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Service
Manual
Refer to inside cover for additional serial number information
(from serial number 9154)
Part No. 77828
Rev B
July 2005
Introduction
July 2005
Introduction
Important
Serial Number Information
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.
Genie Industries offers the following Service
Manuals for these models:
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.
Title
Part No.
S-60 and S-65 Service Manual
(before serial number 2575) ................................. 34476
S-60 and S-65 Service Manual
(from serial number 2575 to 6623) ....................... 48412
S-60 and S-65 Service Manual
(from serial number 6624 to 9153) ....................... 65196
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-mail: [email protected]
Copyright © 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.
Printed on recycled paper
Printed in U.S.A.
ii
S-60 • S-65
Part No. 77828
July 2005
INTRODUCTION
Serial Number Legend
Model: S-60
S6005-12345
Serial number:
Model year: 2005 Manufacture date: 04/12/05
Electrical schematic number: E0186
Machine unladen weight: 20,736lbs / 9,406kg
Foam Tires add 764 lbs/347 kg to weight
Rated work load (including occupants): 500 lb / 227 kg
Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
Air Tires 2 deg / Foam Tires 4.5 deg
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 60 ft 2 in/ 18.3 m
Maximum platform reach : 50 ft 4 in/ 15.3 m
Gradeability: 45%
S6005 05 - 12345
Model
Sequence
number
Model year
Country of manufacture: USA
This machine complies with:
ANSI A92.5
CAN B.354.4
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
PN - 77055
Part No. 77828
S-60 • S-65
iii
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iv
S-60 • S-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.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 77828
S-60 • S-65
v
Section 1 • Safety Rules
July 2005
SAFETY RULES
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine
use signal words to identify the 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.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
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
indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
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.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Used to indicate operation or
maintenance information.
vi
S-60 • S-65
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
Part No. 77828
July 2005
Table of Contents
Introduction
Important Information .................................................................................................. ii
Serial Number Information ........................................................................................... ii
Serial Number Legend ................................................................................................ iii
Section 1
Safety Rules
General Safety Rules ................................................................................................. iii
Section 2
Section 3
Rev
Specifications
A
Machine Specifications .......................................................................................... 2 - 1
A
Performance Specifications ................................................................................... 2 - 1
B
Hydraulic Specifications ........................................................................................ 2 - 2
B
Manifold Component Specifications ...................................................................... 2 - 3
A
GM 3.0L Engine Specifications .............................................................................. 2 - 4
A
Ford LRG-425 EFI Engine Specifications .............................................................. 2 - 5
B
Deutz F3L-2011 Engine Specifications .................................................................. 2 - 6
B
Perkins 404-22 Engine Specifications ................................................................... 2 - 7
C
Machine Torque Specifications .............................................................................. 2 - 8
B
Hydraulic Hose and Fitting Torque Specifications ................................................. 2 - 9
A
SAE and Metric Fasteners Torque Charts ........................................................... 2 - 10
Rev
Scheduled Maintenance Procedures
Introduction ........................................................................................................... 3 - 1
Pre-Delivery Preparation ....................................................................................... 3 - 3
Maintenance Inspection Report ............................................................................. 3 - 5
C
Part No. 77828
Checklist A Procedures
A-1
Perform Pre-operation Inspection ................................................................ 3 - 7
A-2
Perform Function Tests ............................................................................... 3 - 7
A-3
Perform Engine Maintenance - Deutz Models .............................................. 3 - 8
S-60 • S-65
vii
July 2005
TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures, continued
A-4
Perform Engine Maintenance - GM and Ford Models .................................. 3 - 8
A-5
Perform Engine Maintenance - Perkins Models ........................................... 3 - 9
A-6
Check the High Pressure Hydraulic Filter Condition Indicator ...................... 3 - 9
A-7
Test the Oscillate Axle (if equipped) .......................................................... 3 - 10
A-8
Perform 30 Day Service ............................................................................. 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
B-1
Inspect the Battery ..................................................................................... 3 - 16
B-2
Inspect the Electrical Wiring ....................................................................... 3 - 16
B-3
Check the Exhaust System ........................................................................ 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 Oil Level in the Drive Hubs ....................................................... 3 - 20
B-8
Check and Adjust the Engine RPM - Deutz Models ................................... 3 - 20
B-9
Test the Ground Control Override .............................................................. 3 - 22
B-10 Check the Oscillate Directional Valve Linkage ........................................... 3 - 22
B-11 Test the Platform Self-leveling ................................................................... 3 - 23
viii
S-60 • S-65
Part No. 77828
July 2005
TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures, continued
B-12 Test the Engine Idle Select ........................................................................ 3 - 23
B-13 Test the Fuel Select Operation - GM and Ford Models .............................. 3 - 24
B-14 Test the Drive Brakes ................................................................................ 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
B-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 Models ............................................ 3 - 32
B-22 Perform Engine Maintenance - GM and Ford Models ................................ 3 - 33
B-23 Perform Engine Maintenance - Perkins Models ......................................... 3 - 33
D
Part No. 77828
Checklist C Procedures
C-1
Perform Engine Maintenance - Deutz Models ............................................ 3 - 34
C-2
Grease the Platform Overload Mechanism (if equipped) ........................... 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
S-60 • S-65
ix
July 2005
TABLE OF CONTENTS
Section 3
Rev
C
D
Section 4
Rev
Scheduled Maintenance Procedures, continued
Checklist D Procedures
D-1
Check the Boom Wear Pads ..................................................................... 3 - 40
D-2
Check the Turntable Rotation Bearing Bolts .............................................. 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 .......................................................... 3 - 43
D-6
Replace the Hydraulic Filters ..................................................................... 3 - 45
D-7
Check and Adjust the Air/LPG Mixture - GM Models ................................. 3 - 46
D-8
Perform Engine Maintenance - Deutz Models ............................................ 3 - 47
D-9
Calibrate the Platform Overload System (if equipped) ............................... 3 - 48
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil .............................................................. 3 - 50
E-2
Perform Engine Maintenance - Deutz Models ............................................ 3 - 52
E-3
Perform Engine Maintenance - Deutz Models ............................................ 3 - 52
E-4
Remove and Inspect the Boom Extend/Retract Cables ............................. 3 - 53
Repair Procedures
Introduction ........................................................................................................... 4 - 1
A
B
x
Platform Controls
1-1
ALC-500 Circuit Board ................................................................................. 4 - 2
1-2
Joysticks ...................................................................................................... 4 - 3
Platform Components
2-1
Platform Leveling Slave Cylinder ................................................................. 4 - 7
2-2
Platform Rotator ........................................................................................... 4 - 8
S-60 • S-65
Part No. 77828
July 2005
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures, continued
A
Jib Boom Components, S-65
B
C
C
Part No. 77828
3-1
Jib Boom .................................................................................................... 4 - 11
3-2
Jib Boom Lift Cylinder ................................................................................ 4 - 12
Boom Components
4-1
Cable Track ............................................................................................... 4 - 13
4-2
Boom ......................................................................................................... 4 - 18
4-3
Boom Lift Cylinder ..................................................................................... 4 - 19
4-4
Boom Extension Cylinder .......................................................................... 4 - 20
4-5
Boom Extend/Retract Cables ..................................................................... 4 - 22
4-6
Platform Leveling Master Cylinder ............................................................. 4 - 25
Engines
5-1
RPM Adjustment - Deutz Models ............................................................... 4 - 26
5-2
RPM Adjustment - Perkins Models ............................................................ 4 - 26
5-3
Flex Plate ................................................................................................... 4 - 26
5-4
Engine Fault Codes - GM and Ford Models ............................................... 4 - 30
Hydraulic Pumps
6-1
Function Pump .......................................................................................... 4 - 32
6-2
Drive Pump ................................................................................................ 4 - 33
S-60 • S-65
xi
July 2005
TABLE OF CONTENTS
Section 4
Rev
D
Repair Procedures, continued
Manifolds
7-1
Function Manifold Components ................................................................. 4 - 36
7-2
Valve Adjustments - Function Manifold ...................................................... 4 - 40
7-3
Jib Boom / Platform Rotate Manifold Components ..................................... 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 ........................................................ 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 Coils ................................................................................................. 4 - 55
C
Turntable Rotation Components
8-1
C
Axle Components
9-1
Section 5
Rev
Turntable Rotation Assembly ..................................................................... 4 - 57
Oscillate Axle Cylinders ............................................................................. 4 - 59
Fault Codes
Introduction ........................................................................................................... 5 - 1
xii
A
Fault Codes - Control System ............................................................................... 5 - 2
A
Fault Codes - Ford Engine .................................................................................... 5 - 6
S-60 • S-65
Part No. 77828
July 2005
TABLE OF CONTENTS
Section 6
Rev
Schematics
Introduction ........................................................................................................... 6 - 1
Part No. 77828
A
Electrical Symbols Legend .................................................................................... 6 - 2
A
Hydraulic Symbols Legend .................................................................................... 6 - 3
A
GM 3.0L Engine Harness ...................................................................................... 6 - 5
A
Ford LRG-425 EFI Engine Harness....................................................................... 6 - 6
B
Electrical Schematic, S-60, GM 3.0L Models ......................................................... 6 - 7
B
Ground Control Box Terminal Strip Wiring Diagram,
S-60, GM 3.0L Models ................................................................................. 6 - 9
B
Ground Control Box Switch Panel Wiring Diagram,
S-60, GM 3.0L Models ............................................................................... 6 - 10
B
Platform Control Box Terminal Strip Wiring Diagram,
S-60, GM 3.0L Models ............................................................................... 6 - 11
B
Platform Control Box Switch Panel Wiring Diagram,
S-60, GM 3.0L Models ............................................................................... 6 - 12
C
Electrical Schematic, S-65, GM 3.0L Models ....................................................... 6 - 13
B
Ground Control Box Terminal Strip Wiring Diagram,
S-65, GM 3.0L Models ............................................................................... 6 - 15
B
Ground Control Box Switch Panel Wiring Diagram,
S-65, GM 3.0L Models ............................................................................... 6 - 16
B
Platform Control Box Terminal Strip Wiring Diagram,
S-65, GM 3.0L Models ............................................................................... 6 - 17
B
Platform Control Box Switch Panel Wiring Diagram,
S-65, GM 3.0L Models ............................................................................... 6 - 18
S-60 • S-65
xiii
July 2005
TABLE OF CONTENTS
Section 6
xiv
Rev
Schematics, continued
A
Electrical Schematic, S-60, Ford LRG-425 EFI Models
(before serial number 11880) ..................................................................... 6 - 19
A
Electrical Schematic, S-60, Ford LRG-425 EFI Models
(after serial number 11879) ........................................................................ 6 - 21
A
Ground Control Box Terminal Strip Wiring Diagram,
S-60, Ford LRG-425 EFI Models (before serial number 11880) ................. 6 - 23
A
Ground Control Box Switch Panel Wiring Diagram,
S-60, Ford LRG-425 EFI Models (before serial number 11880) ................. 6 - 24
A
Ground Control Box Terminal Strip Wiring Diagram,
S-60, Ford LRG-425 EFI Models (after serial number 11879) .................... 6 - 25
A
Ground Control Box Switch Panel Wiring Diagram,
S-60, Ford LRG-425 EFI Models (after serial number 11879) .................... 6 - 26
A
Platform Control Box Terminal Strip Wiring Diagram,
S-60, Ford LRG-425 EFI Models ............................................................... 6 - 27
A
Platform Control Box Switch Panel Wiring Diagram,
S-60, Ford LRG-425 EFI Models ............................................................... 6 - 28
B
Electrical Schematic, S-65, Ford LRG-425 EFI Models
(before serial number 11880) ..................................................................... 6 - 29
A
Electrical Schematic, S-65, Ford LRG-425 EFI Models
(after serial number 11879) ........................................................................ 6 - 31
A
Ground Control Box Terminal Strip Wiring Diagram,
S-65, Ford LRG-425 EFI Models (before serial number 11880) ................. 6 - 33
A
Ground Control Box Switch Panel Wiring Diagram,
S-65, Ford LRG-425 EFI Models (before serial number 11880) ................. 6 - 34
A
Ground Control Box Terminal Strip Wiring Diagram,
S-65, Ford LRG-425 EFI Models (after serial number 11879) .................... 6 - 35
A
Ground Control Box Switch Panel Wiring Diagram,
S-65, Ford LRG-425 EFI Models (after serial number 11879) .................... 6 - 36
A
Platform Control Box Terminal Strip Wiring Diagram,
S-65, Ford LRG-425 EFI Models ............................................................... 6 - 37
A
Platform Control Box Switch Panel Wiring Diagram,
S-65, Ford LRG-425 EFI Models ............................................................... 6 - 38
S-60 • S-65
Part No. 77828
July 2005
TABLE OF CONTENTS
Section 6
Rev
Part No. 77828
Schematics, continued
C
Electrical Schematic, S-60, Deutz F3L-2011 Models
(before serial number 11880) ..................................................................... 6 - 39
A
Electrical Schematic, S-60, Deutz F3L-2011 Models
(after serial number 11879) ........................................................................ 6 - 41
C
Electrical Schematic, S-60, CE Models, Deutz F3L-2011 Models
(before serial number 11880) ..................................................................... 6 - 43
A
Electrical Schematic, S-60, CE Models, Deutz F3L-2011 Models
(after serial number 11879) ........................................................................ 6 - 45
B
Ground Control Box Terminal Strip Wiring Diagram,
S-60, Deutz F3L-2011 Models (before serial number 11880) .................... 6 - 47
B
Ground Control Box Switch Panel Wiring Diagram,
S-60, Deutz F3L-2011 Models (before serial number 11880) .................... 6 - 48
A
Ground Control Box Terminal Strip Wiring Diagram,
S-60, Deutz F3L-2011 Models (after serial number 11879) ....................... 6 - 49
A
Ground Control Box Switch Panel Wiring Diagram,
S-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,
S-60, CE Models, Deutz F3L-2011 Models
(after serial number 11879) ........................................................................ 6 - 54
B
Platform Control Box Terminal Strip Wiring Diagram,
S-60, Deutz F3L-2011 Models ................................................................... 6 - 55
B
Platform Control Box Switch Panel Wiring Diagram,
S-60, Deutz F3L-2011 Models ................................................................... 6 - 56
S-60 • S-65
xv
July 2005
TABLE OF CONTENTS
Section 6
xvi
Rev
Schematics, continued
D
Electrical Schematic, S-65, Deutz F3L-2011 Models
(before serial number 11880) ..................................................................... 6 - 57
A
Electrical Schematic, S-65, Deutz F3L-2011 Models
(after serial number 11879) ........................................................................ 6 - 59
D
Electrical Schematic, S-65, CE Models, Deutz F3L-2011 Models
(before serial number 11880) ..................................................................... 6 - 61
A
Electrical Schematic, S-65, CE Models, Deutz F3L-2011 Models
(after serial number 11879) ........................................................................ 6 - 63
B
Ground Control Box Terminal Strip Wiring Diagram,
S-65, Deutz F3L-2011 Models (before serial number 11880) .................... 6 - 65
B
Ground Control Box Switch Panel Wiring Diagram,
S-65, Deutz F3L-2011 Models (before serial number 11880) .................... 6 - 66
A
Ground Control Box Terminal Strip Wiring Diagram,
S-65, Deutz F3L-2011 Models (after serial number 11879) ....................... 6 - 67
A
Ground Control Box Switch Panel Wiring Diagram,
S-65, Deutz F3L-2011 Models (after serial number 11879) ....................... 6 - 68
B
Ground Control Box Terminal Strip Wiring Diagram,
S-65, CE Models, Deutz F3L-2011 Models
(before serial number 11880) ..................................................................... 6 - 69
B
Ground Control Box Switch Panel Wiring Diagram,
S-65, CE Models, Deutz F3L-2011 Models
(before serial number 11880) ..................................................................... 6 - 70
A
Ground Control Box Terminal Strip Wiring Diagram,
S-65, CE Models, Deutz F3L-2011 Models
(after serial number 11879) ........................................................................ 6 - 71
A
Ground Control Box Switch Panel Wiring Diagram,
S-65, CE Models, Deutz F3L-2011 Models
(after serial number 11879) ........................................................................ 6 - 72
B
Platform Control Box Terminal Strip Wiring Diagram,
S-65, Deutz F3L-2011 Models ................................................................... 6 - 73
B
Platform Control Box Switch Panel Wiring Diagram,
S-65, Deutz F3L-2011 Models ................................................................... 6 - 74
S-60 • S-65
Part No. 77828
July 2005
TABLE OF CONTENTS
Section 6
Rev
Part No. 77828
Schematics, continued
C
Electrical Schematic, S-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
Ground Control Box Terminal Strip Wiring Diagram,
S-60, Perkins 404-22 Models (before serial number 11880) ...................... 6 - 79
B
Ground Control Box Switch Panel Wiring Diagram,
S-60, Perkins 404-22 Models (before serial number 11880) ...................... 6 - 80
A
Ground Control Box Terminal Strip Wiring Diagram,
S-60, Perkins 404-22 Models (after serial number 11879) ......................... 6 - 81
A
Ground Control Box Switch Panel Wiring Diagram,
S-60, Perkins 404-22 Models (after serial number 11879) ......................... 6 - 82
B
Platform Control Box Terminal Strip Wiring Diagram,
S-60, Perkins 404-22 Models ..................................................................... 6 - 83
B
Platform Control Box Switch Panel Wiring Diagram,
S-60, Perkins 404-22 Models ..................................................................... 6 - 84
D
Electrical Schematic, S-65, Perkins 404-22 Models
(before serial number 11880) ..................................................................... 6 - 85
A
Electrical Schematic, S-65, Perkins 404-22 Models
(after serial number 11879) ........................................................................ 6 - 87
B
Ground Control Box Terminal Strip Wiring Diagram,
S-65, Perkins 404-22 Models (before serial number 11880) ...................... 6 - 89
B
Ground Control Box Switch Panel Wiring Diagram,
S-65, Perkins 404-22 Models (before serial number 11880) ...................... 6 - 90
A
Ground Control Box Terminal Strip Wiring Diagram,
S-65, Perkins 404-22 Models (after serial number 11879) ......................... 6 - 91
A
Ground Control Box Switch Panel Wiring Diagram,
S-65, Perkins 404-22 Models (after serial number 11879) ......................... 6 - 92
B
Platform Control Box Terminal Strip Wiring Diagram,
S-65, Perkins 404-22 Models ..................................................................... 6 - 93
B
Platform Control Box Switch Panel Wiring Diagram,
S-65, Perkins 404-22 Models ..................................................................... 6 - 94
D
Hydraulic Schematic, 2WD Models ..................................................................... 6 - 95
D
Hydraulic Schematic, 4WD Models ..................................................................... 6 - 96
S-60 • S-65
xvii
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xviii
S-60 • S-65
Part No. 77828
July 2005
Section 2 • Specifications
Specifications
REV A
Machine Specifications
Performance Specifications
Tires and wheels
Boom function speeds, maximum
from platform controls
Wheel lugs
Lug nut torque, dry
Lug nut torque, lubricated
9 @ 5/8 -18
170 ft-lbs
225 Nm
130 ft-lbs
176 Nm
Tire ply rating
14
Jib boom up, S-65
60 to 70 seconds
Jib boom down, S-65
40 to 50 seconds
Boom up
60 to 70 seconds
Boom down
60 to 70 seconds
Boom extend
58 to 66 seconds
Boom retract
53 to 62 seconds
Turntable rotate, 360°
boom stowed
78 to 86 seconds
Overall tire diameter
(Rough terrain tires)
36.9 in
93.7 cm
Overall tire diameter
(Hi-flotation tires)
40.3 in
102.4 cm
Tire pressure
(Rough terrain tires)
70 psi
4.92 bar
Turntable rotate, 360°
boom raised or extended
Tire pressure
(Hi-flotation tires)
60 psi
4.13 bar
Platform rotate, 180°
S-60
8 to 12 seconds
Platform rotate, 160°
S-65
8 to 12 seconds
Fluid capacities
LPG tank
33.5 pounds
15.2 kg
Braking distance, maximum
Hydraulic tank
45 gallons
170 liters
High range on paved surface
Hydraulic system
(including tank)
65 gallons
246 liters
Drive speed, maximum
stowed position
Drive hubs
20 fl oz
0.6 liters
Drive hub oil type:
SAE 90 multipurpose hypoid gear oil API service
classification GL5
For operational specifications, refer to the
Operator's Manual.
125 to 165 seconds
3 to 6 ft
0.9 to 1.8 m
2WD models
40 ft / 6.2 sec
12.2 m / 6.2 sec
4WD models
40 ft / 7.8 sec
12.2 m / 7.8 sec
Drive speed, maximum
raised or extended position
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.
Part No. 77828
S-60 • S-65
2-1
Section 2 • Specifications
July 2005
SPECIFICATIONS
REV B
Hydraulic Specifications
Drive pump
Hydraulic Oil Specifications
Type:
Hydraulic oil type
Chevron Rykon MV equivalent
Approximate SAE grade
5W-20
Viscosity index rating
200
Flow rate @ 2500 rpm
Cleanliness level, minimum
Drive pressure, maximum
Water content, maximum
15/13
200 ppm
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index
rating of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
bi-directional, variable
displacement piston pump
32.4 gpm
122.6 L/min
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
Optional fluids
Function pump
Biodegradable
Fire resistant
Mineral based
Petro Canada Premium ECO 46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
UCON Hydrolube HP-5046
Quintolubric 822
Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Use Chevron Aviation A hydraulic
oil when in ambient temperatures
consistently below 0°F / -18°C.
Use Shell Tellus T46 hydraulic oil
when oil temperatures consistently
exceed 205°F / 96°C.
Type:
2 section tandem gear pump
Displacement - Pump 1 (inner)
1.4 cu in
23 cc
Flow rate @ 2500 rpm
15.3 gpm
58 L/min
Displacement - Pump 2 (outer)
0.24 cu in
4 cc
Flow rate @ 2500 rpm
2 gpm
7.6 L/min
Auxiliary pump
Type:
Displacement
gear, fixed displacement
1.75 gpm
2.8 L/min
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
2-2
S-60 • S-65
Part No. 77828
July 2005
Section 2 • Specifications
REV B
SPECIFICATIONS
Function manifold
System relief valve pressure
3000 psi
207 bar
Manifold Component
Specifications
Plug torque
Steer flow regulator
Jib boom / platform rotate
flow regulator
Oscillate relief valve pressure
3.5 gpm
13.2 L/min
0.6 gpm
2.27 L/min
800 psi
55 bar
Drive manifold
Hot oil relief valve pressure
280 psi
19.3 bar
Drive motors, 4WD models
SAE No. 2
36 in-lbs / 4 Nm
SAE No. 4
10 ft-lbs / 13 Nm
SAE No. 6
14 ft-lbs / 19 Nm
SAE No. 8
38 ft-lbs / 51 Nm
SAE No. 10
41 ft-lbs / 55 Nm
SAE No. 12
56 ft-lbs / 76 Nm
Valve coil resistance specifications
Displacement per revolution,
high speed
0.79 cu in
13 cc
Solenoid valve, 3 position 4 way, 10V DC
(schematic items D, V and Y)
5 to 7Ω
Displacement per revolution,
low speed
1.83 cu in
30 cc
Solenoid valve, 3 position 4 way, 10V DC
(schematic item BB)
4 to 6Ω
Solenoid valve, 2 position 3 way, 10V DC
(schematic items B, C, E, F and FF)
5 to 7Ω
Solenoid valve, 2 position 3 way, 10V DC
(schematic items KK and LL)
5.5 to 7.5Ω
Drive motors, 2WD models
Displacement per revolution,
high speed
1.28 cu in
20.9 cc
Displacement per revolution,
low speed
2.14 cu in
35 cc
Hydraulic filters
High pressure filter
Beta 3 ³ 200
High pressure filter
bypass pressure
51 psi
3.5 bar
Medium pressure filter
Beta 3 ³ 200
Medium pressure filter
bypass pressure
51 psi
3.5 bar
Hydraulic return filter
Part No. 77828
Proportional solenoid valve, 12V DC
(schematic items M and T)
4 to 6Ω
Proportional solenoid valve, 12V DC
(schematic item Q)
3.7 to 5.7Ω
10 micron with
25 psi / 1.7 bar bypass
S-60 • S-65
2-3
Section 2 • Specifications
July 2005
SPECIFICATIONS
REV A
GM 3.0L EFI Engine
Starter motor
Displacement
181 cu in
3 liters
Number of cylinders
Bore & stroke
4
4 x 3.6 inches
101.6 x 91.44 mm
Normal engine cranking speed
Current draw, normal load
400A
Current draw, maximum load
600A
Current draw, minimum
100A
Battery
Horsepower
Intermittent
Continuous
67 @ 2300 rpm
60 @ 2300 rpm
Firing order
1-3-4-2
Type
12V DC
Size
13 x 613/16 x 93/8 inches
33 x 17.3 x 23.8 cm
Low idle
1650 rpm
Quantity
High idle
2500 rpm
Cold cranking ampere
Compression ratio
9.25:1
Compression pressure - minimum
Pressure (psi or bar) of lowest cylinder
must be at least 75% of highest cylinder
Valve clearances
350 rpm
100 psi
6.9 bar
Reserve capacity @ 25A rate
1
1000A
200 minutes
Electronic fuel pump
Fuel pressure, static
9 to 11 psi
0.6 to 0.76 bar
Zero lash + 1 full turn
Fuel flow rate
Lubrication system
Oil pressure, minimum
(operating temp. @ 2000 rpm)
18 psi
1.24 bar
Oil capacity
(including filter)
5 quarts
4.7 liters
0.3 gpm
1.14 L/min
Ignition system
Spark plug type
AC ACMR-43-LTS
Spark plug gap
0.040 inches
1.01 mm
Oil viscosity requirements
Engine coolant
Below 0° F / -17.8° C
5W-30
Above 0° F / -17.8° C
10W-30
Capacity
Only use engine oils labeled "For Gasoline Engines"
by the American Petroleum Institute (API).
Alternator output
Fan belt deflection
2-4
S-60 • S-65
12 quarts
11.4 liters
66A @ 12V DC
1/2
inch
12 mm
Part No. 77828
July 2005
Section 2 • Specifications
REV A
SPECIFICATIONS
Ford LRG-425 EFI Engine
Displacement
Engine coolant
153 cu in
2.5 liters
Number of cylinders
4
Bore & stroke
3.78 x 3.4 inches
96.01 x 86.36 mm
Horsepower
70 @ 2500 rpm
52 kw @ 2500 rpm
Firing order
1-3-4-2
Capacity
Starter motor
Normal engine cranking speed
Current draw, normal load
Current draw, maximum load
1600 rpm
320 Hz
Brush length, minimum
High idle (computer controlled)
2500 rpm
500 Hz
Commutator run-out, maximum
9.4:1
Compression pressure (approx.)
Pressure (psi or bar) of lowest cylinder must be
at least 75% of highest cylinder
Valve clearances collapsed tappet
140-200A
800A
0.25 in
6.35 mm
0.005 inches
0.127 mm
Electronic fuel pump
Fuel pressure, static
0.035 to 0.055 inches
0.889 to 1.397 mm
200 to 250 rpm
Circuit voltage drop
0.5V DC
while starting, maximum (normal temperature)
Low idle (computer controlled)
Compression ratio
11.5 quarts
10.9 liters
Fuel flow rate
63 psi
4.3 bar
0.58 gpm
2.2 L/min
Alternator
Lubrication system
Oil pressure
(operating temperature @ 2500 rpm)
40 to 60 psi
2.75 to 4.1 bar
Oil capacity
(including filter)
4.5 quarts
4.3 liters
Output
Battery
Type
12V DC
Size
13 x 613/16 x 93/8 inches
33 x 17.3 x 23.8 cm
Oil viscosity requirements
Above -15°F / -26°C
10W-40
Above -22°F / -30°C
5W-30
Use oils meeting API classification SJ or SH.
Units ship with 15W-40 SJ.
95A, 14.5V DC
Quantity
Cold cranking ampere
Reserve capacity @ 25A rate
1
1000A
200 minutes
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
S-60 • S-65
2-5
Section 2 • Specifications
July 2005
SPECIFICATIONS
REV B
Deutz F3L 2011 Engine
Displacement
Oil temperature switch
142 cu in
2.33 liters
Number of cylinders
Bore and stroke
3
3.7 x 4.409 inches
94 x 112 mm
Horsepower
48 @ 2800 rpm
Firing order
1-2-3
Low idle
1500 rpm
High idle
2500 rpm
Compression ratio
Compression pressure
Governor
18.5:1
362 to 435 psi
25 to 30 bar
centrifugal mechanical
Torque
8-18 ft-lbs
11-24 Nm
Temperature switch point
220° F
104° C
Oil pressure switch
Torque
8-18 ft-lbs
11-24 Nm
Oil pressure switch point
15 psi
1 bar
Fuel injection system
Injection pump make
Bosch
Injection pump pressure, maximum
15000 psi
1034 bar
Injector opening pressure
3046 psi
210 bar
Valve clearance, cold
Fuel requirement
Intake
Exhaust
0.012 in
0.3 mm
0.020 in
0.5 mm
#2 Diesel
Starter motor
Current draw, no load
90A
Brush length, new
0.72 in
18.5 mm
Lubrication system
Oil pressure
Oil capacity
(including filter)
20 to 44 psi
1.4 to 3 bar
7.6 quarts
8 liters
Oil viscosity requirements
-22° F to 86° F/ -30° C to 30° C
5W-30
(synthetic)
-4° F to 90° F / -20° C to 32° C
10W-40
Above 23° F / -5° C
20W-50
Engine oil should have minimum properties of API
classification CC/SG or CD/SG grades.
Units ship with 10W-40 CH-4
2-6
Brush length, minimum
0.27 in
7 mm
Battery
Type
12V DC
Size
13 x 613/16 x 93/8 inches
33 x 17.3 x 23.8 cm
Quantity
1
Cold cranking ampere
Reserve capacity @ 25A rate
Alternator output
Fan belt deflection
S-60 • S-65
1000A
200 minutes
60A @ 14V DC
3 /8
to 1/2 inch
9 to 12 mm
Part No. 77828
July 2005
Section 2 • Specifications
REV B
SPECIFICATIONS
Perkins 404-22 Engine
Lubrication system
Displacement
134 cu in
2.2 liters
Number of cylinders
Bore and stroke
4
3.31 x 3.94 inches
84 x 100 mm
Oil pressure, cold
(at 2500 rpm)
Oil capacity
(including filter)
gross intermittent
horsepower @ 3000 rpm
51
47.6
Firing order
1-3-4-2
9.3 quarts
8.8 liters
Oil viscosity requirements
Below 86°F / 30°C
Horsepower
60 psi
4.1 bar
5W-20
-4°F to 104°F / -20°C to 40°C
10W-30
Above 14°F / -10°C
15W-40
Low idle
1300 rpm
Engine oil should have minimum properties of API
classification CH-4. Units ship with CH-4
High idle
2500 rpm
Oil pressure sending unit
Compression ratio
23.3:1
Compression pressure
426 psi
29.4 bar
Torque
Oil pressure switch point
Pressure (psi) of lowest cylinder must
be within 50 psi / 3.45 bar of highest cylinder
Fuel injection system
Governor
Injection pump make
centrifugal mechanical
Valve clearance, cold
Intake
Exhaust
0.008 in
0.2 mm
0.008 in
0.2 mm
8-18 ft-lbs
11-24 Nm
14.2 psi
1 bar
Zexel
Injection pressure
2133 psi
147 bar
Fuel requirement
#2 Diesel
Alternator output
Fan belt deflection
55A @ 12V DC
3/8
in
10 mm
Starter motor
Current draw, no load
Part No. 77828
90A
Brush length, new
0.7480 in
19 mm
Brush length, minimum
0.5 in
12.7 mm
S-60 • S-65
2-7
Section 2 • Specifications
July 2005
SPECIFICATIONS
REV C
Machine Torque Specifications
Battery
Type
12V DC
Size
13 x 613/16 x 93/8 inches
33 x 17.3 x 23.8 cm
Quantity
Cold cranking ampere
Reserve capacity @ 25A rate
1
200 minutes
Temperature switch point
3 /8
-16 bolts, GR 8
44 ft-lbs
60 Nm
Drive motor and hubs
7.7 quarts
7.3 liters
180 ft-lbs
244 Nm
Drive motor mounting bolts, lubricated
55 ft-lbs
75 Nm
Turntable bearing
8-18 ft-lbs
11-24 Nm
221° F
105° C
Rotate bearing mounting bolts, lubricated
180 ft-lbs
244 Nm
Turntable rotation assembly
Backlash pivot plate
2-8
480 ft-lbs
651 Nm
Drive hub mounting bolts, lubricated
Coolant temperature sending unit
Torque
1 -8 center bolt, GR 8
1000A
Engine coolant
Capacity
Platform rotator
S-60 • S-65
260 ft-lbs
352.5 Nm
Part No. 77828
July 2005
Section 2 • Specifications
REV B
SPECIFICATIONS
Seal-Lok® fittings
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
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).
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
SAE Dash size
Torque
-4
11 ft-lbs / 14.9 Nm
2 Lubricate the O-ring before installation.
-6
23 ft-lbs / 31.2 Nm
-8
40 ft-lbs / 54.2 Nm
3 Be sure that the face seal O-ring is seated and
retained properly.
-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
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port
Seal-Lok Fittings
(tube fitting - installed into Steel)
(hose end)
®
SAE Dash size
Torque
SAE Dash size
Torque
-4
16 ft-lbs / 21.7 Nm
-4
18 ft-lbs / 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-lbs / 190 Nm
-24
315 ft-lbs / 427.1 Nm
-24
165 ft-lbs / 223.7 Nm
Part No. 77828
S-60 • S-65
2-9
Section 2 • Specifications
July 2005
SPECIFICATIONS
REV A
SAE FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
SIZE
Grade 5
THREAD
LUBED
20
28
1/4
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
100
90
11.3
10.1
80
120
9
13.5
140
120
15.8
13.5
110
160
12.4
18
130
140
14.7
15.8
LUBED
5/16
A574 High Strength
Black Oxide Bolts
LUBED
Grade 8
DRY
LUBED
DRY
LUBED
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
METRIC FASTENER TORQUE CHART
• This chart is to be used as a guide only unless noted elsewhere in this manual •
Class 4.6
Size
(m m )
5
6
7
LUBED
2 - 10
DRY
LUBED
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
information and step-by-step instructions.
Observe and Obey:
Symbols Legend
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.
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.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Failure to perform each procedure
as presented and scheduled may
cause death, serious injury or
substantial damage.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Immediately tag and remove from service a
damaged or malfunctioning machine.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Repair any machine damage or malfunction
before operating machine.
Keep records on all inspections for three years.
Unless otherwise specified, perform each
maintenance procedure with the machine in the
following configuration:
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
· Machine parked on a firm, level surface
· Boom in stowed position
Used to indicate operation or
maintenance information.
· Turntable rotated with the boom between
the non-steer wheels
· Turntable secured with the turntable
rotation lock
Indicates that a specific result is expected after
performing a series of steps.
· Key switch in the off position with the
key removed
Indicates that an incorrect result has occurred
after performing a series of steps.
· Wheels chocked
· All external AC power disconnected
from the machine
Part No. 77828
S-60 • S-65
3-1
Section 3 • Scheduled Maintenance Procedures
July 2005
SCHEDULED MAINTENANCE PROCEDURES
Pre-delivery Preparation Report
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
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 Scheduled Maintenance Procedures
Section and the Maintenance Inspection Report
have been divided into five subsections—A, B, C,
D and E. Use the following chart to determine which
group(s) of procedures are required to perform a
scheduled inspection.
Inspection
Indicates that a cold engine will be
required to perform this procedure.
Checklist
Daily or every 8 hours
Quarterly or every 250 hours
Indicates that a warm engine will be
required to perform this procedure.
Six months or every 500 hours
Annual or every 1000 hours
Indicates that dealer service is required
to perform this procedure.
Two years or every 2000 hours
A
A+B
A+B+C
A+B+C+D
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.
3-2
S-60 • S-65
Part No. 77828
Pre-Delivery Preparation
July 2005
Section 3 • Scheduled Maintenance Procedures
Fundamentals
Instructions
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
Use the operator’s manual on your machine.
The Pre-delivery Preparation is performed prior to each
delivery. The inspection is designed to discover if anything
is apparently wrong with a machine before it is put into
service.
A damaged or modified machine must never be used. If
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed from
service.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's
specifications.
Scheduled maintenance inspections shall be performed by
qualified service technicians, according to the
manufacturer's specifications and the requirements listed in
the responsibilities manual.
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
N = no, unable to complete
R = repaired
Comments
Pre-Delivery Preparation
Y
N
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA
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 © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.
Rev B
Part No. 77828
S-60 • S-65
3-3
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Section 3 • Scheduled Maintenance Procedures
July 2005
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3-4
S-60 • S-65
Part No. 77828
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Section 3 • Scheduled Maintenance Procedures
Maintenance Inspection Report
Model
Checklist A - Rev C
Serial number
A-1 Pre-operation
inspection
Date
A-2 Functions tests
Hour meter
A-3 Engine maintenance Deutz models
Machine owner
A-4 Engine maintenance GM and Ford models
Inspected by (print)
A-5 Engine maintenance Perkins models
Inspector signature
A-6 Filter condition indicator
Y N R
Checklist B - Rev C
B-2 Inspect electrical
wiring
B-3 Exhaust system
B-4 Oil cooler and finsDeutz models
B-5 Lug nut torque
B-6 Brake configuration
B-7 Drive hub oil level
A-7 Oscillate axle
B-8 Engine RPM Deutz models
Perform after 50 hours:
B-9 Ground control override
A-8 30 day service
B-10 Directional valve
Perform every 100 hours:
B-11 Platform leveling
Instructions
· Make copies of this report to use for
each inspection.
A-9 Engine maintenance GM, Ford and
Perkins models
B-12 Engine idle select
· Select the appropriate checklist(s) for
the type of inspection to be
performed.
A-10 Fuel filter/separator Diesel models
Inspector title
Inspector company
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
A
A+B
Six Month or 500 hour
Inspection:
A+B+C
A-11 Check engine RPMPerkins models
A-12 Rotation bearing
Perform every 200 hours:
A-13 Engine maintenance GM and Ford models
A-14 Engine maintenance Perkins models
Y N R
B-1 Inspect battery
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
Annual or 1000 hours
Inspection:
A+B+C+D
B-20 Fuel filter element Perkins models
2 Year or 2000 hour
Inspection:
A+B+C+D+E
Perform every 400 hours:
B-21 Engine maintenance Deutz models
· Place a check in the appropriate box
after each inspection procedure is
completed.
· If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
B-22 Engine maintenance GM and Ford models
B-23 Engine maintenance Perkins models
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Part No. 77828
S-60 • S-65
3-5
Section 3 • Scheduled Maintenance Procedures
July 2005
MAINTENANCE INSPECTION REPORT
Model
Checklist C - Rev D
Serial number
C-1 Engine maintenance Deutz models
E-1 Hydraulic oil
Date
C-2 Grease platform
overload (if equipped)
E-2 Engine maintenance Deutz models
Hour meter
C-3 Test platform overload
(if equipped)
Perform every 12,000 hours:
Machine owner
C-4 Boom extend/retract
cables
Inspected by (print)
Perform every 600 hours:
Inspector signature
C-5 Engine maintenance Perkins models
Inspector title
Perform every 800 hours:
Inspector company
C-6 Engine maintenance GM and Ford models
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:
Quarterly or 250 hour
Inspection:
Checklist D - Rev C
Y N R
Checklist E - Rev D
Y N R
Perform every 3000 hours:
E-3 Engine maintenance Deutz models
Perform every 5 years:
E-4 Remove and inspect
boom extend/
retract cables
Y N R
D-1 Boom wear pads
D-2 Turntable bearing bolts
D-3 Turntable bearing
wear
D-4 Drive hub oil
A
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
D-5 Free-wheel
configuration
D-6 Hydraulic filters
D-7 Air/LPG mixture GM models
D-8 Engine maintenance Deutz models
D-9 Calibrate platform
overload system
(if equipped)
· Place a check in the appropriate box
after each inspection procedure is
completed.
· If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
3-6
S-60 • S-65
Part No. 77828
July 2005
REV C
Section 3 • Scheduled Maintenance Procedures
Checklist A Procedures
A-1
Perform Pre-operation
Inspection
A-2
Perform Function Tests
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.
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 Manual on your machine.
Complete information to perform this procedure is
available in the Genie S-60 and Genie S-65
Operator's Manual on your machine.
Part No. 77828
S-60 • S-65
3-7
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST A PROCEDURES
REV C
A-3
Perform Engine Maintenance Deutz Models
A-4
Perform Engine Maintenance GM and Ford Models
Engine specifications require that
this procedure be performed daily
or every 10 hours, whichever
comes first.
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.
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).
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).
Deutz FL 2011 Operation Manual
Genie part number
84794
GM 3.0L Operator Handbook
Genie part number
101095
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.
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.
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.
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.
3-8
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Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
REV C
CHECKLIST A PROCEDURES
A-5
Perform Engine Maintenance Perkins Models
A-6
Check the High Pressure
Hydraulic Filter Condition
Indicator
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
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
component damage.
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.
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.
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, Replace the Hydraulic
Filters.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
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
S-60 • S-65
3-9
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST A PROCEDURES
REV C
A-7
Test the Oscillate Axle
(if equipped)
A-8
Perform 30 Day Service
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.
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:
2 Drive the right steer tire up onto 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.
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.
Result: The non-steer tires should stay in firm
contact with the ground.
• A-9
Perform Engine Maintenance GM, Ford and Perkins Models
• A-12
Grease the Turntable Bearing and
Rotate Gear
• B-5
Check the Lug Nut Torque
(including tires and wheels)
• B-7
Check the Oil Level in the Drive Hubs
• C-1
Perform Engine Maintenance Deutz Models
• D-2
Check the Turnable Rotation Bearing
Bolts
• D-6
Replace the Hydraulic Filters
If the chassis does not remain
level during test, see Repair
Procedure 7-6, How to Set Up the
Oscillate Directional Valve.
3 - 10
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
REV C
CHECKLIST A PROCEDURES
A-9
Perform Engine Maintenance GM, Ford and Perkins Models
A-10
Inspect the Fuel Filter/Water
Separator - Diesel 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) or the
Perkins 400 Series Operation Manual
(Perkins part number TPD 1443S) .
GM 3.0L Operator Handbook
Genie part number
Ford LRG 425 EFI Operator Handbook
Genie part number
Perkins 400 Series Operation Manual
Genie part number
Part No. 77828
101095
84792
94890
Engine specifications require that
this procedure be performed every
100 hours.
Proper maintenance of the fuel filter/water separator
is essential for good engine performance. Failure to
perform this procedure can lead to poor engine
performance and component damage.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated 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 Put on protective clothing and eye wear.
2 Open the engine side turntable cover and locate
the fuel filter/water separator next to the
hydraulic return filter on the bulkhead.
3 Inspect the filter bowl for water buildup.
Result: If water is present in the filter bowl
continue with steps 4 through 8.
S-60 • S-65
3 - 11
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST A PROCEDURES
REV C
8 Start the engine from the ground controls and
check the fuel filter/water separator and vent
plug for leaks.
4 Loosen the vent plug located on the fuel filter/
water separator head.
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.
a
d
c
Deutz Models:
b
1 Put on protective clothing and eye wear.
a
b
c
d
2 Remove the engine tray retaining fastener
located under the engine tray.Swing the engine
tray out and away from the machine.
vent plug
drain plug
filter bowl
separator head
3 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
5 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
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.
6 Tighten the vent plug.
If the fuel filter/water separator is
completely drained, you must
prime the fuel filter/water separator
before starting the engine.
See B-20, Replace The Fuel Filter
Element - Perkins Models, for
instructions on how to prime the
fuel filter/water separator.
7
4 Locate the fuel filter/water separator next to the
oil filter.
Clean up any fuel that may have spilled.
3 - 12
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
REV C
CHECKLIST A PROCEDURES
5 Loosen the drain plug located at the bottom of
the filter. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
A-11
Check and Adjust the
Engine RPM - Perkins Models
Do not completely drain the filter.
Engine specifications require that
this procedure be performed every
100 hours.
a
b
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.
a
b
fuel filter/water separator
drain valve
1 Connect a tachometer to the engine. Start the
engine from the ground controls.
6 Clean up any fuel that may have spilled.
7 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
Result: Low idle should be 1300 rpm.
Skip to step 3 if the low idle rpm is correct.
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
S-60 • S-65
3 - 13
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST A PROCEDURES
REV C
2 Loosen the low idle lock nut and turn the low idle
adjustment screw clockwise to increase the
rpm, or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and confirm the
rpm.
A-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.
a
b
c
a
b
c
d
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.
d
solenoid boot
high idle adjustment nut
yoke
low idle lock nut and adjustment
screw
3 Apply grease to each tooth of the drive gear,
located under the turntable.
3 Move the function enable toggle switch to the
high idle (rabbit symbol) position.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
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.
3 - 14
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
REV C
A-13
Perform Engine Maintenance GM and Ford Models
A-14
Perform Engine Maintenance Perkins Models
Engine specifications require that
this procedure be performed every
200 hours.
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.
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).
Required maintenance procedures and additional
engine information are available in the
Perkins 400 Series Operation Manual
(Perkins part number TPD 1443S).
GM 3.0L Operator Handbook
Genie part number
Perkins 400 Series Operation Manual
Genie part number
94890
101095
To access the engine:
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.
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.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
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.
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
S-60 • S-65
3 - 15
Section 3 • Scheduled Maintenance Procedures
July 2005
Checklist B Procedures
REV C
B-1
Inspect the Battery
B-2
Inspect the Electrical Wiring
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.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.
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.
3 Be sure that the battery hold-down bracket and
cable connections are tight.
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.
The battery is a maintenance free
battery and does not require the
replenishing of electrolyte.
Adding terminal protectors and a
corrosion preventative sealant will
help eliminate corrosion on the
battery terminals and cables.
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.
3 - 16
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
REV C
6 Inspect the following areas for burnt, chafed,
corroded and loose wires:
B-3
Check the Exhaust System
· Inside of the ground control box
· Hydraulic manifold wiring
7 Inspect for a liberal coating of dielectric grease
at the following location:
· All wire harnesses connectors to the
ground control box
Maintaining the exhaust system is essential to
good engine performance and service life. Running
the engine with a damaged or leaking exhaust
system can cause component damage and unsafe
operating conditions.
Bodily injury hazard. Do not
inspect while the engine is running.
Remove the key to secure from
operation.
8 Start the engine from the ground controls and
raise the boom above the turntable covers.
9 Inspect the turntable area for burnt, chafed and
pinched cables.
Burn hazard. Beware of hot engine
components. Contact with hot
engine components may result in
severe burns.
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:
1 Remove the engine tray retaining fastener
located under the engine tray.Swing the engine
tray out and away from the machine.
· Cable track on the primary boom
· Cables on the primary, and jib booms
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
· Jib boom/Platform rotate manifold
· Inside of the platform control box
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.
12 Inspect for a liberal coating of dielectric grease
at the 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.
3 Be sure that all nuts and bolts are tight.
4 Inspect all welds for cracks.
5 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.
Part No. 77828
S-60 • S-65
3 - 17
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST B PROCEDURES
REV C
3 Remove the fasteners from the engine side
cover, then remove the cover.
B-4
Check the Oil Cooler and
Cooling Fins - Deutz Models
4 Inspect the oil cooler for leaks and physical
damage.
a
b
c
Maintaining the oil cooler in good condition is
essential for good engine performance. Operating a
machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
cooling system.
Bodily injury hazard. Do not
inspect while the engine
is running. Remove the key to
secure from operation.
Burn hazard. Beware of hot engine
components. Contact with hot
engine components may result in
severe burns.
a
b
c
oil cooler
cylinder head cooling fins
fan blower fins
5 Clean the oil cooler of debris and foreign
material.
Oil cooler
Cooling and fan blower fins
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
6 Inspect the fan blower fins for physical damage.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
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.
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 plate retaining
fastener.
3 - 18
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
REV C
B-5
Check the Lug Nut Torque
(including the tires and wheels)
B-6
Confirm the Proper
Brake Configuration
Maintaining the tires and wheels in good
condition is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.
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.
Bodily injury hazard. An overinflated tire can explode and could
cause death or serious injury.
1 Check each drive hub disconnect cap to be sure
it is in the engaged position.
brake disengaged position
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.
brake engaged position
2 Be sure the free-wheel valve on the drive pump
is closed (clockwise).
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque.
d
4 Check the pressure in each air-filled tire.
c
a
b
a
b
c
d
drive pump
free-wheel valve
lift pump
screwdriver
The free-wheel valve is located on
the side of the drive pump.
The free-wheel valve should
always remain closed.
Part No. 77828
S-60 • S-65
3 - 19
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST B PROCEDURES
REV C
B-7
Check the Oil Level
in the Drive Hubs
B-8
Check and Adjust the
Engine RPM - Deutz Models
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and continued
use may cause component damage.
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.
1 Drive the machine to rotate the hub until the
plugs are located one on top and the other at
90 degrees.
This procedure will require two
people.
a
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.
a
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.
drive hub plugs
2 Remove the plug located at 90 degrees and
check the oil level.
3 Connect an rpm gauge to the engine, and then
start the engine from the ground controls.
Result: The oil level should be even with the
bottom of the side plug hole.
Result: Low idle should be 1500 rpm.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
Skip to step 5 if the low idle rpm is correct.
4 Install the plug(s) into the drive hub.
5 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
6 Repeat this procedure for each drive hub.
3 - 20
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
REV C
4 Loosen the low idle lock nut, then turn the low
idle adjustment screw clockwise to increase the
rpm or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and recheck the
rpm.
6 Loosen the yoke lock nut, then turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Be sure the solenoid fully retracts
when activating high idle.
f
7 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener.
e
a
b
a
b
c
d
e
f
c
d
solenoid boot
high idle adjustment nut
yoke lock nut
yoke
low idle adjustment screw
low idle lock nut
5 Move the function enable/rpm select toggle
switch to the high idle (rabbit symbol) position at
the ground controls.
Result: High idle should be 2500 rpm.
If high idle rpm is correct, disregard adjustment
step 6.
Part No. 77828
S-60 • S-65
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Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST B PROCEDURES
REV C
B-9
Test the Ground Control
Override
B-10
Check the Oscillate Directional
Valve Linkage
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.
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 Push in the platform red Emergency Stop button
to the off position.
1 Remove the drive chassis cover from the
non-steer end of the machine.
2 Start the engine from the ground controls.
2 Locate the oscillate directional valve inside of
the non-steer axle and inspect the linkage for
the following:
3 At the ground controls, operate each boom
function through a partial cycle.
Result: All boom functions should operate.
Perform this test only on models
equipped with a oscillating axle.
· 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
3 - 22
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
REV C
B-11
Test the Platform Self-leveling
B-12
Test the Engine Idle Select
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 selfleveling failure creates an unsafe working condition
for platform and ground personnel.
A properly operating engine idle select switch
is essential to good engine performance and safe
machine operation. There are two settings.
Foot switch activated low idle (turtle symbol)
allows the operator to control individual boom
functions.
Foot switch activated high idle (rabbit symbol)
should be used for normal machine operation. This
selection activates high idle only when the foot
switch is pressed down.
1 Start the engine from the ground controls and
lower the boom into the stowed position.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
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.
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).
3 Raise and lower the primary boom through
a full cycle.
Result: The platform should remain level at
all times to within ±5 degrees.
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).
Result: The engine should not change to
high idle.
6 Press down the foot switch.
Result: The engine should change to high idle.
6 Move the engine idle control switch to foot
switch activated low idle (turtle symbol).
Result: The engine should change to low idle.
Part No. 77828
S-60 • S-65
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Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST B PROCEDURES
REV C
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.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate fuel
system problems that could develop into a
hazardous situation.
6 Restart the engine and allow it to run at
low idle.
7 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
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.
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 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
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.
3 - 24
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
REV C
5 Bring the machine to top drive speed before
reaching the test line. Release the drive joystick
when your reference point on the machine
crosses the test line.
B-14
Test the Drive Brakes
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear to
operate normally when they are actually not fully
operational.
6 Measure the distance between the test line and
your machine reference point. Refer to
Section 2, Specifications.
The brakes must be able to hold
the machine on any slope it is able
to climb.
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
S-60 • S-65
3 - 25
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST B PROCEDURES
REV C
B-15
Test the Drive Speed Stowed Position
B-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.
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 obstructions.
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.
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.
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.
3 Move the engine idle select switch to foot switch
activated high idle (rabbit and foot switch
symbol).
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 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.
3 - 26
4 Raise the boom above horizontal.
6 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
7 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Specifications.
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
REV C
8 Lower the boom to the stowed position and
extend the boom 1 foot / 30 cm.
B-17
Test the Alarm Package Optional Equipment
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.
The alarm package includes:
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.
· 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.
Part No. 77828
S-60 • S-65
3 - 27
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST B PROCEDURES
REV C
3 S-65: Move the function enable/rpm select
toggle switch to either side and activate the jib
boom toggle switch in the down position, hold
for a moment and then release it.
Result: The descent alarm should sound when
the switch is held down.
4 Turn the key switch to platform control.
Result: The flashing beacon should be on
and flashing.
5 Press down the foot switch. Move the boom
control handle to the down position, hold for a
moment and then release it.
B-18
Perform Hydraulic Oil Analysis
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.
Result: The descent alarm should sound when
the control handle is held down.
6 S-65: Press down the foot switch. Move the jib
boom toggle switch to the down position, hold
for a moment and then release it.
Result: The descent alarm should sound when
the control handle is held down.
7 Press down the foot switch. Move the drive
control handle off center, hold for a moment and
then release it. Move the drive control handle off
center in the opposite direction, hold for a
moment and then release it.
Before replacing the hydraulic oil,
the oil may be tested by an oil
distributor for specific levels of
contamination to verify that
changing the oil is necessary. If
the hydraulic oil is not replaced
at the two year inspection, test
the oil quarterly. Replace the
oil when it fails the test.
See E-1, Test or Replace the
Hydraulic Oil.
Result: The travel alarm should sound when the
drive control handle is moved off center in either
direction.
3 - 28
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
REV C
3 Loosen the vent plug located on the fuel filter/
water separator head.
B-19
Replace the Fuel Filter/ Water
Separator Element Perkins Models
a
f
e
Replacing the diesel fuel filter/water separator
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 require that the filter be replaced
more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated 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.
b
d
c
a
b
c
d
e
f
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.
Part No. 77828
S-60 • S-65
3 - 29
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST B PROCEDURES
REV C
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.
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.
Bleed the system:
It is important to allow the starter
motor to cool for 30 seconds
between each 15 second interval
of operation.
12 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
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.
13 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
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.
17 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener.
a
b
c
a
b
c
3 - 30
vent plug
fuel injection pump
fuel lift pump
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
REV C
CHECKLIST B PROCEDURES
B-20
Replace the Fuel Filter Element Perkins Models
3 Thoroughly clean the outside surfaces of the
fuel filter assembly.
4 Place a suitable container under the fuel filter
element.
5 Disconnect and plug the fuel line from the fuel
pump to the fuel filter element.
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.
a
b
c
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated 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.
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
a
b
c
fuel line
filter head
fuel filter element
6 Remove the fuel filter element with a filter
wrench.
7 Apply a thin layer of fuel to the new fuel filter
element o-ring.
8 Install the new fuel filter element and tighten it
securely by hand. Clean up any fuel that may
have spilled during the installation procedure.
9 Use a permanent ink marker to write the date
and number of hours from the hour meter on the
oil filter housing.
S-60 • S-65
3 - 31
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST B PROCEDURES
REV C
Bleed the fuel system:
9 Loosen the vent plug on top of the fuel injection
pump.
B-21
Perform Engine Maintenance Deutz Models
a
Engine specifications require that
this procedure be performed every
400 hours.
b
c
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.
a
b
c
Required maintenance procedures and additional
engine information are available in the
Deutz FL 2011 Operation Manual
(Deutz part number 0297-9929).
vent plug
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.
Deutz FL 2011 Operation Manual
Genie part number
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.
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 interval
of operation.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
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.
3 - 32
84794
S-60 • S-65
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
CHECKLIST B PROCEDURES
REV C
B-22
Perform Engine Maintenance GM and Ford Models
B-23
Perform Engine Maintenance Perkins Models
Engine specifications require that
this procedure be performed every
400 hours.
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.
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).
Required maintenance procedures and additional
engine information are available in the
Perkins 400 Series Operation Manual
(Perkins part number TPD 1443S).
GM 3.0L Operator Handbook
Genie part number
Perkins 400 Series Operation Manual
Genie part number
94890
101095
To access the engine:
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.
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.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
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.
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
S-60 • S-65
3 - 33
Section 3 • Scheduled Maintenance Procedures
July 2005
Checklist C Procedures
C-1
Perform Engine Maintenance Deutz Models
C-2
Grease the Platform Overload
Mechanism (if equipped)
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 part number
REV D
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.
84794
2 Thoroughly pump grease into each grease fitting
using a mulit-purpose grease.
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.
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 - 34
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
REV D
4 Using a suitable lifting device, place an
appropriate test weight equal to the maximum
platform capacity in one of the locations shown.
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 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.
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 lbs / 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, 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.
Part No. 77828
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Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST C PROCEDURES
REV D
11 Lift the test weights off the platform floor using a
suitable lifting device.
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: The platform overload indicator light and
alarm should turn 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.
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.
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.
If the platform overload system is
not operating properly, see D-9,
Calibrate the Platform Overload
System (if equipped).
Result: All ground control functions should not
operate.
Machine functions should still
operate with auxiliary power at the
ground controls.
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Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
REV D
5 Visually inspect the cables and components
through both inspection holes for the following:
C-4
Inspect the Boom Extend/
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
the extension and retraction of the number 3 boom
tube. Inspecting for foreign objects, damage and/or
improper adjustment of the boom extend/retract
cables and related components on a regular basis
is essential to good machine performance and safe
machine operation. The boom extend and retract
functions should operate smoothly and be free of
hesitation, jerking and unusual noise.
· Split or cracked cable ends
1 Raise the boom to horizontal and fully extend
the boom.
· No unusual or excessive pulley wear
· Cables are on all pulleys
· Cable break limit switch arm is centered in
the pivot plate
· Cables have equal tension
· Cables at end of adjustment range
· No broken or damaged pulleys
· All fasteners in place and secure
2 After the boom is fully extended, lower the boom
until the platform is at chest height. Turn the
machine off.
A flashlight and inspection mirror
may be necessary to thoroughly
inspect the above items.
3 Remove the boom end cover from the pivot end
of the boom.
A pulley groove gauge should be
used to check the condition of the
pulleys.
4 Remove the retaining fasteners from the access
covers located on the side of the boom at the
platform end of the machine. Remove the
covers.
6 Install the cover at the pivot end of the boom
and the access panels on the sides of the
boom.
7 Start the engine from the ground controls and
fully retract and lower the boom to the stowed
position.
Part No. 77828
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Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST C PROCEDURES
REV D
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.
C-5
Perform Engine Maintenance Perkins Models
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 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.
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.
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 - 38
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
REV D
C-6
Perform Engine Maintenance GM and Ford Models
Engine specifications require that
this procedure be performed every
800 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
to perform the 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
Ford LRG 425 EFI Operator Handbook
Genie part number
101095
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.
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
S-60 • S-65
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Section 3 • Scheduled Maintenance Procedures
July 2005
Checklist D Procedures
D-1
Check the Boom Wear Pads
REV B
D-2
Check the Turntable Rotation
Bearing Bolts
Maintaining the boom wear pads in good condition
is essential to safe machine operation. Wear pads
are placed on boom tube surfaces to provide a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued
use of worn out wear pads may result in component
damage and unsafe operating conditions.
1 Start the engine from the ground controls.
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.
2 Raise the end of the primary boom to a
comfortable working height (chest high), then
extend the boom 1 foot / 30 cm.
Crushing hazard. Keep hands
away from cylinders and all moving
parts when lowering the boom.
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.
The lift cylinder safety chock is
available through Genie
(Genie part number 75097).
2 Turn the engine off.
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.
3 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
4 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Always maintain squareness
between the outer and inner
boom tubes.
Wear pad specifications
New
Minimum
5/8
inch
12.7 mm
Bottom wear pads
(platform end of boom)
3/4
5/8 inch
15.9 mm
Top and side wear pads
(pivot end of boom)
5/8
inch
12.7 mm
3/4
5/8 inch
15.9 mm
Top and side wear pads
(platform end of boom)
Bottom wear pads
(pivot end of boom)
3 - 40
inch
15.9 mm
inch
19 mm
inch
15.9 mm
inch
19 mm
1 /2
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.
1 /2
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
REV B
5 Be sure that each turntable mounting bolt is
torqued in sequence to specifications. Refer to
Section 2, Specifications.
13
1
19
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.
15
7
10
22
12
6
24
18
4
3
17
23
5
11
21
8
16
20
2
14
9
Bolt torque sequence
Bolt torque sequence
6 Start the engine form the ground controls.
11 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener.
7 Raise the secondary boom and remove the
safety chock.
8 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
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Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST D PROCEDURES
REV D
D-3
Inspect for Turntable Bearing
Wear
a
b
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.
c
d
a
b
c
d
turntable
dial indicator
drive chassis
turntable rotation bearing
5 At the dial indicator, adjust it to "zero" the
indicator.
6 Fully extend the boom and lower to a horizontal
position.
7 Note the reading on the dial indicator.
3 Start the machine from the ground controls and
raise the boom to full height. Do not extend the
boom.
4 Place a dial indicator between the drive chassis
and the turntable at a point that is directly
under, or inline with, the boom and no more than
1 inch / 2.5 cm from the bearing.
To obtain an accurate
measurement, place the dial
indicator no more than 1 inch /
2.5 cm from the turntable rotation
bearing.
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.
3 - 42
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
REV D
D-4
Replace the Drive Hub Oil
D-5
Check the Free-wheel
Configuration
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.
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.
Collision hazard. Select a work site
that is firm and level.
2 Remove both plugs and drain the oil.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
Non-steer Wheels: All Models
a
1 Chock the steer wheels to prevent the machine
from rolling.
2 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the non-steer tires.
3 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
a
drive hub plugs
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Install the plugs into the drive hub. Refer to
Section 2, Specifications.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
non-steer wheel hub.
disengaged position
5 Repeat steps 1 through 4 for all the other drive
hubs.
engaged position
Part No. 77828
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Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST D PROCEDURES
REV D
5 Manually rotate each non-steer wheel.
Result: Each non-steer wheel should rotate with
minimum effort.
12 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Raise the machine and
remove the jack stands.
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the jack stands.
Collision hazard. Failure to
re-engage the drive hubs may
cause death or serious injury and
property damage.
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).
Steer Wheels: 4WD Models
7 Chock the non-steer wheels to prevent the
machine from rolling.
d
8 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the steer tires.
c
b
a
9 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
a
b
c
d
10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
steer wheel hub.
disengaged position
drive pump
free-wheel valve
lift pump
screwdriver
The free-wheel valve is located on
the side of the drive pump.
The free-wheel valve should
always remain closed.
engaged position
11 Manually rotate each steer wheel.
Result: Each steer wheel should rotate with
minimum effort.
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Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
REV D
5 Install the new filter element into the filter
housing.
D-6
Replace the Hydraulic Filters
6 Push the filter element down to be sure the
o-ring on the element is fully seated into the
housing.
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
oil. Contact with hot oil may cause
severe burns.
Perform this procedure with the
engine off.
7 Rotate the filter element clockwise to lock it in
place.
8 Install the filter housing cap.
9 Use a 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
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.
Hydraulic return filter
The medium pressure filter is
located on the right. The high
pressure filter, with filter condition
indicator, is located on the left.
1 Open the ground controls side turntable cover
and locate the hydraulic return filter housing on
top of the hydraulic tank.
11 Place a suitable container under each filter.
2 Remove the cap from the filter housing.
3 Lift the handle on the filter element and rotate
the element counterclockwise to release the
element from the housing.
4 Remove the filter element from the filter
housing.
Part No. 77828
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.
S-60 • S-65
3 - 45
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST D PROCEDURES
REV D
15 Install the new filter elements into the housings
and tighten them securely.
The medium and high pressure
filters use the same elements.
D-7
Check and Adjust the Air/LPG
Mixture - GM Models
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.
Maintaining the proper air-to-fuel mixture during
LPG operation is essential to good engine
performance.
18 Start the engine from the ground controls.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an approved
fire extinguisher within easy reach.
19 Inspect the filter housings and related
components to be sure that there are no leaks.
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.
3 - 46
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D 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.
D-8
Perform Engine Maintenance Deutz Models
Engine specifications require that
this procedure be performed every
1000 hours.
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 Adjust the low idle mixture adjustment screw to
obtain an air-to-fuel mixture ratio of 13.0:1 to
13.2:1.
Preliminary setting: turn low idle
adjustment screw clockwise all the
way in. Turn low idle adjustment
screw counterclockwise 2 3/4
turns.
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.
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
S-60 • S-65
3 - 47
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST D PROCEDURES
REV D
D-9
Calibrate the Platform Overload
System (if equipped)
Genie specifications require that
this procedure be performed every
1000 hours of operation or yearly.
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.
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.
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 overload indicator light and alarm
turn on.
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.
3 - 48
S-60 • S-65
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 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
REV D
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 a
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 lb / 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 Test 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 ground
controls.
Result: All ground control functions should not
operate.
If the platform overload system is
not operating properly, repeat
steps 1 through 4.
Part No. 77828
S-60 • S-65
3 - 49
Section 3 • Scheduled Maintenance Procedures
July 2005
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
REV D
3 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.
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.
open
closed
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.
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.
3 Place a suitable container underneath the
hydraulic tank.
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).
4 Remove the drain plug from the hydraulic tank.
5 Completely drain the tank into a suitable
container. See capacity specifications.
6 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.
7 Disconnect and plug the return filter hydraulic
hose at the return filter. Cap the fitting on the
filter housing.
3 - 50
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Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
REV D
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.
Crushing hazard. The hydraulic
tank could become unbalanced
and fall if not properly supported
when removed from the machine.
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.
12 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic
return filter housing from the hydraulic tank.
Always use pipe thread sealant
when installing the suction hose
fittings and the drain plug.
13 Remove the suction 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
S-60 • S-65
3 - 51
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST E PROCEDURES
REV D
E-2
Perform Engine Maintenance Deutz Models
E-3
Perform Engine Maintenance Deutz Models
Engine specifications require that
this procedure be performed every
3000 hours.
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.
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).
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
Deutz FL 2011 Operation Manual
Genie part number
84794
84794
To access the engine:
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.
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.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
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.
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 - 52
S-60 • S-65
Part No. 77828
July 2005
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
REV D
4 Replace the boom extend cables if there is any
damage to the cables.
E-4
Remove and Inspect the
Boom Extend/Retract Cables
The extend cables must be
replaced in pairs.
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
on the ground.
3 Visually inspect the boom extend cables and
components for the following:
· Frayed or broken wire strands
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.
· Kinks in the cables
A cable pulling tool is available
through Genie Service Parts
Department, part no. 94510.
· Corrosion
· Paint or foreign materials on the cable
· Split or cracked cable ends
· Cables at end of adjustment range
Part No. 77828
10 At the platform end of the boom, pull on the
boom retract cable that has the rope attached
to it.
