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Service Manual Serial Number Range S-40 S-45 TM from S40-7001 to S4012-17231 TM Part No. 102521 Rev E October 2013 Introduction October 2013 Important Serial Number Information Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine before attempting any maintenance or repair procedure. Genie 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 Compliance Machine Classification Group B/Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance. Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Copyright © 2011 by Terex Industries 102521 Rev E October 2013 Fourth Edition, Fifth Printing "Genie" and "S" are registered trademarks of Terex South Dakota, Inc. in the USA and many other countries. Contact Us: Printed on recycled paper Printed in U.S.A. http://www.genielift.com e-mail: [email protected] ii S-40 • S-45 Part No. 102521 October 2013 Revision History Revision Date Section Procedure / Schematic Page / Description D 2/2012 2 - Spec. 2-1, 2-2, 2-13 3 - Maint. 3-1, 3-3, 3-9 to 3-15, 3-17, 3-35 to 3-38, 3-54 4 - Repair 4-4, 4-5, 4-6, 4-7, 4-48, 4-49, 4-50, 4-51, 4-60 6 - Schem. 6-4, 6-5, 6-32 to 6-64, 6-92 to 6-125, 6-138, 6-139, 6-150, 6-151, 6-153 2 - Spec. 2-1, 2-2 3 - Maint. 3-9, 3-33 to 3-34 4 - Repair 4-59 to 4-60 4- Repair 4-3 6 - Schem. 6-19, 6-29, 6-33, 6-93 D1 D2 10/1012 10/2013 REFERENCE EXAMPLES: 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. 4-48_Section 4_Repair Procedure Page #. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. Part No. 102521 S-40 • S-45 Electronic Version Click on any procedure or page number highlighted in blue to view the update. October 2013 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. 4-48_Section 4_Repair Procedure Page #. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. S-40 • S-45 Electronic Version Click on any procedure or page number highlighted in blue to view the update. Part No. 102521 October 2013 Section 1 • Safety Rules 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: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. Part No. 102521 S-40 • S-45 v 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 symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. 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 October 2013 Table of Contents Introduction Important Information ................................................................................................... ii Serial Number Legend ................................................................................................. iv Section 1 Safety Rules General Safety Rules .................................................................................................. v Section 2 Rev 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 Checklist A Procedures Part No. 102521 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 October 2013 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures, continued A-5 Inspect the Track Components, TRAX option .............................................. 3 - 9 A-6 Perform 30 Day Service ............................................................................. 3 - 10 A-7 Perform Engine Maintenance - Deutz and Ford Models .............................. 3 - 10 A-8 Replace the Drive Hub Oil .......................................................................... 3 - 11 A-9 Perform Engine Maintenance - Perkins Models .......................................... 3 - 12 A-10 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12 A-11 Perform Engine Maintenance - Ford Models ............................................... 3 - 13 A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 14 A-13 Perform Engine Maintenance - Deutz 1011F Models .................................. 3 - 14 A-14 Perform Engine Maintenance - Ford Models ............................................... 3 - 15 Checklist B Procedures B-1 Inspect the Battery ..................................................................................... 3 - 16 B-2 Inspect the Electrical Wiring ....................................................................... 3 - 17 B-3 Inspect the Air Filter ................................................................................... 3 - 18 B-4 Test the Key Switch ................................................................................... 3 - 19 B-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 19 B-6 Check the Exhaust System ....................................................................... 3 - 20 B-7 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 20 B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 21 B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 22 B-10 Confirm the Proper Brake Configuration ...................................................... 3 - 23 B-11 Check and Adjust the Engine RPM ............................................................ 3 - 24 B-12 Test the Engine Idle Select ........................................................................ 3 - 25 B-13 Test the Fuel Select Operation - Ford Models ............................................ 3 - 26 B-14 Test the Ground Control Override ............................................................... 3 - 27 B-15 Check the Directional Valve Linkeage ........................................................ 3 - 27 B-16 Test the Platform Self-leveling ................................................................... 3 - 28 viii S-40 • S-45 Part No. 102521 October 2013 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures, continued B-17 Test the Drive Brakes ................................................................................ 3 - 28 B-18 Test the Drive Speed - Stowed Position ..................................................... 3 - 29 B-19 Test the Drive Speed - Raised or Extended Position .................................. 3 - 29 B-20 Perform Hydraulic Oil Analysis ................................................................... 3 - 30 B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 31 B-22 Inspect the Fuel and Hydraulic Tank Cap Venting System ......................... 3 - 32 B-23 Check the Track Tension and Fastener Torque - TRAX Option .................. 3 - 33 B-24 Perform Engine Maintenance - Ford Models ............................................... 3 - 34 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 Part No. 102521 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 October 2013 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 - 8 2-2 Platform Rotator ........................................................................................... 4 - 9 2-3 Platform Overload System ......................................................................... 4 - 11 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 x 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 October 2013 TABLE OF CONTENTS Section 4 Rev 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 (from serial number 7568 to 15822) .. 4 - 48 7-13 Traction Manifold Components, 4WD (from serial number 15823) ............... 4 - 50 7-14 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 52 7-15 Valve Coils ................................................................................................. 4 - 53 7-16 Drive Oil Diverter Manifold Components (welder option) ............................. 4 - 55 Turntable Rotation Components 8-1 Turntable Rotation Assembly ..................................................................... 4 - 56 Axle Components 9-1 Oscillate Axle Cylinders ............................................................................. 4 - 58 Track Components 10-1 Track Assembly - TRAX Option ................................................................. 4 - 59 Generators 10-1 Hydraulic Generator .................................................................................... 4 - 61 Part No. 102521 S-40 • S-45 xi October 2013 TABLE OF CONTENTS Section 5 Rev Fault Codes Introduction ............................................................................................................ 5 - 1 Fault Codes - Control System ................................................................................ 5 - 2 Fault Codes - Ford LRG-425 Engine ....................................................................... 5 - 6 Fault Codes - Ford DSG-423 EFI Engine ............................................................. 5 - 12 Section 6 Rev Schematics Introduction ............................................................................................................ 6 - 1 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 xii S-40 • S-45 Part No. 102521 October 2013 TABLE OF CONTENTS Section 6 Rev Schematics, continued 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 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i Models Perkins 404-22 Models (from serial number 12510 to 14831) ...................... 6 - 32 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i Models Perkins 404-22 Models (from serial number 14832 to 15662) ...................... 6 - 36 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i Models - ANSI / CSA / AS Perkins 404-22 Models (from serial number 15663 to 16419) ...................... 6 - 40 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i Models - CE Perkins 404-22 Models (from serial number 15663 to 16419) ...................... 6 - 44 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i Models - ANSI / CSA / AS Perkins 404-22 Models (from serial number 16420) .................................... 6 - 48 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i Models - CE Perkins 404-22 Models (from serial number 16420) .................................... 6 - 52 Ground Control Box Wiring Diagram, Deutz F3L-2011/Deutz D2011L03i Models Perkins 404-22 Models (before serial number 14832) ................................. 6 - 56 Ground Control Box Wiring Diagram, Deutz F3L-2011/Deutz D2011L03i Models Perkins 404-22 Models (from serial number 14832) .................................... 6 - 57 Part No. 102521 S-40 • S-45 xiii October 2013 TABLE OF CONTENTS Section 6 Rev Schematics, continued Platform Control Box Wiring Diagram Deutz F3L-2011/Deutz D2011L03i Models Perkins 404-22 Models (before serial number 14832) ................................. 6 - 60 Platform Control Box Wiring Diagram Deutz F3L-2011/Deutz D2011L03i Models Perkins 404-22 Models (from serial number 14832) .................................... 6 - 61 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 - 64 Platform Control Box Switch Panel Wiring Diagram Deutz F3L-2011/Deutz D2011L03i Models Perkins 404-22 Models (from serial number 12510) .................................... 6 - 65 Electrical Schematic, Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 68 Ground Control Box Wiring Diagram, Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 71 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 74 Platform Control Box Switch Panel Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 75 Electrical Schematic, Ford LRG-425 EFI Models (from serial number 7597 to 11066) ............................................................ 6 - 78 Ground Control Box Wiring Diagram, Ford LRG-425 EFI Models (from serial number 7597 to 11066) ............................................................ 6 - 81 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) ............................................................ 6 - 84 xiv S-40 • S-45 Part No. 102521 October 2013 TABLE OF CONTENTS Section 6 Rev Schematics, continued Platform Control Box Switch Panel Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) ............................................................ 6 - 85 Electrical Schematic, Ford DSG-423 EFI Models (from serial number 11067 to 12509) .......................................................... 6 - 88 Electrical Schematic, Ford DSG-423 EFI Models (from serial number 12510 to 14831) .......................................................... 6 - 92 Electrical Schematic, Ford DSG-423 EFI Models (from serial number 12510 to 15662) .......................................................... 6 - 96 Electrical Schematic, Ford DSG-423 EFI Models - ANSA / CSA / AS (from serial number 15663 to 16419) ......................................................... 6 - 100 Electrical Schematic, Ford DSG-423 EFI Models - CE (from serial number 15663 to 16419) ......................................................... 6 - 104 Electrical Schematic, Ford DSG-423 EFI Models - ANSA / CSA / AS (from serial number 16420) ........................................................................ 6 - 108 Electrical Schematic, Ford DSG-423 EFI Models - CE (from serial number 16420) ........................................................................ 6 - 112 Ground Control Box Wiring Diagram, Ford DSG-423 EFI Models (before serial number 14832) ........................... 6 - 116 Ground Control Box Wiring Diagram, Ford DSG-423 EFI Models (from serial number 14832) .............................. 6 - 117 Platform Control Box Wiring Diagram Ford DSG-423 EFI Models (before serial number 14832) ........................... 6 - 120 Platform Control Box Wiring Diagram Ford DSG-423 EFI Models (from serial number 14832) .............................. 6 - 121 Platform Control Box Switch Panel Wiring Diagram, Ford DSG-423 EFI Models (from serial number 11067 to 12509) ............... 6 - 124 Platform Control Box Switch Panel Wiring Diagram Ford DSG-423 EFI Models (from serial number 12510) .............................. 6 - 125 Part No. 102521 S-40 • S-45 October 2013 TABLE OF CONTENTS Section 6 Rev Schematics, continued Engine Harness, Ford LRG-425 EFI Models (before serial number 11067) ..................................................................... 6 - 128 Engine Harness, Ford DSG-423 EFI Models (from serial number 11067 to 11784) ......................................................... 6 - 129 Engine Harness, Ford DSG-423 EFI Models (from serial number 11785) ........................................................................ 6 - 132 Joystick Connector Diagram ............................................................................... 6 - 133 CTE Option Wiring Diagram ................................................................................ 6 - 136 MTE Hydraulic Generator Option Wiring Diagram ................................................ 6 - 138 Hydraulic Generator Wiring Diagram (welder option) ............................................ 6 - 139 Hydraulic Schematic, 2WD Non-oscillating S-40 Models (before serial number 7569) ....................................................................... 6 - 142 Hydraulic Schematic, 2WD Non-oscillating S-45 Models (before serial number 7569) ....................................................................... 6 - 143 Hydraulic Schematic, 4WD Oscillating S-40 Models (before serial number 7569) ....................................................................... 6 - 146 Hydraulic Schematic, 4WD Oscillating S-45 Models (before serial number 7569) ....................................................................... 6 - 147 Hydraulic Schematic, 2WD (from serial number 7569) ........................................ 6 - 150 Hydraulic Schematic, 4WD (from serial number 7569) ........................................ 6 - 151 Generator Hydraulic Schematic (welder option) ................................................... 6 - 153 S-40 • S-45 Part No. 102521 October 2013 Section 2 • Specifications Specifications Machine Specifications S-40 and S-45 Models Track Components, TRAX option Track material Rubber Tires and wheels Weight, assembly (each) 480 lbs 218 kg Tire size, 2WD front tires only rear tires only 12.5L-16SL 12-16.5 NHS Fluid capacities Fuel tank Tire size, 2WDRT & 4WD front & rear 20 gallons 75.7 liters 12-16.5 NHS Fuel tank, Option 30 gallons 114 liters Tire weight, new foam-filled (minimum) (Rough terrain) Tire ply rating Tire contact area Overall tire diameter 300 lbs 136 kg 12 8 88 sq in 568 sq cm 57 sq in 368 sq cm LPG tank Hydraulic tank 45 gallons 170 liters Hydraulic system (including tank) 55 gallons 208 liters 33.7 in 85.6 cm 33.2 in 84.3 cm Tire pressure (Rough terrain) 45 psi 3.1 bar 45 psi 3.1 bar Drive hub (before serial number 7569) Tire pressure (Rough terrain) 60 psi 4.1 bar 60 psi 4.1 bar Drive hub (from serial number 7569 to 15677) Wheel diameter 16 in 40.6 cm 161/2 in 41.9 cm Drive hub (from serial number 15678) Wheel width 10 in 25.4 cm 9 3/4 in 24.8 cm Turntable rotation drive hub 8@ 5/8 -18 9@ 5/8 -18 Wheel lugs Lug nut torque - Drive and 9-bolt non-drive hubs Lug nut, dry Lug nut, lubricated 230 ft-lbs 312 Nm 33.5 pounds 15.2 kg 17 fl oz 0.5 liters 24 fl oz 0.71 liters 20 fl oz 0.6 liters 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. 170 ft-lbs 230 Nm Lug nut torque - 8-bolt non-drive spindles Lug nut, dry 170 ft-lbs 230 Nm Lug nut, lubricated 130 ft-lbs 176 Nm 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 October 2013 SPECIFICATIONS Performance Specifications All Models Hydraulic Oil Specifications Drive speeds, 2WD and 4WD Hydraulic oil type Viscosity grade Viscosity index Drive speed, stowed Hydraulic Oil Specifications 40 ft / 5.2 - 5.9 sec 12.2 m / 5.2 - 5.9 sec Drive speed, raised or extended 40 ft / 40 - 45 sec 12.2 m / 40 - 45 sec Drive speed, TRAX option Drive speed, stowed 40 ft / 11 sec 12.2 m / 11 sec Drive speed, raised or extended 40 ft / 40 sec 12.2 m / 40 sec Gradeability See Operator's Manual Boom function speeds, maximum from platform controls Chevron Rando HD MV equivalent Multi-viscosity 200 Cleanliness level, minimum Water content, maximum 15/13 200 ppm Chevron Rando HD 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 Boom up 50 to 60 seconds Boom down 45 to 60 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 Biodegradable Fire resistant Mineral based Platform level (10° range of motion) ANSI CE/Austrailia 3 to 5 seconds 20 to 22 seconds Jib boom up, S-45 models 35 to 45 seconds Jib boom down, S-45 models 20 to 30 seconds Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE-S UCON Hydrolube HP-5046 Quintolubric 822 Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron Aviation A Eni Arnica 32 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 October 2013 Section 2 • Specifications SPECIFICATIONS Continued use of Chevron Aviation A hydraulic oil when ambient temperatures are consistently above 32°F / 0°C may result in component damage. Note: Use Chevron Aviation A hydraulic oil when ambient temperatures are consistently below 0°F / -18°C. Note: Use Shell Tellus S2 V 46 hydraulic oil when oil temperatures consistently exceed 205°F / 96°C. 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 October 2013 SPECIFICATIONS 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 October 2013 Section 2 • Specifications SPECIFICATIONS Manifold Component Specifications Valve Coil Resistance Specifications Plug torque Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / 20°C that your air temperature increases or decreases from 68°F / 20°C. 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 Ω Solenoid valve, 3 position 4 way, 10V DC (schematic item AT and AZ) 6.3 Ω Solenoid valve, 2 position 3 way, 10V DC (schematic items AU, AV, AX, and AY) 6.3 Ω Solenoid valve, 3 position 4 way, 10V DC (schematic items AZ and BF) 6.3 Ω Proportional solenoid valve, 12V DC (schematic items AW and BB) Specification 9Ω Solenoid valve, 2 position 3 way, 10V DC (schematic item CC) 6.8 Ω Solenoid valve, 2 position 3 way, 10V DC (schematic items DA) 3.3 Ω Solenoid valve, 2 position 3 way, 12V DC (schematic items CE) 4.8 Ω 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 October 2013 SPECIFICATIONS Ford LRG-425 EFI Engine Displacement 153 cu in 2.5 liters Number of cylinders 4 Bore & stroke Horsepower Gross intermittent Continuous Gross intermittent Continuous Starter motor 3.78 x 3.4 in 96.01 x 86.36 mm 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 Compression ratio 9.4:1 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 October 2013 Section 2 • Specifications SPECIFICATIONS Ford DSG-423 EFI Engine Displacement Electronic fuel pump 140.4 cu in 2.3 liters Number of cylinders Bore & stroke Horsepower Continuous horsepower Peak horsepower Continuous horsepower Peak horsepower 4 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 Compression ratio 9.7:1 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 280°F 138°C Engine shut-down temperature 300°F 149°C 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 @ 0°F 1000A Reserve capacity @ 25A rate 200 minutes Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 102521 S-40 • S-45 2-7 Section 2 • Specifications October 2013 SPECIFICATIONS Deutz F3L-1011F Engine Injection system Displacement 125 cu in 2.05 liters Number of cylinders Bore and stroke Horsepower 3.58 x 4.13 inches 91 x 105 mm 36 @ 3000 rpm 26.8 kW @ 3000 rpm 1-2-3 Compression ratio Injection pump pressure 4351 psi 300 bar Injector opening pressure 3626 psi 250 bar 18.5:1 362 to 435 psi 25 to 30 bar Fuel requirement For fuel requirement, refer to the engine Operator's Manual on your machine. Alternator output 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 1 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 Starter motor Low idle rpm Frequency Governor OMAP 3 Firing order Compression pressure Injection pump make to 1/2 inch 9 to 12 mm 8.5 quarts 8 liters Oil viscosity requirements Temperature below 60°F / 15.5°C (synthetic) 5W-30 -10°F to 90°F / -23°C to 32°C 10W-40 Temperature above -4°F / -34°C 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 October 2013 Section 2 • Specifications 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 3 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 Exhaust Part No. 102521 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) 0.012 in 0.3 mm 8-18 ft-lbs 11-24 Nm 220° F 104° C Oil pressure switch centrifugal mechanical Valve clearance, cold Intake 40-60 psi 2.8 to 4.1 bar Oil pressure switch point (Deutz D2011L03i Engine) 8-18 ft-lbs 11-24 Nm 7 psi .5 bar 22 psi 1.5 bar 0.020 in 0.5 mm S-40 • S-45 2-9 Section 2 • Specifications October 2013 SPECIFICATIONS 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 1 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 October 2013 Section 2 • Specifications 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 below 68°F / 20°C (synthetic) 5W-20 5°F to 104°F / -15°C to 40°C 10W-30 above 14°F / -10°C 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. 1-3-4-2 17.5:1 Injection system 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 Injection pump make Injection pump pressure (stage one) (stage two) 2755 psi 3336 psi 190 bar 230 bar Low idle rpm Frequency 1600 rpm 246.7 Hz Injector opening pressure 3626 psi 250 bar High idle rpm Frequency 2200 rpm 339.2 Hz Compression pressure Governor centrifugal mechanical Fuel requirement For fuel requirement, refer to the engine Operator's Manual on your machine. Engine coolant Valve clearance, cold Intake 0.014 in 0.35 mm Exhaust 0.014 in 0.35 mm Lubrication system Oil pressure (at 2600 rpm) 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 S-40 • S-45 1 1000A 200 minutes 3 /8 in 10 mm 2 - 11 Section 2 • Specifications October 2013 SPECIFICATIONS Perkins 404-22 Engine Oil viscosity requirements Displacement 134 cu in 2.2 liters Number of cylinders 4 Bore and stroke 3.31 x 3.94 inches 84 x 100 mm 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 ½ in 9 to 12 mm Part No. 102521 October 2013 Section 2 • Specifications SPECIFICATIONS Machine Torque Specifications TRAX Torque Specifications Platform rotator Hub to drive sprocket fasteners 1-8 center bolt, Gr 5, dry 640 ft-lbs 868 Nm Lug nut, dry 230 ft-lbs 312 Nm 1-8 center bolt, Gr 5, lubricated 480 ft-lbs 651 Nm Lug nut, lubricated 170 ft-lbs 230 Nm 3/8 -16 bolts, Gr 8, lubricated *use blue thread-locking compound 35 ft-lbs* 47.5 Nm Idler and bogey wheel fasteners 3/4 -10 bolts, GR 8, dry 375 ft-lbs 508 Nm Drive hub mounting bolts, dry 210 ft-lbs 284 Nm 3/4 -10 bolts, GR 8, lubricated 281 ft-lbs 381 N Drive hub mounting bolts, lubricated* *use blue thread-locking compound 160 ft-lbs 217 Nm Turntable rotator 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 October 2013 SPECIFICATIONS Seal-Lok® fittings Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal-Lok® fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed. 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 October 2013 Section 2 • Specifications SPECIFICATIONS SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • SIZE Grade 5 THREAD LUBED 20 28 1/4 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 1/2 LUBED DRY DRY in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm 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 5/16 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 October 2013 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Observe and Obey: Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Each procedure includes a description, safety information and step-by-step instructions. Symbols Legend Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Scheduled maintenance inspections shall be completed daily, quarterly, six months, annually and every 2 years as specified on the Maintenance Inspection Report. The frequency and extent of periodic examinations and tests may also depend on national regulations. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Failure to perform each procedure as presented and scheduled may cause death, serious injury or substantial damage. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Immediately tag and remove from service a damaged or malfunctioning machine. With safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Repair any machine damage or malfunction before operating machine 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 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. • Boom in the stowed position • Turntable rotated with the boom between the non-steer wheels • Turntable secured with the turntable rotation lock • Key switch in the off position with the key removed • Wheels chocked • All external AC power supply disconnected from the machine Part No. 102521 S-40 • S-45 3-1 Section 3 • Scheduled Maintenance Procedures October 2013 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 subsections—A, B, C, D and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection. Inspection Checklist Daily or every 8 hours 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 operator’s manual on your machine. The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service. A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual. The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests. Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator’s manual. If any inspection receives an N, remove the machine from service, repair and reinspect 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 Terex South Dakota, Inc USA 500 Oak Wood Road PO Box 1150 Watertown, SD 57201-6150 (605) 882-4000 Genie UK The Maltings, Wharf Road Grantham, Lincolnshire NG31- 6BH England (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D Y N R Section 3 • Scheduled Maintenance Procedures October 2013 This page intentionally left blank. 3-4 S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Y N R A-1 Inspect the Decals Checklist B A-2 Pre-operation inspection B-1 Battery A-3 Functions tests B-3 Air filter element Hour meter A-4 Engine maintenance all models B-4 Key switch Machine owner A-5 Inspect tracks TRAX option B-5 Engine maintenance Deutz and Perkins models Perform after 40 hours: B-6 Exhaust system A-6 30 Day Service Perform after first 50 hours: B-7 Oil cooler and finsDeutz models A-7 Engine maintenance Deutz and Ford models B-8 Tires, wheels and lug nut torque Serial number Date Inspected by (print) Inspector signature Inspector title Inspector company B-2 Electrical wiring A-8 Drive Hub Oil B-9 Drive hub maintenance Instructions • Make copies of this report to use for each inspection. Perform every 50 hours: B-10 Brake configuration A-9 Engine maintenancePerkins models B-11 Engine RPM • Select the appropriate checklist(s) for the type of inspection to be performed. Perform every 100 hours: B-13 Fuel select Ford models 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 A-10 Fuel filter/water separator Deutz models A-11 Engine maintenance Ford models B-12 Engine idle select B-14 Ground control B-15 Directional valve linkage A-12 Rotation bearing B-16 Platform self-leveling Perform after first 125 hours: B-17 Drive brakes A-13 Engine maintenance Deutz 1011F models B-18 Drive speed stowed position Perform every 200 hours: B-19 Drive speed raised position A-14 Engine maintenance Ford models Y N R B-20 Hydraulic oil analysis B-21 Alarm package • 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. Comments B-22 Fuel and hydraulic cap venting systems B-23 Check track tension TRAX option Perform every 400 hours: B-24 Engine maintenance Ford models • 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 Part No. 102521 S-40 • S-45 3-5 Section 3 • Scheduled Maintenance Procedures October 2013 MAINTENANCE INSPECTION REPORT Model Checklist C Serial number C-1 Engine maintenance Deutz and Perkins models Date Y N R 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 • Select the appropriate checklist(s) for the type of inspection to be performed. D-3 Free-wheel configuration Daily or 8 hour Inspection: Quarterly or 250 hour Inspection: E-2 Steer axle wheel bearings, 2WD models C-5 Fuel inline strainer Deutz models Inspector title 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 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 E-5 Engine maintenance Deutz and Perkins models Y N R D-1 Boom wear pads Y N R E-1 Hydraulic oil C-4 Air filter element Deutz and Perkins models Inspected by (print) Checklist E 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 October 2013 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 operator’s and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition. In addition, maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions. 