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3. T N 7 3 BATGND C7B 3 GROUND C2P 3 C41RPM OR BK C2B 3 9 sc 8 5 T a 61 4 C30FWD WH C1B 4 5 21 WH BK FORWARD gt 15 5 T o 3 CIPS C31REV WH BK C1B 5 C520 WH BK DRIVE REVERSE 4 1 DRIVE MODE WH RD i TRAVELALARM z eo OPTION 5 RAT 8 C26 1 C26 2 152 C32BRK WH RD 1 3 lt 6 25 23 C32BRK WH RD Al RELEASE x a 8 28 1 28 2 5 T T 2 o 01 C29MS RD WH C1B 3 5 24 29 5 RD WH D 22 E 8 5 CDE3 BL RD gt 16 n 5 3 25 1 C252
4. N N c7P 3 BATGND C7B 3 1 GROUND 2 o 4 C2P 3 C41RPM OR BK C2B 3 a 5 lt lt lt 8 5 9 m T 2 a Haze 6 WH C1B 4 25 21 C30FWD WH BK DAVE FORWARD 15 3 g o 3 gt 01955 WH BK C1B 5 5 20___ 1 RD rj DHIVEHEV RSE 2 5 5 es jit eet on pee hed DRIVE MODE C130TA WH RD 2 4 TRAVEL ALARM gt 558 Lt OPTION 8 ease ee 9 g C26 1 026 2 gt m 2 C32BRK WH RD T E IK eeg C1B 6 5 23 C32BRK WH RD hi fe es ees ae gt 8 28 1 C28 2 5 T C29MS RD WH 2 C29MS RD WH o taze CiP C1B 3 5 24 MOTOR STROKE 5 n 8 ES gt CDESBURD syra 8 C254 025 2 2 2 1 11 C37SCW C1B 11 C37SCW BL BK Prem 27 15
5. P22LS BK gt ROCKER STEER OPTION ONLY C7P 3 BATGND C7B 3 7 GROUND gt Lee 23 C41 RPM OR BK C2B 3 5 9 a 4 C30FWD WH 1 4 25 21 C30FWD WH BK cL RD a 15 lt DRIVE FORWARD 215 o Haze CIPS C31REV WH BK C1B 5 C5 20 C31REV WH BK ADD BK ARVE REVERSE g 5 2 fi PRR RRS RS eR Se Se nd did ie HH ee t DRIVE MODE C130TA WH RD 27 TRAVEL ALARM 8 OPTION 8 N C26 1 026 2 1 6 1 6 5 23 C32BRK WH RD 2 WH RD n BRAKE RELEASE x u E 8 C28 1 C282 z 2 IMS RD WH 29MS RD WH Bil 9 E 61 3 C29MS RD WI C1B 3 0524 C29MS In 2 N E 8 5 5 5 C25 1 025 2 E CDE2 BBK 1 11 C37SCW
6. NOTES Ford LRG 425 EFI Models after serial number 11879 Electrical Schematic S 60 Section 6 Schematics ale 8 m lt s u 5 1 rae a gra 1 9 C35RPM BK RD C1B 9 ENGINE 5 OIL PRESSURE SPEED 25PSR WH BK 3 8 SENDER OPTION 5 VOLT METER OPTION 0 e LOW RPM ENABLE B 8 C26TSR WH RD 4 WATER TEMPERATURE 1 HIGH RPM 4 DE engl ir ie en N ie a BE EN uk ee GENERATOR 8 st C2P 7 C45GEN GRWH C2B 7 65 12 GR WH Itl o 1 M re 1 i
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9. 6 34 enie A TEREX COMPANY 5 60 5 65 G Part No 77828 July 2005 Section 6 Schematics __________ Ground Control Box Switch Panel Wiring Diagram 5 65 Ford LRG 425 EFI Models before serial number 11880 Section 6 Schematics July 2005 _______________ Ground Control Box Terminal Strip Wiring Diagram 5 65 Ford LRG 425 EFI Models after serial number 11879 REVA July 2005 Ground Control Box Terminal Strip Wiring Diagram S 65 Ford LRG 425 EFI Models after serial number 11879 Section 6 Schematics 1108
10. 20 E ze a gt 2 9 5 80 53 2 860 LISTHO r4 GVOTHSAOWHOSIVId 1 o a 9 eer 51 GVOTHSAO WHOALYId 7 80 GH HO AAAS JAN SH 6 860 H4 GH HO a NUHOPH H3MOd NHOH GH Y x7 5 a 8 85 1 820 N3OSVO 9 O 21 50 5 z 212 FNS yas usta P vel _ 21 MS Q C4 Sad E 0 SS 1948 HMdtE LO H3 HM 849614 o A vel BE ZISTOHMMAFELD P I 215 7 6 QVO 183AO 9 20 49 49 UMdrEIO 169 68 lt 20 SSTHM 26860 Je 9PTHM Oo 11 869 9 9v 3 on 2 o 9 820 HO NHH9vO kr 2 255 nao Je dmiold HOLVNYSLIV n 5 2 2 2019190151090 P 2 18 WOO 2 822 151070 ul orsoqungaweo TO
11. P22LS BK REV 3 C7B 3 GROUND 2 E 9 ps C41RPM C2B 3 5 8 C30FWD WH C1B 4 5 21 WH RDS DRIVE FORWARD gt 15 B 8 n 6185 C31REV WH BK C1B 5 C5 20 WH BK p BK DAVE REVERSE gi 4 4 77 DRIVE MODE C130TA WH RD TRAVEL ALARM 3 U OPTION Q CEET EEE ERBEN 2 9 26 1 C262 gt m eut C328RK WH RD C1B6 El CGBRKWHRD 6 2401 7 2 am 3 C28 1 C282 a a 1 C29MS RD WH C1B3 5 24 29 5 RD WH 21 9 8 5 o a CDE3 BURD S76 5 2 3 C251 C252 CDE2 BL BK 5 C37SCW BL BK C37SCW BL BK Br gt Inge 01 C1B 11 STEER RIGHT E m RIGHT VE ENABLE C36STCC BL B C36SCC BL s nz cc CIP10
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15. amp 55 gg ela ai gt a x RS a p 9 C35RPM BK RD C1B 9 8 FOOTSW HIGH e e 5 9 FOOTSW LOW 28 x 8 5 RPM x FUNCTION HIGH RPM pi BK RD m BAN Lect IDLE RELAY 2 1 5 1 80 65 18 Ne HIGH RPM SOLENOID o cz o ____ ______ 3 N i 5 2 7 C45GEN GRWH C2B 7 C45GEN GR WH 5 12 Al LOENERATOR OPTION bM 3 12 DLITE BL WH C3B 12 om 1 DRIVE LIGHT work OTS v 4 C DRIVE LIGHT OPTION u 55 5 2 N an WORK LIGHTS OPTION 85 cap 2 YY C2P 10 a RS 5 pe eS 2 11 C2P 9 Z x 8 en y 5 tr a C1P 8 BK WH C1B 8 C34SA BK WH 5 22 4 1 2 5 GLOW GLOW PLUG RELAY PLUG 12 i dX 242 GLOW PLUG PLUG 000 5 a o C26TSR WH RD OIL TEMPERATURE LED 5 e z 599
16. NOTE DASHED LINES INDICATE OPTION WIRES enie G A TEREX COMPANY 5 60 5 65 77828 6 25 Section 6 Schematics Ford LRG 425 EFI Models after serial number 11879 Ground Control Box Switch Panel Wiring Diagram S 60 July 2005 REVA 6 26 enie T 5 5 zz gt or 8 5 582848 9 lt 2 8 8 5392585 828 j o wi 92 55 aalge cuu 5 5 2 25505 gl 218152152 6 oae 95 248 2 93 alkilo 58995 85 86 8 52 50 65 2 5 82 gu 5 5 2 5 2 2 oj H 2
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18. July 2005 Deutz 2011 Models before serial number 11880 Electrical Schematic S 65 CE Models Section 6 Schematics ele c ge 5 EB y C35RPM BK RD C1B 9 9 38 FOOTSW HIGH 5 FoorSw Low 28 3 x oe 8 5 LOW RPM FUNCTION ENA HIGH RPM C35RPM BK RD BRN 4 LIGHIDLE RELAY 1 a 8 HIGH RPM SOLENOID N Y 5 GRWH C2B 7 C45GEN GRWH 5 12 IA d GENERATOR OPTION E 3 C3P 12 DLITE BLWH C3B 12 1 DRIVE LIGHT mem S
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23. PLATFORM CONTROL HARNESS TO CONTROL BOX DRIVE LIGHTS WORK LIGHTS DLITE RD RD __ __ _____________________________________________________________________89__ JC2 OPTION TILT ALARM LED JC3 BK OPTION PRIMARY BOOM 7 4 DRIVE UP DOWN 7 1 7 i FORWARD REVERSE 7 amp TURNTABLE ROTATE BOOM TS15 8 STEER LEFT RIGHT 18 DRIVE LEFT RIGHT 148 6 6 ENABLE 6 COMPONENT INDEX bg JC2 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE 3 3 2 5 JC1 BOOM PROPORTIONAL JOYSTICK 2 8 BOOM EXTEND RETRACT 2 4 4 JC3 DRIVE STEER PROPORTIONAL JOYSTICK pi i 11 DRIVE ENABLE LED 3 3 4 14 PLATFORM OVERLOAD LED T 1 1 PLATFORM 147 LOWER RETRACT BOOM LED Me 148 BOOM TILTED LED 1 2 m 2 AD 2 EMERGENCY STOP BUTTON De HORN SWITCH 1 pd 1 TS1 AUXILIARY POWER TOGGLE SWITCH 4 N 152 ENGINE START TOGGLE SWITCH E 18 rg Lm TS3 FUEL SELECT TOGGLE SWITCH SE 6 754 HI LOW RPM TOGGLE SWITCH BAN Pd bd ee eee 757 PLATFOR
24. P22LS BK REV B 7 3 BATGND C7B 3 o E 62 3 CA1RPM OR BK C2B 3 i T B o a C30FWD WH C1B 4 5 21 C30FWD WH BK DRIVE FORWARD 8 gt 15 5 2 C31REV WH BK C1B 5 C5 20 C31REV WH BK BK 1 z DRIVE MODE C130TA WH RD ir TRAVELALARM z LI OPTION PN 8 C26 1 026 2 gt 5 C32BRK WH RD 2 Haze CIPS C1B 6 5 23 WH RD Tal SHAKE RELEASE 5 C28 1 28 2 C29MS RD WH C29MS RD WH o lt lt OP S CERE 9 lt gt MOTOR STROKE amp N 8 T gt 5 5 5 C25 1 25 2 2 CDE2BL BK ave C37SCW BUBK 11 E C37SCW BUBK 1 SEHR gt STEER RIGHT RIGHT VE P C36STCC BL B C36SCC BL f BIGHT 3 2 lt lt 10 G1B 10 z STEER LEFT dz CDE1 BL WH g C241 C242 Sus 1 BL g RKOUT B A EK C3P 6 C6TRF WH RD C3B 6 8 vour s WH 4 8
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26. A TEREX COMPANY 5 60 5 65 G Part No 77828 O July 2005 Section 6 Schematics SS Ground Control Box Switch Panel Wiring Diagram S 60 Deutz F3L 2011 Models before serial number 11880 Section 6 Schematics July 2005 7 Ground Control Box Terminal Strip Wiring Diagram 5 60 Deutz F3L 201 1 Models after serial number 11879 REVA July 2005 Ground Control Box Terminal Strip Wiring Diagram S 60 Deutz F3L 201 1 Models after serial number 11879 Section 6 Schematics 1108
27. HOLIMS OL SS3NHVH NOTE DASHED LINES INDICATE OPTION WIRES enie A TEREX COMPANY S 60 S 65 G Part No 77828 6 51 Section 6 Schematics Deutz F3L 2011 Models before serial number 11880 Ground Control Box Switch Panel Wiring Diagram S 60 CE Models July 2005 REV B 6 52 enie A TEREX COMPANY 5 60 5 65 G Part No 77828 x 9 a r 956 5 5 amp 922 5 2 lt E 4 545 595 928 55428 zz 9 56 21566 2 9 54201 552 ZERIE EIE 86 25554 WIS lt 0 5 8 0 0 0 2 5 E SE u u
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29. Electrical Schematic S 65 CE Models Deutz F3L 201 1 Models after serial number 11879 Section 6 Schematics s xs 5 ale n o t d 5 o C35RPM C1B 9 o 8 FOOTSW HIGH e FOOTSW LOW ou b 25 LOW RPM x o 4 FUNCTION ENA C35RPM BK RD BRN RPM HIGH IDLE RELAY 2 5 BIRD 65 18 HIGH RPM SOLENOID cz ee 3 1 5 C2P 7 C45GEN GRWH 28 7 z C45GEN GR WH 5 12 GENERATOR OFTION NE MHIL LAM 9 12 DLITE BLWH C3B 12 1 DRIVE LIGHT g Vo WORK LIGHT 2 RD C DRIVE LIGHT OPTION 9 lt gg 8 TS n z WORK LIGHTS OPTION iat 2 12 C2P 10 8 es 1 a ins s 1 OS TEP REE OE RINGE 2 11 gt 02 9 9 8 1 m amp 1 sae SE EH y 3 tr 8 5 9 8 C34SA BK WH C34SA BK WH 05 22 1 ciow Pic RELAY 1 GLOW PLUG b Fe e 9 0 G
30. 77828 July 2005 Section 6 Schematics E Ground Control Box Switch Panel Wiring Diagram S 60 GM 3 0L Models Section 6 e Schematics July 2005 nun nn Platform Control Box Wiring Diagram S 60 GM 3 0L Models REV 12V DC PLATFORM POWER CONNECTOR FOOTSWITCH CONNECTOR CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH DESCRIPTION TILT ALARM ALC 500 CONTROL BOARD CWLITE WH TS49 TO SWITCH PLATFORM CONTROL PANEL HARNESS C19JSV GR WH TS7 C19JSV GR WH 7 BRN JC3 BRN GND RD E STOP C1P C4P 48 PIN CONNECTOR BLOCK ITEM H1 7 C9 U13 J1 J2 J3 CR27 CR30 LS18 C134PWR RD H1 C32BRK WH RD 1 6 C32BRK WH RD J2 19 C134PWR 1518 July 2005 NOTE WIRE CONNECTS TO JC3 6 FOR STEER ROCKER SWITCH OPTION Platform Control Box Wiring Diagram S 60 Section 6 Schematics GM 3 0L Models 401 5 OR C2P 2 P24FS WH C9P 2 P23BAT WH C7P 2 1 12 P22BAT 7 1 C19JSV GR WH 7 C18PRR GR BK C4P 6 C17PRL GR C4P 5 C15PLD OR BK C4P 3 C14
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34. Deutz F3L 2011 Models before serial number 11880 July 2005 B gt ROCKER STEER OPTION ONLY P22LS BK REVC N N C7P 3 BATGND C7B 3 GRouND E C2P 3 OR BK C2B 3 8 EK 8 5 e A 7 C30FWD WH C1B 4 C5 21 C30FWD WH BK c RD DRIVE FORWARD gt 15 E LIPS os C31REV WH BK qc 6185 y 05 20 WHIBK FF BK DRIVE REVERSE gl t DRIVE WH RD TRAVEL ALARM 3 OPTION 9 ee o NE 9 8 C26 1 C262 C32BRK WH RD lt C1B 6 i C5 23 __ C32BRK WH RD V ORARE RELEASE x 2 8 C28 1 C282 T C29MS RD WH 2 C29MS RD WH o CIPS C1B 3 _ 5 24 Il n 8 5 _ 5
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39. 6 83 B Platform Control Box Switch Panel Wiring Diagram 5 60 Perkins 404 22 6 84 D Electrical Schematic 5 65 Perkins 404 22 Models before serial number 11880 6 85 Electrical Schematic 5 65 Perkins 404 22 Models after serial number 11879 6 87 B Ground Control Box Terminal Strip Wiring Diagram 5 65 Perkins 404 22 Models before serial number 11880 6 89 B Ground Control Box Switch Panel Wiring Diagram 5 65 Perkins 404 22 Models before serial number 11880 6 90 A Ground Control Box Terminal Strip Wiring Diagram 5 65 Perkins 404 22 Models after serial number 11879 6 91 A Ground Control Box Switch Panel Wiring Diagram 5 65 Perkins 404 22 Models after serial number 11879 6 92 Platform Control Box Terminal Strip Wiring Diagram 5 65 Perkins 404 22 6 93 B Platform Control Box Switch Panel Wiring Diagram 5 65 Perkins 404 22 6 94 D Hydraulic Schematic 2WD Models 6 95 D Hydraulic Schematic 4WD Models 6 96 Genie Part No 77828 S 60 5 65 July 2005 ee This page intentionally left blank Genie xviii 5 60 5 65 Part No 77828 July 2005 Section 2 Specifications REVA
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41. sea 5 1 9 C35RPM BK RD C1B 9 I ENGINE 5 OIL PRESSURE SPEED C25PSR WH BK 207 8 SENDER OPTION 5 VOLT METER OPTION LOW RPM FUNCTION ENABLE 8 C26TSR WH RD WATER TEMPERATURE 1 HIGH RPM SENDER OPTION I BEE 1 1 2 5 GENERATOR HYDRAULIC Ja 5 t 2 7 C45GEN GR WH C2B 7 C45GEN GR WH GENERATOR OPTIOI Dec eR CEN EUER 2355 24 25242235574 545 VEN TIEREN a a E ee 222 A AO 5 a C2P 4 DLITE OR RD C2B 4 1 8 DRIVELIGHT ya 1 RD DRIVE LIGHT 9 8 lt gt OPTION 5 25 3 WORKLIGHT 8 S 8 m WH N BK 50 lt gt 196 BEN WORK LIGHTS OPTION 56 1 4444 HH HH Sees eee sene eise es J WH BK 10 1 1 a 1 ut C21IGN WH HOUR METER 1 S Ln BL WH CHECK ENGINE LED BR 5 4 I RUN TEST SWITCH 5 5 amp 88 o 2 C2P 1 C39LP BURD C2B 1 9 8 FUEL o C5 19 P23BAT WH FEH 16 PIN1 SELECT 3 UE FUEL 05 11 C21IGN WH 71 PIN21 T 1877 SELECT 8 a S
42. ALC 500 circuit board drive steer joystick controller c secondary boom up down joystick controller d primary boom up down and turntable rotate left right joystick controller 4 2 5 60 5 65 REVA 1 1 ALC 500 Circuit Board AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 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 Pushin 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 hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 77828 July 2005 Section 4 Repair Procedures E REV A PLATFORM CONTROLS 4 Attach a grounded wrist strap to the ground 1 2 screw inside the platform control box Joysticks Component damage hazard CAUTION Electrostatic discharge ESD can How to Calibrate a Joystick damage printed circuit board components Maintain firm contact The joysticks on this machine utilize di
43. _____ _ ______ ______________ UMdt LO gg Doe 18 5 o 1 va an amp S 12 04 2 HOLIMS qu E HM HM 157 01816 Tm 1661 HOLIMS 4018 AONSDYANA QH HM 18861 QH HM i 82846149 e Yl Wyo GL WYO OL MSZ HOISIS3H HOISIS3H 31v10H INOZ H3ddn FIAVLNHNL INOOS vH Yok 8 MSZ HOLSIS3H 1 HOLSISSY STaVLNYNL NMOG dn ed woog 1 uuo S QH HM 52 YA July 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram 5 60 Perkins 404 22 Models after serial number 11879 July 2005 Section 6 Schematics I asny Platform Control Box Wiring Diagram S 60 Perkins 404 22 Models REV 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
44. bm oot E S Q X sf TS2 TS47 ENGINE GENERATOR START OPTION 6 10 SHSEO 2 69 HM Sd ed TS4 HIGH LOW RPM WH 24 RD j vv 287 BS dio 533555 Moa Imc 5 5 ols 25 AA 88 o Sg SS SIR TS3 FUEL SELECT IOS no nc 201 o RD UE NOTE DASHED LINES INDICATE OPTION WIRES Part No 77828 5 60 5 65 Section 6 Schematics m me nn Platform Control Box Switch Panel Wiring Diagram 5 60 GM 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 TS4 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 LIGH
45. Diode Hour meter of Gauge sending unit Batt LED d d Toggle switch DPDT p A 25A 7424 Fuse with amperage 419 Circuit breaker with amperage Control relay contact Fuel or RPM normally open solenoid Starting aid glow plug or flame ignitor Coil REVA FS1 BLK Foot switch P1 a Emergency Stop button normally closed Hydraulic oil cooling fan Auxiliary pump 510 Resistor with ohm value Tilt sensor gt Key switch after serial number 22050 Genie REX COMPANY 6 2 5 60 5 65 Part No 77828 July 2005 Section 6 Schematics Hydraulic Symbols Legend REV 1 7 bar FORES ll Ges w X Orifice with size Solenoid operated 3 position Solenoid operated Filter with 4 way directional valve 3 position way bypass valve relief setting Q Pump fixed displacement 79 8 e bi directional variable displacement 5 bi directional A Motor 2 speed bi directional E Pump prime mover engine or motor Double acting cylinder Check valve i 200 psi 13 8 bar 1 Relief valve with pressure setting Dire
46. 3 52 E 3 Perform Engine Maintenance Deutz 3 52 E 4 Remove and Inspect the Boom Extend Retract Cables 3 53 Section 4 Rev Repair Procedures Introduelion gb m 4 1 A Platform Controls 1 1 AEC 500 Circuit Board sssini iunie as tra na Ros e esi ra 4 2 1 2 4 3 B Platform Components 2 1 Platform Leveling Slave Cylinder 4 7 2 2 eere 22 n EE rte 4 8 Genie x 5 60 5 65 Part 77828 July 2005 lt TABLE OF CONTENTS Section4 Rev Repair Procedures continued Jib Boom Components 5 65 gA AD BOON 4 11 3 2 Boom Lift 4 12 Components 451 Cable Track elek 4 13 4 2 BOOM ce n eset ex tr pei ee tee uta ei 4 18 4 3 Boom Lift Cylinder 4 19 4 4 Boom Extension Cylinder 4 2 000000000 4 20 4 5 Extend Retract 4 22 4 6 Platform Leveling Master 4 25 C Engines 5 1 RPM Adjustment Deutz 4 26 5 2 RPM Adjustment Perkins 4 26 5 3 dodi
47. Part No 77828 RD RD NOTE DASHED LINES INDICATE OPTION WIRES ER 5 2885 5258 Puzk 2 hat gt 25 C59CNK 11 WLITEWH T C17PRL GR 5 X D a BRN WH CR27 ER CT8J8V GRIWH 7 BK J1 2 RD J1 1 C18PRR GR BK C4P 6 OR Ji 11 BRN J1 12 5 T C14PLU OR 2 58 49 m C15PLD OR BK 3 2 lt 595 ug O RD 5 46 GR 2 5 121 25 ud 5 July 2005 Section 6 Schematics __________ Platform Control Box Switch Panel Wiring Diagram 5 60 Deutz F3L 201 1 Models 2215 REV D July 2005
48. manual fuel shutoff valve 4 34 5 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV HYDRAULIC PUMPS 5 Have another person crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar 6 GM and Ford models Connect the LPG hose to the LPG tank and open the valve on the tank Move the fuel select switch to the gasoline position Perkins models Connect the engine wiring harness to the fuel solenoid Deutz models Release the manual fuel shutoff valve 7 Start the engine from the ground controls and check for hydraulic leaks Genie Part No 77828 5 60 5 65 4 35 Section 4 Repair Procedures July 2005 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 Platform level down 2 Counterbalance valve uus Platform level 3 Proportional solenoid valve Boom extend retract 4 Solenoid valve 2 position 3 way Gasen Boom retract 5 Solenoid valve 2 position way Boom extend
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53. 3 22 B 11 Test the Platform Self leveling 222 2 040420 0 3 23 Genie viii 5 60 5 65 77828 July 2005 TABLE OF CONTENTS Section3 Rev Scheduled Maintenance Procedures continued B 12 Test the Engine Idle 3 23 B 13 Test the Fuel Select Operation GM and Ford Models 3 24 B 14 Test the Drive Brakes nnn 3 25 B 15 Test the Drive Speed Stowed Position 3 26 B 16 Test the Drive Speed Raised or Extended Position 3 26 B 17 Test the Alarm Package Optional Equipment 3 27 B 18 Perform Hydraulic Oil Analysis 3 28 19 Replace the Fuel Filter Water Separator Element Perkins Models 3 29 B 20 Replace the Fuel Filter Element Perkins Models 3 31 B 21 Perform Engine Maintenance Deutz 3 32 B 22 Perform Engine Maintenance GM and Ford Models 3 33 B 23 Perform Engine Maintenance Perkins Models 3 33 Checklist C Procedures C 1 Perform Engine Maintenance Deutz 3 34 C 2 Grease the Platform Overload Mechanism if equipped
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62. Genie Mb Electrical Symbols Legend Hydraulic Symbols Legend GM 3 0L Engine Harness Ford LRG 425 EFI Engine Electrical Schematic 5 60 GM 3 0L Models TABLE OF CONTENTS Part No 77828 S 60 5 65 Xiii July 2005 TABLE OF CONTENTS Section6 Rev Schematics continued A Electrical Schematic 5 60 Ford LRG 425 EFI Models before serial number 11880 6 19 A Electrical Schematic S 60 Ford LRG 425 EFI Models after serialnumber 11879 een nu 6 21 A Ground Control Box Terminal Strip Wiring Diagram 5 60 Ford LRG 425 EFI Models before serial number 11880 6 23 A Ground Control Box Switch Panel Wiring Diagram 5 60 Ford LRG 425 EFI Models before serial number 11880 6 24 A Ground Control Box Terminal Strip Wiring Diagram 5 60 Ford LRG 425 EFI Models after serial number 11879 6 25 A Ground Control Box Switch Panel Wiring Diagram 5 60 Ford LRG 425 EFI Models after serial number 11879 6 26 A Platform Control Box Terminal Strip Wiring Diagram 5 60 Ford LRG 425 EFI Models 6 27 A Platform Control Box Switch Panel Wiring Diagram 5 60 Ford LRG 425 EFI 15 6 28 B Electrical Schematic S 65 F
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71. July 2005 Perkins 404 22 Models before serial number 11880 Electrical Schematic S 60 Section 6 Schematics ale x 55 2 OE 8 N E N y CIP 9 C35RPM BK RD C1B 9 S FOOTSW HIGH e 8 8 FooTsw Low E 20 5 ou 9 gt LOW RPM x o ap FUNCTION ENA C35RPM BK RD BRN 4 gt t a 9 HIGH IDLE RELAY 2 5 BARD 65 19 HIGH RPM SOLENOID 5 gt 2 2 5 C2P 7 C45GEN GRWH 28 7 5 C45GEN GRWH 5 12 121 V GENERATOR GP HAN g 8 5 C3P 12 DLITE BL WH C3B 12 o n 4 DRIVELIGHT 2 8 WORK LIGHT DRIVE LIGHT OPTION 9 5 9 FUSE10A 5b a ans 47 46 WORK LIGHTS OPTION 2 C2P 10 a 95 N 2 47 l s d yt Ce ie TS CRN ne TE NETTE Me EI ar ei EN Ie pe reas
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75. 30 92 2 T G31 A E E i WHOdlVld __ spp c i assyar a m z 9289 arz HM arzHM i i 2 2 202 GEZ HM i Mer le EE E 22114 1089 2 8 a a FS 0 1 HOLIMS au AA LSY HM 1551 HOLIMS 4018 ld 1886190 I 2 886 1 QH HM 96 uuo 872 96 WYO OL aumm mesra l HOLSISIH HOLSIS3H 3NOZ H3ddn WOOS AHVWIHd vH 91H 1 wyo g msaa H HOLSISSY 1 HOLSISIU STaVINYNL NMoa an woog 1 WYO lt 2 July 2005 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram 5 65 Perkins 404 22 Models after serial number 11879 July 2005 Section 6 Schematics n Platform Control Box Wiring Diagram S 65 Perkins 404 22 Models July 2005 Section 6 Schematics REV 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 BOAR
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85. 3 34 C 3 Test the Platform Overload System if equipped 3 35 C 4 Inspect the Boom Extend Retract Cables 3 37 C 5 Perform Engine Maintenance Perkins Models 3 38 C 6 Perform Engine Maintenance GM and Ford Models 3 39 Genie Mb Part No 77828 S 60 5 65 ix July 2005 a IMM TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued C Checklist D Procedures D 1 Check the Boom Wear 3 40 D 2 Check the Turntable Rotation Bearing Bohs 3 40 D 3 Inspect for Turntable Bearing Wear 3 42 D 4 Replace the Drive Hub Oil 3 43 D 5 Check the Free wheel Configuration 2 2 3 43 0 6 Replace the Hydraulic 3 45 D 7 Check and Adjust the Air LPG Mixture GM Models 3 46 D 8 Perform Engine Maintenance Deutz 3 47 D 9 Calibrate the Platform Overload System if equipped 3 48 Checklist E Procedures E 1 Testor Replace the Hydraulic 4 7 3 50 E 2 Perform Engine Maintenance Deutz
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100. Y lo 1 u p 1 ee Sat AUXILIARY a PUMP ala t C2TAUX RD n AUXILIARY POWER RELAY og AUXILIARY T PUMP 8 Si 1 1 C27AUX RD 1 1 2 m AUXILIARY PUMP zv 2 C28TTA RD BK D C28TTA RD BK 8 wH DT 5 TILT ALARM 1 1 S WH C7P 2 P23BAT WH C7B 2 4 4 P134TTSR RD RD p BK BRN SENSOR m o e ROMS 3 a a amp a NAY RD C1P 2 C28TTA RD BK OSEE gt BK C2P 5 C46HRN GR C2B 5 5 C46HRN GR qu A HOBN FEEAY N 3 C7P 1 2 C7B4 E P22HRN BK R46HRN BK C6 9 5 2 2 m 2 6 P134PWR C2B 6 e M n HYDRAULIC OIL R21IGN WH C54 e TEMPERATURE SWITCH OPTION C21IGN WH gj 5 2 C116 OR C5 1 4 COOLING FAN Yao i 815 H OPTION NE GM HARNESS GM HARNESS Q Q T 1 5 es 1 2 Nig t act m i me 8 8 624 4 2 i re 8 al P20BAT RD C7B4 1 20 11 1 amp a a N e N 77828 enie A TEREX COMPANY S 60 5 65 G 6 13 Section 6 Schematics GM 3 0L Models Electrical Schematic S 65 July 2005 gt ROCKER STEER OPTION ONLY
101. sm 91 i 9 260 GiZHM 8 I 6 2 1 gt G a rS o 2608 areas HOLIMS ABM us LSY z Are DELS M Ae HOLIMS dOLS 215790 Id Nua Nua 9ig HWdg O 6 a 96 WYO OL ZISTHO MSc Sc Hd 31Vd 9LH HWWQH 196 HOLSIS3H 3NOZ WOOS WOO8 PEHI 91H 1 wyo 5 H 1 10 18 1 1 221 vH O WOO 2 viH 96 WYO 5 July 2005 Section 6 Schematics _________ Ground Control Box Switch Panel Wiring Diagram 5 60 Perkins 404 22 Models before serial number 11880 Section 6 Schematics July 2005 fT Ground Control Box Terminal Strip Wiring Diagram S 60 Perkins 404 22 Models after serial number 11879 July 2005 Section 6 Schematics REVA Ground Control Box Terminal Strip Wiring Diagram S 60 Perkins 404 22 Models after serial number 11879 4181 257 7 69 HARNESS 1108 C5 ENGINE
102. 2 IGNITION SENSOR TAN BLACK 18 85 ALTERNATOR RELAY COIL RED 12 RED 12 RED 16 GREEN 18 2 LT GREEN RED 18 PURPLE LT BLUE 18 5 RED 14 a RED 16 A n 5 THROTTLE 87 PINK DK GREEN 16 PINK DK GREEN 16 PINKIDKGREEN16 ALTERNATOR TAN ORANGE 18 4 153 1 RED TAN 14 86 8 POWER WHITE BLUE 18 85 RELAY A TEREX COMPANY 5 60 5 65 July 2005 Section 6 Schematics GM 3 0L Engine Wire Harness July 2005 Section 6 Schematics REV A Ford LRG 425 EFI Engine Wire Harness 2 m D 6 361 R 16 361 16 361 16 361 R16 361 16 7 555 116 555 T 16 FORD 8 557 BR Y 16 557 BR Y 16 ETT des En 10 556 W 16 556 W 16 STE INJECTOR 1 INJECTOR 3 INJECTOR 4 INJECTOR 2 CONNECTOR INJG 12 359 GY R 18 STO BIGW 16 nwe 16 WATER TEMP AUX OUT 2 EGR 21 180 18 WATER 19 198 06 0 18 AUX ANA PD1 MB 20 358 LG BK 18 pp EICHE LO 1 FPP 4 15 151 LB BK 151 LB BK 2 27 743 GY 18 307 BK Y 18 307 18 28 354 LG R 18 35410818 ECT 17 307 BK Y 18 570 BK W 16 5 AUX ANA PU1 FPP2 570 BK W 16 570 BK W 16 150 DG W 18 570 BK W 12 34 GROUND 16 114 LB Y 18 22 352 BR LG 18 EGR PWM 23 POET 16 R LG 18 16 R LG 18
103. 5 9 aa YSU 39 Neg z 431 avoluano 3NION3 E WHO4LW1d sm 91 069 3978 i 9 260 g 8 T 1 i 2 YMdreld gt c 1 22 va 5 5 Q 22 04 s p ES E HOLIMS SA ORJ u3MOd HM HOLIMS 4018 Nua 0 a WYO OL 21510 4 MSc ScHH 9LH HMW QH 1 HOISIS3H INOZ H3ddn WOO8 WOOS 91H 96 wyo 5 HOISIS3H E 31V108 FI8VLNUNL vH WOO 96 WYO 5 July 2005 Section 6 Schematics __________ Ground Control Box Switch Panel Wiring Diagram 5 65 Perkins 404 22 Models before serial number 11880 July 2005 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram 5 65 Perkins 404 22 Models after serial number 11879 July 2005 Section 6 Schematics REVA Ground Control Box Terminal Strip Wiring Diagram S 65 Perkins 404 22 Models after serial number 11879 860
104. 9 LINOWIO vz P rau H3MOdHOIIMS A34 62 ot Jp Q FHM 2 8 0 HM 1V8EZd OE46 HO HM 17928 2 22 OLOGAZ 1 LLO 0 WHOSLV1d OL 20 21 22 860 2151224 sa 5 1 820 1v8zed Suoo8 o H3MOd 12 90 P a WH HM 6 90 WaH8zLo 18 240 HM 02 2 02 198024 PP 1 8192 Jp 61 3NWAL1O313S 6k G4 TSS EHO 1 1 80 HWHO P 8 WHO4IYld 81 O OO 9 80 2 1337 ZH O CH 708135 i 1 470 NIO 1 120 14810 Jp Bt NMOO 3A TWHOdIY id St O OD Jp z HH H 688 1 HO 114810 2 er amp O W viwouwau 8 iO vv Wuviv w O CH se 2 01 869 18 WB Vi var LOEO guna Wade Jg 6 MOH 1 Wd 6 O 5 6 43469 5 1 10 98489 Jp 19 Wood AUVs C gos ama 8 8 8 1 Jp CIN3DGINOOR AHVWIBA 721 197 951 1
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107. Part No 77828 July 2005 Section 3 Scheduled Maintenance Procedures REVC A 13 Perform Engine Maintenance GM and Ford Models 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 GM 3 0L Operator Handbook GM part number 36100007 or the Ford LRG 425 EFI Operator Handbook Ford part number FPP 194 302 GM 3 0L Operator Handbook Genie part number 101095 Ford LRG 425 EFI Operator Handbook Genie part number 84792 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 5 60 5 65 CHECKLIST PROCEDURES A 14 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 200 ho
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109. az lt 1 ee Be C r eE u Ss FE ios July 2005 Section 6 Schematics TEE TEE ee Hydraulic Schematic 4WD Models 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 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 Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Phone 34 93 579 5042 Fax 34 93 579 5059 Genie G rmany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
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111. y 9 C35RPM BK RD C1B 9 9 8 FOOTSW HIGH oT FOOTSW Low gt 29 3 x ou 9 amp 5 LOW RPM FUNCTION ENA HIGH RPM pi BK RD 4 LiGHIDLE RELAY 1 8 65 18 HIGH RPM SOLENOID cz o o Sn SS SS ee epo OIM lt lt lt lt lt lt lt mE N 5 5 2 7 C45GEN GRWH C2B 7 GRWH 5 12 GENERATOR OPTION post cx c ccc cc ul ecce lb cse shoe i 1 1 C3P 12 DLITE BUWH 088 12 1 i 1 9 work CHTS ap i DRIVE LIGHT OPTION Qe bx aa 8 rs N 1 is 3 E 7 C WORK LIGHTS OPTION C2P 12 2 10 a ne 1 2 11 C2P 9 2 x 8 8 5 5 hs a 2 1 8 C34SA CiB 8 C34SA BK WH 5 22 4 2 5 GLOW PLUG 8 GLOW e ee PLUG 90 2 C26TSR WH RD OIL TEMPERATURE LED 2 4 858 gt 8 595 oz 28 5 a 12 2 5 axo E 3 C33STRBK g4 C1B7 reme aa gt 4 65 14 OIL TEMPERATURE SWITCH ENGINE a EE OE 50 89 START 5 ai e x Ct F ENGINE BERE 65 16 8 5 2 99969990 7 OIL PRESSURE SWITCH 4 C25PSR WH BK L S6 e 3 ne
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114. 9 1 C2P 4 DLITE OR RD C2B 4 gt DRIVELIGHT Y DRIVELIGHT 5 gt 3 m 8 1 e Fd S 9 WORKLIGHT 8 8 an Sex Eg gt 4 gt 1185 os WORK LIGHTS 8 OPTION 1 1 9 4 9 St a a iia BILE SM a i ra p tat Min ype ia MEI re S re ne et La oye u gt BK DER 1 e I d lee nn E 1 C21IGN WH 3 we BL WH CHECK ENGINE LED 9 g BR 4 8 8 6 RUN TEST SWITCH 2 47 ga 253 8 8 o I 8 C2P 1 C39LP BL RD C2B 1 8 EB C5 19 P23BAT WH FEH 16 PIN1 SELECT 8 e 8 lt lt FUEL C5 11 C21IGN WH FEH 71 PIN21 gt SELECT 2 B 5 9 C128RPM OR RD FEH 306 PIN24 C41RPM OR BK y C288 OUER N C108ESL BL WH 658 PING 68 C127TSW GR 458 PIN18 E 5 a C5 10 C39LP FEH 72 PIN7 85 B C5 18 C35RPM BK RD FEH 307A PIN23 29 8 55 8 P20BAT RD FEH 361 PIN9 7 C33STRBK 7 GND BR 570 PIN34 8 1 ENGINE C52 C41RPM OR BK FEH 11 PIN2 8 START 4 5 wo 8 5 5 R33STR FEH 32 15 IGN START RELAY Ex Se START E C33STR BK FEH 32 PIN13 52 BL WH 787 PINS 135 BL WH ag BK m 25 4 a cz n ann u
115. A s 49 135 CABLE TENSION LIMIT SWITCH tn 15 54 48 5 a 4 Al RD RD S BR C7PBE BK TEND St lt L EXTEND on 5 BOOM 37 1 37 2 Ci 1 16 2 9 11 RETRACT Ss io 8 E CPBRBKWH Al Boom RETRACT 1 1 a x x 5 Ci74 17 2 0 uo ul BRN 1 s SE N CP CII8LSROR RD 48 4 OR RD 38 3 38 4 1317 UP DOWN P24FS WH 5 eo Us SPEED REDUCTION LIMIT SWITCH on x x 2 _Pe4FSWH BL RD C4B 1 BL RD C9 1 MH C92 1 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK 9 E 23 5 N 2 2 599 a 3 56 11 2 WH BK LS1 PRIMARY BOOM EXTEND 5 Sve DRIVE LIMIT SWITCH 8 J1 FH WH c10 1 BK WH C102 LS2 PRIMARY BOOM UP x DRIVE LIMIT SWITCH E C40LS OR C2B 2 9 I 1 2 m t no 1 uo P22LS 11 59 BL BK C3B 11 BL BK BK 373 42 WH _ 374 LS5 CABLE TENSION LED eve 8 E 4 m P134 RD RD C38 1 5 RD aC BR C38 2 I5 LS17 BOOM UP DOWN a Ny a SPEED REDUCTION LIMIT SWITCH 8 y 04P2 OR lt C4B 2 R55 FUP ZI e PLATFROM LEVEL 5 1 DOWN C4P 3 C15PLD OR BK C4B 3 c c 20 1 020 2 8 c T i CI4PL
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121. 2 TS15 DRE LED BL RD TS14 RD WH s e C134PWR RD LS18 C28TTA RD BK C1P 2 C7P BATGRN C7P 3 ES C9 FOOT SWITCH C7P 12V DC BATTERY C4P BR C3P GR C2P BK C1P GY Part No 77828 19 18 CONTROL CABLE a ee ee eed le ORBIT AGE g RD BK 28 C134PWR C2P 6 CWLITE BK BRN BRN RD TILT CWLITE WH 549 TEREX COMPANY 5 60 5 65 G TILT ALARM 6 11 REV B July 2005 E D PLATFORM CONTROL HARNESS TO CONTROL BOX TS48 DRIVE LIGHTS WORK LIGHTS DITE RD ED OPTION HH HH 1 JC2 463 JC1 DRIVE F 34 BOOM UP DOWN 7 7 FORWARD REVERSE 7 amp TURNTABLE ROTATE BOOM 8 STEER LEFT RIGHT EXTEND RETRACT TS15 LEFT RIGHT pd DRIVE 090 148 6 6 ENABLE TILT ALARM LED 1 5 2 5 MS ies 4 d 4 je 4 BE 4 Po 1 1 3 E 3
122. 222 CHT ECT Low Voltage 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 Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification Coolant temperature at the cylinder head is 240 F Engine cooling system is malfunctioning and Repair engine cooling system problems OR connections open or shorted OR sensor is faulty OR coolant level is low 223 CHT Higher Than Expected overheating the engine OR sensor wires and or repair open or shorted wiring to sensor OR 1 replace sensor OR fill engine coolant level to connections open or shorted OR sensor is faulty specification OR coolant level is low Coolant temperature at the cylinder head is 250 p Repair engine cooling system problems OR F Engine cooling system is malfunctioning and Ags CHT Higher Than Expected repair open or shorted wiring to sensor OR overheating the engine OR sensor wires and or 2 replace sensor fill engine coolant level to specification 231 MAP High Pressure Open or shorted wiring and or connections to MAP sensor OR sensor is faulty Repair wiring and or connections to sensor OR replace MAP sensor 232 MAP Low Voltage Open or shorted wiring and or connections to MAP sensor OR
123. 28 22 BEN D 1 5 HM 9 820 2 e 1 amp 55 TT 140 qon tI 1 89 x iu 18 1 1 1 gg g 9 ua 1 4 59 50 m 8 m 5 Iz oul a 9 amp 35 g D S RIO Ox Qo lt c x 588 SEL x 52265 e S SWSFHM 5 gt gt HM 20 g z p m 6 99 32 8 5 au 8 3 Nua 1HVIS NOLLINSI U r A Part No 77828 enie A TEREX COMPANY 5 60 5 65 G 6 47 Section 6 Schematics A Deutz F3L 2011 Models before serial number 11880 Ground Control Box Switch Panel Wiring Diagram S 60 July 2005 REV B 6 48 enie N iO T 5 x o 5 ees 954 lt 3 9
124. COOLANT TEMPERATURE SWITCH gt ENGINE 8 251559 START 5 to c C5 a3 ve se S ENGINE fol fo fol fol 5 16 tA lee eese ec s OIL PRESSURE SWITCH m C25PSR WH BK 5 lt g oz E N RELAY BE B o op C21GN2 WH 5 11 8 5 E gt FUEL SOLENOID aja 1 C27AUX RD C1B 1 4 Of SEHEN WH HOUR METER 88 E IGN START RELAY 40 x R33STRBK C55 5 i gie mz 2 a 16 12 m Ew bd L 5 0 AG 55 essed xl o 5 n a AUXILIARY rf C27AUX RD x PUMP RD d SPEED REDUCTION RELAY 5 C7B 2 C27AUX RD C7P 2 P23BAT WH AUXILIARY POWER RELAY N a AUXILIARY PUMP 2 WH 4 8 rer aan m 8182 B 28 RD BK WH iir C28TTA RD BK TILT ALARM P134TTSR RD RD LEVEL SENSOR C3B 12 C3P 12 C133PLA Y gt T C2B 5 E ic C2P 5 C46HRN GR 5 C46HRN GR HORN BELAY GR BK N 7 P22BAT C7B 1 g I 22 A HORN 8 8 5 uo M 86 E C1P 12 C132PLIBL WH C1B 12 1 gt g 5 8 P134FB WH FLASHING BEACONS Cope s PISAPWRGRIBK 0286
125. Read each 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 Genie 5 60 5 65 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 after troubleshooting 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 personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or
126. a GIP 12 1842 gt BE z e 9 2 P134FB WH FLASHING BEACONS PIMPWRGRIBK 0288 gt 27 OPTION 2 ji 8 RD M m 5 So oz C2IIGNWH R2IIGN WH s 054 4 4 HYDRAULIC OIL TEMPERATURE SWITCH OPTION p 5 8115 8199 Oe 55 R116 OR C51 cooLiNG FAN 5 lee D le gt LT OPTION oz ia 5 4 8 x m C41RPM C2B 3 C41RPM OR BK C5 2 i i ll WH 8 B s 4 8 ae x 5 5 mis 8 8 A 4 i 5 L mc o a Sc 8 RD i C7B 4 P20BAT RD 4 4 a N e 10 i AND PLATFORM OVERLOAD OPTION ONLY NOTES enie A TEREX COMPANY S 60 5 65 G Part No 77828 6 41 Section 6 Schematics Electrical Schematic S 60 Deutz F3L 2011 Models after serial number 11879 July 2005
127. g J P2 TS8 RR EMERGENCY 197 2 1514 TS2 TS4 STE HORN PLATFORM JIB TS1 HIGH LOW TS47 ENGINE HIGH LOW PLATFORM ROTATE BOOM AUXILIARY 2WD 4WD GENERATOR START RPM 5 LEVEL 4 PUMP OPTION Bk D27 WH 24 ____ RD RD RD RD CE LIFT DRIVE OPTION REPLACE WIRE WITH CR27 amp CR30 NOTE DASHED LINES INDICATE OPTION WIRES A TEREX COMPANY Part No 77828 S 60 5 65 6 18 July 2005 Section 6 Schematics E Platform Control Box Switch Panel Wiring Diagram S 65 GM 3 0L Models REVA P22LS BK July 2005 Ford LRG 425 EFI Models before serial number 11880 Electrical Schematic S 60 Section 6 Schematics eg lt 5 SEES a 9 sed C35RPM BK RD C1B 9 98 ENGINE E sx SPEED 8 25PSR WH BK
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130. CWLITE WH TS49 enie A TEREX COMPANY 5 60 5 65 G Part No 77828 6 93 REV B July 2005 Section 6 Schematics Platform Control Box Switch Panel Wiring Diagram S 65 D Perkins 404 22 Models PLATFORM CONTROL HARNESS TO CONTROL BOX COMPONENT INDEX CR13 JIB BOOM CUTOUT RELAY JC2 BOOM PROPORTIONAL JOYSTICK BOOM UP DOWN TURNTABLE ROTATE WORK LIGHTS DLITE RD RD OPTION D C DEED ee aa nn JC1 BOOM PROPORTIONAL JOYSTICK JC2 JES BOOM EXTEND RETRACT BOOM UP DOWN JC1 DRIVE JC3 DRIVE STEER PROPORTIONAL JOYSTICK amp TURNTABLE ROTATE 7 BOO 7 AA f L1 DRIVE ENABLE LED LEFT RIGHT EXTEND RETRACT RE 5 ids LEFI RIGHT 14 PLATFORM OVERLOAD LED 6 6 POY TILT ALARM LED mo 147 LOWER RETRACT BOOM LED a ENABLE 6 1 148 BOOM TILTED LED P2 EMERGENC
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132. Platform level up down 20 25 ft lbs 27 34 Nm 31 Solenoid valve 3 position 4 way bee Platform rotate and jib boom up down 9 65 20 25 ft lbs 27 34 Nm 4 38 5 60 5 65 Part No 77828 Section 4 Repair Procedures July 2005 MANIFOLDS REV D 8 0 0 0 4 9 9 G X COMPA 5 60 5 65 TERES 39 PartNo 77828 Section 4 Repair Procedures July 2005 a MANIFOLDS REV D 7 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Perform this procedure with the boom in the stowed position 1 Connect 0 to 5000 psi 0 to 350 bar pressure gauge to the port on the function manifold 2 Start the engine from the ground controls 3 Hold the function enable rpm select toggle switch to the high idle position Activate and hold the boom retract toggle switch with the boom fully retracted 4 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the relief valve and remove the cap item K 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valve higher than specified 7 Repeats
133. SENDER OPTION e VOLT METER OPTION Ta 0 oO 2 LOWRPM FUNCTION ENABLE 5 8 C26TSR WH RD WATER TEMPERATURE 1 HIGH RPM i SENDER OPTION 5 e e x NUI ee eee x rax SERRE MI E nr eT T ETERNA S ee er i 2 7 GENERATOR HYDRAULIC d 2 7 C45GEN GR WH 2 7 65 12 C45GEN GR WH GENERATOR 1 M P 1 re ee AAA AS C2P 4 DLITE OR RD C2B 4 g gt DRIVELIGHT RD YY DRIVE LIGHT g 4 9 1 OPTION iQ 1 5 pos WORKLIGHT 8 9 ze 4 4 2 55 RD 1 lt WH BK 158 5 1185 WORK LIGHTS E EO OPTION 565 1 1 9 WH BK am Gp Bog Oh ducam rc crc i el gt 2 5 2 e 1 1 d ER ES ARE PER NEUTER WH n gt HOUR METER BL WH CHECK ENGINE LED QU f BR 8 5 2 I RUN TEST SWITCH E 5 T e a EE gs 88 b C2P 1 C39LP BL RD C2B 1 Bol 8 H FUEL SET C5 19 P23BAT WH FEH 16 PIN1 s SELECT 8 e FG FI
