box Switch Panel Wiring Diagram S 60 Perkins 404 22 Models B A D C PLATFORM CONTROL HARNESS TO CONTROL BOX COMPONENT INDEX JC2 BOOM PROPORTIONAL JOYSTICK TS48 BOOM UP DOWN TURNTABLE ROTATE DRIVE LIGHTS JC1 BOOM PROPORTIONAL JOYSTICK OPTION _DUTERD 5 525 BOOM EXTEND RETRACT JC2 JC3 JC3 DRIVE STEER PROPORTIONAL JOYSTICK JC1 DRIVE L1 DRIVE ENABLE LED BOOM UP DOWN 7 7 FORWARD REVERSE 7 L4 PLATFORM OVERLOAD LED amp TUE ome mE amp 147 LOWER RETRACT BOOM LED 6 EXTEND RETRACT 6 OQ O NO T LEFT RIGHT 6 L48 BOOM TILTED LED 1 ENABLE IU P sssi E ANSI CSA P EMERCENOY STOP BUTTON 5 751 AUXILIARY TOGGLE SWITCH x x is T
319. 8 8480 17260 95788 38325 ch 205 eos a 9 1 860 38920 an a P 9 TOWINOD STAVINENL 9 O C 3sss agi 2 9 8 0 GH HM 38199 A 5 5 8 5 2 LO 88150 V2 TANEN 3 3 959 X8 HM 88150 1431 317109 STEVINEAL romm P 951 T860 1 E Jp 1081409 WOO8 Y 5 HOLIMS Nua HIWQH 38460 8 O NMOGWOOS GS a 1951 2 aadeo Wuvivoigiau di 1 210 au nadro 1951709 q 81 9 4 E E NOILdO 4371009 NOLLdO o Lu E Ji SHO 5 NHOH Tr C EE i 5 2 8 Hor f ii a Mc Ec 2 lt Hd a 50 o 9 o 9 amp m 8 Sas 9 8 o9 amp 2 i i cz Q W zuo Nua Bi tH9 H3MOd AVTSH 181 gt NOILIN I
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321. 8 88 82 22188 SS3NHVH 3SV8 5156961665165 6120 ON TE AST6LO E q6L HWH9 YSL STOHLNOO 951 wa PH 6951 g amoy Cf WHO4LW1d lt OoOo 1951 U J qmequ J qsi yg do zao YSL 3NION3 180 e G815ig H5 G812ig H5 E 19 15 SNOLLdO pong SHO avana 0 x SOM STaVLNYNL zodi 9561 pane ais 280 au au 9 S Jg HM QS 48 HM 2 20 4 2 x Q8 lovuldu o 8 21 noos amp 5951 woog 1951 PO _ 5 qu u HWGQH o lt y T o s a a o 2 wall Q EOE E E E ET ul 9H ig uo I 5 NOlldO39 WOOS AD Z 1 1 E WHOdlVld __ 3NION3 E st yug 9 260 GIZHM E k i caver Ge
322. 8 Nm pump pump shaft pump coupler flex plate with raised spline engine flywheel 3 16 inch 4 8 mm gap Diesel Models 1 16 inch 1 5 mm gap Ford LRG 425 0 080 inch 2 mm gap Ford DSG 423 4 5 32 inch 3 8 mm gap GM Models 4 Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw 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 Ibs 19 Nm Then torque the flex plate mounting bolts in sequence to 20 ft Ibs 27 Nm Apply a high viscosity coupling grease Genie part number 128025 to the splines of the pump shaft and flex plate to 61 ft Ibs 83 Nm Grease Specification 5 Proceed to Repair Procedure How to Install the Shell Alvania Grease CG NLGI 0 1 or equivalent Pump and Bell Housing Assembly TEREX COMPANY 4 40 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures 1 Perkins models A TEREX COMPANY ENGINES How to Install the Pump and Bell Housing Assembly Install the pump and bell housing assembly Ford LRG 425 and Deutz models Torque the bell housing mounting bolts labeled C in sequence to 28 ft lbs 38 Nm Then torque the bell housing mounting bolts labeled C in sequence to 40 ft lbs 54 Nm Ford DSG 423 models Torque the bell housing mounting bol
323. 8 S RD BR C38 2 7 LS17 BOOM UP DOWN A Sy a SPEED REDUCTION LIMIT SWITCH 2 8 2 _ C4B 2 UP 21 DOWNS 3 _ C15PLD OR BK C4B 3 1 AP 15 eSP 20 1 C202 m 8 B op DM PLATFORM LEVEL UP PLATFORM LEVEL Gerhana PLATFORM LEVEL DOWN 5 Git C21 2 5 x C4P 6 C18JD PRR GR BK C4B 6 FRIGHT PLATFORM ROTATE LEFT C17JU PRL GR C4B 5 z 231 23 2 a D PLATFORM ROTATE RIGHT PLATFORM tLEFT i 4 PLATFORM ROTATE LEFT C224 C22 2 MM E MM C129 HD BK DESCENT ALARM OPTION 2 558 z n 0 x E 4 enie G S 60 S 65 S 60 6 87 Part No 77828 February 2012 Section 6 Schematics E Electrical 5 60 Perkins 404 22 Models before serial number 11880 Section 6 Schematics February2012 Electrical Schematic S 60 Perkins 404 22 Models after serial number 11879 C22LS February 2012
324. 810 Xnvzzo visa 92 HOLIMS 92 71 60 GH HM 54920 52 92 SrsoxgHwusiszo O SINSDISIHI 9 5 9 ba e a ve Oo H3MOd HOLIMS Q4 SHM 7 920 HM Lva ed ZWSFHM ec e et ec ASA DU 260 vazza 7 260 1Vazzd HOLIMS U OL OG 21 22 NOISN3L 2010 2151220 a syza agvo N E 5 iz H3MOd 1 80 HM 2 22 iu WH HM HM e QNO NH8 et 0c 1 SHMOdOGN 807 151 8 3ATVA 123136 WOO oa 7 8 5 612 qN31X3 P 8 8L 89 8 WHOSLW 1d m 320 HO m dn 8Ir 133131V1Ot WHO Q4 lt 8 2 9 xl Si SL 1 120 X8 HO tO sssryauo 29810 X8 HO 014910 rh WHOSLV 1d vb PTT 6581 80 2 90 aro 2 navman 8 v INSOSSGNMOGWOOsaIr H O Q4 vO RED 01 859 18 WHVIVar 6 WOO 6 PT
325. 9 a C7P 1 22 C7B 1 9 P22BAT BK og FH BK 8 m 99 a e e a 1 12 C132PLI 1 12 E 4 53 gt 5 P134FB WH v FLASHING BEACONS 2 6 PI34PWR GR BK 2 6 5 Ae x OPTION 1 x i Te gt 1 1 i 34 RD m So 4 BK 52 y C C2NGNWH R21IGN WH 05 4 HYDRAULIC OIL TEMPERATURE 8 SWITCH OPTION 4 Eo PH6HYDRD 8145 E 56 5 RT16 OR C54 COOLING FAN g 3 A OPTION ec 8 5 m C41RPM OR BK C2B 3 C41RPM OR BK 65 2 j C21IGN WH ae E di 8 uma 08 8512921 5 nmm o I t EF tet ff SE 531 8 Bra 21 5 c q 4 i 5 ws 4 5 5 5 B RD C7B 4 2 RD 4 12V DC B2 Part No 77828 gt CE AND PLATFORM OVERLOAD OPTION ONLY NOTES A TEREA 5 60 5 65 5 60 G 6 50 Section 6 Schematics Electrical Schematic S 60 Deutz F3L 2011 Models before serialnumber 11880 February2012
326. 9 4 _ Nua q 9r u9 2 H31002 110 Noudo _ 8 219 c NOILZO 95 820 Naa 1 NE Av13H ala NHOH 1 80 HO T Suo if EE 8 dial 5 S9 wore mici amp 1 ni d CODE EE I 59 2 555 x Nua LYVLS N DASHED LINES INDICATE OPTION WIRES NOTE TANWd HOLIMS OL SSANYVH A TEREX DWG S 60 5 65 5 60 HC Part No 77828 6 22 Section 6 Schematics February 2012 GM 3 0L Models Ground Control Box Switch Panel Wiring Diagram S 65 A N LO 5 zz lt 85 515
327. 97 2 Turn the engine off 3 sure that each turntable mounting bolt is torqued in sequence to specifications Refer to Section 2 Specifications 20 2 Bolt torque sequence oO Genie 5 60 5 65 S 60 HC Start the engine form the ground controls Raise the boom and remove the safety chock Lower the boom to the stowed position Remove drive chassis covers from both the steer end and the non steer end of the machine Check to ensure that each lower bearing mounting bolt under the drive chassis is torqued in sequence to specifications Refer to Section 2 Specifications 10 15 6 7 12 13 17 3 4 1 14 6 __ 5 8 9 16 2 Bolt torque sequence Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures D 3 Inspect for Turntable Bearing Wear Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the machine on a firm level surface and the boom in the stowed position 1 Grease the turntable bearing See A 12 Grease the
328. AN m m amp OPTION 0 EE 5 C41RPM OR BK C2B 3 p C41RPM OR BK C52 El P WM 1 cB vmm mimi m mimi u C21IGN WH B lg 2 aes 8 ae e lt m 5 ts by t q lt 1 i Re g seio PIER B o 59 8 a 8 RD 4 C7B 4 2 RD l i S a Part No 77828 5 60 5 65 S 60 HC G 6 52 Section 6 Schematics February2012 Electrical Schematic S 60 Deutz F3L 2011 Models after serial number 11879 A N c LO C7P 3 BATGND C7B 3 GROUND z hze C41 RPM C2B 3 5 8 x m a 01 4 C30FWD WH C1B 4 6521 C3OFWD WH BK 82 4 DRIVE FORWARD gt 15 H Haze 0
329. AWH 1l 1 BOOM RETRACT m L 11 x i lt 5 n 17 2 d n 9 BRN 9 49 1 amp gea E prze CH8LSROR RD C4B4 OR RD 38 3 v WH C384 1317 UP DOWN P24FS WH ove SPEED REDUCTION LIMIT SWITCH E x P24FS WH x 2 a tn z 71 UR c C94 BK 7 1 13DE BL RD 48 1 BURD E WH 92 ou LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK 5 lt 5 t 3 x 20 N C2P 2 d 9 a 4 LS1 PRIMARY BOOM EXTEND 11 2 cna 514 O0 5 stus DRIVE LIMIT SWITCH o E J1 EH WH BK WH C102 LS2 PRIMARY BOOM UP lt DRIVE LIMIT SWITCH oo ppsespesscenaeeicoeccnesecscecssee 2pe zi C40LS OR C2B 2 I SE OR x Ei i t gt 4 2215 4 1 C59CNK C3B 11 BL BK o 6 5 BK 37 3 BK 4 2 WH C37 4 3 OH 4 LS5 CABLE TENSION LED eve g 5 5 m P134 RD RD C38 1 E RD BR C38 2 1517 UP DOWN a NN SPEED REDUCTION SWITCH 2 2 C14PLU OR 2 8 o 99 __ LEVEL _ C15PLD OR BK C4B 3 7 3 cis f T gt lt C20 1 20 2 o Lus i CI4PLU OR Il 1 PLATFORM LEVEL UP Hel PLATFORM LEVEL TEDOWN CISEED 1 PLATFORM LEVEL DOWN E 5 C21 2 B a 5 6 C18JD PRR GR BK C4B 6 RIGHT P
330. BIS til PLATFORM LEVEL DOWN E m C21 1 C21 2 a 5 C4P 6 C18JD PRR GR BK C4B 6 F PLATFORM ROTATE t LEFT C17JU PRL GR C4B 5 23 1 C232 5 C18JD PRR GR BK 4 5 i PLATFORM ROTATE RIGHT 8 PLATFORM M34 ROTATE CTP GR D PLATFORM ROTATE LEFT C224 C22 2 Creo RDB B DESCENT ALARM OPTION z RC a EP 1 lt m gat gt 5 ira cc 6 89 5 60 5 65 S 60 HC G Part No 77828 February 2012 Section 6 Schematics Electrical Schematic S 60 Perkins 404 22 Models after serial number 11879 Section 6 Schematics February2012 w rs sO lt IIEsOmOI v Ground Control Box Terminal Strip Wiring Diagram S 60 Perkins 404 22 Models before serial number 11880 February 2012 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 60 Perkins 404 22 Models before serialnumber 11880 FUNCTIONS HARNESS ENGINE C5 H3MOd 957 HOLMS NOISN3L anayo 1571 HOLIMS woog f Ns 29819 eit 61 81 vO BED 1 6L 8L 19 WHOSLV1d OL H3MOd Od H6 ONLY
331. BRN E pre CWLITE WH TS49 A TEREX DWG S 60 S 65 S 60 HC PartNo 77828 6 18 JC2 BOOM UP DOWN amp TURNTABLE ROTATE LEFT RIGHT February 2012 E D PLATFORM CONTROL HARNESS TO CONTROL BOX TS48 DRIVE LIGHTS ORTON DLITE RD RD EU ALIE a EA TIEN NI eu lI ESTEE M 1 JC3 JC1 DRIVE 7 7 PC CE FORWARD REVERSE 7 BOOM 7615 i amp STEER bag EXTEND RETRACT ids LEFT RIGHT bg DRIVE 6 6 ENABLE TILT ALARM LED i i 1 l 1 5 5 g 2 1 I I 4 E 4 3 5 3 4 L PLATFORM 1 OVERLOAD 2 1 2 CEOPTION Pd DRIVE bo a E ENABLE 1 P l 1 z E 1 E E 147 H L bg d RETRACT B E BOOM i bd BRN 1 8 i 1 1 19 ct BRN _ F18 E 1 E pd FUSE 10A D Fd I i i WORKLIGHT ONLY E g bod E lg I i lo l i g gg zo 1 N B m g E z 58 n 15 t 2 x I 19 9 1D m T EY 1215 g
332. Be sure that the battery separator wire connections are tight if equipped Fully charge the battery s and allow the battery s to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 8 Perform an equalizing charge OR fully charge the battery s and allow the battery s to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Genie S 60 5 65 5 60 HC 3 17 Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 O
333. C1B 5 C5 20 C31REV WH BK AD DRIVE REVERSE pi 8 4 DRIVE C130TA WH RD TRAVELALARM 1 OPTION IPE ea ane es e m 8 C26 1 C26 2 382 aeg C32BRK WH RD C1B 6 i 5 23 CS2BHK WH RD BRAKE RELEASE gt Ea z a 8 C28 1 C282 z T C29MS RD WH C29MS RD WH o zo qc 1 3 C1B 3 5 24 D MOTOR STROKE 5 5 8 5 Ob 9 BURD gt 16 X _ Eu 5 5 C251 C252 2 CDE2 C1P 11 C37SCW BL BK C1B 11 E C37SCW BL BK Brem 22227 I STEER RIGHT Em t DRIVE ENABLE t RIGHT 5 10 C36STCC BL C1B 10 C36SCC BL D 5 0 x CDE1 BLWH 8 24 1 C242 9 i a S A ase 1 BL g amp 03 6 C6TRF WH RD C3B 6 9 g Your s WH a git 42 8 555 CP CATRL WH C3B 4 WH D TURNTABLE ROTATE LEFT OR 19 PWR S 13 14 1 14 2 if BRN 52403 5 C5TRR WH BK 5 WH BK 0 TURNTABLE ROTATE RIGHT 15 15 1 15 2 1 I RIGHT 8 15 C15 D 1 TURNTABLE ROTATE LEFT PE zs Fi t 8 FI C6TRF WH RD io TURNTABLE ROTATE FLOW CONTROL 12 1 2 2 GIPBURD Ibi PRIMARY BOOM UP 1 C2PBD RD BK 4 unte 1 1 PRIMARY BOOM DOWN i C13 1 C13 2 7 lt 8 8 ig ES ES RD WH 18 vour s
334. C293 C292 Sik Us ae 1 C1PBU RD C3B 1 3 11 BRN B ig ano 2 12 z lt lt 3 2 C2PBD RD BK C3B 2 lt C3P 3 C3PBF RD WH C3B 3 7 8 gt o 1 2 32 9 C9PER BK RD C3B 9 C9PER BK RD oe 2 5 PRIMARY BOOM EXTEND RETRACT FLOW CONTROL 32 8 s C8PBR C3B 8 il lt C3P 7 C7PBE BK C3B 7 iu ae 122 z ag LS5 CABLE TENSION LIMIT SWITCH 1 our sc E 3 E RD RD a BR C7PBE BK BOGWEXTEND Sig 5 o 37 1 37 2 Ci6 1 C16 2 9 t RETRACT a BRN 2 10 Q pa g CaP BAEK HT lt BOOM RETRACT _ s x lt 8 i 17 1 Ci72 E n E E BRN Q 899 8 2 E r lt CH8LSROR RD C4B 4 OR RD C38 8 BK WH C384 LS17 BOOM UP DOWN P24FS WH 5 stus SPEED REDUCTION LIMIT SWITCH 5 2 2 5 429 Ez OP C13DE BL RD BL RD BK WH C92 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK Y gt 3 gt 2 z 9 oo EX Rs 999 2 C11 2 BK cn LS1 PRIMARY BOOM EXTEND 5 stus DRIVE LIMIT SWITCH eis 5 3 J1 F H WH 010 1 WH C10 2 LS2 PRIMARY BOOM UP oz DRIVE LIMIT SWITCH oo C40LS OR C2B 2 x E 1 LlB O p 1 9 9 221
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336. C524 29 5 4 MOTONSTROKE 2 5 5 2 w CDE3BLRD s 5 E gt 8 251 025 2 E BL BK 1 11 C37SCW BL BK 1 11 C37SCW BL BK nn Prem 72 7 STEER RIGHT Er i nieur ENABLE C36STCC BL C36SCC BL 2 t X 1 10 3 C1B 10 gt 216 x GDETBE WH C241 C242 g 6 5 PER E E a Z IP 76 1 I BL EI 1 6 lt 6 WH RD C3B 6 vorpe W 15577 n lt if 1 42 85 1955 CP C4TRL WH C3B 4 C4TRL WH 1 LEFT ig PRE 5 C5TRR WH BK C3B 5 C5TRR WH BK E m XD 52 lt Ls E lt id 4 TURNTABLE ROTATE RIGHT A IR 8 TURNTABLE gy quw C6TRF WH RD n TURNTABLE ROTATE us ES gt FLOW CONTROL a C12 1 pes 1PBU RD 1 CIPBU PRIMARY BOOM PRIMARY BOOM C2PBD RD BK PRIMARY BOOM DOWN I E C134 C13 2 E 8 lt Bi 5 2 FEE Bs p x B cr 15 vourg 2 CSF BF RD WH lt gt PRIMARY BOOM FLOW CONTROL RD C294 C292 SE UNS TR Ue C3P 1 C1PBU RD C3B 1 14 pwr 3 KI y 18 16 2 12 2 C2PBD RD BK C3B 2 15 7 lt E lt gar e 5 lt lt 6323 RDWH C3B 3 1 2 9 C9PER BK RD C3B 9 C9PER BK RD PRIMARY BOOM EXTEND RETRACT
337. CONTROL 8 BK WH C3B 8 i lt i ii us C3P 7 C7PBE BK C3B 7 s lt E r 49 135 CABLE TENSION LIMIT SWITCH m YEL 3 RD mp amp BOOWEXTEND 5 4 1 EXTEND Sig Ex 5 EE BOOM aa C372 12 pwr s 9 t RETRACT 1 8 BK WH HETRACT x lt lt t1 Ci74 Ci72 ri eases 2j o t E BRN gt gt 9 49 8 CH8LSROR RD C4B 4 OR RD C38 3 BK WH C38 4 LS17 BOOM UP DOWN P24FS WH 6 s SPEED REDUCTION LIMIT SWITCH 9 T x B 2 P24FS WH 92 24 E fage BL RD C4B 1 i BURD C9 1 s BK WH C92 4 LS3 DRIVE ENABLE LIMIT SWITCH P2GESTPBK 9 2 5 S 2 C2P 2 8 99 EX S ge C11 2 WH Cita LS1 PRIMARY BOOM EXTEND 5 SVE DRIVE LIMIT SWITCH n J1 EH WH C104 BK WH C10 2 LS2 PRIMARY BOOM UP DRIVE LIMIT SWITCH 9 4 C40LS OR C2B 2 i F H OR x m Leno so HB pee 15 S P22LS BK 1 C59CNK BL BK 11 BUBK 37 3 BK 42 WH C37 4 x X 135 TENSION LED ove g w o P134 RD RD RD C382 _ 5 1 17 UP DOWN ON H SPEED REDUCTION LIMIT SWITCH 2 8 2 _ OR C4B 2 Noo Sup PLATFORM LEVEL 1 DOWN
338. DG EK 18 36 ROADSPEED 3 sma gt 18 LGBK 18 35 ROADSPEED TAB 18 TAB 18 GOV1 24 GOV SELECT 1 C128 RPM DGW TS OL PRESS 5 GY 18 BENI CRE 16 ECT TE BK 18 LB BK 18 AUX ANA PU1 39 WA 18 18 HP LPTEMP AUX ANA PU2 18 IVS AUX WILB 18 RILG 18 RILG 18 BAG 18 18 BRAKE AUX DIG 3 BKY 18 BY 18 PEEM GOV2 AUX DIG 4 LES vsw DEWIS AUX ANA PUD2 re AUXANAPUDI au ames Y DB 18 FUELSELECT AUX DIG1 Aux v 2 winds BRN 18 23 GOV SELECT 2 C35 RPM ESB meet 22 x FL DGP 18 pen reas ran DG018 Se Se d Dao 18 _________ lt _ _ C l C C jJ PC RX DB W 18 DB W 18 e L KNOCK 2 12 FPP2 em i Ku sawam 18 31 VREF EGOH1 INJ HS NS r BKILG BOSCH THROTTLE BALB 16 ALTERNATOR 18 18 18 18 19518 18 0618 tec i GROUND 2 BRW18 18 BED INISLS 71 GY R 18 18 AD FAM Pt 18 ARTER RN TE PK LG 18 BKR T6 m ass 18018 FUELPUMP ATIS rT ur id Bi BKW 16 GROUND 42 GYJO18 Dew 6 21 AUX PWMS RBK 18 RW 18 16 AUX PWM 4 AUX P
339. DURES Turntable rotate drive hub 1 Remove the plug located on the side of the hub and check the oil level Result The oil level should be even with the bottom of the plug hole a drain fillplug b mounting fasteners 2 If necessary add oil until the oil level is even with the bottom of the plug hole 3 Apply pipe thread sealant to the plug and install the plug in the drive hub 4 Checkthe torque of the turntable drive hub mounting fasteners Refer to Section 2 Specifications Genie Part No 77828 S 60 S 65 S 60 3 23 Section Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 9 Check and Adjust the Engine RPM Ford and Deutz Models Note Genie specifications require that this procedure 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 Ford models Note The engine rpm is controlled by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is required please contact Genie Service Department OR your local Ford dealer Deutz models Note This procedure will require two people 1 Removethe engine tray retaining fastener located under the engine tray Swing th
340. E 50 Je 1 80 0 7 55 mE a yo 62 5 62 O 8LO HIWQH SIN6ZO 82 82 11820 WuVTVv H 2 80 xg au 11822 42 dWndAHvixnv Z Q4 22 a 551 LZ 98 6EHI o f Gann O O 4 OQ O 9 P ve O C4 rud 984 2HO QH gz HOLIMS AJJ Z Q4 Je a SAHM 2 80 HM OE466HO HM 22 2 22 2 60 X8 Jp 661 220 HOLINS 1 8224 22 1 2 21 22 CH NOISNAL 1 860 LIS Teed a sya aav 5 1 8 2 8 1 22 Jp iz WIMOANOLINSI TZ 6 52 HM 2 20 a WH HM 6 59 WdH8c 5 Z85eHO HM 02 2 21 02 waded Jp Q 1vaozd 280 04 eU MS 8 s z O V2 6l 193135 alr 610 G 7jss tuus GN31X3 17 872 ASr6L i woos _ 5 nm 2 8 WEOAIVId 81 O G ssrEyxaus 1 2 L dnwoosarisnaliviouWwHOdlvid ZL O C4 1 5 79 Y9 1 1 120 014910 Bt 81 tar EM Tom uomans 2 amemon serus i 2 80 E
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342. EL dana L2 SYNC 5 nuva 608 0 7 WuviwiN3Os3aNMOGQWOOSSIRT 9 O 01 80 18 6 Loco 2 7819 NOLLONN 1 1 6 6 69 43469 HM P 8 860 8 48980 F280 28420 JP 410 OF 5951 1 80 88420 Gum JB 9 NOWONNS 9 O 0 9 8 GH HM 38190 LCPIDNSHANHISO Jp 5 1 31V1OH STAVLNEAL 5 5 8 M8 HM 99159 15 Hw Tiro Jp v 1441 SLVLOY 318v1Nunl O LARN 7 69 119 179 Jp 3 7091409 NOLLONnH WOO 5 95 38489 g 2 WOO8 2 a Wuvivolg ad UO 2 Los1 au 2 v g a 3svavNINH31 A WP Pf T LL SNOudO0tGO0QH 3 nua 9 t 5371009 110 8 1H9 g 8 S prae e J Lmnm H ass HM NDILZO 9 820 e e 2 5 65 bd Avi3H BS ENSEM NHOH 1 69 HO T Suo l 1 og i B X 3 iod TSA
343. ELAY 6 9 x R33STR 5 5 gie mz ES a STARTER MOTOR n D gt 2 gt 5 AUXILIARY 9 3 z e PUMP RD C27AUX RD x ie AUXILIARY POWER RELAY E NE 7 2 mE AUXILIARY PUMP i x s s Nig zi y WH ui SR 5 RD BK 8 C1B 2 8 m g ferm tm T C28TTA RD BK anm C2BTTA RD BK Dog P134TTSR RD RD IBK BRN LEVEL SENSOR C3B 12 lt lt yy C8P 12 C133PLA BLWH a T C2B 5 5 Pus C2P 5 C46HRN GR C46HRN GR HORN RELAY gt c ox GREK a C7P 1 P22BAT BK C7B 1 g I 5 1 2 P22BAT BK F H BK gt 8 lo DCUM C1P 12 CIG2PLIBLUWH _ C1IB 12 ISE 4 1 5 Ee LIP P134FB WH ve FLASHING BEACONS 134 2 6 5 OPTION lt gt ER 1 8 RD 5 So 4 BK Hz _ EB R21IGNWH s C amp 4 7 HYDRAULIC OIL TEMPERATURE 8 d ca SWITCH OPTION 5 1 Sgt UN gt COOLING FAN _ 25 R116 OR 05 1 4 5 8 H x x m C41RPM OR BK C2B 3 C41RPM OR BK C52 qoe C21IGN WH e as i
344. ELECT C128LPRM gt STARTER BLUE WHITE 18 CAN RELAY PURPLEDDKBLUET8 8 AUXOUT1 87A LT BLUE PINK 16 WHITE 16 30 gc MTRTWR8 WPTWR1 4 87 PINK BLACK 16 STARTER 18 86 6 SOLENOID H IGRAY ORANGE 18 85 YELLOW 18 FL GRAY BROWN 18 cr RED TAN 14 R REDi4 RED12 do LT GREEN RED 20 BLACK WHITE 18 A AUX IN PD2 C27AUX PuRPLE ORANGE 18 BATTE 1 YELLOW DKBLUE 18 8 AUX IN PU2 C35HRPM DK BLUE YELLOW 18 WPSHD1 THIS JUNCTION PINK YELLOW 16 FUEL PUMP C135FP BE WITHIN 3 6 INCHES DISTRIBUTOR BLACK 16 D GROUND GND OF CONNECTOR CONNECTOR PINK DK GREEN 16 RELAY FUSED C21IGN SPLICE TO ASSEMBLY END WIRE t Fa 2 MTRTWR6 v 87 PINK YELLOW 16 1 f CRANKSHAFT FUEL 15 PURPLE WHITE 18 POSITION 5 PUMP 2 IGNITION SENSOR TAN BLACK 18 85 RELAY ALTERNATOR COIL RED 12 RED 12 c RED 16 O GREEN 18 LT GREEN RED 18 PURPLE T BLUE 18 5 BOSCH RED 14 F3 ALTERNATOR LT BLUE DK BLUE 18 LER Lm guo PINKAWHITE 18 jh THROTTLE A PINK DK GREEN 16 Fi PINK DK GREEN 16 PINKIDKGREEN16 B JAN ORANGEITS 1 RED TAN 14 86 15A 8 POWER WHITE BLUE 18 RELAY gt gt THESE CONNECTORS ARE CONNECTED TO GENIE HARNESS 88833 Genie DWG 5 60 5 65 5 60 HC 6 11 Part No 77828 Fe
345. EV WH BK C1B 5 C5 20 C31REV WH BK AD DRIVE REVERSE Pl 4 DRIVE C130TA WH RD i TRAVELALARM 8 RN 9 8 C26 1 C26 2 C32BRK WH RD 3 E haze CI lt C1B 6 C528 2 WH RD 4 BRAKE RELEASE gt x s 8 C28 1 C282 5 T T E z o 01 C29MS RD WH C1B 3 5 24 __ C29MS RD WH D MOTOR STROKE z 5 5 5 9 BURD gt 16 m 5 3 C251 C252 2 01 11 C37SCW BL BK 1 11 C37SCW BL BK STEER nn 1 LEFT 2 EE DRIVE ENABLE u x t RIGHT Sa 10 C36STCC BL C1B 10 C36SCC BL D 215 x CDE1 BLWH 8 24 1 C242 9 3 S A alze z D 1 BL g 6 lt 5 6 WH RD C3B 6 3 lt 5 YOUT 5 4 sid 42 85 15555 4 CATRL WH C3B 4 C4TRL WH TURNTABLE ROTATE LEFT ig RS pan 2219 5 C5TRR WH BK C3B 5 P C5TRR WH BK CITI enol 9 s n 0 TURNTABLE RIGHT ES 5 a 8 15 1 Ci52 D 1 a TURNTABLE ROTATE LEFT PE Em 2 FI C6TRF WH RD es 2 TURNTABLE ROTATE FLOW CONTROL 12 1 2 2 D GIPBURD Ibi PRIMARY BOOM UP T C2PBD RD BK 4 unte 1 1 PRIMARY BOOM DOWN i C13 1 C13 2 lt HE E lt HE
346. EVEL CIBBLDOR EK 1 DOWN til PLATFORM LEVEL DOWN E B C21 1 C21 2 a 5 C4P 6 C18JD PRR GR BK C4B 6 E FRIGHT PLATFORM ROTATE t LEFT C17JU PRL GR C4B 5 C283 C23 2 5 C18JD PRR GR BK 4 5 3 ES i lt lt PLATFORM ROTATE RIGHT FRIGHT PLATFORM ROTATE CTP GR D PLATFORM ROTATE LEFT 224 C222 Creo RDB B DESCENT ALARM OPTION 2 i CNN CERE RUE 565053 1 lt m gat gt See x ala t cc 6 57 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 6 Schematics JEE GGS XK E a s 1 Electrical Schematic 60 CE Models Deutz F3L 2011 Models after serial number 11879 Section 6 Schematics February2012 X eee Ground Control Box Terminal Strip Wiring Diagram S 60 Deutz F3L 2011 Models before serialnumber 11880 February 2012 Ground Control Terminal Strip Wiring Diagram 5 60 Deutz F3L 2011 Models before serialnumber 11880 Section 6 Schematics Ei og annoy
347. EX DANO 5 60 5 65 5 60 HC G Part No 77828 February 2012 Section 6 Schematics pum UU Electrical Schematic S 60 Deutz F3L 201 1 Models before serial number 11880 Section 6 Schematics February 2012 ki IEE ux i lt a s iia ra ssa3sJN383983m5z i Electrical Schematic S 60 Deutz F3L 2011 Models after serialnumber 11879 2215 February 212 Deutz F3L 201 1 Models after serial number 11879 Electrical Schematic S 60 Section 6 Schematics gg n m g lt I N EE 5 s ER p CtP C35RPM BK RD C1B 9 8 FOOTSW HIGH e FOOTSW LOW E x x F im b hs 86 LOW RPM z IGI FUNCTION ENA C35RPM BK RD BRN HIGH R
348. FORM fo ROTATE 2 i CD YT PY a SS Ss ee pe i i C129 RDK DESCENTALARMOPTION _ Ma 2 7 C19JSV GR WH ne CTS ro E 2 2 8 m 5 5 JIB VALVE JIB VALVE x 2o m o r s x z E ala a enie G A TEREK WG S 60 S 65 S 60 HC 6 21 Part No 77828 February 2012 Section 6 Schematics M MH Electrical Schematic S 65 GM 3 0L Models Section 6 Schematics February 2012 n Hm g Ground Control Box Terminal Strip Wiring Diagram S 65 GM 3 0L Models February 2012 Section 6 Schematics Ground Control Terminal Strip Wiring Diagram 5 65 GM 3 0L Models FUNCTION HARNESS ENGINE C5 957 HOLIMS NOISN3L 318vO 151 HOLIMS 1 woog 2929819 eit 61 81 vO RED L 64 84 42 OL 5 158 7951
349. GN START RELAY ORA ge Smale R33STRBK 5 5 Jd a i E a INE T Ew 4 Le STARTER MOTOR 0 E u 8 ond z EMISSION CONTROL a PUMP C27AUX RD x t RD JA SPEED REDUCTION RELAY C7B 2 BEES AUXILIARY POWER RELAY 8 C7P 2 P23BAT WH S N m B 2 EN e I 33 AUXILIARY PUMP E TES AER 2 WH l 8 ere 2 RD BK EB 8 E 8 cee C28TTA RD BK 3 C28TTA RD BK PM yo ON A ME P134TTSR RD RD IBK BRN aa YW LEVEL SENSOR Sy C3B 12 E NE BT i c3P 12 C133PLA BLWH e o QU Grek o g cep C46HRN GR oe E 21 ou C2P 5 C46HRN GR i HORN RELAY 418 a GR BK a E Oz 7 1 22 C7B 1 2 P22BAT BK i FH BK N f HORN 5 D 2 C132PLIBLWH _ C1B 12 i z 5 9 S UL P134FB WH 2 6 PI34PWR GR BK C2B 6 A 9 gt FLASHING BEACONS gt s SEI eri m E dpt E 1 RD i M m Ne E BE T oz C2IGNWH R21IGN WH C54 _ HYDRAULIC OIL TEMPERATURE SWITCH z P116HYDRD_ 3 Oe E 5 58 R16 OR cs 1 Z COOLING 256 amp OPTION J 5 i C41RPM O
350. Genie A TEREX BRAND Serial Number Range S 60 5 65 5 60 Part No 77828 Rev 1 January 2013 Introduction February2012 Introduction Important Read understand and obey the safety rules and operating instructions in the Genie S 60 and Genie S 65 Operator s Manualor the Genie S 60 HC Operator s Manualbefore attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Serial Number Information Genie offers the following Service Manuals for these models Title Part No S 60 and S 65 Service Manual before serial number 2575 34476 5 60 5 65 Service Manual from serial number 2575 to 6623 48412 S 60 and S 65 Service Manual from serial number 6624 to 9153 65196 5 60 5 65 Service Manual from serial number 14782 to 21000 139188 5 60 5 65 560 HC and TRAX Service
351. Ground Control Box Terminal Strip Wiring Diagram S 65 CE Models Deutz F3L 2011 Models after serial number 11879 February 2012 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 65 CE Models Deutz F3L 2011 Models after serial number 11879 1108 29099 N d JINON LYVLS NOLINDI HOA 72 21 ssaid HO dWal OL 820 151 NO EIHIMO NOI 26027 e 25 xINO SVD 201 8 0000000 O 57 60 148310 MS AIM OL 2 1
352. H TILT ALARM 1 1 RD LEVEL SENSOR Ka W 8 C3B 12 x 81 12 C133PLABLWH lt GRBK GR E E ail cin NE 4 9 un nom C2P 5 C46HRN GR cm z C46HRN GR yh HORN RELAY 5 Po 5 lt uo 418 n Grek 1 7 1 22 C7B 1 E 5 i 5 P22BAT BK le EH BK Yf 92 8 m eo jc pe Ee P CiP i2 CI32PLIBL WH _ C1B 12 2 5 o iS P134FB WH FLASHING BEACONS 2 6 P134PWRGRIBK C2B 6 NE s g Pris a pan rut ER ESO ORENSE 5 RD i EC e So BK o oz 4 C2IGNWH B R21IGN WH gt gt C54 t HYDRAULIC OIL TEMPERATURE 2 a d SWITCH OPTION Y PH6HYDRD 8115 u 8 5 R116 OR Z COOLING FAN gt 214 amp LT OPTION 0 x 8 3 l C2B 3 C41RPM OR BK C52 amp G21IGN WH n eM T T RA 4 T 1 88 95 a ws m lt 55 8 RD C7B 4 P20BAT RD 4 ii a amp S m e e LO Part No 77828 A BRAND 5 60 5 65 5 60 HC G 6 56 Section 6 Schematics
353. HITE 5 gt BLACK BLACK BLACK 126 GREEN IS GREEN 20 AMP CIRCUIT vc T T T BRASS 120V AC GFI GREEN 12GA 12 GA3 CONDUCTOR BRASS ENCLOSURE 110 VAC GFI 7N SILVER WHITE gt C GREEN GREEN BLACK 9 6 107 A TEPE BAND 12 GA3 CONDUCTOR Genie Y 5 60 5 65 5 60 HC Part No 77828 P25FS RD TO 24 TO 23 P26FS BK ALC 500 P24FS WH FOOTSWITCH TS4 TS47 a B E HH 8 i i 2 5 3 m o 5 4 012 2 7 9 8 g I b 8 8 8 8 5 3 12 5 lt Ei PLATFORM 5 a GROUND mp tkohms 124 ohms A1 BATTERY 29 35 45 2 _ A2 SENSOR POWER 5 VDC 4 1 5 BATTERY 2 p e B1 VALVE 0 FWD COIL V151HG GN B2 VALVE 1 NC m V150HG GN BK B3 DIGITAL OUTPUT BYPASS OMRON 3GND sswiNPUT 2321 0 C1 TxD OMRONRELAY 4 BS gt RS232RxD C2 RxD TIME DELAYMODULE 4S peu 1 3
354. HO z vel 21 MS vel Qd a 55117814 V2 a 951 Z8T dd UMdTELO Je MS WriavodH340 91 9 820 69 69 3 260 SS THM XNO6SO Je OPM 8 9659 2 9r NHOH Qd 2 o 5 820 NHH9rO I Ww 3579 HOIVNH3LIV M 8 2 90 WdHIrO Jp Q iO 2 4 Or d3MOLS WOO 6 2 010 161090 2 822 15707 Je 610 O 1 820 41659 1 20 915 59 JP 2 SEE ZE TAS P 9 1 3931 slo O 01 810 19 221596 919991890 p2 S G33dS NOLLON 0d Qd 6 910 QU M8 SHSEO 22 50 HMM VSr O Je ve OOF 8 8 VSr O P 3NION3 1591 Qd 55199 1 810 X8 915859 52 59 Je E O mewa 9 8LO QU HM 02 50 Addio Je G 3943438 O 9 81 5 ae As 2 Jp 0 O T 8l0 HM GMd40FO 62 15 HOLOW O H 92 59 HWQH 5620 JP NH8 8LO HWQH 9 4620 82 8 VLLS2O o 2 80 118 9 22 22 Qd 22 V2 Q 1951
355. HO1SIS3H 318v1NunL woog vl m a f wyo S m Qu HM February 2012 Section 6 Schematics n qax Ground Control Box Switch Panel Wiring Diagram S 60 CE Models Deutz F3L 201 1 Models after serial number 11879 Section 6 Schematics February2012 Platform Control Box Wiring Diagram S 60 Deutz F3L 2011 Models February 2012 Section 6 Schematics Platform Control Box Wiring Diagram S 60 Deutz F3L 201 1 Models DESCRIPTION TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR ALC 500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH ITEM H1 C7P C9 C1P C4P 48 PIN CONNECTOR BLOCK U13 J1 2 J3 CR27 CR30 LS18 CWLITE WH TS49 PLATFORM CONTROL HARNESS TO SWITCH PANEL C19JSV GRWHTS7 C19JSV GR WH C4P 7 BRN JC3 BRN GND RD E STOP NOTE WIRE CONNECTS TO JC3 6 FOR STEER ROCKER SWITCH OPTION C134PWR RD H1 CR27 CR30 C32BRK WH RD C1P 6 C40LS OR C2P 2 C40LS OR J2 4 P24FS WH C9P 2 P23BAT WH C7P 2 C1
356. HS18110 8 9 H4 QH HO NOH s NHH9rH Suo Qs QH 9 4 829 N39SrO 51 89 8 5 s E vel e WIONHOMavoT vet Q GH 5 5 Je 228095138 vel MS WI GVO1 FEL Qd ZISTQH HMdfELd 9H QH 9 820 69 O GH 280 561 8 18 060 evioena a 8 2652 NUOHSOIAUSS oF 2 Suo u9 95 820 HD 3STnd HOLWNYALIV 230 Wald HO 820 ov 5 WOO8 ov Q Q 2 010 HO 161070 2 822 15100 6 an 6 tu 1 lHoH33IS 18 ite 1 929 38 18 5 Je irato MOSZEO 2 14729718 595955 2 01 810 18 95960 yo se NOILONNJ HOH Q 6 810 IdHSEO STMMOS vHO Qu i8 z sonmmavsreo HWE 8 819 HME 5 ee 3NION3 LYVLS Q4 21 810 48 HLSEED ENSIS et ee 34 62 30 QU HM 2 0 V2 WHTV CH HM Missis i 3SH3A3H T3dOHd i Ble 02 50 ASH IEO 2 i il l ee 05 T3dOHd 05 5 12 89 HM GOED YAL HM AMAO 62 mosyon O O 9 30 SWezo
357. IMIT SWITCH I 5 15 our sc YE 8 Il id RD RD S BR C7PBE BK Ble ic LEGEND i e BOOM EXTEND is on 5 BOOM 37 1 C372 Ci 1 C162 2 Pwi 9 1 RETRACT E 14 8 enof 10 C8PBR BK WH lt lt tt gt gt BOOM RETRACT es cem x lt lt 1 E Ci71 CI72 n Mme t BRN ss 9 39 E lt lt CH8LSROR RD C4B 4 OR RD C38 3 BK WH C38 4 LS17 BOOM UP DOWN P24FS WH 5 E stUx SPEED REDUCTION LIMIT SWITCH 2 a Pears WH 5 499 2 E fage 04 C13DE BL RD C4B 1 BL RD C94 WH 9 2 LS3 DRIVE ENABLE SWITCH P26ESTP BK m S gt 5 eS 5 299 B CPP 599 B ge lt WH BK LS1 PRIMARY BOOM EXTEND 5 stus DRIVE LIMIT SWITCH N 8 JI EH WH BK WH C10 2 LS2 PRIMARY BOOM UP a Ue DRIVE LIMIT SWITCH C40LS OR C2B 2 x 1 1 1 1 4 we I oz par P B 855 P22LS C3P 11 59 BL BK C3B 11 BL BK 2 5 BK C37 3 4 Z 3 LS5 CABLE TENSION LED Bs Re oS z 2 w m 3 5 o P134 RD RD C381 y RD ac BR 2 C38 2 1 LS17 BOOM UP DOWN amp SS a SPEED REDUCTION LIMIT SWITCH 2 E us 92 _ OR lt go PLATFORM LEVEL t DOWN C4P 3 C15PLD C4B 3 5 20 1 20 2 2 op i CIAPEU OR DA PLATFORM LEVEL UP PLATFORM L