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 October 2013 PROCEDURES A-2 Perform Pre-operation Inspection A-4 Perform Engine Maintenance 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. Complete information to perform this procedure is available in the Operator's Manual on your machine. A-3 Perform Function Tests Genie specifications require that this procedure be performed daily. 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. 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 1011F Operation Manual (Deutz part number 0297 9683) or the Deutz 2011 Operation Manual (Deutz part number 0312 3547). Deutz 1011F Operation Manual Genie part number Deutz 2011 Operation Manual Genie part number 52883 139320 Complete information to perform this procedure is available in the Operator's Manual on your machine. 3-8 S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST A Perkins models Required maintenance procedures and additional engine information are available in the Perkins 404-22 Operation Manual (Perkins part number TPD 1443S). Perkins 404-22 Operation Manual Genie part number 94890 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) or the Ford MSG-425 EFI Operator Handbook (Ford part number 1020010). Ford LRG 425 EFI Operation Manual Genie part number Ford DSG 423 EFI Operator Handbook Genie part number Ford MSG-425 EFI Operator Handbook Genie part number 84792 PROCEDURES A-5 Inspect the Track Components, TRAX option Note: Genie specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Maintaining tracks and track assembly components is essential to safe operation and good performance. A track assembly failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion. 1 Thoroughly clean the track assembly of any dirt, rocks, clay, etc. 2 Inspect the following areas for damaged, cracked, loose or missing parts and fasteners: • Track • Idler wheels • Drive sprocket and hub 119488 • Bogey wheels • Undercarriage 215322 • Kingpin and steering linkage bushings 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 October 2013 PROCEDURES A-6 Perform 30 Day Service A-7 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 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 0312 3547). Deutz 1011F Operation Manual Genie part number Deutz 2011 Operation Manual Genie part number 3 - 10 S-40 • S-45 52883 139320 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures 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) or the Ford MSG-425 EFI Operator Handbook (Ford part number 1020010). Ford LRG 425 EFI Operation Manual Genie part number Ford DSG 423 EFI Operator Handbook Genie part number Ford MSG-425 EFI Operator Handbook Genie part number 84792 PROCEDURES A-8 Replace the Drive Hub Oil 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. 119488 215322 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. 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 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. a models with pipe plugs Part No. 102521 S-40 • S-45 a drive hub plugs 3 - 11 Section 3 • Scheduled Maintenance Procedures CHECKLIST A October 2013 PROCEDURES A-9 Perform Engine Maintenance Perkins Models A-10 Inspect the Fuel Filter/Water Separator - Deutz Models Engine specifications require that this procedure be performed every 50 hours. Genie specifications require that this procedure be performed every 100 hours or monthly, 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. Perkins models 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. Required maintenance procedures and additional engine information are available in the Perkins 404-22 Operation Manual (Perkins part number TPD 1443S). Perkins 404-22 Operation Manual Genie part number 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. 94890 To access the engine: Note: Perform this procedure with the engine off. 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. 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. Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. 3 - 12 S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES A-11 Perform Engine Maintenance Ford Models a b a b Engine specifications require that this procedure be performed every 100 hours. 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. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. 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) or the Ford MSG-425 EFI Operator Handbook (Ford part number 1020010) . Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG-425 EFI Operator Handbook Genie part number 215322 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 - 13 Section 3 • Scheduled Maintenance Procedures CHECKLIST A October 2013 PROCEDURES A-12 Grease the Turntable Rotation Bearing and Rotate Gear A-13 Perform Engine Maintenance Deutz 1011F Models Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist. Engine specifications require that this procedure be performed after the first 125 hours. 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. Grease specification Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent 3 - 14 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. 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 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST A PROCEDURES To access the engine: A-14 Perform Engine Maintenance Ford Models 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. 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. Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. 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) or the Ford MSG-425 EFI Operator Handbook (Ford part number 1020010) . Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG-425 EFI Operator Handbook Genie part number 215322 Part No. 102521 S-40 • S-45 3 - 15 Section 3 • Scheduled Maintenance Procedures October 2013 Checklist B Procedures 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. • Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C. Result: All battery cells display an adjusted specific gravity of 1.277 or higher. The battery is fully charged. Proceed to step 11. 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. 7 Perform an equalizing charge, OR fully charge the batteries and allow the batteries to rest at least 6 hours. 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 Fully charge the batteries and allow the batteries to rest at least 6 hours. 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 6 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: 3 - 16 Result: One or more battery cells display a specific gravity of 1.217 or below. Proceed to step 8. 8 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 9 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. 10 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. 11 Install the vent caps and neutralize any electrolyte that may have spilled with baking soda. S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 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. Part No. 102521 S-40 • S-45 3 - 17 Section 3 • Scheduled Maintenance Procedures October 2013 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. 3 - 18 S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 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. 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 3 Check all machine function from the ground controls. Required maintenance procedures and additional engine information are available in the Perkins 404-22 Operation Manual (Perkins part number TPD 1443S). Result: All machine functions should not operate. 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 404-22 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 - 19 Section 3 • Scheduled Maintenance Procedures October 2013 CHECKLIST B PROCEDURES 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. 2 Remove the fasteners from the engine side cover, and remove the cover. Crushing hazard. Failure to install the fasteners into the engine tray to secure it from moving could result in death or serious injury. 3 - 20 3 Inspect the oil cooler for leaks and physical damage. 4 Clean the oil cooler of debris and foreign material. S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES a b B-8 Inspect the Tires, Wheels and Lug Nut Torque c 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. 3 Check each lug nut for proper torque. Refer to Section 2, Specifications. 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 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 3 - 21 Section 3 • Scheduled Maintenance Procedures October 2013 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. a 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 3 - 22 a drive hub plugs S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 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. b d 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. c a 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 Part No. 102521 S-40 • S-45 3 - 23 Section 3 • Scheduled Maintenance Procedures October 2013 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 rpm is incorrect and continued use may cause component damage. a 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. b c d 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. 3 - 24 S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 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. a b c 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. d 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. Part No. 102521 S-40 • S-45 3 - 25 Section 3 • Scheduled Maintenance Procedures October 2013 CHECKLIST B PROCEDURES 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. 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). 3 - 26 S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 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. Part No. 102521 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 3 - 27 Section 3 • Scheduled Maintenance Procedures October 2013 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. 3 - 28 S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 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. Part No. 102521 S-40 • S-45 3 - 29 Section 3 • Scheduled Maintenance Procedures October 2013 CHECKLIST B PROCEDURES 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. 3 - 30 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 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 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. Part No. 102521 S-40 • S-45 3 - 31 Section 3 • Scheduled Maintenance Procedures October 2013 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. 3 - 32 S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 5 Visually inspect the section of track under the bogey wheels. B-23 Check the Track Tension and Fastener Torque, TRAX option Result: There should be between 0.75 - 1 inch / 1.9 - 2.5 cm of gap between the bogey wheels and the inside surface of the track. Proceed to step 7. Note: Manufacturer specifications require that this procedure be performed every 250 hours or quarterly. Result: There is 1 inch / 2.5 cm or more of gap between the bogey wheels and the inside surface of the track. Proceed to step 6. Maintaining proper track tension and properly torqued fasteners is essential to good machine performance and service life. The machine will not operate properly with a track that is incorrectly tensioned. Continued use of a machine with incorrectly tensioned tracks may cause component damage. half sprocket 1 Thoroughly clean the track assembly of any dirt, rocks, clay, etc. 2 Chock the tracks at one end of the machine to prevent the machine from rolling. 3 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis between the tracks at the other end of the machine. idler wheel tensioner assembly bogey wheel 4 Lift the machine until the tracks are off the ground and then place jack stands under the drive chassis for support. Part No. 102521 S-40 • S-45 3 - 33 Section 3 • Scheduled Maintenance Procedures October 2013 CHECKLIST B PROCEDURES 6 Loosen the tensioner jam nut and idler axle bolts on both sides of the tensioner wheel and tighten the tensioner nut until there is between 0.75 - 1 inch / 1.9 - 2.5 cm of gap between the bogey wheels and the inside surface of the track. Component damage hazard. Do not over tighten the track. Overtightening the track will cause the machine to lose power during operation. 7 Tighten the jam nut. 8 Check the torque of the track assembly fasteners. Refer to Section 2, Specifications. 9 Raise the machine, remove the jack stands and lower the machine. 10 Repeat this procedure for each track assembly. B-24 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 FFord DSG-423 EFI Operator Handbook (EDI part number 1060020) or the Ford MSG-425 EFI Operator Handbook (Ford part number 1020010) . Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG-425 EFI Operator Handbook Genie part number 215322 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 October 2013 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 404-22 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 404-22 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 0312 3547). Deutz 1011F Operation Manual Genie part number Deutz 2011 Operation Manual Genie part number Part No. 102521 94890 Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. 52883 139320 S-40 • S-45 3 - 35 Section 3 • Scheduled Maintenance Procedures CHECKLIST C October 2013 PROCEDURES 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 six 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 inaccurate test. 4 Using a suitable lifting device, place a test weight equal to that of the available capacity at 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). 3 - 36 S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES 7 Using a suitable lifting device, remove the test weights, restart the engine and carefully move the test weights to each remaining location on the platform. Refer to Illustration 1. Result: The alarm should sound, the engine should shut off and the platform overload indicator lights should be flashing at both the ground and platform controls. Illustration 1 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). 6 Using a suitable lifting device, place an additional 50 lbs / 23 kg of weight onto the platform. Note: There may be a 2 second delay before the overload indicator lights flash, the alarm sounds and the engine shuts off. 8 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 9 Turn the key switch to ground control. Result: The alarm should sound and the engine should shut off. The platform overload indicator lights should be flashing at both the ground and platform controls. Result: The alarm does not sound, the engine does not shut off 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, the alarm sounds and the engine shuts off. Part No. 102521 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). 10 Test all machine functions from the ground controls. Result: All ground control functions should not operate. 11 Activate the auxiliary power toggle switch. 12 Using auxiliary power, test all machine functions from the ground controls. Result: All ground control functions should operate. 13 Using a suitable lifting device, lift the additional test weight from the platform. Result: The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound. S-40 • S-45 3 - 37 Section 3 • Scheduled Maintenance Procedures CHECKLIST C October 2013 PROCEDURES 14 Start the engine and test all machine functions from the ground controls. 21 Using Illustration 3 as a guide, locate D31 Valve Power LED on the ALC500 printed circuit board. Result: All ground control functions should operate normally. Valve Power LED 15 Turn the key switch to platform control. ALC 500 Board 16 Test all machine functions from the platform controls. 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). 17 Push in the red Emergency stop button at the platform to shut off engine. 18 Using a suitable lifting device, remove all test weights from the platform. 19 Pull out the red Emergency stop button to the on position at the platform controls. 20 Remove the fasteners securing the lid to the platform controls. Using Illustration 2 as a guide, locate the timer relay inside the platform control box. Tag and disconnect the red wire from terminal 5 on the timer relay. Illustration 3 22 Step on the footswitch at the platform. Result: The Valve Power LED should not illuminate. Result: The Valve Power LED is illuminated. Remove the machine from service and contact the Genie Service Department. 23 Securely install the red wire, disconnected in step 20, onto terminal 5 of the relay timer. 24 Step on the footswitch at the platform. Result: The Valve Power LED should illuminate. Result: The Valve Power LED is not illuminated. Remove the machine from service and contact the Genie Service Department. Timer Relay Orange Wire 25 Using a suitable lifting device, place a test weight equal to that of the available capacity at the center location shown in Illustration 1. Terminal 5 Illustration 2 3 - 38 S-40 • S-45 Part No. 102521 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST 26 Using a suitable lifting device, place an additional 50 lbs / 23 kg of weight onto the platform. Result: The alarm should sound and the Valve Power LED should not light. The platform overload indicator lights should be flashing at both the ground and platform controls. 27 Working from outside the platform and standing next to the platform rotator, locate the orange wire, which enters into the base of the platform control box from the load sense switch and locate the wire terminal at the end of the wire. Tag and disconnect the connectors. Refer to Illustration 2. 28 Using a multimeter set to read resistance (ohms), securely install a lead from the multimeter to the connector on the orange wire, and securely connect the other multimeter lead to a ground point in the control box. Result: The readout on the multimeter should indicate zero resistance. Result: The readout on the multimeter shows resistance. Remove the machine from service and contact the Genie Service Department. 29 Using a suitable lifting device, remove all weight from the platform. Note the result on the multimeter. Result: The readout on the multimeter should indicate infinite resistance. Result: The readout on the multimeter shows zero resistance. Remove the machine from service and contact the Genie Service Department. C PROCEDURES C-4 Replace the Engine Air Filter Element - Deutz and Perkins 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. 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. 31 Turn off the multimeter and remove the leads from the machine. Securely connect the wires disconnected in step 27. 32 Close the platform control box. Install and securely tighten the fasteners. Do not overtighten. Part No. 102521 S-40 • S-45 3 - 39 Section 3 • Scheduled Maintenance Procedures CHECKLIST C October 2013 PROCEDURES C-5 Replace the In-line Fuel Strainer Deutz Models C-6 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Engine specifications require that this procedure be performed every 800 hours. 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. 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. 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. 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) or the Ford MSG-425 EFI Operator Handbook (Ford part number 1020010) . Note: Perform this procedure with the engine off. Ford LRG 425 EFI Operation Manual Genie part number 1 Put on protective clothing and eye wear. 2 Locate the inline strainer above the throttle actuator solenoid. 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG-425 EFI Operator Handbook Genie part number 215322 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. 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 October 2013 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 D October 2013 PROCEDURES D-2 10 1 15 13 Check the Turntable Rotation Bearing Bolts 7 6 19 18 12 3 4 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 2 9 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 October 2013 Section 3 • Scheduled Maintenance Procedures 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 1 D PROCEDURES D-3 Check the Free-wheel Configuration 15 13 7 6 19 18 Genie specifications requires that this procedure be performed every 1000 hours or annually, whichever comes first. 12 3 4 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 2 9 Bolt torque sequence 10 Swing the engine back to its original position and install the engine pivot plate retaining fasteners. Collision hazard. Select a work site that is firm and level. Crushing hazard. Failure to install the fasteners into the engine tray to secure it from moving could result in death or serious injury. 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 D October 2013 PROCEDURES All Models: 5 Manually rotate each non-steer wheel. Result: Each non-steer wheel should rotate with minimum effort. 6 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the jack stands. 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 a 7 Chock the non-steer wheels to prevent the machine from rolling. d 8 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis between the steer tires. 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 October 2013 Section 3 • Scheduled Maintenance Procedures 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. a 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 a drive hub plugs S-40 • S-45 3 - 45 Section 3 • Scheduled Maintenance Procedures CHECKLIST D October 2013 PROCEDURES 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 0312 3547). Deutz 1011F Operation Manual Genie part number Deutz 2011 Operation Manual Genie part number 52883 139320 Perkins models Required maintenance procedures and additional engine information are available in the Perkins 404-22 Operation Manual (Perkins part number TPD 1443S). Perkins 404-22 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 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST 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. 8 Install the filter housing cap. 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housing. Medium and high pressure 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 D October 2013 PROCEDURES D-7 Inspect for Turntable Bearing Wear a b 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 c d a b c d turntable dial indicator drive chassis turntable rotation bearing 5 At the dial indicator, adjust it to "zero" the indicator. 6 Fully extend the boom and lower to a horizontal position. 7 Note the reading on the dial indicator. 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 October 2013 Section 3 • Scheduled Maintenance Procedures 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 October 2013 Checklist E Procedures E-1 Test or Replace the Hydraulic Oil 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 October 2013 Section 3 • Scheduled Maintenance Procedures 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 October 2013 PROCEDURES 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 October 2013 Section 3 • Scheduled Maintenance Procedures 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 404-22 Operation Manual (Perkins part number TPD 1443S). Perkins 404-22 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 October 2013 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 0312 3547). 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 Deutz 2011 Operation Manual Genie part number 52883 139320 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 October 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST E Perkins models Required maintenance procedures and additional engine information are available in the Perkins 404-22 Operation Manual (Perkins part number TPD 1443S). Perkins 404-22 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 0312 3547). Deutz 1011F Operation Manual Genie part number Deutz 2011 Operation Manual Genie part number 52883 139320 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 October 2013 CHECKLIST E PROCEDURES 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 0312 3547). 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 0312 3547). Deutz 1011F Operation Manual Genie part number Deutz 1011F Operation Manual Genie part number Deutz 2011 Operation Manual Genie part number 52883 139320 To access the engine: . Deutz 2011 Operation Manual Genie part number 139320 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 52883 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 October 2013 Section 3 • Scheduled Maintenance Procedures 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) or the Ford MSG-425 EFI Operator Handbook (Ford part number 1020010) . Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG-425 EFI Operator Handbook Genie part number 215322 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 October 2013 CHECKLIST E PROCEDURES This page intentionally left blank. 3 - 58 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Observe and Obey: Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Perform disassembly procedures to the point where repairs can be completed. To re-assemble, perform the disassembly steps in reverse order. Symbols Legend Immediately tag and remove from service a damaged or malfunctioning machine. Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Repair any machine damage or malfunction before operating the machine. Before Repairs Start: Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Read, understand and obey the safety rules and operating instructions in the Genie S-40 and Genie S-45 Operator’s 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 symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • 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 October 2013 Platform Controls The platform control box contains one printed circuit board. The ALC-500 circuit board inside the platform control box controls all proportional machine functions from the platform. The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment. The operating parameters of the joysticks are stored in memory at the ECM circuit board at the platform controls. If a joystick error occurs or if a joystick is replaced, it will need to be calibrated before that particular machine function will operate. See 1-2, How to Calibrate a Joystick. 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. a 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. c d a b c d 4-2 b ALC-500 circuit board drive/steer joystick controller secondary boom up/down joystick controller primary boom up/down and turntable rotate left/right joystick controller S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures PLATFORM CONTROLS 4 Attach a grounded wrist strap to the ground screw inside the platform control box. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 5 Carefully disconnect the wire connectors from the circuit board. 6 Remove the ALC-500 circuit board mounting fasteners. 7 Carefully remove the ALC-500 circuit board from the platform control box. 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 3 Turn the key switch to platform control. Do not start the engine. 4 Select a joystick to calibrate. 5 Disconnect the wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds. Connect the wire harness connector to the joystick. 6 Move the joystick full stroke in either direction and hold for 5 seconds. 