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Service Manual

Serial Number Range

S-40
S-45
TM

from S40-7001

TM

Part No. 102521


Rev C3
July 2009

Introduction

July 2009

Important

Serial Number Information

Read, understand and obey the safety rules and


operating instructions in the Genie S-40 and S-45
Operator's Manual before attempting any
maintenance or repair procedure.

Genie Industries offers the following Service


Manuals for these models:

This manual provides detailed scheduled


maintenance information for the machine owner
and user. It also provides troubleshooting fault
codes and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.

Title

Part No.

S-40 and S-45 Service Manual


(before serial number 3804) ................................ 32222
S-40 and S-45 Service Manual
(from serial number 3804 to 4728) ....................... 52271
S-40 and S-45 Service Manual
(from serial number 4729 to 7000) ....................... 72136

Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are
subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.

Contact Us:

Copyright 1994 by Genie Industries

http://www.genieindustries.com
e-mail: awp.techpub@terex.com

102521 Rev C July 2007


Fourth Edition, Third Printing
"Genie" and "S" are registered trademarks of
Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.

ii

S-40 S-45

Part No. 102521

July 2009

Section 1 Safety Rules

INTRODUCTION

Serial Number Legend

Model: S-40
S4006-12345
Serial number:
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: ES0274
Machine unladen 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:
0 deg
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 60 ft 6 in/ 18.3 m

S40 06 - 12345
Sequence
number

Model

Maximum platform reach : 34 ft 3 in/ 10.4 m


Gradeability: N/A

Model year

Country of manufacture: USA


This machine complies with:
ANSI A92.5
CAN B.354.4

Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA

Sequence number
(stamped on chassis)

Serial label
(located under cover)

PN - 77055

Part No. 102521

S-40 S-45

iii

Section 1 Safety Rules

July 2007

This page intentionally left blank.

iv

S-40 S-45

Part No. 102521

July 2007

Section 1 Safety Rules

Safety Rules

Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-40 and S-45
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.

Do Not Perform Maintenance


Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturers instructions and safety rules
- employers safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Part No. 102521

S-40 S-45

Section 1 Safety Rules

July 2007

SAFETY RULES

Be sure to wear protective eye wear and


other protective clothing if the situation
warrants it.

Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.

Read each procedure thoroughly. This


manual and the decals on the machine
use signal words to identify the following:
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
minor or moderate injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.

Be aware of potential crushing hazards


such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.

Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable
and combustible materials like battery
gases and engine fuels. Always have an approved
fire extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
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.

vi

S-40 S-45

Part No. 102521

July 2009

Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................. iv
Section 1

Safety Rules
General Safety Rules .................................................................................................. v

Section 2

Rev
E

Specifications
Machine Specifications .......................................................................................... 2 - 1
Hydraulic Oil Specifications ................................................................................... 2 - 2
Manifold Component Specifications ....................................................................... 2 - 5
Valve Coil Resistance Specifications ..................................................................... 2 - 5
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7
Deutz F3L-1011F Engine Specifications ................................................................ 2 - 8
Deutz F3L-2011/Deutz D2011L03i Engine Specifications ....................................... 2 - 9
Perkins 704-30 Engine Specifications .................................................................. 2 - 10
Perkins 404-22 Engine Specifications .................................................................. 2 - 11
Machine Torque Specifications ............................................................................ 2 - 12
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 13
SAE and Metric Fastener Torque Chart ............................................................... 2 - 14

Section 3

Rev

Scheduled Maintenance Procedures


Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5

Part No. 102521

Checklist A Procedures
A-1

Inspect the Decals and Manuals .................................................................. 3 - 7

A-2

Perform Pre-operation Inspection ................................................................. 3 - 8

A-3

Perform Function Tests ................................................................................ 3 - 8

A-4

Perform Engine Maintenance ....................................................................... 3 - 9

S-40 S-45

vii

July 2009

TABLE OF CONTENTS

Section 3

Rev

Scheduled Maintenance Procedures, continued


A-5

Perform 30 Day Service ............................................................................. 3 - 10

A-6

Perform Engine Maintenance - Deutz and Ford Models ............................ 3 - 10

A-7

Perform Engine Maintenance - Perkins Models ......................................... 3 - 11

A-8

Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12

A-9

Perform Engine Maintenance - Ford Models ............................................... 3 - 13

A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13
A-11 Perform Engine Maintenance - Deutz 1011F Models .................................. 3 - 14
A-12 Replace the Drive Hub Oil .......................................................................... 3 - 14
A-13 Perform Engine Maintenance - Ford Models ............................................... 3 - 15
D

Checklist B Procedures
B-1

Inspect the Battery ..................................................................................... 3 - 17

B-2

Inspect the Electrical Wiring ....................................................................... 3 - 18

B-3

Inspect the Air Filter ................................................................................... 3 - 19

B-4

Test the Key Switch ................................................................................... 3 - 20

B-5

Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 20

B-6

Check the Exhaust System ....................................................................... 3 - 20

B-7

Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 21

B-8

Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 22

B-9

Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 23

B-10 Confirm the Proper Brake Configuration ...................................................... 3 - 24


B-11 Check and Adjust the Engine RPM ............................................................ 3 - 25
B-12 Test the Engine Idle Select ........................................................................ 3 - 26
B-13 Test the Fuel Select Operation - Ford Models ............................................ 3 - 27
B-14 Test the Ground Control Override ............................................................... 3 - 28
B-15 Check the Directional Valve Linkeage ........................................................ 3 - 28
B-16 Test the Platform Self-leveling ................................................................... 3 - 29

viii

S-40 S-45

Part No. 102521

July 2009

TABLE OF CONTENTS

Section 3

Rev

Scheduled Maintenance Procedures, continued


B-17 Test the Drive Brakes ................................................................................ 3 - 29
B-18 Test the Drive Speed - Stowed Position .................................................... 3 - 30
B-19 Test the Drive Speed - Raised or Extended Position ................................. 3 - 30
B-20 Perform Hydraulic Oil Analysis .................................................................. 3 - 31
B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 32
B-22 Inspect the Fuel and Hydraulic Tank Cap Venting System ......................... 3 - 33
B-23 Perform Engine Maintenance - Ford Models ............................................... 3 - 34

Part No. 102521

Checklist C Procedures
C-1

Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 35

C-2

Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 36

C-3

Test the Platform Overload Mechanism (if equipped) ................................. 3 - 36

C-4

Replace the Engine Air Filter - Deutz and Perkins Models .......................... 3 - 39

C-5

Replace the Inline Fuel Strainer .................................................................. 3 - 39

C-6

Perform Engine Maintenance Ford Models ................................................. 3 - 40

Checklist D Procedures
D-1

Check the Boom Wear Pads ...................................................................... 3 - 41

D-2

Check the Turntable Rotation Bearing Bolts ............................................... 3 - 42

D-3

Check the Free-wheel Configuration ........................................................... 3 - 43

D-4

Replace the Drive Hub Oil .......................................................................... 3 - 45

D-5

Perform Engine Maintenance - Deutz Models ............................................. 3 - 46

D-6

Replace the Hydraulic Filters ...................................................................... 3 - 47

D-7

Inspect for Turntable Bearing Wear ............................................................ 3 - 48

Checklist E Procedures
E-1

Test or Replace the Hydraulic Oil ............................................................... 3 - 50

E-2

Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 52

E-3

Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 53

E-4

Perform Engine Maintenance - Ford Models ............................................... 3 - 54

E-5

Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 54

S-40 S-45

ix

July 2009

TABLE OF CONTENTS

Section 3

Section 4

Rev Scheduled Maintenance Procedures, continued

Rev

E-6

Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 55

E-7

Perform Engine Maintenance - Deutz Models ............................................. 3 - 56

E-8

Perform Engine Maintenance - Deutz Models ............................................. 3 - 56

E-9

Perform Engine Maintenance - Ford Models ............................................... 3 - 57

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 - 7

2-2

Platform Rotator ........................................................................................... 4 - 8

2-3

Platform Overload System ......................................................................... 4 - 10

Jib Boom Components


3-1

Jib Boom .................................................................................................... 4 - 14

3-2

Jib Boom Lift Cylinder ................................................................................ 4 - 15

Boom Components
4-1

Cable Track ................................................................................................ 4 - 16

4-2

Boom ......................................................................................................... 4 - 18

4-3

Boom Lift Cylinder ...................................................................................... 4 - 19

4-4

Boom Extension Cylinder ........................................................................... 4 - 20

4-5

Platform Leveling Master Cylinder .............................................................. 4 - 21

Engines
5-1

RPM Adjustment - Deutz Models ............................................................... 4 - 24

5-2

RPM Adjustment - Perkins Models ............................................................. 4 - 24

5-3

Flex Plate ................................................................................................... 4 - 24

5-4

Engine Fault Codes - Ford Models ............................................................. 4 - 28

S-40 S-45

Part No. 102521

July 2009

TABLE OF CONTENTS

Section 4

Rev
A

Repair Procedures, continued


Hydraulic Pumps
6-1

Function Pump ........................................................................................... 4 - 29

6-2

Drive Pump ................................................................................................ 4 - 30

Manifolds
7-1

Function Manifold Components ................................................................. 4 - 32

7-2

Valve Adjustments - Function Manifold ...................................................... 4 - 36

7-3

Jib Select and Platform Rotate Manifold Components ............................... 4 - 37

7-4

Brake Manifold Components


(before serial number 7569) ....................................................................... 4 - 38

7-5

Brake/Two-Speed Manifold Components


(after serial number 7568) .......................................................................... 4 - 39

7-6

Oscillate Directional Valve Manifold Components ...................................... 4 - 40

7-7

Valve Adjustments, Oscillate Relief Valve .................................................. 4 - 42

7-8

Traction Manifold Components, 2WD (before serial number 7569) ............ 4 - 43

7-9

Traction Manifold Components, 2WD (after serial number 7568) ............... 4 - 44

7-10 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 45


7-11 Traction Manifold Components, 4WD (before serial number 7569) ............ 4 - 46
7-12 Traction Manifold Components, 4WD (after serial number 7568) ............... 4 - 48
7-13 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 50
7-14 Valve Coils ................................................................................................. 4 - 51
7-15 Drive Oil Diverter Manifold Components (welder option) ............................ 4 - 53
A

Turntable Rotation Components


8-1

Axle Components
9-1

Turntable Rotation Assembly ..................................................................... 4 - 54

Oscillate Axle Cylinders ............................................................................. 4 - 56

Generators
10-1 Valve Adjustments - Hydraulic Generator .................................................. 4 - 57

Part No. 102521

S-40 S-45

xi

July 2009

TABLE OF CONTENTS

Section 5

Rev

Fault Codes
Introduction ............................................................................................................ 5 - 1

Section 6

Fault Codes - Control System ................................................................................ 5 - 2

Fault Codes - Ford LRG-425 Engine ....................................................................... 5 - 6

Fault Codes - Ford DSG-423 EFI Engine ............................................................. 5 - 12

Rev

Schematics
Introduction ............................................................................................................ 6 - 1

xii

Electrical Symbols Legend .................................................................................... 6 - 2

Hydraulic Symbols Legend .................................................................................... 6 - 3

Ford DSG-423 Engine Relay Layout ....................................................................... 6 - 4

Connector Pin Legend ............................................................................................ 6 - 5

Electrical Schematic, Deutz F3L 1011 Models


(before serial number 7544) .......................................................................... 6 - 8

Ground Control Box Wiring Diagram


Deutz F3L-1011F Models ........................................................................... 6 - 11

Platform Control Box Wiring Diagram


Deutz F3L-1011F Models ........................................................................... 6 - 14

Platform Control Box Switch Panel Wiring Diagram


Deutz F3L-1011F Models ........................................................................... 6 - 15

Electrical Schematic, Perkins 704-30 Models


(before serial number 7472) ........................................................................ 6 - 18

Ground Control Box Wiring Diagram


Perkins 704-30 Models ............................................................................... 6 - 21

Platform Control Box Wiring Diagram


Perkins 704-30 Models ............................................................................... 6 - 24

Platform Control Box Switch Panel Wiring Diagram


Perkins 704-30 Models ............................................................................... 6 - 25

Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models
(from serial number 7544 to 12509)
Perkins 404-22 Models
(from serial number7472 to 12509) ............................................................. 6 - 28

S-40 S-45

Part No. 102521

July 2009

TABLE OF CONTENTS

Section 6

Rev

Schematics, continued

Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models (after serial number 12509) .................................... 6 - 32

Ground Control Box Wiring Diagram,


Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models ............................................................................... 6 - 35

Platform Control Box Wiring Diagram


Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models ............................................................................... 6 - 38

Platform Control Box Switch Panel Wiring Diagram


Deutz F3L-2011/Deutz D2011L03i Models
(from serial number 7544 to 12509)
Perkins 404-22 Models
(from serial number 7472 to 12509) ............................................................ 6 - 39

Platform Control Box Switch Panel Wiring Diagram


Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models (after serial number 12509) .................................... 6 - 41

Electrical Schematic,
Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 44

Ground Control Box Wiring Diagram,


Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 47

Platform Control Box Wiring Diagram


Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 50

Platform Control Box Switch Panel Wiring Diagram


Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 51

Electrical Schematic,
Ford LRG-425 EFI Models
(from serial number 7597 to 11066) ............................................................ 6 - 54

Ground Control Box Wiring Diagram,


Ford LRG-425 EFI Models
(from serial number 7597 to 11066) ............................................................ 6 - 57

Platform Control Box Wiring Diagram


Ford LRG-425 EFI Models
(from serial number 7597 to 11066) ............................................................ 6 - 60

Platform Control Box Switch Panel Wiring Diagram


Ford LRG-425 EFI Models
(from serial number 7597 to 11066) ............................................................ 6 - 61

Part No. 102521

S-40 S-45

xiii

July 2009

TABLE OF CONTENTS

Section 6

xiv

Rev

Schematics, continued

Electrical Schematic, Ford DSG-423 EFI Models


(from serial number 11067 to 12509) .......................................................... 6 - 64

Electrical Schematic, Ford DSG-423 EFI Models


(after serial number 12509) ......................................................................... 6 - 68

Ground Control Box Wiring Diagram,


Ford DSG-423 EFI Models ......................................................................... 6 - 71

Platform Control Box Wiring Diagram


Ford DSG-423 EFI Models ......................................................................... 6 - 74

Platform Control Box Switch Panel Wiring Diagram,


Ford DSG-423 EFI Models (from serial number 11067 to 12509) ................ 6 - 75

Platform Control Box Switch Panel Wiring Diagram


Ford DSG-423 EFI Models (after serial number 12509) ............................... 6 - 77

Engine Harness, Ford LRG-425 EFI Models


(before serial number 11067) ...................................................................... 6 - 80

Engine Harness, Ford DSG-423 EFI Models


(from serial number 11067 to 11784) .......................................................... 6 - 81

Engine Harness, Ford DSG-423 EFI Models


(after serial number 11784) ......................................................................... 6 - 83

Joystick Connector Diagram ................................................................................ 6 - 85

CTE Option Wiring Diagram ................................................................................. 6 - 88

Hydraulic Generator Wiring Diagram (welder option) ............................................. 6 - 89

Hydraulic Schematic, 2WD Non-oscillating S-40 Models


(before serial number 7569) ........................................................................ 6 - 91

Hydraulic Schematic, 2WD Non-oscillating S-45 Models


(before serial number 7569) ........................................................................ 6 - 93

Hydraulic Schematic, 4WD Oscillating S-40 Models


(before serial number 7569) ........................................................................ 6 - 95

Hydraulic Schematic, 4WD Oscillating S-45 Models


(before serial number 7569) ........................................................................ 6 - 97

Hydraulic Schematic, 2WD (after serial number 7568) ......................................... 6 - 99

Hydraulic Schematic, 4WD (after serial number 7568) ........................................ 6 - 101

Hydraulic Generator Schematic (welder option) ................................................... 6 - 103

S-40 S-45

Part No. 102521

July 2009

Section 2 Specifications

Specifications

REV E

Machine Specifications
S-40 and S-45 Models

Fluid capacities

Tires and wheels


Tire size, 2WD
front tires only
rear tires only

12.5L-16SL
12-16.5 NHS

Tire size,
2WDRT & 4WD front & rear

12-16.5 NHS

Tire ply rating


Tire contact area
Overall tire diameter

12

88 sq in
568 sq cm

57 sq in
368 sq cm

33.7 in
85.6 cm

33.2 in
84.3 cm

45 psi
3.1 bar

45 psi
3.1 bar

Wheel diameter

16 in
40.6 cm

161/2 in
41.9 cm

Wheel width

10 in
25.4 cm

9 3/4 in
24.8 cm

8@ 5/8 -18

9@ 5/8 -18

Tire pressure

Wheel lugs
Lug nut torque, dry
Lug nut torque, lubricated

170 ft-lbs / 230 Nm


130 ft-lbs / 176 Nm

Fuel tank

20 gallons
75.7 liters

Fuel tank, Option

30 gallons
114 liters

LPG tank

33.5 pounds
15.2 kg

Hydraulic tank

45 gallons
170 liters

Hydraulic system
(including tank)

55 gallons
208 liters

Drive hub
(before serial number 7569)

17 fl oz
0.5 liters

Drive hub
(after serial number 7568)

24 fl oz
0.71 liters

Turntable rotation
drive hub

8 fl oz
0.24 liters

Drive hub oil type:


SAE 90 multipurpose hypoid gear oil API service
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. 102521

S-40 S-45

2-1

Section 2 Specifications

July 2009

SPECIFICATIONS

REV E

Performance Specifications
All Models

Hydraulic Oil Specifications

Drive speeds, 2WD and 4WD

Hydraulic oil type


Viscosity grade
Viscosity index

Drive speed, stowed

40 ft / 5.2 - 5.9 sec


12.2 m / 5.2 - 5.9 sec

Drive speed, raised or extended


Gradeability

Hydraulic Oil Specifications

40 ft / 40 - 45 sec
12.2 m / 40 - 45 sec
See Operator's Manual

Boom function speeds, maximum


from platform controls
Boom up

40 to 60 seconds

Boom down

50 to 80 seconds

Boom extend

30 to 60 seconds

Boom retract

15 to 35 seconds

Turntable rotate, 360


boom fully stowed

70 to 100 seconds

Turntable rotate, 360


boom fully extended

120 to 140 seconds

Platform rotate, 160

Cleanliness level, minimum


Water content, maximum

25 to 50 seconds

Platform level down

15 to 35 seconds

Jib boom up, S-45 models

35 to 45 seconds

Jib boom down, S-45 models

20 to 30 seconds

15/13
200 ppm

Chevron Rykon MV oil is fully compatible and


mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable

Fire resistant

6 to 12 seconds

Platform level up

Chevron Rykon MV equivalent


Multi-viscosity
200

Mineral based

Petro Canada Environ MV46


Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
UCON Hydrolube HP-5046
Quintolubric 822
Shell Tellus T32
Shell Tellus T46
Chevron Aviation A

Braking distance, maximum


High range on paved surface

3 to 4 ft
0.9 to 1.2 m

Continuous improvement of our products is a


Genie policy. Product specifications are subject
to change without notice.

2-2

S-40 S-45

Part No. 102521

July 2009

Section 2 Specifications

REV E

SPECIFICATIONS

Continued use of Chevron Aviation


A hydraulic oil when ambient
temperatures are consistently
above 32F / 0C may result in
component damage.
Note: Use Chevron Aviation A hydraulic oil when
ambient temperatures are consistently
below 0F / -18C.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205F / 96C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.

Hydraulic Component
Specifications
Drive pump
Type:

bi-directional,
variable displacement piston pump

Displacement per revolution, variable, 4WD models


0 to 2.8 cu in
0 to 46 cc
Flow rate @ 2500 rpm
Drive pressure, maximum

0 to 28 gpm
106 L/min
3625 psi
250 bar

Charge pump
Type:
Displacement
Flow rate @ 2500 rpm
Charge pressure @ 2500 rpm
Neutral position

gerotor pump
0.85 cu in
13.9 cc
9 gpm
34.1 L/min
310 psi
21.4 bar

Function pump
Type
Displacement
Flow rate @ 2500 rpm

gear, pressure balanced


1.04 cu in
17 cc
10.69 gpm
40.5 L/min

Oscillation pump
Type
Displacement
Flow rate @ 2500 rpm

gear, fixed displacement


0.37 cu in
6 cc
2.8 gallons per minute
10.6 liters per minute

Continuous improvement of our products is a


Genie policy. Product specifications are subject
to change without notice.

Part No. 102521

S-40 S-45

2-3

Section 2 Specifications

July 2009

SPECIFICATIONS

REV E

Auxiliary pump

Steer-end drive motors, 4WD


(before serial number 7569)

Type: fixed displacement gear pump


Displacement - static
Displacement

0.151 cu in
2.47 cc
1.75 gallons per minute
6.62 liters per minute

Function manifold
Function relief valve pressure
S-40
S-45

Displacement per revolution

1.52 cu in / 25 cc

Non-steer end drive motors, 2WD and 4WD


(before serial number 7569)
Displacement per revolution

2.13 cu in / 35 cc

Two-speed drive motors, 2WD and 4WD


(after serial number 7568)
2600 psi / 179 bar
2900 psi / 200 bar

Displacement per revolution


low speed

0.99 cu in / 16.3 cc

Boom down
relief valve pressure

2200 psi
152 bar

Displacement per revolution


high speed

1.83 cu in / 30 cc

Boom extend

1950 psi
134 bar

Hydraulic Filters

Oscillate axle

950 psi
66 bar

Steer regulator,
All models

2 gallons per minute


7.6 liters per minute

Medium pressure filter

Beta 3 200

Medium pressure filter


bypass pressure

51 psi
3.5 bar

Hydraulic tank circuit


return line filter

10 micron with
25 psi / 1.7 bar bypass

Traction manifold, 2WD and 4WD


(before serial number 7569)
Hot oil relief pressure

210 psi
14.5 bar

Traction manifold, 2WD and 4WD


(after serial number 7568)
Hot oil relief pressure

280 psi
19.3 bar

Continuous improvement of our products is a


Genie policy. Product specifications are subject
to change without notice.

2-4

S-40 S-45

Part No. 102521

July 2009

Section 2 Specifications

REV E

SPECIFICATIONS

Manifold Component
Specifications

Valve Coil Resistance


Specifications

Plug torque

Note: The following coil resistance specifications


are at an ambient temperature of 68F / 20C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18F / 20C
that your air temperature increases or decreases
from 68F / 20C.

SAE No. 2

36 in-lbs / 4.1 Nm

SAE No. 4

10 ft-lbs / 13.6 Nm

SAE No. 6

14 ft-lbs / 19 Nm

SAE No. 8

38 ft-lbs / 51.5 Nm

SAE No. 10

41 ft-lbs / 55.6 Nm

Description

SAE No. 12

56 ft-lbs / 75.9 Nm

Solenoid valve, 2 position 3 way, 10V DC


(schematic items AC and AE)

6.3

Solenoid valve, 3 position 4 way, 10V DC


(schematic item AT and AZ)

6.3

Solenoid valve, 2 position 3 way, 10V DC


(schematic items AU, AV, AX, and AY)

6.3

Solenoid valve, 3 position 4 way, 10V DC


(schematic items AZ and BF)

6.3

Proportional solenoid valve, 12V DC


(schematic items AW and BB)

Specification

Solenoid valve, 2 position 3 way, 10V DC


(schematic item CC)

6.8

Solenoid valve, 2 position 3 way, 10V DC


(schematic items DA)

3.3

Solenoid valve, 2 position 3 way, 12V DC


(schematic items CE)

4.8

Continuous improvement of our products is a


Genie policy. Product specifications are subject
to change without notice.

Part No. 102521

S-40 S-45

2-5

Section 2 Specifications

July 2009

SPECIFICATIONS

REV E

Ford LRG-425 EFI Engine


153 cu in
2.5 liters

Displacement

Number of cylinders

3.78 x 3.4 in
96.01 x 86.36 mm

Bore & stroke


Horsepower
Gross intermittent
Continuous
Gross intermittent
Continuous

Starter motor
Normal engine cranking speed
Current draw, normal load
Current draw, maximum load
Current draw, no load

70 @ 2500 rpm
60 @ 2500 rpm
52 kW @ 2500 rpm
44.7 kW @ 2500 rpm
1-3-4-2

Low idle rpm


Frequency

1600 rpm
396.8 Hz

High idle rpm


Frequency

2500 rpm
620 Hz
9.4:1

Compression ratio
Compression pressure (approx.)
Pressure (psi) of lowest cylinder must be
at least 75% of highest cylinder
Valve clearances collapsed tappet

Oil pressure
(operating temp. @ 2000 rpm)
Oil capacity
(including filter)

Type

70A

12V DC, Group 31

Quantity
Cold cranking ampere
Reserve capacity @ 25A rate

1
1000A
200 minutes

Electronic fuel pump


Fuel pressure, static
Fuel flow rate

64 psi
4.4 bar
0.58 gpm
2.18 L/min

0.035 to 0.055 in
0.889 to 1.397 mm

40 to 60 psi
2.75 to 4.1 bar
4.5 quarts
4.3 liters

Spark plug type


(before serial number 4546)

Motorcraft AWSF-52-C

Spark plug type


(after serial number 4545)

Motorcraft AGSF-32-FM

Spark plug gap


Spark plug torque

Oil viscosity requirements

Engine coolant

Unit ships with 5W-30 oil.


Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.

Capacity

8-18 ft-lbs
11-24 Nm
3-5 psi
0.21-0.34 bar

0.042 to 0.046 inches


1.07 to 1.17 mm
5-10 ft-lbs
7-14 Nm

11.5 quarts
10.9 liters

Coolant temperature switch


Torque

Oil pressure switch specifications

2-6

800A

Ignition System

Lubrication system

Oil pressure switch point

140-200A

Battery

Firing order

Torque

200 to 250 rpm

Temperature switch point

8-18 ft-lbs
11-24 Nm
230 F
112 C

Alternator

S-40 S-45

Part No. 102521

July 2009

Section 2 Specifications

REV E

SPECIFICATIONS

Ford DSG-423 EFI Engine

Electronic fuel pump


140.4 cu in
2.3 liters

Displacement

Number of cylinders
Bore & stroke
Horsepower
Continuous horsepower
Peak horsepower
Continuous horsepower
Peak horsepower

3.44 x 3.7 inches


87.5 x 94 mm
59 @ 2500 rpm
69 @ 2500 rpm
44 kW @ 2500 rpm
51 kW @ 2500 rpm

Fuel pressure, static

64 psi
4.4 bar

Fuel flow rate

0.43 gpm
1.6 L/min

Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Ignition system
Spark plug type

Motorcraft AGSF-32-FEC

1-3-4-2

Spark plug gap

Low function idle (computer controlled)


Frequency

1600 rpm
53.3 Hz

0.049 to 0.053 inches


1.244 to 1.346 mm

Engine coolant

High function idle (computer controlled)


Frequency

2500 rpm
83.3 Hz

Firing order

9.7:1

Compression ratio
Compression pressure (approx.)
Pressure (psi or bar) of lowest cylinder must be
at least 75% of highest cylinder

Capacity
Cylinder head temperature sending unit
Fault code set temperature

280F
138C

Engine shut-down temperature

300F
149C

Lubrication system
Oil pressure
(at operating temperature @ 2500 rpm)

29 to 39 psi
2 to 2.7 bar

Starter motor
Normal engine cranking speed

Oil capacity
(including filter)

4 quarts
3.8 liters

10 quarts
9.5 liters

Current draw, normal load

Oil viscosity requirements

Current draw, maximum load

Unit ships with 5-W20 oil.


Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.

Alternator
Output

200 to 250 rpm


140-200A
800A

95A, 13.8V DC

Battery
Type
Quantity

12V DC, Group 31


1

Cold cranking ampere @ 0F

1000A

Reserve capacity @ 25A rate

200 minutes

Continuous improvement of our products is a


Genie policy. Product specifications are subject
to change without notice.

Part No. 102521

S-40 S-45

2-7

Section 2 Specifications

July 2009

SPECIFICATIONS

REV E

Deutz F3L-1011F Engine

Injection system
125 cu in
2.05 liters

Displacement

Horsepower

3.58 x 4.13 inches


91 x 105 mm
36 @ 3000 rpm
26.8 kW @ 3000 rpm
1-2-3

Firing order

18.5:1

Compression ratio
Compression pressure

Injection pump pressure

4351 psi
300 bar

Injector opening pressure

3626 psi
250 bar

362 to 435 psi


25 to 30 bar

Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.

Starter motor
Current draw, no load

1500 rpm
313 Hz

Brush length, new

High idle rpm


Frequency

2300 rpm
479.9 Hz

Brush length, minimum

centrifugal mechanical

Valve clearance, cold


0.012 in
0.3 mm

Exhaust

0.020 in
0.5 mm

Lubrication system
Oil pressure

0.7480 in
19 mm
0.5 in
12.7 mm

12V, Group 31

Quantity

Cold cranking ampere

1000A

Reserve capacity @ 25A rate

200 minutes

Fan belt deflection

3 /8

26 to 87 psi
1.8 to 6.0 bar

Oil capacity
(including filter)

90A

Battery
Type

Intake

55A, 14V

Alternator output

Low idle rpm


Frequency

Governor

OMAP

Number of cylinders
Bore and stroke

Injection pump make

to 1/2 inch
9 to 12 mm

8.5 quarts
8 liters

Oil viscosity requirements


Temperature below 60F / 15.5C (synthetic)

5W-30

-10F to 90F / -23C to 32C

10W-40

Temperature above -4F / -34C

15W-40

Extreme operating temperatures may require the use of


alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.

2-8

Continuous improvement of our products is a


Genie policy. Product specifications are subject
to change without notice.

S-40 S-45

Part No. 102521

July 2009

Section 2 Specifications

REV E

SPECIFICATIONS

Deutz F3L-2011 Engine


Deutz D2011L03i Engine
Displacement
Number of cylinders
Bore and stroke

Lubrication system
Oil pressure, hot @ 2000 rpm
142 cu in
2.33 liters

Oil capacity
(including filter)
(Deutz F3L2011 Engine)

8.5 quarts
8 liters

3.7 x 4.4 inches


94 x 112 mm

Oil capacity
(including filter)
(Deutz D2011L03i Engine)

9.5 quarts
9 liters

48.7 @ 2800 rpm


46.2 @ 2800 rpm
36 kW @ 2800 rpm
34.5 kW @ 2800 rpm

Oil viscosity requirements

Horsepower
Net
Net
Net
Net

intermittent
continuous
intermittent
continuous

Firing order

1-2-3

Low idle rpm


Frequency

1500 rpm
313 Hz

High idle rpm


Frequency

2500 rpm
521.7 Hz

Compression ratio
Compression pressure
Governor

Unit ships with 15-W40 oil.


Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.
Oil temperature switch
Torque
Temperature switch point

19:1
362 to 435 psi
25 to 30 bar

Torque
Oil pressure switch point
(Deutz F3L2011 Engine)

Intake

0.012 in
0.3 mm

Exhaust

0.020 in
0.5 mm

8-18 ft-lbs
11-24 Nm
220 F
104 C

Oil pressure switch

centrifugal mechanical

Valve clearance, cold

Part No. 102521

40-60 psi
2.8 to 4.1 bar

Oil pressure switch point


(Deutz D2011L03i Engine)

S-40 S-45

8-18 ft-lbs
11-24 Nm
7 psi
.5 bar
22 psi
1.5 bar

2-9

Section 2 Specifications

July 2009

SPECIFICATIONS

REV E

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 requirement, refer to the engine Operator's
Manual on your machine.
Starter motor
Current draw, normal load

140-200A

Brush length, new

0.72 in
18.5 mm

Brush length, minimum

0.27 in
7 mm

Battery
Type

12V, Group 31

Quantity

Cold cranking ampere


Reserve capacity @ 25A rate
Alternator output
Fan belt deflection

2 - 10

1000A
200 minutes
60A @ 14V DC
3 /8

to 1/2 inch
9 to 12 mm

S-40 S-45

Part No. 102521

July 2009

Section 2 Specifications

REV E

SPECIFICATIONS

Perkins 704-30 Engine


Displacement
Number of cylinders
Bore and stroke
Horsepower
Firing order
Compression ratio

Oil viscosity requirements


183 cu in
2.9 liters
4

3.82 x 3.94 inches


97 x 100 mm
63 @ 2600 rpm
47 kW @ 2600 rpm

17.5:1

300 to 500 psi


20.7 to 34.5 bar
Pressure (psi) of lowest cylinder must be within
50 psi (3.45 bar) of highest cylinder

Low idle rpm


Frequency

1600 rpm
246.7 Hz

High idle rpm


Frequency

2200 rpm
339.2 Hz
centrifugal mechanical

5F to 104F / -15C to 40C

10W-30

above 14F / -10C

15W-40

Engine oil should have properties of API classification


CC/SE. API classification CD/SE or CCMC D4 can be
used, but is not recommended during the first 50 hours
nor for light load applications.

Injection system
Injection pump make

Intake

0.014 in
0.35 mm

Exhaust

0.014 in
0.35 mm

Lubrication system

Injection pump pressure


(stage one)
(stage two)

2755 psi
3336 psi

190 bar
230 bar

Injector opening pressure

3626 psi

250 bar

Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.

Capacity
Alternator output

Type
41 psi
2.8 bar
7.3 quarts
8.3 liters

65A, 12V

12V, Group 31

Quantity

Reserve capacity @ 25A rate


Fan belt deflection

Part No. 102521

111/2 quarts
10.9 liters

Battery

Cold cranking ampere


Oil capacity
(including filter)

Zexel PFR-KX

Engine coolant

Valve clearance, cold

Oil pressure
(at 2600 rpm)

5W-20

1-3-4-2

Compression pressure

Governor

below 68F / 20C (synthetic)

S-40 S-45

1
1000A
200 minutes
3 /8

in
10 mm

2 - 11

Section 2 Specifications

July 2009

SPECIFICATIONS

REV E

Perkins 404-22 Engine

Oil viscosity requirements


134 cu in
2.2 liters

Displacement

Number of cylinders

3.31 x 3.94 inches


84 x 100 mm

Bore and stroke

Unit ships with 15-W40 oil.


Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.
Oil pressure sending unit
Torque

Horsepower
gross intermittent
continuous
gross intermittent
continuous

50 @ 2800 rpm
41 @ 2800 rpm
37.3 kW @ 2800 rpm
31 kW @ 2800 rpm

Oil pressure switch point

Torque

1-3-4-2

Low idle rpm


Frequency

1300 rpm
200.5 Hz

Temperature switch point

Low Idle rpm with generator option


Frequency

1500 rpm
231.3 Hz

Fuel injection system

High idle rpm


Frequency

2500 rpm
385.5 Hz

426 psi
29.4 bar

Pressure (psi) of lowest cylinder must


be within 50 psi / 3.45 bar of highest cylinder
Governor

centrifugal mechanical

Exhaust

Injection pressure

0.008 in
0.2 mm
0.008 in
0.2 mm

8-18 ft-lbs
11-24 Nm
221 F
105 C

Zexel
2133 psi
147 bar

Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.
Battery
Type

Valve clearance, cold


Intake

Injection pump make

22.4:1

Compression pressure

14.2 psi
1 bar

Coolant temperature sending unit

Firing order

Compression ratio

8-18 ft-lbs
11-24 Nm

Quantity
Cold cranking ampere
Reserve capacity @ 25A rate

12V, Group 31
1
1000A
200 minutes

Starter motor
Lubrication system
Current draw, normal load
Oil pressure, hot
(at 2000 rpm)
Oil capacity
(including filter)

2 - 12

40 to 60 psi
2.8 to 4.1 bar
9.4 quarts to 11.2 quarts
8.9 liters to 10.6 liters

Alternator output
Fan belt deflection

S-40 S-45

140-200A
65A @ 13.8V DC
3/8 to in
9 to 12 mm

Part No. 102521

July 2009

Section 2 Specifications

REV E

SPECIFICATIONS

Machine Torque Specifications


Platform rotator
1-8 center bolt, Gr 5, dry

640 ft-lbs
868 Nm

1-8 center bolt, Gr 5, lubricated

480 ft-lbs
651 Nm

3/8

35 ft-lbs*
47.5 Nm

-16 bolts, Gr 8, lubricated


*use blue thread-locking compound
Turntable rotator
Drive hub mounting bolts, dry

210 ft-lbs
284 Nm

Drive hub mounting bolts, lubricated*


*use blue thread-locking compound

160 ft-lbs
217 Nm

Drive motor and hubs


Drive hub mounting bolts, dry
Drive hub mounting bolts, lubricated
*use blue thread-locking compound

210 ft-lbs
284 Nm
160 ft-lbs*
217 Nm

Drive motor mounting bolts, dry

49 ft-lbs
66.4 Nm

Drive motor mounting bolts, lubricated

37 ft-lbs
50 Nm

Turntable bearing
Turntable bearing mounting bolts, lubricated 180 ft-lbs
244 Nm

Part No. 102521

S-40 S-45

2 - 13

Section 2 Specifications

July 2009

SPECIFICATIONS

REV E

Seal-Lok fittings

Hydraulic Hose and Fitting


Torque Specifications
Your machine is equipped with Parker Seal-Lok
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.

SAE O-ring Boss Port


(tube fitting - installed into Aluminum)

1 Replace the O-ring. The O-ring must be replaced


anytime the seal has been broken. The O-ring
cannot be re-used if the fitting or hose end has
been tightened beyond finger tight.
Note: The O-rings used in the Parker Seal Lok
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
number 49612).
2 Lubricate the O-ring before installation.

SAE Dash size

Torque

-4

14 ft-lbs / 18.9 Nm

-6

23 ft-lbs / 31.2 Nm

-8

36 ft-lbs / 48.8 Nm

-10

62 ft-lbs / 84.1 Nm

-12

84 ft-lbs / 113.9 Nm

-16

125 ft-lbs / 169.5 Nm

-20

151 ft-lbs / 204.7 Nm

-24

184 ft-lbs / 250 Nm

3 Be sure that the face seal O-ring is seated and


retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.

SAE O-ring Boss Port

Seal-Lok Fittings (ORFS)

(tube fitting - installed into Steel)

(hose end)

SAE Dash size

Torque

SAE Dash size

Torque

-4

15 ft-lbs / 20.3 Nm

-4

18 ft-lbs / 24.4 Nm

-6

35 ft-lbs / 47.5 Nm

-6

30 ft-lbs / 40.7 Nm

-8

60 ft-lbs / 81.3 Nm

-8

40 ft-lbs / 54.2 Nm

-10

100 ft-lbs / 135.6 Nm

-10

60 ft-lbs / 81.3 Nm

-12

135 ft-lbs / 183 Nm

-12

85 ft-lbs / 115 Nm

-16

200 ft-lbs / 271 Nm

-16

110 ft-lbs / 149 Nm

-20

250 ft-lbs / 334 Nm

-20

140 ft-lbs / 190 Nm

-24

305 ft-lbs / 414 Nm

-24

180 ft-lbs / 244 Nm

2 - 14

S-40 S-45

Part No. 102521

July 2009

Section 2 Specifications

REV E

SPECIFICATIONS

SAE FASTENER TORQUE CHART


This chart is to be used as a guide only unless noted elsewhere in this manual

Grade 5

SIZE THREAD
LUBED
20
28

1/4

DRY

5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8

1
1 1/8
1 1/4
1 1/2

LUBED

DRY

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

80
90

9
10.1

100
120

11.3
13.5

110
120

12.4
13.5

140
160

15.8
18

130
140

14.7
15.8

LUBED
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12

A574 High Strength


Black Oxide Bolts
LUBED

Grade 8

DRY

LUBED

DRY

LUBED

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640

17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223

17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190

23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969

18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670

24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620

25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560

33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826

21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000

28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067

METRIC FASTENER TORQUE CHART


This chart is to be used as a guide only unless noted elsewhere in this manual

Class 4.6

Size
(mm)
5
6
7

LUBED

LUBED

DRY

Class 10.9

8.8

DRY

LUBED

Class 12.9

10.9

DRY

LUBED

12.9

DRY

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

16
19
45

1.8
3.05
5.12

21
36
60

2.4
4.07
6.83

41
69
116

4.63
7.87
13.2

54
93
155

6.18
10.5
17.6

58
100
167

6.63
11.3
18.9

78
132
223

8.84
15
25.2

68
116
1.95

7.75
13.2
22.1

91
155
260

10.3
17.6
29.4

LUBED
8
10
12
14
16
18
20
22
24

Class 8.8

4.6

DRY

LUBED

DRY

LUBED

DRY

LUBED

DRY

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

5.4
10.8
18.9
30.1
46.9
64.5
91
124
157

7.41
14.7
25.6
40.8
63.6
87.5
124
169
214

7.2
14.4
25.1
40
62.5
86.2
121
166
210

9.88
19.6
34.1
54.3
84.8
117
165
225
285

14
27.9
48.6
77.4
125
171
243
331
420

19.1
37.8
66
105
170
233
330
450
570

18.8
37.2
64.9
103
166
229
325
442
562

25.5
50.5
88
140
226
311
441
600
762

20.1
39.9
69.7
110
173
238
337
458
583

27.3
54.1
94.5
150
235
323
458
622
791

26.9
53.2
92.2
147
230
317
450
612
778

36.5
72.2
125
200
313
430
610
830
1055

23.6
46.7
81
129
202
278
394
536
682

32
63.3
110
175
274
377
535
727
925

31.4
62.3
108
172
269
371
525
715
909

42.6
84.4
147
234
365
503
713
970
1233

Part No. 102521

S-40 S-45

2 - 15

July 2007

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:


Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.

Symbols Legend
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Scheduled maintenance inspections shall be


completed daily, quarterly, six months, annually
and every 2 years as specified on the
Maintenance Inspection Report.

Used to indicate the presence of


an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.

Failure to perform each procedure


as presented and scheduled may
cause death, serious injury or
substantial damage.

Used to indicate the presence of a


potentially hazardous situation
which, if not avoided, could result
in death or serious injury.

Immediately tag and remove from service a


damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine

With safety alert symbolused to


indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.

Use only Genie approved replacement parts.


Machines that have been out of service for a
period longer than three months must complete
the quarterly inspection.
Unless otherwise specified, perform each
maintenance procedure with the machine in the
following configuration:
Machine parked on a firm, level surface
Boom in the stowed position

Used to indicate the presence of a


potentially hazardous situation
which, if not avoided, may result in
property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
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

Part No. 102521

S-40 S-45

3-1

Section 3 Scheduled Maintenance Procedures

July 2007

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend

Pre-delivery Preparation Report

Note: The following symbols have been used in


this manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.

The pre-delivery preparation report contains


checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation
Report to use for each inspection. Store completed
forms as required.
Maintenance Schedule

Indicates that tools will be required to


perform this procedure.

Indicates that new parts will be required


to perform this procedure.

Indicates that a cold motor, pump or


engine will be required to perform this
procedure.

There are five types of maintenance inspections


that must be performed according to a schedule
daily, quarterly, every six months, annual and
two years. The Scheduled Maintenance
Procedures Section and the Maintenance
Inspection Report have been divided into five
subsectionsA, B, C, D and E. Use the following
chart to determine which group(s) of procedures
are required to perform a scheduled inspection.
Inspection

Checklist

Daily or every 8 hours

Indicates that a warm motor or pump


will be required to perform this
procedure.

Quarterly or every 250 hours


Six months or every 500 hours
Annual or every 1000 hours

Indicates that dealer service is required


to perform this procedure.

Two years or every 2000 hours

A
A+B
A+B+C
A+B+C+D
A+B+C+D+E

Maintenance Inspection Report


The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and govermental regulations
and requirements.

3-2

S-40 S-45

Part No. 102521

Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals

Instructions

It is the responsibility of the dealer to perform the


Pre-delivery Preparation.

Use the operators manual on your machine.

The Pre-delivery Preparation is performed prior to


each delivery. The inspection is designed to discover if
anything is apparently wrong with a machine before it
is put into service.
A damaged or modified machine must never be used.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged
and removed from service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications.
Scheduled maintenance inspections shall be
performed by qualified service technicians, according
to the manufacturer's specifications and the
requirements listed in the responsibilities manual.

The Pre-delivery Preparation consists of completing


the Pre-operation Inspection, the Maintenance items
and the Function Tests.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operators manual.
If any inspection receives an N, remove the machine
from service, repair and re-inspect it. After repair,
place a check in the R box.
Legend
Y = yes, completed
N = no, unable to complete
R = repaired
Comments

Pre-Delivery Preparation
Pre-operation inspection
completed
Maintenance items completed
Function tests completed

Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
(425) 881-1800

Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333

Copyright 2002 by Genie Industries. Genie is a registered trademark of Genie


Industries. Rev B

Section 3 Scheduled Maintenance Procedures

July 2007

This page intentionally left blank.

3-4

S-40 S-45

Part No. 102521

July 2007 2007


September

Section 3 Scheduled Maintenance Procedures

Maintenance Inspection Report


Model

Checklist A - Rev C

Y N R

Checklist B - Rev D

A-1 Inspect the Decals

B-1 Battery

A-2 Pre-operation
inspection

B-2 Electrical wiring

A-3 Functions tests

B-4 Key switch

Hour meter

A-4 Engine maintenance all models

Machine owner

Perform after 40 hours:

B-5 Engine maintenance Deutz and Perkins


models

Inspected by (print)

A-5 30 Day Service

B-6 Exhaust system

Perform after first 50 hours:

B-7 Oil cooler and finsDeutz models

Serial number
Date

B-3 Air filter element

Inspector signature

A-6 Engine maintenance Deutz and Ford models

Inspector title

Perform every 50 hours:

Inspector company

A-7 Engine maintenancePerkins models

B-9 Drive hub maintenance

Instructions
Make copies of this report to use for
each inspection.

Perform every 100 hours:

B-11 Engine RPM

A-8 Fuel filter/water


separator Deutz models

B-12 Engine idle select

A-9 Engine maintenance Ford models

B-14 Ground control

Select the appropriate checklist(s) for


the type of inspection to be
performed.

A-10 Rotation bearing

Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:

A
A+B

Six Month or 500 hour


Inspection:
A+B+C
Annual or 1000 hours
Inspection:
A+B+C+D
2 Year or 2000 hour
Inspection:
A+B+C+D+E

Perform after first 125 hours:


A-11 Engine maintenance Deutz 1011F models
Perform after first 150 hours:
A-12 Drive hub oil
Perform every 200 hours:
A-13 Engine maintenance Ford models

B-8 Tires, wheels and lug


nut torque
B-10 Brake configuration

B-13 Fuel select Ford models


B-15 Directional
valve linkage
B-16 Platform
self-leveling
B-17 Drive brakes
B-18 Drive speed stowed position
B-19 Drive speed raised position
B-20 Hydraulic oil analysis
B-21 Alarm package
B-22 Fuel and hydraulic cap
venting systems

Place a check in the appropriate box


after each inspection procedure is
completed.
Use the step-by-step procedures in
this section to learn how to perform
these inspections.
If any inspection receives an N, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the R box.

Y N R

Perform every 400 hours:


B-23 Engine maintenance Ford models

Comments

Legend
Y = yes, acceptable
N = no, remove from service
R = repaired

Part No. 102521

S-40 S-45

3-5

Section 3 Scheduled Maintenance Procedures

July 2007

MAINTENANCE INSPECTION REPORT

Model

Checklist C - Rev B

Serial number

C-1 Engine maintenance Deutz and Perkins


models

Date
Hour meter

C-2 Platform overload


(if equipped)

Machine owner

C-3 Platform overload


(if equipped)

Inspector signature

Perform every 2000 hours:


E-3 Engine maintenance Deutz and
Perkins models
Perform every 2400 hours:
E-4 Engine maintenance Ford models
Perform every 3000 hours:

Perform every 800 hours:

Inspector company

C-6 Engine maintenance Ford models

Instructions
Make copies of both pages to use for
each inspection.

Checklist D - Rev B

Select the appropriate checklist(s) for


the type of inspection to be
performed.

D-3 Free-wheel
configuration

Daily or 8 hour
Inspection:

D-1 Boom wear pads


D-2 Turntable bearing bolts

A
A+B

Six Month or 500 hour


Inspection:
A+B+C

D-4 Drive hub oil


D-5 Engine maintenanceDeutz and Perkins
models

E-5 Engine maintenance Deutz and


Perkins models
Y N R

Perform every 5000 hours:


E-6 Engine maintenance Deutz models
Perform every 6000 hours:
E-7 Engine maintenance Deutz and
Perkins models
Perform every 12,000 hours:

D-6 Hydraulic filters

E-8 Engine maintenance Deutz models

D-7 Turntable bearing wear

Perform every 4 years:


E-9 Engine maintenance Ford models

Annual or 1000 hours


Inspection:
A+B+C+D
2 Year or 2000 hour
Inspection:
A+B+C+D+E

Y N R

E-2 Steer axle


wheel bearings,
2WD models

C-5 Fuel inline strainer Deutz models

Inspector title

Checklist E - Rev B
E-1 Hydraulic oil

C-4 Air filter element Deutz and Perkins


models

Inspected by (print)

Quarterly or 250 hour


Inspection:

Y N R

Comments

Place a check in the appropriate box


after each inspection procedure is
completed.
Use the step-by-step procedures in
this section to learn how to perform
these inspections.
If any inspection receives an N, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired

3-6

S-40 S-45

Part No. 102521

July 2007

REV C

Section 3 Scheduled Maintenance Procedures

Checklist A Procedures

A-1
Inspect the Manuals and Decals
Genie specifications require that this procedure be
performed daily.
Maintaining the operators and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.

3 Open the operator's manual to the decals


inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
required decals, and all decals are legible and
in good condition.
Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie Industries if replacement manuals or decals
are needed.

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 is illegible. Remove the
machine from service until the manual is
replaced.

Part No. 102521

S-40 S-45

3-7

Section 3 Scheduled Maintenance Procedures

CHECKLIST A

July 2007

PROCEDURES

REV C

A-2
Perform Pre-operation Inspection

A-3
Perform Function Tests

Genie specifications require that this procedure be


performed daily.

Genie specifications require that this procedure be


performed daily.

Completing a Pre-operation Inspection is essential


to safe machine operation. The Pre-operation
Inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently
wrong with a machine before the operator performs
the function tests. The Pre-operation Inspection
also serves to determine if routine maintenance
procedures are required.

Completing the function tests is essential to safe


machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.

Complete information to perform this procedure is


available in the Operator's Manual on your
machine.

3-8

Complete information to perform this procedure is


available in the Operator's Manual on your
machine.

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV C

CHECKLIST A

Perkins models

A-4
Perform Engine Maintenance

Required maintenance procedures and additional


engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).

Engine specifications require that this procedure


be performed every 8 hours or daily, whichever
comes first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Deutz models
Required maintenance procedures and additional
engine information are available in the

Deutz 2011 Operation Manual


Genie part number

Perkins 404C-22 Operation Manual


Genie part number

Required maintenance procedures and additional


engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).

Ford DSG 423 EFI Operator Handbook


Genie part number

52883

84794

94890

Ford models

Ford LRG 425 EFI Operation Manual


Genie part number

Deutz 1011F Operation Manual


(Deutz part number 0297 9683) or the
Deutz 2011 Operation Manual
(Deutz part number 0297 9929).
Deutz 1011F Operation Manual
Genie part number

PROCEDURES

84792

119488

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

Part No. 102521

S-40 S-45

3-9

Section 3 Scheduled Maintenance Procedures

CHECKLIST A

PROCEDURES

REV C

A-5
Perform 30 Day Service

A-6
Perform Engine Maintenance Deutz and Ford Models

The 30 day maintenance procedure is a one time


sequence of procedures to be performed after the
first 30 days or 40 hours of usage, whichever
comes first. After this interval, refer to the
maintenance tables for continued scheduled
maintenance.
1 Perform the following maintenance procedures:

A-10

Grease the Turntable Bearing and


Rotate Gear

B-8

Inspect the Tires, Wheels and Lug Nut


Torque

B-9

Check the Drive Hub Oil Level and


Fastener Torque

D-2

Check the Turnable Rotation Bearing


Bolts

D-6

Replace the Hydraulic Filter Elements

3 - 10

July 2007

Engine specifications require that this procedure


be performed after the first 50 hours of operation.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Deutz models
Required maintenance procedures and additional
engine information are available in the

Deutz 1011F Operation Manual


(Deutz part number 0297 9683) or the
Deutz 2011 Operation Manual
(Deutz part number 0297 9929).
Deutz 1011F Operation Manual
Genie part number

52883

Deutz 2011 Operation Manual


Genie part number

84794

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV C

CHECKLIST A

Ford models
Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).
Ford LRG 425 EFI Operation Manual
Genie part number
Ford DSG 423 EFI Operator Handbook
Genie part number

PROCEDURES

A-7
Perform Engine Maintenance Perkins Models

Engine specifications require that this procedure


be performed every 50 hours.
84792

119488

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

Proper engine maintenance, following the engine


manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Perkins models

Required maintenance procedures and additional


engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).
Perkins 404C-22 Operation Manual
Genie part number

94890

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

Part No. 102521

S-40 S-45

3 - 11

Section 3 Scheduled Maintenance Procedures

CHECKLIST A

July 2007

PROCEDURES

REV C

A-8
Inspect the Fuel Filter/Water
Separator - Deutz Models
a

Genie specifications require that this procedure be


performed every 100 hours or monthly, whichever
comes first.
Proper maintenance of the fuel filter/water
separator is essential for good engine
performance. Failure to perform this procedure can
lead to poor engine performance and/or hard
starting, and continued use may result in
component damge. Extremely dirty conditions may
require this procedure be performed more often.

a
b

fuel filter
drain plug

2 Clean up any fuel that may have spilled.


3 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.