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136. 5 a 42 5 gt E lt oa CHBLSROR RD C4B4 OR RD BK 2 C38 4 LS17 BOOM UP DOWN B SPEED REDUCTION LIMIT SWITCH SES I o E d 2 PAS 3225 5 Pp 422 s c C41 BL RD C4B 1 BL RD 27 c9 2 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK t 3 8 gt o a 8 2 2 88 a ges WH BK LS1 PRIMARY BOOM EXTEND 5 SUE DRIVE LIMIT SWITCH J1 EH WH 1 1 C10 2 LS2 PRIMARY BOOM UP a UE DRIVE LIMIT SWITCH C40LS OR C2B 2 z OR x S i z a 1 NO so ES DER pee 1 5 o P22LS BK Cay C3P 11___C59CNK BL BK C3B 11 BL BK 9 o 2 5 37 3 9 2 37 4 5 gt LS5 CABLE TENSION LED m 8 3 5 amp 3 o a P134 RD ug RD 38 1 RD BR C382 1 LS17 BOOM UP DOWN a Ny a SPEED REDUCTION LIMIT SWITCH 8 CI4PLU OR 2 eG E n 2 PLATFROM LEVEL 3 1 DOWN C4P 8 CI5PLD OR BK C4B 3 4 20 1 20 2 a o E Bor UP C14PLU OR I PLATFORM LEVEL UP S PLATFROM LEVEL DOWN 11 PLATFORM LEVEL DOWN E n a 21 1 21 2 26 a 10 C129JDA BL C3B 10 5 6 C18JD PRR GR BK C4B 6 mw mE C17JU PRL GR C4B 5 GER 12 2 a C23 1 023 2 1 A 1 8 G1EJD ERRIGR BR Al PLATFORM ROTATE RIGHT
137. C7PBE BK 512 ic e BOOM EXTEND E os 5 BOOM 37 1 37 2 Ci 1 16 2 PWR 3 9 t RETRACT i 8 BP8 5s io 8 8 CBPBRBKWH Itl 3 4 BOOM RETRACT BL x lt 5 E Ci71 CI72 xi E a BRN SS 9 329 E CHBLSROR RD C4B 4 OR RD C38 3 BK WH 38 4 1317 UP DOWN P24FS WH 5 5 1 SPEED REDUCTION LIMIT SWITCH 2 gt 21 x m e P24FSWH 5 B 42 C4B 1 5 BL RD C9 1 WH C92 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK x eds n 5 8 qz 2 2 4S 2 WH BK LS1 PRIMARY BOOM EXTEND 5 aE DRIVE LIMIT SWITCH 9 J1 FH WH C10 1 BK gt MH C10 2 LS2 PRIMARY BOOM UP a Us DRIVE LIMIT SWITCH E C40LS OR C2B 2 ZI OR x 8 m 1 t no t d Quo 1 vz gt par 11118 57 8555 i i 2215 1 11 59 BL BK C3B 11 BK 373 A Z WH cor4 1 LS5 CABLE TENSION LED sU g 8 8 o P134 RD C38 1 RD 2 BR C382 5 LS17 BOOM UP DOWN 5 gs N SPEED REDUCTION LIMIT SWITCH 2 e y 04P2 OR lt 0482 89 g PLATFROM LEVEL DOWN C4P 3 C15PLD C4B 3 C204 20 2 8 5 PLU OR P rus i CH PLATFORM LEVEL UP Hi PLATFROM LEVEL t DOWN i D PLATFORM LEVEL DOWN x 5
138. F i AUXILIARY 5 PUMP x t RD CETAUXBD Ju 4 SPEED REDUCTION RELAY 5 C7B 2 BESTAND AUXILIARY POWER RELAY 8 C7P 2 P23BAT WH N a Sr AUXILIARY PUMP 2 WH 1 9 D RD BK S s C1B 2 28 RD BK gt C28TTA RD BK 5 TILT ALARM 4 ince aw FISATTSRRD AD LEVELSENSOR Sy C3B 12 4 iA 87 C133PLA BLWH 2 L ORBI 1 C2B 5 B 21 sit oS CASHEN GH GR 2 HORN RELAY 448 amp GRBK Ko a P22BAT BK 7 1 2 1 1 5 22 e IE 4 HORN 8 H ee e d o 1 peer Eee ce ned prc PETERE ee 1 12 32 C1B 12 gt o 32 P134FB WH C2P 6 PI34PWR GR BK 2 6 Fe gt FLASHING BEACONS gt R 1 25 55 51 0521 P S e ser LEES IE EAE ae ah T 54 RD m E So oz 2 ED 3 RetIGNWH gt gt 05 4 HYDRAULIC OIL TEMPERATURE g a ES 0 SWITCH OPTION x 815 85 8 1811608 gt gt 05 1 COOLING FAN 9 vie ke OPTION c m C41RPM C2B 3 C41RPM OR BK C52 a N C21IGN WH 5 tas 4 T T 1 s 5 a T m5 ms u o T OTa 4 a
139. GH ZEL S10VOT183A0 WHYO41V1d G4 NOLLONGSY 43345 1411 CH Seco HE r4 588 860 4 S aei 58819 H3MOd NHOH usr CH 2 su ae a Sr NOILdO 9 GH 8 5 1 820 N39SPO 81 80 HWHO 2 2 tr vel AZ L 1 7 vel 1V1d cau 2 0 951 9 H3 HM 849614 TU vel MS et O CH 9 822 48 49 9 9 ne 9 1 8 69 5 SEO HNDESO or 0 2 o 5 820 NHH9PO 8 759 Nao 12 dn old 35108 HOLVNH3ITV 12 Sl i 3 148170 ENSI AE HO A or 18 W008 2820 151050 835017 gt 1 820 41662 26 5 1 20 915 89 915 59 9 H33L 9 2 Treo 18 0015950 8 01 910 9918959 Je SE 43345 NOLLONNS SE a Qd 7551 6 810 SHSEO 22 50 vsreo pind More 88 HM See SHWE es 1HVIS t Q Qd 1 810 515559 Eens 18 26 25 52 50 9 10 GH HM TANVd HOLIMS OL 0250 Nam i
140. Travel alarm Descent alarm 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 The alarms and 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 July 2005 CHECKLIST B PROCEDURES REVC 3 5 65 Move the function enable rpm select B 18 toggle switch to either side and activate the jib boom toggle switch in the down position hold Perform Hyd raulic Oil Analysis for a moment and then release it Result The descent alarm should sound when the switch is held down Replacement or testing of the hydraulic oil is 4 Turn the key switch to platform control essential for good machine performance and service life Dirty and a clogged suction strainer Result The flashing beacon should be on may cause the machine to perform poorly and and flashing continued use may cause component damage
141. ez E Cip SER 6187 ERECS Face 65 14 Ge OIL TEMPERATURE SWITCH I lt gt 1 12 t START 8 552550966 8 ENGINE ES 5 16 4 START OIL PRESSURE SWITCH a C25PSR WH BK I lt E oz E B 8 5 a o iy A POWER RELAY RE B 0 a CE le C2 1IGN2 WH cen H FUEL SOLENOID N NN aja AUX e ee PUMP 4 C27AUX RD C1B 1 5 amp GPHGNWH E HOUR METER 88 1 li IGN START RELAY 5 8 9 x o R33STR BK C5 5 8 a STARTER MOTOR 0 8 E D i x a 2 AUXILIARY 5 4 PUMP RD C27AUX RD d AUXILIARY POWER RELAY A S C7B 2 Sly GP PESBATWH 4 AUXILIARY PUMP 4 g N RD BK 5 gt 2 WH 4 8 RD BK CiB2 8 CNRC EE gt E C28TTA RD BK WH 1 4882 d er TILT ALARM ex 7 P134TTSR RD RD 1d IBK BRN Le LEVEL SENSOR 12 ee C133PLA BUWH C2B 5 B 2 5 C46HRN GR 4 C46HRN GR HORN RELAY GR BK 1 a 7 1 22 C7B 1 E x 5 22 BK A 8 N 8 n a x C1P 12 CIG2PLIBUWH 2 5 gt 5 z 2 P134FB WH lt gt FLASHING BEACONS 1
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151. 6 Solenoid valve 3 position 4 way ID cues Turntable rotate T Proportional solenoid valve Tissus Boom up down circuit 8 Solenoid valve 3 position 4 way Steer 9 Check valve 30 psi 2 Diu Differential sensing circuit platform rotate left and jib boom up 5 65 10 Check valve 30 psi 2 bar p Differential sensing circuit platform rotate right and jib boom down 5 65 11 Check Nui Differential sensing circuit boom extend retract 12 Solenoid valve 2 position way Fue Boom down 13 Solenoid valve 2 position way E es BOOM Ups une nn 14 Check Ole Differential sensing circuit turntable rotate 15 Check Differential sensing circuit boom up down 16 Priority flow regulator valve 3 5 13 2 L min AA Steer left right circuit 17 Differential sensing valve 110 psi 7 6 Boom up down circuit 18 Differential sensing valve 150 psi 10 3 b
152. C16DRE BURD 1 C7PBE BK C3P 7 24FS WH i i i i i i i T 40155 OR C2P 2 C9PER BK RD C3P 9 24FS WH C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 C31REV WH BK C1P 5 P C2PBD RD BK C3P 2 C2P C36STCC 10 RD WH C3P 3 C37STC BL BK C1P 11 C5TRR WH BK C3P 5 C32BRK WH RD C1P 6 LI ag C4TRL WH C3P 4 C29MS RD WH C1P 3 013 ALC 500 J2 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 1515 BL BK DRE LED BL RD TS14 RD WH RD BK L4 C28TTA RD BK C1P 2 BATGRN C7P 3 ES C9 FOOT SWITCH C7P 12V DC BATTERY C4P BR C3P GR 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 19 18 CONTROL CABLE
153. Deutz F3L 2011 Models before serial number 11880 Electrical Schematic S 65 Section 6 Schematics amp 55 gg c A gy B 5 y C35RPM BK RD C1B 9 9 565 FOOTSW HIGH 5 FOOTSW Low FE zB 5 x su 25 5 LOW RPM x o FUNCTION ENA BK RD BRN t gt i HIGH IDLE RELAY 1 a 8 BKRD 05 18 HIGH RPM SOLENOID o cz lt E LED c M lt lt I E 4 E N 5 T 5 C2P 7 GRWH 2 7 5 GRWH 5 12 il ENEAATORORTION IF 1 1 1 o8 5 2 y DLITE BUWH C3B 12 l i DRIVE LIGHT work TS DRIVE LIGHT OPTION 8 rs 1 5 8 m e WORK LIGHTS OPTION E 5 C2P 12 AX C2P 10 B 5 a 1 o 1 528 Q 4 4 2 11 C2P 9 2 x m 5 3 e 5 hs a p 1 8 C34SA BK WH 6 C34SA BK WH 5 22 4 4 e GLOW 8 GLOW 1 PLUG oi 5 C26TSR WH RD OIL TEMPERATURE LED n io 2 E 8 2 55 gt 8 595 o 2 405 8
154. ENT S 3 I I 1 I 88 er 8 E dn EY STARTER MOTOR 1 Y lo 1 u p 1 ee Sat AUXILIARY a PUMP ala t C2TAUX RD n AUXILIARY POWER RELAY og AUXILIARY T PUMP 8 Si 1 1 C27AUX RD 1 1 2 m AUXILIARY PUMP zv 2 C28TTA RD BK D C28TTA RD BK 8 wH DT 5 TILT ALARM 1 1 S WH C7P 2 P23BAT WH C7B 2 4 4 P134TTSR RD RD p BK BRN SENSOR m o e ROMS 3 a a amp a NAY RD C1P 2 C28TTA RD BK OSEE gt BK C2P 5 C46HRN GR C2B 5 5 C46HRN GR qu A HOBN FEEAY N 3 C7P 1 2 C7B4 E P22HRN BK R46HRN BK C6 9 5 2 2 m 2 6 P134PWR C2B 6 e M n HYDRAULIC OIL R21IGN WH C54 e TEMPERATURE SWITCH OPTION C21IGN WH gj 5 2 C116 OR C5 1 4 COOLING FAN Yao i 815 H OPTION NE GM HARNESS GM HARNESS Q Q T 1 5 es 1 2 Nig t act m i me 8 8 624 4 2 i re 8 al P20BAT RD C7B4 1 20 11 1 amp a a N e N 77828 A TEREX COMPANY 5 60 5 65 G Section 6 Schematics July 2005 GM 3 0L Models Electrical Schematic S 60 REV B
155. H RIGHT PLATFROM t LEFT i i is lt lt Inl sy 1 PLATFORM ROTATE LEFT 1 1 C223 C222 5 ei RIGHT PLATFROM e ___ __ E NX PP 1 C129 HD BK DESCENT ALARM OPTION _ 2 7 C19JSV GRWH C4B 7 2 2 m H I E tn 5 JIB VALVE JIB VALVE 8 9 a a TISSE amp 6 30 enie A TEREX COMPANY S 60 S 65 G Part No 77828 July 2005 Section 6 Schematics t Electrical Schematic 5 65 Ford LRG 425 EFI Models before serial number 11880 REVA P22LS BK P134PWR July 2005 NOTES Ford LRG 425 EFI Models after serial number 11879 Electrical Schematic S 65 Section 6 Schematics
156. 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 The medium pressure filter is located on the right The high pressure filter with filter condition indicator is located on the left 11 Place a suitable container under each filter 12 Remove the filter housings by using a wrench on the nut provided on the bottom of the housings 13 Remove the filter elements from the housings 14 Inspect the housing seals and replace them if necessary Section 3 Scheduled Maintenance Procedures July 2005 CHECKLIST D PROCEDURES 15 Install the new filter elements into the housings and tighten them securely 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 5 60 5 65 0 D 7 Check and Adjust the Air LPG Mixture GM Models Maintaining the proper air to fuel mixture during LPG operation is essential to good engine performance ADANGER Explosion a
157. WHITE BLACK 18 WHITE RED 18 MTRTWR8 18 18 ORANGE BLUE 16 REDWHITE 18 16 BROWN BLUE 16 17 BROWNIGREEN 16 o LTBLUEWHITE 18 22 35 TANIDK GREEN 18 33 38 DK BLUE 18 2 Ans ENGINE 31 YELLOWIGRAY 18 COOLANT 39 PURPLE VELLOW 18 36 DK BLUE YELLOW 18 TEMPERATURE 19 BLACK 16 SENDER 2 20 BLACK 16 22 39 BLACKILT GREEN 18 YELLOW GRAY 18 22 50 LT GREENRED 18 21 __ 18 BLACK LT GREEN 18 B 55 DK GREEN ORANGE 18 41 TWIST WIRES 10 TURNS 860 DEGJFOOT FULL LENGTH eie C743 _ GRAYIBROWN 18 14 PURPLE ORANGE 18 TWIST WIRES 10 TURNS 860 DEG FOOT FULL LENGTH LT GREEN 18 gt 11 PURPLEWHITE 18 LT GREEN RED 18 s E lt 12 WHITE PURPLE 18 TAN 18 2 72722 16 BLACKATGREENE 23 RED TAN 16 9 GRAY ORANGE 18 WHITEIBLACK 18 MAP SENSOR 5 1 TAN BLACK 18 Z 10 WHITELT BLUE 18 3 53 PURPLEILT BLUE 18 T BLACK 12 54 LT BLUE DK BLUE 18 BLACK 16 24 PINKWHITE 18 5225 18 22237 IT GREENBLACK 18 REDMAN 16 56 YELLOWLT GREEN 18 16 26 LT BLUE BLACK 18 GROUND 22 57 BLACKWHITE 18 20 PURPLE DK BLUE 18 40__ TANBROWN 18 48 YELLOW DK BLUE 18 1 34 GRAY DK BLUE 18 FINGTAN 18 5 5 WHTERED 18 2243 BLUEIPINK 18 TWIST WIRES TURNS 360 DEGJFOOT FULL LENGTH 5A 15244 BLUEMHITE 18 L3 DK GREEN 18 LET OIL PRESSURE 4 1 gt 29 SENSOR PINK 18 vew passar 30 DK BLUE 18 8 228 PURPLE YELLOW 18
158. WHY Tv GVOTHSAO WHOALVId EEL 21 80 zo Sa 281 B lt sr 5 GH 5 5 4 QH m 8 s QH kd 318 al 829 8 2 42 B 185 PITE 2 wi ms WIONHOAMAVOT 965 5 G m E 6 160 8138 vel L 5 21508 9820 UMdPELd Piso 2 5 CD 8 O 9v 6 2 5 5 95 820 9 mo o 8104 HO1VNH3 EIV 52 V2 20 X8 HO WdH tro ov 5 ov 2 019 181092 aoe E CH 01 89 2 5951 H33lS 15 2 1 820 MOSZEO Je MOSLO 23 08 2 1 29 18 59595 Je 01 810 18 008960 samen TO 2 se Gt 6 819 WdHSEO 2 ve wen O 8 819 HME VStEO V2 3NION3 1 18 TED 21 810 X8 HLSEED 98 6250
159. WORK LIGHT 64842 DRIVE LIGHT OPTION ES 1 1 ala 8 5 gg 59 ie C4B 11 RD 2 12 N C2P 10 2 WORK LIGHTS OPTION Du cz a MERE C2P 11 lt lt C2P 9 lowe aa en we we x 1 8 8 P134FB WH u 4 FLASHING BEACONS m OPTION NI Son n S C21HM WH 1 HOUR METER E War c 9 RUN TEST SWITCH 9 a 5 C58 C1278W GR lt lt GM 5 18 BK RD lt lt GM CONNG gt D BAN E lt lt GM a 8 canw p P us C2P 1 39LP BL RD C2B 1 5 11 21 22 pie FUEL SELECT Z GAS 0 nel sevect GAS 1 C59 CI26LRPM OR RD E lt lt 5 6510 C39LP BL RD D 22 GM CONNS C41RPM OR BK C2B 3 C5 2 CA1RPM OR BK C lt lt GM z C5 6 C27AUX RD 22 GMCONNS CHECK ENGINE LED C5 13 C108ESL lt lt N 1 7 C33STRBK 1 7 i 3 len CES J lt lt 0 a 2 5 19 P23BAT WH A lt GM CONN10 ENGINE Tre START c 5 8 2 RSSSTRIBK GM HARNESS 0 eo S
160. Wiring and or connections to fuel pump shorted to power OR fuel pump is faulty Repair wiring and or connections to fuel pump OR replace fuel pump MegaJector delivery pressure higher than expected 353 Fuel pressure too high OR LPG lockoff not sealing correctly OR the line between the Megadector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace Megajector delivery pressure lower than 354 Fuel pressure too low OR LPG lockoff not opening completely OR the line between the MegaJector and carburetor is kinked or restricted Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system expected or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty ORirepl ce the MegaJector aum The ECM doesn t get any response from the Check CAN circuits for continuity and shorts to MegaJector communication yen 355 lost MegaJector or an incorrect response for 500ms power or ground and for continuity and repair period or longer as necessary OR replace the MegaJector MegaJector voltage supply 361 The MegauJector detects voltage greater than 18 volts for 5 seconds anyti
161. all inspections for three years 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 PartNo 77828 Genie 5 60 5 65 3 1 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety information and step by step instructions Symbols Legend 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 ADANGER Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION With safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation wh
162. solenoid boot b high idle adjustment nut yoke d low idle lock nut and adjustment screw 3 Move the function enable toggle switch to the high idle rabbit symbol position O Result High idle should be 2500 rpm If high idle rpm is correct dis regard 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 Be sure the solenoid fully retracts when activating high idle Genie 5 60 5 65 12 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and 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 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
163. 1 BRAKE RELEASE gt gt amp 8 281 28 2 5 C29MS C1B 3 5 24 C29MS RD WH MOTOR STROKE 9 5 5 5 ok F CDE3 BL RD T 16 Eu 5 3 251 025 2 H CDE2 BLBK 1 11 C37SCW BL BK C1B 11 C37SCW BUBK Bi 0 CLEFT 2 18 STEER RIGHT ko DRIVE ENABLE 1 RIGHT 9 0 ss C36STCC BL 91810 2 C36SCC BL glo 8 Na x CDE1 2 0 244 C242 wig ee eee m BER I A 8 3 RKOUT 632 6 WH RD C3B 6 IE vour s 553 git z 4 C4TRL WH C3B 4 C4TRLWH TURNTABLE ROTATE LEFT EM 18 8 E BT 5 C5TRR WH BK C3B 5 WH BK TURNTABLE ROTATE RIGHT 5 2 a 8 Cib1 15 2 EN a gt TURNTABLE ROTATE 2 gy z B ani WH RD JD TURNTABLE 4 FLOW CONTROL C31 1 C31 2 C121 4012 2 t GIRBURD lt lt A gt gt PRIMARY BOOM UP FRIMARYBOOM C2PBD RD BK PRIMARY BOOM DOWN i C1314 0132 E zo gi 5 2 sg 2 1 UY ES RD WH PRIMARY BOOM FLOW CONTROL 1 c291 C292 5 1 CIPBU RD C3B 1 11 N 12 03 2 C2PBD RD BK C3B 2 i c 6373 RD WH C3B 3 2 m M 03 9 5 C9PER BK RD C3B 9 C9PER BK RD 0307 2 2302 PRIMARY BOOM EXTEND RETRACT 4 F
164. 12 C133PLA BLWH g 9 8 2 5 2 C2P 5 C46HRN GR C46HRN GR ol A HORN RELAY 44 Po a GRBK 1 a 7 1 P22BAT 7 1 E 8 1 3 22 yy 4 BEN 5 p Mpapa HH WAS C1P 12_ C132PLIBL WH 1 12 5 Nis z P134FB WH Cop PISPWRGRIBK Cabo 2 9 ol m FLASHING BEACONS gt E re Darel Mite art meee T 5 RD i M 5 2 So i 53 4 C2IGNWH RZIIGNWH C54 T HYDRAULIC OIL TEMPERATURE 2 8 d SWITCH OPTION T 1 e P116HYDRD 81 E 5 5 s 05 1 27 4 COOLING FAN z 2 21 4 Gu 219 OPTION oz Pe 5 4 5 C41RPM OR BK C2B 3 C41RPM OR BK 5 2 E WH 8 x 2 5 4 T c 1 1 lt a z clay le 91 ETEY Of 5 4 t lt pu 4 gs a Niet MENTO ae 53 8 RD 4 C7B 4 P20BAT RD 5 5 i amp a N e Part No 77828 gt CE AND PLATFORM OVERLOAD OPTION ONLY NOTES enie A TEREX COMPANY S 60 S 65 G 6 63 Section 6 Schematics July 2005 Electrical Schematic S 65 CE Models Deutz F3L 201 1 Models after serial number 11879 REVA
165. 1360 1844 1530 2074 1240 1510 1700 1950 2370 2670 3000 e e 5 EE 18 24 16 24 20 13 20 12 18 18 34 10 ___16 9 14 8 12 7 12 mE GNE 12 6 12 7 75 91 10 3 116 155 5 2 1 95 260 DRY LUBED ft lbs Nm ft lbs Nm 36 5 23 6 32 31 4 42 6 2 46 7 62 3 81 108 129 172 202 269 278 371 394 535 536 8 1055 682 E wo 4 N ATO 09 gt a PES ee pol po OA co N Of po gt olol o OF OT po A gt eo 583 2 10 5 60 5 65 Part No 77828 July 2005 Section 3 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 six months annually and every 2 years as specified on the Maintenance Inspection Report Failure to perform each procedure AWARNING as presented and scheduled may cause death serious injury or substantial damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records
166. 21 11608 5 1 COOLING FAN P116HYD RD 3 8 8 6 pe C107AF WH 510 c C5 8 za gs t 80 85 wt 8 nn E E Ba T ax 89 TEE 64 4 piad 21 5 5 5 R9 1 E 3 e 2593 884 834 amp ER ifl L zen E666 2158 i 208 p 45 5 22 P20BAT RD 07844 5 Te rJ 2 gt 99 9 2 A 77828 A TEREX COMPANY 5 60 5 65 G 6 19 Section 6 Schematics July 2005 Electrical Schematic S 60 Ford LRG 425 EFI Models before serial number 11880 REVA A P22LS BK e iO 7 3 BATGND C7B 3 GROUND 2 E ls
167. 5 5 a C7P 1 22 C7B 1 P22HRNBK P46HRN BK C6 9 rer 5 2 T m x m ao gt P134PWR GR BK C2P 6 C2B 6 R21IGN WH s 5 4 TEMPERATURE SWITCH P134PWR RD 4 N P22LS BK aie C116 OR C54 5 COOLING FAN Ba P116HYD RD E HI OPTION Ex 3 E p 6 m C107AF WH 2 CES sion 2 3 5 4 lee eu gd T 4 1 Q5 5 Sn eee c 1 55 5 5 m Ti 5 5 89 pO 1 E ae E 3 259 4 asc 1 Ory amp 1 13 12 2 4 7 ES amp S 8156 SA roa HAO mess 17 58208 20 P20BAT RD C7B 4 83598 3208 8 8 9 A E a a N e Part No 77828 enie A TEREX COMPANY 5 60 5 65 G 6 29 Section 6 Schematics Electrical Schematic S 65 Ford LRG 425 EFI Models before serial number 11880 July 2005 gt ROCKER STEER OPTION ONLY
168. 5 5 al lz P anwaiomasar 2 879 8 o NMOG SIP LHOIY 31VLOH WHOdLV Td 8r 34 1 820 38 49 Jp 1551 9 o io 4 1431 1 WHOdLV Td 13 1 80 O 1581 48 eas Sr NMOGT3A31WHOdlYId SL zl ls Q4 1 129 38 80 078919 2 6951 4 een vL dnT3A31WHOdlVid Ph 5 1 029 Je 8851 Set Beers er El 1 012 Je Qd 8 waaay 8 O 855118 6 7HIO ONDdl3 X3 Wid 6 Qd T 1 06 OYMA 93469 P 8 10 8 1210 8 860 8 4 X I 1 0 55 38420 E9518 1 80 39 39429 mq n S m 9 31VLOH 9 169 38190 2 mie 8 31VLOH 18 1 8 1710 N8 HM 88155 Je Z9S1 48 HM nn v 1 9 Q4 HM THL 2951 ene OH1NOO 6 Gt 1 629 4 JP SOO 2 NMOQWOOSAHVWIHd 8 8 5 Qs 19s Lxg au
169. C2P 3 C30FWD WH C1P 4 RD C3P 1 C31REV WH BK C1P 5 C2PBD RD BK C3P 2 C36STCC BL C1P 10 WH WH C2P FOOT SWITCH C3PBF RD WH C3P 3 C37STC BL BK C1P 11 WH BK C3P 5 C32BRK WH RD C1P 6 CATRL WH 4 C4P BR 9 9 C29MS RD WH 3 J2 U13 ALC 500 C3P GR Part No 77828 C35RPM BK RD C1P 9 C34SA BK WH 8 C33STR BK 7 C27AUX RD C1P 1 C2P BK J1 JC1 3 OR JC2 4 RD JC1 2 BRN JC2 5 BK JC2 3 OR C1P GY 19 18 CONTROL CABLE JC1 5 YEL JC2 2 BRN JC3 5 WH JC3 3 OR JC3 4 BL JC3 2 BRN TS15 BUWH C28TTA RD BK C1P 2 TS15 B BUBK DRE LED BL RD TS14 RD WH Ne ey BATGRN C7P 3 GR BK C133TTA 12 C28TTA RD BK C1P 2 se ee ee ee ee E ed RD BK L48 NON CE _____ 2 C134PWR RD C2P 6 C134PWR RD LS18 RD TILT CWLITE BK BRN BRN BRN enie A TEREX COMPANY S 60 5 65 G Q a RR eR re 2 RD BK 28 TILT ALARM CWLITE WH TS49 6 83 July 2005
170. CR en TTE gt i RD M m Bic So 4 o 2 a C21IGN WH RZIIGNWH s 054 7 HYDRAULIC OIL TEMPERATURE 2 8 d c2 SWITCH OPTION e PH6HYD RD E 855 R116 OR 5 1 gt COOLING FAN gt lt 5 Qe LT option 8 d z 5 m C41RPM C2B 3 C41RPM OR BK 65 2 a Qe py 87771 C21IGN WH T 4 EL of a 1 as g a o t t 5 j os E i msi i 0541094 als NNI eR eee 1 mz 9 8 8 a RD 4 C7B 4 2 RD 5 5 i 1 s amp T a N e Part No 77828 gt AND PLATFORM OVERLOAD OPTION ONLY NOTES A TEREX COMPANY 5 60 5 65 G 6 85 Section 6 Schematics Electrical Schematic S 65 Perkins 404 22 Models before serial number 11880 July 2005 P22LS BK RE
171. FUNCTION ENA 5 BEN THIGH RP BKIRD a HIGH IDLE RELAY i 1 BERD 65 18 HIGH RPM SOLENOID go cz 23 a E 5 5 C2P 7 GRWH C2B 7 s C45GEN GRWH 5 12 L GENEBATOB OPTION ey ee ew 35 16 25274 12257424 2322 ein ee cU ITE 1 f 12 DLITE q 038 12 l DRIVE LIGHT 2 4 OS C DRIVE LIGHT OPTION ws i o 9 5 ge 9 FUSE 10A N ni WORK LIGHTS OPTION C2P 12 2 10 a i Daten C2P 9 i 8 8 5 y 5 tr a 2 C348A BK WH C1B 8 C34SA BK WH C522 4 aLow ive 1 PLUG 8 00 E X ads GLOW PLUGS 4 PLUG 000 5 So S z n 000 00 gt C26TSR WH RD COOLANT TEMPERATURE LED a 0 5 e 599 59 5 BS 8 2 2 2 2 202 2 7 CSSSTRBK 01 7 EE gt eu aT COOLANT TEMPERATURE SWITCH i ENGINE START b 55646848966 8 alo o e e 9 ici EE 5 16 4 OIL PRESSURE SWITCH a 5 5 C25PSR WH BK N 1 S6 lt oz E B E N 9 fan o 4 POWER RELAY
172. Machine Specifications Tires and wheels Specifications Performance Specifications Boom function speeds maximum from platform controls Wheel lugs 9 5 8 18 Jib boom up 5 65 60 to 70 seconds Lug nut torque dry 170 ft lbs 225 Nm Jib boom down S 65 40 to 50 seconds Lug nut torque lubricated 130 ft lbs Boom up 60 to 70 seconds 176 Nm Boom down 60 to 70 seconds Tire ply rating 14 Boom extend 58 to 66 seconds Overall tire diameter 36 9 in Rough terrain tires 93 7 Boom retract 53 to 62 seconds Overall tire diameter 40 3in Turntable rotate 360 78 to 86 seconds Hi flotation tires 102 4cm stowed Tire pressure 70psi Turntable rotate 360 125 to 165 seconds Rough terrain tires 4 92 bar boom raised or extended Tire pressure 60 psi Platform rotate 180 8 to 12 seconds Hi flotation tires 4 13 bar S 60 Fluid capacities Platform rotate 160 8 to 12 seconds S 65 LPG tank 33 5 pounds 15 2 kg Braking distance maximum Hydraulic tank 45 gallons High range on paved surface 3 to 6 ft 170 liters 0 9 to 1 8 m Hydraulic system 65 gallons Drive speed maximum including tank 246 liters stowed position 2 2WD models 40 ft 6 2 sec 12 2 6 2 sec Drive hub oil type SAE 90 multipurpose hypoid gear oil API service 4WD models 40 ft 7 8 sec classification GL5 For operational specifications refer to the Operator s Manua
173. NOTE DASHED LINES INDICATE OPTION WIRES Genie COMPANY 5 60 5 65 Part No 77828 6 53 Section 6 Schematics Deutz F3L 2011 Models after serial number 11879 Ground Control Box Switch Panel Wiring Diagram S 60 CE Models July 2005 REVA 6 54 P enie A TEREX COMPANY 5 60 5 65 G Part No 77828 a 1956 5 amp 225 5 Tx o 545 8 585828 2542 9 Oe ul 2 55 cus za 0 gt gt TE z MEEIEIEESGSGulIS9 9 l8 6 2 5 8 5 5 u 1 0 lt w o ouu aig 219 2 9 s zc 9 29 95 alg H 28 594 351 ag g 2 gt E E
174. NOTaNs 28019 G AINO 9 201 8 0000000 e O INO 199310 MS AA OL 1 zi Aava 9 9 S CH HMdXDY v 5 6 Wi pue 2 4 Anuo CH 1 OL t O oa seujsnpu E amp 5 860 157 ES olz v g WHY Tv GVOTHSAO WHOALVId EEL 24 51 959 Ct 21 810 3385 LAN Qa z USI8HO us WSMOAAV EH 8 9 m NuH9rH Suo QH 829 21 99 8 5 7 ms vet Q GH 5 5 Je vel L 5 WI QVO1 PEL ZISTQH JP 65 G31WOO8l1OVHI3H 66 Qd 280 951 3878 2 5 8 O 2 9 5 GO ue E 9 dfbioId SING 1 WAHO Wald HO QNONu8 9 820 X8 HO
175. PWR gt 9 git RETRACT 20 8 3 BOOM RETRACT 1 lt 17 2 lt 5 E a BAN 2 589 5 2 CHB8LSROR RD C4B4 OR RD 38 3 WH C38 4 LS17 BOOM UP DOWN P24FS WH a Ur SPEED REDUCTION LIMIT SWITCH E 2 200 P24FS WH 6 B 425 24 BURD C4B 1 BL RD 9 1 BK C92 LS3 DRIVE ENABLE LIMIT SWITCH 26 gt y E a 022 9 22 2 eA EES WH BK cna LS1 PRIMARY BOOM EXTEND 5 SVE DRIVE LIMIT SWITCH uo J1 WH C10 1 BK WH 10 2 LS2 PRIMARY BOOM UP STE DRIVE LIMIT SWITCH E C40LS OR C2B 2 _ x 3 m LAR g9 9 B 4 5 2 y 5 1 mp 2215 11 59 BL BK C3B 11 BL BK 5 s 5 BK 037 3 WH 37 4 3 i LS5 CABLE TENSION LED eve g 5 8 m o P134 RD RD 5 RD ac BR 038 2 LS17 BOOM UP DOWN Ny SPEED REDUCTION LIMIT SWITCH m 2 CI4PLU OR C4B 2 4 UP 2 lt 5 29 4 PLATFROM LEVEL 1 DOWN C4P 3 C15PLD C4B 3 C20 1 20 2 2 4 PLATFORM LEVEL UP f PLATFROM LEVEL t DOWN i EISRED ORBR PLATFORM LEVEL DOWN 5 21 1 C212 10 C129JDA BL C3B 10 62 8 6 C18JD PRR C4B 6 DOWN
176. RD ROTATE RD RD RD NOTE DASHED LINES INDICATE OPTION WIRES CE LIFT DRIVE OPTION REPLACE WIRE WITH CR27 amp CR30 A TEREX COMPANY Part No 77828 5 60 5 65 6 38 July 2005 Section 6 Schematics SER SSS eS Platform Control Box Switch Panel Wiring Diagram S 65 Ford LRG 425 EFI Models 2215 July 2005 Deutz 2011 Models before serial number 11880 Electrical Schematic S 60 Section 6 Schematics z amp 5 gt N amp C35RPM BK RD 3 FOOTSW HIGH e e 5 FOOTSW Low E 28 5 x oe 8 5 Low RPM FUNCTION HIGH RPM C35RPM BK RD BIGHIDLE RELAY 5
177. RR 52 22 272015 d tat 5 E 5 JIB VALVE 8 JIB VALVE a tn I lt amp 4826 cc 6 32 enie A TEREX COMPANY S 60 S 65 G Part No 77828 July 2005 Section 6 Schematics Sees SSS Electrical Schematic S 65 Ford LRG 425 EFI Models after serial number 11879 Section 6 Schematics July 2005 ________________ Ground Control Box Terminal Strip Wiring Diagram 5 65 Ford LRG 425 EFI Models before serial number 11880 REVA July 2005 Ground Control Box Terminal Strip Wiring Diagram S 65 Ford LRG 425 EFI Models before serial number 11880 Section 6 Schematics Ei
178. S 60 5 65 G 6 79 Section 6 Schematics A Perkins 404 22 Models before serial number 11880 Ground Control Box Switch Panel Wiring Diagram S 60 July 2005 REV B 6 80 enie A TEREX COMPANY S 60 5 65 G PartNo 77828 5 5 zz E 5 56 o 5 5 222 5 5 gt 54 gt 4 u 1669 68 So 0025 19 AES co 5 2 Eu 2166 zu S gt CES 58518 695 8x2 usu 59 2 BEEBEE EaI lt Ela g zZz ot 23 zziz 5 gt 2210 EEE 2 215 Lz amp TIME 818 85543495 98 28323208 855 SEE a 5 99985 5 555 Ss 22 588 5 2100 5
179. Schematics M M W Hydraulic Schematic 2WD Models Section 6 Schematics PLATFORM ROTATE OIL COOLER OPTION 6 96 Hydraulic Schematic 4WD Models enie A TEREX COMPANY S 60 5 65 G July 2005 Part No 77828 REV D
180. Specifications REVA Ford LRG 425 EFI Engine Displacement 153 2 5 liters Number of cylinders 4 3 78 x 3 4 inches 96 01 x 86 36 mm Bore amp stroke SPECIFICATIONS Engine coolant Capacity 11 5 quarts 10 9 liters Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140 200A Horsepower 70 2500 rpm t 52 kw 2500 rpm Current draw maximum load 800 Firi Circuit voltage drop 0 5V DC iring order In while starting maximum normal temperature Low idle computer controlled 1600 rpm Brush length minimum 0 25 in 320 Hz 6 35 High idle computer controlled 2500 rpm Commutator run out maximum 0 005 inches 500 Hz 0 127 mm Compression ratio 9 4 1 Electronic fuel pump Compression pressure approx Fuel pressure static 63 psi Pressure psi or bar of lowest cylinder must be 4 3 bar at least 75 of highest cylinder Fuel flow rate 0 58 Valve clearances 0 035 to 0 055 inches 5 5 L min collapsed tappet 0 889 to 1 397 mm ES Alternator Lubrication system Output 95A 14 5V DC Oil pressure 40 to 60 psi operating temperature 2500 rpm 2 75 to 4 1 bar Battery Oil capacity 4 5 quarts Type 12V DC including filter 4 3 liters Size 13 x 613 16 x 93 8 inches Cil viscosity requirements 33 x 17 3 x 23 8 cm Above 15 F 26 C 10W 40 Quantity 1 Above 22 F 30 C 5W 30 Cold c
181. Wheels chocked All external AC power disconnected from the machine PartNo 77828 5 60 5 65 5 1 Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie S 60 and Genie S 65 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate fault code thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 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 Perform all troubleshooting ona firm level surface Two persons will be required to safely perform some troubleshooting procedures Section 5 Fault Codes July 2005 FAULT CODES Fault Codes Control System 3 How to Retrieve Control System Fault Codes At least one fault code is present when the alarm at the platform controls produces two short b
182. er WORK LIGHT RD M DRIVE LIGHT OPTION 1 1 lt ala N 15 E RD al E WORK LIGHTS OPTION iu C2P 12 9 C2P 10 Eos 9 le E a Sb 2 11 C2P 9 2 3 5 1 m E d 5 hs a p C34SA BK WH C34SA BK WH 5 22 e GLOW PLUG 9 4 ES slow 4 4 PLUG um 000 2 C26TSR WH RD OIL TEMPERATURE LED a 2 gt 9 2 e 5 5 m 2 335 CIB 7 Eas gt 05 14 OIL TEMPERATURE SWITCH 4 5 ENGINE SES START 9 22 goa 3 Fafo ggg 2 ENGINE s 5 16 OIL PRESSURE SWITCH x START Ove a t 4 C25PSR WH BK SL 8 ne 1 8 o if POWER RELAY a 1 Qe e C2 IGN2 WH on A FUEL SOLENOID S a N 4 C27AUX RD 1 1 SEIEN wet HOUR METER 88 1 IGN START RELAY 2 WOO Wye 2020 ae 5 2 R33STRBK 5 5 i Bp FEE ES E a ae a 5 STARTER MOTOR T E 151 5 9 1 AUXILIARY 5 x t HD CETAUX AD AUXILIARY POWER RELAY 2 zi 2 q 8 5 C7B 2 B 212 mon 1 88 4 AUXILIARY PUMP N boo m uu
183. gt ws 1 BLACKILTGREENTS 0 gt _2 RED WHITE 18 7 LT BLUE BLK 18 108 5 6 1 LT GREEN RED 18 LTGREENREDi8 16 en J START IN INTERUPT TYPE C33STR BIKE GREEN dE START IN AUTOCRANKING MTRTWR10 1 BLK LT GREEN 18 GREEN ORANGE 18 PINK DK GREEN 16 GREEN 18 BLACK 18 5 5 LTGREENRED 18 TWR gt DK GREEN 18 aly MTRTWR4_EGO LTBLUEWHITE 18 auxour2 mx ENGINE TEST SWITCH TELLOWLTGREENTa AUXINPDI TAN BROWN 18 COMM D FUELSELECT AU 18 GOVSELECT C128LPRM gt STARTER BLUEMHITE 18 RELAY PURPLE DKBLUE 18 AUXOUT1 87A LT BLUE PINK 16 WPTWR1 WHITE 16 30 xc MTRTWR8 87 PINKIBLACK 16 STARTER 18 86 6 SOLENOID IGRAY ORANGE 18 85 YELLOW 18 FL F2 RED14 RED 12 GRAY BROWN 18 cL RED TAN 14 LT GREEN RED B 20A BLACK WHITE 18 1 AUX IN PD2 C27AUX E E RUE AUX IN PU2 WPSHDN THIS JUNCTION TO PINK YELLOW 16 5 FUEL PUMP G136FP BE WITHIN 3 6 INCHES DISTRIBUTOR BLACK 16 GROUND CONNECTOR CONNECTOR 5 FINKDKGREENTS RELAY FUSED POWER 2 SPLICE TO ASSEMBLY 8 SEAL END OF OPEN WIRE 7 14 30 F4 MTRTWR6 87 PINK YELLOW 16 ams WHITE PURPLE 18 fe CRANKSHAFT PINK TAN 18 86 15A POSITION FUEL PURPLEWHITE 18 Lb PUMP
184. 1 21 MS QVO1 Q Qd 1151 69 1 O CH 1 160 567 8 18 8 YNO6SO 2 9v ue 9 5 12 8104 HOLWNHALIV 1 2 50 QNO Nu8 8 829 ov 5 W008 Ov 20100161090 2 829 15100 P aas 5 1 820 41680 1 iss O i5 z 1 820 MOSZEO o z 96 13109315 O m 1 20 18 2259602 01 810 18008980 2 se Q CH 21 6 810 WdHSEO ve emawoe CH 22 52 HME 9551 8810 HWA VSPEO 3NION3 1H V1S 42810 48 HLSEEO ENSIS 1 IBNVd HOLIMS OL 62 50 2 9 8 0 GH HM 5 i 3SH3A3H T3dOHd IE 02 50 SAID 05 T3dOHd oc 9 i 12 50 QM40EO 810 HM 62 O O 9 30 5622 Nua EALO 814620 1 vLISZO 2 810 72 Qd
185. 1 DRIVE C130TA WH RD TRAVEL ALARM E L OPTION ER EEE REES RE SER SEEN e a 8 C26 1 C26 2 C32BRK WH RD 1 2 2 1 Hace lt C1B 6 5 23 C32BRK WH RD BRAKE RELEASE E 8 C28 1 C282 z F 2 z C29MS RD WH C188 524 C29MS RD WH D MOTOR STROKE 5 5 5 E 3 0251 C252 CDE2BLBK C37SCW BUBK 1 11 E 087801 BLEK STEER RIGHT 2 P 2 5 5 DRIVE ENABLE RIGHT 72 10 C36STCC BL 1 10 C36SCC BL Al 25 0 x amp CDE1 BLWH 8 244 0 C242 9 g 8 lt 8 lt 08 6 C6TRF WH RD C3B 6 9 5 WH 4 git az B Ix P A CATRL WH C3B 4 CATRL WH I TURNTABLE ROTATE LEFT iw ewn sc 14 1 4 14 2 ra 59 scc C3P 5 CSTRR WH BK C3B 5 CSTRR WH BK FURNALE ROTATE RIGHT E 14 lt 8 2 Ci51 15 2 r a TURNTABLE ROTATE rn 1 2 8 C814 C812 ii Pd WH RD lt TURNTABLE ROTATE We gt t CONTROL 12 1 4012 2 PRIMARY BOOM UP PRIMARY BOOM DOWN C2PBD RD BK PRIMARY BOOM DOWN 4 N 8 C133 1 01 EG E R A E 16 vour pe 2 PRIMARY BOOM FLOW CONTROL 29 1 29 2 Us
186. 1 Qd uu AWALIVE 9 9 8 Q4 Nua INN HMAXNV H G 8 Wi pue itana e Q4 in ossa H3l3WOHOVL 4 Anuo 2 CH AvidHlHVIS L OL 10 oa seujsnpu E amp 5 860 157 881I QU 4O ES WHY Tv GVOTHSAO WHOALVId EEL S 51 959 VIdEELO 281 2 1 21 810 10 8 260 45 LAN 8 Qa z us WSMOdAVEUNHOH 5859 ex a NuH9rd 5908 Qs QH 2 829 9 2 42 8 5 vel MS WI1 QVO1 FEL 5 5 Q eee vel 1 1 5 WM FEL 15 Je 65 Qd 280 951 878 680 2 2 9v 8 O GO 5 E 8 820 9 o 6104 HOIVNH3 ETV 250 20 X8 HO ov 5 W008 ov 2 019 151075 2920 151070 fa 66 15 43315 1 22 5
187. 1 13 HO2S Open Inactive Heated Oxygen Sensor wiring and or connections Repair wiring and or connections OR replace Bank 2 open or shorted OR sensor is faulty sensor 114 Post cat oxygen sensor open 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 Repair wiring and or connections OR replace the post cat oxygen sensor 121 Closed Loop Multiplier High Gasoline 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 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 122 Closed Loop Multiplier Low Gasoline 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 Adjust or replace sensors OR clean or repair fuel injectors 124 Closed Loop Multiplier Low LPG 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 Repair wiring and or connect
188. 2 CDE2 BL BK 1 11 C37SCW 1 11 C37SCW nn CLEFT 18 STEER RIGHT DRIVE ENABLE C36STCC BL C36SCC BL 2x 1 RIGHT S1P 10 36 10 5 36 D STEERLEFT PERS BUWH 244 42 wag pi 5 552 A 4 3 X BL g amp 6 WH RD C3B 6 5 WH a gia 42 8 19 55 oz 4 CATRL WH C3B 4 C4TRL WH D TURNTABLE ROTATE LEFT PRS pan 2219 5 C5TRR WH BK C3B 5 5 WH BK 13 5 I TURNTABLE ROTATE RIGHT 15 1 15 2 lt FRIGHT g es ets E ee TURNTABLE ROTATE ee tLEFT 35 5 E NN E C314 C812 o d C6TRF WH RD y p V TURNTABLE ROTATE FLOW CONTROL 12 1 12 2 t GIRBURD Ibi PRIMARY BOOM UP C2PBD RD BK s Ber E 1 PRIMARY BOOM DOWN i C13 1 0132 ES E E g 18 your BK CaPBF RD WH PRIMARY BOOM FLOW CONTROL RD C29 1 C29 2 SE C3B 1 1 pwr B 6 8 BRN a ig 2 12 lt lt 2 C2PBD RD BK C3B 2 i E X 182223 s 6923 C3PBF RD WH C3B 3 304 30 2 8 C9PER BK RD C3B 9 S C9PER BK RD Jp PRIMARY BOOM EXTEND RETRACT FLOW CONTROL C3P 8 C8PBR BK WH C3B 8 i 1 13 D 7 lt 7 C7PBE 48 155 CABLE TENSION LIMIT SWITCH 3 i RD RD 5
189. 210 o a x E a a 2 VL lt 3 aja enie A TEREX COMPANY S 60 5 65 G 6 88 Part No 77828 July 2005 Section 6 Schematics Electrical Schematic S 65 Perkins 404 22 Models after serial number 11879 July 2005 Section 6 Schematics Ground Control Box Terminal Strip Wiring Diagram 5 65 Perkins 404 22 Models before serial number 11880 REV July 2005 Ground Control Box Terminal Strip Wiring Diagram S 65 Perkins 404 22 Models before serial number 11880 Section 6 Schematics FUNCTIONS HARNESS E ENGINE C5 957 HOLIMS NOISN3L 31av9 51 HOLIMS 1 woog 293819 28618 vO RED H 61 81 20 OL
190. 3 gt i lt PLATFORM ROTATE RIGHT RS RIGHT PLATFROM a ROTATE CIzJUPREGR D PLATFORM ROTATE LEFT C224 022 2 A ee C120 RD EK DESCENT ALARM OPTION 2 52561 ccrte 2 E I lt amp o o x E gt N July 2005 Section 6 Schematics SSS Electrical Schematic S 60 Deutz F3L 2011 Models after serial number 11879 2215 July 2005 Deutz F3L 2011 Models before serial number 11880 Electrical Schematic S 60 CE Models Section 6 Schematics amp 55 gg a o5 zu
191. 3 9 7 the Oscillate Axle if equipped 3 10 8 Perform 30 Day 2 0000000 3 10 A 9 Perform Engine Maintenance GM Ford and Perkins Models 3 11 A 10 Inspect the Fuel Filter Water Separator Diesel Models 3 11 A 11 Check and Adjust the Engine RPM Perkins Models 3 13 A 12 Grease the Turntable Rotation Bearing and Rotate Gear 3 14 A 13 Perform Engine Maintenance GM and Ford Models 3 15 A 14 Perform Engine Maintenance Perkins Models 3 15 C Checklist B Procedures 1 Inspect the Battery sense ann 3 16 B 2 Inspect the Electrical 3 16 B 3 Check the Exhaust 3 17 B 4 Check the Oil Cooler and Cooling Fins Deutz Models 3 18 B 5 Check the Lug Nut Torque including the tires and wheels 3 19 B 6 Confirm the Proper Brake Configuration 3 19 B 7 Check the Level in the Drive 3 20 B 8 Check and Adjust the Engine RPM Deutz Models 3 20 B 9 Test the Ground Control 3 22 B 10 Check the Oscillate Directional Valve Linkage
192. 3 C1B 3 C5 24 D MOTOR STROKE 88 8 9 o COESBURD sl 5 3 25 1 25 2 CDE2 1 11 C37SCW BL BK C1B 11 C37SCW BL BK nN P CLEFT 1 18 s STEER RIGHT Em DRIVE ENABLE 5 2 t RIGHT S1P 10 C36STCC BL 10 C36SCC BL D 538 x CDE1 BUWH 24 1 24 2 9 a E 852 o 7 Z BL g 64 45 4 lt 03 6 C6TRF WH RD C3B 6 vour sc 1 4 1 git 42 8 15555 z 4 C4TRL WH C3B 4 CATRLWH DX TURNTABLE ROTATE LEFT 1 S Pun S 2213 a 144 4 14 2 12 2 lt lt SPS GOTHHIWHIBK Conn WHIBIC I TURNTABLE ROTATE RIGHT 2 2151 0152 1 RIGHT E EL TURNTABLE ROTATE tLEFT BI as 2 2 gt 6314 0312 9 Sch WH RD gt TURNTABLE ROTATE gt FLOW CONTROL 12 1 12 2 SIEBURD PRIMARY BOOM UP C2PBD RD BK ERE 1 PRIMARY BOOM DOWN i 1 C13 1 C13 2 x E 8 HE C3PBF RD WH 19 Your s 2 t PRIMARY BOOM FLOW CONTROL w C29 1 29 2 SE MUS 1 RD C3B 1 53 6 gt PWR 3 11 15 BRN B ig 2 12 ee 0 2 C2PBD RD BK C3B 2 X s zc 3 RD WH C3B 3 2 m Haze C9PER BK RD C3B 9 F C9PER BK RD Cn 2 5 2 PRIMARY BOOM FLOW CONTROL ee 5 CPP ss C8PBR BK WH 638 7 C7PBE BK C3B 7 E
193. 4 2 6 3 29 OPTION gt i gt 11 5 15 511 2027 1152 ne ee 34 RD ra m Bic So 4 o 2 a C21IGN WH RZIIGNWH s 054 7 HYDRAULIC OIL TEMPERATURE g a D c SWITCH OPTION 9 1 so e PH6HYD RD R116 OR 5 1 COOLING FAN 5 Qe 8 5 5 C41RPM C2B 3 C41RPM OR BK 65 2 2 22 22 ns 5 C21IGN WH Sd 4 EL of n i als o o 43 5 lt lt mis 2 5 E 5 C lt lt 1 a als NNI eR eee 1 mz 9 8 8 a RD 4 C7B 4 2 RD 1 i 1 amp T a N e Part No 77828 gt AND PLATFORM OVERLOAD OPTION ONLY NOTES enie A TEREX COMPANY S 60 S 65 G 6 57 Section 6 Schematics Electrical Schematic S 65 Deutz F3L 2011 Models before serial number 11880 July 2005 gt ROCKER STEER OPTION ONLY
194. 4 DRIVE MODE 130 WH RD TRAVEL ALARM OPTION 8 C26 1 C26 2 EE C32BRK WH RD 1 3 lt 6 C528 2 WH RD T BRAKE RELEASE x 8 C28 1 28 2 5 T T 2 o C29MS RD WH C1B 3 5 24 C29MS RD WH D 2 8 5 8 CDES 5 3 25 1 C252 CDE2 1 11 C37SCW BL BK C1B 11 C37SCW BL BK CLEFT 18 STEER RIGHT DRIVE ENABLE C36STCC BL C36SCC BL 2x 1 RIGHT Sa GIP 10 36 10 5 36 D STEERTEET 215 x CDE1 BL WH 241 24 2 9 ot A 0 X BL g amp 6 C6TRF WH RD C3B 6 9 Your s WH a 42 8 19 55 oz 4 CATRL WH C3B 4 C4TRL WH 7 TURNTABLE ROTATE LEFT PwR s 13 14 1 14 2 age SPS COTHHWHIBK CS E Corn WRIBIC 121 TURNTABLE ROTATE RIGHT E 5 3 3 IR 8 FRIGHT eit 1 An TURNTABLE ROTATE 8i se as amp 5 WH RD car dice TURNTABLE ROTATE FLOW CONTROL C12 1 4 12 2 D GIRBURD Ibi PRIMARY BOOM UP C2PBD RD BK s eee E PRIMARY BOOM DOWN i C13 1 0132 s 25 E 6 lt 88 16 2 RD WH PRIMARY BOOM FLOW CONTROL a RD 29 1 29 2 C3P 1 C1PBU RD