S-60 • S-65
3 - 53
Section 3 • Scheduled Maintenance Procedures
July 2005
CHECKLIST E PROCEDURES
REV D
11 Pull the boom retract cable completely out of the
boom tube and lay it flat on 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.
3 - 54
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
Perform disassembly procedures to the point
where repairs can be completed. To re-assemble,
perform the disassembly steps in reverse order.
Symbols Legend
Immediately tag and remove from service a
damaged or malfunctioning machine.
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.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Read, understand and obey the safety rules and
operating instructions in the Genie S-60 and
Genie S-65 Operator’s Manual.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Be sure that all necessary tools and parts are
available and ready for use.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
· Turntable rotated with the boom between
the non-steer wheels
Without safety alert symbol—used
to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
· Turntable secured with the turntable
rotation lock
Used to indicate operation or
maintenance information.
· Machine parked on a firm, level surface
· Boom in stowed position
· Key switch in the off position with the
key removed
· Wheels chocked
· All external AC power disconnected
from the machine
Part No. 77828
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.
S-60 • S-65
4-1
Section 4 • Repair Procedures
July 2005
Platform Controls
REV A
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.
a
1-1
ALC-500 Circuit Board
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 Push in 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.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
c
d
a
b
c
d
4-2
b
ALC-500 circuit board
drive/steer joystick controller
secondary boom up/down
joystick controller
primary boom up/down and
turntable rotate left/right
joystick controller
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
PLATFORM CONTROLS
REV A
4 Attach a grounded wrist strap to the ground
screw inside the platform control box.
1-2
Joysticks
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
How to Calibrate a Joystick
The joysticks on this machine utilize digital Hall
Effect technology for proportional control. If a
joystick is disconnected or replaced, it must be
calibrated before that particular machine function
will operate.
5 Carefully disconnect the wire connectors from
the circuit board.
The joystick must be calibrated
before the threshold, max-out or
ramping can be set.
6 Remove the ALC-500 circuit board mounting
fasteners.
7 Carefully remove the ALC-500 circuit board from
the platform control box.
Perform this procedure with the
engine off.
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.
Result: The alarm should sound indicating
successful joystick calibration.
6 Repeat this 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 • S-65
4-3
Section 4 • Repair Procedures
July 2005
PLATFORM CONTROLS
REV A
8 Start the engine from the platform controls and
press down the foot switch.
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.
9 Start a timer and activate the machine function
that needs to be adjusted. Record the time it
takes for that function to complete a full cycle
(ie; boom up).
10 Compare the machine function time with the
function times listed in Section 2,
Specifications. Determine whether the function
time needs to increase or decrease.
11 While the joystick is activated, adjust the maxout 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.
2 Turn the key switch to platform control. Do not
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
12 Repeat steps 9 through 11 for each joystick
controlled machine function.
4 Do not press down the foot switch.
13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
settings to be saved.
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.
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.
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
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV A
PLATFORM CONTROLS
How to Adjust the Joystick
Ramp Rate Setting
10 Compare the function ramp rate time with the
table below and determine whether the ramp
rate time needs to increase or decrease.
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.
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.
Perform this procedure with the
boom in the stowed position.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to platform control. Do not
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
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.
4 Do not press down the foot switch.
Do not operate any machine
function during the 10 second
waiting time.
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.
Ramp rate (factory settings)
7 Momentarily activate the drive enable toggle
switch in the right direction 6 times.
Result: There should be a pause and the alarm
should sound 6 times indicating that the
machine is in ramp rate calibration mode.
8 Start the engine from the platform controls and
press down the foot switch.
9 Start a timer and simultaneously move the
joystick in either direction full stroke. Note how
long it takes the function to reach maximum
speed. This is the ramp rate.
Part No. 77828
Boom up/down
transition accelerate
transition decelerate
S ramp accelerate
S ramp decelerate
1 second
10 seconds
3 seconds
1 second
Boom extend/retract
accelerate
decelerate
2 seconds
0.5 second
Turntable rotate
accelerate
decelerate
2 seconds
0.5 second
Drive
accelerate
decelerate to neutral
decelerate, change of direction
decelerate, coasting
decelerate, braking
decelerate, shift from low to high speed
decelerate, shift from high to low speed
S-60 • S-65
2 seconds
0.5 second
0.5 second
0.75 second
1 second
1 second
4 seconds
4-5
Section 4 • Repair Procedures
July 2005
PLATFORM CONTROLS
REV A
How to Adjust the Joystick
Threshold Setting
10 Slowly move the joystick off center in either
direction just until the function begins to move.
The threshold setting of a joystick is the minimum
output at which a function proportional valve can
open and allow the function to operate.
11 Slowly move the joystick back to the neutral
position. Just before the function stops moving,
move the drive enable toggle switch to either
side to set the threshold.
Perform this procedure with the
boom in the stowed position.
Result: The alarm should sound indicating a
successful calibration.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
12 Repeat steps 9 through 11 for each boom
joystick controlled machine function (boom up/
down, boom extend/retract and turntable rotate).
2 Turn the key switch to platform control. Do not
start the engine.
13 Return the joystick to the neutral position and
wait for approximately 10 seconds.
3 Push in the platform controls red Emergency
Stop button to the off position.
Result: The alarm should sound indicating that
the settings have been saved in memory.
4 Do not press down the foot switch.
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.
Do not operate any machine
function during the 10 second
waiting time.
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 Start the engine from the platform controls and
press down the foot switch.
9 Select a boom function joystick to set the
threshold.
4-6
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
Platform Components
REV B
2-1
Platform Leveling Slave Cylinder
4 Remove the pin retaining fastener from the slave
cylinder rod-end pivot pin. Use a soft metal drift
to drive the rod-end pivot pin out.
Crushing hazard. The jib boom
could fall when the slave cylinder
rod-end pivot pin is removed if not
properly supported.
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.
5 Remove the external snap rings from the barrelend pivot pin.
6 Use a soft metal drift to drive the barrel-end
pivot pin out.
How to Remove the Platform
Leveling Slave Cylinder
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.
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.
1 Extend the primary boom until the slave cylinder
barrel-end pivot pin is accessible.
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.
2 Raise the primary boom slightly and place
blocks under the platform for support.
1 Raise the primary boom to a horizontal position.
3 Lower the primary boom until the platform is
resting on the blocks just enough to support the
platform.
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.
Do not rest the entire weight of the
boom on the blocks.
Part No. 77828
S-60 • S-65
4-7
Section 4 • Repair Procedures
July 2005
PLATFORM COMPONENTS
REV B
2 Tag, disconnect and plug the hydraulic hoses
from the platform rotator manifold. Cap the
fittings on the rotator.
2-2
Platform Rotator
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.
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
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 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
way in the left 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 Remove the platform and platform support.
4-8
3 S-65: Support the jib boom leveling arms and
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.
Crushing hazard. The platform
mounting weldment could become
unbalanced and fall if not properly
supported when removed from the
machine.
5 Support the platform rotator with an appropriate
lifting device. Do not apply any lifting pressure.
S-60:
6 Support the rod end of the platform leveling
slave cylinder. Protect the cylinder rod from
damage.
7 Remove the pivot pin retaining fasteners from
both the slave cylinder rod-end pivot pin and the
rotator pivot pin.
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV B
PLATFORM COMPONENTS
8 Use a soft metal drift to remove both pivot pins.
Remove the platform rotator from the machine.
How to Bleed the Platform
Rotator
Crushing hazard. The platform
rotator may become unbalanced
and fall if not properly supported.
When installing the platform rotator
fasteners, torque the fasteners to
specifications.
This procedure will require two
people. Do not start the engine.
Use auxiliary power for this
procedure.
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.
1 Move the function enable toggle switch to either
side and activate the platform rotate toggle
switch to the right then the left through two
platform rotation cycles, then hold the switch to
the right position until the platform is fully
rotated to the right.
7 Support the jib boom leveling arms.
Before serial number 9154:
8 Use a soft metal drift to drive both pins out, then
remove the platform rotator from the machine.
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.
S-65:
Bodily injury hazard. The jib boom
leveling arms may fall if not
properly supported.
3 Open the top bleed valve on the rotator, but do
not remove it.
9 Lower the jib boom leveling arms.
a
Crushing hazard. The platform
rotator may become unbalanced
and fall if not properly supported.
When installing the platform rotator
fasteners, torque the fasteners to
specifications.
d
c
a
b
c
d
Part No. 77828
S-60 • S-65
b
top bleed valve
bottom bleed valve
container
clear hose
4-9
Section 4 • Repair Procedures
July 2005
PLATFORM COMPONENTS
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
valve. Close the bleed valve.
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.
Crushing hazard. Keep clear of the
platform during rotation.
Crushing hazard. Keep clear of the
platform during rotation.
5 Connect the clear hose to the bottom bleed
valve and open the valve. Do not remove the
bleed valve.
5 Open the bottom bleed screw on the rotator, but
do not remove it.
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
valve. Close the bleed valve.
Crushing hazard. Keep clear of the
platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions and
inspect the bleed valves for leaks.
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
screw. Close the bleed screw.
Crushing hazard. Keep clear of the
platform during rotation.
After serial number 9153:
7 Clean up any hydraulic oil that may have spilled.
2 Place a suitable container underneath the
platform rotator.
3 Open the top bleed screw on the rotator, but do
not remove it.
8 Rotate the platform fully in both directions and
inspect the bleed screws for leaks.
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.
4 - 10
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
Jib Boom Components, S-65
REV A
3-1
Jib Boom
6 Attach a lifting strap from an overhead crane to
the jib boom assembly.
How to Remove the Jib Boom
7 Place blocks under the platform leveling cylinder
for support. Protect the cylinder rod from
damage.
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.
8 Remove the pin retaining fastener from the slave
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin.
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.
9 Remove the pin retaining fastener from the jib
boom bellcrank to primary boom pivot pin.
1 Remove the platform.
2 Remove the platform mounting weldment.
3 Remove the hose and cable cover from the side
of the jib boom.
10 Use a soft metal drift to remove the pin and
carefully remove the jib boom assembly from
the primary boom.
4 Remove the hose and cable clamp from the jib
boom pivot pin. Lay all hoses and cables to the
side.
Component damage hazard. Hoses
and cables can become damaged
if they are kinked or pinched.
Crushing hazard. The jib boom
could become unbalanced and fall
when removed from the machine if
not properly attached to the
overhead crane.
5 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 77828
S-60 • S-65
4 - 11
Section 4 • Repair Procedures
July 2005
JIB BOOM COMPONENTS, S-65
REV A
3-2
Jib Boom Lift Cylinder
3 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
How to Remove the Jib Boom
Lift Cylinder
4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
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.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Then
lower the jib boom until the platform is resting
on the blocks just enough to support the
platform.
5 Support the jib boom lift cylinder with a lifting
device.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pin and
let the cylinder hang down.
Crushing hazard. The platform and
jib boom could become unbalanced
and fall when the jib boom barrelend pivot pin is removed if not
properly supported.
Do not rest the entire weight of the
boom on the blocks.
7 Attach a lifting strap from an overhead crane to
the lug on the rod end of the jib boom lift
cylinder.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
8 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pin. Remove the cylinder from
the machine.
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.
4 - 12
S-60 • S-65
Crushing hazard. The jib boom lift
cylinder could become unbalanced
and fall when removed from the
machine if not properly attached to
the overhead crane.
Part No. 77828
July 2005
Section 4 • Repair Procedures
Boom Components
REV B
5 Remove the hose and cable clamp from the
platform support.
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.
6 Tag, disconnect and plug the hydraulic hoses
from the counterbalance valve manifold located
on the platform rotator. Cap the fittings on the
manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
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 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.
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.
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.
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.
Part No. 77828
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.
S-60 • S-65
4 - 13
Section 4 • Repair Procedures
July 2005
BOOM COMPONENTS
REV B
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.
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.
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.
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.
13 Pull the hydraulic hoses out of the primary
boom.
Crushing hazard. The cable track
could become unbalanced and fall
if not properly attached to the
overhead crane.
14 Place blocks in between the upper and lower
cable tracks and secure the upper and lower
tracks together.
Component damage hazard.
Cables and hoses can be damaged
if they are kinked or pinched.
Crushing hazard. If the upper and
lower cable tracks are not properly
secured together, the cable track
could become unbalanced and fall
when removed from the machine.
Component damage hazard. The
cable track can be damaged if it is
twisted.
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
a new one.
4 - 14
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
BOOM COMPONENTS
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
and Fitting Torque Specifications.
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.
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.
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.
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.
3 Raise the boom to a horizontal position.
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.
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.
Part No. 77828
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.
S-60 • S-65
4 - 15
Section 4 • Repair Procedures
July 2005
BOOM COMPONENTS
REV B
13 Carefully pull the cables and connector
receptacles out of the primary boom.
19 Attach a lifting strap from an overhead crane to
the cable track.
14 Tag, disconnect and plug all hydraulic hoses
that enter the cable track from the bulkhead
fittings at the pivot end of the boom.
20 Remove the mounting fasteners that attach the
lower cable track to the boom.
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.
21 Carefully remove the cable track from the
machine and place it on a structure capable of
supporting it.
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.
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
a new one.
Component damage hazard. The
cable track can be damaged if it is
twisted.
17 Remove the cable track pull tube guide
fasteners from the cable track guide at the
platform end of the boom. Remove the cable
track guide from the boom.
18 Place blocks in between the upper and lower
cable tracks and secure the upper and lower
tracks together.
Crushing hazard. If the upper and
lower cable tracks are not properly
secured together, the cable track
could become unbalanced and fall
when removed from the machine.
4 - 16
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV B
BOOM COMPONENTS
7 Connect the ends of the replacement cable track
section to the existing cable track using the
snap rings.
How to Repair the Cable Track
Component damage hazard.
The boom cable track can be
damaged if it is twisted.
8 Install the rollers onto the new section of cable
track.
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.
9 Operate the boom extend/retract function
through a full cycle to ensure smooth operation
of the new section of cable track.
1 Visually inspect the cable track and determine
which 4 link section needs to be replaced.
2 Carefully remove the snap rings from each end
of the damaged section of cable track.
3 Remove the retaining fasteners from the upper
black rollers from the 4 link section of cable
track to be replaced. Remove the rollers.
4 Lift up the hoses and cables and carefully
remove the damaged 4 link section of cable
track.
Component damage hazard. Hoses
and cables can be damaged if they
are kinked or pinched.
5 Remove the upper rollers from the replacement
section of cable track.
6 Lift up the hoses and cables and carefully insert
the new 4 link section of cable track.
Component damage hazard.
Hoses and cables can be damaged
if they are kinked or pinched.
Part No. 77828
S-60 • S-65
4 - 17
Section 4 • Repair Procedures
July 2005
BOOM COMPONENTS
REV B
Component damage hazard.
When lowering the master cylinder
down, be sure not to damage the
master cylinder hoses or fittings.
4-2
Boom
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.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
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.
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.
4 - 18
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV B
BOOM COMPONENTS
4 Remove the pin retaining fastener from the
primary boom lift cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin.
4-3
Boom Lift Cylinder
The primary boom will fall if not
properly supported when the
primary boom rod-end pivot pin is
removed.
The boom lift cylinder raises and lowers the boom.
The boom lift cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.
How to Remove the Boom
Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
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 to a horizontal position.
5 Using auxiliary power, activate the boom down
function so the cylinder will retract. Retract the
cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
boom. Turn the machine off.
6 Tag, disconnect and plug the boom lift cylinder
hydraulic hoses. Cap the fittings on the cylinder.
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.
8 Use a slide hammer to remove the barrel-end
pivot pins.
Crushing hazard. The boom lift
cylinder could become unbalanced
and fall if not properly supported
and secured to the lifting device.
2 Attach a 5 ton / 5000 kg overhead crane to the
boom at the platform end for support. Do not lift
the boom.
3 Support and secure both ends of the boom lift
cylinder to a second overhead crane or similar
lifting device.
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.
Crushing hazard. The boom lift
cylinder could become unbalanced
and fall if not properly supported
and secured to the lifting device.
Part No. 77828
S-60 • S-65
4 - 19
Section 4 • Repair Procedures
July 2005
BOOM COMPONENTS
REV B
3 Remove the boom end cover from the pivot end
of the boom.
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.
4 Fully loosen the lock nuts on the extend cables.
Do not remove the nuts.
5 Loosen the retract cable nut at the platform end
of the boom. Pull the cable rod from the support
and let it hang down.
6 Remove the cable guard fasteners and remove
the cable guard.
How to Remove the Boom
Extension Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
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.
a
a
b
1 Raise the boom to a horizontal position.
b
cable guard
retaining block
2 Remove the access covers from both sides of
the boom at the pivot end.
4 - 20
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV B
BOOM COMPONENTS
7 Locate the retaining plates that secure the
retract cables to the inside of the number 3
boom tube.
12 Pull back on the extend cable mounting plate
until it clears the blocks welded to the inside of
the number 1 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.
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.
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 mounting plates to the inside of
the number 1 boom tube.
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
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
a
b
a
b
c
d
Part No. 77828
c
extend
extend
extend
extend
d
cable lock nuts
cable mounting plate
cable mounting plate fastener
cable bracket
S-60 • S-65
4 - 21
Section 4 • Repair Procedures
July 2005
BOOM COMPONENTS
REV B
21 Attach a lifting strap from a 5 ton / 5000 kg
overhead crane to lug at the rod end of the
boom extension cylinder.
4-5
Boom Extend/Retract Cables
22 Lift the boom extension cylinder with the crane
until it clears the cylinder saddle inside the
number 2 boom tube.
How to Adjust the Boom Extend/
Retract Cables
23 Carefully support and slide the extension
cylinder out of the boom.
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.
Crushing hazard. The extension
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.
Component damage hazard. Be
careful not to damage the
counterbalance valves on the
primary boom extension cylinder
when removing the cylinder from
the boom.
During removal of the extension
cylinder, the overhead crane strap
will need to be carefully adjusted
for proper balancing.
4 - 22
Perform this procedure with the
boom in a horizontal position.
This procedure will require two
people.
1 Fully extend the boom.
2 Retract the boom approximately
12 inches / 30 cm.
3 Remove the boom cover at the pivot end of the
boom.
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV B
BOOM COMPONENTS
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.
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.
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.
If the retract cable adjustment nut
is loosened, remove the nut and
replace it with 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.
a
1 Remove the boom extension cylinder. See 4-4,
How to Remove the Boom Extension Cylinder.
Boom extend cables:
2 Remove the cables from the lower boom extend
cable bracket that attaches to the number 3
boom tube.
3 Remove the rue rings and clevis pins from the
boom extend cables located near the cable
break limit switch.
b
c
a
b
c
Part No. 77828
cable break limit switch
extend cable adjustment nut
extend cable pivot plate
S-60 • S-65
4 - 23
Section 4 • Repair Procedures
July 2005
BOOM COMPONENTS
REV B
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.
12 Attach a lifting strap from an overhead crane to
the platform end of the boom.
13 Raise the boom using the overhead crane and
place a wood block under the number 2 boom
tube between the number 1 and number 2 boom
tubes for support. This will create clearance
between the boom tubes to remove the retract
cables.
14 Attach the cable pulling tool or a rope to one of
the boom retract cables at the pivot end of the
boom.
A cable pulling tool is available
through Genie Service Parts
Department, part no. 94510.
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.
Boom retract cables:
10 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.
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.
4 - 24
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 through 19 for the other boom
retract cable.
21 At the platform end of the boom, install the
retract cables, clevis pins and new cotter pins
to the adjustment plate.
22 Remove and discard the old boom retract
pulleys from the pivot end of the boom
extension cylinder.
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV B
BOOM COMPONENTS
23 Install the new boom retract pulleys to the pivot
end of the boom extension cylinder.
2 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
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.
3 Place a 2 x 4 x 48 inches / 5 x 10 x 120 cm
block of wood across the turntable covers.
Position the block under the master cylinder.
4 Remove the pin retaining fastener from the
master cylinder rod-end pivot pin.
5 Place a rod through the rod-end pivot pin and
twist to remove the pin. Lower the rod end of the
master cylinder onto the block.
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.
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.
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.
Part No. 77828
S-60 • S-65
4 - 25
Section 4 • Repair Procedures
July 2005
Engines
REV C
5-1
RPM Adjustment - Deutz Models
How to Remove the Flex Plate
Refer to Maintenance Procedure B-8, Check and
Adjust the Engine RPM - Deutz Models.
1 Remove the tailpipe bracket mounting fasteners
from the engine bell housing.
Deutz models:
2 Support the drive pump assembly with an
appropriate lifting device.
5-2
RPM Adjustment - Perkins
Models
3 Remove all of the engine bell housing fasteners.
4 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Refer to Maintenance Procedure A-12, Check and
Adjust the Engine RPM - Perkins Models.
5 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
5-3
Flex Plate
GM models:
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.
a
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
b
c
d
e
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 Support the engine with a suitable lifting device.
Do not lift it.
5 Remove the engine plate to vibration isolator
fasteners.
f
a
b
c
d
e
f
4 - 26
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 gap - GM Models
1/16 inch / 1.5 mm gap - Ford Models
6 Remove the engine mounting plate to bell
housing fasteners.
S-60 • S-65
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
REV C
ENGINES
7 Slide the engine mounting plate towards the
pump as far as it will go.
8 Remove the engine mounting plate to bell
housing fasteners.
8 Support the drive pump assembly with an
appropriate lifting device.
9 Raise the engine slightly to take the weight off
of the engine mounting plate.
9 Remove all of the engine bell housing fasteners.
10 Slide the engine mounting plate towards the
pump as far as it will go.
10 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
11 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
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 and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
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.
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
can be damaged if they are kinked
or pinched.
7 Remove the engine plate to vibration isolator
fasteners.
6 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
Part No. 77828
S-60 • S-65
4 - 27
Section 4 • Repair Procedures
July 2005
ENGINES
REV C
1
How to Install the Flex Plate
1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
2 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.
2
3
Perkins models: Torque the flex plate mounting
bolts in sequence to 49 ft-lbs / 66 Nm.
3 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 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.
Perkins models: Torque the flex plate mounting
bolts in sequence to 70 ft-lbs / 95 Nm.
a
b
c
d
e
1
3
6
f
a
b
c
d
e
f
5
4
2
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.
Ford and Deutz models
4 - 28
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV C
ENGINES
1
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.
7
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.
8
C
4
C
C
3
C
9
C
C
5
2
Ford models
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
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.
6
C
C
Component damage hazard. When
installing the pump, do not force
the pump coupler into the flexplate
or damage to the pump shaft seal
may occur.
7 Ford and Deutz models: Torque the bell
housing mounting bolts labeled "C" in sequence
to 40 ft-lbs / 54 Nm.
C
6
1
C
C
10
8
C
4
11
C
C
C
C
C
3
12
C
C
C
7
C
5
9
2
Deutz models
6
1
A
A
B
B
4
B
5
B
B
8
9
B
B
7
3
2
Perkins models
Part No. 77828
S-60 • S-65
4 - 29
Section 4 • Repair Procedures
July 2005
ENGINES
REV C
3 Quickly activate and release the start toggle
switch/button. Do not start the engine.
5-4
Engine Fault Codes GM and Ford Models
4 Move and hold the run/test toggle switch to the
test position.
Result: The check engine light should turn on.
The check engine light should begin to blink.
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.
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.
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.
6 Refer to Section 5, Fault Codes, for definition of
engine fault codes.
Ford models:
Perform this procedure with the
key switch in the off position.
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.
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.
4 - 30
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV C
ENGINES
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.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
3 Connect the negative battery cable to the
battery.
Part No. 77828
S-60 • S-65
4 - 31
Section 4 • Repair Procedures
July 2005
Hydraulic Pumps
REV C
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.
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.
2 Tag, disconnect and plug the function pump
hydraulic hoses. Cap the fittings on the pump.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
3 Remove the pump mounting bolts. Carefully
remove the pump.
Models with hydraulic tank shut-off valves:
Component damage hazard. Be
sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
Models without hydraulic tank shut-off valves:
open
closed
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
S-60 • S-65
Component damage hazard. Be
sure to fill the hydraulic tank to
specification and prime the pump
after installing the pump.
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV C
HYDRAULIC PUMPS
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.
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
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.
How to Remove the Drive Pump
Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
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.
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.
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.
1 Disconnect the electrical connection at the
electro-proportional controller located on the
drive pump.
Part No. 77828
closed
S-60 • S-65
4 - 33
Section 4 • Repair Procedures
July 2005
HYDRAULIC PUMPS
REV C
4 Support the pump with a lifting device and
remove the two drive pump mounting fasteners.
5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
How to Prime the Pump
1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the test port on the drive pump.
2 Remove the safety pin (if equipped) from the
engine pivot plate latch.
6 Remove the drive pump from the machine.
Component damage hazard. The
hydraulic pump may become
unbalanced and fall if not properly
supported.
Component damage hazard. When
installing the pump, do not force
the pump coupler into the flexplate
or damage to the pump shaft seal
may occur.
Models with hydraulic tank shut-off valves:
Component damage hazard. Be
sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
Models without hydraulic tank shut-off valves:
Component damage hazard. Be
sure to fill the hydraulic tank to
specification and prime the pump
after installing the pump.
The engine pivot plate latch is
located under the engine turntable
pivot plate at the counterweight
end of the machine.
3 Open the engine pivot plate latch and swing the
engine pivot plate out and away from the
machine.
4 GM and Ford models: Close the valve on the
LPG tank then disconnect the hose from the
tank. Move the fuel select switch to the LPG
position.
Perkins models: Disconnect the engine wiring
harness from the fuel solenoid at the injector
pump.
Deutz models: Hold the manual fuel shutoff
valve clockwise to the closed position.
a
a
4 - 34
S-60 • S-65
manual fuel shutoff valve
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV C
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.
Part No. 77828
S-60 • S-65
4 - 35
Section 4 • Repair Procedures
July 2005
Manifolds
REV D
7-1
Function Manifold Components
The function manifold is located underneath the ground controls side turntable cover.
Index
No.
Description
Schematic
Item
1
Counterbalance valve ....................... H ........... Platform level down .......................... 30-35 ft-lbs / 41-47 Nm
2
Counterbalance valve ....................... G ........... Platform level up ............................... 30-35 ft-lbs / 41-47 Nm
3
Proportional solenoid valve .............. M .......... Boom extend/retract ......................... 30-35 ft-lbs / 41-47 Nm
4
Solenoid valve, 2 position 3 way ...... C ........... Boom retract ..................................... 30-35 ft-lbs / 41-47 Nm
5
Solenoid valve, 2 position 3 way ...... B ........... Boom extend .................................... 30-35 ft-lbs / 41-47 Nm
6
Solenoid valve, 3 position 4 way ...... D ........... Turntable rotate ................................ 20-25 ft-lbs / 27-34 Nm
7
Proportional solenoid valve .............. T ........... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
8
Solenoid valve, 3 position 4 way ...... BB ......... Steer left/right .................................... 20-25 ft-lbs / 27-34 Nm
9
Check valve, 30 psi / 2 bar ................ I ............ Differential sensing circuit,
platform rotate left and
jib boom up (S-65) ............................ 20-25 ft-lbs / 27-34 Nm
10
Check valve, 30 psi / 2 bar ................ J ............ Differential sensing circuit,
platform rotate right and
jib boom down (S-65) ....................... 20-25 ft-lbs / 27-34 Nm
11
Check valve ....................................... N ........... Differential sensing circuit,
boom extend/retract .......................... 10-12 ft-lbs / 14-16 Nm
12
Solenoid valve, 2 position 3 way ...... F ........... Boom down ....................................... 30-35 ft-lbs / 41-47 Nm
13
Solenoid valve, 2 position 3 way ...... E ........... Boom up ........................................... 30-35 ft-lbs / 41-47 Nm
14
Check valve ....................................... O ........... Differential sensing circuit,
turntable rotate ................................. 10-12 ft-lbs / 14-16 Nm
15
Check valve ....................................... R ........... Differential sensing circuit,
boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
16
Priority flow regulator valve,
3.5 gpm / 13.2 L/min .......................... AA ......... Steer left/right circuit ......................... 30-35 ft-lbs / 41-47 Nm
17
Differential sensing valve,
110 psi / 7.6 bar ................................. S ........... Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
18
Differential sensing valve,
150 psi / 10.3 bar .............................. P ........... Turntable rotate circuit ...................... 30-35 ft-lbs / 41-47 Nm
Function
Torque
This list continues. Please turn the page
4 - 36
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV D
MANIFOLDS
1
2
3
4
5
6
7
8
9
10
31
11
30
12
13
14
29
15
28
27
16
26
25
17
24
18
23
22
Part No. 77828
21
S-60 • S-65
20
19
4 - 37
Section 4 • Repair Procedures
July 2005
MANIFOLDS
REV D
Function Manifold Components, continued
Index
No.
Description
Schematic
Item
Function
Torque
19
Check valve, 5 psi / 0.3 bar ............... A ........... Blocks flow from auxiliary pump
to function pump ............................... 30-35 ft-lbs / 41-47 Nm
20
Relief valve, 3000 psi / 206.8 bar ..... K ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
21
Flow control valve,
0.1 gpm / 0.38 L/min .......................... DD ........ Bleeds off differential sensing
valves to tank .................................... 20-25 ft-lbs / 27-34 Nm
22
Differential sensing valve,
150 psi / 10.3 bar .............................. CC ........ Differential sensing circuit,
meters flow to functions .................... 30-35 ft-lbs / 41-47 Nm
23
Check valve ....................................... W .......... Differential sensing circuit,
platform level up ............................... 10-12 ft-lbs / 14-16 Nm
24
Check valve ....................................... X ........... Differential sensing circuit,
platform level down .......................... 10-12 ft-lbs / 14-16 Nm
25
Proportional solenoid valve .............. Q ........... Turntable rotate left/right .................. 20-25 ft-lbs / 27-34 Nm
26
Flow control valve,
0.6 gpm / 2.27 L/min .......................... Z ........... Platform rotate and
jib boom (S-65) ................................. 20-25 ft-lbs / 27-34 Nm
27
Check valve, 30 psi / 2 bar ................ EE ......... 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 bar ................................. L ........... Boom extend/retract circuit ............... 30-35 ft-lbs / 41-47 Nm
29
Needle valve ..................................... U ........... Platform level circuit ......................... 30-35 ft-lbs / 41-47 Nm
30
Solenoid valve, 3 position 4 way ...... V ........... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
31
Solenoid valve, 3 position 4 way ...... Y ........... Platform rotate and jib boom
up/down (S-65) ................................. 20-25 ft-lbs / 27-34 Nm
4 - 38
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV D
MANIFOLDS
1
2
3
4
5
6
7
8
9
10
31
11
30
12
13
14
29
15
28
27
16
26
25
17
24
18
23
22
Part No. 77828
21
S-60 • S-65
20
19
4 - 39
Section 4 • Repair Procedures
July 2005
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 a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the PTEST port on the function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggle
switch to the high idle position. Activate and
hold the boom retract toggle switch with the
boom fully retracted.
4 Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item K).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 5 and recheck relief
valve pressure.
8 Remove the pressure gauge.
4 - 40
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV D
MANIFOLDS
7-3
Jib Boom / Platform Rotate Manifold Components
Index
No.
Description
Schematic
Item
1
Solenoid valve, 2 position 3 way ..... FF ......... Platform rotate/jib boom select ......... 20-25 ft-lbs / 27-34 Nm
Function
Torque
1
Part No. 77828
S-60 • S-65
4 - 41
Section 4 • Repair Procedures
July 2005
MANIFOLDS
REV D
7-4
Brake/Two-Speed Manifold Components
The brake/two-speed manifold is mounted near the turntable rotator.
Index
No.
Description
Schematic
Item
1
Orifice, 0.025 inch / 0.64 mm .......... JJ ............ Turntable rotation brake release
2
Solenoid valve, 2 position 3 way ... KK ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
3
Solenoid valve, 2 position 3 way .... LL ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm
4
Check valve ...................................... II ............ Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm
Function
1
Torque
2
3
4
4 - 42
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV D
MANIFOLDS
7-5
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor.
Index
No.
Description
Schematic
Item
1
Shuttle valve, 2 position 3 way ...... OO ........... Turntable rotation brake release ..... 10-13 ft-lbs / 14-18 Nm
2
Counterbalance valve .................... MM .......... Turntable rotate right ....................... 35-40 ft-lbs / 47-54 Nm
3
Counterbalance valve .................... NN ........... Turntable rotate left .......................... 35-40 ft-lbs / 47-54 Nm
4
Orifice, 0.030 inch / 0.76 mm ......... PP ........... Brake release circuit
(located inside port)
Function
1
Torque
2
4
3
Part No. 77828
S-60 • S-65
4 - 43
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
1
Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm
2
Spool valve ...................................................... Directional control
Function
Torque
1
2
4 - 44
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
MANIFOLDS
REV D
7 To level the drive chassis, start the engine and
push up or pull down on the threaded rod until
the machine is completely level.
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.
8 Verify that the ground and drive chassis are
completely level.
9 Adjust the heim joint until the hole lines up with
the retaining fastener hole in the axle.
1 Lower the boom to the stowed position.
2 Use a "bubble type" level to be sure the floor is
completely level.
Tip-over hazard. Failure to perform
this procedure on a level floor
could compromise the stability of
the machine resulting in the
machine tipping over.
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).
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.
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.
4 Remove the drive chassis cover and the nonsteer 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.
Part No. 77828
S-60 • S-65
4 - 45
Section 4 • Repair Procedures
July 2005
MANIFOLDS
REV D
7-7
Valve Adjustments - Oscillate
Relief Valve
How to Adjust the Oscillate
Relief Valve Pressure
1 Remove the drive chassis cover from the nonsteer 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 Turn the 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.
Tip-over hazard. Do not adjust the
relief valve higher than specified.
9 Repeat steps 4 through 7 and manually activate
the valve to confirm the valve pressure.
10 Turn the engine off, remove the pressure gauge
and assemble the directional valve linkage.
11 Install the cover on the non-steer end of the
drive chassis.
4 - 46
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV D
MANIFOLDS
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Part No. 77828
S-60 • S-65
4 - 47
Section 4 • Repair Procedures
July 2005
MANIFOLDS
REV D
7-8
Traction Manifold Components, 2WD
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
1
Relief valve, 280 psi / 19.3 bar ......... TT ......... Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
2
Flow divider/combiner valve ............. WW ....... Controls flow to drive motors
in forward and reverse ............... 90-100 ft-lbs / 122-136 Nm
3
Check valve ....................................... SS ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
4
Check valve ....................................... XX ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
5
Shuttle valve, 3 position 3 way ......... UU ........ Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ............................ 50-55 ft-lbs / 68-75 Nm
6
Orifice, 0.070 inch / 1.78 mm ............ VV ......... Drive motor circuit
4 - 48
Schematic
Item
Function
S-60 • S-65
Torque
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV D
MANIFOLDS
1
6
Part No. 77828
2
5
4
S-60 • S-65
3
4 - 49
Section 4 • Repair Procedures
July 2005
MANIFOLDS
REV D
7-9
Valve Adjustments, 2WD
Traction Manifold
How to Adjust the Charge
Pressure Relief Valve
1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the test port on the drive pump.
2 Hold the charge pressure relief valve and
remove the cap (item TT).
3 Turn the internal hex socket clockwise fully until
it stops. Install the cap.
4 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.
7 Hold the charge pressure relief valve and
remove the cap (item TT).
8 Start the 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 - 50
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV D
MANIFOLDS
This page intentionally left blank.
Part No. 77828
S-60 • S-65
4 - 51
Section 4 • Repair Procedures
July 2005
MANIFOLDS
REV D
7-10
Traction Manifold Components, 4WD
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
1
Check valve ....................................... TT ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 14-16 Nm
2
Check valve ....................................... SS ......... Non-steer end drive motor circuit ..... 35-40 ft-lbs / 14-16 Nm
3
Flow divider/combiner valve ............. AB ......... Controls flow to flow
divider/combiner valves
11 and 13 ...................................... 80-90 ft-lbs / 108-122 Nm
4
Check valve ....................................... AF ......... Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm
5
Orifice, 0.040 inch / 1 mm .................. AC ........ Equalizes pressure on both sides
of flow divider/combiner valve 3
6
Orifice, 0.040 inch / 1 mm .................. AE ......... Equalizes pressure on both sides
of flow divider/combiner valve 11
7
Orifice, 0.040 inch / 1 mm .................. WW ....... Equalizes pressure on both sides
of flow divider/combiner valve 13
8
Check valve ....................................... AG ........ Steer end drive motor circuit ............ 60-70 ft-lbs / 81-95 Nm
9
Check valve ....................................... ZZ ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 14-16 Nm
10
Shuttle valve, 3 position 3 way ......... VV ......... Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
11
Flow divider/combiner valve ............. AD ........ Controls flow to steer end
drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
12
Check valve ....................................... YY ......... Non-steer end drive motor circuit ..... 35-40 ft-lbs / 14-16 Nm
13
Flow divider/combiner valve ............. XX ......... Controls flow to non-steer end
drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
7
Relief valve, 280 psi / 19.3 bar ......... UU ........ Charge pressure circuit .................... 35-40 ft-lbs / 14-16 Nm
4 - 52
Schematic
Item
Function
S-60 • S-65
Torque
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV D
MANIFOLDS
1
2
14
13
12
11
3
4
10
9
8
7
6
5
Part No. 77828
S-60 • S-65
4 - 53
Section 4 • Repair Procedures
July 2005
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 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.
7 Hold the charge pressure relief valve and
remove the cap (item UU).
8 Start the 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
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
REV D
MANIFOLDS
7-12
Valve Coils
How to Test a Coil Diode
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.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Genie incorporates spike suppressing diodes in all
of its directional valve coils except proportional
valves and those coils with a metal case. Properly
functioning coil diodes protect the electrical circuit
by suppressing voltage spikes. Voltage spikes
naturally occur within a function circuit following the
interruption of electrical current to a coil. Faulty
diodes can fail to protect the electrical system,
resulting in a tripped circuit breaker or component
damage.
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.
1 Test the coil for resistance. See, How to Test a
Coil.
2 Test the coil resistance.
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
Valve Coil Resistance Specification
Description
Specification
Solenoid valve, 3 position 4 way, 10V DC
(schematic items D, V and Y)
5 to 7Ω
Solenoid valve, 3 position 4 way, 10V DC
(schematic item BB)
4 to 6Ω
Solenoid valve, 2 position 3 way, 10V DC
(schematic items B, C, E, F and FF)
5 to 7Ω
Solenoid valve, 2 position 3 way, 10V DC
(schematic items KK and LL)
5.5 to 7.5Ω
Proportional solenoid valve, 12V DC
(schematic items M and T)
4 to 6Ω
Proportional solenoid valve, 12V DC
(schematic item Q)
3.7 to 5.7Ω
Part No. 77828
S-60 • S-65
4 - 55
Section 4 • Repair Procedures
July 2005
MANIFOLDS
REV D
2 Connect a 10Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.
3 Set a multimeter to read DC current.
Resistor, 10W
Genie part number
4 Connect the negative lead to the other terminal
on the coil.
27287
The multimeter, when set to read
DC current, should be capable of
reading up to 800 mA.
If testing a single-terminal coil,
connect the negative lead to the
internal metallic ring at either end
of the coil.
The battery should read 9V DC or
more when measured across the
terminals.
a
AMMETER
COIL
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
d
-
b
+
c
10 W
RESISTOR
9V
BATTERY
+
c
b
a
b
c
d
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
multimeter
9V DC battery
10Ω resistor
coil
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Note: Dotted lines in illustration indicate a
reversed connection as specified in
step 6
4 - 56
S-60 • S-65
Part No. 77828
July 2005
REV C
Section 4 • Repair Procedures
Turntable Rotation Components
3 Loosen the backlash pivot plate and adjustment
bolts.
8-1
Turntable Rotation Assembly
How to Remove the Turntable
Rotation Assembly
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
machine on a firm and level
surface.
a
1 Secure the turntable from rotating with the
turntable rotation lock pin.
a
b
c
The turntable rotation lock pin is
located next to the boom rest pad.
2 Tag, disconnect and plug the hydraulic hoses
from the turntable rotation drive motor. Cap the
fittings on the drive motor.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
b
c
backlash pivot plate
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.
Crushing hazard. The turntable
could rotate unexpectedly when
the rotation drive hub assembly is
removed if the turntable is not
secured with the turntable rotation
lock pin.
Crushing hazard. The turntable
rotation drive hub assembly could
become unbalanced and fall when
removed from the machine if not
properly supported.
Part No. 77828
S-60 • S-65
4 - 57
Section 4 • Repair Procedures
July 2005
TURNTABLE ROTATION COMPONENTS
REV C
When installing the drive hub assembly:
6 Install the drive hub. Torque the back lash pivot
plate mounting bolts to 260 ft-lbs / 352.5 Nm.
2 Loosen the backlash pivot plate mounting
fasteners.
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 on a
firm and level surface.
a
b
a
b
c
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.
c
backlash pivot plate
adjustment bolt with lock nut
backlash pivot plate mounting bolts
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).
3 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 plate away from the
turntable until it contacts the adjustment bolt.
Then torque the mounting fasteners on the
backlash pivot plate to 260 ft-lbs / 352.5 Nm.
7 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.
4 - 58
S-60 • S-65
Part No. 77828
July 2005
Section 4 • Repair Procedures
Axle Components
REV C
9-1
Oscillating Axle Cylinders
3 Remove the pin retaining fasteners from the rodend pivot pin. Use a soft metal drift to remove
the pin.
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.
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.
How to Remove an Oscillate
Axle Cylinder
Perform this procedure on firm,
level surface with the boom in the
stowed position.
Crushing hazard. The oscillate
cylinder could become unbalanced
and fall if not properly attached to
the overhead crane when removed
from the machine.
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.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Part No. 77828
S-60 • S-65
4 - 59
Section 4 • Repair Procedures
July 2005
This page intentionally left blank.
4 - 60
S-60 • S-65
Part No. 77828
July 2005
Section 5 • Fault Codes
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.
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
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.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
Electrocution hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
· Machine parked on a firm, level surface
· Boom in stowed position
· Turntable rotated with the boom between
the non-steer wheels
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.
· 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
Perform all troubleshooting on a
firm, level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.
Part No. 77828
S-60 • S-65
5-1
Section 5 • Fault Codes
July 2005
FAULT CODES
REV A
Fault Codes - Control System
How to Retrieve Control System
Fault Codes
At least one fault code is present
when the alarm at the platform
controls produces two short beeps
every 30 seconds for 10 minutes.
Perform this procedure with the
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.
3 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.
4 Determine the error type: The yellow LED
indidates the error type and will flash two
separate codes. The first code will indicate the
first digit of the two digit code, flashing once per
second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
When the yellow LED is flashing
the code, the red LED will be on
solid.
1 Open the platform control box lid.
Electrocution hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
5 Use the fault code table on the following pages
to aid in troubleshooting the machine by
pinpointing the area or component affected.
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.
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.
5-2
S-60 • S-65
Part No. 77828
July 2005
Section 5 • Fault Codes
REV A
FAULT CODES
Error Source
ID
21
22
23
31
32
Name
Boom 1 joystick
(primary boom up/
down)
Error Type
ID
11
12
15
16
Name
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
Boom 1 directional
valves
Boom 1 flow
control valve
Boom 2 joystick
(secondary boom
up/down or
primary boom
extend/retract)
Boom 2 directional
valves
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1 second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Solution
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Continued on next page
Part No. 77828
S-60 • S-65
5-3
Section 5 • Fault Codes
July 2005
FAULT CODES
REV A
Error Source
ID
33
41
42
43
44
5-4
Name
Boom 2 flow
control valve
Turntable rotate
joystick
Error Type
ID
Name
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
21
Fault
Turntable rotate
directional valves
Turntable rotate
flow control valve
Drive enable
override switches
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Solution
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Enable override
direction is frozen at
neutral.
S-60 • S-65
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Part No. 77828
July 2005
Section 5 • Fault Codes
REV A
FAULT CODES
Error Source
ID
51
53
54
55
61
62
Name
Drive joystick
Drive flow valve
(EDC)
Error Type
ID
11
12
15
16
Name
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
12
15
Value too high
Value too low
17
Not calibrated
18
Just calibrated
21
Fault
21
Fault
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
Drive brake valve
High speed drive
motor valve
Steer joystick
Steer directional
valves
Part No. 77828
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Motor speed frozen in
the low state. Alarm
sounds indicating
fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
S-60 • S-65
Solution
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
5-5
Section 5 • Fault Codes
July 2005
Ford Engine Fault Codes
REV A
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.
5-6
S-60 • S-65
Part No. 77828
July 2005
Section 5 • Fault Codes
REV A
FORD ENGINE FAULT CODES
Code
Problem
111
Closed Loop Multiplier High
(LPG)
112
113
HO2S Open/Inactive
(Bank 1)
HO2S Open/Inactive
(Bank 2)
114
Post-cat oxygen sensor
open
121
Closed Loop Multiplier High
(Gasoline)
122
Closed Loop Multiplier Low
(Gasoline)
124
Closed Loop Multiplier Low
(LPG)
133
Gasoline cat monitor
There are exhaust leaks OR the catalyst system
efficiency is below the acceptable level.
134
LPG cat monitor
There are exhaust leaks OR the catalyst system
efficiency is below the acceptable level.
135
NG cat monitor
There are exhaust leaks OR the catalyst system
efficiency is below the acceptable level.
141
Adaptive Lean Fault - High
Limit (Gasoline)
142
Adaptive Rich Fault - Low
Limit (Gasoline)
143
Adaptive Learn High (LPG)
144
Adaptive Learn Low (LPG)
161
162
System Voltage Low
211
IAT High Voltage
212
IAT Low Voltage
System Voltage High
Cause
Heated Oxygen Sensor wiring and/or connections
open or shorted OR sensor is faulty OR there are
vacuum leaks or exhaust leaks.
Heated Oxygen Sensor wiring and/or connections
open or shorted OR sensor is faulty.
Heated Oxygen Sensor wiring and/or connections
open or shorted OR sensor is faulty.
The post cat Heated Oxygen Sensor wiring
and/or connections are open or shorted OR
sensor is cold, non-responsive or inactive for 60
seconds or longer.
Heated Oxygen Sensor wiring and/or connections
open or shorted OR sensor is faulty OR there are
vacuum leaks or exhaust leaks OR fuel pressure
is low OR the fuel injectors need cleaning or
replacing.
MAP, IAT or ECT sensors not in correct position
OR wiring and/or connections for sensors open or
shorted OR sensor is faulty OR one or more fuel
injectors are stuck open OR there is electromagnetic interference from a faulty crankshaft
and/or camshaft position sensor.
Heated Oxygen Sensor wiring and/or connections
open or shorted OR sensor is faulty OR fuel
quality is poor OR fuel system components may
be faulty.
Heated Oxygen Sensor wiring and/or connections
open or shorted OR sensor is faulty OR there are
vacuum or exhaust leaks OR one or more fuel
injectors faulty or stuck closed OR fuel quality is
poor OR fuel pressure is too low.
MAP, IAT or ECT sensors not in correct position
OR wiring and/or connections for sensors open or
shorted OR sensor is faulty OR one or more fuel
injectors are stuck closed OR there is electromagnetic interference from a faulty crankshaft
and/or camshaft position sensor.
Heated Oxygen Sensor wiring and/or connections
open or shorted OR sensor is faulty OR there are
vacuum leaks or exhaust leaks OR fuel quality is
poor OR fuel system components may be faulty.
Engine wire harness may have an intermittent
short to 5V DC or 12V DC OR fuel system
components may be faulty.
Battery is faulty OR alternator is not charging OR
battery supply wiring to ECM is open or shorted.
Alternator is overcharging the battery when
engine RPM is greater than 1500 rpm.
IAT sensor wiring and/or connections are open or
shorted OR sensor is faulty OR engine intake air
temperature is too cold.
IAT sensor wiring and/or connections are open or
shorted OR sensor is faulty OR engine intake air
temperature is too hot.
Solution
Repair wiring and/or connections OR replace
sensor OR repair vacuum and exhaust leaks.
Repair wiring and/or connections OR replace
sensor.
Repair wiring and/or connections OR replace
sensor.
Repair wiring and/or connections OR replace
the post cat oxygen sensor.
Repair wiring and/or connections OR replace
sensor OR repair any vacuum and exhaust
leaks OR test the fuel pressure OR clean or
replace the fuel injectors.
Adjust or replace sensors OR clean or repair
fuel injectors.
Repair wiring and/or connections OR replace
sensor OR replace fuel OR test and repair the
fuel system components.
Repair exhaust leaks OR there is an
emissions compliance issue. Contact Ford
Power Products for assistance.
Repair exhaust leaks OR there is an
emissions compliance issue. Contact Ford
Power Products for assistance.
Repair exhaust leaks OR there is an
emissions compliance issue. Contact Ford
Power Products for assistance.
Repair heated oxygen sensor wiring and/or
connections OR replace sensor OR repair
vacuum and exhaust leaks OR test the fuel
pressure OR clean or replace the fuel
injectors.
Adjust or replace sensors OR clean or repair
fuel injectors.
Repair wiring and/or connections OR replace
sensor OR repair any vacuum and exhaust
leaks OR replace fuel OR test and repair the
fuel system components.
Repair short in engine wire harness OR test
and repair the fuel system components.
Replace battery OR repair alternator OR repair
battery supply wiring to ECM.
Repair or replace the alternator.
Repair wiring and/or connections OR replace
sensor OR direct warmer air into air intake.
Repair wiring and/or connections OR replace
sensor OR direct cooler air into air intake.
Continued on next page
Part No. 77828
S-60 • S-65
5-7
Section 5 • Fault Codes
July 2005
FORD ENGINE FAULT CODES
Code
Problem
213
IAT Higher Than Expected
(1)
214
IAT Higher Than Expected
(2)
215
Oil Pressure Low
221
CHT/ECT High Voltage
222
CHT/ECT Low Voltage
223
CHT Higher Than Expected
(1)
224
CHT Higher Than Expected
(2)
231
232
234
235
MAP High Pressure
MAP Low Voltage
BP High Pressure
BP Low Pressure
REV A
Cause
Solution
Air intake temperature is greater than 200° F with
the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.
Air intake temperature is greater than 210° F with
the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.
Faulty oil pressure sensor OR sensor wiring
and/or connections open or shorted OR engine oil
level too low.
Engine cooling system is malfunctioning OR
sensor wires and/or connections open or shorted
OR sensor is faulty.
Engine cooling system is malfunctioning and
overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.
Coolant temperature at the cylinder head is 240°
F. Engine cooling system is malfunctioning and
overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.
Coolant temperature at the cylinder head is 250°
F. Engine cooling system is malfunctioning and
overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.
Open or shorted wiring and/or connections to
MAP sensor OR sensor is faulty.
Open or shorted wiring and/or connections to
MAP sensor OR sensor is faulty.
Check air intake system for damage and
proper routing of air intake components OR
replace the IAT sensor.
Check air intake system for damage and
proper routing of air intake components OR
replace the IAT sensor.
Replace oil pressure sensor OR repair sensor
wiring and/or connections OR fill engine oil
level to specification.
Repair engine cooling system problems OR
repair open or shorted wiring to sensor OR
replace sensor.
Repair engine cooling system problems OR
repair open or shorted wiring to sensor OR
replace sensor OR fill engine coolant level to
specification.
MAP sensor is faulty OR ECM is faulty.
Replace MAP sensor OR replace the ECM.
MAP sensor is faulty OR ECM is faulty.
Replace MAP sensor OR replace the ECM.
Crankshaft position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.
Crankshaft position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.
Camshaft position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.
Camshaft position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.
Knock sensor wiring and/or connections open or
shorted OR sensor is faulty.
Knock sensor wiring and/or connections open or
shorted OR there is excessive engine vibration
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.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace sensor.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace sensor.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace sensor.
Repair wiring and/or connections to knock
sensor OR replace knock sensor.
Check for excessive engine vibration OR
repair wiring and/or connections to knock
sensor OR replace knock sensor.
Repair wiring and/or connections to fuel
injector #1 OR replace fuel injector #1 OR
replace the ECM.
Repair wiring and/or connections to fuel
injector #1 OR replace fuel injector #1 OR
replace the ECM.
Repair wiring and/or connections to fuel
injector #2 OR replace fuel injector #2 OR
replace the ECM.
Repair wiring and/or connections to fuel
injector #2 OR replace fuel injector #2 OR
replace the ECM.
242
Crank Sync Noise
243
Never Crank Synced At
Start
244
Camshaft Sensor Loss
245
Camshaft Sensor Noise
253
Knock Sensor Open
254
Excessive Knock Signal
311
Injector Driver #1 Open
Open wiring and/or connections to fuel injector #1
OR fuel injector #1 is faulty OR ECM is faulty.
312
Injector Driver #1 Shorted
Wiring and/or connections to fuel injector #1
shorted OR fuel injector #1 is faulty OR ECM is
faulty.
313
Injector Driver #2 Open
Open wiring and/or connections to fuel injector #2
OR fuel injector #2 is faulty OR ECM is faulty.
314
Injector Driver #2 Shorted
Wiring and/or connections to fuel injector #2
shorted OR fuel injector #2 is faulty OR ECM is
faulty.
5-8
S-60 • S-65
Repair engine cooling system problems OR
repair open or shorted wiring to sensor OR
replace sensor OR fill engine coolant level to
specification.
Repair engine cooling system problems OR
repair open or shorted wiring to sensor OR
replace sensor OR fill engine coolant level to
specification.
Repair wiring and/or connections to sensor OR
replace MAP sensor.
Repair wiring and/or connections to sensor OR
replace MAP sensor.
Part No. 77828
July 2005
Section 5 • Fault Codes
REV A
FORD ENGINE FAULT CODES
Code
Problem
Cause
315
Injector Driver #3 Open
Open wiring and/or connections to fuel injector #3
OR fuel injector #3 is faulty OR ECM is faulty.
316
Injector Driver #3 Shorted
Wiring and/or connections to fuel injector #3
shorted OR fuel injector #3 is faulty OR ECM is
faulty.
321
Injector Driver #4 Open
Open wiring and/or connections to fuel injector #4
OR fuel injector #4 is faulty OR ECM is faulty.
322
Injector Driver #4 Shorted
351
Fuel Pump Loop Open or
High Side Short To Ground
352
Fuel Pump High Side
Shorted To Power
353
MegaJector delivery
pressure higher than
expected
354
Megajector delivery
pressure lower than
expected
355
MegaJector communication
lost
361
MegaJector voltage supply
high
362
MegaJector voltage supply
low
363
Megajector internal
actuator fault detection
The MegaJector detects an internal fault. Open or
short in power, ground or CAN circuits.s
364
Megajector internal circuitry
fault detection
The MegaJector detects an internal circuitry
failure. Open or short in power, ground or CAN
circuits.
365
MegaJector internal
communication fault
detection
The MegaJector detects an internal
communications failure. Open or short in power,
ground or CAN circuits.
411
412
413
414
Coil Driver #1 Open
Coil Driver #1 Shorted
Coil Driver #2 Open
Coil Driver #2 Shorted
Wiring and/or connections to fuel injector #4
shorted OR fuel injector #4 is faulty OR ECM is
faulty.
Open wiring and/or connections to fuel pump OR
fuel pump power shorted to ground OR fuel pump
is faulty.
Wiring and/or connections to fuel pump shorted to
power OR fuel pump is faulty.
Fuel pressure too high OR LPG lockoff not
sealing correctly OR the line between the
MegaJector and carburetor is kinked or restricted
or is leaking OR engine cooling system is not
operating properly OR MegaJector is faulty.
Fuel pressure too low OR LPG lockoff not
opening completely OR the line between the
MegaJector and carburetor is kinked or restricted
or is leaking OR engine cooling system is not
operating properly OR MegaJector is faulty.
The ECM doesn’t get any response from the
MegaJector, or an incorrect response for 500ms
period or longer.
The MegaJector detects voltage greater than 18
volts for 5 seconds anytime the engine is
cranking or running.
The MegaJector detects voltage less than 9.5
volts for 5 seconds anytime the engine is
cranking or running.
Open wiring and/or connections to ignition coil #1
OR ignition coil #1 is faulty.
Wiring and/or connections to ignition coil #1
shorted OR ignition coil #1 is faulty.
Open wiring and/or connections to ignition coil #2
OR ignition coil #2 is faulty.
Wiring and/or connections to ignition coil #2
shorted OR ignition coil #2 is faulty.
Solution
Repair wiring and/or connections to fuel
injector #3 OR replace fuel injector #3 OR
replace the ECM.
Repair wiring and/or connections to fuel
injector #3 OR replace fuel injector #3 OR
replace the ECM.
Repair wiring and/or connections to fuel
injector #4 OR replace fuel injector #4 OR
replace the ECM.
Repair wiring and/or connections to fuel
injector #4 OR replace fuel injector #4 OR
replace the ECM.
Repair wiring and/or connections to fuel pump
OR replace fuel pump.
Repair wiring and/or connections to fuel pump
OR replace fuel pump.
Check fuel pressure OR repair LPG lockoff OR
repair the line between the MegaJector and
carburetor OR repair engine cooling system
OR replace MegaJector.
Check fuel pressure OR repair LPG lockoff OR
repair the line between the MegaJector and
carburetor OR repair engine cooling system
OR replace the MegaJector.
Check CAN circuits for continuity and shorts to
power or ground and for continuity and repair
as necessary OR replace the MegaJector.
Repair charging system OR replace the
MegaJector.
Repair VBAT power or ground circuit to ECM
and MegaJector OR replace battery OR repair
charging system OR replace the MegaJector.
Check Power, Ground and CAN circuits at
MegaJector and all connections and repair as
necessary OR MegaJector has an internal
fault. Contact Ford Power Products for
assistance.
Check Power, Ground and CAN circuits at
MegaJector and all connections and repair as
necessary OR MegaJector has an internal
fault. Contact Ford Power Products for
assistance.
Check Power, Ground and CAN circuits at
MegaJector and all connections and repair as
necessary OR MegaJector has an internal
fault. Contact Ford Power Products for
assistance.
Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
Repair wiring and/or connections to ignition
coil #2 OR replace ignition coil #2.
Continued on next page
Part No. 77828
S-60 • S-65
5-9
Section 5 • Fault Codes
July 2005
FORD ENGINE FAULT CODES
REV A
Code
Problem
511
512
513
514
521
522
FPP1 High Voltage
Not used.
FPP1 Low Voltage
Not used.
FPP1 Higher than IVS Limit
Not used.
FPP1 Lower than IVS Limit
Not used.
FPP2 High Voltage
Not used.
FPP2 Low Voltage
Not used.
531
TPS1 (Signal Voltage) High
532
TPS1 (Signal Voltage) Low
533
TPS2 (Signal Voltage) High
534
TPS2 (Signal Voltage) Low
535
TPS1 Higher than TPS2
536
TPS1 Lower than TPS2
537
Throttle Unable to Open
538
Throttle Unable to Close
545
Governor Interlock Failure
551
Max Governor Speed
Override
552
Fuel Rev Limit
553
Spark Rev Limit
611
COP Failure
Loose wire connections to ECM OR ECM is
faulty.
612
Invalid Interrupt
Loose wire connections to ECM OR ECM is
faulty.
613
A/D Loss
Loose wire connections to ECM OR ECM is
faulty.
5 - 10
Cause
The #1 throttle position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR throttle position
sensor #1 is faulty.
The #1 throttle position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR throttle position
sensor #1 is faulty.
The #2 throttle position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR throttle position
sensor #2 is faulty.
The #2 throttle position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR throttle position
sensor #2 is faulty.
The throttle position sensor wiring and/or
connections for either TPS1 or TPS2 open or
shorted OR there is a poor system ground
connection OR one or both throttle position
sensors are faulty.
The throttle position sensor wiring and/or
connections for either TPS1 or TPS2 open or
shorted OR there is a poor system ground
connection OR one or both throttle position
sensors are faulty.
Governor actuator is stuck closed OR wiring
and/or connections open or shorted OR governor
actuator is faulty.
Governor actuator is stuck open OR wiring and/or
connections open or shorted OR governor
actuator is faulty.
Engine harness wiring and/or connections open
or shorted OR there is a poor system ground
connection OR ECM is faulty.
ECM needs to be re-programmed OR throttle is
sticking open OR there are air leaks between the
throttle body and cylinder head.
ECM needs to be re-programmed OR throttle is
sticking open OR there are air leaks between the
throttle body and cylinder head.
ECM needs to be re-programmed OR throttle is
sticking open OR there are air leaks between the
throttle body and cylinder head.
S-60 • S-65
Solution
If this fault appears on your machine, contact
Genie Industries Service Department.
If this fault appears on your machine, contact
Genie Industries Service Department.
If this fault appears on your machine, contact
Genie Industries Service Department.
If this fault appears on your machine, contact
Genie Industries Service Department.
If this fault appears on your machine, contact
Genie Industries Service Department.
If this fault appears on your machine, contact
Genie Industries Service Department.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace throttle
position sensor #1.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace throttle
position sensor #1.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace throttle
position sensor #2.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace throttle
position sensor #2.
Be sure engine harness wiring and
connections are in place and secure OR repair
wiring and/or connections to one or both TPS
sensors OR replace one or both TPS sensors.
Be sure engine harness wiring and
connections are in place and secure OR repair
wiring and/or connections to one or both TPS
sensors OR replace one or both TPS sensors.
Repair wiring and/or connections to governor
actuator OR replace the governor actuator.
Repair wiring and/or connections to governor
actuator OR replace the governor actuator.
Repair wiring and/or connections in engine
harness OR replace the ECM.
Re-program ECM OR repair binding throttle
operation OR repair any air leaks between the
throttle body and cylinder head.
Re-program ECM OR repair binding throttle
operation OR repair any air leaks between the
throttle body and cylinder head.
Re-program ECM OR repair binding throttle
operation OR repair any air leaks between the
throttle body and cylinder head.
Locate and repair any engine harness wiring
damage or shorts to ECM to be sure they are
secure OR replace ECM.
Locate and repair any engine harness wiring
damage or shorts to ECM to be sure they are
secure OR replace ECM.
Locate and repair any engine harness wiring
damage or shorts to ECM to be sure they are
secure OR replace ECM.
Part No. 77828
July 2005
Section 5 • Fault Codes
REV A
FORD ENGINE FAULT CODES
Code
Problem
Cause
614
RTI 1 Loss
Loose wire connections to ECM OR ECM is
faulty.
615
Flash Checksum Invalid
Loose wire connections to ECM OR ECM is
faulty.
616
RAM Failure
Loose wire connections to ECM OR ECM is
faulty.
631
External 5V DC Ref Lower
than Expected
Engine 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
Engine harness wiring and/or connections open
or shorted to ground OR there is a faulty engine
sensor OR ECM is faulty.
655
RTI 2 Loss
Loose wire connections to ECM OR ECM is
faulty.
656
RTI 3 Loss
Loose wire connections to ECM OR ECM is
faulty.S
Part No. 77828
S-60 • S-65
Solution
Locate and repair any engine harness wiring
damage or shorts to ECM to be sure they are
secure OR replace ECM.
Locate and repair any engine harness wiring
damage or shorts to ECM to be sure they are
secure OR replace ECM.
Locate and repair any engine harness wiring
damage or shorts to ECM to be sure they are
secure OR replace ECM.
Locate and repair any engine harness wiring
damage or shorts OR locate and troubleshoot
or repair faulty engine sensor OR replace
ECM.
Locate and repair any engine harness wiring
damage or shorts OR locate and troubleshoot
or repair faulty engine sensor OR replace
ECM.
Locate and repair any engine harness wiring
damage or shorts to ECM to be sure they are
secure OR replace ECM.
Locate and repair any engine harness wiring
damage or shorts to ECM to be sure they are
secure OR replace ECM.
5 - 11
Section 5 • Fault Codes
July 2005
This page intentionally left blank.
5 - 12
S-60 • S-65
Part No. 77828
July 2005
Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey:
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Hydraulic Schematics
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.
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 S-60 & Genie S-65 Operator's Manual on
your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
General Repair Process
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
Part No. 77828
S-60 • S-65
problem
solved
Inspect
and test
Perform
repair
6-1
Section 6 • Schematics
July 2005
Electrical Symbols Legend
REV A
FS1
BLK
BLK
P3
WHT
Quick disconnect
terminal
N.O.H.C
Coil
solenoid or relay
N.C.H.O
Limit switch
Horn button
normally open
P1
KS1
TB21
WHT #21
Foot switch
LS3
PLATFORM
OTS2
N.O.
GROUND
T-circuits connect
at terminal
H1
Horn or alarm
Key switch
(before serial number 22051)
Oil temperature
switch
normally open
T-circuits
connect
Emergency Stop
button normally
closed
FAN
FB
PR1
CTS1
N.O.
Flashing beacon
Power relay
Coolant temperature
switch
normally open
Connection
no terminal
G1
TS2
START
ENGINE
Gauge
Aux
Pump
Auxiliary pump
OPS1
N.C.
Circuits crossing
no connection
510
HM
Diode
Hydraulic oil
cooling fan
Toggle switch SPDT
Oil pressure switch
normally closed
Resistor with
ohm value
Hour meter
TS6
+
PLATFORM LEVEL
-
Battery
LED
F1
UP
DOWN
L3
Gauge sending unit
Tilt sensor
Toggle switch DPDT
15A
Fuse
with amperage
CR4
N.O.
