102521 rev c - manuals - genie liftmanuals.gogenielift.com/parts and service...

Service Manual

Part No. 102521

Rev E

October 2013

Serial Number Range

from S40-7001 toS4012-17231S-40

S-45

TM

TM

S-40 • S-45 Part No. 102521

October 2013

ii

Introduction

Serial Number Information

Genie offers the following Service Manuals forthese models:

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

Copyright © 2011 by Terex Industries

102521 Rev E October 2013Fourth Edition, Fifth Printing

"Genie" and "S" are registered trademarks ofTerex South Dakota, Inc. in the USA and manyother countries.

Printed on recycled paper Printed in U.S.A.

Important

Read, understand and obey the safety rules andoperating instructions in the appropriate operator'smanual on your machine before attempting anymaintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine owner anduser. It also provides troubleshooting fault codesand repair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skills arerequired to perform most procedures. However,several procedures require specialized skills, tools,lifting equipment and a suitable workshop. In theseinstances, we strongly recommend thatmaintenance and repair be performed at anauthorized Genie dealer service center.

Compliance

Machine ClassificationGroup B/Type 3 as defined by ISO 16368

Machine Design LifeUnrestricted with proper operation, inspection andscheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest degreeof accuracy possible. However, continuousimprovement of our products is a Genie policy.Therefore, product specifications are subject tochange without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.

Contact Us:

http://www.genielift.come-mail: [email protected]

Part No. 102521 S-40 • S-45

October 2013

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

D1 10/1012 2 - Spec. 2-1, 2-2

3 - Maint. 3-9, 3-33 to 3-34

4 - Repair 4-59 to 4-60

D2 10/2013 4- Repair 4-3

6 - Schem. 6-19, 6-29, 6-33, 6-93

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 #.

Electronic Version

Click on any procedure or page numberhighlighted in blue to view the update.

Revision History

S-40 • S-45 Part No. 102521

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 #.

Electronic Version

Click on any procedure or page numberhighlighted in blue to view the update.

Part No. 102521 S-40 • S-45

October 2013

S40 06 - 12345

Model

Model year

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5

CAN B.354.4

Model: S-40

Serial number: S4006-12345

Electrical schematic number: ES0274

Machine unladen weight:

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : 150 lb / 670 N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 01/05/062006

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 60 ft 6 in/ 18.3 m

Maximum platform reach : 34 ft 3 in/ 10.4 m

Sequence number(stamped on chassis)

Serial label(located under cover)

iii

Section 1 • Safety Rules

Serial Number Legend

S-40 • S-45 Part No. 102521

July 2007

iv

This page intentionally left blank.

Section 1 • Safety Rules

Part No. 102521 S-40 • S-45

July 2007 Section 1 • Safety Rules

Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie S-40 and S-45Operator's Manual will result in death or seriousinjury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance on this machine.

You read, understand and obey:- manufacturer’s instructions and safety rules- employer’s safety rules and worksiteregulations- applicable governmental regulations

You have the appropriate tools, lifting equipmentand a suitable workshop.

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S-40 • S-45 Part No. 102521

July 2007

vi

SAFETY RULES

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machine usesignal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free

of debris that could get into machine componentsand cause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work areais properly ventilated and well lit.

Section 1 • Safety Rules July 2007

Part No. 102521 S-40 • S-45

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

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

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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

Part No. 102521 S-40 • S-45

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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

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


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S-40 • S-45 Part No. 102521

October 2013

TABLE OF CONTENTS



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

Section 4 Rev 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

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

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Part No. 102521 S-40 • S-45

October 2013

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

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S-40 • S-45 Part No. 102521

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

Platform Control Box Wiring DiagramDeutz F3L-1011F Models ........................................................................... 6 - 14

Platform Control Box Switch Panel Wiring DiagramDeutz F3L-1011F Models ........................................................................... 6 - 15

Electrical Schematic, Perkins 704-30 Models(before serial number 7472) ........................................................................ 6 - 18

Ground Control Box Wiring DiagramPerkins 704-30 Models ............................................................................... 6 - 21

Platform Control Box Wiring DiagramPerkins 704-30 Models ............................................................................... 6 - 24

Platform Control Box Switch Panel Wiring DiagramPerkins 704-30 Models ............................................................................... 6 - 25

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Part No. 102521 S-40 • S-45

October 2013

xiii

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 ModelsPerkins 404-22 Models (from serial number 12510 to 14831) ...................... 6 - 32

Electrical Schematic,Deutz F3L-2011/Deutz D2011L03i ModelsPerkins 404-22 Models (from serial number 14832 to 15662) ...................... 6 - 36

Electrical Schematic,Deutz F3L-2011/Deutz D2011L03i Models - ANSI / CSA / ASPerkins 404-22 Models (from serial number 15663 to 16419) ...................... 6 - 40

Electrical Schematic,Deutz F3L-2011/Deutz D2011L03i Models - CEPerkins 404-22 Models (from serial number 15663 to 16419) ...................... 6 - 44

Electrical Schematic,Deutz F3L-2011/Deutz D2011L03i Models - ANSI / CSA / ASPerkins 404-22 Models (from serial number 16420) .................................... 6 - 48

Electrical Schematic,Deutz F3L-2011/Deutz D2011L03i Models - CEPerkins 404-22 Models (from serial number 16420) .................................... 6 - 52

Ground Control Box Wiring Diagram,Deutz F3L-2011/Deutz D2011L03i ModelsPerkins 404-22 Models (before serial number 14832) ................................. 6 - 56

Ground Control Box Wiring Diagram,Deutz F3L-2011/Deutz D2011L03i ModelsPerkins 404-22 Models (from serial number 14832) .................................... 6 - 57

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S-40 • S-45 Part No. 102521

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Platform Control Box Wiring DiagramDeutz F3L-2011/Deutz D2011L03i ModelsPerkins 404-22 Models (before serial number 14832) ................................. 6 - 60

Platform Control Box Wiring DiagramDeutz F3L-2011/Deutz D2011L03i ModelsPerkins 404-22 Models (from serial number 14832) .................................... 6 - 61

Platform Control Box Switch Panel Wiring DiagramDeutz 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 DiagramDeutz F3L-2011/Deutz D2011L03i ModelsPerkins 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 DiagramFord LRG-425 EFI Models (before serial number 7597) .............................. 6 - 74

Platform Control Box Switch Panel Wiring DiagramFord 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 DiagramFord LRG-425 EFI Models(from serial number 7597 to 11066) ............................................................ 6 - 84

TABLE OF CONTENTS

Part No. 102521 S-40 • S-45

October 2013


Platform Control Box Switch Panel Wiring DiagramFord 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 - 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 DiagramFord DSG-423 EFI Models (before serial number 14832) ...........................6 - 120

Platform Control Box Wiring DiagramFord 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 DiagramFord DSG-423 EFI Models (from serial number 12510)..............................6 - 125

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S-40 • S-45 Part No. 102521

October 2013

TABLE OF CONTENTS


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

Part No. 102521 S-40 • S-45 2 - 1

Section 2 • SpecificationsOctober 2013

Specifications

Machine SpecificationsS-40 and S-45 Models

Tires and wheels

Tire size, 2WDfront tires only 12.5L-16SLrear tires only 12-16.5 NHS

Tire size,2WDRT & 4WD front & rear 12-16.5 NHS

Tire weight, new foam-filled (minimum) 300 lbs(Rough terrain) 136 kg

Tire ply rating 12 8

Tire contact area 88 sq in 57 sq in568 sq cm 368 sq cm

Overall tire diameter 33.7 in 33.2 in85.6 cm 84.3 cm

Tire pressure 45 psi 45 psi(Rough terrain) 3.1 bar 3.1 bar

Tire pressure 60 psi 60 psi(Rough terrain) 4.1 bar 4.1 bar

Wheel diameter 16 in 161/2 in40.6 cm 41.9 cm

Wheel width 10 in 9 3/4 in25.4 cm 24.8 cm

Wheel lugs 8@ 5/8 -18 9@ 5/8 -18

Lug nut torque - Drive and 9-bolt non-drive hubs

Lug nut, dry 230 ft-lbs312 Nm

Lug nut, lubricated 170 ft-lbs230 Nm

Lug nut torque - 8-bolt non-drive spindles



Track Components, TRAX option

Track material Rubber

Weight, assembly (each) 480 lbs218 kg

Fluid capacities

Fuel tank 20 gallons75.7 liters

Fuel tank, Option 30 gallons114 liters

LPG tank 33.5 pounds15.2 kg

Hydraulic tank 45 gallons170 liters

Hydraulic system 55 gallons(including tank) 208 liters

Drive hub 17 fl oz(before serial number 7569) 0.5 liters

Drive hub 24 fl oz(from serial number 7569 to 15677) 0.71 liters

Drive hub 20 fl oz(from serial number 15678) 0.6 liters

Turntable rotation 8 fl ozdrive hub 0.24 liters

Drive hub oil type:SAE 90 multipurpose hypoid gear oil API serviceclassification GL5

For operational specifications, refer to theOperator's Manual.

Continuous improvement of our products is a Geniepolicy. Product specifications are subject to changewithout notice.

2 - 2 S-40 • S-45 Part No. 102521

Section 2 • Specifications October 2013

SPECIFICATIONS

Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.

Performance SpecificationsAll Models

Drive speeds, 2WD and 4WD

Drive speed, stowed 40 ft / 5.2 - 5.9 sec12.2 m / 5.2 - 5.9 sec

Drive speed, raised or extended 40 ft / 40 - 45 sec12.2 m / 40 - 45 sec

Drive speed, TRAX option

Drive speed, stowed 40 ft / 11 sec12.2 m / 11 sec

Drive speed, raised or extended 40 ft / 40 sec12.2 m / 40 sec

Gradeability See Operator's Manual

Boom function speeds, maximumfrom platform controls

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

Platform level (10° range of motion)ANSI 3 to 5 secondsCE/Austrailia 20 to 22 seconds

Jib boom up, S-45 models 35 to 45 seconds

Jib boom down, S-45 models 20 to 30 seconds

Braking distance, maximum

High range on paved surface 3 to 4 ft0.9 to 1.2 m

Hydraulic Oil Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rando HD MV equivalentViscosity grade Multi-viscosityViscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rando HD MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Environ MV46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus S2 V 32Shell Tellus S2 V 46Chevron Aviation A

Eni Arnica 32

Part No. 102521 S-40 • S-45 2 - 3


Hydraulic ComponentSpecifications

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 0 to 28 gpm106 L/min

Drive pressure, maximum 3625 psi250 bar

Charge pump

Type: gerotor pump

Displacement 0.85 cu in13.9 cc

Flow rate @ 2500 rpm 9 gpm34.1 L/min

Charge pressure @ 2500 rpm 310 psiNeutral position 21.4 bar

Function pump

Type gear, pressure balanced

Displacement 1.04 cu in17 cc

Flow rate @ 2500 rpm 10.69 gpm40.5 L/min

Oscillation pump

Type gear, fixed displacement

Displacement 0.37 cu in6 cc

Flow rate @ 2500 rpm 2.8 gallons per minute10.6 liters per minute

Continued use of Chevron AviationA hydraulic oil when ambienttemperatures are consistentlyabove 32°F / 0°C may result incomponent damage.

Note: Use Chevron Aviation A hydraulic oil whenambient temperatures are consistentlybelow 0°F / -18°C.

Note: Use Shell Tellus S2 V 46 hydraulic oil whenoil temperatures consistently exceed 205°F / 96°C.

Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.

SPECIFICATIONS


2 - 4 S-40 • S-45 Part No. 102521


SPECIFICATIONS

Steer-end drive motors, 4WD(before serial number 7569)

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)

Displacement per revolution 0.99 cu in / 16.3 cclow speed

Displacement per revolution 1.83 cu in / 30 cchigh speed

Hydraulic Filters

Medium pressure filter Beta 3 ≥ 200

Medium pressure filter 51 psibypass pressure 3.5 bar

Hydraulic tank circuit 10 micron withreturn line filter 25 psi / 1.7 bar bypass

Auxiliary pump

Type: fixed displacement gear pump

Displacement - static 0.151 cu in2.47 cc

Displacement 1.75 gallons per minute6.62 liters per minute

Function manifold

Function relief valve pressureS-40 2600 psi / 179 barS-45 2900 psi / 200 bar

Boom down 2200 psirelief valve pressure 152 bar

Boom extend 1950 psi134 bar

Oscillate axle 950 psi66 bar

Steer regulator, 2 gallons per minuteAll models 7.6 liters per minute

Traction manifold, 2WD and 4WD(before serial number 7569)

Hot oil relief pressure 210 psi14.5 bar

Traction manifold, 2WD and 4WD(after serial number 7568)

Hot oil relief pressure 280 psi19.3 bar


Part No. 102521 S-40 • S-45 2 - 5



Manifold ComponentSpecifications

Plug torque

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




SPECIFICATIONS

Valve Coil ResistanceSpecificationsNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / 20°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Description Specification

Solenoid valve, 2 position 3 way, 10V DC 6.3 Ω(schematic items AC and AE)

Solenoid valve, 3 position 4 way, 10V DC 6.3 Ω(schematic item AT and AZ)

Solenoid valve, 2 position 3 way, 10V DC 6.3 Ω(schematic items AU, AV, AX, and AY)

Solenoid valve, 3 position 4 way, 10V DC 6.3 Ω(schematic items AZ and BF)

Proportional solenoid valve, 12V DC 9 Ω(schematic items AW and BB)

Solenoid valve, 2 position 3 way, 10V DC 6.8 Ω(schematic item CC)

Solenoid valve, 2 position 3 way, 10V DC 3.3 Ω(schematic items DA)

Solenoid valve, 2 position 3 way, 12V DC 4.8 Ω(schematic items CE)

2 - 6 S-40 • S-45 Part No. 102521


SPECIFICATIONS

Ford LRG-425 EFI Engine

Displacement 153 cu in2.5 liters

Number of cylinders 4

Bore & stroke 3.78 x 3.4 in96.01 x 86.36 mm

HorsepowerGross intermittent 70 @ 2500 rpmContinuous 60 @ 2500 rpmGross intermittent 52 kW @ 2500 rpmContinuous 44.7 kW @ 2500 rpm

Firing order 1 - 3 - 4 - 2

Low idle rpm 1600 rpmFrequency 396.8 Hz

High idle rpm 2500 rpmFrequency 620 Hz

Compression ratio 9.4:1

Compression pressure (approx.)Pressure (psi) of lowest cylinder must beat least 75% of highest cylinder

Valve clearances - 0.035 to 0.055 incollapsed tappet 0.889 to 1.397 mm

Lubrication system

Oil pressure 40 to 60 psi(operating temp. @ 2000 rpm) 2.75 to 4.1 bar

Oil capacity 4.5 quarts(including filter) 4.3 liters

Oil viscosity requirements

Unit ships with 5W-30 oil.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theengine Operator's Manual on your machine.

Oil pressure switch specifications

Torque 8-18 ft-lbs11-24 Nm

Oil pressure switch point 3-5 psi0.21-0.34 bar

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Current draw, maximum load 800A

Current draw, no load 70A

Battery

Type 12V DC, Group 31

Quantity 1

Cold cranking ampere 1000A

Reserve capacity @ 25A rate 200 minutes

Electronic fuel pump

Fuel pressure, static 64 psi4.4 bar

Fuel flow rate 0.58 gpm2.18 L/min

Ignition System

Spark plug type Motorcraft AWSF-52-C(before serial number 4546)

Spark plug type Motorcraft AGSF-32-FM(after serial number 4545)

Spark plug gap 0.042 to 0.046 inches1.07 to 1.17 mm

Spark plug torque 5-10 ft-lbs7-14 Nm

Engine coolant

Capacity 11.5 quarts10.9 liters

Coolant temperature switch


Temperature switch point 230° F112° C

Alternator

Part No. 102521 S-40 • S-45 2 - 7


Ford DSG-423 EFI Engine

Displacement 140.4 cu in2.3 liters


Bore & stroke 3.44 x 3.7 inches87.5 x 94 mm

HorsepowerContinuous horsepower 59 @ 2500 rpmPeak horsepower 69 @ 2500 rpmContinuous horsepower 44 kW @ 2500 rpmPeak horsepower 51 kW @ 2500 rpm


Low function idle (computer controlled) 1600 rpmFrequency 53.3 Hz

High function idle (computer controlled) 2500 rpmFrequency 83.3 Hz


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

Lubrication system

Oil pressure 29 to 39 psi(at operating temperature @ 2500 rpm) 2 to 2.7 bar

Oil capacity 4 quarts(including filter) 3.8 liters


Unit ships with 5-W20 oil.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theengine Operator's Manual on your machine.

Electronic fuel pump

Fuel pressure, static 64 psi4.4 bar

Fuel flow rate 0.43 gpm1.6 L/min

Fuel requirement

For fuel requirements, refer to the engine Operator'sManual on your machine.

Ignition system

Spark plug type Motorcraft AGSF-32-FEC

Spark plug gap 0.049 to 0.053 inches1.244 to 1.346 mm

Engine coolant

Capacity 10 quarts9.5 liters

Cylinder head temperature sending unit

Fault code set temperature 280°F138°C

Engine shut-down temperature 300°F149°C

Starter motor

Normal engine cranking speed 200 to 250 rpm


Current draw, maximum load 800A

Alternator

Output 95A, 13.8V DC

Battery

Type 12V DC, Group 31

Quantity 1

Cold cranking ampere @ 0°F 1000A



SPECIFICATIONS

2 - 8 S-40 • S-45 Part No. 102521


SPECIFICATIONS

Injection system

Injection pump make OMAP

Injection pump pressure 4351 psi300 bar

Injector opening pressure 3626 psi250 bar

Fuel requirement

For fuel requirement, refer to the engine Operator'sManual on your machine.

Alternator output 55A, 14V

Starter motor

Current draw, no load 90A

Brush length, new 0.7480 in19 mm

Brush length, minimum 0.5 in12.7 mm

Battery

Type 12V, Group 31

Quantity 1



Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Deutz F3L-1011F Engine



Bore and stroke 3.58 x 4.13 inches91 x 105 mm

Horsepower 36 @ 3000 rpm26.8 kW @ 3000 rpm

Firing order 1 - 2 - 3


Compression pressure 362 to 435 psi25 to 30 bar

Low idle rpm 1500 rpmFrequency 313 Hz

High idle rpm 2300 rpmFrequency 479.9 Hz

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in0.3 mm

Exhaust 0.020 in0.5 mm

Lubrication system

Oil pressure 26 to 87 psi1.8 to 6.0 bar

Oil capacity 8.5 quarts(including filter) 8 liters


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 ofalternative engine oils. For oil requirements, refer to theengine Operator's Manual on your machine. Continuous improvement of our products is a

Genie policy. Product specifications are subjectto change without notice.

Part No. 102521 S-40 • S-45 2 - 9


SPECIFICATIONS

Deutz F3L-2011 EngineDeutz D2011L03i Engine




Horsepower

Net intermittent 48.7 @ 2800 rpmNet continuous 46.2 @ 2800 rpmNet intermittent 36 kW @ 2800 rpmNet continuous 34.5 kW @ 2800 rpm

Firing order 1 - 2 - 3

Low idle rpm 1500 rpmFrequency 313 Hz


Compression ratio 19:1

Compression pressure 362 to 435 psi25 to 30 bar





Lubrication system

Oil pressure, hot @ 2000 rpm 40-60 psi2.8 to 4.1 bar

Oil capacity 8.5 quarts(including filter) 8 liters(Deutz F3L2011 Engine)

Oil capacity 9.5 quarts(including filter) 9 liters(Deutz D2011L03i Engine)



Oil temperature switch


Temperature switch point 220° F104° C

Oil pressure switch


Oil pressure switch point 7 psi(Deutz F3L2011 Engine) .5 bar

Oil pressure switch point 22 psi(Deutz D2011L03i Engine) 1.5 bar

2 - 10 S-40 • S-45 Part No. 102521


Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum 15000 psi1034 bar

Injector opening pressure 3046 psi210 bar

Fuel requirement


Starter motor


Brush length, new 0.72 in18.5 mm

Brush length, minimum 0.27 in7 mm

Battery

Type 12V, Group 31

Quantity 1



Alternator output 60A @ 14V DC

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

SPECIFICATIONS

Part No. 102521 S-40 • S-45 2 - 11


SPECIFICATIONS

Perkins 704-30 Engine




Horsepower 63 @ 2600 rpm47 kW @ 2600 rpm



Compression pressure 300 to 500 psi20.7 to 34.5 bar

Pressure (psi) of lowest cylinder must be within50 psi (3.45 bar) of highest cylinder







Lubrication system

Oil pressure 41 psi(at 2600 rpm) 2.8 bar

Oil capacity 7.3 quarts(including filter) 8.3 liters


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 classificationCC/SE. API classification CD/SE or CCMC D4 can beused, but is not recommended during the first 50 hoursnor for light load applications.

Injection system

Injection pump make Zexel PFR-KX

Injection pump pressure(stage one) 2755 psi 190 bar(stage two) 3336 psi 230 bar

Injector opening pressure 3626 psi 250 bar

Fuel requirement


Engine coolant

Capacity 111/2 quarts10.9 liters

Alternator output 65A, 12V

Battery

Type 12V, Group 31

Quantity 1



Fan belt deflection 3/8 in10 mm

2 - 12 S-40 • S-45 Part No. 102521


Perkins 404-22 Engine




Horsepower

gross intermittent 50 @ 2800 rpmcontinuous 41 @ 2800 rpmgross intermittent 37.3 kW @ 2800 rpmcontinuous 31 kW @ 2800 rpm



Low Idle rpm with generator option 1500 rpmFrequency 231.3 Hz



Compression pressure 426 psi29.4 bar

Pressure (psi) of lowest cylinder mustbe within 50 psi / 3.45 bar of highest cylinder





Lubrication system

Oil pressure, hot 40 to 60 psi(at 2000 rpm) 2.8 to 4.1 bar

Oil capacity 9.4 quarts to 11.2 quarts(including filter) 8.9 liters to 10.6 liters



Oil pressure sending unit


Oil pressure switch point 14.2 psi1 bar

Coolant temperature sending unit


Temperature switch point 221° F 105° C

Fuel injection system

Injection pump make Zexel

Injection pressure 2133 psi147 bar

Fuel requirement


Battery

Type 12V, Group 31

Quantity 1



Starter motor


Alternator output 65A @ 13.8V DC

Fan belt deflection 3/8 to ½ in9 to 12 mm

SPECIFICATIONS

Part No. 102521 S-40 • S-45 2 - 13


SPECIFICATIONS

Machine Torque Specifications

Platform rotator

1-8 center bolt, Gr 5, dry 640 ft-lbs868 Nm

1-8 center bolt, Gr 5, lubricated 480 ft-lbs651 Nm

3/8 -16 bolts, Gr 8, lubricated 35 ft-lbs**use blue thread-locking compound 47.5 Nm

Turntable rotator

Drive hub mounting bolts, dry 210 ft-lbs284 Nm

Drive hub mounting bolts, lubricated* 160 ft-lbs*use blue thread-locking compound 217 Nm

Drive motor and hubs

Drive hub mounting bolts, dry 210 ft-lbs284 Nm

Drive hub mounting bolts, lubricated 160 ft-lbs**use blue thread-locking compound 217 Nm

Drive motor mounting bolts, dry 49 ft-lbs66.4 Nm

Drive motor mounting bolts, lubricated 37 ft-lbs50 Nm

Turntable bearing

Turntable bearing mounting bolts, lubricated 180 ft-lbs244 Nm

TRAX Torque Specifications

Hub to drive sprocket fasteners



Idler and bogey wheel fasteners

3/4 -10 bolts, GR 8, dry 375 ft-lbs508 Nm

3/4 -10 bolts, GR 8, lubricated 281 ft-lbs381 N

2 - 14 S-40 • S-45 Part No. 102521


Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must be replacedanytime the seal has been broken. The O-ringcannot be re-used if the fitting or hose end hasbeen 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 areavailable in the O-ring field service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

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

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 15 ft-lbs / 20.3 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 100 ft-lbs / 135.6 Nm

-12 135 ft-lbs / 183 Nm

-16 200 ft-lbs / 271 Nm

-20 250 ft-lbs / 334 Nm

-24 305 ft-lbs / 414 Nm

Seal-Lok® Fittings (ORFS)(hose end)


-4 18 ft-lbs / 24.4 Nm

-6 30 ft-lbs / 40.7 Nm

-8 40 ft-lbs / 54.2 Nm

-10 60 ft-lbs / 81.3 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 149 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 244 Nm

SPECIFICATIONS

Part No. 102521 S-40 • S-45 2 - 15


SIZE THREAD

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm

18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5

DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8

LUBED

1/4

LUBED DRY LUBED DRY

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

5/16

3/8

7/16

1/2

Size

(mm)in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm

5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.610 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6

DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8

DRY

SPECIFICATIONS

10.9 12.98.84.6

Part No. 102521 S-40 • S-45 3 - 1

October 2013 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every 2 years as specified on theMaintenance Inspection Report. The frequencyand extent of periodic examinations and testsmay also depend on national regulations.

Failure to perform each procedureas presented and scheduled maycause death, serious injury orsubstantial damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine

Use only Genie approved replacement parts.

Machines that have been out of service for aperiod longer than three months must completethe quarterly inspection.

Unless otherwise specified, perform eachmaintenance procedure with the machine in thefollowing configuration:

• Machine parked on a firm, level surface

• Boom in the stowed position

• Turntable rotated with the boom betweenthe non-steer wheels

• Turntable secured with the turntablerotation lock

• Key switch in the off position with thekey removed

• Wheels chocked

• All external AC power supply disconnectedfrom the machine

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetyinformation and step-by-step instructions.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.


Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

3 - 2 S-40 • S-45 Part No. 102521

October 2013Section 3 • Scheduled Maintenance Procedures

Maintenance Symbols Legend

Note: The following symbols have been used inthis manual to help communicate the intent of theinstructions. When one or more of the symbolsappear at the beginning of a maintenanceprocedure, it conveys the meaning below.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold motor, pump orengine will be required to perform thisprocedure.

Indicates that a warm motor or pumpwill be required to perform thisprocedure.

Indicates that dealer service is requiredto perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

Make copies of the Pre-delivery PreparationReport to use for each inspection. Store completedforms as required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, every six months, annual andtwo years. The Scheduled MaintenanceProcedures Section and the MaintenanceInspection Report have been divided into fivesubsections—A, B, C, D and E. Use the followingchart to determine which group(s) of proceduresare required to perform a scheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six months or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two years or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Maintain completedforms for a minimum of 4 years or in compliancewith employer, jobsite and govermental regulationsand requirements.

SCHEDULED MAINTENANCE PROCEDURES

Terex South Dakota, Inc USA500 Oak Wood RoadPO Box 1150Watertown, SD 57201-6150(605) 882-4000Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc.133192 Rev D

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspectioncompleted

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completingthe Pre-operation Inspection, the Maintenance itemsand the Function Tests.

Use this form to record the results. Place a check inthe appropriate box after each part is completed.Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machinefrom service, repair and reinspect it. After repair, placea check in the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover ifanything is apparently wrong with a machine before it isput into service.

A damaged or modified machine must never be used.If damage or any variation from factory deliveredcondition is discovered, the machine must be taggedand removed from service.

Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications.

Scheduled maintenance inspections shall be performedby qualified service technicians, according to themanufacturer's specifications and the requirementslisted in the responsibilities manual.

3 - 4 S-40 • S-45 Part No. 102521



Part No. 102521 S-40 • S-45 3 - 5


Checklist A Y N R

A-1 Inspect the Decals

A-2 Pre-operationinspection

A-3 Functions tests

A-4 Engine maintenance -all models

A-5 Inspect tracks -TRAX option

Perform after 40 hours:

A-6 30 Day Service

Perform after first 50 hours:

A-7 Engine maintenance -Deutz and Ford models

A-8 Drive Hub Oil

Perform every 50 hours:

A-9 Engine maintenance-Perkins models


A-10 Fuel filter/waterseparator -Deutz models

A-11 Engine maintenance -Ford models

A-12 Rotation bearing

Perform after first 125 hours:

A-13 Engine maintenance -Deutz 1011F models


A-14 Engine maintenance -Ford models

Checklist B Y N R

B-1 Battery

B-2 Electrical wiring

B-3 Air filter element

B-4 Key switch

B-5 Engine maintenance -Deutz and Perkinsmodels

B-6 Exhaust system

B-7 Oil cooler and fins-Deutz models

B-8 Tires, wheels and lugnut torque

B-9 Drive hub maintenance

B-10 Brake configuration

B-11 Engine RPM

B-12 Engine idle select

B-13 Fuel select -Ford models

B-14 Ground control

B-15 Directionalvalve linkage

B-16 Platformself-leveling

B-17 Drive brakes

B-18 Drive speed -stowed position

B-19 Drive speed -raised position

B-20 Hydraulic oil analysis

B-21 Alarm package

B-22 Fuel and hydraulic capventing systems

B-23 Check track tension -TRAX option


B-24 Engine maintenance -Ford models

Maintenance Inspection Report

Instructions• Make copies of this report to use for

each inspection.

• Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

• Place a check in the appropriate boxafter each inspection procedure iscompleted.

• Use the step-by-step procedures inthis section to learn how to performthese inspections.

• If any inspection receives an “N”, tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Comments

3 - 6 S-40 • S-45 Part No. 102521


Checklist C Y N R

C-1 Engine maintenance -Deutz and Perkinsmodels

C-2 Platform overload(if equipped)

C-3 Platform overload(if equipped)

C-4 Air filter element -Deutz and Perkinsmodels

C-5 Fuel inline strainer -Deutz models


C-6 Engine maintenance -Ford models

Checklist D Y N R

D-1 Boom wear pads

D-2 Turntable bearing bolts

D-3 Free-wheelconfiguration

D-4 Drive hub oil

D-5 Engine maintenance-Deutz and Perkinsmodels

D-6 Hydraulic filters

D-7 Turntable bearing wear

MAINTENANCE INSPECTION REPORT

Checklist E Y N R

E-1 Hydraulic oil

E-2 Steer axlewheel bearings,2WD models


E-3 Engine maintenance -Deutz andPerkins models


E-4 Engine maintenance -Ford models




E-6 Engine maintenance -Deutz models



Perform every 12,000 hours:

E-8 Engine maintenance -Deutz models

Perform every 4 years:

E-9 Engine maintenance -Ford models

Comments

Instructions• Make copies of both pages to use for

each inspection.

• Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

• Place a check in the appropriate boxafter each inspection procedure iscompleted.

• Use the step-by-step procedures inthis section to learn how to performthese inspections.

• If any inspection receives an “N”, tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Part No. 102521 S-40 • S-45 3 - 7


Checklist A Procedures

A-1Inspect the Manuals and DecalsGenie specifications require that this procedure beperformed daily.

Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.

2 Examine the pages of each manual to be surethat they are legible and in good condition.

Result: The operator's manual is appropriate forthe machine and all manuals are legible and ingood condition.

Result: The operator's manual is notappropriate for the machine or all manuals arenot in good condition or is illegible. Remove themachine from service until the manual isreplaced.

3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.

Result: The machine is equipped with allrequired decals, and all decals are legible andin good condition.

Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.

4 Always return the manuals to the storagecontainer after use.

Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.

3 - 8 S-40 • S-45 Part No. 102521


CHECKLIST A PROCEDURES

A-4Perform Engine Maintenance

Engine specifications require that this procedure beperformed every 8 hours or daily, whichever comesfirst.

Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.

Deutz models

Required maintenance procedures and additionalengine information are available in the

Deutz 1011F Operation Manual(Deutz part number 0297 9683) or theDeutz 2011 Operation Manual(Deutz part number 0312 3547).

Deutz 1011F Operation ManualGenie part number 52883

Deutz 2011 Operation ManualGenie part number 139320

A-3Perform Function TestsGenie specifications require that this procedure beperformed daily.

Completing the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the Operator's Manual on yourmachine.

A-2Perform Pre-operation InspectionGenie specifications require that this procedure beperformed daily.

Completing a Pre-operation Inspection is essentialto safe machine operation. The Pre-operationInspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparentlywrong with a machine before the operator performsthe function tests. The Pre-operation Inspectionalso serves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the Operator's Manual on yourmachine.

Part No. 102521 S-40 • S-45 3 - 9


Perkins models

Required maintenance procedures and additionalengine information are available in thePerkins 404-22 Operation Manual(Perkins part number TPD 1443S).

Perkins 404-22 Operation ManualGenie part number 94890

Ford models

Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) or theFord DSG-423 EFI Operator Handbook(EDI part number 1060020) or theFord MSG-425 EFI Operator Handbook(Ford part number 1020010).

Ford LRG 425 EFI Operation ManualGenie part number 84792

Ford DSG 423 EFI Operator HandbookGenie part number 119488

Ford MSG-425 EFI Operator HandbookGenie part number 215322

To access the engine:

Remove the engine tray retaining fastenerslocated under the engine tray. Loosen the pivotfastener located at the platform end of theengine tray. Swing the engine tray out andaway from the machine and secure it frommoving.

Crushing hazard. Failure to securethe engine pivot plate from movingcould result in death or seriousinjury.


A-5Inspect the Track Components,TRAX option

Note: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.

Maintaining tracks and track assembly componentsis essential to safe operation and goodperformance. A track assembly failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired 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

• Bogey wheels

• Undercarriage

• Kingpin and steering linkage bushings

3 - 10 S-40 • S-45 Part No. 102521



A-7Perform Engine Maintenance -Deutz and Ford Models

Engine specifications require that this procedure beperformed after the first 50 hours of operation.


Deutz models

Required maintenance procedures and additionalengine information are available in the

Deutz 1011F Operation Manual(Deutz part number 0297 9683) or theDeutz 2011 Operation Manual(Deutz part number 0312 3547).



A-6Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage, whichevercomes first. After this interval, refer to themaintenance tables for continued scheduledmaintenance.

1 Perform the following maintenance procedures:

• A-10 Grease the Turntable Bearing andRotate Gear

• B-8 Inspect the Tires, Wheels and Lug NutTorque

• B-9 Check the Drive Hub Oil Level andFastener Torque

• D-2 Check the Turnable Rotation BearingBolts

• D-6 Replace the Hydraulic Filter Elements

Part No. 102521 S-40 • S-45 3 - 11


Ford models

Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) or theFord DSG-423 EFI Operator Handbook(EDI part number 1060020) or theFord MSG-425 EFI Operator Handbook(Ford part number 1020010).








A-8Replace the Drive Hub Oil

Manufacturer drive hub specifications require thatthis one-time procedure be performed after the first150 hours.

Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the torque hub oil after the first 50 hours ofuse may cause the machine to perform poorly andcontinued use may cause component damage.

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Refer to Section 2, Specifications.

5 Install the plugs. Use pipe thread sealant onunits with pipe plugs.

6 Repeat steps 1 through 5 for all the other drivehubs.

models with pipe plugs a drive hub plugs

a

3 - 12 S-40 • S-45 Part No. 102521



A-10Inspect the Fuel Filter/WaterSeparator - Deutz Models

Genie specifications require that this procedure beperformed every 100 hours or monthly, whichevercomes first.

Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and/or hardstarting, and continued use may result incomponent damge. Extremely dirty conditions mayrequire this procedure be performed more often.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Note: Perform this procedure with the engine off.

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

A-9Perform Engine Maintenance -Perkins Models

Engine specifications require that this procedure beperformed every 50 hours.


Perkins models






Part No. 102521 S-40 • S-45 3 - 13


A-11Perform Engine Maintenance -Ford Models



Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) or theFord DSG-423 EFI Operator Handbook(EDI part number 1060020) or theFord MSG-425 EFI Operator Handbook(Ford part number 1020010) .







a

b

a fuel filterb drain plug

2 Clean up any fuel that may have spilled.

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

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.


3 - 14 S-40 • S-45 Part No. 102521



A-13Perform Engine Maintenance -Deutz 1011F Models

Engine specifications require that this procedurebe performed after the first 125 hours.


Required maintenance procedures and additionalengine information are available in theDeutz 1011F Operation Manual(Deutz part number 0297 9683).



1 Remove the engine tray retaining fastenerslocated under the engine tray. Loosen the pivotfastener located at the platform end of theengine tray. Swing the engine tray out andaway from the machine and secure it frommoving.


A-12Grease the Turntable RotationBearing and Rotate Gear

Genie specifications require that this procedure beperformed every 100 hours of operation. Performthis procedure more often if dusty conditions exist.

Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Raise the boom enugh to access the turntablegearing.

2 Locate the grease fitting on the platform end ofthe engine side bulkhead.

3 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of4 to 5 inches / 10 to 13 cm at a time and repeatthis step until the entire bearing has beengreased.

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

Part No. 102521 S-40 • S-45 3 - 15


A-14Perform Engine Maintenance -Ford Models











3 - 16 S-40 • S-45 Part No. 102521


Checklist B Procedures

B-1Inspect the Battery

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions.

Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections arefree of corrosion.

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosionon the battery terminals and cables.

3 Be sure that the battery hold downs and cableconnections are tight.

4 Fully charge the batteries and allow the batteriesto rest at least 6 hours.

5 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

6 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjustedspecific gravity of 1.277 or higher. The batteryis fully charged. Proceed to step 11.

Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 8.

7 Perform an equalizing charge, OR fully chargethe batteries and allow the batteries to rest atleast 6 hours.

8 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

9 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specific gravityof 1.277 or greater. The battery is fully charged.Proceed to step 11.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.217. Replace the battery.

10 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.

11 Install the vent caps and neutralize anyelectrolyte that may have spilled with bakingsoda.

Part No. 102521 S-40 • S-45 3 - 17


CHECKLIST B PROCEDURES

B-2Inspect the Electrical Wiring


Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

1 Open the engine side turntable cover.

2 Remove the engine tray retaining fastenerslocated under the engine tray. Swing the enginetray out and away from the machine and secureit from moving.


3 Inspect the following areas for burnt, chafed,corroded and loose wires:

• Engine wiring harness

• Hydraulic manifold wiring

4 Inspect for a liberal coating of dielectric greasein the following locations:

• 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 controlside 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 andraise the boom above the turntable covers.

8 Inspect the turntable area for burnt, chafed andpinched cables.

9 Lower the boom to the stowed position and turnthe 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 greasein all connections between the ECM and theplatform controls.

12 Swing the engine back to its original positionand install the engine pivot plate retainingfasteners.

Crushing hazard. Failure to installthe fasteners into the engine trayto secure it from moving couldresult in death or serious injury.

3 - 18 S-40 • S-45 Part No. 102521



B-3Inspect the Air Filter

Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first. Perform thisprocedure more often if dusty conditions exist.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Open the engine side cover. Empty the dustdischarge valve by pressing together the sidesof the discharge slot. Clean the discharge slotas needed.

2 Inspect the dust discharge valve. If the valveshows any signs of damage, replace the valve.

a clampb canister end capc dust discharge valve

3 Disconnect the latches and remove the end capof the air cleaner canister.

4 Remove the filter element.

5 Clean the inside of the canister and the gasketwith a damp cloth.

6 Clean the filter using dry compressed air. Blowout from inside to outside. Check filter gasketfor damage.

7 Re-install the filter element, or if there are anysigns of loss of filtration, replace the element.

8 Install the end cap onto the canister. Secure theclamps.

Note: Be sure the dust discharge valve is pointingdown.

Part No. 102521 S-40 • S-45 3 - 19


B-5Perform Engine Maintenance -Deutz and Perkins Models

Engine specifications require that this procedure beperformed quarterly or every 250 hours, whichevercomes first.

Deutz models

Required maintenance procedures and additionalengine information are available in theDeutz 1011F Operation Manual(Deutz part number 0297 9683).


Perkins models






B-4Test the Key SwitchGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Proper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Turn the key switch to ground control, start theengine and then turn the key switch to platformcontrol.

3 Check all machine function from the groundcontrols.

Result: All machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check all machine function from the platformcontrols.

Result: All machine functions should notoperate.

6 Turn the key switch to the off position.

Result: The engine should stop and nofunctions should operate.


3 - 20 S-40 • S-45 Part No. 102521



B-7Check the Oil Cooler and CoolingFins - Deutz Models


Maintaining the oil cooler in good condition isessential for good engine performance. Operatinga machine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.

Burn hazard. Beware of hotengine components. Contact withhot engine components may resultin severe burns.

Oil cooler

1 Remove the engine tray retaining fastenerslocated under the engine tray. Loosen the pivotfastener located at the platform end of theengine tray. Swing the engine tray out andaway from the machine and secure it frommoving.


2 Remove the fasteners from the engine sidecover, and remove the cover.

3 Inspect the oil cooler for leaks and physicaldamage.

4 Clean the oil cooler of debris and foreignmaterial.

B-6Check the Exhaust System


Maintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.

Bodily injury hazard. Do notinspect while the engine isrunning. Remove the key tosecure from operation.

Burn hazard. Beware of hotengine components. Contact withhot engine components may resultin severe burns.



2 Be sure that all nuts and bolts are tight.

3 Inspect all welds for cracks.

4 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.



Part No. 102521 S-40 • S-45 3 - 21


B-8Inspect the Tires, Wheelsand Lug Nut Torque


Maintaining the tires and wheels in goodcondition including proper wheel fastener torque isessential to safe operation and good performance.Tire and/or wheel failure could result in a machinetip-over. Component damage may also result ifproblems are not discovered and repaired in atimely fashion.

Bodily injury hazard. An over-inflated tire can explode and couldcause death or serious injury.

Tip-over hazard. Do not usetemporary flat tire repair products.

Note: The tires on some machines are foam-filledand do not need air added to them.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracks.

3 Check each lug nut for proper torque. Refer toSection 2, Specifications.

Models with air-filled tires:

4 Check pressure in each air-filled tire. Add air asnecessary. Refer to Section 2, Specifications.

a oil coolerb cylinder head cooling finsc fan blower fins

Cooling and fan blower fins

5 Inspect the fan blower fins for physical damage.

6 Clean the fan blower fins of debris and foreignmaterial.

7 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.

8 Clean the cylinder head cooling passages ofdebris and foreign material.

9 Install the engine side cover.

10 Swing the engine back to its original positionand install the engine pivot plate retainingfasteners. Tighten the pivot fastener.


cba


3 - 22 S-40 • S-45 Part No. 102521



Turntable rotate drive hub

1 Remove the plug located on the side of the huband check the oil level.

Result: The oil level should be even with thebottom of the plug hole.

turntable drive huba plug

2 If necessary, add oil until the oil level is evenwith the bottom of the plug hole.

3 Apply pipe thread sealant to the plug, andinstall the plug in the drive hub.

4 Check the torque of the turntable drive hubmounting fasteners. Refer to Section 2,Specifications.

a

B-9Check the Drive Hub Oil Leveland Fastener Torque


Failure to maintain proper drive hub oil levels maycause the machine to perform poorly andcontinued use may cause component damage.

1 Drive the machine to rotate the hub until theplugs are located one on top and the otherat 90 degrees.

2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the side plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole. Refer to Section 2,Specifications.

4 Install the plug(s) in the drive hub. Use pipethread sealant on units with pipe plugs.

5 Check the torque of the drive hub mountingfasteners. Refer to Section 2, Specifications.

6 Repeat this procedure for each drive hub.


a

Part No. 102521 S-40 • S-45 3 - 23


brake disengaged position

brake engaged position

B-10Confirm the ProperBrake Configuration


Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

1 Check each drive hub disconnect cap to besure it is in the engaged position.

2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

Note: The free-wheel valve is located on thebottom of the drive pump.

a drive pumpb screwdriverc lift pumpd free-wheel valve

Note: The free-wheel valve should always remainclosed.

a

d

c

b


3 - 24 S-40 • S-45 Part No. 102521



a solenoid bootb high idle adjustment nutc yoke lock nutd yokee low idle adjustment screwf low idle lock nut

If high idle rpm is correct, disregardadjustment step 4.

4 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and re-check the rpm.

Note: Be sure the solenoid fully retracts whenactivating high idle.

Perkins Models

1 Connect a tachometer to the engine. Start theengine from the ground controls. Refer toSection 2, Specifications.

B-11Check and Adjust theEngine RPM


Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

Note: This procedure will require two people.

Ford Models

Note: The engine rpm is controlled by the ECMand can only be adjusted by re-programming theECM. If rpm adjustment or service is required,please contact Genie Industries ServiceDepartment OR your local Ford dealer.

Deutz Models

1 Connect a tachometer to the engine. Start theengine from the ground controls. Refer toSection 2, Specifications.

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

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

3 Move the function enable/rpm select toggleswitch to the high idle (rabbit symbol) positionat the ground controls. Refer to Section 2,Specifications.

f

e

c dba

Part No. 102521 S-40 • S-45 3 - 25


a b c d

B-12Test the Engine Idle SelectGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

A properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are two settings.

Foot switch activated low idle (turtle symbol)allows the operator to control individual boomfunctions.

Foot switch activated high idle (rabbit symbol)should be used for normal machine operation. Thisselection activates high idle only when the footswitch is pressed down.


2 Start the engine from the ground controls thenmove and hold the function enable/rpm selecttoggle switch to the high idle (rabbit symbol).

Result: The engine should change to high idle.

3 Release the function enable/rpm select toggleswitch.

Result: The engine should return to low idle.

4 Turn the key switch to platform controls.

5 Move the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

Result: The engine should not change tohigh idle.

6 Press down the foot switch.

Result: The engine should change to high idle.

7 Move the engine idle control switch to footswitch activated low idle (turtle symbol).

Result: The engine should change to low idle.

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

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

Tighten the low idle lock nut and confirm therpm.

a solenoid bootb high idle adjustment nutc clevisd low idle lock nut and adjustment

screw

3 Move the function enable toggle switch to thehigh idle (rabbit symbol) position. Refer toSection 2, Specifications.

If high idle rpm is correct, disregardadjustment step 4.

4 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and re-check the rpm.

Note: Be sure the solenoid fully retracts whenactivating high idle.


3 - 26 S-40 • S-45 Part No. 102521



2 Start the engine from the platform controls andallow it to run at low idle. Press down the footswitch to allow the engine to run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

3 Release the foot switch and shut the engine offby pushing the red Emergency Stop buttonin to the off position.

4 Move the fuel select switch to LPG.

5 Start the engine and allow it to run atlow idle. Press down the foot switch to allow theengine to run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

Note: The engine may hesitate momentarily andthen continueto run on the selected fuel if switched whilerunning.

B-13Test the Fuel Select Operation -Ford Models


The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade when the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicatefuel system problems that could develop into ahazardous situation.

Note: Perform this test after checking the gasolineand LPG fuel levels, and warming the engine tonormal operating temperature.

1 Move the fuel select switch to gasoline and thenmove the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

Part No. 102521 S-40 • S-45 3 - 27


B-14Test the Ground Control OverrideGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether or not the red EmergencyStop button on the platform controls is in the on oroff position. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.

1 Push in the platform red Emergency Stopbutton to the off position.

2 Start the engine from the ground controls.

3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.

B-15Check the Directional ValveLinkage


Note: Perform this test only on models equippedwith a oscillating axle.

Proper axle oscillation is essential to safe machineoperation. If the directional valve linkage is notoperating correctly, the stability of the machine iscompromised and it may tip over.

1 Remove the drive chassis cover and the axlecovers from the non-steer end of the drivechassis.

2 Locate the directional valve inside of the non-steer axle and inspect the linkage for thefollowing:

• Lock nut is tight against yoke

• Yoke clevis pins are installed

• Cotter pins are installed through clevispins

• Linkage is properly attached todirectional valve


3 - 28 S-40 • S-45 Part No. 102521



B-17Test the Drive Brakes


Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydrostatic brakes and hydraulically-released individual wheel brakes can appear tooperate normally when they are actually not fullyoperational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.See B-10, Confirm the ProperBrake Configuration.

Note: Select a test area that is firm, level and freeof 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 tofoot switch activated high idle (rabbit andfoot switch symbol), then lower the boom intothe stowed position.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

5 Bring the machine to top drive speed beforereaching the test line. Release the drive joystickwhen your reference point on the machinecrosses the test line.

6 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.

Note: The brakes must be able to hold the machineon any slope it is able to climb.

B-16Test the Platform Self-leveling


Automatic platform self-leveling throughoutthe full cycle of primary boom raising and loweringis essential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom.

A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.

1 Start the engine from the ground controls andlower the boom to the stowed position.

2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.

3 Raise and lower the primary boom through a fullcycle.

Result: The platform should remain level atall times to within ±5 degrees.

Part No. 102521 S-40 • S-45 3 - 29


B-19Test the Drive Speed -Raised or Extended Position


Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.


3 Move the engine idle select switch to foot switchactivated high idle (rabbit and foot switchsymbol).

4 Raise the boom above horizontal.

5 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

B-18Test the Drive Speed -Stowed Position


Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.


3 Move the engine idle control switch tofoot switch activated high idle (rabbit and footswitch symbol), then lower the boom into thestowed position.


5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

6 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.


3 - 30 S-40 • S-45 Part No. 102521



B-20Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction strainermay cause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.See E-1, Test or Replace the Hydraulic Oil.


7 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

8 Lower the boom to the stowed position andextend the boom 1 foot / 30 cm.



11 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

Part No. 102521 S-40 • S-45 3 - 31


3 Move the function enable/rpm select toggleswitch to either side and activate the jib boomtoggle switch in the down position, hold for amoment and then release it.

Result: The descent alarm should sound whenthe toggle switch is held down.

4 Turn the key switch to platform controls.

Result: The flashing beacons should be onand flashing.

5 Press down the foot switch. Move the boomcontroller to the down position, hold for amoment and then release it.

Result: The descent alarm should sound whenthe controller is held down.

6 Press down the foot switch. Move the jib boomtoggle switch to the down position, hold for amoment and then release it.

Result: The descent alarm should sound whenthe controller is held down.

7 Press down the foot switch. Move the drivecontroller off center, hold for a moment andthen release it. Move the drive controller offcenter in the opposite direction, hold for amoment and then release it.

Result: The travel alarm should sound when thedrive controller is moved off center in eitherdirection.

B-21Test the Alarm Package(if equipped) and theDescent AlarmGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

The alarm package includes:

• Travel alarm

• Flashing beacons

Alarms and beacons are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theturntable rear cover. Beacons are installed on bothturntable covers.

Note: The alarms and beacons will operate withthe engine running or not running.

Note: The descent alarm is standard equipmentbeginning with serial number 12602.

1 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

Result: Both flashing beacons should be on andflashing.

2 Hold the function enable switch to either sideand activate the boom toggle switch in thedown position, hold for a moment and thenrelease it.

Result: The descent alarm should sound whenthe toggle switch is held down.


3 - 32 S-40 • S-45 Part No. 102521



2 Check for proper venting.

Note: When checking for positive fuel tank capventing, air should pass freely through the cap.