195. 4 85 is AUX 1 4 PUMP C27AUX RD C1B 1 of ala HOUR METER 98 E IGN START RELAY m 89 155 manc Sale re az 40 Q 2 gt 4 1012 STARTER MOTOR o Key a ete Pape ceed 5 S EMISSIOIN CONTROL x SPEED REDUCTION RELAY C27AUX RD WER RELAY bun P23BAT WH 782 I AUXILIARY PO a N i 8 EB 4 eC 1 05 AUXILIARY PUMP 1 4 e RD BK E C1B 2 8 llamo ag 4 28 RD BK 8 C28TTA RD BK Les TILT ALARM Ss en 1 1 BK BRN Le LEVEL SENSOR C3B 12 Id C3P 12 C133PLA BL WH e 2 3 2 C46HRN GR en HORN RELAY puo GR BK a P22BAT g I 11 HORN 8 cette 5 1 C1P 12 O132PLIBUWH _ ISE e FLASHING BEACONS Cops PIMPWRORIK 026 6 NE 5 gt 125225 ta ent re en 5 RD i e So i BK oz b R21IGN WH 05 4 e 4 HYDRAULIC OIL TEMPERATURE a a SWITCH OPTION T x lt 8 5 R116 OR 5 1 COOLING FAN T gt lt jie n EP OPTION 5 5 5 3 C41RPM OR BK C2B 3 iz C41RPM OR BK N 106511 2227 2 a lt 2 i
196. 5 65 July 2005 TABLE OF CONTENTS Section6 Rev D Schematics continued Electrical Schematic S 65 Deutz F3L 2011 Models before serial number 11880 6 57 Electrical Schematic S 65 Deutz F3L 2011 Models after serial number 11879 u nenn 6 59 Electrical Schematic 5 65 CE Models Deutz 2011 Models before serial number 11880 0 00 6 61 Electrical Schematic 5 65 CE Models Deutz 2011 Models after serial number 11879 6 63 Ground Control Box Terminal Strip Wiring Diagram 5 65 Deutz F3L 2011 Models before serial number 11880 6 65 Ground Control Box Switch Panel Wiring Diagram 5 65 Deutz F3L 2011 Models before serial number 11880 6 66 Ground Control Box Terminal Strip Wiring Diagram 5 65 Deutz F3L 2011 Models after serial number 11879 6 67 Ground Control Box Switch Panel Wiring Diagram 5 65 Deutz F3L 2011 Models after serial number 11879 6 68 Ground Control Box Terminal Strip Wiring Diagram 5 65 CE Models Deutz F3L 2011 Models before serial number 11880 6 69 Ground Control Box Switch Panel Wiring Diagram 5 65 CE Models Deutz F3L 2011 Models before serial number 11880 00000 6 70 Ground Control Box Terminal Strip Wiring Diagram 5 65
197. 5 Press down the foot switch Move the boom Extremely dirty conditions may require oil changes control handle to the down position hold for a to be performed more often moment and then release it Before replacing the hydraulic oil O Result The descent alarm should sound when the oil may be tested by an oil the control handle is held down distributor for specific levels of 7 contamination to verify that 6 S 65 Press down the foot switch Move the jib changing the oil is necessary If boom toggle switch to the down position hold the hydraulic oil is not replaced for a moment and then release it at the two year inspection test O Result The descent alarm should sound when the oil quarterly Replace the the control handle is held down oil when it fails the test See E 1 Test or Replace the 7 Press down the foot switch Move the drive Hydraulic Oil control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold fora moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction Genie 3 28 5 60 5 65 Part No 77828 July 2005 Section Scheduled Maintenance Procedures REVC B 19 Replace the Fuel Filter Water Separator Element Perkins Models Replacing the diesel fuel filter water separator element is essential for good engine performance and servic
198. 66 are 03 7 C7PBE 48 185 CABLE TENSION LIMIT SWITCH IE P YEL 18 gt gt 31 i RD 5 C7PBE BK Boo EXTEND 5 EXTEND 515 lt 5 BOOM C37 1 C37 2 0162 mB RETRACT lt BRN 35310 8 E C8PBR BK WH 1 BOOM RETRACT lt lt 1 o 1 n 8 BPN gt gt 9 899 E CHBLSROR RD C4B 4 OR RD 38 3 C384 LS17 BOOM UP DOWN P24FS WH stus SPEED REDUCTION LIMIT SWITCH ala 2 e o e m amp PA4FS wH o B 499 24 E sacer BL RD C4B 1 BL RD 9 1 zs WH 09 2 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK 2 ke 5 gt Ld 2 2 Q 22 wH BK LS1 PRIMARY BOOM EXTEND 5 stus DRIVE LIMIT SWITCH o 4 J1 FH WH C10 1 WH C102 LS2 PRIMARY BOOM UP DRIVE LIMIT SWITCH 99 eee eo ee C40LS OR C2B 2 T FH OR x 8 go ge pee 15 5 0356 2215 11 __ 59 BL BK C3B 11 BL BK ex 5 BK 037 3 BK WH 374 3 ox gj 4 LS5 CABLE TENSION LED ove 8 3 5 2 P134 RD F RD RD 82_ 2 LS17 800MUP DOWN 4 E SPEED REDUCTION LIMIT SWITCH 8 2 Ci4PLU OR 4 2 FUP 522 Et PLATFROM LEVEL 3 DOWN CI5PLD OR BK C4B 3 4 C20 1 C20 2 2 op i CIAPLU il 4 PLATFORM LE
199. DRIVE ENABLE TOGGLE SWITCH E Qio id TS47 GENERATOR TOGGLE SWITCH OPTION E 212 EIS I TS48 DRIVE LIGHT WORK LIGHT TOGGLE SWITCH OPTION 115 Im m 101 Lo 5 1 iO 2 DD 1215 BK 1 19 9 m m iE 1 iS A rm 1 ii 10 1 1 2 1510 ii Big 19 242 25 1915 lt B 8 mim ears 3452 2120 3 img 25 r ioo IIR 222210 PI Sz E 2 FEE 5 2 6 3 je 28 519 2 82255835 1 PO vu w 7 ie 21010 8 B g 8 5 8 gg 885 S 2 5 ee 13 Jj gt 16 16 75 ES El i 29 2 5 9 5 m a 18 29 3322 E z 2 2 d 2 ig E 9 9 5 a 8 g 2857 55 Rs 6 5 8 Q E 9 E E 189 53 5 e 5 iz e IK IL oU g 5 B 2 iQ E 2 12 a 5 5 5 5 T gt o Er WH WH 012 753 D FUEL SELECT 7 of 1 9 ODO EMERGENCY STOP anes 614 9 rs 59 WH TS8 51 HIGH LOW TS47 Den HIGH LOW D HORN 2 PLATFORM GR BK JIB AUXILIARY 2WD AWD GENERATOR RPM LEVEL a Boom PUMP OPTION Bi PLATFORM 027 WH
200. EGR RECIRC 1 570 BK W 16 570 16 POWER GROUND 2570 BKW16 S70 BK W16 MAP_CONN POWER GROUND 361 14 361814 _ 361912 mace 13 359 GY R 18 570 BK W 16 ANA RTN T 4 lt 14 351 BR W 18 351 BR W 18 serwi 1 7 3 ereis OO 16 R LG 18 33 350 GY 18 358 LG BK 18 358 LG BK 18 CRANK B 32 349 DB 18 359 GY R 18 1 CRANK A 35 452 GY R 18 18 18 23 18 18 198 06 0 18 1 44 1 41 198 06 0 18 34 282 DB O 18 38 EGR ANAIN 32 ANA AUX PD1 CAM CAM 4 361 16 150 DG W 18 150 DG W 18 37 ANA AUX PU1 5 361816 361814 114 LE Y 18 utt adt 42 2 25 392 R LG 18 i 352 BR LG 18 40 EGR PWM I 2 360 BR PK 18 41 EGR REC ane 26 02 SENSOR 361 14 1 11 29 1 359 GY R 18 359 GY R 18 ag ANAETN 4 30 ki 351 BR W 18 31 VREF 16 R LG 18 32 R LB 16 MTRTWR6 MTRSHD6 THROTTLE J1 BLACK 13 STARTER CONTROL E EX FUEL PUMP _ 570 Bk w 16 X KO O 355 GY W 18 STARTER SZ RELAY RELAY 74 GY LB 18 392 R LG 18 151 LB BK 18 359 GY R 18 317 GY O 18 B 151 LB BK 18 4 D 317 GY O 18 351 BR W 18 E F eere is O
201. FUEL 5 11 C21IGN WH FEH 71 PIN21 SELECT 2 2 B C5 9 C128RPM OR RD FEH 306 PIN24 C41RPM OR BK gt gt C283 N C108ESL BL WH FEH 658 PING 5 C127TSW GR FEH 458 PIN18 5 10 C39LP BL RD FEH 72 PIN7 186 B C5 18 BK RD FEH 307A PIN23 19 5 ga 8 2 RD FEH 361 PINS 5 7 C33STRBK CIB7 GND BR FEH 570 a 5 FS ENGINE 05 2 C41RPM OR BK FEH 11 START GI p ENGINE m 055 R33STR BK 82 PIN15 IGN START RELAY START sms C33STR BK FEH 32 PIN13 gt BL WH FEH 787A PINS x C135FP BUWH es P a aye 2 C33STR BK In 22 m z 1 800 9 amp 8 1 58 to 4 STARTER MOTOR FUR buc AUXILIARY a GETAUXHD 1 AUXILIARY POWER RELAY C27AUX RD 1 1 1 T 5 L 4 AUXILIARY PUMP 4 1 8 1 C28TTA RD BK TE u gt Ed 285 5 E TILT ALARM 1 1 RD BK BRN x WH C7P 2 P23BAT WH C7B 2 P134TTS RD n roo EVEL SENSOR a 5 lt d m 8 8 m RD 1 2 28 RD BK 1 2 Nat ya ad P134FB WH u FLASHING Ko AA BEACONS OPTION 5 BK 2 C2P 5 C46HRN GR C2B 5 C46HRN GR HORN RELAY 4 2
202. Ground Control Box Switch Panel Wiring Diagram S 60 REVA A B Ford LRG 425 EFI Models before serial number 11880 e e 0 5 2 gt 55 256 54 5 amp 2298 Be 545 25 X 0 lt 5 Sq Eg 52156 2 8 8 109 ec 205 488 22 3482 55584536 5 lt 6 0 2 5 6 S 8854 2958 85400068 52818888 8 5585 5 c 3645 82862225 555586 5 Nw ze 8 8 6568 2030 gt 22255 5 gt gt 9 5 5 tu Eae 55 9 gt Za zz 9 41 5 5509 5 5255 5 w 05 IT aa lt
203. Gt ISLO HM Jp Z9SL HM en 7OH1NOO WOOS 6 Cot 1 620 8 JP 8 0 HWH 48460 2 WOOS 2 5 195 m Wuvivoia ad 9 1esL au UL 81 2 Ex SUE 1951 H 2860 LISTHO H31000 110 2 T 8 1380 555 Slale amp WuH 103138 NYOH WOO8 9334 9NIMS a a 6 80 c 5 853 N 7 5 2 3 85 5 50 200 40 a 8 1 35 8 2 8 5 X Z z 55 E 8215 5955 5 E 8 S 1 o 8 i Sit 4555 4 1 i g T oe 2j 9826 5 SNSFHM i 81 5 5 zeo 8 EI 1 8 m 9 i 118 1 9 1 255 592 i 4 5250 1 Ld 180 HOLIMS OL WH TB21 OPTIONS FUSE 10 DRIVE LIGHT ONLY WH OPTIONS
204. HOLSISIU HOLSISSY 349104 INOZ H3ddN 3aviNunL WOOS vH 91H Yok unos HOLSISAH 31v10H HOLSISIU Nmoa dn ed woog CC 961 S lt 2 8190 July 2005 Section 6 Schematics 5 C_____ 4 Ground Control Box Switch Panel Wiring Diagram 5 60 Deutz F3L 2011 Models after serial number 11879 Section 6 Schematics July 2005 2 m Ground Control Box Terminal Strip Wiring Diagram S 60 CE Models Deutz F3L 2011 Models before serial number 11880 July 2005 Section 6 Schematics REV Ground Control Box Terminal Strip Wiring Diagram S 60 CE Models Deutz F3L 2011 Models before serial number 11880 FUNCTION HARNESS ENGINE C5 H3MOd 951 HOLIMS NOISN3L anayo 161 HOLMS woog 29819 et 64 84 vO 59 681 20 INHOAS 1YId OL H3MOd
205. I o o 8 a amp pro u BI 5 8 3 5 g geras i 2 18 2 9029 3 9 5 2 8 Ra 9 uszE 2 2 2 5895 gt 5 8 2 2 2 ols 2 9 9 9 9 9178 9 m 5 9 5 26 22 g s o o 58 29 S 5 5 2 ie 5 m 3 er 5 EN cT N a 5 m 5 5 e 8 2 n ET RD RD yp aes 899 elec 1 bg 1 i 1 RD Ig 012 GR 1 SH 1969 eT QOD QOD nelnelne EMERGENCY STOP TS7 TS6 TS2 754 5 WH PLATFORM JIB GLOW PLUG ENGINE HIGH LOW HORN TS9 TS1 HIGH LOW zen TS47 PLATFORM ROTATE 4 BOOM AUXILIARY 2WD 4WD RPM GENERATOR o LEVEL PUMP OPTION 027 WH 24 RR RD RD RD RD NOTE DASHED LINES INDICATE OPTION WIRES Part No 77828 A TEREX COMPANY S 60 5 65 July 2005 Section 6 Schematics LESSEE SS SS SS Se Platform Control Box Switch Panel Wiring Diagram S 65 Perkins 404 22 Models Section 6 Schematics Hydraulic Schematic 2WD Models July 2005 REVD
206. LOAD SENSE LIMIT SWITCH TILT ALARM ITEM DESCRIPTION H1 7 CR27 CR30 1518 C9 48 PIN CONNECTOR BLOCK U13 J1 J2 J3 July 2005 Platform Control Box Wiring Diagram S 60 Section 6 Schematics Perkins 404 22 Models CWLITE WH TS49 TO SWITCH PLATFORM CONTROL PANEL HARNESS C19JSV GR WH TS7 C19JSV GR WH 7 BRN JC3 BRN GND RD E STOP C134PWR RD H1 134 RDLS18 M RM C32BRKWH RDCIPS 0 0 000000000 C32BRK WH RD 12 19 BK C1P 12 C40LS OR C2P 2 P24FS WH C9P 2 P23BAT WH C7P 2 P22BAT BK C7P 1 i 19 8 7 C18PRR GR BK 4 6 C17PRL C4P 5 C15PLD OR BK C4P 3 C14PLU OR 2 C129JDA BL C3P 10 788 C46HRN GR C2P 5 L C59CHK BL BK 11 L47 C59CNK BL BK C3P 11 P26BAT BK C9 1 P2 P25FS RD C9 3 TS2 P24FS WH 9 2 TS4 CDLITE OR RD C2P 4 C45GEN GR WH C2P 7 C46HRN GR C2P 5 P26ESTP BK WH RD C1P 6 ES f I 7 9 JIB 12V DC BATTERY C118LSR OR RD C4P 4 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 C16DRE BL RD C4P 1 C7PBE BK C3P 7 401 55 OR C2P 2 C9PER BK RD C3P 9 C41RPM
207. Lae aan 8 38920 Jg 9 9 E 2 9 8 9 QU HM 3919 ee E 5 aTav nan S 0 59 v 5 HHLSO e g v 1431 31 1 3 8VINHQL s 15910 HM Jp 2951 2 7 80 HM 1917 rez mE Je JOHINOONOHONDJWOOSAHVAIHd O 0 Y S _ 6 8 0 39455 g FELO Jp NMOGWOOS a 1961 2 8 E amour o 1 869 va 81 asya 2 4 1 431009 ET nn NOLLdO o Nua 1 Lj 880 gt a NHOH o tig 55 1 o aa 33 E a E lt 5 a 50 2 o 8 0 9 3 m 8 9 9 amp gt dS h I I a a Nd I ui h 5 0 H3MOd H3MOd 1HVIS 2 NOLLINDI N Part No 77828 A TEREX COMPANY 5 60 5 65 G 6 23 Section 6 Schematics July 2005
208. NOTES enie A TEREX COMPANY S 60 5 65 G 6 61 Section 6 Schematics Electrical Schematic S 65 CE Models Deutz F3L 2011 Models before serial number 11880 July 2005 P22LS BK REVD N N 7 3 BATGND C7B 3 RouND C2P 3 OR BK C2B 3 g EX 8 5 2 C30FWD WH 18 4 C521 C30FWD WH RD ORIVE FORWARD 15 215 mg CIPS C31REV LIBS 5 0520 CSIREVWHBK RDD BK DRIVE REVERSE x 5 7 t DRIVE MODE WH RD X TRAVELALARM z OPTION 5 dc oe nu a g 0261 26 2 T C32BRK WH RD 6 0523 C32BHK WH RD
209. STEER RIGHT t BONES C36STCC BL C36SCC BL hi zx RIGHT 72 36 10 36 PEE x amp CDE1 BL WH g 24 1 24 2 ju 1 E 2 2 lt BL NER RKour e4 7 6 WH RD C3B 6 5 ig WH lt gH nn CATRL WH SIE 4 gt 55 1 cc 4 C3B 4 CATRL WH TURNTABLE ROTATE LEFT 1 1 3 a 13 2 14 lt lt 5 GETRRIWHIBK 038 TURNTABLE ROTATE RIGHT 15 lt 8 RIGHT ee 4 r I TURNTABLE ROTATE gy LEFT 8 i Vul d 1 WH RD n TURNTABLE ROTATE E FE S D FLOW CONTROL C31 1 31 2 a B C12 1 12 2 CIFBURD PRIMARY BOOM UP PRIMARY BOOM C2PBD RD BK EN 4 PRIMARY BOOM DOWN xd x C13 1 Rx BI sd 9 8 Ix d T 16 2 ES RD WH PRIMARY BOOM FLOW CONTROL np C20 1 29 2 SiE 03 1 C1PBU RD C3B 1 1 pwr 3 11 y 16 BRN ig 2 12 2 C2PBD RD BK C3B 2 E 12 7 lt E p lt QE LL 63 3 C3PBF RD WH C3B 3 2 C30 1 30 2 47 9 C9PER BK RD C3B 9 E C9PER BK RD lt PRIMARY BOOM EXTEND RETRACT EX FLOW CONTROL pios 4 0398 C8PBR BK WH C3B 8 m 124 2 ig sq face PZ 32 185 CABLE TENSION LIMIT SWITCH is i 15 x RD RD M BR C7PBE BK BOOM EXTE
210. There may be an approximate 2 second delay before the overload indicator light and alarm turn off 12 Test all machine functions from the ground controls Result All ground control functions should operate normally 13 Turn the key switch to platform control 14 Test all machine functions from the platform controls Result All platform control functions should operate If the platform overload system is not operating properly see D 9 Calibrate the Platform Overload System if equipped Part No 77828 July 2005 Section Scheduled Maintenance Procedures REV D CHECKLIST C PROCEDURES C 4 5 Visually inspect the cables and components Inspect the Boom Extend through both inspection holes for the following Retract Cables Frayed or broken wire strands Kinks in the cables Corrosion Paint or foreign materials on the cable The boom extend retract cables are responsible for Split or cracked cable ends the extension and retraction of the number 3 boom tube Inspecting for foreign objects damage and or Cables are on all pulleys improper adjustment of the boom extend retract Cable break limit switch arm is centered in cables and related components on a regular basis the pivot plate is essential to good machine performance and safe Cables have equal tension machine operation The boom extend and retract 3 functions should operate smoothly and be free of Cables at e
211. and Fitting Torque Specifications 1 Open the platform control box 2 Tag and 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 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 Genie BOOM COMPONENTS 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 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 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 Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections ver
212. i C17JU PRL GR C4B 5 5 231 0232 8 2 i CT amp ID PRR GR BK 1 PLATFORM ROTATE RIGHT F RIGHT PLATFROM LEFT ROTATE C17JU PRL GR PLATFORM ROTATE LEET C224 022 2 5 RIGHT PLATFROM p It LEFT p 0 35 20 15 12200 50 21 56 it 129 RD BK DESCENT ALARM OPTION t u 2 p 7 C19JSV GR WH C4B 7 te d 2 2 5 5 8 hd JIB VALVE JIB VALVE i a z SS 3 ala iv 5 6 14 A TEREX COMPANY S 60 5 65 G Part No 77828 July 2005 Section 6 Schematics Electrical Schematic S 65 GM 3 0L Models Section 6 Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram S 65 GM 3 0L Models July 2005 Section 6 Schematics REV B Ground Control Box Terminal Strip Wiring Diagram S 65 GM 3 0L Models E
213. o o BRN bd PLATFORM OVERLOAD 1 2 2 ii OPTION N DRIVE E ENABLE r pda 1 1 1 147 1 lt bog RETRACT Y N IB Aude E E E BRN dg bd bg E Bk 18 BRN oo BRN BRN BRN F18 9 i E d FUSE 10A E EM N WORKLIGHTONLY 2 IQ IE IB ig 1 144 19 12 165 s 1 Ed g 5 ii BK 19 8 9 m o 3 m em lm sz w V 5 18 0 I 0 15 2 2 lo 2 2 m Im 1 zo iz 5 1 IS 219 x m m im im 10 19 1 2 1 g 1 m IQ a 2 E nin Xd Sie iN IM Sle 12 151 5 2 us zm gu 2 e 9A 6 Bld 5 S dcO 9 dvO 144109 TS9 PLATFORM LEVEL RD 9 49 49 Z dvO 5 6 1249 HM 2 gt 2 9 2 2 9 v v WH WH e O PLATFORM TS1 ROTATE AUXILIARY PUMP RD HM 8 17 HWQH SW629 1 TS14 HIGH LOW 2WD AWD 2 38 S B 4 2 2 w 8 2 B 9 ig is IN
214. zie El e gt gs 899 3 E 40 554 50 53 35 55 5 3858 12553548 28 355 35 25 05258552858 55 5 2 5 6 9 216 969 2 a NIN dIHLS TWNIWHAL OL 28888888568 SS3NHVH 3SV8 3156961665156 6120 END 6 0 NE G6L HWHS VSLSTOUINCO pK 6951 a amoy CDW INYO LYId 4 Lag 1651 U J YSL 3NION3 9 189 G815ig H5 5 8 SNOLLdO er CHO 31v10H amp ECT M 5 280 9 S Jg HM 2260 x aa lovuldu 0 QN31X3 nd noos 4 5981 z woos 01 2 1951 PO HWGQH lt S o a a 2 o 8
215. 0L Engine 2 4 Ford LRG 425 EFI Engine 2 5 Deutz F3L 2011 Engine 2 6 Perkins 404 22 Engine Specifications 0 2 7 Machine Torque 2 8 Hydraulic Hose and Fitting Torque Specifications 2 9 SAE and Metric Fasteners Torque 2 10 Scheduled Maintenance Procedures Introduction 3 1 Pre Delivery Preparation 4 een 3 3 Maintenance Inspection 3 5 Checklist A Procedures A 1 Perform Pre operation Inspection 3 7 A 2 Perform Function Tests entree rede ek 3 7 A 3 Perform Engine Maintenance Deutz 3 8 Genie Part No 77828 S 60 5 65 July 2005 a IMM TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued 4 Perform Engine Maintenance GM and Ford Models 3 8 5 Perform Engine Maintenance Perkins Models 3 9 A 6 Check the High Pressure Hydraulic Filter Condition Indicator
216. 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 5 60 5 65 0 5 Perform Engine Maintenance Perkins Models 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 1443S Perkins 400 Series Operation Manual Genie part number 94890 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 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 July 2005 Section Scheduled Maintenance Procedures REV D CHECKLIST C PROCEDURES C 6 Perform Engine Maintenance GM and Ford Models Engine specifications require that this
217. 32 R LB 16 32 R LB 16 15 STARTER IN INTERUPT 39 STARTER IN AUTOCRANK J2 GREY 342 LG P 18 4 570 BK W 16 5 SPK PWR GROUND 1 850 18 eva omas 2 a 361AR 16 2 361AR 16 359 GY R 18 D 787A PK BK 16 FUEL PUMP T 5 COIL 3 13 3 C y LOCKOFF SOLENOID 669 DG W 18 B COILS 458 O BK 18 A COIL6 STARTER LOCKOUT FUEL LOCKOFF 23 252 9 926A LB O 18 S28ALB O 18 RELAY CONTROL rn 6 31 357 18 253 DG W 18 28 181 18 81 15 OIL PRESSURE DBW 29 317 GY O 18 BRAKE Mond 6 511 LG R 18 511 LG R 18 A BRAKE OIL PRESSURE e 26 OILPRES TACH 2 TACH FUEL PUMP MON 14 72 YK 18 T2 7 FUEL SELECT AUX ANA PU2 10 AUX ANA PU2 Seins 2 s estesa fetes 00 9072 26 77 DB Y 18 un 33 349A DB 18 349A DB 18 Pe S49ADB T8 OVERSPEED 30 OVERSPEED RS 485 3 RS 485 Sud E 669 559 DG W 18 669 DAWIE o RS 2324 8 RS 232 RX 35 458 O BK 18 O BK 18 1 458 O BK 18 18 RS 232 TWR SHD W 16 TRIM VALVE 570 A A PLUG GROUND 61 16 77 DB Y 18 PLUG RELAY POWER 459 0818 lc PLUG CAN B 361A 16 1 361A 16
218. 4 LS17 BOOM UP DOWN P24FS WH 5 2 IE SPEED REDUCTION LIMIT SWITCH LL x m a PMFSWH 5 B 499 s qc 4 1 C4B 1 _ BL RD C9 1 ts WH 09 2 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK 2 gt 3 gt 7 N o a 2 CPP 9 22 wH LS1 PRIMARY BOOM EXTEND 5 STE DRIVE LIMIT SWITCH o 4 J1 WH C10 1 BK WH C102 LS2 PRIMARY BOOM UP DRIVE LIMIT SWITCH EEE LEER d C40LS OR C2B 2 OR x 8 ji z m tR F 1 10 9 P22LS 11 C59CNK BL BK C3B 11 BUBK 3 o ar ae Ej 4 LS5 CABLE TENSION LED 8 3 5 o P134 RD RD 38 1 RD BR 382 7 LS17 BOOM UP DOWN VN SPEED REDUCTION LIMIT SWITCH 2 2 CI4PLU OR C4B 2 ET 589 PLATFROM LEVEL E 1 DOWN CI5PLD OR BK C4B 3 204 20 2 2 B B op C14PLU Al 1 PLATFORM LEVEL UP PLATFROM LEVEL DOWN CISPLD IA PLATFORM LEVEL DOWN B C214 C212 26 10 C129JDA BL C3B 10 EZ 8 e C4P 6 C18JD PRR GR BK 4 6 ere DOWN TUP__BOOM C17JU PRL GR C4B 5 GES z E 023 1 023 2 8 CEGJVCRR GREK Il PLATFORM ROTATE RIGHT F RIGHT PLATFROM LEFT ROTATE C17JU PRL GR t i 403 2 4 PLATFORM ROTATE LEFT C224 C222 5 5 B RIGHT PLATFROM
219. 5 ES C35RPM BK RD C1B 9 o9 8 FOOTSW HIGH ce FOOTSW LOW 28 5 eu 5 25 LOW RPM FUNCTION ENA HIGH RPM gt C35RPM BK RD BAN near 2 a e 65 19 HIGH RPM SOLENOID e 4 4 4 5 1 5 GRWH C2B 7 C45GEN GRWH C512 IA A GENERATOR OPTION 228 1 i e DLITE BWH C3B 12 i DRIVE LIGHT o m GHT LIGHTS p v8 WORK LIGHT RI C DRIVE LIGHT OPTION 18 Sx 519 C WORK LIGHTS OPTION iw C2P 12 2 10 a A 1 EX 2 11 C2P 9 ege cde Ea greg crc ccc Deo e I E m 7 lt lt x i gi 1 al IS ees amp MM lee eee 5 8 C34SA BK WH 6 C34SA BK WH 5 22 d GLOWPLUG RELAY e 9 GLOW ti PLUG b L1 Fe X 2 9 0 GLOW PLUG PLUG 2 000 5 8 a lt 5 C26TSR WH RD OIL TEMPERATURE LED a E 5 Ed Exa 853 gt Sly 8 9 C33STR BK SSSTHB C1B7 2852 ee Gs OIL TEMPERATURE SWITCH ENGINE a 25 START 9 5626 ei 3 amp ENGINE C5 16 2 1 lelelelele OIL PRESSURE SWITCH a C25PSR WH BK 5 F 8 g o RELAY n E EL ye FUEL SOLENOID
220. 60 5 65 Section 5 Fault Codes July 2005 Ford Engine Fault Codes Fault codes Ford Engine 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 Repair Procedure 5 4 How to Retrieve Engine Fault Codes Use the Fault Code Chart on the following pages to aid in identifying the fault REVA Genie 5 6 5 60 5 65 PartNo 77828 July 2005 Section 5 Fault Codes REVA FORD ENGINE FAULT CODES Code Problem Cause Solution 111 Closed Loop Multiplier High LPG Heated Oxygen Sensor wiring and or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks Repair wiring and or connections OR replace sensor OR repair vacuum and exhaust leaks 112 HO2S Open Inactive Heated Oxygen Sensor wiring and or connections Repair wiring and or connections OR replace Bank 1 open or shorted OR sensor is faulty sensor
221. 662 DG P 18 D PLUG CAN WPTWR2_GY MTRTWR4 MTRSHD4 A TEREX COMPANY Part No 77828 5 60 5 65 6 6 July 2005 Section 6 Schematics LL Ford LRG 425 Engine Wire Harness REV B C28TTA RD BK C28TTA RD BK July 2005 Electrical Schematic S 60 Section 6 Schematics GM 3 0L Models I Q m 4 515 a a 9 poe C35RPM BK RD C1B 9 FOOTSW HIGH e e 9 FOOTSW LOW za 50 8 Pas 1 8 LOW RPM 218 e FUNCTION ENABLE 5 8 9 HIGH RPM oe ve ee ee ee i 1 GENERATOR 5 ON C2P 7 C45GEN GR WH C2B 7 2 05 12 GR WH A GENERATOR OPTION 15 E owe SSS 2 a 2 6 DLITE GR BK C2B 6 o S DRIVE LIGHT LIGHTS
222. 7 9551 2 2240 Q 9 QU HM 1 arc Hw a S48 HM Gi HM 2 269 ca A 12 aN31X3 Lu noos 5981 woog Q gt 1951 QG 2 lt aa S o 5 o I H313N 92 CH HM 5 NOLLdO 39 x 3NION3 5 NHOALVId A Nag 9 260 arz HM T 5 NNNM TERRENI 5 5 FS o 1 2 HOLIMS 2 AIA LS 1 2 i HM AECA ISSL HOLIMS 4018 ZISTHO Nua E O g Q 5 Sc HH 9 1951 30151534 3NOZ H3ddn di3ds INOO8 woog s 2 g au MSZ 88 HOLSISIU 1 HOLSISIU NMOGan ya woog 1 wyo g Sc Hd
223. 77828 A TEREX COMPANY 5 60 5 65 G 6 21 Section 6 Schematics July 2005 Electrical Schematic S 60 Ford LRG 425 EFI Models after serial number 11879 REVA A e Ke N C7P 3 BATGND C7B 3 GROUND 2 E C2P 3 C41RPM OR BK C2B 3 6 e Q haze 01 4 C30FWD WH C1B 4 5 C521 WH BK DRIVE FORWARD 15 215 heze 01 C31REV WH BK C1B 5 C5 20 C31REV WH BK AD REVERSE 4 DRIVE MODE C130TA WH RD X TRAVELALARM _ E OPTION 8 9 8 C26 1 C26 2 E 3 E 1 En C32BRK WH RD C1B 6 5 23 C32BRK WH RD 1 BRAKE RELEASE gt E 8 C28 1 _ C282 z T C29MS RD WH x C29MS RD WH Oz ze 1
224. 8 5 9 128 OR RD FEH 306 24 C41RPM OR BK y 6283 So C108ESL BL WH FEH 658 PING oz C127T8W GR FEH 458 PIN18 5 C5 10 C39LP FEH 72 7 55 a 4 5 18 C35RPM BK RD FEH 307A PIN23 29 8 20 RD FEH 361 PIN9 5 7 5 1 7 GND BR 570 5 7 ENGINE C52 C41RPM OR BK FEH 11 PIN2 8 START e B C55 R33STR FEH 32 PIN15 IGN START RELAY START 5 EO C33STR BK FEH 32 PIN13 8 52 BL WH FEH 787A PINS E x 135 BL WH B 111 deem 1 ux 8 ES C33STR BK 1 5 5 1 N amp E 20 i E 9 14 STARTER MOTOR 8 8 T a x 2 i 2 Meese tee umm 4 SPEED REDUCTION RELAY it AUXILIARY a 1 PUMP C27AUX RD 88 AUXILIARY AUXILIARY POWER RELAY PUMP C1P 1 C27AUX RD C1P 1 AUXILIARY PUMP 11 C28TTA RD BK 0 5 g RD BK TILT ALARM e BRN x WH C7P 2 P23BATWH 9782 P134TTS RD I EVENBENBOR a 1 a e gt m RD ciP 2 28 RD BK 2 5 seJ Lj P134FBWH FLASHING No 5 5 x 2 5 C46HRN GR C2B 5 C46HRN GR RN BETAY 2 o 7 1 P22BATBK C7B 1 P22HRN BK R46HRN BK 6 9 Le 8 9 g a 4 B P134PWR GR BK 22 HYDRAULIC C2P 6 C2B 6
225. 88 AINON O4 esrauna 2 1 820 41660 2 o 5 yanad szeo Jp 1381 55215 019760 96 9 2 2 016 0 O 351 i LLI 01 910 18 5915959 SE 81 50 V2 951 9 6 810 SHSEO 2 ve aasnnn 8 810 2 1HVIS Q4 27 810 16660 aud 9 10 02 50 TO 2 16 9 810 M8 HM A3HIEO zsonmamas P 06 810 HM vzsouwiddsmezo 2 62 SOULS HOLOW Nua 810 5622 82 82 1vaozd ks 2 80 11822 lad xnvzzo V2 2 ee 1951 09 9 50 aasnnn 9210 O 8 5 8 519 H3MOd H33V3H8 7 Jp H3MOd HOLIMS m 2 820 HM Lvaezd 7 608 Iv zzd Jp 22 WHOALYId OL 2210 HOLIMS _ NOISNAL 2010992151885 V2 H WHOALW 1d OL OQ Sos agvo 5 1 8 0 1 Wsouwzwonzo H3MOd NOLLINSI wa
226. 9 1 Oscillate Axle 4 59 Section5 Rev Fault Codes LEE 5 1 Fault Codes Control System 4 04 00 00 5 2 A Fault Codes tener e 5 6 Genie 5 60 5 65 77828 July 2005 Section6 Rev Schematics Introduction U gt gt gt gt Ground Control Box Terminal Strip Wiring Diagram 5 60 GM 3 0L B Ground Control Box Switch Panel Wiring Diagram 5 60 GM 3 0L B Platform Control Box Terminal Strip Wiring Diagram 5 60 GM 3 0L B Platform Control Box Switch Panel Wiring Diagram 5 60 GM 3 0L Models Electrical Schematic 5 65 GM 3 0L Models B Ground Control Box Terminal Strip Wiring Diagram 5 65 GM 3 0L B Ground Control Box Switch Panel Wiring Diagram 5 65 GM 3 0L Platform Control Box Terminal Strip Wiring Diagram 5 65 3 0L 15 Platform Control Box Switch Panel Wiring Diagram 5 65 GM 3 0L Models
227. B 8 22 BOOM RETRACT 41 x X 5 t4 x CI74 17 2 n E BAN 9 329 CHB8LSROR RD C4B 4 OR RD C38 3 BK WH C38 4 LS17 BOOM UP DOWN PHMFSWH 52 5 STE SPEED REDUCTION LIMIT SWITCH gt x m e P24FS WH 5 899 5 E s qc BURD C4B 1 BURD _ es WH LSS DHIVE ENABLE LIMIFSWITCH P26ESTP BK 2 UF Ss gt j 9 299 49 112 WH LS1 PRIMARY BOOM EXTEND gt SUE DRIVE LIMIT SWITCH n J1 FH WH BK WH C10 2 LS2 PRIMARY BOOM UP SUE DRIVE LIMIT SWITCH oo lt 1 C40LS OR C2B 2 T OR 9 I NO go DE 2 P22LS 11 59 BL BK C3B 11 BL BK 3 BK 37 3 BK 2 0974 A 09 LS5 CABLE TENSION LED eve 8 5 m P134 RD RD C381 y RD 38 2 71 LS17 BOOM UP DOWN a XR a SPEED REDUCTION LIMIT SWITCH 2 2 CI4PLUOR C4B 2 2 gt lt n 2 m PLATFROM LEVEL 4 t DOWN C4P 3 C15PLD OR BK C4B 3 20 1 C20 2 o 8 UE GIAPEU OR D PLATFORM LEVEL UP ae PLATFROM LEVEL DOWN 1 PLATFORM LEVEL DOWN E m C202 5 5 4 6 C18JD PRR GR BK C4B 6 E BRIGHT PLATFROM ROTATE f LEFT C17JU PRL GR C4B 5 234 2 5 C18JD PRR GR BK 4
228. 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 If any inspection receives an 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 Comments Checklist C Rev D July 2005 Checklist E Rev D Y NR C 1 Engine maintenance Deutz models C 2 Grease platform overload if equipped C 3 Test platform overload if equipped C 4 Boom extend retract cables Perform every 600 hours C 5 Engine maintenance Perkins models Perform every 800 hours C 6 Engine maintenance GM and Ford models ChecklistD RevC D Rev D 1 Boom wear pads D 2 Turntable bearing bolts D 3 Turntable bearing wear D 4 Drive hub 0 5 Free wheel configuration D 6 Hydraulic filters 0 7 Air LPG mixture GM models D 8 Engine maintenance Deutz models D 9 Calibrate platform overload system if equipped 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 5 years E 4 Remove and inspect boom extend retract cables
229. B21IGN WH C54 4 TEMPERATURE SWITCH P134PWR RD a ETE P22LS BK C116 OR C5 1 COOLING FAN 2 116 818 E Ex z 3 Lj 107 9 sion 05 3 LZ Lll QM VISUM _ So 2 T mi INE WO 0 00 0 0 lt 5 45 3 SI nf 3 Eomd 1 3 cle 5i 8 21 1 Or 1 T Eu Mos JEN P ER gt lt 1 i 2056 6 Hcet 88 EROS 25 P20BAT RD f 4599 8 A N Part No 77828 A TEREX COMPANY 5 60 5 65 G 6 31 Section 6 Schematics Electrical Schematic S 65 Ford LRG 425 EFI Models after serial number 11879 July 2005 ROCKER STEER OPTION ONLY P22LS BK REVA
230. BL DE1 J1 6 5 C34SA BK WH C1P 8 rz BUBK DE2 J1 7 a 8 YLJ1 3 za OR J1 9 BRN 41 10 C29MS RD WH J1 8 e3 8 N DO To Nj 2 WH CR30 lu gt 5 C27AUX RD 1 1 E mc zu 985 z sa o lt 5 98 mae I O22 50 E WH JIB WH JIB C129JDA BL C3P 10 z a o FR ___ _________ 66 __ DLITE OR RD C2P 4 _ 2 Ho ris 5 0965 net 8 a m JEFO X c Puxa 250 9 BL BK C3P 11 II EM 2 wurEWH CI7PRLGR C4P 5 C19JSV GR WH 2 BRN WH CR27 Er C19JSV GR WH 4 7 5 BK J1 2 RD 1 1 C18PRR 4 6 OR J1 11 BRN J1 12 P24FS WH e C14PLU OR 4 2 99 Eg a C15PLD OR BK C4P 3 RD Part No 77828 RD RD NOTE DASHED LINES INDICATE OPTION WIRES RD E BOOM UP DOWN amp TURNTABLE ROTATE LEFT RIGHT C46HRN GR C2P 5 P3 HORN July 2005 Section 6 Schematics 5 Platform Control Box Switch Panel Wiring Diagram 5 65 Deutz F3L 201 1 Models C22LS
231. C1B 11 C37SCW Prem 72 7 38 STEER RIGHT DRIVE ENABLE 5 RIGHT C36STCC BL C1B 10 C36SCC BL STEER 22 4 o x CDE1 BUWH 241 24 2 ____ 8 63 i E Zr gee 64 lt lt C3P 6 C6TRF WH RD C3B 6 E lt lt lt lt 9 8 YOUT 5 4 8ip fact 15 515 4 C4TRL WH C3B 4 C4TRL WH lt TURNTABLE ROTATE LEFT pwp 13 a C141 40142 pu 5 C5TRR WH BK C3B 5 C5TRR WH BK emf 14 9 t 4 TURNTABLE ROTATE RIGHT 15 154 15 2 lt 8 cle B mucus TURNTABLE ROTATE 2 m eo BO d C6TRF WH RD TURNTABLE ROTATE m if FLOW CONTROL 31 1 312 11 C124 4 12 2 top t CiPBU RD lt lt 4 gt gt 7 PRIMARY BOOM UP PRIMARY BOOM t DOWN C2PBD RD BK PRINS m T 7 PRIMARY BOOM DOWN 8 C13 1 C13 2 ui Pip IR lt e r2 2 E B 18 your s z PRIMARY BOOM FLOW CONTROL C29 1 C292 51 Ve eee 1 C1PBU RD C3B 1 1 PWR 3 11 6 2 12 Irre C2PBD RD BK C3B 2 i lt lt 63 3 C3PBF RD WH C3B 3 C30 1 C30 2 O9 s C9PER BK RD C3B 9 p C9PER BK RD PRIMARY BOOM EXTEND RETRACT FLOW CONTROL ace Sr BK WH C3B 8 i lt E
232. C3B 1 pwr 3 11 6 BRN ig GND 2 12 2 C2PBD RD BK C3B 2 i 15 7 lt E X 182223 s 6923 C3PBF RD WH C3B 3 8 C30 30 2 8 C9PER BK RD C3B 9 S C9PER BK RD Jp PRIMARY BOOM EXTEND RETRACT FLOW CONTROL C3P 8 C8PBR BK WH C3B 8 i 1 13 808 i x 7 C3B sc 12 7 3B 7 42 185 CABLE TENSION LIMIT SWITCH E pac 3 RD RD 5 BR C7PBE BK 5 amp lt L EXTEND m 5 BOOM 37 1 37 2 Ci 1 16 2 9 1 RETRACT BRN m t 2 8 C OPEFPBIOWH Itl gt BOOM RETRACT x 5 17 1 17 2 xi n E a BRN SS 9 39 E CHBLSROR RD C4B 4 OR RD C38 3 BK WH 38 4 1317 UP DOWN P24FSWH 5 SPEED REDUCTION LIMIT SWITCH oe x le 5 age 1 Li sas BL RD C4B 1 5 BL RD C9 1 WH C92 LS3 DRIVE ENABLE LIMIT SWITCH P26ESTP BK x eds 4 S 2 2 599 B 4 BIER 1 2 WH Cina LS1 PRIMARY BOOM EXTEND 5 stes DRIVE LIMIT SWITCH 8 J1 FH WH C10 1 BK 2 WH C10 2 LS2 PRIMARY BOOM UP DRIVE LIMIT SWITCH ii i ea E C40LS OR C2B 2 OR x g a 1 t no t d Quo 1 vz gt par F 57 8655 i i 2215 11 59 BL BK C3B 11 BL BK amp BK
233. E 8 9 a o m POWER RELAY 1 I 5 a 52 0 C21 IGN2 WH ce A FUEL SOLENOID N NIN amp aa AUX N PUMP 1 1 C27AUX RD 1 1 5 Glen WH HOUR METER 88 A 9 IGN START RELAY ae x 10 R33STR BK C5 5 a Zur mz 4 STARTER MOTOR 14 E 8 AUXILIARY 5 x e PUMP RD F4 C27AUX RD e A 7 2 B pee C7P 2 P23BAT WH E 1 en 8 E 2 WH 4 ADBK C1B 2 8 E C28TTA RD BK mLTAD BM 1 ELT P134TTSR RD ss LEVEL SENSOR C3B 12 4 gt 81 12 C183PLA BL WH 6 oY 8 GREK cop s sus C2P 5 C46HRN GR gt C46HRN GR BORN RELAY n 414 GRBK 12 7 1 P22BAT 7 1 E 1 5 22 4 HORN CiP 12 C132PLIBLWH CTB 12 5 5 o a P134FB WH 2 6 P134PWRGRIBK 2 6 5 ar 4 FLASHING BEACONS gt m Em EE A 4461 RTT se abel yee ect nese tl i 5 RD M 55 So 5 oz a e C21IGNWH R21IGNWH s 054 1 HYDRAULIC OIL TEMPERATURE 2 2 42 1 SWITCH OPTION 815 81 4 R116 OR 54 COOLING FAN 5 gt LT OPTION 5 8 le 3 2 4 5 C41RPM C2B 3 C41RPM OR BK 05 2 N a
234. FEH 72 PIN7 5 84 C5 18 C35RPM BK RD FEH 307A PIN23 18 Sx P20BAT RD FEH 361 PINS Lg C1P 7 C33STRBK CiB 7 GND BR 570 PINS4 3 5 1 ENGINE 5 2 C41RPM OR BK 11 PIN2 8 START e T m bi 055 R33STR BK FEH 32 PIN15 IGN START RELAY START S Eo C33STR BK FEH 32 PIN13 62 BL WH FEH 787A PINS x C135FP BL WH a eg N S m z C33STR BK 5 K gt 8 i e 58 to B Ig 1 STARTER MOTOR 2 e E 1 aes AUXILIARY a TRUMP C27AUX RD 1 AUXILIARY POWER RELAY C27AUX RD t AUXILIARY PUMP C28TTA RD BK D Baur x C28TTA RD BK I RD x WH 7 2 2 WH C7B 2 134 5 SENSOR T a x lt en gt 5 a RD 1 2 28 2 amp q gt Li P134FBWH FLASHING AK BEACONS OPTION 3 BK 2 5 C46HRN GR C2B 5 C46HRN GR d HORN RELAY 2 a 7 1 22 C7B 1 P22HRNBK R46HRN BK C6 9 3 e g a P134PWR GR BK 8 LwDRAULICOIL 2 6 C2B 6 R21IGN WH s C amp 4 TEMPERATURE SWITCH aot P134PWR RD yN o S 8708 4 5 LJ P22LS BK
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236. Install the fastener that was just removed through the engine tray and into the engine tray boom tubes anchor hole in the turntable Crushing hazard Failure to install Wear pad specifications New Minimum AWARNING the fastener into the engine tray Top and side wear pads 5 8 inch 1 2 inch platform end of boom 15 9 mm 12 7 mm moving death or serious injury Bottom wear pads 3 4 inch 5 8 inch platform end of boom 19mm 15 9 mm Top and side wear pads 5 8 inch 1 2 inch pivot end of boom 15 9 mm 12 7 mm Bottom wear pads 3 4 inch 5 8 inch pivot end of boom 19 mm 15 9 mm 3 40 S 60 5 65 Part No 77828 July 2005 Section 3 Scheduled Maintenance Procedures REV B 5 Be sure that each turntable mounting bolt is torqued in sequence to specifications Refer to Section 2 Specifications Bs 9 N Bolt torque sequence Start the engine form the ground controls N Raise the secondary boom and remove the safety chock Lower the boom to the stowed position 9 Remove drive chassis covers from both the steer end and the non steer end of the machine Part No 77828 Genie S 60 5 65 3 41 CHECKLIST D PROCEDURES 10 Check to ensure that each lower bearing mounting bolt under the drive chassis is torqued in sequence to specifications Refer to Section 2 Specifications o 16 2 Bolt torque sequence 11 Swing the engine back to its original position a
237. L4 BRN J1 14 BK BK TS15 1 RD PDLITE RD C45GEN GR WH C2P 7 5 2 lt 2 556 56 64 T rua ut 0 56 x A 1 gt or Lg aa SCug 8 EC 2 5 AVE 2352 RD P24FS WH C9 2 C35HS BK RD C1P 9 9 a EE COSS TTATIDIBISEHES n C133PLA GR BK D39 5 5 5 x II lt 20 9 25 tan Sb 475 i 138 lt D a 52 _C134PWR RD E STOP iue 25 28 cWMPWRRDE STOP 2 C33STR 7 AD D ges rd P25FS RD C9 3 25 BL RD DE3 01 16 _ 258 5 5 BL DE1 J1 6 5 8 BK BK C34SA 8 rz BL BK DE2 J1 7 a 55 YL J1 8 OR J1 9 293 BRN J1 10 C29MS RD WH J1 8 255 QN 2 WH CR30 E C27AUX RD 1 gt G oc 223 rei 85 5 lt 22 n WLITE WH ure DE EA E ERN DLITE OR RD C2P 4 _
238. Open wiring and or connections to ignition coil 1 OR ignition coil 1 is faulty Repair wiring and or connections to ignition 1 OR replace ignition coil 1 412 Coil Driver 1 Shorted Wiring and or connections to ignition coil 1 shorted OR ignition coil 1 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 Coil Driver 2 Open 413 Open wiring and or connections to ignition coil 2 OR ignition coil 2 is faulty Repair wiring and or connections to ignition coil 1 OR replace ignition coil 1 414 Coil Driver 2 Shorted Wiring and or connections to ignition coil 2 shorted OR ignition coil 2 is faulty Repair wiring and or connections to ignition coil 2 OR replace ignition coil 2 enie Continued on next page 25 Part No 77828 A TEREX COMPANY 5 60 5 65 5 9 Section 5 Fault Codes July 2005 FORD ENGINE FAULT CODES REVA Code Problem Cause Solution If this fault appears on your machine contact 51 1 BEE High Voltage Not usod Genie Industries Service Department If this fault appears on your machine contact 51 2 Genie Industries Service Department m If this fault appears on your machine contact 51 3 PPPT Higher than morse Genie Industries Service Department 514 Lower than IVS Limit Not used If this fault appears on y
239. P 5 lt 4 GPTION 5116 m gt ah 52 22 ROK HAIE Mn Para stent T St RD M B 2 4 BK o 52 RZIIGNWH C54 zT 4 HYDRAULIC OIL TEMPERATURE e 8 SWITCH OPTION i P116HYD 8115 55 8 1811608 051 COOLING FAN L OPTION 5 le 9 Leje 8 E amp ae 5 5 3 C41RPM OR BK C2B 3 C41RPM OR BK C52 27 C21IGN WH c c af a a O 91 NIS zc 5 b RD C7B 4 P20BAT RD 1 8 amp m N e Part No 77828 i AND PLATFORM OVERLOAD OPTION ONLY NOTES enie A TEREX COMPANY S 60 5 65 G 6 77 Section 6 Schematics Electrical Schematic S 60 Perkins 404 22 Models after serial number 11879 July 2005 gt ROCKER STEER OPTION ONLY
240. P LEN 2 2 a La RD BK L4 RD BK L48 NON CE C134PWR RD C2P 6 C134PWR RD LS18 RD TILT z CWLITE BK BRN CD BRN BRN CWLITE WH 549 6 73 Section 6 Schematics Deutz F3L 201 1 Models Platform Control Box Switch Panel Wiring Diagram S 65 July 2005 REV B 2 5 E 5 rc 8 Ele J gt 5 Eu 55 255 5269 5415 Is ale 8 2988 3 A358 35 55 0 39 8 8483 2 wuz gt So 5 9 595 92 5 2 Gala a o O 5 lt 50 lt 5 nach zi 2 25 598 Ex gt 5 0 56 605 212 5 2 2 2 gt 59 2245056552 59 55 gt lt 5 9 ze 59 S 5 5 ax wo P22BAT BK C7P 1
241. 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 P 1 C28TTA RD BK C1P 2 TS15 B BL BK e DRE LED BL RD TS14 RD WH e C28TTA RD BK C1P 2 BATGRN C7P 3 ES C9 C7P M FOOT OPTION SWITCH 12V DC BATTERY C4P BR C3P GR Part No 77828 C2P BK C1P GY 19 18 CONTROL CABLE a RD BK 28 7 7 RD BK L48 NON CE C134PWR RD LS18 C134PWR RD C2P 6 RD TILT CWLITE BK BRN CWLITE WH 549 Platform Control Box Wiring Diagram S 65 Section 6 Schematics GM 3 0L Models enie A TEREX COMPANY S 60 5 65 G H1 TILT ALARM 6 17 REV B BRN BK July 2005 Section 6 Schematics EE Platform Control Box Switch Panel Wiring Diagram S 65 GM 3 0L Models F E D 200 1 CONTROL CR13 BOOM CUTOUT RELAY HARNES Jc2 BOOM PROPORTIONAL JOYSTICK TO CONTROL B
242. SWITCH P26ESTP BK eX gt 3 5 N 72 2 2 49 4 pEr WH BK cna LS1 PRIMARY BOOM EXTEND 5 sus DRIVE LIMIT SWITCH 3 J1 WH BK WH C102 LS2 PRIMARY BOOM UP STE DRIVE LIMIT SWITCH 1 C40LS OR C2B 2 ZI OR x 9 rege DES P22LS 1 C3P 11 59 BL BK C3B 11 BL BK g O BK 037 3 42 WH 37 B LS5 CABLE TENSION LED ove 8 5 o P134 RD F RD C381 y RD 382 LS17 BOOM UP DOWN a SPEED REDUCTION LIMIT SWITCH 8 2 CI4PLUOR C4B 2 o 2 lt 2929 PLATFROM LEVEL a t DOWN C4P 3 C15PLD C4B 3 C20 1 20 2 2 op i CI4EEUOR 1 PLATFORM LEVEL UP ___ PLATFROM LEVEL 1 DOWN PLATFORM LEVEL DOWN x E 3 2 21 1 C212 5 gt 8 10 C129JDA BL C3B 10 52 8 6 C18JD PRR GR BK C4B 6 DOWN 1 JIB EN C17JU PRL GR C4B 5 023 1 C282 i m ads 8 8 i C18JD PRR GR BK 8 PLATFORM ROTATE RIGHT P PLATFROM ur PLERF SROTATE I PLATFORM ROTATE LEFT C224 C222 RIGHT PLATFROM fo ERBE LEFT Las IBE 1 i 1 C129 RD BK DESCENT 1 1 2 1 2 7 4 7 C19JSV GR WH C4B 7