Circuit breaker
with amperage
Control relay contact
normally open
B
C
HOLD
CB1
A
PULL IN
KS1
25A
Key switch
(after serial number 22050)
Fuel or RPM
solenoid
Starting aid:
glow plug or
flame ignitor
Coil
6-2
S-60 • S-65
Part No. 77828
July 2005
Section 6 • Schematics
Hydraulic Symbols Legend
REV A
25 psi
(1.7 bar)
.035"
(0.89 mm)
Orifice with size
Solenoid operated 3 position,
4 way, directional valve
Filter with
bypass valve
relief setting
Solenoid operated
3 position, 4 way,
proportional directional valve
Check valve
200 psi
(13.8 bar)
2 position, 3 way, shuttle valve
Pump
fixed displacement
Relief valve
with pressure setting
Priority
flow regulator valve
o
Brake
Pump
bi-directional,
variable displacement
Solenoid operated 2 position,
3 way, directional valve
Directional valve
(mechanically activated)
3000 psi
(206.8 bar)
3:1
Needle valve
50%
Motor
bi-directional
Motor
2-speed,
bi-directional
50%
Flow divider/combiner valve
with pressure balancing orifice
and flow percentages
Counterbalance valve
with pressure and pilot ratio
Pilot operated 3 position,
3 way, shuttle valve
2 position, 2 way
solenoid valve
E
Pump prime mover
(engine or motor)
Differential
sensing valve
Directional valve
pilot operated
2 position, 2 way
Double acting
cylinder
Solenoid operated
proportional valve
Part No. 77828
S-60 • S-65
6-3
Section 6 • Schematics
6-4
July 2005
S-60 • S-65
Part No. 77828
July 2005
Section 6 • Schematics
REV A
GM 3.0L Engine Wire Harness
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TWR
FCI
211 PC 56 2S 0 009 CONNECTOR
211 A 56 7007 LOCKING CAM
211 A 56 0008 COVER
211 CC 2S 1120 TERM
INJ +
INJ 1
INJ 2
AUX OUT 2
AUX ANA PD1
MAP
FPP
IAT
ECT
IVS
AUX ANA PU1
POWER GROUND
POWER GROUND
ANA_RTN
5 VOLT REF
VSW
EGO 1
KNK +
KNK CAM +
CAM CRANK +
CRANK VBAT
VBAT
STARTER LOCKOUT
FUEL LOCKOFF
FUEL PUMP
RELAY CONTROL
TPS1
TPS2
DBW +
DBW OIL PRESSURE
TACH
MIL
AUX ANA PD2
AUX OUT 1
FUEL SELECT
AUX ANA PU2
GOV SELECT
GASEOUS TRIM
CAN +
CAN RS 232 TX
RS 232 RX
COIL 1
INJ 3
INJ 4
INJ 5
INJ 6
INJ 7
INJ 8
AUX OUT 3
18
16
17
30
35
33
38
32
31
39
36
19
20
49
50
21
55
41
42
13
14
11
12
22
23
9
8
7
10
53
54
24
25
37
56
26
47
29
40
48
34
15
43
44
51
52
27
29
30
28
1
2
7
6
ORANGE/BLUE 16
BROWN/BLUE 16
BROWN/GREEN 16
LT BLUE/WHITE 18
TAN/DK GREEN 18
LT GRN 18
DK BLUE 18
TAN 18
YELLOW/GRAY 18
PURPLE/YELLOW 18
DK BLUE/YELLOW 18
BLACK 16
BLACK 16
BLACK/LT GREEN 18
LT GREEN/RED 18
PINK/TAN 18
DK GREEN/ORANGE 18
GRAY/BROWN 18
PURPLE/ORANGE 18
PURPLE/WHITE 18
WHITE/PURPLE 18
RED/TAN 16
RED/TAN 16
GRAY/ORANGE 18
WHITE/BLACK 18
TAN/BLACK 18
WHITE/LT BLUE 18
PURPLE/LT BLUE 18
LT BLUE/DK BLUE 18
PINK/WHITE 18
TAN/ORANGE 18
LT GREEN/BLACK 18
YELLOW/LT GREEN 18
LT BLUE/BLACK 18
BLACK/WHITE 18
PURPLE/DK BLUE 18
TAN/BROWN 18
YELLOW/DK BLUE 18
GRAY/DK BLUE 18
WHITE/RED 18
BLUE/PINK 18
BLUE/WHITE 18
DK GREEN 18
ORANGE 18
YELLOW 18
A
B
C
D
E
F
G
H
1
MTRTWR8
ENGINE
COOLANT
TEMPERATURE
SENDER
YELLOW GRAY 18
2
A
BLACK/LT GREEN 18 B
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
LT GREEN 18
LT GREEN/RED 18
TAN 18
BLACK/LT GREEN 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
4
3
2
1
MAP SENSOR
BLACK 16
BLACK 16
3
BLACK 12
RED/TAN 16
RED/TAN 16
GROUND
F1
PINK/TAN 18
5A
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
1
OIL PRESSURE
SENSOR
TWR
PINK 18
A
DK BLUE 18
B
PURPLE/YELLOW 18
C
BLACK/LT GREEN 18
D
E
LT BLUE/BLK 18
F
LT GREEN/RED 18
G
H
LT BLUE/PINK 16
J
PINK/BLACK 16
K
RED/WHITE 18
LT GREEN/RED 18
BLK/LT GREEN 18
BLK/LT GREEN 18
D
LT GREEN/RED 18
C
DK GREEN 18
B
ORANGE 18
A
RTN
MIL - C108ESL
VREF
START IN (INTERUPT TYPE) - C33STR
START IN (AUTOCRANKING)
MTRTWR10
TWR
A
B
C
D
BLK/LT GREEN 18
DK GREEN/ORANGE 18
PINK/DK GREEN 16
BLACK 18
TWR
4
VSW- P23BAT
FPP1
IVS
ANA RTN
5
5V
MTRTWR4_EGO
TX
LT BLUE/WHITE 18
TAN/DK GREEN 18
YELLOW/LT GREEN 18
TAN/BROWN 18
GRAY/DK BLUE 18
BLUE/PINK 18
BLUE/WHITE 18
PURPLE/DK BLUE 18
ENGINE TEST SWITCH
RX
COMM
STARTER
RELAY
1
WHITE 16
WPTWR1
TWR
STARTER
SOLENOID
YELLOW 18
LT GREEN/RED
SEAL END OF OPEN WIRE
THIS JUNCTION TO
BE WITHIN 3-6 INCHES
OF CONNECTOR
SPLICE TO ASSEMBLY
87
PINK/TAN 18
86
GRAY/ORANGE 18
85
PURPLE/WHITE 18
IGNITION
COIL
TWR
B
A
BLK/LT GREEN 18
LT GREEN/RED 18
PURPLE/LT BLUE 18
LT BLUE/DK BLUE 18
PINK/WHITE 18
TAN/ORANGE 18
1
F2
RED/TAN 14
C
RED 14
RED 12
1
20A
BLACK/WHITE 18
YELLOW/DK BLUE 18
DK BLUE/YELLOW 18
PINK/YELLOW 16
BLACK 16
PINK/DK GREEN 16
BATT+ 1
A
DISTRIBUTOR
CONNECTOR
CRANKSHAFT
POSITION
SENSOR
2
3
6
5
4
1
BOSCH
THROTTLE
THESE CONNECTORS ARE CONNECTED TO GENIE HARNESS #88833
AUX OUT 2
AUX IN PD1
TACH - C41RPM
FUEL SELECT - C39LP
GOV SELECT - C128LPRM
CAN +
CAN AUX OUT 1
6
RED 14
WHITE/PURPLE 18
A
B
C
D
E
F
G
H
MTRTWR8
PINK/BLACK 16
B
PURPLE/ORANGE 18
WPSHD1
87A LT BLUE/PINK 16
30
D
GRAY/BROWN 18
SHD
1
TWR
RED 14
30
86
WHITE/BLUE 18
85
87 PINK/YELLOW 16
86
TAN/BLACK 18
85
FUEL
PUMP
RELAY
PINK/DK GREEN 16
87
RED/TAN 14
Part No. 77828
30
PINK/TAN 18
POWER
RELAY
F4
PINK/YELLOW 16
ECM
ORANGE/BLUE 16
BROWN/BLUE 16
BROWN/GREEN 16
WHITE/BLACK 18
WHITE/RED 18
PINK/TAN 18
RED/WHITE 18
TWR
A
B
C
D
E
F
AUX IN PD2 - C27AUX
AUX IN PU2 - C35HRPM
AUX IN PU1
FUEL PUMP - C135FP
GROUND - GND
RELAY FUSED POWER - C21IGN
7
MTRTWR6
15A
BATT+ 2
ALTERNATOR
RED 12
RED 16
F3
PINK/DK GREEN 16
15A
S-60 • S-65
RED 12
RED 16
A
PINK/DK GREEN 16
B
ALTERNATOR
8
6-5
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
N
M
INJ +
INJ 1
INJ 3
INJ 4
INJ 2
INJ 5
INJ 6
AUX OUT 2
EGR
AUX ANA PD1
MAP
FPP 1
IAT
ECT
IVS
AUX ANA PU1
FPP 2
EGR PWM
EGR RECIRC
POWER GROUND
POWER GROUND
ANA_RTN
5 VOLT REF
VSW
CRANK CRANK +
CAM CAM +
VBAT
VBAT
EGO 2
EGO 1
EGO 3
KNK +
KNK -
L
SPK PWR GROUND
COIL 1
COIL 2
COIL 3
COIL 4
COIL 5
COIL 6
STARTER LOCKOUT
FUEL LOCKOFF
FUEL PUMP
RELAY CONTROL
TPS1
TPS2
DBW +
DBW BRAKE SWITCH
OIL PRESSURE
TACH
MIL
FUEL PUMP MON
AUX OUT 1
FUEL SELECT
AUX ANA PU2
GOV SELECT 1
GOV SELECT 2
ROAD SPEED +
ROAD SPEED GASEOUS TRIM
OVERSPEED
CAN +
CAN RS 485 +
RS 485 RS 232 TX
RS 232 RX
TWR
A
B
J
I
H
G
6
361 R 16
361 R 16
7
555 T 16
555 T 16
8
557 BR-Y 16
557 BR-Y 16
9
558 BR-LB 16
558 BR-LB 16
10
556 W 16
F
E
361 R 16
INJECTOR #1
743 GY 18
12
INJECTOR #3
C
B
361 R 16
INJECTOR #4
INJECTOR #2
570 BK-W 16
359 GY-R 18
31
39 R-W 18
18 O-Y 18
19
198 DG-O 18
20
358 LG-BK 18
15
151 LB-BK 18
151 LB-BK
151 LB-BK
27
743 GY 18
307 BK-Y 18
307 BK-Y 18
28
354 LG-R 18
354 LG-R 18
ACT
359 GY-R 18
570 BK-W 16
17
307 BK-Y 18
18
150 DG-W 18
570 BK-W 16
ECT
16
114 LB-Y 18
22
352 BR-LG 18
23
360 BR-PK 18
1
570 BK-W 16
570 BK-W 16
2
570 BK-W 16
570 BK-W 16
13
359 GY-R 18
570 BK-W 16
14
351 BR-W 18
351 BR-W 18
3
16 R-LG 18
33
350 GY 18
32
349 DB 18
35
570 BK-W 12
570 BK-W 16
16 R-LG 18
F2
351 BR-W 18
C
358 LG-BK 18
358 LG-BK 18
359 GY-R 18
359 GY-R 18
570 BK-W 12
16 R-LG 18
361 R 14
TWR
F1 30A
5A
MAP_CONN
16 R-LG 18
F3 20A
361 R 14
361 R 12
A
18 O-Y 18
282 DB-O 18
198 DG-O 18
198 DG-O 18
4
361 R 16
150 DG-W 18
150 DG-W 18
5
361 R 16
114 LB-Y 18
114 LB-Y 18
25
392 R-LG 18
352 BR-LG 18
352 BR-LG 18
24
74 GY-LB 18
360 BR-PK 18
360 BR-PK 18
361 R 14
O2 SENSOR
26
30
361A R 16
361A R 16
570 BK-W 16
570 BK-W 16
O2
SENSOR
359 GY-R 18
359 GY-R 18
351 BR-W 18
351 BR-W 18
MTRTWR6 MTRSHD6
355 GY-W 18
357 Y-W 18
74 GY-LB 18
392 R-LG 18
151 LB-BK 18
359 GY-R 18
359 GY-R 18
317 GY-O 18
359 GY-R 18
351 BR-W 18
4
570 BK-W 16
1
850 Y-BK 18
2
851 Y-R 18
3
TWR
361A R 16
1 COIL 1
2 VBAT
3 COIL 2
13
1
2
3
A
B
242 DG 18
25
SHD
TWR
A
A
B
B
C
C
D
D
E
E
F
F
16 R-LG 18
THROTTLE
355 GY-W 18
357 Y-W 18
151 LB-BK 18
317 GY-O 18
351 BR-W 18
359 GY-R 18
FUEL PUMP
RELAY
6
5
4
1
3
2
86
32 R-LB 16
86
16 WATER TEMP
14 FPP1
34 GROUND
1 VSW
9 VBATT
D
351 BR-W 18
C
669 DG-W 18
B
458 O-BK 18
A
3
87
87
32 ANA AUX PD1
37 ANA AUX PU1
12 FPP2
40 EGR PWM
41 EGR REC
33 ANA RTN
32 R-LB 16
87A
RTN
FPP_COMM
787A PK-BK 16
4
31 VREF
13 STARTER CONTROL
87A
32 R-LB 16
85
38 EGR ANA IN
15 STARTER IN (INTERUPT)
39 STARTER IN (AUTOCRANK)
342 LG-P 18
359 GY-R 18
2
25 IVS
STARTER
RELAY
30
85
30
342 LG-P 18
361A R 16
LOCKOFF SOLENOID
24
18 O-Y 18
361 R 14
29
1
B
452 GY-R 18
CRANK
FORD
42 PIN
CONNECTOR
361 R 14
34
CAM
A
WATER
TEMP
21
5
F4 15A
787A PK-BK 16
5 FUEL PUMP
5V
TX
RX
TWR
86
POWER
RELAY
30
22
342 LG-P 18
23
242 DG 18
9
926A LB-O 18
32
15 R-Y 18
30
355 GY-W 18
31
357 Y-W 18
28
151 LB-BK 18
29
317 GY-O 18
6
511 LG-R 18
511 LG-R 18
511 LG-R 18
7
253 DG-W 18
253 DG-W 18
253 DG-W 18
8
11 T-Y 18
11 T-Y 18
27
658 PK-LG 18
658 PK-LG 18
11 T-Y 18
10
238 DG-Y 18
238 DG-Y 18
5
71 O-LG 18
71 O-LG 18
14
72 Y-BK 18
72 Y-BK 18
15
148 Y-R 18
148 Y-R 18
16
306 T-LB 18
306 T-LB 18
306 T-LB 18
17
307 BK-Y 18
307 BK-Y 18
307 BK-Y 18
11
169 LG-BK 18
169 LG-BK 18
172 LB-R 18
172 LB-R 18
169 LG-BK 18
12
26
33
77 DB-Y 18
349A DB 18
349A DB 18
349A DB 18
18
662 DG-P 18
662 DG-P 18
662 DG-P 18
19
459 O-LG 18
459 O-LG 18
459 O-LG 18
20
642 DG-O 18
642 DG-O 18
642 DG-O 18
21
461 O 18
461 O 18
461 O 18
34
669 DG-W 18
669 DG-W 18
35
458 O-BK 18
458 O-BK 18
669 DG-W 18
458 O-BK 18
85
926A LB-O 18
15 R-Y 18
87
87A
361 R 16
F5 15A
361 R 16
6
OIL PRESSURE
253 DG-W 18
658 PK-LG 18
71 O-LG 18
72 Y-BK 18
148 Y-R 18
172 LB-R 18
570 BK-W 16
TRIM VALVE
361A R 16
77 DB-Y 18
361A R 16
D
361 R 16
556 W 16
11
J1 BLACK
J2 GREY
K
459 O-LG 18
361A R 16
662 DG-P 18
WPTWR2_GY
MTRTWR4
Part No. 77828
S-60 • S-65
TWR
4 BRAKE
26 OIL PRES
2 TACH
6 MIL
21 AUX OUT1
7 FUEL SELECT
10 AUX ANA PU2
7
24 GOV SELECT 1
23 GOV SELECT 2
35 ROADSPEED +
36 ROADSPEED 30 OVERSPEED
28 CAN +
29 CAN 11 RS 485+
3 RS 48520 RS 232+
8
18 RS 232-
SHD
PLUG (GROUND)
A
A
B
B
C
C
PLUG (CAN -)
D
D
PLUG (CAN +)
PLUG (RELAY POWER)
MTRSHD4
6-6
July 2005
Section 6 • Schematics
Ford LRG-425 EFI Engine Wire Harness
C41RPM OR/BK
P26ESTP BK
1
C28TTA RD/BK
C28TTA RD/BK
P26ESTP BK
FOOTSW. LOW
FOOTSW. HIGH
GENERATOR
ON
C1P-9
C2P-7
C2P-6
LIGHTS
C2P-1
C1P-2
C7P-2
C1P-1
C1P-7
FUEL SELECT
C2P-11
C2P-12
WORK LIGHT
DRIVE LIGHT
LP
GAS
C41RPM OR/BK
ENGINE
START
AUXILIARY
PUMP
C28TTA RD/BK
WH
RD
BK C2P-5
C35RPM BK/RD
C1B-9
FUNCTION ENABLE
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C2B-6
C1B-7
C2B-3
FUEL SELECT
C2B-1
DLITE GR/BK
C2P-10
C2P-9
C39LP BL/RD
LP
GAS
C33STR BK
ENGINE
START
AUXILIARY
PUMP
C27AUX RD
P23BAT WH
C28TTA RD/BK
C46HRN GR
C1P-1
C7B-2
C1P-2
C2B-5
TB33
D12
C7B-1
P134FB WH
RD
C5-12
C4B-12
RD
C5-18
C5-8
C4B-11
C21HM WH
C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
P22HRN BK
C5-11
C5-9
C5-10
C5-6
C5-2
C5-13
C5-5
C5-19
C45GEN GR/WH
R33STR BK
WH
RD
R46HRN BK
L29
R21IGN WH
C116 OR
C127SW GR
C35HRPM BK/RD
BRN
C135FP BL/WH
C21IGN WH
C128LRPM OR/RD
C39LP BL/RD
C41RPM OR/BK
C27AUX RD
C108ESL BL/WH
C33STR BK
P23BAT WH
BRN
BRN
GM HARNESS
BK
C6-9
C5-4
GM HARNESS
GM HARNESS
C5-1
H2
NO
M1 FAN
P22BAT BK
C2B-6
P116HYD RD
HM
_
M2
C
SW3
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
FLASHING BEACONS
OPTION
HOUR METER
GM CONN8
GM CONN8
GM CONN8
GM CONN8
GM CONN6
GM CONN6
GM CONN6
GM CONN6
GM CONN4
RUN/TEST SWITCH
A
B
E
D
F
E
D
C
B
F
GM CONN10
GM CONN10
GM CONN10
CHECK ENGINE LED
J
A
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
HORN RELAY
HORN
HYDRAULIC OIL
TEMPERATURE SWITCH
(OPTION)
COOLING FAN
(OPTION)
Part No. 77828
+
STARTER
AUX
PUMP
B2
C7P-1
P134PWR
TB21
L29
S8
S
CR23
C21IGN WH
FLD.
FB1
I
+
7
FUEL
PUMP
REGULATOR
A
12V DC
M4
+
NO
B
A
STA.
PR1
CR5
CR17
NO
86
FUSE 10A
C2P-6
C7B-4
6
S-60 • S-65
6-7
P20BAT RD
8
LINK
BAT.
85
87a 87
TS64
L2
FUSE
30
GND.
NO
NO
ALTERNATOR
TB35
P134PWR
TB24
CR23
CR1
D1
D3
TB39
P134PWR
TB27
PBOX GND
TS54
TS53
D10
TS52
D13
TB45
TB41
TB23
RD
5
D14
TB46
CB3
15A
TB20
D2
RD
RD
TS51
C22LS RD
L30
TS4
TS47
TS48
ENGINE
SPEED
RD
RD
TS2
L30
KS1
P1
H1
D4
4
TB22
TB134
CB2
P3
HORN
WH(FS)
TS3
TS1
2
FS1
D11
P24FS WH
RD
WH
P25FS RD
P24FS WH
C9P-3
C9P-2
RD(FS)
BK(FS)
C9P-1 BK
P2
RD
N
M
L
K
J
I
H
G
F
E
D
C
B
A
PLAT
RD
15A
3
July 2005
Section 6 • Schematics
REV B
Electrical Schematic, S-60
GM 3.0L Models
GRND
-
Electrical Schematic, S-60
REV B
C28TTA RD/BK
1
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
3
BL
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
CDE1 BL/WH
RIGHT
7
RKOUT 6
4
YOUT 5
PWR 3
1
GND 2
7
6
YOUT 5
PWR
2
XOUT 4
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
3
4
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
C3P-4
C3P-6
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C5TRR WH/BK
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-5
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
TURNTABLE ROTATE
PRIMARY BOOM
C4B-4
BOOM
C118LSR OR/RD
J1 F.H. WH
WH
C4B-1
C11-2
C13DE BL/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C4P-4
C4P-1
C2P-2
C40LS OR
P22LS BK
C15PLD OR/BK
C14PLU OR
C59CNK BL/BK
C4P-2
C3P-11
C4P-3
C3B-1
C3B-3
C3B-2
C3B-9
C3B-8
C3B-7
TB5
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
PLATFROM LEVEL
C4B-6
C4B-5
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
BK
BK
RD
C25-2
C28-2
C26-2
RD
C28-1
C25-1
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
3
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
6-8
S-60 • S-65
Part No. 77828
7
U4
2
TB22
CR34
4
P134 RD
PLATFROM LEVEL
UP
DOWN
C18JD/PRR GR/BK
C17JU/PRL GR
PLATFROM
ROTATE
C129 RD/BK
BK
BK
BRN
6
4
14
TB3
1
LS17
NO
HC
13
LS3
NO
NC
14
TB2
H4
TB59
LS1
NO
HC
13
22
14
21
LS17
NC
HO 22
P26ESTP BK
DOWN
UP
C4P-6
PLATFROM ROTATE
C4P-5
RIGHT
LEFT
D29
TB30
TB31
TB32
TB29
TB37
TB36
TB4
TB6
TB9
D30
21 LS5
NC
13
LS5
13
NO
14
TB13
TB1
TB7
TB40
14
TB14
CR34
TB134
TB8
13
TB15
TB118
D28
L46
H3
RIGHT
LEFT
TS57
LS2
NO
NC
TB18
5
TB17
TS59
R16
10
4
TS62
TS61
TS63
R4
5
R14
5
L1
3
CE
LIFT/
DRIVE
OPTION
J1
J1
J1
J1
J3
CR30
NO
J2
U13 JOYSTICK CONTROL CARD
D27
D9
RD
RD
L47
3
TS9
TS7
TS14
TS15
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
2
CR27
NC
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
GM 3.0L Models
July 2005
Section 6 • Schematics
Electrical Schematic, S-60
GM 3.0L Models
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-60
GM 3.0L Models
6-9
BRN
BK-33D
BK-33D
RD-24C
S-60 • S-65
BK C5-5
BK/RD-TS63
8
Part No. 77828
GR/BK-TS57
A
WH C11-2
BRN
BRN C37-2
NOTE: DASHED LINES INDICATE OPTION WIRES
OR-LS17 C38-2
OR/RD-LS17 C38-3
C45GEN GR/WH C2B-7
R46HRN BK
C118BSR OR/RD C4B-4
C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
Ground Control Box Terminal Strip Wiring Diagram, S-60
L
M
ENGINE
C5
D29
GROUND BOLT
B
45
46R
118
132
133
K
OR-CR34
OR/RD-118B
GENERATOR OPTION
HORN RELAY POWER
LIFT SPEED REDUCTION
PLATFORM OVERLOAD LS
PLATFORM OVERLOAD ALARM
134
PLAT. OVERLOAD LIM. SW. +12V (2)
C59CNK BL/BK C3B-11
C59CNK WH-LS5 C37-4
C134PWR GR/BK C2B-6
C134PWR RD-LS17 C38-1
C134PWR BK-LS5 C37-3
P134TTSR RD A
BRN-GND
45
46R
118
132
133
134
PLAT. OVERLOAD LIM. SW. +12V (1)
134
59
134
RETRACT BOOM LED
C37
GR/WH C5-12
BK-CR5
OR/RD-FH C38-3
RD-24D
P134FB WH-FH
RD-KS
59
+12V DC
POWER
J
WH-L46+
46
41
HORN
ALTERNATOR PULSE PICKUP
41
#1
C5
#2
F.H.
46
40
C35HS BK/RD C1B-9
C35HS BK/RD C5-18
C36STCC BL C1B-10
C36STCC BL C24-1
C37STC BL/BK C1B-11
C37STC BL/BK C25-1
C39LP BL/RD C2B-1
C39LP BL/RD C5-10
C40LS1 OR C2B-2
C40LS1 OR C10-2
C41RPM OR/BK C2B-3
C41RPM OR/BK C5-2
C46HRN GR C2B-5
C34SA BK/WH C1B-8
C11
GR-CR5
39
BOOM STOWED
40
37
STEER LEFT
37
LIQUID PROPANE FUEL
36
STEER RIGHT
36
39
35
HIGH FUNCTION SPEED
34
(UNUSED)
34
35
33
ENGINE START
33
P20BAT RD
BRN
I
BL/RD-TS53
RD-TS54
BK-TS52
32
31
BRAKE
DRIVE REVERSE
31
32
30
C27AUX RD C1B-1
C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C32BRK WH/RD C5-23
C33STR BK C1B-7
CABLE
TENSION
LIMIT SWITCH
LS5
H
WH/RD-ALRM
29
MOTOR STROKE
DRIVE FORWARD
30
28
TILT ALARM
28
29
26
27
(UNUSED)
AUXILARY PUMP
C5
#2
F.H.
27
25
(UNUSED)
25
#1
26
23
24
KEY SWITCH POWER
CIRCUIT BREAKER POWER
23
22
+12V DC TO PLATFORM (2)
22
24
22
+12V DC TO PLATFORM (1)
22
C21IGN2 WH C5-11
P22BAT BK C7B-1
C22LS17 BK C10-2
P22BAT BK C11-1
P22BAT BK C9-2
P23BAT WH C7B-2
P20BAT RD
P20BAT RD
BOOM
EXTEND
LIMIT SWITCH
LS1
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12V DC
POWER TO
PLATFORM
C7
TS64
RUN/TEST
SWITCH
G
C5-6 RD
RD-TS51
WH-KS
RD-CR1
RD-134D
21
IGNITION POWER
20
+12V DC POWER
21
19
JIB BOOM SELECT VALVE
F.H.
19
#2
20
18
PLATFORM ROTATE RIGHT/JIB DOWN
18
15
17
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL DOWN
14
17
15
PLATFORM LEVEL UP
13
DRIVE ENABLE
14
44
JIB BBOM DOWN DESCENT ALARM
9
13
BOOM EXT/RET FUNCTION CTRL
44
9
BRN
C5-8 GR
F
WH-HM
BK-CR5
BK-KS
7
8
BOOM EXTEND
BOOM RETRACT
7
8
6
TURNTABLE ROTATE FUNCTION CTRL
6
C5
GR/WH-TS57
RD-CB2
4
5
#1
GR-TS57
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
C1PBU RD C3B-1
C1PBU RD C12-1
C2PBD RD/BK C3B-2
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C6TRF WH/RD C31-1
C7PBE BK C3B-7
C7PBE RD-LS5 C37-1
C8PBR BK/WH C3B-8
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
C9PER BK/RD C30-1
JDALARM BL C3B-10
RD/BK-ALARM
C13DRE BL/RD C4B-1
C13DRE BL/RD C10-1
C14PLU OR C4B-2
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C15PLD OR/BK C21-1
C17JU GR C4B-5
C17JU GR C22-1
C18JD GR/BK C4B-6
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
E
OR/BK-TS59
OR-TS59
BL-TS58
4
5
3
A
D
BK/WH-TS63
BK-TS63
WH/RD-TS62
WH/BK-TS62
BOOM FUNCTION CONTROL
2
BOOM DOWN
B
2
3
2
1
BOOM UP
TERMINAL BASE (TB)
1
RD/WH-R16
BRN
1
C
WH-TS62
BK-22C1
C
R43DLITE1 RD
R43DLITE2 RD
D
5
RD-TS61
RD/BK-ALARM
RD/BK-TS61
BRN
RD-CB3
C21IGN WH
CR17
HYDRAULIC
OIL COOLER
OPTION
3
GR-46D
RD-CB3 OPTIONS
C2B-5 GR
CR22
DRIVE LIGHT
OPTION
OR C5-1
B
BRN
F.H.
4
CR5
HORN
RELAY
6
BK-46R
C5
A
GROUND HARNESS
TO SWITCH PANEL
7
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV B
GM 3.0L Models
N
FUNCTION
HARNESS
F.H.
BRN-TS64
BRN C7B-3
BK C16-1
WH LS2 C10-2
C5
#2
F.H.
D30
July 2005
REV B
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
GM 3.0L Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
BASE BOX HARNESS
(TO TERMINAL STRIP)
D9
RD
RD
TS57
PLATFORM
ROTATE
TS62
TURNTABLE
ROTATE
TS61
BOOM
UP/DOWN
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
1
RD
RD
D4
RD
RD
TS59
PLATFORM
LEVEL
RD
GR/WH-19D
OR/BK-15D
RD
OR-14D
GR/BK-18D
GR-17D
3
4
BK/RD-35D
RD-20C
CB2
CIRCUIT
BREAKER
CONTROLS 15A
CB3
CIRCUIT
BREAKER
OPTIONS 15A
RD
RD CR22
RD CR17
RD-20C
BK-33D
WH-4D
WH/BK-5D
WH/RD-6D
RD C32-7
BK-7D
RD-1D
TS63
BOOM EXTEND/
RETRACT
BL/RD-39D
BK/RD-9D
BK/WH-8D
RD/WH-CR34
RD/WH
5
RD
RD
RD
RD
RD
LABEL
RD
BRN
TS52
ENGINE
START
D14
RD
RD
TS54
FUNCTION
ENABLE
2
D13
2
HOUR METER
1
NC
RD
1
NC
RD
WH-21D
BRN
BRN
BRN
P1
EMERGENCY
STOP SWITCH
RD/WH-R16
CR34
BOOM
SPEED
REDUCTION
RD/WH-TS61
RD/WH-R16
OR-LS17
RD
DALE RH-25 25W
5 ohm 1%
RD
TS53
FUEL SELECT
+
RD/WH
OR
RD
RD
RD/BK-2D
BL/WH-38
BRN-GND
+
L46
LOWER/ RETRACT
BOOM
LED
BL/BK-59D
L2
CHECK
ENGINE
LED
WH-21D
WH-23
RD
R14
UP/DOWN
RESISTOR
GR/BK-H6-
BRN
D2
4
3
-
B
B1
2
WH-23D
RD-134D2
BK-22D1
1
KS1
KEY SWITCH
WH
RD/WH-TB3D
RD
RD/WH
RD
RD C32-6
C134PWR RD
WH
RD-27
OR-LS17
DALE RH-25 25W
10 ohm 1%
R16
BOOM UPPER ZONE
RESISTOR
R4
TURNTABLE ROTATE
RESISTOR
WH
RD-27D
RD
WH
RD
DALE RH-25 25W
5 ohm 1%
RD
RD
RD-20C
RD
2
RD
C19JSV GR/WH
GR/BK-18D
RD
GR-17D
RD
WH-4
WH/BK-5
WH/RD-6
RD
RD
RD/WH
RD
RD
TS51
AUXILIARY
POWER
D3
RD
RD
RD
RD-1
-
+
RD
RD/BK-2
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
DESCRIPTION
CB2
CB3
CR1
CR5
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
SERVICE HORN RELAY
CR17
CR22
CR34
HYDRAULIC OIL COOLER RELAY
DRIVE LIGHT RELAY (OPTION)
BOOM SPEED REDUCTION RELAY
HM
KS1
L2
L46
L45
P1
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
R4
R14
R16
TS51
TS52
TS53
TS54
TS57
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 5 OHMS
TS59
TS61
TS62
TS63
TS64
PLATFORM LEVEL TOGGLE SWITCH
BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
RUN/TEST TOGGLE SWITCH
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
FUNCTION ENABLE TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
6
7
8
6 - 10
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
GM 3.0L Models
Section 6 • Schematics
July 2005
Platform Control Box Wiring Diagram, S-60
GM 3.0L Models
* NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
C19JSV GR/WH TS7
C19JSV GR/WH C4P-7
BRN JC3
BRN GND
RD-E-STOP
C134PWR RD-H1+
CWLITE WH TS49
C134PWR RD LS18
OPT.
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
GR/BK C133TTA C3P-12
GR/BK-L4- (CE)
F.S.
RD/BK-28
RD/BK-L48- (NON-CE)
C134PWR RD C2P-6
RD-TILT
OPTION
C32BRK WH/RD C1P-6
C32BRK WH/RD J2-19
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129JDA BL C3P-10 TS8
C46HRN GR C2P-5
C59CHK BL/BK C3P-11 L47+
C59CNK BL/BK C3P-11
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
C7P
P24FS WH C9-2 TS4
C7P
CDLITE OR/RD C2P-4
C45GEN GR/WH C2P-7
C46HRN GR C2P-5
C39LP BL/RD C2P-1
C4P
TS7 WH
TS1 WH
1
P26ESTP BK
C118LSR OR/RD C4P-4
C6TRF WH/RD C3P-6
C8PBR BK/WH C3P-8
C16DRE BL/RD C4P-1
C7PBE BK C3P-7
C40LSS OR C2P-2
C9PER BK/RD C3P-9
C41RPM OR/BK C2P-3
C30FWD WH C1P-4
C1PBU RD C3P-1
C31REV WH/BK C1P-5
C3P
BRN
Part No. 77828
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C35RPM BK/RD C1P-9
C33STR BK C1P-7
C27AUX RD C1P-1
C28TTA RD/BK C1P-2
BRN
19/18 CONTROL CABLE
P24FS WH
1
LS18
(CE)
FOOT
SWITCH
+
P24FS WH
BRN
JC1-3 OR
JC1-2 BRN
JC2-4 RD
JC2-3 OR
JC2-5 BK
JC2-2 BRN
JC1-5 YEL
JC3-3 OR
JC3-5 WH
JC3-4 BL *
JC3-2 BRN
TS15 BL/WH
TS15 B BL/BK
TS14 RD/WH
DRE LED BL/RD
BRN
C134PWR RD LS18
RD/BK-L4-
11
JIB
12V DC
BATTERY
H1
TILT
ALARM
9
BK C1P-12
C3P
C7P
C9
D39
3
CWLITE BK
BRN
C2P
6
C4P
BATGRN C7P-3
WH/RD C1P-6
C1P
C28TTA RD/BK C1P-2
1
J3
CR27
CR30
5
TILT ALARM
12V DC PLATFORM POWER CONNECTOR
FOOTSWITCH CONNECTOR
48 PIN CONNECTOR BLOCK
H1
C7P
C9
C1P-C4P
PLATFORM
CONTROL
HARNESS
(TO SWITCH
PANEL)
CE LIFT/DRIVE OPTION
J2
J1
C7P
8
RD LS18 CABLE
7
S-60 • S-65
6 - 11
CWLITE WH TS49
4
BRN
BRN
DESCRIPTION
ITEM
1
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
U13
J1
J2
J3
CR27
CR30
LS18
2
REV B
Platform Control Box Wiring Diagram, S-60
N
M
L
K
J
I
H
G
F
E
D
C
B
A
U13
ALC-500
3
July 2005
Section 6 • Schematics
GM 3.0L Models
July 2005
REV B
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-60
GM 3.0L Models
N
M
L
K
J
I
H
G
F
E
D
C
PLATFORM
CONTROL
HARNESS
(TO CONTROL BOX)
TS48
DRIVE LIGHTS/
WORK LIGHTS
(OPTION)
JC2
BOOM UP/DOWN
& TURNTABLE ROTATE
LEFT/RIGHT
DLITE RD
RD
BK
JC1
7
7
BOOM
EXTEND/RETRACT
6
3
BRN
3
2
+
2
BRN
BK
BK
WH J1-4
BL J1-5
OR J1-13
BRN J1-14
BK
RD
BRN
RD
TS7
PLATFORM
ROTATE
TS9
TS14
TS15
TS47
TS48
PLATFORM LEVEL TOGGLE SWITCH
DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)
P22BAT BK C7P-1
P26BAT BK J3-3
P23BAT WH C7P-2
P26BAT BK C9-1
RD-H1+
C134PWR RD L48+
C134PWR RD L4+
BK TS15
C39LP BL/RD C2P-1
PDLITE RD
P24FS WH C9-2
C35HS BK/RD C1P-9
C33STR BK C1P-7
P25FS RD C9-3
BK
C45GEN GR/WH C2P-7
C29MS RD/WH J1-8
WH CR30
C27AUX RD C1P-1
C17PRL GR C4P-5
WH CR27
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
WH
DRIVE/STEER PROPORTIONAL JOYSTICK
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
LOWER/RETRACT BOOM LED
BOOM TILTED LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
HI/LOW RPM TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
2
3
6
WH
TS3
FUEL
SELECT
3
TS9
PLATFORM
LEVEL
JC3
L1
L4
L47
L48
P2
P3
TS1
TS2
TS3
TS4
TS7
5
1
1
7
1
NC NC NC
P3
HORN
BOOM PROPORTIONAL JOYSTICK:
BOOM EXTEND/RETRACT
1
4
F18
FUSE 10A
(WORKLIGHT ONLY)
C28TTA RD/BK H1C133PLA GR/BK D39
C134PWR RD E-STOP
C134PWR RD E-STOP
BK
BL/RD-DE3 J1-16
BL-DE1 J1-6
BL/BK-DE2 J1-7
YL J1-3
OR J1-9
BRN J1-10
WLITE WH
DLITE OR/RD C2P-4
C59CNK BL/BK C3P-11
WLITE WH
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C46HRN GR C2P-5
NO
JC1
BL J1-5 (ROCKER SWITCH OPTION ONLY)
BK
BRN
BRN
D12
4
BOOM PROPORTIONAL JOYSTICK:
BOOM UP/DOWN , TURNTABLE ROTATE
1
RD
BRN
COMPONENT INDEX
JC2
2
+
BK
BRN
A
3
+
BRN
WH
4
L4
PLATFORM
OVERLOAD
(CE OPTION)
L1
DRIVE
ENABLE
1
L47
RETRACT
BOOM
6
RD
4
BK
4
7
5
BK
5
L48
TILT ALARM LED
(ANSI/CSA OPT.)
BK
5
1
TS15
DRIVE
ENABLE
6
JC3
DRIVE
FORWARD/REVERSE
& STEER
LEFT/RIGHT
+
B
TS1
AUXILIARY
PUMP
TS14
HIGH/LOW
(2WD/4WD)
TS4
HIGH/LOW
RPM
TS2
ENGINE
START
TS47
GENERATOR
(OPTION)
2
2
D11
2
P2
EMERGENCY
STOP
BK
WH-24
RD
RD
RD
RD
8
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
6 - 12
July 2005
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-60
GM 3.0L Models
C41RPM OR/BK
P26ESTP BK
1
C28TTA RD/BK
C28TTA RD/BK
P26ESTP BK
FOOTSW. LOW
FOOTSW. HIGH
GENERATOR
ON
C1P-9
C2P-7
C2P-6
LIGHTS
C2P-1
C1P-2
C7P-2
C1P-1
C1P-7
FUEL SELECT
C2P-11
C2P-12
WORK LIGHT
DRIVE LIGHT
LP
GAS
C41RPM OR/BK
ENGINE
START
AUXILIARY
PUMP
C28TTA RD/BK
WH
RD
BK C2P-5
C35RPM BK/RD
C1B-9
FUNCTION ENABLE
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C2B-6
C1B-7
C2B-3
FUEL SELECT
C2B-1
DLITE GR/BK
C2P-10
C2P-9
C39LP BL/RD
LP
GAS
C33STR BK
ENGINE
START
AUXILIARY
PUMP
C27AUX RD
P23BAT WH
C28TTA RD/BK
C46HRN GR
C1P-1
C7B-2
C1P-2
C2B-5
TB33
D12
C7B-1
P134FB WH
RD
C5-12
C4B-12
RD
C5-18
C5-8
C4B-11
C21HM WH
C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
P22HRN BK
C5-11
C5-9
C5-10
C5-6
C5-2
C5-13
C5-5
C5-19
C45GEN GR/WH
R33STR BK
WH
RD
R46HRN BK
L29
R21IGN WH
C116 OR
C127SW GR
C35HRPM BK/RD
BRN
C135FP BL/WH
C21IGN WH
C128LRPM OR/RD
C39LP BL/RD
C41RPM OR/BK
C27AUX RD
C108ESL BL/WH
C33STR BK
P23BAT WH
BRN
BRN
GM HARNESS
BK
C6-9
C5-4
GM HARNESS
GM HARNESS
C5-1
H2
NO
M1 FAN
P22BAT BK
C2B-6
P116HYD RD
HM
_
M2
C
SW3
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
FLASHING BEACONS
OPTION
HOUR METER
GM CONN8
GM CONN8
GM CONN8
GM CONN8
GM CONN6
GM CONN6
GM CONN6
GM CONN6
GM CONN4
RUN/TEST SWITCH
A
B
E
D
F
E
D
C
B
F
GM CONN10
GM CONN10
GM CONN10
CHECK ENGINE LED
J
A
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
HORN RELAY
HORN
HYDRAULIC OIL
TEMPERATURE SWITCH
(OPTION)
COOLING FAN
(OPTION)
Part No. 77828
+
STARTER
AUX
PUMP
B2
C7P-1
P134PWR
TB21
L29
S8
S
CR23
C21IGN WH
FLD.
FB1
I
+
7
FUEL
PUMP
REGULATOR
A
12V DC
M4
+
NO
B
A
STA.
PR1
CR5
CR17
NO
86
FUSE 10A
C2P-6
C7B-4
6
S-60 • S-65
6 - 13
P20BAT RD
8
LINK
BAT.
85
87a 87
TS64
L2
FUSE
30
GND.
NO
NO
ALTERNATOR
TB35
P134PWR
TB24
CR23
CR1
D1
D3
TB39
P134PWR
TB27
PBOX GND
TS54
TS53
D10
TS52
D13
TB45
TB41
TB23
RD
5
D14
TB46
CB3
15A
TB20
D2
RD
RD
TS51
C22LS RD
L30
TS4
TS47
TS48
ENGINE
SPEED
RD
RD
TS2
L30
KS1
P1
H1
D4
4
TB22
TB134
CB2
P3
HORN
WH(FS)
TS3
TS1
2
FS1
D11
P24FS WH
RD
WH
P25FS RD
P24FS WH
C9P-3
C9P-2
RD(FS)
BK(FS)
C9P-1 BK
P2
RD
N
M
L
K
J
I
H
G
F
E
D
C
B
A
PLAT
RD
15A
3
July 2005
Section 6 • Schematics
REV C
Electrical Schematic, S-65
GM 3.0L Models
GRND
-
Electrical Schematic, S-65
REV C
C28TTA RD/BK
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
BL
WH
OR
BRN
BK
RD
OR
BRN
15
8
16
7
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
CDE1 BL/WH
RIGHT
7
RKOUT 6
YOUT 5
4
PWR 3
1
3
YEL
OR
BRN
1
2
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
C3P-4
C3P-6
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C5TRR WH/BK
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-5
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
TURNTABLE ROTATE
PRIMARY BOOM
C4B-4
BOOM
C118LSR OR/RD
C4B-1
WH
C13DE BL/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C3P-5
C3P-1
C3P-2
C3P-3
C3P-8
C3P-9
C3P-7
C4P-4
C4P-1
C11-2
J1 F.H. WH
C3B-1
C3B-2
C3B-3
C3B-9
C3B-8
C3B-7
TB5
C4B-2
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
BK
BK
RD
C25-2
C28-2
C26-2
RD
C28-1
C25-1
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
3
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
7
U4
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
JIB VALVE
6 - 14
S-60 • S-65
Part No. 77828
GND 2
7
6
2
XOUT 4
YOUT 5
GND
PWR
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
3
4
C2P-2
C40LS OR
P22LS BK
C59CNK BL/BK
C14PLU OR
C3P-11
C4P-2
C17JU/PRL GR
C18JD/PRR GR/BK
C15PLD OR/BK
C14PLU OR
14
2
TB22
CR34
4
C129 RD/BK
BK
BK
BRN
1
14
21
LS17
NC
HO 22
H4
TB59
LS17
NO
HC
13
LS3
NO
NC
13
14
22
LS1
NO
HC
NO
14
TB36
6
21 LS5
NC
13
LS5
13
4
P134 RD
PLATFROM LEVEL
C4B-3
D29
TB30
TB31
TB32
TB29
TB37
TB2
2
P26ESTP BK
DOWN
UP
C15PLD OR/BK
C4B-5
C4B-6
PLATFROM LEVEL
PLATFROM
ROTATE
C4B-7
C3B-10
C4P-3
UP
C129JDA BL
LEFT
RIGHT
DOWN
C3P-10
C18JD/PRR GR/BK
C17JU/PRL GR
C4P-6
C4P-5
PLATFROM
ROTATE
DOWN JIB
UP
BOOM
LEFT
RD
RD
TB4
TB6
TB3
D9
R4
5
R14
5
C19JSV GR/WH
TB15
14
TB14
TB18
TB13
TB1
TB7
TB8
LS2
NO
NC
13
TB40
3
C4P-7
TB19
TB9
D30
5
TB17
CR34
TB134
TB44
TS62
TS61
TS63
R16
10
TB118
D28
L46
H3
RIGHT
C19JSV GR/WH
TS59
CE
LIFT/
DRIVE
OPTION
J1
J1
J1
J1
TS14
TS15
4
TS58
J2
U13 JOYSTICK CONTROL CARD
D27
J3
CR30
NO
JIB VALVE
TS57
L47
3
TS9
TS8
TS7
CR27
NC
CR13
NC
CR13
L1
WH
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
1
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
GM 3.0L Models
BRN
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
6 - 15
BRN
BK-33D
BK-33D
RD-24C
S-60 • S-65
BK C5-5
BK/RD-TS63
8
Part No. 77828
GR/BK-TS57
A
WH C11-2
BRN
BRN C37-2
NOTE: DASHED LINES INDICATE OPTION WIRES
OR-LS17 C38-2
OR/RD-LS17 C38-3
C45GEN GR/WH C2B-7
R46HRN BK
C118BSR OR/RD C4B-4
C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
Ground Control Box Terminal Strip Wiring Diagram, S-65
L
M
ENGINE
C5
D29
GROUND BOLT
B
45
46R
118
132
133
K
OR-CR34
OR/RD-118B
GENERATOR OPTION
HORN RELAY POWER
LIFT SPEED REDUCTION
PLATFORM OVERLOAD LS
PLATFORM OVERLOAD ALARM
134
PLAT. OVERLOAD LIM. SW. +12V (2)
C59CNK BL/BK C3B-11
C59CNK WH-LS5 C37-4
C134PWR GR/BK C2B-6
C134PWR RD-LS17 C38-1
C134PWR BK-LS5 C37-3
P134TTSR RD A
BRN-GND
45
46R
118
132
133
134
PLAT. OVERLOAD LIM. SW. +12V (1)
134
59
134
RETRACT BOOM LED
C37
GR/WH C5-12
BK-CR5
OR/RD-FH C38-3
RD-24D
P134FB WH-FH
RD-KS
59
+12V DC
POWER
J
WH-L46+
46
41
HORN
ALTERNATOR PULSE PICKUP
41
#1
C5
#2
F.H.
46
40
C35HS BK/RD C1B-9
C35HS BK/RD C5-18
C36STCC BL C1B-10
C36STCC BL C24-1
C37STC BL/BK C1B-11
C37STC BL/BK C25-1
C39LP BL/RD C2B-1
C39LP BL/RD C5-10
C40LS1 OR C2B-2
C40LS1 OR C10-2
C41RPM OR/BK C2B-3
C41RPM OR/BK C5-2
C46HRN GR C2B-5
C34SA BK/WH C1B-8
C11
GR-CR5
39
BOOM STOWED
40
37
STEER LEFT
37
LIQUID PROPANE FUEL
36
STEER RIGHT
36
39
35
HIGH FUNCTION SPEED
34
(UNUSED)
34
35
33
ENGINE START
33
P20BAT RD
BRN
I
BL/RD-TS53
RD-TS54
BK-TS52
32
31
BRAKE
DRIVE REVERSE
31
32
30
C27AUX RD C1B-1
C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C32BRK WH/RD C5-23
C33STR BK C1B-7
CABLE
TENSION
LIMIT SWITCH
LS5
H
WH/RD-ALRM
29
MOTOR STROKE
DRIVE FORWARD
30
28
TILT ALARM
28
29
26
27
(UNUSED)
AUXILARY PUMP
C5
#2
F.H.
27
25
(UNUSED)
25
#1
26
23
24
KEY SWITCH POWER
CIRCUIT BREAKER POWER
23
22
+12V DC TO PLATFORM (2)
22
24
22
+12V DC TO PLATFORM (1)
22
C21IGN2 WH C5-11
P22BAT BK C7B-1
C22LS17 BK C10-2
P22BAT BK C11-1
P22BAT BK C9-2
P23BAT WH C7B-2
P20BAT RD
P20BAT RD
BOOM
EXTEND
LIMIT SWITCH
LS1
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12V DC
POWER TO
PLATFORM
C7
TS64
RUN/TEST
SWITCH
G
C5-6 RD
RD-TS51
WH-KS
RD-CR1
RD-134D
21
IGNITION POWER
20
+12V DC POWER
21
19
JIB BOOM SELECT VALVE
F.H.
19
#2
20
18
PLATFORM ROTATE RIGHT/JIB DOWN
18
15
17
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL DOWN
14
17
15
PLATFORM LEVEL UP
13
DRIVE ENABLE
14
44
JIB BBOM DOWN DESCENT ALARM
9
13
BOOM EXT/RET FUNCTION CTRL
44
9
BRN
C5-8 GR
F
WH-HM
BK-CR5
BK-KS
7
8
BOOM EXTEND
BOOM RETRACT
7
8
6
TURNTABLE ROTATE FUNCTION CTRL
6
C5
GR/WH-TS57
RD-CB2
4
5
#1
GR-TS57
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
C1PBU RD C3B-1
C1PBU RD C12-1
C2PBD RD/BK C3B-2
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C6TRF WH/RD C31-1
C7PBE BK C3B-7
C7PBE RD-LS5 C37-1
C8PBR BK/WH C3B-8
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
C9PER BK/RD C30-1
JDALARM BL C3B-10
RD/BK-ALARM
C13DRE BL/RD C4B-1
C13DRE BL/RD C10-1
C14PLU OR C4B-2
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C15PLD OR/BK C21-1
C17JU GR C4B-5
C17JU GR C22-1
C18JD GR/BK C4B-6
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
E
OR/BK-TS59
OR-TS59
BL-TS58
4
5
3
A
D
BK/WH-TS63
BK-TS63
WH/RD-TS62
WH/BK-TS62
BOOM FUNCTION CONTROL
2
BOOM DOWN
B
2
3
2
1
BOOM UP
TERMINAL BASE (TB)
1
RD/WH-R16
BRN
1
C
WH-TS62
BK-22C1
C
R43DLITE1 RD
R43DLITE2 RD
D
5
RD-TS61
RD/BK-ALARM
RD/BK-TS61
BRN
RD-CB3
C21IGN WH
CR17
HYDRAULIC
OIL COOLER
OPTION
3
GR-46D
RD-CB3 OPTIONS
C2B-5 GR
CR22
DRIVE LIGHT
OPTION
OR C5-1
B
BRN
F.H.
4
CR5
HORN
RELAY
6
BK-46R
C5
A
GROUND HARNESS
TO SWITCH PANEL
7
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV B
GM 3.0L Models
N
FUNCTION
HARNESS
F.H.
BRN-TS64
BRN C7B-3
BK C16-1
WH LS2 C10-2
C5
#2
F.H.
D30
July 2005
Section 6 • Schematics
REV B
Ground Control Box Switch Panel Wiring Diagram, S-65
GM 3.0L Models
I
H
G
F
E
C
B
GR/BK
RD
D28
RD
C19JSV GR/WH
3
GR/WH-19D
OR/BK-15D
RD
OR-14D
GR-17D
GR/BK-18D
TS58
JIB BOOM
UP/DOWN
GR
RD
BL-44D
WH-4D
WH/BK-5D
WH/RD-6D
BK-7D
RD-1D
BK/RD-9D
BK/WH-8D
TS63
BOOM EXTEND/
RETRACT
RD
RD/WH-CR34
RD/BK-2D
RD
BK/RD-35D
5
RD
RD-20C
RD-20C
RD
RD/WH
LABEL
RD
RD
RD
CB2
CIRCUIT
BREAKER
CONTROLS 15A
RD
CB3
CIRCUIT
BREAKER
OPTIONS 15A
RD/WH
WH-23
RD-20C
BK-33D
RD CR22
RD CR17
RD C32-7
TS53
FUEL SELECT
-
+
BL/RD-39D
RD
BL/WH-38
BRN-GND
L2
CHECK
ENGINE
LED
WH-21D
WH-23D
4
3
D2
RD
RD-134D2
BK-22D1
B
B1
2
1
KS1
KEY SWITCH
WH
RD/WH-TB3D
RD
OR
RD
RD
TS52
ENGINE
START
BRN
D14
2
RD
TS54
FUNCTION
ENABLE
NC
2
D13
NC
HOUR METER
1
RD
1
RD
WH-21D
BRN
BRN
BRN
P1
EMERGENCY
STOP SWITCH
RD/WH-R16
CR34
BOOM
SPEED
REDUCTION
RD/WH-TS61
RD/WH-R16
OR-LS17
RD
DALE RH-25 25W
5 ohm 1%
GR/BK-H6-
BRN
+
L46
LOWER/ RETRACT
BOOM
LED
BL/BK-59D
RD C32-6
C134PWR RD
WH
RD-27
WH
RD-27D
OR-LS17
DALE RH-25 25W
10 ohm 1%
WH
RD/WH
RD
RD
GR
GR/BK
4
RD
R16
BOOM UPPER ZONE
RESISTOR
R4
TURNTABLE ROTATE
RESISTOR
TS59
PLATFORM
LEVEL
RD
RD
2
RD
D4
RD
RD
R14
UP/DOWN
RESISTOR
GR-17D
RD
RD
RD
DALE RH-25 25W
5 ohm 1%
GR/BK
GR/BK-18D
RD
WH-4
WH/BK-5
WH/RD-6
RD
RD
RD/WH
RD
RD
TS51
AUXILIARY
POWER
D3
RD
RD
RD
RD-1
-
+
RD
RD/BK-2
A
1
D9
RD
RD
D
BASE BOX HARNESS
(TO TERMINAL STRIP)
J
TS57
PLATFORM
ROTATE
K
TS62
TURNTABLE
ROTATE
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
DESCRIPTION
CB2
CB3
CR1
CR5
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
SERVICE HORN RELAY
CR17
CR22
CR34
HYDRAULIC OIL COOLER RELAY
DRIVE LIGHT RELAY (OPTION)
BOOM SPEED REDUCTION RELAY
HM
KS1
L2
L46
L45
P1
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
R4
R14
R16
TS51
TS52
TS53
TS54
TS57
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 5 OHMS
TS58
TS59
TS61
TS62
TS63
TS64
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
RUN/TEST TOGGLE SWITCH
6
7
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
FUNCTION ENABLE TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
8
6 - 16
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
GM 3.0L Models
Section 6 • Schematics
July 2005
Platform Control Box Wiring Diagram, S-65
GM 3.0L Models
BRN
BRN
* NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
C19JSV GR/WH TS7
C19JSV GR/WH C4P-7
BRN JC3
BRN GND
RD-E-STOP
C134PWR RD-H1+
TILT ALARM
12V DC PLATFORM POWER CONNECTOR
FOOTSWITCH CONNECTOR
48 PIN CONNECTOR BLOCK
H1
C7P
C9
C1P-C4P
CWLITE WH TS49
WH
BK
C134PWR RD LS18
JIB
JIB
OPT.
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
GR/BK C133TTA C3P-12
GR/BK-L4- (CE)
F.S.
RD/BK-28
RD/BK-L48- (NON-CE)
C134PWR RD C2P-6
RD-TILT
OPTION
C32BRK WH/RD C1P-6
C32BRK WH/RD J2-19
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129JDA BL C3P-10 TS8
C46HRN GR C2P-5
C59CHK BL/BK C3P-11 L47+
C59CNK BL/BK C3P-11
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
C7P
P24FS WH C9-2 TS4
C7P
CDLITE OR/RD C2P-4
C45GEN GR/WH C2P-7
C46HRN GR C2P-5
C39LP BL/RD C2P-1
C4P
TS7 WH
TS1 WH
1
P26ESTP BK
C118LSR OR/RD C4P-4
C6TRF WH/RD C3P-6
C8PBR BK/WH C3P-8
C16DRE BL/RD C4P-1
C7PBE BK C3P-7
C40LSS OR C2P-2
C9PER BK/RD C3P-9
C41RPM OR/BK C2P-3
C30FWD WH C1P-4
C1PBU RD C3P-1
C31REV WH/BK C1P-5
C3P
BRN
Part No. 77828
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C35RPM BK/RD C1P-9
C33STR BK C1P-7
C27AUX RD C1P-1
C28TTA RD/BK C1P-2
BRN
19/18 CONTROL CABLE
P24FS WH
1
LS18
(CE)
FOOT
SWITCH
+
P24FS WH
BRN
JC1-3 OR
JC1-2 BRN
JC2-4 RD
JC2-3 OR
JC2-5 BK
JC2-2 BRN
JC1-5 YEL
JC3-3 OR
JC3-5 WH
JC3-4 BL *
JC3-2 BRN
TS15 BL/WH
TS15 B BL/BK
BRN
DRE LED BL/RD
TS14 RD/WH
RD/BK-L4-
CWLITE BK
11
JIB
12V DC
BATTERY
H1
TILT
ALARM
9
BK C1P-12
C3P
C7P
C9
D39
3
C134PWR RD LS18
BRN
C2P
6
C4P
BATGRN C7P-3
WH/RD C1P-6
C1P
C28TTA RD/BK C1P-2
1
J3
CR27
CR30
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
U13
J1
J2
J3
CR27
CR30
LS18
2
DESCRIPTION
ITEM
1
5
PLATFORM
CONTROL
HARNESS
(TO SWITCH
PANEL)
CE LIFT/DRIVE OPTION
J2
J1
C7P
8
RD LS18 CABLE
7
S-60 • S-65
6 - 17
CWLITE WH TS49
4
REV B
Platform Control Box Wiring Diagram, S-65
N
M
L
K
J
I
H
G
F
E
D
C
B
A
U13
ALC-500
3
July 2005
Section 6 • Schematics
GM 3.0L Models
July 2005
REV B
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-65
GM 3.0L Models
N
M
L
K
J
I
H
G
F
E
D
C
PLATFORM
CONTROL
HARNESS
(TO CONTROL BOX)
TS48
DRIVE LIGHTS/
WORK LIGHTS
(OPTION)
JC2
BOOM UP/DOWN
& TURNTABLE ROTATE
LEFT/RIGHT
DLITE RD
RD
BK
JC1
7
7
BOOM
EXTEND/RETRACT
6
3
BRN
2
+
BRN
1
2
L1
DRIVE
ENABLE
1
JIB BOOM
CUTOUT
+
BRN
BK
BRN
BRN
BK
F18
FUSE 10A
(WORKLIGHT ONLY)
C28TTA RD/BK H1C133PLA GR/BK D39
BK
WH
TS8
JIB
BOOM
TS7
PLATFORM
ROTATE GR/BK
D27
RD
DRIVE/STEER PROPORTIONAL JOYSTICK
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
LOWER/RETRACT BOOM LED
BOOM TILTED LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
HI/LOW RPM TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
TS9
TS14
TS15
TS47
TS48
PLATFORM LEVEL TOGGLE SWITCH
DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)
P22BAT BK C7P-1
P26BAT BK J3-3
RD
TS9
PLATFORM
LEVEL
JC3
L1
L4
L47
L48
P2
P3
TS1
TS2
TS3
TS4
TS7
TS8
2
3
5
1
1
6
7
1
NC NC NC
P3
HORN
BOOM PROPORTIONAL JOYSTICK:
BOOM EXTEND/RETRACT
4
P23BAT WH C7P-2
P26BAT BK C9-1
RD-H1+
C134PWR RD L48+
C134PWR RD L4+
BK TS15
C39LP BL/RD C2P-1
PDLITE RD
NO
RD
BRN
C35HS BK/RD C1P-9
P24FS WH C9-2
C33STR BK C1P-7
P25FS RD C9-3
BK
C45GEN GR/WH C2P-7
C29MS RD/WH J1-8
WH CR30
C27AUX RD C1P-1
WH-JIB
C129JDA BL C3P-10
C19JSV GR/WH
C17PRL GR C4P-5
WH CR27
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
P24FS WH
TS3
FUEL
SELECT
GR
3
BOOM PROPORTIONAL JOYSTICK:
BOOM UP/DOWN , TURNTABLE ROTATE
JC1
1
WH
D12
4
WH J1-4
BL J1-5
OR J1-13
BRN J1-14
BK
C134PWR RD E-STOP
C134PWR RD E-STOP
BK
BL/RD-DE3 J1-16
BL-DE1 J1-6
BL/BK-DE2 J1-7
YL J1-3
OR J1-9
BRN J1-10
WH-JIB
WLITE WH
DLITE OR/RD C2P-4
C59CNK BL/BK C3P-11
WLITE WH
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C46HRN GR C2P-5
WH
JC2
1
RD
BRN
COMPONENT INDEX
JIB BOOM CUTOUT RELAY
2
+
BK
BRN
3
A
CR13
BL J1-5 (ROCKER SWITCH OPTION ONLY)
CR13
L47
RETRACT
BOOM
4
L4
PLATFORM
OVERLOAD
(CE OPTION)
3
BRN
6
RD
4
BK
4
7
5
BK
5
L48
TILT ALARM LED
(ANSI/CSA OPT.)
BK
5
DRIVE
FORWARD/REVERSE
& STEER
LEFT/RIGHT
+
TS15
DRIVE
ENABLE
6
JC3
B
TS1
AUXILIARY
PUMP
TS14
HIGH/LOW
(2WD/4WD)
TS4
HIGH/LOW
RPM
TS2
ENGINE
START
TS47
GENERATOR
(OPTION)
2
2
D11
2
P2
EMERGENCY
STOP
BK
WH-24
RD
RD
RD
8
NOTE: DASHED LINES INDICATE OPTION WIRES
CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30
Part No. 77828
S-60 • S-65
6 - 18
July 2005
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-65
GM 3.0L Models
RD
RD
C7P-1
RD
ENGINE
SPEED
GENERATOR
DRIVELIGHT
WH
WH
WORKLIGHT
FUEL
SELECT
C41RPM OR/BK
ENGINE
START
C2B-6
D12
C1P-9
C2P-7
C2P-4
C2P-1
C1P-7
C1P-1
C7P-2
C1P-2
BK C2P-5
H1
C7B-1
AUXILIARY
PUMP
C28TTA RD/BK
WH
RD
P22BAT BK
P134PWR GR/BK
C2P-6
C35RPM BK/RD
C1B-9
C2B-7
FUNCTION ENABLE
C45GEN GR/WH
C2B-4
HIGH RPM
LOW RPM
DLITE OR/RD
BK
BK
C39LP BL/RD
FUEL
SELECT
C33STR BK
ENGINE
START
C2B-1
C2B-3
C1B-7
AUXILIARY
PUMP
C27AUX RD
P23BAT WH
C28TTA RD/BK
C46HRN GR
C1P-1
C7B-2
C1P-2
C2B-5
BL/WH
C21IGN WH
C5-19
C5-11
C5-9
C5-10
C5-18
C5-2
C5-5
C5-12
C25PSR WH/BK
C26TSR WH/RD
RD
RD
C45GEN GR/WH
BR
P23BAT WH FEH(16) PIN1
C21IGN WH FEH(71) PIN21
C128RPM OR/RD FEH(306) PIN24
C108ESL BL/WH FEH(658) PIN6
C127TSW GR FEH(458) PIN18
C39LP BL/RD FEH(72) PIN7
C35RPM BK/RD FEH(307A) PIN23
P20BAT RD FEH(361) PIN9
(GND) BR FEH(570) PIN34
C41RPM OR/BK FEH(11) PIN2
BK
C6-9
C5-4
C5-1
BRN
BRN
BK
R33STR BK FEH(32) PIN15
C33STR BK FEH(32) PIN13
BL/WH FEH(787A) PIN5
R46HRN BK
P134FB WH
RD
WH
C135FP BL/WH
C33STR BK
C27AUX RD
C28TTA RD/BK
P134TTS RD
C46HRN GR
P22HRN BK
R21IGN WH
C116 OR
510
NO
G1
P116HYD RD
C107AF WH
H2
M1 FAN
OIL PRESSURE
SENDER (OPTION)
VOLT METER (OPTION)
WATER TEMPERATURE
SENDER (OPTION)
HYDRAULIC
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
HOUR METER
CHECK ENGINE LED
RUN/TEST SWITCH
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
FLASHING
BEACONS OPTION
HORN RELAY
HORN
HYDRAULIC OIL
TEMPERATURE SWITCH
(OPTION)
COOLING FAN
(OPTION)
Part No. 77828
S-60 • S-65
+
6 - 19
C
SW3
FORD 42 PIN
QUICK DISCONNECT
L29
L29
HM
_
M4
M2
TB35
CR39
G2
G3
L2
C5-3
8
+
FUEL
PUMP
STARTER
AUX
PUMP
FB1
B1
CR17
S8
TB46R
I
R6
S
P134PWR RD
C7B-4
FLD.
P26ESTP BK
P22LS BK
P20BAT RD
REGULATOR
A
12V DC
7
CR23
NO
C5-8 GR
C5-13 BL/WH
NO
B
A
STA.
PR1
CR5
NO
86
30
GND.
85
87a 87
FUSE
10A
BAT.
LINK
C21IGN WH
TB21
C21IGN WH
TS64
ALTERNATOR
FUSE
6
TB33
CR2
CR2
NO
CR1
NO
TB39
BL/RD
RD
CR39
NC
TB24
P24BAT RD
RD
D13
TB20
D4
TS53
L30
TS4
TS47
TS48
TS49
TS3
TS54
D10
TS52
D14
RD
TB27
TB23
TB46
TB45
TB134
CB3
15A
5
RD
RD
TS51
PLATFORM
BOX GROUND
D2
TB41
CB1
15A
D3
4
TS1
L30
PLAT
RD
15A
TB134
TB22
P1
CB2
3
L48
P3
WH(FS)
BK(FS)
FUSE 10A
P24FS WH
RD
WH
P25FS RD
P24FS WH
C9P-3
C9P-2
RD(FS)
FS1
C9P-1 BK
P2
D11
TS2
2
C28TTA RD/BK
1. ALL LIMIT SWITCHES SHOWN WITH BOOM
IN STOWED POSITION.
C1B & C1P - GRAY; C2B & C2P - BLACK;
2
C3B & C3P - GREEN; C4B & C4P - BROWN.