Result: Air should pass through the fuel tankcap. Proceed to step 4.

Result: Air is not passing through the fuel tankcap. Clean or replace the cap.Proceed to step 3.

3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 2.

4 Install the fuel tank cap onto the fuel tank.

All models:

5 Remove the breather cap from the hydraulictank.

6 Check for proper venting.

Result: Air should pass through the breathercap. Proceed to step 8.

Result: If air does not pass through the breathercap, clean or replace the cap.Proceed to step 7.

Note: When checking for positive tank cap venting,air should pass freely through the cap.

7 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 6.

8 Install the breather cap onto the hydraulic tank.

B-22Inspect the Fuel and HydraulicTank Cap Venting Systems

Genie specifications require that this procedure beperformed quarterly or every 250 hours, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

A free-breathing fuel and hydraulic tank cap isessential for good machine performance andservice life. A dirty or clogged cap may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the cap be inspectedmore often.


Gasoline/LPG models (before serialnumber 13740) and Diesel models (all):


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

1 Remove the cap from the fuel tank.

Part No. 102521 S-40 • S-45 3 - 33


5 Visually inspect the section of track under thebogey wheels.

Result: There should be between 0.75 - 1 inch /1.9 - 2.5 cm of gap between the bogey wheelsand the inside surface of the track. Proceed tostep 7.

Result: There is 1 inch / 2.5 cm or more of gapbetween the bogey wheels and the insidesurface of the track. Proceed to step 6.

bogey wheeltensioner

assembly

idler wheel

half sprocket

B-23Check the Track Tension andFastener Torque, TRAX option

Note: Manufacturer specifications require that thisprocedure be performed every 250 hours orquarterly.

Maintaining proper track tension and properlytorqued fasteners is essential to good machineperformance and service life. The machine will notoperate properly with a track that is incorrectlytensioned. Continued use of a machine withincorrectly tensioned tracks may cause componentdamage.

1 Thoroughly clean the track assembly of any dirt,rocks, clay, etc.

2 Chock the tracks at one end of the machine toprevent the machine from rolling.

3 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the tracks at the other end of themachine.

4 Lift the machine until the tracks are off theground and then place jack stands under thedrive chassis for support.


3 - 34 S-40 • S-45 Part No. 102521


B-24Perform Engine Maintenance -Ford Models



Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) or theFFord DSG-423 EFI Operator Handbook(EDI part number 1060020) or theFord MSG-425 EFI Operator Handbook(Ford part number 1020010) .







6 Loosen the tensioner jam nut and idler axle boltson both sides of the tensioner wheel and tightenthe tensioner nut until there is between 0.75 - 1inch /1.9 - 2.5 cm of gap between the bogey wheelsand the inside surface of the track.

Component damage hazard.Do not over tighten the track.Overtightening the track will causethe machine to lose power duringoperation.

7 Tighten the jam nut.

8 Check the torque of the track assemblyfasteners. Refer to Section 2, Specifications.

9 Raise the machine, remove the jack stands andlower the machine.

10 Repeat this procedure for each track assembly.


Part No. 102521 S-40 • S-45 3 - 35


Checklist C Procedures

C-1Perform Engine Maintenance -Deutz and Perkins Models



Deutz models

Required maintenance procedures and additionalengine information are available in theDeutz 1011F Operation Manual(Deutz part number 0297 9683) or theDeutz 2011 Operation Manual(Deutz part number 0312 3547).



Perkins models






3 - 36 S-40 • S-45 Part No. 102521


CHECKLIST C PROCEDURES

C-2Grease the Platform OverloadMechanism (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or 6 months, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.

1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.

2 Thoroughly pump grease into each greasefitting using a multi-purpose grease.

Grease type

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

C-3Test the Platform OverloadSystem (if equipped)

Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first.

Testing the platform overload system regularly isessential to safe machine operation. Continued useof an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.

Note: Perform this procedure with the machine on afirm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in aninaccurate test.

4 Using a suitable lifting device, place a testweight equal to that of the available capacity atone of the locations shown.Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lights areon and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

Part No. 102521 S-40 • S-45 3 - 37



7 Using a suitable lifting device, remove the testweights, restart the engine and carefully movethe test weights to each remaining location onthe platform. Refer to Illustration 1.

Result: The alarm should sound, the engineshould shut off and the platform overloadindicator lights should be flashing at both theground and platform controls.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-4, How toCalibrate the Platform Overload System (ifequipped).

Note: There may be a 2 second delay before theoverload indicator lights flash, the alarm soundsand the engine shuts off.

8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.


10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

11 Activate the auxiliary power toggle switch.

12 Using auxiliary power, test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate.

13 Using a suitable lifting device, lift the additionaltest weight from the platform.

Result: The platform overload indicator lightsshould turn off at both the ground and platformcontrols and the alarm should not sound.

Illustration 1

5 Carefully move the test weight to eachremaining location. Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lights areon and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

6 Using a suitable lifting device, place anadditional 50 lbs / 23 kg of weight onto theplatform.

Result: The alarm should sound and the engineshould shut off. The platform overload indicatorlights should be flashing at both the ground andplatform controls.

Result: The alarm does not sound, the enginedoes not shut off and the platform overloadindicator lights are not flashing. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

Note: There may be a 2 second delay before theoverload indicator lights flash, the alarm soundsand the engine shuts off.

3 - 38 S-40 • S-45 Part No. 102521



14 Start the engine and test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate normally.

15 Turn the key switch to platform control.


Result: All platform control functions shouldoperate.

Note: If the platform overload system is notoperating properly, Refer to Repair Procedure 2-4,How to Calibrate the Platform Overload System (ifequipped).

17 Push in the red Emergency stop button at theplatform to shut off engine.

18 Using a suitable lifting device, remove all testweights from the platform.

19 Pull out the red Emergency stop button to the onposition at the platform controls.

20 Remove the fasteners securing the lid to theplatform controls. Using Illustration 2 as aguide, locate the timer relay inside the platformcontrol box. Tag and disconnect the red wirefrom terminal 5 on the timer relay.

Illustration 2

Timer Relay

OrangeWire

Terminal 5

21 Using Illustration 3 as a guide, locate D31 ValvePower LED on the ALC500 printed circuit board.

Illustration 3

22 Step on the footswitch at the platform.

Result: The Valve Power LED should notilluminate.

Result: The Valve Power LED is illuminated.Remove the machine from service and contactthe Genie Service Department.

23 Securely install the red wire, disconnected instep 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 contactthe Genie Service Department.

25 Using a suitable lifting device, place a testweight equal to that of the available capacity atthe center location shown in Illustration 1.

Valve Power LED

ALC 500 Board

Part No. 102521 S-40 • S-45 3 - 39


C-4Replace the Engine Air FilterElement - Deutz and PerkinsModels

Genie specifications requires that this procedurebe performed every 500 hours or 6 months,whichever comes first.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.

1 Open the evacuator valve located on the aircleaner cap by squeezing the sides togetherwith your fingers.

2 Disconnect the latches on the air cleaner cap.Remove the end cap from the air cleanercanister.

3 Remove the filter element.

4 Clean the inside of the canister and the gasketwith a damp cloth.

5 Install the new filter element.

6 Install the end cap on the canister and re-connect the latches.

Note: Be sure the evacuator valve is pointingdown.


26 Using a suitable lifting device, place anadditional 50 lbs / 23 kg of weight onto theplatform.

Result: The alarm should sound and the ValvePower LED should not light. The platformoverload indicator lights should be flashing atboth the ground and platform controls.

27 Working from outside the platform and standingnext to the platform rotator, locate the orangewire, which enters into the base of the platformcontrol box from the load sense switch andlocate 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 themultimeter to the connector on the orange wire,and securely connect the other multimeter leadto a ground point in the control box.

Result: The readout on the multimeter shouldindicate zero resistance.

Result: The readout on the multimeter showsresistance. Remove the machine from serviceand contact the Genie Service Department.

29 Using a suitable lifting device, remove all weightfrom the platform. Note the result on themultimeter.

Result: The readout on the multimeter shouldindicate infinite resistance.

Result: The readout on the multimeter showszero resistance. Remove the machine fromservice and contact the Genie ServiceDepartment.

31 Turn off the multimeter and remove the leadsfrom the machine. Securely connect the wiresdisconnected in step 27.

32 Close the platform control box. Install andsecurely tighten the fasteners. Do notovertighten.

3 - 40 S-40 • S-45 Part No. 102521


C-6Perform Engine Maintenance -Ford Models



Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) OR theFord DSG-423 EFI Operator Handbook(EDI part number 1060020) or theFord MSG-425 EFI Operator Handbook(Ford part number 1020010) .








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

Engine specifications require that this procedurebe performed every 500 hours or 6 months,whichever comes first.

Replacing the diesel fuel strainer is essential forgood engine performance and service life. A dirtyor clogged filter may cause the engine to performpoorly and continued use may cause componentdamage.



1 Put on protective clothing and eye wear.

2 Locate the inline strainer above the throttleactuator solenoid.

4 Place a suitable container under the filter.

5 Loosen the clamp holding the strainer to theengine mount. Loosen the clamps securing thefuel lines to the strainer. Remove and replace.

Part No. 102521 S-40 • S-45 3 - 41


D-1Check the Boom Wear Pads

Genie specifications requires that this procedurebe performed every 1000 hours or annually,whichever comes first.

Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions.


2 Raise the end of the primary boom to acomfortable working height (chest high), thenextend the boom 1 foot / 30 cm.

3 Measure each wear pad. Replace the wear padonce it reaches the minimum allowablethickness. If the wear pad is still withinspecification, shim as necessary to obtainminimum clearance with zero binding.

Note: The minimum shim clearance for primaryboom wear pads is 0.070 inch / 1.8 mm and themaximum allowable shim clearance is 0.188 inch /4.8 mm.

Wear padspecifications Minimum

all wear pads 9/16 inch14.3 mm

4 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the boom.

Note: Always maintain squareness between theouter and inner boom tubes.

Checklist D Procedures

3 - 42 S-40 • S-45 Part No. 102521


CHECKLIST D PROCEDURES

1

713

16

10

4

2

8 14

1711

20 5

3

9

15

18

19

12

6

Bolt torque sequence

4 Be sure that each turntable mounting bolt istorqued in sequence to specifications. Refer toSection 2, Specifications.

5 Start the engine form the ground controls.

6 Raise the secondary boom and remove thesafety chock.

7 Lower the boom to the stowed position.

8 Remove drive chassis covers from both thesteer end and the non-steer end of themachine.

D-2

Check the Turntable RotationBearing Bolts


Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Raise the primary boom and place safetychocks on the lift cylinders rods. Carefully lowerthe boom onto the lift cylinders safety chocks.

Crushing hazard. Keep handsaway from cylinders and allmoving parts when lowering theboom.

Note: The lift cylinder safety chock is availablethrough Genie (Genie part number 75097).

2 Turn the engine off.



Part No. 102521 S-40 • S-45 3 - 43


1

713

16

10

4

2

8 14

1711

20 5

3

9

15

18

19

12

6

9 Check to ensure that each lower bearingmounting bolt under the drive chassis istorqued in sequence to specifications. Refer toSection 2, Specifications.

Bolt torque sequence



disengaged position

engaged position

D-3

Check the Free-wheelConfiguration


Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily fortowing. A machine configured to free-wheel withoutoperator knowledge may cause death or seriousinjury and property damage.

Collision hazard. Select a worksite that is firm and level.

Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.

Non-steer Wheels: All Models

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of sufficient capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the non-steer tires.

3 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

4 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachnon-steer wheel hub.


3 - 44 S-40 • S-45 Part No. 102521



All Models:

13 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

Note: The free-wheel valve is located on thebottom of the drive pump.

Note: The free-wheel valve should always remainclosed.

a drive pumpb screwdriverc lift pumpd free-wheel valve

a

d

c

b

5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate withminimum effort.

6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the jack stands.

Collision hazard. Failure tore-engage the drive hubs maycause death or serious injury andproperty damage.

Steer Wheels: 4WD Models

7 Chock the non-steer wheels to prevent themachine from rolling.

8 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the steer tires.

9 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

10 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachsteer wheel hub.

11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate withminimum effort.

12 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Raise the machine andremove the jack stands.

Collision hazard. Failure tore-engage the drive hubs maycause death or serious injury andproperty damage.

Part No. 102521 S-40 • S-45 3 - 45


D-4Replace the Drive Hub Oil


Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the torque hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Refer to Section 2, Specifications.

5 Install the plugs. Use pipe thread sealant onunits with pipe plugs.

6 Repeat steps 1 through 5 for all the other drivehubs.


a

Turntable Rotate Drive Hub:

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

1 Raise the secondary boom until the platformend of the lower secondary boom arm isapproximately 8 feet / 2.4 m off the ground.

2 Secure the turntable from rotating with theturntable rotation lock pin.

3 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotate drive motor. Cap thefittings on the drive motor.

turntable drive huba plug

4 Attach a suitable lifting device to the lifting eyeslocated near the drive motor.

a


3 - 46 S-40 • S-45 Part No. 102521



Perkins models




Remove the engine tray retaining fastenerslocated under the engine tray. Loosen the pivotfastener located at the platform end of theengine tray. Swing the engine tray out andaway from the machine and secure it frommoving

Crushing hazard. Failure to securethe engine pivot plate from movingcould result in death or seriousinjury

D-5Perform Engine Maintenance -Deutz and Perkins Models


Deutz models




5 Remove the drive hub mounting bolts. Carefullyremove the turntable rotate drive hub assemblyfrom the machine.

Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall if notproperly supported by the liftingdevice.

6 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.

7 Install the drive hub assembly onto themachine. Torque the drive hub mounting boltsto specification. Refer toSection 2, Specifications.

8 Fill the drive hub with oil from the side hole untilthe oil level is even with the bottom of the hole.Apply pipe thread sealant to the plug. Install theplug.

Part No. 102521 S-40 • S-45 3 - 47


D-6Replace the Hydraulic FilterElements

Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first. Perform this proceduremore often if dusty conditions exist.

Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filters be replaced more often.

Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.


Hydraulic return filter

1 Open the ground controls side turntable coverand locate the hydraulic return filter housing ontop of the hydraulic tank.

2 Remove the cap from the filter housing.

3 Lift the handle on the filter element and rotatethe element counterclockwise to release theelement from the housing.

4 Remove the filter element from the filterhousing.

5 Install the new filter element into the filterhousing.

6 Push the filter element down to be sure theo-ring on the element is fully seated into thehousing.


7 Rotate the filter element clockwise to lock it inplace.

8 Install the filter housing cap.

9 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter housing.

Medium and high pressure filter

Note: The medium pressure filter is for the chargepump and the high pressure filter (if equipped) isfor all machine functions except the drive circuitand oscillating axle circuit.

10 Open the engine side turntable cover andlocate the medium pressure filter mounted tothe engine tray.

11 Place a suitable container under each filter.

12 Remove the filter housings by using a wrenchon the nut provided on the bottom of thehousings.

13 Remove the filter elements from the housings.

14 Inspect the housing seals and replace them ifnecessary.

15 Install the new filter elements into the housingsand tighten them securely.

16 Clean up any oil that may have spilled duringthe installation procedure.

17 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter housings.


19 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.

3 - 48 S-40 • S-45 Part No. 102521



a turntableb dial indicatorc drive chassisd turntable rotation bearing

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

6 Fully extend the boom and lower to a horizontalposition.

7 Note the reading on the dial indicator.

Result: The measurement is less than0.063 inch / 1.6 mm. The bearing is good.

Result: The measurement is more than0.063 inch / 1.6 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the boom and raise the boom to fullheight. Visually inspect the the dial indicator tobe sure the needle returns to the "zero"position.

a

b

c

d

D-7Inspect for Turntable BearingWear


Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.

Note: Perform this procedure with the machine ona firm, level surface and the boom in the stowedposition.

3 Start the machine from the ground controls andraise the boom to full height. Do not extend theboom.

4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no morethan 1 inch / 2.5 cm from the bearing.

Note: To obtain an accurate measurement, placethe dial indicator no more than 1 inch / 2.5 cm fromthe turntable rotation bearing.

Part No. 102521 S-40 • S-45 3 - 49


9 Remove the dial indicator and rotate theturntable 90°.

10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.

11 Lower the boom to the stowed position and turnthe machine off.

12 Remove the dial indicator from the machine.


3 - 50 S-40 • S-45 Part No. 102521


3 Models with hydraulic tank shut-off valves:Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.

Component damage hazard. Theengine must not be started withthe hydraulic tank shut-off valvesin the closed position orcomponent damage will occur. Ifthe tank valves are closed,remove the key from the keyswitch and tag the machine toinform personnel of the condition.

4 Remove the drain plug and completely drain thetank into a suitable container. Refer toSection 2, Specifications.

5 Tag, disconnect and plug the two suction hosesand supply hose for the auxiliary pump from thehydraulic tank. Cap the fittings on the tank.

Note: The hoses can be accessed through theaccess hole under the turntable.

6 Disconnect and plug the return filter hydraulichose at the return filter. Cap the fitting on thefilter housing.

7 Remove the ground controls side turntablecover.

E-1Test or Replace the Hydraulic Oil

Genie specifications require that this procedure beperformed every 2000 hours or 2 years, whichevercomes first.

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.

Note: Perform this procedure with the boom in thestowed position.

1 Ford models: Turn the valve on the LPG tankclockwise to the off position (if equipped). Thenslowly disconnect the hose from the LPG tank.

2 Ford models: Open the clamps from the LPGtank straps and remove the LPG tank from themachine (if equipped).

Checklist E Procedures

open closed

Part No. 102521 S-40 • S-45 3 - 51


CHECKLIST E PROCEDURES

8 Support the hydraulic tank with an appropriatelifting device.

9 Remove the hydraulic tank mounting fasteners.

10 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if not properly supportedwhen removed from the machine.

11 Remove the hydraulic return filter housingmounting fasteners. Remove the hydraulicreturn filter housing from the hydraulic tank.

12 Remove the suction strainers from the tank andclean them using a mild solvent.

13 Rinse out the inside of the tank using a mildsolvent.

14 Install the suction strainers using a threadsealant on the threads.

15 Install the drain plug using a thread sealant onthe threads.

16 Install the hydraulic return filter housing onto thehydraulic tank.

17 Install the hydraulic tank onto the machine.

18 Install the two suction hoses to the suctionstrainers.

19 Install the supply hose for the auxiliary powerunit and the return filter hose.

20 Models with hydraulic tank shut-off valves:Open the two hydraulic tank valves at thehydraulic tank.

21 Fill the tank with hydraulic oil until the level iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.

22 Clean up any oil that may have spilled.

23 Prime the pump. Refer to Repair Procedure6-2, How to Prime the Pump.

Note: Always use pipe thread sealant wheninstalling the suction hose fittings and the drainplug.

3 - 52 S-40 • S-45 Part No. 102521



E-2Grease the Steer AxleWheel Bearings, 2WD Models

Genie specifications require that this procedure beperformed every 2000 hours or 2 years, whichevercomes first.

Maintaining the steer axle wheel bearings isessential for safe machine operation and servicelife. Operating the machine with loose or wornwheel bearings may cause an unsafe operatingcondition and continued use may result incomponent damage. Extremely wet or dirtyconditions or regular steam cleaning and pressurewashing of the machine may require that thisprocedure be performed more often.

1 Loosen the wheel lug nuts. Do not removethem.

2 Block the non-steering wheels. Center a liftingjack under the steer axle.

3 Raise the machine 6 inches / 15 cm Placeblocks under the drive chassis for support.

4 Remove the lug nuts. Remove the tire andwheel assembly.

5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should be no side to side or upand down movement.

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

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

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

8 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: If there is no side to side or up anddown movement, continue to step 11 andgrease the wheel bearings.

Result: If there is side to side or up and downmovement, continue to step 11 and replace thewheel bearings with new ones.

Note: When replacing a wheel bearing, both theinner and outer bearings, including the pressed-inraces, must be replaced.

10 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

11 Remove the castle nut.

12 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.

13 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.

Part No. 102521 S-40 • S-45 3 - 53


14 Pack both bearings with clean, fresh grease.

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

16 Install a new bearing grease seal into the hubby pressing it evenly into the hub until it is flush.

Note: Always replace the bearing grease sealwhen removing the hub.

17 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.

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

21 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

22 Install a new cotter pin. Bend the cotter pinto lock it in.

23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

E-3Perform Engine Maintenance -Deutz and Perkins Models



Deutz 1011F models

Required maintenance procedures and additionalengine information is available in theDeutz 1011F Operation Manual(Deutz part number 0297 9683).


Perkins models




Remove the engine tray retaining fastenerslocated under the engine tray. Swing the enginetray out and away from the machine and secureit from moving.



3 - 54 S-40 • S-45 Part No. 102521












E-4Perform Engine Maintenance -Ford Models

Engine specifications require that this procedurebe performed every 2400 hours.

Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) or theFord DSG-423 EFI Operator Handbook(EDI part number 1060020).






Part No. 102521 S-40 • S-45 3 - 55


Perkins models
















3 - 56 S-40 • S-45 Part No. 102521



E-8Perform Engine Maintenance -Deutz Models

Engine specifications require that this procedure beperformed every 12,000 hours.








E-7Perform Engine Maintenance -Deutz Models







. Remove the engine tray retaining fastenerslocated under the engine tray. Loosen the pivotfastener located at the platform end of theengine tray. Swing the engine tray out andaway from the machine and secure it frommoving.


Part No. 102521 S-40 • S-45 3 - 57


E-9Perform Engine Maintenance -Ford Models

Engine specifications require that this procedure beperformed every 4 years.









3 - 58 S-40 • S-45 Part No. 102521




Part No. 102521 S-40 • S-45 4 - 1

October 2013 Section 4 • Repair Procedures

Repair Procedures

About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the point whererepairs can be completed. To re-assemble, performthe disassembly steps in reverse order.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.


Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.


Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start:Read, understand and obey the safety rules andoperating instructions in the Genie S-40 andGenie S-45 Operator’s Manual on your machine.

Be sure that all necessary tools and parts areavailable and ready for use.

Use only Genie approved replacement parts.

Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

• Machine parked on a flat, level surface

• Boom in the stowed position

• Turntable rotated with the boom betweenthe non-steering wheels

• Turntable secured with the turntablerotation lock pin

• Key switch in the off position with thekey removed

• Wheels chocked

• All external AC power supply disconnectedfrom the machine

4 - 2 S-40 • S-45 Part No. 102521

October 2013Section 4 • Repair Procedures

The platform control box contains one printedcircuit board. The ALC-500 circuit board inside theplatform control box controls all proportionalmachine functions from the platform. The joystickcontrollers at the platform controls utilize HallEffect technology and require no adjustment. Theoperating parameters of the joysticks are stored inmemory at the ECM circuit board at the platformcontrols. If a joystick error occurs or if a joystick isreplaced, it will need to be calibrated before thatparticular machine function will operate. See 1-2,How to Calibrate a Joystick.

Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

a ALC-500 circuit boardb drive/steer joystick controllerc secondary boom up/down

joystick controllerd primary boom up/down and

turntable rotate left/rightjoystick controller

1-1ALC-500 Circuit Board

Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand 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.

How to Remove the ALC-500Circuit Board1 Push in the red Emergency Stop button to the

off position at both the ground and platformcontrols.

2 Remove the platform control box lid retainingfasteners. Open the control box lid.

3 Locate the ALC-500 circuit board mounted tothe inside of the platform control box.

Platform Controls

bcd

a

Part No. 102521 S-40 • S-45 4 - 3


1-2Joysticks

How to Calibrate a JoystickThe joysticks on this machine utilize digital HallEffect technology for proportional control. If ajoystick is disconnected or replaced, it must becalibrated before that particular machine functionwill operate.

Note: The joystick must be calibrated before thethreshold, max-out or ramping can be set.


1 Open the platform control box.

4 Attach a grounded wrist strap to the groundscrew inside the platform control box.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

5 Carefully disconnect the wire connectors fromthe circuit board.

6 Remove the ALC-500 circuit board mountingfasteners.

7 Carefully remove the ALC-500 circuit boardfrom the platform control box.

PLATFORM CONTROLS


3 Turn the key switch to platform control. Do notstart the engine.

4 Select a joystick to calibrate.

5 Disconnect the wire harness connector from thejoystick for approximately 10 seconds or untilthe alarm sounds. Connect the wire harnessconnector to the joystick.

6 Move the joystick full stroke in either directionand hold for 5 seconds.

7 Return the joystick to the neutral position, pausefor a moment, then move the joystick full strokein the opposite direction. Hold for 5 seconds.

Result: The alarm should sound indicatingsuccessful joystick calibration.

Result: The alarm does not sound. Check theelectrical connections or replace the joystick.

8 Repeat this procedure for each joystickcontrolled machine function including the thumbrocker steer switch.

Note: No machine fuction should operate whileperforming the joystick calibration procedure.

4 - 4 S-40 • S-45 Part No. 102521


PLATFORM CONTROLS

How to Adjust the JoystickMax-out SettingThe max-out setting of a joystick controls themaximum speed of a joystick-controlled machinefunction. Whenever a hydraulic cylinder, drivemotor or hydraulic pump is replaced, the max-outsetting should be adjusted to maintain optimumperformance. The max-out settings on the joystickcan be changed to compensate for hydraulic pumpwear to maintain peak performance from themachine.




3 Push in the platform controls red EmergencyStop button to the off position.

4 Do not press down the foot switch.

5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.

6 When the alarm sounds, release the driveenable toggle switch.

7 Momentarily activate the drive enable toggleswitch in the right direction 4 times.

Result: There should be a pause and the alarmshould sound 4 times indicating that themachine is in max-out calibration mode.

Result: The alarm does not sound. Repeat steps3 through 7.

8 Start the engine from the platform controls andpress down the foot switch.

9 Start a timer and activate the machine functionthat needs to be adjusted. Record the time ittakes for that function to complete a full cycle(ie; boom up).

10 Compare the machine function time with thefunction times listed in Section 2,Specifications. Determine whether the functiontime needs to increase or decrease.

11 While the joystick is activated, adjust the max-out setting to achieve the proper function cycletime. Momentarily move the drive enable toggleswitch in the right direction to increase thefunction speed or momentarily move the driveenable toggle switch in the left direction todecrease the function speed.

Note: Each time the drive enable toggle switch ismomentarily moved, the function speed will changein 2% increments.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.

Part No. 102521 S-40 • S-45 4 - 5


PLATFORM CONTROLS

13 Return the joystick to the neutral position andwait for approximately 10 seconds to allow thesettings to be saved.

Result: The alarm should sound indicating thatthe settings have been saved in memory.

Result: The alarm does not sound. Theminimum or maximum adjustment has beenobtained. No changes can be saved.

Note: Do not operate any machine function duringthe 10 second waiting time.

14 Cycle the red Emergency Stop button off, thenback on.

How to Adjust the JoystickRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.




3 Push in the platform controls red EmergencyStop button to the off position.





Result: There should be a pause and the alarmshould sound 6 times indicating that themachine is in ramp rate calibration mode.



9 Start a timer and simultaneously move thejoystick in either direction full stroke. Note howlong it takes the function to reach maximumspeed. This is the ramp rate.

10 Compare the function ramp rate time with thetable below and determine whether the ramprate time needs to increase or decrease.

11 Release the foot switch.

4 - 6 S-40 • S-45 Part No. 102521


PLATFORM CONTROLS

12 While the joystick is activated, set the ramprate. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.

Note: Each time the drive enable toggle switch ismomentarily moved, the time will change in 5%increments.

13 Repeat steps 9 through 11 for each joystickcontrolled machine function.

14 Return the joystick to the neutral position andwait for approximately 10 seconds to allow thesettings to be saved.




Ramp rate (factory settings)

Boom up/downaccelerate 3 seconddecelerate 1 seconds

Turntable rotateaccelerate 2 secondsdecelerate 1 second

Driveaccelerate 2 secondsdecelerate to neutral 0.5 seconddecelerate, change of direction 0.5 seconddecelerate, coasting 0.75 seconddecelerate, braking 1 seconddecelerate, shift from low to high speed 1 seconddecelerate, shift from high to low speed 3 seconds

Part No. 102521 S-40 • S-45 4 - 7


How to Adjust the JoystickThreshold SettingThe threshold setting of a joystick is the minimumoutput at which a function proportional valve canopen and allow the function to operate.




3 Push in the red Emergency Stop button to theoff position at the platform controls.





Result: There should be a pause and the alarmshould sound 8 times indicating that themachine is in threshold calibration mode.



9 Select a boom function joystick to set thethreshold.

10 Slowly move the joystick off center in eitherdirection just until the function begins to move.

11 Slowly move the joystick back to the neutralposition. Just before the function stops moving,move the drive enable toggle switch to eitherside to set the threshold.

Result: The alarm should sound indicating asuccessful calibration.

12 Repeat steps 9 through 11 for each boomjoystick-controlled machine function (boom up/down, boom extend/retract and turntable rotate).

13 Return the joystick to the neutral position andwait for approximately 10 seconds.




PLATFORM CONTROLS

4 - 8 S-40 • S-45 Part No. 102521


Platform Components

2-1Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.

How to Remove the PlatformLeveling Slave CylinderNote: Before cylinder removal is considered, bleedthe slave cylinder to be sure there is noair in the closed loop.


1 Extend the primary boom until the slave cylinderbarrel-end pivot pin is accessible.

2 Raise the primary boom slightly and placeblocks under the platform for support.

3 Lower the primary boom until the platform isresting on the blocks just enough to support theplatform.

Note: Do not rest the entire weight of the boom onthe blocks.

4 Protect the slave cylinder rod from damage.

S-40 Models:

5 Tag, disconnect and plug the hydraulic hosesfrom the slave cylinder at the union locatednear the platform rotate counterbalance valvemanifold and connect them together using aconnector. Cap the fittings on the cylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

S-45 Models:

6 Tag, disconnect and plug the slave cylinderhoses at the union.

7 Pull the slave cylinder hoses through theplatform rotator.

8 Remove the pin retaining fastener fromthe slave cylinder rod-end pivot pin. Do notremove the pin.

9 Remove the external retaining fastener from thebarrel-end pivot pin.

10 Use a soft metal drift to drive the rod-end pivotpin out.

11 Use a soft metal drift and drive the barrel-endpin out.

12 Carefully pull the cylinder out of the boom.

Component damage hazard. Hosescan be damaged if they are kinkedor pinched.

How to Bleed the Slave CylinderNote: Do not start the engine. Use auxiliary powerfor this procedure.

1 Raise the primary boom to a horizontal position.

2 Move the platform level toggle switch up anddown through two platform leveling cycles toremove any air that might be in the system.

Part No. 102521 S-40 • S-45 4 - 9


PLATFORM COMPONENTS

2-2Platform Rotator

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform160 degrees.

How to Remove thePlatform Rotator

Component damage hazard. Markthe platform mounting weldmentand the rotator flange beforeremoving the platform mountingweldment. The platform mountingweldment must be replaced in theexact same position on the rotatorflange as it was before removal. Ifa new rotator is installed or therotator is disassembled, properalignment can be achieved byrotating the rotator all the way tothe left and then installing theplatform mounting weldment allthe way in the left position.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.

1 Remove the platform and platform support.

S-40 Models:

2 Tag, disconnect and plug the hydraulic hosesfrom the platform rotator. Cap the fittings on therotator.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

S-45 Models:

3 Tag and disconnect the hydraulic hoses fromthe "V1" and "V2" ports on the counterbalancevalve manifold located on the platform rotatorand connect them together using a connector.Cap the fittings on the manifold.

4 Support the platform leveling arms and platformmounting weldment with an appropriate liftingdevice, but do not apply any lifting pressure.

All Models:

5 Remove the six mounting bolts from theplatform mounting weldment. Remove thecenter bolt and slide the platform mountingweldment off of the platform rotator.

Crushing hazard. The platformmounting weldment could becomeunbalanced and fall if it is notproperly supported.

6 Support the platform rotator with an appropriatelifting device. Do not apply any lifting pressure.

4 - 10 S-40 • S-45 Part No. 102521


7 Support the platform leveling slave cylinder.Protect the cylinder rod from damage.

8 Remove the pin retaining fasteners from boththe slave cylinder rod-end pivot pin, and therotator pivot pin.

9 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Crushing hazard. The platformrotator could become unbalancedand fall if it is not properlysupported.

How to Bleed the PlatformRotatorNote: This procedure will require two people. Do notstart the engine. Use auxiliary power for thisprocedure.

1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right then the left through twoplatform rotation cycles, then hold the switch tothe right position until the platform is fullyrotated to the right.

2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a containerto collect any drainage. Secure the container tothe boom.

3 Open the top bleed valve on the rotator, but donot remove it.

a top bleed valveb bottom bleed valvec containerd clear hose

4 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the left position until the platform is fullyrotated to the left. Continue holding the toggleswitch until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear ofthe platform during rotation.

5 Connect the clear hose to the bottom bleedvalve and open the valve. Do not remove thebleed valve.

6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear ofthe platform during rotation.

7 Remove the hose from the bleed valve andclean up any hydraulic oil that may have spilled.

8 Rotate the platform fully in both directions andinspect the bleed valves for leaks.

PLATFORM COMPONENTS

a

d c b

Part No. 102521 S-40 • S-45 4 - 11


2-3Platform Overload System

The platform overload system is designed toprevent the machine from continuing to operatewhen the load in the platform exceeds maximumrated capacity. Refer to the machine serial label formaximum capacity information.

If maximum platform capacity is exceeded, thealarm will sound at the platform controls and theplatform overload indicator lights will flash at boththe ground and platform controls. The ground andplatform controls will become disabled and theengine will stop. Before normal machine operationcan continue, the excess load will need to beremoved from the platform.

If the excess load cannot be removed or if theoperator at the platform controls is unable to correctthe overloaded condition, another person at theground controls can operate the machine usingauxiliary power. There will be limited control ofboom functions from the ground controls whenusing auxiliary power. Auxiliary power can be usedto correct the overloaded platform condition in orderto resume normal, safe operation of the machine.

Note: When the engine is shut off in an overloadedcondition, it will not be possible to re-start theengine until the overloaded condition is corrected.

How to Calibrate the PlatformOverload System (if equipped)

Calibration of the platform overload system isessential to safe machine operation. Continued useof an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.


1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in anincorrect calibration.

4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the center of the platform floor.

PLATFORM COMPONENTS

4 - 12 S-40 • S-45 Part No. 102521


7 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.

Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 8.

Result: The overload indicator lights are flashingat the platform and ground controls, the alarm issounding, and the engine stops. Repeat thisprocedure beginning with step 5.

Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.

8 Add an additional 10 lb / 4.5 kg test weight tothe platform.

Result: The overload indicator light is flashing atboth the ground and platform controls, the alarmis sounding, and the engine stops. Proceed tostep 9.

Result: The overload indicator light is off at boththe ground and platform controls, and the alarmdoes not sound. Remove the additional 10 lb /4.5 kg test weight. Repeat this procedurebeginning with step 6.

Note: There may be a 2 second delay before theoverload indicator lights and alarm turn off.


Result: All platform control functions should notoperate.



Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 6.

Result: The overload indicator lights are flashingat the platform and ground controls, the alarm issounding, and the engine stops. Slowly tightenthe load spring adjustment nut in a clockwisedirection in 10° increments until the overloadindicator light turns off, and the alarm does notsound. Proceed to step 8.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.



Result: The overload indicator lights are off atthe platform and ground controls, and the alarmdoes not sound. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, the alarm sounds, and the enginestops. Proceed to step 7.

Result: The overload indicator lights are flashingat the platform and ground controls, the alarm issounding, and the engine stops. Repeat thisprocedure beginning with step 5.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.


PLATFORM COMPONENTS

Part No. 102521 S-40 • S-45 4 - 13



Result: All ground control functions utilizingengine power should not operate. (Only limitedground control functions utilizing APU powershould function).

12 Using a suitable lifting device, lift the test weightoff the platform floor.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.

Note: There may be a 2 second delay before theoverload indicator lights and alarm turn off.



Result: All ground control functions shouldoperate normally.

15 Turn the key switch to platform control.


Result: All platform control functions shouldoperate normally.

PLATFORM COMPONENTS

4 - 14 S-40 • S-45 Part No. 102521


3-1Jib Boom

How to Remove the Jib BoomNote: Perform this procedure with the boom in thestowed position.


1 Remove the platform.

2 Remove the platform mounting weldment,and the platform rotator. See 2-2, How toRemove the Platform Rotator.

3 From the ground controls, raise the jib boom toa horizontal position.

4 Support the jib boom with a strap from anoverhead crane.

5 Tag, disconnect and plug the hydraulic hosesfrom the jib boom lift cylinder. Cap the fittingson the cylinder.


6 Remove the hose cover, hoses and cables fromthe side of the jib boom and set them aside.

Component damage hazard. Hosesand cables can be damaged if theyare kinked or pinched.

7 Place blocks under the platform leveling cylinderfor support. Protect the cylinder rod fromdamage.

8 Remove the pin retaining fasteners from the jibboom lift cylinder barrel-end pivot pin. Do notremove the pin.

9 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

10 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin.

11 Use a soft metal drift to remove the jib boom liftcylinder barrel-end pivot pin, then remove thejib boom cylinder.

Crushing hazard. The jib boomlift cylinder could becomeunbalanced and fall when it isremoved from the machine if it isnot properly attached to theoverhead crane.

12 Remove the pin retaining fasteners from the jibboom pivot pin. Use a soft metal drift to removethe pin, then remove the jib boom from thebellcrank.

Crushing hazard. The jib boomcould become unbalanced and fallwhen it is removed from themachine if it is not properlyattached to the overhead crane.

Jib Boom Components, S-45

Part No. 102521 S-40 • S-45 4 - 15


3-2Jib Boom Lift Cylinder

How to Remove the Jib BoomLift CylinderNote: Perform this procedure with the boom in thestowed position.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.

Note: Do not rest the entire weight of the boom onthe blocks.

2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

4 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out. Thenlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.

5 Support the jib boom lift cylinder with a liftingdevice.

6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pin andlet the cylinder hang down.

Crushing hazard. The platformand jib boom could becomeunbalanced and fall when the jibboom barrel-end pivot pin isremoved if not properly supported.

7 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

8 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the cylinder fromthe machine.

Crushing hazard. The jib boom liftcylinder could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

JIB BOOM COMPONENTS, S-45

4 - 16 S-40 • S-45 Part No. 102521


4-1Cable Track

The primary boom cable track guides the cablesand hoses running up the boom. It can be repairedlink by link without removing the cables and hosesthat run through it. Removing the entire primaryboom cable track is only necessary whenperforming major repairs that involve removing theprimary boom.

How to Remove the Cable TrackNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Raise the primary boom to a horizontal position.

2 Locate the cables from the cable track to theplatform control box. Number each cable andits entry location at the platform control box.

3 Disconnect the cables from the platform controlbox.

4 Remove the electrical outlet box bracketmounting fasteners. Remove the outlet box andlay it to the side.

5 Remove the hose and cable clamp from theplatform support.

Boom Components

6 Tag, disconnect and plug the hydraulic hosesfrom the counterbalance valve manifold locatedon the platform rotator. Cap the fittings on themanifold.


7 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling cylinder at the unionand connect the hoses from the cylindertogether using a connector.


8 Locate all electrical cables that enter the cabletrack.

9 Tag and disconnect the electrical connectors forall cables that enter the cable track.

10 Remove the retaining fasteners from theelectrical connector receptacles for the cablesthat enter the cable track.

11 Remove the fasteners from the drive speed limitswitch mounted on the side of the cable track atthe pivot end of the boom. Do not disconnectthe wiring.

Part No. 102521 S-40 • S-45 4 - 17


12 Remove the fasteners from the side panel onthe lower cable track, then remove the panel.Pull all of the cables out of the channel.

13 Remove the cable cover on the side of theboom.

14 Place blocks in between the upper and lowercable tracks and secure the upper and lowertracks together.

Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen it is removed from themachine.

15 Attach a lifting strap from an overhead crane tothe cable track.

16 Remove the mounting fasteners from the uppercable track at the platform end of the extensionboom.

17 Remove the cable track mounting fasteners thatattach the lower cable track to the boom.

18 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif it is not properly attached to theoverhead crane.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

How to Repair the Cable TrackComponent damage hazard.The boom cable track can bedamaged if it is twisted.

Note: A cable track repair kit is available throughthe Genie Industries Service Parts Department,part no. 81007. The kit includes a 4 link section ofcable track.

1 Visually inspect the cable track and determinewhich 4 link section needs to be replaced.

2 Remove the snap-on cable track spacers.

3 Carefully remove the external snap rings fromthe pivot pins at each end of the 4-link sectionto be removed.

4 Lift up the hoses and cables and carefullyremove the damaged 4 link section of cabletrack.

Component damage hazard. Hosesand cables can be damaged if theyare kinked or pinched.

5 Remove the snap-on spacers from thereplacement section of the cable track.

6 Lift up the hoses and cables and carefully insertthe new 4 link section of cable track.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

7 Connect the ends of the replacement cabletrack section to the existing cable track usingthe pivot pins and external snap rings.

Note: Be sure the pivot pins are installed from theinside out so the external snap rings are on theoutside of the cable track.

8 Operate the boom extend/retract functionthrough a full cycle to ensure smooth operationof the new section of cable track.

BOOM COMPONENTS

4 - 18 S-40 • S-45 Part No. 102521


BOOM COMPONENTS

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

2 Remove the platform rotator and leveling slavecylinder. See 2-3, How to Remove the PlatformRotator.

3 S-45 Models: Remove the jib boom. See 3-1,How to Remove the Jib Boom.

4 Remove the mounting fasteners from the jibboom/platform rotate valve manifold on the endof the boom. Remove the manifold and set itaside.

5 Remove the fasteners from the limit switchmounted on the side of the cable track. Do notdisconnect the wiring.

6 Support the cable track with an overhead crane.

7 Remove the hose/cable clamp from the pivotend of the boom.

8 Remove the hose/cable clamp at the platformend of the cable track.

9 Remove the fasteners from the large cable trackguide at the platform end of the cable track.Remove the guide.

10 Remove the cotter pin from the clevis pin at theplatform end of the cable track. Remove theclevis pin.

Note: Always replace the cotter pin with a new onewhen removing a clevis pin.

11 Remove the fasteners from the side panel onthe cable track to access the cable trackmounting fasteners.

4-2Boom

How to Remove the BoomConsult the Genie Industries Service Departmentfor instructions on how to safely remove the boomassembly from the machine. Failure to read andfollow the warnings listed below could result indeath or serious injury.

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.



Part No. 102521 S-40 • S-45 4 - 19


12 Remove the cable track mounting fasteners,then remove the cable track from the boom andlay it off to the side.

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

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

13 Remove the turntable end cover.

14 Remove the retaining fastener from the mastercylinder rod-end pivot pin. Use a soft metal driftto remove the pin. Pull the cylinder back andsecure it from moving.

Component damage hazard.When pulling the master cylinderback, be sure not to damage themaster cylinder hoses or fittings.

15 Remove the fasteners from the limit switchmounted to the turntable riser at the pivot end ofthe boom. Do not disconnect the wiring.

16 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on the cylinder.


17 Attach an overhead 5 ton / 4500 kg crane to thecenter point of the boom.

18 Attach a similar lifting device to the boom liftcylinder.

19 Use the overhead crane to lift the boom to ahorizontal position.

20 Place support blocks under the boom liftcylinder, across the turntable.

21 Remove the pin retaining fastener from theboom lift cylinder rod-end pin. Use a soft metaldrift to remove the pin.

Crushing hazard. The boom liftcylinder will fall if not properlysupported.

22 Lower the rod end of the lift cylinder ontosupport blocks. Protect the cylinder rod fromdamage.

23 Remove the pin retaining fastener from theboom pivot pin.

24 Use a soft metal drift to remove the boom pivotpin, then carefully remove the boom from themachine.

Crushing hazard. The primaryboom could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

4 - 20 S-40 • S-45 Part No. 102521


How to Disassemble the BoomNote: Complete disassembly of the boom is onlynecessary if the secondary boom tube must bereplaced. The extension cylinder can be removedwithout completely disassembling the boom. See 4-4, How to Remove the Extension Cylinder.

1 Remove the boom. See 4-2, How to Remove theBoom.

2 Place blocks under the extension cylinder forsupport.

3 Remove the external snap rings from theextension cylinder barrel-end pivot pin at thepivot end of the primary boom tube. Use a softmetal drift to remove the pin.

4 Remove and label the wear pads from the topside of the primary boom tube at the platformend of the boom.

Note: Pay careful attention to the location andamount of shims used with each wear pad.

5 Attach a lifting strap from an overhead crane tothe secondary boom tube at the platform end ofthe boom for support.

6 Support and slide the secondary boom tube outof the primary boom tube. Place the secondaryboom tube on blocks for support.

Crushing hazard. The secondaryboom tube could becomeunbalanced and fall when removedfrom the primary boom tube if notproperly supported.

Note: During removal, the overhead crane strap willneed to be carefully adjusted for proper balancing.

7 Remove and label the wear pads from the topside of the secondary boom tube at the platformend of the boom.

8 Remove the trunnion pin retaining fasteners atthe base end of the secondary boom tube. Usea slide hammer to remove the trunnion pins.

9 Carefully rotate the base end of the extensioncylinder until the pin mounting bore is in avertical position.

10 Remove the external snap rings from theextension cylinder rod-end pivot pin at theplatform end of the secondary boom tube. Use asoft metal drift to remove the pin.

11 Support and slide the extension cylinder out ofthe base end of the secondary boom tube.Place the extension cylinder on blocks forsuppport.

Crushing hazard. The extensioncylinder may become unbalancedand fall when removed from thesecondary boom tube if notproperly supported.

Note: During removal, the overhead crane strap willneed to be carefully adjusted for proper balancing.

12 Remove the label the wear pads from theextension cylinder.

Note: Pay careful attention to the location of eachwear pad.

Part No. 102521 S-40 • S-45 4 - 21


4-3Boom Lift Cylinder

The boom lift cylinder raises and lowers the boom.The boom lift cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the BoomLift Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Raise the boom to a horizontal position.

2 Place support blocks across the turntable underthe boom lift cylinder.

3 Attach a 5 ton / 5000 kg overhead crane to theboom at the platform end for support. Do not liftthe boom.

4 Support and secure both ends of the boom liftcylinder to a second overhead crane or similarlifting device.

5 Tag, disconnect and plug the boom lift cylinderhydraulic hoses. Cap the fittings on the cylinder.


6 Remove the pin retaining fastener from theboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin. Lower the liftcylinder onto the blocks. Protect the cylinderrod from damage.

Crushing hazard. The lift cylindercould become unbalanced and fallif it is not properly supported.

7 Remove the four mounting fasteners from thelift cylinder barrel-end pivot pin mounting plate.

8 With the lift cylinder being supported by theoverhead crane, pull the cylinder toward theplatform to remove it from the machine.

Crushing hazard. The lift cylindercould become unbalanced and fallif it is not properly supported.

Component damage hazard. Thecables and hydraulic hoses can bedamaged if the lift cylinder ispulled across them.

9 Using auxiliary power, activate the boom downfunction so the cylinder will retract. Retract thecylinder just enough until the rod end of thecylinder will clear the mounting bracket on theboom. Turn the machine off.

BOOM COMPONENTS

4 - 22 S-40 • S-45 Part No. 102521


BOOM COMPONENTS

4-4Extension Cylinder

The extension cylinder extends and retracts theboom extension tube. The extension cylinder isequipped with counterbalance valves to preventmovement in the event of a hydraulic line failure.

How to Remove theExtension Cylinder

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools could cause death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.

1 Extend the boom until the extension cylinderrod-end pivot pins are accessible in theextension tube.

2 Remove the master cylinder. See 4-5, How toRemove the Master Cylinder.

3 Raise the boom to a horizontal position.

4 Remove the external snap rings from theextension cylinder rod-end pins (at the platformend). Use a soft metal drift to remove the pins.

5 Remove the turntable end cover.

6 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


7 Remove the barrel-end pivot pin retainingfasteners.

8 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

9 Support and slide the extension cylinder out ofthe pivot end of the boom.

Crushing hazard. The extensioncylinder will fall when it is removedfrom the extension boom if it is notproperly supported.

Note: Note the length of the cylinder after removal.The cylinder must be at the same length forinstallation.

Part No. 102521 S-40 • S-45 4 - 23


BOOM COMPONENTS

4-5Platform LevelingMaster Cylinder

The master cylinder acts as a pump for the slavecylinder. It is part of the closed circuit hydraulicloop that keeps the platform level through theentire range of boom motion. The master cylinderis located at the base of the boom.

How to Remove the PlatformLeveling Master CylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.

1 Remove the turntable end cover to access themaster cylinder.

2 Raise the boom until the master cylinderrod-end pivot pin is accessible.

3 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.


4 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder.

5 Remove the pin retaining fasteners from themaster cylinder barrel-end pivot pin.

6 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

7 Remove the pin retaining fastener from the rod-end pivot pin.

8 Use a soft metal drift to remove the pin.

9 Remove the master cylinder from the machine.

Crushing hazard. The mastercylinder could become unbalancedand fall if it is not properly attachedto the overhead crane.

4 - 24 S-40 • S-45 Part No. 102521


5-1RPM Adjustment - Deutz Models

Refer to Maintenance Procedure B-11, Check andAdjust the Engine RPM.

5-2RPM Adjustment - PerkinsModels

Refer to Maintenance Procedure B-11, Check andAdjust the Engine RPM.

Engines

5-3Flex Plate

The flex plate acts as a coupler between the engineand the pump. It is bolted to the engine flywheeland has a splined center to drive the pump.

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.18 inch / 4.6 mm gap - Deutz Models

0.070 inch / 1.8 mm gap - Perkins Models0.0625 inch / 1.6 mm gap - Ford LRG-4250.080 inch / 2 mm gap - Ford DSG-423

How to Remove the Flex PlateDeutz models:

1 Remove the tailpipe bracket mounting fastenersfrom the engine bell housing.

2 Support the drive pump assembly with anappropriate lifting device.

3 Remove all of the engine bell housing fasteners.

4 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.


5 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.

a b c d e

f

Part No. 102521 S-40 • S-45 4 - 25


ENGINES

Ford LRG-425 EFI models:

1 Disconnect the electrical connector for theoxygen sensor at the tailpipe. Do not removethe oxygen sensor.

2 Remove the engine oil dipstick fasteners fromthe muffler bracket. Remove the dipstick fromthe engine.

3 Remove the muffler retaining fasteners from theexhaust pipe.

4 Support the muffler and bracket assembly withan overhead crane or other suitable liftingdevice.

5 Remove the muffler bracket mounting fasteners.Carefully remove the muffler and bracketassembly from the engine.

6 Support the engine with a suitable lifting device.Do not lift it.

7 Remove the engine plate to vibration isolatorfasteners.

8 Remove the engine mounting plate to bellhousing fasteners.

9 Raise the engine slightly to take the weight offof the engine mounting plate.

10 Slide the engine mounting plate towards thepump as far as it will go.






Ford DSG-423 EFI models:

1 Disconnect the electrical connectors from bothoxygen sensors at the tailpipe and exhaustmanifold. Do not remove the oxygen sensors.