243. Section 6 Schematics SS SSS Sy REV Platform Control Box Switch Panel Wiring Diagram S 60 Perkins 404 22 Models N M L K J H G F E D PLATFORM CONTROL HARNESS TO CONTROL BOX COMPONENT INDEX JC2 BOOM PROPORTIONAL JOYSTICK TS48 BOOM UP DOWN TURNTABLE ROTATE 2 DRIVE LICHTS JC1 BOOM PROPORTIONAL JOYSTICK SCE TION gt BOOM EXTEND RETRACT JC2 JC3 JC3 DRIVE STEER PROPORTIONAL JOYSTICK JC1 BANE L1 DRIVE ENABLE LED BOOM UP DOWN 7 E 7 1 FORWARD REVERSE 7 14 PLATFORM OVERLOAD LED amp BOOM TS15 8 STEER 147 LOWER RETRACT BOOM LED EXTEND RETRACT DRIVE 148 LEFT RIGHT 148 BOOM TILTED LED E 6 d 6 ENABLE TILT ALARM LED 6 ANSUCSA OPT i P2 EMERGENCY STOP BUTTON E P3 HORN SWITCH 5 bg 5 3 5 TS AUXILIARY TOGGLE SWITCH 3 15 52 ENGINE START TOGGLE SWITCH 9 TS4 RPM TOGGLE SWITCH 4 4 4 TS6 GLO
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245. Wiring Diagram 5 60 Ford LRG 425 EFI Models after serial number 11879 Section 6 e Schematics July 2005 Platform Control Box Wiring Diagram 5 60 Ford LRG 425 EFI Models REVA July 2005 Platform Control Box Wiring Diagram S 60 LRG 425 EFI Models Section 6 Schematics CWLITE WH TS49 gt SO lt or C19JSV GR WH TS7 1 C19JSV GR WH 7 BRN JC3 BRN GND 269 RD E STOP 1 sz C134PWR RD LS18 2N C134PWR RD H1 4 LIFT DRIVE OPTION JIB CR27 RD LS18 CABLE 122222222 G82BRKWHAD CIPS ___________ CR30 12 4015 OR C2P 2 P23BAT WH C7P 2 P22BAT BK 7 1 1 C19JSV GR WH 7 C18PRR GR BK C4P 6 C17PRL 5 C15PLD OR BK C4P 3 C14PLU 2 1 C129DA BL 10 TS8 C46HRN GR 2 5 C59CNK C3P 11 147 P26BAT 9 1 P2 P25FS RD C9 3 TS2 P24FS WH 9 2 54 a CDLITE OR RD C2P 4 ES C45GEN GR WH 2 7 C46HRN GR C2P 5 12V DC PLATFORM POWER CONNECTOR FOOT SWITCH CONNECTOR ALC 500 CONTROL BOARD CONTROL BOARD INPUT CONNECTOR CONTROL BOAR
246. X COMPANY S 60 5 65 Part No 77828 July 2005 Section Scheduled Maintenance Procedures REVC A 1 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 Genie S 60 and Genie S 65 Operator s Manualon your machine PartNo 77828 5 60 5 65 3 7 Checklist Procedures A 2 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 Genie S 60 and Genie S 65 Operator s Manualon your machine Section Scheduled Maintenance Procedures July 2005 CHECKLIST A PROCEDURES A 3 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed daily or every 10 hours whiche
247. a new one 11 Full retract and lower the boom to the stowed position How to Replace the Boom Extend Retract Cables 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 clevis pins from the boom extend cables located near the cable break limit switch Section 4 Repair Procedures July 2005 BOOM COMPONENTS 4 Remove the external snap rings from the boom extend cable pulley pivot pin Use a soft metal drift to remove the pin 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 Be sure the boom extend cables are routed through the grooves of the pulley and the upper wear pad on the extension cylinder 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 Boomretract cables 10 Remove the cotter
248. after serial number 11879 0 000400 00 000 6 45 B Ground Control Box Terminal Strip Wiring Diagram 5 60 Deutz F3L 2011 Models before serial number 11880 6 47 B Ground Control Box Switch Panel Wiring Diagram 5 60 Deutz F3L 2011 Models before serial number 11880 6 48 A Ground Control Box Terminal Strip Wiring Diagram 5 60 Deutz F3L 2011 Models after serial number 11879 6 49 A Ground Control Box Switch Panel Wiring Diagram 5 60 Deutz F3L 2011 Models after serial number 11879 6 50 B Ground Control Box Terminal Strip Wiring Diagram S 60 CE Models Deutz F3L 2011 Models before serial number 11880 6 51 B Ground Control Box Switch Panel Wiring Diagram S 60 CE Models Deutz F3L 2011 Models before serial number 11880 6 52 A Ground Control Box Terminal Strip Wiring Diagram S 60 CE Models Deutz F3L 2011 Models after serial number 11879 6 53 A Ground Control Box Switch Panel Wiring Diagram 5 60 CE Models Deutz F3L 2011 Models after serial number 11879 6 54 Platform Control Box Terminal Strip Wiring Diagram 5 60 Deutz F3L 2011 6846 6 55 B Platform Control Box Switch Panel Wiring Diagram 5 60 Deutz F3L 2011 2 4 8 6 56 Genie Part No 77828 5 60
249. 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 Always replace the cotter pin with anew one 5 60 5 65 REV 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 pinched CAUTION Component damage hazard The cable track can be damaged if it is twisted CAUTION Part No 77828 July 2005 Section 4 Repair Procedures REV B How to Remove the Cable Track S 65 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose
250. cracked cable ends Cables at end of adjustment range Part No 77828 Genie 5 60 5 65 CHECKLIST E PROCEDURES 4 Replace the boom extend cables if there is any damage to the cables The extend cables must be replaced in pairs If the cables are replaced the cable sheaves or pulleys should also be replaced 5 Remove the cotter pins and clevis pins from the boom retract cables at the platform end of the boom Always use a new cotter pin when installing a clevis pin 6 Remove the wear pad fasteners from the upper wear pads on the number 1 boom tube Remove the wear pads Pay attention to the location of each wear pad and the quantity of shims for each one 7 Attach a lifting strap from an overhead crane to the platform end of the boom 8 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 9 Attach the cable pulling tool or a rope to one of the boom retract cables at the pivot end of the boom A cable pulling tool is available through Genie Service Parts Department part no 94510 10 At the platform end of the boom pull on the boom retract cable that has the rope attached to it Section Scheduled Maintenance Procedures July 2005 CHECKLIST E PROCEDURES 11 Pull the boom retract cable completely out of the boom
251. fall when removed from the machine if not properly attached to the overhead crane S 60 5 65 77828 July 2005 Section 4 Repair Procedures REV B 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom to a horizontal position 2 Locate the cables from the primary 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 Remove the outlet box and lay it to the side PartNo 77828 Genie 5 60 5 65 Boom Components 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 Sprayi
252. from the machine if not properly supported 5 60 5 65 4 57 Section 4 Repair Procedures July 2005 TURNTABLE ROTATIONCOMPONENTS REV When installing the drive hub assembly 2 Loosen the backlash pivot plate mounting fasteners 6 Install the drive hub Torque the back lash pivot plate mounting bolts to 260 ft lbs 352 5 Nm 7 Adjust turntable rotation gear backlash See How to Adjust the Turntable Rotation Gear Backlash How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing ring gear Perform this procedure with the boom between the non steer end tires and with the machine ona firm and level surface 1 Secure the turntable from rotating with the a backlash pivot plate turntable rotation lock pin b adjustment bolt with lock nut backlash pivot plate mounting bolts The turntable rotation lock pin is located next to the boom rest pad 2 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 4 Turn the adjustment bolt clockwise until it contacts the backlash pivot plate 5 Turn the adjustment bolt 1 2 turn counterclockwise Tighten the lock nut on the adjustment bolt 6 Rotate the backlash pivot
253. gap GM Models 1 16 inch 1 5 mm gap Ford Models gt o 070 S 60 5 65 How to Remove Flex Plate Deutz models 1 Remove the tailpipe bracket mounting fasteners from the engine bell housing 2 Support the drive pump assembly with an appropriate lifting device 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 CAUTION can be damaged if they are kinked or pinched 5 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel 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 CAUTION Component damage hazard The engine could fall and the crankshaft position sensor can become damaged if the engine is not properly supported when the fasteners are removed Part No 77828 July 2005 Section 4 Repair Procedures REVC 7 Slide the engine mounting plate towards the pump as far as it will go 8 Support the drive pump as
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257. pins and clevis pins from the boom retract cables at the platform end of the boom 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 Pay attention to the location of each wear pad and the quantity of shims for each one 5 60 5 65 REV 12 Attach 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 A cable pulling tool is available through Genie Service Parts Department 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 boom retract cable 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 throug
258. plate away from the turntable until it contacts the adjustment bolt Then torque the mounting fasteners on the backlash pivot plate to 260 ft Ibs 352 5 Nm 7 Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary Genie TEREX COMPANY 4 58 S 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV 9 1 Oscillating Axle Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the axle to maintain a level chassis while driving over uneven terrain The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic hose failure How to Remove an Oscillate Axle Cylinder Perform this procedure on firm level surface with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two 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
259. 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 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 GM 3 0L Operator Handbook Genie part number 101095 Ford LRG 425 EFI Operator Handbook Genie part number 84792 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 Genie Part No 77828 5 60 5 65 3 39 Section Scheduled Maintenance Procedures July 2005 Checklist D Procedures D 1 Check the Boom Wear Pads 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 Improper
260. procedure will require two people 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 Connectan rpm gauge to the engine and then start the engine from the ground controls O Result Low idle should be 1500 rpm Skip to step 5 if the low idle rpm is correct Part No 77828 July 2005 Section 3 Scheduled Maintenance Procedures REVC 4 Loosen the low idle lock nut then turn the low 6 idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and recheck the 7 solenoid boot b high idle adjustment nut yoke lock nut d yoke e low idle adjustment screw f low idle lock nut 5 Movethe function enable rpm select toggle Switch to the high idle rabbit symbol position at the ground controls O Result High idle should be 2500 rpm If high idle rpm is correct disregard adjustment step 6 CHECKLIST B PROCEDURES 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
261. second It will then pause for 1 5 seconds and flash the second digit once per 0 5 second When the yellow LED is flashing the code the red LED will be on solid Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected 5 2 S 60 5 65 PartNo 77828 July 2005 Section 5 Fault Codes REVA FAULT CODES Condition Solution 21 Boom 1 joystick 11 Limited speed and primary boom up 12 a M h direction frozen at Power up down 15 Valu too si zero and neutral controller with 16 Alarm sounds problem corrected Value at OV indicating fault 17 Not calibrated Joystick speed and direction frozen at zero and neutral Calibrate joystick 18 Just calibrated Initiate 1 second beep of alarm Self clearing transient 22 Boom 1 directional valves 21 Fault Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected 23 Boom 1 flow control valve 12 Value too high 15 Value too low Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected 17 Not calibrated 18 Just calibrated Normal function except threshold for one or both directions is zero Calibrate valve thresholds Self clearing transient 3
262. sensor OR replace sensor 253 Knock Sensor Open Knock sensor wiring and or connections open or shorted OR sensor is faulty Repair wiring and or connections to knock sensor OR replace knock sensor 254 Excessive Knock Signal Knock sensor wiring and or connections open or shorted OR there is excessive engine vibration OR sensor is faulty Check for excessive engine vibration OR repair wiring and or connections to knock sensor OR replace knock sensor njector Driver 1 Open 311 Open wiring and or connections to fuel injector 1 OR fuel injector 1 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 1 OR replace fuel injector 1 OR replace the ECM 312 njector Driver 1 Shorted Wiring and or connections to fuel injector 1 shorted OR fuel injector 1 is faulty OR ECM is faulty Repair wiring and or connections to fue injector 1 OR replace fuel injector 1 OR replace the ECM 313 njector 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 fue injector 2 OR replace fuel injector 2 OR replace the ECM 314 njector Driver 2 Shorted Wiring and or connections to fuel injector 2 shorted OR fuel injector 2 is faulty OR ECM is faulty Repair wiring and or connections to fuel injector 2 OR replace fuel injector 2 OR repla
263. sensor is faulty Repair wiring and or connections to sensor OR replace MAP sensor 234 BP High Pressure MAP sensor is faulty OR ECM is faulty Replace MAP sensor OR replace the ECM 235 BP Low Pressure MAP sensor is faulty OR ECM is faulty Replace MAP sensor OR replace the ECM 242 Crank Sync Noise Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor Never Crank Synced At Start 243 Crankshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor 244 Camshaft Sensor Loss Camshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace sensor 245 Camshaft Sensor Noise Camshaft position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR sensor is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to
264. serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures July 2005 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 5 5 HAGE amp g GB e e e 63
265. system Injection pump make Bosch Injection pump pressure maximum 15000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement 2 Diesel Starter motor Current draw no load 90A Brush length new 0 72 in 18 5 Brush length minimum 0 27 in 7mm Battery Type 12V DC Size 13 x 613 16 x 93 8 inches 33 x 17 3 x 23 8 cm Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Alternator output 60A 14V DC Fan belt deflection 3 8 to 1 2 inch 9to 12mm 5 60 5 65 Part 77828 July 2005 Section 2 Specifications REV B Perkins 404 22 Engine Lubrication system SPECIFICATIONS Oil pressure cold 60 psi Displacement 134 cu in 2 2 liters at 2500 rpm 4 1 bar Oil capacity 9 3 quarts Number of cylinders 4 ne including filter 8 8 liters Bore and stroke 3 31 x 3 94 inches 84 x 100 mm Oil viscosity requirements Horsepower Below 86 F 30 C 5W 20 gross intermittent 51 4 F to 104 F 20 to 40 C 10W 30 horsepower 3000 rpm 47 6 Above 14 F 10 C 15W 40 Firing order Engine should have minimum properties of Low idle 1300 rpm classification CH 4 Units ship with CH 4 High idle 2500 rpm Oil pressure sending unit Torque 8 18 ft lbs t 23 3 1 Compression ratio 3 3 11 24 Nm Compression pressure 426 psi 2 E 29 4 Oil pressure switch point 14 2 psi Pressur
266. 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 July 2005 Section 3 Scheduled Maintenance Procedures REV D E 4 Remove and Inspect the Boom Extend Retract Cables Genie specifications require that this procedure be performed at 5 years or 5000 hours whichever comes first and every 2 years thereafter until the cables are replaced The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Removal and inspection of the boom extend retract cables on a regular basis is essential to good machine performance and safe machine operation The boom extend retract functions should operate smoothlyand be free of hesitation jerking and unusual noise 1 Remove the boom extend cylinder from the machine See Repair Procedure 4 4 How to Remove the Boom Extension Cylinder 2 Remove the extend cables from the boom extension cylinder assembly and lay them flat onthe ground 3 Visually inspect the boom extend cables and components for the following Frayed or broken wire strands Kinks in the cables Corrosion Paint or foreign materials on the cable Split or
267. the free wheel valve on the drive pump is closed clockwise a drive pump b free wheel valve c liftpump d screwdriver The free wheel valve is located on the side of the drive pump The free wheel valve should always remain closed Section 3 Scheduled Maintenance Procedures July 2005 CHECKLIST B PROCEDURES B 7 Check the Oil Level in the Drive Hubs 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 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 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole gt Install the plug s into the drive hub Check the torque of the drive hub mounting bolts Refer to Section 2 Specifications Repeat this procedure for each drive hub Genie 5 60 5 65 8 Check and Adjust the Engine RPM Deutz Models 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 This
268. 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 Open the top bleed valve on the rotator but do not remove it top bleed valve b bottom bleed valve container d clear hose Section 4 Repair Procedures Sy PLATFORM COMPONENTS 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 Cushing hazard Keep clear of the 7 platform during rotation Remove t
269. tube and lay it flat the ground 12 Repeat steps 9 and 10 for the other boom retract cable 13 Visually inspect the boom retract cables and components 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 at end of adjustment range 14 Replace the cables if there is any damage to the cables The retract cables must be replaced in pairs If the cables are replaced the cable sheaves or pulleys should also be replaced 15 At the pivot end of the boom pull the boom retract cables into the boom assembly using the rope 16 Install the boom extension cylinder assembly into the boom 17 Adjust the boom extend retract cables See Repair Procedure 4 5 How to Adjust the Boom Extend Retract Cables REVD 3 54 5 60 5 65 Part No 77828 July 2005 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 operating the machine Before Repairs Start M Read understand and obey the safety rules and operating instructions in the Genie S 60 and Genie S 65 Operator s Manual Be sure that all necessary tools and parts are available and ready for use
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272. 1 40 FIVA 1981 HOLSIS3H NoLLOnaad 3NOZ 03345 91H woog vedo 2 wyog MSZ HOLSISIH 31v1OH II8VLNUNL HOLSIS3H vd 96 WYO 5 ScHH July 2005 Section 6 Schematics R Ground Control Box Switch Panel Wiring Diagram S 65 GM 3 0L Models Section 6 e Schematics July 2005 Platform Control Box Wiring Diagram 5 65 GM 3 0L Models REV B 12V DC PLATFORM POWER CONNECTOR FOOTSWITCH CONNECTOR CONTROL BOARD INPUT CONNECTOR CONTROL BOARD OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH DESCRIPTION TILT ALARM ALC 500 CONTROL BOARD CWLITE WH TS49 TO SWITCH PLATFORM CONTROL PANEL HARNESS C19JSV GR WH 57 WH C19JSV GR WH C4P 7 BRN JC3 BK BRN GND RD E STOP C1P C4P 48 PIN CONNECTOR BLOCK ITEM H1 7 013 J1 J2 J3 CR27 CR30 LS18 July 2005 NOTE WIRE CONNECTS TO JC3 6 FOR STEER ROCKER SWITCH OPTION C134PWR RD H1 B C134PWR LS18 C32BRK WH RD C1P 6 C32BRK WH RD J2 19 12 C40LS OR C2P 2 P24FS WH C
273. 1 Boom 2 joystick secondary boom up down or primary boom extend retract 11 Value at 5V 12 Value too high 15 Value too low 16 Value at OV Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected 17 Not calibrated Joystick speed and direction frozen at zero and neutral Calibrate joystick 18 Just calibrated Initiate 1 second beep of alarm Self clearing transient 32 Boom 2 directional valves 21 Fault Limited speed and direction frozen at zero and neutral Alarm sounds indicating fault Power up controller with problem corrected Part No 77828 Genie Me 257 Continued on next 5 60 5 65 5 3 on 5 Fault Codes July 2005 FAULT CODES REV Error Source Error Type Condition Solution ID Name ID Name 33 Boom 2 flow Limited speed and control valve 12 Value too high direction frozen 15 Value too low zero and neutral controller wit Alarm sounds problem corrected indicating fault Normal function except threshold for Calibrate valve 17 Not calibrated or both directions thresholds is zero 18 Just calibrated Self clearing transient 41 Turntable rotate 11 Value at 5V Limited speed and joystick 12 Value too high dir
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277. 2 2874 3 gt LS5 CABLE TENSION LED oc ey o 2 9 x 3 5 o P134 RD m RD C38 1 gt RD BR C38 2 1517 UP DOWN a NA a SPEED REDUCTION LIMIT SWITCH 2 CI4PLUOR C4B 2 I2 E 2 lt z L2 po UM PLATFROM LEVEL 9 t DOWN C4P 3 C15PLD OR BK C4B 3 20 1 C202 2 op i CIPEL OR DA PLATFORM LEVEL UP PLATFROM LEVEL DOWN 1 PLATFORM LEVEL DOWN E m C21 1 C21 2 5 gt C4P 6 C18JD PRR GR BK C4B 6 E ERIGH PLATFROM ROTATE t LEFT C17JU PRL GR C4B 5 Caps 234 2 8 C18JD PRR GR BK 4 3 Mt lt lt PLATFORM ROTATE RIGHT P RIGHT PLATFROM ROTATE A sno SI IURAE GH PLATFORM ROTATE LEFT C224 022 2 E RDBK O DESCENTALARM OPTION 2 4 x Bx o x E gt 2858 N amp a 6 46 enie A TEREX COMPANY S 60 5 65 G Part No 77828 July 2005 Section 6 Schematics Electrical Schematic S 60 Models Deutz F3L 2011 Models after serial number 11879 Section 6 Schematics July 2005 O Ground Control Box Terminal Strip Wiring Diagram 5 60 Deutz F3L 2011 Models before serial number 11880 REV Ei og annoy July 2005 Gro
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279. 2 1 ILLEFT ROTATE MN 1 t ig 1 hs 7 C19JSV GR WH C4B 7 MUTET a tun cae Ae he EN 2 2 E B gt E m o JIB VALVE JIB VALVE AlS a c ao 3 u 28458 8 5 a 6 58 enie A TEREX COMPANY S 60 5 65 G Part No 77828 July 2005 Section 6 Schematics Electrical Schematic 5 65 Deutz F3L 2011 Models before serial number 11880 2215 REVA July 2005 Deutz F3L 201 1 Models after serial number 11879 Electrical Schematic S 65 Section 6 Schematics z ES ale a n OE g 5 8 x 208 N
280. 2005 Section 4 Repair Procedures REV B 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 closed circuit hydraulic loop with the master 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 1 Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Extend the primary boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the primary boom slightly and place blocks under the platform for support 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks Part No 77828 Genie 5 60 5 65 4 7 Platform Components 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 The jib boom could fall w
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284. 4 26 5 4 Engine Fault Codes GM and Ford 4 30 C Hydraulic Pumps 6 1 Function PUMP icio io een 4 32 6 2 Drive PUMP 4 33 Genio Part No 77828 5 60 5 65 Xi July 2005 TABLE OF CONTENTS Section4 Rev Repair Procedures continued D Manifolds 7 1 Function Manifold Components 4 36 7 2 Valve Adjustments Function 4 40 7 3 Jib Boom Platform Rotate Manifold 4 41 7 4 Brake Two speed Manifold Components 4 42 7 5 Turntable Rotation Manifold Components 4 43 7 6 Oscillate Directional Valve Components 4 44 7 7 Valve Adjustments Oscillate Relief Valve 4 46 7 8 Traction Manifold Components 2WD 2 2 4 48 7 9 Valve Adjustments 2WD Traction Manifold 4 50 7 10 Traction Manifold Components 4WD 4 52 7 11 Valve Adjustments 4WD Traction Manifold 4 54 7 12 Valve eel sl 4 55 Turntable Rotation Components 8 1 Turntable Rotation 4 57 Axle Components
285. 4 5 21 C30FWD WH BK AD DRIVE FORWARD g gt 15 o 01 C31REV WH BK C1B 5 _ 5 20 WH BK BK DRIVEREVEBSE 5 5 EL ee M E z ri DRIVE MODE C130TA WH RD X TRAVEL ALARM er 5 aan 9 8 C26 1 C26 2 i haze HIPS C32BRK WH RD C1B 6 25 23 C32BRK WH RD 14 gt 3 zz m 8 28 1 C282 a a o o T DWH C29MS RD WH 2 C29MS RI C1B 3 C5 24 D MOTOR STROKE 22 E DE 5 5 gs 516 5 Nul _ B 3 C254 C252 CDE2 C37SCW BL BK C37SCW BL BK 0 P DET 5 7 CIP Inl STEER RIGHT DRIVE PNO C36STCC BL C36SCC BL t RIGHT IP 10 36 C1B 10 236 x 241 242 9 7 5 2 A Bee Bl g amp 03 6 C6TRF WH RD C3B 6 9 yout 52455 4 SE 15555 Hoze 32 4 CATRL WH C3B 4 C4TRL WH IM TURNTABLE ROTATE LEFT OR 1 PWR SC 3313 m C14 1 14 2 BRN Su zz 5 C5TRR WH BK 5 WH BK ni 4 TURNTABLE ROTATE RIGHT 4 16 2 C151 152 1 1 m fs er TURNTABLE ROTATE US t e ER 8 o C6TRF WH RD csti TURNTABLE ROTATE FLOW CONTROL as C1PBU RD 12 1 BER PRIMARY BOOM UP pow
286. 4181 1 657 HARNESS 1 5 ENGINE ss 220 HOLIMS NOISNAL 157 HOLIMS woog 20910 2 6181 618 10 WHOALVId OL H3MOd 21 48098 N d LYVLS NOLINDI HOA 72 21 inw4 SS3Hd OL 3 280109 G AINO 99 2 1 4 8 0000000 0 MS
287. 5 8 C141 440142 IE 52 CPS 038 5 c CSTRR WH BK TURNTABLE ROTATE RIGHT iD 5 RK L RIGHT 15 1 15 2 PENA d A TURNTABLE ROTATE LEFT 8 8 WH RD NR TURNTABLE ROTATE E a FLOW CONTROL AA 1 1 1 2 1 1 a 2 1 440122 CIPBURD 1 PRIMARY BOOM UP PRIMARY BOOM ADEK Ini 1 PRIMARY BOOM DOWN 1 C13 1 013 2 ea 7 lt 8 ze 8 EK L MC 8 16 2 C9PBERDWH e PRIMARY BOOM FLOW CONTROL 8 291 C292 SUE ema 15 C1PBU RD 12 pwr 3 T E a 18 BRN SS io Irre 03 2 C2PBD RD BK C3B 2 E lt DE o 5 lt 633 RD WH C3B 3 2 30 1 C302 ace 099 C9PER BK RD C3B 9 C9PER BK RD PRIMARY BOOM EXTEND RETRACT FLOW CONTROL TEM ace 0928 C8PBR BK WH C3B 8 i 124 i lt face 7 C7PBE BK 7 49 155 CABLE TENSION LIMIT SWITCH 5 I our s YEL 3 i 5 3 i RD RD BR C7PBE BK Al 1 BOOM EXTEND 315 n 5 BOOM 37 1 gt cma C16 1 016 2 pwr s 9 1 RETRACT 8 EPN SSi 8 4 C8PBR BK WH BOOM RETRACT x lt 5 a Ci71 17 2 8 BRN 5 9 42 8 E oes CTIBLSROR RD C4B 4 OR RD 38 3 22 C38 4 LS17 BOOM UP DOWN 5 ST SPEED REDUCTION LIMIT SWITCH x 2 800 Pasw B 99 24
288. 5 AUXILIARY POWER RELAY 3 2 gt 5 EE p e Rese AT Wet 1 1 1 88 AUXILIARY PUMP a i Cr or lt 2 g s N I RD BK gt 1 2 5 EDER E 28TTA RD BK C28TTA RD BK WE 8 N lt TILT ALARM 1 M P134TTSR RD RD IBK BRN Ye gt LEVEL SENSOR C133PLA BWH Y 8 1 C46HRN GR 5 C46HRN GR HORN RELAY 22 HORN a LJ 8 AM eect oe m to 9 C1P 12 CIS2PLIBUWH 1842 8 P134FB WH FLASHING BEACONS 6 P134PWR GR BK 2 6 5 5 lt gt OPTION i 11 11 5 i N m 5 a C2MGNWH RZUGNWH gt gt C54 4 HYDRAULIC OIL TEMPERATURE 5 N SWITCH OPTION 3 x ho PHeHYDRD 8115 E as 5 R116 OR 5 1 COOLING FAN 5 2 OPTION pe 5 5 C41RPM OR BK 5 2 PD D i lt box iS EL 16 18 5 5 asi g 813 05 als ur o TOT EN a 1 1 ws 8 2 5 20 RD 12V DC B2 Part No 77828 gt CE AND PLATFORM OVERLOAD OPTION ONLY NOTES enie A TEREX COMPANY S 60 5 65 G 6 39 Section 6 Schematics Electrical Schematic S 60
289. 5 gt 6 C18JD PRR GR BK C4B 6 E FRIGHT PLATFROM ROTATE LEFT C17JU PRL GR C4B 5 PE 5 C282 5 C18JD PRR GR BK 3 i PLATFORM ROTATE RIGHT PLATFROM e tLEFT i 1 PLATFORM ROTATE LEFT C2231 C222 B p CIS ROBE DESCENT ALARM OPTION I 8 a e xim gon c x N amp 6 40 enie A TEREX COMPANY S 60 5 65 G Part No 77828 July 2005 Section 6 Schematics Electrical Schematic 5 60 Deutz F3L 2011 Models before serial number 11880 July 2005 Section 6 Schematics REVA Electrical Schematic S 60 Deutz F3L 201 1 Models after serial number 11879 C22LS BK
290. 5 859 LISTHO 431009 110 TH QH HM T n 8 Alena 1 1 Anay Nua 103188 Auch H WOO8 93848 ONIMS al Suo v HO 5 Sla 5 5 2 8 2 e 3 55 5 ee M e diee 1 Pg 1 d o 1 1 1 12 1 8 m 2 m gt i 3 4 5 88 8 g Ed 3 E amp g e iii i 8 3 55 2 5 5 B i B Big 5 el 1 o 5 9 8 1 n 5 5 1 1 2290 240 T N N
291. 520 BI jj BK S DRIVE REVERSE 8 4 gt DRIVE MODE C130TA WH RD ivy TRAVELALARM Lee LI OPTION 8 9 3 0262 T 2 S ul C32BRK WH RD C1B 6 65 28 CS2BRICWEV RD h BRAKE RELEASE gt 2 28 1 P C28 2 z o amp jag C29MS RD WH C1B 3 a 524 C29MS RD WH MOTOR STROKE f d 8 5 E p 5 5 5 25 1 25 2 CDE2 BLIBK CIP M C37SCW BUBK c1B 11 C378CW BL BK 7 18 STEER RIGHT 10 C36STCC BL C1B 10 C36SCC BL 4 s lt lt 9 5 lt lt E STEER LEFT 9 CDE1 BL WH 8490 0241 242 o 4 3 RES g 64 5 6 WH RD C3B 6 o vour s wh 4 gif z 55 oze 4 CATRL WH C3B 4 CATRL WH 11 TURNTABLE ROTATE LEFT on 1 pwr s 13 14 1 4014 2 D MM NEC 5 C5TRR WH BK C3B 5 5 WH BK 11 TURNTABLE ROTATE RIGHT UE IS ne 3 15 1 0152 TURNTABLE ROTATE 2 g UEL 8 zo C6TRF WH RD Ds TURNTABLE ROTATE FLOW CONTROL 31 1 31 2 Ci24 4 12 2 C1PBU RD IA PRIMARY BOOM UP PRIMARY BOOM raum T PRIMARY BOOM DOWN
292. 58 N amp a 6 78 enie A TEREX COMPANY S 60 5 65 G Part No 77828 July 2005 Section 6 Schematics Electrical Schematic S 60 Perkins 404 22 Models after serial number 11879 Section 6 Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram 5 60 Perkins 404 22 Models before serial number 11880 REV July 2005 Ground Control Box Terminal Strip Wiring Diagram S 60 Perkins 404 22 Models before serial number 11880 Section 6 Schematics FUNCTIONS HARNESS 1108 GNNOYD ENGINE C5 951 HOLMS NOISN3L anayo 151 HOLMS 1 woog 29819 61 81 vO RED 186181 42 WHOdlV ld OL H3MOd H6 CE OPTION ONLY
293. 66650 5 33 ASP6ELO 13131 061 SIOHLNOO ei WHO41V1d 31VLOH cou 6951 WHOSLW 1d 3 2851 ES joa M ej 8 280 VSI ANION 5 180 Pl Enero i woos air 1 18 E YSL SNOLLdO ro 31VLOH m 1 3naviNunL 9 NOM 9 2951 000 419 6 f eee 9551 arr a 2 S Jg HM THM 2 20 I Q8 LOWHLSY N woog tr woog 1961 2 as auma 8 lt a o pp H313W 0 lt 040 39 e ANIDNA E 465 4818 9 260 r e X amp 5 1 2 2 c
294. 7 pi ee ee rIS 1951 Z 8 9 LISTHO 431009 110 T 5 2 E E 8 6 6 uer send 444222 Anay 23845 103138 NHOH 9334 ONIMS a SHO 6 80 c 33 g x S 8 1 Ha i i sl alt la bog 2 25 8 8 1g ii 2215 B E 2 2185 5266585 BN gi 3 5 1 8 i X 1 E al gto 5 8 1 4 y 2i 5 5 8 z gt 54 8 aia 8 3 82 5 1 E didi 3 Rug i 8 z 1 1 5 8555 1 li Isi Sade ALN NH8 T N iO N HOLIMS OL SS3NHVH ANNOYS WH TB21 OPTIONS FUSE 10A DRIVE LIGHT ONLY NOTE DASHED LINES INDICATE OPTION WIRES enie G A TEREX COMPANY S 60 S 65 Part No 77828 6 71 Section 6 Schematics Deutz F3L 2011 Models after serial number 11879 Ground Control Box Switch Panel Wiring Diagram S 65 CE Models July 2005 REVA
295. 70 C 8 50 Jadeo O 2 IGHINOS NOHONIHINOOS HOLIMS Nua 48469 8 8 HAGO Wooa Qa 5 EISEN 2 60 Wuvivoig ad LO lt Qj 1951 09 1 860 v a 9 9 100 8 4068008 NOILdO Nua Q9r H5 431009 110 8 829 Lo d 1 rd N ee a a ee NHOH 1 80 HO Suo 8 BB 18 13 9 1 1 g 8 wore 0 1845 55085555052 Hd So 8 83 1HVLS L NOILIN I 1 N 10 N Section 6 Schematics GM 3 0L Models Ground Control Box Switch Panel Wiring Diagram S 65 July 2005 REV B 6 16 enie A TEREX COMPANY G
296. 8 C15 C15 EE TURNTABLE ROTATE LEFT 9 amp o 6 WH RD cor TURNTABLE ROTATE FLOW CONTROL go GIPBUBD 2 1 12 2 t PRIMARY BOOM UP a PRIMARY BOOM C2PBD RD BK 1 d PRIMARY BOOM DOWN f rc ge Bi 5 c Bu 5 m iz e 2 ES B HD WH p PRIMARY BOOM FLOW CONTROL 2 1 29 1 29 2 S GH 5 eee 1 C1PBU RD C3B 1 15 pwr 11 16 BRN 2 12 2 C2PBD RD BK C3B 2 5 7 lt X ee s lt lt 03 3 RD WH C3B 3 8 304 30 2 Haze 9 C9PER BK RD C3B 9 C9PER BK RD Jj PRIMARY BOOM EXTEND RETRACT FLOW CONTROL C3P 8 C8PBR BK WH C3B 8 i E gt Kanun ii face 7 C7PBE BK 48 155 CABLE TENSION LIMIT SWITCH YEL Sm RD RD C7PBE BK REND 5 1 EXTEND Sig 54 5 Hm BOOM 37 1 37 2 c16 1 16 2 EO pmp 9 RETRACT BRN 1 awpn SPER EKWH vg IA gt gt BOOM RETRACT x lt lt a CIL 2 o 1 a a BRN ss 9 882 8 CH8LSROR RD 4 4 5 OR RD C38 3 BK WH 38 4 1317 UP DOWN P24FS WH 5 5 2 SPEED REDUCTION LIMIT SWITCH gt amp 2 __ __ 5 42 ett C4B 1 BL RD WH C92 LS3 DRIVE ENABLE LIMIT
297. 8 Nav ivar vO o 6 1 Wd 6 O CH ay 2 weusi 1 069 5951 6 860 Quia 5 8 8 O GH E 1 210 HMM 69S HWE i 8 4 WOO8 AHVWIHd s 1 280 55 38420 1 80 38925 49 9 7IH19 NOILONN 4 1 10 9 N E 8 1 10 QU HM 39190 48190 5 E 31V 10H 3I8VLNHNL 9 Qd lt 5 r4 1 10 89190 29S18 HM t wo lt 8 0 HHLSO 8 v mamona r O gt 1 819 1179 Z9SL HM gt 1860 8 D NOLONMHWOOSAHWWd O GH 1 620 8455 48460 5 2 NMOGWOOS 2 5 1 810 196 1 O G 1951 09 1 gt 1 3 Nad tO 1 d 81 asva TWNIWHAL guz 1 256 1 5 1 H I 2860 LISTHO 025 iW 9 431009110 TH QH HM 5 8 1 EKN BEE al i t i Sl S 1 1 1 1
298. 9 1 BK WH 9 2 LS3 DRIVE ENABLE LIMIT SWITCH 5 ots P26ESTP BK gt 3 0 299 a 6262 2 WH BK LS1 PRIMARY BOOM EXTEND 5 DRIVE LIMIT SWITCH 9 J1 FH WH BK _ C102 LS2 PRIMARY BOOM UP SUE DRIVE LIMIT SWITCH PSS Sess se os See C40LS OR C2B 2 OR 9 1 1 T 1 ue gt par 115 S 4555 P22LS 11 5 BL BK C3B 11 BL BK V o 5 BK 37 3 BK 4 2 2874 3 gt LS5 CABLE TENSION LED oc ey o 2 9 x 3 5 o P134 RD m RD C38 1 gt RD BR C38 2 1517 UP DOWN a NA a SPEED REDUCTION LIMIT SWITCH 2 CI4PLUOR C4B 2 I2 E 2 lt z L2 po UM PLATFROM LEVEL 9 t DOWN C4P 3 C15PLD OR BK C4B 3 20 1 C202 2 op i CIPEL OR DA PLATFORM LEVEL UP PLATFROM LEVEL DOWN 1 PLATFORM LEVEL DOWN E m C21 1 C21 2 5 gt C4P 6 C18JD PRR GR BK C4B 6 E ERIGH PLATFROM ROTATE t LEFT C17JU PRL GR C4B 5 Caps 234 2 8 C18JD PRR GR BK 4 3 Mt lt lt PLATFORM ROTATE RIGHT P RIGHT PLATFROM ROTATE A sno SI IURAE GH PLATFORM ROTATE LEFT C224 022 2 E RDBK O DESCENTALARM OPTION 2 4 x Bx o x E gt 28
299. 9P 2 P23BAT WH C7P 2 P22BAT BK C7P 1 C19JSV GR WH 7 C18PRR GR BK 4 6 C17PRL GR 4 5 C15PLD OR BK C4P 3 C129JDA BL C3P 10 TS8 C46HRN GR C2P 5 C59CHK BL BK C3P 11 147 C59CNK BL BK C3P 11 P26BAT BK C9 1 P2 PT 6 JIB P25FS RD C9 3 TS2 1 C14PLU 2 7 P24FS WH 9 2 TS4 CDLITE OR RD C2P 4 C45GEN GR WH 2 7 C46HRN GR C2P 5 C39LP BURD C2P 1 P26ESTP BK e e J3 e 6 WH RD C1P C118LSR OR RD C4P 4 C6TRF WH RD C3P 6 C8PBR BK WH C3P 8 24FS WH 24FS WH J2 SP C16DRE BL RD 1 C7PBE BK C3P 7 1 i i i 1 i i i i i i i i i i 40155 OR 2 2 C40LSS OR C e C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 C1PBU RD C3P 1 31 WH BK C1P 5 C2P C2PBD RD BK C3P 2 C36STCC BL 10 RD WH C3P 3 C37STC BUBK C1P 11 5 WH BK C3P 5 C32BRK WH RD C1P 6 C4TRL WH C3P 4 C29MS RD WH C1P 3 U13 ALC 500 C35RPM BK RD C1P 9 C33STR BK C1P 7 C27AUX
300. ARE gt aT COOLANT TEMPERATURE SWITCH 5 ENGINE 5552 5226 START b 552688906 8 1 2 2 ENGINE 9 999 999098 5516 OIL PRESSURE SWITCH 5 m C25PSR WH BK I lt E oz E B 5 a o iy A POWER RELAY a 5 0 a CE le C2 1IGN2 WH cen H FUEL SOLENOID N NN a N e oe rie 4 C27AUX RD C1B 1 4 amp GPHGNWH E HOUR METER 88 1 li IGN START RELAY 5 8 9 x o R33STR BK C5 5 pp ct mz a STARTER MOTOR 0 8 E 8 AUXILIARY ee m E C27AUX RD x PUMP RD AUXILIARY POWER RELAY A S C7B 2 Sly GP PESBATWH 4 AUXILIARY PUMP a Rg gt 2 WH 2 9 Y RD BK ER 1 C28TTARD BK C28TTA RD BK 2 wet 4685 TILT ALARM 111 0 ee P134TTSR RD m jBK BRN Le LEVEL SENSOR 12 ee o 12 C133PLA BL WH 8 5 C2P 5 C46HRN GR as C46HRN GR m HORN RELAY n GR BK 7 1 P22BAT 7 1 x 1 5 22 le FH BK A o jo 8 1 5 C1B 12 ils 1 C1P 12 CIS2PLI BLWH ez 5 m V mE P134FB WH FLASHING BEACONS 2 6 P134PWRGRIBK C2B 6 gt 5
301. B 12 2 1 DRIVE LIGHT we Bini o m HD DRIVE LIGHT OPTION EE 5 9 rS 51 WORK LIGHTS OPTION us cap 2 C2P 10 a Not 28 c BEEE MN LIEN NLIS 2 11 C2P 9 a A 9 gi 1 m L 4 3 t a n Eu 8 C34SA BK WH 6 C34SA BK WH 5 22 GLOW PLUG RELAY 4 e GLOW PLUG b ex xo GLOW PLUG PLUG 00 R a v gt C26TSR WH RD OIL TEMPERATURE LED a zi Sse 3 4 258 5 g 852 oz EY BES Lees 8 n 5 r CIE 3381 95 65 14 OIL TEMPERATURE SWITCH n _ ENGINE a 5 START b 8 ENGINE Econ oris 5 16 8 OIL PRESSURE SWITCH m C25PSR WH BK BK e E o lt oO oz B E N nN 9 5 m POWER RELAY 5 Fg conan wi cs A FUEL SOLENOID NS 7 em a 9 4 1 C27AUX RD C1B 1 2 id Ceon wn HOUR METER oo 98 E IGN START RELAY m ala ae im R33STR BK C5 5 1 1 ai Bo te i cz 16 12 3 1 4 5 n up 1 s 8 vol 5 E 6 EMISSION CONTROL
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303. BOOM UP PRIMARY BOOM DOWN C2PBD RD BK 220 3 PRIMARY BOOM DOWN 4C 5 5 C13 1 C13 2 5 I c o Pir of lt ES 5 t RD WH PRIMARY BOOM FLOW CONTROL 1 C1PBU C3B 1 deme E 6 lt lt gt lt lt 5 9 5 lt 03 2 C2PBD RD BK C3B 2 i c E ee 4 s zc 8 C3PBF RD WH C3B 3 a C30 1 C302 Haze C3P 9 C9PER BK RD C3B 9 BK RD He PRIMARY BOOM EXTEND RETRACT FLOW CONTROL isses Haze 8 8 C8PBR C3B 8 7 C3B 7 amp lt 2 lt 2 32 185 CABLE TENSION LIMIT SWITCH YEL B E 8 our RD mp 5 C7PBE BK gt e BOOM EXTEND 5 48 5 BOOM 37 1 37 2 Ci 1 16 2 35 7 gt 9 1 1 RETRACT BRN 3 PBR BK WH GND 24 75 10 KWH il gt gt BOOM RETRACT T lt E l E 5 17 1 C17 2 E BRN ss 9 432 8 CHI8LSROR RD 4 4 E OR RD 38 3 BK C38 4 1817 UP DOWN gt SPEED REDUCTION LIMIT SWITCH mos Pears WH 5 888 BURD BL RD WH 2 1 LSS DRIVE ENABLE LIMIT SWITCH stus P2GESTPBK STE 5 99 3 zu 2 2 899 a WH BK Cina LS1 PRIMARY BOOM EXTEND 5 1 DRIVE LIMIT SWITCH os J1 EH WH BK WH C102 LS2 PRIMARY BOOM UP gu DRIVE LIMIT SW
304. C373 A Z WH cor4 3 1 LS5 CABLE TENSION LED sU g R 5 o P134 RD C38 1 RD BR C382 5 LS17 BOOM UP DOWN a 54 SPEED REDUCTION LIMIT SWITCH 2 e 04P2 OR lt 6482 89 g PLATFROM LEVEL DOWN C4P 3 C15PLD C4B 3 20 1 20 2 8 5 PLU OR P rus i PLATFORM LEVEL UP Hi PLATFROM LEVEL t DOWN i D PLATFORM LEVEL DOWN E i 21 1 C212 N 8 10 C129JDA BL C3B 10 8 6 C18JD PRR GR BK C4B 6 DOWN de JIB 1 UP C17JU PRL GR C4B 5 CIPS amp B 023 1 C282 8 C18JD PRR GR BK 8 i lt PLATFORM ROTATE RIGHT RIGHT PLATFROM gt 1 LEFT C17JU PRL GR 1 PLATFORM ROTATE LEFT C224 C222 RIGHT PLATFROM LIE x It LEFT i B C DESCENT ALARM OPTION t o 8 E 7 C19JSV GR WH C4B 7 RN ERSTER 1 a 2 5 5 x JIB VALVE 58 JIB VALVE x I 6 0 a x E 2 58 80 Ex ale 5 enie A TEREX COMPANY S 60 5 65 G 6 60 Part No 77828 July 2005 Section 6 Schematics sevooc_rb _ Electrical Schematic S 65 Deutz F3L 2011 Models after serial number 11879 2215 REV D