358. INE 5 2 C41RPM OR BK FEH 11 PIN2 e T 5 5 gt R33STR FEH 32 PIN15 IGN START RELAY START 5 EO C33STR BK FEH 32 PIN13 8 oz BL WH FEH 787A 5 E C135FP BL WH s BK e 66666658 i 8 K Q ES C33STR BK f E z 8 8 5 22 i 2 9 4 1 4 STARTER MOTOR 88 t 2 5 it CUT 8 SPEED REDUCTION RELAY 4 AUXILIARY 8 PUMP G27AUX RD 1 1 AUXILIARY POWER RELAY S 1 1 C27AUX RD 1 1 Ig 4 le 4 AUXILIARY PUMP 2 4 ES a Ba C28TTA RD BK a 5 g C26TTA RD BK ALARM fsa BRN x WH C7P 2 2 WH 46782 2 P134TTS RD REVEIVSENSOR e m RD Y 2 RD BK 2 seJ L P134FBWH y FLASHING NA BEACONS OPTION 3 si BK C2P 5 C46HRN GR C2B 5 C46HRN GR p 4 HORN RELAY E a o 7 1 P22BATBK 7 1 E P22HRN BK R46HRN BK C6 9 e HORN 9 a P134PWR GR BK amp HYDRAULIC OIL R21IGN WH gt gt 05 4 TEMPERATURE SWITCH P134PWR RD m OPTION oO 4 P22LS BK zm C116 OR C5 1 COOLING FAN g 81 116 RD n 9 Lt amp 6 Lj 107 510 5 3 gs x 8 SQ Sa amp m T T z NO i i 1 lt Os i 8m m
359. Jp 5 62 3WOHISHOION 62 H 9 30 SWezo Jp 810 5620 VL182O JP r4 2815 VLLEZO dnd E alz H 2 Q 1561 08 xnv zo r7 aT 98 61 0 O HOLIMS 1491009 O 2 8 8 92 HOLIMS aunssatid 10 2 Q4 91 50 1920 OLNSPIS HM 5 al O ve ve Coo O ez H3MOd HOLIMSA34 C4 S V2 SX HM 2 840 HM ZWSI HM O zz WHOAIWId z O 653 eO 2 60 1vgzzd MT 1 0 8 1vgzzd a zz z Q 34 859 LIS Teed sg NOLLINSI te 5 39 HM WH HM WSNOUEOKCE s lt gt TCU 1vaozd 2 189 0H asmuo 5 3AWAIOSISSI 6 2200 HOLIMS s s O 2 O SSI HWH9 GN31X3 woos 2 879 ASr 619 e 8IP LHOIH 31vLOH WHOALVId cis D Q4 Y 1 820 Qr810 16SL38 00 9 892 x8 H9 Orso ab 817 137 31vLOH WHOALW Td ab 1 80 25819 S grO H9 s NMOGT3A31WHOdlYid SL E J 129 8 80 65S158 HO 8 8rO 01990 20919 Ey 8 dn3A31WHOdlVid Qd 22 15 12 1020 6sS1
360. L 29 888 88 8 8 88 8 SS3NHVvH 3SV8 IF IF IF Gvz au 318vN3 6 612 13 31 061 Md WuOd1V1d sia aiviou SA WHO41V1d Geb lt 000 2951 90 ela 1 280 VSI 3NION3 Q41 H5 180 e 902 4 1 YSL SNOILdO GS 31v10H amp e CN Do num e 280 3 SI8 HM GS5I8g HM T HM AHM 8 LOVHLSY o aN31X3 Lu a noos 1097135 c 6951 woog N wi 5951 1951 oO QGO SOO do 5 u HWGH o lt y T a o 1 sS I 4313W unoH i 5 30 woog 51 69 z Ki 10 1 e WuO31V1d H3MO1 Spi p wn X03H9 6 6 GIZ HM GIZ HM 2 i __ ____ _______
361. L Models C28TTA RD BK C28TTA RD BK a m o 9 5 5 a 8 u A 8 8 8 1 9 M C35RPM BK RD C1B 9 FOOTSW HIGH L FOOTSW LOW 5 e B LOW RPM 8 e FUNCTION ENABLE HIGH RPM gt 4 4 14 4 4 4 4 4 9 5 X e 2 7 GR WH C2B 7 z C5 12 C45GEN GR WH 2 1 gx E lal ore eS I II di ey 2 g 2 6 DLITE GR BK C2B 6 9 i DRIVE LIGHT o LIGHTS V7 WORK LIGHT AD Or DRIVE LIGHTOPTION 657 lt ala 3 A
362. LATFORM ROTATE t LEFT C17JU PRL GR C4B 5 m C233 C23 2 i Cis PPAR CHEK 4 PLATFORM ROTATE RIGHT PLATFORM ROTATE 5 CHJUPRL GR Itl 4 PLATFORM ROTATE LEFT 221 222 C129 RD BK DESCENTALARMOPTION 2 1 x xm m 258 z 45559 ale gt ROCKER STEER OPTION ONLY enie G A TEREX DWG S 60 S 65 S 60 6 27 Part No 77828 February 2012 Section 6 Schematics JEE EE E E E E E Q III IFE ZS i lt xe Electrical Schematic 5 60 Ford LRG 425 EFI Models before serial number 11880 Section 6 Schematics February 2012 Electrical Schematic S 60 Ford LRG 425 EFI Models from serial number 11880 to 14053 2215 P134PWR RD February2012 NOTES Ford LRG 425 EFI Models from serial number 11880 to 14053 Electrical Schematic 5 60 Section 6 Schematics
363. LENOID amp a c9 4 C27AUX RD C1B 1 l C21IGN WH dig 2 METER 1 88 m IGN START RELAY 29 5 R33STR 5 5 X amp e E cms st STARTER MOTOR 6 ee 8 gt gt b EMISSIOIN CONTROL m AUXILIARY 5 gt C27AUX RD x RD j pu 4 SPEED REDUCTION RELAY 9 C27AUX RD x 8 m ETT C7B2 iA AUXILIARY POWER RELAY g gt m 8 M 84 1 1173 AUXILIARY PUMP 9 Na i lt gt T d WH 1 ui 2 o E C28TTA RD BK P 7 z C28TTA RD BK s Fd RD IBK BRN PISITTSRRD i He LEVEL SENSOR C3B 12 LoSsenseend O 5 C133PLA BLWH a C2B 5 C46HRN GR 2 C46HRN GR 14 HORN RELAY 22 amp w lt Grek a u C7P 1 P22BAT BK C7B 1 E 5 o 8 4 P22BAT BK FH BK TAON 9 A 5 io o 8 z 1 CiPi2 CIG2PLIBLWH 12 5 s gt EE z e Jg Xu P134FB WH FLASHING BEACONS Cop PIMPWRGRIBK C2B6 5 0 4 ee gt gt T 5 RD i M ale So BK o oz 4 R21IGN WH 05 4 4 HYDRAULIC OIL TEMPERATURE 2 d SWITCH OPTION B P116HYD 8 56 Rtte yy G5 1 gt COOLING F
364. M GENERATOR o LEVEL PUMP OPTION WH 24 RD RD RD AD 8 NOTE DASHED LINES INDICATE OPTION WIRES Genie Part No 77828 A TEPEX 5 60 5 65 5 60 HC 6 105 February 2012 Section 6 Schematics EE EE E EE EI E E EE IEEE T i Axblip l3 nan gt uai 1 Platform Control Box Switch Panel Wiring Diagram S 65 Perkins 404 22 Models K J H G 120V AC W REGULATOR CB 51 RD 4 E 30A 1191 RD 12VDC RED E WT eh WH 5 WH 2 86 85 5 9 BRN BRN GND lt O 1 BRN BK 2 BK 2 GR lt lt E BK WH BK RD BK RD WHT NEUTRAL 120 7 AUTO 4 120 15 220 AC W REGULATOR KON 87a 3 gt RD e 1 E 30A PEE RED 12V E 87 WT WH WH 2 86 185 5 3 BRN BRN L BK WH lt BKWH BK RD BK RD 5 WHT NEUTRAL 220V AUTO di RESET CB BLK 220VAC e e 12 5A February 2012 Section 6
365. Manual from serial number 21001 147753 Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement communications will be carefully considered for future printings of this and all other manuals Contact Us http Awww genielift com e mail awp techpub terex com Genie ii S 60 S 65 S 60 HC Copyright O 2011 Terex Corporation 77828 Rev February 2012 Fourth Edition Fifth Printing Genie and S are registered trademarks of Terex South Dakota Inc in the USA and many other countries ry 6 Printed on recycled paper Printed in U S A Part No 77828 February 2012 Revision History Revision Date Section Procedure Schematic Page Description Revision History Added zi 3 6 E 4 REFERENCE EXAMPLES Kubota Engine Section2 Specifications Electronic Version 6 3 7 3 Maintenance Procedure 3 2 6 4 9 1 Section4 Repair Procedure Click on any procedure or page number Fault Cod
366. N15 GN START RELAY START 59 BL WH 787 5 18 zs START d o CP FORD ENGINE HARNESS N N A c a aja 2 8 A N 9 4 STARTER MOTOR Es x om 5 n SPEED REDUCTION RELAY AUXILIARY a RD AUXILIARY POWER RELAY x C1P 1 C27AUX RD C1P 1 1g 5 E 58 L 4 AUXILIARY PUMP e LONE j 51 C28TTARD BBK fr a 5 9 28 ALARM 1 1 RD BK x WH C7P 2 P23BAT WH C7B 2 Lin P134TTS RD n Y UE VED SENSOR o x E q e i 9 N RD C1P 2 C28TTA RD BK C1P 2 m ec r 14 1 4 oU FLASHING p BEACONS OPTION S E BK C2P 5 C46HRN GR C2B 5 C46HRN GR HORN RELAY e a a 1 C7P 1 P22BATBK C7B 1 P22HRNBK B46HRNBK C6 9 9 g a P134PWR HYDRAULIC OIL C2P 6 C2B 6 R21IGN WH C5 4 TEMPERATURE SWITCH P134PWR RD a OPTION a 8 2215 T 5 1 2 COOLING FAN 5 8115 eko UE x a a Ly ALTERNATOR FIELD FORD ENGINE HARNESS 8 55 Xm asap asam sie E a 1 S NO E 89 3 2 58 id S
367. NTS 20 Using a suitable lifting device remove the test weights from the platform 2 Pull out the red Emergency Stop button to the on position at the ground controls and visually inspect the LEDs on the operational and safety controllers O Result Both the green and red LEDs on both controllers should be off indicating the system is calibrated Note If an LED is blinking on either controller the load sense system is not calibrated correctly or a fault may exist Refer to Section 5 Fault Codes to determine the system fault Section 4 Repair Procedures February 2012 Jib Boom Components S 65 3 1 Jib Boom How to Remove the Jib Boom 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 the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Removethe platform 2 Remove the platform mounting weldment 3 Remove the hose and cable cover from the side of the jib boom 4 Remove the hose and cable clamp from the jib boom pivot pin Lay all hoses and cables to the side Component damage hazard Hoses and cables can become damaged if they are kinked or pinched 5 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING
368. NvOZ8d V1HOdWOO A NVOZBG Ter Oro JAHM INSIZIS uns QH HWINSOZIS 2i 8 50 HM SOTO 1599910 O aa 5842 ae C VIO Sia prc sia Ta 714 2 5 Nvozed f NVOz8G LYSE tH owowe iid 9 00 ge 85 o Za ES LWOT8AOHESIA 20 S ZYO WAND GES IWowaivexa 9 170 HM oreo 19890 reso 21 650 15 7 10 699 IN3OLIS pea 9 970 HM lwaezad 5 271 260 2 10 1 8 gt S650 5991710 gt 9 5 SNVE9d HD zuo 1 50 1 y 1 6998210 93H95 HWHO ONV6OI d em amp lo Dae 4 PE 8 BL 6 650 1549910 i BK gt 1 WW ne 1530 1 y 970 6 10 as HIWEO 1646014 1 To 2 270 EMO 1542910 og 41 8 e e e z a9 z a 2 o 8 816 8 g 2 amp WO M MM N 5 i32 8 amp 88
369. O41V1d v dn 14 31 WHOSLW ld v L 318vN3 L 1 325308 7819 138 1X3 Wid Jovul3H AHVWIHd 1 WOO8 AHVWiHd 1919 NOLLONNS 3 1V1OH 3 18VINHRLL SLVLOY 318V1NH L 1 31 1 108 STEVLNYENL 7IOHLNOO WOO8 AHVWIHd WOO8 AHVWIHd dn INOO8 AHVWiHd 3uvds R134BAT RD L45 9H GY 1 8 O O O 0 22 5 18 6990 9SH9 xnvzeo 6751 9469 6751 13989 6751 9465 8 lt 6 070 HM HMdEcO GND BR R18 PRIMARY BOOM EXTEND BYPASS asva TVNINH3L CR59 MODULE POWER HI CAPACITY o olooo o o o H8 QNO CR56 RECOVERY HIGH CAPACITY 30 02281 29 OLO HM 57228 85 7 L 86 6751 HWE 88988 6751 1 2 0 1 8 820 2157 267 gs 60 8 95 X n ul H3MOd 957 459 L HOLIMS N
370. OISN3L anavo A 5 o i 15 H HOLIMS woog ry y 1 xi mi zo 10 g 6V8L ANN 79350 L 6 8 g x 8 8 98 586 1o gi gs 21 l 3 28 u SrrGdlvgreld i 5 3 x goj 1 So 58 2 i 5 EE cias 232 55886 gt rot nono 5 52 2 u 9 28 22 8 lt 9 lt 15 Sa 5 co 5 S z 325 us 51015 vido SL H Iva 8 B 9 jid vazza 38 179224 06 6989 IVVEIH Sa HW 138489 5 5 5 j 9982 5 v 9649 po 8 HW 9369 2 186940 8 E 59 5751 1905715 26761 Ta 2 8 2 0 1 S081 HM i HM 2890 198910 Ei 949 1832219 2 SS VSHO MB HM 1 317156 99 7960 QH HM 130415 98 65HO HM 1VBEZd 05 6550 IVBPELH 8 0 HM 0 g SSHO 1V8tZLd 7181 Ld 2 0 2 HM 38924 TS73 CALIBRATION SWITCH O R17 PRIMARY BOOM DOWN BYPASS
371. ON oil Contact with hot oil may cause severe burns Note Perform this procedure with the engine off Hydraulic return filter 1 Openthe ground controls side turntable cover and locate the hydraulic return filter housing on top of the hydraulic tank 2 Remove the cap from the filter housing 3 Liftthe handle on the filter element and rotate the element counterclockwise to release the element from the housing 4 Remove the filter element from the filter housing 5 Install the new filter element into the filter housing Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures 6 Push the filter element down to be sure the O ring on the element is fully seated into the housing 7 Rotate the filter element clockwise to lock it in place 8 Install the filter housing cap 9 Usea permanent ink marker to write the date and number of hours from the hour meter on the oil filer housing Medium and high pressure filters Note The medium pressure filter is for the charge pump and the high pressure filter is for all machine functions except the drive circuit and oscillating axle circuit 10 Open the engine side turntable cover and locate the medium and high pressure filters near the pump Note The medium pressure filter is located on the right The high pressure filter with filter condition indicator is located on the left 11 Place a suitable container under each filter 12 Remove the fil
372. ONTROL BOARD CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH DESCRIPTION TILT ALARM 48 PIN CONNECTOR BLOCK ITEM H1 C9 U13 J1 J2 J3 CR27 CR30 LS18 OPTION F S 12V DC BATTERY i i i i i i A i w La Lj E C39LP BL RD C2P 1 pog o I 1 i 26 m d pog E Log d N C118LSR OR RD C4P 4 x C6TRF WH RD C3P 6 4 w 7 BURD 4 1 pog t lt C8PBR BK WH C3P 8 EN C40LSS OR C2P 2 n P24FS WH 4 N i C9PER BK RD C3P 9 P24FS e CA1RPM C2P 3 a C30FWD WH 4 C1PBU C3P 1 C31REV WH BK 5 e e C2PBD RD BK C3P 2 e C36SCC BL 10 RD WH C3P 3 i a C37SCW 1 11 5 C5TRR WH BK C3P 5 4 C32BRK WH RD C1P 6 C4 P B C4TRL WH C3P 4 lt 5 lt C29MS RD WH 3 J 95 C3P GR
373. OR ALC 500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH ITEM H1 C7P C9 C1P C4P 48 PIN CONNECTOR BLOCK U13 J1 J2 J3 CR27 CR30 LS18 CWLITE WH TS49 PLATFORM CONTROL HARNESS TO SWITCH PANEL NOTE WIRE CONNECTS TO JC3 6 FOR STEER ROCKER SWITCH OPTION C134PWR RD H1 CR27 CR30 C32BRK WH RD C1P 6 C40LS OR C2P 2 C40LS OR J2 4 P24FS WH C9P 2 P23BAT WH C7P 2 C19JSV GR WH TS7 58 WH C19JSV GR WH 7 BRN JC3 Es BRN GND RD E STOP B C134PWR RD LS18 BK C1P 12 P22BAT BK C7P 1 C19JSV GR WH 7 C18PRR GR BK 6 C17PRL GR C4P 5 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C129JDA BL C3P 10 TS8 C46HRN GR C2P 5 C59CHK BL BK C3P 11 L47 C59CNK BL BK C3P 11 P26BAT BK C9 1 P2 n O JIB RD LS18 CABLE _____________ OPTION JIB 25 5 RD 9 3 TS2 P24FS 9 2 TS4 CDLITE OR RD C2P 4 C45GEN GR WH C2P 7 C46HRN GR C2P 5 P26ESTP BK C118LSR OR RD C4P 4 WH RD C1P 6 C6TRF WH RD C3P 6 e e J3 e 9
374. P 11 C37SCW BL BK 1 11 C37SCW BL BK Il o PTIT I 7 STEER RIGHT DRIVE ENABLE t RIGHT 35 CIP 10 C36STCC BL C1B 10 C36SCC BL til STEERIEET 0 lx CDE1 BLWH C24 1 C24 2 ua a SE 6 lt se gu Ue BL SER g Peour s lt lt 03 6 WH RD C3B 6 5 WH SS gu 3c BL 155 515 C3P 4 CATRL WH C3B 4 C4TRL WH I TURNTABLE ROTATE LEFT x 14 ewn sc 8 55 18 C141 4 14 2 FEM e zz 5 CSTRR WH BK C3B 5 CSTRR WH BK TURNTABLE ROTATE RIGHT E ne 8 agar E C151 C152 gt t TURNTABLE ROTATE tz LEFT gi o BIOS E 8 C 31 31 2 o xil Fd WH RD H TURNTABLE ROTATE ANM FLOW CONTROL G B GIPBURB 12 1 4 12 2 PRIMARY BOOM E PRIMARY BOOM C2PBD RD BK T PRIMARY BOOM DOWN i 131 C132 4 s ES Bi of 9 aed m ig 8 t ERE RD WH 9 Your s 2 PRIMARY BOOM FLOW CONTROL g RD C29 1 C29 2 SiE xoi Us 1 C1PBU RD C3B 1 15 KI id BRN ig 2 12 32 2 C2PBD RD BK C3B 2 E L lt us n 6323 RDWH C3B 3 a C304 C302 Haze C99 C9PER BK RD C3B 9 C9PER BK RD PRIMARY BOOM EXTEND RETRACT H FLOW CONTROL C3P 8 C8PBR BK WH C3B 8 MM 4 i 7 s lt face C9P7 C7PBE BK C3B 7 99 LS5 CABLE TENSION LIMIT SWITCH I 15 our sz YE
375. P 9 C33STR C1P 7 C27AUX RD C1P 1 C2P BK J1 1 JC1 3 OR JC2 4 RD JC1 2 BRN JC2 5 BK JC2 3 OR JC1 5 YEL C1P GY 19 18 CONTROL CABLE JC2 2 BRN JC3 5 WH JC3 3 OR JC3 4 BL JC3 2 BRN TS15 BLANH C28TTA RD BK C1P 2 TS15 B BL BK DRE LED BL RD TS14 RD WH e C28TTA RD BK C1P 2 BATGRN C7P 3 a RD BK 28 gt 7 7 ARDER LE aa S aa a aa aaa RD BK L48 NON CE _____ C134PWR RD C2P 6 C134PWR RD LS18 RD TILT CWLITE BK Q BRN BRN A TEPEX BAKO 5 60 5 65 5 60 HC G H1 TILT ALARM CWLITE WH TS49 6 24 February 2012 Section 6 Schematics imum c c MH H M Platform Control Box Switch Panel Wiring Diagram S 65 GM 3 0L Models N M L K J H G F E D C B A MPONENT INDEX PLATFORM COMPO 1 CONTROL CR13 JIB BOOM CUTOUT RELAY HARNESS JC2 BOOM PROPORTIONAL JOYSTICK TO CONTROL BOX BOOM UP DOWN TURNTABLE ROTATE JC1 BOOM PROPORTIONAL JOYSTICK BOOM EXTEND RETRACT JC3 DRIVE STEER P
376. PM a HIGH IDLE RELAY 180 65 18 HIGH RPM SOLENOID 2 8 o r UE ee 22 N E 5 C2P 7 C45GEN GR WH 28 7 z C45GEN GR WH 5 12 L GENERATOR OPTION mS E ume o 29 ccr gt gt 3 is 2 DLITE BL WH C3B 12 4 DRIVE LIGHT work OTS m v DRIVE LIGHT OPTION B En is 88 8 w ov in Ger amp WORK LIGHTS OPTION 85 10 a 8o rg A mz C2P M v C2P 9 a A E UE ye 4 i ja B 9 gi m ns ba ioci o 5 tr a 1 8 C34SA BK WH C1B 8 C34SA BK WH 5 22 GLOW PLUG RELAY 4 GLOW PLUG 7 PLUG 8 Glow s PLUG Os tie GLOW PLUG lt R a 5 MEN C26TSR WH RD OIL TEMPERATURE LED 27 a Sse 2 zig 5 2 552 955 8 az D C33STR BK Pte ore Gh Gta Ge are gt 65 14 OIL TEMPERATURE SWITCH 2 _ ENGINE EGO START b 55646489966 8 F ENGINE Ei Nono 5 16 ENGIN ee cele s OIL PRESSURE SWITCH L C25PSR WH BK a 1 8 BK e E o E 3 ng g o 5 POWER RELAY e i 58 B g ge faq C2 1IGN2 WH en Jj FUEL SO
377. Pull out the red Emergency Stop button to the on position at both the ground and platform controls Turn the key switch to platform control Do not start the engine Push in the platform controls red Emergency Stop button to the off position Do not press down the foot switch Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position When the alarm sounds release the drive enable toggle switch 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 Part No 77828 ATE 5 60 5 65 5 60 HC 4 5 COMPANY Section 4 Repair Procedures PLATFORM CONTROLS 8 Startthe engine from the platform controls and press down the foot switch 9 Startatimer 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 Section 2 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 dr
378. R BK C2B 3 55 OR BK 5 2 E C21IGN WH le lt 8 1 4 1 E 8 8 78 5 t F s xa 1 c lt lt ms ETEY OISE ONA 4 t lt Fd i m a ws 23 8 5 RD 4 C7B 4 N P20BAT RD 4 8 8 e e LO i AND PLATFORM OVERLOAD OPTION ONLY NOTES A TEREX DWG 5 60 5 65 5 60 HC Part No 77828 6 74 Section 6 Schematics February 2012 Electrical Schematic S 65 CE Models Deutz F3L 201 1 Models after serial number 11879 N c BATGND C7B 3 rouno z C2P 3 C41RPM OR BK C2B 3 9 8 5 amp m x a CIP4 C30FWD WH 1 4 gt 60521 C30FWDWH BK PD DRIVE FORWARD gt 15 o CIPS C31REV WH BK
379. RD _ C33STR C1P 7 LR m P25FS RD C9 3 F zb BL RD DE3 J1 16 gt LS _ 258 naa Ni 3 BL DE1 J1 6 egi BK BK BKWH C1P 8 rz BUBK DE2 J1 7 a YL J1 3 OR J1 9 BRN J1 10 C29MS RD WH 1 8 Pe 8 O O TT ON e WH CR30 E C27AUX RD C1P 1 9 lt m 233 ret 8 lt I 22 cp ey ee eee WUTE WH UE Ree TEE DLITE OH RD C2P 4 BOOM LED WH C59CNK BL BK C3P 11 WLITE WH TS48 DRIVE LIGHTS WORK LIGHTS OPTION Q BRN 147 RETRACT C17PRL GR 5 PLATFORM ROTATE 5 60 5 65 5 60 HC Part No 77828 RD RD NOTE DASHED LINES INDICATE OPTION WIRES n CR27 CT8J8V GRIWH C4P 7 BK J1 2 C18PRR GR BK 4 6 OR Ji 11 BRN J1 12 gt 2 5 2 BEE EG B C15PLD OR BK C4P 3 o5 Sok 5 BE giu 85 d i P C46HRN GR C2P 5 2 26 February 2012 Section 6 Schematics JES iS EE EE IEEE ESE ii i iias Platform Control Box Switch Panel Wiring Diagram S 6
380. RD C4B 4 OR RD C38 3 BK WH C38 4 LS17 BOOM UP DOWN gt SPEED REDUCTION LIMIT SWITCH Aa x m e e a Pears WH P 499 BL RD C4B 1 BL RD C934 BK ue WH C92 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK EK gt 3 5 N 5 499 C2P 2 9 2 lt I CH 2 WH Cit LS1 PRIMARY BOOM EXTEND 5 stus DRIVE LIMIT SWITCH J1 EH WH C104 BK C102 LS2 PRIMARY BOOM UP a Ue DRIVE LIMIT SWITCH 4 C40LS C2B 2 x l 1 m 1 1 oo g uo PS SPI it L S sao P22LS P C3P 11 C59CNK BL BK C3B 11 BL BK 5 ee T 8 5 BK 37 3 BK 42 C37 4 3 n i LS5 CABLE TENSION LED eve 8 2 o P134 RD RD C384 RD A BR 26582 1317 UP DOWN 5 8 SPEED REDUCTION LIMIT SWITCH 8 2 C14PLU OR C4B 2 e PRG PLATFORM LEVEL 29 DOWN C4P 3 C15PLD OR BK C4B 3 20 1 C20 2 o UP CUP UE PLATFORM LEVEL UP PLATFORM LEVEL 1 DOWN Il PLATFORM LEVEL DOWN 3 5 E C214 021 2 5 o 6 10 C129JDA BL C3B 10 6 C18JD PRR GR BK C4B 6 y C17JU PRL GR C4B 5 C283 C282 8 CI 6JDIPRRGR BE 1 4 PLATFORM ROTATE RIGHT TRIGHT PLATFORM LEFT ROTATE C17JU PRL GR Ii PUTFOBMROTATETEET i 224 C222 5 RIGHT PLAT
381. ROPORTIONAL JOYSTICK 11 DRIVE ENABLE LED TS48 14 PLATFORM OVERLOAD LED DRIVE LIGHTS 147 LOWER RETRACT BOOM LED WORK LIGHTS 148 BOOM TILTED LED 2 OPTION pouce p n l Eu JC3 P2 EMERGENCY STOP BUTTON JC2 HORN SWITCH DRIVE TS1 AUXILIARY TOGGLE SWITCH BOOM UP DOWN 7 i JC1 7 FORWARD REVERSE 7 amp TURNTABLE ROTATE amp STEER TS2 ENGINE START TOGGLE SWITCH LEFT RIGHT I I abe LEFT RIGHT 153 SELECT TOGGLE SWITCH 6 E 6 ENABLE T T J TILT ALARM LED 6 1 TS4 HILOW RPM TOGGLE SWITCH ANSUCSA TS7 PLATFORM ROTATE TOGGLE SWITCH bg TS8 JIB BOOM UP DOWN TOGGLE SWITCH 5 1 5 m m TS9 PLATFORM LEVEL TOGGLE SWITCH EN g P m 1514 DRIVE SPEED TOGGLE SWITCH 3 4 1 4 4 7515 DRIVE ENABLE TOGGLE SWITCH ba 7547 GENERATOR TOGGLE SWITCH OPTION oe TS48 DRIVE LIGHT WORK LIGHT TOGGLE SWITCH OPTION 3 i 3 14 3 I 1 bd PLATFORM bg OVERLOAD CEOPTION 1 2 E 2 L1 2 n DRIVE o 1 1 1 ENABLE L i 1 l l 1 257 5d CR13 H LEH L a 4 JIB BOOM ie bog CUTOUT bg d BRN 1 B mM E BEEN V l7 O5s4ttsg sc mum 2 BK a 18 BRN BRN BRN BRN
382. RPM SOLENOID I 1 2P 45GEN GR WH E 45GEN GR WH 42 I C2P 7 GR WI C2B 7 z C45GEN GR WI C5 dIGENERATOR OPTION E s 12 DLITE BLWH C3B 12 o i i DRIVE LIGHT a GHT LIGHTS i WORKLIGHT RD DRIVE LIGHT OPTION 1 1 g 84 S A 3 nie a BD WORK LIGHTS OPTION Dub C2P 12 C2P 10 g wr Sc 26 Et B u s a ee ee C2P 11 q C2P 9 Z A S mi d A y a B 1P C34SA BK WH 1B C34SA BKWH 22 is CIES tg e f GLOW PLUG RELAY gt PLUG B E atow lt gt tes GLOW PLUG PLUG 000 5 R 2 3 u gt C26TSR WH RD OIL TEMPERATURE LED a Ao 5 Ed 5 e 599 gt o 9 5 S D C33STR BK CIP i gt 4 OIL TEMPERATURE SWITCH ENGINE EY REO START 9 pss Ee 8 ENGINE E se ye C5 16 ete s 4 OIL PRESSURE SWITCH t G C25PSR WH BK REN BK lt B i 9 x d POWER RELAY i B o oo C21GN2 WH 65 1 fel FUEL SOLENOID a aja N lt 4 1 C27AUX RD C1B 1 4 o iz SIGN wn HOUR METER E I
383. RY BOOM FLOW CONTROL a RD C29 1 C29 2 SE TS Ur sz 1 1 C3B 1 2 pwr 3 KI g 5 BRN 35 12 y C9P C2PBD RD BK C3B 2 i le 1 E P C3P 3 RD WH C3B 3 DEED 3 8 2 I C30 1 C302 haze C9PER BK RD C3B 9 E C9PER BK RD Hs PRIMARY BOOM EXTEND RETRACT FLOW CONTROL 1 O8 ss C8PBR BK WH lt 638 lt _ _ m lt 9 lt face 7 G PBE BK CT r 49 135 CABLE TENSION LIMIT SWITCH E 15 8 nl RD RD BR C7PBE BK 5E sc DESEND BOOM EXTEND n 5 37 1 C372 Ci 1 C16 2 gt gt 11 RETRACT i BRN BK WH anoen Q Bi 8 COPBHBIWH 52 gt BOOM RETRACT _ x P lt 8 5 C17 2 R n el is 5 aoo 42 8 2 lt 0 4 CH8LSROR RD C4B 4 OR RD C38 3 BK WH C38 4 LS17 BOOM UP DOWN oT SPEED REDUCTION LIMIT SWITCH 5 P24FS WH x Bo 499 P LLL ISR s z BL RD C4B 1 _ BURD C9 1 BK WH C92 LS3 DRIVE ENABLE LIMIT SWITCH stu 0 5 599 C2P 2 2 e lt CH 2 WH LS1 PRIMARY BOOM 5 SVE DRIVE LIMIT SWITCH uo J1 EH WH BK Z wW C10 2 LS2 PRIMARY BOOM UP es DRIVE LIMIT SWITCH w E C40LS OR C2B 2 I ZI x 1 2 no 1
384. S 65 if equipped Note Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload System could result in the system not sensing an overloaded platform condition Machine stablity 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 halts all normal boom operation giving visual and audible warning to the operator Models equipped with the platform overload option are provided with additional machine components an adjustable spring loaded platform support subassembly a limit switch an electronic module which receives the overload signal and interrupts power and an audio visual warning indication to alert the operator of the overload Genie 5 60 5 65 S 60 HC The platform support subassembly utilizes two load support arms that are opposed in a full parallelogram link This isolates platform loads into a shear or vertical state which translates into a compressive load A spring in the parallelogram link supports this purely compressive load regardless of where the load is placed in the platform As weight is added to the platform the spring wi
385. S2 ENGINE START TOGGLE SWITCH bag til TS4 RPM TOGGLE SWITCH 4 4 4 TS6 GLOW PLUG TOGGLE SWITCH ii TS7 PLATFORM ROTATE TOGGLE SWITCH 124 8 BEN 3 PLATFORM 3 159 PLATFORM LEVEL TOGGLE SWITCH OVERLOAD TS14 DRIVE SPEED TOGGLE SWITCH 1 CEOPTION TS15 DRIVE ENABLE TOGGLE SWITCH 2 E 2 e Bs 2 TS47 GENERATOR TOGGLE SWITCH OPTION d ENABLE 1548 DRIVE LIGHT WORK LIGHT TOGGLE SWITCH OPTION 1 2 E 1 B 1 1 uri T NU PON 1 z 8 z BRN x bd bg 2 d BK BE s SET Ld BRN BRN BRN E F18 3 I I E 1 EE B FUSE 10A D E 55 WORKLIGHTONLY E gi isis 810 ie z 015 19 15 mi g 3 BK I o 5 mm ibis d E zm 5z g 5 55 9 210 xm Blo m m m imm 23 2 slo 119 2 lt m m w D 19 10 200 lt mg Br Ta sieg 5 HE m BI 2 jN s 5 1212 o yore 5 mme ee ly s lolo xy O o v o S E 8 8 mie geras B 5 9g 5 9 5 gt a amp 9 o 155255 EE gt lt 5 5 o gt iz a
386. SOR RELAY CONTROL 10 WHITE LT BLUE 18 3 TESI 53 PURPLE LT BLUE 18 BLACK 16 Scis E lt LT BLUEIDK BLUE 18 BLACK 16 _ 25 TAN ORANGE 18 OIL PRESSURE lt LT GREENIBLACK 18 REDMAN 16 MACH gt 56 GREEN 18 RED TAN 16 Mi 25 26 LTBLUEIBLACK 18 GROUND AU ANA PD2 47 BLACKWHITE 18 AUX QUT 1 29 PURPLE DK BLUE 18 FUEL SELECT 40 TAN BROWN 18 48 YELLOW DK BLUE 18 AUX ANA PU2 PINK TAN 18 34 GRAY DK BLUE 18 ET 15 WHITERRED 18 GASEOUSTRIM gt 43 BLUE PINK 18 TWIST WIRES 10 TURNS 350 DEGJFOOT FULL LENGTH 5 CAN 44 BLUE WHITE 18 CAN gt s DKGHEEN 18 gt RS 232 TX lt 52 ORANGE 18 OIL PRESSURE a 4 cott zr SENSOR PINK 18 ia 2 30 DK BLUE 18 gt 28 PURPLE YELLOW 18 5 gt 1 GREEN 18 ANARIN NS RED WHITE 18 H gt LT BLUEBLK 18 MIL C108ESL 1 LT GREEN RED 18 LTGREEN REDi8 vaer H SRS 1 STARTIN INTERUPT Ca3STR SURE GREEN E K START IN AUTOCRANKING ER MTRTWR10 1 BLK LT GREEN 18 DK GREEN ORANGE 18 m PINK DK GREEN 16 GREEN 18 mel BLACK 18 B 5 UTGREENRED 18 TWR DK GREEN 18 B MTRTWR4_EGO LTBLUEWHITE 18 AUXOUT2 ORANGE TS A ENGINE TEST SWITCH AUXIN PoI YELLOWILT GREEN T8 TACH COMM TAN BROWN 18 D FUEL SELECT C39LP 18 GOV S
387. SS Section 6 Schematics ss lt 8 ss wmrr T sFna a nEa srrs esas Platform Control Box Switch Panel Wiring Diagram S 65 Ford Models A PLATFORM CONTROL TO CONTROL BOX NOTE DASHED LINES INDICATE OPTION WIRES CE LIFT DRIVE OPTION REPLACE WIRE WITH CR27 amp CR30 Genie Part No 77828 WORK LIGHTS DLITE RD i NN ele ere ce ee a ee Da 3 JC2 OPTION ALARM LED JC3 OPTION BANE PRIMARY BOOM UP DOWN 7 zh JC1 7 QA FORWARD REVERSE amp TURNTABLE ROTATE BOOM TS15 8 STEER LEFT RIGHT DRIVE G D O I 125 LEFT RIGHT COMPONENT INDEX 6 6 ENABLE CR13 JIB BOOM CUT OUT RELAY TNT NE JC2 BOOM PROPORTIONAL JOYSTICK x 5 BOOM UP DOWN TURNTABLE ROTATE g z JC1 BOOM PROPORTIONAL JOYSTICK iz E 18 BOOM EXTEND RETRACT 4 4 JC3 DRIVE STEER PROPORTIONAL JOYSTICK I L1 DRIVE ENABLE LED 3 3 14 14 PLATFORM OVERLOAD LED pd PLATFORM 147 LOWER RETRACT BOOM LED _ bg CEON _ 148 BOOM TILTED LED 2 2 e 2 EMERGENCY STOP BUTTON al d P3 HORN SWITCH 1 Pd 1 i TS1 AUXILIARY POWER TOGGLE SWITCH
388. TRAVELALARM 5 LI OPTION Poi p 9 8 C26 1 C26 2 gt 2 WH RD E 4 lt LIPS C1B 6 5 23 C32BRK WH RD BRAKE RELEASE 8 8 28 1 28 2 T C29MS RD WH E C29MS RD WH CIP8 C1B 3 C5 24 Wi MOTOR STROKE N A z BL RD 5 5 8 C251 025 2 z CDE2 BL BK 1 11 C37SCW BL BK 1 11 C37SCW BL BK Prem 72 7 18 1 STEER RIGHT E RIVE ENABLE C36STCC BL C36SCC BL t RIGHT C1B 10 STEER EFE 23 x CDET BUWH g C241 242 t 4 gt Beg 1 BL g 66 03 6 C6TRF WH RD C3B 6 vour s 4 58 32 8 027 C3P 4 C4TRL WH C3B 4 C4TRL WH TURNTABLE ROTATE LEFT OR a RO 7219 C5TRR WH BK E WH BK e 8 lt lt G3P 5 2 5 cs TURNTABLE ROTATE RIGHT t C15 1 p lt B 1 E 9 TURNTABLE ROTATE P mS wit m zo 8 n C6TRF WH RD TURNTABLE ROTATE if FLOW CONTROL AVAVA C31 1 C31 2 a C12 1 C1PBU RD PRIMARY BOOM UP PRIMARY BOOM tDOWN C2PBD RD BK 7 i T PRIMARY BOOM DOWN i 5 C13 2 3 ES Bi 8 E e I lt AA agg B B vour s BK 2 Ex COREE lt gt gt 1 PRIMARY BOOM FLOW CONTROL RD C202 C292 SIE TUS 22 s 8P1 1 C3B 1 2 pwr
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391. WH p PRIMARY BOOM FLOW CONTROL Sie xop gt 1 6294 292 516 oH 5 1 C1PBU RD C3B 1 PWR 3 11 i 8 ig 2 12 C2PBD RD BK C3B 2 lt LOS 3 s lt lt C3P 3 RD WH C3B 3 8 0 1 30 2 Haze C3P 9 C9PER BK RD C3B 9 t C9PER BK RD Ji PRIMARY BOOM EXTEND RETRACT FLOW CONTROL 8 C8PBR BK WH C3B 8 i E gt gt lt E999 Kis lt face 7 ae 155 CABLE TENSION LIMIT SWITCH ES YEL x RD 8 Il 5 amp lt t 1 BOOM EXTEND EE 5 BOOM C37 1 C37 2 Ci 1 C16 2 pwmp 1 RETRACT i BRN 81 BK WH p 2 lt gt t Q E KW gt gt BOOM RETRACT __ x lt 5 x 17 2 iron 4 a al 29 BRN ss 9 42 rx C4P 4 C118LSR OR RD C4B 4 OR RD C38 3 BK WH C38 4 LS17 BOOM UP DOWN P24FS WH as SPEED REDUCTION LIMIT SWITCH Ew B 499 E s G4P 1 BL RD C4B 1 BL RD C931 BK WH C92 LSS DRIVE ENABLE LIMIT SWITCH P26ESTP BK StUx n 53 gt os N 8 CP 499 ge lt CH 2 WH LS1 PRIMARY BOOM 5 gus DRIVE LIMIT SWITCH 8 J1 EH WH 10 1 BK gt 10 2 LS2 PRIMARY BOOM UP ave DRIVE LIMIT SWITCH C40LS OR 2 2 OR x d u
392. WM5 01018 AUX PWM1 L BKO 12 2515 87 T GN 18 DG 18 26 OIL PRES AUX PWM3 SER 8 MIL CIG BESL go 16 16 18 FUEL PUMP C21 IGN pee PUMP AUX lt OLG 18 39 AUX OUTI C135 FP 816 wis m 18 7 FUEL ser 30 LP eee TON 18 27 AUX OUT 2 ponts T RS 232 WR18 m 018 3 RS232 C127 TSW INJECTOR CYL 2 FUEL PUMP R16 BNAB16 LPG WIPK 16 19 START IN AUTOCRANK PKIBK 16 PK BK 16 16 TEMPERATURE e 5 FUEL PUMP 135 FPs 1 ANART 15 1 HR BRWI8 2 REF 018 4 SUN Wisk 18 Pc nx FUEL RELAY INJECTOR CYL 4 81518 15 oS unuseo ines STARTER STARTER RELAY CAN LPG 18 7 lows SOLENOID TERMINATION L ash SA eie 16 16 LOCKOFF E22 kNock 8 LBPK16 30 CONNECTOR s weke Eia SENSOR DIAGNOSTIC CONNECTOR wie wie R LG 18 Lar 18 8 PK BK 16 PK BK 16 ALTERNATOR EPR INJECTOR CYL 1 CONNECTOR RELAYED POWER Genie A TEAEX Part No 77828 5 60 5 65 5 60 HC 6 13 February 2012 Section 6 Schematics M E Ford DSG 423 EFI Engine Wire Harness Section 6 Schematics February 2012 s Electrical Schematic S 60 GM 3 0L Models February 2012 Section 6 Schematics Electrical Schematic 5 60 GM 3 0