N
M
L
K
J
I
H
G
F
E
D
C
B
A
P22LS BK
P134PWR RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
NOTES:
1
July 2005
Section 6 • Schematics
REV A
Electrical Schematic, S-60
Ford LRG-425 EFI Models (before serial number 11880)
KS1
GRND
C35RPM BK/RD
-
Electrical Schematic, S-60
REV A
DRIVE MODE
CDE3 BL/RD
3
BL
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
CDE2 BL/BK
LEFT
CDE1 BL/WH
RIGHT
7
RKOUT 6
4
YOUT 5
PWR 3
1
GND 2
7
6
PWR
2
XOUT 4
YOUT 5
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
3
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
C7P-3
C2P-3
C1P-4
C1P-5
C1P-6
C1P-3
C1P-11
C1P-10
C3P-4
C3P-6
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-7
C3P-8
C4P-4
C4P-1
BATGND
C41RPM OR/BK
C30FWD WH
C31REV WH/BK
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36STCC BL
C4TRL WH
C6TRF WH/RD
PRIMARY BOOM
TURNTABLE ROTATE
C5TRR WH/BK
RIGHT
LEFT
UP
DOWN
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C9PER BK/RD
C7PBE BK
C8PBR BK/WH
EXTEND
BOOM
C4B-4
RETRACT
C118LSR OR/RD
C4B-1
J1 F.H. WH
WH
C13DE BL/RD
C11-2
C40LS OR
C7B-3
C2B-3
C1B-4
C1B-5
C1B-6
C1B-3
C1B-11
C1B-10
C3B-6
C3B-4
C3B-5
C3B-2
C3B-1
C3B-3
C3B-9
C3B-7
C3B-8
TB5
C4B-2
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-3
PLATFROM LEVEL
C59CNK BL/BK
P22LS BK
C14PLU OR
C15PLD OR/BK
UP
DOWN
C4B-5
C4B-6
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
BK
BK
RD
C25-2
C28-2
C26-2
RD
C28-1
C25-1
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C37-1
C38-3
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
3
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
6 - 20
S-60 • S-65
Part No. 77828
U4
2
TB22
CR34
C2P-2
C3P-11
C4P-2
C4P-3
C17JU/PRL GR
C18JD/PRR GR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
C129 RD/BK
BK
BK
BRN
7
4
6
1
14
TB2
H4
TB59
LS17
NO
HC
13
14
LS17
NC
HO 22
LS1
LS3
NO
NC
13
14
21
NO
HC
NO
14
TB3
D30
21 LS5
NC
22
13
LS5
13
4
P134 RD
PLATFROM LEVEL
C4P-6
PLATFROM ROTATE
PLATFROM
ROTATE
D29
TB30
TB31
TB32
TB29
TB37
TB36
TB4
TB6
TB9
14
TB14
5
R16
10
TB13
TB1
TB7
TB8
13
TB40
TB15
CR34
TB134
LS2
NO
NC
TB18
UP
DOWN
LEFT
RIGHT
C4P-5
TS57
L46
H3
RIGHT
LEFT
TB17
TS59
TB118
D28
4
TS62
TS61
TS63
R4
5
R14
5
L1
3
CE
LIFT/
DRIVE
OPTION
J1
J1
J1
J1
J3
CR30
NO
J2
U13 JOYSTICK CONTROL CARD
D27
D9
RD
RD
L47
3
TS9
TS7
TS14
TS15
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
2
P26ESTP BK
CR27
NC
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
C28TTA RD/BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Ford LRG-425 EFI Models (before serial number 11880)
1
July 2005
Section 6 • Schematics
Electrical Schematic, S-60
Ford LRG-425 EFI Models (before serial number 11880)
P134PWR RD
RD
RD
C7P-1
ENGINE
SPEED
C1P-9
C2P-7
C2P-4
C2P-1
C1P-7
C1P-1
C7P-2
C1P-2
BK C2P-5
C35RPM BK/RD
C1B-9
C2B-7
FUNCTION ENABLE
C45GEN GR/WH
C2B-4
HIGH RPM
LOW RPM
DLITE OR/RD
BK
BK
C39LP BL/RD
FUEL
SELECT
C33STR BK
ENGINE
START
C2B-1
C2B-3
C1B-7
AUXILIARY
PUMP
C27AUX RD
P23BAT WH
C28TTA RD/BK
C46HRN GR
C1P-1
C7B-2
C1P-2
C2B-5
BL/WH
C21IGN WH
C5-19
C5-11
C5-9
C5-10
C5-18
C5-2
C5-5
C5-12
C25PSR WH/BK
C26TSR WH/RD
RD
RD
C45GEN GR/WH
BR
P23BAT WH FEH(16) PIN1
C21IGN WH FEH(71) PIN21
C128RPM OR/RD FEH(306) PIN24
C108ESL BL/WH FEH(658) PIN6
C127TSW GR FEH(458) PIN18
C39LP BL/RD FEH(72) PIN7
C35RPM BK/RD FEH(307A) PIN23
WH
RD
R21IGN WH
R46HRN BK
P134FB WH
BK
C6-9
C5-4
C5-1
BRN
BRN
BK
R33STR BK FEH(32) PIN15
C33STR BK FEH(32) PIN13
BL/WH FEH(787A) PIN5
P20BAT RD FEH(361) PIN9
(GND) BR FEH(570) PIN34
C41RPM OR/BK FEH(11) PIN2
C135FP BL/WH
C33STR BK
C27AUX RD
C28TTA RD/BK
P134TTS RD
C46HRN GR
P22HRN BK
+
GENERATOR
DRIVELIGHT
WH
WH
WORKLIGHT
FUEL
SELECT
C41RPM OR/BK
ENGINE
START
D12
H1
C7B-1
AUXILIARY
PUMP
C28TTA RD/BK
WH
RD
P22BAT BK
C2B-6
C116 OR
510
NO
RD
P134PWR GR/BK
C2P-6
P116HYD RD
C107AF WH
H2
SW3
M1 FAN
OIL PRESSURE
SENDER (OPTION)
VOLT METER (OPTION)
WATER TEMPERATURE
SENDER (OPTION)
HYDRAULIC
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
HOUR METER
CHECK ENGINE LED
RUN/TEST SWITCH
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
SPEED REDUCTION RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
FLASHING
BEACONS OPTION
HORN RELAY
HORN
HYDRAULIC OIL
TEMPERATURE SWITCH
(OPTION)
COOLING FAN
(OPTION)
Part No. 77828
S-60 • S-65
+
6 - 21
C
FORD 42 PIN
QUICK DISCONNECT
L29
L29
HM
_
M4
M2
CR19
FUEL
PUMP
STARTER
AUX
PUMP
FB1
B1
S8
TB46R
I
R6
S
7
CR17
G1
C5-3
FLD.
P26ESTP BK
P22LS BK
C7B-4
8
P20BAT RD
REGULATOR
A
12V DC
CR23
NO
C5-8 GR
C5-13 BL/WH
NO
B
A
STA.
PR1
CR5
NO
86
30
GND.
85
87a 87
FUSE
10A
BAT.
LINK
6
D14
RD
G2
G3
L2
TS64
ALTERNATOR
FUSE
CR2
CR2
NO
C21IGN WH
TB21
C21IGN WH
TB35
CR39
CR1
NO
TB39
TB33
CR39
NC
TB24
P24BAT RD
RD
TB20
5
TS53
D13
TB45
TB134
CB3
15A
TB27
TB23
TB46
BL/RD
RD
CB1
15A
D4
FUSE 10A
TS54
D10
TS52
PLATFORM
BOX GROUND
TB41
D2
D3
4
RD
RD
TS51
L30
P1
3
TS4
TS47
TS48
TS49
TS3
TS2
L30
PLAT
RD
15A
TB134
TB22
CB2
L48
P3
WH(FS)
BK(FS)
C9P-1 BK
TS1
P24FS WH
RD
WH
P25FS RD
P24FS WH
C9P-3
C9P-2
RD(FS)
FS1
P2
D11
2
C28TTA RD/BK
1. ALL LIMIT SWITCHES SHOWN WITH BOOM
IN STOWED POSITION.
C1B & C1P - GRAY; C2B & C2P - BLACK;
2
C3B & C3P - GREEN; C4B & C4P - BROWN.
N
M
L
K
J
I
H
G
F
E
D
C
B
A
P22LS BK
P134PWR RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
NOTES:
1
July 2005
Section 6 • Schematics
REV A
Electrical Schematic, S-60
Ford LRG-425 EFI Models (after serial number 11879)
KS1
GRND
C35RPM BK/RD
-
Electrical Schematic, S-60
REV A
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
BL
WH
OR
BRN
BK
RD
OR
BRN
15
8
16
7
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
CDE1 BL/WH
RIGHT
7
RKOUT 6
4
YOUT 5
PWR 3
3
YEL
OR
BRN
10
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
C3P-4
C3P-6
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-5
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
TURNTABLE ROTATE
C5TRR WH/BK
C13DE BL/RD
C118LSR OR/RD
PRIMARY BOOM
C11-2
BOOM
J1 F.H. WH
WH
C4B-1
C4B-4
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C4P-4
C4P-1
C2P-2
C40LS OR
C15PLD OR/BK
C14PLU OR
C3B-1
C3B-3
C3B-2
C3B-9
C3B-8
C3B-7
TB5
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
C4B-6
PLATFROM LEVEL
C59CNK BL/BK
P22LS BK
C4P-2
C3P-11
C4P-3
UP
DOWN
C18JD/PRR GR/BK
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
BK
BK
RD
C25-2
C28-2
C26-2
RD
C28-1
C25-1
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
7
U4
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
6 - 22
S-60 • S-65
Part No. 77828
GND 2
1
7
6
YOUT 5
PWR
2
XOUT 4
GND
1
7
6
4
OUT 5
PWR 3
1
1
2
3
4
4
P134 RD
PLATFROM LEVEL
C4P-6
PLATFROM ROTATE
C4B-5
C17JU/PRL GR
C129 RD/BK
BK
GND 2
BRN
P24FS WH
P24FS WH
P26ESTP BK
DOWN
UP
LEFT
C17JU/PRL GR
PLATFROM
ROTATE
14
3
TB22
CR34
4
14
21
LS17
NC
HO 22
BK
BRN
1
LS17
NO
HC
13
LS3
NO
HC
13
14
22
LS2
NO
HC
NO
14
H4
TB59
6
21 LS5
NC
13
LS5
13
2
L46
H3
RIGHT
LEFT
D29
TB30
TB36
TB4
TB3
L1
TB31
TB32
TB29
TB37
TB2
14
TB14
TB18
TB6
TB9
D30
TB1
TB7
TB8
LS1
NO
HC
13
TB40
TB15
CR19
CR34
TB134
R16
10
TB13
R4
7.5
R2
5
1
C28TTA RD/BK
5
TB17
RIGHT
C4P-5
TS57
TB118
D28
D9
R14
5
4
TS62
TS61
TS63
TS59
CE
LIFT/
DRIVE
OPTION
J1
J1
J1
J1
J3
CR30
NO
3
RD
RD
L47
J2
U13 JOYSTICK CONTROL CARD
D27
2
CR27
NC
TS14
TS15
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS7
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Ford LRG-425 EFI Models (after serial number 11879)
July 2005
Section 6 • Schematics
Electrical Schematic, S-60
Ford LRG-425 EFI Models (after serial number 11879)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-60
Ford LRG-425 EFI Models (before serial number 11880)
6 - 23
BK-33C
RD-24C
S-60 • S-65
BK C5-5
NOTE: DASHED LINES INDICATE OPTION WIRES
8
WH-TB21 OPTIONS
FUSE 10A
(DRIVE LIGHT ONLY)
Part No. 77828
WH-23C
A
WH C10-2
BRN
BRN C37-2
OR-LS17 C38-2
OR/RD-LS17 C38-3
C108ESL BL/WH C5-13
C45GEN GR/WH C2B-7
R46HRN BK
C118LSR OR/RD C4B-4
C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
L
ENGINE
FUNCTIONS
HARNESS
C5
D29
C9 (LS3)
C11 (LS2)
LS17 (C38)
Ground Control Box Terminal Strip Wiring Diagram, S-60
M
GROUND BOLT
B
45
46R
118
132
133
134
GENERATOR OPTION
HORN RELAY POWER
LIFT SPEED REDUCTION
PLATFORM OVERLOAD LS
PLATFORM OVERLOAD ALARM
C59CNK BL/BK C3B-11
C59CNK BL/BK-LS5 C37-4
P134PWR GR/BK C2B-6
P134PWR RD-LS17 C38-1
P134PWR BK-LS5 C37-3
P134TTS RD A
BRN-GND
45
46R
118
132
133
134
134 PLAT. OVERLOAD LIM. SW. +12V DC (2)
59
46
+12V DC
POWER
K
OR-CR34
OR/RD-118B
BL/WH-L2-
HORN
RETRACT BOOM LED
134 PLAT. OVERLOAD LIM. SW. +12V DC (1)
59
46
40
41
BOOM STOWED
ALTERNATOR PULSE PICKUP
40
41
39
C34SA BK/WH C1B-8
C35RPM BK/RD C1B-9
C35RPM BK/RD C5-18
C36SCC BL C1B-10
C36SCC BL C24-1
C37SCW BL/BK C1B-11
C37SCW BL/BK C25-1
C39LP BL/RD C2B-1
C39LP BL/RD C5-10
C40LS1 OR C2B-2
C40LS1 OR C10-2
C41RPM OR/BK C2B-3
C41RPM OR/BK C5-2
C46HRN GR C2B-5
C37
GR/WH C5-12
BK-CR5
OR/RD-FH C38-3
36
37
LIQUID PROPANE FUEL (LPG)
STEER LEFT
STEER RIGHT
36
37
35
39
HIGH FUNCTION SPEED
34
35
33
34
ENGINE START
(UNUSED)
33
#1
C5
#2
F.H.
P134FB WH-FH
RD-KS
31
32
BRAKE
32
P20BAT RD
BRN
J
BL/BK-L46+
30
C27AUX RD C1B-1
C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C32BRK WH/RD C5-23
C33STR BK C1B-7
C11
GR-CR5
30
MOTOR STROKE
DRIVE FORWARD
29
26
I
BL/RD-TS53
RD-TS54
29
TILT ALARM
28
DRIVE REVERSE
28
AUXILARY PUMP
27
31
27
(UNUSED)
26
H
WH/RD-ALRM
BK-CR1#86
BK-TS52
RD-CR39#86
RD-TS51
RD-CR2#86
CABLE
TENSION
LIMIT SWITCH
C37 (LS5)
BOOM
EXTEND
LIMIT SWITCH
C11 (LS1)
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12 V DC
POWER TO
PLATFORM
C7
TS64
RUN/TEST
SWITCH
G
25
(UNUSED)
24
23
22
25
23
CIRCUIT BREAKER POWER
22
21
22
P20BAT RD
P20BAT RD
C128RPM OR/RD C5-9
C21IGN2 WH C5-3
P22BAT BK C7B-1
P22LS17 BK C38-4
P22BAT BK C11-1
P22BAT BK C9-2
P23BAT WH C7B-2
C5
#2
F.H.
24
+12 V DC TO PLATFORM (2)
KEY SWITCH POWER
22
20
#1
RD-CB1
IGNITION POWER
+12 V DC TO PLATFORM (1)
21
18
19
BRN
C5-8 GR
F
WH-CR39#30
WH-KS
WH-CR2#87
WH-HM
BK-CR5
BK-KS
+12 V DC POWER
20
15
17
F.H.
JIB SELECT VALVE
PLATFORM ROTATE RIGHT/JIB DOWN
PLATFORM ROTATE LEFT/JIB BOOM UP
14
13
44
#2
19
18
17
15 PLATFORM LEVEL DOWN
14 PLATFORM LEVEL UP
8
9
C1PBU RD C3B-1
C1PBU RD C12-1
C2PBD RD/BK C3B-2
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C6TRF WH/RD C31-1
C7PBE BK C3B-7
C7PBE RD-LS5 C37-1
C8PBR BK/WH C3B-8
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
C9PER BK/RD C30-1
JDALARM BL C3B-10
RD/BK-ALARM
C13DE BL/RD C4B-1
C13DE BL/RD C10-1
C14PLU OR C4B-2
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C15PLD OR/BK C21-1
C17JU GR C4B-5
C17JU GR C22-1
C18JD GR/BK C4B-6
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
C5
GR/WH-TS57
RD-CB2
GR/BK-TS57
JIB DOWN DESCENT ALARM
13 DRIVE ENABLE
44
PRIMARY BOOM RETRACT
PRIM. BOOM EXT/RET FLOW CONTROL
6
7
A
#1
GR-TS57
8
9
TURNTABLE ROTATE FLOW CONTROL
PRIMARY BOOM EXTEND
5
4
3
2
B
E
OR/BK-TS59
OR-TS59
BL-TS58
BK/RD-TS63
6
7
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM FUNCTION CONTROL
PRIMARY BOOM DOWN
1
D
BK/WH-TS63
BK-TS63
WH/RD-TS62
5
4
3
2
TERMINAL BASE (TB)
PRIMARY BOOM UP
2
WH/BK-TS62
BRN
1
1
RD/WH-R16
BK-22C1
C
HYDRAULIC OIL
COOLER OPTION
C21IGN WH
OR C5-1
C
WH-TS62
D
RD-24B
RD-CB3
WH-C5-19
RD-TS61
RD/BK-ALARM
RD/BK-TS61
RD-27C
C2B-4 OR/RD
WH-C5-11
DRIVE LIGHT
OPTION RELAY
CR17
3
GR-46D
WH-OPTIONS
R43DLITE1 RD
R43DLITE2 RD
CR23
WH C5-4
B
BRN
WH-21C
CR5
F.H.
CR39
4
HORN
RELAY
BK-46R
C5
CR2
AUXILIARY
POWER RELAY
A
GROUND HARNESS
TO SWITCH PANEL
7
POWER RELAY
6
BRN
BRN
5
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV A
Ford LRG-425 EFI Models (before serial number 11880)
N
F.H.
BRN-TS64
BRN C7B-3
BK C16-1
WH LS2 C11-2
C5
#2
F.H.
D30
July 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Ford LRG-425 EFI Models (before serial number 11880)
H
G
F
E
GR/WH-19D
CIRCUIT
BREAKER
CONTROLS 15A
RD-24D
BK/RD-35D
4
CB2
RD-20C
RD-20C
5
NOTE:
DASHED LINES INDICATE
OPTION WIRES
RD
OR
RD-20D
RD-24D
CB1
RD
BRN
RD
RD
D14
FUNCTION
ENABLE
RD
D13
2
TS54
2
CIRCUIT
BREAKER
ENGINE 15A
TS52
ENGINE
START
1
NC
H.M.
HOUR METER
1
RD
WH-21D
BRN
BRN
P1
EMERGENCY
STOP
RD/WH-R16
RD/WH-TS61
RD/WH-R16
OR-LS17
CR34
PRIMARY BOOM
SPEED REDUCTION
RELAY
DALE RH-25 25W
5 ohm 1%
RD
RD
BRN
RD
PRIMARY UP/DOWN
RESISTOR
R14
RD
RD
NC
2
TS59
PLATFORM
LEVEL
OR/BK-15D
RD
OR-14D
GR/BK-18D
GR-17D
RD-20C
RD/WH
RD
A
3
RD-20D
RD
RD CR17
CIRCUIT
BREAKER
OPTIONS 15A
CB3
TS53
FUEL
SELECT
RD/WH
WH-23
RD-20C
BK-33D
WH-4D
WH/BK-5D
WH/RD-6D
BK-7D
RD-1D
BK/RD-9D
BK/WH-8D
BL/RD-39D
RD
-
4
+
TS63
BOOM EXTEND/
RETRACT
RD
RD/BK-2D
GR/BK-H6BK/RD C5-13
BRN-GND
RD/WH-CR34
BRN
L46 +
LOWER/
RETRACT BOOM
L2
CHECK
ENGINE
WH-21D
B1
2
WH-23D
RD-134D2
BK-22D1
1
B
D2
3
KS1
KEY SWITCH
WH
RD/WH-TB3D
RD
BL/BK-59D
C134PWR RD
WH
RD-27
WH
RD-27D
OR-LS17
DALE RH-25 25W
10 ohm 1%
PRIMARY BOOM
UPPER ZONE
RESISTOR
R16
RD
RD
B
RD
D4
RD
RD
RD/WH
RD
C19JSV GR/WH
GR/BK-18D
RD
RD
RD
RD
RD
TURNTABLE ROTATE
RESISTOR
R4
WH-4
WH/BK-5
WH/RD-6
RD
RD
DALE RH-25 25W
5 ohm 1%
RD
RD-1
RD/WH
RD
RD
RD
D3
TS51
AUXILIARY
POWER
RD/BK-2
-
+
RD
WH
C
1
D9
RD
RD
D
GROUND CONTROL BOX HARNESS
(TO TERMINAL STRIP)
I
TS57
PLATFORM
ROTATE
J
GR-17D
K
TS62
TURNTABLE
ROTATE
L
TS61
PRIMARY
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
RD
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR5
CR17
CR23
CR34
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
BOOM SPEED REDUCTION RELAY
CR39
HM
KS1
L2
L46
L45
P1
R4
R14
R16
TS51
TS52
TS53
TS54
AUXILIARY POWER RELAY
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
FUNCTION ENABLE TOGGLE SWITCH
TS57
TS59
TS61
TS62
TS63
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
TS64
RUN/TEST TOGGLE SWITCH
6
7
8
6 - 24
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Ford LRG-425 EFI Models (before serial number 11880)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-60
Ford LRG-425 EFI Models (after serial number 11879)
6 - 25
8
S-60 • S-65
WH-OPTIONS
WH-TB21 OPTIONS
FUSE 10A
(DRIVE LIGHT ONLY)
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
BK-33C
RD/WH-TS61
RD/WH-R16
WH/RD-R2
WH/RD-R4
BK-46R
PLATFORM OVERLOAD ALARM
133
D29
OR/RD-LS17 C38-3
D30
C108ESL BL/WH C5-13
A
C133PLA BL/WH C3B-12
C132PLI BL/WH C1B-12
C118LSR OR/RD C4B-4
BRN C37-2
BL/WH -L2-
133
132
R46HRN BK
WH C11-2
GROUND BOLT
PLATFORM OVERLOAD LS
132
118
FUNCTION
HARNESS
LS17 (C38)
L
C11 (LS2)
C9 (LS3)
K
OR/RD-118B
B
LIFT SPEED REDUCTION
118
C45GEN GR/WH C2B-7
+12V POWER
C5
ENGINE
OR/RD-FH C38-3
45
46R
F.H.
HORN RELAY POWER
#2
F.H.
GENERATOR OPTION
P134TTS RD A
#2
46R
134
C5
F.H.
45
LOAD WEIGHING LIM. SW. +12V (2)
P134PWR RD-LS17 C38-1
P134PWR BK-LS5 C37-3
C5
#2
BK-CR5
134
134
P134PWR GR/BK C2B-6
C59CNK BL/BK-LS5 C37-4
C59CNK BL/BK C3B-11
BRN-GND
GR/WH C5-12
LOAD WEIGHING LIM. SW. +12V (1)
134
59
46
C46HRN GR C2B-5
C41RPM OR/BK C5-2
C41RPM OR/BK C2B-3
C40LS1 OR C10-2
C40LS1 OR C2B-2
C39LP BL/RD C5-10
C39LP BL/RD C2B-1
C37SCW BL/BK C25-1
C37SCW BL/BK C1B-11
C36SCC BL C24-1
C36SCC BL C1B-10
C35RPM BK/RD C5-18
C35RPM BK/RD C1B-9
C34SA BK/WH C1B-8
C37
RD-KS
P134FB WH-FH
SERVICE HORN
RETRACT BOOM LED
59
46
41
C32BRK WH/RD C5-23
C33STR BK C1B-7
BRN
P20BAT RD
J
BL/BK-L46+
ALTERNATOR PULS PICKUP
41
40
39
37
36
35
34
33
32
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C11
GR-CR5
LIQUID PROPANE FUEL
BOOM STOWED
STEER RIGHT
37
40
STEER LEFT
36
39
HIGH FUNCTION SPEED
(UNUSED)
34
35
START ENGINE
33
BRAKE
31
C31REV WH/BK C1B-5
C30FWD WH C5-21
C30FWD WH C1B-4
C29MS RD/WH C5-24
C29MS RD/WH C1B-3
C28TTA RD/BK B
C28TTA RD/BK C1B-2
C27AUX RD PR1
C27AUX RD C1B-1
RD-CR2 #86
P23BAT WH C7B-2
CABLE
TENSION
LIMIT SWITCH
C37 (LS5)
I
BL/RD TS53
RD-TS54
BK-TS52
32
PROPEL REVERSE
31
P22LS17 BK C38-4
P22BAT BK C9-2
P22BAT BK C11-1
BOOM
EXTEND
LIMIT SWITCH
C11 (LS1)
H
BK-CR1 #86
WH/RD-ALRM
30
MOTOR STROKE
29
PROPEL FORWARD
29
TILT ALARM
28
30
28
AUXILARY PUMP
27
C21IGN2 WH C5-3
P22BAT BK C7B-1
#1
27
26
(UNUSED)
26
P20BAT RD
P20BAT RD
C128RPM OR/RD C5-9
2
RD-TS51
25
(UNUSED)
25
24
23
22
22
21
CIRCUIT BREAKER POWER
RD/WH-3D
24
KEYSWITCH POWER
+12 VOLT TO PLATFORM (2)
22
23
+12 VOLT TO PLATFORM (1)
IGNITION POWER
22
21
20
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12 VOLT
POWER TO
PLATFORM
C7
TS64
RUN/TEST
SWITCH
G
RD-CR19#86
RD-CB1
WH-KS
WH-CR39 #30
BK-KS
BK-CR5
+12 VOLT POWER
20
19
18
C18JD GR/BK C4B-6
C17JU GR C22-1
C17JU GR C4B-5
C15PLD OR/BK C21-1
C5-8 GR
BRN
F
WH-HM
WH-CR2 #87
JIB SELECT VALVE
PLATFORM ROTATE RIGHT/JIB DOWN
15
17
C14PLU OR C20-1
C15PLD OR/BK C4B-3
#2
19
18
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL DOWN
14
C14PLU OR C4B-2
C13DE BL/RD C10-1
C13DE BL/RD C4B-1
RD/BK-ALARM
JDALARM BL C3B-10
C9PER BK/RD C30-1
C9PER BK/RD C3B-9
C8PBR BK/WH C17-1
C8PBR BK/WH C3B-8
C7PBE RD-LS5 C37-1
C7PBE BK C3B-7
C6TRF WH/RD C31-1
C6TRF WH/RD C3B-6
C5TRR WH/BK C14-1
C5TRR WH/BK C3B-5
C4TRL WH C15-1
C4TRL WH C3B-4
C3PBF RD/WH C29-1
C3PBF RD/WH C3B-3
C2PBD RD/BK C13-1
C2PBD RD/BK C3B-2
C1PBU RD C12-1
C1PBU RD C3B-1
C5
RD-CB2
15
17
PLATFORM LEVEL UP
13
44
A
F.H.
GR/WH-TS57
GR/BK-TS57
GR-TS57
14
DRIVE ENABLE
9
8
7
6
5
4
3
2
B
#1
OR/BK-TS59
JIB DOWN DESCENT ALARM
13
PRIM. BOOM EXT/RET FUNC. CTRL
PRIMARY BOOM RETRACT
44
9
8
PRIMARY BOOM EXTEND
TURNTABLE ROTATE FUNCTION CTRL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM FUNCTION CONTROL
PRIMARY BOOM DOWN
1
E
GROUND HARNESS
TO SWITCH PANEL
7
OR-TS59
BL-TS58
BK/RD-TS63
7
6
5
4
3
2
TERMINAL BASE (TB)
PRIMARY BOOM UP
D
BK/WH-TS63
BK-TS63
WH/RD-CR19
WH/BK-TS62
BK-22C1
1
RD-27C
C
C2B-4 OR/RD
WH-TS62
GR-46D
OR-LS17 C38-2
C21IGN WH
1
RD/WH-CR34
BK C5-5
C
RD/BK-TS61
WH/RD-6D
RD-CB3
R43DLITE2 RD
RD/WH-TS61
R43DLITE1 RD
CR17
HYDRAULIC
OIL COOLER
OPTION
BRN
D
RD-24B
OR C5-1
WH C5-4
B
RD/BK-ALARM
BRN
RD-TS61
BRN
RD/WH-R16
CR4
AUXILIARY
POWER RELAY
WH/RD-R4
WH-C5-19
CR34
PRIMARY BOOM
SPEED
REDUCTION
RELAY
F.H.
CR23
DRIVE LIGHT
OPTION
WH-OPTIONS
WH/RD-R2
WH-C5-11
BRN
WH-21C
CR19
SWING SPEED
SELECT
RELAY
BRN
WH-23C
CR5
HORN
RELAY
5
C32
C5
BRN
A
C32
6
RD
CR2
POWER
RELAY
4
WH-ISM9
BRN
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-60
REV A
Ford LRG-425 EFI Models (after serial number 11879)
M
N
F.H.
BRN
BRN-TS64
BK C16-1
WH LS2 C10-2
#1
BRN C7B-3
C5
3
July 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Ford LRG-425 EFI Models (after serial number 11879)
I
H
G
F
E
D
WH/RD
WH/RD
2
RD
C19JSV GR/WH
GR/BK-18D
RD
RD/WH
RD
RD
D4
RD
WH-4
WH/BK-5
+
RD
RD
RD
RD-1
-
RD
D3
A
BASE BOX HARNESS
(TO TERMINAL STRIP)
RD/WH
TS57
PLATFORM
ROTATE
RD
RD
RD/BK-2
TS51
AUXILIARY
POWER
B
1
RD
WH/RD
C
GR-17D
J
TS62
TURNTABLE
ROTATE
K
D9
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
WH/RD
WH/RD
RD
GR-17D
CIRCUIT
BREAKER
CONTROLS 15A
RD
RD-20C
RD-20C
CB2
5
RD
RD
RD
RD/WH
4
RD-24D
BK/RD-35D
RD-20D
OR/BK-15D
RD
OR-14D
GR/BK-18D
BK-33D
CIRCUIT
BREAKER
OPTIONS 15A
CB3
TS53
FUEL
SELECT
RD/WH
WH-23
RD-20C
RD CR22
RD CR17
WH-4D
WH/BK-5D
BK-7D
RD-1D
RD/WH-CR34#87a
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD
-
+
BL/RD-39D
RD/WH
RD/BK-2D
GR/BK-H6-
BRN
BRN-GND
BK/RD C5-13
L46
+
LOWER/
RETRACT BOOM
L2
CHECK
ENGINE
WH-21D
WH-23D
2
B1
D2
4
WH
RD
RD/WH
BL/BK-59D
C134PWR RD
RD-134D2
BK-22D1
B
RD
3
KS1
KEY
SWITCH
1
WH
TS59
PLATFORM
GR/WH-19D LEVEL
WH
RD-27
WH
RD-27D
WH/RD CR34#87
WH/RD CR19#87
WH/RD CR19#87a
DALE RH-25 25W
7.5 ohm 1%
R4
TURNTABLE
ROTATE
RESISTOR
R2
TURNTABLE
ROTATE
RESISTOR
3
RD
WH/RD
WH/RD
BRN
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
RD
WH-21D
TS52
ENGINE
START
RD-20D
DALE RH-25 25W
10 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
DALE RH-25 25W
5 ohm 1%
6
2
RD
RD
RD
D14
TS54
FUNCTION
ENABLE
2
D13
1
NC
HOUR METER
1
NC
RD
P1
EMERGENCY
STOP SWITCH
RD
R14
BOOM
UP/DOWN
RESISTOR
RD
BRN
DALE RH-25 25W
5 ohm 1%
RD
RD
WH/RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
HM
KS1
L2
L46
L45
P1
R2
R4
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 7.5 OHMS
R14
R16
TS51
TS52
TS53
TS54
TS56
TS57
TS59
TS61
TS62
TS63
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 26
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Ford LRG-425 EFI Models (after serial number 11879)
Section 6 • Schematics
July 2005
Platform Control Box Wiring Diagram, S-60
Ford LRG-425 EFI Models
C19JSV GR/WH TS7
C19JSV GR/WH C4P-7
BRN JC3
BRN GND
RD-E-STOP
C134PWR RD-H1+
REV A
Platform Control Box Wiring Diagram, S-60
Y
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
GR/BK C133TTA C3P-12
GR/BK-L4- (CE)
JIB
RD/BK-L48- (NON-CE)
C134PWR RD C2P-6
RD-TILT
DESCRIPTION
H1
C7P
C9
TILT ALARM
12V DC PLATFORM POWER CONNECTOR
FOOT SWITCH CONNECTOR
48 PIN CONNECTOR BLOCK
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
C1P-C4P
U13
J1
J2
J3
CR27
CR30
LS18
CWLITE WH TS49
C134PWR RD LS18
RD LS18 CABLE
F.S.
C32BRK WH/RD C1P-6
C32BRK WH/RD J2-19
C40LS OR C2P-2
C40LS OR J2-4
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129DA BL C3P-10 TS8
C46HRN GR C2P-5
C59CNK BL/BK C3P-11 L47+
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
CDLITE OR/RD C2P-4
C45GEN GR/WH C2P-7
C46HRN GR C2P-5
C39LP BL/RD C2P-1
C118LSR OR/RD C4P-4
C6TRF WH/RD C3P-6
C7PBE BK C3P-7
C13DE BL/RD C4P-1
C8PBR BK/WH C3P-8
C40LSS OR C2P-2
C9PER BK/RD C3P-9
C41RPM OR/BK C2P-3
C30FWD WH C1P-4
C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36SCC BL C1P-10
C3PBF RD/WH C3P-3
C37SCW BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C35RPM BK/RD C1P-9
C33STR BK C1P-7
C27AUX RD C1P-1
C2P
Y
Y
C28TTA RD/BK C1P-2
C3P
C3P
TS7 WH
TS1 WH
P26ESTP BK
P24FS WH
1
ITEM
8
P24FS WH
BRN
JC1-3 OR
JC1-2 BRN
JC2-4 RD
JC2-3 OR
JC2-5 BK
JC2-2 BRN
JC1-5 YEL
JC3-3 OR
JC3-5 WH
JC3-4 BL *
JC3-2 BRN
TS15 BL/WH
TS15 B BL/BK
RD/BK-L48
TS14 RD/WH
DRE LED BL/RD
BRN
C134PWR RD LS18
BRN
Part No. 77828
S-60 • S-65
6 - 27
1
OPT.
OPTION
F.S.
19/18 CONTROL CABLE
H1
TILT
ALARM
11
LS18
(CE)
12V DC BATTERY
D39
9
JIB
BOOM
C9
+
C4P
C4P
5
C7P
C7P
C7P
BATGRN C7P-3
C1P
C28TTA RD/BK C1P-2
C7P
7
BRN
6
CWLITE BK
BRN
4
3
U13
ALC-500
Y
PLATFORM
CONTROL
HARNESS
(TO SWITCH
PANEL)
CE LIFT/DRIVE OPTION
J2
J1
2
1
J3
CR27
CR30
N
M
L
K
J
I
H
G
F
E
D
C
B
A
* NOTE:
WIRE CONNECTS TO JC3-6
FOR STEER ROCKER SWITCH OPTION.
CWLITE WH TS49
3
BRN
BRN
1
July 2005
Section 6 • Schematics
Ford LRG-425 EFI Models
BK C1P-12
July 2005
REV A
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-60
Ford LRG-425 EFI Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
PLATFORM CONTROL
HARNESS
(TO CONTROL BOX)
2
DRIVE LIGHTS/
WORK LIGHTS
(OPTION)
JC2
PRIMARY BOOM
UP/DOWN
& TURNTABLE ROTATE
LEFT/RIGHT
DLITE RD
RD
JC1
7
7
BOOM
EXTEND/RETRACT
6
3
BRN
3
2
+
2
4
3
L4
PLATFORM
OVERLOAD
(CE OPTION)
+
2
BRN
1
1
L1
DRIVE
ENABLE
BK
BRN
BRN
BK
BRN
BRN
BK
F18 FUSE 10A
(WORKLIGHT ONLY)
C28TTA RD/BK H1C133PLA GR/BK D39
BK
NOTE: DASHED LINES INDICATE OPTION WIRES
BOOM PROPORTIONAL JOYSTICK:
BOOM UP/DOWN , TURNTABLE ROTATE
JC1
BOOM PROPORTIONAL JOYSTICK:
BOOM EXTEND/RETRACT
JC3
L1
L4
L47
L48
P2
P3
TS1
TS2
TS3
TS4
DRIVE/STEER PROPORTIONAL JOYSTICK
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
LOWER/RETRACT BOOM LED
BOOM TILTED LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
HI/LOW RPM TOGGLE SWITCH
TS7
TS9
TS14
TS15
TS47
TS48
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)
P22BAT BK C7P-1
P26BAT BK J3-3
RD
RD
TS7
PLATFORM
ROTATE
P23BAT WH C7P-2
P26BAT BK C9-1
RD-H1+
C134PWR RD L48+
C134PWR RD L4+
C39LP BL/RD C2P-1
PDLITE RD
BK TS15
WH
WH J1-4
BL J1-5
OR J1-13
BRN J1-14
BK
BRN
C35RPM BK/RD C1P-9
P24FS WH C9-2
C33STR BK C1P-7
P25FS RD C9-3
BK
C45GEN GR/WH C2P-7
C29MS RD/WH J1-8
WH CR30
C27AUX RD C1P-1
C17PRL GR C4P-5
WH CR27
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
3
4
NO
TS3
FUEL SELECT
1
DRIVE
SPEED
TS9
PLATFORM
LEVEL
JC2
3
4
5
6
WH
D12
P3
HORN
RD
C134PWR RD E-STOP
C134PWR RD E-STOP
BK
BL/RD-DE3 J1-16
BL-DE1 J1-6
BL/BK-DE2 J1-7
YL J1-3
OR J1-9
BRN J1-10
WLITE WH
DLITE OR/RD C2P-4
C59CNK BL/BK C3P-11
WLITE WH
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C46HRN GR C2P-5
WH
RD
+
BRN
BL J1-5 (ROCKER SWITCH OPTION ONLY)
L47
RETRACT
BOOM
COMPONENT INDEX
6
RD
4
BK
4
7
5
BK
5
DRIVE
FORWARD/REVERSE
& STEER
LEFT/RIGHT
L48
BK
5
1
TS15
DRIVE
ENABLE
6
TS48/
TS49
JC3
TILT ALARM LED
(ANSI/CSA OPTION)
+
BK
TS1
AUXILIARY
PUMP
1
7
1
NC NC NC
TS14
HIGH/LOW
(2WD/4WD)
TS2
ENGINE
START
TS47
GENERATOR
(OPTION)
TS4
HIGH/LOW
RPM
2
2
2
P2
EMERGENCY
STOP
D11
BK
WH
RD
RD
RD
8
CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30
Part No. 77828
S-60 • S-65
6 - 28
July 2005
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-60
Ford LRG-425 EFI Models
P134PWR RD
RD
RD
C7P-1
RD
ENGINE
SPEED
GENERATOR
DRIVELIGHT
WH
WH
WORKLIGHT
FUEL
SELECT
C41RPM OR/BK
ENGINE
START
C2B-6
D12
C1P-9
C2P-7
C2P-4
C2P-1
C1P-7
C1P-1
C7P-2
C1P-2
BK C2P-5
H1
C7B-1
AUXILIARY
PUMP
C28TTA RD/BK
WH
RD
P22BAT BK
P134PWR GR/BK
C2P-6
C35RPM BK/RD
C1B-9
C2B-7
FUNCTION ENABLE
C45GEN GR/WH
C2B-4
HIGH RPM
LOW RPM
DLITE OR/RD
BK
BK
C39LP BL/RD
FUEL
SELECT
C33STR BK
ENGINE
START
C2B-1
C2B-3
C1B-7
AUXILIARY
PUMP
C27AUX RD
P23BAT WH
C28TTA RD/BK
C46HRN GR
C1P-1
C7B-2
C1P-2
C2B-5
BL/WH
C21IGN WH
C5-19
C5-11
C5-9
C5-10
C5-18
C5-2
C5-5
C5-12
C25PSR WH/BK
C26TSR WH/RD
RD
RD
C45GEN GR/WH
BR
P23BAT WH FEH(16) PIN1
C21IGN WH FEH(71) PIN21
C128RPM OR/RD FEH(306) PIN24
C108ESL BL/WH FEH(658) PIN6
C127TSW GR FEH(458) PIN18
C39LP BL/RD FEH(72) PIN7
C35RPM BK/RD FEH(307A) PIN23
P20BAT RD FEH(361) PIN9
(GND) BR FEH(570) PIN34
C41RPM OR/BK FEH(11) PIN2
BK
C6-9
C5-4
C5-1
BRN
BRN
BK
R33STR BK FEH(32) PIN15
C33STR BK FEH(32) PIN13
BL/WH FEH(787A) PIN5
R46HRN BK
P134FB WH
RD
WH
C135FP BL/WH
C33STR BK
C27AUX RD
C28TTA RD/BK
P134TTS RD
C46HRN GR
P22HRN BK
R21IGN WH
C116 OR
510
NO
M2
G1
P116HYD RD
C107AF WH
H2
SW3
M1 FAN
OIL PRESSURE
SENDER (OPTION)
VOLT METER (OPTION)
WATER TEMPERATURE
SENDER (OPTION)
HYDRAULIC
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
HOUR METER
CHECK ENGINE LED
RUN/TEST SWITCH
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
FLASHING
BEACONS OPTION
HORN RELAY
HORN
HYDRAULIC OIL
TEMPERATURE SWITCH
(OPTION)
COOLING FAN
(OPTION)
Part No. 77828
S-60 • S-65
+
6 - 29
C
FORD 42 PIN
QUICK DISCONNECT
L29
L29
HM
_
M4
D14
RD
G2
G3
L2
C5-3
8
+
FUEL
PUMP
STARTER
AUX
PUMP
FB1
B1
S8
TB46R
I
P26ESTP BK
P22LS BK
C7B-4
FLD.
R6
S
7
P20BAT RD
REGULATOR
A
12V DC
CR23
NO
C5-8 GR
C5-13 BL/WH
NO
B
A
STA.
PR1
CR17
85
87a 87
CR5
NO
86
30
GND.
CR2
FUSE
10A
BAT.
LINK
C21IGN WH
TB21
C21IGN WH
TB35
CR2
NO
TS64
ALTERNATOR
FUSE
6
TB33
CR39
CR1
NO
TB39
BL/RD
RD
CR39
NC
TB24
P24BAT RD
RD
D13
TB20
5
TB27
TB23
TB46
TB45
TB134
CB3
15A
D4
TS53
TS4
TS47
TS48
TS49
TS3
TS54
D10
TS52
PLATFORM
BOX GROUND
D2
TB41
CB1
15A
D3
4
RD
RD
TS51
L30
PLAT
TS1
L30
P1
3
RD
15A
TB134
TB22
CB2
L48
P3
WH(FS)
BK(FS)
FUSE 10A
P24FS WH
RD
WH
P25FS RD
P24FS WH
C9P-3
C9P-2
RD(FS)
FS1
C9P-1 BK
P2
D11
TS2
2
C28TTA RD/BK
1. ALL LIMIT SWITCHES SHOWN WITH BOOM
IN STOWED POSITION.
C1B & C1P - GRAY; C2B & C2P - BLACK;
2
C3B & C3P - GREEN; C4B & C4P - BROWN.
N
M
L
K
J
I
H
G
F
E
D
C
B
A
P22LS BK
P134PWR RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
NOTES:
1
July 2005
Section 6 • Schematics
REV B
Electrical Schematic, S-65
Ford LRG-425 EFI Models (before serial number 11880)
KS1
GRND
C35RPM BK/RD
-
Electrical Schematic, S-65
REV B
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
BL
WH
OR
BRN
BK
RD
OR
BRN
15
8
16
7
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
CDE1 BL/WH
RIGHT
7
YOUT 5
RKOUT 6
4
PWR 3
1
3
YEL
OR
BRN
1
2
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
C3P-4
C3P-6
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-5
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
TURNTABLE ROTATE
C5TRR WH/BK
PRIMARY BOOM
C4B-4
BOOM
C118LSR OR/RD
J1 F.H. WH
WH
C4B-1
C11-2
C13DE BL/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C4P-4
C4P-1
C2P-2
C40LS OR
C14PLU OR
C59CNK BL/BK
P22LS BK
C4P-2
C15PLD OR/BK
C3P-11
C4P-3
C3B-2
C3B-1
C3B-3
C3B-9
C3B-7
C3B-8
TB5
C4B-2
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-3
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
BK
BK
RD
C25-2
C28-2
C26-2
RD
C28-1
C25-1
C24-2
C15-2
C31-2
C14-2
C31-1
C12-2
C15-1
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C14-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
3
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
7
U4
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
JIB VALVE
6 - 30
S-60 • S-65
Part No. 77828
GND 2
7
6
PWR
2
XOUT 4
YOUT 5
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
3
4
4
P134 RD
PLATFROM LEVEL
C4B-5
C4B-6
PLATFROM LEVEL
C3B-10
PLATFROM
ROTATE
14
2
TB22
CR34
4
C129 RD/BK
BK
BK
BRN
1
14
21
LS17
NC
HO 22
H4
TB59
LS17
NO
HC
13
LS3
NO
NC
13
14
22
LS1
NO
HC
TB36
TB4
TB6
TB3
6
21 LS5
NC
13
LS5
13
NO
14
TB30
TB31
TB32
TB29
TB37
TB2
2
P26ESTP BK
DOWN
UP
UP
C129JDA BL
LEFT
RIGHT
DOWN
C3P-10
C18JD/PRR GR/BK
C17JU/PRL GR
C4P-6
C4P-5
PLATFROM
ROTATE
DOWN JIB
UP
BOOM
LEFT
C4B-7
D29
R4
5
R14
5
C19JSV GR/WH
TB15
14
TB14
TB18
TB13
TB1
TB7
TB8
LS2
NO
NC
13
R16
10
TB19
TB9
D30
5
TB17
CR34
TB134
TB44
TB40
3
C4P-7
TS58
TB118
D28
TS62
TS61
TS63
TS59
L46
H3
RIGHT
JIB VALVE
C19JSV GR/WH
D9
RD
RD
J1
J1
J1
J1
J3
CR30
NO
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
1
C28TTA RD/BK
4
TS57
L47
TS14
TS15
JC3
L1
WH
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS8
TS7
CR27
NC
CR13
NC
CR13
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Ford LRG-425 EFI Models (before serial number 11880)
BRN
July 2005
Section 6 • Schematics
Electrical Schematic, S-65
Ford LRG-425 EFI Models (before serial number 11880)
P134PWR RD
RD
RD
C7P-1
ENGINE
SPEED
C1P-9
C2P-7
C2P-4
C2P-1
C1P-7
C1P-1
C7P-2
C1P-2
BK C2P-5
C35RPM BK/RD
C1B-9
C2B-7
FUNCTION ENABLE
C45GEN GR/WH
C2B-4
HIGH RPM
LOW RPM
DLITE OR/RD
BK
BK
C39LP BL/RD
FUEL
SELECT
C33STR BK
ENGINE
START
C2B-1
C2B-3
C1B-7
AUXILIARY
PUMP
C27AUX RD
P23BAT WH
C28TTA RD/BK
C46HRN GR
C1P-1
C7B-2
C1P-2
C2B-5
BL/WH
C21IGN WH
C5-19
C5-11
C5-9
C5-10
C5-18
C5-2
C5-5
C5-12
C25PSR WH/BK
C26TSR WH/RD
RD
RD
C45GEN GR/WH
BR
P23BAT WH FEH(16) PIN1
C21IGN WH FEH(71) PIN21
C128RPM OR/RD FEH(306) PIN24
C108ESL BL/WH FEH(658) PIN6
C127TSW GR FEH(458) PIN18
C39LP BL/RD FEH(72) PIN7
C35RPM BK/RD FEH(307A) PIN23
WH
RD
R21IGN WH
R46HRN BK
P134FB WH
BK
C6-9
C5-4
C5-1
BRN
BRN
BK
R33STR BK FEH(32) PIN15
C33STR BK FEH(32) PIN13
BL/WH FEH(787A) PIN5
P20BAT RD FEH(361) PIN9
(GND) BR FEH(570) PIN34
C41RPM OR/BK FEH(11) PIN2
C135FP BL/WH
C33STR BK
C27AUX RD
C28TTA RD/BK
P134TTS RD
C46HRN GR
P22HRN BK
+
GENERATOR
DRIVELIGHT
WH
WH
WORKLIGHT
FUEL
SELECT
C41RPM OR/BK
ENGINE
START
D12
H1
C7B-1
AUXILIARY
PUMP
C28TTA RD/BK
WH
RD
P22BAT BK
C2B-6
C116 OR
510
NO
RD
P134PWR GR/BK
C2P-6
P116HYD RD
C107AF WH
H2
SW3
M1 FAN
OIL PRESSURE
SENDER (OPTION)
VOLT METER (OPTION)
WATER TEMPERATURE
SENDER (OPTION)
HYDRAULIC
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
HOUR METER
CHECK ENGINE LED
RUN/TEST SWITCH
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
SPEED REDUCTION RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
FLASHING
BEACONS OPTION
HORN RELAY
HORN
HYDRAULIC OIL
TEMPERATURE SWITCH
(OPTION)
COOLING FAN
(OPTION)
Part No. 77828
S-60 • S-65
+
6 - 31
C
FORD 42 PIN
QUICK DISCONNECT
L29
L29
HM
_
M4
M2
CR19
FUEL
PUMP
STARTER
AUX
PUMP
FB1
B1
S8
TB46R
I
R6
S
7
CR17
G1
C5-3
FLD.
P26ESTP BK
P22LS BK
C7B-4
8
P20BAT RD
REGULATOR
A
12V DC
CR23
NO
C5-8 GR
C5-13 BL/WH
NO
B
A
STA.
PR1
CR5
NO
86
30
GND.
85
87a 87
FUSE
10A
BAT.
LINK
6
D14
RD
G2
G3
L2
TS64
ALTERNATOR
FUSE
CR2
CR2
NO
C21IGN WH
TB21
C21IGN WH
TB35
CR39
CR1
NO
TB39
TB33
CR39
NC
TB24
P24BAT RD
RD
TB20
5
TS53
D13
TB45
TB134
CB3
15A
TB27
TB23
TB46
BL/RD
RD
CB1
15A
D4
FUSE 10A
TS54
D10
TS52
PLATFORM
BOX GROUND
TB41
D2
D3
4
RD
RD
TS51
L30
P1
3
TS4
TS47
TS48
TS49
TS3
TS2
L30
PLAT
RD
15A
TB134
TB22
CB2
L48
P3
WH(FS)
BK(FS)
C9P-1 BK
TS1
P24FS WH
RD
WH
P25FS RD
P24FS WH
C9P-3
C9P-2
RD(FS)
FS1
P2
D11
2
C28TTA RD/BK
1. ALL LIMIT SWITCHES SHOWN WITH BOOM
IN STOWED POSITION.
C1B & C1P - GRAY; C2B & C2P - BLACK;
2
C3B & C3P - GREEN; C4B & C4P - BROWN.
N
M
L
K
J
I
H
G
F
E
D
C
B
A
P22LS BK
P134PWR RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
NOTES:
1
July 2005
Section 6 • Schematics
REV A
Electrical Schematic, S-65
Ford LRG-425 EFI Models (after serial number 11879)
KS1
GRND
C35RPM BK/RD
-
Electrical Schematic, S-65
REV A
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
3
BL
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
CDE1 BL/WH
RIGHT
7
4
YOUT 5
RKOUT 6
PWR 3
GND 2
1
7
6
PWR
2
XOUT 4
YOUT 5
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
3
4
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C3P-4
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
C3B-5
TURNTABLE ROTATE
PRIMARY BOOM
BOOM
C4B-4
J1 F.H. WH
WH
C4B-1
C11-2
C40LS OR
C14PLU OR
C59CNK BL/BK
P22LS BK
C4P-2
C15PLD OR/BK
C3P-11
C13DE BL/RD
C118LSR OR/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C5TRR WH/BK
C3P-6
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-7
C3P-8
C4P-4
C4P-1
C2P-2
P134 RD
PLATFROM LEVEL
C4P-3
C3B-2
C3B-1
C3B-3
C3B-9
C3B-7
C3B-8
TB5
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
C4B-5
C4B-6
PLATFROM LEVEL
C3B-10
PLATFROM
ROTATE
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
BK
BK
RD
C25-2
C28-2
C26-2
RD
C28-1
C25-1
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
C129 RD/BK
3
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
JIB VALVE
6 - 32
S-60 • S-65
Part No. 77828
7
U4
2
TB22
CR34
4
14
2
P26ESTP BK
UP
DOWN
UP
C18JD/PRR GR/BK
C129JDA BL
LEFT
RIGHT
DOWN
C4P-6
C17JU/PRL GR
C3P-10
C4P-5
PLATFROM
ROTATE
DOWN JIB
UP
BOOM
LEFT
C4B-7
BK
BK
BRN
1
14
21
LS17
NC
HO 22
TB30
TB31
TB32
TB29
TB36
TB4
TB6
TB3
H4
TB59
LS17
NO
HC
13
LS3
NO
HC
13
14
22
LS2
NO
HC
NO
14
R2
6
21 LS5
NC
13
LS5
13
R4
7.5
TB37
TB2
14
TB14
TB18
L46
H3
RIGHT
C19JSV GR/WH
D29
TB1
TB7
TB8
LS1
NO
HC
TB15
TB9
D30
5
TB17
R14
5
TS14
TS15
3
C4P-7
TB19
13
R16
10
TB13
CR19
TB134
TS62
TS61
TS63
5
CR34
TB44
TB40
D9
RD
RD
J1
J1
J1
J1
1
C28TTA RD/BK
4
TS58
TB118
D28
CE
LIFT/
DRIVE
OPTION
C19JSV GR/WH
TS59
J2
U13 JOYSTICK CONTROL CARD
D27
J3
CR30
NO
JIB VALVE
TS57
L47
L1
WH
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS8
TS7
CR27
NC
CR13
NC
CR13
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Ford LRG-425 EFI Models (after serial number 11879)
BRN
July 2005
Section 6 • Schematics
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, S-65
Ford LRG-425 EFI Models (before serial number 11880)
8
6 - 33
BK-33C
RD-24C
S-60 • S-65
BK C5-5
NOTE: DASHED LINES INDICATE OPTION WIRES
WH-TB21 OPTIONS
FUSE 10A
(DRIVE LIGHT ONLY)
Part No. 77828
WH-23C
A
WH C10-2
BRN
BRN C37-2
OR-LS17 C38-2
OR/RD-LS17 C38-3
C108ESL BL/WH C5-13
C45GEN GR/WH C2B-7
R46HRN BK
C118LSR OR/RD C4B-4
C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
L
ENGINE
FUNCTIONS
HARNESS
C5
D29
C9 (LS3)
C11 (LS2)
LS17 (C38)
Ground Control Box Terminal Strip Wiring Diagram, S-65
M
GROUND BOLT
B
45
46R
118
132
133
134
GENERATOR OPTION
HORN RELAY POWER
LIFT SPEED REDUCTION
PLATFORM OVERLOAD LS
PLATFORM OVERLOAD ALARM
C59CNK BL/BK C3B-11
C59CNK BL/BK-LS5 C37-4
P134PWR GR/BK C2B-6
P134PWR RD-LS17 C38-1
P134PWR BK-LS5 C37-3
P134TTS RD A
BRN-GND
45
46R
118
132
133
134
134 PLAT. OVERLOAD LIM. SW. +12V DC (2)
59
46
+12V DC
POWER
K
OR-CR34
OR/RD-118B
BL/WH-L2-
HORN
RETRACT BOOM LED
134 PLAT. OVERLOAD LIM. SW. +12V DC (1)
59
46
40
41
BOOM STOWED
ALTERNATOR PULSE PICKUP
40
41
39
C34SA BK/WH C1B-8
C35RPM BK/RD C1B-9
C35RPM BK/RD C5-18
C36SCC BL C1B-10
C36SCC BL C24-1
C37SCW BL/BK C1B-11
C37SCW BL/BK C25-1
C39LP BL/RD C2B-1
C39LP BL/RD C5-10
C40LS1 OR C2B-2
C40LS1 OR C10-2
C41RPM OR/BK C2B-3
C41RPM OR/BK C5-2
C46HRN GR C2B-5
C37
GR/WH C5-12
BK-CR5
OR/RD-FH C38-3
36
37
LIQUID PROPANE FUEL (LPG)
STEER LEFT
STEER RIGHT
36
37
35
39
HIGH FUNCTION SPEED
(UNUSED)
34
35
33
34
ENGINE START
33
#1
C5
#2
F.H.
P134FB WH-FH
RD-KS
31
32
BRAKE
32
P20BAT RD
BRN
J
BL/BK-L46+
DRIVE FORWARD
30
C27AUX RD C1B-1
C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C32BRK WH/RD C5-23
C33STR BK C1B-7
C11
GR-CR5
30
MOTOR STROKE
29
26
I
BL/RD-TS53
RD-TS54
29
TILT ALARM
28
DRIVE REVERSE
28
AUXILARY PUMP
27
31
27
(UNUSED)
26
H
WH/RD-ALRM
BK-CR1#86
BK-TS52
RD-CR39#86
RD-TS51
RD-CR2#86
CABLE
TENSION
LIMIT SWITCH
C37 (LS5)
BOOM
EXTEND
LIMIT SWITCH
C11 (LS1)
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12 V DC
POWER TO
PLATFORM
C7
TS64
RUN/TEST
SWITCH
G
25
(UNUSED)
24
23
22
25
23
CIRCUIT BREAKER POWER
22
21
22
P20BAT RD
P20BAT RD
C128RPM OR/RD C5-9
C21IGN2 WH C5-3
P22BAT BK C7B-1
P22LS17 BK C38-4
P22BAT BK C11-1
P22BAT BK C9-2
P23BAT WH C7B-2
C5
#2
F.H.
24
+12 V DC TO PLATFORM (2)
KEY SWITCH POWER
22
20
#1
RD-CB1
IGNITION POWER
+12 V DC TO PLATFORM (1)
21
18
19
BRN
C5-8 GR
F
WH-CR39#30
WH-KS
WH-CR2#87
WH-HM
BK-CR5
BK-KS
+12 V DC POWER
20
15
17
F.H.
JIB SELECT VALVE
PLATFORM ROTATE RIGHT/JIB DOWN
PLATFORM ROTATE LEFT/JIB BOOM UP
14
13
44
#2
19
18
17
15 PLATFORM LEVEL DOWN
14 PLATFORM LEVEL UP
8
9
C1PBU RD C3B-1
C1PBU RD C12-1
C2PBD RD/BK C3B-2
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C6TRF WH/RD C31-1
C7PBE BK C3B-7
C7PBE RD-LS5 C37-1
C8PBR BK/WH C3B-8
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
C9PER BK/RD C30-1
JDALARM BL C3B-10
RD/BK-ALARM
C13DE BL/RD C4B-1
C13DE BL/RD C10-1
C14PLU OR C4B-2
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C15PLD OR/BK C21-1
C17JU GR C4B-5
C17JU GR C22-1
C18JD GR/BK C4B-6
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
C5
GR/WH-TS57
RD-CB2
GR/BK-TS57
JIB DOWN DESCENT ALARM
13 DRIVE ENABLE
44
PRIMARY BOOM RETRACT
PRIM. BOOM EXT/RET FLOW CONTROL
6
7
A
#1
GR-TS57
8
9
TURNTABLE ROTATE FLOW CONTROL
PRIMARY BOOM EXTEND
5
4
3
2
B
E
OR/BK-TS59
OR-TS59
BL-TS58
BK/RD-TS63
6
7
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM FUNCTION CONTROL
PRIMARY BOOM DOWN
1
D
BK/WH-TS63
BK-TS63
WH/RD-TS62
5
4
3
2
TERMINAL BASE (TB)
PRIMARY BOOM UP
2
WH/BK-TS62
BRN
1
1
RD/WH-R16
BK-22C1
C
HYDRAULIC OIL
COOLER OPTION
C21IGN WH
OR C5-1
C
WH-TS62
D
RD-24B
RD-CB3
WH-C5-19
RD-TS61
RD/BK-ALARM
RD/BK-TS61
RD-27C
C2B-4 OR/RD
WH-C5-11
DRIVE LIGHT
OPTION RELAY
CR17
3
GR-46D
WH-OPTIONS
R43DLITE1 RD
R43DLITE2 RD
CR23
WH C5-4
B
BRN
WH-21C
CR5
F.H.
CR39
4
HORN
RELAY
BK-46R
C5
CR2
AUXILIARY
POWER RELAY
A
GROUND HARNESS
TO SWITCH PANEL
7
POWER RELAY
6
BRN
BRN
5
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV A
Ford LRG-425 EFI Models (before serial number 11880)
N
F.H.
BRN-TS64
BRN C7B-3
BK C16-1
WH LS2 C11-2
C5
#2
F.H.
D30
July 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Ford LRG-425 EFI Models (before serial number 11880)
H
G
F
E
RD
C19JSV GR/WH
TS59
PLATFORM
LEVEL
GR
GR/WH-19D
OR/BK-15D
RD
OR-14D
4
CIRCUIT
BREAKER
CONTROLS 15A
RD-24D
BK/RD-35D
RD-20D
GR-17D
GR/BK-18D
NOTE:
DASHED LINES INDICATE
OPTION WIRES
RD-20C
RD-20C
CB2
RD
RD-20C
RD/WH
RD
RD-20D
RD-24D
CB1
RD
BRN
FUNCTION
ENABLE
RD
RD
D14
RD
D13
2
TS54
2
CIRCUIT
BREAKER
ENGINE 15A
TS52
ENGINE
START
1
NC
H.M.
HOUR METER
1
RD
WH-21D
BRN
BRN
P1
EMERGENCY
STOP
RD/WH-R16
RD/WH-TS61
RD/WH-R16
OR-LS17
CR34
PRIMARY BOOM
SPEED REDUCTION
RELAY
DALE RH-25 25W
5 ohm 1%
RD
RD
BRN
RD
PRIMARY UP/DOWN
RESISTOR
R14
RD
RD
NC
2
3
OR
RD
A
TS58
JIB BOOM
UP/DOWN
CIRCUIT
BREAKER
OPTIONS 15A
RD CR17
CB3
TS53
FUEL
SELECT
RD/WH
WH-23
RD-20C
BK-33D
BL-44D
WH-4D
WH/BK-5D
WH/RD-6D
BK-7D
RD-1D
BK/RD-9D
BK/WH-8D
BL/RD-39D
RD
-
GR
RD
4
+
TS63
BOOM EXTEND/
RETRACT
RD
RD/BK-2D
GR/BK-H6BK/RD C5-13
BRN-GND
RD/WH-CR34
BRN
L46 +
LOWER/
RETRACT BOOM
L2
CHECK
ENGINE
WH-21D
B1
2
WH-23D
BL/BK-59D
C134PWR RD
RD-134D2
BK-22D1
1
B
D2
3
KS1
KEY SWITCH
WH
RD/WH-TB3D
RD
D28
GR/BK
WH
RD-27
WH
RD-27D
OR-LS17
DALE RH-25 25W
10 ohm 1%
PRIMARY BOOM
UPPER ZONE
RESISTOR
R16
RD
GR-17D
RD
RD
RD
B
RD
D4
RD
RD
RD
TURNTABLE ROTATE
RESISTOR
R4
RD
RD
RD
DALE RH-25 25W
5 ohm 1%
WH-4
WH/BK-5
WH/RD-6
RD
RD/WH
RD
RD-1
RD/WH
RD
RD
RD
D3
TS51
AUXILIARY
POWER
RD/BK-2
GR/BK
-
+
RD
WH
C
1
D9
RD
RD
D
GROUND CONTROL BOX HARNESS
(TO TERMINAL STRIP)
I
TS57
PLATFORM
ROTATE
J
GR/BK
GR/BK-18D
K
TS62
TURNTABLE
ROTATE
L
TS61
PRIMARY
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
RD
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR5
CR17
CR23
CR34
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
BOOM SPEED REDUCTION RELAY
CR39
HM
KS1
L2
L46
L45
P1
R4
R14
R16
TS51
TS52
TS53
TS54
AUXILIARY POWER RELAY
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
FUNCTION ENABLE TOGGLE SWITCH
5
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
TS57
PLATFORM ROTATE TOGGLE SWITCH
TS58
TS59
TS61
TS62
TS63
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
TS64
RUN/TEST TOGGLE SWITCH
6
7
8
6 - 34
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Ford LRG-425 EFI Models (before serial number 11880)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-65
Ford LRG-425 EFI Models (after serial number 11879)
6 - 35
8
S-60 • S-65
WH-OPTIONS
FUSE 10A
(DRIVE LIGHT ONLY)
WH-TB21 OPTIONS
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
BK-33C
RD/WH-TS61
RD/WH-R16
WH/RD-R2
WH/RD-R4
BK-46R
PLATFORM OVERLOAD ALARM
133
D29
OR/RD-LS17 C38-3
D30
C108ESL BL/WH C5-13
A
C133PLA BL/WH C3B-12
C132PLI BL/WH C1B-12
C118LSR OR/RD C4B-4
BRN C37-2
BL/WH -L2-
133
132
R46HRN BK
WH C11-2
GROUND BOLT
PLATFORM OVERLOAD LS
132
118
FUNCTION
HARNESS
LS17 (C38)
L
C11 (LS2)
C9 (LS3)
K
OR/RD-118B
B
LIFT SPEED REDUCTION
118
C45GEN GR/WH C2B-7
+12V POWER
C5
ENGINE
OR/RD-FH C38-3
45
F.H.
46R
F.H.
HORN RELAY POWER
#2
F.H.
GENERATOR OPTION
P134TTS RD A
#2
46R
134
C5
45
LOAD WEIGHING LIM. SW. +12V (2)
P134PWR RD-LS17 C38-1
P134PWR BK-LS5 C37-3
C5
#2
BK-CR5
134
134
P134PWR GR/BK C2B-6
C59CNK BL/BK-LS5 C37-4
C59CNK BL/BK C3B-11
BRN-GND
GR/WH C5-12
LOAD WEIGHING LIM. SW. +12V (1)
134
59
46
C46HRN GR C2B-5
C41RPM OR/BK C5-2
C41RPM OR/BK C2B-3
C40LS1 OR C10-2
C40LS1 OR C2B-2
C39LP BL/RD C5-10
C39LP BL/RD C2B-1
C37SCW BL/BK C25-1
C37SCW BL/BK C1B-11
C36SCC BL C24-1
C36SCC BL C1B-10
C35RPM BK/RD C5-18
C35RPM BK/RD C1B-9
C34SA BK/WH C1B-8
C37
RD-KS
P134FB WH-FH
SERVICE HORN
RETRACT BOOM LED
59
46
41
C32BRK WH/RD C5-23
C33STR BK C1B-7
BRN
P20BAT RD
J
BL/BK-L46+
ALTERNATOR PULS PICKUP
41
40
39
37
36
35
34
33
32
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C11
GR-CR5
LIQUID PROPANE FUEL
BOOM STOWED
STEER RIGHT
37
40
STEER LEFT
36
39
HIGH FUNCTION SPEED
(UNUSED)
34
35
START ENGINE
33
BRAKE
31
C31REV WH/BK C1B-5
C30FWD WH C5-21
C30FWD WH C1B-4
C29MS RD/WH C5-24
C29MS RD/WH C1B-3
C28TTA RD/BK B
C28TTA RD/BK C1B-2
C27AUX RD PR1
C27AUX RD C1B-1
RD-CR2 #86
P23BAT WH C7B-2
CABLE
TENSION
LIMIT SWITCH
C37 (LS5)
I
BL/RD TS53
RD-TS54
BK-TS52
32
PROPEL REVERSE
31
P22LS17 BK C38-4
P22BAT BK C9-2
P22BAT BK C11-1
H
BK-CR1 #86
WH/RD-ALRM
30
MOTOR STROKE
29
PROPEL FORWARD
29
TILT ALARM
28
30
28
AUXILARY PUMP
27
C21IGN2 WH C5-3
P22BAT BK C7B-1
#1
27
26
(UNUSED)
26
P20BAT RD
P20BAT RD
C128RPM OR/RD C5-9
2
RD-TS51
25
(UNUSED)
25
24
23
22
22
21
CIRCUIT BREAKER POWER
RD/WH-3D
24
KEYSWITCH POWER
+12 VOLT TO PLATFORM (2)
22
23
+12 VOLT TO PLATFORM (1)
IGNITION POWER
22
21
20
BOOM
EXTEND
LIMIT SWITCH
C11 (LS1)
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12 VOLT
POWER TO
PLATFORM
C7
TS64
RUN/TEST
SWITCH
G
RD-CR19#86
RD-CB1
WH-KS
WH-CR39 #30
BK-KS
BK-CR5
+12 VOLT POWER
20
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
C5-8 GR
BRN
F
WH-HM
WH-CR2 #87
RD-CB2
19
18
C18JD GR/BK C4B-6
C17JU GR C22-1
C17JU GR C4B-5
F.H.