7 Return the joystick to the neutral position, pause for a moment, then move the joystick full stroke in the opposite direction. Hold for 5 seconds. Result: The alarm should sound indicating successful joystick calibration. 1-2 Joysticks Result: The alarm does not sound. Check the electrical connections or replace the joystick. 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. 8 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch. Note: No machine fuction should operate while performing the joystick calibration procedure. Note: The joystick must be calibrated before the threshold, max-out or ramping can be set. Note: Perform this procedure with the engine off. 1 Open the platform control box. Part No. 102521 S-40 • S-45 4-3 Section 4 • Repair Procedures October 2013 PLATFORM CONTROLS 7 Momentarily activate the drive enable toggle switch in the right direction 4 times. How to Adjust the Joystick Max-out Setting The max-out setting of a joystick controls the maximum speed of a joystick-controlled machine function. Whenever a hydraulic cylinder, drive motor or hydraulic pump is replaced, the max-out setting should be adjusted to maintain optimum performance. The max-out settings on the joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine. Note: Perform this procedure with the boom in the stowed position. 1 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. Result: There should be a pause and the alarm should sound 4 times indicating that the machine is in max-out calibration mode. Result: The alarm does not sound. Repeat steps 3 through 7. 8 Start the engine from the platform controls and press down the foot switch. 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. 4-4 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures PLATFORM CONTROLS 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. Result: The alarm does not sound. The minimum or maximum adjustment has been obtained. No changes can be saved. 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. Note: Do not operate any machine function during the 10 second waiting time. 14 Cycle the red Emergency Stop button off, then back on. 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. How to Adjust the Joystick Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output, when moved out of the neutral position. The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine. Note: Perform this procedure with the boom in the stowed position. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. Result: The alarm does not sound. Repeat steps 3 through 7. 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. 10 Compare the function ramp rate time with the table below and determine whether the ramp rate time needs to increase or decrease. 11 Release the foot switch. Part No. 102521 S-40 • S-45 4-5 Section 4 • Repair Procedures October 2013 PLATFORM CONTROLS 12 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. Ramp rate (factory settings) Boom up/down accelerate decelerate 3 second 1 seconds Note: Each time the drive enable toggle switch is momentarily moved, the time will change in 5% increments. Turntable rotate accelerate decelerate 2 seconds 1 second 13 Repeat steps 9 through 11 for each joystick controlled machine function. 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 14 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved. Result: The alarm should sound indicating that the settings have been saved in memory. 2 seconds 0.5 second 0.5 second 0.75 second 1 second 1 second 3 seconds Note: Do not operate any machine function during the 10 second waiting time. 15 Cycle the red Emergency Stop button off, then back on. 4-6 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures PLATFORM CONTROLS 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. 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 8 times. 14 Cycle the red Emergency Stop button off, then back on. Result: There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode. Result: The alarm does not sound. Repeat steps 3 through 7. Part No. 102521 S-40 • S-45 4-7 Section 4 • Repair Procedures October 2013 Platform Components 2-1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform. The slave cylinder keeps the platform level through the entire range of boom motion. It operates in a closed-circuit hydraulic loop with the 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. 4-8 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures PLATFORM COMPONENTS 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. Part No. 102521 S-40 • S-45 4-9 Section 4 • Repair Procedures October 2013 PLATFORM COMPONENTS 3 Open the top bleed valve on the rotator, but do not remove it. 7 Support the platform leveling slave cylinder. Protect the cylinder rod from damage. 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. c b 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. 4 - 10 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures PLATFORM COMPONENTS 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 and the engine will stop. 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: When 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. Part No. 102521 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 4 - 11 Section 4 • Repair Procedures October 2013 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, the alarm is sounding, and the engine stops. 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, the alarm is sounding, and the engine stops. 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, the alarm sounds, and the engine stops. Proceed to step 7. Result: The overload indicator lights are flashing at the platform and ground controls, the alarm is sounding, and the engine stops. 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, the alarm is sounding, and the engine stops. 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. 4 - 12 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures PLATFORM COMPONENTS 11 Test all machine functions from the ground controls. Result: All ground control functions utilizing engine power should not operate. (Only limited ground control functions utilizing APU power should function). 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 Start the engine from the ground controls. 14 Test all machine functions from the ground controls. Result: All ground control functions should operate normally. 15 Turn the key switch to platform control. 16 Test all machine functions from the platform controls. Result: All platform control functions should operate normally. Part No. 102521 S-40 • S-45 4 - 13 Section 4 • Repair Procedures October 2013 Jib Boom Components, S-45 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 October 2013 Section 4 • Repair Procedures 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 October 2013 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. 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 October 2013 Section 4 • Repair Procedures 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 October 2013 BOOM COMPONENTS 4-2 Boom 1 Remove the platform. See 2-1, How to Remove the Platform. How to Remove the Boom 2 Remove the platform rotator and leveling slave cylinder. See 2-3, How to Remove the Platform Rotator. 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 October 2013 Section 4 • Repair Procedures 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 October 2013 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 October 2013 Section 4 • Repair Procedures 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 October 2013 BOOM COMPONENTS 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 October 2013 Section 4 • Repair Procedures 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 October 2013 Engines 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 b c d e 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 October 2013 Section 4 • Repair Procedures ENGINES 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 October 2013 ENGINES 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. a b c d e 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 October 2013 Section 4 • Repair Procedures ENGINES 3 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. 1 1 5 7 8 6 C C 5 4 6 2 Ford LRG 425 models (after serial number 7596) 6 1 1 A 10 4 C C 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. 8 C C 9 2 6 C C 3 7 C A 8 3 4 4 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. B B 2 6 B Perkins models (after serial number 7471) 1 6 10 8 C 10 1 C C 4 3 11 12 11 4 5 2 C C C C Component damage hazard. When installing the pump, do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur. Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. 3 12 C C 7 9 2 Deutz 1011 models (before serial number 7544) 8 C C 7 7 3 2 9 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. B 8 5 7 5 B 12 11 9 B B C 5 9 Deutz 2011 models (after serial number 7543) 6 1 B B A 4 3 A C C 7 B 5 2 Ford DSG 423 models Part No. 102521 S-40 • S-45 4 - 27 Section 4 • Repair Procedures October 2013 ENGINES 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 October 2013 Section 4 • Repair Procedures Hydraulic Pumps 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 October 2013 HYDRAULIC PUMPS 6-2 Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electro-proportional controller, located on the pump. The only adjustment that can be made to the pump is the neutral or null adjustment. Any internal service to the pump should only be performed at an authorized Eaton Hydraulics center. Call Genie Industries Service Department to locate your local authorized service center. 2 Models with hydraulic tank shut-off valves: Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Close the valves. open Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. How to Remove the Drive Pump Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended. 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 October 2013 Section 4 • Repair Procedures 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 2013 Manifolds 7-1 Function Manifold Components The function manifold is located underneath the ground controls side turntable cover. Index No. Description Schematic Item Function Torque 1 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 1 Flow regulator valve, 0.6 gpm / 2.27 L/min .......................... AA ......... platform rotate (S-40) ........................ 20-25 ft-lbs / 27-34 Nm 2 Check valve ....................................... AB ......... Differential sensing circuit, platform rotate right and jib boom down (S-45) ........................ 10-12 ft-lbs / 14-16 Nm 3 Solenoid valve, 2 position 3 way ....... AC ........ Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm 4 Check valve ....................................... AD ........ Differential sensing circuit, platform level up ............................... 10-12 ft-lbs / 14-16 Nm 5 Solenoid valve, 2 position 3 way ....... AE ......... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm 6 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 9 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 2013 Section 4 • Repair Procedures MANIFOLDS 1 2 3 4 5 6 7 8 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 AY AZ BI 36 BH 35 Part No. 102521 BG 34 BF 33 BE BD BC BB 32 31 30 29 26 27 BA 28 S-40 • S-45 4 - 33 Section 4 • Repair Procedures October 2013 MANIFOLDS 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 2013 Section 4 • Repair Procedures MANIFOLDS 1 2 3 4 5 6 7 8 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 AY AZ BI 36 BH 35 Part No. 102521 BG 34 BF 33 BE BD BC BB 32 31 30 29 26 27 BA 28 S-40 • S-45 4 - 35 Section 4 • Repair Procedures October 2013 MANIFOLDS 7-2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Note: Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the 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 2013 Section 4 • Repair Procedures MANIFOLDS 7-3 Jib Select, Platform Rotate and Generator Manifold Components Index No. Description Schematic Item 1 Counterbalance valve ........................ CA ........ Platform rotate right .......................... 30-35 ft-lbs / 41-47 Nm Function Torque 2 Counterbalance valve ........................ CB ........ Platform rotate left ............................. 30-35 ft-lbs / 41-47 Nm 3 Relief valve ........................................ CD ........ Generator overload relief .................. 30-35 ft-lbs / 41-47 Nm 4 Solenoid valve ................................... CE ........ Controls generator on / off ................ 50-55 ft-lbs / 68-75 Nm 5 Solenoid valve, 2 position 3 way ....... CC ........ Platform rotate/jib boom select ......... 18-20 ft-lbs / 25-27 Nm 5 CC Jib Select Manifold CA 4 1 CE Platform Rotate Manifold Generator Manifold CB 2 CD 3 Part No. 102521 S-40 • S-45 4 - 37 Section 4 • Repair Procedures October 2013 MANIFOLDS 7-4 Brake Manifold Components (before serial number 7569) Index No. Description Schematic Item 1 Solenoid valve, 2 position 3 way ... DA ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm 2 Orifice, 0.025 inch / 0.635 mm ....... DB ........... Turntable rotation brake release Function Torque DA DB 4 - 38 S-40 • S-45 1 2 Part No. 102521 October 2013 Section 4 • Repair Procedures MANIFOLDS 7-5 Brake/Two-Speed Manifold Components (after serial number 7568) Index No. Description Schematic Item 1 Orifice, 0.025 inch / 0.63 mm ......... EA ........... Turntable rotation brake release 2 Solenoid valve, 2 position 3 way ... EB ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm 3 Solenoid valve, 2 position 3 way ... EC ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm 4 Check valve .................................... ED ........... Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm 1 Torque 3 2 EA 4 Function EB EC ED Part No. 102521 S-40 • S-45 4 - 39 Section 4 • Repair Procedures October 2013 MANIFOLDS 7-6 Oscillate Directional Valve Components The oscillate directional valve is mounted inside the drive chassis at the non-steer end. Index No. Description Function Torque 1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm 2 Spool valve ....................................................... Directional control 2 Relief valve ....................................................... Pressure adjustment 1 2 3 4 - 40 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures MANIFOLDS 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 2013 MANIFOLDS 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 2013 Section 4 • Repair Procedures MANIFOLDS 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 1 Relief valve, 210 psi / 14.5 bar ......... FA ......... Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm 2 Flow divider/combiner valve ............. FB ......... Controls flow to drive motors in forward and reverse ................ 90-100 ft-lbs / 122-136 Nm 3 Orifice, 0.070 inch / 1.78 mm ............ FC ......... Equalizes flow across flow divider/combiner valve (item FB) 4 Shuttle valve, 3 position 3 way .......... FD ......... Charge pressure, hot oil shuttle ........ 50-55 ft-lbs / 68-75 Nm 5 Diagnostic nipple ............................... FE ......... Testing 1 FA Function Torque 2 FB FC 3 2WD FD FE Part No. 102521 S-40 • S-45 4 5 4 - 43 Section 4 • Repair Procedures October 2013 MANIFOLDS 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 1 Relief valve, 280 psi / 19.3 bar ......... GA ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm 2 Flow divider/combiner valve ............. GB ........ Controls flow to drive motors in forward and reverse ................ 90-100 ft-lbs / 122-136 Nm 3 Check valve ....................................... GC ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm 4 Check valve ....................................... GD ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm 5 Flow divider/combiner valve .............. GE ........ Controls flow to drive motors in forward and reverse ...................... 50-55 ft-lbs / 68-75 Nm 6 Orifice, 0.070 inch / 1.78 mm ............ GF ........ Equalizes flow across flow divider/combiner valve (item GB) Function Torque 1 GA GB GC GD GE GF 4 - 44 S-40 • S-45 2 3 4 5 6 Part No. 102521 October 2013 Section 4 • Repair Procedures MANIFOLDS 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 2013 MANIFOLDS 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 1 Flow divider/combiner valve ............. HA ........ Controls flow to steer end drive motors in forward/reverse ........................... 90-100 ft-lbs / 122-136 Nm 2 Flow divider/combiner valve .............. HB ........ Controls flow to non-steer end drive motors in forward/reverse ........................... 90-100 ft-lbs / 122-136 Nm 3 Orifice, 0.070 inch / 1.778 mm .......... HC ........ Rear drive motor circuit 4 Orifice, 0.070 inch / 1.778 mm .......... HD ........ Equalizes pressure on both sides of flow divider/combiner valve 7 5 Shuttle valve, 3 position 3 way .......... HE ........ Charge pressure, hot oil shuttle ........ 50-55 ft-lbs / 68-75 Nm 6 Diagnostic nipple ............................... HF ......... Testing 7 Flow divider/combiner valve .............. HG ........ Controls flow to flow divider/combiner valves 1 and 2 ........................................ 90-100 ft-lbs / 122-136 Nm 8 Relief valve, 210 psi / 14.5 bar .......... HH ........ Charge pressure circuit ..................... 30-35 ft-lbs / 41-47 Nm 9 Orifice, 0.052 inch / 1.32 mm ............ HI .......... Front drive motor circuit 4 - 46 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures MANIFOLDS 9 HI HA HB 8 7 1 2 HH HG HC HD HE 3 4 5 HF 6 Part No. 102521 S-40 • S-45 4 - 47 Section 4 • Repair Procedures October 2013 MANIFOLDS 7-12 Traction Manifold Components, 4WD (from serial number 7568 to 15822) The traction manifold is mounted inside the drive chassis at the non-steer end. Index No. Description 1 Relief valve, 280 psi / 19.3 bar ......... JA ......... Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm 2 Flow divider/combiner valve .............. JB ......... Controls flow to non-steer end drive motors in forward and reverse ................................... 80-90 ft-lbs / 108-122 Nm 3 Check valve ....................................... JC ......... Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm 4 Check valve ....................................... JD ......... Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm 5 Flow divider/combiner valve .............. JE ......... Controls flow to flow divider/combiner valves 2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm 6 Check valve ....................................... JF ......... Non-steer end drive motor circuit ...... 60-70 ft-lbs / 81-95 Nm 7 Orifice, 0.040 inch / 1 mm ................. JG ......... Equalizes pressure on both sides of flow divider/combiner valve 5 8 Orifice, 0.040 inch / 1 mm ................. JH ......... Equalizes pressure on both sides of flow divider/combiner valve 2 9 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 2013 Section 4 • Repair Procedures MANIFOLDS JA JB JC 14 JM JE JF 12 11 10 2 3 JN JD 13 1 4 5 6 JL JK JJ 9 Part No. 102521 JG JH JI 8 S-40 • S-45 7 4 - 49 Section 4 • Repair Procedures October 2013 MANIFOLDS 7-13 Traction Manifold Components, 4WD (from serial number 15823) The traction manifold is mounted inside the drive chassis at the non-steer end. Index No. Description 1 Relief valve, 280 psi / 19.3 bar ......... KA ......... Charge pressure circuit .................... 55-60 ft-lbs / 74-81 Nm 2 Flow divider/combiner valve ............. KB ......... Controls flow to non-steer end drive motors in forward and reverse ................................... 80-90 ft-lbs / 108-122 Nm 3 Check valve ....................................... KC ........ Steer end drive motor circuit ............ 55-60 ft-lbs / 74-81 Nm 4 Check valve ....................................... KD ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 74-81 Nm 5 Check valve ....................................... KE ......... Non-steer end drive motor circuit ... 70-75 ft-lbs / 95-100 Nm 6 Flow divider/combiner valve ............. KF ......... Controls flow to flow divider/combiner valves 2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm 7 Orifice, 0.040 inch / 1 mm .................. KG ........ Equalizes pressure on both sides of flow divider/combiner valve 5 8 Orifice, 0.040 inch / 1 mm .................. KH ........ Equalizes pressure on both sides of flow divider/combiner valve 2 9 Orifice, 0.040 inch / 1 mm .................. KI .......... Equalizes pressure on both sides of flow divider/combiner valve 13 11 Shuttle valve, 3 position 3 way ......... KJ ......... Charge pressure circuit that directs hot oil out of low pressure side of drive pump ............................ 35-40 ft-lbs / 48-54 Nm 10 Check valve ....................................... KK ......... Steer end drive motor circuit .......... 55-60 ft-lbs / 95-100 Nm 12 Check valve ....................................... KL ......... Steer end drive motor circuit .......... 70-75 ft-lbs / 95-100 Nm 13 Flow divider/combiner valve ............. KM ........ Controls flow to steer end drive motors in forward and reverse ................................... 80-90 ft-lbs / 108-122 Nm 14 Check valve ....................................... KN ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 74-81 Nm 4 - 50 Schematic Item Function S-40 • S-45 Torque Part No. 102521 October 2013 Section 4 • Repair Procedures MANIFOLDS KA KB KC 14 13 KN KD KM KE KF 12 11 10 1 2 3 4 5 6 KL KK 4WD KJ KI Part No. 102521 KG KH 9 8 S-40 • S-45 7 4 - 51 Section 4 • Repair Procedures October 2013 MANIFOLDS 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. 7-14 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. 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 - 52 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. (from serial no. 7569 to 15822) 5 Turn the engine off, and remove the hot oil shuttle relief valve cap (item KA). Adjust the internal hex socket clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap. (from serial no. 15823) 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. S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures MANIFOLDS 7-15 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 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / 10°C that your air temperature increases or decreases from 68°F / 20°C. 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 Ω Solenoid valve, 3 position 4 way, 10V DC (schematic item AT and AZ) 6.3 Ω Solenoid valve, 2 position 3 way, 10V DC (schematic items AU, AV, AX, and AY) 6.3 Ω Solenoid valve, 3 position 4 way, 10V DC (schematic items AZ and BF) 6.3 Ω Proportional solenoid valve, 12V DC (schematic items AW and BB) 9Ω Solenoid valve, 2 position 3 way, 10V DC (schematic item CC) 6.8 Ω Solenoid valve, 2 position 3 way, 10V DC (schematic items DA) 3.3 Ω Solenoid valve, 2 position 3 way, 12V DC (schematic items CE) 4.8 Ω 2 Test the coil resistance using a multimeter set to resistance (Ω). 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 - 53 Section 4 • Repair Procedures October 2013 MANIFOLDS How to Test a Coil Diode a d 10 W RESISTOR c 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 b a b c d multimeter 9V DC battery 10Ω 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. Ω Resistor, 10Ω Genie part number b + c 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 10Ω resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil. 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 - 54 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures MANIFOLDS 7-16 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 Schematic Item 1 Directional Valve ............................ CY ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm Function Torque 2 Orifice disc ...................................... CW .......... Delays shift to drive ......................... 35-40 ft-lbs / 47-54 Nm 3 Solenoid valve ............................... CV ........... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm 4 Relief valve .................................... CX ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm 5 Check valve .................................... CU ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm 5 CU CY CW CV CX Part No. 102521 S-40 • S-45 1 2 3 4 4 - 55 Section 4 • Repair Procedures October 2013 Turntable Rotation Components 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. f e d Unlocked position a b c d e f c b a brake assembly drive hub backlash plate mounting bolts backlash plate manifold motor Locked position 4 - 56 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures 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 - 57 Section 4 • Repair Procedures October 2013 Axle Components 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 - 58 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures Track Components 10-1 Track Assembly - TRAX option How to Replace the Track How to Remove a Track Assembly 1 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis between the tracks. Note: Perform this procedure on a firm, level surface with the boom in the stowed position. 2 Refer to illustration 1 and place the drive hub disconnect cap in the brake disengaged position. Note: The sprocket is comprised of two halves. 1 Chock the tracks at the opposite end of the machine to prevent the machine from rolling. 2 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis between the tracks. 3 Lift the machine until the tracks are off the ground and then place jack stands under the drive chassis for support. 4 Remove the lug nut bolts holding each half sprocket on the drive hub. Rotate the sprockets until only one sprocket is contacting the track. Remove the lower half sprocket from the track assembly. 5 Rotate the remaining half sprocket 180° so that it is free of the track. 6 Attach a lifting strap from an overhead crane to the center-point of the track assembly, above the sprocket. 3 Lift the machine until the tracks are off the ground and then place jack stands under the drive chassis for support. 4 Loosen the idler axle bolt, tensioner jam nut and tension nut on both sides of the assembly to allow maximum play in the tensioner wheel. 5 Remove the lug nut bolts holding each half sprocket on the drive hub. Rotate the sprockets until only one sprocket is contacting the track. Remove the lower half sprocket from the track assembly. 6 Rotate the remaining half sprocket 180° so that it is free of the track. 7 Carefully remove the track from the undercarriage. brake disengaged position 7 Remove the fasteners holding the TRAX mounting pin located underneath the axle. Remove the pin supporting the TRAX assembly. brake engaged position 8 Carefully remove the track assembly from the drive hub and set aside. Illustration 1 Crushing hazard. The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Part No. 102521 S-40 • S-45 4 - 59 Section 4 • Repair Procedures October 2013 11 Install the other sprocket half, removed in step 4. half sprocket 12 Install the lug nuts onto the wheel hub and torque to specification. Refer to Section 2, Specifications. 13 Adjust the track tension. Tighten the tensioner nut on both sides of the idler wheel until there is about 0.75 - 1.0 inch / 19 - 25 mm of droop between the inside of the rubber track and the bottom surface of the bogey wheels. idler wheel tensioner assembly Note: Make sure that both sides of the track have the same amount of clearance between the rollers and the track. bogey wheel Illustration 2 14 Tighten the jam nuts and idler axle bolts on both tensioner assemblies. 8 Install the new track onto the undercarriage. Note: Be sure the idler and bogey wheels are aligned with the inside surface of the track. 9 Using a suitable lifting device, lift up on the rubber track and rotate the half sprocket until one of the sprocket teeth is engaging the track. 10 Continue rotating the half sprocket until it is fully engaging the track. 4 - 60 S-40 • S-45 Part No. 102521 October 2013 Section 4 • Repair Procedures Generators outlet at the generator. 11-1 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. a flow regulator Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. a 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. 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. 5 Connect the positive and negative leads from a multimeter of sufficient capacity to the electrical Part No. 102521 9 Repeat steps 2 through 5 to confirm the generator AC voltage. S-40 • S-45 4 - 61 Section 4 • Repair Procedures October 2013 GENERATORS How to Purge the Hydraulic Line on the MTE Generator Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: This procedure should be performed if the hydaulic line to the generator has been removed. Note: Perform this procedure with the machine on a firm, level surface. 