305. CE Models Deutz F3L 2011 Models after serial number 11879 6 71 Ground Control Box Switch Panel Wiring Diagram S 65 CE Models Deutz F3L 2011 Models after serial number 11879 6 72 Platform Control Box Terminal Strip Wiring Diagram 5 65 Deutz F3L 2011 6 73 Platform Control Box Switch Panel Wiring Diagram 5 65 Deutz F3L 2011 Models tette oes a 6 74 Genie Xvi S 60 5 65 Part No 77828 July 2005 TABLE OF CONTENTS Section6 Rev Schematics continued C Electrical Schematic 5 60 Perkins 404 22 Models before serial number 11880 6 75 A Electrical Schematic S 60 Perkins 404 22 Models after serial number 11879 6 77 B gt Ground Control Box Terminal Strip Wiring Diagram 5 60 Perkins 404 22 Models before serial number 11880 6 79 B Ground Control Box Switch Panel Wiring Diagram 5 60 Perkins 404 22 Models before serial number 11880 6 80 A Ground Control Box Terminal Strip Wiring Diagram 5 60 Perkins 404 22 Models after serial number 11879 6 81 A Ground Control Box Switch Panel Wiring Diagram 5 60 Perkins 404 22 Models after serial number 11879 6 82 B Platform Control Box Terminal Strip Wiring Diagram 5 60 Perkins 404 22
306. CWLITE WH 7549 6 55 Section 6 Schematics Deutz F3L 201 1 Models Platform Control Box Switch Panel Wiring Diagram S 60 July 2005 REV B 2 5 5 x 9 5 SE 9 5 Elu xolg aja 5 SIT 2 90 2 5 s le 0 55489852 2 gt gt 555558184 45235 2 8 Sul oo uj Hoo 55525 39 s 5244 a 8 Sa 5 5082 lt amp Eu ug gt o 098 a m lels Sul gt 5 5 2 EI ES ED 5 3505 gt gt 9 5 5 55 lt d 8 8 8 548 085222992 o9 8 111 gt ry 5 2 lt lt u P22BAT BK C7P 1 P26BAT BK J3 3 P23BAT WH C7P 2 6 56 enie A TEREX COMPANY S 60 5 65 G BL J1 5 ROCKER SWITCH OPTION ONLY P26BAT BK C9 1 RD H1 C134PWR L48 1 2 2 OR J1 13 C134PWR RD
307. CoP M C2P 9 4 5 esee t ceret zioni crt e 5 tcr 9 8 C34SA C34SA BK WH 5 22 4 GLOW PLUG 9 1 cow 51 GLOW PLUGS PLUG Sb 00 a a 000 C26TSR WH RD 0 COOLANT TEMPERATURE LED ox HE 5 5 2 898 nz 325 0 gt 20 a ul 5 Sr 7 x BK 40187 EIS 5 5 E EE Cot e 6 COOLANT TEMPERATURE SWITCH Os x gt gt 2 START 9 65042588905 3 6 ENGINE 5 16 2 ete 9 9999 99 9 8 OIL PRESSURE SWITCH S t 4 C25PSR WH BK a 4 lt 3 Nz E 5 9 a o x A POWER RELAY m E 8 e epg C21IGN2 WH 11 JM FUEL SOLENOID amp aja e tc 1 C27AUX RD C1B 1 did 9 C2 IGN WH HOUR METER 818 D IGN START RELAY 0 0 gg 5 R33STR BK C5 5 1 gi rat mx rae 4 5 i STARTER MOTOR 0 19 x B AUXILIARY a g C27AUX RD x PUMP RD oU E AUXILIARY POWER RELAY T 5 a E E ANA cre 1 1 5 AUXILIARY PUMP m 2 eur y N SI RD BK 2 2 WH 8 RD BK SER 8 Y 555 B C2BTTA RD BK iiir C28TTA RD BK z P134TTSR RD RD BRN i L LEVEL SENS
308. D 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 7 C9 C1P C4P 48 PIN CONNECTOR BLOCK U13 J1 J2 43 CR27 CR30 LS18 C134PWR RD H1 C32BRK WH RD 6 C32BRK WH RD J2 19 C40LS OR C2P 2 12 P24FS WH C9P 2 P23BAT WH C7P 2 P22BAT BK C7P 1 C19JSV GR WH 7 C18PRR 6 C17PRL GR C4P 5 C15PLD OR BK C4P 3 C14PLU OR C4P 2 C129JDA BL C3P 10 TS8 C59CHK C3P 11 147 C3P 11 P26BAT BK C9 1 P2 CWLITE WH TS49 oruz 55502 TOTES C19JSV GR WH TS7 WH C19JSV GR WH 7 BRN JC3 BK BRN GND 6 C134PWR RD 1518 0 0 JIB RD LS18 CABLE OPTION P25FS RD C9 3 TS2 P24FS WH C9 2 TS4 i i 1 1 1 1 i 1 1 1 1 1 1 1 C46HRN GR C2P 5 1 1 1 1 1 1 1 L CDLITE OR RD C2P 4 C45GEN GR WH 2 7 3l C46HRN GR C2P 5 P26ESTP BK C118LSR OR RD C4P 4 6 WH RD C3P 6 e e C8PBR BK WH C3P 8
309. D OUTPUT CONNECTOR CONTROL BOARD POWER CONNECTOR CONTROL RELAY CE OPTION CONTROL RELAY CE OPTION LOAD SENSE LIMIT SWITCH DESCRIPTION TILT ALARM 48 PINCONNECTOR BLOCK ITEM H1 7 C9 U13 J1 J2 43 CR27 CR30 LS18 OPTION F S 12V DC BATTERY i i i 2 i Fd NE 108 i C39LP BL RD 2 1 E P26ESTP bg 7 dg rd io 1 1 e C118LSR OR RD 4 pog WH RD 6 E 4 C7PBE C3P 7 i e BURD C4P 1 1 C8PBR BK WH C3P 8 EN E P24FS WH e C40LSS OR C2P 2 e N C9PER BK RD 9 P24FS WH e C41 RPM OR BK C2P 3 a C30FWD WH 4 C1PBU RD 1 C31REV 5 a e C2PBD RD BK 2 5 C36SCC 10 e C3PBF RD WH C3P 3 i 8 C37SCW 1 11 5 i 5 WH BK C3P 5 8 C32BRK WH RD C1P 6 e 4P B no WH 4 1 5 gt lt C29M
310. FAS HO G3MOLS 2 019 151092 28 15710 aeo MONSO o 41660 16 1331 83315 210 0 1820 915 59 JP 11 812 915 59 05188680 86 01 81018 2215980 2 35 03345 HBIH 86 Q Qd 6810 SHSEO ve ve lt O SIs MOND O OF 8 810 HME 9559 2 55 1HVIS 72 810 515555 2 50 Jp ZONES O 9 810 GH HM oZ amm Ao 2 19 5 810 A3HIEO P 06 o 7 10 62 SOULS 62 vESOHWGHSWeo 07500 0 Nua HWGH 501620 2 82 DIL Ivaoed 11820 2 10 1820 12 xnvzzo A 1951709 au xnvzzo 2 2 9 HOLIMS 3HnlVH3dW3l1NV1000 9 5 82 82 Srsoxsmmusiszo 5 o 2 mE P HOLIMS rH 2 8 0 HM 1 8624 ZNSFHM 2 65 1 2 22 2 NHOsLW1d OL 1 10 Ivazed 22 21 ec zaoa
311. FOOT SWITCH 12V DC BATTERY Part No 77828 19 18 CONTROL CABLE enie A TEREX COMPANY S 60 5 65 G H1 TILT ALARM Platform Control Box Wiring Diagram S 65 Section 6 Schematics Deutz F3L 2011 Models a o a 224 C118LSR OR RD CAP 4 z e e 1 C6TRF WH RD 6 2 C8PBR BK WH C3P 8 e C16DRE 7 7 24FS WH C40LSS OR C2P 2 C9PER BK RD C3P 9 WH e CA1RPM OR BK C2P 3 C30FWD WH 4 RN e C1PBU RD C3P 1 WH BK 5 of 4 e e C2PBD RD BK C3P 2 A 5 C36STCC BL 10 RD WH C3P 3 C37STC C1P 11 WH BK C3P 5 4 C32BRK WH RD C1P 6 e CAP BR 2 CATRL C3P 4 e a C29MS RD WH C1P 3 20 m lt C3P GR Sr C35RPM BK RD C1P 9 C34SA BK WH C1P 8 C33STR 7 C27AUX RD C1P 1 H C2P BK i J 5 a i JC1 3 OR 9 4 5 JC2 4 RD N JC1 2 BRN e C1P GY 362308 1 5 YEL JC2 2 BRN e 5 JC3 5 WH o JC3 3 OR 1 JC3 4 BL JC3 2 BRN e 1515 BWH A 28 RD BK C1P 2 4 1815 BUBK DRE LED BL RD e e 1 1514 RD WH o d 5 a z 5 lt 5 8 4 _ GB BK C133TTA C3P 12_ es
312. G 425 EFI Models after serial number 11879 Ground Control Box Switch Panel Wiring Diagram S 65 July 2005 REVA 6 36 enie 9 o 65 4115 mi 9 25 256 8 18505285 2252596 5 aua 259 5 685 24555 9 59 8 8 8 wE oc 9 4 Ojo 2056 99 lm 5 5 858 lt 58 5555555812 945558 510101012 2 0 22225230 253 52 2 4 5 a 21 2 24 83858522 85 225552808 823528 52158452 58 045 485 lt 5 0 4 41815 TVNIWH3L OL 558 84 8 92 2 898988888888 SS3NHVH 3578 2
313. GR C4B 5 5 23 1 023 2 4 5 7 8 of 8 C18JD PRR GR BK A 1 PLATFORM ROTATE RIGHT 5 ROTATE C17JU PRL GR Ibi PLATFORM ROTATE LEFT 22 1 22 B LE 1 al ML Es RP 2 5 22224 02222223 E i E Meas 1 DESCENT ALARM OPTION 8 n 4 gos 25 an n amp IS EIN oO P22LS BK enie A TEREX COMPANY S 60 5 65 G 6 76 Part No 77828 July 2005 Section 6 Schematics Electrical Schematic S 60 Perkins 404 22 Models before serial number 11880 REVA C22LS BK July 2005 Perkins 404 22 Models after serial number 11879 Electrical Schematic S 60 Section 6 S
314. Genie Service Manual Refer to inside cover for additional serial number information Part No 77828 Rev July 2005 5 60 5 65 from serial number 9154 Introduction July 2005 Introduction Important Read understand and obey the safety rules and operating instructions in the Genie S 60 and Genie S 65 Operator s Manual before 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 Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us http www genieindustries com e ma
315. Ground Control Box Switch Panel Wiring Diagram 5 65 Deutz F3L 2011 Models after serial number 11879 Section 6 Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram 5 65 CE Models Deutz F3L 2011 Models before serial number 11880 REV FUNCTION HARNESS ENGINE C5 HOLIMS HOLIMS July 2005 Ground Control Box Terminal Strip Wiring Diagram S 65 CE Models Deutz F3L 2011 Models before serial number 11880 Section 6 Schematics 1 18098 LYVLS NOLINDI HOA 2 21 55388 HO dWAL 01 6 z 6
316. H BK FURNALE ROTATE RIGHT E 14 lt 8 2 Ci51 15 2 r a TURNTABLE ROTATE rn 1 2 8 C814 C812 ii Pd WH RD lt TURNTABLE ROTATE We gt t CONTROL 12 1 4012 2 PRIMARY BOOM UP PRIMARY BOOM DOWN C2PBD RD BK PRIMARY BOOM DOWN 4 N 8 C133 1 01 EG E R A E 16 vour pe 2 PRIMARY BOOM FLOW CONTROL 29 1 29 2 Us 1 C1PBU RD C3B 1 15 pwr 1 16 BRN GND 2 12 C2PBD RD BK C3B 2 i 8 222 La lt 8 RD WH C3B 3 8 304 302 632 9 C9PER BK RD C3B 9 F C9PER BK RD PRIMARY BOOM EXTEND RETRACT FLOW CONTROL C3P 8 C8PBR BK WH C3B 8 i 2i BK Kanun T lt a ad face C9P7 C7PBE BK C3B 7 49 155 CABLE TENSION LIMIT SWITCH E 15 amp 4 Il id RD RD C7PBE BK x DESEND i V BOOM EXTEND 515 oA 5 37 1 37 2 C164 C16 2 9 1 RETRACT i aopen i CBEBRIBIOWH gt 2 11 BOOM RETRACT 1 N I 7 x 5 t 17 2 u a BRN 9 429 CHI8LSROR RD 48 4 OR RD 38 3 WH 38 4 LS17 BOOM UP DOWN PMFSWH 5 8 5 E SPEED REDUCTION LIMIT SWITCH a Pears WH 5 499 2 C4P 1 BURD C4B 1 BURD C
317. H RD C3B 6 e Your Sg sa 5 155515 9 4 CATRL WH C3B 4 CATRL WH TURNTABLE ROTATE LEFT 4 PWR SC 3213 B C14 1 14 2 8 su 0325 WH BK lt 6385 n CSTRR WH BK EMS TURNTABLE ROTATE RIGHT 4 5 2 C15 1 152 1 lt LE TURNTABLE ROTATE gy 8 8 C6TRF WH RD TURNTABLE ROTATE 4 SI FLOW CONTROL AM 31 1 C124 12 2 CIPBURD Il PRIMARY BOOM UP PRIMARY BOOM t A PRIMARY BOOM DOWN 12 3 134 132 Or dc 2 5 tj p PRIMARY BOOM FLOW CONTROL C3P 1 1 RD C3B 1 u ee 3 8 m E C3P 2 C2PBD RD BK C3B 2 5 lt CE s qz CoP C3PBF RD WH C3B 3 a C304 30 2 6329 C9PER BK RD C3B 9 C9PER BK RD PRIMARY BOOM EXTEND RETRACT FLOW CONTROL PE EERS aze 8 C8PBR e tk 8 eg eT 5 7 42 LS5 CABLE TENSION LIMIT SWITCH YEL m d RD C7PBE gt i BOOM EXTEND E 5 1 1 EXTEND C374 V C164 16 2 OR gt 1 PWR 3 gt 9 t RETRACT i BRN 8 amp 8 8 il BOOM RETRACT _ lt 5 T 17 2 pe 4 E 5 5909 _____________ gt 1 c 8 rze CHB8LSROR RD 4 4 OR RD C38 3 BK WH 038
318. HINOO est WHO4LW1d 31v108 6951 LINOHIO INHOALVId Gri HO 1881 002 24 1 ANISNA 1 9 002 1140980 4 180 2 as 49 49 G8124g 85 5 ee Pee WOO8 90 8551 YSL SNOLLdO x PENLAN 31vi0H COS a BPO s MOTO 2961 9 5 9551 9 arra 2240 208 ego 9 QU HM 9 1 S 4g HM T HM 1 260 12 woog tr 5951 wooa 2 1951 3 o AS n HW H lt y T o m 142 3 m HEED o 92 8 x 1 Q 39 woog z IN LOWES 3NION3 4 8 g on a o pag 9 260 GIZ HM 8 u NC 2 c 2 LAZZ za C o HOLIMS HM HM 19 els 5
319. IGHTS 2 NR T RR RENNES ME RD JC2 OPTION TILT ALARM LED JC3 BK OPTION BANE PRIMARY BOOM UP DOWN 7 JC1 7 FORWARD REVERSE amp TURNTABLE ROTATE BOOM TS15 amp STEER COMPONENT INDEX LEFT RIGHT bg EXTEND RETRACT DRIVE OHO ee LEFT RIGHT 6 6 ENABLE CR13 JIB BOOM CUT OUT RELAY rd JC2 BOOM PROPORTIONAL JOYSTICK 1 1 tt BOOM UP DOWN TURNTABLE ROTATE 5 pd 5 1 1 g R JC1 BOOM PROPORTIONAL JOYSTICK 3 11 2 BOOM EXTEND RETRACT 4 E 4 4 3 DRIVE STEER PROPORTIONAL JOYSTICK bg L1 DRIVE ENABLE LED 3 3 14 14 PLATFORM OVERLOAD LED pd PLATFORM 147 LOWER RETRACT BOOM LED ii OVERLOAD 2 i 2 GEOPTION _ 148 BOOM TILTED LED M P2 EMERGENCY STOP BUTTON 8 P3 HORN SWITCH E 1 ps a 18 TS1 AUXILIARY POWER TOGGLE SWITCH 1 um 1 n a i TS2 ENGINE START TOGGLE SWITCH 4 E CR13 VY E TS3 FUEL SELECT TOGGLE SWITCH Ld Ton 1 5 TS4 HI LOW RPM TOGGLE SWITCH BRN En ka sl mr Tee P TS7 PLATFORM ROTATE TOGGLE SWITCH 1 BK Li 18 758 JIB BOOM UP DOWN TOGGLE SWITCH BRN 1 F18 FUSE 10A 3 TS9 PLATFORM LEVEL TOGGLE SWITCH E N WORKLIGHT ONLY E TS14 DRIVE SPEED TOGGLE SWITCH lo olo A ig TS15
320. IST B PROCEDURES 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 e a fuelline b filter head fuelfilter 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 5 60 5 65 3 31 Section 3 Scheduled Maintenance Procedures July 2005 CHECKLIST B PROCEDURES Bleed the fuel system 9 Loosen the vent plug on top of the fuel injection pump vent plug b fuel injection pump fuel lift pump 10 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 11 Clean up any fuel that may have spilled during this procedure 12 Operate the starter motor for intervals of 15 seconds until the engine starts 13 Swing the engine back to its original position and install the engine pivot plate retaining fastener It is important to allow the starter motor to cool for 30 seconds between each 15 second inter
321. ITCH C40LS OR C2B 2 Se FH OR x 1 1 2 m 1 22 WEEE o i P22LS BK f 11 C59CNK BL BK 11 21 5 BK C373 BK 42 WH 037 4 3 LS5 CABLE TENSION LED g 3 o P134 RD Fino RD BR 2 1817 UP DOWN a VN SPEED REDUCTION LIMIT SWITCH 2 8 2 CI4PLU OR C4B 2 Noo UP po PLATFROM LEVEL a DOWN _ CIBPLD OR BK C4B 3 020 1 20 2 2 op CIHPEU PLATFORM LEVEL UP py PLATFROM LEVEL icin ORBE D PLATFORM LEVEL DOWN E N B C21 1 C21 2 CAPE 2 C18JD PRR GR BK 948 6 Trient LLL PLATFROM ROTATE 1 LEFT C17JU PRL GR C4B 5 m 231 C282 a 8 i il PLATFORM ROTATE RIGHT RIGHT PLATFROM ROTATE RO PLATFORM ROTATE LEFT C224 C222 Sie ROBE Ei DESCENT ALARM OPTION 2 al 22000 1 x x 888 c skeu ala a enie A TEREX COMPANY S 60 S 65 G 6 20 Part No 77828 July 2005 Section 6 Schematics a i ssa Electrical Schematic S 60 Ford LRG 425 EFI Models before serial number 11880 REV P22LS BK P134PWR RD July 2005
322. L BEI LIS Teed N S 8 1 1 Suo 1 re NOILINDI 2 5 39 HM P WH HM 1 1 lt gt oz 02 CH 1 1 a 180 is 1 8 3 HOLIMS 8 E shaders a E 0 GA FINE I woog 2 879 AST6L9 NMOG 31vLOH WHOSLW1d 8 Q4 1 820 8 9 APBLO 168L38 00 9 8 0 13 817 137 31vLOH 1 14 4 1 220 1 6 9 H9 s NMOGT3A31WHOdlYVid 81 E 129 0148 3 2 6551 48 29819 2 dn3A31WHOdlVid EI 240 1020 Je 6SS1 HO IT nn r El Je 1 SE 1 306530 NMOG Qd 8 were 8 O 8951 18 01 859 18 a vo RED 6 6 O CH A 1 089 460 gi E 6 860 auma 53460 5 SAISPROOPANR 7 8 L ll 34 V2 9 EIS LHMAE ra 8 860 HWE Had8O 1 AHVWIHd L 3 4 1 1450 95 389 0 V2 1 1 B X nn 9 1810 9 1 x 1 160 38180
323. L 1 DOWN Crore PLATFORM LEVEL DOWN 5 021 1 C212 8 5 gt 4 6 C18JD PRR GR BK C4B6 tid r ft _____ PLATFROM ROTATE Lg LEFT C17JU PRL GR C4B 5 EE 5 EN C283 C282 8 A PLATFORM ROTATE RIGHT FS RIGHT PLATFROM BE tLEFT ROTATE i 1740 GR 121 PLATFORM ROTATE LEFT ryt C224 C222 B LY tect E E ee SS TP ES E C129 DESCENTALARMOPTION 2 8 Ms set t te ae ta eile ka a a ROTEN CR J x x E u z N 5 8 10 amp a cc 6 62 enie A TEREX COMPANY S 60 5 65 G Part No 77828 July 2005 Section 6 Schematics Electrical Schematic S 65 Models Deutz F3L 2011 Models before serial number 11880 2215 REVA July 2005
324. LECT 1 OEC 5 C 969 No ne ne EMERGENCY O Q STOP TS4 160 TS9 WH TS1 HIGH LOW TS47 ENGINE HIGH LOW HORN PLATFORM AUXILIARY 2WD AWD GENERATOR START RPM LEVEL 187 PUMP OPTION BK PLATFORM WH i RD ROTATE RD RD RD 8 NOTE DASHED LINES INDICATE OPTION WIRES CE LIFT DRIVE OPTION REPLACE WIRE WITH CR27 amp CR30 A TEREX COMPANY Part No 77828 S 60 5 65 6 28 July 2005 Section 6 Schematics _ E Platform Control Box Switch Panel Wiring Diagram S 60 Ford LRG 425 EFI Models REV B P22LS BK July 2005 Ford LRG 425 EFI Models before serial number 11880 Electrical Schematic S 65 Section 6 Schematics 8 555 eg a 5 lt 5 7 oO a 9 BK RD C1B 9 m ENGINE 5 OIL PRESSURE SPEED a 25PSR WH BK 21 8
325. LOW CONTROL Haze 3 8 C8PBR BK WH C3B 8 7 C7PBE 7 49 185 CABLE TENSION LIMIT SWITCH m ap 5 C7PBE BK Itl EXTEND 5 C37 1 Es 37 2 C161 C162 9 t RETRACT 10 g BOOM RETRACT lt i 7 x 5 CI72 N 29 8 BRN ss Q 42 a DECR 11815 OR RD C4B 4 OR RD C38 3 BK C38 4 LS17 BOOM UP DOWN 5 5 SPEED REDUCTION LIMIT SWITCH 2 Eon Pasw 5 222 faze 64 5 BK WH C92 LS3 DRIVE ENABLE LIMIT SWITCH stus PRESTPBK 2 oz CP 88 4 lt CH 2 wH LS1 PRIMARY BOOM EXTEND 5 STE DRIVE LIMIT SWITCH J1 FH WH BK WH 10 2 LS2 PRIMARY BOOM UP DRIVE LIMIT SWITCH T EAE N E C40LS OR C2B 2 OR x e i 55 us i DS pee 4 5 57 ai P22LS BK 11 59 C3B 11 BL BK a 5 C37 3 BK 9 2 C37 4 3 LS5 CABLE TENSION LED 5 e P134 RD RD gt HD BR yz 038 2 A 1817 UP DOWN a Va SPEED REDUCTION LIMIT SWITCH 2 8 2 CI4PLU OR C4B 2 522 PLATFROM LEVEL 3 t DOWN _ CI5PLD OR BK C4B 3 4 204 20 2 8 F I op 2 PLATFORM LEVEL UP PLATFROM LEVE
326. LOW PLUG PLUG 00 lt R a lt 5 i C26TSR WH RD OIL TEMPERATURE LED 208 Bea 5 808 T 8 D C5 14 1 7 amp alee gt TEMPERATURE SWITCH gt ENGINE 8 251559 START 5 lt S _ 9 He 5 16 gt 4 OIL PRESSURE SWITCH a C25PSR WH BK BK a S x g oz o x POWER RELAY a e gs o C21IGN2 WH c5 11 8 5 le d FUEL SOLENOID 1 C27AUX RD C1B 1 4 ala C21IGN WH De HOUR METER 88 E IGN START RELAY 20 x 10 R33STR BK C5 5 Se a 1 SE 2 5 5 5 4 r STARTER MOTOR en 1 5 s 8 2 101 2 EMISSION CONTROL 8 0 tc 1 AUXILIARY 5 5 PUMP x t RD CETAUIGRO JA 4 SPEED REDUCTION RELAY C27AUX RD i shar wit C7B 2 S AUXILIARY POWER RELAY m ur on sd B 12 aa I 84 4 AUXILIARY PUMP NO 2 WH S RD BK 8 C28TTA RD BK 1 258 GESTTARDIBR e TILT ALARM t un Io MEO P134TTSR RD RD ver SENSOR 8l 12 ae Wi c Ti iA 87 1
327. M LINOHIO i S J8 HM 08 48 82 ala ni T HM Gi HM 2 260 2 LOVUL3U aNa1xa W008 Wood 591 103138 1951 2 ESSL o as auma 800 2 J a am woog 39 2 2 WHO4LV1d ANIONS sh CS al assyar a 9 260 arz HM g z 2 c a 2 HMdt LO ec v ia 1022 kW azza G a el 9 a 22 a E O AM HM HOLIMS OO 15 T BJEN 1551 4018 AON3OHaW3 Nua id 9L8 HWQH 5 I a wyo OL 18180 MSc 82 9LH HNWGH 3 HOLSIS3H INOZ WOO 43395 91H woog 1 wyo 8 52 HOLSIS3H 31v10H 3 av1NHn L Q YOLSISJ H vu Q NMOQ dN 52 92
328. M ROTATE TOGGLE SWITCH E BK 18 759 PLATFORM LEVEL TOGGLE SWITCH BRN Li BRN BRN BRN L F18 FUSE 10A ig 7514 DRIVE SPEED TOGGLE SWITCH T T N WORKLIGHT ONLY RS 7515 DRIVE ENABLE TOGGLE SWITCH m olo ig 1547 GENERATOR TOGGLE SWITCH OPTION Dept 1818 id TS48 DRIVE LIGHT WORK LIGHT TOGGLE SWITCH OPTION ij w ar HE E 5 qm 5 2 Did 19 S o 5 EE gt gt i3 ux 5 12 ia sie 2 2 m im 2o 2522 Ido lt m m mim Dig 23 img 2 N 1010 1 zs jS z 19 0 5 2 55508 2 6 ER ME ig 2 522555 1 T o 7 Oy om 8 2 B 80 8 3 12 g 884 888585 58 U UU 5 59 gt 1O 0 ID e A 0 0 2 2 o 2 c o Im o 9 gt gt gt gt 2 o c D lt E 2 im gt 22 33 6 o 2 5 86 Io o Et 55 9s 2 2 2 2 2 2 o alo 915 3 o o o i 8 o 88 58 T a 1 5 I r old Q i n P 2 6 OS 7 r7 5 5 4 5 E Ig 9 i IN I WH WH 012 TS3 7 i FUEL SE
329. MEVEID ver PAZI Wid O CH ona 9 820 489 99 6S 6S 1 60 SST HM INO6SO Je eel e EE HOP IHM 11 86 69 x 2 oF NIOH Flo o4 255 2 5 5 820 12 dn old 8104 HOLVNYSLIV 12 9 2 52 NAH IVO V2 STH 6 820 8 ZWSI Ig HO 01240151055 2 Or 5 W008 2 822 1510 IHOSI Jp 65 5 1 820 41659 4 1 929 915759 1 810 915 59 951599 Je 9 1 93315 50 01 910 18 2015980 2 3348 HOIH SE Qd vSsrau 6 8LO SHSED 22 90 8 ve OF 8 810 8 2 6 3NION3 LYVLS Q Q4 12 810 915559 62 50 QH HM eee OT raum 9 810 QU HM MEM Jg o 9 910 Y9 HM AJY LED 0 12 52 HM GMAOED Jp 06 810 HM Sz HM UHISNGED 2 62 SOULS HOLOW BLO 5 1620 1 8 V11820 82 2 80 xg au x I 14 42 20 P 1561 08 5 1 810 20 QU HM 164920 HOLIMS 10 92 Qd Sram a 52 HOLIM
330. MOL 1 AWALIVE 9 s S s Qd INN HMdXDV v H G iA pue e EXC 2 4 Anuo 2 CH P la AvidHlHVIS 1 OL t O oa seujsnpu 3 5 amp 2 151 5 5 9 83 v 20 ii O WHY Tv GVOTHSAO WHOALVId EEL Coo 51 859 zc QH 5 lt 21 810 5 20 O 3385 LAN Qa z t 860 m NuH9rH SHINE Qs QH d 4 820 21 99 8 5 7 ms vet Q GH 5 5 Jp 228095138 UMdPEId Ha HM Gavel vel 0 5 WI QVO1 PEL ZISTQH 9 22 UMdPELd 65 1 O CH 280 SST HE TE 8 2652 O 2 9v 5 GO m SING HOIVNH3LETV 250 8 40 QNONu8 820 X8 HO Wd Y9 ov 5 W008 ov 2 010 161070 2 82
331. ND 5 BOOM C37 1 C372 16 2 9 RETRACT 1 em g 8 IM BOOM RETRACT x lt lt ci7 1 0172 Lee oe 4 o 1 a 29 E BRN 9 42 E pge CHB8LSROR RD C4B4 OR RD C38 3 BK WH C384 LS17 BOOM UP DOWN P24FS WH d SPEED REDUCTION LIMIT SWITCH 2 m 2 m m 2 P24FS WH ae 5 tj qm 422 Erg C13DE C4B 1 _ BL RD C91 BK WH co2 d LS3 DRIVE ENABLE LIMIT SWITCH stus P26ESTP BK ex gt gt N S 8 C2P 2 E lt WH BK Ctt4 LS1 PRIMARY BOOM EXTEND 5 sti DRIVE LIMIT SWITCH 9 J1 EH WH BK 10 2 LS2 PRIMARY BOOM ave DRIVE LIMIT SWITCH 9 PR esse C40LS OR C2B 2 _ OR EU 8 1 No so NS age m 9 P22LS BK 11 BL BK 11 BUBK 5 o BK 37 3 BK 9 2 0374 gt LS5 CABLE TENSION LED 8 E P134 RD ln RD RD C382 1 LS17 BOOMUP DOWN a Va a SPEED REDUCTION LIMIT SWITCH 2 2 CI4PLUOR 2 UP ZI ATENOM LEVEL C4P 3 CIBPLD OR BK 4 3 B gt S C20 1 20 2 o 8 Al PLATFORM LEVEL UP n PLATFROM LEVEL DOWN GISREDONIBIC PLATFORM LEVEL DOWN 5 021 1 C212 5 4 6 C18JD PRR GR BK 4 6 2111 CENSUM PLATFROM ROTATE t LEFT C17JU PRL
332. Not calibrated direction frozen at Calibrate joystick zero and neutral 18 Just calibrated Initiate 1 second beep Self clearing of alarm transient 53 Drive flow valve Limited speed and EDC 12 Val direction frozen at Power up alue too high zero and neutral controller with 15 Value too low Al arm sounds problem corrected indicating fault Normal function Calibrate valve except threshold for thresholds or both directions Self clearing is zero transient 54 Drive brake valve Limited speed and direction frozen at Power up 21 Fault zero and neutral controller with Alarm sounds problem corrected indicating fault High rive Motor speed frozen in 95 d the low Alarm Power up 21 Fault aise controller with sounds indicating fault problem corrected 61 Steer joystick 11 Value at 5V Limited speed and 12 Value too high direction frozen at Power up 15 Value too low zero and neutral controller with 16 Value at OV Alarm sounds problem corrected indicating fault Joystick speed and 17 Not calibrated direction frozen at Calibrate joystick zero and neutral 18 Just calibrated Initiate 1 second beep Self clearing of alarm transient 62 Steer directional Limited speed and valves direction frozen at Power up 21 Fault zero and neutral controller with Alarm sounds problem corrected indicating fault Part No 77828 Genie hec 5
333. OAD SENSE LIMIT SWITCH DESCRIPTION TILT ALARM ITEM H1 7 C9 C1P C4P 48 PIN CONNECTOR BLOCK U13 J1 J2 CR27 CR30 LS18 July 2005 Platform Control Box Wiring Diagram S 60 Section 6 Schematics Deutz F3L 2011 Models CWLITE WH TS49 PLATFORM CONTROL HARNESS TO SWITCH PANEL C19JSV GR WH 57 C19JSV GR WH 4 7 BRN JC3 BRN GND RD E STOP 3 C134PWR RD LS18 C134PWR RD H1 CR27 RDLSI8CABLE ____________ C32BRK WH RD C1P 6 CE CR30 EN CAMOLSORO2P 2 a ee C40LS OR J2 4 P24FS WH C9P 2 BK C1P 12 P23BAT WH C7P 2 P22BAT BK C7P 1 C19JSV GR WH 7 C18PRR GR BK C4P 6 7 5 C15PLD OR BK C4P 3 C14PLU OR 2 C129JDA C3P 10 758 C46HRN GR C2P 5 L C59CHK BL BK C3P 11 147 C59CNK BL BK C3P 11 P26BAT BK C9 1 P2 P25FS RD C9 3 TS2 P24FS WH C9 2 TS4 CDLITE OR RD C2P 4 3 ES C45GEN GR WH C2P 7 C46HRN GR C2P 5 C9 P26ESTP BK WH RD C1P 6 C118LSR OR RD C4P 4 C6TRF WH RD C3P 6 e e J3 C8PBR BK WH C3P 8 C16DRE BURD 1
334. OM UP DRIVE LIMIT SWITCH C40LS OR C2B 2 _ x 1 a T no 1 so kape Mass EEE 9 2215 11 C3B 11 BL BK amp 5 BK 37 3 BK 9 2 WH _ 3 4 LS5 CABLE TENSION LED eves x 5 m o P134 RD F rD B vis 1517 UP DOWN a XS SPEED REDUCTION LIMIT SWITCH 8 2 CI4PLU OR C4B 2 n E 529 Dow C15PLD OR BK C4B 3 t gt _ J C204 20 2 8 T CISPEUOR A PLATFORM LEVEL UP PLATFROM LEVEL t DOWN i ETSFEDIORBIE 4 PLATFORM LEVEL DOWN E 8 21 1 21 2 a 5 C4P 6 gt C18JD PRR GR BK lt C4B 6 i pe _ gi ATFROM ROTATE t LEFT C17JU PRL GR C4B 5 C4P 5 z B C284 C23 2 is i C18JD PRR GR BK 11 PLATFORM ROTATE RIGHT Ld RIGHT PLATFROM ROTATE LLEFT CITJU PRL GR 11 PLATFORM ROTATE LEFT i C22 1 22 2 i C124 RDVEK DESCENT ALARM OPTION lt 1 Bx x a s ERIS 85558 x ala 41826 amp cc 5 enie A TEREX COMPANY S 60 5 65 G 6 44 Part No 77828 July 2005 Section 6 Schematics A Electrical Schematic S 60 CE Models Deutz F3L 2011 Models before se
335. OR C3B 12 12 C133PLA S a 2 a n C46HRN GR gt 5 tu C2P 5 z C46HRN GR b HORN RELAY B GR BK 4 P22BAT BK C7B 1 g r P22BAT Y eem 1 1 1B 12 s C1S2PLIBLWH Ss i s z Vwi 8 P134FB WH FLASHING BEACONS 2 6 1 4 GR BK 2 6 4 5 Al ie OPTION gt gt NER 5 RD i M e 4 Pr tr o oz p 2 R21IGNWH C amp 4 7 HYDRAULIC TEMPERATURE A z c swircH OPTION NU P116HYD RD 8 18 a8 5 5 4 42 4 edt OPTION x 63 5 C41RPM OR BK C2B 3 C41RPM OR BK 5 2 N C21IGN WH 5 21 8 8 a a 3 gt 8 50 i 524 024 a als 0 lt 53 8 a RD C7B 4 P20BATRD i i a amp a T a N e Part No 77828 gt AND PLATFORM OVERLOAD OPTION ONLY NOTES enie A TEREX COMPANY 5 60 5 65 G 6 75 Section 6 Schematics July 2005 Electrical Schematic S 60 Perkins 404 22 Models before serial number 11880 REVC
336. OUT FUEL LOCKOFF FUEL PUMP RELAY CONTROL TPS1 TPS2 DBW DBW OIL PRESSURE TACH MIL AUX PD2 AUX OUT 1 FUEL SELECT AUX ANA PU2 GOV SELECT GASEOUS TRIM CAN CAN RS 232 TX RS 232 RX COIL1 3 4 5 6 7 INJ 8 AUX OUT 3 July 2005 Section Schematics GM 3 0L Engine Wire Harness gt THESE CONNECTORS ARE CONNECTED GENIE HARNESS 88833 Part No 77828 Genie A TWR ORANGE BLUE 16 n 1 BROWN BLUE 16 BROWN GREEN 16
337. OX BOOM UP DOWN TURNTABLE ROTATE JC1 BOOM PROPORTIONAL JOYSTICK BOOM EXTEND RETRACT JC3 DRIVE STEER PROPORTIONAL JOYSTICK 11 DRIVE ENABLE LED 14 PLATFORM OVERLOAD LED 147 LOWER RETRACT BOOM LED SD L48 BOOM TILTED LED 2 JC3 P2 EMERGENCY STOP BUTTON DRIVE SWITCH 1 TER 7 TS2 ENGINE START TOGGLE SWITCH LEFT RIGHT m TS3 FUEL SELECT TOGGLE SWITCH ES TS4 HI LOW RPM TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB BOOM UP DOWN TOGGLE SWITCH TS9 PLATFORM LEVEL TOGGLE SWITCH 514 DRIVE SPEED TOGGLE SWITCH 3 TS15 DRIVE ENABLE TOGGLE SWITCH TS47 GENERATOR TOGGLE SWITCH OPTION TS48 DRIVE LIGHT WORK LIGHT TOGGLE SWITCH OPTION BRN BRN BRN BRN CUTOUT TS48 DRIVE LIGHTS WORK LIGHTS OPTION i JC2 BOOM UP DOWN 7 JC1 7 amp TURNTABLE ROTATE LEFT RIGHT EXTEND RETRACT 515 L48 6 6 ENABLE 1 1 Y TILT ALARM LED 5 5 1 1 8 4 1214 14 3 3 PLATFORM OVERLOAD 2 2 CE OPTION DRIVE o ENABLE 1 1 CR13 H JIB BOOM i 9 E Ko Ik e 1B i 17 2 d m IB 19 c iv w 2 122
338. P26BAT BK J3 3 P23BAT WH C7P 2 6 74 enie A TEREX COMPANY S 60 5 65 G BL J1 5 ROCKER SWITCH OPTION ONLY P26BAT BK C9 1 RD H1 C134PWR L48 1 2 2 OR J1 13 C134PWR RD L4 BRN J1 14 BK BK TS15 1 RD PDLITE RD C45GEN GR WH C2P 7 5 2 556 55 64 28 x 8 B E Cy E 5 al gt g 5 ls RD P24FS WH C9 2 9 aoe siete Gas Mee cerro C35HS BK RD C1P 9 4 5 5 2 n C133PLA GR BK D39 a saz Weg NE 288 5 7 lt 225 E tan Sb 475 i 238 lt x o 52 2 ______ CT84PWR RD E STOP_ gi EX ee eed _ 134 5 C33STR 7 RD azi 2 lt P25FS RD C9 3 For BL RD DE3 J1 16 2 Es _ 258 3
339. PLU OR C4P 2 C129JDA BL C3P 10 TS8 C59CHK BL BK C3P 11 147 59 BL BK C3P 11 P26BAT BK 9 1 P2 RDESI8 CABLE 0 gt 3 m S P25FS RD C9 3 TS2 C46HRN GR C2P 5 T P24FS WH 9 2 54 ly CDLITE OR RD C2P 4 C45GEN GR WH 2 7 C46HRN GR C2P 5 C39LP BURD C2P 1 P26ESTP BK e e J3 6 WH RD C1P C118LSR OR RD C4P 4 C6TRF WH RD C3P 6 C8PBR BK WH 8 24FS WH 24FS WH C16DRE BL RD 1 C7PBE BK C3P 7 401 55 OR C2P 2 C9PER BK RD C3P 9 C41RPM OR BK C2P 3 C30FWD WH C1P 4 U13 ALC 500 C1PBU RD C3P 1 WH BK C1P 5 C2PBD RD BK C3P 2 C3P C36STCC BL 10 RD WH C3P 3 C37STC BUBK C1P 11 C5TRR WH BK 5 C32BRK WH RD C1P 6 WH C3P 4 NEUE m un COR C29MS RD WH C1P 3 J2 C35RPM BK RD C1P 9 C33STR BK C1P 7 C27AUX RD 1 1 JC1 3 OR J1 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 JC3 2 BRN TS15 BL WH C28TTA RD BK
340. PRIMARY BOOM C2PBD RD BK IA 2 T PRIMARY BOOM DOWN x 13 1 0132 lt 3 ES E s ES 18 your 2 Je PRIMARY BOOM FLOW CONTROL C29 1 C29 2 SE Rune RD C3B 1 pl OR 5 6 E Pwr 8 11 amp 2c BAN 512 2 C2PBD RD BK C3B 2 5 15 EZS lt 3 RD WH C3B 3 8 2 m C3P 9 C9PER BK RD C3B 9 C9PER BK RD 0304 _ 0392 PRIMARY BOOM EXTEND RETRACT EX FLOW CONTROL ee 2 3 8 C8PBR BK WH lt 638 i 1 face 7 C7PBE BK C3B 7 ag LS5 CABLE TENSION LIMIT SWITCH E YEL oute gt s T RD 5 X C7PBE BK ni Sk lt EXTEND BOOM EXTEND ME ES 5 BOOM 37 1 037 2 C16 1 16 2 28 3 8 11 RETRACT BRN lt C055 to 2 E 22 gt BOOM RETRACT e x E 5 8 0 uo BANS 42 N 21 P4 CH8LSR OR RD C4B 4 OR RD 38 3 WH C384 LS17 BOOM UP DOWN sti SPEED REDUCTION LIMIT SWITCH P24FSWH gt gt 5 200 P24FS WH B Lj sas s c BL RD C4B 1 BURD 9 WH 09 2 LS3 DRIVE ENABLE LIMIT SWITCH 2 P26ESTP 5 gt 31 599 9 4 lt Ein vw BK LS1 PRIMARY BOOM EXTEND 5 SUE DRIVE LIMIT SWITCH J1 EH WH C104 BK Z wW 10 2 LS2
341. PRIMARY BOOM UP a UE DRIVE LIMIT SWITCH 99 peer Rees C40LS OR C2B 2 _ T x 5 1 x 1 1 T 3 892 89 1 1 9 215 212223 2215 1 P 1 59 BL BK C3B 11 A 3 5 BK 037 3 4 2 WH 037 4 3 gt LS5 CABLE TENSION LED oe 8 5 5 m P134 RD RD C381 5 RD G BR 8382 _ 5 LS17 BOOM UP DOWN amp NN a SPEED REDUCTION LIMIT SWITCH 2 Sy _ OR lt RGO E FUP PLATFROM LEVEL 5 t DOWN 3 C15PLD C4B 3 20 1 20 2 8 c oe i CIAPEULOR Inl PLATFORM LEVEL UP PLATFROM LEVEL t DOWN CISPEDIOFUBIS 1 PLATFORM LEVEL DOWN x 2 2 E C214 21 2 26 8 10 C129JDA BL C3B 10 52 9 4 6 C18JD PRR GR BK C4B 6 DOWN tre JIB ERN C17JU PRL GR C4B 5 CIE 1 c231 C232 Bil 8 a i CTEJD PHR GRIBK gt PLATFORM ROTATE RIGHT P 1 PLATFROM g LEFT ROTATE C17JU PRL GR D PLATFORM C223 C222 RIGHT PLATFROM g LEFT ROTATE 2 129 RD BK E 1 DESCENTALARM OPTION _ C4P 7 C19JSV GR WH C4B 7 1 Pr Ss DISISVORMWH 0 Tar o E a A JIB VALVE 58 JIB VALVE amp
342. Remove the Boom 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 Lift Cylinder cylinder just enough until the rod end of the n cylinder will clear the mounting bracket on the AWARNING 9 lt 1 injury hazard This boom Turn the machine off procedure requires specific repair skills lifting equipment and a 6 Tag disconnect and plug the boom lift cylinder suitable workshop Attempting this hydraulic hoses Cap the fittings on the cylinder procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose 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 Remove the pin retaining fasteners from the boom lift cylinder barrel end pivot pins Do not remove the pins and Fitting Torque Specifications 8 Use slide hammer to remove the barrel end 1 Raise the boom to a horizontal position 2 Attach a 5 ton 5000 kg overhead crane to the boom at the platform end
343. Repair Procedures July 2005 PLATFORM CONTROLS 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 Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Pushin the platform controls red Emergency Stop button to the off position 4 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 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle Switch in the right direction 4 times Result There should be a pause and the alarm should sound 4 times indicating that the machine is in max out calibration mode 4 4 5 60 5 65 REVA 8 Start the engine from the platform controls and press down the foot switch 9 Start a and activate the machine function that needs to be adjusted Record the t
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346. S 60 S 65 G Part No 77828 6 91 Section 6 Schematics Perkins 404 22 Models after serial number 11879 Ground Control Box Switch Panel Wiring Diagram S 65 July 2005 REVA 6 92 enie A TEREX COMPANY S 60 5 65 G Part No 77828 a 5 gt 8 a x 5 5 5 5 5 52226 5454 lt 5 ESI Bla 5 509 2 21 9 0 0 0 ol ale salola 2 6 285 25853 5 lt oouu oa 9 5 amp du Jets lt lt lt amp 25 gt 92 2 gt Sle QO GOES 9 7 2 gt 5 5 la 5 Els
347. S RD WH 3 A I C3P GR C35RPM BK RD 9 n i C33STR BK 7 l C27AUX RD C1P 1 gt gt I JC1 3 OR le JC2 4 RD 5 1 JC1 2 BRN 9 p 22 C1P GY JC2 3 OR le 5 x i JC1 5 YEL 1 JC2 2 BRN le f JC3 5 WH zu wee JC3 3 OR le i JC3 4 BL grg JC3 2 BRN le TS15 BUWH 28 RD BK 1 2 4 TS15 BUBK DRE LED le q 7514 RD WH A 5 x 5 2 lt 2 1 GR BK C133TTA 12 GR BK L4 CE 4 2 e i i en a RD BK L48 NON CE 2 C134PWR RD C2P 6 C134PWR RD 1518 RD TILT i CWLITE BK gt 2 m D tee ea X BRN BRN Part No 77828 19 18 CONTROL CABLE enie A TEREX COMPANY 5 60 5 65 G TILT H1 ALARM CWLITE WH TS49 6 27 July 2005 Section 6 Schematics EE REV A Platform Control Box Switch Panel Wiring Diagram S 60 Ford LRG 425 EFI Models N M L K J H G D
348. SI HM cam avi 2 nes a gt 9 HM 2 O WdH HOIH a cl 2 55 5 98 Srg 22 1 84 HM du 8 3 DE NU Nua 1HVIS NOLLINOI L Part No 77828 enie A TEREX COMPANY S 60 5 65 G 6 65 Section 6 Schematics Ground Control Box Switch Panel Wiring Diagram S 65 July 2005 6 66 REV B A TEREX COMPANY S 60 5 65 G Part No 77828 O N T 5 lt 5 zz lt gt or o9 oo t 489111 920 Uu 10 0 2125 0 21515010 MEI 2 22 S 5S 5 u aus 5 255 28555458 26 26 5 2 24544 5 8955554288986 m n c m Bas 8 15 58 5 gt E m lt
349. SSS SS Sy MANIFOLDS 7 8 July 2005 REV D Traction Manifold Components 2WD The traction manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Relief valve 280 psi 19 3 bar gu Charge pressure 30 35 ft lbs 41 47 Nm 2 Flow divider combiner valve WW Controls flow to drive motors in forward and reverse 90 100 ft Ibs 122 136 Nm Check 59 Drive 30 35 ft lbs 41 47 Nm Check Drive 00 30 35 ft lbs 41 47 Nm 5 Shuttle valve position way UU us Charge pressure circuit that directs hot oil out of low pressure side of drive pump 50 55 ft lbs 68 75 Nm 6 Orifice 0 070 inch 1 78 mm Drive motor circuit 4 48 S 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV D MANIFOLDS 5 3 Genie Part No 77828 5 60 5 65 4 49 Section 4 Repair Procedures B XM SSS Ty MANIFOLDS 7 9 Valve Adjustments 2WD Traction Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect 0 to 600 psi to 50 bar pressure gaug
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351. T TOGGLE SWITCH OPTION P2 EMERGENCY STOP A TEREX COMPANY 6 12 July 2005 Section 6 Schematics E Platform Control Box Switch Panel Wiring Diagram S 60 GM 3 0L Models C28TTA RD BK C28TTA RD BK July 2005 Electrical Schematic S 65 Section 6 Schematics GM 3 0L Models I Q m 4 515 a a 9 poe C35RPM BK RD C1B 9 FOOTSW HIGH e e 9 FOOTSW LOW za 50 8 Pas 1 8 LOW RPM 218 e FUNCTION ENABLE 5 8 9 HIGH RPM oe ve ee ee ee i 1 GENERATOR 5 ON C2P 7 C45GEN GR WH C2B 7 2 05 12 GR WH A GENERATOR OPTION 15 E owe SSS 2 a 2 6 DLITE GR BK C2B 6 o S DRIVE LIGHT LIGHTS WORK LIGHT 64842 DRIVE LIGHT OPTION ES 1 1 ala 8 5
352. Turntable Bearing and Rotate Gear 5 Check the Lug Nut Torque including tires and wheels e 7 Check the Oil Level in the Drive Hubs 1 Perform Engine Maintenance Deutz Models e 0 2 Check the Turnable Rotation Bearing Bolts e 0 6 Replace the Hydraulic Filters Part No 77828 July 2005 Section Scheduled Maintenance Procedures REV CHECKLIST A PROCEDURES A 9 A 10 Perform Engine Maintenance GM Ford and Perkins Models 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 orthe Perkins 400 Series Operation Manual Perkins part number TPD 14435 GM 3 0L Operator Handbook Inspect the Fuel Filter Water Separator Diesel Models Engine specifications require that this procedure be performed every 100 hours Proper maintenance of the fuel filter water separator is ess
353. U OR 1 1 PLATFORM LEVEL UP PLATFROM LEVEL t DOWN EISBEDIOR BK D PLATFORM LEVEL DOWN E B C21 1 C21 2 a 5 6 C18JD PRR GR BK 4 6 E FRIGHT PLATFROM ROTATE t LEFT C17JU PRL GR C4B 5 A 5 4 5 8 11 5 C18JD PRR GR BK 3 pE lt lt gt gt PLATFORM ROTATE RIGHT f LRIGHT pLATFROM ___ C17JU PRL GR Al PLATFORM ROTATE LEFT C224 C222 B EE eee ee DESCENT ALARM 2 12625 42 27 251225251707 1 xim gol un I a x E mu 2 2454 22 5 enie A TEREX COMPANY S 60 S 65 G 6 22 77828 July 2005 Section 6 Schematics Electrical Schematic 5 60 Ford LRG 425 EFI Models after serial number 11879 Section 6 Schematics July 2005 __________________ Ground Control Box Terminal Strip Wiring Diagram 5 60 Ford LRG 425 EFI Models before serial number 11880 REVA July 2005 Ground Control Box Terminal Strip Wiring Diagram S 60 Ford LRG 425 EFI Models before serial number 11880 Section 6 Schematics 859 2161 267 257 69 FUNCTIONS HARNESS Ei ENGINE C5 H3MOd 661 220 HOLIMS NOISNAL gqigavo 157 HOLIMS woog 29819 Z 64 84 vO
354. VD N 10 C7P 8 BATGND 783 Grounp gt E lt lt eoa C41RPM OR BK C2B 3 5 9 m i rece C30FWD WH C1B 4 5 21 C30FWD WH BK AD SANE FORWARD 8 18 25 1 5 WH BK C1B 5 5 20 WH BK RD p BK DRIVE REVERSE n 5 4 4 DRIVE MODE C130TA WH RD TRAVEL ALARM gt gt 81 1 OPTION 5 E PY a 8 26 2 g 19 lt C32BRK WH RD C1B 6 Fd 60522 C32BRK WH RD 44 BRAKE RELEASE gt 8 3 6992 5 T EX 2 29 5 RD WH 29 5 RD WH 9 amp C29MS RD W C1B 3 524 29 5 MOTOR STROKE r E OE 5 z CDESBURD 5 5 5 025 2 su 0 CDE2BUBK C37SCW BL BK C1B 11 C37SCW D STER PIBHT CLEFT 2 ES 10 C36STCC BL 10 C36SCC BL Bi 2x lt lt 2 qM 4 STEERLEFT 629 BL WH 0 0 amp C24 2 as j 6 lt nae 6 C6TRF WH RD lt lt C3B 6 o 4 8i BL 55 107 4 CATRL WH C3B 4 C4TRL WH 6 TURNTABLE ROTATE LEFT
355. VEL UP PLATFROM LEVEL t DOWN i 15 I PLATFORM LEVEL DOWN 5 C213 C212 a 5 6 C18JD PRR GR BK C4B 1 PLATFROM ROTATE t LEFT C17JU PRL GR C4B 5 5 E C28 1 023 2 8 2 CIs DEE GRIBIS Al PLATFORM ROTATE RIGHT RIGHT PLATFROM 1 ELLE LEFT ROTATE C17JU PRL GR IA BOTATE TERT 221 C222 1 MCCC E i E RD BK 4 DESCENT ALARM OPTION 1 e 1 x x amp ala 5268 a a enie A TEREX COMPANY S 60 S 65 G Part No 77828 July 2005 Section 6 Schematics Electrical Schematic S 60 GM 3 0L Models Section 6 Schematics July 2005 5 Ground Control Box Terminal Strip Wiring Diagram 5 60 GM 3 0L Models REV B July 2005 Ground Control Box Terminal Strip Wiring Diagram S 60 Section 6 Schematics GM 3 0L Models E
356. W PLUG TOGGLE SWITCH m T TS7 PLATFORM ROTATE TOGGLE SWITCH bog 1 3 3 PLATFORM 3 TS9 PLATFORM LEVEL TOGGLE SWITCH bg OVERLOAD TS14 DRIVE SPEED TOGGLE SWITCH 1 CEOPTION TS15 DRIVE ENABLE TOGGLE SWITCH 2 E 2 DAVE 2 TS47 GENERATOR TOGGLE SWITCH OPTION s bog ENABLE 7548 DRIVE LIGHT WORK LIGHT TOGGLE SWITCH OPTION 4 2 1 2 1 1 A 4 1 ge Q bd bd 19 BRN bg 5 bd bg ii pod bog Fo 5 11 BK Ld BRN Dd BRN BRN BRN it F18 E EN FUSE 10A D 5 E PM Nu WORKLIGHT ONLY E amp lo 8 5 5 2 b 15 Y 9 imi m im 101 5 m a 212 5 BK a Siz 0 58 D 2 Blo BRE 2 b gi 2 9 2 9 EIN 1918 zo m m 9 im Im 2 2 O lt 5 lt 0 1 IN I r 1 ys E m go 5 iJ 550510 J o 019 LI 2 AIR IB io i 1 i o o v o 2 7 91 34 2 b 3 KE R 5 g 5 E S 8 mim 2 225545 55 6 o 2 e 5 AX o8 225 2 2 2 2 9 o Blo g Q Q 2 I o eS 8 2 5 A 5