2 Remove the exhaust pipe fasteners at themuffler.

3 Support the muffler and bracket assembly with asuitable lifting device.

4 Remove the muffler bracket mounting fastenersfrom the bell housing. Carefully remove themuffler and bracket assembly from the engine.

5 Support the engine with an overhead crane orother suitable lifting device. Do not lift it.

6 Remove the engine mounting plate to bellhousing fasteners.

7 Raise the engine slightly using the overheadcrane and place a block of wood under the oilpan for support.

8 Support the drive pump assembly with anoverhead crane or other suitable lifting device.Do not apply any lifting pressure.

4 - 26 S-40 • S-45 Part No. 102521


After serial number 13739: Torque the flexplate mounting bolts in sequence to20 ft-lbs / 27 Nm.

Deutz models:Torque the flex plate mounting bolts insequence to28 ft-lbs / 38 Nm.

Perkins models:Before serial number 7472: Torque the flexplate mounting bolts in sequence to28 ft-lbs / 38 Nm.From serial number 7472 to 13773: Torque theflex plate mounting bolts in sequence to49 ft-lbs / 66 Nm.After serial number 13773: Torque the flexplate mounting bolts in sequence to14 ft-lbs / 19.1 Nm.

3 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pump endplate for your engine.

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.18 inch / 4.6 mm gap - Deutz Models

0.070 inch / 1.8 mm gap - Perkins Models0.0625 inch / 1.6 mm gap - Ford LRG-4250.080 inch / 2 mm gap - Ford DSG-423

4 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 61 ft-lbs / 83 Nm.

5 Install the pump and bell housing assembly.

9 Remove all of the engine bell housing retainingfasteners.




Perkins models:

1 Remove the fuel filter/water separator mountingfasteners.

2 Remove the fuel filter/water separator and lay itto the side. Do not disconnect the hoses.






How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump.

2 Apply Loctite® removable thread sealant to thescrews. Torque the flex plate in a star patternusing the following values.

Ford models:Before serial number 13740: Torque the flexplate mounting bolts in sequence to24 ft-lbs / 32 Nm.

ENGINES

a b c d e

f

Part No. 102521 S-40 • S-45 4 - 27


1 6

5 2

34

C C

CC

CC

CC

7 8

9

C

6 1

9

5

7

32

8

4

A A

B

B

B

B

B

B

B

CC

BB

A

A

B

1

2

3

4

5

6

7

Ford LRG 425 models(after serial number 7596)

Ford DSG 423 models

Perkins models(after serial number 7471)

ENGINES

Ford LRG-425 models:Before serial number 7597: Torque the bellhousing mounting bolts in sequence to23 ft-lbs / 31 Nm.After serial number 7596: Torque the bellhousing mounting bolts labeled "C" in sequenceto 47 ft-lbs / 63 Nm. Torque the bell housingmounting bolts labeled "B" in sequence to61 ft-lbs / 83 Nm.

Ford DSG-423 models:Torque the bell housing mounting bolts labeled"A" and "B" in sequence to 28 ft-lbs / 38 Nmand the mounting bolts labeled "C" to 49 ft-lbs /66 Nm. Then torque the bell housing mountingbolts labeled "A" and "B" in sequence to 40 ft-lbs / 54 Nm and the mounting bolts labeled "C"to 70 ft-lbs / 95 Nm.

Deutz models:Before serial number 7544: Torque the bellhousing mounting bolts in sequence to28 ft-lbs / 38 Nm.After serial number 7543: Torque the bellhousing mounting bolts in sequence to47 ft-lbs / 63 Nm.

Perkins models:Before serial number 7472: Torque the bellhousing mounting bolts in sequence to28 ft-lbs / 38 Nm.After serial number 7471: Torque the bellhousing mounting bolts labeled "B" in sequenceto 28 ft-lbs / 38 Nm and the mounting boltslabeled "A" to 49 ft-lbs / 66 Nm. Then torque thebell housing mounting bolts labeled "B" insequence to 40 ft-lbs / 54 Nm and the mountingbolts labeled "A" to 70 ft-lbs / 95 Nm.

Component damage hazard. Wheninstalling the pump, do not forcethe pump coupler into the flexplateor damage to the pump shaft sealmay occur.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

10

6 1

8

4

11

7 5

92

12

3

C

C C

C

C

C

C

CC

C

C

C

Deutz 2011 models(after serial number 7543)

Deutz 1011 models(before serial number 7544)

Ford LRG 425 models(before serial number 7597)

Perkins models(before serial number 7472)

1

2

3

4

5

67

8

1

2

34

5

6

7

8

9

10

11 12

1

2

34

5

6

7

8

9

10

11 12

4 - 28 S-40 • S-45 Part No. 102521


5-4Engine Fault Codes -Ford Models

How to Retrieve Engine FaultCodesWhen an engine malfunction is detected by theElectronic Control Module (ECM), a fault code isrecorded and the check engine light will turn on atthe ground controls. Special equipment is requiredto retrieve fault codes stored within the ECM.Contact Genie Industries Service Department forassistance in retrieving fault codes.

Note: Perform this procedure with the key switch inthe off position.

1 Open the ground controls side cover and locatethe run/test toggle switch on the side of theground control box.


3 Quickly activate and release the start toggleswitch/button. Do not start the engine.(before serial no. 7597)

4 Move and hold the run/test toggle switch to thetest 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 thetest position and count the blinks.

Note: If any fault codes are present, the ECM willuse the check engine light to blink a three digitcode.It will blink the first digit of a three digit code,pause, blink the second digit, pause, and then blinkthe third digit. For example: the check engine lightblinks 5 consecutive times, blinks 3 times and then1 time. That would indicate code 531. There will bea longer pause between codes.

6 Refer to Section 5, Fault Codes, for definition ofengine fault codes.

Note: Once a fault code has been retrieved and therepair has been completed, the ECM memory mustbe reset to clear the fault code from the ECM. SeeHow to Clear Engine Fault Codes from the ECM.

How to Clear Engine FaultCodes from the ECMNote: Perform this procedure with the engine offand the key switch in the off position.

1 Open the engine side turntable cover and locatethe battery.

2 Disconnect the negative battery cable from thebattery for a minimum of 5 minutes.

Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

3 Connect the negative battery cable to thebattery.

ENGINES

Part No. 102521 S-40 • S-45 4 - 29


Hydraulic Pumps

6-1Function Pump

How to Remove theFunction PumpNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.


Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

Models without hydraulic tank shut-offvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. See capacityspecifications.

2 Tag, disconnect and plug the function pumphydraulic hoses. Cap the fittings on the pump.


3 Remove the pump mounting bolts. Carefullyremove the pump.

Models with hydraulic tank shut-off valves:

Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.

Models without hydraulic tank shut-off valves:

Component damage hazard. Besure to fill the hydraulic tank tospecification and prime the pumpafter installing the pump.

open closed

4 - 30 S-40 • S-45 Part No. 102521


HYDRAULIC PUMPS

6-2Drive Pump

The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electro-proportional controller,located on the pump. The only adjustment that canbe made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorized EatonHydraulics center. Call Genie Industries ServiceDepartment to locate your local authorized servicecenter.

How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Disconnect the electrical connection at theelectro-proportional controller located on thedrive pump.


Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

Models without hydraulic tank shut-offvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. See capacityspecifications.

3 Tag and disconnect and plug the hydraulichoses from the drive and function pumps.Cap the fittings on the pumps.


open closed

Part No. 102521 S-40 • S-45 4 - 31


a

4 Support the pump with a lifting device andremove the two drive pump mounting fasteners.

5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

6 Remove the drive pump from the machine.

Component damage hazard. Thehydraulic pump may becomeunbalanced and fall if not properlysupported.

Models with hydraulic tank shut-off valves:

Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.

Models without hydraulic tank shut-off valves:

Component damage hazard. Besure to fill the hydraulic tank tospecification and prime the pumpafter installing the pump.

How to Prime the Pump1 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 theengine pivot plate latch.

Note: The engine pivot plate latch is located underthe engine turntable pivot plate at the counterweightend of the machine.

3 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.

4 Ford models: Close the valve on the LPG tankthen disconnect the hose from the tank. Movethe fuel select switch to the LPG position.

Perkins models: Disconnect the engine wiringharness from the fuel solenoid at the injectorpump.

Deutz models: Hold the manual fuel shutoffvalve clockwise to the closed position.

a manual fuel shutoff valve

5 Have another person crank the engine with thestarter motor for 15 seconds, wait 15 seconds,then crank the engine an additional 15 secondsor until the pressure reaches 320 psi / 22 bar.

6 Ford models: Connect the LPG hose to theLPG tank and open the valve on the tank. Movethe fuel select switch to the gasoline position.

Perkins models: Connect the engine wiringharness to the fuel solenoid.

Deutz models: Release the manual fuel shutoffvalve.

7 Start the engine from the ground controls andcheck for hydraulic leaks.

HYDRAULIC PUMPS

4 - 32 S-40 • S-45 Part No. 102521


Manifolds

7-1Function Manifold Components

The function manifold is located underneath the ground controls side turntable cover.

Index SchematicNo. Description 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 andjib 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

7 Differential sensing valve,150 psi / 10.3 bar ............................... AG ........ Turntable rotate circuit ...................... 30-35 ft-lbs / 41-47 Nm

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

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

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

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

This list continues. Please turn the page

Part No. 102521 S-40 • S-45 4 - 33


AA AB AC AD AE AF AG AH AI AJ AK AL AM AN

AO

AP

AQ

AR

AS

AT

AU

AV

AW

AX

AY

AZ

BABBBCBDBEBFBGBHBI

35 34 33 32 31 30 29 28

15

27

18

17

19

21

20

16

22

23

24

25

26

1 2 3 4 5 6 7 8 9 10 11 12 13 14

36

MANIFOLDS

4 - 34 S-40 • S-45 Part No. 102521


Function Manifold Components, continued


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 pumpto 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 boomup/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 andjib boom up (S-45) ............................ 10-12 ft-lbs / 14-16 Nm

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

MANIFOLDS

Part No. 102521 S-40 • S-45 4 - 35


MANIFOLDS

AA AB AC AD AE AF AG AH AI AJ AK AL AM AN

AO

AP

AQ

AR

AS

AT

AU

AV

AW

AX

AY

AZ

BABBBCBDBEBFBGBHBI

35 34 33 32 31 30 29 28

15

27

18

17

19

21

20

16

22

23

24

25

26

1 2 3 4 5 6 7 8 9 10 11 12 13 14

36

4 - 36 S-40 • S-45 Part No. 102521


MANIFOLDS

7-2Valve Adjustments -Function Manifold

How to Adjust the SystemRelief ValveNote: Perform this procedure with the boom in thestowed position.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the PTEST port on the functionmanifold.


3 Hold the function enable/rpm select toggleswitch to the high idle position. Activate andhold the boom retract toggle switch with theboom fully retracted.

4 Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item AQ).

6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.

Tip-over hazard. Do not adjustthe relief valve higher thanspecified.

7 Repeat steps 2 through 5 and recheck reliefvalve pressure.

8 Remove the pressure gauge.

Part No. 102521 S-40 • S-45 4 - 37


MANIFOLDS

7-3Jib Select, Platform Rotate and Generator Manifold Components


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

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

CA

CB

CC

CD

CE

1

2

3

4

5

Jib Select Manifold

Generator Manifold

Platform Rotate Manifold

4 - 38 S-40 • S-45 Part No. 102521


MANIFOLDS

7-4Brake Manifold Components (before serial number 7569)


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

DA

DB

1

2

Part No. 102521 S-40 • S-45 4 - 39


MANIFOLDS

7-5Brake/Two-Speed Manifold Components (after serial number 7568)


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

EA EB EC

ED

1 32

4

4 - 40 S-40 • S-45 Part No. 102521


7-6Oscillate Directional Valve Components

The oscillate directional valve is mounted inside the drive chassis at the non-steer end.

IndexNo. 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

MANIFOLDS

3

Part No. 102521 S-40 • S-45 4 - 41


MANIFOLDS

How to Set Up the OscillateDirectional ValveNote: Adjustment of the oscillate directional valvelinkage is only necessary when the linkage or valvehas been replaced.

1 Lower the boom to the stowed position.

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

Tip-over hazard. Failure toperform this procedure on a levelfloor could compromise thestability of the machine resulting inthe machine tipping over.

3 Check the tire pressure in all four tires and addair if needed to meet specification.

Note: The tires on some machines are foam-filledand do not need air added to them.

4 Remove the drive chassis cover and the non-steer axle covers.

5 Place a "bubble type" level across the drivechassis non-steer end. Check to be sure thedrive chassis is completely level.

6 To level the drive chassis, start the engine andloosen the lock nuts on both sides of theurethane cushions.

7 Push up or pull down on the threaded rod untilthe machine is completely level.

8 Verify that the ground and drive chassis arecompletely level.

9 Tighten the nuts on both sides of the urethanecushions until they are snug. Tighten thelocknuts.

10 Verify that the ground and drive chassis arecompletely level.

11 Measure the distance between the drivechassis and the non-steer axle on both sides(from the inside of the drive chassis).

Note: If the distance is not equal and theadjustment to the linkage was completed with theground and drive chassis level, repeat steps 6through 11 OR consult Genie Industries ServiceDepartment.

4 - 42 S-40 • S-45 Part No. 102521


7-7Valve Adjustments - OscillateRelief Valve

How to Adjust the Oscillate ReliefValve Pressure1 Remove the drive chassis cover from the non-

steer end of the machine.

2 Connect a 0 to 2000 psi / 0 to 150 bar pressuregauge to the diagnostic nipple located near theoscillate directional valve.

3 Disconnect the directional valve linkage, byremoving the heim joint and retaining fastenerfrom the axle.


5 With the engine running, manually activate thevalve and observe the pressure reading on thepressure gauge.

Oscillate relief valve specification

Pressure 950 psi65.5 bar

6 Turn the engine off.

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

8 Adjust the internal screw. Turn it clockwise toincrease the pressure or counterclockwise todecrease the pressure. Install the valve cap.

Tip-over hazard. Do not adjust therelief valve higher than specified.

9 Repeat steps 4 through 7 and manually activatethe valve to confirm the valve pressure.

10 Turn the engine off, remove the pressure gaugeand assemble the directional valve linkage.

11 Install the cover on the non-steer end of thedrive chassis.

MANIFOLDS

Part No. 102521 S-40 • S-45 4 - 43


MANIFOLDS

7-8Traction Manifold Components, 2WD (before serial number 7569)

The traction manifold is mounted inside the drive chassis at the non-steer end.


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

3 Orifice, 0.070 inch / 1.78 mm ............ FC ......... Equalizes flow across flowdivider/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

2WD

FA FB

FC

FD

FE5

4

1 2

3

4 - 44 S-40 • S-45 Part No. 102521


MANIFOLDS

7-9Traction Manifold Components, 2WD (after serial number 7568)



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

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

GA

GB

GC

GD

GE

GF6

2

5

3

4

1

Part No. 102521 S-40 • S-45 4 - 45


MANIFOLDS

7-10Valve Adjustments, 2WDDrive Manifold

How to Adjust the Hot Oil ShuttleRelief ValveNote: The pressure differential between the chargepump relief valve (located in the drive pump) andthe hot oil shuttle relief valve (located in the drivemanifold) is necessary to return hot oil from theclosed loop drive circuit to the hydraulic tank forcooling. This pressure differential must bemaintained at 40 psi / 14.5 bar.

Note: The following procedure will require twopeople.

1 Open the engine side turntable cover andconnect a 0 to 600 psi / 0 to 41 bar pressuregauge to the diagnostic nipple on the drivepump.

2 Start the engine from the platform controls andallow the engine to run at high idle. Note thepressure reading on the pressure gauge.

3 Turn the engine off and connect a0 to 600 psi / 0 to 41 bar pressure gauge to thediagnostic nipple located on the drive manifold.

4 Start the engine from the platform controls anddrive the machine slowly in the forwarddirection. Note the pressure reading on thepressure gauge.

5 Turn the engine off, and remove the hot oilshuttle relief valve cap (item FA). Adjust theinternal hex socket clockwise to increase thepressure or counterclockwise to decrease thepressure. Install the valve cap.(before serial no. 7569)

5 Turn the engine off, and remove the hot oilshuttle relief valve cap (item GA). Adjust theinternal hex socket clockwise to increase thepressure or counterclockwise to decrease thepressure. Install the valve cap.(after serial no. 7568)

6 Repeat steps 4 and 5 until the pressure readingon the guage is 40 psi / 2.8 bar less than thepressure reading at the pump.

4 - 46 S-40 • S-45 Part No. 102521


7-11Traction Manifold Components, 4WD (before serial number 7569)



1 Flow divider/combiner valve ............. HA ........ Controls flow to steerend drive motors inforward/reverse ........................... 90-100 ft-lbs / 122-136 Nm

2 Flow divider/combiner valve .............. HB ........ Controls flow to non-steerend drive motors inforward/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 sidesof 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 flowdivider/combiner valves1 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

MANIFOLDS

Part No. 102521 S-40 • S-45 4 - 47


MANIFOLDS

HA

HB

HC

HD

HE

HF

HG

HH

HI

1

7

2

3

4

5

6

9

8

4 - 48 S-40 • S-45 Part No. 102521


7-12Traction Manifold Components, 4WD (from serial number 7568 to 15822)



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 enddrive motors in forwardand 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 flowdivider/combiner valves2 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 sidesof flow divider/combiner valve 5

8 Orifice, 0.040 inch / 1 mm ................. JH ......... Equalizes pressure on both sidesof flow divider/combiner valve 2

9 Orifice, 0.040 inch / 1 mm ................. JI ........... Equalizes pressure on both sidesof 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 thatdirects hot oil out of low pressureside of drive pump ........................ 80-90 ft-lbs / 108-122 Nm

13 Flow divider/combiner valve .............. JM ......... Controls flow to steer enddrive motors in forwardand 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

MANIFOLDS

Part No. 102521 S-40 • S-45 4 - 49


MANIFOLDS

JA

JB

JC

JD

JE

JF

JN

JM

JI

JL

JK

JJ

JH JG

10

11

13

4

5

3

2

1

14

12

6

789

4 - 50 S-40 • S-45 Part No. 102521


7-13Traction Manifold Components, 4WD (from serial number 15823)



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 enddrive motors in forwardand 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 flowdivider/combiner valves2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm

7 Orifice, 0.040 inch / 1 mm .................. KG ........ Equalizes pressure on both sidesof flow divider/combiner valve 5

8 Orifice, 0.040 inch / 1 mm .................. KH ........ Equalizes pressure on both sidesof flow divider/combiner valve 2

9 Orifice, 0.040 inch / 1 mm .................. KI .......... Equalizes pressure on both sidesof flow divider/combiner valve 13

11 Shuttle valve, 3 position 3 way ......... KJ ......... Charge pressure circuit thatdirects hot oil out of low pressureside 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 enddrive motors in forwardand 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

MANIFOLDS

Part No. 102521 S-40 • S-45 4 - 51


KA

KB

KC

KD

KE

KF

KGKHKI

KJ

KK

KL

KM

KN

4WD

9 8 7

10

11

13

6

5

3

2

4

1

14

12

MANIFOLDS

4 - 52 S-40 • S-45 Part No. 102521


MANIFOLDS

7-14Valve Adjustments, 4WDDrive Manifold

How to Adjust the Hot Oil ShuttleRelief ValveNote: The pressure differential between the chargepump relief valve (located in the drive pump) andthe hot oil shuttle relief valve (located in the drivemanifold) is necessary to return hot oil from theclosed loop drive circuit to the hydraulic tank forcooling. This pressure differential must bemaintained at 40 psi / 14.5 bar.

Note: The following procedure will require twopeople.

1 Open the engine side turntable cover andconnect a 0 to 600 psi / 0 to 41 bar pressuregauge to the diagnostic nipple on the drivepump.

2 Start the engine from the platform controls andallow the engine to run at high idle. Note thepressure reading on the pressure gauge.

3 Turn the engine off and connect a0 to 600 psi / 0 to 41 bar pressure gauge to thediagnostic nipple located on the drive manifold.

4 Start the engine from the platform controls anddrive the machine slowly in the forwarddirection. Note the pressure reading on thepressure gauge.

5 Turn the engine off, and remove the hot oilshuttle relief valve cap (item HH). Adjust theinternal hex socket clockwise to increase thepressure or counterclockwise to decrease thepressure. Install the valve cap.(before serial no. 7569)

5 Turn the engine off, and remove the hot oilshuttle relief valve cap (item JA). Adjust theinternal hex socket clockwise to increase thepressure or counterclockwise to decrease thepressure. Install the valve cap.(from serial no. 7569 to 15822)

5 Turn the engine off, and remove the hot oilshuttle relief valve cap (item KA). Adjust theinternal hex socket clockwise to increase thepressure or counterclockwise to decrease thepressure. Install the valve cap.(from serial no. 15823)

6 Repeat steps 4 and 5 until the pressure readingon the guage is 40 psi / 2.8 bar less than thepressure reading at the pump.

Part No. 102521 S-40 • S-45 4 - 53


MANIFOLDS

7-15Valve Coils

How to Test a CoilA properly functioning coil provides anelectromagnetic force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil. Zero resistance or infiniteresistance indicates the coil has failed.

Since coil resistance is sensitive to temperature,resistance values outside specification can produceerratic operation. When coil resistance decreasesbelow specification, amperage increases. Asresistance rises above specification, voltageincreases.

While valves may operate when coil resistance isoutside specification, maintaining coils withinspecification will help ensure proper valve functionover a wide range of operating temperatures.


Note: If the machine has been in operation, allowthe coil to cool at least 3 hours before performingthis test.

1 Tag and disconnect the wiring from the coil to betested.

2 Test the coil resistance using a multimeter setto resistance (Ω). Refer to the Valve CoilResistance Specification table.

Result: If the resistance is not within theadjusted specification, plus or minus 10%,replace the coil.

Valve Coil ResistanceSpecificationNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / 10°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Description Specification

Solenoid valve, 2 position 3 way, 10V DC 6.3 Ω(schematic items AC and AE)

Solenoid valve, 3 position 4 way, 10V DC 6.3 Ω(schematic item AT and AZ)

Solenoid valve, 2 position 3 way, 10V DC 6.3 Ω(schematic items AU, AV, AX, and AY)

Solenoid valve, 3 position 4 way, 10V DC 6.3 Ω(schematic items AZ and BF)

Proportional solenoid valve, 12V DC 9 Ω(schematic items AW and BB)

Solenoid valve, 2 position 3 way, 10V DC 6.8 Ω(schematic item CC)

Solenoid valve, 2 position 3 way, 10V DC 3.3 Ω(schematic items DA)

Solenoid valve, 2 position 3 way, 12V DC 4.8 Ω(schematic items CE)

4 - 54 S-40 • S-45 Part No. 102521


How to Test a Coil DiodeGenie incorporates spike suppressing diodes in allof its directional valve coils except proportionalvalves and those coils with a metal case. Properlyfunctioning coil diodes protect the electrical circuitby suppressing voltage spikes. Voltage spikesnaturally occur within a function circuit following theinterruption of electrical current to a coil. Faultydiodes can fail to protect the electrical system,resulting in a tripped circuit breaker or componentdamage.


1 Test the coil for resistance. See, How to Test aCoil.

2 Connect a 10Ω resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.

Resistor, 10ΩΩΩΩΩGenie part number 27287

Note: The battery should read 9V DC or more whenmeasured 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.

a multimeterb 9V DC batteryc 10Ω resistord coil

Note: Dotted lines in illustration indicate areversed connection as specified instep 6

4 Connect the negative lead to the other terminalon the coil.

Note: If testing a single-terminal coil, connect thenegative lead to the internal metallic ring at eitherend of the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current reading.

6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.

Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.

Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.

9VBATTERY

10

RESISTOR

�

AMMETERCOIL

+

-

+

-

d

a

b

b

c

c

MANIFOLDS

Part No. 102521 S-40 • S-45 4 - 55


7-16Drive Oil Diverter Manifold Components (welder option)

The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.


1 Directional Valve ............................ CY ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm

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

MANIFOLDS

CU

CX

CY

CW

CV

1

3

4

5

2

4 - 56 S-40 • S-45 Part No. 102521


2 Tag, disconnect and plug the hydraulic hosesfrom the motor, brake and manifold. Cap thefittings on the motor, brake and manifold.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do notallow oil to squirt or spray.

3 Attach a suitable lifting device to the turntablerotator assembly.

a brake assemblyb drive hubc backlash plate mounting boltsd backlash platee manifoldf motor

8-1Turntable Rotation Assembly

How to Remove the TurntableRotation AssemblyNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation.Refer to Section 2, Hydraulic Hose and FittingTorque Specifications.

Note: Perform this procedure with the machine on afirm and level surface.

1 Secure the turntable from rotating with theturntable rotation lock pin.

Unlocked position

Locked position

e

f

acd b

Turntable Rotation Components

Part No. 102521 S-40 • S-45 4 - 57


4 Remove the turntable rotation assemblymounting fasteners.

5 Carefully remove the turntable rotation assemblyfrom the machine.

Crushing hazard. The turntablecould rotate unexpectedly whenthe rotation drive hub assembly isremoved if the turntable is notsecured with the turntable rotationlock pin.

Crushing hazard. The turntablerotation drive hub assembly couldbecome unbalanced and fall whenremoved from the machine if notproperly supported.

When installing the drive hub assembly:

6 Install the drive hub. Apply Loctite® removablethread sealant and torque the backlash platemounting fasteners to 160 ft-lbs / 217 Nm.

TURNTABLE ROTATION COMPONENTS

4 - 58 S-40 • S-45 Part No. 102521


9-1Oscillate Cylinders

The oscillating axle cylinders extend and retractbetween the drive chassis and the axle to maintaina level chassis while driving over uneven terrain.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic hose failure.

How to Remove an OscillatingAxle Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills and a suitable workshop.Attempting this procedure withoutthese skills and tools could resultin death or serious injury andsignificant component damage.Dealer service is stronglyrecommended.

Note: Perform this procedure on a firm, levelsurface with the boom inthe stowed position.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation.Refer to Section Two, Hydraulic Hose and FittingTorque Specifications.

1 Rotate the turntable until the boom is betweenthe steer tires.

2 Remove the fasteners from drive chassis coverat the steer end. Remove the cover.

3 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on theoscillate cylinder.


4 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.

5 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.

6 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pin.

7 Remove the cylinder from the machine.

Crushing hazard. The oscillatecylinder could become unbalancedand fall when it is removed fromthe machine if it is not properlyattached to the overhead crane.

Axle Components

Part No. 102521 S-40 • S-45 4 - 59


Track Components

10-1Track Assembly - TRAX option

How to Remove a TrackAssemblyNote: Perform this procedure on a firm, levelsurface with the boom in the stowed position.

1 Chock the tracks at the opposite end of themachine to prevent the machine from rolling.

2 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the tracks.


4 Remove the lug nut bolts holding each halfsprocket on the drive hub. Rotate the sprocketsuntil only one sprocket is contacting the track.Remove the lower half sprocket from the trackassembly.

5 Rotate the remaining half sprocket 180° so thatit is free of the track.

6 Attach a lifting strap from an overhead crane tothe center-point of the track assembly, abovethe sprocket.

7 Remove the fasteners holding the TRAXmounting pin located underneath the axle.Remove the pin supporting the TRAX assembly.

8 Carefully remove the track assembly from thedrive hub and set aside.

Crushing hazard. The trackassembly could becomeunbalanced and fall when removedfrom the machine if not properlysupported by the overhead crane.

How to Replace the TrackNote: The sprocket is comprised of two halves.

1 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the tracks.

2 Refer to illustration 1 and place the drive hubdisconnect cap in the brake disengagedposition.


4 Loosen the idler axle bolt, tensioner jam nut andtension nut on both sides of the assembly toallow maximum play in the tensioner wheel.

5 Remove the lug nut bolts holding each halfsprocket on the drive hub. Rotate the sprocketsuntil only one sprocket is contacting the track.Remove the lower half sprocket from the trackassembly.

6 Rotate the remaining half sprocket 180° so thatit is free of the track.

7 Carefully remove the track from theundercarriage.

Illustration 1

brake disengaged position

brake engaged position

4 - 60 S-40 • S-45 Part No. 102521


8 Install the new track onto the undercarriage.

Note: Be sure the idler and bogey wheels arealigned with the inside surface of the track.

9 Using a suitable lifting device, lift up on therubber track and rotate the half sprocket untilone of the sprocket teeth is engaging the track.

10 Continue rotating the half sprocket until it is fullyengaging the track.

bogey wheeltensioner

assembly

idler wheel

half sprocket

Illustration 2

11 Install the other sprocket half, removed in step4.

12 Install the lug nuts onto the wheel hub andtorque to specification. Refer to Section 2,Specifications.

13 Adjust the track tension. Tighten the tensionernut on both sides of the idler wheel until there isabout 0.75 - 1.0 inch / 19 - 25 mm of droopbetween the inside of the rubber track and thebottom surface of the bogey wheels.

Note: Make sure that both sides of the track havethe same amount of clearance between the rollersand the track.

14 Tighten the jam nuts and idler axle bolts on bothtensioner assemblies.

Part No. 102521 S-40 • S-45 4 - 61


Generators

11-1Hydraulic Generator

How to Adjust the GeneratorVoltage



Note: Be sure that the hydraulic oil level is withinthe top 2 inches / 5 cm of the sight gauge.


1 Disconnect all electrical tools from the machine.


3 Press the generator select switch.

4 Connect an electrical tool, which does not drawmore than 15A, to the electrical outlet at theplatform controls and run the tool at full speed.

5 Connect the positive and negative leads from amultimeter of sufficient capacity to the electrical

outlet at the generator.

Result: The reading on the multimeter should be112 to 118V AC.

Result: If the reading on the multimeter is not112 to 118V AC, proceed to step 6.

6 Turn the key switch to the off position.

7 Use a wrench to hold the generator flowregulator valve (item AM) and remove the cap.

a flow regulator

8 Adjust the internal hex socket. Turn it clockwiseto increase the AC voltage or counterclockwiseto decrease the AC voltage. Install the flowregulator valve cap.

Component damage hazard.Failure to adjust the generator asinstructed may result in damage tothe generator or other electricalequipment. Do not adjust thegenerator to other than specified.

9 Repeat steps 2 through 5 to confirm thegenerator AC voltage.

a

4 - 62 S-40 • S-45 Part No. 102521


GENERATORS

How to Purge the Hydraulic Lineon the MTE Generator

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Note: This procedure should be performed if thehydaulic line to the generator has been removed.


1 Locate the blue purge wire with the male spadeconnector from the MTE generator harness.

2 Connect a jumper wire of sufficient length fromthe positive battery terminal to the spadeconnector on the purge wire.

3 Start the engine and turn on the generator. Allowthe generator to run for three minutes.

4 Turn off the generator and turn off the engine.

5 Remove the jumper wire from the positivebattery terminal and disconnect from the purgewire.

6 Start the engine and turn on the generator. Usinga digital multimeter check the voltage at theoutlet.

Result: The generator produces a voltage ±10%of rated output. The generator is ready for use.

Result: The generator output voltage is outsidethe ±10% voltage range. Repeat the procedurebeginning with step 2.

Part No. 102521 S-40 • S-45 5 - 1

October 2013 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theGenie S-40 and S-45 Operator’s Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.



Note: Perform all troubleshooting on a firm levelsurface.

Note: Two persons will be required to safelyperform some troubleshooting procedures.

Fault Codes

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

• Machine parked on a firm, level surface

• Boom in stowed position

• Turntable rotated with the boom between the non-steer wheels

• Turntable secured with the turntable rotation lock

• Key switch in the off position with the key removed

• Wheels chocked

• All external AC power disconnectedfrom the machine

5 - 2 S-40 • S-45 Part No. 102521

October 2013Section 5 • Fault Codes

FAULT CODES

Fault Code Chart -Control System

How to Retrieve Control SystemFault CodesNote: At least one fault code is present when thealarm at the platform controls produces two shortbeeps every 30 seconds for 10 minutes.

Note: Perform this procedure with the engine off,the key switch turned to platform controls and thered Emergency Stop button pulled out to the onposition at both the ground and platform controls.

1 Open the platform control box lid.


2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platform controlbox. Do not touch the circuit board.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. If the circuit boarddoes need to be handled, maintainfirm contact with a metal part ofthe machine that is grounded at alltimes when handling the printedcircuit board OR use a groundedwrist strap.

3 Determine the error source: The red LEDindicates the error source and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

Note: When the red LED is flashing the code, theyellow LED will be on solid.

4 Determine the error type: The yellow LEDindidates the error type and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash 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 pagesto aid in troubleshooting the machine bypinpointing the area or component affected.

Part No. 102521 S-40 • S-45 5 - 3


Continued on next page

FAULT CODES

Error Source Error Type Condition Solution ID Name ID Name

21 Boom 1 Joystick (primary boom up/ down)

11 12 15 16

Value at 5V Value too high Value too low Value at 0V

Function is inoperative until joystick is calibrated. Alarm sounds indicating fault.

Cycle power off, then on and problem should be corrected.

17 Not calibrated

Function is inoperative until joystick is calibrated.

Calibrate joystick

22 Boom 1 directional valves

21 Fault

Valve is operating outside of operational limits. Alarm sounds indicating fault.


23

Boom 1 flow control valve

12 15

Value too high Value too low



17 Not calibrated

Normal function except threshold for one or both directions is zero.

Calibrate valve thresholds

24

Boom 1 angle sensor

11 12 15 16


Reduced speed. Cycle power off, then on and problem should be corrected.

31 Invalid setup Initiate 1 second beep of alarm.

Calibrate angle sensor.

31 Boom 2 Joystick (secondary boom up/down or primary boom extend/retract)

11 12 15 16


Joystick is operating outside of operational limits. Alarm sounds indicating fault.


17 Not calibrated

Function is inoperative until joystick is calibrated.

Calibrate joystick

32 Boom 2 directional valves

21 Fault



5 - 4 S-40 • S-45 Part No. 102521


FAULT CODES

Error Source Error Type ID Name ID Name

Condition Solution

12 15




33 Boom 2 flow control valve

17 Not calibrated



11 12 15 16




41 Turntable rotate joystick

17 Not calibrated Function is inoperative until joystick is calibrated.

Calibrate joystick

42 Turntable rotate directional valves

21 Fault



12 15




43 Turntable rotate flow control valve

17 Not calibrated


Calibrate valve thresholds.

44 Drive enable toggle switch

21 Fault

Drive enable function is inoperative.


Part No. 102521 S-40 • S-45 5 - 5


FAULT CODES

Error Source Error Type ID Name ID Name

Condition Solution 11 12 15 16




51 Drive joystick


Calibrate joystick

12 15




53 Drive flow valve (EDC)

17 Not calibrated



54 Drive brake valve

21 Fault



55 High speed drive motor Valve 21 Fault

Motor speed frozen in the low state. Alarm sounds indicating fault.


11 12 15 16




61 Steer joystick


Calibrate Joystick

62 Steer directional valves

21 Fault



5 - 6 S-40 • S-45 Part No. 102521


FAULT CODES

Ford LRG-425 EFI Engine

How to Retrieve Ford EngineFault CodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM also usessignals from the sensors to initiate sequential fuelinjection and make constant and instantaneouschanges to ignition timing, fuel delivery and throttleposition to maintain the engine's running conditionat its highest efficiency while at the same timekeeping exhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault code inmemory that relates to the appropriate sensor andwill turn on the Check Engine Light.

Note: Perform this procedure with the key switch inthe off position.

1 Open the ground controls side cover and locatethe run/test toggle switch on the side of theground control box.


3 Quickly activate and release the start toggleswitch/button. Do not start the engine.

4 Move and hold the run/test toggle switch to thetest position.


5 Continue to hold the run/test toggle switch in thetest position and count the blinks.

Note: Before the fault codes are displayed, thecheck engine light will blink a code 123 three times.After the fault codes, the check engine light willblink a code 123 three times again indicating theend of the stored codes.

Note: If any fault codes are present, the ECM willblink a three digit code three times for each codestored in memory. It will blink the first digit of athree 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 indicatecode 531.

Note: Once a fault code has been retrieved and therepair has been completed, the ECM memory mustbe reset to clear the fault code from the ECM. SeeHow to Clear Engine Fault Codes from the ECM.


1 Open the engine side turntable cover and locatethe battery.

2 Disconnect the negative battery cable from thebattery for a minimum of 5 minutes.



Part No. 102521 S-40 • S-45 5 - 7


FAULT CODES

Code Problem Cause Solution

111

112

113

114

121

122

124

133

134

135

141

142

143

144

Closed Loop MultiplierHigh (LPG)

HO2S Open/Inactive(Bank 1)

HO2S Open/Inactive(Bank 2)

Post-cat oxygensensor open

Closed Loop MultiplierHigh (Gasoline)

Closed Loop MultiplierLow (Gasoline)

Closed Loop MultiplierLow (LPG)

Gasoline cat monitor

LPG cat monitor

NG cat monitor

Adaptive Lean Fault -High Limit (Gasoline)

Adaptive Rich Fault -Low Limit (Gasoline)

Adaptive Learn High(LPG)

Adaptive Learn Low(LPG)

Heated Oxygen Sensor wiring and/orconnections open or shorted OR sensor is faultyOR there are vacuum leaks or exhaust leaks.

Heated Oxygen Sensor wiring and/or connectionsopen or shorted OR sensor is faulty.

The post cat Heated Oxygen Sensor wiringand/or connections are open or shorted ORsensor is cold, non-responsive or inactive for60 seconds or longer.

Heated Oxygen Sensor wiring and/orconnections open or shorted OR sensor isfaulty OR there are vacuum leaks or exhaustleaks OR fuel pressure is low OR the fuelinjectors need cleaning or replacing.

MAP, IAT or ECT sensors not in correct positionOR wiring and/or connections for sensors openor shorted OR sensor is faulty OR one or morefuel injectors are stuck open OR there iselectro-magnetic interference from a faultycrankshaft and/or camshaft position sensor.

Heated Oxygen Sensor wiring and/orconnections open or shorted OR sensor isfaulty OR fuel quality is poor OR fuel systemcomponents may be faulty.

There are exhaust leaks OR the catalyst systemefficiency is below the acceptable level.

Heated Oxygen Sensor wiring and/orconnections open or shorted OR sensor isfaulty OR there are vacuum or exhaust leaksOR one or more fuel injectors faulty or stuckclosed OR fuel quality is poor OR fuelpressure is too low.

MAP, IAT or ECT sensors not in correct positionOR wiring and/or connections for sensors openor shorted OR sensor is faulty OR one or morefuel injectors are stuck closed OR there iselectro-magnetic interference from a faultycrankshaft and/or camshaft position sensor.

Heated Oxygen Sensor wiring and/orconnections open or shorted OR sensor isfaulty OR there are vacuum leaks or exhaustleaks OR fuel quality is poor OR fuel systemcomponents may be faulty.

Engine wire harness may have an intermittentshort to 5V DC or 12V DC OR fuel systemcomponents may be faulty.

Heated Oxygen Sensor wiring and/or connectionsopen or shorted OR sensor is faulty.

Repair wiring and/or connections OR replacesensor OR repair vacuum and exhaust leaks.

Repair wiring and/or connections ORreplace sensor.

Repair wiring and/or connections OR replacethe post cat oxygen sensor.

Repair wiring and/or connections OR replacesensor OR repair any vacuum and exhaust leaksOR test the fuel pressure OR clean or replace thefuel injectors.

Adjust or replace sensors OR clean or repairfuel injectors.

Repair wiring and/or connections OR replacesensor OR replace fuel OR test and repair thefuel system components.

Repair exhaust leaks OR there is an emissionscompliance issue. Contact Ford Power Productsfor assistance.

Repair heated oxygen sensor wiring and/orconnections OR replace sensor OR repairvacuum and exhaust leaks OR test the fuelpressure OR clean or replace the fuel injectors.

Repair wiring and/or connections OR replacesensor OR repair any vacuum and exhaustleaks OR replace fuel OR test and repair thefuel system components.

Repair short in engine wire harnessOR test and repair the fuel systemcomponents.

Adjust or replace sensors OR clean or repairfuel injectors.

5 - 8 S-40 • S-45 Part No. 102521


FAULT CODES


242 Crank Sync NoiseCrankshaft position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR sensor is faulty.

235 BP Low Pressure MAP sensor is faulty OR ECM is faulty.

234 BP High Pressure MAP sensor is faulty OR ECM is faulty.

232 MAP Low VoltageOpen or shorted wiring and/or connections to MAPsensor OR sensor is faulty.

231 MAP High PressureOpen or shorted wiring and/or connections to MAPsensor OR sensor is faulty.

215 Oil Pressure LowFaulty oil pressure sensor OR sensor wiringand/or connections open or shorted OR engineoil level too low.

Replace oil pressure sensor OR repair sensorwiring and/or connections OR fill engine oil levelto specification.

214IAT Higher ThanExpected (2)

Air intake temperature is greater than 210 F withthe engine greater than 1000 rpm OR air intakesystem has leaks OR IAT sensor is faulty.

°

213IAT Higher ThanExpected (1)

Air intake temperature is greater than 200 F withthe engine greater than 1000 rpm OR air intakesystem has leaks OR IAT sensor is faulty.

°

212 IAT Low VoltageIAT sensor wiring and/or connections are open orshorted OR sensor is faulty OR engine intake airtemperature is too hot.

Repair wiring and/or connections OR replacesensor OR direct cooler air into air intake.

224CHT Higher ThanExpected (2)

Coolant temperature at the cylinder head is 250 F.Engine cooling system is malfunctioning andoverheating the engine OR sensor wires and/orconnections open or shorted OR sensor is faultyOR coolant level is low.

°

223CHT Higher ThanExpected (1)

Coolant temperature at the cylinder head is 240 F.Engine cooling system is malfunctioning andoverheating the engine OR sensor wires and/orconnections open or shorted OR sensor is faultyOR coolant level is low.

°Repair engine cooling system problems ORrepair open or shorted wiring to sensor ORreplace sensor OR fill engine coolant level tospecification.

222 CHT/ECT Low Voltage

Engine cooling system is malfunctioning andoverheating the engine OR sensor wires and/orconnections open or shorted OR sensor is faultyOR coolant level is low.

221 CHT/ECT High VoltageEngine cooling system is malfunctioning ORsensor wires and/or connections open or shortedOR sensor is faulty.

Repair engine cooling system problems ORrepair open or shorted wiring to sensor ORreplace sensor.

211 IAT High VoltageIAT sensor wiring and/or connections are open orshorted OR sensor is faulty OR engine intake airtemperature is too cold.

Repair wiring and/or connections OR replacesensor OR direct warmer air into air intake.

162 System Voltage HighAlternator is overcharging the battery whenengine RPM is greater than 1500 rpm.

Repair or replace the alternator.

161 System Voltage LowBattery is faulty OR alternator is not charging ORbattery supply wiring to ECM is open or shorted.

Replace battery OR repair alternator OR repairbattery supply wiring to ECM.

Camshaft Sensor Loss244Crankshaft position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR sensor is faulty.

243Never Crank SyncedAt Start

Crankshaft position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR sensor is faulty.

Be sure system ground connections are in placeand secure OR repair wiring and/or connectionsto sensor OR replace sensor.

Check air intake system for damage and properrouting of air intake components OR replace theIAT sensor.

Repair wiring and/or connections to sensor ORreplace MAP sensor.

Replace MAP sensor OR replace the ECM.

Part No. 102521 S-40 • S-45 5 - 9


FAULT CODES


253 Knock Sensor OpenKnock sensor wiring and/or connections open orshorted OR sensor is faulty.

Repair wiring and/or connections to knock sensorOR replace knock sensor.

Camshaft Sensor Noise

Camshaft position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR sensor is faulty.

245Be sure system ground connections are in placeand secure OR repair wiring and/or connectionsto sensor OR replace sensor.

Excessive Knock SignalKnock sensor wiring and/or connections open orshorted OR there is excessive engine vibrationOR sensor is faulty.

254Check for excessive engine vibration OR repairwiring and/or connections to knock sensor ORreplace knock sensor.

Injector Driver #1 OpenOpen wiring and/or connections to fuel injector #1OR fuel injector #1 is faulty OR ECM is faulty.311

Repair wiring and/or connections to fuel injector #1OR replace fuel injector #1 OR replace the ECM.

Injector Driver #1 ShortedWiring and/or connections to fuel injector #1 isshorted OR fuel injector #1 is faulty ORECM is faulty.

312




314




316




322

Fuel Pump Loop Open orHigh Side Short to Ground

Open wiring and/or connections to fuel pump ORfuel pump power shorted to ground OR fuel pumpis faulty.

351Repair wiring and/or connections to fuel pump ORreplace fuel pump.

Wiring and/or connections to fuel pump shorted topower OR fuel pump is faulty.352

Fuel Pump High SideShorted to Power

Fuel pressure too high OR LPG lockoff not openingcompletely OR the line between the MegaJectorand carburetor is kinked or restricted or is leakingOR engine cooling system is not operating properlyOR MegaJector is faulty.

353MegaJector DeliveryPressure Higher ThanExpected Check fuel pressure OR repair LPG lockoff OR

repair the line between the MegaJector andcarburetor OR repair engine cooling system ORreplace the MegaJector.

Fuel pressure too low OR LPG lockoff not openingcompletely OR the line between the MegaJectorand carburetor is kinked or restricted or is leakingOR engine cooling system is not operating properlyOR MegaJector is faulty.

354MegaJector DeliveryPressure Lower ThanExpected

The ECM doesn't get any response from theMegaJector, or an incorrect response for 500msperiod or longer.

355MegaJectorCommunication Lost

Check CAN circuits for continuity and shorts topower or ground and for continuity and repair asnecessary OR replace the MegaJector.

The MegaJector detects voltage greater than 18volts for 5 seconds anytime the engine is crankingor running.

361MegaJector VoltageSupply High

Repair charging system OR replace theMegaJector.

The MegaJector detects voltage less than 9.5 voltsfor 5 seconds anytime the engine is cranking orrunning.

362Repair VBAT power or ground circuit to ECM andMegaJector OR replace battery OR repaircharging system OR replace the MegaJector.

MegaJector VoltageSupply Low

5 - 10 S-40 • S-45 Part No. 102521


FAULT CODES


MegaJector InternalActuator Fault Detection

The MegaJector detects an internal fault. Open orshort in power, ground or CAN circuits.363

Check Power, Ground and CAN circuits atMegaJector and all connections and repair asnecessary OR MegaJector has an internal fault.Contact Ford Power Products for assistance.

MegaJector InternalCircuitry Fault Detection

The MegaJector detects an internal circuitry failure.Open or short in power, ground or CAN circuits.364

MegaJector InternalCommunication FaultDetection

The MegaJector detects an internalcommunications failure. Open or short in power,ground or CAN circuits.

365

Open wiring and/or connections to ignitioncoil #1 OR ignition coil #1 is faulty.

Repair wiring and/or connections to ignitioncoil #1 OR replace ignition coil #1.

Coil Driver #1 Open411

Wiring and/or connections to ignition coil #1shorted OR ignition coil #1 is faulty

Coil Driver #1 Shorted412

Open wiring and/or connections to ignitioncoil #2 OR ignition coil #2 is faulty.

Repair wiring and/or connections to ignitioncoil #2 OR replace ignition coil #2.

Coil Driver #2 Open413

Wiring and/or connections to ignition coil #2shorted OR ignition coil #2 is faulty

Coil Driver #2 Shorted414

Not used.

FPP1 High Voltage511

If this fault appears on your machine, contactthe Genie Industries Service Department.

512 FPP1 Low Voltage

513 FPP1 Higher than IVS Limit

514

521 FPP2 High Voltage

FPP1 Lower than IVS Limit

522 FPP2 High Voltage

The #1 throttle position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR throttle positionsensor #1 is faulty.

531 TPS1 (Signal Voltage) HighBe sure system ground connections are in placeand secure OR repair wiring and/or connectionsto sensor OR replace throttle position sensor #1.

532 TPS1 (Signal Voltage) Low

The #2 throttle position sensor wiring and/orconnections open or shorted OR there is a poorsystem ground connection OR throttle positionsensor #2 is faulty.

533 TPS2 (Signal Voltage) HighBe sure system ground connections are in placeand secure OR repair wiring and/or connectionsto sensor OR replace throttle position sensor #2.

534 TPS2 (Signal Voltage) Low

The throttle position sensor wiring and/orconnections for either TPS1 or TPS2 open orshorted OR there is a poor system groundconnection OR one or both throttle positionsensors are faulty.

TPS1 Higher than TPS2535

536 TPS1 Lower than TPS2

Be sure engine harness wiring and connectionsare in place and secure OR repair wiring and/orconnections to one or both TPS sensors ORreplace one or both TPS sensors.

Governor actuator is stuck closed OR wiringand/or connections open or shorted ORgovernor actuator is faulty.

Throttle Unable to Open537Repair wiring and/or connections to governoractuator OR replace the governor actuator.

Governor actuator is stuck open OR wiringand/or connections open or shorted ORgovernor actuator is faulty.

Throttle Unable to Close538

Engine harness wiring and/or connections openor shorted OR there is a poor system groundconnection OR ECM is faulty.

Governor Interlock Failure545Repair wiring and/or connections in engineharness OR replace the ECM.

Part No. 102521 S-40 • S-45 5 - 11


FAULT CODES


ECM needs to be re-programmed OR throttle issticking open OR there are air leaks between thethrottle body and cylinder head.

Max Governor SpeedOverride

Re-program ECM OR repair binding throttleoperation OR repair any air leaks between thethrottle body and cylinder head.

551

552 FPP1 Low Voltage

553 FPP1 Higher than IVS Limit

Loose wire connections to ECM OR ECM is faulty.

COP Failure611

Locate and repair any engine harness wiringdamage or shorts to ECM to be sure they aresecure OR replace ECM.

612 Invalid Interrupt

613 A/D Loss

614

615 Flash Checksum Invalid

RTI 1 Loss

616 RAM Failure

Locate and repair any engine harness wiringdamage or shorts OR locate and troubleshoot orrepair faulty engine sensor OR replace ECM.

External 5V DC RefLower than Expected Engine harness wiring and/or connections open

or shorted to ground OR there is a faulty enginesensor OR ECM is faulty.

631

632External 5V DC RefHigher than Expected

Locate and repair any engine harness wiringdamage or shorts to ECM to be sure they aresecure OR replace ECM.

