147753

Introduction December 2013
Introduction
Important Serial Number Information

Read, understand and obey the safety rules and Genie offers the following Service Manuals for
operating instructions in the appropriate operator's these models:
manual on your machine before attempting any
maintenance or repair procedure. Title Part No.
This manual provides detailed scheduled S-60 and S-65 Service Manual
maintenance information for the machine owner and (before serial number 2575) ................................ 34476
user. It also provides troubleshooting fault codes
and repair procedures for qualified service S-60 and S-65 Service Manual
(from serial number 2575 to 6623) ....................... 48412
professionals.
Basic mechanical, hydraulic and electrical skills are S-60 and S-65 Service Manual
required to perform most procedures. However, (from serial number 6624 to 9153) ....................... 65196
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these S-60, S-65 and S-60 HC Service Manual
(from serial number 9154 to 14781) .................... 77828
instances, we strongly recommend that
maintenance and repair be performed at an S-60, S-65, S-60HC and TRAX Service Manual
authorized Genie dealer service center. (from serial number 14782 to 21000) ................ 139188
S-60/65, S-60HC, S-60X/XC, and TRAX

Compliance Service Manual (from serial number 26296) ..... 825591
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life

Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All Copyright © 2012 Terex Corporation
communications will be carefully considered for
147753 Rev D December 2013
future printings of this and all other manuals. Sixth Edition, Fourth Printing
"Genie" and "S" are registered trademarks of

Terex South Dakota, Inc. in the USA and many
Contact Us: other countries.
Printed on recycled paper

http://www.genielift.com
e-mail: awp.techpub@terex.com Printed in U.S.A.
ii S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753

S-60 HC • S-60X • S-60XC
December 2013
Revision History
Revision Date Section Procedure / Schematic Page / Description
A 9/2010 New release
A1 1/2011 2 - Spec. Machine Specifications
4 - Repair 1-2
6-Schem. 6-96
A2 10/2011 4 - Repair 1-2
B 2/2012 Introduction Revision History Added

3 - Maint. 3-1
C 10/2012 Added Ford MSG-425 Engine to all sections.

Added Deutz TD2011L04i Engine to all sections.
2 - Spec. Ford MSG-425, Deutz TD2011L04i

4 - Repair 7-12, 7-13, 7-15,
5 - Faults Updated Fault Codes
6 - Schem. 6 - 1 Revised all schematics and grouped by Markets.

ANSI/CSA, CE, AS
Added Options Section
C1 12/2012 2 - Spec. Machine Torque Spec.
5 - Faults Separated Ford Fault Codes

Updated Ford DSG-423 Fault Codes
Updated Ford MSG-425 Fault Codes
C2 1/2013 3 - Maint. 3-6, E-4

D 12/2013 4 - Repair 7-4, 7-5
6 - Schem. 6-25, 6-29
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications. Electronic Version

A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX iii
S-60 HC • S-60X • S-60XC
December 2013
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
Kubota Engine_Section 2_Specifications. Electronic Version

A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-35, 6-56, 6-104_Section 6_Schematic Page #.
iv S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753

S-60 HC • S-60X • S-60XC
December 2013
INTRODUCTION
Serial Number Legend
Model: S-60
Serial number: S6010-12345
Model year: 2010 Manufacture date: 04/12/05
Electrical schematic number: E0396
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
S60 10 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 60 ft 2 in/ 18.3 m Model Sequence
Maximum platform reach : 50 ft 4 in/ 15.3 m number
Gradeability: 45% Model year
Country of manufacture: USA
This machine complies with:
Terex South Dakota

500 Oak Wood Road
PO Box 1150
Watertown, SD 57201 Serial label
USA (located under cover)
Serial number
(stamped on chassis)
PN - 77055
Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX v

S-60 HC • S-60X • S-60XC
Section 1 • Safety Rules December 2013
Safety Rules
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This

Danger manual and the decals on the machine,
use signal words to identify the following:
Failure to obey the instructions and safety rules in
this manual, and the appropriate operator's manual Safety alert symbol—used to alert
on your machine will result in death or serious personnel to potential personal
injury. injury hazards. Obey all safety
messages that follow this symbol
Many of the hazards identified in the operator's to avoid possible injury or death.
manual are also safety hazards when maintenance
and repair procedures are performed. Indicates an imminently hazardous
situation which, if not avoided, will
Do Not Perform Maintenance result in death or serious injury.
Unless: Indicates a potentially hazardous
situation which, if not avoided,
You are trained and qualified to perform could result in death or serious
maintenance on this machine. injury.
You read, understand and obey: Indicates a potentially hazardous
- manufacturer’s instructions and safety rules situation which, if not avoided,
- employer’s safety rules and worksite may cause minor or moderate
regulations injury.
- applicable governmental regulations
Indicates a potentially hazardous
You have the appropriate tools, lifting situation which, if not avoided,
equipment and a suitable workshop. may result in property damage.
Be sure to wear protective eye wear and

other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards

such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
vi S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753

S-60 HC • S-60X • S-60XC
December 2013 Section 1 • Safety Rules
SAFETY RULES
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.
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. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX vii
S-60 HC • S-60X • S-60XC
December 2013
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Information ............................................................................................ ii
Revision History .......................................................................................................... iii
Serial Number Legend ................................................................................................. v
Section 1 Safety Rules

General Safety Rules .................................................................................................. vi
Section 2 Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Specifications ........................................................................................ 2 - 3
Manifold Component Specifications ....................................................................... 2 - 4
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 5
Ford MSG-425 EFI Engine Specifications .............................................................. 2 - 6
Deutz D2011L03i Engine Specifications ................................................................. 2 - 7
Deutz TD2011L04i Engine Specifications ............................................................... 2 - 9
Perkins 404-22 Engine Specifications .................................................................. 2 - 11
Machine Torque Specifications .............................................................................. 2 -12
Trax Torque Specifications .................................................................................. 2 - 13
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 14
SAE and Metric Fasteners Torque Charts ............................................................ 2 - 16
viii S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753
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December 2013
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................. 3 - 8
A-3 Perform Function Tests ................................................................................ 3 - 8
A-4 Perform Engine Maintenance ....................................................................... 3 - 9
A-5 Check the High Pressure Hydraulic Filter Condition Indicator ....................... 3 - 9
A-6 Test the Oscillate Axle (if equipped) ........................................................... 3 - 10
A-7 Inspect the Track Components and Fastener Torque,
S-60 TRAX and S-65 TRAX ....................................................................... 3 - 10
A-8 Perform 30 Day Service ............................................................................. 3 - 11
A-9 Check the Track Tension, S-60 TRAX and S-65 TRAX .............................. 3 - 11
A-10 Perform Engine Maintenance - Ford and Perkins Models ........................... 3 - 13
A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 13
A-12 Check and Adjust the Engine RPM - Perkins Models ................................. 3 - 15
A-13 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 16
A-14 Replace the Drive Hub Oil .......................................................................... 3 - 17
A-15 Perform Engine Maintenance - Ford Models ............................................... 3 - 19
A-16 Perform Engine Maintenance - Perkins Models .......................................... 3 - 19
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December 2013
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued

Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 20
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 21
B-3 Check the Exhaust System ....................................................................... 3 - 22
B-4 Inspect the Engine Air Filter - Ford, Deutz and Perkins Models .................. 3 - 23
B-5 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 23
B-6 Inspect the Tires, Wheels and Lug Nut Torque,
S-60, S-65, S-60 HC, S-60X and S-60XC ................................................... 3 - 24
B-7 Confirm the Proper Brake Configuration ...................................................... 3 - 25
B-8 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 25
B-9 Check and Adjust the Engine RPM - Ford and Deutz Models ..................... 3 - 28
B-10 Test the Ground Control Override ............................................................... 3 - 29
B-11 Check the Oscillate Directional Valve Linkage ........................................... 3 - 29
B-12 Test the Platform Self-leveling ................................................................... 3 - 30
B-13 Test the Engine Idle Select ........................................................................ 3 - 30
B-14 Test the Fuel Select Operation - Ford Models ............................................ 3 - 31
B-15 Test the Drive Brakes ................................................................................ 3 - 32
B-16 Test the Drive Speed - Stowed Position ..................................................... 3 - 32
B-17 Test the Drive Speed - Raised or Extended Position .................................. 3 - 33
B-18 Test the Alarm Package - Optional Equipment ........................................... 3 - 34
B-19 Perform Hydraulic Oil Analysis ................................................................... 3 - 35
B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 35
B-21 Replace the Fuel Filter Element - Perkins Models ...................................... 3 - 36
B-22 Inspect the Boom Extend/Retract Cables ................................................... 3 - 38
B-23 Perform Engine Maintenance - Deutz Models ............................................. 3 - 39
B-24 Perform Engine Maintenance - Ford Models ............................................... 3 - 40
B-25 Replace the Engine Air Filter Element - Ford Models ................................. 3 - 40
B-26 Perform Engine Maintenance - Perkins Models .......................................... 3 - 41
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December 2013
TABLE OF CONTENTS
Section 3 Scheduled Maintenance Procedures, continued

Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models ............................................. 3 - 42
C-2 Grease the Platform Overload Mechanism (if equipped),
S-60, S-65, S-60 TRAX and S-65 TRAX .................................................... 3 - 42
C-3 Test the Platform Overload System, S-60 and S-65 (if equipped),
S-60, S-65, S-60 TRAX and S-65 TRAX .................................................... 3 - 43
C-4 Test the Platform Load Sense System, S60 HC ........................................ 3 - 46
C-5 Replace the Fuel Filter/Water Separator Element - Perkins Models ............ 3 - 48
C-6 Replace the Engine Air Filter Element - Deutz and Perkins Models ............ 3 - 50
C-7 Check the Safety Envelope Limit Switches and Angle Sensor,
S-60X and S-60XC ..................................................................................... 3 - 50
C-8 Perform Engine Maintenance - Perkins Models .......................................... 3 - 53
C-9 Perform Engine Maintenance - Ford Models ............................................... 3 - 53
Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 54
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 55
D-3 Inspect for Turntable Bearing Wear ............................................................ 3 - 56
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 57
D-5 Check the Free-wheel Configuration ........................................................... 3 - 59
D-6 Replace the Hydraulic Filters ...................................................................... 3 - 61
D-7 Perform Engine Maintenance - Deutz Models ............................................. 3 - 63
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 64
E-2 Perform Engine Maintenance - Deutz Models ............................................. 3 - 66
E-3 Perform Engine Maintenance - Deutz Models ............................................. 3 - 66
E-4 Replace the Boom Extend/Retract Cables .................................................. 3 - 67
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December 2013
TABLE OF CONTENTS
Section 4 Repair Procedures

Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1 ALC-500 Circuit Board .................................................................................. 4 - 2
1-2 Joysticks ..................................................................................................... 4 - 3
Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 9
2-2 Platform Rotator ......................................................................................... 4 - 10
2-3 Platform Overload System, S-60, S-65, S-60 TRAX and
S-65 TRAX (if equipped) ............................................................................. 4 - 12
2-4 Platform Load Sense System, S-60 HC ..................................................... 4 - 14
Jib Boom Components, S-65 and S-65 TRAX
3-1 Jib Boom .................................................................................................... 4 - 18
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 19
Boom Components
4-1 Cable Track ................................................................................................ 4 - 20
4-2 Boom ......................................................................................................... 4 - 25
4-3 Boom Lift Cylinder ...................................................................................... 4 - 28
4-4 Boom Extension Cylinder ........................................................................... 4 - 29
4-5 Boom Extend/Retract Cables ..................................................................... 4 - 32
4-6 Platform Leveling Master Cylinder .............................................................. 4 - 35
4-7 Primary Boom Angle Sensor - S-60X and S-60XC ..................................... 4 - 36
Engines
5-1 RPM Adjustment - Ford and Deutz Models ................................................ 4 - 37
5-2 RPM Adjustment - Perkins Models ............................................................. 4 - 37
5-3 Flex Plate ................................................................................................... 4 - 37
5-4 Engine Fault Codes - Ford Models ............................................................. 4 - 42
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December 2013
TABLE OF CONTENTS
Section 4 Repair Procedures, continued

Hydraulic Pumps
6-1 Function Pump ........................................................................................... 4 - 43
6-2 Drive Pump ................................................................................................ 4 - 44
Manifolds
7-1 Function Manifold Components .................................................................. 4 - 46
7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 49
7-3 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 50
7-4 Brake/Two-speed Manifold Components (to SN 25201) .............................. 4 - 51
7-5 Brake/Two-speed Manifold Components (from SN 25202) .......................... 4 - 52
7-6 Turntable Rotation Manifold Components ................................................... 4 - 53
7-7 Oscillate Directional Valve Components ..................................................... 4 - 54
7-8 Valve Adjustments - Oscillate Relief Valve ................................................ 4 - 56
7-9 Drive Oil Diverter Manifold (welder option) .................................................. 4 - 57
7-10 Traction Manifold Components, 2WD ......................................................... 4 - 58
7-11 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 59
7-12 Traction Manifold Components, 4WD (from SN 21001 to 21231) ................ 4 - 60
7-13 Traction Manifold Components, 4WD (after SN 21231) ............................... 4 - 62
7-14 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 64
7-15 Hydraulic Generator Manifold Components, 3kW (after SN 21396) ............. 4 - 65
7-16 Valve Coils ................................................................................................. 4 - 66
Turntable Rotation Components
8-1 Turntable Rotation Assembly ..................................................................... 4 - 68
Axle Components
9-1 Oscillate Axle Cylinders ............................................................................. 4 - 70
Track Components
10-1 Track Assembly, S-60 TRAX and S-65 TRAX ............................................ 4 - 71
Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX xiii
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TABLE OF CONTENTS
Section 5 Fault Codes

Introduction ............................................................................................................ 5 - 1
Fault Codes - Control System ................................................................................ 5 - 2
Fault Codes - Ford DSG-423 EFI Engine ............................................................... 5 - 8
Fault Codes - Ford MSG-425 EFI Engine ............................................................. 5 - 15
Fault Codes - Platform Load Sense System, S-60 HC ......................................... 5 - 21
Section 6 Schematics
Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend .................................................................................... 6 - 2
Hydraulic Symbols Legend .................................................................................... 6 - 3
Limit Switch Location Legend ................................................................................ 6 - 4
Ford Engine Relay Layout ...................................................................................... 6 - 5
Ford DSG-423 Engine Wire Harness ...................................................................... 6 - 8
Ford MSG-425 Engine Wire Harness ..................................................................... 6 - 9
Electrical Schematic, Options (All Models) ............................................................ 6 -12
Wiring Diagram, Belt Driven Generator ................................................................. 6 - 13
Wiring Diagram, 3kW Hydraulic Generator ........................................................... 6 - 16
Wiring Diagram, 12kW Hydraulic Generator - Welder Option ................................ 6 - 17
Electrical Schematic, 12kW Hydraulic Generator - Welder Option ........................ 6 - 20
Hydraulic Schematic, 12kW Hydraulic Generator - Welder Option ........................ 6 - 21
Hydraulic Schematic, 2WD Models (from SN 21001 to 21396) ............................. 6 - 24
Hydraulic Schematic, 2WD Models (after SN 21396) ........................................... 6 - 25
Hydraulic Schematic, 4WD Models (from SN 21001 to 21396) ............................. 6 - 28
Hydraulic Schematic, 4WD Models (after SN 21396) ........................................... 6 - 29
xiv
December 2013
TABLE OF CONTENTS
Section 6 Schematics, continued

Electrical Schematics - ANSI/CSA
Electrical Schematic, S-65 Ford Engine Models (ANSI / CSA) ............................ 6 - 32
Ground Control Box Terminal Strip Wiring Diagram, S-65
Ford Engine Models (ANSI / CSA) ............................................................. 6 - 36
Ground Control Box Switch Panel Wiring Diagram, S-65
Platform Control Box Wiring Diagram, S-65
Ford Engine Models (ANSI/CSA) ............................................................... 6 - 40
Platform Control Box Switch Panel Wiring Diagram, S-65
Electrical Schematic, S-65/S60 TRAX/S65 TRAX
Deutz D2011L03i Models (ANSI / CSA) ...................................................... 6 - 44
Deutz TD2011L04i Models (ANSI / CSA) ................................................... 6 - 48
Ground Control Box Terminal Strip Wiring Diagram, S-65/S60 TRAX/S65 TRAX
Deutz Engine Models (ANSI / CSA) ........................................................... 6 - 52
Ground Control Box Switch Panel Wiring Diagram, S-65/S60 TRAX/S65 TRAX
Platform Control Box Wiring Diagram, S-65/S60 TRAX/S65 TRAX
Platform Control Box Switch Panel Wiring Diagram, S-65/S60 TRAX/S65 TRAX
Perkins Engine Models (ANSI / CSA) ........................................................ 6 - 60
Ground Control Box Terminal Strip Wiring Diagram, S-65/S60 TRAX/S65 TRAX
Ground Control Box Switch Panel Wiring Diagram, S-65/S60 TRAX/S65 TRAX
Platform Control Box Wiring Diagram, S-65/S60 TRAX/S65 TRAX
Platform Control Box Switch Panel Wiring Diagram, S-65/S60 TRAX/S65 TRAX
Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX xv

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December 2013
TABLE OF CONTENTS

Electrical Schematics - ANSI/CSA
Electrical Schematic, S-60X and S-60XC
Ground Control Box Terminal Strip Wiring Diagram, S-60X and S-60XC
Ground Control Box Switch Panel Wiring Diagram, S-60X and S-60XC
Platform Control Box Wiring Diagram, S-60X and S-60XC
Platform Control Box Switch Panel Wiring Diagram, S-60X and S-60XC
Deutz D2011L03i Models (ANSI/CSA) ........................................................ 6 - 84
Deutz TD2011L04i Models (ANSI/CSA) ...................................................... 6 - 88
Deutz Engine Models (ANSI/CSA) ............................................................. 6 - 92
Perkins Engine Models (ANSI/CSA) .......................................................... 6 - 100
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TABLE OF CONTENTS

Electrical Schematics - CE
Electrical Schematic, S-60/S-65
Ford Engine Models (CE) (from SN 21001 to 22516) ................................. 6 - 112
Ford Engine Models (CE) ( after SN 22516) ............................................... 6 - 116
Ground Control Box Terminal Strip Wiring Diagram, S-60/S-65
Ford Engine Models (CE) (from SN 21001 to 22516) ................................. 6 - 120
Ford Engine Models, (CE) (after SN 22516) ............................................... 6 - 121
Ground Control Box Switch Panel Wiring Diagram, S-60/S-65
Ford Engine Models (CE) .......................................................................... 6 - 124
Platform Control Box Wiring Diagram, S-60/S-65
Platform Control Box Switch Panel Wiring Diagram, S-60/S-65
Electrical Schematic, S-60/S-65/S60 TRAX/S65 TRAX
Deutz D2011L03i Models (CE) .................................................................. 6 - 130
Deutz TD2011L04i Models (CE) ................................................................ 6 - 134
S60 TRAX/S65 TRAX Deutz Engine Models (CE) ..................................... 6 - 138
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TABLE OF CONTENTS

Electrical Schematics - CE
Perkins Engine Models (CE) ..................................................................... 6 - 146
S60 TRAX/S65 TRAX Perkins Engine Models (CE) .................................. 6 - 150
Electrical Schematic, S-60 HC (CE) .................................................................... 6 - 158
Chassis Wiring Diagram, S-60 HC (CE) .............................................................. 6 - 159
Ground Control Box Terminal Strip Wiring Diagram, S-60 HC
(CE) (from SN 21001 to 21287) ................................................................ 6 - 162
Ground Control Box Terminal Strip Wiring Diagram, S-60 HC
(CE) (after SN 21287) ................................................................................ 6 - 163
Platform Control Box Wiring Diagram, S-60 HC (CE) ........................................... 6 - 166
Electrical Schematics - AS, From SN 21001 to 21629
Ford Engine Models (AS) ( from SN 21001 to 21629) ................................ 6 - 168
Ford Engine Models (AS) (from SN 21001 to 21629) ................................. 6 - 172
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TABLE OF CONTENTS

AS, From SN 21001 to 21629
Deutz D2011L03i Models (AS) (from SN 21001 to 21629) ......................... 6 - 180
Deutz TD2011L04i Models (AS) (from SN 21001 to 21629) ....................... 6 - 184
S60 TRAX/S65 TRAX Deutz Engine Models
(AS) (from SN 21001 to 21629) ................................................................. 6 - 188
(AS) (from SN 21001 to 21629) ................................................................. 6 - 189
(AS) (from SN 21001 to 21629) ................................................................. 6 - 192
(AS) (from SN 21001 to 21629) ................................................................. 6 - 193
Perkins Engine Models (AS) (from SN 21001 to 21629) ............................ 6 - 196
S60 TRAX/S65 TRAX Perkins Engine Models
(AS) (from SN 21001 to 21629) ................................................................. 6 - 200
S60 TRAX/S65 TRAX
Perkins Engine Models (AS) (from SN 21001 to 21629) ............................ 6 - 201
(AS) (from SN 21001 to 21629) ................................................................. 6 - 204
(AS) (from SN 21001 to 21629) ................................................................. 6 - 205
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December 2013
TABLE OF CONTENTS

Electrical Schematics - AS, After SN 21629
Ford Engine Models (AS) (after SN 22516) ................................................ 6 - 212
Ford Engine Models (AS) (after SN 22516)) ............................................... 6 - 217
Deutz D2011L03i Models (AS) (after SN 21629) ........................................ 6 - 226
Deutz TD2011L04i Models (AS) (after SN 21629) ...................................... 6 - 230
S60 TRAX/S65 TRAX Deutz Engine Models (AS) (after SN 21629) .......... 6 - 234
Platform Control Box Wiring Diagram, S-60/S-65/S60 TRAX/S65 TRAX
Deutz Engine Models (AS) (after SN 21629) .............................................. 6 - 238
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TABLE OF CONTENTS

Perkins Engine Models (AS) (after SN 21629) ........................................... 6 - 242
S60 TRAX/S65 TRAX Perkins Engine Models (AS) (after SN 21629) ........ 6 - 246
Platform Control Box Wiring Diagram, S-60/S-65/S60 TRAX/S65 TRAX
Perkins Engine Models (AS) (after SN 21629) ........................................... 6 - 250
Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX xxi
S-60 HC • S-60X • S-60XC
December 2013
TABLE OF CONTENTS
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xxii S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753
S-60 HC • S-60X • S-60XC
December 2013 Section 2 • Specifications
Specifications
Machine Specifications Track Components, S-60 TRAX and S-65 TRAX
Tires and wheels, S-60, S-65, S-60 HC, S-60X and Track material Rubber
S-60XC Tensioning system Pressurized grease
Tire size Weight (each) 1,500 lbs
(Rough terrain) 355/55D625 680 kg
Tire weight, new foam-filled (minimum) 415 lbs Fluid capacities
(Rough terrain) 188 kg
Fuel tank 35 gallons
Tire size (Deutz and Perkins Models) 132.5 liters
(Hi-flotation) 41/18LL x 22.5
(Ford models) 30 gallons
Tire ply rating 113.5 liters
(Rough terrain and Hi-flotation) 14
LPG tank 33.5 pounds
Wheel lugs 9 @ 5/8 -18 15.2 kg
Lug nut torque, dry 240 ft-lbs Hydraulic tank 45 gallons
325 Nm 170 liters
Lug nut torque, lubricated 180 ft-lbs Hydraulic system 55 gallons

244 Nm (including tank) 208 liters
Drive hubs 20 fl oz
Overall tire diameter 36.9 in
0.6 liters
(Rough terrain, low profile tires) 93.7 cm
Turntable rotation drive hub 40 fl oz
Overall tire diameter 40.3 in (before serial number 20367) 1.2 liters
(Hi-flotation tires) 102.4 cm
(after serial number 20366) 43 oz
Tire pressure 70 psi
1.3 liters
(Rough terrain, low profile tires) 4.92 bar
Drive hub oil type:
Tire pressure 60 psi SAE 90 multipurpose hypoid gear oil API service
(Hi-flotation tires) 4.13 bar classification GL5
For operational specifications, refer to the

Operator's Manual.
Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.
Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX 2-1
S-60 HC • S-60X • S-60XC
Section 2 • Specifications December 2013
SPECIFICATIONS
Performance Specifications Drive speed, maximum

stowed position
Boom function speeds, maximum
from platform controls 2WD models 40 ft / 6.2 sec
12.2 m / 6.2 sec
Jib boom up (S-65 models) 60 to 70 seconds
4WD models 40 ft / 7.2 sec
Jib boom down (S-65 models) 40 to 50 seconds 12.2 m / 7.2 sec
Boom up 60 to 70 seconds S-60 TRAX and S-65 TRAX 40 ft / 12 sec

12.2 m / 12 sec
Boom down 60 to 70 seconds
Drive speed, maximum
Boom extend 58 to 66 seconds raised or extended position
Boom retract 53 to 62 seconds S-60, S-65, S-60 HC, S-60X 40 ft / 40 sec
and S-60XC 12.2 m / 40 sec
Turntable rotate, 360° 78 to 86 seconds
boom stowed S-60 TRAX and S-65 TRAX 40 ft / 57 sec
12.2 m / 57 sec
Turntable rotate, 360° 125 to 165 seconds
boom extended Gradeability See Operator's Manual
Platform rotate, 160° 8 to 12 seconds
Braking distance, maximum
High range on paved surface 3 to 6 ft

0.9 to 1.8 m

Genie policy. Product specifications are subject
to change without notice.
2-2 S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753
S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Hydraulic Specifications Note: Use Chevron Aviation A hydraulic oil when

ambient temperatures consistently below
Hydraulic Oil Specifications 0°F / -18°C.
Hydraulic oil type Chevron Rando HD MV equivalent Note: Use Shell Tellus T46 hydraulic oil when oil
Approximate SAE grade 5W-20 temperatures consistently exceed 205°F / 96°C.
Viscosity index rating 200
Note: Genie specifications require additional
Cleanliness level, minimum 15/13 equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Water content, maximum 200 ppm
Service Department before use.
Chevron Rando HD MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils. Drive pump
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic Type: bi-directional, variable
systems, have the ability to perform over a wide displacement piston pump
temperature range, and the viscosity index should Flow rate @ 2500 rpm 32.4 gpm
exceed 140. They should provide excellent antiwear, 122.6 L/min
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties. Drive pressure, maximum 3750 psi
259 bar
Optional fluids
Charge pump
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32 Type: gerotor
BP Biohyd SE-S
Displacement 0.85 cu in
Fire resistant UCON Hydrolube HP-5046 13.9 cc
Quintolubric 822
Flow rate @ 2500 rpm 9.2 gpm
Mineral based Shell Tellus S2 V 32 34.8 L/min
Shell Tellus S2 V 46
Chevron Aviation A Charge pressure @ 2500 rpm 310 psi
ARNICA 32 21.4 bar
Function pump
Continued use of Chevron Aviation Type: 2 section tandem gear pump
A hydraulic oil when ambient
temperatures are consistently Displacement - Pump 1 (inner) 1.4 cu in
above 32°F / 0°C may result in 23 cc
component damage. Flow rate @ 2500 rpm 15.3 gpm
58 L/min
Displacement - Pump 2 (outer) 0.24 cu in

(oscillate models) 4 cc
Flow rate @ 2500 rpm 2 gpm

7.6 L/min

S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Auxiliary pump Manifold Component

Type: gear, fixed displacement Specifications
Displacement 1.75 gpm Plug torque
2.8 L/min
SAE No. 2 36 in-lbs / 4 Nm
Function manifold
SAE No. 4 10 ft-lbs / 13 Nm
System relief valve pressure 3000 psi
207 bar SAE No. 6 14 ft-lbs / 19 Nm
Steer flow regulator 3.5 gpm SAE No. 8 38 ft-lbs / 51 Nm

13.2 L/min
SAE No. 10 41 ft-lbs / 55 Nm
Jib boom / platform rotate 0.6 gpm
flow regulator 2.27 L/min SAE No. 12 56 ft-lbs / 76 Nm
Oscillate relief valve pressure (@ 2500 rpm) 800 psi

55 bar
Drive manifold
Hot oil relief valve pressure 280 psi

19.3 bar
Drive motors, 4WD models
Displacement per revolution, 0.79 cu in

high speed 13 cc

low speed 30 cc
Drive motors, 2WD models

high speed 20.9 cc

low speed 35 cc
Hydraulic filters
High pressure filter Beta 3 ≥ 200
High pressure filter 51 psi

bypass pressure 3.5 bar
Medium pressure filter Beta 3 ≥ 200
Medium pressure filter 51 psi

bypass pressure 3.5 bar
Hydraulic return filter 10 micron with Continuous improvement of our products is a

25 psi / 1.7 bar bypass Genie policy. Product specifications are subject
S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Ford DSG-423 EFI Engine Electronic fuel pump
Displacement 140.4 cu in Fuel pressure, static 64 psi

2.3 liters 4.4 bar
Number of cylinders 4 Fuel flow rate 0.43 gpm

1.6 L/min
Bore & stroke 3.44 x 3.7 inches
87.5 x 94 mm Fuel requirement
Horsepower 59 @ 2500 rpm For fuel requirements, refer to the engine Operator's
44 kW @ 2500 rpm Manual on your machine.
Firing order 1-3-4-2 Ignition system
Low function idle (computer controlled) 1600 rpm Spark plug type Motorcraft AGSF-32-FEC
53.3 Hz Spark plug gap 0.049 to 0.053 inches
High function idle (computer controlled) 2500 rpm 1.244 to 1.346 mm
83.3 Hz Engine coolant
Compression ratio 9.7:1 Capacity 10 quarts
Compression pressure (approx.) 9.5 liters
Pressure (psi or bar) of lowest cylinder must be Cylinder head temperature sending unit
at least 75% of highest cylinder
Fault code set temperature 280°F
Lubrication system 138°C
Oil pressure 29 to 39 psi Engine shut-down temperature 300°F
(at operating temperature @ 2500 rpm) 2 to 2.7 bar 149°C
Oil capacity 4 quarts Starter motor
(including filter) 3.8 liters
Normal engine cranking speed 200 to 250 rpm
Oil pressure switch
Current draw, normal load 140-200A
Oil pressure switch point 7.5 psi
0.51 bar Current draw, maximum load 800A
Oil viscosity requirements Alternator
Extreme operating temperatures may require the use of Output 95A, 13.8V DC
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine. Battery
Type 12V DC, Group 31
Quantity 1
Cold cranking ampere @ 0°F 1000A
Reserve capacity @ 25A rate 200 minutes

S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Ford MSG-425 EFI Engine Electronic fuel pump
Displacement 152.5 cu in Fuel pressure, static 60 psi

2.5 liters 4.1 bar
Number of cylinders 4 Fuel flow rate 0.43 gpm

1.6 L/min
Bore & stroke 3.50 x 3.94 inches
89 x 100 mm Fuel requirement
Horsepower 60 @ 2500 rpm For fuel requirements, refer to the engine Operator's
44.7 kW @ 2500 rpm Manual on your machine.
Firing order 1-3-4-2 Ignition system
Low function idle (computer controlled) 1600 rpm Spark plug type Motorcraft AYFS-32Y-R
53.3 Hz Spark plug gap 0.049 to 0.053 inches
High function idle (computer controlled) 2500 rpm 1.25 to 1.35 mm
83.3 Hz Engine coolant
Compression ratio 9.7:1 Capacity 10 quarts
Compression pressure (approx.) 9.5 liters
Pressure (psi or bar) of lowest cylinder must be Cylinder head temperature sending unit
at least 75% of highest cylinder
Fault code set temperature 280°F
Lubrication system 138°C
Oil pressure 29 to 39 psi Engine shut-down temperature 300°F
(at operating temperature @ 2500 rpm) 2 to 2.7 bar 149°C
Oil capacity 6.7 quarts Starter motor
Normal engine cranking speed 200 to 250 rpm
Oil pressure switch
Oil pressure switch point 7 to 9 psi
0.48 to 0.62 bar Current draw, maximum load 800A
Oil viscosity requirements Alternator
Extreme operating temperatures may require the use of Output 95A, 13.8V DC
Engine Operator Handbook on your machine. Battery
Type 12V DC, Group 31
Quantity 1
Cold cranking ampere @ 0°F 1000A

S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Deutz D2011L03i Engine Lubrication system
Displacement 142 cu in Oil pressure 40 to 60 psi

2.33 liters (@ 2000 rpm) 1.4 to 3 bar
Number of cylinders 3 Oil capacity 9.5 quarts

(including filter) 9 liters
Bore and stroke 3.7 x 4.4 inches
94 x 112 mm Oil viscosity requirements
Horsepower 48 @ 2800 rpm -22° F to 86° F/ -30° C to 30° C 5W-30

36 kW @ 2800 rpm (synthetic)
Firing order 1-2-3 -4° F to 90° F / -20° C to 32° C 10W-40
Low idle 1500 rpm Above 23° F / -5° C 20W-50

313 Hz Units ship with 15W-40.
High idle 2500 rpm Extreme operating temperatures may require the use of
521.7 Hz alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Compression ratio 19:1
Oil temperature switch
Compression pressure 362 to 435 psi
25 to 30 bar Temperature switch point 220°F
104°C
Governor centrifugal mechanical
Oil pressure switch
Valve clearance, cold
Oil pressure switch point 22 psi
Intake 0.012 in 1.5 bar
0.3 mm
Exhaust 0.020 in
0.5 mm

S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Deutz D2011L03i Engine, continued
Fuel injection system
Injection pump make Bosch
Injection pump pressure, maximum 15000 psi

1034 bar
Injector opening pressure 3046 psi

210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's

Manual on your machine.
Starter motor
Current draw, normal load 140A to 200A
Brush length, new 0.72 in

18.5 mm
Brush length, minimum 0.27 in

7 mm
Battery
Type 12V DC
Size 13 x 613/16 x 93/8 inches

33 x 17.3 x 23.8 cm
Quantity 1
Cold cranking ampere 1000A
Alternator output 60A @ 14V DC
Fan belt deflection 3 /8to 1/2 inch

9 to 12 mm

S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Deutz TD2011L04i Engine Lubrication system
Displacement 220.9 cu in Oil pressure, hot 40 to 60 psi

3.62 liters (at 2000 rpm) 2.8 to 4.1 bar

Horsepower -22°F to 86°F / -30°C to 30°C 5W-30

Net intermittent @ 2400 rpm 74 / 55 kW (synthetic)
Induction system turbocharged -4°F to 104°F / -20°C to 40°C 10W-40
Firing order 1-3-4-2 Above 5°F / -15°C 15W-40
Low idle 1500 rpm Units ship with 15W-40.

450 Hz Extreme operating temperatures may require the use of
High idle 2350 rpm Engine Operator Handbook on your machine.
705 Hz
Compression ratio 17.5:1
Installation torque 8-18 ft-lbs
Compression pressure 11-24 Nm
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder. Oil temperature switch point 275°F
135°C
Oil pressure switch
Valve clearance, cold
Installation torque 8-18 ft-lbs
Intake 0.012 in 11-24 Nm
0.3 mm
Oil pressure switch point 22 psi
Exhaust 0.020 in 1.5 bar
0.5 mm

S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Deutz TD2011L04i Engine, continued
Fuel injection system
Injection pump make Motorpal
Injection pump pressure, maximum 15,000 psi

1034 bar
Injector opening pressure 3046 psi

210 bar
Fuel requirement

Manual on your machine.
Starter motor
Cranking speed 250-350 rpm
Battery
Type 12V DC

33 x 17.3 x 23.8 cm
Quantity 1
Cold cranking ampere 1000A

3
Fan belt deflection /8 to 1/2 inch
9 to 12 mm

2 - 10 S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753

S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Perkins 404-22 Engine Lubrication system
Displacement 134 cu in Oil pressure, cold 60 psi

2.2 liters (at 2500 rpm) 4.1 bar

Horsepower 51 @ 2500 rpm Below 86°F / 30°C 5W-20

38 kW @ 2500 rpm -4°F to 104°F / -20°C to 40°C 10W-30
Firing order 1-3-4-2 Above 14°F / -10°C 15W-40
Low idle 1300 rpm Units ship with 15W-40.
229.7 Hz Extreme operating temperatures may require the use of
High idle 2500 rpm alternative engine oils. For oil requirements, refer to the
441.7 Hz Engine Operator Handbook on your machine.
Compression ratio 23.3:1 Oil pressure sending unit
Compression pressure 426 psi Oil pressure switch point 14.2 psi
29.4 bar 1 bar
Pressure (psi) of lowest cylinder must Fuel injection system
be within 50 psi / 3.45 bar of highest cylinder
Injection pump make Zexel
Injection pressure 2133 psi
Valve clearance, cold 147 bar
Intake 0.008 in Fuel requirement
0.2 mm
Exhaust 0.008 in Manual on your machine.
0.2 mm
Fan belt deflection 3/8 in

10 mm
Starter motor
Current draw, no load 90A
Brush length, new 0.7480 in

19 mm
Brush length, minimum 0.5 in

12.7 mm

Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX 2 - 11

S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Perkins 404-22 Engine, continued Machine Torque Specifications

Battery Platform rotator
Type 12V DC 1-8 center bolt, GR 5 640 ft-lbs
867 Nm
33 x 17.3 x 23.8 cm 3 /8 -16 bolts, GR 8 33 ft-lbs*
45 Nm
Quantity 1
(use a removable thread locking compound)
Cold cranking ampere 1000A 1 /2 -13 bolts, GR 8 80 ft-lbs
Reserve capacity @ 25A rate 200 minutes 108 Nm
Engine coolant Drive motor and hubs
Capacity 7.7 quarts Drive hub mounting bolts, lubricated 160 ft-lbs
7.3 liters 217 Nm
Coolant temperature sending unit Drive motor mounting bolts, lubricated 55 ft-lbs
75 Nm
Temperature switch point 221° F
105° C Turntable bearing
Rotate bearing mounting bolts, lubricated 180 ft-lbs

244 Nm
Turntable rotation assembly
Backlash pivot plate, lubricated 320 ft-lbs

433 Nm


S-60 HC • S-60X • S-60XC
SPECIFICATIONS
TRAX Torque Specifications

Sprocket to hub adapter fasteners
3/4 -10 nuts, GR 8, dry 317 ft-lbs
430 Nm
3/4 -10 nuts, GR 8, lubricated 281 ft-lbs
381 Nm
1/2 -13 FHS screws, dry 80 ft-lbs
108 Nm
1/2 -13 FHS screws, lubricated 60 ft-lbs
81 Nm
Hub adapter to drive hub fasteners
Lug nut torque, dry 240 ft-lbs

325 Nm
Lug nut torque, lubricated 180 ft-lbs

244 Nm
Sprocket bearing hub fasteners
1-14 bolts, GR 8, dry 650 ft-lbs

881 Nm
1-14 bolts, GR 8, lubricated 488 ft-lbs

662 Nm
Idler and bogey wheel fasteners

3/4 -10 bolts, GR 8, dry 375 ft-lbs
508 Nm
3/4 -10 bolts, GR 8, lubricated 281 ft-lbs
381 Nm


S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Hydraulic Hose and Fitting SAE O-ring Boss Port

(tube fitting - installed into Aluminum)
Torque Specifications (all types)
Your machine is equipped with Parker Seal-Lok™
SAE Dash size Torque
ORFS or 37° JIC fittings and hose ends.
Genie specifications require that fittings and hose -4 14 ft-lbs / 19 Nm
ends be torqued to specification when they are
-6 23 ft-lbs / 31.2 Nm
removed and installed or when new hoses or fittings
are installed. -8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
Seal-Lok™ Fittings
(hose end - ORFS) -12 84 ft-lbs / 114 Nm
SAE Dash size Torque -16 125 ft-lbs / 169.5 Nm
-4 10 ft-lbs / 13.6 Nm -20 151 ft-lbs / 204.7 Nm
-6 30 ft-lbs / 40.7 Nm -24 184 ft-lbs / 249.5 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm Jamb nut Non-adjustable

-12 85 ft-lbs / 115 Nm fitting (Non-adj)
Adjustable
-16 110 ft-lbs / 150 Nm
fitting (Adj)
-20 140 ft-lbs / 190 Nm
SAE O-ring Boss Port
-24 180 ft-lbs / 245 Nm (tube fitting - installed into Steel)
SAE Dash size Torque
JIC 37° Fittings -4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm

(swivel nut or hose connection) ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
SAE Dash size Thread Size Flats
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
-4 7/16-20 2 37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-6 9/16-18 1 1/4 -8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm

3/4-16
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-8 1
7/8-14
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
-10 1
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 1 1/16-12 1
-12 (All types) 135 ft-lbs / 183 Nm
-16 1 5/16-12 1
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 1 5/8-12 1
-20 (All types) 250 ft-lbs / 339 Nm
-24 1 7/8-12 1
-24 (All types) 305 ft-lbs / 413.5 Nm

S-60 HC • S-60X • S-60XC
SPECIFICATIONS
Torque Procedure
Seal-Lok™ fittings
a
1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring c b
cannot be re-used if the fitting or hose end has
been tightened beyond finger tight.
Note: The O-rings used in the Parker Seal Lok™
Figure 1
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are a hex nut
available in the O-ring field service kit (Genie part b reference mark
number 49612). c body hex fitting
2 Lubricate the O-ring before installation. 3 Working clockwise on the body hex fitting, make
a second mark with a permanent ink marker to
3 Be sure that the face seal O-ring is seated and indicate the proper tightening position. Refer to
retained properly. Figure 2.
4 Position the tube and nut squarely on the face Note: Use the JIC 37° Fittings table on the previous
seal end of the fitting and tighten the nut finger page to determine the correct number of flats for
tight. the proper tightening position.
5 Tighten the nut or fitting to the appropriate Note: The marks indicate that the correct tightening
torque per given size as shown in the table. positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
6 Operate all machine functions and inspect the
joint after it has been loosened.
hoses and fittings and related components to
confirm that there are no leaks.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose of b

the fitting body (body hex fitting) and tighten the a
hex nut to the body hex fitting to hand-tight, c
b
approximately 30 in-lbs / 3.4 Nm.
2 Make a reference mark on one of the flats of the
hex nut, and continue it on to the body hex Figure 2
fitting with a permanent ink marker. Refer to
Figure 1. a body hex fitting
b reference mark
c second mark
4 Tighten the hex nut until the mark on the hex nut
is aligned with the second mark on the body hex
fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.

S-60 HC • S-60X • S-60XC
SPECIFICATIONS
4.6 8.8 10.9 12.9

S-60 HC • S-60X • S-60XC
December 2013 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
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, semi-annually,
Used to indicate the presence of
annually and every 2 years as specified on the
an imminently hazardous situation
Maintenance Inspection Report. The frequency
which, if not avoided, will result in
and extent of periodical examinations and tests
death or serious injury.
may also depend on national regulations.
Used to indicate the presence of a
Failure to perform each procedure
potentially hazardous situation
as presented and scheduled may
which, if not avoided, could result
cause death, serious injury or
in death or serious injury.
substantial damage.
Used to indicate the presence of a
Immediately tag and remove from service a
potentially hazardous situation
damaged or malfunctioning machine.
which, if not avoided, may cause
Repair any machine damage or malfunction minor or moderate injury.
before operating machine. Used to indicate the presence of a
Use only Genie approved replacement parts. potentially hazardous situation
which, if not avoided, may result in
Unless otherwise specified, perform each property damage.
maintenance procedure with the machine in the
following configuration: Indicates that a specific result is expected after
performing a series of steps.
• Machine parked on a firm, level surface
Indicates that an incorrect result has occurred
• Boom in stowed position after performing a series of steps.
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
S-60 HC • S-60X • S-60XC
Section 3 • Scheduled Maintenance Procedures December 2013
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

The following symbols have been used in this The pre-delivery preparation report contains
manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation Report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annual and
two years. The Scheduled Maintenance Procedures
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
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
Indicates that a cold engine will be scheduled inspection.
required to perform this procedure.
Inspection Checklist
Indicates that a warm engine will be Daily or every 8 hours A

required to perform this procedure.
Quarterly or every 250 hours A+B
Semi-annually or every 500 hours A+B+C

Indicates that dealer service is required
to perform this procedure. Annual or every 1000 hours A+B+C+D
Two years or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and governmental regulations
and requirements.
S-60 HC • S-60X • S-60XC
Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing the
The Pre-delivery Preparation is performed prior to each Pre-operation Inspection, the Maintenance items and the
delivery. The inspection is designed to discover if anything Function Tests.
is apparently wrong with a machine before it is put into
service. Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
A damaged or modified machine must never be used. If instructions in the operator’s manual.
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed from If any inspection receives an N, remove the machine from
service. service, repair and re-inspect it. After repair, place a check
in the R box.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's Legend
specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed by N = no, unable to complete
qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements listed in Comments
the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Terex South Dakota, Inc USA Genie UK

500 Oak Wood Road The Maltings, Wharf Road
PO Box 1150 Grantham, Lincolnshire
Watertown, SD 57201-6150 NG31- 6BH England
(605) 882-4000 (44) 1476-584333
Copyright © 2012 Terex Corporation. Genie® is a registered trademark of Terex South
Dakota, Inc. 147753 Rev C
S-60 HC • S-60X • S-60XC
Maintenance Inspection Report

Model Checklist A Y N R Checklist B Y N R
A-1 Manuals and decals B-1 Inspect battery
Serial number
A-2 Pre-operation B-2 Inspect electrical
Date inspection wiring
A-3 Functions tests B-3 Exhaust system
Hour meter A-4 Engine maintenance B-4 Inspect air filter -
A-5 Filter condition indicator Ford, Deutz and
Machine owner Perkins models
A-6 Oscillate axle
B-5 Oil cooler and fins-
Inspected by (print) A-7 Inspect tracks,
Deutz models
S-60 TRAX and
Inspector signature S-65 TRAX B-6 Tires and wheels,
S-60, S-65, S-60 HC
Perform after 40 hours:
S-60X and S-60XC
Inspector title A-8 30 day service
B-7 Brake configuration
Inspector company Perform every 30 days:
B-8 Drive hub oil level
A-9 Check track tension,
B-9 Engine RPM -
Instructions S-60 TRAX and
Ford and Deutz models
• Make copies of this report to use for S-65 TRAX
B-10 Ground control override
each inspection. Perform every 100 hours:
B-11 Directional valve
• Select the appropriate checklist(s) for A-10 Engine maintenance -
the type of inspection to be Ford and Perkins B-12 Platform leveling
performed. models B-13 Engine idle select
A-11 Fuel filter/separator - B-14 Fuel select -
Daily or 8 hour Diesel models Ford models
Inspection: A
A-12 Check engine RPM- B-15 Drive brakes
Quarterly or 250 hour Perkins models B-16 Drive speed -
Inspection: A+B
A-13 Rotation bearing stowed position
Semi-annual or 500 hour
Perform after 150 hours: B-17 Drive speed -
Inspection: A+B+C
A-14 Drive hub oil raised position
Annual or 1000 hours B-18 Alarm package
Inspection: A+B+C+D Perform every 200 hours:
A-15 Engine maintenance - B-19 Hydraulic oil analysis
2 Year or 2000 hour
Ford models B-20 Fuel and hydraulic
Inspection: A+B+C+D+E
A-16 Engine maintenance - tank cap venting
• Place a check in the appropriate box Perkins models B-21 Fuel filter element -
after each inspection procedure is Perkins models
completed. B-22 Inspect the Boom
• Use the step-by-step procedures in extend/retract cables
this section to learn how to perform
these inspections.
• If any inspection receives an “N”, tag
and remove the machine from
service, repair and re-inspect it. After
repair, place a check in the “R” box.
Legend Comments
Y = yes, acceptable
N = no, remove from service
R = repaired
S-60 HC • S-60X • S-60XC
MAINTENANCE INSPECTION REPORT
Model Checklist B (cont) Y N R Checklist D Y N R

Perform every 400 hours: D-1 Boom wear pads
Serial number
B-23 Engine maintenance - D-2 Turntable bearing bolts
Date Deutz models D-3 Turntable bearing
B-24 Engine maintenance - wear
Hour meter Ford models D-4 Drive hub oil
B-25 Replace air filter - D-5 Free-wheel
Machine owner Ford models configuration
B-26 Engine maintenance - D-6 Hydraulic filters
Inspected by (print) Perkins models
D-7 Engine maintenance -
Inspector signature Deutz models
Checklist C Y N R
Inspector title C-1 Engine maintenance - Checklist E Y N R
Deutz models
Inspector company E-1 Hydraulic oil
C-2 Grease platform
Perform every 3000 hours:
overload (if equipped)
Instructions E-2 Engine maintenance -
C-3 Test platform overload,
• Make copies of this report to use for Deutz models
S-60, S-65,
each inspection. Perform every 12,000 hours:
S-60 TRAX and
• Select the appropriate checklist(s) for S-65 TRAX E-3 Engine maintenance -
the type of inspection to be (if equipped) Deutz models
performed. C-4 Test load sense, Perform every 10 years:
S-60 HC E-4 Replace the Boom
Daily or 8 hour
Inspection: A C-5 Fuel filter/separator - Extend/Retract cables
Perkins models
Quarterly or 250 hour
Inspection: A+B C-6 Replace air filter -
Deutz and Perkins
Semi-annual or 500 hour models
Inspection: A+B+C
C-7 Safety envelope
Annual or 1000 hours S-60X, S-60XC
Inspection: A+B+C+D
Perform every 600 hours:
2 Year or 2000 hour
C-8 Engine maintenance -
Inspection: A+B+C+D+E
Perkins models
• Place a check in the appropriate box Perform every 800 hours:
after each inspection procedure is C-9 Engine maintenance -
completed. Ford models
• Use the step-by-step procedures in
this section to learn how to perform
these inspections. Comments
• 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
S-60 HC • S-60X • S-60XC
Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Genie specifications require that this procedure be and damage.
performed daily or every 8 hours, whichever comes Result: The machine is equipped with all
first. required decals, and all decals are legible and in
Maintaining the operator’s and safety manuals in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each machine required decals, or one or more decals are
and should be stored in the container provided in illegible or in poor condition. Remove the
the platform. An illegible or missing manual will not machine from service until the decals are
provide safety and operational information replaced.
necessary for a safe operating condition.
4 Always return the manuals to the storage
In addition, maintaining all of the safety and container after use.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators Note: Contact your authorized Genie distributor or
and personnel to the many possible hazards Genie if replacement manuals or decals are
associated with using this machine. They also needed.
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could result
in unsafe operating conditions.
1 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not appropriate
for the machine or all manuals are not in good
condition or are illegible. Remove the machine
from service until the manual is replaced.
S-60 HC • S-60X • S-60XC
CHECKLIST A PROCEDURES
A-2 A-3
Perform Pre-operation Perform Function Tests
Inspection Completing the function tests is essential to safe
Completing a Pre-operation Inspection is essential machine operation. Function tests are designed to
to safe machine operation. The Pre-operation discover any malfunctions before the machine is
Inspection is a visual inspection performed by the put into service. A malfunctioning machine must
operator prior to each work shift. The inspection is never be used. If malfunctions are discovered, the
designed to discover if anything is apparently wrong machine must be tagged and removed from
with a machine before the operator performs the service.
function tests. The Pre-operation Inspection also Complete information to perform this procedure is
serves to determine if routine maintenance available in the appropriate operator's manual. Refer
procedures are required. to the Operator's Manual on your machine.
Complete information to perform this procedure is
available in the appropriate operator's manual. Refer
to the Operator's Manual on your machine.
S-60 HC • S-60X • S-60XC
A-4 A-5
Perform Engine Maintenance Check the High Pressure
Hydraulic Filter Condition
Indicator
Engine specifications require that this procedure be Genie specifications require that this procedure be
performed daily or every 8 hours, whichever comes performed daily or every 8 hours, whichever comes
first. first.
Proper engine maintenance, following the engine Maintaining the high pressure hydraulic filter in
manufacturer's maintenance schedule, is essential good condition is essential to good system
to good engine performance and service life. Failure performance and safe machine operation. The filter
to perform the maintenance procedures can lead to condition indicator will show when the hydraulic flow
poor engine performance and component damage. is bypassing a clogged filter. If the filter is not
frequently checked and replaced, impurities will
Required maintenance procedures and additional remain in the hydraulic system and cause
engine information are available in the component damage.
Deutz 2011 Series Operation Manual
(Deutz part number 0312-3547) OR the 1 Open the engine side turntable cover.
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020) OR the 2 Start the engine from the ground controls.
Ford MSG-425 EFI Operator Handbook 3 Change the engine idle to high rpm (rabbit
(EDI part number 1020010) OR the symbol).
Perkins 400 Series Operation Manual
(Perkins part number TPD 1443S). 4 Visually inspect the filter condition indicator.
Result: The filter condition indicator should be
Deutz 2011 Series Operation Manual operating with the plunger in the green area.
Genie part number 139320
Result: If the indicator displays the plunger in
Ford DSG 423 EFI Operator Handbook the red area, this indicates that the hydraulic
Genie part number 119488 filter is being bypassed and the filter should be
replaced. See D-6, Replace the Hydraulic
Ford MSG 425 EFI Operator Handbook Filters.

S-60 HC • S-60X • S-60XC
A-6 A-7
Test the Oscillate Axle Inspect the Track Components,
(if equipped) S-60 TRAX and S-65 TRAX
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed daily or every 8 hours, whichever comes performed daily or every 8 hours, whichever comes
first. first.
Proper axle oscillation is essential to safe machine Maintaining tracks and track assembly components
operation. If the axle oscillation system is not is essential to safe operation and good
operating correctly, the stability of the machine is performance. A track assembly failure could result
compromised and it may tip over. in a machine tip-over. Component damage may
also result if problems are not discovered and
1 Start the engine from the platform controls. repaired in a timely fashion.
2 Drive the right steer tire or track (if equipped) up 1 Thoroughly clean the track assembly of any dirt,
onto a 6 inch / 15 cm block or curb. rocks, clay, etc.
Result: The three remaining tires or tracks (if 2 Inspect the following areas for damaged,
equipped) should stay in firm contact with the cracked, loose or missing parts and fasteners:
ground and the chassis should remain level at
all times. • Track
3 Drive the left steer tire or track (if equipped) up • Idler wheels
onto a 6 inch / 15 cm block or curb. • Drive sprocket and hub
Result: The three remaining tires or tracks (if • Bogey wheels
equipped) should stay in firm contact with the • Undercarriage
ground and the chassis should remain level at
• Rotation limiter brackets attached to axles
all times.
• Track assembly fasteners
4 Drive both steer tires or tracks (if equipped) up
onto a 6 inch / 15 cm block or curb. • King pin bushings
Result: The non-steer tires or tracks (if

equipped) should stay in firm contact with the
ground.
Note: If the chassis does not remain level during
test, refer to Repair Procedure 7-6, How to Set Up
the Oscillate Directional Valve.

S-60 HC • S-60X • S-60XC
A-8 A-9
Perform 30 Day Service Check the Track Tension and
Fastener Torque, S-60 TRAX
and S-65 TRAX
The 30 day maintenance procedure is a one time
sequence of procedures to be performed after the
first 30 days or 40 hours of usage, whichever
comes first. After this interval, refer to the Manufacturer specifications require that this
maintenance tables for continued scheduled procedure be performed every 30 days.
maintenance.
Maintaining proper track tension and properly
1 Perform the following maintenance procedures: torqued fasteners is essential to good machine
performance and service life. The machine will not
• A-10 Perform Engine Maintenance - operate properly with a track that is incorrectly
Ford and Perkins Models tensioned. Continued use of a machine with
• A-13 Grease the Turntable Bearing and incorrectly tensioned tracks may cause component
Rotate Gear damage.
• B-6 Inspect the Tires, Wheels and 1 Thoroughly clean the track assembly of any dirt,
Lug Nut Torque, S-60, S-65, rocks, clay, etc.
S-60 HC, S-60X and S-60XC
2 Chock the tracks at one end of the machine to
• B-8 Check the Drive Hub Oil Level and prevent the machine from rolling.
Fastener Torque
3 Center a lifting jack of ample capacity
• C-1 Perform Engine Maintenance -
(20,000 lbs / 10,000 kg) under the drive chassis
Deutz Models
between the tracks at the other end of the
• D-2 Check the Turnable Rotation machine.
Bearing Bolts
4 Lift the machine until the tracks are off the
• D-6 Replace the Hydraulic Filters ground and then place jack stands under the
drive chassis for support.

S-60 HC • S-60X • S-60XC
5 Visually inspect the section of track under the 7 Locate the grease zerk fitting on the other side
bogey wheels. of the track tension cylinder.
Result: There should be less than 1 inch / 8 Pump grease into the grease zerk fitting until
2.5 cm of gap between the bogey wheels and grease, free from air, comes out of the grease
the inside surface of the track. Proceed to step plug. Securely tighten the grease plug. Do not
12. overtighten.
Result: There is 1 inch / 2.5 cm or more of gap 9 Continue to pump grease into the grease zerk
between the bogey wheels and the inside fitting just until the idler wheel moves. Check
surface of the track. Proceed to step 6. the track tension.
10 If necessary, continue to pump grease into the
cylinder until the track has proper tension.
Component damage hazard.
Do not over tighten the track.
Overtightening the track will cause
the machine to lose power during
operation.
Note: If the track becomes too tight, loosen the
grease plug on the cylinder to remove grease and
loosen the track.
11 Clean up any grease that may have spilled.
a 12 Check the torque of the track assembly

fasteners. Refer to Section 2, Specifications.
a bogey wheels
13 Raise the machine, remove the jack stands and
6 Locate the grease plug on the track tension lower the machine.
cylinder. Loosen the plug, but do not remove it.
14 Repeat this procedure for each track assembly.
Outside Inside
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent.
a b
a grease zerk
b grease plug

S-60 HC • S-60X • S-60XC
A-10 A-11
Perform Engine Maintenance - Inspect the Fuel Filter/Water
Ford and Perkins Models Separator - Diesel Models
Engine specifications require that this procedure be Genie specifications require that this procedure be
performed every 100 hours. Perform this procedure performed every 100 hours or monthly, whichever
more often if dusty conditions exist or the machine comes first.
is subjected to extended low idle operation.
Proper maintenance of the fuel filter/water separator
Proper engine maintenance, following the engine is essential for good engine performance. Failure to
manufacturer's maintenance schedule, is essential perform this procedure can lead to poor engine
to good engine performance and service life. Failure performance and/or hard starting, and continued
to perform the maintenance procedures can lead to use may result in component damage. Extremely
poor engine performance and component damage. dirty conditions may require this procedure be
performed more often.
Required maintenance procedures and additional
engine information are available in the Explosion and fire hazard. Engine
Ford DSG-423 EFI Operator Handbook fuels are combustible. Perform this
(EDI part number 1060020) OR the procedure in an open, well-
Ford MSG-425 EFI Operator Handbook ventilated area away from heaters,
(EDI part number 1020010) OR the sparks, flames and lighted
Perkins 400 Series Operation Manual tobacco. Always have an approved
(Perkins part number TPD 1443S) . fire extinguisher within easy reach.
Note: Perform this procedure with the engine off.
Ford DSG 423 EFI Operator Handbook
Genie part number 119488 Perkins Models:
Ford MSG 425 EFI Operator Handbook 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 HC • S-60X • S-60XC
4 Loosen the vent plug located on the fuel filter/ 8 Start the engine from the ground controls and
water separator head. check the fuel filter/water separator and vent
plug for leaks.
Explosion and fire hazard. If a fuel
a
leak is discovered, keep any
d additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
c
Deutz Models:
b
1 Put on protective clothing and eye wear.
2 Remove the engine tray retaining fastener
located under the engine tray.Swing the engine
tray out and away from the machine.
a vent plug
b drain plug 3 Install the fastener that was just removed
c filter bowl through the engine tray and into the engine tray
d separator head
anchor hole in the turntable.
5 Loosen the drain plug located at the bottom of
Crushing hazard. Failure to install
the bowl. Allow the water to drain into a suitable
the fastener into the engine tray
container until fuel starts to come out.
anchor hole to secure the engine
Immediately tighten the drain plug.
tray from moving could result in
6 Tighten the vent plug. death or serious injury.
Note: If the fuel filter/water separator is completely 4 Locate the fuel filter/water separator next to the
drained, you must prime the fuel filter/water oil filter.
separator before starting the engine. See C-6,
Replace The Fuel Filter/Water Separator Element -
Perkins Models, for instructions on how to prime
the fuel filter/water separator.
7 Clean up any fuel that may have spilled.