Explosion and fire hazard. Engine


fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.

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.

Note: Perform this procedure with the engine off.


1 Loosen the drain plug located at the bottom of
the filter. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.

3 - 12

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV C

CHECKLIST A

PROCEDURES

A-9
Perform Engine Maintenance Ford Models

A-10
Grease the Turntable Rotation
Bearing and Rotate Gear

Engine specifications require that this procedure


be performed every 100 hours.

Genie specifications require that this procedure be


performed every 100 hours of operation. Perform
this procedure more often if dusty conditions exist.

Proper engine maintenance, following the engine


manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).
Ford LRG 425 EFI Operation Manual
Genie part number
Ford DSG 423 EFI Operator Handbook
Genie part number

84792

119488

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 Raise the boom enugh to access the turntable
gearing.
2 Locate the grease fitting on the platform end of
the engine side bulkhead.
3 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of
4 to 5 inches / 10 to 13 cm at a time and repeat
this step until the entire bearing has been
greased.
4 Apply grease to each tooth of the drive gear,
located under the turntable.

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.

Grease specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent

Crushing hazard. Failure to secure


the engine pivot plate from moving
could result in death or serious
injury.

Part No. 102521

S-40 S-45

3 - 13

Section 3 Scheduled Maintenance Procedures

CHECKLIST A

July 2007

PROCEDURES

REV C

A-11
Perform Engine Maintenance Deutz 1011F Models

A-12
Replace the Drive Hub Oil

Engine specifications require that this procedure


be performed after the first 125 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Deutz 1011F Operation Manual
(Deutz part number 0297 9683).
Deutz 1011F Operation Manual
Genie part number

52883

To access the engine:


1 Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.

Manufacturer drive hub specifications require that


this one-time procedure be performed after the first
150 hours.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the torque hub oil after the first 50 hours of
use may cause the machine to perform poorly and
continued use may cause component damage.
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Refer to Section 2, Specifications.
5 Install the plugs. Use pipe thread sealant on
units with pipe plugs.
6 Repeat steps 1 through 5 for all the other drive
hubs.

Crushing hazard. Failure to secure


the engine pivot plate from moving
could result in death or serious
injury.

models with pipe plugs

3 - 14

S-40 S-45

drive hub plugs

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV C

CHECKLIST A

PROCEDURES

A-13
Perform Engine Maintenance Ford Models

Engine specifications require that this procedure


be performed every 200 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).
Ford LRG 425 EFI Operation Manual
Genie part number
Ford DSG 423 EFI Operator Handbook
Genie part number

84792

119488

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

Part No. 102521

S-40 S-45

3 - 15

Section 3 Scheduled Maintenance Procedures

CHECKLIST A

September
July 2007

PROCEDURES

This page intentionally left blank.

3 - 16

S-40 S-45

Part No. 102521

September 2007

Section 3 Scheduled Maintenance Procedures

Checklist B Procedures

REV D

7 Check the ambient air temperature and adjust


the specific gravity reading for each cell as
follows:

B-1
Inspect the Battery

Add 0.004 to the reading of each cell for


every 10 / 5.5 C above 80 F / 26.7 C.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions.

Result: All battery cells display an adjusted


specific gravity of 1.277 or higher. The battery
is fully charged. Proceed to step 11.
Result: One or more battery cells display a
specific gravity of 1.217 or below. Proceed to
step 8.

Electrocution/burn hazard. Contact


with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.
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.
4 Be sure that the battery separator wire
connections are tight.
5 Fully charge the batteries and allow the
batteries to rest at least 6 hours.
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.

Part No. 102521

Subtract 0.004 from the reading of each cell for


every 10 / 5.5 C below 80 F / 26.7 C.

8 Perform an equalizing charge, OR fully charge


the batteries and allow the batteries to rest at
least 6 hours.
9 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
10 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
Add 0.004 to the reading of each cell for
every 10 / 5.5 C above 80 F / 26.7 C.
Subtract 0.004 from the reading of each cell for
every 10 / 5.5 C below 80 F / 26.7 C.
Result: All battery cells display a specific gravity
of 1.277 or greater. The battery is fully charged.
Proceed to step 11.
Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
than 1.217. Replace the battery.
11 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
12 Install the vent caps and neutralize any
electrolyte that may have spilled with baking
soda.

S-40 S-45

3 - 17

Section 3 Scheduled Maintenance Procedures

CHECKLIST B

September 2007

PROCEDURES

REV D

4 Inspect for a liberal coating of dielectric grease


in the following locations:

B-2
Inspect the Electrical Wiring

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
Electrocution/burn hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
1 Open the engine side turntable cover.
2 Remove the engine tray retaining fasteners
located under the engine tray. Swing the engine
tray out and away from the machine and secure
it from moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.
3 Inspect the following areas for burnt, chafed,
corroded and loose wires:

Engine wiring harness

Hydraulic manifold wiring

Between the ground and platform controls

Between the ground and drive controls

All harness connectors

Level sensor

5 Open the turntable cover at the ground control


side of the machine.
6 Inspect the following areas for burnt, chafed,
corroded and loose wires:

Inside of the ground control box

Hydraulic manifold wiring

7 Start the engine from the ground controls and


raise the boom above the turntable covers.
8 Inspect the turntable area for burnt, chafed and
pinched cables.
9 Lower the boom to the stowed position and turn
the engine off.
10 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:

Cable track on the primary boom

Cables on the primary, and jib booms

Jib boom/Platform rotate manifold

Inside of the platform control box

11 Inspect for a liberal coating of dielectric grease


in all connections between the ECM and the
platform controls.
12 Swing the engine back to its original position
and install the engine pivot plate retaining
fasteners.
Crushing hazard. Failure to install
the fasteners into the engine tray
to secure it from moving could
result in death or serious injury.

3 - 18

S-40 S-45

Part No. 102521

September 2007

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

4 Remove the filter element.

B-3
Inspect the Air Filter

5 Clean the inside of the canister and the gasket


with a damp cloth.
6 Clean the filter using dry compressed air. Blow
out from inside to outside. Check filter gasket
for damage.

Note: Genie specifications require that this


procedure be performed every 250 hours or
quarterly, whichever comes first. Perform this
procedure more often if dusty conditions exist.

7 Re-install the filter element, or if there are any


signs of loss of filtration, replace the element.

Maintaining the engine air filter in good condition is


essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.

8 Install the end cap onto the canister. Secure the


clamps.
Note: Be sure the dust discharge valve is pointing
down.

Note: Perform this procedure with the engine off.


1 Open the engine side cover. Empty the dust
discharge valve by pressing together the sides
of the discharge slot. Clean the discharge slot
as needed.
2 Inspect the dust discharge valve. If the valve
shows any signs of damage, replace the valve.

a
b
c

clamp
canister end cap
dust discharge valve

3 Disconnect the latches and remove the end cap


of the air cleaner canister.

Part No. 102521

S-40 S-45

3 - 19

Section 3 Scheduled Maintenance Procedures

CHECKLIST B

September 2007

PROCEDURES

REV D

B-4
Test the Key Switch
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
a hazardous operating situation.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to ground control, start the
engine and then turn the key switch to platform
control.
3 Check all machine function from the ground
controls.
Result: All machine functions should not
operate.

B-5
Perform Engine Maintenance Deutz and Perkins Models

Engine specifications require that this procedure


be performed quarterly or every 250 hours,
whichever comes first.
Deutz models
Required maintenance procedures and additional
engine information are available in the
Deutz 1011F Operation Manual
(Deutz part number 0297 9683).
Deutz 1011F Operation Manual
Genie part number

52883

Perkins models

Required maintenance procedures and additional


engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).

4 Turn the key switch to ground control.


5 Check all machine function from the platform
controls.
Result: All machine functions should not
operate.
6 Turn the key switch to the off position.
Result: The engine should stop and no
functions should operate.

Perkins 404C-22 Operation Manual


Genie part number

94890

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

3 - 20

S-40 S-45

Part No. 102521

September 2007

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B

B-6
Check the Exhaust System

B-7
Check the Oil Cooler and Cooling
Fins - Deutz Models

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
Maintaining the exhaust system is essential to
good engine performance and service life. Running
the engine with a damaged or leaking exhaust
system can cause component damage and unsafe
operating conditions.
Bodily injury hazard. Do not
inspect while the engine is
running. Remove the key to
secure from operation.

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
Maintaining the oil cooler in good condition is
essential for good engine performance. Operating
a machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
cooling system.
Bodily injury hazard. Do not
inspect while the engine
is running. Remove the key to
secure from operation.

Burn hazard. Beware of hot


engine components. Contact with
hot engine components may result
in severe burns.
1 Remove the engine tray retaining fasteners
located under the engine tray. Swing the engine
tray out and away from the machine and secure
it from moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.
2 Be sure that all nuts and bolts are tight.

Burn hazard. Beware of hot


engine components. Contact with
hot engine components may result
in severe burns.
Oil cooler
1 Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

3 Inspect all welds for cracks.


4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
5 Swing the engine back to its original position
and install the engine pivot plate retaining
fasteners.
Crushing hazard. Failure to install
the fasteners into the engine tray
to secure it from moving could
result in death or serious injury.

Part No. 102521

PROCEDURES

2 Remove the fasteners from the engine side


cover, and remove the cover.
3 Inspect the oil cooler for leaks and physical
damage.
4 Clean the oil cooler of debris and foreign
material.

S-40 S-45

3 - 21

Section 3 Scheduled Maintenance Procedures

CHECKLIST B

September 2007

PROCEDURES

REV D

B-8
Inspect the Tires, Wheels
and Lug Nut Torque

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.

a
b
c

Maintaining the tires and wheels in good


condition 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.

oil cooler
cylinder head cooling fins
fan blower fins

Cooling and fan blower fins

Bodily injury hazard. An overinflated tire can explode and could


cause death or serious injury.

5 Inspect the fan blower fins for physical damage.


6 Clean the fan blower fins of debris and foreign
material.

Tip-over hazard. Do not use


temporary flat tire repair products.

7 Inspect the head cooling passages and fins for


physical damage or foreign material, using a
flashlight.

Note: The tires on some machines are foam-filled


and do not need air added to them.

8 Clean the cylinder head cooling passages of


debris and foreign material.

1 Check all tire treads and sidewalls for cuts,


cracks, punctures and unusual wear.

9 Install the engine side cover.

2 Check each wheel for damage, bends and


cracks.

10 Swing the engine back to its original position


and install the engine pivot plate retaining
fasteners. Tighten the pivot fastener.
Crushing hazard. Failure to install
the fasteners into the engine tray
to secure it from moving could
result in death or serious injury.

3 - 22

3 Check each lug nut for proper torque. Refer to


Section 2, Specifications.
Models with air-filled tires:
4 Check pressure in each air-filled tire. Add air as
necessary. Refer to Section 2, Specifications.

S-40 S-45

Part No. 102521

September 2007

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B

PROCEDURES

Turntable rotate drive hub

B-9
Check the Drive Hub Oil Level
and Fastener Torque

1 Remove the plug located on the side of the hub


and check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and
continued use may cause component damage.

1 Drive the machine to rotate the hub until the


plugs are located one on top and the other
at 90 degrees.
2 Remove the plug located at 90 degrees and
check the oil level.

turntable drive hub


a plug

Result: The oil level should be even with the


bottom of the side plug hole.

2 If necessary, add oil until the oil level is even


with the bottom of the plug hole.

3 If necessary, remove the top plug and add oil


until the oil level is even with the bottom of the
side plug hole. Refer to Section 2,
Specifications.

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.

4 Install the plug(s) in the drive hub. Use pipe


thread sealant on units with pipe plugs.
5 Check the torque of the drive hub mounting
fasteners. Refer to Section 2, Specifications.
6 Repeat this procedure for each drive hub.
a

models with pipe plugs

Part No. 102521

drive hub plugs

S-40 S-45

3 - 23

Section 3 Scheduled Maintenance Procedures

CHECKLIST B

September 2007

PROCEDURES

REV D

2 Be sure the free-wheel valve on the drive pump


is closed (clockwise).

B-10
Confirm the Proper
Brake Configuration

Note: The free-wheel valve is located on the


bottom of the drive pump.

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.

Proper brake configuration is essential to safe


operation and good machine performance.
Hydrostatic brakes and hydraulically-released,
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully
operational.
1 Check each drive hub disconnect cap to be
sure it is in the engaged position.

a
b
c
d

drive pump
screwdriver
lift pump
free-wheel valve

Note: The free-wheel valve should always remain


closed.

brake disengaged position

brake engaged position

3 - 24

S-40 S-45

Part No. 102521

September 2007

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B

PROCEDURES

B-11
Check and Adjust the
Engine RPM
f
e

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpmaais incorrect and
continued use may cause component damage.

a
b
c
d
e
f

Note: This procedure will require two people.


Ford Models
Note: The engine rpm is controlled by the ECM
and can only be adjusted by re-programming the
ECM. If rpm adjustment or service is required,
please contact Genie Industries Service
Department OR your local Ford dealer.
Deutz Models
1 Connect a tachometer to the engine. Start the
engine from the ground controls. Refer to
Section 2, Specifications.

solenoid boot
high idle adjustment nut
yoke lock nut
yoke
low idle adjustment screw
low idle lock nut

If high idle rpm is correct, disregard


adjustment step 4.
4 Loosen the yoke lock nut. 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 re-check the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
Perkins Models

Skip to step 3 if the low idle rpm is correct.


2 Loosen the low idle lock nut and turn the low
idle adjustment screw clockwise to increase the
rpm or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and re-check the
rpm.

1 Connect a tachometer to the engine. Start the


engine from the ground controls. Refer to
Section 2, Specifications.

3 Move the function enable/rpm select toggle


switch to the high idle (rabbit symbol) position
at the ground controls. Refer to Section 2,
Specifications.

Part No. 102521

S-40 S-45

3 - 25

Section 3 Scheduled Maintenance Procedures

CHECKLIST B

September 2007

PROCEDURES

REV D

Skip to step 3 if the low idle rpm is correct.


2 Loosen the low idle lock nut. Turn the low idle
adjustment screw clockwise to increase the
rpm, or counterclockwise to decrease the rpm.

B-12
Test the Engine Idle Select
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
A properly operating engine idle select switch
is essential to good engine performance and safe
machine operation. There are two settings.
Foot switch activated low idle (turtle symbol)
allows the operator to control individual boom
functions.
Foot switch activated high idle (rabbit symbol)
should be used for normal machine operation. This
selection activates high idle only when the foot
switch is pressed down.

1 Pull out the red Emergency Stop button to the


on position at both the ground and platform
controls.

Tighten the low idle lock nut and confirm the


rpm.
a
b
c
d

2 Start the engine from the ground controls then


move and hold the function enable/rpm select
toggle switch to the high idle (rabbit symbol).

solenoid boot
high idle adjustment nut
clevis
low idle lock nut and adjustment
screw

Result: The engine should change to high idle.

3 Move the function enable toggle switch to the


high idle (rabbit symbol) position. Refer to
Section 2, Specifications.
If high idle rpm is correct, disregard
adjustment step 4.
4 Loosen the yoke lock nut. 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 re-check the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.

3 Release the function enable/rpm select toggle


switch.
Result: The engine should return to low idle.
4 Turn the key switch to platform controls.
5 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Result: The engine should not change to
high idle.
6 Press down the foot switch.
Result: The engine should change to high idle.
7 Move the engine idle control switch to foot
switch activated low idle (turtle symbol).
Result: The engine should change to low idle.

3 - 26

S-40 S-45

Part No. 102521

September 2007

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B

B-13
Test the Fuel Select Operation Ford Models

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
The ability to select and switch between
gasoline and LPG fuels as needed is essential to
safe machine operation. A fuel selection can be
made when the engine is running or not.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate
fuel system problems that could develop into a
hazardous situation.

PROCEDURES

2 Start the engine from the platform controls and


allow it to run at low idle. 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.
3 Release the foot switch and shut the engine off
by pushing the red Emergency Stop button
in to the off position.
4 Move the fuel select switch to LPG.
5 Start the engine and allow it to run at
low idle. 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.
Note: The engine may hesitate momentarily and
then continue
to run on the selected fuel if switched while
running.

Note: Perform this test after checking the gasoline


and LPG fuel levels, and warming the engine to
normal operating temperature.
1 Move the fuel select switch to gasoline and then
move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
symbol).

Part No. 102521

S-40 S-45

3 - 27

Section 3 Scheduled Maintenance Procedures

CHECKLIST B

PROCEDURES

REV D

B-14
Test the Ground Control Override
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
A properly functioning ground control override is
essential to safe machine operation. The ground
control override function is intended to allow
ground personnel to operate the machine from the
ground controls whether or not the red Emergency
Stop button on the platform controls is in the on or
off position. This function is particularly useful if the
operator at the platform controls cannot return the
boom to the stowed position.
1 Push in the platform red Emergency Stop
button to the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boom
function through a partial cycle.
Result: All boom functions should operate.

3 - 28

September 2007

B-15
Check the Directional Valve
Linkage

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
Note: Perform this test only on models equipped
with a oscillating axle.
Proper axle oscillation is essential to safe machine
operation. If the directional valve linkage is not
operating correctly, the stability of the machine is
compromised and it may tip over.
1 Remove the drive chassis cover and the axle
covers from the non-steer end of the drive
chassis.
2 Locate the directional valve inside of the nonsteer axle and inspect the linkage for the
following:

S-40 S-45

Lock nut is tight against yoke

Yoke clevis pins are installed

Cotter pins are installed through clevis


pins

Linkage is properly attached to


directional valve

Part No. 102521

September 2007

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B

PROCEDURES

B-16
Test the Platform Self-leveling

B-17
Test the Drive Brakes

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.

Automatic platform self-leveling throughout


the full cycle of primary boom raising and lowering
is essential for safe machine operation. The
platform is maintained at level by the platform
leveling slave cylinder which operates in a closed
loop hydraulic circuit with the master cylinder
located at the base of the boom.

Proper brake action is essential to safe machine


operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear to
operate normally when they are actually not fully
operational.

A platform self-leveling failure creates an unsafe


working condition for platform and ground
personnel.

Collision hazard. Be sure that the


machine is not in free-wheel or
partial free-wheel configuration.
See B-10, Confirm the Proper
Brake Configuration.

1 Start the engine from the ground controls and


lower the boom to the stowed position.
2 Hold the function enable toggle switch to either
side and adjust the platform to a level position
using the platform level toggle switch.
3 Raise and lower the primary boom through a full
cycle.
Result: The platform should remain level at
all times to within 5 degrees.

Note: Select a test area that is firm, level and free


of obstructions.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls.
3 Move the engine idle control switch to
foot switch activated high idle (rabbit and
foot switch symbol), then lower the boom into
the stowed position.
4 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the test line.
5 Bring the machine to top drive speed before
reaching the test line. Release the drive joystick
when your reference point on the machine
crosses the test line.
6 Measure the distance between the 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.

Part No. 102521

S-40 S-45

3 - 29

Section 3 Scheduled Maintenance Procedures

CHECKLIST B

September 2007

PROCEDURES

REV D

B-18
Test the Drive Speed Stowed Position

B-19
Test the Drive Speed Raised or Extended Position

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.

Proper drive function movement is essential to


safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.

Proper drive function movement is essential to


safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.

Note: Select a test area that is firm, level and free


of obstructions.

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.

1 Create start and finish lines by marking two


lines on the ground 40 feet / 12.2 m apart.

2 Start the engine from the platform controls.

2 Start the engine from the platform controls.

3 Move the engine idle control switch to


foot switch activated high idle (rabbit and foot
switch symbol), then lower the boom into the
stowed position.

3 Move the engine idle select switch to foot switch


activated high idle (rabbit and foot switch
symbol).

4 Choose a point on the machine; i.e., contact


patch of a tire, as a visual reference for use
when crossing the start and finish lines.

4 Raise the boom above horizontal.


5 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.

5 Bring the machine to top drive speed before


reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
6 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Specifications.

3 - 30

S-40 S-45

Part No. 102521

September 2007

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B

6 Bring the machine to top drive speed before


reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
7 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Specifications.
8 Lower the boom to the stowed position and
extend the boom 1 foot / 30 cm.
9 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the start and finish lines.
10 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
11 Continue at top speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Specifications.

Part No. 102521

PROCEDURES

B-20
Perform Hydraulic Oil Analysis

Genie specifications require that this procedure be


performed every 250 hours or quarterly, whichever
comes first.
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
See E-1, Test or Replace the Hydraulic Oil.

S-40 S-45

3 - 31

Section 3 Scheduled Maintenance Procedures

CHECKLIST B

September 2007

PROCEDURES

REV D

3 Move the function enable/rpm select toggle


switch to either side and activate the jib boom
toggle switch in the down position, hold for a
moment and then release it.

B-21
Test the Alarm Package
(if equipped) and the
Descent Alarm
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
The alarm package includes:

Travel alarm

Flashing beacons

Result: The descent alarm should sound when


the toggle switch is held down.
4 Turn the key switch to platform controls.
Result: The flashing beacons should be on
and flashing.
5 Press down the foot switch. Move the boom
controller to the down position, hold for a
moment and then release it.

Alarms and beacons are installed to alert operators


and ground personnel of machine proximity and
motion. The alarm package is installed on the
turntable rear cover. Beacons are installed on both
turntable covers.
Note: The alarms and beacons will operate with
the engine running or not running.
Note: The descent alarm is standard equipment
beginning with serial number 12602.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
Result: Both flashing beacons should be on and
flashing.

Result: The descent alarm should sound when


the controller is held down.
6 Press down the foot switch. Move the jib boom
toggle switch to the down position, hold for a
moment and then release it.
Result: The descent alarm should sound when
the controller is held down.
7 Press down the foot switch. Move the drive
controller off center, hold for a moment and
then release it. Move the drive controller off
center in the opposite direction, hold for a
moment and then release it.
Result: The travel alarm should sound when the
drive controller is moved off center in either
direction.

2 Hold the function enable switch to either side


and activate the boom toggle switch in the
down position, hold for a moment and then
release it.
Result: The descent alarm should sound when
the toggle switch is held down.

3 - 32

S-40 S-45

Part No. 102521

September 2007

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B

PROCEDURES

2 Check for proper venting.

B-22
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems

Note: When checking for positive fuel tank cap


venting, air should pass freely through the cap.
Result: Air should pass through the fuel tank
cap. Proceed to step 4.

Genie specifications require that this procedure be


performed quarterly or every 250 hours, whichever
comes first. Perform this procedure more often if
dusty conditions exist.
A free-breathing fuel and hydraulic tank cap is
essential for good machine performance and
service life. A dirty or clogged cap may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the cap be inspected
more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.

Result: Air is not passing through the fuel tank


cap. Clean or replace the cap.
Proceed to step 3.
3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
All models:
5 Remove the breather cap from the hydraulic
tank.
6 Check for proper venting.
Result: Air should pass through the breather
cap. Proceed to step 8.
Result: If air does not pass through the breather
cap, clean or replace the cap.
Proceed to step 7.

Gasoline/LPG models (before serial


number 13740) and Diesel models (all):

Note: When checking for positive tank cap venting,


air should pass freely through the cap.

Note: Perform this procedure with the engine off.


Note: Gasoline/LPG models use a pressurized cap
beginning with serial number 13740.

7 Using a mild solvent, carefully wash the cap


venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 6.

1 Remove the cap from the fuel tank.

8 Install the breather cap onto the hydraulic tank.

Part No. 102521

S-40 S-45

3 - 33

Section 3 Scheduled Maintenance Procedures

CHECKLIST B

PROCEDURES

September 2007

REV D

B-23
Perform Engine Maintenance Ford Models

Engine specifications require that this procedure


be performed every 400 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).
Ford LRG 425 EFI Operation Manual
Genie part number
Ford DSG 423 EFI Operator Handbook
Genie part number

84792

119488

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

3 - 34

S-40 S-45

Part No. 102521

September
July
2007 2007

REV B

Section 3 Scheduled Maintenance Procedures

Checklist C Procedures
Perkins models

C-1
Perform Engine Maintenance Deutz and Perkins Models

Required maintenance procedures and additional


engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).

Engine specifications require that this procedure


be performed every 500 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Deutz models

Perkins 404C-22 Operation Manual


Genie part number

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.

Required maintenance procedures and additional


engine information are available in the
Deutz 1011F Operation Manual
(Deutz part number 0297 9683) or the
Deutz 2011 Operation Manual
(Deutz part number 0297 9929).
Deutz 1011F Operation Manual
Genie part number

52883

Deutz 2011 Operation Manual


Genie part number

84794

Part No. 102521

94890

S-40 S-45

Crushing hazard. Failure to secure


the engine pivot plate from moving
could result in death or serious
injury.

3 - 35

Section 3 Scheduled Maintenance Procedures

CHECKLIST

July 2007

PROCEDURES

REVB

C-2
Grease the Platform Overload
Mechanism (if equipped)

C-3
Test the Platform Overload
System (if equipped)

Genie specifications require that this procedure be


performed every 500 hours or 6 months, whichever
comes first. Perform this procedure more often if
dusty conditions exist.

Genie specifications require that this procedure be


performed every 500 hours or 6 months, whichever
comes first.

Application of lubrication to the platform overload


mechanism is essential to safe machine operation.
Continued use of an improperly greased platform
overload mechanism could result in the system not
sensing an overloaded platform condition and will
result in component damage.

Testing the platform overload system regularly is


essential to safe machine operation. Continued
use of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stablity
could be compromised resulting in the machine
tipping over.

1 Locate the grease fittings on each pivot pin of


the platform overload assembly.

Note: Perform this procedure with the machine on


a firm, level surface.

2 Thoroughly pump grease into each grease


fitting using a multi-purpose grease.

1 Turn the key switch to platform control. Start the


engine and level the platform.

Grease type

2 Determine the maximum platform capacity.


Refer to the machine serial plate.

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)


or equivalent

3 Remove all weight, tools and accessories from


the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect test.

3 - 36

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV B

CHECKLIST

4 Using a suitable lifting device, place a test


weight equal to that of the available capacity
one of the locations shown.
Refer to Illustration 1.
Result: The platform overload indicator lights
should be off at both the ground and platform
controls and the alarm should not sound.
Result: The platform overload indicator lights
are on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Procedure 2-4, How to Calibrate the Platform
Overload System (if equipped).
5 Carefully move the test weight to each
remaining location. Refer to Illustration 1.
Result: The platform overload indicator lights
should be off at both the ground and platform
controls and the alarm should not sound.
Result: The platform overload indicator lights
are on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Procedure 2-4, How to Calibrate the Platform
Overload System (if equipped).

C PROCEDURES

6 Using a suitable lifting device, place an


additional 50 lbs / 23 kg of weight onto the
platform.
Result: The alarm should sound.
The platform overload indicator lights should be
flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-4, How to
Calibrate the Platform Overload System (if
equipped).
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
7 Carefully move the test weights to each
remaining location on the platform.
Refer to Illustration 1.
Result: The alarm should sound.
The platform overload indicator lights should be
flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-4, How to
Calibrate the Platform Overload System (if
equipped).
Note: There may be a two second delay before the
overload indicator lights flash and the alarm
sounds.

Illustration 1

Part No. 102521

S-40 S-45

3 - 37

Section 3 Scheduled Maintenance Procedures

CHECKLIST

July 2007

PROCEDURES

REV B

8 Test all machine functions from the platform


controls.

14 Start the engine and test all machine functions


from the ground controls.

Result: All platform control functions should not


operate.

Result: All ground control functions should


operate normally.

9 Turn the key switch to ground control.

15 Turn the key switch to platform control.

10 Test all machine functions from the ground


controls.

16 Test all machine functions from the platform


controls.

Result: All ground control functions should not


operate.
11 Activate the auxiliary power toggle switch.

Result: All platform control functions should


operate.
Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-4,
How to Calibrate the Platform Overload System (if
equipped).

Note: The engine will turn off when the auxiliary


power is activated.
12 Using auxiliary power, test all machine functions
from the ground controls.

17 Using a suitable lifting device, remove the


remaining test weights from the platform.

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 two second delay before
the overload indicator lights and alarm turn off.

3 - 38

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV B

CHECKLIST

C-4
Replace the Engine Air Filter
Element - Deutz and Perkins
Models

C-5
Replace the In-line Fuel Strainer Deutz Models

Genie specifications requires that this procedure


be performed every 500 hours or 6 months,
whichever comes first.
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.

Engine specifications require that this procedure


be performed every 500 hours or 6 months,
whichever comes first.
Replacing the diesel fuel strainer is essential for
good engine performance and service life. A dirty
or clogged filter may cause the engine to perform
poorly and continued use may cause component
damage.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.

1 Open the evacuator valve located on the air


cleaner cap by squeezing the sides together
with your fingers.
2 Disconnect the latches on the air cleaner cap.
Remove the end cap from the air cleaner
canister.
3 Remove the filter element.
4 Clean the inside of the canister and the gasket
with a damp cloth.
5 Install the new filter element.
6 Install the end cap on the canister and reconnect the latches.
Note: Be sure the evacuator valve is pointing
down.

Part No. 102521

C PROCEDURES

Note: Perform this procedure with the engine off.


1 Put on protective clothing and eye wear.
2 Locate the inline strainer above the throttle
actuator solenoid.
4 Place a suitable container under the filter.
5 Loosen the clamp holding the strainer to the
engine mount. Loosen the clamps securing the
fuel lines to the strainer. Remove and replace.

S-40 S-45

3 - 39

Section 3 Scheduled Maintenance Procedures

CHECKLIST

PROCEDURES

July 2007

REV B

C-6
Perform Engine Maintenance Ford Models

Engine specifications require that this procedure


be performed every 800 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) OR the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).
Ford LRG 425 EFI Operation Manual
Genie part number
Ford DSG 423 EFI Operator Handbook
Genie part number

84792

119488

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

3 - 40

S-40 S-45

Part No. 102521

July 2007

REV B

Section 3 Scheduled Maintenance Procedures

Checklist D Procedures

D-1
Check the Boom Wear Pads

Wear pad
specifications
all wear pads

Minimum
9/16

inch
14.3 mm

Genie specifications requires that this procedure


be performed every 1000 hours or annually,
whichever comes first.

4 Extend and retract the boom through the entire


range of motion to check for tight spots that
may cause binding or scraping of the boom.

Maintaining the boom wear pads in good condition


is essential to safe machine operation. Wear pads
are placed on boom tube surfaces to provide a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued
use of extremely worn wear pads may result in
component damage and unsafe operating
conditions.

Note: Always maintain squareness between the


outer and inner boom tubes.

1 Start the engine from the ground controls.


2 Raise the end of the primary boom to a
comfortable working height (chest high), then
extend the boom 1 foot / 30 cm.
3 Measure each wear pad. Replace the wear pad
once it reaches the minimum allowable
thickness. If the wear pad is still within
specification, shim as necessary to obtain
minimum clearance with zero binding.
Note: The minimum shim clearance for primary
boom wear pads is 0.070 inch / 1.8 mm and the
maximum allowable shim clearance is 0.188 inch /
4.8 mm.

Part No. 102521

S-40 S-45

3 - 41

Section 3 Scheduled Maintenance Procedures

CHECKLIST

July 2007

PROCEDURES

REV B

D-2

10

15

13

Check the Turntable Rotation


Bearing Bolts

19

18

12

11

Genie specifications requires that this procedure


be performed every 1000 hours or annually,
whichever comes first.
Maintaining proper torque on the turntable bearing
bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
1 Raise the primary boom and place safety
chocks on the lift cylinders rods. Carefully lower
the boom onto the lift cylinders safety chocks.
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).

17
20

5
8

14
16

Bolt torque sequence

4 Be sure that each turntable mounting bolt is


torqued in sequence to specifications. Refer to
Section 2, Specifications.
5 Start the engine form the ground controls.
6 Raise the secondary boom and remove the
safety chock.
7 Lower the boom to the stowed position.
8 Remove drive chassis covers from both the
steer end and the non-steer end of the
machine.

2 Turn the engine off.


3 Remove the engine tray retaining fasteners
located under the engine tray. Swing the engine
tray out and away from the machine and secure
it from moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

3 - 42

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV B

CHECKLIST

9 Check to ensure that each lower bearing


mounting bolt under the drive chassis is
torqued in sequence to specifications. Refer to
Section 2, Specifications.
10

D PROCEDURES

D-3
Check the Free-wheel
Configuration

15

13

19

18

Genie specifications requires that this procedure


be performed every 1000 hours or annually,
whichever comes first.

12

11

17
20

Proper use of the free-wheel configuration is


essential to safe machine operation. The
free-wheel configuration is used primarily for
towing. A machine configured to free-wheel without
operator knowledge may cause death or serious
injury and property damage.

5
8

14
16

Bolt torque sequence

10 Swing the engine back to its original position


and install the engine pivot plate retaining
fasteners.
Crushing hazard. Failure to install
the fasteners into the engine tray
to secure it from moving could
result in death or serious injury.

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 Wheels: All Models
1 Chock the steer wheels to prevent the machine
from rolling.
2 Center a lifting jack of sufficient capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the non-steer tires.
3 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
non-steer wheel hub.
disengaged position

engaged position

Part No. 102521

S-40 S-45

3 - 43

Section 3 Scheduled Maintenance Procedures

CHECKLIST

July 2007

REV B

PROCEDURES

5 Manually rotate each non-steer wheel.

All Models:

Result: Each non-steer wheel should rotate with


minimum effort.
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the jack stands.
Collision hazard. Failure to
re-engage the drive hubs may
cause death or serious injury and
property damage.
Steer Wheels: 4WD Models

13 Be sure the free-wheel valve on the drive pump


is closed (clockwise).
Note: The free-wheel valve is located on the
bottom of the drive pump.
Note: The free-wheel valve should always remain
closed.

b
c

7 Chock the non-steer wheels to prevent the


machine from rolling.

8 Center a lifting jack of ample capacity


(20,000 lbs / 10,000 kg) under the drive chassis
between the steer tires.
9 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.

a
b
c
d

drive pump
screwdriver
lift pump
free-wheel valve

10 Disengage the drive hubs by turning over the


drive hub disconnect caps on each
steer wheel hub.
11 Manually rotate each steer wheel.
Result: Each steer wheel should rotate with
minimum effort.
12 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Raise the machine and
remove the jack stands.
Collision hazard. Failure to
re-engage the drive hubs may
cause death or serious injury and
property damage.

3 - 44

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV B

CHECKLIST

D PROCEDURES

Turntable Rotate Drive Hub:

D-4
Replace the Drive Hub Oil

Note: When removing a hose assembly or fitting,


the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.

Genie specifications requires that this procedure


be performed every 1000 hours or annually,
whichever comes first.

1 Raise the secondary boom until the platform


end of the lower secondary boom arm is
approximately 8 feet / 2.4 m off the ground.

Replacing the drive hub oil is essential for good


machine performance and service life. Failure to
replace the torque hub oil at yearly intervals may
cause the machine to perform poorly and
continued use may cause component damage.

2 Secure the turntable from rotating with the


turntable rotation lock pin.
3 Tag, disconnect and plug the hydraulic hoses
from the turntable rotate drive motor. Cap the
fittings on the drive motor.

1 Select the drive hub to be serviced. Drive the


machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Refer to Section 2, Specifications.

5 Install the plugs. Use pipe thread sealant on


units with pipe plugs.
6 Repeat steps 1 through 5 for all the other drive
hubs.

turntable drive hub


a
plug
a

4 Attach a suitable lifting device to the lifting eyes


located near the drive motor.

models with pipe plugs

Part No. 102521

drive hub plugs

S-40 S-45

3 - 45

Section 3 Scheduled Maintenance Procedures

CHECKLIST

July 2007

PROCEDURES

REV B

5 Remove the drive hub mounting bolts. Carefully


remove the turntable rotate drive hub assembly
from the machine.
Crushing hazard. The turntable
rotate drive hub assembly could
become unbalanced and fall if not
properly supported by the lifting
device.
6 Remove the plug from the side of the drive hub.
Drain the oil from the hub into a suitable
container.
7 Install the drive hub assembly onto the
machine. Torque the drive hub mounting bolts
to specification. Refer to
Section 2, Specifications.
8 Fill the drive hub with oil from the side hole until
the oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plug. Install the
plug.

D-5
Perform Engine Maintenance Deutz and Perkins Models

Engine specifications require that this procedure


be performed every 1000 hours.
Deutz models
Required maintenance procedures and additional
engine information are available in the
Deutz 1011F Operation Manual
(Deutz part number 0297 9683) or the
Deutz 2011 Operation Manual
(Deutz part number 0297 9929).
Deutz 1011F Operation Manual
Genie part number

52883

Deutz 2011 Operation Manual


Genie part number

84794

Perkins models
Required maintenance procedures and additional
engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).
Perkins 404C-22 Operation Manual
Genie part number

94890

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury

3 - 46

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

CHECKLIST

REV B

D PROCEDURES

7 Rotate the filter element clockwise to lock it in


place.

D-6
Replace the Hydraulic Filter
Elements

Genie specifications require that this procedure be


performed every 1000 hours or annually,
whichever comes first. Perform this procedure
more often if dusty conditions exist.
Replacement of the hydraulic filters is essential for
good machine performance and service life. A dirty
or clogged filter may cause the machine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filters be replaced more often.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.

Install the filter housing cap.

Use a permanent ink marker to write the date


and number of hours from the hour meter on
the oil filter housing.

Medium and high pressure filter


Note: The medium pressure filter is for the charge
pump and the high pressure filter (if equipped) is
for all machine functions except the drive circuit
and oscillating axle circuit.
10 Open the engine side turntable cover and
locate the medium pressure filter mounted to
the engine tray.
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.

Note: Perform this procedure with the engine off.

13 Remove the filter elements from the housings.

Hydraulic return filter

14 Inspect the housing seals and replace them if


necessary.

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.
5 Install the new filter element into the filter
housing.

15 Install the new filter elements into the housings


and tighten them securely.
16 Clean up any oil that may have spilled during
the installation procedure.
17 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter housings.
18 Start the engine from the ground controls.
19 Inspect the filter housings and related
components to be sure that there are no leaks.

6 Push the filter element down to be sure the


o-ring on the element is fully seated into the
housing.

Part No. 102521

S-40 S-45

3 - 47

Section 3 Scheduled Maintenance Procedures

CHECKLIST

July 2007

REV B

PROCEDURES

D-7
Inspect for Turntable Bearing
Wear

Genie specifications requires that this procedure


be performed every 1000 hours or annually,
whichever comes first.
Periodic inspection of turntable bearing wear is
essential to safe machine operation, good machine
performance and service life. Continued use of a
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious
injury and component damage.
Note: Perform this procedure with the machine on
a firm, level surface and the boom in the stowed
position.
3 Start the machine from the ground controls and
raise the boom to full height. Do not extend the
boom.
4 Place a dial indicator between the drive chassis
and the turntable at a point that is directly
under, or inline with, the boom and no more
than 1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, place
the dial indicator no more than 1 inch / 2.5 cm from
the turntable rotation bearing.

3 - 48

a
b
c
d

turntable
dial indicator
drive chassis
turntable rotation bearing

5 At the dial indicator, adjust it to "zero" the


indicator.
6 Fully extend the boom and lower to a horizontal
position.
7 Note the reading on the dial indicator.
Result: The measurement is less than
0.063 inch / 1.6 mm. The bearing is good.
Result: The measurement is more than
0.063 inch / 1.6 mm. The bearing is worn and
needs to be replaced.
8 Fully retract the boom and raise the boom to full
height. Visually inspect the the dial indicator to
be sure the needle returns to the "zero"
position.

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV B

CHECKLIST

D PROCEDURES

9 Remove the dial indicator and rotate the


turntable 90.
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90 apart.
11 Lower the boom to the stowed position and turn
the machine off.
12 Remove the dial indicator from the machine.

Part No. 102521

S-40 S-45

3 - 49

Section 3 Scheduled Maintenance Procedures

July 2007

Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil

REV B

3 Models with hydraulic tank shut-off valves:


Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.

Genie specifications require that this procedure be


performed every 2000 hours or 2 years, whichever
comes first.
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.

open

closed

Component damage hazard. The


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

Note: Before replacing the hydraulic oil, the oil may


be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
Note: Perform this procedure with the boom in the
stowed position.

4 Remove the drain plug and completely drain the


tank into a suitable container. Refer to
Section 2, Specifications.

1 Ford models: Turn the valve on the LPG tank


clockwise to the off position (if equipped). Then
slowly disconnect the hose from the LPG tank.

5 Tag, disconnect and plug the two suction hoses


and supply hose for the auxiliary pump from the
hydraulic tank. Cap the fittings on the tank.

2 Ford models: Open the clamps from the LPG


tank straps and remove the LPG tank from the
machine (if equipped).

Note: The hoses can be accessed through the


access hole under the turntable.
6 Disconnect and plug the return filter hydraulic
hose at the return filter. Cap the fitting on the
filter housing.
7 Remove the ground controls side turntable
cover.

3 - 50

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV B

CHECKLIST E

8 Support the hydraulic tank with an appropriate


lifting device.
9 Remove the hydraulic tank mounting fasteners.
10 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulic
tank could become unbalanced
and fall if not properly supported
when removed from the machine.
11 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic
return filter housing from the hydraulic tank.
12 Remove the suction strainers from the tank and
clean them using a mild solvent.

PROCEDURES

20 Models with hydraulic tank shut-off valves:


Open the two hydraulic tank valves at the
hydraulic tank.
21 Fill the tank with hydraulic oil until the level is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
22 Clean up any oil that may have spilled.
23 Prime the pump. Refer to Repair Procedure
6-2, How to Prime the Pump.
Note: Always use pipe thread sealant when
installing the suction hose fittings and the drain
plug.

13 Rinse out the inside of the tank using a mild


solvent.
14 Install the suction strainers using a thread
sealant on the threads.
15 Install the drain plug using a thread sealant on
the threads.
16 Install the hydraulic return filter housing onto the
hydraulic tank.
17 Install the hydraulic tank onto the machine.
18 Install the two suction hoses to the suction
strainers.
19 Install the supply hose for the auxiliary power
unit and the return filter hose.

Part No. 102521

S-40 S-45

3 - 51

Section 3 Scheduled Maintenance Procedures

CHECKLIST E

July 2007

PROCEDURES

REV B

6 Remove the dust cap from the hub. Remove the


cotter pin from the castle nut.

E-2
Grease the Steer Axle
Wheel Bearings, 2WD Models

7 Tighten the castle nut to 158 ft-lbs / 214 Nm to


seat the bearings.
Note: Rotate the hub by hand while torqueing the
castle nut to make sure the bearings seat properly.

Genie specifications require that this procedure be


performed every 2000 hours or 2 years, whichever
comes first.
Maintaining the steer axle wheel bearings is
essential for safe machine operation and service
life. Operating the machine with loose or worn
wheel bearings may cause an unsafe operating
condition and continued use may result in
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
washing of the machine may require that this
procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove
them.
2 Block the non-steering wheels. Center a lifting
jack under the steer axle.
3 Raise the machine 6 inches / 15 cm Place
blocks under the drive chassis for support.

8 Loosen the castle nut one full turn and then


torque to 35 ft-lbs / 47 Nm.
9 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: If there is no side to side or up and
down movement, continue to step 11 and
grease the wheel bearings.
Result: If there is side to side or up and down
movement, continue to step 11 and replace the
wheel bearings with new ones.
Note: When replacing a wheel bearing, both the
inner and outer bearings, including the pressed-in
races, must be replaced.
10 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
11 Remove the castle nut.

4 Remove the lug nuts. Remove the tire and


wheel assembly.

12 Pull the hub off of the spindle. The washer and


outer bearing should fall loose from the hub.

5 Check for wheel bearing wear by attempting to


move the wheel hub side to side, then up and
down.

13 Place the hub on a flat surface and gently pry


the bearing seal out of the hub. Remove the
rear bearing.

Result: There should be no side to side or up


and down movement.
Skip to step 10 if there is no movement.

3 - 52

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV B

CHECKLIST E

14 Pack both bearings with clean, fresh grease.


15 Place the large inner bearing into the rear of the
hub.

PROCEDURES

E-3
Perform Engine Maintenance Deutz and Perkins Models

16 Install a new bearing grease seal into the hub


by pressing it evenly into the hub until it is flush.
Note: Always replace the bearing grease seal
when removing the hub.

Engine specifications require that this procedure


be performed every 2000 hours.

17 Slide the hub onto the yoke spindle.


Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
18 Place the outer bearing into the hub.
19 Install the washer and castle nut.

Proper engine maintenance, following the engine


manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Deutz 1011F models

20 Tighten the slotted nut to 158 ft-lbs / 214 Nm to


seat the bearings.
21 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
22 Install a new cotter pin. Bend the cotter pin
to lock it in.

Required maintenance procedures and additional


engine information is available in the
Deutz 1011F Operation Manual
(Deutz part number 0297 9683).
Deutz 1011F Operation Manual
Genie part number

23 Install the dust cap, then the tire and wheel


assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.

52883

Perkins models
Required maintenance procedures and additional
engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).
Perkins 404C-22 Operation Manual
Genie part number

94890

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Swing the engine
tray out and away from the machine and secure
it from moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

Part No. 102521

S-40 S-45

3 - 53

Section 3 Scheduled Maintenance Procedures

CHECKLIST E

July 2007

REV B

PROCEDURES

E-4
Perform Engine Maintenance Ford Models

E-5
Perform Engine Maintenance Deutz and Perkins Models

Engine specifications require that this procedure


be performed every 2400 hours.

Engine specifications require that this procedure


be performed every 3000 hours.

Required maintenance procedures and additional


engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).

Proper engine maintenance, following the engine


manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.

Ford LRG 425 EFI Operation Manual


Genie part number
Ford DSG 423 EFI Operator Handbook
Genie part number

84792

119488

Required maintenance procedures and additional


engine information are available in the
Deutz 1011F Operation Manual
(Deutz part number 0297 9683) or the
Deutz 2011 Operation Manual
(Deutz part number 0297 9929).

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

Deutz 1011F Operation Manual


Genie part number

52883

Deutz 2011 Operation Manual


Genie part number

84794

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

3 - 54

S-40 S-45

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV B

CHECKLIST E

Perkins models
Required maintenance procedures and additional
engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).
Perkins 404C-22 Operation Manual
Genie part number

94890

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

PROCEDURES

E-6
Perform Engine Maintenance Deutz and Perkins Models

Engine specifications require that this procedure


be performed every 5000 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Deutz 1011F Operation Manual
(Deutz part number 0297 9683) or the
Deutz 2011 Operation Manual
(Deutz part number 0297 9929).
Deutz 1011F Operation Manual
Genie part number

52883

Deutz 2011 Operation Manual


Genie part number

84794

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

Part No. 102521

S-40 S-45

3 - 55

Section 3 Scheduled Maintenance Procedures

CHECKLIST E

July 2007

PROCEDURES

REV B

E-7
Perform Engine Maintenance Deutz Models

E-8
Perform Engine Maintenance Deutz Models

Engine specifications require that this procedure


be performed every 6000 hours.

Engine specifications require that this procedure


be performed every 12,000 hours.

Proper engine maintenance, following the engine


manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.

Proper engine maintenance, following the engine


manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.

Required maintenance procedures and additional


engine information are available in the
Deutz 1011F Operation Manual
(Deutz part number 0297 9683) or the
Deutz 2011 Operation Manual
(Deutz part number 0297 9929).

Required maintenance procedures and additional


engine information are available in the
Deutz 1011F Operation Manual
(Deutz part number 0297 9683) or the
Deutz 2011 Operation Manual
(Deutz part number 0297 9929).

Deutz 1011F Operation Manual


Genie part number

52883

Deutz 1011F Operation Manual


Genie part number

52883

Deutz 2011 Operation Manual


Genie part number

84794

Deutz 2011 Operation Manual


Genie part number

84794

To access the engine:


.

To access the engine:

Remove the engine tray retaining fasteners


located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.

Remove the engine tray retaining fasteners


located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.

Crushing hazard. Failure to secure


the engine pivot plate from moving
could result in death or serious
injury.

3 - 56

S-40 S-45

Crushing hazard. Failure to secure


the engine pivot plate from moving
could result in death or serious
injury.

Part No. 102521

July 2007

Section 3 Scheduled Maintenance Procedures

REV B

CHECKLIST E

PROCEDURES

E-9
Perform Engine Maintenance Ford Models

Engine specifications require that this procedure


be performed every 4 years.
Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).
Ford LRG 425 EFI Operation Manual
Genie part number
Ford DSG 423 EFI Operator Handbook
Genie part number

84792

119488

To access the engine:


Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.

Part No. 102521

S-40 S-45

3 - 57

Section 3 Scheduled Maintenance Procedures

CHECKLIST E

July 2007

PROCEDURES

This page intentionally left blank.

3 - 58

S-40 S-45

Part No. 102521

April 2009

Section 4 Repair Procedures

Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.

Observe and Obey:


Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.

Perform disassembly procedures to the point where


repairs can be completed. To re-assemble, perform
the disassembly steps in reverse order.
Symbols Legend

Immediately tag and remove from service a


damaged or malfunctioning machine.

Safety alert symbolused to alert


personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Repair any machine damage or malfunction


before operating the machine.

Before Repairs Start:

Used to indicate the presence of


an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.

Read, understand and obey the safety rules and


operating instructions in the Genie S-40 and
Genie S-45 Operators Manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use.

Used to indicate the presence of a


potentially hazardous situation
which, if not avoided, could result
in death or serious injury.

Use only Genie approved replacement parts.


Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.

With safety alert symbolused to


indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.

Unless otherwise specified, perform each


repair procedure with the machine in the
following configuration:

Machine parked on a flat, level surface

Boom in the stowed position

Turntable rotated with the boom between


the non-steering wheels

Turntable secured with the turntable


rotation lock pin

Key switch in the off position with the


key removed

Wheels chocked

All external AC power supply disconnected


from the machine

Part No. 102521

Used to indicate the presence of a


potentially hazardous situation
which, if not avoided, may result in
property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

S-40 S-45

4-1

Section 4 Repair Procedures

April 2009

Platform Controls

REV D

The platform control box contains one printed


circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall
Effect technology and require no adjustment. The
operating parameters of the joysticks are stored in
memory at the ECM circuit board at the platform
controls. If a joystick error occurs or if a joystick is
replaced, it will need to be calibrated before that
particular machine function will operate. See 1-2,
How to Calibrate a Joystick.

1-1
ALC-500 Circuit Board

Each joystick controller should operate smoothly


and provide proportional speed control over its
entire range of motion.

How to Remove the ALC-500


Circuit Board

Electrocution hazard. Contact


with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Note: When the ALC-500 circuit board is replaced,
the joystick controllers will need to be calibrated.
See 1-2, How to Calibrate a Joystick.

1 Push in the red Emergency Stop button to the


off position at both the ground and platform
controls.