JIB SELECT VALVE
PLATFORM ROTATE RIGHT/JIB DOWN
15
17
C15PLD OR/BK C21-1
C15PLD OR/BK C4B-3
C14PLU OR C20-1
C14PLU OR C4B-2
C13DE BL/RD C10-1
C13DE BL/RD C4B-1
RD/BK-ALARM
JDALARM BL C3B-10
C9PER BK/RD C30-1
C9PER BK/RD C3B-9
C8PBR BK/WH C17-1
C8PBR BK/WH C3B-8
C7PBE RD-LS5 C37-1
C7PBE BK C3B-7
C6TRF WH/RD C31-1
C6TRF WH/RD C3B-6
C5TRR WH/BK C14-1
C5TRR WH/BK C3B-5
C4TRL WH C15-1
C4TRL WH C3B-4
C3PBF RD/WH C29-1
C3PBF RD/WH C3B-3
C2PBD RD/BK C13-1
C2PBD RD/BK C3B-2
C1PBU RD C12-1
C1PBU RD C3B-1
#2
19
18
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL DOWN
A
C5
GR/WH-TS57
GR/BK-TS57
15
17
14
13
44
9
8
7
6
5
4
3
2
B
#1
GR-TS57
PLATFORM LEVEL UP
DRIVE ENABLE
14
JIB DOWN DESCENT ALARM
13
PRIM. BOOM EXT/RET FUNC. CTRL
PRIMARY BOOM RETRACT
44
9
8
PRIMARY BOOM EXTEND
TURNTABLE ROTATE FUNCTION CTRL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
PRIMARY BOOM FUNCTION CONTROL
PRIMARY BOOM DOWN
1
E
OR/BK-TS59
OR-TS59
BL-TS58
BK/RD-TS63
7
6
5
4
3
2
TERMINAL BASE (TB)
PRIMARY BOOM UP
D
BK/WH-TS63
BK-TS63
WH/RD-CR19
WH/BK-TS62
BK-22C1
WH-TS62
GR-46D
OR-LS17 C38-2
C21IGN WH
OR C5-1
WH C5-4
1
RD/WH-CR34
BK C5-5
C
RD/BK-TS61
WH/RD-6D
1
RD-27C
C
C2B-4 OR/RD
RD/BK-ALARM
BRN
RD-CB3
R43DLITE2 RD
RD/WH-TS61
R43DLITE1 RD
CR17
HYDRAULIC
OIL COOLER
OPTION
BRN
D
RD-24B
RD-TS61
BRN
RD/WH-R16
CR4
AUXILIARY
POWER RELAY
WH/RD-R4
WH-C5-19
CR34
PRIMARY BOOM
SPEED
REDUCTION
RELAY
WH-OPTIONS
WH/RD-R2
WH-C5-11
BRN
F.H.
CR23
DRIVE LIGHT
OPTION
B
GROUND HARNESS
TO SWITCH PANEL
7
WH-21C
CR19
SWING SPEED
SELECT
RELAY
BRN
WH-23C
CR5
HORN
RELAY
5
C32
C5
BRN
A
C32
6
RD
CR2
POWER
RELAY
4
WH-ISM9
BRN
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-65
REV A
Ford LRG-425 EFI Models (after serial number 11879)
M
N
F.H.
BRN
BK C16-1
BRN-TS64
BRN C7B-3
WH LS2 C10-2
#1
C5
3
July 2005
Section 6 • Schematics
REV A
Ground Control Box Switch Panel Wiring Diagram, S-65
Ford LRG-425 EFI Models (after serial number 11879)
F
E
RD
RD
D
RD/WH
GR/BK
WH/RD
WH/RD
GR/BK
D28
RD
RD
C19JSV GR/WH
RD-24D
BK/RD-35D
4
RD-20C
CIRCUIT
BREAKER
CONTROLS 15A
RD-20C
CB2
5
RD
RD
RD
RD/WH
TS59
PLATFORM
GR/WH-19D LEVEL
RD-20D
GR-17D
GR/BK-18D
TS58
JIB BOOM
UP/DOWN
CIRCUIT
BREAKER
OPTIONS 15A
CB3
TS53
FUEL
SELECT
WH-23
RD-20C
RD CR22
RD CR17
BL-44D
WH-4D
WH/BK-5D
BK-7D
RD-1D
RD/WH-CR34#87a
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD
BL/RD-39D
RD/WH
RD/BK-2D
GR/BK-H6-
BRN
BRN-GND
BK/RD C5-13
L46
+
LOWER/
RETRACT BOOM
+
4
RD/WH
D2
-
B1
2
L2
CHECK
ENGINE
WH-21D
WH-23D
BL/BK-59D
C134PWR RD
RD-134D2
BK-22D1
1
B
3
KS1
KEY
SWITCH
WH
RD
RD/WH
3
RD
WH
RD-27
WH
RD-27D
WH/RD CR34#87
WH/RD CR19#87
WH/RD CR19#87a
DALE RH-25 25W
7.5 ohm 1%
R4
TURNTABLE
ROTATE
RESISTOR
R2
TURNTABLE
ROTATE
RESISTOR
GR
RD
RD
WH/RD
WH/RD
RD-24D
RD-20D
CB1
CIRCUIT
BREAKER
ENGINE 15A
TS52
ENGINE
START
RD
WH-21D
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
DALE RH-25 25W
5 ohm 1%
DALE RH-25 25W
10 ohm 1%
BRN
2
RD
RD
D14
TS54
FUNCTION
ENABLE
2
RD
D13
1
NC
HOUR METER
1
NC
RD
P1
EMERGENCY
STOP SWITCH
RD
R14
BOOM
UP/DOWN
RESISTOR
RD
BRN
DALE RH-25 25W
5 ohm 1%
RD
RD
RD
2
GR
WH/RD
WH/RD
A
WH/RD
BK-33D
WH/RD
WH
GR/BK
GR/BK-18D
RD
RD/WH
RD
RD
D4
RD
WH-4
WH/BK-5
+
TS51
AUXILIARY
POWER
D3
RD
RD
RD
RD-1
-
RD
B
1
RD
RD/BK-2
C
BASE BOX HARNESS
(TO TERMINAL STRIP)
G
TS57
PLATFORM
ROTATE
H
GR-17D
I
OR/BK-15D
RD
OR-14D
J
TS62
TURNTABLE
ROTATE
K
D9
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
HM
KS1
L2
L46
L45
P1
R2
R4
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 7.5 OHMS
R14
R16
TS51
TS52
TS53
TS54
TS56
TS57
TS58
TS59
TS61
TS62
TS63
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
6
7
8
6 - 36
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Ford LRG-425 EFI Models (after serial number 11879)
Section 6 • Schematics
July 2005
Platform Control Box Wiring Diagram, S-65
Ford LRG-425 EFI Models
REV A
Platform Control Box Wiring Diagram, S-65
Y
Y
C2P
CWLITE WH TS49
TILT ALARM
12V DC PLATFORM POWER CONNECTOR
FOOT SWITCH CONNECTOR
48 PIN CONNECTOR BLOCK
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
U13
J1
J2
J3
CR27
CR30
LS18
WH
Y
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
GR/BK C133TTA C3P-12
GR/BK-L4- (CE)
RD/BK-L48- (NON-CE)
C134PWR RD C2P-6
RD-TILT
DESCRIPTION
H1
C7P
C9
C1P-C4P
BK
C134PWR RD LS18
JIB
JIB
C19JSV GR/WH TS7
C19JSV GR/WH C4P-7
BRN JC3
BRN GND
RD-E-STOP
C134PWR RD-H1+
C32BRK WH/RD C1P-6
C32BRK WH/RD J2-19
C40LS OR C2P-2
C40LS OR J2-4
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129DA BL C3P-10 TS8
C46HRN GR C2P-5
C59CNK BL/BK C3P-11 L47+
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
CDLITE OR/RD C2P-4
C45GEN GR/WH C2P-7
C46HRN GR C2P-5
C39LP BL/RD C2P-1
C118LSR OR/RD C4P-4
C6TRF WH/RD C3P-6
C7PBE BK C3P-7
C13DE BL/RD C4P-1
C8PBR BK/WH C3P-8
C40LSS OR C2P-2
C9PER BK/RD C3P-9
C41RPM OR/BK C2P-3
C30FWD WH C1P-4
C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36SCC BL C1P-10
C3PBF RD/WH C3P-3
C37SCW BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C35RPM BK/RD C1P-9
C33STR BK C1P-7
C27AUX RD C1P-1
BRN
RD LS18 CABLE
F.S.
Y
C28TTA RD/BK C1P-2
C3P
C3P
TS7 WH
TS1 WH
P26ESTP BK
P24FS WH
P24FS WH
BRN
JC1-3 OR
JC1-2 BRN
JC2-4 RD
JC2-3 OR
JC2-5 BK
JC2-2 BRN
JC1-5 YEL
JC3-3 OR
JC3-5 WH
JC3-4 BL *
JC3-2 BRN
TS15 BL/WH
TS15 B BL/BK
DRE LED BL/RD
TS14 RD/WH
RD/BK-L48
C134PWR RD LS18
BRN
Part No. 77828
S-60 • S-65
6 - 37
1
ITEM
8
OPTION
F.S.
19/18 CONTROL CABLE
H1
TILT
ALARM
1
OPT.
12V DC BATTERY
D39
11
LS18
(CE)
C9
+
9
JIB
BOOM
C7P
7
CWLITE BK
BRN
6
C4P
C4P
5
C7P
C7P
C7P
BATGRN C7P-3
C1P
C28TTA RD/BK C1P-2
BRN
Y
4
3
U13
ALC-500
Y
PLATFORM
CONTROL
HARNESS
(TO SWITCH
PANEL)
CE LIFT/DRIVE OPTION
J2
J1
2
1
J3
CR27
CR30
N
M
L
K
J
I
H
G
F
E
D
C
B
A
* NOTE:
WIRE CONNECTS TO JC3-6
FOR STEER ROCKER SWITCH OPTION.
CWLITE WH TS49
3
BRN
BRN
1
July 2005
Section 6 • Schematics
Ford LRG-425 EFI Models
BK C1P-12
July 2005
REV A
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-65
Ford LRG-425 EFI Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
PLATFORM CONTROL
HARNESS
(TO CONTROL BOX)
DRIVE LIGHTS/
WORK LIGHTS
(OPTION)
JC2
PRIMARY BOOM
UP/DOWN
& TURNTABLE ROTATE
LEFT/RIGHT
DLITE RD
BK
JC1
7
7
BOOM
EXTEND/RETRACT
6
2
+
BRN
1
3
4
3
L4
PLATFORM
OVERLOAD
(CE OPTION)
+
2
BRN
2
1
1
+
L1
DRIVE
ENABLE
BK
BRN
BRN
BRN
BK
F18 FUSE 10A
(WORKLIGHT ONLY)
C28TTA RD/BK H1C133PLA GR/BK D39
BK
JIB BOOM CUT OUT RELAY
JC2
BOOM PROPORTIONAL JOYSTICK:
BOOM UP/DOWN , TURNTABLE ROTATE
JC1
BOOM PROPORTIONAL JOYSTICK:
BOOM EXTEND/RETRACT
JC3
L1
L4
L47
L48
P2
P3
TS1
TS2
TS3
TS4
DRIVE/STEER PROPORTIONAL JOYSTICK
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
LOWER/RETRACT BOOM LED
BOOM TILTED LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUEL SELECT TOGGLE SWITCH
HI/LOW RPM TOGGLE SWITCH
TS7
TS8
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
TS9
TS14
TS15
TS47
TS48
PLATFORM LEVEL TOGGLE SWITCH
DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)
P22BAT BK C7P-1
P26BAT BK J3-3
BK TS15
RD
TS8
JIB
BOOM
WH
GR/BK
RD
P23BAT WH C7P-2
P26BAT BK C9-1
RD-H1+
C134PWR RD L48+
C134PWR RD L4+
C39LP BL/RD C2P-1
PDLITE RD
1
DRIVE
SPEED
TS7
PLATFORM
ROTATE
WH J1-4
BL J1-5
OR J1-13
BRN J1-14
BK
BRN
C35RPM BK/RD C1P-9
P24FS WH C9-2
C33STR BK C1P-7
P25FS RD C9-3
BK
C45GEN GR/WH C2P-7
C29MS RD/WH J1-8
WH CR30
C27AUX RD C1P-1
C129JDA BL C3P-10
WH-JIB
C17PRL GR C4P-5
C19JSV GR/WH
WH CR27
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
3
4
NO
TS3
FUEL SELECT
GR
TS9
PLATFORM
LEVEL
CR13
3
4
5
6
WH
D12
P3
HORN
RD
C134PWR RD E-STOP
C134PWR RD E-STOP
BK
BL/RD-DE3 J1-16
BL-DE1 J1-6
BL/BK-DE2 J1-7
YL J1-3
OR J1-9
BRN J1-10
WH-JIB
WLITE WH
DLITE OR/RD C2P-4
C59CNK BL/BK C3P-11
WLITE WH
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
C14PLU OR C4P-2
P24FS WH
C15PLD OR/BK C4P-3
C46HRN GR C2P-5
WH
BK
BRN
BRN
BL J1-5 (ROCKER SWITCH OPTION ONLY)
CR13
RD
L47
RETRACT
BOOM
COMPONENT INDEX
6
RD
4
BK
4
7
5
BK
5
JC3
DRIVE
FORWARD/REVERSE
& STEER
LEFT/RIGHT
L48
BK
5
BRN
TS15
DRIVE
ENABLE
6
TS48/
TS49
3
2
RD
TILT ALARM LED
(ANSI/CSA OPTION)
+
D27
TS1
AUXILIARY
PUMP
1
7
1
NC NC NC
TS14
HIGH/LOW
(2WD/4WD)
TS2
ENGINE
START
TS47
GENERATOR
(OPTION)
TS4
HIGH/LOW
RPM
2
2
2
P2
EMERGENCY
STOP
D11
BK
WH
RD
RD
RD
8
NOTE: DASHED LINES INDICATE OPTION WIRES
CE LIFT/DRIVE OPTION, REPLACE WIRE WITH CR27 & CR30
Part No. 77828
S-60 • S-65
6 - 38
July 2005
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-65
Ford LRG-425 EFI Models
C1P-12
FUSE 10A
RD/BK
C7P-1
C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
FOOTSW. LOW
C1P-9
C3P-12
C2P-5
C7B-1
REV C
Electrical Schematic, S-60
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C7B-2
C1B-2
C3B-12
C2B-5
C1B-8
C3B-12
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
AUXILIARY
PUMP
P23BAT WH
WH
C133PLA BL/WH
C28TTA RD/BK
RD
RD
C46HRN GR
RD
BK
C27AUX RD C1B-1
ENGINE
START
C1B-7
DLITE BL/WH
PBOX GND
FOOTSW. HIGH
C2P-7
C3P-12
C1P-2
C7P-2
C1P-1
C1P-7
C1P-8
LIGHTS
C2P-11
C2P-12
WORK LIGHT
DRIVE LIGHT
GLOW
PLUG
ENGINE
START
AUX
PUMP
RD/BK
C2B-6
C1B-12
P22BAT BK
C132PLI BL/WH
P134PWR GR/BK
GR/BK
C35RPM BK/RD
C45GEN GR/WH
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
C5-12
C5-22
RD
RD
C5-18
C5-14
C5-16
C5-11
F.H. BK
R116 OR
R21IGN WH
RD
WH
BK/RD
C5-5
P134FB WH
C21IGN WH
P22BAT BK
CR4
P116HYD RD
C5-2
C5-4
C5-1
BRN
Q3
L29
SW3
NO
L29
SW2
CR23
C41RPM OR/BK
BK
H2
P24FS WH
C2P-6
RD
C2B-3
C21IGN WH
P20BAT RD
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
OIL TEMPERATURE LED
OIL TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
HM
M2
AUX
PUMP
REGULATOR
Part No. 77828
S-60 • S-65
-
6 - 39
C7B-4
8
NO
FAN
M1
_
NC
C
SW3
IND.
+
M3
PR2
NO
PR2
PR2
NO
S8
STARTER
B2
FB1
7
BK
C41RPM OR/BK
RD
EXCT.
NO
STA.
PR1
+
12V DC
85
87a 87
ALTERNATOR
D1
6
BAT.
BAT.
B
A
NO
NO
CR5
CR23
CR4
NO
TB26
TB25
CR17
CR2
NO
NO
RD
FUSE
10A
86
OIL
TEMP.
TB46
5
30
D22
TB21
TB21
C5-3
TB45
L43
U1
TB35
C3
+
CR1
15A
D13
TB34
TB24
RD
CR2
TB134
3MF
CB3
TB23
TB41
TB33
TB27
WH
D3
D14
CB1
7
U33
TB28
TB133
15A
6
D2
D4
8
C32-8
12
4
GRD
TS4
TS47
TS48
TS54
TS56
TS52
TS51
5
4
PLAT
3
1
TB22
KS1
D12
D40
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB20
RD
P1
H1
L30
TB132
RD
RD
15AMP.
3
L48
L30
Platform
Overload
Option
Only
ENGINE
SPEED
RD
RD
TS1
P3
TS6
TS2
2
FS1
RD
P25FS RD
P24FS WH
C9P-3
C9P-2
RD-(FS)
WH-(FS)
BK-(FS)
C9P-1 BK
P2
C22LS BK
C28TTA RD/BK
C28TTA RD/BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
CB2
July 2005
Section 6 • Schematics
Deutz F3L-2011 Models (before serial number 11880)
+
Electrical Schematic, S-60
REV C
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
15
8
16
7
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
BRN
OR
RD
BK
OR
BRN
BL
WH
BL
CDE1 BL/WH
RIGHT
7
YOUT 5
RKOUT 6
4
PWR 3
3
YEL
OR
BRN
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
C3P-4
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
C3B-5
TURNTABLE ROTATE
PRIMARY BOOM
C4B-4
BOOM
C118LSR OR/RD
J1 F.H. WH
WH
C4B-1
C14PLU OR
C15PLD OR/BK
UP
DOWN
C3B-2
C3B-1
C3B-3
C3B-9
C3B-7
C3B-8
C4B-2
C38-1
TB5
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-3
C4B-5
C4B-6
PLATFROM LEVEL
C59CNK BL/BK
P22LS BK
C40LS OR
C11-2
C13DE BL/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C5TRR WH/BK
C3P-6
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-7
C3P-8
C4P-4
C4P-1
C2P-2
C3P-11
C4P-2
C4P-3
C17JU/PRL GR
C18JD/PRR GR/BK
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
RD
BK
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C24-2
C15-2
C31-2
C14-2
C31-1
C12-2
C15-1
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C14-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
3
7
U4
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
6 - 40
S-60 • S-65
Part No. 77828
GND 2
1
7
6
PWR
2
XOUT 4
YOUT 5
GND
1
7
6
4
OUT 5
PWR 3
1
1
2
3
4
4
P134 RD
PLATFROM LEVEL
C4P-6
PLATFROM ROTATE
PLATFROM
ROTATE
14
GND 2
BRN
P24FS WH
P24FS WH
P26ESTP BK
UP
DOWN
LEFT
RIGHT
C4P-5
RIGHT
LEFT
LS17
NO
HC
14
2
TB22
CR34
4
C129 RD/BK
BK
BK
BRN
1
14
13
LS3
NO
NC
13
21
LS17
NC
HO 22
22
LS1
NO
HC
H4
TB59
6
21 LS5
NC
13
LS5
13
NO
14
TB4
TB6
TS14
TS15
TB30
TB36
TB9
14
L1
TB31
TB32
TB29
TB37
TB2
TB14
TB18
TB3
D30
TB1
TB7
TB8
LS2
NO
NC
TB40
R16
10
TB13
1
C28TTA RD/BK
5
TB17
CR34
TB134
TS62
TS61
TS63
TS59
TB118
D28
L46
H3
D9
4
TS57
13
TB15
R4
5
R14
5
J1
J1
J1
J1
J3
CR30
NO
3
RD
RD
L47
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
2
CR27
NC
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS7
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Deutz F3L-2011 Models (before serial number 11880)
D29
July 2005
Section 6 • Schematics
Electrical Schematic, S-60
Deutz F3L-2011 Models (before serial number 11880)
P24FS WH
P25FS RD
P24FS WH
C1P-12
C2P-6
FUSE 10A
RD/BK
C7P-1
C22LS BK
C28TTA RD/BK
1
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
FOOTSW. LOW
C1P-9
C3P-12
C2P-5
C7B-1
REV A
Electrical Schematic, S-60
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C1B-8
C3B-12
C2B-5
C3B-12
C1B-2
C7B-2
RD
BK
C1B-7
DLITE BL/WH
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD C1B-1
AUXILIARY
PUMP
P23BAT WH
WH
C133PLA BL/WH
C28TTA RD/BK
RD
RD
C46HRN GR
GR/BK
C35RPM BK/RD
C45GEN GR/WH
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
F.H. C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
P22BAT BK
BK/RD
C5-5
P134FB WH
C5-12
RD
RD
C5-18
C5-11
C5-16
C5-14
C5-22
WH
RD
F.H. BK
R21IGN WH
C5-4
C5-1
BRN
Q3
FOOTSW. HIGH
C2P-7
C3P-12
C1P-2
C7P-2
C1P-1
C1P-7
C1P-8
LIGHTS
C2P-11
C2P-12
WORK LIGHT
DRIVE LIGHT
GLOW
PLUG
ENGINE
START
AUX
PUMP
RD/BK
C2B-6
C1B-12
P22BAT BK
C132PLI BL/WH
P134PWR GR/BK
C21IGN WH
R116 OR
NO
L29
L29
SW3
NO
L43
CR4
P116HYD RD
C5-2
BK
H2
CR23
C41RPM OR/BK
C21IGN WH
P20BAT RD
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
GLOW PLUG RELAY
GLOW PLUG
OIL TEMPERATURE LED
OIL TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
EMISSIOIN CONTROL
SPEED REDUCTION RELAY
AUXILIARY POWER RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
HM
M2
AUX
PUMP
REGULATOR
Part No. 77828
S-60 • S-65
-
6 - 41
RD
C2B-3
C7B-4
8
NO
_
SW2
SW3
FAN
+
M3
NC
C
M1
S8
STARTER
B2
FB1
IND.
7
NO
-
BAT.
BK
C41RPM OR/BK
RD
EXCT.
PR2
PR2
NO
PR2
PR1
BAT.
+
12V DC
ALTERNATOR
D1
STA.
FUSE 70A
87a 87
85
CR17
CR19
B
A
NO
NO
CR5
CR23
CR4
NO
TB26
6
NO
NO
RD
TB25
86
CR2
TB46
FUSE
10A
30
D22
TB21
TB21
C5-3
TB45
OIL
TEMP.
CR1
15A
D13
TB34
TB24
RD
U1
TB35
C3
+
TB23
TB41
TB33
TB27
WH
D3
D14
CB1
PBOX GND
4
7
U33
D2
D4
8
C32-8
12
CR2
TB134
3MF
CB3
5
6
TB28
TB133
15A
GRD
TS4
TS47
TS48
TS54
TS56
TS52
TS51
5
4
PLAT
3
1
TB22
KS1
D12
D40
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB20
RD
H1
L30
TB132
RD
RD
15AMP.
3
L48
L30
Platform
Overload
Option
Only
ENGINE
SPEED
RD
RD
TS1
P3
TS6
TS2
2
FS1
RD
C9P-3
C9P-2
RD-(FS)
WH-(FS)
BK-(FS)
C9P-1 BK
P2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
P1
CB2
July 2005
Section 6 • Schematics
Deutz F3L-2011 Models (after serial number 11879)
+
Electrical Schematic, S-60
REV A
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
3
BL
CDE1 BL/WH
RIGHT
7
RKOUT 6
4
YOUT 5
PWR 3
GND 2
1
7
6
YOUT 5
PWR
2
XOUT 4
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
3
4
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C3P-4
C3P-6
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
LEFT
UP
DOWN
C1PBU RD
PRIMARY BOOM
C2PBD RD/BK
C3PBF RD/WH
C9PER BK/RD
C8PBR BK/WH
C7PBE BK
EXTEND
BOOM
C4B-4
RETRACT
C118LSR OR/RD
J1 F.H. WH
WH
C4B-1
C11-2
C14PLU OR
C15PLD OR/BK
C3B-1
C3B-3
C3B-2
C3B-9
C3B-8
C3B-7
C38-1
TB5
TB30
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
C4B-5
C4B-6
PLATFROM LEVEL
C59CNK BL/BK
P22LS BK
C40LS OR
C13DE BL/RD
C3P-11
C4P-2
UP
DOWN
C18JD/PRR GR/BK
C4P-3
TURNTABLE ROTATE
C3B-5
P134 RD
PLATFROM LEVEL
C4P-6
PLATFROM ROTATE
RIGHT
C5TRR WH/BK
C2P-2
C4P-1
C4P-4
C3P-7
C3P-8
C3P-9
C3P-3
C3P-2
C3P-1
C3P-5
D9
C17JU/PRL GR
PLATFROM
ROTATE
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
RD
BK
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
7
U4
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
6 - 42
S-60 • S-65
Part No. 77828
3
TB22
CR34
P24FS WH
P26ESTP BK
DOWN
UP
LEFT
RIGHT
C4P-5
RIGHT
LEFT
C129 RD/BK
BK
BK
BRN
2
L46
H3
6
4
14
TS14
TS15
1
14
H4
TB59
LS17
NO
HC
13
LS3
NO
HC
13
21
LS17
NC
HO 22
22
LS2
NO
HC
NO
14
14
21 LS5
NC
13
LS5
13
TB4
TB6
L1
TB31
TB32
TB29
TB36
TB9
14
R16
10
TB37
TB2
TB14
TB18
TB3
D30
TB1
TB7
TB8
LS1
NO
HC
TB40
R4
7.5
R2
5
1
C28TTA RD/BK
5
TB17
TB118
D28
TB13
CR19
CR34
TB134
TS62
TS61
TS63
TS59
13
TB15
R14
5
4
TS57
J1
J1
J1
J1
J3
CR30
NO
3
RD
RD
L47
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
2
CR27
NC
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS7
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Deutz F3L-2011 Models (after serial number 11879)
D29
July 2005
Section 6 • Schematics
Electrical Schematic, S-60
Deutz F3L-2011 Models (after serial number 11879)
C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
FOOTSW. LOW
C1P-9
C2P-7
C3P-12
C1P-7
C1P-1
C7P-2
C1P-2
C3P-12
C2P-5
C7B-1
REV C
Electrical Schematic, S-60, CE Models
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C7B-2
C1B-2
C3B-12
C2B-5
C1B-8
C3B-12
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
AUXILIARY
PUMP
P23BAT WH
WH
C28TTA RD/BK
C133PLA BL/WH
C46HRN GR
RD
BK
C27AUX RD C1B-1
ENGINE
START
C1B-7
DLITE BL/WH
PBOX GND
FOOTSW. HIGH
C1B-12
C1P-8
LIGHTS
C2P-11
C2P-12
WORK LIGHT
DRIVE LIGHT
GLOW
PLUG
ENGINE
START
AUX
PUMP
GR/BK
C132PLI BL/WH
P22BAT BK
C1P-12
D14
GR/BK
C35RPM BK/RD
C45GEN GR/WH
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
P22BAT BK
C5-2
C5-12
C5-22
RD
RD
C5-18
C5-14
C5-16
C5-11
F.H. BK
R116 OR
R21IGN WH
RD
WH
BK/RD
C5-5
C21IGN WH
P134FB WH
P116HYD RD
C41RPM OR/BK
C21IGN WH
P20BAT RD
C5-4
C5-1
BRN
Q3
L29
L29
SW3
NO
CR23
ENGINE
SPEED
C2B-6
C7P-1
RD/BK
FUSE 10A
P134PWR GR/BK
RD
C2B-3
C7B-4
BK
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
OIL TEMPERATURE LED
OIL TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
HM
M2
H2
Part No. 77828
S-60 • S-65
6 - 43
NO
SW2
SW3
FAN
_
NC
C
FB1
IND.
+
M3
AUX
PUMP
REGULATOR
NO
S8
STARTER
B2
PR2
NO
PR2
PR2
NO
STA.
PR1
+
12V DC
BK
C41RPM OR/BK
RD
8
EXCT.
M1
7
D1
L43
CR4
CR17
85
87a 87
ALTERNATOR
6
BAT.
BAT.
B
A
NO
NO
CR5
CR23
CR4
NO
TB26
TB25
86
CR2
NO
NO
RD
TB35
TB134
FUSE
10A
30
D22
TB21
TB21
C5-3
TB45
OIL
TEMP.
15A
D13
TB34
TB24
RD
CR2
CR1
5
D4
U1
C3
+
TB46
3MF
CB3
TB33
TB27
WH
TS52
TS51
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB23
TB41
TB28
15A
7
D2
4
D3
U33
TB133
CB1
TS54
TS56
6
GRD
8
C32-8
12
RD
RD
5
4
PLAT
3
1
TB22
KS1
L45
H6
TB20
RD
D39
L30
L30
TB132
RD
RD
15AMP.
D12
D40
P24FS WH
C2P-6
2
Platform
Overload
Option
Only
3
H1
L4
TS4
TS47
TS48
TS6
TS2
RD
RD
TS1
1
P3
FS1
RD
P25FS RD
P24FS WH
C9P-3
C9P-2
RD-(FS)
WH-(FS)
BK-(FS)
LS18
C9P-1 BK
P2
NC
C22LS BK
C28TTA RD/BK
C28TTA RD/BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
P1
CB2
July 2005
Section 6 • Schematics
Deutz F3L-2011 Models (before serial number 11880)
+
-
Electrical Schematic, S-60, CE Models
REV C
C28TTA RD/BK
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
3
BL
CDE1 BL/WH
RIGHT
7
RKOUT 6
YOUT 5
4
PWR 3
1
GND 2
7
6
YOUT 5
PWR
XOUT 4
2
1
GND
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
3
DOWN
UP
RIGHT
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C7P-3
C41RPM OR/BK
BATGND
C7B-3
C1B-6
C2B-3
C32BRK WH/RD
C1B-3
C2P-3
C1P-6
C29MS RD/WH
C1B-11
C1B-4
C1P-3
C37SCW BL/BK
C1B-10
C1B-5
C1P-11
C36STCC BL
C3B-6
C31REV WH/BK
C1P-10
C6TRF WH/RD
C3B-4
C30FWD WH
C3P-6
C4TRL WH
C1P-4
C3P-4
LEFT
UP
DOWN
C1PBU RD
PRIMARY BOOM
C2PBD RD/BK
C3PBF RD/WH
C9PER BK/RD
C8PBR BK/WH
C7PBE BK
EXTEND
BOOM
C4B-4
RETRACT
C118LSR OR/RD
J1 F.H. WH
WH
C4B-1
C11-2
C14PLU OR
C15PLD OR/BK
UP
DOWN
C3B-1
C3B-3
C3B-2
C3B-9
C3B-8
C3B-7
C4B-2
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-3
C4B-5
C4B-6
PLATFROM LEVEL
C59CNK BL/BK
P22LS BK
C40LS OR
C13DE BL/RD
C3P-11
C4P-2
C17JU/PRL GR
C18JD/PRR GR/BK
C4P-3
TURNTABLE ROTATE
C3B-5
P134 RD
PLATFROM LEVEL
C4P-6
RIGHT
C5TRR WH/BK
C2P-2
C4P-1
C4P-4
C3P-7
C3P-8
C3P-9
C3P-3
C3P-2
C3P-1
C3P-5
C1P-5
3
PLATFROM ROTATE
C4P-5
RIGHT
PLATFROM
ROTATE
RD
BK
C10-1
C5-21
C5-20
C5-23
C5-24
RD
C31REV WH/BK
C30FWD WH
RD
BK
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
BK
WH
WH
C26-1
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
C37-4
BL/BK
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
U4
GROUND
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
8
DESCENT ALARM OPTION
6 - 44
S-60 • S-65
3
7
2
TB22
CR34
14
Part No. 77828
4
C129 RD/BK
BK
BK
BRN
1
14
TB36
TB4
TB6
H4
TB59
LS17
NO
HC
13
LS3
NO
NC
TB2
6
14
22
LS1
NO
HC
NO
14
13
21
LS17
NC
HO 22
21 LS5
NC
13
LS5
13
TB30
TB9
L1
TB31
TB32
TB29
TB37
14
TB3
D30
TS62
TS61
5
TB5
TB40
R16
10
TB13
TB1
TB7
TB8
13
TB15
CR34
TB134
LS2
NO
NC
TB14
TB18
R4
5
R14
5
TS14
TS15
4
LEFT
TB17
CE
LIFT/
DRIVE
OPTION
J1
J1
J1
J1
J3
CR30
NO
TS63
TS59
TB118
D28
L47
LEFT
TS57
L46
H3
D9
RD
RD
P26ESTP BK
CR27
NC
J2
U13 JOYSTICK CONTROL CARD
D27
2
3
TS9
TS7
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
1
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Deutz F3L-2011 Models (before serial number 11880)
D29
July 2005
Section 6 • Schematics
Electrical Schematic, S-60, CE Models
Deutz F3L-2011 Models (before serial number 11880)
C41RPM OR/BK
C1P-9
C2P-7
C3P-12
C1P-7
C1P-1
C7P-2
C1P-2
C3P-12
C2P-5
C7B-1
REV A
Electrical Schematic, S-60, CE Models
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C1B-8
C3B-12
C2B-5
C3B-12
C1B-2
C7B-2
RD
BK
C1B-7
DLITE BL/WH
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD C1B-1
AUXILIARY
PUMP
P23BAT WH
WH
C28TTA RD/BK
C133PLA BL/WH
C46HRN GR
D14
GR/BK
C35RPM BK/RD
C45GEN GR/WH
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
F.H. C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
BK/RD
C5-5
P134FB WH
C21IGN WH
C41RPM OR/BK
P116HYD RD
P22BAT BK
NO
FOOTSW. LOW
C1B-12
C1P-8
LIGHTS
C2P-11
GR/BK
C132PLI BL/WH
P22BAT BK
C1P-12
C2B-6
PBOX GND
FOOTSW. HIGH
GLOW
PLUG
ENGINE
START
AUX
PUMP
C2P-12
WORK LIGHT
DRIVE LIGHT
ENGINE
SPEED
P134PWR GR/BK
C7P-1
RD/BK
FUSE 10A
C2P-6
RD
C2B-3
C21IGN WH
P20BAT RD
C5-12
RD
RD
C5-18
C5-11
C5-16
C5-14
C5-22
WH
RD
F.H. BK
R21IGN WH
R116 OR
C5-2
C5-4
C5-1
BK
BRN
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
GLOW PLUG RELAY
GLOW PLUG
OIL TEMPERATURE LED
OIL TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
EMISSION CONTROL
SPEED REDUCTION RELAY
AUXILIARY POWER RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
CR4
CR4
CR23
CR23
Q3
L29
SW3
NO
L29
SW2
_
M2
H2
Part No. 77828
S-60 • S-65
-
6 - 45
C7B-4
8
NO
FAN
M1
7
HM
M3
STARTER
NC
C
FB1
SW3
IND.
AUX
PUMP
REGULATOR
NO
+
B2
PR2
PR2
NO
PR2
PR1
-
BAT.
BK
C41RPM OR/BK
RD
EXCT.
NO
STA.
CR19
D1
6
BAT.
+
12V DC
85
87a 87
ALTERNATOR
S8
FUSE 70A
B
A
NO
NO
CR5
CR17
CR1
TB26
TB25
86
TB35
TB134
FUSE
10A
30
D22
TB21
CR2
NO
NO
RD
L43
U1
CR2
3MF
CB3
C3
+
TB46
5
RD
15A
TB21
C5-3
TB45
OIL
TEMP.
15A
D13
TB34
TB24
TB28
TB20
TB33
TB27
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB23
TB41
D4
12
D2
WH
D3
7
U33
TB133
L45
H6
CB1
TS54
TS52
TS51
D12
D40
TS56
6
GRD
8
C32-8
4
RD
RD
5
4
PLAT
3
1
TB22
KS1
L30
L30
TB132
RD
RD
15AMP.
D39
TS4
TS47
TS48
TS6
TS2
2
Platform
Overload
Option
Only
3
H1
L4
P24FS WH
P25FS RD
P24FS WH
C9P-3
C9P-2
P2
RD
RD
TS1
1
P3
FS1
RD
RD-(FS)
WH-(FS)
BK-(FS)
C9P-1 BK
LS18
C41RPM OR/BK
P26ESTP BK
P26ESTP BK
NC
C22LS BK
C28TTA RD/BK
C28TTA RD/BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
RD
P1
CB2
July 2005
Section 6 • Schematics
Deutz F3L-2011 Models (after serial number 11879)
+
Electrical Schematic, S-60, CE Models
REV A
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
3
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
3
BL
CDE1 BL/WH
RIGHT
7
RKOUT 6
4
YOUT 5
PWR 3
GND 2
1
7
6
YOUT 5
PWR
2
XOUT 4
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
P26ESTP BK
DOWN
UP
LEFT
RIGHT
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C3P-4
C3P-6
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C5TRR WH/BK
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-5
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
TURNTABLE ROTATE
PRIMARY BOOM
BOOM
C4B-4
J1 F.H. WH
WH
C4B-1
C11-2
C40LS OR
C3B-1
C3B-3
C3B-2
C3B-9
C3B-8
C3B-7
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
C4B-6
PLATFROM LEVEL
C59CNK BL/BK
P22LS BK
C14PLU OR
C15PLD OR/BK
UP
DOWN
C18JD/PRR GR/BK
C4P-3
C4P-2
C3P-11
C13DE BL/RD
C118LSR OR/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C4P-4
C4P-1
C2P-2
P134 RD
PLATFROM LEVEL
C4P-6
PLATFROM ROTATE
C4B-5
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
RD
BK
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
3
7
U4
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
6 - 46
S-60 • S-65
Part No. 77828
2
TB22
CR34
14
R14
5
C17JU/PRL GR
PLATFROM
ROTATE
C129 RD/BK
BK
BK
BRN
4
6
1
14
21
LS17
NC
HO 22
TB4
TB6
H4
TB59
LS17
NO
HC
13
LS3
NO
HC
13
14
22
LS2
NO
HC
NO
14
TB36
TB9
14
21 LS5
NC
13
LS5
13
TB30
TB31
TB32
TB29
TB37
TB2
TB14
TB18
TB3
D30
TB5
TB40
L1
3
C4P-5
RIGHT
LEFT
TB17
R4
7.5
R2
5
TS14
TS15
5
TB1
TB7
TB8
LS1
NO
HC
13
TB15
TB13
CR19
CR34
TB134
R16
10
TB118
D28
TS62
TS61
TS63
TS59
J1
J1
J1
J1
J3
CR30
NO
1
C28TTA RD/BK
4
TS57
L46
H3
D9
RD
RD
L47
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
2
CR27
NC
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS7
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Deutz F3L-2011 Models (before serial number 11879)
D29
July 2005
Section 6 • Schematics
Electrical Schematic, S-60, CE Models
Deutz F3L-2011 Models (after serial number 11879)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-60
Deutz F3L-2011 Models (before serial number 11880)
6 - 47
7
BK C5-5
BK
WH
S-60 • S-65
BK
WH
8
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
BK
WH
+ C3
ENGINE START
GLOW PLUG
HIGH FUNCTION SPEED
STEER RIGHT
STEER LEFT
(UNUSED)
BOOM STOWED
33
34
35
36
37
39
40
BRN
BK
WH
D33
4 7 10 9 2
START RELAY
TACHOMETER
U1
START INPUT
AUX PWR UNIT
GROUND
BATTERY
TO KEY SW (DIESEL ONLY)
JUMP TO 7 (GAS ONLY)
IGN OR FUEL ON
TEMP OR PRESS FAULT
OR-LS17 C38-2
OR/RD-LS17 C38-3
C45GEN GR/WH C2B-7
R46HRN BK
C118BSR OR/RD C4B-4
C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
C59CNK BL/BK C3B-11
C59CNK WH-LS5 C37-4
C134PWR GR/BK C2B-6
C134PWR RD-LS17 C38-1
C134PWR BK-LS5 C37-3
P134TTSR RD A
Ground Control Box Terminal Strip Wiring Diagram, S-60
M
GROUND BOLT
12/24 Volt IGNITON/START MODULE P/N 56057
1 3
1
2
3
4
5
6
7
8
9
10
A
D30
TO REMOVE:
45
46R
118
132
133
134
134
59
H6
CE ONLY
Push gently
and lift
41
46
C40LS1 OR C2B-2
C40LS1 OR C10-2
C41RPM OR/BK C2B-3
C41RPM OR/BK C5-2
C46HRN GR C2B-5
C36STCC BL C1B-10
C36STCC BL C24-1
C37STC BL/BK C1B-11
C37STC BL/BK C25-1
C39LP BL/RD C2B-1
C34SA BK/WH C1B-8
C34SA BK/WH C5-22
C35HS BK/RD C1B-9
WH C11-2
Genie Industries
GENERATOR OPTION
HORN RELAY POWER
LIFT SPEED REDUCTION
PLATFORM OVERLOAD LS
PLATFORM OVERLOAD ALARM
PLAT. OVERLOAD LIM. SW. +12V (2)
45
46R
118
132
133
PLAT. OVERLOAD LIM. SW. +12V (1)
134
RETRACT BOOM LED
HORN
134
59
46
40
39
37
36
35
32
L
WH-CR2
WH/BK-25D
BRAKE
32
BRN
BRN C37-2
1
2
3
4
5
6
7
8
9
10
DRIVE REVERSE
31
+12V DC
POWER
ENGINE
BK-CR1
OR/BK-41C
BK-33C
RD-27C
BRN
RD-24C
WH-23C
B
DRIVE FORWARD
30
P20BAT RD
BRN
K
OR-CR34
OR/RD-118B
33
34
MOTOR STROKE
29
C37
GR/WH C5-12
BK-CR5
OR/RD-FH C38-3
BL/WH C32-3
GR/BK-H6-
RD-H6+
P134FB WH-FH
RD-KS
31
TILT ALARM
28
CABLE
TENSION
LIMIT SWITCH
LS5
J
WH-L46+
D52
ALTERNATOR PULSE PICKUP
30
AUXILARY PUMP
27
#1
C5
#2
F.H.
41
29
OIL TEMPERATURE SWITCH
26
C5
#2
F.H.
C26PSR WH/RD C5-14
C27AUX RD C1B-1
C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C32BRK WH/RD C5-23
C33STR BK C1B-7
C25TSR WH/BK C5-16
RD-CR2
C11
GR-CR5
28
OIL PRESSURE SWITCH
25
24
#1
I
OR/BK-ISM2
BRN-GND
27
CIRCUIT BREAKER POWER
24
23
22
+
BK/WH-TS56
BK/RD-CR4
RD-TS54
26
KEY SWITCH POWER
C22LS17 BK C10-2
P22BAT BK C11-1
P22BAT BK C9-2
P23BAT WH C7B-2
H
WH/RD-ALRM
BK-ISM3
BK-TS52
25
+12V DC TO PLATFORM (2)
22
23
22
P20BAT RD
P20BAT RD
C21IGN WH CR2
C21IGN2 WH C5-11
G
WH/RD-L2RD-ISM4
RD-TS51
+12V DC TO PLATFORM (1)
22
21
IGNITION POWER
21
20
P134PWR RD-134C
GR/BK-133B
GR/BK-L45
WH/BK-ISM10
D29
+12V DC POWER
#2
20
BOOM
EXTEND
LIMIT SWITCH
LS1
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12V DC
POWER TO
PLATFORM
C7
F
BK C32-4
WH-ISM7
WH-KS
RD-ISM6
RD-CB1
JIB BOOM SELECT VALVE
19
C5
19
18
PLATFORM ROTATE RIGHT/JIB DOWN
18
15
17
PLATFORM LEVEL DOWN
C1PBU RD C3B-1
C1PBU RD C12-1
C2PBD RD/BK C3B-2
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C6TRF WH/RD C31-1
C7PBE BK C3B-7
C7PBE RD-LS5 C37-1
C8PBR BK/WH C3B-8
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
C9PER BK/RD C30-1
JDALARM BL C3B-10
RD/BK-ALARM
C13DRE BL/RD C4B-1
C13DRE BL/RD C10-1
C14PLU OR C4B-2
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C15PLD OR/BK C21-1
C17JU GR C4B-5
C17JU GR C22-1
C18JD GR/BK C4B-6
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
F.H.
GR/WH-TS57
RD-CB2
RD-CB1
BRN-<GND>
WH-HM
BK-CR5
BK-KS
GR/BK-TS57
13
14
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL UP
14
44
15
DRIVE ENABLE
13
17
JIB BOOM DOWN DESCENT ALARM
44
9
A
#1
GR-TS57
BOOM EXT/RET FUNCTION CTRL
9
7
8
B
E
OR/BK-TS59
OR-TS59
BL-TS58
BOOM EXTEND
BOOM RETRACT
7
6
TURNTABLE ROTATE FUNCTION CTRL
6
8
4
5
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
4
5
2
3
BOOM DOWN
BOOM FUNCTION CONTROL
2
1
3
BOOM UP
D
BK/RD-TS63
BK/WH-TS63
BK-TS63
BK-22C1
WH/RD-TS62
BRN
1
1
WH/BK-TS62
BRN
TERMINAL BASE (TB)
BK C7B-1
RD-TS51
RD-TS52
GR/BK H6
BRN
WH-TS62
6
C
RD/WH-R16
C
R43DLITE1 RD
R43DLITE2 RD
D
RD-24B
C21IGN WH C5-3
RD-TS61
RD/BK-ALARM
RD/BK-TS61
C5-18 BK/RD
BRN
RD-CB3
4
GR-46D
RD-CB3 OPTIONS
WH-21B
C21IGN WH
C32 CONNECTOR
PLUG ANSI/CSA ONLY
CR17
HYDRAULIC
OIL COOLER
OPTION
RD H6
BL/WH-132B
BK-22D2
C2B-5 GR
OR C5-1
C32
B
BRN
BK/RD-35C
CR22
DRIVE LIGHT
OPTION
5
CR5
HORN
RELAY
CR4
HIGH RPM
SOLENOID
RELAY
BRN
5
6
7
8
12
F.H.
WH
2
1
3
4
BK-46R
C5
C32
WH
BRN
RD
BRN
3
BRN
WH-ISM9
RD
CR2
POWER
RELAY
A
GROUND HARNESS
TO SWITCH PANEL
BK-ISM1
CR1
IGNITION/START
RELAY
Section 6 • Schematics
July 2005
REV B
Deutz F3L-2011 Models (before serial number 11880)
N
FUNCTION
HARNESS
C5
F.H.
BK C16-1
WH LS2 C10-2
BRN C7B-3
C5
#2
F.H.
July 2005
REV B
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Deutz F3L-2011 Models (before serial number 11880)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
RD
RD
RD
D4
2
RD
C19JSV GR/WH
RD
GR-17D
GR/BK-18D
RD
WH-4
WH/BK-5
WH/RD-6
RD
RD/WH
+
RD
RD
RD
D3
TS51
AUXILIARY
POWER
RD-1
-
RD/BK-2
RD
BASE BOX HARNESS
(TO TERMINAL STRIP)
D9
RD
RD
TS57
PLATFORM
ROTATE
TS62
TURNTABLE
ROTATE
TS61
BOOM
UP/DOWN
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
1
RD
RD
RD
3
TS59
PLATFORM
GR/WH-19D LEVEL
GR-17D
OR/BK-15D
RD
OR-14D
CIRCUIT
BREAKER
CONTROLS 15A
RD
RD-24D
BK/RD-35D
RD-20D
BK-33D
5
RD-20C
RD-20C
CB2
CB3
CIRCUIT
BREAKER
OPTIONS 15A
RD-20C
RD CR22
RD CR17
RD C32-7
BK/WH-34D
BK-7D
RD-1D
WH-4D
WH/BK-5D
WH/RD-6D
GR/BK-18D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD/WH
RD/WH
4
RD
RD
RD/WH-CR34
GR/BK-H6WH/RD-26
BRN-GND
-
+
3
D2
RD
WH-23
RD/WH
RD/BK-2D
BRN
L46
+
LOWER/
RETRACT BOOM
BL/BK-59D
L2
CHECK
ENGINE
WH-21D
RD
4
WH
WH-23D
RD-134D2
BK-22D1
2
B1
B
KS1
KEY
SWITCH
RD/WH-TB3D
1
WH
RD C32-6
C134PWR RD
WH
RD-27
OR-LS17
DALE RH-25 25W
10 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
R4
TURNTABLE
ROTATE
RESISTOR
WH
RD-27D
RD
RD
RD
OR
6
2
RD
RD-20D
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
TS52
ENGINE
START
BK/WH-34D
RD
BRN
RD
RD
D14
TS54
FUNCTION
ENABLE
2
D13
1
NC
HOUR METER
1
NC
RD
WH-21D
BRN
BRN
P1
EMERGENCY
STOP SWITCH
RD/WH-R16
CR34
BOOM
SPEED
REDUCTION
RD/WH-TS61
RD/WH-R16
OR-LS17
RD
DALE RH-25 25W
5 ohm 1%
RD
RD
BRN
RD
R14
BOOM
UP/DOWN
RESISTOR
RD
TS56
GLOW
PLUG
DALE RH-25 25W
5 ohm 1%
RD
RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
CR34
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
BOOM SPEED REDUCTION RELAY
HM
KS1
L2
L46
L45
P1
R4
R14
R16
TS51
TS52
TS54
TS56
TS57
TS59
TS61
TS62
TS63
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 48
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Deutz F3L-2011 Models (before serial number 11880)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-60
Deutz F3L-2011 Models (after serial number 11879)
6 - 49
BRN
BK
WH
WH-OPTIONS
S-60 • S-65
8
WH-TB21 OPTIONS
FUSE 10A
(DRIVE LIGHT ONLY)
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
RD/WH-R16
WH/RD-R4
+
C3
BK-46R
RD/WH-TS61
WH/RD-R2
BRN
BK
BK
BK
RD
RD
RD
WH
WH
WH
WH/BK-25D
D33
1
3
4
7
10
9
2
IGN OR FUEL ON
JUMP TO 7 (GAS ONLY)
TO KEY SW (DIESEL ONLY)
BATTERY
GROUND
10 TEMP OR PRESS FAULT
9
8
7
6
5
AUX PWR UNIT
START INPUT
TACHOMETER
START RELAY
U1
LS17 (C38)
C11 (LS2)
C9 (LS3)
Ground Control Box Terminal Strip Wiring Diagram, S-60
M
GROUND BOLT
12/24 Volt IGNITON/START MODULE P/N 56057
10
9
8
7
6
5
4
3
2
1
OR/RD-LS17 C38-3
C133PLA BL/WH C3B-12
C132PLI BL/WH C1B-12
C118LSR OR/RD C4B-4
R46HRN BK
C45GEN GR/WH C2B-7
P134TTS RD A
FUNCTION
HARNESS
WH-CR2
WH-23C
RD-24C
and lift
Push gently
TO REMOVE:
P134PWR RD-LS17 C38-1
P134PWR BK-LS5 C37-3
+12V POWER
L
BRN
4
3
A
D30
RD-CR19
BK-33C
Genie Industries
133
132
118
46R
45
134
134
P134PWR GR/BK C2B-6
C59CNK BL/BK-LS5 C37-4
C59CNK BL/BK C3B-11
WH C11-2
2
1
PLATFORM OVERLOAD ALARM
PLATFORM OVERLOAD LS
LIFT SPEED REDUCTION
HORN RELAY POWER
GENERATOR OPTION
LOAD WEIGHING LIM. SW. +12V (2)
LOAD WEIGHING LIM. SW. +12V (1)
46
59
C41RPM OR/BK C5-2
C46HRN GR C2B-5
BRN C37-2
OR/BK-41C
133
132
118
SERVICE HORN
RETRACT BOOM LED
41
C41RPM OR/BK C2B-3
C40LS1 OR C10-2
C40LS1 OR C2B-2
F.H.
46R
45
134
134
59
46
39
40
C39LP BL/RD C2B-1
C37SCW BL/BK C25-1
C37SCW BL/BK C1B-11
C36SCC BL C24-1
C36SCC BL C1B-10
C35RPM BK/RD C1B-9
C34SA BK/WH C5-22
C34SA BK/WH C1B-8
C33STR BK C1B-7
H6
CE
OPTION ONLY
BK-CR1
B
40
C31REV WH/BK C5-20
C32BRK WH/RD C5-23
C32BRK WH/RD C1B-6
BRN
P20BAT RD
K
OR/RD-118B
(UNUSED)
BOOM STOWED
39
37
36
35
34
33
32
31
C31REV WH/BK C1B-5
C30FWD WH C5-21
C30FWD WH C1B-4
C29MS RD/WH C5-24
C29MS RD/WH C1B-3
C28TTA RD/BK B
C28TTA RD/BK C1B-2
C27AUX RD PR1
C27AUX RD C1B-1
C26PS WH/RD C5-14
C25TS WH/BK C5-16
#2
F.H.
GR/BK-H6-
STEER RIGHT
37
ALTERNATOR PULS PICKUP
STEER LEFT
41
HIGH FUNCTION SPEED
36
GLOW PLUG
START ENGINE
BRAKE
35
34
33
32
PROPEL REVERSE
31
30
MOTOR STROKE
29
PROPEL FORWARD
29
TILT ALARM
28
30
28
AUXILARY PUMP
27
27
26
25
RD-CR2
C5
#2
F.H.
BL/WH C32-3
OIL PRESSURE SWITCH
25
24
P23BAT WH C7B-2
CABLE
TENSION
LIMIT SWITCH
C37 (LS5)
BOOM
EXTEND
LIMIT SWITCH
C11 (LS1)
C5
ENGINE
OR/RD-FH C38-3
CIRCUIT BREAKER POWER
24
22
23
C5
#2
BK-CR5
KEYSWITCH POWER
23
P22BAT BK C9-2
P22BAT BK C11-1
P22LS17 BK C38-4
C21IGN2 WH C5-3
C21IGN WH CR2
P20BAT RD
P20BAT RD
RD-TS52
GR/WH C5-12
+12 VOLT TO PLATFORM (2)
22
OIL TEMPERATURE SWITCH
+12 VOLT TO PLATFORM (1)
22
26
21
IGNITION POWER
21
22
20
+12 VOLT POWER
20
C37
RD-KS
P134FB WH-FH
RD-H6+
JIB SELECT VALVE
19
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
18/19 #2
C1 & C2
J
BL/BK-L46+
GR-CR5
PLATFORM ROTATE RIGHT/JIB DOWN
18
C18JD GR/BK C4B-6
C17JU GR C22-1
C17JU GR C4B-5
C15PLD OR/BK C21-1
C11
BRN-GND
PLATFORM ROTATE LEFT/JIB UP
C14PLU OR C20-1
C15PLD OR/BK C4B-3
I
OR/BK-ISM2
RD-TS54
BK/RD-CR4
BK/WH-TS56
BK-TS52
PLATFORM LEVEL DOWN
15
17
14
C14PLU OR C4B-2
C13DE BL/RD C10-1
C13DE BL/RD C4B-1
18/19 #1
C3 & C4
H
BK-ISM3
WH/RD-ALRM
D52
RD-TS51
PLATFORM LEVEL UP
14
13
44
RD/BK-ALARM
#1
RD-CR19#86
DRIVE ENABLE
13
C9PER BK/RD C30-1
JDALARM BL C3B-10
G
WH/RD-L2-
JIB DOWN DESCENT ALARM
44
9
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
GR/BK-L45
WH/BK-ISM10
RD-CB1
RD-ISM6
WH-KS
WH-ISM7
BK C32-4
BK-KS
BK-CR5
PRIM. BOOM EXT/RET FUNC. CTRL
9
8
C8PBR BK/WH C3B-8
C7PBE RD-LS5 C37-1
C7PBE BK C3B-7
+12 VOLT
POWER TO
PLATFORM
C7
F
WH-HM
D29
BRN-<GND>
PRIMARY BOOM RETRACT
8
7
C6TRF WH/RD C31-1
#2
RD-CB1
19
PRIMARY BOOM EXTEND
7
6
C6TRF WH/RD C3B-6
C5TRR WH/BK C14-1
C5TRR WH/BK C3B-5
C5
RD-CB2
18
TURNTABLE ROTATE FUNCTION CTRL
6
5
4
C3PBF RD/WH C29-1
C4TRL WH C15-1
C4TRL WH C3B-4
F.H.
GR/WH-TS57
GR/BK-TS57
15
17
TURNTABLE ROTATE RIGHT
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
#1
GR-TS57
TURNTABLE ROTATE LEFT
5
3
4
RD/WH-3D
PRIMARY BOOM FUNCTION CONTROL
RD-24B
3
2
C1PBU RD C12-1
C2PBD RD/BK C3B-2
E
OR/BK-TS59
OR-TS59
BL-TS58
BK/RD-TS63
BK/WH-TS63
BK-22C1
D
BK-TS63
GR-46D
C1PBU RD C3B-1
1
WH/RD-CR19
WH/RD-6D
WH/BK-TS62
BRN
WH-TS62
C21IGN WH C5-11
PRIMARY BOOM DOWN
R43DLITE2 RD
A
BRN
2
B
BRN
RD/WH-CR34
C2B-4 OR/RD
1
GR/BK-133B
TERMINAL BASE (TB)
P134PWR RD-134C
BK-22D2
PRIMARY BOOM UP
BL/WH-132B
4
1
3
C
C32
OR-LS17 C38-2
C32 CONNECTOR
PLUG ANSI/CSA ONLY
RD-CB3
RD H6
RD/WH-TS61
R43DLITE1 RD
CR17
HYDRAULIC
OIL COOLER
OPTION
1
RD/BK-TS61
BK C5-5
C
RD/BK-ALARM
BRN
C21IGN WH
U33
PLATFORM
OVER LOAD
(CE ONLY)
D
WH-21B
RD-TS61
RD-27C
RD/WH-R16
BK/RD-35C
WH/RD-R4
C5-18 BK/RD
OR C5-1
B
WH/RD-R2
CR4
HIGH RPM
SOLENOID RELAY
RD-ISM4
WH-OPTIONS
WH C5-4
7
CR34
PRIMARY BOOM
SPEED
REDUCTION
RELAY
8
BRN
12
CR19
SWING SPEED
SELECT
RELAY
BRN
RD-TS51
CR5
HORN
RELAY
F.H.
BK C7B-1
6
C32
C5
C32
5
C32
5
BRN
WH
CR23
DRIVE LIGHT
OPTION
A
GROUND HARNESS
TO SWITCH PANEL
7
BRN
RD
2
WH-ISM9
6
RD
CR2
POWER
RELAY
4
BK-ISM1
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV A
Deutz F3L-2011 Models (after serial number 11879)
N
F.H.
+
BRN
WH LS2 C10-2
BK C16-1
GR/BK H6
#1
BRN C7B-3
C5
3
July 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Deutz F3L-2011 Models (after serial number 11879)
I
H
G
F
E
D
WH/RD
RD
D4
RD
WH/RD
2
RD
C19JSV GR/WH
WH-4
WH/BK-5
RD
RD/WH
GR/BK-18D
+
RD
RD-1
-
RD
RD
RD
D3
TS51
AUXILIARY
POWER
A
BASE BOX HARNESS
(TO TERMINAL STRIP)
RD/WH
TS57
PLATFORM
ROTATE
RD
RD
RD/BK-2
WH/RD
B
1
RD
RD
C
GR-17D
J
TS62
TURNTABLE
ROTATE
K
D9
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
WH/RD
WH/RD
RD
GR-17D
CIRCUIT
BREAKER
CONTROLS 15A
RD
RD-20C
RD-20C
CB2
5
RD
RD
RD
RD
RD/WH
4
RD-24D
BK/RD-35D
RD-20D
OR/BK-15D
RD
OR-14D
GR/BK-18D
BK-33D
CIRCUIT
BREAKER
OPTIONS 15A
CB3
RD/WH
RD-20C
RD CR22
RD CR17
BK/WH-34D
RD C32-7
WH-4D
WH/BK-5D
RD/WH-CR34#87a
BK-7D
RD-1D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD/WH
-
+
D2
RD
WH-23
RD/WH
RD/BK-2D
GR/BK-H6-
BRN
BRN-GND
WH/RD-26
L46
+
LOWER/
RETRACT BOOM
BL/BK-59D
L2
CHECK
ENGINE
WH-21D
WH-23D
2
B1
4
WH
RD C32-6
C134PWR RD
RD-134D2
BK-22D1
B
RD
3
KS1
KEY
SWITCH
1
WH
TS59
PLATFORM
GR/WH-19D LEVEL
WH
RD-27
WH
RD-27D
WH/RD CR34#87
WH/RD CR19#87
WH/RD CR19#87a
DALE RH-25 25W
7.5 ohm 1%
R4
TURNTABLE
ROTATE
RESISTOR
R2
TURNTABLE
ROTATE
RESISTOR
3
RD
WH/RD
WH/RD
RD-20D
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
BK/WH-34D
RD
BRN
BRN
WH-21D
TS52
ENGINE
START
RD
DALE RH-25 25W
10 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
DALE RH-25 25W
5 ohm 1%
6
2
RD
RD
RD
D14
TS54
FUNCTION
ENABLE
2
D13
1
NC
HOUR METER
1
NC
RD
P1
EMERGENCY
STOP SWITCH
RD
R14
BOOM
UP/DOWN
RESISTOR
RD
TS56
GLOW
PLUG
DALE RH-25 25W
5 ohm 1%
RD
RD
WH/RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
HM
KS1
L2
L46
L45
P1
R2
R4
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 7.5 OHMS
R14
R16
TS51
TS52
TS54
TS56
TS57
TS59
TS61
TS62
TS63
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 50
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Deutz F3L-2011 Models (after serial number 11879)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models
Deutz F3L-2011 Models (before serial number 11880)
8
6 - 51
BK C5-5
BK
WH
S-60 • S-65
BK
WH
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
BK
WH
+ C3
START ENGINE
GLOW PLUG
HIGH FUNCTION SPEED
STEER RIGHT
STEER LEFT
(UNUSED)
BOOM STOWED
33
34
35
36
37
39
40
BRN
BK
WH
D33
4 7 10 9 2
START RELAY
TACHOMETER
U1
START INPUT
AUX PWR UNIT
GROUND
BATTERY
TO KEY SW (DIESEL ONLY)
JUMP TO 7 (GAS ONLY)
IGN OR FUEL ON
TEMP OR PRESS FAULT
OR-LS17 C38-2
OR/RD-LS17 C38-3
C45GEN GR/WH C2B-7
R46HRN BK
C118BSR OR/RD C4B-4
C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
C59CNK BL/BK C3B-11
C59CNK WH-LS5 C37-4
C134PWR GR/BK C2B-6
C134PWR RD-LS17 C38-1
C134PWR BK-LS5 C37-3
P134TTSR RD A
Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models
M
GROUND BOLT
12/24 Volt IGNITON/START MODULE P/N 56057
1 3
1
2
3
4
5
6
7
8
9
10
A
D30
TO REMOVE:
45
46R
118
132
133
134
134
59
H6
CE ONLY
Push gently
and lift
41
46
C40LS1 OR C2B-2
C40LS1 OR C10-2
C41RPM OR/BK C2B-3
C41RPM OR/BK C5-2
C46HRN GR C2B-5
C36STCC BL C1B-10
C36STCC BL C24-1
C37STC BL/BK C1B-11
C37STC BL/BK C25-1
C39LP BL/RD C2B-1
C34SA BK/WH C1B-8
C34SA BK/WH C5-22
C35HS BK/RD C1B-9
WH C11-2
Genie Industries
GENERATOR OPTION
HORN RELAY POWER
LIFT SPEED REDUCTION
PLATFORM OVERLOAD LS
PLATFORM OVERLOAD ALARM
PLAT. OVERLOAD LIM. SW. +12V (2)
45
46R
118
132
133
PLAT. OVERLOAD LIM. SW. +12V (1)
134
RETRACT BOOM LED
HORN
134
59
46
40
39
37
32
L
WH-CR2
WH/BK-25D
BRAKE
32
BRN
BRN C37-2
1
2
3
4
5
6
7
8
9
10
36
DRIVE REVERSE
31
+12V DC
POWER
ENGINE
BK-CR1
OR/BK-41C
BK-33C
RD-27C
BRN
RD-24C
WH-23C
B
35
DRIVE FORWARD
30
P20BAT RD
BRN
K
OR-CR34
OR/RD-118B
33
34
MOTOR STROKE
29
C37
GR/WH C5-12
BK-CR5
OR/RD-FH C38-3
BL/WH C32-3
GR/BK-H6-
RD-H6+
P134FB WH-FH
RD-KS
31
TILT ALARM
28
CABLE
TENSION
LIMIT SWITCH
LS5
J
WH-L46+
D52
ALTERNATOR PULS PICKUP
30
AUXILARY PUMP
27
#1
C5
#2
F.H.
41
29
OIL TEMPERATURE SWITCH
26
C5
#2
F.H.
C26PSR WH/RD C5-14
C27AUX RD C1B-1
C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C32BRK WH/RD C5-23
C33STR BK C1B-7
C25TSR WH/BK C5-16
RD-CR2
C11
GR-CR5
28
OIL PRESSURE SWITCH
25
24
#1
I
OR/BK-ISM2
BRN-GND
27
CIRCUIT BREAKER POWER
24
23
22
+
BK/WH-TS56
BK/RD-CR4
RD-TS54
26
KEY SWITCH POWER
23
C22LS17 BK C10-2
P22BAT BK C11-1
P22BAT BK C9-2
P23BAT WH C7B-2
H
WH/RD-ALRM
BK-ISM3
BK-TS52
25
+12V DC TO PLATFORM (2)
22
22
P20BAT RD
P20BAT RD
C21IGN WH CR2
C21IGN2 WH C5-11
G
WH/RD-L2RD-ISM4
RD-TS51
+12V DC TO PLATFORM (1)
22
21
IGNITION POWER
21
20
P134PWR RD-134C
GR/BK-133B
GR/BK-L45
WH/BK-ISM10
D29
+12V DC POWER
BOOM
EXTEND
LIMIT SWITCH
LS1
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12V DC
POWER TO
PLATFORM
C7
F
BK C32-4
WH-ISM7
WH-KS
RD-ISM6
RD-CB1
JIB BOOM SELECT VALVE
19
#2
20
F.H.
19
18
PLATFORM ROTATE RIGHT/JIB DOWN
18
15
17
PLATFORM LEVEL DOWN
C1PBU RD C3B-1
C1PBU RD C12-1
C2PBD RD/BK C3B-2
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C6TRF WH/RD C31-1
C7PBE BK C3B-7
C7PBE RD-LS5 C37-1
C8PBR BK/WH C3B-8
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
C9PER BK/RD C30-1
JDALARM BL C3B-10
RD/BK-ALARM
C13DRE BL/RD C4B-1
C13DRE BL/RD C10-1
C14PLU OR C4B-2
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C15PLD OR/BK C21-1
C17JU GR C4B-5
C17JU GR C22-1
C18JD GR/BK C4B-6
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
C5
GR/WH-TS57
RD-CB2
RD-CB1
BRN-<GND>
WH-HM
BK-CR5
BK-KS
GR/BK-TS57
13
14
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL UP
14
44
15
DRIVE ENABLE
13
17
JIB BOOM DOWN DESCENT ALARM
44
9
A
#1
GR-TS57
BOOM EXT/RET FUNCTION CTRL
9
7
8
B
E
OR/BK-TS59
OR-TS59
BL-TS58
BK/RD-TS63
BOOM EXTEND
BOOM RETRACT
7
6
TURNTABLE ROTATE FUNCTION CTRL
6
8
4
5
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
4
5
2
3
BOOM DOWN
BOOM FUNCTION CONTROL
2
3
1
D
BK/WH-TS63
BK-TS63
WH/RD-TS62
BK-22C1
BOOM UP
1
WH/BK-TS62
BRN
1
TERMINAL BASE (TB)
BK C7B-1
RD-TS51
RD-TS52
GR/BK H6
BRN
WH-TS62
BRN
C
RD/WH-R16
C
R43DLITE1 RD
R43DLITE2 RD
D
C5-18 BK/RD
BRN
RD-CB3
RD-24B
C21IGN WH C5-3
RD-TS61
RD/BK-ALARM
RD/BK-TS61
BK/RD-35C
C21IGN WH
3
CR17
HYDRAULIC
OIL COOLER
OPTION
RD H6
BL/WH-132B
BK-22D2
C2B-5 GR
4
OR C5-1
B
GR-46D
RD-CB3 OPTIONS
WH-21B
BRN
5
CR22
DRIVE LIGHT
OPTION
C32
U33
PLATFORM
OVERLOAD
(CE ONLY)
5
6
7
8
12
F.H.