S-60 HC • S-60X • S-60XC
5 Loosen the drain plug located at the bottom of A-12

the filter. Allow the water to drain into a suitable
container until fuel starts to come out. Check and Adjust the
Immediately tighten the drain plug. Engine RPM - Perkins Models
Note: Do not completely drain the filter.
Engine specifications require that this procedure be

performed every 100 hours.
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine
a performance and service life. The machine will not
operate properly if the rpm is incorrect and
b continued use may cause component damage.
Note: This procedure will require two people.
1 Connect a tachometer to the engine. Start the

a fuel filter/water separator engine from the ground controls and check the
b drain valve rpm. Refer to Section 2, Specifications.
6 Clean up any fuel that may have spilled. Skip to step 3 if the low idle rpm is correct.
7 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
8 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener.

S-60 HC • S-60X • S-60XC
2 Loosen the low idle lock nut and turn the low idle A-13
adjustment screw clockwise to increase the
rpm, or counterclockwise to decrease the rpm. Grease the Turntable Rotation
Tighten the low idle lock nut and confirm the Bearing and Rotate Gear
rpm.
Genie specifications require that this procedure be

performed every 100 hours of operation. Perform
this procedure more often if dusty conditions exist.
Frequent application of lubrication to the turntable
bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.
1 Locate the grease fitting on the front turntable

cover.
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of 4 to 5
inches / 10 to 13 cm at a time and repeat this
a b c d step until the entire bearing has been greased.
a solenoid boot 3 Apply grease to each tooth of the drive gear,
b high idle adjustment nut
c yoke
located under the turntable.
d low idle lock nut and adjustment
screw Grease Specification
3 Move the function enable toggle switch to the
high idle (rabbit symbol) position and note the
or equivalent
rpm. Refer to Section 2, Specifications.
If high idle rpm is correct, disregard adjustment
step 4.
4 Loosen the yoke lock nut, then turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.

S-60 HC • S-60X • S-60XC
A-14 S-60 TRAX and S-65 TRAX:

Replace the Drive Hub Oil 1 Select the drive hub to be serviced. Loosen and
remove as many sprocket retaining fasteners as
possible from the hub adapter.
2 Drive the machine in either direction just enough
Manufacturer drive hub specifications require that to access the remaining fasteners. Do not
this one-time procedure be performed after the first remove the retaining fasteners.
150 hours.
3 Chock the tracks at the opposite end of the
Replacing the drive hub oil is essential for good machine to prevent the machine from rolling.
machine performance and service life. Failure to
replace the drive hub oil after the first 150 hours of
use may cause the machine to perform poorly and
between the tracks.
continued use may cause component damage.
S-60, S-65, S-60 HC, S-60X and S-60XC:
ground and then place jack stands under the
1 Select the drive hub to be serviced. Drive the drive chassis for support.
machine until one of the two plugs is at the 6 Attach a lifting strap from an overhead crane to
lowest point. the center-point of the track assembly, above
2 Remove both plugs and drain the oil into a the sprocket.
suitable container. 7 Remove the remaining sprocket retaining
3 Drive the machine until both plugs are fasteners from the hub adapter.
horizontal. 8 Carefully remove the track assembly from the
drive hub and set aside.
a
Crushing hazard. The track
assembly could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.
a drive hub plugs
4 Fill the hub until the oil level is even with the
bottom of the plug hole. Refer to Section 2,
Specifications.
5 Install the plugs into the drive hub.
6 Repeat this procedure for the other drive hub.

S-60 HC • S-60X • S-60XC
9 Locate the hub disconnect pin in the center of 16 Raise the machine, remove the jack stands and
the drive hub. Manually depress the pin and lower the machine.
rotate the drive hub until one of the two plugs is
17 Drive the machine in either direction just until
at the lowest point.
the remaining sprocket retaining fasteners can
be installed onto the drive hub adapter. Turn the
machine off.
18 Install the remaining sprocket retaining fasteners
to the drive hub adapter and torque to
specification. Refer to Section 2, Specifications.
19 Repeat this procedure for each drive hub.
a
a drive hub plugs
10 Remove both plugs and drain the oil into a

suitable container.
11 Manually depress the hub disconnect pin and
rotate the drive hub until both plugs are
horizontal.
bottom of the side plug hole. Refer to Section 2,
Specifications.
14 Attach a lifting strap from an overhead crane to
the center-point of the track assembly, above
the sprocket.
15 Install the track assembly onto the drive hub
adapter while guiding the hub adapter studs into
the sprocket of the track assembly. Install as
many sprocket retaining fasteners as possible
to the hub adapter and torque to specification.
Refer to Section 2, Specifications.

S-60 HC • S-60X • S-60XC
A-15 A-16
Perform Engine Maintenance - Perform Engine Maintenance -
Ford Models Perkins Models
Engine specifications require that this procedure be Engine specifications require that this procedure be
performed every 200 hours. performed every 200 hours.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure to good engine performance and service life. Failure
to perform the maintenance procedures can lead to to perform the maintenance procedures can lead to
poor engine performance and component damage. poor engine performance and component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
Ford DSG-423 EFI Operator Handbook Perkins 400 Series Operation Manual
(EDI part number 1060020) OR the (Perkins part number TPD 1443S).
Ford MSG-425 EFI Operator Handbook
(EDI part number 1020010). Perkins 400 Series Operation Manual
Ford MSG 425 EFI Operator Handbook


S-60 HC • S-60X • S-60XC
Checklist B Procedures
B-1 4 Be sure that the battery separator wire
connections are tight (if equipped).
Inspect the Battery
5 Fully charge the battery(s) and allow the
battery(s) to rest at least 6 hours.
6 Remove the battery vent caps and check the
Genie specifications require that this procedure be specific gravity of each battery cell with a
performed every 250 hours or quarterly, whichever hydrometer. Note the results.
comes first. 7 Check the ambient air temperature and adjust
Proper battery condition is essential to good engine the specific gravity reading for each cell as
performance and operational safety. Improper fluid follows:
levels or damaged cables and connections can • Add 0.004 to the reading of each cell for
result in engine component damage and hazardous every 10° / 5.5° C above 80° F / 26.7° C.
conditions.
• Subtract 0.004 from the reading of each cell for
Electrocution/burn hazard. Contact every 10° / 5.5° C below 80° F / 26.7° C.
with hot or live circuits could result
in death or serious injury. Remove Result: All battery cells display an adjusted
all rings, watches and other specific gravity of 1.277 or higher. The battery
jewelry. is fully charged. Proceed to step 11.
Bodily injury hazard. Batteries Result: One or more battery cells display a
contain acid. Avoid spilling or specific gravity of 1.217 or below. Proceed to
contacting battery acid. Neutralize step 8.
battery acid spills with baking soda 8 Perform an equalizing charge OR fully charge
and water. the battery(s) and allow the battery(s) to rest at
1 Put on protective clothing and eye wear. least 6 hours.
2 Be sure that the battery cable connections are 9 Remove the battery vent caps and check the
free of corrosion. specific gravity of each battery cell with a
hydrometer. Note the results.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion on
the battery terminals and cables.
3 Be sure that the battery hold downs and cable

connections are tight.

S-60 HC • S-60X • S-60XC
CHECKLIST B PROCEDURES
10 Check the ambient air temperature and adjust B-2

the specific gravity reading for each cell as
follows: Inspect the Electrical Wiring
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for Genie specifications require that this procedure be
every 10° / 5.5° C below 80° F / 26.7° C. performed every 250 hours or quarterly, whichever
Result: All battery cells display a specific comes first.
gravity of 1.277 or greater. The battery is fully Maintaining electrical wiring in good condition is
charged. Proceed to step 13. essential to safe operation and good machine
Result: The difference in specific gravity performance. Failure to find and replace burnt,
readings between cells is greater than 0.1 OR chafed, corroded or pinched wires could result in
the specific gravity of one or more cells is less unsafe operating conditions and may cause
than 1.177. Replace the battery. component damage.
11 Check the battery acid level. If needed, Electrocution/burn hazard. Contact

replenish with distilled water to 1/8 inch / 3 mm with hot or live circuits could result
below the bottom of the battery fill tube. Do not in death or serious injury. Remove
overfill. all rings, watches and other
jewelry.
12 Install the vent caps and neutralize any
electrolyte that may have spilled. 1 Open the engine side turntable cover.
located under the engine tray. Swing the engine
3 Install the fastener that was just removed
through the engine tray and into the engine tray

S-60 HC • S-60X • S-60XC
4 Inspect the following areas for burnt, chafed, B-3

corroded and loose wires:
Check the Exhaust System
• Engine wiring harness
• Hydraulic manifold wiring
5 Open the ground controls side turntable cover.
6 Inspect the following areas for burnt, chafed, performed every 250 hours or quarterly, whichever
corroded and loose wires: comes first.
• Inside of the ground control box Maintaining the exhaust system is essential to
• Hydraulic manifold wiring good engine performance and service life. Running
7 Inspect for a liberal coating of dielectric grease the engine with a damaged or leaking exhaust
at the following location: system can cause component damage and unsafe
operating conditions.
• All wire harnesses connectors to the
ground control box Bodily injury hazard. Do not
inspect while the engine is running.
Remove the key to secure from
raise the boom above the turntable covers.
operation.
9 Inspect the turntable area for burnt, chafed and
Burn hazard. Beware of hot engine
pinched cables.
components. Contact with hot
10 Lower the boom to the stowed position and turn engine components may result in
the engine off. severe burns.
11 Inspect the following areas for burnt, chafed, 1 Remove the engine tray retaining fastener
corroded, pinched and loose wires: located under the engine tray.Swing the engine
• Cable track on the primary boom
• Cables on the primary, and jib booms
• Jib boom/Platform rotate manifold anchor hole in the turntable.
• Inside of the platform control box Crushing hazard. Failure to install
12 Inspect for a liberal coating of dielectric grease the fastener into the engine tray
at the following location: anchor hole to secure the engine
• All wire harnesses connectors to the
platform control box
13 Swing the engine back to its original position 3 Be sure that all nuts and bolts are tight.
and install the engine tray retaining fastener. 4 Inspect all welds for cracks.
5 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
and install the engine tray retaining fastener.

S-60 HC • S-60X • S-60XC
B-4 B-5
Inspect the Engine Air Filter - Check the Oil Cooler and
Ford, Deutz and Perkins Models Cooling Fins - Deutz Models
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Maintaining the engine air filter in good condition is Maintaining the oil cooler in good condition is
essential to good engine performance and service essential for good engine performance. Operating a
life. Failure to perform this procedure can lead to machine with a damaged oil cooler may result in
poor engine performance and component damage. engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
Note: Perform this procedure with the engine off. cooling system.
1 Locate the engine air filter assembly. Bodily injury hazard. Do not
2 Release the latches from the air cleaner canister inspect while the engine
end cap. Remove the end cap. is running. Remove the key to
secure from operation.
3 Remove the filter element.
Burn hazard. Beware of hot engine
4 Clean the inside of the canister and the end cap components. Contact with hot
with a damp cloth. engine components may result in
5 Inspect the air filter element. If needed, blow severe burns.
from the inside out using low pressure dry Oil cooler:
compressed air, or carefully tap out dust.
Replace the filter if needed. 1 Remove the engine tray retaining fastener
6 Install the filter element. tray out and away from the machine.
7 Install the air filter canister end cap and secure 2 Install the fastener that was just removed
the end cap latches. through the engine tray and into the engine tray
Note: Be sure the discharge valve is pointing down anchor hole in the turntable.
when the cap is installed. Crushing hazard. Failure to install

S-60 HC • S-60X • S-60XC
3 Remove the fasteners from the engine side B-6

cover, then remove the cover.
Inspect the Tires, Wheels and
4 Inspect the oil cooler for leaks and physical
damage.
Lug Nut Torque, S-60, S-65,
S-60 HC, S60X and S-60XC
a b c

performed every 250 hours or quarterly, whichever
comes first.
Maintaining the tires and wheels, including proper

wheel fastener torque, is essential to safe operation
and good performance. Tire and/or wheel failure
could result in a machine tip-over. Component
damage may also result if problems are not
discovered and repaired in a timely fashion.
a oil cooler
b cylinder head cooling fins Bodily injury hazard. An over-
c fan blower fins inflated tire can explode and could
cause death or serious injury.
5 Clean the oil cooler of debris and foreign
material. Tip-over hazard. Do not use
temporary flat tire repair products.
Cooling and fan blower fins:
Note: The tires on some machines are foam-filled
6 Inspect the fan blower fins for physical damage. and do not need air added to them.
7 Clean the fan blower fins of debris and foreign
1 Check all tire treads and sidewalls for cuts,
material.
cracks, punctures and unusual wear.
8 Inspect the head cooling passages and fins for
2 Check each wheel for damage, bends and
physical damage or foreign material, using a
cracked welds.
flashlight.
3 Check each lug nut for proper torque.
9 Clean the cylinder head cooling passages of
debris and foreign material.
4 Check the pressure in each air-filled tire.
10 Install the engine side cover.
and install the engine pivot plate retaining
fastener.

S-60 HC • S-60X • S-60XC
B-7 B-8
Confirm the Proper Check the Drive Hub Oil Level
Brake Configuration and Fastener Torque
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Proper brake configuration is essential to safe Failure to maintain proper drive hub oil levels may
operation and good machine performance. cause the machine to perform poorly and continued
Hydrostatic brakes and hydraulically-released, use may cause component damage.
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully S-60, S-65, S-60 HC, S-60X and S-60XC:
operational. 1 Drive the machine to rotate the hub until the
1 Locate the drive hub disconnect cap. plugs are both horizontal.
a
Models with RT tires Models with TRAX
a drive hub plugs
2 Remove one plug and check the oil level.

a
Result: The oil level should be even with the
a drive hub disconnect cap bottom of the plug hole.
2 Check each drive hub disconnect cap to be sure 3 If necessary, remove the other plug and add oil
it is in the engaged position. until the oil level is even with the bottom of the
plug hole.
brake disengaged position 4 Install the plug(s) into the drive hub.
5 Check the torque of the drive hub mounting
bolts. Refer to Section 2, Specifications.
brake engaged position

S-60 HC • S-60X • S-60XC
S-60 TRAX and S-65 TRAX: 9 Locate the hub disconnect pin in the center of
the drive hub. Manually depress the pin and
1 Select the drive hub to be serviced. Loosen and rotate the drive hub until the plugs are both
remove as many sprocket retaining fasteners as horizontal.
to access the remaining fasteners. Do not
remove the retaining fasteners.
machine to prevent the machine from rolling.
between the tracks.
a
drive chassis for support. a drive hub plugs
6 Attach a lifting strap from an overhead crane to 10 Remove one plug and check the oil level.
Result: The oil level should be even with the
the sprocket.
bottom of the plug hole.
7 Remove the remaining sprocket retaining
fasteners from the hub adapter. 11 If necessary, remove the other plug and add oil
until the oil level is even with the bottom of the
8 Carefully remove the track assembly from the plug hole. Refer to Section 2, Specifications.
12 Install the plug(s) into the drive hub.
from the machine if not properly 14 Attach a lifting strap from an overhead crane to
supported by the overhead crane. the center-point of the track assembly, above
the sprocket.

S-60 HC • S-60X • S-60XC
15 Install the track assembly onto the drive hub Turntable rotate drive hub
the sprocket of the track assembly. Install as 1 Remove the plug located on the side of the hub
many sprocket retaining fasteners as possible and check the oil level.
to the hub adapter and torque to specification. Result: The oil level should be even with the
Refer to Section 2, Specifications. bottom of the plug hole.
lower the machine.
machine off.
a drain/fill plug
b mounting fasteners
2 If necessary, add oil until the oil level is even

with the bottom of the plug hole.
3 Apply pipe thread sealant to the plug, and
install the plug in the drive hub.
4 Check the torque of the turntable drive hub
mounting fasteners. Refer to Section 2,
Specifications.

S-60 HC • S-60X • S-60XC
B-9 Skip to step 5 if the low idle rpm is correct.

Check and Adjust the 4 Loosen the low idle lock nut, then turn the low
Engine RPM - Ford and Deutz idle adjustment screw clockwise to increase the
rpm or counterclockwise to decrease the rpm.
Models Tighten the low idle lock nut and recheck the
rpm.

comes first.
f
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine e
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.
Ford models:
a b c d
Note: The engine rpm is controlled by the ECM and
can only be adjusted by re-programming the ECM. a solenoid boot
b high idle adjustment nut
If rpm adjustment or service is required, please c yoke lock nut
contact Genie Service Department OR your local d yoke
Ford dealer. e low idle adjustment screw
f low idle lock nut
Deutz models:
5 Move the function enable/rpm select toggle
Note: This procedure will require two people. switch to the high idle (rabbit symbol) position at
the ground controls and check the rpm. Refer to
1 Remove the engine tray retaining fastener Section 2, Specifications.
tray out and away from the machine. If high idle rpm is correct, disregard adjustment
step 6.
through the engine tray and into the engine tray 6 Loosen the yoke lock nut, then turn the high idle
anchor hole in the turntable. 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.
tray from moving could result in Note: Be sure the solenoid fully retracts when
death or serious injury. activating high idle.
3 Connect a tachometer to the engine, and then 7 Swing the engine back to its original position
start the engine from the ground controls and and install the engine pivot plate retaining
check the rpm. Refer to Section 2, fastener.
Specifications.

S-60 HC • S-60X • S-60XC
B-10 B-11
Test the Ground Control Check the Oscillate Directional
Override Valve Linkage
comes first.
A properly functioning ground control override is performed every 250 hours or quarterly, whichever
essential to safe machine operation. The ground comes first.
control override function is intended to allow ground
personnel to operate the machine from the ground Note: Perform this test only on models equipped
controls whether or not the Emergency Stop button with a oscillating axle.
on the platform controls is in the on or off position. Proper axle oscillation is essential to safe machine
This function is particularly useful if the operator at operation. If the oscillate directional valve linkage is
the platform controls cannot return the boom to the not operating correctly, the stability of the machine
stowed position. is compromised and it may tip over.
1 Push in the platform red Emergency Stop button 1 Remove the drive chassis cover from the
to the off position. non-steer end of the machine.
2 Start the engine from the ground controls. 2 Locate the oscillate directional valve inside of
3 At the ground controls, operate each boom the non-steer axle and inspect the linkage for
function through a partial cycle. the following:
Result: All boom functions should operate. • 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

S-60 HC • S-60X • S-60XC
B-12 B-13
Test the Platform Self-leveling Test the Engine Idle Select
comes first.
performed every 250 hours or quarterly, whichever A properly operating engine idle select switch
comes first. is essential to good engine performance and safe
machine operation. There are two settings.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is Foot switch activated low idle (turtle symbol)
essential for safe machine operation. The allows the operator to control individual boom
platform is maintained at level by the platform functions.
leveling slave cylinder which operates in a closed
loop hydraulic circuit with the master cylinder Foot switch activated high idle (rabbit symbol)
located at the base of the boom. should be used for normal machine operation. This
A platform self-leveling failure creates an unsafe selection activates high idle only when the foot
working condition for platform and ground switch is pressed down.
personnel. 1 Pull out the red Emergency Stop button to the
1 Start the engine from the ground controls and on position at both the ground and platform
lower the boom into the stowed position. controls.
2 Hold the function enable/rpm select toggle 2 Start the engine from the ground controls then
switch to either side and adjust the platform to a move and hold the function enable/rpm select
level position using the platform level toggle toggle switch to the high idle (rabbit symbol).
switch. Result: The engine should change to high idle.
3 Raise and lower the primary boom through 3 Release the function enable/rpm select toggle
a full cycle. switch.
Result: The platform should remain level at Result: The engine should return to low idle.
all times to within ±5 degrees.
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.
7 Move the engine idle control switch to foot
switch activated low idle (turtle symbol).
Result: The engine should change to low idle.

S-60 HC • S-60X • S-60XC
B-14 4 Release the foot switch and shut the engine off
by pushing in the red Emergency Stop button in
Test the Fuel Select Operation - to the off position.
Ford Models 5 Move the fuel select switch to LPG.
6 Restart the engine and allow it to run at
low idle.
Genie specifications require that this procedure be 7 Press down the foot switch to allow the engine
performed every 250 hours or quarterly, whichever to run at high idle.
comes first.
Result: The engine should start promptly and
The ability to select and switch between operate smoothly in low and high idle.
gasoline and LPG fuels as needed is essential to
Note: The engine may hesitate momentarily and
safe machine operation. A fuel selection can be
then continue to run on the selected fuel if the fuel
made when the engine is running or not.
source is switched while the engine is running.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate fuel
system problems that could develop into a
hazardous situation.
Note: Perform this test after checking the gasoline
and LPG fuel levels, and warming the engine to
normal operating temperature.
1 At the platform controls, move the fuel select

switch to gasoline and then move the engine
idle control switch to foot switch activated high
idle (rabbit and foot switch symbol).
2 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.

S-60 HC • S-60X • S-60XC
B-15 B-16
Test the Drive Brakes Test the Drive Speed -
Stowed Position

comes first.
Proper brake action is essential to safe machine comes first.
operation. The drive brake function should operate
Proper drive function movement is essential to safe
smoothly, free of hesitation, jerking and unusual
machine operation. The drive function should
noise. Hydrostatic brakes and hydraulically-
respond quickly and smoothly to operator control.
released individual wheel brakes can appear to
Drive performance should also be free of hesitation,
operate normally when they are actually not fully
jerking and unusual noise over the entire
operational.
proportionally controlled speed range.
Collision hazard. Be sure that the
Note: Select a test area that is firm, level and free
machine is not in free-wheel or
of obstructions.
partial free-wheel configuration.
See B-7, Confirm the Proper Brake 1 Create start and finish lines by marking two lines
Configuration. on the ground 40 feet / 12.2 m apart.
Note: Select a test area that is firm, level and free 2 Start the engine from the platform controls.
of obstructions.
3 Move the engine idle control switch to
1 Mark a test line on the ground for reference. foot switch activated high idle (rabbit and foot
switch symbol), then lower the boom into the
2 Start the engine from the platform controls.
stowed position.
3 Move the engine idle control switch to
4 Choose a point on the machine; i.e., contact
foot switch activated high idle (rabbit and
patch of a tire, as a visual reference for use
foot switch symbol), then lower the boom into
when crossing the start and finish lines.
the stowed position.
5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
when crossing the test line.
start line.
6 Continue at full speed and note the time when
reaching the test line. Release the drive joystick
the machine reference point crosses the finish
when your reference point on the machine
line. Refer to Section 2, Specifications.
crosses the test line.
6 Measure the distance between the test line and
your machine reference point. Refer to
Section 2, Specifications.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.

S-60 HC • S-60X • S-60XC
B-17 7 Continue at full speed and note the time when

the machine reference point crosses the finish
Test the Drive Speed - line. Refer to Section 2, Specifications.
Raised or Extended Position 8 Lower the boom to the stowed position and
extend the boom 4 feet / 1.2 m.
comes first. 10 Bring the machine to top drive speed before
Proper drive function movement is essential to safe reference point on the machine crosses the
machine operation. The drive function should start line.
respond quickly and smoothly to operator control.
Drive performance should also be free of hesitation, 11 Continue at top speed and note the time when
jerking and unusual noise over the entire the machine reference point crosses the finish
proportionally controlled speed range. line. Refer to Section 2, Specifications.
Note: Select a test area that is firm, level and free

of obstructions.
1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
3 Move the engine idle select switch to foot switch
activated high idle (rabbit and foot switch
symbol).
4 Press down the foot switch and raise the
primary boom above horizontal.
reference point on the machine crosses the
start line.

S-60 HC • S-60X • S-60XC
B-18 3 S-65 and S-65 TRAX: Move the function enable/

rpm select toggle switch to either side and
Test the Alarm Package - activate the jib boom toggle switch in the down
Optional Equipment position, hold for a moment and then release it.
Genie specifications require that this procedure be Result: The descent alarm should sound when
performed every 250 hours or quarterly, whichever the switch is held down.
comes first. 4 Turn the key switch to platform control.
The alarm package includes: Result: The flashing beacon should be on
• Travel alarm and flashing.
• Descent alarm 5 Press down the foot switch. Move the boom
• Flashing beacon control handle to the down position, hold for a
Note: The descent alarm is standard equipment on moment and then release it.
all models after serial number 15908. Result: The descent alarm should sound when
Alarms and a beacon are installed to alert operators the control handle is held down.
and ground personnel of machine proximity and 6 S-65 and S-65 TRAX: Press down the foot
motion. The alarm package is installed on the switch. Move the jib boom toggle switch to the
turntable covers. down position, hold for a moment and then
Note: The alarms and beacon will operate with the release it.
engine running or not running. Result: The descent alarm should sound when
the control handle is held down.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on 7 Press down the foot switch. Move the drive
position at both the ground and platform control handle off center, hold for a moment and
controls. then release it. Move the drive control handle off
center in the opposite direction, hold for a
Result: The flashing beacon should be on and
moment and then release it.
flashing.
Result: The travel alarm should sound when the
2 Move the function enable/rpm select toggle
drive control handle is moved off center in either
switch to either side and activate the boom
direction.
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.

S-60 HC • S-60X • S-60XC
B-19 B-20
Perform Hydraulic Oil Analysis Inspect the Fuel and Hydraulic
Tank Cap Venting Systems

Genie requires that this procedure be performed
comes first.
every 250 hours or quarterly, whichever comes
Replacement or testing of the hydraulic oil is first. Perform this procedure more often if dusty
essential for good machine performance and conditions exist.
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and Free-breathing fuel and hydraulic tank caps are
continued use may cause component damage. essential for good machine performance and
Extremely dirty conditions may require oil changes service life. A dirty or clogged tank cap may cause
to be performed more often. For hydraulic oil the machine to perform poorly and continued use
specifications, refer to Section 2, Specifications. may cause component damage. Extremely dirty
conditions may require that the caps be inspected
Note: Before replacing the hydraulic oil, the oil may more often.
be tested by an oil distributor for specific levels of
Explosion and fire hazard. Engine
contamination to verify that changing the oil is
fuels are combustible. Perform this
necessary. If the hydraulic oil is not replaced at
procedure in an open, well-
the two year inspection, test the oil quarterly.
ventilated area away from heaters,
Replace the oil when it fails the test.
sparks, flames and lighted
See E-1, Test or Replace the Hydraulic Oil.
tobacco. Always have an approved
fire extinguisher within easy reach.
1 Remove the cap from the fuel tank.

2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Proceed to step 4.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.

S-60 HC • S-60X • S-60XC
3 Using a mild solvent, carefully wash the cap B-21

venting system. Dry using low pressure
compressed air. Repeat this procedure Replace the Fuel Filter Element -
beginning with step 2. Perkins Models
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank. Engine specifications require that this procedure be
6 Check for proper venting. performed every 250 hours or quarterly, whichever
comes first.
Result: Air passes through the hydraulic tank
cap. Proceed to step 8. Replacing the diesel fuel filter element is essential
for good engine performance and service life. A
Result: If air does not pass through the cap, dirty or clogged filter may cause the engine to
clean or replace the cap. Proceed to step 7. perform poorly and continued use may cause
Note: When checking for positive tank cap venting, component damage. Extremely dirty conditions
air should pass freely through the cap. may required that the filter be replaced more often.
7 Using a mild solvent, carefully wash the cap Explosion and fire hazard. Engine
venting system. Dry using low pressure fuels are combustible. Perform this
compressed air. Repeat this procedure procedure in an open, well-
beginning with step 6. ventilated area away from heaters,
sparks, flames and lighted
8 Install the breather cap onto the hydraulic tank. tobacco. Always have an approved
fire extinguisher within easy reach.


S-60 HC • S-60X • S-60XC
3 Thoroughly clean the outside surfaces of the Bleed the fuel system:
fuel filter assembly.
10 Loosen the vent plug on top of the fuel injection
4 Place a suitable container under the fuel filter pump.
element.
5 Disconnect and plug the fuel line from the fuel
pump to the fuel filter element.
a
c b
a
a vent plug
b fuel injection pump
c fuel lift pump
a fuel line
b filter head
c fuel filter element 11 Operate the priming lever or priming bulb (if
equipped) of the fuel lift pump until fuel, free
6 Remove the fuel filter element with a filter from air, comes from the vent plug. Tighten the
wrench. vent plug.
7 Apply a thin layer of fuel to the new fuel filter 12 Clean up any fuel that may have spilled during
element O-ring. this procedure.
8 Install the new fuel filter element and tighten it 13 Operate the starter motor for intervals of 15
securely by hand. Clean up any fuel that may seconds until the engine starts.
have spilled during the installation procedure.
9 Use a permanent ink marker to write the date and install the engine pivot plate retaining
and number of hours from the hour meter on the fastener.
oil filter housing.
Note: It is important to allow the starter motor to
cool for 30 seconds between each 15 second
interval of operation.
Note: If the engine runs correctly for a short time

and then stops or runs roughly, check for air in the
fuel system. If there is air in the fuel system, there
is probably a leak in the low pressure side of the
system.

S-60 HC • S-60X • S-60XC
B-22 4 Remove the retaining fasteners from the access

covers located on the side of the boom at the
Inspect the Boom platform end of the machine. Remove the
Extend/Retract Cables covers.
5 Visually inspect the cables and components
through both inspection holes for the following:
• Frayed or broken wire strands
performed every 250 hours or quarterly, whichever • Kinks in the cables
comes first. • Corrosion
The boom extend/retract cables are responsible for • Paint or foreign materials on the cable
the extension and retraction of the number 3 boom • Split or cracked cable ends
tube. Inspecting for foreign objects, damage and/or
improper adjustment of the boom extend/retract • Cables are on all pulleys
cables and related components on a regular basis • Extend cable break limit switch arm is
is essential to good machine performance and safe centered in the pivot plate
machine operation. The boom extend and retract • Cables have equal tension
functions should operate smoothly and be free of
hesitation, jerking and unusual noise. • Cables at end of adjustment range
• No broken or damaged pulleys
1 Raise the boom to horizontal and fully extend
the boom. • No unusual or excessive pulley wear
• 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 • S-60 HC: String potentiometer cable break
machine off. limit switch arm is securely attached to end
of cable
3 S-60, S-65, S-60X, S-60XC, S-60 TRAX and
S-65 TRAX: Remove the boom end cover Note: A flashlight and inspection mirror may be
retaining fasteners and remove the cover. necessary to thoroughly inspect the above items.
S-60 HC: Remove the boom end cover from the Note: A pulley groove gauge should be used to
pivot end of the boom while guiding the small check the condition of the pulleys.
cable from the string potentiometer out of the
slot of the cover. Rest the cover and string
potentiometer on the counterweight.
Component damage hazard. The
cable from the string potentiometer
can become damaged if it is
kinked or pinched.

S-60 HC • S-60X • S-60XC
6 S-60, S-65, S-60X, S-60XC, S-60 TRAX and B-23

S-65 TRAX: Install the cover at the pivot end of
the boom. Perform Engine Maintenance -
S-60 HC: Install the boom end cover at the pivot
Deutz Models
end of the boom while guiding the small cable
from the string potentiometer into the slot of the
cover.
Component damage hazard. The performed every 400 hours.
can become damaged if it is Proper engine maintenance, following the engine
kinked or pinched. manufacturer's maintenance schedule, is essential
to good engine performance and service life. Failure
Note: Be sure the cable from the string
to perform the maintenance procedures can lead to
potentiometer is correctly routed around the small
poor engine performance and component damage.
pulley before installing the boom end cover.
7 Install the access panels on the sides of the
engine information are available in the
boom.
8 Start the engine from the ground controls and (Deutz part number 0312-3547).
fully retract and lower the boom to the stowed
position. Deutz 2011 Series Operation Manual
9 Turn the key switch to the platform controls. Genie part number 139320
10 Extend the boom approximately 2 feet / 0.6 m.

11 Retract the boom. While retracting the boom,
visually inspect the number 2 and number 3
boom tubes.
Result: The number 2 boom tube should not
move more than 1/2 inch / 13 mm before the
number 3 boom tube begins to retract.
Note: If the number 2 boom tube moves more than
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.

S-60 HC • S-60X • S-60XC
B-24 B-25
Perform Engine Maintenance - Replace the Engine Air Filter
Ford Models Element - Ford Models
Proper engine maintenance, following the engine Maintaining the engine air filter in good condition is
manufacturer's maintenance schedule, is essential essential to good engine performance and service
to good engine performance and service life. Failure life. Failure to perform this procedure can lead to
to perform the maintenance procedures can lead to poor engine performance and component damage.
engine information are available in the 1 Locate the engine air filter assembly.
Ford DSG-423 EFI Operator Handbook 2 Release the latches from the air cleaner canister
(EDI part number 1060020) OR the end cap. Remove the end cap.
(EDI part number 1020010). 3 Remove and discard the filter element.
4 Clean the inside of the canister and the end cap
Ford DSG 423 EFI Operator Handbook with a damp cloth.
5 Install the new filter element.
Ford MSG 425 EFI Operator Handbook 6 Install the air filter canister end cap and secure
Genie part number 215322 the end cap latches.
Note: Be sure the discharge valve is pointing down
when the cap is installed.

S-60 HC • S-60X • S-60XC
B-26
Perform Engine Maintenance -
Perkins Models

Proper engine maintenance, following the engine

manufacturer's maintenance schedule, is essential
(Perkins part number TPD 1443S).


S-60 HC • S-60X • S-60XC
Checklist C Procedures
C-1 C-2
Perform Engine Maintenance - Grease the Platform Overload
Deutz Models Mechanism (if equipped), S-60,
S-65, S-60 TRAX and S-65 TRAX

Proper engine maintenance, following the engine performed every 500 hours or six months,
manufacturer's maintenance schedule, is essential whichever comes first. Perform this procedure more
to good engine performance and service life. Failure often if dusty conditions exist.
Application of lubrication to the platform overload
mechanism is essential to safe machine operation.
Required maintenance procedures and additional Continued use of an improperly greased platform
engine information are available in the overload mechanism could result in the system not
Deutz 2011 Series Operation Manual sensing an overloaded platform condition and will
(Deutz part number 0312-3547). result in component damage.
1 Locate the grease fittings on each pivot pin of

Deutz 2011 Series Operation Manual the platform overload assembly.
2 Thoroughly pump grease into each grease
fitting.

or equivalent

S-60 HC • S-60X • S-60XC
CHECKLIST C PROCEDURES
C-3 Models equipped with the platform overload option

are provided with additional machine components:
Test the Platform Overload an adjustable spring-loaded platform support
System (if equipped), S-60, S-65, subassembly, a limit switch, an electronic module
which receives the overload signal and interrupts
S-60 TRAX and S-65 TRAX power, and an audio/visual warning indication to
alert the operator of the overload.
The platform support subassembly utilizes two load
Genie specifications require that this procedure be support arms that are opposed in a full
performed every 500 hours or six months, parallelogram link. This isolates platform loads into
whichever comes first. a shear or vertical state, which translates into a
compressive load. A spring in the parallelogram link
Testing the platform overload system regularly is supports this purely compressive load regardless of
essential to safe machine operation. Continued use where the load is placed in the platform.
of an improperly operating platform overload
system could result in the system not sensing an As weight is added to the platform, the spring will
overloaded platform condition. Machine stability compress until, when the platform is overloaded,
could be compromised resulting in the machine the lower arm contacts a limit switch and thereby
tipping over. activating the overload signal. When adjusted
correctly, the platform overload system will
The platform overload system is designed to detect deactivate normal boom operation at platform
an overloaded platform and prevent machine capacity.
operation anytime the machine is turned on. When
activated, the system halts all normal boom Note: Perform this procedure with the boom fully
operation, giving visual and audible warning to the retracted and in the stowed position and with the
operator. machine on a firm, level surface.
1 Remove all weight, tools and equipment from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.

out the red Emergency Stop button to the on
position at both the ground and platform
controls. Start the engine from the ground
controls and level the platform. Do not turn the
engine off.

S-60 HC • S-60X • S-60XC
3 Determine the maximum platform capacity. 6 Using a suitable lifting device, place an
Refer to the machine serial plate. additional 50 lbs / 23 kg of weight onto the
platform.
4 Using a suitable lifting device, place a test
weight equal to that of the available capacity in Result: The alarm should sound.
one of the locations shown. The platform overload indicator lights should be
Refer to Illustration 1. flashing at both the ground and platform
controls.
Result: The platform overload indicator lights
should be off at both the ground and platform Result: The alarm does not sound and the
controls and the alarm should not sound. platform overload indicator lights are not
flashing. Calibrate the platform overload
Result: The platform overload indicator lights are
system. Refer to Repair Procedure 2-3,
on and the alarm is sounding. Calibrate the
How to Calibrate the Platform Overload System
platform overload system. Refer to Repair
(if equipped), S-60, S-65, S-60 TRAX and
Procedure 2-3, How to Calibrate the Platform
S-65 TRAX.
Overload System (if equipped), S-60, S-65,
S-60 TRAX and S-65 TRAX. Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
5 Carefully move the test weight to each
sounds.
remaining location. Refer to Illustration 1.
Result: The platform overload indicator lights 7 Carefully move the test weights to each
remaining location on the platform.
should be off at both the ground and platform
Refer to Illustration 1.
controls and the alarm should not sound.
Result: The alarm should sound.
Result: The platform overload indicator lights are
on and the alarm is sounding. Calibrate the The platform overload indicator lights should be
platform overload system. Refer to Repair flashing at both the ground and platform
Procedure 2-3, How to Calibrate the Platform controls.
Overload System (if equipped), S-60, S-65, Result: The alarm does not sound and the
S-60 TRAX and S-65 TRAX. platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-3,
How to Calibrate the Platform Overload System
(if equipped), S-60, S-65, S-60 TRAX and
S-65 TRAX.
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
Illustration 1

S-60 HC • S-60X • S-60XC
8 Test all machine functions from the platform 16 Test all machine functions from the platform
controls. controls.
Result: All platform control functions should not Result: All platform control functions should
operate. operate.
9 Turn the key switch to ground control. Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-3,
10 Test all machine functions from the ground
How to Calibrate the Platform Overload System (if
controls.
equipped), S-60, S-65, S-60 TRAX and S-65 TRAX.
Result: All ground control functions should not
17 Using a suitable lifting device, remove the
operate.
remaining test weights from the platform.
11 Activate the auxiliary power toggle switch.
Note: The engine will turn off when the auxiliary
power is activated.
12 Using auxiliary power, test all machine functions

from the ground controls.
Result: All ground control functions should
operate.
13 Using a suitable lifting device, lift the additional
test weight from the platform.
Result: The platform overload indicator lights
should turn off at both the ground and platform
controls and the alarm should not sound.
Note: There may be an 2 second delay before the
overload indicator lights and alarm turn off.
14 Start the engine and test all machine functions

from the ground controls.
Result: All ground control functions should
operate normally.
15 Turn the key switch to platform control.

S-60 HC • S-60X • S-60XC
C-4 The platform support subassembly utilizes two load

support arms that are opposed in a full
Test the Platform Load Sense parallelogram link. This isolates platform loads into
System, S-60 HC a shear or vertical state, which translates into a
compressive load. A spring in the parallelogram link
supports this purely compressive load regardless of
where the load is placed in the platform.
Genie specifications require that this procedure be As weight is added to the platform, the spring will
performed every 500 hours or six months, compress until, when the platform is overloaded,
whichever comes first. the lower arm contacts a limit switch and thereby
activating the overload signal. When adjusted
Testing the platform overload system regularly is correctly, the platform overload system will
essential to safe machine operation. Continued use deactivate normal boom operation at platform
of an improperly operating platform overload capacity.
system could result in the system not sensing an
overloaded platform condition. Machine stability Note: Perform this procedure with the boom fully
could be compromised resulting in the machine retracted and in the stowed position and with the
tipping over. machine on a firm, level surface.
The platform overload system is designed to detect Note: Be sure that no load sense system faults
an overloaded platform and prevent machine exist prior to performing this procedure.
operation anytime the machine is turned on. When
activated, the system halts all normal boom Note: On a properly functioning machine, the LEDs
operation, giving visual and audible warning to the on both control modules, located next to the ground
operator. control box, should be off.
Models equipped with the platform overload option Note: If your machine is equipped with any platform
are provided with additional machine components: accessories or options, they must be removed from
an adjustable spring-loaded platform support the platform OR the weights of those options or
subassembly, a limit switch, an electronic module accessories must be subtracted from the test
which receives the overload signal and interrupts weights to accurately calibrate the platform load
power, and an audio/visual warning indication to sense system.
alert the operator of the overload. 1 Remove all weight, tools and equipment from
the platform.
inaccurate test.

S-60 HC • S-60X • S-60XC
2 Turn the key switch to ground control and pull 6 Using a suitable lifting device, remove the test
out the red Emergency Stop button to the on weights from the platform.
position at both the ground and platform
7 Push in the ground controls red Emergency Stop
controls.
button to the off position, then pull the red
3 Start the engine from the ground controls. Emergency Stop button out to the on position to
Do not turn the engine off. reset the control system.
4 Using a suitable lifting device, place an Recovery process from the platform controls:
appropriate test weight equal to 750 lbs /
340.2 kg on to the center of the platform floor. Note: This procedure only operates if the platform
is overloaded or enters the safety envelope.
Result: The amber restricted range of motion
LED at the platform controls should come on 1 With the key switch turned to platform controls,
and the engine should continue to run. activate the auxiliary power toggle switch.
Result: If the amber restricted range of motion Result: The boom will automatically retract until
LED at the platform controls does not come on, it is in the unrestricted zone.
there is no alarm and the engine continues to 2 Push in the platform controls red Emergency
run, the platform load sense system needs to Stop button to the off position, then pull out the
be calibrated. See Repair Procedure 2-4, red Emergency Stop button to the on position to
How to Calibrate the Platform Load Sense reset the system.
System, S-60 HC.
3 Start the engine and lower the boom to the
5 Using a suitable lifting device, place an stowed position.
additional appropriate test weight equal to
501 to 510 lbs / 227.2 to 231.3 kg on to the Recovery process from the ground controls:
center of the platform floor. The total weight in
Note: This procedure only operates if the platform
the platform must equal 1251 to 1260 lbs /
is overloaded or enters the safety envelope.
567.4 to 571.5 kg.
Result: The alarm should sound and the engine 1 Turn the key switch to ground controls.
should turn off. The platform overload indicator 2 Locate the recovery toggle switch on the side of
light should be on at both the ground and the ground control box. Activate the recovery
platform controls. The platform load sense toggle switch and the auxiliary power toggle
system is functioning properly. switch at the same time.
Result: If the alarm does not sound, the engine Result: The boom will automatically fully retract
does not turn off or the platform indicator light and then lower to the stowed position.
does not come on at both the ground and
platform controls, see Repair Procedure 2-4, 3 Push in the ground controls red Emergency Stop
How to Calibrate the Platform Load Sense button to the off position, then pull out the red
System, S-60 HC. Emergency Stop button to the on position to
reset the system.
Note: The weight in the platform must be
1200 lbs / 544.3 kg or less before the engine can
be restarted.

S-60 HC • S-60X • S-60XC
C-5
a
Replace the Fuel Filter/Water
Separator - Perkins Models f
e b
d
performed every 500 hours or six months, c
whichever comes first.
Regular replacement of the fuel filter/water

separator is essential for good engine performance.
Failure to perform this procedure can lead to poor a vent plug
engine performance and/or hard starting, and b main fuel line
continued use may result in component damage. c drain plug
Extremely dirty conditions may require this d filter bowl
e filter element
procedure be performed more often. f separator head
Explosion and fire hazard. Engine 4 Place a suitable container under the filter bowl.
fuels are combustible. Perform this Loosen the drain plug located at the bottom of
procedure in an open, well- the bowl. Completely drain the fuel.
ventilated area away from heaters,
sparks, flames and lighted 5 Rotate the filter bowl counterclockwise and
tobacco. Always have an approved remove it from the element.
fire extinguisher within easy reach. 6 Rotate the filter element counterclockwise and
Note: Perform this procedure with the engine off. remove it from the filter head.
1 Open the engine side turntable cover and locate 7 Install the bowl onto the new filter element.
the fuel filter/water separator on the bulkhead. 8 Apply a thin layer of oil onto the element gasket.
2 Disconnect and plug the fuel supply hose from Install the filter/bowl assembly onto the filter
the fuel tank to the fuel filter/water separator. head. Tighten the drain plug and vent plug.
3 Loosen the vent plug located on the fuel filter/

water separator head.

S-60 HC • S-60X • S-60XC
9 Clean up any diesel fuel that may have spilled 15 Operate the priming lever or priming bulb (if
during the installation procedure. equipped) of the fuel lift pump until fuel, free
from air, comes from the vent plug. Tighten the
10 Install the fuel supply hose from the fuel tank to
vent plug.
the fuel filter/water separator. Tighten the
clamp. 16 Clean up any fuel that may have spilled during
this procedure.
11 Use a permanent ink marker to write the date
and number of hours from the hour meter on the 17 Operate the starter motor for intervals of 15
oil filter housing. seconds until the engine starts.
Bleed the system: Note: It is important to allow the starter motor to
cool for 30 seconds between each 15 second
12 Remove the engine tray retaining fastener interval of operation.
tray out and away from the machine. Note: If the engine runs correctly for a short time
and then stops or runs roughly, check for air in the
fuel system. If there is air in the fuel system, there
is probably a leak in the low pressure side of the
system.
the fastener into the engine tray 18 Swing the engine back to its original position
anchor hole to secure the engine and install the engine pivot plate retaining
fastener.
14 Loosen the vent plug on top of the fuel injection
pump.
c b
a vent plug
b fuel injection pump
c fuel lift pump

S-60 HC • S-60X • S-60XC
C-6 C-7
Replace the Engine Air Filter Check the Safety Envelope Limit
Element - Deutz and Perkins Switches and Angle Sensor,
Models S-60X and S-60XC

performed every 500 hours or every six months,
performed every 500 hours or six months,
Maintaining the engine air filter in good condition is
Testing the safety envelope system regularly is
essential to good engine performance and service
essential to safe machine operation. Continued use
life. Failure to perform this procedure can lead to
of an improperly operating safety envelope could
result in the system not restricting the range of
Note: Perform this procedure with the engine off. motion. Machine stability could be compromised
resulting in the machine tipping over.
1 Locate the engine air filter assembly.
Note: Perform this procedure with the machine on a
2 Release the latches from the air cleaner canister firm, level surface with all weight, tools and
end cap. Remove the end cap. equipment removed from the platform.
3 Remove and discard the filter element. Note: Start this procedure with the boom fully
4 Clean the inside of the canister and the end cap retracted and in the stowed position.
with a damp cloth.
Ground controls:
5 Install the new filter element.
6 Install the air filter canister end cap and secure out the red Emergency Stop button to the on
the end cap latches. position.
2 Start the engine from the ground controls.

S-60 HC • S-60X • S-60XC
3 Turn and hold the function enable switch to the Note: The following step can be done using a
restricted maximum platform capacity and raise measuring tape or a digital protractor (Genie part
the primary boom until it is fully elevated. number 58377).
a b 7 Measuring Tape:
Measure the distance between the center of the
pivot pins as shown, 171 inches / 434 cm
1000 lbs / 500 lbs /
454 kg 227 kg ± 2.0 inch / 5 cm.
Digital Protractor:
Place the digital protractor on the turntable
chassis and reset the protractor to 0°. Place the
protractor on top of the primary boom. The
protractor should display 58° ± 2°.
Result: The primary boom angle is not within
specifications. Consult Genie Industries Service
a restricted maximum platform Department.
capacity
b unrestricted maximum platform
capacity
4 Extend the primary boom until it is fully

extended.
5 Lower the primary boom until it stops. Measure between
the centers of these
Result: The boom will automatically stop after pivot pins
10 degrees.
Result: The primary boom does not stop after 10
degrees. Check limit switches LST3O and
LST3S.
6 Turn the key switch to the off position and push
in the red Emergency Stop button.

S-60 HC • S-60X • S-60XC
Platform controls: 5 Lower the primary boom until it stops.

Note: Start this procedure with the boom fully Result: The boom will automatically stop after
retracted and in the stowed position. 10 degrees and the unrestricted platform
capacity light will flash.
1 Pull out the red Emergency Stop button to the
on position and start the engine. Result: The primary boom does not stop after 10
degrees. Calibrate the boom angle sensor. Refer
2 Select the restricted maximum platform capacity to Repair Procedure 1-2, How to Calibrate the
with the toggle switch. Boom angle Sensor.
a b 6 Move the primary boom down joystick off center
and retract the primary boom until the
unrestricted platform capacity light stops
flashing.
1000 lbs / 500 lbs / Result: Primary boom down should return to
454 kg 227 kg normal operation.
7 Lower the primary boom 5 feet / 1.5 m and
activate primary boom extend.
Result: Primary boom extend will stop and the
unrestricted platform capacity light will start
a restricted maximum platform
flashing.
capacity
8 Activate primary boom extend and raise the
b unrestricted maximum platform
capacity primary boom until the unrestricted platform
capacity light stops flashing.
3 Raise the primary boom until it is fully elevated.
Result: Primary boom extend should return to
4 Extend the primary boom until it is fully normal operation.
extended.
9 Return the machine to the fully stowed position.

S-60 HC • S-60X • S-60XC
C-8 C-9
Perkins Models Ford Models
Perkins 400 Series Operation Manual Ford DSG-423 EFI Operator Handbook
(Perkins part number TPD 1443S). (EDI part number 1060020) OR the
Perkins 400 Series Operation Manual (EDI part number 1020010).
Ford MSG 425 EFI Operator Handbook


S-60 HC • S-60X • S-60XC
Checklist D Procedures
D-1 4 Extend and retract the primary boom through the
entire range of motion to check for tight spots
Check the Boom Wear Pads that may cause binding or scraping of the boom.
Note: Always maintain squareness between the
outer and inner boom tubes.

performed every 1000 hours or annually, whichever Wear pad specifications Minimum
comes first. 1/2 inch
Top and side wear pads
Maintaining the boom wear pads in good condition (platform end of boom) 12.7 mm
is essential to safe machine operation. Wear pads
Bottom wear pads 5/8 inch
are placed on boom tube surfaces to provide a low
(platform end of boom) 15.9 mm
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued 1/2 inch
Top and side wear pads
use of worn out wear pads may result in component
(pivot end of boom) 12.7 mm
damage and unsafe operating conditions.
Bottom wear pads 5/8 inch
(pivot end of boom) 15.9 mm
2 Raise the end of the primary boom to a
comfortable working height (chest high), then
extend the boom 1 foot / 30 cm.
3 Measure each wear pad. Replace the wear pad
once it reaches the minimum allowable
thickness. If the wear pad is still within
specification, shim as necessary to obtain
minimum clearance with zero binding.

S-60 HC • S-60X • S-60XC
CHECKLIST D PROCEDURES
D-2 4 Start the engine form the ground controls.

Check the Turntable Rotation 5 Raise the boom and remove the safety chock.
Bearing Bolts 6 Lower the boom to the stowed position.
7 Remove drive chassis covers from both the
steer end and the non-steer end of the machine.
8 Check to ensure that each lower bearing
mounting bolt under the drive chassis is torqued
performed every 1000 hours or annually, whichever
in sequence to specifications. Refer to
comes first.
Maintaining proper torque on the turntable bearing
bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
1 Raise the boom and place a safety chock on the

lift cylinder rod. Carefully lower the boom onto
the lift cylinder safety chock.
Crushing hazard. Keep hands
away from cylinders and all moving
parts when lowering the boom.
Note: The lift cylinder safety chock is available
through Genie (Genie part number 75097). Bolt torque sequence
2 Turn the engine off.

3 Be sure that each turntable mounting bolt is
torqued in sequence to specifications. Refer to
1 19
13 15
10 7
22 12
6
24
18
4
3
17
23
5
11 21
8 9
16 14
20 2
Bolt torque sequence

S-60 HC • S-60X • S-60XC
D-3 4 Place a dial indicator between the drive chassis

and the turntable at a point that is directly
Inspect for Turntable Bearing under, or inline with, the boom and no more than
Wear 1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, place
the dial indicator no more than 1 inch / 2.5 cm from
the turntable rotation bearing.
comes first. a
Periodic inspection of turntable bearing wear is

essential to safe machine operation, good machine
performance and service life. Continued use of a
b
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious
injury and component damage.
c
firm, level surface and the boom in the stowed
position. d
1 Grease the turntable bearing. See A-13, Grease a turntable

the Turntable Bearing and Rotate Gear. b dial indicator
c drive chassis
2 Torque the turntable bearing bolts to d turntable rotation bearing
specification. See D-2, Check the Turntable
Rotation Bearing Bolts. 5 At the dial indicator, adjust it to "zero" the
indicator.
3 Start the machine from the ground controls and
raise the boom to full height. Do not extend the 6 Fully extend the boom and lower to a horizontal
boom. position.
7 Note the reading on the dial indicator.
Result: The measurement is less than
0.063 inch / 1.6 mm. The bearing is good.
Result: The measurement is more than
0.063 inch / 1.6 mm. The bearing is worn and
needs to be replaced.

S-60 HC • S-60X • S-60XC
8 Fully retract the boom and raise the boom to full D-4
height. Visually inspect the dial indicator to be
sure the needle returns to the "zero" position. Replace the Drive Hub Oil
9 Remove the dial indicator and rotate the
turntable 90°.
10 Repeat steps 4 through 9 until the rotation Genie specifications require that this procedure be
bearing has been checked in at least four performed every 1000 hours or annually, whichever
equally spaced areas 90° apart. comes first.
11 Lower the boom to the stowed position and turn Replacing the drive hub oil is essential for good
the machine off. machine performance and service life. Failure to
12 Remove the dial indicator from the machine. replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and continued
use may cause component damage.
S-60, S-65, S-60 HC, S-60X and S-60XC:
1 Select the drive hub to be serviced. Drive the

machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until both plugs are
horizontal.
a drive hub plugs
Specifications.

S-60 HC • S-60X • S-60XC
S-60 TRAX and S-65 TRAX: 9 Locate the hub disconnect pin in the center of
the drive hub. Manually depress the pin and
1 Select the drive hub to be serviced. Loosen and rotate the drive hub until one of the two plugs is
remove as many sprocket retaining fasteners as at the lowest point.
to access the remaining fasteners. Do not
remove the retaining fasteners.
machine to prevent the machine from rolling.
between the tracks.
5 Lift the machine until the tracks are off the a
a drive hub plugs
drive chassis for support. 10 Remove both plugs and drain the oil into a
suitable container.
the center-point of the track assembly, above 11 Manually depress the hub disconnect pin and
the sprocket. rotate the drive hub until both plugs are
horizontal.
fasteners from the hub adapter. 12 Fill the hub until the oil level is even with the
8 Carefully remove the track assembly from the
Specifications.
assembly could become 14 Check the torque of the drive hub mounting
unbalanced and fall when removed bolts. Refer to Section 2, Specifications.
the sprocket.

S-60 HC • S-60X • S-60XC
16 Install the track assembly onto the drive hub D-5

the sprocket of the track assembly. Install as Check the Free-wheel
many sprocket retaining fasteners as possible Configuration
lower the machine. Genie specifications require that this procedure be
comes first.
be installed onto the drive hub adapter. Turn the Proper use of the free-wheel configuration is
machine off. essential to safe machine operation. The
19 Install the remaining sprocket retaining fasteners free-wheel configuration is used primarily for towing.
to the drive hub adapter and torque to A machine configured to free-wheel without operator
specification. Refer to Section 2, Specifications. knowledge may cause death or serious injury and
property damage.
Collision hazard. Select a work site
that is firm and level.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
Non-steer end: All Models
1 Chock the steer wheels or tracks (if equipped) to

prevent the machine from rolling.
between the non-steer tires or tracks.
3 Lift the wheels or tracks off the ground and then
place jack stands under the drive chassis for
support.

S-60 HC • S-60X • S-60XC
4 Disengage the drive hubs by turning over the Steer end: 4WD Models
drive hub disconnect caps on each
non-steer end drive hub. 7 Chock the non-steer wheels or tracks to prevent
the machine from rolling.
Models with RT tires Models with TRAX 8 Center a lifting jack of ample capacity
between the steer tires or tracks.
9 Lift the wheels or tracks off the ground and then
place jack stands under the drive chassis for
support.
10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
steer end drive hub.
a
Models with RT tires Models with TRAX
a drive hub disconnect cap
5 Manually rotate each non-steer wheel or track.

Result: Each non-steer wheel or track should
rotate with minimum effort.
Note: S-60 TRAX and S-65 TRAX: Due to the
additional components of the track system, which
increase rotational friction, the track may not be
able to be rotated manually.
a
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel or a drive hub disconnect cap
track to check for engagement. Lift the machine
11 Manually rotate each steer wheel or track.
and remove the jack stands.
Result: Each steer wheel or track should rotate
Collision hazard. Failure to
with minimum effort.
re-engage the drive hubs could
result in death or serious injury and Note: S-60 TRAX and S-65 TRAX: Due to the
property damage. additional components of the track system, which
increase rotational friction, the track may not be
disengaged position able to be rotated manually.
engaged position

S-60 HC • S-60X • S-60XC
12 Re-engage the drive hubs by turning over D-6

the hub disconnect caps. Rotate each wheel or
track to check for engagement. Raise the Replace the Hydraulic Filters
machine, remove the jack stands and lower the
machine.
Collision hazard. Failure to
re-engage the drive hubs may
every 1000 hours or annually, whichever comes
cause death or serious injury and
first. Perform this procedure more often if dusty
property damage.
conditions exist.
disengaged position 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
engaged position
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.
Hydraulic return filter:
1 Open the ground controls side turntable cover

and locate the hydraulic return filter housing on
top of the hydraulic tank.
2 Remove the cap from the filter housing.
3 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.

S-60 HC • S-60X • S-60XC
5 Install the new filter element into the filter 15 Install the new filter elements into the housings
housing. and tighten them securely.
6 Push the filter element down to be sure the Note: The medium and high pressure filters use the
O-ring on the element is fully seated into the same elements.
housing.
16 Clean up any oil that may have spilled during the
7 Rotate the filter element clockwise to lock it in installation procedure.
place.
17 Use a permanent ink marker to write the date
8 Install the filter housing cap. and number of hours from the hour meter on the
9 Use a permanent ink marker to write the date oil filter housings.
and number of hours from the hour meter on the 18 Start the engine from the ground controls.
oil filter housing.
19 Inspect the filter housings and related
Medium and high pressure filters: components to be sure that there are no leaks.
Note: The medium pressure filter is for the charge
pump and the high pressure filter is for all machine
functions except the drive circuit and oscillating
axle circuit.
10 Open the engine side turntable cover and locate

the medium and high pressure filters near the
pump.
Note: The medium pressure filter is located on the
right. The high pressure filter, with filter condition
indicator, is located on the left.
11 Place a suitable container under each filter.