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394. _______ _ ggg 204 Day gy ea L Q o 22 49 Qzz ad HOLIMS AJA O IS 2 HM 2 Auvnixnv 1991 HOLIMS 4015 AON3OH3W3 Id LgitvEHO QH HM 2816190 QH HM i 2 8 6 149 tt m 1 uuo SL WYO 01 MSZ 52 52 30191534 HOLSISSY 31vioH INOZ H3ddn 3aviNunL WOOS AHVWIHd vH 91H Yok wyo S 52 HOLSISAHY 31v10H HO1SIS3H 1 NMOG dn ed woog blu 1 uuo S QU HM MSZ 6 35 S 60 5 65 5 60 HC Part No 77828 February 2012 Section 6 Schematics psg Ground Control Box Switch Panel Wiring Diagram S 60 Ford Models after serial number 11879 Section 6 Schematics February 2012 SSS SSS A Ii Platform Control Box Wiring Diagram S 60 Ford Models CWLITE WH 549 m 2398 50 lt C19JSV GR WH 57 J C19JSV GR WH C4P
395. a 05 10 avs T8L9 62 veso 5 620 JP Be 0 Nua 810 6 9 82 82 1v80zd ayadu vezo Jp o 0 2 810 11820 Maes 22 IHd xnvzzo x 20 ANNA a H 1951 09 20 2 9 sesoauHmusazo O HOLIMS SYNLWHAdWAL 1 1 2 Qd S SR 5 2 vz H3MOd LInodio ve Qd zuo 9Wsrau Pa HOLIMS Q4 mE 2 80 HM Laced Ma Jp 22 2 OL 90 Qd 4 20109215725 t WHO41V1d OL E a 58 5 s4938 iz H3MOd d 2 Q G7 WH HM 280 HM NOILZO lt gt 02 dudveoza Jp 02 H3MOd 2 5 02 8 193138 WOO8 T O 2870 ASP6LO nam 9 2 Bt WHO4 VId 81 O 9 8rO ME US 2 2 L dn amp ir 143131v108 WHO41V1d H 9 90 NPLLO x SL 2 P Osseo 8FO 074910 029 HO Marlo E z 18 31 WHOSLV Id Qd 2 80
396. a UF SPEED REDUCTION LIMIT SWITCH gt x m e em PAMFSWH _ 499 2 58 8 BL RD C4B 1 gt C94 w 9 2 race CP E 5 2 d LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK 2 2 d 99 a 3 g 2 LS1 PRIMARY BOOM 5 SUS 1 DRIVE LIMIT SWITCH 8 J1 F H WH BK C102 LS2 PRIMARY BOOM UP LIMIT SWITCH r k C40LS OR x t 8 Sige cil o o A MR 2215 59 BL BK BL BK 89 WH _ C37 4 wx gt o 1 LS5 CABLE TENSION LED g 5 5 m P134 RD oA C382 _ 1517 UP DOWN RUNS SPEED REDUCTION LIMIT SWITCH C14PLU OR 8 o 29 pown PLATFORM LEVEL 3 CI5PLD OR BK C4B 3 7 3 C15 t gt A s C204 20 2 8 CT4PEU OR il 1 PLATFORM LEVEL UP Rom 2 PLATFORM LEVEL t DOWN CISRED ORB 1 PLATFORM LEVEL DOWN 5 E 21 1 C212 N Q 5 C4P 6 C18JD PRR GR BK ime PLATFORM ROTATE P LEFT C17JU PRL GR I 5 B 23 1 C23 2 C18ID PRR GREK 1 PLATFORM ROTATE RIGHT IRIGHT CYJWPREGH Il PLATFORM ROTATE LEFT C224 C222 i eee 5 i C128 RD BK DESCENTALARMOPTION e 8 i 1 x 555 z 20 0 5 2e gig 5 8 cc m 6 51 A TER
397. after serial number 11879 Section 6 Schematics 1108 49098 N d 3 InGOW LYVLS NOLINDI 2 21 inva 55399 dWal OF 0L TY 2151 5 26007 1 e Q m 579 2 14 8 0000000 e O XINO 18530 OL 2 Aava 9 s Ot osea IH s s Q4 AND HMdXDY v in LUYIS Wi pue Q4 osea lt z
398. alancing orifice and flow percentages Pilot operated 3 position 3 way shuttle valve Differential sensing valve Solenoid operated proportional valve E Priority flow regulator valve T Solenoid operated 2 position 3 way directional valve 3000 psi 206 8 bar us Le 1 1 1 Counterbalance valve with pressure pilot ratio gt 2 position 2 Solenoid valve a Directional valve pilot operated 2 position 2 way Genie Part No 77828 5 60 d 2 position 3 way shuttle valve Brake Needle valve X Shut off valve S 65 S 60 HC Section 6 Schematics February2012 Ford Engine Relay Layout Ford LRG 425 EFI before serial number 14054 Power Relay F5 15A 4 15 20 F2 5A F1 30A Starter Relay Fuel Pump Relay Empty F1 10A F2 5A F3 10A F4 15A F5 15A Genie 6 4 S
399. alibrated Normal function except threshold for one or both directions is zero Calibrate valve thresholds Self clearing transient Drive brake valve High speed drive motor Valve Steer joystick Value at 5V Value too high Value too low Value at 0V Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Motor speed frozen in the low state Alarm sounds indicating fault Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected Power up controller with problem corrected Power up controller with problem corrected Not calibrated Joystick speed and direction frozen at zero and neutral Calibrate Joystick Just calibrated Initiate 1 second beep of alarm Self clearing transient Steer directional valves Part No 77828 Genie Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected S 60 S 65 S 60 Section 5 Fault Codes February 2012 FAULT CODES Ford LRG 425 EFI Engine How to Retrieve Ford Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel
400. alve CU ee 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 Pilot valve to diverter 35 40 ft lbs 47 54 Nm 4 Relief Charge pressure circuit 35 40 ft lbs 47 54 Nm 5 Check valve Prevents oil to generator 35 40 ft Ibs 47 54 Nm Co A TEREX COMPANY 4 60 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures 7 9 Traction Manifold Components MANIFOLDS The traction manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item 1 Relief valve 280 psi 19 3 bar Ts 2 Flow divider combiner valve WW Check valve mentes SS Check 5 Shuttle valve 3 position 3 way UU 6 Orifice 0 070 inch 1 78 mm VV Part No 77828 5 60 5 65 5 60 HC 2WD Function Torque Charge pressure circuit 30 35 ft lbs 41 47 Nm Controls flow to drive motors in forward and reverse 90 100 ft lbs 122 136 Nm s D
401. ance Procedure B 9 Check and Adjust the Engine RPM Ford and Deutz Models 5 2 RPM Adjustment Perkins Models Referto Maintenance Procedure A 11 Checkand Adjust the Engine RPM Perkins Models A TEREX Ct 4 36 5 60 5 65 5 60 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 coupler installed onto the pump splined shaft Type B flex plates combines the pump coupler as part of the flex plate which is installed onto the engine flywheel Type A flexplate with separate coupler Type B flexplate with coupler combined Part No 77828 February 2012 Section 4 Repair Procedures How to Remove the Flex Plate Deutz models 1 Removethe tailpipe bracket mounting fasteners from the engine bell housing 2 Supportthe drive pump assembly with an appropriate lifting device 3 Remove all of the engine bell housing fasteners 4 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 5 Remove the flex plate mounting fasteners Remove the flex plate from the flywhee
402. and interrupts power and an audio visual warning indication to alert the operator of the overload Part No 77828 Genie S 60 S 65 S 60 HC CHECKLIST C PROCEDURES The platform support subassembly utilizes two load support arms that are opposed in a full parallelogram link This isolates platform loads into a shear or vertical state which translates into a compressive load A spring in the parallelogram link supports this purely compressive load regardless 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 arm contacts a limit switch and thereby activating the overload signal When adjusted correctly the platform overload system will deactivate normal boom operation at platform capacity Note Perform this procedure with the boom fully retracted and in the stowed position and with the machine on a firm level surface Note Be sure that no load sense system faults exist prior to performing this procedure Note On a properly functioning machine the LEDs on both control modules located next to the ground control box should be off Note If your machine is equipped with any platform accessories or options they must be removed from the platform OR the weights of those options or accessories must be subtracted from the test weights to accurately calibrate the platform load sense system 1 Remove all weight t
403. apacity atthe center of the platform floor A TEREX COMPANY Move the platform down 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 load spring adjustment nut in a clockwise direction in 10 increments until the overload indicator light turns off and the alarm does not sound Proceed to step 8 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator light and alarm responds 6 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 at the platform and ground controls and the alarm does not sound Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10 increments until the overload indicator light flashes at both the platform and ground controls and the alarm sounds Proceed to step 7 Result The overload indicator lights are flashing atthe platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note The platform wi
404. ar or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist Y NR Checklist B Y NR A 1 Manuals and decals B 1 Inspect battery A 2 Pre operation inspection B 2 Inspect electrical wiring A 3 Functions tests B 3 Exhaust system A 4 Engine maintenance A 5 Filter condition indicator A 6 Oscillate axle Perform after 40 hours 7 30 service Perform every 100 hours 8 Inspect air filter GM models 9 Engine maintenance GM Ford and Perkins models A 10 Fuel filter separator Diesel models B 4 Inspect air filter Ford Deutz and Perkins models B 5 Oil cooler and fins Deutz models B 6 Tires and wheels B 7 Brake configuration B 8 Hub oil and Torque B 9 Engine RPM Ford and Deutz model B 10 Ground control override B 11 Directional valve B 12 Platform leveling A 11 Check engine RPM Perkins models A 12 Rotation bearing Perform after 150 hours B 13 Engine idle select B 14 Fuel select GM a
405. ard Spraying AWARNING 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 General Repair Process Identify symptoms Malfunction _ gt Troubleshoot discovered problem still exists Perform Return to b repair service problem solved Section 6 Schematics February2012 Electrical Symbols Legend ex Quick disconnect terminal TB21 WHT 21 at terminal T circuits connect Connection no terminal Circuits crossing no connection Diode Battery cM 15 Circuit breaker with amperage Coil solenoid or relay H1 Horn or alarm Flashing beacon L3 f LED FA 25A Fuse with amperage Starting aid glow plug or flame ignitor 153 Limit switch KS1 PLATFORM 1 GROUND I I I I L Key switch before serial number 22051 PRI Power relay 18715 3NI9N3 Toggle switch SPDT BAJI WHOd1V 1d Toggle switch DPDT Control relay contact normally open q Horn button normally open 2 OTS2 0 Oil temperature sw
406. are equipped with counterbalance valves to prevent movement in the event of a hydraulic hose failure How to Remove an Oscillate Axle Cylinder Note Perform this procedure on firm level surface 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 the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable until the boom is between the steer tires 2 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 A TEREX COMPANY 5 60 5 65 5 60 HC 3 Removethe pin retaining fasteners from the rod end pivot pin Use a soft metal drift to remove the pin 4 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder 5 Remove the pin retaining fasteners from the barrel end pivot pin Use a soft metal drift to remove the pin 6 Remove cylinder from the machine Crushing hazard The oscillate AWARNING cylinder could become unbalanced and fall if not properly attached to the overhead crane when removed from the mac
407. ate from the flywheel How to Install a Type A Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump Ford models Torque the flex plate mounting bolts in sequence to 14 ft lbs 19 Nm Then torque the flex plate mounting bolts in sequence to 20 ft Ibs 27 Nm GM models Torque the flex plate mounting bolts in sequence to 22 ft Ibs 30 Nm Then torque the flex plate mounting bolts in sequence to 31 ft lbs 42 Nm Deutz models Torque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Then torque the flex plate mounting bolts in sequence to 40 ft Ibs 54 Nm Perkins models Torque the flex plate mounting bolts in sequence to 49 ft Ibs 66 Nm Then torque the flex plate mounting bolts in sequence to 70 ft Ibs 95 Nm ENGINES GM models A TEREX COMPANY Part No 77828 S 60 5 65 5 60 HC Section 4 Repair Procedures February 2012 ENGINES 3 Install the pump coupler onto the pump shaft How to Install a Type B with the set screw toward the pump Leave the FI Plat appropriate gap between coupler and pump end ex ate plate for your engine 1 Install the flex plate onto the engine flywheel with the rubber vibration isolators towards the pump 2 Apply Loctite removable thread sealant to the flex plate fasteners and loosely install the fasteners 3 Deutz models Torque the flex plate mounting bolts in sequence to 28 ft Ibs 3
408. au o 8 wooa 199135 981 und z woog 951 gt 1951 35 AS 5 ay P u lt ala y T mic a o l mig I H313W o lt 39 1 51 59 gt s i WHO4LW1d 3NION3 spp MO3HO 6 GLZHM 2 2 i ss sus s sc sos esa 5 8 2 2 HOLIMS qu LSY i nw m 1551 HOLIMS 401 1 QH HM Z8 61HO QH HM 886LHO QH HM z i Yl WYO GL 1 1 WYO 01 MSZ 50151534 O uolsisau 31V1OH INOZ 3aviNunL WOOS AHVINIHd vH LLL Yok WYO S MSZ HOLSISSHY 1 HO1SIS3H STaVLNYNL J woog viH 1 wyo S Sc HH February 2012 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram S 65 Ford Models after serial nu
409. ault corrected 43 Turntable rotate Valve is operating Cycle power off flow control valve 12 Value too high outside of operational then on and 15 Value too low limits Alarm sounds problem should be indicating fault corrected Normal function Calibrate valve except threshold for thresholds one or both directions Self clearing transient 44 Drive enable toggle switch 21 Fault Drive enable function is inoperative Cycle power then on and problem should be corrected Genie S 60 5 65 5 60 HC Part No 77828 February 2012 Section 5 Fault Codes w scas T lt s P wKs wTVW FAULT CODES Value too high Value too low Value at 0V 5 Source 5 Error Type Condition Solution 51 Drive joystick 11 Value at 5V Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected Drive flow valve EDC Not calibrated Just calibrated Value too high Value too low Joystick speed and direction frozen at zero and neutral Initiate 1 second beep of alarm Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Calibrate joystick Self clearing transient Power up controller with problem corrected Not calibrated Just c
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411. beacon will operate with the engine running or not running 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Result The flashing beacon should be on and flashing 2 Move the function enable rpm select toggle switch to either side and activate the boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the switch is held down Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES 3 S 65 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 O Result The flashing beacon should be on and flashing 5 Press down the foot switch Move the boom control handle to the down position hold moment and then release it Result The descent alarm should sound when the control handle is held down 6 5 65 Press down the foot switch Move the jib boom toggle switch to the down position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down 7 Press down the foot switch Move the drive control handle off center hold for a mome
412. bracket to release it from the number 3 boom tube 18 While pushing the lower extend cable bracket towards the platform pull the extend cable mounting plate towards the pivot end of the boom 19 Secure the extend cable bracket and cables to the cylinder to prevent them from falling off when removing the cylinder 20 Remove the external snap rings from the extension cylinder pin at the pivot end of the boom 21 Use a soft metal drift to remove the pin 22 Tag disconnect and plug the boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 Part No 77828 A TEREX 5 60 5 65 5 60 HC MPANY BOOM COMPONENTS 23 Attach 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 number 2 boom tube 25 Carefully support and slide the extension cylinder out of the boom AWARNING Crushing hazard The extension cylinder could fall when removed from the boom if not properly supported Component damage hazard careful not to damage the cable break limit switch Component damage hazard careful not to damage the co
413. bruary 2012 Section 6 Schematics Ford LRG 425 EFI Engine Wire Harness lt A c I D C B A 6 361 R 16 361 16 361 16 361 16 361 16 i 7 555 T16 555 T 16 FORD 8 557 16 557 BR Y 16 9 558 BRLB 16 558 BR LB 16 5 42 10 556 W 16 556 W 16 7 pu INJECTOR 1 INJECTOR 43 INJECTOR 4 INJECTOR 2 CONNECTOR INJG 12 359 GY R 18 16 AUX OUT 2 gt 180 18 19 198 06 0 18 AUX PD1 NS 20 358 LG BK 18 3 15 lt 5 151 LB BK 151 LB BK 354 LG R 18 307 BK Y 18 150 DG W 18 16 114 LB Y 18 22 352 BR LG 18 23 360 BR PK 18 570 BK W 16 570 16 __570 BK W 16 570 BK W 16 5 AUX ANA PU1 FPP2 EGR PWM EGR RECIRC POWER GROUND 570 BK W 12 34 GROUND 16 R LG 18 16 R LG 18 570 BK W 16 2 570 BK W 16 570 BK W 16 POWER GROUND MAP CONN 18 359 GY R 18 2 570 BK W 16 4 R1 361 R 12 ANA RTN e 14 351 BR W 18 351 BR W 18 351 BR W 18 5 VOLT REF VSW CRANK CRANK CAM 3 16 R LG 18 33 350 GY 18 32 349 DB 18 35 452 GY R 18 359 GY R 18 ______ SSS 198 06 0 18 198 DG O 18 38 EGR ANA IN
414. cement 181 cu in 3 liters Number of cylinders 4 Bore amp stroke 4 x 8 6 inches 101 6 x 91 44 mm Horsepower Intermittent 67 2300 rpm 50 kW 2300 rpm Continuous 60 2300 rpm 45 kW 2300 rpm Firing order 1 3 4 2 Low idle 1650 rpm 386 Hz High idle 2500 rpm 585 Hz Compression ratio 9 25 1 Compression pressure minimum 100 psi Pressure psi or bar of lowest cylinder 6 9 bar must be at least 75 of highest cylinder Valve clearances Zero lash 1 full turn Lubrication system Oil pressure minimum 18 psi operating temp 2000 rpm 1 24 bar Oil capacity 5 quarts including filter 4 7 liters Cil viscosity requirements Below 0 F 17 8 C 5W 30 Above 0 F 17 8 C 10W 30 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Part No 77828 Genie S 60 S 65 5 60 HC SPECIFICATIONS Starter motor Normal engine cranking speed 350 rpm Current draw normal load 400A Current draw maximum load 600A Current draw minimum 100A Battery Type 12V DC Group 31 Quantity 1 Cold cranking ampere 09 1000A Reserve capacity 25A rate 200 minutes Electronic fuel pump Fuel pressure static 9 to 11 psi 0 6 to 0 76 bar Fuel flow rate 0 3 gom 1 14 L min Fuel requirement For fuel requirements refer to the engine Operator s Manual on your
415. ched Component damage hazard The cable track can be damaged if it is twisted Section 4 Repair Procedures February 2012 BOOM COMPONENTS How to Remove the Cable Track S 65 Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Openthe platform control box 2 Tagand disconnect the foot switch wiring from the terminal strip inside the platform control box Pull the wiring out of the platform control box Raise the boom to a horizontal position 4 Disconnect the wire connectors from the bottom of the platform control box Note When installing the wire connectors to the bottom of the platform control box match the color of the connectors to those on the control box to be sure they are installed in the correct location 5 Remove the mounting fasteners from the power to platform outlet box bracket Lay the outlet box and bracket assembly off to the side 6 Remove the hose and cable clamps from the platform support and jib boom A TEREX COMPANY 5 60 5 65 5 60 HC 7 Tag disconnect and plug the platform leveling slave cylinder hydraulic hoses from the bulkhead fittings on the side of the primary boom Cap the bulkhead fittings AWARNING sna injury hazard Spraying ydraulic oil can penetrat
416. conds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar 6 GMand Ford models Connect the LPG hose to the LPG tank and open the valve on the tank Move the fuel select switch to the gasoline position Perkins models Connectthe engine wiring harness to the fuel solenoid Deutz models Release the manual fuel shutoff valve 7 Startthe engine from the ground controls and check for hydraulic leaks TEREX COMPANY Part No 77828 S 60 5 65 5 60 HC 4 47 Section 4 Repair Procedures February 2012 sr This page intentionally left blank TEREX COMPANY 4 48 S 60 S 65 S 60 HC Part No 77828 February 2012 Section 4 Repair Procedures Manifolds 7 1 Function Manifold Components The function manifold is located underneath the ground controls side turntable cover Index Schematic No Description Item Function 1 Counterbalance valve m Platform level down 2 Counterbalance valve Platform level up 3 Proportional solenoid valve M Boom extend retract 4 Solenoid valve 2 position 3 way Boom retract 5 Solenoid valve 2 position 3 way Boom extend 6 Solenoid valve 3 position
417. consecutive times blinks 3 times and then 1 time That would indicate code 531 Note Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See How to Clear Engine Fault Codes from the ECM How to Clear Engine Fault Codes from the ECM Note Perform this procedure with the engine off and the key switch in the off position 1 Openthe engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Connectthe negative battery cable to the battery Part No 77828 February 2012 Section 5 Fault Codes Code 167 zr N N Part No 77828 Genie 5 60 5 65 S 60 HC FAULT CODES 212 IAT intake air temperature low voltage 213 IAT intake air temperature higher expected 1 214 IAT intake air temperature higher than expected 2 Pats o 221 engine cylinder head temp high voltage 222 engine cylinder head temp low voltage 223 224 ommeweencus 225 226 231 manifold absolute pressu
418. ctrostatic discharge ESD can damage printed circuit board components If the circuit board does need to be handled maintain firm contact with a metal part of the machine that is grounded at all times when handling the printed circuit board OR use a grounded wrist strap Genie 5 2 S 60 S 65 5 60 HC 3 Determine the error source The red LED indicates the error source and will flash two separate codes The first code will indicate the first digit of the two digit code flashing once per second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second Note When the red LED is flashing the code the yellow LED will be on solid 4 Determine the error type The yellow LED indidates the error type 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 Note When the yellow LED is flashing the code the red LED will be on solid 5 Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected Part No 77828 February 2012 Section 5 Fault Codes v r rhsas sa PartNo 77828 Genie FAULT CODES Error Source Error Type Condition Solution ID Name ID Name 21 Boom 1 Joystick 11 Value at 5V
419. d RD WH C7P 2 P23BAT WH C7B 2 be P134TTS RD 7 SENSOR T a 5 lt RSS a Sass SSS s p 5 o r B RD C1P 2 C28TTA RD BK 2 carm at ac P134FB WH FLASHING Neu Ne BEACONS OPTION z E e 2 5 C46HRN GR C2B 5 C46HRN GR HORN REPAV 1 d 7 1 P22BAT BK C7B 1 P22HRNBK R46HRN BK C6 9 3 g P134PWR GR BK B 8 HYDRAULIC OIL C2P 6 C2B 6 2 C54 _ TEMPERATURE SWITCH P134PWR RD G OPTION A 9 2215 p eneon 5 1 COOLING PH6HYDRD 8 S amp 78 L 9 107 WH 53575 c C5 8 gs ered iby pee pe m el gE 9i 89 respec T 21 5 LOL lt 5 89 pe ups 1 E 3 2592 884 1854 i u EST Ln EN a E Sog EAE 66 2158 4 E 56 2 45 E P20BAT RD h ss C7B 4 gt 2 gt 99 9 2 E amp N Part No 77828 5 60 5 65 5 60 6 26 Section 6 Schematics February 2012 Electrical Schematic S 60 Ford LRG 425 EFI Models before serial number 11880 A
420. d LRG 425 EFI Engine Specifications 2 6 Ford DSG 423 EFI Engine Specifications 2 7 Deutz F3L 2011 Engine 222 40 0 0 2 8 Perkins 404 22 Engine Specifications 2 10 Machine Torque Specifications 2 11 Hydraulic Hose and Fitting Torque Specifications 2 12 SAE and Metric Fasteners Torque 2 13 Genie vill 5 60 S 65 5 60 HC Part No 77828 February 2012 TABLE CONTENTS Section 3 Scheduled Maintenance Procedures 3 1 Pre Delivery Preparation 3 3 Maintenance Inspection Report menn 3 5 Checklist A Procedures A 1 Inspect the Manuals and Decals 3 7 2 Perform Pre operation Inspection 3 8 A 3 Perform Function 3 8 4 Perform Engine 3 9 A 5 Check the High Pressure Hydraulic Filter Condition Indicator 3 9 6 Test the Oscillate Axle 3 10 A 7 Perform 30 Day Service a 3 10 8 Inspect the Engine Air Filter GM 3 11 9 Perform Engine
421. d S 65 if equipped 5 Carefully move the test weight to each remaining location Refer to Illustration 1 O Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights on and the alarm is sounding Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System S 60 and S 65 if equipped Illustration 1 Part No 77828 CHECKLIST C PROCEDURES Using a suitable lifting device place an additional 50 Ibs 23 kg of weight onto the platform Result The alarm should sound The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System S 60and S 65 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 and the platform overload indicator lights are not
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423. d or connections OR replace sensor OR repair any vacuum and exhaust leaks OR replace fuel OR test and repair the fuel system components Repair short in engine wire harness OR test and repair the fuel system components S 60 S 65 S 60 Section 5 Fault Codes February 2012 FAULT CODES IAT High Voltage IAT Low Voltage IAT Higher Than Expected 1 IAT Higher Than Expected 2 Oil Pressure Low CHT ECT High Voltage CHT ECT Low Voltage CHT Higher Than Expected 1 CHT Higher Than Expected 2 IAT sensor wiring and or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too cold IAT sensor wiring and or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too hot Air intake temperature is greater than 200 with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty Air intake temperature is greater than 210 F with the engine greater than 1000 rpm OR air intake system has leaks OR sensor is faulty Faulty oil pressure sensor OR sensor wiring and or connections open or shorted OR engine oil level too low Engine cooling system is malfunctioning OR sensor wires and or connections open or shorted OR sensor is faulty Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant
424. d plug the hydraulic hoses from the slave cylinder Cap the fittings on the cylinder AWARNING 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 How to Bleed the Slave Cylinder Note Do not start the engine Use auxiliary power for this procedure 1 Simultaneously activate the boom up function and the platform level up function until the boom is fully raised 2 Simultaneously activate the boom down function and the platform level down function until the boom is fully lowered Part No 77828 February 2012 Section 4 Repair Procedures 2 2 2 5 60 HC Tag and disconnect the electrical Platform Rotator connector from the platform load sense module 3 disconnect and plug the hydraulic hoses The platform rotator is a hydraulically activated from the platform rotator manifold Cap the helical gear assembly used to rotate the platform fittings on the rotator 160degrees AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and How to Remove the burn skin Loosen hydraulic Platform Rotator connections very slowly to allow the oil pressure to dissipate Component damage hazard Mark gradually Do not allow oil to squirt the platform mounting weldment or spray and the rotator flange before removing t
425. de 2 i 4 5 5 lt i 8 AVTSY LUVLS VY NOLLINSI TuS 189 Part No 77828 NOTE DASHED LINES INDICATE OPTION WIRES A TEREK DSG S 60 S 65 S 60 HC 6 92 Section 6 Schematics 6 93 A TEREK DWG G S 60 S 65 S 60 Perkins 404 22 Models after serial number 11879 Ground Control Box Switch Panel Wiring Diagram S 60 February 2012 Part No 77828 T o 5 gt 5 0 S 16 lt 5 5 8 226 B 5E x55 u sx Za kes j zz FE 58 2605 la S E E gt gt mE Z e z 95 29 3 5 5 Sf lt u o O u 152050 29
426. delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Note Perform this procedure with the key switch in the off position 1 Openthe ground controls side cover and locate the run test toggle switch on the side of the ground control box 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Quickly activate and release the start toggle switch button Do not start the engine 4 Move and hold the run test toggle switch to the test position O Result The check engine light should turn on The check engine light should begin to blink 5 6 S 60 5 65 S 60 HC 5 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 123 three times After the fault codes the check engine light will blink a code 123 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a three digit code three times for each code stored in memory It will blink the first digit of a three digit code pause blink the second digit