RTI2 Loss655

656 RTI3 Loss

Loose wire connections to ECM OR ECM is faulty.

5 - 12 S-40 • S-45 Part No. 102521


FAULT CODES

Ford DSG-423 EFI Engine

How to Retrieve Ford EngineFault CodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM alsouses signals from the sensors to initiatesequential fuel injection and make constant andinstantaneous changes to ignition timing, fueldelivery and throttle position to maintain theengine's running condition at its highest efficiencywhile at the same time keeping exhaustemissions to a minimum. When a sensor fails orreturns signals that are outside of setparameters, the ECM will store a fault code inmemory that relates to the appropriate sensorand will turn on the Check Engine Light.

Note: Perform this procedure with the key switchin the off position.

1 Open the ground controls side cover andlocate the run/test toggle switch on the side ofthe ground control box.


3 Quickly activate and release the start toggleswitch/button. Do not start the engine.

4 Move and hold the run/test toggle switch tothe test position.


5 Continue to hold the run/test toggle switch inthe test position and count the blinks.

Note: Before the fault codes are displayed, thecheck engine light will blink a code 123 threetimes. After the fault codes, the check enginelight will blink a code 123 three times againindicating the end of the stored codes.

Note: If any fault codes are present, the ECM willblink a three digit code three times for each codestored in memory. It will blink the first digit of athree digit code, pause, blink the second digit,pause, and then blink the third digit. For example:the check engine light blinks 5 consecutivetimes, blinks 3 times and then 1 time. That wouldindicate code 531.

Note: Once a fault code has been retrieved andthe repair has been completed, the ECM memorymust be reset to clear the fault code from theECM. See How to Clear Engine Fault Codes fromthe ECM.


1 Open the engine side turntable cover andlocate the battery.

2 Disconnect the negative battery cable fromthe battery for a minimum of 5 minutes.

Electrocution/burn hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.


Part No. 102521 S-40 • S-45 5 - 13


FAULT CODES

Code Description

212

213

214

215 Oil pressure low

222

223

224

CHT higher than expected 1

225

IAT (intake air temperature) low voltage

IAT (intake air temperature) higher than expected 1

IAT (intake air temperature) higher than expected 2

221 ECT/CHT (engine/cylinder head temp) high voltage

ECT/CHT (engine/cylinder head temp) low voltage

CHT higher than expected 2

ECT higher than expected 1

226

231

232

MAP (manifold absolute pressure) high pressure

234

ECT higher than expected 2

MAP (manifold absolute pressure) low pressure

BP (barometric pressure) high pressure

235

242

243

Crank sync noise

244

Never crank synced at start

Cam loss

BP (barometric pressure) low pressure

245

246

253

Crank loss

254

Knock 1-2 sensor open 1

Cam sync noise

Knock 1-2 excessive signal 1

Code Description

111 CL (closed loop) high LPG

112 EGO open / lazy pre-cat 1

113

114 EGO open / lazy post-cat 1

EGO open / lazy pre-cat 2/post-cat 1

115

121

122

124

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

133

134

141

142

Gasoline catalyst monitor 1

LPG catalyst monitor

AL (adaptive learning) high gasoline bank 1

AL (adaptive learning) low gasoline bank 1

143

144

161

162

Battery voltage high

AL (adaptive learning) high LPG

AL (adaptive learning) low LPG

Battery voltage low

163

164

165

166

AUX analog PD1 high

AUX analog PD1 low

AUX analog PU3 high

AUX analog PU3 low

167

168

171

172

AUX analog PUD1 high

AUX analog PUD1 low


AUX analog PUD2 low

173

174

181

182


AUX analog PUD3 low

AUX DIG1 high

AUX DIG1 low

183

184

185

186

211 IAT (intake air temperature) high voltage

AUX DIG2 high

AUX DIG2 low

AUX DIG3 high

AUX DIG3 low

5 - 14 S-40 • S-45 Part No. 102521


FAULT CODES

Code Description

261 FP (fuel pressure) high voltage

262

271

272

FT (fuel temperature) gasoline high voltage

273

274

311

312

Injector loop open OR low-side short to ground 1

313

314

315

316


Injector coil shorted 2



321

322

351

352

FPump motor loop open OR high-side shorted to ground



Fpump motor high-side shorted to power

353

354

355

359

EPR delivery pressure higher than expected

EPR delivery pressure lower than expected

EPR comm lost

Fuel run-out longer than expected

361

362

363

364

EPR voltage supply high

EPR voltage supply low

EPR internal actuator fault detection

EPR internal circuitry fault detection

365

411

412

413

EPR internal comm fault detection

Primary loop open OR low-side short to ground 1

Primary coil shorted 1


414

415

416

421

422 Primary coil shorted 4





FP (fuel pressure) low voltage

FT (fuel temperature) gasoline low voltage

FT (fuel temperature) gaseous fuel high voltage

FT (fuel temperature) gaseous fuel low voltage


Code Description

531

532

533

534

536

537

538

Unable to reach higher TPS (throttle position sensor)

539

TPS1 (throttle position sensor) high voltage

535 TPS1 (throttle position sensor) higher than TPS2

TPS1 (throttle position sensor) lower than TPS2

Unable to reach lower TPS (throttle position sensor)

TPS 1-2 simultaneous voltages

541

542

543

544

AUX analog PU1 high

551

552

553

Fuel rev limit

611

Spark rev limit

COP failure

Max govern speed override

612

613

614

A/D loss

615

RTI 1 loss

Invalid interrupt

Flash checksum invalid

TPS1 (throttle position sensor) low voltage

TPS2 (throttle position sensor) high voltage

TPS2 (throttle position sensor) low voltage

AUX analog PU1 low

AUX analog PU2 high

AUX analog PU2 low

Part No. 102521 S-40 • S-45 5 - 15


FAULT CODES

For further engine fault code troubleshooting anddiagnostic information, refer to the Ford DSG-423EFI Service Manual (EDI part number 1060040).Genie part number 119494.


Code Description

744

761

762

763

772

1629

1630

J1939 TSC1 message receipt lost

PWM5 short to power

771 Tach output ground short

Tach output short to power

J1939 ETC message receipt lost

MIL (malfunction indicator light) control ground short

MIL (malfunction indicator light) open

MIL (malfunction indicator light) control short to power

Code Description

616 RAM failure

631

632

633

5VE1 high voltage

634

635

641

642

Rx inactive

643

644

646

647

Invalid packet format

Shutdown request

CAN Tx failure

CAN Rx failure

648

655

656

711

RTI 3 loss

CAN address conflict failure

RTI 2 loss

Relay control ground short

712

713

714

715

Relay coil open

Relay coil short to power

Fpump relay control ground short

Fpump relay coil open

716

721

722

723

Fpump relay coil short to power

Start relay control ground short

Start relay coil open

Start relay coil short to power

731

732

733

734

PWM1-gauge1 open / ground short

PWM1-gauge1 short to power

735

736

741

742

743

5VE1 low voltage

5VE1-5VE2 simultaneous out-of-range

Rx noise

5VE2 high voltage

5VE2 low voltage





PWM4 open / ground short

PWM4 short to power

PWM5 open / ground short

5 - 16 S-40 • S-45 Part No. 102521



Part No. 102521 S-40 • S-45 6 - 1

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in theGenie S-40 & Genie S-45 Operator's Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

Schematics

October 2013 Section 6 • Schematics

6 - 2 S-40 • S-45 Part No. 102521

Connectionno terminal

P3

Horn buttonnormally open

T-circuitsconnect

FB

Flashing beacon

Diode

Circuits crossingno connection

Quick disconnectterminal

BLK

WHT

T-circuits connectat terminal

WHT #21 TB21

Battery

+

-

Circuit breakerwith amperage

15A

CB1

Horn or alarm

H1 Emergency Stopbutton normally

closed

P1

Coilsolenoid or relay

Key switch(before serial number 22051)

KS1

GROUND

PLATFORM

Power relay

PR1

Toggle switch SPDT

TS2

START

EN

GIN

E

Toggle switch DPDT

TS6

UP

DO

WN

PLATFO

RM

LEV

EL

Gauge sending unit

HM

Hour meter

N.O.OTS2

Oil temperatureswitch

normally open

N.O.CTS1

Coolant temperatureswitch

normally open

Oil pressure switchnormally closed

N.C.OPS1

BLK

FS1

Foot switch

PumpAux

Auxiliary pump

FAN

Hydraulic oilcooling fan

G1

Gauge

Tilt sensorLED

L3

Limit switch

N.C.H.ON.O.H.C

LS3

Fusewith amperage

25A

F1

510

Resistor withohm value

Starting aid:glow plug orflame ignitor

Control relay contactnormally open

CR4N.O.

Coil

Fuel or RPMsolenoid

PU

LL

IN

HO

LD

CA B

Key switch(after serial number 22050)

KS1

October 2013Section 6 • Schematics

Electrical Symbols Legend

Part No. 102521 S-40 • S-45 6 - 3


Hydraulic Symbols Legend

Pumpfixed displacement

Motorbi-directional

Check valve

2 position, 3 way, shuttle valve

Double actingcylinder

Priorityflow regulator valve

Differentialsensing valve

Solenoid operatedproportional valve

Brake

Pilot operated 3 position,3 way, shuttle valve

Filter withbypass valverelief setting

25 psi(1.7 bar)

Motor2-speed,

bi-directional

Pumpbi-directional,

variable displacement

E

Pump prime mover(engine or motor)

Directional valve(mechanically activated)

o

Relief valvewith pressure setting

200 psi(13.8 bar)

Orifice with size

.035"(0.89 mm)

Solenoid operated 3 position,4 way, directional valve

Directional valvepilot operated

2 position, 2 way

Flow divider/combiner valvewith pressure balancing orifice

and flow percentages

50% 50%

Counterbalance valvewith pressure and pilot ratio

(206.8 bar)3000 psi

3:1

Solenoid operated 2 position,3 way, directional valve

2 position, 2 waysolenoid valve

Solenoid operated3 position, 4 way,

proportional directional valve

Needle valve

6 - 4 S-40 • S-45 Part No. 102521


Power

Relay

Starter

Relay

Fuel

Pump

Relay

F5-15A

F4-15AF3-10A

F2-5AF1-10A

Empty

Ford DSG-423 Engine Relay Layout

F6-10A

F6-10A

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A

Part No. 102521 S-40 • S-45 6 - 5


Connector Pin Legend

1

2

3

5

6

4

CKT # PIN #

9

8

10

12

11

7

GR/BK

GR/WH

GR

PLUG

PLUG

PLUG

C43HRN

C45GEN

PLUG

PLUG

JDALARM

C2P DT06-12SB

OR/RD

COLOR

OR/BK

BL/RD

OR C40LS1

C41RPM

C39LP

3

2

4

5

CKT # PIN #

7

8

9

10

12

6

C30EDC+WH

WH/BK

BK/WH

BK/RD

BL/BK

BL/WH

WH/RD

BL

BK

C35RPM

C36STC

C37STCC 11

C31EDC-

C33STR

C34SA

C32BRK

COLOR

RD/WH

RD/BK

RD C27AUX

C28TTA

C29MS

1

C1P DT06-12SA

GR/BK

GR/WH

11PLUG

PLUG 12

PLUG

PLUG

PLUG

C18JD

C19JSV

8

10

9

7

6

C14PLU

C15PLD

C13DRE

C17JU

C4P DT06-12SD

OR/BK

GR/BK

GR

BL/RD

OR

COLOR

3

4

5

2

1

CKT # PIN #

CKT # PIN #

3C3PBFRD/WH

WH/BK

BK/WH

GR/BK

BL/WH

WH/RD

BL/BK

BL

BK

WH

8C8PBR

JALARM

C11SBD

C12SBF

C10SBU

11

12

10

9

C7PBE

C6TRF

C4TRL

C5TRR

7

6

4

5

C3P DT06-12SC

COLOR

RD/BK

RD C1PBU

C2PBD 2

1

RD/BK

WH/RD

BL/WH

BL/BK

GR/WH

38

39

40

C45GEN

C40LS1 OR

35

37

36

34

33

30

32

31

29

28

R116HYD

C36STC

C37STCC

R21IGN

BL

WH

OR

P46PWR

C32TA

C28TTA

COLOR

RD/BK

WH/BK

RD/WH

BK/WH

WH/RD

BL/RD

GR/BK

OR/BK

RD/BK

C6TRF6

22

25

26

27

24

23

21

20

18

19

17

C116HYD

C134PWR

C27AUX

GND

BK

BR

RD

RD

C18JD

C17JU

C2DA

GR

11

14

15

16

13

12

10

9

7

8

C14PLU

C13DRE

C15PLD

R43HRN

OR

BK

C8PBR

C7PBE BK

3

5

4

2

1

C3PBF

C4TRL

C5TRR

C2PBD

C1PBU

WH

RD

CIRCUIT # CIRCUIT # COLOR

C1PBU

C2PBD

C5TRR

C4TRL

C3PBF

C7PBE

C8PBR

C6TRF WH/RD

BK/WH

BK

RD/WH

WH/BK

RD/BK

WH

RD

R43HRN

C15PLD

C13DRE

C14PLU

C2DA

C17JU

C18JD

RD/BK

GR/BK

OR/BK

BL/RD

BK

GR

OR

RDC23BAT

C27AUX

C28TTA RD/BK

RD

WH/RDC32TA

P46PWR BL/WH

C37STCC

C36STC

C40LS1

C45GEN GR/WH

OR

BL/BK

BL

PIN# CKT# COLOR

PIN# COLOR CKT#

18

C31EDC

C30EDC

C32BRK22

23

20

21

19

C21IGN

C38ESL

15

17

16

13

14

12

WH/RD

WH/BK

WH

WH

BL/WH

5

TB23

C39LP

8

10

11

9

6

7

C107AF

C41RPM1

3

4

2

BL/RD

WH

OR/BK

WH

18

21

23

22

20

19

C31EDC

C30EDC

C32BRK

WH

WH/RD

WH/BK

4

11

14

16

17

15

13

12

7

9

10

8

6

5

2

3

1

C21IGN

C25PSR

C26TSR

C38ESL

C127TST

VSW

C39LP

C35RPM

R33STR

WH(12)

WH/RD

WH/BK

WH

GR

BL/WH

BL/RD

BK/RD

BK

C107AF

C41RPMOR/BK

WH

R27AUXRD

WH R21IGN

24 C29MS RD/WH 24 RD/WH C29MS

C34SA BK/WH

C4

C2

BROWN

BLACK

GRAY

GREEN

C3

C1

C7BK

WH

BRN

COLOR CKT # PIN #

P23BAT

BATGND

PLUG

P22BAT

C7: DTP06-4S

4

2

3

1

A

C6

C1

C2

C4

C3

C7

C5-GBOX

C5-ENGINE HARNESS

C9 FS DT04-4P

RD

WH

BK

COLOR

3P25BAT

N/C 4

P24FS

CKT # PIN #

P22ESTOP 1

2

C9

N/A

* NOTE: WIRE ONLY IN C7B CONNECTOR.

C6-GBOX C6-FUNCTION HARNESS

C133PLA

C134PWR

C132PLI


6 - 6

Connector Pin Legend

6 - 5


6 - 7

Electrical SchematicDeutz F3L 1011F Models (before serial number 7544)

6 - 8

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N


6 - 8 S-40 • S-45 Part No. 102521

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

-

IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TIL

TA

LA

RM

PUMP

BR

NB

K

OR

/BK

-41

12 VDC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-13

4

RD

-27

RD

/BK

-28

BK

-43

CR5NO CR5

PR1

RD

WH

NO

PR1

WA

TE

RT

EM

P

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

SW

ITC

H

FU

EL

RE

LA

Y

OIL

PR

ES

SU

RE

SW

ITC

H

NC

OTS

NO

FL

AS

HIN

GB

EA

CO

NS

GL

OW

PL

UG

OP

TI O

N

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

WH

-24

OPS

TB25 TB26

WH

-21

NOCR1 CR1

CR2NO

TB21

7

10

9

8CR2

ENG. FAULT

KEY BYPASSIGN./FUEL ON

KEY PWR.

GR

/WH

-45

C5

-22

PR2NOPR2

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

4

3

5

2

1

AUX. ONGROUND

TACHOMETERSTART INPUT

IGN./START

MODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

C3

4S

AB

K/W

H

TB34

BK TB45

TS56

C1

-8

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

TS6

BRN

BK

/RD

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55

RD

RD

WH

BK

OR/BK

C1

-9

GE

NE

RA

TO

R

G2 G3

G1

VO

LT

ME

TE

R

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

L24

TB24

C5

-15

C5

-16

C5

-14

C5

-5

C6

-27

C6

-28

C6

-23

TB43

C6

-16

C5

-2

C5

-3

FAN

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.S

WIT

CH

HY

DR

AU

LIC

OIL

NOOTS

CR17NO

CR17

CB3

20AMP.

C6

-33

C6

-34

C6

-25

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

H6 L45

6 U33

12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1P3

LS18

RD

L4

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40D39B

K/R

D-C

5-8

NO CR4

NO CR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

FU

NC

TIO

NE

NA

.

2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

IN THE STOWED POSITION AND KEYSWITCH "OFF".

1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

NOTE:

WH

/BK

C6

-39

L5

D6

C6

-26

TS17

TS4

HIG

HR

PM

(FS

)

SEE NOTE 2

SEE NOTE 2

AUXHM

STARTER

STA

RT

EN

GIN

E

PU

MP

AU

XIL

IAR

Y

ON

PL

UG

GL

OW

STA

RT

EN

GIN

E

ON

GL

OW

PL

UG

PU

MP

AU

XIL

AR

Y


TB 134 IS WAGO TERMINAL BLOCK 42TB 133 IS WAGO TERMINAL BLOCK 16TB 132 IS WAGO TERMINAL BLOCK 38

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 9


C6

-4

C6

-6

C6

-2

C6

-3

C6

-8

C6

-18

DR

IVE

LIM

ITS

WIT

CH

BO

OM

RE

TR

AC

T

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

LS

2-P

RIM

AR

YB

OO

MU

P

DE

SC

EN

TA

LA

RM

OP

TIO

N

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

JIB

VA

LV

ES

BRN

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

DR

IVE

LIM

ITS

WIT

CH

NOHC NONC

WH

BK

WH

BK

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

NOHCW

H

BK

TB22

H3

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C5

-21

C6

-36

C6

-37

C5

-20

C5

-23

H4

GR

OU

ND

14

13

12C19JSV GR/WH

TS59

TB19

TB17TB18

C6

-17

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

P-7

JD

AL

AR

MG

R/B

K

C1

7JU

GR

C1

8JD

GR

/BK

TS57TS58

TB44

C4

P-5

C2

P-6

C4

P-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

KC1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

C6

-7

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0L

S1

OR

C4

P-2

C4

P-3

C3

P-7

C3

P-8

C2

P-2

C1

3D

RE

BL

/RD

TS63

C4

P-1

C3

P-2

C3

P-3

TS9

BRN

JIB

VA

LV

E

WH

CR13

TS8TS7

GR

/BK

-44

WH

NCCR13

WH

BK

OR/BK

JOYSTICK CONTROL CARD

TS13

CE

OPTION

LIFT/DRIVE

4

NOCR30

CR27NC

BR

N

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK

16

15

1920

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3C

6-1

C6

-5

TB1

TB2TB5

TB4

TB32

TB37

TB36 TB31

TB30

C1

PB

UR

D

TS61 C4

TR

LW

HTS62

C3

P-1

C3

P-6

C3

P-4

C3

P-5

C1

P-6

C1

P-1

1

C1

P-1

0

C1

P-4

C1

P-5

BR

N-2

C2

P-3

RD

BK

BR

N

OR

J2

6

J1

12 111 2

9

7

PRI UP/DN & TT ROTATE

YO

UT

XO

UT

GN

D

1 2 43 5 6

PW

R

JC2

DR

EA

BL

/WH

DR

EB

BL

/BK

BR

N

OR

BL

WH

DR

EL

ED

BL

/RD

J1

13

14 54 6

J1

7

16 8

15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

76

DRIVE & STEERING

JC3

TS15 L1

5

C6

-32

C6

-13

C6

-40

C6

-15

C6

-14

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H SJ1-WH

C4

0L

S1

OR

C1

7JU

GR

C1

8JD

GR

/BK

AB

DC

C6

-19

RD

/BKC6-30

C1

3D

RE

BL

/RD

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

POSITION EXCEPT AS NOTED.

1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED

NOTE:

7.5 R2R15

LE

FT

RIG

HT

PL

AT

RO

TA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

EX

TE

ND

RE

TR

AC

T BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIB

BO

OM

RIG

HT

LE

FT

JIB

BO

OM

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

LE

FT

RIG

HT

TR

OTA

TE

UP

DO

WN

PR

IMA

RY

BO

OM


1

2

34

5

6

7

6

5

4

3

2

1

Deutsch

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7

Joystick Adaptor Harness


6 - 10


6 - 9

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 11


Ground Control Box Wiring DiagramDeutz F3L 1011F Models

EN

GIN

E

C5

HARNESS:TO BASE

WIRING

BRN GND

WH-23C

BK-C23-5

BR-GNDSTUD

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

C6

C3

B

19

/18

CA

BL

ES

C2

BC

4B

3

2C7

B

1

CR23

RD C4B-11

RD C4B-12

BK/RD-9B

RD-CB3 SP

ALL BR WIRES

BRGROUND STUD

GR

OU

ND

ST

UD

DRIVE LIGHT OPTION RELAY

12

V

32WH/RD-C1B-6

11BL/BK-C3B-11BL-C3B-10

BK/WH-C3B-8BK/RD-C3B-9

RD/WH-C3B-3WH-C3B-4WH/BK-C3B-5WH/RD-C3B-6BK-C3B-7

RD-C3B-1RD/BK-C3B-2

RD-C6-1

D

BK/WH-C6-8

WH/BK-C6-5

RD/WH-C6-3WH-C6-4

WH/RD-C6-6BK-C6-7

RD/BK-C6-2

C B

6

23

1

54

87

109

44B+RD/BK-C6-19

RD-C5-1

WH/BK-C1B-5WH-C1B-4RD/WH-C1B-3

RD-C1B-1

WH-C7B-2

RD/BK-C1B-2

GR/WH-C4B-7GR/BK-C4B-6

BK-C23-4WH-C5-3+C5-11

GR-C4B-5OR/RD-C4B-4

OR-C4B-2OR/BK-C4B-3

BL/RD-C4B-1BL/WH-C3B-12

GR/BK-C6-18

WH-CR2#87

GR-C6-17

BL/RD-C6-13

WH-C6-34

RD-C6-27WH/RD-C5-14WH/BK-C5-16

BK-CR5#30WH-S.P.

16

1312

1514

191817

2120

RED-CR1#30

RD-ISM#4

242322

2526

292827

3031

D6

GR/BK-C2B-6GR/WH-C2B-7

OR/BK-C2B-3

BL/RD-C2B-1OR-C2B-2

OR/RD-C2B-4

BK/RD-C1B-9BK/WH-C1B-8

BL/BK-C1B-11BL-C1B-10

BL/WH-C1B-12

BK-C1B-7

BK/WH-C5-10OR-C6-40OR/BK-C5-2

BK-ISM#3

GR/WH-C6-39

42OR/BK-ISM#2

37

3433

3536

3938

4041

4443

45

RD-S.P.

A

TURN. ROT. L

PRI. BOOM DOWNPRI. BOOM F.C.TURN. ROT. R

TURN. ROT. F.C.BOOM EXTENDBOOM RETRACT

PRI. BOOM UP

WH/RD-S.P.

RD/WH-S.P.

WH/BK-S.P.

RD/BK-S.P.

WH-S.P.

BK/WH-S.P.BK-S.P.

JIB VALVE

PLAT. LEVEL. UPPLAT. LEVEL DN.

PLAT. ROT. L.PLAT. ROT. R.

DRV. ENA. LT.

IGNITION PWR.

OR/BK-S.P.OR-S.P.

GR/WH-SPGR/BK-S.P.GR-S.P.

TILT ALARM

E.D.C.+E.D.C.-

AUX. PWR.

KEYSWITCH PWR/FBPWR. TO PLAT.

ENGINE POWERWH/BK-S.P.WH/RD-S.P.

RD-S.P.WH-S.P.BK-S.P.

RD-S.P.

C134PWR

LIMIT SWITCH SIG.

GLOW PLUG

STEER LEFT

RPMSTEER RIGHT

C132PLI

START

PULSE PICKUP

BK/WH-S.P.BK/RD-S.P.

BK-S.P.

BL/RD-S.P. L.P.

GEN. OPTIONJDALARM JIB

HORN

BRAKE/TRAVEL ALARM

OIL PRESSURE SENDERWATER TEMP. SENDER

IGN./START

MODULEAUX. ON4

BK-ISM#1

BK-C5-5 WH-21B

RD-ISM#6

WH-ISM#9RD-24B

CR1

WH-CR2#86

WH-23BRD-CR2#30

BR-GND.

CR2

KEY BYPASS

ENG. FAULT

IGN./FUEL ON

10

89

67

5BATTERY

KEY PWR.

GROUND

RD-27B

BK-33D

OR/BK-41B

BK-CR1#86


START RELAY

321

BK-C6-16

CR5

BK-22B

BL-C6-36BL/BK-C6-37

RD/BK-C6-28

OR-C6-14OR/BK-C6-15

LIMIT SWITCH POWER46

SPARE

WH/BK-C5-20WH-C5-21

WH/RD-C5-23

BL/WH-C6-30

WH/RD-C6-32

GR-43D

BL/WH-L2

CR17

OR-C6-33

RD-CB3 SP

BK-C6-25

BR-GND+C6-26

GR-C2B-5 GR-CR5#86

BK/WH-C5-22

RD-C5-19

BK/RD-C5-9

BK/RD-35B

CR3 CR4

BK/RD-CR23#87 DRIVE LIGHT OPTION

C133PLA

GR/BK-2B

H6U33PLATFORM LOAD

C23

BL/WH-C23-3

BL/WH-38D - C23-3 RD-C23-1

RD-H6+

RD-42B

RD-KS1-2 S.P.RD-C6-23

RD-TS51 - C23-6

BR - GND - C23-12

RD-H6+ - C23-1

RD-TS55 - C23-7

GN/BK-C23-8 GN/BK-H6-

GN/BK-L45-GN/BK-16A

BK-22C - C23-4BK-C7-1 - C23-5

GN/BK-16B - C23-8

RD- 12VOLT CB3-SP CB2-SP CB1 - SP 12 VOLT BATTERY POWER

KS1

TS56

B

B1

1

24

3

RD

KEY SWITCH

WH/RD-26A

BR (GROUND)

WH-21A

WH/BK-25A

G3G2G1

WH-21A

BR (GROUND)

BK/WH-34A

TS52BK-33A

BK/RD-35A

CB1 CB2

CB3

TS58

TS59

TS57

TS62

RD- 20A

RD- 20B

RD- 20C

RD- 24A

RD-CR17#30

P1

NC

NC

RD- P1 E-STOP

TS61

TS63

BK-22A

L2

WH-23A

BL/WH-C5-15BL/WH-ISM#10

RD-C23-6

TS55

OR-14A

OR/BK-15A

GR-17A

GR/BK-18A

GR/WH-19A

RD-H6+

OR/RD-H6-

WH-4

WH/BK-5WH/RD-6

GR/BK-44A

R2

BK-7ABK/WH-8A

RD-1ARD/BK-2ARD/WH-3A

L45

RD-CB2

D13

D14

GR/BK-S.P.

RD-42ARD-27A

TS51

HM

RD-C23-7

KS1

CB1

CB3

CB2

L28

CR1

U33

L45

TS63

CR17

CR4

CR3

CR2

TS62

TS58

TS61

TS57

TS51

TS55

TS52

LABEL

TS59

IGN. POWER RELAY

PLAT OVERLOAD MODULE

PLATFORM OVERLOAD ALARM

PLAT OVERLOAD LED

COOLING FAN RELAY

HIGH IDLE (RPM) CUTOUT RELAY

RPM RELAY

DESCRIPTION

IGN. START RELAY

CIRCUIT BREAKER, OPTIONS, 20A

RESISTOR, 7.5 OHM,TURNTABLE FUNCTION

BOOM EXTEND/RETRACT SWITCH

CIRCUIT BREAKER, ENGINE, 15A

CIRCUIT BREAKER, CONTROLS, 15A

PRIMARY BOOM UP/DOWN SWITCH

PLATFORM ROTATE SWITCH

TURNTABLE ROTATE SWITCH

PLATFORM LEVEL SWITCH

JIB BOOM UP/DOWN SWITCH

EMERGENCY STOP BUTTON

OIL PRESSURE GAGE

ENGINE START SWITCH

OIL TEMP. GAGE

HOUR METER

STARTER AID

VOLT METER GAGE

KEY SWITCH

FUNCTION ENABLE

AUXILIARY SWITCH

CR2

CR17

CR4

CR3

H6

PART #

13037

CB3

R2

CB2

CB1

56298

CR1

G3

HM

G2

G1G1

HM

G3

G2

R2

P1

42730

KS1

13037

13037

16397

13037

16397

13037

16397

P1

BK/RD CR3-#30

WH-ISM #7

R1

RESISTOR, 5 OHM, BOOM FUNCTION R1 R1


6 - 12

Ground Control Box Wiring DiagramDeutz F3L 1011F Models

6 - 11


6 - 13

Platform Control Box Wiring Diagram- ALC-500Deutz F3L 1011F Models

6 - 14

1

2

3

4

5

6

7

8



6 - 14 S-40 • S-45 Part No. 102521

TILT ALARM 45383

COMPONENT INDEX PART NUMBER

H1

ALC-500 89353

D4

0

RE

D/B

LK

-28

H1

ALALRMTILT

RE

D-T

ILT

D3

9

BR

N

GN/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C7P

C4P

C3P

C2

8T

TA

RD

/BK

C1

P-2

GN

/BK

L4

8

C2

9M

SR

D/W

H

C1

3L

ED

BL

/RD

DR

EB

BL

/BK

DR

EA

BL

/WH

C28TTA RD/BK C1P-2

RE

D-T

ILT

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

H

JC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

1

9

RD

/BK

L4

J1

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0

C1

3D

RE

BL

/RD

C4

P-1

C11

SB

DB

L/B

KC

3P

-11

C4

0L

S1

OR

C2

P-2

C1

2S

BF

BL

/WH

C3

P-1

2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C1

PB

UR

DC

3P

-1

C3

1E

DC

-W

H/B

KC

1P

-5

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

BL

/BK

C1

P-1

1

C3

PB

FR

D/W

HC

3P

-3

C3

6S

TC

CB

LC

1P

-10

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6

C5

TR

RW

H/B

KC

3P

-5

C2

9M

SR

D/W

HC

1P

-3

C2P

J2

11

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H

J3

1

3

C3P

OPT.

BR

N

F.S.

C9P

F.S.

LS18JIB

C1

9JS

VG

R/W

HC

4P

-7A

ND

TS

8

C3

9L

PB

L/R

DC

2P

-1

C4

5G

EN

GR

/WH

C2

P-7

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

DL

ITE

GR

/BK

C2

P-6

C1

7JU

GR

C4

P-5

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2

P2

5F

SR

DC

9P

-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

JD

AL

AR

MG

R/B

KC

2P

-6

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

C1

32

PL

IB

KC

1P

-12

RD

H1

RD

P2

P2

6B

AT

BK

HARNESS

PBOX WIRING

DR

IVE

LT

BK

/RD

C3

P-9

Platform Control Box Wiring DiagramDeutz F3L 1011F Models

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 15


Platform Control Box Switch Panel Wiring DiagramDeutz F3L 1011F Models

EMERGENCY STOP

P2START

TS2

DRV.ENA

TS15

L1

AUXILIARY PUMP

TS13

PRIMARY

BOOM

EXTEND/

RETRACT

TS8JIB

PLATFORMTS7

PLATFORM

LEVEL

TS9P3HORN

ROTATE

TS1

GR

-43

OR

-14

OR

/BK

-15

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HJIB

C1

7JU

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

RD

-25

BK

-33

WH

-23

P2

6B

AT

BK

C9

P-1

P2

2B

AT

BK

C7

P-1

BK

-22

RD

LS

18

RD

P2

WH

GR/BK

GR

BK

/WH

-8

BL

/RD

-DE

3J1

-16

BL

/WH

-DE

1J1

-6

BK

-7

WH

WH

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

HARNESSPBOX WIRING

BL

/BK

-DE

2J1

-7

OR

J1

-13

BR

NJ1

-14

BL

J1

-4

WH

J1

-5

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3JC2

CR13

WH

-JIB

C1

9JS

VG

R/W

H

WH

-24

BR

N

WH

-JIB

4

2

1

3

5

6

7

WH

-24

BK

-22

WH

-24

(SPLICE TO R40LS1)

(SPLICE TO C32BRK)

OR R40LS1

WH/RD C32BRK

WH TS7

CR30

CR27WH TS1

DETAIL A: LIFT/DRIVE OPTION

REPLACE WIRE WITH THIS WIRING DIAGRAM

(GND STUD)

BRN BATGND

CE SEE DETAIL A

RD

WL

1

DL

ITE

/R

DW

L2

WH

J1

-5

+

C3

4S

AB

K/W

HC

1P

-8

GLOW PLUG

TS6

RD

L4

L48

4

2

1

3

5

6

7

RD

/BK

H1

GN

/BK

H1

RD

P3

RD

RD

1) DASHED LINES INDICATE OPTION WIRES.

NOTE:

+

+

DR

IVE

LT

BK

/RD

-C3

P-9

(OPTION)

TS47

GENERATOR

GR

/WH

-45

RD

RD

WH

-24

REMOVE FOR GENERATOR OPTION

BK

/RD

-35

TS4

WH

-24

HIGH/LOW

RPM

TS47

JC3L1

JC2

TS1

TS13

TS4

TS15

TS8

TS6

TS9

TS7

TS2

P2P3

BOOM PROPORTIONAL JOYSTICK:

DRIVE PROPORTIONAL JOYSTICKDRIVE ENABLE LED

AUXILIARY SWITCH

GENERATOR SWITCH ( OPTION )

START ENGINE SWITCH



GLOW PLUG OPTION

JIB UP/DOWN SWITCH

PRIMARY BOOM EXTEND/RETRACT SWITCH

HI/L0 RPM SWITCH

DRIVE ENABLE SWITCH


COMPONENT INDEX

HORN SWITCH

PRIMARY UP/DN , TURNTABLE ROTATE

PART NUMBER

66812, 7380566813, 668164273013037

27378

16397130371303713037

1303727378

56298

62390

75565

TS48-9 WORK/DRIVE LIGHT ( OPTION ) 27378

56298

TS48/TS49

WORK/ DRIVE LITE

NO 34

12

12

NC

NC


6 - 16

Platform Control Box Switch Panel Wiring DiagramDeutz F3L 1011F Models

6 - 15


6 - 17

Electrical SchematicPerkins 704-30 Models (before serial number 7472)

6 - 18

1

2

3

4

5

6

7

8



6 - 18 S-40 • S-45 Part No. 102521

STA

RT

ER

MO

TO

R

H2

REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

RT

ILT

AL

AR

MB

RN

BK

OR

/BK

-41

12 VDC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-P1

34 R

D-2

7

RD

/BK

-28BK

-43

CR5NO

CR5

PR1RD

WH

NO

PR1

OIL

TE

MP

IGN

./STA

RT

RE

LA

Y

_S

WIT

CH

FU

EL

RE

LA

Y

OIL

PR

ES

SU

RE

SW

ITC

H

NC

OTS

NO

OP

TIO

NG

EN

ER

AT

OR

BK

-33

+

WH

-24

WH

-24

OPS

TB25 TB26

WH

-21

NOCR1

CR1CR2NO

TB21

CR2

GR

/WH

-45

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)

BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

BK

/RD

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55

RD

RD

WH

BK

OR/BK

GE

NE

RA

TO

R

L5

G2 G3

G1

VO

LT

ME

TE

R

OIL

PR

ES

SU

RE

GA

UG

E

OIL

TE

MP

GA

UG

E

TB34

CO

NT

RO

LL

ER

1

6

5

74

3

GL

OW

PL

UG

L24

L28

TB24 C6

-39

C5

-15

C5

-16

C5

-14

C5

-5

C6

-27

C6

-28

C6

-23

TB43

C6

-16

C5

-2

C5

-3

FAN

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.S

WIT

CH

HY

DR

AU

LIC

OIL

NOOTS

CR17NO

CR17

CB320AMP.

C6

-33

C6

-34

C6

-25

C1

-12

NO CR4

NO CR3

BK

/RD

-C5

-8

HIG

HID

LE

RE

LA

Y

HIG

HR

PM

SO

LE

NO

IDTB134

P1RD

TB22

PLAT

GRD

KS1

RD

H6 L45

6 U33

12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1

P3

LS18

RD

L4

P2

C28TTA RD/BK RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40D39

OP

TIO

NF

LA

SH

ING

BE

AC

ON

S

FB

WH

/RD

WH

/BK

D6

C1

-9

TS4

HIG

HR

PM

(FS

)

SEE NOTE 2

SEE NOTE 2

TS17

C6

-26

AU

XIL

IAR

YP

UM

P

HO

UR

ME

TE

R

HM

AU

XIL

IAR

YP

UM

P

STA

RT

EN

GIN

E

EN

GIN

ES

TA

RT

NOTE:




CO

NT

RO

LL

ER

GL

OW

PL

UG

PUMPAUX

STARTER

6 BATTERY7

10

9

8

ENG. FAULT


KEY PWR.

4

3

5

2

1

AUX. ONGROUND


IGN./START

MODULE

START RELAY



1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 19



1

2

34

5

6

7

6

5

4

3

2

1

Deutsch

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7


C6

-4

C6

-6

C6

-2

C6

-3

C6

-8

C6

-18

DR

IVE

LIM

IT S

WIT

CH

BO

OM

RE

TR

AC

T

LS

1-P

RIM

AR

Y B

OO

M E

XT

EN

D

LS

2-P

RIM

AR

Y B

OO

M U

P

DE

SC

EN

T A

LA

RM

OP

TIO

N

PLA

TF

OR

M R

OTA

TE

RIG

HT

/ JIB

DO

WN

PLA

TF

OR

M R

OTA

TE

LE

FT

/ JIB

UP

JIB

VA

LVE

S

BRN

PLA

T L

EV

EL U

P

PLA

T L

EV

EL D

OW

N

DR

IVE

LIM

IT S

WIT

CH

NOHC NCHO

WH

BK

WH

BK

BO

OM

EX

TE

ND

LIM

IT S

WIT

CH

DR

IVE

EN

AB

LE

NOHC

WH

BK

TB22

BR

AK

E R

ELE

AS

E V

ALV

E

TR

AV

EL A

LA

RM

OP

TIO

N

DR

IVE

ED

C R

EV

ER

SE

DR

IVE

ED

C F

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

LE

FT

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

FLO

W C

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

W C

ON

TR

OL

ST

EE

R L

EF

T

ST

EE

R R

IGH

T

C5

-21

C6

-36

C6

-37

C5

-20

C5

-23

H4

GR

OU

ND

14

13

12C19JSV GR/WH

TS59

TB19

TB17

TB18

C6

-17

TB15

C1

9JS

V G

R/W

H

RD

RD

C4

P-7

JD

ALA

RM

GR

/BK

C1

7JU

GR

C1

8JD

GR

/BK

TS57

TS58

TB44

C4

P-5

C2

P-6

C4

P-6

C3

PB

F R

D/W

H

C2

PB

D R

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

C6

-7

TB8

TB7 TB13TB40

C7

PB

E B

K

C8

PB

R B

K/W

H

C4

0LS

1 O

R

C4

P-2

C4

P-3

C3

P-7

C3

P-8

C2

P-2

C1

3D

RE

BL/R

D

TS63

C4

P-1

C3

P-2

C3

P-3

TS9

BRN

JIB

VA

LVE

WH

CR13

TS8TS7

GR

/BK

-44

WH

NCCR13

WH

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE

4

NOCR30

CR27NC

BR

N

P2

4F

S W

H

P2

4F

S W

H

P2

6E

ST

P B

K3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK

16

15

19

20

17

1811

10

C3

0E

DC

+ W

H

C3

2B

RK

WH

/RD

C6

TR

F W

H/R

D

C3

6S

TC

BL

C3

7S

TC

C B

L/B

K

C3

1E

DC

- WH

/BK

C5

TR

R W

H/B

K

TB6TB3

C6

-1

C6

-5

TB1

TB2 TB5

TB4 TB32TB37TB36 TB31 TB30

C1

PB

U R

D

TS61 C4

TR

L W

H

TS62

C3

P-1

C3

P-6

C3

P-4

C3

P-5

C1

P-6

C1

P-1

1

C1

P-1

0

C1

P-4

C1

P-5

BR

N-2

C2

P-3

RD

BK

BR

N

OR

J2

6

J1

12 111 2

9

7


YO

UT

XO

UT

GN

D

1 2 43 5 6

PW

R

JC2

DR

E A

BL/W

H

DR

E B

BL/B

K

BR

N

OR BL

WH

DR

E L

ED

BL/R

D

J1

13

14 54 6

J1

7 16 8 15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

76

DRIVE & STEERING

JC3TS15 L1

5

C6

-32

C6

-13

C6

-40

C6

-15

C6

-14

C3

1E

DC

- WH

/BK

C3

0E

DC

+ W

H

C3

2B

RK

WH

/RD

C3

7S

TC

C B

L/B

K

C3

6S

TC

BL

C6

TR

F W

H/R

D

C5

TR

R W

H/B

K

C4

TR

L W

H

C1

PB

U R

D

C2

PB

D R

D/B

K

C3

PB

F R

D/W

H

C7

PB

E B

K

C8

PB

R B

K/W

H

SJ1-WH

C4

0LS

1 O

RC1

7JU

GR

C1

8JD

GR

/BK

AB

DC

C6

-19

RD

/BK

C6-30

C1

3D

RE

BL/R

DC1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK



NOTE:

7.5

R2R1

5

Y17 Y16 Y19 Y20 Y26 Y25H4

Y12 Y21 Y22 Y13 Y29 Y23 Y4 Y3 Y2 Y51

BL/WH

C1

P-3

C5

-19

C2

9M

S R

D/W

H

Y27

MO

TO

R S

TR

OK

E

TB29

C2

9M

S R

D/W

H

TS14

PLA

T R

OTA

TE

LE

FT

RIG

HT

JIB

BO

OM

UP

DO

WN

BO

OM

RE

TR

AC

T

EX

TE

ND

PLA

T R

OTA

TE

LE

FT

RIG

HT

JIB

BO

OM

UP

DO

WN

PLA

T L

EV

EL

UP

DO

WN

UP

DO

WN

PLA

TF

OR

M L

EV

EL

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN

BO

OM

LE

FT

RIG

HTT

RO

TA

TE

C2

9M

S

DR

IVE

EN

AB

LE


6 - 20


6 - 19

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 21


Ground Control Box Wiring DiagramPerkins 704-30 Models

C7

B

12

VT

OP

LA

T

BK-C23-5

GR

OU

ND

ST

UD

ALL BR WIRES

GROUND STUDBR

C4

BC

2B

C3

BC

6C

1B

C5

EN

GIN

EF

UN

CT

ION

S1

9/1

8C

AB

LE

S

WH-23C12

GN/BK-16B - C23-8

BK-C7-1 - C23-5BK-22C - C23-4

RD-TS55 - C23-7

RD-H6+ - C23-1

BR - GND - C23-12

RD-TS51 - C23-6

BL/WH-38D - C23-3

12

V

BR-GND STUD3

PLATFORMLOAD

U33 C23

GN/BK-16AGN/BK-L45-

RD-42BRD-C23-1

H6

32WH/RD-C1B-6




RD-C3B-1RD/BK-C3B-2

RD-C6-1

D

BK/WH-C6-8

WH/BK-C6-5

RD/WH-C6-3WH-C6-4

WH/RD-C6-6BK-C6-7

RD/BK-C6-2

C B

6

23

1

54

8

7

109

44B+RD/BK-C6-19

RD-C5-1

WH/BK-C1B-5WH-C1B-4RD/WH-C1B-3

RD-C1B-1

RD- C5-19

RD/BK-C1B-2


BK-C23-4WH-C5-3+C5-11

GR-C4B-5OR/RD-C4B-4

OR-C4B-2OR/BK-C4B-3


GR/BK-C6-18

WH-CR2#87

GR-C6-17

BL/RD-C6-13

WH-C6-34

RD-C6-27

BK-CR5#30WH-S.P.

16

1312

15

14

19

1817

21

20

RED-CR1#30

RD-ISM#4

242322

2526

29

2827

3031

D6


OR/BK-C2B-3

BL/RD-C2B-1

OR-C2B-2

OR/RD-C2B-4



BL/WH-C1B-12

BK-C1B-7

BK/WH-C5-10OR-C6-40OR/BK-C5-2

BK-ISM#3

GR/WH-C6-39

42OR/BK-ISM#2

37

3433

3536

3938

4041

44

43

45

RD-S.P.

A

TURN. ROT. R

PRI. BOOM DOWN

PRI. BOOM F.C.

TURN. ROT. LTURN. ROT. F.C.

PRI. BOOM UP

WH/RD-S.P.

RD/WH-S.P.

WH/BK-S.P.

RD/BK-S.P.

WH-S.P.

BK/WH-S.P.BK-S.P.

JIB VALVE



DRV. ENA. LT.

IGNITION PWR.

OR/BK-S.P.

OR-S.P.


TILT ALARM

E.D.C.+E.D.C.-

AUX. PWR.


ENGINE POWERWH/BK-S.P.

WH/RD-S.P.

RD-S.P.

BK-S.P.

RD-S.P.

C134PWR

LIMIT SWITCH SIG.

GLOW PLUG

STEER LEFT

RPMSTEER RIGHT

C132PLI

START

PULSE PICKUP


BK-S.P.

BL/RD-S.P. L.P.

GEN. OPTION

HORN

BRAKE/TRAVEL ALARM


BL-C6-36

BL/BK-C6-37

RD/BK-C6-28

OR-C6-14

OR/BK-C6-15

46

SPARE

WH/BK-C5-20WH-C5-21

WH/RD-C5-23

BL/WH-C6-30

WH/RD-C6-32

GR-C2B-5 GR-CR5#86

BK/WH-C5-22


C133PLA

GR/BK-2B

BL/WH-C23-3

RD-H6+ RD-KS1-2 S.P.RD-C6-23

GR/BK-C23-8 GR/BK-H6-


GR/BK-S.P.

BK/RD CR3-#30

WH-SP. 46A+WH

LIMIT SWITCH POWER

HARNESS:TO BASE

WIRING

KS1B

B1

1

24

3

RD

KEY SWITCH

WH/RD-26A

BR (GROUND)

WH-21A

WH/BK-25A

G3G2G1

WH-21A

BR (GROUND)

BK/WH-34ATS52BK-33A

BK/RD-35A

CB1 CB2

CB3

TS58

TS59

TS57

TS62

RD- 20A

RD- 20B

RD- 20C

RD- 24A

RD-CR17#30

P1

NC

NC

RD- P1 E-STOP

TS61

TS63

BK-22A

L2

WH-23A

BL/WH-C5-15BL/WH-ISM#10

RD-C23-6

TS55

OR-14A

OR/BK-15A

GR-17A

GR/BK-18A

GR/WH-19A

RD-H6+

OR/RD-H6-

WH-4

WH/BK-5WH/RD-6

GR/BK-44A

R2

BK-7ABK/WH-8A

RD-1ARD/BK-2ARD/WH-3A

L45

RD-CB2

D13

D14

RD-42ARD-27A

TS51

HM

RD-C23-7

R1IGN./START

MODULEAUX. ON4

BK-ISM#1

BK-C5-5 WH-21B

RD-ISM#6

WH-ISM#9RD-24B

CR1

WH-CR2#86

WH-23BRD-CR2#30

BR-GND.

CR2

KEY BYPASS

ENG. FAULT

IGN./FUEL ON

10

89

67

5BATTERY

KEY PWR.

GROUND

RD-27B

BK-33D

OR/BK-41B

BK-CR1#86


START RELAY

321

BK-C6-16

CR5

BK-22BGR-43D

BL/WH-L2

CR17

OR-C6-33

RD-CB3 SP

BK-C6-25

BR-GND+C6-26

BK/RD-C5-9

BK/RD-35B

CR3 CR4

L28

+

-BR-GND

BRN GND

CR23

RD C4B-11

RD C4B-12

BK/RD-9B

RD-CB3 SP


KS1

CB1

CB3

CB2

L28

CR1

U33

L45

TS63

CR17

CR4

CR3

CR2

TS62

TS58

TS61

TS57

TS51

TS55

TS52

LABEL

TS59

IGN. POWER RELAY



PLAT OVERLOAD LED

COOLING FAN RELAY


RPM RELAY

DESCRIPTION

IGN. START RELAY


RESISTOR, 7.5 OHM,TURNTABLE FUNCTION










OIL PRESSURE GAGE

ENGINE START SWITCH

OIL TEMP. GAGE

HOUR METER

STARTER AID

VOLT METER GAGE

KEY SWITCH

FUNCTION ENABLE

AUXILIARY SWITCH

CR2

CR17

CR4

CR3

H6

PART #

13037

CB3

R2

CB2

CB1

56298

CR1

G3

HM

G2

G1G1

HM

G3

G2

R2

P1

42730

KS1

13037

13037

16397

13037

16397

13037

16397

P1


BK-ISM#3

JDALARM JIB

WH/RD-C5-14WH/BK-C5-16

WH-C7B-2

BOOM RETRACTBOOM EXTEND


6 - 22

Ground Control Box Wiring DiagramPerkins 704-30 Models

6 - 21


6 - 23

Platform Control Box Wiring DiagramPerkins 704-30 Models

6 - 24

1

2

3

4

5

6

7

8



6 - 24 S-40 • S-45 Part No. 102521

Platform Control Box Wiring DiagramPerkins 704-30 Models

TILT ALARM 45383


H1

ALC-500 89353

D4

0

RE

D/B

LK

-28

H1

ALALRMTILT

RE

D-T

ILT

D3

9

BR

N

GN/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C7P

C4P

C3P

C2

8T

TA

RD

/BK

C1

P-2

GN

/BK

L4

8

C2

9M

SR

D/W

H

C1

3L

ED

BL

/RD

DR

EB

BL

/BK

DR

EA

BL

/WH

C28TTA RD/BK C1P-2

RE

D-T

ILT

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

H

JC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

1

9

RD

/BK

L4

J1

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0

C1

3D

RE

BL

/RD

C4

P-1

C11

SB

DB

L/B

KC

3P

-11

C4

0L

S1

OR

C2

P-2

C1

2S

BF

BL

/WH

C3

P-1

2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C1

PB

UR

DC

3P

-1

C3

1E

DC

-W

H/B

KC

1P

-5

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

BL

/BK

C1

P-1

1

C3

PB

FR

D/W

HC

3P

-3

C3

6S

TC

CB

LC

1P

-10

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6

C5

TR

RW

H/B

KC

3P

-5

C2

9M

SR

D/W

HC

1P

-3

C2P

J2

11

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H

J3

1

3

C3P

OPT.