1 Locate the blue purge wire with the male spade connector from the MTE generator harness. 2 Connect a jumper wire of sufficient length from the positive battery terminal to the spade connector on the purge wire. 3 Start the engine and turn on the generator. Allow the generator to run for three minutes. 4 Turn off the generator and turn off the engine. 5 Remove the jumper wire from the positive battery terminal and disconnect from the purge wire. 6 Start the engine and turn on the generator. Using a digital multimeter check the voltage at the outlet. Result: The generator produces a voltage ±10% of rated output. The generator is ready for use. Result: The generator output voltage is outside the ±10% voltage range. Repeat the procedure beginning with step 2. 4 - 62 S-40 • S-45 Part No. 102521 October 2013 Section 5 • Fault Codes Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions printed in the Genie S-40 and S-45 Operator’s Manual. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Read each appropiate fault code thoroughly. Attempting shortcuts may produce hazardous conditions. Be aware of the following hazards and follow generally accepted safe workshop practices. Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement. Repair any machine damage or malfunction before operating the machine. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: Electrocution/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 October 2013 FAULT CODES Fault Code Chart Control System How to Retrieve Control System Fault Codes Note: At least one fault code is present when the alarm at the platform controls produces two short beeps every 30 seconds for 10 minutes. Note: Perform this procedure with the engine off, the key switch turned to platform controls and the red Emergency Stop button pulled out to the on position at both the ground and platform controls. 1 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 October 2013 Section 5 • Fault Codes FAULT CODES Error Source ID 21 22 23 24 31 32 Name Boom 1 Joystick (primary boom up/ down) Boom 1 directional valves Error Type ID 11 12 15 16 Name 17 Not calibrated Value at 5V Value too high Value too low Value at 0V 21 Fault 12 15 Value too high Value too low 17 Not calibrated 11 12 15 16 Value at 5V Value too high Value too low Value at 0V 31 Invalid setup 11 12 15 16 Value at 5V Value too high Value too low Value at 0V 17 Not calibrated Boom 1 flow control valve Boom 1 angle sensor Boom 2 Joystick (secondary boom up/down or primary boom extend/retract) Boom 2 directional valves 21 Fault Condition Function is inoperative until joystick is calibrated. Alarm sounds indicating fault. Function is inoperative until joystick is calibrated. 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. Reduced speed. Solution Cycle power off, then on and problem should be corrected. Calibrate joystick Cycle power off, then on and problem should be corrected. Cycle power off, then on and problem should be corrected. Calibrate valve thresholds Initiate 1 second beep of alarm. Cycle power off, then on and problem should be corrected. Calibrate angle sensor. Joystick is operating outside of operational limits. Alarm sounds indicating fault. Cycle power off, then on and problem should be corrected. Function is inoperative until joystick is calibrated. Valve is operating outside of operational limits. Alarm sounds indicating fault. Calibrate joystick 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 October 2013 FAULT CODES Error Source ID 33 41 42 43 44 5-4 Name Boom 2 flow control valve Turntable rotate joystick Turntable rotate directional valves Turntable rotate flow control valve Drive enable toggle switch Error Type ID Name 12 15 Value too high Value too low 17 Not calibrated 11 12 15 16 Value at 5V Value too high Value too low Value at 0V 17 Not calibrated 21 Fault 12 15 Value too high Value too low 17 Not calibrated 21 Fault Condition 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. 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. Drive enable function is inoperative. S-40 • S-45 Solution Cycle power off, then on and problem should be corrected. Calibrate valve thresholds Cycle power off, then on and problem should be corrected. Calibrate joystick Cycle power off, then on and problem should be corrected. Cycle power off, then on and problem should be corrected. Calibrate valve thresholds. Cycle power off, then on and problem should be corrected. Part No. 102521 October 2013 Section 5 • Fault Codes FAULT CODES Error Source ID 51 53 54 55 61 62 Name Drive joystick Drive flow valve (EDC) Error Type ID 11 12 15 16 Name Value at 5V Value too high Value too low Value at 0V 17 Not calibrated 12 15 Value too high Value too low 17 Not calibrated Drive brake valve High speed drive motor Valve Steer joystick Steer directional valves Part No. 102521 21 Fault 21 Fault 11 12 15 16 Value at 5V Value too high Value too low Value at 0V 17 Not calibrated 21 Fault Condition Joystick is operating outside of operational limits. Alarm sounds indicating fault. Function is inoperative until joystick is calibrated. Valve is operating outside of operational limits. Alarm sounds indicating fault. Normal function except threshold for one or both directions is zero. Valve is operating outside of operational limits. Alarm sounds indicating fault. Motor speed frozen in the low state. Alarm sounds indicating fault. Joystick is operating outside of operational limits. Alarm sounds indicating fault. Function is inoperative until joystick is calibrated. Valve is operating outside of operational limits. Alarm sounds indicating fault. S-40 • S-45 Solution Cycle power off, then on and problem should be corrected. Calibrate joystick Cycle power off, then on and problem should be corrected. Calibrate valve thresholds Cycle power off, then on and problem should be corrected. Cycle power off, then on and problem should be corrected. Cycle power off, then on and problem should be corrected. Calibrate Joystick Cycle power off, then on and problem should be corrected. 5-5 Section 5 • Fault Codes October 2013 FAULT CODES Ford LRG-425 EFI Engine How to Retrieve Ford Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel 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 October 2013 Section 5 • Fault Codes FAULT CODES Code Problem Cause Solution 111 Closed Loop Multiplier High (LPG) Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks. Repair wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks. 112 HO2S Open/Inactive (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 October 2013 FAULT CODES Code Problem 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 October 2013 Section 5 • Fault Codes FAULT CODES 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 October 2013 FAULT CODES Code 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 October 2013 Section 5 • Fault Codes FAULT CODES 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 October 2013 FAULT CODES Ford DSG-423 EFI Engine How to Retrieve Ford Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle position to maintain the engine's running condition at its 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 October 2013 Section 5 • Fault Codes FAULT CODES 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 October 2013 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 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 October 2013 Section 5 • Fault Codes FAULT CODES 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 October 2013 This page intentionally left blank. 5 - 16 S-40 • S-45 Part No. 102521 October 2013 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 October 2013 Electrical Symbols Legend 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 A 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 October 2013 Section 6 • Schematics Hydraulic Symbols Legend 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 October 2013 Ford DSG-423 Engine Relay Layout Starter Relay Fuel Pump Relay Power Relay Empty F1-10A F2-5A F3-10A F4-15A F5-15A F6-10A F6-10A 6-4 S-40 • S-45 Part No. 102521 October 2013 Section 6 • Schematics Connector Pin Legend N M L C1P DT06-12SA K J I C7: DTP06-4S C1 COLOR PIN # 1 BK P22BAT 1 RD/BK C28TTA 2 WH P23BAT 2 RD/WH C29MS 3 BRN BATGND 3 WH C30EDC+ 4 N/A PLUG 4 WH/BK C31EDC- 5 WH/RD C32BRK 6 BK C33STR 7 BK/WH C34SA 8 BK/RD C35RPM 9 BL C36STC 10 BL/BK C37STCC C132PLI 11 BL/WH CKT # C6 C6-GBOX C39LP 1 C40LS1 2 OR/BK C41RPM 3 OR/RD 4 GR C134PWR C43HRN GR/BK JDALARM 6 GR/WH C45GEN 7 PLUG 8 PLUG 9 PLUG 10 PLUG 11 PLUG 12 RD C1PBU 1 C2PBD 2 RD/WH C3PBF 3 WH C4TRL 4 WH/BK C5TRR 5 WH/RD C6TRF 6 BK C7PBE 7 BK/WH C8PBR 8 GR/BK 9 BL/BK JALARM C10SBU C11SBD BL/WH C12SBF BL C1PBU C2PBD 3 4 C3PBF C4TRL 5 6 CIRCUIT # COLOR RD C1PBU C2PBD RD RD/BK RD/WH RD/BK RD/WH WH C3PBF C4TRL C5TRR WH/BK C5TRR WH/BK C6TRF WH/RD C6TRF WH/RD 7 C7PBE BK C7PBE BK 8 9 C8PBR BK/WH C8PBR BK/WH 13 14 C3 GREEN WH 10 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 BL/RD CKT # C134PWR RD 25 C116HYD BK 26 GND C27AUX BR RD C23BAT C28TTA RD/BK 30 P46PWR BL/WH 32 C32TA WH/RD 33 R116HYD OR 34 R21IGN WH 36 C36STC 37 C37STCC 2 OR/BK C15PLD 3 GR/BK C133PLA 4 GR C17JU 5 GR/BK C18JD 6 GR/WH BROWN 7 39 PLUG 8 40 C40LS1 PLUG 9 PLUG 10 11 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 CKT# OR/BK WH C41RPM C107AF BK RD R33STR R27AUX WH BK/RD BL/RD WH(12) GR BL/WH WH/RD R21IGN C35RPM C39LP VSW C127TST C38ESL C26TSR WH/BK WH C25PSR C21IGN WH/BK WH C31EDC C30EDC WH/RD RD/WH C32BRK C29MS 3 4 C9 C9 FS DT04-4P COLOR C27AUX C28TTA P46PWR CKT # PIN # RD RD/BK BL/WH C32TA WH/RD BL C36STC BL BL/BK C37STCC BL/BK GR/WH C45GEN GR/WH OR C40LS1 OR BK P22ESTOP 1 WH P24FS 2 RD P25BAT 3 N/C 4 7 8 38 C19JSV PLUG 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 35 C4 C45GEN PLUG C5-ENGINE HARNESS RD 29 1 OR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 PIN # C13DRE C14PLU COLOR 6 31 COLOR CKT# 21 22 28 C4 1 BL/RD OR 16 17 18 19 20 27 12 A 5 C13DRE C14PLU 15 23 A 11 C4P DT06-12SD B 12 PIN # RD/BK 1 2 COLOR 10 11 C3 C3P DT06-12SC CKT # C2 BLACK 5 C 2 PIN# C6-FUNCTION HARNESS PIN # OR D C5-GBOX PIN# C2 BL/RD E * NOTE: WIRE ONLY IN C7B CONNECTOR. CIRCUIT # COLOR C7 12 C2P DT06-12SB COLOR GRAY F CKT # PIN # CKT # C27AUX C1 G C7 RD COLOR H Part No. 102521 S-40 • S-45 6-5 October 2013 Section 6 • Schematics Connector Pin Legend 6-5 6-6 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L 1011F Models (before serial number 7544) 6-8 6-7 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L 1011F Models (before serial number 7544) A B C D E F G H I J K L M N 1 RD/BK TB41 C2-3 OR/BK P26ESTP BK LS18 P2 FS1 BK-(FS) C9-1 BK 2 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 7 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 5 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 6 4 C28TTA RD/BK PLAT GRD 5 C133PLA OR/RD 4 C43HRN GR 3 1 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 3 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) 8 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 7 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 6 OTS NO DRE LED BL/RD DRE B BL/BK DRE A BL/WH 12 13 14 8 7 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 16 7 5 6 WH 7 RKOUT 6 14 13 4 OR BRN BL 4 PWR 3 1 2 1 11 12 1 2 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 5 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 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 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 C40LS1 OR 7 C6-40 C7PBE BK C8PBR BK/WH C14PLU OR C15PLD OR/BK 7 BK WH BK WH BK WH H3 B GROUND DRIVE EDC FORWARD LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH C 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 6-9 S-40 • S-45 Part No. 102521 GND 2 7 RD 6 OR BK YOUT 5 XOUT 4 BRN 1 GND 2 PWR 3 BRN P24FS WH C4P-1 C40LS1 OR C6-7 C6-8 C6-14 C6-15 JIB VALVES PLATFORM ROTATE LEFT / JIB UP PLATFORM ROTATE RIGHT / JIB DOWN NOTE: P24FS WH 3 C2P-2 EXTEND BOOM PLATFORM LEVEL C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK RETRACT UP DOWN C18JD GR/BK 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED 4 4 C3P-7 C3P-8 JDALARM GR/BK C18JD GR/BK C6-18 C17JU GR NONC H4 SJ1-WH R2 C17JU GR C6-17 NOHC POSITION EXCEPT AS NOTED. P26ESTP BK 3 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 TB7 8 NOHC BRN 6 5 C6-30 TB22 1 Deutsch TB3 TB2 TB6 TB31 TB32 TB36 TB30 TB37 TB5 JIB BOOM 3 LEFT 4 RIGHT 3 2 RIGHT PLAT LEFT ROTATE 2 5 5 TB8 TB14 TB15 TB18 TB17 TS62 TS61 TB4 TB1 TB13 TB40 C19JSV GR/WH 4 GND PWR XOUT YOUT RKOUT Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 1 6 AMP Joystick Adaptor Harness 6 Pin1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 TB44 TB19 J2 3 C4P-7 TS57 CR30 NO R1 J1 J1 J1 J3 YOUT 5 PRI UP/DN & TT ROTATE 4 TS63 TS59 TS58 TS13 JOYSTICK CONTROL CARD 2 CR27 NC CR13 NC CR13 TS9 TS8 TS7 JIB VALVE C19JSV GR/WH WH WH CE LIFT/ DRIVE OPTION L1 TS15 DRIVE & STEERING JC3 JC2 WH 1 A B C D E F G H I J K L M N Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L 1011F Models (before serial number 7544) RD/BK OR/BK BK BRN October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L 1011F Models (before serial number 7544) 6-9 6 - 10 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Deutz F3L 1011F Models N M L 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. A 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 E CR2 RD C4B-11 BR (GROUND) RD C4B-12 BRN GND BK-22A P1 RD-CB2 KEY SWITCH KS1 2 3 NC WH-23A RD-42A RD-27A RD-C23-6 4 3 TS51 B NC EMERGENCY STOP BUTTON 2 KEY SWITCH AUXILIARY SWITCH ENGINE START SWITCH FUNCTION ENABLE PLATFORM ROTATE SWITCH 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 RESISTOR, 7.5 OHM,TURNTABLE FUNCTION WH-21A HM BR (GROUND) 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 TS62 CB3 BK/WH-34A TS56 RD- 20C RD-CR17#30 WH-4 WH/RD-6 WH/BK-5 TS58 CB1 TS55 LABEL DESCRIPTION 1 B1 RD-H6+ OR/RD-H6- D13 BK-ISM#1 1 WH/BK-25A WH/RD-26A CB2 RD- 20A PART # 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 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 BK/RD-35A CR5 A BK/RD-9B WH-21A TS57 CR17 B CR23 RD-C23-7 BK-C6-25 C G3 G2 G1 R2 BK-22B GR-43D D RD-CB3 SP D14 RD-CB3 SP CR1 F 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 G 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 C WH-CR2#86 BL/WH-L2 4 5 6 H6 U33 L45 7 RD- 24A BK-C5-5 C5 19/18 CABLES FUNCTIONS ENGINE D RD-C23-1 RD-42B H 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 I RD 12V TO PLAT C23 U33 PLATFORM LOAD BR-GND 3 STUD BK-C23-5 1 2 WH-23C J 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 8 BK/RD-C5-9 GROUND STUD BR WIRING HARNESS: TO BASE ALL BR WIRES Part No. 102521 S-40 • S-45 6 - 11 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Deutz F3L 1011F Models 6 - 11 6 - 12 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram- ALC-500 Deutz F3L 1011F Models 6 - 14 6 - 13 11 1 1 P26BAT BK P24FS WH P24FS WH C132PLI BK C1P-12 RD P2 RD H1 F.S. P23SWBAT WH C7P-2 P22BAT BK C7P-1 C4P(BR) C3P(GR) C2P(BK) C1P(GY) RED/BLK-28 RED-TILT H1 OPT. LS18 JIB C9P C19JSV GR/WH C4P-7 AND TS8 BRN D39 F.S. C19JSV GR/WH JIB C18JD GR/BK C4P-6 C17JU GR C4P-5 C15PLD OR/BK C4P-3 C14PLU OR C4P-2 6 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 BRN 8 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 1 DRE B BL/BK C13LED BL/RD C29MS RD/WH C3P C3P D40 C7P BATGND C7P-3 12V BATT 19/18 CONTROL CABLE TILT ALALRM Part No. 102521 S-40 • S-45 6 - 14 C4P GN/BK C4P-4 C7P 7 C1P C28TTA RD/BK C1P-2 5 HARNESS PBOX WIRING J2 J1 J3 GN/BK L48 4 9 3 3 45383 89353 TILT ALARM ALC-500 H1 C2P PART NUMBER COMPONENT INDEX 1 N M L K J I H G F E D C B A ALC-500 RED-TILT 2 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Deutz F3L 1011F Models October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Deutz F3L 1011F Models N M L K J I H G F E D C B A 1 HARNESS PBOX WIRING 7 7 TS48/ TS49 WORK/ DRIVE LITE 6 6 TS47 GENERATOR (OPTION) TS15 DRV.ENA 5 4 5 4 3 3 2 JC2 1 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 1 5 WH TS1 WH/RD C32BRK (SPLICE TO C32BRK) CR30 6 OR R40LS1 (SPLICE TO R40LS1) 1 2 NC TS2 START CR27 WH TS7 P22BAT BK C7P-1 2 TS6 TS1 GLOW PLUG AUXILIARY PUMP NC 3 4 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 3 + WH TS7 PLATFORM ROTATE DRIVE PROPORTIONAL JOYSTICK DRIVE ENABLE LED EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH 4 L48 GR GR/BK JC3 L1 P2 P3 TS1 TS2 2 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 7 RD REMOVE FOR GENERATOR OPTION P2 EMERGENCY STOP CE SEE DETAIL A NOTE: 8 1) DASHED LINES INDICATE OPTION WIRES. Part No. 102521 S-40 • S-45 6 - 15 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Deutz F3L 1011F Models 6 - 15 6 - 16 Section 6 • Schematics October 2013 Electrical Schematic Perkins 704-30 Models (before serial number 7472) 6 - 18 6 - 17 October 2013 Section 6 • Schematics Electrical Schematic Perkins 704-30 Models (before serial number 7472) A B C D E F G H I 1 J K L M 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 1 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) 8 6 - 18 6 7 + AUX PUMP BK FAN C5-16 WH-21 FB 4 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 7 BAT. - C6-25 BAT. + CR17 NO C6-33 12 V DC OR/BK-41 EXCT. C5-2 C5-3 6 ALTERNATOR C35ESPD BK/RD CR2 NO TB21 OTS NO HIGH RPM(FS) 5 CR1 TB35 L5 BK/RD CR1 NO HIGH RPM 7 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 8 TS52 TS51 4 CB1 TS4 TS2 C1-1 C7-2 RD C28TTA RD/BK 7 H6 TS17 RD RD C133PLA OR/RD U33 D40 C1-2 5 12 C9-2 START D39 L48 C4-4 6 L4 H1 TB43 3 4 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 3 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 2 RD-(FS) N 3 12 13 14 8 7 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 7 16 6 5 4 14 13 2 1 11 12 1 2 4 C2P-3 C1P-4 C1P-5 C1P-6 C1P-3 C1P-11 C1P-10 C3P-6 C3P-5 C3P-4 7.5 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 C3P-3 C3P-2 C3P-1 C13DRE BL/RD C3PBF RD/WH C2PBD RD/BK C1PBU RD BOOM C4P-1 C40LS1 OR DOWN UP C2P-2 JDALARM GR/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 C6-3 C30EDC+ WH A C31EDC- WH/BK D C32BRK WH/RD C37STCC BL/BK C29MS RD/WH 7 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 C40LS1 OR C18JD GR/BK C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK C6-40 C6-7 C6-8 C6-14 C6-15 C6-18 WH BK WH BK WH BK B GROUND DRIVE EDC REVERSE DRIVE EDC FORWARD LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH C 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 LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH DESCENT ALARM OPTION DRIVE ENABLE LIMIT SWITCH BOOM EXTEND BOOM RETRACT PLAT LEVEL DOWN PLAT LEVEL UP PLATFORM ROTATE LEFT / JIB UP PLATFORM ROTATE RIGHT / JIB DOWN JIB VALVES 6 - 19 S-40 • S-45 C29MS DRE B BL/BK DRE LED BL/RD OR BRN WH BL DRE A BL/WH DRIVE ENABLE 7 RKOUT 6 YOUT 5 4 PWR 3 GND 2 1 7 6 YOUT 5 BK XOUT 4 RD PWR 3 OR GND 2 BRN 1 BRN P24FS WH P26ESTP BK 4 C8PBR BK/WH C7PBE BK EXTEND BOOM RETRACT C3P-8 C14PLU OR C3P-7 C4P-2 C15PLD OR/BK C2P-6 C18JD GR/BK PLAT LEVEL C4P-3 UP C4P-6 C17JU GR DOWN C4P-5 NCHO NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. P24FS WH 3 BOOM PLATFORM LEVEL RETRACT EXTEND UP DOWN GR/BK-44 DOWN JIB BOOM NOHC Part No. 102521 8 NOHC BRN Y51 Y2 Y27 Y29 Y13 Y21 Y22 Y12 H4 Y25 Y26 Y20 Y19 SJ1-WH Deutsch Y16 Y17 C6-30 TB22 C17JU GR 1 C6-17 3 Y23 Y3 4 DOWN UP JIB BOOM 3 H4 Y4 2 2 RIGHT PLAT ROTATE 5 5 LEFT C19JSV GR/WH TB18 5 TB14 TB30 TB31 TB32 TB37 TB36 TB4 TB1 TB29 TB6 TB3 TB8 TB17 TB5 TB2 TB13 TB40 3 J2 RIGHT PLAT ROTATE LEFT C4P-7 7 TB44 TB7 TB15 R2 R1 L1 4 TS62 TS61 TS63 TS59 TS57 6 4 GND PWR XOUT YOUT RKOUT 1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 6 AMP Joystick Adaptor Harness 6 Pin1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 TS58 TB19 UP RD J1 J1 J1 J3 JIB VALVE RD TS13 TS9 TS8 TS7 JOYSTICK CONTROL CARD C19JSV GR/WH CR27 NC CR13 NC CR13 CR30 CE NO LIFT/ DRIVE OPTION 2 TS14 WH WH JC3 JC2 BRN TS15 DRIVE & STEERING PRI UP/DN & TT ROTATE WH 1 A B C D E F G H I J K L M N Section 6 • Schematics October 2013 Electrical Schematic Perkins 704-30 Models (before serial number 7472) BL/WH RD/BK OR/BK BK October 2013 Section 6 • Schematics Electrical Schematic Perkins 704-30 Models (before serial number 7472) 6 - 19 6 - 20 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Perkins 704-30 Models N M L K 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 RD-ISM#4 C6 D6 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 3 KEY SWITCH KS1 TS51 B NC 3 NC WH-23A RD-42A RD-27A RD-C23-6 4 1 B1 2 EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH ENGINE START SWITCH WH-21A HM BR (GROUND) L45 FUNCTION ENABLE PLATFORM ROTATE SWITCH 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 RESISTOR, 7.5 OHM,TURNTABLE FUNCTION 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 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 VOLT METER GAGE OIL PRESSURE GAGE OIL TEMP. GAGE STARTER AID 4 5 CB1 CB2 CB3 R1 R2 G1 G2 G3 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 PLATFORM OVERLOAD ALARM PLAT OVERLOAD MODULE PLAT OVERLOAD LED RD- 20B RD- P1 E-STOP OR/BK-15A PART # P1 KS1 TS51 TS52 R1 R2 G1 G2 G3 COOLING FAN RELAY RD- 24A OR-C6-33 BR-GND+C6-26 2 RD C4B-12 BRN GND WH/BK-25A WH/RD-26A BK/RD-35A CR5 1 CR23 TS57 CR17 A BK/RD-9B BK-22B GR-43D BK-ISM#1 BK/RD-35B B RD C4B-11 RD-C23-7 CR2 WH-21B C RD-CB3 SP R2 BK-C6-25 BK-C5-5 D DRIVE LIGHT OPTION RELAY BR (GROUND) D14 RD-CB3 SP CR1 G3 G2 G1 WH-21A BR-GND A 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 E 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. B BK-CR1#86 OR/BK-41B BK-33D RD-27B BR-GND. RD-CR2#30 WH-23B F GR/BK-S.P. GR/BK-2B GR-CR5#86 RD-H6+ OR/BK-ISM#2 C D C5 12V TO PLAT 19/18 CABLES FUNCTIONS ENGINE 3 BR-GND STUD 1 BK-C23-5 2 WH-23C G R1 GROUND STUD OR/BK-C6-15 OR-C6-14 BL/RD-C6-13 H 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 I 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 J 6 7 H6 U33 L45 OR-14A GR-17A CR4 GR/WH-19A GR/BK-18A 8 BK/RD-C5-9 GROUND STUD BR WIRING HARNESS: TO BASE ALL BR WIRES Part No. 102521 S-40 • S-45 6 - 21 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Perkins 704-30 Models 6 - 21 6 - 22 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Perkins 704-30 Models 6 - 24 6 - 23 1 P26BAT BK P24FS WH 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 8 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 1 DRE B BL/BK C13LED BL/RD C29MS RD/WH GN/BK L48 1 C9P C7P RED-TILT Part No. 102521 S-40 • S-45 6 - 24 C7P BATGND C7P-3 12V BATT 19/18 CONTROL CABLE TILT ALALRM 11 JIB 7 C4P GN/BK C4P-4 BRN 6 C1P C28TTA RD/BK C1P-2 5 J3 RED-TILT 4 9 3 HARNESS PBOX WIRING J2 J1 3 45383 89353 TILT ALARM ALC-500 H1 C2P PART NUMBER COMPONENT INDEX 1 N M L K J I H G F E D C B A ALC-500 2 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Perkins 704-30 Models October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Perkins 704-30 Models N M L K J I H G F E D C B A 1 HARNESS PBOX WIRING 7 7 TS48/ TS49 WORK/ DRIVE LITE 6 6 TS47 GENERATOR (OPTION) TS15 DRV.ENA 5 4 5 4 3 3 2 JC2 1 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 3 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 RD P3 P22BAT BK C7P-1 WH TS1 5 WH/RD C32BRK (SPLICE TO C32BRK) CR30 TS2 START OR R40LS1 (SPLICE TO R40LS1) 1 2 TS4 HIGH/LOW RPM NC L24 GLOW PLUG 1 2 + TS1 AUXILIARY PUMP CR27 WH TS7 6 NC 3 4 NO TS8 JIB (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 2 + 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 7 CE SEE DETAIL A NOTE: 1) DASHED LINES INDICATE OPTION WIRES. 8 Part No. 102521 S-40 • S-45 6 - 25 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Perkins 704-30 Models 6 - 25 6 - 26 Section 6 • Schematics October 2013 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 October 2013 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) A B C D E F G H I J K L M N 1 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 3 WATER TEMP GAUGE THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. WATER TEMP SWITCH 2 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) 8 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 6 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 2 TS17 L30 TB33 TB23 L45 ON GLOW PLUG H6 15AMP. C33STR BK RD CB1 TS56 ENGINE TB27 BK 8 TS52 START RD 7 TS51 PUMP AUXILIARY U33 12 C27AUX RD 6 P23BAT WH 5 C28TTA RD/BK C43HRN GR 4 GRD BAT. + TS48 RD 3 C133PLA OR/RD 1 4 7 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 3 TB22 PLAT 12 V DC TS49 WH ON GLOW PLUG P22BAT BK C132PLI BL/WH L4 TB132 KS1 5 FUSE 10A RD RD TB20 P24FS WH TS2 TB134 RD P1 P25FS RD C9-2 3 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 3 P2 LS18 2 C29MS DRE B BL/BK DRE LED BL/RD DRE A BL/WH DRIVE ENABLE 7 RKOUT 6 WH BL OR BRN 3 12 13 14 8 7 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 7 16 6 5 4 14 13 2 1 11 12 1 2 4 C2P-3 C1P-4 C1P-5 C1P-6 C1P-3 C1P-11 C1P-10 C3P-6 C3P-5 C3P-4 7.5 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 C3P-3 C3P-2 C3P-1 C13DRE BL/RD C3PBF RD/WH C2PBD RD/BK C1PBU RD BOOM C4P-1 C40LS1 OR DOWN UP C2P-2 JDALARM GR/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 C6-3 C30EDC+ WH A C31EDC- WH/BK D C32BRK WH/RD C37STCC BL/BK C29MS RD/WH 7 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 C18JD GR/BK C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK C40LS1 OR 6 C6-40 C6-7 C6-8 C6-14 C6-15 C6-18 C17JU GR WH BK WH BK WH BK B GROUND DRIVE EDC REVERSE DRIVE EDC FORWARD LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH C 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 LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH DESCENT ALARM OPTION DRIVE ENABLE LIMIT SWITCH BOOM EXTEND BOOM RETRACT PLAT LEVEL DOWN PLAT LEVEL UP PLATFORM ROTATE LEFT / JIB UP PLATFORM ROTATE RIGHT / JIB DOWN JIB VALVES 6 - 29 S-40 • S-45 Part No. 102521 YOUT 5 4 PWR 3 GND 2 1 7 6 YOUT 5 BK XOUT 4 RD PWR 3 OR GND 2 BRN 1 BRN P24FS WH P26ESTP BK 4 C8PBR BK/WH C7PBE BK EXTEND BOOM RETRACT C3P-8 C14PLU OR C3P-7 C4P-2 C15PLD OR/BK C2P-6 C18JD GR/BK PLAT LEVEL C4P-3 UP C4P-6 C17JU GR DOWN C4P-5 C6-17 NCHO NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. P24FS WH 3 BOOM PLATFORM LEVEL RETRACT EXTEND UP DOWN GR/BK-44 DOWN JIB BOOM DOWN UP JIB BOOM RIGHT PLAT ROTATE LEFT NOHC Y21 Y22 8 NOHC BRN Y51 Y2 Y27 Y13 Y29 Y23 Y3 SJ1-WH TB30 TB31 TB32 TB37 H4 Y4 C6-30 Y12 H4 Y25 Y26 Y20 TB13 TB40 TB14 TB22 5 TB6 TB3 TB8 TB17 TB29 TB5 TB7 TB36 TB4 TB1 C19JSV GR/WH TB18 Y19 Y16 Y17 TB44 TB2 TB15 R2 R1 4 TS62 TS61 TS63 TS59 TS57 L1 3 J2 RIGHT PLAT ROTATE LEFT C4P-7 TS58 TB19 UP RD J1 J1 J1 J3 JIB VALVE RD TS13 JOYSTICK CONTROL CARD CR30 CE NO LIFT/ DRIVE OPTION C19JSV GR/WH CR27 NC CR13 NC CR13 TS9 TS8 TS7 2 TS14 WH WH JC3 JC2 BRN TS15 DRIVE & STEERING PRI UP/DN & TT ROTATE WH 1 A B C D E F G H I J K L M N Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509) Perkins 404-22 Models (from serial number 7472 to 12509) BL/WH RD/BK OR/BK BK October 2013 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 October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510 to 14831) 6 - 32 6 - 31 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510 to 14831) A B C D E F G H I J K L M 1 N BL/WH RD/BK TB41 C2-3 OR/BK P26ESTP BK BK F18 LS18 P2 2 FUSE 10A FS1 C9-1 BK BK-(FS) RD-(FS) C9-3 P25FS RD WH-(FS) C9-2 P24FS WH TS6 2 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 4 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 3 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 3 1 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: 2 6 - 32 G1 NC 1. L29 CR3 Y29 HM BRN BR 8 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 7 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 6 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 5 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 8 TS52 START ENGINE 7 12 RD U33 TS51 PUMP AUXILIARY 6 4 C27AUX RD 5 P23BAT WH GRD C28TTA RD/BK PLAT C133PLA OR/RD 4 C45GEN GR/WH TB22 C43HRN GR KS1 BRN DRE LED BL/RD DRE B BL/BK 4 5 13 14 1 2 3 12 13 14 8 7 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 7 16 6 5 BL/WH 4 WH/RD 3 BL/WH 2 OR 1 BRN 2 1 11 12 6 6 5 4 RD/WH 3 WH/RD OR 2 1 BRN DRE A BL/WH RKOUT YOUT XOUT PWR GND YOUT XOUT PWR GND BRN P24FS WH 4 3 C2P-3 C1P-5 C1P-4 C1P-6 C1P-3 C1P-11 C1P-10 C3P-6 C3P-5 C3P-4 7.5 BRN-2 C31EDC- WH/BK C30EDC+ WH C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C6TRF WH/RD C5TRR WH/BK C4TRL WH LEFT TT ROTATE RIGHT C3P-3 C3P-2 C3P-1 C13DRE BL/RD C3PBF RD/WH C2PBD RD/BK C1PBU RD UP PRI BOOM DOWN C4P-1 C40LS1 OR C2P-6 C18JD GR/BK JDALARM GR/BK 5 C2P-2 C8PBR BK/WH C7PBE BK EXTEND BOOM RETRACT C3P-8 C14PLU OR C3P-7 C4P-2 C15PLD OR/BK C4P-6 C17JU GR RIGHT PLAT ROTATE LEFT C19JSV GR/WH 5 TB18 C5-20 C5-21 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 D A 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 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 C6-18 C6-17 B GROUND DRIVE EDC FORWARD LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH C LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. PLATFORM ROTATE RIGHT / JIB DOWN PLAT LEVEL DOWN PLAT LEVEL UP BOOM RETRACT BOOM EXTEND DRIVE ENABLE LIMIT SWITCH DESCENT ALARM 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 8 PLATFORM ROTATE LEFT / JIB UP JIB VALVES 6 - 33 S-40 • S-45 Part No. 102521 7 NCHO NOTE: P24FS WH P26ESTP BK 4 EXTEND BOOM RETRACT C4P-3 UP PLAT LEVEL DOWN C4P-5 UP PLAT LEVEL DOWN GR/BK-44 JIB BOOM C4P-7 Y25 NOHC 6 Y26 NOHC BRN Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y22 Y21 Y12 H4 H4 SJ1-WH TB29 TB6 TB3 TB8 TB30 TB31 TB32 TB37 TB36 TB4 TB5 TB2 TB13 TB40 TB7 TB15 Y20 Y19 Y16 Y17 TS59 R2 R1 4 TS62 TS63 TB1 DOWN UP JIB BOOM TB44 TB14 TB17 DOWN UP RD 3 J2 PLAT ROTATE RIGHT LEFT RD J1 J1 J1 J3 JIB VALVE TS58 TB19 WH WH TS61 TS57 TS13 TS9 TS8 TS7 JOYSTICK CONTROL CARD C19JSV GR/WH CR27 NC CR13 NC CR13 CR30 NO CE LIFT/ DRIVE OPTION 2 TS14 L1 TS15 DRIVE & STEERING 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 October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510 to 14831) BL/WH RD/BK OR/BK BK BRN October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510 to 14831) 6 - 33 6 - 34 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832 to 15662) 6 - 36 6 - 35 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832 to serial 15662) A B C D E F G H I J K L M N 1 BL/WH RD/BK TB41 C2-3 OR/BK P26ESTP BK BK F18 LS18 P2 FUSE 10A FS1 2 C9-1 BK BK-(FS) RD-(FS) C9-3 P25FS RD WH-(FS) C9-2 P24FS WH C3P-9 GENERATOR HIGH RPM(FS) WH TS4 C2-7 BK C27AUX RD BK C1-1 P23BAT WH C1-8 C7-2 C28TTA RD/BK TB132 3 1 RD C35ESPD BK/RD RD L2 C6-39 TB21 CR2 NO TB35 BK/RD CR2 CR1 CR1 NO CR5 TB34 C2B-4 CR5 NO LOW RPM FUNCTION ENA. HIGH RPM CB3 20AMP. C45GEN GR/WH 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 TB33 TB23 L45 H6 D64 ON GLOW PLUG RD CB1 15AMP. TS56 BK TB27 D2 BK 8 TS52 START ENGINE 7 RD U33 12 PUMP AUXILIARY 6 4 TS51 C33STR BK GRD 5 C133PLA OR/RD 4 PLAT C1-9 TB43 6 TB22 C43HRN GR KS1 5 TS17 RD RD TB20 L30 L30 C1-7 C1-2 C4-4 C2-5 C7-1 C2-4 PUMP AUXILIARY ENGINE D39 GLOW PLUG L48 WH TS1 H1 ON START L4 WORK LIGHT 6 P3 HORN C1-12 TB42 RD P1 15AMP. TS6 DRIVE LIGHT P22BAT BK C41RPM OR/BK C134PWR OR/RD C132PLI BL/WH TS2 D40 CB2 WH C28TTA RD/BK RD 3 TS48 FUSE 10A GR/WH-45 C5-22 BK/RD C4B-12 PR7 NO C4B-10 PR7 RD S2 S1 L29 L29 NO HIGH IDLE RELAY HIGH RPM SOLENOID GENERATOR OPTION DRIVE LIGHT OPTION 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 2 WORK LIGHTS OPTION SECOND GLOW PLUG OPTION (DEUTZ ONLY) GLOW PLUG OPTION 10A FUSE ADDED AT SERIAL NUMBER 15574 C4B-9 C4B-11 WATER TEMP GAUGE FUEL SOLENOID ADDED AT SERIAL NUMBER 15574 5 OIL TEMPERATURE SWITCH CB7 10A FUSE ADDED AT SERIAL NUMBER 15573 4 6 OIL PRESSURE SWITCH 3 OIL PRESSURE GAUGE SECOND GLOW PLUG OPTION ADDED AT SERIAL NUMBER 15151 RPM FILTER (DEUTZ ONLY) FUEL SOLENOID FUEL RELAY VOLT METER HOUR METER IGN./START RELAY STARTER MOTOR EMISSION CONTROL 2 CB7 10A 3 C5-8 RD C5-14 WH/RD G1 NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 PR3 CR3 CR4 NO PR3 NO Y29 HM _ AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR TILT ALARM FLASHING BEACONS OPTION SERVICE HORN SERVICE HORN RELAY HYDRAULIC OIL TEMP. SWITCH + - COOLING FAN (OPTION) S-40 • S-45 CR23 + STARTER BRN BR 1. 