2 Remove the platform control box lid retaining


fasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to
the inside of the platform control box.

d
a
b
c
d

4-2

ALC-500 circuit board


drive/steer joystick controller
secondary boom up/down
joystick controller
primary boom up/down and
turntable rotate left/right
joystick controller

S-40 S-45

Part No. 102521

April 2009

Section 4 Repair Procedures

PLATFORM CONTROLS

REV D

4 Attach a grounded wrist strap to the ground


screw inside the platform control box.

1-2
Joysticks

Component damage hazard.


Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.

How to Calibrate a Joystick


The joysticks on this machine utilize digital Hall
Effect technology for proportional control. If a
joystick is disconnected or replaced, it must be
calibrated before that particular machine function
will operate.

5 Carefully disconnect the wire connectors from


the circuit board.

Note: The joystick must be calibrated before the


threshold, max-out or ramping can be set.

6 Remove the ALC-500 circuit board mounting


fasteners.

Note: Perform this procedure with the engine off.

7 Carefully remove the ALC-500 circuit board


from the platform control box.

1 Pull out the red Emergency Stop button to the


on position at both the ground and platform
controls.
2 Turn the key switch to platform control. Do not
start the engine.
3 Select a joystick to calibrate.
4 Move the joystick full stroke in either direction
and hold for 5 seconds.
5 Return the joystick to the neutral position,
pause for a moment, then move the joystick full
stroke in the opposite direction. Hold for 5
seconds and return the joystick to the neutral
position.
Result: The alarm should sound indicating
successful joystick calibration.
6 Repeat this procedure for each joystick
controlled machine function including the thumb
rocker steer switch.
Note: No machine fuction should operate while
performing the joystick calibration procedure.

Part No. 102521

S-40 S-45

4-3

Section 4 Repair Procedures

April 2009

PLATFORM CONTROLS

REV D

8 Start the engine from the platform controls and


press down the foot switch.

How to Adjust the Function


Speeds
The max-out setting of a joystick controls the
maximum speed of a joystick-controlled machine
function. Whenever a hydraulic cylinder, drive
motor or hydraulic pump is replaced, the max-out
setting should be adjusted to maintain optimum
performance. The max-out settings on the joystick
can be changed to compensate for hydraulic pump
wear to maintain peak performance from the
machine.
Note: Perform this procedure with the boom in the
stowed position.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to platform control. Do not
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Emergency Stop button to the on position.

9 Start a timer and activate the machine function


that needs to be adjusted. Record the time it
takes for that function to complete a full cycle
(ie; boom up).
10 Compare the machine function time with the
function times listed in Section 2,
Specifications. Determine whether the function
time needs to increase or decrease.
11 While the joystick is activated, adjust the maxout setting to achieve the proper function cycle
time. Momentarily move the drive enable toggle
switch in the right direction to increase the
function speed or momentarily move the drive
enable toggle switch in the left direction to
decrease the function speed.
Note: Each time the drive enable toggle switch is
momentarily moved, the function speed will change
in 2% increments.
12 Repeat steps 9 through 11 for each joystick
controlled machine function.
13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
settings to be saved.
Result: The alarm should sound indicating that
the settings have been saved in memory.

6 When the alarm sounds, release the drive


enable toggle switch.

Note: Do not operate any machine function during


the 10 second waiting time.

7 Momentarily activate the drive enable toggle


switch in the right direction 4 times.
Result: There should be a pause and the alarm
should sound 4 times indicating that the
machine is in max-out calibration mode.

4-4

S-40 S-45

Part No. 102521

April 2009

Section 4 Repair Procedures

PLATFORM CONTROLS

REV D

How to Adjust the Joystick


Ramp Rate Setting

10 Compare the function ramp rate time with the


table below and determine whether the ramp
rate time needs to increase or decrease.

The ramp rate setting of a joystick controls the time


at which it takes for the joystick to reach maximum
output, when moved out of the neutral position.
The ramp rate settings of a joystick can be
changed to compensate for hydraulic pump wear
to maintain peak performance from the machine.

11 While the joystick is activated, set the ramp


rate. Momentarily move the drive enable toggle
switch in the right direction to increase the time
or momentarily move the drive enable toggle
switch in the left direction to decrease the time.

Note: Perform this procedure with the boom in the


stowed position.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to platform control. Do not
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Emergency Stop button to the on position.
6 When the alarm sounds, release the drive
enable toggle switch.
7 Momentarily activate the drive enable toggle
switch in the right direction 6 times.
Result: There should be a pause and the alarm
should sound 6 times indicating that the
machine is in ramp rate calibration mode.
8 Start the engine from the platform controls and
press down the foot switch.
9 Start a timer and simultaneously move the
joystick in either direction full stroke. Note how
long it takes the function to reach maximum
speed. This is the ramp rate.

Part No. 102521

Note: Each time the drive enable toggle switch is


momentarily moved, the time will change in 5%
increments.
12 Repeat steps 9 through 11 for each joystick
controlled machine function.
13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
settings to be saved.
Result: The alarm should sound indicating that
the settings have been saved in memory.
Note: Do not operate any machine function during
the 10 second waiting time.
Ramp rate (factory settings)
Boom up/down
accelerate
decelerate

3 second
1 seconds

Turntable rotate
accelerate
decelerate

2 seconds
1 second

Drive
accelerate
decelerate to neutral
decelerate, change of direction
decelerate, coasting
decelerate, braking
decelerate, shift from low to high speed
decelerate, shift from high to low speed

S-40 S-45

2 seconds
0.5 second
0.5 second
0.75 second
1 second
1 second
3 seconds

4-5

Section 4 Repair Procedures

April 2009

PLATFORM CONTROLS

REV D

8 Start the engine from the platform controls and


press down the foot switch.

How to Adjust the Joystick


Threshold Setting
The threshold setting of a joystick is the minimum
output at which a function proportional valve can
open and allow the function to operate.
Note: Perform this procedure with the boom in the
stowed position.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to platform control. Do not
start the engine.
3 Push in the red Emergency Stop button to the
off position at the platform controls.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Emergency Stop button to the on position.

9 Select a boom function joystick to set the


threshold.
10 Slowly move the joystick off center in either
direction just until the function begins to move.
11 Slowly move the joystick back to the neutral
position. Just before the function stops moving,
move the drive enable toggle switch to either
side to set the threshold.
Result: The alarm should sound indicating a
successful calibration.
12 Repeat steps 9 through 11 for each boom
joystick-controlled machine function (boom up/
down, boom extend/retract and turntable rotate).
13 Return the joystick to the neutral position and
wait for approximately 10 seconds.
Result: The alarm should sound indicating that
the settings have been saved in memory.
Note: Do not operate any machine function during
the 10 second waiting time.

6 When the alarm sounds, release the drive


enable toggle switch.
7 Momentarily activate the drive enable toggle
switch in the right direction 8 times.
Result: There should be a pause and the alarm
should sound 8 times indicating that the
machine is in threshold calibration mode.

4-6

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

Platform Components

REV B

2-1
Platform Leveling Slave Cylinder
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.

How to Remove the Platform


Leveling Slave Cylinder

S-40 Models:
5 Tag, disconnect and plug the hydraulic hoses
from the slave cylinder at the union located
near the platform rotate counterbalance valve
manifold and connect them together using a
connector. Cap the fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
S-45 Models:

Note: Before cylinder removal is considered, bleed


the slave cylinder to be sure there is no
air in the closed loop.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Extend the primary boom until the slave cylinder
barrel-end pivot pin is accessible.
2 Raise the primary boom slightly and place
blocks under the platform for support.
3 Lower the primary boom until the platform is
resting on the blocks just enough to support the
platform.

6 Tag, disconnect and plug the slave cylinder


hoses at the union.
7 Pull the slave cylinder hoses through the
platform rotator.
8 Remove the pin retaining fastener from
the slave cylinder rod-end pivot pin. Do not
remove the pin.
9 Remove the external retaining fastener from the
barrel-end pivot pin.
10 Use a soft metal drift to drive the rod-end pivot
pin out.
11 Use a soft metal drift and drive the barrel-end
pin out.
12 Carefully pull the cylinder out of the boom.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.

Note: Do not rest the entire weight of the boom on


the blocks.
4 Protect the slave cylinder rod from damage.

How to Bleed the Slave Cylinder


Note: Do not start the engine. Use auxiliary power
for this procedure.
1 Raise the primary boom to a horizontal position.
2 Move the platform level toggle switch up and
down through two platform leveling cycles to
remove any air that might be in the system.

Part No. 102521

S-40 S-45

4-7

Section 4 Repair Procedures

July 2007

PLATFORM COMPONENTS

REV B

S-40 Models:

2-2
Platform Rotator
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
160 degrees.

2 Tag, disconnect and plug the hydraulic hoses


from the platform rotator. Cap the fittings on the
rotator.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

How to Remove the


Platform Rotator
Component damage hazard. Mark
the platform mounting weldment
and the rotator flange before
removing the platform mounting
weldment. The platform mounting
weldment must be replaced in the
exact same position on the rotator
flange as it was before removal. If
a new rotator is installed or the
rotator is disassembled, proper
alignment can be achieved by
rotating the rotator all the way to
the left and then installing the
platform mounting weldment all
the way in the left position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section Two, Hydraulic Hose
and Fitting Torque Specifications.

S-45 Models:
3 Tag and disconnect the hydraulic hoses from
the "V1" and "V2" ports on the counterbalance
valve manifold located on the platform rotator
and connect them together using a connector.
Cap the fittings on the manifold.
4 Support the platform leveling arms and platform
mounting weldment with an appropriate lifting
device, but do not apply any lifting pressure.
All Models:
5 Remove the six mounting bolts from the
platform mounting weldment. Remove the
center bolt and slide the platform mounting
weldment off of the platform rotator.
Crushing hazard. The platform
mounting weldment could become
unbalanced and fall if it is not
properly supported.

1 Remove the platform and platform support.

6 Support the platform rotator with an appropriate


lifting device. Do not apply any lifting pressure.

4-8

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

REV B

PLATFORM COMPONENTS

7 Support the platform leveling slave cylinder.


Protect the cylinder rod from damage.

3 Open the top bleed valve on the rotator, but do


not remove it.
a

8 Remove the pin retaining fasteners from both


the slave cylinder rod-end pivot pin, and the
rotator pivot pin.
9 Use a soft metal drift to drive both pins out, then
remove the platform rotator from the machine.
Crushing hazard. The platform
rotator could become unbalanced
and fall if it is not properly
supported.

How to Bleed the Platform


Rotator

d
a
b
c
d

Note: This procedure will require two people. Do not


start the engine. Use auxiliary power for this
procedure.
1 Move the function enable toggle switch to either
side and activate the platform rotate toggle
switch to the right then the left through two
platform rotation cycles, then hold the switch to
the right position until the platform is fully
rotated to the right.
2 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container
to collect any drainage. Secure the container to
the boom.

top bleed valve


bottom bleed valve
container
clear hose

4 Move the function enable toggle switch to either


side and hold the platform rotate toggle switch
to the left position until the platform is fully
rotated to the left. Continue holding the toggle
switch until air stops coming out of the bleed
valve. Close the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
5 Connect the clear hose to the bottom bleed
valve and open the valve. Do not remove the
bleed valve.
6 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch
to the right position until the platform is fully
rotated to the right. Continue holding the toggle
switch until air stops coming out of the bleed
valve. Close the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions and
inspect the bleed valves for leaks.

Part No. 102521

S-40 S-45

4-9

Section 4 Repair Procedures

July 2007

PLATFORM COMPONENTS

REV B

2-3
Platform Overload System

How to Calibrate the Platform


Overload System (if equipped)

The platform overload system is designed to


prevent the machine from continuing to operate
when the load in the platform exceeds maximum
rated capacity. Refer to the machine serial label for
maximum capacity information.
If maximum platform capacity is exceeded, the
alarm will sound at the platform controls and the
platform overload indicator lights will flash at both
the ground and platform controls. The ground and
platform controls will become disabled. Before
normal machine operation can continue, the excess
load will need to be removed from the platform.
If the excess load cannot be removed or if the
operator at the platform controls is unable to correct
the overloaded condition, another person at the
ground controls can operate the machine using
auxiliary power. There will be limited control of
boom functions from the ground controls when
using auxiliary power. Auxiliary power can be used
to correct the overloaded platform condition in order
to resume normal, safe operation of the machine.
Note: Even though platform and ground controls are
disabled when an overloaded condition is detected,
the engine will continue to run. If the engine is shut
off in an overloaded condition, it will not be possible
to re-start the engine until the overloaded condition
is corrected.

4 - 10

Calibration of the platform overload system is


essential to safe machine operation. Continued use
of an improperly calibrated platform overload
system could result in the system failing to sense
an overloaded platform. The stability of the
machine is compromised and it could tip over.
Note: Perform this procedure with the machine on a
firm, level surface.
1 Turn the key switch to platform control. Start the
engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform capacity
at the center of the platform floor.

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

REV B

PLATFORM COMPONENTS

5 Move the platform up and down by hand, so it


bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.

7 Move the platform up and down by hand, so it


bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.

Result: The overload indicator lights are off and


the alarm does not sound. Proceed to step 6.

Result: The overload indicator lights are off and


the alarm does not sound. Proceed to step 8.

Result: The overload indicator lights are flashing


at the platform and ground controls, and the
alarm is sounding. Slowly tighten the load spring
adjustment nut in a clockwise direction in 10
increments until the overload indicator light
turns off, and the alarm does not sound.
Proceed to step 8.

Result: The overload indicator lights are flashing


at the platform and ground controls, and the
alarm is sounding. Repeat this procedure
beginning with step 5.

Note: The platform will need to be moved up and


down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
6 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The overload indicator lights are off at
the platform and ground controls, and the alarm
does not sound. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
in 10 increments until the overload indicator
light flashes at both the platform and ground
controls, and the alarm sounds.
Proceed to step 7.
Result: The overload indicator lights are flashing
at the platform and ground controls, and the
alarm is sounding. Repeat this procedure
beginning with step 5.

Note: There may be a 2 second delay before the


platform overload indicator light and alarm
responds.
8 Add an additional 10 lb / 4.5 kg test weight to
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.
Result: The overload indicator light is off at both
the ground and platform controls, and the alarm
does not sound. Remove the additional 10 lb /
4.5 kg test weight. Repeat this procedure
beginning with step 6.
Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
9 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
10 Turn the key switch to ground control.

Note: The platform will need to be moved up and


down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.

Part No. 102521

S-40 S-45

4 - 11

Section 4 Repair Procedures

July 2007

REV B

PLATFORM COMPONENTS

11 Test all machine functions from the ground


controls.
Result: All ground control functions should not
operate.
12 Using a suitable lifting device, lift the test weight
off the platform floor.
Result: The platform overload indicator light
should be off at both the ground and platform
controls and the alarm should not sound.
Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
13 Test all machine functions from the ground
controls.
Result: All ground control functions should
operate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate normally.

4 - 12

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

PLATFORM COMPONENTS

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Part No. 102521

S-40 S-45

4 - 13

Section 4 Repair Procedures

July 2007

Jib Boom Components, S-45

REV A

3-1
Jib Boom

7 Place blocks under the platform leveling cylinder


for support. Protect the cylinder rod from
damage.

How to Remove the Jib Boom

8 Remove the pin retaining fasteners from the jib


boom lift cylinder barrel-end pivot pin. Do not
remove the pin.

Note: Perform this procedure with the boom in the


stowed position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Remove the platform.

9 Attach a lifting strap from an overhead crane to


the lug on the rod end of the jib boom lift
cylinder.
10 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin.
11 Use a soft metal drift to remove the jib boom lift
cylinder barrel-end pivot pin, then remove the
jib boom cylinder.

2 Remove the platform mounting weldment,


and the platform rotator. See 2-2, How to
Remove the Platform Rotator.

Crushing hazard. The jib boom


lift cylinder could become
unbalanced and fall when it is
removed from the machine if it is
not properly attached to the
overhead crane.

3 From the ground controls, raise the jib boom to


a horizontal position.
4 Support the jib boom with a strap from an
overhead crane.
5 Tag, disconnect and plug the hydraulic hoses
from the jib boom lift cylinder. Cap the fittings
on the cylinder.

12 Remove the pin retaining fasteners from the jib


boom pivot pin. Use a soft metal drift to remove
the pin, then remove the jib boom from the
bellcrank.

Bodily injury hazard. Spraying


hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Crushing hazard. The jib boom


could become unbalanced and fall
when it is removed from the
machine if it is not properly
attached to the overhead crane.

6 Remove the hose cover, hoses and cables from


the side of the jib boom and set them aside.
Component damage hazard. Hoses
and cables can be damaged if they
are kinked or pinched.

4 - 14

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

REV A

JIB BOOM COMPONENTS, S-45

4 Use a soft metal drift to tap the jib boom lift


cylinder rod-end pivot pin half way out. Then
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.

3-2
Jib Boom Lift Cylinder
How to Remove the Jib Boom
Lift Cylinder
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Then
lower the jib boom until the platform is resting
on the blocks just enough to support the
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.

5 Support the jib boom lift cylinder with a lifting


device.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pin and
let the cylinder hang down.
Crushing hazard. The platform
and jib boom could become
unbalanced and fall when the jib
boom barrel-end pivot pin is
removed if not properly supported.
7 Attach a lifting strap from an overhead crane to
the lug on the rod end of the jib boom lift
cylinder.
8 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pin. Remove the cylinder from
the machine.

Bodily injury hazard. Spraying


hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Crushing hazard. The jib boom lift


cylinder could become unbalanced
and fall when removed from the
machine if not properly attached to
the overhead crane.

3 Remove the pin retaining fasteners from the jib


boom lift cylinder rod-end pivot pin. Do not
remove the pin.

Part No. 102521

S-40 S-45

4 - 15

Section 4 Repair Procedures

July 2007

Boom Components
4-1
Cable Track
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses
that run through it. Removing the entire primary
boom cable track is only necessary when
performing major repairs that involve removing the
primary boom.

How to Remove the Cable Track


Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.

REV A

6 Tag, disconnect and plug the hydraulic hoses


from the counterbalance valve manifold located
on the platform rotator. Cap the fittings on the
manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
7 Tag, disconnect and plug the hydraulic hoses
from the platform leveling cylinder at the union
and connect the hoses from the cylinder
together using a connector.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

1 Raise the primary boom to a horizontal position.


2 Locate the cables from the cable track to the
platform control box. Number each cable and
its entry location at the platform control box.
3 Disconnect the cables from the platform control
box.

8 Locate all electrical cables that enter the cable


track.

4 Remove the electrical outlet box bracket


mounting fasteners. Remove the outlet box and
lay it to the side.

9 Tag and disconnect the electrical connectors for


all cables that enter the cable track.

5 Remove the hose and cable clamp from the


platform support.

10 Remove the retaining fasteners from the


electrical connector receptacles for the cables
that enter the cable track.
11 Remove the fasteners from the drive speed limit
switch mounted on the side of the cable track at
the pivot end of the boom. Do not disconnect
the wiring.

4 - 16

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

REV A

BOOM COMPONENTS

12 Remove the fasteners from the side panel on


the lower cable track, then remove the panel.
Pull all of the cables out of the channel.

How to Repair the Cable Track


Component damage hazard.
The boom cable track can be
damaged if it is twisted.

13 Remove the cable cover on the side of the


boom.
14 Place blocks in between the upper and lower
cable tracks and secure the upper and lower
tracks together.
Crushing hazard. If the upper and
lower cable tracks are not properly
secured together, the cable track
could become unbalanced and fall
when it is removed from the
machine.
15 Attach a lifting strap from an overhead crane to
the cable track.
16 Remove the mounting fasteners from the upper
cable track at the platform end of the extension
boom.

Note: A cable track repair kit is available through


the Genie Industries Service Parts Department,
part no. 81007. The kit includes a 4 link section of
cable track.
1 Visually inspect the cable track and determine
which 4 link section needs to be replaced.
2 Remove the snap-on cable track spacers.
3 Carefully remove the external snap rings from
the pivot pins at each end of the 4-link section
to be removed.
4 Lift up the hoses and cables and carefully
remove the damaged 4 link section of cable
track.
Component damage hazard. Hoses
and cables can be damaged if they
are kinked or pinched.

17 Remove the cable track mounting fasteners that


attach the lower cable track to the boom.
18 Remove the cable track from the machine and
place it on a structure capable of supporting it.
Crushing hazard. The cable track
could become unbalanced and fall
if it is not properly attached to the
overhead crane.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.

5 Remove the snap-on spacers from the


replacement section of the cable track.
6 Lift up the hoses and cables and carefully insert
the new 4 link section of cable track.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
7 Connect the ends of the replacement cable
track section to the existing cable track using
the pivot pins and external snap rings.
Note: Be sure the pivot pins are installed from the
inside out so the external snap rings are on the
outside of the cable track.
8 Operate the boom extend/retract function
through a full cycle to ensure smooth operation
of the new section of cable track.

Part No. 102521

S-40 S-45

4 - 17

Section 4 Repair Procedures

July 2007

BOOM COMPONENTS

REV A

1 Remove the platform. See 2-1, How to Remove


the Platform.

4-2
Boom

2 Remove the platform rotator and leveling slave


cylinder. See 2-3, How to Remove the Platform
Rotator.

How to Remove the Boom


Consult the Genie Industries Service Department
for instructions on how to safely remove the boom
assembly from the machine. Failure to read and
follow the warnings listed below could result in
death or serious injury.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.

3 S-45 Models: Remove the jib boom. See 3-1,


How to Remove the Jib Boom.
4 Remove the mounting fasteners from the jib
boom/platform rotate valve manifold on the end
of the boom. Remove the manifold and set it
aside.
5 Remove the fasteners from the limit switch
mounted on the side of the cable track. Do not
disconnect the wiring.
6 Support the cable track with an overhead crane.
7 Remove the hose/cable clamp from the pivot
end of the boom.

Note: Perform this procedure with the boom in the


stowed position.

8 Remove the hose/cable clamp at the platform


end of the cable track.

Note: When removing a hose assembly or fitting,


the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.

9 Remove the fasteners from the large cable track


guide at the platform end of the cable track.
Remove the guide.
10 Remove the cotter pin from the clevis pin at the
platform end of the cable track. Remove the
clevis pin.
Note: Always replace the cotter pin with a new one
when removing a clevis pin.
11 Remove the fasteners from the side panel on
the cable track to access the cable track
mounting fasteners.

4 - 18

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

REV A

12 Remove the cable track mounting fasteners,


then remove the cable track from the boom and
lay it off to the side.
Component damage hazard.
The boom cable track can be
damaged if it is twisted.

18 Attach a similar lifting device to the boom lift


cylinder.
19 Use the overhead crane to lift the boom to a
horizontal position.
20 Place support blocks under the boom lift
cylinder, across the turntable.

Component damage hazard.


Hoses can be damaged if they are
kinked or pinched.

21 Remove the pin retaining fastener from the


boom lift cylinder rod-end pin. Use a soft metal
drift to remove the pin.

13 Remove the turntable end cover.


14 Remove the retaining fastener from the master
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin. Pull the cylinder back and
secure it from moving.
Component damage hazard.
When pulling the master cylinder
back, be sure not to damage the
master cylinder hoses or fittings.
15 Remove the fasteners from the limit switch
mounted to the turntable riser at the pivot end of
the boom. Do not disconnect the wiring.

Crushing hazard. The boom lift


cylinder will fall if not properly
supported.
22 Lower the rod end of the lift cylinder onto
support blocks. Protect the cylinder rod from
damage.
23 Remove the pin retaining fastener from the
boom pivot pin.
24 Use a soft metal drift to remove the boom pivot
pin, then carefully remove the boom from the
machine.

16 Tag, disconnect and plug the extension cylinder


hydraulic hoses. Cap the fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Crushing hazard. The primary


boom could become unbalanced
and fall when removed from the
machine if not properly attached to
the overhead crane.

17 Attach an overhead 5 ton / 4500 kg crane to the


center point of the boom.

Part No. 102521

S-40 S-45

4 - 19

Section 4 Repair Procedures

July 2007

REV A

How to Disassemble the Boom


Note: Complete disassembly of the boom is only
necessary if the secondary boom tube must be
replaced. The extension cylinder can be removed
without completely disassembling the boom. See 44, How to Remove the Extension Cylinder.
1 Remove the boom. See 4-2, How to Remove the
Boom.
2 Place blocks under the extension cylinder for
support.
3 Remove the external snap rings from the
extension cylinder barrel-end pivot pin at the
pivot end of the primary boom tube. Use a soft
metal drift to remove the pin.

8 Remove the trunnion pin retaining fasteners at


the base end of the secondary boom tube. Use
a slide hammer to remove the trunnion pins.
9 Carefully rotate the base end of the extension
cylinder until the pin mounting bore is in a
vertical position.
10 Remove the external snap rings from the
extension cylinder rod-end pivot pin at the
platform end of the secondary boom tube. Use a
soft metal drift to remove the pin.
11 Support and slide the extension cylinder out of
the base end of the secondary boom tube.
Place the extension cylinder on blocks for
suppport.
Crushing hazard. The extension
cylinder may become unbalanced
and fall when removed from the
secondary boom tube if not
properly supported.

4 Remove and label the wear pads from the top


side of the primary boom tube at the platform
end of the boom.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.

Note: During removal, the overhead crane strap will


need to be carefully adjusted for proper balancing.

5 Attach a lifting strap from an overhead crane to


the secondary boom tube at the platform end of
the boom for support.
6 Support and slide the secondary boom tube out
of the primary boom tube. Place the secondary
boom tube on blocks for support.

12 Remove the label the wear pads from the


extension cylinder.
Note: Pay careful attention to the location of each
wear pad.

Crushing hazard. The secondary


boom tube could become
unbalanced and fall when removed
from the primary boom tube if not
properly supported.
Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.
7 Remove and label the wear pads from the top
side of the secondary boom tube at the platform
end of the boom.

4 - 20

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

REV A

BOOM COMPONENTS

5 Tag, disconnect and plug the boom lift cylinder


hydraulic hoses. Cap the fittings on the cylinder.

4-3
Boom Lift Cylinder

Bodily injury hazard. Spraying


hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

The boom lift cylinder raises and lowers the boom.


The boom lift cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.

How to Remove the Boom


Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.

6 Remove the pin retaining fastener from the


boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin. Lower the lift
cylinder onto the blocks. Protect the cylinder
rod from damage.
Crushing hazard. The lift cylinder
could become unbalanced and fall
if it is not properly supported.
7 Remove the four mounting fasteners from the
lift cylinder barrel-end pivot pin mounting plate.
8 With the lift cylinder being supported by the
overhead crane, pull the cylinder toward the
platform to remove it from the machine.
Crushing hazard. The lift cylinder
could become unbalanced and fall
if it is not properly supported.

1 Raise the boom to a horizontal position.


2 Place support blocks across the turntable under
the boom lift cylinder.
3 Attach a 5 ton / 5000 kg overhead crane to the
boom at the platform end for support. Do not lift
the boom.
4 Support and secure both ends of the boom lift
cylinder to a second overhead crane or similar
lifting device.

Part No. 102521

Component damage hazard. The


cables and hydraulic hoses can be
damaged if the lift cylinder is
pulled across them.
9 Using auxiliary power, activate the boom down
function so the cylinder will retract. Retract the
cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
boom. Turn the machine off.

S-40 S-45

4 - 21

Section 4 Repair Procedures

July 2007

BOOM COMPONENTS

REV A

4-4
Extension Cylinder

4 Remove the external snap rings from the


extension cylinder rod-end pins (at the platform
end). Use a soft metal drift to remove the pins.

The extension cylinder extends and retracts the


boom extension tube. The extension cylinder is
equipped with counterbalance valves to prevent
movement in the event of a hydraulic line failure.

5 Remove the turntable end cover.


6 Tag, disconnect and plug the extension cylinder
hydraulic hoses. Cap the fittings on the
cylinder.

How to Remove the


Extension Cylinder
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools could cause death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section Two, Hydraulic Hose
and Fitting Torque Specifications.

Bodily injury hazard. Spraying


hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
7 Remove the barrel-end pivot pin retaining
fasteners.
8 Place a rod through the barrel-end pivot pin and
twist to remove the pin.

1 Extend the boom until the extension cylinder


rod-end pivot pins are accessible in the
extension tube.
2 Remove the master cylinder. See 4-5, How to
Remove the Master Cylinder.
3 Raise the boom to a horizontal position.

9 Support and slide the extension cylinder out of


the pivot end of the boom.
Crushing hazard. The extension
cylinder will fall when it is removed
from the extension boom if it is not
properly supported.
Note: Note the length of the cylinder after removal.
The cylinder must be at the same length for
installation.

4 - 22

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

REV A

BOOM COMPONENTS

4-5
Platform Leveling
Master Cylinder

4 Attach a lifting strap from an overhead crane to


the lug on the rod end of the master cylinder.

The master cylinder acts as a pump for the slave


cylinder. It is part of the closed circuit hydraulic
loop that keeps the platform level through the
entire range of boom motion. The master cylinder
is located at the base of the boom.

6 Place a rod through the barrel-end pivot pin and


twist to remove the pin.

5 Remove the pin retaining fasteners from the


master cylinder barrel-end pivot pin.

How to Remove the Platform


Leveling Master Cylinder
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section Two, Hydraulic Hose
and Fitting Torque Specifications.
1 Remove the turntable end cover to access the
master cylinder.

7 Remove the pin retaining fastener from the rodend pivot pin.
8 Use a soft metal drift to remove the pin.
9 Remove the master cylinder from the machine.

2 Raise the boom until the master cylinder


rod-end pivot pin is accessible.
3 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.

Crushing hazard. The master


cylinder could become unbalanced
and fall if it is not properly attached
to the overhead crane.

Bodily injury hazard. Spraying


hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Part No. 102521

S-40 S-45

4 - 23

Section 4 Repair Procedures

September 2007

Engines

REV D

5-1
RPM Adjustment - Deutz Models

5-3
Flex Plate

Refer to Maintenance Procedure B-11, Check and


Adjust the Engine RPM.

The flex plate acts as a coupler between the engine


and the pump. It is bolted to the engine flywheel
and has a splined center to drive the pump.
a

5-2
RPM Adjustment - Perkins
Models
Refer to Maintenance Procedure B-11, Check and
Adjust the Engine RPM.

f
a
b
c
d
e
f

pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
0.18 inch / 4.6 mm gap - Deutz Models
0.070 inch / 1.8 mm gap - Perkins Models
0.0625 inch / 1.6 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423

How to Remove the Flex Plate


Deutz models:
1 Remove the tailpipe bracket mounting fasteners
from the engine bell housing.
2 Support the drive pump assembly with an
appropriate lifting device.
3 Remove all of the engine bell housing fasteners.
4 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
5 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.

4 - 24

S-40 S-45

Part No. 102521

September 2007

Section 4 Repair Procedures

ENGINES

REV D

Ford LRG-425 EFI models:

12 Remove all of the engine bell housing fasteners.

1 Disconnect the electrical connector for the


oxygen sensor at the tailpipe. Do not remove
the oxygen sensor.

13 Carefully pull the pump and bell housing


assembly away from the engine and secure it
from moving.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.

2 Remove the engine oil dipstick fasteners from


the muffler bracket. Remove the dipstick from
the engine.
3 Remove the muffler retaining fasteners from the
exhaust pipe.

14 Remove the flex plate mounting fasteners.


Remove the flex plate from the flywheel.

4 Support the muffler and bracket assembly with


an overhead crane or other suitable lifting
device.

Ford DSG-423 EFI models:

5 Remove the muffler bracket mounting fasteners.


Carefully remove the muffler and bracket
assembly from the engine.
6 Support the engine with a suitable lifting device.
Do not lift it.
7 Remove the engine plate to vibration isolator
fasteners.

9 Raise the engine slightly to take the weight off


of the engine mounting plate.

11 Support the drive pump assembly with an


appropriate lifting device.

2 Remove the exhaust pipe fasteners at the


muffler.
3 Support the muffler and bracket assembly with a
suitable lifting device.
4 Remove the muffler bracket mounting fasteners
from the bell housing. Carefully remove the
muffler and bracket assembly from the engine.

8 Remove the engine mounting plate to bell


housing fasteners.

10 Slide the engine mounting plate towards the


pump as far as it will go.

1 Disconnect the electrical connectors from both


oxygen sensors at the tailpipe and exhaust
manifold. Do not remove the oxygen sensors.

5 Support the engine with an overhead crane or


other suitable lifting device. Do not lift it.
6 Remove the engine mounting plate to bell
housing fasteners.
7 Raise the engine slightly using the overhead
crane and place a block of wood under the oil
pan for support.
8 Support the drive pump assembly with an
overhead crane or other suitable lifting device.
Do not apply any lifting pressure.

Part No. 102521

S-40 S-45

4 - 25

Section 4 Repair Procedures

September 2007

ENGINES

REV D

9 Remove all of the engine bell housing retaining


fasteners.
10 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
11 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
Perkins models:
1 Remove the fuel filter/water separator mounting
fasteners.
2 Remove the fuel filter/water separator and lay it
to the side. Do not disconnect the hoses.
3 Support the drive pump assembly with an
appropriate lifting device.
4 Remove all of the engine bell housing fasteners.

After serial number 13739: Torque the flex


plate mounting bolts in sequence to
20 ft-lbs / 27 Nm.
Deutz models:
Torque the flex plate mounting bolts in
sequence to
28 ft-lbs / 38 Nm.
Perkins models:
Before serial number 7472: Torque the flex
plate mounting bolts in sequence to
28 ft-lbs / 38 Nm.
From serial number 7472 to 13773: Torque the
flex plate mounting bolts in sequence to
49 ft-lbs / 66 Nm.
After serial number 13773: Torque the flex
plate mounting bolts in sequence to
14 ft-lbs / 19.1 Nm.
3 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
appropriate gap between coupler and pump end
plate for your engine.

5 Carefully pull the pump and bell housing


assembly away from the engine and secure it
from moving.

Component damage hazard. Hoses


can be damaged if they are kinked
or pinched.
6 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.

f
a
b
c
d
e
f

How to Install the Flex Plate


1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
2 Apply Loctite removable thread sealant to the
screws. Torque the flex plate in a star pattern
using the following values.
Ford models:
Before serial number 13740: Torque the flex
plate mounting bolts in sequence to
24 ft-lbs / 32 Nm.

4 - 26

pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
0.18 inch / 4.6 mm gap - Deutz Models
0.070 inch / 1.8 mm gap - Perkins Models
0.0625 inch / 1.6 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423

4 Apply Loctite removable thread sealant to the


pump coupler set screw. Torque the set screw
to 61 ft-lbs / 83 Nm.
5 Install the pump and bell housing assembly.

S-40 S-45

Part No. 102521

September 2007

Section 4 Repair Procedures

ENGINES

REV D

Ford LRG-425 models:


Before serial number 7597: Torque the bell
housing mounting bolts in sequence to
23 ft-lbs / 31 Nm.
After serial number 7596: Torque the bell
housing mounting bolts labeled "C" in sequence
to 47 ft-lbs / 63 Nm. Torque the bell housing
mounting bolts labeled "B" in sequence to
61 ft-lbs / 83 Nm.

Ford LRG 425 models


(after serial number 7596)
6

1
A

10

Ford LRG 425 models


(before serial number 7597)

Ford DSG-423 models:


Torque the bell housing mounting bolts labeled
"A" and "B" in sequence to 28 ft-lbs / 38 Nm
and the mounting bolts labeled "C" to 49 ft-lbs /
66 Nm. Then torque the bell housing mounting
bolts labeled "A" and "B" in sequence to 40 ftlbs / 54 Nm and the mounting bolts labeled "C"
to 70 ft-lbs / 95 Nm.

Deutz models:
Before serial number 7544: Torque the bell
housing mounting bolts in sequence to
28 ft-lbs / 38 Nm.
After serial number 7543: Torque the bell
housing mounting bolts in sequence to
47 ft-lbs / 63 Nm.

Perkins models
(after serial number 7471)

10

10

1
C

11

12 11

5
2

Component damage hazard. When


installing the pump, do not force
the pump coupler into the flexplate
or damage to the pump shaft seal
may occur.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.

12

C
C

Deutz 1011 models


(before serial number 7544)

8
C

Perkins models
(before serial number 7472)

Perkins models:
Before serial number 7472: Torque the bell
housing mounting bolts in sequence to
28 ft-lbs / 38 Nm.
After serial number 7471: Torque the bell
housing mounting bolts labeled "B" in sequence
to 28 ft-lbs / 38 Nm and the mounting bolts
labeled "A" to 49 ft-lbs / 66 Nm. Then torque the
bell housing mounting bolts labeled "B" in
sequence to 40 ft-lbs / 54 Nm and the mounting
bolts labeled "A" to 70 ft-lbs / 95 Nm.

12

11

5
9

Deutz 2011 models


(after serial number 7543)
6

Ford DSG 423 models

Part No. 102521

S-40 S-45

4 - 27

Section 4 Repair Procedures

September 2007

ENGINES

REV D

5 Continue to hold the run/test toggle switch in the


test position and count the blinks.

5-4
Engine Fault Codes Ford Models
How to Retrieve Engine Fault
Codes
When an engine malfunction is detected by the
Electronic Control Module (ECM), a fault code is
recorded and the check engine light will turn on at
the ground controls. Special equipment is required
to retrieve fault codes stored within the ECM.
Contact Genie Industries Service Department for
assistance in retrieving fault codes.
Note: Perform this procedure with the key switch in
the off position.
1 Open the ground controls side cover and locate
the run/test toggle switch on the side of the
ground control box.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.

Note: If any fault codes are present, the ECM will


use the check engine light to blink a three digit
code.
It will blink the first digit of a three digit code,
pause, blink the second digit, pause, and then blink
the third digit. For example: the check engine light
blinks 5 consecutive times, blinks 3 times and then
1 time. That would indicate code 531. There will be
a longer pause between codes.
6 Refer to Section 5, Fault Codes, for definition of
engine fault codes.
Note: Once a fault code has been retrieved and the
repair has been completed, the ECM memory must
be reset to clear the fault code from the ECM. See
How to Clear Engine Fault Codes from the ECM.

How to Clear Engine Fault


Codes from the ECM
Note: Perform this procedure with the engine off
and the key switch in the off position.
1 Open the engine side turntable cover and locate
the battery.

3 Quickly activate and release the start toggle


switch/button. Do not start the engine.
(before serial no. 7597)
4 Move and hold the run/test toggle switch to the
test position.

2 Disconnect the negative battery cable from the


battery for a minimum of 5 minutes.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.

Result: The check engine light should turn on.


The check engine light should begin to blink.

3 Connect the negative battery cable to the


battery.

4 - 28

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

Hydraulic Pumps

REV A

Models without hydraulic tank shut-off


valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a suitable container. See capacity
specifications.

6-1
Function Pump
How to Remove the
Function Pump
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Models with hydraulic tank shut-off valves:
Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.

2 Tag, disconnect and plug the function pump


hydraulic hoses. Cap the fittings on the pump.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
3 Remove the pump mounting bolts. Carefully
remove the pump.
Models with hydraulic tank shut-off valves:
Component damage hazard. Be
sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
Models without hydraulic tank shut-off valves:

open

closed

Component damage hazard. The


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

Part No. 102521

S-40 S-45

Component damage hazard. Be


sure to fill the hydraulic tank to
specification and prime the pump
after installing the pump.

4 - 29

Section 4 Repair Procedures

July 2007

HYDRAULIC PUMPS

REV A

6-2
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electro-proportional controller,
located on the pump. The only adjustment that can
be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized Eaton
Hydraulics center. Call Genie Industries Service
Department to locate your local authorized service
center.

2 Models with hydraulic tank shut-off valves:


Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.

open

Component damage hazard. The


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

How to Remove the Drive Pump


Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Disconnect the electrical connection at the
electro-proportional controller located on the
drive pump.

4 - 30

closed

Models without hydraulic tank shut-off


valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a suitable container. See capacity
specifications.
3 Tag and disconnect and plug the hydraulic
hoses from the drive and function pumps.
Cap the fittings on the pumps.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

REV A

HYDRAULIC PUMPS

4 Support the pump with a lifting device and


remove the two drive pump mounting fasteners.
5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
6 Remove the drive pump from the machine.
Component damage hazard. The
hydraulic pump may become
unbalanced and fall if not properly
supported.

4 Ford models: Close the valve on the LPG tank


then disconnect the hose from the tank. Move
the fuel select switch to the LPG position.
Perkins models: Disconnect the engine wiring
harness from the fuel solenoid at the injector
pump.
Deutz models: Hold the manual fuel shutoff
valve clockwise to the closed position.
a

Models with hydraulic tank shut-off valves:


Component damage hazard. Be
sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
Models without hydraulic tank shut-off valves:
Component damage hazard. Be
sure to fill the hydraulic tank to
specification and prime the pump
after installing the pump.
a

5 Have another person crank the engine with the


starter motor for 15 seconds, wait 15 seconds,
then crank the engine an additional 15 seconds
or until the pressure reaches 320 psi / 22 bar.

How to Prime the Pump


1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the test port on the drive pump.
2 Remove the safety pin (if equipped) from the
engine pivot plate latch.
Note: The engine pivot plate latch is located under
the engine turntable pivot plate at the counterweight
end of the machine.
3 Open the engine pivot plate latch and swing the
engine pivot plate out and away from the
machine.

Part No. 102521

manual fuel shutoff valve

6 Ford models: Connect the LPG hose to the


LPG tank and open the valve on the tank. Move
the fuel select switch to the gasoline position.
Perkins models: Connect the engine wiring
harness to the fuel solenoid.
Deutz models: Release the manual fuel shutoff
valve.
7 Start the engine from the ground controls and
check for hydraulic leaks.

S-40 S-45

4 - 31

Section 4 Repair Procedures

October 2007

Manifolds

REV C

7-1
Function Manifold Components
The function manifold is located underneath the ground controls side turntable cover.
Index
No.

Description

Schematic
Item

Function

Torque

Flow regulator valve,


0.8 gpm / 3.03 L/min .......................... AA ......... platform rotate and
jib boom (S-45) ................................. 20-25 ft-lbs / 27-34 Nm

Flow regulator valve,


0.6 gpm / 2.27 L/min .......................... AA ......... platform rotate (S-40) ........................ 20-25 ft-lbs / 27-34 Nm

Check valve ....................................... AB ......... Differential sensing circuit,


platform rotate right and
jib boom down (S-45) ........................ 10-12 ft-lbs / 14-16 Nm

Solenoid valve, 2 position 3 way ....... AC ........ Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm

Check valve ....................................... AD ........ Differential sensing circuit,


platform level up ............................... 10-12 ft-lbs / 14-16 Nm

Solenoid valve, 2 position 3 way ....... AE ......... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm

Check valve ....................................... AF ......... Differential sensing circuit,


boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
Differential sensing valve,
150 psi / 10.3 bar ............................... AG ........ Turntable rotate circuit ...................... 30-35 ft-lbs / 41-47 Nm

7
8

Differential sensing valve,


150 psi / 10.3 bar ............................... AH ........ Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm

Relief valve, 2200 psi / 152 bar ........ AI .......... Boom down relief .............................. 20-25 ft-lbs / 27-34 Nm

10

Flow regulator valve,


0.1 gpm / 0.38 L/min .......................... AJ ......... Bleeds off differential sensing
valves to tank .................................... 20-25 ft-lbs / 27-34 Nm

11

Check valve ....................................... AK ......... Differential sensing circuit,


boom up/down .................................. 10-12 ft-lbs / 14-16 Nm

12

Relief valve, 1950 psi / 134 bar ........ AL ......... Extend cylinder relief ........................ 20-25 ft-lbs / 27-34 Nm

13

Check valve ....................................... AM ........ Differential sensing circuit,


boom extend/retract .......................... 10-12 ft-lbs / 14-16 Nm
Flow regulator valve,
2.0 gpm / 7.6 L/min ............................ AN ........ Steer left/right circuit ......................... 30-35 ft-lbs / 41-47 Nm

14

15

Check valve ....................................... AO ........ Platform level up .......................................... 14 ft-lbs / 19 Nm

16

Diagnostic nipple ............................... AP ......... Testing

This list continues. Please turn the page

4 - 32

S-40 S-45

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

AA AB AC AD AE AF AG AH

9
AI

10

11

AJ AK

12

13

14

AM

AL

AN

AO 15
AP 16

17
AQ 18
AR 19
AS 20
AT 21

AU 22
AV 23
AW 24
AX 25

BI
36

BH
35

Part No. 102521

BG
34

BF
33

BE BD BC BB
32

31

30

29

AY

26

AZ

27

BA
28

S-40 S-45

4 - 33

Section 4 Repair Procedures

October 2007

MANIFOLDS

REV C

Function Manifold Components, continued


Index
No.

Description

Schematic
Item

Function

Torque

18

Relief valve,
2900 psi / 200 bar ............................. AQ ........ System relief (S-45) .......................... 30-35 ft-lbs / 41-47 Nm

18

Relief valve,
2600 psi / 179 bar ............................. AQ ........ System relief (S-40) .......................... 30-35 ft-lbs / 41-47 Nm

19

Flow regulator valve,


4.5 gpm / 17.03 L/min ........................ AR ........ Boom extend/retract circuit ............... 30-35 ft-lbs / 41-47 Nm

20

Check valve ....................................... AS ......... Blocks flow from auxiliary pump


to function pump ............................... 30-35 ft-lbs / 41-47 Nm

21

Solenoid valve, 3 position 4 way ...... AT ......... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm

22

Solenoid valve, 2 position 3 way ...... AU ........ Boom extend .................................... 30-35 ft-lbs / 41-47 Nm

23

Solenoid valve, 2 position 3 way ...... AV ......... Boom retract ..................................... 30-35 ft-lbs / 41-47 Nm

24

Proportional solenoid valve .............. AW ........ Boom up/down circuit ....................... 20-25 ft-lbs / 27-34 Nm

25

Solenoid valve, 2 position 3 way ...... AX ......... Boom up ........................................... 30-35 ft-lbs / 41-47 Nm

26

Solenoid valve, 2 position 3 way ...... AY ......... Boom down ....................................... 30-35 ft-lbs / 41-47 Nm

27

Solenoid valve, 3 position 4 way ...... AZ ......... Turntable rotate ................................ 20-25 ft-lbs / 27-34 Nm

28

Check valve ....................................... BA ......... Platform level down .......................... 10-12 ft-lbs / 14-16 Nm

29

Proportional solenoid valve .............. BB ......... Turntable rotate left/right .................. 20-25 ft-lbs / 27-34 Nm

30

Counterbalance valve ....................... BC ........ Platform level up ............................... 30-35 ft-lbs / 41-47 Nm

31

Needle Valve .................................... BD ........ Platform level circuit ......................... 20-25 ft-lbs / 27-34 Nm

32

Counterbalance valve ....................... BE ......... Platform level down .......................... 30-35 ft-lbs / 41-47 Nm

33

Solenoid valve, 3 position 4 way ...... BF ......... Platform rotate and jib boom
up/down (S-45) ................................. 20-25 ft-lbs / 27-34 Nm

34

Differential sensing valve,


150 psi / 10.3 bar ............................... BG ........ Differential sensing circuit,
meters flow to functions .................... 30-35 ft-lbs / 41-47 Nm

35

Check valve ....................................... BH ........ Differential sensing circuit,


platform rotate left and
jib boom up (S-45) ............................ 10-12 ft-lbs / 14-16 Nm

36

Diagnostic nipple .............................. BI .......... Testing

4 - 34

S-40 S-45

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

AA AB AC AD AE AF AG AH

9
AI

10

11

AJ AK

12

13

14

AM

AL

AN

AO 15
AP 16

17
AQ 18
AR 19
AS 20
AT 21

AU 22
AV 23
AW 24
AX 25

BI
36

BH
35

Part No. 102521

BG
34

BF
33

BE BD BC BB
32

31

30

29

AY

26

AZ

27

BA
28

S-40 S-45

4 - 35

Section 4 Repair Procedures

October 2007

MANIFOLDS

REV C

7-2
Valve Adjustments Function Manifold
How to Adjust the System
Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the PTEST port on the function
manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggle
switch to the high idle position. Activate and
hold the boom retract toggle switch with the
boom fully retracted.
4 Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item AQ).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 5 and recheck relief
valve pressure.
8 Remove the pressure gauge.

4 - 36

S-40 S-45

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

7-3
Jib Select, Platform Rotate and Generator Manifold Components
Index
No.

Description

Counterbalance valve ........................ CA ........ Platform rotate right .......................... 30-35 ft-lbs / 41-47 Nm

Counterbalance valve ........................ CB ........ Platform rotate left ............................. 30-35 ft-lbs / 41-47 Nm

Relief valve ........................................ CD ........ Generator overload relief .................. 30-35 ft-lbs / 41-47 Nm

Solenoid valve ................................... CE ........ Controls generator on / off ................ 50-55 ft-lbs / 68-75 Nm

Solenoid valve, 2 position 3 way ....... CC ........ Platform rotate/jib boom select ......... 18-20 ft-lbs / 25-27 Nm

Schematic
Item

Function

Torque

CC

Jib Select Manifold


CA

CE

Platform Rotate Manifold


Generator Manifold
CB

CD
3

Part No. 102521

S-40 S-45

4 - 37

Section 4 Repair Procedures

October 2007

MANIFOLDS

REV C

7-4
Brake Manifold Components (before serial number 7569)
Index
No.

Description

Solenoid valve, 2 position 3 way ... DA ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm

Orifice, 0.025 inch / 0.635 mm ....... DB ........... Turntable rotation brake release

Schematic
Item

Function

Torque

DA

DB

4 - 38

S-40 S-45

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

7-5
Brake/Two-Speed Manifold Components (after serial number 7568)
Index
No.

Description

Orifice, 0.025 inch / 0.63 mm ......... EA ........... Turntable rotation brake release

Schematic
Item

Function

Torque

Solenoid valve, 2 position 3 way ... EB ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm

Solenoid valve, 2 position 3 way ... EC ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm

Check valve .................................... ED ........... Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm

1
EA

2
EB

EC

ED

Part No. 102521

S-40 S-45

4 - 39

Section 4 Repair Procedures

October 2007

MANIFOLDS

REV C

7-6
Oscillate Directional Valve Components
The oscillate directional valve is mounted inside the drive chassis at the non-steer end.
Index
No.

Description

Function

Torque

Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm

Spool valve ....................................................... Directional control

Relief valve ....................................................... Pressure adjustment

4 - 40

S-40 S-45

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

7 Push up or pull down on the threaded rod until


the machine is completely level.

How to Set Up the Oscillate


Directional Valve
Note: Adjustment of the oscillate directional valve
linkage is only necessary when the linkage or valve
has been replaced.

8 Verify that the ground and drive chassis are


completely level.

1 Lower the boom to the stowed position.

9 Tighten the nuts on both sides of the urethane


cushions until they are snug. Tighten the
locknuts.

2 Use a "bubble type" level to be sure the floor is


completely level.

10 Verify that the ground and drive chassis are


completely level.

Tip-over hazard. Failure to


perform this procedure on a level
floor could compromise the
stability of the machine resulting in
the machine tipping over.
3 Check the tire pressure in all four tires and add
air if needed to meet specification.
Note: The tires on some machines are foam-filled
and do not need air added to them.

11 Measure the distance between the drive


chassis and the non-steer axle on both sides
(from the inside of the drive chassis).
Note: If the distance is not equal and the
adjustment to the linkage was completed with the
ground and drive chassis level, repeat steps 6
through 11 OR consult Genie Industries Service
Department.

4 Remove the drive chassis cover and the nonsteer axle covers.
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
6 To level the drive chassis, start the engine and
loosen the lock nuts on both sides of the
urethane cushions.

Part No. 102521

S-40 S-45

4 - 41

Section 4 Repair Procedures

October 2007

MANIFOLDS

REV C

8 Adjust the internal screw. Turn it clockwise to


increase the pressure or counterclockwise to
decrease the pressure. Install the valve cap.

7-7
Valve Adjustments - Oscillate
Relief Valve

Tip-over hazard. Do not adjust the


relief valve higher than specified.

How to Adjust the Oscillate Relief


Valve Pressure

9 Repeat steps 4 through 7 and manually activate


the valve to confirm the valve pressure.

1 Remove the drive chassis cover from the nonsteer end of the machine.

10 Turn the engine off, remove the pressure gauge


and assemble the directional valve linkage.