12 Remove the 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 HC • S-60X • S-60XC
D-7
Perform Engine Maintenance -
Deutz Models

Proper engine maintenance, following the engine

manufacturer's maintenance schedule, is essential
(Deutz part number 0312-3547).


S-60 HC • S-60X • S-60XC
Checklist E Procedures
E-1 1 Ford models: Turn the valve on the LPG tank
clockwise to the off position (if equipped). Then
Test or Replace the Hydraulic Oil slowly disconnect the hose from the LPG tank.
2 Ford models: Open the clamps from the LPG
tank straps and remove the LPG tank from the
machine (if equipped).
every 2000 hours or every two years, whichever 3 Open the ground controls side turntable cover
comes first. Perform this procedure more often if and locate the two hydraulic tank valves at the
dusty conditions exist. hydraulic tank. Close the valves.
Replacement or testing of the hydraulic oil is Component damage hazard. The

essential for good machine performance and engine must not be started with the
service life. Dirty oil and suction strainers may hydraulic tank shut-off valves in
cause the machine to perform poorly and continued the closed position or component
use may cause component damage. Extremely damage will occur. If the tank
dirty conditions may require oil changes to be valves are closed, remove the key
performed more often. from the key switch and tag the
machine to inform personnel of the
Note: Before replacing the hydraulic oil, the oil may condition.
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.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
hose end must be replaced. All connections must open closed
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting 4 Place a suitable container underneath the
Torque Specifications. hydraulic tank.
Note: Perform this procedure with the boom in the 5 Remove the drain plug from the hydraulic tank.
stowed position.
6 Completely drain the tank into a suitable
container. See capacity specifications.

S-60 HC • S-60X • S-60XC
CHECKLIST E PROCEDURES
7 Tag, disconnect and plug the two suction hoses 18 Install the hydraulic return filter housing onto the
and supply hose for the auxiliary pump from the hydraulic tank.
hydraulic tank. Cap the fittings on the tank.
19 Install the hydraulic tank onto the machine.
Note: The hoses can be accessed through the
20 Install the two suction hoses to the suction
access hole under the turntable.
strainers.
8 Disconnect and plug the return filter hydraulic 21 Install the supply hose for the auxiliary power
hose at the return filter. Cap the fitting on the unit and the return filter hose.
filter housing.
22 Open the two hydraulic tank valves at the
9 Remove the ground controls side turntable hydraulic tank.
cover.
23 Fill the tank with hydraulic oil until the level is
10 Support the hydraulic tank with an appropriate
within the top 2 inches / 5 cm of the sight
lifting device.
gauge. Do not overfill.
11 Remove the hydraulic tank mounting fasteners.
24 Clean up any oil that may have spilled.
12 Remove the hydraulic tank from the machine.
25 Prime the pump. Refer to Repair Procedure 6-2,
Crushing hazard. The hydraulic How to Prime the Pump.
tank could become unbalanced
Note: Always use pipe thread sealant when
and fall if not properly supported
installing the suction hose fittings and the drain
when removed from the machine.
plug.
13 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic
return filter housing from the hydraulic tank.
14 Remove the suction strainers from the tank and
clean them using a mild solvent.
15 Rinse out the inside of the tank using a mild
solvent.
16 Install the suction strainers using a thread
sealant on the threads.
17 Install the drain plug using a thread sealant on
the threads.

S-60 HC • S-60X • S-60XC
E-2 E-3
Deutz Models Deutz Models
performed every 3000 hours. performed every 12,000 hours.
Deutz 2011 Series Operation Manual Deutz 2011 Series Operation Manual
(Deutz part number 0312-3547). (Deutz part number 0312-3547).
Deutz 2011 Series Operation Manual Deutz 2011 Series Operation Manual
Genie part number 139320 Genie part number 139320

S-60 HC • S-60X • S-60XC
E-4
Replace the Boom Extend/
Retract Cables

performed every 10 years.
The boom extend/retract cables are responsible for

the extension and retraction of the number 3 boom
tube. Replacement of the boom extend/retract
cables is essential to good machine performance
and safe machine operation. The boom extend/
retract functions should operate smoothly and be
free of hesitation, jerking and unusual noise.
1 Replace the boom extend/retract cables. See
Repair Procedure 4-5, Boom Extend/Retract
Cables.

S-60 HC • S-60X • S-60XC

S-60 HC • S-60X • S-60XC
December 2013 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
Observe and Obey: the problem.
Perform disassembly procedures to the point where

Repair procedures shall be completed by a repairs can be completed. To re-assemble, perform
person trained and qualified on the repair of this the disassembly steps in reverse order.
machine.
Symbols Legend
Immediately tag and remove from service a
damaged or malfunctioning machine. Safety alert symbol—used to alert
personnel to potential personal
Repair any machine damage or malfunction
injury hazards. Obey all safety
before operating the machine. messages that follow this symbol
to avoid possible injury or death.
Before Repairs Start:
Used to indicate the presence of
Read, understand and obey the safety rules and an imminently hazardous situation
operating instructions in the appropriate which, if not avoided, will result in
Operator's Manual on your machine. death or serious injury.
Be sure that all necessary tools and parts are Used to indicate the presence of a
available and ready for use. potentially hazardous situation
which, if not avoided, could result
Use only Genie approved replacement parts.
in death or serious injury.
Read each procedure completely and adhere Used to indicate the presence of a
to the instructions. Attempting shortcuts may potentially hazardous situation
produce hazardous conditions. which, if not avoided, may cause
Unless otherwise specified, perform each minor or moderate injury.
repair procedure with the machine in the Used to indicate the presence of a
following configuration: potentially hazardous situation
• Machine parked on a firm, level surface which, if not avoided, may result in
property damage.
• Boom in stowed position
• Turntable rotated with the boom between Indicates that a specific result is expected after
the non-steer wheels performing a series of steps.
• Turntable secured with the turntable Indicates that an incorrect result has occurred
rotation lock after performing a series of steps.
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power disconnected
from the machine
S-60 HC • S-60X • S-60XC
Section 4 • Repair Procedures December 2013
Platform Controls
The platform control box contains one printed 1-1
circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional ALC-500 Circuit Board
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall Electrocution/burn hazard. Contact
Effect technology and require no adjustment. The with electrically charged circuits
operating parameters of the joysticks are stored in could result in death or serious
memory at the ECM circuit board at the platform injury. Remove all rings, watches
controls. If a joystick error occurs or if a joystick is and other jewelry.
replaced, it will need to be calibrated before that Note: When the ALC-500 circuit board is replaced,
particular machine function will operate. See 1-2, the joystick controllers will need to be calibrated.
How to Calibrate a Joystick. See 1-2, How to Calibrate a Joystick.
Each joystick controller should operate smoothly
and provide proportional speed control over its How to Remove the ALC-500
entire range of motion. Circuit Board
1 Push in the red Emergency Stop button to the
a 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/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
c b
a ALC-500 circuit board

b drive/steer joystick controller
c primary boom up/down,
extend/retract and
turntable rotate right/left
joystick controller
S-60 HC • S-60X • S-60XC
PLATFORM CONTROLS
4 Attach a grounded wrist strap to the ground 1-2

screw inside the platform control box.
Joysticks
Electrostatic discharge (ESD) can
damage printed circuit board
How to Calibrate a Joystick
components. Maintain firm contact The joysticks on this machine utilize digital Hall
with a metal part of the machine Effect technology for proportional control. If a
that is grounded at all times when joystick is disconnected or replaced, it must be
handling printed circuit boards OR calibrated before that particular machine function
use a grounded wrist strap. will operate.
5 Carefully disconnect the wire connectors from Note: The joystick must be calibrated before the
the circuit board. threshold, max-out or ramping can be set.
6 Remove the ALC-500 circuit board mounting
fasteners.
1 Open the platform control box.
7 Carefully remove the ALC-500 circuit board from
the platform control box. 2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
3 Turn the key switch to platform control. Do not
start the engine.
4 Select a joystick to calibrate.
5 Disconnect the wire harness connector from the
joystick for approximately 10 seconds or until
the alarm sounds. Connect the wire harness
connector to the joystick.
6 Move the joystick full stroke in either direction
and hold for 5 seconds.
7 Return the joystick to the neutral position, pause
for a moment, then move the joystick full stroke
in the opposite direction. Hold for 5 seconds.
Result: The alarm should sound indicating
successful joystick calibration.
Result: The alarm does not sound. Check the
electrical connections or replace the joystick.
8 Repeat this procedure for each joystick
controlled machine function including the thumb
rocker steer switch.
Note: No machine fuction should operate while
performing the joystick calibration procedure.
S-60 HC • S-60X • S-60XC
PLATFORM CONTROLS
How to Adjust the Joystick 9 Select a boom function joystick to set the
threshold.
Threshold Setting
10 Slowly move the joystick off center in either
The threshold setting of a joystick is the minimum direction just until the function begins to move.
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,
Note: Perform this procedure on a firm, level move the drive enable toggle switch to either
surface. side to set the threshold.
1 Pull out the red Emergency Stop button to the 12 Repeat steps 9 through 11 for each boom
on position at the ground controls. joystick controlled machine function (boom up/
down, boom extend/retract and turntable rotate).
start the engine. 13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
3 Push in the platform controls red Emergency settings to be saved.
Stop button to the off position.
Result: The alarm should sound indicating that
4 Do not press down the foot switch. the settings have been saved in memory.
5 Move and hold the drive enable toggle switch in
Note: Do not operate any machine function during
the right position and pull out the red
the 10 second waiting time.
Emergency Stop button to the on position.
14 Cycle the red Emergency Stop button off, then
6 As soon as the alarm sounds, release the drive
back on.
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.
Result: The alarm does not sound. Repeat steps
3 through 7.
press down the foot switch.
S-60 HC • S-60X • S-60XC
PLATFORM CONTROLS
How to Adjust the Joystick 7 Momentarily activate the drive enable toggle
Max-out Setting
The max-out setting of a joystick controls the should sound 4 times indicating that the
maximum speed of a joystick-controlled machine machine is in max-out calibration mode.
function. Whenever a hydraulic cylinder, drive
motor or hydraulic pump is replaced, the max-out Result: The alarm does not sound. Repeat steps
setting should be adjusted to maintain optimum 3 through 7.
performance. The max-out settings on the joystick 8 Start the engine from the platform controls and
can be changed to compensate for hydraulic pump press down the foot switch.
wear to maintain peak performance from the
machine. 9 Start a timer and activate the machine function
that needs to be adjusted. Record the time it
Note: Perform this procedure on a firm, level takes for that function to complete a full cycle
surface. (ie; boom up).
1 Pull out the red Emergency Stop button to the 10 Compare the machine function time with the
on position at the ground controls. function times listed in Section 2,
Specifications. Determine whether the function
time needs to increase or decrease.
start the engine.
11 While the joystick is activated, adjust the max-
3 Push in the platform controls red Emergency
out setting to achieve the proper function cycle
time. Momentarily move the drive enable toggle
4 Do not press down the foot switch. switch in the right direction to increase the
function speed or momentarily move the drive
5 Move and hold the drive enable toggle switch in enable toggle switch in the left direction to
the right position and pull out the red decrease the function speed.
Note: Each time the drive enable toggle switch is
6 When the alarm sounds, release the drive
momentarily moved, the function speed will change
in 2% increments from a default of 100%, with a
minimum of 60% and a maximum of 120%.
S-60 HC • S-60X • S-60XC
PLATFORM CONTROLS
12 Repeat steps 9 through 11 for each joystick How to Adjust the Joystick
controlled machine function.
Ramp Rate Setting
13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the The ramp rate setting of a joystick controls the time
settings to be saved. at which it takes for the joystick to reach maximum
output, when moved out of the neutral position. The
Result: The alarm should sound indicating that ramp rate settings of a joystick can be changed to
the settings have been saved in memory. compensate for hydraulic pump wear to maintain
Result: The alarm does not sound. The peak performance from the machine.
minimum or maximum adjustment has been Note: Perform this procedure on a firm, level
obtained. No changes can be saved. surface.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
14 Cycle the red Emergency Stop button off, then controls.
back on. 2 Turn the key switch to platform control. Do not
start the engine.
3 Push in the platform controls red Emergency
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
machine is in ramp rate calibration mode.
Result: The alarm does not sound. Repeat steps
3 through 7.
S-60 HC • S-60X • S-60XC
PLATFORM CONTROLS
8 Start the engine from the platform controls and Ramp rate (factory settings)
9 Start a timer and simultaneously move the Boom up/down
transition accelerate 1 second
joystick in either direction full stroke. Note how
transition decelerate 10 seconds
long it takes the function to reach maximum
S ramp accelerate 1 second
speed. This is the ramp rate. S ramp decelerate 0.45 second
10 Compare the function ramp rate time with the
table and determine whether the ramp rate time Boom extend/retract
needs to increase or decrease. accelerate 2 seconds
decelerate 0.5 second
11 Release the foot switch.
Turntable rotate
12 Activate the joystick and adjust the ramp rate. accelerate 2 seconds
Momentarily move the drive enable toggle decelerate 0.75 second
switch in the right direction to increase the time
or momentarily move the drive enable toggle Drive
switch in the left direction to decrease the time. accelerate 2 seconds
decelerate to neutral 0.5 second
Note: Each time the drive enable toggle switch is decelerate, change of direction 0.5 second
momentarily moved, the time will change in 5% decelerate, coasting 0.75 second
increments from a default of 100%, with a minimum decelerate, braking 1 second
of 50% and a maximum of 150%. decelerate, shift from low to high speed 1 second
decelerate, shift from high to low speed 4 seconds
13 Repeat steps 9 through 11 for each joystick
controlled machine function.
14 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
settings to be saved.
Result: The alarm should sound indicating that
the settings have been saved in memory.
Result: The alarm does not sound. The
minimum or maximum adjustment has been
obtained. No changes can be saved.
15 Cycle the red Emergency Stop button off, then
back on.
S-60 HC • S-60X • S-60XC
PLATFORM CONTROLS
How to Calibrate the Boom 8 Raise the primary boom to the fully elevated
position.
Angle Sensor
Note: Manually reduce the boom speed as it
The boom angle sensor controls the maximum reaches the fully elevated position.
angle that the boom can attain.
Note: Perform this procedure on a firm, level switch to the right 1 time to set the elevated
surface. position.
1 Pull out the red Emergency Stop button to the Result: The alarm will sound indicating that the
on position at the ground controls. angle sensor has been calibrated.
2 Turn the key switch to platform controls. 10 Release the joystick and the foot switch and
wait for 10 seconds.
3 Move and hold the drive enable toggle switch to
the right and pull out the red Emergency Stop Result: The alarm will sound indicating that the
button to the on position. settings have been saved and is leaving
calibration mode.
enable toggle switch. 11 Cycle the red Emergency Stop button off, then
back on. Start the machine and return to the
stowed position.
switch to the right 12 times.
machine is in Angle Sensor calibration mode.
switch to the right 1 time to set the stowed
position.
Note: The alarm will not sound indicating the
setting.
S-60 HC • S-60X • S-60XC
Platform Components
2-1 4 Remove the pin retaining fastener from the slave
cylinder rod-end pivot pin. Use a soft metal drift
Platform Leveling Slave Cylinder to drive the rod-end pivot pin out.
The slave cylinder and the rotator pivot are the Crushing hazard. S-65 and
two primary supports for the platform. The slave S-65 TRAX: The jib boom could
cylinder keeps the platform level through the fall when the slave cylinder rod-end
entire range of boom motion. It operates in a pivot pin is removed if not properly
closed-circuit hydraulic loop with the master supported.
cylinder. The slave cylinder is equipped with 5 Remove the external snap rings from the barrel-
counterbalance valves to prevent movement in end pivot pin.
the event of a hydraulic line failure.
6 Use a soft metal drift to drive the barrel-end
How to Remove the Platform pivot pin out.
Leveling Slave Cylinder 7 Carefully pull the cylinder out of the boom to
access the hydraulic hoses.
Note: Before cylinder removal is considered, bleed
the slave cylinder to be sure there is no air in the 8 Tag, disconnect and plug the hydraulic hoses
closed loop. from the slave cylinder. Cap the fittings on the
cylinder.
the O-ring (if equipped) on the fitting and/or the Bodily injury hazard. Spraying
hose end must be replaced. All connections must hydraulic oil can penetrate and
be torqued to specification during installation. Refer burn skin. Loosen hydraulic
to Section 2, Hydraulic Hose and Fitting Torque connections very slowly to allow
Specifications. the oil pressure to dissipate
gradually. Do not allow oil to
1 Extend the boom until the slave cylinder barrel- squirt or spray.
end pivot pin is accessible.
How to Bleed the Slave Cylinder
2 Raise the boom slightly and place blocks under
the platform for support. Note: Do not start the engine. Use auxiliary power
for this procedure.
3 Lower the boom until the platform is resting on
the blocks just enough to support the platform. 1 Simultaneously activate the boom up function
Note: Do not rest the entire weight of the boom on and the platform level up function until the boom
the blocks. is fully raised.
2 Simultaneously activate the boom down function
and the platform level down function until the
boom is fully lowered.
S-60 HC • S-60X • S-60XC
PLATFORM COMPONENTS
2-2 2 S-60 HC: Tag and disconnect the electrical

connector from the platform load sense module.
Platform Rotator
3 Tag, disconnect and plug the hydraulic hoses
The platform rotator is a hydraulically activated from the platform rotator manifold. Cap the
helical gear assembly used to rotate the platform fittings on the rotator.
160 degrees. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove the burn skin. Loosen hydraulic
Platform Rotator connections very slowly to allow
the oil pressure to dissipate
Component damage hazard. Mark gradually. Do not allow oil to squirt
the platform mounting weldment or spray.
and the rotator flange before
removing the platform mounting 4 S-65 and S-65 TRAX: Support the jib boom
weldment. The platform mounting leveling arms and the platform mounting
weldment must be replaced in the weldment with an appropriate lifting device. Do
exact same position on the rotator not apply any lifting pressure.
flange as it was before removal. If 5 Remove the mounting bolts from the platform
a new rotator is installed or the mounting weldment. Remove the center bolt and
rotator is disassembled, proper slide the platform mounting weldment off of the
alignment can be achieved by platform rotator.
rotating the rotator all the way to
the left and then installing the Crushing hazard. The platform
platform mounting weldment all the mounting weldment could become
way in the left position. unbalanced and fall if not properly
supported when removed from the
Note: When removing a hose assembly or fitting, machine.
hose end must be replaced. All connections must 6 Support the platform rotator with an appropriate
be torqued to specification during installation. Refer lifting device. Do not apply any lifting pressure.
to Section 2, Hydraulic Hose and Fitting Torque
S-60, S-60X, S-60XC and S-60 TRAX:
Specifications.
7 Support the rod end of the platform leveling
1 Remove the platform and platform support.
slave cylinder. Protect the cylinder rod from
Note: S-60 HC: If the load sense components are damage.
disassembled and/or removed from the platform
support, the platform load sense system will need
to be calibrated. See 2-4, Platform Load Sense
System, S-60 HC.

S-60 HC • S-60X • S-60XC
PLATFORM COMPONENTS
8 Remove the pivot pin retaining fasteners from How to Bleed the Platform
both the slave cylinder rod-end pivot pin and the
rotator pivot pin. Rotator
9 Use a soft metal drift to remove both pivot pins. Note: This procedure will require two people. Do not
Remove the platform rotator from the machine. start the engine. Use auxiliary power for this
procedure.
Crushing hazard. The platform
rotator may become unbalanced 1 Move the function enable toggle switch to either
and fall if not properly supported. side and activate the platform rotate toggle
switch to the right then the left through two
Note: When installing the platform rotator fasteners, platform rotation cycles, then hold the switch to
torque the fasteners to specifications. the right position until the platform is fully
10 Lower the jib boom leveling arms. rotated to the right.
Crushing hazard. The platform 2 Place a suitable container underneath the

rotator may become unbalanced platform rotator.
and fall if not properly supported. 3 Open the top bleed screw on the rotator, but do
Note: When installing the platform rotator fasteners, not remove it.
torque the fasteners to specifications. Bodily injury hazard. Spraying
S-65 and S-65 TRAX: hydraulic oil can penetrate and
burn skin. Loosen hydraulic
7 Remove the pin retaining fasteners from the jib connections very slowly to allow
boom and jib boom leveling arms to platform the oil pressure to dissipate
rotator pivot pins. Do not remove the pins. gradually. Do not allow oil to
squirt or spray.
8 Support the jib boom leveling arms.
4 Move the function enable toggle switch to either
9 Use a soft metal drift to drive both pins out, then side and hold the platform rotate toggle switch
remove the platform rotator from the machine. to the left position until the platform is fully
Bodily injury hazard. The jib boom rotated to the left. Continue holding the toggle
leveling arms may fall if not switch until air stops coming out of the bleed
properly supported. screw. Close the bleed screw.
10 Lower the jib boom leveling arms. Crushing hazard. Keep clear of the
platform during rotation.
Crushing hazard. The platform
rotator may become unbalanced
and fall if not properly supported.
Note: When installing the platform rotator fasteners,
torque the fasteners to specifications.

S-60 HC • S-60X • S-60XC
PLATFORM COMPONENTS
5 Open the bottom bleed screw on the rotator, but 2-3

do not remove it.
Platform Overload System,
Bodily injury hazard. Spraying
S-60, S-65, S-60 TRAX and
burn skin. Loosen hydraulic S-65 TRAX (if equipped)
connections very slowly to allow
the oil pressure to dissipate How to Calibrate the Platform
squirt or spray. Overload System
6 Move the function enable toggle switch to either Calibration of the platform overload system is
side and hold the platform rotate toggle switch essential to safe machine operation. Continued use
to the right position until the platform is fully of an improperly calibrated platform overload
rotated to the right. Continue holding the toggle system could result in the system failing to sense
switch until air stops coming out of the bleed an overloaded platform. The stability of the
screw. Close the bleed screw. machine is compromised and it could tip over.
Crushing hazard. Keep clear of the Note: For S-60 HC models, refer to Repair
platform during rotation. Procedure 2-4, Platform Load Sense System,
S-60 HC.
7 Clean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions and
firm, level surface.
inspect the bleed screws for leaks.
1 Turn the key switch to platform control. Start the

engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
incorrect calibration.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform capacity
at the center of the platform floor.

S-60 HC • S-60X • S-60XC
PLATFORM COMPONENTS
5 Move the platform up and down by hand, so it 7 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2 bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle. inches. Allow the platform to settle.
Result: The overload indicator lights are off and Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6. the alarm does not sound. Proceed to step 8.
Result: The overload indicator lights are flashing Result: The overload indicator lights are flashing
at the platform and ground controls, and the at the platform and ground controls, and the
alarm is sounding. Slowly tighten the load spring alarm is sounding. Repeat this procedure
adjustment nut in a clockwise direction in 10° beginning with step 5.
increments until the overload indicator light
turns off, and the alarm does not sound.
platform overload indicator light and alarm
Proceed to step 8.
responds.
Note: The platform will need to be moved up and
down and allowed to settle between each 8 Add an additional 10 lb / 4.5 kg test weight to
adjustment. the platform.
Result: The overload indicator light is flashing at
both the ground and platform controls, and the
alarm is sounding. Proceed to step 9.
responds.
Result: The overload indicator light is off at both
6 Move the platform up and down by hand, so it
the ground and platform controls, and the alarm
bounces approximately 2.5 to 5 cm / 1 to 2
does not sound. Remove the additional 10 lb /
inches. Allow the platform to settle.
4.5 kg test weight. Repeat this procedure
Result: The overload indicator lights are off at beginning with step 6.
the platform and ground controls, and the alarm
does not sound. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
responds.
in 10° increments until the overload indicator
light flashes at both the platform and ground 9 Test all machine functions from the platform
controls, and the alarm sounds. controls.
Proceed to step 7.
Result: All platform control functions should not
Result: The overload indicator lights are flashing operate.
at the platform and ground controls, and the
alarm is sounding. Repeat this procedure 10 Turn the key switch to ground control.
beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
platform overload indicator lights and alarm
responds.

S-60 HC • S-60X • S-60XC
PLATFORM COMPONENTS
11 Test all machine functions from the ground 2-4

controls.
Platform Load Sense System,
Result: All ground control functions should not
operate.
S-60 HC
12 Using a suitable lifting device, lift the test weight How to Calibrate the Platform
off the platform floor.
Load Sense System
Result: The platform overload indicator light
should be off at both the ground and platform Proper calibration of the load sense system is
controls and the alarm should not sound. essential to safe machine operation. Continued use
of an improperly calibrated load sense system
Note: There may be a 2 second delay before the could result in the system failing to sense an
overload indicator lights and alarm turn off. overloaded platform. The stability of the machine is
13 Test all machine functions from the ground compromised and it could tip over.
controls. Note: For S-60, S-65, S-60 TRAX and S-65 TRAX
Result: All ground control functions should models, refer to Repair Procedure 2-3, Platform
operate normally. Overload System, S-60, S-65, S-60 TRAX and
S-65 TRAX (if equipped).
14 Turn the key switch to platform control.
Note: Perform this procedure with the boom fully
15 Test all machine functions from the platform retracted and in the stowed position and with the
controls. machine on a firm, level surface.
Result: All platform control functions should
Note: The platform overload system will not allow
operate normally.
partial calibration and must be completed in its
entirety.
1 At the ground controls, turn the key switch to

the off position and push in the red Emergency
Stop button to the off position. Pull out the red
Emergency Stop button to the on postion at the
platform controls.

S-60 HC • S-60X • S-60XC
PLATFORM COMPONENTS
2 Remove all weight, tools and equipment from 5 Activate and release the calibration toggle
the platform. switch 3 times within 2 seconds after the alarm
sounds to enter calibration mode.
Tip-over hazard. Failure to remove
all weight, options, accessories Result: The alarm should sound for 1 second
and/or tools from the platform or indicating the first calibration step was
subtracting the weight of those accepted. The green LED on the operational
items from the test weights, will controller should be blinking fast and the red
result in the platform load sense LED should be blinking twice indicating that
system not calibrating correctly. step 2 of calibration is next.
This will allow too much weight to
Result: The alarm did not sound and the green
be added to the platform which will
LED on the operational controller is not blinking
result in the machine tipping over.
fast. Repeat this procedure beginning with
3 Open the ground control box and locate the step 1.
calibration toggle switch near the relays.
Note: Once calibration mode is entered and begun,
Note: If either the operational and/or safety there is a 8 minute time limit between each
controller has been replaced or if the software has calibration step. If any one step passes the 8
been updated, restore the system to the default minute time limit, the system will time out and the
settings and then continue to step 4. See How to calibration process will need to be repeated
Restore the Default Settings. Otherwise, continue beginning with step 1.
to step 4 to enter calibration mode.

out the red Emergency Stop button to the on
position.
Result: The alarm sound for approximately f a
2 seconds. e b
How to Restore the System

Default Settings
1 Turn the key switch to ground control and
pull out the red Emergency Stop button to
the on position.
Result: The alarm should sound a long tone.
d c
2 Activate and hold the calibration toggle
switch for 5 seconds.
a green LED (operational control module)
Result: The alarm should sound a tone for b red LED (operational control module)
c operational control module
1 second. d safety control module
e red LED (safety control module)
3 Push in the red Emergency Stop button to f green LED (safety control module)
the off position.

S-60 HC • S-60X • S-60XC
PLATFORM COMPONENTS
6 Start the engine from the ground controls. 8 Activate the calibration toggle switch inside the
ground control box 1 time.
7 Raise the boom until the distance, when
measured between the centers of the pivot pins Result: The alarm should sound for 1 second
shown, equals 108.75 inches / 276 cm indicating the second calibration step was
± 0.75 inch / 19 mm. accepted. The green LED on the operational
controller should be blinking fast and the red
Crushing hazard. Keep clear of all
LED should be blinking three times indicating
moving parts of the boom while the
that step 3 of calibration is next.
boom is raising. Do not attempt to
measure between the pivot pins 9 Raise the boom until the distance, when
while the boom is moving. measured between the centers of the pivot pins
shown, equals 167.25 inches / 424.8 cm
± 0.75 inch / 19 mm.
Crushing hazard. Keep clear of all
moving parts of the boom while the
boom is raising. Do not attempt to
Measure between measure between the pivot pins
the centers of these
while the boom is moving.
pivot pins
10 Activate and release the calibration toggle
switch inside the ground control box 1 time.
Result: The alarm should sound for 1 second
indicating the third calibration step was
accepted. The green LED on the operational
controller should be blinking fast and the red
LED should be blinking four times indicating that
step 4 of calibration is next.
11 Fully raise and extend the boom.
Operational Control Module LED Status
Description Definition
Green AND Red LED's System calibrated

not flashing
Green LED System in calibration

flashing rapidly mode
Red LED flashing Indicates next calibration

with pauses step (ie; 2, 3, etc.)
Safety Control Module LED Status

Description Definition
Green AND Red LED's System calibrated

not flashing
Green AND Red LED's System not calibrated

flashing alternately

S-60 HC • S-60X • S-60XC
PLATFORM COMPONENTS
12 Activate and release the calibration toggle 17 Activate and release the calibration toggle
switch inside the ground control box 1 time. switch inside the ground control box 1 time.
Result: The alarm should sound for 1 second Result: The alarm should sound for 1 second
indicating the fourth calibration step was indicating the sixth calibration step was
accepted. The green LED on the operational accepted. The engine may turn off and the
controller should be blinking fast and the red alarm may sound indicating an overloaded
LED should be blinking five times indicating that platform.
18 At the ground controls, push in the red
13 Fully retract and lower the boom to the stowed Emergency Stop button to the off position, then
position. pull out the red Emergency Stop button to the
on position to reset the system.
14 Using a suitable lifting device, place an
appropriate test weight equal to 19 Visually inspect the LEDs on the controllers.
750 lbs / 340.2 kg on to the center of the
Result: All LEDs on both controllers should be
platform floor.
off indicating the platform load sense system is
Note: If your machine is equipped with any platform calibrated.
accessories or options, they must be removed from
20 At the ground controls, push in the red
the platform OR the weights of those options or
Emergency Stop button to the off position.
accessories must be subtracted from the test
weights to accurately calibrate the platform load 21 Using a suitable lifting device, remove the test
sense system. weights from the platform.
15 Activate and release the calibration toggle 22 Pull out the red Emergency Stop button to the
switch inside the ground control box 1 time. on position at the ground controls and visually
inspect the LEDs on the operational and safety
Result: The alarm should sound for 1 second
controllers.
indicating the fifth calibration step was
accepted. The green LED on the operational Result: Both the green and red LEDs on both
controller should be blinking fast and the red controllers should be off indicating the system
LED should be blinking six times indicating that is calibrated.
Note: If an LED is blinking on either controller, the
16 Using a suitable lifting device, place an load sense system is not calibrated correctly or a
additional test weight equal to 510 lbs / 231.3 kg fault may exist. Refer to Section 5, Fault Codes to
on to the center of the platform floor. The total determine the system fault.
weight in the platform must equal
1260 lbs / 571.5 kg.

S-60 HC • S-60X • S-60XC
Jib Boom Components,

S-65 and S-65 TRAX
3-1 6 Attach a lifting strap from an overhead crane to
the jib boom assembly.
Jib Boom
7 Place blocks under the platform leveling cylinder
for support. Protect the cylinder rod from
How to Remove the Jib Boom damage.
Note: Perform this procedure with the boom in the 8 Remove the pin retaining fastener from the slave
stowed position. cylinder rod-end pivot pin. Use a soft metal drift
Note: When removing a hose assembly or fitting, to remove the pin.
the O-ring (if equipped) on the fitting and/or the Crushing hazard. The jib boom
hose end must be replaced. All connections must could fall when the slave cylinder
be torqued to specification during installation. Refer rod-end pivot pin is removed if not
to Section 2, Hydraulic Hose and Fitting Torque properly attached to the overhead
Specifications. crane.
1 Remove the platform. 9 Remove the pin retaining fastener from the jib
boom bellcrank to primary boom pivot pin.
2 Remove the platform mounting weldment.
10 Use a soft metal drift to remove the pin and
3 Remove the hose and cable cover from the side
carefully remove the jib boom assembly from
of the jib boom.
the primary boom.
4 Remove the hose and cable clamp from the jib
Crushing hazard. The jib boom
boom pivot pin. Lay all hoses and cables to the
could become unbalanced and fall
side.
when removed from the machine if
Component damage hazard. Hoses not properly attached to the
and cables can become damaged overhead crane.
if they are kinked or pinched.
5 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
squirt or spray.

S-60 HC • S-60X • S-60XC
JIB BOOM COMPONENTS, S-65 AND S-65 TRAX
3-2 3 Remove the pin retaining fasteners from the jib

boom lift cylinder rod-end pivot pin. Do not
Jib Boom Lift Cylinder remove the pin.
4 Use a soft metal drift to tap the jib boom lift
How to Remove the Jib Boom cylinder rod-end pivot pin half way out. Then
Lift Cylinder lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
Note: Perform this procedure with the boom in the
opposite leveling arm. Do not remove the pin.
stowed position.
5 Support the jib boom lift cylinder with a lifting
Note: When removing a hose assembly or fitting, device.
hose end must be replaced. All connections must 6 Remove the pin retaining fastener from the jib
be torqued to specification during installation. Refer boom lift cylinder barrel-end pivot pin. Use a
to Section 2, Hydraulic Hose and Fitting Torque soft metal drift to remove the barrel-end pin and
Specifications. let the cylinder hang down.
1 Raise the jib boom slightly and place blocks Crushing hazard. The platform and
under the platform mounting weldment. Then jib boom could become unbalanced
lower the jib boom until the platform is resting and fall when the jib boom barrel-
on the blocks just enough to support the end pivot pin is removed if not
platform. properly supported.
Note: Do not rest the entire weight of the boom on 7 Attach a lifting strap from an overhead crane to
the blocks. 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 8 Use a soft metal drift to remove the jib boom lift
cylinder. cylinder rod-end pin. Remove the cylinder from
the machine.
hydraulic oil can penetrate and Crushing hazard. The jib boom lift
burn skin. Loosen hydraulic cylinder could become unbalanced
connections very slowly to allow and fall when removed from the
the oil pressure to dissipate machine if not properly attached to
gradually. Do not allow oil to the overhead crane.
squirt or spray.

S-60 HC • S-60X • S-60XC
Boom Components
4-1 5 Remove the hose and cable clamp from the
platform support.
Cable Track
The primary boom cable track guides the cables from the counterbalance valve manifold located
and hoses running up the boom. It can be repaired on the platform rotator. Cap the fittings on the
link by link without removing the cables and hoses manifold.
that run through it. Removing the entire primary Bodily injury hazard. Spraying
boom cable track is only necessary when hydraulic oil can penetrate and
performing major repairs that involve removing the burn skin. Loosen hydraulic
primary boom. connections very slowly to allow
How to Remove the Cable Track, gradually. Do not allow oil to
S-60, S-60X, S-60XC, S-60 HC squirt or spray.
and S-60 TRAX 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.
hose end must be replaced. All connections must
be torqued to specification during installation. Refer Bodily injury hazard. Spraying
to Section 2, Hydraulic Hose and Fitting Torque hydraulic oil can penetrate and
Specifications. burn skin. Loosen hydraulic
1 Raise the boom to a horizontal position. the oil pressure to dissipate
2 Locate the cables from the boom cable track to gradually. Do not allow oil to
the platform control box. Number each cable squirt or spray.
and its entry location at the platform control 8 Locate all electrical cables under the boom at
box. the pivot end that enter the cable track.
3 Disconnect the cables from the platform control 9 Tag and disconnect the electrical connectors for
box. all cables that enter the cable track.
4 Remove the electrical outlet box bracket 10 Remove the retaining fasteners from the
mounting fasteners. Remove the outlet box and electrical connector receptacles for the cables
lay it to the side. that enter the cable track.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
11 Carefully pull the cables and connector 18 Remove the cable track mounting fasteners that
receptacles out of the primary boom. attach the lower cable track to the primary
boom.
12 Tag, disconnect and plug all hydraulic hoses
that enter the cable track from the bulkhead 19 Carefully remove the cable track from the
fittings at the pivot end of the boom. machine and place it on a structure capable of
supporting it.
hydraulic oil can penetrate and Crushing hazard. The cable track
burn skin. Loosen hydraulic could become unbalanced and fall
connections very slowly to allow if not properly attached to the
the oil pressure to dissipate overhead crane.
squirt or spray.
Cables and hoses can be damaged
13 Pull the hydraulic hoses out of the primary if they are kinked or pinched.
boom.
14 Place blocks in between the upper and lower cable track can be damaged if it is
cable tracks and secure the upper and lower twisted.
tracks together.
How to Remove the Cable Track,
Crushing hazard. If the upper and
lower cable tracks are not properly S-65 and S-65 TRAX
secured together, the cable track Note: When removing a hose assembly or fitting,
could become unbalanced and fall the O-ring (if equipped) on the fitting and/or the
when removed from the machine. hose end must be replaced. All connections must
15 Attach a strap from an overhead crane to the be torqued to specification during installation. Refer
cable track. to Section 2, Hydraulic Hose and Fitting Torque
Specifications.
16 Remove the cotter pin from the cable track pull
tube at the platform end of the boom. 1 Open the platform control box.
Note: Always replace the cotter pin with a new one. 2 Tag and disconnect the foot switch wiring from
the terminal strip inside the platform control box.
17 Remove the cable track pull tube guide Pull the wiring out of the platform control box.
fasteners from the cable track guide at the
platform end of the boom. Remove the cable 3 Raise the boom to a horizontal position.
track guide from the boom.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
4 Disconnect the wire connectors from the bottom 9 Remove the hose and cable cover from the side
of the platform control box. of the jib boom.
Note: When installing the wire connectors to the 10 Locate all electrical cables under the boom at
bottom of the platform control box, match the color the pivot end that enter the cable track.
of the connectors to those on the control box to be
11 Tag and disconnect the electrical connectors for
sure they are installed in the correct location.
all cables that enter the cable track.
5 Remove the mounting fasteners from the power 12 Remove the retaining fasteners from the
to platform outlet box bracket. Lay the outlet electrical connector receptacles for the cables
box and bracket assembly off to the side. that enter the cable track.
6 Remove the hose and cable clamps from the 13 Carefully pull the cables and connector
platform support and jib boom. receptacles out of the primary boom.
7 Tag, disconnect and plug the platform leveling
14 Tag, disconnect and plug all hydraulic hoses
slave cylinder hydraulic hoses from the
that enter the cable track from the bulkhead
bulkhead fittings on the side of the primary
fittings at the pivot end of the boom.
squirt or spray.
squirt or spray.
15 Pull the hydraulic hoses out of the primary
boom.
from the "V1" and "V2" ports of the jib boom/
platform rotate manifold. Cap the fittings on the 16 Remove the cotter pin from the upper cable
manifold. track at the platform end of the boom.
Bodily injury hazard. Spraying Note: Always replace the cotter pin with a new one.
burn skin. Loosen hydraulic 17 Remove the cable track pull tube guide
connections very slowly to allow fasteners from the cable track guide at the
the oil pressure to dissipate platform end of the boom. Remove the cable
gradually. Do not allow oil to track guide from the boom.
squirt or spray.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
18 Place blocks in between the upper and lower How to Repair the Cable Track
cable tracks and secure the upper and lower
tracks together. Component damage hazard.
The boom cable track can be
Crushing hazard. If the upper and damaged if it is twisted.
lower cable tracks are not properly
secured together, the cable track Note: A cable track repair kit is available through
could become unbalanced and fall the Genie Industries Service Parts Department,
when removed from the machine. part no. 77896. The kit includes a 4 link section of
cable track.
the cable track. 1 Visually inspect the cable track and determine
which 4 link section needs to be replaced.
20 Remove the mounting fasteners that attach the
lower cable track to the boom. 2 Carefully remove the snap rings from each end
of the damaged section of cable track.
21 Carefully remove the cable track from the
machine and place it on a structure capable of 3 Remove the retaining fasteners from the upper
supporting it. black rollers from the 4 link section of cable
track to be replaced. Remove the rollers.
Crushing hazard. The cable track
could become unbalanced and fall 4 Lift up the hoses and cables and carefully
if not properly attached to the remove the damaged 4 link section of cable
overhead crane. track.
Component damage hazard. Component damage hazard. Hoses
Cables and hoses can be damaged and cables can be damaged if they
if they are kinked or pinched. are kinked or pinched.
Component damage hazard. The 5 Remove the upper rollers from the replacement
cable track can be damaged if it is section of cable track.
twisted.
6 Lift up the hoses and cables and carefully insert
the new 4 link section of cable track.
Hoses and cables can be damaged
if they are kinked or pinched.
7 Connect the ends of the replacement cable track
section to the existing cable track using the
snap rings.
8 Install the rollers onto the new section of cable
track.
9 Operate the boom extend/retract function
through a full cycle to ensure smooth operation
of the new section of cable track.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
a b
k c
f
j
a short link arm to boom pivot pin

b boom
c boom lift cylinder rod-end pivot pin
d boom lift cylinder
e long link arm (ground controls side)
f long link arm (engine side)
g long link arm to turntable pivot pin
h master cylinder cam
i master cylinder cam link
j short link arm to turntable pivot pin
k long link arm to boom pivot pin
l master platform level cylinder
i m short link arm weldment

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
4-2 1 Remove the jib boom. See 3-1, How to Remove

the Jib Boom.
Boom
2 Remove the cable track. See 4-1, How to
Remove the Cable Track.
How to Remove the Boom
Note: S-60X and S-60XC: Disconnect the two limit
TIp-over hazard. This procedure switch connectors at the platform end of the cable
requires the removal of the track.
turntable counterweight. Failure to
remove the counterweight before 3 Raise the boom until the short and long link arm
removing the boom assembly will to boom pivot pins are above the turntable
result in the machine tipping over. covers.
Do not remove the boom without
4 Place a block of wood measuring
first removing the counterweight.
4 x 4 x 60 inches / 10 x 10 x 152 cm under the
TIp-over hazard. When installing long link arm, across the turntable covers.
the boom onto the machine, the
5 Slowly lower the boom until the long link arm
boom assembly must be first
contacts the wood block. Do not rest the entire
installed prior to the installation of
weight of the boom on the block. Turn the
the counterweight. If the
machine off.
counterweight is installed before
the boom assembly, the machine Component damage hazard. The
will tip over resulting in death or turntable covers can become
serious injury. damaged if the weight of the boom
is allowed to rest on the block.
TIp-over hazard. The turntable
counterweight is essential for 6 Place wood blocks between the short link arm
machine stability. Failure to install and the turntable weldment for support.
the counterweight after installing
the boom assembly will 7 Insert a 1.125 x 12 inches / 32 x 300 mm
compromise machine stability eye-bolt through each hole located on the top
resulting in the machine tipping surface of the counterweight. Secure the eye-
over. Death or serious injury will bolts in position with flat washers and nuts.
result. 8 Securely attach lifting straps or chains with a
Bodily injury hazard. This minimum rating of 5 tons / 5000 kg to the lifting
procedure requires specific repair points on the top of the turntable counterweight.
skills, lifting equipment and a Attach the lifting straps or chains to a
suitable workshop. Attempting this 5 ton / 5000 kg overhead crane.
procedure without these skills and Note: A spreader bar and other hardware may be
tools could result in death or needed to safely remove the counterweight.
serious injury and significant
component damage. Dealer
service is strongly recommended.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
9 Slowly operate the overhead crane to apply 14 Using auxiliary power, activate the boom down
tension to the lifting straps. Do not attempt to function so the cylinder will retract. Retract the
lift the machine with the overhead crane. cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
10 Locate and remove the counterweight retaining
boom. Turn the machine off.
fastener at the center of the counterweight.
Carefully lift the counterweight upwards and Crushing hazard. The boom lift
remove the counterweight from the machine. cylinder could fall if not properly
Set the counterweight on the ground. Do not supported and secured to the lifting
leave the counterweight suspended above the device.
ground.
15 Using the overhead crane, carefully lower the
Crushing hazard. The turntable boom lift cylinder and allow it to rest on the
counterweight will fall if not boom rest pad. Protect the cylinder rod from
properly supported by the overhead damage.
crane resulting in death or serious
16 S-60, S-60X, S-60XC, S-65, S-60 TRAX and
injury. Keep personnel away from
S-65 TRAX: Remove the boom end cover
the area when removing the
retaining fasteners and remove the cover.
counterweight.
S-60 HC: Remove the boom end cover from the
11 Attach lifting straps from a 5 ton / 5000 kg
pivot end of the boom while guiding the small
overhead crane to each end of the boom.
Support the boom. Do not apply any lifting
pressure.
potentiometer on the counterweight.
12 Support and secure the rod end of the boom lift
cylinder to a second overhead crane or similar
lifting device.
13 Remove the lift cylinder rod-end pivot pin kinked or pinched.
retaining fasteners. Use a soft metal drift to
17 S-60 HC: Remove the string potentiometer cable
remove the pin.
break limit switch mounting fasteners.
Crushing hazard. The boom could
18 S-60 HC:Remove the pulley retaining plate from
fall if not properly supported when
the string potentiometer pulley bracket.
the lift cylinder rod-end pivot pin is
Carefully remove the string potentiometer cable
removed.
and limit switch assembly from the boom.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
19 S-60X and S-60XC: Disconnect the boom angle 25 Remove the external snap rings from both boom
sensor harness. pivot pins at the short and long link arms. Do
not remove the pins.
20 Tag, disconnect and plug the boom extension
cylinder hydraulic hoses. Cap the fittings on the 26 Using the overhead crane, adjust the boom as
cylinder. necessary to relieve pressure from the pivot
pins.
hydraulic oil can penetrate and 27 Use a soft metal drift to remove each boom
burn skin. Loosen hydraulic pivot pin. Carefully remove the boom assembly
connections very slowly to allow from the machine and place it on a structure
the oil pressure to dissipate capable of supporting it.
Crushing hazard. The boom could
squirt or spray.
fall if not properly supported by the
21 Tag and disconnect the electrical connector for overhead crane when each boom
the cable break limit switch. pivot pin is removed.
22 Tag and disconnect all boom wire harness Crushing hazard. The long and
electrical connectors located at the pivot end of short link arms may fall if not
the boom. properly supported when the boom
pivot pins are removed.
23 Support the platform leveling master cylinder.
Remove the master cylinder rod-end pivot pin
retaining fasteners. Place a rod through the pin
and twist to remove. Carefully lower the master
cylinder down.
from the bulkhead fittings at the pivot end of the
squirt or spray.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
4-3 5 Using auxiliary power, activate the boom down

function so the cylinder will retract. Retract the
Boom Lift Cylinder cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
The boom lift cylinder raises and lowers the boom. boom. Turn the machine off.
The boom lift cylinder is equipped with
counterbalance valves to prevent movement in the 6 Tag, disconnect and plug the boom lift cylinder
event of a hydraulic line failure. hydraulic hoses. Cap the fittings on the cylinder.
How to Remove the Boom hydraulic oil can penetrate and
Lift Cylinder burn skin. Loosen hydraulic
Bodily injury hazard. This the oil pressure to dissipate
procedure requires specific repair gradually. Do not allow oil to
skills, lifting equipment and a squirt or spray.
suitable workshop. Attempting this
procedure without these skills and 7 Remove the pin retaining fasteners from the
tools could result in death or boom lift cylinder barrel-end pivot pins. Do not
serious injury and significant remove the pins.
component damage. Dealer 8 Use a slide hammer to remove the barrel-end
service is strongly recommended. pivot pins.
Note: When removing a hose assembly or fitting, Crushing hazard. The boom lift
the O-ring (if equipped) on the fitting and/or the cylinder could become unbalanced
hose end must be replaced. All connections must and fall if not properly supported
be torqued to specification during installation. Refer and secured to the lifting device.
Specifications. 9 Move the boom lift cylinder towards the
counterweight end of the machine. Rotate the
1 Raise the boom to a horizontal position. boom lift cylinder until the barrel-end pivot pin
2 Attach a 5 ton / 5000 kg overhead crane to the bores will clear the boom linkage.
boom at the platform end for support. Do not lift 10 Carefully remove the boom lift cylinder from the
the boom. machine.
3 Support and secure both ends of the boom lift Crushing hazard. The boom lift
cylinder to a second overhead crane or similar cylinder could become unbalanced
lifting device. and fall if not properly supported
4 Remove the pin retaining fastener from the and secured to the lifting device.
boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
Crushing hazard. The boom will fall
if not properly supported when the
primary boom rod-end pivot pin is
removed.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
4-4 2 S-60, S-60X, S-60XC, S-65, S-60 TRAX and

S-65 TRAX: Remove the boom end cover
Boom Extension Cylinder retaining fasteners and remove the cover.
The boom extension cylinder is located inside the S-60 HC: Remove the boom end cover from the
boom assembly and incorporates cables and pivot end of the boom while guiding the small
pulleys that are responsible for extending the cable from the string potentiometer out of the
number 3 boom tube. The primary boom extension slot of the cover. Rest the cover and string
cylinder is equipped with counterbalance valves to potentiometer on the counterweight.
prevent movement in the event of a hydraulic line Component damage hazard. The
failure. cable from the string potentiometer
How to Remove the Boom kinked or pinched.
Extension Cylinder 3 S-60 HC: Remove the string potentiometer cable
Bodily injury hazard. This break limit switch mounting fasteners.
procedure requires specific repair 4 S-60 HC:Remove the pulley retaining plate from
skills, lifting equipment and a the string potentiometer pulley bracket.
suitable workshop. Attempting this Carefully remove the string potentiometer cable
procedure without these skills and and limit switch assembly from the boom.
tools could result in death or
serious injury and significant 5 Remove the access covers from both sides of
component damage. Dealer the boom at the pivot end.
service is strongly recommended.
6 Fully loosen the lock nuts on the extend cables.
Note: When removing a hose assembly or fitting, Do not remove the nuts.
7 Loosen the retract cable nut at the platform end
of the boom. Pull the cable rod from the support
be torqued to specification during installation. Refer
and let it hang down.
Specifications.
Note: Perform this procedure with the boom fully
retracted.
1 Raise the boom to a horizontal position.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
8 Remove the cable guard fasteners and remove 12 Disconnect the wire connector to the extend
the cable guard. cable break limit switch.
13 Remove the retaining fasteners that secure the
extend cable mounting plates to the inside of
the number 1 boom tube.
a b
a cable guard a b c d
b retaining block
a extend cable lock nuts
9 Locate the retaining plates that secure the b extend cable mounting plate
retract cables to the inside of the number 3 c extend cable mounting plate fastener
boom tube. d extend cable bracket
10 Remove the cable retaining plates and pull the 14 Pull back on the extend cable mounting plate
retract cables off of the pulleys. Lay the cables until it clears the blocks welded to the inside of
flat and out of the way. the number 1 boom tube.
11 Remove the fasteners from the retaining blocks
from the extension cylinder saddle. Remove the
blocks.
Note: Access the fasteners through the access
hole in the outer boom tube at the pivot end.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
15 Lift up the extend cable mounting plate and push 23 Attach a lifting strap from a 5 ton / 5000 kg
the extend cables towards the platform to create overhead crane to the lug at the rod end of the
slack in the cables. Rest the cable and bracket boom extension cylinder.
assembly on top of the extend cylinder.
24 Lift the boom extension cylinder with the crane
16 Locate the lower extend cable bracket on the until it clears the cylinder saddle inside the
bottom of the number 3 boom tube. number 2 boom tube.
17 Remove the lower extend cable bracket 25 Carefully support and slide the extension
mounting fasteners and pull back on the bracket cylinder out of the boom.
to release it from the number 3 boom tube.
Crushing hazard. The extension
18 While pushing the lower extend cable bracket cylinder could fall when removed
towards the platform, pull the extend cable from the boom if not properly
mounting plate towards the pivot end of the supported.
boom.
Component damage hazard. Be
19 Secure the extend cable bracket and cables to careful not to damage the cable
the cylinder to prevent them from falling off break limit switch.
when removing the cylinder.
20 Remove the external snap rings from the careful not to damage the
extension cylinder pin at the pivot end of the counterbalance valves on the
boom. primary boom extension cylinder
when removing the cylinder from
21 Use a soft metal drift to remove the pin.
the boom.
22 Tag, disconnect and plug the boom extension
Note: During removal of the extension cylinder, the
overhead crane strap will need to be carefully
cylinder.
adjusted for proper balancing.
squirt or spray.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
4-5 4 Adjust the extend cable adjustment nuts until

approximately 1.5 inches / 4 cm of threads are
Boom Extend/Retract Cables visible past the nylock nut.
Note: If the cables have been replaced, be sure the
How to Adjust the Boom Extend/ adjustment nuts have been replaced. Do not re-use
Retract Cables the existing nuts.
The boom extend/retract cables are responsible for 5 Extend the boom until there is approximately 3
the extension and retraction of the number 3 boom feet / 1 m of travel left. Do not fully extend the
tube. Proper adjustment of the boom extend/retract boom.
cables and related components on a regular basis
is essential to good machine performance and safe 6 Locate the retract cable adjustment nut on the
machine operation. The boom extend and retract bottom of the number 1 boom tube at the
functions should operate smoothly and be free of platform end of the boom.
hesitation, jerking and unusual noise. 7 Using a dial type torque wrench, torque the
retract cable adjustment nut to 32-36 ft lbs /
Note: Perform this procedure with the boom in a
43-49 Nm using gentle and steady torque.
horizontal position.
8 Retract and extend the boom approximately
1 Fully retract the boom. 3 feet / 1 m two times and stop during the
2 S-60, S-60X, S-60XC, S-65, S-60 TRAX and extension cycle. This will create slack in the
S-65 TRAX: Remove the boom end cover retract cables.
retaining fasteners and remove the cover. Note: Be sure to not fully extend the boom. Stop
S-60 HC: Remove the boom end cover from the when there is approximately 3 feet / 1 m of
pivot end of the boom while guiding the small travel left.
9 Repeat steps 7 and 8 two to three times.
potentiometer on the counterweight. 10 Fully extend the boom then retract the boom
approximately 12 inches / 30 cm.
cable from the string potentiometer 11 At the pivot end of the boom, visually inspect
can become damaged if it is the boom extend cables for even cable droop or
kinked or pinched. sag.
3 Inspect the threaded ends of the boom extend Note: If the boom extend cables are uneven,
cables. The threads must be clean and in good tighten the boom extend cable adjustment nut at
condition with no damaged threads. the pivot end of the boom for the appropriate cable.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
12 Visually inspect the cable break limit switch arm How to Replace the Boom
to be sure the wheel of the limit switch arm is
centered in the notch of the pivot plate. Extend/Retract Cables
Note: If the boom extend cables are adjusted Note: The cable pulleys must also be replaced
evenly, the wheel of the limit switch arm should be when replacing the cables.
centered in the notch of the pivot plate.
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
a cable bracket that attaches to the number 3
boom tube.
3 Remove the rue rings and clevis pins from the
boom extend cables located near the extend
cable break limit switch.
4 Remove the external snap rings from the boom
extend cable pulley pivot pin. Use a soft metal
drift to remove the pin.
Note: When driving the pivot pin out, be sure to
drive it 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
b c
boom extend pulley bracket.
a cable break limit switch 7 Install the new boom extend cable pulley, pivot
b extend cable adjustment nut pin and snap rings.
c extend cable pivot plate
Note: Be sure the boom extend cables are routed
13 Install the boom end cover at the pivot end of through the grooves of the pulley and the upper
the boom. wear pad on the extension cylinder.
14 Fully retract and lower the boom to the stowed 8 Install the boom extend cable clevis pins and
position. 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.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
Boom retract cables: 17 Securely attach the rope to the same end of the
new boom retract cable.
10 Remove the cotter pins and clevis pins from the
boom retract cables at the platform end of the 18 At the pivot end of the boom, carefully pull the
boom. rope with the new retract cable attached.
Note: Always use a new cotter pin when installing a 19 Pull the new cable towards the pivot end of the
clevis pin. boom until the end of the cable is at the end of
the boom tube. Remove the rope.
11 Remove the wear pad fasteners from the upper
wear pads on the number 1 boom tube. Remove 20 Repeat steps 14 through 19 for the other boom
the wear pads. retract cable.
Note: Pay attention to the location of each wear 21 At the platform end of the boom, install the
pad and the quantity of shims for each one. retract cables, clevis pins and new cotter pins
to the adjustment plate.
the platform end of the boom. 22 Remove and discard the old boom retract
pulleys from the pivot end of the boom
13 Raise the boom using the overhead crane and extension cylinder.
place a wood block under the number 2 boom
tube between the number 1 and number 2 boom 23 Install the new boom retract pulleys to the pivot
tubes for support. This will create clearance end of the boom extension cylinder.
between the boom tubes to remove the retract 24 Install the boom extension cylinder assembly
cables. into the boom.
14 Attach the cable pulling tool or a rope to one of Note: Before lowering the extension cylinder into
the boom retract cables at the pivot end of the the saddles of the number 1 boom tube, wrap the
boom. boom retract cables around the pulleys.
Note: A cable pulling tool is available through Genie 25 Adjust the boom extend/retract cables.
Service Parts Department (Genie part no. 94510) See 4-5, How to Adjust the Boom Extend/
15 At the platform end of the boom, pull on the Retract Cables.
boom retract cable that has the rope attached
to it.
16 Pull the old cable completely out of the boom
tube. Remove the rope. Discard the old boom
retract cable.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
4-6 4 Remove the pin retaining fastener from the

master cylinder rod-end pivot pin.
Platform Leveling
5 Place a rod through the rod-end pivot pin and
Master Cylinder twist to remove the pin. Lower the rod end of the
master cylinder onto the block.
The master cylinder acts as a pump for the slave
cylinder. It’s part of the closed circuit hydraulic loop 6 Remove the pin retaining fastener from the
that keeps the platform level through the entire barrel-end pivot pin.
range of boom motion. The master cylinder is
7 Place a rod through the barrel-end pivot pin and
located at the pivot end of the boom.
twist to remove the pin.
How to Remove the Platform 8 Remove the master cylinder from the machine.
Leveling Master Cylinder
Specifications.
1 Raise the boom until the master cylinder is
above the turntable covers.
2 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the cylinder.
squirt or spray.
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.

S-60 HC • S-60X • S-60XC
BOOM COMPONENTS
4-7
Primary Boom Angle Sensor
S-60X and S-60XC
The primary boom angle sensor works in
conjunction with the boom extend limit switches
when restricted maximum platform load is selected
a
from the platform controls maintaining the working
envelope. The primary boom angle sensor is
located on the ground control side long link arm.
How to Replace the Primary

Boom Angle Sensor d
1 From the ground controls raise the primary boom

until it is fully elevated. c
2 Push in the red Emergency Stop button to the
b
off position and turn the key switch to the off
position.
a button cable ties
3 Locate the primary boom angle sensor mounted b start orientation
on the ground control side long link arm. c finish orientation
d gusset plate
4 Cut and discard the two button cable ties
securing the angle sensor harness to the gusset 8 Install the angle sensor retaining fastners. Do
plate. not tighten at this time.
5 Locate and disconnect the angle sensor harness 9 Route the angle sensor harness through the
connector. gusset plate and secure using two button cable
ties.
6 Remove the angle sensor retaining fasteners
and set aside. Remove the angle sensor. 10 Securely connect the angle sensor harness to
7 Install the angle sensor onto the hex key. Refer the main harness.
to the illustration for proper alignment. 11 Turn the key switch to platform controls. Pull up
red Emergency Stop buttons at the ground and
platform controls to the on position.
12 Using a volt meter set to DC volts, back probe
the angle sensor harness connector. Insert the
negative lead into terminal 2, the positive lead
into terminal 3.
13 Adjust the angle sensor until the volt meter
reads 3.8V dc to 4.2V dc and securely tighten
the fasteners.
14 Calibrate the boom angle sensor. Refer to Repair
Procedure 1-2, How to Calibrate the Boom
Angle Sensor.