6 - 36 G3 NC 8 NO CR23 NO TB26 J144-4 H2 FAN M2 PUMP BK 7 IND. J144-6 RD REGULATOR 5 4 G6 M1 C5-13 WH PR2 NO S7 FB C5-16 WH/BK PR2 WH NO STA. G2 3MF PR1 PR1 BAT. - WH-21 BK-33 WH CR17 RD CR17 NO RD-27 BK-43 EXCT. BAT. + 12 V DC BK ALTERNATOR OR/BK-41 6 TB25 R21IGN NO FUSE 70A WH FUSE 70A C5-5 OTS RD/BK-28 RD-134 C5-2 C5-3 WH BL/WH BRN LED BL/RD 4 5 13 14 6 16 12 13 14 8 7 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 DRE B BL/BK DRIVE ENABLE DRE A BL/WH 2 1 11 12 8 6 RKOUT 5 BL/WH YOUT 4 WH/RD XOUT 3 BL/WH OR PWR 2 BR GND 1 1 DRIVE MODE C29MS RD/WH 6 5 YOUT 4 RD/WH XOUT 3 WH/RD OR PWR 2 GND 1 BR 2 4 C2-3 C1-4 C1-5 C1-6 C1-3 C1-11 C1-10 C3-6 C3-5 C3-4 7.5 5 C3-2 C3-1 C3-3 C4-1 BR-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 UP DOWN C1PBU RD C2PBD RD/BK C3PBF RD/WH C40LS1 OR C13DRE BL/RD BOOM 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 C6-13 C6-40 C6-30 C6-7 C6-8 C6-14 6 C30EDC+ WH 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 C6-19 RD/BK C3PBF RD/WH C40LS1 OR C13DRE BL/RD C7PBE BK C8PBR BK/WH C14PLU OR A D WH BK WH BK WH BK C15PLD OR/BK B GROUND DRIVE EDC FORWARD DRIVE EDC REVERSE TRAVEL ALARM OPTION BRAKE RELEASE VALVE MOTOR STROKE STEER CCW STEER CW TURNTABLE ROTATE CW TURNTABLE ROTATE CCW TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL DESCENT ALARM OPTION LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH IN THE STOWED POSITION AND KEYSWITCH "OFF". PLATFORM ROTATE CCW / JIB DOWN PLAT LEVEL DOWN PLAT LEVEL UP BOOM RETRACT BOOM EXTEND DRIVE ENABLE LIMIT SWITCH LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH C 8 PLATFORM ROTATE CW / JIB UP JIB VALVES 6 - 37 S-40 • S-45 Part No. 102521 7 P24FS WH GND BR P24FS WH C2-2 EXTEND RETRACT C7PBE BK C8PBR BK/WH C14PLU OR C15PLD OR/BK C6-15 C6-18 C18JD GR/BK C17JU GR 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM 3 4 C3-7 C3-8 C4-2 C4-3 D28 UP PLATFORM LEVEL DOWN JDALARM GR/BK C18JD GR/BK C17JU GR C6-17 NOTE: 3 EXTEND BOOM RETRACT UP PLATFORM LEVEL DOWN C2-6 C4-6 C4-5 C19JSV GR/WH BR 7 Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y22 Y21 Y12 22 21 NC 14 13 NO D30 D29 H4 SJ1-WH H4 22 21 NC 14 13 NO NC 14 13 NO 1 2 1 2 3 4 22 21 Y26 Y25 Y20 Y19 Y16 Y17 TB13 TB30 TB31 TB32 TB37 TB36 TB4 5 TB29 TB6 TB3 TB8 TB5 TB7 R1 4 TS62 TS63 TS59 TB2 TB15 TB14 TB18 TB17 GR/BK-44 DOWN JIB BOOM UP JIB TIME DELAY CIRCUIT RD TB1 DOWN UP JIB BOOM TB44 CCW PLAT ROTATE CW TS58 TB19 CCW CW PLAT ROTATE C4-7 + TS61 TS57 P26ESTP BK JIB VALVE P134PWR RD - R2 RD J1 J3 TS15 DRIVE & STEERING 3 J2 JOYSTICK CONTROL CARD J1 J1 TS8 TS7 CR30 NO CE LIFT/ DRIVE OPTION GR/WH TS13 TS9 CR14 NO CR27 NC CR13 NC CR13 D27 2 WH WH TS14 L1 JC3 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 October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832 to 15662) BL/WH RD/BK OR/BK BK BR October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832 to 15662) 6 - 37 6 - 38 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 15663 to 16419) 6 -40 6 - 39 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 15663 to 16419) A B C D E F G H I J K L M N 1 RD BL/WH RD/BK TB41 C2-3 OR/BK OR/BK 2 P26ESTP BK BK F18 P2 FUSE 10A FS1 C9-1 BK BK-(FS) RD-(FS) C9-3 P25FS RD WH-(FS) C9-2 P24FS WH TS48 WH RD TS17 TS4 HIGH RPM(FS) C3P-9 GENERATOR WH C2-7 C1-8 C28TTA RD/BK D12 BK BK TB132 DRIVE LIGHT WORK LIGHT WH ON GLOW PLUG L30 L30 C1-7 C1-1 C7-2 C1-2 C4-4 C2-5 C7-1 PUMP AUXILIARY D40 ENGINE L48 H1 D39 TS6 START P22BAT BK C2-4 TB134 RD P1 RD RD C1-9 15AMP. TS1 P3 HORN C1-12 TB132 IS WAGO TERMINAL BLOCK 36 TB133 IS WAGO TERMINAL BLOCK 16 TB 134 IS WAGO TERMINAL BLOCK 42 CB2 C132PLI BL/WH C134PWR OR/RD C41RPM OR/BK 3 TS2 TB43 3 1 TB22 TB45 D14 D13 15AMP. TB24 CR5 NO CR2 CR1 CR1 NO CR5 TB21 CR2 NO TB35 TB34 TB9 L2 BK/RD CB3 20AMP. 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 10 ENG. FAULT D6 TB28 RD RD RD TB33 TB23 D2 C35ESPD BK/RD PBOX GND TS55 LOW RPM FUNCTION ENA. HIGH RPM ON GLOW PLUG BK ENGINE D64 BK/RD TS56 BK D3 D4 C34SA BK/WH C33STR BK TS52 START TB27 GR/BK TB20 PUMP AUXILIARY 8 CB1 5 RD TB133 C27AUX RD RD 12 GBOX GND 7 C32 CONN. PLUG P23BAT WH 5 6 C28TTA RD/BK 4 C133PLA OR/RD PLAT GRD TS51 C45GEN GR/WH KS1 C43HRN GR 4 FUSE 10A BK/RD PR7 CB7 10A RD RD NO C4B-9 L29 C4B-11 HIGH IDLE RELAY HIGH RPM SOLENOID GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHTS OPTION GLOW PLUG OPTION SECOND GLOW PLUG OPTION (DEUTZ ONLY) WATER TEMP GAUGE OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH OIL PRESSURE GAUGE RPM FILTER DEUTZ FUEL RELAY VOLT METER HOUR METER FUEL SOLENOID IGN./START RELAY STARTER MOTOR EMISSION CONTROL DEUTZ 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: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM L29 C5-8 S1 NC Part No. 102521 C4B-12 PR7 NO C4B-10 PR3 C5-14 WH/RD J144-4 J144-6 C5-16 WH/BK S2 CR4 NO PR3 NO CR3 GR/WH-45 G3 Y29 G1 HM _ BR + - BR S-40 • S-45 CR23 CR23 NO TB26 + STARTER AUX M2 PUMP IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 40 C5-13 WH WH-21 D52 NO G6 BK IND. H2 3MF NO M1 FAN TB25 G2 C5-11 PR2 PR2 S7 FB C21IGN2 WH NO STA. FUSE 70A BK-33 PR1 PR1 BAT. - REGULATOR 8 WH RD CR17 RD-27 BK-43 CR17 NO RD 7 BK EXCT. BAT. + 12 V DC OR/BK-41 ALTERNATOR C5-5 NO D22 RD/BK-28 RD-134 OTS FUSE 70A WH BL/WH C5-22 WH C5-2 C5-3 6 BRN BR LED BL/RD 4 5 13 14 6 16 12 13 14 8 7 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 DRE B BL/BK DRIVE ENABLE DRE A BL/WH 2 1 11 12 8 6 RKOUT 5 BL/WH YOUT 4 WH/RD XOUT 3 BL/WH OR PWR 2 BR GND 1 1 DRIVE MODE C29MS RD/WH 6 5 YOUT 4 RD/WH XOUT 3 WH/RD OR PWR 2 GND 1 BR 2 3 C2-3 C1-4 C1-5 C1-6 C1-3 C1-11 C1-10 C3-6 C3-5 C3-4 7.5 5 C3-2 C3-1 C3-3 C4-1 BR-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 UP DOWN C1PBU RD C2PBD RD/BK C3PBF RD/WH C13DRE BL/RD 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 C6-13 C6-40 C6-30 C6-7 C6-8 C6-14 C30EDC+ WH 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 RD/BK C3PBF RD/WH C6-19 C13DRE BL/RD 6 C40LS1 OR C7PBE BK C8PBR BK/WH C14PLU OR A D WH BK WH BK WH BK C15PLD OR/BK C18JD GR/BK B GROUND DRIVE EDC FORWARD DRIVE EDC REVERSE TRAVEL ALARM OPTION BRAKE RELEASE VALVE MOTOR STROKE STEER CCW STEER CW TURNTABLE ROTATE CW TURNTABLE ROTATE CCW TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL DESCENT ALARM OPTION LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH IN THE STOWED POSITION AND KEYSWITCH "OFF". PLATFORM ROTATE CCW / JIB DOWN PLAT LEVEL DOWN PLAT LEVEL UP BOOM RETRACT BOOM EXTEND DRIVE ENABLE LIMIT SWITCH LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH C 8 PLATFORM ROTATE CW / JIB UP JIB VALVES 6 - 41 S-40 • S-45 Part No. 102521 7 P24FS WH GND BR 4 BOOM C40LS1 OR EXTEND RETRACT C7PBE BK C8PBR BK/WH C14PLU OR C15PLD OR/BK C6-15 C6-18 C17JU GR 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM 3 C2-2 C3-7 C3-8 C4-2 C4-3 D28 UP PLATFORM LEVEL DOWN JDALARM GR/BK C18JD GR/BK C17JU GR C6-17 NOTE: P24FS WH 4 EXTEND BOOM RETRACT UP PLATFORM LEVEL DOWN C2-6 C4-6 C4-5 C19JSV GR/WH BR 7 Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y22 Y21 Y12 22 21 NC 14 13 NO D30 D29 H4 SJ1-WH H4 22 21 NC 14 13 NO NC 14 13 NO 1 2 1 2 3 4 22 21 Y26 Y25 Y20 Y19 Y16 Y17 TB13 TB30 TB31 TB32 TB37 TB36 TB4 5 TB29 TB6 TB3 TB8 TB5 TB7 R1 4 TS62 TS63 TS59 TB2 TB15 TB14 TB18 TB17 GR/BK-44 DOWN JIB BOOM UP JIB TIME DELAY CIRCUIT RD TB1 DOWN UP JIB BOOM TB44 CCW PLAT ROTATE CW TS58 TB19 CCW CW PLAT ROTATE C4-7 + TS61 TS57 P26ESTP BK JIB VALVE P134PWR RD - R2 RD J1 J3 CR30 NO CE LIFT/ DRIVE OPTION 2 TS15 DRIVE & STEERING 3 J2 JOYSTICK CONTROL CARD J1 J1 TS13 TS8 TS7 D27 GR/WH CR27 NC CR13 NC CR13 TS9 CR14 NO WH WH TS14 L1 JC3 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 October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 15663 to 16419) BL/WH RD/BK OR/BK BK October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 15663 to 16419) 6 - 41 6 - 42 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 15663 to 16419) 6 - 44 6 - 43 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 15663 to 16419) A B C D E F G H I J K L M N 1 RD BL/WH C132PLI2 BK RD/BK TB41 C2-3 OR/BK OR/BK D89 P26ESTP BK 2 P2 LS18 PBOX GND BK F18 LS18A FUSE 10A FS1 BK C9-1 BK D88 RD-(FS) C9-3 P25FS RD WH-(FS) C9-2 P24FS WH TS48 WH RD TS4 HIGH RPM(FS) C3P-9 GENERATOR WH DRIVE LIGHT WORK LIGHT TS17 C2-7 C1-8 C28TTA RD/BK D12 BK BK TB132 L30 L30 C1-7 C7-2 C1-2 C4-4 C2-5 C7-1 PBOX GND WH C1-1 U35 D40 ENGINE H1 D39 START NO 30A PUMP AUXILIARY L48 TS1 TS6 ON GLOW PLUG BK 2 SEC C4-10 P22BAT BK C2-4 TB134 RD P1 RD RD C1-9 15AMP. R20 4.7 K P3 HORN C1-12 TB132 IS WAGO TERMINAL BLOCK 36 TB133 IS WAGO TERMINAL BLOCK 16 TB 134 IS WAGO TERMINAL BLOCK 42 CB2 C132PLI BL/WH C134PWR OR/RD C41RPM OR/BK 3 TS2 TB43 TB45 TB33 GR/BK TB20 15AMP. H6 5 L45 D6 TB28 RD TB24 CR5 NO CR1 CR1 NO CR5 CR2 TB21 CR2 NO TB34 TB35 TB9 L2 BK/RD CB3 20AMP. 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 10 ENG. FAULT RD RD D14 D13 CB1 C35ESPD BK/RD TS55 LOW RPM FUNCTION ENA. HIGH RPM PBOX GND C45GEN GR/WH BK/RD C34SA BK/WH D64 ON GLOW PLUG BK TB23 TS56 ENGINE U34 C33STR BK NO 10A BK TB27 D2 D3 D4 TS52 START 8 2 SEC C21IGN WH 12 GBOX GND TB133 PUMP AUXILIARY 7 TS51 RD RD LOAD SENSE MODULE C27AUX RD 6 P23BAT WH 5 C28TTA RD/BK 4 GRD C133PLA OR/RD PLAT 4 3 1 TB22 C43HRN GR KS1 FUSE 10A GR/WH-45 BK/RD CB7 10A RD RD L29 NO C4B-9 C5-8 S1 L29 C4B-11 HIGH IDLE RELAY HIGH RPM SOLENOID GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHTS OPTION GLOW PLUG OPTION SECOND GLOW PLUG OPTION (DEUTZ ONLY) WATER TEMP GAUGE OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH OIL PRESSURE GAUGE RPM FILTER DEUTZ FUEL RELAY VOLT METER HOUR METER FUEL SOLENOID IGN./START RELAY STARTER MOTOR EMISSION CONTROL DEUTZ AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM Part No. 102521 C4B-12 C4B-10 S2 NC TILT ALARM FLASHING BEACONS OPTION SERVICE HORN RELAY SERVICE HORN HYDRAULIC OIL TEMP. SWITCH + - COOLING FAN (OPTION) S-40 • S-45 PR7 Y29 G1 HM _ IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 44 PR7 NO + STARTER AUX M2 PUMP BR BR 8 PR3 CR3 CR4 NO PR3 NO C5-14 WH/RD H2 FAN G3 J144-4 IND. J144-6 D52 CR23 CR23 NO TB26 G6 BK REGULATOR 3MF NO S7 C5-13 WH PR2 C5-16 WH/BK PR2 M1 7 WH-21 RD STA. TB25 G2 C5-11 NO FB C21IGN2 WH PR1 PR1 BAT. - FUSE 70A BK-33 WH CR17 RD CR17 NO RD-27 BK-43 BK EXCT. BAT. + 12 V DC OR/BK-41 ALTERNATOR C5-5 RD/BK-28 NO D22 NO C5-22 WH C5-2 C5-3 6 OTS FUSE 70A WH BL/WH BRN LED BL/RD 4 5 13 14 6 16 12 13 14 8 7 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 DRE B BL/BK DRIVE ENABLE DRE A BL/WH 2 1 11 12 8 6 RKOUT 5 BL/WH YOUT 4 WH/RD XOUT 3 BL/WH OR PWR 2 BR GND 1 1 DRIVE MODE C29MS RD/WH 6 5 YOUT 4 RD/WH XOUT 3 WH/RD OR PWR 2 GND 1 BR 2 3 C2-3 C1-4 C1-5 C1-6 C1-3 C1-11 C1-10 C3-6 C3-5 C3-4 7.5 5 C3-2 C3-1 C3-3 C4-1 BR-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 UP DOWN C1PBU RD C2PBD RD/BK C3PBF RD/WH C13DRE BL/RD 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 C6-13 C6-40 C6-30 C6-7 C6-8 C6-14 C30EDC+ WH 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 RD/BK C3PBF RD/WH C6-19 C13DRE BL/RD 6 C40LS1 OR C7PBE BK C8PBR BK/WH C14PLU OR A D WH BK WH BK WH BK C15PLD OR/BK C18JD GR/BK B GROUND DRIVE EDC FORWARD DRIVE EDC REVERSE TRAVEL ALARM OPTION BRAKE RELEASE VALVE MOTOR STROKE STEER CCW STEER CW TURNTABLE ROTATE CW TURNTABLE ROTATE CCW TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL DESCENT ALARM OPTION LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH IN THE STOWED POSITION AND KEYSWITCH "OFF". PLATFORM ROTATE CCW / JIB DOWN PLAT LEVEL DOWN PLAT LEVEL UP BOOM RETRACT BOOM EXTEND DRIVE ENABLE LIMIT SWITCH LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH C 8 PLATFORM ROTATE CW / JIB UP JIB VALVES 6 - 45 S-40 • S-45 Part No. 102521 7 P24FS WH GND BR 4 BOOM C40LS1 OR EXTEND RETRACT C7PBE BK C8PBR BK/WH C14PLU OR C15PLD OR/BK C6-15 C6-18 C17JU GR 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM 3 C2-2 C3-7 C3-8 C4-2 C4-3 D28 UP PLATFORM LEVEL DOWN JDALARM GR/BK C18JD GR/BK C17JU GR C6-17 NOTE: P24FS WH 4 EXTEND BOOM RETRACT UP PLATFORM LEVEL DOWN C2-6 C4-6 C4-5 C19JSV GR/WH BR 7 Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y22 Y21 Y12 22 21 NC 14 13 NO H4 22 21 NC 14 13 NO NC 14 13 NO 1 2 1 2 3 4 22 21 Y26 Y25 Y20 Y19 Y16 Y17 H4 SJ1-WH D30 D29 TB30 TB31 TB32 TB37 TB36 TB4 5 TB29 TB6 TB3 TB8 TB5 TB2 TB7 R1 4 TS62 TS63 TS59 TB13 TB15 TB14 TB18 TB17 GR/BK-44 DOWN JIB BOOM UP JIB TIME DELAY CIRCUIT RD TB1 DOWN UP JIB BOOM TB44 CCW PLAT ROTATE CW TS58 TB19 CCW CW PLAT ROTATE C4-7 + TS61 TS57 P26ESTP BK JIB VALVE P134PWR RD - R2 RD J1 J3 TS15 DRIVE & STEERING 3 J2 JOYSTICK CONTROL CARD J1 J1 TS8 TS7 CR30 NO CE LIFT/ DRIVE OPTION GR/WH TS13 TS9 CR14 NO CR27 NC CR13 NC CR13 D27 2 WH WH TS14 L1 JC3 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 October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 15663 to 16419) BL/WH RD/BK OR/BK BK BR October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 15663 to 16419) 6 - 45 6 - 46 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 16420) 6 - 48 6 - 47 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 16420) A B C D E F G H I J K L M N 1 RD BL/WH RD/BK C2-3 TB41 OR/BK BK P26ESTP BK 2 P2 C9-1 BK TS4 BK BK D12 C1-9 LOW RPM FUNCTION ENA. HIGH RPM CR2 NO TB35 2 L2 FUSE 10A BK/RD TB21 TB45 C6-39 CR2 CR1 CR1 NO BR C6-34 C45GEN GR/WH C4B-12 C4B-10 NO CR4 CB7 10A C5-8 RD RD PR7 L29 C4B-11 L29 BR HIGH IDLE RELAY HIGH RPM SOLENOID LIGHTS PACKAGE GENERATOR OPTION WORK LIGHTS OPTION DRIVE LIGHT OPTION SECOND GLOW PLUG OPTION (DEUTZ ONLY) DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453 C4B-9 GLOW PLUG OPTION Part No. 102521 C5-22 S-40 • S-45 PR7 NO WATER TEMP GAUGE OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH OIL PRESSURE GAUGE RPM FILTER (DEUTZ ONLY) FUEL SOLENOID VOLT METER IGNITION RELAY HOUR METER START RELAY STARTER MOTOR EMISSION CONTROL AUXILIARY POWER RELAY AUXILIARY PUMP WORK LIGHTS RELAY (OPTION) LEVEL SENSOR TILT ALARM FLASHING BEACONS OPTION SERVICE HORN SERVICE HORN RELAY HYDRAULIC OIL TEMP. SWITCH + - COOLING FAN (OPTION) NOTE: IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 48 PR3 S1 NO 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM 2 CR23 CR23 NO CR3 Y29 S2 NC 8 WH/RD G1 PR3 NO C5-14 C6-26 + HM _ J144-4 J144-6 WH/BK G6 FUSE 70A TB26 WH 3MF PR2 STARTER AUX M2 PUMP BK H2 TB25 C5-16 R21IGN WH PR2 NO G2 C5-13 C5-5 C6-27 FB FAN M1 IND. PR1 NO PR1 S7 STA. REGULATOR WH CR17 C6-16 BAT. - C6-33 BAT. + 12 V DC CR17 NO RD EXCT. C6-25 D22 ALTERNATOR 7 CR5 C6-28 CR5 NO C6-23 C5-2 C5-3 6 NO FUSE 70A NO D14 D13 TB34 RD RD C35RPM BK/RD TS55 C45GEN GR/WH CR45 C34SA BK/WH ENGINE CR45 NO D64 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT TB24 RD TS56 TB33 TB23 D2 C33STR BK START RD TB27 D6 OTS HIGH RPM(FS) C2-7 ENG SPEED GENERATOR WH L30 L30 C1-8 C1-7 C27AUX RD P23BAT WH TS52 TS51 D4 TB28 CB1 15AMP. CB3 20AMP. WH C28TTA RD/BK C1-1 C7-2 8 GR/BK 5 TB133 C28TTA RD/BK GBOX GND 7 C1-2 RD C32 CONN. PLUG D40 C133PLA OR/RD 5 12 L48 C4-4 C43HRN GR 3 4 TS1 + H1 D39 TS17 TS6 TS2 TB43 6 TB20 C2-5 C7-1 TB132 1 KS1 TB22 PLAT GRD P22BAT BK TB134 RD 4 C1-12 P1 C2-4 CB2 15AMP. C132PLI1 BL/WH P134PWR RD C41RPM OR/BK 3 P25FS RD P24FS WH C9-2 RD P3 HORN WH FS1 C9-3 6 16 17 18 20 19 16 15 5 C41RPM OR/BK LED BL/RD 4 5 13 14 9 11 10 6 7 8 14 13 12 3 C2-3 C1-4 C1-5 C1-6 C1-3 C1-11 C1-10 C3-6 C3-5 C3-4 7.5 5 C3-2 C3-1 C3-3 C4-1 BR-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 UP DOWN C1PBU RD C2PBD RD/BK C3PBF RD/WH BOOM C40LS1 OR C13DRE BL/RD EXTEND RETRACT C7PBE BK C8PBR BK/WH C14PLU OR 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 C6-3 C6-13 C6-40 C6-30 C6-7 C6-8 C6-14 C6-15 C6-18 C31EDC- WH/BK C30EDC+ WH 6 C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C4TRL WH C5TRR WH/BK C6TRF WH/RD C1PBU RD C2PBD RD/BK C6-19 RD/BK C3PBF RD/WH C40LS1 OR C13DRE BL/RD C7PBE BK C8PBR BK/WH A D WH BK WH BK WH BK C15PLD OR/BK C14PLU OR C18JD GR/BK C17JU GR B C GROUND DRIVE EDC FORWARD DRIVE EDC REVERSE TRAVEL ALARM OPTION BRAKE RELEASE VALVE MOTOR STROKE STEER CCW STEER CW TURNTABLE ROTATE CW TURNTABLE ROTATE CCW TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH DESCENT ALARM OPTION LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH DRIVE ENABLE LIMIT SWITCH BOOM RETRACT BOOM EXTEND PLAT LEVEL UP PLAT LEVEL DOWN PLATFORM ROTATE CCW / JIB DOWN IN THE STOWED POSITION AND KEYSWITCH "OFF". PLATFORM ROTATE CW / JIB UP JIB VALVES 6 - 49 S-40 • S-45 15 DRE B BL/BK DRIVE ENABLE DRE A BL/WH 2 1 11 12 8 6 RKOUT 5 BL/WH YOUT 4 WH/RD XOUT 3 BL/WH OR PWR 2 BR GND 1 1 DRIVE MODE C29MS RD/WH 6 5 YOUT 4 RD/WH XOUT 3 WH/RD OR PWR 2 GND 1 BR 2 4 7 P24FS WH GND BR 3 C2-2 C3-7 C3-8 C4-2 C4-3 D28 UP PLATFORM LEVEL DOWN JDALARM GR/BK C18JD GR/BK C17JU GR C6-17 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM Part No. 102521 8 NOTE: P24FS WH 4 EXTEND BOOM RETRACT UP PLATFORM LEVEL DOWN C2-6 C4-6 C4-5 C19JSV GR/WH BR 7 Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y22 Y21 Y12 22 21 NC 14 13 NO D30 D29 TB30 TB31 TB32 TB37 TB36 TB4 H4 SJ1-WH H4 22 21 NC 14 13 NO NC 14 13 NO 1 2 1 2 3 4 22 21 Y26 Y25 Y20 Y19 Y16 Y17 TB13 TB7 R1 5 TB29 TB6 TB3 TB8 TB5 TB2 TB15 TS62 TS63 TS59 TB1 DOWN UP JIB BOOM TB44 TB14 TB18 TB17 GR/BK-44 DOWN JIB BOOM UP JIB TIME DELAY CIRCUIT RD 4 CCW PLAT ROTATE CW TS58 TB19 CCW CW PLAT ROTATE C4-7 + TS61 TS57 P26ESTP BK JIB VALVE P134PWR RD - R2 RD J1 J3 TS15 DRIVE & STEERING 3 J2 JOYSTICK CONTROL CARD J1 J1 TS8 TS7 CR30 NO CE LIFT/ DRIVE OPTION GR/WH TS13 TS9 CR14 NO CR27 NC CR13 NC CR13 D27 2 WH WH TS14 L1 JC3 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 October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 16420) BL/WH RD/BK OR/BK BK BR October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI /CSA / AS (from serial number 16420) 6 - 49 6 - 50 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 16420) 6 - 52 6 - 51 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 16420) A B C D E F G H I J K L M N 1 RD BL/WH RD/BK C132PLI2 BK D89 PBOX GND 2 D12 BK C1-9 TB21 CR2 CR2 NO TB35 2 L2 FUSE 10A BR C6-34 BK/RD C45GEN GR/WH CR4 C4B-12 C4B-10 CB7 10A C5-8 RD RD Y29 BR HIGH IDLE RELAY HIGH RPM SOLENOID LIGHTS PACKAGE GENERATOR OPTION WORK LIGHTS OPTION DRIVE LIGHT OPTION SECOND GLOW PLUG OPTION (DEUTZ ONLY) Part No. 102521 DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453 PR7 NO CR3 L29 L29 C4B-9 C4B-11 GLOW PLUG OPTION S-40 • S-45 C5-22 + - IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 52 PR7 NO COOLANT TEMP GAUGE OIL TEMPERATURE SWITCH 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM 2 PR3 NO OIL PRESSURE SWITCH OIL PRESSURE GAUGE RPM FILTER (DEUTZ ONLY) FUEL SOLENOID VOLT METER IGNITION RELAY HOUR METER START RELAY STARTER MOTOR AUXILIARY PUMP EMISSION CONTROL AUXILIARY POWER RELAY LEVEL SENSOR TILT ALARM FLASHING BEACONS OPTION SERVICE HORN RELAY SERVICE HORN HYDRAULIC OIL TEMP. SWITCH COOLING FAN (OPTION) NOTE: PR3 NO CR23 CR23 NO S1 NC 8 G3 WH/RD S2 G1 FUSE 70A C5-14 C6-26 + HM _ J144-4 J144-6 G6 TB26 WH PR2 STARTER AUX M2 PUMP BK H2 3MF WH/BK PR2 NO G2 TB25 C5-16 R21IGN WH RD FB FAN M1 7 PR1 S7 STA. REGULATOR IND. PR1 NO C6-16 BAT. - CR17 C6-33 BAT. + 12 V DC CR17 NO WH EXCT. C6-25 D22 ALTERNATOR C5-13 C5-5 C6-27 C6-28 C6-23 C5-2 C5-3 CR5 NO 6 NO FUSE 70A OTS C35RPM BK/RD CR1 CR1 NO TB45 RD D14 D13 TB34 RD BK/RD CR45 LOW RPM FUNCTION ENA. HIGH RPM 1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT C6-39 CR45 NO D64 TS55 TB33 D6 RD C45GEN GR/WH TB27 TB23 C34SA BK/WH U34 C33STR BK D4 TS56 ENGINE NO 10A RD D2 C21IGN WH 2 SEC TS52 START C27AUX RD TS51 TB24 CR5 NO HIGH RPM(FS) C2-7 C1-8 C1-7 L30 ENG SPEED C1-1 L30 TS4 GENERATOR WH WH C28TTA RD/BK C3-10 BK P23BAT WH L45 H6 GR/BK CB1 15AMP. TS17 TS6 TS2 PBOX GND TB28 CB3 20AMP. 5 U35 C7-2 RD GBOX GND TB20 NO 30A - D40 C28TTA RD/BK TB133 TS1 2 SEC C1-2 5 D39 H1 C133PLA OR/RD C43HRN GR 3 4 C9-2 + GR/BK C4-4 TB43 6 LOAD SENSE 7 MODULE 12 U33 8 4 C2-5 TB132 1 KS1 TB22 PLAT GRD C7-1 RD P22BAT BK C2-4 P1 TB134 P25FS RD-(FS) P24FS WH-(FS) BK R20 4.7K L4 C1-12 CB2 15AMP. C132PLI1 BL/WH P134PWR RD C41RPM OR/BK 3 WH FS1 C9-3 C9-1 RD P3 HORN OR/BK BK P26ESTP BK P2 LS18 D88 C2-3 TB41 LS18A LED BL/RD 4 5 13 14 6 16 3 12 13 14 8 7 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 DRE B BL/BK DRIVE ENABLE DRE A BL/WH 2 1 11 12 8 6 RKOUT 5 BL/WH YOUT 4 WH/RD XOUT 3 BL/WH OR PWR 2 BR GND 1 1 DRIVE MODE C29MS RD/WH 6 5 YOUT 4 RD/WH XOUT 3 WH/RD OR PWR 2 GND 1 BR 2 7 P24FS WH GND BR 4 C2-3 C1-4 C1-5 C1-6 C1-3 C1-11 C1-10 C3-6 C3-5 C3-4 7.5 5 C3-2 C3-1 C3-3 C4-1 BR-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 UP DOWN C1PBU RD C2PBD RD/BK C3PBF RD/WH BOOM C40LS1 OR C13DRE BL/RD EXTEND RETRACT C7PBE BK C8PBR BK/WH C14PLU OR 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 C6-3 C6-13 C6-40 C6-30 C6-7 C6-8 C6-14 C6-15 C6-18 C31EDC- WH/BK C30EDC+ WH 6 C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C4TRL WH C5TRR WH/BK C6TRF WH/RD C1PBU RD C2PBD RD/BK C6-19 RD/BK C3PBF RD/WH C40LS1 OR C13DRE BL/RD C7PBE BK C8PBR BK/WH A D WH BK WH BK WH BK C15PLD OR/BK C14PLU OR C18JD GR/BK C17JU GR GROUND DRIVE EDC FORWARD DRIVE EDC REVERSE TRAVEL ALARM OPTION BRAKE RELEASE VALVE MOTOR STROKE STEER CCW STEER CW TURNTABLE ROTATE CW TURNTABLE ROTATE CCW TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL DESCENT ALARM OPTION LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH C B 7 LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH DRIVE ENABLE LIMIT SWITCH BOOM RETRACT BOOM EXTEND PLAT LEVEL UP PLAT LEVEL DOWN PLATFORM ROTATE CCW / JIB DOWN IN THE STOWED POSITION AND KEYSWITCH "OFF". PLATFORM ROTATE CW / JIB UP JIB VALVES 6 - 53 S-40 • S-45 Part No. 102521 8 NOTE: 3 C2-2 C3-7 C3-8 C4-2 C4-3 D28 UP PLATFORM LEVEL DOWN JDALARM GR/BK C18JD GR/BK C17JU GR C6-17 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM P24FS WH 4 EXTEND BOOM RETRACT UP PLATFORM LEVEL DOWN C2-6 C4-6 C4-5 CCW PLAT ROTATE CW C19JSV GR/WH BR Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y22 Y21 Y12 22 21 NC 14 13 NO TB30 TB31 TB32 TB37 TB36 TB4 H4 SJ1-WH H4 22 21 NC 14 13 NO NC 14 13 NO 1 2 1 2 3 4 22 21 Y26 Y25 Y20 Y19 Y16 Y17 TB13 TB7 D30 D29 TB29 TB6 TB3 5 TB8 TB5 TB2 TB15 TS62 TS63 TS59 TB1 DOWN UP JIB BOOM TB44 TB14 TB18 TB17 GR/BK-44 DOWN JIB BOOM UP CCW CW PLAT ROTATE C4-7 JIB TIME DELAY CIRCUIT RD 4 TS58 TB19 P26ESTP BK JIB VALVE P134PWR RD + R1 3 - TS61 TS57 J1 J3 CR30 NO CE LIFT/ DRIVE OPTION R2 RD J2 JOYSTICK CONTROL CARD J1 J1 TS8 TS7 D27 GR/WH TS13 TS9 CR14 NO CR27 NC CR13 NC CR13 TS15 DRIVE & STEERING 2 WH WH TS14 L1 JC3 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 October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 16420) BL/WH RD/BK OR/BK BK BR October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 16420) 6 - 53 6 - 54 Section 6 • Schematics October 2013 Ground Control Box Wiring Diagram Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (before serial number 14832) 6 - 56 6 - 55 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (before serial number 14832) A B C D E F G H I J K L M N 1 PLATFORM LOAD 2 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 3 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 4 GR/BK-C6-18 GR-C6-17 BR-GND STUD C7B 3 1 BK-C32-5 2 WH-23C C2B 5 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 BK/RD CR3-#30 BK/RD-S.P. BK/WH-S.P. BK-S.P. 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 GR/BK-C32-8 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. GR/BK-H6OR/BK-S.P. OR-S.P. WH/BK-25A WH/RD-26A BK-22A KS1 RD-CB2 3 NC WH-23A RD-42A RD-27A RD-C23-6 BK/RD-CR23#86 44B+RD/BK-C6-19 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. 4 2 A TACHOMETER START INPUT AUX. ON GROUND 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 CR4 TS63 TURNTABLE ROTATE TS52 RD- 24A RD- 20B RD- P1 E-STOP OR/BK-15A OR-14A GR-17A GR/WH-19A GR/BK-18A GR-43D BK-22B CR17 BK-C6-25 RD-CB3 SP WIRING GROUND STUD HARNESS: BR TO BASE ALL BR WIRES S-40 • S-45 TS56 13037 TS55 13037 16397 TS56 D14 CB1 Part No. 102521 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 ENGINE START D13 BK/RD-35A CR5 STARTER AID FUNCTION ENABLE SWITCH 13037 TS58 JIB BOOM UP/DOWN TS62 CB2 TS57 OR-C6-33 13037 13037 RD-C32-7 BK-C6-16 TS52 TS63 FUNCTION ENABLE WH-21B 42730 ENGINE START SWITCH BOOM EXTEND/RETRACT SWITCH R2 CR3 KS1 TS51 WH-21A TS55 CR2 KS1 AUXILIARY SWITCH TS59 RD- 20C RD-CR17#30 WH/BK-5A WH/RD-6A WH-4A BK/RD-35B KEY SWITCH TS57 STARTER AID MODULE P1 PLATFORM LEVEL SWITCH BK/WH-34A IGN./START PART # P1 PLATFORM ROTATE SWITCH RD START RELAY 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT C5 ENGINE 1 B1 LABEL EMERGENCY STOP BUTTON GR/BK-H6- RD- 20A GROUND STUD TS51 B NC DESCRIPTION AUXILIARY KEY SWITCH P1 BL/WH-ISM#10 BK/RD-C5-9 6 - 56 RD C4B-12 BRN GND BK-ISM#1 8 RD C4B-11 BR (GROUND) 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. RD-KS1-2 S.P. BR -3MF CAP BL/RD-S.P. CR1 BK-C5-5 BK/RD-9B G3 WH-21A SPARE GEN. OPTION RD-ISM#6 WH-ISM#9 RD-24B C6 FUNCTIONS CR23 G2 G1 R1 1 2 3 4 5 WH-L2 DIODE 7 GR/BK-L45GR/BK-16A B BK-CR1#86 OR/BK-41B BK-33B RD-27B BR-GND. RD-CR2#30 H6 GR/BK-S.P. GR/BK-2B GR-CR5#85 RD-H6+ OR/BK-ISM#2 C D 6 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-CB3 SP RD-C32-1 RD-42B 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 GR/WH-C6-39 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 TS59 PLATFORM LEVEL PLATFORM ROTATE 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 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832) M L K J I H G F E D C B A 1 LOAD SENSE OPTION - TIMER RELAY U33 RD-C6-23 OR/BK-C5-2 OR-C6-40 BK/WH-C5-10 BL/WH-C32-3 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 C2B C7B 12V TO PLAT 12 V OR/BK-C6-15 OR-C6-14 BL/RD-C6-13 3 BR-GND STUD 1 BK-C32-5 2 WH-23C 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 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 C B C3B C4B C1B BK-CR1#86 OR/BK-41B BK-33B RD-27B BR-GND. RD-CR2#30 WH-23B 1 2 3 4 5 6 7 8 9 10 RD-ISM#6 WH-ISM#9 RD-24B C6 FUNCTIONS WH-CR2#86 WH-L2 DIODE START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT H6 WH-CR2#86 SPARE GEN. OPTION JDALARM JIB HORN GR/BK-S.P. RD-KS1-2 S.P. BR -3MF CAP P134PWR (DEUTZ ONLY) PULSE PICKUP LIMIT SWITCH SIG. L.P. C132PLI STEER CCW STEER CW 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. CCW PLAT. ROT. CW C133PLA PLAT. LEVEL DN. PLAT. LEVEL. UP DRV. ENA. LT. BL/RD-S.P. BK/RD-S.P. BK/WH-S.P. BK-S.P. 