427. e Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Perkins 400 Series Operation Manual Perkins part number TPD 14435 Perkins 400 Series Operation Manual Genie part number 94890 To access the engine 1 Removethe engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 77828 February 2012 Section Scheduled Maintenance Procedures Checklist C Procedures C 1 C 2 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 500 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual Deutz part number 0297 9929 Deutz FL 2011 Operation
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429. e and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports of the jib boom platform rotate manifold Cap the fittings on the manifold AWARNING siad injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Remove the hose and cable cover from the side of the jib boom 10 Locate all electrical cables under the boom at the pivot end that enter the cable track 11 Tag and disconnect the electrical connectors for all cables that enter the cable track 12 Remove the retaining fasteners from the electrical connector receptacles for the cables that enter the cable track Part No 77828 February 2012 Section 4 Repair Procedures 13 Carefully pull the cables and connector receptacles out of the primary boom 14 Tag disconnect and plug all hydraulic hoses that enter the cable track from the bulkhead fittings at the pivot end of the boom AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and BOOM COMPONENTS 19 Attach a lifting strap from an overhead crane to the cable track 20 Remove the mounting fasteners that attach the lower cable track to the boom 21 Carefully remove the cable track from t
430. e engine tray out and away from the machine Genie 5 60 5 65 S 60 HC 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury 3 Connect a tachometer to the engine and then start the engine from the ground controls and check the rpm Refer to Section 2 Specifications Skip to step 5 if the low idle rpm is correct 4 Loosen the low idle lock nut then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and recheck the rpm solenoid boot b high idle adjustment nut yoke lock nut d yoke e low idle adjustment screw f low idle lock nut Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures 5 Movethe function enable rpm select toggle Switch to the high idle rabbit symbol position at the ground controls and check the rpm Refer to Section 2 Specifications If high idle rpm is correct disregard adjustment step 6 6 Loosen the yoke lock nut then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Note Be sure the solenoid fully retrac
431. e in the Deutz FL 2011 Operation Manual Deutz part number 0297 9929 Deutz FL 2011 Operation Manual Genie part number 84794 E 3 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 12 000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual Deutz part number 0297 9929 Deutz FL 2011 Operation Manual Genie part number 84794 access the engine 1 Removethe engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Genie 5 60 5 65 S 60 HC To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and in
432. e non steer wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the steer tires 9 Liftthe wheels off the ground and then place jack stands under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub Section Scheduled Maintenance Procedures February 2012 CHECKLIST D PROCEDURES 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Raise the machine remove the jack stands and lower the machine AWARNING Collision hazard Failure to re engage the drive hubs may cause death or serious injury and property damage Genie 3 54 5 60 5 65 S 60 HC D 6 Replace the Hydraulic Filters Note Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic filters is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filters be replaced more often Bodily injury hazard Beware of hot ACAUTI
433. e overload system Boom range of motion is Calibrate the platform load sense limited system Just calibrated sod to clear diagnostic Self clearing codes Genie 5 60 5 65 S 60 HC Part No 77828 February 2012 Section 5 Fault Codes Load Cell Safety C94LDS Error Type Sensor tolerance fault Output short high Value too high Output short low Condition Power relays disengaged Power relays disengaged Load cell wiring open or shorted to voltage Power relays disengaged Load cell wiring open or shorted to voltage Platform may be overloaded Power relays disengaged Load cell wiring open or shorted to ground Platform may be reverse loaded Power relays disengaged Load cell wiring open or shorted to ground FAULT CODES Repair wiring and or connections OR replace platform load cell and calibrate overload system Repair wiring and or connections OR replace platform load cell and calibrate overload system Repair wiring and or connections OR replace platform load cell and calibrate overload system OR remove excess weight from platform Repair wiring and or connections OR replace platform load cell and calibrate overload system Check binding of the overload component linkage and be sure platform is not touching the ground or being supported from underneath Repair wiring and or connections OR replace platform load cell a
434. e right Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw AWARNING Cushing hazard Keep clear of the platform during rotation 7 Clean up any hydraulic oil that may have spilled 8 Rotate the platform fully in both directions and inspect the bleed screws for leaks TEREX 5 60 5 65 5 60 Section 4 Repair Procedures February 2012 PLATFORM COMPONENTS 2 3 Platform Overload System S 60 and S 65 if equipped How to Calibrate the Platform Overload System Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note For S 60 HC models refer to Repair Procedure 2 4 Platform Load Sense System S 60 HC Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an incorrect calibration 4 Using a suitable lifting device place a test weight equal to the maximum platform c
435. e the outlet box and lay it to the side A TEREX COMPANY 5 60 5 65 5 60 HC 5 Remove the hose and cable clamp from the platform support 6 Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold AWARNING 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 hoses from the bulkhead fittings on the side of the primary boom Cap the bulkhead fittings AWARNING injury hazard Spraying ydraulic 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 8 Locate all electrical cables under the boom at the pivot end that enter the cable track 9 Tagand disconnect the electrical connectors for all cables that enter the cable track 10 Remove the retaining fasteners from the electrical connector receptacles for the cables that enter the cable track Part No 77828 February 2012 Section 4 Repair Procedures 11 Carefully pull the cables and connector receptacles out of the primary boom 12 Tag disconnect and plug all hydraulic hoses that enter the cable track from the bulkhead fittings at the pi
436. ection 6 Schematics February 2012 Electrical Schematic S 65 Ford LRG 425 EFI Models from serial number 11880 to 14053 February 2012 Section 6 Schematics Electrical Schematic 5 65 Ford LRG 425 EFI Models from serial number 11880 to 14053 P22LS BK xxx ale cS 5 z z O 5 u amp lt gt 3 SIE amp 1 9 C35RPM BK RD C1B 9 K j OIL PRESSURE SPEED C25PSR WH BK m 8 SENDER OPTION P 5 VOLT METER 9 B LOWRPM FUNCTION ENABLE L B 8 C26TSR WH RD WATER TEMPERATURE HIGH RPM 4 gt i SENDER OPTION 5 2 UI I I I I RI I I RI I GENERATOR HYDRAULIC C2P 7 C45GEN GR WH C2B 7 C5 12 GR WH GENERATOR ig
437. edure be from the machine if equipped performed every 2000 hours or every two years whichever comes first Perform this procedure more 3 Models with hydraulic tank shut off valves often if dusty conditions exist Locate the two hydraulic tank valves at the hydraulic tank through the access hole Replacement or testing of the hydraulic oil is underneath the turntable Close the valves essential for good machine performance and service life Dirty oil and suction strainers may Component damage hazard The cause the machine to perform poorly and continued engine must not be started with the use may cause component damage Extremely hydraulic tank shut off valves in dirty conditions may require oil changes to be the closed position or component performed more often damage will occur If the tank valves are closed remove the key Note Before replacing the hydraulic oil the oil may from the key switch and tag the be tested by an oil distributor for specific levels of machine to inform personnel of the contamination to verify that changing the oil is condition necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note When removing a hose assembly or fitting im the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and
438. elder option 4 60 7 9 Traction Manifold Components 2WD 22 4 61 7 10 Valve Adjustments 2WD Traction Manifold 4 63 7 11 Traction Manifold Components 4 0 2 4 65 7 12 Valve Adjustments 4WD Traction Manifold 4 67 7 19 mh a oe rd d Eee 4 68 Turntable Rotation Components 8 1 Turntable Rotation Assembly 4 70 Axle Components 9 1 Oscillate Axle Cylinders 00 2 0000000 4 72 Genie Part No 77828 S 60 S 65 S 60 HC XIII February 2012 TABLE OF CONTENTS Section 5 Fault Codes Fault Codes Control System Fault Codes Ford LRG 425 EFI Engine Fault Codes Ford DSG 423 EFI Engine Fault Codes Platform Load Sense System S 60 HC Section 6 Schematics Electrical Symbols Legend Hydraulic Symbols Legend Ford Engine Relay Limit Switch Location Legend Electrical Schematic 5 60 HC from serial number 12800 Chassis Wiring Diagram 5 60 HC from serial number 12800
439. eo L 1 z ajo i 88 eet 8 y Lh L STARTER MOTOR ed 19 a eo Y lo in I 2 bese ell AUXILIARY a 2 t GETAUXRD n AUXILIARY POWER RELAY RI c 9 27AUX 1P 1 C1P 1 gt sis AUXILIARY PUMP 6 ee M C28TTA RD BK u X C28TTA RD BK Pera 1 1 RD BK BRN x WH C7P 2 P23BAT WH C7B2 4 P134TTSR RD I GEVEL SENSOR q e lt d o a N o gt NAY RD C1P 2 C28TTA RD BK CIP 2 UH NA z BK 2 5 C46HRN GR C2B 5 C46HRN GR CRN RELAY EJ y 2 a lt 7 1 _ 22 BK 7 1_ P22HRNBK R46HRN C6 9 GEN g 5 2 2 6___ 1 4 2 6 29 I HYDRAULIC OIL R21IGN WH gt C54 TEMPERATURE SWITCH Ne G OPTION C21IGN WH WE 9 o z5 8 C1160R C51 4 COOLING FAN e 4 3 OPTION 9 10 Ns On GM HARNESS GM HARNESS a P T 5 a TI le ais mis 684 Bs 2m J gcssesm A a al P20BAT RD r C7B4 1 J amp o a w T N LO Section 6 Schematics February 2012 GM 3 0L Models Electrical Schematic S 60
440. ep procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist C Y NR February2012 Checklist E Y NR C 1 Engine maintenance Deutz models 2 Grease platform overload S 60 and S 65 if equipped C 3 Test platform overload 5 60 5 65 if equipped 4 Test load sense 5 60 HC C 5 Fuel filter separator Perkins models C 6 Replace air filter Deutz and Perkins models Perform every 600 hours C 7 Engine maintenance Perkins models Perform every 800 hours C 8 Engine maintenance GM and Ford models Checklist D D 1 Boom wear pads D 2 Turntable bearing bolts D 3 Turntable bearing wear D 4 Drive hub oil D 5 Free wheel configuration D 6 Hydraulic filters 0 7 Air LPG mixture GM models D 8 Engine maintenance Deutz models Comments Genie E 1 Hydraulic oil Perform every 3000 hours E 2 Engine maintenance Deutz models Perform every 12 000 hours E 3 Engine maintenance Deutz models Perform every 10 years E 4 Replace the Boom Extend Retract cables S 60 S 65 5 60 HC Part No 77828 February 2012 Secti
441. epeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the boom to the stowed position and turn the machine off 12 Remove the dial indicator from the machine Genie 5 60 5 65 S 60 HC D 4 Replace the Drive Hub Oil Note 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 cause component damage 1 Selectthe drive hub to be serviced Then drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil 3 Drive the machine until one plug is at the top and the other is at 90 degrees a drive hub plugs 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side plug hole Refer to Section 2 Specifications 5 Install the plugs into the drive hub 6 Checkthe torque of the drive hub mounting bolts Refer to Section 2 Specifications 7 Repeatthis procedure for each drive hub Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures D 5 Check the Free wheel Configuration Note Genie specifications require that this procedure be performed every 1000 hours or
442. es 4 92 bar Tire pressure 85 psi Rough terrain tall tires 5 9 bar Tire pressure 60 psi Hi flotation tires 4 13 bar For operational specifications refer to the Operator s Manual Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 77828 5 60 5 65 5 60 HC 2 1 Section 2 Specifications February 2012 SPECIFICATIONS Performance Specifications Boom function speeds maximum from platform controls Jib boom up S 65 60 to 70 seconds Jib boom down S 65 40 to 50 seconds Boom up 60 to 70 seconds Boom down 60 to 70 seconds Boom extend 58 to 66 seconds Boom retract 53 to 62 seconds Turntable rotate 360 78 to 86 seconds boom stowed Turntable rotate 360 125 to 165 seconds boom raised or extended Platform rotate 160 8 to 12 seconds Braking distance maximum High range on paved surface 3 to 6 ft 0 9 to 1 8 m Drive speed maximum stowed position 2WD models 40 ft 6 2 sec 12 2 m 6 2 sec 4WD models 40 ft 7 6 sec 12 2 m 7 6 sec Drive speed maximum raised or extended position All models 40 ft 40 sec 12 2 m 40 sec Gradeability See Operator s Manual Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie 2 2 5 60 5 65 5 60 HC Part No 77828 Febr
443. es Section 5 highlighted in blue to view the update 6 35 6 56 6 104 Section 6 Schematic Page Genie Part No 77828 5 60 S 65 S 60 HC February 2012 REVISION HISTORY CONTINUED Revision Date Section Procedure Schematic Page Description REFERENCE EXAMPLES Kubota Engine Section2 Specifications Electronic Version A 6 B 3 C 7 Section3 Maintenance Procedure 3 2 6 4 9 1_Section 4_Repair Procedure Click on any procedure or page number Fault Codes Section 5 highlighted in blue to view the update 6 35 6 56 6 104 Section 6 Schematic Page Genie iv 5 60 S 65 S 60 HC Part No 77828 February 2012 wa Serial Number Legend Genie A TEREX BRAND Model S 60 Serial number 56005 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number 20186 Machine unladen weight 20 736lbs 9 406kg Foam Tires add 764 165 347 kg to weight Rated work load including occupants 500 Ib 227 kg Maximum number of platfrm occupants 2 Maximum allowable side force 15016 670 Maximum allowable inclination of the chassis Air Tires 2 deg Foam Tires 4 5 deg S60 05 1 2345 Maximum wind speed 28 mph 12 5 m s Maximum platform height 60 ft 2 in 18 3 m r Model Maximum platform reach 50 ft 4 15 3 m Sequence number Gradeability 45 Model year Country of manufacture USA This mac
444. essure Open or shorted wiring and or connections to MAP sensor OR sensor is faulty MAP Low Voltage Open or shorted wiring and or connections to MAP sensor OR sensor is faulty BP High Pressure MAP sensor is faulty OR ECM is faulty BP Low Pressure MAP sensor is faulty OR ECM is faulty Repair wiring and or connections to sensor OR replace MAP sensor Replace MAP sensor OR replace the ECM Crank Sync Noise Never Crank Synced At Start Camshaft Sensor Loss Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Genie Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor S 60 5 65 5 60 Part No 77828 February 2012 Section 5 Fault Codes FAULT CODES oe Ge sm Camshaft position sensor wiring and or Be sure system ground connections are in place Camshaft Sensor Noise connections open or shorted OR there is a poor and secure OR repair wiring and or connections system ground connection OR sensor is faulty to sensor OR replace sensor
445. est line and your machine reference point Refer to Section 2 Specifications Note The brakes must be able to hold the machine on any slope it is able to climb See B 7 Confirm the Proper Brake Configuration Note Select a test area that is firm level and free of obstructions 1 Mark atest line on the ground for reference 2 Startthe engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol then lower the boom into the stowed position Genie Part No 77828 S 60 5 65 5 60 HC 3 29 Section Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 16 Test the Drive Speed Stowed Position Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch s
446. esult The boom will automatically fully retract and then lower to the stowed position Push in the ground controls red Emergency Stop button to the off position then pull out the red Emergency Stop button to the on position to reset the system 3 44 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures 5 Replace the Fuel Filter Water Separator Perkins Models Note Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Regular replacement of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or hard starting and continued use may result in component damge Extremely dirty conditions may require this procedure be performed more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Open the engine side turntable cover and locate the fuel filter water separator on the bulkhead 2 Disconnect and plug the fuel supply hose from the fuel tank to the fuel filter water separator Part No 77828 Genie S 60 S 65 S 60 HC CHECKLIST C PROCEDURES 3 Loosen the vent
447. esult in death or serious injury 14 Loosen the vent plug on top of the fuel injection pump a vent plug b fuel injection pump c fuel lift pump 15 Operate the priming lever or priming bulb if equipped of the fuel lift pump until fuel free from air comes from the vent plug Tighten the vent plug 16 Clean up any fuel that may have spilled during this procedure 17 Operate the starter motor for intervals of 15 seconds until the engine starts Note It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation Note If the engine runs correctly for a short time and then stops or runs roughly check for air in the fuel system If there is air in the fuel system there is probably a leak in the low pressure side of the system 18 Swing the engine back to its original position and install the engine pivot plate retaining fastener Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures C 6 Replace the Engine Air Filter Element Deutz and Perkins Models Note Engine specifications require that this procedure be performed every 500 hours or every six months whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine
448. first Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure it is in the engaged position hh o brake disengaged position ar fj u brake engaged position Genie 5 60 5 65 S 60 HC 8 Check the Drive Hub Oil Level and Fastener Torque Note 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 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees a drive hub plugs 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the side plug hole 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Install the plug s into the drive hub 5 Checkthe torque of the drive hub mounting bolts Refer to Section 2 Specifications 6 Repeatthis procedure for each drive hub Part No 77828 February 2012 Section Scheduled Maintenance Procedures CHECKLIST B PROCE
449. form OR the weights of those options or accessories must be subtracted from the test weights to accurately calibrate the platform load sense system Part No 77828 February 2012 Section 4 Repair Procedures 15 Activate and release the calibration toggle Switch inside the ground control box 1 time O Result The alarm should sound for 1 second indicating the fifth calibration step was accepted The green LED on the operational controller should be blinking fast and the red LED should be blinking six times indicating that step 6 of calibration is next 16 Using a suitable lifting device place an additional test weight equal to 510 Ibs 231 3 kg on to the center of the platform floor The total weight in the platform must equal 1260 Ibs 571 5 kg 17 Activate and release the calibration toggle switch inside the ground control box 1 time O Result The alarm should sound for 1 second indicating the sixth calibration step was accepted The engine may turn off and the alarm may sound indicating an overloaded platform 18 At the ground controls push in the red Emergency Stop button to the off position then pull out the red Emergency Stop button to the on position to reset the system 19 Visually inspect the LEDs on the controllers Result LEDs on both controllers should be off indicating the platform load sense system is calibrated Part No 77828 A TEREX COM 5 60 5 65 5 60 HC PLATFORM COMPONE
450. g c zaver ad 2 a 4 va e 8 HOLIMS A33 eH ISA QUO 2 H3MOd OBICs 4018 1951 25180 ld Nua 5 1 WYO OL 215790 MSZ 9LH HWQH 1961 3885 YOLSISSY WOO INOZ WOOS g E 31V1OH 318v Q HOLSISSY AHVWIHd cun 1 6 ScHH enie G A TEREX DWG S 60 S 65 S 60 6 33 Part No 77828 February 2012 Section 6 Schematics Ei E EE E iZ ZEES Ground Control Box Switch Panel Wiring Diagram S 60 Ford LRG 425 EFI Models before serial number 11880 Section 6 Schematics February 2012 mr 25 Ground Control Box Terminal Strip Wiring Diagram S 60 Ford Models after serial number 11879 February 2012 Ground Control Terminal Strip Wiring Diagram 5 60 Ford Models after serial number 11879 Section 6 Schematics
451. gine Use auxiliary power for this procedure 1 Move the function enable toggle switch to either side and activate the platform rotate toggle Switch to the right then the left through two platform rotation cycles then hold the switch to the right position until the platform is fully rotated to the right Before serial number 9154 2 Connect a clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Secure the container to the boom 3 Openthe top bleed valve on the rotator but do not remove it a bleed b bottom bleed valve container d clear hose Part No 77828 February 2012 Move the 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 valve Close the bleed valve AWARNING Crushing hazard Keep clear of the 5 platform during rotation Connect the clear hose to the bottom bleed valve and open the valve Do not remove the bleed valve Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right Continue holding the toggle switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the 7 p
452. gine Air Filter Ford Deutz and Perkins Models Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the engine air filter in good condition is essentialto good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Locate the engine air filter assembly 2 Release the latches from the air cleaner canister end cap Remove the end cap Remove the filter element 4 Clean the inside of the canister and the end with a damp cloth 5 Inspect the air filter element If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust Replace the filter if needed Install the filter element Install the air filter canister end cap and secure the end cap latches Note Be sure the discharge valve is pointing down when the cap is instaled Genie 5 60 5 65 S 60 HC 5 Check the Oil Cooler and Cooling Fins Deutz Models Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the oil cooler in good condition is essential for good engine performance Operating a machine with a damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the perf
453. has flashing LEDs Note If the LEDs are flashing on both controllers determine the fault code on one controller at a time 4 Determinethe 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 Determine the error type The green LED indicates the error type 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 Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected il VEEN UD 4s Via lo of ith MES N 1 green LED operational control module red LED operational control module operational control module safety control module red LED safety control module green LED safety control module S 60 S 65 S 60 HC Part No 77828 February 2012 Safety envelope reached Power relays disengaged Platform load greater than 1250 pounds Power relays di
454. he machine and place it on a structure capable of supporting it 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 track guide at the platform end of the boom Remove the cable track guide from the boom 18 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and AWARNING lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine AWARNING Crushing hazard The cable track could become unbalanced and fall if not properly attached to the overheadcrane Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Component damage hazard The cable track can be damaged if it is twisted A TEREX COMPANY Part No 77828 5 60 5 65 5 60 HC Section 4 Repair Procedures February 2012 BOOM COMPONENTS How to Repair the Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Pa
455. he O ring before installation 3 sure that face seal O ring 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 per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Loke Fittings tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft Ibs 21 7 Nm 4 18 ft Ibs 25 Nm 6 35 ft Ibs 47 5 Nm 6 30 ft Ibs 40 Nm 8 60 ft Ibs 81 3 Nm 8 40 ft Ibs 55 Nm 10 105 ft Ibs 142 4 Nm 10 60 ft Ibs 80 Nm 12 140 ft Ibs 190 Nm 12 85 ft Ibs 115 Nm 16 210 ft Ibs 284 7 Nm 16 110 ft Ibs 150 Nm 20 260 ft Ibs 352 5 Nm 20 140 ft Ibs 190 Nm 24 315 ft Ibs 427 1 Nm 24 180 ft Ibs 245 Nm Genie S 60 5 65 S 60 HC Part 77828 February 2012 Section 2 Specifications SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this THREAD Grade 8 62 574 High Strength LUBED Black Oxide Bolts DRY LUBED 140 130 14 7 160 140 15 8 DRY LUBED 41 5 25 339 28 4 27 36 6 44 59 6 49 66 4 70 94 7 108 4 110 149 12 120 150 170 210 240 380 420 420 610
456. he 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 Startthe engine from the platform controls and allow it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle Genie 3 28 5 60 S 65 5 60 HC Part 77828 February 2012 Section 3 Scheduled Maintenance Procedures B 15 Test the Drive Brakes Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational AWARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration CHECKLIST B PROCEDURES 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 6 Measure the distance between the t
457. he platform mounting 4 65 Support the jib boom leveling arms and weldment The platform mounting the platform mounting weldment with an weldment must be replaced in the appropriate lifting device Do not apply any exact same position on the rotator lifting pressure flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to 5 Remove the mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator the left and then installing the AWARNING Crushing hazard The platform platform mounting weldment all the mounting weldment could become way in the left position unbalanced and fall if not properly supported when removed from the Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the s hose end must be replaced All connections must 6 Supportthe platform rotator with an appropriate be torqued to specification during installation Refer lifting device Do not apply any lifting pressure E S 60 Section 2 Hydraulic Hose and Fitting Torque Specifications 7 Supportthe rod end of the platform leveling 1 Remove the platform and platform support idi cylinder Protect the cylinder rod from amage Note S 60 HC If the load sense components are disassembled and or removed from the platform support the platform