S-60 HC • S-60X • S-60XC
Engines
5-1 5-3
RPM Adjustment - Ford and Flex Plate
Deutz Models
The flex plate acts as a coupler between the engine
Refer to Maintenance Procedure B-9, Check and and the pump. It is bolted to the engine flywheel
Adjust the Engine RPM - Ford and Deutz Models. and has a splined center to drive the pump.
Two different styles of flex plates have been used

in the production of your machine model.
Type "A" flex plates utilize a flex plate installed
5-2 onto the flywheel of the engine and a separate
RPM Adjustment - Perkins coupler installed onto the pump splined shaft.
Models Type "B" flex plates combines the pump coupler,
as part of the flex plate, which is installed onto the
Refer to Maintenance Procedure A-12, Check and engine flywheel.
Adjust the Engine RPM - Perkins Models.
Type "A" Type "B"

(flexplate with (flexplate with
separate coupler) coupler combined)

S-60 HC • S-60X • S-60XC
ENGINES
How to Remove the Flex Plate 6 Remove the engine mounting plate to bell
housing fasteners.
Deutz models:
7 Raise the engine slightly using the overhead
1 Remove the tailpipe bracket mounting fasteners crane and place a block of wood under the oil
from the engine bell housing. pan for support.
2 Support the drive pump assembly with an 8 Support the drive pump assembly with an
appropriate lifting device. overhead crane or other suitable lifting device.
Do not apply any lifting pressure.
3 Remove all of the engine bell housing fasteners.
9 Remove all of the engine bell housing retaining
4 Carefully pull the pump and bell housing fasteners.
assembly away from the engine and secure it
from moving. 10 Carefully pull the pump and bell housing
assembly away from the engine and secure it
Component damage hazard. Hoses from moving.
can be damaged if they are kinked
or pinched. Component damage hazard. Hoses
5 Remove the flex plate mounting fasteners. or pinched.
Remove the flex plate from the flywheel.
11 Remove the flex plate mounting fasteners.
Ford models: Remove the flex plate from the flywheel.
1 Disconnect the electrical connectors from both Perkins models:
oxygen sensors at the tailpipe and exhaust
manifold. Do not remove the oxygen sensors. 1 Remove the fuel filter/water separator mounting
fasteners.
2 Remove the exhaust pipe fasteners at the
muffler. 2 Remove the fuel filter/water separator and lay it
to the side. Do not disconnect the hoses.
3 Support the muffler and bracket assembly with a
suitable lifting device. 3 Support the drive pump assembly with an
appropriate lifting device.
4 Remove the muffler bracket mounting fasteners
from the bell housing. Carefully remove the 4 Remove all of the engine bell housing fasteners.
muffler and bracket assembly from the engine.
5 Carefully pull the pump and bell housing
5 Support the engine with an overhead crane or assembly away from the engine and secure it
other suitable lifting device. Do not lift it. from moving.
Component damage hazard. Hoses
or pinched.
6 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.

S-60 HC • S-60X • S-60XC
ENGINES
How to Install a Type "A" 3 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
Flex Plate appropriate gap between coupler and pump end
1 Install the flex plate onto the engine flywheel plate for your engine.
with the raised spline towards the pump.
a b c d e
2 Ford models: Torque the flex plate mounting
bolts in sequence to 14 ft-lbs / 19 Nm.
Then torque the flex plate mounting bolts in
sequence to 20 ft-lbs / 27 Nm.
Deutz models: Torque the flex plate mounting
Then torque the flex plate mounting bolts in f
sequence to 40 ft-lbs / 54 Nm.
a pump
Perkins models: Torque the flex plate mounting b pump shaft
c pump coupler
bolts in sequence to 49 ft-lbs / 66 Nm. d flex plate with raised spline
Then torque the flex plate mounting bolts in e engine flywheel
sequence to 70 ft-lbs / 95 Nm. f 3/16 inch / 4.8 mm gap - Diesel Models
0.080 inch / 2 mm gap - Ford Models
1
4 Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
6 3 to 61 ft-lbs / 83 Nm.
5 Proceed to Repair Procedure, How to Install the
Pump and Bell Housing Assembly.
4 5
2
Ford and Deutz models
2 3
Perkins models

S-60 HC • S-60X • S-60XC
ENGINES
How to Install a Type "B" 6 1

Flex Plate
1 Install the flex plate onto the engine flywheel
with the rubber vibration isolators towards the
pump. 4 3
2 Apply Loctite® removable thread sealant to the
flex plate fasteners and loosely install the
fasteners.
3 Deutz models: Torque the flex plate mounting
2 5
Then torque the flex plate mounting bolts in
sequence to 40 ft-lbs / 54 Nm. Deutz models
Ford and Perkins models: Torque the flex 1

plate mounting bolts in sequence to
14 ft-lbs / 19 Nm. Then torque the flex plate
mounting bolts in sequence to 20 ft-lbs / 27 Nm. 6 3
4 Apply a high viscosity coupling grease
(Genie part number 128025) to the splines of the
pump shaft and flex plate.
4 5
Shell Alvania® Grease CG, NLGI 0/1 or equivalent.
2
Ford models
6 3
4 5
Perkins models

S-60 HC • S-60X • S-60XC
ENGINES
How to Install the Pump and Bell 6 1

Housing Assembly 10 C C 8
C C
1 Install the pump and bell housing assembly.
Deutz models: Torque the bell housing 4 3
C C
mounting bolts labeled "C" in sequence to 28 ft-
lbs / 38 Nm. Then torque the bell housing
mounting bolts labeled "C" in sequence to 40 ft- C C
11 12
lbs / 54 Nm.
Ford models: Torque the bell housing mounting C C
bolts labeled "A" and "B" in sequence to 28 ft- 7 C C 5
lbs / 38 Nm and the mounting bolts labeled "C"
to 49 ft-lbs / 66 Nm. Then torque the bell 2 9
housing mounting bolts labeled "A" and "B" in Deutz models
sequence to 40 ft-lbs / 54 Nm and the mounting
bolts labeled "C" to 70 ft-lbs / 95 Nm.
6
Perkins models: Torque the bell housing 1 B
B
mounting bolts labeled "B" in sequence to 3
A
28 ft-lbs / 38 Nm and the mounting bolts labeled
"A" to 49 ft-lbs / 66 Nm. Then torque the bell
housing mounting bolts labeled "B" in sequence
to 40 ft-lbs / 54 Nm and the mounting bolts 4 A
labeled "A" to 70 ft-lbs / 95 Nm.

Component damage hazard. C C
Type "A" flexplate: When 5
7 B
installing the pump, do not force 2
the pump coupler into the flexplate
or damage to the pump shaft seal Ford models
may occur.
Component damage hazard. Do 6 1
not force the drive pump during A A
installation or the flex plate teeth
may become damaged.
9
B
B
4 5
B
B B
8 B B 7
2 3
Perkins models

S-60 HC • S-60X • S-60XC
ENGINES
5-4
Engine Fault Codes -
Ford Models
How to Retrieve Engine Fault

Codes
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel
injection and make constant and instantaneous
changes to ignition timing, fuel delivery and throttle
position to maintain the engine's running condition
at its highest efficiency while at the same time
keeping exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of
set parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor and
will turn on the Check Engine Light.
Refer to Section 5, How to Retrieve Engine Fault

Codes for your specific model of engine. Use the
Fault Code Chart within Section 5 to aid in
identifying the fault.

S-60 HC • S-60X • S-60XC
Hydraulic Pumps
6-1 2 Tag, disconnect and plug the function pump
hydraulic hoses. Cap the fittings on the pump.
Function Pump
How to Remove the burn skin. Loosen hydraulic
Function Pump connections very slowly to allow
squirt or spray.
be torqued to specification during installation. Refer 3 Remove the pump mounting bolts. Carefully
to Section 2, Hydraulic Hose and Fitting Torque remove the pump.
Specifications.
1 Locate the two hydraulic tank valves at the sure to open the two hydraulic tank
hydraulic tank through the access hole valves and prime the pump after
underneath the turntable. Close the valves. installing the pump.

engine must not be started with the
hydraulic tank shut-off valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
open closed

S-60 HC • S-60X • S-60XC
HYDRAULIC PUMPS
6-2 2 Locate the two hydraulic tank valves at the

hydraulic tank through the access hole
Drive Pump underneath the turntable. Close the valves.
The drive pump is a bi-directional variable Component damage hazard. The

displacement piston pump. The pump output is engine must not be started with the
controlled by the electro-proportional controller, hydraulic tank shut-off valves in
located on the pump. The only adjustment that can the closed position or component
be made to the pump is the neutral or null damage will occur. If the tank
adjustment. Any internal service to the pump valves are closed, remove the key
should only be performed at an authorized Eaton from the key switch and tag the
Hydraulics center. Call Genie Industries Service machine to inform personnel of the
Department to locate your local authorized service condition.
center.
How to Remove the Drive Pump

work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system open closed
and cause severe component
damage. Dealer service is 3 Tag and disconnect and plug the hydraulic
recommended. hoses from the drive and function pumps.
Cap the fittings on the pumps.
the O-ring (if equipped) on the fitting and/or the Bodily injury hazard. Spraying
hose end must be replaced. All connections must hydraulic oil can penetrate and
be torqued to specification during installation. Refer burn skin. Loosen hydraulic
to Section 2, Hydraulic Hose and Fitting Torque connections very slowly to allow
Specifications. the oil pressure to dissipate
1 Disconnect the electrical connection at the squirt or spray.
electro-proportional controller located on the
drive pump. 4 Support the pump with a lifting device and
remove the two drive pump mounting fasteners.

S-60 HC • S-60X • S-60XC
HYDRAULIC PUMPS
5 Carefully pull the drive pump out until the pump 4 Ford models: Close the valve on the LPG tank
coupler separates from the flex plate. then disconnect the hose from the tank. Move
the fuel select switch to the LPG position.
6 Remove the drive pump from the machine.
Perkins models: Disconnect the engine wiring
harness from the fuel solenoid at the injector
hydraulic pump may become
pump.
unbalanced and fall if not properly
supported. Deutz models: Hold the manual fuel shutoff
valve clockwise to the closed position.
Component damage hazard. When
installing the pump, do not force a
the pump coupler into the flexplate
or damage to the pump shaft seal
may occur.
sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
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 a manual fuel shutoff valve
engine pivot plate latch.
5 Have another person crank the engine with the
Note: The engine pivot plate latch is located under starter motor for 15 seconds, wait 15 seconds,
the engine turntable pivot plate at the counterweight then crank the engine an additional 15 seconds
end of the machine. or until the pressure reaches 320 psi / 22 bar.
3 Open the engine pivot plate latch and swing the 6 Ford models: Connect the LPG hose to the
engine pivot plate out and away from the LPG tank and open the valve on the tank. Move
machine. 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.
check for hydraulic leaks.

S-60 HC • S-60X • S-60XC
Manifolds
7-1
Function Manifold Components
The function manifold is located underneath the ground controls side turntable cover.
Index Schematic
No. Description Item Function Torque
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, S-65 TRAX) ........ 20-25 ft-lbs / 27-34 Nm
10 Check valve, 30 psi / 2 bar ................ J ............ Differential sensing circuit,
platform rotate right and
jib boom down (S-65, S-65 TRAX) ... 20-25 ft-lbs / 27-34 Nm
11 Check valve ....................................... N ........... Differential sensing circuit,
boom extend/retract .......................... 10-12 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
150 psi / 10.3 bar .............................. P ........... Turntable rotate circuit ...................... 30-35 ft-lbs / 41-47 Nm

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

S-60 HC • S-60X • S-60XC
MANIFOLDS
Function Manifold Components, continued

Index Schematic
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
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, S-65 TRAX) ............. 20-25 ft-lbs / 27-34 Nm
27 Check valve, 30 psi / 2 bar ................ EE ......... Platform rotate and jib
boom circuit (S-65, S-65 TRAX)
(prevents hydraulic hoses
from draining back to tank) ............... 20-25 ft-lbs / 27-34 Nm
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, S-65 TRAX) ............. 20-25 ft-lbs / 27-34 Nm

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-2
Valve Adjustments -
Function Manifold
How to Adjust the System

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

gauge to the PTEST port on the function manifold.
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.

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-3
Jib Boom / Platform Rotate Manifold Components
Index Schematic
1 Solenoid valve, 2 position 3 way ..... FF ......... Platform rotate/jib boom select ......... 20-25 ft-lbs / 27-34 Nm
FF

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-4
Brake/Two-Speed Manifold Components (to SN 25201)
The brake/two-speed manifold is mounted near the turntable rotator.
Index Schematic
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
1 2 3
JJ KK LL
II
4

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-5
Brake/Two-Speed Manifold Components (from SN 25202)
The brake/two-speed manifold is mounted near the turntable rotator.
Index Schematic
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
1 2
KK LL
II
4
JJ
3

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-6
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor.
Index Schematic
1 Counterbalance valve .................... MM .......... Turntable rotate right ....................... 35-40 ft-lbs / 47-54 Nm
2 Counterbalance valve .................... NN ........... Turntable rotate left .......................... 35-40 ft-lbs / 47-54 Nm
3 Shuttle valve, 2 position 3 way ...... OO ........... Turntable rotation brake release ..... 10-13 ft-lbs / 14-18 Nm
4 Orifice, 0.030 inch / 0.76 mm ......... PP ........... Brake release circuit
(located inside port)
1 2
MM NN
PP
4
OO
3

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-7
Oscillate Directional Valve Components
The oscillate directional valve is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Cap ................................................................... Breather .......................................... 20-25 ft-lbs / 27-33 Nm

2 Spool valve ....................................... JJ .......... Directional control ..........................
3 Relief valve, 800 psi / 55 bar ............ LL ......... Oscillate relief ................................. 30-35 ft-lbs / 41-47 Nm
JJ
2
LL
3

S-60 HC • S-60X • S-60XC
MANIFOLDS
How to Set Up the Oscillate 8 Verify that the ground and drive chassis are
completely level.
Directional Valve
9 Adjust the heim joint until the hole lines up with
Note:Adjustment of the oscillate directional valve the retaining fastener hole in the axle.
linkage is only necessary when the linkage or valve
has been replaced. 10 Install the heim joint to the axle and tighten the
jam nut.
1 Lower the boom to the stowed position.
11 Check to be sure the drive chassis is
2 Use a "bubble type" level to be sure the floor is completely level.
completely level.
12 Measure the distance between the drive chassis
Tip-over hazard. Failure to perform and the non-steer axle on both sides (from the
this procedure on a level floor inside of the drive chassis).
could compromise the stability of
the machine resulting in the Note: If the distance is not equal and the
machine tipping over. adjustment to the linkage was completed with the
ground and drive chassis level, repeat steps 6
3 Check the tire pressure in all four tires and add through 11 OR consult Genie Industries Service
air if needed to meet specification. Department.
Note: The tires on some machines are foam-filled
and do not need air added to them.
4 Remove the drive chassis cover and the non-

steer axle covers.
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
6 Remove the heim joint retaining fastener from
the axle.
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.

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-8
Valve Adjustments - Oscillate
Relief Valve
How to Adjust the Oscillate

Relief Valve Pressure
1 Remove the drive chassis cover from the non-
steer end of the machine.
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.
Move the engine idle toggle switch to the
maintained high idle position.
5 With the engine running in high rpm, manually
activate the valve and observe the pressure
reading on the pressure gauge. Refer to
7 Locate the relief valve on the directional valve
and loosen the jamb nut.
8 Adjust the hex screw. Turn it clockwise to
increase the pressure or counterclockwise to
decrease the pressure. Tighten the jamb nut.
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.

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-9
Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
1 Directional valve ............................ CU ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm
2 Orifice disc, 0.030 inch / 0.080 cm . CV ........... Delays shift to drive
3 Solenoid valve ............................... CW .......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
4 Relief valve .................................... CX ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm
5 Pressure switch 200 psi / 18.6 bar . CZ ........... Generator relay switch ................................ 16 ft-lbs / 22 Nm
6 Connector fitting ...................................................................................................................... 11 ft-lbs / 15 Nm
7 Check valve .................................... CY ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm
CY
7
CU
1
CV
2
CW
3
CX
6 4
CZ
5

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-10
Traction Manifold Components, 2WD
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
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
TT 1
WW 2
VV UU XX SS
6 5 4 3

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-11 9 Adjust the internal hex socket until the pressure

reading on the gauge is 30 psi / 2 bar less than
Valve Adjustments, 2WD the pressure reading on the pump. Turn it
Traction Manifold clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the valve cap.
How to Adjust the Charge
Pressure Relief Valve 10 Repeat steps 7 through 9 until the pressure
reading at the drive manifold is 30 psi / 2 bar
1 Connect a 0 to 600 psi / 0 to 50 bar pressure less than the pressure reading at the pump.
11 Turn the engine off and remove the pressure
2 Hold the charge pressure relief valve and gauge.
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.
6 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the traction manifold.
Press down the foot switch and slowly move the
drive control handle off center just until the
machine begines to move. Note the reading on
the pressure gauge. Turn the machine off.
8 Hold the charge pressure relief valve and
remove the cap (item TT).

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-12
Traction Manifold Components, 4WD (from SN 21001 to 21231)
Index Schematic
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
7 Orifice, 0.040 inch / 1 mm .................. WW ....... Equalizes pressure on both sides
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
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
14 Relief valve, 280 psi / 19.3 bar ......... UU ........ Charge pressure circuit .................... 35-40 ft-lbs / 14-16 Nm

S-60 HC • S-60X • S-60XC
MANIFOLDS
1 2
TT SS
UU
14
XX
13
YY
12
AD
11
AB
3
AF
4
VV
10
ZZ
9
AG
8
WW
7
AE
6
AC

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-13
Traction Manifold Components, 4WD (after SN 21231)
Index Schematic
1 Flow divider/combiner valve ............. XX ......... Controls flow to non-steer end
2 Relief valve, 280 psi / 19.3 bar ......... UU ........ Charge pressure circuit .................... 35-40 ft-lbs / 14-16 Nm
3 Check valve ....................................... TT ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 14-16 Nm
4 Flow divider/combiner valve ............. AB ......... Controls flow to flow
divider/combiner valves
1 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
5 Orifice, 0.040 inch / 1 mm .................. WW ....... Equalizes pressure on both sides
6 Orifice, 0.040 inch / 1 mm .................. AE ......... Equalizes pressure on both sides
7 Orifice, 0.040 inch / 1 mm .................. AC ........ Equalizes pressure on both sides
8 Check valve ....................................... SS ......... Non-steer end drive motor circuit ..... 35-40 ft-lbs / 14-16 Nm
9 Check valve ....................................... AF ......... Non-steer end drive motor circuit ..... 60-70 ft-lbs / 81-95 Nm
10 Check valve ....................................... ZZ ......... Steer end drive motor circuit ............ 35-40 ft-lbs / 14-16 Nm
11 Check valve ....................................... AG ........ Steer end drive motor circuit ............ 60-70 ft-lbs / 81-95 Nm
12 Shuttle valve, 3 position 3 way ......... VV ......... Charge pressure circuit that
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
13 Flow divider/combiner valve ............. AD ........ Controls flow to steer end
14 Check valve ....................................... YY ......... Non-steer end drive motor circuit ..... 35-40 ft-lbs / 14-16 Nm

S-60 HC • S-60X • S-60XC
MANIFOLDS
1 2 3 4
XX UU TT AB
YY
14
AD
13
VV
12
AG
11
10 ZZ
AF
9
SS
8
WW
5
AC AE
7 6

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-14 9 Adjust the internal hex socket until the pressure

reading on the gauge is 30 psi / 2 bar less than
Valve Adjustments, 4WD the pressure reading on the pump. Turn it
Traction Manifold clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the valve cap.
How to Adjust the Charge
Pressure Relief Valve 10 Repeat steps 7 through 9 until the pressure
reading at the drive manifold is 30 psi / 2 bar
1 Connect a 0 to 600 psi / 0 to 50 bar pressure less than the pressure reading at the pump.
11 Turn the engine off and remove the pressure
2 Hold the charge pressure relief valve and gauge.
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.
6 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the traction manifold.
Press down the foot switch and slowly move the
drive control handle off center just until the
machine begines to move. Note the reading on
the pressure gauge. Turn the machine off.
8 Hold the charge pressure relief valve and
remove the cap (item UU).

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-15
Hydraulic Generator Manifold Components, 3kW (after SN 21396)
The generator manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
1 Proportional solenoid valve ................. HH ........ Generator speed ........................... 33-37 ft-lbs / 45-50 Nm
2 Relief valve, 2700 psi / 186 bar ........... GG ........ Generator circuit ........................... 20-25 ft-lbs / 27-34 Nm
HH
1
GG
2

S-60 HC • S-60X • S-60XC
MANIFOLDS
7-16 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromotive force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / 10°C
within the coil. Zero resistance indicates the coil that your air temperature increases or decreases
has failed. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Valve Coil Resistance Specification

resistance values outside specification can produce
erratic operation. When coil resistance decreases Description Specification
below specification, amperage increases. As
resistance rises above specification, voltage Solenoid valve, 3 position 4 way, 10V DC 5 to 7Ω
increases. (schematic items D, V and Y)
While valves may operate when coil resistance is Solenoid valve, 3 position 4 way, 10V DC 4 to 6Ω
outside specification, maintaining coils within (schematic item BB)
specification will help ensure proper valve function
over a wide range of operating temperatures. Solenoid valve, 2 position 3 way, 10V DC 5 to 7Ω
(schematic items B, C, E, F and FF)
with electrically charged circuits Solenoid valve, 2 position 3 way, 10V DC 5.5 to 7.5Ω
could result in death or serious (schematic items KK and LL)
and other jewelry. Proportional solenoid valve, 12V DC 4 to 6Ω
(schematic items M and T)
1 Tag and disconnect the wiring from the coil to be
tested. Proportional solenoid valve, 12V DC 3.7 to 5.7Ω
2 Test the coil resistance. (schematic item Q)
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.

S-60 HC • S-60X • S-60XC
MANIFOLDS
How to Test a Coil Diode

a
Genie incorporates spike suppressing diodes in all COIL AMMETER
of its directional valve coils except proportional d

valves and those coils with a metal case. Properly
functioning coil diodes protect the electrical circuit
by suppressing voltage spikes. Voltage spikes c - b
naturally occur within a function circuit following the
+
interruption of electrical current to a coil. Faulty
10 W 9V
diodes can fail to protect the electrical system, RESISTOR BATTERY
resulting in a tripped circuit breaker or component
c
damage. b
+
Electrocution/burn hazard. Contact -
with electrically charged circuits a multimeter
b 9V DC battery
c 10Ω resistor
injury. Remove all rings, watches d coil
and other jewelry.
Note: Dotted lines in illustration indicate a
1 Test the coil for resistance. See, How to Test a reversed connection as specified in
Coil. step 6
2 Connect a 10Ω resistor to the negative terminal 3 Set a multimeter to read DC current.
of a known good 9V DC battery. Connect the Note: The multimeter, when set to read DC current,
other end of the resistor to a terminal on the should be capable of reading up to 800 mA.
coil.
4 Connect the negative lead to the other terminal
Ω
Resistor, 10Ω on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
Note: The battery should read 9V DC or more when
measured across the terminals. 5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
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.

S-60 HC • S-60X • S-60XC
Turntable Rotation Components

8-1 3 Loosen the backlash pivot plate and adjustment
bolts.
Turntable Rotation Assembly
How to Remove the Turntable

Rotation Assembly
Specifications.
firm and level surface.
1 Secure the turntable from rotating with the

turntable rotation lock pin. a b c
Note: The turntable rotation lock pin is located next a backlash pivot plate
to the boom rest pad. b adjustment bolt with lock nut
c backlash pivot plate mounting bolts
from the turntable rotation drive motor. Cap the 4 Attach a suitable lifting device to the lifting eyes
fittings on the drive motor. on the drive hub assembly.
Bodily injury hazard. Spraying 5 Remove the backlash pivot plate mounting
hydraulic oil can penetrate and bolts. Carefully remove the drive hub assembly
burn skin. Loosen hydraulic from the machine.
Crushing hazard. The turntable
could rotate unexpectedly when
gradually. Do not allow oil to squirt
the rotation drive hub assembly is
or spray.
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.

S-60 HC • S-60X • S-60XC
TURNTABLE ROTATION COMPONENTS
When installing the drive hub assembly: 2 Loosen the backlash pivot plate mounting
fasteners.
6 Install the drive hub. Torque the back lash pivot
plate to specification. Refer to Section 2,
Specifications.
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.
Note: Perform this procedure with the boom

between the non-steer end tires and with the a b c
machine on a firm and level surface.
1 Secure the turntable from rotating with the a backlash pivot plate
b adjustment bolt with lock nut
turntable rotation lock pin. c backlash pivot plate mounting bolts
Note: The turntable rotation lock pin is located next 3 Push the backlash pivot plate towards the
to the boom rest pad. turntable as far as possible (this will push the
rotation gear into the turntable bearing ring
gear).
4 Loosen the lock nut on the adjustment bolt.
5 Turn the adjustment bolt clockwise until it
contacts the backlash pivot plate.
6 Turn the adjustment bolt 1/2 turn
counterclockwise. Tighten the lock nut on the
adjustment bolt.
7 Rotate the backlash pivot plate away from the
turntable until it contacts the adjustment bolt.
Then torque the mounting fasteners on the
backlash pivot plate to specification. Refer to
8 Rotate the turntable through an entire rotation.
Check for tight spots that could cause binding.
Readjust if necessary.

S-60 HC • S-60X • S-60XC
Axle Components
9-1 3 Remove the pin retaining fasteners from the rod-
end pivot pin. Use a soft metal drift to remove
Oscillating Axle Cylinders the pin.
The oscillating axle cylinders extend and retract 4 Attach a lifting strap from an overhead crane to
between the drive chassis and the axle to maintain the barrel end of the oscillating cylinder.
a level chassis while driving over uneven terrain. 5 Remove the pin retaining fasteners from the
The cylinders are equipped with counterbalance barrel-end pivot pin. Use a soft metal drift to
valves to prevent movement in the event of a remove the pin.
hydraulic hose failure.
6 Remove the cylinder from the machine.
How to Remove an Oscillate Crushing hazard. The oscillate
Axle Cylinder cylinder could become unbalanced
and fall if not properly attached to
Note: Perform this procedure on firm, level surface the overhead crane when removed
with the boom in the stowed position. from the machine.
Specifications.
1 Rotate the turntable until the boom is between
the steer tires or tracks.
2 Tag, disconnect and plug the oscillating axle
cylinder.
or spray.

S-60 HC • S-60X • S-60XC
Track Components
10-1 How to Replace the Track
Track Assembly, 1 Remove the track assembly from the machine.
S-60 TRAX and S-65 TRAX See How to Remove a Track Assembly.
Note: The sprocket is comprised of two halves.
How to Remove a Track Before removing the track assembly from the
Assembly machine and to ease the removal of the sprocket,
drive the machine until one complete half of the
Note: Perform this procedure on a firm, level sprocket is located above the undercarriage of the
surface with the boom in the stowed position. track assembly.
1 Select a track assembly to remove. Loosen and 2 Loosen the grease plug on the track tension
remove as many sprocket retaining fasteners as cylinder to relieve the track tension. Clean up
possible from the hub adapter. any grease that has spilled.
2 Drive the machine in either direction just enough 3 Remove the 2 sprocket retaining fasteners.
to access the remaining fasteners. Do not Remove the sprocket half from the track
remove the retaining fasteners. assembly.
3 Chock the tracks at the opposite end of the 4 Carefully remove the track from the
machine to prevent the machine from rolling. undercarriage.
4 Center a lifting jack of ample capacity 5 Use an overhead crane to lay the undercarriage
(20,000 lbs / 10,000 kg) under the drive chassis on its side with the drive sprocket bearing
between the tracks. assembly facing upward and the track tension
cylinder towards the ground.
drive chassis for support.
the sprocket.
fasteners from the hub adapter.
8 Carefully remove the track assembly from the

S-60 HC • S-60X • S-60XC
TRACK COMPONENTS
6 Install the new track onto the undercarriage. 9 Rotate the sprocket half until the split tooth of
the sprocket is lower than the other side.
the center-point of the track, above the a
sprocket.
8 Use the overhead crane to raise the track
assembly to an upright position. Rest the
assembly on the floor or ground to remove any
slack in the lower portion of the track.
Note: Be sure the idler and bogey wheels are
aligned with the inside surface of the track.
a split tooth
10 Using an overhead crane or other suitable lifting

device, lift up on the rubber track to create
enough room to install the other sprocket half.
11 Install the sprocket half, removed in step 3,
while engaging the sprocket teeth with the
rubber track.
a b a
Note: Be sure to align the split tooth in both of the
a idler wheels sprocket halves.
b bogey wheels
12 Insert a pin or rod through the wheel stud hole
closest to the split tooth to hold the sprocket in
place.
13 Insert a pointed pry bar into the wheel stud hole
near the top of the sprocket. Insert another
pointed pry bar into the wheel stud hole at the
opposite side of the split tooth.

S-60 HC • S-60X • S-60XC
TRACK COMPONENTS
14 Using the pry bars, lift the sprocket half into 19 Pump grease into the grease zerk fitting until
position. Install the 2 sprocket retaining grease, free from air, comes out of the grease
fasteners and torque to specification. Refer to plug. Securely tighten the grease plug. Do not
Section 2, Specifications. overtighten.
15 Attach a lifting strap from an overhead crane to 20 Continue to pump grease into the grease fitting
the center-point of the track assembly, above just until the idler wheel moves. Check the track
the sprocket. tension.
16 Install the track assembly onto the drive hub Result: There should be less than 1 inch /
adapter while guiding the hub adapter studs into 2.5 cm of gap between the bogey wheels and
the sprocket of the track assembly. Install as the inside surface of the track.
many sprocket retaining fasteners as possible Proceed to step 22.
Result: There is 1 inch / 2.5 cm or more of gap
between the bogey wheels and the inside
Crushing hazard. The track surface of the track. Proceed to step 21.
unbalanced and fall when installed
onto the machine if not properly
17 Adjust the track tension. Locate the grease plug
on the track tension cylinder. Loosen the plug,
but do not remove it.
18 Locate the grease zerk fitting on the other side
of the track tension cylinder.
Outside Inside
a bogey wheels
a b
a grease zerk
b grease plug

S-60 HC • S-60X • S-60XC
TRACK COMPONENTS
21 Continue to pump grease into the cylinder until

the track has proper tension.
Do not over tighten the track.
Overtightening the track will cause
the machine to lose power during
operation.
Note: If the track becomes too tight, loosen the
grease plug on the cylinder to remove grease and
loosen the track.

lower the machine.
machine off.

or equivalent.

S-60 HC • S-60X • S-60XC
December 2013 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions in the appropriate
operator's manual on your machine before
attempting any maintenance or repair procedure.
Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
Troubleshooting and repair procedures shall be Read each appropriate fault code thoroughly.
completed by a person trained and qualified on Attempting shortcuts may produce hazardous
the repair of this machine. conditions.
Immediately tag and remove from service a Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
Repair any machine damage or malfunction Electrocution/burn hazard. Contact
before operating the machine. with electrically charged circuits
Unless otherwise specified, perform each repair injury. Remove all rings, watches
procedure with the machine in the following and other jewelry.
configuration:
Note: Two persons will be required to safely
• Machine parked on a firm, level surface perform some troubleshooting procedures.
• Boom in stowed position
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Welder disconnected from the machine (if
equipped with the weld cable to platform
option)
• Wheels chocked
• All external AC power disconnected from the
machine
S-60 HC • S-60X • S-60XC
Section 5 • Fault Codes December 2013
Control System Fault Codes
Control System 3 Determine the error source: The red LED

indicates the error source and will flash two
separate codes. The first code will indicate the
How to Retrieve Control System first digit of the two digit code, flashing once per
Fault Codes second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Note: At least one fault code is present when the
alarm at the platform controls produces two short Note: When the red LED is flashing the code, the
beeps every 30 seconds for 10 minutes. yellow LED will be on solid.
Note: Perform this procedure with the engine off, 4 Determine the error type: The yellow LED
the key switch turned to platform controls and both indicates the error type and will flash two
red Emergency Stop button pulled out to the on separate codes. The first code will indicate the
position at both the ground and platform controls. first digit of the two digit code, flashing once per
second. It will then pause for 1.5 seconds and
1 Open the platform control box lid. flash the second digit once per 0.5 second.
Electrocution/burn hazard. Contact Note: When the yellow LED is flashing the code,
with electrically charged circuits the red LED will be on solid.
injury. Remove all rings, watches 5 Use the fault code table on the following pages
and other jewelry. to aid in troubleshooting the machine by
pinpointing the area or component affected.
2 Locate the red and yellow fault LEDs on the
ALC-500 circuit board inside the platform control
box. Do not touch the circuit board.
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.
S-60 HC • S-60X • S-60XC
Error Source Error Type Condition Solution

ID Name ID Name
21 Primary Up / Down 11 Value at 5V Function is Cycle power off,

Joystick 12 Value too high inoperative. then on after
15 Value too low Alarm sounds problem has been
16 Value at 0V indicating a fault. corrected.
17 Not calibrated Calibrate joystick.
22 Primary 21 Fault Valve is operating Cycle power off,

Up / Down outside of limits. then on after
Directional Alarm sounds problem has been
Valves indicating a fault. corrected.
23 Primary 12 Value too high Valve is operating Cycle power off,

Up / Down 15 Value too low outside of limits. then on after
Flow Valve Alarm sounds problem has been
indicating a fault. corrected.
17 Not calibrated Normal function Calibrate valve

except threshold threshold.
for one or both
directions is zero.
24 Angle sensor 11 Value at 5V Reduced speed Cycle power off,

12 Value too high function. then on after
15 Value too low Alarm sounds problem has been
17 Not calibrated Calibrate angle sensor.
31 Invalid setup Initiate 1 -second Calibrate angle sensor.

beep of Alarm Buzzer
and required retract
into safe envelope
S-60 HC • S-60X • S-60XC

ID Name ID Name
26 Angle sensor 19 Out of range Reduced speed, Power up controller with

cross check required retract into problem corrected
safe envelope
31 Primary 11 Value at 5V Function is Cycle power off,

Ext. / Ret. 12 Value too high inoperative. then on after
Joystick 15 Value too low Alarm sounds problem has been
32 Primary 21 Fault Valve is operating Cycle power off,

Ext. / Ret. outside of limits. then on after
Directional Alarm sounds problem has been
Valves indicating a fault. corrected.
33 Primary 12 Value too high Valve is operating Cycle power off,

Ext. / Ret. 15 Value too low outside of limits. then on after
Flow Valve Alarm sounds problem has been

for one or both
directions is zero.
34 Ext. Ret. 31 Invalid setup Initiate 1-second beep Fully retract, then lower
Limit Switch of Alarm Buzzer boom
-1000lb. Mode: Check and service ext/

Required retract into ret and fully stowed
“FULLY RETRACTED” switches
state before lowering
-500lb. Mode:
Operates normally
S-60 HC • S-60X • S-60XC

ID Name ID Name
41 Turntable 11 Value at 5V Limited speed Cycle power off,

Rotate 12 Value too high and direction then on after
Joystick 15 Value too low frozen at zero problem has been
16 Value at 0V and neutral. corrected.
Alarm sounds
indicating a fault.
42 Turntable 21 Fault Limited direction. Cycle power off,

Rotate Frozen at zero then on after
Directional and neutral. problem has been
Valves Alarm sounds corrected.
indicating a fault.
43 Turntable 12 Value too high Limited speed Cycle power off,

Rotate 15 Value too low and direction. then on after
Flow Valve Frozen at zero problem has been
and neutral. corrected.
Alarm sounds
indicating a fault.

for one or both
directions is zero.
44 Drive Enable 21 Fault Drive enable Cycle power off,

Override override direction then on after
Switch is frozen at problem has been
neutral. corrected.
S-60 HC • S-60X • S-60XC

ID Name ID Name
45 Platform Level Switch 21 Fault Platform level Power up controller with

frozen at neutral problem corrected
46 Primary Extend/Retract 21 Fault Platform Ext/Ret Power up controller with

Switch frozen at neutral problem corrected
51 Drive Joystick 11 Value at 5V Limited speed Cycle power off,

12 Value too high and direction. then on after
15 Value too low Frozen at zero problem has been
Alarm sounds
indicating a fault.
53 Drive Flow 12 Value too high Limited speed Cycle power off,
Valve (EDC) 15 Value too low and direction. then on after
Frozen at zero problem has been
Alarm sounds
indicating a fault.

for one or both
directions is zero.
S-60 HC • S-60X • S-60XC

ID Name ID Name
54 Drive Brake 21 Fault Drive frozen Cycle power off,

Valve at zero and then on after
neutral. problem has been
Alarm sounds corrected.
indicating a fault.
55 High Drive 21 Fault Motor speed Cycle power off,

Motor Speed in the low state. then on after
Valve Alarm sounds problem has been
56 Platform Level Value 21 Fault Direction frozen at Power up controller with

zero and neutral, AB problem corrected
57 Foot switch/ECU 12 Value too high Direction frozen at Power up controller with
Power Crosscheck 15 Value too low zero and neutral, AB problem corrected
61 Steer Joystick 11 Value at 5V Limited speed Cycle power off,

12 Value too high and direction. then on after
15 Value too low Frozen at zero problem has been
Alarm sounds
indicating a fault.
62 Steer 21 Fault Limited speed Cycle power off,

Directional and direction. then on after
Valve Frozen at zero problem has been
Alarm sounds
indicating a fault.
S-60 HC • S-60X • S-60XC
Ford DSG-423 EFI Engine Fault Codes
Ford DSG-423 EFI Engine Note: Before the fault codes are displayed, the
check engine light will blink a code 1-2-3 three
times. After the fault codes, the check engine light
How to Retrieve Ford Engine will blink a code 1-2-3 three times again indicating
Fault Codes the end of the stored codes.
The ECM constantly monitors the engine by the Note: If any fault codes are present, the ECM will
use of sensors on the engine. The ECM also uses blink a three digit code three times for each code
signals from the sensors to initiate sequential fuel stored in memory. It will blink the first digit of a
injection and make constant and instantaneous three digit code, pause, blink the second digit,
changes to ignition timing, fuel delivery and throttle pause, and then blink the third digit. For example:
position to maintain the engine's running condition the check engine light blinks 5 consecutive times,
at its highest efficiency while at the same time blinks 3 times and then 1 time. That would indicate
keeping exhaust emissions to a minimum. When a code 531.
set parameters, the ECM will store a fault code in Note: Once a fault code has been retrieved and the
memory that relates to the appropriate sensor and repair has been completed, the ECM memory must
will turn on the Check Engine Light. be reset to clear the fault code from the ECM. See
How to Clear Engine Fault Codes from the ECM.
Note: Perform this procedure with the key switch in
the off position. How to Clear Engine Fault
1 Open the ground controls side cover and locate Codes from the ECM
the run/test toggle switch on the side of the Note: Perform this procedure with the engine off
ground control box. and the key switch in the off position.
2 Pull out the red Emergency Stop button to the 1 Open the engine side turntable cover and locate
on position at both the ground and platform the battery.
controls.
2 Disconnect the negative battery cable from the
3 Move and hold the run/test toggle switch to the
battery for a minimum of 5 minutes.
test position.
Result: The check engine light should turn on.
The check engine light should begin to blink.
4 Continue to hold the run/test toggle switch in the injury. Remove all rings, watches
test position and count the blinks. and other jewelry.
3 Connect the negative battery cable to the
battery.
S-60 HC • S-60X • S-60XC
Code Description Code Description

11 Intake cam / distributor position 171 AL high gasoline bank1
16 Never crank synced at start 172 AL low gasoline bank1
24 Exhaust cam position 174 AL high gasoline bank2
91 FP low voltage 175 AL low gasoline bank2
92 FP high voltage 182 FT Gasoline Low Voltage
107 MAP Low Voltage 183 FT Gasoline High Voltage
108 MAP High Pressure 187 FT Gaseaous fuel low voltage
111 IAT higher than expected 1 188 FT Gaseaous fuel high voltage
112 IAT low voltage 217 ECT higher than expected 2
113 IAT high voltage 219 Max govern speed override
116 ECT higher than expected 1 221 TPS1 higher than TPS2
117 ECT/CHT Low Voltage 222 TPS2 low voltage
118 ECT/CHT High Voltage 223 TPS2 high voltage
121 TPS1 lower than TPS2 236 TIP Active
122 TPS1 low voltage 237 TIP Low Voltage
123 TPS1 high voltage 238 TIP High Voltage
127 IAT higher than expected 2 261 Injector Loop Open or Low-side
short to Ground
129 BP low pressure
262 Injector Coil Shorted
134 EGO open/lazy pre-cat 1
264 Injector Loop Open or Low-side
140 EGO open/lazy post-cat 1 short to Ground
154 EGO open/lazy pre-cat 2/post-cat 1 265 Injector Coil Shorted
160 EGO open/lazy post-cat 2 267 Injector Loop Open or Low-side
short to Ground
Code Description
For further engine fault code troubleshooting and

diagnostic information, refer to the Ford MSG-425/
Ford DSG-423 EFI Diagnostic Manual (EDI part
number 1080030).
Ford MSG-425/DSG-423 EFI Diagnostic Manual

S-60 HC • S-60X • S-60XC
268 Injector Coil Shorted 304 Emissions/catalyst damaging misfire

270 Injector Loop Open or Low-side 305 Emissions/catalyst damaging misfire
short to Ground
306 Emissions/catalyst damaging misfire
short to Ground
326 Knock 1 Excessive Signal
276 Injector Loop Open or Low-side 327 Knock 1 sensor Open
short to Ground 331 Knock 2 Excessive Signal
277 Injector Coil Shorted 332 Knock 2 sensor Open
279 Injector Loop Open or Low-side 336 Crank sync noise
short to Ground
337 Crank loss
341 Cam sync noise
short to Ground 342 Cam loss
283 Injector Coil Shorted 420 Gasoline cat monitor
285 Injector Loop Open or Low-side 430 Gasoline cat monitor

short to Ground 524 Oil pressure low
286 Injector Coil Shorted 562 Battery Voltage Low
288 Injector Loop Open or Low-side 563 Battery Voltage High
short to Ground
601 Flash checksum invalid
604 RAM failure
606 COP failure
615 Start relay coil open
Code Description
Code Description

number 1080030).


S-60 HC • S-60X • S-60XC
616 Start relay control ground short 1154 CL low NG

617 Start relay coil short to power 1155 CL high gasoline bank1
627 Fpump relay coil open 1156 CL low gasoline bank1
628 FPump motor loop open or 1157 CL high gasoline bank2
high-side shorted to ground
1158 CL low gasoline bank2
628 Fpump relay control ground short
1161 AL high LPG
629 FPump motor high-side shorted to power
1162 AL low LPG
629 Fpump relay coil short to power
1163 AL high NG
642 5VE1 low voltage
1164 AL low NG
643 5VE1 high voltage
1165 LPG cat monitor
650 MIL open
1166 NG cat monitor
652 5VE2 low voltage
1171 Megajector delivery pressure
653 5VE2 high voltage higher than expected
685 Relay Coil Open 1172 Megajector delivery pressure
lower than expected
686 Relay Control ground short
1173 Megajector comm lost
687 Relay coil short to power
1174 Megajector voltage supply high
1111 Fuel rev limit
1175 Megajector voltage supply low
1112 Spark rev limit
1176 Megajector internal actuator fault detection
1121 FPP1/2 simultaneous voltages out of range
1177 Megajector internal circuitry fault detection
1122 FPP1/2 do not match each other or the IVS
1178 Megajector internal comm fault detection
1151 CL high LPG
1181 Fuel run-out longer than expected
1152 CL low LPG
1153 CL high NG
Code Description
Code Description

number 1080030).


S-60 HC • S-60X • S-60XC
1182 Fuel impurity level high 1543 AUX analog PUD2 high
1183 Megajector autozero / lockoff failed 1544 AUX analog PUD2 low
1311 Misfire detected 1545 AUX analog PUD3 high
1312 Misfire detected 1546 AUX analog PUD3 low
1313 Misfire detected 1547 AUX analog PUD4 high
1314 Misfire detected 1548 AUX analog PUD4 low
1315 Misfire detected 1551 AUX DIG1 high
1316 Misfire detected 1552 AUX DIG1 low
1317 Misfire detected 1553 AUX DIG2 high
1318 Misfire detected 1554 AUX DIG2 low
1511 AUX analog PU1 high 1555 AUX DIG3 high
1512 AUX analog PU1 low 1556 AUX DIG3 low
1513 AUX analog PU2 high 1561 AUX analog PD2 high
1514 AUX analog PU2 low 1562 AUX analog PD2 low
1515 AUX analog PD1 high 1563 AUX analog PD3 high
1516 AUX analog PD1 low 1564 AUX analog PD3 low
1517 AUX analog PU3 high 1611 5VE 1/2 simultaneous out-of-range
1518 AUX analog PU3 low 1612 RTI 1 loss
1521 CHT higher than expected 1 1613 RTI 2 loss
1522 CHT higher than expected 2 1614 RTI 3 loss
1531 IVS/Brake/Trans-Park interlock failure 1615 A/D loss
1541 AUX analog PUD1 high 1616 Invalid interrupt
1542 AUX analog PUD1 low
Code Description
Code Description

number 1080030).


S-60 HC • S-60X • S-60XC
1621 Rx Inactive 1644 MIL control ground short

1622 Rx Noise 1645 MIL control short to power
1623 Invalid Packet Format 1661 PWM6 open / ground short
1624 Shutdown Request 1662 PWM6 short to power
1625 Shutdown Request 1663 PWM7 open / ground short
1626 CAN Tx failure 1664 PWM7 short to power
1627 CAN Rx failure 1665 PWM8 open / ground short
1628 CAN addresss conflict failure 1666 PWM8 short to power
1629 J1939 TSC1 message receipt lost 1669 PWM9 open / ground short
1630 J1939 ETC message receipt lost 1670 PWM9 short to power
1631 PWM1-Gauge1 open / ground short 2111 Unable to reach lower TPS
1632 PWM1-Gauge1 short to power 2112 Unable to reach higher TPS
1633 PWM2-Gauge2 open /ground short 2115 FPP1 higher than IVS limit
1634 PWM2-Gauge2 short to power 2116 FPP2 higher than IVS limit
1635 PWM3-Gauge3 open / ground short 2120 FPP1 invalid voltage and
FPP2 disagrees with IVS
1636 PWM3-Gauge3 short to power
2121 FPP1 lower than FPP2
1637 PWM4 open / ground short
2122 FPP1 high voltage
1638 PWM4 short to power
2123 FPP1 low voltage
1639 PWM5 open / ground short
2125 FPP2 invalid voltage and
1640 PWM5 short to power FPP1 disagrees with IVS
1641 Buzzer control ground short 2126 FPP1 higher than FPP2
1642 Buzzer open 2127 FPP2 low voltage
1643 Buzzer control short to power
Code Description
Code Description

number 1080030).


S-60 HC • S-60X • S-60XC
2128 FPP2 high voltage 2316 Primary Coil Shorted

2130 IVS stuck at-idle, FPP1/2 match 2318 Primary Loop Open or Low-side
Short to Ground
2131 IVS stuck off-idle, FPP1/2 match
2319 Primary Coil Shorted
2135 TPS1/2 simultaneous voltages out of range
2321 Primary Loop Open or Low-side
2139 FPP1 lower than IVS limit
Short to Ground
2229 BP high pressure 2324 Primary Loop Open or Lowside
2300 Primary Loop Open or Low-side Short to Ground
Short to Ground
2303 Primary Loop Open or Low-side Short to Ground
Short to Ground 2328 Primary Coil Shorted
2304 Primary Coil Shorted 2618 Tach output ground short
2619 Tach output short to power
Short to Ground
Short to Ground
Short to Ground
Short to Ground
Code Description

number 1080030).


S-60 HC • S-60X • S-60XC
Ford MSG-425 EFI Engine Fault Codes
Ford MSG-425 EFI Engine Note: Before the fault codes are displayed, the
check engine light will blink a code 1-6-5-4 three
times. After the fault codes, the check engine light
How to Retrieve Ford Engine will blink a code 1-6-5-4 three times again indicating
Fault Codes the end of the stored codes.
The ECM constantly monitors the engine by the Note: If any fault codes are present, the ECM will
use of sensors on the engine. The ECM also uses blink a three digit code three times for each code
signals from the sensors to initiate sequential fuel stored in memory. It will blink the first digit of a
injection and make constant and instantaneous three digit code, pause, blink the second digit,
changes to ignition timing, fuel delivery and throttle pause, and then blink the third digit. For example:
position to maintain the engine's running condition the check engine light blinks 5 consecutive times,
at its highest efficiency while at the same time blinks 3 times and then 1 time. That would indicate
keeping exhaust emissions to a minimum. When a code 531.
set parameters, the ECM will store a fault code in Note: Once a fault code has been retrieved and the
memory that relates to the appropriate sensor and repair has been completed, the ECM memory must
will turn on the Check Engine Light. be reset to clear the fault code from the ECM. See
How to Clear Engine Fault Codes from the ECM.
Note: Perform this procedure with the key switch in
the off position. How to Clear Engine Fault
1 Open the ground controls side cover and locate Codes from the ECM
the run/test toggle switch on the side of the Note: Perform this procedure with the engine off
ground control box. and the key switch in the off position.
2 Pull out the red Emergency Stop button to the 1 Open the engine side turntable cover and locate
on position at both the ground and platform the battery.
controls.
2 Disconnect the negative battery cable from the
3 Move and hold the run/test toggle switch to the
battery for a minimum of 5 minutes.
test position.
Result: The check engine light should turn on.
The check engine light should begin to blink.
4 Continue to hold the run/test toggle switch in the injury. Remove all rings, watches
test position and count the blinks. and other jewelry.
3 Connect the negative battery cable to the
battery.

S-60 HC • S-60X • S-60XC

16 Never crank synced at start 182 FT Gasoline Low Voltage
91 FP low voltage 183 FT Gasoline High Voltage
92 FP high voltage 187 FT Gaseaous fuel low voltage
107 MAP Low Voltage 188 FT Gaseaous fuel high voltage
108 MAP High Pressure 217 ECT higher than expected 2
111 IAT higher than expected 1 219 Max govern speed override
112 IAT low voltage 221 TPS1 higher than TPS2
113 IAT high voltage 222 TPS2 low voltage
116 ECT higher than expected 1 223 TPS2 high voltage
117 ECT/CHT Low Voltage 236 TIP Active
118 ECT/CHT High Voltage 237 TIP Low Voltage
121 TPS1 lower than TPS2 238 TIP High Voltage
122 TPS1 low voltage 261 Injector Loop Open or Low-side
short to Ground
123 TPS1 high voltage
127 IAT higher than expected 2
129 BP low pressure
short to Ground
134 EGO open/lazy pre-cat 1
140 EGO open/lazy post-cat 1
154 EGO open/lazy pre-cat 2/post-cat 1 short to Ground
160 EGO open/lazy post-cat 2 268 Injector Coil Shorted
171 AL high gasoline bank1 270 Injector Loop Open or Low-side
short to Ground
172 AL low gasoline bank1
174 AL high gasoline bank2
175 AL low gasoline bank2 short to Ground

number 1080030).


S-60 HC • S-60X • S-60XC

274 Injector Coil Shorted 326 Knock 1 Excessive Signal
276 Injector Loop Open or Low-side 327 Knock 1 sensor Open
short to Ground
331 Knock 2 Excessive Signal
332 Knock 2 sensor Open
336 Crank sync noise
short to Ground
280 Injector Coil Shorted 337 Crank loss
282 Injector Loop Open or Low-side 341 Cam sync noise

short to Ground 342 Cam loss
283 Injector Coil Shorted 420 Gasoline cat monitor
285 Injector Loop Open or Low-side 430 Gasoline cat monitor
short to Ground
524 Oil pressure low
562 Battery Voltage Low
short to Ground 563 Battery Voltage High
289 Injector Coil Shorted 601 Flash checksum invalid
301 Emissions/catalyst damaging misfire 604 RAM failure
302 Emissions/catalyst damaging misfire 606 COP failure
303 Emissions/catalyst damaging misfire 615 Start relay coil open
304 Emissions/catalyst damaging misfire 616 Start relay control ground short
305 Emissions/catalyst damaging misfire 617 Start relay coil short to power
306 Emissions/catalyst damaging misfire 627 Fpump relay coil open
307 Emissions/catalyst damaging misfire 628 FPump motor loop open or

high-side shorted to ground
628 Fpump relay control ground short
629 FPump motor high-side shorted to power

number 1080030).


S-60 HC • S-60X • S-60XC

629 Fpump relay coil short to power 1163 AL high NG
642 5VE1 low voltage 1164 AL low NG
643 5VE1 high voltage 1165 LPG cat monitor
650 MIL open 1166 NG cat monitor
652 5VE2 low voltage 1171 Megajector delivery pressure
higher than expected
653 5VE2 high voltage
1172 Megajector delivery pressure
685 Relay Coil Open lower than expected
686 Relay Control ground short 1173 Megajector comm lost
687 Relay coil short to power 1174 Megajector voltage supply high
1111 Fuel rev limit 1175 Megajector voltage supply low
1112 Spark rev limit 1176 Megajector internal actuator fault detection
1121 FPP1/2 simultaneous voltages out of range 1177 Megajector internal circuitry fault detection
1122 FPP1/2 do not match each other or the IVS 1178 Megajector internal comm fault detection
1151 CL high LPG 1311 Misfire detected
1152 CL low LPG 1312 Misfire detected
1153 CL high NG
1313 Misfire detected
1154 CL low NG
1155 CL high gasoline bank1
1156 CL low gasoline bank1 1316 Misfire detected
1157 CL high gasoline bank2 1317 Misfire detected
1158 CL low gasoline bank2 1318 Misfire detected
1161 AL high LPG 1511 AUX analog PU1 high
1162 AL low LPG 1512 AUX analog PU1 low

number 1080030).


S-60 HC • S-60X • S-60XC

1513 AUX analog PU2 high 1564 AUX analog PD3 low
1514 AUX analog PU2 low 1611 5VE 1/2 simultaneous out-of-range
1515 AUX analog PD1 high 1612 RTI 1 loss
1516 AUX analog PD1 low 1613 RTI 2 loss
1517 AUX analog PU3 high 1614 RTI 3 loss
1518 AUX analog PU3 low 1615 A/D loss
1521 CHT higher than expected 1 1616 Invalid interrupt
1522 CHT higher than expected 2 1621 Rx Inactive
1531 IVS/Brake/Trans-Park interlock failure 1622 Rx Noise
1541 AUX analog PUD1 high 1623 Invalid Packet Format
1542 AUX analog PUD1 low 1624 Shutdown Request
1543 AUX analog PUD2 high 1625 Shutdown Request
1544 AUX analog PUD2 low 1626 CAN Tx failure
1545 AUX analog PUD3 high 1627 CAN Rx failure
1551 AUX DIG1 high 1628 CAN addresss conflict failure
1552 AUX DIG1 low 1629 J1939 TSC1 message receipt lost
1553 AUX DIG2 high 1630 J1939 ETC message receipt lost
1554 AUX DIG2 low 1631 PWM1-Gauge1 open / ground short
1555 AUX DIG3 high 1632 PWM1-Gauge1 short to power
1556 AUX DIG3 low 1633 PWM2-Gauge2 open /ground short
1561 AUX analog PD2 high 1634 PWM2-Gauge2 short to power
1562 AUX analog PD2 low 1635 PWM3-Gauge3 open / ground short
1563 AUX analog PD3 high 1636 PWM3-Gauge3 short to power

number 1080030).


S-60 HC • S-60X • S-60XC

Code Description
1641 Buzzer control ground short Code Description
1642 Buzzer open 2229 BP high pressure
1643 Buzzer control short to power 2300 Primary Loop Open or Low-side
Short to Ground
1644 MIL control ground short
1645 MIL control short to power
2111 Unable to reach lower TPS Short to Ground
2112 Unable to reach higher TPS 2304 Primary Coil Shorted
2115 FPP1 higher than IVS limit 2306 Primary Loop Open or Low-side
2116 FPP2 higher than IVS limit Short to Ground
2120 FPP1 invalid voltage and 2307 Primary Coil Shorted
FPP2 disagrees with IVS 2309 Primary Loop Open or Low-side
2121 FPP1 lower than FPP2 Short to Ground
2122 FPP1 high voltage 2310 Primary Coil Shorted
2123 FPP1 low voltage 2312 Primary Loop Open or Low-side
Short to Ground
2125 FPP2 invalid voltage and
FPP1 disagrees with IVS 2313 Primary Coil Shorted
2126 FPP1 higher than FPP2 2315 Primary Loop Open or Low-side
Short to Ground
2127 FPP2 low voltage
2128 FPP2 high voltage
2130 IVS stuck at-idle, FPP1/2 match Short to Ground
2131 IVS stuck off-idle, FPP1/2 match 2319 Primary Coil Shorted
2135 TPS1/2 simultaneous voltages out of range 2321 Primary Loop Open or Low-side
2139 FPP1 lower than IVS limit Short to Ground
2618 Tach output ground short
2619 Tach output short to power
number 1080030).


S-60 HC • S-60X • S-60XC
Load Sense System Fault Codes
Platform Load Sense System, 4 Determine the error source: The red LED
indicates the error source and will flash two
S-60 HC separate codes. The first code will indicate the
first digit of the two digit code, flashing once per
How to Retrieve Platform Load second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Sense System Fault Codes
5 Determine the error type: The green LED
Note: Perform this procedure with the engine off,
indicates the error type and will flash two
the key switch turned to ground controls and the
separate codes. The first code will indicate the
red Emergency Stop buttons pulled out to the on
first digit of the two digit code, flashing once per
position at both the ground and platform controls.
second. It will then pause for 1.5 seconds and
1 Open the ground controls side turntable cover. flash the second digit once per 0.5 second.
2 Locate the operational and safety controllers 6 Use the fault code table on the following pages
near the ground control box. to aid in troubleshooting the machine by
pinpointing the area or component affected.
3 Determine whether a safety or operational fault
exists by visually inspecting which controller
has flashing LEDs.
Note: If the LEDs are flashing on both controllers,
determine the fault code on one controller at a time.
f a
e b
d c
a green LED (operational control module)

b red LED (operational control module)
c operational control module
d safety control module
e red LED (safety control module)
f green LED (safety control module)

S-60 HC • S-60X • S-60XC
Error Source 12, System Checks

Error Type Condition Solution
ID Name
11 Safety envelope reached Power relays disengaged. Use recovery switch and APU from the
ground controls to recover the
machine to stowed position or within the
operating envelope.
12 Platform load greater Power relays disengaged. Remove weight from platform until load is
than 1250 lbs/567 kg 1200 lbs/544 kg or less.
13 CAN communication failure Power relays disengaged. Repair CAN bus wiring and/or
connections.
14 Sensor power failure Power relays disengaged. Use recovery switch and APU from the
ground controls to recover the machine
to stowed position or within the operating
envelope.
21 Angle sensor Power relays disengaged. Inspect boom angle sensor for
not active proper operation and be sure it is
connected to boom properly OR replace
boom angle sensor.
22 String potentiometer Power relays disengaged. Inspect string potentiometer for proper
not active operation and be sure it is connected to
boom properly OR replace string
potentiometer.
23 Power relay output Power relays disengaged. Repair system wiring and/or connections.
short high Relay wiring open or
shorted to voltage.
24 Power relay output Power relays disengaged. Repair system wiring and/or connections.
short low Relay wiring open or
shorted to ground.
25 Directional relay output Boom up/down and Repair system wiring and/or connections.
short high extend/retract inoperative.
Relay wiring open or
shorted to voltage.
26 Output short low Boom up/down and Repair system wiring and/or connections.
extend/retract inoperative.
Relay wiring open or
shorted to ground.