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. RD-TB134(A)C WH-21A BR (GROUND) BR-GND SPARE BOOM RETRACT BOOM EXTEND 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 TURN. ROT. F.C. TURN. ROT. CCW TURN. ROT. CW PRI. BOOM F.C. PRI. BOOM DOWN PRI. BOOM UP WH/BK-25A WH/RD-26A BK-22A RD-CB2 TS51 B NC NC D2 3 1 B1 4 WH-23A RD-134A RD-27A DESCRIPTION 2 EMERGENCY STOP BUTTON D4 RD-C32-6 DRIVE LIGHT OPTION RELAY GR/BK-H6- CR23 WH-21A 85 87 BN-GND RD C4B-10 RD C4B-12 L45 WH-C5-13 WH-21B TS61 RD/WH-3A RD/BK-2A RD-1A WORK LIGHT OPTION RELAY TS63 BK/WH-8A BK-7A GR/BK-44A BK-33A RD-20C D64 TS52 TS62 CR45 CB3 TS58 D27 CB1 CB2 TS59 TS51 TS52 TS56 FUNCTION ENABLE TS55 PLATFORM ROTATE SWITCH TS57 PLATFORM LEVEL SWITCH TS59 BOOM EXTEND/RETRACT SWITCH TS63 PRIMARY BOOM UP/DOWN SWITCH TS61 TURNTABLE ROTATE SWITCH TS62 JIB BOOM UP/DOWN SWITCH TS58 CIRCUIT BREAKER, ENGINE, 15A CB2 CB3 R2 VOLT METER GAGE G1 OIL PRESSURE GAGE G2 OIL TEMP. GAGE G3 CHECK ENG LED L2 CR1 IGN. POWER RELAY CR2 HIGH IDLE (RPM) CUTOUT RELAY CR3 RPM RELAY CR4 CR5 CR17 PLATFORM OVERLOAD ALARM RD-20A PLAT OVERLOAD MODULE RD-24A LOAD SENSE TIME DELAY RELAY (10A) U34 PLAT OVERLOAD LED L45 RD-P1 E-STOP 7 H6 BK/RD-35A RD-20B 6 HM IGN. START RELAY COOLING FAN RELAY 5 R1 RESISTOR, 7.5 OHM,TURNTABLE FUNCT HOUR METER 4 CB1 CIRCUIT BREAKER, OPTIONS, 20A HORN RELAY TS55 D13 OR-C6-33 BK-C6-16 WH-W.L. CABLE WH-21C TS57 CR4 BR-GND 87 TS56 D14 CR3 85 86 P1 KS1 STARTER AID RESISTOR, 5 OHM, BOOM FUNCTION 30 LABEL ENGINE START SWITCH CIRCUIT BREAKER, CONTROLS, 15A R2 WH-21B C5 30 86 CHECK ENG LED L2 HM KEY SWITCH AUXILIARY SWITCH RD-24C RD BR (GROUND) 3 REPLACE WIRE WITH THIS WIRING DIAGRAM KEY SWITCH KS1 P1 RD-20C RD-CR17#30 WH/BK-5A WH/RD-6A WH-4A IGN./START MODULE 5 U34 BK/WH-34A BK/RD-C5-9 ENGINE 3 BL/WH-ISM#10 BK-ISM#1 BK-C5-5 2 2 BK-C3B-10 RD-C32-7 CR2 9 G3 BK/RD-35B CR1 8 WH-ISM#9 G2 G1 R1 19/18 CABLES D RD-CR23#30 WH-C7B-2 BK-C32-4 C634&CR45#86 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 46 45 GR/WH-35B 2 44 GR/BK-2B 43 GR-CR5#85 134A RD-H6+ 134 41 OR/BK-ISM#2 40 39 132 37 2 36 35 BK/RD CR3-#30 GR/WH-45B 34 33 BK-ISM#3 32 WH/RD-C6-32 31 30 29 28 27 RD-ISM#4 D6 26 25 24 RED-CR1#30 23 WH-ISM #7 22 BK-CR5#30 21 WH-CR2#87&CR23#86 20 CB2-SP 19 18 17 133 GR/BK-C32-8 15 14 13 12 11 10 9 8 7 6 5 4 3 2 44B+RD/BK-C6-19 1 RD-C32-1 RD-134B GR/BK-L45GR/BK-133A RD GR/WH-C2B-7 GR/BK-C2B-6 GR-C2B-5 RD-U34-2 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-C6-39 RD-H6+ - C32-1 BL/WH-132D - C32-3 BK-22C - C32-4 BK-C7-1 - C32-5 RD-TS51 - C32-6 RD-TS55 - C32-7 GR/BK-133B - C32-8 BR - GND - C32-12 C32 PLATFORM LOAD U33 OR/BK-15A OR-14A GR-17A 8 GR/WH-19A GR/BK-18A CR5 GR-43D BK-22B GROUND STUD N CR17 BK-C6-25 RD-CB3 SP WIRING HARNESS: TO BASE GROUND STUD BR ALL BR WIRES 2 DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453 Part No. 102521 S-40 • S-45 6 - 57 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832) 6 - 57 6 - 58 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (before serial number 14832) 6 - 60 6 - 59 11 1 1 P26BAT BK P24FS WH P24FS WH BRN 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 1 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 9 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 C1P C28TTA RD/BK C1P-2 J2 J1 C3P C3P D40 D39 H1 8 C4P GR/BK C4P-4 6 S-40 • S-45 6 - 60 RED-TILT 7 GR/BK L4 4 HARNESS PBOX WIRING 3 3 PART NUMBER 45383 94771 COMPONENT INDEX TILT ALARM ALC-500 H1 5 C2P N M L K J I H G F E D C B A ALC-500 RED-TILT 2 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram- ALC-500 Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (before serial number 14832) 1 R Y BR RD R B BR B Y P134PWR RD RD R20 4700 R R26ESTP BK C9P-1 R B GR/WH P23BAT WH C7P-2 P22BAT BK C7P-1 C19JSV GR/WH C4P-7 C18JD GR/BK C4P-6 C17JU GR C4P-5 C15PLD OR/BK C4P-3 C14PLU OR C4P-2 C43HRN GR C2P-5 C8PBR BK/WH C3P-8 C7PBE BK C3P-7 P26ESTP BK C9P-1 P25FS RD C9P-3 P24FS WH C9P-2 JDALARM GR/BK C2P-6 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 WH BK 6 D39 RD-TILT RD/BK-28 C1P(GY) C2P(BK) C3P(GR) C4P(BR) 7 OPT. B B RD OUTPUT BR C1 C19JSV GR/WH TS7 C19JSV GR/WH C4P-7 BR JC3 BR GND RD-E-STOP P134PWR RD-H1+ CR13-#86 GR/WH P134PWR RD RD-H1+ P26ESTP BK E-STOP BR GND P26ESTP BK P24FS WH 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 P134PWR 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 D40 JIB C132PLI2 BK C3P-10 6 - 61 S-40 • S-45 Part No. 102521 GR/WH + B B 4 B U35 87 85 Y Y B RD LS18 CABLE D89 C132PLI1 BK C1P-12 LS18 JIB C9P C7P F.S. 12V BATT 19/18 CONTROL CABLE P24FS WH 1 B GR/WH 1 COM NO 2 3 5 3 86 11 D88 GR/WH C7P BATGND C7P-3 BR JC1-2 OR JC2-3 WH/RD JC1-1 BR JC2-4 RD/WH JC2-2 OR JC1-4 WH/BK JC2-1 BR JC3-4 WH/RD JC3-2 OR JC3-3,5 BL/WH JC3-1 BR DRE A BL/WH DRE B BL/BK C13LED BL/RD C29MS RD/WH GR/BK L4 RD-TILT C2P BR TILT ALARM JIB TIME DELAY JIB DELAY RELAY LOAD SENSE TIME DELAY RELAY (30A) H1 C1 CR14 U35 OPTION TILT ALALRM C4P GR/BK C4P-4 3 5 C1P C28TTA RD/BK C1P-2 J2 J1 1 J3 CR14 30 9 2 ALC-500 1 A B C D E F G H I J K L M N Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram- ALC-500 Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832) LOAD SENSE OPTION C3P H1 COMPONENT INDEX 8 October 2013 Section 6 • Schematics Platform Control Box Wiring Diagram- ALC-500 Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832) 6 - 61 6 - 62 Section 6 • Schematics October 2013 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 - 64 6 - 63 October 2013 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) A B C D E F G H I J K L M N 1 HARNESS PBOX WIRING 2 7 7 10 AMP FUSE TS48 6 JC2 WORK/ DRIVE LITE 5 5 TS15 DRV.ENA 4 3 2 JC2 PRIMARY BOOM EXTEND/ RETRACT 56298 JC3 L1 DRIVE PROPORTIONAL JOYSTICK 75565 56298 66812, 95406 66813, 66815 42730 13037 TS4 TS6 TS7 TS8 2 TS13 62390 CHASSIS TILT LED L4 1 RD WL2 1 JC3 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE L48 P2 P3 TS1 TS2 4 3 3 PART NUMBER COMPONENT INDEX 6 DRIVE ENABLE LED EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH 56298 CE PLATFORM LED HI/L0 RPM SWITCH 56457 13037 GLOW PLUG OPTION 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 ) 16397 13037 13037 13037 56457 13037 27378 27378 4 WH-24 + CR13 + L1 RD DETAIL A: LIFT/DRIVE OPTION L4 DRIVE LT BK/RD-C3P-9 L48 BRN BATGND RD RD P3 P22BAT BK C7P-1 RD LS18 BK-22 P26BAT BK C9P-1 1 (SPLICE TO R40LS1) 1 1 2 NC NC NC 2 2 TS8 JIB TS1 AUXILIARY PUMP TS14 TS6 HIGH/LOW DRIVE SPEED GLOW PLUG 8 S-40 • S-45 CR30 EMERGENCY STOP CE SEE DETAIL A 6 - 64 WH-23 PLATFORM ROTATE GR/BK GR/WH-45 3 4 NO TS9 PLATFORM LEVEL WH/RD C32BRK (SPLICE TO C32BRK) P2 7 HORN 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 C17JU GR C4P-5 C19JSV GR/WH C19JSV GR/WH JIB GENERATOR (OPTION) WH TS7 WH TS1 OR R40LS1 TS47 GR WH CR27 WH TS7 REMOVE FOR GENERATOR OPTION WH P3 (GND STUD) WH J1-5 BL J1-4 WH J1-5 OR J1-13 BRN J1-14 RD/BK H1 GR/BK H1 WH-24 BL/RD-DE3 J1-16 BL/WH-DE1 J1-6 BK-22 BRN WH-JIB BK/WH-8 BK-7 BL/BK-DE2 J1-7 RD WL1 C18JD GR/BK C4P-6 OR-14 OR/BK-15 RD P2 GR-43 6 BK J1-2 RD J1-1 OR J1-11 BRN J1-12 5 REPLACE WIRE WITH THIS WIRING DIAGRAM + Part No. 102521 TS4 RD HIGH/LOW RPM NOTE: 1) DASHED LINES INDICATE OPTION WIRES. October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510) N M L K J I H G F E D C B A 1 HARNESS PBOX WIRING 2 10 AMP FUSE WORK/ DRIVE LITE TS48 PRIMARY BOOM UP/DOWN 1 DRIVE ENABLE TS15 JC2 JC3 TURNTABLE ROTATE RD WL2 PRIMARY BOOM EXTEND/ RETRACT RD WL1 JC2 COMPONENT INDEX BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE JC3 DRIVE PROPORTIONAL JOYSTICK L48 L1 P2 P3 TS1 TS2 TS3 TS4 L4 TS7 TS8 TS9 TS13 TS14 TS15 TS47 TS49 CHASSIS TILT LED DRIVE ENABLE LED EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH (FORD EFI ONLY) HI/L0 RPM SWITCH CE PLATFORM 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 ) DRIVE/STEER 3 4 WH-24 TS13 + CR13 86 + 87A L1 DETAIL A: LIFT/DRIVE OPTION J1-5 BL/WH JC3-5 GN/BK H1 RD/BK H1 WH-24 J1-4 WH/RD JC3-4 L48 J1-13 OR JC3-2 + J1-5 BL/WH JC3-3 J1-14 BR JC3-1 BL/RD-DE3 J1-16 BR BK-7 BK/WH-8 BL/WH-DE1 J1-6 BK-22 85 RD L4 BL/BK-DE2 J1-7 J1-2 RD/WH JC2-4 J1-11 OR JC2-2 J1-1 WH/RD JC2-3 J1-12 BR JC2-1 DRIVE LT BK/RD-C3P-9 30 REPLACE WIRE WITH THIS WIRING DIAGRAM BRN BATGND WH/RD C32BRK (SPLICE TO C32BRK) WH TS7 (GND STUD) CR27 86 87A 30 5 WH TS1 85 RD RD LS18 RD P3 BK-22 P22BAT BK C7P-1 WH-23 P26BAT BK C9P-1 NC NC NC TS14 TS6 TS4 TS2 DRIVE SPEED JIB GN/WH-45 BK/RD-35 WH-24 PLATFORM ROTATE GN/BK D27 C33STR BK C1P-7 TS1 6 85 AUXILIARY PUMP GLOW PLUG RD START HIGH/LOW RPM RD (SPLICE TO R40LS1) EMERGENCY STOP P2 TS17 HIGH/LOW PLATFORM LEVEL RD-25 C34SA BK/WH C1P-8 WH-24 C29MS RD/WH J1-8 WH-24 C27AUX RD C1P-1 TS8 WH-JIB JDALARM GR/BK-44 C2P-6 C17JU GN C4P-5 C19JSV GN/WH JIB C19JSV GN/WH TS7 87 OR R40LS1 GR NO HORN P3 C18JD GN/BK C4P-6 OR-14 WH OR/BK-15 RD P2 GN-43 TS9 WH CR30 86 30 7 NOTE: GENERATOR (OPTION) 1) DASHED LINES INDICATE OPTION WIRES. CE SEE DETAIL A 1 TS48 REMOVED FROM PLATFORM BOX AT SERIAL NUMBER 16420 8 Part No. 102521 S-40 • S-45 6 - 65 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510) 6 - 65 6 - 66 Section 6 • Schematics October 2013 Electrical Schematic Ford LRG-425 EFI Models (before serial number 7597) 6 - 68 6 - 67 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 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 G3 G2 OR/BK-41 OTS NC G1 HM _ REGULATOR PR1 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. C5-2 C5-3 + C134PWR OR/RD C41RPM OR/BK RD BAT. BAT. 12 V DC STA. 7 CR17 PR1 NO EXCT. 7 CB3 FB CR17 NO ALTERNATOR 8 9 10 CR2 CR2 NO CR1 CR1 NO CR5 CR5 NO 20AMP. P24BAT TB24 OTS NO 6 TB35 TS22 L2 TB24 5 D6 TB27 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 TB28 TB133 CB1 TB39 4 TS1 TS53 SEE NOTE 2 TS17 TS3 TS2 TS55 TS52 PLAT GRD D40 D39 TS4 L4 TS51 TB22 KS1 TB134 RD P1 CB2 L48 H1 P3 HORN OR/BK C2-3 TB41 RD TB43 RD RD 15AMP. S-40 • S-45 6 - 68 RD 2 WH P25FS RD P24FS WH C9-3 C9-2 RD-(FS) WH-(FS) FS1 BK-(FS) P2 RD/BK C28TTA RD/BK 1 N M L K J I H G F E D C B A FORD ENGINE HARNESS 8 TB 134 IS WAGO TERMINAL BLOCK 42 3 Section 6 • Schematics October 2013 Electrical Schematic Ford LRG-425 EFI Models (before serial number 7597) P26ESTP BK BK TB21 + - DRE LED BL/RD DRE B BL/BK DRE A BL/WH WH 7 RKOUT 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 16 7 6 5 4 13 14 BL 4 OR BRN YOUT 5 GND 2 PWR 3 1 7 RD 6 7 8 14 13 12 3 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 5 C3P-4 C3P-1 C3P-2 C13DRE BL/RD C3P-3 C4P-1 C40LS1 OR C3PBF RD/WH C2P-2 EXTEND BOOM C7PBE BK RETRACT C8PBR BK/WH C14PLU OR C15PLD OR/BK PLAT DOWN LEVEL UP 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 C30EDC+ WH C B 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 A 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 - 69 S-40 • S-45 Part No. 102521 6 OR BK YOUT 5 XOUT 4 BRN 1 2 1 11 12 PWR 3 1 GND 2 BRN 2 4 4 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 C6-18 C17JU GR NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. P24FS WH P24FS WH P26ESTP BK 3 RD C17JU GR C6-17 AMP GR/BK-44 RD C4P-5 RIGHT JIB BOOM LEFT NOHC NOHC NONC BRN H4 SJ1-WH C6-30 TB22 1 Deutsch RIGHT PLAT LEFT ROTATE 3 TB30 C19JSV GR/WH 3 4 DOWN JIB BOOM UP C4P-7 2 2 TB14 TB18 TB5 TB2 3 RIGHT PLAT LEFT ROTATE JIB VALVE 5 1 5 Joystick Adaptor Harness 4 6 TB6 TB8 5 TB3 TB7 TB15 TB17 TB31 TB1 TB32 TB37 TB36 J1 J1 J1 4 TS62 TS61 TB4 TB13 TB40 6 6 7 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 TB44 TB19 TS63 TS59 TS58 TS57 TS13 TS9 TS8 TS7 J2 C19JSV GR/WH CR27 NC CR13 NC CR13 J3 JOYSTICK CONTROL CARD 2 WH WH CR30 NO CE LIFT/ DRIVE OPTION L1 JC3 DRIVE & STEERING TS15 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 October 2013 Electrical Schematic Ford LRG-425 EFI Models (before serial number 7597) RD/BK OR/BK BK BRN October 2013 Section 6 • Schematics Electrical Schematic Ford LRG-425 EFI Models (before serial number 7597) 6 - 69 6 - 70 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) N M 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 H 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 B 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 B A 1 NC 1 B1 WH-23A RD-42A RD-27A BL/RD-39A RD-C23-6 RD-H6+ 4 3 TS51 B 3 2 OR/RD-H6- 4 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 C G3 G2 NC D13 WH-21B WH-TS22#4 D WH/BK-25A WH/RD-26A BK-22A BK-ISM#1 BK-C5-5 E 2 BK-22B GR-43D RD-CB3 SP BK-C6-25 F BR (GROUND) A BK-CR1#86 OR/BK-41B BK-33B RD-27B BR-GND. RD-CR2#30 WH-TS22#6 G WH-21A HM C CR1 I BR (GROUND) C3B C4B C7B D 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 J 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 K RD RD/BK-C6-28 RD- C6-27 WH/RD-C5-14 WH/BK-C5-16 L OR/BK-15A 5 6 7 OR-14A GR-17A GR/WH-19A GR/BK-18A 8 WIRING HARNESS: TO BASE GROUND STUD BR ALL BR WIRES Part No. 102521 S-40 • S-45 6 - 71 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) 6 - 71 6 - 72 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) 6 - 74 6 - 73 1 9 11 1 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 J2 C132PLI BK C1P-12 RD P2 RD H1 P23SWBAT WH C7P-2 P22BAT BK C7P-1 C19JSV GR/WH C4P-7 AND TS8 BRN F.S. C19JSV GR/WH JIB C18JD GR/BK C4P-6 C17JU GR C4P-5 C15PLD OR/BK C4P-3 C14PLU OR C4P-2 C4P(BR) C3P(GR) C2P(BK) C1P(GY) RED/BLK-28 H1 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 Part No. 102521 1 J3 DRE B BL/BK C13LED BL/RD C29MS RD/WH BRN 8 C3P C3P D40 C4P GR/BK C4P-4 12V BATT 19/18 CONTROL CABLE TILT ALALRM C7P BATGND C7P-3 6 C1P C28TTA RD/BK C1P-2 5 S-40 • S-45 6 - 74 GR/BK L48 4 HARNESS PBOX WIRING J1 3 3 ALC-500 RED-TILT 2 COMPONENT INDEX PART NUMBER TILT ALARM ALC-500 45383 89353 H1 C2P N M L K J I H G F E D C B A C7P 7 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) N M L K J I H G F E D C B A 1 HARNESS PBOX WIRING COMPONENT INDEX TS48 / TS49 WORK / DRIVE LITE TS15 DRV.ENA 7 7 6 6 5 3 2 JC2 5 4 DLITE/ RD WL2 RD WL1 4 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 5 WH/RD C32BRK (SPLICE TO C32BRK) CR30 6 (SPLICE TO R40LS1) 1 1 TS3 FUEL SELECT 1 RD 2 TS2 START 2 TS47 GENERATOR (OPTION) 2 TS1 AUXILIARY PUMP TS4 HIGH/LOW RPM NC NC NC 3 4 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 4 REPLACE WIRE WITH THIS WIRING DIAGRAM WH P3 HORN 3 13037 27378 27378 DETAIL A: LIFT/DRIVE OPTION WH TS7 WH 2 + 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 ) 1 PART NUMBER JC2 NOTE: P2 EMERGENCY STOP DASHED LINES INDICATE OPTION WIRES 7 CE SEE DETAIL A REMOVE FOR GENERATOR OPTION 8 Part No. 102521 S-40 • S-45 6 - 75 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) 6 - 75 6 - 76 Section 6 • Schematics October 2013 Electrical Schematic Ford LRG-425 EFI Models (from serial number 7597 to 11066) 6 - 78 6 - 77 P22BAT BK C3-9 GENERATOR C2-7 HIGH RPM(FS) WH WH C1-7 ENGINE BL/WH 1 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 ENGINE BK C6-39 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 SERVICE HORN RELAY HYDRAULIC OIL TEMP. SWITCH COOLING FAN (OPTION) 42 PIN FORD CONNECTOR REFER TO E0375 FOR FORD HARNSS START C6-28 C6-23 C6-16 C6-25 C6-26 OR/BK PIN 2 3 START C2-1 RD C27AUX RD P23BAT WH C28TTA RD/BK 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 2 L29 L29 TS4 C134PWR RD TS22 C5-3 3 L30 2 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 - 78 M1 CR23 CR23 NO G3 TB26 G2 _ OPS IND. S7 TB21 CR39 TB35 CR1 TB24 + FUEL PUMP FB FAN AUX M2 PUMP REGULATOR CR17 EXCT. TB33 D6 TB45 CB1 BRN 7 PR2 PR2 12 V DC STA. PR1 PR1 NO BAT. BAT. + CR17 NO ALTERNATOR 6 C28TTA RD/BK TS55 TS52 TB25 OTS NO NC CR5 NO TB39 L2 CR1 NO CR2 CR2 NO CR5 20AMP. 5 TB23 RD TS1 L48 PBOX GND 4 D40 TS53 TS51 PLAT GRD CR39 CB3 RD KS1 TB22 TB27 TB28 15AMP. TB20 TB43 TB134 RD P1 CB2 RD RD 15AMP. NOTE: 8 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 2 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 3 Section 6 • Schematics October 2013 Electrical Schematic 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 7 RKOUT 6 BL 14 13 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 7 16 6 OR 5 4 BRN 4 YOUT 5 PWR 3 11 9 10 6 7 8 14 13 12 3 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 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 BOOM 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 D A 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 C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK C40LS1 OR 7 C6-40 C6-30 C6-7 C6-8 C6-14 C6-15 C18JD GR/BK WH BK WH BK BK WH B GROUND DRIVE EDC FORWARD LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH C 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 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 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 - 79 S-40 • S-45 Part No. 102521 1 GND 2 BK RD OR BRN 1 2 4 3 RETRACT EXTEND C8PBR BK/WH C7PBE BK C14PLU OR C15PLD OR/BK UP PLATFORM LEVEL DOWN C6-18 C17JU GR NCHO 2 1 11 12 7 6 YOUT 5 XOUT 4 PWR 3 GND 2 1 P24FS WH BRN P24FS WH P26ESTP BK C3P-7 C3P-8 C4P-2 C4P-3 JDALARM GR/BK C18JD GR/BK C17JU GR TB18 8 NOHC Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y22 Y21 7 NOHC BRN 4 EXTEND PLATFORM LEVEL RETRACT C4P-5 C4P-6 C2P-6 UP PLATFORM LEVEL DOWN GR/BK-44 DOWN UP JIB BOOM C6-17 SJ1-WH Y12 H4 Y25 Y26 Y20 Y19 Y16 Y17 H4 1 Deutsch DOWN UP JIB BOOM 3 TB32 TB37 TB36 TB4 TB1 RIGHT LEFT PLAT ROTATE 3 4 J2 RIGHT LEFT PLAT ROTATE 2 2 TB6 TB3 TB14 TB30 TB31 C19JSV GR/WH 5 1 5 5 TB8 TB17 TB13 TB40 TB7 TS62 TS61 TB29 TB5 TB2 TB15 R2 R1 6 4 6 AMP Joystick Adaptor Harness 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 TB44 3 C4P-7 RD J1 J1 J1 JIB VALVE RD TS63 TS59 TS57 CR27 NC 4 TS58 TB19 WH WH JOYSTICK CONTROL CARD CR30 CE NO LIFT/ DRIVE OPTION C19JSV GR/WH TS13 TS7 J3 2 CR13 NC CR13 TS9 TS8 TS14 L1 JC3 DRIVE & STEERING TS15 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 October 2013 Electrical Schematic Ford LRG-425 EFI Models (from serial number 7597 to 11066) OR/BK BL/WH RD/BK BK BRN October 2013 Section 6 • Schematics Electrical Schematic Ford LRG-425 EFI Models (from serial number 7597 to 11066) 6 - 79 6 - 80 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) N M L 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. B P1 RD-CB2 KS1 KEY SWITCH 3 NC 4 1 3 2 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 A 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 5 6 7 OR-14A GR-17A WH-23B C5 A 1 B1 WH-23A RD-42A RD-27A BL/RD-39A BK-33B CR5 B TS51 B NC BK/RD-9B BK-C6-16 C WH/BK-25A WH/RD-26A BK-22A RD-24B TS22 D 2 RD- 20C RD-CR17#30 WH/BK-5A WH/RD-6A WH-4A BK-C5-5 E BR (GROUND) TS52 CR1 F G3 G2 BR (GROUND) BK/RD-CR23#86 GR-C5-12 ENGINE G1 HM GR-43B BK-22B GROUND STUD G WH-21A 3 BR-GND STUD 1 BK-22C 2 WH-23C C2B C1B BK-CR1#85 D5 WH/RD-C6-32 C C3B C4B C7B D 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. H 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 I 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+ J 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 K GR/WH-19A GR/BK-18A WIRING HARNESS: TO BASE 8 GROUND STUD BR ALL BR WIRES Part No. 102521 S-40 • S-45 6 - 81 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) 6 - 81 6 - 82 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) 6 - 84 6 - 83 11 1 1 P26BAT BK P24FS WH P24FS WH J2 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 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 6 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 C3P C3P D40 F.S. D39 RED-TILT 8 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 GR/BK L48 BRN Part No. 102521 S-40 • S-45 6 - 84 C4P GR/BK C4P-4 12V BATT 19/18 CONTROL CABLE TILT ALALRM C7P BATGND C7P-3 C7P 7 C1P C28TTA RD/BK C1P-2 5 3 RED-TILT 4 9 3 HARNESS PBOX WIRING J1 1 J3 PART NUMBER TILT ALARM 45383 H1 COMPONENT INDEX 1 C2P N M L K J I H G F E D C B A ALC-500 2 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to11066) N M L K J I H G F E D 10 AMP FUSE 7 7 6 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 6 3 3 2 JC3 1 + 1 62390 2 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 3 4 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 6 1 1 RD TS3 FUEL SELECT 1 TS2 START 2 TS47 GENERATOR (OPTION) 2 TS14 DRIVE SPEED HIGH/LOW 2 TS1 AUXILIARY PUMP TS4 HIGH/LOW RPM NC NC NC 3 4 NO TS7 PLATFORM ROTATE TS8 JIB WH TS1 (SPLICE TO R40LS1) WH WH 5 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 1 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE WH TS7 P3 HORN A COMPONENT INDEX JC2 TS15 DRV.ENA 4 B HARNESS PBOX WIRING TS48 / TS49 WORK / DRIVE LITE 5 C NOTE: P2 EMERGENCY STOP DASHED LINES INDICATE OPTION WIRES 7 CE SEE DETAIL A REMOVE FOR GENERATOR OPTION 8 Part No. 102521 S-40 • S-45 6 - 85 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) 6 - 85 6 - 86 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models (from serial number 11067 to 12509) 6 - 88 6 - 87 BL/WH 1 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 C4B-12 C4B-11 D B C A 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 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 C27AUX RD WH BK 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 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 1K C6-27 RD/BK RD C6-26 FORD ENGINEHARNESS 42 PIN FORD CONNECTOR 3 BK ENGINE C6-28 RD C6-33 IN THE STOWED POSITION AND KEYSWITCH "OFF". RD 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 - 88 NOTE: L29 L29 OPS FORD ENGINE HARNESS TB45 TB9 TB23 2 C2-3 15AMP. 8 G1 HM _ 7 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 5 TS49 C28TTA RD/BK TS17 TS2 TS3 TB35 RD TB24 CB1 15AMP. TB20 G3 NO 6 3 TB27 TB28 TB39 B RD 2 TS52 CB2 TB43 B1 BK P26ESTP BK RD TB22 4 1 RD TB42 TS51 PLAT GRD 4 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 2 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 3 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models (from serial number 11067 to 12509) RD/BK OR/BK F18 - 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 1 2 14 13 6 7 3 12 13 14 8 7 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 7 16 5 6 WH 4 7 RKOUT 6 BL GND 2 OR 4 YOUT 5 XOUT 4 YOUT 5 BRN 1 GND 2 4 2 1 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 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 D A 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 B 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 C 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 - 89 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 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 7 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 October 2013 Electrical Schematic Ford DSG-423 EFI Models (from serial number 11067 to 12509) BL/WH OR/BK BK RD/BK BRN TB18 October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models (from serial number 11067 to 12509) 6 - 89 6 - 90 Section 6 • Schematics February 2012 Electrical Schematic Ford DSG-423 EFI Models (from serial number 12510 to 14831) 6 - 92 6 - 91 BL/WH 1 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 D B C A 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 R43HRN BK C6-26 3 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 C6-16 C6-25 C6-33 C41RPM PR2 2 DRIVELIGHT C1-7 ENGINE C2-1 C1-1 C7-2 C1-2 C133PLA OR/RD C43HRN GR R3 C6-34 C5-2 PR2 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". L29 L29 OPS FORD ENGINE HARNESS Y29 + TB45 TB9 TB23 ESO433C 1. G1 HM _ G6 WORKLIGHT WH START LP FUEL GAS AUXILIARY PUMP C2-5 C7-1 C2-4 P22BAT BK C134PWR RD C2-3 TB25 P20BAT RD Part No. 102521 S-40 • S-45 + 6 - 92 PR1 CR23 CR23 NO G2 FUEL PUMP TB26 FUEL PUMP L2 CR1 CR1 NO CR2 CR2 NO CR39 5 PBOX GND TB33 15AMP. 8 NO CR17 AUX PUMP H2 M2 FB FAN M1 7 S7 12 V DC TB21 TB41 TB35 RD TB24 TS52 TB39 TS22 DIAGNOSTIC G3 NO PR1 CR17 NO RD CR5 TB27 TB28 3 OTS 6 3 RD TB22 L30 L30 2 TS17 TS2 TS3 TS55 4 1 BK P26ESTP BK RD RD CR39 NC CR5 NO CB3 20AMP. TB43 B1 TS49 C28TTA RD/BK RD C41RPM OR/BK 3 TS51 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 2 N M L K J I H G F E D C B A TS53 4 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models (from serial number 12510 to 14831) RD/BK OR/BK F18 - DRE LED BL/RD DRE B BL/BK 4 5 13 14 1 2 3 12 13 14 8 7 6 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 7 16 6 5 BL/WH 4 WH/RD 3 BL/WH 2 OR 1 BRN 2 1 11 12 6 6 5 4 RD/WH 3 WH/RD OR 2 1 BRN DRE A BL/WH RKOUT YOUT XOUT PWR GND YOUT XOUT PWR GND BRN P24FS WH 4 3 C2P-3 C1P-5 C1P-4 C1P-6 C1P-3 C1P-11 C1P-10 C3P-6 C3P-5 C3P-4 7.5 BRN-2 C31EDC- WH/BK C30EDC+ WH C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C6TRF WH/RD C5TRR WH/BK C4TRL WH LEFT TT ROTATE RIGHT C3P-3 C3P-2 C3P-1 C13DRE BL/RD C3PBF RD/WH C2PBD RD/BK C1PBU RD UP PRI BOOM DOWN C4P-1 C40LS1 OR C2P-6 C18JD GR/BK JDALARM GR/BK 5 C2P-2 C8PBR BK/WH C7PBE BK EXTEND BOOM RETRACT C3P-8 C14PLU OR C3P-7 C4P-2 C15PLD OR/BK C4P-6 C17JU GR RIGHT PLAT ROTATE LEFT C19JSV GR/WH C5-20 C5-21 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 D A 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 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 C6-18 C6-17 B GROUND DRIVE EDC FORWARD LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH C TRAVEL ALARM OPTION DRIVE EDC REVERSE BRAKE RELEASE VALVE MOTOR STROKE STEER LEFT STEER RIGHT TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM DOWN PRIMARY BOOM UP PRIMARY BOOM FLOW CONTROL LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH DESCENT ALARM DRIVE ENABLE LIMIT SWITCH BOOM RETRACT BOOM EXTEND PLAT LEVEL DOWN PLAT LEVEL UP PLATFORM ROTATE RIGHT / JIB DOWN 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. PLATFORM ROTATE LEFT / JIB UP JIB VALVES 6 - 93 S-40 • S-45 8 NCHO Part No. 102521 7 NOHC NOTE: P24FS WH P26ESTP BK 4 EXTEND BOOM RETRACT C4P-3 UP PLAT LEVEL DOWN C4P-5 UP PLAT LEVEL DOWN GR/BK-44 JIB BOOM C4P-7 Y25 NOHC BRN Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y22 Y21 Y12 H4 6 Y26 Y20 Y19 Y16 Y17 TB6 TB3 TB8 H4 SJ1-WH TB29 TB14 TB30 TB31 TB32 TB37 TB36 TB4 TB5 TB2 TB13 TB40 TB7 TB15 TB1 DOWN UP JIB BOOM TB44 R2 R1 4 TS62 TS63 TS59 5 TB18 TB17 DOWN UP RD 3 J2 PLAT ROTATE RIGHT LEFT RD J1 J1 J1 J3 JIB VALVE TS58 TB19 WH WH TS61 TS57 TS13 TS9 TS8 TS7 JOYSTICK CONTROL CARD C19JSV GR/WH CR27 NC CR13 NC CR13 CR30 NO CE LIFT/ DRIVE OPTION 2 TS14 L1 TS15 DRIVE & STEERING 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 October 2013 Electrical Schematic Ford DSG-423 EFI Models (from serial number 12510 to 14831) OR/BK BK BL/WH RD/BK BRN October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models (from serial number 12510 to 14831) 6 - 93 6 - 94 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models (from serial number 14832 to 15662) 6 - 96 6 - 95 2 P22BAT BK HIGH RPM(FS) RD BK BK C1-9 C35RPM BK/RD LOW RPM FUNCTION ENA. HIGH RPM C45GEN GR/WH DLITE BK/RD C33STR BK START ENGINE RD C27AUX RD P23BAT WH C28TTA RD/BK C43HRN GR TB28 D14 D13 TB23 ENG SPEED C1-2 C7-2 C3-9 C2-7 GENERATOR C2-5 C7-1 C2-4 C6-28 C6-23 C6-39 C45GEN GR/WH C4B-12 C4B-10 A D B C WH/BK RD/GR GY/RD GY/YL RD BK/BL WH/BK RD RD Y29 R43HRN BK C6-33 PR2 BK C6-26 BLUE/PINK C41RPM OR/BK PIN 2 PR2 BR C38ESL BL/WH PIN 6 VSW WH PIN 1 C135RET BL PIN 18 C135FP BL/WH PIN 5 C39LP BL/RD PIN 7 R21IGN WH PIN 24 R33STR BK PIN 15 C35RPM BK/RD PIN 23 C21IGN WH PIN 16 C127TSW GR PIN 3 C26TSR WH/RD PIN 39 C5-16 R21IGN WH C5-14 C5-12 C5-17 C5-5 C5-9 C5-10 C5-8 C5-11 C5-13 RD WH C27AUX RD RD C6-16 C6-25 RD/BK C6-27 C6-34 C5-2 L29 L29 C4-11 C4-9 OPS WH C1-7 C1-1 C2-1 WH P134PWR RD C2-3 P20BAT RD S7 TS17 C41RPM OR/BK RD 15AMP. H2 LPG LOCKOUT TEMP GAUGE AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR TILT ALARM FLASHING BEACONS OPTION SERVICE HORN SERVICE HORN RELAY HYDRAULIC OIL TEMP. SWITCH STARTER RELAY FORD ENGINE 42 PIN FORD CONNECTOR COOLING FAN (OPTION) FORD 42 PIN PLUG GASOLINE SENSOR OIL PRESSURE GAUGE HOUR METER VOLT METER WORK LIGHTS OPTION DRIVE LIGHT OPTION GENERATOR OPTION BR STARTER MOTOR Part No. 102521 S-40 • S-45 - 6 - 96 NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 8 G1 FAN M1 STARTER 12 V DC CR23 CR23 NO G2 + HM _ G6 AUX M2 PUMP FB PR1 FORD ENGINE HARNESS 7 CR17 CR1 NO TB25 G3 OTS NO PR1 NO CR17 NO RD TB21 TB41 CR1 RD CR2 PBOX GND TB35 TB45 TB24 TS22 DIAGNOSTIC TB26 FUEL PUMP L2 CR5 CR5 NO FUEL PUMP 6 TB9 CB3 20AMP. TS53 TS51 TB33 D4 TB27 CR2 NO CR39 CR39 NC 5 TB39 3 D2 TS55 TS52 CB2 TB22 RD D10 4 1 CB1 15AMP. TB20 2 L30 L30 D12 TB43 RD B1 TS4 TS1 L48 D11 C28TTA RD/BK TS2 TS3 H1 P3 HORN TS49 P25FS RD P24FS WH C9-1 BK C9-2 RD FUSE 10A FS1 C9-3 P2 N M L K J I H G F E D C B A D40 3 TB42 KS1 P1 PLAT GRD B 4 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models (from serial number 14832 to 15662) RD 1 BL/WH OR/BK BK RD/BK WH P26ESTP BK F18 + 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 7 16 4 5 13 6 BL/WH OR 14 6 7 8 14 13 12 3 4 BOOM C2-3 C1-4 C1-5 C1-6 C1-3 C1-11 C1-10 C3-6 C3-5 C3-4 7.5 5 BR-2 C30EDC+ WH C31EDC- WH/BK C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C6TRF WH/RD C5TRR WH/BK BOOM