458. he wood block Do not rest the entire weight of the boom on the block Turn the machine off Component damage hazard The turntable covers can become damaged if the weight of the boom is allowed to rest on the block 6 Place wood blocks between the short link arm and the turntable weldment for support 7 Attach lifting straps from a 5 ton 5000 kg overhead crane to each end of the boom Support the boom Do not apply any lifting pressure 8 Support and secure the rod end of the boom lift cylinder to a second overhead crane or similar lifting device 9 Remove the lift cylinder rod end pivot pin retaining fasteners Use a soft metal drift to remove the pin The boom could fall if not properly AWARNING supported when the lift cylinder rod end pivot pin is removed 10 Using auxiliary power activate the boom down function so the cylinder will retract Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom Turn the machine off AWARNING Crushing hazard The boom lift cylinder could fall if not properly supported and secured to the lifting device Part No 77828 February 2012 Section 4 Repair Procedures 11 Using the overhead crane carefully lower the boom lift cylinder and allow it to rest on the boom rest pad Protect the cylinder rod from damage 12 S 60 and S 65 Remove the boom end cover retaining fasteners and remove the cover 5 60 HC Remove
459. hine Part No 77828 February 2012 Section 5 Fault Codes Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on firm level surface Boom in stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock Key switch the off position with the key removed Wheels chocked All external AC power disconnected from the machine Part No 77828 Genie S 60 S 65 5 60 HC 5 1 Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie 5 60 and 5 65 Operator s Manual or the Genie S 60 HC Operator s Manualon your machine Be sure that all necessary tools and test equipment are available and ready for use Readeach appropiate fault code thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic
460. hine complies with ANSI 92 5 CAN B 354 4 Terex South Dakota Inc 500 Oak Wood Road PO Box 1150 Watertown SD 57201 Serial label USA located under cover Serial number tamed oncai 77055 Genie Part No 77828 S 60 S 65 S 60 HC V Section 1 Safety Rules February2012 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie S 60 and Genie S 65 Operator s Manual or the Genie 5 60 Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Genie vi 5 60 5 65 S 60 HC Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the follo
461. hone 0800 180 9017 Phone 0049 4221 491 821 Fax 0049 4221 491 820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Singapore Phone 65 67533544 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 82 2 558 7267 822 558 3910 Genie U K 0044 1476 584 333 0044 1476 584 330 Brasil Phone 55 11 4082 5600 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 31 183 581 566 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm
462. hread sealant on the threads 17 Install the drain plug using a thread sealant on the threads Part No 77828 Genie S 60 S 65 S 60 HC CHECKLIST E PROCEDURES 18 Install the hydraulic return filter housing onto the hydraulic tank 19 Install the hydraulic tank onto the machine 20 Install the two suction hoses to the suction strainers 21 Install the supply hose for the auxiliary power unit and the return filter hose 22 Models with hydraulic tank shut off valves Open the two hydraulic tank valves at the hydraulic tank 23 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 24 Clean up any oil that may have spilled 25 Prime the pump Refer to Repair Procedure 6 2 How to Prime the Pump Note Always use pipe thread sealant when installing the suction hose fittings and the drain plug Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST E PROCEDURES E 2 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 3000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are availabl
463. i e 5 hs g a 9 8 C34SA BK WH C34SA BKWH C5 22 GioW PLUG RELAY 2 5 GLOW PLUG b ES atow X GLOW PLUG PLUG X 000 lt 5 a lt C26TSR WH RD OIL TEMPERATURE LED a Sse 2 StS 258 gt 2 I Bub eR 0 1 7 C33STRBK 7 amp gt 5 14 lt 4 OIL TEMPERATURE SWITCH ENGINE i START b 6 e lt S 8 F ENGINE P se sineret C5 16 e s lt OIL PRESSURE SWITCH 3 t C25PSR WH BK a S ne lt 8 4 E B g o POWER RELAY e e B us I o op C21IGN2 WH 5 11 2 5 e 9 Jt FUEL SOLENOID a 9 a 4 1 1 C27AUX RD C1B 1 N S HOUR METER 88 E IGN START RELAY wa 4 ARA 8 R33STR 5 5 d 8 mS a i ME l _ STARTER MOTOR T 2 S 4 EMISSION CONTROL a gp AUXILIARY 5 gt REUME RD MD n 4 SPEED REDUCTION RELAY a E d C27AUX RD Q 7 RELAY 8 C7B 2 AUXILIARY POWER S QN af EC S o o 8 33 AUXILIARY PUMP lt I amp 1 2 WH 1 ui To RD BK EE C1B 2 8 m 38 C28TTA RD BK NS N
464. ial number 11879 Section 6 Schematics February2012 p mec Electrical Schematic S 65 CE Models Deutz F3L 201 1 Models before serial number 11880 2215 February 2012 C Deutz F3L 201 1 Models before serial number 11880 Electrical Schematic S 65 CE Models Section 6 Schematics 55 gg S o m u e 5 EB C35RPM BK RD C1B 9 8 FOOTSW HIGH e e FooTsw Low Es 28 5 x oe 8 g E LOW RPM FUNCTION ENA B BK RD BRN t HIGH IDLE RELAY I 5 HIGH RPM SOLENOID
465. 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 to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the caps be inspected more often Note Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Remove the cap from the fuel tank 2 Checkfor proper venting O Result Air passes through the fuel tank cap Proceed to step 4 W Result If air does not pass through the cap clean or replace the cap Proceed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap Part No 77828 Genie S 60 S 65 S 60 HC CHECKLIST B PROCEDURES 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 4 Install the fuel tank cap onto the fuel tank 5 Remove the breather cap from the hydraulic tank 6 Check for proper venting Result Air passes through the fuel tank cap Proceed to step 8 W Result If air does not pass through the clean or replace the cap Proceed to step 7
466. imit sss see _ Fen eem ez m 615 Part 77828 February 2012 Section 5 Fault Codes Code 648 omano 11 memes 13 menses 14 U 15 21 NN 22 smera 23 31 ______ A M SERE ol m G G CO OJORA OIN gt N A FAULT CODES 62 n 1629 U 1630 reser For further engine fault code troubleshooting and diagnostic information refer to the Ford DSG 423 EFI Service Manual EDI part number 1060040 Genie Part No 77828 S 60 S 65 S 60 Genie part number 119494 Ford DSG 423 EFI Operator Handbook Genie part number 119488 5 15 Section 5 Fault Codes February 2012 FAULT CODES Platform Load Sense System S 60 HC How to Retrieve Platform Load Sense System Fault Codes Note Perform this procedure with the engine off the key switch turned to ground controls and the red Emergency Stop buttons pulled out to the on position at both the ground and platform controls 1 Openthe ground controls side turntable cover 2 Locate the operational and safety controllers near the ground control box 3 Determine whether a safety or operational fault exists by visually inspecting which controller
467. inder 8 Install the boom extend cable clevis pins and rue rings to the pivot plate near the cable break limit switch 9 Install the boom extend cables to the lower extend cable bracket that mounts to the number 3 boom tube A TEREX COMPANY Part No 77828 S 60 5 65 5 60 HC Section 4 Repair Procedures February 2012 BOOM COMPONENTS Boomretract cables 10 Remove the cotter pins and clevis pins from the boom retract cables at the platform end of the boom Note Always use a new cotter pin when installing a clevis pin 11 Remove the wear pad fasteners from the upper wear pads on the number 1 boom tube Remove the wear pads Note Pay attention to the location of each wear pad and the quantity of shims for each one 12 Attach a lifting strap from an overhead crane to the platform end of the boom 13 Raise the boom using the overhead crane and place a wood block under the number 2 boom tube between the number 1 and number 2 boom tubes for support This will create clearance between the boom tubes to remove the retract cables 14 Attach the cable pulling tool or a rope to one of the boom retract cables at the pivot end of the boom Note A cable pulling tool is available through Genie Parts Department Genie 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 Discard the old boo
468. injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 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 A TEREX COMPANY 5 60 5 65 5 60 HC 4 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The boom will fall if not properly supported when the primary boom rod end pivot pin is removed 5 Using auxiliary power activate the boom down function so the cylinder will retract Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom Turn the machine off 6 Tag disconnect and plug the boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 Remo
469. ip Wiring Diagram S 65 Perkins 404 22 Models before serialnumber 11880 FUNCTIONS HARNESS E 5 957 HOLINS NOISN3L 318vO 51 HOLIMS 1 woog 22319 eit 61 81 79855 6 8 19 WHOALV1d OL H6 ONLY 29099 JINGOW LYVLS NOLINDI HOA 2 21 33 HO dW31 OF o C 6 6 m 1 59 zoian 8 135314 MS AIA OL 4 L GH A 9 91 G4 S s s G4 reds HMd XNY t v O4 naa T INANI LUYIS glo H3l3WOHOVL Z lt z 5225 LUVLS OG 2 m seujsnpu H
470. ircuits Check Power Ground and CAN circuits at Megavector and all connections and repair as necessary OR has an internal fault Contact Ford Power Products for assistance Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 Repair wiring and or connections to ignition coil 2 OR replace ignition coil 2 If this fault appears on your machine contact the Genie Industries Service Department Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 1 Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 2 Be sure engine harness wiring and connections are in place and secure OR repair wiring and or connections to one or both TPS sensors OR replace one or both TPS sensors Repair wiring and or connections to governor actuator OR replace the governor actuator Repair wiring and or connections in engine harness OR replace the ECM 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 5 Fault Codes FAULT CODES Ge sn Max Governor Speed Override ECM needs to be re programmed OR throttle is 552 FPP1 Low Voltage sticking open OR there are air leaks between the throttle body and cylinder head 553 FPP1 Higher than 5 Limit 611 COP Failure
471. is procedure be performed every 1000 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual Deutz part number 0297 9929 Deutz FL 2011 Operation Manual Genie part number 84794 access the engine 1 Removethe engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury CHECKLIST D PROCEDURES Genie Part No 77828 S 60 S 65 S 60 HC Section 3 Scheduled Maintenance Procedures 2012 Checklist E Procedures E 1 1 GM and Ford models Turn the valve on the LPG tank clockwise to the off position if Test or Replace the Hydraulic Oil equipped Then slowly disconnect the hose from the LPG tank 2 Ford models Open the clamps from the LPG tank straps and remove the LPG tank Note Genie requires that this proc
472. is not operating properly OR is faulty The ECM doesn t get any response from the Check CAN circuits for continuity and shorts to MegaJector or an incorrect response for 500ms power or ground and for continuity and repair as period or longer necessary OR replace the MegaJector MegaJector Communication Lost The Megavector detects voltage greater than 18 volts for 5 seconds anytime the engine is cranking or running MegaJector Voltage Supply High Repair charging system OR replace the Megavector The Megavector detects voltage less than 9 5 volts Repair VBAT power or ground circuit to ECM and for 5 seconds anytime the engine is cranking or MegaJector OR replace battery OR repair running charging system OR replace the MegaJector Voltage Supply Low Genie Part No 77828 S 60 5 65 5 60 HC 5 9 Section 5 Fault Codes February 2012 FAULT CODES Code MegaJector Internal Circuitry Fault Detection MegaJector Internal Communication Fault Detection Coil Driver 1 Open Coil Driver 2 Open TPS1 Signal Voltage High TPS1 Signal Voltage Low TPS2 Signal Voltage High TPS2 Signal Voltage Low TPS1 Higher than TPS2 TPS1 Lower than TPS2 Throttle Unable to Open Throttle Unable to Close Governor Interlock Failure The Megavector detects an internal communications failure Open or short in power ground or CAN circuits Open wiring and or c
473. itch normally open n CTS1 0 Coolant temperature switch normally open OPS1 N C Oil pressure switch normally closed Gauge sending unit PULL IN SS HOLD Fuel or RPM solenoid FS1 BLK Foot switch P1 a 1 1 1 K Emergency Stop button normally closed Hydraulic oil cooling fan Auxiliary pump 510 Q Resistor with ohm value Tilt sensor M Key switch after serial number 22050 Genie 5 60 5 65 5 60 Part No 77828 February 2012 Section 6 Schematics Hydraulic Symbols Legend 25 psi 1 7 bar TIS T lt gt 0 89 mm us I X Orifice with size gu Solenoid operated 3 position 4 Filter with 4 way directional valve proportional directional valve bypass valve lt D relief setting C Pump fixed displacement z Pum bi directional variable displacement s bi directional aos Motor 2 speed bi directional E Pump prime mover engine or motor Double acting cylinder Check valve 1 200 psi 13 8 bar 1 e NE Relief valve with pressure setting Directional valve mechanically activated 50 50 Flow divider combiner valve with pressure b
474. ive 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 296 increments 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 O 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 14 Cycle the red Emergency Stop button off then back on Section 4 Repair Procedures PLATFORM CONTROLS How to Adjust the Joystick Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Perform this procedure 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 Turn the key switch to platform control Do not start the engine Push in the platform controls red Emergency Stop button to the off position Do not press down the foot switch Move and hold the drive enable toggle switch in the right position and p
475. k calibration 8 Repeatthis procedure for each joystick controlled machine function including the thumb rocker steer switch Note No machine function should operate while performing the joystick calibration procedure A TEREX COMPANY Part No 77828 S 60 5 65 5 60 HC 4 3 Section 4 Repair Procedures February 2012 PLATFORM CONTROLS How to Adjust the Joystick Threshold Setting The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate 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 start the engine 3 Pushin 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 8 times Result There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode 8 Startthe engine from the platform controls and press down the foot switch 9 Select a boom function joystick to set the
476. l ENGINES GM models 1 Remove the muffler clamp at the exhaust pipe 2 Remove the muffler bracket to bell housing fasteners Remove the muffler and bracket assembly 3 Disconnect the electrical connector for the crankshaft position sensor located at the bottom of the bell housing 4 Supportthe engine with a suitable lifting device Do not lift it 5 Remove the engine plate to vibration isolator fasteners 6 Remove the engine mounting plate to bell housingfasteners Componentdamage hazard The engine could fall and the crankshaft position sensor can become damaged if the engine is not properly supported when the fasteners are removed 7 Slidethe engine mounting plate towards the pump as far as it will go 8 Supportthe drive pump assembly with an appropriate lifting device 9 Remove all of the engine bell housing fasteners 10 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked orpinched 11 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel A TEREX COMPANY Part No 77828 S 60 5 65 5 60 HC 4 37 Section 4 Repair Procedures sua 5 LRG 425 EFI models 1 Disconnect the electrical connector for the oxygen sensor at the tailpipe Do not remove the oxygen sensor Remove the engine oil dipstick fasteners from the muffle
477. l switch to foot Switch activated low idle turtle symbol Result The engine should change to low idle Genie 5 60 5 65 5 60 HC 8 07 Section 3 Scheduled Maintenance Procedures February2012 CHECKLIST PROCEDURES B 14 4 Release the foot switch and shut the engine off w b hing in th E t tton i Test the Fuel Select Operation to the off position GM and Ford Models 5 Move the fuel select switch to LPG 6 Restart the engine and allow it to run at low idle Note Genie specifications require that this 7 Press down the foot switch to allow the engine procedure be performed every 250 hours or to run at high idle quarterly whichever comes first O Result The engine should start promptly and The ability to select and switch between operate smoothly in low and high idle gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made when the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Note The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running Note Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Att
478. latform during rotation Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled Rotate the platform fully in both directions and inspect the bleed valves for leaks After serial number 9153 2 Place a suitable container underneath the platform rotator Open the top bleed screw on the rotator but do not remove it AWARNING 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 Part No 77828 Section 4 Repair Procedures PLATFORM COMPONENTS 4 Move the 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 AWARNING Crushing hazard Keep clear of the platform during rotation 5 Open the bottom bleed screw on the rotator but do not remove it AWARNING 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 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to th
479. level is low Coolant temperature at the cylinder head is 240 F Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Coolant temperature at the cylinder head is 250 F Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low System Voltage Low Battery is faulty OR alternator is not charging OR Replace battery OR repair alternator OR repair y 9 battery supply wiring to is open or shorted battery supply wiring to ECM Alternator is overcharging the battery when System Voltage High engine RPM is greater than 1500 rpm Repair or replace the alternator Repair wiring and or connections OR replace sensor OR direct warmer air into air intake Repair wiring and or connections OR replace sensor OR direct cooler air into air intake Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor Replace oil pressure sensor OR repair sensor wiring and or connections OR fill engine oil level to specification Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification MAP High Pr
480. ll compress until when the platform is overloaded the lower arm contacts a limit switch and thereby activating the overload signal When adjusted correctly the platform overload system will deactivate normal boom operation at platform capacity Note Perform this procedure with the boom fully retracted and in the stowed position and with the machine on a firm level surface 1 Remove all weight tools and equipment from the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Start the engine from the ground controls and level the platform Do not turn the engine off 3 Determine the maximum platform capacity Refer to the machine serial plate Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures 4 Using a suitable lifting device place a test weight equal to that of the available capacity one of the locations shown Refer to Illustration 1 O Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Proceedure 2 3 How to Calibrate the Platform Overload System S 60 an
481. ll need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator lights and alarm responds 4 12 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures 7 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 8 Result The overload indicator lights are flashing atthe platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note There may be a 2 second delay before the platform overload indicator light and alarm responds 8 Add an additional 10 Ib 4 5 kg test weight to the platform O Result The overload indicator light is flashing at both the ground and platform controls and the alarm is sounding 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 Ib 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 Testall machine functions from the platform controls Result All platform control functions should not operate 10 Turn the key switch to ground cont
482. load sense system will need to be calibrated See 2 4 How to Calibrate the Platform Load Sense System S 60 HC Genie A TEREX COMPANY Part No 77828 S 60 5 65 5 60 HC 4 9 Section 4 Repair Procedures February 2012 PLATFORM COMPONENTS 8 Remove the pivot pin retaining fasteners from both the slave cylinder rod end pivot pin and the rotator pivot pin 9 Use a soft metal drift to remove both pivot pins Remove the platform rotator from the machine Crushing hazard The platform ACAUTION rotator may become unbalanced and fall if not properly supported Note When installing the platform rotator fasteners torque the fasteners to specifications S 65 7 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins Do not remove the pins 8 Supportthe jib boom leveling arms 9 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine Bodily injury hazard The jib boom ACAUTION leveling arms may fall if not properly supported 10 Lower the jib boom leveling arms Crushing hazard The platform ACAUTION rotator may become unbalanced and fall if not properly supported Note When installing the platform rotator fasteners torque the fasteners to specifications A TEREX COMPANY 5 60 5 65 5 60 HC How to Bleed the Platform Rotator Note This procedure will require two people Do not start the en
483. ls before serial number 11880 2215 February 2012 Deutz F3L 201 1 Models before serial number 11880 Electrical Schematic S 60 CE Models Section 6 Schematics amp 55 gg cla a m u amp a E Es a s 9 C35RPM BK RD C1B 9 8 FOOTSW HIGH dj FoorSw Low ES 28 E ou b Za e S LOWHPM E a HIGH RPM BK RD d BRN HIGH IDLE RELAY 2 g eee 65 18 HIGH RPM SOLENOID T2 8 o go SSeS a C gt C cc 4 3 T T 5 C2P 7 C45GEN GR WH C2B 7 z GR WH 05 12 JAGENERATOR OPTION P
484. luding filter 8 8 liters Cil viscosity requirements Below 86 30 5W 20 4 F to 104 F 20 C to 40 10W 30 Above 14 F 10 15W 40 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Cil 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 requirement For fuel requirements refer to the engine Operator s Manual on your machine Alternator output 55A Q 12V DC Fan belt deflection 3 8 in 10 mm Starter motor Current draw no load 90A Brush length new 0 7480 in 19 mm Brush length minimum 0 5 in 12 7 mm Part No 77828 February 2012 Section 2 Specifications m SPECIFICATIONS Battery Machine Torque Specifications Type 12VDC platform rotator Size 13 x 613 16 x 93 8 inches center bolt GR 8 480 ft lbs 33 x 17 3 x 23 8 cm 651 Quantity 1 38 16 bolts GR 8 44 ft lbs Cold cranking ampere 1000A 60 Nm Reserve capacity 25A rate 200 minutes Drive motor and hubs Engine coolant Drive hub mounting bolts lubricated 160 ft Ibs 217 Nm it 7 7 quarts Capacity Drive motor mounting bolts lubricated 55 ft lbs 7 3 liters 75 Nm Coolant temperature sending unit Turntable bearing Temperature switch
485. m retract cable 4 34 5 60 5 65 5 60 HC 17 Remove the rope from the old cable and 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 new cable towards the pivot end of the boom until the end of the cable is at the end of the boom tube Remove the rope 20 Repeat steps 14 through 19 for the other boom retract cable 21 At the platform end of the boom install the retract cables clevis pins and new cotter pins to the adjustment plate 22 Remove and discard the old boom retract pulleys from the pivot end of the boom extension cylinder 23 Install the new boom retract pulleys to the pivot end of the boom extension cylinder 24 Install the boom extension cylinder assembly into the boom Note Before lowering the extension cylinder into the saddles of the number 1 boom tube wrap the boom retract cables around the pulleys 25 Adjust the boom extend retract cables See 4 5 How to Adjust the Boom Extend Retract Cables Part No 77828 February 2012 Section 4 Repair Procedures as BOOM COMPONENTS 4 6 5 Place a rod through the rod end pivot pin and Platform Leveling twist to remove the pin Lower the rod end of the master cylinder onto the block Master Cylinder 6 Remove the pin retaining fastener from the barrel end pivot pin The master cylinder acts as a pump for the
486. machine Ignition system Spark plug type AC ACMR 43 LTS Spark plug gap 0 040 inches 1 01 mm Engine coolant Capacity 12 quarts 11 4 liters Alternator output 66A 12V DC Fan belt deflection 1 2 inch 12 Continuous improvement of our products is Genie policy Product specifications are subject to change without notice Section 2 Specifications February 2012 SPECIFICATIONS Ford LRG 425 EFI Engine Displacement 153 cu in 2 5 liters Number of cylinders 4 3 78 x 3 4 inches 96 01 x 86 36 mm Bore amp stroke Horsepower 70 2500 rpm 52 kW 2500 rpm Firing order 1 3 4 2 Low function idle computer controlled 1600 rpm 395 Hz High function idle computer controlled 2500 rpm 620 Hz Compression ratio 9 4 1 Compression pressure approx Pressure psi or bar of lowest cylinder must be at least 75 of highest cylinder 0 035 to 0 055 inches 0 889 to 1 397 mm Valve clearances collapsed tappet Lubrication system Oil pressure operating temperature 2500 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity 4 5 quarts including filter 4 3 liters Cil pressure switch Oil pressure switch point 7 5 psi 0 51 bar Cil viscosity requirements Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Genie 5 60 5 65 S 60 HC Electronic fuel pump
487. maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the GM 3 0L Operator Handbook GM part number 36100007 OR the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 GM 3 0L Operator Handbook Genie part number 101095 Ford LRG 425 EFI Operator Handbook Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Genie 3 48 S 60 5 65 S 60 HC Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures Checklist D Procedures D 1 Check the Boom Wear Pads Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions 1 Startthe 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
488. matics HB H J Ford LRG 425 EFI Engine Wire Harness February 2012 Section 6 Schematics Ford DSG 423 EFI Engine Wire Harness K J H G D C B A IGNITION COILS HOS ds 816 1 was T ovnis pio GY LB 18 eee 1 DOP 15 SPK COILIA 2 DB O 18 18 SPK COIL1B 3 D SPARK COIL2A Gyn 18 GYN 18 skano D 7 0 V 5 DGP COIL2B 5 SPK COIL3A S c wv SPK COIL3B CYL in avae GASOLINE UEGOC LG W 18 SENSOR INTERFACE UEGPR wis 18 FRP AUX ANA PD2 A Dar is DG P 18 MTRTWR4 2 CaN Sis OLG 18 42 PIN cam Pe CONNECTOR 17 e P 19 18 P ER Q GY R 18 GROUND gj BR 16 EBO GY Y 18 BKW 12 LG BK 18 RING Gv te ORANK pi i IET en ane 5 1 5VEXT2 E 2
489. mber 11879 Section 6 Schematics February 2012 HERE Tss lt s I EOErrr sati Platform Control Box Wiring Diagram S 65 Ford Models February 2012 Platform Control Wiring Diagram 5 65 Section 6 Schematics Ford Models CWLITE WH TS49 Sans 0654 Om util 2 2 5 lt C19JSV GR WH 57 J gt WH 2S C19JSV GR WH C4P 7 BRN JC3 BK BRN GND a RD E STOP s C134PWR RD LS18 C134PWR RD H1 CE LIFT DRIVE OPTION JIB CR27 RD LS18 CABLE ____________________ 6__ ____________ CR30 BK C1P 12 C40LS OR C2P 2 P23BAT WH C7P 2 P22BAT BK C7P 1 T C19JSV GR WH 7 C18PRR GR BK 6 C17PRL GR 5 C15PLD OR BK CAP 3 C14PLU 2 T 1 C129DA BL C3P 10 TS8 GR C2P 5 C59CNK BL BK 11 147 P26BAT BK C9 1 P2 P25FS RD C9 3 TS2 P24FS WH C9 2 TS4 CDLITE OR RD C2P 4 C45GEN GR WH 2 7 GR C2P 5 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL BOARD INPUT CONNECTOR CONTROL RELAY CE OPTION ALC 500 C