S-60 HC • S-60X • S-60XC
Error Source 21, String Potentiometer Operational Sensor (C167PSL)

ID Name
5 Sensor tolerance fault Power relays disengaged. Repair wiring and/or connections OR
replace string potentiometer and calibrate
overload system.
11 Output short high Power relays disengaged. Repair wiring and/or connections OR
String potentiometer wiring replace string potentiometer
open or shorted to voltage. and calibrate overload system.
12 Value too high Power relays disengaged. Repair wiring and/or connections OR
open or shorted to voltage. and calibrate overload system.
15 Value too low Power relays disengaged. Repair wiring and/or connections OR
open or shorted to ground. and calibrate overload system.
16 Output short low Power relays disengaged. Repair wiring and/or connections OR
open or shorted to ground. and calibrate overload system.
17 Not calibrated Boom range of motion Calibrate the platform load sense
is limited. system.
18 Just calibrated Used to clear Self-clearing.

diagnostic codes.

S-60 HC • S-60X • S-60XC
Error Source 22, String Potentiometer Safety Sensor (C167PSL)

ID Name
replace string potentiometer and calibrate
overload system.
11 Output short high Power relays disengaged. Repair wiring and/or connections OR
String potentiometer replace string potentiometer and
wiring open or shorted calibrate overload system.
to voltage.
wiring open or shorted calibrate overload system.
to voltage.
wiring open OR calibrate overload system.
shorted to ground OR string
potentiometer is faulty.
wiring open OR calibrate overload system.
shorted to ground.
17 Not calibrated Boom range of motion Calibrate the platform load

is limited. sense system.

diagnostic codes.
21 Inconsistent Checks operational Repair wiring and/or connections OR

and safety sensor replace string potentiometer and
values against each other. calibrate overload system.

S-60 HC • S-60X • S-60XC
Error Source 31, Boom Angle Operational Sensor (C123PBS)

ID Name
replace boom angle sensor and calibrate
overload system.
11 Output short high Power relays disengaged. Repair wiring and/or connections
Boom angle sensor OR replace boom angle sensor
wiring open or shorted and calibrate overload system.
to voltage.
12 Value too high Power relays disengaged. Repair wiring and/or connections
Boom angle sensor wiring OR adjust or replace boom angle sensor
open or shorted to voltage and calibrate overload system.
OR sensor is out of
operating range.
15 Value too low Power relays disengaged. Repair wiring and/or connections
open OR shorted to ground and calibrate overload system.
OR sensor is out of
operating range.
16 Output short low Power relays disengaged. Repair wiring and/or connections
Boom angle sensor wiring OR replace boom angle sensor
open OR shorted to ground. and calibrate overload system.
17 Not calibrated Boom range of Calibrate the platform load sense

motion is limited. system.

diagnostic codes.

S-60 HC • S-60X • S-60XC
Error Source 32, Boom Angle Safety Sensor (C141PBS)

ID Name ID Name
replace boom angle sensor and calibrate
overload system.
Boom angle sensor OR replace boom angle sensor
wiring open or shorted and calibrate overload system.
to voltage.
12 Value too high Power relays disengaged. Repair wiring and/or connections
open or shorted to voltage and calibrate overload system.
OR sensor is out of
operating range.
15 Value too low Power relays disengaged. Repair wiring and/or connections
open OR shorted to ground and calibrate overload system.
OR sensor is out of
operating range.
16 Output short low Power relays disengaged. Repair wiring and/or connections
Boom angle sensor wiring OR replace boom angle sensor
open OR shorted to ground. and calibrate overload system.


diagnostic codes.
21 Inconsistent Checks operational Repair wiring and/or connections

and safety sensor OR replace boom angle sensor and
values against calibrate overload system.
each other.

S-60 HC • S-60X • S-60XC
Error Source 41, Load Cell Operational (C175LDS)

ID Name
replace platform load cell and calibrate
overload system.
Load cell wiring open OR OR replace platform load cell
shorted to voltage. and calibrate overload system.
Load cell wiring open OR replace platform load cell OR remove
shorted to voltage. excess weight from platform.
Platform may be overloaded.
Load cell wiring open OR replace platform load cell and
shorted to ground. calibrate overload system.
Platform may be reverse Check for binding of the overload
loaded. component linkage and be sure platform
is NOT on the ground OR supported from
underneath.
Load cell wiring open replace platform load cell and calibrate
OR shorted to ground. overload system.


diagnostic codes.

S-60 HC • S-60X • S-60XC
Error Source 42, Load Cell Safety (C94LDS)

ID Name
replace platform load cell and calibrate
overload system.
Load cell wiring open OR OR replace platform load cell
shorted to voltage. and calibrate overload system.
Load cell wiring open OR replace platform load cell and calibrate
shorted to voltage. overload system OR remove
Platform may be overloaded. excess weight from platform.
Load cell wiring open OR replace platform load cell and
shorted to ground. calibrate overload system.
Platform may be reverse Check for binding of the overload
loaded. component linkage and be sure platform
is NOT on the ground OR supported from
underneath.
Load cell wiring open replace platform load cell and calibrate
OR shorted to ground. overload system.


diagnostic codes.
21 Inconsistent Checks operational Repair wiring and/or connections

and safety sensor OR replace platform load cell and
values against calibrate overload system.
each other.

S-60 HC • S-60X • S-60XC
December 2013 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
Observe and Obey: could result in death or serious
Troubleshooting and repair procedures shall be and other jewelry.
completed by a person trained and qualified on
the repair of this machine. Hydraulic Schematics
Immediately tag and remove from service a Bodily injury hazard. Spraying
damaged or malfunctioning machine. hydraulic oil can penetrate and
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
Before Troubleshooting: or spray.
Read, understand and obey the safety rules and General Repair Process
operating instructions in the appropriate
operator's manual on your machine before
attempting any maintenance or repair procedure.
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot

discovered symptoms
problem
still exists
Return to Inspect Perform

service and test repair
problem
solved
S-60 HC • S-60X • S-60XC
Section 6 • Schematics December 2013
Electrical Symbols Legend
FS1
BK BK
LS3
N.O.H.C. N.C.H.O. P3
WH Foot switch
Quick disconnect Limit switch
Horn button P1
terminal Coil, soleniod normally open
or relay PLATFORM
TB21 GROUND
KS1 SW3
N.O. Emergancy Stop button
T-circuits connect H1 normally closed
at terminal
Horn or alarm Key switch normally open
FAN
T-circuits connect SW1

N.O.
PR1 Hydraulic oil
FB
Coolant temperature cooling fan
Power relay switch, normally open
Flashing beacon
M2
Connection SW2
N.C.
no terminal TS2
Auxiliary pump
G1 Oil pressure switch
START
ENGINE
normally closed
510W
Gauge
Circuits crossing Resistor with
no connection ohm value
Toggle switch SPDT
HM Gauge sending unit
Diode Hour meter TS6 A B C

PULL IN
HOLD
Tilt sensor
DOWN LEVEL
UP
+
L3
PLATFORM
- Fuel or RPM soleniod

KS1
LED
Battery F1
Toggle switch DPDT
Key switch
25A
CB1 Coil with suppresion
Fuse with amperage
15A CR4
Circuit breaker N.O.
with amperage
Control relay contact
DiodeStarting aid: normally open (NO)
glow plug or
flame ignitor
S-60 HC • S-60X • S-60XC
Hydraulic Symbols Legend
.035
Orifice with size Solenoid operated 3 position,
Solenoid operated 3 position, 4 way, proportional
Filter with bypass 4 way, directional valve directional valve
relief valve
Check valve
2 position, 3 way, shuttle valve
200 psi
Pump, fixed displacement 13.8 bar Priority flow regulator valve
Reilief valve with
pressure setting
o Brake
Solenoid operated 2 position,

Pump, bi-directional Directional valve 3 way, directional valve
variable displacement (mechanically activated) Shut off valve
3000 psi
206.8 bar
3:1
50% 50%
Flow divider/combiner valve

Motor, bi-directional
Counterbalance valve with
pressure and pilot ratio
Pilot operated 3 position,

3 way, shuttle valve
Motor 2 speed
bi-directional 2 position, 2 way,
solenoid valve
E
Pump, prime mover
Differential sensing valve
(engine or motor)
Pilot operated 2 position,

Double acting cylinder
2 way, directional valve
Solenoid operated
proportional valve
S-60 HC • S-60X • S-60XC
Limit Switch Location Legend
PRIMARY BOOM
ANGLE SENSOR
(EXCLUDES THE S-60 HC) LST3O
LSB2S
LSB1RO
LST1O LST2O
ALL MODELS EXCEPT AS NOTED
STRING POT
(S-60 HC MODELS)
LST3S
(S-60X / S-60XC)
LSB1ES
(S-60X / S-60XC)
LSB1EO
PRIMARY BOOM (S-60X / S-60XC) LS18 / LS18A
ANGLE SENSOR (CE MODELS)
(S-60 HC)
S-60 HC, S-60X AND S-60XC AS NOTED
S-60 HC • S-60X • S-60XC
Ford Engine Relay Layout
Ford MSG-425 EFI

Power Fuel
Relay Pump Starter
Relay Relay
Starter
20A F1-10A F2-5A
Empty F3-10A F4-15A
Empty F5-15A EMPTY
Ford DSG-423 EFI

Starter Empty
Relay
F1-10A F2-5A
Fuel Power
Pump Relay F3-10A F4-15A
Relay
F5-15A F6-10A
S-60 HC • S-60X • S-60XC
S-60 HC • S-60X • S-60XC
Ford DSG-423 Engine Wire Harness
6-7 6-8
Ford DSG-423 Engine Wire Harness
A B C D E F G H I J K L M N
IGNITION COILS HO2S #1

HO2S #2
1 ENGINE ECM Y/BK 18
R 16 R 16 R 16
CONNECTOR W/PK 18 BK/LG 18 GY/R 18 SHD

Y/RD 18 GY/LB 18 GY/YL 18 A
GY/LB 18
Y/BK 18 R 16 B
1 DG/P 18 GY/R 18
SPK_COIL1A W/PK 18 DB/O 18 BK/LB 18 C
2
SPK_COIL1B D
3 Y/RD 18
SPARK_COIL2A GY/R 18 GY/Y 18
4 BK/W 16
SPK_GND DG/P
5
SPK_COIL2B
6
SPK_COIL3A
7
SPK_COIL3B
UEGOS
8 CYL #2 CYL #3 CYL #4 CYL #1 GY/R 18 TWR GASOLINE
9 A
UEGOC
10 CAM
LG/W 18
B SENSOR
UEGOP BR/W 18
UEGPR
11
W/LG 18 W/LG 18 C INTERFACE
12 DG/O 18 D
AUX ANA PD1
13 W/LG 18
FORD
2 (FRP) AUX ANA PD2
CAN1 +
CAN1 -
14
15
DG/P 18
O/LG 18
DG/P 18
O/LG 18
MTRTWR4 42 PIN
CONNECTOR
16
CAN2 - BR/W 18
17
CAN2 + LG/R 18 LG/R 18
18
AUX ANA PD3 BR/W 18
5V EXT 1
19
GY/R 18 GY/R 18 GY/R 18
GROUND BR 16 BR 16
20 34 GND
5V RTN GY/LB 18
21
EGO1 GY/Y 18 BK/W 12
22
EGO2
23 LG/BK 18 BOSCH RING
MAP
AUX ANA PUD3
24 TMAP
25 GY 18
CRANK + DBL 18
26 LG/BK 18
CRANK - GY/R 18 BR/W 18 4
27
CAM +
28 DB/O 18 GY 18
3 CHT
CAM - DG/BK GY/R 18 2
29
SPEED + LB/R 18 1
30
3
SPEED -
31 LG/W
5V EXT 2 DG/BK
32 LB/R 18 36 ROADSPEED -
5V RTN 2
33 LB/R 18 LG/BK 18 35 ROADSPEED +
PULSE IN T/LB 18 T/LB 18
34 T/LB 18 24 GOV SELECT 1 C128 RPM
GOV 1 DG/W 18
35
OIL PRESS GY 18 BK/W 16
36
IAT LG/R 18 BK/W 16
37
ECT LG/W LB/BK 18 LB/BK 18
38 14 FPP1
(FRT) AUX ANA PU1 W/R 18 BK/LB 18
39
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
40 BK/O 18
F2
41 W/LB 18 R/LG 18 R/LG 18 R/LG 18 R/LG 18
(BRAKE) AUX DIG 3 1 VSW P23 BAT
42 BK/Y 18 BK/Y 18
(GOV2) AUX DIG 4
43 T/Y 18 5A VSW
TACH R/LG 18
44
VSW DB/W 18
45
AUX ANA PUD2
46 P/LB 18 F3
AUX ANA PUD1 GY/W 18 R/T 14
47 R/T 14 R 14
TPS 1
4 (FUELSELECT)AUX DIG1
TPS 2
48
49
Y/W 18
Y/DB 18 10A ECM
50
AUX DIG 2 BK/Y 18
51 Y/R 18 23 GOV SELECT 2 C35 RPM
KNOCK + GY 18
52 DG/P 18
KNOCK - DBL 18 O/LG 18
LB/BK 18 29 CAN -
53 DG/P 18
FPP1 28 CAN +
54 LB/Y 18
(FPP2) FPP2-IVS DG/O 18 DG/O 18
55 DG 18 32 ANA AUX PD1
PC TX
56 O 18
PC RX DB/W 18 DB/W 18
57 37 AUX ANA PU2B
KNOCK 2+
KNOCK 2-
58 CRANK LB/Y 18 LB/Y 18
12 FPP2
59
VBAT PROT R/T 16 RD/T 14
60
VBAT BK/LB 18 GY/R 18 GY/R 18 GY/R 18
61 33 ANA RTN
EGOH 2 BK/LG 18 BR/W 18 BR/W 18 BR/W 18
62 31 VREF
EGOH 1
63 R 14
INJ HS T 16
64
INJ1 LS
5 INJ2 LS
INJ3 LS
65
66
67
BR/Y 16
BR/LB 16
W 16
BK/LG 18
GY/W 18
BOSCH THROTTLE
GY/W 18
BATT(+) R 12 R 12
ALTERNATOR
INJ4 LS
68 Y/W 18 Y/W 18 6 RING R 16
INJ5 LS 5 3
69 BK/W 16 LB/DG 18 LB/DG 18
GROUND 4 2
70 BR/W 18 BR/W 18 RED/TAN
INJ6 LS BK/W 16 GY/R 18 GY/R 18 3 1
71
AUX PWM8 LG/P 18 GY/O 18 GY/O 18 2
72
STARTER R/Y 18 1
73
RELAY PK/LG 18
74
MIL BK/R 16
75
UEGO H
76
AUX PWM7 W/BK 18
77
LOCKOFF LB/O 18 LG/P 18 DG/W 18
78
(FUEL PUMP) AUX PWM6 R/T 16 R/Y 18
79
VBAT LB/DG 18
80
DBW +
81 BK/W 16 OIL PRESSURE
GROUND
6 AUX PWM5 REC
DBW -
82
83
84
GY/O 18
R/BK 18
R/BK 18
R/W 18
R/BK 18
R/W 18
21 AUX PWM 5
AUX PWM5 16 AUX PWM 4
85 O/LG 18
AUX PWM1 R/W 18 BK/O 18
86 BK/O 18 25 IVS
AUX PWM4 T/GN 18 DG/W 18
87 DG/W 18 26 OIL PRES
AUX PWM2 T/Y 18
88 T/Y 18 2 TACH
AUX PWM4 REC C41 RPM
89 PK/LG 18 PK/LG 18 6 MIL
FP REC AUX PWM3 REC C10 BESL
90 BK/R 16 BK/R 16 BK/R 16
FUEL PUMP AUX PWM3 18 FUEL PUMP - C21 IGN
O/LG 18 O/LG 18
39 AUX OUT1 C135 FP
R 16 W 16 Y/DB 18 Y/DB 18
7 FUEL SELECT C39 LP
P/LB 18 P/LB 18
10 AUX ANA PD1B
T/GN 18 T/GN 18
27 AUX OUT 2
W/LB 18 W/LB 18
4 BRAKE
DG 18 DG 18 11 RS 232+
W/R 18 O 18 O 18 3 RS 232- C127 TSW
A
INJECTOR CYL #2 FUEL PUMP
7 GY/R 18
B
F4
LB/PK 16 15 START IN INTERUPT R33 STR
R 16 BN/LB 16 LPG PK/BK 16 PK/BK 16
W/PK 16 19 START IN AUTOCRANK
PK/BK 16
TEMPERATURE 5 FUEL PUMP + C135 FP+
GY/R 18 1
ANA RTN 15A
BR/W 18 2
TWR 5V REF
DG 18 3
PC TX
W/BK 18 O 18 4
PC RX
FUEL PUMP RELAY
INJECTOR CYL #4 R/LG 18 A
B
DG/P 18 5
6
UNUSED
LB/O 18 LB/O 18
STARTER STARTER RELAY CAN
85
LPG
Y/R 18
DG/P 18 7
UNUSED
R 16 30 SOLENOID 87A
TERMINATION
CAN + LB/PK 16
R 16 BR/Y 16
LOCKOFF O/LG 18 8 PK/BK 16 30 CONNECTOR
KNOCK CAN -
R/LG 18
87 LB/PK 16
87 W/PK 16
86
SENSOR DIAGNOSTIC CONNECTOR 87A RING W 18
SHD TWR
W 18 2
R/LG 18 R/LG 18 86 CAN + TERM
R 16 RELAY
OMRON
8 INJECTOR CYL #3
LG/P 18 85
FPP
DG/P 18
O/LG 18
BK/W 18
3
1
6
CAN +
CAN -
GROUND
PK/BK 16 PK/BK 16 4
R 16 T 16 UNUSED
5
UNUSED
8
UNUSED
F6 F1
R 16 R16 R/LB 16 7
POWER
POWER RELAY
R/Y 18 85 10A ALTERNATOR 10A EPR EPR
INJECTOR CYL #1 R 16
R 16 R 16 R 16
30
F5 R 16 CONNECTOR
87
R 16 R 16
R/T 18 86
87A
15A RELAYED POWER
S-60 HC • S-60X • S-60XC
Ford MSG-425 Engine Wire Harness
N M L K J I H G F E D C B A
SPK_COIL1A 1 YELLOW/BLACK 18 YELLOW/BLACK 18

DK BLUE/ORANGE 18 GRAY/RED 18
SHD
A
SPK_COIL1B 2 WHITE/PINK 18 GRAY/RED 18 GRAY/LT BLUE 18 HO2S #1
SPARK_COIL2A 3 YELLOW/RED 18 YELLOW/RED 18 BROWN/WHITE 18 RED 16
BLACK/LT GREEN 18
B
C
SHD
1
SPK_GND 4 BLACK/WHITE 16 D GRAY/RED 18
A
SPK_COIL2B 5 DK GREEN/PURPLE 18 RED 16
DK GREEN/PURPLE 18
RED 16 3 2 1
GRAY/YELLOW 18 B HO2S #2
SPK_COIL3A 6 RED 16
BLACK/LT BLUE 18
C
SPK_COIL3B 7 CAMSHAFT POSITION SENSOR D
TWR
UEGOS 8 GRAY/RED 18
LT GREEN/WHITE 18
A GASOLINE
UEGOC 9 2 1 BROWN/WHITE 18
B SENSOR
UEGOP 10 IGNITION COIL CYL #4 2 1 2 1 2 1 WHITE/LT GREEN 18
C INTERFACE
D
UEGPR 11 IGNITION COIL CYL #3 IGNITION COIL CYL #2 IGNITION COIL CYL #1
DK GREEN/ORANGE 18 MTRTWR4
AUX ANA PD1 12 DK GREEN/ORANGE 18
WHITE/LT GREEN 18
(FRP) AUX ANA PD2 13 WHITE/LT GREEN 18 DK GREEN/PURPLE 18
CAN1 + 14 DK GREEN/PURPLE 18 ORANGE/LT GREEN 18
CAN1 - 15 ORANGE/LT GREEN 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
CAN2 -
CAN2 +
16
17
GRAY/LT BLUE 18
GRAY/YELLOW 18 2
LT GREEN/RED 18
AUX ANA PD3 18
BROWN/WHITE 18
5V EXT 1 19 BROWN/WHITE 18
GRAY/RED 18
5V RTN 20 GRAY/RED 18 GRAY/RED 18
EGO1 21 GRAY/LT BLUE 18

EGO2 22 GRAY/YELLOW 18
MAP 23 LT GREEN/BLACK 18 CHT
AUX ANA PUD3 24 BLACK/LT BLUE 18
1 2
CRANK + 25 GRAY 18 BLACK/WHITE 16 GROUND
CRANK - 26 DK BLUE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH BLACK/WHITE 16 BLACK/WHITE 12 10MM
CAM + 27 GRAY/RED 18 BLACK/WHITE 16 RING
CAM - 28 DK BLUE/ORANGE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
SPEED + 29 DK GREEN/BLACK 18
SPEED - 30 LT BLUE/RED 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
TMAP SENSOR
RED/LT GREEN 18
F2
RED/LT GREEN 18
3
5V EXT 2 31 LT GREEN/BLACK 18 4 MAP
5V RTN 2 32 BROWN/WHITE 18 3 5V
2 IAT
5A
F3
LT BLUE/RED 18 36 ROADSPEED -
GRAY 18
PULSE IN 33 GRAY/RED 18 1 5V RTN
VSW RED/TAN 14 RED 12 RED 14 DK GREEN/BLACK 18 35 ROADSPEED +
GOV 1 34 TAN/LT BLUE 18 10A
TAN/LT BLUE 18 24 GOV SELECT 1 C128RPM 24 OR/BK - LOW IDLE INPUT(12V)
OIL PRESS 35 DK GREEN/WHITE 18 ECM LT BLUE/BLACK 18 14 FPP1
IAT 36 GRAY 18 RED/LT GREEN 18 1 VSW R23BAT 1 WH - KEYSWITCH POWER(12V)
ECT 37 LT GREEN/RED 18 BLACK/YELLOW 18
BLACK/YELLOW 18 23 GOV SELECT 2 C35RPM 23 BK/RD - HIGH IDLE SWITCH INPUT(12V)
(FRT) AUX ANA PU1 38 LT GREEN/WHITE 18 DK BLUE/WHITE 18
DK GREEN/ORANGE 18 32 ANA AUX PD1
(LPTEMP) AUX ANA PU2 39 LT BLUE/YELLOW 18
DK BLUE/WHITE 18 37 AUX ANA PU2B
(IVS) AUX ANA PU3 40 BLACK/ORANGE 18 RED 14
LT BLUE/YELLOW 18 12 FPP2
(BRAKE) AUX DIG 3 41 WHITE/LT BLUE 18 BLACK/YELLOW 18
GRAY/RED 18 33 ANA RTN
(GOV2) AUX DIG 4 42 BLACK/YELLOW 18 RED 16
3 ALTERNATOR BROWN/WHITE 18 31 VREF
TACH
VSW
43
44
TAN/YELLOW 18
RED/LT GREEN 18 RED/LT GREEN 18
BLACK/ORANGE 18 25 IVS 4
WHITE 18
2 DK GREEN/WHITE 18 26 OIL PRES
AUX ANA PUD2 45 DK BLUE/WHITE 18 BATT+ RED 12
RED/TAN 18 TAN/YELLOW 18 2 TACH C41RPM 2 OR/BK - ENGINE SPEED (2 PULSES/REV)
1
AUX ANA PUD1 46 PURPLE/LT BLUE 18 1 2 PINK/LT GREEN 18 6 MIL C108ESL 6 BL/WH - DIAGNOSTIC LAMP OUTPUT(GND)
TPS 1 47 GRAY/WHITE 18 CRANK SENSOR 8MM
RING 500OHM, 3 WATT ORANGE/LT GREEN 18 39 AUX OUT1 C26TSR 39 WH/RD - COOLANT TEMP SENDER OUTPUT
TPS 2 48 YELLOW/WHITE 18 RED/TAN 18 YELLOW/DK BLUE 18 7 FUEL SELECT C39LP 7 BL/RD - FUEL SELECT SWITCH INPUT(12V)
(FUELSELECT)AUX DIG1 49 YELLOW/DK BLUE 18 BLACK/LT GREEN 18
PURPLE/LT BLUE 18 10 AUX ANA PD1B
AUX DIG 2 50 TTI - RS2B 500 1
TAN/GREEN 18 27 AUX OUT 2
KNOCK + 51 YELLOW/RED 18 (or Equivalent)
WHITE/LT BLUE 18 4 BRAKE
KNOCK - 52 DK GREEN/PURPLE 18 LT BLUE/BLACK 18 ALTERNATOR S TERMINAL
RED/BLACK 18 16 AUX PWM 5 C21IGN 16 WH - ENGINE RUNNING OUTPUT(GND)
FPP1 53 LT BLUE/BLACK 18 ORANGE/LT GREEN 18 29 CAN - CAN - 29 GR
(FPP2) FPP2-IVS 54 LT BLUE/YELLOW 18 DK GREEN/PURPLE 18 28 CAN + CAN + 28 YL
PC TX 55 DK GREEN 18 DK GREEN 18
DK GREEN 18 11 RS 232+ TWIST WIRES 10 TURNS(360 DEG)/FOOT
ORANGE 18
PC RX 56 ORANGE 18 BLACK/ORANGE 18
ORANGE 18 3 RS 232- C127TSW 3 GR - DIAGNOSTIC SWITCH INPUT(GND) 5
KNOCK 2+ 57 DK GREEN/WHITE 18 LT BLUE/PINK 18 15 START COMMAND R33STR 15 BK - ENGINE START INPUT(12V)
KNOCK 2- 58 TAN/YELLOW 18 PINK/BLACK 16 5 FUEL PUMP + C135FP 5 BL/WH - FUEL PUMP (12V)
VBAT PROT 59 PINK/LT GREEN 18 BLACK/RED 16 18 FUEL PUMP - C135RET 18 BL - FUEL PUMP (GND)
VBAT 60 RED/TAN 16 YELLOW/DK BLUE 18
EGOH 2 61 BLACK/LT BLUE 18 PURPLE/LT BLUE 18
WHITE/LT BLUE 18
EGOH 1 62 BLACK/LT GREEN 18 BLACK/WHITE 16 DK GREEN/WHITE 18
INJ HS 63 BOSCH THROTTLE
INJ1 LS 64 TAN 16
DK GREEN/PURPLE 18
INJ2 LS 65 BROWN/YELLOW 16 GRAY/WHITE 18

OIL PRESSURE
INJ3 LS 66 BROWN/LT BLUE 16 6
YELLOW/RED 18
YELLOW/WHITE 18 5
INJ4 LS 67 WHITE 16 LT BLUE/DK GREEN 18 4
INJ5 LS 68 BROWN/WHITE 18
3
GROUND 69 BLACK/WHITE 16 GRAY/RED 18 2 DIAGNOSTIC CONNECTOR
INJ6 LS 70 TWR LPG LOCKOFF
GRAY/ORANGE 18 1 6
AUX PWM8 71 BROWN/WHITE 18 2 3 DK GREEN 18
STARTER 72 LT GREEN/PURPLE 18
WHITE/BLACK 18
RED/LT GREEN 18
A GRAY/RED 18 1 4 ORANGE 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
RELAY 73 RED/YELLOW 18 B
8 ORANGE/LT GREEN 18
MIL 74 PINK/LT GREEN 18 5
6 7 DK GREEN/PURPLE 18
UEGO H 75 BLACK/RED 16 KNOCK SENSOR
RED/BLACK 18
AUX PWM7 76 RED/LT GREEN 18
LOCKOFF 77 WHITE/BLACK 18 ORANGE/LT GREEN 18
(FUEL PUMP) AUX PWM6 78 LT BLUE/ORANGE 18 TAN/GREEN 18
VBAT 79 RED/TAN 16 PINK/BLACK 16 CAN TERMINATION CONNECTOR
DBW + 80 LT BLUE/DK GREEN 18 BLACK/RED 16 SHD TWR
GRAY/ORANGE 18
GROUND 81 BLACK/WHITE 16 LT BLUE/PINK 18 WHITE 18 DEPR
DBW - 82 GRAY/ORANGE 18 RED/LT BLUE 16 V-RELAY
AUX PWM5 REC
AUX PWM5
83
84 RED/BLACK 18
STARTER SOLENOID DK GREEN/PURPLE 18
WHITE 18
CAN +
CAN TERM
7
1 2 3
AUX PWM1 85 ORANGE/LT GREEN 18 6MM BLACK/WHITE 18 GROUND
AUX PWM4 86 RED/WHITE 18 RING ORANGE/LT GREEN 18 CAN -
VBAT
4 5 6
AUX PWM2 87 TAN/GREEN 18 RED/TAN 18 RED/TAN 18
AUX PWM4 REC 88 RED 18 STARTER RELAY

FP REC AUX PWM3 REC 89 PINK/BLACK 16 87A
FUEL PUMP AUX PWM3 90 BLACK/RED 16 LT BLUE/PINK 16 30
M1
87 RED/TAN 16 RED 16
LT BLUE/PINK 18 86 20A F4
PINK/BLACK 16 PINK/BLACK 16
STARTER
15A
85
LT GREEN/PURPLE 18 85 FUEL PUMP
RED 16 30
RELAY_OMRON_FPP
TAN 16
LT BLUE/ORANGE 18
PINK/BLACK 16
RED/LT GREEN 18
87
86 RED 18
F6
RED/TAN 18
8
WHITE 16 87A FUELPUMPRELAY
10A
RED/WHITE 18
RED/YELLOW 18 85
ALTERNATOR
BROWN/YELLOW 16 RED 16 30
BROWN/LT BLUE 16 RED 14 87 F1
RED 16 RED/LT BLUE 16
RED/TAN 14 RED/TAN 14 86
RED 18 RED 16 87A POWERRELAY 10A
EPR
- + INJ CYL #4 INJ CYL #3 INJ CYL #2 INJ CYL #1
VVT SOLENOID F5
RED 16
15A
2 1 2 1 2 1 2 1 RELAYED POWER
RED 16
S-60 HC • S-60X • S-60XC
Ford MSG-425 Engine Wire Harness
6-9 6 - 10
Electrical Schematic, Options (All Models)
6 - 11 6 - 12
Electrical Schematic, Options (All Models)
P2 FS1 C9P-3
1 C9P-1
BK P25FS RD P25FS RD
P22BAT BK
P24FS WH P24FS WH P24FS WH
C9P-2
P134PWR RD TS43 TS47

CONTROL BOX WH GENERATOR
HEATER
WH
2
L30 L30
THS1
NC
R21 R22
10W 10W
BR
BR
C2-7
TB45
4 TB21
RD
TB21 TB21
C21IGN WH
C5-12
G1
CR45
5 F19
10A
SECOND BATTERY OPTION G3 G2

B1BAT RD
C5-7
C45GEN GR/WH
BAT2 APU
C26TSR WH/RD
C25PSR WH/BK
AUX MAIN
6
J144-2
CR1
NO
EXCT
RED
RED
12VDC 12VDC PR2 PR1
BAT+ BAT- NO
+ +
D51 L29 L29 ES0396R
STA M3 ES0186U
M2 ES0193U
7 - -
CR46 Y29 ES0390J
B2 B1 REGULATOR
C5-6
IND
SEPERATOR
BATTERY
STARTER
CONTROL BATTERY
DRIVE LIGHTS
START BATTERY
ALTERNATOR
HEATER OPTION
PLATFROM BOX
WORK LIGHTS
WORK LIGHTS
GAUGE
COOLANT TEMP.
VOLT METER
GAUGE
OIL PRESSURE
AUXILIARY PUMP
OPTION
GENERATOR
BELT DRIVEN
OPTION
GENERATOR
HYDRAULIC
8

S-60 HC • S-60X • S-60XC
Wiring Diagram, Belt Driven Generator
120V AC W/REGULATOR 120V AC W/O REGULATOR 1

CB CB
87a 3 87a 3
RD RD
4
110V AC REGULATOR
30A 1 30
RD/12VDC 30A 1 30 4
RED
87 87
WT WH WH WT
86 85 86 85
2 5 2 5
BRN BRN GND BRN BRN
2
BRN
BK BK
GR
GR
BK/WH BK/WH
(BK/RD) (BK/RD)
WHT-NEUTRAL WHT-NEUTRAL 3
120V AC 120V AC
AUTO AUTO
RESET CB RESET CB
BLK-120VAC BLK-120VAC 4
15A 15A
220V AC W/REGULATOR
87a 3
RD
1 30 4 6
220V AC REGULATOR
30A RED/12V RED
87
WT WH WH
86 85
2 5
BRN BRN BRN
BK BK
7
BK/WH BK/WH
(BK/RD) (BK/RD)
WHT-NEUTRAL
220V AC
8
AUTO
RESET CB
BLK-220VAC
12.5A

S-60 HC • S-60X • S-60XC
Wiring Diagram, Belt Driven Generator
6 - 13 6 - 14
Wiring Diagram, 3kW Hydraulic Generator
6 - 15 6 - 16
Wiring Diagram, 3kW Hydraulic Generator
1 120V AC 60HZ 120V AC 50HZ
CB CB
BLACK BLACK
BLACK BLACK BLACK RED BLACK BLACK
L1 L1
T1 T1
T2 WHITE T2 WHITE
2 WHITE WHITE GREEN YELLOW WHITE GREEN
BLACK BLACK
RED RED
GREEN BLACK GREEN BLACK

GROUND GROUND
BLUE BLUE
T3 WHITE WHITE YELLOW T3 WHITE BLACK YELLOW
WHITE L2 WHITE L2
3 T4 T4
BLACK BLACK GND 1 2 3 4 GREEN WHITE GND 1 2 3 4
DTP04-4P DTP04-4P
5 RED 5 BLACK
DTP06-4S DTP06-4S
CAPACITOR CAPACITOR
1 2 3 4 1 2 3 4
4 8 RED YELLOW 8 BLACK YELLOW
DIAGNOSTIC DIAGNOSTIC
BLUE BLUE
+12VDC (PURGE) +12VDC (PURGE)
BLACK BLACK
-12VDC -12VDC
RED +12VDC GEN OFF/ON RED +12VDC GEN OFF/ON
5
240VAC 50HZ
CB
BLACK
RED BLACK WHITE L2
T1
6
T2 WHITE
YELLOW WHITE GREEN
GREEN GROUND
RED
T3 WHITE WHITE
BLACK
GND BLUE
T4 CB YELLOW
7 GREEN BLACK
BLACK L1
BLACK 1 2 3 4
DTP04-4P
5 BLACK
DTP06-4S
CAPACITOR
8
1 2 3 4
8 BLACK YELLOW
DIAGNOSTIC
BLUE
+12VDC (PURGE)
BLACK
-12VDC
RED +12VDC GEN OFF/ON

S-60 HC • S-60X • S-60XC
Wiring Diagram, 12kW Hydraulic Generator - Welder Option
NEUTRAL BUSS BAR 1
NEMA 4 CONTROL BOX

L1 L2 L3 (PLATFORM) Y X 2
GENERATOR ENCLOSURE
50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI 208 VAC

OUTLET
L2 3 6
RED RED Z
5 4
3
ORANGE
N L3
1 2 WHITE
L1 BLACK
4
WHITE BLACK BLACK 12GA GREEN
12 GA
WHITE
GREEN 20 AMP GROUND

CIRCUIT BREAKER STUD ON
DIN RAIL
5
BLACK
120V AC GFI 12GA
SILVER 8 GA 4 CONDUCTOR
8 GA 5 CONDUCTOR
WHITE BRASS
12GA
SHRINK TUBE
6
GREEN 12GA
ENCLOSURE
(TURNTABLE)
110 VAC GFI
(PLATFORM)
7
WHITE SILVER BRASS
GREEN
GREEN
8
BLACK
110 VAC PLUG 12 GA 3 CONDUCTOR

(TURNTABLE)

S-60 HC • S-60X • S-60XC
Wiring Diagram, 12kW Hydraulic Generator - Welder Option
6 - 17 6 - 18
Electrical Schematic, 12kW Hydraulic Generator

Welder Option
6 - 19 6 - 20
Electrical Schematic, 12kW Hydraulic Generator

Welder Option
FS1
1 P2
P25FS-RD
P26BAT-BK
P22BAT
P24FS-WH
TS4 TS47
RPM GENERATOR
SELECT ON
ALC-500
RPM LO
RPM HI
2
16
19
20
15
C2P-7
C32BRK WH/RD
C1P-9
C1P-5
C1P-6
C1P-4
C1P-3
3
C35RPM BK/RD
C32BRK WH/RD
C29MS RD/WH
C45GEN GR/WH
C31EDC WH/BK
C30EDC WH
8 N.C. U36
4 1 N.O.
2 COM
WH/RD
C1B-3
C1B-9
C1B-6
C1B-5
C1B-4
RED
RED
C57-2
7
8
3 GND 5 SW INPUT TB23
WHT
TIME DELAY MODULE
C2B-7
5
BK-2
TB24
4 SECOND
D99
C5-1
D100
4 2
6
TB35 TB32 TB45
RED
3 TB29
C5-20
C5-21
1k ohms D98 D65

124 ohms A1 BATTERY + (RED)
5
2 A2 SENSOR POWER +5 VDC (RED)
A3 BATTERY- (BRN)
1
1
6 124 ohms CR66
C5-18
C5-23
C5-24
B1 VALVE 0 FWD COIL (GRN) OMRON RELAY
V151HG GR B2 VALVE 1 NC
V150HG GR/BK B3 DIGITAL OUTPUT BYPASS (GRN/BLK)
WH (16/4)
1 3 2 4 8 RD (16/4) A RS232TxD C1 TxD (YLW)
CR50 J129 B RS232RxD C2 RxD (GRN)
OMRON NC C C3 /BOOT
RELAY C57-1
GR/WH
D1 ANALOG 0 JOYSTICK (WHT)
7 5 6 7
RD-1
Y75-1 D2 ANALOG 1 NC
D3 DIG IN 3 NC
VALVE
STROKE
MOTOR
RELAY
HIGH IDLE
CR4
RELEASE
BRAKE
PRESSURE SWITCH E1 NOT USED
BYPASS COIL
200 PSI E2 NOT USED

D
E3 NOT USED
PS4
N.O. F1 DIG IN 0
U4 F2 DIG IN 1 GENERATOR ON (GRN/WHT)
8 F3 DIG IN 2
SX CONTROLLER
GR/WH
DRIVE EDC -
DRIVE EDC +
Y75-2 PILOT PRESSURE SIGNAL

FROM GENERATOR MANIFOLD
BR
(16/4)
DIVERTER MANIFOLD

S-60 HC • S-60X • S-60XC
Hydraulic Schematic, 12kW Hydraulic Generator Option
B
1
FUNCTION 3.5 GPM / 13.25 L/min DRIVE PUMP

MANIFOLD
A
PMP B CLR PMP A
WELDER
MANIFOLD
3
CW
0.031 inch / CV
0.79 mm PRESSURE SWITCH
200 PSI / 13.8 BAR 4
N.O.
CX CU
CZ
270 PSI / 18.6 BAR

@ 3.5 GPM / 13.25 L/min 5
CY
G2
21 GPM /
79.5 L/min
MTR B MTR A G1 6
79.5 L/min
21 GPM /
HYDRAULIC
3
COUPLER
ROTARY
7
1
0.047 inch /
1.2 mm
8
G2 G1
24CC
HS0078K
GENERATOR
12.5 KW

S-60 HC • S-60X • S-60XC
Hydraulic Schematic, 12kW Hydraulic Generator Option
6 - 21 6 - 22
Hydraulic Schematic, 2WD Models (from SN 21001 to 21396)
6 - 23 6 - 24
TURNTABLE ROTATE
(2.8 gpm / 10.6 L/min) L R
1 PRIMARY BOOM
LIFT CYLINDER PLATFORM LEVEL QQ RR PLATFORM
(8 gpm / 30.3 L/min) CYLINDERS ROTATE
PRIMARY BOOM
BRAKE / 2 SPEED MEDIUM EXTENSION CYLINDER
MANIFOLD (7 gpm / 26.5 L/min)
0.025 IN 51 psi PRESSURE AUXILIARY MM NN SLAVE
0.64 mm 3.5 bar FILTER M 1.7
PUMP PR2 PR1
JJ
T2
II CP
JIB
HYDRAULIC GENERATOR SELECT J1
2 A
(OPTION)
0.030 in MANIFOLD FF
KK LL HIGH 0.76 mm OO (S-65 MOD)
BRAKE 2 SPEED TEST PRESSURE S1 J2

3750 psi PP ACCUMULATOR
259 bar
FILTER MASTER
51 psi 1000 psi
V2 V1
3.5 bar 69 bar V2 V1
AUX EXT RET SW1 SW2 P1 P2 ACCUM PL1 PL2 PR2 PR1 JIB BOOM CYLINDER
(S-65 MODELS)
C
B G H
2400 psi
A
3 165.5 bar PRESS
B
E F 30 psi 30 psi
D 2.1 bar 2.1 bar
PTEST I J
310 psi W X
21.4 bar L S Y
P V
3000 psi
E 9 15 2
FUNCTION 207 bar N O R 0.6 gpm
PUMP K M U 2.27 L/min
AA Q T Z 30 psi
4
13.2 L/min
3.5 gpm
DRIVE PUMP 2.1 bar
0.1 gpm EE
BB CC 0.38 L/min
TANK DD
FUNCTION MANIFOLD
RESERVOIR
25 psi SWV ST1 ST2
1.7 bar
RETURN
FILTER
5 6 8 3 1 7 2 4 5
P1 P2
HYDRAULIC ROTARY COUPLER
PRIMARY LIFT CYLINDER
(S60 HC MODELS)
6A 6B 6C 8C 8B 8A 3 1 2A 2C 2B 7 4 5
6
TEST A B LEFT RIGHT
STEER
TRACTION MANIFOLD CYLINDERS
RIGHT M2
REAR
B OSCILLATE CYLINDERS
UU
CDR LEFT RIGHT
A
SS TT TEST
7 M4 HYDRAULIC
GENERATOR
OPTION
50%
280 psi
19.3 bar OIL COOLER SWV
0.070 in
VV
1.78 mm RETURN TANK
50% JJ
FILTER
IN A FUNCTION
WW MANIFOLD
XX B
8 M1 OUT
800 psi
2
CDL T 55 bar HYDRAULIC ROTARY COUPLER

A OIL COOLER OPTION
LL OSCILLATE OPTION
B OSCILLATE VALVE HS0078J
LEFT M3
REAR

S-60 HC • S-60X • S-60XC
Hydraulic Schematic, 2WD Models (after SN 21396)
TURNTABLE ROTATE
(2.8 gpm / 10.6 L/min) L R
PRIMARY BOOM
1
PRIMARY BOOM
1
PUMP PR2 PR1
JJ JJ
T2
II CP
JIB
A
(OPTION)
0.030 in MANIFOLD FF 2

259 bar
FILTER MASTER
51 psi 1000 psi
2700 psi V2 V1
GG
186 bar
(S-65 MODELS)
C
B HH G H
PRESS
A B
E F 30 psi 30 psi
3
D 2.1 bar 2.1 bar
PTEST I J
310 psi W X
21.4 bar L S Y
P V
3000 psi
E 9 15 2
AA Q T Z 30 psi
4
13.2 L/min
3.5 gpm
DRIVE PUMP 2.1 bar
0.1 gpm EE
BB CC 0.38 L/min
TANK DD
FUNCTION MANIFOLD
RESERVOIR
25 psi SWV ST1 ST2
1.7 bar
RETURN
FILTER 5
6 8 3 1 7 2 4 5
P1 P2
(S60 HC MODELS)
6A 6B 6C 8C 8B 8A 3 1 2A 2C 2B 7 4 5
1 ORIFICE RELOCATED AFTER SERIAL NUMBER 25201
6
TEST A B LEFT RIGHT
STEER
TRACTION MANIFOLD CYLINDERS
RIGHT M2
REAR
B
UU
CDR LEFT RIGHT
A
SS TT TEST 7
M4 HYDRAULIC
GENERATOR
OPTION
50%
280 psi
19.3 bar OIL COOLER SWV
0.070 in
VV
1.78 mm RETURN TANK
50% JJ
FILTER
IN A FUNCTION
WW MANIFOLD
XX B 8
M1 OUT 2
800 psi
CDL T 55 bar HYDRAULIC ROTARY COUPLER
A OIL COOLER OPTION
LL OSCILLATE OPTION
B OSCILLATE VALVE HS0078L
LEFT M3
REAR

S-60 HC • S-60X • S-60XC
6 - 25 6 - 26
6 - 27 6 - 28
TURNTABLE ROTATE
(2.8 gpm / 10.6 L/min) L R
1 PRIMARY BOOM
PRIMARY BOOM
PUMP PR2 PR1
JJ
T2
II CP
JIB
2 A
(OPTION)
0.030 in MANIFOLD FF

259 bar
FILTER MASTER
51 psi 1000 psi
V2 V1
(S-65 MODELS)
C
G H
B 2400 psi
A
3 165.5 bar PRESS
B
E F 30 psi 30 psi
D 2.1 bar 2.1 bar
PTEST I J
W X
310 psi
L P S Y
21.4 bar V
3000 psi
E 9 15 2
AA Q T Z 30 psi
4
13.2 L/min
3.5 gpm
DRIVE PUMP 2.1 bar
0.1 gpm EE
BB CC 0.38 L/min
TANK DD
FUNCTION MANIFOLD
RESERVOIR
25 psi SWV ST1 ST2
1.7 bar
RETURN
FILTER
5 6 8 3 1 7 2 4 5
P1 P2
(S60 HC MODELS)
8B 8C 6B 6C 6A 8A 3 1 2A 2C 2B 7 4 5
6
TEST A B
LEFT RIGHT
SS TT RIGHT STEER
RIGHT M5 M6 CYLINDERS
FRONT
REAR
B B
OSCILLATE CYLINDERS
VV
CDR
A A
UU M8
M7 LEFT RIGHT
TEST
7 HYDRAULIC
GENERATOR
50% 280 psi 50% OPTION
0.040 in 19.3 bar 0.040 in
WW AE
1 mm 1 mm
50% AB 50% 50% 50%
OIL COOLER SWV
XX AD RETURN
YY ZZ JJ TANK
AC
M3 M4 FILTER
IN A FUNCTION
CDL 0.040 in MANIFOLD
1 mm B B
B
8 OUT
800 psi
2
TRACTION MANIFOLD 55 bar HYDRAULIC ROTARY COUPLER
A AF AG A
M1 M2 LEFT OIL COOLER OPTION
LEFT
FRONT LL OSCILLATE OPTION
REAR
T
OSCILLATE VALVE HS0078J

S-60 HC • S-60X • S-60XC
TURNTABLE ROTATE
(2.8 gpm / 10.6 L/min) L R
PRIMARY BOOM
1
PRIMARY BOOM
MANIFOLD 0.025 IN (7 gpm / 26.5 L/min)
51 psi PRESSURE AUXILIARY MM NN SLAVE
0.64 mm 3.5 bar M
FILTER 1.7
PUMP PR2 PR1
1 JJ JJ
T2
II CP
JIB
A
(OPTION)
0.030 in MANIFOLD FF 2

259 bar
FILTER MASTER
51 psi 1000 psi
2700 psi V2 V1
GG 186 bar
(S-65 MODELS)
C
HH G H
B
PRESS
A B
E F 30 psi 30 psi
3
D 2.1 bar 2.1 bar
PTEST I J
W X
310 psi
L P S Y
21.4 bar V
3000 psi
E 9 15 2
AA Q T Z 30 psi
4
13.2 L/min
3.5 gpm
DRIVE PUMP 2.1 bar
0.1 gpm EE
BB CC 0.38 L/min
TANK DD
FUNCTION MANIFOLD
RESERVOIR
25 psi SWV ST1 ST2
1.7 bar
RETURN
FILTER 5
6 8 3 1 7 2 4 5
P1 P2
(S60 HC MODELS)
8B 8C 6B 6C 6A 8A 3 1 2A 2C 2B 7 4 5
1 ORIFICE RELOCATED AFTER SERIAL NUMBER 25201
6
TEST A B
LEFT RIGHT
SS TT RIGHT STEER
RIGHT M5 M6 CYLINDERS
FRONT
REAR
B B
OSCILLATE CYLINDERS
VV
CDR
A A
UU M8
M7 LEFT RIGHT
TEST
7
HYDRAULIC
GENERATOR
50% 280 psi 50% OPTION
0.040 in 19.3 bar 0.040 in
WW AE
1 mm 1 mm
50% AB 50% 50% 50%
OIL COOLER SWV
XX AD JJ RETURN
YY ZZ AC
TANK
M3 M4 FILTER
IN A FUNCTION
CDL 0.040 in MANIFOLD
B
1 mm B B 8
OUT 2
800 psi
TRACTION MANIFOLD 55 bar HYDRAULIC ROTARY COUPLER
A AF AG A
M1 M2 LEFT OIL COOLER OPTION
LEFT
FRONT LL OSCILLATE OPTION
REAR
T
OSCILLATE VALVE HS0078L

S-60 HC • S-60X • S-60XC
6 - 29 6 - 30
Electrical Schematic, S-65 Ford Engine Models (ANSI / CSA)
6 - 31 6 - 32
P22LS BK P22LS BK
P134PWR RD P134PWR RD
1 C28TTA RD/BK C28TTA RD/BK
P22LS BK
P134PWR RD
C41RPM OR/BK C41RPM OR/BK
P26ESTP BK P26ESTP BK
RD FS1
P2
RD C9P-3 P25FS RD
C2P-6
C9P-1 BK
WH C9P-2 P24FS WH P24FS WH
C7P-1
P134PWR GR/BK
TS1 TS2 D10 TS3 TS4
AUXILIARY ENGINE FUEL ENGINE
P22BAT BK
PUMP START SELECT RPM
2
L48
2 P3
C7B-1
C2B-6
H1
4 TB134 RD
BK
D40
WH
D12
KS1
CB2 1 3
15A TB22
P1
C1P-7
C1P-9
C2P-5
C1P-2
C7P-2
C1P-1
C2P-1
3 4 5
RD PLAT
D4
3 1 GND
6 D3 RD
7 RD
TS52 D11 TS53 TS54
12 8 TS51 ENGINE FUEL ENGINE
START SELECT RPM
P23BAT WH
GR/BK
C28TTA RD/BK
C33STR BK
C39LP BL/RD
C35RPM RD/BK
C46HRN GR
C27AUX RD
C32
P4
P20BAT RD
PUMP
AUXILIARY
FUNCTION
ENABLE
C1B-1
C1B-7
C1B-9
C2B-5
C1B-2
C7B-2
C2B-1
CB1
15A TB41
TB33 TB39
BL/RD
RD
D2 TB23 TB27 RD
TB134 D13
RD P24BAT RD TB24
TB20
CR1 CR2 CR4 TB35
CB3 NO NO NC
5 15A
TB21
C5-3 C21ING WH
C35RPM RB/BK
P116HYD RD
P22HRN BK
P134TTS RD
C27AUX RD
C27AUX RD
C46HRN GR
C28TTA RD/BK
TS64 L2
FUSE ALTERNATOR ENGINE
LINK FAULT
C5-18
C5-19
C5-5
C5-2
C5-9
C5-11
C5-10
BAT+ 1
C21ING WH
1
BAT-
Ford DSG 423 Engine Ford MSG 425 Engine
C6-27
C6-26
C6-28
C6-23
CR17 CR5 PR8

NO NO NO C5-8 GR
CR19
6 STA A B
C5-13 BL/WH
R21ING WH
P134FB WH
R33STR BK FEH PIN 15
P23BAT WH FEH PIN 1

R46HRN BK
C41RPM OR/BK FEH PIN 2

C116 OR
C135FP BL/WH FEH PIN 5
C35RPM BK/RD FEH PIN 23
C127TSW GR FEH PIN 6

C108ESL BL/WH FEH PIN 6
C21ING WH FEH PIN 16

C128RPM OR/RD FEH PIN 24
C39LP BL/RD FEH PIN 7
WH
RD
FLD PR1 D C B A D C B A
REGULATOR NO
A
12V DC
S
RD/GN
WH/GN
BR/WH
GN/WH
GY/RD
RD/GR
BK/BL
RD
GY/YL
GY/RD
BR
WH/BK
WH/BK
+ S8
I
M4
C5-1
C5-4
FB1 FB1 +
M3
C6-10
M2 G6
BK PIN 18
BK
FORD ENGINE FORD ENGINE -

-
SW4 C HARNESS HARNESS
7 M1
NO
H2
BRN
B1
BRN
ES0396R
FUEL SENSOR
BATTERY
FUEL SENSOR
LPG LOCKOUT
TOGGLE SWITCH
ENGINE FAULT
HOUR METER
LEVEL SENSOR
LPG LOCKOUT
CHECK ENGINE LED
ALTERNATOR
(OPTION)
OIL COOLER FAN
(OPTION)
OIL COOLER TEMP. SWITCH
(OPTION)
FLASHING BEACONS
SERVICE HORN
RELAY
SERVICE HORN
TILT ALARM
AUXILIARY PUMP
POWER RELAY
AUXILIARY PUMP
STARTER
START SIGNAL (FEH)
RELAY
IGNITION / START
CR1
1 FORD DSG 423 ENGINE ONLY
FORD 42 PIN CONNECTOR

(REFER TO SPECIFIC FORD
8 ENGINE HARNESS DIAGRAM,
FOR YOUR ENGINE MODEL)
Ford DSG-423 EFI Engine

Ford MSG-425 EFI Engine

S-60 HC • S-60X • S-60XC
1
8
Section 6 • Schematics
6 - 33
C7P-3 BATGND C7B-3

GROUND
YL
5 6
BR S18
OR PRIMARY BOOM ANGLE
4
C6-33 C123PBS RD/BK SENSOR - SAFETY

A
BL
3
BR C4P-4 SNSR-GND OR/RD C4B-4 C6-34 SNSR-GND BR

BK
S17
2
GR/WH C4P-9 P109ANG OR/WH C4B-9 C6-20 P109ANG GR/WH

RD PRIMARY BOOM ANGLE
1
SENSOR - OPERATIONAL
J114
RD/BK C4P-8 C123PBS GR/RD C4B-8

2
9
C2P-3 C41RPM OR/BK C2B-3 C5-21 C30FWD WH BK RD
4
5 EDC - DRIVE FORWARD

TB30
U4
J2
10
J1
C1P-4 C30FWD WH C1B-4 C5-20 C31REV WH/BK

1
15 EDC - DRIVE REVERSE

S-60 • S-65 • S-60 TRAX • S-65 TRAX
RD BK
B
C1P-5 C31REV WH/BK C1B-5

16
15
TB31
H3
C6-32 C130TA WH/RD TRAVEL ALARM

TS14
(OPTION)
S-60 HC • S-60X • S-60XC
ROCKER / STEER OPTION
DRIVE MODE C26-1 C26-2

8 C1P-6 C32BRK WH/RD C1B-6 C5-23 C32BRK WH/RD
C29MS RD/WH 19 BRAKE RELEASE
Y2
TB32
Y27
CDE3 BL/RD C28-1 C28-2

C1P-3 C29MS RD/WH C1B03 C5-24 C29MS RD/WH 2 SPEED
J1
16 20
L1
MOTOR STROKE
TB29
Y3
C25-1 C25-2
TS15
CDE1 BL/WH C1P-11 C37SCW BL/BK C1B-11 C6-37 C37SCW BL/BK

7 18 STEER CW
RIGHT
C
DRIVE ENABLE C24-1 C24-2

LEFT C1P-10 C36SCC BL C1B-10 C6-36 C36SCC BL
17 STEER CCW
J2
6
Y4
CDE2 BL/BK
C3P-6 C6TRF WH/RD C3B-6
Y23
11
C14-1 C14-2
C3P-4 C4TRL WH C3B-4 C6-4 C4TRL WH TURNTABLE ROTATE
10
CW
TB4
C15-1 C15-2
4 C3P-5 C5TRR WH/BK C3B-5 C6-5 C5TRR WH/BK TURNTABLE ROTATE
9
CCW
TB5
5
Y24
C159STC BL/WH
C159STC BL/WH
C160JPL WH/RD
RIGHT
13 TURNTABLE ROTATE
P162JPW OR
J1
LEFT
TS62
7.5W
LEFT
R2
CR19
D
14
C31-1 C31-2
C6-6 C6TRF WH/RD TURNTABLE ROTATE
BR
5W
R2
FLOW CONTROL
Y13
J25
6
5
4
3
2
C9PER BK/RD
1
C3P-9 C3B-9
14
C41RPM OR/BK
C28TTA RD/BK
LSB2S
JC3
P26ESTP BK
Y26
C3P-8 C8PBR BK/WH C3B-8

J2
C6-7
13 LOOSE CABLE
P24FS WH
C16-1 C16-2
RD
BR
BATGND
LIMIT SWITCH
22
NC 21
C3P-7 C7PBE BK C3B-7 C37-1

12
RD PRIMARY BOOM
TB7
C37-2
EXTEND
ALC-500 JOYSTICK
CONTROL CARD
EXTEND
Y25
PRIMARY BOOM
TB8
C17-1 C17-2
TS63
RETRACT C6-8 C8PBR BK/WH PRIMARY BOOM

E
U13
RETRACT
Part No. 147753
TB9
December 2013
C30-1 C30-2 PRIMARY BOOM

C6-9 C9PER BK/RD
EXTEND / RETRACT
FLOW CONTROL
Y15
F
1
5
10
J8
8
7
6
P134 RD C6-25 BL
G
4 3 2 1
RD LST3O - ZONE A
NO
NC
21
13
2 BR GROUND BOX
BK SPEED REDUCTION
22
14
WH OPERATIONAL LIMIT SWITCH

Y22
TB1
3 C6-1 C12-1 C12-2

C1PBU RD PRIMARY BOOM
2 UP UP
PRIMARY BOOM
1
C164PES RD/WH
C165TRS WH/RD
C13-1 C13-2
C163PLS WH/BK
DOWN C6-2 C2PBD RD/BK PRIMARY BOOM

J1
11 DOWN
TS61
P162JPW OR
Y21
H
R16
5W
TB3
P26 ESTP
PRIMARY BOOM
12 C6-3 C3PBF RD/WH C29-1 C29-2
UP / DOWN
C118LS OR
CR34
FLOW CONTROL
BR
Y12
J127
10W
R14
CR34 - SPEED REDUCTION