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358. Y STOP BUTTON 5 1 5 m HORN SWITCH 21 A 1 2 TS AUXILIARY TOGGLE SWITCH i 4 4 i 4 52 ENGINE START TOGGLE SWITCH bd TS4 HI LOW RPM TOGGLE SWITCH pi 14 i TS6 GLOW PLUG TOGGLE SWITCH 3 BRN E 3 PLATFORM 3 TS7 PLATFORM ROTATE TOGGLE SWITCH bg OVERLOAD TS8 JIB BOOM UP DOWN TOGGLE SWITCH CEOPTION TS9 PLATFORM LEVEL TOGGLE SWITCH N 2 B 2 2 BRN DRIVE TS14 DRIVE SPEED TOGGLE SWITCH ENABLE gt SR TS15 DRIVE ENABLE TOGGLE SWITCH D 1 1 1 2 1 1 N 1 TS47 GENERATOR TOGGLE SWITCH OPTION er CR13 19 bd la TS48 DRIVE LIGHT WORK LIGHT TOGGLE SWITCH OPTION em JIB BOOM 6 im BOOM 2 E it CUTOUT BRN id ig 1 Lj Rm 5 i x BK p il BRN BRN BRN BRN F18 E T T T 1 E FUSE 10 E 5 pd ois bg WORKLIGHT ONLY 2 ie Has io IE 2 IET UU 190 1 0 1 IE w 1019 1 5 5 3 S BK 1 iS E w 9 1D D 5 5 DE 2 b z Z g9 5 1915 zo lt m m BG IB 5 6 24 N 10 10 1 A 1 Slo IN I alc c c 1 iE E 5 im lokalis D A o 910 6 1 1 1 1 Q
359. a s en lt 24 8 a RD 4 C7B 4 P20BAT RD 1 11 a amp T N e 10 N gt AND PLATFORM OVERLOAD OPTION ONLY NOTES enie A TEREX COMPANY S 60 5 65 G Part No 77828 6 45 Section 6 Schematics Electrical Schematic S 60 CE Models Deutz F3L 2011 Models before serial number 11879 July 2005 gt ROCKER STEER OPTION ONLY P22LS BK REVA N N C7P 3 BATGND C7B 3 GROUND 2 C2P 3 C41RPM OR BK C2B 3 5 lt 5 9 m B a C30FWD WH 1 4 C5 21 C30FWD WH BK 82 4 DRIVE FORWARD 15 235 1 5 C31REV WH BK C1B 5 65 20 C3IREVWH BK _ RD p BK DRIVE REVERSE e lt 4 2 gl
360. ad indicator light and alarm turn on There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds The platform will need to be moved up and down and allowed to settle in between adjustments Part No 77828 July 2005 Section Scheduled Maintenance Procedures REV D CHECKLIST D PROCEDURES Confirm the setting 5 Turn the key switch to platform control Start the engine from the platform controls 6 Lift the test weight off the platform floor using suitable lifting device 7 Place the test weight back onto the center of the platform floor using a suitable lifting device Result The alarm should be off The platform overload indicator light should be off at both the ground and platform controls There may be an approximate 2 second delay before the overload indicator light and alarm turn off 8 Add an additional 10 Ib 4 5 kg test weight to the original test weight to overload the platform Result The alarm should be sounding The platform overload indicator light should be flashing at both the ground and platform controls There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds 9 all machine functions from the platform controls Result All platform control functions should not operate 10 Turn the key switch to ground control 11 Test all machine functions from the gro
361. ailable 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 GM 3 0L Operator Handbook Genie part number 101095 Ford LRG 425 EFI Operator Handbook Genie part number 84792 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 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 July 2005 Section 3 Scheduled Maintenance Procedures 5 Perform Engine Maintenance Perkins Models 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 Perkins 400 Series Operation Manual Perkins part number TPD 1443S Perkins 400 Series Operation Manual Genie part number 94890 To acce
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363. al Strip Wiring Diagram S 65 Deutz F3L 201 1 Models after serial number 11879 REVA July 2005 Ground Control Box Terminal Strip Wiring Diagram S 65 Deutz F3L 201 1 Models after serial number 11879 Section 6 Schematics 48098 LYVLS NOLINDI HOA 72 21 dWAL OL 0L 880 4181 UO NOI 8 260291 e 25 9 2 01 0000000 O Geti MS A
364. ar Turntable rotate circuit This list continues Please turn the page Genie REV D Torque 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 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 4 36 S 60 5 65 77828 Section 4 Repair Procedures July 2005 MANIFOLDS REV D 8 0 0 0 4 9 9 G X COMPA 5 60 5 65 TERES 37 PartNo 77828 Section 4 Repair Procedures I X M Sy MANIFOLDS Function Manifold Components continued July 2005 REVD Index Schematic No Description Item Function Torque 19 Check valve 5 psi 0 3 bar Blocks flow from auxiliary pump to function pump 30 35 ft lbs 41 47 Nm 20 Relief valve 3000 psi 206 8 bar System relief 30 35 ft lbs 41 47 Nm 21 Flow control val
365. arefully remove the pump Models with hydraulic tank shut off valves CAUTION Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Models without hydraulic tank shut off valves CAUTION Component damage hazard Be sure to fill the hydraulic tank to specification and prime the pump after installing the pump S 60 5 65 77828 July 2005 Section 4 Repair Procedures REV 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 CAUTION 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the ele
366. aster 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 Place a 2 x 4 48 inches 5 x 10 x 120 cm block of wood across the turntable covers Position the block under the master cylinder 4 Remove the pin retaining fastener from the master cylinder rod end pivot pin 5 Place a rod through the rod end pivot pin twist to remove the pin Lower the rod end of the master cylinder onto the block 6 Remove the pin retaining fastener from the barrel end pivot pin 7 Place a rod through the barrel end pivot pin and twist to remove the pin 8 Remove the master cylinder from the machine Section 4 Repair Procedures July 2005 Engines 5 1 RPM Adjustment Deutz Models Refer to Maintenance Procedure B 8 Check and Adjust the Engine RPM Deutz Models 5 2 RPM Adjustment Perkins Models Refer to Maintenance Procedure A 12 Check and Adjust the Engine RPM Perkins Models 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 pump pump shaft pump coupler flex plate with raised spline engine flywheel 0 18 inch 11 mm gap Diesel Models 0 15 inch 3 8 mm
367. at there are no leaks Seal Lok Fittings tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft lbs 21 7 Nm 4 18 ft lbs 24 4 Nm 6 35 ft lbs 47 5 Nm 6 27 ft lbs 36 6 Nm 8 60 ft lbs 81 3 Nm 8 40 ft lbs 54 2 Nm 10 105 ft lbs 142 4 Nm 10 63 ft lbs 85 4 Nm 12 140 ft lbs 190 Nm 12 90 ft lbs 122 Nm 16 210 ft lbs 284 7 Nm 16 120 ft lbs 162 7 Nm 20 260 ft lbs 352 5 Nm 20 140 ft Ibs 190 Nm 24 315 ft lbs 427 1 Nm 24 165 ft lbs 223 7 Nm Part No 77828 5 60 5 65 2 9 Section 2 Specifications July 2005 SPECIFICATIONS REVA SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade Black Oxide Bolts LUBED DRY LUBED in Ibs in Ibs Nm 100 11 3 80 9 130 14 7 10 1 120 120 LUBED DRY LUBED DRY LUBED Nm Nm is Nm 76 17 18 191719 20 312 33 35 I 23 352 37 50 55 813 eo 1084 68 91 80 85 90 1211 90 122 120 730 EB 176 180 270 366 280 379 298 300 310 430 583 450 610 510 691 474 470 500 560 755 640 867 680 922 770 1044 78 710 750 1016 990 1342 840 1139 7 790 1071 970 1315 1090 1477 908 890 1080 1220 1654 7 1120 1518
368. ce the ECM enie A TEREX COMPANY S 60 S 65 Part No 77828 July 2005 Section 5 Fault Codes REVA FORD ENGINE FAULT CODES Code 315 Problem njector Driver 3 Open Cause Open wiring and or connections to fuel injector 3 OR fuel injector 3 is faulty OR ECM is faulty Solution Repair wiring and or connections to fuel injector 3 OR replace fuel injector 3 OR replace the ECM 316 njector Driver 3 Shorted Wiring and or connections to fuel injector 3 shorted OR fuel injector 3 is faulty OR ECM is faulty Repair wiring and or connections to fuel njector 3 OR replace fuel injector 3 OR replace the ECM 321 njector Driver 4 Open Open wiring and or connections to fuel injector 4 OR fuel injector 4 is faulty OR ECM is faulty Repair wiring and or connections to fuel njector 4 OR replace fuel injector 4 OR eplace the ECM njector Driver 4 Shorted 322 Wiring and or connections to fuel injector 4 shorted OR fuel injector 4 is faulty OR ECM is faulty Repair wiring and or connections to fuel njector 4 OR replace fuel injector 4 OR replace the ECM Fuel Pump Loop Open or High Side Short To Ground 351 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 replace fuel pump Fuel Pump High Side Shorted To Power 352
369. cedures July 2005 CHECKLIST A PROCEDURES A 7 Test the Oscillate Axle if equipped 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 Start the engine from the platform controls 2 Drive the right steer tire up a 6 inch 15 cm block or curb 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 If the chassis does not remain level during test see Repair Procedure 7 6 How to Set Up the Oscillate Directional Valve Genie 5 60 5 65 8 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 50 hours of usage whichever comes first After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures A 9 Perform Engine Maintenance GM Ford and Perkins Models A 12 Grease the
370. cheduled 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 performa scheduledinspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Six months or every 500 hours A B C Annual or every 1000 hours A B C D Two years or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years 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 t
371. chematic No Description Item Function Torque Check valve TT Steer end drive motor circuit 35 40 ft lbs 14 16 Nm 2 Check 59 Non steer end drive motor circuit 35 40 ft lbs 14 16 Nm Flow divider combiner valve AB Controls flow to flow divider combiner valves T1 and 19 ees 80 90 ft lbs 108 122 Nm Check VAVE AF Non steer end drive motor circuit 60 70 ft lbs 81 95 Nm Orifice 0 040 inch 1 Equalizes pressure both sides of flow divider combiner valve 3 6 Orifice 0 040 inch 1 Equalizes pressure on both sides of flow divider combiner valve 11 7 Orifice 0 040 inch 1 WW Equalizes pressure on both sides of flow divider combiner valve 13 Check AG Steer end drive motor circuit 60 70 ft lbs 81 95 Nm Check Valve eee hene 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 Controls flow to steer end drive
372. chematics gg 8 2 8 SE a p BK RD C1B 9 5 FOOTSW HIGH 9 2 QI FOOTSW LOW 20 LOW RPM x o 5 6 C UNCTIONENA 8 C35RPM BK RD BRN 7 HIGH IDLE RELAY 1 80 05 18 RPM SOLENOID o 5 Di De E a E E 4 2P 45GEN GR WH H 45 GR WH 12 3 C2P7 CASGENIGR MI Dor CASGEN 5 GENERATOR OPTION n MM 1 12 DLITE BWH C3B 12 i DRIVE LIGHT 2 work OTS 2 C DRIVE LIGHT OPTION 15 FUSE 10 8 an WORK LIGHTS OPTION 5 cap 2 2 10 a 1 ei ei ee e iE 1 x 2 C2P 11 q C2P 9 9 8 5 5 tr a 9 8 C34SA BK WH 6 C34SA BK WH 05 22 4 1 GLOW PLUG 0 00 ow lt gt ste GLOW PLUGS PLUG x m 000 7 2 500 2 C26TSR WH RD 0 COOLANT TEMPERATURE LED a 5 Ed 5 898 5 gt o 9 2o A 9 CiP 7 C33STRBK 7 Pai lobe gals 5 14 161 6 SE mg
373. crew 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 5 60 5 65 No 77828 Section 4 Repair Procedures July 2005 Jib Boom 3 1 6 Jib Boom 7 How to Remove the Jib Boom Perform this procedure with the 8 boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 9 1 Remove the platform Remove the platform mounting weldment 3 Remove the hose and cable cover from the side of the jib boom Components S 65 Attach a lifting strap from an overhead crane to the jib boom assembly Place blocks under the platform leveling cylinder for support Protect the cylinder rod from damage Remove the pin retaining fastener from the slave cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The jib boom could fall when the slave cylinder rod end pivot pin is removed if not properly attached to the overhead crane 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 j
374. ctional valve mechanically activated y 50 50 5 Flow divider combiner valve with pressure balancing orifice and flow percentages 2 H Nl Pilot operated 3 position 3 way shuttle valve Differential sensing valve Solenoid operated proportional valve Part No 77828 E Priority flow regulator valve ili T Solenoid operated 2 position 3 way directional valve 3000 206 8 31 Counterbalance valve with pressure and pilot ratio H H 14 09 2 2 solenoid valve gt Directional valve pilot operated 2 position 2 way Genie proportional directional valve d 2 position 3 way shuttle valve Needle valve X COMPANY 5 60 5 65 Section 6 Schematics July 2005 e SSS SSS Genie 6 4 S 60 5 65 Part No 77828 REVA N 211 PC 56 28 0 009 CONNECTOR 211 A56 7007 LOCKING CAM 211 56 0008 COVER 211 CC 28 1120 TERM ECM INJ 1 INJ 2 AUX OUT 2 AUX ANA PD1 MAP FPP ECT S AUX ANA PUT POWER GROUND POWER GROUND 5 VOLT REF vsw EGO1 KNK KNK CAM CRANK CRANK VBAT VBAT STARTER LOCK
375. ctrical connection at the electro proportional controller located on the drive pump PartNo 77828 Genie S 60 5 65 HYDRAULIC PUMPS 2 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 open closed Component damage hazard The CAUTION 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 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 3 Tag and 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 July 2005 e c LLL LLL ol HYDRAULIC PUMPS REVC 4 Supportthe pump with a lifting device and How to Prime the Pump remove the two drive pump mounting fasteners 1 Connect a 0 to 600 psi 0 to 50 bar pressure 5 Carefully pull the drive pump out until the pump gauge to the t
376. cylinders 4 Bore amp stroke 4 x 3 6 inches 101 6 x 91 44 mm Horsepower Intermittent 67 2300 rpm Continuous 60 2300 rpm Firing order 1 3 4 2 Low idle 1650 rpm High idle 2500 rpm 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 Oil viscosity requirements Below 0 17 8 C 5W 30 Above 0 17 8 10W 30 Only use engine oils labeled For Gasoline Engines by the American Petroleum Institute API 5 60 5 65 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 Size 13 x 613 16 x 93 8 inches 33 x 17 3 x 23 8 cm Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes 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 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 12mm Part No 77828 July 2005 Section 2
377. d s E WH 8 ae RD BK E 8 888 28 RD BK Z wa 1 B28 28 RD BK bas TILTAL RM go 322891 M P134TTSR RD RD a BRN pe asl Ye LEVEL SENSOR Si um C3B 12 lt SNC IS gt 1 12 C133PLA BL WH 27 GNEK UO 2 C2P 5 C46HRN GR C46HRN GR HORN RELAY 449 7 1 P22BAT 2 5 22 Y B HORN 5 o Pop C1P 12_ C132PLIBLWH 1 12 ez 5 5 8 P134FB WH FLASHING BEACONS 2 6 P134PWRGR BK 2 6 5 lt gt OPTION m ipu P 9 EPOR PPM ETERNI 5 4 RD N m q So 4 BK Hz a 4 2 RBIIGNWH 05 4 HYDRAULIC OIL TEMPERATURE 5 8 SWITCH OPTION x 81 5 E 56 58 R116 OR i COOLING FAN 5 eu Ad OPTION tx 5 C2B 3 x C41RPM OR BK 65 2 a Mese elle C21IGN WH Za d 2 1 11811 lt amp m mis u t 1 o TOT E alg RENT RM Y 54 8 5 C7B 4 P20BAT RD lt E a amp a N e Part No 77828 gt AND PLATFORM OVERLOAD OPTION ONLY
378. d Remove the rollers 4 Liftup the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Hoses CAUTION 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 CAUTION Component damage hazard Hoses and cables can be damaged if they are kinked or pinched Genie BOOM COMPONENTS 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 9 Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track PartNo 77828 5 60 5 65 4 17 Section 4 Repair Procedures e SSS Ty BOOM COMPONENTS 4 2 Boom July 2005 REV B CAUTION Componentdamage hazard How to Remove the Boom Consult the Genie Industries Service Department for instructions on how to safely remove the boom assembly from the machine Failure to read and follow the warnings listed below could result in death or serious injury AWARNING AWARNING AWARNING 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 i
379. dissipate gradually Do not allow oil to squirt or spray Section 4 Repair Procedures July 2005 BOOM COMPONENTS 21 Attach a lifting strap from a 5 ton 5000 kg overhead crane to lug at the rod end of the boom extension cylinder 22 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside the number 2 boom tube 23 Carefully support and slide the extension cylinder out of the boom Crushing hazard The extension AWARNING cylinder could fall when removed from the boom if not properly supported Component damage hazard Be careful not to damage the cable break limit switch CAUTION Component damage hazard Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the boom CAUTION During removal of the extension cylinder the overhead crane strap will need to be carefully adjusted for proper balancing S 60 5 65 REV B 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 Perform this proc
380. draulic Filters Genie requires that this procedure be performed yearly or every 1000 hours 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 ACAUTION oil Contact with hot oil may cause severe burns Perform this procedure with the engine off Hydraulic return filter 1 Open the ground controls side turntable cover and locate the hydraulic return filter housing on top of the hydraulic tank Remove the cap from the filter housing 3 Lift the handle on the filter element and rotate the element counterclockwise to release the element from the housing 4 Remove the filter element from the filter housing Part No 77828 Genie 5 60 5 65 CHECKLIST D PROCEDURES 5 Install the new filter element into the filter housing 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 filter housing Medium and high pressure filters
381. dures 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 REVD E 3 Perform Engine Maintenance Deutz Models 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 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 5 60 5 65 To access the engine 1 Remove the engine tray retaining fastener located under the engine tray Swing
382. e psi of lowest cylinder must 1 bar be within 50 psi 3 45 bar of highest cylinder Fuel injection system Governor centrifugal mechanical Injection pump make Zexel Valve clearance cold Injection pressure 2133 psi Intake 0 008 in 147 bar temm Fuel requirement 2 Diesel Exhaust 2 Alternator output 55A 12V DC Fan belt deflection 3 8 in 10 mm Starter motor Current draw no load 90A Brush length new 0 7480 in 19mm Brush length minimum 0 5 in 12 7 Part No 77828 5 60 5 65 2 7 Section 2 Specifications July 2005 SPECIFICATIONS REV Battery Machine Torque Specifications Type 12VDC platform rotator Size 13 619 16 93 8 inches 4 8 center bolt GR 8 480 ft lbs 33 x 17 3 x 23 8 cm 651 Nm Quantity 1 8 g 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 180 ft lbs 244 Nm Capacit 7 7 quarts Drive motor mounting bolts lubricated 55 ft lbs 7 3 liters 75 Nm Coolant temperature sending unit Turntable bearing Torque 8 18 ft lbs 11 24 Rotate bearing mounting bolts lubricated 180 ft lbs 244 Nm Temperature switch point 221 Turntable rotation assembly 105 C Backlash pivot plate 260 ft lbs 352 5 Nm 2 8 S 60 5 65 Part No 77828 July 2005 Section 2 Specifications REV B Hydraulic Hose and Fitti
383. e test position Result The check engine light should turn on The check engine light should begin to blink 5 Continue to hold the run test toggle switch in the test position and count the blinks If any fault codes are present the ECM will use the check engine light to blink a three digit code 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 consecutive times blinks 3 times and then 1 time That would indicate code 531 There will be a longer pause between codes 6 Refer to Section 5 Fault Codes for definition of engine fault codes 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 Part No 77828 July 2005 Section 4 Repair Procedures ___________ 5 How to Clear Engine Fault Codes from the ECM Perform this procedure with the engine off and the key switch in the off position 1 Open the 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 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
384. e Procedures July 2005 CHECKLIST B 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 filter housing Bleed the 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 result in death or serious injury 14 Loosen the vent plug on top of the fuel injection pump vent plug b fuel injection pump c fuel lift pump Genie 5 60 5 65 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 It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation If the engine runs correctly for a short time and then st
385. e 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 Chock the 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 Lift the 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 disengaged position arf 2 2 engaged position 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort Genie MR REVD 12 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Raise 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 All Models 13 Be sure the free wheel valve on the drive pump is closed clockwise a drive pump b free wheel valve liftpump d screwdriver The free wheel valve is located on the side of the drive pump The free wheel valve should always remain closed 3 44 5 60 5 65 PartNo 77828 July 2005 Section 3 Scheduled Maintenance Procedures REV D D 6 Replace the Hy
386. e 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 Check the tire pressure in all four tires and add air if needed to meet specification 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 PartNo 77828 Genie S 60 5 65 MANIFOLDS 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 thatthe 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 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 Genie Industries Service Department Section 4 Repair Procedures Ju
387. e life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced 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 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 PartNo 77828 5 60 5 65 CHECKLIST PROCEDURES 3 Loosen the vent 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 7 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 3 Scheduled Maintenanc
388. e to the test port on the drive pump Hold the charge pressure relief valve and remove the cap item TT Turn the internal hex socket clockwise fully until it stops Install the cap Start the engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position Note the reading on the pressure gauge 5 Turn the engine off 6 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold Hold the charge pressure relief valve and remove the cap item TT Start the engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position Adjust the internal hex socket until the pressure reading on the gauge is 40 psi 2 8 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 Turn the engine off and remove the pressure gauge Genie July 2005 REV D TEREX COMPANY 4 50 S 60 5 65 77828 July 2005 Section 4 Repair Procedures E REV D MANIFOLDS This page intentionally left blank Genie Part No 77828 S 60 5 65 4 51 Section 4 Repair Procedures July 2005 er ET nn MANIFOLDS REVD 7 10 Traction Manifold Components 4WD The traction manifold is mounted inside the drive chassis at the non steer end Index S
389. ecals on the machine use signal words to identify the following 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 ADANGER Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury other protective clothing if the situation e Be sure to wear protective eye wear and warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes aware of potential crushing hazards Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage NN Be sure that all tools and working areas other lifting or supporting device is fully capable of supporti
390. ection An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics 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 General Repair Process Identify symptoms Malfunction gt Troubleshoot discovered problem still exists Perform repair Return to service problem solved Section 6 Schematics July 2005 Electrical Symbols Legend 4 HR WHT 153 Quick disconnect terminal Coil Limit switch pe solenoid or relay WHT 321 21 T 4 OTS2 GROUND NO T circuits connect H1 at terminal switch Horn or alarm Key switch normally open before serial number 22051 T circuits connect we FB erst N O Flashing beacon Power relay Coolant temperature Connection itch no terminal switc normally open Gauge Circuits crossing E connection Toggle switch SPDT Oil pressure switch normally closed
391. ection frozen at Power up 15 Value too low zero and neutral controller with 16 Value at OV Alarm sounds problem corrected indicating fault Joystick speed and 17 Not calibrated direction frozen at Calibrate joystick zero and neutral 18 Just calibrated Initiate 1 second beep Self clearing of alarm transient 42 Turntable rotate Limited speed and directional valves direction frozen at Power up 21 Fault zero and neutral controller with Alarm sounds problem corrected indicating fault 43 Turntable rotate Limited speed and flow control valve 12 Value too high direction frozen 15 Value too low zero and neutral controller wit Alarm sounds problem corrected indicating fault Normal function Calibrate valve except threshold for thresholds or both directions Self clearing 18 Just calibrated ie sao transient 44 Drive enable Enable override Power up override switches 21 Fault direction is frozen at controller with neutral problem corrected Genie 5 4 5 60 5 65 Part No 77828 July 2005 Section 5 Fault Codes REV A FAULT CODES Error Source Error Type Condition Solution ID Name ID Name 51 Drive joystick 11 Value at 5V Limited speed and 12 Value too high direction frozen at Power up 15 Value too low zero and neutral controller with 16 Value at OV Alarm sounds problem corrected indicating fault Joystick speed and 17
392. ections are open or shorted OR sensor is faulty OR engine intake air temperature is too hot Repair wiring and or connections OR replace sensor OR direct cooler air into air intake enie Continued on next page AR Part No 77828 A TEREX COMPANY S 60 S 65 5 7 Section 5 Fault Codes July 2005 FORD ENGINE FAULT CODES REVA Code Problem Cause Solution Air intake temperature is greater than 200 F with Check air intake system for damage and 21 3 2 Higher Than Expected the engine greater than 1000 rpm OR air intake proper routing of air intake components OR system has leaks OR IAT sensor is faulty replace the IAT sensor IAT Higher Than Expected Air intake temperature is greater than 210 F with Check air intake system for damage and 21 4 9 P the engine greater than 1000 rpm OR air intake proper routing of air intake components OR system has leaks OR IAT sensor is faulty replace the IAT sensor Oil Pressure Low 215 Faulty oil pressure sensor OR sensor wiring and or connections open or shorted OR engine oil level too low Replace oil pressure sensor OR repair sensor wiring and or connections OR fill engine oil level to specification 221 CHT ECT High Voltage Engine cooling system is malfunctioning OR sensor wires and or connections open or shorted OR sensor is faulty Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor
393. ed OR there is a poor system ground connection OR throttle position sensor 2 is faulty Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 2 535 TPS1 Higher than TPS2 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 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 536 TPS1 Lower than 52 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 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 537 Throttle Unable to Open Governor actuator is stuck closed OR wiring and or connections open or shorted OR governor actuator is faulty Repair wiring and or connections to governor actuator OR replace the governor actuator 538 Throttle Unable to Close Governor actuator is stuck open OR wiring and or connections open or shorted OR governor actuator is faulty Repair wiring and or connections t
394. ed OR there is electro magnetic interference from a faulty crankshaft and or camshaft position sensor Adjust or replace sensors OR clean or repair fuel injectors 143 Adaptive Learn High LPG 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 Repair wiring and or connections OR replace sensor OR repair any vacuum and exhaust leaks OR replace fuel OR test and repair the fuel system components 144 Adaptive Learn Low LPG Engine wire harness may have an intermittent short to 5V DC or 12V DC OR fuel system components may be faulty Repair short in engine wire harness OR test and repair the fuel system components 161 System Voltage Low Battery is faulty OR alternator is not charging OR battery supply wiring to ECM is open or shorted Replace battery OR repair alternator OR repair battery supply wiring to ECM 162 System Voltage High Alternator is overcharging the battery when engine RPM is greater than 1500 rpm Repair or replace the alternator 211 IAT High Voltage IAT sensor wiring and or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too cold Repair wiring and or connections OR replace sensor OR direct warmer air into air intake 212 IAT Low Voltage IAT sensor wiring and or conn
395. edure with the boom in a horizontal position This procedure will require two people 1 Fully extend the boom 2 Retractthe boom approximately 12 inches 30 cm 3 Remove the boom cover at the pivot end of the boom Part No 77828 July 2005 Section 4 Repair Procedures REV B 4 Locate the extend cable adjustment nuts 5 Tighten each cable adjustment nut evenly until the number 3 boom tube just begins to move Do not loosen the nuts If an extend cable adjustment nut is loosened remove the nut and replace it with a new one 6 Visually inspect the cable break limit switch arm to be sure the wheel of the limit switch arm is centered in the notch of the pivot plate Result If the wheel of the limit switch arm is not centered in the notch of the pivot plate tighten the appropriate extend cable adjustment nut to center the limit switch arm 7 Install the boom end cover at the pivot end of the boom cable break limit switch extend cable adjustment nut extend cable pivot plate PartNo 77828 Genie 5 60 5 65 BOOM COMPONENTS 8 Fully retract the boom then extend the boom approximately 1 foot 30 cm 9 Locate the retract cable adjustment nut at the platform end of the boom 10 Tighten the retract cable adjustment nut just until the number 3 boom tube begins to move Do not loosen the nut If the retract cable adjustment nut is loosened remove the nut and replace it with
396. eeps every 30 seconds for 10 minutes Perform this procedure with the 4 engine off the key switch turned to platform controls and both red Emergency Stop button pulled out to the on position at both the ground and platform controls 1 Open the platform control box lid AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious 5 injury Remove all rings watches and other jewelry 2 Locate the red and yellow fault LED s on the ALC 500 circuit board inside the platform control box Do not touch the circuit board Component damage hazard CAUTION Electrostatic discharge ESD can damage printed circuit board components If the circuit board does need to be handled maintain firm contact with a metal part of the machine that is grounded at all times when handling the printed circuit board OR use a grounded wrist strap Genie REVA Determine the error source The red LED indidates 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 When the red LED is flashing the code the yellow LED will be on solid 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
397. ential for good engine performance Failure to perform this procedure can lead to poor engine performance and component damage IN J 813 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 Perform this procedure with the engine off Perkins Models 1 Puton protective clothing and eye wear 2 Openthe engine side turntable cover and locate Genie part number 101095 the fuel filter water separator next to the hydraulic return filter on the bulkhead Ford LRG 425 EFI Operator Handbook Genie number 84792 Inspect the filter bowl for water buildup Perkins 400 Series Operation Manual Result If water is present in the filter bowl erkins eries Operation Manua Genie pait number 94890 continue with steps 4 through 8 Part No 77828 S 60 5 65 3 11 Section 3 Scheduled Maintenance Procedures July 2005 CHECKLIST A PROCEDURES REV 4 Loosen the vent plug located on the fuel filter 8 Start the engine from the ground controls and water separator head check the fuel filter water separator and vent plug for leaks 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 Puton protec
398. es consistently exceed 205 F 96 C Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Genie S 60 5 65 REV Drive pump Type bi directional variable displacement piston pump Flow rate 2500 rpm 32 4 122 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 23 Flow rate 2500 rpm 15 3 58 L min Displacement Pump 2 outer 0 24 cu in 4cc Flow rate 2500 rpm 2 gpm 7 6 L min Auxiliary pump Type gear fixed displacement Displacement 1 75 2 8 L min Part No 77828 July 2005 REV Function manifold System relief valve pressure 3000 psi 207 bar Steer flow regulator 3 5 13 2 L min Jib boom platform rotate 0 6 flow regulator 2 27 L min Oscillate relief valve pressure 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 Displacement per revolution 1 83 cu in low speed 30 cc Drive motors 2WD m
399. est port on the drive pump coupler separates from the flex plate 2 Remove the safety pin if equipped from the 6 Remove the drive pump from the machine engine pivot plate latch Component damage hazard The CAUTION hydraulic pump may become unbalanced and fall if not properly supported The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine Component damage hazard When CAUTION installing the pump do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur 4 GM Ford models Close the valve on the LPG tank then disconnect the hose from the tank Move the fuel select switch to the LPG 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine Models with hydraulic tank shut off valves Component damage hazard Be position CAUTION t the two hydraulic tank LL vo tan Perkins models Disconnect the engine wiring valves and prime the pump anter harness from the fuel solenoid at the injector installing the pump pump Models without hydraulic tank shut off valves Deutz models Hold the manuail tuelsh toti t h B valve clockwise to the closed position CAUTION hazard Be sure to fill the hydraulic tank to specification and prime the pump after installing the pump e 4 d i
400. 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 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 lifting device Genie Part No 77828 5 60 5 65 Section 4 Repair Procedures July 2005 BOOM COMPONENTS 4 4 Boom Extension Cylinder The primary 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 2 dlily 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
401. ft lbs 54 Nm Perkins models Torque the bell housing mounting bolts labeled B in sequence to 40 ft lbs 54 Nm and the mounting bolts labeled A to 70 ft lbs 95 Nm Perkins models Genie Part No 77828 5 60 5 65 4 29 Section 4 Repair Procedures July 2005 ENGINES 5 4 Engine Fault Codes GM and Ford Models How to Retrieve Engine Fault Codes When an engine malfunction is detected by the Electronic Control Module ECM a fault code is recorded and the check engine light will turn on at the ground controls Special equipment is required to retrieve fault codes stored within the ECM Contact Genie Industries Service Department for assistance in retrieving fault codes GM models If the check engine light is on and the engine is stopped tag the machine and remove from service Contact service personnel immediately If the check engine light is on and the engine is still running contact service personnel within 24 hours Ford models Perform this procedure with the key switch in the off position 1 Open the 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 5 60 5 65 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 th
402. g the test line Release the drive joystick Test the Drive Brakes when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Refer to Proper brake action is essential to safe machine Section 2 Specifications operation The drive brake function should operate smoothly free of hesitation jerking and unusual The brakes must be able to hold noise Hydrostatic brakes and hydraulically the machine on any slope it is able released individual wheel brakes can appear to to climb 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 Refer to B 6 Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark a test line on the ground for reference 2 Start the engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol then lower the boom into the stowed position 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 Part No 77828 5 60 5 65 3 25 Section 3 Scheduled Maintenance Procedures July 2005 CHECKLIST B PROCEDURES B 15 Test the Drive Speed Stowed Position Proper drive function movement is essentia