BR

N

F.S.

C9P

F.S.

LS18JIB

C1

9JS

VG

R/W

HC

4P

-7A

ND

TS

8

C3

9L

PB

L/R

DC

2P

-1

C4

5G

EN

GR

/WH

C2

P-7

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

DL

ITE

GR

/BK

C2

P-6

C1

7JU

GR

C4

P-5

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2

P2

5F

SR

DC

9P

-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

JD

AL

AR

MG

R/B

KC

2P

-6

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

C1

32

PL

IB

KC

1P

-12

RD

H1

RD

P2

P2

6B

AT

BK

HARNESS

PBOX WIRING

DR

IVE

LT

BK

/RD

C3

P-9

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 25


Platform Control Box Switch Panel Wiring DiagramPerkins 704-30 Models

EMERGENCY STOP

P2START

TS2

DRV.ENA

TS15

L1

AUXILIARY PUMP

TS13

PRIMARY

BOOM

EXTEND/

RETRACT

TS8JIB

PLATFORMTS7

PLATFORM

LEVEL

TS9P3HORN

ROTATE

TS1

GR

-43

OR

-14

OR

/BK

-15

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HJIB

C1

7JU

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

RD

-25

BK

-33

WH

-23

P2

6B

AT

BK

C9

P-1

P2

2B

AT

BK

C7

P-1

BK

-22

RD

LS

18

RD

P2

WH

GR/BK

GR

BK

/WH

-8

BL

/RD

-DE

3J1

-16

BL

/WH

-DE

1J1

-6

BK

-7

WH

WH

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

HARNESSPBOX WIRING

BL

/BK

-DE

2J1

-7

OR

J1

-13

BR

NJ1

-14

BL

J1

-4

WH

J1

-5

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3JC2

CR13

WH

-JIB

C1

9JS

VG

R/W

H

WH

-24

BR

N

WH

-JIB

4

2

1

3

5

6

7

WH

-24

BK

-22

WH

-24

(SPLICE TO R40LS1)

(SPLICE TO C32BRK)

OR R40LS1

WH/RD C32BRK

WH TS7

CR30

CR27WH TS1



(GND STUD)

BRN BATGND

CE SEE DETAIL A

RD

WL

1

DL

ITE

/R

DW

L2

WH

J1

-5+

C3

4S

AB

K/W

HC

1P

-8

GLOW PLUG

L24

L4

L48

4

2

1

3

5

6

7

RD

/BK

H1

GN

/BK

H1

RD

P3

RD

RD


NOTE:

+

+

DR

IVE

LT

BK

/RD

-C3

P-9

(OPTION)

TS47

GENERATOR

GR

/WH

-45

RD

RD

WH

-24


BK

/RD

-35

TS4

WH

-24

HIGH/LOW

RPM

TS47

JC3L1

JC2

TS1

TS13

TS4

TS15

TS8

L24

TS9

TS7

TS2

P2P3



AUXILIARY SWITCH


START ENGINE SWITCH



GLOW PLUG INDICATOR

JIB UP/DOWN SWITCH


HI/L0 RPM SWITCH

DRIVE ENABLE SWITCH


COMPONENT INDEX

HORN SWITCH


PART NUMBER

66812, 7380566813, 668164273013037

27378

16397130371303713037

1303727378

56298

62390

75565


56298

TS48/TS49

WORK/ DRIVE LITE

NO 34

12

12

NC

NC

+

BR

N

RD

-TIL

T


6 - 26

Platform Control Box Switch Panel Wiring DiagramPerkins 704-30 Models

6 - 25


6 - 27

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)

Perkins 404-22 Models (from serial number 7472 to 12509)

6 - 28

1

2

3

4

5

6

7

8



6 - 28 S-40 • S-45 Part No. 102521

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)Perkins 404-22 Models (from serial number 7472 to 12509)

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

RT

ILT

AL

AR

M

PUMP

BR

NB

K

OR

/BK

-41

12 VDC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-13

4

RD

-27

RD

/BK

-28

BK

-43

CR5NO CR5

PR1

RD

WH

NO

PR1W

AT

ER

TE

MP

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

SW

ITC

H

FU

EL

RE

LA

Y

OIL

PR

ES

SU

RE

SW

ITC

H

NCNO

FL

AS

HIN

GB

EA

CO

NS

GL

OW

PL

UG

OP

TIO

N

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

TB25 TB26

WH

-21

NO

CR1 CR1CR2NO

TB21

7

1098CR2

ENG. FAULT


KEY PWR.

GR

/WH

-45

C5

-22

PR3NOPR3

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

C3

4S

AB

K/W

H

TB34

BK TB45

TS56

C1

-8

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

TS6

BRN

BK

/RD

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55

RD

RD

WH

BK

OR/BK

C1

-9

GE

NE

RA

TO

R

G2 G3

G1

VO

LT

ME

TE

R

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB24

C5

-13

C5

-5

C6

-27

C6

-28

C6

-23

TB43

C6

-16

C5

-2

C5

-3

FAN

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.S

WIT

CH

HY

DR

AU

LIC

OIL

NOOTS

CR17NO

CR17

CB320AMP.

C6

-33

C6

-34

C6

-25

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

H6L45

6U33

12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RR

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1

P3

LS18

RD

L4

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40D39

BK

/RD

-C5

-8

NO CR4

NO CR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HI D

LE

RE

LA

Y

FU

NC

TIO

NE

NA

.

WH

C6

-39

L2

D6

C6

-26

TS17

TS4

HIG

HR

PM

(FS

)

3

3MF

RP

MF

ILT

ER

3

F18

BK

BK

WH

WH

TS49

RD

RD

TS48

OP

TIO

NW

OR

KL

IGH

TS

OP

TI O

ND

RI V

EL

I GH

T

CR23CR23

NO

PBOX GND

DL

ITE

OR

/RD

C2

B-4

C3

P- 9

FUSE 10A

L29 L29

L30L30

M1

S7

M2

PR2 PR2

G6

S2 S1Y29

C4

B-1

1

BL/WH

C5

-16

WH

/BK

WH

/RD

C5

-14

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

AUXSTARTER

STA

RT

EN

GIN

E

STA

RT

EN

GIN

E

WO

RK

LIG

HT

ON

HM

GL

OW

PL

UG

ON

GL

OW

PL

UG

2

2 THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

IN THE STOWED POSITION AND KEYSWITCH "OFF".1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

NOTE:

C.E. OPTION ONLY3

DR

IVE

LIG

HT

J1

44

-6

J1

44

-4

EM

ISS

ION

CO

NT

RO

L

FU

EL

SO

LE

NO

I DR

EL

AY

C2

1IG

N2

C5

- 11

TB132 IS WAGO TERMINAL BLOCK 42TB133 IS WAGO TERMINAL BLOCK 16TB134 IS WAGO TERMINAL BLOCK 38

NOTE:


1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 29


Electrical SchematicDeutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)


C6

-4

C6

-6

C6

-2

C6

-3

C6

-8

C6

-18

DR

IVE

LIM

IT S

WIT

CH

BO

OM

RE

TR

AC

T

LS

1-P

RIM

AR

Y B

OO

M E

XT

EN

D

LS

2-P

RIM

AR

Y B

OO

M U

P

DE

SC

EN

T A

LA

RM

OP

TIO

N

PLA

TF

OR

M R

OTA

TE

RIG

HT

/ JIB

DO

WN

PLA

TF

OR

M R

OTA

TE

LE

FT

/ JIB

UP

JIB

VA

LVE

S

BRN

PLA

T L

EV

EL U

P

PLA

T L

EV

EL D

OW

N

DR

IVE

LIM

IT S

WIT

CH

NOHC NCHO

WH

BK

WH

BK

BO

OM

EX

TE

ND

LIM

IT S

WIT

CH

DR

IVE

EN

AB

LE

NOHC

WH

BK

TB22

BR

AK

E R

ELE

AS

E V

ALV

E

TR

AV

EL A

LA

RM

OP

TIO

N

DR

IVE

ED

C R

EV

ER

SE

DR

IVE

ED

C F

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

LE

FT

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

FLO

W C

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

W C

ON

TR

OL

ST

EE

R L

EF

T

ST

EE

R R

IGH

T

C5

-21

C6

-36

C6

-37

C5

- 20

C5

-23

H4

GR

OU

ND

14

13

12C19JSV GR/WH

TS59

TB19

TB17

TB18

C6

-17

TB15

C1

9JS

V G

R/W

H

RD

RD

C4

P-7

JD

ALA

RM

GR

/BK

C1

7JU

GR

C1

8JD

GR

/BK

TS57

TS58

TB44

C4

P-5

C2

P-6

C4

P-6

C3

PB

F R

D/W

H

C2

PB

D R

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

C6

-7

TB8

TB7 TB13TB40

C7

PB

E B

K

C8

PB

R B

K/W

H

C4

0LS

1 O

R

C4

P-2

C4

P-3

C3

P-7

C3

P-8

C2

P-2

C1

3D

RE

BL/R

D

TS63

C4

P-1

C3

P-2

C3

P-3

TS9

BRN

JIB

VA

LVE

WH

CR13

TS8TS7

GR

/BK

-44

WH

NCCR13

WH

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE

4

NOCR30

CR27NC

BR

N

P2

4F

S W

H

P2

4F

S W

H

P2

6E

ST

P B

K3

J3

13 4 2

8 7

C4

1R

PM

OR

/ BK

16

15

19

20

17

1811

10

C3

0E

DC

+ W

H

C3

2B

RK

WH

/RD

C6

TR

F W

H/R

D

C3

6S

TC

BL

C3

7S

TC

C B

L/B

K

C3

1E

DC

- WH

/BK

C5

TR

R W

H/B

K

TB6TB3

C6

-1

C6

-5

TB1

TB2 TB5

TB4 TB32TB37TB36 TB31 TB30

C1

PB

U R

D

TS61 C4

TR

L W

H

TS62

C3

P-1

C3

P-6

C3

P-4

C3

P-5

C1

P-6

C1

P-1

1

C1

P-1

0

C1

P-4

C1

P-5

BR

N-2

C2

P-3

RD

BK

BR

N

OR

J2

6

J1

12 111 2

9

7


YO

UT

XO

UT

GN

D

1 2 43 5 6

PW

R

JC2

DR

E A

BL/W

H

DR

E B

BL/B

K

BR

N

OR BL

WH

DR

E L

ED

BL/R

D

J1

13

14 54 6

J1

7 16 8 15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

76

DRIVE & STEERING

JC3TS15 L1

5

C6

-32

C6

-13

C6

-40

C6

-15

C6

-14

C3

1E

DC

- WH

/BK

C3

0E

DC

+ W

H

C3

2B

RK

WH

/RD

C3

7S

TC

C B

L/B

K

C3

6S

TC

BL

C6

TR

F W

H/R

D

C5

TR

R W

H/B

K

C4

TR

L W

H

C1

PB

U R

D

C2

PB

D R

D/B

K

C3

PB

F R

D/W

H

C7

PB

E B

K

C8

PB

R B

K/W

H

SJ1-WH

C4

0LS

1 O

RC1

7JU

GR

C1

8JD

GR

/BK

AB

DC

C6

-19

RD

/BK

C6-30

C1

3D

RE

BL/R

DC1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK



NOTE:

7.5

R2R1

5

Y17 Y16 Y19 Y20 Y26 Y25H4

Y12 Y21 Y22 Y13 Y29 Y23 Y4 Y3 Y2 Y51

BL/WH

C1

P-3

C5

-19

C2

9M

S R

D/W

H

Y27

MO

TO

R S

TR

OK

E

TB29

C2

9M

S R

D/W

H

TS14

PLA

T R

OTA

TE

LE

FT

RIG

HT

JIB

BO

OM

UP

DO

WN

BO

OM

RE

TR

AC

T

EX

TE

ND

PLA

T R

OTA

TE

LE

FT

RIG

HT

JIB

BO

OM

UP

DO

WN

PLA

T L

EV

EL

UP

DO

WN

UP

DO

WN

PLA

TF

OR

M L

EV

EL

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN

BO

OM

LE

FT

RIG

HTT

RO

TA

TE

C2

9M

S

DR

IVE

EN

AB

LE


6 - 30

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)Perkins 404-22 Models (from serial number 7472 to 12509)

6 - 29


6 - 31

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models

(from serial number 12510 to 14831)

6 - 32

1

2

3

4

5

6

7

8



6 - 32 S-40 • S-45 Part No. 102521

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models(from serial number 12510 to 14831)

Note:TB132 is WAGO terminal block 42TB133 is WAGO terminal block 16TB134 is WAGO terminal block 38

FAN

FUSE 70A

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TIL

TA

LA

RM

PUMPBK

OR

/BK

-41

12 V

DC

+

+BAT.

STA.

BAT.-

EXCT.

RD

-13

4

RD

-27

RD

/BK

-28B

K-4

3

CR5NO CR5

PR1

RD

WH

NO

PR1

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

FU

EL

RE

LA

Y

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

TB25 TB26

WH

-21

NO

CR1CR1

CR2

NOTB21

7

1098CR2

ENG. FAULT


KEY PWR.

GR

/WH

-45

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./START

MODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55RD

RD

WH

BK

OR/BK

TS17TS4

C1

-9

GE

NE

RA

TO

R

HIG

HR

PM

(FS

)

G2 G3

G1

VO

LT

ME

TE

R

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB24

TB43

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.

SW

ITC

HH

YD

RA

UL

ICO

IL

NO

OTS

CR17NO

CR17

CB3

20AMP.

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

H6 L45

6

U33

12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1P3

LS18

RD

L4

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40

D39

FU

NC

TIO

NE

NA

.

L2

M1

S7

M2

PR2PR2

NO

U1

Y29

G6

3MF

RP

MF

ILT

ER

D6

D3

D2

C5

-5

C5

-2

C5

-3

EM

ISS

ION

CO

NT

RO

L

C5

-14

WH

/RD

C5

-16

WH

/BK

C5

-13

WH

NC

S2

SW

ITC

H

SW

ITC

H

OIL

TE

MP

ER

AT

UR

E

OIL

PR

ES

SU

RE

NO

S1

BR

RD

WH

BK

BL/WH WH

GL

OW

PL

UG

GL

OW

PL

UG

ON

ON

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

HMSTARTER

BL/WH

GL

OW

PL

UG

OP

TIO

N

PR3NO

PR3

C3

4S

AB

K/W

H

TB34

BK

TS56

C1

-8

TS6

C5

-22

J1

44

-6

J1

44

-4

IN THE STOWED POSITION AND KEYSWITCH "OFF".ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

NOTE:

4

1.

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

4

2

BR

N

BK

/RD

BK

/RD

-C5

-8

NO CR4

NOCR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

L30L30

WH

C3

P-9

WH

FUSE 10A

F18

TS48

PBOX GND

BK

BK

CR23

NO

CR23

L29

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0

RD

C4

B-1

2

RD

WO

RK

LIG

HT

DR

IVE

LIG

HT

DL

ITE

OR

/RD

C4B-9 C4B-11

ALTERNATOR

C2

B-4

C6

-39

3

3 70A FUSE ADDED AT SERIAL NUMBER 12978

2

2 THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 33




UP

DO

WN

UP

DO

WN

UP

DO

WN

UP

DO

WN

UP

DO

WN

RIG

HT

LE

FT

RIG

HT

LE

FT

RIG

HT

LE

FT

EX

TE

ND

RE

TR

AC

T

EX

TE

ND

RE

TR

AC

TB

OO

M

BO

OM

PLA

T L

EV

EL

PLA

T R

OTA

TE

JIB

BO

OM

JIB

BO

OM

PLA

T R

OTA

TE

PLA

T L

EV

EL

PR

I BO

OM

TT

RO

TA

TE

WH

PW

R

XO

UT

YO

UT

5 62 3 4

JC2

GN

D1


OR

1 211

12

BR

N

RD

/WH

WH

/RD

XO

UT

BL/W

H

JC3 GN

D

PW

R

YO

UT

RK

OU

T

14

13 45

BL/W

H

WH

/RD

OR

BR

N

DRIVE & STEERING

5421 3 6

TS14

C2

9M

S R

D/W

H

TB29

MO

TO

R S

TR

OK

E

Y27

C2

9M

S R

D/W

HC

5-1

9C

1P-3

BL/WH

Y51Y2Y3Y4Y23Y29Y13Y22Y21Y12H4

Y25Y26Y20Y19Y16Y17

5

R1 R2

7.5

RD/BK

C1

5P

LD

OR

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C1

4P

LU

OR

C1

3D

RE

BL/R

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C6

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C6

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RD

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CD

BA

C4

0LS

1 O

R

SJ1-WH

C8

PB

R B

K/W

H

C7

PB

E B

K

C3

PB

F R

D/ W

H

C2

PB

D R

D/B

K

C1

PB

U R

D

C4

TR

L W

H

C5

TR

R W

H/ B

K

C6

TR

F W

H/R

D

C3

6S

TC

BL

C3

7S

TC

C B

L/ B

K

C3

2B

RK

WH

/ RD

C3

0E

DC

+ W

H

C3

1E

DC

- WH

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C6

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C6

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C6

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C6

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5

L1TS15

158167

J1

6

J1

DR

E L

ED

BL/R

D

DR

E B

BL/ B

K

DR

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BL/W

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9

J1

6

J2

C2

P-3

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P-5

C1

P-4

C1

P-1

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C1

P-1

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C1

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P-5

C3

P-4

C3

P-6

C3

P-1 TS62 C

4T

RL W

H

TS61

C1

PB

U R

D

TB30TB31TB36 TB37 TB32TB4

TB5TB2

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C6

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C6

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TR

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BL

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+ W

H

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11 1817

20

19

15

16

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1R

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OR

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243 1

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3P

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ES

TP

BK

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S W

H

P2

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CR30NO

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DRIVELIFT/

OPTION

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OR/BKBK

WH

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WH

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P-2

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P-1

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P-7

RD

RD

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TB15

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TB18TB17

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12

13

14

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C5

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C5

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C6

-37

C6

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ST

EE

R R

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T

ST

EE

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EF

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FLO

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ON

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BO

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UP

PR

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BO

OM

FLO

W C

ON

TR

OL

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RN

TA

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RO

TA

TE

TU

RN

TA

BLE

RO

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OR

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AK

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P

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PLA

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OR

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OTA

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LE

FT

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UP

PLA

TF

OR

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OTA

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RIG

HT

/ JIB

DO

WN

DE

SC

EN

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LA

RM

LS

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AR

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OO

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XT

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BO

OM

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TR

AC

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DR

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LIM

IT S

WIT

CH

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C6

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C6

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GR

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ND

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GR

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VA

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GR

JD

ALA

RM

GR

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JIB

VA

LVE

S

NOTE:




6 - 34


6 - 33


6 - 35



6 - 36

1

2

3

4

5

6

7

8



6 - 36 S-40 • S-45 Part No. 102521

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models(from serial number 14832 to serial 15662)

FAN

FUSE 70A

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

PUMPBK

OR

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12 V

DC

+

+BAT.

STA.

BAT.-

EXCT.

RD

-13

4

RD

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RD

/BK

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K-4

3

CR5NO CR5

PR1

RD

WH

NO

PR1

IGN

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RT

RE

LA

Y

HO

UR

ME

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FU

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FL

AS

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GB

EA

CO

NS

OP

TIO

N

OP

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N

GE

NE

RA

TO

R

BK

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+

TB25 TB26

WH

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NO

CR1CR1

CR2

NOTB21

7

1098CR2

ENG. FAULT


KEY PWR.

GR

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FB

TB41

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1R

PM

OR

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-5

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WH-(FS)BK-(FS)

FS1

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C9-3

C3

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TR

BK

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43

5

21

AUX. ONGROUND


IGN./START

MODULE

START RELAY

BK

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EN

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RP

MF

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EU

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ON

LY)

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ION

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NT

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WH

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NC

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MP

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NO

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OW

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UG

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OW

PL

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ON

EN

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ES

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RT

EN

GIN

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TA

RT

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MP

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MP

AU

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OW

PL

UG

OP

TIO

N

PR3NO

PR3

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4S

AB

K/W

H

TB34

BK

TS56

C1

-8

TS6

C5

-22

J1

44

-6

J1

44

-4

IN THE STOWED POSITION AND KEYSWITCH "OFF".ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

NOTE:1.

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

BR

N

BK

/RD

BK

/RD

NO CR4

NOCR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

L30L30

WH

C3

P-9

WH

FUSE 10A

F18

TS48

PBOX GND

BK

BK

CR23

NO

CR23

L29

WO

RK

LIG

HT

S

OP

TIO

N

DR

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LIG

HT

OP

TIO

N

L29

C4

B-1

0

RD

C4

B-1

2

RD

WO

RK

LIG

HT

DR

IVE

LIG

HT

DL

ITE

OR

/RD

C4B-9 C4B-11

ALTERNATOR

C2

B-4

C6

-39

C 7 10A FUSE ADDED AT SERIAL NUMBER 15573B

SECOND GLOW PLUG OPTION ADDED AT SERIAL NUMBER 15151

D64

PR7NO

PR7

SE

CO

ND

GL

OW

PL

UG

OP

TIO

N(D

EU

TZ

ON

LY)

FUSE 70A

2

3

2

6

6

6

CB710A

C5

-8

3

R2

1IG

N

4

WH

FU

EL

SO

LE

NO

ID

FUEL SOLENOID ADDED AT SERIAL NUMBER 155744

10A FUSE ADDED AT SERIAL NUMBER 155745

5

FUSE 10A

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 37




NOTE:

1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM


GR

OU

ND

GN

DB

R

P1

34

PW

RR

D

JIB TIME DELAY CIRCUIT

+

-

GR/WH

JIB

VA

LVE

S

JD

ALA

RM

GR

/BKTS58

TB44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

CR14NO

D2

8

C1

8JD

GR

/BK

C1

7JU

GR

WH

C6

-4

C6

-6

C6

-2

C6

-3

C6

-8

C6

-18

DR

IVE

LIM

ITS

WIT

CH

BO

OM

RE

TR

AC

T

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

LS

2-P

RIM

AR

YB

OO

MU

P

DE

SC

EN

TA

LA

RM

OP

TIO

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

DR

IVE

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

DR

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EN

AB

LE

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

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ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

CW

TU

RN

TA

BLE

RO

TA

TE

CC

W

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

CW

ST

EE

RC

W

C5

-21

C6

-36

C6

-37

C5

-20

C5

-23

H4

14

13

12

TS59

TB19

TB17TB18

C6

-17

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

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TB14

C6

-7

TB8

TB7 TB13

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

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C4

-2

C4

-3

C3

-7

C3

-8

C2

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C1

3D

RE

BL/R

D

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

WH

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK

16

15

19

2017

18

11

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

C6

-1

C6

-5

TB1

TB2 TB5

TB4TB32

TB37TB36TB31 TB30

C1

PB

UR

D

TS61 C4

TR

LW

H

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

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C1

-11

C1

-10

C1

-4

C1

-5

BR

-2

C2

-3

J2

6

J1

9

DR

EA

BL/W

H

DR

EB

BL/B

K

LE

DB

L/R

D

J1

6

J1

7 16 8 15

TS15L1

5

C6

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C6

-13

C6

-40

C6

-15

C6

-14

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

C6

-19

C6

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C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

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RD/BK

Y17 Y16 Y19 Y20 Y25 Y26H4

Y12 Y21 Y22 Y13 Y29 Y23 Y4 Y3 Y2Y51

BL/WH

C1

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5-1

9C

29

MS

RD

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Y27

MO

TO

RS

TR

OK

E

TB29

C2

9M

SR

D/W

H

TS14

631 2 4 5

DRIVE & STEERING

BR

OR

WH

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BL/W

H5 413

14

RK

OU

TY

OU

T

PW

R

GN

D

JC3

BL/W

H

XO

UT

WH

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RD

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BR

12

11 21

OR


1G

ND

JC2

432 65

YO

UT

XO

UT

PW

R

C2

9M

SR

D/W

H

RD

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D27

D29 D30

R1

5

7.5 R2

SJ1-WH

CC

W

CW

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

CC

W

CW

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN P

LAT

FO

RM

LEV

EL

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN

DR

IVE

EN

AB

LE

DR

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MO

DE

34 WH

BK

NC

21

NO

13

22

14 14

22

13

NO

21

NC

BK

WH

2 1 2 1WH

BK

NC

21

NO

13

22

14


6 - 38


6 - 37


6 - 39

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS


6 -40

1

2

3

4

5

6

7

8



6 - 40 S-40 • S-45 Part No. 102521

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS(from serial number 15663 to 16419)

BR

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

PUMP

BK

OR

/BK

-41

12 V

DC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-13

4

RD

-27

RD

/BK

-28B

K-4

3

CR5NO CR5

PR1

RD

WH

NO

PR1

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

FU

EL

RE

LA

Y

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

TB25 TB26

WH

-21

NOCR1

CR1

CR2

NOTB21

7

1098CR2

ENG. FAULT


KEY PWR.

GR

/WH

-45

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55RD

RD

WH

BK

OR/BK

TS17TS4

C1

-9

GE

NE

RA

TO

R

HIG

HR

PM

(FS

)

G2 G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB24

TB43

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.

SW

ITC

HH

YD

RA

UL

ICO

IL

NO

OTS

CR17NO

CR17

CB3

20AMP.

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

6

C32CONN.PLUG12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1

P3

RD

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40

D39

FU

NC

TIO

NE

NA

.

L2

M1

S7

M2

PR2PR2

NO

U1

Y29

G6

3MF

RP

MF

ILTE

RD

EU

TZ

D6

D3

D4

C5

-5

C5

-2

C5

-3

FU

EL

SO

LE

NO

ID

D52

C5

-11C

21

IGN

2W

H

BL/WH

EM

ISS

ION

CO

NT

RO

LD

EU

TZ

C5

-14

WH

/RD

C5

-16

WH

/BK

C5

-13

WH

NC

S2

SW

ITC

H

SW

ITC

H

OIL

TE

MP

ER

AT

UR

E

OIL

PR

ES

SU

RE

NO

S1

TB9

BR

RD

WH

BK

BL/WH WH

STARTERAUX HM

STA

RT

EN

GIN

E

GL

OW

PL

UG

OP

TIO

N

PR3NO

PR3

C3

4S

AB

K/W

H

TB34

BK

TS56

C1

-8

TS6

C5

-22

J1

44

-6

J1

44

-4

BK

/RD

BK

/RD

NO CR4

NOCR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

FAN


ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

NOTE:

1.

L30L30

WH

C3

P-9

WH

FUSE 10A

F18

TS48

PBOX GND

BK

BK

CR23

NO

CR23

L29

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0

RD

C4

B-1

2

RD

WO

RK

LIG

HT

DR

IVE

LIG

HT

FUSE 10A

BK

/RD

C4B-9 C4B-11

TB132 IS WAGO TERMINAL BLOCK 36133 IS WAGO TERMINAL BLOCK 16

TB 134 IS WAGO TERMINAL BLOCK 42TB

STA

RT

EN

GIN

E

ON

GL

OW

PL

UG

ON

GL

OW

PL

UG

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

FUSE 70A

D64

FUSE 70A

PR7NO

PR7

SE

CO

ND

GL

OW

PL

UG

OP

TIO

N(D

EU

TZ

ON

LY)

GR

/BK

GBOXGND

RD

D2

OR/BK

D22

C5

-8

CB710A

D14D13

D12

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 41




NOTE:



GR

OU

ND

GN

DB

R

P1

34

PW

RR

D


+

-

GR/WH

JIB

VA

LVE

S

JD

ALA

RM

GR

/BKTS58

TB44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

CR14NO

D2

8

C1

8JD

GR

/BK

C1

7JU

GR

WH

C6

-4

C6

-6

C6

-2

C6

-3

C6

-8

C6

-18

DR

IVE

LIM

ITS

WIT

CH

BO

OM

RE

TR

AC

T

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

LS

2-P

RIM

AR

YB

OO

MU

P

DE

SC

EN

TA

LA

RM

OP

TIO

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

DR

IVE

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

CW

TU

RN

TA

BLE

RO

TA

TE

CC

W

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

CW

ST

EE

RC

W

C5

-21

C6

-36

C6

-37

C5

-20

C5

-23

H4

14

13

12

TS59

TB19

TB17TB18

C6

-17

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

C6

-7

TB8

TB7 TB13

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

C1

3D

RE

BL/R

D

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

WH

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK

16

15

19

2017

18

11

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

C6

-1

C6

-5

TB1

TB2 TB5

TB4TB32

TB37TB36TB31 TB30

C1

PB

UR

D

TS61 C4

TR

LW

H

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5

BR

-2

C2

-3

J2

6

J1

9

DR

EA

BL/W

H

DR

EB

BL/B

K

LE

DB

L/R

D

J1

6

J1

7 16 8 15

TS15L1

5

C6

-32

C6

-13

C6

-40

C6

-15

C6

-14

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

C6

-19

C6

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C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

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RD/BK

Y17 Y16 Y19 Y20 Y25 Y26H4

Y12 Y21 Y22 Y13 Y29 Y23 Y4 Y3 Y2Y51

BL/WH

C1

-3C

5-1

9C

29

MS

RD

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Y27

MO

TO

RS

TR

OK

E

TB29

C2

9M

SR

D/W

H

TS14

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DRIVE & STEERING

BR

OR

WH

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BL/W

H5 413

14

RK

OU

TY

OU

T

PW

R

GN

D

JC3

BL/W

H

XO

UT

WH

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RD

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BR

12

11 21

OR


1G

ND

JC2

432 65

YO

UT

XO

UT

PW

R

C2

9M

SR

D/W

H

RD

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D27

D29 D30

R1

5

7.5 R2

SJ1-WH

CC

W

CW

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

CC

W

CW

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN P

LAT

FO

RM

LEV

EL

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN

DR

IVE

EN

AB

LE

DR

IVE

MO

DE

34 WH

BK

NC

21

NO

13

22

14 14

22

13

NO

21

NC

BK

WH

2 1 2 1WH

BK

NC

21

NO

13

22

14


6 - 42

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS(from serial number 15663 to 16419)

6 - 41


6 - 43

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE


6 - 44

1

2

3

4

5

6

7

8



6 - 44 S-40 • S-45 Part No. 102521

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE(from serial number 15663 to 16419)

BR

6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

AL

AR

M

PUMP

BK

OR

/BK

-41

12 V

DC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-27

RD

/BK

-28B

K-4

3

CR5NO CR5

PR1

RD

WH

NO

PR1

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

FU

EL

RE

LA

Y

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

TB25 TB26

WH

-21

NOCR1

CR1

CR2

NOTB21

7

1098

CR2ENG. FAULT


KEY PWR.

GR

/WH

-45

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55RD

RD

WH

BK

OR/BK

TS17TS4

C1

-9

GE

NE

RA

TO

R

HIG

HR

PM

(FS

)

G2 G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

WA

TE

RT

EM

PG

AU

GE

TB24

TB43

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.

SW

ITC

HH

YD

RA

UL

ICO

IL

NO

OTS

CR17NO

CR17

CB3

20AMP.

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

6LOADSENSEMODULE

12 8

7

1

4

3

5

TB132

C1

32

PL

IB

L/W

H

C1

34

PW

RO

R/R

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1

P3

RD

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40

D39

FU

NC

TIO

NE

NA

.

L2

M1

S7

M2

PR2PR2

NO

U1

Y29

G6

3MF

RP

MF

ILTE

RD

EU

TZ

D6

D3

D4

C5

-5

C5

-2

C5

-3

FU

EL

SO

LE

NO

ID

D52

C5

-11C

21

IGN

2W

H

BL/WH

EM

ISS

ION

CO

NT

RO

LD

EU

TZ

C5

-14

WH

/RD

C5

-16

WH

/BK

C5

-13

WH

NC

S2

SW

ITC

H

SW

ITC

H

OIL

TE

MP

ER

AT

UR

E

OIL

PR

ES

SU

RE

NO

S1

TB9

BR

RD

WH

BK

BL/WH WH

STARTERAUX HMS

TA

RT

EN

GIN

E

GL

OW

PL

UG

OP

TIO

N

PR3NO

PR3

C3

4S

AB

K/W

H

TB34

BK

TS56

C1

-8

TS6

C5

-22

J1

44

-6

J1

44

-4

BK

/RD

BK

/RD

NO CR4

NOCR3

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

FAN



NOTE:

1.

L30L30

WH

C3

P-9

WH

FUSE 10A

F18

TS48

PBOX GND

BK

BK

CR23

NO

CR23

L29

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0

RD

C4

B-1

2

RD

WO

RK

LIG

HT

DR

IVE

LIG

HT

FUSE 10A

BK

/RD

C4B-9 C4B-11

TB132 IS WAGO TERMINAL BLOCK 36133 IS WAGO TERMINAL BLOCK 16

TB 134 IS WAGO TERMINAL BLOCK 42TB

STA

RT

EN

GIN

E

ON

GL

OW

PL

UG

ON

GL

OW

PL

UG

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

FUSE 70A

D64

FUSE 70A

PR7NO

PR7

SE

CO

ND

GL

OW

PL

UG

OP

TIO

N(D

EU

TZ

ON

LY)

GR

/BK

GBOXGND

RD

D2

OR/BK

D22

C5

-8

CB710A

D14D13

D12

H6L45

D88

D89

PBOXGND

R204.7 K

LS18

LS18A

PBOXGND

2 SEC

U35

NO30A

BK

2 SEC

U34

NO10A

C2

1IG

NW

H

C4

-10

C132PLI2 BK

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 45




NOTE:



GR

OU

ND

GN

DB

R

P1

34

PW

RR

D


+

-

GR/WH

JIB

VA

LVE

S

JD

ALA

RM

GR

/BKTS58

TB44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

CR14NO

D2

8

C1

8JD

GR

/BK

C1

7JU

GR

WH

C6

-4

C6

-6

C6

-2

C6

-3

C6

-8

C6

-18

DR

IVE

LIM

ITS

WIT

CH

BO

OM

RE

TR

AC

T

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

LS

2-P

RIM

AR

YB

OO

MU

P

DE

SC

EN

TA

LA

RM

OP

TIO

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

DR

IVE

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

CW

TU

RN

TA

BLE

RO

TA

TE

CC

W

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

CW

ST

EE

RC

W

C5

-21

C6

-36

C6

-37

C5

-20

C5

-23

H4

14

13

12

TS59

TB19

TB17TB18

C6

-17

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

C6

-7

TB8

TB7 TB13

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

C1

3D

RE

BL/R

D

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

WH

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK

16

15

19

2017

18

11

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

C6

-1

C6

-5

TB1

TB2 TB5

TB4TB32

TB37TB36TB31 TB30

C1

PB

UR

D

TS61 C4

TR

LW

H

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5

BR

-2

C2

-3

J2

6

J1

9

DR

EA

BL/W

H

DR

EB

BL/B

K

LE

DB

L/R

D

J1

6

J1

7 16 8 15

TS15L1

5

C6

-32

C6

-13

C6

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C6

-15

C6

-14

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

C6

-19

C6

-30

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

Y17 Y16 Y19 Y20 Y25 Y26H4

Y12 Y21 Y22 Y13 Y29 Y23 Y4 Y3 Y2Y51

BL/WH

C1

-3C

5-1

9C

29

MS

RD

/WH

Y27

MO

TO

RS

TR

OK

E

TB29

C2

9M

SR

D/W

H

TS14

631 2 4 5

DRIVE & STEERING

BR

OR

WH

/RD

BL/W

H5 413

14

RK

OU

TY

OU

T

PW

R

GN

D

JC3

BL/W

H

XO

UT

WH

/RD

RD

/WH

BR

12

11 21

OR


1G

ND

JC2

432 65

YO

UT

XO

UT

PW

R

C2

9M

SR

D/W

H

RD

/BK

D27

D29 D30

R1

5

7.5 R2

SJ1-WH

CC

W

CW

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

CC

W

CW

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN P

LAT

FO

RM

LEV

EL

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN

DR

IVE

EN

AB

LE

DR

IVE

MO

DE

34 WH

BK

NC

21

NO

13

22

14 14

22

13

NO

21

NC

BK

WH

2 1 2 1WH

BK

NC

21

NO

13

22

14


6 - 46

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE(from serial number 15663 to 16419)

6 - 45


6 - 47


(from serial number 16420)

6 - 48

1

2

3

4

5

6

7

8



6 - 48 S-40 • S-45 Part No. 102521

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS(from serial number 16420)

C32CONN.PLUG

CR3NO

CR4NO

HIG

HID

LE

RE

LA

Y

HIG

HR

PM

SO

LE

NO

ID

BK

/RD



NOTE:

CR45NO CR45

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

S

C4B-11C4B-9

RD

RD

L29L29

C4

B-1

2

C4

B-1

0

CR23

NOCR23

BR

FUSE 10A

L30L30

BK

BK

WH

WH

LIGHTS PACKAGE

SE

CO

ND

GLO

WP

LU

GO

PT

ION

PR7NOPR7

C5

-22

PR3NOPR3

D64

J1

44

-6

J1

44

-4

TS6

C1

-8

TS56

TB34

C3

4S

AB

K/W

H

PR3NO

PR3

GLO

WP

LU

GO

PT

ION

(DE

UT

ZO

NLY

)

10ACB7

C5

-8

RD

R2

1IG

NW

HF

UE

LS

OLE

NO

ID

FUSE 70A

FUSE 70A

EN

GS

PE

ED

SW

ITC

H

SW

ITC

HO

ILT

EM

PE

RA

TU

RE

OIL

PR

ES

SU

RE

NO

S1

NC

S2

C5

-13

C5

-14

WH

/RD

WH

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C5

-16

BL/WH

EM

ISS

ION

CO

NT

RO

L

Y29G6

PR2PR2

M2

M1

RP

MF

ILTE

R(D

EU

TZ

ON

LY)

3MF

HIG

HR

PM

(FS

)

TS4

TS17

C6

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D6

L2

C6

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FUN

CTIO

NE

NA

.

TB133

C2-3

C4

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13

3P

LA

OR

/RD

RD/BK

C2

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TA

RD

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P2

RD

P3

C7

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HORN

P2

2B

AT

BK

C2

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C1

-12

P1

34

PW

RR

D

C1

32

PLI1

BL/W

H

TB132RD

KS1

GRD

PLAT

TB22

P1TB134

C6

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C6

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C6

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CB3

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NO

HY

DR

AU

LIC

OIL

TE

MP.

SW

ITC

H

CO

OLIN

GFA

N(O

PT

ION

)

C5

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C5

-2

C6

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C6

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C6

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C6

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C5

-5

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WA

TE

RT

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PG

AU

GE

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PR

ES

SU

RE

GA

UG

E

VO

LTM

ET

ER

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G2

GE

NE

RA

TO

R

C1

-9

OR/BK

BK

WH

RD

RD

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WR

PM

HIG

HR

PM

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PM

BK

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BR

P26ESTP BK

P25FS RD

P24FS WH

TS2

C2

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45

GE

NG

R/W

H

C1

-7

TS52

START RELAY

MODULEIGN./START

START INPUTTACHOMETER

GROUNDAUX. ON

12

5

34

TB33

C3

3S

TR

BK

C9-3

C9-2

FS1

BKC9-1

C1

-1

C7

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C1

-2

TS51

C2

-5

TB27

RD

TB28

TB23

C4

3H

RN

GR

C2

7A

UX

RD

C2

8T

TA

RD

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P2

3B

AT

WH

CB1

15AMP.

RD

RD

CB2

TB20 15AMP.

C4

1R

PM

OR

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TB41

FB

KEY PWR.

IGN./FUEL ONKEY BYPASS

ENG. FAULT

CR2 89

10

7

TB21 NOCR2

CR1CR1NO

TB26TB25

+

GE

NE

RA

TO

R

OP

TIO

N

OP

TIO

N

FLA

SH

ING

BE

AC

ON

S

IGN

ITIO

NR

ELA

Y

_

HO

UR

ME

TE

R

STA

RT

RE

LA

Y

PR1

NO

PR1

CR5NOCR5

EXCT.

ALTERNATOR

-BAT.

STA.

BAT.+

+

DC12 V

PUMP

TILT

ALA

RM

LE

VE

LS

EN

SO

R

RE

LA

Y

SE

RV

ICE

HO

RN

SE

RV

ICE

HO

RN

RE

LA

Y

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

UM

P

IND.-

REGULATOR H2

STA

RT

ER

MO

TO

R

BATTERY6

L48

D40

D39

S7

WH

RD

BK

WH

D2

D4

D13D14

D22

D12

NO

C4

5G

EN

GR

/WH

TS1

WO

RK

LIG

HT

SR

ELA

Y(O

PT

ION

)

TB35TB45

FAN

+

H1-

GBOX GND

STA

RT

EN

GIN

EHM

AUX STARTER

GR

/BK

1 3

5

7

8

4

6

12

DIODE BETWEEN T 35 AND TB45 ADDED AT SERIAL NUMBER 16453B2

2

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 49




NOTE:



GR

OU

ND

GN

DB

R

P1

34

PW

RR

D


+

-

GR/WH

JIB

VA

LVE

S

JD

ALA

RM

GR

/BKTS58

TB44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

CR14NO

D2

8

C1

8JD

GR

/BK

C1

7JU

GR

WH

C6

-4

C6

-6

C6

-2

C6

-3

C6

-8

C6

-18

DR

IVE

LIM

ITS

WIT

CH

BO

OM

RE

TR

AC

T

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

LS

2-P

RIM

AR

YB

OO

MU

P

DE

SC

EN

TA

LA

RM

OP

TIO

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

DR

IVE

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

CW

TU

RN

TA

BLE

RO

TA

TE

CC

W

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

CW

ST

EE

RC

W

C5

-21

C6

-36

C6

-37

C5

-20

C5

-23

H4

14

13

12

TS59

TB19

TB17TB18

C6

-17

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

C6

-7

TB8

TB7 TB13

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

C1

3D

RE

BL/R

D

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

WH

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK

16

15

19

2017

18

11

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

C6

-1

C6

-5

TB1

TB2 TB5

TB4TB32

TB37TB36TB31 TB30

C1

PB

UR

D

TS61 C4

TR

LW

H

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5

BR

-2

C2

-3

J2

6

J1

9

DR

EA

BL/W

H

DR

EB

BL/B

K

LE

DB

L/R

D

J1

6

J1

7 16 8 15

TS15L1

5

C6

-32

C6

-13

C6

-40

C6

-15

C6

-14

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

C6

-19

C6

-30

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

Y17 Y16 Y19 Y20 Y25 Y26H4

Y12 Y21 Y22 Y13 Y29 Y23 Y4 Y3 Y2Y51

BL/WH

C1

-3C

5-1

9C

29

MS

RD

/WH

Y27

MO

TO

RS

TR

OK

E

TB29

C2

9M

SR

D/W

H

TS14

631 2 4 5

DRIVE & STEERING

BR

OR

WH

/RD

BL/W

H5 413

14

RK

OU

TY

OU

T

PW

R

GN

D

JC3

BL/W

H

XO

UT

WH

/RD

RD

/WH

BR

12

11 21

OR


1G

ND

JC2

432 65

YO

UT

XO

UT

PW

R

C2

9M

SR

D/W

H

RD

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D27

D29 D30

R1

5

7.5 R2

SJ1-WH

CC

W

CW

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

CC

W

CW

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN P

LAT

FO

RM

LEV

EL

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN

DR

IVE

EN

AB

LE

DR

IVE

MO

DE

34 WH

BK

NC

21

NO

13

22

14 14

22

13

NO

21

NC

BK

WH

2 1 2 1WH

BK

NC

21

NO

13

22

14


6 - 50

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI /CSA / AS(from serial number 16420)

6 - 49


6 - 51



6 - 52

1

2

3

4

5

6

7

8



6 - 52 S-40 • S-45 Part No. 102521

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE(from serial number 16420)

10ANO

U34

PBOX GND

30ANO

U35

2 SEC

2 SEC

BK

/RD

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

NO CR4

NO CR3

U33

LOADSENSEMODULE

NOTE:



CR45NOCR45

LIGHTS PACKAGE

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29 L29

C4B-9 C4B-11

CR23NO

CR23

C4

B-1

0

C4

B-1

2

RD

RD

BR

FUSE 10A

WH

BK

L30

WH

L30

GLO

WP

LU

GO

PT

ION

PR3NOPR3

C3

4S

AB

K/W

H

TB34

TS56

C1

-8

TS6

J1

44

-4

J1

44

-6

D64

PR3NO

PR3

C5

-22

PR7NO

PR7

GLO

WP

LU

GO

PT

ION

SE

CO

ND

(DE

UT

ZO

NLY

)6 BATTERY

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

ALA

RM

PUMP

BK

12 VDC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

CR5NO CR5

PR1

RD

WH

NO

PR1

STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

IGN

ITIO

NR

ELA

Y

FLA

SH

ING

BE

AC

ON

S

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

+

TB25 TB26

NOCR1

CR1CR2NOTB21

7

1098

CR2ENG. FAULT


KEY PWR.

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

15AMP.

CB1

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

C9-1BK

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

43

5

21

AUX. ONGROUND


IGN./STARTMODULE

START RELAY

TS52

C1

-7

C4

5G

EN

GR

/WH

C2

-7

TS2

P24FS WH-(FS)

P25FS RD-(FS)

P26ESTP BK

C3

5R

PM

BK

/RD

HIG

HR

PM

LO

WR

PM

TS55

C1

-9

GE

NE

RA

TO

R

G2 G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

CO

OLA

NT

TE

MP

GA

UG

E

TB24

C5

-5

C6

-27

C6

-28

C6

-23

TB43

C6

-16

(OP

TIO

N)

CO

OLIN

GFA

N

TE

MP.

SW

ITC

HH

YD

RA

ULIC

OIL

NO

OTS

CR17NO

CR17

CB3

20AMP.

C6

-33

C6

-34

C6

-25

TB134P1

TB22

PLAT

GRD

KS1

RD TB132

C1

32

PLI1

BL/W

H

P1

34

PW

RR

D

C1

-12

C2

-4

P2

2B

AT

BK

HORN

C7

-1

P3

RD

P2

C2

8T

TA

RD

/BK

C1

33

PLA

OR

/RD

C4

-4

C2-3

TB133

FU

NC

TIO

NE

NA

.

C6

-39

L2

D6

C6

-26

TS17

TS4

HIG

HR

PM

(FS

)

3MF

RP

MF

ILTE

R(D

EU

TZ

ON

LY)

M1

S7

M2

PR2 PR2

G6Y29

EM

ISS

ION

CO

NT

RO

L

C5

-16

WH

/BK

WH

/RD

C5

-14

C5

-13

S2

NC

S1

NO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

SW

ITC

H

EN

GS

PE

ED

FUSE 70A

FUSE 70A

FU

EL

SO

LE

NO

IDR

21

IGN

WH

BK/RDC

5-8

CB710A

D39L4

D40

C2

1IG

NW

H

C132PLI2 BK

C3

-10

C5

-3

C5

-2

BR

RD

RD

WH

BK

OR/BK

RD/BK

BL/WH

RD

BK

WH

D2

D22

D4

D12

D14D13

GR

/BK

RD

NO

C4

5G

EN

GR

/WH

TS1

TB35TB45

FAN

GR

/BK

STARTERAUXHM

STA

RT

EN

GIN

E

GBOX GND

L45H6

D88

D89

PBOX GND

LS18

LS18A

4.7KR20

-H1

+

1 3

54

6

7

12 8

RD


2

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 53




NOTE:



GR

OU

ND

GN

DB

R

P1

34

PW

RR

D


+

-

GR/WH

JIB

VA

LVE

S

JD

ALA

RM

GR

/BKTS58

TB44

C2

-6

BR

JIB

VA

LVE

CR13

TS8

GR

/BK

-44

NCCR13

C1

7JU

GR

C1

8JD

GR

/BK

CR14NO

D2

8

C1

8JD

GR

/BK

C1

7JU

GR

WH

C6

-4

C6

-6

C6

-2

C6

-3

C6

-8

C6

-18

DR

IVE

LIM

ITS

WIT

CH

BO

OM

RE

TR

AC

T

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

LS

2-P

RIM

AR

YB

OO

MU

P

DE

SC

EN

TA

LA

RM

OP

TIO

N

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

BR

PLA

TLE

VE

LU

P

PLA

TLE

VE

LD

OW

N

DR

IVE

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

BR

AK

ER

ELE

AS

EV

ALV

E

TR

AV

EL

ALA

RM

OP

TIO

N

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BLE

RO

TA

TE

CW

TU

RN

TA

BLE

RO

TA

TE

CC

W

TU

RN

TA

BLE

RO

TA

TE

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FLO

WC

ON

TR

OL

ST

EE

RC

CW

ST

EE

RC

W

C5

-21

C6

-36

C6

-37

C5

-20

C5

-23

H4

14

13

12

TS59

TB19

TB17TB18

C6

-17

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

-7

TS57

C4

-5

C4

-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

C6

-7

TB8

TB7 TB13

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

C4

-2

C4

-3

C3

-7

C3

-8

C2

-2

C1

3D

RE

BL/R

D

TS63

C4

-1

C3

-2

C3

-3

TS9

WH

TS7

WH

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE 4

NOCR30

CR27NC

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K3

J3

13 4 2

8 7

C4

1R

PM

OR

/BK

16

15

19

2017

18

11

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

C6

-1

C6

-5

TB1

TB2 TB5

TB4TB32

TB37TB36TB31 TB30

C1

PB

UR

D

TS61 C4

TR

LW

H

TS62

C3

-1

C3

-6

C3

-4

C3

-5

C1

-6

C1

-11

C1

-10

C1

-4

C1

-5

BR

-2

C2

-3

J2

6

J1

9

DR

EA

BL/W

H

DR

EB

BL/B

K

LE

DB

L/R

D

J1

6

J1

7 16 8 15

TS15L1

5

C6

-32

C6

-13

C6

-40

C6

-15

C6

-14

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0LS

1O

R

AB

DC

C6

-19

C6

-30

C1

3D

RE

BL/R

D

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

Y17 Y16 Y19 Y20 Y25 Y26H4

Y12 Y21 Y22 Y13 Y29 Y23 Y4 Y3 Y2Y51

BL/WH

C1

-3C

5-1

9C

29

MS

RD

/WH

Y27

MO

TO

RS

TR

OK

E

TB29

C2

9M

SR

D/W

H

TS14

631 2 4 5

DRIVE & STEERING

BR

OR

WH

/RD

BL/W

H5 413

14

RK

OU

TY

OU

T

PW

R

GN

D

JC3

BL/W

H

XO

UT

WH

/RD

RD

/WH

BR

12

11 21

OR


1G

ND

JC2

432 65

YO

UT

XO

UT

PW

R

C2

9M

SR

D/W

H

RD

/BK

D27

D29 D30

R1

5

7.5 R2

SJ1-WH

CC

W

CW

PLA

TR

OTA

TE

UP

DO

WN

PLA

TF

OR

MLE

VE

L

CC

W

CW

PLA

TR

OTA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN P

LAT

FO

RM

LEV

EL

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIB

BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN

DR

IVE

EN

AB

LE

DR

IVE

MO

DE

34 WH

BK

NC

21

NO

13

22

14 14

22

13

NO

21

NC

BK

WH

2 1 2 1WH

BK

NC

21

NO

13

22

14


6 - 54

Electrical SchematicDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE(from serial number 16420)

6 - 53


6 - 55

Ground Control Box Wiring DiagramDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models

(before serial number 14832)

6 - 56

1

2

3

4

5

6

7

8



6 - 56 S-40 • S-45 Part No. 102521

Ground Control Box Wiring DiagramDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models(before serial number 14832)

EN

GIN

E

C5

HARNESS:

TO BASE

WIRING

BRN GND

WH-23C

BK-C32-5

BR-GND STUD

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

C6

C3

B

19

/18

CA

BL

ES

C2

BC

4B

3

2

C7

B 1

CR23

RD C4B-11

RD C4B-12

BK/RD-9B

RD-CB3 SP

ALL BR WIRES

BR

GROUND STUD

GR

OU

ND

ST

UD


12

V

32WH/RD-C1B-6

11BL/BK-C3B-11

BL-C3B-10

BK/WH-C3B-8

BK/RD-C3B-9

RD/WH-C3B-3

WH-C3B-4

WH/BK-C3B-5

WH/RD-C3B-6

BK-C3B-7

RD-C3B-1

RD/BK-C3B-2

RD-C6-1

D

BK/WH-C6-8

WH/BK-C6-5

RD/WH-C6-3

WH-C6-4

WH/RD-C6-6

BK-C6-7

RD/BK-C6-2

C B

6

2

3

1

5

4

8

7

10

9

44B+RD/BK-C6-19

RD-C5-1

WH/BK-C1B-5

WH-C1B-4

RD/WH-C1B-3

RD-C1B-1

WH-C7B-2

RD/BK-C1B-2

GR/WH-C4B-7

GR/BK-C4B-6

BK-C32-4

WH-C5-3+C5-11

GR-C4B-5

OR/RD-C4B-4

OR-C4B-2

OR/BK-C4B-3

BL/RD-C4B-1

BL/WH-C3B-12

GR/BK-C6-18

WH-CR2#87

GR-C6-17

BL/RD-C6-13

WH-C6-34

RD-C6-27

BK-CR5#30

WH-S.P.