2 Connect a 0 to 2000 psi / 0 to 150 bar pressure


gauge to the diagnostic nipple located near the
oscillate directional valve.

11 Install the cover on the non-steer end of the


drive chassis.

3 Disconnect the directional valve linkage, by


removing the heim joint and retaining fastener
from the axle.
4 Start the engine from the platform controls.
5 With the engine running, manually activate the
valve and observe the pressure reading on the
pressure gauge.
Oscillate relief valve specification
Pressure

950 psi
65.5 bar

6 Turn the engine off.


7 Locate the relief valve on the directional valve
and remove the cap.

4 - 42

S-40 S-45

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

7-8
Traction Manifold Components, 2WD (before serial number 7569)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.

Description

Schematic
Item

Relief valve, 210 psi / 14.5 bar ......... FA ......... Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm

Flow divider/combiner valve ............. FB ......... Controls flow to drive motors


in forward and reverse ................ 90-100 ft-lbs / 122-136 Nm

Orifice, 0.070 inch / 1.78 mm ............ FC ......... Equalizes flow across flow
divider/combiner valve (item FB)

Shuttle valve, 3 position 3 way .......... FD ......... Charge pressure, hot oil shuttle ........ 50-55 ft-lbs / 68-75 Nm

Diagnostic nipple ............................... FE ......... Testing

1
FA

Function

Torque

2
FB

FC

2WD
FD

FE

Part No. 102521

S-40 S-45

4 - 43

Section 4 Repair Procedures

October 2007

MANIFOLDS

REV C

7-9
Traction Manifold Components, 2WD (after serial number 7568)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.

Description

Schematic
Item

Relief valve, 280 psi / 19.3 bar ......... GA ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm

Flow divider/combiner valve ............. GB ........ Controls flow to drive motors


in forward and reverse ................ 90-100 ft-lbs / 122-136 Nm

Check valve ....................................... GC ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm

Check valve ....................................... GD ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm

Flow divider/combiner valve .............. GE ........ Controls flow to drive motors


in forward and reverse ...................... 50-55 ft-lbs / 68-75 Nm

Orifice, 0.070 inch / 1.78 mm ............ GF ........ Equalizes flow across flow
divider/combiner valve (item GB)

Function

Torque

1
GA

GB

GC

4 - 44

S-40 S-45

GD

GE

GF

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

4 Start the engine from the platform controls and


drive the machine slowly in the forward
direction. Note the pressure reading on the
pressure gauge.

7-10
Valve Adjustments, 2WD
Drive Manifold
How to Adjust the Hot Oil Shuttle
Relief Valve
Note: The pressure differential between the charge
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the drive
manifold) is necessary to return hot oil from the
closed loop drive circuit to the hydraulic tank for
cooling. This pressure differential must be
maintained at 40 psi / 14.5 bar.
Note: The following procedure will require two
people.

5 Turn the engine off, and remove the hot oil


shuttle relief valve cap (item FA). Adjust the
internal hex socket clockwise to increase the
pressure or counterclockwise to decrease the
pressure. Install the valve cap.
(before serial no. 7569)
5 Turn the engine off, and remove the hot oil
shuttle relief valve cap (item GA). Adjust the
internal hex socket clockwise to increase the
pressure or counterclockwise to decrease the
pressure. Install the valve cap.
(after serial no. 7568)
6 Repeat steps 4 and 5 until the pressure reading
on the guage is 40 psi / 2.8 bar less than the
pressure reading at the pump.

1 Open the engine side turntable cover and


connect a 0 to 600 psi / 0 to 41 bar pressure
gauge to the diagnostic nipple on the drive
pump.
2 Start the engine from the platform controls and
allow the engine to run at high idle. Note the
pressure reading on the pressure gauge.
3 Turn the engine off and connect a
0 to 600 psi / 0 to 41 bar pressure gauge to the
diagnostic nipple located on the drive manifold.

Part No. 102521

S-40 S-45

4 - 45

Section 4 Repair Procedures

October 2007

MANIFOLDS

REV C

7-11
Traction Manifold Components, 4WD (before serial number 7569)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.

Description

Schematic
Item
Function

Torque

Flow divider/combiner valve ............. HA ........ Controls flow to steer


end drive motors in
forward/reverse ........................... 90-100 ft-lbs / 122-136 Nm

Flow divider/combiner valve .............. HB ........ Controls flow to non-steer


end drive motors in
forward/reverse ........................... 90-100 ft-lbs / 122-136 Nm

Orifice, 0.070 inch / 1.778 mm .......... HC ........ Rear drive motor circuit

Orifice, 0.070 inch / 1.778 mm .......... HD ........ Equalizes pressure on both sides
of flow divider/combiner valve 7

Shuttle valve, 3 position 3 way .......... HE ........ Charge pressure, hot oil shuttle ........ 50-55 ft-lbs / 68-75 Nm

Diagnostic nipple ............................... HF ......... Testing

Flow divider/combiner valve .............. HG ........ Controls flow to flow


divider/combiner valves
1 and 2 ........................................ 90-100 ft-lbs / 122-136 Nm

Relief valve, 210 psi / 14.5 bar .......... HH ........ Charge pressure circuit ..................... 30-35 ft-lbs / 41-47 Nm

Orifice, 0.052 inch / 1.32 mm ............ HI .......... Front drive motor circuit

4 - 46

S-40 S-45

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

HI

HA
HB

1
2

HH

HG

HC

HD

HE

HF
6

Part No. 102521

S-40 S-45

4 - 47

Section 4 Repair Procedures

October 2007

MANIFOLDS

REV C

7-12
Traction Manifold Components, 4WD (after serial number 7568)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.

Description

Relief valve, 280 psi / 19.3 bar ......... JA ......... Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm

Flow divider/combiner valve .............. JB ......... Controls flow to non-steer end


drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm

Check valve ....................................... JC ......... Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm

Check valve ....................................... JD ......... Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm

Flow divider/combiner valve .............. JE ......... Controls flow to flow


divider/combiner valves
2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm

Check valve ....................................... JF ......... Non-steer end drive motor circuit ...... 60-70 ft-lbs / 81-95 Nm

Orifice, 0.040 inch / 1 mm ................. JG ......... Equalizes pressure on both sides


of flow divider/combiner valve 5

Orifice, 0.040 inch / 1 mm ................. JH ......... Equalizes pressure on both sides


of flow divider/combiner valve 2

Orifice, 0.040 inch / 1 mm ................. JI ........... Equalizes pressure on both sides


of flow divider/combiner valve 13

10

Check valve ....................................... JJ .......... Steer end drive motor circuit ............. 60-70 ft-lbs / 81-95 Nm

11

Check valve ....................................... JK ......... Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm

12

Shuttle valve, 3 position 3 way .......... JL .......... Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm

13

Flow divider/combiner valve .............. JM ......... Controls flow to steer end


drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm

14

Check valve ....................................... JN ......... Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm

4 - 48

Schematic
Item
Function

S-40 S-45

Torque

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

14
13

12

11

10

JA

JB

JC

JD

JE

JF

JN
JM

JL

JK

JJ

Part No. 102521

JG

JH

JI

S-40 S-45

4 - 49

Section 4 Repair Procedures

October 2007

MANIFOLDS

REV C

4 Start the engine from the platform controls and


drive the machine slowly in the forward
direction. Note the pressure reading on the
pressure gauge.

7-13
Valve Adjustments, 4WD
Drive Manifold
How to Adjust the Hot Oil Shuttle
Relief Valve
Note: The pressure differential between the charge
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the drive
manifold) is necessary to return hot oil from the
closed loop drive circuit to the hydraulic tank for
cooling. This pressure differential must be
maintained at 40 psi / 14.5 bar.
Note: The following procedure will require two
people.

5 Turn the engine off, and remove the hot oil


shuttle relief valve cap (item HH). Adjust the
internal hex socket clockwise to increase the
pressure or counterclockwise to decrease the
pressure. Install the valve cap.
(before serial no. 7569)
5 Turn the engine off, and remove the hot oil
shuttle relief valve cap (item JA). Adjust the
internal hex socket clockwise to increase the
pressure or counterclockwise to decrease the
pressure. Install the valve cap.
(after serial no. 7568)
6 Repeat steps 4 and 5 until the pressure reading
on the guage is 40 psi / 2.8 bar less than the
pressure reading at the pump.

1 Open the engine side turntable cover and


connect a 0 to 600 psi / 0 to 41 bar pressure
gauge to the diagnostic nipple on the drive
pump.
2 Start the engine from the platform controls and
allow the engine to run at high idle. Note the
pressure reading on the pressure gauge.
3 Turn the engine off and connect a
0 to 600 psi / 0 to 41 bar pressure gauge to the
diagnostic nipple located on the drive manifold.

4 - 50

S-40 S-45

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

7-14
Valve Coils

Valve Coil Resistance


Specification

How to Test a Coil


A properly functioning coil provides an
electromagnetic force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil. Zero resistance or infinite
resistance indicates the coil has failed.

Note: The following coil resistance specifications


are at an ambient temperature of 68F / 20C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18F / 20C
that your air temperature increases or decreases
from 68F / 20C.

Since coil resistance is sensitive to temperature,


resistance values outside specification can produce
erratic operation. When coil resistance decreases
below specification, amperage increases. As
resistance rises above specification, voltage
increases.

Description

While valves may operate when coil resistance is


outside specification, maintaining coils within
specification will help ensure proper valve function
over a wide range of operating temperatures.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to be
tested.

Specification

Solenoid valve, 2 position 3 way, 10V DC


(schematic items AC and AE)

6.3

Solenoid valve, 3 position 4 way, 10V DC


(schematic item AT and AZ)

6.3

Solenoid valve, 2 position 3 way, 10V DC


(schematic items AU, AV, AX, and AY)

6.3

Solenoid valve, 3 position 4 way, 10V DC


(schematic items AZ and BF)

6.3

Proportional solenoid valve, 12V DC


(schematic items AW and BB)

Solenoid valve, 2 position 3 way, 10V DC


(schematic item CC)

6.8

Solenoid valve, 2 position 3 way, 10V DC


(schematic items DA)

3.3

Solenoid valve, 2 position 3 way, 12V DC


(schematic items CE)

4.8

2 Test the coil resistance using a multimeter set


to resistance (). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.

Part No. 102521

S-40 S-45

4 - 51

Section 4 Repair Procedures

October 2007

MANIFOLDS

REV C

How to Test a Coil Diode

a
d

10 W
RESISTOR

27287

Note: The battery should read 9V DC or more when


measured across the terminals.
3 Set a multimeter to read DC current.
Note: The multimeter, when set to read DC current,
should be capable of reading up to 800 mA.

9V
BATTERY

a
b
c
d

multimeter
9V DC battery
10 resistor
coil

Note: Dotted lines in illustration indicate a


reversed connection as specified in
step 6

1 Test the coil for resistance. See, How to Test a


Coil.

Resistor, 10
Genie part number

Electrocution/burn hazard. Contact


with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.

2 Connect a 10 resistor to the negative terminal


of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.

AMMETER

COIL

Genie incorporates spike suppressing diodes in all


of its directional valve coils except proportional
valves and those coils with a metal case. Properly
functioning coil diodes protect the electrical circuit
by suppressing voltage spikes. Voltage spikes
naturally occur within a function circuit following the
interruption of electrical current to a coil. Faulty
diodes can fail to protect the electrical system,
resulting in a tripped circuit breaker or component
damage.

4 Connect the negative lead to the other terminal


on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
end of the coil.
5 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.

4 - 52

S-40 S-45

Part No. 102521

October 2007

Section 4 Repair Procedures

MANIFOLDS

REV C

7-15
Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index
No.

Description

Directional Valve ............................ CY ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm

Orifice disc ...................................... CW .......... Delays shift to drive ......................... 35-40 ft-lbs / 47-54 Nm

Solenoid valve ............................... CV ........... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm

Relief valve .................................... CX ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm

Check valve .................................... CU ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm

Schematic
Item

Function

Torque

CU

CY

CW

CV

CX

Part No. 102521

S-40 S-45

4 - 53

Section 4 Repair Procedures

July 2007

Turntable Rotation Components

REV A

2 Tag, disconnect and plug the hydraulic hoses


from the motor, brake and manifold. Cap the
fittings on the motor, brake and manifold.

8-1
Turntable Rotation Assembly

Bodily injury hazard. Spraying


hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not
allow oil to squirt or spray.

How to Remove the Turntable


Rotation Assembly
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.

3 Attach a suitable lifting device to the turntable


rotator assembly.

Note: Perform this procedure with the machine on a


firm and level surface.
1 Secure the turntable from rotating with the
turntable rotation lock pin.

d
Unlocked position

a
b
c
d
e
f

brake assembly
drive hub
backlash plate mounting bolts
backlash plate
manifold
motor

Locked position

4 - 54

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

REV A

TURNTABLE ROTATION COMPONENTS

4 Remove the turntable rotation assembly


mounting fasteners.
5 Carefully remove the turntable rotation assembly
from the machine.
Crushing hazard. The turntable
could rotate unexpectedly when
the rotation drive hub assembly is
removed if the turntable is not
secured with the turntable rotation
lock pin.
Crushing hazard. The turntable
rotation drive hub assembly could
become unbalanced and fall when
removed from the machine if not
properly supported.
When installing the drive hub assembly:
6 Install the drive hub. Apply Loctite removable
thread sealant and torque the backlash plate
mounting fasteners to 160 ft-lbs / 217 Nm.

Part No. 102521

S-40 S-45

4 - 55

Section 4 Repair Procedures

July 2007

Axle Components

REV A

2 Remove the fasteners from drive chassis cover


at the steer end. Remove the cover.

9-1
Oscillate Cylinders
The oscillating axle cylinders extend and retract
between the drive chassis and the axle to maintain
a level chassis while driving over uneven terrain.
The cylinders are equipped with counterbalance
valves to prevent movement in the event of a
hydraulic hose failure.

3 Tag, disconnect and plug the oscillating axle


cylinder hydraulic hoses. Cap the fittings on the
oscillate cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

How to Remove an Oscillating


Axle Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills and a suitable workshop.
Attempting this procedure without
these skills and tools could result
in death or serious injury and
significant component damage.
Dealer service is strongly
recommended.

4 Remove the pin retaining fasteners from the


rod-end pivot pin. Use a soft metal drift to
remove the pin.
5 Attach a lifting strap from an overhead crane to
the barrel end of the oscillating cylinder.
6 Remove the pin retaining fasteners from the
barrel-end pivot pin. Use a soft metal drift to
remove the pin.
7 Remove the cylinder from the machine.

Note: Perform this procedure on a firm, level


surface with the boom in
the stowed position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section Two, Hydraulic Hose and Fitting
Torque Specifications.

Crushing hazard. The oscillate


cylinder could become unbalanced
and fall when it is removed from
the machine if it is not properly
attached to the overhead crane.

1 Rotate the turntable until the boom is between


the steer tires.

4 - 56

S-40 S-45

Part No. 102521

July 2007

Section 4 Repair Procedures

Generators

REV A

5 Connect the positive and negative leads from a


multimeter of sufficient capacity to the electrical
outlet at the generator.

10-1
Valve Adjustments Hydraulic Generator

Result: The reading on the multimeter should be


112 to 118V AC.

How to Adjust the Generator


Voltage

Result: If the reading on the multimeter is not


112 to 118V AC, proceed to step 6.

Bodily injury hazard. Spraying


hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

6 Turn the key switch to the off position.


7 Use a wrench to hold the generator flow
regulator valve (item AM) and remove the cap.

Electrocution/burn hazard. Contact


with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.

Note: Be sure that the hydraulic oil level is within


the top 2 inches / 5 cm of the sight gauge.
Note: Perform this procedure with the machine on a
firm, level surface.
1 Disconnect all electrical tools from the machine.

flow regulator

8 Adjust the internal hex socket. Turn it clockwise


to increase the AC voltage or counterclockwise
to decrease the AC voltage. Install the flow
regulator valve cap.
Component damage hazard.
Failure to adjust the generator as
instructed may result in damage to
the generator or other electrical
equipment. Do not adjust the
generator to other than specified.

2 Start the engine from the platform controls.


3 Press the generator select switch.
4 Connect an electrical tool, which does not draw
more than 15A, to the electrical outlet at the
platform controls and run the tool at full speed.

9 Repeat steps 2 through 5 to confirm the


generator AC voltage.

Part No. 102521

S-40 S-45

4 - 57

Section 4 Repair Procedures

July 2007

GENERATORS

This page intentionally left blank.

4 - 58

S-40 S-45

Part No. 102521

July 2007

Section 5 Fault Codes

Fault Codes

REV A

Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Genie S-40 and S-45 Operators Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.

Observe and Obey:


Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.

Read each appropiate fault code thoroughly.


Attempting shortcuts may produce hazardous
conditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.

Repair any machine damage or malfunction


before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:

Electrocution/burn hazard. Contact


with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.

Machine parked on a firm, level surface


Boom in stowed position
Turntable rotated with the boom between
the non-steer wheels

Bodily injury hazard. Spraying


hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Turntable secured with the turntable


rotation lock
Key switch in the off position with the
key removed
Wheels chocked
All external AC power disconnected
from the machine

Note: Perform all troubleshooting on a firm level


surface.
Note: Two persons will be required to safely
perform some troubleshooting procedures.

Part No. 102521

S-40 S-45

5-1

Section 5 Fault Codes

July 2007

FAULT CODES

REV A

Fault Code Chart Control System


How to Retrieve Control System
Fault Codes
Note: At least one fault code is present when the
alarm at the platform controls produces two short
beeps every 30 seconds for 10 minutes.
Note: Perform this procedure with the engine off,
the key switch turned to platform controls and the
red Emergency Stop button pulled out to the on
position at both the ground and platform controls.
1 Open the platform control box lid.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.

3 Determine the error source: The red LED


indicates the error source and will flash two
separate codes. The first code will indicate the
first digit of the two digit code, flashing once per
second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Note: When the red LED is flashing the code, the
yellow LED will be on solid.
4 Determine the error type: The yellow LED
indidates the error type and will flash two
separate codes. The first code will indicate the
first digit of the two digit code, flashing once per
second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Note: When the yellow LED is flashing the code,
the red LED will be on solid.
5 Use the fault code table on the following pages
to aid in troubleshooting the machine by
pinpointing the area or component affected.

2 Locate the red and yellow fault LEDs on the


ALC-500 circuit board inside the platform control
box. Do not touch the circuit board.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. If the circuit board
does need to be handled, maintain
firm contact with a metal part of
the machine that is grounded at all
times when handling the printed
circuit board OR use a grounded
wrist strap.

5-2

S-40 S-45

Part No. 102521

July 2007

Section 5 Fault Codes

FAULT CODES

REV A

Error Source
ID

21

22
23

31

32

Name
Boom 1 Joystick
(primary boom up/
down)

Boom 1 directional
valves

Boom 1 flow
control valve

Boom 2 Joystick
(secondary boom
up/down or
primary boom
extend/retract)

Boom 2 directional
valves

Error Type
ID
11
12
15
16

Name

17

Not calibrated

18

Just calibrated

21

Fault

12
15

Value too high


Value too low

17

Not calibrated

18

Just calibrated

11
12
15
16

Value at 5V
Value too high
Value too low
Value at 0V

17

Not calibrated

18

Just calibrated

21

Fault

Value at 5V
Value too high
Value too low
Value at 0V

Condition
Function is inoperative
until joystick is
calibrated. Alarm
sounds indicating
fault.
Function is inoperative
until joystick is
calibrated.
Initiate 1-second beep
of alarm.
Valve is operating
outside of operational
limits. Alarm sounds
indicating fault.
Valve is operating
outside of operational
limits. Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Joystick is operating
outside of operational
limits. Alarm sounds
indicating fault.
Function is inoperative
until joystick is
calibrated.
Initiate 1 second beep
of alarm.
Valve is operating
outside of operational
limits. Alarm sounds
indicating fault.

Solution
Cycle power off,
then on and
problem should be
corrected.
Calibrate joystick
Self-clearing.
(transient)
Cycle power off,
then on and
problem should be
corrected.
Cycle power off,
then on and
problem should be
corrected.
Calibrate valve
thresholds
Self-clearing.
(transient)
Cycle power off,
then on and
problem should be
corrected.
Calibrate joystick
Self-clearing.
(transient)
Cycle power off,
then on and
problem should be
corrected.

Continued on next page

Part No. 102521

S-40 S-45

5-3

Section 5 Fault Codes

July 2007

REV A

FAULT CODES

Error Source
ID

33

41

42

43

44

5-4

Name
Boom 2 flow
control valve

Turntable rotate
joystick

Error Type
ID

Name

12
15

Value too high


Value too low

17

Not calibrated

18

Just calibrated

11
12
15
16

Value at 5V
Value too high
Value too low
Value at 0V

17

Not calibrated

18

Just calibrated

21

Fault

12
15

Value too high


Value too low

17

Not calibrated

18

Just calibrated

21

Fault

Turntable rotate
directional valves

Turntable rotate
flow control valve

Drive enable
override switches

Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.

Solution
Power up
controller with
problem corrected.

Calibrate valve
thresholds.
Self-clearing.
(transient)

Limited speed and


direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Enable override
direction is frozen at
neutral.

S-40 S-45

Power up
controller with
problem corrected.

Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.

Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.

Part No. 102521

July 2007

Section 5 Fault Codes

FAULT CODES

REV A

Error Source
ID

51

53

54

55
61

62

Name
Drive joystick

Drive flow valve


(EDC)

Error Type
ID
11
12
15
16

Name
Value at 5V
Value too high
Value too low
Value at 0V

17

Not calibrated

18

Just calibrated

12
15

Value too high


Value too low

17

Not calibrated

18

Just calibrated

21

Fault

21

Fault

11
12
15
16

Value at 5V
Value too high
Value too low
Value at 0V

17

Not calibrated

18

Just calibrated

21

Fault

Drive brake valve

High speed drive


motor Valve

Steer joystick

Steer directional
valves

Part No. 102521

Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Motor speed frozen in
the low state. Alarm
sounds indicating
fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.

S-40 S-45

Solution
Power up
controller with
problem corrected.

Calibrate joystick
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Calibrate valve
thresholds
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.

Calibrate Joystick
Self-clearing.
(transient)
Power up
controller with
problem corrected.

5-5

Section 5 Fault Codes

July 2007

FAULT CODES

REV A

Ford LRG-425 EFI Engine


How to Retrieve Ford Engine
Fault Codes
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel
injection and make constant and instantaneous
changes to ignition timing, fuel delivery and throttle
position to maintain the engine's running condition
at its highest efficiency while at the same time
keeping exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of
set parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor and
will turn on the Check Engine Light.
Note: Perform this procedure with the key switch in
the off position.
1 Open the ground controls side cover and locate
the run/test toggle switch on the side of the
ground control box.

Note: If any fault codes are present, the ECM will


blink a three digit code three times for each code
stored in memory. It will blink the first digit of a
three digit code, pause, blink the second digit,
pause, and then blink the third digit. For example:
the check engine light blinks 5 consecutive times,
blinks 3 times and then 1 time. That would indicate
code 531.
Note: Once a fault code has been retrieved and the
repair has been completed, the ECM memory must
be reset to clear the fault code from the ECM. See
How to Clear Engine Fault Codes from the ECM.

How to Clear Engine Fault


Codes from the ECM
Note: Perform this procedure with the engine off
and the key switch in the off position.
1 Open the engine side turntable cover and locate
the battery.
2 Disconnect the negative battery cable from the
battery for a minimum of 5 minutes.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.

2 Pull out the red Emergency Stop button to the


on position at both the ground and platform
controls.
3 Quickly activate and release the start toggle
switch/button. Do not start the engine.
4 Move and hold the run/test toggle switch to the
test position.

3 Connect the negative battery cable to the


battery.

Result: The check engine light should turn on.


The check engine light should begin to blink.
5 Continue to hold the run/test toggle switch in the
test position and count the blinks.
Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three times.
After the fault codes, the check engine light will
blink a code 123 three times again indicating the
end of the stored codes.

5-6

S-40 S-45

Part No. 102521

July 2007

Section 5 Fault Codes

FAULT CODES

REV A

Code

Problem

Cause

Solution

111

Closed Loop Multiplier


High (LPG)

Heated Oxygen Sensor wiring and/or


connections open or shorted OR sensor is faulty
OR there are vacuum leaks or exhaust leaks.

Repair wiring and/or connections OR replace


sensor OR repair vacuum and exhaust leaks.

112

HO2S Open/Inactive
(Bank 1)

Heated Oxygen Sensor wiring and/or connections


open or shorted OR sensor is faulty.

113

HO2S Open/Inactive
(Bank 2)

Heated Oxygen Sensor wiring and/or connections


open or shorted OR sensor is faulty.

114

Post-cat oxygen
sensor open

The post cat Heated Oxygen Sensor wiring


and/or connections are open or shorted OR
sensor is cold, non-responsive or inactive for
60 seconds or longer.

Repair wiring and/or connections OR replace


the post cat oxygen sensor.

121

Closed Loop Multiplier


High (Gasoline)

Heated Oxygen Sensor wiring and/or


connections open or shorted OR sensor is
faulty OR there are vacuum leaks or exhaust
leaks OR fuel pressure is low OR the fuel
injectors need cleaning or replacing.

Repair wiring and/or connections OR replace


sensor OR repair any vacuum and exhaust leaks
OR test the fuel pressure OR clean or replace the
fuel injectors.

Closed Loop Multiplier


Low (Gasoline)

MAP, IAT or ECT sensors not in correct position


OR wiring and/or connections for sensors open
or shorted OR sensor is faulty OR one or more
fuel injectors are stuck open OR there is
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.

Adjust or replace sensors OR clean or repair


fuel injectors.

Heated Oxygen Sensor wiring and/or


connections open or shorted OR sensor is
faulty OR fuel quality is poor OR fuel system
components may be faulty.

Repair wiring and/or connections OR replace


sensor OR replace fuel OR test and repair the
fuel system components.

There are exhaust leaks OR the catalyst system


efficiency is below the acceptable level.

Repair exhaust leaks OR there is an emissions


compliance issue. Contact Ford Power Products
for assistance.

Adaptive Lean Fault High Limit (Gasoline)

Heated Oxygen Sensor wiring and/or


connections open or shorted OR sensor is
faulty OR there are vacuum or exhaust leaks
OR one or more fuel injectors faulty or stuck
closed OR fuel quality is poor OR fuel
pressure is too low.

Repair heated oxygen sensor wiring and/or


connections OR replace sensor OR repair
vacuum and exhaust leaks OR test the fuel
pressure OR clean or replace the fuel injectors.

142

Adaptive Rich Fault Low Limit (Gasoline)

MAP, IAT or ECT sensors not in correct position


OR wiring and/or connections for sensors open
or shorted OR sensor is faulty OR one or more
fuel injectors are stuck closed OR there is
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.

Adjust or replace sensors OR clean or repair


fuel injectors.

143

Adaptive Learn High


(LPG)

Heated Oxygen Sensor wiring and/or


connections open or shorted OR sensor is
faulty OR there are vacuum leaks or exhaust
leaks OR fuel quality is poor OR fuel system
components may be faulty.

Repair wiring and/or connections OR replace


sensor OR repair any vacuum and exhaust
leaks OR replace fuel OR test and repair the
fuel system components.

144

Adaptive Learn Low


(LPG)

Engine wire harness may have an intermittent


short to 5V DC or 12V DC OR fuel system
components may be faulty.

Repair short in engine wire harness


OR test and repair the fuel system
components.

122

124

Closed Loop Multiplier


Low (LPG)

133

Gasoline cat monitor

134

LPG cat monitor

135

NG cat monitor

141

Part No. 102521

S-40 S-45

Repair wiring and/or connections OR


replace sensor.

5-7

Section 5 Fault Codes

July 2007

FAULT CODES

Code

Problem

REV A

Cause

Solution

161

System Voltage Low

Battery is faulty OR alternator is not charging OR


battery supply wiring to ECM is open or shorted.

Replace battery OR repair alternator OR repair


battery supply wiring to ECM.

162

System Voltage High

Alternator is overcharging the battery when


engine RPM is greater than 1500 rpm.

Repair or replace the alternator.

211

IAT High Voltage

IAT sensor wiring and/or connections are open or


shorted OR sensor is faulty OR engine intake air
temperature is too cold.

Repair wiring and/or connections OR replace


sensor OR direct warmer air into air intake.

212

IAT Low Voltage

IAT sensor wiring and/or connections are open or


shorted OR sensor is faulty OR engine intake air
temperature is too hot.

Repair wiring and/or connections OR replace


sensor OR direct cooler air into air intake.

213

IAT Higher Than


Expected (1)

Air intake temperature is greater than 200 F with


the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.

214

IAT Higher Than


Expected (2)

Air intake temperature is greater than 210 F with


the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.

215

Oil Pressure Low

Faulty oil pressure sensor OR sensor wiring


and/or connections open or shorted OR engine
oil level too low.

Replace oil pressure sensor OR repair sensor


wiring and/or connections OR fill engine oil level
to specification.

221

CHT/ECT High Voltage

Engine cooling system is malfunctioning OR


sensor wires and/or connections open or shorted
OR sensor is faulty.

Repair engine cooling system problems OR


repair open or shorted wiring to sensor OR
replace sensor.

222

CHT/ECT Low Voltage

Engine cooling system is malfunctioning and


overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.

223

CHT Higher Than


Expected (1)

Coolant temperature at the cylinder head is 240 F.


Engine cooling system is malfunctioning and
overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.

224

CHT Higher Than


Expected (2)

Coolant temperature at the cylinder head is 250 F.


Engine cooling system is malfunctioning and
overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.

231

MAP High Pressure

Open or shorted wiring and/or connections to MAP


sensor OR sensor is faulty.

MAP Low Voltage

Open or shorted wiring and/or connections to MAP


sensor OR sensor is faulty.

BP High Pressure

MAP sensor is faulty OR ECM is faulty.

BP Low Pressure

MAP sensor is faulty OR ECM is faulty.

242

Crank Sync Noise

Crankshaft position sensor wiring and/or


connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.

243

Never Crank Synced


At Start

Crankshaft position sensor wiring and/or


connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.

244

Camshaft Sensor Loss

Crankshaft position sensor wiring and/or


connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.

232
234
235

5-8

Check air intake system for damage and proper


routing of air intake components OR replace the
IAT sensor.

Repair engine cooling system problems OR


repair open or shorted wiring to sensor OR
replace sensor OR fill engine coolant level to
specification.

Repair wiring and/or connections to sensor OR


replace MAP sensor.

Replace MAP sensor OR replace the ECM.

S-40 S-45

Be sure system ground connections are in place


and secure OR repair wiring and/or connections
to sensor OR replace sensor.

Part No. 102521

July 2007

Section 5 Fault Codes

FAULT CODES

REV A

Code

Problem

Cause

245

Camshaft Sensor Noise

Camshaft position sensor wiring and/or


connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.

Be sure system ground connections are in place


and secure OR repair wiring and/or connections
to sensor OR replace sensor.

253

Knock Sensor Open

Knock sensor wiring and/or connections open or


shorted OR sensor is faulty.

Repair wiring and/or connections to knock sensor


OR replace knock sensor.

254

Excessive Knock Signal

Knock sensor wiring and/or connections open or


shorted OR there is excessive engine vibration
OR sensor is faulty.

Check for excessive engine vibration OR repair


wiring and/or connections to knock sensor OR
replace knock sensor.

311

Injector Driver #1 Open

Open wiring and/or connections to fuel injector #1


OR fuel injector #1 is faulty OR ECM is faulty.

312

Injector Driver #1 Shorted

Wiring and/or connections to fuel injector #1 is


shorted OR fuel injector #1 is faulty OR
ECM is faulty.

313

Injector Driver #2 Open

Open wiring and/or connections to fuel injector #2


OR fuel injector #2 is faulty OR ECM is faulty.

314

Injector Driver #2 Shorted

Wiring and/or connections to fuel injector #2 is


shorted OR fuel injector #2 is faulty OR
ECM is faulty.

315

Injector Driver #3 Open

Open wiring and/or connections to fuel injector #3


OR fuel injector #3 is faulty OR ECM is faulty.

316

Injector Driver #3 Shorted

Wiring and/or connections to fuel injector #3 is


shorted OR fuel injector #3 is faulty OR
ECM is faulty.

321

Injector Driver #4 Open

Open wiring and/or connections to fuel injector #4


OR fuel injector #4 is faulty OR ECM is faulty.

322

Injector Driver #4 Shorted

Wiring and/or connections to fuel injector #4 is


shorted OR fuel injector #4 is faulty OR
ECM is faulty.

351

Fuel Pump Loop Open or


High Side Short to Ground

Open wiring and/or connections to fuel pump OR


fuel pump power shorted to ground OR fuel pump
is faulty.

352

Fuel Pump High Side


Shorted to Power

Wiring and/or connections to fuel pump shorted to


power OR fuel pump is faulty.

353

MegaJector Delivery
Pressure Higher Than
Expected

Fuel pressure too high OR LPG lockoff not opening


completely OR the line between the MegaJector
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly
OR MegaJector is faulty.

354

MegaJector Delivery
Pressure Lower Than
Expected

Fuel pressure too low OR LPG lockoff not opening


completely OR the line between the MegaJector
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly
OR MegaJector is faulty.

355

MegaJector
Communication Lost

The ECM doesn't get any response from the


MegaJector, or an incorrect response for 500ms
period or longer.

Check CAN circuits for continuity and shorts to


power or ground and for continuity and repair as
necessary OR replace the MegaJector.

361

MegaJector Voltage
Supply High

The MegaJector detects voltage greater than 18


volts for 5 seconds anytime the engine is cranking
or running.

Repair charging system OR replace the


MegaJector.

362

MegaJector Voltage
Supply Low

The MegaJector detects voltage less than 9.5 volts


for 5 seconds anytime the engine is cranking or
running.

Repair VBAT power or ground circuit to ECM and


MegaJector OR replace battery OR repair
charging system OR replace the MegaJector.

Part No. 102521

S-40 S-45

Solution

Repair wiring and/or connections to fuel injector #1


OR replace fuel injector #1 OR replace the ECM.

Repair wiring and/or connections to fuel injector #2


OR replace fuel injector #2 OR replace the ECM.

Repair wiring and/or connections to fuel injector #3


OR replace fuel injector #3 OR replace the ECM.

Repair wiring and/or connections to fuel injector #4


OR replace fuel injector #4 OR replace the ECM.

Repair wiring and/or connections to fuel pump OR


replace fuel pump.

Check fuel pressure OR repair LPG lockoff OR


repair the line between the MegaJector and
carburetor OR repair engine cooling system OR
replace the MegaJector.

5-9

Section 5 Fault Codes

July 2007

FAULT CODES

Code

REV A

Problem

Cause

363

MegaJector Internal
Actuator Fault Detection

The MegaJector detects an internal fault. Open or


short in power, ground or CAN circuits.

364

MegaJector Internal
Circuitry Fault Detection

The MegaJector detects an internal circuitry failure.


Open or short in power, ground or CAN circuits.

365

MegaJector Internal
Communication Fault
Detection

The MegaJector detects an internal


communications failure. Open or short in power,
ground or CAN circuits.

411

Coil Driver #1 Open

Open wiring and/or connections to ignition


coil #1 OR ignition coil #1 is faulty.

412

Coil Driver #1 Shorted

Wiring and/or connections to ignition coil #1


shorted OR ignition coil #1 is faulty

413

Coil Driver #2 Open

Open wiring and/or connections to ignition


coil #2 OR ignition coil #2 is faulty.

414

Coil Driver #2 Shorted

Wiring and/or connections to ignition coil #2


shorted OR ignition coil #2 is faulty

511

FPP1 High Voltage

512

FPP1 Low Voltage

513

FPP1 Higher than IVS Limit

Check Power, Ground and CAN circuits at


MegaJector and all connections and repair as
necessary OR MegaJector has an internal fault.
Contact Ford Power Products for assistance.

Repair wiring and/or connections to ignition


coil #1 OR replace ignition coil #1.

Repair wiring and/or connections to ignition


coil #2 OR replace ignition coil #2.

Not used.

If this fault appears on your machine, contact


the Genie Industries Service Department.

The #1 throttle position sensor wiring and/or


connections open or shorted OR there is a poor
system ground connection OR throttle position
sensor #1 is faulty.

Be sure system ground connections are in place


and secure OR repair wiring and/or connections
to sensor OR replace throttle position sensor #1.

The #2 throttle position sensor wiring and/or


connections open or shorted OR there is a poor
system ground connection OR throttle position
sensor #2 is faulty.

Be sure system ground connections are in place


and secure OR repair wiring and/or connections
to sensor OR replace throttle position sensor #2.

The throttle position sensor wiring and/or


connections for either TPS1 or TPS2 open or
shorted OR there is a poor system ground
connection OR one or both throttle position
sensors are faulty.

Be sure engine harness wiring and connections


are in place and secure OR repair wiring and/or
connections to one or both TPS sensors OR
replace one or both TPS sensors.

514

FPP1 Lower than IVS Limit

521

FPP2 High Voltage

522

FPP2 High Voltage

531

TPS1 (Signal Voltage) High

532

TPS1 (Signal Voltage) Low

533

TPS2 (Signal Voltage) High

534

TPS2 (Signal Voltage) Low

535

TPS1 Higher than TPS2

536

TPS1 Lower than TPS2

537

Throttle Unable to Open

Governor actuator is stuck closed OR wiring


and/or connections open or shorted OR
governor actuator is faulty.

538

Throttle Unable to Close

Governor actuator is stuck open OR wiring


and/or connections open or shorted OR
governor actuator is faulty.

545

Governor Interlock Failure

Engine harness wiring and/or connections open


or shorted OR there is a poor system ground
connection OR ECM is faulty.

5 - 10

Solution

S-40 S-45

Repair wiring and/or connections to governor


actuator OR replace the governor actuator.

Repair wiring and/or connections in engine


harness OR replace the ECM.

Part No. 102521

July 2007

Section 5 Fault Codes

FAULT CODES

REV A

Code

Problem

551

Max Governor Speed


Override

552

FPP1 Low Voltage

553

FPP1 Higher than IVS Limit

611

COP Failure

612

Invalid Interrupt

613

A/D Loss

614

RTI 1 Loss

615

Flash Checksum Invalid

616

RAM Failure

631

External 5V DC Ref
Lower than Expected

632

External 5V DC Ref
Higher than Expected

655

RTI2 Loss

656

RTI3 Loss

Part No. 102521

Cause

Solution

ECM needs to be re-programmed OR throttle is


sticking open OR there are air leaks between the
throttle body and cylinder head.

Re-program ECM OR repair binding throttle


operation OR repair any air leaks between the
throttle body and cylinder head.

Loose wire connections to ECM OR ECM is faulty.

Locate and repair any engine harness wiring


damage or shorts to ECM to be sure they are
secure OR replace ECM.

Engine harness wiring and/or connections open


or shorted to ground OR there is a faulty engine
sensor OR ECM is faulty.

Locate and repair any engine harness wiring


damage or shorts OR locate and troubleshoot or
repair faulty engine sensor OR replace ECM.

Loose wire connections to ECM OR ECM is faulty.

Locate and repair any engine harness wiring


damage or shorts to ECM to be sure they are
secure OR replace ECM.

S-40 S-45

5 - 11

Section 5 Fault Codes

July 2007

FAULT CODES

REV A

Ford DSG-423 EFI Engine


How to Retrieve Ford Engine
Fault Codes
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also
uses signals from the sensors to initiate
sequential fuel injection and make constant and
instantaneous changes to ignition timing, fuel
delivery and throttle position to maintain the
engine's running condition at its highest efficiency
while at the same time keeping exhaust
emissions to a minimum. When a sensor fails or
returns signals that are outside of set
parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor
and will turn on the Check Engine Light.
Note: Perform this procedure with the key switch
in the off position.
1 Open the ground controls side cover and
locate the run/test toggle switch on the side of
the ground control box.

Note: If any fault codes are present, the ECM will


blink a three digit code three times for each code
stored in memory. It will blink the first digit of a
three digit code, pause, blink the second digit,
pause, and then blink the third digit. For example:
the check engine light blinks 5 consecutive
times, blinks 3 times and then 1 time. That would
indicate code 531.
Note: Once a fault code has been retrieved and
the repair has been completed, the ECM memory
must be reset to clear the fault code from the
ECM. See How to Clear Engine Fault Codes from
the ECM.

How to Clear Engine Fault


Codes from the ECM
Note: Perform this procedure with the engine off
and the key switch in the off position.
1 Open the engine side turntable cover and
locate the battery.
2 Disconnect the negative battery cable from
the battery for a minimum of 5 minutes.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

2 Pull out the red Emergency Stop button to the


on position at both the ground and platform
controls.
3 Quickly activate and release the start toggle
switch/button. Do not start the engine.

3 Connect the negative battery cable to the


battery.

4 Move and hold the run/test toggle switch to


the test position.
Result: The check engine light should turn on.
The check engine light should begin to blink.
5 Continue to hold the run/test toggle switch in
the test position and count the blinks.
Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three
times. After the fault codes, the check engine
light will blink a code 123 three times again
indicating the end of the stored codes.

5 - 12

S-40 S-45

Part No. 102521

July 2007

Section 5 Fault Codes

FAULT CODES

REV A

Code

111
112
113
114
115
121
122
124
133
134
141
142
143
144
161
162
163
164
165
166
167
168
171
172
173
174
181
182
183
184
185
186
211

Description
CL (closed loop) high LPG
EGO open / lazy pre-cat 1
EGO open / lazy pre-cat 2/post-cat 1
EGO open / lazy post-cat 1
EGO open / lazy post-cat 2
CL (closed loop) high gasoline bank 1
CL (closed loop) low gasoline bank 1
CL (closed loop) low LPG
Gasoline catalyst monitor 1
LPG catalyst monitor
AL (adaptive learning) high gasoline bank 1
AL (adaptive learning) low gasoline bank 1
AL (adaptive learning) high LPG
AL (adaptive learning) low LPG
Battery voltage high
Battery voltage low
AUX analog PD1 high
AUX analog PD1 low
AUX analog PU3 high
AUX analog PU3 low
AUX analog PUD1 high

Code

212
213
214
215
221
222
223
224
225
226
231
232
234
235
242
243
244
245
246
253
254

Description
IAT (intake air temperature) low voltage
IAT (intake air temperature) higher than expected 1
IAT (intake air temperature) higher than expected 2
Oil pressure low
ECT/CHT (engine/cylinder head temp) high voltage
ECT/CHT (engine/cylinder head temp) low voltage
CHT higher than expected 1
CHT higher than expected 2
ECT higher than expected 1
ECT higher than expected 2
MAP (manifold absolute pressure) high pressure
MAP (manifold absolute pressure) low pressure
BP (barometric pressure) high pressure
BP (barometric pressure) low pressure
Crank sync noise
Never crank synced at start
Cam loss
Cam sync noise
Crank loss
Knock 1-2 sensor open 1
Knock 1-2 excessive signal 1

AUX analog PUD1 low


AUX analog PUD2 high
AUX analog PUD2 low
AUX analog PUD3 high
AUX analog PUD3 low
AUX DIG1 high
AUX DIG1 low
AUX DIG2 high
AUX DIG2 low
AUX DIG3 high
AUX DIG3 low
IAT (intake air temperature) high voltage

Part No. 102521

S-40 S-45

5 - 13

Section 5 Fault Codes

July 2007

FAULT CODES

Code

261
262
271
272
273
274
311
312
313
314
315
316
321
322
351
352
353
354
355
359
361
362
363
364
365
411
412
413
414
415
416
421
422

5 - 14

REV A

Description

Code

FP (fuel pressure) high voltage


FP (fuel pressure) low voltage
FT (fuel temperature) gasoline high voltage
FT (fuel temperature) gasoline low voltage
FT (fuel temperature) gaseous fuel high voltage
FT (fuel temperature) gaseous fuel low voltage
Injector loop open OR low-side short to ground 1
Injector coil shorted 1
Injector loop open OR low-side short to ground 2
Injector coil shorted 2
Injector loop open OR low-side short to ground 3
Injector coil shorted 3
Injector loop open OR low-side short to ground 4
Injector coil shorted 4
FPump motor loop open OR high-side shorted to ground
Fpump motor high-side shorted to power
EPR delivery pressure higher than expected
EPR delivery pressure lower than expected
EPR comm lost
Fuel run-out longer than expected
EPR voltage supply high

531
532
533
534
535
536
537
538
539
541
542
543
544
551
552
553
611
612
613
614
615

Description
TPS1 (throttle position sensor) high voltage
TPS1 (throttle position sensor) low voltage
TPS2 (throttle position sensor) high voltage
TPS2 (throttle position sensor) low voltage
TPS1 (throttle position sensor) higher than TPS2
TPS1 (throttle position sensor) lower than TPS2
Unable to reach higher TPS (throttle position sensor)
Unable to reach lower TPS (throttle position sensor)
TPS 1-2 simultaneous voltages
AUX analog PU1 high
AUX analog PU1 low
AUX analog PU2 high
AUX analog PU2 low
Max govern speed override
Fuel rev limit
Spark rev limit
COP failure
Invalid interrupt
A/D loss
RTI 1 loss
Flash checksum invalid

EPR voltage supply low


EPR internal actuator fault detection
EPR internal circuitry fault detection
EPR internal comm fault detection
Primary loop open OR low-side short to ground 1
Primary coil shorted 1
Primary loop open OR low-side short to ground 2
Primary coil shorted 2
Primary loop open OR low-side short to ground 3
Primary coil shorted 3
Primary loop open OR low-side short to ground 4
Primary coil shorted 4

S-40 S-45

Part No. 102521

July 2007

Section 5 Fault Codes

FAULT CODES

REV A

Code

616
631
632
633
634
635
641
642
643
644
646
647
648
655
656
711
712
713
714
715
716
721
722
723
731
732
733
734
735
736
741
742
743

Description
RAM failure
5VE1 low voltage
5VE1 high voltage
5VE2 high voltage
5VE2 low voltage
5VE1-5VE2 simultaneous out-of-range
Rx inactive
Rx noise

Code

744
761
762
763
771
772
1629
1630

Description
PWM5 short to power
MIL (malfunction indicator light) control ground short
MIL (malfunction indicator light) open
MIL (malfunction indicator light) control short to power
Tach output ground short
Tach output short to power
J1939 TSC1 message receipt lost
J1939 ETC message receipt lost

Invalid packet format


Shutdown request
CAN Tx failure
CAN Rx failure
CAN address conflict failure
RTI 2 loss
RTI 3 loss
Relay control ground short
Relay coil open
Relay coil short to power
Fpump relay control ground short
Fpump relay coil open
Fpump relay coil short to power
Start relay control ground short
Start relay coil open
Start relay coil short to power
PWM1-gauge1 open / ground short
PWM1-gauge1 short to power
PWM2-gauge2 open / ground short
PWM2-gauge2 short to power
PWM3-gauge3 open / ground short
PWM3-gauge3 short to power
PWM4 open / ground short

For further engine fault code troubleshooting and


diagnostic information, refer to the Ford DSG-423
EFI Service Manual (EDI part number 1060040).
Genie part number 119494.

PWM4 short to power


PWM5 open / ground short

Part No. 102521

Ford DSG 423 EFI Operator Handbook


Genie part number

S-40 S-45

119488

5 - 15

Section 5 Fault Codes

July 2007

This page intentionally left blank.

5 - 16

S-40 S-45

Part No. 102521

July 2007

Section 6 Schematics

Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics

Observe and Obey:

Electrocution/burn hazard. Contact


with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.

Troubleshooting and repair procedures shall be


completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.

Hydraulic Schematics
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

Repair any machine damage or malfunction


before operating the machine.

Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-40 & Genie S-45 Operator's Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.

General Repair Process

Identify
symptoms

Malfunction
discovered

Troubleshoot

problem
still exists

Return to
service

Part No. 102521

S-40 S-45

problem
solved

Inspect
and test

Perform
repair

6-1

Section 6 Schematics

July 2007

Electrical Symbols Legend


REV A

FS1

BLK

BLK
P3

WHT

Quick disconnect
terminal

N.O.H.C

Coil
solenoid or relay

N.C.H.O

Limit switch

Horn button
normally open
P1

KS1

TB21

WHT #21

Foot switch

LS3

PLATFORM

OTS2
N.O.

GROUND

T-circuits connect
at terminal

H1

Horn or alarm
T-circuits
connect

Key switch

(before serial number 22051)

Oil temperature
switch
normally open

Emergency Stop
button normally
closed

FAN

FB

PR1

CTS1
N.O.

Flashing beacon

Power relay
Coolant temperature
switch
normally open

Connection
no terminal
G1

TS2

START

ENGINE

Gauge

Aux
Pump

Auxiliary pump
OPS1
N.C.

Circuits crossing
no connection

510
HM

Diode

Hydraulic oil
cooling fan

Toggle switch SPDT

Oil pressure switch


normally closed

Resistor with
ohm value

Hour meter
TS6

PLATFORM LEVEL

LED

KS1

25A
CB1
15A

Fuse
with amperage

CR4
N.O.

Circuit breaker
with amperage
Control relay contact
normally open
Starting aid:
glow plug or
flame ignitor

6-2

Tilt sensor

Toggle switch DPDT


B

C
HOLD

F1

Gauge sending unit

PULL IN

Battery

UP

DOWN

L3

Key switch

(after serial number 22050)

Fuel or RPM
solenoid

Coil

S-40 S-45

Part No. 102521

July 2007

Section 6 Schematics

Hydraulic Symbols Legend


REV A

25 psi
(1.7 bar)

.035"
(0.89 mm)

Orifice with size


Solenoid operated 3 position,
4 way, directional valve

Filter with
bypass valve
relief setting

Solenoid operated
3 position, 4 way,
proportional directional valve

Check valve
200 psi
(13.8 bar)

Pump
fixed displacement

Relief valve
with pressure setting

2 position, 3 way, shuttle valve

Priority
flow regulator valve

o
Brake

Pump
bi-directional,
variable displacement

Directional valve
(mechanically activated)

Solenoid operated 2 position,


3 way, directional valve
3000 psi
(206.8 bar)
3:1

Needle valve
50%

Motor
bi-directional

Motor
2-speed,
bi-directional

50%

Flow divider/combiner valve


with pressure balancing orifice
and flow percentages

Counterbalance valve
with pressure and pilot ratio

Pilot operated 3 position,


3 way, shuttle valve
2 position, 2 way
solenoid valve

E
Pump prime mover
(engine or motor)

Differential
sensing valve

Directional valve
pilot operated
2 position, 2 way

Double acting
cylinder

Solenoid operated
proportional valve

Part No. 102521

S-40 S-45

6-3

Section 6 Schematics

July 2007

REV A

Ford DSG-423 Engine Relay Layout

Starter
Relay

Fuel
Pump
Relay

Power
Relay

Empty

F1-10A

F2-5A

F3-10A

F4-15A

F5-15A

6-4

S-40 S-45

Part No. 102521

July 2007

Section 6 Schematics

REV A

Connector Pin Legend

C1P DT06-12SA

C7: DTP06-4S

C1

CKT #

PIN #
1

BK

P22BAT

RD/BK

C28TTA

WH

P23SWBAT

RD/WH

C29MS

BRN

BATGND

WH

C30EDC+

N/A

PLUG

WH/BK

C31EDC-

WH/RD

C32BRK

BK

C33STR

BK/WH

C34SA

BK/RD

C35ESPD

BL

C36STC

10

BL/BK

C37STCC
C132PLI

11

BL/WH

CKT #

OR

C40LS1

OR/BK

C41RPM

3
4

GR

C134PWR
C43HRN

GR/BK

JDALARM

GR/WH

C45GEN

PLUG

PLUG

PLUG

10

PLUG

11

PLUG

12

CKT #
C1PBU

C2PBD

RD/WH

C3PBF

WH

C4TRL

WH/BK

C5TRR

WH/RD

C6TRF

BK

C7PBE

BK/WH

C8PBR

BK/RD

BL/BK

DRVLT
PLUG
PLUG

BL/WH

PLUG

GREEN

COLOR

CIRCUIT #

COLOR

RD

C1PBU
C2PBD

RD

3
4

C3PBF
C4TRL

RD/WH

RD/WH

WH

C3PBF
C4TRL

C5TRR

WH/BK

C5TRR

WH/BK

C6TRF

WH/RD

C6TRF

WH/RD

C7PBE

BK

C7PBE

BK

8
9

C8PBR

BK/WH

C8PBR

BK/WH

RD/BK

RD/BK
WH

10

C13DRE
C14PLU

BL/RD
OR

C13DRE
C14PLU

C15PLD

OR/BK

C15PLD

OR/BK

R43HRN

BK

R43HRN

BK

C17JU
C18JD
C2DA

GR
GR/BK
RD/BK

C17JU
C18JD
C2DA

GR
GR/BK
RD/BK

CKT #

C134PWR

RD

C134PWR

RD

25

C116HYD

BK

26

GND
C27AUX

BR
RD

C27AUX

RD

RD/BK

C28TTA

RD/BK

C28TTA

30

P46PWR

BL/WH

P46PWR

BL/WH

C32TA

WH/RD

32

C32TA

WH/RD

33

R116HYD

OR

OR

34

R21IGN

WH

OR/BK

C15PLD

35

OR/RD

C133PLA

GR

C17JU

GR/BK

C18JD

38

GR/WH

C19JSV

PLUG

PLUG

PLUG

10

PLUG

11

PLUG

12

C39LP
TB23

BL/RD
WH

C38ESL

BL/WH

C21IGN

WH

C31EDC
C30EDC
C34SA
C32BRK
C29MS

WH/BK
WH
BK/WH
WH/RD
RD/WH

COLOR

FORD

COLOR

PERKINS

COLOR

C4
BROWN

DEUTZ

OR/BK
WH

C41RPM
C107AF

OR/BK
WH

C41RPM
C107AF

OR/BK
WH

C41RPM
C107AF

BK
RD

R33STR
R27AUX

BK

R33STR

BK

R33STR

WH
BK/RD
BL/RD
WH(12)
GR
BL/WH
WH/RD

R21IGN
C35RPM
C39LP
VSW
C127TST
C38ESL
C26TSR

BK/RD

C35RPM

BK/RD

C35RPM

WH/RD

TSWITCH

WH/RD

TSWITCH

WH/BK
WH

C25PSR
C21IGN

WH/BK

PSWITCH

WH/BK

PSWITCH

WH/BK
WH

C31EDC
C30EDC

WH/RD
RD/WH

C32BRK
C29MS

WH/BK
WH
BK/WH
WH/RD
RD/WH

C31EDC
C30EDC
C34SA
C32BRK
C29MS

WH/BK
WH
BK/WH
WH/RD
RD/WH

C31EDC
C30EDC
C34SA
C32BRK
C29MS

C9 FS DT04-4P

29

C13DRE
C14PLU

BL/RD

OR/BK
WH

C41RPM
C107AF

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

C9

24

28

C4
PIN #

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

21
22

31
COLOR

BL/RD
OR

16
17
18
19
20

27

12

15

23

11

C4P DT06-12SD

CIRCUIT #

13
14

C3

COLOR

12

PIN #

RD

C6-FUNCTION HARNESS

10
11

C3

RD/BK

BL

BLACK

C6-GBOX

C1PBU
C2PBD

1
2

C3P DT06-12SC
COLOR

C6

C2

* NOTE: WIRE ONLY IN C7B CONNECTOR.