CR4
HIGH RPM
SOLENOID
RELAY
BRN
1
3
4
CR5
HORN
RELAY
C5
C32
WH
BRN
WH
2
BK-46R
BRN
WH-ISM9
RD
RD
BRN
A
GROUND HARNESS
TO SWITCH PANEL
BK-ISM1
7
CR2
POWER
RELAY
6
CR1
IGNITION/START
RELAY
Section 6 • Schematics
July 2005
REV B
Deutz F3L-2011 Models (before serial number 11880)
N
FUNCTION
HARNESS
C5
F.H.
BK C16-1
WH LS2 C10-2
BRN C7B-3
C5
#2
F.H.
July 2005
REV B
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models
Deutz F3L-2011 Models (before serial number 11880)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
WH/RD
RD
WH/RD
WH/RD
2
RD
C19JSV GR/WH
GR-17D
GR/BK-18D
WH-4
WH/BK-5
RD
RD
D4
RD
RD
RD/WH
RD
TS51
AUXILIARY
POWER
D3
RD
RD
RD
RD-1
-
+
RD/BK-2
BASE BOX HARNESS
(TO TERMINAL STRIP)
RD/WH
TS57
PLATFORM
ROTATE
TS62
TURNTABLE
ROTATE
RD
RD
D9
TS61
BOOM
UP/DOWN
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
1
WH/RD
WH/RD
3
RD
GR-17D
CIRCUIT
BREAKER
CONTROLS 15A
RD
RD-20C
RD-20C
CB2
5
RD
RD
RD
RD
RD/WH
4
RD-24D
BK/RD-35D
RD-20D
BK-33D
OR/BK-15D
RD
OR-14D
GR/BK-18D
CB3
CIRCUIT
BREAKER
OPTIONS 15A
RD-20C
RD CR22
RD CR17
BK/WH-34D
RD C32-7
WH-4D
WH/BK-5D
RD/WH-CR34#87a
BK-7D
RD-1D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD/WH
D2
RD
RD/WH
-
4
3
+
RD
WH-23
RD/WH
RD/BK-2D
GR/BK-H6-
BRN
BRN-GND
WH/RD-26
L46
+
LOWER/
RETRACT BOOM
BL/BK-59D
L2
CHECK
ENGINE
WH-21D
WH-23D
RD C32-6
C134PWR RD
B
B1
2
1
RD-134D2
BK-22D1
WH
RD-27D
KS1
KEY
SWITCH
WH
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
DALE RH-25 25W
7.5 ohm 1%
R4
TURNTABLE
ROTATE
RESISTOR
R2
TURNTABLE
ROTATE
RESISTOR
WH
TS59
PLATFORM
GR/WH-19D LEVEL
WH
RD-27
RD
WH/RD
WH/RD
6
RD-20D
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
BK/WH-34D
RD
BRN
WH-21D
TS52
ENGINE
START
RD
DALE RH-25 25W
10 ohm 1%
DALE RH-25 25W
5 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
BRN
2
RD
RD
RD
D14
TS54
FUNCTION
ENABLE
2
D13
1
NC
HOUR METER
1
NC
RD
P1
EMERGENCY
STOP SWITCH
RD
R14
BOOM
UP/DOWN
RESISTOR
RD
TS56
GLOW
PLUG
DALE RH-25 25W
5 ohm 1%
RD
RD
WH/RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
HM
KS1
L2
L46
L45
P1
R2
R4
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 7.5 OHMS
R14
R16
TS51
TS52
TS54
TS56
TS57
TS59
TS61
TS62
TS63
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 52
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models
Deutz F3L-2011 Models (before serial number 11880)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models
Deutz F3L-2011 Models (after serial number 11879)
8
6 - 53
S-60 • S-65
BK
WH
WH-OPTIONS
WH-TB21 OPTIONS
FUSE 10A
(DRIVE LIGHT ONLY)
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
RD/WH-R16
WH/RD-R4
+
C3
BK-46R
7
RD/WH-TS61
WH/RD-R2
BRN
BK
BK
BK
RD
RD
RD
WH
WH
WH
WH/BK-25D
D33
1
3
4
7
10
9
2
IGN OR FUEL ON
JUMP TO 7 (GAS ONLY)
TO KEY SW (DIESEL ONLY)
BATTERY
GROUND
10 TEMP OR PRESS FAULT
9
8
7
6
5
AUX PWR UNIT
START INPUT
TACHOMETER
START RELAY
U1
LS17 (C38)
C11 (LS2)
C9 (LS3)
Ground Control Box Terminal Strip Wiring Diagram, S-60, CE Models
M
GROUND BOLT
12/24 Volt IGNITON/START MODULE P/N 56057
10
9
8
7
6
5
4
3
2
1
FUNCTION
HARNESS
WH-CR2
WH-23C
RD-24C
and lift
Push gently
TO REMOVE:
OR/RD-LS17 C38-3
C133PLA BL/WH C3B-12
C132PLI BL/WH C1B-12
C118LSR OR/RD C4B-4
L
BRN
4
3
Genie Industries
A
D30
RD-CR19
BK-33C
2
1
133
132
R46HRN BK
BRN C37-2
OR/BK-41C
PLATFORM OVERLOAD ALARM
PLATFORM OVERLOAD LS
118
WH C11-2
BK-CR1
B
133
132
LIFT SPEED REDUCTION
K
OR/RD-118B
GR/BK-H6-
118
F.H.
BL/WH C32-3
C45GEN GR/WH C2B-7
+12V POWER
C5
ENGINE
OR/RD-FH C38-3
45
#2
F.H.
46R
P134TTS RD A
#2
HORN RELAY POWER
GENERATOR OPTION
134
P134PWR BK-LS5 C37-3
P134PWR RD-LS17 C38-1
P134PWR GR/BK C2B-6
C59CNK BL/BK-LS5 C37-4
C59CNK BL/BK C3B-11
C5
F.H.
46R
45
LOAD WEIGHING LIM. SW. +12V (2)
134
59
46
C5
#2
BK-CR5
134
LOAD WEIGHING LIM. SW. +12V (1)
RETRACT BOOM LED
SERVICE HORN
C46HRN GR C2B-5
C41RPM OR/BK C5-2
C41RPM OR/BK C2B-3
C40LS1 OR C10-2
C40LS1 OR C2B-2
C39LP BL/RD C2B-1
C37SCW BL/BK C25-1
C37SCW BL/BK C1B-11
C36SCC BL C24-1
C36SCC BL C1B-10
C35RPM BK/RD C1B-9
C34SA BK/WH C5-22
C34SA BK/WH C1B-8
RD-TS52
GR/WH C5-12
134
59
46
41
40
39
37
C32BRK WH/RD C5-23
C33STR BK C1B-7
C37
RD-KS
P134FB WH-FH
RD-H6+
BOOM STOWED
40
ALTERNATOR PULS PICKUP
(UNUSED)
39
41
STEER RIGHT
37
36
35
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
BRN
P20BAT RD
J
BL/BK-L46+
GR-CR5
STEER LEFT
34
33
32
31
C31REV WH/BK C1B-5
C30FWD WH C5-21
C30FWD WH C1B-4
C29MS RD/WH C5-24
C29MS RD/WH C1B-3
C28TTA RD/BK B
C28TTA RD/BK C1B-2
C27AUX RD PR1
C27AUX RD C1B-1
C26PS WH/RD C5-14
C25TS WH/BK C5-16
RD-CR2
P23BAT WH C7B-2
C11
BRN-GND
HIGH FUNCTION SPEED
36
GLOW PLUG
START ENGINE
BRAKE
35
34
33
32
PROPEL REVERSE
31
30
MOTOR STROKE
29
PROPEL FORWARD
29
TILT ALARM
28
30
28
AUXILARY PUMP
27
27
26
25
24
23
22
I
OR/BK-ISM2
RD-TS54
BK/RD-CR4
BK/WH-TS56
BK-TS52
OIL PRESSURE SWITCH
25
COOLANT TEMPERATURE SWITCH
CIRCUIT BREAKER POWER
24
26
KEYSWITCH POWER
CABLE
TENSION
LIMIT SWITCH
C37 (LS5)
H
BK-ISM3
WH/RD-ALRM
RD-TS51
D52
RD-CR19#86
+12 VOLT TO PLATFORM (2)
22
23
P22BAT BK C9-2
P22BAT BK C11-1
P22LS17 BK C38-4
C21IGN2 WH C5-3
G
WH/RD-L2-
+12 VOLT TO PLATFORM (1)
22
22
21
IGNITION POWER
21
P20BAT RD
P20BAT RD
C21IGN WH CR2
#1
WH/BK-ISM10
RD-CB1
RD-ISM6
WH-KS
WH-ISM7
BK C32-4
BK-KS
BK-CR5
20
+12 VOLT POWER
20
BOOM
EXTEND
LIMIT SWITCH
C11 (LS1)
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12 VOLT
POWER TO
PLATFORM
C7
F
WH-HM
D29
BRN-<GND>
JIB SELECT VALVE
19
C19JSV GR/WH C4B-7
C18JD GR/BK C23-1
C18JD GR/BK C4B-6
C17JU GR C22-1
C17JU GR C4B-5
C15PLD OR/BK C21-1
C15PLD OR/BK C4B-3
C14PLU OR C20-1
C14PLU OR C4B-2
C13DE BL/RD C10-1
C13DE BL/RD C4B-1
RD/BK-ALARM
JDALARM BL C3B-10
C9PER BK/RD C30-1
C9PER BK/RD C3B-9
C8PBR BK/WH C17-1
C8PBR BK/WH C3B-8
C7PBE RD-LS5 C37-1
C7PBE BK C3B-7
C6TRF WH/RD C31-1
#2
RD-CB1
19
PLATFORM ROTATE RIGHT/JIB DOWN
18
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C5
RD-CB2
18
PLATFORM ROTATE LEFT/JIB UP
C4TRL WH C15-1
C5TRR WH/BK C3B-5
F.H.
GR/WH-TS57
GR/BK-TS57
15
17
PLATFORM LEVEL DOWN
15
17
14
13
C3PBF RD/WH C29-1
C4TRL WH C3B-4
#1
GR-TS57
44
9
PLATFORM LEVEL UP
PRIM. BOOM EXT/RET FUNC. CTRL
9
8
14
PRIMARY BOOM RETRACT
8
7
JIB DOWN DESCENT ALARM
PRIMARY BOOM EXTEND
7
6
5
4
DRIVE ENABLE
TURNTABLE ROTATE FUNCTION CTRL
6
RD/WH-3D
13
TURNTABLE ROTATE RIGHT
5
RD-24B
44
TURNTABLE ROTATE LEFT
4
3
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
E
OR/BK-TS59
OR-TS59
BL-TS58
BK/RD-TS63
BK/WH-TS63
PRIMARY BOOM FUNCTION CONTROL
C1PBU RD C12-1
D
BK-TS63
BK-22C1
C2PBD RD/BK C3B-2
1
WH/RD-CR19
GR-46D
WH/BK-TS62
WH/RD-6D
3
C21IGN WH C5-11
WH-TS62
BRN
C1PBU RD C3B-1
BRN
2
R43DLITE2 RD
A
BRN
PRIMARY BOOM DOWN
B
RD-TS51
2
C2B-4 OR/RD
1
6
TERMINAL BASE (TB)
BK C7B-1
PRIMARY BOOM UP
GR/BK-133B
5
1
P134PWR RD-134C
BK-22D2
C
3
OR-LS17 C38-2
C32
RD-CB3
BL/WH-132B
4
RD/WH-TS61
R43DLITE1 RD
CR17
HYDRAULIC
OIL COOLER
OPTION
3
D
RD-27C
RD/WH-R16
RD H6
RD/WH-CR34
BK C5-5
C21IGN WH
GR/BK-L45
1
RD/BK-TS61
BRN
C
RD/BK-ALARM
6
RD-TS61
WH-21B
WH/RD-R4
C5-18 BK/RD
OR C5-1
WH C5-4
C32
B
WH/RD-R2
CR4
HIGH RPM
SOLENOID RELAY
CR34
PRIMARY BOOM
SPEED
REDUCTION
RELAY
WH-OPTIONS
RD-ISM4
BK/RD-35C
BRN
5
CR19
SWING SPEED
SELECT
RELAY
BRN
7
CR5
HORN
RELAY
4
F.H.
8
C32
C5
12
C32
CR23
DRIVE LIGHT
OPTION
U33
PLATFORM
OVER LOAD
(CE ONLY)
BRN
WH
RD
BRN
2
WH-ISM9
BRN
RD
CR2
POWER
RELAY
A
GROUND HARNESS
TO SWITCH PANEL
BK-ISM1
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV A
Deutz F3L-2011 Models (after serial number 11879)
N
H6
F.H.
+
BRN
BK C16-1
WH LS2 C10-2
GR/BK H6
#1
BRN C7B-3
C5
July 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models
Deutz F3L-2011 Models (after serial number 11879)
I
H
G
F
E
D
WH/RD
RD
D4
RD
WH/RD
2
RD
C19JSV GR/WH
WH-4
WH/BK-5
RD
RD/WH
GR/BK-18D
+
RD
RD-1
-
RD
RD
RD
D3
TS51
AUXILIARY
POWER
A
BASE BOX HARNESS
(TO TERMINAL STRIP)
RD/WH
TS57
PLATFORM
ROTATE
RD
RD
RD/BK-2
WH/RD
B
1
RD
RD
C
GR-17D
J
TS62
TURNTABLE
ROTATE
K
D9
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
WH/RD
WH/RD
RD
GR-17D
CIRCUIT
BREAKER
CONTROLS 15A
RD
RD-20C
RD-20C
CB2
5
RD
RD
RD
RD
RD/WH
4
RD-24D
BK/RD-35D
RD-20D
OR/BK-15D
RD
OR-14D
GR/BK-18D
BK-33D
CIRCUIT
BREAKER
OPTIONS 15A
CB3
RD/WH
RD-20C
RD CR22
RD CR17
BK/WH-34D
RD C32-7
WH-4D
WH/BK-5D
RD/WH-CR34#87a
BK-7D
RD-1D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD/WH
-
+
4
D2
RD
WH-23
RD/WH
RD/BK-2D
GR/BK-H6-
BRN
BRN-GND
WH/RD-26
L46
+
LOWER/
RETRACT BOOM
L2
CHECK
ENGINE
WH-21D
WH-23D
RD C32-6
C134PWR RD
2
B1
B
RD
3
KS1
KEY
SWITCH
1
RD-134D2
BK-22D1
WH
RD-27D
WH
BL/BK-59D
RD
WH
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
DALE RH-25 25W
7.5 ohm 1%
R4
TURNTABLE
ROTATE
RESISTOR
R2
TURNTABLE
ROTATE
RESISTOR
3
TS59
PLATFORM
GR/WH-19D LEVEL
WH
RD-27
WH/RD
WH/RD
WH/RD
RD-20D
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
BK/WH-34D
RD
BRN
BRN
WH-21D
TS52
ENGINE
START
RD
DALE RH-25 25W
10 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
DALE RH-25 25W
5 ohm 1%
6
2
RD
RD
RD
D14
TS54
FUNCTION
ENABLE
2
D13
1
NC
HOUR METER
1
NC
RD
P1
EMERGENCY
STOP SWITCH
RD
R14
BOOM
UP/DOWN
RESISTOR
RD
TS56
GLOW
PLUG
DALE RH-25 25W
5 ohm 1%
RD
RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
HM
KS1
L2
L46
L45
P1
R2
R4
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 7.5 OHMS
R14
R16
TS51
TS52
TS54
TS56
TS57
TS59
TS61
TS62
TS63
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 54
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60, CE Models
Deutz F3L-2011 Models (after serial number 11879)
Section 6 • Schematics
July 2005
Platform Control Box Wiring Diagram, S-60
Deutz F3L-2011 Models
U13
J1
J2
J3
CR27
CR30
LS18
* NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
1
CWLITE WH TS49
C32BRK WH/RD C1P-6
C32BRK WH/RD J2-19
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129JDA BL C3P-10 TS8
C46HRN GR C2P-5
C59CHK BL/BK C3P-11 L47+
C59CNK BL/BK C3P-11
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
C134PWR RD LS18
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
FOOT SWITCH
OPT.
LS18
(CE)
GR/BK C133TTA C3P-12
GR/BK-L4- (CE)
F.S.
RD/BK-28
RD/BK-L48- (NON-CE)
C134PWR RD C2P-6
RD-TILT
OPTION
+
P24FS WH C9-2 TS4
C7P
CDLITE OR/RD C2P-4
C45GEN GR/WH C2P-7
C46HRN GR C2P-5
C7P
JIB
C9
C7P
C118LSR OR/RD C4P-4
C6TRF WH/RD C3P-6
C8PBR BK/WH C3P-8
C16DRE BL/RD C4P-1
C7PBE BK C3P-7
C40LSS OR C2P-2
C9PER BK/RD C3P-9
C4P
C19JSV GR/WH TS7
C19JSV GR/WH C4P-7
BRN JC3
BRN GND
RD-E-STOP
C134PWR RD-H1+
CE LIFT/DRIVE OPTION
J2
TS7 WH
1
TS1 WH
11
P26ESTP BK
P24FS WH
C41RPM OR/BK C2P-3
C30FWD WH C1P-4
C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
C28TTA RD/BK C1P-2
C3P
BRN
Part No. 77828
P24FS WH
BRN
JC1-3 OR
DRE LED BL/RD
TS15 B BL/BK
TS15 BL/WH
JC3-4 BL *
JC3-2 BRN
JC3-3 OR
JC3-5 WH
JC2-2 BRN
JC1-5 YEL
JC2-3 OR
JC2-5 BK
JC1-2 BRN
JC2-4 RD
1
TS14 RD/WH
RD/BK-L4-
CWLITE BK
9
BK C1P-12
C3P
C7P
12V DC BATTERY
19/18 CONTROL CABLE
H1
TILT
ALARM
3
C134PWR RD LS18
BRN
C2P
6
C4P
BATGRN C7P-3
WH/RD C1P-6
C1P
C28TTA RD/BK C1P-2
J3
TILT ALARM
12V DC PLATFORM POWER CONNECTOR
FOOT SWITCH CONNECTOR
48 PIN CONNECTOR BLOCK
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
C1P-C4P
5
PLATFORM
CONTROL
HARNESS
(TO SWITCH
PANEL)
BRN
J1
CR27
CR30
BRN
D39
8
RD LS18 CABLE
7
S-60 • S-65
6 - 55
CWLITE WH TS49
4
BRN
BRN
DESCRIPTION
H1
C7P
C9
1
ITEM
2
REV B
Platform Control Box Wiring Diagram, S-60
N
M
L
K
J
I
H
G
F
E
D
C
B
A
U13
ALC-500
3
July 2005
Section 6 • Schematics
Deutz F3L-2011 Models
July 2005
REV B
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-60
Deutz F3L-2011 Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
PLATFORM CONTROL
HARNESS (TO CONTROL BOX)
TS48
DRIVE LIGHTS/
WORK LIGHTS
(OPTION)
COMPONENT INDEX
DLITE RD
JC2
BOOM UP/DOWN &
TURNTABLE ROTATE
LEFT/RIGHT
RD
JC1
7
BOOM
EXTEND/RETRACT
5
4
4
3
2
BRN
1
L4
PLATFORM
OVERLOAD
(CE OPTION)
L1
DRIVE
ENABLE
LED
1
3
2
+
1
BK
RD
+
BRN
BRN
BK
BRN
BRN
C28TTA RD/BK H1-
BK
WH J1-4
BL J1-5
OR J1-13
BRN J1-14
BK
P26BAT BK J3-3
P22BAT BK C7P-1
RD
WH
3
4
6
7
1
RD
TS9
PLATFORM
LEVEL
DRIVE/STEER PROPORTIONAL JOYSTICK
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
LOWER/RETRACT BOOM LED
BOOM TILTED LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HI/LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)
D12
3
TS7
PLATFORM
ROTATE
JC3
L1
L4
L47
L48
P2
P3
TS1
TS2
TS4
TS6
TS7
TS9
TS14
TS15
TS47
TS48
RD
1
1
NC NC NC
P3
HORN
BOOM PROPORTIONAL JOYSTICK:
BOOM EXTEND/RETRACT
5
P23BAT WH C7P-2
P26BAT BK C9-1
RD-H1+
C134PWR RD L48+
C134PWR RD L4+
BK TS15
C45GEN GR/WH C2P-7
PDLITE RD
C35HS BK/RD C1P-9
P24FS WH C9-2
C33STR BK C1P-7
P25FS RD C9-3
C34SA BK/WH C1P-8
C29MS RD/WH J1-8
WH CR30
C27AUX RD C1P-1
C17PRL GR C4P-5
WH CR27
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C46HRN GR C2P-5
NO
JC1
2
WH
RD
4
RD
BRN
C133PLA GR/BK D39
C134PWR RD E-STOP
C134PWR RD E-STOP
BL/RD-DE3 J1-16
BL-DE1 J1-6
BL/BK-DE2 J1-7
YL J1-3
OR J1-9
BRN J1-10
WLITE WH
DLITE OR/RD C2P-4
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
C59CNK BL/BK C3P-11
WLITE WH
BK
F18 FUSE 10A
(WORK LIGHT ONLY)
RD
WH
BL J1-5 (ROCKER SWITCH OPTION ONLY)
L47
RETRACT
BOOM
LED
BRN
4
2
+
6
5
3
BRN
7
RD
5
L48
TILT ALARM LED
(ANSI/CSA OPT.)
BK
6
DRIVE
FORWARD/REVERSE
& STEER
LEFT/RIGHT
+
BK
6
BOOM PROPORTIONAL JOYSTICK:
BOOM UP/DOWN , TURNTABLE ROTATE
JC3
TS15
DRIVE
ENABLE
7
JC2
TS1
AUXILIARY
PUMP
TS14
HIGH/LOW
(2WD/4WD)
TS2
ENGINE
START
TS6
GLOW PLUG
TS4
HIGH/LOW
RPM
2
TS47
GENERATOR
(OPTION)
22
P2
EMERGENCY
STOP
WH-24
RD
RD
RD
RD
8
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
6 - 56
July 2005
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-60
Deutz F3L-2011 Models
C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
C1P-9
REV D
Electrical Schematic, S-65
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C1B-8
C3B-12
C2B-5
C3B-12
C1B-2
C7B-2
RD
BK
C1B-7
DLITE BL/WH
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD C1B-1
AUXILIARY
PUMP
P23BAT WH
WH
C133PLA BL/WH
C28TTA RD/BK
RD
RD
C46HRN GR
D14
GR/BK
C35RPM BK/RD
C45GEN GR/WH
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
C5-2
C5-12
C5-22
RD
RD
C5-18
C5-14
C5-16
C5-11
F.H. BK
R116 OR
R21IGN WH
RD
WH
BK/RD
C5-5
P134FB WH
C21IGN WH
C41RPM OR/BK
P116HYD RD
P22BAT BK
CR4
NO
FOOTSW. LOW
C2P-7
C3P-12
C1P-7
C1P-1
C7P-2
C1P-2
C3P-12
C2P-5
C7B-1
PBOX GND
FOOTSW. HIGH
C1B-12
C2B-6
C1P-8
LIGHTS
C2P-11
C2P-12
WORK LIGHT
DRIVE LIGHT
GLOW
PLUG
ENGINE
START
RD/BK
AUX
PUMP
C132PLI BL/WH
P22BAT BK
C1P-12
C7P-1
RD/BK
FUSE 10A
P134PWR GR/BK
CR23
C5-4
C5-1
BRN
Q3
L29
SW3
NO
L29
SW2
CR23
C21IGN WH
P20BAT RD
BK
H2
P24FS WH
C2P-6
RD
C2B-3
C7B-4
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
OIL TEMPERATURE LED
OIL TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
HM
M2
AUX
PUMP
REGULATOR
Part No. 77828
S-60 • S-65
6 - 57
BK
C41RPM OR/BK
RD
8
NO
NC
C
SW3
FAN
_
IND.
+
M3
PR2
PR2
NO
S8
STARTER
B2
FB1
M1
7
EXCT.
NO
STA.
PR2
NO
+
12V DC
85
TB33
CR4
NO
TB26
CR5
87a 87
PR1
BAT.
BAT.
B
A
NO
6
NO
RD
TB25
86
CR17
ALTERNATOR
D1
TB46
FUSE
10A
30
D22
TB21
CR2
NO
CR1
15A
L43
U1
TB35
C3
+
TB21
C5-3
TB45
OIL
TEMP.
5
D13
TB34
TB28
CR2
TB134
3MF
CB3
TB23
TB41
TB24
RD
15A
TB133
CB1
7
U33
TB27
WH
D4
8
C32-8
12
D3
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB20
6
D2
4
GRD
TS4
TS47
TS48
TS54
TS56
TS52
TS51
5
4
PLAT
3
1
TB22
KS1
L30
RD
P1
H1
L30
TB132
RD
RD
15AMP.
L48
D12
D40
ENGINE
SPEED
RD
RD
TS1
P3
TS6
TS2
2
Platform
Overload
Option
Only
3
FS1
RD
P25FS RD
P24FS WH
C9P-3
C9P-2
RD-(FS)
WH-(FS)
BK-(FS)
C9P-1 BK
P2
C22LS BK
C28TTA RD/BK
C28TTA RD/BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
CB2
July 2005
Section 6 • Schematics
Deutz F3L-2011 Models (before serial number 11880)
+
-
Electrical Schematic, S-65
REV D
1
C28TTA RD/BK
DRIVE MODE
CDE3 BL/RD
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
CDE2 BL/BK
LEFT
3
BL
CDE1 BL/WH
RIGHT
7
RKOUT 6
YOUT 5
4
PWR 3
1
GND 2
7
6
2
XOUT 4
YOUT 5
GND
PWR
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
3
DOWN
UP
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C3P-4
C3P-6
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
LEFT
UP
DOWN
PRIMARY BOOM
C2PBD RD/BK
C1PBU RD
C3PBF RD/WH
C9PER BK/RD
C8PBR BK/WH
C7PBE BK
EXTEND
BOOM
C4B-4
RETRACT
C118LSR OR/RD
J1 F.H. WH
WH
C4B-1
C11-2
C14PLU OR
C15PLD OR/BK
UP
DOWN
C3B-10
C3B-1
C3B-2
C3B-3
C3B-9
C3B-8
C3B-7
C4B-2
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-3
C4B-5
C4B-6
PLATFROM LEVEL
C59CNK BL/BK
P22LS BK
C40LS OR
C13DE BL/RD
C3P-11
C4P-2
C129JDA BL
C4P-3
TURNTABLE ROTATE
C3B-5
P134 RD
PLATFROM LEVEL
RIGHT
C5TRR WH/BK
C2P-2
C4P-1
C4P-4
C3P-7
C3P-8
C3P-9
C3P-3
C3P-2
C3P-1
C3P-5
3
C3P-10
C17JU/PRL GR
C18JD/PRR GR/BK
RIGHT
PLATFROM
ROTATE
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
BR
RD
BK
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C17-2
C38-4
C9-2
C11-1
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
U4
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
WH
WH
C26-1
C5-20
C32BRK WH/RD
C130TA WH/RD
C5-23
C29MS RD/WH
BK
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
C36SCC BL
C37SCW BL/BK
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
C129 RD/BK
GROUND
DRIVE FORWARD
DRIVE REVERSE
TRAVEL ALARM
OPTION
BRAKE RELEASE
MOTOR STROKE
STEER LEFT
STEER RIGHT
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
8
DESCENT ALARM OPTION
JIB VALVE
6 - 58
S-60 • S-65
Part No. 77828
3
7
2
TB22
CR34
4
4
LEFT
C4B-7
BK
BK
BRN
1
14
H4
TB59
LS17
NO
HC
14
TB4
TB6
TB3
6
14
13
LS3
NO
NC
13
21
LS17
NC
HO 22
TB9
14
22
LS1
NO
HC
TB2
TS14
TS15
TB30
TB31
TB32
TB29
TB37
TB36
D30
5
TB5
TB40
21 LS5
NC
13
LS5
13
NO
14
TB13
TB1
TB7
TB8
13
TB15
CR34
TB134
TB44
LS2
NO
NC
TB14
TB18
R4
5
R14
5
C19JSV GR/WH
TB17
TB118
D28
TS62
TS61
TS63
TS59
R16
10
TB19
C4P-6
C4P-5
PLATFROM
ROTATE
DOWN JIB
UP
BOOM
LEFT
C4P-7
TS58
L46
H3
RIGHT
C19JSV GR/WH
D9
RD
RD
J1
J1
J1
J1
J3
CR30
NO
JIB VALVE
TS57
L47
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
2
P26ESTP BK
CR13
NC
JC3
JC2
JC1
L1
WH
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS8
TS7
CR27
NC
CR13
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Deutz F3L-2011 Models (before serial number 11880)
BRN
D29
July 2005
Section 6 • Schematics
Electrical Schematic, S-65
Deutz F3L-2011 Models (before serial number 11880)
C1P-12
C2P-6
FUSE 10A
RD/BK
C7P-1
C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
FOOTSW. LOW
C1P-9
C2P-7
C3P-12
LIGHTS
REV A
Electrical Schematic, S-65
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C1B-8
C3B-12
C2P-10
C2P-9
C34SA BK/WH
C2B-5
C3B-12
C1B-2
C7B-2
RD
BK
C1B-7
DLITE BL/WH
PBOX GND
FOOTSW. HIGH
WORK LIGHT
C2P-12
C2P-11
C1P-8
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD C1B-1
AUXILIARY
PUMP
P23BAT WH
WH
C133PLA BL/WH
C28TTA RD/BK
RD
RD
C46HRN GR
D14
GR/BK
C35RPM BK/RD
C45GEN GR/WH
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
F.H. C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
P22BAT BK
BK/RD
C5-5
C21IGN WH
P134FB WH
P116HYD RD
C5-12
RD
RD
C5-18
C5-11
C5-16
C5-14
C5-22
WH
RD
F.H. BK
R21IGN WH
R116 OR
C5-2
C5-4
C5-1
BRN
Q3
L29
L29
DRIVE LIGHT
GLOW
PLUG
C1P-7
C1P-1
C7P-2
C1P-2
C3P-12
C2P-5
C7B-1
CR23
C41RPM OR/BK
BK
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
GLOW PLUG RELAY
GLOW PLUG
OIL TEMPERATURE LED
OIL TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
EMISSIOIN CONTROL
SPEED REDUCTION RELAY
AUXILIARY POWER RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
ENGINE
START
AUX
PUMP
RD/BK
C2B-6
C1B-12
P22BAT BK
C132PLI BL/WH
P134PWR GR/BK
RD
C2B-3
H2
CR4
CR23
C21IGN WH
P20BAT RD
NO
SW3
NO
_
SW2
FAN
M1
HM
M3
STARTER
NC
C
FB1
SW3
M2
AUX
PUMP
REGULATOR
PR2
NO
PR2
PR2
NO
+
B2
Part No. 77828
S-60 • S-65
-
6 - 59
C7B-4
8
BK
C41RPM OR/BK
RD
EXCT.
NO
STA.
PR1
-
BAT.
IND.
7
D1
BAT.
+
12V DC
ALTERNATOR
S8
FUSE 70A
CR4
NO
CR5
87a 87
85
CR17
CR19
B
A
NO
NO
TB26
TB25
6
NO
RD
FUSE
10A
86
TB21
CR2
NO
CR1
TB46
5
30
D22
OIL
TEMP.
15A
TB21
C5-3
TB45
L43
U1
TB35
C3
+
CR2
TB134
3MF
CB3
TB33
TB27
D13
TB34
TB24
RD
15A
TB20
D3
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB23
TB41
TB28
TB133
CB1
7
U33
D2
WH
D4
8
C32-8
12
4
6
TS4
TS47
TS48
TS54
TS56
TS52
GRD
D12
D40
TS51
5
4
PLAT
3
1
TB22
KS1
L48
L30
TB132
RD
RD
15AMP.
3
H1
L30
Platform
Overload
Option
Only
ENGINE
SPEED
RD
RD
TS1
P3
P24FS WH
P25FS RD
P24FS WH
C9P-3
C9P-2
TS6
TS2
2
FS1
RD
RD-(FS)
WH-(FS)
BK-(FS)
C9P-1 BK
P2
C22LS BK
C28TTA RD/BK
C28TTA RD/BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
RD
P1
CB2
July 2005
Section 6 • Schematics
Deutz F3L-2011 Models (after serial number 11879)
+
Electrical Schematic, S-65
REV A
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
3
BL
CDE1 BL/WH
RIGHT
7
RKOUT 6
4
YOUT 5
PWR 3
GND 2
1
7
6
YOUT 5
PWR
2
XOUT 4
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
3
4
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C3P-4
C3P-6
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-5
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
TURNTABLE ROTATE
C5TRR WH/BK
C4P-3
C4P-2
C3P-11
PRIMARY BOOM
BOOM
C4B-4
WH
C4B-1
C11-2
J1 F.H. WH
C15PLD OR/BK
C14PLU OR
C59CNK BL/BK
P22LS BK
C40LS OR
C13DE BL/RD
C118LSR OR/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C4P-4
C4P-1
C2P-2
P134 RD
PLATFROM LEVEL
C3B-1
C3B-3
C3B-2
C3B-9
C3B-8
C3B-7
C38-1
TB5
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
C4B-5
C4B-6
PLATFROM LEVEL
C3B-10
PLATFROM
ROTATE
C4B-7
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
RD
BK
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
C129 RD/BK
3
7
U4
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
JIB VALVE
6 - 60
S-60 • S-65
Part No. 77828
2
TB22
CR34
P24FS WH
P26ESTP BK
DOWN
UP
UP
C18JD/PRR GR/BK
C129JDA BL
LEFT
RIGHT
DOWN
C4P-6
C17JU/PRL GR
C19JSV GR/WH
BK
BK
BRN
4
14
TB30
TB31
TB32
TB29
H4
TB59
LS17
NO
HC
14
TB4
TB6
1
14
13
LS3
NO
HC
13
21
LS17
NC
HO 22
22
LS2
NO
HC
R2
TS14
TS15
6
21 LS5
NC
13
LS5
13
NO
14
5
TB36
TB9
14
R4
TB37
TB2
TB14
TB18
TB3
D30
TB1
TB7
TB8
LS1
NO
HC
7.5
1
C28TTA RD/BK
5
TB17
C3P-10
C4P-5
PLATFROM
ROTATE
DOWN JIB
UP
BOOM
LEFT
C4P-7
TB19
TB40
R16
10
TB118
D28
TB13
CR19
CR34
TB134
TB44
TS62
TS61
TS63
TS59
13
TB15
R14
5
4
TS58
L46
H3
RIGHT
JIB VALVE
C19JSV GR/WH
D9
RD
RD
J1
J1
J1
J1
J3
CR30
NO
3
TS57
L47
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
2
CR13
NC
JC3
JC2
JC1
L1
WH
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS8
TS7
CR27
NC
CR13
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Deutz F3L-2011 Models (after serial number 11879)
BRN
D29
July 2005
Section 6 • Schematics
Electrical Schematic, S-65
Deutz F3L-2011 Models (after serial number 11879)
C1P-12
C2P-6
FUSE 10A
RD/BK
C7P-1
C41RPM OR/BK
FOOTSW. LOW
C1P-9
C2P-7
C3P-12
LIGHTS
REV D
Electrical Schematic, S-65, CE Models
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C7B-2
C1B-2
C3B-12
C2B-5
C1B-8
C3B-12
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
AUXILIARY
PUMP
P23BAT WH
WH
C28TTA RD/BK
C133PLA BL/WH
C46HRN GR
RD
BK
C27AUX RD C1B-1
ENGINE
START
C1B-7
DLITE BL/WH
PBOX GND
FOOTSW. HIGH
WORK LIGHT
C2P-12
C2P-11
C1P-8
C1P-7
C1P-1
C7P-2
C1P-2
C3P-12
C2P-5
C7B-1
D14
GR/BK
C35RPM BK/RD
C45GEN GR/WH
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
P22BAT BK
C5-12
C5-22
RD
RD
C5-18
C5-14
C5-16
C5-11
F.H. BK
R21IGN WH
RD
WH
BK/RD
C5-5
P134FB WH
C21IGN WH
R116 OR
C5-2
C5-4
C5-1
BRN
Q3
L29
L29
DRIVE LIGHT
GLOW
PLUG
ENGINE
START
AUX
PUMP
GR/BK
C1B-12
P22BAT BK
C132PLI BL/WH
C2B-6
NO
P116HYD RD
C41RPM OR/BK
BK
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
OIL TEMPERATURE LED
OIL TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
CR23
ENGINE
SPEED
P134PWR GR/BK
RD
C2B-3
H2
CR4
CR4
CR23
C21IGN WH
P20BAT RD
NO
SW3
NO
_
SW2
FAN
M1
HM
M3
STARTER
NC
C
FB1
SW3
M2
AUX
PUMP
REGULATOR
PR2
NO
PR2
PR2
NO
S8
+
B2
Part No. 77828
S-60 • S-65
-
6 - 61
C7B-4
8
BK
C41RPM OR/BK
RD
EXCT.
NO
STA.
PR1
+
12V DC
IND.
7
D1
BAT.
BAT.
B
A
NO
NO
CR5
CR17
85
87a 87
ALTERNATOR
6
CR1
TB26
TB25
TB35
TB134
FUSE
10A
86
TB21
CR2
NO
NO
RD
CR2
5
30
D22
OIL
TEMP.
15A
TB21
C5-3
TB45
L43
U1
C3
+
TB46
3MF
CB3
TB33
TB27
WH
TS52
TS51
D13
TB34
TB28
H6
TB23
TB41
TB24
RD
15A
7
D2
D3
U33
TB133
L45
CB1
TS54
TS56
6
GRD
D4
12
RD
RD
5
4
PLAT
3
1
TB22
KS1
TS4
TS47
TS48
TS6
D12
D40
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB20
RD
P1
8
C32-8
4
TB132
RD
RD
15AMP.
D39
L30
L30
Platform
Overload
Option
Only
3
H1
L4
P24FS WH
P25FS RD
P24FS WH
C9P-3
C9P-2
BK-(FS)
RD
RD
TS1
1
P3
TS2
2
FS1
RD
RD-(FS)
WH-(FS)
P2
C9P-1 BK
LS18
C41RPM OR/BK
P26ESTP BK
P26ESTP BK
NC
C22LS BK
C28TTA RD/BK
C28TTA RD/BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
CB2
July 2005
Section 6 • Schematics
Deutz F3L-2011 Models (before serial number 11880)
+
Electrical Schematic, S-65, CE Models
REV D
C28TTA RD/BK
DRIVE MODE
CDE3 BL/RD
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
3
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
CDE2 BL/BK
LEFT
3
BL
CDE1 BL/WH
RIGHT
7
YOUT 5
RKOUT 6
4
PWR 3
1
GND 2
7
6
2
XOUT 4
YOUT 5
GND
PWR
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
P26ESTP BK
UP
DOWN
LEFT
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C7P-3
C2P-3
C1P-4
C1P-5
C41RPM OR/BK
BATGND
C1B-4
C2B-3
C7B-3
C1B-6
C30FWD WH
C32BRK WH/RD
C1B-3
C1B-5
C29MS RD/WH
C1B-11
C31REV WH/BK
C1P-3
C37SCW BL/BK
C1P-6
C1P-11
C4TRL WH
C3B-5
C3B-4
RIGHT
PRIMARY BOOM
TURNTABLE ROTATE
C5TRR WH/BK
LEFT
UP
DOWN
C2PBD RD/BK
C1PBU RD
C3PBF RD/WH
C9PER BK/RD
C7PBE BK
C8PBR BK/WH
EXTEND
BOOM
C4B-4
RETRACT
C118LSR OR/RD
J1 F.H. WH
WH
C4B-1
C11-2
C14PLU OR
C3B-2
C3B-1
C3B-3
C3B-9
C3B-7
C3B-8
C4B-2
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-3
C4B-5
C4B-6
PLATFROM LEVEL
C59CNK BL/BK
P22LS BK
C40LS OR
C13DE BL/RD
C3P-11
C4P-2
DOWN
UP
C15PLD OR/BK
C17JU/PRL GR
C18JD/PRR GR/BK
C4P-3
C3B-6
C1B-10
P134 RD
PLATFROM LEVEL
C4P-6
C6TRF WH/RD
C36STCC BL
C2P-2
C4P-1
C4P-4
C3P-7
C3P-8
C3P-9
C3P-3
C3P-2
C3P-1
C3P-5
C3P-4
C3P-6
C1P-10
3
PLATFROM ROTATE
RIGHT
PLATFROM
ROTATE
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
BR
RD
BK
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C24-2
C15-2
C31-2
C14-2
C31-1
C12-2
C15-1
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C17-2
C38-4
C9-2
C11-1
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C10-2
C17-1
C29-1
C14-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
U4
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
WH
WH
C26-1
C5-20
C32BRK WH/RD
C130TA WH/RD
C5-23
C29MS RD/WH
BK
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
C36SCC BL
C37SCW BL/BK
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
GROUND
DRIVE FORWARD
DRIVE REVERSE
TRAVEL ALARM
OPTION
BRAKE RELEASE
MOTOR STROKE
STEER LEFT
STEER RIGHT
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
8
DESCENT ALARM OPTION
6 - 62
S-60 • S-65
Part No. 77828
3
7
2
TB22
CR34
4
C129 RD/BK
BK
BK
BRN
1
14
H4
TB59
LS17
NO
HC
14
5
TB30
TB2
6
14
13
LS3
NO
NC
13
21
LS17
NC
HO 22
22
LS1
NO
HC
NO
14
TB4
TB6
L1
TB31
TB32
TB29
TB37
TB36
TB9
14
TB3
D30
TB5
TB40
21 LS5
NC
13
LS5
13
TB13
TB1
TB7
TB8
LS2
NO
NC
13
TB15
CR34
TB134
R16
10
TB118
D28
TS62
TS61
TS63
TS59
TS14
TS15
4
LEFT
TB17
TB14
TB18
R4
5
R14
5
J1
J1
J1
J1
J3
CR30
NO
RIGHT
D27
2
CR27
NC
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
C4P-5
TS57
L46
H3
D9
RD
RD
L47
3
TS9
TS7
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
1
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Deutz F3L-2011 Models (before serial number 11880)
D29
July 2005
Section 6 • Schematics
Electrical Schematic, S-65, CE Models
Deutz F3L-2011 Models (before serial number 11880)
C1P-12
C2P-6
FUSE 10A
RD/BK
C7P-1
C22LS BK
C28TTA RD/BK
1
C28TTA RD/BK
C41RPM OR/BK
FOOTSW. LOW
C1P-9
REV A
Electrical Schematic, S-65, CE Models
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C7B-2
C1B-2
C3B-12
C2B-5
C1B-8
C3B-12
C133PLA BL/WH
RD
BK
C1B-7
DLITE BL/WH
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD C1B-1
AUXILIARY
PUMP
P23BAT WH
WH
C3P-12
C46HRN GR
C28TTA RD/BK
C2P-5
C7B-1
PBOX GND
FOOTSW. HIGH
C2P-7
C3P-12
C1P-2
C7P-2
C1P-1
C1P-7
C1P-8
LIGHTS
C2P-11
C2P-12
WORK LIGHT
DRIVE LIGHT
GLOW
PLUG
ENGINE
START
AUX
PUMP
GR/BK
C1B-12
P22BAT BK
C132PLI BL/WH
C2B-6
D14
GR/BK
C35RPM BK/RD
C45GEN GR/WH
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
F.H. C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
P22BAT BK
BK/RD
C5-5
P134FB WH
C21IGN WH
C5-12
RD
RD
C5-18
C5-11
C5-16
C5-14
C5-22
WH
RD
F.H. BK
R21IGN WH
R116 OR
C5-4
C5-1
BRN
Q3
L29
SW3
NO
L29
SW2
ENGINE
SPEED
P134PWR GR/BK
P116HYD RD
C5-2
BK
H2
CR23
C41RPM OR/BK
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
GLOW PLUG RELAY
GLOW PLUG
OIL TEMPERATURE LED
OIL TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
EMISSION CONTROL
SPEED REDUCTION RELAY
AUXILIARY POWER RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
HM
M2
AUX
PUMP
REGULATOR
Part No. 77828
S-60 • S-65
-
6 - 63
NO
CR4
CR23
C21IGN WH
P20BAT RD
8
NO
_
NC
C
SW3
FAN
M1
+
M3
STARTER
B2
FB1
IND.
7
+
12V DC
RD
C2B-3
C7B-4
EXCT.
PR2
NO
PR2
PR2
NO
BAT.
BAT.
BK
C41RPM OR/BK
RD
D1
STA.
PR1
S8
FUSE 70A
ALTERNATOR
L43
CR4
NO
CR5
87a 87
85
CR17
CR19
B
A
NO
NO
6
CR2
NO
NO
TB35
TB134
TB26
TB25
86
TB21
TB21
C5-3
TB45
OIL
TEMP.
RD
D13
TB34
TB24
RD
FUSE
10A
30
D22
TB33
TB27
WH
CR2
CR1
15A
TB23
TB41
TB28
H6
7
D2
D3
U33
U1
C3
+
TB46
3MF
CB3
5
6
D4
4
L45
CB1
TS54
TS56
TS52
TS51
GRD
5
4
PLAT
8
C32-8
12
RD
RD
3
1
TB22
KS1
TB133
15A
RD
P1
TS4
TS47
TS48
TS6
D12
D40
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB20
TB132
RD
RD
15AMP.
D39
L30
L30
Platform
Overload
Option
Only
3
H1
L4
P24FS WH
P25FS RD
P24FS WH
C9P-3
C9P-2
P2
RD
RD
TS1
1
P3
TS2
2
FS1
RD
RD-(FS)
WH-(FS)
BK-(FS)
C9P-1 BK
LS18
C41RPM OR/BK
P26ESTP BK
P26ESTP BK
NC
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
CB2
July 2005
Section 6 • Schematics
Deutz F3L-2011 Models (after serial number 11879)
+
Electrical Schematic, S-65, CE Models
REV A
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
3
BL
CDE1 BL/WH
RIGHT
7
RKOUT 6
4
YOUT 5
PWR 3
GND 2
1
7
6
YOUT 5
PWR
2
XOUT 4
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
3
4
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C3P-4
C3P-6
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-5
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
TURNTABLE ROTATE
C5TRR WH/BK
C4P-3
C4P-2
C3P-11
PRIMARY BOOM
BOOM
C4B-4
WH
C4B-1
C11-2
J1 F.H. WH
C15PLD OR/BK
C14PLU OR
C59CNK BL/BK
P22LS BK
C40LS OR
C13DE BL/RD
C118LSR OR/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C4P-4
C4P-1
C2P-2
P134 RD
PLATFROM LEVEL
C3B-1
C3B-3
C3B-2
C3B-9
C3B-8
C3B-7
C38-1
TB5
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
C4B-5
C4B-6
PLATFROM LEVEL
C3B-10
PLATFROM
ROTATE
C4B-7
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
RD
BK
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
C129 RD/BK
3
7
U4
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
JIB VALVE
6 - 64
S-60 • S-65
Part No. 77828
2
TB22
CR34
P24FS WH
P26ESTP BK
DOWN
UP
UP
C18JD/PRR GR/BK
C129JDA BL
LEFT
RIGHT
DOWN
C4P-6
C17JU/PRL GR
C19JSV GR/WH
BK
BK
BRN
4
14
TB30
TB31
TB32
TB29
H4
TB59
LS17
NO
HC
14
TB4
TB6
1
14
13
LS3
NO
HC
13
21
LS17
NC
HO 22
22
LS2
NO
HC
R2
TS14
TS15
6
21 LS5
NC
13
LS5
13
NO
14
5
TB36
TB9
14
R4
TB37
TB2
TB14
TB18
TB3
D30
TB1
TB7
TB8
LS1
NO
HC
7.5
1
C28TTA RD/BK
5
TB17
C3P-10
C4P-5
PLATFROM
ROTATE
DOWN JIB
UP
BOOM
LEFT
C4P-7
TB19
TB40
R16
10
TB118
D28
TB13
CR19
CR34
TB134
TB44
TS62
TS61
TS63
TS59
13
TB15
R14
5
4
TS58
L46
H3
RIGHT
JIB VALVE
C19JSV GR/WH
D9
RD
RD
J1
J1
J1
J1
J3
CR30
NO
3
TS57
L47
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
2
CR13
NC
JC3
JC2
JC1
L1
WH
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS8
TS7
CR27
NC
CR13
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Deutz F3L-2011 Models (after serial number 11879)
BRN
D29
July 2005
Section 6 • Schematics
Electrical Schematic, S-65, CE Models
Deutz F3L-2011 Models (after serial number 11879)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-65
Deutz F3L-2011 Models (before serial number 11880)
6 - 65
BK C5-5
7
BK
WH
S-60 • S-65
BK
WH
NOTE: DASHED LINES INDICATE OPTION WIRES
8
Part No. 77828
BK
WH
+ C3
ENGINE START
GLOW PLUG
HIGH FUNCTION SPEED
STEER RIGHT
STEER LEFT
(UNUSED)
BOOM STOWED
33
34
35
36
37
39
40
BRN
BK
WH
D33
4 7 10 9 2
START RELAY
TACHOMETER
U1
START INPUT
AUX PWR UNIT
GROUND
BATTERY
TO KEY SW (DIESEL ONLY)
JUMP TO 7 (GAS ONLY)
IGN OR FUEL ON
TEMP OR PRESS FAULT
OR-LS17 C38-2
OR/RD-LS17 C38-3
C45GEN GR/WH C2B-7
R46HRN BK
C118BSR OR/RD C4B-4
C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
C59CNK BL/BK C3B-11
C59CNK WH-LS5 C37-4
C134PWR GR/BK C2B-6
C134PWR RD-LS17 C38-1
C134PWR BK-LS5 C37-3
P134TTSR RD A
Ground Control Box Terminal Strip Wiring Diagram, S-65
M
GROUND BOLT
12/24 Volt IGNITON/START MODULE P/N 56057
1 3
1
2
3
4
5
6
7
8
9
10
A
D30
TO REMOVE:
45
46R
118
132
133
134
134
59
H6
CE ONLY
Push gently
and lift
41
46
C40LS1 OR C2B-2
C40LS1 OR C10-2
C41RPM OR/BK C2B-3
C41RPM OR/BK C5-2
C46HRN GR C2B-5
C36STCC BL C1B-10
C36STCC BL C24-1
C37STC BL/BK C1B-11
C37STC BL/BK C25-1
C39LP BL/RD C2B-1
C34SA BK/WH C1B-8
C34SA BK/WH C5-22
C35HS BK/RD C1B-9
BRN
BRN C37-2
Genie Industries
GENERATOR OPTION
HORN RELAY POWER
LIFT SPEED REDUCTION
PLATFORM OVERLOAD LS
PLATFORM OVERLOAD ALARM
PLAT. OVERLOAD LIM. SW. +12V (2)
45
46R
118
132
133
PLAT. OVERLOAD LIM. SW. +12V (1)
134
RETRACT BOOM LED
HORN
134
59
46
40
39
37
32
L
WH-CR2
WH/BK-25D
BRAKE
32
WH C11-2
1
2
3
4
5
6
7
8
9
10
36
DRIVE REVERSE
31
+12V DC
POWER
ENGINE
BK-CR1
OR/BK-41C
BK-33C
RD-27C
BRN
RD-24C
WH-23C
B
35
DRIVE FORWARD
30
P20BAT RD
BRN
K
OR-CR34
OR/RD-118B
33
34
MOTOR STROKE
29
C37
GR/WH C5-12
BK-CR5
OR/RD-FH C38-3
BL/WH C32-3
GR/BK-H6-
RD-H6+
P134FB WH-FH
RD-KS
31
TILT ALARM
28
CABLE
TENSION
LIMIT SWITCH
LS5
J
WH-L46+
D52
ALTERNATOR PULSE PICKUP
30
AUXILARY PUMP
27
#1
C5
#2
F.H.
41
29
OIL TEMPERATURE SWITCH
26
C5
#2
F.H.
C26PSR WH/RD C5-14
C27AUX RD C1B-1
C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C32BRK WH/RD C5-23
C33STR BK C1B-7
C25TSR WH/BK C5-16
RD-CR2
C11
GR-CR5
28
OIL PRESSURE SWITCH
25
24
#1
I
OR/BK-ISM2
BRN-GND
27
CIRCUIT BREAKER POWER
24
23
22
+
BK/WH-TS56
BK/RD-CR4
RD-TS54
26
KEY SWITCH POWER
23
C22LS17 BK C10-2
P22BAT BK C11-1
P22BAT BK C9-2
P23BAT WH C7B-2
H
WH/RD-ALRM
BK-ISM3
BK-TS52
25
+12V DC TO PLATFORM (2)
22
22
P20BAT RD
P20BAT RD
C21IGN WH CR2
C21IGN2 WH C5-11
G
WH/RD-L2RD-ISM4
RD-TS51
+12V DC TO PLATFORM (1)
22
21
IGNITION POWER
21
20
P134PWR RD-134C
GR/BK-133B
GR/BK-L45
WH/BK-ISM10
D29
+12V DC POWER
BOOM
EXTEND
LIMIT SWITCH
LS1
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12V DC
POWER TO
PLATFORM
C7
F
BK C32-4
WH-ISM7
WH-KS
RD-ISM6
RD-CB1
JIB BOOM SELECT VALVE
19
#2
20
F.H.
19
18
PLATFORM ROTATE RIGHT/JIB DOWN
18
15
17
PLATFORM LEVEL DOWN
C1PBU RD C3B-1
C1PBU RD C12-1
C2PBD RD/BK C3B-2
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C6TRF WH/RD C31-1
C7PBE BK C3B-7
C7PBE RD-LS5 C37-1
C8PBR BK/WH C3B-8
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
C9PER BK/RD C30-1
JDALARM BL C3B-10
RD/BK-ALARM
C13DRE BL/RD C4B-1
C13DRE BL/RD C10-1
C14PLU OR C4B-2
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C15PLD OR/BK C21-1
C17JU GR C4B-5
C17JU GR C22-1
C18JD GR/BK C4B-6
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
C5
GR/WH-TS57
RD-CB2
RD-CB1
BRN-<GND>
WH-HM
BK-CR5
BK-KS
GR/BK-TS57
13
14
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL UP
14
44
15
DRIVE ENABLE
13
17
JIB BOOM DOWN DESCENT ALARM
44
9
A
#1
GR-TS57
BOOM EXT/RET FUNCTION CTRL
9
7
8
B
E
OR/BK-TS59
OR-TS59
BL-TS58
BOOM EXTEND
BOOM RETRACT
7
6
TURNTABLE ROTATE FUNCTION CTRL
6
8
4
5
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
4
5
2
3
BOOM DOWN
BOOM FUNCTION CONTROL
2
3
1
D
BK/RD-TS63
BK/WH-TS63
BK-TS63
WH/RD-TS62
BK-22C1
BOOM UP
1
WH/BK-TS62
BRN
1
R43DLITE1 RD
R43DLITE2 RD
TERMINAL BASE (TB)
BK C7B-1
RD-TS51
RD-TS52
GR/BK H6
BRN
WH-TS62
BRN
C
RD/WH-R16
C
RD-24B
C21IGN WH C5-3
D
4
RD-TS61
RD/BK-ALARM
RD/BK-TS61
6
BRN
RD-CB3
C5-18 BK/RD
GR-46D
RD-CB3 OPTIONS
WH-21B
C21IGN WH
C32 CONNECTOR
PLUG ANSI/CSA ONLY
CR17
HYDRAULIC
OIL COOLER
OPTION
RD H6
BL/WH-132B
BK-22D2
C2B-5 GR
OR C5-1
C32
B
BRN
BK/RD-35C
CR22
DRIVE LIGHT
OPTION
5
CR5
HORN
RELAY
CR4
HIGH RPM
SOLENOID
RELAY
BRN
5
6
7
8
12
F.H.
WH
2
1
3
4
BK-46R
C5
C32
WH
BRN
RD
BRN
3
BRN
WH-ISM9
RD
CR2
POWER
RELAY
A
GROUND HARNESS
TO SWITCH PANEL
BK-ISM1
CR1
IGNITION/START
RELAY
Section 6 • Schematics
July 2005
REV B
Deutz F3L-2011 Models (before serial number 11880)
N
FUNCTION
HARNESS
C5
F.H.
BK C16-1
WH LS2 C10-2
BRN C7B-3
C5
#2
F.H.
July 2005
REV B
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Deutz F3L-2011 Models (before serial number 11880)
H
G
F
E
C
GR/BK
RD
RD
RD
C19JSV GR/WH
GR/BK
GR/BK-18D
RD
WH-4
WH/BK-5
WH/RD-6
RD
RD/WH
+
RD-1
-
RD
TS51
AUXILIARY
POWER
D3
RD
RD
RD
D4
A
1
RD
RD/BK-2
RD
B
D9
RD
RD
D
BASE BOX HARNESS
(TO TERMINAL STRIP)
I
TS57
PLATFORM
ROTATE
J
GR-17D
K
TS62
TURNTABLE
ROTATE
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
2
RD
RD
GR
RD
GR/BK
RD-24D
BK/RD-35D
4
CIRCUIT
BREAKER
CONTROLS 15A
CB2
5
RD-20C
RD/WH
TS59
PLATFORM
GR/WH-19D LEVEL
GR-17D
RD-20D
OR/BK-15D
RD
OR-14D
GR/BK-18D
RD
RD-20C
CIRCUIT
BREAKER
OPTIONS 15A
CB3
RD-20C
RD/WH
BK-33D
BL-44D
RD CR22
RD CR17
RD C32-7
BK/WH-34D
BK-7D
RD-1D
WH-4D
WH/BK-5D
WH/RD-6D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
3
TS58
JIB BOOM
UP/DOWN
RD
GR
RD
RD
RD
RD/WH-CR34
GR/BK-H6WH/RD-26
BRN-GND
-
+
3
D2
RD
WH-23
RD/WH
RD/BK-2D
BRN
L46
+
LOWER/
RETRACT BOOM
BL/BK-59D
L2
CHECK
ENGINE
WH-21D
RD
4
WH
WH-23D
RD-134D2
BK-22D1
B1
2
1
B
KS1
KEY
SWITCH
RD/WH-TB3D
RD C32-6
C134PWR RD
WH
RD-27
OR-LS17
DALE RH-25 25W
10 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
R4
TURNTABLE
ROTATE
RESISTOR
WH
RD-27D
RD
RD
RD
OR
2
RD
RD-20D
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
TS52
ENGINE
START
BK/WH-34D
RD
BRN
RD
RD
D14
TS54
FUNCTION
ENABLE
2
D13
1
NC
HOUR METER
1
NC
RD
WH-21D
BRN
BRN
BRN
P1
EMERGENCY
STOP SWITCH
RD/WH-R16
CR34
BOOM
SPEED
REDUCTION
RD/WH-TS61
RD/WH-R16
OR-LS17
RD
DALE RH-25 25W
5 ohm 1%
RD
RD
6
RD
R14
BOOM
UP/DOWN
RESISTOR
RD
TS56
GLOW
PLUG
DALE RH-25 25W
5 ohm 1%
WH
D28
RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
CR34
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
BOOM SPEED REDUCTION RELAY
HM
KS1
L2
L46
L45
P1
R4
R14
R16
TS51
TS52
TS54
TS56
TS57
TS58
TS59
TS61
TS62
TS63
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 66
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Deutz F3L-2011 Models (before serial number 11880)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-65
Deutz F3L-2011 Models (after serial number 11879)
6 - 67
BK
WH
8
WH-OPTIONS
S-60 • S-65
WH-TB21 OPTIONS
FUSE 10A
(DRIVE LIGHT ONLY)
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
RD/WH-R16
WH/RD-R4
+
C3
BK-46R
RD/WH-TS61
WH/RD-R2
BRN
BK
BK
BK
RD
RD
RD
WH
WH
WH
WH/BK-25D
D33
1
3
4
7
10
9
2
IGN OR FUEL ON
JUMP TO 7 (GAS ONLY)
TO KEY SW (DIESEL ONLY)
BATTERY
GROUND
10 TEMP OR PRESS FAULT
9
8
7
6
5
AUX PWR UNIT
START INPUT
TACHOMETER
START RELAY
U1
LS17 (C38)
C11 (LS2)
C9 (LS3)
Ground Control Box Terminal Strip Wiring Diagram, S-65
M
GROUND BOLT
12/24 Volt IGNITON/START MODULE P/N 56057
10
9
8
7
6
5
4
3
2
1
OR/RD-LS17 C38-3
FUNCTION
HARNESS
WH-CR2
WH-23C
RD-24C
and lift
Push gently
TO REMOVE:
A
C133PLA BL/WH C3B-12
C132PLI BL/WH C1B-12
C118LSR OR/RD C4B-4
R46HRN BK
C45GEN GR/WH C2B-7
P134TTS RD A
+12V POWER
L
BRN
4
3
133
132
D30
RD-CR19
BK-33C
Genie Industries
PLATFORM OVERLOAD ALARM
PLATFORM OVERLOAD LS
118
P134PWR RD-LS17 C38-1
P134PWR BK-LS5 C37-3
WH C11-2
2
1
133
132
LIFT SPEED REDUCTION
46R
45
134
134
P134PWR GR/BK C2B-6
C59CNK BL/BK-LS5 C37-4
C59CNK BL/BK C3B-11
F.H.
HORN RELAY POWER
GENERATOR OPTION
LOAD WEIGHING LIM. SW. +12V (2)
LOAD WEIGHING LIM. SW. +12V (1)
59
46
#2
F.H.
118
SERVICE HORN
RETRACT BOOM LED
C46HRN GR C2B-5
C41RPM OR/BK C5-2
C41RPM OR/BK C2B-3
C40LS1 OR C10-2
C40LS1 OR C2B-2
C39LP BL/RD C2B-1
C37SCW BL/BK C25-1
C37SCW BL/BK C1B-11
C36SCC BL C24-1
C36SCC BL C1B-10
C35RPM BK/RD C1B-9
C34SA BK/WH C5-22
C34SA BK/WH C1B-8
#2
F.H.
46R
45
134
134
59
46
41
40
39
C32BRK WH/RD C5-23
C33STR BK C1B-7
BRN C37-2
OR/BK-41C
40
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
BRN
P20BAT RD
H6
CE
OPTION ONLY
BK-CR1
B
(UNUSED)
BOOM STOWED
39
37
36
35
34
33
32
31
C31REV WH/BK C1B-5
C30FWD WH C5-21
C30FWD WH C1B-4
C29MS RD/WH C5-24
C29MS RD/WH C1B-3
C28TTA RD/BK B
C28TTA RD/BK C1B-2
C27AUX RD PR1
C27AUX RD C1B-1
C26PS WH/RD C5-14
C25TS WH/BK C5-16
CABLE
TENSION
LIMIT SWITCH
C37 (LS5)
K
OR/RD-118B
STEER RIGHT
37
ALTERNATOR PULS PICKUP
STEER LEFT
41
HIGH FUNCTION SPEED
36
GLOW PLUG
START ENGINE
BRAKE
35
34
33
32
PROPEL REVERSE
31
30
MOTOR STROKE
29
PROPEL FORWARD
29
TILT ALARM
28
30
28
AUXILARY PUMP
27
27
26
25
RD-CR2
#2
GR/BK-H6-
OIL PRESSURE SWITCH
25
24
P23BAT WH C7B-2
C5
BL/WH C32-3
CIRCUIT BREAKER POWER
24
23
22
P22BAT BK C9-2
P22BAT BK C11-1
P22LS17 BK C38-4
C21IGN2 WH C5-3
BOOM
EXTEND
LIMIT SWITCH
C11 (LS1)
C5
ENGINE
OR/RD-FH C38-3
KEYSWITCH POWER
23
P20BAT RD
P20BAT RD
C21IGN WH CR2
C5
BK-CR5
GR/WH C5-12
+12 VOLT TO PLATFORM (2)
22
OIL TEMPERATURE SWITCH
+12 VOLT TO PLATFORM (1)
22
26
21
IGNITION POWER
21
22
20
+12 VOLT POWER
20
C37
RD-KS
P134FB WH-FH
RD-H6+
JIB SELECT VALVE
19
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
18/19 #2
C1 & C2
J
BL/BK-L46+
GR-CR5
PLATFORM ROTATE RIGHT/JIB DOWN
18
C18JD GR/BK C4B-6
C17JU GR C22-1
C17JU GR C4B-5
C15PLD OR/BK C21-1
C11
BRN-GND
PLATFORM ROTATE LEFT/JIB UP
C14PLU OR C20-1
C15PLD OR/BK C4B-3
I
OR/BK-ISM2
RD-TS54
BK/RD-CR4
BK/WH-TS56
BK-TS52
PLATFORM LEVEL DOWN
15
17
14
C14PLU OR C4B-2
C13DE BL/RD C10-1
C13DE BL/RD C4B-1
18/19 #1
C3 & C4
H
BK-ISM3
WH/RD-ALRM
D52
RD-TS51
PLATFORM LEVEL UP
14
13
44
RD/BK-ALARM
#1
RD-CR19#86
DRIVE ENABLE
13
C9PER BK/RD C30-1
JDALARM BL C3B-10
+12 VOLT
POWER TO
PLATFORM
C7
G
WH/RD-L2-
JIB DOWN DESCENT ALARM
44
9
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
GR/BK-L45
WH/BK-ISM10
RD-CB1
RD-ISM6
WH-KS
WH-ISM7
BK C32-4
BK-KS
BK-CR5
PRIM. BOOM EXT/RET FUNC. CTRL
9
8
C8PBR BK/WH C3B-8
C7PBE RD-LS5 C37-1
C7PBE BK C3B-7
C6TRF WH/RD C31-1
F
WH-HM
D29
BRN-<GND>
PRIMARY BOOM RETRACT
8
7
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
#2
RD-CB1
19
PRIMARY BOOM EXTEND
7
6
C4TRL WH C15-1
C5TRR WH/BK C3B-5
F.H.