16

13

12

15

14

19

18

17

21

20

RED-CR1#30

RD-ISM#4

24

23

22

25

26

29

28

27

30

31

D6

GR/BK-C2B-6

GR/WH-C2B-7

OR/BK-C2B-3

BL/RD-C2B-1

OR-C2B-2

OR/RD-C2B-4

BK/RD-C1B-9

BK/WH-C1B-8

BL/BK-C1B-11

BL-C1B-10

BL/WH-C1B-12

BK-C1B-7

BK/WH-C5-10

OR-C6-40

OR/BK-C5-2

BK-ISM#3

GR/WH-C6-39

42

OR/BK-ISM#2

37

34

33

35

36

39

38

40

41

44

43

45

RD-S.P.

A

TURN. ROT. R

PRI. BOOM DOWN

PRI. BOOM F.C.

TURN. ROT. L

TURN. ROT. F.C.

PRI. BOOM UP

WH/RD-S.P.

RD/WH-S.P.

WH/BK-S.P.

RD/BK-S.P.

WH-S.P.

BK/WH-S.P.

BK-S.P.

JIB VALVE

PLAT. LEVEL. UP

PLAT. LEVEL DN.

PLAT. ROT. L.

PLAT. ROT. R.

DRV. ENA. LT.

IGNITION PWR.

OR/BK-S.P.

OR-S.P.

GR/WH-SP

GR/BK-S.P.

GR-S.P.

TILT ALARM

E.D.C.+

E.D.C.-

AUX. PWR.

KEYSWITCH PWR/FB

PWR. TO PLAT.

ENGINE POWER

WH/BK-S.P.

WH/RD-S.P.

RD-S.P.

WH-S.P.

BK-S.P.

RD-S.P.

C134PWR

LIMIT SWITCH SIG.

GLOW PLUG

STEER LEFT

RPM

STEER RIGHT

C132PLI

START

PULSE PICKUP

BK/WH-S.P.

BK/RD-S.P.

BK-S.P.

BL/RD-S.P. L.P.

GEN. OPTION

HORN

BRAKE/TRAVEL ALARM

OIL PRESSURE SENDER

WATER TEMP. SENDER

IGN./START

MODULEAUX. ON4

BK-ISM#1

BK-C5-5 WH-21B

RD-ISM#6

WH-ISM#9

RD-24B

CR1

WH-CR2#86

WH-23B

RD-CR2#30

BR-GND.

CR2

KEY BYPASS

ENG. FAULT

IGN./FUEL ON

10

8

9

6

7

5

BATTERY

KEY PWR.

GROUND

RD-27B

BK-33B

OR/BK-41B

BK-CR1#86

TACHOMETER

START INPUT

START RELAY

3

2

1

BL-C6-36

BL/BK-C6-37

RD/BK-C6-28

OR-C6-14

OR/BK-C6-15

46

MOTOR SPEED

WH/BK-C5-20

WH-C5-21

WH/RD-C5-23

BL/WH-C6-30

WH/RD-C6-32

WH-L2 DIODE

GR-C2B-5 GR-CR5#85

BK/WH-C5-22

BK/RD-C5-9

BK/RD-35B

CR3 CR4


C133PLA

GR/BK-2B

H6

U33

PLATFORM LOAD

C32

BL/WH-C23-3

BL/WH-38D - C32-3RD-C32-1

RD-H6+

RD-42B

RD-KS1-2 S.P.RD-C6-23

RD-TS51 - C32-6

BR - GND - C32-12

RD-H6+ - C32-1

RD-TS55 - C32-7


GR/BK-L45-

GR/BK-16A

BK-22C - C32-4

BK-C7-1 - C32-5

GR/BK-16B - C32-8


KS1

TS56

B

B1

1

24

3

RD

KEY SWITCH

WH/RD-26A

BR (GROUND)

WH-21A

WH/BK-25A

G3G2G1

WH-21A

BR (GROUND)

BK/WH-34A

TS52BK-33A

BK/RD-35A

CB1 CB2

CB3

TS58

TS59

TS57

TS62

RD- 20A

RD- 20B

RD- 20C

RD- 24A

RD-CR17#30

P1

NC

NC

RD- P1 E-STOP

TS61

TS63

BK-22A

L2

WH-23A

WH-C5-13

BL/WH-ISM#10

RD-C23-6

TS55

OR-14A

OR/BK-15A

GR-17A

GR/BK-18A

GR/WH-19A

RD

GR/BK-H6-

WH-4A

WH/BK-5A

WH/RD-6A

GR/BK-44A

R2

BK-7A

BK/WH-8A

RD-1A

RD/BK-2A

RD/WH-3A

L45

RD-CB2

D13

D14

GR/BK-S.P.

RD-42ARD-27A

TS51

HM

RD-C32-7

KS1

CB1

CB3

CB2

CR1

U33

L45

TS63

CR17

CR4

CR3

CR2

TS62

TS58

TS61

TS57

TS51

TS55

TS52

LABEL

TS59

IGN. POWER RELAY



PLAT OVERLOAD LED

COOLING FAN RELAY


RPM RELAY

DESCRIPTION

IGN. START RELAY











OIL PRESSURE GAGE

ENGINE START SWITCH

OIL TEMP. GAGE

HOUR METER

STARTER AID

VOLT METER GAGE

KEY SWITCH

FUNCTION ENABLE SWITCH

AUXILIARY SWITCH

CR2

CR17

CR4

CR3

H6

PART #

13037

CB3

CB2

CB1

CR1

G3

HM

G2

G1G1

HM

G3

G2

P1

42730

KS1

13037

13037

16397

13037

16397

13037

16397

P1

BK/RD CR3-#30

WH-ISM #7

R1


R2R2RESISTOR, 7.5 OHM,TURNTABLE FUNCT

SPARE

TS56 13037

BR -3MF CAP

GND

3MF

RD/WH-C5-24

OR-C6-33

BK-C6-25

RD-CB3 SP

CR17

BK-22B

GR-43D

BK-C6-16

CR5

BOOM RETRACT

BOOM EXTEND

AUXILIARY

FUNCTIONENABLE

ENGINESTART

PLATFORMROTATE

PLATFORMLEVEL

BOOMEXTEND/RETRACT

PRIMARY BOOMUP/DOWN

TURNTABLEROTATE

JIB BOOMUP/DOWN

STARTER AID

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 57


Ground Control Box Wiring DiagramDeutz D2011L03i and Perkins 404-22 Models



D64

SPARE

CR23

RD-24C


RD C4B-10

RD C4B-12

WH-21B

BN-GND

BR-GND

WH-21C

WH-W.L. CABLE

WORK LIGHT OPTION RELAY

RD-20C

CR45

87

86

30

85

87

86

30

85

TS56

BK/WH-34A

44B+RD/BK-C6-19

GR/BK-2B

WH/RD-C6-32

JDALARM JIB

RD-C32-7

GR/BK-133B - C32-8

BK-C7-1 - C32-5

BK-22C - C32-4

GR/BK-C32-8

RD-TS55 - C32-7

RD-H6+ - C32-1

BR - GND - C32-12

RD-TS51 - C32-6

BL/WH-132D - C32-3

BK-C32-4

BL/WH-C32-3

RD-H6+

PLATFORM LOAD

U33 C32

C133PLAGR/BK-H6-

C132PLI

P134PWR

GR/BK-H6-

RD-C32-6

RD

GR/BK-133A

GR/BK-L45-

RD-134B

RD-C32-1

H6

L45

CR17

RD-CB3 SP

BK-C6-25

OR-C6-33

RD-C6-23 RD-KS1-2 S.P.

BK-C3B-10

BR-GND

RD-TB134(A)C

WH-ISM#9

WH-CR2#86

LOAD SENSE OPTION - TIMER RELAY

GR

OU

ND

ST

UD

KEY SWITCH

RD

B

B1

1

24

3

KS1

D2

D4

D27

CIRCUIT BREAKER, ENGINE, 15A CB2

RESISTOR, 7.5 OHM,TURNTABLE FUNCT

RESISTOR, 5 OHM, BOOM FUNCTION



COOLING FAN RELAY

LOAD SENSE TIME DELAY RELAY (10A)



RPM RELAY

U34

U33

CR17

H6

CR4

OIL TEMP. GAGE

HOUR METER

IGN. START RELAY

IGN. POWER RELAY

VOLT METER GAGE

OIL PRESSURE GAGE

G3

CR3

CR2

CR1

HM

R2

G2

G1

R1

CB3

ENGINE START SWITCH







DESCRIPTION

AUXILIARY SWITCH

FUNCTION ENABLE

STARTER AID

TS59

TS62

TS58

CB1

TS61

TS63

TS55

TS57

TS56

TS52

TS51

KEY SWITCH

LABEL

P1

KS1

BOOM EXTEND7

BK-C6-16

GR-43D

BK-22B

CR2

CR5

WH-L2 DIODE

RD-24BWH-ISM#9

RD-ISM#6

BK-C5-5

BK-ISM#1

WH-21B

CR1

ENG. FAULT10

RD/WH-C6-3

RD/BK-C6-2

RD-C6-1

D

BK-C6-7

WH/RD-C6-6

WH-C6-4

WH/BK-C6-5

1 START RELAY

RD-CR2#30

WH-23B

WH-CR2#86

OR/BK-41B

BK-33B

RD-27B

BR-GND.

KEY PWR.

BATTERY

IGN./FUEL ON

KEY BYPASS

9

8

7

6

START INPUT

TACHOMETER

GROUND

AUX. ON

5

4

2

3

RD/BK-C3B-2

WH/RD-C3B-6

WH/BK-C3B-5

RD/WH-C3B-3

BK-CR1#86

RD-C3B-1

C

BK-C3B-7

WH-C3B-4

1

2

5

4

3

6

GR/BK-18A

BK/RD-C5-9

CR3

BK/RD-35B

CR4

PRI. BOOM UP

TURN. ROT. F.C.TURN. ROT. CCW

PRI. BOOM F.C.

PRI. BOOM DOWN

TURN. ROT. CW

MODULEIGN./START

BK-S.P.

WH-S.P.

RD/BK-S.P.

WH/BK-S.P.

RD/WH-S.P.

WH/RD-S.P.

RD-S.P.

B A

RD-P1 E-STOP

OR/BK-15A

GR/WH-19A

GR-17A

OR-14A

RD-24A

RD-20B

RD-20A

BK/RD-35A

D13

TS55

D14 CB1 CB2

WH/RD-6AWH-4A

WH/BK-5A

RD-CR17#30

RD-20C

BK-7AGR/BK-44A

BK-33A

BK/WH-8A

R2

TS52CB3

OR/BK-ISM#2

RED-CR1#30

45GR/WH-C6-39 GR/WH-C2B-7

26

WH-C5-3+C5-11

GR-C6-17

BK/WH-C6-8

OR/BK-C6-15

OR-C6-14

BL/RD-C6-13

RD- 12VOLT

GR/BK-C6-18

BL/WH-C6-30

RD-C5-1

GR-C4B-5

BL/WH-C3B-12

OR/BK-C4B-3

OR/RD-C4B-4

BK/WH-C3B-8

BL/BK-C3B-11

BL-C3B-10

BL/RD-C4B-1

OR-C4B-2

12

9

8

10

11

14

13

15

133

GR/BK-C4B-6

GR/WH-C4B-7

CB3-SP

C634&CR45#86

WH-C7B-2

CB2-SP

WH-CR2#87&CR23#86

19

17

18

20

21

WH-ISM #7BK-CR5#30

24

22

23

25

WH/BK-C5-20

RD/WH-C5-24

WH-C5-21

RD/BK-C6-28

RD-C6-27

BK/WH-C5-22

WH/RD-C5-23

BL/BK-C6-37

BL-C6-36

OR-C6-40

BK/WH-C5-10

OR/BK-C5-2

BL-C1B-10

BK/WH-C1B-8

BK/RD-C1B-9

RD/BK-C1B-2

RD/WH-C1B-3

WH/BK-C1B-5

WH/RD-C1B-6

RD-C1B-1

WH-C1B-4

BK-C1B-7

31

RD-ISM#427

28

30

29

BK-ISM#333

32

35

34

BL/WH-C1B-12

BL/BK-C1B-11

OR/RD-C2B-4

OR/BK-C2B-3

GR/BK-C2B-6

OR-C2B-2

BL/RD-C2B-1

GR-C2B-5

132

36

37

40

39

GR-CR5#85

41

134

43

44

46

BR (GROUND)GEN. OPTION

WATER TEMP. SENDERWH/RD-S.P.

12 VOLT BATTERY POWER

OIL PRESSURE SENDER

ENGINE POWER

PWR. TO PLAT.

KEYSWITCH PWR/FB

IGNITION PWR.

DRV. ENA. LT.

PLAT. ROT. CCW

PLAT. ROT. CW

PLAT. LEVEL DN.

PLAT. LEVEL. UP

JIB VALVE

BOOM RETRACT

GR-S.P.

OR-S.P.

OR/BK-S.P.

BK/WH-S.P.

CB1 - SP

BK-S.P.

WH-S.P.

RD-S.P.

WH/BK-S.P.

GR/BK-S.P.

GR/WH-SP

WH-S.P.

MOTOR SPEED

BRAKE/TRAVEL ALARM

HORN

PULSE PICKUP

START

STEER CCW

STEER CW

GLOW PLUG

LIMIT SWITCH SIG.

AUX. PWR.

E.D.C.-

E.D.C.+

TILT ALARM

BK-S.P.

BK/RD-S.P.

BK/WH-S.P.

RD-S.P.D6

RPM

BR -3MF CAP

GR/BK-S.P.

BL/RD-S.P. L.P.

BR (GROUND)

BL/WH-ISM#10

RD/WH-3A

RD/BK-2A

RD-1A

WH-C5-13

WH-21A

HMLED L2

RD-27ARD-134AWH-23A

RD-CB2

NC

NC

P1

BK-22A

WH/BK-25A

WH/RD-26A

SPARE WH-21A

G1 G2

TS59

TS57

TS58 R1

TS63

TS62

TS61

TS51

G3

CHECK ENG

CHECK ENG LED L2

(DEUTZ ONLY)

HORN RELAY CR5

PLAT OVERLOAD LED L45

134ARD-U34-2



RD-CR23#30

GR/WH-35B

BK/RD CR3-#30 GR/WH-45B

C7

B

12

VT

OP

LA

T

C4

BC

2B

C3

BC

6C

1B

C5

EN

GIN

EF

UN

CT

ION

S1

9/1

8C

AB

LE

S

1

2

12

V

3

BK-C32-5

ALL BR WIRES

GROUND STUD

BR

WH-23C

TO BASE

HARNESS:

WIRING

BR-GND STUD

53

9

8

U34

2


2

2


6 - 586 - 57

Ground Control Box Wiring DiagramDeutz D2011L03i and Perkins 404-22 Models(from serial number 14832)


6 - 59

Platform Control Box Wiring DiagramDeutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models


6 - 60

1

2

3

4

5

6

7

8



6 - 60 S-40 • S-45 Part No. 102521

Platform Control Box Wiring Diagram- ALC-500Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models(before serial number 14832)

TILT ALARM 45383


H1

ALC-500 94771

D4

0

RD

/BK

-28

H1

ALALRMTILT

RE

D-T

ILT

D3

9

GR/BK C4P-4

BATGND C7P-3

19/18 CONTROL CABLE

C3

P(G

R)

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

12V BATT

C7P

C7P

C4P

C3P

C2

8T

TA

RD

/BK

C1

P-2

GR

/BK

L4

C2

9M

SR

D/W

H

C1

3L

ED

BL

/RD

DR

EB

BL

/BK

DR

EA

BL

/WH

C28TTA RD/BK C1P-2

RE

D-T

ILT

JC

1-2

BR

N

JC

2-2

BR

N

JC

3-4

,6W

H

JC

3-2

BR

N

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

5R

PM

BK

/RD

C1

P-9

C3

3S

TR

BK

C1

P-7

C1

34

PW

RR

DC

2P

-4

C1P

1

9

RD

/BK

L4

8

J1

C6

TR

FW

H/R

DC

3P

-6

C1

0S

BU

BL

C3

P-1

0C

13

DR

EB

L/R

DC

4P

-1C

11

SB

DB

L/B

KC

3P

-11

C4

0L

S1

OR

C2

P-2

C1

2S

BF

BL

/WH

C3

P-1

2C

41

RP

MO

R/B

KC

2P

-3C

30

ED

C+

WH

C1

P-4

C1

PB

UR

DC

3P

-1C

31

ED

C-

WH

/BK

C1

P-5

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

BL

/BK

C1

P-1

1C

3P

BF

RD

/WH

C3

P-3

C3

6S

TC

CB

LC

1P

-10

C4

TR

LW

HC

3P

-4C

32

BR

KW

H/R

DC

1P

-6C

5T

RR

WH

/BK

C3

P-5

C2

9M

SR

D/W

HC

1P

-3

C2P

J211

1

JC

1-5

YE

L

JC

3-5

BL

JC

3-3

OR

JC

2-4

RD

JC

1-3

OR

JC

2-3

OR

JC

2-5

BK ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H

C3P

OPT.

BR

N

F.S.

C9P LS18

C1

9JS

VG

R/W

HC

4P

-7A

ND

TS

8

C3

9L

PB

L/R

DC

2P

-1

C4

5G

EN

GR

/WH

C2

P-7

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C1

7JU

GR

C4

P-5

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P-2

P2

4F

SW

HC

9P

-2P

25

FS

RD

C9

P-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8C

43

HR

NG

RC

2P

-5

JD

AL

AR

MG

R/B

KC

2P

-6

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

C1

32

PL

IB

KC

1P

-12

RD

H1

RD

P2

P2

6B

AT

BK

HARNESSPBOX WIRING

DR

IVE

LT

BK

/RD

C3

P-9

3

1

J3

JIB

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 61


Platform Control Box Wiring Diagram- ALC-500Deutz D2011L03i and Perkins 404-22 Models


C3

9LP

BL/R

DC

2P-1

TS

48

-WL1

RD

C2

P-1

2

TS

48

-WL2

RD

C2

P-1

1

BR

BR

B

RD

C1

CR14

GR/WH

P1

34

PW

RR

D

CR

13

-#8

6G

R/W

H

GR

/WH

RD

GR/WH

BY

Y

B

RR

RBR -

RD OUTPUT

GR/WH +

B

BK

JIB

R

BBY Y

B

B

WH

B

B

D4

0

H1

ALALRM

TILT

RD

-TILT

RD

/BK

-28

D3

9

BATGND C7P-3

GR/BK C4P-4

C3P

19/18 CONTROL CABLE

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

DR

EA

BL/W

H

DR

EB

BL/B

KC

13

LE

DB

L/R

DC

29

MS

RD

/WH

C2

8T

TA

RD

/BK

C1

P-2

RD

-TILT

GR

/BK

L4

JC

3-1

BR

JC

3-3

,5B

L/W

H

JC

2-1

BR

JC

1-1

BR

P1

34

PW

RR

DC

2P-4

C3

3S

TR

BK

C1

P-7

C3

5R

PM

BK

/RD

C1

P-9

C3

4S

AB

K/W

HC

1P-8

C2

7A

UX

RD

C1

P-1

C1P

C2P

J1

1

9

RD

/BK

L4

8

C2

9M

SR

D/W

HC

1P-3

C5

TR

RW

H/B

KC

3P-5

C3

2B

RK

WH

/RD

C1

P-6

C4

TR

LW

HC

3P-4

C3

6S

TC

CB

LC

1P-1

0C

3P

BF

RD

/WH

C3

P-3

C3

7S

TC

BL/B

KC

1P-1

1

C2

PB

DR

D/B

KC

3P-2

C3

1E

DC

-W

H/B

KC

1P-5

C1

PB

UR

DC

3P-1

C3

0E

DC

+W

HC

1P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL/W

HC

3P-1

2

C4

0LS

1O

RC

2P-2

C1

1S

BD

BL/B

KC

3P-1

1

C1

3D

RE

BL/R

DC

4P-1

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P-6

J2

1

11

1

JC

1-4

WH

/BK

JC

3-2

OR

JC

3-4

WH

/RD

JC

2-4

RD

/WH

JC

2-2

OR

JC

1-2

OR

JC

2-3

WH

/RD

ALC-500

BR

P2

4F

SW

H

P2

4F

SW

H

J3

3

F.S.

C9P

COMPONENT INDEX

TILT ALARM

C1

7JU

GR

C4

P-5

JD

ALA

RM

GR

/BK

C2

P-6

C4

3H

RN

GR

C2

P-5

C8

PB

RB

K/W

HC

3P-8

C7

PB

EB

KC

3P-7

P2

6E

ST

PB

KC

9P-1

P2

5F

SR

DC

9P-3

P2

4F

SW

HC

9P-2

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C4

5G

EN

GR

/WH

C2

P-7

C1

8JD

GR

/BK

C4

P-6

P2

2B

AT

BK

C7

P-1

P2

3B

AT

WH

C7

P-2

C1

9JS

VG

R/W

HC

4P-7

P2

6E

ST

PB

K

H1

C1

9JS

VG

R/W

HT

S7

C1

9JS

VG

R/W

HC

4P-7

BR

GN

D

BR

JC

3

RD

-E-S

TO

P

P1

34

PW

RR

D-H

1+

OPT.JIB LS18

OPTION

JIB TIME DELAY

JIB DELAY RELAY

C1

CR14

RD LS18 CABLE

C132PLI1 BK C1P-12

C132PLI2 BK C3P-10

COM

32NO

5P

26

ES

TP

BK

E-S

TO

PB

RG

ND

RD

-H1

+

P1

34

PW

RR

D

R2

6E

ST

PB

KC

9P-1

U35

LOAD SENSE OPTION

D88

D89

LOAD SENSE TIME DELAY RELAY (30A)U35

R2

0

47

00

BR

86

30

8785


6 - 62

Platform Control Box Wiring Diagram- ALC-500Deutz D2011L03i and Perkins 404-22 Models(from serial number 14832)

6 - 61


6 - 63

Platform Control Box Switch Panel Wiring DiagramDeutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)


6 - 64

1

2

3

4

5

6

7

8



6 - 64 S-40 • S-45 Part No. 102521

Platform Control Box Switch Panel Wiring DiagramDeutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)Perkins 404-22 Models (from serial number 7472 to 12509)

EMERGENCY STOP

P2

DRV.ENA

TS15

L1

TS13

PRIMARYBOOM

EXTEND/

RETRACT

P3HORN

TS47

JC3

L1

JC2

TS1

TS13

TS4

TS15

TS8

TS6

TS9

TS7

TS2

P2

P3


DRIVE PROPORTIONAL JOYSTICK

DRIVE ENABLE LED

AUXILIARY SWITCH


START ENGINE SWITCH



GLOW PLUG OPTION

JIB UP/DOWN SWITCH


HI/L0 RPM SWITCH

DRIVE ENABLE SWITCH

CE PLATFORM LED


COMPONENT INDEX

HORN SWITCH


PART NUMBER

66812, 95406

66813, 66815

42730

13037

56457

16397

13037

13037

13037

13037

27378

56298

62390

75565

GR

-43

OR

-14

OR

/BK

-15

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HJIB

C1

7JU

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

RD

-25

C3

3S

TR

BK

C1

P-7

WH

-23

P2

6B

AT

BK

C9

P-1

P2

2B

AT

BK

C7

P-1

BK

-22

RD

LS

18

RD

P2

WH

BK

/WH

-8

BL

/RD

-DE

3J1

-16

BL

/WH

-DE

1J1

-6

BK

-7

WH

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

HARNESS

PBOX WIRING

BL

/BK

-DE

2J1

-7

OR

J1

-13

BR

NJ1

-14

BL

J1

-4

WH

J1

-5

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3JC2

CR13

WH

-JIB

C1

9JS

VG

R/W

H

WH

-24

BR

N

WH

-JIB

4

2

1

3

5

6

7

WH

-24

BK

-22

WH

-24

(SPLICE TO R40LS1)

(SPLICE TO C32BRK)

OR R40LS1

WH/RD C32BRK

WH TS7

CR30

CR27

WH TS1



(GND STUD)

BRN BATGND

CE SEE DETAIL A

TS48

WORK/ DRIVE LITE

TS48 WORK/DRIVE LIGHT ( OPTION ) 27378

RD

WL

1

RD

WL

2

56298

WH

J1

-5

13037

+

C3

4S

AB

K/W

HC

1P

-8

GLOW PLUG

TS6

L4

L48

4

2

1

3

5

6

7

GR

/BK

H1

RD

/BK

H1

RD

P3

RD


NOTE:

+

+

DR

IVE

LT

BK

/RD

-C3

P-9

(OPTION)

TS47GENERATOR

RD

TS

47

BK

/RD

-35

TS4

WH

-24

HIGH/LOW

RPM

10 AMP FUSE

L48 CHASSIS TILT LED 56298

C2

9M

SR

D/W

HJ1

-8

WH

-24

HIGH/LOW

TS14

DRIVE

SPEED

WH

-24

GR

/WH

-45

REMOVE FOR

GENERATOR OPTION

RD

TS14 DRIVE SPEED SWITCH 56457

RD

4 3NO

LEVEL

PLATFORM

TS9ROTATE

PLATFORM

TS7

GR/BK

WH

GR

JIB

TS8

AUXILIARY PUMP

TS1

2 NC

NC

NC

22

11

1

L4

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 65


Platform Control Box Switch Panel Wiring DiagramDeutz D2011L03i and Perkins 404-22 Models


GN

/WH

-45

GENERATOR

(OPTION)RD

TS17

RD

+

+

C1

9JS

VG

N/W

H

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

GN/BK

GR

JIB

TS8

WH

-24

BR

WH

-JIB

CR13

C2

9M

SR

D/W

HJ1

-8

C3

3S

TR

BK

C1

P-7

C2

7A

UX

RD

C1

P-1

C1

7JU

GN

C4

P-5

C1

9JS

VG

N/W

HJIB

C1

8JD

GN

/BK

C4

P-6

OR

/BK

-15

ROTATEPLATFORM

HORN

TS9

P3PLATFORM

LEVEL

TS7

D27

SPEEDDRIVE

CE SEE DETAIL A

WH

AUXILIARY PUMP

TS1

TS14

HIGH/LOW START

TS2

GN

-43

J1

-12

BR

JC

2-1

RD

P2

WH

OR

-14

J1

-2R

D/W

HJC

2-4

J1

-1W

H/R

DJC

2-3

J1

-11O

RJC

2-2

TURNTABLE ROTATE

PRIMARY BOOMUP/DOWN

JC2

DR

IVE

LTB

K/R

D-C

3P

-9

BK

-7

BK

/WH

-8

BL

/BK

-DE

2J1

-7

WH

-24

TS13

RETRACT

EXTEND/BOOM

PRIMARY

BK

-22

WH

-24

BL

/WH

-DE

1J1

-6

BL

/RD

-DE

3J1

-16

WH

-24

RD

-25

L1

+

TS15DRIVE ENABLE

BK

/RD

-35

P2

2B

AT

BK

C7

P-1

P2

6B

AT

BK

C9

P-1

HIGH/LOWRPM

TS4 EMERGENCY STOPP2

CR30

PBOX WIRING

HARNESS

L4

RD

/BK

H1

GN

/BK

H1

WH

-24

L48

J1

-5B

L/W

HJC

3-5

J1

-5B

L/W

HJC

3-3

J1

-4W

H/R

DJC

3-4

J1

-14

BR

JC

3-1

J1

-13

OR

JC

3-2

WH

-23

BK

-22

RD

LS

18

RD

P3

RD

DRIVE/STEER

JC3


CR27

C3

4S

AB

K/W

HC

1P

-8

GLOW PLUG

TS6

RD

RD

WL

1

TS48

WORK/

RD

WL

2

10 AMP FUSE

DRIVE LITE


NOTE:

OR R40LS1

(SPLICE TO R40LS1)


WH TS7WH TS1

BRN BATGND

(GND STUD)

WH/RD C32BRK

(SPLICE TO C32BRK)

NC

NC

NC

NO

TS49

TS2

TS7

TS3

TS8

TS15

TS4

TS13

TS47

TS9

L4

JC2

P3TS1

P2L1

JC3

WORK/DRIVE LIGHT ( OPTION )

FUEL SELECT SWITCH (FORD EFI ONLY)


GENERATOR SWITCH ( OPTION )DRIVE ENABLE SWITCH

HI/L0 RPM SWITCH

JIB UP/DOWN SWITCHPLATFORM LEVEL SWITCH


START ENGINE SWITCH




HORN SWITCHEMERGENCY STOP BUTTON

AUXILIARY SWITCH

DRIVE ENABLE LED

COMPONENT INDEX

TS14 DRIVE SPEED SWITCH

CE PLATFORM LED

CHASSIS TILT LEDL48

T 48 REMOVED FROM PLATFORM BOX AT SERIAL NUMBER 16420S1

1

86

3087A

85

85

30

8687A

85

30

8687


6 - 66

Platform Control Box Switch Panel Wiring DiagramDeutz D2011L03i and Perkins 404-22 Models(from serial number 12510)

6 - 65


6 - 67

Electrical SchematicFord LRG-425 EFI Models


6 - 68

1

2

3

4

5

6

7

8



6 - 68 S-40 • S-45 Part No. 102521

Electrical SchematicFord LRG-425 EFI Models(before serial number 7597)

STA

RT

ER

MO

TO

R

H2REGULATOR

-

IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TIL

TA

LA

RM

BR

NB

K

OR

/BK

-41

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-P1

34

RD

-27

RD

/BK

-28

BK

-43

CR5NO

CR5

PR1

RD

WH

NO

PR1

IGN

./STA

RT

RE

LA

Y

HO

UR

ME

TE

R

_

SW

ITC

H

FU

EL

RE

LA

Y

OIL

PR

ES

SU

RE

SW

ITC

H

NC OTS

NO

OP

TIO

NG

EN

ER

AT

OR

BK

-33

+

WH

/RD

-24

WH

/BK

-24

OPS

TB25 TB26WH

-21

NOCR1 CR1

CR2NO

TB21

CR2

GR

/WH

-45

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

BK

/RD

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55

RD

RD

WH

BK

OR/BK

C1

-9

GE

NE

RA

TO

R

G2 G3

G1

VO

LT

ME

TE

R

OIL

PR

ES

SU

RE

GA

UG

E

DG

RN

(FE

H2

42

)

RD

(FE

H3

61

A)

LP

GL

OC

KO

UT

SO

LE

NO

ID

HARNESSENGINEFORD

42

PIN

PL

UG

FU

EL

PU

MP FO

RD

BK

/WH

(FE

H7

2)

PIN

7

BL

/WH

(FE

H7

87

)P

IN5

OR

/RD

(FE

H3

07

A)

PIN

23

WH

(FE

H1

6A

)P

IN1

BR

(FE

H5

70

C)

PIN

34

PUMPFUEL

BK

/RD

(FE

H4

58

)P

IN3

WH

(FE

H3

06

)P

IN2

4

BL

(FE

H6

58

)P

IN6

TB24

TB24

TS3

TS53

TB39

TE

ST

RU

N

TS22

P24BAT

C3

5R

PM

2

C3

9L

P

C2

11

GN

2

TS

W

C3

8E

SL

C6

-39

C5

-13

C5

-12

C5

-17

C5

-10

C5

-9

C5

-11

C5

-15

C5

-16

C5

-14

C5

-5

C6

-27

C6

-28

C6

-23

TB43

C6

-16

C5

-2

C5

-3

C2

-1

FAN

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.

SW

ITC

HH

YD

RA

UL

ICO

IL

NOOTS

CR17NO

CR17

CB320AMP.

C6

-33

C6

-34

C6

-25

TB134P1RD

TB22

PLAT

GRD

KS1

RD

C1

34

PW

RO

R/R

D

C2

-4

P2

2B

AT

BK

HORN

C7

-1

H1P3

RD

L4

P2

C28TTA RD/BK RD/BK

C1

33

PL

AO

R/R

DC

4-4

C2-3

TB133

L48

D40D39

OP

TIO

NF

LA

SH

ING

BE

AC

ON

S

FB

WA

TE

RT

EM

PG

AU

GE

WA

TE

RT

EM

P

NOTE:




D6

HIG

HR

PM

(FS

)

SEE NOTE 2

TS4

TS17

C6

-26

LPGA

SF

UE

L

PU

MP

AU

XIL

IAR

Y

LP

GA

S FU

EL

FU

NC

TIO

NE

NA

.

PU

MP

AU

XIL

IAR

Y

HMS

TA

RT

EN

GIN

E

STA

RT

EN

GIN

E

12 VDC

PUMPAUX STARTER

L26 BATTERY7

10

9

8

ENG. FAULT


KEY PWR.

4

3

5

2

1

AUX. ONGROUND


IGN./START

MODULE

START RELAY

TB 134 IS WAGO TERMINAL BLOCK 42

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 69




C6

-4

C6

-6

C6

-2

C6

-3

C6

-8

C6

-18

DR

IVE

LIM

ITS

WIT

CH

BO

OM

RE

TR

AC

T

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

LS

2-P

RIM

AR

YB

OO

MU

P

DE

SC

EN

TA

LA

RM

OP

TIO

N

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

JIB

VA

LV

ES

BRN

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

DR

IVE

LIM

ITS

WIT

CH

NOHC NONC

WH

BK

WH

BK

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

NOHC

WH

BK

TB22

H3

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C5

-21

C6

-36

C6

-37

C5

-20

C5

-23

H4

GR

OU

ND

C19JSV GR/WH

TS59

TB19

TB17TB18

C6

-17

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

P-7

JD

AL

AR

MG

R/B

K

C1

7JU

GR

C1

8JD

GR

/BK

TS57TS58

TB44

C4

P-5

C2

P-6

C4

P-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

C6

-7

TB8

TB7

TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0L

S1

OR

C4

P-2

C4

P-3

C3

P-7

C3

P-8

C1

3D

RE

BL

/RD

TS63

C3

P-2

C3

P-3

TS9

BRN

JIB

VA

LV

E

WH

CR13

TS8TS7

GR

/BK

-44

WH

NC

CR13

WH

BK

OR/BK


TS13

CR27NC

J3

C4

1R

PM

OR

/BK

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

C6

-1

C6

-5

TB1

TB36TB30

C1

PB

UR

D

TS61

C4

TR

LW

H

TS62

C3

P-1

BR

N-2

C2

P-3

J2

J1

DR

EA

BL

/WH

DR

EB

BL

/BK

DR

EL

ED

BL

/RD

J1

6

J1

7

16 8

15

TS15 L1

C6

-32

C6

-13

C6

-40

C6

-15

C6

-14

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

SJ1-WH

C4

0L

S1

ORC

17

JU

GR

C1

8JD

GR

/BK

AB

DC

C6

-19

RD

/BK

C6-30

C1

3D

RE

BL

/RD

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

5

RIG

HT

LE

FT

PL

AT

RO

TA

TE

DO

WN

UP

JIB

BO

OM

DO

WN

UP

PL

AT

LE

VE

L

EX

TE

ND

RE

TR

AC

T

BO

OM

RIG

HT

LE

FT

PL

AT

RO

TA

TE

RIG

HT

LE

FT

JIB

BO

OM

UP

DO

WN

PL

AT

LE

VE

L

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN

PR

IMA

RY

BO

OM

LE

FT

RIG

HT

TR

OTA

TE

7.5



NOTE:

NOCR30

CE

OPTION

LIFT/DRIVE

BR

N

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K

13 4 2

C2

P-2

C4

P-1

4 3 14

13

12

8 7 6 16

15

1920

17

18

11

10

C3

P-6

C3

P-4

C3

P-5

C1

P-6

C1

P-1

1

C1

P-1

0

C1

P-4

C1

P-5

9 5

RD

BK

BR

N

OR

12 111 2

7


YO

UT

XO

UT

GN

D

1 2 43 5 6

PW

R

JC2

BR

N

OR

BL

WH

13

14 54

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

76

DRIVE & STEERING

JC3

TB2

TB3

TB4

TB5

TB6

TB37 TB32

TB31

1

2

34

5

6

7

6

5

4

3

2

1

Deutsch

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7



6 - 70

Electrical SchematicFord LRG-425 EFI Models(before serial number 7597)

6 - 69

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 71


Ground Control Box Wiring DiagramFord LRG-425 EFI Models

(before serial number 7597)E

NG

INE

C5

BRN GND

WH-23C

BK-22C

BR-GND STUD

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

C6

C3

B

19

/18

CA

BL

ES

C2

BC

4B

3

2C7

B 1

CR23

RD C4B-11

RD C4B-12

RD-CB3 SP

ALL BR WIRES

BRGROUND STUD

GR

OU

ND

ST

UD


12

V

CHECK ENGINE

CHECK ENGINE SWITCH


ENGINE START SWITCH


AUXILIARY SWITCH

DESCRIPTION

FUNCTION ENABLE


VOLT METER GAGE

OIL PRESSURE GAGE

WATER TEMP. GAGE








G3

L2

G1

G2

LABEL

TS22

HM

R2

CB2

CB1

TS62

TS58

TS63

TS61

HOUR METER

TS52

TS59

TS57

TS55

KS1

TS51

P1

KEY SWITCH

32WH/RD-C1B-6




RD-C3B-1RD/BK-C3B-2

RD-C6-1

D

BK/WH-C6-8

WH/BK-C6-5

RD/WH-C6-3WH- C6-4

WH/RD-C6-6BK- C6-7

RD/BK-C6-2

C B

6

2

3

1

54

8

7

109

44B-RD/BK-C6-19

WH/BK-C1B-5

WH-C1B-4RD/WH-C1B-3

RD-C1B-1

WH-C7B

RD/BK-C1B-2


BK-C7BWH-C5-3+C6-34

GR-C4B-5OR/RD-C4B-4

OR-C4B-2OR/BK-C4B-3


GR/BK-C6-18

WH-CR2#87

GR- C6-17

BL/RD-C6-13

RD- C6-23

WH-C5-11

RD- C6-27

BK-CR5#30WH-S.P.

16

13

12

15

14

1918

17

2120

WH-TS22#5

RED-CR1#30

RD-ISM#4

242322

2526

2928

27

3031


OR/BK-C2B-3

BL/RD-C2B-1OR-C2B-2

OR/RD-C2B-4


BL/BK-C1B-11

BL-C1B-10

BL/WH-C1B-12

BK-C1B-7

BK/RD-C5-9

BK/WH-C5-10OR- C6-40OR/BK-C5-2

GR/WH-C6-39

42

BK-CR1#85

37

3433

3536

39

38

4041

D5

4443

45

RD-S.P.

TURN. ROT. R

PRI. BOOM DOWN

PRI. BOOM F.C.

TURN. ROT. LTURN. ROT. F.C.BOOM EXTENDBOOM RETRACT

PRI. BOOM UP

WH/RD-S.P.

RD/WH-S.P.

WH/BK-S.P.

RD/BK-S.P.

WH-S.P.

BK/WH-S.P.

BK-S.P.

JIB VALVE



DRV. ENA. LT.

IGNITION PWR.

OR/BK-S.P.OR-S.P.


TILT ALARM

E.D.C.+

E.D.C.-

AUX. PWR.


ENGINE POWER

WH/BK-S.P.WH/RD-S.P.

RD-S.P.

WH-S.P.BK-S.P.

RD-S.P.

SPARE

LIMIT SWITCH SIG.

GLOW PLUG

STEER LEFT

RPM

STEER RIGHT

CHECK ENGINE

START

PULSE PICKUP


BK-S.P.

BL/RD-S.P. L.P.

GEN. OPTIONSPARE

HORN

BRAKE/TRAVEL ALARM


BL- C6-36BL/BK-C6-37

RD/BK-C6-28

OR- C6-14

OR/BK-C6-15

LIMIT SWITCH POWER46

SPARE

TS53LP/GAS SWITCH

WH/BK-C5-20WH- C5-21

WH/RD-C5-23 WH/RD-C6-32

GR-C2B-5 GR-CR5#85

PART #

P1

KS1

16397

13037

56457

13037

13037

42730

13037

CB1

CB2

42730

16397

16397

13037

56298

G3

G2

G1

R2

HM

CB3CB3CIRCUIT BREAKER, OPTIONS, 20A

BL/WH-C6-30

TS63

TS58

GR/BK-18A

WIRING

TO BASEHARNESS:

GR/WH-19A

GR-17A

OR-14A

OR/BK-15A

RD- P1 E-STOP

RD- 20B

TS55

RD- 24A

RD- 20A

BK/RD-35A

D13

TS52

GR/BK-18AGR/WH-19A

RD-CR17#30

RD- 20C

GR-17A

D14

GR/BK-44A

BK-33A

BK/WH-8A

BK-7A

CB2CB1

R2

CB3

BR (GROUND)

HM

RD/WH-3A

RD/BK-2A

RD-1A

BR (GROUND)

WH-21A

L2

RD-27ARD-42A

WH-23A

RD-CB2

NC

NC

P1

BK-22A

WH/BK-25A

WH/RD-26A

KEY SWITCHB

B1

1

24

3

RD

KS1

WH-21A

G1 G2

TS59

TS57

TS62

TS61

TS51

G3

BL/RD-39A

TS53

A

GR/BK-2B GR/BK-SP

R1R1RESISTOR, 5 OHM, BOOM FUNCTION

R1

BL - C5-13

GR/BK C2B-6

WH/RD-C5-14

WH/BK-C5-16

BL/WH-C5-13

BL/WH-ISM#10 BL/WT-S.P.

BK-ISM#3

D6

RD- C5-1

BK-ISM#1

TS22

BR-R1BR-GND

BK/RD-C5-12

CHECK ENGINE TOGGLE SWITCH

BK-C5-5

45

12

63

WH CR2#87WH-C5-17

BLK-33BWH-23BWH-ISM#7

WH-TS22#4

WH-21B

RD-ISM#6WH-ISM#9RD-24B

CR1 CR2

BK-C6-16

CR5

BK-22BGR-43D

CR17

OR-C6-33

RD-CB3 SP

BK-C6-25

BR-GND+C6-26

L45

OR/RD-H6-

RD-H6+

RD-C23-6

BL/WH-ISM#10

IGN./START

MODULEAUX. ON4

WH-CR2#86

WH-TS22#6

RD-CR2#30BR-GND.

KEY BYPASS

ENG. FAULTIGN./FUEL ON

10

8

9

6

7

5

BATTERYKEY PWR.

GROUND

RD-27BBK-33BOR/BK-41BBK-CR1#86


START RELAY

3

2

1

BK/WH-38B


6 - 72

Ground Control Box Wiring DiagramFord LRG-425 EFI Models(before serial number 7597)

6 - 71


6 - 73

Platform Control Box Wiring DiagramFord LRG-425 EFI Models


6 - 74

1

2

3

4

5

6

7

8



6 - 74 S-40 • S-45 Part No. 102521

Platform Control Box Wiring DiagramFord LRG-425 EFI Models(before serial number 7597)

TILT ALARM 45383


H1

D4

0

RE

D/B

LK

-28

H1

ALALRMTILT

RE

D-T

ILT

D3

9

BR

N

BATGND C7P-3

GR/BK C4P-4

C3P

19/18 CONTROL CABLE

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

DR

EA

BL

/WH

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

C2

8T

TA

RD

/BK

C1

P-2

RE

D-T

ILT

GR

/BK

L4

8

JC

3-2

BR

NJC

3-4

,6W

H

JC

2-2

BR

N

JC

1-2

BR

N

C1

34

PW

RR

DC

2P

-4

C3

3S

TR

BK

C1

P-7

C3

5R

PM

BK

/RD

C1

P-9

C3

4S

AB

K/W

HC

1P

-8

C2

7A

UX

RD

C1

P-1

C1P

C2P

J1

1

9

RD

/BK

L4

C2

9M

SR

D/W

HC

1P

-3

C5

TR

RW

H/B

KC

3P

-5C

32

BR

KW

H/R

DC

1P

-6C

4T

RL

WH

C3

P-4

C3

6S

TC

CB

LC

1P

-10

C3

PB

FR

D/W

HC

3P

-3C

37

ST

CB

L/B

KC

1P

-11

C2

PB

DR

D/B

KC

3P

-2C

31

ED

C-

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1C

30

ED

C+

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2C

40

LS

1O

RC

2P

-2C

11

SB

DB

L/B

KC

3P

-11

C1

3D

RE

BL

/RD

C4

P-1

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

J2

1

11

1

JC

1-5

YE

L

JC

3-3

OR

JC

3-5

BL

JC

2-5

BK

JC

2-3

OR

JC

1-3

OR

JC

2-4

RD

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H J3

3

C3P

OPT.

F.S.

C9P

F.S.

LS18JIB

C4

P-7

AN

DT

S8

C1

9JS

VG

R/W

H

BR

NC

17

JU

GR

C4

P-5

DR

IVE

LT

BK

/RD

C3

P-9

JD

AL

AR

MG

R/B

KC

2P

-6

C4

3H

RN

GR

C2

P-5

C8

PB

RB

K/W

HC

3P

-8

C7

PB

EB

KC

3P

-7P

26

BA

TB

KC

9P

-1P

25

FS

RD

C9

P-3

P2

4F

SW

HC

9P

-2

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

DL

ITE

GR

/BK

C2

P-6

TS

48

-WL

1R

DC

2P

-12

TS

48

-WL

2R

DC

2P

-11

C4

5G

EN

GR

/WH

C2

P-7

C3

9L

PB

L/R

DC

2P

-1

C1

32

PL

IB

KC

1P

-12

C1

8JD

GR

/BK

C4

P-6

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

C1

9JS

VG

R/W

HJIB

RD

P2

RD

H1

P2

6B

AT

BK

PBOX WIRING

HARNESS

ALC-500 89353

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 75


Platform Control Box Switch Panel Wiring DiagramFord LRG-425 EFI Models


EMERGENCY STOP

P2FUEL SELECT

DRV.ENATS15

L1

AUXILIARY

TS13PRIMARYBOOM

EXTEND/RETRACT

TS8

JIB

PLATFORM

TS7PLATFORM

LEVEL

TS9P3

HORN

ROTATE

TS1

TS47

JC3L1

JC2

TS1

TS13

TS4

TS15

TS8

TS3

L3

TS9

TS7

TS2

P2

P3



AUXILIARY SWITCH


START ENGINE SWITCH



CHECK ENGINE LIGHT

JIB UP/DOWN SWITCH


HI/L0 RPM SWITCH

DRIVE ENABLE SWITCH



COMPONENT INDEX

HORN SWITCH


PART NUMBER

66812, 7380566813, 668164273013037

56457

16397130371303713037

1303727378

56298

62390

75565

GR

-43

OR

-14

OR

/BK

-15

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HJIB

C1

7JU

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

BL

/RD

-39

WH

-23

P2

6B

AT

BK

C9

P-1

P2

2B

AT

BK

C7

P-1

BK

-22

RD

WH

GR

RD

TS3

BK

/WH

-8

BL

/RD

-DE

3J1

-16

BL

/WH

-DE

1J1

-6

BK

-7

WH

WH

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

HARNESS

PBOX WIRING

DASHED LINES INDICATE

OPTION WIRES

NOTE:

RD

-TIL

T

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

BL

J1

-4

WH

J1

-5

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3JC2

CR13

WH

-JIB

C1

9JS

VG

R/W

H

WH

-24

BR

N

WH

-JIB

4

2

1

3

5

6

7


WH

-24

BK

-22

WH

-24

(SPLICE TO R40LS1)

(SPLICE TO C32BRK)

OR R40LS1

WH/RD C32BRK

WH TS7

CR30

CR27

WH TS1



(GND STUD)

BRN BATGND

CE SEE DETAIL A

WORK /TS48 / TS49

DRIVE LITE


RD

WL

1

DL

ITE

/R

DW

L2

56457

WH

J1

-5

56298

RD

+

BK

/RD

-35

WH

-24

RPM

HIGH/LOW

TS4

START

TS2

BK

-33

RD

-25

DR

IVE

LT

BK

/RD

-C3

P-9

RD

/BK

H1

L4

+

RD

-TIL

T

WH

-TS

47

GENERATOR

(OPTION)

TS47

WH

-24

GR

/WH

-45

WH

-TS

4

RDPUMP

4 3NO

NC

NC

NC

11

1

22

2


6 - 76

Platform Control Box Switch Panel Wiring DiagramFord LRG-425 EFI Models(before serial number 7597)

6 - 75


6 - 77



6 - 78

1

2

3

4

5

6

7

8



6 - 78 S-40 • S-45 Part No. 102521

Electrical SchematicFord LRG-425 EFI Models(from serial number 7597 to 11066)

STA

RT

ER

MO

TO

R

H2REGULATOR

- IND.