490. mber 11880 Section 6 Schematics February 2012 mr va s Ground Control Box Terminal Strip Wiring Diagram S 65 Ford Models after serial number 11879 February 2012 Ground Control Terminal Strip Wiring Diagram 5 65 Ford Models after serial number 11879 Section 6 Schematics 2151 287 gs 69 HARNESS 1108 5 AZi 857 220 HOLIMS NOISNAL savo s Ho HOLIMS woos 20310 61 81 70350 MW GUBL 19 WHOsLV1d OLH3MOd 21 HOLIMS 1S3LNnH 951 10 DRIVE LIGHT ONLY 51 50 HW18 1938010 lt T HW1g ZISTQH HO Qe S eer GVOTHSAO WHOdlVid
491. n or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty The post cat Heated Oxygen Sensor wiring and or connections are open or shorted OR sensor is cold non responsive or inactive for 60 seconds or longer Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing MAP IAT or ECT sensors not in correct position OR wiring and or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck open OR there is electro magnetic interference from a faulty crankshaft and or camshaft position sensor Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR fuel quality is poor OR fuel system components may be faulty There are exhaust leaks OR the catalyst system efficiency is below the acceptable level Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum or exhaust leaks OR one or more fuel injectors faulty or stuck closed OR fuel quality is poor OR fuel pressure is too low MAP IAT or ECT sensors not in correct position OR wiring and or connections for sensors open or shorted OR sensor is
492. n the machine off 8 Hold the charge pressure relief valve and remove the cap item TT Part No 77828 A TEREX 5 60 5 65 5 60 HC MANIFOLDS 9 Adjust the internal hex socket until the pressure reading on the gauge is 30 psi 2 bar less than the pressure reading on the pump Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap 10 Repeat steps 7 through 9 until the pressure reading at the drive manifold is 30 psi 2 bar less than the pressure reading at the pump 11 Turn the engine off and remove the pressure gauge Section 4 Repair Procedures February 2012 _____ MANIFOLDS This page intentionally left blank TEREX COMPANY 4 64 S 60 S 65 S 60 HC Part No 77828 February 2012 Section 4 Repair Procedures MANIFOLDS 7 11 Traction Manifold Components 4WD The traction manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque Check Steer end drive motor circuit 35 40 ft lbs 14 16 Nm 2 Check valve etin SS 2 Non steer end drive motor 35 40 ft lbs 14 16 Nm Flow divider combiner valve AB Controls flow to flow divider combiner valves trand eei 80 90 ft lbs 108 122 Nm Check
493. nd Ford models B 15 Drive brakes A 13 Drive hub oil Perform every 200 hours A 14 Engine maintenance GM and Ford models A 15 Engine maintenance Perkins models B 16 Drive speed stowed position B 17 Drive speed raised position B 18 Alarm package B 19 Hydraulic oil analysis Comments Genie Part No 77828 B 20 Fuel and hydraulic tank cap venting B 21 Fuel filter element Perkins models B 22 Boom extend retract cables Perform every 400 hours B 23 Engine maintenance Deutz models B 24 Engine maintenance GM and Ford models B 25 Replace air filter GM and Ford models B 26 Engine maintenance Perkins models 5 60 5 65 5 60 Section 3 Scheduled Maintenance Procedures s MAINTENANCEINSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by st
494. nd calibrate overload system limited system codes Inconsistent Value too low Checks operational and safety sensor values against each other Genie Part No 77828 Repair wiring and or connections OR replace platform load cell and calibrate overload system S 60 5 65 5 60 HC Section 5 Fault Codes February2012 p This page intentionally left blank Genie 5 24 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine 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 necessary tools and test equipment are available and ready for use Part No 77828 Genie S 60 5 65 5 60 HC 6 1 Schematics About This Section There are two groups of schematics in this section Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches andother jewelry Hydraulic Schematics Bodily injury haz
495. nds to allow the settings to be saved O Result The alarm should sound indicating that the settings have been saved in memory Result The alarm does not sound The minimum or maximum adjustment has been obtained No changes can be saved Note Do not operate any machine function during the 10 second waiting time 15 Cycle the red Emergency Stop button off then back on February 2012 Section 4 Repair Procedures rate factory settings Boomup down transition accelerate 1 second transition decelerate 10 seconds S ramp accelerate 1 second S ramp decelerate 0 45 second Boom extend retract accelerate 2 seconds decelerate 0 5 second Turntable rotate accelerate 2 seconds decelerate 0 75 second Drive accelerate 2 seconds decelerate to neutral 0 5 second decelerate change of direction 0 5 second decelerate coasting 0 75 second decelerate braking 1 second decelerate shift from low to high speed 1 second decelerate shift from high to low speed 4 seconds G Part No 77828 S 60 5 65 S 60 ATER COMPANY PLATFORM CONTROLS Section 4 Repair Procedures February 2012 Platform Components 2 1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates in a closed circuit hydraulic loop with the mas
496. ng and or connections Repair system wiring and or connections Repair system wiring and or connections S 60 5 65 5 60 HC Section 5 Fault Codes February2012 FAULT CODES String Potentiometer Operational sensor C167PSL Error Type Sensor tolerance fault Output short high Value too high Value too low Output short low Genie Condition Power relays disengaged Power relays disengaged String potentiometer wiring open or shorted to voltage Power relays disengaged String potentiometer wiring open or shorted to voltage Power relays disengaged String potentiometer wiring open or shorted to ground Power relays disengaged String potentiometer wiring open or shorted to ground Repair wiring and or connections OR replace string potentiometer and calibrate overload system Repair wiring and or connections OR replace string potentiometer and calibrate overload system Repair wiring and or connections OR replace string potentiometer and calibrate overload system Repair wiring and or connections OR replace string potentiometer and calibrate overload system Repair wiring and or connections OR replace string potentiometer and calibrate overload system Not calibrated Boom range of motion is Calibrate the platform load sense orea limited system Just calibrated used to clear diagnostic Self clearing 5 60 5 65 5 60 HC
497. nnect a 0 to 2000 psi 0 to 150 bar pressure gauge to the diagnostic nipple located near the oscillate directional valve 3 Disconnect the directional valve linkage by removing the heim joint and retaining fastener from the axle 4 Startthe engine from the platform controls 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 Section 2 Specifications 6 Turnthe engine off 7 Locate the relief valve on the directional valve and remove the cap 8 Adjustthe internal screw Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap AWARNING hazard Do not adjust the relief valve higher than specified 9 Repeat steps 4 through 7 and manually activate the valve to confirm the valve pressure 10 Turn the engine off remove the pressure gauge and assemble the directional valve linkage 11 Install the cover on the non steer end of the drive chassis A TEREX COMPANY Part No 77828 S 60 5 65 5 60 HC 4 59 Section 4 Repair Procedures February 2012 MANIFOLDS 7 8 Drive Oil Diverter Manifold Components welder option The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment Index Schematic No Description Item Function Torque 1 Directional V
498. ns 404 22 Models after serial number 11879 February2012 E gt ROCKER STEER OPTION ONLY P22LS BK N c LO C7P 3 BATGND C7B 3 GROUND gt C2P 3 C41RPM OR BK C2B 3 o 5 g 5 9 m a 1 4 C30FWD WH C1B 4 6521 C30FWD WH BK RD 4 DRIVE FORWARD gt 15 5 C31REV WH BK C1B 5 05 20 C31REVWHIBK RD BK DRIVE REVERSE e z e lt D gl 1 DRIVE WH RD TRAVEL ALARM eS 5 0 2 PEN 9 8 C26 1 C26 2 C32BRK WH RD 5 4 2 Hae lt C1B 6 5 23 __ WH RD DAKE RELENE s 8 C28 1 C282 z B o EK C1P 3 C29MS RD WH C1B 3 C5 24 C29MS RD WH D MOTOR STROKE 5 N BL RD I gt 16 o 5 5 5 C25 1 025 2 2 CDE2BLBK _ C1
499. nsists 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 box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend yes completed no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures February 2012 This intentionally left blank Genie 3 4 5 60 S 65 5 60 HC Part 77828 February 2012 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection Semi annual 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Ye
500. nt and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction Genie 5 60 5 65 S 60 HC 19 Perform Hydraulic Oil Analysis Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often For hydraulic oil specifications refer to Section 2 Specifications Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures B 20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Note Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often
501. ntiometer and calibrate overload system Part No 77828 5 60 5 65 5 60 Section 5 Fault Codes February 2012 FAULT CODES Boom Angle Operational Sensor C123PBS ErrorSource Error Type ID Name 1 Condition Power relays Sensor tolerance fault disengaged Power relays disengaged Boom angle sensor wiring open or shorted to voltage Output short high Power relays disengaged Boom angle sensor wiring open or shorted to voltage OR sensor is out of operating range Value too high Power relays disengaged Boom angle sensor wiring open or shorted to ground OR sensor is out of operating range Value too low Power relays disengaged Boom angle sensor wiring open or shorted to ground Output short low Repair wiring and or connections OR replace boom angle sensor and calibrate overload system Repair wiring and or connections OR replace boom angle sensor and calibrate overload system Repair wiring and or connections OR adjust or replace boom angle sensor and calibrate overload system Repair wiring and or connections OR adjust or replace boom angle sensor and calibrate overload System Repair wiring and or connections OR replace boom angle sensor and calibrate overload system 17 Not calibrated Boom range of motion is Calibrate the platform load sense limited system Just calibrated Self clearing codes Genie S 60 S 65
502. nuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie S 60 S 65 S 60 HC Part No 77828 February 2012 Section 2 Specifications Er SPECIFICATIONS Battery Type 12V DC Size 13 x 613 16 x 93 8 inches 38 x 17 3 x 23 8 cm Quantity 1 Cold cranking ampere 1000A Reserve capacity 25 rate 200 minutes Alternator output 60A Q 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Genie Part No 77828 S 60 5 65 S 60 HC 2 9 Section 2 Specifications February 2012 SPECIFICATIONS Perkins 404 22 Engine Displacement 134 cu in 2 2 liters Number of cylinders 4 Bore and stroke 3 31 x 3 94 inches 84 x 100 mm Horsepower 51 Q 2500 rpm 38 kW 2500 rpm Firing order 1 3 4 2 Low idle 1300 rpm 201 Hz High idle 2500 rpm 231 Hz Compression ratio 23 3 1 Compression pressure 426 psi 29 4 bar Pressure psi of lowest cylinder must be within 50 psi 3 45 bar of highest cylinder Governor centrifugal mechanical Valve clearance cold Intake 0 008 in 0 2 mm Exhaust 0 008 in 0 2 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 10 Genie 5 60 S 65 S 60 HC Lubrication system Oil pressure cold 60 psi at 2500 rpm 4 1 bar Oil capacity 9 3 quarts inc
503. ol Box Switch Panel Wiring Diagram 5 60 Deutz F3L 201 1 Models nnne 6 67 Genie Part No 77828 S 60 5 65 5 60 HC xvii February 2012 TABLE CONTENTS Section 6 Schematics continued Electrical Schematic S 65 Deutz F3L 2011 Models before serial number 11880 6 68 Electrical Schematic S 65 Deutz F3L 2011 Models after serial number 11879 nene 6 70 Electrical Schematic 5 65 CE Models Deutz F3L 2011 Models before serial number 11880 6 72 Electrical Schematic 5 65 Models Deutz F3L 2011 Models afterserialnumber11879 a 6 74 Ground Control Box Terminal Strip Wiring Diagram 5 65 Deutz F3L 2011 Models before serial number 11880 6 76 Ground Control Box Switch Panel Wiring Diagram 5 65 Deutz F3L 2011 Models before serial number 11880 6 77 Ground Control Box Terminal Strip Wiring Diagram 5 65 Deutz F3L 201 1 Models after serial number 11879 6 78 Ground Control Box Switch Panel Wiring Diagram 5 65 Deutz F3L 201 1 Models after serial number 11879 6 79 Ground Control Box Terminal Strip Wiring Diagram 5 65 CE Models Deutz F3L 2011 Models before serial number 11880 6 80 Ground Control Box Switch Panel Wiring Diagram 5 65 CE Models Deutz F3L 2011 Models
504. om the string potentiometer out of the slot of the cover Rest the cover and string potentiometer on the counterweight Component damage hazard The cable from the string potentiometer can become damaged if it is kinked or pinched Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES 4 Remove the retaining fasteners from the access 6 60 and S 65 Install the cover at the pivot end covers located on the side of the boom at the platform end of the machine Remove the covers 5 Visually inspect the cables and components through both inspection holes for the following Frayed or broken wire strands Kinks in the cables Corrosion Paint or foreign materials on the cable Split or cracked cable ends Cables are on all pulleys Extend cable break limit switch arm is centered in the pivot plate Cables have equal tension Cables at end of adjustment range No broken or damaged pulleys No unusual or excessive pulley wear All fasteners in place and secure S 60 HC String potentiometer cable break limit switch arm is securely attached to end of cable Note A flashlight and inspection mirror may be necessary to thoroughly inspect the above items Note A pulley groove gauge should be used to check the condition of the pulleys 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 slo
505. on 3 Scheduled Maintenance Procedures Checklist A Procedures A 1 Inspect the Manuals and Decals Note Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Checkto make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or are illegible Remove the machine from
506. on 4 Repair Procedures February 2012 MANIFOLDS 7 3 Jib Boom Platform Rotate Manifold Components Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position way EF sus Platform rotate jib boom select 20 25 ft lbs 27 34 Nm FF A TEREX COMPANY 4 54 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures 7 4 Brake Two Speed Manifold Components The brake two speed manifold is mounted near the turntable rotator Index No Description 1 2 3 4 Check valve Orifice 0 025 inch 0 64 mm Solenoid valve 2 position 3 way Schematic Solenoid valve 2 position 3 way LL JJ Part No 77828 MANIFOLDS Function Torque Turntable rotation brake release RE Brake release 20 25 ft lbs 27 34 Nm Two speed motor shift 20 25 ft lbs 27 34 Nm Brake release circuit 20 25 ft lbs 27 34 KK LL A TEREX COMPANY 5 60 5 65 5 60 HC 4 55 Section 4 Repair Procedures February 2012 lt MANIFOLDS 7 5 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor Index Schematic No Description Item Function Torque 1 Counterbalance valve MM Turntable rotate right
507. on 6 Schematics February 2012 p m H Electrical Schematic S 65 Ford DSG 423 EFI Models after serial number 14053 2215 P134PWR RD February2012 NOTES Ford DSG 423 EFI Models after serial number 14053 Electrical Schematic 5 65 Section 6 Schematics gg Sea 5 lt zu 5 4 Ez s gt 1 9 C35RPM BK RD C1B 9 o lt j eene 5 OIL PRESSURE SPEED 25258 WH BK wl 8 CeSPSR Wey 1 SENDER OPTION e 5 1 VOLT METER n 9 3 FIOWRPM cTONENABLEL 8 C26TSR WH RD PIN 39 _ WATER TEMPERATURE t HIGH RPM 4 gt i SENDER OPTION 5 GENERATOR 5 ar C2P 7 C45GEN GR WH C2B 7 C5 12 CA5GENGR WH p GENERATOR 7 OPTION o 1
508. on the pump Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap 10 Repeat steps 7 through 9 until the pressure reading at the drive manifold is 30 psi 2 bar less than the pressure reading at the pump 11 Turn the engine off and remove the pressure gauge 4 67 Section 4 Repair Procedures February 2012 MANIFOLDS 7 13 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious 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
509. onal control module operational control module safety control module red LED safety control module green LED safety control module 6 Startthe engine from the ground controls Operational Control Module LED Status Green and red LEDs not flashing Green LED flashing rapidly Red LED flashing w ith pauses Definition System is calibrated System is in calibration mode Indicates next calibration step ie 2 3 etc Safety Control Module LED Status System is calibrated System is not calibrated Description Green and red LEDs not flashing Green and red LEDs flashing alternately Part No 77828 5 60 5 65 S 60 Section 4 Repair Procedures February 2012 PLATFORM COMPONENTS 7 Raisethe boom until the distance when measured between the centers of the pivot pins shown equals 108 75 inches 276 cm x 0 75 inch 19 mm AWARNING Crushing hazard Keep clear of all moving parts of the boom while the boom is raising Do not attempt to measure between the pivot pins while the boom is moving Measure between the centers of these pivot pins 8 Activate the calibration toggle switch inside the ground control box 1 time Result The alarm should sound for 1 second indicating the second calibration step was accepted The green LED on the operational controller should be blinking fast and the red LED should be blinking three times indica
510. onnections to ignition coil 1 OR ignition coil 1 is faulty Open wiring and or connections to ignition coil 2 OR ignition coil 2 is faulty qms Wiring and or connections to ignition coil 1 Driver 1 snared shorted OR ignition coil 1 is faulty psi Wiring and or connections to ignition coil 2 shorted OR ignition 2 is faulty The 1 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 1 is faulty The 2 throttle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 2 is faulty The throttle position sensor wiring and or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty Governor actuator is stuck closed OR wiring and or connections open or shorted OR governor actuator is faulty Governor actuator is stuck open OR wiring and or connections open or shorted OR governor actuator is faulty Engine harness wiring and or connections open or shorted OR there is a poor system ground connection OR ECM is faulty Genie Megavector Internal The MegaJector detects an internal fault Open or Actuator Fault Detection short in power ground or CAN circuits The MegaJector detects an internal circuitry failure Open or short in power ground or CAN c
511. ools and equipment from the platform 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Section 3 Scheduled Maintenance Procedures February 2012 CHECKLIST C PROCEDURES 3 Startthe engine from the ground controls Do not turn the engine off 4 Using a suitable lifting device place an appropriate test weight equal to 750 Ibs 340 2 kg on to the center of the platform floor O Result The amber restricted range of motion LED at the platform controls should come on and the engine should continue to run W 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 See Repair Procedure 2 4 How to Calibrate the Platform Load Sense System S 60 HC 5 Using a suitable lifting device place an additional appropriate test weight equal to 501 to 510 Ibs 227 2 to 231 3 kg on to the center of the platform floor The total weight in the platform must equal 1251 to 1260 Ibs 567 4 to 571 5 kg Result The alarm should sound and the engine should turn off The platform overload indicator light should be on at both the ground and platform controls The platform load sense system is functioning properly 6 7 Using a suitable lifting device remove the test weights from the platform
512. op i CIARLU OR Il 4 PLATFORM LEVEL UP ___ _ PLATFORM LEVEL teen ae 1 DOWN Il PLATFORM LEVEL DOWN E 21 1 C21 2 6 C18JD PRR GR BK C4B 6 RIGHT PLATFORM ROTATE t LEFT C17JU PRL GR C4B 5 IPS C284 23 2 2 i GREK D PLATFORM ROTATE RIGHT RIGHT PLATFORM ROTATE LLEFT 2 CITJU PRLGR Itl PLATFORM ROTATE LEFT C224 C222 imam E C129 RD BK DESCENTALARMOPTION 2 d x Bx E ala z amp amp NS 5 enie G S 60 S 65 S 60 HC 6 15 Part No 77828 February 2012 Section 6 Schematics _ Electrical Schematic 5 60 GM 3 0L Models Section 6 Schematics February 2012 n 25 Ground Control Box Terminal Strip Wiring Diagram S 60 GM 3 0L Models February 2012 Section 6 Schematics Ground Control Terminal Strip Wiring Diagram 5 60 GM 3 0L Models FUNCTION HARNESS ENGINE C5 957 HOLIMS NOISN3L 318vO 151 HOLIMS 1 woog 2929819 eit 61 81 vO RED L 64 84 42 OL 5 158 7951
513. operation If the oscillate directional valve linkage is not operating correctly the stability of the machine is compromised and it may tip over 1 Remove the drive chassis cover from the non steer end of the machine 2 Locate the oscillate directional valve inside of the non steer axle and inspect the linkage for the following Lock nut is tight against yoke Yoke clevis pins are installed Cotter pins are installed through clevis pins Linkage is properly attached to directional valve Genie 5 60 5 65 S 60 HC 12 Test the Platform Self leveling Note 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 for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Startthe engine from the ground controls and lower the boom into the stowed position 2 Holdthe function enable rpm select toggle Switch to either side and adjust the platform to a level position using the platform level toggle Switch 3 Raise and lower the primary boom through a full cycle Result The platform should
514. ormance of the cooling system AWARNING injury hazard Do not inspect while the engine is running Remove the key to secure from operation Burn hazard Beware of hot engine ACAUTION components Contact with hot engine components may result in severe burns Oil cooler 1 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures 3 Remove the fasteners from the engine side cover then remove the cover 4 Inspect the oil cooler for leaks and physical damage a oilcooler b cylinder head cooling fins c blower fins 5 Clean the oil cooler of debris and foreign material Cooling and fan blower fins 6 Inspect the fan blower fins for physical damage 7 Cleanthe fan blower fins of debris and foreign material 8 Inspect the head cooling passages and fins for physical damage or foreign material using a flashlight 9 Clean the cylinder head cooling passages of debris and foreign material 10 Install the engine side cover 11 Swing the engine back to
515. ose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the boom fully retracted 1 Raise the boom to a horizontal position ATER IX COMPANY BOOM COMPONENTS S 60 and S 65 Remove the boom end cover retaining fasteners and remove the cover S 60 HC Remove the boom end cover from the pivot end of the boom while guiding the small cable from the string potentiometer out of the slot of the cover Rest the cover and string potentiometer on the counterweight Component damage hazard The cable from the string potentiometer can become damaged if it is kinked or pinched 60 HC Remove the string potentiometer cable break limit switch mounting fasteners S 60 HC Remove the pulley retaining plate from the string potentiometer pulley bracket Carefully remove the string potentiometer cable and limit switch assembly from the boom Remove the access covers from both sides of the boom at the pivot end Fully loosen the lock nuts on the extend cables Do not remove the nuts Loosen the retract cable nut at the platform end of the boom Pull the cable rod from the support and let it hang down Part No 77828 5 60 5 65 5 60 HC 4 29 Section 4 Repair Procedures February 2012 BOOM COMPONENTS
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517. pecifications require that this procedure be performed every 100 hours or monthly whichever comes first Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and or hard starting and continued use may result in component damge Extremely dirty conditions may require this procedure be performed more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off Perkins Models 1 Puton protective clothing and eye wear 2 Openthe engine side turntable cover and locate the fuel filter water separator next to the hydraulic return filter on the bulkhead 3 Inspectthe filter bowl for water buildup O Result If water is present in the filter bowl continue with steps 4 through 8 4 Loosenthe vent plug located on the fuel filter water separator head a vent plug b drain plug c fiterbowl d separator head 5 Loosen the drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug 6 Tighten the vent plug Note If the fuel filter water separator is completely drained you mu
518. perating temperature 2500 rpm 2 to 2 7 bar Oil capacity 4 quarts including filter 3 8 liters Cil pressure switch Oil pressure switch point 7 5 psi 0 51 bar Cil viscosity requirements Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 77828 Genie S 60 5 65 5 60 HC SPECIFICATIONS Electronic fuel pump Fuel pressure static 64 psi 4 4 bar Fuel flow rate 0 43 gpm 1 6 L min Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Ignition system Spark plug type Motorcraft AGSF 32 FEC 0 049 to 0 053 inches 1 244 to 1 346 mm Spark plug gap Engine coolant Capacity 10 quarts 9 5 liters Cylinder head temperature sending unit Fault code set temperature 280 F 138 C Engine shut down temperature 300 F 149 C Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140 200A Current draw maximum load 800A Alternator Output 95A 13 8V DC Battery Type 12V DC Group 31 Quantity 1 Cold cranking ampere 09 1000A Reserve capacity 25A rate 200 minutes 2 7 Section 2 Specifications February 2012 SPECIFICATIONS Deu
519. perating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manualon your machine Be sure that all necessary tools and parts are available and ready for use Useonly Genie approved replacement parts Readeach procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Boom in stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine Part No 77828 A TEREX 5 60 5 65 5 60 HC 4 1 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure aftertroubleshooting the problem Perform disassembly procedures to the point where repairs can be completed To re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow
520. r 1060020 GM 3 0L Operator Handbook Genie part number 101095 Ford LRG 425 EFI Operator Handbook Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 3 37 Section Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 25 Replace the Engine Air Filter Element GM and Ford Models Note Engine specifications require that this procedure be performed every 400 hours Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Locate the engine air filter assembly 2 Release the latches from the air cleaner canister end cap Remove the end cap Remove and discard the filter element 4 Clean the inside of the canister and the end cap with a damp cloth 5 Install the new filter element 6 Install the air filter canister end cap and secure the end cap latches Note Be sure the discharge valve is pointing down when the cap is instaled Genie 5 60 5 65 S 60 HC 26 Perform Engine Maintenance Perkins Models Note Engine specifications require that this procedure be performed every 400 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service lif