C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK RETRACT EXTEND C40LS1 OR C13DRE BL/RD C3PBF RD/WH C2PBD RD/BK C1PBU RD PRIMARY BOOM UP DOWN C4TRL WH C3-1 C3-2 C3-3 C4-1 C2-2 C3-7 C3-8 C4-2 C4-3 UP PLATFORM LEVEL DOWN JDALARM GR/BK C18JD GR/BK D28 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 C6-13 C6-40 C6-30 C6-7 C6-8 C6-14 C6-15 C6-18 C31EDC- WH/BK C30EDC+ WH 6 C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C4TRL WH C5TRR WH/BK C6TRF WH/RD C1PBU RD C2PBD RD/BK D A WH BK WH BK WH BK RD/BK C3PBF RD/WH C6-19 C13DRE BL/RD C40LS1 OR C7PBE BK C8PBR BK/WH C14PLU OR C15PLD OR/BK C18JD GR/BK C17JU GR B GROUND DRIVE EDC FORWARD TRAVEL ALARM OPTION DRIVE EDC REVERSE BRAKE RELEASE VALVE MOTOR STROKE STEER CCW STEER CW TURNTABLE ROTATE CW TURNTABLE ROTATE CCW TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH DESCENT ALARM LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". PLATFORM ROTATE CCW / JIB DOWN PLAT LEVEL DOWN PLAT LEVEL UP BOOM RETRACT BOOM EXTEND DRIVE ENABLE LIMIT SWITCH C 8 PLATFORM ROTATE CW / JIB UP JIB VALVES 6 - 97 S-40 • S-45 DRIVE SPEED C29MS RD/WH DRE LED BL/RD DRE B BL/BK DRIVE ENABLE BRN WH/RD BL/WH DRE A BL/WH 6 RKOUT 5 YOUT 4 XOUT 3 PWR 2 GND1 RD/WH 11 12 2 1 WH/RD OR BRN 2 1 6 5 YOUT 4 XOUT 3 PWR 2 GND 1 BR 3 4 P24FS WH P24FS WH EXTEND RETRACT C2-6 UP PLATFORM LEVEL DOWN GR/BK-44 C4-6 C17JU GR C6-17 BR 22 21 NC 14 13 NO Part No. 102521 7 Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y21 Y22 Y12 22 21 NC 14 13 NO 14 2 1 2 1 4 3 H4 22 21 NC 13 NO Y25 Y26 H4 SJ1-WH D30 D29 5 TB13 TB40 TB7 TB30 TB31 DOWN UP JIB BOOM TB18 TB29 TB5 TB32 TB37 TB4 TB1 TB36 TB6 TB3 TB8 R2 4 TS62 TS63 TS59 TB2 TB15 TB14 TB17 Y19 Y20 Y16 Y17 TB44 CCW CW PLAT ROTATE TS58 D27 C4-5 JIB TIME DELAY CIRCUIT TS61 TS57 C19JSV GR/WH TB19 DOWN UP JIB BOOM PLAT ROTATE CCW CW C4-7 + R1 RD P26ESTP BK JIB VALVE RD J1 J1 J1 J3 JC3 3 - WH WH J2 JOYSTICK CONTROL CARD CR30 NO CE LIFT/ DRIVE OPTION GR/WH TS13 TS8 TS7 CR27 NC CR13 NC CR13 TS9 CR14 NO 2 TS14 LO L1 HI TS15 DRIVE & STEERING BR 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 October 2013 Electrical Schematic Ford DSG-423 EFI Models (from serial number 14832 to 15662) RD BL/WH OR/BK BK RD/BK October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models (from serial number 14832 to 15662) 6 - 97 6 - 98 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 15663 to 16419) 6 - 100 6 - 99 HIGH RPM(FS) C1-9 C35RPM BK/RD LOW RPM FUNCTION ENA. HIGH RPM C45GEN GR/WH DLITE BK/RD TB23 ENG SPEED C2-7 C3-9 BK BK C33STR BK ENGINE START RD C27AUX RD P23BAT WH C28TTA RD/BK C133PLA OR/RD D10 C43HRN GR TB27 D14 D13 R24PWR GENERATOR WH WH C3-10 C1-7 C2-1 C1-1 C7-2 C1-2 GR/BK C4-4 C2-5 C7-1 GN/BK C6-39 C5-10 C5-8 C5-5 C5-9 C5-17 C5-12 C5-14 C5-11 C5-13 RD WH C27AUX RD C6-25 C6-16 RD/BK A D B C RD RD WH/BK GY/RD GY/YL RD BK/BL RD/GR WH/BK R43HRN BK C6-33 PR2 BK BLUE/PINK C6-26 BR C38ESL BL/WH PIN 6 VSW WH PIN 1 C135RET BL PIN 18 C135FP BL/WH PIN 5 C39LP BL/RD PIN 7 R21IGN WH PIN 24 R33STR BK PIN 15 C35RPM BK/RD PIN 23 C21IGN WH PIN 16 C127TSW GR PIN 3 C26TSR WH/RD PIN 39 C5-16 R21IGN WH C4B-10 C4B-12 C45GEN GR/WH C6-27 C6-28 C6-23 C6-34 C5-2 Y29 C41RPM OR/BK PIN 2 GND BR PR2 STARTER RELAY FORDENGINE 42 PIN FORD CONNECTOR COOLING FAN (OPTION) HYDRAULIC OIL TEMP. SWITCH SERVICE HORN SERVICE HORN RELAY FLASHING BEACONS OPTION LEVEL SENSOR TILT ALARM WORK LIGHT RELAY (OPTION) AUXILIARY PUMP AUXILIARY POWER RELAY TEMP GAUGE LPG LOCKOUT GASOLINE SENSOR OIL PRESSURE GAUGE HOUR METER VOLT METER WORK LIGHTS OPTION DRIVE LIGHT OPTION GENERATOR OPTION BR STARTER MOTOR Part No. 102521 STARTER RELAY PR8 ADDED AT SERIAL NUMBER 15703 1 2 C28TTA RD/BK BK P22BAT BK C1-12 C2-4 C132PLI1 BL/WH P134PWR RD C2-3 S7 D11 C41RPM OR/BK M2 AUX PUMP H2 STARTER 12 V DC S-40 • S-45 - 6 - 100 P20BAT RD NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". L29 L29 C4-11 C4-9 OPS FORDENGINE HARNESS 7 CR17 FORD 42 PIN PLUG 8 G1 G6 + HM _ FB FAN M1 PR1 PR1 NO CR17 NO RD CR23 CR23 NO TB25 D12 RD RD 15AMP. TB41 TS22 DIAGNOSTIC TB26 FUEL PUMP OTS CR2 NO G2 FUEL PUMP RD 12 PR8 NO L2 CR5 CR5 NO G3 NO 6 TB21 TB9 CB3 20AMP. U34 TB35 CR1 CR1 NO CR2 L45 H6 CR39 CR39 NC 5 TB45 P24PWR RD TB24 CB1 15AMP. TB20 PBOX GND NO 10A TB33 D4 TB133 6 LOAD SENSE 7 MODULE 12 U33 8 TB28 D2 RD GBOX GND 2 SEC TB39 5 4 PLAT GRD 3 B CB2 L30 L30 TS55 TS52 TS53 TS51 3 1 D40 TS17 TS2 TS3 RD TB43 B1 U35 - D39 L4 3 PBOX GND KS1 NO 30A H1 BK C9-1 TS4 TS1 2 SEC + P3 HORN TS49 P25FS RD P24FS WH C9-2 R20 4.7K FUSE 10A FS1 C9-3 RD WH F18 D88 PBOX GND P26ESTP BK P2 LS18 2 OR/BK BK LS18A D89 N M L K J I H G F E D C B A TB132 TB134 RD 2 P1 TB22 4 1 4 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 15663 to 16419) 1 BL/WH RD RD/BK C132PLI2 BK + 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 7 16 4 5 13 6 BL/WH OR 14 6 7 8 14 13 12 3 4 BOOM C2-3 C1-4 C1-5 C1-6 C1-3 C1-11 C1-10 C3-6 C3-5 C3-4 7.5 5 BR-2 C30EDC+ WH C31EDC- WH/BK C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C6TRF WH/RD C5TRR WH/BK BOOM C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK RETRACT EXTEND C40LS1 OR C13DRE BL/RD C3PBF RD/WH C2PBD RD/BK C1PBU RD PRIMARY BOOM UP DOWN C4TRL WH C3-1 C3-2 C3-3 C4-1 C2-2 C3-7 C3-8 C4-2 C4-3 UP PLATFORM LEVEL DOWN JDALARM GR/BK C18JD GR/BK D28 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 C6-13 C6-40 C6-30 C6-7 C6-8 C6-14 C6-15 C6-18 C31EDC- WH/BK C30EDC+ WH 6 C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C5TRR WH/BK C4TRL WH C6TRF WH/RD C1PBU RD C2PBD RD/BK D A WH BK WH BK WH BK RD/BK C3PBF RD/WH C6-19 C13DRE BL/RD C40LS1 OR C7PBE BK C8PBR BK/WH C14PLU OR C15PLD OR/BK C18JD GR/BK C17JU GR B GROUND DRIVE EDC FORWARD DRIVE EDC REVERSE TRAVEL ALARM OPTION BRAKE RELEASE VALVE MOTOR STROKE STEER CCW STEER CW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH DESCENT ALARM LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". PLATFORM ROTATE CCW / JIB DOWN PLAT LEVEL DOWN PLAT LEVEL UP BOOM RETRACT BOOM EXTEND DRIVE ENABLE LIMIT SWITCH C 8 PLATFORM ROTATE CW / JIB UP JIB VALVES 6 - 101 S-40 • S-45 DRIVE SPEED C29MS RD/WH DRE LED BL/RD DRE B BL/BK DRIVE ENABLE BRN WH/RD BL/WH DRE A BL/WH 6 RKOUT 5 YOUT 4 XOUT 3 PWR 2 GND1 RD/WH 11 12 2 1 WH/RD OR BRN 2 1 6 5 YOUT 4 XOUT 3 PWR 2 GND 1 BR 3 4 P24FS WH P24FS WH EXTEND RETRACT C2-6 UP PLATFORM LEVEL DOWN GR/BK-44 C4-6 C17JU GR C6-17 BR 22 21 NC 14 13 NO Part No. 102521 7 Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y21 Y22 Y12 22 21 NC 14 13 NO 14 2 1 2 1 4 3 H4 22 21 NC 13 NO Y25 Y26 H4 SJ1-WH D30 D29 5 TB13 TB40 TB7 TB30 TB31 DOWN UP JIB BOOM TB18 TB29 TB5 TB32 TB37 TB4 TB1 TB36 TB6 TB3 TB8 R2 4 TS62 TS63 TS59 TB2 TB15 TB14 TB17 Y19 Y20 Y16 Y17 TB44 CCW CW PLAT ROTATE TS58 D27 C4-5 JIB TIME DELAY CIRCUIT TS61 TS57 C19JSV GR/WH TB19 DOWN UP JIB BOOM PLAT ROTATE CCW CW C4-7 + R1 RD P26ESTP BK JIB VALVE RD J1 J1 J1 J3 JC3 3 - WH WH J2 JOYSTICK CONTROL CARD CR30 NO CE LIFT/ DRIVE OPTION GR/WH TS13 TS8 TS7 CR27 NC CR13 NC CR13 TS9 CR14 NO 2 TS14 LO L1 HI TS15 DRIVE & STEERING BR 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 October 2013 Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 15663 to 16419) RD BL/WH OR/BK BK RD/BK October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 15663 to 16419) 6 - 101 6 - 102 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 15663 to 16419) 6 - 104 6 - 103 HIGH RPM(FS) ENG SPEED C3-9 C2-7 GENERATOR WH WH C3-10 C1-7 C2-1 C1-1 C7-2 C1-2 BK BK GR/BK C4-4 C2-5 C7-1 C1-9 C35RPM BK/RD LOW RPM FUNCTION ENA. HIGH RPM C45GEN GR/WH DLITE BK/RD C33STR BK ENGINE START RD C27AUX RD P23BAT WH C28TTA RD/BK C133PLA OR/RD C43HRN GR GN/BK C6-39 C5-10 C5-8 C5-5 C5-9 C5-17 C5-12 C5-14 C5-11 C5-13 RD WH C27AUX RD C6-25 C6-16 RD/BK A D B C RD RD WH/BK GY/RD GY/YL RD BK/BL RD/GR WH/BK R43HRN BK C6-33 BK C6-26 BR C38ESL BL/WH PIN 6 VSW WH PIN 1 C135RET BL PIN 18 C135FP BL/WH PIN 5 C39LP BL/RD PIN 7 R21IGN WH PIN 24 R33STR BK PIN 15 C35RPM BK/RD PIN 23 C21IGN WH PIN 16 C127TSW GR PIN 3 C26TSR WH/RD PIN 39 C5-16 R21IGN WH C4B-10 C4B-12 C45GEN GR/WH C6-27 C6-28 C6-23 C6-34 C5-2 BLUE/PINK PR2 GENERATOR OPTION DRIVE LIGHT OPTION WORK LIGHTS OPTION VOLT METER HOUR METER OIL PRESSURE GAUGE GASOLINE SENSOR LPG LOCKOUT TEMP GAUGE AUXILIARY POWER RELAY AUXILIARY PUMP WORK LIGHT RELAY (OPTION) LEVEL SENSOR TILT ALARM FLASHING BEACONS OPTION SERVICE HORN RELAY SERVICE HORN HYDRAULIC OIL TEMP. SWITCH COOLING FAN (OPTION) 42 PIN FORD CONNECTOR FORDENGINE STARTER RELAY Part No. 102521 C28TTA RD/BK BK P22BAT BK C1-12 C2-4 C132PLI1 BL/WH D10 BR STARTER MOTOR STARTER RELAY PR8 ADDED AT SERIAL NUMBER 15703 1 2 Y29 C41RPM OR/BK PIN 2 GND BR PR2 - 7 P134PWR RD C2-3 S7 D11 C41RPM OR/BK P20BAT RD NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". L29 L29 C4-11 C4-9 OPS FORDENGINE HARNESS M2 AUX PUMP H2 STARTER 12 V DC S-40 • S-45 6 - 104 CR17 FORD 42 PIN PLUG 8 G1 G6 + HM _ FB FAN M1 PR1 PR1 NO CR17 NO RD CR23 CR23 NO TB25 TS22 DIAGNOSTIC TB26 FUEL PUMP OTS D12 RD RD 15AMP. TB41 G2 FUEL PUMP RD 12 PR8 NO L2 CR5 CR5 NO G3 NO 6 TB21 TB9 CB3 20AMP. CR1 NO CR2 NO 5 D14 D13 TB23 TB35 P24PWR CR1 RD CR2 L45 H6 CR39 CR39 NC TB45 R24PWR TB24 CB1 15AMP. TB20 U34 D4 TB133 TB27 RD PBOX GND NO 10A TB33 6 LOAD SENSE 7 MODULE 12 U33 8 TB28 D2 GBOX GND 2 SEC TB39 5 4 PLAT GRD 3 B CB2 L30 L30 TS55 TS52 TS53 TS51 3 1 U35 - L4 D40 TS17 TS2 TS3 RD TB43 B1 + PBOX GND KS1 NO 30A D39 TS4 TS1 2 SEC P3 HORN TS49 P25FS RD P24FS WH C9-2 R20 4.7K BK C9-1 WH P26ESTP BK P2 F18 LS18 FUSE 10A FS1 C9-3 RD D88 PBOX GND 2 OR/BK BK LS18A D89 N M L K J I H G F E D C B A H1 3 TB132 TB134 RD 2 P1 TB22 4 1 4 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 15663 to 16419) 1 BL/WH RD RD/BK C132PLI2 BK + 4 5 13 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 BL/WH OR 14 6 7 C2-3 C1-4 C1-5 C1-6 C1-3 C1-11 C1-10 C3-5 C3-6 C3-4 7.5 5 BR-2 C30EDC+ WH C31EDC- WH/BK C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C6TRF WH/RD C5TRR WH/BK BOOM C8PBR BK/WH C7PBE BK RETRACT EXTEND C40LS1 OR C13DRE BL/RD C3PBF RD/WH C2PBD RD/BK C1PBU RD PRIMARY BOOM UP DOWN C4TRL WH C3-1 C3-2 C3-3 C4-1 C2-2 C3-7 C3-8 C14PLU OR C15PLD OR/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 C6-13 C6-40 C6-30 C6-7 C6-8 C6-14 C6-15 C6-18 6 C30EDC+ WH C31EDC- WH/BK C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C5TRR WH/BK C4TRL WH C6TRF WH/RD C6-19 D A WH BK WH BK WH BK RD/BK C3PBF RD/WH C2PBD RD/BK C1PBU RD C40LS1 OR C13DRE BL/RD C7PBE BK C8PBR BK/WH C15PLD OR/BK C14PLU OR B GROUND DRIVE EDC FORWARD DRIVE EDC REVERSE TRAVEL ALARM OPTION BRAKE RELEASE VALVE MOTOR STROKE STEER CCW STEER CW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH DESCENT ALARM LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH PLAT LEVEL DOWN PLAT LEVEL UP BOOM RETRACT BOOM EXTEND DRIVE ENABLE LIMIT SWITCH C 8 NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". PLATFORM ROTATE CW / JIB UP PLATFORM ROTATE CCW / JIB DOWN JIB VALVES 6 - 105 S-40 • S-45 DRIVE SPEED C29MS RD/WH 7 16 6 DRE LED BL/RD DRE B BL/BK DRIVE ENABLE BRN WH/RD BL/WH DRE A BL/WH 6 RKOUT 5 YOUT 4 XOUT 3 PWR 2 GND1 2 1 11 12 RD/WH WH/RD OR BRN 8 14 13 12 3 4 BOOM C4-2 C4-3 UP PLATFORM LEVEL DOWN JDALARM GR/BK C18JD GR/BK D28 C18JD GR/BK C17JU GR BR 22 21 NC 14 13 NO Part No. 102521 7 Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y21 Y22 Y12 22 21 NC 14 13 NO 6 5 YOUT 4 XOUT 3 PWR 2 GND 1 2 1 4 BR P24FS WH 3 P24FS WH P26ESTP BK EXTEND RETRACT C2-6 UP PLATFORM LEVEL DOWN GR/BK-44 C4-6 C17JU GR C6-17 2 1 2 1 4 3 H4 22 21 NC 14 13 NO Y25 Y26 H4 SJ1-WH D30 D29 5 TB5 TB2 DOWN UP JIB BOOM TB18 TB8 TB17 TB29 TB36 TB6 TB3 TB13 TB40 TB7 TB15 TB14 TB30 TB31 TB32 TB37 TB4 TB1 CCW CW PLAT ROTATE TS58 Y19 Y20 Y16 Y17 TB44 TS63 TS59 R2 C19JSV GR/WH TB19 4 TS62 TS61 TS57 D27 JIB TIME DELAY CIRCUIT R1 RD C4-5 + DOWN UP JIB BOOM C4-7 RD 3 PLAT ROTATE CCW CW - JC3 J1 J1 J1 J3 GR/WH TS13 J2 JOYSTICK CONTROL CARD CR30 NO CE LIFT/ DRIVE OPTION CR14 NO WH WH JIB VALVE CR13 TS9 TS8 TS7 CR27 NC CR13 NC 2 TS14 LO L1 HI TS15 DRIVE & STEERING BR 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 October 2013 Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 15663 to 16419) BL/WH RD OR/BK BK RD/BK October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 15663 to 16419) 6 - 105 6 - 106 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 16420) 6 - 108 6 - 107 WH C2-5 C7-1 C4-4 C1-2 C7-2 C2-7 C1-7 C1-1 C2-1 GENERATOR ENG SPEED HIGH RPM(FS) WH P22BAT BK C2-4 C1-12 C132PLI1 BL/WH P134PWR RD C2-3 BK BK C1-9 C35RPM BK/RD LOW RPM FUNCTION ENA. HIGH RPM C45GEN GR/WH C33STR BK START ENGINE RD C27AUX RD P23BAT WH C28TTA RD/BK C133PLA OR/RD C43HRN GR GR/BK C6-28 C6-23 C6-39 BR C45GEN GR/WH C4B-12 C4B-10 A D B C RD RD WH/BK RD/GR GY/RD GY/YL RD BK/BL WH/BK Y29 R43HRN BK C6-33 BK C41RPM OR/BK PIN 2 PR2 C6-26 BLUE/PINK GND BR PR2 BR C38ESL BL/WH PIN 6 VSW WH PIN 1 C135RET BL PIN 18 C135FP BL/WH PIN 5 C39LP BL/RD PIN 7 R21IGN WH PIN 24 R33STR BK PIN 15 C35RPM BK/RD PIN 23 C21IGN WH PIN 16 C127TSW GR PIN 3 C26TSR WH/RD PIN 39 C5-16 R21IGN WH C5-14 C5-12 C5-17 C5-5 C5-9 C5-10 C5-8 C5-11 C5-13 RD WH C27AUX RD RD C6-16 C6-25 RD/BK C6-27 C6-34 C5-2 P20BAT RD L29 L29 C4B-11 C4B-9 OPS FORD ENGINE HARNESS GENERATOR OPTION WORK LIGHTS OPTION DRIVE LIGHT OPTION VOLT METER HOUR METER TEMP GAUGE LPG LOCKOUT GASOLINE SENSOR OIL PRESSURE GAUGE LIGHTS PACKAGE COOLING FAN (OPTION) HYDRAULIC OIL TEMP. SWITCH SERVICE HORN SERVICE HORN RELAY FLASHING BEACONS OPTION LEVEL SENSOR TILT ALARM AUXILIARY PUMP AUXILIARY POWER RELAY WORK LIGHTS RELAY (OPTION) FORD 42 PIN PLUG 42 PIN FORD CONNECTOR FORDENGINE STARTER RELAY STARTER MOTOR ES0433K DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453 1 2 TS17 C41RPM OR/BK RD 15AMP. NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 8 G1 H2 Part No. 102521 S-40 • S-45 6 - 108 S7 CR23 CR23 NO TB25 G2 TS22 DIAGNOSTIC + HM _ G6 FAN M1 STARTER 12 V DC TB21 TB41 BR 7 CR17 AUX M2 PUMP FB PR1 PR1 NO CR17 NO PR8 NO RD 6 TB24 G3 TB26 FUEL PUMP L2 CR5 CR5 NO OTS NO TB28 D14 D13 TB23 TB35 1 2 CR1 CR1 NO TB45 FUSE 10A RD CR2 CR2 NO CR39 CR39 NC FUEL PUMP RD 7 CR45 CB3 20AMP. 8 12 CR45 NO 5 TB133 D2 RD TB33 D4 TB27 TS52 TB39 B CB2 CB1 15AMP. TB20 6 3 4 3 1 TB22 5 4 PLAT GRD 4 1 C32 CONN. PLUG GBOX GND TS55 TS53 TS51 RD D10 RD B1 L30 L30 D12 TB43 TB132 RD 2 D39 TS4 TS1 L48 D11 C28TTA RD/BK C9-2 RD TS2 TS3 H1 P3 HORN P25FS RD P24FS WH C9-1 BK FS1 C9-3 P2 2 N M L K J I H G F E D C B A D40 3 TB134 KS1 P1 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 16420) 1 BL/WH RD OR/BK BK RD/BK WH P26ESTP BK + - 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 7 16 4 5 13 6 BL/WH OR 14 6 7 8 14 13 12 3 4 BOOM C2-3 C1-4 C1-5 C1-6 C1-3 C1-11 C1-10 C3-6 C3-5 C3-4 7.5 5 BR-2 C30EDC+ WH C31EDC- WH/BK C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C6TRF WH/RD C5TRR WH/BK BOOM C15PLD OR/BK C14PLU OR C8PBR BK/WH C7PBE BK RETRACT EXTEND C40LS1 OR C13DRE BL/RD C3PBF RD/WH C2PBD RD/BK C1PBU RD PRIMARY BOOM UP DOWN C4TRL WH C3-1 C3-2 C3-3 C4-1 C2-2 C3-7 C3-8 C4-2 C4-3 UP PLATFORM LEVEL DOWN JDALARM GR/BK 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 C6-13 C6-40 C6-30 C6-7 C6-8 C6-14 C6-15 C6-18 6 C30EDC+ WH C31EDC- WH/BK C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C5TRR WH/BK C4TRL WH C6TRF WH/RD C6-19 D A WH BK WH BK WH BK RD/BK C3PBF RD/WH C2PBD RD/BK C1PBU RD C40LS1 OR C13DRE BL/RD C7PBE BK C8PBR BK/WH C15PLD OR/BK C14PLU OR C18JD GR/BK C17JU GR B GROUND DRIVE EDC FORWARD DRIVE EDC REVERSE TRAVEL ALARM OPTION BRAKE RELEASE VALVE MOTOR STROKE STEER CCW STEER CW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH DESCENT ALARM LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH PLAT LEVEL DOWN PLAT LEVEL UP BOOM RETRACT BOOM EXTEND DRIVE ENABLE LIMIT SWITCH C 8 NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". PLATFORM ROTATE CW / JIB UP PLATFORM ROTATE CCW / JIB DOWN JIB VALVES 6 - 109 S-40 • S-45 DRIVE SPEED C29MS RD/WH DRE LED BL/RD DRE B BL/BK DRIVE ENABLE BRN WH/RD BL/WH DRE A BL/WH 6 RKOUT 5 YOUT 4 XOUT 3 PWR 2 GND1 2 1 11 12 RD/WH WH/RD OR BRN 6 5 YOUT 4 XOUT 3 PWR 2 GND 1 2 1 3 4 BR P24FS WH P24FS WH P26ESTP BK EXTEND RETRACT C2-6 UP PLATFORM LEVEL DOWN GR/BK-44 C4-6 D28 C6-17 BR 22 21 NC 14 13 NO Part No. 102521 7 Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y21 Y22 Y12 22 21 NC 14 13 NO 14 2 1 2 1 4 3 H4 22 21 NC 13 NO Y25 Y26 H4 SJ1-WH D30 D29 4 C17JU GR TB8 TB30 TB31 TB32 DOWN UP JIB BOOM TB18 5 TB29 TB36 TB6 TB3 TB13 TB40 TB7 TB15 TB14 TB17 TB5 TB2 TB37 TB4 TB1 CCW CW PLAT ROTATE TS58 Y19 Y20 Y16 Y17 TB44 TS63 TS59 R2 C19JSV GR/WH TB19 TS62 TS61 TS57 D27 JIB TIME DELAY CIRCUIT R1 RD C4-5 RD 3 DOWN UP JIB BOOM C4-7 + JC3 J1 J1 J1 J3 PLAT ROTATE CCW CW - TS13 J2 JOYSTICK CONTROL CARD CR30 NO CE LIFT/ DRIVE OPTION GR/WH WH WH JIB VALVE CR13 TS9 CR14 NO TS8 TS7 CR27 NC CR13 NC 2 TS14 LO L1 HI TS15 DRIVE & STEERING BR 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 October 2013 Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 16420) BL/WH RD OR/BK BK RD/BK October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 16420) 6 - 109 6 - 110 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 16420) 6 - 112 6 - 111 C3-10 C1-7 C1-1 C2-1 C2-7 GENERATOR ENG SPEED HIGH RPM(FS) WH WH C28TTA RD/BK BK P22BAT BK C7-2 C1-2 GR/BK C4-4 C2-5 C7-1 C1-12 C2-4 C132PLI1 BL/WH BK BK C1-9 C35RPM BK/RD LOW RPM FUNCTION ENA. HIGH RPM C45GEN GR/WH C33STR BK ENGINE START RD C27AUX RD P23BAT WH C28TTA RD/BK C133PLA OR/RD C43HRN GR D14 GN/BK C6-39 BR C5-10 C5-8 C5-5 C5-9 C5-17 C5-12 C5-14 C5-11 C5-13 RD WH C27AUX RD C6-25 C6-16 RD/BK A D B C RD RD WH/BK GY/RD GY/YL RD BK/BL RD/GR WH/BK R43HRN BK C6-33 PR2 BK BLUE/PINK C6-26 BR C38ESL BL/WH PIN 6 VSW WH PIN 1 C135RET BL PIN 18 C135FP BL/WH PIN 5 C39LP BL/RD PIN 7 R21IGN WH PIN 24 R33STR BK PIN 15 C35RPM BK/RD PIN 23 C21IGN WH PIN 16 C127TSW GR PIN 3 C26TSR WH/RD PIN 39 C5-16 R21IGN WH C4B-10 C4B-12 C45GEN GR/WH C6-27 C6-28 C6-23 C6-34 C5-2 L29 L29 C4B-11 C4B-9 OPS FORDENGINE HARNESS TS4 P134PWR RD C2-3 D10 STARTER RELAY FORDENGINE 42 PIN FORD CONNECTOR COOLING FAN (OPTION) HYDRAULIC OIL TEMP. SWITCH SERVICE HORN SERVICE HORN RELAY FLASHING BEACONS OPTION LEVEL SENSOR TILT ALARM WORK LIGHT RELAY (OPTION) AUXILIARY PUMP AUXILIARY POWER RELAY TEMP GAUGE LPG LOCKOUT GASOLINE SENSOR OIL PRESSURE GAUGE HOUR METER VOLT METER DRIVE LIGHT OPTION WORK LIGHTS OPTION GENERATOR OPTION BR STARTER MOTOR NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Y29 C41RPM OR/BK PIN 2 GND BR PR2 DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453 1 2 D11 C41RPM OR/BK P20BAT RD Part No. 102521 S-40 • S-45 6 - 112 S7 FORD 42 PIN PLUG G1 G6 M2 AUX PUMP H2 STARTER 7 12 V DC TB25 LIGHTS PACKAGE 8 CR17 CR23 NO FUEL PUMP + HM _ FB FAN M1 PR1 PR1 NO CR17 NO PR8 NO RD CR23 TB26 FUEL PUMP G2 RD CR45 D12 RD RD 15AMP. TB41 CR1 NO CR2 NO TS22 DIAGNOSTIC G3 NO L2 CR5 CR5 NO OTS 6 TB21 CB3 20AMP. U34 TB35 1 2 P24PWR CR1 RD CR2 L45 CR39 FUSE 10A H6 CR39 NC CR45 NO TB45 5 NO 10A TB33 D4 D13 TB23 RD R24PWR TB24 CB1 15AMP. TB20 TB27 TB28 D2 GBOX GND 2 SEC TB39 5 4 TB133 6 LOAD SENSE 7 MODULE 12 U33 8 3 B CB2 L30 L30 TS55 TS52 TS53 TS51 3 1 TB22 D40 TS17 TS2 TS3 RD TB43 B1 U35 L4 D39 H1 PBOX GND KS1 NO 30A 3 C9-2 R20 4.7K TS1 2 SEC + P3 HORN P25FS RD P24FS WH BK C9-1 PBOX GND WH 2 P26ESTP BK P2 LS18 FS1 C9-3 RD D88 OR/BK BK LS18A D89 N M L K J I H G F E D C B A TB132 TB134 RD 2 P1 PLAT GRD 4 1 4 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 16420) 1 BL/WH RD RD/BK C132PLI2 BK + - 10 9 11 17 18 20 19 16 15 5 C41RPM OR/BK 15 8 7 16 4 5 13 6 BL/WH OR 14 6 7 8 14 13 12 3 C2-3 C1-4 C1-5 C1-6 C1-3 C1-11 C1-10 C3-6 C3-5 C3-4 7.5 5 BR-2 C30EDC+ WH C31EDC- WH/BK C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C6TRF WH/RD C5TRR WH/BK BOOM C8PBR BK/WH C7PBE BK RETRACT EXTEND C40LS1 OR C13DRE BL/RD C3PBF RD/WH C2PBD RD/BK C1PBU RD PRIMARY BOOM UP DOWN C4TRL WH C3-1 C3-2 C3-3 C4-1 C2-2 C3-7 C3-8 C14PLU OR C15PLD OR/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 C6-13 C6-40 C6-30 C6-7 C6-8 C6-14 C31EDC- WH/BK C30EDC+ WH 6 C32BRK WH/RD C29MS RD/WH C37STCC BL/BK C36STC BL C5TRR WH/BK C4TRL WH C6TRF WH/RD C1PBU RD C2PBD RD/BK D A WH BK WH BK WH BK RD/BK C3PBF RD/WH C6-19 C13DRE BL/RD C40LS1 OR C7PBE BK C8PBR BK/WH C14PLU OR C15PLD OR/BK C18JD GR/BK B GROUND DRIVE EDC FORWARD DRIVE EDC REVERSE TRAVEL ALARM OPTION BRAKE RELEASE VALVE MOTOR STROKE STEER CCW STEER CW TURNTABLE ROTATE CCW TURNTABLE ROTATE CW TURNTABLE ROTATE FLOW CONTROL PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FLOW CONTROL LS2-PRIMARY BOOM UP DRIVE LIMIT SWITCH DESCENT ALARM LS1-PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". PLATFORM ROTATE CCW / JIB DOWN PLAT LEVEL DOWN PLAT LEVEL UP BOOM RETRACT BOOM EXTEND DRIVE ENABLE LIMIT SWITCH C 8 PLATFORM ROTATE CW / JIB UP JIB VALVES 6 - 113 S-40 • S-45 DRIVE SPEED C29MS RD/WH DRE LED BL/RD DRE B BL/BK DRIVE ENABLE BRN WH/RD BL/WH DRE A BL/WH 6 RKOUT 5 YOUT 4 XOUT 3 PWR 2 GND1 11 12 RD/WH WH/RD OR BRN 2 1 2 1 BR 6 5 YOUT 4 XOUT 3 PWR 2 GND 1 P24FS WH 3 4 4 BOOM C4-2 C4-3 C6-15 C6-18 C17JU GR BR 22 21 NC 14 13 NO Part No. 102521 7 Y51 Y2 Y27 Y3 Y4 Y23 Y29 Y13 Y21 Y22 Y12 22 21 NC 14 13 NO H4 SJ1-WH D30 D29 5 UP PLATFORM LEVEL DOWN JDALARM GR/BK C18JD GR/BK D28 C6-17 2 1 2 1 4 3 H4 22 21 NC 14 13 NO Y25 Y26 P24FS WH EXTEND RETRACT C2-6 UP PLATFORM LEVEL DOWN GR/BK-44 C4-6 C17JU GR DOWN UP JIB BOOM TB18 TB29 TB5 TB2 TB13 TB40 TB30 TB31 TB32 TB37 TB4 TB1 TB36 TB6 TB3 TB8 R2 4 TS62 TS63 TS59 TB7 TB15 TB14 TB17 Y19 Y20 Y16 Y17 TB44 CCW CW PLAT ROTATE TS58 D27 C4-5 JIB TIME DELAY CIRCUIT TS61 TS57 C19JSV GR/WH TB19 DOWN UP JIB BOOM PLAT ROTATE CCW CW C4-7 + R1 RD P26ESTP BK JIB VALVE RD J1 J1 J1 J3 JC3 3 - WH WH J2 JOYSTICK CONTROL CARD CR30 NO CE LIFT/ DRIVE OPTION GR/WH TS13 TS8 TS7 CR27 NC CR13 NC CR13 TS9 CR14 NO 2 TS14 LO L1 HI TS15 DRIVE & STEERING BR 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 October 2013 Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 16420) BL/WH RD OR/BK BK RD/BK October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 16420) 6 - 113 6 - 114 Section 6 • Schematics October 2013 Ground Control Box Wiring Diagram Ford DSG-423 EFI Models (before serial number 14832) 6 - 116 6 - 115 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford DSG-423 EFI Models (before serial number 14832) A B C D E F G H I J K L M N 1 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 2 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 3 WH-C5-3+C5-8 RD- 12 VOLT OR/BK-C6-15 OR- C6-14 BL/RD-C6-13 4 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 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 5 D 3 C7B 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 BL/RD-S.P. BK/RD-S.P. BK/WH-S.P. BK-S.P. D5 BK-CR1#85 WH/RD-C6-32 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) RD-CR39#85 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 G3 WH-21A BR (GROUND) WH/BK-25A WH/RD-26A BK-22A KEY SWITCH KS1 P1 TS51 B RD-CB2 NC 3 1 NC B1 WH-23A RD-42A RD-27A BL/RD-39A 4 KEY SWITCH KS1 2 WH-23A L2 BR (GROUND) 44B-RD/BK-C6-19 1 RD-S.P. C 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 BL/WH-C5-13 TS61 RD/WH-3A RD/BK-2A RD-1A A B TS63 BK/WH-8A BK-7A GR/BK-44A BK-33A BR-GND STUD BK-22C TS62 1 2 WH-23C CB3 TS52 (BR) C4B C3B (GR) 19/18 CABLES R1 RD-24B CR2 CR1 R2 C2B (BK) BK-33B CB1 C1B (GY) BK-C5-5 CB2 CR23 TS55 C6 L2 DESCRIPTION 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 RD C4B-11 BK/RD-35A OR-C6-33 WH-C5-11 2 BK/RD-9B TS59 TS22 FUNCTIONS RD-CB3 S.P. TS57 WH-21B WH-C5-17 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/BK-18A C5 ENGINE GR/WH-19A WIRING HARNESS: TO BASE GROUND STUD 8 6 - 116 TS58 RD-CR17/CR23 #30 WH/BK-5A WH/RD-6A WH-4A BK-C6-16 7 Note: Removed resistor R3 and changed L2 to incandescent TS53 RD- 20C 6 4 Check Engine Light (after serial number 13739) WH-21A DRIVE LIGHT OPTION 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. 1 B1 HM BK/RD-CR23#86 B 3 R3 GR/WH-C4B-7 GR/BK-C4B-6 GR-C4B-5 OR/RD-C4B-4 GR/BK-C6-18 GR- C6-17 RD-KS1-2 S.P. GEN. OPTION JDALARM JIB RD WH-C7B-2 BK-C7B-1 WH-C6-34 RD-S.P.(CB3) RD- C6-23 BL/WH-C6-30 GR/BK-S.P. GR/BK-2B GR-CR5#85 RD RD/BK-C6-28 RD- C6-27 WH/RD-C5-14 WH/BK-C5-16 SPARE 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 ESO433 GROUND STUD BR ALL BR WIRES S-40 • S-45 Part No. 102521 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford DSG-423 EFI Models (from serial number 14832) M L K J I H G F E D C B A 1 LOAD SENSE OPTION - TIMER RELAY U33 PLATFORM LOAD BL/BK-C6-37 BL- C6-36 BK/RD-C5-9 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 RD- C6-23 BL/WH-C6-30 WH-C5-3+C5-8 RD- 12 VOLT GR/BK-C6-18 GR- C6-17 C RD-KS1-2 S.P. BL/RD-S.P. BK/RD-S.P. BK/WH-S.P. BK-S.P. 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) GR/WH-SP GR/BK-S.P. GR-S.P. OR/BK-S.P. OR-S.P. 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. BR-GND P134PWR PULSE PICKUP LIMIT SWITCH SIG. L.P. C132PLI STEER CW STEER CCW 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 JIB VALVE PLAT. ROT. CCW PLAT. ROT. CW C133PLA PLAT. LEVEL DN. PLAT. LEVEL. UP DRV. ENA. LT. P1 NC C3B (GR) C2B (BK) C1B (GY) KEY SWITCH KS1 B 1 3 D2 B1 4 2 TS51 TS53 D10 BL/WH-C5-13 RD C4B-12 TS61 RD/WH-3A RD/BK-2A RD-1A BK/WH-8A BK-7A GR/BK-44A BK-33A RD-20C TS52 WH-W.L. CABLE TS58 TS55 CB1 D28 TS57 CB2 TS59 BK/RD-35A RD-20A C6 RD-20B RD- P1 E-STOP OR/BK-15A CR17 C5 BK-C6-25 RD-CB3 SP OR-14A WIRING HARNESS: TO BASE 1 CR45 30 85 BR-GND 86 87 TS62 CB3 RD-20C RD-CR17/CR23 #30 WH/BK-5A WH/RD-6A WH-4A OR-C6-33 5 WORK LIGHT OPTION RELAY TS63 RD-24A GROUND STUD BR 4 WH-21B WH-21B WH-C5-17 WH-23B 3 CR23 30 85 BN-GND 86 87 RD C4B-10 BR (GROUND) D13 GR-C5-12 U34 RD-24C HM SPARE BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN. ROT. CCW TURN. ROT. CW PRI. BOOM F.C. PRI. BOOM DOWN PRI. BOOM UP CR39 5 REPLACE WIRE WITH THIS WIRING DIAGRAM L2 WH-21A R2 RD-27B 3 D4 D14 GR-43B BK-22B 2 2 DRIVE LIGHT OPTION RELAY BK-33B CR5 ENGINE NC WH-23A RD-42A RD-27A BL/RD-39A A WH-C5-11 9 BK-C3B-10 WH/BK-25A WH/RD-26A BK-22A RD-CB2 8 WH-ISM#9 RD-TB134(A)C CR2 BK-C6-16 WH-CR2#86 G3 SPARE GEN. OPTION JDALARM JIB HORN GR/BK-S.P. B CR1 TS22 G2 G1 WH-21A BR (GROUND) RD-24B BK-C5-5 FUNCTIONS H6 WH-21C R1 19/18 CABLES 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 D C4B (BR) C7B 12V TO PLAT 12 V OR/BK-C6-15 OR- C6-14 BL/RD-C6-13 RD-C32-1 RD-134B GR/BK-L45GR/BK-133A RD 46 GR/WH-C2B-7 45 GR/WH-35B 1 GR/BK-C2B-6 GR/BK-2B 44 GR-C2B-5 43 GR-CR5#85 RD-U34-2 134A RD-C2B-4 RD-H6+ 134 41 OR/BK-C2B-3 40 OR-C2B-2 39 BL/RD-C2B-1 BL/WH-C1B-12 132 BL/BK-C1B-11 37 36 BL-C1B-10 1 35 GR/WH-45B BK/RD-C1B-9 BK/WH-C1B-8 34 33 BK-CR1#85 D5 BK-C1B-7 WH/RD-C6-32 WH/RD-C1B-6 32 WH/BK-C1B-5 31 30 WH-C1B-4 RD/WH-C1B-3 29 28 RD/BK-C1B-2 27 RD-CR39#85 RD-C1B-1 26 25 24 RED-CR1#30 RD-CR23#30 23 CR39 #30 WH-C7B-2 22 BK-CR5#30 BK-C7B-1 C6-34 &CR45#86 21 WH-CR2#87& CR23#86 RD-S.P.(CB3) 20 RD-S.P.