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TIL

TA

LA

RM

PUMP

BR

NB

K

12 V DC

+

+BAT.

STA.

BAT.-

ALTERNATOR

EXCT.

RD

-13

4

RD

-27

RD

/BK

-28

BK

-43

CR5

NO CR5

PR1

RD

WH

NO

PR1

HO

UR

ME

TE

R

_

STA

RT

RE

LA

Y

OTS

FL

AS

HIN

GB

EA

CO

NS

OP

TI O

N

OP

TIO

N

GE

NE

RA

TO

R

BK

-33

+

OPS

TB25 TB26

WH

-21

CR1

NO

TB21

CR1

GR

/WH

-45

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

RD

15AMP.

CB1

RD

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

C1

-1

TS1

C9-1 BKRD-(FS)

WH-(FS)BK-(FS)

FS1

C9-2

C9-3

C3

3S

TR

BK

TB33

BK

TS52

C1

-7

C4

5G

EN

GR

/WH

TB45

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BK

BRN

C3

5E

SP

DB

K/R

D

HIG

HR

PM

LO

WR

PM

TB35

TS55

RD

RD

WH

BK

OR/BKC

1-9

GE

NE

RA

TO

R

G2 G3

G1

VO

LT

ME

TE

R

OIL

PR

ES

SU

RE

GA

UG

E

TE

MP

GA

UG

E

C5

-16

C5

-14

C6

-27

C6

-28

C6

-23

TB43

C6

-16

C5

-2

C5

-3

FAN

(OP

TIO

N)

CO

OL

ING

FA

N

TE

MP.S

WIT

CH

HY

DR

AU

LIC

OIL

NOOTS

CR17NO

CR17

CB3

20AMP.

C6

-33

C6

-34

C6

-25

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

C1

34

PW

RR

DC

2-4

P2

2B

AT

BK

C7

-1

H1

RD

P2

C28TTA RD/BK

RD/BK

C1

33

PL

AO

R/R

D

C2-3

L48

D40

FU

NC

TIO

NE

NA

.

THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.



NOTE:

WH

/BK

WH

/RD

C6

-39

L2

D6

C6

-26

TS17

TS4

HIG

HR

PM

(FS

)

F18

BK

BK

WH

WH

TS49

RD

RD

OP

TIO

NW

OR

KL

IGH

TS

OP

TIO

ND

RI V

EL

I GH

T

CR23CR23

NO

PBOX GND

DL

ITE

BK

/RD

C3

-9

FUSE 10A

L29 L29

L30L30

2

M1

S7

M2

PR2PR2

G6Y29

C4

B-1

1

C4

B-1

2

DG

RN

(FE

H2

42

)

LP

GL

OC

KO

UT

SO

LE

NO

ID

FORDENGINE

HARNESS

RD

(FE

H3

61

A)

BL

/WH

PIN

5

FU

EL

PU

MP

FUELPUMP

C2

-1

TB39

TS53

TS3

BK

PIN

13

BK

PIN

15

C3

9L

PB

L/R

DP

IN7

RD

PIN

9

WH

PIN

1

C3

8E

SL

BL

/WH

PIN

6

TS22

GR

PIN

18

C1

27

TS

T

BR

PIN

34

BK

/RD

PIN

23

C3

5R

PM

42

PIN

PL

UG

FO

RD

CR39

NC

CR39

TB24

WH

PIN

21

VS

W

VB

AT

T

C3

3S

TR

C2

1IG

N

R3

3S

TR

CR2NO

CR2

C5

-11

C5

-10

C5

-12

C5

-5

C5

-17

C5

-9

C5

-13

BL/WH

C4

1R

PM

OR

/BK

PIN

24

2P

INF

OR

DC

ON

NE

CT

OR

R2

1IG

NW

HP

IN2

4C

5-8

2

1.

3 REFER TO E0375 FOR FORD HARNSS

3

51

0O

HM

STARTERAUXHM

HORNP3

PU

MP

AU

XIL

IAR

Y

PU

MP

AU

XIL

IAR

Y

LP

GA

S FU

EL

STA

RT

EN

GIN

EE

NG

INE

STA

RT

TB 134 IS WAGO TERMINAL BLOCK 42

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 79






NOTE:

MO

TO

RS

TR

OK

E

Y27

C2

9M

SR

D/W

HC

5-1

9C

1P

-3

BL/WH

Y51Y2Y3Y4Y23Y29Y13Y22Y21Y12H4Y25Y26Y20Y19Y16Y17

5

R1 R2

7.5

RD/BK

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C1

3D

RE

BL

/RD

C6

-30

C6

-19

RD

/BK

CD

BA

C1

8JD

GR

/BK

C1

7JU

GR

C4

0L

S1

OR

SJ1-WH

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

C4

TR

LW

H

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

C3

1E

DC

-W

H/B

K

C6

-14

C6

-15

C6

-40

C6

-13

C6

-32

5

L1TS15

JC3DRIVE & STEERING

6 7

GN

D

PW

R

5421 3

YO

UT

RK

OU

T

158

167

J1

64 5

14

13

J1

DR

EL

ED

BL

/RDW

H

BL

OR

BR

N

DR

EB

BL

/BK

DR

EA

BL

/WH

JC2

PW

R

653 421

GN

D

XO

UT

YO

UT


7

9

211 1

12

J1

6

J2

OR

BR

N

BK

RD

C2

P-3

BR

N-2

C1

P-5

C1

P-4

C1

P-1

0

C1

P-1

1

C1

P-6

C3

P-5

C3

P-4

C3

P-6

C3

P-1

TS62 C4

TR

LW

H

TS61

C1

PB

UR

D

TB30TB31

TB36 TB37 TB32TB4

TB5TB2

TB1

C6

-5

C6

-1TB3 TB6

C5

TR

RW

H/B

K

C3

1E

DC

-W

H/B

K

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

10

11

18

17

20

19

15

16

C4

1R

PM

OR

/BK

78

243 1

J3

3P

26

ES

TP

BK

P2

4F

SW

H

P2

4F

SW

H

BR

N

NCCR27

CR30NO

4DRIVELIFT/

OPTION

CE

TS13


OR/BK

BK

WH

CR13NC

WH

GR

/BK

-44

TS7TS8

CR13

WH

JIB

VA

LV

E

BRN

TS9

C3

P-3

C3

P-2

C4

P-1

TS63

C1

3D

RE

BL

/RD

C2

P-2

C3

P-8

C3

P-7

C4

P-3

C4

P-2

C4

0L

S1

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

TB40 TB13TB7

TB8

C6

-7

TB14

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C4

P-6

C2

P-6

C4

P-5

TB44

TS58

TS57

C1

8JD

GR

/BK

C1

7JU

GR

JD

AL

AR

MG

R/B

K

C4

P-7

RD

RD

C1

9JS

VG

R/W

H

TB15

C6

-17

TB18

TB17

TB19

TS59

C19JSV GR/WH

12

13

14

GR

OU

ND

H4

C5

-23

C5

-20

C6

-37

C6

-36

C5

-21

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

FL

OW

CO

NT

RO

L

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

PR

IMA

RY

BO

OM

DO

WN

DR

IVE

ED

CF

OR

WA

RD

DR

IVE

ED

CR

EV

ER

SE

TR

AV

EL

AL

AR

MO

PT

ION

BR

AK

ER

EL

EA

SE

VA

LV

E

BK

WH

NOHC

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

BO

OM

EX

TE

ND

BK

WH

BK

WH

NCHONOHC

DR

IVE

LIM

ITS

WIT

CH

PL

AT

LE

VE

LD

OW

N

PL

AT

LE

VE

LU

P

BRN

JIB

VA

LV

ES

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

DE

SC

EN

TA

LA

RM

OP

TIO

N

LS

2-P

RIM

AR

YB

OO

MU

P

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

BO

OM

RE

TR

AC

T

DR

IVE

LIM

ITS

WIT

CH

C6

-18

C6

-8

C6

-3

C6

-2

C6

-6

C6

-4

TB29

C2

9M

SR

D/W

H

TS14

RIG

HT

LE

FT

PL

AT

RO

TA

TE

DO

WN

UP

JIB

BO

OM

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

EX

TE

ND

RE

TR

AC

TP

LA

TF

OR

ML

EV

EL

PL

AT

RO

TA

TE

RIG

HT

LE

FT

DO

WN

UP

JIB

BO

OM

UP

DO

WN P

LA

TF

OR

ML

EV

EL

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN

PR

IMA

RY

BO

OM

LE

FT

RIG

HT T

RO

TA

TE

1

2

34

5

6

7

6

5

4

3

2

1

Deutsch

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7



6 - 80

Electrical SchematicFord LRG-425 EFI Models(from serial number 7597 to 11066)

6 - 79

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 81


Ground Control Box Wiring DiagramFord LRG-425 EFI Models

(from serial number 7597 to 11066)E

NG

INE

C5

BRN GND

WH-23C

BK-22C

BR-GND STUD

12

VT

OP

LA

T

C1

B

FU

NC

TIO

NS

C6

C3

B

19

/18

CA

BL

ES

C2

BC

4B

3

2C7

B 1

CR23

RD C4B-11

RD C4B-12

RD-CB3 SP

ALL BR WIRES

BRGROUND STUD

GR

OU

ND

ST

UD


12

V

CHECK ENGINE

CHECK ENGINE SWITCH


ENGINE START SWITCH


AUXILIARY SWITCH

DESCRIPTION

FUNCTION ENABLE


VOLT METER GAGE

OIL PRESSURE GAGE

WATER TEMP. GAGE








G3

L2

G1

G2

LABEL

TS22

HM

R2

CB2

CB1

TS62

TS58

TS63

TS61

HOUR METER

TS52

TS59

TS57

TS55

KS1

TS51

P1

KEY SWITCH

32WH/RD-C1B-6




RD-C3B-1RD/BK-C3B-2

RD-C6-1

D

BK/WH-C6-8

WH/BK-C6-5

RD/WH-C6-3WH- C6-4

WH/RD-C6-6BK- C6-7

RD/BK-C6-2

C B

6

2

3

1

54

8

7

109

44B-RD/BK-C6-19

WH/BK-C1B-5

WH-C1B-4RD/WH-C1B-3

RD-C1B-1

WH-C7B-2

RD/BK-C1B-2


BK-C7B-1WH-C5-3+C5-8

GR-C4B-5OR/RD-C4B-4

OR-C4B-2OR/BK-C4B-3


GR/BK-C6-18

WH-CR2#87

GR- C6-17

BL/RD-C6-13

RD- C6-23

WH-C6-34

RD- C6-27

BK-CR5#30WH-S.P.

16

13

12

15

14

1918

17

2120

CR39 #30

RED-CR1#30

RD-CR39#85

242322

2526

2928

27

3031


OR/BK-C2B-3

BL/RD-C2B-1OR-C2B-2

OR/RD-C2B-4


BL/BK-C1B-11

BL-C1B-10

BL/WH-C1B-12

BK-C1B-7

BK/RD-C5-9

BL/RD-C5-10OR- C6-40OR/BK-C5-2

GR/WH-C6-39

42

BK-CR1#85

37

3433

3536

39

38

4041

D5

4443

45

RD-S.P.

TURN. ROT. R

PRI. BOOM DOWN

PRI. BOOM F.C.

TURN. ROT. LTURN. ROT. F.C.BOOM EXTENDBOOM RETRACT

PRI. BOOM UP

WH/RD-S.P.

RD/WH-S.P.

WH/BK-S.P.

RD/BK-S.P.

WH-S.P.

BK/WH-S.P.

BK-S.P.

JIB VALVE



DRV. ENA. LT.

IGNITION PWR.

OR/BK-S.P.OR-S.P.


TILT ALARM

E.D.C.+

E.D.C.-

AUX. PWR.


ENGINE POWER

WH/BK-S.P.WH/RD-S.P.

RD-S.P.

WH-S.P.BK-S.P.

RD-S.P.

C134PWR

LIMIT SWITCH SIG.

GLOW PLUG

STEER LEFT

RPM

STEER RIGHT

C132PLI

START

PULSE PICKUP


BK-S.P.

BL/RD-S.P. L.P.


HORN

BRAKE/TRAVEL ALARM


TS22

BK-C5-5 WH-21B

RD-24B

CR1 CR2


RD/BK-C6-28

OR- C6-14

OR/BK-C6-15

SPARE46

MOTOR SPEED

TS53LP/GAS SWITCH


WH/RD-C5-23 WH/RD-C6-32

GR-C2B-5 GR-CR5#85

PART #

P1

KS1

16397

13037

56457

13037

13037

13480

13037

CB1

CB2

42730

16397

16397

13037

56298

G3

G2

G1

R2

HM

CB3CB3CIRCUIT BREAKER, OPTIONS, 20A

BL/WH-C6-30

TS63

TS58

GR/BK-18A

WIRING

TO BASEHARNESS:

GR/WH-19A

GR-17A

OR-14A

OR/BK-15A

RD- P1 E-STOP

RD- 20B

TS55

RD- 24A

RD- 20A

BK/RD-35A

D13

TS52

WH/BK-5A

WH/RD-6A

RD-CR17#30

RD- 20C

WH-4A

D14

GR/BK-44A

BK-33A

BK/WH-8A

BK-7A

CB2CB1

R2

CB3

BR (GROUND)

HM

RD/WH-3A

RD/BK-2A

RD-1A

BR (GROUND)

WH-21A

L2

RD-27ARD-42A

WH-23A

RD-CB2

NC

NC

P1

BK-22A

WH/BK-25A

WH/RD-26A

KEY SWITCHB

B1

1

24

3

RD

KS1

WH-21A

G1 G2

TS59

TS57

TS62

TS61

TS51

G3

BL/RD-39A

TS53

A

GR/BK-2B GR/BK-SP

R1R1RESISTOR, 5 OHM, BOOM FUNCTION

R1

C133PLT

BK-33B

WH-C5-17

GR-C5-12

BL/WH-C23-3

RD-H6+


DRIVE LIGHT OPTIONBK/RD-CR23#86

BK/RD-9B

WH-C5-11

RD-27B

BK-C6-16

GR-43BBK-22B

CR5

OR-C6-33

RD-CB3 SP

CR39BK-C6-25

CR17

WH/RD-C5-14

WH/BK-C5-16

BL/WH-C5-13

RD-KS1-2 S.P.

RD- 12 VOLT RD-S.P.(CB3) RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY

RD/WH-C5-24

WH-23B


6 - 82

Ground Control Box Wiring DiagramFord LRG-425 EFI Models(from serial number 7597 to 11066)

6 - 81


6 - 83

Platform Control Box Wiring DiagramFord LRG-425 EFI Models


6 - 84

1

2

3

4

5

6

7

8



6 - 84 S-40 • S-45 Part No. 102521

Platform Control Box Wiring DiagramFord LRG-425 EFI Models(from serial number 7597 to 11066)

TILT ALARM 45383


H1

D4

0

RE

D/B

LK

-28

H1

ALALRMTILT

RE

D-T

ILT

D3

9

BR

N

BATGND C7P-3

GR/BK C4P-4

C3P

19/18 CONTROL CABLE

C1

P(G

Y)

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

12V BATT

C7P

C4P

C7P

C28TTA RD/BK C1P-2

DR

EA

BL

/WH

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

C2

8T

TA

RD

/BK

C1

P-2

RE

D-T

ILT

GR

/BK

L4

8

JC

3-2

BR

NJC

3-4

,6W

H

JC

2-2

BR

N

JC

1-2

BR

N

C1

34

PW

RR

DC

2P

-4

C3

3S

TR

BK

C1

P-7

C3

5R

PM

BK

/RD

C1

P-9

C3

4S

AB

K/W

HC

1P

-8

C2

7A

UX

RD

C1

P-1

C1P

C2P

J1

1

9

RD

/BK

L4

C2

9M

SR

D/W

HC

1P

-3

C5

TR

RW

H/B

KC

3P

-5C

32

BR

KW

H/R

DC

1P

-6C

4T

RL

WH

C3

P-4

C3

6S

TC

BL

C1

P-1

0C

3P

BF

RD

/WH

C3

P-3

C3

7S

TC

CB

L/B

KC

1P

-11

C2

PB

DR

D/B

KC

3P

-2C

31

ED

C-

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1C

30

ED

C+

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2C

40

LS

1O

RC

2P

-2C

11

SB

DB

L/B

KC

3P

-11

C1

3D

RE

BL

/RD

C4

P-1

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

J2

1

11

1

JC

1-5

YE

L

JC

3-3

OR

JC

3-5

BL

JC

2-5

BK

JC

2-3

OR

JC

1-3

OR

JC

2-4

RD

ALC-500

BR

N

P2

4F

SW

H

P2

4F

SW

H J3

3

C3P

OPT.

F.S.

C9P

F.S.

LS18JIB

C4

P-7

AN

DT

S8

C1

9JS

VG

R/W

H

BR

NC

17

JU

GR

C4

P-5

DR

IVE

LT

BK

/RD

C3

P-9

JD

AL

AR

MG

R/B

KC

2P

-6

C4

3H

RN

GR

C2

P-5

C8

PB

RB

K/W

HC

3P

-8

C7

PB

EB

KC

3P

-7P

26

BA

TB

KC

9P

-1P

25

FS

RD

C9

P-3

P2

4F

SW

HC

9P

-2

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

DL

ITE

BK

/RD

C3

P-9

TS

48

-WL

1R

DC

2P

-12

TS

48

-WL

2R

DC

2P

-11

C4

5G

EN

GR

/WH

C2

P-7

C3

9L

PB

L/R

DC

2P

-1

C1

32

PL

IB

KC

1P

-12

C1

8JD

GR

/BK

C4

P-6

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

C1

9JS

VG

R/W

HJIB

RD

P2

RD

H1

P2

6B

AT

BK

PBOX WIRING

HARNESS

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 85


Platform Control Box Switch Panel Wiring DiagramFord LRG-425 EFI Models

(from serial number 7597 to11066)

EMERGENCY STOP

P2FUEL SELECT

DRV.ENATS15

L1

AUXILIARY

TS13PRIMARYBOOM

EXTEND/RETRACT

TS8

JIB

PLATFORM

TS7PLATFORM

LEVEL

TS9P3

HORN

ROTATE

TS1

TS47

JC3

L1

JC2

TS1

TS13

TS4

TS15

TS8

TS3

L4

TS9

TS7

TS2

P2P3



AUXILIARY SWITCH


START ENGINE SWITCH



CHASSIS TILT LED

JIB UP/DOWN SWITCH


HI/L0 RPM SWITCH

DRIVE ENABLE SWITCH



COMPONENT INDEX

HORN SWITCH


PART NUMBER

66812, 9450666813, 668164273013037

56457

16397130371303713037

1303727378

56298

62390

75565

GR

-43

OR

-14

OR

/BK

-15

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HJIB

C1

7JU

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

BL

/RD

-39

WH

-23

P2

6B

AT

BK

C9

P-1

P2

2B

AT

BK

C7

P-1

BK

-22

RD

WH

GR

RD

TS3

BK

/WH

-8

BL

/RD

-DE

3J1

-16

BL

/WH

-DE

1J1

-6

BK

-7

WH

WH

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

HARNESS

PBOX WIRING


OPTION WIRES

NOTE:

RD

-TIL

T

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

BL

J1

-4

WH

J1

-5

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3JC2

CR13

WH

-JIB

C1

9JS

VG

R/W

H

WH

-24

BR

N

WH

-JIB

4

2

1

3

5

6

7


WH

-24

BK

-22

WH

-24

(SPLICE TO R40LS1)

(SPLICE TO C32BRK)

OR R40LS1

WH/RD C32BRK

WH TS7

CR30

CR27

WH TS1



(GND STUD)

BRN BATGND

CE SEE DETAIL A

WORK /TS48 / TS49

DRIVE LITE


RD

WL

1

DL

ITE

/R

DW

L2

56457

WH

J1

-5

56298

RD

+

BK

/RD

-35

WH

-24

RPM

HIGH/LOW

TS4

START

TS2

BK

-33

RD

-25

DR

IVE

LT

BK

/RD

-C3

P-9

RD

/BK

H1

L4

+

RD

-TIL

T

WH

-TS

47

10 AMP FUSE

DRIVE

TS14

C2

9M

SR

D/W

HJ1

-8

WH

-24

SPEED

HIGH/LOW

GENERATOR

(OPTION)

TS47

WH

-24

GR

/WH

-45

WH

-TS

4

RD

TS14 DRIVE SPEED SWITCH 56457

PUMP

4 3NO

NC

NC

NC

22

2

11

1


6 - 86

Platform Control Box Switch Panel Wiring DiagramFord LRG-425 EFI Models(from serial number 7597 to 11066)

6 - 85


6 - 87

Electrical SchematicFord DSG-423 EFI Models


6 - 88

1

2

3

4

5

6

7

8



6 - 88 S-40 • S-45 Part No. 102521

B1

B3

1

4

2

C2

7A

UX

RD

P2

0B

AT

RD

BL/WH

C4

B-1

2

C4

B-1

1

Y29

G6

PR

2

PR

2

M2

S7

M1

L30 L30

L29L29

FUSE 10A

C3

-9D

LIT

EB

K/R

D

PBOX GND

NOCR23

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

S

OP

TIO

N

RD

RD

TS49

WH W

H

BK

BK

F18

HIG

HR

PM

(FS

)

TS4

TS17

C6

-26

C6

-39

WH

/BK

FU

NC

TIO

NE

NA

.

L48

C2

-3

C1

33

PL

AO

R/R

D

RD/BK

C28TTA RD/BK

P2

RD

P3H1

C7

-1

HORN

P2

2B

AT

BK

C2

-4C

13

4P

WR

RD

RD

KS1

GRD

PLAT

TB22RD

P1TB42

C6

-25

C6

-34

C6

-33

20AMP. CB3

CR17

NOCR17

OTS

NO

HY

DR

AU

LIC

OIL

TE

MP.S

WIT

CH

CO

OL

ING

FA

N(O

PT

ION

)

C5

-2

C6

-16

TB43

C6

-23

C6

-28

C6

-27

C5

-16

TE

MP

GA

UG

E

OIL

PR

ES

SU

RE

GA

UG

E

VO

LT

ME

TE

R

G1

G3

G2

GE

NE

RA

TO

R

C1

-9

OR/BK

BK

WH

RD

RD

TS55

TB35

LO

WR

PM

HIG

HR

PM

C3

5E

SP

DB

K/R

D

BRN

P26ESTP BK

P25FS RD

P24FS WH

TS2

C2

-7

TB45

C4

5G

EN

GR

/WH

C1

-7

TS52

TB33

C3

3S

TR

BK

C9-3

C9-2

FS1

BK(FS)WH(FS)

RD(FS)C9-1 BK

TS1

C1

-1

C7

-2

C1

-2

TS51

C2

-5

TB27

RD

TB28

TB23

C4

3H

RN

GR

C2

7A

UX

RD

C2

8T

TA

RD

/BK

P2

3B

AT

WH

CB1

15

AM

P.

RD

RD

CB2

TB20 15AMP.

C4

1R

PM

OR

/BK

TB41

FB

GR

/WH

TB21

R2

1IG

NW

H

TB26

TB25

OPS

+

GE

NE

RA

TO

R

OP

TIO

N

OP

TIO

N

FL

AS

HIN

GB

EA

CO

NS

_

HO

UR

ME

TE

R

PR1

NO

WH

RD

PR1

CR5NOCR5

R4

3H

RN

BK

RD

/BK

RD

+

DC12 V

BK PUMP

TIL

TA

LA

RM

LE

VE

LS

EN

SO

R

RE

LA

Y

SE

RV

ICE

HO

RN

SE

RV

ICE

HO

RN

RE

LA

Y

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

UM

P

-

H2

STA

RT

ER

MO

TO

R

1K

R3

WH

/RD

PIN

39

DIAGNOSTIC

BL

UE

/PIN

KH

AR

NE

SS

EN

GIN

EF

OR

D

C1

35

RE

T

C1

35

FP

BL

PIN

18

GA

SO

LIN

ES

EN

SO

R

GY

/RD

GY

/YL

RD

BK

/BL

D C B A

C5

-8W

HP

IN2

4R

21

IGN

42

PIN

FO

RD

CO

NN

EC

TO

RO

R/B

KP

IN2

C4

1R

PM

C5

-13

C5

-9

C5

-17

C5

-5

C5

-12

C5

-10

C5

-11

CR2

NOCR2

R3

3S

TR

C2

1IG

N

VS

W

WH

PIN

16

TB24

CR39

NCCR39

FO

RD

42

PIN

PL

UG

C3

5R

PM

BK

/RD

PIN

23

C1

27

TS

WG

RP

IN3

TS22

BL

/WH

PIN

6C

38

ES

L

WH

PIN

1

BL

/RD

PIN

7C

39

LP

BK

PIN

15

TS3

TS53

TB39

C2

-1

PUMPFUEL

FUEL PUMP

BL

/WH

PIN

5

RD

/GN

HARNESSENGINEFORD

LP

GL

OC

KO

UT

WH

/BK

L2

C2

6T

SR

C5

-14

CR1

NOCR1

STA

RT

ER

RE

LA

Y

BR

N

TB9

2

1.

2

NOTE:




FAN

HM

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

LP

GA

SF

UE

L

LP

GA

SF

UE

L

STA

RT

EN

GIN

E

STA

RT

EN

GIN

E

WO

RK

LI G

HT

DR

IVE

LIG

HT

ESO433B

C1

07

AF

WH

C5

-3T

OA

LT

ER

NA

TO

RF

IEL

D5

00

AUX

R4

3

3 RESISTOR R4 REMOVED AT SERIAL NUMBER 11785 .

Electrical SchematicFord DSG-423 EFI Models(from serial number 11067 to 12509)

TB 134 IS WAGOTERMINAL BLOCK 42

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 89




WH C2

9M

SR

D/W

H

LOHI

DR

IVE

SP

EE

D

TS14

CR30NO

NCCR27

5

R1 R2

C6

-30

C2

9M

SR

D/W

H

TB29

C6

-4

C6

-6

C6

-2

C6

-3

C6

-8

C6

-18

DR

IVE

LIM

ITS

WIT

CH

BO

OM

RE

TR

AC

T

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

LS

2-P

RIM

AR

YB

OO

MU

P

DE

SC

EN

TA

LA

RM

OP

TIO

N

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

BRN

PL

AT

LE

VE

LU

P

PL

AT

LE

VE

LD

OW

N

DR

IVE

LIM

ITS

WIT

CH

NOHC NCHO

WH

BK

WH

BK

BO

OM

EX

TE

ND

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

NOHC

WH

BK

BR

AK

ER

EL

EA

SE

VA

LV

E

TR

AV

EL

AL

AR

MO

PT

ION

DR

IVE

ED

CR

EV

ER

SE

DR

I VE

ED

CF

OR

WA

RD

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RI G

HT

TU

RN

TA

BL

ER

OTA

TE

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

PR

I MA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C5

-21

C6

-36

C6

-37

C5

-20

C5

-23

H4

14

13

12

TS59

TB19

TB17

TB18

C6

-17

TB15

C1

9JS

VG

R/W

H

RD

RD

C4

P-7

TS57

C4

P-5

C4

P-6

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

4P

LU

OR

C1

5P

LD

OR

/BK

TB14

C6

-7

TB8

TB7 TB13TB40

C7

PB

EB

K

C8

PB

RB

K/W

H

C4

0L

S1

OR

C4

P-2

C4

P-3

C3

P-7

C3

P-8

C2

P-2

C1

3D

RE

BL

/RD

TS63

C4

P-1

C3

P-2

C3

P-3

TS9

WH

TS7

WH

BK

OR/BK


TS13

CE

OPTION

LIFT/DRIVE

4

P2

4F

SW

H

P2

4F

SW

H

P2

6E

ST

PB

K3

J3

13 4 2

8 7

C4

1R

PM

OR

/ BK1

6

15

19

20

17

1811

10

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

1E

DC

-W

H/B

K

C5

TR

RW

H/B

K

TB6TB3

C6

-1

C6

-5

TB1

TB2 TB5

TB4 TB32TB37

TB36

TB31 TB30

C1

PB

UR

D

TS61 C4

TR

LW

H

TS62

C3

P-1

C3

P-6

C3

P-4

C3

P-5

C1

P-6

C1

P-1

1

C1

P-1

0

C1

P-4

C1

P-5

BR

N-2

C2

P-3

RD

BK

BR

N

OR

J2

6

J1

12 1

11 2

9

7


YO

UT

XO

UT

GN

D

1 2 43 5 6

PW

R

JC2

DR

EA

BL

/WH

DR

EB

BL

/BK

BR

N

OR

BL

WH

DR

EL

ED

BL

/ RD

J1

13

14 54 6

J1

7

16 8

15

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

76

DRIVE & STEERING

JC3 TS15L1

5

C6

-32

C6

-13

C6

-40

C6

-15

C6

-14

C3

1E

DC

-W

H/B

K

C3

0E

DC

+W

H

C3

2B

RK

WH

/RD

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C5

TR

RW

H/ B

K

C4

TR

LW

H

C1

PB

UR

D

C2

PB

DR

D/B

K

C3

PB

FR

D/ W

H

C7

PB

EB

K

C8

PB

RB

K/W

H

SJ1-WH

C4

0L

S1

OR

AB

DC

C6

-19

RD

/BK

C1

3D

RE

BL

/RD

C1

4P

LU

OR

C1

5P

LD

OR

/BK

RD/BK

7.5

Y17 Y16 Y19 Y20 Y26 Y25 H4 Y12 Y21 Y22 Y13 Y29 Y23 Y4 Y3 Y2

Y51

BL/WH

C1

P-3

C5

-24

C2

9M

SR

D/W

H

Y27

MO

TO

RS

TR

OK

E

GR

OU

ND

BR

N

NOTE:



JIB

VA

LV

ES

C19JSV GR/WH

JD

AL

AR

MG

R/B

K

C1

7JU

GR

C1

8JD

GR

/BK

TS58

TB44

C2

P-6

BRN

JIB

VA

LV

E

CR13

TS8

GR

/BK

-44

NC

CR13

C1

7JU

GR

C1

8JD

GR

/BK

LE

FT

RIG

HTPL

AT

RO

TA

TE

LE

FT

RIG

HTPL

AT

RO

TA

TE

DO

WN

UP

JIB

BO

OM

DO

WN

UP

PL

AT

FO

RM

LE

VE

L

DO

WN

UP

JIB

BO

OM

DO

WN

UP

PL

AT

FO

RM

LE

VE

L

RE

TR

AC

T

EX

TE

ND

BO

OM

RE

TR

AC

T

EX

TE

ND

BO

OM

DO

WN

UP

PR

I MA

RY

BO

OM

RIG

HT

LE

FTT

TR

OTA

TE

ESO433


6 - 90


6 - 89

February 2012Section 6 • Schematics

6 - 91



6 - 92

1

2

3

4

5

6

7

8



6 - 92 S-40 • S-45 Part No. 102521


B1

B3

1

4

2

C2

7A

UX

RD

P2

0B

AT

RD

BL/WH

C4

B-1

2

C4

B-1

1

Y29

G6

PR

2

PR

2

M2

S7

M1

L30 L30

L29L29

FUSE 10A

C3

-9D

LIT

EB

K/R

D

PBOX GND

NOCR23

CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

S

OP

TI O

N

RD

RD

TS49

WH W

H

BK

BK

F18

HIG

HR

PM

(FS

)

TS4

TS17

C6

-26

C6

-39

WH

/BK

FU

NC

TI O

NE

NA

.

L48

C2

-3

C1

33

PL

AO

R/R

D

RD/BK

C28TTA RD/BK

P2

RD

P3H1

C7

-1

HORN

P2

2B

AT

BK

C2

-4C

13

4P

WR

RD

RD

KS1

GRD

PLAT

TB22RD

P1TB42

C6

-25

C6

-34

C6

-33

20AMP. CB3

CR17

NOCR17

OTS

NO

HY

DR

AU

LIC

OIL

TE

MP.

SW

ITC

H

CO

OL

ING

FA

N(O

PT

ION

)

C5

-2

C6

-16

TB43

C6

-23

C6

-28

C6

-27

C5

-16

TE

MP

GA

UG

E

OIL

PR

ES

SU

RE

GA

UG

E

VO

LT

ME

TE

R

G1

G3

G2

GE

NE

RA

TO

R

C1

-9

OR/BK

BK

WH

RD

RD

TS55

TB35

LO

WR

PM

HIG

HR

PM

C3

5E

SP

DB

K/R

D

BRN

P26ESTP BK

P25FS RD

P24FS WH

TS2

C2

-7

TB45

C4

5G

EN

GR

/WH

C1

-7

TS52

TB33

C3

3S

TR

BK

C9-3

C9-2

FS1

BK(FS)WH(FS)

RD(FS)C9-1 BK

TS1

C1

-1

C7

-2

C1

-2

TS51

C2

-5

TB27

RD

TB28

TB23

C4

3H

RN

GR

C2

7A

UX

RD

C2

8T

TA

RD

/BK

P2

3B

AT

WH

CB1

15

AM

P.

RD

RD

CB2

TB20 15AMP.

C4

1R

PM

OR

/BK

TB41

FB

GR

/WH

TB21

R2

1IG

NW

H

TB26

TB25

OPS

+

GE

NE

RA

TO

R

OP

TIO

N

OP

TI O

N

FL

AS

HIN

GB

EA

CO

NS

_

HO

UR

ME

TE

R

PR1

NO

WH

RD

PR1

CR5NOCR5

R4

3H

RN

BK

RD

/BK

RD

+

DC12 V

BK PUMP

TIL

TA

LA

RM

LE

VE

LS

EN

SO

R

RE

LA

Y

SE

RV

ICE

HO

RN

SE

RV

ICE

HO

RN

RE

LA

Y

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

UM

P

-

H2

STA

RT

ER

MO

TO

R

1K

R3

WH

/RD

PIN

39

DIAGNOSTIC

BL

UE

/PIN

KH

AR

NE

SS

EN

GIN

EF

OR

D

C1

35

RE

T

C1

35

FP

BL

PIN

18

GA

SO

LIN

ES

EN

SO

R

GY

/RD

GY

/YL

RD

BK

/BL

D C B A

C5

-8W

HP

IN2

4R

21

IGN

42

PIN

FO

RD

CO

NN

EC

TO

RO

R/B

KP

IN2

C4

1R

PM

C5

-13

C5

-9

C5

-17

C5

-5

C5

-12

C5

-10

C5

-11

CR2

NOCR2

R3

3S

TR

C2

1IG

N

VS

W

WH

PIN

16

TB24

CR39

NCCR39

FO

RD

42

PIN

PL

UG

C3

5R

PM

BK

/RD

PIN

23

C1

27

TS

WG

RP

IN3

TS22

BL

/WH

PIN

6C

38

ES

L

WH

PIN

1

BL

/RD

PIN

7C

39

LP

BK

PIN

15

TS3

TS53

TB39

C2

-1

PUMPFUEL

FUEL PUMP

BL

/WH

PIN

5

RD

/GN

HARNESSENGINEFORD

LP

GL

OC

KO

UT

WH

/BK

L2

C2

6T

SR

C5

-14

CR1

NOCR1

STA

RT

ER

RE

LA

Y

BR

N

TB9

3

1.

2

NOTE:




FAN

HM

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

LP

GA

SF

UE

L

LP

GA

SF

UE

L

STA

RT

EN

GIN

E

STA

RT

EN

GIN

E

WO

RK

LI G

HT

DR

IVE

LI G

HT

ESO433C

C5

-3

AUX

3 RESISTOR R3 REMOVED AT SERIAL NUMBER 13740.CHECK ENGINE LAMP L2 CHANGED TO INCANDESCENT.

2

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 93




UP

DO

WN

UP

DO

WN

UP

DO

WN

UP

DO

WN

UP

DO

WN

RIG

HT

LE

FT

RIG

HT

LE

FT

RIG

HT

LE

FT

EX

TE

ND

RE

TR

AC

T

EX

TE

ND

RE

TR

AC

TB

OO

M

BO

OM

PLA

T L

EV

EL

PLA

T R

OTA

TE

JIB

BO

OM

JIB

BO

OM

PLA

T R

OTA

TE

PLA

T L

EV

EL

PR

I BO

OM

TT

RO

TA

TE

WH

PW

R

XO

UT

YO

UT

5 62 3 4

JC2

GN

D1


OR

1 211

12

BR

N

RD

/WH

WH

/RD

XO

UT

BL/W

H

JC3 GN

D

PW

R

YO

UT

RK

OU

T

14

13 45

BL/W

H

WH

/RD

OR

BR

N

DRIVE & STEERING

5421 3 6

TS14

C2

9M

S R

D/W

H

TB29

MO

TO

R S

TR

OK

E

Y27

C2

9M

S R

D/W

HC

5-1

9C

1P-3

BL/WH

Y51Y2Y3Y4Y23Y29Y13Y22Y21Y12H4

Y25Y26Y20Y19Y16Y17

5

R1 R2

7.5

RD/BK

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C1

3D

RE

BL/R

D

C6

-30

C6

-19

RD

/BK

CD

BA

C4

0LS

1 O

R

SJ1-WH

C8

PB

R B

K/W

H

C7

PB

E B

K

C3

PB

F R

D/ W

H

C2

PB

D R

D/B

K

C1

PB

U R

D

C4

TR

L W

H

C5

TR

R W

H/ B

K

C6

TR

F W

H/R

D

C3

6S

TC

BL

C3

7S

TC

C B

L/ B

K

C3

2B

RK

WH

/ RD

C3

0E

DC

+ W

H

C3

1E

DC

- WH

/BK

C6

-14

C6

-15

C6

-40

C6

-13

C6

-32

5

L1TS15

158167

J1

6

J1

DR

E L

ED

BL/R

D

DR

E B

BL/ B

K

DR

E A

BL/W

H

9

J1

6

J2

C2

P-3

BR

N-2

C1

P-5

C1

P-4

C1

P-1

0

C1

P-1

1

C1

P-6

C3

P-5

C3

P-4

C3

P-6

C3

P-1 TS62 C

4T

RL W

H

TS61

C1

PB

U R

D

TB30TB31TB36 TB37 TB32TB4

TB5TB2

TB1

C6

-5

C6

-1

TB3 TB6

C5

TR

R W

H/B

K

C3

1E

DC

- WH

/BK

C3

7S

TC

C B

L/B

K

C3

6S

TC

BL

C6

TR

F W

H/R

D

C3

2B

RK

WH

/RD

C3

0E

DC

+ W

H

10

11 1817

20

19

15

16

C4

1R

PM

OR

/ BK

78

243 1

J3

3P

26

ES

TP

BK

P2

4F

S W

H

P2

4F

S W

HNCCR27

CR30NO

4

DRIVELIFT/

OPTION

CE

TS13


OR/BKBK

WH

TS7

WH

TS9

C3

P-3

C3

P-2

C4

P-1

TS63

C1

3D

RE

BL/R

D

C2

P-2

C3

P-8

C3

P-7

C4

P-3

C4

P-2

C4

0LS

1 O

R

C8

PB

R B

K/W

H

C7

PB

E B

K

TB40 TB13TB7

TB8

C6

-7

TB14

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

PB

D R

D/B

K

C3

PB

F R

D/W

H

C4

P-6

C4

P-5

TS57

C4

P-7

RD

RD

C1

9JS

V G

R/W

H

TB15

C6

-17

TB18TB17

TB19

TS59

12

13

14

H4

C5

-23

C5

-20

C6

-37

C6

-36

C5

- 21

ST

EE

R R

I GH

T

ST

EE

R L

EF

T

FLO

W C

ON

TR

OL

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

FLO

W C

ON

TR

OL

TU

RN

TA

BLE

RO

TA

TE

TU

RN

TA

BLE

RO

TA

TE

RIG

HT

TU

RN

TA

BLE

RO

TA

TE

LE

FT

PR

IMA

RY

BO

OM

DO

WN

DR

IVE

ED

C F

OR

WA

RD

DR

IVE

ED

C R

EV

ER

SE

TR

AV

EL A

LA

RM

OP

TIO

N

BR

AK

E R

ELE

AS

E V

ALV

E

BK

WH

NOHCD

RIV

E E

NA

BLE

LIM

IT S

WIT

CH

BO

OM

EX

TE

ND

BK

WH

BK

WH

NCHONOHC

DR

IVE

LIM

IT S

WIT

CH

PLA

T L

EV

EL D

OW

N

PLA

T L

EV

EL U

P

BRN

PLA

TF

OR

M R

OTA

TE

LE

FT

/ JIB

UP

PLA

TF

OR

M R

OTA

TE

RIG

HT

/ JIB

DO

WN

DE

SC

EN

T A

LA

RM

LS

2-P

RIM

AR

Y B

OO

M U

P

LS

1-P

RIM

AR

Y B

OO

M E

XT

EN

D

BO

OM

RE

TR

AC

T

DR

IVE

LIM

IT S

WIT

CH

C6

-18

C6

-8

C6

-3

C6

-2

C6

- 6

C6

-4

BR

N

GR

OU

ND

C1

8JD

GR

/BK

C1

7JU

GR

CR13NC

GR

/BK

-44

TS8

CR13

JIB

VA

LVE

BRN

C2

P-6

TB44

TS58

C1

8JD

GR

/BK

C1

7JU

GR

JD

ALA

RM

GR

/BK

C19JSV GR/WH

JIB

VA

LVE

S

NOTE:




6 - 94


6 - 93


6 - 95



6 - 96

1

2

3

4

5

6

7

8



6 - 96 S-40 • S-45 Part No. 102521


FO

RD

42

PIN

PLU

G

DIAGNOSTIC

BLU

E/P

INK

EN

GIN

EF

OR

D

C1

35

RE

TB

LP

IN1

8

C1

35

FP

BL/W

HP

IN5

GA

SO

LIN

ES

EN

SO

R

GY

/RD

GY

/YL

RD

BK

/BL

D C B A

C5

-8R

21

IGN

WH

PIN

24

42

PIN

FO

RD

CO

NN

EC

TO

RC

41

RP

MO

R/B

KP

IN2

C5

-13

C5

-9

C5

-17

C5

-5

C5

-12

C5

-10

C5

-11

CR2

NOCR2

R3

3S

TR

BK

PIN

15

C2

1IG

NW

HP

IN1

6

VS

WW

HP

IN1

TB24

CR39NCCR39

C3

5R

PM

BK

/RD

PIN

23

C1

27

TS

WG

RP

IN3

TS22

C3

8E

SL

BL/W

HP

IN6

C3

9LP

BL/R

DP

IN7

TS3

TS53

TB39

C2

-1

PUMPFUEL

FUEL PUMP

RD

/GR

HARNESSENGINEFORD

LP

GLO

CK

OU

TW

H/B

K

L2

C2

6T

SR

WH

/RD

PIN

39

C5

-14

CR1

NOCR1

STA

RT

ER

RE

LA

Y

D10

D11

BR

EN

GS

PE

ED

B1

B3

1

4

2

C2

7A

UX

RD

P2

0B

AT

RD

RD

Y29

G6

PR

2

PR

2

M2

S7

M1

HIG

HR

PM

(FS

)

TS4

TS17

C6

-26

C6

-39

WH

/BK

FU

NC

TIO

NE

NA

.

L48

C2

-3

C28TTA RD/BK

P2

RD

P3H1

C7

-1

HORN

P2

2B

AT

BK

C2

-4P

13

4P

WR

RD

RD

KS1

GRD

PLAT

TB22

RD

P1T 42B

C6

-25

C6

-34

C6

-33

20AMP. CB3

CR17

NOCR17

OTS

NO

HY

DR

AU

LIC

OIL

TE

MP.

SW

ITC

H

CO

OLIN

GFA

N(O

PT

ION

)

C5

-2

C6

-16

TB43

C6

-23

C6

-28

C6

-27

C5

-16

TE

MP

GA

UG

E

OIL

PR

ES

SU

RE

GA

UG

E

VO

LTM

ET

ER

G1

G3

G2

GE

NE

RA

TO

R

C1

-9

TS55

LO

WR

PM

HIG

HR

PM

C3

5R

PM

BK

/RD

P26ESTP BK

P25FS RD

P24FS WH

TS2

C2

-7C

45

GE

NG

R/W

H

C1

-7

TS52

TB33

C3

3S

TR

BK

TS1

C1

-1

C7

-2

C1

-2

TS51

C2

-5

TB27

RD

TB28

TB23

C4

3H

RN

GR

C2

7A

UX

RD

C2

8T

TA

RD

/BK

P2

3B

AT

WH

CB1

15

AM

P.

RD

CB2

TB20 15AMP.

C4

1R

PM

OR

/BK

TB41

FB

TB21

R2

1IG

NW

H

TB26

TB25

OPS

+

GE

NE

RA

TO

R

OP

TIO

N

OP

TIO

N

FLA

SH

ING

BE

AC

ON

S

_

HO

UR

ME

TE

R

PR1

NO

WH

RD

PR1

CR5NOCR5

R4

3H

RN

BK

RD

/BK

RD

+

DC12 V

BK PUMP

TILT

ALA

RM

LE

VE

LS

EN

SO

R

RE

LA

Y

SE

RV

ICE

HO

RN

SE

RV

ICE

HO

RN

RE

LA

Y

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

UM

P

-

H2

STA

RT

ER

MO

TO

R

RD

BL/WH

RD/BK

OR/BKBK

WH

BR

RD

RD

D13D14

D12

D4

D40

D2

C9-3

C9-2

FS1

BKC9-1

C4

5G

EN

GR

/WH

TB35TB45

STA

RT

EN

GIN

E

HMAUXSTARTER

NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITHTHE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF".

FAN

CR23NO

CR23

L29

WO

RK

LIG

HT

SO

PT

ION

DR

I VE

LI G

HT

OP

TIO

N

L29

C4

B-1

0R

D

C4

B-1

2R

D

C4-9 C4-11

F18

BK

BK

WH

WH

TS49

FUSE 10A

L30L30

TB9

PBOX GND

DL

ITE

BK

/RD

C3

-9

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 97




CR13NC

GR

/BK

-44

TS8

BR

C2

-6

TB44

TS58

JD

ALA

RM

GR

/BK

JIB

VA

LVE

S

CR13

JIB

VA

LVE

GR/WH

-

+


CR14NO

C1

7JU

GR

C1

8JD

GR

/BK

C1

8JD

GR

/BK

C1

7JU

GR

D2

8

D2

7

BR

GR

OU

ND

WH

J1 J1

PW

R

XO

UT

YO

UT

5 62 3 4

JC2 GN

D1


OR

1 2

11

12

BR

N

RD

/WH

WH

/RD

XO

UT

BL/W

H

JC3 GN

D

PW

R

YO

UT

RK

OU

T

14

13 45

BL/W

H

WH

/RD

OR

BR

N

DRIVE & STEERING

5421 3 6

MO

TO

RS

TR

OK

E

Y27

C2

9M

SR

D/W

HC

5-2

4C

1-3


7.5

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C6

-19

CD

BA

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

C4

TR

LW

H

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

C3

1E

DC

-W

H/B

K

C6

-14

C6

-15

C6

-40

C6

-13

C6

-32

5

L1TS15

158167

J1

6

DR

ELE

DB

L/R

D

DR

EB

BL/B

K

DR

EA

BL/W

H

96

J2

C2

-3

BR

-2

C1

-5

C1

-4

C1

-10

C1

-11

C1

-6

C3

-5

C3

-4

C3

-6

C3

-1

TS62 C4

TR

LW

H

TS61

C1

PB

UR

D

TB30TB31

TB36

TB37 TB32TB4

TB5TB2

TB1

C6

-5

C6

-1

TB3 TB6

C5

TR

RW

H/B

K

C3

1E

DC

-W

H/B

K

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

10

11

1817 20

19

15

16

C4

1R

PM

OR

/BK

78

243 1

J3

3P

26

ES

TP

BK

P2

4F

SW

H

P2

4F

SW

H

4

DRIVELIFT/

OPTION

CE

TS13


WH

TS7TS9

C3

-3

C3

-2

C4

-1

TS63

C1

3D

RE

BL/R

D

C2

-2

C3

-8

C3

-7

C4

-3

C4

-2

C4

0LS

1O

R

C8

PB

RB

K/W

H

C7

PB

EB

K

TB40 TB13TB7

TB8

C6

-7

TB14

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C4

-6

C4

-5

TS57

C4

-7C

19

JS

VG

R/W

H

TB15

C6

-17

TB18TB17

TB19

TS59

12

13

14

H4

C5

-23

C5

-20

C6

-37

C6

-36

C5

-21

ST

EE

RC

CW

ST

EE

RC

W

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

FLO

WC

ON

TR

OL

TU

RN

TA

BLE

RO

TA

TE

TU

RN

TA

BLE

RO

TA

TE

CC

W

TU

RN

TA

BLE

RO

TA

TE

CW

PR

IMA

RY

BO

OM

DO

WN

DR

IVE

ED

CF

OR

WA

RD

DR

IVE

ED

CR

EV

ER

SE

TR

AV

EL

ALA

RM

OP

TIO

N

BR

AK

ER

ELE

AS

EV

ALV

E

BO

OM

EX

TE

ND

PLA

TLE

VE

LD

OW

N

PLA

TLE

VE

LU

P

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BO

OM

RE

TR

AC

T

C6

-18

C6

-8

C6

-3

C6

-2

C6

-6

C6

-4

TB29

C2

9M

SR

D/W

H

C6

-30

R2R1

5

CR27NC

NOCR30

TS14

DR

IVE

SP

EE

D

HI LO

C2

9M

SR

D/W

H

RD

/BK

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

C4

0LS

1O

R

C1

3D

RE

BL/R

D

SJ1-WH

D29 D30

DR

IVE

LIM

ITS

WIT

CH

DR

IVE

LIM

ITS

WIT

CH

LS

2-P

RIM

AR

YB

OO

MU

P

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

DR

IVE

EN

AB

LE

UP

DO

WN

PR

IMA

RY

BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIBB

OO

M

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN PLA

TF

OR

MLE

VE

L

DO

WN

UP

JIB

BO

OM

CC

W

CW

PLA

TR

OTA

TE

UP

DO

WN PLA

TF

OR

MLE

VE

L

CC

W

CW

PLA

TR

OTA

TE

34 WH

BK

NC

21

NO

13

22

14 14

22

13NO

21

NC

BK

WH

2 1 2 1WH

BK

NC

21

NO

13

22

14


BR

RD

RD

WH

BKOR/BK

RD/BK

RD

BL/WH


6 - 98


6 - 97


6 - 99

Electrical SchematicFord DSG-423 EFI Models- ANSI / CSA / AS


6 - 100

1

2

3

4

5

6

7

8



6 - 100 S-40 • S-45 Part No. 102521

Electrical SchematicFord DSG-423 EFI Models- ANSI / CSA / AS(from serial number 15663 to 16419)

LOADSENSEMODULE

U33

2 SEC

U35

NO30A

PBOX GND

U34

10ANO

2 SEC

STA

RT

ER

RE

LA

Y

CR1NO

CR1

C5

-14

L2

LP

GLO

CK

OU

TFORDENGINE

HARNESS

FUEL PUMP

FUELPUMP

C2

-1

TB39

TS53

TS3

TS22

CR39NC

CR39

TB24

CR2NO

CR2

C5

-11

C5

-10

C5

-12

C5

-5

C5

-17

C5

-9

C5

-13

42

PIN

FO

RD

CO

NN

EC

TO

R

C5

-8

ABCD

GA

SO

LIN

ES

EN

SO

R

FO

RD

EN

GIN

E

DIAGNOSTIC

42 PIN PLUGFORD

WH

/BK

RD

/GR

BK

/BL

RD

GY

/YL

GY

/RD

D10

D11

C2

6T

SR

WH

/RD

PIN

39

C3

9LP

BL/R

DP

IN7

C3

8E

SL

BL/W

HP

IN6

C1

27

TS

WG

RP

IN3

C3

5R

PM

BK

/RD

PIN

23

VS

WW

HP

IN1

C2

1IG

NW

HP

IN1

6

R3

3S

TR

BK

PIN

15

R2

1IG

NW

HP

IN2

4

C1

35

FP

BL/W

HP

IN5

C1

35

RE

TB

LP

IN1

8

C4

1R

PM

OR

/BK

PIN

2

BLU

E/P

INK

GN

DB

R

BR

STA

RT

ER

MO

TO

R

H2

-

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

ALA

RM

PUMP

BK

12 VDC

+

RD

/BK

R4

3H

RN

BK

CR5NO

CR5

PR1

RD

WH

NO

PR1

HO

UR

ME

TE

R

_

FLA

SH

ING

BE

AC

ON

S

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

+

OPS

TB25

TB26

R2

1IG

NW

H

TB21

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

15

AM

P.