521. r bracket Remove the dipstick from the engine Remove the muffler retaining fasteners from the exhaust pipe Support the muffler and bracket assembly with an overhead crane or other suitable lifting device Remove the muffler bracket mounting fasteners Carefully remove the muffler and bracket assembly from the engine Support the engine with a suitable lifting device Do not lift it Remove the engine plate to vibration isolator fasteners Remove the engine mounting plate to bell housingfasteners Raise the engine slightly to take the weight off of the engine mounting plate 10 Slide the engine mounting plate towards the pump as far as it will go 11 Support the drive pump assembly with an 12 Remove all of the engine bell housing fasteners appropriate lifting device 13 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 14 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel February 2012 Ford DSG 423 EFI models 1 Disconnect the electrical connectors from both oxygen sensors at the tailpipe and exhaust manifold Do not remove the oxygen sensors Remove the exhaust pipe fasteners at the muffler Support the muffler and bracket assembly with suitable lifting device Remove the muffler bracket mounting fasteners from the bell ho
522. r end tires and 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 Part No 77828 A TEREX 5 60 5 65 5 60 HC TURNTABLE ROTATION COMPONENTS 2 Loosen the backlash pivot plate mounting fasteners backlash pivot plate b adjustment bolt with lock nut backlash pivot plate mounting bolts Push the backlash pivot plate towards the turntable as far as possible this will push the rotation gear into the turntable bearing ring gear Loosen the lock nut on the adjustment bolt Turn the adjustment bolt clockwise until it contacts the backlash pivot plate Turn the adjustment bolt 2 turn counterclockwise Tighten the lock nut on the adjustment bolt 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 Section 2 Specifications Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary Section 4 Repair Procedures February 2012 Axle Components 9 1 Oscillating Axle Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the axle to maintain alevel chassis while driving over uneven terrain The cylinders
523. r engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz FL 2011 Operation Manual Deutz part number 0297 9929 Deutz FL 2011 Operation Manual Genie part number 84794 access the engine 1 Removethe engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 77828 Genie S 60 5 65 5 60 HC CHECKLIST B PROCEDURES B 24 Perform Engine Maintenance GM and Ford Models Note Engine specifications require that this procedure be performed every 400 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the GM 3 0L Operator Handbook GM part number 36100007 OR the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDI part numbe
524. razza e 22 HOLIMS T HM HM LSY Auvrixnv 1551 HOLIMS 4018 AON3OH3N3 28 7 0 QH HM 28 61HO QH HM 2 8 6149 z Yok WYO S Eep Yok WYO 01 30151534 tO1sis3u 31viOH INOZ 318viNunL WOOS AHVWIHd vu 91H 961 wyo g MwezseHHzwa qu 50151534 SINLOW 80151538 STaVLNYNL NMOG dn zu woog Yok WYO S MSZ SHY gva 6 83 5 60 5 65 5 60 HC Part 77828 February 2012 Section 6 Schematics FEE KEE E EZE 4666 466 66 iu 111 LLL LLILILLILLILILILILLOZLILILLLLILZLIILUUULL LU Ground Control Box Switch Panel Wiring Diagram S 65 CE Models Deutz F3L 2011 Models after serial number 11879 Section 6 Schematics February 2012 Platform Control Box Wiring Diagram S 65 Deutz F3L 201 1 Models February 2012 Section 6 Schematics Platform Control Box Wiring Diagram S 65 Deutz F3L 201 1 Models DESCRIPTION TILT ALARM 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECT
525. rd models 3 38 B 26 Perform Engine Maintenance Perkins Models 3 38 Genie x 5 60 S 65 5 60 HC Part No 77828 February 2012 TABLE CONTENTS Section 3 Scheduled Maintenance Procedures continued ChecklistC Procedures C 1 Perform Engine Maintenance Deutz Models 3 39 2 Grease the Platform Overload Mechanism 5 60 and S 65 if equipped 3 39 C 3 Testthe Platform Overload System 5 60 S 65 if equipped 3 40 C 4 Testthe Platform Load Sense System S60 HC 3 43 C 5 Replace the FuelFilter Water Separator Element Perkins Models 3 45 C 6 Replace the Engine Air Filter Element Deutz and Perkins Models 3 47 C 7 Perform Engine Maintenance Perkins Models 3 47 C 8 Perform Engine Maintenance GM and Ford Models 3 48 Checklist D Procedures D 1 Check the Boom Wear Pads 3 49 0 2 Check the Turntable Rotation Bearing Bolts 3 50 0 3 Inspect for Turntable Bearing 3 51 0 4 Replace the Drive Hub Oil 3 52 0 5 Checkthe Free wheel Configuration 3
526. re Indicates that new parts will be required to perform this procedure Indicates that a cold engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service is required to perform this procedure E E LEE Genie 3 2 5 60 5 65 S 60 HC Pre delivery Report Thepre delivery preparation report contains checklists for each type of scheduled inspection Make copies ofthe Pre delivery Preparation Report to use for each inspection Store completed forms asrequired Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annual and two years The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours Semi annually or every 500 hours Annual every 1000 hours A B C D Two years or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain comple
527. re high pressure 232 MAP manifold absolute pressure low pressure 234 er prononcon ______ 235 srteweesesenbeream _ 240 248 248 omens 246 comes 253 errar 7254 wwe mani Section 5 Fault Codes February 2012 FAULT CODES F P fuel pressure high voltage P fuel pressure low voltage N 1 1 T fuel temperature gasoline high voltage 272 T fuel temperature gasoline low voltage 273 FT fuel temperature gaseous fuel high voltage 274 FT fuel temperature gaseous fuel low voltage 5 jector loop open low side short to ground 1 njector coil shorted 1 njector loop open OR low side short to ground 2 njector coil shorted 2 njector loop open OR low side short to ground 3 njector coil shorted 3 njector loop open OR low side short to ground 4 Genie 5 60 S 65 5 60 HC TPS1 throttle position sensor high voltage TPS1 throttle position sensor low voltage TPS2 throttle position sensor high voltage TPS2 throttle position sensor low voltage TPS1 throttle position sensor higher than TPS2 TPS1 throttle position sensor lower than TPS2 537 Unable to reach higher TPS throttle position sensor Unable to reach lower TPS throttle position sensor TPS 1 2 simultaneous voltages AUX analog PU1 high AUX analog PU1 low AUX analog PU2 high AUX analog PU2 low Max govern speed override Fuel rev l
528. re serial number 11880 Section 6 Schematics February 2012 Electrical Schematic 5 65 CE Models Deutz F3L 201 1 Models after serial number 11879 February 2012 Section 6 Schematics Electrical Schematic S 65 CE Models Deutz F3L 201 1 Models after serial number 11879 C22LS 6 55 gg m o d 5 9 BK RD C1B 9 8 FOOTSW HIGH FOOTSW LOW 28 x b x 8 LOW RPM x FUNCTION ENA id qp HIGH IDLE RELAY g 8 l BKRD 65 18 HIGH
529. remain level at all times to within 5 degrees Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures B 13 Test the Engine Idle Select Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are two settings Foot switch activated low idle turtle symbol allows the operator to control individual boom functions Foot switch activated high idle rabbit symbol should be used for normal 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 Part No 77828 CHECKLIST B PROCEDURES Start the engine from the ground controls then move and hold the function enable rpm select toggle switch to the high idle rabbit symbol Result The engine should change to high idle Release the function enable rpm select toggle Switch Result The engine should return to low idle Turn the key switch to platform controls Move the engine idle control switch to foot Switch activated high idle rabbit and foot switch symbol Result The engine should not change to high idle Press down the foot switch Result The engine should change to high idle Move the engine idle contro
530. rence for use when crossing the start and finish lines Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures 6 Bringthe machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications 8 Lowerthe boom to the stowed position and extend the boom 1 foot 30 cm 9 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 10 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 11 Continue at top speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications Part No 77828 Genie S 60 S 65 S 60 HC 3 31 CHECKLIST B PROCEDURES B 18 Test the Alarm Package Optional Equipment Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The alarm package includes Travelalarm e Descentalarm e Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable covers Note The alarms and
531. rive cire it u k suasana 30 35 ft lbs 41 47 Nm Drive circuit 30 35 ft lbs 41 47 Nm Charge pressure circuit that directs hot oil out of low pressure side of drive pump 50 55 ft lbs 68 75 Nm Drive motor circuit Genie TEREX COMPANY 4 61 Section 4 Repair Procedures February 2012 MANIFOLDS TT ww lt oo 2 XX ss 6 5 4 3 Genie 4 62 S 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures 7 10 Valve Adjustments 2WD Traction Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi 0 to 50 bar pressure gauge to the test port on the drive pump 2 Holdthe charge pressure relief valve and remove the cap item TT 3 Turn the internal hex socket clockwise fully until it stops Install the cap 4 Startthe engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position Note the reading on the pressure gauge 5 Turnthe engine off 6 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold 7 Startthe 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 Tur
532. rm Engine Maintenance GM Ford and Perkins Models 12 Grease the Turntable Bearing and Rotate Gear B 6 Inspect the Tires Wheels and Lug Nut Torque B 8 Check the Drive Hub Oil Level and Fastener Torque 1 Engine Maintenance Deutz Models e D 2 Check the Turnable Rotation Bearing Bolts D 6 Replace the Hydraulic Filters Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures A 8 Inspect the Engine Air Filter GM Models Note Engine specifications require that this procedure be performed weekly or every 40 hours whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essentialto good engine performance and service life Failure to perform this procedure can lead to poorengine performance and component damage Note Perform this procedure with the engine off 1 Locate the engine air filter assembly 2 Release the latches from the air cleaner canister end cap Remove the end cap 3 Remove the filter element 4 Clean the inside of the canister and the end cap with a damp cloth 5 Inspect the air filter element If needed blow from the inside out using low pressure dry compressed air or carefully tap out dust Replace the filter if needed Install the filter element 7 Install the air filter canister end cap and secure the end cap latches Note Be sure the di
533. rol Part No 77828 A TEREX 5 60 5 65 5 60 HC PLATFORM COMPONENTS 11 Test all machine functions from the ground controls Result All ground control functions should not operate 12 Using a suitable lifting device lift the test weight off the platform floor O Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls O Result All ground control functions should operate normally 14 Turn the key switch to platform control 15 Test all machine functions from the platform controls Result All platform control functions should operate normally Section 4 Repair Procedures February 2012 PLATFORM COMPONENTS 2 4 Platform Load Sense System S 60 HC How to Calibrate the Platform Load Sense System Proper calibration of the load sense system is essential to safe machine operation Continued use of an improperly calibrated load sense system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note For S 60 and S 65 models refer to Repair Procedure 2 3 Platform Overload System S 60 and S 65 if equipped Note Perform this procedure with the boom fully retracted and in
534. round control and pull out the red Emergency Stop button to the on position Result The alarm should sound a long tone Activate and hold the calibration toggle Switch for 5 seconds Result The alarm should sound a tone for 1 second Push in the red Emergency Stop button to the off position Part No 77828 February 2012 Section 4 Repair Procedures 5 Activate and release the calibration toggle switch 3 times within 2 seconds after the alarm sounds to enter calibration mode O Result The alarm should sound for 1 second indicating the first calibration step was accepted The green LED on the operational controller should be blinking fast and the red LED should be blinking twice indicating that step 2 of calibration is next Result The alarm did not sound and the green LED on the operational controller is not blinking fast Repeatthis procedure beginning with step 1 Note Once calibration mode is entered and begun there is a 8 minute time limit between each calibration step If any one step passes the 8 minute time limit the system will time out and the calibration process will need to be repeated beginning with step 1 PLATFORM COMPONENTS od f fofi A 9 5 JH Gi e green LED operational control module red LED operati
535. rts Department part no 77896 The kit includes a 4 link section of cable track 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Carefully remove the snap rings from each end of the damaged section of cable track 3 Removethe retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 4 Liftup the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 5 Remove the upper rollers from the replacement section of cable track 6 Liftup the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched Connect the ends of the replacement cable track section to the existing cable track using the snap rings Install the rollers onto the new section of cable track Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track A TEREX COMPANY 4 24 5 60 5 65 5 60 Part No 77828 February 2012 Section 4 Repair Procedures BOOM COMPONENTS Part No 77828 TAT Q G G Q D 3 short link arm to boom pivot pin boom boom lift cylinder rod end pivot pin
536. s original position and install the engine pivot plate retaining fastener Note It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation Note If the engine runs correctly for a short time and then stops or runs roughly check for air in the fuel system If there is air in the fuel system there is probably a leak in the low pressure side of the system Part No 77828 Genie S 60 S 65 S 60 HC CHECKLIST B PROCEDURES B 22 Inspect the Boom Extend Retract Cables Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Inspecting for foreign objects damage and or improper adjustment of the boom extend retract cables and related components on a regular basis is essential to good machine performance and safe machine operation The boom extend and retract functions should operate smoothly and be free of hesitation jerking and unusual noise 1 Raise the boom to horizontal and fully extend the boom 2 After the boom is fully extended lower the boom until the platform is at chest height Turn the machine off 3 S 60and S 65 Remove the boom end cover retaining fasteners and remove the cover 5 60 HC Remove the boom end cover from the pivot end of the boom while guiding the small cable fr
537. scharge valve is pointing down when the cap is instaled Part No 77828 Genie S 60 S 65 S 60 HC CHECKLIST A PROCEDURES A 9 Perform Engine Maintenance GM Ford and Perkins Models Note Engine specifications require that this procedure be performed every 100 hours Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the GM 3 0L Operator Handbook GM part number 36100007 OR the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 OR the Ford DSG 423 EFI Operator Handbook EDI part number 1060020 OR the Perkins 400 Series Operation Manual Perkins part number 14435 GM 3 0L Operator Handbook Genie part number 101095 Ford LRG 425 EFI Operator Handbook Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Perkins 400 Series Operation Manual Genie part number 94890 3 11 Section Scheduled Maintenance Procedures February 2012 CHECKLIST A PROCEDURES A 10 Inspect the Fuel Filter Water Separator Diesel Models Note Genie s
538. sengaged Section 5 Fault Codes FAULT CODES Use recovery switch and APU from the ground controls to recover the machine to stowed position or within the operating envelope Remove weight from platform until load is 1200 16 544 kg or less 3 CAN communication Power relays Repair CAN bus wiring and or failure disengaged connections Power relays Sensor power failure disengaged Power relays Angl i sensor active disengaged String potentiometer not active Power relays disengaged Power relays disengaged Relay wiring open or shorted to voltage Power relay output short high Power relays disengaged Relay wiring open or shorted to ground Power relay output short low Boom up down and extend retract inoperative Relay wiring open or shorted to voltage Directional relay output short high Boom up down and extend retract inoperative Relay wiring open or shorted to ground Output short low Genie Part No 77828 Use recovery switch and APU from the ground controls to recover the machine to stowed position or within the operating envelope Inspect boom angle sensor for proper operation and be sure it is connected to boom properly OR replace boom angle sensor Inspect string potentiometer for proper operation and be sure it is connected to boom properly OR replace string potentiometer Repair system wiring and or connections Repair system wiri
539. serialnumber 11880 Ground Control Box Switch Panel Wiring Diagram S 60 CE Models February2012 6 63 S 60 S 65 S 60 HC Part 77828 9 gt Qr 508 5 5 38328 sasa lt 5 u 5 a s 8 8 z5 82S j i 2 5 2156 zo Gl z E gt gt EIE IRIE E Z 6 82 85 ES ES alas 065 olouu 61445 15 5 o cc ex lulu u u 915 a S SVL EGS lE 5 22825556 2 2 Soo 5 5 2 5 6 9216 lt a MIN LS TWNIWHAL OL 9 9
540. speed 30 cc Drive motors 2WD models Displacement per revolution 1 28 cu in high speed 20 9 cc Displacement per revolution 2 14 cu in low speed 35 cc Hydraulic filters High pressure filter Beta 3 gt 200 High pressure filter 51 psi bypass pressure 3 5 bar Medium pressure filter Beta 3 gt 200 Medium pressure filter 51 psi bypass pressure 3 5 bar 10 micron with 25 psi 1 7 bar bypass Hydraulic return filter Genie S 60 S 65 5 60 HC Manifold Component Specifications Plug torque SAE No 2 36 in Ibs 4 Nm SAE No 4 10 ft Ibs 18 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft Ibs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft lbs 76 Nm Valve coil resistance specifications Solenoid valve 3 position 4 way 10V DC 51070 schematic items D V and Solenoid valve 3 position 4 way 10V DC 4 to 60 schematic item BB Solenoid valve 2 position 3 way 10V DC 51070 schematic items C E F and FF Solenoid valve 2 position way 10V 5 5 7 50 schematic items KK and LL Proportional solenoid valve 12V DC 4 to 60 schematic items M and T Proportional solenoid valve 12V DC 3 7 to 5 70 schematic item Q Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 77828 February 2012 Section 2 Specifications 3 01 Displa
541. st prime the fuel filter water separator before starting the engine See C 6 Heplace The Fuel Filter Water Separator Element Perkins Models for instructions on how to prime the fuel filter water separator Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures 7 Clean up any fuel that may have spilled 8 Startthe engine from the ground controls and check the fuel filter water separator and vent plug for leaks ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Deutz Models 1 Put on protective clothing and eye wear 2 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 3 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury 4 Locate the fuel filter water separator next to the oil filter Part No 77828 Genie S 60 S 65 S 60 HC CHECKLIST A PROCEDURES 5 Loosen the drain plug located at the bottom of the filter Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug Note Do
542. stener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Thoroughly clean the outside surfaces of the fuel filter assembly Place a suitable container under the fuel filter element Disconnect and plug the fuel line from the fuel pump to the fuel filter element lt d 5 uma a fuelline b filter head fuel filter element Remove the fuel filter element with a filter wrench Apply a thin layer of fuel to the new fuel filter element O ring Install the new fuel filter element and tighten it securely by hand Clean up any fuel that may have spilled during the installation procedure Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housing Genie 3 34 5 60 5 65 S 60 HC Part 77828 February 2012 Section 3 Scheduled Maintenance Procedures Bleed the fuel system 10 Loosen the vent plug on top of the fuel injection pump ventplug b fuelinjection pump c fuel lift pump 11 Operate the priming lever or priming bulb if equipped of the fuel lift pump until fuel free from air comes from the vent plug Tighten the vent plug 12 Clean up any fuel that may have spilled during this procedure 13 Operate the starter motor for intervals of 15 seconds until the engine starts 14 Swing the engine back to it
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544. t efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Note Perform this procedure with the key switch in the off position 1 Openthe ground controls side cover and locate the run test toggle switch on the side of the ground control box 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Quickly activate and release the start toggle switch button Do not start the engine 4 Move and hold the run test toggle switch to the test position O Result The check engine light should turn on The check engine light should begin to blink 5 12 S 60 5 65 S 60 HC 5 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 123 three times After the fault codes the check engine light will blink a code 123 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a three digit code three times for each code stored in memory It will blink the first digit of a three digit code pause blink the second digit pause and then blink the third digit For example the check engine light blinks 5
545. t lbs 27 34 Nm 20 25 ft lbs 27 34 Nm February 2012 Section 4 Repair Procedures MANIFOLDS D 000000 G M C B H 7 re lt S 60 S 65 S 60 HC Part No 77828 52 February 2012 Section 4 Repair Procedures er MANIFOLDS 7 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Note Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the PrEsr port on the function manifold 2 Startthe engine from the ground controls 3 Holdthe 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 Observethe pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the relief valve and remove the cap item K 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valve higher than specified 7 Repeatsteps 2 through 5 and recheck relief valve pressure 8 Removethe pressure gauge A TEREX COMPANY Part No 77828 5 60 5 65 5 60 HC 4 53 Secti
546. t 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 string potentiometer is correctly routed around the small pulley before installing the boom end cover 7 Install the access panels on the sides of the boom 8 Start the engine from the ground controls and fully retract and lower the boom to the stowed position 9 Turn the key switch to the platform controls 10 Extend the boom approximately 2 feet 0 6 m 11 Retract the boom While retracting the boom visually inspect the number 2 and number 3 boom tubes Result The number 2 boom tube should not move more than 1 2 inch 13 mm before the number 3 boom tube begins to retract Note If the number 2 boom tube moves more than inch 13 mm before the number 3 boom tube begins to retract the boom extend retract cables need to be adjusted See Repair Procedure 4 5 How to Adjust the Boom Extend Retract Cables 3 36 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures B 23 Perform Engine Maintenance Deutz Models Note Engine specifications require that this procedure be performed every 400 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poo
547. ted forms for a minimum of 4 years or in compliance with employer jobsite and governmental regulations andrequirements Part No 77828 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Genie UK The Maltings Wharf Road Grantham Lincolnshire Watertown SD 57201 6150 NG31 6BH England 605 882 4000 44 1476 584333 Copyright 2011 Terex Corporation a registered trademark of Terex South Dakota Inc 133192 Rev D Instructions Make copies of this form to use for each Pre Delivery Preparation Use the operator s manual on your machine The Pre delivery Preparation co
548. ted by the Electronic Control Module ECM a fault code is recorded and the check engine light will turn on at the ground controls Special equipment is required to retrieve fault codes stored within the ECM Contact the Genie Service Department for assistance in retrieving fault codes Note If the check engine light is on and the engine is stopped tag the machine and remove from service Contact service personnel immediately Note If the check engine light is on and the engine is still running contact service personnel within 24 hours Ford models The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light Refer to Section 5 How to Retrieve Engine Fault Codes for your specific model of engine Use the Fault Code Chart within Section 5 to aid in identifying the fault TEREX COMPANY Part No 77828 S 60 5 65 5 60 HC 4 43 Section 4 Repair Procedures February 2012 Hydraulic Pumps 6 1
549. ter cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder Note Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the boom slightly and place 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 A TEREX COMPANY 4 8 5 60 5 65 5 60 HC 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 AWARNING Crushing hazard S 65 The jib boom could fall when the slave cylinder rod end pivot pin is removed if not properly supported 5 Remove the external snap rings from the barrel end pivot pin 6 Use a soft metal drift to drive the barrel end pivot pin out 7 Carefully pull the cylinder out of the boom to access the hydraulic hoses 8 Tag disconnect an
550. ter housings by using a wrench on the nut provided on the bottom of the housings 13 Remove the filter elements from the housings 14 Inspect the housing seals and replace them if necessary Part No 77828 Genie S 60 S 65 S 60 HC CHECKLIST D PROCEDURES 15 Install the new filter elements into the housings 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 there are no leaks Section Scheduled Maintenance Procedures February 2012 CHECKLIST D PROCEDURES D 7 Check and Adjust the Air LPG Mixture GM Models Note Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the proper air to fuel mixture during LPG operation is essential to good engine performance ADANGER Explosion and fire hazard Engine fuels combustible this procedure an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note The engine should be warmed to normal operating temperat
551. ter serial number 11879 6 52 Electrical Schematic 5 60 Models Deutz F3L 2011 Models before serial number 11880 6 54 Electrical Schematic 5 60 CE Models Deutz F3L 2011 Models after serial number 11879 sss eene 6 56 Ground Control Box Terminal Strip Wiring Diagram 5 60 Deutz F3L 2011 Models before serial number 11880 6 58 Ground Control Box Switch Panel Wiring Diagram 5 60 Deutz F3L 2011 Models before serial number 11880 6 59 Ground Control Box Terminal Strip Wiring Diagram 5 60 Deutz F3L 201 1 Models after serial number 11879 6 60 Ground Control Box Switch Panel Wiring Diagram 5 60 Deutz F3L 201 1 Models after serial number 11879 6 61 Ground Control Box Terminal Strip Wiring Diagram 60 CE Models Deutz F3L 2011 Models before serial number 11880 6 62 Ground Control Box Switch Panel Wiring Diagram 5 60 CE Models Deutz F3L 2011 Models before serial number 11880 6 63 Ground Control Box Terminal Strip Wiring Diagram 5 60 Models Deutz F3L 2011 Models after serial number 11879 6 64 Ground Control Box Switch Panel Wiring Diagram 5 60 Models Deutz F3L 2011 Models after serial number 118790 6 65 Platform Control Box Terminal Strip Wiring Diagram 5 60 Deutz F3L 201 1 6 66 Platform Contr