(CB2) GR/WH-C4B-7 19 18 GR/BK-C4B-6 17 GR-C4B-5 OR/RD-C4B-4 133 15 OR/BK-C4B-3 14 OR-C4B-2 13 BL/RD-C4B-1 BL/WH-C3B-12 12 11 BL/BK-C3B-11 10 BL-C3B-10 9 8 BK/WH-C3B-8 7 BK-C3B-7 6 WH/RD-C3B-6 5 WH/BK-C3B-5 4 WH-C3B-4 3 RD/WH-C3B-3 2 44B-RD/BK-C6-19 RD/BK-C3B-2 1 RD-C3B-1 OR/BK-C5-2 OR- C6-40 BL/RD-C5-10 3 BR-GND STUD 1 BK-22C 2 WH-23C RD-H6+ - C32-1 BL/WH-132D - C32-3 BK-22C - C32-4 BK-C7-1 - C32-5 RD-TS51 - C32-6 RD-TS55 - C32-7 GR/BK-133B - C32-8 BR - GND - C32-12 C32 GR/WH-C6-39 GROUND STUD N GR-17A GR/WH-19A GR/BK-18A DIODE ADDED AT SERIAL NUMBER 16453 ALL BR WIRES Part No. 102521 6 DESCRIPTION LABEL EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH ENGINE START SWITCH LP/GAS SWITCH FUNCTION ENABLE PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH JIB BOOM UP/DOWN SWITCH CHECK ENGINE SWITCH CIRCUIT BREAKER, CONTROLS, 15A CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, OPTIONS, 20A RESISTOR, 5 OHM, BOOM FUNCTION RESISTOR, 7.5 OHM,TURNTABLE FUNCT VOLT METER GAGE OIL PRESSURE GAGE WATER TEMP. GAGE CHECK ENGINE HOUR METER LOAD SENSE TIME DELAY RELAY (10A) P1 KS1 TS51 TS52 TS53 TS55 TS57 TS59 TS63 TS61 TS62 TS58 TS22 CB1 CB2 CB3 R1 R2 G1 G2 G3 L2 HM U34 S-40 • S-45 7 8 6 - 117 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford DSG-423 EFI Models (from serial number 14832) 6 - 117 6 - 118 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Ford DSG-423 EFI Models (before serial number 14832) 6 - 120 6 - 119 11 1 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 6 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 C36STC BL C1P-10 C3PBF RD/WH C3P-3 F.S. D39 RED-TILT F.S. TILT P26BAT BK P24FS WH C1PBU RD C3P-1 C30EDC+ WH C1P-4 C31EDC- WH/BK C1P-5 C2PBD RD/BK C3P-2 C5TRR WH/BK C3P-5 BATGND C7P-3 C37STCC BL/BK C1P-11 C29MS RD/WH C1P-3 C32BRK WH/RD C1P-6 C4TRL WH C3P-4 C35RPM BK/RD C1P-9 C134PWR RD C2P-4 C33STR BK C1P-7 C34SA BK/WH C1P-8 C27AUX RD C1P-1 RD/BK L4 C28TTA RD/BK C1P-2 C7P BRN Part No. 102521 C3P C3P D40 C4P GR/BK C4P-4 P24FS WH BRN JC1-3 OR JC2-4 RD JC2-3 OR JC1-2 BRN JC2-5 BK JC3-3 OR JC1-5 YEL JC2-2 BRN JC3-5 BL 1 DRE A BL/WH JC3-4,6 WH JC3-2 BRN J2 J1 12V BATT 19/18 CONTROL CABLE ALALRM 9 JIB C7P 7 C1P C28TTA RD/BK C1P-2 5 3 DRE B BL/BK C13LED BL/RD 4 J3 C29MS RD/WH GR/BK L48 RED-TILT HARNESS PBOX WIRING 3 ALC-500 N M L K J I H G F E D C B A S-40 • S-45 6 - 120 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Ford DSG-423 EFI Models (before serial number 14832) 1 2 C2P H1 8 ESO433 Y BR RD R B BR R20 R 4700 R26ESTP BK C9P-1 B Y P134PWR RD RD P23BAT WH C7P-2 P22BAT BK C7P-1 C19JSV GR/WH C4P-7 C18JD GR/BK C4P-6 C17JU GR C4P-5 C15PLD OR/BK C4P-3 C14PLU OR C4P-2 C43HRN GR C2P-5 C8PBR BK/WH C3P-8 C7PBE BK C3P-7 P26ESTP BK C9P-1 P25FS RD C9P-3 P24FS WH C9P-2 JDALARM GR/BK C2P-6 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 R R GR/WH B C19JSV GR/WH TS7 C19JSV GR/WH C4P-7 BR JC3 BR GND RD-E-STOP P134PWR RD-H1+ CR13-#86 GR/WH P134PWR RD RD-H1+ P26ESTP BK E-STOP BR GND P26ESTP BK P24FS WH 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 P134PWR RD C2P-4 C35RPM BK/RD C1P-9 C34SA BK/WH C1P-8 C33STR BK C1P-7 C27AUX RD C1P-1 RD/BK L4 WH BK GR/WH B B GR/WH + RD OUTPUT BR C1 4 B B Y Y RD/BK-28 OPT. 7 C4P(BR) C3P(GR) C2P(BK) C1P(GY) 6 - 121 S-40 • S-45 Part No. 102521 RD LS18 CABLE JIB C132PLI2 BK C3P-10 D39 RD-TILT F.S. 12V BATT 19/18 CONTROL CABLE 6 D89 C132PLI1 BK C1P-12 LS18 JIB C9P C7P D88 C7P BATGND C7P-3 B U35 GR/WH 1 B CR14 11 1 B C28TTA RD/BK C1P-2 C2P D40 C3P BR C4P GR/BK C4P-4 P24FS WH BR J2 5 C1P C28TTA RD/BK C1P-2 OPTION TILT ALALRM JC1-2 OR JC2-3 WH/RD JC1-1 BR JC2-4 RD/WH JC2-2 OR JC1-4 WH/BK JC2-1 BR JC3-4 WH/RD JC3-2 OR JC3-3,5 BL/WH JC3-1 BR DRE A BL/WH DRE B BL/BK C13LED BL/RD C29MS RD/WH JIB TIME DELAY LOAD SENSE TIME DELAY RELAY (30A) COM NO 2 3 5 PLAT CONT HARNESS (TO SWITCH PANEL) 3 1 J3 C1 U35 J1 3 GR/BK L48 JIB DELAY RELAY RD-TILT TILT ALARM CR14 9 LOAD SENSE OPTION ALC-500 H1 1 A B C D E F G H I J K L M N Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Ford DSG-423 EFI Models (from serial number 14832) 2 COMPONENT INDEX H1 8 October 2013 Section 6 • Schematics Platform Control Box Wiring Diagram Ford DSG-423 EFI Models (from serial number 14832) 6 - 121 6 - 122 Section 6 • Schematics October 2013 Platform Control Box Switch Panel Wiring Diagram Ford DSG-423 EFI Models (from serial number 11067 to 12509) 6 - 124 6 - 123 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford DSG-423 EFI Models (from serial number 11067 to 12509) A B C D E F G H I J K L M N 1 10 AMP FUSE HARNESS PBOX WIRING 2 WORK / DRIVE LITE TS49 DRV.ENA TS15 7 6 6 5 5 RD WL1 4 3 DLITE/ RD WL2 3 PRIMARY BOOM EXTEND/ RETRACT 4 3 2 2 JC2 JC3 1 1 TS13 CR13 WH-24 4 + COMPONENT INDEX BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE PART NUMBER 62390 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 ) 75565 56298 66812, 95406 66813, 66816 42730 13037 56457 56457 56298 16397 13037 13037 13037 56457 13037 27378 27378 + BL/RD-DE3 J1-16 WH J1-5 BL J1-4 WH J1-5 OR J1-13 BRN J1-14 RD/BK H1 WH-24 BL/WH-DE1 J1-6 BK-22 BL/BK-DE2 J1-7 DETAIL A: LIFT/DRIVE OPTION RD-TILT DRIVE LT BK/RD-C3P-9 L4 L1 BRN WH-JIB BK-7 BK/WH-8 BK J1-2 RD J1-1 OR J1-11 BRN J1-12 5 JC2 7 REPLACE WIRE WITH THIS WIRING DIAGRAM BRN BATGND (GND STUD) P22BAT BK C7P-1 RD-TILT BK-22 WH-23 RD P26BAT BK C9P-1 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 JDALARM GR/BK-44 C2P-6 WH-JIB C17JU GR C4P-5 C19JSV GR/WH C19JSV GR/WH JIB C18JD GR/BK C4P-6 OR-14 OR/BK-15 RD GR-43 6 WH TS7 CR27 WH TS1 WH/RD C32BRK (SPLICE TO C32BRK) CR30 WH TS9 TS7 TS8 TS1 GR TS47 TS14 7 HORN P3 PLATFORM LEVEL WH PLATFORM ROTATE GR/BK JIB AUXILIARY PUMP DRIVE SPEED HIGH/LOW OR R40LS1 TS2 WH START HIGH/LOW RPM TS4 TS3 (SPLICE TO R40LS1) FUEL SELECT GENERATOR (OPTION) EMERGENCY STOP P2 RD CE SEE DETAIL A REMOVE FOR GENERATOR OPTION 8 6 - 124 S-40 • S-45 Part No. 102521 NOTE: DASHED LINES INDICATE OPTION WIRES October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford DSG-423 EFI Models (from serial number 12510) N M L K J I H G F E D C B A HARNESS PBOX WIRING 10 AMP FUSE 1 2 DRIVE/STEER DRIVE ENABLE TS15 COMPONENT INDEX 6 6 1 JC2 1 TT ROTATE PRIMARY BOOM EXTEND/ RETRACT JC3 3 DLITE/ RD WL2 BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE 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 ) RD WL1 + TS13 CR13 85 L4 + J1-5 BL/WH JC3-5 J1-4 WH/RD JC3-4 J1-5 BL/WH JC3-3 J1-13 OR JC3-2 RD-P2 GR/BK H1 RD/BK H1 WH-24 BL/RD-DE3 J1-16 BR BK/WH-8 BK-7 BK/WH-8 J1-14 BR JC3-1 L1 BL/WH-DE1 J1-6 BK-22 86 BL/BK-DE2 J1-7 J1-2 RD/WH JC2-4 J1-11 OR JC2-2 J1-1 WH/RD JC2-3 J1-12 BRN JC2-1 REPLACE WIRE WITH THIS WIRING DIAGRAM + 87A DRIVE LT BK/RD-C3P-9 30 DETAIL A: LIFT/DRIVE OPTION 4 L48 WH-24 JC3 L1 P2 P3 TS1 TS2 TS3 TS4 L4 TS7 TS8 TS9 TS13 TS14 TS15 TS47 TS49 2 WORK / DRIVE LITE TS49 PRI. BOOM UP/DOWN JC2 1 5 BR BATGND RD-TILT P22BAT BK C7P-1 BK-22 P26ESTP BK C9P-1 RD HIGH/LOW RPM TS3 START FUEL SELECT 1 1 1 GENERATOR (OPTION) 2 2 2 DRIVE SPEED HIGH/LOW TS2 NCNCNC AUXILIARY PUMP TS47 TS14 7 P2 EMERGENCY STOP RD CE SEE DETAIL A 1 2 WH-23 JIB BL/RD-39 D27 PLATFORM ROTATE GR/BK RD WH BK/RD-35 WH-24 TS1 GR PLATFORM LEVEL RD-25 (SPLICE TO R40LS1) BK-33 OR R40LS1 D11 D12 6 TS4 86 HORN P3 GR/WH-45 TS8 WH-24 WH TS7 3 NO WH-24 TS9 87 4 30 C29MS RD/WH J1-8 CR30 85 C27AUX RD C1P-1 (SPLICE TO C32BRK) WH-JIB JDALARM GR/BK-44 C2P-6 C17JU GR C4P-5 WH/RD C32BRK C19JSV GR/WH WH TS1 86 C19JSV GR/WH JIB C18JD GR/BK C4P-6 OR-14 87A OR/BK-15 30 RD WH TS7 GR-43 (GND STUD) CR27 85 DRIVE/WORK LIGHT OPTION CHANGED AT SERIAL NUMBER 16420 NOTE: DASHED LINES INDICATE OPTION WIRES Part No. 102521 8 S-40 • S-45 6 - 125 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford DSG-423 EFI Models (from serial number 12510) 6 - 125 6 - 126 Section 6 • Schematics October 2013 Engine Wire Harness Ford LRG-425 EFI Models (before serial number 11067) 6 - 128 6 - 127 October 2013 Section 6 • Schematics Engine Wire Harness Ford LRG-425 EFI Models (before serial number 11067) A B C D E F G H I J K L M N 1 INJ + INJ 1 INJ 3 INJ 4 INJ 2 INJ 5 INJ 6 AUX OUT 2 EGR 2 AUX ANA PD1 MAP FPP 1 IAT ECT IVS AUX ANA PU1 FPP 2 EGR PWM EGR RECIRC POWER GROUND 3 POWER GROUND ANA_RTN 5 VOLT REF VSW CRANK CRANK + CAM CAM + VBAT VBAT EGO 2 4 EGO 1 EGO 3 KNK + KNK - 361 R 16 6 361 R 16 7 555 T 16 8 557 BR-Y 16 557 BR-Y 16 9 558 BR-LB 16 558 BR-LB 16 10 556 W 16 361 R 16 743 GY 18 12 359 GY-R 18 INJECTOR #1 COIL 1 COIL 3 COIL 4 COIL 5 COIL 6 STARTER LOCKOUT FUEL LOCKOFF 6 FUEL PUMP RELAY CONTROL TPS1 TPS2 DBW + DBW BRAKE SWITCH OIL PRESSURE TACH MIL FUEL PUMP MON 7 AUX OUT 1 FUEL SELECT AUX ANA PU2 GOV SELECT 1 GOV SELECT 2 ROAD SPEED + ROAD SPEED GASEOUS TRIM OVERSPEED CAN + CAN - 8 RS 485 + RS 485 RS 232 TX RS 232 RX A B 570 BK-W 16 39 R-W 18 16 WATER TEMP WATER TEMP 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 17 307 BK-Y 18 18 150 DG-W 18 16 114 LB-Y 18 22 352 BR-LG 18 23 1 360 BR-PK 18 570 BK-W 16 570 BK-W 16 2 570 BK-W 16 570 BK-W 16 13 359 GY-R 18 570 BK-W 16 14 351 BR-W 18 351 BR-W 18 3 16 R-LG 18 33 350 GY 18 358 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 4 150 DG-W 18 150 DG-W 18 5 361 R 16 361 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 ACT 151 LB-BK 151 LB-BK 307 BK-Y 18 570 BK-W 16 ECT 570 BK-W 12 361 R 14 O2 SENSOR 26 F2 570 BK-W 12 5A 16 R-LG 18 MAP_CONN 361 R 14 F3 20A 361 R 14 C 30 361A R 16 361A R 16 570 BK-W 16 570 BK-W 16 O2 SENSOR A 18 O-Y 18 359 GY-R 18 351 BR-W 18 MTRTWR6 MTRSHD6 355 GY-W 18 74 GY-LB 18 392 R-LG 18 357 Y-W 18 151 LB-BK 18 359 GY-R 18 359 GY-R 18 317 GY-O 18 351 BR-W 18 850 Y-BK 18 2 851 Y-R 18 TWR 361A R 16 3 1 COIL 1 2 VBAT 1 2 3 A B 242 DG 18 361A R 16 LOCKOFF SOLENOID 24 25 SHD TWR A A B B C C D D E E F F 16 R-LG 18 THROTTLE 355 GY-W 18 357 Y-W 18 151 LB-BK 18 317 GY-O 18 351 BR-W 18 359 GY-R 18 FUEL PUMP RELAY 6 5 4 1 32 R-LB 16 86 87 30 38 EGR ANA IN 32 ANA AUX PD1 37 ANA AUX PU1 12 FPP2 40 EGR PWM 41 EGR REC 32 R-LB 16 32 R-LB 16 3 2 85 87 87A 359 GY-R 18 D 351 BR-W 18 C B 458 O-BK 18 A RTN FPP_COMM 787A PK-BK 16 F4 15A 787A PK-BK 16 RX TWR 86 39 STARTER IN (AUTOCRANK) 9 926A LB-O 18 32 15 R-Y 18 30 355 GY-W 18 31 357 Y-W 18 28 29 151 LB-BK 18 317 GY-O 18 6 511 LG-R 18 511 LG-R 18 511 LG-R 18 7 253 DG-W 18 253 DG-W 18 253 DG-W 18 8 11 T-Y 18 11 T-Y 18 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 5 71 O-LG 18 71 O-LG 18 14 71 O-LG 18 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 11 307 BK-Y 18 169 LG-BK 18 169 LG-BK 18 12 172 LB-R 18 169 LG-BK 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 21 642 DG-O 18 461 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 18 172 LB-R 18 570 BK-W 16 361A R 16 459 O-LG 18 662 DG-P 18 MTRTWR4 Part No. 102521 15 STARTER IN (INTERUPT) TX 23 361A R 16 13 STARTER CONTROL 5V 342 LG-P 18 361A R 16 31 VREF 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 86 342 LG-P 18 3 COIL 2 13 1 VSW B 351 BR-W 18 1 34 GROUND 361 R 14 359 GY-R 18 570 BK-W 16 25 IVS 361 R 14 29 4 361 R 12 TWR 351 BR-W 18 16 R-LG 18 CRANK F1 30A 570 BK-W 16 16 R-LG 18 CAM 14 FPP1 359 GY-R 18 570 BK-W 16 WPTWR2_GY 6 - 128 INJECTOR #2 18 O-Y 18 TRIM VALVE TWR INJECTOR #4 21 J2 GREY COIL 2 INJECTOR #3 FORD 42 PIN CONNECTOR 31 359 GY-R 18 SPK PWR GROUND 361 R 16 556 W 16 11 J1 BLACK 5 361 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 A A PLUG (GROUND) B B PLUG (RELAY POWER) C C D D PLUG (CAN -) PLUG (CAN +) MTRSHD4 October 2013 Section 6 • Schematics Engine Wire Harness Ford DSG-423 EFI Models (from serial number 11067 to 11784) N M L K 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 J I H G 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 E HO2S #1 IGNITION COILS Y/BK 18 W/PK 18 Y/RD 18 1 2 3 4 5 F 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 2 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 3 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 4 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 5 R 14 R 12 R 16 3 2 1 ALTERNATOR DG/W 18 LG/P 18 R/Y 18 6 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 A GY/R 18 FUEL PUMP B 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 LB/PK 16 RING 87A LB/PK 16 87 W/PK 16 30 86 87A R/LG 18 CAN TERMINATION CONNECTOR STARTER RELAY STARTER SOLENOID 87 R/LG 18 LG/P 18 INJECTOR CYL #3 T 16 7 15A 86 R 16 85 W 18 SHD RELAY OMRON FPP PK/BK 16 TWR W 18 2 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 1 BK/W 12 Y/R 18 DG/P 18 LB/BK 18 LB/Y 18 DG 18 O 18 R 16 A 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 B GY/Y 18 BR/W 18 GY/R 18 GY/LB 18 GY/Y 18 LG/BK 18 R 16 C 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 D 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 8 POWER EPR CONNECTOR F5 R 16 7 CAN + TERM CAN + CAN GROUND UNUSED UNUSED UNUSED ES0400A S-40 • S-45 6 - 129 October 2013 Section 6 • Schematics Engine Wire Harness Ford DSG-423 EFI Models (from serial number 11101 to 11784) 6 - 129 6 - 130 Section 6 • Schematics October 2013 Engine Wire Harness Ford DSG-423 EFI Models (from serial number 11785) 6 - 132 6 - 131 October 2013 Section 6 • Schematics Engine Wire Harness Ford DSG-423 EFI Models (from serial number 11785) A B C 1 2 3 4 5 6 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 E F R 16 Y/BK 18 W/PK 18 Y/RD 18 Y/BK 18 W/PK 18 Y/RD 18 BK/W 16 DG/P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 GY/LB 18 DG/P 18 DB/O 18 GY/R 18 CYL #2 CYL #3 CYL #4 G H HO2S #1 IGNITION COILS R 16 ENGINE ECM CONNECTOR D GY/R 18 GY/YL 18 R 16 BK/LB 18 CYL #1 DG/P 18 O/LG 18 GASOLINE SENSOR INTERFACE FORD 42 PIN CONNECTOR MTRTWR4 BR/W 18 LG/R 18 LG/R 18 GY/R 18 GY/R 18 GROUND BOSCH TMAP LG/BK 18 BR/W 18 GY 18 GY/R 18 BR 16 BR 16 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 LB/BK 18 R/LG 18 BK/Y 18 R/LG 18 R/T 14 R/T 14 F2 1 VSW VSW 5A R 14 ECM 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 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 A GY/R 18 FUEL PUMP B 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 15A FUEL PUMP RELAY LB/O 18 LB/O 18 85 R 16 PK/BK 16 30 R/LG 18 86 LB/PK 16 RING 87A R/LG 18 INJECTOR CYL #3 87A LB/PK 16 87 W/PK 16 30 R/LG 18 86 LG/P 18 85 W 18 SHD RELAY OMRON FPP PK/BK 16 T 16 CAN TERMINATION CONNECTOR STARTER RELAY STARTER SOLENOID 87 R 16 TWR W 18 2 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 R 16 POWER RELAY 30 R 16 87 R/T 18 86 S-40 • S-45 Part No. 102521 R/LB 16 R/LB 16 10A 85 R 16 87A 6 - 132 14 FPP1 R/LG 18 R/LG 18 10A R/T 16 BK/LB 18 BK/LG 18 R 16 36 ROADSPEED 35 ROADSPEED + 24 GOV SELECT 1 F3 Y/R 18 DG/P 18 LB/BK 18 LB/Y 18 DG 18 O 18 8 34 GND RING 4 3 2 1 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 SHD A B C D BK/W 12 GY 18 DBL 18 GY/R 18 DB/O 18 DG/BK LB/R 18 7 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 K GY/Y 18 DG/O 18 W/LG 18 DG/P 18 O/LG 18 R 16 J 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 I EPR R 16 15A RELAYED POWER POWER EPR CONNECTOR F5 R 16 7 CAN + TERM CAN + CAN GROUND UNUSED UNUSED UNUSED ES0400A L M N October 2013 Section 6 • Schematics Joystick Connector Diagram N M L K J I H G PRIMARY BOOM UP/DOWN F 7 E DRIVE/STEER JC2 7 YOUT 5 4 PWR 3 1 GND 2 6 7 YOUT 5 XOUT 4 PWR 3 1 GND 2 RKOUT 6 DRIVE & STEERING BL WH 4 5 2 13 BK 1 OR RD 11 14 OR 12 BRN BRN J1 JC3 5 JC3 PRI UP/DN & TT ROTATE TURNTABLE ROTATE C B A 2 7 5 4 4 3 3 2 2 1 1 3 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 1 6 6 JC2 D 7 1 6 2 5 3 4 4 3 5 5 2 6 1 7 AMP JC3 6 DRIVE & STEERING YOUT 4 RKOUT 5 OR BL/WH WH/RD BL/WH 6 XOUT 3 BRN RD/WH GND 1 WH/RD PWR 2 YOUT 4 OR 6 XOUT 3 BRN 5 GND 1 PWR 2 TURNTABLE ROTATE 7 5 4 13 14 2 1 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 8 Deutsch - 6 Pin Connector Part No. 102521 S-40 • S-45 6 - 133 October 2013 Section 6 • Schematics Joystick Connector Diagram 6 - 133 6 - 134 Section 6 • Schematics October 2013 CTE Option Wiring Diagram 6 - 136 6 - 135 C20-2 PLAT LEVEL UP PLAT LEVEL DOWN S-40 • S-45 PLAT LEVEL 8 Part No. 102521 GROUND 86 30 85 WIRING DIAGRAM OR-TS59 OR/BK-TS59 C40LS1 OR CR20#30 K L TB134 GROUND BOLT 14 14 PLATFORM LEVEL UP 85 15 40 RD-H6+ RD-KS1-2 S.P. C14PLU OR C6-14 J 15 PLATFORM LEVEL DOWN 40 BOOM STOWED 87 OR C2B-2 OR C6-40 30 134 87 I 134 P134PWR 86 H OR/RD-C2B-4 RD-C6-23 + LS PWR-C6-30 TB40 C15PLD OR/BK C6-15 C15PLD OR/BK 15-D G C15PLD OR/BK C4B-3 C15PLD OR/BK CR21#86 C14PLU OR C4B-2 C14PLU OR CR20#86 CR21 F C14PLU OR 14-D BR CR20 PLAT LEVEL 4 DOWN RELAY E CR20 C20-1 C21-2 6 - 136 TB14 LIMIT SWITCHES CR21 R14PLU OR C21-1 7 C14PLU OR 5 R15PLD OR/BK 6 C15PLD OR/BK 3 TB15 D UP RELAY TB22 C BR 2 B BR-GND STUD A C40LS1 OR 40-A February 2012 Section 6 • Schematics CTE Option Wiring Diagram M N 1 FUNCTION HARNESS Section 6 • Schematics February 2012 MTE Hydraulic Generator Option Wiring Diagram 6 - 138 6 - 137 October 2013 Section 6 • Schematics MTE Hydraulic Generator Option Wiring Diagram A B C D E F G H I J K L M 1 WHITE T3 GREEN GND WHITE 1 2 3 4 GR/WH BR BL BLACK 5 BLACK 8 WHITE WHITE BLACK L1 WHITE WHITE GREEN GND DTP04-4P C45GEN-GR/WH-4 BATGND-BR-4 5 T4 8 BLACK WHITE BLACK L2 RED RED PURGE-BL PURGE-BL T1 RED BLACK WHITE L2 GREEN GND PLUG BL BR GR/WH 6 GENERATOR JUMPER HARNESS 1 2 3 4 T2 T3 YELLOW WHITE WHITE WHITE GREEN BLACK 1 2 3 4 DTP04-4P 7 T4 5 BLACK BLACK WHITE BLACK 8 8 BLACK L1 YELLOW BLUE BLACK AC RED GENERATOR GREEN WHITE BLACK 240VAC, 50Hz, 1 PH 6 - 138 S-40 • S-45 Part No. 102521 DTP04-4P 1 2 3 4 GENERATOR JUMPER HARNESS 5 PURGE-BL 1 2 3 4 120VAC, 60Hz, 1 PH 120VAC, 50Hz, 1 PH 4 T3 1 2 3 4 GENERATOR JUMPER HARNESS L2 BLACK WHITE T2 PLUG GREEN BLACK T4 3 WHITE L1 C45GEN-GR/WH-4 BATGND-BR-4 2 BLACK BLACK PLUG WHITE YELLOW WHITE T2 T1 BLACK WHITE GREEN RED AC BLACK BLUE GENERATOR YELLOW BLACK GR/WH BR BL T1 BLACK WHITE GREEN RED AC BLACK GENERATOR BLUE YELLOW BLACK BLACK C45GEN-GR/WH-4 BATGND-BR RED SCHEMATIC - MTE HYDRUALIC GENERATOR OPTIONS N October 2013 Section 6 • Schematics Hydraulic Generator Wiring Diagram- Welder Option N M L K J I H G F E D C B A 1 FOOTSWITCH P2 P25FS-RD P26ESTP-BK P22PWR-BK P24FS-WH ALC-500 19 20 15 16 TS4 RPM SELECT RPM HI RPM LO TS47 GENERATOR ON 2 C2P-7 C45GEN GR/WH C32BRK WH/RD 4 C1B-9 C1B-3 C1B-4 C1B-5 1 N.O. 3 C35RPM BK/RD C29MS RD/WH C30EDC WH C31EDC WH/BK U36 8 N.C. C1P-6 C1P-9 C1P-3 C1P-4 C1P-5 C32BRK WH/RD 2 COM 3 GND CR66 OMRON RELAY 5 SW INPUT C1B-4 TIME DELAY MODULE 4 SECOND C2B-7 7 8 C5-21 C1B-5 C5-1 WH C5-20 TB24 5 D99 5 1 6 2 A1 BATTERY + A2 SENSOR POWER +5 VDC A3 BATTERY- D65 TB21 TB45 TB41 6 1 C5-21 C5-20 124 ohms TB32 D98 3 TB29 4 2 TB35 3 1k ohms 124 ohms C1 TxD (YLW) C2 RxD (GRN) C3 /BOOT D1 ANALOG 0 JOYSTICK D2 ANALOG 1 NC D3 DIG IN 3 NC 7 C6-39 BRAKE RELEASE E1 NOT USED E2 NOT USED E3 NOT USED CR4 HIGH IDLE RELAY BR-2 (16-2) N.O. RS232TxD RS232RxD MOTOR STROKE VALVE DRIVE EDC + DRIVE EDC - Y75-2 PS4 PRESSURE SWITCH 200 PSI BYPASS COIL C B A D U4 RD-1 Y75 7 6 BK-2 5 A J129 B C C41RPM OR/BK C57 C57 C45GEN GR/WH BK 16-2 C5-6 8 4 C5-12 2 C5-23 1 3 CR50 OMRON NC RELAY C5-18 V150HG GR/BK C5-24 B1 VALVE 0 FWD COIL) B2 VALVE 1 NC B3 DIGITAL OUTPUT BYPASS V151HG GR F1 DIG IN 0 F2 DIG IN 1 GENERATOR ON F3 DIG IN 2 8 SX Controller PILOT PRESSURE SIGNAL FROM GENERATOR MANIFOLD DIVERTER MANIFOLD Part No. 102521 S-40 • S-45 6 - 139 October 2013 Section 6 • Schematics Hydraulic Generator Wiring Diagram- Welder Option 6 - 139 6 - 140 Section 6 • Schematics October 2013 2WD Non-Oscillating Hydraulic Schematic S-40 Models (before serial number 7569) 6 - 142 6 - 141 October 2013 Section 6 • Schematics 2WD Non-Oscillating Hydraulic Schematic S-40 Models (before serial number 7569) A B C D E F G 1 H BRAKE MANIFOLD .025 DB 2 2 gpm 7.6 L/min MEDIUM PRESSURE FILTER T2 CP K F SLAVE L F C D D PLATFORM ROTATE C M PLATFORM LEVEL CYLINDERS 3 gpm 11.4 bar B C TEST BRAKE PRIMARY LIFT CYLINDER A A DA J TURNTABLE ROTATE EXTEND RETRACT CYL 4 gpm 15.1 L/min 51 psi 3.5 bar I CB CA MASTER .030 S1 A M AUXILIARY PUMP 1.7 B V2 AUX TEST HYDRAULIC COOLER OPTION 315 psi 21.7 bar 3 SW2 BG P2 P1 PL2 BE E AD AV AU AE AG AS COUNTERBALANCE VALVE RATIO AC A AH AA BD 4.5 gpm 17 L/min AR FUNCTION PUMP 9 7 AB BF PRESS 3625 psi 250 bar E BH BA AY AX AZ PR2 PR1 E 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 4 AQ 25 psi 1.7 bar AJ BG 2.0 gpm 7.6 L/min 1000 PSI 2000 PSI B 3:1 C 3:1 3000 PSI D 3:1 3300 PSI E 3:1 3500 PSI F 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 AUX T2 ST1 BI ST2 FUNCTION MANIFOLD LS TEST RESERVOIR T1 5 PRESS x 8 3 6 2 1 x 7 4 OPTIONAL GENERATOR MANIFOLD 5 2400 psi 165.5 bars HYDRAULIC ROTARY COUPLER 6 PRESS 3:1 x 8A x 8B x x 8C 6B 6C x 3 6B x 1 2A 2C x 2B x 7 4 5 FUNCTION PUMP A REAR RIGHT 7 B TANK 7 TEST M3 RELEASE T2 FE 185 psi 12.7 bar FRR FRB FLB FLR M1 RIGHT STEERING OPTIONAL GENERATOR TO HYD ROTARY COUPLER LEFT 210 psi 14.5 bar 50% FC .070 50% FB FA FD M4 8 Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. T1 REAR LEFT T 185 psi 12.7 bar M2 RELEASE TRACTION MANIFOLD 6 - 142 S-40 • S-45 Part No. 102521 N October 2013 Section 6 • Schematics 2WD Non-Oscillating Hydraulic Schematic S-45 Models (before serial number 7569) N M L K J I H G F EXTEND RETRACT CYL BRAKE MANIFOLD .025 DB 2 gpm 7.6 L/min MEDIUM PRESSURE FILTER T2 CP D C TURNTABLE ROTATE 4 GPM 15.1 L/min 50 psi 3.5 bar E PRIMARY LIFT CYLINDER A A F SLAVE B 1 S45 JIB BOOM PLATFORM LEVEL CYLINDERS F A C J2 3 GPM 11.4 L/min V1 J1 C DA B C C TEST BRAKE C 2 CC MASTER V2 .030 CA PR1 D S1 A M B 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 3 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 4 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 D PLATFORM ROTATE AB BF AR DRIVE PUMP CB BA AE AU AS 9 7 JIB SELECT MANIFOLD AY AX AZ PR2 E E PRESS 3625 psi 249.9 bar E PR1 AI AL 1950 psi 134.4 bar T1 SW1 BG AUX T2 ST1 BI ST2 FUNCTION MANIFOLD LS TEST RESERVOIR 5 T1 PRESS OPTIONAL GENERATOR MANIFOLD COUNTERBALANCE VALVE x 8 3 6 2 1 x 7 4 5 RATIO HYDRAULIC ROTARY COUPLER x 8A x 8B x x 8C 6C 6B x 3 6B A REAR RIGHT x 1 B 2A 2C x 2B x 7 4 5 TEST FE M3 PRESS A 3:1 1000 PSI B 3:1 2000 PSI C 3:1 3000 PSI D 3:1 3300 PSI E 3:1 3500 PSI F 5:1 3500 PSI 2400 psi 165.5 bar FUNCTION PUMP 6 TANK 7 T2 7 185 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 8 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 T TRACTION MANIFOLD Part No. 102521 S-40 • S-45 6 - 143 October 2013 Section 6 • Schematics 2WD Non-Oscillating Hydraulic Schematic S-45 Models (before serial number 7569) 6 - 143 6 - 144 Section 6 • Schematics October 2013 4WD Oscillating Hydraulic Schematic S-40 Models (before serial number 7569) 6 - 146 6 - 145 October 2013 Section 6 • Schematics 4WD Oscillating Hydraulic Schematic S-40 Models (before serial number 7569) A B C D E F G H EXTEND RETRACT CYL 1 4 gpm 15.1 L/min 50 psi 3.4 bar BRAKE MANIFOLD .025 DB I 2 gpm 7.6 L/min MEDIUM PRESSURE FILTER J TURNTABLE ROTATE A K F F 3 gpm 11.4 L/min A T2 M N PLATFORM LEVEL CYLINDERS SLAVE PRIMARY LIFT CYLINDER L CA D CP DA C 2 C C B MASTER TEST BRAKE .030 CB D S1 A V2 B M TEST 1.7 AUXILIARY PUMP 315 psi 21.7 bar AUX HYDRAULIC COOLER OPTION PTEST AP FUNCTION MANIFOLD AO PL1 SW1 SW2 P1 BG P2 2200 psi 151.7 bar AL BH AE AU AS AG 4.5 gpm 17 L/min AR FUNCTION PUMP 2 AM AC AA 0.6 gpm 2.27 L/min AF BB A AH BD 7 RATIO BF 3625 psi 249.9 bar 9 COUNTERBALANCE VALVE AB BA AK AW 0.6 gpm 2 L/min AN RETURN FILTER DRIVE PUMP AQ 25 psi 1.7 bar 4 2600 psi 179.3 bar TANK 3 psi 0.2 bar 0.1 gpm 0.38 L/min AT 2000 PSI 3:1 3:1 3000 PSI D 3:1 3300 PSI E 3:1 3500 PSI F 5:1 3500 PSI G 1.5:1 3000 PSI AUX ST1 BI ST2 LS TEST FUNCTION MANIFOLD RESERVOIR T1 5 PRESS x 8 6 3 2 1 7 4 5 7 4 5 OPTIONAL GENERATOR MANIFOLD 2400 psi 165.5 bar HYDRAULIC ROTARY COUPLER x 8A 6 x 8B x x 8C 6B x 6C 6A 3 1 2A 2C 2B FUNCTION PUMP HF REAR LEFT 7 TEST A TANK 2 T2 M4 FRONT LEFT M5 FRR M2 HH 210 psi 14.5 bar RIGHT HE FRB FLB STEERING TO HYD ROTARY COUPLER LEFT HA TEST .052 HC HG 50% .070 HD HI IN 50% 950 psi 65.5 bar FRONT RIGHT T1 RIGHT LEFT OSCILLATE VALVE M6 M1 B A OUT M8 M3 G TRACTION MANIFOLD OPTIONAL GENERATOR FLR 50% 67% 33% .070 REAR RIGHT 7 B M7 50% 6 - 146 1000 PSI B 3 psi 0.2 bar T2 8 3:1 C AJ BG 2.0 gpm 7.6 L/min PRESS AY AX PRESS E PLATFORM ROTATE PR2 PR1 E AD AV AZ PL2 BE E AI 1950 psi 134.4 bar T1 3 RET EXT V1 T OSCILLATE CYLINDERS S-40 • S-45 Part No. 102521 G Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. October 2013 Section 6 • Schematics 4WD Oscillating Hydraulic Schematic S-45 Models (before serial number 7569) N M L K J I H G F 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 E A D F F B 1 C J2 3 gpm 11.4 L/min A T2 A S45 JIB BOOM PLATFORM LEVEL CYLINDERS SLAVE PRIMARY LIFT CYLINDER C V1 J1 CP C DA C C C B TEST BRAKE 2 CC MASTER V2 .030 CA PR1 D S1 A 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 2 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 3 AH AN DRIVE PUMP D PLATFORM ROTATE AY AX AU AS 7 CB AB BH PRESS 9 JIB SELECT MANIFOLD BF 3625 psi 249.9 bar E PR2 PR2 PR1 E AV AZ PL2 BE E AI AL 1950 psi 134.5 bar T1 V1 LS TEST RESERVOIR A 3:1 1000 PSI B 3:1 2000 PSI C 3:1 3000 PSI D 3:1 3300 PSI E 3:1 3500 PSI F 5:1 3500 PSI G 1.5:1 3000 PSI 4 5 AUX x 8 6 3 2 1 7 4 5 7 4 5 FUNCTION MANIFOLD HYDRAULIC ROTARY COUPLER x 8A x 8B x x 8C 6B x 6C 6A HF REAR LEFT TEST 3 1 A B T1 2C 2B 2400 psi 165.5 bar M4 FRONT LEFT 210 psi 14.5 bar RIGHT HE FRB FLB STEERING 7 FLR 67% 33% 7 TANK 2 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 G G TRACTION MANIFOLD FUNCTION PUMP LEFT 50% .070 HC FRR M2 HH 50% 6 PRESS OPTIONAL GENERATOR MANIFOLD M7 M5 REAR RIGHT 2A TO HYD ROTARY COUPLER 8 Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. T OSCILLATE CYLINDERS Part No. 102521 S-40 • S-45 6 - 147 October 2013 Section 6 • Schematics 4WD Oscillating Hydraulic Schematic S-45 Models (before serial number 7569) 6 - 147 6 - 148 Section 6 • Schematics October 2013 2WD Hydraulic Schematic (from serial number 7569) 6 - 150 6 - 149 October 2013 Section 6 • Schematics 2WD Hydraulic Schematic (from serial number 7569) A B C D E F G H I J K L M 1 N .030 orifice added after serial number 8445 removed at serial number 16791 EXTEND RETRACT CYLINDER (4 gpm / 15.1 L/min) 50 psi 3.5 bar BRAKE/2 SPEED MANIFOLD EA 025. 2 TURNTABLE ROTATE (2 gpm / 7.5 L/min) MEDIUM PRESSURE FILTER A V1 0.030 J1 C B C C C MASTER EC CC .030 TEST BRAKE 2SPEED V2 S1 A M 1.7 AUXILIARY PUMP B V2 AUX HYDRAULIC COOLER OPTION TEST 3 A C J2 F T2 CP ED EB F PRIMARY LIFT CYLINDER (3 gpm / 11.3 L/min) S45 JIB BOOM PLATFORM LEVEL CYLINDERS SLAVE 315 psi 21.7 bar PTEST AP SW1 SW2 RET EXT FUNCTION MANIFOLD AO BC P2 P1 2200 psi 151.6 bar 1950 psi 134.5 bar T1 PRESS AE AU AS 2 4.5 gpm 17 L/m FUNCTION PUMP DRIVE PUMP AQ X 25 psi 1.7 bar X BB COUNTERBALANCE VALVE AA 0.8 gpm 3 L/min (S-45) 0.6 gpm 2.2 L/min AK AF AM AW 0.6 gpm 2 L/min (S-40) 5 RETURN FILTER AJ 0.1 gpm 0.3 L/min 2600 psi 179 bar (S-40) T2 RATIO 3:1 3:1 3:1 3:1 3:1 5:1 1.5:1 A B Valve BD changed to 0.2 gpm at serial number 16791 BG 2.0 gpm 7.5 L/m AT 2900 psi 200 bar (S-45) TANK 3 psi 0.20 bar 3 psi 0.20 bar D PLATFORM ROTATE AN 4 CB AC BD 7 JIB SELECT MANIFOLD AH AG AR 9 AB BF 3625 psi 249.9 bar E L PR2 BH BA AY AX AZ PR2 PR1 E AD AI AV R BE E AL ST1 ST2 D CA PR1 PL2 PL1 V1 BI C Valve AA changed to 0.4 gpm at serial number 16791 S45 valve AA changed to 0.6 gpm at serial number 18302 D E F G PRESS 1000 PSI 2000 PSI 3000 PSI 3300 PSI 3500 PSI 3500 PSI 3000 PSI LS TEST RESERVOIR AUX HYDRAULIC GENERATOR OPTION to serial number 16452 FUNCTION MANIFOLD T1 FUNCTION PUMP PRESS 8 6 3 1 7 2 4 5 HYDRAULIC ROTARY COUPLER 6 X 8C X X 8B 6B 6C 6A X 1 TEST A B 2A X OPTIONAL GENERATOR MANIFOLD 2C 2B 7 4 5 HYDRAULIC GENERATOR OPTION 2400 psi 165.4 bar RELIEF VALVE SET @ 2700 PSI 2400 psi 165.4 bar PORT ON SIDE OF MOTOR TO OC 3 8A MTE HYDRAULIC GENERATOR OPTION from serial number 16453 F 7 RIGHT REAR FRR M4 A B RIGHT GC M2 STEERING 7 2 FLR LEFT OPTIONAL GENERATOR CD (PORT ON TOP OF MOTOR) B A IN OUT GB 50% 950 psi 65.5 bar GD LEFT RIGHT T M3 TRACTION MANIFOLD OSCILLATE VALVE G OSCILLATE CYLINDERS OPTION 6 - 150 S-40 • S-45 Part No. 102521 T PMP FUNCTION MANIFOLD A B TO HYD ROTARY COUPLER TEST 280 psi 19.3 bar .070 LEFT REAR P T2 GA GF M1 CDL FLB TANK GE CDR 50% 8 FRB FUNCTION PUMP OSCILLATE CYLINDERS G Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. TO OC OIL COOLER October 2013 Section 6 • Schematics 4WD Hydraulic Schematic (from serial number 7569) N M L K J I H G F E D C B A .030 orifice added after serial number 8445 removed at serial number 16791 BRAKE/2 SPEED MANIFOLD EXTEND RETRACT CYLINDER (4 gpm / 15.1 L/min) MEDIUM PRESSURE FILTER 50 psi 3.5 bar A F PRIMARY LIFT CYLINDER (3 gpm / 11.3 L/min) A PLATFORM LEVEL CYLINDERS SLAVE C J2 F V1 T2 CP ED 0.030 2 J1 C EB S45 JIB BOOM TURNTABLE ROTATE (2 gpm / 7.5 L/min) EA .025 EC C B C C MASTER TEST CC BRAKE 2SPEED V2 S1 A M 1.7 B TEST AUXILIARY PUMP AUX HYDRAULIC COOLER OPTION 315 psi 21.7 bar V1 V2 AO RET EXT PTEST AP PL1 SW1 SW2 BC P2 2200 psi E 151.6 bar P1 FUNCTION MANIFOLD T1 1950 psi 134.5 bar PR1 AZ AB BA 4.5 gpm 17 L/min FUNCTION PUMP AM AA 0.6 gpm 2.2 L/min AK AF BB 0.8 gpm 3 L/min (S-45) AW 0.6 gpm 2 L/min (S-40) COUNTERBALANCE VALVE RATIO 3:1 3:1 3:1 3:1 3:1 5:1 1.5:1 AN DRIVE PUMP X 25 psi 1.7 bar X AT 2900 psi 200 bar (S-45) TANK 3 psi 0.20 bar 3 psi 0.20 bar BG 2.0 gpm 7.5 L/min AQ A Valve BD changed to 0.2 gpm at serial number 16791 AJ Valve AA changed to 0.4 gpm at serial number 16791 S45 valve AA changed to 0.6 gpm at serial number 18302 0.1 gpm 0.3 L/min 2600 psi 179 bar (S-40) B C D E RETURN FILTER F ST1 T2 ST2 G BI LS TEST PRESS 1000 PSI 2000 PSI 3000 PSI 3300 PSI 3500 PSI 3500 PSI 3000 PSI 4 5 RESERVOIR AUX HYDRAULIC GENERATOR OPTION to serial number 16452 FUNCTION MANIFOLD 8 3 1 2 7 4 FUNCTION PUMP 5 HYDRAULIC ROTARY COUPLER 8B 6B 6C 6A 3 8A 1 2A 2C OPTIONAL GENERATOR MANIFOLD 2B 4 7 5 MTE HYDRAULIC GENERATOR OPTION from serial number 16453 T1 PRESS 6 HYDRAULIC GENERATOR OPTION 2400 psi 165.4 bar PORT ON SIDE OF MOTOR F TEST A RIGHT REAR JD M7 B JC M6 JA 280 psi 19.3 bar JH LEFT 7 P T2 OPTIONAL GENERATOR JI JN JK 50% 50% .040 JG CD (PORT ON TOP OF MOTOR) B A IN OUT JM 50% 950 psi 65.5 bar M4 JF JJ M2 A RIGHT LEFT OSCILLATE VALVE LEFT FRONT T PMP FUNCTION MANIFOLD B B TRACTION MANIFOLD TO HYD ROTARY COUPLER TEST .040 JE JB 50% M1 2 B 50% .040 A 7 FLR JL M5 50% LEFT REAR FLB TANK STEERING CDR M3 CDL FRB RIGHT A A B FRR RIGHT FRONT M8 6 TO OC RELIEF VALVE SET @ 2700 PSI 2400 psi 165.4 bar FUNCTION PUMP 3 D PLATFORM ROTATE AC BD 2 CB AH AG AR 7 JIB SELECT MANIFOLD BF AE AS 9 L PR2 BH AD AU 3625 psi 249.9 bar E PR2 AY AX D R BE E AI AV CA PR1 PL2 AL PRESS 8C 1 G T G TO OC OIL COOLER 8 Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. OSCILLATE CYLINDERS OPTION OSCILLATE CYLINDERS Part No. 102521 S-40 • S-45 6 - 151 October 2013 Section 6 • Schematics 4WD Hydraulic Schematic (from serial number 7569) 6 - 151 6 - 152 October 2013 Section 6 • Schematics Generator Hydraulic Schematic- Welder Option I H G F E D C B A 1 HYDRAULIC WELDER OPTION 2 B DRIVE PUMP 3.5 GPM OIL COOLER A 3 PMP A CLR PMP B WELDER MANIFOLD AJ AK AL 4 NO PRESS SW 200 PSI AM Ø.031 AN AI 270 PSI @ 3.5 GPM G2 5 AH G1 MTR A MTR B 3 6 TANK 21CC G2 1 J HYDRAULIC ROTARY COUPLER K 3 L 1 M 21 GPM N 7 G1 12.5 KW GENERATOR 8 Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. Part No. 102521 S-40 • S-45 6 - 153 October 2013 Section 6 • Schematics Generator Hydraulic Schematic- Welder Option 6 - 153 6 - 154 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. Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. 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