403. gg 59 ie C4B 11 RD 2 12 N C2P 10 2 WORK LIGHTS OPTION Du cz a MERE C2P 11 lt lt C2P 9 lowe aa en we we x 1 8 8 P134FB WH u 4 FLASHING BEACONS m OPTION NI Son n S C21HM WH 1 HOUR METER E War c 9 RUN TEST SWITCH 9 a 5 C58 C1278W GR lt lt GM 5 18 BK RD lt lt GM CONNG gt D BAN E lt lt GM a 8 canw p P us C2P 1 39LP BL RD C2B 1 5 11 21 22 pie FUEL SELECT Z GAS 0 nel sevect GAS 1 C59 CI26LRPM OR RD E lt lt 5 6510 C39LP BL RD D 22 GM CONNS C41RPM OR BK C2B 3 C5 2 CA1RPM OR BK C lt lt GM z C5 6 C27AUX RD 22 GMCONNS CHECK ENGINE LED C5 13 C108ESL lt lt N 1 7 C33STRBK 1 7 i 3 len CES J lt lt 0 a 2 5 19 P23BAT WH A lt GM CONN10 ENGINE Tre START c 5 8 2 RSSSTRIBK GM HARNESS 0 eo S ENT S 3 I I 1 I 88 er 8 E dn EY STARTER MOTOR 1
404. gital Hall with a metal part of the machine Effect technology for proportional control If a that is grounded at all times when joystick is disconnected or replaced it must be handling printed circuit boards OR calibrated before that particular machine function use a grounded wrist strap will operate 5 Carefully disconnect the wire connectors from ia The joystick must be calibrated the circuit board before the threshold max out or 6 Remove the ALC 500 circuit board mounting ramping can be set fasteners Perform this procedure with the 7 Carefully remove the ALC 500 circuit board from engine off the platform control box 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Select a joystick to calibrate 4 Move the joystick full stroke in either direction and hold for 5 seconds 5 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 joystick calibration 6 Repeatthis procedure for each joystick controlled machine function including the thumb rocker steer switch No machine fuction should operate while performing the joystick calibration procedure Part No 77828 S 60 5 65 4 3 Section 4
405. h 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 Part No 77828 July 2005 Section 4 Repair Procedures REV B 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 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 How to Adjust the Boom Extend Retract Cables 4 6 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion The master cylinder is located at the pivot end of the boom How to Remove the Platform Leveling Master Cylinder When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then 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 PartNo 77828 Genie S 60 5 65 BOOMCOMPONENTS 2 Tag disconnect and plug the m
406. he 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 July 2005 REV B 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 the right Continue holding the toggle switch until air stops coming out of the bleed s
407. he platform controls red Emergency Stop button to the off position 4 Do 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 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 threshold 4 6 5 60 5 65 REVA 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 up down boom extend retract and turntable rotate 13 Return the joystick to the neutral position and wait for approximately 10 seconds Result The alarm should sound indicating that the settings have been saved in memory Do not operate any machine function during the 10 second waiting time Part No 77828 July
408. he requirements listed in the responsibilities manual a A TEREX COMPANY Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond WA 98073 9730 425 881 1800 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Copyright 92002 by Genie Industries GenieG 5 a registered trademark of Genie Industries RevB Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate 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 Y 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 July 2005 cama SS nn This page intentionally left blank 3 4 S 60 5 65 Part No 77828 July 2005 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Seria
409. hen 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 primary boom to access the hydraulic hoses 8 Tag disconnect and 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 Do not start the engine Use auxiliary power for this procedure 1 Raise the primary boom to a horizontal position 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system Section 4 Repair Procedures PLATFORM COMPONENTS 2 2 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees S 65 or 180 degrees S 60 How to Remove the Platform Rotator Component damage hazard Mark CAUTION the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator
410. i Q1 nn 5 6518 HIGH RPM SOLENOID lt lt 4 Not GRWH C45GEN GRWH 5 12 GENERATOR OPTION quc cac E tuc ce cc c d Ue EI HN s E 5 5 DLITE BL WH o 4 DRIVE LIGHT 1 S WORK LIGHT HD C DRIVE LIGHT OPTION 1 1 5 ae 8 28 gt 6 61 B gt WORK LIGHTS OPTION 2 12 2 10 2 15 1 us 1 2 11 9 5 x e 9 B p C34SA BK WH C34SA BK WH 5 22 a GLOW PLUG 9 F 4 1 PLUG 000 C26TSR WH RD OIL TEMPERATURE LED 2 e z 5 5 Se 2 ks a 5 2 ESE Bee gt 65 14 OIL TEMPERATURE SWITCH 5 ENGINE a MEE START iD ST Fs 2 ENGINE e 05 16 OIL PRESSURE SWITCH 5 t 25 WH BK is 1 o i POWER RELAY i 55 B a GE ate C21GN2 WH A FUEL SOLENOID RE c z C27AUX RD 1 1 WH HOUR METER 88 9 IGN START RELAY an i T SR un x R33STRBK C55 8 amp qe u We STARTER MOTOR pet 9 8 AUXILIARY PUMP x i
411. ib boom assembly from the primary boom 4 Remove the hose and cable clamp from the jib AWARNING Cushing hazard The jib boom boom pivot pin Lay all hoses and cables to the side CAUTION 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 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 Genie deem could become unbalanced and fall when removed from the machine if not properly attached to the overheadcrane PartNo 77828 5 60 S 65 4 11 Section 4 Repair Procedures M IMM JIB BOOM COMPONENTS 5 65 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder 1 Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Raise the jib boom slightly and place blocks underthe platform mounting weldment Then lower the jib boom until the platform is resting on the blocks just enough to support the platform Do not rest the ent
412. ice 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 1443S Perkins 400 Series Operation Manual Genie part number 94890 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 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 Section Scheduled Maintenance Procedures July 2005 Checklist C Procedures C 1 Perform Engine Maintenance Deutz Models 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 Manual Genie par
413. ich if not avoided may result in property damage CAUTION Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures July 2005 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 amaintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure 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 3 2 5 60 5 65 Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation Report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly every six months annual and two years The S
414. il techsup genieind com Genie ii S 60 5 65 Serial Number Information Genie Industries offers the following Service Manuals for these models Title Part No 5 60 and 5 65 Service Manual before serial number 2575 34476 S 60 and S 65 Service Manual from serial number 2575 to 6623 48412 5 60 and 5 65 Service Manual from serial number 6624 to 9153 65196 Copyright O 1995 by Genie Industries 77828 Rev B July 2005 Fourth Edition Second Printing Genie and S are registered trademarks of Genie Industries in the USA and many other countries ry Printed on recycled paper Printed in U S A Part No 77828 July 2005 INTRODUCTION Serial Number Legend Genie Model S 60 Serial number S6005 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number E0186 Machine unladen weight 20 736lbs 9 406kg Foam Tires add 764 Ibs 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 N Maximum allowable inclination of the chassis Air Tires 2 deg Foam Tires 4 5 deg 56005 05 1 2345 Maximum wind speed 28 mph 12 5 m s Maximum platform height 60 ft 2 in 18 3 m Model 5 Maximum platform reach 50 ft 4 in 15 3 equence Gradeabilit
415. ime 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 time or momentarily move the drive enable toggle switch in the left direction to decrease the time Each time the drive enable toggle switch is momentarily moved the time will change in 2 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 Result The alarm should sound indicating that the settings have been saved in memory Do not operate any machine function during the 10 second waiting time Part No 77828 July 2005 Section 4 Repair Procedures REVA 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 Perform this procedure with the boom in the
416. ions OR replace sensor OR replace fuel OR test and repair the fuel system components 133 Gasoline cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance 134 LPG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance 135 NG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level Repair exhaust leaks OR there is an emissions compliance issue Contact Ford Power Products for assistance 141 Adaptive Lean Fault High Limit Gasoline 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 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 142 Adaptive Rich Fault Low Limit Gasoline 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 clos
417. ire 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 Genie July 2005 REVA Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 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 Support the jib boom lift cylinder with a lifting device 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 AWARNING Crushing hazard The platform and jib boom could become unbalanced and fall when the jib boom barrel 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 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
418. is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the July 2005 REV 2 disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the rotator 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 5 65 Support the jib boom leveling arms the platform mounting weldment with an appropriate lifting device Do not apply any lifting pressure 4 Remove the mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator AWARNING Crushing hazard The platform mounting weldment could become unbalanced and fall if not properly supported when removed from the machine way in the left position 5 Supportthe platform rotator with an appropriate lifting device Do not apply any lifting pressure 5 60 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 6 Support the rod end of the platform leveling slave cylinder Protect the cy
419. is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Perform this procedure with the boom fully retracted 1 Raise the boom to a horizontal position 2 Remove the access covers from both sides of the boom at the pivot end REV B Remove the boom end cover from the pivot end of the boom 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 Remove the cable guard fasteners and remove the cable guard a cable guard b retaining block Genie MR 4 20 5 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV B 7 Locate the retaining plates that secure the retract cables to the inside of the number 3 boom tube 8 Remove the cable retaining plates and pull the retract cables off of the pulleys Lay the cables flat and out of the way 9 Remove the fasteners from the retaining blocks from the extension cylinder saddle Remove the blocks Access the fasteners through the access hole in the outer boom tube at the pivot end 10 Disconnect the wire connector to the cable break limit switch 11 Remove the retaining fasteners that secure the extend cable m
420. j t m 5 T m a Sepa 5 2 ME i LELS SI gt LS f zin XE E RE 9 7 a 1 1 1 28 2 owe 59 5 Q a 1 gt 595 07 28 23 1 1 e lt QEK Lu 2 SS a 3 AP 4 55 S lt gt es u zi gar aaa 1 1 dor TEN 1 4 28 8 5 82 BR Bet T 5 2 f gt 9 lt 1 m 1 eo o Q 9 2 a 50 8 i g 5 Sea m E 9 1 Op 4 8 1 ty t 328 EA 5 i 58 416 BN iiss tir 4 2 Ex poc mpm ees ec eem e D 4 ive fa 2 ii E lt S i 1 Cx i as p 6 95 enie A TEREX COMPANY S 60 5 65 G Part No 77828 July 2005 Section 6
421. l Part No 77828 Genie seid Drive speed maximum raised or extended position 12 2 7 8 sec All models 40 ft 40 sec 12 2 m 40 sec Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice S 60 5 65 Section 2 Specifications July 2005 SPECIFICATIONS Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W 20 Viscosity index rating 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron 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 have a minimum viscosity index rating of 150 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Premium ECO 46 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 Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below O F 18 C Use Shell Tellus T46 hydraulic oil when oil temperatur
422. l 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 A B Six Month or 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 If any inspection receives 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 Comments Checklist A Rev C Checklist B Rev C A 1 Pre operation inspection A 2 Functions tests B 1 Inspect battery B 2 Inspect electrical wiring A 3 Engine maintenance Deutz models 4 Engine maintenance GM and Ford models A 5 Engine maintenance Perkins models A 6 Filter condition indicator A 7 Oscillate axle Perform after 50 hours A 8 30 day service Perform every 100 hours A 9 Engine maintenance GM Ford and Perkins models A 10 Fuel filter separator Diesel models A 11 Check engine RPM Perkins models A 12 Rotation bearing Perfor
423. l 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 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 Start the engine from the platform controls 3 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol then lower the boom into the stowed position 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 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 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 16 Test the Drive Speed Raised or Extended Position 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 Select a test area that is firm level and free of obs
424. le f JC3 5 WH gu 188 JC3 3 OR le i JC3 4 BL grg JC3 2 BRN le TS15 BUWH 28 RD BK 1 2 4 TS15 BUBK N DRE LED BURD le Al TS14 RD WH x 2 5 E amp i 3 GR BK C133TTA C3P 12 GR BK L4 CE 4 2 H PEE 2 8 a en RD BK L48 NON CE 2 C134PWR RD C2P 6 C134PWR RD 1518 RD TILT i CWLITE BK gt 2 m Pecos PAN aes Ete era X BRN BRN Part No 77828 19 18 CONTROL CABLE enie A TEREX COMPANY S 60 5 65 G TILT H1 ALARM CWLITE WH TS49 6 37 July 2005 Section 6 Schematics E REV A Platform Control Box Switch Panel Wiring Diagram S 65 Ford LRG 425 EFI Models N M L K J H G D C B A PLATFORM CONTROL 1 HARNESS TO CONTROL BOX DRIVE LIGHTS 2 WORK L
425. lectrical Schematic S 65 Section 6 Schematics ale 8805 5 2 5 N E 55 y C35RPM BK RD C1B 9 5 4 FOOTSW HIGH o 6 dj Low FE zB 5 x su zu 2 86 LOW RPM x FUNCTION ENA BK RD BRN t gt i HIGH IDLE RELAY 9 BKRD 05 18 HIGH RPM SOLENOID 8 o lt E LED c M lt lt I E 4 E N 5 T 5 C2P 7 GRWH 2 7 5 GRWH 5 12 il ENEAATORORTION IF 1 1 1 1 2 amp 2 y DLITE BUWH C3B 12 o DRIVE LIGHT work TS DRIVE LIGHT OPTION o 6 FUSE 10A N E 517 sn u Vi WORK LIGHTS OPTION E 5 C2P 12 AX C2P 10 B 5 a 1 o 1 528 Q 4 4 2 11 C2P 9 2 x m 5 5 a 9 1 8 348 6 C34SA 5 22 4 e GLOW 8 Lire ele GLOW PLUGS T2 5 C26TSR WH RD COOLANT TEMPERATURE LED e a io 2 E 8 2 258 gt 595 g Ws aes 8 12 5 5 Eu 5 P Cm EIE BK 7 EEOSE
426. linder rod from damage 7 Remove the pivot pin retaining fasteners from both the slave cylinder rod end pivot pin and the rotator pivot pin 1 Remove the platform and platform support 5 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV B 8 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 When installing the platform rotator fasteners torque the fasteners to specifications S 65 6 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins Do not remove the pins 7 Support the jib boom leveling arms 8 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 9 Lower the jib boom leveling arms Crushing hazard The platform ACAUTION rotator may become unbalanced and fall if not properly supported When installing the platform rotator fasteners torque the fasteners to specifications Part No 77828 Genie S 60 5 65 4 9 PLATFORM COMPONENTS How to Bleed the Platform Rotator This procedure will require two people Do not start the engine Use auxiliary power for this procedure 1 Move the function enable toggle switch
427. lt in death or serious injury 4 Inspect the following areas for burnt chafed corroded and loose wires Engine wiring harness Hydraulic manifold wiring 5 Open the ground controls side turntable cover Part No 77828 July 2005 Section 3 Scheduled Maintenance Procedures REVC 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 Cable track 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 pivot plate retaining fastener Part No 77828 5 60 5 65 3 17 CHECKLIST PROCEDURES B 3 Check the Exhaust System Maintaining the exhaust system is essential to good engine perfo
428. ly 2005 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 Connect 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 Start the engine from the platform controls 5 With the engine running 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 Adjust the 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 REV D 4 46 5 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures Ee REV D MANIFOLDS This page intentionally left blank Genie Part No 77828 5 60 5 65 4 47 Section 4 Repair Procedures EE
429. ly 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 If the wear pad is still within specification shim as necessary to obtain minimum clearance with zero binding 4 Extend and retract the primary boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Always maintain squareness between the outer and inner REV B D 2 Check the Turntable Rotation Bearing Bolts 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 secondary boom and place safety chocks on the lift cylinders rods Carefully lower the boom onto the lift cylinders safety chocks AWARNING Crushing hazard Keep hands away from cylinders and all moving parts when lowering the boom The lift cylinder safety chock is available through Genie Genie partnumber 75097 2 Turnthe engine off 3 Remove the engine tray retaining fastener located under the engine tray Swing the engine tray out and away from the machine 4
430. m every 200 hours A 13 Engine maintenance GM and Ford models A 14 Engine maintenance Perkins models Genie Part No 77828 B 3 Exhaust system B 4 Oil cooler and fins Deutz models B 5 Lug nut torque B 6 Brake configuration B 7 Drive hub oil level B 8 Engine RPM Deutz models B 9 Ground control override B 10 Directional valve B 11 Platform leveling B 12 Engine idle select B 13 Fuel select GM and Ford models B 14 Drive brakes B 15 Drive speed stowed position B 16 Drive speed raised position B 17 Alarm package B 18 Hydraulic oil analysis B 19 Fuel filter separator Perkins models B 20 Fuel filter element Perkins models Perform every 400 hours B 21 Engine maintenance Deutz models B 22 Engine maintenance GM and Ford models B 23 Engine maintenance Perkins models REX COMPANY 5 60 5 65 Section 3 Scheduled Maintenance Procedures O 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 A B Six Month or 500 hour Inspection A
431. mance of the cooling system 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 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 Genie 5 60 5 65 3 Remove the fasteners from the engine side cover then remove the cover 4 Inspect the oil cooler for leaks and physical damage oil cooler b cylinder head cooling fins fan 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 Clean the 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 its original position and install the engine pivot pla
432. me the engine is Repair charging system OR replace the high cranking running MegaJector voltage suppl The MegaJector detects voltage less than 9 5 Repair VBAT power or ground circuit to ECM 362 9 volts for 5 seconds anytime the engine is and MegaJector OR replace battery OR repair cranking or running charging system OR replace the MegaJector Megajector internal actuator fault detection 363 The Megadector detects an internal fault Open or short in power ground or CAN circuits s Check Power Ground and CAN circuits at MegaJector and all connections and repair necessary OR Megavector has an internal fault Contact Ford Power Products for assistance Megajector internal circuitry fault detection 364 The MegayJector detects an internal circuitry failure Open or short in power ground or CAN circuits Check Power Ground and CAN circuits at MegaJector and all connections and repair necessary OR Megavector has an internal fault Contact Ford Power Products for assistance MegaJector internal communication fault detection 365 The MegaJector detects an internal communications failure Open or short in power ground or CAN circuits Check Power Ground and CAN circuits at MegaJector and all connections and repair necessary OR Megavector has an internal fault Contact Ford Power Products for assistance 411 Coil Driver 1 Open
433. motors in forward and reverse 80 90 ft lbs 108 122 Nm 12 Check Y Y sonis Non steer end drive motor circuit 35 40 ft lbs 14 16 Nm 13 Flow divider combiner valve XX acis Controls flow to non steer end drive motors in forward and reverse 80 90 ft lbs 108 122 Nm 7 Relief valve 280 psi 19 3 bar UU us Charge pressure circuit 35 40 ft lbs 14 16 Nm 4 52 5 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV D MANIFOLDS 0 0 Genie Part No 77828 5 60 5 65 4 53 Section 4 Repair Procedures July 2005 B XM SSS Ty MANIFOLDS REV D 7 11 Valve Adjustments 4WD 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 Hold the 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 Removethe pressure gauge from the drive pump Connect the gauge to the test por
434. mounted to the turntable rotation motor Index Schematic No Description Item Function 1 Shuttle valve 2 position 3 way Turntable rotation brake release 2 Counterbalance valve MM Turntable rotate right 3 Counterbalance valve NN Turntable rotate 4 Orifice 0 030 inch 0 76 su Brake release circuit located inside port Genie MANIFOLDS Torque 10 13 ft lbs 14 18 Nm EST 35 40 ft Ibs 47 54 Nm is 35 40 ft lbs 47 54 Nm A TEREX COMPANY Part No 77828 S 60 S 65 Section 4 Repair Procedures July 2005 MANIFOLDS REV D 7 6 Oscillate Directional Valve Components The oscillate directional valve is mounted inside the drive chassis at the non steer end Index No Description Function Torque 1 Breather yoo 20 25 ft lbs 27 33 Nm 2 Spool valve Directional control Genie A TEREX COMPANY 4 44 5 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV D How to Set Up the Oscillate Directional Valve Adjustment of the oscillate directional valve linkage is only necessary when the linkage or valve has been replaced 1 Lower the boom to the stowed position 2 Usea bubble type level to be sure th
435. n acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 that the battery cable connections are free of corrosion 3 sure that the battery hold down bracket and cable connections are tight The battery is a maintenance free battery and does not require the replenishing of electrolyte Adding terminal protectors anda corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Genie S 60 5 65 REVC B 2 Inspect the Electrical Wiring 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 componentdamage AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Open the 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 AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could resu
436. n death or serious injury and significant component damage Dealer service is strongly recommended 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 Crushing hazard The boom lift cylinder and primary boom will fall if not properly supported Crushing hazard The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Genie When lowering the master cylinder down be sure not to damage the master cylinder hoses or fittings Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 5 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV B BOOM COMPONENTS 4 3 4 Remove the pin retaining fastener from the Boom Lift Cylinder primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin The boom lift cylinder raises and lowers the boom AWARNING The Primary boom will fall if not The boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to
437. nd bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses CAUTION can be damaged if they are kinked or pinched 14 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Perkins models 1 Remove the fuel filter water separator mounting fasteners 2 Remove the fuel filter water separator and lay it to the side Do not disconnect the hoses 3 Support the drive pump assembly with an appropriate lifting device 4 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 CAUTION can be damaged if they are kinked or pinched 6 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Section 4 Repair Procedures July 2005 ENGINES How to Install the 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 Deutz models Torque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Perkins models Torque the flex plate mounting bolts in sequence to 49 ft lbs 66 Nm Ford models Torque the flex plate mounting bolts in sequence to 20 ft lbs 27 Nm Deutz models Torque the flex plate mounting bolts in sequence to 40 ft lbs 54 Nm Perkins m
438. nd 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 The engine should be warmed to normal operating temperature before performing this procedure 1 Move the fuel select toggle switch to LPG fuel and start the engine from the ground controls 2 Locate the high idle mixture adjustment screw on the LPG venturi that attaches to the air cleaner air cleaner hose 3 Loosen the lock nut on the high idle mixture adjustment screw 4 Load the system by activating the primary boom retract function then move the function enable toggle switch to the high idle rabbit symbol position Part No 77828 July 2005 Section 3 Scheduled Maintenance Procedures REV D 5 Adjust the 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 Preliminary setting is 1 4 inch 6 4 mm of threads showing Measure from top of lock nut to top of adjustment screw 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 Adjustthe low idle mixture adjustment screw to obtain an air to fuel mix
439. nd install the engine pivot plate retaining fastener Section 3 Scheduled Maintenance Procedures July 2005 CHECKLIST D PROCEDURES D 3 Inspect for Turntable Bearing Wear 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 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 Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification See D 2 Check the Turntable Rotation Bearing Bolts Start the machine from the ground controls and raise the boom to full height Do not extend the boom 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing 5 60 5 65 0 turntable dial indicator drive chassis turntable rotation bearing ao oo 5 At the dial indicator adjust it to zero the indicator 6 Fully extend the boom and lower to a horizo
440. nd of adjustment range hesitation jerking and unusual noise No broken or damaged pulleys 1 Raise the boom to horizontal and fully extend No unusual or excessive pulley wear the boom All fasteners in place and secure 2 After the boom is fully extended lower the boom A flashlight and inspection mirror until the platform is at chest height Turn the may be necessary to thoroughly machine off inspect the above items 3 Remove the boom end cover from the pivot end A pulley groove gauge should be of the boom used to check the condition of the lleys 4 Remove the retaining fasteners from the access PES covers located on the side of the boom at the 6 Install the cover at the pivot end of the boom platform end of the machine Remove the and the access panels on the sides of the covers boom 7 Startthe engine from the ground controls and fully retract and lower the boom to the stowed position Genie Part No 77828 5 60 5 65 3 37 Section Scheduled Maintenance Procedures July 2005 CHECKLIST C PROCEDURES 8 Turn the key switch to the platform controls 9 Extend the boom approximately 2 feet 0 6 m 10 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 If the number 2 boom tube moves more than 1 2 inch 13 mm before the number
441. ng 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 lbs 31 2 Nm 8 40 ft lbs 54 2 Nm 10 69 ft lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft lbs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SAE O ring Boss Port SPECIFICATIONS 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 the O ring before installation 3 Besure that the 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 th
442. ng 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 Tag and 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 Section 4 Repair Procedures July 2005 BOOM COMPONENTS 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 pivot 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
443. ng 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 de 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 CAUTION Without safety alert symbol used to indicate the presence of a Be sure to properly dispose of old oil or potentially hazardous situation 4 other fluids Use an approved container which if not avoided may result in Please be environmentally safe property damage Be sure that your workshop or work area Used to indicate operation or Hi 5 properly ventilated and well lit maintenance information Genie vi S 60 5 65 Part No 77828 July 2005 Introduction Section 1 Section2 Rev gt gt gt u gt gt Section3 Rev Table of Contents Important nio ruarz vifo ro ii Seriali Number Irformation ij Serial Number iii Safety Rules General Safety een iii Specifications Machine Specifications iex nineteenth ripe ERR 2 1 Performance Specifications u nun 2 1 Hydraulic Specifications 2 2 Manifold Component Specifications 2 3 GM 3
444. ngine harness wiring and or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty 632 External 5V DC Ref Higher than Expected ECM Locate and repair any engine harness wiring 655 RTI 2 Loss 5 OR ECM s damage or shorts to ECM to be sure they are y secure OR replace ECM Locate and repair engine harness wiring 656 RTI 3 Loss 4 ECM damage or shorts to ECM to be sure they are secure OR replace ECM A TEREX COMPANY Part No 77828 S 60 5 65 5 11 Section 5 Fault Codes July 2005 jr SSS SSS This page intentionally left blank 5 12 5 60 5 65 Part No 77828 July 2005 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 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 printed in the Genie 5 60 amp Genie 5 65 Operator s Manualon your machine Be sure that all necessary tools and test equipment are available and ready for use Part No 77828 5 60 5 65 6 1 Schematics About This Section There are two groups of schematics in this s
445. ntal position 7 Note the reading on the dial indicator Result The measurement is less than 0 063 inch 1 6 mm The bearing is good Result The measurement is more than 0 063 inch 1 6 mm The bearing is worn and needs to be replaced 8 Fully retract the boom and raise the boom to full 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 90 10 Repeat 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 Part No 77828 July 2005 Section 3 Scheduled Maintenance Procedures REV D D 4 Replace the Drive Hub Oil 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 Select the drive hub to be serviced Then drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil 3 Drive the machine until one plug is at the top and the other is at 90 degrees 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 hole Install the plugs into the d
446. o governor actuator OR replace the governor actuator 545 Governor Interlock Failure Engine harness wiring and or connections open or shorted OR there is a poor system ground connection OR ECM is faulty Repair wiring and or connections in engine harness OR replace the ECM 551 Max Governor Speed Override ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the hrottle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 552 Fuel Rev Limit ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the hrottle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 553 Spark Rev Limit ECM needs to be re programmed OR throttle is sticking open OR there are air leaks between the hrottle body and cylinder head Re program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head 611 COP Failure Loose wire connections to ECM OR ECM is aulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM 612 Invalid Interrupt Loose wire connections to ECM OR ECM is aulty Locate and repair any engine harness wiring damage or sh
447. o 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 2 Start the engine from the ground controls then move and hold the function enable rpm select toggle switch to the high idle rabbit symbol O Result The engine should change to high idle 3 Release the function enable rpm select toggle Switch Result The engine should return to low idle 4 Turn the key switch to platform controls 5 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol O Result The engine should not change to high idle 6 Press down the foot switch O Result The engine should change to high idle 6 Move the engine idle control switch to foot switch activated low idle turtle symbol O Result The engine should change to low idle Section Scheduled Maintenance Procedures July 2005 CHECKLIST B PROCEDURES B 13 Test the Fuel Select Operation GM and Ford Models The ability to select and switch between 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 Swi
448. odels 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 Hydraulic return filter 10 micron with 25 psi 1 7 bar bypass Part No 77828 Genie 3 8 1 Section 2 Specifications r Eee JY sic SPECIFICATIONS Manifold Component Specifications Plug torque SAE 2 36 in Ibs 4 Nm SAE No 4 10 ft Ibs 18 Nm SAE No 6 14 ft Ibs 19 Nm SAE No 8 38 ft Ibs 51 Nm SAE No 10 41 ft Ibs 55 Nm SAE No 12 56 ft lbs 76 Nm Valve coil resistance specifications 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 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 2 3 S 60 5 65 Section 2 Specifications July 2005 SPECIFICATIONS GM 3 0L EFI Engine Displacement 181 cuin 3 liters Number of
449. odels Torque the flex plate mounting bolts in sequence to 70 ft lbs 95 Nm Ford and Deutz models REVC Perkins models 4 Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine 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 Models 5 32 inch 3 8 mm gap GM Models 5 Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw to 61 ft lbs 83 Nm S 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV ENGINES 6 Install the pump and bell housing assembly Ford and Deutz models Torque the bell housing mounting bolts labeled C in sequence to 28 ft lbs 38 Nm Perkins models Torque the bell housing mounting bolts labeled B in sequence to 28 ft lbs 38 Nm and the mounting bolts labeled A to 49 ft lbs 66 Nm Component damage hazard When CAUTION 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 CAUTION not force the drive pump during installation or the flex plate teeth may become damaged 7 Ford and Deutz models Torque the bell housing mounting bolts labeled C in sequence to 40
450. odels before serial number 11880 Section 6 Schematics 18098 N d FINGOW LYYLS NOLINDI JNV dWAL OL ol 0 1914 6 m 5 9 2014 8 98000000 810 AINO 138410 MS A34 OL 4 41 Q4 ez M 9 e G4 G4 Mus 20 LINN XNV 1 1ndNIlHVIS wy pue G h HALSWOHOVL lt Anue SI ano 5 gt L 1 18 3AOW3H OL gt LE seujsnpu a 5 lt 5 LI 0 860 54 2 860 LISTHO y g YEHO HO r4 WHOdlVid Sel G4 OH ED nn zer 51 GVOTHSAO 6 Qd eco HWA 0334S 141 GH 4 80 GH HO HS88
451. oil to squirt or spray PartNo 77828 Genie S 60 5 65 Axle Components 3 Remove the 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 the 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 machine Section 4 Repair Procedures July 2005 ae SSS This page intentionally left blank 4 60 5 60 5 65 Part No 77828 July 2005 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 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