552. tform Control Terminal Strip Wiring Diagram 5 65 GM 3 0L Models a a 6 24 Platform Control Switch Panel Wiring Diagram S 65 GM SiO edt 6 25 Electrical Schematic 5 60 Ford LRG 425 EFI Models before serial number 11880 6 26 Electrical Schematic S 60 Ford LRG 425 EFI Models from serial number 11880 to 14053 6 28 Electrical Schematic 5 60 Ford DSG 423 EFI Models after serial number 14053 6 30 Ground Control Box Terminal Strip Wiring Diagram 5 60 Ford LRG 425 EFI Models before serial number 11880 6 32 Ground Control Box Switch Panel Wiring Diagram 5 60 Ford LRG 425 EFI Models before serial number 11880 6 33 Genie Part No 77828 S 60 S 65 S 60 2012 TABLE CONTENTS Section 6 Schematics continued Ground Control Box Terminal Strip Wiring Diagram 5 60 Ford Models after serial number 11879 6 34 Ground Control Box Switch Panel Wiring Diagram 5 60 Ford Models after serial number 11879 6 35 Platform Control Box Terminal Strip Wiring Diagram 5 60 Ford Models rear c E e vau 6 36 Platform Control Box Switch Panel Wiring Diagram 8 6
553. the boom end cover from the pivot end of the boom while guiding the small cable from the string potentiometer out of the slot of the cover Rest the cover and string potentiometer on the counterweight Component damage hazard The cable from the string potentiometer can become damaged if it is kinked or pinched 13 S 60 HC Remove the string potentiometer cable break limit switch mounting fasteners 14 S 60 HC Remove the pulley retaining plate from the string potentiometer pulley bracket Carefully remove the string potentiometer cable and limit switch assembly from the boom 15 Tag disconnect and plug the boom extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 Part No 77828 A TEREX 5 60 5 65 S 60 BOOM COMPONENTS 16 Tag and disconnect the electrical connector for the cable break limit switch 17 Tag and disconnect all boom wire harness electrical connectors located at the pivot end of the boom 18 Support the platform leveling master cylinder Remove the master cylinder rod end pivot pin retaining fasteners Place a rod through the pin and twist to remove Carefully lower the master cylinder down 19 Tag disconnect and plug the hydraulic hoses from the bulkhead fit
554. the stowed position and with the machine on a firm level surface Note The platform overload system will not allow partial calibration and must be completed in its entirety 1 Atthe ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position Pull out the red Emergency Stop button to the on postion at the platform controls 2 Remove all weight tools and equipment from the platform 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 weights will result in the platform load sense System not calibrating correctly This will allow too much weight to be added to the platform which will result in the machine tipping over TEREX COMPANY 5 60 5 65 5 60 HC 3 ground control box and locate the calibration toggle switch near the relays Note If either the operational and or safety controller has been replaced or if the software has been updated restore the system to the default settings and then continue to step 4 See How to Restore the Default Settings Otherwise continue to step 4 to enter calibration mode 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position O Result The alarm sound for approximately 2 seconds How to Restore the System Default Settings Turn the key switch to g
555. this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates the presence of a ACAUTION potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures February 2012 Platform Controls The platform control box contains one printed circuit board The ALC 500 circuit board inside the platform control box controls all proportional machine functions from the platform The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment The operating parameters of the joysticks are stored in memory at the ECM circuit board at the platform controls If a joystick error occurs or if a joystick is replaced it will need to be calibrated before that particular machine function will operate See 1 2 How to Calibrate a Joystick Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion
556. ting that step 3 of calibration is next Genie 5 60 5 65 5 60 HC 9 Raise the boom until the distance when measured between the centers of the pivot pins shown equals 167 25 inches 424 8 cm 0 75 inch 19 mm AWARNING Crushing hazard Keep clear of all moving parts of the boom while the boom is raising Do not attempt to measure between the pivot pins while the boom is moving 10 Activate and release the calibration toggle switch inside the ground control box 1 time Result The alarm should sound for 1 second indicating the third calibration step was accepted The green LED on the operational controller should be blinking fast and the red LED should be blinking four times indicating that step 4 of calibration is next 11 Fully raise and extend the boom 12 Activate and release the calibration toggle switch inside the ground control box 1 time Result The alarm should sound for 1 second indicating the fourth calibration step was accepted The green LED on the operational controller should be blinking fast and the red LED should be blinking five times indicating that step 5 of calibration is next 13 Fully retract and lower the boom to the stowed position 14 Using a suitable lifting device place an appropriate test weight equal to 750 Ibs 340 2 kg on to the center of the platform floor Note If your machine is equipped with any platform accessories or options they must be removed from the plat
557. ting Cycle power off valves 21 Fault outside of operational then on and limits Alarm sounds problem should be indicating fault corrected as Continued on next page S 60 S 65 S 60 5 3 Section 5 Fault Codes February2012 ss FAULTCODES Error Source Error Type ID Name ID Name Condition Solution 33 Boom 2 flow control valve 12 Value too high 15 Value too low Valve is operating outside of operational limits Alarm sounds indicating fault Cycle power then on and problem should be corrected 17 Not calibrated 18 Just calibrated Normal function except threshold for one or both directions is zero Calibrate valve thresholds Self clearing transient 41 Turntable rotate joystick 11 Value at 5V 12 Value too high 15 Value too low 16 Value at 0V Joystick is operating outside of operational limits Alarm sounds indicating fault Cycle power then on and problem should be corrected 17 Not calibrated Function is inoperative until joystick is calibrated Calibrate joystick 18 Just calibrated Initiate 1 second beep of alarm Self clearing transient 42 Turntable rotate Valve is operating Cycle power 18 Just calibrated is zero directional valves 21 Fault outside of operational then on and limits Alarm sounds problem should be indicating f
558. ting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old or other fluids Use approved container Please environmentally safe Be sure that your workshop or work area is y properly ventilated and well lit SAFETY RULES Genie Part No 77828 S 60 S 65 S 60 HC vii February 2012 Table of Contents Introduction Important Information ii li mem Serial Number Legend enn Section 1 Safety Rules General Safety Rules e dae qd vi Section 2 Specifications Machine Specifications nennen nnne 2 1 Performance 2 2 Hydraulic Specifications a 2 3 Manifold Component Specifications 0 0000 2 4 GM 3 0L Engine Specifications 2 5 For
559. tings at the pivot end of the boom Cap the bulkhead fittings AWARNING 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 20 Remove the external snap rings from both boom pivot pins at the short and long link arms Do not remove the pins 21 Using the overhead crane adjust the boom as necessary to relieve pressure from the pivot pins 22 Use a soft metal drift to remove each boom pivot pin Carefully remove the boom assembly from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The boom could fall if not properly supported by the overhead crane when each boom pivot pin is removed Crushing hazard The long and A CAUTION short link arms may fall if not properly supported when the boom pivot pins are removed Section 4 Repair Procedures February 2012 BOOM COMPONENTS 4 3 Boom Lift Cylinder The boom lift cylinder raises and lowers the boom The boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Boom Lift Cylinder AWARNING 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
560. tion 6 Schematics Electrical Schematic 5 65 Ford LRG 425 EFI Models before serial number 11880 P22LS BK e gg z O 5 k lt s 0 5 t SER 1 9 K 8 s B C35RPM BK RD C1B 9 E ENGINE 5 OIL PRESSURE SPEED 25258 WH BK E 8 BEEN SENDER OPTION e E 4 VOLT METER OPTION 2 LOWRPM 8 C26TSR WH RD WATER TEMPERATURE t HIGH RPM 5 gt i SENDER OPTION 5 Toc MM ve rrr ee ees a eee ee cree eet ge Q IWE C RU LEM PITE CR ee EE e cee PET M GENERATOR I E HYDRAULIC uu 2 7 C45GEN GR WH C2B 7 5 12 C45GEN GR WH 4 GENERATOR e l 1 k II s eel eats E II IIArmAI 1 g C2P 4 DLITE OR RD C2B 4
561. tion 6 Schematics ESS 8 Hydraulic Schematic 12kW Hydraulic Generator Option G F E D 1 IB q I I DRIVE i m PUMP SWVI ANCONA 2 MANIFOLD 1 PMPB _____ ___ E 3 m o e I DIVERTER ew 1 MANIFOLD L L I N I I 4 I I NN J 0 081 i 1 l I N CU I T We I __ lt I 5 IG2 280 psi I Gil tps ER eto eee seus I I I I 6 c HIH ols I I L ___ 7 ur 2i 8 G2 G1 HYDRAULIC GENERATOR Genie Part No 77828 S 60 5 65 5 60 HC 6 108 February 2012 Section 6 Schematics SM 9 Hydraulic Schematic 12kW Hydraulic Generator Option Section 6 Schematics Hydraulic Schematic 2WD Models February 2012
562. tions February 2012 m H M Rr This page intentionally left blank Genie 2 14 5 60 5 65 5 60 HC Part No 77828 February 2012 Section Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report The frequency and extent of periodic examinations and tests may also depend on national regulations Failure to perform each procedure AWARNING as presented and scheduled may cause death serious injury or substantial damage M Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Use only Genie approved replacement parts Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Boom in stowed position Turntable rotated with the boom between the non steer wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power disconnected from the machine Part No 77828 Genie 5 6
563. to the engine tray anchor hole in the turntable AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures E 4 Replace the Boom Extend Retract Cables Note Genie specifications require that this procedure be performed every 10 years The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Replacement of the boom extend retract cables is essential to good machine performance and safe machine operation The boom extend retract functions should operate smoothly and be free of hesitation jerking and unusual noise 1 Replace the boom extend retract cables See Repair Procedure 4 5 How to Adjust the Boom Extend Retract Cables CHECKLIST E PROCEDURES Genie Part No 77828 5 60 5 65 5 60 HC Section 3 Scheduled Maintenance Procedures February 2012 This intentionally left blank Genie 3 62 5 60 S 65 5 60 HC Part 77828 February 2012 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before o
564. trical Schematic S 65 Perkins 404 22 Models after serial number 11879 T e c LO C7P 3 BATGND C7B 3 GROUND 2 E C2P 3 OR BK C2B 3 9 5 lt 8 5 m z a haze 01 4 C30FWD WH C1B 4 5 21 C30FWD WH BK DRIVE FORWARD gt 15 7 01 C31REV WH BK C1B 5 5 20 CS1REV WH BK AD BK DBVEIREVERSE e gl 4 J DRIVE C130TA WH RD TRAVEL ALARM 5 E 505 9 26 1 262 m 5 s ES Have CIPS C32BRK WH RD 6 C5 28 _ 2 WH RD sl BRAKE RELEASE gt x S 8 C28 1 C282 55 C29MS RDWH z C29MS RD WH 5 ag CIP3 CIE 05724 D MOTOR STROKE r E oe 5 n Q 8 BL RD 16
565. trical Schematic S 65 Deutz F3L 201 1 Models before serial number 11880 Section 6 Schematics February2012 XE EZ IE iai SZMEEEEEE ii s 52 i Electrical Schematic S 65 Deutz F3L 2011 Models after serialnumber 11879 2215 February 2012 C Deutz F3L 201 1 Models after serial number 11879 Electrical Schematic S 65 Section 6 Schematics 55 gg E A m I E d 5 o 9 C35RPM BK RD C1B 9 FOOTSW HIGH FOOTSW LOW E 28 x ow b 8 LOW RPM x UNCTIONENA C35RPM BK RD BRN t 1 HIGH IDLE RELAY 8 5 6518 HIGH RPM SOLENOID e
566. ts labeled A and B in sequence to 28 ft Ibs 38 Nm and the mounting bolts labeled to 49 ft Ibs 66 Nm Then torque the bell housing mounting bolts labeled A and B in sequence to 40 ft Ibs 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 Ibs 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 Ibs 54 Nm and the mounting bolts labeled A to 70 ft lbs 95 Nm GM models Torque the bellhousing mounting bolts in sequence to 28 ft lbs 38 Nm Then torque the bell housing mounting bolts in sequence to 40 ft lbs 54 Nm Component damage hazard Type A flexplate When installing the pump do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged Part No 77828 S 60 5 65 5 60 HC 4 41 Section 4 Repair Procedures February 2012 ENGINES GM models Deutz models Genie 4 42 5 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures ri ENGINES 5 4 Engine Fault Codes GM and Ford Models How to Retrieve Engine Fault Codes GM models When an engine malfunction is detec
567. ts when activating high idle 7 Swingthe engine back to its original position and install the engine pivot plate retaining fastener Part No 77828 Genie 5 60 5 65 5 60 HC CHECKLIST B PROCEDURES B 10 Test the Ground Control Override Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the on or off position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Pushin the platform red Emergency Stop button to the off position 2 Startthe engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle Result All boom functions should operate Section Scheduled Maintenance Procedures February 2012 CHECKLIST B PROCEDURES B 11 Check the Oscillate Directional Valve Linkage Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Note Perform this test only on models equipped with a oscillating axle Proper axle oscillation is essential to safe machine
568. tz F3L 2011 Engine Displacement Number of cylinders Bore and stroke Horsepower Firing order Low idle High idle Compression ratio Compression pressure 142 cu in 2 33 liters 3 3 7 x 4 4 inches 94 x 112 mm 48 Q 2800 rpm 36 kW 2800 rpm 1 2 3 1500 rpm 313 Hz 2500 rpm 522 Hz 19 1 362 to 435 psi Cil viscosity requirements 22 F to 86 F 30 C to 309 C 5W 30 synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 20W 50 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil temperature switch Temperature switch point 300 F 149 Oil pressure switch Oil pressure switch point 7 psi 0 48 bar Fuel injection system 25 to 30 bar Governor centrifugal mechanical Injection pump make Pasch Injection pump pressure maximum 15000 psi Valve clearance cold 1034 bar Intake one Injector opening pressure 3046 psi 0 3 mm 210 bar Exhaust Fuel requirement 0 5 mm Lubricati t For fuel requirements refer to the engine Operator s Manual your machine Oil pressure 20 to 44 psi 1 4 to 3 bar Starter motor A Oil capacity 8 5 quarts Current draw no load 90 including filter 8 liters Brush length new 0 72 in 18 5 mm Brush length minimum 0 27 in 7 mm Conti
569. u HWQH I9S L HWQH Q HOLSIS3H INOZ u3ddn d33ds WOO8 AHVWIHd woog 1 wyo s au ScHH 151539 314104 HO1SIS3H 1 1 vH woog FE H z H O 6 77 S 60 S 65 S 60 HC Part No 77828 February 2012 Section 6 Schematics JEE EE EE EEE E Ground Control Box Switch Panel Wiring Diagram S 65 Deutz F3L 2011 Models before serial number 11880 Section 6 Schematics February2012 w ss rrrrrrc li sasrrrm Ground Control Box Terminal Strip Wiring Diagram S 65 Deutz F3L 2011 Models after serial number 11879 February 2012 Ground Control Terminal Strip Wiring Diagram 5 65 Deutz F3L 2011 Models after serial number 11879 Section 6 Schematics ros
570. uary 2012 Section 2 Specifications Hydraulic Specifications Hydraulic Oil Specifications Chevron Rando HD MV equivalent Multi viscosity Hydraulic oil type Viscosity grade Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rando HD oil is fully compatible and mixable with Shell Donax TG Dexron III oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exeed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optionalfluids Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable UCON Hydrolube HP 5046 Quintolubric 822 Fire resistant Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Continued use of Chevron Aviation A hydraulic oil when in ambient temperatures consistently below 18 C may result in component damage Note Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below O F 18 Note Use Shell Tellus 46 hydraulic when oil temperatures consistently exceed 205 F 96 C Note Genie specifications require additional equipment and special installation instructions for the approved optional
571. ull out the red Emergency Stop button to the on position When the alarm sounds release the drive enable toggle switch Momentarily activate the drive enable toggle Switch in the right direction 6 times Result There should be a pause and the alarm should sound 6 times indicating that the machine is in ramp rate calibration mode Result The alarm does not sound Repeat steps 3through 7 A TEREX COMPANY 5 60 5 65 5 60 HC Part No 77828 February 2012 8 Startthe engine from the platform controls and press down the foot switch 9 Startatimer 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 time with the table and determine whether the ramp rate time needs to increase or decrease 11 Release the foot switch 12 Activate the joystick and adjust the ramp rate Momentarily move the drive enable toggle switch in the right direction to increase the time or momentarily move the drive enable toggle switch in the left direction to decrease the time Note Each time the drive enable toggle switch is momentarily moved the time will change in 5 increments from a default of 100 with a minimum of 5096 and a maximum of 150 13 Repeat steps 9 through 11 for each joystick controlled machine function 14 Return the joystick to the neutral position and wait for approximately 10 seco
572. umber 11879 Section 6 Schematics February2012 EX ee Ground Control Box Terminal Strip Wiring Diagram S 65 Deutz F3L 2011 Models before serialnumber 11880 February 2012 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram S 65 Deutz F3L 2011 Models before serialnumber 11880 FUNCTION HARNESS GNNOYD 5 551 HOLIMS NOISN3L 318vO 51 HOLINS woog 20919 et 61 81 79855 L 61 84 42 WuOd1V1d OL H6 CE ONLY 49099 N d JINON 1HV LS NOLINOI HOA
573. unterbalance valves on the primary boom extension cylinder when removing the cylinder from the boom Note During removal of the extension cylinder the overhead crane strap will need to be carefully adjusted for proper balancing 4 31 Section 4 Repair Procedures February 2012 BOOM COMPONENTS 4 5 Boom Extend Retract Cables How to Adjust the Boom Extend Retract Cables The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Proper 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 hesitation jerking and unusual noise Note Perform this procedure with the boom in a horizontal position 1 Fully retract the boom 2 S 60and S 65 Remove the boom end cover retaining fasteners and remove the cover 5 60 HC Remove the boom end cover from the pivot end of the boom while guiding the small cable from the string potentiometer out of the slot of the cover Rest the cover and string potentiometer on the counterweight Component damage hazard The cable from the string potentiometer can become damaged if it is kinked or pinched Inspect the threaded ends of the boom extend cables The threads must be clean and in good condition with no damaged threads 4 32 TEREX COMPANY
574. ure before performing this procedure 1 Move the fuel select toggle switch to LPG fuel and start the engine from the ground controls 2 Locate the high idle mixture adjustment screw on the LPG venturi that attaches to the air cleaner air cleaner hose 3 Loosen the lock nut on the high idle mixture adjustment screw 4 Load the system by activating the primary boom retract function then move the function enable toggle switch to the high idle rabbit symbol position 5 Adjustthe high idle adjustment screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 2 1 using an exhaust gas analyzer Note Preliminary setting is inch 6 4 mm of threads showing Measure from top of lock nut to top of adjustment screw Note If an exhaust gas analyzer is not available adjust to obtain peak or optimum rpm 6 Hold the adjustment screw and tighten the lock nut 7 Return the function enable toggle switch to the center position 8 Locate the low idle mixture adjustment screw on the LPG regulator 9 Agjust the low idle mixture adjustment screw to obtain an air to fuel mixture ratio of 13 0 1 to 13 211 Note Preliminary setting turn low idle adjustment screw clockwise all the way in Turn low idle adjustment screw counterclockwise 2 turns Part No 77828 February 2012 Section 3 Scheduled Maintenance Procedures D 8 Perform Engine Maintenance Deutz Models Note Engine specifications require that th
575. using Carefully remove the muffler and bracket assembly from the engine Support the engine with an overhead crane or other suitable lifting device Do not lift it Remove the engine mounting plate to bell housingfasteners Raise the engine slightly using the overhead crane and place a block of wood under the oil pan for support Support the drive pump assembly with an overhead crane or other suitable lifting device Do not apply any lifting pressure Remove all of the engine bell housing retaining fasteners 10 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked orpinched 11 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel TEREX COMPANY S 60 5 65 5 60 HC Part No 77828 February 2012 Section 4 Repair Procedures Perkins models 1 Remove the fuel filter water separator mounting fasteners Remove the fuel filter water separator and lay it to the side Do not disconnect the hoses Support the drive pump assembly with an appropriate lifting device Remove all of the engine bell housing fasteners 5 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched Remove the flex plate mounting fasteners Remove the flex pl
576. ve the pin retaining fasteners from the boom lift cylinder barrel end pivot pins Do not remove the pins 8 Useaslide hammer to remove the barrel end pivot pins AWARNING Crushing hazard The boom lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device 9 Move the boom lift cylinder towards the counterweight end of the machine Rotate the boom lift cylinder until the barrel end pivot pin bores will clear the boom linkage 10 Carefully remove the boom lift cylinder from the machine AWARNING Crushing hazard The boom lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device Part No 77828 February 2012 Section 4 Repair Procedures 4 4 Boom Extension Cylinder The boom extension cylinder is located inside the boom assembly and incorporates cables and pulleys that are responsible for extending the number 3 boom tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Boom Extension Cylinder AWARNING P 4dily 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 h
577. vot end of the boom AWARNING 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 13 Pull the hydraulic hoses out of the primary boom 14 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and AWARNING lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine 15 Attach a strap from an overhead crane to the cable track 16 Remove the cotter pin from the cable track pull tube at the platform end of the boom Note Always replace the cotter pin with a new one Part No 77828 A TEREX 5 60 5 65 S 60 BOOM COMPONENTS 17 Remove the cable track pull tube guide fasteners from the cable track guide at the platform end of the boom Remove the cable track guide from the boom 18 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom 19 Carefully remove the cable track from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The cable track could become unbalanced and fall if not properly attached to the overhead crane Component damage hazard Cables and hoses can be damaged if they are kinked or pin
578. w Inconsistent Genie Repair wiring and or connections OR replace boom angle sensor and calibrate overload system Part No 77828 5 60 5 65 5 60 Section 5 Fault Codes February 2012 FAULT CODES Load Cell Operational C175LDS Output short high Value too high Value too low Output short low Error Source Error Type ID 5 Sensor tolerance fault Condition Power relays disengaged Power relays disengaged Load cell wiring open or shorted to voltage Power relays disengaged Load cell wiring open or shorted to voltage Platform may be overloaded Power relays disengaged Load cell wiring open or shorted to ground Platform may be reverse loaded 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 Repair wiring and or connections OR replace platform load cell and calibrate overload system Repair wiring and or connections OR replace platform load cell and calibrate overload system OR remove excess weight from platform 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 touching the ground or being supported from underneath Repair wiring and or connections OR replace platform load cell and calibrat
579. wing Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may result in minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such moving parts free swinging unsecured components when lifting or placing loads Always wear approved steel toed shoes Part No 77828 February 2012 Section 1 Safety Rules Workplace Safety lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure to keep sparks flames and are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage lt N Be sure that all tools and working areas other lifting or supporting device is fully capable of suppor
580. y connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than mA and are different by a minimum of 20 The coil is good W Result If one or both of the current readings 0 mA or if the two current readings do not differ by a minimum of 2095 the coil and or its internal diode are faulty and the coil should be replaced Section 4 Repair Procedures February 2012 Turntable Rotation Components 8 1 Turntable Rotation Assembly How to Remove the Turntable Rotation Assembly Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this 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 AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections
581. ymbol then lower the boom into the stowed position 4 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 5 Bringthe machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Section 2 Specifications Genie 5 60 5 65 S 60 HC 17 Test the Drive Speed Raised or Extended Position Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe engine from the platform controls 3 Move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 4 Press down the foot switch and raise the primary boom above horizontal 5 Choose point on the machine i e contact patch of a tire as a visual refe

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