PIN #

C39LP

C5-ENGINE HARNESS
CKT#

PIN#

C2

C5-GBOX
PIN#

12

BL/RD

OR/RD

GRAY

C7

C2P DT06-12SB
COLOR

C1

C7

C27AUX

COLOR

CKT # PIN #

RD

COLOR

36

C36STC

BL

C36STC

BL

37

C37STCC

BL/BK

C37STCC

BL/BK

39

C45GEN

GR/WH

C45GEN

GR/WH

40

C40LS1

OR

C40LS1

OR

COLOR

CKT #

PIN #

BK

P26BAT

WH

P24BAT

RD

P25BAT

N/C

Part No. 102521

S-40 S-45

6-5

July 2007

Section 6 Schematics

Connector Pin Legend

6-5
6-6

Section 6 Schematics

July 2007

Electrical Schematic
Deutz F3L 1011F Models (before serial number 7544)

6-8
6-7

July 2007

Section 6 Schematics
REV B

Electrical Schematic
Deutz F3L 1011F Models (before serial number 7544)
A

1
RD/BK
TB41

C2-3

OR/BK

P26ESTP BK

LS18

P2

FS1
BK-(FS)

C9-1 BK

C9-3 P25FS RD
C9-2 P24FS WH

RD-(FS)
WH-(FS)

TS2

SEE NOTE 2

TS17

ON GLOW
PLUG

TS4

SEE NOTE 2

C2-7

C1-8

C1-9

TB43

TB45

RD
RD

C35ESPD BK/RD

LOW RPM
FUNCTION ENA.
HIGH RPM

TB34
TB35
L5
BK/RD

8
9
10

TS55

C6-39

CR2
NO

START RELAY
TACHOMETER
START INPUT
IGN./START
AUX. ON
GROUND
MODULE
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT

C45GEN GR/WH

CR2

CR1

CR1
NO

1
2
3
4
5
6

C34SA BK/WH

CR5

TB24

C6-28

CR5
NO

20AMP.

C6-23

CB3

ON GLOW
PLUG BK

RD

D6

TB28

TS56

TB33

TB23
TB133

START BK

L45

H6

15AMP.

ENGINE

RD

CB1
TB20

PUMP
AUXILARY

TB27

TS52

C33STR BK

TS51

RD

7
8

12

C27AUX RD

U33

P23BAT WH

C28TTA RD/BK

PLAT
GRD

C133PLA OR/RD

C43HRN GR

KS1 TB22

HIGH RPM(FS)

L24
C1-7

ENGINE

C1-1

C7-2

C1-2

C4-4

C2-5

C7-1

GENERATOR

TS1

L48
D40

TS6

START

D39

PUMP AUXILIARY

P3
HORN

L4
H1

TB132

TB134

RD

P22BAT BK

C2-4

RD

C1-12

P1
RD

C132PLI BL/WH

CB2
15AMP.

C134PWR OR/RD

C41RPM OR/BK

WH

C28TTA RD/BK

RD

TB 134 IS WAGO TERMINAL BLOCK 42


TB 133 IS WAGO TERMINAL BLOCK 16
TB 132 IS WAGO TERMINAL BLOCK 38

BK

TB21

OPS

OTS

NC

NO

CR3

NO CR4
BK/RD-C5-8

G1

GR/WH-45

C5-22

HM

NO

PR2

C5-14

G3

WH-24

C5-16
WH/BK

STARTER

TB26
PR2
NO

PR1

PR1
NO

AUX
PUMP

BK
BRN

C6-26

BRN
HIGH IDLE RELAY

HIGH RPM SOLENOID

GENERATOR
OPTION

GLOW PLUG OPTION

Part No. 102521

WATER TEMP GAUGE

S-40 S-45

WATER TEMP
SWITCH

+
-

2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

OIL PRESSURE
SWITCH

NOTE:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
IN THE STOWED POSITION AND KEYSWITCH "OFF".

OIL PRESSURE GAUGE

FUEL RELAY

VOLT METER

HOUR METER

IGN./START RELAY

STARTER MOTOR

AUXILIARY POWER
RELAY

AUXILIARY PUMP

LEVEL SENSOR

TILT ALARM

FLASHING BEACONS
OPTION

SERVICE HORN

SERVICE HORN
RELAY

HYDRAULIC OIL
TEMP. SWITCH

COOLING FAN
(OPTION)

6-8

C5-15

G2

WH-21

BK-33

RD-27

FB
H2

REGULATOR

C5-5

C6-27

WH

RD

STA.

IND.

TB25

BK-43

CR17

FAN

RD/BK-28

RD-134

C6-16

C6-25

BAT.
-

CR17
NO
C6-33

BAT.
+

C6-34

EXCT.
12 V
DC

OR/BK-41

ALTERNATOR

C5-2

C5-3

OTS
NO

DRE LED BL/RD


DRE B BL/BK

DRE A BL/WH

12

13

14

10

11

17

18

20

19

16

15

C41RPM OR/BK

15

8
16
7

WH

RKOUT 6

2
1
11
12

14

13

OR
BRN

BL

4
PWR 3

GND 2

RD

OR

BK

YOUT 5
XOUT 4
BRN

GND 2

PWR 3

BRN
P24FS WH

C1P-6

C1P-5

C1P-4

C37STCC BL/BK

C32BRK WH/RD

C31EDC- WH/BK

C30EDC+ WH

BRN-2

C1P-11
C36STC BL

C2P-3

C1P-10

LEFT
TROTATE
RIGHT

C4TRL WH

C5TRR WH/BK

7.5

C6TRF WH/RD

RD

C3P-6

RD

C3P-5
C3P-4

C3P-1
C3P-2
C3P-3

C4P-1

UP
PRIMARY
DOWN BOOM

C1PBU RD
C2PBD RD/BK
C3PBF RD/WH

C13DRE BL/RD

C40LS1 OR

C5-21
C5-20
C6-32
C5-23

C6-37
C6-36

C6-4
C6-5
C6-6

C6-1
C6-2
C6-3

C30EDC+ WH
A

C31EDC- WH/BK D

C32BRK WH/RD

C37STCC BL/BK
C36STC BL

C4TRL WH
C5TRR WH/BK
C6TRF WH/RD

C1PBU RD
C2PBD RD/BK
C3PBF RD/WH

C13DRE BL/RD

C6-19 RD/BK

C6-13

C15PLD OR/BK

C14PLU OR

C8PBR BK/WH

C7PBE BK

C40LS1 OR

C6-40

C6-7
C6-8

C6-14
C6-15

7
BK

WH

BK

WH

BK

WH

H3

GROUND

DRIVE EDC FORWARD

LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH

TRAVEL ALARM OPTION

DRIVE EDC REVERSE

BRAKE RELEASE VALVE

STEER RIGHT
STEER LEFT

TURNTABLE ROTATE LEFT


TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM
FLOW CONTROL

LS1-PRIMARY BOOM EXTEND


DRIVE LIMIT SWITCH

DESCENT ALARM OPTION

DRIVE ENABLE
LIMIT SWITCH

BOOM EXTEND
BOOM RETRACT

PLAT LEVEL UP
PLAT LEVEL DOWN

PLATFORM ROTATE RIGHT / JIB DOWN


PLATFORM ROTATE LEFT / JIB UP

JIB VALVES

6-9
S-40 S-45
Part No. 102521

H4
SJ1-WH
C18JD GR/BK

NOTE:

P24FS WH
3

C2P-2

EXTEND
BOOM

PLATFORM
LEVEL

C15PLD OR/BK

C14PLU OR

C8PBR BK/WH

C7PBE BK

RETRACT

UP
DOWN

C6-18

C17JU GR

NONC

1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED

C3P-7
C3P-8

JDALARM GR/BK

C18JD GR/BK
C17JU GR

C6-17

NOHC

POSITION EXCEPT AS NOTED.

P26ESTP BK

RETRACT

EXTEND BOOM

C4P-2

C2P-6

PLATFORM
UP
DOWN LEVEL C4P-3

GR/BK-44

C4P-6
DOWN JIB
BOOM C4P-5
UP

DOWN
UP JIB BOOM

JIB BOOM

TB7

8
NOHC
BRN

6
5

C6-30

TB22
1

Deutsch

LEFT

RIGHT

RIGHT PLAT
LEFT ROTATE

3
2

TB3 TB2 TB6

TB31
TB32
TB36

TB30
TB37
TB5
C19JSV GR/WH

2
5

AMP

Joystick Adaptor Harness

GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
1

5
TB8

TB14
TB15
TB18
TB17

TS62
TS61

TB4

TB1
TB13

3
C4P-7

TS57

J2

4
TS63
TS59
TS58

TB40

R2
R1

YOUT 5

PRI UP/DN & TT ROTATE

J1
J1

J1
J3

CR30
NO

JIB VALVE

C19JSV GR/WH

TS13

JOYSTICK CONTROL CARD

DRIVE & STEERING

JC3
JC2
WH

2
CR27
NC

CR13
NC
CR13

CE
LIFT/
DRIVE
OPTION

L1
TS15
WH
WH

TS9
TS8
TS7

TB44
TB19

Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
6

Electrical Schematic
REV B

1
A
B
C
D
E
F
G
H
I
J
K
L
M
N

Section 6 Schematics
July 2007

Deutz F3L 1011F Models (before serial number 7544)

RD/BK
OR/BK
BK

BRN

July 2007

Section 6 Schematics

Electrical Schematic
Deutz F3L 1011F Models (before serial number 7544)

6-9
6 - 10

July 2007

Section 6 Schematics

REV A

Ground Control Box Wiring Diagram


Deutz F3L 1011F Models

K
RD-H6+ - C23-1
BL/WH-38D - C23-3
BK-22C - C23-4
BK-C7-1 - C23-5
RD-TS51 - C23-6
RD-TS55 - C23-7
GN/BK-16B - C23-8
BR - GND - C23-12

12 V
C7B
C1B C2B C3B C4B

BK-CR1#86
OR/BK-41B
BK-33D
RD-27B
BR-GND.
RD-CR2#30
WH-23B

RD-KS1-2 S.P.

BK/RD-S.P.
BK/WH-S.P.
BK-S.P.

BK/RD CR3-#30
BK-ISM#3
WH/RD-C6-32

D6

RD-ISM#4
RED-CR1#30
WH-ISM #7
BK-CR5#30
WH-CR2#87
CB2-SP

GN/BK-C23-8

RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
CB1 - SP
GR/WH-SP
GR/BK-S.P.
GR-S.P.
GN/BK-H6OR/BK-S.P.
OR-S.P.

BK/RD-CR23#87

BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
44B+RD/BK-C6-19 RD/BK-S.P.
RD-S.P.

B
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
5 GROUND
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT

IGN./START
MODULE

CR2

RD C4B-11

BR (GROUND)

RD C4B-12
BRN GND

BK-22A

P1
RD-CB2

KEY SWITCH
KS1

NC
WH-23A
RD-42A
RD-27A
RD-C23-6

TS51

NC

LABEL

DESCRIPTION

1
B1

EMERGENCY STOP BUTTON

KEY SWITCH
AUXILIARY SWITCH
ENGINE START SWITCH

RD-H6+
OR/RD-H6-

FUNCTION ENABLE
PLATFORM ROTATE SWITCH

WH-21A

HM

BR (GROUND)

PLATFORM LEVEL SWITCH


BOOM EXTEND/RETRACT SWITCH
PRIMARY BOOM UP/DOWN SWITCH
TURNTABLE ROTATE SWITCH
JIB BOOM UP/DOWN SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, OPTIONS, 20A
RESISTOR, 5 OHM, BOOM FUNCTION

L45
L2

BL/WH-C5-15
BL/WH-ISM#10
RD/WH-3A
RD/BK-2A
RD-1A

TS61

TS63

BK/WH-8A
BK-7A
GR/BK-44A
BK-33A

TS52

CB3

BK/WH-34A

TS58

CB1

CB2

TS55

RD- 20A

P1
KS1
TS51
TS52

P1
KS1
42730
13037

TS55

13037
16397
13037
13037
16397
16397
13037

TS57
TS59
TS63
TS61
TS62
TS58
CB1
CB2
CB3
R1

VOLT METER GAGE


OIL PRESSURE GAGE
OIL TEMP. GAGE

R2
G1
G2
G3

R2
G1
G2
G3

STARTER AID

L28

56298

HOUR METER
IGN. START RELAY
IGN. POWER RELAY
HIGH IDLE (RPM) CUTOUT RELAY

HM
CR1
CR2
CR3

HM
CR1
CR2
CR3

RPM RELAY

CR4

CR4

CR17

CR17

COOLING FAN RELAY


PLATFORM OVERLOAD ALARM
PLAT OVERLOAD MODULE
PLAT OVERLOAD LED

TS59

PART #

CB1
CB2
CB3
R1

RESISTOR, 7.5 OHM,TURNTABLE FUNCTION

TS62

TS56
RD- 20C
RD-CR17#30
WH-4
WH/RD-6
WH/BK-5

D13

BK-ISM#1

WH/BK-25A
WH/RD-26A

BK/RD-35A
CR5

BK/RD-9B

WH-21A

TS57

CR17

CR23

RD-C23-7

BK-C6-25

G3

G2

G1

R2

BK-22B
GR-43D

RD-CB3 SP

D14

RD-CB3 SP
CR1

H6

LIMIT SWITCH POWER


GEN. OPTION
JDALARM JIB
HORN
C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
C132PLI
STEER LEFT
STEER RIGHT
RPM
GLOW PLUG
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
SPARE
TILT ALARM
AUX. PWR.
WATER TEMP. SENDER
OIL PRESSURE SENDER
ENGINE POWER
KEYSWITCH PWR/FB
PWR. TO PLAT.
IGNITION PWR.
12 VOLT BATTERY POWER
JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.
C133PLA
PLAT. LEVEL DN.
PLAT. LEVEL. UP
DRV. ENA. LT.

DRIVE LIGHT OPTION


BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP

DRIVE LIGHT OPTION RELAY

GN/BK-16A

BL/RD-S.P.

RD-ISM#6
WH-ISM#9
RD-24B

C6

GN/BK-L45-

GR/BK-S.P.

GR/BK-2B
GR-CR5#86
RD-H6+
OR/BK-ISM#2

WH-CR2#86
BL/WH-L2

H6
U33
L45

RD- 24A

BK-C5-5

C5

19/18 CABLES
FUNCTIONS
ENGINE

RD-C23-1
RD-42B

R1

GROUND STUD

46
GR/WH-C2B-7 45
GR/WH-C6-39
GR/BK-C2B-6 44
43
GR-C2B-5
OR/RD-C2B-4 42
RD-C6-23
OR/BK-C2B-3 41
OR/BK-C5-2
40
OR-C2B-2
OR-C6-40
BK/WH-C5-10
BL/RD-C2B-1 39
BL/WH-C23-3
BL/WH-C1B-12 38
BL/BK-C6-37
BL/BK-C1B-11 37
36
BL-C6-36
BL-C1B-10
BK/RD-C1B-9 35
BK/WH-C5-22
BK/WH-C1B-8 34
33
BK-C1B-7
WH/RD-C5-23
WH/RD-C1B-6 32
WH/BK-C5-20
WH/BK-C1B-5 31
30
WH-C5-21
WH-C1B-4
RD/WH-C1B-3 29
RD/BK-C6-28
RD/BK-C1B-2 28
27
RD-C6-27
RD-C1B-1
26
WH/RD-C5-14
25
WH/BK-C5-16
24
RD-C5-1
23
RD-C5-19
WH-C7B-2
22
BL/WH-C6-30
BK-C23-4
21
WH-C5-3+C5-11 WH-C6-34
20
CB3-SP
RD- 12VOLT
GR/WH-C4B-7 19
GR/BK-C6-18
GR/BK-C4B-6 18
17
GR-C6-17
GR-C4B-5
OR/RD-C4B-4 16
OR/BK-C6-15
OR/BK-C4B-3 15
14
OR-C6-14
OR-C4B-2
BL/RD-C6-13
BL/RD-C4B-1 13
BL/WH-C3B-12 12
BL/BK-C3B-11 11
BL-C3B-10
10
BK/RD-C3B-9 9
BK/WH-C6-8
BK/WH-C3B-8 8
7
BK-C6-7
BK-C3B-7
WH/RD-C6-6
WH/RD-C3B-6 6
WH/BK-C6-5
WH/BK-C3B-5 5
4
WH-C6-4
WH-C3B-4
RD/WH-C6-3
RD/WH-C3B-3 3
RD/BK-C3B-2 2
RD/BK-C6-2
RD-C6-1
1
RD-C3B-1

RD

12V TO PLAT

C23
U33
PLATFORM LOAD

BR-GND
3 STUD
BK-C23-5
1
2 WH-23C

WH-21B
BK/RD-35B
CR3

OR-C6-33
BR-GND+C6-26

BK-C6-16

RD- 20B
RD- P1 E-STOP
OR/BK-15A
OR-14A
GR-17A

CR4

GR/WH-19A
GR/BK-18A

BK/RD-C5-9

GROUND STUD
BR

WIRING
HARNESS:
TO BASE

ALL BR WIRES

Part No. 102521

S-40 S-45

6 - 11

July 2007

Section 6 Schematics

Ground Control Box Wiring Diagram


Deutz F3L 1011F Models

6 - 11
6 - 12

Section 6 Schematics

July 2007

Platform Control Box Wiring Diagram- ALC-500


Deutz F3L 1011F Models

6 - 14
6 - 13

P26BAT BK

P24FS WH
P24FS WH

11
1

C132PLI BK C1P-12

RD P2
RD H1

P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH
C4P-7 AND TS8
BRN

C4P(BR)

C3P(GR)

C2P(BK)

F.S.

OPT.
LS18

C1P(GY)

RED/BLK-28

H1

C19JSV GR/WH JIB


C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2

D39

F.S.

C43 HRN GR C2P-5


C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
JDALARM GR/BK C2P-6
DRIVE LT BK/RD C3P-9
C45GEN GR/WH C2P-7
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE GR/BK C2P-6

C6TRF WH/RD C3P-6


C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3

C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4

C28TTA RD/BK C1P-2

JIB
C9P
RED-TILT

BRN

JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH

DRE B BL/BK
C13LED BL/RD
C29MS RD/WH

C3P
C3P

D40

C7P
BATGND C7P-3

BRN

Part No. 102521


S-40 S-45
6 - 14

C4P
GN/BK C4P-4

12V BATT
19/18 CONTROL CABLE

TILT
ALALRM

C1P
C28TTA RD/BK C1P-2

HARNESS
PBOX WIRING
J2
J1

J3
GN/BK L48

ALC-500
RED-TILT

45383
89353
TILT ALARM
ALC-500
H1

C2P

PART NUMBER
COMPONENT INDEX

N
M
L
K
J
I
H
G
F
E
D
C
B
A

C7P

Section 6 Schematics
July 2007

REV A

Platform Control Box Wiring Diagram


Deutz F3L 1011F Models

July 2007
REV B

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Deutz F3L 1011F Models

HARNESS
PBOX WIRING

7
TS48/ TS49
WORK/ DRIVE LITE

6
TS47
GENERATOR
(OPTION)

TS15
DRV.ENA

5
4

5
4

2
JC2

JC3
DLITE/ RD WL2

TS13
PRIMARY
BOOM
EXTEND/
RETRACT

2
1

75565
56298
66812, 73805
66813, 66816
42730
13037

TS4
TS6
TS7
TS8
TS9
TS13

HI/L0 RPM SWITCH


GLOW PLUG OPTION
PLATFORM ROTATE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL SWITCH
PRIMARY BOOM EXTEND/RETRACT SWITCH

27378
56298
16397
13037
13037
13037

WH-24

DRIVE LT BK/RD-C3P-9

13037
27378
27378

DETAIL A: LIFT/DRIVE OPTION


REPLACE WIRE WITH THIS WIRING DIAGRAM

BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BK-22

BRN BATGND
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14

RD/BK H1

GN/BK H1

WH-24

RD

GR/WH-45

WH-24

BRN

WH-JIB

BK-7

BK/WH-8

BL/BK-DE2 J1-7

RD WL1
BK J1-2
RD J1-1

OR J1-11
BRN J1-12

RD P3

WH TS1

WH/RD C32BRK
(SPLICE TO C32BRK)
CR30

OR R40LS1
(SPLICE TO R40LS1)

NC

TS2
START

CR27

WH TS7
P22BAT BK C7P-1

TS6
TS1
GLOW PLUG
AUXILIARY PUMP

NC

NO

TS4
HIGH/LOW
RPM

(GND STUD)

RD LS18

WH-23

BK-22
P26BAT BK C9P-1

BK/RD-35
WH-24

BK-33
RD
RD-25

C34SA BK/WH C1P-8

WH-24

C27AUX RD C1P-1

WH-JIB

JDALARM GR/BK-44 C2P-6

C19JSV GR/WH

C17JU GR C4P-5

C19JSV GR/WH JIB

C18JD GR/BK C4P-6

OR-14

OR/BK-15

RD P2

GR-43

TS8
JIB

WH

TS7
PLATFORM
ROTATE

DRIVE PROPORTIONAL JOYSTICK


DRIVE ENABLE LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH

L48

GR

GR/BK

JC3
L1
P2
P3
TS1
TS2

L4

L1

WH

62390

+
+

CR13

RD

TS9
PLATFORM
LEVEL

PART NUMBER

BOOM PROPORTIONAL JOYSTICK:


PRIMARY UP/DN , TURNTABLE ROTATE

TS15 DRIVE ENABLE SWITCH


TS47 GENERATOR SWITCH ( OPTION )
TS48-9 WORK/DRIVE LIGHT ( OPTION )

WH

P3
HORN

COMPONENT INDEX
JC2

RD

RD

REMOVE FOR GENERATOR OPTION

P2
EMERGENCY STOP

CE SEE DETAIL A

NOTE:

1) DASHED LINES INDICATE OPTION WIRES.

Part No. 102521

S-40 S-45

6 - 15

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Deutz F3L 1011F Models

6 - 15
6 - 16

Section 6 Schematics

July 2007

Electrical Schematic
Perkins 704-30 Models (before serial number 7472)

6 - 18
6 - 17

July 2007

Section 6 Schematics
REV B

Electrical Schematic
Perkins 704-30 Models (before serial number 7472)
A

C28TTA RD/BK

TB41

RD/BK

C2-3

OR/BK

P26ESTP BK

P2

LS18

C9-1 BK

FS1
BK-(FS)

RD

P24FS WH

WH

C1-12

C1-9

8
9
10

CR2

C6-34
C5-14

3
5

HM

G1

CR3

NO CR4
BK/RD-C5-8

WH/RD

WH-24

WH-24

C5-15

WH/BK

STARTER

OTS

OPS
NC

NO

BRN

BRN
HIGH IDLE RELAY

HIGH RPM SOLENOID

GENERATOR
OPTION

GLOW PLUG
CONTROLLER

GLOW PLUG

OIL TEMP GAUGE

Part No. 102521

OIL TEMP
SWITCH

S-40 S-45

OIL PRESSURE
SWITCH

+
-

2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

OIL PRESSURE GAUGE

NOTE:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
IN THE STOWED POSITION AND KEYSWITCH "OFF".

FUEL RELAY

VOLT METER

HOUR METER

IGN./START RELAY

STARTER MOTOR

AUXILIARY POWER

RELAY
AUXILIARY PUMP

TILT ALARM
LEVEL SENSOR

FLASHING BEACONS
OPTION

SERVICE HORN

SERVICE HORN
RELAY

HYDRAULIC OIL
TEMP. SWITCH

COOLING FAN
(OPTION)

6 - 18

AUX
PUMP
BK

FAN

C5-16

WH-21

FB

GR/WH-45

BK-33

CR17
H2

G3

G2

PR1

NO

TB26

TB25

CONTROLLER

C5-5

RD-27

WH

RD

PR1
NO

C6-27

RD/BK-28

RD-P134

BK-43

REGULATOR
IND.

C6-16

STA.

C6-26

BAT.
-

C6-25

BAT.
+

CR17
NO
C6-33

12 V
DC

OR/BK-41

EXCT.

C5-2

C5-3

ALTERNATOR

C35ESPD BK/RD

CR2
NO
TB21

OTS
NO

HIGH RPM(FS)

CR1

TB35

L5

BK/RD

CR1
NO

HIGH RPM

TB45

START RELAY
TACHOMETER
START INPUT
IGN./START
AUX. ON
GROUND
MODULE
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT

C6-39

1
2
3
4
5
6

TB24

C6-28

C6-23

CR5 CR5
NO

TS55
LOW RPM

TB28

RD

C45GEN GR/WH

TB133

CB3

C2-7
GENERATOR

ENGINE

TB23

L45

20AMP.

SEE NOTE 2

TB33

D6

15AMP.

L28

C33STR BK

START
BK

AUXILIARY
PUMP

RD

TB27

TB20

L24

TB34

C1-7

ENGINE

C27AUX RD

P23BAT WH

TS52

TS51

4
CB1

TS4

TS2

C1-1

C7-2

RD

C28TTA RD/BK

H6

TS17

RD
RD
C133PLA OR/RD

U33

D40

C1-2

12

C9-2

START

D39

L48

C4-4

L4
H1

TB43

PLAT
GRD

P3
HORN

TB132
1

TB22

WH-(FS)

BK

SEE NOTE 2

C43HRN GR

KS1

P25FS RD

AUXILIARY
PUMP

C7-1

TB134

RD
RD

RD

C9-3

TS1

C2-5

P22BAT BK

C1-12

P1

C132PLI BL/WH

CB2
15AMP.

C134PWR OR/RD C2-4

TB 134 IS WAGO TERMINAL BLOCK 42


TB 133 IS WAGO TERMINAL BLOCK 16
TB 132 IS WAGO TERMINAL BLOCK 38

C41RPM OR/BK

RD-(FS)

DRE LED BL/RD


DRE B BL/BK

DRE A BL/WH

14

2
1
11
12

9
10

11

17

18

20

19

16

15

C1P-10

C1P-11

C1P-6

C1P-5

C1P-4

C6TRF WH/RD

C36STC BL

C37STCC BL/BK

C32BRK WH/RD

C31EDC- WH/BK

C30EDC+ WH

BRN-2

C3P-6

LEFT
TROTATE
RIGHT

C3P-5
C3P-4

C3P-1
C3P-2
C3P-3

7.5

C5TRR WH/BK
C4TRL WH

C2P-3

C41RPM OR/BK

15

16

WH

RKOUT 6

RD

13

BL

OR
BRN

YOUT 5

GND 2

PWR 3

OR

6
YOUT 5
XOUT 4
BRN

6
7
8

14
13

12

C4P-1

UP
PRIMARY
DOWN BOOM

C1PBU RD
C2PBD RD/BK
C3PBF RD/WH

C13DRE BL/RD

C5-21
C5-20
C6-32
C5-23

C6-37
C6-36

C6-4
C6-5
C6-6
C6-1
C6-2

C30EDC+ WHA
C31EDC- WH/BK

C32BRK WH/RD

WH
BK
WH
BK

BK

WH

C37STCC BL/BK
C36STC BL

C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH

C13DRE BL/RD

C6-3

C6-13
C40LS1 OR

C6-19 RD/BK

C6-40

GROUND

DRIVE EDC FORWARD


DRIVE EDC REVERSE

LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH

C
TRAVEL ALARM OPTION
BRAKE RELEASE VALVE

STEER RIGHT
STEER LEFT

TURNTABLE ROTATE LEFT


TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE
FLOW CONTROL

PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM
FLOW CONTROL

LS1-PRIMARY BOOM EXTEND


DRIVE LIMIT SWITCH

DESCENT ALARM OPTION

DRIVE ENABLE
LIMIT SWITCH

BOOM EXTEND
BOOM RETRACT

PLAT LEVEL UP
PLAT LEVEL DOWN

6 - 19
S-40 S-45
Part No. 102521

BK

PWR 3
1

GND 2

BRN

1
2
3
C40LS1 OR

C15PLD OR/BK

C14PLU OR

C8PBR BK/WH

C7PBE BK

C6-7
C6-8

C6-14
C6-15

JIB VALVES

PLATFORM ROTATE LEFT / JIB UP

PLATFORM ROTATE RIGHT / JIB DOWN

NOTE:

P24FS WH
P24FS WH

4
C2P-2

JIB BOOM

C15PLD OR/BK

C14PLU OR

C8PBR BK/WH

C7PBE BK

EXTEND
BOOM
RETRACT

UP
DOWN

C18JD GR/BK
C17JU GR

1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED


POSITION EXCEPT AS NOTED.

7
H3

2
P26ESTP BK

C18JD GR/BK

JDALARM GR/BK

C4P-6

C6-18
C6-17

NONC

R2
C17JU GR

PLAT
ROTATE

NOHC

H4
SJ1-WH
C6-30

8
NOHC

BRN

C3P-7
C3P-8

EXTEND BOOM

C4P-2

UP
PLATFORM
DOWN LEVEL C4P-3

RETRACT

RD
RD

C4P-5

GR/BK-44 C2P-6

DOWN
UP JIB BOOM

TB3 TB2 TB6

TB30
TB31
TB37
TB32
TB5

DOWN
UP JIB BOOM

RIGHT

TB8
TB14
TB18

TB22

AMP
Deutsch

LEFT

RIGHT PLAT
ROTATE

2
4

LEFT

TB19

C19JSV GR/WH

3
2

TB44

5
TB7
TB15
TB17

TS62
TS61

TB36
TB4

TB1
TB13
TB40

3
C4P-7

TS57

J2

J1

JIB VALVE

JC2

BRN

J1
J1

CR30
NO

R1

JC3
DRIVE & STEERING
PRI UP/DN & TT ROTATE

WH

4
TS63
TS59
TS58

TS13
TS9
TS8
TS7

J3
JOYSTICK CONTROL CARD
C19JSV GR/WH

CR27
NC

CR13
NC
CR13

CE
LIFT/
DRIVE
OPTION

L1
TS15

WH
WH

6
4

GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
1

Joystick Adaptor Harness

Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
6

Electrical Schematic
REV B

1
A
B
C
D
E
F
G
H
I
J
K
L
M
N

Section 6 Schematics
July 2007

Perkins 704-30 Models (before serial number 7472)

RD/BK
OR/BK
BK

July 2007

Section 6 Schematics

Electrical Schematic
Perkins 704-30 Models (before serial number 7472)

6 - 19
6 - 20

July 2007

Section 6 Schematics

REV A

Ground Control Box Wiring Diagram


Perkins 704-30 Models

RD/BK-C6-28
RD-C6-27
WH/RD-C5-14
WH/BK-C5-16
WH-C7B-2
BL/WH-C6-30
WH-C5-3+C5-11
RD- 12VOLT

12 V
C7B
C1B C2B C3B C4B

BK/WH-C6-8
BK-C6-7
WH/RD-C6-6
WH/BK-C6-5
WH-C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1

WH-CR2#86
BL/WH-L2

BK/RD CR3-#30
BK-ISM#3
WH/RD-C6-32

C6

D6

RD-ISM#4
RED-CR1#30
BK-CR5#30
WH-CR2#87
CB2-SP

GR/BK-C23-8

BK/RD-CR23#87

44B+RD/BK-C6-19

BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.

DRIVE LIGHT OPTION


BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP

IGN./START
MODULE

BK-22A

P1
RD-CB2

KEY SWITCH
KS1

TS51

NC
3

NC
WH-23A
RD-42A
RD-27A
RD-C23-6

1
B1

EMERGENCY STOP BUTTON


KEY SWITCH
AUXILIARY SWITCH
ENGINE START SWITCH

WH-21A

HM

BR (GROUND)

L45

FUNCTION ENABLE
PLATFORM ROTATE SWITCH

L2

BL/WH-C5-15
BL/WH-ISM#10
RD/WH-3A
RD/BK-2A
RD-1A

PLATFORM LEVEL SWITCH


BOOM EXTEND/RETRACT SWITCH
PRIMARY BOOM UP/DOWN SWITCH
TURNTABLE ROTATE SWITCH
JIB BOOM UP/DOWN SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, OPTIONS, 20A
RESISTOR, 5 OHM, BOOM FUNCTION

TS61

TS63

BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
BK/WH-34A

TS52

+
-

RD- 20C
RD-CR17#30
WH-4
WH/RD-6
WH/BK-5

TS62
CB3

L28
TS58

TS55
D13

CR3

BK-C6-16

LABEL

DESCRIPTION

RD-H6+
OR/RD-H6-

CB1

CB2

TS59

RD- 20A

P1
KS1
42730
13037

TS55

13037
16397
13037
13037
16397
16397
13037

TS57
TS59
TS63
TS61
TS62
TS58
CB1
CB2
CB3
R1

VOLT METER GAGE


OIL PRESSURE GAGE
OIL TEMP. GAGE

R2
G1
G2
G3

R2
G1
G2
G3

STARTER AID

L28

56298

HOUR METER
IGN. START RELAY
IGN. POWER RELAY
HIGH IDLE (RPM) CUTOUT RELAY

HM
CR1
CR2
CR3

HM
CR1
CR2
CR3

RPM RELAY

CR4

CR4

CR17

CR17

COOLING FAN RELAY


PLATFORM OVERLOAD ALARM
PLAT OVERLOAD MODULE
PLAT OVERLOAD LED

RD- 20B
RD- P1 E-STOP
OR/BK-15A

PART #

P1
KS1
TS51
TS52

CB1
CB2
CB3
R1

RESISTOR, 7.5 OHM,TURNTABLE FUNCTION

RD- 24A

OR-C6-33
BR-GND+C6-26

RD C4B-12
BRN GND

WH/BK-25A
WH/RD-26A

BK/RD-35A
CR5

CR23

TS57

CR17

BK/RD-9B

BK-22B
GR-43D

BK-ISM#1

BK/RD-35B

RD C4B-11

RD-C23-7

CR2

WH-21B

RD-CB3 SP

R2

BK-C6-25

BK-C5-5

DRIVE LIGHT OPTION RELAY

BR (GROUND)

D14

RD-CB3 SP
CR1

G3

G2

G1
WH-21A

BR-GND

1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
5 GROUND
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT

RD-ISM#6
WH-ISM#9
RD-24B

H6

LIMIT SWITCH POWER


GEN. OPTION
JDALARM JIB
HORN
RD-KS1-2 S.P.
C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
BL/RD-S.P.
C132PLI
STEER LEFT
STEER RIGHT
BK/RD-S.P.
RPM
BK/WH-S.P.
GLOW PLUG
BK-S.P.
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
SPARE
TILT ALARM
RD-S.P.
AUX. PWR.
WH/RD-S.P.
WATER TEMP. SENDER
OIL PRESSURE SENDER
WH/BK-S.P.
RD-S.P.
ENGINE POWER
WH-SP.+WH46A KEYSWITCH PWR/FB
BK-S.P.
PWR. TO PLAT.
WH-S.P.
IGNITION PWR.
CB1 - SP
12 VOLT BATTERY POWER
GR/WH-SP
JIB VALVE
GR/BK-S.P.
PLAT. ROT. R.
GR-S.P.
PLAT. ROT. L.
C133PLA
GR/BK-H6OR/BK-S.P.
PLAT. LEVEL DN.
OR-S.P.
PLAT. LEVEL. UP
DRV. ENA. LT.

BK-CR1#86
OR/BK-41B
BK-33D
RD-27B
BR-GND.
RD-CR2#30
WH-23B

GR/BK-S.P.

GR/BK-2B
GR-CR5#86
RD-H6+
OR/BK-ISM#2

C5

12V TO PLAT

19/18 CABLES
FUNCTIONS
ENGINE

3 BR-GND STUD
1 BK-C23-5
2 WH-23C

R1

GROUND STUD

OR/BK-C6-15
OR-C6-14
BL/RD-C6-13

RD

BK/WH-C5-22
BK-ISM#3
WH/RD-C5-23
WH/BK-C5-20
WH-C5-21

GR/BK-C6-18
GR-C6-17

46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
RD-C5-1
RD- C5-19
23
22
BK-C23-4
21
WH-C6-34
CB3-SP
20
GR/WH-C4B-7 19
GR/BK-C4B-6 18
17
GR-C4B-5
OR/RD-C4B-4 16
OR/BK-C4B-3 15
OR-C4B-2
14
BL/RD-C4B-1
13
BL/WH-C3B-12 12
BL/BK-C3B-11 11
BL-C3B-10
10
9
BK/RD-C3B-9
BK/WH-C3B-8 8
7
BK-C3B-7
WH/RD-C3B-6 6
WH/BK-C3B-5 5
4
WH-C3B-4
RD/WH-C3B-3 3
2
RD/BK-C3B-2
1
RD-C3B-1
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1

RD-C6-23
OR/BK-C5-2
OR-C6-40
BK/WH-C5-10
BL/WH-C23-3
BL/BK-C6-37
BL-C6-36

RD-H6+ - C23-1
BL/WH-38D - C23-3
BK-22C - C23-4
RD-C23-1
BK-C7-1 - C23-5
RD-42B
RD-TS51 - C23-6 GN/BK-L45RD-TS55 - C23-7 GN/BK-16A
GN/BK-16B - C23-8
BR - GND - C23-12

U33
C23
PLATFORM
LOAD

GR/WH-C6-39

H6
U33
L45

OR-14A
GR-17A

CR4

GR/WH-19A
GR/BK-18A

BK/RD-C5-9

GROUND STUD
BR

WIRING
HARNESS:
TO BASE

ALL BR WIRES

Part No. 102521

S-40 S-45

6 - 21

July 2007

Section 6 Schematics

Ground Control Box Wiring Diagram


Perkins 704-30 Models

6 - 21
6 - 22

Section 6 Schematics

July 2007

Platform Control Box Wiring Diagram


Perkins 704-30 Models

6 - 24
6 - 23

P26BAT BK

P24FS WH

C132PLI BK C1P-12

RD P2
RD H1

P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2

C19JSV GR/WH
C4P-7 AND TS8
BRN

C4P(BR)

C3P(GR)

C2P(BK)

F.S.

OPT.
LS18
C1P(GY)

RED/BLK-28

H1

C43 HRN GR C2P-5


C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
JDALARM GR/BK C2P-6
DRIVE LT BK/RD C3P-9
C45GEN GR/WH C2P-7
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE GR/BK C2P-6

C6TRF WH/RD C3P-6


C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3

C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4

C28TTA RD/BK C1P-2

C3P
C3P
D40

F.S.
D39

Part No. 102521

P24FS WH

C9P
C7P
RED-TILT

BRN

JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH

DRE B BL/BK
C13LED BL/RD
C29MS RD/WH

GN/BK L48

C7P
BATGND C7P-3

12V BATT
19/18 CONTROL CABLE

TILT
ALALRM

11

JIB

C4P
GN/BK C4P-4

BRN

C1P
C28TTA RD/BK C1P-2

J3
RED-TILT

HARNESS
PBOX WIRING
J2
J1

ALC-500

45383
89353
TILT ALARM
ALC-500
H1

C2P

PART NUMBER
COMPONENT INDEX

N
M
L
K
J
I
H
G
F
E
D
C
B
A

S-40 S-45
6 - 24

Section 6 Schematics
July 2007

REV A

Platform Control Box Wiring Diagram


Perkins 704-30 Models

July 2007

Section 6 Schematics

REV B

Platform Control Box Switch Panel Wiring Diagram


Perkins 704-30 Models

HARNESS
PBOX WIRING

7
TS48/ TS49
WORK/ DRIVE LITE

6
TS47
GENERATOR
(OPTION)

TS15
DRV.ENA

5
4

5
4

2
JC2

JC3
DLITE/ RD WL2

TS13
PRIMARY
BOOM
EXTEND/
RETRACT

2
1

WH-24

CR13

DRIVE LT BK/RD-C3P-9

75565
56298
66812, 73805
66813, 66816
42730
13037

TS4
L24
TS7
TS8
TS9
TS13

HI/L0 RPM SWITCH


GLOW PLUG INDICATOR
PLATFORM ROTATE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL SWITCH
PRIMARY BOOM EXTEND/RETRACT SWITCH

27378
56298
16397
13037
13037
13037

13037
27378
27378

4
DETAIL A: LIFT/DRIVE OPTION
REPLACE WIRE WITH THIS WIRING DIAGRAM

BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BK-22

BRN BATGND
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14

RD/BK H1

GN/BK H1

WH-24

RD

GR/WH-45

WH-24

BRN

WH-JIB

BK-7

BK/WH-8

BL/BK-DE2 J1-7

RD WL1
BK J1-2
RD J1-1

OR J1-11
BRN J1-12

WH TS1

RD P3

WH/RD C32BRK
(SPLICE TO C32BRK)
CR30

OR R40LS1

(SPLICE TO R40LS1)
1

TS2
START

TS1
AUXILIARY PUMP

NC

TS8
JIB

TS4
HIGH/LOW
RPM

CR27

WH TS7
P22BAT BK C7P-1

NO

L24
GLOW PLUG

NC

(GND STUD)

RD LS18

BK-22
P26BAT BK C9P-1

WH-23
RD-TILT

BK/RD-35
WH-24

BK-33
RD
RD-25

C34SA BK/WH C1P-8

BRN

WH-24

C27AUX RD C1P-1

WH-JIB

JDALARM GR/BK-44 C2P-6

C17JU GR C4P-5

C19JSV GR/WH

C19JSV GR/WH JIB

C18JD GR/BK C4P-6

OR-14

OR/BK-15

RD P2

GR-43

TS7
PLATFORM
ROTATE

DRIVE PROPORTIONAL JOYSTICK


DRIVE ENABLE LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH

L48

WH

GR/BK

JC3
L1
P2
P3
TS1
TS2

L4

L1

WH

62390

+
+

GR

TS9
PLATFORM
LEVEL

PART NUMBER

BOOM PROPORTIONAL JOYSTICK:


PRIMARY UP/DN , TURNTABLE ROTATE

TS15 DRIVE ENABLE SWITCH


TS47 GENERATOR SWITCH ( OPTION )
TS48-9 WORK/DRIVE LIGHT ( OPTION )

WH

P3
HORN

COMPONENT INDEX
JC2

RD
RD

REMOVE FOR GENERATOR OPTION

P2
EMERGENCY STOP

CE SEE DETAIL A

NOTE:
1) DASHED LINES INDICATE OPTION WIRES.

Part No. 102521

S-40 S-45

6 - 25

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Perkins 704-30 Models

6 - 25
6 - 26

Section 6 Schematics

July 2007

Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)
Perkins 404-22 Models (from serial number 7472 to 12509)

6 - 28
6 - 27

July 2007

Section 6 Schematics
REV A

Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)
Perkins 404-22 Models (from serial number 7472 to 12509)
A

BL/WH
RD/BK

TB41

C2-3

OR/BK

P26ESTP BK

BK

F18
FS1
BK-(FS)

C9-1 BK

HIGH RPM(FS)

C3P-9

GENERATOR

WH

WH

DRIVE LIGHT

TS4

C2-7

BK

BK

C1-9

RD

LOW RPM
FUNCTION ENA.
HIGH RPM
BK/RD

C6-39

C2B-4

GR/WH-45

CR3

CR4
BK/RD-C5-8

C4B-11

C5-11
RD

RD

S1

Y29

G1
L29

NO

L29

BRN

C6-26

NC

BRN

HIGH IDLE RELAY

HIGH RPM SOLENOID

GENERATOR
OPTION

DRIVE LIGHT
OPTION

WORK LIGHTS
OPTION

Part No. 102521

FUEL SOLENOID RELAY

C.E. OPTION ONLY

GLOW PLUG OPTION

WATER TEMP GAUGE

THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

WATER TEMP
SWITCH

OIL PRESSURE
SWITCH

NOTE:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
IN THE STOWED POSITION AND KEYSWITCH "OFF".

OIL PRESSURE GAUGE

RPM FILTER

VOLT METER

FUEL RELAY

HOUR METER

IGN./START RELAY

STARTER MOTOR

EMISSION CONTROL

AUXILIARY PUMP

AUXILIARY POWER
RELAY

TILT ALARM
LEVEL SENSOR

FLASHING BEACONS
OPTION

SERVICE HORN
RELAY

SERVICE HORN

HYDRAULIC OIL
TEMP. SWITCH

+
-

COOLING FAN
(OPTION)

S-40 S-45

C35ESPD BK/RD

C45GEN GR/WH

DLITE OR/RD

C21IGN2

C5-22

CR23

CR23
NO

NO

NO
PR3

WH/RD

HM
_

PR3
NO

C5-14

J144-4

WH/BK

J1 44-6

BK

G6

M2 PUMP

TB35

L2

G3

S2

STARTER

AUX

C34SA BK/WH

TB34

TB26

C5-16

PR2

S7

H2

C5-13 WH

WH-21

BK-33

RD-27

WH

RD

3MF
PR2

TS55

TB45

PBOX GND

C5-5

C6-27

G2

PR1

FB

M1

REGULATOR
IND.

TB21

CR2
NO

TB25

PR1
NO

STA.
FAN

RD/BK-28

RD-134

CR17

C6-33

BAT.
-

CR17
NO

CR2

CR1

CR1
NO

BK-43

EXCT.

C6-25

OR/BK-41

ALTERNATOR

CR5

C6-16

C6-34

C5-2

C5-3

OTS
NO

C6-23

CR5
NO

TB24

C6-28

CB3

BK

TB28

RD

20AMP.

1 START RELAY
2 TACHOMETER
3 START INPUT
IGN./START
4 AUX. ON
MODULE
5 GROUND
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT

D6

TB133

6 - 28

TS17

L30

TB33

TB23

L45

ON GLOW
PLUG

H6

15AMP.

C33STR BK

RD

CB1

TS56

ENGINE

TB27

BK

TS52

START

RD

TS51
PUMP AUXILIARY

U33

12

C27AUX RD

P23BAT WH

C28TTA RD/BK

C43HRN GR

GRD

BAT.
+

TS48

RD

C133PLA OR/RD

L30

C1-8

C1-7

PUMP AUXILIARY

C1-1

C7-2

C1-2

C4-4

TB43

WORK LIGHT

TS1

L48
D40

D39

TS6

START ENGINE

H1

C2-5

C7-1

C1-12

TB22

PLAT

12 V
DC

TS49

WH

ON GLOW
PLUG

P22BAT BK

C132PLI BL/WH

L4

TB132

KS1

FUSE 10A

RD

RD

TB20

P24FS WH

TS2

TB134

RD

P1

P25FS RD

C9-2

HORN

C2-4

CB2
15AMP.

C9-3

WH-(FS)

C28TTA RD/BK

P3

NOTE:
TB132 IS WAGO TERMINAL BLOCK 42
TB TB133
134 ISISWAGO
BLOCK 16
42
WAGO TERMINAL
TERMINAL BLOCK
TB TB134
133 ISISWAGO
BLOCK 38
16
WAGO TERMINAL
TERMINAL BLOCK
TB 132 IS WAGO TERMINAL BLOCK 38

RD-(FS)

RD

C134PWR RD

C41RPM OR/BK

P2

LS18

Electrical Schematic
REV A

C29MS

DRE LED BL/RD


DRE B BL/BK
DRIVE ENABLE

DRE A BL/WH

BL

WH

14

13

OR

RD

BK

12

11

15
16

19

20

18
17

11

10

6
7
8

14
13
12

C2P-3

C1P-4

C1P-5

C1P-6

C1P-3

C1P-11

C1P-10

C3P-6

C3P-5
C3P-4

7.5

BRN-2

C30EDC+ WH

C31EDC- WH/BK

C32BRK WH/RD

C29MS RD/WH

C37STCC BL/BK

C36STC BL

C6TRF WH/RD

C5TRR WH/BK
C4TRL WH

TROTATE
RIGHT

LEFT

C4P-1

C3P-3

C3P-2

C3P-1

C40LS1 OR

C13DRE BL/RD

C3PBF RD/WH

C2PBD RD/BK

C1PBU RD

PRIMARY BOOM
DOWN

UP

C2P-2

C8PBR BK/WH

C7PBE BK

EXTEND
JIB BOOM
RETRACT

C3P-8

C14PLU OR

C3P-7

C4P-2
C15PLD OR/BK

C5-21
C5-20

C6-32

C5-23

C5-19

C6-37

C6-36

C6-4
C6-5

C6-6

C6-1
C6-2

C13DRE BL/RD

C6-3

C6-13

C6-15

C6-14

C6-8

C6-7

C40LS1 OR

6
C6-40

C6-18
C6-17

C30EDC+ WH

C6-30

C31EDC- WH/BK

C32BRK WH/RD

C29MS RD/WH

C37STCC BL/BK

C36STC BL

C4TRL WH
C5TRR WH/BK

C6TRF WH/RD

C1PBU RD
C2PBD RD/BK

C3PBF RD/WH

C6-19 RD/BK

C7PBE BK

C8PBR BK/WH

C14PLU OR
C15PLD OR/BK

C18JD GR/BK
C17JU GR

7
WH

BK
WH
BK

WH
BK

GROUND

DRIVE EDC FORWARD

LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH

TRAVEL ALARM OPTION

DRIVE EDC REVERSE

BRAKE RELEASE VALVE

MOTOR STROKE

STEER RIGHT
STEER LEFT

TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE LEFT

TURNTABLE ROTATE
FLOW CONTROL

PRIMARY BOOM DOWN

PRIMARY BOOM UP

PRIMARY BOOM
FLOW CONTROL

LS1-PRIMARY BOOM EXTEND


DRIVE LIMIT SWITCH

DESCENT ALARM OPTION

DRIVE ENABLE
LIMIT SWITCH

BOOM EXTEND
BOOM RETRACT

PLAT LEVEL UP
PLAT LEVEL DOWN

PLATFORM ROTATE RIGHT / JIB DOWN


PLATFORM ROTATE LEFT / JIB UP

JIB VALVES

6 - 29
S-40 S-45

C41RPM OR/BK

15

16
7

RKOUT 6

OR

7
YOUT 5

BRN

5
4

4
PWR 3
1

GND 2

XOUT 4

YOUT 5

BRN

GND 2

PWR 3

BRN
P24FS WH
P24FS WH
P26ESTP BK

3
4

BOOM

C4P-3

JDALARM GR/BK

PLATFORM LEVEL

RETRACT

EXTEND

UP
DOWN

C2P-6

C18JD GR/BK

DOWN
UP JIB BOOM

C4P-6

C17JU GR

DOWN
UP JIB BOOM

NOTE:
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
POSITION EXCEPT AS NOTED.