452. omentarily activate the drive enable toggle transition accelerate 1 second switch in the right direction 6 times transition decelerate 10 seconds Result There should be a pause and the alarm E m on 2 should sound 6 times indicating that the machine is in ramp rate calibration mode Boom extend retract accelerate 2 seconds 8 Startthe engine from the platform controls and decelerate 0 5 second press down the foot switch Turntable rotate 9 Start a timer and simultaneously move the accelerate 2 seconds joystick in either direction full stroke Note how decelerate 0 5 second long it takes the function to reach maximum speed This is the ramp rate 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 Part No 77828 S 60 5 65 4 5 Section 4 Repair Procedures July 2005 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 Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Pushin t
453. on strainers from the tank and clean them using a mild solvent 14 Rinse out the inside of the tank using a mild solvent 15 Install the suction strainers using a thread sealant on the threads 16 Install the drain plug using a thread sealant on the threads 17 Install the hydraulic return filter housing onto the hydraulic tank 18 Install the hydraulic tank onto the machine 19 Install the two suction hoses to the suction strainers 20 Install the supply hose for the auxiliary power unit and the return filter hose Part No 77828 Genie 5 60 5 65 3 51 CHECKLIST E PROCEDURES 21 Models with hydraulic tank shut off valves Open the two hydraulic tank valves at the hydraulic tank 22 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 23 Clean up any oil that may have spilled 24 Prime the pump See Repair Procedure 6 2 How to Prime the Pump Always use pipe thread sealant when installing the suction hose fittings and the drain plug Section Scheduled Maintenance Procedures July 2005 CHECKLIST E PROCEDURES E 2 Perform Engine Maintenance Deutz Models 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 proce
454. onal 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 a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution 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 Description Specification Solenoid valve 3 position 4 way 10V DC 5 to 7Q schematic items D V and Y Solenoid valve 3 position 4 way 10V DC 4060 schematic item Solenoid valve 2 position 3 way 10V DC 5 to 7Q schematic items B C E F and FF Solenoid valve 2 position 3 way 10V DC 5 5 to 7 5Q schematic items KK and LL Proportional solenoid valve 12V DC 4 to 6Q schematic items M and T Proportional solenoid valve 12V DC 3 7 to 5 7Q schematic item Q Genie Part No 77828 5 60 5 65 4 55 Section 4 Repair Procedures July 2005 nn MANIFOLDS REV D 2 Connect a 100 resistor to the negative terminal Seta multimeter to read DC current of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil The multimeter when set to read DC c
455. ons require that this procedure be performed every 1000 hours of operation or yearly Yearly 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 Perform this procedure with the machine on a firm level surface 1 Level the platform 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Using a suitable lifting device place an appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor 5 60 5 65 0 Determine the limit switch trigger point 4 Gently move the platform up and down by hand so it bounces approximately 2 5 to 5 cm Allow the platform to settle Result The overload indicator light and the alarm is on Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off The platform will need to be moved up and down and allowed to settle in between adjustments There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds Result The overload indicator light and alarm is off Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overlo
456. ops 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 17 Swing the engine back to its original position and install the engine pivot plate retaining fastener Part No 77828 July 2005 Section 3 Scheduled Maintenance Procedures REV B 20 Replace the Fuel Filter Element Perkins Models 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 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 Perform this procedure with the engine off 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 PartNo 77828 CHECKL
457. ord LRG 425 EFI Models before serial number 11880 sse 6 29 A Electrical Schematic S 65 Ford LRG 425 EFI Models after serial number 11879 6 31 Ground Control Box Terminal Strip Wiring Diagram 5 65 Ford LRG 425 EFI Models before serial number 11880 6 33 Ground Control Box Switch Panel Wiring Diagram 5 65 Ford LRG 425 EFI Models before serial number 11880 6 34 A Ground Control Box Terminal Strip Wiring Diagram 5 65 Ford LRG 425 EFI Models after serial number 11879 6 35 A Ground Control Box Switch Panel Wiring Diagram 5 65 Ford LRG 425 EFI Models after serial number 11879 6 36 Platform Control Box Terminal Strip Wiring Diagram 5 65 LRG 425 EFI 5 6 37 A Platform Control Box Switch Panel Wiring Diagram 5 65 Ford LRG 425 EFI Models 6 38 Genie S 60 5 65 Part 77828 July 2005 TABLE OF CONTENTS Section6 Rev Schematics continued C Electrical Schematic 5 60 Deutz F3L 2011 Models before serial number 11880 6 39 Electrical Schematic 5 60 Deutz F3L 2011 Models after serial number 11879 00 000400 000 6 41 C Electrical Schematic 5 60 CE Models Deutz F3L 2011 Models before serial number 11880 6 43 A Electrical Schematic S 60 CE Models Deutz F3L 2011 Models
458. orts to ECM to be sure they are secure OR replace ECM 613 A D Loss Loose wire connections to ECM OR ECM is aulty Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM enie A TEREX COMPANY S 60 S 65 Part No 77828 July 2005 Section 5 Fault Codes FORD ENGINE FAULT CODES Code Problem Cause Solution Locate and repair any engine harness wiring 61 4 RTI 1 Loss ed OR ECM is damage or shorts to ECM to be sure they are secure OR replace ECM Locate and repair any engine harness wiring 615 Flash Checksum Invalid 0068 wire connections damage or shorts to ECM to be sure they are faulty secure OR replace ECM Locate and repair any engine harness wiring 616 RAM Failure Wire onnsbtions to EOM OR ECM is 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 OR locate and troubleshoot or repair faulty engine sensor OR replace Engine harness wiring and or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty 631 External 5V DC Ref Lower than Expected E
459. ounting 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 PartNo 77828 Genie 5 60 5 65 BOOM COMPONENTS 12 Pull back on the extend cable mounting plate until it clears the blocks welded to the inside of the number 1 boom tube 13 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 14 Locate the lower extend cable bracket on the bottom of the number 3 boom tube 15 Remove the lower extend cable bracket mounting fasteners and pull back on the bracket to release it from the number 3 boom tube 16 While pushing the lower extend cable bracket towards the platform pull the extend cable mounting plate towards the pivot end of the boom 17 Secure the extend cable bracket and cables to the cylinder to prevent them from falling off when removing the cylinder 18 Remove the external snap rings from the extension cylinder pin at the pivot end of the boom 19 Use a soft metal drift to remove the pin 20 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
460. our machine contact Genie Industries Service Department If this fault appears on your machine contact 521 FPP2 High Voltage Notused Genie Industries Service Department 522 FPP2 Low Voltage Not used If this fault appears on your machine contact Genie Industries Service Department 531 TPS1 Signal Voltage High 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 Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 1 532 TPS1 Signal Voltage Low 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 Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 1 533 TPS2 Signal Voltage High 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 Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 2 534 TPS2 Signal Voltage Low The 2 throttle position sensor wiring and or connections open or short
461. ov 5 W008 ov 2 010 161070 2820 15100 2 asn 6 1 820 41620 O 15 43315 1 929 MOSZED 11810 MOSZ6O s ISTUSUS 18 595955 Jp O O 01 810 18 995950 Je se Q Gt a 6 819 NdUSEO ve omamo O CH 22 50 9551 8 819 HME 5 Jp 3NION3 LYVLS Co 21 810 48 ENSIS eg ee Coo 6250 220 ie 3SH3A3H T3dOHd Ble 02 50 12515 05 T3dOHd 05 E 18 50 HM 306 Jp O 9 30 SWezo 810 811620 wavivru 20 1 2 10 Iz dWnd Advan aa aaxnviz 2 Q 1551 HOLIMS LNY 1000 P 91 30 QU HM 84920 2 8 8 se HOLIMS 3UNSS3Ud 10 52 Q4 91 59 51520 OLNSPS HM 5 ve ve Coo Q 80 9NSI QH WEMOdHOLIMSASN Qd SX HM 2 829 HM ZWSI HM O WHOAIWId 221 O CH 2 60 1 veo ue
462. pen closed Component damage hazard The CAUTION 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 Place a suitable container underneath the hydraulic tank Remove the drain plug from the hydraulic tank 5 Completely drain the tank into a suitable container See capacity specifications Tag disconnect and plug the two suction hoses and supply hose for the auxiliary pump from the hydraulic tank Cap the fittings on the tank The hoses can be accessed through the access hole under the turntable Disconnect and plug the return filter hydraulic hose at the return filter Cap the fitting on the filter housing Genie 3 50 5 60 5 65 PartNo 77828 July 2005 Section Scheduled Maintenance Procedures REVD 8 Remove the ground controls side turntable cover 9 Support the hydraulic tank with an appropriate lifting device 10 Remove the hydraulic tank mounting fasteners 11 Remove the hydraulic tank from the machine AWARNING Cushing hazard The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine 12 Remove the hydraulic return filter housing mounting fasteners Remove the hydraulic return filter housing from the hydraulic tank 13 Remove the sucti
463. r 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 Part No 77828 July 2005 Section Scheduled Maintenance Procedures REV CHECKLIST B PROCEDURES B 11 B 12 Test the Platform Self leveling 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 Start the engine from the ground controls and lower the boom into the stowed position 2 Hold the 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 remain level at all times to within 5 degrees Part No 77828 5 60 5 65 Test the Engine Idle Select A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are tw
464. r fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Perform this procedure with the machine on a firm and level surface 1 Secure the turntable from rotating with the turntable rotation lock pin 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 2odil 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 PartNo 77828 Genie 3 Loosen the backlash pivot plate and adjustment bolts a 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 AWARNING could rotate unexpectedly when the rotation drive hub assembly is removed if the turntable is not secured with the turntable rotation lock pin Crushing hazard The turntable rotation drive hub assembly could become unbalanced and fall when removed
465. r 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 A DANGER 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 Part No 77828 5 60 5 65 CHECKLIST PROCEDURES A 11 Check and Adjust the Engine RPM Perkins Models Engine specifications require that this procedure be performed every 100 hours Maintaining the engine rpm at the proper setting for both 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 This procedure will require two people 1 Connect a tachometer to the engine Start the engine from the ground controls Result Low idle should be 1300 rpm Skip to step 3 if the low idle rpm is correct Section 3 Scheduled Maintenance Procedures July 2005 CHECKLIST A PROCEDURES 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
466. ranking ampere 1000A Use oils meeting API classification SJ or SH Reserve capacity 25A rate 200 minutes Units ship with 15W 40 SJ Ignition system Spark plug type Motorcraft AGSF 32 FM Spark plug gap 0 042 to 0 046 inches 1 07 to 1 17 mm Part No 77828 5 60 5 65 2 5 Section 2 Specifications July 2005 SPECIFICATIONS Deutz F3L 2011 Engine Displacement Number of cylinders Bore and stroke Horsepower Firing order Low idle High idle Compression ratio Compression pressure Governor Valve clearance cold 142 2 33 liters 3 3 7 x 4 409 inches 94 x 112 mm 48 2800 rpm 1 2 3 1500 rpm 2500 rpm 18 5 1 362 to 435 psi 25 to 30 bar centrifugal mechanical Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure 20 to 44 psi 1 4 to 3 bar Oil capacity 7 6 quarts including filter 8 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 90 20 to 32 10W 40 Above 23 5 20W 50 Engine oil should have minimum properties of API classification CC SG or CD SG grades Units ship with 10W 40 CH 4 Genie REV Oil temperature switch Torque 8 18 ft lbs 11 24 Nm Temperature switch point 220 F 104 Oil pressure switch Torque 8 18 ft lbs 11 24 Nm Oil pressure switch point 15 psi 1 bar Fuel injection
467. rd Models 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 GM 3 0L Operator Handbook Genie part number 101095 Ford LRG 425 EFI Operator Handbook Genie part number 84792 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 5 60 5 65 CHECKLIST PROCEDURES B 23 Perform Engine Maintenance Perkins Models 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 serv
468. rial number 11880 July 2005 Section 6 Schematics REVA Electrical Schematic S 60 CE Models Deutz F3L 201 1 Models after serial number 11879 C22LS E EX ale E m Ol zu 5 mE 5 g y CIP C35RPM BK RD C1B 9 o 8 FOOTSW HIGH 9 9 FOOTSW LOW zQ 5 x oe 8 5 E 5 LOW RPM FUNCTIONENA C35RPM BK RD BRN 8 m HIGH IDLE RELAY 1 BRAD 65 18 HIGH RPM SOLENOID 8 2 8 2 3 5 C2P 7 C45GEN C2B 7 5 C45GEN GRWH 5 12 IA GENERATOR GETAN reru ie ci eer neues uses eivai ey TS PI 1 12 DLITE BWH C3
469. rive hub Refer to Section 2 Specifications 5 Repeat steps 1 through 4 for all the other drive hubs PartNo 77828 Genie 5 60 5 65 CHECKLIST D PROCEDURES D 5 Check the Free wheel Configuration 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 CAUTION machine must be towed do not exceed 2 mph 3 2 km h Non steer Wheels All Models 1 Chockthe 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 Liftthe wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steer wheel hub TREE disengaged position arf E art pe engaged position Section Scheduled Maintenance Procedures July 2005 CHECKLIST D PROCEDURES 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 machin
470. rmance 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 pivot plate retaining fastener Section Scheduled Maintenance Procedures July 2005 CHECKLIST B PROCEDURES B 4 Check the Oil Cooler and Cooling Fins Deutz Models 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 perfor
471. s REVA Ground Control Box Terminal Strip Wiring Diagram S 60 CE Models Deutz F3L 201 1 Models after serial number 11879 4181 257 7 69 HARNESS 1108 C5 ENGINE 661 220 HOLIMS NOISNAL EIGA 0167 HOLIMS wooa 20310 2 6181 70350 19 WHOALVId OL 48098 N d LYVLS NOLINDI HOA 72 21 5334 OF 0
472. sembly 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 CAUTION can be damaged if they are kinked or pinched 11 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Ford models 1 Disconnect the electrical connector for the oxygen sensor at the tailpipe Do not remove the oxygen sensor 2 Remove the engine oil dipstick fasteners from the muffler bracket Remove the dipstick from the engine 3 Remove the muffler retaining fasteners from the exhaust pipe 4 Support the muffler and bracket assembly with an overhead crane or other suitable lifting device 5 Remove the muffler bracket mounting fasteners Carefully remove the muffler and bracket assembly from the engine 6 Support the engine with a suitable lifting device Do not lift it 7 Remove the engine plate to vibration isolator fasteners PartNo 77828 Genie S 60 5 65 ENGINES 8 Remove the engine mounting plate to bell housingfasteners 9 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 appropriate lifting device 12 Remove all of the engine bell housing fasteners 13 Carefully pull the pump a
473. serial number 11880 Ground Control Box Switch Panel Wiring Diagram S 65 July 2005 A TEREX COMPANY S 60 5 65 G Part No 77828 REV B s Sc HH 5 5 zz o lt 8 29 6 gt 54 15 ul 669 5 225 02 Su 125 10 2 2 0520 EISE 18455585 884288 2 8 2 BE 325555 54682859456 aco So S gt 3 555 998 ex u 9u5ooog 8Ssk lt lt lt lt gt 92 50 259068 2 2 59555258 28555504 E 5 2 2 5 5 2 5 555 65 255520
474. sink Omuczcil SO lt or C19JSV GR WH 57 j WH C19JSV GR WH 7 1 578 BRN JC3 BRN GND a RD E STOP 3 C134PWR RD LS18 2N C134PWR RD H1 LIFT DRIVE OPTION JIB CR27 RD LS18 CABLE 122222222 G82BRKWHAD CIPS ___________ CR30 C1P 12 C40LS OR C2P 2 P23BAT WH C7P 2 P22BAT BK 7 1 1 C19JSV GR WH 7 C18PRR GR BK C4P 6 C17PRL 5 C15PLD OR BK C4P 3 C14PLU 2 1 C129DA BL 10 TS8 C46HRN GR 2 5 C59CNK C3P 11 147 P26BAT 9 1 P2 P25FS RD C9 3 TS2 P24FS WH 9 2 54 CDLITE OR RD C2P 4 ES C45GEN GR WH 2 7 C46HRN GR C2P 5 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 DESCRIPTION TILT ALARM 48 PINCONNECTOR BLOCK ITEM H1 7 C9 U13 J1 J2 43 CR27 CR30 LS18 OPTION F S 12V DC BATTERY
475. ss 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 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 5 60 5 65 CHECKLIST PROCEDURES A 6 Check the High Pressure Hydraulic Filter Condition Indicator Maintaining the hydraulic return 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 componentdamage 1 Open the engine side turntable cover 2 Start the engine from the ground controls 3 Change the engine idle to high rpm rabbit symbol 4 Visually inspect the filter condition indicator 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 filter is being bypassed and the filter should be replaced See D 6 Heplace the Hyaraulic Filters Section 3 Scheduled Maintenance Pro
476. stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 the key switch to platform control Do not start the engine 3 Push in platform controls red Emergency Stop button to the off position 4 Donotpress 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 PLATFORM CONTROLS 10 Compare the function ramp rate time with the table below and determine whether the ramp rate time needs to increase or decrease 11 While the joystick is activated set 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 Each time the drive enable toggle switch is momentarily moved the time will change in 10 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 Result The alarm should sound indicating that the settings have been saved in memory Do not operate any machine function during the 10 second waiting time Ramp rate factory settings Boom up down 7 M
477. 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 Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine from the platform controls 2 Level the platform 3 Determine the maximum platform capacity Refer to the machine serial plate Part No 77828 Genie 5 60 5 65 CHECKLIST PROCEDURES 4 Using a suitable lifting device place an appropriate test weight equal to the maximum platform capacity in one of the locations shown Result The platform overload indicator light should be off at both the ground and platform controls 5 Carefully move the test weight to each remaining location Result The platform overload indicator light should be off at both the ground and platform controls 6 Add an additional 66 Ibs 30 kg of weight to overload the platform Result The alarm should be sounding The platform overload indicator light should be flashing at both the ground and platform controls Result If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations the platform overload system needs to be calibrated See D 9 Calibra
478. t located on the traction manifold 7 Holdthe charge pressure relief valve and remove the cap item UU 8 Startthe engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position 9 Adjust the internal hex socket until the pressure reading on the gauge is 40 psi 2 8 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 Turn the engine off and remove the pressure gauge 4 54 5 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV D 7 12 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 that provides this force field AWARNING Electrocution 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 the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Specification MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its directi
479. t number 84794 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 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 5 60 5 65 0 2 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or 6 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 in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting using a mulit purpose grease Part No 77828 July 2005 Section 3 Scheduled Maintenance Procedures REV D C 3 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or six months Testing the platform overload
480. tching 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 Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 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 O Result The engine should start promptly and operate smoothly in low and high idle 4 Release the foot switch and shut the engine off by pushing in the red Emergency Stop button in to the off position 5 Move the fuel select switch to LPG REVC Restart the engine and allow it to run at low idle Press down the foot switch to allow the engine to run at high idle O Result The engine should start promptly and operate smoothly in low and high idle 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 Genie 3 24 5 60 5 65 Part No 77828 July 2005 Section Scheduled Maintenance Procedures REVC CHECKLIST B PROCEDURES B 14 5 Bringthe machine to top drive speed before reachin
481. te retaining fastener Part No 77828 July 2005 Section Scheduled Maintenance Procedures REV CHECKLIST B PROCEDURES B 5 B 6 Check the Lug Nut Torque including the tires and wheels Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result tip over Component damage also result if problems are not discovered and repaired in a timely fashion AWARNING 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 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 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque 4 Check the pressure in each air filled tire Part No 77828 5 60 5 65 Confirm the Proper Brake Configuration 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 brake disengaged position brake engaged position 2 Besure
482. te the Platform Overload System if equipped There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds Section 3 Scheduled Maintenance Procedures July 2005 CHECKLIST C PROCEDURES 7 Carefully move the test weights to each remaining location in the platform Result The alarm should be sounding The platform overload indicator light should be flashing at both the ground and platform controls Result If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations the platform overload system needs to be calibrated See D 9 Calibrate the Platform Overload System if equipped There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds 8 Test all machine functions from the platform controls 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 Result All ground control functions should not operate Machine functions should still operate with auxiliary power at the ground controls 5 60 5 65 0 11 Lift the test weights off the platform floor using suitable lifting device Result The platform overload indicator light and alarm should turn off at both the ground and platform controls
483. teps 2 through 5 and recheck relief valve pressure 8 Removethe pressure gauge Genie TEREX COMPANY 4 40 S 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV D MANIFOLDS 7 3 Jib Boom Platform Rotate Manifold Components Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way Platform rotate jib boom select 20 25 ft lbs 27 34 Nm Genie Part No 77828 5 60 5 65 4 41 Section 4 Repair Procedures July 2005 MIN MANIFOLDS REVD 7 4 Brake Two Speed Manifold Components The brake two speed manifold is mounted near the turntable rotator Index Schematic No Description Item Function Torque 1 Orifice 0 025 inch 0 64 mm Jae Turntable rotation brake release 2 Solenoid valve 2 position way KK Brake release 20 25 ft lbs 27 34 Nm 3 Solenoid valve 2 position 3 way LL Two speed motor shift 20 25 ft lbs 27 34 Nm 4 Check ll usos Brake release circuit 20 25 ft lbs 27 34 Nm Genie TEREX COMPANY 4 42 S 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures SSS REV D 7 5 Turntable Rotation Manifold Components The turntable rotation manifold is
484. the battery Genie Part No 77828 5 60 5 65 4 31 Section 4 Repair Procedures July 2005 Hydraulic Pumps 6 1 Function Pump How to Remove the Function Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 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 open closed CAUTION 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 4 32 Genio 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 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 C
485. ther AWARNING Crushing hazard If the upper and REV B 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 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 CAUTION Cables and hoses can be damaged if they are kinked or pinched Component damage hazard The CAUTION cable track can be damaged if it is twisted lower cable tracks are not properly secured together the cable track could become unbalanced and fal when removed from the machine Genie 4 16 5 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REV B How to Repair the Cable Track 7 Component damage hazard CAUTION The boom cable track can be damaged if it is twisted A cable track repair kit is available through the Genie Industries Service Parts Department part no 77896 The kit includes a 4 link section of cable track 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Carefully remove the snap rings from each end of the damaged section of cable track 3 Removethe retaining fasteners from the upper black rollers from the 4 link section of cable track to be replace
486. tive 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 vent plug b drain plug 3 Install the fastener that was just removed c filter bowl j accum through the engine tray and into the engine tray anchor hole in the turntable 5 Loosenthe 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 AWARNING Crushing hazard Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in 6 Tighten the vent plug death or serious injury If the fuel filter water separator is completely drained you must prime the fuel filter water separator before starting the engine See B 20 The Fuel Filter Element Perkins Models for instructions on how to prime the fuelfilter water separator 4 Locate the fuel filter water separator next to the oil filter 7 Clean up any fuel that may have spilled Genie 3 12 S 60 5 65 Part No 77828 July 2005 Section 3 Scheduled Maintenance 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 Do not completely drain the filter a fuel filte
487. tructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 4 Raisethe boom above horizontal 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 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 Part No 77828 July 2005 Section Scheduled Maintenance Procedures REVC 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 PartNo 77828 5 60 5 65 3 27 CHECKLIST PROCEDURES B 17 Test the Alarm Package Optional Equipment The alarm package includes
488. ture ratio of 13 0 1 to 13 211 Preliminary setting turn low idle adjustment screw clockwise all the way in Turn low idle adjustment screw counterclockwise 2 3 4 turns Part No 77828 Genie 5 60 5 65 CHECKLIST D PROCEDURES D 8 Perform Engine Maintenance Deutz Models Engine specifications require that this 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 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 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 Section Scheduled Maintenance Procedures July 2005 CHECKLIST D PROCEDURES D 9 Calibrate the Platform Overload System if equipped Genie specificati
489. und controls Result All ground control functions should not operate If the platform overload system is not operating properly repeat steps 1 through 4 Genie Part No 77828 5 60 5 65 3 49 Section Scheduled Maintenance Procedures July 2005 Checklist E Procedures E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often 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 Perform this procedure with the boom in the stowed position 1 GM and Ford models Turn the valve on the LPG tank clockwise to the off position if equipped Then slowly disconnect the hose from the LPG tank 2 GM and Ford models Open the clamps from the LPG tank straps and remove the LPG tank from the machine if equipped REVD 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 o
490. und Control Box Terminal Strip Wiring Diagram S 60 Deutz F3L 2011 Models before serial number 11880 Section 6 Schematics 18098 FINGOW LYVLS NOLINDI HOA 21 dWAL OF C4 6 6027 Eel 8228 zoar 9 0000000 slo AINO 186310 MS AIA OL 2 C4 9 9 ot s G4 2 v G4 yaa Oo in INANI wpe gl AN u3i3WOHOVh 200041 Aways GH oz I LHVIS OL ILG 2 gt tc A Sseujsnpu 5a flx z T 5 mms LL 5 859 15 88LI Qu HO 53 2 860 LISTHO 7 E id Zi GEO HMA VETO p QVO TH3AO WHOALV1d
491. urrent should be capable of reading up to 800 mA Resistor lO 4 Connectthe negative lead to the other terminal Genie part number 27287 on the coil If testing a single terminal coil The battery should read 9V DC or connect the negative lead to the more when measured across the internal metallic ring at either end terminals of the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading coi AMMETER 6 Atthe battery or coil terminals reverse the Om connections Note and record the current reading b Result Both current readings are greater than all p 0 mA and are different by a minimum of 20 ov The coil is good a Result If one or both of the current readings PRA her eos 4 0 mA or if the two current readings do not differ by a minimum of 20 the and or its internal diode are faulty and the coil should be replaced a multimeter b 9V DC battery 100 resistor d coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 4 56 5 60 5 65 Part No 77828 July 2005 Section 4 Repair Procedures REVC 8 1 Turntable Rotation Components Turntable Rotation Assembly How to Remove the Turntable Rotation Assembly When removing a hose assembly o
492. urs 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 1443S Perkins 400 Series Operation Manual Genie part number 94890 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 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 Section 3 Scheduled Maintenance Procedures July 2005 Checklist B Procedures B 1 Inspect the Battery 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 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 contai
493. val of operation 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 Genie 5 60 5 65 21 Perform Engine Maintenance Deutz Models 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 Deutz FL 2011 Operation Manual Deutz part number 0297 9929 Deutz FL 2011 Operation Manual Genie part number 84794 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 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 July 2005 Section 3 Scheduled Maintenance Procedures REV B 22 Perform Engine Maintenance GM and Fo
494. ve 0 1 gpm 0 38 L MIN Bleeds off differential sensing valves to tank 20 25 ft lbs 27 34 Nm 22 Differential sensing valve 150 psi 10 3 bar Differential sensing circuit meters flow to functions 30 35 ft lbs 41 47 Nm 23 Check W Differential sensing circuit platform level up 10 12 ft Ibs 14 16 Nm 24 Check OT Differential sensing circuit platform level down 10 12 ft Ibs 14 16 Nm 25 Proportional solenoid valve Turntable rotate left right 20 25 ft lbs 27 34 Nm 26 Flow control valve 0 6 gpm 2 27 Platform rotate jib boom 5 65 20 25 ft lbs 27 34 Nm 27 Check valve 30 psi 2 bar Platform rotate and jib boom circuit S 65 prevents hydraulic hoses from draining back to tank 20 25 ft lbs 27 34 Nm 28 Differential sensing valve 110 psi 7 6 Dare Bann Boom extend retract circuit 30 35 ft Ibs 41 47 Nm 29 Needle valve 2 2 2 1 uas Platform level circuit 30 35 ft lbs 41 47 Nm 30 Solenoid valve 3 position 4 way
495. ver 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 Deutz FL 2011 Operation Manual Genie part number 84794 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 Genie 5 60 5 65 4 Perform Engine Maintenance GM and Ford Models 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 av
496. x i m C213 C212 26 8 10 C129JDA BL C3B 10 EZ 8 6 C18JD PRR GR BK C4B 6 DOWN de JIB 1 UP C17JU PRL GR C4B 5 amp B C294 C282 8 C18JD PRR GR BK 8 lt PLATFORM ROTATE RIGHT RIGHT PLATFROM gt 1 LEFT C17JU PRL GR PLATFORM ROTATE LEFT C221 C222 5 B RIGHT PLATFROM LIE x 51 it CI29D BK If DESCENTALARMOPTION 1 o 18 E C4P 7 C19JSV GR WH C4B 7 1 5 5 22 35 1 EI CREER 0 1 2 5 5 5 x JIB VALVE 58 JIB VALVE x I a x E 2 58 80 Ex ale 5 enie A TEREX COMPANY S 60 5 65 G 6 64 Part No 77828 July 2005 Section 6 Schematics Electrical Schematic S 65 Models Deutz F3L 2011 Models after serial number 11879 Section 6 Schematics July 2005 Ground Control Box Terminal Strip Wiring Diagram 5 65 Deutz F3L 2011 Models before serial number 11880 REV July 2005 Ground Control Box Terminal Strip Wiring Diagram S 65 Deutz F3L 2011 M
497. x a C33STR BK fp 1 5 i 8005 1 5 22 STARTER MOTOR 8 8 5 2 5 t gt Oi SEE EEE i N SPEED REDUCTION RELAY 4 AUXILIARY a AUXILIARY POWER RELAY C1P 1 C27AUX RD C1P 1 1 EN Le 5 L 4 AUXILIARY PUMP 4 a 1 amp 1 5 C28TTA RD BK SiP u x C28TTA RD BK WH TI TALARM a x C7P 2 P23BAT WH C7B 2 nir P134TTS RD RD Ye BRN EVEL SENSOR y lt 4 a e 5 o m x N C1P 2 C28TTARD BK C1P 2 ad P134FB WH FLASHING BEACONS OPTION C2P 5 C46HRN GR C2B 5 C46HRN GR gp BORN RELAY RD S 4 5 2 Y 7 1 22 P22HRN E R46HRN C6 9 Y ER i P134PWR B 5 2 nypmAULIC Oll C2P 6 R21IGN WH 5 4 4 TEMPERATURE SWITCH P134PWR RD OPTION a P22LS BK E CH6OR 05 1 EX COOLING FAN Ba P116HYD RD Box s 5 e C107AFWH_ u CES sion 8 52 5 m a a T E ms c z z 89 po ES ae 3 5 35 54151 1 1 m 5 50 PE 5 e 5 22 asd gsc wes 1 or 1654 1 2865 amp 50 EROS 5 P20BAT RD oh 0784 IT a J200 8 lt S 2 2 N e iO Part No
498. y 45 number Model year Country of manufacture USA odel y This machine complies with ANSI A92 5 CAN B 354 4 Genie Industries 18340 NE 76th Street Redmond WA 98052 USA PN 77055 Genie A TEREX COMPANY Part No 77828 S 60 5 65 July 2005 ee This page intentionally left blank Genie iv 5 60 5 65 Part No 77828 July 2005 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie S 60 and Genie S 65 Operator s Manual 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 M 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 Mb Part No 77828 S 60 5 65 V Section 1 Safety Rules July 2005 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the d
499. y 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 PartNo 77828 5 60 5 65 4 15 Section 4 Repair Procedures July 2005 BOOM COMPONENTS 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 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 Always replace the cotter pin with anew 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 toge
500. yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle Swing the engine back to its original position and install the engine pivot plate retaining fastener No 77828 S 60 5 65 3 21 Section Scheduled Maintenance Procedures July 2005 CHECKLIST B PROCEDURES B 9 Test the Ground Control Override 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 Start the engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle Result All boom functions should operate Genie 5 60 5 65 10 Check the Oscillate Directional Valve Linkage Perform this test only on models equipped with a oscillating axle Proper axle oscillation is essential to safe machine 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 stee

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