6
5
4
3
2
1
RELAY
OR C6-29
JC7
C3P-1 C1PBU RD C3B-1

6
TB2
C3P-2 C2PBD RD/BK C3B-2

7
BR C3PBF RD/WH C3B-3
1 C3P-3
8
I
J2
P24FS WH
2 C4P-1
3 RD
NO
NC
J3
LST1O
21
13
C8
P24 C2P-2 BR
4 4 P22LS BK DRIVE ENABLE
BK
2 1
LIMIT SWITCH
22
14
P26EST WH C2P-4 C13DE BL/RD C4B-1 BL/RD C6-13 C13DRE BL/RD
3 WH
1
D24
D23
RD
NO
NC
C10
LST2O - STOWED ANGLE
21
13
BR DRIVE SPEED REDUCTION
2 1
BK LIMIT SWITCH
22
14
C40LS OR C2B-2 C6-40 C40LS OR
WH
LIFT / DRIVE
CR27
CR30
NO
NC
RD
J
(OPTION)
C42LS OR/RD C2B-4 OR/RD C6-31 C42LS OR/RD
NO
NC
LSB1RO - BOOM RETRACT
C11
21
13
BR DRIVE / ROTATE SPEED
C6-22 P22LS BK
TB22
2 1
BK LIMIT SWITCH
22
14
WH
L46
P22LS BK L46 / L47
TB59
LOOSE CABLE LED
C3P-11 C59CNK BL/BK C3B-11 C6-11 BL/BK
L47
NO
TB134 LSB2S
P134 RD BK C6-24 C37-3 BK WH C37-4
LOOSE CABLE
13
14
LIMIT SWITCH
C4P-2 C14PLU OR C4B-2
TS9
DOWN PLATFORM
K
UP LEVEL C4P-3 C15PLD OR/BK C4B-3
Y20
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
PLAT. LEVEL C21-1 C21-2
DOWN C6-15 C15PLD OR/BK
(S-65 OPTION)
WH
PLATFORM LEVEL DOWN

BR
TB15
Y19
TB44
JIB BOOM
C3P-10 C129JDA BL C3B-10

C4P-6 C18JD/PRR GR/BK C4B-6
TS8
DOWN
D27
UP C4P-5 C17JU/PRL GR C4B-5
Y16
TB18
D28
C23-1 C23-2
TS58
C6-18 C18JD/PRR GR/BK PLATFORM ROTATE RIGHT
L
DOWN JIB BOOM (JIB BOOM DOWN / S-65 OPTION)

CR13
PLATFORM
(S-65 OPTION) C22-1 C22-2

NC
UP C6-17 C17JU/PRL GR PLATFORM ROTATE LEFT

ROTATE
(JIB BOOM UP / S-65 OPTION)
TB17
Y17
D29
TS7
CW
CCW CW
PLAT. ROTATE
CCW
TS57
C6-19 C129 RD/BK
DESCENT ALRM
D30
H4
TB19
C4P-7 C19JSV GR/WH C4B-7
M
C1
RD
JIB VALVE
-
+
Y11
C41RPM OR/BK
NO
C28TTA RD/BK
RD (AUX & FE)

P26ESTP BK
CR14
P24FS WH
P22LS BK
N
RD (AUX)
P134 RD
BR
Electrical Schematic, S-65

Ford Engine Models, (ANSI / CSA)
6 - 33 6 - 34

Ford Engine Models (ANSI / CSA)
6 - 35 6 - 36
8
7
6
5
4
3
2
1
6 - 36
CR1 CR2 CR4 CR45
BRN
BRN
8
7
6
5
1
3
4
BK-33C
12
RD-24B
C32
BK C5-5
WH-21C
RD CB3-2
WH-C5-11
WH-C5-19
WH-23C (2)
C21IGN WH
P48PWR WH
C5
BK-22D
C32
RD-TS52
RD-TS51
BK C7B-1
B
C6
S-65 MODELS
BRN
RD-27C
WH C5-4
BK-46R
GR-46D
OR C5-1
WH/RD-6D
RD/WH-3D
BK-22C (1)
BRN

CR19

CR34
C21IGN WH21A (1)

C
CR5
C6
C5
WH/RD-R2 CR17
WH/RD-R4
RD/WH-R16 OR C6-29
S-65 Ford Engine Models (ANSI / CSA)
RD/WH-TS61
RD-CB3
S-60 HC • S-60X • S-60XC

TS64
S-60 • S-65 • S-60 TRAX • S-65 TRAX

ENGINE FAULT
D
TOGGLE SWITCH
D C TERMINAL BASE (TB) B A C1PBU RD C3B-1 BRN

RD-TS61 C1PBU RD C6-1 C5-8 GR
1 PRIMARY BOOM UP 1
RD/BK-ALARM C2PBD RD/BK C3B-2
RD/BK-TS61 C2PBD RD/BK C6-2
2 PRIMARY BOOM DOWN 2
D29
C3PBF RD/WH C3B-3
RD/WH-CR34 C3PBF RD/WH C6-3
3 PRIMARY BOOM FUNCTION CONTROL 3
C4TRL WH C3B-4
WH-TS62 C4TRL WH C6-4
4 TURNTABLE ROTATE LEFT 4
C5TRR WH/BK C3B-5
WH/BK-TS62 C5TRR WH/BK C6-5 GND BRN
5 TURNTABLE ROTATE RIGHT 5
E
C6TRF WH/RD C3B-6

WH/RD-CR19 C6TRF WH/RD C6-6 P48PWR WH C45-87
Ground Control Box Terminal Strip Wiring Diagram
OPT
6 TURNTABLE ROTATE FUNCTION CTRL 6

C7PBE BK C3B-7
BK-TS63 C7PBE RD C6-7
7 PRIMARY BOOM EXTEND 7
C8PBR BK/WH C3B-8
BK/WH-TS63 C8PBR BK/WH C6-8
8 PRIMARY BOOM RETRACT 8
C9PER BK/RD C3B-9
BK/RD-TS63 C9PER BK/RD C6-9
9 PRIM. BOOM EXT/RET FUNC. CTRL 9
C14PLU OR C4B-2
OR-TS59 C14PLU OR C6-14
14 PLATFORM LEVEL UP 14
C15PLD OR/BK C4B-3
Part No. 147753

December 2013
OR/BK-TS59 C15PLD OR/BK C6-15

15 PLATFORM LEVEL DOWN 15
C17JU GR C4B-5
GR-TS57 C17JU GR C6-17
17 PLATFORM ROTATE LEFT/JIB UP 17
C18JD GR/BK C4B-6
GR/BK-TS57 C18JD GR/BK C6-18
18 PLATFORM ROTATE RIGHT/JIB DOWN 18
C19JSV GR/WH C4B-7
GR/WH-TS57
19 JIB SELECT VALVE 19
RD-CB2 P20BAT RD P20BAT RD
20 +12 VOLT POWER (1) 20
BRN
12V DC
G
20 +12 VOLT POWER (2) 20

C21IGN WH CR17 #86
C128RPM WH C5-9
BATTERY POWER
21 IGNITION POWER (1) 21

WH TB21
WH-HM
BK-CR5
C5
C6
C3
C4
C7
F19
BK-KS1-1 C6-39
22 +12 VOLT TO PLATFORM (1) 22
P22BAT BK C6-22
BK-C32-4
23 KEYSWITCH POWER (1) 23

WH-CR4 #30 P23BAT WH C7B-2
H
WH-KS1-3
RD CR2#86 C4B
RD-CB1 (BROWN)
24 CIRCUIT BREAKER POWER 24
18/22
25 (UNUSED) 25 C3B
CABLE #1
(GREEN)
26 (UNUSED) 26
RD-CR19#86 C27AUX RD C1B-1
RD-TS51 C27AUX RD C6-27
27 AUXILARY PUMP 27 C2B
C29MS RD/WH C1B-3
(BLACK)
I
C29MS RD/WH C5-24

29 MOTOR STROKE 29
C30FWD WH C1B-4
18/19
C30FWD WH C5-21
30 PROPEL FORWARD 30 C1B
CABLE #2
C31REV WH/BK C1B-5

WH/RD-R2
WH/RD-R4
(GREY)
RD/WH-R16
C31REV WH/BK C5-20

RD/WH-TS61
31 PROPEL REVERSE 31
C32BRK WH/RD C1B-6
BRN
WH/RD-C6-32 C32BRK WH/RD C5-23

32 BRAKE 32
BK CR1#86 C33STR BK C1B-7
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
HARNESS TO
SWITCH PANEL
34 (UNUSED) 34
J
C35RPM BK/RD C1B-9

C35RPM BK/RD C5-18
35 HIGH FUNCTION SPEED 35
C1B-10 C36SCC BL C6-36
C39LP BL/RD C2B-1

C4B-1 C13DE BL/RD C6-13
C2B-4 C42LS OR/RD C6-31
C1B-2 C28TTA RD/BK C6-28
C4B-4 SNSR GND BR C6-34

C1B-12 C177LS BL/RD C6-21
BL/RD-TS53 C39LP BL/RD C5-10

C4B-8 C123PBS RD/BK C6-33
C1B-11 C37SCW BL/BK C6-37
C3B-12 P109LS GR/WH C6-16
39 FUEL SELECT (GAS/LP) 39

C4B-9 P109ANG GR/WH C6-20
C40LS1 OR C2B-2
C40LS1 OR C6-40
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C6
C41RPM OR/BK C5-2

41 ALTERNATOR PULS PICKUP 41
HARNESS
C129JDA BL C3B-10
FUNCTION
BL-TS58 RD/BK-ALARM C6-19

44 JIB DOWN DESCENT ALARM OPT. 44
D30
C45GEN GR/WH C5-12

C3
K
C45GEN GR/WH C2B-7

45 GENERATOR OPTION 45
C59CNK BL/BK C3B-11
BL/BK-L46+ C59CNK BL/BK C6-11
59 RETRACT BOOM LED 59
P134PWR RD C2B-6
RD-KS1-2 P134FB RD C6-23
134 LOAD WEIGHING LIM. SW. +12V (1) 134
P134BAT BK C6-25
P134BAT RD C6-24
P134TTS RD C6-26
C6
C7
C5
C2
C5
210 DUAL CAPACITY +12V 210

L
ENGINE
HARNESS
NOTE: DASHED LINES INDICATE OPTIONS.
C46HRN GR C2B-5 C46HRN GR CR5#86

M
C7P
12V DC
BRN
POWER TO PLATFORM
BRN C7B-3
ES0396R
GROUND BOLT
N
Ground Control Box Switch Panel Wiring Diagram

CONNECTIONS
CONTROL BOX
1
TO GROUND
WH/RD-CR19#87A
RD/WH-CR34#87A
WH/RD-CR19#87
RD/WH-CR34#87
WH/RD TS62-6
RD/WH-TS61-3
BR-GND STUD
GR/WH-TB19D
OR/BK-TB15D
GR/BK-TB18D
BK/RD-TB35D
RD-C134D (2)
BL/RD-TB39D
BL/WH-C5-13
BL/BK-TB59D
WH/BK-TB5D
BK/WH-TB8D
BR-CR34#85
BK/RD-TB9D
RD/BK-TB2D
RD/WH-R16
WH-TS51-2
WH-TB23D
WH-TB21D
RD-TS51-5
RD-TS51-1
WH/RD-R2
RD-TS61-2
WH/RD-R4
RD TS62-4
OR-TB14D
RD TS61-2
GR-TB17D
RD-TB27D
RD-TB20C
RD-TB20C
RD-TB20D
RD-TB24D
WH-KS1-1
BK-TB22D
BK-TB33D
BL-TB44D
RD-CB2-1
WH-TB4D
RD-C6-33
BR-L46(-)
RD-TB1D
BK-TB7D
BR-G6(-)
RD-P1-2
RD-R14
RD-P4
2
TS52
1
1
3
TS51
P4
2
D3
3
4
3
NO
4
6
4
3
NO
1
G6
1
WH/RD
WH/RD
CB2
TS61
6
2
D4
4
R2
R4
4
D11
L46
1
3
TS62
1
4
4
TS53
+
TS63
KS1
2
B1
3
RD/WH 5
2
6
1
D28
D13
1
D2
TS54
CB1
TS58
R16
R14
1
6
2
3
1A
1B
RD
P1
NC
NC
2A
2B
1
TS59
1
7
L2
TS57
CB3
3
2
1
+
2
COMPONENT INDEX - GROUND CONTROLS
CB1 ENGINE CIRCUIT BREAKER, 15A L2 LED - CHECK ENGINE TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
CB2 CONTROLS CIRCUIT BREAKER, 15A L46 LED - CABLE TENSION TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
CB3 CIRCUIT BREAKER, 15A (OPTION) P1 EMERGENCY STOP BUTTON TS62 TURNTABLE ROTATE TOGGLE SWITCH
CB7 HIGH IDLE CIRCUIT BREAKER P4 FUNCTION ENABLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
CR1 START RELAY R2 RESISTOR, 5W, TURNTABLE ROTATE SPEED 8
CR2 IGNITION / FUEL RELAY R4 RESISTOR, 7.5W, TURNTABLE ROTATE SPEED
CR4 HIGH IDLE RELAY R14 RESISTOR, 10W, PRIMARY BOOM UPPER ZONE SPEED
CR5 HORN RELAY R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED NOTE: DASHED LINES INDICATE OPTIONS.
CR17 HYDRAULIC OIL COOLER RELAY (OPTION) TS51 AUXILIARY PUMP TOGGLE SWITCH
CR19 TURNTABLE SPEED REDUCTION RELAY TS52 ENGINE START TOGGLE SWITCH
CR23
CR34
DRIVE LIGHTS RELAY (OPTION)
PRIMARY BOOM SPEED REDUCTION RELAY
TS53
TS54
FUEL SELECT TOGGLE SWITCH
RPM SELECT TOGGLE SWITCH
ES0396R
G6 HOUR METER TS57 PLATFORM ROTATE TOGGLE SWITCH
KS1 KEY SWITCH TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-65 OPTION)

S-60 HC • S-60X • S-60XC

6 - 37 6 - 38
Platform Control Box Wiring Diagram

6 - 39 6 - 40
CWLITE WH TS49
N
ES0396R
M
CONTROL HARNESS
SWITCH PANEL
TO PLATFORM
GR/WH
RD
C19JSV GR/WH TS7

C19JSV GR/WH C4P-7
L
BRN JC3 BR BK
BRN GND
RD-E-STOP
P134PWR RD-H1+
CR13-#86 RD BR
GR/WH
OPT.
C1
RD OUTPUT
GR/WH +
TS7 WH
CR14
C134PWR RD
LIFT / DRIVE
BRN -
(OPTION)

K
CR27
BR
RD RD
JIB
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
OPT.
CR30
D24
J
C40LS OR
C42LS OR/RD
D23
TS14 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
(S-65 OPT.)
C18PRR GR/BK C4P-6

BR
C17PRL GR C4P-5
JIB
C15PLD OR/BK C4P-3

I
C14PLU OR C4P-2
C129JDA BL C3P-10 TS8
J8-P109LS GR/WH C3P-12
C59CNK BL/BK C3P-11 L47+
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
F.S.
H
C45GEN GR/WH C2P-7

C46HRN GR C2P-5
F.S.
C39LP BL/RD C2P-1

C9
P26ESTP BK
C3P
C4P
C7P
C2P
11
3
C42LS OR/RD C2P-4

C6TRF WH/RD C3P-6
J3
C123PBS RD/BK C4P-8

C7PBE BK C3P-7
C13DE BL/RD C4P-1
G
C8PBR BK/WH C3P-8

P24FS WH C40LS OR C2P-2
C9PER BK/RD C3P-9
P24FS WH C41RPM OR/BK C2P-3
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36SCC BL C1P-10
C3PBF RD/WH C3P-3
ALC-500
C37SCW BL/BK C1P-11

C5TRR WH/BK C3P-5
F
December 2013
Part No. 147753

U13
C32BRK WH/RD C1P-6

C4TRL WH C3P-4
J2
C29MS RD/WH C1P-3
12V BATT
P109ANG GR/WH C4P-9
C7P
SENSOR GND BR C4P-4
J8
6
C7P
C3P
C4P
C1P
C2P
E
C4P(BR)
BR
1
J7
C3P(GR)
D
C35RPM BK/RD C1P-9
S-60 • S-65 • S-60 TRAX • S-65 TRAX

C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
S-60 HC • S-60X • S-60XC

J1
9
P109ANG GR/WH
C165TRS WH/RD
SENSOR GND BR
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS WH/BK
C
GND BR
C160JPL WH/RD
P162JPW OR
C159STC BL/WH

GND BR
C143DEL BL/BK C28TTA RD/BK C1P-2
C144DER BL/WH
C28TTA RD/BK C1P-2

C13DE BL/RD
C29MS RD/WH
BATGRN C7P-3
B
D40
C28TTA RD/BK
RD/BK-L48 RD/BK-L48
H1
P134PWR RD C2P-6
P134PWR RD RD-TILT
+
CWLITE BK
A
BRN
BRN
CWLITE WH TS49
6 - 40
1
8
Platform Control Box Switch Panel Wiring Diagram

CONTROL HARNESS 1
TO PLATFORM BOX
BK C7P-1
RD H1(+)
RD/WH J1-2
BK J3-3
BR J1-14
BL/WH J1-5
BK C9-1
BR J1-12
OR J1-11
BK/RD C1P-9
RD C9P-3
BL/WH J1-7
RD/WH J1-8
RD C1P-1
BL/RD C2P-1
BR GND STUD
RD/BK H1 (D40)
BL/BK J1-6
WH C9P-2
BL/RD J1-16
GR/WH C2P-7
BK C1P-7
GR C2P-5
OR/BK C4P-3
OR C4P-2
CR14-#86 RD
GR/BK C4P-6
GR/WH C4P-7
GR C4P-5
BL/BK C3P-11
OR J1-13
C129JDA BL C3P-10
WH/RD J1-4
WH/BLK C4P-9
WH/RD J1-1
WH/BK J1-3
WH C7P-2
TS3 TS4 TS15 2
1
D12
JC7 D10 JC3
3
TS2
+
6
1 L47
+
WH
WH L1
BK
4
CR13 1 6
WH
TS9 TS8 TS1 TS47 TS48
TS7 TS14
NO
+
NC
P3
L48 5
P2
BK
RD
RD
D27
COMPONENT INDEX
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTIONS.
C1 CAPACITOR, JIB CIRCUIT (S-65 OPTION) TS9
CR13 JIB SELECT RELAY (S-65 OPTION) TS14 DRIVE SPEED TOGGLE SWITCH 1 ROCKER / STEER OPTION.
CR14 JIB VALVE RELAY (S-65 OPTION) TS15 DRIVE ENABLE TOGGLE SWITCH
CR27 RELAY - BRAKE CIRCUIT (LIFT / DRIVE OPTION) TS47 GENERATOR (OPTION)
CR30 RELAY - LIMIT SWITCH CIRCUIT (LIFT / DRIVE OPTION) TS48 DRIVE LIGHTS (OPTION)
H1 TILT ALARM U13 ALC500 JOYSTICK CONTROLLER CARD 7
JC3 JOYSTICK - DRIVE / STEER
JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE
L1 LED - DRIVE ENABLE
L47 LED - CABLE TENSION
L48 LED - TILT ALARM
P2 EMERGENCY STOP BUTTON
P3 HORN BUTTON
TS1 AUXILIARY PUMP TOGGLE SWITCH
TS2 ENGINE START TOGGLE SWITCH 8
TS3 FUEL SELECT TOGGLE SWITCH
TS4 RPM SELECT TOGGLE SWITCH
TS7 PLATFORM ROTATE TOGGLE SWITCH
TS8 JIB BOOM UP / DOWN TOGGLE SWITCH (S-65 OPTION) Ford DSG-423 EFI Engine
ES0396R Ford MSG-425 EFI Engine

S-60 HC • S-60X • S-60XC

6 - 41 6 - 42

Deutz D2011L03i Models (ANSI / CSA)
6 - 43 6 - 44
C41RPM OR/BK
C28TTA RD/BK
RD (AUX + FE)
P26ESTP BK
P24FS WH
P22LS BK
RD (AUX)
P134 RD
N
BRN
CR4
ENGINE
TB35
D12
C1B-9
RPM
C1P-9 C35RPM BK/RD C35RPM BK/RD BRN

TS4
RPM CONTROL RELAY

HIGH
LOW
NO
CB7
10A
D13
ENGINE
TS54
RPM
BK/RD C5-18
D4
D3
RPM SOLENOID
LOW
CR4
Q3
HIGH
M
L
K
FUNC. ENABLE
P4
J
TB34
GLOW
PLUG
C1P-8 C34SA BK/WH C1B-8 C34SA BK/WH C5-22 GLOW PLUG

TS6
CONTROL RELAY
CR15
NO
GLOW
PLUG
TS56
GLOW PLUG
70A
F22
L2
D64
IGN / START
I
MODULE
U1
TB26
ENGINE
ENGINE FAULT
SW3
TACHOMETER
AUXILIARY ON
IGN / FUEL ON
START
START RELAY
NO
START INPUT
KEY BYPASS
C1B-7
KEY POWER
C1P-7 C33STR BK C5-14 C26TS WH/RD OIL TEMPERATURE

TS2
BATTERY
GROUND
SWITCH
ENGINE
START
TS52
10
C25PS WH/BK
2
3
4
5
6
7
8
9
1
C5-16 OIL PRESSURE

SWITCH
SW2
TB25
NC
BK
TB33
H
FUEL SOLENOID
CONTROL RELAY
C41RPM OR/BK
C28TTA RD/BK
CR2
NO
P26ESTP BK
P24FS WH
C21IGN2 WH
P25FS RD
C5-11
P22LS BK
FUEL SOLENOID
P134 RD
TB21
D52
AUXILIARY
G
C21IGN WH
PUMP
G6
HOUR METER
+
TS1
-
C1B-1
C1P-1 C27AUX RD IGNITION / STRTER
RELAY
C9P-3
C9P-2
CR1
NO
R33STR BK C5-5
TB24
STARTER
POWER RELAY
WH
RD
PR2
NO
FS1
M3
STARTER
BK
F
December 2013
Part No. 147753

TS51
CR19
EMISSION CONTROL
C9P-1
AUXILIARY
TB27
PUMP
RD C27AUX RD PRIMARY BOOM SPEED
REDUCTION RELAY
C27AUX RD (F.H.) C6-27 AUXILIARY PUMP
BK
C7B-2
P23BAT WH POWER RELAY
TB23
C7P-2
PR1
NO
P2
D2
M2
AUXILIARY PUMP
L48
WH
C1P-2 WH
E
Electrical Schematic, S-65 / S60 TRAX / S65 TRAX
RD/BK
D40
C1B-2
C
C28TTA RD/BK C28TTA RD/BK C6-28 WH
TILT ALARM
S8
P134TTS RD
-
C6-26 BR
+
RD BK
H1
LEVEL SENSOR
B
A
RD
C2B-5 C46HRN GR
C2P-5 C46HRN GR SERVICE HORN
RELAY
P3
GR/BK
CR5
NO
H2
C7B-1
D
C7P-1 P22BAT BK
S-60 • S-65 • S-60 TRAX • S-65 TRAX

P22BAT BK R46HRN BK C6-10
SERVICE HORN
FB1
3
S-60 HC • S-60X • S-60XC

C32
TB134
FLASHING BEACONS
C2P-6 P134PWR GR/BK C2B-6 (OPTION)
1
P134FB WH C6-23
FB1
12
4
6
TB134
RD
C
SW4
NO
BK
C21IGN WH OIL COOLER TEMP. SWITCH
TB22
R21IGN WH C5-4
(OPTION)
RD
WH
CR17
NO
PLAT
GND
P116HYD RD R116 OR C5-1 OIL COOLER FAN
M1
(OPTION)
3mF
C3
2
1
3
B1
KS1
TB41
C41RPM OR/BK C41RPM OR/BK C5-2
C5-3
B
RD
D22
EXCT
C107AF RD
BAT-
STA
IND
RD
RD
P1
REGULATOR
ALTERNATOR
RD
CB1
CB3
15A
15A
BAT+
CB2
15A
ES0186U
A
TB20
-
+
RD P20BAT RD
BATTERY
12V DC
B1
6 - 44
1
8
1
8

6 - 45
C7P-3 BATGND C7B-3

GROUND
YL
5 6
BR S18
4

A
BL
3

BK
S17
2

1
J114

2
9
4

TB30
U4
J2
10
J1

1

RD BK
S-60 • S-65 • S-60 TRAX • S-65 TRAX
C1B-5
B
C1P-5 C31REV WH/BK

16
15
TB31
H3

TS14
(OPTION)
S-60 HC • S-60X • S-60XC

Y2
TB32
Y27

J1
16 20
L1
MOTOR STROKE
TB29
Y3
C25-1 C25-2
TS15

7 18 STEER CW
RIGHT
C

17 STEER CCW
J2
6
Y4
CDE2 BL/BK
Y23
11
C14-1 C14-2
10
CW
TB4
C15-1 C15-2
9
CCW
TB5
5
Y24
C159STC BL/WH
C159STC BL/WH
C160JPL WH/RD
RIGHT
13 TURNTABLE ROTATE
P162JPW OR
J1
LEFT
TS62
7.5W
LEFT
R2
CR19
14
D
C31-1 C31-2
BR
5W
R2
FLOW CONTROL
Y13
J25
6
5
4
3
2
C9PER BK/RD
1
C3P-9 C3B-9
14
C41RPM OR/BK
C28TTA RD/BK
LSB2S
JC3
P26ESTP BK
Y26

J2
C6-7
13 LOOSE CABLE
P24FS WH
C16-1 C16-2
RD
BR
BATGND
LIMIT SWITCH
22
NC 21

12
RD PRIMARY BOOM
TB7
C37-2
EXTEND
ALC-500 JOYSTICK
CONTROL CARD
EXTEND
Y25
PRIMARY BOOM
TB8
C17-1 C17-2
TS63

U13
E
RETRACT
Part No. 147753
TB9
December 2013

C6-9 C9PER BK/RD
EXTEND / RETRACT
FLOW CONTROL
Y15
F
1
5
10
J8
8
7
6
P134 RD C6-25 BL
G
4 3 2 1
RD LST3O - ZONE A
NO
NC
21
13
2 BR GROUND BOX
BK SPEED REDUCTION
22
14

Y22
TB1
3 C6-1 C12-1 C12-2

2 UP UP
PRIMARY BOOM
1
C164PES RD/WH
C165TRS WH/RD
C13-1 C13-2
C163PLS WH/BK

J1
11 DOWN
TS61
P162JPW OR
Y21
H
R16
5W
TB3
P26 ESTP
PRIMARY BOOM
12 C6-3 C3PBF RD/WH C29-1 C29-2
UP / DOWN
C118LS OR
CR34
FLOW CONTROL
BR
Y12
J127
10W
R14

6
5
4
3
2
1
RELAY
OR C6-29
JC7

6
TB2

7
1 C3P-3
8
I
J2
P24FS WH
2 C4P-1
3 RD
NO
NC
J3
LST1O
21
13
C8
P24 C2P-2 BR
BK
2 1
LIMIT SWITCH
22
14
3 WH
1
D24
D23
RD
NO
NC
C10
21
13
2 1
BK LIMIT SWITCH
22
14
WH
LIFT / DRIVE
CR27
CR30
NO
NC
RD
(OPTION)
J
NO
NC
C11
21
13
C6-22 P22LS BK
TB22
2 1
BK LIMIT SWITCH
22
14
WH
L46
P22LS BK L46 / L47
TB59
LOOSE CABLE LED
L47
NO
TB134 LSB2S
P134 RD BK C6-24 C37-3 BK WH C37-4
LOOSE CABLE
13
14
LIMIT SWITCH
TS9
DOWN PLATFORM
K
Y20
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
(S-65 OPTION)
WH
PLATFORM LEVEL DOWN

BR
TB15
Y19
TB44
JIB BOOM

TS8
DOWN
D27
Y16
TB18
D28
C23-1 C23-2
TS58
L

CR13
PLATFORM
(S-65 OPTION) C22-1 C22-2

NC

ROTATE
TB17
Y17
D29
TS7
CW
CCW CW
PLAT. ROTATE
CCW
TS57
C6-19 C129 RD/BK
DESCENT ALRM
D30
H4
TB19
M
C1
RD
JIB VALVE
-
+
Y11
C41RPM OR/BK
NO
C28TTA RD/BK
RD (AUX & FE)

P26ESTP BK
CR14
P24FS WH
P22LS BK
N
RD (AUX)
P134 RD
BR

6 - 45 6 - 46

Deutz TD2011L04i Models (ANSI / CSA)
6 - 47 6 - 48
BRN
P134 RD
P22LS BK
C41RPM OR/BK
P26ESTP BK
C28TTA RD/BK
N
P24FS WH
RD (AUX + FE)
RD (AUX)
D12
TB35
C1P-9 C35RPM BK/RD C1B-9 BRN

HIGH IDLE RELAY
FOOTSW. HIGH
ANSI/CSA
CR4
FOOTSW. LOW RD
HOLD
A
TS4
WH HIGH RPM SOLENOID

D13
PULL IN
ENGINE
SPEED
BRN
BK
WH
RD
TS54
C
M
CB7
15A
LOW RPM
D4
D3
ENGINE SPEED
CR4
NO
TIME DELAY
HIGH RPM
MODULE
S-500
MOM N.O.
+BAT
-GND
+AUX
RPM MODULE
C5-18
L
K
FUNC. ENABLE
P4
J
PR2
U16
NO
C34SA BK/WH C5-22

GLOW PLUG RELAY
TIMER30
GLOW PLUG
F22 70A
PR2
NO
30 SEC GLOW
L2
PLUG TIMER
I
ENGINE CHECK LED

IGN./START
TS6
C1P-8 C1B-8
MODULE
U1
TB34
ON C34SA BK/WH
GLO PLUG
SW3
ON
NO
G. PLUG
TB25
TACHOMETER
START RELAY
IGN./FUEL ON
TS56
START INPUT
KEY BYPASS
ENG. FAULT
C5-14 C26TS WH/RD OIL TEMPERATURE

KEY PWR.
D64
BATTERY
GROUND
AUX. ON
TS2
C1P-7 C1B-7 SWITCH

START C33STR BK
ENGINE
10
1
2
3
4
5
6
7
8
9
C5-16 C25PS WH/BK OIL PRESSURE

ENGINE
C28TTA RD/BK
START SWITCH
TS52
TB26
H
SW2
BK
P22LS BK
NC
TB33
P134 RD
CR2
POWER RELAY
P26ESTP BK
TB21
P24FS WH
P25FS RD
AUX. PUMP C21IGN2 WH C5-11

FUEL SOLENOID
TS1
NO
CR2
C1P-1 C27AUX RD C1B-1

D52
G
C21IGN WH
C9P-3
C9P-2
HM
HOUR METER
_
IGN./START RELAY
CR1
NO
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
PR2
NO
M3
STARTER MOTOR
FS1
F
December 2013
Part No. 147753

BK-(FS)
TS51
AUXILIARY
TB27
C9P-1
PUMP RD C27AUX RD AUXILIARY POWER

RELAY
PR1
TB23
NO
BK
C7B-2
C7P-2 P23BAT WH
M2
C6-27 AUXILIARY PUMP
P2
D2
L48
E
RD/BK
C1P-2 WH
D40
RD/BK
C1B-2
C
H1
TILT ALARM
P134TTS RD C6-26 RD BK BRN
LEVEL SENSOR
C3B-12
B
C3P-12 C133PLA BL/WH
TB46
S8
RD
C2B-5
C2P-5 C46HRN GR C46HRN GR SERVICE HORN
RELAY
P3
GR/BK
D
CR5
NO
H2
S-60 • S-65 • S-60 TRAX • S-65 TRAX

C7P-1 P22BAT BK C7B-1

SERVICE HORN
8
5
S-60 HC • S-60X • S-60XC

FB1
TB134
3
C32
C2B-6 C6-23 P134FB WH FLASHING BEACONS
C2P-6 C134PWR GR/BK
OPTION
1
P22LS BK
P134 RD
12
4
6
TB134
RD
C
CR17
SW3
WH
NO
BK
C21IGN WH R21IGN WH C5-4
86
85
TB22
HYD. OIL TEMP. SWITCH
WH
RD
P116HYD RD
87
(OPTION)
30
PLAT
GRD
C41RPM OR/BK
87a
R116 OR C5-1
M1 FAN
C3 3MF
COOLING FAN
2
4
KS1
1
3
B1
+
TB41
B
C5-3
D22
RD
EXCT.
C107AF RD
STA.
BAT.
IND.
RD
RD
P1
-
ALTERNATOR
REGULATOR
RD
15AMP.
15AMP.
CB1
CB3
BAT.
+
15AMP.
A
CB2
TB20
-
RD P20BAT RD
12 V
6 - 48
DC
1
8
1
8

6 - 49
C7P-3 BATGND C7B-3

GROUND
YL
5 6
BR S18
4

A
BL
3

BK
S17
2

1
J114

2
9
4

TB30
U4
J2
10
J1

1

S-60 • S-65 • S-60 TRAX • S-65 TRAX
RD BK
B

16
15
TB31
H3

TS14
(OPTION)
S-60 HC • S-60X • S-60XC

Y2
TB32
Y27

J1
16 20
L1
MOTOR STROKE
TB29
Y3
C25-1 C25-2
TS15

7 18 STEER CW
RIGHT
C

17 STEER CCW
J2
6
Y4
CDE2 BL/BK
Y23
11
C14-1 C14-2
10
CW
TB4
C15-1 C15-2
9
CCW
TB5
5
Y24
C159STC BL/WH
C159STC BL/WH
C160JPL WH/RD
RIGHT
13 TURNTABLE ROTATE
P162JPW OR
J1
LEFT
TS62
7.5W
LEFT
R2
CR19
D
14
C31-1 C31-2
BR
5W
R2
FLOW CONTROL
Y13
J25
6
5
4
3
2
C9PER BK/RD
1
C3P-9 C3B-9
14
C41RPM OR/BK
C28TTA RD/BK
LSB2S
JC3
P26ESTP BK
Y26

J2
C6-7
13 LOOSE CABLE
P24FS WH
C16-1 C16-2
RD
BR
BATGND
LIMIT SWITCH
22
NC 21

12
RD PRIMARY BOOM
TB7
C37-2
EXTEND
ALC-500 JOYSTICK
CONTROL CARD
EXTEND
Y25
PRIMARY BOOM
TB8
C17-1 C17-2
TS63

E
U13
RETRACT
Part No. 147753
TB9
December 2013

C6-9 C9PER BK/RD
EXTEND / RETRACT
FLOW CONTROL
Y15
F
1
5
10
J8
8
7
6
P134 RD C6-25 BL
G
4 3 2 1
RD LST3O - ZONE A
NO
NC
21
13
2 BR GROUND BOX
BK SPEED REDUCTION
22
14

Y22
TB1
3 C6-1 C12-1 C12-2

2 UP UP
PRIMARY BOOM
1
C164PES RD/WH
C165TRS WH/RD
C13-1 C13-2
C163PLS WH/BK

J1
11 DOWN
TS61
P162JPW OR
Y21
H
R16
5W
TB3
P26 ESTP
PRIMARY BOOM
12 C6-3 C3PBF RD/WH C29-1 C29-2
UP / DOWN
C118LS OR
CR34
FLOW CONTROL
BR
Y12
J127
10W
R14

6
5
4
3
2
1
RELAY
OR C6-29
JC7

6
TB2

7
1 C3P-3
8
I
J2
P24FS WH
2 C4P-1
3 RD
NO
NC
J3
LST1O
21
13
C8
P24 C2P-2 BR
BK
2 1
LIMIT SWITCH
22
14
3 WH
1
D24
D23
RD
NO
NC
C10
21
13
2 1
BK LIMIT SWITCH
22
14
WH
LIFT / DRIVE
CR27
CR30
NO
NC
RD
J
(OPTION)
NO
NC
C11
21
13
C6-22 P22LS BK
TB22
2 1
BK LIMIT SWITCH
22
14
WH
L46
P22LS BK L46 / L47
TB59
LOOSE CABLE LED
L47
NO
TB134 LSB2S
P134 RD BK C6-24 C37-3 BK WH C37-4
LOOSE CABLE
13
14
LIMIT SWITCH
TS9
DOWN PLATFORM
K
Y20
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
(S-65 OPTION)
WH
PLATFORM LEVEL DOWN

BR
TB15
Y19
TB44
JIB BOOM

TS8
DOWN
D27
Y16
TB18
D28
C23-1 C23-2
TS58
L

CR13
PLATFORM
(S-65 OPTION) C22-1 C22-2

NC

ROTATE
TB17
Y17
D29
TS7
CW
CCW CW
PLAT. ROTATE
CCW
TS57
C6-19 C129 RD/BK
DESCENT ALRM
D30
H4
TB19
M
C1
RD
JIB VALVE
-
+
Y11
C41RPM OR/BK
NO
C28TTA RD/BK
RD (AUX & FE)

P26ESTP BK
CR14
P24FS WH
P22LS BK
N
RD (AUX)
P134 RD
BR

6 - 49 6 - 50

S60 TRAX/S65 TRAX Deutz Engine Models (ANSI / CSA)
6 - 51 6 - 52
8
7
6
5
4
3
2
1
RD
6 - 52
BRN
CR1 CR2 CR45
RD
A
BK-ISM1
BRN
CR4
BRN
WH ISM9
CB7
8
7
6
5
1
3
4
12
C32
CB3-2 RD
BAT
AUX
WH-21B
P48PWR WH
C21IGN WH
BK
RD-24B
CB7 BK/RD
BK C5-5
BK/RD-35C
BRN
BRN
C21IGN WH C5-11
BK/RD-CR4
BK-22D
B
C5
RD-TS52
RD-TS51
BK C7B-1
C5-18 BK/RD C32
C6
S-65 MODELS
BRN
WH C5-4
RD-27C
BK-22C1
BK C6-10
GR C2B-5
OR C5-1
RD/WH-3D
WH/RD-6D
BRN CR19
CR34
C21IGN WH
C
CR5
C6
C5
RD-ISM4
WH/RD-R2 CR17
WH/RD-R4
RD/WH-R16 OR C38-2
RD/WH-TS61
S-60 HC • S-60X • S-60XC

RD-CB3
C6-19
D C TERMINAL BASE (TB) B A C1PBU RD C3B-1
RD-TS61 C1PBU RD C6-1
S-60 • S-65 • S-60 TRAX • S-65 TRAX

1 PRIMARY BOOM UP 1
D

D29
C3PBF RD/WH C3B-3
3 PRIMARY BOOM UP/DOWN FUNC CTRL 3
C4TRL WH C3B-4
C5TRR WH/BK C3B-5
C6TRF WH/RD C3B-6
WH/RD-CR19 C6TRF WH/RD C6-6
OPT
6 TURNTABLE ROTATE FUNC CONTROL 6
Deutz D2011L03i Engine and Deutz TD2011L04i Engine

C7PBE BK C3B-7 P48PWR WH C45-87
BK-TS63 C7PBE BK-LS5 C6-7
E

C8PBR BK/WH C3B-8
C9PER BK/RD C3B-9
BK
RD
WH
9 PRIMARY BOOM EXT/RET FUNC. CTRL 9
C14PLU OR C4B-2
C15PLD OR/BK C4B-3

C17JU GR C4B-5
C18JD GR/BK C4B-6
Part No. 147753

December 2013

C19JSV GR/WH C4B-7
GR/WH-TS57 BRN
19 JIB SELECT VALVE (S-65 OPTION) 19
20 +12 VOLT POWER (1) 20
12V DC
D52 20 +12 VOLT POWER (2) 20

BRN-<GND> C21IGN WH CR2
C21IGN2 WH C5-3
BATTERY POWER

WH TB21
WH-HM
G
C5
C3
C6
C4
BK-CR5
BK-KS1-1
22 +12 VOLT TO PLATFORM (1) 22 C5-7
P22BAT BK C6-22
BK C32-4

WH-ISM7 P23BAT WH C7B-2
WH-KS1-3
23 KEYSWITCH POWER (2) 23 C4B
RD-ISM6 RD-CR2
RD-CB1 (BROWN)
H
WH-ISM10 C25PS WH/BK C5-16

18/22
25 OIL PRESSURE SWITCH 25 C3B

CABLE #1
WH/RD-L2- C26TS WH/RD C5-14 (GREEN)

26 OIL TEMPERATURE SWITCH 26
C29MS RD/WH C1B-3
C29MS RD/WH C5-24
(BLACK)
29 MOTOR STROKE 29
BK
RD
C30FWD WH C1B-4
WH
18/19
C30FWD WH C5-21
C31REV WH/BK C1B-5
CABLE #2
(GREY)
WH/RD-R2
WH/RD-R4
C31REV WH/BK C5-20

RD/WH-R16
RD/WH-TS61
I
C32BRK WH/RD C1B-6

32 BRAKE 32
BK-ISM3 C33STR BK C1B-7
BK-TS52
C6
C2
C7
C4
C3
C1
C5
33 START ENGINE 33
C34SA BK/WH C1B-8
HARNESS TO
SWITCH PANEL
BK/WH-TS56 C34SA BK/WH C5-22

34 GLOW PLUG 34
BK/RD-CR4 C35RPM BK/RD C1B-9
C39LP BL/RD C2B-1
39 (UNUSED) 39
C40LS1 OR C2B-2
C1B-12 C177LS BL/ RD C6-21
C40LS1 OR C6-40
J
40 BOOM STOWED 40
OR/BK-ISM2 C41RPM OR/BK C2B-3
C6
BRN-GND C41RPM OR/BK C5-2

C129JDA BL C3B-10
HARNESS
FUNCTION

44 JIB DOWN DESCENT ALARM 44
D30
C45GEN GR/WH C5-12

C45GEN GR/WH C2B-7
C59CNK BL/BK C3B-11
P134PWR RD C2B-6
+

P134BAT BK C6-25
K
P134BAT RD C6-24
C3

P134TTS RD C6-26
C7
C4
C6
C2
C5
210 (UNUSED) 210

C5
C6
L
ENGINE
C6-20 P109ANG GR/WH C4B-9

HARNESS
BK
C6-34 SNSR BR C4B-4

RD
WH

BRN
C6-33 C123PBS RD/BK C4B-8

C6-13 C13DE BL/RD C4B-1
Genie Industries
BK-CR1
1 TO REMOVE: 1 START RELAY
OR/BK-41C
2 PUSH GENTLY 2 TACHOMETER
BK-33C
3 AND LIFT. 3 START INPUT
RD-CR19
4 4 AUX PWR UNIT
C7P
BRN
M
5
12V DC
U1 5 GROUND
RD-24C
6 6 BATTERY
WH-23C
7 7 TO KEY SW (DIESEL ONLY)
8 8 JUMP TO 7 (GAS ONLY)
BRN
WH-CR2
POWER TO PLATFORM
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH-25D
ES0186U
10
BRN C7B-3
10 TEMP OR PRESS FAULT

12/24 Volt IGNITON/START MODULE P/N 56057
GROUND BOLT
N

CONNECTIONS
CONTROL BOX
1
TO GROUND
WH/RD-CR19#87A
RD/WH-CR34#87A
WH/RD-CR19#87
RD/WH-CR34#87
WH/RD TS62-6
RD/WH-TS61-3
BR-GND STUD
GR/WH-TB19D
BK/WH-TB34D
OR/BK-TB15D
GR/BK-TB18D
BK/RD-TB35D
BL/BK-TB59D
WH/BK-TB5D
WH/RD-TB26
BK/WH-TB8D
BR-CR34#85
BK/RD-TB9D
RD/BK-TB2D
RD/WH-R16
WH-TS51-2
WH-TB23D
WH-TB21D
RD-TS51-5
RD-TS51-1
WH/RD-R2
RD-TS61-2
WH/RD-R4
RD TS62-4
OR-TB14D
RD TS61-2
GR-TB17D
RD-TB27D
RD-TB20C
RD-C134D
RD-TB20C
RD-TB20D
RD-TB24D
WH-KS1-1
BK-TB22D
BK-TB33D
BL-TB44D
RD-L45(+)
RD-CB2-1
WH-TB4D
RD-C6-33
BR-L46(-)
RD-TB1D
BR-HM(-)
BK-TB7D
RD-P1-2
RD-R14
RD-P4
TS52
2
1
3
TS51
P4
2
D3
3
4
3
NO
4
6
D64
4
3
3
NO
1
G6
1
WH/RD
WH/RD
CB2
1
TS61
6
4
2
2
D4
3
TS56
4
R2
R4
L46
3
TS62
1
4
4
+
TS63
KS1
B1
B
RD/WH
2 5
6
1
D28
D13
1
D2
TS54
CB1
TS58
R16
R14
1
6
2
3
1A
1B
RD
P1
NC
NC
2A
2B
1
TS59
1
L2
TS57
CB3
3
2
1
+ 7
2
CR1 START RELAY R2 RESISTOR, 5W, TURNTABLE ROTATE SPEED U1 IGNITION START MODULE
CR2 IGNITION / FUEL RELAY R4 RESISTOR, 7.5W, TURNTABLE ROTATE SPEED 8
CR19 TURNTABLE SPEED REDUCTION RELAY TS52 ENGINE START TOGGLE SWITCH ES0186U
CR23
CR34
TS54
TS56
GLOW PLUG TOGGLE SWITCH
Deutz D2011L03i Engine
G6
KS1
HOUR METER
KEY SWITCH
TS57
TS58
PLATFORM ROTATE TOGGLE SWITCH
JIB BOOM UP / DOWN TOGGLE SWITCH (S-65 OPTION)
Deutz TD2011L04i Engine

S-60 HC • S-60X • S-60XC

6 - 53 6 - 54

6 - 55 6 - 56
CWLITE WH TS49
N
ES0186U
M
CONTROL HARNESS
SWITCH PANEL
TO PLATFORM
GR/WH
RD
C19JSV GR/WH TS7

C19JSV GR/WH C4P-7
L
BRN JC3 BR BK
BRN GND
RD-E-STOP
P134PWR RD-H1+
CR13-#86 RD BR
GR/WH
OPT.
C1
RD OUTPUT
GR/WH +
TS7 WH
CR14
C134PWR RD
LIFT / DRIVE
BRN -
(OPTION)

K
CR27
BR
RD RD
JIB
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
OPT.
CR30
D24
J
C40LS OR
C42LS OR/RD
D23
TS14 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
(S-65 OPT.)
C18PRR GR/BK C4P-6

BR
C17PRL GR C4P-5
JIB
C15PLD OR/BK C4P-3

I
C14PLU OR C4P-2
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
F.S.
H
C45GEN GR/WH C2P-7

C46HRN GR C2P-5
F.S.
C9
P26ESTP BK
C3P
C4P
C7P
C2P
11
3
C42LS OR/RD C2P-4

C6TRF WH/RD C3P-6
J3
C123PBS RD/BK C4P-8

C7PBE BK C3P-7
C13DE BL/RD C4P-1
G
C8PBR BK/WH C3P-8

C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36SCC BL C1P-10
C3PBF RD/WH C3P-3
ALC-500
C37SCW BL/BK C1P-11

C5TRR WH/BK C3P-5
F
December 2013
Part No. 147753

U13
C32BRK WH/RD C1P-6

C4TRL WH C3P-4
J2
C29MS RD/WH C1P-3
12V BATT
P109ANG GR/WH C4P-9
C7P
SENSOR GND BR C4P-4
J8
6
C7P
C3P
C4P
C1P
C2P
E
C4P(BR)
BR
1
J7
C3P(GR)
D
C35RPM BK/RD C1P-9
S-60 • S-65 • S-60 TRAX • S-65 TRAX

C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
S-60 HC • S-60X • S-60XC

J1
9
P109ANG GR/WH
C165TRS WH/RD
SENSOR GND BR
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS WH/BK
C
GND BR
C160JPL WH/RD
P162JPW OR
C159STC BL/WH

GND BR

C144DER BL/WH
C28TTA RD/BK C1P-2

C13DE BL/RD
C29MS RD/WH
BATGRN C7P-3
B
D40
C28TTA RD/BK
RD/BK-L48 RD/BK-L48
H1
P134PWR RD C2P-6
P134PWR RD RD-TILT
+
CWLITE BK
A
BRN
BRN
CWLITE WH TS49
6 - 56
1
8

CONTROL HARNESS 1
TO PLATFORM BOX
BK C7P-1
RD H1(+)
RD/WH J1-2
BK J3-3
BR J1-14
BL/WH J1-5
BK C9-1
BR J1-12
OR J1-11
BK/RD C1P-9
RD C9P-3
BL/WH J1-7
RD/WH J1-8
RD C1P-1
BK/WH C1P-8
BR GND STUD
RD/BK H1 (D40)
BL/BK J1-6
WH C9P-2
BL/RD J1-16
GR/WH C2P-7
BK C1P-7
GR C2P-5
OR/BK C4P-3
OR C4P-2
CR14-#86 RD
GR/BK C4P-6
GR/WH C4P-7
GR C4P-5
BL/BK C3P-11
OR J1-13
C129JDA BL C3P-10
WH/RD J1-4
WH/BK C4P-9
WH/RD J1-1
WH/BK J1-3
WH C7P-2
TS4 TS15 2
1
D12
JC7 JC3
3
TS2 TS6
+
6
1 L47
+
WH
WH L1
4
CR13 1 6 BK
WH
TS7 TS14
NO
+
NC
P3
L48 5
P2
BK
RD
RD
D27
COMPONENT INDEX
C1 CAPACITOR, JIB CIRCUIT (S-65 OPTION) TS9 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
CR13 JIB SELECT RELAY (S-65 OPTION) TS14 DRIVE SPEED TOGGLE SWITCH 1 ROCKER / STEER OPTION.
P3 HORN BUTTON
TS6 GLOW PLUG TOGGLE SWITCH
TS8 JIB BOOM UP / DOWN TOGGLE SWITCH (S-65 OPTION) Deutz D2011L03i Engine
ES0186U Deutz TD2011L04i Engine

S-60 HC • S-60X • S-60XC

6 - 57 6 - 58

Perkins Engine Models (ANSI / CSA)
6 - 59 6 - 60
C41RPM OR/BK
C28TTA RD/BK
RD (AUX + FE)
P26ESTP BK
P24FS WH
P22LS BK
RD (AUX)
P134 RD
N
BRN
CR4
ENGINE
TB35
D12
C1B-9
RPM

TS4
RPM CONTROL RELAY

HIGH
LOW
NO
CB7
10A
D13
ENGINE
TS54
RPM
BK/RD C5-18
D4
D3
RPM SOLENOID
LOW
CR4
Q3
HIGH
M
L
K
FUNC. ENABLE
P4
J
TB34
GLOW
PLUG

TS6
CONTROL RELAY
CR15
NO
GLOW
PLUG
TS56
GLOW PLUG
70A
F22
L2
D64
IGN / START
I
MODULE
U1
TB26
ENGINE
ENGINE FAULT
SW3
TACHOMETER
AUXILIARY ON
IGN / FUEL ON
START
START RELAY
NO
START INPUT
KEY BYPASS
C1B-7
KEY POWER
C1P-7 C33STR BK C5-14 C26TS WH/RD WATER TEMPERATURE

TS2
BATTERY
GROUND
SWITCH
ENGINE
START
TS52
10
C25PS WH/BK
2
3
4
5
6
7
8
9
1
C5-16 OIL PRESSURE

SWITCH
SW2
TB25
NC
BK
TB33
H
FUEL SOLENOID
CONTROL RELAY
C41RPM OR/BK
C28TTA RD/BK
CR2
NO
P26ESTP BK
P24FS WH
C21IGN2 WH
P25FS RD
C5-11
P22LS BK
FUEL SOLENOID
P134 RD
TB21
D52
AUXILIARY
G
C21IGN WH
PUMP
G6
HOUR METER
+
TS1
-
C1B-1
RELAY
C9P-3
C9P-2
CR1
NO
R33STR BK C5-5
TB24
STARTER
POWER RELAY
WH
RD
PR2
NO
FS1
M3
STARTER
BK
F
December 2013
Part No. 147753

TS51
CR19
EMISSION CONTROL
C9P-1
AUXILIARY
TB27
PUMP
REDUCTION RELAY
BK
C7B-2
TB23
C7P-2
PR1
NO
P2
D2
M2
AUXILIARY PUMP
L48
WH
C1P-2 WH
E
RD/BK
D40
C1B-2
C
TILT ALARM
S8
P134TTS RD
-
C6-26 BR
+
RD BK
H1
LEVEL SENSOR
B
A
RD
C2B-5 C46HRN GR
RELAY
P3
GR/BK
CR5
NO
H2
C7B-1
D
C7P-1 P22BAT BK
S-60 • S-65 • S-60 TRAX • S-65 TRAX

SERVICE HORN
5
FB1
3
S-60 HC • S-60X • S-60XC

C32
TB134
FLASHING BEACONS
1
P134FB WH C6-34
FB1
12
4
6
TB134
RD
C
SW4
NO
BK
TB22
R21IGN WH C5-4
(OPTION)
RD
WH
CR17
NO
PLAT
GND
M1
(OPTION)
1
2
4
B1
Perkins 404-22 Engine

KS1
TB41
C5-3
B
RD
D22
EXCT
C107AF RD
BAT-
STA
IND
RD
RD
P1
REGULATOR
ALTERNATOR
RD
CB1
CB3
15A
15A
BAT+
CB2
15A
ES0193U
A
TB20
-
+
RD P20BAT RD
BATTERY
12V DC
B1
6 - 60
1
8
1
8
6 - 61
C7P-3 BATGND C7B-3

GROUND
YL
5 6
BR S18
4

A
BL
3

BK
S17
2

1
J114

2
9
4

TB30
U4
J2
10
J1

1

RD BK
S-60 • S-65 • S-60 TRAX • S-65 TRAX
B

16
15
TB31
H3

TS14
(OPTION)
S-60 HC • S-60X • S-60XC


Y2
TB32
Y27

J1
16 20
L1
MOTOR STROKE
TB29
Y3
C25-1 C25-2
7 18 STEER CW
RIGHT
C

17 STEER CCW
J2
6
Y4
CDE2 BL/BK
Y23
11
C14-1 C14-2
10
CW
TB4
C15-1 C15-2
9
CCW
TB5
5
Y24
C159STC BL/WH
C159STC BL/WH
C160JPL WH/RD
RIGHT
13 TURNTABLE ROTATE
P162JPW OR
J1
LEFT
TS62
7.5W
LEFT
R2
CR19
14
D
C31-1 C31-2
BR
5W
R2
FLOW CONTROL
Y13
J25
6
5
4
3
2
C9PER BK/RD
1
C3P-9 C3B-9
14
C41RPM OR/BK
C28TTA RD/BK
LSB2S
JC3
P26ESTP BK
Y26

J2
C6-7
13 LOOSE CABLE
P24FS WH
C16-1 C16-2
RD
BR
BATGND
LIMIT SWITCH
22
NC 21

12
RD PRIMARY BOOM
TB7
C37-2
EXTEND
ALC-500 JOYSTICK
CONTROL CARD
EXTEND
Y25
PRIMARY BOOM
TB8
C17-1 C17-2
TS63

U13
E
RETRACT
Part No. 147753
TB9
December 2013

C6-9 C9PER BK/RD
EXTEND / RETRACT
FLOW CONTROL
Y15
F
1
5
10
J8
8
7
6
P134 RD C6-25 BL
G
4 3 2 1
RD LST3O - ZONE A
NO
NC
21
13
2 BR GROUND BOX
BK SPEED REDUCTION
22
14

Y22
TB1
3 C6-1 C12-1 C12-2

2 UP UP
PRIMARY BOOM
1
C164PES RD/WH
C165TRS WH/RD
C13-1 C13-2
C163PLS WH/BK

J1
11 DOWN
TS61
P162JPW OR
Y21
H
R16
5W
TB3
P26 ESTP
PRIMARY BOOM
12 C6-3 C3PBF RD/WH C29-1 C29-2
UP / DOWN
C118LS OR
CR34
FLOW CONTROL
BR
Y12
J127
10W
R14

6
5
4
3
2
1
RELAY
OR C6-29
JC7

6
TB2

7
1 C3P-3
8
I
J2
P24FS WH
2 C4P-1
3 RD
NO
NC
J3
LST1O
21
13
C8
P24 C2P-2 BR
BK
2 1
LIMIT SWITCH
22
14
3 WH
1
D24
D23
RD
NO
NC
C10
21
13
2 1
BK LIMIT SWITCH
22
14
WH
LIFT / DRIVE
CR27
CR30
NO
NC
RD
(OPTION)
J
NO
NC
C11
21
13
C6-22 P22LS BK
TB22
2 1
BK LIMIT SWITCH
22
14
WH
L46
P22LS BK L46 / L47
TB59
LOOSE CABLE LED
L47
NO
TB134 LSB2S
P134 RD BK C6-24 C37-3 BK WH C37-4
LOOSE CABLE
13
14
LIMIT SWITCH
TS9
DOWN PLATFORM
K
Y20
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
(S-65 OPTION)
WH
PLATFORM LEVEL DOWN

BR
TB15
Y19
TB44
JIB BOOM

TS8
DOWN
D27
Y16
TB18
D28
C23-1 C23-2
TS58
L

CR13
PLATFORM
(S-65 OPTION) C22-1 C22-2

NC

ROTATE
TB17
Y17
D29
TS7
CW
CCW CW
PLAT. ROTATE
CCW
TS57
C6-19 C129 RD/BK
DESCENT ALRM
D30
H4
TB19
M
C1
RD
JIB VALVE
-
+
Y11
C41RPM OR/BK
NO
C28TTA RD/BK
RD (AUX & FE)

P26ESTP BK
CR14
P24FS WH
P22LS BK
N
RD (AUX)
P134 RD
BR

6 - 61 6 - 62

S60 TRAX/S65 TRAX Perkins Engine Models (ANSI / CSA)
6 - 63 6 - 64
8
7
6
5
4
3
2
1
RD
6 - 64
BRN
CR1 CR2 CR45
RD
A
BK-ISM1
BRN
CR4
BRN
WH ISM9
CB7
8
7
6
5
1
3
4
12
C32
RD CB3-2
BAT
AUX
C21IGN WH
P48PWR WH
BK
RD-24B
CB7 BK/RD
BK C5-5
BK/RD-35C
BRN
BRN
C21IGN WH C5-11
WH-21B (1)
BK/RD-CR4
B
BK-22D
C5
RD-TS52
RD-TS51
BK C7B-1
C5-18 BK/RD C32
C6

S-65 MODELS
BRN
WH C5-4
RD-27C
BK-22C1
BK C6-10
GR C2B-5
OR C5-1
RD/WH-3D
WH/RD-6D
BRN CR19
CR34
C21IGN WH
C
CR5
C6
C5
RD-ISM4
WH/RD-R2 CR17
WH/RD-R4
RD/WH-R16 OR C38-2
RD/WH-TS61
S-60 HC • S-60X • S-60XC

RD-CB3
C6-19
S-60 • S-65 • S-60 TRAX • S-65 TRAX

D
1 PRIMARY BOOM UP 1
D29
C3PBF RD/WH C3B-3
C4TRL WH C3B-4
C5TRR WH/BK C3B-5
C6TRF WH/RD C3B-6
OPT

E
BK-TS63 C7PBE BK-LS5 C6-7

C8PBR BK/WH C3B-8
C9PER BK/RD C3B-9
BK
RD
WH
C14PLU OR C4B-2

C15PLD OR/BK C4B-3

C17JU GR C4B-5
Part No. 147753

December 2013

C18JD GR/BK C4B-6
C19JSV GR/WH C4B-7
GR/WH-TS57 BRN
20 +12 VOLT POWER (1) 20
12V DC
D52 20 +12 VOLT POWER (2) 20

C21IGN2 WH C5-3
BATTERY POWER

WH TB21
G
WH-HM
C5
C3
C6
C4
BK-CR5
BK-KS1-1
P22BAT BK C6-22
BK C32-4

WH-KS1-3
RD-ISM6 RD-CR2
RD-CB1 (BROWN)
H

18/22

CABLE #1

C29MS RD/WH C1B-3
C29MS RD/WH C5-24
(BLACK)
29 MOTOR STROKE 29
BK
RD
C30FWD WH C1B-4
WH
18/19
C30FWD WH C5-21
C31REV WH/BK C1B-5
CABLE #2
I
(GREY)
WH/RD-R2
WH/RD-R4
C31REV WH/BK C5-20