NCHO

Part No. 102521

8
NOHC
BRN

NOHC

Y51
Y2
Y27
Y3
Y4
Y29 Y23
Y13
Y21 Y22
Y12
H4

Y25
Y26
Y19 Y20
Y17 Y16

H4
SJ1-WH

TB22

TB30
TB31
TB32
TB37
TB36
TB4

4
C4P-5

RD

5
TB6

TB14

R2
R1

TB29
TB3

TB8
TB17

TB5
TB2
TB13
TB40

TB7
TB15

TB1

RIGHT
PLAT ROTATE
LEFT

TB44
C19JSV GR/WH

TB18

GR/BK-44

DOWN
JIB BOOM
UP

C4P-7

TS58
TB19

RIGHT
PLAT ROTATE
LEFT

JIB VALVE

RD

J1
J1
J1

J3

2
TS14
L1
TS15

JC3

DRIVE & STEERING

3
J2

JOYSTICK CONTROL CARD

TS62
TS61

TS63
TS59
TS57

TS13
TS9

TS8
TS7

CR27
NC

CR13
NC
CR13

CR30
CE NO
LIFT/
DRIVE
OPTION
C19JSV GR/WH

WH
WH

JC2

PRI UP/DN & TT ROTATE

WH

1
A
B
C
D
E
F
G
H
I
J
K
L
M
N

Section 6 Schematics
July 2007

Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)


Perkins 404-22 Models (from serial number 7472 to 12509)

RD/BK

BL/WH

BK

OR/BK

BRN

July 2007

Section 6 Schematics

Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)
Perkins 404-22 Models (from serial number 7472 to 12509)

6 - 29
6 - 30

Section 6 Schematics

July 2007

Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models
(after serial number 12509)

6 - 32
6 - 31

July 2007

Section 6 Schematics
REV B

Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models
(after serial number 12509)
A

N
BL/WH
RD/BK

TB41

C2-3
OR/BK

P26ESTP BK
BK

F18
LS18
P2

FUSE 10A

FS1
C9-1 BK

BK-(FS)

RD-(FS)

C9-3

P25FS RD

WH-(FS)

C9-2

P24FS WH

TS6

DRIVE LIGHT

TS17

TS4

HIGH RPM(FS)

C3P-9

GENERATOR

WH

GLOW
PLUG

L30

L30

C2-7

C1-8

C1-7

C1-1

C7-2

C1-2

C4-4

C2-5

C7-1

C2-4

PUMP AUXILIARY

ENGINE

D39

WH

TS1
L48

H1

ON

START

L4

WORK LIGHT

P3
HORN

C1-12
TB132

BK

BK

TB134

RD

P1
RD

RD

C1-9

15AMP.

P22BAT BK

C134PWR OR/RD

C132PLI BL/WH

C41RPM OR/BK

CB2

TS2

D40

WH

C28TTA RD/BK

RD

Note:
TB132 is WAGO terminal block 42
TB133 is WAGO terminal block 16
TB134 is WAGO terminal block 38

TS48

TB43
2

C35ESPD BK/RD

GR/WH-45

CR4

RD
L29

BK/RD-C5-8

RD

S1
NO

C4B-9

C4B-11

HIGH IDLE RELAY

70A FUSE ADDED AT SERIAL NUMBER 12978


C.E. OPTION ONLY
WHEN C.E. OPTION IS NOT INSTALLED A JUMPER HARNESS
CONNECTS PIN 4 TO PIN 5 AND PIN 6 TO PIN 7
LS18 - PLATFORM OVERLOAD SWITCH

HIGH RPM SOLENOID

3
4

GENERATOR
OPTION

DRIVE LIGHT
OPTION

WORK LIGHTS
OPTION

GLOW PLUG OPTION

WATER TEMP GAUGE

OIL TEMPERATURE
SWITCH

THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION

OIL PRESSURE
SWITCH

OIL PRESSURE GAUGE

RPM FILTER

ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM


IN THE STOWED POSITION AND KEYSWITCH "OFF".

Part No. 102521

C6-39

C4B-12

C4B-10

S2

FUEL RELAY

VOLT METER

S-40 S-45

HOUR METER

IGN./START RELAY

STARTER MOTOR

EMISSION CONTROL

AUXILIARY POWER
RELAY

AUXILIARY PUMP

LEVEL SENSOR

TILT ALARM

FLASHING BEACONS
OPTION

SERVICE HORN
RELAY

SERVICE HORN

HYDRAULIC OIL
TEMP. SWITCH

+
-

COOLING FAN
(OPTION)

NOTE:

6 - 32

G1

NC

1.

L29

CR3

Y29
HM

BRN

BR

PR3

+
_

NO

NO

PR3
NO

C5-14 WH/RD

H2

FAN

G3

J144-4

IND.

CR23

CR23
NO

TB26

G6
STARTER

M2 PUMP

BK

REGULATOR

J144-6

RD

NO

M1

C5-16 WH/BK

PR2

PR2

S7

FB

STA.

WH-21

BK-33

RD-27

RD

WH

NO

C5-13 WH

C5-5

RD/BK-28

RD-134

BK-43

BK

OR/BK-41

3MF

PR1

PR1

BAT.
-

BAT.
+

12 V
DC

CR17

TB25
G2

TB35

FUSE 70A

WH

C5-22

WH

C5-2

C5-3
EXCT.

CR17
NO

L2

3
NO

ALTERNATOR

TB21

CR2
NO

BL/WH
OTS

CR2

CR1

CR1
NO

CR5

TB34

C2B-4

CR5
NO

RD

BK/RD

CB3
20AMP.

LOW RPM
FUNCTION ENA.
HIGH RPM

TB24

DLITE OR/RD

RD

C34SA BK/WH

TB28

TB45

1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
IGN./START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS U1
9 IGN./FUEL ON
10ENG. FAULT

D6

TB133

PBOX GND

TS55

RD

TB33

TB23

L45

H6

ON GLOW
PLUG

15AMP.

TS56

BK

RD

CB1
TB20

C33STR BK

TB27

D3
D2

BK

TS52

START ENGINE

12

RD

U33

TS51

PUMP AUXILIARY

C27AUX RD

P23BAT WH

GRD

C28TTA RD/BK

PLAT

C133PLA OR/RD

C45GEN GR/WH

TB22

C43HRN GR

KS1

BRN

Electrical Schematic
REV B

DRE LED BL/RD


DRE B BL/BK

BL/WH
OR

BL/WH
WH/RD

14

5
13

12

13

14

10

11

17

18

20

19

16

15

C41RPM OR/BK

15

16

BRN

11

RD/WH

12

DRE A BL/WH

GND 1

WH/RD
OR

BRN

1
2
4
3
4

BOOM

C2P-3

BRN-2

C1P-3

C1P-6

C37STCC BL/BK

C29MS RD/WH

C32BRK WH/RD

C31EDC- WH/BK

C1P-11
C36STC BL

C30EDC+ WH

C1P-10

C6TRF WH/RD

C1P-5

C3P-6
C5TRR WH/BK

C1P-4

C3P-5
C4TRL WH

PRI BOOM

LEFT TT ROTATE
RIGHT

C3P-4

7.5

DOWN
UP

C1PBU RD
C2PBD RD/BK
C3PBF RD/WH

C13DRE BL/RD

BOOM

C40LS1 OR

EXTEND

C15PLD OR/BK

C14PLU OR

C8PBR BK/WH

C7PBE BK

RETRACT

JDALARM GR/BK

C3P-1
C3P-2
C3P-3

C4P-1

C2P-2

C3P-8

C3P-7

C2P-6

C18JD GR/BK

C5-21
C31EDC- WH/BK

C30EDC+ WH
D

C6-5

C6-4

C6-36

C6-37

C5-19

C5-23

C6TRF WH/RD

C5TRR WH/BK

C4TRL WH

C36STC BL

C37STCC BL/BK

C29MS RD/WH

C32BRK WH/RD

C2PBD RD/BK

C1PBU RD

C6-2

C3PBF RD/WH

C6-13
C13DRE BL/RD

C6-17

C6-18

C17JU GR

C18JD GR/BK

C15PLD OR/BK

C14PLU OR

WH
BK

BK

WH

BK

WH

C7PBE BK

C40LS1 OR

C6-30

C6-7
C6-8

C6-14
C6-15

C8PBR BK/WH

C6-40

C6-19 RD/BK

C6-3

C6-1

C6-6

C6-32

C5-20

5
TB18

B
C

GROUND

1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED


PLATFORM ROTATE LEFT / JIB UP

PLATFORM ROTATE RIGHT / JIB DOWN

PLAT LEVEL DOWN

PLAT LEVEL UP

BOOM RETRACT

BOOM EXTEND

DRIVE ENABLE
LIMIT SWITCH

LS1-PRIMARY BOOM EXTEND


DRIVE LIMIT SWITCH

LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH

DESCENT ALARM OPTION

PRIMARY BOOM
FLOW CONTROL

PRIMARY BOOM DOWN

PRIMARY BOOM UP

TURNTABLE ROTATE
FLOW CONTROL

TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE LEFT

STEER LEFT

STEER RIGHT

MOTOR STROKE

BRAKE RELEASE VALVE

TRAVEL ALARM OPTION

DRIVE EDC REVERSE

DRIVE EDC FORWARD

7
JIB VALVES

6 - 33
S-40 S-45
Part No. 102521

RKOUT 5
YOUT 4
XOUT 3
PWR 2

6
5
YOUT 4
XOUT 3
PWR 2
GND 1

BRN
P24FS WH
P24FS WH
P26ESTP BK

EXTEND
RETRACT

C4P-2
C4P-3

C4P-6
C17JU GR

JIB BOOM

DOWN
UP

PLAT ROTATE

8
NOTE:

NCHO
NOHC
NOHC
BRN

Y51
Y2
Y27
Y3
Y4
Y23
Y29
Y13
Y22
Y21
Y12
H4

Y25

TB6
TB3

TB30
TB31

TB32
TB37

DOWN
PLAT LEVEL
UP

C4P-5

DOWN
PLAT LEVEL
UP

GR/BK-44

JIB BOOM

RIGHT
LEFT

SJ1-WH

TB29
TB14

TB5
TB2

TB36

TB4

TB1

C19JSV GR/WH

TB8
TB17

R2
R1

H4

Y26
Y20

TS63

TB13
TB40
TB7
TB15

TS61
TS59

3
C4P-7

TB44

Y19
Y16
Y17

DOWN
UP

PLAT ROTATE

RD

TS15

4
TS58
TB19

RIGHT
LEFT

JIB VALVE

RD

J1
J1
J1
J3

TS62
TS57

J2

JOYSTICK CONTROL CARD

CR30
NO
CE
LIFT/
DRIVE
OPTION

C19JSV GR/WH

TS9
TS8

TS7

CR27
NC
CR13
NC

CR13

TS13

TS14
L1
DRIVE & STEERING

2
WH

WH

JC3
JC2 PRI UP/DN & TT ROTATE

WH

1
A
B
C
D
E
F
G
H
I
J
K
L
M
N

Section 6 Schematics
July 2007

Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models


(after serial number 12509)

OR/BK
BK

BL/WH
RD/BK

BRN

POSITION EXCEPT AS NOTED.

July 2007

Section 6 Schematics

Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models
(after serial number 12509)

6 - 33
6 - 34

July 2007

Section 6 Schematics

REV A

Ground Control Box Wiring Diagram


Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models

PLATFORM LOAD

RD-C6-23
OR/BK-C5-2
OR-C6-40
BK/WH-C5-10
BL/WH-C23-3
BL/BK-C6-37
BL-C6-36
BK/WH-C5-22
WH/RD-C5-23
WH/BK-C5-20
WH-C5-21
RD/WH-C5-24
RD/BK-C6-28
RD-C6-27

RD-C5-1
BL/WH-C6-30
WH-C5-3+C5-11
RD- 12VOLT
GR/BK-C6-18
GR-C6-17

BR-GND STUD

C7B

3
1

BK-C32-5

2 WH-23C

C2B

12V TO PLAT

12 V

OR/BK-C6-15
OR-C6-14
BL/RD-C6-13

BK/WH-C6-8
BK-C6-7
WH/RD-C6-6
WH/BK-C6-5
WH-C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1

WH-C7B-2
BK-C32-4
WH-C6-34
CB3-SP
GR/WH-C4B-7
GR/BK-C4B-6
GR-C4B-5
OR/RD-C4B-4
OR/BK-C4B-3
OR-C4B-2
BL/RD-C4B-1
BL/WH-C3B-12
BL/BK-C3B-11
BL-C3B-10
BK/RD-C3B-9
BK/WH-C3B-8
BK-C3B-7
WH/RD-C3B-6
WH/BK-C3B-5
WH-C3B-4
RD/WH-C3B-3
RD/BK-C3B-2
RD-C3B-1

C1B
C4B

19/18 CABLES

C3B

WH-23B
WH-CR2#86
WH-L2 DIODE

G2

BK/RD-9B

G3

BK/RD-S.P.
BK/WH-S.P.
BK-S.P.

D6

RD-ISM#4

RED-CR1#30
WH-ISM #7
BK-CR5#30
WH-CR2#87
CB2-SP

GR/BK-C32-8

RD C4B-12

BR (GROUND)

RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
CB1 - SP
GR/WH-SP
GR/BK-S.P.
GR-S.P.
GR/BK-H6OR/BK-S.P.
OR-S.P.

WH/BK-25A
WH/RD-26A
BK-22A
KS1

RD-CB2

TS51

NC

3
NC
WH-23A
RD-42A
RD-27A
RD-C23-6

1
B1

BK/RD-CR23#86

DRIVE LIGHT OPTION


BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP

BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.
A

6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT

KEY SWITCH

KS1

KS1

AUXILIARY SWITCH

TS51

42730

ENGINE START SWITCH

TS52

13037

STARTER AID

TS56

13037

FUNCTION ENABLE SWITCH

TS55

13037
16397

TS57
TS59

13037

WH-21A

BOOM EXTEND/RETRACT SWITCH

TS63

13037

HM

BR (GROUND)

L2
L45

WH-C5-13

PRIMARY BOOM
UP/DOWN
TS61

RD/WH-3A
RD/BK-2A
RD-1A
BOOM
EXTEND/RETRACT
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A

TS63
TURNTABLE
ROTATE

TS52

ENGINE
START

TS56

D14

FUNCTION
ENABLE

CB1

PRIMARY BOOM UP/DOWN SWITCH

TS61

16397

TURNTABLE ROTATE SWITCH

TS62

16397

JIB BOOM UP/DOWN SWITCH

TS58

13037

CIRCUIT BREAKER, CONTROLS, 15A

CB1

CB1

CIRCUIT BREAKER, ENGINE, 15A

CB2

CB2

CIRCUIT BREAKER, OPTIONS, 20A

CB3

CB3

RESISTOR, 5 OHM, BOOM FUNCTION

R1

R1

RESISTOR, 7.5 OHM,TURNTABLE FUNCT

R2

R2

VOLT METER GAGE

G1

G1

OIL PRESSURE GAGE

G2

G2

OIL TEMP. GAGE

G3

G3

HM

CB3

TS58
JIB BOOM
UP/DOWN

TS62

R2
CB2
TS57

BK/RD-35B

P1

PLATFORM LEVEL SWITCH

RD- 20C
RD-CR17#30
WH/BK-5A
WH/RD-6A
WH-4A

MODULE

PART #

P1

PLATFORM ROTATE SWITCH

RD

STARTER AID
IGN./START

LABEL

EMERGENCY STOP BUTTON

GR/BK-H6-

BK/WH-34A

START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND

DESCRIPTION

AUXILIARY

KEY SWITCH

P1

BL/WH-ISM#10

44B+RD/BK-C6-19

RD C4B-11

BRN GND
HORN
C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
3MF
C132PLI
STEER LEFT
STEER RIGHT
GND
RPM
GLOW PLUG
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
MOTOR SPEED
TILT ALARM
AUX. PWR.
WATER TEMP. SENDER
OIL PRESSURE SENDER
ENGINE POWER
KEYSWITCH PWR/FB
PWR. TO PLAT.
IGNITION PWR.
12 VOLT BATTERY POWER
JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.
C133PLA
PLAT. LEVEL DN.
PLAT. LEVEL. UP
DRV. ENA. LT.

BL/RD-S.P.

BK/RD CR3-#30

RD-CB3 SP

WH-21A

RD-KS1-2 S.P.
BR -3MF CAP

BK-ISM#3
WH/RD-C6-32

CR23

GR/BK-S.P.

GR/BK-2B
GR-CR5#85
RD-H6+
OR/BK-ISM#2

RD-ISM#6
WH-ISM#9
RD-24B

C6

H6

G1

B
1
2
3
4
5

R1

BK-CR1#86
OR/BK-41B
BK-33B
RD-27B
BR-GND.
RD-CR2#30

RD-C32-1
RD-42B
GR/BK-L45GR/BK-16A

SPARE
GEN. OPTION

FUNCTIONS

46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

RD

GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1

DRIVE LIGHT OPTION RELAY

RD-H6+ - C32-1
BL/WH-38D - C32-3
BK-22C - C32-4
BK-C7-1 - C32-5
RD-TS51 - C32-6
RD-TS55 - C32-7
GR/BK-16B - C32-8
BR - GND - C32-12

C32
U33

GR/WH-C6-39

RD-C32-7

HOUR METER

HM

IGN. START RELAY

CR1

CR1

IGN. POWER RELAY

CR2

CR2

HIGH IDLE (RPM) CUTOUT RELAY

CR3

CR3

RPM RELAY

CR4

CR4

COOLING FAN RELAY

CR17

CR17

PLATFORM OVERLOAD ALARM

H6

PLAT OVERLOAD MODULE

U33

PLAT OVERLOAD LED

L45

TS55
CR1

CR2

CR4

CR3

D13
BK/RD-35A

BK-ISM#1

TS59
PLATFORM
LEVEL

PLATFORM
ROTATE

RD- 20A
BK-C5-5

RD- 24A

WH-21B

RD- 20B

C5

ENGINE

BK/RD-C5-9
BK-C6-16

RD- P1 E-STOP
OR-C6-33

OR/BK-15A
OR-14A
GR-17A
GR/WH-19A

GR/BK-18A
CR5

GR-43D

GROUND STUD

BK-22B

GROUND STUD
BR

CR17

BK-C6-25
RD-CB3 SP

WIRING
HARNESS:
TO BASE

ALL BR WIRES

Part No. 102521

S-40 S-45

6 - 35

July 2007

Section 6 Schematics

Ground Control Box Wiring Diagram


Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models

6 - 35
6 - 36

Section 6 Schematics

July 2007

Platform Control Box Wiring Diagram


Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models

6 - 38
6 - 37

11
1

P26BAT BK

P24FS WH

P24FS WH
BRN

PART NUMBER
45383
94771
COMPONENT INDEX
TILT ALARM
ALC-500
H1

RD P2
RD H1
C132PLI BK C1P-12

P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2

C19JSV GR/WH
C4P-7 AND TS8
BRN

OPT.
LS18
JIB

C4P(BR)

C3P(GR)

C2P(BK)

C1P(GY)

F.S.

C43 HRN GR C2P-5


C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
JDALARM GR/BK C2P-6
DRIVE LT BK/RD C3P-9
C45GEN GR/WH C2P-7
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1

C6TRF WH/RD C3P-6


C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L48

C28TTA RD/BK C1P-2

RD/BK-28

Part No. 102521

JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH

C9P
C7P

J3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH

C7P
BATGND C7P-3

12V BATT
19/18 CONTROL CABLE
TILT
ALALRM

C3P
C3P

D40

D39

H1

S-40 S-45
6 - 38

RED-TILT

C4P
GR/BK C4P-4

C1P
C28TTA RD/BK C1P-2

J2
J1

GR/BK L4

HARNESS
PBOX WIRING

REV A

Platform Control Box Wiring Diagram- ALC-500

C2P

N
M
L
K
J
I
H
G
F
E
D
C
B
A

ALC-500
RED-TILT

Section 6 Schematics
July 2007

Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models

July 2007
REV A

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)
Perkins 404-22 Models (from serial number 7472 to 12509)

HARNESS
PBOX WIRING

10 AMP FUSE

TS48

JC2

WORK/ DRIVE LITE

TS15
DRV.ENA

JC2

PRIMARY
BOOM
EXTEND/
RETRACT

56298

DRIVE PROPORTIONAL JOYSTICK

75565
56298
66812, 95406
66813, 66815
42730
13037

TS4
TS6
TS7
TS8

RD WL2

TS13

DRIVE ENABLE LED


EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH

WH-24

L1

PLATFORM ROTATE SWITCH

TS9
TS13
TS14

JIB UP/DOWN SWITCH


PLATFORM LEVEL SWITCH
PRIMARY BOOM EXTEND/RETRACT SWITCH
DRIVE SPEED SWITCH

TS15
TS47
TS48

DRIVE ENABLE SWITCH


GENERATOR SWITCH ( OPTION )
WORK/DRIVE LIGHT ( OPTION )

DRIVE LT BK/RD-C3P-9

L48

(GND STUD)

WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14

CR27

WH TS7
RD

RD P3

P22BAT BK C7P-1

RD LS18

WH-23

BK-22
P26BAT BK C9P-1

GR/WH-45

WH-24

BK/RD-35
WH-24

C33STR BK C1P-7
RD TS47
RD-25

C34SA BK/WH C1P-8

WH-24
C29MS RD/WH J1-8

WH-24

C27AUX RD C1P-1

JDALARM GR/BK-44 C2P-6

WH-JIB

C19JSV GR/WH

C17JU GR C4P-5

C19JSV GR/WH JIB

C18JD GR/BK C4P-6

WH TS1

WH/RD C32BRK

(SPLICE TO C32BRK)

CR30

REMOVE FOR
GENERATOR OPTION
OR R40LS1
1

(SPLICE TO R40LS1)

1 1

GENERATOR
(OPTION)

NC NC NC

TS47

2 2

NO

PLATFORM
LEVEL

BRN BATGND

RD/BK H1

GR/BK H1

WH-24

BL/RD-DE3 J1-16

BL/WH-DE1 J1-6
BK-22

BRN

WH-JIB

BK-7

BK/WH-8

BL/BK-DE2 J1-7

RD WL1
BK J1-2
RD J1-1

OR J1-11
BRN J1-12

OR-14

OR/BK-15

RD P2

GR-43

HORN

13037
27378
27378

REPLACE WIRE WITH THIS WIRING DIAGRAM

P2
EMERGENCY STOP

WH
PLATFORM
ROTATE
GR/BK

13037
13037
56457

DETAIL A: LIFT/DRIVE OPTION

GR

WH

16397
13037

RD

WH

TS9

56457
13037

GLOW PLUG OPTION

L4

P3

56298

CE PLATFORM LED
HI/L0 RPM SWITCH

CR13

TS7

62390

CHASSIS TILT LED

JC3
L1

L4

JC3

BOOM PROPORTIONAL JOYSTICK:


PRIMARY UP/DN , TURNTABLE ROTATE

L48

P2
P3
TS1
TS2

PART NUMBER

COMPONENT INDEX

TS8
JIB

TS1
AUXILIARY PUMP

TS14

TS6

TS4

HIGH/LOW
DRIVE
SPEED

GLOW PLUG

HIGH/LOW
RPM

RD

NOTE:
1) DASHED LINES INDICATE OPTION WIRES.

CE SEE DETAIL A

Part No. 102521

S-40 S-45

6 - 39

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)
Perkins 404-22 Models (from serial number 7472 to 12509)

6 - 39
6 - 40

July 2007
REV A

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models
(after serial number 12509)

HARNESS
PBOX WIRING

10 AMP FUSE
WORK/ DRIVE LITE
TS48

PRIMARY BOOM
UP/DOWN

DRIVE/STEER

DRIVE ENABLE
TS15

JC2

JC3

TURNTABLE ROTATE

RD WL2

RD WL1

PRIMARY
BOOM
EXTEND/
RETRACT

4
WH-24

TS13

J1-5 BL/WH JC3-5

J1-4 WH/RD JC3-4

J1-13 OR JC3-2

GR/BK H1

RD/BK H1

WH-24

J1-5 BL/WH JC3-3

DETAIL A: LIFT/DRIVE OPTION


REPLACE WIRE WITH THIS WIRING DIAGRAM

BRN BATGND

(GND STUD)

WH TS7

CR27
WH TS1

RD

RD LS18

RD P3

BK-22

P22BAT BK C7P-1

WH-23

P26BAT BK C9P-1

GR/WH-45

BK/RD-35
WH-24

C33STR BK C1P-7

RD-25

C34SA BK/WH C1P-8

WH/RD C32BRK
(SPLICE TO C32BRK)

CR30

(SPLICE TO R40LS1)
TS1

TS14

TS6

TS4

TS2

DRIVE
SPEED
JIB

J1-14 BRN JC3-1

L48

WH-24
C29MS RD/WH J1-8

PLATFORM
ROTATE
GR/BK

BL/RD-DE3 J1-16

WH

BL/WH-DE1 J1-6
BK-22

BL/BK-DE2 J1-7

PLATFORM
LEVEL

OR R40LS1

GR

HORN
P3

RD

L4

WH-24

C27AUX RD C1P-1

WH-JIB

JDALARM GR/BK-44 C2P-6

C17JU GR C4P-5

C19JSV GR/WH JIB

C19JSV GR/WH

C18JD GR/BK C4P-6

TS8

L1

DRIVE LT BK/RD-C3P-9

BRN

BK-7

BK/WH-8

J1-2 RD/WH JC2-4

J1-11 OR JC2-2

J1-1 WH/RD JC2-3

J1-12 BRN JC2-1

WH

OR-14

OR/BK-15

RD P2

GR-43

WH

TS7

TS9

CR13

HIGH/LOW
AUXILIARY PUMP

EMERGENCY STOP
P2

TS17
GLOW PLUG

RD

START

HIGH/LOW
RPM
RD

7
NOTE:

GENERATOR
(OPTION)

1) DASHED LINES INDICATE OPTION WIRES.

CE SEE DETAIL A

Part No. 102521

S-40 S-45

6 - 41

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Deutz F3L-2011Deutz D2011L03i and Perkins 404-22 Models
(after serial number 12509)

6 - 41
6 - 42

Section 6 Schematics

July 2007

Electrical Schematic
Ford LRG-425 EFI Models
(before serial number 7597)

6 - 44
6 - 43

C9-1 BK

HIGH RPM(FS)

GENERATOR

LP
FUEL
GAS

C2-7

C2-1

C1-7
ENGINE

C2-5

C7-1

C4-4

C1-2

C7-2

C1-1

PUMP AUXILIARY

START

P22BAT BK

C2-4

RD

C1-9
C35ESPD BK/RD

LOW RPM FUNCTION


HIGH RPM ENA.

C45GEN GR/WH

BK

ENGINE

LP FUEL
GAS

C33STR BK

START

TB45

AUXILIARY
PUMP
RD

C27AUX RD
P23BAT WH

C28TTA RD/BK

C133PLA OR/RD

BK/RD

C6-39

TEST
RUN

C6-28
C6-23

GR/WH-45

C5-13
C5-12
C5-17
C5-10
C5-9

C5-15

C5-5

C6-27

BRN

OR/BK-41

BL/WH (FEH 787) PIN5


BR (FEH 570C) PIN34

C5-14

WH/RD-24

WH/BK-24
C5-16

BK

C6-26

BRN

DGRN (FEH 242)

RD (FEH 361A)

C6-33

NOTE:

2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

FUEL PUMP

FORD
42 PIN PLUG

GENERATOR
OPTION

1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM


IN THE STOWED POSITION AND KEYSWITCH "OFF".

FUEL RELAY

OIL PRESSURE GAUGE

OIL PRESSURE
SWITCH

WATER TEMP
SWITCH

WATER TEMP GAUGE

C38ESL BL (FEH 658) PIN6


BK/RD (FEH 458) PIN3
TSW
C211GN2 WH (FEH 306) PIN24
BK/WH (FEH 72) PIN7
C39LP
C35RPM2 OR/RD (FEH 307A) PIN23
WH (FEH 16A) PIN1
C5-11

RD

WH

WH-21

BK-33

RD-27

C6-25

BK-43

RD/BK-28
RD-P134

C6-16

C6-34

C5-2

C5-3

OTS
NC
G1
HM

_
REGULATOR

PR1

G3
G2

P24BAT
TB24

TB26

TB25

FUEL
PUMP

OPS
+
STARTER

AUX
PUMP
H2

FAN

LPG LOCKOUT SOLENOID


VOLT METER

HOUR METER
IGN./START RELAY

STARTER MOTOR

AUXILIARY POWER
RELAY
AUXILIARY PUMP

LEVEL SENSOR

TILT ALARM

FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN

HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)

Part No. 102521

NO
IND.

C134PWR OR/RD

C41RPM OR/BK

RD

STA.

CR17
BAT.
BAT.

12 V
DC

CB3

PR1
NO
EXCT.

8
9
10

CR2
CR2
NO
CR1
CR1
NO
CR5 CR5
NO
20AMP.

FB

CR17
NO
ALTERNATOR

S-40 S-45
6 - 44

TB24

OTS
NO

TB35
TS22
L2
START RELAY
TACHOMETER
START INPUT
IGN./START
AUX. ON
GROUND
MODULE
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
1
2
3
4
5
6

TB23
RD

TB20 15AMP.

TB33
D6

TB27

TB39

TB28
TB133
CB1

TS53
PLAT
GRD

SEE NOTE 2
TS17

TS3
TS2

TS1

OR/BK
C2-3
TB41

TS55
TS52
TS51
TB22
KS1

TB134
RD

P1
CB2

D40
D39

TS4
L4

RD-(FS)
WH-(FS)
FS1
BK-(FS)

P2

RD/BK
C28TTA RD/BK

RD

TB43
RD
RD
15AMP.

L48
H1
P3
HORN

WH
P25FS RD
P24FS WH
C9-3
C9-2
RD

REV B

Electrical Schematic

N
M
L
K
J
I
H
G
F
E
D
C
B
A

FORD
ENGINE
HARNESS

TB 134 IS WAGO TERMINAL BLOCK 42

Section 6 Schematics
July 2007

Ford LRG-425 EFI Models


(before serial number 7597)

P26ESTP BK

BK

TB21

WH

DRE LED BL/RD


DRE B BL/BK

DRE A BL/WH

WH

RKOUT 6

10

11

17

18

20

19

16

15

C41RPM OR/BK

15

8
16
7
6

5
4
13
14

BL

OR
BRN

YOUT 5

GND 2

PWR 3

RD

6
7
8

14
13
12

C1P-10

C1P-11

C1P-6

C1P-5

C1P-4

C6TRF WH/RD

C36STC BL

C37STCC BL/BK

C32BRK WH/RD

C31EDC- WH/BK

C30EDC+ WH

BRN-2

C3P-6
C5TRR WH/BK

C2P-3

C3P-5

C2PBD RD/BK

C1PBU RD

UP
PRIMARY
DOWN BOOM

LEFT
TROTATE
RIGHT

C4TRL WH

7.5

C3P-4

C3P-1
C3P-2
C3P-3

C13DRE BL/RD

C3PBF RD/WH

C4P-1

C40LS1 OR

BOOM

C7PBE BK
C8PBR BK/WH
C14PLU OR
C15PLD OR/BK
PLAT
DOWN LEVEL

UP

RETRACT

EXTEND

C2P-2

C3P-7
EXTEND BOOM
C3P-8
RETRACT
C4P-2
UP
PLAT
DOWN LEVEL C4P-3

JDALARM GR/BK

C18JD GR/BK

C2P-6

C4P-6

C5-21
C5-20
C6-32
C5-23

C6-37
C6-36

C6-4
C6-5
C6-6

C6-1
C6-2
C6-3

C6-13

C6-40

C6-7
C6-8

C6-14
C6-15

C6-18

C30EDC+ WH

C32BRK WH/RD

C37STCC BL/BK
C36STC BL

C4TRL WH
C5TRR WH/BK
C6TRF WH/RD

C1PBU RD
C2PBD RD/BK
C3PBF RD/WH

C6-19 RD/BK

C13DRE BL/RD

C40LS1 OR

C7PBE BK
C8PBR BK/WH

C14PLU OR
C15PLD OR/BK

C18JD GR/BK

BK

WH

BK

WH

BK

WH

C31EDC- WH/BK D

7
H3

PLATFORM ROTATE LEFT / JIB UP

PLATFORM ROTATE RIGHT / JIB DOWN

PLAT LEVEL DOWN

PLAT LEVEL UP

BOOM RETRACT

BOOM EXTEND

DRIVE ENABLE
LIMIT SWITCH

LS1-PRIMARY BOOM EXTEND


DRIVE LIMIT SWITCH

LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH

DESCENT ALARM OPTION

PRIMARY BOOM
FLOW CONTROL

PRIMARY BOOM DOWN

PRIMARY BOOM UP

TURNTABLE ROTATE
FLOW CONTROL

TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE LEFT

STEER LEFT

STEER RIGHT

BRAKE RELEASE VALVE

TRAVEL ALARM OPTION

DRIVE EDC REVERSE

DRIVE EDC FORWARD

GROUND

8
JIB VALVES

6 - 45
S-40 S-45
Part No. 102521

OR

BK

YOUT 5
XOUT 4
BRN

2
1
11
12

PWR 3
1

GND 2

BRN

2
4
4

RD

C17JU GR

C17JU GR

NOTE:
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
POSITION EXCEPT AS NOTED.

P24FS WH
P24FS WH
P26ESTP BK

RD

C4P-5

C6-17

AMP

GR/BK-44

DOWN JIB
BOOM
UP

RIGHT JIB
BOOM
LEFT

RIGHT PLAT
LEFT ROTATE

NOHC NOHC NONC


BRN

H4
SJ1-WH
C6-30

TB22
1

Deutsch

C19JSV GR/WH

TB36

3
RIGHT PLAT
LEFT ROTATE

C4P-7

2
4

TB6
TB8
TB14
TB18

TB5
TB2

TB30
TB1

TB32
TB37
TB13
TB40

5
TB3
TB7
TB15
TB17

TB31

TB4

4
TS62
TS61

J1

J1
J1

JIB VALVE

Joystick Adaptor Harness

4
1

TB44
TB19

TS63
TS59
TS58

TS57

J2
C19JSV GR/WH

CR27
NC
TS13
TS9

TS8
TS7

J3
JOYSTICK CONTROL CARD

2
CR13
NC
CR13

CR30
NO
CE
LIFT/
DRIVE
OPTION

L1

JC3

DRIVE & STEERING

TS15

JC2

PRI UP/DN & TT ROTATE

WH
WH

6
6

Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
6

Electrical Schematic
REV B

1
A
B
C
D
E
F
G
H
I
J
K
L
M
N

Section 6 Schematics
July 2007

Ford LRG-425 EFI Models


(before serial number 7597)

RD/BK
OR/BK
BK

BRN

July 2007

Section 6 Schematics

Electrical Schematic
Ford LRG-425 EFI Models
(before serial number 7597)

6 - 45
6 - 46

July 2007

Section 6 Schematics

REV A

Ground Control Box Wiring Diagram


Ford LRG-425 EFI Models
(before serial number 7597)

GR/WH-C6-39

OR/BK-C5-2
OR- C6-40
BK/WH-C5-10
BL C5-13
BL/BK-C6-37
BL- C6-36
BK/RD-C5-9
BK-ISM#3
WH/RD-C5-23
WH/BK-C5-20
WH- C5-21

RD- C6-23
BL/WH-C6-30
WH-C5-3+C6-34
GR/BK-C6-18
GR- C6-17

12 V
C2B
C1B

GR/WH-SP
GR/BK-S.P.
GR-S.P.

JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.

OR/BK-S.P.
OR-S.P.

PLAT. LEVEL DN.


PLAT. LEVEL. UP
DRV. ENA. LT.

GR/BK-SP

BL/RD-S.P.
BL/WT-S.P.

BL/WH-ISM#10

BK/RD-S.P.
BK/WH-S.P.
BK-S.P.

D6

RD-ISM#4
RED-CR1#30
WH-TS22#5
BK-CR5#30
WH-CR2#87

BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.

44B-RD/BK-C6-19

3 BR-GND STUD
1 BK-22C
2 WH-23C

G1

1
2
3
4
5
6
7
8
9
10

WH-CR2#86
BK/WH-38B
RD-ISM#6
WH-ISM#9
RD-24B

CR17

CR2

P1
RD-CB2

C6

OR-C6-33
BR-GND+C6-26

TS22

36
25
14

KS1
KEY SWITCH

NC

1
B1

WH-23A
RD-42A
RD-27A
BL/RD-39A
RD-C23-6
RD-H6+

TS51

B
3

OR/RD-H6-

WH-21A

TS53
L2
L45

BL/WH-C5-13

BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP

BL/WH-ISM#10

DESCRIPTION

TS61

RD/WH-3A
RD/BK-2A

EMERGENCY STOP BUTTON

RD-1A

TS63

BK/WH-8A
BK-7A
GR/BK-44A
BK-33A

START RELAY
TACHOMETER
START INPUT IGN./START
AUX. ON
MODULE
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT

TS62
TS52

CB3

RD- 20C
RD-CR17#30
GR-17A
GR/WH-19A
GR/BK-18A

RD-CB3 SP

TS58

CR23
GR/BK C2B-6

R2
D14

CB1

RD C4B-11

TS57

CB2

RD C4B-12
BRN GND

CR5

TS55

TS59

DRIVE LIGHT OPTION RELAY

P1

PART #
P1

KEY SWITCH

KS1

KS1

AUXILIARY SWITCH

TS51

42730

ENGINE START SWITCH

TS52

13037

LP/GAS SWITCH

TS53

56457
13037

FUNCTION ENABLE

TS55

PLATFORM ROTATE SWITCH

TS57

16397

PLATFORM LEVEL SWITCH

TS59

13037

BOOM EXTEND/RETRACT SWITCH

TS63

13037

PRIMARY BOOM UP/DOWN SWITCH

TS61

16397

TURNTABLE ROTATE SWITCH

TS62

16397

JIB BOOM UP/DOWN SWITCH

TS58

13037
42730

CHECK ENGINE SWITCH

TS22

CIRCUIT BREAKER, CONTROLS, 15A

CB1

CB1

CIRCUIT BREAKER, ENGINE, 15A

CB2

CB2
CB3

CIRCUIT BREAKER, OPTIONS, 20A

CB3

RESISTOR, 5 OHM, BOOM FUNCTION

R1

R1

RESISTOR, 7.5 OHM,TURNTABLE FUNCT

R2

R2

VOLT METER GAGE

G1

G1

OIL PRESSURE GAGE

G2

G2

RD- 24A

WATER TEMP. GAGE

G3

G3

RD- 20B

CHECK ENGINE

L2

56298

HOUR METER

HM

HM

RD- P1 E-STOP

WH-ISM#7
WH-23B
BLK-33B
WH CR2#87
WH-C5-17

LABEL

RD- 20A

BK/RD-35A

BK-C6-16

CHECK ENGINE TOGGLE SWITCH


BR-R1
BR-GND
BK/RD-C5-12

G3

G2

NC

D13
WH-21B
WH-TS22#4

WH/BK-25A
WH/RD-26A
BK-22A

BK-ISM#1
BK-C5-5

BK-22B
GR-43D

RD-CB3 SP
BK-C6-25

BR (GROUND)

A
BK-CR1#86
OR/BK-41B
BK-33B
RD-27B
BR-GND.
RD-CR2#30
WH-TS22#6

WH-21A

HM

CR1

BR (GROUND)

C3B C4B

C7B

C5

FUNCTIONS
ENGINE
GROUND STUD

BK/WH-C6-8
BK- C6-7
WH/RD-C6-6
WH/BK-C6-5
WH- C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1

RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.

LIMIT SWITCH POWER


GEN. OPTION
SPARE
HORN
SPARE
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
CHECK ENGINE
STEER LEFT
STEER RIGHT
RPM
GLOW PLUG
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
SPARE
TILT ALARM
AUX. PWR.
WATER TEMP. SENDER
OIL PRESSURE SENDER
ENGINE POWER
KEYSWITCH PWR/FB
PWR. TO PLAT.
IGNITION PWR.

GR/BK-2B
GR-CR5#85

BK-CR1#85 D5
WH/RD-C6-32

R1

19/18 CABLES

12V TO PLAT

OR/BK-C6-15
OR- C6-14
BL/RD-C6-13

46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
RD- C5-1
24
23
WH-C7B
22
BK-C7B
WH-C5-11
21
20
GR/WH-C4B-7 19
GR/BK-C4B-6 18
GR-C4B-5
17
OR/RD-C4B-4 16
OR/BK-C4B-3 15
OR-C4B-2
14
13
BL/RD-C4B-1
BL/WH-C3B-12 12
BL/BK-C3B-11 11
10
BL-C3B-10
9
BK/RD-C3B-9
BK/WH-C3B-8 8
7
BK-C3B-7
WH/RD-C3B-6 6
WH/BK-C3B-5 5
4
WH-C3B-4
RD/WH-C3B-3 3
RD/BK-C3B-2
2
1
RD-C3B-1
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1

RD

RD/BK-C6-28
RD- C6-27
WH/RD-C5-14
WH/BK-C5-16

OR/BK-15A

OR-14A
GR-17A
GR/WH-19A

GR/BK-18A

WIRING
HARNESS:
TO BASE
GROUND STUD
BR
ALL BR WIRES

Part No. 102521

S-40 S-45

6 - 47

July 2007

Section 6 Schematics

Ground Control Box Wiring Diagram


Ford LRG-425 EFI Models
(before serial number 7597)

6 - 47
6 - 48

Section 6 Schematics

July 2007

Platform Control Box Wiring Diagram


Ford LRG-425 EFI Models
(before serial number 7597)

6 - 50
6 - 49

11
1

P26BAT BK

P24FS WH
P24FS WH
BRN

JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH

C132PLI BK C1P-12

RD P2
RD H1

P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2

C19JSV GR/WH
C4P-7 AND TS8
BRN

C4P(BR)

C3P(GR)

C2P(BK)

C1P(GY)

RED/BLK-28

H1

COMPONENT INDEX

PART NUMBER
TILT ALARM
ALC-500

45383
89353
H1

J2

OPT.
LS18
JIB
C9P

C43 HRN GR C2P-5


C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
JDALARM GR/BK C2P-6
DRIVE LT BK/RD C3P-9
C45GEN GR/WH C2P-7
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE GR/BK C2P-6

C6TRF WH/RD C3P-6


C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4

C28TTA RD/BK C1P-2

F.S.
D39
RED-TILT

F.S.
12V BATT

1
J3

DRE B BL/BK
C13LED BL/RD
C29MS RD/WH

C3P
C3P
D40

C4P
GR/BK C4P-4

BRN

Part No. 102521


S-40 S-45
6 - 50

C7P
BATGND C7P-3

C1P
C28TTA RD/BK C1P-2

19/18 CONTROL CABLE


TILT
ALALRM

GR/BK L48

HARNESS
PBOX WIRING
J1

ALC-500
RED-TILT

REV A

Platform Control Box Wiring Diagram

C2P

N
M
L
K
J
I
H
G
F
E
D
C
B
A

C7P

Section 6 Schematics
July 2007

Ford LRG-425 EFI Models


(before serial number 7597)

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram

REV A

Ford LRG-425 EFI Models


(before serial number 7597)
N

HARNESS
PBOX WIRING

COMPONENT INDEX

TS48 / TS49
WORK / DRIVE LITE
TS15
DRV.ENA

3
2
JC2

5
4

DLITE/ RD WL2

RD WL1

TS13
PRIMARY
BOOM
EXTEND/
RETRACT

3
2
JC3

1
+

62390

JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L3
TS7
TS8
TS9
TS13

DRIVE PROPORTIONAL JOYSTICK


DRIVE ENABLE LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH
FUEL SELECT SWITCH (FORD EFI ONLY)
HI/L0 RPM SWITCH
CHECK ENGINE LIGHT
PLATFORM ROTATE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL SWITCH
PRIMARY BOOM EXTEND/RETRACT SWITCH

75565
56298
66812, 73805
66813, 66816
42730
13037
56457
56457
56298
16397
13037
13037
13037

L4

BL/RD-DE3 J1-16

WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14

RD-TILT

RD/BK H1

WH-24

BRN BATGND
(GND STUD)

CR27

P22BAT BK C7P-1

RD-TILT

WH-23

BK-22
P26BAT BK C9P-1

RD

BL/RD-39

RD

WH-24
BK/RD-35

WH/RD C32BRK
(SPLICE TO C32BRK)

CR30

(SPLICE TO R40LS1)

1
1

TS3
FUEL SELECT

RD

TS2
START

TS47
GENERATOR
(OPTION)

TS1
AUXILIARY
PUMP

TS4
HIGH/LOW
RPM

NC NC NC

NO

TS7
PLATFORM
ROTATE

TS8
JIB

WH-TS47

RD-25

BK-33

WH-24

WH-TS4

GR/WH-45

WH-24

C27AUX RD C1P-1

WH-JIB

JDALARM GR/BK-44 C2P-6

C19JSV GR/WH

C17JU GR C4P-5

C19JSV GR/WH JIB

C18JD GR/BK C4P-6

OR-14

OR/BK-15

RD

GR-43

WH

WH TS1

OR R40LS1

GR

TS9
PLATFORM
LEVEL

REPLACE WIRE WITH THIS WIRING DIAGRAM

WH

P3
HORN

13037
27378
27378

DETAIL A: LIFT/DRIVE OPTION

WH TS7

WH

L1

BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7

BRN

WH-JIB

BK-7

BK/WH-8

BK J1-2
RD J1-1

OR J1-11
BRN J1-12

DRIVE LT BK/RD-C3P-9

WH-24

CR13

BOOM PROPORTIONAL JOYSTICK:


PRIMARY UP/DN , TURNTABLE ROTATE

TS15 DRIVE ENABLE SWITCH


TS47 GENERATOR SWITCH ( OPTION )
TS48-9 WORK/DRIVE LIGHT ( OPTION )

PART NUMBER

JC2

NOTE:
P2
EMERGENCY STOP

DASHED LINES INDICATE


OPTION WIRES

CE SEE DETAIL A

REMOVE FOR GENERATOR OPTION

Part No. 102521

S-40 S-45

6 - 51

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Ford LRG-425 EFI Models
(before serial number 7597)

6 - 51
6 - 52

Section 6 Schematics

July 2007

Electrical Schematic
Ford LRG-425 EFI Models
(from serial number 7597 to 11066)

6 - 54
6 - 53

P22BAT BK

C3-9

GENERATOR

C2-7

HIGH RPM(FS)

WH

WH

C1-7

ENGINE

REV B

Electrical Schematic

BL/WH

BK

P26ESTP BK

RD

C1-9

BK

BK

C35ESPD BK/RD

FUNCTION ENA.

LOW RPM

HIGH RPM

C45GEN GR/WH

DLITE BK/RD

C33STR BK

BK

ENGINE
START

C6-39

C6-28

GR/WH-45

C5-12
C5-17

C5-9

C5-13

C5-5

C5-10

C5-8

C5-11

C4B-12

C4B-11

WH-21

RD

RD

C5-14 WH/RD

C5-16 WH/BK

RD (FEH 361A)
DGRN (FEH 242)

C21IGN

C127TST

WH PIN 21

GR PIN 18

BK/RD PIN 23

BL/WH PIN 6

BK PIN 15

C38ESL

WH PIN 24

C35RPM

R33STR

BL/RD PIN 7

WH PIN 1
BK PIN 13

BK

BRN

BR PIN34

C39LP

R21IGN

RD PIN 9
BL/WH PIN 5

VBATT

VSW
C33STR

BK-33

WH

RD-27

RD/BK-28

RD

C6-27

RD-134

BK-43

GENERATOR
OPTION

DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION

LPG LOCKOUT SOLENOID

VOLT METER

HOUR METER

TEMP GAUGE

FORD
42 PIN PLUG

OIL PRESSURE GAUGE

FUEL PUMP

START RELAY
STARTER MOTOR

AUXILIARY POWER
RELAY
AUXILIARY PUMP

LEVEL SENSOR

TILT ALARM

FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN

HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)

42 PIN FORD CONNECTOR

REFER TO E0375 FOR FORD HARNSS

START

C2-1

RD

C27AUX RD

P23BAT WH

C28TTA RD/BK

C6-23

C6-16

C6-25

C6-26

OR/BK PIN 2

PBOX GND

C133PLA OR/RD

C43HRN GR

C6-34

C6-33

C41RPM

THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

PUMP AUXILIARY

LP FUEL
GAS

C1-2

C7-2

C1-1

PUMP AUXILIARY

C2-5
C7-1

C2-4

C5-2

510 OHM

L29
L29

TS4
C134PWR RD

TS22
C5-3

L30

TS17
C41RPM OR/BK

RD

ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM


1.
IN THE STOWED POSITION AND KEYSWITCH "OFF".

OTS
STARTER

FORD
ENGINE
HARNESS

Y29
G1
HM

G6
H2

Part No. 102521


S-40 S-45
6 - 54

M1

CR23
CR23
NO
G3
TB26
G2

OPS
IND.

S7

TB21
CR39

TB35
CR1

L2
CR1
NO
CR2
TB24

FUEL
PUMP
FB
FAN

AUX
M2 PUMP
REGULATOR

CR17
EXCT.

TB33
D6

TB45
CB1

BRN

PR2 PR2
12 V DC

STA.

PR1
PR1
NO
BAT.
BAT.
+

CR17
NO
ALTERNATOR

C28TTA RD/BK

TS55
TS52

TB25
OTS
NO

NC
CR5
NO

TS1
L48

CR2
NO
CR5

20AMP.

TB23
RD

TB39

D40

TS53
TS51
PLAT
GRD

CR39
CB3

RD

KS1
TB22

TB27

TB28
15AMP.

TB20

TB43
TB134
RD

P1
CB2

RD
RD
15AMP.