RD-CB2
18
TURNTABLE ROTATE FUNCTION CTRL
6
5
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C5
GR/WH-TS57
GR/BK-TS57
15
17
TURNTABLE ROTATE RIGHT
5
4
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
#1
GR-TS57
TURNTABLE ROTATE LEFT
3
4
RD/WH-3D
PRIMARY BOOM FUNCTION CONTROL
RD-24B
3
2
C1PBU RD C12-1
C2PBD RD/BK C3B-2
E
OR/BK-TS59
OR-TS59
BL-TS58
BK C5-5
BK/RD-TS63
BK-22C1
BK/WH-TS63
GR-46D
D
BK-TS63
WH/RD-6D
C1PBU RD C3B-1
1
WH/RD-CR19
RD-27C
WH/BK-TS62
BRN
WH-TS62
C21IGN WH C5-11
PRIMARY BOOM DOWN
R43DLITE2 RD
A
BRN
2
B
BRN
RD/WH-CR34
C2B-4 OR/RD
1
GR/BK-133B
RD/BK-TS61
BRN
C
RD/BK-ALARM
P134PWR RD-134C
BK-22D2
TERMINAL BASE (TB)
BL/WH-132B
4
PRIMARY BOOM UP
3
1
RD H6
C
C32 CONNECTOR
PLUG ANSI/CSA ONLY
OR-LS17 C38-2
C32
RD-CB3
1
RD/WH-TS61
R43DLITE1 RD
CR17
HYDRAULIC
OIL COOLER
OPTION
U33
PLATFORM
OVER LOAD
(CE ONLY)
D
WH-21B
RD-TS61
BK/RD-35C
RD/WH-R16
C5-18 BK/RD
WH/RD-R4
5
C21IGN WH
B
WH/RD-R2
CR4
HIGH RPM
SOLENOID RELAY
OR C5-1
8
RD-ISM4
WH-OPTIONS
WH C5-4
12
CR34
PRIMARY BOOM
SPEED
REDUCTION
RELAY
RD-TS52
BRN
7
CR19
SWING SPEED
SELECT
RELAY
BRN
RD-TS51
CR5
HORN
RELAY
F.H.
C32
BK C7B-1
6
C32
C5
CR23
DRIVE LIGHT
OPTION
5
C32
BRN
WH
RD
A
GROUND HARNESS
TO SWITCH PANEL
7
BRN
2
WH-ISM9
BRN
6
RD
CR2
POWER
RELAY
4
BK-ISM1
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV A
Deutz F3L-2011 Models (after serial number 11879)
N
F.H.
+
BRN
BK C16-1
BRN C7B-3
WH LS2 C10-2
GR/BK H6
#1
C5
3
July 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Deutz F3L-2011 Models (after serial number 11879)
G
F
E
RD
RD
D
RD/WH
GR/BK
RD
C19JSV GR/WH
WH-4
WH/BK-5
RD
RD/WH
WH/RD
2
WH/RD
WH/RD
GR
WH/RD
GR/BK
GR/BK-18D
+
RD
D4
RD
RD
RD
A
1
RD-1
-
RD
TS51
AUXILIARY
POWER
D3
RD
RD
B
WH/RD
RD
RD/BK-2
C
BASE BOX HARNESS
(TO TERMINAL STRIP)
H
TS57
PLATFORM
ROTATE
I
GR-17D
J
TS62
TURNTABLE
ROTATE
K
D9
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
GR/BK
D28
RD
GR
TS59
PLATFORM
GR/WH-19D LEVEL
GR-17D
OR/BK-15D
RD
OR-14D
GR/BK-18D
BL-44D
WH-4D
WH/BK-5D
RD/WH-CR34#87a
BK-7D
RD-1D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD/WH
RD/BK-2D
GR/BK-H6-
BRN
L46
+
LOWER/
RETRACT BOOM
RD C32-6
C134PWR RD
BL/BK-59D
RD
WH
RD-27D
3
RD
TS58
JIB BOOM
UP/DOWN
WH
RD-27
WH/RD
WH/RD
WH/RD
CB2
RD-20C
5
RD
RD
RD
RD
RD/WH
CIRCUIT
BREAKER
CONTROLS 15A
RD
RD-24D
BK/RD-35D
RD-20D
BK-33D
CIRCUIT
BREAKER
OPTIONS 15A
RD-20C
RD/WH
RD-20C
RD CR22
RD CR17
BK/WH-34D
CB3
-
+
4
D2
RD
WH-23
RD/WH
RD C32-7
BRN-GND
WH/RD-26
B1
2
L2
CHECK
ENGINE
WH-21D
WH-23D
RD-134D2
BK-22D1
B
RD
3
KS1
KEY
SWITCH
1
WH
WH
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
R4
TURNTABLE
ROTATE
RESISTOR
DALE RH-25 25W
7.5 ohm 1%
4
R2
TURNTABLE
ROTATE
RESISTOR
RD
RD-20D
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
BK/WH-34D
RD
BRN
WH-21D
TS52
ENGINE
START
RD
DALE RH-25 25W
10 ohm 1%
DALE RH-25 25W
5 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
BRN
RD
RD
RD
TS54
FUNCTION
ENABLE
2
D14
2
D13
1
NC
HOUR METER
1
NC
RD
P1
EMERGENCY
STOP SWITCH
RD
R14
BOOM
UP/DOWN
RESISTOR
6
TS56
GLOW
PLUG
DALE RH-25 25W
5 ohm 1%
RD
RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
HM
KS1
L2
L46
L45
P1
R2
R4
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 7.5 OHMS
R14
R16
TS51
TS52
TS54
TS56
TS57
TS58
TS59
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
TS61
TS62
TS63
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 68
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Deutz F3L-2011 Models (after serial number 11879)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models
Deutz F3L-2011 Models (before serial number 11880)
7
8
6 - 69
BK C5-5
BK
WH
S-60 • S-65
BK
WH
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
BK
WH
+ C3
GLOW PLUG
HIGH FUNCTION SPEED
STEER RIGHT
STEER LEFT
(UNUSED)
BOOM STOWED
35
36
37
39
40
BRN
BK
WH
D33
4 7 10 9 2
START RELAY
TACHOMETER
U1
START INPUT
AUX PWR UNIT
GROUND
BATTERY
TO KEY SW (DIESEL ONLY)
JUMP TO 7 (GAS ONLY)
IGN OR FUEL ON
TEMP OR PRESS FAULT
OR-LS17 C38-2
OR/RD-LS17 C38-3
Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models
M
GROUND BOLT
12/24 Volt IGNITON/START MODULE P/N 56057
1 3
1
2
3
4
5
6
7
8
9
10
D30
TO REMOVE:
A
C45GEN GR/WH C2B-7
R46HRN BK
C118BSR OR/RD C4B-4
C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
C59CNK BL/BK C3B-11
C59CNK WH-LS5 C37-4
C134PWR GR/BK C2B-6
C134PWR RD-LS17 C38-1
C134PWR BK-LS5 C37-3
P134TTSR RD A
C40LS1 OR C2B-2
C40LS1 OR C10-2
C41RPM OR/BK C2B-3
C41RPM OR/BK C5-2
C46HRN GR C2B-5
H6
CE ONLY
Push gently
and lift
45
46R
118
132
133
134
134
59
46
41
40
BRN
BRN C37-2
Genie Industries
GENERATOR OPTION
HORN RELAY POWER
LIFT SPEED REDUCTION
PLATFORM OVERLOAD LS
PLATFORM OVERLOAD ALARM
PLAT. OVERLOAD LIM. SW. +12V (2)
45
46R
118
132
133
PLAT. OVERLOAD LIM. SW. +12V (1)
134
RETRACT BOOM LED
HORN
134
59
46
37
39
C36STCC BL C1B-10
C36STCC BL C24-1
C37STC BL/BK C1B-11
C37STC BL/BK C25-1
C39LP BL/RD C2B-1
C34SA BK/WH C1B-8
C34SA BK/WH C5-22
C35HS BK/RD C1B-9
L
WH-CR2
WH/BK-25D
START ENGINE
33
34
32
WH C11-2
1
2
3
4
5
6
7
8
9
10
36
BRAKE
32
ENGINE
BK-CR1
OR/BK-41C
BK-33C
RD-27C
BRN
RD-24C
WH-23C
B
35
DRIVE REVERSE
31
+12V DC
POWER
K
OR-CR34
OR/RD-118B
33
34
DRIVE FORWARD
30
C37
GR/WH C5-12
BK-CR5
OR/RD-FH C38-3
BL/WH C32-3
GR/BK-H6-
RD-H6+
P134FB WH-FH
RD-KS
31
MOTOR STROKE
29
P20BAT RD
BRN
J
WH-L46+
D52
ALTERNATOR PULS PICKUP
30
TILT ALARM
28
#1
C5
#2
F.H.
41
29
AUXILARY PUMP
27
C11
GR-CR5
28
OIL TEMPERATURE SWITCH
26
C5
#2
F.H.
C26PSR WH/RD C5-14
C27AUX RD C1B-1
C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C32BRK WH/RD C5-23
C33STR BK C1B-7
C25TSR WH/BK C5-16
RD-CR2
#1
I
OR/BK-ISM2
BRN-GND
27
OIL PRESSURE SWITCH
25
24
+
BK/WH-TS56
BK/RD-CR4
RD-TS54
26
CIRCUIT BREAKER POWER
24
23
22
CABLE
TENSION
LIMIT SWITCH
LS5
H
WH/RD-ALRM
BK-ISM3
BK-TS52
25
KEY SWITCH POWER
C22LS17 BK C10-2
P22BAT BK C11-1
P22BAT BK C9-2
P23BAT WH C7B-2
G
WH/RD-L2RD-ISM4
RD-TS51
+12V DC TO PLATFORM (2)
22
23
22
P20BAT RD
P20BAT RD
C21IGN WH CR2
C21IGN2 WH C5-11
P134PWR RD-134C
GR/BK-133B
GR/BK-L45
WH/BK-ISM10
+12V DC TO PLATFORM (1)
22
21
IGNITION POWER
21
20
BOOM
EXTEND
LIMIT SWITCH
LS1
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12V DC
POWER TO
PLATFORM
C7
F
BK C32-4
WH-ISM7
WH-KS
RD-ISM6
RD-CB1
D29
+12V DC POWER
F.H.
20
#2
19
JIB BOOM SELECT VALVE
19
C5
GR/WH-TS57
RD-CB2
RD-CB1
BRN-<GND>
WH-HM
BK-CR5
BK-KS
18
PLATFORM ROTATE RIGHT/JIB DOWN
18
15
17
PLATFORM LEVEL DOWN
C1PBU RD C3B-1
C1PBU RD C12-1
C2PBD RD/BK C3B-2
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C6TRF WH/RD C31-1
C7PBE BK C3B-7
C7PBE RD-LS5 C37-1
C8PBR BK/WH C3B-8
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
C9PER BK/RD C30-1
JDALARM BL C3B-10
RD/BK-ALARM
C13DRE BL/RD C4B-1
C13DRE BL/RD C10-1
C14PLU OR C4B-2
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C15PLD OR/BK C21-1
C17JU GR C4B-5
C17JU GR C22-1
C18JD GR/BK C4B-6
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
1
GR/BK-TS57
13
14
PLATFORM ROTATE LEFT/JIB UP
PLATFORM LEVEL UP
14
44
15
DRIVE ENABLE
13
17
JIB BOOM DOWN DESCENT ALARM
44
9
A
#1
GR-TS57
BOOM EXT/RET FUNCTION CTRL
9
7
8
B
E
OR/BK-TS59
OR-TS59
BL-TS58
BK/RD-TS63
BOOM EXTEND
BOOM RETRACT
7
6
TURNTABLE ROTATE FUNCTION CTRL
6
8
4
5
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
4
5
2
3
BOOM DOWN
BOOM FUNCTION CONTROL
2
3
1
D
BK/WH-TS63
BK-TS63
WH/RD-TS62
WH/BK-TS62
BK-22C1
BOOM UP
BK C7B-1
RD-TS51
RD-TS52
GR/BK H6
BRN
WH-TS62
BRN
1
TERMINAL BASE (TB)
C
RD/WH-R16
C
R43DLITE1 RD
R43DLITE2 RD
D
C5-18 BK/RD
BRN
RD-CB3
RD-24B
C21IGN WH C5-3
RD-TS61
RD/BK-ALARM
RD/BK-TS61
BRN
C21IGN WH
3
CR17
HYDRAULIC
OIL COOLER
OPTION
RD H6
BL/WH-132B
BK-22D2
C2B-5 GR
4
OR C5-1
B
GR-46D
RD-CB3 OPTIONS
WH-21B
BRN
BK/RD-35C
CR22
DRIVE LIGHT
OPTION
C32
U33
PLATFORM
OVERLOAD
(CE ONLY)
5
6
7
8
12
F.H.
CR4
HIGH RPM
SOLENOID
RELAY
BRN
1
3
4
CR5
HORN
RELAY
C5
C32
WH
2
BK-46R
BRN
WH-ISM9
WH
BRN
RD
BRN
A
GROUND HARNESS
TO SWITCH PANEL
BK-ISM1
RD
6
CR2
POWER
RELAY
5
CR1
IGNITION/START
RELAY
Section 6 • Schematics
July 2005
REV B
Deutz F3L-2011 Models (before serial number 11880)
N
FUNCTION
HARNESS
C5
F.H.
BK C16-1
WH LS2 C10-2
BRN C7B-3
C5
#2
F.H.
July 2005
REV B
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models
Deutz F3L-2011 Models (before serial number 11880)
H
G
F
E
C
GR/BK
RD
RD
RD
C19JSV GR/WH
GR/BK
GR/BK-18D
RD
WH-4
WH/BK-5
WH/RD-6
RD
RD/WH
+
RD-1
-
RD
TS51
AUXILIARY
POWER
D3
RD
RD
RD
D4
A
1
RD
RD/BK-2
RD
B
D9
RD
RD
D
BASE BOX HARNESS
(TO TERMINAL STRIP)
I
TS57
PLATFORM
ROTATE
J
GR-17D
K
TS62
TURNTABLE
ROTATE
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
2
RD
RD
GR
RD
GR/BK
RD-24D
BK/RD-35D
4
CIRCUIT
BREAKER
CONTROLS 15A
CB2
5
RD-20C
RD/WH
TS59
PLATFORM
LEVEL
GR/WH-19D
RD-20D
OR/BK-15D
RD
OR-14D
GR-17D
GR/BK-18D
RD
RD-20C
CIRCUIT
BREAKER
OPTIONS 15A
CB3
RD-20C
RD/WH
BK-33D
BL-44D
RD CR22
RD CR17
RD C32-7
BK/WH-34D
BK-7D
RD-1D
WH-4D
WH/BK-5D
WH/RD-6D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
3
TS58
JIB BOOM
UP/DOWN
RD
GR
RD
RD
RD
RD/WH-CR34
GR/BK-H6WH/RD-26
BRN-GND
-
+
4
D2
RD
WH-23
RD/WH
RD/BK-2D
BRN
L46
+
LOWER/
RETRACT BOOM
BL/BK-59D
L2
CHECK
ENGINE
WH-21D
2
B1
RD
3
WH
WH-23D
RD-134D2
BK-22D1
1
B
KS1
KEY
SWITCH
RD/WH-TB3D
RD C32-6
C134PWR RD
WH
RD-27
OR-LS17
DALE RH-25 25W
10 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
R4
TURNTABLE
ROTATE
RESISTOR
WH
RD-27D
RD
RD
RD
OR
2
RD
RD-20D
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
TS52
ENGINE
START
BK/WH-34D
RD
BRN
RD
RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
D14
TS54
FUNCTION
ENABLE
2
D13
1
NC
HOUR METER
1
NC
RD
WH-21D
BRN
BRN
BRN
P1
EMERGENCY
STOP SWITCH
RD/WH-R16
CR34
BOOM
SPEED
REDUCTION
RD/WH-TS61
RD/WH-R16
OR-LS17
RD
DALE RH-25 25W
5 ohm 1%
RD
RD
6
RD
R14
BOOM
UP/DOWN
RESISTOR
RD
TS56
GLOW
PLUG
DALE RH-25 25W
5 ohm 1%
WH
D28
RD
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
CR34
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
BOOM SPEED REDUCTION RELAY
HM
KS1
L2
L46
L45
P1
R4
R14
R16
TS51
TS52
TS54
TS56
TS57
TS58
TS59
TS61
TS62
TS63
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 70
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models
Deutz F3L-2011 Models (before serial number 11880)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models
Deutz F3L-2011 Models (after serial number 11879)
6 - 71
BK
WH
8
WH-OPTIONS
S-60 • S-65
WH-TB21 OPTIONS
FUSE 10A
(DRIVE LIGHT ONLY)
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
RD/WH-R16
WH/RD-R4
+
C3
BK-46R
RD/WH-TS61
WH/RD-R2
BRN
BK
BK
BK
RD
RD
RD
WH
WH
WH
WH/BK-25D
D33
1
3
4
7
10
9
2
IGN OR FUEL ON
JUMP TO 7 (GAS ONLY)
TO KEY SW (DIESEL ONLY)
BATTERY
GROUND
10 TEMP OR PRESS FAULT
9
8
7
6
5
AUX PWR UNIT
START INPUT
TACHOMETER
START RELAY
U1
OR/RD-LS17 C38-3
LS17 (C38)
C11 (LS2)
C9 (LS3)
Ground Control Box Terminal Strip Wiring Diagram, S-65, CE Models
M
GROUND BOLT
12/24 Volt IGNITON/START MODULE P/N 56057
10
9
8
7
6
5
4
3
2
1
A
C133PLA BL/WH C3B-12
C132PLI BL/WH C1B-12
C118LSR OR/RD C4B-4
+12V POWER
FUNCTION
HARNESS
WH-CR2
WH-23C
RD-24C
and lift
Push gently
TO REMOVE:
133
132
R46HRN BK
C45GEN GR/WH C2B-7
P134TTS RD A
P134PWR BK-LS5 C37-3
P134PWR RD-LS17 C38-1
P134PWR GR/BK C2B-6
C59CNK BL/BK-LS5 C37-4
C59CNK BL/BK C3B-11
BRN
P20BAT RD
L
BRN
4
3
Genie Industries
PLATFORM OVERLOAD ALARM
PLATFORM OVERLOAD LS
118
46R
45
134
134
D30
RD-CR19
BK-33C
2
1
133
132
LIFT SPEED REDUCTION
HORN RELAY POWER
GENERATOR OPTION
LOAD WEIGHING LIM. SW. +12V (2)
LOAD WEIGHING LIM. SW. +12V (1)
59
46
F.H.
118
SERVICE HORN
RETRACT BOOM LED
C46HRN GR C2B-5
C41RPM OR/BK C5-2
C41RPM OR/BK C2B-3
C40LS1 OR C10-2
C40LS1 OR C2B-2
C39LP BL/RD C2B-1
C37SCW BL/BK C25-1
C37SCW BL/BK C1B-11
C36SCC BL C24-1
C36SCC BL C1B-10
C35RPM BK/RD C1B-9
C34SA BK/WH C5-22
C34SA BK/WH C1B-8
#2
F.H.
46R
45
134
134
59
46
41
40
39
C32BRK WH/RD C5-23
C33STR BK C1B-7
BRN C37-2
OR/BK-41C
40
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
WH C11-2
BK-CR1
B
(UNUSED)
BOOM STOWED
39
37
36
35
34
33
32
31
C31REV WH/BK C1B-5
C30FWD WH C5-21
C30FWD WH C1B-4
C29MS RD/WH C5-24
C29MS RD/WH C1B-3
C28TTA RD/BK B
C28TTA RD/BK C1B-2
C27AUX RD PR1
C27AUX RD C1B-1
C26PS WH/RD C5-14
C25TS WH/BK C5-16
CABLE
TENSION
LIMIT SWITCH
C37 (LS5)
K
OR/RD-118B
STEER RIGHT
37
ALTERNATOR PULS PICKUP
STEER LEFT
41
HIGH FUNCTION SPEED
36
GLOW PLUG
START ENGINE
BRAKE
35
34
33
32
PROPEL REVERSE
31
30
MOTOR STROKE
29
PROPEL FORWARD
29
TILT ALARM
28
30
28
AUXILARY PUMP
27
27
26
25
RD-CR2
#2
GR/BK-H6-
OIL PRESSURE SWITCH
25
24
P23BAT WH C7B-2
C5
F.H.
BL/WH C32-3
CIRCUIT BREAKER POWER
24
23
22
P22BAT BK C9-2
P22BAT BK C11-1
P22LS17 BK C38-4
C21IGN2 WH C5-3
BOOM
EXTEND
LIMIT SWITCH
C11 (LS1)
18/19 #2
C1 & C2
C5
ENGINE
OR/RD-FH C38-3
KEYSWITCH POWER
23
P20BAT RD
P20BAT RD
C21IGN WH CR2
C5
#2
BK-CR5
+12 VOLT TO PLATFORM (2)
22
COOLANT TEMPERATURE SWITCH
+12 VOLT TO PLATFORM (1)
22
26
21
IGNITION POWER
21
22
20
+12 VOLT POWER
20
RD-TS52
GR/WH C5-12
JIB SELECT VALVE
19
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
C37
RD-KS
P134FB WH-FH
RD-H6+
PLATFORM ROTATE RIGHT/JIB DOWN
18
C18JD GR/BK C4B-6
C17JU GR C22-1
C17JU GR C4B-5
C15PLD OR/BK C21-1
J
BL/BK-L46+
GR-CR5
PLATFORM ROTATE LEFT/JIB UP
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C11
BRN-GND
PLATFORM LEVEL DOWN
15
17
14
C14PLU OR C4B-2
C13DE BL/RD C10-1
C13DE BL/RD C4B-1
18/19 #1
C3 & C4
I
OR/BK-ISM2
RD-TS54
BK/RD-CR4
BK/WH-TS56
BK-TS52
PLATFORM LEVEL UP
14
13
44
RD/BK-ALARM
H
BK-ISM3
WH/RD-ALRM
RD-TS51
D52
RD-CR19#86
DRIVE ENABLE
13
C9PER BK/RD C30-1
JDALARM BL C3B-10
+12 VOLT
POWER TO
PLATFORM
C7
G
WH/RD-L2-
JIB DOWN DESCENT ALARM
44
9
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
#1
WH/BK-ISM10
RD-CB1
RD-ISM6
WH-KS
WH-ISM7
BK C32-4
BK-KS
BK-CR5
PRIM. BOOM EXT/RET FUNC. CTRL
9
8
C8PBR BK/WH C3B-8
C7PBE RD-LS5 C37-1
C7PBE BK C3B-7
C6TRF WH/RD C31-1
F
WH-HM
D29
BRN-<GND>
PRIMARY BOOM RETRACT
8
7
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
#2
RD-CB1
19
PRIMARY BOOM EXTEND
7
6
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5
RD-CB2
18
TURNTABLE ROTATE FUNCTION CTRL
6
5
C3PBF RD/WH C29-1
C4TRL WH C3B-4
F.H.
GR/WH-TS57
GR/BK-TS57
15
17
TURNTABLE ROTATE RIGHT
5
4
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
#1
GR-TS57
TURNTABLE ROTATE LEFT
3
4
RD/WH-3D
PRIMARY BOOM FUNCTION CONTROL
RD-24B
3
2
C1PBU RD C12-1
E
OR/BK-TS59
OR-TS59
BL-TS58
BK/RD-TS63
BK/WH-TS63
BK-22C1
D
BK-TS63
WH/RD-6D
C2PBD RD/BK C3B-2
1
WH/RD-CR19
C21IGN WH C5-11
WH/BK-TS62
BRN
C1PBU RD C3B-1
BRN
PRIMARY BOOM DOWN
R43DLITE2 RD
A
BRN
2
B
RD-TS51
WH-TS62
C2B-4 OR/RD
1
6
TERMINAL BASE (TB)
BK C7B-1
PRIMARY BOOM UP
GR/BK-133B
5
1
P134PWR RD-134C
BK-22D2
C
BL/WH-132B
4
D
3
RD/WH-CR34
GR-46D
OR-LS17 C38-2
C32
RD-CB3
RD H6
RD/WH-TS61
R43DLITE1 RD
CR17
HYDRAULIC
OIL COOLER
OPTION
C21IGN WH
GR/BK-L45
1
RD/BK-TS61
BK C5-5
C
RD/BK-ALARM
BRN
RD-TS61
RD-27C
RD/WH-R16
C5-18 BK/RD
WH/RD-R4
5
OR C5-1
WH C5-4
C32
B
WH/RD-R2
CR4
HIGH RPM
SOLENOID RELAY
CR34
PRIMARY BOOM
SPEED
REDUCTION
RELAY
WH-OPTIONS
RD-ISM4
BK/RD-35C
BRN
WH-21B
CR19
SWING SPEED
SELECT
RELAY
BRN
7
CR5
HORN
RELAY
F.H.
8
C32
C5
12
C32
6
BRN
WH
CR23
DRIVE LIGHT
OPTION
U33
PLATFORM
OVER LOAD
(CE ONLY)
WH-ISM9
BRN
RD
A
GROUND HARNESS
TO SWITCH PANEL
7
BRN
4
RD
CR2
POWER
RELAY
2
BK-ISM1
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV A
Deutz F3L-2011 Models (after serial number 11879)
N
H6
F.H.
+
BRN
BK C16-1
WH LS2 C10-2
GR/BK H6
#1
BRN C7B-3
C5
3
July 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models
Deutz F3L-2011 Models (after serial number 11879)
G
F
E
RD
RD
D
RD/WH
GR/BK
WH/RD
A
RD
C19JSV GR/WH
WH-4
WH/BK-5
RD
WH/RD
2
WH/RD
WH/RD
GR
WH/RD
GR/BK
GR/BK-18D
+
RD/WH
RD
RD
D4
RD
RD
RD-1
-
RD
TS51
AUXILIARY
POWER
D3
RD
RD
B
1
RD
RD/BK-2
C
BASE BOX HARNESS
(TO TERMINAL STRIP)
H
TS57
PLATFORM
ROTATE
I
GR-17D
J
TS62
TURNTABLE
ROTATE
K
D9
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
GR/BK
D28
RD
3
RD-24D
BK/RD-35D
4
RD-20C
CIRCUIT
BREAKER
CONTROLS 15A
RD-20C
CB2
5
RD
RD
RD
RD
RD/WH
TS59
PLATFORM
GR/WH-19D LEVEL
GR-17D
RD-20D
OR/BK-15D
RD
OR-14D
GR/BK-18D
RD
RD-20C
CIRCUIT
BREAKER
OPTIONS 15A
CB3
RD/WH
BK-33D
BL-44D
RD CR22
RD CR17
BK/WH-34D
RD C32-7
WH-4D
WH/BK-5D
RD/WH-CR34#87a
BK-7D
RD-1D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD/WH
-
+
D2
RD
WH-23
RD/WH
RD/BK-2D
GR/BK-H6-
BRN
BRN-GND
WH/RD-26
L46
+
LOWER/
RETRACT BOOM
L2
CHECK
ENGINE
WH-21D
WH-23D
2
B1
4
WH
RD C32-6
C134PWR RD
RD-134D2
BK-22D1
B
RD
3
KS1
KEY
SWITCH
1
WH
BL/BK-59D
RD
WH
RD-27D
WH/RD CR34#87
WH/RD CR19#87
WH/RD CR19#87a
DALE RH-25 25W
7.5 ohm 1%
R4
TURNTABLE
ROTATE
RESISTOR
R2
TURNTABLE
ROTATE
RESISTOR
GR
RD
TS58
JIB BOOM
UP/DOWN
WH
RD-27
WH/RD
WH/RD
WH/RD
RD-20D
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
BK/WH-34D
RD
BRN
BRN
WH-21D
TS52
ENGINE
START
RD
DALE RH-25 25W
10 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
DALE RH-25 25W
5 ohm 1%
6
RD
RD
RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
TS54
FUNCTION
ENABLE
2
D14
2
D13
1
NC
HOUR METER
1
NC
RD
P1
EMERGENCY
STOP SWITCH
RD
R14
BOOM
UP/DOWN
RESISTOR
RD
TS56
GLOW
PLUG
DALE RH-25 25W
5 ohm 1%
RD
RD
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
HM
KS1
L2
L46
L45
P1
R2
R4
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 7.5 OHMS
R14
R16
TS51
TS52
TS54
TS56
TS57
TS58
TS59
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
TS61
TS62
TS63
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 72
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65, CE Models
Deutz F3L-2011 Models (after serial number 11879)
July 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-65
Deutz F3L-2011 Models
CWLITE WH TS49
WH
Y
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
RD/BK-28
RD/BK-L48- (NON-CE)
C134PWR RD C2P-6
RD-TILT
GR/BK C133TTA C3P-12
GR/BK-L4- (CE)
RD LS18 CABLE
BK
C134PWR RD LS18
JIB
JIB
OPT.
LS18
(CE)
C32BRK WH/RD C1P-6
C32BRK WH/RD J2-19
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129JDA BL C3P-10 TS8
C46HRN GR C2P-5
C59CHK BL/BK C3P-11 L47+
C59CNK BL/BK C3P-11
P26BAT BK C9-1 P2
BRN
OPTION
+
P25FS RD C9-3 TS2
C7P
P24FS WH C9-2 TS4
C7P
CDLITE OR/RD C2P-4
C45GEN GR/WH C2P-7
C46HRN GR C2P-5
C4P
JIB
C9
C7P
C118LSR OR/RD C4P-4
C6TRF WH/RD C3P-6
C8PBR BK/WH C3P-8
C16DRE BL/RD C4P-1
C7PBE BK C3P-7
C40LSS OR C2P-2
C9PER BK/RD C3P-9
C41RPM OR/BK C2P-3
C30FWD WH C1P-4
C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
C28TTA RD/BK C1P-2
BRN
C2P
Y
U13
J1
J2
J3
CR27
CR30
LS18
* NOTE: WIRE CONNECTS TO JC3-6 FOR STEER ROCKER SWITCH OPTION.
C19JSV GR/WH TS7
C19JSV GR/WH C4P-7
BRN JC3
BRN GND
RD-E-STOP
C134PWR RD-H1+
CE LIFT/DRIVE OPTION
J2
TS7 WH
1
TS1 WH
1
P26ESTP BK
P24FS WH
P24FS WH
BRN
JC1-3 OR
RD/BK-L4-
TS14 RD/WH
DRE LED BL/RD
TS15 B BL/BK
TS15 BL/WH
JC3-4 BL *
JC3-2 BRN
JC3-3 OR
JC3-5 WH
JC2-2 BRN
JC1-5 YEL
JC2-3 OR
JC2-5 BK
JC1-2 BRN
JC2-4 RD
1
C134PWR RD LS18
CWLITE BK
11
FOOT SWITCH
12V DC BATTERY
19/18 CONTROL CABLE
H1
TILT
ALARM
Part No. 77828
S-60 • S-65
6 - 73
D39
8
F.S.
7
9
BK C1P-12
C3P
C7P
C3P
6
C4P
BATGRN C7P-3
WH/RD C1P-6
C1P
C28TTA RD/BK C1P-2
3
U13
ALC-500
TILT ALARM
12V DC PLATFORM POWER CONNECTOR
FOOT SWITCH CONNECTOR
48 PIN CONNECTOR BLOCK
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
C1P-C4P
PLATFORM
CONTROL
HARNESS
(TO SWITCH
PANEL)
BRN
J1
CR27
CR30
BRN
5
CWLITE WH TS49
4
BRN
BRN
DESCRIPTION
H1
C7P
C9
1
ITEM
2
REV B
Platform Control Box Wiring Diagram, S-65
N
M
L
K
J
I
H
G
F
E
D
C
B
A
J3
3
July 2005
Section 6 • Schematics
Deutz F3L-2011 Models
July 2005
REV B
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-65
Deutz F3L-2011 Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
PLATFORM CONTROL
HARNESS (TO CONTROL BOX)
COMPONENT INDEX
TS48
DRIVE LIGHTS/
WORK LIGHTS
(OPTION)
DLITE RD
RD
JC2
BOOM UP/DOWN &
TURNTABLE ROTATE
LEFT/RIGHT
JC1
7
BOOM
EXTEND/RETRACT
5
4
4
3
2
+
BRN
1
L4
PLATFORM
OVERLOAD
(CE OPTION)
L1
DRIVE
ENABLE
LED
1
1
+
BK
JIB BOOM
CUTOUT
BRN
2
+
BRN
BK
BRN
BRN
C28TTA RD/BK H1-
BK
WH J1-4
BL J1-5
OR J1-13
BRN J1-14
BK
P26BAT BK J3-3
TS8
JIB
BOOM
GR/BK
TS7
PLATFORM
ROTATE
JC3
L1
L4
L47
L48
P2
P3
TS1
TS2
TS4
TS6
TS7
TS8
DRIVE/STEER PROPORTIONAL JOYSTICK
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
LOWER/RETRACT BOOM LED
BOOM TILTED LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HI/LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
TS9
TS14
TS15
TS47
TS48
PLATFORM LEVEL TOGGLE SWITCH
DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)
3
4
6
7
D12
1
WH
RD
BOOM PROPORTIONAL JOYSTICK:
BOOM EXTEND/RETRACT
P22BAT BK C7P-1
P23BAT WH C7P-2
P26BAT BK C9-1
RD-H1+
RD
RD
TS9
PLATFORM
LEVEL
JC1
2
5
1
1
NC NC NC
P3
HORN
BOOM PROPORTIONAL JOYSTICK:
BOOM UP/DOWN , TURNTABLE ROTATE
RD
GR
3
C134PWR RD L48+
C134PWR RD L4+
BK TS15
C45GEN GR/WH C2P-7
PDLITE RD
C35HS BK/RD C1P-9
P24FS WH C9-2
C33STR BK C1P-7
P25FS RD C9-3
C34SA BK/WH C1P-8
C29MS RD/WH J1-8
WH CR30
C27AUX RD C1P-1
C129JDA BL C3P-10
WH-JIB
C17PRL GR C4P-5
C19JSV GR/WH
WH CR27
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C14PLU OR C4P-2
P24FS WH
C15PLD OR/BK C4P-3
C46HRN GR C2P-5
NO
JC2
WH
RD
4
RD
BRN
C133PLA GR/BK D39
C134PWR RD E-STOP
C134PWR RD E-STOP
BL/RD-DE3 J1-16
BL-DE1 J1-6
BL/BK-DE2 J1-7
YL J1-3
OR J1-9
BRN J1-10
WH-JIB
WLITE WH
DLITE OR/RD C2P-4
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
C59CNK BL/BK C3P-11
WLITE WH
BK
F18 FUSE 10A
(WORK LIGHT ONLY)
RD
WH
BL J1-5 (ROCKER SWITCH OPTION ONLY)
CR13
3
RD
L47
RETRACT
BOOM
LED
BRN
4
2
BRN
6
5
3
BRN
7
RD
5
L48
TILT ALARM LED
(ANSI/CSA OPT.)
BK
6
DRIVE
FORWARD/REVERSE
& STEER
LEFT/RIGHT
+
BK
6
JIB BOOM CUT OUT RELAY
JC3
TS15
DRIVE
ENABLE
7
CR13
TS1
AUXILIARY
PUMP
TS14
HIGH/LOW
(2WD/4WD)
TS2
ENGINE
START
TS6
GLOW PLUG
D27
TS4
HIGH/LOW
RPM
2
TS47
GENERATOR
(OPTION)
22
P2
EMERGENCY
STOP
WH-24
RD
RD
RD
8
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
6 - 74
July 2005
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-65
Deutz F3L-2011 Models
C2P-6
C1P-12
FUSE 10A
RD/BK
C7P-1
C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
FOOTSW. LOW
C1P-9
C2P-7
C3P-12
LIGHTS
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C3B-12
C1B-2
C7B-2
RD
AUXILIARY
PUMP
P23BAT WH
WH
C133PLA BL/WH
C2B-5
C1B-8
C3B-12
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
BK
C27AUX RD C1B-1
ENGINE
START
C1B-7
DLITE BL/WH
PBOX GND
FOOTSW. HIGH
WORK LIGHT
C2P-12
C2P-11
C1P-8
C1P-7
C1P-1
C7P-2
C1P-2
C3P-12
C46HRN GR
C28TTA RD/BK
C2P-5
C7B-1
GR/BK
C35RPM BK/RD
C45GEN GR/WH
FUSE 10A
C34SA BK/WH
P22BAT BK
C5-2
C5-12
C5-22
RD
RD
C5-18
C5-14
C5-16
C5-11
F.H. BK
R116 OR
R21IGN WH
RD
WH
BK/RD
C5-5
C21IGN WH
C41RPM OR/BK
P116HYD RD
P134FB WH
C46HRN GR
P134TTSR RD
C28TTA RD/BK
C27AUX RD
R33STR BK
C21IGN WH
C21IGN2 WH
C25PSR WH/BK
C26TSR WH/RD
CR23
C5-4
C5-1
BRN
Q3
L29
SW3
NO
L29
SW2
DRIVE LIGHT
GLOW
PLUG
ENGINE
START
AUX
PUMP
RD/BK
C2B-6
C1B-12
P22BAT BK
C132PLI BL/WH
P134PWR GR/BK
RD
C2B-3
BK
H2
CR4
CR23
C21IGN WH
P20BAT RD
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
GLOW PLUGS
COOLANT TEMPERATURE LED
COOLANT TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
HM
M2
AUX
PUMP
REGULATOR
Part No. 77828
S-60 • S-65
-
6 - 75
C7B-4
8
NO
M1
FAN
_
NC
C
SW3
IND.
+
M3
B2
NO
PR2
PR2
NO
S8
STARTER
PR2
NO
W
STA.
PR1
+
12V DC
BK
C41RPM OR/BK
RD
EXCT.
FB1
7
D1
L43
CR4
NO
CR5
CR17
85
87a 87
ALTERNATOR
6
BAT.
BAT.
B
A
NO
NO
TB26
86
CR2
NO
NO
RD
TB25
30
D22
TB21
TB21
C5-3
TB45
OIL
TEMP.
15AMP.
D13
TB34
TB24
RD
CR2
CR1
5
D4
U1
TB35
C3
+
TB46
TB134
3MF
CB3
TB23
TB41
TB33
TB27
WH
D3
D14
CB1
7
U33
TB28
TB133
15AMP.
6
D2
4
GRD
TS4
TS47
TS48
TS54
TS56
TS52
TS51
5
4
PLAT
8
C32-8
12
RD
RD
3
1
TB22
KS1
D12
D40
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB20
RD
P1
L48
L30
TB132
RD
RD
15AMP.
3
H1
L30
Platform
Overload
Option
Only
ENGINE
SPEED
RD
RD
TS1
P3
P24FS WH
P25FS RD
P24FS WH
C9P-3
C9P-2
TS6
TS2
2
FS1
RD
RD-(FS)
WH-(FS)
BK-(FS)
C9P-1 BK
P2
C22LS BK
C28TTA RD/BK
C28TTA RD/BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
CB2
July 2005
Section 6 • Schematics
REV C
Electrical Schematic, S-60
Perkins 404-22 Models (before serial number 11880)
+
Electrical Schematic, S-60
REV C
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
3
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
3
BL
CDE1 BL/WH
RIGHT
7
RKOUT 6
4
YOUT 5
PWR 3
1
GND 2
7
6
PWR
2
XOUT 4
YOUT 5
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
P26ESTP BK
UP
DOWN
LEFT
RIGHT
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C3P-4
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
C3B-5
C3P-6
C5TRR WH/BK
TURNTABLE ROTATE
PRIMARY BOOM
BOOM
C4B-4
J1 F.H. WH
WH
C4B-1
C11-2
C40LS OR
P22LS BK
C3B-2
C3B-1
C3B-3
C3B-9
C3B-7
C3B-8
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
C4B-5
C4B-6
PLATFROM LEVEL
C59CNK BL/BK
C14PLU OR
DOWN
UP
C15PLD OR/BK
C17JU/PRL GR
C18JD/PRR GR/BK
C4P-3
C4P-2
C3P-11
C13DE BL/RD
C118LSR OR/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C4P-4
C4P-1
C2P-2
P134 RD
PLATFROM LEVEL
C4P-6
PLATFROM ROTATE
RIGHT
PLATFROM
ROTATE
5
TB5
RD
BK
C10-1
C5-21
C5-20
C5-23
C5-24
RD
C31REV WH/BK
C30FWD WH
RD
BK
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
BK
WH
WH
C26-1
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C17-2
C38-4
C9-2
C11-1
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
U4
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
GROUND
DRIVE FORWARD
DRIVE REVERSE
TRAVEL ALARM
OPTION
BRAKE RELEASE
MOTOR STROKE
STEER LEFT
STEER RIGHT
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
8
DESCENT ALARM OPTION
6 - 76
S-60 • S-65
3
7
2
TB22
CR34
Part No. 77828
4
C129 RD/BK
BK
BK
BRN
1
14
TB9
H4
TB59
LS17
NO
HC
14
TB2
6
14
13
LS3
NO
NC
13
21
LS17
NC
HO 22
22
LS1
NO
HC
NO
14
TB30
TB36
TB4
TB6
TB3
D30
L1
TB31
TB32
TB29
TB37
14
21 LS5
NC
13
LS5
13
TB13
TB1
TB7
TB8
LS2
NO
NC
TB40
R16
10
TB118
D28
13
TB15
CR34
TB134
TS62
TS61
TS63
TS59
TS14
TS15
4
LEFT
TB17
TB14
TB18
R4
5
R14
5
J1
J1
J1
J1
J3
CR30
NO
1
C28TTA RD/BK
3
C4P-5
TS57
L46
H3
D9
RD
RD
L47
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
2
CR27
NC
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS7
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Perkins 404-22 Models (before serial number 11880)
D29
July 2005
Section 6 • Schematics
Electrical Schematic, S-60
Perkins 404-22 Models (before serial number 11880)
C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
C1P-9
REV A
Electrical Schematic, S-60
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C1B-8
C3B-12
BK
C1B-7
DLITE BL/WH
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
ENGINE
START
C27AUX RD C1B-1
C2B-5
C3B-12
C1B-2
C7B-2
RD
AUXILIARY
PUMP
P23BAT WH
WH
C133PLA BL/WH
C28TTA RD/BK
RD
RD
C46HRN GR
D13
TB34
FOOTSW. LOW
C2P-7
C3P-12
LIGHTS
PBOX GND
FOOTSW. HIGH
WORK LIGHT
C1P-8
C1P-7
C1P-1
C7P-2
C1P-2
C3P-12
C2P-5
C7B-1
D14
GR/BK
C35RPM BK/RD
C45GEN GR/WH
FUSE 10A
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
F.H. C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
P22BAT BK
BK/RD
C5-5
P134FB WH
C5-12
RD
RD
C5-18
C5-11
C5-16
C5-14
C5-22
WH
RD
F.H. BK
R21IGN WH
C5-4
C5-1
BRN
Q3
L29
SW3
NO
L29
SW2
C2P-12
C2P-11
C1B-12
C2B-6
C21IGN WH
R116 OR
C5-2
NO
DRIVE LIGHT
GLOW
PLUG
ENGINE
START
RD/BK
AUX
PUMP
C132PLI BL/WH
P22BAT BK
C1P-12
C7P-1
RD/BK
FUSE 10A
P134PWR GR/BK
P116HYD RD
C41RPM OR/BK
C21IGN WH
P20BAT RD
BK
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
GLOW PLUGS
COOLANT TEMPERATURE LED
COOLANT TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
SPEED REDUCTION RELAY
AUXILIARY POWER RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
P24FS WH
C2P-6
RD
C2B-3
C7B-4
BRN
7
HM
M2
AUX
PUMP
REGULATOR
Part No. 77828
S-60 • S-65
6 - 77
NO
FAN
M1
_
NC
C
FB1
SW3
IND.
+
M3
PR2
S8
STARTER
H2
B2
NO
PR2
PR2
NO
+
12V DC
W
PR1
BAT.
BAT.
BK
C41RPM OR/BK
RD
8
EXCT.
6
CR4
CR17
85
87a 87
ALTERNATOR
D1
STA.
FUSE 70A
CR19
B
A
NO
NO
CR5
CR23
CR23
86
TB33
CR4
NO
TB26
TB25
30
D22
TB21
CR2
NO
NO
RD
L43
CR2
CR1
15AMP.
TB21
C5-3
TB45
OIL
TEMP.
5
TB23
TB41
D3
U1
TB35
C3
+
TB46
TB134
3MF
CB3
7
U33
TB27
WH
D4
8
C32-8
12
TB24
RD
15AMP.
6
D2
4
GRD
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB133
CB1
TS54
TS56
TS52
TS51
5
4
PLAT
TB28
TB20
RD
3
1
TB22
KS1
L30
L30
TB132
RD
RD
15AMP.
H1
D12
D40
ENGINE
SPEED
L48
TS4
TS47
TS48
TS6
TS2
RD
RD
TS1
P3
2
Platform
Overload
Option
Only
3
FS1
RD
P25FS RD
P24FS WH
C9P-3
C9P-2
RD-(FS)
WH-(FS)
BK-(FS)
C9P-1 BK
P2
C22LS BK
C28TTA RD/BK
C28TTA RD/BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
P1
CB2
July 2005
Section 6 • Schematics
Perkins 404-22 Models (after serial number 11879)
+
-
Electrical Schematic, S-60
REV A
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
3
4
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
3
BL
CDE1 BL/WH
RIGHT
7
RKOUT 6
4
YOUT 5
PWR 3
GND 2
1
7
6
YOUT 5
PWR
2
XOUT 4
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
P26ESTP BK
DOWN
UP
LEFT
RIGHT
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C3P-4
C3P-6
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C5TRR WH/BK
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-5
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
TURNTABLE ROTATE
PRIMARY BOOM
BOOM
C4B-4
J1 F.H. WH
WH
C4B-1
C11-2
C40LS OR
C3B-1
C3B-3
C3B-2
C3B-9
C3B-8
C3B-7
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
C4B-6
PLATFROM LEVEL
C59CNK BL/BK
P22LS BK
C14PLU OR
C15PLD OR/BK
UP
DOWN
C18JD/PRR GR/BK
C4P-3
C4P-2
C3P-11
C13DE BL/RD
C118LSR OR/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-8
C3P-7
C4P-4
C4P-1
C2P-2
P134 RD
PLATFROM LEVEL
C4P-6
PLATFROM ROTATE
C4B-5
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
RD
BK
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
3
7
U4
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
6 - 78
S-60 • S-65
Part No. 77828
2
TB22
CR34
14
R14
5
C17JU/PRL GR
PLATFROM
ROTATE
C129 RD/BK
BK
BK
BRN
4
6
1
14
21
LS17
NC
HO 22
TB4
TB6
H4
TB59
LS17
NO
HC
13
LS3
NO
HC
13
14
22
LS2
NO
HC
NO
14
TB36
TB9
14
21 LS5
NC
13
LS5
13
TB30
TB31
TB32
TB29
TB37
TB2
TB14
TB18
TB3
D30
TB5
TB40
L1
3
C4P-5
RIGHT
LEFT
TB17
R4
7.5
R2
5
TS14
TS15
5
TB1
TB7
TB8
LS1
NO
HC
13
TB15
TB13
CR19
CR34
TB134
R16
10
TB118
D28
TS62
TS61
TS63
TS59
J1
J1
J1
J1
J3
CR30
NO
1
C28TTA RD/BK
4
TS57
L46
H3
D9
RD
RD
L47
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
2
CR27
NC
JC3
JC2
JC1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS7
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Perkins 404-22 Models (after serial number 11879)
D29
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, S-60
Perkins 404-22 Models (before serial number 11880)
6 - 79
7
BK
WH
S-60 • S-65
BK C5-5
BK-TS63
BK/RD-TS63
BK
WH
8
Part No. 77828
GR/BK-TS57
+ C3
ENGINE START
GLOW PLUG
HIGH FUNCTION SPEED
STEER RIGHT
STEER LEFT
(UNUSED)
BOOM STOWED
33
34
35
36
37
39
40
BK
WH
BRN
BK
WH
NOTE: DASHED LINES INDICATE OPTION WIRES
D33
4 7 10 9 2
1
2
3
4
5
6
7
8
9
10
OR-LS17 C38-2
OR/RD-LS17 C38-3
C45GEN GR/WH C2B-7
R46HRN BK
C118BSR OR/RD C4B-4
C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
C59CNK BL/BK C3B-11
C59CNK WH-LS5 C37-4
C134PWR GR/BK C2B-6
C134PWR RD-LS17 C38-1
C134PWR BK-LS5 C37-3
P134TTSR RD A
Ground Control Box Terminal Strip Wiring Diagram, S-60
M
GROUND BOLT
A
START RELAY
TACHOMETER
U1
START INPUT
AUX PWR UNIT
GROUND
BATTERY
TO KEY SW (DIESEL ONLY)
JUMP TO 7 (GAS ONLY)
IGN OR FUEL ON
TEMP OR PRESS FAULT
12/24 Volt IGNITON/START MODULE P/N 56057
1 3
Push gently
and lift
45
46R
118
132
133
134
134
59
D30
TO REMOVE:
41
46
C40LS1 OR C2B-2
C40LS1 OR C10-2
C41RPM OR/BK C2B-3
C41RPM OR/BK C5-2
C46HRN GR C2B-5
C36STCC BL C1B-10
C36STCC BL C24-1
C37STC BL/BK C1B-11
C37STC BL/BK C25-1
C39LP BL/RD C2B-1
C34SA BK/WH C1B-8
C34SA BK/WH C5-22
C35HS BK/RD C1B-9
WH C11-2
Genie Industries
GENERATOR OPTION
HORN RELAY POWER
LIFT SPEED REDUCTION
PLATFORM OVERLOAD LS
PLATFORM OVERLOAD ALARM
PLAT. OVERLOAD LIM. SW. +12V (2)
45
46R
118
132
133
PLAT. OVERLOAD LIM. SW. +12V (1)
134
RETRACT BOOM LED
HORN
134
59
46
40
39
37
36
33
32
L
WH-CR2
WH/BK-25D
BRAKE
32
BRN
BRN C37-2
1
2
3
4
5
6
7
8
9
10
35
DRIVE REVERSE
31
+12V DC
POWER
ENGINE
BK-CR1
OR/BK-41C
BK-33C
RD-27C
BRN
RD-24C
WH-23C
B
34
DRIVE FORWARD
30
P20BAT RD
BRN
K
OR-CR34
OR/RD-118B
31
MOTOR STROKE
29
C37
GR/WH C5-12
BK-CR5
OR/RD-FH C38-3
BL/WH C32-3
GR/BK-H6-
RD-H6+
P134FB WH-FH
RD-KS
30
TILT ALARM
28
ALTERNATOR PULSE PICKUP
29
AUXILARY PUMP
27
J
WH-L46+
D52
C26PSR WH/RD C5-14
C27AUX RD C1B-1
C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C32BRK WH/RD C5-23
C33STR BK C1B-7
C5
#2
F.H.
#1
C5
#2
F.H.
41
28
COOLANT TEMPERATURE SWITCH
26
C25TSR WH/BK C5-16
RD-CR2
C11
GR-CR5
27
OIL PRESSURE SWITCH
25
24
#1
I
OR/BK-ISM2
BRN-GND
26
CIRCUIT BREAKER POWER
24
H6 CE OPTION ONLY
+
BK/WH-TS56
BK/RD-CR4
RD-TS54
25
KEY SWITCH POWER
23
CABLE
TENSION
LIMIT SWITCH
LS5
H
WH/RD-ALRM
BK-ISM3
BK-TS52
22
+12V DC TO PLATFORM (2)
22
C22LS17 BK C10-2
P22BAT BK C11-1
P22BAT BK C9-2
P23BAT WH C7B-2
BOOM
EXTEND
LIMIT SWITCH
LS1
G
WH/RD-L2RD-ISM4
RD-TS51
22
+12V DC TO PLATFORM (1)
22
23
21
IGNITION POWER
21
P20BAT RD
P20BAT RD
C21IGN WH CR2
C21IGN2 WH C5-11
P134PWR RD-134C
GR/BK-133B
GR/BK-L45
WH/BK-ISM10
D29
20
19
JIB BOOM SELECT VALVE
19
#2
+12V DC POWER
18
PLATFORM ROTATE RIGHT/JIB DOWN
18
F.H.
20
15
17
PLATFORM LEVEL DOWN
PLATFORM ROTATE LEFT/JIB UP
15
17
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12V DC
POWER TO
PLATFORM
C7
F
BK C32-4
WH-ISM7
WH-KS
RD-ISM6
RD-CB1
PLATFORM LEVEL UP
14
C1PBU RD C3B-1
C1PBU RD C12-1
C2PBD RD/BK C3B-2
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C6TRF WH/RD C31-1
C7PBE BK C3B-7
C7PBE RD-LS5 C37-1
C8PBR BK/WH C3B-8
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
C9PER BK/RD C30-1
JDALARM BL C3B-10
RD/BK-ALARM
C13DRE BL/RD C4B-1
C13DRE BL/RD C10-1
C14PLU OR C4B-2
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C15PLD OR/BK C21-1
C17JU GR C4B-5
C17JU GR C22-1
C18JD GR/BK C4B-6
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
C5
GR/WH-TS57
RD-CB2
RD-CB1
BRN-<GND>
WH-HM
BK-CR5
BK-KS
DRIVE ENABLE
13
A
#1
GR-TS57
13
14
JIB BOOM DOWN DESCENT ALARM
44
44
9
BOOM EXT/RET FUNCTION CTRL
9
B
E
OR/BK-TS59
OR-TS59
BL-TS58
7
8
BOOM EXTEND
BOOM RETRACT
7
5
6
TURNTABLE ROTATE FUNCTION CTRL
6
8
4
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
4
5
2
3
BOOM DOWN
BOOM FUNCTION CONTROL
2
1
3
BOOM UP
D
BK/WH-TS63
BK-22C1
WH/RD-TS62
R43DLITE1 RD
R43DLITE2 RD
TERMINAL BASE (TB)
1
WH/BK-TS62
BRN
1
C21IGN WH
BK C7B-1
RD-TS51
RD-TS52
GR/BK H6
BRN
WH-TS62
BRN
C
RD/WH-R16
C
WH-21B
D
RD-24B
C21IGN WH C5-3
RD-TS61
RD/BK-ALARM
RD/BK-TS61
C5-18 BK/RD
CR17
HYDRAULIC
OIL COOLER
OPTION
C32 CONNECTOR
PLUG ANSI/CSA ONLY
GR-46D
RD-CB3 OPTIONS
BK/RD-35C
C2B-5 GR
5
RD H6
BL/WH-132B
BK-22D2
CR22
DRIVE LIGHT
OPTION
BRN
RD-CB3
B
BRN
4
OR C5-1
5
6
7
8
12
C32
CR5
HORN
RELAY
CR4
HIGH RPM
SOLENOID
RELAY
BRN
1
3
4
F.H.
WH
BRN
WH
2
BK-46R
C5
C32
6
BRN
WH-ISM9
RD
RD
BRN
3
CR2
POWER
RELAY
A
GROUND HARNESS
TO SWITCH PANEL
BK-ISM1
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV B
Perkins 404-22 Models (before serial number 11880)
N
FUNCTIONS
HARNESS
C5
F.H.
BK C16-1
WH LS2 C10-2
BRN C7B-3
C5
#2
F.H.
July 2005
REV B
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Perkins 404-22 Models (before serial number 11880)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
RD
RD
D4
RD
RD
TS59
PLATFORM
LEVEL
RD
GR/WH-19D
OR/BK-15D
RD
OR-14D
RD-24D
BK/RD-35D
RD-20D
RD-20C
CB2
CIRCUIT
BREAKER
CONTROLS 15A
RD
5
RD
D14
RD
RD
TS54
FUNCTION
ENABLE
D13
RD-24D
CIRCUIT
BREAKER
ENGINE 15A
TS52
ENGINE
START
RD
RD
GR-17D
GR/BK-18D
RD-20C
BK-33D
RD CR22
RD CR17
BK/WH-34D
RD
TS56
GLOW
PLUG
RD
HOUR METER
2
BRN
WH-21D
2
RD
RD/WH-R16
RD/WH-TS61
RD/WH-R16
OR-LS17
BRN
BRN
P1
EMERGENCY
STOP SWITCH
1
NC
4
RD
RD
DALE RH-25 25W
5 ohm 1%
CR34
PRIMARY BOOM
SPEED REDUCTION
1
NC
RD
RD
RD
CB3
CIRCUIT
BREAKER
OPTIONS 15A
RD
RD
BRN
3
RD-20D
RD
OR
RD
R14
BOOM UP/DOWN
RESISTOR
BK/WH-34D
RD C32-7
BK-7D
RD-1D
WH-4D
WH/BK-5D
WH/RD-6D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD/WH
RD
RD
RD-20C
D2
RD
RD/WH-CR34
GR/BK-H6WH/RD-26
BRN-GND
-
RD/WH
3
4
+
RD
WH-23
RD/WH
RD/BK-2D
BRN
L46
+
LOWER/
RETRACT BOOM
BL/BK-59D
L2
CHECK
ENGINE
WH-21D
WH-23D
RD-134D2
BK-22D1
B1
2
1
B
WH
RD/WH-TB3D
KS1
KEY SWITCH
WH
RD C32-6
C134PWR RD
WH
RD-27
OR-LS17
DALE RH-25 25W
10 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
R4
TURNTABLE ROTATE
RESISTOR
WH
RD-27D
RD
DALE RH-25 25W
5 ohm 1%
RD
RD
CB1
RD
2
RD
C19JSV GR/WH
RD
GR-17D
GR/BK-18D
RD
WH-4
WH/BK-5
WH/RD-6
RD
RD/WH
+
RD
D3
TS51
AUXILIARY
POWER
RD
RD
RD
RD-1
-
RD/BK-2
RD
RD
BASE BOX HARNESS
(TO TERMINAL STRIP)
D9
RD
RD
TS57
PLATFORM
ROTATE
TS62
TURNTABLE
ROTATE
TS61
PRIMARY
BOOM
UP/DOWN
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
1
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
CR34
HM
KS1
L2
L46
L45
P1
R4
R14
R16
TS51
TS52
TS54
TS56
TS57
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER RELAY
DRIVE LIGHT RELAY (OPTION)
BOOM SPEED REDUCTION RELAY
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
TS59
TS61
TS62
TS63
PLATFORM LEVEL TOGGLE SWITCH
BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
6
7
8
6 - 80
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Perkins 404-22 Models (before serial number 11880)
Section 6 • Schematics
July 2005
Ground Control Box Terminal Strip Wiring Diagram, S-60
Perkins 404-22 Models (after serial number 11879)
8
6 - 81
BK
WH
WH-OPTIONS
S-60 • S-65
WH-TB21 OPTIONS
FUSE 10A
(DRIVE LIGHT ONLY)
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
RD/WH-R16
WH/RD-R4
+
C3
BK-46R
7
RD/WH-TS61
WH/RD-R2
BRN
BK
BK
BK
RD
RD
RD
WH
WH
WH
WH/BK-25D
D33
1
3
4
7
10
9
2
IGN OR FUEL ON
JUMP TO 7 (GAS ONLY)
TO KEY SW (DIESEL ONLY)
BATTERY
GROUND
10 TEMP OR PRESS FAULT
9
8
7
6
5
AUX PWR UNIT
START INPUT
TACHOMETER
START RELAY
U1
LS17 (C38)
C11 (LS2)
C9 (LS3)
Ground Control Box Terminal Strip Wiring Diagram, S-60
M
GROUND BOLT
12/24 Volt IGNITON/START MODULE P/N 56057
10
9
8
7
6
5
4
3
2
1
FUNCTION
HARNESS
WH-CR2
WH-23C
RD-24C
and lift
Push gently
TO REMOVE:
OR/RD-LS17 C38-3
L
BRN
4
3
D30
RD-CR19
BK-33C
Genie Industries
A
C133PLA BL/WH C3B-12
C132PLI BL/WH C1B-12
C118LSR OR/RD C4B-4
BRN C37-2
2
1
133
132
R46HRN BK
WH C11-2
OR/BK-41C
PLATFORM OVERLOAD ALARM
PLATFORM OVERLOAD LS
118
H6
CE
OPTION ONLY
BK-CR1
B
133
132
LIFT SPEED REDUCTION
K
OR/RD-118B
GR/BK-H6-
118
F.H.
BL/WH C32-3
C45GEN GR/WH C2B-7
+12V POWER
C5
ENGINE
OR/RD-FH C38-3
45
#2
F.H.
46R
P134TTS RD A
#2
HORN RELAY POWER
GENERATOR OPTION
134
P134PWR BK-LS5 C37-3
P134PWR RD-LS17 C38-1
P134PWR GR/BK C2B-6
C59CNK BL/BK-LS5 C37-4
C59CNK BL/BK C3B-11
C5
F.H.
46R
45
LOAD WEIGHING LIM. SW. +12V (2)
134
59
46
C5
#2
BK-CR5
134
LOAD WEIGHING LIM. SW. +12V (1)
RETRACT BOOM LED
SERVICE HORN
C46HRN GR C2B-5
C41RPM OR/BK C5-2
C41RPM OR/BK C2B-3
C40LS1 OR C10-2
C40LS1 OR C2B-2
C39LP BL/RD C2B-1
C37SCW BL/BK C25-1
C37SCW BL/BK C1B-11
C36SCC BL C24-1
C36SCC BL C1B-10
C35RPM BK/RD C1B-9
C34SA BK/WH C5-22
C34SA BK/WH C1B-8
RD-TS52
GR/WH C5-12
134
59
46
41
40
39
37
C32BRK WH/RD C5-23
C33STR BK C1B-7
C37
RD-KS
P134FB WH-FH
RD-H6+
BOOM STOWED
40
ALTERNATOR PULS PICKUP
(UNUSED)
39
41
STEER RIGHT
37
36
35
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
BRN
P20BAT RD
J
BL/BK-L46+
GR-CR5
STEER LEFT
34
33
32
31
C31REV WH/BK C1B-5
C30FWD WH C5-21
C30FWD WH C1B-4
C29MS RD/WH C5-24
C29MS RD/WH C1B-3
C28TTA RD/BK B
C28TTA RD/BK C1B-2
C27AUX RD PR1
C27AUX RD C1B-1
C26PS WH/RD C5-14
C25TS WH/BK C5-16
RD-CR2
P23BAT WH C7B-2
C11
BRN-GND
HIGH FUNCTION SPEED
36
GLOW PLUG
START ENGINE
BRAKE
35
34
33
32
PROPEL REVERSE
31
30
MOTOR STROKE
29
PROPEL FORWARD
29
TILT ALARM
28
30
28
AUXILARY PUMP
27
27
26
25
24
23
22
I
OR/BK-ISM2
RD-TS54
BK/RD-CR4
BK/WH-TS56
BK-TS52
OIL PRESSURE SWITCH
25
COOLANT TEMPERATURE SWITCH
CIRCUIT BREAKER POWER
24
26
KEYSWITCH POWER
CABLE
TENSION
LIMIT SWITCH
C37 (LS5)
H
BK-ISM3
WH/RD-ALRM
RD-TS51
D52
RD-CR19#86
+12 VOLT TO PLATFORM (2)
22
23
P22BAT BK C9-2
P22BAT BK C11-1
P22LS17 BK C38-4
C21IGN2 WH C5-3
G
WH/RD-L2-
+12 VOLT TO PLATFORM (1)
22
22
21
IGNITION POWER
21
P20BAT RD
P20BAT RD
C21IGN WH CR2
#1
WH/BK-ISM10
RD-CB1
RD-ISM6
WH-KS
WH-ISM7
BK C32-4
BK-KS
BK-CR5
20
+12 VOLT POWER
20
BOOM
EXTEND
LIMIT SWITCH
C11 (LS1)
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12 VOLT
POWER TO
PLATFORM
C7
F
WH-HM
D29
BRN-<GND>
JIB SELECT VALVE
19
C19JSV GR/WH C4B-7
C18JD GR/BK C23-1
C18JD GR/BK C4B-6
C17JU GR C22-1
C17JU GR C4B-5
C15PLD OR/BK C21-1
C15PLD OR/BK C4B-3
C14PLU OR C20-1
C14PLU OR C4B-2
C13DE BL/RD C10-1
C13DE BL/RD C4B-1
RD/BK-ALARM
JDALARM BL C3B-10
C9PER BK/RD C30-1
C9PER BK/RD C3B-9
C8PBR BK/WH C17-1
C8PBR BK/WH C3B-8
C7PBE RD-LS5 C37-1
C7PBE BK C3B-7
C6TRF WH/RD C31-1
#2
RD-CB1
19
PLATFORM ROTATE RIGHT/JIB DOWN
18
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C5
RD-CB2
18
PLATFORM ROTATE LEFT/JIB UP
C4TRL WH C15-1
C5TRR WH/BK C3B-5
F.H.
GR/WH-TS57
GR/BK-TS57
15
17
PLATFORM LEVEL DOWN
15
14
13
17
44
9
C3PBF RD/WH C29-1
C4TRL WH C3B-4
#1
GR-TS57
PRIM. BOOM EXT/RET FUNC. CTRL
9
8
PLATFORM LEVEL UP
PRIMARY BOOM RETRACT
8
7
14
PRIMARY BOOM EXTEND
7
6
JIB DOWN DESCENT ALARM
TURNTABLE ROTATE FUNCTION CTRL
6
5
4
3
DRIVE ENABLE
TURNTABLE ROTATE RIGHT
5
RD/WH-3D
13
TURNTABLE ROTATE LEFT
4
RD-24B
44
PRIMARY BOOM FUNCTION CONTROL
3
C2PBD RD/BK C13-1
E
OR/BK-TS59
OR-TS59
BL-TS58
BK/RD-TS63
BK/WH-TS63
BK-22C1
D
BK-TS63
GR-46D
C3PBF RD/WH C3B-3
1
WH/RD-CR19
WH/RD-6D
WH/BK-TS62
BRN
WH-TS62
C21IGN WH C5-11
2
R43DLITE2 RD
C1PBU RD C12-1
BRN
PRIMARY BOOM DOWN
BRN
C2PBD RD/BK C3B-2
3
C1PBU RD C3B-1
RD-TS51
A
6
2
B
BK C7B-1
RD/WH-CR34
C2B-4 OR/RD
1
GR/BK-133B
5
TERMINAL BASE (TB)
P134PWR RD-134C
BK-22D2
PRIMARY BOOM UP
BL/WH-132B
4
1
3
C
C32
OR-LS17 C38-2
C32 CONNECTOR
PLUG ANSI/CSA ONLY
RD-CB3
RD H6
RD/WH-TS61
R43DLITE1 RD
CR17
HYDRAULIC
OIL COOLER
OPTION
GR/BK-L45
1
D
RD-27C
RD/WH-R16
C21IGN WH
U33
PLATFORM
OVER LOAD
(CE ONLY)
RD/BK-TS61
BK C5-5
C
RD/BK-ALARM
BRN
RD-TS61
6
WH/RD-R4
C5-18 BK/RD
OR C5-1
WH C5-4
C32
B
WH/RD-R2
CR4
HIGH RPM
SOLENOID RELAY
CR34
PRIMARY BOOM
SPEED
REDUCTION
RELAY
WH-OPTIONS
RD-ISM4
BK/RD-35C
BRN
WH-21B
CR19
SWING SPEED
SELECT
RELAY
BRN
7
CR5
HORN
RELAY
4
F.H.
8
C32
C5
CR23
DRIVE LIGHT
OPTION
12
C32
5
BRN
WH
RD
BRN
2
WH-ISM9
BRN
RD
CR2
POWER
RELAY
A
GROUND HARNESS
TO SWITCH PANEL
BK-ISM1
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV A
Perkins 404-22 Models (after serial number 11879)
N
F.H.