RD/WH-R16
RD/WH-TS61
C32BRK WH/RD C1B-6

32 BRAKE 32
BK-TS52
C6
C2
C7
C4
C3
C1
C5
33 START ENGINE 33
C34SA BK/WH C1B-8
HARNESS TO
SWITCH PANEL

34 GLOW PLUG 34
C39LP BL/RD C2B-1
J
39 (UNUSED) 39
C40LS1 OR C2B-2
C1B-12 C177LS BL/ RD C6-21
C40LS1 OR C6-40
40 BOOM STOWED 40
C6
C41RPM OR/BK C5-2

C129JDA BL C3B-10
HARNESS
FUNCTION

44 JIB DOWN DESCENT ALARM 44
D30
C45GEN GR/WH C5-12

C45GEN GR/WH C2B-7
C59CNK BL/BK C3B-11
P134PWR RD C2B-6
K
RD-H6+ P134FB RD C6-23

P134FB WH-C6-23 P134BAT BK C6-25
RD-KS P134BAT RD C6-24
P134TTS RD C6-26
C7
C4
C6
C2
C5

L
C5
C6
ENGINE

HARNESS
BK
C6-34 SNSR BR C4B-4

RD
WH

Genie Industries
BK-CR1
OR/BK-41C
M
BK-33C
RD-CR19
4 4 AUX PWR UNIT
C7P
BRN
5
12V DC
U1 5 GROUND
RD-24C
6 6 BATTERY
WH-23C
BRN
WH-CR2
POWER TO PLATFORM
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH-25D
ES0193U
10
BRN C7B-3

N
GROUND BOLT

CONNECTIONS
CONTROL BOX
1
TO GROUND
WH/RD-CR19#87A
RD/WH-CR34#87A
WH/RD-CR19#87
RD/WH-CR34#87
WH/RD TS62-6
RD/WH-TS61-3
BR-GND STUD
GR/WH-TB19D
BK/WH-TB34D
OR/BK-TB15D
GR/BK-TB18D
BK/RD-TB35D
BL/BK-TB59D
WH/BK-TB5D
WH/RD-TB26
BK/WH-TB8D
BR-CR34#85
BK/RD-TB9D
RD/BK-TB2D
RD/WH-R16
WH-TS51-2
WH-TB23D
WH-TB21D
RD-TS51-5
RD-TS51-1
WH/RD-R2
RD-TS61-2
WH/RD-R4
RD TS62-4
OR-TB14D
RD TS61-2
GR-TB17D
RD-TB27D
RD-TB20C
RD-C134D
RD-TB20C
RD-TB20D
RD-TB24D
WH-KS1-1
BK-TB22D
BK-TB33D
BL-TB44D
RD-L45(+)
RD-CB2-1
WH-TB4D
RD-C6-33
BR-L46(-)
RD-TB1D
BR-HM(-)
BK-TB7D
RD-P1-2
RD-R14
RD-P4
2
TS52
1
1
3
TS51
P4
2
D3
3
4
3
NO
4
6
D64
3
4
3
NO
1
G6
1
WH/RD
WH/RD
CB2
1
TS61
6
4
2
2
D4
3
TS56
4
R2
R4
L46
3
TS62
1
4
4
+
TS63
KS1
B1
B
RD/WH 5
2
6
1
D28
D13
1
D2
TS54
CB1
TS58
R16
R14
2
6
2
3
1A
1B
RD
P1
NC
NC
2A
2B
1
TS59
1
7
L2
TS57
CB3
3
2
1
+
2
CR1 START RELAY R2 RESISTOR, 5W, TURNTABLE ROTATE SPEED U1 IGNITION START MODULE 8
CR23 DRIVE LIGHTS RELAY (OPTION) TS54 RPM SELECT TOGGLE SWITCH ES0193U
CR34 PRIMARY BOOM SPEED REDUCTION RELAY TS56 GLOW PLUG TOGGLE SWITCH
KS1 KEY SWITCH TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-65 OPTION)

S-60 HC • S-60X • S-60XC

6 - 65 6 - 66

6 - 67 6 - 68
CWLITE WH TS49
N
ES0193U
M
CONTROL HARNESS
SWITCH PANEL
TO PLATFORM
GR/WH
RD
C19JSV GR/WH TS7

C19JSV GR/WH C4P-7
L
BRN JC3 BR BK
BRN GND
RD-E-STOP
P134PWR RD-H1+
CR13-#86 RD BR
GR/WH
OPT.
C1
RD OUTPUT
GR/WH +
TS7 WH
CR14
C134PWR RD
LIFT / DRIVE
BRN -
(OPTION)

K
JIB
CR27
BR
RD RD
C32BRK WH/RD C1P-6
C32BRK WH/RD J2-19
OPT.
CR30
D24
J
C40LS OR
C42LS OR/RD
D23
TS14 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
(S-65 OPT.)
C18PRR GR/BK C4P-6

BR
C17PRL GR C4P-5
JIB
C15PLD OR/BK C4P-3

I
C14PLU OR C4P-2
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
F.S.
H
C45GEN GR/WH C2P-7

C46HRN GR C2P-5
F.S.
C9
P26ESTP BK
C3P
C4P
C7P
C2P
11
3
C42LS OR/RD C2P-4

C6TRF WH/RD C3P-6
J3
C123PBS RD/BK C4P-8

C7PBE BK C3P-7
C13DE BL/RD C4P-1
G
C8PBR BK/WH C3P-8

C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36SCC BL C1P-10
C3PBF RD/WH C3P-3
ALC-500
C37SCW BL/BK C1P-11

C5TRR WH/BK C3P-5
F
December 2013
Part No. 147753

U13
C32BRK WH/RD C1P-6

C4TRL WH C3P-4
J2
C29MS RD/WH C1P-3
12V BATT
P109ANG GR/WH C4P-9
C7P
SENSOR GND BR C4P-4
J8
6
C7P
C3P
C4P
C1P
C2P
E
C4P(BR)
BR
1
J7
C3P(GR)
D
C35RPM BK/RD C1P-9
S-60 • S-65 • S-60 TRAX • S-65 TRAX

C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
S-60 HC • S-60X • S-60XC

J1
9
P109ANG GR/WH
C165TRS WH/RD
SENSOR GND BR
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS WH/BK
C
GND BR
C160JPL WH/RD
P162JPW OR
C159STC BL/WH
GND BR

C144DER BL/WH
C28TTA RD/BK C1P-2

C13DE BL/RD
C29MS RD/WH
BATGRN C7P-3
B
D40
C28TTA RD/BK
RD/BK-L48 RD/BK-L48
H1
P134PWR RD C2P-6
P134PWR RD RD-TILT
+
CWLITE BK
A
BRN
BRN
CWLITE WH TS49
6 - 68
1
8

CONTROL HARNESS 1
TO PLATFORM BOX
BK C7P-1
H1 (+)
RD/WH J1-2
BK J3-3
BR J1-14
BL/WH J1-5
BK C9-1
BR J1-12
OR J1-11
BK/RD C1P-9
RD C9P-3
BL/WH J1-7
RD/WH J1-8
RD C1P-1
BK/WH C1P-8
BR GND STUD
RD/BK H1 (D40)
BL/BK J1-6
WH C9P-2
BL/RD J1-16
GR/WH C2P-7
BK C1P-7
GR C2P-5
OR/BK C4P-3
OR C4P-2
CR14-#86 RD
GR/BK C4P-6
GR/WH C4P-7
GR C4P-5
BL/BK C3P-11
OR J1-13
C129JDA BL C3P-10
WH/RD J1-4
WH/RD J1-1
WH/BK J1-3
WH C7P-2
WH/BK C4P-9
TS4 TS15
2
1
D12
JC7 JC3
TS6
3
TS2
+
6
1 L47
+
WH
WH L1
4
CR13 1 6
BK
WH
TS7 TS14
NO
+
NC
P3
L48 5
P2
BK
RD
RD
D27
COMPONENT INDEX
PLATFORM LEVEL UP / DOWN TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTIONS.
C1 CAPACITOR, JIB CIRCUIT (S-65 OPTION) TS9
CR13 JIB SELECT RELAY (S-65 OPTION) TS14 DRIVE SPEED TOGGLE SWITCH
1 ROCKER / STEER OPTION.
P3 HORN BUTTON
TS8 JIB BOOM UP / DOWN TOGGLE SWITCH (S-65 OPTION)
ES0193U

S-60 HC • S-60X • S-60XC

6 - 69 6 - 70

6 - 71 6 - 72

P22LS BK P22LS BK
P134PWR RD P134PWR RD
1 C28TTA RD/BK C28TTA RD/BK
P22LS BK
P134PWR RD
RD P2 FS1
RD C9P-3 P25FS RD
C2P-6
C9P-1 BK
C7P-1
P134PWR GR/BK
TS1 TS2 D10 TS3 TS4
AUXILIARY ENGINE FUEL ENGINE
P22BAT BK
PUMP START SELECT RPM
2
L48
P210PWR BK
2 P3
C7B-1
C2B-6
H1
4 TB134 RD
BK
D40
WH
D101 D12
KS1
CB2 1 3
15A TB210
TB22
P1
C1P-7
C1P-9
C2P-5
C1P-2
C7P-2
C1P-1
C2P-1
3 4 5
RD PLAT
3 D4
1 GND
6 D3 RD
7 RD
ZONE A
TS52 D11 TS53 TS54
ENGINE FUEL OFF ENGINE
12 8 TS51
START SELECT ZONE B RPM
P23BAT WH
GR/BK
C28TTA RD/BK
C33STR BK
C39LP BL/RD
C35RPM RD/BK
C46HRN GR
C27AUX RD
C32
P20BAT RD
PUMP
AUXILIARY
P4
FUNCTION
ENABLE
4
C1B-1
C1B-7
C1B-9
C2B-5
C1B-2
C7B-2
C2B-1
CB1
15A TB41
TB33 TB39
BL/RD
RD
D2 TB23 TB27 RD
TB134 D13
RD P24BAT RD TB24
TB20
CR1 CR2 CR4 TB35
5 CB3 NO NO NC
15A
C5-3 C21ING WH TB21
C35RPM RB/BK
P116HYD RD
P22HRN BK
P134TTS RD
C27AUX RD
C27AUX RD
C46HRN GR
C28TTA RD/BK
TS64 L2
LINK FAULT
C5-18
C5-19
C5-5
C5-2
C5-9
C5-11
C5-10
BAT+ 1
C21ING WH
1
BAT-
C6-27
C6-26
C6-28
C6-23
6 CR17
NO
CR5
NO NO
PR8
C5-8 GR Ford DSG 423 Engine Ford MSG 425 Engine
CR19 C5-13 BL/WH
STA A B
R21ING WH
P134FB WH
R33STR BK FEH(32) PIN 15
P23BAT WH FEH(16) PIN 1

R46HRN BK
C41RPM OR/BK FEH(11) PIN 2

C116 OR
C135FP BL/WH FEH(787A) PIN 5
C35RPM BK/RD FEH(307A) PIN 23
C127TSW GR FEH(458) PIN 6

C108ESL BL/WH FEH(658) PIN 6
C21ING WH FEH(71) PIN 16

C128RPM OR/RD FEH(306) PIN 24
C39LP BL/RD FEH(72)PIN 7
WH
RD
REGULATOR NO
A
12V DC
S
BR
RD/GN
WH/GN
BR/WH
GN/WH
GY/RD
RD/GR
BK/BL
RD
GY/YL
GY/RD
WH/BK
WH/BK
+ S8
I
M4
C5-1
C5-4
FB1 FB1 +
M3
C6-10
M2 G6
BK PIN 18
BK
-
7 -
SW4 C
FORD ENGINE
HARNESS
FORD ENGINE
HARNESS
M1 H2
NO
BRN
B1
BRN
ES0396R
BATTERY
TOGGLE SWITCH
ENGINE FAULT
HOUR METER
LEVEL SENSOR
CHECK ENGINE LED

ALTERNATOR
(OPTION)
OIL COOLER FAN
(OPTION)
(OPTION)
FLASHING BEACONS
SERVICE HORN
RELAY
SERVICE HORN
TILT ALARM
AUXILIARY PUMP
POWER RELAY
AUXILIARY PUMP
STARTER
FUEL SENSOR
FUEL SENSOR
LPG LOCKOUT
LPG LOCKOUT
START SIGNAL (FEH)

RELAY
IGNITION / START
CR1
8 FORD 42 PIN CONNECTOR

ENGINE HARNESS DIAGRAM,


S-60 HC • S-60X • S-60XC
1
8

6 - 73
C7P-3 BATGND C7B-3

GROUND
YL
5 6
BR S18
4

A
BL
3

BK
S17
2

1
J114

2
9
4

TB30
U4
J2
10
J1

1

RD BK
S-60 • S-65 • S-60 TRAX • S-65 TRAX

B
16
15
TB31
H3

TS14
(OPTION)
S-60 HC • S-60X • S-60XC

Y2
TB32
Y27

J1
16 20
L1
MOTOR STROKE
TB29
Y3
C25-1 C25-2
TS15

7 18 STEER CW
RIGHT
C

17 STEER CCW
J2
6
Y4
CDE2 BL/BK
Y23
11
C14-1 C14-2
10
CW
TB4
C15-1 C15-2
9
CCW
TB5
5
Y24
C159STC BL/WH
C159STC BL/WH
C160JPL WH/RD
RIGHT
13 TURNTABLE ROTATE
P162JPW OR
J1
LEFT
TS62
7.5W
LEFT
R2
CR19
14
D
C31-1 C31-2
BR
5W
R2
FLOW CONTROL
Y13
J25
6
5
4
3
2
C9PER BK/RD
1
C3P-9 C3B-9
14
C41RPM OR/BK
C28TTA RD/BK
LSB2S
JC3
P26ESTP BK
Y26

J2
C6-7
13 LOOSE CABLE
P24FS WH
C16-1 C16-2
RD
BR
BATGND
LIMIT SWITCH
22
NC 21

12
RD PRIMARY BOOM
TB7
C37-2
EXTEND
ALC-500 JOYSTICK
CONTROL CARD
EXTEND
Y25
PRI. BOOM
TB8
C17-1 C17-2
TS63

U13
E
RETRACT
TB9
Part No. 147753

December 2013

C6-9 C9PER BK/RD
EXTEND / RETRACT
FLOW CONTROL
Y15
CR53
CR69
RD LST3S - ZONE A
NO
NC
21
13
GR BR PRIMARY BOOM
STOWED ANGLE
2 1
BK
22
14
SAFETY LIMIT SWITCH

6
WH
BR
2
GR/WH C3-12 P109LS GR/WH C6-16 GR/WH

F
1
1
WH BK/WH
NO
NC
LSB1ES - PRIMARY BOOM

21
13
3 2
C169LED2 BL BK
5 EXTEND CAPACITY
ZONE B BL
L50
22
SAFETY LIMIT SWITCH

14
5
C6-38 C212LO GR/BK

4
OR BR
BK
J134
J133
C169LED1 GR
10
ZONE A
4
L51
C6-30 C211LO BL/BK

J8
RD BK/WH
NO
NC
LSB1EO - PRIMARY BOOM

21
13
4 3 2
BK EXTEND CAPACITY
TS75
SNSR BR
BL
BL OPERATIONAL LIMIT SWITCH

22
8
14
1
B BL/RD C1-12 C177LS BL/WH C6-21 BL/RD

7 BK BR
ZONE SELECT
A
6
3
P109TS GR/WH
P134 RD C6-25 BL
G
4 3 2 1
RD LST3O - ZONE A
NO
NC
C184PL WH
21
13
2 GROUND BOX
P4 TB210
BR
BK SPEED REDUCTION
22
14
P210PWR OPERATIONAL LIMIT SWITCH

WH
BK
C6-12
CR52
CR68
Y22
TB1
3 C6-1 C12-1 C12-2

2 UP UP
PRI. BOOM
1
C164PES RD/WH
C165TRS WH/RD
C13-1 C13-2
C163PLS WH/BK

J1
11 DOWN
TS61
P162JPW OR
Y21
H
7.5W
R16
TB3
P26 ESTP
PRIMARY BOOM
12 C6-3 C3PBF RD/WH C29-1 C29-2
UP / DOWN
C118LS OR
CR34
FLOW CONTROL
BR
Y12
J127
10W
R14

6
5
4
3
2
1
RELAY
OR C6-29
JC7

6
TB2

7
1 C3P-3
8
I
J2
P24FS WH
2 C4P-1
3 RD
NO
NC
J3
LST1O
21
13
C8
P24 C2P-2 BR
BK
2 1
LIMIT SWITCH
22
14
3 WH
1
D24
D23
RD
NO
NC
C10
21
13
2 1
BK LIMIT SWITCH
22
14
WH
LIFT / DRIVE
CR27
CR30
NO
NC
RD
(OPTION)

J
NO
NC
C11
21
13
C6-22 P22LS BK
TB22
2 1
BK LIMIT SWITCH
22
14
WH
L46
P22LS BK L46 / L47
TB59
LOOSE CABLE LED
L47
NO
TB134 LSB2S
P134 RD BK C6-24 C37-3 BK WH C37-4
LOOSE CABLE
13
14
LIMIT SWITCH
TS9
DOWN PLATFORM
K
Y20
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
WH
PLATFORM LEVEL DOWN
TB15
Y19
C4P-5 C17JU/PRL GR C4B-5
Y16
TB18
C6-18 C23-1 C23-2
C18JD/PRR GR/BK
L
PLATFORM ROTATE RIGHT

PLATFORM
C6-17 C17JU/PRL GR C22-1 C22-2

PLATFORM ROTATE LEFT
ROTATE
TB17
Y17
TS7
CW
CCW CW
PLAT. ROTATE
CCW
TS57
C6-19 C129 RD/BK
DESCENT ALRM
H4
M
C41RPM OR/BK
C28TTA RD/BK
RD (AUX & FE)

P26ESTP BK
P24FS WH
P22LS BK
N
RD (AUX)
P134 RD
BR

6 - 73 6 - 74

S-60X and S-60XC, Ford Engine Models (ANSI / CSA)
6 - 75 6 - 76
8
7
6
5
4
3
2
1
BK
6 - 76
C7PBE BK TS63
C2PBD RD/BK TS61
CB52 CR53 CR68 CR69
A
GND BR C212LO GR/BK C6-38
C211LO BL/BK C6-30

CR1 CR2 CR4 CR45
C6
BRN
BRN
8
7
6
5
1
3
4
BK-33C
12
RD-24B
C32
BK C5-5
WH-21C
RD CB3-2
WH-C5-11
WH-C5-19
WH-23C (2)
C21IGN WH
P48PWR WH
C7PBE BK-7D

C2PBD RD/BK-2D
C5
BK-22D
C32
RD-TS52
RD-TS51
BK C7B-1
C6
S-65 MODELS
C
BRN
RD-27C
WH C5-4
BK-46R
GR-C2B-5
OR C5-1
WH/RD-6D
RD/WH-3D
BK-22C (1)
BRN CR19
CR34
C21IGN WH21A (1)
S-60 HC • S-60X • S-60XC

CR5
C6
C5
WH/RD-R2 CR17
S-60 • S-65 • S-60 TRAX • S-65 TRAX

WH/RD-R4
D
RD/WH-R16 OR C6-29
RD/WH-TS61
RD-CB3
TS64
RD/BK-ALARM C6-19
ENGINE FAULT
TOGGLE SWITCH

1 PRIMARY BOOM UP 1
E
RD/BK-CR68-87A C2PBD RD/BK C6-2

C3PBF RD/WH C3B-3

C4TRL WH C3B-4
C5TRR WH/BK C3B-5
C6TRF WH/RD C3B-6
OPT
P48PWR WH C45-87
C7PBE BK C3B-7
BK-CR69-87A C7PBE RD C6-7
Part No. 147753

December 2013
C8PBR BK/WH C3B-8

C9PER BK/RD C3B-9
C14PLU OR C4B-2
C15PLD OR/BK C4B-3
C17JU GR C4B-5
17 PLATFORM ROTATE LEFT 17
C18JD GR/BK C4B-6
G
18 PLATFORM ROTATE RIGHT 18

C19JSV GR/WH C4B-7
GR/WH-TS57
20 +12 VOLT POWER (1) 20
BRN
12V DC
20 +12 VOLT POWER (2) 20

C21IGN WH CR17 #86
C128RPM WH C5-9
BATTERY POWER

WH TB21
WH-HM
BK-CR5
C5
C6
C3
C4
C7
H
F19
BK-KS1-1
P22BAT BK C6-22
BK-C32-4

WH-KS1-3
RD CR2#86 C4B
RD-CB1 (BROWN)
18/22
25 (UNUSED) 25 C3B
I
CABLE #1
(GREEN)
26 (UNUSED) 26
C29MS RD/WH C1B-3
(BLACK)
C29MS RD/WH C5-24
29 MOTOR STROKE 29
C30FWD WH C1B-4
18/19
C30FWD WH C5-21
CABLE #2
C31REV WH/BK C1B-5

WH/RD-R2
WH/RD-R4
(GREY)
RD/WH-R16
C31REV WH/BK C5-20

RD/WH-TS61
C32BRK WH/RD C1B-6
BRN

J
32 BRAKE 32
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
HARNESS TO
SWITCH PANEL
34 (UNUSED) 34
C35RPM BK/RD C1B-9
C35RPM BK/RD C5-18
C39LP BL/RD C2B-1




C40LS1 OR C2B-2
C40LS1 OR C6-40
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C6
K
C41RPM OR/BK C5-2

HARNESS
FUNCTION
44 (UNUSED) 44
C45GEN GR/WH C5-12
C3
C45GEN GR/WH C2B-7

C59CNK BL/BK C3B-11
P134PWR RD C2B-6
P134FB RD C6-23
P134FB WH-C6-23 134 LOAD WEIGHING LIM. SW. +12V (1) 134
P134BAT BK C6-25
RD-KS1-2 P134BAT RD C6-24
L
C6
C7
C5
C2
P134TTS RD C6-26
BK-P4 P210PWR BK C6-12

C5

ENGINE
HARNESS

M

C7P
12V DC
BRN
POWER TO PLATFORM
BRN C7B-3
ES0396J
N
GROUND BOLT

CONNECTIONS
CONTROL BOX
1
TO GROUND
WH/RD-CR19#87A
RD/WH-CR34#87A
WH/RD-CR19#87
RD/WH-CR34#87
WH/RD TS62-6
RD/WH-TS61-3
BR-GND STUD
GR/WH-TB19D
OR/BK-TB15D
GR/BK-TB18D
BK/RD-TB35D
BL/RD-TB39D
RD-C134D (2)
BL/BK-TB59D
WH/BK-TB5D
WH/RD-TB26
BK/WH-TB8D
BR-CR34#85
BK/RD-TB9D
RD/BK-TB2D
RD/WH-R16
WH-TS51-2
BK-TB210D
WH-TB23D
WH-TB21D
RD-TS51-5
RD-TS51-1
WH/RD-R2
RD-TS61-2
WH/RD-R4
RD TS62-4
OR-TB14D
RD TS61-2
BK-TS51-4
GR-TB17D
RD-TB27D
RD-TB20C
RD-TB20C
RD-TB20D
RD-TB24D
WH-KS1-1
BK-TB22D
BK-TB33D
RD-CB2-1
WH-TB4D
RD-C6-33
BR-L46(-)
RD-TB1D
BK-TB7D
BR-G6(-)
RD-P1-2
RD-R14
RD-P4
BK-P4
TS52
2
1
3
D101
TS51
P4
2
D3
4
3
4
3
NO
6
4
3
3
NO
1
G6
1
WH/RD
WH/RD
CB2
TS61
6
2
D4
4
R2
R4
4
D11
L46
3
TS62
1
4
4
TS53
+
TS63
KS1
2
B1
3
RD/WH 5
2
6
1
D13
1
D2
TS54
CB1
R16
R14
2
6
2
3
1A
1B
RD
P1
TS57
NC
NC
2A
2B
1
1
4
TS59
7
L2
CB3
3
2
1
+
2
3
6
CB1 ENGINE CIRCUIT BREAKER, 15A L2 LED - CHECK ENGINE TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
CB2 CONTROLS CIRCUIT BREAKER, 15A L46 LED - CABLE TENSION TS62 TURNTABLE ROTATE TOGGLE SWITCH
CB3 CIRCUIT BREAKER, 15A (OPTION) P1 EMERGENCY STOP BUTTON TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
CB7 HIGH IDLE CIRCUIT BREAKER P4 FUNCTION ENABLE SWITCH
CR5 HORN RELAY R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
CR23
CR34
TS53
TS54
FUEL SELECT TOGGLE SWITCH
ES0396J
KS1 KEY SWITCH TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH

S-60 HC • S-60X • S-60XC

6 - 77 6 - 78

6 - 79 6 - 80
CWLITE WH TS49
N
ES0396J
M
CONTROL HARNESS
SWITCH PANEL
TO PLATFORM
L
OPT.
TS7 WH
LIFT / DRIVE
(OPTION)

K
CR27
BR
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
OPT.
CR30
D24
J
C40LS OR
C42LS OR/RD
D23
TS14 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
C18PRR GR/BK C4P-6
BR
OPT.
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
I
C14PLU OR C4P-2
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
F.S.
H
C45GEN GR/WH C2P-7

C46HRN GR C2P-5
F.S.
C39LP BL/RD C2P-1

C9
P26ESTP BK
C3P
C4P
C7P
C2P
11
3
C42LS OR/RD C2P-4

C6TRF WH/RD C3P-6
J3
C123PBS RD/BK C4P-8

C7PBE BK C3P-7
C13DE BL/RD C4P-1
G
C8PBR BK/WH C3P-8

C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36SCC BL C1P-10
C3PBF RD/WH C3P-3
ALC-500
C37SCW BL/BK C1P-11

C5TRR WH/BK C3P-5
F
December 2013
Part No. 147753

U13
C32BRK WH/RD C1P-6

C4TRL WH C3P-4
J2
C29MS RD/WH C1P-3
12V BATT
P109ANG GR/WH C4P-9
C7P
SENSOR GND BR C4P-4
J8
6
TS75-1 P109TS GR/WH

C7P
C3P
C4P
C1P
C2P
C3P-12 P109LS GR/WH

C1P-12 C177LS BL/RD
E
TS75-2 C184PL WH
TS-3 SNSR BR
C4P(BR)
L51(-) C169LED1 GR
L50(-) C169LED2 BL
BR
1
J7
C3P(GR)
D
C35RPM BK/RD C1P-9
S-60 • S-65 • S-60 TRAX • S-65 TRAX

C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
S-60 HC • S-60X • S-60XC

J1
9
P109ANG GR/WH
C165TRS WH/RD
SENSOR GND BR
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS WH/BK
C
GND BR
C160JPL WH/RD
P162JPW OR
C159STC BL/WH

GND BR
BATGRN C7P-3
C144DER BL/WH
C28TTA RD/BK C1P-2

C13DE BL/RD
C29MS RD/WH
B
D40
C28TTA RD/BK
RD/BK-L48 RD/BK-L48
H1
P134PWR RD C2P-6
P134PWR RD RD-TILT
+
CWLITE BK
A
BRN
BRN
CWLITE WH TS49
6 - 80
1
8

CONTROL HARNESS 1
TO PLATFORM BOX
BK C7P-1
RD H1(+)
RD/WH J1-2
BK J3-3
BR J8-10 ZONE B
BL J8-5
BR J1-14
BL/WH J1-5
BK C9-1
BR J1-12
OR J1-11
BK/RD C1P-9
RD C9P-3
BL/WH J1-7
RD/WH J1-8
RD C1P-1
BL/RD C2P-1
BR GND STUD
RD/BK H1 (D40)
BL/BK J1-6
WH C9P-2
BL/RD J1-16
BK C1P-7
GR C2P-5
OR/BK C4P-3
OR C4P-2
GR J8-10
GR/WH J8-6 ZONE A

GR/BK C4P-6
GR/WH C4P-7
GR C4P-5
BL/BK C3P-11
OR J1-13
C129JDA BL C3P-10
WH/RD J1-4
WH/RD J1-1
WH/BK J1-3
WH J8-2
WH C7P-2
TS4 TS15
TS3 2
1
D12
D10
JC7 JC3
3
TS2
+
6
1 L47
+
WH
L1
4
1 6
TS9 TS1
TS7 TS14
NO
+
NC
+
+
P3
L48 L51 TS50 L50 5
ZONE A ZONE SELECT ZONE B P2
1000 500
WH
BK BK
BK
RD
COMPONENT INDEX
C1 CAPACITOR, JIB CIRCUIT (S-65 OPTION) TS7 PLATFORM ROTATE TOGGLE SWITCH 1 ROCKER / STEER OPTION.
CR13 JIB SELECT RELAY (S-65 OPTION) TS9 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
CR14 JIB VALVE RELAY (S-65 OPTION) TS14 DRIVE SPEED TOGGLE SWITCH
CR27 BRAKE CIRCUIT (LIFT / DRIVE OPTION) TS15 DRIVE ENABLE TOGGLE SWITCH
CR30 LIMIT SWITCH (LIFT / DRIVE OPTION) TS50 ZONE SELECT TOGGLE SWITCH
L50 LED - ZONE A
L51 LED - ZONE B
P3 HORN BUTTON 8
TS2 ENGINE START TOGGLE SWITCH
TS3 FUEL SELECT TOGGLE SWITCH
TS4 RPM SELECT TOGGLE SWITCH Ford DSG-423 EFI Engine
ES0396J

S-60 HC • S-60X • S-60XC

6 - 81 6 - 82

Deutz D2011L03i Models (ANSI/CSA)
6 - 83 6 - 84
C41RPM OR/BK
C28TTA RD/BK
RD (AUX + FE)
P26ESTP BK
P24FS WH
P22LS BK
RD (AUX)
P134 RD
N
BRN
CR4
ENGINE
TB35
D12
C1B-9
RPM

TS4
RPM CONTROL RELAY

HIGH
LOW
NO
CB7
10A
D13
ENGINE
TS54
RPM
BK/RD C5-18
D4
D3
RPM SOLENOID
LOW
CR4
Q3
HIGH
M
L
TB210
P210PWR BK
K
ZONE A
ZONE B
D101
OFF
FUNCTION
ENABLE
P4
J
TB34
GLOW
PLUG

TS6
CONTROL RELAY
CR15
NO
GLOW
PLUG
TS56
GLOW PLUG
70A
F22
L2
D64
IGN / START
I
MODULE
U1
TB26
ENGINE
ENGINE FAULT
SW3
TACHOMETER
AUXILIARY ON
IGN / FUEL ON
START
START RELAY
NO
START INPUT
KEY BYPASS
C1B-7
KEY POWER
C1P-7 C33STR BK C5-14 C26TS WH/RD OIL TEMPERATURE

TS2
BATTERY
GROUND
SWITCH
ENGINE
START
TS52
10
C25PS WH/BK
2
3
4
5
6
7
8
9
1
C5-16 OIL PRESSURE

SWITCH
SW2
TB25
NC
BK
TB33
H
FUEL SOLENOID
CONTROL RELAY
C41RPM OR/BK
C28TTA RD/BK
CR2
NO
P26ESTP BK
P24FS WH
C21IGN2 WH
P25FS RD
C5-11
P22LS BK
FUEL SOLENOID
P134 RD
TB21
D52
AUXILIARY
G
C21IGN WH
PUMP
G6
HOUR METER
+
TS1
-
C1B-1
RELAY
C9P-3
C9P-2
CR1
NO
R33STR BK C5-5
TB24
STARTER
POWER RELAY
WH
RD
PR2
NO
FS1
M3
STARTER
BK
F
December 2013
Part No. 147753

TS51
CR19
EMISSION CONTROL
C9P-1
AUXILIARY
TB27
PUMP
REDUCTION RELAY
BK
C7B-2
TB23
C7P-2
PR1
NO
P2
D2
M2
AUXILIARY PUMP
L48
WH
C1P-2 WH
E
RD/BK
D40
C1B-2
C
TILT ALARM
S8
P134TTS RD
-
C6-26 BR
+
RD BK
H1
LEVEL SENSOR
B
A
RD
C2B-5 C46HRN GR
RELAY
P3
GR/BK
CR5
NO
H2
C7B-1
D
C7P-1 P22BAT BK
S-60 • S-65 • S-60 TRAX • S-65 TRAX

SERVICE HORN
5
FB1
3
S-60 HC • S-60X • S-60XC

C32
TB134
FLASHING BEACONS
1
P134FB WH C6-23
FB1
12
4
6
TB134
RD
C
SW4
NO
BK
TB22
R21IGN WH C5-4
(OPTION)
RD
WH
CR17
NO
PLAT
GND
M1
(OPTION)
3mF
C3
2
1
3
B1
KS1
TB41
C5-3
B
RD
D22
EXCT
C107AF RD
BAT-
STA
IND
RD
RD
P1
REGULATOR
ALTERNATOR
RD
CB1
CB3
15A
15A
BAT+
CB2
15A
ES0186U
A
TB20
-
+
RD P20BAT RD
BATTERY
12V DC
B1
6 - 84
1
8
1
8
6 - 85
C7P-3 BATGND C7B-3

GROUND
YL
5 6
BR S18
4

A
BL
3

BK
S17
2

1
J114

2
9
4

TB30
U4
J2
10
J1

1

S-60 • S-65 • S-60 TRAX • S-65 TRAX
RD BK
B

16
15
TB31
H3

TS14
(OPTION)
S-60 HC • S-60X • S-60XC

Y2
TB32
Y27

J1
16 20
L1
MOTOR STROKE
TB29
Y3
C25-1 C25-2
TS15

7 18 STEER CW
RIGHT
C

17 STEER CCW
J2
6
Y4
CDE2 BL/BK
Y23
11
C14-1 C14-2
10
CW
TB4
C15-1 C15-2
9
CCW
TB5
5
Y24
C159STC BL/WH
C159STC BL/WH
C160JPL WH/RD
RIGHT
13 TURNTABLE ROTATE
P162JPW OR
J1
LEFT
TS62
7.5W
LEFT
R2
CR19
D
14
C31-1 C31-2
BR
5W
R2
FLOW CONTROL
Y13
J25
6
5
4
3
2
C9PER BK/RD
1
C3P-9 C3B-9
14
C41RPM OR/BK
C28TTA RD/BK
LSB2S
JC3
P26ESTP BK
Y26

J2
C6-7
13 LOOSE CABLE
P24FS WH
C16-1 C16-2
RD
BR
BATGND
LIMIT SWITCH
22
NC 21

12
RD PRIMARY BOOM
TB7
C37-2
EXTEND
ALC-500 JOYSTICK
CONTROL CARD
EXTEND
Y25
PRI. BOOM
TB8
C17-1 C17-2
TS63

E
U13
RETRACT
Part No. 147753
TB9
December 2013

C6-9 C9PER BK/RD
EXTEND / RETRACT
FLOW CONTROL
Y15
CR53
CR69
RD LST3S - ZONE A
NO
NC
21
13
GR BR PRIMARY BOOM
STOWED ANGLE
2 1
BK
22
14
SAFETY LIMIT SWITCH

6
WH
BR
2
F

1
1
WH BK/WH
NO
NC

21
13
3 2
C169LED2 BL BK
5 EXTEND CAPACITY
ZONE B BL
L50
22
SAFETY LIMIT SWITCH

14
5
C6-38 C212LO GR/BK

4
OR BR
BK
J134
J133
C169LED1 GR
10
ZONE A
4
L51
C6-30 C211LO BL/BK

J8
RD BK/WH
NO
NC

21
13
4 3 2
BK EXTEND CAPACITY
TS75
SNSR BR
BL

22
8
14
1

7 BK BR
ZONE SELECT
A
6
3
P109TS GR/WH
P134 RD C6-25 BL
G
4 3 2 1
RD LST3O - ZONE A
NO
NC
C184PL WH
21
13
2 GROUND BOX
P4 TB210
BR
BK SPEED REDUCTION
22
14

WH
BK
C6-12
CR52
CR68
Y22
TB1
3 C6-1 C12-1 C12-2

2 UP UP
PRI. BOOM
1
C164PES RD/WH
C165TRS WH/RD
C13-1 C13-2
C163PLS WH/BK

J1
11 DOWN
TS61
P162JPW OR
Y21
H
7.5W
R16
TB3
P26 ESTP
PRIMARY BOOM
12 C6-3 C3PBF RD/WH C29-1 C29-2
UP / DOWN
C118LS OR
CR34
FLOW CONTROL
BR
Y12
J127
10W
R14

6
5
4
3
2
1
RELAY
OR C6-29
JC7

6
TB2

7
1 C3P-3
8
I
J2
P24FS WH
2 C4P-1
3 RD
NO
NC
J3
LST1O
21
13
C8
P24 C2P-2 BR
BK
2 1
LIMIT SWITCH
22
14
3 WH
1
D24
D23
RD
NO
NC
C10
21
13
2 1
BK LIMIT SWITCH
22
14
WH
LIFT / DRIVE
CR27
CR30
NO
NC
RD
J
(OPTION)
NO
NC
C11
21
13
C6-22 P22LS BK
TB22
2 1
BK LIMIT SWITCH
22
14
WH
L46
P22LS BK L46 / L47
TB59
LOOSE CABLE LED
L47
NO
TB134 LSB2S
P134 RD BK C6-24 C37-3 BK WH C37-4
LOOSE CABLE
13
14
LIMIT SWITCH
TS9
DOWN PLATFORM
K
Y20
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
WH
PLATFORM LEVEL DOWN
TB15
Y19
Y16
TB18
C6-18 C23-1 C23-2 PLATFORM ROTATE RIGHT
C18JD/PRR GR/BK
L
(JIB BOOM DOWN / S-65 OPTION)

PLATFORM
C6-17 C17JU/PRL GR C22-1 C22-2

ROTATE
TB17
Y17
TS7
CW
CCW CW
PLAT. ROTATE
CCW
TS57
C6-19 C129 RD/BK
DESCENT ALRM
H4
M
C41RPM OR/BK
C28TTA RD/BK
RD (AUX & FE)

P26ESTP BK
P24FS WH
P22LS BK
N
RD (AUX)
P134 RD
BR

6 - 85 6 - 86

Deutz TD2011L04i Models (ANSI/CSA)
6 - 87 6 - 88
BRN
P134 RD
P22LS BK
C41RPM OR/BK
P26ESTP BK
C28TTA RD/BK
N
P24FS WH
RD (AUX + FE)
RD (AUX)
D12
TB35
C1P-9 C35RPM BK/RD C1B-9 BRN

HIGH IDLE RELAY
FOOTSW. HIGH
ANSI/CSA
CR4
FOOTSW. LOW RD
HOLD
A
TS4
WH HIGH RPM SOLENOID

D13
PULL IN
ENGINE
SPEED
BRN
BK
WH
RD
TS54
C
M
CB7
15A
LOW RPM
D4
D3
ENGINE SPEED
CR4
NO
TIME DELAY
HIGH RPM
MODULE
S-500
MOM N.O.
+BAT
-GND
+AUX
RPM MODULE
C5-18
L
K
FUNC. ENABLE
P4
J
PR2
U16
NO
C34SA BK/WH C5-22

GLOW PLUG RELAY
TIMER30
GLOW PLUG
F22 70A
PR2
NO
30 SEC GLOW
L2
PLUG TIMER
I
ENGINE CHECK LED

IGN./START
TS6
C1P-8 C1B-8
MODULE
U1
TB34
ON C34SA BK/WH
GLO PLUG
SW3
ON
NO
G. PLUG
TB25
TACHOMETER
START RELAY
IGN./FUEL ON
TS56
START INPUT
KEY BYPASS
ENG. FAULT
C5-14 C26TS WH/RD OIL TEMPERATURE

KEY PWR.
D64
BATTERY
GROUND
AUX. ON
TS2
C1P-7 C1B-7 SWITCH

START C33STR BK
ENGINE
10
1
2
3
4
5
6
7
8
9
C5-16 C25PS WH/BK OIL PRESSURE

ENGINE
C28TTA RD/BK
START SWITCH
TS52
TB26
H
SW2
BK
P22LS BK
NC
TB33
P134 RD
CR2
POWER RELAY
P26ESTP BK
TB21
P24FS WH
P25FS RD
AUX. PUMP C21IGN2 WH C5-11

FUEL SOLENOID
TS1
NO
CR2
C1P-1 C27AUX RD C1B-1

D52
G
C21IGN WH
C9P-3
C9P-2
HM
HOUR METER
_
IGN./START RELAY
CR1
NO
WH-(FS)
RD-(FS)
R33STR BK C5-5
TB24
PR2
NO
M3
STARTER MOTOR
FS1
F
December 2013
Part No. 147753

BK-(FS)
TS51
AUXILIARY
TB27
C9P-1
PUMP RD C27AUX RD AUXILIARY POWER

RELAY
PR1
TB23
NO
BK
C7B-2
C7P-2 P23BAT WH
M2
C6-27 AUXILIARY PUMP
P2
D2
L48
E
RD/BK C1P-2 WH
D40
RD/BK
C1B-2
C
H1
TILT ALARM
P134TTS RD C6-26 RD BK BRN
LEVEL SENSOR
C3B-12
B
C3P-12 C133PLA BL/WH
TB46
S8
RD
C2B-5
C2P-5 C46HRN GR C46HRN GR SERVICE HORN
RELAY
P3
GR/BK
D
CR5
NO
H2
S-60 • S-65 • S-60 TRAX • S-65 TRAX

C7P-1 P22BAT BK C7B-1
SERVICE HORN
8
5
S-60 HC • S-60X • S-60XC

FB1
TB134
3
C32
C2B-6 C6-23 P134FB WH FLASHING BEACONS
C2P-6 C134PWR GR/BK
OPTION
1
P22LS BK
P134 RD
12
4
6
TB134
RD
C
CR17
SW3
WH
NO
BK
C21IGN WH R21IGN WH C5-4
86
85
TB22
HYD. OIL TEMP. SWITCH
WH
RD
P116HYD RD
87
(OPTION)
30
PLAT
GRD
C41RPM OR/BK
87a
R116 OR C5-1
M1 FAN
C3 3MF
COOLING FAN
2
4
KS1
1
3
B1
+
TB41
B
C5-3
D22
RD
EXCT.
C107AF RD
STA.
BAT.
IND.
RD
RD
P1
-
ALTERNATOR
REGULATOR
RD
15AMP.
15AMP.
CB1
CB3
BAT.
+
15AMP.
A
CB2
TB20
-
RD P20BAT RD
12 V
6 - 88
DC
1
8
1
8
6 - 89
C7P-3 BATGND C7B-3

GROUND
YL
5 6
BR S18
4

A
BL
3

BK
S17
2

1
J114

2
9
4

TB30
U4
J2
10
J1

1

S-60 • S-65 • S-60 TRAX • S-65 TRAX
RD BK
B

16
15
TB31
H3

TS14
(OPTION)
S-60 HC • S-60X • S-60XC

Y2
TB32
Y27

J1
16 20
L1
MOTOR STROKE
TB29
Y3
C25-1 C25-2
TS15

7 18 STEER CW
RIGHT
C

17 STEER CCW
J2
6
Y4
CDE2 BL/BK
Y23
11
C14-1 C14-2
10
CW
TB4
C15-1 C15-2
9
CCW
TB5
5
Y24
C159STC BL/WH
C159STC BL/WH
C160JPL WH/RD
RIGHT
13 TURNTABLE ROTATE
P162JPW OR
J1
LEFT
TS62
7.5W
LEFT
R2
CR19
D
14
C31-1 C31-2
BR
5W
R2
FLOW CONTROL
Y13
J25
6
5
4
3
2
C9PER BK/RD
1
C3P-9 C3B-9
14
C41RPM OR/BK
C28TTA RD/BK
LSB2S
JC3
P26ESTP BK
Y26

J2
C6-7
13 LOOSE CABLE
P24FS WH
C16-1 C16-2
RD
BR
BATGND
LIMIT SWITCH
22
NC 21

12
RD PRIMARY BOOM
TB7
C37-2
EXTEND
ALC-500 JOYSTICK
CONTROL CARD
EXTEND
Y25
PRI. BOOM
TB8
C17-1 C17-2
TS63

E
U13
RETRACT
Part No. 147753
December 2013
TB9

C6-9 C9PER BK/RD
EXTEND / RETRACT
FLOW CONTROL
Y15
CR53
CR69
RD LST3S - ZONE A
NO
NC
21
13
GR BR PRIMARY BOOM
STOWED ANGLE
2 1
BK
22
14
SAFETY LIMIT SWITCH

6
WH
BR
F

1
1
WH BK/WH
NO
NC

21
13
3 2
C169LED2 BL BK
5 EXTEND CAPACITY
ZONE B BL
L50
22
SAFETY LIMIT SWITCH

14
5
C6-38 C212LO GR/BK

4
OR BR
BK
J134
J133
C169LED1 GR
10
ZONE A
4
L51
C6-30 C211LO BL/BK

J8
RD BK/WH
NO
NC

21
13
4 3 2
BK EXTEND CAPACITY
TS75
SNSR BR
BL

22
8
14
1

7 BK BR
ZONE SELECT
A
6
3
P109TS GR/WH
P134 RD C6-25 BL
G
4 3 2 1
RD LST3O - ZONE A
NO
NC
C184PL WH
21
13
2 GROUND BOX
P4 TB210
BR
BK SPEED REDUCTION
22
14

WH
BK
C6-12
CR52
CR68
Y22
TB1
3 C6-1 C12-1 C12-2

2 UP UP
PRI. BOOM
1
C164PES RD/WH
C165TRS WH/RD
C13-1 C13-2
C163PLS WH/BK

J1
11 DOWN
TS61
P162JPW OR
Y21
H
7.5W
R16
TB3
P26 ESTP
PRIMARY BOOM
12 C6-3 C3PBF RD/WH C29-1 C29-2
UP / DOWN
C118LS OR
CR34
FLOW CONTROL
BR
Y12
J127
10W
R14

6
5
4
3
2
1
RELAY
OR C6-29
JC7

6
TB2

7
1 C3P-3
8
I
J2
P24FS WH
2 C4P-1
3 RD
NO
NC
J3
LST1O
21
13
C8
P24 C2P-2 BR
BK
2 1
LIMIT SWITCH
22
14
3 WH
1
D24
D23
RD
NO
NC
C10
21
13
2 1
BK LIMIT SWITCH
22
14
WH
LIFT / DRIVE
CR27
CR30
NO
NC
RD
J
(OPTION)
NO
NC
C11
21
13
C6-22 P22LS BK
TB22
2 1
BK LIMIT SWITCH
22
14
WH
L46
P22LS BK L46 / L47
TB59
LOOSE CABLE LED
L47
NO
TB134 LSB2S
P134 RD BK C6-24 C37-3 BK WH C37-4
LOOSE CABLE
13
14
LIMIT SWITCH
TS9
DOWN PLATFORM
K
Y20
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
WH
PLATFORM LEVEL DOWN
TB15
Y19
Y16
TB18
C18JD/PRR GR/BK
L

PLATFORM
C6-17 C17JU/PRL GR C22-1 C22-2

ROTATE
TB17
Y17
TS7
CW
CCW CW
PLAT. ROTATE
CCW
TS57
C6-19 C129 RD/BK
DESCENT ALRM
H4
M
C41RPM OR/BK
C28TTA RD/BK
RD (AUX & FE)

P26ESTP BK
P24FS WH
P22LS BK
N
RD (AUX)
P134 RD
BR

6 - 89 6 - 90

S-60X and S-60XC, Deutz Engine Models (ANSI/CSA)
6 - 91 6 - 92
8
7
6
5
4
3
2
1
C7PBE BK TS63 BK
6 - 92
C2PBD RD/BK TS61
CB52 CR53 CR68 CR69
A
C211LO BL/BK C6-30

RD-24B
CR45
RD
BK-ISM1
B
C6
BRN
CR1 CR2 CR4
CB7 BRN
8
7
6
5
1
3
4
12
C32
WH ISM9
BAT
AUX
CB3-2 RD
P48PWR WH

C21IGN WH
BK
BK/RD-35C
BK C5-5
CB7 BK/RD
C2PDB RD/BK-2D
C7PBE BK-7D
BRN
BRN
C21IGN WH C5-11
BK/RD-CR4
WH-21B (1)

C5 BK-22D
RD-TS52
RD-TS51
BK C7B-1
C5-18 BK/RD C32
C6
C
S-65 MODELS
BRN
WH C5-4
RD-27C
BK-22C1
BK C6-10
GR C2B-5
OR C5-1
RD/WH-3D
WH/RD-6D
BRN CR19
CR34
C21IGN WH
S-60 HC • S-60X • S-60XC

CR5
C6
C5
RD-ISM4
WH/RD-R2 CR17
S-60 • S-65 • S-60 TRAX • S-65 TRAX

WH/RD-R4
D
RD/WH-R16 OR C38-2
RD/WH-TS61
RD-CB3
RD/BK-ALARM C6-19
1 PRIMARY BOOM UP 1
C3PBF RD/WH C3B-3

C4TRL WH C3B-4
E

C5TRR WH/BK C3B-5

C6TRF WH/RD C3B-6
OPT

C7PBE BK C3B-7
BK-CR69-87A C7PBE BK-LS5 C6-7
C8PBR BK/WH C3B-8
C9PER BK/RD C3B-9
BK
RD
WH
C14PLU OR C4B-2
Part No. 147753

December 2013

C15PLD OR/BK C4B-3
C17JU GR C4B-5
17 PLATFORM ROTATE LEFT 17
C18JD GR/BK C4B-6
18 PLATFORM ROTATE RIGHT 18
C19JSV GR/WH C4B-7
GR/WH-TS57 BRN
20 +12 VOLT POWER (1) 20
G
12V DC
20 +12 VOLT POWER (2) 20

D52

C21IGN2 WH C5-3
BATTERY POWER

WH TB21
WH-HM
C5
C6
C3
C4
BK-CR5
BK-KS1-1
P22BAT BK C6-22
BK C32-4
H

WH-KS1-3
RD-ISM6 RD-CR2
RD-CB1 (BROWN)
18/22

CABLE #1

C29MS RD/WH C1B-3
(BLACK)
I
C29MS RD/WH C5-24

29 MOTOR STROKE 29
BK
RD
C30FWD WH C1B-4
WH
18/19
C30FWD WH C5-21
C31REV WH/BK C1B-5
CABLE #2
(GREY)
WH/RD-R2
WH/RD-R4
C31REV WH/BK C5-20

RD/WH-R16
RD/WH-TS61
C32BRK WH/RD C1B-6

32 BRAKE 32
BK-TS52
C6
C2
C7
C4
C3
C1
C5
33 START ENGINE 33
C34SA BK/WH C1B-8
HARNESS TO
SWITCH PANEL

34 GLOW PLUG 34
J

C39LP BL/RD C2B-1
39 (UNUSED) 39
C40LS1 OR C2B-2
C1B-12 C177LS BL/ RD C6-21
C40LS1 OR C6-40
40 BOOM STOWED 40
C6

HARNESS
FUNCTION
44 (UNUSED) 44
C45GEN GR/WH C5-12
C45GEN GR/WH C2B-7
C59CNK BL/BK C3B-11
K

P134PWR RD C2B-6
+

C3

P134TTS RD C6-26
C6
C2
C5
C7
C4

L
C5
C6
ENGINE

HARNESS
BK
C6-34 SNSR BR C4B-4

RD
WH
BRN

NOTE: DASHED LINES INDICATE OPTION WIRES.
Genie Industries
BK-CR1
OR/BK-41C
M

BK-33C
RD-CR19
4 4 AUX PWR UNIT
C7P
BRN
5
12V DC
U1 5 GROUND
RD-24C
6 6 BATTERY
WH-23C
BRN
WH-CR2
POWER TO PLATFORM
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH-25D
ES0186U
10
BRN C7B-3

N
GROUND BOLT

CONNECTIONS
CONTROL BOX
1
TO GROUND
WH/RD-CR19#87A
RD/WH-CR34#87A
WH/RD-CR19#87
RD/WH-CR34#87
WH/RD TS62-6
RD/WH-TS61-3
BR-GND STUD
GR/WH-TB19D
BK/WH-TB34D
OR/BK-TB15D
GR/BK-TB18D
BK/RD-TB35D
BL/BK-TB59D
WH/BK-TB5D
WH/RD-TB26
BK/WH-TB8D
BR-CR34#85
BK/RD-TB9D
RD/BK-TB2D
RD/WH-R16
WH-TS51-2
BK-TB210D
WH-TB23D
WH-TB21D
RD-TS51-5
RD-TS51-1
WH/RD-R2
RD-TS61-2
WH/RD-R4
RD TS62-4
OR-TB14D
RD TS61-2
BK-TS51-4
GR-TB17D
RD-TB27D
RD-TB20C
RD-C134D
RD-TB20C
RD-TB20D
RD-TB24D
WH-KS1-1
BK-TB22D
BK-TB33D
RD-L45(+)
RD-CB2-1
WH-TB4D
RD-C6-33
BR-L46(-)
RD-TB1D
BR-HM(-)
BK-TB7D
RD-P1-2
RD-R14
RD-P4
BK-P4
TS52
2
1
3
D101
TS51
P4
2
D3
4
3
4
3
NO
6
D64
4
3
3
NO
1
G6
1
WH/RD
WH/RD
CB2
1
TS61
6
4
2
2
D4
3
TS56
4
R2
R4
L46
3
TS62
1
4
4
+
TS63
KS1
B1
B
RD/WH 5
2
6
1
D13
1
D2
TS54
CB1
R16
R14
2
6
2
3
1A
1B
RD
TS57
P1
NC
NC
2A
2B
1
TS59
7
L2
CB3
3
2
1
+
2
3
6
CB7 HIGH IDLE CIRCUIT BREAKER P4 FUNCTION ENABLE SWITCH U1 IGNITION START MODULE
CR23
CR34
TS54
TS56
GLOW PLUG TOGGLE SWITCH
Deutz D2011L03i
ES0186U Engine

S-60 HC • S-60X • S-60XC

6 - 93 6 - 94

6 - 95 6 - 96
CWLITE WH TS49
N
ES0186U
M
CONTROL HARNESS
SWITCH PANEL
TO PLATFORM
L
OPT.
TS7 WH
LIFT / DRIVE
(OPTION)

K
CR27
BR
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
OPT.
CR30
D24
J
C40LS OR
C42LS OR/RD
D23
TS14 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
C18PRR GR/BK C4P-6
BR
OPT.
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
I
C14PLU OR C4P-2
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
F.S.
H
C45GEN GR/WH C2P-7

C46HRN GR C2P-5
F.S.
C9
P26ESTP BK
C3P
C4P
C7P
C2P
11
3
C42LS OR/RD C2P-4

C6TRF WH/RD C3P-6
J3
C123PBS RD/BK C4P-8

C7PBE BK C3P-7
C13DE BL/RD C4P-1
G
C8PBR BK/WH C3P-8

C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36SCC BL C1P-10
C3PBF RD/WH C3P-3
ALC-500
C37SCW BL/BK C1P-11

C5TRR WH/BK C3P-5
F
December 2013
Part No. 147753

U13
C32BRK WH/RD C1P-6

C4TRL WH C3P-4
J2
C29MS RD/WH C1P-3
12V BATT
P109ANG GR/WH C4P-9
C7P
SENSOR GND BR C4P-4
J8
6
TS75-1 P109TS GR/WH

C7P
C3P
C4P
C1P
C2P
C3P-12 P109LS GR/WH

C1P-12 C177LS BL/RD

E
TS75-2 C184PL WH
TS-3 SNSR BR
C4P(BR)
L51(-) C169LED1 GR
L50(-) C169LED2 BL
BR
1
J7
C3P(GR)
D
C35RPM BK/RD C1P-9
S-60 • S-65 • S-60 TRAX • S-65 TRAX

C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
S-60 HC • S-60X • S-60XC

J1
9
P109ANG GR/WH
C165TRS WH/RD
SENSOR GND BR
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS WH/BK
C
GND BR
C160JPL WH/RD
P162JPW OR
C159STC BL/WH

GND BR

BATGRN C7P-3
C144DER BL/WH
C28TTA RD/BK C1P-2

C13DE BL/RD
C29MS RD/WH
B
D40
C28TTA RD/BK
RD/BK-L48 RD/BK-L48
H1
P134PWR RD C2P-6
P134PWR RD RD-TILT
+
CWLITE BK
A
BRN
BRN
CWLITE WH TS49
6 - 96
1
8

CONTROL HARNESS 1
TO PLATFORM BOX
BK C7P-1
H1 (+)
RD/WH J1-2
BK J3-3
BR J8-10 ZONE B
BL J8-5
BR J1-14
BL/WH J1-5
BK C9-1
BR J1-12
OR J1-11
BK/RD C1P-9
RD C9P-3
BL/WH J1-7
RD/WH J1-8
RD C1P-1
BK/WH C1P-8
BR GND STUD
RD/BK H1 (D40)
BL/BK J1-6
WH C9P-2
BL/RD J1-16
GR/WH C2P-7
BK C1P-7
GR C2P-5
OR/BK C4P-3
OR C4P-2
GR J8-10
GR/WH J8-6 ZONE A

GR/BK C4P-6
GR/WH C4P-7
GR C4P-5
BL/BK C3P-11
OR J1-13
WH/RD J1-4
WH/BK C4P-9
WH/RD J1-1
WH/BK J1-3
WH J8-2
WH C7P-2
TS4 TS15
2
1
D12
JC7 JC3
TS2 TS6
3
+
6
1 L47
+
WH
L1
4
1 6
BK
TS9 TS1 TS47 TS48

TS7 TS14
NO
+
NC
+
+
P3
L48 L51 TS50 L50
ZONE A ZONE SELECT ZONE B
5
P2
1000 500
BK BK
BK
RD
RD

C1 CAPACITOR, JIB CIRCUIT (S-65 OPTION) TS7 PLATFORM ROTATE TOGGLE SWITCH
CR13 JIB SELECT RELAY (S-65 OPTION) TS9 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH 1 ROCKER / STEER OPTION.
CR30 LIMIT SWITCH (LIFT / DRIVE OPTION) TS47 GENERATOR (OPTION)
H1 TILT ALARM TS48 DRIVE LIGHTS (OPTION) 7
JC3 JOYSTICK - DRIVE / STEER TS50 ZONE SELECT TOGGLE SWITCH
JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE U13 ALC500 JOYSTICK CONTROLLER CARD
L50 LED - ZONE A
L51 LED - ZONE B
P3 HORN BUTTON 8
ES0186U Deutz D2011L03i Engine


S-60 HC • S-60X • S-60XC

6 - 97 6 - 98

Perkins Engine Models (ANSI/CSA)
6 - 99 6 - 100
C41RPM OR/BK
C28TTA RD/BK
RD (AUX + FE)
P26ESTP BK
P24FS WH
P22LS BK
RD (AUX)
P134 RD
N
BRN
CR4
ENGINE
TB35
D12
C1B-9
RPM