NOTE:

C9-1 BK

TS2
TS3
H1

P3
HORN

P24FS WH

WH
P25FS RD
C9-2

FUSE 10A
C9-3
WH-(FS)
BK-(FS)

RD-(FS)

FS1
P2

TS49
RD

OR/BK
C2-3

TB41

N
M
L
K
J
I
H
G
F
E
D
C
B
A

L30

TB 134 IS WAGO TERMINAL BLOCK 42

Section 6 Schematics
July 2007

Ford LRG-425 EFI Models


(from serial number 7597 to 11066)

RD/BK

F18

DRE B BL/BK

DRE LED BL/RD

DRE A BL/WH

WH

RKOUT 6
BL

14

13

16

15

19

20

17

18

11
9
10

6
7
8

14
13
12

C1P-10

C1P-11

C1P-3

C1P-6

C1P-5

C1P-4

C6TRF WH/RD

C36STC BL

C37STCC BL/BK

C29MS RD/WH

C32BRK WH/RD

C31EDC- WH/BK

C30EDC+ WH

BRN-2

C3P-6
C5TRR WH/BK

C2P-3

C3P-5
C4TRL WH

C40LS1 OR

RETRACT

EXTEND

UP PLATFORM LEVEL
DOWN

C15PLD OR/BK

C14PLU OR

C8PBR BK/WH

C7PBE BK

BOOM

C13DRE BL/RD

C3PBF RD/WH

C2PBD RD/BK

C1PBU RD

UP
PRIMARY
DOWN BOOM

LEFT TROTATE
RIGHT

C3P-4

7.5

5
C3P-1
C3P-2
C3P-3

C4P-1

C2P-2

C3P-7
C3P-8

C4P-2
C4P-3

JDALARM GR/BK

C18JD GR/BK
C17JU GR

C5-21

C5-20

C6-32

C5-23

C5-19

C6-37

C6-36

C6-4
C6-5

C6-6

C6-1
C6-2

C6-3

C31EDC- WH/BK

C30EDC+ WH

C32BRK WH/RD

C29MS RD/WH

C37STCC BL/BK

C36STC BL

C4TRL WH
C5TRR WH/BK

C6TRF WH/RD

C1PBU RD
C2PBD RD/BK

C3PBF RD/WH

C13DRE BL/RD

C6-19 RD/BK

C6-13

C6-30

C6-7

C6-8

C6-14
C6-15

C17JU GR

C18JD GR/BK

C15PLD OR/BK

C14PLU OR

C8PBR BK/WH

C7PBE BK

C40LS1 OR

C6-40

C6-18
C6-17

WH

BK
WH
BK

BK

WH

GROUND

DRIVE EDC FORWARD

LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH

TRAVEL ALARM OPTION

DRIVE EDC REVERSE

BRAKE RELEASE VALVE

MOTOR STROKE

STEER RIGHT
STEER LEFT

TURNTABLE ROTATE LEFT


TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM
FLOW CONTROL

LS1-PRIMARY BOOM EXTEND


DRIVE LIMIT SWITCH

DESCENT ALARM OPTION

DRIVE ENABLE
LIMIT SWITCH

BOOM EXTEND
BOOM RETRACT

PLAT LEVEL UP
PLAT LEVEL DOWN

1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED


POSITION EXCEPT AS NOTED.

PLATFORM ROTATE RIGHT / JIB DOWN

NOTE:

PLATFORM ROTATE LEFT / JIB UP

JIB VALVES

6 - 55
S-40 S-45

C41RPM OR/BK

15

16

OR

5
4

BRN

YOUT 5
PWR 3
1

GND 2

BK
RD
OR
BRN

2
1
11
12

7
6
YOUT 5
XOUT 4
PWR 3
GND 2
1

P24FS WH

BRN

P24FS WH
P26ESTP BK

EXTEND PLATFORM LEVEL


RETRACT

C4P-5

C4P-6

C2P-6

UP
PLATFORM LEVEL
DOWN

GR/BK-44

DOWN
UP JIB BOOM

DOWN
UP JIB BOOM

NCHO

TB30

RIGHT
LEFT PLAT ROTATE

TB18

NOHC

Part No. 102521

7
NOHC
BRN

Y51
Y2
Y27
Y3
Y4
Y23
Y29
Y13
Y22
Y21
Y12
H4
Y25
Y26
Y20
Y19
Y16
Y17

SJ1-WH

TB6
TB3
TB14

H4
1

Deutsch

5
TB8
TB17

TB13
TB40
TB7

TB32
TB37
TB36
TB4
TB1

TB29
TB5
TB2
TB15

R2
R1

TB31
C19JSV GR/WH

RIGHT
LEFT PLAT ROTATE

RD

J1
J1

J1

3
C4P-7

2
4

AMP

Joystick Adaptor Harness

TB44

TS62
TS61
TS63

J2

JOYSTICK CONTROL CARD


J3

6
4
1

WH
WH

4
TS58
TB19

TS59
TS57

CR27
NC
TS7

JIB VALVE

RD

TS13
TS9
TS8

TS14
L1

JC3

DRIVE & STEERING

TS15

JC2

PRI UP/DN & TT ROTATE

WH

2
CR13
NC
CR13

CR30
CE NO
LIFT/
DRIVE
OPTION
C19JSV GR/WH

Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
6

Electrical Schematic
REV B

1
A
B
C
D
E
F
G
H
I
J
K
L
M
N

Section 6 Schematics
July 2007

Ford LRG-425 EFI Models


(from serial number 7597 to 11066)

OR/BK

BL/WH

RD/BK

BK

BRN

July 2007

Section 6 Schematics

Electrical Schematic
Ford LRG-425 EFI Models
(from serial number 7597 to 11066)

6 - 55
6 - 56

July 2007

Section 6 Schematics

REV A

Ground Control Box Wiring Diagram


Ford LRG-425 EFI Models
(from serial number 7597 to 11066)

GR/WH-C6-39

OR/BK-C5-2
OR- C6-40
BL/RD-C5-10
BL/WH-C23-3
BL/BK-C6-37
BL- C6-36
BK/RD-C5-9

RD- C6-23
BL/WH-C6-30
WH-C5-3+C5-8
RD- 12 VOLT
GR/BK-C6-18
GR- C6-17

12 V

RD-CR39#85
RED-CR1#30
CR39 #30
BK-CR5#30
WH-CR2#87
RD-S.P.(CB2)

GR/BK-C23-8

44B-RD/BK-C6-19

BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.

P1
RD-CB2

KS1
KEY SWITCH
3

NC
4

WH-21A

DRIVE LIGHT OPTION


BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP

TS53
L2

BL/WH-C5-13

DESCRIPTION

TS61

RD/WH-3A
RD/BK-2A

EMERGENCY STOP BUTTON

RD-1A

KEY SWITCH
AUXILIARY SWITCH

ENGINE START SWITCH

TS63

BK/WH-8A
BK-7A
GR/BK-44A
BK-33A

TS62
CB3
RD-CB3 SP

TS58

CR2

CR23

R2
D14

CB1

RD C4B-11

TS57

CB2

RD C4B-12
BRN GND

WH-21B
WH-C5-17

TS55
D13
WH-C5-11

TS59

DRIVE LIGHT OPTION RELAY

CR39

BK-C6-25
RD-CB3 SP

KS1
TS51

PART #
P1
KS1
13480

TS52

13037

LP/GAS SWITCH

TS53

56457

FUNCTION ENABLE

TS55

13037

PLATFORM ROTATE SWITCH

TS57

16397

PLATFORM LEVEL SWITCH

TS59

13037

BOOM EXTEND/RETRACT SWITCH

TS63

13037

PRIMARY BOOM UP/DOWN SWITCH

TS61

16397

TURNTABLE ROTATE SWITCH

TS62

16397

JIB BOOM UP/DOWN SWITCH

TS58

13037
42730

CHECK ENGINE SWITCH

TS22

CIRCUIT BREAKER, CONTROLS, 15A

CB1

CB1

CIRCUIT BREAKER, ENGINE, 15A

CB2

CB2
CB3

CIRCUIT BREAKER, OPTIONS, 20A

CB3

RESISTOR, 5 OHM, BOOM FUNCTION

R1

R1

RESISTOR, 7.5 OHM,TURNTABLE FUNCT

R2

R2

VOLT METER GAGE

G1

G1

G2

G2

RD- 24A

WATER TEMP. GAGE

G3

G3

RD- 20B

CHECK ENGINE

L2

56298

HOUR METER

HM

HM

OR/BK-15A

CR17

P1

OIL PRESSURE GAGE

RD- P1 E-STOP

RD-27B

LABEL

RD- 20A

BK/RD-35A

OR-C6-33

OR-14A
GR-17A

WH-23B

C5

1
B1

WH-23A
RD-42A
RD-27A
BL/RD-39A

BK-33B

CR5

TS51

NC

BK/RD-9B

BK-C6-16

WH/BK-25A
WH/RD-26A
BK-22A

RD-24B

TS22

RD- 20C
RD-CR17#30
WH/BK-5A
WH/RD-6A
WH-4A

BK-C5-5

BR (GROUND)

TS52

CR1

G3

G2

BR (GROUND)

BK/RD-CR23#86

GR-C5-12

ENGINE

G1

HM

GR-43B
BK-22B

GROUND STUD

WH-21A

3 BR-GND STUD
1 BK-22C
2 WH-23C

C2B
C1B

BK-CR1#85 D5
WH/RD-C6-32

C3B C4B

C7B

SPARE
GEN. OPTION
JDALARM JIB
HORN
RD-KS1-2 S.P. C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
BL/RD-S.P.
L.P.
C132PLI
STEER LEFT
STEER RIGHT
BK/RD-S.P.
RPM
BK/WH-S.P.
GLOW PLUG
START
BK-S.P.
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
MOTOR SPEED
TILT ALARM
AUX. PWR.
RD-S.P.
WH/RD-S.P. WATER TEMP. SENDER
WH/BK-S.P. OIL PRESSURE SENDER
RD-S.P.
ENGINE POWER
KEYSWITCH PWR/FB
WH-S.P.
PWR. TO PLAT.
BK-S.P.
WH-S.P.
IGNITION PWR.
RD-S.P.(CB1) 12V BATTERY SUPPLY
GR/WH-SP
JIB VALVE
GR/BK-S.P.
PLAT. ROT. R.
GR-S.P.
PLAT. ROT. L.
GR/BK-H6C133PLT
OR/BK-S.P.
PLAT. LEVEL DN.
OR-S.P.
PLAT. LEVEL. UP
DRV. ENA. LT.

GR/BK-SP

C6

FUNCTIONS

BK/WH-C6-8
BK- C6-7
WH/RD-C6-6
WH/BK-C6-5
WH- C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1

R1

19/18 CABLES

12V TO PLAT

OR/BK-C6-15
OR- C6-14
BL/RD-C6-13

GR/BK-2B
GR-CR5#85
RD-H6+

RD

WH/RD-C5-23
WH/BK-C5-20
WH- C5-21
RD/WH-C5-24
RD/BK-C6-28
RD- C6-27
WH/RD-C5-14
WH/BK-C5-16

46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
WH-C7B-2
22
BK-C7B-1
WH-C6-34
21
RD-S.P.(CB3)
20
GR/WH-C4B-7 19
GR/BK-C4B-6 18
GR-C4B-5
17
OR/RD-C4B-4 16
OR/BK-C4B-3 15
OR-C4B-2
14
13
BL/RD-C4B-1
BL/WH-C3B-12 12
BL/BK-C3B-11 11
10
BL-C3B-10
9
BK/RD-C3B-9
BK/WH-C3B-8 8
7
BK-C3B-7
WH/RD-C3B-6 6
WH/BK-C3B-5 5
4
WH-C3B-4
RD/WH-C3B-3 3
RD/BK-C3B-2
2
1
RD-C3B-1
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1

GR/WH-19A
GR/BK-18A

WIRING
HARNESS:
TO BASE
GROUND STUD
BR
ALL BR WIRES

Part No. 102521

S-40 S-45

6 - 57

July 2007

Section 6 Schematics

Ground Control Box Wiring Diagram


Ford LRG-425 EFI Models
(from serial number 7597 to 11066)

6 - 57
6 - 58

Section 6 Schematics

July 2007

Platform Control Box Wiring Diagram


Ford LRG-425 EFI Models
(from serial number 7597 to 11066)

6 - 60
6 - 59

11
1

P26BAT BK

P24FS WH
P24FS WH

C132PLI BK C1P-12

RD P2
RD H1

P23SWBAT WH C7P-2
P22BAT BK C7P-1

F.S.

C19JSV GR/WH
C4P-7 AND TS8
BRN

C4P(BR)

C3P(GR)

C2P(BK)

C1P(GY)

RED/BLK-28

H1

PART NUMBER
TILT ALARM

45383
H1

COMPONENT INDEX

J2

OPT.
LS18
JIB
C9P

C19JSV GR/WH JIB


C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2

C43 HRN GR C2P-5


C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
JDALARM GR/BK C2P-6
DRIVE LT BK/RD C3P-9
C45GEN GR/WH C2P-7
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE BK/RD C3P-9

C6TRF WH/RD C3P-6


C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4

C28TTA RD/BK C1P-2

F.S.
D39
RED-TILT

Part No. 102521

BRN

JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH

BRN

C3P
C3P
D40

C4P
GR/BK C4P-4

12V BATT
19/18 CONTROL CABLE
TILT
ALALRM

C7P
BATGND C7P-3

C7P

C1P
C28TTA RD/BK C1P-2

1
J3

DRE B BL/BK
C13LED BL/RD
C29MS RD/WH

GR/BK L48
RED-TILT

HARNESS
PBOX WIRING
J1

ALC-500

REV A

Platform Control Box Wiring Diagram

C2P

N
M
L
K
J
I
H
G
F
E
D
C
B
A

S-40 S-45
6 - 60

Section 6 Schematics
July 2007

Ford LRG-425 EFI Models


(from serial number 7597 to 11066)

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram

REV B

Ford LRG-425 EFI Models


(from serial number 7597 to11066)
N

10 AMP FUSE

5
4

DLITE/ RD WL2

RD WL1

TS13
PRIMARY
BOOM
EXTEND/
RETRACT

2
JC2

JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L4
TS7
TS8
TS9
TS13
TS14
TS15
TS47
TS48-9

3
2
JC3

1
+

62390

DRIVE PROPORTIONAL JOYSTICK


DRIVE ENABLE LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH
FUEL SELECT SWITCH (FORD EFI ONLY)
HI/L0 RPM SWITCH
CHASSIS TILT LED
PLATFORM ROTATE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL SWITCH
PRIMARY BOOM EXTEND/RETRACT SWITCH
DRIVE SPEED SWITCH
DRIVE ENABLE SWITCH
GENERATOR SWITCH ( OPTION )
WORK/DRIVE LIGHT ( OPTION )

75565
56298
66812, 94506
66813, 66816
42730
13037
56457
56457
56298
16397
13037
13037
13037
56457
13037
27378
27378

L4

DETAIL A: LIFT/DRIVE OPTION

BL/RD-DE3 J1-16

REPLACE WIRE WITH THIS WIRING DIAGRAM

WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14

RD-TILT

RD/BK H1

WH-24

BRN BATGND
(GND STUD)

P22BAT BK C7P-1

RD-TILT

WH-23

BK-22
P26BAT BK C9P-1

RD

BL/RD-39

RD

WH-24
BK/RD-35

WH-TS47

RD-25

BK-33

WH-24

WH-TS4

GR/WH-45

WH-24

WH-24

C29MS RD/WH J1-8

C27AUX RD C1P-1

WH-JIB

JDALARM GR/BK-44 C2P-6

C17JU GR C4P-5

C19JSV GR/WH JIB

C19JSV GR/WH

C18JD GR/BK C4P-6

OR-14

OR/BK-15

RD

GR-43

WH/RD C32BRK
(SPLICE TO C32BRK)

CR30

1
1

RD

TS3
FUEL SELECT

TS2
START

TS47
GENERATOR
(OPTION)

TS14
DRIVE
SPEED
HIGH/LOW

TS1
AUXILIARY
PUMP

TS4
HIGH/LOW
RPM

NC NC NC

NO

TS7
PLATFORM
ROTATE

TS8
JIB

WH TS1

(SPLICE TO R40LS1)

WH

WH

CR27

OR R40LS1

GR

TS9
PLATFORM
LEVEL

PART NUMBER

L1
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7

BRN

WH-JIB

BK-7

BK/WH-8

BK J1-2
RD J1-1

OR J1-11
BRN J1-12

DRIVE LT BK/RD-C3P-9

WH-24

CR13

WH

BOOM PROPORTIONAL JOYSTICK:


PRIMARY UP/DN , TURNTABLE ROTATE

WH TS7

P3
HORN

COMPONENT INDEX
JC2

TS15
DRV.ENA

HARNESS
PBOX WIRING

TS48 / TS49
WORK / DRIVE LITE

NOTE:
P2
EMERGENCY STOP

DASHED LINES INDICATE


OPTION WIRES

CE SEE DETAIL A

REMOVE FOR GENERATOR OPTION

Part No. 102521

S-40 S-45

6 - 61

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Ford LRG-425 EFI Models
(from serial number 7597 to 11066)

6 - 61
6 - 62

Section 6 Schematics

July 2007

Electrical Schematic
Ford DSG-423 EFI Models
(from serial number 11067 to 12509)

6 - 64
6 - 63

BL/WH

HIGH RPM(FS)

C3-9

C2-7

GENERATOR

WH

C1-9
C35ESPD BK/RD

LOW RPM
FUNCTION ENA.
HIGH RPM

C45GEN GR/WH

DLITE BK/RD

C6-39
GR/WH

1K
C6-27

C4B-12

C4B-11

B
C

RD

RD

500

GR PIN 3
WH PIN 16

WH/RD PIN 39

C21IGN

BK PIN 15

BK/RD PIN 23

C26TSR

C35RPM

BL/WH PIN 5

BL/RD PIN 7

BL PIN 18

WH PIN 24

C135RET

C135FP

WH PIN 1

R21IGN

VSW

BL/WH PIN 6

BK

BRN

C38ESL

C39LP

R33STR

C127TSW

C107AF WH

WH/BK

RD/GN

BK/BL

RD

GY/YL

GY/RD

C5-16 WH/BK

R21IGN WH

C5-3

C5-14
C5-12
C5-17
C5-9
C5-5
C5-8
C5-10

C5-11

C5-13

WH

C27AUX RD

RD/BK

RD

C6-26

GENERATOR
OPTION

DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION

VOLT METER

HOUR METER

OIL PRESSURE GAUGE

GASOLINE SENSOR

LPG LOCKOUT

TO ALTERNATOR FIELD
TEMP GAUGE

AUXILIARY POWER
RELAY
AUXILIARY PUMP

LEVEL SENSOR

TILT ALARM

IN THE STOWED POSITION AND KEYSWITCH "OFF".


FORD
42 PIN PLUG

FLASHING BEACONS
OPTION

SERVICE HORN
RELAY
SERVICE HORN

HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)

RESISTOR R4 REMOVED AT SERIAL NUMBER 11785 .

DRIVELIGHT

ENGINE

C6-28

RD

C6-33

FORD ENGINEHARNESS

42 PIN FORD CONNECTOR

BK

BK

C33STR BK

START

LP
FUEL
GAS

AUXILIARY
PUMP

RD

C27AUX RD

P23BAT WH

C28TTA RD/BK

C6-23

R43HRN BK

C6-25

BRN
OR/BK PIN 2
BLUE/PINK

STARTER RELAY
STARTER MOTOR

THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

ESO433B
2

WORKLIGHT

WH

C1-7
ENGINE

C2-1

C1-1

C7-2

C1-2

C133PLA OR/RD

C43HRN GR

C6-16

C6-34

PR2

C41RPM

PR2

ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM


1.

START

FUEL
GAS

LP

AUXILIARY
PUMP

C2-5
C7-1

C2-4

P22BAT BK

C134PWR RD

C5-2

P20BAT RD

Part No. 102521


S-40 S-45
+

6 - 64

NOTE:

L29
L29
OPS
FORD ENGINE
HARNESS

TB45
TB9
TB23

C2-3

15AMP.

G1
HM

TB25
TS22
DIAGNOSTIC

Y29
+
FAN M1

CR23
CR23
NO
G2
FUEL
PUMP

G6
AUX
PUMP
H2

M2
FB

FUEL PUMP

3
S7
12 V
DC

TB21
TB41

R4
NO
CR17

PR1
PR1
CR17
NO
RD

L2
R3

TB26
OTS

CR5
CR5
NO
CB3
20AMP.

PBOX GND
TB33

L30
L30

TS55
TS53

CR1
CR1
NO
CR2
CR2
NO
CR39
CR39
NC

TS49
C28TTA RD/BK

TS17
TS2
TS3

TB35
RD
TB24
CB1
15AMP.
TB20

G3
NO

TB27
TB28

TB39
B

BK
P26ESTP BK

RD
B1

TS52
CB2

TB43
RD
2

REV B

Electrical Schematic

RD
TB22
4
1
RD

TB42

TS51
PLAT
GRD

KS1
P1

TS1
L48

WH
C9-2

BK(FS)
C9-1 BK

TS4
H1
P3
HORN

FUSE 10A
P25FS RD
P24FS WH
C9-3
RD(FS)
WH(FS)
FS1
P2

N
M
L
K
J
I
H
G
F
E
D
C
B
A

RD
C41RPM OR/BK

TB 134 IS WAGO
TERMINAL BLOCK 42

Section 6 Schematics
July 2007

Ford DSG-423 EFI Models


(from serial number 11067 to 12509)

RD/BK

OR/BK

F18

Electrical Schematic
REV B

DRIVE SPEED
C29MS RD/WH

DRE LED BL/RD


DRE B BL/BK

DRE A BL/WH

PWR 3

RD

BK

BRN

OR

12

11

14

13

7
6

12

13

14

10

11

17

18

20

19

16

15

C41RPM OR/BK

15

16

WH
4

7
RKOUT 6
BL

GND 2

OR

YOUT 5

XOUT 4

YOUT 5

BRN

GND 2

PWR 3
1

BRN
P24FS WH
P24FS WH
P26ESTP BK
3
4

EXTEND
BOOM
RETRACT

C2P-3

C1P-4

C1P-5

C1P-6

C1P-3

C1P-11

C1P-10

C3P-5

C3P-6

C3P-4

7.5

BRN-2

C30EDC+ WH

C31EDC- WH/BK

C32BRK WH/RD

C29MS RD/WH

C37STCC BL/BK

C36STC BL

C5TRR WH/BK

C6TRF WH/RD

C4TRL WH
LEFT
TT ROTATE
RIGHT

C4P-1

C3P-3

C3P-2

C3P-1

C40LS1 OR

C13DRE BL/RD

C3PBF RD/WH

C2PBD RD/BK

C1PBU RD

UP
PRIMARY BOOM
DOWN

C2P-2

C3P-8

C14PLU OR

C8PBR BK/WH

C7PBE BK

EXTEND
BOOM
RETRACT

C4P-2
C15PLD OR/BK

C3P-7

C4P-3

JDALARM GR/BK

UP
PLATFORM LEVEL
DOWN

C2P-6

C18JD GR/BK

C5-21

C5-20
C6-32

C5-23

C5-24

C6-37

C6-36

C6-4
C6-5

C6-6

C6-1
C6-2

C6-3

C31EDC- WH/BK

C30EDC+ WH

C37STCC BL/BK

C29MS RD/WH

C32BRK WH/RD

C36STC BL

C4TRL WH

C1PBU RD

C5TRR WH/BK

C2PBD RD/BK

C6TRF WH/RD

C3PBF RD/WH

C6-19 RD/BK

C13DRE BL/RD

WH

BK

BK

WH

BK

WH

C15PLD OR/BK

C14PLU OR

C7PBE BK

C6-13

C6-30

C6-7

C6-8

C6-14
C6-15

C17JU GR

C18JD GR/BK

C8PBR BK/WH

C40LS1 OR

6
C6-40

C6-18
C6-17

GROUND

DRIVE EDC FORWARD

DRIVE EDC REVERSE


TRAVEL ALARM OPTION

BRAKE RELEASE VALVE

MOTOR STROKE

STEER RIGHT

STEER LEFT

TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE LEFT

TURNTABLE ROTATE
FLOW CONTROL

PRIMARY BOOM DOWN

PRIMARY BOOM UP

PRIMARY BOOM
FLOW CONTROL

LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH

DESCENT ALARM OPTION

LS1-PRIMARY BOOM EXTEND


DRIVE LIMIT SWITCH

PLAT LEVEL UP

BOOM RETRACT

BOOM EXTEND

DRIVE ENABLE
LIMIT SWITCH

8
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
JIB VALVES

PLATFORM ROTATE LEFT / JIB UP

PLATFORM ROTATE RIGHT / JIB DOWN

PLAT LEVEL DOWN

ESO433
POSITION EXCEPT AS NOTED.

6 - 65
S-40 S-45
Part No. 102521

Y2

TB30
TB31

DOWN
JIB BOOM
UP

NOTE:

NCHO

TB32

UP
PLATFORM LEVEL
DOWN

C4P-6

C17JU GR

C19JSV GR/WH

BRN

NOHC

Y27
Y25

NOHC

Y3
Y4
Y23
Y22

Y29
Y21

Y13
Y12

7
H4
Y26
Y20

TB13

5
TB40
TB7
TB15

H4

Y19

TB5
TB2

TB37
TB4
TB1

TB29
TB36
TB6
TB3
TB14

SJ1-WH

Y16
Y17

TB44
RIGHT
PLAT ROTATE
LEFT

TS58

TB8
TB17

TS61
TS63
TS59

R2
R1
C4P-5

RD

TS15

Y51

4
TS62
TS57

GR/BK-44

DOWN
JIB BOOM
UP

C4P-7

TB19

RIGHT
PLAT ROTATE
LEFT

JIB VALVE

RD

J1
J1
J1
J3

CR30
NO

J2
JOYSTICK CONTROL CARD

TS14
LO
HI
L1
DRIVE & STEERING
PRI UP/DN & TT ROTATE

3
C19JSV GR/WH

TS13
TS9
TS8
TS7

CR27
NC
CR13
NC
CR13

CE
LIFT/
DRIVE
OPTION

2
WH
WH

JC3
JC2
WH

1
A
B
C
D
E
F
G
H
I
J
K
L
M
N

Section 6 Schematics
July 2007

Ford DSG-423 EFI Models


(from serial number 11067 to 12509)

RD/BK

BL/WH

OR/BK
BK

BRN

TB18

July 2007

Section 6 Schematics

Electrical Schematic
Ford DSG-423 EFI Models
(from serial number 11067 to 12509)

6 - 65
6 - 66

Section 6 Schematics

March 2007

Electrical Schematic
Ford DSG-423 EFI Models
(after serial number 12509)

6 - 68
6 - 67

BL/WH

HIGH RPM(FS)

C2-7

GENERATOR

C1-9
C35ESPD BK/RD

LOW RPM
FUNCTION ENA.
HIGH RPM

C45GEN GR/WH

DLITE BK/RD

C6-39
GR/WH

C4B-12

C4B-11

B
C

RD

RD

C5-14
C127TSW

C26TSR

BK/RD PIN 23

WH PIN 16

GR PIN 3

WH/RD PIN 39

WH/BK

RD/GN

BK/BL

RD

GY/YL

GY/RD

C5-16 WH/BK

R21IGN WH

C5-3

C5-12

C35RPM

C21IGN

BK PIN 15

C5-17

R33STR

C5-9
C5-5

BL/RD PIN 7

WH PIN 24

BL/WH PIN 5

R21IGN

BL PIN 18

C5-8

C135RET

C135FP

WH PIN 1

C39LP

VSW

BL/WH PIN 6

C5-10

C5-11

C38ESL

BRN

C5-13

C27AUX RD

WH
BK

GENERATOR
OPTION

DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION

VOLT METER

HOUR METER

OIL PRESSURE GAUGE

FORD
42 PIN PLUG

GASOLINE SENSOR

LPG LOCKOUT

TEMP GAUGE

AUXILIARY POWER
RELAY
AUXILIARY PUMP

LEVEL SENSOR

TILT ALARM

FLASHING BEACONS
OPTION

SERVICE HORN
RELAY
SERVICE HORN

HYDRAULIC OIL
TEMP. SWITCH

NOTE:
STARTER MOTOR

STARTER RELAY

FORD ENGINEHARNESS

42 PIN FORD CONNECTOR

COOLING FAN
(OPTION)

RESISTOR R3 REMOVED AT SERIAL NUMBER 13740.


CHECK ENGINE LAMP L2 CHANGED TO INCANDESCENT.

C3-9

1K
C6-27

RD/BK

RD

C6-26

WH

ENGINE

C6-28

RD

BRN
OR/BK PIN 2
BLUE/PINK

THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

BK

BK

C33STR BK

START

LP
FUEL
GAS

AUXILIARY
PUMP

RD

C27AUX RD

P23BAT WH

C28TTA RD/BK

C6-23

R43HRN BK

C6-25

C6-33

PR2

C41RPM

PR2

DRIVELIGHT

C1-7
ENGINE

C2-1

C1-1

C7-2

C1-2

C133PLA OR/RD

C6-16

C5-2

P20BAT RD

ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM


IN THE STOWED POSITION AND KEYSWITCH "OFF".

L29
L29
OPS
FORD ENGINE
HARNESS

ESO433C
1.

G1
HM

Y29
+

TB45
TB9
TB23

C43HRN GR

R3

C6-34

TB25

WORKLIGHT

WH

START

LP
FUEL
GAS

AUXILIARY
PUMP

C2-5
C7-1

C2-4

P22BAT BK

C134PWR RD

C2-3

PR1

CR23
CR23
NO
G2
FUEL
PUMP

TB26
FUEL PUMP
L2

G6
AUX
PUMP
H2

M2
FB

Part No. 102521


S-40 S-45
+

6 - 68

TB21
TB41

CR1
CR1
NO
CR2
CR2
NO
CR39

PBOX GND
TB33

15AMP.

S7
12 V
DC

FAN M1

NO
CR17

TB27

TB35
RD
TB24

TS52
TB39

TS22
DIAGNOSTIC
G3
NO

PR1
CR17
NO
RD

CR5

3
OTS

BK
P26ESTP BK

RD
TB22

TB28

TS55
4
1

REV B

Electrical Schematic

RD
RD

L30
L30

2
TS17
TS2
TS3
C41RPM OR/BK

CR39
NC
CR5
NO
CB3
20AMP.

TB43
B1

TS49
C28TTA RD/BK

RD

TS53
PLAT
GRD
B
CB2

TB42
2

RD

CB1
15AMP.
TB20

KS1
P1

TS1
L48

WH
C9-2

BK(FS)
C9-1 BK

TS4
H1
P3
HORN

FUSE 10A
P25FS RD
P24FS WH
C9-3
RD(FS)
WH(FS)
FS1
P2

N
M
L
K
J
I
H
G
F
E
D
C
B
A

TS51

Section 6 Schematics
July 2007

Ford DSG-423 EFI Models


(after serial number 12509)

RD/BK

OR/BK

F18

Electrical Schematic
REV B

DRIVE SPEED
C29MS RD/WH

DRE B BL/BK

DRE LED BL/RD

DRE A BL/WH

YOUT 4
OR

WH/RD

RD/WH

12

11

15

16

19

20

12

13

14

10

11

17

18

C41RPM OR/BK

15

16

BL/WH

6
RKOUT 5
5
13

OR

BL/WH

WH/RD

PWR 2
14

YOUT 4

BRN

XOUT 3
GND 1

XOUT 3
BRN

GND 1

PWR 2

BRN
P24FS WH
P24FS WH
P26ESTP BK
3

EXTEND
RETRACT

BOOM

C2P-3

C1P-4

C1P-5

C1P-6

C1P-3

C1P-11

C1P-10

C3P-6
C3P-5
C3P-4

7.5

BRN-2

C30EDC+ WH

C31EDC- WH/BK

C32BRK WH/RD

C29MS RD/WH

C37STCC BL/BK

C36STC BL

C6TRF WH/RD
C5TRR WH/BK
C4TRL WH

LEFT
TT ROTATE
RIGHT

C3P-2

C3P-1

C3PBF RD/WH

C2PBD RD/BK

C1PBU RD

PRI BOOM

C3P-3

C13DRE BL/RD

UP

DOWN

C4P-1

C40LS1 OR

BOOM

C2P-2

EXTEND

C3P-8

C14PLU OR

C8PBR BK/WH

C7PBE BK

RETRACT

C4P-2
C15PLD OR/BK

C3P-7

C4P-3

JDALARM GR/BK

DOWN
PLAT LEVEL
UP

C2P-6

C18JD GR/BK

C5-21

C5-20
C6-32

C5-23

C5-24

C6-37

C6-36

C6-4
C6-5

C6-6

C6-1
C6-2

C6-3

C31EDC- WH/BK

C30EDC+ WH

C37STCC BL/BK

C29MS RD/WH

C32BRK WH/RD

C36STC BL

C4TRL WH

C1PBU RD

C5TRR WH/BK

C2PBD RD/BK

C6TRF WH/RD

C3PBF RD/WH

C6-19 RD/BK

C13DRE BL/RD

WH

BK

BK

WH

BK

WH

C14PLU OR

C7PBE BK

C15PLD OR/BK

C17JU GR

C18JD GR/BK

C8PBR BK/WH

C6-13

C6-30

C6-7

C6-8

C6-14
C6-15

C6-17

C40LS1 OR

6
C6-40

C6-18

Y2

7
Y51

GROUND

DRIVE EDC FORWARD

LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH

TRAVEL ALARM OPTION

DRIVE EDC REVERSE

BRAKE RELEASE VALVE

MOTOR STROKE

STEER RIGHT

STEER LEFT

TURNTABLE ROTATE LEFT


TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE
FLOW CONTROL

PRIMARY BOOM UP
PRIMARY BOOM DOWN

PRIMARY BOOM
FLOW CONTROL

LS1-PRIMARY BOOM EXTEND


DRIVE LIMIT SWITCH

DESCENT ALARM OPTION

DRIVE ENABLE
LIMIT SWITCH

BOOM EXTEND
BOOM RETRACT

PLAT LEVEL UP
PLAT LEVEL DOWN

POSITION EXCEPT AS NOTED.


PLATFORM ROTATE RIGHT / JIB DOWN

1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED


PLATFORM ROTATE LEFT / JIB UP

JIB VALVES

6 - 69
S-40 S-45
Part No. 102521

Y27

TB30
TB31

8
NCHO

NOTE:

NOHC

TB32
TB37

DOWN
PLAT LEVEL
UP

C4P-6

C17JU GR

C19JSV GR/WH

BRN

NOHC

Y3
Y4
Y23
Y22

Y29
Y21

Y13
Y12
Y25

TB13
TB40
TB7
TB15

H4
Y26
Y20

TB36
TB5
TB2

H4

Y19

5
TB29
TB6
TB3
TB14

SJ1-WH

Y16
Y17

TS63

TB4
TB1

RIGHT
PLAT ROTATE
LEFT

TB44

TB8
TB17

TS62
TS61
TS59

R2
R1
C4P-5

C4P-7

TS58

GR/BK-44

DOWN
UP
JIB BOOM

PLAT ROTATE

RD

3
RIGHT
LEFT

RD

2
TS14
LO
HI
L1
TS15
DRIVE & STEERING
JC3

J1
J1
J1
J3

CR30
NO

4
TS57

TS13

J2
JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
C19JSV GR/WH

CR27
NC
CR13
NC
CR13

TS9
TS8
TS7

JIB VALVE

TB19

WH
WH

PRI UP/DN & TT ROTATE


JC2
WH

1
A
B
C
D
E
F
G
H
I
J
K
L
M
N

Section 6 Schematics
July 2007

Ford DSG-423 EFI Models


(after serial number 12509)

BL/WH

OR/BK

RD/BK

BK

BRN

TB18

July 2007

Section 6 Schematics

Electrical Schematic
Ford DSG-423 EFI Models
(after serial number 12509)

6 - 69
6 - 70

July 2007

Section 6 Schematics

REV B

Ground Control Box Wiring Diagram


Ford DSG-423 EFI Models

GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8

GR/WH-C6-39

OR/BK-C5-2
OR- C6-40
BL/RD-C5-10
BL/BK-C6-37
BL- C6-36
BK/RD-C5-9

BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1

WH/RD-C5-23
WH/BK-C5-20
WH- C5-21
RD/WH-C5-24

WH-C5-3+C5-8
RD- 12 VOLT

OR/BK-C6-15
OR- C6-14
BL/RD-C6-13

BK/RD-C3B-9
BK/WH-C3B-8
BK-C3B-7
WH/RD-C3B-6
WH/BK-C3B-5
WH-C3B-4
RD/WH-C3B-3
RD/BK-C3B-2

RD- C6-1

RD-C3B-1

12 V

BK/WH-C6-8
BK- C6-7
WH/RD-C6-6
WH/BK-C6-5
WH- C6-4
RD/WH-C6-3
RD/BK-C6-2
D

C7B

GR/BK-S.P.
RD-KS1-2 S.P.

BL/RD-S.P.

BK/RD-S.P.
BK/WH-S.P.
BK-S.P.

D5
BK-CR1#85
WH/RD-C6-32

RD-CR39#85

RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
RD-S.P.(CB1)

RED-CR1#30
CR39 #30
BK-CR5#30
WH-CR2#87
RD-S.P.(CB2)

HORN
C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
C132PLI
STEER LEFT
STEER RIGHT
RPM
GLOW PLUG
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
MOTOR SPEED
TILT ALARM
AUX. PWR.
WATER TEMP. SENDER
OIL PRESSURE SENDER
ENGINE POWER
KEYSWITCH PWR/FB
PWR. TO PLAT.
IGNITION PWR.
12V BATTERY SUPPLY

GR/WH-SP
GR/BK-S.P.
GR-S.P.

JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.
C133PLT

OR/BK-S.P.
OR-S.P.

PLAT. LEVEL DN.


PLAT. LEVEL. UP
DRV. ENA. LT.

G2

G1

WH/BK-25A
WH/RD-26A
BK-22A
KEY SWITCH
KS1

P1
NC

TS51

RD-CB2

NC

B1

WH-23A
RD-42A
RD-27A
BL/RD-39A

KEY SWITCH KS1

DRIVE LIGHT OPTION

44B-RD/BK-C6-19

BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.

WH-23A

RD-S.P.

L2

Note: Removed resistor R3 and


changed L2 to incandescent

TS53

BL/WH-C5-13

TS61

RD/WH-3A
RD/BK-2A
RD-1A

TS63

BK/WH-8A
BK-7A
GR/BK-44A
BK-33A

TS62
CB3
TS52
TS58

(BR)

RD-CR17/CR23 #30
WH/BK-5A
WH/RD-6A
WH-4A

RD-24B
CR2

CR1

R2

C2B

(BK)

CB1

C1B

RD-CB3 S.P.

CB2
TS57

WH-21B
WH-C5-17

CR23

TS55

OR-C6-33

WH-C5-11

C6

4
DESCRIPTION
L2

LABEL

PART#

EMERGENCY STOP BUTTON

P1

P1

KEY SWITCH

KS1

KS1

AUXILIARY SWITCH

TS51

13480

ENGINE START SWITCH

TS52

13037

LP/GAS SWITCH

TS53

56457

FUNCTION ENABLE

TS55

13037

PLATFORM ROTATE SWITCH

TS57

16397

PLATFORM LEVEL SWITCH

TS59

13037

BOOM EXTEND/RETRACT SWITCH

TS63

13037

PRIMARY BOOM UP/DOWN SWITCH

TS61

16397

TURNTABLE ROTATE SWITCH

TS62

16397

JIB BOOM UP/DOWN SWITCH

TS58

13037

CHECK ENGINE SWITCH

TS22

42730

CIRCUIT BREAKER, CONTROLS, 15A

CB1

CB1

CIRCUIT BREAKER, ENGINE, 15A

CB2

CB2

CIRCUIT BREAKER, OPTIONS, 20A

CB3

CB3

RESISTOR, 5 OHM, BOOM FUNCTION

R1

R1

RESISTOR, 7.5 OHM,TURNTABLE FUNCT

R2

R2

VOLT METER GAGE

G1

G1

OIL PRESSURE GAGE

G2

G2

WATER TEMP. GAGE

G3

G3

CHECK ENGINE (before serial number 13740)

L2

110395

CHECK ENGINE (after serial number 13739)

L2

119870

HOUR METER

HM

HM

RESISTOR, 1K OHM/2W, CHECK ENGINE

R3

104333

BK/RD-9B

TS59
BK-C6-16

Check Engine Light


(after serial number 13739)

BL/WH-C5-13

BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. R
TURN. ROT. L
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP

1
B1

HM

BK/RD-CR23#86

B
3

WH-21A

TS22

BK/RD-35A

RD C4B-11

RD- 20A

RD C4B-12

RD- 24A

BRN GND

RD- 20B
RD- P1 E-STOP

CR5
GR-43B
BK-22B

RD-27B

CR39

BK-C6-25

DRIVE LIGHT OPTION RELAY

OR/BK-15A

CR17

OR-14A

RD-CB3 SP

GR-C5-12

GR-17A

WH-23B

GR/WH-19A

GR/BK-18A

C5

ENGINE

2 WH-23C

(GY)

BR (GROUND)

BK-33B

FUNCTIONS

G3

BR (GROUND)

BK-C5-5

WH-21A

BK-22C

(GR)

C4B

R1

C3B

GEN. OPTION
JDALARM JIB

RD- 20C

19/18 CABLES

SPARE
GR/BK-2B
GR-CR5#85

BR-GND STUD

12V TO PLAT

OR/BK-C4B-3
OR-C4B-2
BL/RD-C4B-1
BL/WH-C3B-12
BL/BK-C3B-11
BL-C3B-10

R3

GR/WH-C4B-7
GR/BK-C4B-6
GR-C4B-5
OR/RD-C4B-4

GR/BK-C6-18
GR- C6-17

RD

WH-C7B-2
BK-C7B-1
WH-C6-34
RD-S.P.(CB3)

RD- C6-23
BL/WH-C6-30

46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2

RD

RD/BK-C6-28
RD- C6-27
WH/RD-C5-14
WH/BK-C5-16

GROUND STUD

WIRING
HARNESS:
TO BASE

ESO433

GROUND STUD
BR

ALL BR WIRES

Part No. 102521

S-40 S-45

6 - 71

July 2007

Section 6 Schematics

Ground Control Box Wiring Diagram


Ford DSG-423 EFI Models

6 - 71
6 - 72

Section 6 Schematics

July 2007

Platform Control Box Wiring Diagram


Ford DSG-423 EFI Models

6 - 74
6 - 73

11
1

C132PLI BK C1P-12

RD P2
RD H1

P22BAT BK C7P-1

BRN

C4P(BR)

C3P(GR)

C2P(BK)

C1P(GY)

RED/BLK-28

C19JSV GR/WH
C4P-7 AND TS8

OPT.
LS18
C9P

P23SWBAT WH C7P-2

C17JU GR C4P-5

C19JSV GR/WH JIB


C18JD GR/BK C4P-6

C14PLU OR C4P-2

C15PLD OR/BK C4P-3

P26BAT BK C9P-1

C7PBE BK C3P-7

C43 HRN GR C2P-5


C8PBR BK/WH C3P-8

P24FS WH C9P-2

P25FS RD C9P-3

DRIVE LT BK/RD C3P-9

JDALARM GR/BK C2P-6

C45GEN GR/WH C2P-7

TS48-WL2 RD C2P-11

TS48-WL1 RD C2P-12

DLITE BK/RD C3P-9

C39LP BL/RD C2P-1

C6TRF WH/RD C3P-6


C10SBU BL C3P-10
C11SBD BL/BK C3P-11

C13DRE BL/RD C4P-1

C41RPM OR/BK C2P-3

C12SBF BL/WH C3P-12

C40LS1 OR C2P-2

F.S.

D39

RED-TILT

F.S.
TILT

P26BAT BK

P24FS WH
C1PBU RD C3P-1

C30EDC+ WH C1P-4

C36STC BL C1P-10

C2PBD RD/BK C3P-2

C31EDC- WH/BK C1P-5

C3PBF RD/WH C3P-3


C5TRR WH/BK C3P-5

BATGND C7P-3

C37STCC BL/BK C1P-11


C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3

C35RPM BK/RD C1P-9

C134PWR RD C2P-4

C33STR BK C1P-7

C34SA BK/WH C1P-8

RD/BK L4

C27AUX RD C1P-1

C28TTA RD/BK C1P-2

C7P

BRN

Part No. 102521

C3P
C3P

D40

C4P
GR/BK C4P-4

P24FS WH

BRN

DRE A BL/WH

JC3-4,6 WH
JC3-2 BRN

JC3-3 OR

JC1-5 YEL
JC2-2 BRN
JC3-5 BL

JC2-3 OR

JC1-2 BRN
JC2-5 BK

JC2-4 RD

JC1-3 OR

DRE B BL/BK
C13LED BL/RD

J2
J1

12V BATT
19/18 CONTROL CABLE
ALALRM

JIB
C7P

C1P
C28TTA RD/BK C1P-2

J3

C29MS RD/WH

GR/BK L48

HARNESS
PBOX WIRING

ALC-500

RED-TILT

REV A

Platform Control Box Wiring Diagram

N
M
L
K
J
I
H
G
F
E
D
C
B
A

S-40 S-45
6 - 74

Section 6 Schematics
July 2007

Ford DSG-423 EFI Models

C2P

H1

ESO433

July 2007

Section 6 Schematics

REV A

Platform Control Box Switch Panel Wiring Diagram


Ford DSG-423 EFI Models
(from serial number 11067 to 12509)

10 AMP FUSE

DRV.ENA
TS15

DLITE/ RD WL2

RD WL1

JC2

JC3
1

1
TS13

WH-24

CR13
+

2
PART NUMBER
62390

JC2

COMPONENT INDEX
BOOM PROPORTIONAL JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE

JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L4
TS7
TS8
TS9
TS13
TS14
TS15
TS47
TS49

DRIVE PROPORTIONAL JOYSTICK


DRIVE ENABLE LED
EMERGENCY STOP BUTTON
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH
FUEL SELECT SWITCH (FORD EFI ONLY)
HI/L0 RPM SWITCH
CHASSIS TILT LED
PLATFORM ROTATE SWITCH
JIB UP/DOWN SWITCH
PLATFORM LEVEL SWITCH
PRIMARY BOOM EXTEND/RETRACT SWITCH
DRIVE SPEED SWITCH
DRIVE ENABLE SWITCH
GENERATOR SWITCH ( OPTION )
WORK/DRIVE LIGHT ( OPTION )

PRIMARY
BOOM
EXTEND/
RETRACT

HARNESS
PBOX WIRING

WORK / DRIVE LITE


TS49

75565
56298
66812, 95406
66813, 66816
42730
13037
56457
56457
56298
16397
13037
13037
13037
56457
13037
27378
27378

BL/RD-DE3 J1-16

DETAIL A: LIFT/DRIVE OPTION

WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14

RD-TILT

RD/BK H1

WH-24

BL/WH-DE1 J1-6
BK-22

BL/BK-DE2 J1-7

BRN

WH-JIB

BK/WH-8

BK-7

BK J1-2
RD J1-1

OR J1-11
BRN J1-12

DRIVE LT BK/RD-C3P-9

L4

L1

REPLACE WIRE WITH THIS WIRING DIAGRAM

BRN BATGND
(GND STUD)

P22BAT BK C7P-1

RD-TILT

BK-22

RD

P26BAT BK C9P-1

WH-23

RD

BL/RD-39

WH-24
BK/RD-35

WH-TS47

BK-33

RD-25

WH-24

WH-TS4

GR/WH-45

WH-24

WH-24

C29MS RD/WH J1-8

C27AUX RD C1P-1

WH-JIB

JDALARM GR/BK-44 C2P-6

C19JSV GR/WH

C17JU GR C4P-5

C19JSV GR/WH JIB

C18JD GR/BK C4P-6

OR-14

OR/BK-15

RD

GR-43

CR27

WH TS7

WH TS1

WH/RD C32BRK

(SPLICE TO C32BRK)

CR30
WH
TS9

TS7

TS8

TS1

GR

TS47

WH
HORN
P3

PLATFORM
LEVEL

WH

PLATFORM
ROTATE
GR/BK

JIB

AUXILIARY
PUMP

DRIVE
SPEED
HIGH/LOW

OR R40LS1

TS2

TS14

START

HIGH/LOW
RPM
TS4

TS3

(SPLICE TO R40LS1)

FUEL SELECT

GENERATOR
(OPTION)
EMERGENCY STOP
P2

RD

NOTE: DASHED LINES INDICATE


OPTION WIRES

CE SEE DETAIL A

REMOVE FOR GENERATOR OPTION

Part No. 102521

S-40 S-45

6 - 75

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Ford DSG-423 EFI Models
(from serial number 11067 to 12519)

6 - 75
6 - 76

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram

REV A

Ford DSG-423 EFI Models


(after serial number 12509)
N

10 AMP FUSE

PRI. BOOM

WORK /

UP/DOWN

DRIVE LITE
TS49

JC2

JC3

DLITE/ RD WL2

RD WL1

JC2

COMPONENT INDEX
BOOM PROPORTIONAL JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE

JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L4
TS7
TS8
TS9
TS13
TS14
TS15
TS47
TS49

75565
DRIVE PROPORTIONAL JOYSTICK
DRIVE ENABLE LED
56298
66812, 95406
EMERGENCY STOP BUTTON
66813, 66816
HORN SWITCH
AUXILIARY SWITCH
42730
START ENGINE SWITCH
13037
56457
FUEL SELECT SWITCH (FORD EFI ONLY)
HI/L0 RPM SWITCH
56457
CHASSIS TILT LED
56298
PLATFORM ROTATE SWITCH
16397
JIB UP/DOWN SWITCH
13037
PLATFORM LEVEL SWITCH
13037
PRIMARY BOOM EXTEND/RETRACT SWITCH13037
DRIVE SPEED SWITCH
56457
DRIVE ENABLE SWITCH
13037
GENERATOR SWITCH ( OPTION )
27378
WORK/DRIVE LIGHT ( OPTION )
27378

DRIVE/STEER

PRIMARY
BOOM
EXTEND/
RETRACT

HARNESS
PBOX WIRING

DRV.ENA
TS15

TT ROTATE

PART NUMBER
62390

TS13

WH-24

+
L4

J1-5 BL/WH JC3-5

J1-4 WH/RD JC3-4

J1-13 OR JC3-2

J1-5 BL/WH JC3-3

J1-14 BRN JC3-1

(GND STUD)

P22BAT BK C7P-1

JIB

CR27

WH TS7

RD-TILT

BK-22

P26BAT BK C9P-1

WH-23

RD

BL/RD-39

RD

TS8

PLATFORM
ROTATE GR/BK

BK/RD-35
WH-24

BK-33

RD-25

WH-24

WH-TS4

GR/WH-45

WH-24

WH-24

C29MS RD/WH J1-8

C27AUX RD C1P-1

WH

RD-TILT

RD/BK H1

WH-24

BL/RD-DE3 J1-16

BL/WH-DE1 J1-6
BK-22

BL/BK-DE2 J1-7

BRN

JDALARM GR/BK-44 C2P-6

WH-JIB

PLATFORM
LEVEL

BRN BATGND

WH TS1

WH/RD C32BRK
(SPLICE TO C32BRK)

6
TS4
TS1

AUXILIARY
PUMP

OR R40LS1

TS47

(SPLICE TO R40LS1)

TS2

TS14

HIGH/LOW
RPM

WH
HORN
P3

DETAIL A: LIFT/DRIVE OPTION


REPLACE WIRE WITH THIS WIRING DIAGRAM

CR30

WH
GR

L1

DRIVE LT BK/RD-C3P-9

WH-JIB

BK-7

BK/WH-8

C19JSV GR/WH

C17JU GR C4P-5

C19JSV GR/WH JIB

C18JD GR/BK C4P-6

OR-14

NO

J1-2 RD/WH JC2-4

J1-11 OR JC2-2

J1-1 WH/RD JC2-3

J1-12 BRN JC2-1

OR/BK-15

RD

GR-43

TS7

TS9
4

CR13

DRIVE
SPEED
HIGH/LOW

TS3

START
GENERATOR
(OPTION)

FUEL SELECT
RD

NC

NC

NC

EMERGENCY STOP
P2

NOTE:
DASHED LINES INDICATE

CE SEE DETAIL A

OPTION WIRES

Part No. 102521

S-40 S-45

6 - 77

July 2007

Section 6 Schematics

Platform Control Box Switch Panel Wiring Diagram


Ford DSG-423 EFI Models
(after serial number 12509)

6 - 77
6 - 78

Section 6 Schematics

July 2007

Engine Wire Harness


Ford LRG-425 EFI Models
(before serial number 11067)