+
BRN
BK C16-1
WH LS2 C10-2
GR/BK H6
#1
BRN C7B-3
C5
July 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Perkins 404-22 Models (after serial number 11879)
G
F
E
RD
RD
D
RD/WH
WH/RD
A
RD
C19JSV GR/WH
WH-4
WH/BK-5
RD
WH/RD
WH/RD
GR/BK-18D
+
RD/WH
RD
RD
D4
RD
RD
RD-1
-
RD
TS51
AUXILIARY
POWER
D3
RD
RD
B
1
RD
RD/BK-2
C
BASE BOX HARNESS
(TO TERMINAL STRIP)
H
TS57
PLATFORM
ROTATE
I
GR-17D
J
TS62
TURNTABLE
ROTATE
K
D9
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
2
WH/RD
WH/RD
RD
GR-17D
CIRCUIT
BREAKER
CONTROLS 15A
RD
RD-20C
RD-20C
CB2
5
RD
RD
RD
RD
RD/WH
4
RD-24D
BK/RD-35D
RD-20D
OR/BK-15D
RD
OR-14D
GR/BK-18D
BK-33D
CIRCUIT
BREAKER
OPTIONS 15A
CB3
RD/WH
RD-20C
RD CR22
RD CR17
BK/WH-34D
RD C32-7
WH-4D
WH/BK-5D
RD/WH-CR34#87a
BK-7D
RD-1D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD/WH
-
+
D2
RD
WH-23
RD/WH
RD/BK-2D
GR/BK-H6-
BRN
BRN-GND
WH/RD-26
L46
+
LOWER/
RETRACT BOOM
BL/BK-59D
L2
CHECK
ENGINE
WH-21D
WH-23D
2
B1
4
WH
RD C32-6
C134PWR RD
RD-134D2
BK-22D1
B
RD
3
KS1
KEY
SWITCH
1
WH
TS59
PLATFORM
GR/WH-19D LEVEL
WH
RD-27
WH
RD-27D
WH/RD CR34#87
WH/RD CR19#87
WH/RD CR19#87a
DALE RH-25 25W
7.5 ohm 1%
R4
TURNTABLE
ROTATE
RESISTOR
R2
TURNTABLE
ROTATE
RESISTOR
3
RD
WH/RD
WH/RD
RD-20D
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
BK/WH-34D
RD
BRN
BRN
WH-21D
TS52
ENGINE
START
RD
DALE RH-25 25W
10 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
DALE RH-25 25W
5 ohm 1%
6
2
RD
RD
RD
D14
TS54
FUNCTION
ENABLE
2
D13
1
NC
HOUR METER
1
NC
RD
P1
EMERGENCY
STOP SWITCH
RD
R14
BOOM
UP/DOWN
RESISTOR
RD
TS56
GLOW
PLUG
DALE RH-25 25W
5 ohm 1%
RD
RD
WH/RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
HM
KS1
L2
L46
L45
P1
R2
R4
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 7.5 OHMS
R14
R16
TS51
TS52
TS54
TS56
TS57
TS59
TS61
TS62
TS63
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 82
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-60
Perkins 404-22 Models (after serial number 11879)
July 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-60
Perkins 404-22 Models
BRN
CWLITE WH TS49
C134PWR RD LS18
C2P
C19JSV GR/WH TS7
C19JSV GR/WH C4P-7
BRN JC3
BRN GND
RD-E-STOP
C134PWR RD-H1+
OPTION
C32BRK WH/RD C1P-6
C32BRK WH/RD J2-19
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129JDA BL C3P-10 TS8
C46HRN GR C2P-5
C59CHK BL/BK C3P-11 L47+
C59CNK BL/BK C3P-11
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
GR/BK C133TTA C3P-12
GR/BK-L4- (CE)
RD LS18 CABLE
RD/BK-28
RD/BK-L48- (NON-CE)
C134PWR RD C2P-6
RD-TILT
+
OPT.
FOOT SWITCH
P24FS WH C9-2 TS4
C7P
CDLITE OR/RD C2P-4
C45GEN GR/WH C2P-7
C46HRN GR C2P-5
C118LSR OR/RD C4P-4
C6TRF WH/RD C3P-6
C8PBR BK/WH C3P-8
C16DRE BL/RD C4P-1
C7PBE BK C3P-7
C40LSS OR C2P-2
C9PER BK/RD C3P-9
C41RPM OR/BK C2P-3
C30FWD WH C1P-4
C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
C28TTA RD/BK C1P-2
C7P
TS7 WH
TS1 WH
1
P26ESTP BK
P24FS WH
CWLITE BK
C4P
BRN
19/18 CONTROL CABLE
P24FS WH
BRN
JC1-3 OR
RD/BK-L4-
TS14 RD/WH
DRE LED BL/RD
TS15 B BL/BK
TS15 BL/WH
JC3-4 BL *
JC3-2 BRN
JC3-3 OR
JC3-5 WH
JC2-2 BRN
JC1-5 YEL
JC2-3 OR
JC2-5 BK
JC1-2 BRN
JC2-4 RD
1
C134PWR RD LS18
BRN
Part No. 77828
S-60 • S-65
6 - 83
1
LS18
(CE)
12V DC BATTERY
H1
TILT
ALARM
11
JIB
C9
D39
9
BK C1P-12
C3P
C7P
C3P
6
C4P
BATGRN C7P-3
WH/RD C1P-6
C1P
C28TTA RD/BK C1P-2
3
U13
ALC-500
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
U13
J1
J2
J3
CR27
CR30
LS18
2
DESCRIPTION
ITEM
PLATFORM
CONTROL
HARNESS
(TO SWITCH
PANEL)
CE LIFT/DRIVE OPTION
J2
J1
C7P
8
F.S.
7
BRN
BRN
CR27
CR30
BRN
5
CWLITE WH TS49
4
TILT ALARM
12V DC PLATFORM POWER CONNECTOR
FOOTSWITCH CONNECTOR
C1P-C4P 48 PIN CONNECTOR BLOCK
H1
C7P
C9
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
J3
3
July 2005
Section 6 • Schematics
REV B
Platform Control Box Wiring Diagram, S-60
Perkins 404-22 Models
July 2005
REV B
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-60
Perkins 404-22 Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
PLATFORM CONTROL
HARNESS (TO CONTROL BOX)
COMPONENT INDEX
TS48
DRIVE LIGHTS/
WORK LIGHTS
(OPTION)
DLITE RD
JC1
7
3
BRN
3
2
+
2
4
L4
PLATFORM
OVERLOAD
(CE OPTION)
BRN
L1
DRIVE
ENABLE
1
3
2
+
RD
BK
BRN
BK
BRN
BRN
BK
C28TTA RD/BK H1C133PLA GR/BK D39
BK
BRN
P22BAT BK C7P-1
P26BAT BK J3-3
RD
1
RD
TS7
PLATFORM
ROTATE
6
1
NC NC NC
WH
4
7
D12
1
TS9
PLATFORM
LEVEL
3
RD
3
P3
HORN
DRIVE/STEER PROPORTIONAL JOYSTICK
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
LOWER/RETRACT BOOM LED
BOOM TILTED LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HI/LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)
5
P23BAT WH C7P-2
P26BAT BK C9-1
RD-H1+
C134PWR RD L48+
C134PWR RD L4+
BK TS15
PDLITE RD
C45GEN GR/WH C2P-7
C35HS BK/RD C1P-9
P24FS WH C9-2
C33STR BK C1P-7
P25FS RD C9-3
C34SA BK/WH C1P-8
C29MS RD/WH J1-8
WH CR30
C27AUX RD C1P-1
C17PRL GR C4P-5
WH CR27
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C46HRN GR C2P-5
NO
JC3
L1
L4
L47
L48
P2
P3
TS1
TS2
TS4
TS6
TS7
TS9
TS14
TS15
TS47
TS48
2
WH
RD
4
RD
C134PWR RD E-STOP
C134PWR RD E-STOP
BL/RD-DE3 J1-16
BL-DE1 J1-6
BL/BK-DE2 J1-7
YL J1-3
OR J1-9
BRN J1-10
WLITE WH
DLITE OR/RD C2P-4
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
C59CNK BL/BK C3P-11
WLITE WH
F18
FUSE 10A
(WORKLIGHT ONLY)
RD
WH
BOOM PROPORTIONAL JOYSTICK:
BOOM EXTEND/RETRACT
1
+
BRN
BRN
JC1
BL J1-5 (ROCKER SWITCH OPTION ONLY)
WH J1-4
BL J1-5
OR J1-13
BRN J1-14
BK
L47
RETRACT
BOOM
6
RD
4
7
5
BK
4
L48
TILT ALARM LED
(ANSI/CSA OPT.)
BK
5
1
TS15
DRIVE
ENABLE
6
5
DRIVE
FORWARD/REVERSE
& STEER
LEFT/RIGHT
+
7
BOOM
EXTEND/RETRACT
6
BOOM PROPORTIONAL JOYSTICK:
BOOM UP/DOWN , TURNTABLE ROTATE
RD
JC3
JC2
BOOM UP/DOWN
& TURNTABLE ROTATE
LEFT/RIGHT
JC2
TS1
AUXILIARY
PUMP
TS14
HIGH/LOW
(2WD/4WD)
TS6
GLOW PLUG
TS2
ENGINE
START
TS4
HIGH/LOW
RPM
2
2
P2
EMERGENCY
STOP
2
TS47
GENERATOR
(OPTION)
WH-24
RD
RD
8
RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
6 - 84
July 2005
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-60
Perkins 404-22 Models
P24FS WH
C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
FOOTSW. LOW
C1P-9
C2P-7
C3P-12
LIGHTS
C1P-8
C1P-7
C1P-1
C7P-2
C1P-2
C3P-12
C2P-5
C7B-1
REV D
Electrical Schematic, S-65
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C2B-5
C3B-12
C1B-2
C7B-2
RD
AUXILIARY
PUMP
P23BAT WH
WH
C133PLA BL/WH
C28TTA RD/BK
RD
RD
C46HRN GR
C1B-8
C3B-12
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
BK
C27AUX RD C1B-1
ENGINE
START
C1B-7
DLITE BL/WH
PBOX GND
FOOTSW. HIGH
WORK LIGHT
C2P-12
C2P-11
C1B-12
C2B-6
D14
GR/BK
C35RPM BK/RD
C45GEN GR/WH
FUSE 10A
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
C5-2
C5-12
C5-22
RD
RD
C5-18
C5-14
C5-16
C5-11
F.H. BK
R116 OR
R21IGN WH
RD
WH
BK/RD
C5-5
P134FB WH
C21IGN WH
P22BAT BK
CR4
P116HYD RD
C41RPM OR/BK
C21IGN WH
P20BAT RD
C5-4
C5-1
BRN
Q3
L29
SW3
NO
L29
SW2
DRIVE LIGHT
GLOW
PLUG
ENGINE
START
RD/BK
AUX
PUMP
C132PLI BL/WH
P22BAT BK
C1P-12
P134PWR GR/BK
C7P-1
RD/BK
FUSE 10A
C2P-6
RD
C2B-3
C7B-4
BK
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
GLOW PLUGS
COOLANT TEMPERATURE LED
COOLANT TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
HM
M2
H2
Part No. 77828
S-60 • S-65
6 - 85
BK
C41RPM OR/BK
RD
8
NO
FAN
_
NC
C
SW3
FB1
IND.
AUX
PUMP
REGULATOR
NO
+
M3
B2
PR2
NO
PR2
PR1
S8
STARTER
PR2
NO
W
STA.
M1
7
EXCT.
6
+
12V DC
87a 87
85
CR17
ALTERNATOR
D1
BAT.
BAT.
B
A
NO
NO
CR5
CR23
CR23
86
TB33
CR4
NO
TB26
TB25
30
D22
TB21
CR2
NO
NO
RD
L43
CR2
CR1
15AMP.
TB21
C5-3
TB45
OIL
TEMP.
5
D13
TB34
TB28
U1
TB35
C3
+
TB46
TB134
3MF
CB3
TB23
TB41
TB24
RD
15AMP.
TB133
CB1
7
U33
TB27
WH
D4
8
C32-8
12
D3
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB20
6
D2
4
GRD
TS4
TS47
TS48
TS54
TS56
TS52
TS51
5
4
PLAT
3
1
TB22
KS1
L30
RD
P1
H1
L30
TB132
RD
RD
15AMP.
L48
D12
D40
ENGINE
SPEED
RD
RD
TS1
P3
TS6
TS2
2
Platform
Overload
Option
Only
3
FS1
RD
P25FS RD
P24FS WH
C9P-3
C9P-2
RD-(FS)
WH-(FS)
BK-(FS)
C9P-1 BK
P2
C22LS BK
C28TTA RD/BK
C28TTA RD/BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
CB2
July 2005
Section 6 • Schematics
Perkins 404-22 Models (before serial number 11880)
+
-
Electrical Schematic, S-65
REV D
C28TTA RD/BK
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
3
BL
CDE1 BL/WH
RIGHT
7
YOUT 5
RKOUT 6
4
PWR 3
1
GND 2
7
6
PWR
2
XOUT 4
YOUT 5
GND
1
7
6
OUT 5
4
PWR 3
1
GND 2
BRN
P24FS WH
P24FS WH
3
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C41RPM OR/BK
BATGND
C2B-3
C7B-3
C1B-5
C1B-6
C1B-4
C32BRK WH/RD
C1B-3
C31REV WH/BK
C29MS RD/WH
C30FWD WH
C37SCW BL/BK
C1B-10
C1B-11
C36STCC BL
C3B-6
C4TRL WH
C6TRF WH/RD
C3B-4
PRIMARY BOOM
TURNTABLE ROTATE
C3B-5
RIGHT
C5TRR WH/BK
LEFT
UP
DOWN
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C9PER BK/RD
C7PBE BK
C8PBR BK/WH
BOOM
C4B-4
RETRACT
EXTEND
C118LSR OR/RD
J1 F.H. WH
WH
C4B-1
C14PLU OR
C15PLD OR/BK
C3B-2
C3B-1
C3B-3
C3B-9
C3B-7
C3B-8
C38-1
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
PLATFROM LEVEL
C59CNK BL/BK
P22LS BK
C40LS OR
C11-2
C13DE BL/RD
C3P-11
C4P-2
C4P-3
UP
DOWN
C3B-10
C4B-5
C4B-6
RD
BK
C10-1
C5-20
C31REV WH/BK
C30FWD WH
BR
RD
BK
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C24-2
C15-2
C31-2
C14-2
C31-1
C12-2
C15-1
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C17-2
C38-4
C9-2
C11-1
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C10-2
C17-1
C29-1
C14-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
U4
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
WH
WH
C26-1
C5-21
C32BRK WH/RD
C130TA WH/RD
C5-23
C29MS RD/WH
BK
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
C36SCC BL
C37SCW BL/BK
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
GROUND
DRIVE FORWARD
DRIVE REVERSE
TRAVEL ALARM
OPTION
BRAKE RELEASE
MOTOR STROKE
STEER LEFT
STEER RIGHT
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM UP
JIB VALVE
DESCENT ALARM OPTION
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
8
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
C7P-3
C2P-3
C1P-5
C1P-4
C1P-6
C1P-3
C1P-11
C1P-10
C3P-6
C3P-4
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-7
C3P-8
C4P-4
C4P-1
C2P-2
P134 RD
3
PLATFROM LEVEL
C129JDA BL
C17JU/PRL GR
C18JD/PRR GR/BK
RIGHT
PLATFROM
ROTATE
C129 RD/BK
3
4
LEFT
4
6 - 86
S-60 • S-65
2
TB22
CR34
Part No. 77828
7
BK
BK
BRN
4
DOWN
UP
C3P-10
C4P-6
C4P-5
PLATFROM
ROTATE
C4B-7
TB59
14
H4
6
LS17
NO
HC
14
TB4
TB6
1
14
13
LS3
NO
NC
13
21
LS17
NC
HO 22
22
LS1
NO
HC
5
TB2
TS14
TS15
TB30
TB31
TB32
TB29
TB37
TB36
TB9
14
TB3
D30
TB5
TB40
21 LS5
NC
13
LS5
13
NO
14
TB13
TB1
TB7
TB8
LS2
NO
NC
13
TB15
TB118
D28
R4
5
R14
5
C19JSV GR/WH
TB17
TB14
TB18
R16
10
TB19
TS62
TS61
TS63
TS59
CR34
TB134
TB44
L46
H3
DOWN JIB
UP
BOOM
LEFT
C19JSV GR/WH
D9
RD
RD
J1
J1
J1
J1
RIGHT
C4P-7
TS58
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
2
P26ESTP BK
CR13
NC
J3
CR30
NO
JIB VALVE
TS57
L47
3
TS9
TS8
TS7
CR27
NC
CR13
JC3
JC2
JC1
L1
WH
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
1
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Perkins 404-22 Models (before serial number 11880)
BRN
D29
July 2005
Section 6 • Schematics
Electrical Schematic, S-65
Perkins 404-22 Models (before serial number 11880)
P24FS WH
C41RPM OR/BK
P26ESTP BK
C41RPM OR/BK
P26ESTP BK
FOOTSW. LOW
C1P-9
C2P-7
C3P-12
LIGHTS
C1P-8
C1P-7
C1P-1
C7P-2
C1P-2
C3P-12
C2P-5
C7B-1
REV A
Electrical Schematic, S-65
C35RPM BK/RD
C1B-9
FUNCTION ENA.
C2B-7
HIGH RPM
LOW RPM
C45GEN GR/WH
C2B-5
C3B-12
C1B-2
C7B-2
RD
AUXILIARY
PUMP
P23BAT WH
WH
C133PLA BL/WH
C28TTA RD/BK
RD
RD
C46HRN GR
C1B-8
C3B-12
C2P-10
C2P-9
C34SA BK/WH
GLOW
PLUG
C33STR BK
BK
C27AUX RD C1B-1
ENGINE
START
C1B-7
DLITE BL/WH
PBOX GND
FOOTSW. HIGH
WORK LIGHT
C2P-12
C2P-11
C1B-12
C2B-6
D14
GR/BK
C35RPM BK/RD
C45GEN GR/WH
FUSE 10A
C34SA BK/WH
C26TSR WH/RD
C25PSR WH/BK
C21IGN2 WH
C21IGN WH
R33STR BK
C27AUX RD
F.H. C27AUX RD
C28TTA RD/BK
P134TTSR RD
C46HRN GR
BK/RD
C5-5
P134FB WH
C21IGN WH
P22BAT BK
CR4
P116HYD RD
C5-12
RD
RD
C5-18
C5-11
C5-16
C5-14
C5-22
WH
RD
F.H. BK
R21IGN WH
R116 OR
C5-2
C5-4
C5-1
BRN
Q3
L29
SW3
NO
L29
SW2
CR23
C41RPM OR/BK
C21IGN WH
P20BAT RD
NO
DRIVE LIGHT
GLOW
PLUG
ENGINE
START
RD/BK
AUX
PUMP
C132PLI BL/WH
P22BAT BK
C1P-12
P134PWR GR/BK
C7P-1
RD/BK
FUSE 10A
C2P-6
RD
C2B-3
C7B-4
BK
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR OPTION
DRIVE LIGHT OPTION
WORK LIGHTS OPTION
GLOW PLUGS
COOLANT TEMPERATURE LED
COOLANT TEMPERATURE SWITCH
OIL PRESSURE SWITCH
POWER RELAY
FUEL SOLENOID
HOUR METER
IGN./START RELAY
STARTER MOTOR
SPEED REDUCTION RELAY
AUXILIARY POWER RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
HORN RELAY
HORN
FLASHING BEACONS
OPTION
HYDRAULIC OIL TEMPERATURE
SWITCH (OPTION)
COOLING FAN
(OPTION)
NOTES:
1
CE AND PLATFORM OVERLOAD OPTION ONLY.
HM
M2
REGULATOR
Part No. 77828
S-60 • S-65
-
6 - 87
BK
C41RPM OR/BK
RD
8
NO
FAN
M1
_
NC
C
FB1
IND.
+
M3
PR2
NO
S8
STARTER
AUX
PUMP
H2
B2
PR2
NO
PR2
PR1
-
BAT.
W
CR19
EXCT.
SW3
7
ALTERNATOR
D1
BAT.
+
12V DC
87a 87
85
CR17
6
STA.
FUSE 70A
B
A
NO
NO
CR5
CR23
CR4
NO
TB26
TB25
86
TB21
CR2
NO
NO
RD
5
30
D22
OIL
TEMP.
CR2
CR1
15AMP.
TB21
C5-3
TB45
L43
U1
TB35
C3
+
TB46
TB134
3MF
CB3
WH
D13
TB34
TB24
RD
15AMP.
TB23
TB41
TB33
TB27
D2
D3
1 START RELAY
2 TACHOMETER
3 START INPUT IGNITION/
4 AUX. ON
START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
TB133
CB1
7
U33
TB28
TB20
6
D4
8
C32-8
12
4
GRD
TS4
TS47
TS48
TS54
TS56
TS52
TS51
5
4
PLAT
3
1
TB22
KS1
L30
RD
H1
L30
TB132
RD
RD
15AMP.
L48
D12
D40
ENGINE
SPEED
RD
RD
TS1
P3
TS6
TS2
2
Platform
Overload
Option
Only
3
FS1
RD
P25FS RD
P24FS WH
C9P-3
C9P-2
RD-(FS)
WH-(FS)
BK-(FS)
C9P-1 BK
P2
C22LS BK
C28TTA RD/BK
C28TTA RD/BK
1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TB134
P1
CB2
July 2005
Section 6 • Schematics
Perkins 404-22 Models (after serial number 11879)
+
Electrical Schematic, S-65
REV A
DRIVE MODE
CDE3 BL/RD
CDE2 BL/BK
LEFT
BL
WH
OR
BRN
BK
RD
OR
BRN
YEL
OR
BRN
15
8
16
7
2
1
10
9
3
12
11
1
2
14
13
5
4
6
DRIVE ENABLE
3
BL
CDE1 BL/WH
RIGHT
7
4
YOUT 5
RKOUT 6
PWR 3
GND 2
1
7
6
PWR
2
XOUT 4
YOUT 5
GND
1
7
6
4
OUT 5
PWR 3
1
GND 2
BRN
P24FS WH
3
4
5
15
16
19
20
18
17
11
10
9
6
7
8
14
13
12
1
3
4
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C2P-3
C7P-3
C4TRL WH
C6TRF WH/RD
C36STCC BL
C37SCW BL/BK
C29MS RD/WH
C32BRK WH/RD
C31REV WH/BK
C30FWD WH
C41RPM OR/BK
BATGND
C3B-4
C3B-6
C1B-10
C1B-11
C1B-3
C1B-6
C1B-5
C1B-4
C2B-3
C7B-3
TURNTABLE ROTATE
C3B-5
C3P-4
C4P-2
C3P-11
PRIMARY BOOM
BOOM
C4B-4
WH
C4B-1
C11-2
J1 F.H. WH
C15PLD OR/BK
C14PLU OR
C59CNK BL/BK
P22LS BK
C40LS OR
C13DE BL/RD
C118LSR OR/RD
RETRACT
EXTEND
C7PBE BK
C8PBR BK/WH
C9PER BK/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
DOWN
UP
LEFT
RIGHT
C5TRR WH/BK
C3P-6
C3P-5
C3P-1
C3P-2
C3P-3
C3P-9
C3P-7
C3P-8
C4P-4
C4P-1
C2P-2
P134 RD
PLATFROM LEVEL
C4P-3
C3B-2
C3B-1
C3B-3
C3B-9
C3B-7
C3B-8
C38-1
TB5
OR/RD
BL/RD
C37-3
C3B-11
C2B-2
BK
RD
C4B-2
C4B-3
C4B-5
C4B-6
PLATFROM LEVEL
C3B-10
PLATFROM
ROTATE
RD
BK
C10-1
C5-21
C31REV WH/BK
C30FWD WH
C130TA WH/RD
C32BRK WH/RD
C29MS RD/WH
C37SCW BL/BK
C36SCC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
RD
BK
C28-1
C25-1
BK
RD
C26-2
C28-2
C25-2
C31-1
C15-1
C14-1
C12-2
C31-2
C15-2
C14-2
C24-2
C12-1
C13-2
C30-2
C13-1
C30-1
C16-2
C29-2
C16-1
C11-1
C9-2
C38-4
C17-2
C10-2
C17-1
C29-1
C24-1
C7PBE BK
WH
BL/BK
C37-4
C23-1
C21-1
C20-1
C22-2
C23-2
C21-2
C20-2
C38-2
C22-1
BR
F.H. OR
WH
C8PBR BK/WH
C37-2
BR
C9PER BK/RD
C3PBF RD/WH
BK
WH
WH
C26-1
C5-20
C5-23
C5-24
RD
C38-3
BK
C37-1
C9-1
BK
BK
RD
C14PLU OR
C15PLD OR/BK
C18JD/PRR GR/BK
C17JU/PRL GR
3
7
U4
NOTES:
1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION.
3
ROCKER STEER OPTION ONLY.
PLATFORM ROTATE LEFT
PLATFORM ROTATE RIGHT
PLATFORM LEVEL DOWN
PLATFORM LEVEL UP
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
LS5-CABLE TENSION LED
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
LS1-PRIMARY BOOM EXTEND
DRIVE LIMIT SWITCH
LS3-DRIVE ENABLE LIMIT SWITCH
LS17-BOOM UP/DOWN
SPEED REDUCTION LIMIT SWITCH
BOOM RETRACT
BOOM EXTEND
LS5 CABLE TENSION LIMIT SWITCH
PRIMARY BOOM EXTEND/RETRACT
FLOW CONTROL
PRIMARY BOOM FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE LEFT
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE
TRAVEL ALARM
OPTION
DRIVE REVERSE
DRIVE FORWARD
GROUND
8
DESCENT ALARM OPTION
JIB VALVE
6 - 88
S-60 • S-65
Part No. 77828
2
TB22
CR34
P24FS WH
P26ESTP BK
UP
DOWN
UP
DOWN
C18JD/PRR GR/BK
C129JDA BL
RIGHT
LEFT
C129 RD/BK
BK
BK
BRN
4
14
TB30
TB31
TB32
TB29
H4
TB59
LS17
NO
HC
14
TB4
TB6
1
14
13
LS3
NO
HC
13
21
LS17
NC
HO 22
22
LS2
NO
HC
NO
14
R2
TS14
TS15
6
21 LS5
NC
13
LS5
13
R4
TB36
TB9
14
7.5
TB37
TB2
TB14
TB3
D30
TB1
TB7
TB8
LS1
NO
HC
TB18
TB13
5
C4B-7
TB17
C4P-6
C17JU/PRL GR
C19JSV GR/WH
D28
TB40
R14
5
C3P-10
C4P-5
PLATFROM
ROTATE
DOWN JIB
UP
BOOM
LEFT
C4P-7
TB19
13
TB15
R16
10
TB118
CR19
CR34
TB134
TB44
TS62
TS61
TS63
TS59
1
C28TTA RD/BK
3
5
TS58
L46
H3
RIGHT
JIB VALVE
C19JSV GR/WH
D9
RD
RD
J1
J1
J1
J1
J3
CR30
NO
4
TS57
L47
J2
U13 JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
D27
2
CR13
NC
JC3
JC2
JC1
L1
WH
DRIVE & STEERING
PRI UP/DN & TT ROTATE
PRIMARY EXT/RET
P24FS WH
3
TS9
TS8
TS7
CR27
NC
CR13
P26ESTP BK
C41RPM OR/BK
P24FS WH
P26ESTP BK
P22LS BK
P134 RD
C28TTA RD/BK
C41RPM OR/BK
P26ESTP BK
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 • Schematics
July 2005
Perkins 404-22 Models (after serial number 11879)
BRN
D29
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, S-65
Perkins 404-22 Models (before serial number 11880)
6 - 89
7
BK C5-5
BK
WH
S-60 • S-65
BK-TS63
BK/RD-TS63
BK
WH
8
Part No. 77828
GR/BK-TS57
+ C3
BRAKE
ENGINE START
GLOW PLUG
HIGH FUNCTION SPEED
STEER RIGHT
STEER LEFT
(UNUSED)
BOOM STOWED
32
33
34
35
36
37
39
40
BK
WH
BRN
BK
WH
NOTE: DASHED LINES INDICATE OPTION WIRES
D33
4 7 10 9 2
1
2
3
4
5
6
7
8
9
10
OR-LS17 C38-2
OR/RD-LS17 C38-3
C45GEN GR/WH C2B-7
R46HRN BK
C118BSR OR/RD C4B-4
C132PLI BL/WH C1B-12
C133PLA BL/WH C3B-12
C59CNK BL/BK C3B-11
C59CNK WH-LS5 C37-4
C134PWR GR/BK C2B-6
C134PWR RD-LS17 C38-1
C134PWR BK-LS5 C37-3
P134TTSR RD A
Ground Control Box Terminal Strip Wiring Diagram, S-65
M
GROUND BOLT
A
START RELAY
TACHOMETER
U1
START INPUT
AUX PWR UNIT
GROUND
BATTERY
TO KEY SW (DIESEL ONLY)
JUMP TO 7 (GAS ONLY)
IGN OR FUEL ON
TEMP OR PRESS FAULT
12/24 Volt IGNITON/START MODULE P/N 56057
1 3
Push gently
and lift
45
46R
118
132
133
134
134
59
D30
TO REMOVE:
41
46
C40LS1 OR C2B-2
C40LS1 OR C10-2
C41RPM OR/BK C2B-3
C41RPM OR/BK C5-2
C46HRN GR C2B-5
C36STCC BL C1B-10
C36STCC BL C24-1
C37STC BL/BK C1B-11
C37STC BL/BK C25-1
C39LP BL/RD C2B-1
C34SA BK/WH C1B-8
C34SA BK/WH C5-22
C35HS BK/RD C1B-9
WH C11-2
Genie Industries
GENERATOR OPTION
HORN RELAY POWER
LIFT SPEED REDUCTION
PLATFORM OVERLOAD LS
PLATFORM OVERLOAD ALARM
PLAT. OVERLOAD LIM. SW. +12V (2)
45
46R
118
132
133
PLAT. OVERLOAD LIM. SW. +12V (1)
134
RETRACT BOOM LED
HORN
134
59
46
40
39
37
36
33
32
L
WH-CR2
WH/BK-25D
35
DRIVE REVERSE
31
BRN
BRN C37-2
1
2
3
4
5
6
7
8
9
10
34
DRIVE FORWARD
30
+12V DC
POWER
ENGINE
BK-CR1
OR/BK-41C
BK-33C
RD-27C
BRN
RD-24C
WH-23C
B
31
MOTOR STROKE
29
P20BAT RD
BRN
K
OR-CR34
OR/RD-118B
30
TILT ALARM
28
C37
GR/WH C5-12
BK-CR5
OR/RD-FH C38-3
BL/WH C32-3
GR/BK-H6-
RD-H6+
P134FB WH-FH
RD-KS
29
AUXILARY PUMP
27
C26PSR WH/RD C5-14
C27AUX RD C1B-1
C27AUX RD PR1
C28TTA RD/BK C1B-2
C28TTA RD/BK B
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
C30FWD WH C1B-4
C30FWD WH C5-21
C31REV WH/BK C1B-5
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
C32BRK WH/RD C5-23
C33STR BK C1B-7
CABLE
TENSION
LIMIT SWITCH
LS5
J
WH-L46+
D52
ALTERNATOR PULSE PICKUP
28
COOLANT TEMPERATURE SWITCH
26
C25TSR WH/BK C5-16
RD-CR2
C5
#2
F.H.
#1
C5
#2
F.H.
41
27
OIL PRESSURE SWITCH
25
24
C11
GR-CR5
26
CIRCUIT BREAKER POWER
24
#1
I
OR/BK-ISM2
BRN-GND
25
KEY SWITCH POWER
H6 CE OPTION ONLY
+
BK/WH-TS56
BK/RD-CR4
RD-TS54
22
+12V DC TO PLATFORM (2)
22
23
C22LS17 BK C10-2
P22BAT BK C11-1
P22BAT BK C9-2
P23BAT WH C7B-2
H
WH/RD-ALRM
BK-ISM3
BK-TS52
22
+12V DC TO PLATFORM (1)
22
23
21
IGNITION POWER
21
P20BAT RD
P20BAT RD
C21IGN WH CR2
C21IGN2 WH C5-11
BOOM
EXTEND
LIMIT SWITCH
LS1
18/19 #2
C1 & C2
18/19 #1
C3 & C4
+12V DC
POWER TO
PLATFORM
C7
G
WH/RD-L2RD-ISM4
RD-TS51
D29
20
19
JIB BOOM SELECT VALVE
19
#2
+12V DC POWER
18
PLATFORM ROTATE RIGHT/JIB DOWN
18
F.H.
20
15
17
PLATFORM LEVEL DOWN
PLATFORM ROTATE LEFT/JIB UP
15
17
P134PWR RD-134C
GR/BK-133B
GR/BK-L45
WH/BK-ISM10
PLATFORM LEVEL UP
14
C1PBU RD C3B-1
C1PBU RD C12-1
C2PBD RD/BK C3B-2
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
C3PBF RD/WH C29-1
C4TRL WH C3B-4
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
C6TRF WH/RD C31-1
C7PBE BK C3B-7
C7PBE RD-LS5 C37-1
C8PBR BK/WH C3B-8
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
C9PER BK/RD C30-1
JDALARM BL C3B-10
RD/BK-ALARM
C13DRE BL/RD C4B-1
C13DRE BL/RD C10-1
C14PLU OR C4B-2
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C15PLD OR/BK C21-1
C17JU GR C4B-5
C17JU GR C22-1
C18JD GR/BK C4B-6
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
F
BK C32-4
WH-ISM7
WH-KS
RD-ISM6
RD-CB1
DRIVE ENABLE
13
A
C5
GR/WH-TS57
RD-CB2
RD-CB1
BRN-<GND>
WH-HM
BK-CR5
BK-KS
13
14
JIB BOOM DOWN DESCENT ALARM
44
B
#1
GR-TS57
9
BOOM EXT/RET FUNCTION CTRL
9
44
7
8
BOOM EXTEND
BOOM RETRACT
7
6
TURNTABLE ROTATE FUNCTION CTRL
6
8
4
5
TURNTABLE ROTATE LEFT
TURNTABLE ROTATE RIGHT
4
5
2
3
BOOM DOWN
BOOM FUNCTION CONTROL
2
3
1
E
OR/BK-TS59
OR-TS59
BL-TS58
BK-22C1
BOOM UP
D
BK/WH-TS63
BRN
WH/RD-TS62
R43DLITE1 RD
R43DLITE2 RD
TERMINAL BASE (TB)
1
WH/BK-TS62
BRN
C21IGN WH
BK C7B-1
RD-TS51
RD-TS52
GR/BK H6
BRN
WH-TS62
6
1
WH-21B
C
RD/WH-R16
C
C5-18 BK/RD
D
RD-24B
C21IGN WH C5-3
RD-TS61
RD/BK-ALARM
RD/BK-TS61
4
CR17
HYDRAULIC
OIL COOLER
OPTION
C32 CONNECTOR
PLUG ANSI/CSA ONLY
GR-46D
RD-CB3 OPTIONS
BK/RD-35C
C2B-5 GR
5
RD H6
BL/WH-132B
BK-22D2
CR22
DRIVE LIGHT
OPTION
BRN
RD-CB3
B
BRN
OR C5-1
5
6
7
8
12
C32
CR5
HORN
RELAY
CR4
HIGH RPM
SOLENOID
RELAY
BRN
1
3
4
F.H.
WH
2
BK-46R
C5
C32
WH
BRN
RD
BRN
3
BRN
WH-ISM9
RD
CR2
POWER
RELAY
A
GROUND HARNESS
TO SWITCH PANEL
BK-ISM1
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV B
Perkins 404-22 Models (before serial number 11880)
N
FUNCTIONS
HARNESS
C5
F.H.
BK C16-1
WH LS2 C10-2
BRN C7B-3
C5
#2
F.H.
July 2005
REV B
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Perkins 404-22 Models (before serial number 11880)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
RD
D28
GR/WH-19D
OR/BK-15D
RD
OR-14D
RD-24D
BK/RD-35D
RD-20D
CB2
CIRCUIT
BREAKER
CONTROLS 15A
RD-20C
5
RD
RD-20D
D14
RD
RD
TS54
FUNCTION
ENABLE
D13
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
TS52
ENGINE
START
RD
RD
GR-17D
GR/BK-18D
RD
CB3
CIRCUIT
BREAKER
OPTIONS 15A
BK/WH-34D
RD
TS56
GLOW
PLUG
RD
4
RD
RD
2
HOUR METER
2
BRN
WH-21D
1
NC
RD
RD/WH-R16
RD/WH-TS61
RD/WH-R16
OR-LS17
BRN
BRN
P1
EMERGENCY
STOP SWITCH
1
RD
CR34
PRIMARY BOOM
SPEED REDUCTION
BRN
NC
3
TS58
JIB BOOM
UP/DOWN
RD-20C
BK-33D
BL-44D
RD CR22
RD CR17
RD
RD
RD
RD
RD
DALE RH-25 25W
5 ohm 1%
GR
RD
RD-20C
RD/WH
RD/WH
OR
RD
RD
BK/WH-34D
RD C32-7
BK-7D
RD-1D
WH-4D
WH/BK-5D
WH/RD-6D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD
RD/WH-CR34
GR/BK-H6WH/RD-26
BRN-GND
-
+
3
4
D2
RD
RD/BK-2D
BRN
L46
+
LOWER/
RETRACT BOOM
BL/BK-59D
L2
CHECK
ENGINE
WH-21D
WH-23D
RD-134D2
BK-22D1
B1
2
1
B
KS1
KEY SWITCH
WH
RD/WH-TB3D
RD C32-6
C134PWR RD
WH
RD-27
OR-LS17
DALE RH-25 25W
10 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
R4
TURNTABLE ROTATE
RESISTOR
WH
RD-27D
RD
RD
RD/WH
RD
C19JSV GR/WH
GR/BK
RD
WH-23
TS59
PLATFORM
LEVEL
GR
RD
WH
2
RD
D4
RD
RD
R14
BOOM UP/DOWN
RESISTOR
GR-17D
RD
RD
RD
DALE RH-25 25W
5 ohm 1%
GR/BK
GR/BK-18D
RD
WH-4
WH/BK-5
WH/RD-6
RD
RD/WH
+
RD
D3
TS51
AUXILIARY
POWER
RD
RD
RD
RD-1
-
RD/BK-2
RD
RD
BASE BOX HARNESS
(TO TERMINAL STRIP)
GR/BK
D9
RD
RD
TS57
PLATFORM
ROTATE
TS62
TURNTABLE
ROTATE
TS61
PRIMARY
BOOM
UP/DOWN
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
1
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
CR34
HM
KS1
L2
L46
L45
P1
R4
R14
R16
TS51
TS52
TS54
TS56
TS57
TS58
TS59
TS61
TS62
TS63
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER RELAY
DRIVE LIGHT RELAY (OPTION)
BOOM SPEED REDUCTION RELAY
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
6
7
8
6 - 90
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Perkins 404-22 Models (before serial number 11880)
July 2005
Section 6 • Schematics
Ground Control Box Terminal Strip Wiring Diagram, S-65
Perkins 404-22 Models (after serial number 11879)
8
6 - 91
BK
WH
WH-OPTIONS
S-60 • S-65
WH-TB21 OPTIONS
NOTE: DASHED LINES INDICATE OPTION WIRES
FUSE 10A
(DRIVE LIGHT ONLY)
Part No. 77828
7
RD/WH-R16
WH/RD-R4
+
C3
BK-46R
RD/WH-TS61
WH/RD-R2
BRN
BK
BK
BK
RD
RD
RD
WH
WH
WH
WH/BK-25D
D33
1
3
4
7
10
9
2
IGN OR FUEL ON
JUMP TO 7 (GAS ONLY)
TO KEY SW (DIESEL ONLY)
BATTERY
GROUND
10 TEMP OR PRESS FAULT
9
8
7
6
5
AUX PWR UNIT
START INPUT
TACHOMETER
START RELAY
U1
LS17 (C38)
C11 (LS2)
C9 (LS3)
Ground Control Box Terminal Strip Wiring Diagram, S-65
M
GROUND BOLT
12/24 Volt IGNITON/START MODULE P/N 56057
10
9
8
7
6
5
4
3
2
1
OR/RD-LS17 C38-3
FUNCTION
HARNESS
WH-CR2
WH-23C
RD-24C
and lift
Push gently
TO REMOVE:
A
C133PLA BL/WH C3B-12
C132PLI BL/WH C1B-12
C118LSR OR/RD C4B-4
R46HRN BK
C45GEN GR/WH C2B-7
P134TTS RD A
+12V POWER
L
BRN
4
3
133
132
D30
RD-CR19
BK-33C
Genie Industries
PLATFORM OVERLOAD ALARM
PLATFORM OVERLOAD LS
118
P134PWR RD-LS17 C38-1
P134PWR BK-LS5 C37-3
BRN C37-2
2
1
133
132
LIFT SPEED REDUCTION
46R
45
134
134
P134PWR GR/BK C2B-6
C59CNK BL/BK-LS5 C37-4
C59CNK BL/BK C3B-11
F.H.
HORN RELAY POWER
GENERATOR OPTION
LOAD WEIGHING LIM. SW. +12V (2)
LOAD WEIGHING LIM. SW. +12V (1)
59
46
F.H.
118
SERVICE HORN
RETRACT BOOM LED
C46HRN GR C2B-5
C41RPM OR/BK C5-2
C41RPM OR/BK C2B-3
C40LS1 OR C10-2
C40LS1 OR C2B-2
C39LP BL/RD C2B-1
C37SCW BL/BK C25-1
C37SCW BL/BK C1B-11
C36SCC BL C24-1
C36SCC BL C1B-10
C35RPM BK/RD C1B-9
C34SA BK/WH C5-22
C34SA BK/WH C1B-8
#2
F.H.
46R
45
134
134
59
46
41
40
39
C32BRK WH/RD C5-23
C33STR BK C1B-7
WH C11-2
OR/BK-41C
40
C31REV WH/BK C5-20
C32BRK WH/RD C1B-6
BRN
P20BAT RD
H6
CE
OPTION ONLY
BK-CR1
B
(UNUSED)
BOOM STOWED
39
37
36
35
34
33
32
31
C31REV WH/BK C1B-5
C30FWD WH C5-21
C30FWD WH C1B-4
C29MS RD/WH C5-24
C29MS RD/WH C1B-3
C28TTA RD/BK B
C28TTA RD/BK C1B-2
C27AUX RD PR1
C27AUX RD C1B-1
C26PS WH/RD C5-14
C25TS WH/BK C5-16
CABLE
TENSION
LIMIT SWITCH
C37 (LS5)
K
OR/RD-118B
STEER RIGHT
37
ALTERNATOR PULS PICKUP
STEER LEFT
41
HIGH FUNCTION SPEED
36
GLOW PLUG
START ENGINE
BRAKE
35
34
33
32
PROPEL REVERSE
31
30
MOTOR STROKE
29
PROPEL FORWARD
29
TILT ALARM
28
30
28
AUXILARY PUMP
27
27
26
25
RD-CR2
#2
GR/BK-H6-
OIL PRESSURE SWITCH
25
24
P23BAT WH C7B-2
C5
BL/WH C32-3
CIRCUIT BREAKER POWER
24
23
22
P22BAT BK C9-2
P22BAT BK C11-1
P22LS17 BK C38-4
C21IGN2 WH C5-3
BOOM
EXTEND
LIMIT SWITCH
C11 (LS1)
18/19 #2
C1 & C2
C5
ENGINE
OR/RD-FH C38-3
KEYSWITCH POWER
23
P20BAT RD
P20BAT RD
C21IGN WH CR2
C5
#2
BK-CR5
+12 VOLT TO PLATFORM (2)
22
COOLANT TEMPERATURE SWITCH
+12 VOLT TO PLATFORM (1)
22
26
21
IGNITION POWER
21
22
20
+12 VOLT POWER
20
RD-TS52
GR/WH C5-12
JIB SELECT VALVE
19
C18JD GR/BK C23-1
C19JSV GR/WH C4B-7
C37
RD-KS
P134FB WH-FH
RD-H6+
PLATFORM ROTATE RIGHT/JIB DOWN
18
C18JD GR/BK C4B-6
C17JU GR C22-1
C17JU GR C4B-5
C15PLD OR/BK C21-1
J
BL/BK-L46+
GR-CR5
PLATFORM ROTATE LEFT/JIB UP
C14PLU OR C20-1
C15PLD OR/BK C4B-3
C11
BRN-GND
PLATFORM LEVEL DOWN
15
17
14
C14PLU OR C4B-2
C13DE BL/RD C10-1
C13DE BL/RD C4B-1
18/19 #1
C3 & C4
I
OR/BK-ISM2
RD-TS54
BK/RD-CR4
BK/WH-TS56
BK-TS52
PLATFORM LEVEL UP
14
13
44
RD/BK-ALARM
H
BK-ISM3
WH/RD-ALRM
RD-TS51
D52
RD-CR19#86
DRIVE ENABLE
13
C9PER BK/RD C30-1
JDALARM BL C3B-10
G
WH/RD-L2-
JIB DOWN DESCENT ALARM
44
9
C8PBR BK/WH C17-1
C9PER BK/RD C3B-9
#1
WH/BK-ISM10
RD-CB1
RD-ISM6
WH-KS
WH-ISM7
BK C32-4
BK-KS
BK-CR5
PRIM. BOOM EXT/RET FUNC. CTRL
9
8
C7PBE RD-LS5 C37-1
C7PBE BK C3B-7
C8PBR BK/WH C3B-8
+12 VOLT
POWER TO
PLATFORM
C7
F
WH-HM
D29
BRN-<GND>
PRIMARY BOOM RETRACT
8
7
C6TRF WH/RD C31-1
F.H.
RD-CB1
19
PRIMARY BOOM EXTEND
7
6
C5TRR WH/BK C14-1
C6TRF WH/RD C3B-6
#2
RD-CB2
18
TURNTABLE ROTATE FUNCTION CTRL
6
5
C4TRL WH C15-1
C5TRR WH/BK C3B-5
C5
GR/WH-TS57
GR/BK-TS57
15
17
TURNTABLE ROTATE RIGHT
5
4
C3PBF RD/WH C29-1
C4TRL WH C3B-4
#1
GR-TS57
TURNTABLE ROTATE LEFT
3
4
RD/WH-3D
PRIMARY BOOM FUNCTION CONTROL
RD-24B
3
C2PBD RD/BK C13-1
C3PBF RD/WH C3B-3
E
OR/BK-TS59
OR-TS59
BL-TS58
BK/RD-TS63
BK/WH-TS63
BK-22C1
D
BK-TS63
GR-46D
2
1
WH/RD-CR19
WH/RD-6D
WH/BK-TS62
BRN
WH-TS62
C21IGN WH C5-11
PRIMARY BOOM DOWN
R43DLITE2 RD
C1PBU RD C12-1
BRN
2
BRN
C2PBD RD/BK C3B-2
RD-TS51
C1PBU RD C3B-1
6
A
BK C7B-1
RD/WH-CR34
B
GR/BK-133B
5
RD/BK-TS61
C2B-4 OR/RD
1
P134PWR RD-134C
BK-22D2
TERMINAL BASE (TB)
BL/WH-132B
4
PRIMARY BOOM UP
3
1
RD H6
C
C32
OR-LS17 C38-2
C32 CONNECTOR
PLUG ANSI/CSA ONLY
RD-CB3
GR/BK-L45
1
RD/WH-TS61
R43DLITE1 RD
CR17
HYDRAULIC
OIL COOLER
OPTION
U33
PLATFORM
OVER LOAD
(CE ONLY)
D
RD-27C
RD/WH-R16
C21IGN WH
C
RD/BK-ALARM
BK C5-5
RD-TS61
BRN
WH/RD-R4
C5-18 BK/RD
OR C5-1
WH C5-4
C32
B
WH/RD-R2
CR4
HIGH RPM
SOLENOID RELAY
CR34
PRIMARY BOOM
SPEED
REDUCTION
RELAY
WH-OPTIONS
RD-ISM4
BK/RD-35C
BRN
WH-21B
CR19
SWING SPEED
SELECT
RELAY
BRN
7
CR5
HORN
RELAY
6
F.H.
8
C32
C5
12
C32
5
BRN
WH
CR23
DRIVE LIGHT
OPTION
2
WH-ISM9
BRN
RD
BRN
4
RD
CR2
POWER
RELAY
A
GROUND HARNESS
TO SWITCH PANEL
BK-ISM1
CR1
IGNITION
START RELAY
Section 6 • Schematics
July 2005
REV A
Perkins 404-22 Models (after serial number 11879)
N
F.H.
+
BRN
BK C16-1
BRN C7B-3
WH LS2 C10-2
GR/BK H6
#1
C5
3
July 2005
REV A
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Perkins 404-22 Models (after serial number 11879)
G
F
E
RD
RD
D
RD/WH
GR/BK
RD
C19JSV GR/WH
WH-4
WH/BK-5
RD
RD/WH
WH/RD
2
WH/RD
WH/RD
GR
WH/RD
GR/BK
GR/BK-18D
+
RD
D4
RD
RD
RD
A
1
RD-1
-
RD
TS51
AUXILIARY
POWER
D3
RD
RD
B
WH/RD
RD
RD/BK-2
C
BASE BOX HARNESS
(TO TERMINAL STRIP)
H
TS57
PLATFORM
ROTATE
I
GR-17D
J
TS62
TURNTABLE
ROTATE
K
D9
L
TS61
BOOM
UP/DOWN
M
L45
PLATFORM
OVERLOAD LED
(CE OPTION)
N
GR/BK
D28
RD
3
RD-24D
BK/RD-35D
4
CIRCUIT
BREAKER
CONTROLS 15A
CB2
RD-20C
RD-20C
5
RD
RD
RD
RD
RD/WH
TS59
PLATFORM
GR/WH-19D LEVEL
GR-17D
RD-20D
OR/BK-15D
RD
OR-14D
GR/BK-18D
RD
RD-20C
CIRCUIT
BREAKER
OPTIONS 15A
CB3
RD/WH
BK-33D
BL-44D
RD CR22
RD CR17
BK/WH-34D
RD C32-7
WH-4D
WH/BK-5D
RD/WH-CR34#87a
BK-7D
RD-1D
TS63
BOOM
EXTEND/
RETRACT
BK/RD-9D
BK/WH-8D
RD/WH
-
+
4
D2
RD
WH-23
RD/WH
RD/BK-2D
GR/BK-H6-
BRN
BRN-GND
WH/RD-26
L46
+
LOWER/
RETRACT BOOM
L2
CHECK
ENGINE
WH-21D
WH-23D
RD C32-6
C134PWR RD
2
B1
B
RD
3
KS1
KEY
SWITCH
1
RD-134D2
BK-22D1
WH
RD-27D
WH
BL/BK-59D
RD
WH
WH/RD CR19#87
WH/RD CR34#87
WH/RD CR19#87a
DALE RH-25 25W
7.5 ohm 1%
R4
TURNTABLE
ROTATE
RESISTOR
R2
TURNTABLE
ROTATE
RESISTOR
GR
RD
TS58
JIB BOOM
UP/DOWN
WH
RD-27
WH/RD
WH/RD
WH/RD
RD
RD-20D
RD-24D
CB1
CIRCUIT
BREAKER
ENGINE 15A
BK/WH-34D
RD
BRN
WH-21D
TS52
ENGINE
START
RD
DALE RH-25 25W
10 ohm 1%
DALE RH-25 25W
5 ohm 1%
R16
PRIMARY BOOM
UPPER ZONE
RESISTOR
BRN
RD
RD
RD
TS54
FUNCTION
ENABLE
2
D14
2
D13
1
NC
HOUR METER
1
NC
RD
P1
EMERGENCY
STOP SWITCH
RD
R14
BOOM
UP/DOWN
RESISTOR
6
TS56
GLOW
PLUG
DALE RH-25 25W
5 ohm 1%
RD
RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
LABEL
CB1
CB2
CB3
CR1
CR2
CR4
CR5
CR17
CR22
DESCRIPTION
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, OPTIONS, 15A
IGNITION / START RELAY
IGNITION POWER RELAY
HIGH IDLE RELAY
HORN RELAY
HYDRAULIC OIL COOLER FAN RELAY
DRIVE LIGHT RELAY (OPTION)
HM
KS1
L2
L46
L45
P1
R2
R4
HOUR METER
KEY SWITCH
CHECK ENGINE LED
LOWER/RETRACT BOOM LED
PLATFORM OVERLOAD LED (CE OPTION)
EMERGENCY STOP BUTTON
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 7.5 OHMS
R14
R16
TS51
TS52
TS54
TS56
TS57
TS58
TS59
SPEED LIMITING RESISTOR 5 OHMS
SPEED LIMITING RESISTOR 10 OHMS
AUXILIARY POWER TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
FUNCTION ENABLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM TOGGLE SWITCH
PLATFORM LEVEL TOGGLE SWITCH
TS61
TS62
TS63
PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TURNTABLE ROTATE TOGGLE SWITCH
BOOM EXTEND/RETRACT TOGGLE SWITCH
7
8
6 - 92
July 2005
Section 6 • Schematics
Ground Control Box Switch Panel Wiring Diagram, S-65
Perkins 404-22 Models (after serial number 11879)
July 2005
Section 6 • Schematics
Platform Control Box Wiring Diagram, S-65
Perkins 404-22 Models
BRN
BRN
BRN
CWLITE WH TS49
C32BRK WH/RD C1P-6
C32BRK WH/RD J2-19
C40LS OR C2P-2
C40LS OR J2-4
P24FS WH C9P-2
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C129JDA BL C3P-10 TS8
C46HRN GR C2P-5
C59CHK BL/BK C3P-11 L47+
WH
JIB
DESCRIPTION
ITEM
BK
C134PWR RD LS18
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
GR/BK C133TTA C3P-12
GR/BK-L4- (CE)
F.S.
RD/BK-28
RD/BK-L48- (NON-CE)
C134PWR RD C2P-6
RD-TILT
OPTION
FOOT SWITCH
C59CNK BL/BK C3P-11
BRN
+
OPT.
LS18
(CE)
JIB
12V DC BATTERY
P26BAT BK C9-1 P2
C7P
P25FS RD C9-3 TS2
C7P
P24FS WH C9-2 TS4
C4P
CDLITE OR/RD C2P-4
C45GEN GR/WH C2P-7
C46HRN GR C2P-5
C118LSR OR/RD C4P-4
C6TRF WH/RD C3P-6
C8PBR BK/WH C3P-8
C16DRE BL/RD C4P-1
C7PBE BK C3P-7
C40LSS OR C2P-2
C9PER BK/RD C3P-9
C41RPM OR/BK C2P-3
C30FWD WH C1P-4
C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
C28TTA RD/BK C1P-2
C3P
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
U13
J1
J2
J3
CR27
CR30
LS18
2
C19JSV GR/WH TS7
C19JSV GR/WH C4P-7
BRN JC3
BRN GND
RD-E-STOP
C134PWR RD-H1+
1
TS7 WH
1
TS1 WH
CWLITE BK
11
P26ESTP BK
P24FS WH
P24FS WH
JC1-3 OR
DRE LED BL/RD
TS15 B BL/BK
TS15 BL/WH
JC3-4 BL *
JC3-2 BRN
JC3-3 OR
JC3-5 WH
JC2-2 BRN
JC1-5 YEL
JC2-3 OR
JC2-5 BK
JC1-2 BRN
JC2-4 RD
1
TS14 RD/WH
RD/BK-L4-
BRN
J3
C134PWR RD LS18
BRN
19/18 CONTROL CABLE
H1
TILT
ALARM
3
BK C1P-12
C3P
C7P
C9
D39
9
CR27
CR30
BRN
C2P
6
C4P
BATGRN C7P-3
WH/RD C1P-6
C1P
C28TTA RD/BK C1P-2
Part No. 77828
S-60 • S-65
6 - 93
TILT ALARM
12V DC PLATFORM POWER CONNECTOR
FOOTSWITCH CONNECTOR
C1P-C4P 48 PIN CONNECTOR BLOCK
H1
C7P
C9
1
5
PLATFORM
CONTROL
HARNESS
(TO SWITCH
PANEL)
CE LIFT/DRIVE OPTION
J2
J1
C7P
8
RD LS18 CABLE
7
CWLITE WH TS49
4
REV B
Platform Control Box Wiring Diagram, S-65
N
M
L
K
J
I
H
G
F
E
D
C
B
A
U13
ALC-500
3
July 2005
Section 6 • Schematics
Perkins 404-22 Models
July 2005
REV B
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-65
Perkins 404-22 Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
PLATFORM CONTROL
HARNESS (TO CONTROL BOX)
COMPONENT INDEX
TS48
DRIVE LIGHTS/
WORK LIGHTS
(OPTION)
DLITE RD
RD
JC3
JC2
BOOM UP/DOWN
& TURNTABLE ROTATE
LEFT/RIGHT
JC1
7
7
BOOM
EXTEND/RETRACT
6
BRN
2
+
4
L4
PLATFORM
OVERLOAD
(CE OPTION)
3
2
L1
DRIVE
ENABLE
BRN
BRN
1
1
BRN
1
+
BK
BRN
2
+
BRN
BK
BRN
BRN
BK
C28TTA RD/BK H1C133PLA GR/BK D39
BK
BRN
WH
DRIVE/STEER PROPORTIONAL JOYSTICK
DRIVE ENABLE LED
PLATFORM OVERLOAD LED
LOWER/RETRACT BOOM LED
BOOM TILTED LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY TOGGLE SWITCH
ENGINE START TOGGLE SWITCH
HI/LOW RPM TOGGLE SWITCH
GLOW PLUG TOGGLE SWITCH
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP/DOWN TOGGLE SWITCH
TS9
TS14
TS15
TS47
TS48
PLATFORM LEVEL TOGGLE SWITCH
DRIVE SPEED TOGGLE SWITCH
DRIVE ENABLE TOGGLE SWITCH
GENERATOR TOGGLE SWITCH (OPTION)
DRIVE LIGHT/WORK LIGHT TOGGLE SWITCH (OPTION)
TS7
PLATFORM
ROTATE GR/BK
TS8
JIB
BOOM
TS1
AUXILIARY
PUMP
TS14
HIGH/LOW
(2WD/4WD)
TS6
GLOW PLUG
1
4
6
1
TS2
ENGINE
START
TS4
HIGH/LOW
RPM
2
2
P2
EMERGENCY
STOP
2
TS47
GENERATOR
(OPTION)
WH-24
RD
3
D12
1
D27
RD
BOOM PROPORTIONAL JOYSTICK:
BOOM EXTEND/RETRACT
P22BAT BK C7P-1
P26BAT BK J3-3
P23BAT WH C7P-2
P26BAT BK C9-1
RD-H1+
C134PWR RD L48+
C134PWR RD L4+
RD
TS9
PLATFORM
LEVEL
JC1
JC3
L1
L4
L47
L48
P2
P3
TS1
TS2
TS4
TS6
TS7
TS8
2
5
NC NC NC
P3
HORN
BOOM PROPORTIONAL JOYSTICK:
BOOM UP/DOWN , TURNTABLE ROTATE
7
RD
NO
JC2
RD
GR
3
JIB BOOM CUTOUT RELAY
WH
RD
4
BK TS15
WH
PDLITE RD
C45GEN GR/WH C2P-7
C35HS BK/RD C1P-9
P24FS WH C9-2
C33STR BK C1P-7
P25FS RD C9-3
C34SA BK/WH C1P-8
C29MS RD/WH J1-8
WH CR30
C27AUX RD C1P-1
WH-JIB
C129JDA BL C3P-10
C17PRL GR C4P-5
C19JSV GR/WH
WH CR27
C19JSV GR/WH C4P-7
C18PRR GR/BK C4P-6
P24FS WH
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C46HRN GR C2P-5
RD
RD
C134PWR RD E-STOP
C134PWR RD E-STOP
BL/RD-DE3 J1-16
BL-DE1 J1-6
BL/BK-DE2 J1-7
YL J1-3
OR J1-9
BRN J1-10
WH-JIB
WLITE WH
DLITE OR/RD C2P-4
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
C59CNK BL/BK C3P-11
WLITE WH
F18
FUSE 10A
(WORKLIGHT ONLY)
BL J1-5 (ROCKER SWITCH OPTION ONLY)
WH J1-4
BL J1-5
OR J1-13
BRN J1-14
BK
CR13
JIB BOOM
CUTOUT
3
RD
L47
RETRACT
BOOM
6
RD
4
7
5
BK
4
L48
TILT ALARM LED
(ANSI/CSA OPT.)
BK
5
3
TS15
DRIVE
ENABLE
6
5
DRIVE
FORWARD/REVERSE
& STEER
LEFT/RIGHT
+
CR13
8
RD
RD
NOTE: DASHED LINES INDICATE OPTION WIRES
Part No. 77828
S-60 • S-65
6 - 94
July 2005
Section 6 • Schematics
Platform Control Box Switch Panel Wiring Diagram, S-65
Perkins 404-22 Models
July 2005
Section 6 • Schematics
REV D
Hydraulic Schematic, 2WD Models
N
M
L
K
BRAKE/2 SPEED
MANIFOLD 0.025 in
JJ
I
H
G
F
M
T2
1.7
E
TURNTABLE
ROTATE
(2.8 gpm /
10.6 L/min)
BOOM EXTENSION
CYLINDER
(7 gpm / 26.5 L/min)
MEDIUM
PRESSURE
FILTER
51 psi
3.5 bar
0.64 mm
J
AUXILIARY
PUMP
MM
D
C
B
L
PRIMARY BOOM
LIFT CYLINDER
(8 gpm / 30.3 L/min)
PLATFORM LEVEL
CYLINDERS
A
KK
BRAKE
TEST
2SPEED
S1
PR1
ACCUMULATOR
1000 psi
69 bar
PP
RET
EXT
AUX
2
OO
V2
310 psi
21.4 bar
V1
SW1
SW2
P2
P1
JIB
SELECT
MANIFOLD
MASTER
ACCUM
PL1
PL2
J2
V2
V1
PR2
PR1
C
GG
H
G
HH
2400 psi
165.5 bar
A
PRESS
FUNCTION
PUMP
F
E
I
PTEST
L
2
Y
S
P
J
X
W
15
3
D
3000 psi
207 bar
9
JIB BOOM CYLINDER
(S-65)
30 psi 30 psi
2.1 bar 2.1 bar
B
3750 psi
259 bar
E
PR1
PR2
FF
0.030 in
0.76 mm
51 psi
3.5 bar
B
PR2
1
J1
HYDRAULIC GENERATOR
OPTION
HIGH
PRESSURE
FILTER
LL
PLATFORM
ROTATE
RR
CP
II
R
QQ
SLAVE
NN
A
V
N
K
O
R
0.6 gpm
2.27 L/min
U
M
T
Q
Z
AA
DRIVE PUMP
3.5 gpm
13.2 L/min
CC
BB
DD
0.1 gpm
0.38 L/min
30 psi
2.1 bar
EE
4
TANK
RESERVOIR
6
25 psi
1.7 bar
3
8
SWV
ST1
ST2
2
4
5
LS TEST
FUNCTION MANIFOLD
RETURN
FILTER
1
7
5
HYDRAULIC ROTARY COUPLER
6A
6B
6C
8C
8B
8A
TEST
RIGHT
REAR
M4
3
1
A
B
2A
2C
2B
4
7
5
6
LEFT
TRACTION MANIFOLD
STEER
CYLINDERS
RIGHT
A
B
LEFT
UU
CDR
SS
M2
TT
RIGHT
TEST
HYDRAULIC
GENERATOR
OPTION
50%
280 psi
19.3 bar
0.070 in
1.78 mm
OIL COOLER
RETURN
FILTER
VV
50%
M1
CDL
WW
XX
IN
A
OUT
B
B
M3
SWV
TANK
FUNCTION
MANIFOLD
2
T
800 psi
55 bar
OSCILLATE CYLINDERS
A
LEFT
REAR
7
OSCILLATE VALVE
HYDRAULIC ROTARY COUPLER
OIL COOLER OPTION
8
OSCILLATE AXLE
Part No. 77828
S-60 • S-65
6 - 95
July 2005
Section 6 • Schematics
Hydraulic Schematic, 2WD Models
July 2005
Section 6 • Schematics
REV D
Hydraulic Schematic, 4WD Models
N
M
L
K
BRAKE/2 SPEED
MANIFOLD 0.025 in
JJ
I
H
G
F
M
AUXILIARY
PUMP
1.7
T2
E
TURNTABLE
ROTATE
(2.8 gpm /
10.6 L/min)
BOOM EXTENSION
CYLINDER
(7 gpm / 26.5 L/min)
MEDIUM
PRESSURE
FILTER
51 psi
3.5 bar
0.64 mm
J
MM
D
C
B
L
PRIMARY BOOM
LIFT CYLINDER
(8 gpm / 30.3 L/min)
PLATFORM LEVEL
CYLINDERS
A
KK
TEST
2SPEED
BRAKE
PR1
PR2
PR1
FF
0.030 in
0.76 mm
S1
51 psi
3.5 bar
B
PR2
ACCUMULATOR
1000 psi
69 bar
PP
RET
EXT
AUX
310 psi
21.4 bar
2
OO
V2
V1
SW1
SW2
P2
P1
JIB
SELECT
MANIFOLD
MASTER
ACCUM
PL1
PL2
J2
V2
V1
PR2
PR1
C
H
G
HH
2400 psi
165.5 bar
GG
A
PRESS
FUNCTION
PUMP
F
E
I
PTEST
L
2
Y
S
P
J
X
W
15
3
D
3000 psi
207 bar
9
JIB BOOM CYLINDER
(S-65)
30 psi 30 psi
2.1 bar 2.1 bar
B
3750 psi
259 bar
E
1
J1
HYDRAULIC GENERATOR
OPTION
HIGH
PRESSURE
FILTER
LL
PLATFORM
ROTATE
RR
CP
II
R
QQ
SLAVE
NN
A
V
N
K
O
R
0.6 gpm
2.27 L/min
U
M
T
Q
Z
AA
DRIVE PUMP
3.5 gpm
13.2 L/min
CC
BB
DD
0.1 gpm
0.38 L/min
30 psi
2.1 bar
EE
4
TANK
25 psi
1.7 bar
RESERVOIR
6
8
3
SWV
ST1
ST2
2
4
5
LS TEST
FUNCTION MANIFOLD
RETURN
FILTER
1
7
5
HYDRAULIC ROTARY COUPLER
8B
8C
6B
6C
6A
8A
TEST
RIGHT
REAR
SS
M7
3
1
A
B
2A
5
LEFT
STEER
CYLINDERS
RIGHT
A
VV
CDR
M6
UU
B
LEFT
RIGHT
TEST
50%
HYDRAULIC
GENERATOR
OPTION
50%
280 psi
19.3 bar
0.040 in
1 mm
0.040 in
1 mm
AE
WW
AB
XX
50%
50%
AD
TRACTION
MANIFOLD
OIL COOLER
50%
50%
YY
ZZ
M3
M4
B
AF
B
M2
IN
A
OUT
B
7
SWV
TANK
FUNCTION
MANIFOLD
2
800 psi
55 bar
A
AG
M1
RETURN
FILTER
AC
0.040 in
1 mm
CDL
A
4
7
RIGHT
FRONT
M8
M5
LEFT
REAR
2B
6
TT
A
B
2C
OSCILLATE CYLINDERS
HYDRAULIC ROTARY COUPLER
LEFT
FRONT
OIL COOLER OPTION
8
T
OSCILLATE VALVE
OSCILLATE AXLE
Part No. 77828
S-60 • S-65
6 - 96
July 2005
Section 6 • Schematics
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.
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