TS4
RPM CONTROL RELAY

HIGH
LOW
NO
CB7
10A
D13
ENGINE
TS54
RPM
BK/RD C5-18
D4
D3
RPM SOLENOID
LOW
CR4
Q3
HIGH
M
L
TB210
P210PWR BK
K
ZONE A
ZONE B
D101
OFF
FUNCTION
ENABLE
P4
J
TB34
GLOW
PLUG

TS6
CONTROL RELAY
CR15
NO
GLOW
PLUG
TS56
GLOW PLUG
70A
F22
L2
D64
IGN / START
I
MODULE
U1
TB26
ENGINE
ENGINE FAULT
SW3
TACHOMETER
AUXILIARY ON
IGN / FUEL ON
START
START RELAY
NO
START INPUT
KEY BYPASS
C1B-7
KEY POWER
C1P-7 C33STR BK C5-14 C26TS WH/RD WATER TEMPERATURE

TS2
BATTERY
GROUND
SWITCH
ENGINE
START
TS52
10
C25PS WH/BK
2
3
4
5
6
7
8
9
1
C5-16 OIL PRESSURE

SWITCH
SW2
TB25
NC
BK
TB33
H
FUEL SOLENOID
CONTROL RELAY
C41RPM OR/BK
C28TTA RD/BK
CR2
NO
P26ESTP BK
P24FS WH
C21IGN2 WH
P25FS RD
C5-11
P22LS BK
FUEL SOLENOID
P134 RD
TB21
D52
AUXILIARY
G
C21IGN WH
PUMP
G6
HOUR METER
+
TS1
-
C1B-1
RELAY
C9P-3
C9P-2
CR1
NO
R33STR BK C5-5
TB24
STARTER
POWER RELAY
WH
RD
PR2
NO
FS1
M3
STARTER
BK
F
Part No. 147753

December 2013
TS51
CR19
EMISSION CONTROL
C9P-1
AUXILIARY
TB27
PUMP
REDUCTION RELAY
BK
C7B-2
TB23
C7P-2
PR1
NO
P2
D2
M2
AUXILIARY PUMP
L48
WH
C1P-2 WH
E
RD/BK
D40
C1B-2
C
TILT ALARM
S8
P134TTS RD
-
C6-26 BR
+
RD BK
H1
LEVEL SENSOR
B
A
RD
C2B-5 C46HRN GR
RELAY
P3
GR/BK
CR5
NO
H2
C7B-1
D
C7P-1 P22BAT BK
S-60 • S-65 • S-60 TRAX • S-65 TRAX

SERVICE HORN
5
FB1
3
S-60 HC • S-60X • S-60XC

C32
TB134
FLASHING BEACONS
1
P134FB WH C6-34
FB1
12
4
6
TB134
RD
C
SW4
NO
BK
TB22
R21IGN WH C5-4
(OPTION)
RD
WH
CR17
NO
PLAT
GND
M1
(OPTION)
3
2
1
B1

KS1
TB41
C5-3
B
RD
D22
EXCT
C107AF RD
BAT-
STA
IND
RD
RD
P1
REGULATOR
ALTERNATOR
RD
CB1
CB3
15A
15A
BAT+
CB2
15A
ES0193U
A
TB20
-
+
RD P20BAT RD
BATTERY
12V DC
B1
6 - 100
1
8
1
6 - 101

C7P-3 BATGND C7B-3

GROUND
YL
5 6
BR S18
4

A
BL
3

BK
S17
2

1
J114

2
9
4

TB30
U4
J2
10
J1

1

RD BK
S-60 • S-65 • S-60 TRAX • S-65 TRAX
C1B-5
B
C1P-5 C31REV WH/BK

16
15
TB31
H3

TS14
(OPTION)
S-60 HC • S-60X • S-60XC


Y2
TB32
Y27

J1
16 20
L1
MOTOR STROKE
TB29
Y3
C25-1 C25-2
TS15

7 18 STEER CW
RIGHT
C

17 STEER CCW
J2
6
Y4
CDE2 BL/BK
Y23
11
C14-1 C14-2
10
CW
TB4
C15-1 C15-2
9
CCW
TB5
5
Y24
C159STC BL/WH
C159STC BL/WH
C160JPL WH/RD
RIGHT
13 TURNTABLE ROTATE
P162JPW OR
J1
LEFT
TS62
7.5W
LEFT
R2
CR19
14
D
C31-1 C31-2
BR
5W
R2
FLOW CONTROL
Y13
J25
6
5
4
3
2
C9PER BK/RD
1
C3P-9 C3B-9
14
C41RPM OR/BK
C28TTA RD/BK
LSB2S
JC3
P26ESTP BK
Y26

J2
C6-7
13 LOOSE CABLE
P24FS WH
C16-1 C16-2
RD
BR
BATGND
LIMIT SWITCH
22
NC 21

12
RD PRIMARY BOOM
TB7
C37-2
EXTEND
ALC-500 JOYSTICK
CONTROL CARD
EXTEND
Y25
PRI. BOOM
TB8
C17-1 C17-2
TS63

U13
E
RETRACT
Part No. 147753
TB9
December 2013

C6-9 C9PER BK/RD
EXTEND / RETRACT
FLOW CONTROL
Y15
CR53
CR69
RD LST3S - ZONE A
NO
NC
21
13
GR BR PRIMARY BOOM
STOWED ANGLE
2 1
BK
22
14
SAFETY LIMIT SWITCH

6
WH
BR
2
F

1
1
WH BK/WH
NO
NC

21
13
3 2
C169LED2 BL BK
5 EXTEND CAPACITY
ZONE B BL
L50
22
SAFETY LIMIT SWITCH

14
5
C6-38 C212LO GR/BK

4
OR BR
BK
J134
J133
C169LED1 GR
10
ZONE A
4
L51
C6-30 C211LO BL/BK

J8
RD BK/WH
NO
NC

21
13
4 3 2
BK EXTEND CAPACITY
TS75
SNSR BR
BL

22
8
14
1

7 BK BR
ZONE SELECT
A
6
3
P109TS GR/WH
P134 RD C6-25 BL
G
4 3 2 1
RD LST3O - ZONE A
NO
NC
C184PL WH
21
13
2 GROUND BOX
P4 TB210
BR
BK SPEED REDUCTION
22
14

WH
BK
C6-12
CR52
CR68
Y22
TB1
3 C6-1 C12-1 C12-2

2 UP UP
PRI. BOOM
1
C164PES RD/WH
C165TRS WH/RD
C13-1 C13-2
C163PLS WH/BK

J1
11 DOWN
TS61
P162JPW OR
Y21
H
7.5W
R16
TB3
P26 ESTP
PRIMARY BOOM
12 C6-3 C3PBF RD/WH C29-1 C29-2
UP / DOWN
C118LS OR
CR34
FLOW CONTROL
BR
Y12
J127
10W
R14

6
5
4
3
2
1
RELAY
OR C6-29
JC7

6
TB2

7
1 C3P-3
8
I
J2
P24FS WH
2 C4P-1
3 RD
NO
NC
J3
LST1O
21
13
C8
P24 C2P-2 BR
BK
2 1
LIMIT SWITCH
22
14
3 WH
1
D24
D23
RD
NO
NC
C10
21
13
2 1
BK LIMIT SWITCH
22
14
WH
LIFT / DRIVE
CR27
CR30
NO
NC
RD
(OPTION)
J
NO
NC
C11
21
13
C6-22 P22LS BK
TB22
2 1
BK LIMIT SWITCH
22
14
WH
L46
P22LS BK L46 / L47
TB59
LOOSE CABLE LED
L47
NO
TB134 LSB2S
P134 RD BK C6-24 C37-3 BK WH C37-4
LOOSE CABLE
13
14
LIMIT SWITCH
TS9
DOWN PLATFORM
K
Y20
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
WH
PLATFORM LEVEL DOWN
TB15
Y19
Y16
TB18
C18JD/PRR GR/BK
L

PLATFORM
C6-17 C17JU/PRL GR C22-1 C22-2

ROTATE
TB17
Y17
TS7
CW
CCW CW
PLAT. ROTATE
CCW
TS57
C6-19 C129 RD/BK
DESCENT ALRM
H4
M
C41RPM OR/BK
C28TTA RD/BK
RD (AUX & FE)

P26ESTP BK
P24FS WH
P22LS BK
N
RD (AUX)
P134 RD
BR

6 - 101 6 - 102

S-60X and S-60XC, Perkins Engine Models (ANSI/CSA)
6 - 103 6 - 104
8
7
6
5
4
3
2
1
C7PBE BK TS63 BK
6 - 104
C2PBD RD/BK TS61
CB52 CR53 CR68 CR69
A
C211LO BL/BK C6-30

RD-24B
CR45
RD
BK-ISM1
B
C6
BRN
CR1 CR2 CR4
CB7 BRN
8
7
6
5
1
3
4
12
C32
WH ISM9

BAT
AUX
RD CB3-2
P48PWR WH
C21IGN WH
BK
BK/RD-35C
BK C5-5
CB7 BK/RD
C2PDB RD/BK-2D
C7PBE BK-7D
BRN
BRN
C21IGN WH C5-11
BK/RD-CR4
WH-21B (1)
C5 BK-22D
RD-TS52
RD-TS51
BK C7B-1
C5-18 BK/RD C32
C6
C
S-65 MODELS
BRN
WH C5-4
RD-27C
BK-22C1
BK C6-10
GR C2B-5
OR C5-1
RD/WH-3D
WH/RD-6D
BRN CR19
CR34
C21IGN WH
S-60 HC • S-60X • S-60XC

CR5
C6
C5
RD-ISM4
WH/RD-R2 CR17
S-60 • S-65 • S-60 TRAX • S-65 TRAX

WH/RD-R4
D
RD/WH-R16 OR C38-2
RD/WH-TS61
RD-CB3
RD/BK-ALARM C6-19
1 PRIMARY BOOM UP 1
D29
C3PBF RD/WH C3B-3

C4TRL WH C3B-4
E

C5TRR WH/BK C3B-5

C6TRF WH/RD C3B-6
OPT

BK-CR69-87A C7PBE BK-LS5 C6-7
C8PBR BK/WH C3B-8
C9PER BK/RD C3B-9
BK
RD
WH
C14PLU OR C4B-2
December 2013
Part No. 147753

F

C15PLD OR/BK C4B-3
C17JU GR C4B-5
C18JD GR/BK C4B-6
C19JSV GR/WH C4B-7
GR/WH-TS57 BRN
20 +12 VOLT POWER (1) 20
G
12V DC
20 +12 VOLT POWER (2) 20

D52

C21IGN2 WH C5-3
BATTERY POWER

WH TB21
WH-HM
C5
C6
C3
C4
BK-CR5
BK-KS1-1
P22BAT BK C6-22
BK C32-4
H

WH-KS1-3
RD-ISM6 RD-CR2
RD-CB1 (BROWN)
18/22

CABLE #1

C29MS RD/WH C1B-3
(BLACK)
I
C29MS RD/WH C5-24

29 MOTOR STROKE 29
BK
RD
C30FWD WH C1B-4
WH
18/19
C30FWD WH C5-21
C31REV WH/BK C1B-5
CABLE #2
(GREY)
WH/RD-R2
WH/RD-R4
C31REV WH/BK C5-20

RD/WH-R16
RD/WH-TS61
C32BRK WH/RD C1B-6

32 BRAKE 32
BK-TS52
C6
C2
C7
C4
C3
C1
C5
33 START ENGINE 33
C34SA BK/WH C1B-8
HARNESS TO
SWITCH PANEL

34 GLOW PLUG 34
J

C39LP BL/RD C2B-1
39 (UNUSED) 39
C40LS1 OR C2B-2
C1B-12 C177LS BL/ RD C6-21
C40LS1 OR C6-40
40 BOOM STOWED 40
C6

HARNESS
FUNCTION
44 (UNUSED) 44
C45GEN GR/WH C5-12
C45GEN GR/WH C2B-7
C59CNK BL/BK C3B-11
K

P134PWR RD C2B-6
P134TTS RD C6-26
C6
C2
C5
C7
C4

L
C5
C6
ENGINE

HARNESS
BK
C6-34 SNSR BR C4B-4

RD
WH

Genie Industries
BK-CR1
OR/BK-41C
M

BK-33C
RD-CR19
4 4 AUX PWR UNIT
C7P
BRN
5
12V DC
U1 5 GROUND
RD-24C
6 6 BATTERY
WH-23C
BRN
WH-CR2
POWER TO PLATFORM
9 1 3 4 7 10 9 2 9 IGN OR FUEL ON
WH-25D
ES0193U
10
BRN C7B-3

N
GROUND BOLT

CONNECTIONS
CONTROL BOX
1
TO GROUND
WH/RD-CR19#87A
RD/WH-CR34#87A
WH/RD-CR19#87
RD/WH-CR34#87
WH/RD TS62-6
RD/WH-TS61-3
BR-GND STUD
GR/WH-TB19D
BK/WH-TB34D
OR/BK-TB15D
GR/BK-TB18D
BK/RD-TB35D
BL/BK-TB59D
WH/BK-TB5D
WH/RD-TB26
BK/WH-TB8D
BR-CR34#85
BK/RD-TB9D
RD/BK-TB2D
RD/WH-R16
WH-TS51-2
BK-TB210D
WH-TB23D
WH-TB21D
RD-TS51-5
RD-TS51-1
WH/RD-R2
RD-TS61-2
WH/RD-R4
RD TS62-4
OR-TB14D
RD TS61-2
BK-TS51-4
GR-TB17D
RD-TB27D
RD-TB20C
RD-C134D
RD-TB20C
RD-TB20D
RD-TB24D
WH-KS1-1
BK-TB22D
BK-TB33D
RD-L45(+)
RD-CB2-1
WH-TB4D
RD-C6-33
BR-L46(-)
RD-TB1D
BR-HM(-)
BK-TB7D
RD-P1-2
RD-R14
RD-P4
BK-P4
TS52
2
1
3
D101
TS51
P4
2
D3
4
3
4
3
NO
6
D64
4
3
3
NO
1
G6
1
WH/RD
WH/RD
CB2
1
TS61
6
4
2
2
D4
3
TS56
4
R2
R4
L46
3
TS62
1
4
4
+
TS63
KS1
B1
B
RD/WH 5
2
6
1
D13
1
D2
TS54
CB1
R16
R14
2
6
2
3
1A
1B
RD
TS57
P1
NC
NC
2A
2B
1
TS59
7
L2
CB3
3
2
1
+
2
3
6
CB7 HIGH IDLE CIRCUIT BREAKER P4 FUNCTION ENABLE SWITCH U1 IGNITION START MODULE
CR23 DRIVE LIGHTS RELAY (OPTION) TS54 RPM SELECT TOGGLE SWITCH ES0193U
CR34 PRIMARY BOOM SPEED REDUCTION RELAY TS56 GLOW PLUG TOGGLE SWITCH
S-60 HC • S-60X • S-60XC

6 - 105 6 - 106

6 - 107 6 - 108
CWLITE WH TS49
N
ES0193U
M
CONTROL HARNESS
SWITCH PANEL
TO PLATFORM
L
OPT.
TS7 WH
LIFT / DRIVE
(OPTION)

K
CR27
BR
C32BRK WH/RD C1P-6

C32BRK WH/RD J2-19
OPT.
CR30
D24
J
C40LS OR
C42LS OR/RD
D23
TS14 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
C18PRR GR/BK C4P-6
BR
OPT.
C17PRL GR C4P-5
C15PLD OR/BK C4P-3
I
C14PLU OR C4P-2
P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
F.S.
H
C45GEN GR/WH C2P-7

C46HRN GR C2P-5
F.S.
C9
P26ESTP BK
C3P
C4P
C7P
C2P
11
3
C42LS OR/RD C2P-4

C6TRF WH/RD C3P-6
J3
C123PBS RD/BK C4P-8

C7PBE BK C3P-7
C13DE BL/RD C4P-1
G
C8PBR BK/WH C3P-8

C9PER BK/RD C3P-9
C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36SCC BL C1P-10
C3PBF RD/WH C3P-3
ALC-500
C37SCW BL/BK C1P-11

C5TRR WH/BK C3P-5
F
Part No. 147753

December 2013
U13
C32BRK WH/RD C1P-6

C4TRL WH C3P-4
J2
C29MS RD/WH C1P-3
12V BATT
P109ANG GR/WH C4P-9
C7P
SENSOR GND BR C4P-4
J8
6
TS75-1 P109TS GR/WH

C7P
C3P
C4P
C1P
C2P
C3P-12 P109LS GR/WH

C1P-12 C177LS BL/RD
E
TS75-2 C184PL WH
TS-3 SNSR BR
C4P(BR)
L51(-) C169LED1 GR
L50(-) C169LED2 BL
BR
1
J7
C3P(GR)
D
C35RPM BK/RD C1P-9
S-60 • S-65 • S-60 TRAX • S-65 TRAX

C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
S-60 HC • S-60X • S-60XC

J1
9
P109ANG GR/WH
C165TRS WH/RD
SENSOR GND BR
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS WH/BK
C
GND BR
C160JPL WH/RD
P162JPW OR
C159STC BL/WH
GND BR
BATGRN C7P-3

C144DER BL/WH
C28TTA RD/BK C1P-2

C13DE BL/RD
C29MS RD/WH
B
D40
C28TTA RD/BK
RD/BK-L48 RD/BK-L48
H1
P134PWR RD C2P-6
P134PWR RD RD-TILT
+
CWLITE BK
A
BRN
BRN
6 - 108
CWLITE WH TS49
8

CONTROL HARNESS 1
TO PLATFORM BOX
BK C7P-1
RD/WH J1-2
BK J3-3
BR J8-10 ZONE B
BL J8-5
BR J1-14
BL/WH J1-5
BK C9-1
BR J1-12
OR J1-11
BK/RD C1P-9
RD C9P-3
BL/WH J1-7
RD/WH J1-8
RD C1P-1
BK/WH C1P-8
BR GND STUD
RD/BK H1 (D40)
BL/BK J1-6
WH C9P-2
BL/RD J1-16
GR/WH C2P-7
BK C1P-7
GR C2P-5
OR/BK C4P-3
OR C4P-2
GR J8-10
GR/WH J8-6 ZONE A

GR/BK C4P-6
GR/WH C4P-7
GR C4P-5
BL/BK C3P-11
OR J1-13
WH/RD J1-4
WH/BK C4P-9
WH/RD J1-1
WH/BK J1-3
WH J8-2
WH C7P-2
TS4 TS15
2
1
D12
JC7 JC3
TS2 TS6
3
+
6
1 L47
+
WH
WH L1
4
1 6
BK
TS9 TS1 TS47 TS48

TS7 TS14
NO
+
NC
+
+
P3
L48 L51 TS50 L50
ZONE A ZONE SELECT ZONE B
5
P2
1000 500
BK BK
BK
RD
BK

C1 CAPACITOR, JIB CIRCUIT (S-65 OPTION) TS7 PLATFORM ROTATE TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTIONS.
CR13 JIB SELECT RELAY (S-65 OPTION) TS9 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH 1 ROCKER / STEER OPTION.
CR30 LIMIT SWITCH (LIFT / DRIVE OPTION) TS47 GENERATOR (OPTION)
H1 TILT ALARM TS48 DRIVE LIGHTS (OPTION) 7
JC3 JOYSTICK - DRIVE / STEER TS50 ZONE SELECT TOGGLE SWITCH
JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE U13 ALC500 JOYSTICK CONTROLLER CARD
L50 LED - ZONE A
L51 LED - ZONE B
P3 HORN BUTTON 8
ES0193U
S-60 HC • S-60X • S-60XC

6 - 109 6 - 110
Electrical Schematic, S-60 / S-65

Ford Engine Models (CE) (from SN 21001 to 22516)
6 - 111 6 - 112

D89 C132PL2 LT. BR

P22LS BK P22LS BK
1 P134PWR RD P134PWR RD
C28TTA RD/BK C28TTA RD/BK
LS18A
P22LS BK
P134PWR RD
BR OR NO BK
D88 WH NC RD
LS18 P2 FS1
RD C9P-3 P25FS RD
C2P-6
C1P-12
C9P-1 BK
C7P-1
R20
C132PLI BL/WH
P134PWR GR/BK
RD 4.7KW
TS1 TS2 D10 TS3 TS4
2 AUXILIARY ENGINE FUEL ENGINE
P22BAT BK
P26ESTP BK PUMP START SELECT RPM
P26ESTP BK
L4
2 9
C4P-10
2 P3 + COM
C7B-1
C2B-6
C1B-12
H1 2 SEC
5
4 TB134 RD
NO
BK
D39 D40
WH
8 D12
KS1 -
CB2 1 3
15A 3 U35
TB22
C4B-10
C3P-12
3 P1 30A
C1P-2
C7P-2
C1P-7
C1P-9
C2P-5
C1P-1
C2P-1
3 4 5
RD PLAT
D4
1 GND
6 D3 RD
U33 7 RD
TS52 D11 TS53 TS54
12 8 TS51 ENGINE FUEL U34 ENGINE
START SELECT RPM
P23BAT WH
GR/BK
10A
C133PLA BL/WH
C28TTA RD/BK
C33STR BK
C39LP BL/RD
C35RPM RD/BK
C46HRN GR
C27AUX RD
+
P4
P20BAT RD
PUMP
AUXILIARY
2 SEC FUNCTION
9 ENABLE
5
NO
4
-
3 8
C1B-1
C1B-7
C1B-9
C2B-5
C3B-12
C1B-2
C7B-2
C2B-1
CB1
L45 TB41
15A H6
TB33 TB39
BL/RD
RD
D2 TB23 TB27 RD
TB134 D13
RD P24BAT RD TB24
5 TB20
CR1 CR2 CR4 TB35
CB3 NO NO NC
15A
C5-3 C21ING WH TB21
C35RPM RB/BK
P116HYD RD
P22HRN BK
P134TTS RD
C27AUX RD
C27AUX RD
C46HRN GR
C28TTA RD/BK
TS64 L2
LINK FAULT
C5-18
C5-19
C5-5
C5-2
C5-9
C5-11
C5-10
BAT+ 1
C21ING WH
6 1
BAT-
C6-27
C6-26
C6-28
C6-23
CR17
NO
CR5
NO NO
PR8
CR19
C5-13 BL/WH
STA A B
R21ING WH
P134FB WH

R46HRN BK

C116 OR


WH
RD
REGULATOR NO
A
12V DC
S
BR
RD/GN
WH/GN
BR/WH
GN/WH
GY/RD
RD/GR
BK/BL
RD
GY/YL
GY/RD
WH/BK
WH/BK
+ S8
I
M4
C5-1
C5-4
FB1 FB1 +
M3
C6-10
7 M2 G6
BK PIN 18
BK
-
- FORD ENGINE FORD ENGINE
M1 H2
NO
BRN
B1
BRN
ES0396R
BATTERY
TOGGLE SWITCH
ENGINE FAULT
HOUR METER
LEVEL SENSOR
CHECK ENGINE LED

ALTERNATOR
(OPTION)
OIL COOLER FAN
(OPTION)
(OPTION)
FLASHING BEACONS
SERVICE HORN
RELAY
SERVICE HORN
TILT ALARM
AUXILIARY PUMP
POWER RELAY
AUXILIARY PUMP
STARTER
FUEL SENSOR
FUEL SENSOR
LPG LOCKOUT
LPG LOCKOUT
START SIGNAL (FEH)

RELAY
IGNITION / START
CR1
8
FORD 42 PIN CONNECTOR

S-60 HC • S-60X • S-60XC
1
8
6 - 113
C7P-3 BATGND C7B-3

GROUND
YL
5 6
BR S18
4

A
BL
3

BK
S17
2

1
J114

2
9
4

TB30
U4
J2
10
J1

1

RD BK
S-60 • S-65 • S-60 TRAX • S-65 TRAX
B

16
15
TB31
H3

TS14
(OPTION)
S-60 HC • S-60X • S-60XC

Y2
TB32
Y27

J1
16 20
L1
MOTOR STROKE
TB29
Y3
C25-1 C25-2
TS15

7 18 STEER CW
RIGHT
C

17 STEER CCW
J2
6
Y4
CDE2 BL/BK
Y23
11
C14-1 C14-2
10
CW
TB4
C15-1 C15-2
9
CCW
TB5
5
Y24
C159STC BL/WH
C159STC BL/WH
C160JPL WH/RD
RIGHT
13 TURNTABLE ROTATE
P162JPW OR
J1
LEFT
TS62
7.5W
LEFT
R2
CR19
D
14
C31-1 C31-2
BR
5W
R2
FLOW CONTROL
Y13
J25
6
5
4
3
2
C9PER BK/RD
1
C3P-9 C3B-9
14
C41RPM OR/BK
C28TTA RD/BK
LSB2S
JC3
P26ESTP BK
Y26

J2
C6-7
13 LOOSE CABLE
P24FS WH
C16-1 C16-2
RD
BR
BATGND
LIMIT SWITCH
22
NC 21

12
RD PRIMARY BOOM
TB7
C37-2
EXTEND
ALC-500 JOYSTICK
CONTROL CARD
EXTEND
Y25
PRIMARY BOOM
TB8
C17-1 C17-2
TS63
RETRACT C6-8 C8PBR BK/WH

E
PRIMARY BOOM
U13
RETRACT
TB9
Part No. 147753

December 2013

C6-9 C9PER BK/RD
EXTEND / RETRACT
FLOW CONTROL
Y15
F
1
5
10
J8
8
7
6
G
P134 RD C6-25 BL
4 3 2 1
RD LST3O - ZONE A
NO
NC
21
13
2 BR GROUND BOX
BK SPEED REDUCTION
22
14

Y22
TB1
3 C6-1 C12-1 C12-2

2 UP UP
PRIMARY BOOM
1
C164PES RD/WH
C165TRS WH/RD
C13-1 C13-2
C163PLS WH/BK

J1
11 DOWN
TS61
P162JPW OR
Y21
H
7.5W
R16
TB3
P26 ESTP
PRIMARY BOOM
12 C6-3 C3PBF RD/WH C29-1 C29-2
UP / DOWN
C118LS OR
CR34
FLOW CONTROL
BR
Y12
J127
10W
R14

6
5
4
3
2
1
RELAY
OR C6-29
JC7

6
TB2

7
1 C3P-3
8
I
J2
P24FS WH
2 C4P-1
3 RD
NO
NC
J3
LST1O
21
13
C8
P24 C2P-2 BR
BK
2 1
LIMIT SWITCH
22
14
3 WH
1
D24
D23
RD
NO
NC
C10
21
13
2 1
BK LIMIT SWITCH
22
14
WH
LIFT / DRIVE
CR27
CR30
NO
NC
J
RD
(OPTION)
NO
NC
C11
21
13
C6-22 P22LS BK
TB22
2 1
BK LIMIT SWITCH
22
14
WH
L46
P22LS BK L46 / L47
TB59
LOOSE CABLE LED
L47
NO
TB134 LSB2S
P134 RD BK C6-24 C37-3 BK WH C37-4
LOOSE CABLE
13
14
LIMIT SWITCH
TS9
DOWN PLATFORM
K
Y20
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
(S-65 OPTION)
WH
PLATFORM LEVEL DOWN

BR
TB15
Y19
TB44
JIB BOOM

TS8
DOWN
D27
Y16
TB18
D28
C23-1 C23-2
TS58
L

CR13
PLATFORM
(S-65 OPTION) C22-1 C22-2

NC

ROTATE
TB17
Y17
D29
TS7
CW
CCW CW
PLAT. ROTATE
CCW
TS57
C6-19 C129 RD/BK
DESCENT ALRM
D30
H4
TB19
M
C1
RD
JIB VALVE
-
+
Y11
C41RPM OR/BK
NO
C28TTA RD/BK
RD (AUX & FE)

P26ESTP BK
CR14
P24FS WH
P22LS BK
N
RD (AUX)
P134 RD
BR

6 - 113 6 - 114

Ford Engine Models (CE) (after SN 22516)
6 - 115 6 - 116

D89 C132PL2 LT. BR

P22LS BK P22LS BK
1 P134PWR RD P134PWR RD
LS18A
P134PWR RD
BR OR NO BK
D88 WH NC RD
LS18 P2 FS1
RD C9P-3 P25FS RD
C2P-6
C1P-12
C9P-1 BK
C7P-1
R20
C132PLI BL/WH
P134PWR GR/BK
4.7KW
RD AUXILIARY TS2 TS3 TS4
D10
2 PUMP ENGINE FUEL ENGINE
P22BAT BK
P26ESTP BK TS1 START SELECT RPM
P26ESTP BK
L4
2 9
WH
C4P-10
2 P3 + COM
C7B-1
C2B-6
C1B-12
H1 2 SEC
5
4 TB134 RD
NO
BK
D39
8 D12
KS1 -
D40
C7P-2
CB2 1 3
15A 3 U35
TB22
C4B-10
C3P-12
3 P1 30A
C1P-2
C1P-7
C1P-9
C2P-5
C1P-1
C2P-1
3 4 5
RD PLAT
D4
1 GND C171LS WH/BK
6 D3 RD
U33 7 RD
TS52 D11 TS53 TS54
12 8 TS51 ENGINE FUEL U34 ENGINE
START SELECT RPM
P23BAT WH
GR/BK
10A
C133PLA BL/WH
C28TTA RD/BK
C33STR BK
C39LP BL/RD
C35RPM RD/BK
C46HRN GR
C27AUX RD
+
P4
P20BAT RD
PUMP
AUXILIARY
2 SEC FUNCTION
9 ENABLE
5
NO
4
-
3 8
C1B-1
C1B-7
C1B-9
C2B-5
C3B-12
C1B-2
C7B-2
C2B-1
CB1
L45 TB41
15A H6
TB33 TB39
BL/RD
RD
D2 TB23 TB27 RD
TB134 D13
RD P24BAT RD TB24
5 TB20
CR1 CR2 CR4 TB35
CB3 NO NO NC
15A
C5-3 C21ING WH TB21
C35RPM RB/BK
P116HYD RD
P22HRN BK
P134TTS RD
C27AUX RD
C27AUX RD
C46HRN GR
C28TTA RD/BK
TS64 L2
LINK FAULT
C5-18
C5-19
C5-5
C5-2
C5-9
C5-11
C5-10
BAT+ 1
RUN
TEST
C21ING WH
1
6 BAT-
C6-27
C6-26
C6-28
C6-23
CR5
NO NO
PR8
CR19
C5-13 BL/WH
STA A B
R21ING WH
P134FB WH

R46HRN BK

C116 OR


WH
RD
REGULATOR NO
A
12V DC
S
BR
RD/GN
WH/GN
BR/WH
GN/WH
GY/RD
RD/GR
BK/BL
RD
GY/YL
GY/RD
WH/BK
WH/BK
+ S8
I
M4
C5-1
C5-4
FB1 FB1 +
M3
C6-10
M2 G6
7
BK PIN 18
BK
-
- FORD ENGINE FORD ENGINE
M1 H2
NO
BRN
B1
BRN
ES0396R
BATTERY
TOGGLE SWITCH
ENGINE FAULT
HOUR METER
LEVEL SENSOR
CHECK ENGINE LED

ALTERNATOR
(OPTION)
OIL COOLER FAN
(OPTION)
(OPTION)
FLASHING BEACONS
SERVICE HORN
RELAY
SERVICE HORN
TILT ALARM
AUXILIARY PUMP
POWER RELAY
AUXILIARY PUMP
STARTER
FUEL SENSOR
FUEL SENSOR
LPG LOCKOUT
LPG LOCKOUT
START SIGNAL (FEH)

RELAY
IGNITION / START
CR1
8 FORD 42 PIN CONNECTOR


S-60 HC • S-60X • S-60XC
1
8
6 - 117
C7P-3 BATGND C7B-3

GROUND
YL
5 6
BR S18
A

4

BL
3

BK
S17
2

1
J114

2
9
4

TB30
U4
J2
10
J1

S-60 • S-65 • S-60 TRAX • S-65 TRAX
1

RD BK
B

16
15
TB31
H3

TS14
S-60 HC • S-60X • S-60XC
(OPTION)

Y2
TB32
Y27

J1
16 20
L1
MOTOR STROKE
TB29
Y3
C25-1 C25-2
TS15

C
7 18 STEER CW
RIGHT
17 STEER CCW
J2
6
Y4
CDE2 BL/BK
Y23
11
C14-1 C14-2
10
CW
TB4
C15-1 C15-2
9
CCW
TB5
5
Y24
C159STC BL/WH
C159STC BL/WH
C160JPL WH/RD
RIGHT
13 TURNTABLE ROTATE
P162JPW OR
J1
LEFT
TS62
7.5W
D
LEFT
R2
CR19
14
C31-1 C31-2
BR
5W
R2
FLOW CONTROL
Y13
J25
6
5
4
3
2
C9PER BK/RD
1
C3P-9 C3B-9
14
C41RPM OR/BK
C28TTA RD/BK
LSB2S
JC3
P26ESTP BK
Y26

J2
C6-7
13 LOOSE CABLE
P24FS WH
C16-1 C16-2
RD
BR
BATGND
LIMIT SWITCH
22
NC 21

12
RD PRIMARY BOOM
TB7
C37-2
EXTEND
ALC-500 JOYSTICK
CONTROL CARD
EXTEND
Y25
PRIMARY BOOM
TB8
E
C17-1 C17-2
TS63

U13
RETRACT
Part No. 147753
December 2013
TB9

C6-9 C9PER BK/RD
EXTEND / RETRACT
FLOW CONTROL
Y15
F
1
5
10
J8
8
7
6
G
P134 RD C6-25 BL
4 3 2 1
RD LST3O - ZONE A
NO
NC
21
13
2 BR GROUND BOX
BK SPEED REDUCTION
22
14

Y22
TB1
3 C6-1 C12-1 C12-2

2 UP UP
PRIMARY BOOM
1
C164PES RD/WH
C165TRS WH/RD
C13-1 C13-2
C163PLS WH/BK

J1
11 DOWN
TS61
P162JPW OR
H
Y21
7.5W
R16
TB3
P26 ESTP
PRIMARY BOOM
12 C6-3 C3PBF RD/WH C29-1 C29-2
UP / DOWN
C118LS OR
CR34
FLOW CONTROL
BR
Y12
J127
10W
R14

6
5
4
3
2
1
RELAY
OR C6-29
JC7

6
TB2

7
1 C3P-3
8
I
J2
P24FS WH
2 C4P-1
3 RD
NO
NC
J3
LST1O
21
13
C8
P24 C2P-2 BR
BK
2 1
LIMIT SWITCH
22
14
3 WH
1
D24
D23
RD
NO
NC
C10
21
13
2 1
BK LIMIT SWITCH
22
14
WH
LIFT / DRIVE
CR27
CR30
J
NO
NC
RD
(OPTION)
NO
NC
C11
21
13
C6-22 P22LS BK
TB22
2 1
BK LIMIT SWITCH
22
14
WH
L46
P22LS BK L46 / L47
TB59
LOOSE CABLE LED
L47
NO
TB134 LSB2S
P134 RD BK C6-24 C37-3 BK WH C37-4
LOOSE CABLE
13
14
LIMIT SWITCH
TS9
DOWN PLATFORM
K
Y20
TB14
C20-1 C20-2
TS59
C6-14 C14PLU OR
PLATFORM LEVEL UP
UP
(S-65 OPTION)
WH
PLATFORM LEVEL DOWN

BR
TB15
Y19
TB44
JIB BOOM

TS8
DOWN
D27
Y16
TB18
D28
C23-1 C23-2
TS58
L

CR13
PLATFORM
(S-65 OPTION) C22-1 C22-2

NC

ROTATE
TB17
Y17
D29
TS7
CW
CCW CW
PLAT. ROTATE
CCW
TS57
C6-19 C129 RD/BK
DESCENT ALRM
D30
H4
TB19
M
C1
RD
JIB VALVE
-
+
Y11
C41RPM OR/BK
NO
C28TTA RD/BK
RD (AUX & FE)

P26ESTP BK
CR14
P24FS WH
P22LS BK
N
RD (AUX)
P134 RD
BR

6 - 117 6 - 118

S-60/S-65 Ford Engine Models (CE) (from SN 21001 to 22516)
6 - 119 6 - 120
8
7
6
5
4
3
2
1
CR1 CR2 CR4 CR45
6 - 120
U33
A
WH - TB24C
BRN
BRN
C32
3
2
8
7
6
5
1
3
4
12
BK-33C
RD-24B
BK C5-5
WH-21C
9
8
CB3-2 RD
WH-C5-11
WH-C5-19
RD-CR2 #86
WH-23C (2)
C21IGN WH
5
P48PWR WH
RD-CR19 #86
BRN
BK 22D
C5
RD TS52
RD TS51
RD H6(+)
BK C7B-1
C32
GR/BK H6(-)
U34
C6
BL/WH C1B-12
B
GR/RD C4B-10
BRN
BR - GND
RD-27C
WH C5-4
BK-46R
RD - TB134D (3)
GR-C2B-5
OR C5-1
WH/RD-6D
RD/WH-3D
BK-22C (1)
BRN CR19
CR34
C21IGN WH21A (1)
CR5
C6
C5
+
WH/RD-R2 CR17
C
WH/RD-R4
H6
RD/WH-R16 OR C6-29
RD/WH-TS61
RD-CB3
TS64
S-60 HC • S-60X • S-60XC

ENGINE FAULT
TOGGLE SWITCH

1 PRIMARY BOOM UP 1
S-60 • S-65 • S-60 TRAX • S-65 TRAX

D

D29
C3PBF RD/WH C3B-3
C4TRL WH C3B-4
C5TRR WH/BK C3B-5
C6TRF WH/RD C3B-6
OPT

C7PBE BK C3B-7
Ford DSG-423 EFI Engine and Ford MSG-425 EFI Engine

C8PBR BK/WH C3B-8
E

C9PER BK/RD C3B-9

S-60/S-65 Ford Engine Models (CE) (from SN 21001 to 22516)

C14PLU OR C4B-2
C15PLD OR/BK C4B-3
C133PLA GR/BK C3B-12

C17JU GR C4B-5
C18JD GR/BK C4B-6
December 2013
Part No. 147753

F
C19JSV GR/WH C4B-7

GR/WH-TS57
20 +12 VOLT POWER (1) 20
BRN
12V DC
20 +12 VOLT POWER (2) 20

C21IGN WH CR17 #86
C128RPM WH C5-9
BATTERY POWER
CR45-86 21 IGNITION POWER (1) 21

WH TB21
WH-HM
BK-CR5
C5
C6
C3
C4
C7
F19
BK-KS1-1
G
P22BAT BK C6-22 C6-39

BK-C32-4

WH-KS1-3
WH-U34-9 RD CR2#86 C4B
RD-CB1 (BROWN)
18/22
25 (UNUSED) 25 C3B
CABLE #1
(GREEN)
H
26 (UNUSED) 26
C29MS RD/WH C1B-3
(BLACK)
C29MS RD/WH C5-24
29 MOTOR STROKE 29
C30FWD WH C1B-4
18/19
C30FWD WH C5-21
CABLE #2
C31REV WH/BK C1B-5

WH/RD-R2
WH/RD-R4
(GREY)
RD/WH-R16
C31REV WH/BK C5-20

RD/WH-TS61
C32BRK WH/RD C1B-6
BRN

32 BRAKE 32
I
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
HARNESS TO
SWITCH PANEL
34 (UNUSED) 34
C35RPM BK/RD C1B-9
C35RPM BK/RD C5-18
C39LP BL/RD C2B-1




C40LS1 OR C2B-2
C40LS1 OR C6-40
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C6
C41RPM OR/BK C5-2

HARNESS
C129JDA BL C3B-10
FUNCTION
J

D30
C45GEN GR/WH C5-12

C3
C45GEN GR/WH C2B-7

C59CNK BL/BK C3B-11
P134PWR RD C2B-6
P134BAT BK C6-25
P134BAT RD C6-24
RD-U34-2 P134TTS RD C6-26

C6
C7
C5
C2
K
C5

ENGINE
HARNESS

L
C7P
12V DC
BRN
POWER TO PLATFORM
ES0396R
BRN C7B-3
M
GROUND BOLT
N
N
CR1 CR2 CR4 CR45
U33
M
BRN
BRN
C32
3
2
8
7
6
5
1
3
4
12
BK-33C
RD-24B
BK C5-5
WH-21C
9
8
CB3-2 RD
WH-C5-11
WH-C5-19
WH - CR4
C21IGN WH
5
P48PWR WH
BRN
WH-23C C5 BK 22D
RD TS52
RD TS51
RD H6(+)
BK C7B-1
C32
GR/BK H6(-)
U34
C6
BL/WH C1B-12
L
GR/RD C4B-10
BRN
BR - GND
RD-27C
WH C5-4
BK-46R
RD - TB134D (3)
GR-C2B-5
OR C5-1
WH/RD-6D
RD/WH-3D
BK-22C (1)
BRN CR19
CR34
C21IGN WH21A (1)
CR5
C6
C5
+
WH/RD-R2 CR17
WH/RD-R4
K
H6
RD/WH-R16 OR C6-29
RD/WH-TS61
RD-CB3
TS64
ENGINE FAULT
TOGGLE SWITCH

1 PRIMARY BOOM UP 1
J

D29
C3PBF RD/WH C3B-3
C4TRL WH C3B-4
C5TRR WH/BK C3B-5
C6TRF WH/RD C3B-6
OPT

C7PBE BK C3B-7
I

C8PBR BK/WH C3B-8
C9PER BK/RD C3B-9
C14PLU OR C4B-2
C15PLD OR/BK C4B-3
C133PLA GR/BK C3B-12

C17JU GR C4B-5
C18JD GR/BK C4B-6
H

C19JSV GR/WH C4B-7
GR/WH-TS57
20 +12 VOLT POWER (1) 20
BRN
12V DC
20 +12 VOLT POWER (2) 20

C21IGN WH CR17 #86
C128RPM WH C5-9
BATTERY POWER
CR45-86 21 IGNITION POWER (1) 21

WH TB21
WH-HM
G
BK-CR5
C5
C6
C3
C4
C7
F19
BK-KS1-1
P22BAT BK C6-22
BK-C32-4

WH-KS1-3
WH-U34-9 RD CR2#86 C4B
RD-CB1 (BROWN)
F
18/22
25 (UNUSED) 25 C3B
CABLE #1
(GREEN)
26 (UNUSED) 26
C29MS RD/WH C1B-3
(BLACK)
C29MS RD/WH C5-24
29 MOTOR STROKE 29
C30FWD WH C1B-4
18/19
C30FWD WH C5-21
CABLE #2
C31REV WH/BK C1B-5

December 2013
Part No. 147753

WH/RD-R2
WH/RD-R4
(GREY)
RD/WH-R16
C31REV WH/BK C5-20

RD/WH-TS61
E
C32BRK WH/RD C1B-6

BRN

32 BRAKE 32
BK-TS52
33 START ENGINE 33
C34SA BK/WH C1B-8
HARNESS TO
SWITCH PANEL
34 (UNUSED) 34
C35RPM BK/RD C1B-9
C35RPM BK/RD C5-18
C39LP BL/RD C2B-1




C40LS1 OR C2B-2
C40LS1 OR C6-40
D
40 BOOM STOWED 40
C41RPM OR/BK C2B-3
C6
C41RPM OR/BK C5-2

HARNESS
C129JDA BL C3B-10
FUNCTION

D30
C45GEN GR/WH C5-12

C3
C45GEN GR/WH C2B-7

C59CNK BL/BK C3B-11
P134PWR RD C2B-6
C

P134TTS RD C6-26
C6
C7
C5
C2
C5

ENGINE
HARNESS
S-60 HC • S-60X • S-60XC

B
S-60 • S-65 • S-60 TRAX • S-65 TRAX

C7P
12V DC
BRN
POWER TO PLATFORM
ES0396R
BRN C7B-3
A
GROUND BOLT
S-60/S-65 Ford Engine Models (CE) (after SN 22516)
6 - 121
8
7
6
5
4
3
2
1

S-60 / S-65 Ford Engine Models (CE) (after SN 22516)
6 - 121 6 - 122

S-60/S-65 Ford Engine Models (CE)
6 - 123 6 - 124

CONNECTIONS
CONTROL BOX
1
TO GROUND
WH/RD-CR19#87A
RD/WH-CR34#87A
WH/RD-CR19#87
RD/WH-CR34#87
WH/RD TS62-6
RD/WH-TS61-3
BR-GND STUD
GR/WH-TB19D
OR/BK-TB15D
GR/BK-TB18D
BK/RD-TB35D
RD-C134D (2)
BL/RD-TB39D
BL/BK-TB59D
WH/BK-TB5D
WH/RD-TB26
BK/WH-TB8D
BR-CR34#85
BK/RD-TB9D
RD/BK-TB2D
GR/BK-H6(-)
RD/WH-R16
WH-TS51-2
WH-TB23D
WH-TB21D
RD-TS51-1
WH/RD-R2
RD-TS61-2
WH/RD-R4
RD TS62-4
OR-TB14D
RD TS61-2
GR-TB17D
RD-TB27D
RD-TB20C
RD-TB20C
RD-TB20D
RD-TB24D
WH-KS1-1
BK-TB22D
BK-TB33D
BL-TB44D
RD-L45(+)
RD-CB2-1
WH-TB4D
RD-C32-6
RD-KS1-2
RD-C6-33
RD-C32-7
BR-L46(-)
RD-TB1D
BK-TB7D
BR-G6(-)
RD-P1-2
RD-R14
TS52
2
1
3
L45
TS51
2
P4
D3
+
4
NO
4
6
3
4
NO
3
1
G6
1
WH/RD
WH/RD
CB2
TS61
6
2
D4
4
R2
R4
D11
L46
1
3
TS62
1
4
4
TS53
+
TS63
KS1
2
B1
3
RD/WH
2
6
5
1
D28
D13
1
D2
TS54
CB1
TS58
R16
R14
2
3
6
1A
1B
RD
P1
NC
NC
2A
2B
1
TS59
1
L2
TS57
CB3
3
2
1
7
+
2
CB1 ENGINE CIRCUIT BREAKER, 15A KS1 KEY SWITCH TS57 PLATFORM ROTATE TOGGLE SWITCH
CB2 CONTROLS CIRCUIT BREAKER, 15A L2 LED - CHECK ENGINE TS58 JIB BOOM UP / DOWN TOGGLE SWITCH (S-65 OPTION)
CB3 CIRCUIT BREAKER, 15A (OPTION) L45 LED - PLATFORM OVERLOAD TS59 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
CB7 HIGH IDLE CIRCUIT BREAKER L46 LED - CABLE TENSION TS61 PRIMARY BOOM UP / DOWN TOGGLE SWITCH
CR1 START RELAY P1 EMERGENCY STOP BUTTON TS62 TURNTABLE ROTATE TOGGLE SWITCH
CR2 IGNITION / FUEL RELAY P4 FUNCTION ENABLE SWITCH TS63 PRIMARY BOOM EXTEND / RETRACT TOGGLE SWITCH
8 CR4 HIGH IDLE RELAY R2 RESISTOR, 5W, TURNTABLE ROTATE SPEED U33 LOAD SENSE MODULE
CR5 HORN RELAY R4 RESISTOR, 7.5W, TURNTABLE ROTATE SPEED U34 TIME DELAY RELAY - 2 SECONDS, 10A
CR17 HYDRAULIC OIL COOLER RELAY (OPTION) R14 RESISTOR, 10W, PRIMARY BOOM UPPER ZONE SPEED
CR19 TURNTABLE SPEED REDUCTION RELAY R16 RESISTOR, 7.5W, PRIMARY BOOM UP / DOWN SPEED
CR23 DRIVE LIGHTS RELAY (OPTION) TS51 AUXILIARY PUMP TOGGLE SWITCH ES0396R
CR34 PRIMARY BOOM SPEED REDUCTION RELAY TS52 ENGINE START TOGGLE SWITCH NOTE: DASHED LINES INDICATE OPTIONS.
G6 HOUR METER TS53 FUEL SELECT TOGGLE SWITCH
H6 PLATFORM OVERLOAD ALARM TS54 RPM SELECT TOGGLE SWITCH
S-60 HC • S-60X • S-60XC
1
6 - 125


CWLITE WH TS49
BK
A
BK
R20
5
U35
2+
3-
S-60 • S-65 • S-60 TRAX • S-65 TRAX
C134PWR RD LS18
CONTROL HARNESS
B
ES0396R
SWITCH PANEL
TO PLATFORM
P26BAT BK
P26BAT BK
S-60 HC • S-60X • S-60XC

GR/WH
RD
C19JSV GR/WH TS7

C19JSV GR/WH C4P-7
BRN JC3 BR BK
C
BRN GND
RD-E STOP RD
P134PWR RD-H1+
CR13-#86 RD BR
GR/WH
OPT.
C1
RD LS18 CABLE
RD OUTPUT
GR/WH +
TS7 WH
CR14
C134PWR RD
BRN -
JIB
BK
CR27
BR
D
RD RD
C32BRK WH/RD C1P-6
C32BRK WH/RD J2-19
LS18
CR30
D24
C40LS OR
E
WH
OR
BR
C42LS OR/RD
Part No. 147753
December 2013
D23
TS14 WH
P23BAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
(S-65 OPT.)
C18PRR GR/BK C4P-6

BR
C17PRL GR C4P-5
JIB
C15PLD OR/BK C4P-3

C14PLU OR C4P-2
F

P26BAT BK C9-1 P2
P25FS RD C9-3 TS2
P24FS WH C9-2 TS4
F.S.
C45GEN GR/WH C2P-7

G
C46HRN GR C2P-5
C39LP BL/RD C2P-1
F.S.
C9
BR-GND
P26ESTP BK
C3P
C4P
C7P
C2P
11
D89
3
C42LS OR/RD C2P-4

C6TRF WH/RD C3P-6
J3
D88
C123PBS RD/BK C4P-8

C7PBE BK C3P-7
C13DE BL/RD C4P-1
C8PBR BK/WH C3P-8
C40LS OR C2P-2
H
P24FS WH
C9PER BK/RD C3P-9
C4P-10 BK C132PLI2
C1P-12 BK C132PLI1

C30FWD WH C1P-4
BRN C1PBU RD C3P-1
C31REV WH/BK C1P-5
C2PBD RD/BK C3P-2
C36SCC BL C1P-10
C3PBF RD/WH C3P-3
ALC-500
C37SCW BL/BK C1P-11

C5TRR WH/BK C3P-5
U13
C32BRK WH/RD C1P-6

I
C4TRL WH C3P-4
J2
C29MS RD/WH C1P-3
12V BATT
P109ANG GR/WH C4P-9
C7P
SENSOR GND BR C4P-4
J8
6
C7P
C3P
C4P
C1P
C2P
J
C4P(BR)
BR
1
J7
C3P(GR)
C35RPM BK/RD C1P-9
K
C33STR BK C1P-7
C27AUX RD C1P-1
C2P(BK)
J1
9
P109ANG GR/WH
C165TRS WH/RD
SENSOR GND BR
C164PES RD/WH
C1P(GY)
P162JPW OR
C163PLS WH/BK
GND BR
L
C160JPL WH/RD
P162JPW OR
C159STC BL/WH
GND BR
C144DER BL/WH
C28TTA RD/BK C1P-2

C13DE BL/RD
C29MS RD/WH
BATGRN C7P-3
M
GR/BK C133PLA C3P-12

GR/BK-L4 GR/BK-L4
D39
D40
C28TTA RD/BK
H1
P134PWR RD C2P-6
P134PWR RD LS18 RD-TILT
+
CWLITE BK
BRN
BRN
N
BRN
CWLITE WH TS49

6 - 125 6 - 126

6 - 127 6 - 128

1 CONTROL HARNESS
TO PLATFORM BOX
RD H1(+)
BK C7P-1
RD/WH J1-2
BK J3-3
BR J1-14
BL/WH J1-5
BK C9-1
BR J1-12
OR J1-11
BK/RD C1P-9
WH CR30#30
RD C9P-3
BL/WH J1-7
RD/WH J1-8
RD C1P-1
BK/WH C1P-8
GR/BK H1 (D39)
BR GND STUD
RD/BK H1 (D40)
BL/BK J1-6
WH C9P-2
BL/RD J1-16
GR/WH C2P-7
BK C1P-7
GR C2P-5
OR/BK C4P-3
OR C4P-2
RD CR14-#86
GR/BK C4P-6
GR/WH C4P-7
GR C4P-5
BL/BK C3P-11
OR J1-13
WH/BK C4P-9
C129JDA BL C3P-10
WH/RD J1-4
WH/RD J1-1
WH/BK J1-3
WH CR27#87A
WH C7P-2
TS4 TS15
2 TS3
+
L4 D12
D10
JC7 JC3
3
TS2
+
6
1 L47
+
WH
WH L1
4
CR13 1 6
TS9 TS8 WH TS1 TS49 TS48

TS7 TS14
NO
+
NC
P3
L48
5
P2
RD
BK
RD
RD
D27 BK P22BAT
COMPONENT INDEX
C1 CAPACITOR, JIB CIRCUIT (S-65 OPTION) TS3 FUEL SELECT TOGGLE SWITCH
CR13 JIB SELECT RELAY (S-65 OPTION) TS4 RPM SELECT TOGGLE SWITCH 1 ROCKER / STEER OPTION.
CR14 JIB VALVE RELAY (S-65 OPTION) TS7 PLATFORM ROTATE TOGGLE SWITCH
CR27 RELAY - BRAKE CIRCUIT (LIFT / DRIVE OPTION) TS8 JIB BOOM UP / DOWN TOGGLE SWITCH (S-65 OPTION)
CR30 RELAY - LIMIT SWITCH (LIFT / DRIVE OPTION) TS9 PLATFORM LEVEL UP / DOWN TOGGLE SWITCH
7 CR76 RELAY - LOAD SENSE AUX RECOVERY TS14 DRIVE SPEED TOGGLE SWITCH
H1 TILT ALARM TS15 DRIVE ENABLE TOGGLE SWITCH
JC3 JOYSTICK - DRIVE / STEER TS47 GENERATOR (OPTION)
JC7 JOYSTICK - PRIMARY BOOM UP / DOWN, EXTEND / RETRACT, TURNTABLE ROTATE TS48 DRIVE LIGHTS (OPTION)
L1 LED - DRIVE ENABLE U13 ALC500 JOYSTICK CONTROLLER CARD
L4 LED - PLATFORM OVERLOAD U35 TIME DELAY RELAY
LS18 PLATFORM OVERLOAD LIMIT SWITCH
8 P2 EMERGENCY STOP BUTTON
P3 HORN BUTTON
R20 RESISTOR - 4700W
ES0396R
S-60 HC • S-60X • S-60XC
Electrical Schematic, S-60 / S-65 / S60 TRAX / S65 TRAX

Deutz D2011L03i Models (CE)
6 - 129 6 - 130
Electrical Schematic, S-60 / S-65 / S60 TRAX / S65 TRAX

Deutz D2011L03i Models (CE)

P22LS BK P22LS BK
1 P134 RD P134 RD
D89 LS18A C132PLI2 BK
BR OR NO BK P26ESTP BK P26ESTP BK
D88 WH NC RD P2 FS1 C9P-3
LS18 RD P25FS RD
C9P-1 BK
WH P24FS WH P24FS WH
C1P-12
C2P-6
RD C9P-2 AUXILIARY
PUMP TS2 TS6 TS4
R20 ENGINE GLOW ENGINE
TS1
C7P-1
P134PWR GR/BK
C132PLI BL/WH
4.7KW P26ESTP BK START PLUG RPM
2 P26ESTP BK
+
C4P-10 LT BR
P3 H1
-
HIGH
LOW
P22BAT BK
L4
2 9
+ COM
RD/BK
GR/BK
2 SEC. D12
5
D39 NO
8
D40
TB134
CB2 -
C1P-7
C1P-9
C1P-8
C1P-1
C4B-10 BK
C2B-6
C1B-12
C7B-1
3 U35
C7P-2
C1P-2
15A
P1 RD
C3P-12
30A
C2P-5
2
3 RD RD B1
D4 RD (AUX + FE)
4 D3 RD (AUX)
KS1 1 3
TB22
C133PLA BL/WH
C28TTA RD/BK
C46HRN GR
3 4 5
B PLAT TS52 TS54
C35RPM BK/RD
TS51 TS56 P4
P23BAT WH
C41RPM OR/BK
C34SA BK/WH
C33STR BK
GND U34 ENGINE GLOW FUNC. ENABLE ENGINE
1 6 START RPM
C27AUX RD
2 10A PLUG
U33
PUMP
AUXILIARY
+
BK
RD
WH
7
LOW
HIGH
2 SEC.
9 D64
5
12 8 NO
RD
BK
4
C1B-7
RD
-
C2B-5
C1B-9
C1B-1
C3B-12
C1B-2
C7B-2
3 8
WH D2 TB27
TB33
GR/BK
TB23
C1B-8
TB41 1 START RELAY
H6 L45 2 TACHOMETER
CB1
3 START INPUT
15A 4 AUXILIARY ON U1
TB20 TB24 5 GROUND IGN / START
RD

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Introduction December 2013

Important Serial Number Information

S-60/65, S-60HC, S-60X/XC, and TRAX

Machine Design Life

"Genie" and "S" are registered trademarks of

Printed on recycled paper

ii S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753

A1 1/2011 2 - Spec. Machine Specifications

A2 10/2011 4 - Repair 1-2

B 2/2012 Introduction Revision History Added

C 10/2012 Added Ford MSG-425 Engine to all sections.

2 - Spec. Ford MSG-425, Deutz TD2011L04i

5 - Faults Updated Fault Codes

6 - Schem. 6 - 1 Revised all schematics and grouped by Markets.

5 - Faults Separated Ford Fault Codes

C2 1/2013 3 - Maint. 3-6, E-4

6 - Schem. 6-25, 6-29

Kubota Engine_Section 2_Specifications. Electronic Version

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

Kubota Engine_Section 2_Specifications. Electronic Version

iv S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753

Serial Number Legend

Rated work load (including occupants): 500 lb / 227 kg

Terex South Dakota

Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX v

Read each procedure thoroughly. This

Be sure to wear protective eye wear and

Be aware of potential crushing hazards

vi S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753

Be sure that all tools and working areas

Be sure that fasteners intended for one

Be sure that your workshop or work area is

Section 1 Safety Rules

Section 3 Scheduled Maintenance Procedures

Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX ix

Section 3 Scheduled Maintenance Procedures, continued

x S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753

Section 3 Scheduled Maintenance Procedures, continued

Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX xi

Section 4 Repair Procedures

Section 4 Repair Procedures, continued

Section 5 Fault Codes

Section 6 Schematics, continued

Part No. 147753 S-60 • S-65 • S-60 TRAX • S-65 TRAX xv

Section 6 Schematics, continued

Section 6 Schematics, continued

Section 6 Schematics, continued

Section 6 Schematics, continued

Section 6 Schematics, continued

xx S-60 • S-65 • S-60 TRAX • S-65 TRAX Part No. 147753

Section 6 Schematics, continued

This page intentionally left blank.

Lug nut torque, lubricated 180 ft-lbs Hydraulic system 55 gallons

For operational specifications, refer to the

Continuous improvement of our products is a

Performance Specifications Drive speed, maximum

Boom up 60 to 70 seconds S-60 TRAX and S-65 TRAX 40 ft / 12 sec

Platform rotate, 160° 8 to 12 seconds

Braking distance, maximum

High range on paved surface 3 to 6 ft

Continuous improvement of our products is a

Hydraulic Specifications Note: Use Chevron Aviation A hydraulic oil when

Displacement - Pump 2 (outer) 0.24 cu in