6 - 80
6 - 79

July 2007

Section 6 Schematics
REV A

Engine Wire Harness


Ford LRG-425 EFI Models
(before serial number 11067)
A

1
INJ +
INJ 1
INJ 3
INJ 4
INJ 2
INJ 5
INJ 6
AUX OUT 2
EGR

AUX ANA PD1


MAP
FPP 1
IAT
ECT
IVS
AUX ANA PU1
FPP 2
EGR PWM
EGR RECIRC
POWER GROUND

POWER GROUND
ANA_RTN
5 VOLT REF
VSW
CRANK CRANK +
CAM CAM +
VBAT
VBAT
EGO 2

EGO 1
EGO 3
KNK +
KNK -

361 R 16

361 R 16

555 T 16

557 BR-Y 16

557 BR-Y 16

558 BR-LB 16

558 BR-LB 16

10

556 W 16

361 R 16

743 GY 18

12

359 GY-R 18

INJECTOR #1

21

18 O-Y 18

19

198 DG-O 18

20

358 LG-BK 18

15

151 LB-BK 18

27

743 GY 18

307 BK-Y 18

28

354 LG-R 18

354 LG-R 18

COIL 4
COIL 5
COIL 6
STARTER LOCKOUT
FUEL LOCKOFF

FUEL PUMP
RELAY CONTROL
TPS1
TPS2
DBW +
DBW BRAKE SWITCH
OIL PRESSURE
TACH
MIL
FUEL PUMP MON

AUX OUT 1
FUEL SELECT
AUX ANA PU2
GOV SELECT 1
GOV SELECT 2
ROAD SPEED +
ROAD SPEED GASEOUS TRIM
OVERSPEED
CAN +
CAN -

RS 485 +
RS 485 RS 232 TX
RS 232 RX

17

307 BK-Y 18

A
B

18

150 DG-W 18

16

114 LB-Y 18

22

352 BR-LG 18

23

360 BR-PK 18

570 BK-W 16

570 BK-W 16

570 BK-W 16

570 BK-W 16

151 LB-BK
307 BK-Y 18

570 BK-W 16

ECT

16 WATER TEMP

570 BK-W 12

F1 30A

F2

570 BK-W 12

5A

16 R-LG 18

MAP_CONN

F3 20A

13

359 GY-R 18

570 BK-W 16

14

351 BR-W 18

351 BR-W 18

16 R-LG 18

33

350 GY 18

358 LG-BK 18

358 LG-BK 18

32

349 DB 18

359 GY-R 18

359 GY-R 18

35

452 GY-R 18

18 O-Y 18

34

282 DB-O 18

198 DG-O 18

198 DG-O 18

361 R 16

150 DG-W 18

150 DG-W 18

361 R 16

114 LB-Y 18

114 LB-Y 18

25

392 R-LG 18

352 BR-LG 18

352 BR-LG 18

24

74 GY-LB 18

360 BR-PK 18

360 BR-PK 18

361 R 14

361 R 14

CRANK

O2 SENSOR

26

361 R 14

30

18 O-Y 18

359 GY-R 18
351 BR-W 18

361A R 16

361A R 16

570 BK-W 16

570 BK-W 16

74 GY-LB 18

392 R-LG 18

O2
SENSOR

MTRTWR6 MTRSHD6
355 GY-W 18
151 LB-BK 18

359 GY-R 18

317 GY-O 18

351 BR-W 18

850 Y-BK 18

851 Y-R 18

TWR

361A R 16

1 COIL 1
2 VBAT

A
B

242 DG 18
361A R 16

LOCKOFF SOLENOID

24
25

SHD

TWR
A

16 R-LG 18

THROTTLE
355 GY-W 18
357 Y-W 18
151 LB-BK 18
317 GY-O 18
351 BR-W 18
359 GY-R 18

FUEL PUMP
RELAY

6
5
4
1

32 R-LB 16

86

86

87

38 EGR ANA IN
32 ANA AUX PD1
37 ANA AUX PU1
12 FPP2
40 EGR PWM
41 EGR REC

30

32 R-LB 16
32 R-LB 16

3
2

85

87

87A

359 GY-R 18

351 BR-W 18

C
B

458 O-BK 18

RTN

FPP_COMM

787A PK-BK 16

F4 15A

787A PK-BK 16

RX

TWR

86

926A LB-O 18

32

15 R-Y 18

30

355 GY-W 18

31

357 Y-W 18

28

151 LB-BK 18

29

317 GY-O 18

511 LG-R 18

511 LG-R 18

511 LG-R 18

253 DG-W 18

253 DG-W 18

253 DG-W 18

11 T-Y 18

11 T-Y 18

11 T-Y 18

27

658 PK-LG 18

658 PK-LG 18

658 PK-LG 18

10

238 DG-Y 18

238 DG-Y 18

71 O-LG 18

71 O-LG 18

71 O-LG 18

14

72 Y-BK 18

72 Y-BK 18

72 Y-BK 18

15

148 Y-R 18

148 Y-R 18

148 Y-R 18

16

306 T-LB 18

306 T-LB 18

306 T-LB 18

17

307 BK-Y 18

307 BK-Y 18

307 BK-Y 18

11

169 LG-BK 18

169 LG-BK 18

169 LG-BK 18

12

172 LB-R 18

172 LB-R 18

172 LB-R 18

26
33

77 DB-Y 18
349A DB 18

349A DB 18

349A DB 18

18

662 DG-P 18

662 DG-P 18

662 DG-P 18

19

459 O-LG 18

459 O-LG 18

459 O-LG 18

20

642 DG-O 18

642 DG-O 18

642 DG-O 18

21

461 O 18

461 O 18

461 O 18

34

669 DG-W 18

669 DG-W 18

35

458 O-BK 18

458 O-BK 18

669 DG-W 18
458 O-BK 18

85

926A LB-O 18
15 R-Y 18

87

87A

361 R 16

OIL PRESSURE

5 FUEL PUMP

POWER
RELAY

30

242 DG 18

F5 15A

361 R 16

253 DG-W 18

570 BK-W 16
361A R 16
459 O-LG 18
662 DG-P 18

MTRTWR4

Part No. 102521

39 STARTER IN (AUTOCRANK)

TX

23

361A R 16

15 STARTER IN (INTERUPT)

5V

342 LG-P 18

361A R 16

31 VREF
13 STARTER CONTROL

342 LG-P 18

669 DG-W 18

77 DB-Y 18

33 ANA RTN

87A

22

S-40 S-45

9 VBATT

STARTER
RELAY

30

85

342 LG-P 18

3 COIL 2

13

1 VSW

351 BR-W 18

34 GROUND

361 R 14

359 GY-R 18

570 BK-W 16

25 IVS

361 R 14

29

361 R 12

TWR

351 BR-W 18

16 R-LG 18

CAM

14 FPP1

570 BK-W 16
16 R-LG 18

WPTWR2_GY

6 - 80

39 R-W 18

359 GY-R 18
570 BK-W 16

TRIM VALVE
TWR

570 BK-W 16

151 LB-BK

J2 GREY
COIL 3

INJECTOR #2

WATER
TEMP

359 GY-R 18

COIL 1

INJECTOR #4

ACT

359 GY-R 18

COIL 2

INJECTOR #3

FORD
42 PIN
CONNECTOR

31

357 Y-W 18

SPK PWR GROUND

361 R 16

556 W 16

11

J1 BLACK

361 R 16

555 T 16

TWR

4 BRAKE
26 OIL PRES
2 TACH
6 MIL
21 AUX OUT1
7 FUEL SELECT
10 AUX ANA PU2
24 GOV SELECT 1
23 GOV SELECT 2
35 ROADSPEED +
36 ROADSPEED 30 OVERSPEED
28 CAN +
29 CAN 11 RS 485+
3 RS 48520 RS 232+
18 RS 232-

SHD

PLUG (GROUND)

PLUG (RELAY POWER)

PLUG (CAN -)
PLUG (CAN +)

MTRSHD4

July 2007

Section 6 Schematics

Engine Wire Harness

REV A

Ford DSG-423 EFI Models (from serial number 11067 to 11784)


N

R 16

ENGINE ECM
CONNECTOR
SPK_COIL1A
SPK_COIL1B
SPARK_COIL2A
SPK_GND
SPK_COIL2B
SPK_COIL3A
SPK_COIL3B
UEGOS
UEGOC
UEGOP
UEGPR
AUX ANA PD1
(FRP) AUX ANA PD2
CAN1 +
CAN1 CAN2 CAN2 +
AUX ANA PD3
5V EXT 1
5V RTN
EGO1
EGO2
MAP
AUX ANA PUD3
CRANK +
CRANK CAM +
CAM SPEED +
SPEED 5V EXT 2
5V RTN 2
PULSE IN
GOV 1
OIL PRESS
IAT
ECT
(FRT) AUX ANA PU1
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
(BRAKE) AUX DIG 3
(GOV2) AUX DIG 4
TACH
VSW
AUX ANA PUD2
AUX ANA PUD1
TPS 1
TPS 2
(FUELSELECT)AUX DIG1
AUX DIG 2
KNOCK +
KNOCK FPP1
FPP2-IVS
(FPP2)
PC TX
PC RX
KNOCK 2+
KNOCK 2VBAT PROT
VBAT
EGOH 2
EGOH 1
INJ HS
INJ1 LS
INJ2 LS
INJ3 LS
INJ4 LS
INJ5 LS
GROUND
INJ6 LS
AUX PWM8
STARTER
RELAY
MIL
UEGO H
AUX PWM7
LOCKOFF
AUX PWM6
(FUEL PUMP)
VBAT
DBW +
GROUND
DBW AUX PWM5 REC
AUX PWM5
AUX PWM1
AUX PWM4
AUX PWM2
AUX PWM4 REC
AUX PWM3 REC
FP REC
AUX PWM3
FUEL PUMP

Y/BK 18
W/PK 18
Y/RD 18
BK/W 16
DG/P

6
7
8
9
10
11
12
13
14
15

DG/O 18
W/LG 18
DG/P 18
O/LG 18

R 16

GY/LB 18

DG/P 18

DB/O 18
GY/R 18

CYL #2

CYL #3

CYL #4

HO2S #1

IGNITION COILS

Y/BK 18
W/PK 18
Y/RD 18
1
2
3
4
5

GY/R 18
GY/YL 18
R 16
BK/LB 18

CYL #1

DG/P 18
O/LG 18

LG/BK 18
BR/W 18
GY 18
GY/R 18

GASOLINE
SENSOR
INTERFACE
FORD
42 PIN
CONNECTOR

LG/R 18

GY/R 18

GY/R 18

GROUND

BR 16

BR 16

34 GND

RING

4
3
2
1

CHT
LG/W
DG/BK
LB/R 18
T/LB 18
BK/W 16
BK/W 16
BK/W 16
LB/BK 18
BK/LB 18

LB/R 18
LG/BK 18
T/LB 18

36 ROADSPEED 35 ROADSPEED +
24 GOV SELECT 1

LB/BK 18

R/LG 18
BK/Y 18

R/LG 18

R/T 14

R/T 14

F2

14 FPP1

R/LG 18

R/LG 18

1 VSW

VSW

5A

F3
R 14

ECM

10A

BK/Y 18

GY 18
DBL 18

23 GOV SELECT 2

O/LG 18
DG/P 18

CRANK

29 CAN 28 CAN +

DG/O 18

DG/O 18

DB/W 18
LB/Y 18

DB/W 18

GY/R 18
BR/W 18

GY/R 18
BR/W 18

33 ANA RTN
31 VREF

R/BK 18
R/W 18

R/BK 18
R/W 18

21 AUX PWM 5
16 AUX PWM 4

BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18

BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18

25 IVS
26 OIL PRES
2 TACH
6 MIL
18 FUEL PUMP 39 AUX OUT1
7 FUEL SELECT
10 AUX ANA PD1B
27 AUX OUT 2
4 BRAKE
11 RS 232+
3 RS 232-

LB/PK 16
W/PK 16

15 START IN INTERUPT
19 START IN AUTOCRANK

PK/BK 16

5 FUEL PUMP +

32 ANA AUX PD1


37 AUX ANA PU2B

LB/Y 18

12 FPP2

RD/T 14

R/T 16
BK/LB 18
BK/LG 18

GY/R 18
BR/W 18

T 16
BR/Y 16
BR/LB 16
W 16
BK/W 16
BK/W 16
LG/P 18
R/Y 18
PK/LG 18
BK/R 16
W/BK 18
LB/O 18
R/T 16
LB/DG 18
BK/W 16
GY/O 18

BK/LG 18

BOSCH THROTTLE

GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18

GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18

BATT(+)

R 12

RING

6
5
4
3
2
1

R 14

R 12

R 16

3
2
1

ALTERNATOR

DG/W 18

LG/P 18
R/Y 18

OIL PRESSURE

R/BK 18
O/LG 18
R/W 18
T/GN 18

BK/R 16
W 16

W/R 18

INJECTOR CYL #2

GY/R 18

FUEL PUMP

F4

LPG
TEMPERATURE

BN/LB 16

PK/BK 16
GY/R 18
BR/W 18
DG 18
O 18

TWR

INJECTOR CYL #4

W/BK 18
R/LG 18

A
B

LPG
LOCKOFF

BR/Y 16

DG/P 18
Y/R 18

KNOCK
SENSOR

DG/P 18
O/LG 18

1
2
3
4
5
6
7
8

ANA RTN
5V REF
PC TX
PC RX
UNUSED
UNUSED
CAN +
CAN -

DIAGNOSTIC CONNECTOR

PK/BK 16

FUEL PUMP RELAY


LB/O 18

LB/O 18

85

R 16
PK/BK 16

30

R/LG 18

STARTER
SOLENOID

87

RING

87A

LB/PK 16

87

W/PK 16

30

86
87A

R/LG 18

CAN
TERMINATION
CONNECTOR

STARTER RELAY

LB/PK 16

R/LG 18

LG/P 18

INJECTOR CYL #3
T 16

15A

86

R 16
85

W 18

SHD

RELAY
OMRON
FPP

PK/BK 16

TWR

W 18

DG/P 18
O/LG 18
BK/W 18

3
1
6
4
5
8

PK/BK 16

F1
R16
R/Y 18

INJECTOR CYL #1
R 16

BK/W 12

Y/R 18
DG/P 18
LB/BK 18
LB/Y 18
DG 18
O 18

R 16

SHD
A
B
C
D

MTRTWR4

BR/W 18
LG/R 18

BOSCH
TMAP

T/LB 18
DG/W 18
GY 18
LG/R 18
LG/W
W/R 18
BK/O 18
W/LB 18
BK/Y 18
T/Y 18
R/LG 18
DB/W 18
P/LB 18
GY/W 18
Y/W 18
Y/DB 18

R 16

TWR
A
B
C
D

GY/R 18
LG/W 18
BR/W 18
W/LG 18

W/LG 18

GY 18
DBL 18
GY/R 18
DB/O 18
DG/BK
LB/R 18

R 16

GY/Y 18

BR/W 18
GY/R 18
GY/LB 18
GY/Y 18
LG/BK 18

R 16

HO2S #2

R 16
BK/LG 18
GY/LB 18
GY/R 18

CAM

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90

R 16

POWER RELAY

R 16

30

R 16

87

R/T 18

86
87A

R/LB 16

R/LB 16

10A

85

EPR

R 16

15A

RELAYED POWER

Part No. 102521

CAN +
CAN GROUND
UNUSED
UNUSED
UNUSED

POWER

EPR
CONNECTOR

F5
R 16

CAN + TERM

ES0400A
S-40 S-45

6 - 81

July 2007

Section 6 Schematics

Engine Wire Harness


Ford DSG-423 EFI Models (from serial number 11101 to 11784)

6 - 81
6 - 82

July 2007

Section 6 Schematics

Engine Wire Harness

REV A

Ford DSG-423 EFI Models (after serial number 11784)


N

J
R 16

ENGINE ECM
CONNECTOR
SPK_COIL1A
SPK_COIL1B
SPARK_COIL2A
SPK_GND
SPK_COIL2B
SPK_COIL3A
SPK_COIL3B
UEGOS
UEGOC
UEGOP
UEGPR
AUX ANA PD1
(FRP) AUX ANA PD2
CAN1 +
CAN1 CAN2 CAN2 +
AUX ANA PD3
5V EXT 1
5V RTN
EGO1
EGO2
MAP
AUX ANA PUD3
CRANK +
CRANK CAM +
CAM SPEED +
SPEED 5V EXT 2
5V RTN 2
PULSE IN
GOV 1
OIL PRESS
IAT
ECT
(FRT) AUX ANA PU1
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
(BRAKE) AUX DIG 3
(GOV2) AUX DIG 4
TACH
VSW
AUX ANA PUD2
AUX ANA PUD1
TPS 1
TPS 2
(FUELSELECT)AUX DIG1
AUX DIG 2
KNOCK +
KNOCK FPP1
FPP2-IVS
(FPP2)
PC TX
PC RX
KNOCK 2+
KNOCK 2VBAT PROT
VBAT
EGOH 2
EGOH 1
INJ HS
INJ1 LS
INJ2 LS
INJ3 LS
INJ4 LS
INJ5 LS
GROUND
INJ6 LS
AUX PWM8
STARTER
RELAY
MIL
UEGO H
AUX PWM7
LOCKOFF
AUX PWM6
(FUEL PUMP)
VBAT
DBW +
GROUND
DBW AUX PWM5 REC
AUX PWM5
AUX PWM1
AUX PWM4
AUX PWM2
AUX PWM4 REC
AUX PWM3 REC
FP REC
AUX PWM3
FUEL PUMP

Y/BK 18
W/PK 18
Y/RD 18
BK/W 16
DG/P

6
7
8
9
10
11
12
13
14
15

R 16

GY/LB 18

DG/P 18

DB/O 18
GY/R 18

CYL #2

CYL #3

CYL #4

GY/R 18
GY/YL 18
R 16
BK/LB 18

CYL #1

DG/P 18
O/LG 18

LG/BK 18
BR/W 18
GY 18
GY/R 18

GASOLINE
SENSOR
INTERFACE
FORD
42 PIN
CONNECTOR

LG/R 18

GY/R 18

GY/R 18

GROUND

BR 16

BR 16

34 GND

RING

4
3
2
1

CHT
LG/W
DG/BK
LB/R 18
T/LB 18
BK/W 16
BK/W 16
BK/W 16
LB/BK 18
BK/LB 18

LB/R 18
LG/BK 18
T/LB 18

36 ROADSPEED 35 ROADSPEED +
24 GOV SELECT 1

LB/BK 18

R/LG 18
BK/Y 18

R/LG 18

R/T 14

R/T 14

F2

14 FPP1

R/LG 18

R/LG 18

1 VSW

VSW

5A

F3
R 14

ECM

10A

Y/R 18
DG/P 18
LB/BK 18
LB/Y 18
DG 18
O 18

BK/Y 18

GY 18
DBL 18

23 GOV SELECT 2

O/LG 18
DG/P 18

CRANK

29 CAN 28 CAN +

DG/O 18

DG/O 18

DB/W 18
LB/Y 18

DB/W 18

GY/R 18
BR/W 18

GY/R 18
BR/W 18

33 ANA RTN
31 VREF

R/BK 18
R/W 18

R/BK 18
R/W 18

21 AUX PWM 5
16 AUX PWM 4

BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18

BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18

25 IVS
26 OIL PRES
2 TACH
6 MIL
18 FUEL PUMP 39 AUX OUT1
7 FUEL SELECT
10 AUX ANA PD1B
27 AUX OUT 2
4 BRAKE
11 RS 232+
3 RS 232-

LB/PK 16
W/PK 16

15 START IN INTERUPT
19 START IN AUTOCRANK

PK/BK 16

5 FUEL PUMP +

32 ANA AUX PD1


37 AUX ANA PU2B

LB/Y 18

12 FPP2

RD/T 14

R/T 16
BK/LB 18
BK/LG 18

GY/R 18
BR/W 18

T 16
BR/Y 16
BR/LB 16
W 16
BK/W 16
BK/W 16
LG/P 18
R/Y 18
PK/LG 18
BK/R 16
W/BK 18
LB/O 18
R/T 16
LB/DG 18
BK/W 16
GY/O 18

BK/LG 18

BOSCH THROTTLE

GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18

GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18

BATT(+)

R 12

R 12

RING

6
5
4
3
2
1

R 14

R 16

3
2
1

R/LG 18

ALTERNATOR

DG/W 18

LG/P 18
R/Y 18

OIL PRESSURE

R/BK 18
O/LG 18
R/W 18
T/GN 18

BK/R 16
W 16

W/R 18

INJECTOR CYL #2

GY/R 18

FUEL PUMP

F4

LPG
TEMPERATURE

BN/LB 16

PK/BK 16
GY/R 18
BR/W 18
DG 18
O 18

TWR

INJECTOR CYL #4

W/BK 18
R/LG 18

A
B

LPG
LOCKOFF

BR/Y 16

DG/P 18
Y/R 18

KNOCK
SENSOR

DG/P 18
O/LG 18

1
2
3
4
5
6
7
8

ANA RTN
5V REF
PC TX
PC RX
UNUSED
UNUSED
CAN +
CAN -

DIAGNOSTIC CONNECTOR

PK/BK 16

LB/O 18

LB/O 18

85

R 16
PK/BK 16

30

R/LG 18

STARTER
SOLENOID

87

RING

87A

LB/PK 16

87

W/PK 16

30

86
87A

R/LG 18

CAN
TERMINATION
CONNECTOR

STARTER RELAY

LB/PK 16

INJECTOR CYL #3
T 16

15A
FUEL PUMP RELAY

R/LG 18

86

LG/P 18

85

R 16

W 18

SHD

RELAY
OMRON
FPP

PK/BK 16

TWR

W 18

DG/P 18
O/LG 18
BK/W 18

3
1
6
4
5
8

PK/BK 16

F1
R16
R/Y 18

INJECTOR CYL #1
R 16

SHD
A
B
C
D

MTRTWR4

BR/W 18
LG/R 18

BOSCH
TMAP

T/LB 18
DG/W 18
GY 18
LG/R 18
LG/W
W/R 18
BK/O 18
W/LB 18
BK/Y 18
T/Y 18
R/LG 18
DB/W 18
P/LB 18
GY/W 18
Y/W 18
Y/DB 18

R 16

BK/W 12

GY 18
DBL 18
GY/R 18
DB/O 18
DG/BK
LB/R 18

R 16

TWR
A
B
C
D

GY/R 18
LG/W 18
BR/W 18
W/LG 18

W/LG 18

BR/W 18
GY/R 18
GY/LB 18
GY/Y 18
LG/BK 18

R 16

GY/Y 18

DG/O 18
W/LG 18
DG/P 18
O/LG 18

R 16

HO2S #2

R 16
BK/LG 18
GY/LB 18
GY/R 18

CAM

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90

HO2S #1

IGNITION COILS

Y/BK 18
W/PK 18
Y/RD 18
1
2
3
4
5

R 16

POWER RELAY

R 16

30

R 16

87

R/T 18

86

R/LB 16

R/LB 16

10A

85

EPR

87A

Part No. 102521

R 16

15A

RELAYED POWER

POWER

EPR
CONNECTOR

F5
R 16

CAN + TERM

CAN +
CAN GROUND
UNUSED
UNUSED
UNUSED

ES0400A
S-40 S-45

6 - 83

July 2007

Section 6 Schematics

Engine Wire Harness


Ford DSG-423 EFI Models (after serial number 11784)

6 - 83
6 - 84

July 2007

Section 6 Schematics

REV A

Joystick Connector Diagram

PRIMARY BOOM
UP/DOWN

DRIVE/STEER

JC2

YOUT 5

PWR 3

GND 2

YOUT 5

XOUT 4

PWR 3

GND 2

RKOUT 6

DRIVE & STEERING

BL

WH

13

BK

OR

RD

11

14

OR

12

BRN

BRN

J1

JC3

JC3

PRI UP/DN & TT ROTATE

TURNTABLE ROTATE

J1

4
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14

BK J1-2
RD J1-1

OR J1-11
BRN J1-12

JOYSTICK CONTROL CARD

AMP - 7 Pin Connector

PRIMARY BOOM
UP/DOWN

6
6

1
1

5
5

2
2

4
4

3
3

Deutsch

DRIVE/STEER

Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6

GND
PWR
XOUT
YOUT
RKOUT

Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7

Joystick Adaptor Harness


JC2

JC2

JC3

PRI UP/DN & TT ROTATE

JC2

7
1
6
2
5
3
4
4
3
5

2
6
1
7

AMP

JC3

DRIVE & STEERING

YOUT 4

RKOUT 5

OR

BL/WH

WH/RD

BL/WH

XOUT 3

BRN

RD/WH

GND 1

WH/RD

PWR 2

YOUT 4

OR

XOUT 3

BRN

GND 1

PWR 2

TURNTABLE ROTATE

7
5

13

14

11

12

J1

J1
J1-5 BL/WH JC3-5

J1-4 WH/RD JC3-4

J1-13 OR JC3-2

J1-5 BL/WH JC3-3

J1-14 BRN JC3-1

J1-2 RD/WH JC2-4

J1-11 OR JC2-2

Note: Production changed


from 7 pin to 6 pin Joysticks
at Serial Number 12510

J1-1 WH/RD JC2-3

J1-12 BRN JC2-1

JOYSTICK CONTROL CARD

Deutsch - 6 Pin Connector

Part No. 102521

S-40 S-45

6 - 85

July 2007

Section 6 Schematics

Joystick Connector Diagram

6 - 85
6 - 86

Section 6 Schematics

July 2007

CTE Option Wiring Diagram

6 - 88
6 - 87

6 - 88
GROUND

SCHEMATIC - PLATFORM LEVEL CUTOUT

S-40 S-45
Part No. 102521
14"

WIRING DIAGRAM

OR C2B-2

OR-TS59

OR/BK-TS59

CTE Option Wiring Diagram

K
L

GROUND BOLT

14

14 PLATFORM LEVEL UP

14"

15

C40LS1 OR CR20#30

TB40

15 PLATFORM LEVEL DOWN

40

RD-H6+
RD-KS1-2 S.P.

C15PLD OR/BK C4B-3


C15PLD OR/BK CR21#86
C14PLU OR C4B-2
C14PLU OR CR20#86

5
40 BOOM STOWED

42

OR C6-40

14"
42 P134PWR

14"
C14PLU OR C6-14

OR/RD-C2B-4

CR20
C15PLD OR/BK C6-15

26"
C15PLD OR/BK 15-D

BRN 7.5"

CR21

DOWN RELAY

RD-C6-23 + LS PWR-C6-30

7.5"

PLAT LEVEL

C14PLU OR 14-D

CR20

UP RELAY

TB22

LIMIT SWITCHES

P22LS BK

PLAT LEVEL

CR21

11"

TB15

C40LS1 OR 40-A

6
BRN

C14PLU OR

BR-GND STUD

C20-1

4
R14PLU OR

R15PLD OR/BK

TB134

C20-2

C21-1

3
B

PLAT LEVEL UP

C21-2

PLAT LEVEL DOWN

C15PLD OR/BK

July 2007
Section 6 Schematics
REV A

M
N

TB14

July 2007
REV A

Section 6 Schematics

Hydraulic Generator Wiring Diagram- Welder Option

P25FS-RD
P26FS-BK
P24FS-WH

RPM HI

RPM LO

20

15

16

12.5 KW HYDRAULIC GENERATOR

TS47

GENERATOR ON

TS4

FOOTSWITCH

ALC-500

D12

NEUTRAL BUSS BAR

1 N.O.
2 COM

C45GEN GR/WH

8 N.C.

C35RPM BK/RD

C2P-7

C1P-9

C29MS RD/WH

L3

C30EDC WH

C31EDC WH/BK

L2

L1

C1P-3

C1P-4

C1P-5
NEMA 4 CONTROL BOX

50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI

TB29

124 ohms
1

V151HG GR
V150HG GR/BK
GROUND
STUD ON
PANEL

APBPC
RS232TxD
RS232RxD

A1 BATTERY +
A2 SENSOR POWER +5 VDC
A3 BATTERYB1 VALVE 0 FWD COIL
B2 VALVE 1 NC
B3 DIGITAL OUTPUT BYPASS/OMRON

C1 TxD
C2 RxD
C3 /BOOT

8 GA 5 CONDUCTOR
BRASS

E1 NOT USED
E2 NOT USED
E3 NOT USED

GREEN 12GA

120 VAC GFI

CR4PHIGH IDLE
RELAY

8 GA 4 CONDUCTOR

MOTOR STROKE
VALVE

D1 ANALOG 0 JOYSTICK
D2 ANALOG 1 NC
D3 DIG IN 3 NC

BLACK 12GA
SILVER

C45GEN GR/WH

124 ohms
20 AMP CIRCUIT
BREAKER

F1 DIG IN 0
F2 DIG IN 1 GENERATOR ON
F3 DIG IN 2

U4

SX Controller

BYPASS PCOIL

110 VAC
GFI

DRIVE EDC +

DRIVE EDC -

12 GA 3 CONDUCTOR

ENCLOSURE

3
1k ohms

OMRON
RELAY

GREEN

BLACK 12GA

C5-12

L1

C5-18

C5-24

BLACK

GREEN

TB45

WHITE

BLACK

TB35

C2B-7

4
2

TB22

C5-1

5
1

C5-21

L3

RED

5 SW INPUT

TIME DELAY
MODULE 4S
C5-20

ORANGE
N

3 GND

C1B-9

RED

TB24

C1B-3

L2

C1B-4

C1B-5

208 VAC
OUTLET

7
SILVER

BRASS

WHITE

GREEN
GREEN
BLACK

1. Turning on the Generator supplies current


to the high idle relay through the diode
switching the engine to high RPM. In addition
the diode between TB45 and TB29 supplies
power to the motor stroke valve switching
the motors to high speed/low torque mode.

3. When the AC generator is turned OFF the


SX module will ramp the output to the EDC to
threshold preventing cavitation to the hydraulic
motor powering the generator. When threshold
is reached the bypass valve is turned OFF.

12 GA 3 CONDUCTOR

2. The SX controller is turned ON supplying


power to bypass valve and the change over
relay. The EDC valve is switched over to the
output of the SX controller.

Part No. 102521

Inside
Enclosure

Harness
PIN#
1
2
3
4
5
6
7
8
9
10
11
12

COLOR
BR
WH
WH/BK
BR
BR
WH
WH/BK
BR
GR/WH
GR/BK
WH
BR

S-40 S-45

CKT#
GND
C30EDC+
C31EDCGND
GND
C30EDC+(A)
C31EDC-(A)
GND
C45GEN
V150HG
C22PWR
GND

COLOR
WH/RD
WH
WH/BK
BK/RD
BL/RD
RD
RD/BK
OR/RD
GR/WH
GR/BK
RD/WH
GR

6 - 89

July 2007

Section 6 Schematics

Hydraulic Generator Wiring Diagram- Welder Option

6 - 89
6 - 90

July 2007

Section 6 Schematics

REV C

2WD Non-Oscillating Hydraulic Schematic


S-40 Models (before serial number 7569)

EXTEND RETRACT CYL

.025

DB

2 gpm
7.6 L/min

MEDIUM
PRESSURE
FILTER

BRAKE MANIFOLD

T2
CP

SLAVE

PLATFORM LEVEL
CYLINDERS

D
PLATFORM
ROTATE

TEST

3 gpm
11.4 bar

BRAKE

PRIMARY LIFT
CYLINDER

DA

TURNTABLE
ROTATE

4 gpm
15.1 L/min
51 psi
3.5 bar

CB

CA

MASTER

.030
S1

AUXILIARY
PUMP

1.7

V2
AUX

TEST

HYDRAULIC
COOLER
OPTION

315 psi
21.7 bar

SW2

BG

P2

P1

PL2
BE

E
AD

AV

AU

3625 psi
250 bar

AE
AG

AS

COUNTERBALANCE VALVE
RATIO

AC

AH
AA

BD

4.5 gpm
17 L/min

AR

FUNCTION
PUMP

9 7

AB

BF

PRESS

BH

BA

AY

AX

AZ

PR2

PR1

AI

AL

1950 psi
134 bar

T1

PL1

V1
SW1

2200 psi
151.7 bar

FUNCTION
MANIFOLD

AO

RET

EXT

PTEST

AP

AM

AF

0.6 gpm
2.3 L/min

AK
AW

BB

0.6 gpm
2 L/min
(S-40)

AN

RETURN
FILTER

DRIVE PUMP

AQ

2.0 gpm
7.6 L/min

25 psi
1.7 bar

AJ

BG

3:1

1000 PSI

3:1

2000 PSI

3:1

3000 PSI

3:1

3300 PSI

3:1

3500 PSI

5:1

3500 PSI

0.1 gpm
0.4 L/min

AT

2600 psi
179 bar

TANK
3 psi
0.2 bar

3 psi
0.2 bar

PRESS

AUX
T2

ST1

BI

ST2

FUNCTION
MANIFOLD

LS TEST

RESERVOIR

T1
PRESS

OPTIONAL
GENERATOR
MANIFOLD

2400 psi
165.5 bars

HYDRAULIC ROTARY COUPLER

8A

8B

x x

8C

6B

6C

6B

2A

2C

2B

5
FUNCTION
PUMP

A
REAR
RIGHT

TANK

TEST

M3
RELEASE

T2

FE

185 psi
12.7 bar

FRR

FRB

FLB

OPTIONAL
GENERATOR

FLR

M1

RIGHT

STEERING

TO HYD ROTARY COUPLER

LEFT

210 psi
14.5 bar

50%
FC

.070
50%

FB

FA

Note: 'alpha' callouts refer to


components shown in the
manifold illustrations.
Refer to the Repair Section.

FD

M4

T1

REAR
LEFT

185 psi
12.7 bar M2
RELEASE

TRACTION
MANIFOLD

Part No. 102521

S-40 S-45

6 - 91

July 2007

Section 6 Schematics

2WD Non-Oscillating Hydraulic Schematic


S-40 Models (before serial number 7569)

6 - 91
6 - 92

July 2007

Section 6 Schematics

REV C

2WD Non-Oscillating Hydraulic Schematic


S-45 Models (before serial number 7569)

EXTEND RETRACT CYL

BRAKE MANIFOLD

.025

DB

2 gpm
7.6 L/min

MEDIUM
PRESSURE
FILTER

T2
CP

TURNTABLE
ROTATE

4 GPM
15.1 L/min
50 psi
3.5 bar

PRIMARY LIFT
CYLINDER

SLAVE

S45 JIB BOOM

PLATFORM LEVEL
CYLINDERS

J2

3 GPM
11.4 L/min

V1
J1
C

DA

TEST

BRAKE

CC

MASTER

V2

.030

CA

PR1

S1

AUXILIARY
PUMP

1.7

V2

PL1

V1

PL2

PR2

AUX

HYDRAULIC
COOLER
OPTION

TEST

315 psi
21.7 bars

FUNCTION
MANIFOLD

AO

RET

EXT

PTEST

AP

P2

P1

SW2

2200 psi
151.7 bar

BE

BH
AD

AV

AG

AC

AH
BD

4.5 gpm
17 L/min

FUNCTION
PUMP

AM

AF

0.6 gpm
2.27 L/min

AK
BB

AW

AA

0.8 gpm
3 L/min

AN

RETURN
FILTER
25 psi
1.7 bar

AQ

AJ

BG

2.0 gpm
7.6 L/min

0.1 gpm
0.38 L/min

AT

2900 psi
200 bar

TANK
3 psi
0.2 bar

3 psi
0.2 bar

PLATFORM
ROTATE

AB

BF

AR

DRIVE PUMP

CB

BA

AE

AU
AS

9 7

JIB SELECT
MANIFOLD

AY

AX

AZ

PR2

PRESS
3625 psi
249.9 bar

PR1

AI

AL

1950 psi
134.4 bar

T1

SW1

BG

AUX
T2

ST1

BI

ST2

FUNCTION
MANIFOLD

LS TEST

RESERVOIR

T1
PRESS

OPTIONAL
GENERATOR
MANIFOLD

COUNTERBALANCE VALVE

RATIO

HYDRAULIC ROTARY COUPLER

8A

8B

x x

8C

6C

6B

6B

A
REAR
RIGHT

2A

2C

2B

TEST
FE

M3

PRESS

3:1

1000 PSI

3:1

2000 PSI

3:1

3000 PSI

3:1

3300 PSI

3:1

3500 PSI

5:1

3500 PSI

2400 psi
165.5 bar

FUNCTION
PUMP

TANK

T2

185 psi
12.7 bar
RELEASE

FRR

FRB

FLB

OPTIONAL
GENERATOR

FLR

TO HYD ROTARY COUPLER

M1

RIGHT

STEERING

LEFT

50%
FC

.070
FA

50%

FB

FD

Note: 'alpha' callouts refer to


components shown in the
manifold illustrations.
Refer to the Repair Section.

M4

T1

REAR
LEFT

M2
185 psi
12.7 bar
RELEASE

TRACTION
MANIFOLD

Part No. 102521

S-40 S-45

6 - 93

July 2007

Section 6 Schematics

2WD Non-Oscillating Hydraulic Schematic


S-45 Models (before serial number 7569)

6 - 93
6 - 94

July 2007

Section 6 Schematics

REV C

4WD Oscillating Hydraulic Schematic


S-40 Models (before serial number 7569)

EXTEND RETRACT CYL

BRAKE MANIFOLD

.025

DB

2 gpm
7.6 L/min

MEDIUM
PRESSURE
FILTER

TURNTABLE
ROTATE

4 gpm
15.1 L/min
50 psi
3.4 bar

3 gpm
11.4 L/min

T2

PLATFORM LEVEL
CYLINDERS

SLAVE

PRIMARY LIFT
CYLINDER

CA

CP
DA

MASTER
TEST

BRAKE

.030

CB

S1

V2

B
M
TEST

1.7

AUXILIARY
PUMP

315 psi
21.7 bar

AUX

HYDRAULIC
COOLER
OPTION

PTEST

AP

FUNCTION
MANIFOLD

AO

RET

EXT

PL1

SW1 SW2

P1

BG

P2
2200 psi
151.7 bar

AL

AE
AG

AC

AH
BD

4.5 gpm
17 L/min

AR

FUNCTION
PUMP

RATIO

AM

AA

0.6 gpm
2.27 L/min

AF
BB

AK
AW

0.6 gpm
2 L/min

AN

RETURN
FILTER

DRIVE PUMP

AQ

25 psi
1.7 bar

3 psi
0.2 bar

0.1 gpm
0.38 L/min

AT

2600 psi
179.3 bar

TANK

3:1

1000 PSI

3:1

2000 PSI

3:1

3000 PSI

3:1

3300 PSI

3:1

3500 PSI

5:1

3500 PSI

1.5:1

3000 PSI

AJ

BG

2.0 gpm
7.6 L/min

PRESS

AY

AX

AU
AS

COUNTERBALANCE VALVE

AB

BA

BF

3625 psi
249.9 bar
9

PR2

PR1

BH

PRESS

PLATFORM
ROTATE

BE

E
AD

AV
AZ

PL2

AI

1950 psi
134.4 bar

T1

V1

3 psi
0.2 bar

AUX
T2

ST1

BI

ST2

LS TEST

FUNCTION
MANIFOLD

RESERVOIR

T1
PRESS

OPTIONAL
GENERATOR
MANIFOLD
2400 psi
165.5 bar

HYDRAULIC ROTARY COUPLER


x
8A

x
8B

x x
8C 6B

x
6C 6A

2A

2C

2B

FUNCTION
PUMP
HF

REAR
LEFT

TEST

TANK

T2
M4

M7

FRONT
LEFT

M5

210 psi
14.5 bar

FRR

M2

HH

50%

RIGHT

HE

FRB

FLB

STEERING

67% 33%

TO HYD ROTARY COUPLER

LEFT

HA

TEST

.052
HG

50%

.070
HD

HI

IN

50%

FRONT
RIGHT
T1

M6

M1

B
A

OUT
M8

M3

950 psi
65.5 bar

RIGHT

LEFT

OSCILLATE VALVE

TRACTION
MANIFOLD

OPTIONAL
GENERATOR

FLR

50%

.070
HC

REAR
RIGHT

Note: 'alpha' callouts refer to


components shown in the
manifold illustrations.
Refer to the Repair Section.

OSCILLATE CYLINDERS

Part No. 102521

S-40 S-45

6 - 95

July 2007

Section 6 Schematics

4WD Oscillating Hydraulic Schematic


S-40 Models (before serial number 7569)

6 - 95
6 - 96

July 2007

Section 6 Schematics

REV C

4WD Oscillating Hydraulic Schematic


S-45 Models (before serial number 7569)

EXTEND RETRACT CYL

TURNTABLE
ROTATE

4 gpm
15.1 L/min
50 psi
3.4 bar

BRAKE MANIFOLD

.025

DB

2 gpm
7.6 L/min

MEDIUM
PRESSURE
FILTER

J2

3 gpm
11.4 L/min

T2

S45 JIB BOOM

PLATFORM LEVEL
CYLINDERS

SLAVE

PRIMARY LIFT
CYLINDER

V1
J1

CP

DA

TEST

BRAKE

CC

MASTER

V2

.030

CA

PR1

S1

V2

B
M
TEST

1.7

AUXILIARY
PUMP

315 psi
21.7 bar

AUX

HYDRAULIC
COOLER
OPTION

PTEST

AP

AO

RET

EXT

FUNCTION
MANIFOLD

SW1

PL1

SW2

BG

P2

P1

2200 psi
151.7 bar

AD

BA

AE
AG

AR

4.5 gpm
17 L/min

FUNCTION
PUMP

RETURN
FILTER

AQ

25 PSI

AC

BD
AM

0.6 gpm
2.27 L/min

AK

AF
BB

AW

AA

0.8 gpm
3 L/min

COUNTERBALANCE VALVE
BG

2.0 gpm
7.5 L/min

0.1 gpm
0.3 L/min

AT

3 psi
0.2 bar
T2

ST1

BI

ST2

PRESS

RATIO

AJ

2900 psi
200 bar

TANK
3 psi
0.2 bar

AH

AN

DRIVE PUMP

PLATFORM
ROTATE

AY

AX

AU
AS

CB

AB

BH

PRESS

JIB SELECT
MANIFOLD

BF

3625 psi
249.9 bar
E

PR2

PR2

PR1

AV
AZ

PL2
BE

AI

AL

1950 psi
134.5 bar

T1

V1

LS TEST

RESERVOIR

3:1

1000 PSI

3:1

2000 PSI

3:1

3000 PSI

3:1

3300 PSI

3:1

3500 PSI

5:1

3500 PSI

1.5:1

3000 PSI

AUX

FUNCTION
MANIFOLD

HYDRAULIC ROTARY COUPLER


x
8A

x
8B

x x
8C 6B

x
6C 6A

HF

REAR
LEFT

TEST

T1
2C

2B

2400 psi
165.5 bar

M4
FRONT
LEFT

210 psi
14.5 bar

RIGHT

HE

FRB

FLB

STEERING

FLR

67% 33%

TANK

HA

TEST

.052

HB

HG

50%

.070
HD

T2

HI

IN

50%

FRONT
RIGHT
T1

M6

M1

B
A

OUT
M8

M3

950 psi
65.5 bar

OPTIONAL
GENERATOR

RIGHT

LEFT

OSCILLATE VALVE

TRACTION
MANIFOLD

FUNCTION
PUMP

LEFT

50%

.070
HC

FRR

M2

HH

50%

PRESS

OPTIONAL
GENERATOR
MANIFOLD

M7

M5

REAR
RIGHT

2A

TO HYD ROTARY COUPLER

Note: 'alpha' callouts refer to


components shown in the
manifold illustrations.
Refer to the Repair Section.

OSCILLATE CYLINDERS

Part No. 102521

S-40 S-45

6 - 97

July 2007

Section 6 Schematics

4WD Oscillating Hydraulic Schematic


S-45 Models (before serial number 7569)

6 - 97
6 - 98

September
July 2007 2007

Section 6 Schematics

REV D

2WD Hydraulic Schematic


(after serial number 7568)
M

EXTEND RETRACT CYLINDER


(4 gpm / 15.1 L/min)
50 psi
3.5 bar

BRAKE/2 SPEED
MANIFOLD EA

TURNTABLE
ROTATE
(2 gpm / 7.5 L/min)
A

V1

CC

.030

V2

S1

M 1.7 AUXILIARY
PUMP

V2

AUX

HYDRAULIC
COOLER
OPTION

TEST
315 psi
21.7 bar

PTEST

AP

AO

SW1 SW2

RET

EXT

BC

P2

P1

FUNCTION
MANIFOLD

2200 psi
151.6 bar

1950 psi
134.5 bar

T1

E
AD

BA

AE

AU
AS

4.5 gpm
17 L/m

AR

FUNCTION
PUMP

AM

AF
AX

AY

AW

COUNTERBALANCE VALVE

AA

0.8 gpm
3 L/min
(S-45)

0.6 gpm
2.2 L/min

0.6 gpm
2 L/min
(S-40)

AQ

25 psi
1.7 bar

TANK
3 psi
0.20 bar

3 psi
0.20 bar

2.0 gpm
7.5 L/m

RETURN
FILTER

0.1 gpm
0.3 L/min

2600 psi
179 bar
(S-40)

T2

AJ

BG

AT

2900 psi
200 bar
(S-45)

E
F
G

ST1

ST2

BI

AUX
FUNCTION
MANIFOLD

-8

X
X
8B 6B 6C 6A

8A

2A

2C

2B

RIGHT
REAR

FRR

M4

RIGHT
CDR
GC

M2

LEFT
REAR

M3

T2

LEFT

STEERING

OPTIONAL
GENERATOR

MTR A

-12

TO HYD ROTARY COUPLER

-12

LEFT

RIGHT

-12

Note: 'alpha' callouts refer to


components shown in the
manifold illustrations.
Refer to the Repair Section.

T
OSCILLATE VALVE
G

OSCILLATE CYLINDERS OPTION

TANK

21CC
G2
G1

950 psi
65.5 bar

GD

12.5 KW GENERATOR

B
A

IN
OUT

TRACTION
MANIFOLD

G1
MTR B

-12

TEST

GB

FLR

-8

280 psi
19.3 bar

.070

50%

CU

GA

GF

M1
CDL

FLB

GE

50%

FRB

CY

270 PSI @
3.5 GPM

G2

TANK

A
B

0.031
CW

CX

FUNCTION
PUMP

TEST A

CV

2400 psi
165.4 bar

PMP A

CLR

PMP B

WELDER
MANIFOLD

2400 psi
165.4 bar

OPTIONAL
GENERATOR
MANIFOLD

HYDRAULIC ROTARY COUPLER

DRIVE
PUMP

-12

3.5 GPM

21 GPM

-12

PRESS

HYDRAULIC WELDER OPTION

OIL
COOLER

T1

PRESS
1000 PSI
2000 PSI
3000 PSI
3300 PSI
3500 PSI
3500 PSI
3000 PSI

LS TEST

RESERVOIR

RATIO
3:1
3:1
3:1
3:1
3:1
5:1
1.5:1

AN

DRIVE PUMP
X X

PLATFORM
ROTATE

AC

AK
BB

CB

AH

AG

BD

JIB SELECT
MANIFOLD

BF

3625 psi
249.9 bar

AB

AY

AX

AZ

PR2
BH

AI

AV

PR2

PR1

AL

PRESS

BE

CA

PR1

PL2

PL1

V1

TEST

MASTER

8C

J2

J1

EC

BRAKE 2SPEED

S45 JIB BOOM

PLATFORM LEVEL
CYLINDERS

SLAVE

PRIMARY LIFT
CYLINDER
(3 gpm / 11.3 L/min)

T2
CP

ED

EB

025.

MEDIUM
PRESSURE
FILTER

HYDRAULIC
ROTARY
COUPLER

OSCILLATE CYLINDERS

Part No. 102521

S-40 S-45

6 - 99

July 2007

Section 6 Schematics

2WD Hydraulic Schematic


(after serial number 7568)

6 - 99
6 - 100

September
July 2007 2007

Section 6 Schematics

REV D

4WD Hydraulic Schematic


(after serial number 7568)

.030 orifice added after serial number 8445

TURNTABLE
ROTATE
(2 gpm / 7.5 L/min)
A

EA

V1

T2
CP
C

TEST

BRAKE 2SPEED

CC

V2

S1
A

M 1.7

TEST

AUXILIARY
PUMP
AUX

HYDRAULIC
COOLER
OPTION

315 psi
21.7 bar

V1

V2
AP

AO

RET

EXT

PTEST

PL1

SW1 SW2

BC

P2
2200 psi
E
151.6 bar

P1

FUNCTION
MANIFOLD

T1

1950 psi
134.5 bar

PR1

AZ

FUNCTION
PUMP

BF

4.5 gpm
17 L/min

AA

0.6 gpm
2.2 L/min

AK

AF
BB

AW

0.8 gpm
3 L/min
(S-45)

0.6 gpm
2 L/min
(S-40)

COUNTERBALANCE VALVE

3 psi
0.20 bar

RETURN
FILTER

2600 psi
179 bar
(S-40)

B
C
D
E

ST1

T2

ST2

BI

LS TEST

RESERVOIR
AUX
FUNCTION
MANIFOLD

PRESS

8B 6B 6C 6A

8A

2A 2C

TEST A
JD

M7

M8
A

FRR

RIGHT
FRONT

FRB

M6

JA

CY

270 PSI @
3.5 GPM

G2
CU

OPTIONAL
GENERATOR

LEFT

RIGHT

0.031
CW

CX

TO HYD ROTARY COUPLER

JL

M5

6
CV

T2

FLR

FLB

PMP A

CLR

PMP B

TANK

STEERING

CDR

DRIVE
PUMP

G1
MTR B

-12

MTR A

-12
1

JC

-12

WELDER
MANIFOLD

2400 psi
165.4 bar

FUNCTION
PUMP

RIGHT
REAR

3.5 GPM

OPTIONAL
GENERATOR
MANIFOLD

2B

HYDRAULIC ROTARY COUPLER


3

-12
-8

21 GPM

PRESS
1000 PSI
2000 PSI
3000 PSI
3300 PSI
3500 PSI
3500 PSI
3000 PSI

HYDRAULIC WELDER OPTION

OIL
COOLER

T1

RATIO
3:1
3:1
3:1
3:1
3:1
5:1
1.5:1

0.1 gpm
0.3 L/min

AT

2900 psi
200 bar
(S-45)

TANK

AJ

BG

2.0 gpm
7.5 L/min

AQ

25 psi
1.7 bar

3 psi
0.20 bar

AM

50%

50%
280 psi
19.3 bar

.040
JH

LEFT
REAR

M3
CDL

M1

JN

JK

TEST

.040
JI
JE

JB

50%

50% 50%
.040

JG

PLATFORM
ROTATE

AN

DRIVE PUMP
X

CB

AC

BD

JIB SELECT
MANIFOLD

AH

AG

AR

AB

BA

AE

AS

PR2
BH

AD

AU

3625 psi
249.9 bar

PR2

AY

AX

BE

AI

AV

CA

PR1

PL2

AL

PRESS

8C

2
C

MASTER

EC

0.030

J1

-8

B
A

IN
OUT

JM

50%

950 psi
65.5 bar

M4

-12

TANK

21CC
G2
G1

-12

12.5 KW GENERATOR

RIGHT

LEFT

ED

EB

J2

.025

PRIMARY LIFT
CYLINDER
(3 gpm / 11.3 L/min)

S45 JIB BOOM

PLATFORM LEVEL
CYLINDERS

SLAVE

HYDRAULIC
ROTARY
COUPLER

BRAKE/2 SPEED
MANIFOLD

EXTEND RETRACT CYLINDER


(4 gpm / 15.1 L/min)

MEDIUM
PRESSURE
FILTER

50 psi
3.5 bar

B
JF

JJ

TRACTION
MANIFOLD

M2

LEFT
FRONT

OSCILLATE VALVE
G

OSCILLATE CYLINDERS OPTION

Note: 'alpha' callouts refer to


components shown in the
manifold illustrations.
Refer to the Repair Section.

OSCILLATE CYLINDERS

Part No. 102521

S-40 S-45

6 - 101

July 2007

Section 6 Schematics

4WD Hydraulic Schematic


(after serial number 7568)

6 - 101
6 - 102

July 2007

Section 6 Schematics

REV A

1
1

OIL
COOLER

3.5 GPM

DRIVE
PUMP
A

3
PMP B

CLR

PMP A

WELDER
MANIFOLD

CV

4
4

0.031

CW

CY

CX

5
5

270 PSI @
3.5 GPM

G2

CU

G1

MTR B

MTR A

6
3

TANK
21CC

G2

Note: 'alpha' callouts refer to


components shown in the
manifold illustrations.
Refer to the Repair Section.

HYDRAULIC
ROTARY
COUPLER

Hydraulic Generator Schematic- Welder Option

7
7

G1

8
8

12.5 KW GENERATOR

Part No. 102521

S-40 S-45

6 - 103

July 2007

Section 6 Schematics

Hydraulic Generator Schematic- Welder Option

6 - 103
6 - 104

California Proposition 65

Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.

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