CB1

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

TS1

C3

3S

TR

BK

TB33

TS52

C1

-7

C4

5G

EN

GR

/WH

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BKC

35

RP

MB

K/R

D

HIG

HR

PM

LO

WR

PM

TS55

C1

-9

GE

NE

RA

TO

R

G2

G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

TE

MP

GA

UG

E

C5

-16

C6

-27

C6

-28

C6

-23

TB43

C6

-16

C5

-2

(OP

TIO

N)

CO

OLIN

GFA

N

TE

MP.

SW

ITC

HH

YD

RA

ULIC

OIL

NO

OTS

CR17NO

CR17

CB320AMP.

C6

-33

C6

-34

C6

-25

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

P1

34

PW

RR

DC

2-4

P2

2B

AT

BK

HORN

C7

-1

P3

RD

P2

C2

8T

TA

RD

/BK

C2

-3

FU

NC

TIO

NE

NA

.

WH

/BK

C6

-39

C6

-26

TS17

TS4

HIG

HR

PM

(FS

)

M1

S7

M2

PR

2

PR

2

G6

Y29

RD

P2

0B

AT

RD

C2

7A

UX

RD

2

4

1

3B

B1

EN

GS

PE

ED

C1

-1

D39

D40

L4

TB132

C1

-12

C1

32

PLI1

BL/W

H

C132PLI2 BK

R24PWR

P24PWR

WH

BKOR/BK

RD/BK

BL/WH

RD

BR

RD

RD

D13D14

D12

D2

D4

BK

C9-3

C9-2

FS1

BKC9-1

TB133

GR

/BK

C4

-4C

13

3P

LA

OR

/RD

RD

C4

5G

EN

GR

/WHNO

PR8

RD

WO

RK

LIG

HT

RE

LA

Y(O

PT

ION

)

TB35TB45

STARTER AUX HM

STA

RT

EN

GIN

E

-H1

+

L45

GN

/BK

H6

D88PBOX

LS18

LS18AD89

C3

-10

R204.7K

GBOX GND

812

7

6

4 5

31

GND


FAN

CR23NO

CR23

L29

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0R

D

C4

B-1

2R

D

C4-9 C4-11

F18

BK

BK

WH

WH

TS49

FUSE 10A

L30L30

TB9

PBOX GND

DL

ITE

BK

/RD

C3

-9

STARTER RELAY PR8 ADDED AT SERIAL NUMBER 1570321

21

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 101




CR13NC

GR

/BK

-44

TS8

BR

C2

-6

TB44

TS58

JD

ALA

RM

GR

/BK

JIB

VA

LVE

S

CR13

JIB

VA

LVE

GR/WH

-

+


CR14NO

C1

7JU

GR

C1

8JD

GR

/BK

C1

8JD

GR

/BK

C1

7JU

GR

D2

8

D2

7

BR

GR

OU

ND

WH

J1 J1

PW

R

XO

UT

YO

UT

5 62 3 4

JC2 GN

D1


OR

1 2

11

12

BR

N

RD

/WH

WH

/RD

XO

UT

BL/W

H

JC3 GN

D

PW

R

YO

UT

RK

OU

T

14

13 45

BL/W

H

WH

/RD

OR

BR

N

DRIVE & STEERING

5421 3 6

MO

TO

RS

TR

OK

E

Y27

C2

9M

SR

D/W

HC

5-2

4C

1-3


7.5

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C6

-19

CD

BA

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

C4

TR

LW

H

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

C3

1E

DC

-W

H/B

K

C6

-14

C6

-15

C6

-40

C6

-13

C6

-32

5

L1TS15

158167

J1

6

DR

ELE

DB

L/R

D

DR

EB

BL/B

K

DR

EA

BL/W

H

96

J2

C2

-3

BR

-2

C1

-5

C1

-4

C1

-10

C1

-11

C1

-6

C3

-5

C3

-4

C3

-6

C3

-1

TS62 C4

TR

LW

H

TS61

C1

PB

UR

D

TB30TB31

TB36

TB37 TB32TB4

TB5TB2

TB1

C6

-5

C6

-1

TB3 TB6

C5

TR

RW

H/B

K

C3

1E

DC

-W

H/B

K

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

10

11

1817 20

19

15

16

C4

1R

PM

OR

/BK

78

243 1

J3

3P

26

ES

TP

BK

P2

4F

SW

H

P2

4F

SW

H

4

DRIVELIFT/

OPTION

CE

TS13


WH

TS7TS9

C3

-3

C3

-2

C4

-1

TS63

C1

3D

RE

BL/R

D

C2

-2

C3

-8

C3

-7

C4

-3

C4

-2

C4

0LS

1O

R

C8

PB

RB

K/W

H

C7

PB

EB

K

TB40 TB13TB7

TB8

C6

-7

TB14

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C4

-6

C4

-5

TS57

C4

-7C

19

JS

VG

R/W

H

TB15

C6

-17

TB18TB17

TB19

TS59

12

13

14

H4

C5

-23

C5

-20

C6

-37

C6

-36

C5

-21

ST

EE

RC

CW

ST

EE

RC

W

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

FLO

WC

ON

TR

OL

TU

RN

TA

BLE

RO

TA

TE

TU

RN

TA

BLE

RO

TA

TE

CC

W

TU

RN

TA

BLE

RO

TA

TE

CW

PR

IMA

RY

BO

OM

DO

WN

DR

IVE

ED

CF

OR

WA

RD

DR

IVE

ED

CR

EV

ER

SE

TR

AV

EL

ALA

RM

OP

TIO

N

BR

AK

ER

ELE

AS

EV

ALV

E

BO

OM

EX

TE

ND

PLA

TLE

VE

LD

OW

N

PLA

TLE

VE

LU

P

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BO

OM

RE

TR

AC

T

C6

-18

C6

-8

C6

-3

C6

-2

C6

-6

C6

-4

TB29

C2

9M

SR

D/W

H

C6

-30

R2R1

5

CR27NC

NOCR30

TS14

DR

IVE

SP

EE

D

HI LO

C2

9M

SR

D/W

H

RD

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LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

C4

0LS

1O

R

C1

3D

RE

BL/R

D

SJ1-WH

D29 D30

DR

IVE

LIM

ITS

WIT

CH

DR

IVE

LIM

ITS

WIT

CH

LS

2-P

RIM

AR

YB

OO

MU

P

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

DR

IVE

EN

AB

LE

UP

DO

WN

PR

IMA

RY

BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIBB

OO

M

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN PLA

TF

OR

MLE

VE

L

DO

WN

UP

JIB

BO

OM

CC

W

CW

PLA

TR

OTA

TE

UP

DO

WN PLA

TF

OR

MLE

VE

L

CC

W

CW

PLA

TR

OTA

TE

34 WH

BK

NC

21

NO

13

22

14 14

22

13NO

21

NC

BK

WH

2 1 2 1WH

BK

NC

21

NO

13

22

14


BR

RD

RD

WH

BKOR/BK

RD/BK

RD

BL/WH


6 - 102

Electrical SchematicFord DSG-423 EFI Models- ANSI / CSA / AS(from serial number 15663 to 16419)

6 - 101


6 - 103

Electrical SchematicFord DSG-423 EFI Models- CE


6 - 104

1

2

3

4

5

6

7

8



6 - 104 S-40 • S-45 Part No. 102521

Electrical SchematicFord DSG-423 EFI Models- CE(from serial number 15663 to 16419)

LOADSENSEMODULE

U33

2 SEC

U35

NO30A

PBOX GND

U34

10ANO

2 SEC

STA

RT

ER

RE

LA

Y

CR1NO

CR1

C5

-14

L2

LP

GLO

CK

OU

TFORDENGINE

HARNESS

FUEL PUMP

FUELPUMP

C2

-1

TB39

TS53

TS3

TS22

CR39NC

CR39

TB24

CR2NO

CR2

C5

-11

C5

-10

C5

-12

C5

-5

C5

-17

C5

-9

C5

-13

42

PIN

FO

RD

CO

NN

EC

TO

R

C5

-8

ABCD

GA

SO

LIN

ES

EN

SO

R

FO

RD

EN

GIN

E

DIAGNOSTIC

42 PIN PLUGFORD

WH

/BK

RD

/GR

BK

/BL

RD

GY

/YL

GY

/RD

D10

D11

C2

6T

SR

WH

/RD

PIN

39

C3

9LP

BL/R

DP

IN7

C3

8E

SL

BL/W

HP

IN6

C1

27

TS

WG

RP

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C3

5R

PM

BK

/RD

PIN

23

VS

WW

HP

IN1

C2

1IG

NW

HP

IN1

6

R3

3S

TR

BK

PIN

15

R2

1IG

NW

HP

IN2

4

C1

35

FP

BL/W

HP

IN5

C1

35

RE

TB

LP

IN1

8

C4

1R

PM

OR

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PIN

2

BLU

E/P

INK

GN

DB

R

BR

STA

RT

ER

MO

TO

R

H2

-

AU

XIL

IAR

YP

UM

P

AU

XIL

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YP

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RE

LA

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VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

ALA

RM

PUMP

BK

12 VDC

+

RD

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R4

3H

RN

BK

CR5NO

CR5

PR1

RD

WH

NO

PR1

HO

UR

ME

TE

R

_

FLA

SH

ING

BE

AC

ON

S

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

+

OPS

TB25

TB26

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1IG

NW

H

TB21

FB

TB41

C4

1R

PM

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15AMP.TB20

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15

AM

P.

CB1

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AT

WH

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TA

RD

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C2

7A

UX

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RN

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TB23

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TB27

C2

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C1

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C3

3S

TR

BK

TB33

TS52

C1

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C4

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EN

GR

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TS2

P24FS WH

P25FS RD

P26ESTP BKC

35

RP

MB

K/R

D

HIG

HR

PM

LO

WR

PM

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C1

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GE

NE

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TO

R

G2

G3

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LTM

ET

ER

OIL

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ES

SU

RE

GA

UG

E

TE

MP

GA

UG

E

C5

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C6

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C6

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C6

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TB43

C6

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C5

-2

(OP

TIO

N)

CO

OLIN

GFA

N

TE

MP.

SW

ITC

HH

YD

RA

ULIC

OIL

NO

OTS

CR17NO

CR17

CB320AMP.

C6

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C6

-34

C6

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TB134P1

RD

TB22

PLAT

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.

WH

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C6

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C6

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TS4

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HR

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(FS

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M1

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M2

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2

PR

2

G6

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RD

C2

7A

UX

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4

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GS

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ED

C1

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D40

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C1

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C1

32

PLI1

BL/W

H

C132PLI2 BK

R24PWR

P24PWR

WH

BKOR/BK

RD/BK

BL/WH

RD

BR

RD

RD

D13D14

D12

D2

D4

BK

C9-3

C9-2

FS1

BKC9-1

TB133

GR

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C4

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13

3P

LA

OR

/RD

RD

C4

5G

EN

GR

/WHNO

PR8

RD

WO

RK

LIG

HT

RE

LA

Y(O

PT

ION

)

TB35TB45

STARTER AUX HM

STA

RT

EN

GIN

E

-H1

+

L45

GN

/BK

H6

D88PBOX

LS18

LS18AD89

C3

-10

R204.7K

GBOX GND

812

7

6

4 5

31

GND


FAN

CR23NO

CR23

L29

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

C4

B-1

0R

D

C4

B-1

2R

D

C4-9 C4-11

F18

BK

BK

WH

WH

TS49

FUSE 10A

L30L30

TB9

PBOX GND

DL

ITE

BK

/RD

C3

-9

STARTER RELAY PR8 ADDED AT SERIAL NUMBER 1570321

21

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 105




CR13NC

GR

/BK

-44

TS8

BR

C2

-6

TB44

TS58

JD

ALA

RM

GR

/BK

JIB

VA

LVE

S

CR13

JIB

VA

LVE

GR/WH

-

+


CR14NO

C1

7JU

GR

C1

8JD

GR

/BK

C1

8JD

GR

/BK

C1

7JU

GR

D2

8

D2

7

BR

GR

OU

ND

WH

J1 J1

PW

R

XO

UT

YO

UT

5 62 3 4

JC2 GN

D1


OR

1 2

11

12

BR

N

RD

/WH

WH

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UT

BL/W

H

JC3 GN

D

PW

R

YO

UT

RK

OU

T

14

13 45

BL/W

H

WH

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BR

N

DRIVE & STEERING

5421 3 6

MO

TO

RS

TR

OK

E

Y27

C2

9M

SR

D/W

HC

5-2

4C

1-3


7.5

C1

5P

LD

OR

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C1

4P

LU

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C6

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CD

BA

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

C4

TR

LW

H

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

C3

1E

DC

-W

H/B

K

C6

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C6

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C6

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C6

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C6

-32

5

L1TS15

158167

J1

6

DR

ELE

DB

L/R

D

DR

EB

BL/B

K

DR

EA

BL/W

H

96

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C2

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BR

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C1

-5

C1

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C1

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C1

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C1

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C3

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C3

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C3

-6

C3

-1

TS62 C4

TR

LW

H

TS61

C1

PB

UR

D

TB30TB31

TB36

TB37 TB32TB4

TB5TB2

TB1

C6

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C6

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C5

TR

RW

H/B

K

C3

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DC

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C3

7S

TC

CB

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FW

H/R

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C3

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WH

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DC

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H

10

11

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19

15

16

C4

1R

PM

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78

243 1

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TP

BK

P2

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SW

H

P2

4F

SW

H

4

DRIVELIFT/

OPTION

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TS13


WH

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C3

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C3

-2

C4

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TS63

C1

3D

RE

BL/R

D

C2

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C3

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C3

-7

C4

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C4

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C4

0LS

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R

C8

PB

RB

K/W

H

C7

PB

EB

K

TB40 TB13TB7

TB8

C6

-7

TB14

C1

5P

LD

OR

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C1

4P

LU

OR

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C4

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C4

-5

TS57

C4

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19

JS

VG

R/W

H

TB15

C6

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TB18TB17

TB19

TS59

12

13

14

H4

C5

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C5

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C6

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C6

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C5

-21

ST

EE

RC

CW

ST

EE

RC

W

FLO

WC

ON

TR

OL

PR

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RY

BO

OM

UP

PR

IMA

RY

BO

OM

FLO

WC

ON

TR

OL

TU

RN

TA

BLE

RO

TA

TE

TU

RN

TA

BLE

RO

TA

TE

CC

W

TU

RN

TA

BLE

RO

TA

TE

CW

PR

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RY

BO

OM

DO

WN

DR

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ED

CF

OR

WA

RD

DR

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CR

EV

ER

SE

TR

AV

EL

ALA

RM

OP

TIO

N

BR

AK

ER

ELE

AS

EV

ALV

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BO

OM

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ND

PLA

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LD

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N

PLA

TLE

VE

LU

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PLA

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MR

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CW

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UP

PLA

TF

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MR

OTA

TE

CC

W/

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BO

OM

RE

TR

AC

T

C6

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C6

-8

C6

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C6

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C6

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C6

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C2

9M

SR

D/W

H

C6

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R2R1

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CR27NC

NOCR30

TS14

DR

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SP

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D

HI LO

C2

9M

SR

D/W

H

RD

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LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

C4

0LS

1O

R

C1

3D

RE

BL/R

D

SJ1-WH

D29 D30

DR

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LIM

ITS

WIT

CH

DR

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LIM

ITS

WIT

CH

LS

2-P

RIM

AR

YB

OO

MU

P

LIM

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WIT

CH

DR

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EN

AB

LE

DR

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EN

AB

LE

UP

DO

WN

PR

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RY

BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIBB

OO

M

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN PLA

TF

OR

MLE

VE

L

DO

WN

UP

JIB

BO

OM

CC

W

CW

PLA

TR

OTA

TE

UP

DO

WN PLA

TF

OR

MLE

VE

L

CC

W

CW

PLA

TR

OTA

TE

34 WH

BK

NC

21

NO

13

22

14 14

22

13NO

21

NC

BK

WH

2 1 2 1WH

BK

NC

21

NO

13

22

14


BR

RD

RD

WH

BKOR/BK

RD/BK

RD

BL/WH


6 - 106

Electrical SchematicFord DSG-423 EFI Models- CE(from serial number 15663 to 16419)

6 - 105


6 - 107



6 - 108

1

2

3

4

5

6

7

8



6 - 108 S-40 • S-45 Part No. 102521

Electrical SchematicFord DSG-423 EFI Models- ANSI / CSA / AS(from serial number 16420)

C32CONN.PLUG

LIGHTS PACKAGE

WO

RK

LIG

HT

S

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29 L29

C4B-9 C4B-11

CR23NO

CR23

C4

B-1

0

C4

B-1

2

RD

RD

BR

FUSE 10A

WH

WH

BK

BK

L30 L30

FORD42 PIN PLUG

DIAGNOSTIC

BLU

E/P

INK

EN

GIN

EF

OR

D

C1

35

RE

TB

LP

IN1

8

C1

35

FP

BL/W

HP

IN5

GA

SO

LIN

ES

EN

SO

R

GY

/RD

GY

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RD

BK

/BL

D C B A

C5

-8R

21

IGN

WH

PIN

24

42

PIN

FO

RD

CO

NN

EC

TO

RC

41

RP

MO

R/B

KP

IN2

C5

-13

C5

-9

C5

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C5

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C5

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C5

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C5

-11

CR2

NOCR2

R3

3S

TR

BK

PIN

15

C2

1IG

NW

HP

IN1

6

VS

WW

HP

IN1

TB24

CR39NCCR39

C3

5R

PM

BK

/RD

PIN

23

C1

27

TS

WG

RP

IN3

TS22

C3

8E

SL

BL/W

HP

IN6

C3

9LP

BL/R

DP

IN7

TS3

TS53

TB39

C2

-1

PUMPFUEL

FUEL PUMP

RD

/GR

HARNESSENGINEFORD

LP

GLO

CK

OU

TW

H/B

K

L2

C2

6T

SR

WH

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PIN

39

C5

-14

CR1

NOCR1

STA

RT

ER

RE

LA

Y

D10

D11

GN

DB

R

BR

CR45NO

CR45

EN

GS

PE

ED

B1

B3

1

4

2

C2

7A

UX

RD

P2

0B

AT

RD

RD

Y29

G6

PR

2

PR

2

M2

S7

M1

HIG

HR

PM

(FS

)

TS4

TS17

C6

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C6

-39

WH

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NE

NA

.

L48

C2

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C28TTA RD/BK

P2

RD

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BK

C2

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13

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WR

RD

RD

KS1

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PLAT

TB22

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P1TB134

C6

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C6

-34

C6

-33

20AMP. CB3

CR17

NOCR17

OTS

NO

HY

DR

AU

LIC

OIL

TE

MP.

SW

ITC

H

CO

OLIN

GFA

N(O

PT

ION

)

C5

-2

C6

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TB43

C6

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C6

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C6

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C5

-16

TE

MP

GA

UG

E

OIL

PR

ES

SU

RE

GA

UG

E

VO

LTM

ET

ER

G1

G3

G2

GE

NE

RA

TO

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C1

-9

TS55

LOW

RP

M

HIG

HR

PM

C3

5R

PM

BK

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P26ESTP BK

P25FS RD

P24FS WH

TS2

C2

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45

GE

NG

R/W

H

C1

-7

TS52

TB33

C3

3S

TR

BK

TS1

C1

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C7

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C1

-2

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C2

-5

TB27

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TB28

TB23

C4

3H

RN

GR

C2

7A

UX

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C2

8T

TA

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P2

3B

AT

WH

CB1

15

AM

P.

RD

CB2

TB20 15AMP.

C4

1R

PM

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TB41

FB

TB21R

21

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WH

TB26

TB25

OPS

+

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NE

RA

TO

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OP

TIO

N

OP

TIO

N

FLA

SH

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BE

AC

ON

S

_

HO

UR

ME

TE

R

PR1

NO

WH

RD

PR1

CR5NOCR5

R4

3H

RN

BK

RD

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RD

+

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BK PUMP

TILT

ALA

RM

LE

VE

LS

EN

SO

R

RE

LA

Y

SE

RV

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HO

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SE

RV

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HO

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RE

LA

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AU

XIL

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ER

AU

XIL

IAR

YP

UM

P

-

H2

STA

RT

ER

MO

TO

R

RD

BL/WH

RD/BK

OR/BKBK

WH

BR

RD

RD

D13D14

D12

D4

D40

D2

C9-3

C9-2

FS1

BKC9-1

RD

TB132

C1

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C1

32

PLI1

BL/W

H D39

C1

33

PLA

OR

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C4

-4

TB133

C4

5G

EN

GR

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NO

RD

WO

RK

LIG

HT

SR

ELA

Y(O

PT

ION

)

TB35TB45

STA

RT

EN

GIN

E

HMAUXSTARTER

GBOX GND

12

6

4

8

7

5

31

GR

/BK


FAN

ES0433KDIODE BETWEEN T 35 AND TB45 ADDED AT SERIAL NUMBER 16453B21

21

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 109




CR13NC

GR

/BK

-44

TS8

BR

C2

-6

TB44

TS58

JD

ALA

RM

GR

/BK

JIB

VA

LVE

S

CR13

JIB

VA

LVE

GR/WH

-

+


CR14NO

C1

7JU

GR

C1

8JD

GR

/BK

C1

8JD

GR

/BK

C1

7JU

GR

D2

8

D2

7

BR

GR

OU

ND

WH

J1 J1

PW

R

XO

UT

YO

UT

5 62 3 4

JC2 GN

D1


OR

1 2

11

12

BR

N

RD

/WH

WH

/RD

XO

UT

BL/W

H

JC3 GN

D

PW

R

YO

UT

RK

OU

T

14

13 45

BL/W

H

WH

/RD

OR

BR

N

DRIVE & STEERING

5421 3 6

MO

TO

RS

TR

OK

E

Y27

C2

9M

SR

D/W

HC

5-2

4C

1-3


7.5

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C6

-19

CD

BA

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

C4

TR

LW

H

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

C3

1E

DC

-W

H/B

K

C6

-14

C6

-15

C6

-40

C6

-13

C6

-32

5

L1TS15

158167

J1

6

DR

ELE

DB

L/R

D

DR

EB

BL/B

K

DR

EA

BL/W

H

96

J2

C2

-3

BR

-2

C1

-5

C1

-4

C1

-10

C1

-11

C1

-6

C3

-5

C3

-4

C3

-6

C3

-1

TS62 C4

TR

LW

H

TS61

C1

PB

UR

D

TB30TB31

TB36

TB37 TB32TB4

TB5TB2

TB1

C6

-5

C6

-1

TB3 TB6

C5

TR

RW

H/B

K

C3

1E

DC

-W

H/B

K

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

10

11

1817 20

19

15

16

C4

1R

PM

OR

/BK

78

243 1

J3

3P

26

ES

TP

BK

P2

4F

SW

H

P2

4F

SW

H

4

DRIVELIFT/

OPTION

CE

TS13


WH

TS7TS9

C3

-3

C3

-2

C4

-1

TS63

C1

3D

RE

BL/R

D

C2

-2

C3

-8

C3

-7

C4

-3

C4

-2

C4

0LS

1O

R

C8

PB

RB

K/W

H

C7

PB

EB

K

TB40 TB13TB7

TB8

C6

-7

TB14

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C4

-6

C4

-5

TS57

C4

-7C

19

JS

VG

R/W

H

TB15

C6

-17

TB18TB17

TB19

TS59

12

13

14

H4

C5

-23

C5

-20

C6

-37

C6

-36

C5

-21

ST

EE

RC

CW

ST

EE

RC

W

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

FLO

WC

ON

TR

OL

TU

RN

TA

BLE

RO

TA

TE

TU

RN

TA

BLE

RO

TA

TE

CC

W

TU

RN

TA

BLE

RO

TA

TE

CW

PR

IMA

RY

BO

OM

DO

WN

DR

IVE

ED

CF

OR

WA

RD

DR

IVE

ED

CR

EV

ER

SE

TR

AV

EL

ALA

RM

OP

TIO

N

BR

AK

ER

ELE

AS

EV

ALV

E

BO

OM

EX

TE

ND

PLA

TLE

VE

LD

OW

N

PLA

TLE

VE

LU

P

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BO

OM

RE

TR

AC

T

C6

-18

C6

-8

C6

-3

C6

-2

C6

-6

C6

-4

TB29

C2

9M

SR

D/W

H

C6

-30

R2R1

5

CR27NC

NOCR30

TS14

DR

IVE

SP

EE

D

HI LO

C2

9M

SR

D/W

H

RD

/BK

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

C4

0LS

1O

R

C1

3D

RE

BL/R

D

SJ1-WH

D29 D30

DR

IVE

LIM

ITS

WIT

CH

DR

IVE

LIM

ITS

WIT

CH

LS

2-P

RIM

AR

YB

OO

MU

P

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

DR

IVE

EN

AB

LE

UP

DO

WN

PR

IMA

RY

BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIBB

OO

M

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN PLA

TF

OR

MLE

VE

L

DO

WN

UP

JIB

BO

OM

CC

W

CW

PLA

TR

OTA

TE

UP

DO

WN PLA

TF

OR

MLE

VE

L

CC

W

CW

PLA

TR

OTA

TE

34 WH

BK

NC

21

NO

13

22

14 14

22

13NO

21

NC

BK

WH

2 1 2 1WH

BK

NC

21

NO

13

22

14


BR

RD

RD

WH

BKOR/BK

RD/BK

RD

BL/WH


6 - 110

Electrical SchematicFord DSG-423 EFI Models- ANSI / CSA / AS(from serial number 16420)

6 - 109


6 - 111



6 - 112

1

2

3

4

5

6

7

8



6 - 112 S-40 • S-45 Part No. 102521

Electrical SchematicFord DSG-423 EFI Models- CE(from serial number 16420)

LOADSENSEMODULE

U33

2 SEC

U35

NO30A

PBOX GND

U34

10ANO

2 SEC

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

S

LIGHTS PACKAGE

RD

RD

C4

B-1

2

C4

B-1

0

CR23

NOCR23

C4B-11C4B-9

L29L29

FUSE 10A

BR

L30L30

BK

BK

WH

WH

STA

RT

ER

RE

LA

Y

CR1NO

CR1

C5

-14

L2

LP

GLO

CK

OU

T

FORDENGINEHARNESS

FUEL PUMP

FUELPUMP

C2

-1

TB39

TS53

TS3

TS22

CR39NC

CR39

TB24

CR2NO

CR2

C5

-11

C5

-10

C5

-12

C5

-5

C5

-17

C5

-9

C5

-13

42

PIN

FO

RD

CO

NN

EC

TO

R

C5

-8

ABCD

GA

SO

LIN

ES

EN

SO

R

FO

RD

EN

GIN

E

DIAGNOSTIC

42 PIN PLUGFORD

WH

/BK

RD

/GR

BK

/BL

RD

GY

/YL

GY

/RD

D10

D11

C2

6T

SR

WH

/RD

PIN

39

C3

9LP

BL/R

DP

IN7

C3

8E

SL

BL/W

HP

IN6

C1

27

TS

WG

RP

IN3

C3

5R

PM

BK

/RD

PIN

23

VS

WW

HP

IN1

C2

1IG

NW

HP

IN1

6

R3

3S

TR

BK

PIN

15

R2

1IG

NW

HP

IN2

4

C1

35

FP

BL/W

HP

IN5

C1

35

RE

TB

LP

IN1

8

C4

1R

PM

OR

/BK

PIN

2

BLU

E/P

INK

GN

DB

R

BR

CR45NOCR45

STA

RT

ER

MO

TO

R

H2

-

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

YS

ER

VIC

EH

OR

N

SE

RV

ICE

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

TILT

ALA

RM

PUMP

BK

12 VDC

+

RD

/BK

R4

3H

RN

BK

CR5NO

CR5

PR1

RD

WH

NO

PR1

HO

UR

ME

TE

R

_

FLA

SH

ING

BE

AC

ON

S

OP

TIO

N

OP

TIO

N

GE

NE

RA

TO

R

+

OPS

TB25

TB26

R2

1IG

NW

H

TB21

FB

TB41

C4

1R

PM

OR

/BK

15AMP.TB20

CB2

RD

15

AM

P.

CB1

P2

3B

AT

WH

C2

8T

TA

RD

/BK

C2

7A

UX

RD

C4

3H

RN

GR

TB23

TB28

RD

TB27

C2

-5

TS51

C1

-2

C7

-2

TS1

C3

3S

TR

BK

TB33

TS52

C1

-7

C4

5G

EN

GR

/WH

C2

-7

TS2

P24FS WH

P25FS RD

P26ESTP BKC

35

RP

MB

K/R

D

HIG

HR

PM

LO

WR

PM

TS55

C1

-9

GE

NE

RA

TO

R

G2

G3

G1

VO

LTM

ET

ER

OIL

PR

ES

SU

RE

GA

UG

E

TE

MP

GA

UG

E

C5

-16

C6

-27

C6

-28

C6

-23

TB43

C6

-16

C5

-2

(OP

TIO

N)

CO

OLIN

GFA

N

TE

MP.

SW

ITC

HH

YD

RA

ULIC

OIL

NO

OTS

CR17NO

CR17

CB320AMP.

C6

-33

C6

-34

C6

-25

TB134P1

RD

TB22

PLAT

GRD

KS1

RD

P1

34

PW

RR

DC

2-4

P2

2B

AT

BK

HORN

C7

-1

P3

RD

P2

C2

8T

TA

RD

/BK

C2

-3

FU

NC

TIO

NE

NA

.

WH

/BK

C6

-39

C6

-26

TS17

TS4

HIG

HR

PM

(FS

)

M1

S7

M2

PR

2

PR

2

G6

Y29

RD

P2

0B

AT

RD

C2

7A

UX

RD

2

4

1

3B

B1

EN

GS

PE

ED

C1

-1

D39

D40

L4

TB132

C1

-12

C1

32

PLI1

BL/W

H

C132PLI2 BK

R24PWR

P24PWR

WH

BKOR/BK

RD/BK

BL/WH

RD

BR

RD

RD

D13D14

D12

D2

D4

BK

C9-3

C9-2

FS1

BKC9-1

TB133

GR

/BK

C4

-4C

13

3P

LA

OR

/RD

RD

C4

5G

EN

GR

/WHNO

PR8

RD

WO

RK

LIG

HT

RE

LA

Y(O

PT

ION

)

TB35TB45

STARTER AUX HM

STA

RT

EN

GIN

E

-H1

+

L45

GN

/BK

H6

D88PBOX

LS18

LS18AD89

C3

-10

R204.7K

GBOX GND

812

7

6

4 5

31

GND


FAN


21

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 113




CR13NC

GR

/BK

-44

TS8

BR

C2

-6

TB44

TS58

JD

ALA

RM

GR

/BK

JIB

VA

LVE

S

CR13

JIB

VA

LVE

GR/WH

-

+


CR14NO

C1

7JU

GR

C1

8JD

GR

/BK

C1

8JD

GR

/BK

C1

7JU

GR

D2

8

D2

7

BR

GR

OU

ND

WH

J1 J1

PW

R

XO

UT

YO

UT

5 62 3 4

JC2 GN

D1


OR

1 2

11

12

BR

N

RD

/WH

WH

/RD

XO

UT

BL/W

H

JC3 GN

D

PW

R

YO

UT

RK

OU

T

14

13 45

BL/W

H

WH

/RD

OR

BR

N

DRIVE & STEERING

5421 3 6

MO

TO

RS

TR

OK

E

Y27

C2

9M

SR

D/W

HC

5-2

4C

1-3


7.5

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C6

-19

CD

BA

C8

PB

RB

K/W

H

C7

PB

EB

K

C3

PB

FR

D/W

H

C2

PB

DR

D/B

K

C1

PB

UR

D

C4

TR

LW

H

C5

TR

RW

H/B

K

C6

TR

FW

H/R

D

C3

6S

TC

BL

C3

7S

TC

CB

L/B

K

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

C3

1E

DC

-W

H/B

K

C6

-14

C6

-15

C6

-40

C6

-13

C6

-32

5

L1TS15

158167

J1

6

DR

ELE

DB

L/R

D

DR

EB

BL/B

K

DR

EA

BL/W

H

96

J2

C2

-3

BR

-2

C1

-5

C1

-4

C1

-10

C1

-11

C1

-6

C3

-5

C3

-4

C3

-6

C3

-1

TS62 C4

TR

LW

H

TS61

C1

PB

UR

D

TB30TB31

TB36

TB37 TB32TB4

TB5TB2

TB1

C6

-5

C6

-1

TB3 TB6

C5

TR

RW

H/B

K

C3

1E

DC

-W

H/B

K

C3

7S

TC

CB

L/B

K

C3

6S

TC

BL

C6

TR

FW

H/R

D

C3

2B

RK

WH

/RD

C3

0E

DC

+W

H

10

11

1817 20

19

15

16

C4

1R

PM

OR

/BK

78

243 1

J3

3P

26

ES

TP

BK

P2

4F

SW

H

P2

4F

SW

H

4

DRIVELIFT/

OPTION

CE

TS13


WH

TS7TS9

C3

-3

C3

-2

C4

-1

TS63

C1

3D

RE

BL/R

D

C2

-2

C3

-8

C3

-7

C4

-3

C4

-2

C4

0LS

1O

R

C8

PB

RB

K/W

H

C7

PB

EB

K

TB40 TB13TB7

TB8

C6

-7

TB14

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

PB

DR

D/B

K

C3

PB

FR

D/W

H

C4

-6

C4

-5

TS57

C4

-7C

19

JS

VG

R/W

H

TB15

C6

-17

TB18TB17

TB19

TS59

12

13

14

H4

C5

-23

C5

-20

C6

-37

C6

-36

C5

-21

ST

EE

RC

CW

ST

EE

RC

W

FLO

WC

ON

TR

OL

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

FLO

WC

ON

TR

OL

TU

RN

TA

BLE

RO

TA

TE

TU

RN

TA

BLE

RO

TA

TE

CC

W

TU

RN

TA

BLE

RO

TA

TE

CW

PR

IMA

RY

BO

OM

DO

WN

DR

IVE

ED

CF

OR

WA

RD

DR

IVE

ED

CR

EV

ER

SE

TR

AV

EL

ALA

RM

OP

TIO

N

BR

AK

ER

ELE

AS

EV

ALV

E

BO

OM

EX

TE

ND

PLA

TLE

VE

LD

OW

N

PLA

TLE

VE

LU

P

PLA

TF

OR

MR

OTA

TE

CW

/JIB

UP

PLA

TF

OR

MR

OTA

TE

CC

W/

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BO

OM

RE

TR

AC

T

C6

-18

C6

-8

C6

-3

C6

-2

C6

-6

C6

-4

TB29

C2

9M

SR

D/W

H

C6

-30

R2R1

5

CR27NC

NOCR30

TS14

DR

IVE

SP

EE

D

HI LO

C2

9M

SR

D/W

H

RD

/BK

LS

1-P

RIM

AR

YB

OO

ME

XT

EN

D

C4

0LS

1O

R

C1

3D

RE

BL/R

D

SJ1-WH

D29 D30

DR

IVE

LIM

ITS

WIT

CH

DR

IVE

LIM

ITS

WIT

CH

LS

2-P

RIM

AR

YB

OO

MU

P

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

DR

IVE

EN

AB

LE

UP

DO

WN

PR

IMA

RY

BO

OM

EX

TE

ND

RE

TR

AC

TB

OO

M

DO

WN

UP

JIBB

OO

M

EX

TE

ND

RE

TR

AC

TB

OO

M

UP

DO

WN PLA

TF

OR

MLE

VE

L

DO

WN

UP

JIB

BO

OM

CC

W

CW

PLA

TR

OTA

TE

UP

DO

WN PLA

TF

OR

MLE

VE

L

CC

W

CW

PLA

TR

OTA

TE

34 WH

BK

NC

21

NO

13

22

14 14

22

13NO

21

NC

BK

WH

2 1 2 1WH

BK

NC

21

NO

13

22

14


BR

RD

RD

WH

BKOR/BK

RD/BK

RD

BL/WH


6 - 114

Electrical SchematicFord DSG-423 EFI Models- CE(from serial number 16420)

6 - 113


6 - 115

Ground Control Box Wiring DiagramFord DSG-423 EFI Models


6 - 116

1

2

3

4

5

6

7

8



6 - 116 S-40 • S-45 Part No. 102521

ALL BR WIRES

GROUND STUD

BR

BR-GND STUD

BK-22C

WH-23C

HARNESS:TO BASE

WIRING

GR

OU

ND

ST

UD

B

B1

1

24

3

RD

KEY SWITCH

KS1

44B-RD/BK-C6-19

12

V

EN

GIN

E1

9/1

8C

AB

LE

SF

UN

CT

ION

S1

2V

TO

PL

AT

C5

C6

(GY

)

C1

B

(BR

)

C4

B

(GR

)

C3

B

(BK

)

C2

BC

7B 1

2

3

R2

AD ABCD

WH-23B

RD-27B

GR-C5-12

BK-C5-5

TS22

BK-22B

GR-43B

CR5

BK-C6-16

WH-C5-17

WH-21B

BK-33B

RD-24B

CR1 CR2

C B

OR-C6-33

CR39

RD-CB3 SP

BK-C6-25

WH-C5-11

CR17

RD- 20B

RD- P1 E-STOP

OR/BK-15A

GR/WH-19A

GR/BK-18A

GR-17A

OR-14A

BK/RD-35A

RD- 20A

RD- 24A

TS55

TS52

RD-CR17/CR23 #30

WH-4AWH/RD-6AWH/BK-5A

GR/BK-44A

RD- 20C

BK-7A

BK/WH-8A

BK-33A

CB1 CB2

CB3

D5

35BK/RD-C5-9 BK/RD-C1B-9

GR/BK-C6-18 GR/BK-C4B-6

BL/WH-C3B-12

BL/RD-C4B-1

OR/BK-C4B-3

OR-C4B-2

OR/RD-C4B-4

GR-C4B-5

RD/BK-C3B-2

RD-C3B-1

BK-C3B-7

WH/RD-C3B-6

WH/BK-C3B-5

WH-C3B-4

RD/WH-C3B-3

BK/RD-C3B-9

BK/WH-C3B-8

BL-C3B-10

BL/BK-C3B-11

RD/BK-C6-2

BK- C6-7

WH/RD-C6-6

WH- C6-4

RD/WH-C6-3

WH/BK-C6-5

BK/WH-C6-8

RD- C6-1

OR/BK-C6-15

OR- C6-14

BL/RD-C6-13

GR- C6-17

9

1

2

4

3

5

6

7

8

13

11

10

12

14

15

17

16

RD-S.P.(CB3)

BK-C1B-7

BK/WH-C1B-8

WH-C6-34

BK-C7B-1

GR/WH-C4B-7

RD/BK-C1B-2

WH-C7B-2

RD-C1B-1

RD/WH-C1B-3

WH-C1B-4

WH/BK-C1B-5

WH/RD-C1B-6

WH/RD-C5-14

RD- 12 VOLT

WH/BK-C5-16

BL/WH-C6-30

RD- C6-23

WH-C5-3+C5-8

RD/WH-C5-24

WH/RD-C5-23

WH- C5-21

WH/BK-C5-20

RD/BK-C6-28

RD- C6-27

22

20

18

19

21

24

23

26

25

BK-CR5#30

RD-S.P.(CB2)

WH-CR2#87

RED-CR1#30

CR39 #30

27

28

30

29

33

31

32

34

RD-CR39#85

BK-CR1#85

GR-C2B-5

BL/WH-C1B-12

BL-C1B-10

BL/BK-C1B-11

RD-C2B-4

OR-C2B-2

BL/RD-C2B-1

OR/BK-C2B-3

GR/WH-C2B-7

GR/BK-C2B-6

BL/BK-C6-37

BL- C6-36

OR/BK-C5-2

OR- C6-40

BL/RD-C5-10

GR/WH-C6-39

GR/BK-2B

37

36

38

39

41

40

43

42

GR-CR5#85

46

45

44

BK/RD-S.P. RPM

GR/BK-S.P.

DRV. ENA. LT.

PLAT. ROT. L.

PLAT. LEVEL DN.

PLAT. LEVEL. UP

PRI. BOOM UP

BOOM RETRACT

BOOM EXTEND

TURN. ROT. F.C.

TURN. ROT. R

PRI. BOOM F.C.

PRI. BOOM DOWN

TURN. ROT. L

BK-S.P.

BK/WH-S.P.

WH-S.P.

RD/BK-S.P.

WH/BK-S.P.

RD/WH-S.P.

WH/RD-S.P.

RD-S.P.

GR-S.P.

OR-S.P.

OR/BK-S.P.

C133PLT

12V BATTERY SUPPLY

MOTOR SPEED

WATER TEMP. SENDER

OIL PRESSURE SENDER

BRAKE/TRAVEL ALARM

GLOW PLUG

ENGINE POWER

PWR. TO PLAT.

KEYSWITCH PWR/FB

AUX. PWR.

TILT ALARM

IGNITION PWR.

PLAT. ROT. R.

JIB VALVE

WH/RD-S.P.

RD-S.P.(CB1)

BK-S.P.

WH-S.P.

WH/BK-S.P.

GR/WH-SP

WH-S.P.

RD-S.P.

BK/WH-S.P.

RD-S.P.

BK-S.P.

E.D.C.+

START

E.D.C.-

HM

BL/WH-C5-13

RD/WH-3A

RD-1A

RD/BK-2A

BR (GROUND)

WH-21A

R3

L2 TS53

NC

NC

BL/RD-39A

RD-42ARD-27A

RD-CB2

WH-23A

WH/RD-26A

WH/BK-25A

BK-22A

P1

JDALARM JIB

GEN. OPTION

PULSE PICKUP

STEER RIGHT

STEER LEFT

LIMIT SWITCH SIG.

C134PWR

GR/BK-S.P.

RD-KS1-2 S.P.

BL/RD-S.P.

C132PLI

L.P.

HORN

SPARE

G1

BR (GROUND)

WH-21A

G2

TS57

TS59

R1

TS58

TS63

TS62

TS61

TS51

G3

13480TS51AUXILIARY SWITCH

RESISTOR, 1K OHM/2W, CHECK ENGINE

LP/GAS SWITCH


FUNCTION ENABLE

ENGINE START SWITCH

VOLT METER GAGE


CHECK ENGINE SWITCH

HOUR METER

WATER TEMP. GAGE

CHECK ENGINE (after serial number 13739)

OIL PRESSURE GAGE










R1R1

G3

R3

HM

L2

G1

G2

R2

G3

104333

119870

HM

G1

G2

R2

16397TS61

TS58

TS22

TS62

CB3

CB2

CB1

CB2

CB3

CB1

42730

13037

16397

TS52

TS53

TS57

TS55

TS63

TS59

16397

13037

13037

13037

13037

56457

DESCRIPTION

KEY SWITCH


LABEL

P1

KS1

PART#

KS1

P1

WH/RD-C6-32



CR23

BRN GND

RD-CB3 S.P.

BK/RD-9B

RD C4B-12

RD C4B-11

ESO433

L2 110395CHECK ENGINE (before serial number 13740)

B

B1

1

24

3

RD

KEY SWITCH KS1

BL/WH-C5-13

L2

WH-23A

Check Engine Light

(after serial number 13739)

Note: Removed resistor R3 and

changed L2 to incandescent

Ground Control Box Wiring DiagramFord DSG-423 EFI Models(before serial number 14832)

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 117


Ground Control Box Wiring DiagramFord DSG-423 EFI Models


3

2

1

C7

BC

2B

(BK

)

C3

B

(GR

)

C4

B

(BR

)

C1

B

(GY

)

C6

C5

12

VT

OP

LA

TF

UN

CT

ION

S1

9/1

8C

AB

LE

SE

NG

INE

12

V

WIRING

TO BASEHARNESS:

WH-23C

BK-22C

BR-GND STUD

BRGROUND STUD

ALL BR WIRES

2

U34

8

9

3 5

G3

TS51

TS61

TS62

TS63

TS58

R1

TS59

TS57

G2

WH-21ABR (GROUND)

G1

SPARE

HORN

L.P.C132PLI

BL/RD-S.P.

RD-KS1-2 S.P.

GR/BK-S.P.

P134PWR

LIMIT SWITCH SIG.

STEER CWSTEER CCW

PULSE PICKUP


P1

BK-22A

WH/BK-25AWH/RD-26A

WH-23A

RD-CB2

RD-27ARD-42A

BL/RD-39A

NC

NC

TS53

L2WH-21A

BR (GROUND)

RD/BK-2ARD-1A

RD/WH-3A

BL/WH-C5-13

HM

E.D.C.-

START

E.D.C.+

BK-S.P.

RD-S.P.

BK/WH-S.P.

RD-S.P.

WH-S.P.

GR/WH-SP

WH/BK-S.P.

WH-S.P.BK-S.P.

RD-S.P.(CB1)

WH/RD-S.P.

JIB VALVEPLAT. ROT. CCW

IGNITION PWR.

TILT ALARMAUX. PWR.


ENGINE POWER

GLOW PLUG

BRAKE/TRAVEL ALARM


MOTOR SPEED

12V BATTERY SUPPLY

C133PLA

OR/BK-S.P.OR-S.P.

GR-S.P.

RD-S.P.

WH/RD-S.P.

RD/WH-S.P.

WH/BK-S.P.

RD/BK-S.P.

WH-S.P.

BK/WH-S.P.BK-S.P.

TURN. ROT. CW

PRI. BOOM DOWNPRI. BOOM F.C.

TURN. ROT. CCWTURN. ROT. F.C.BOOM EXTENDBOOM RETRACT

PRI. BOOM UP


PLAT. ROT. CW

DRV. ENA. LT.

GR/BK-S.P.

RPMBK/RD-S.P.

444546

GR-CR5#85

134

43

4041

39132

3637

GR/BK-2BGR/WH-C6-39




OR/BK-C2B-3

BL/RD-C2B-1OR-C2B-2

RD-C2B-4


BL/WH-C1B-12

GR-C2B-5

BK-CR1#85

RD-CR39#85

34

3231

33

2930

2827

CR39 #30RED-CR1#30

WH-CR2#87RD-S.P.(CB2)

BK-CR5#30

2526

2324

21

1918

20

22

RD- C6-27RD/BK-C6-28


WH/RD-C5-23

RD/WH-C5-24

WH-C5-3+C5-8

RD- C6-23BL/WH-C6-30

WH/BK-C5-16

RD- 12 VOLT

WH/RD-C5-14

WH/RD-C1B-6WH/BK-C1B-5WH-C1B-4RD/WH-C1B-3

RD-C1B-1

WH-C7B-2

RD/BK-C1B-2

GR/WH-C4B-7

BK-C7B-1C6-34

BK/WH-C1B-8BK-C1B-7

RD-S.P.(CB3)

13317

1514

12

1011

13

8765

34

2

1

9

GR- C6-17


RD- C6-1

BK/WH-C6-8

WH/BK-C6-5

RD/WH-C6-3WH- C6-4

WH/RD-C6-6BK- C6-7

RD/BK-C6-2


BK/WH-C3B-8


RD-C3B-1RD/BK-C3B-2

GR-C4B-5OR/RD-C4B-4

OR-C4B-2OR/BK-C4B-3


GR/BK-C4B-6GR/BK-C6-18

BK/RD-C1B-9BK/RD-C5-9 35

D5

CB3

CB2CB1

BK-33A

BK/WH-8ABK-7A

RD-20C

GR/BK-44A

WH/BK-5AWH/RD-6AWH-4A

RD-CR17/CR23 #30

TS52

TS55

RD-24A

RD-20A

BK/RD-35A

OR-14A

GR-17A

GR/BK-18A

GR/WH-19A

OR/BK-15A

RD- P1 E-STOP

RD-20BCR17

WH-C5-11

BK-C6-25

RD-CB3 SP

CR39

OR-C6-33

BC

CR2CR1

RD-24B

BK-33B

WH-21B

WH-C5-17

BK-C6-16

CR5

GR-43BBK-22B

TS22

BK-C5-5

GR-C5-12

RD-27B

WH-23B

D C B AD A

R2

KS1

P1

LABEL


KEY SWITCH

DESCRIPTION

TS59

TS63

TS55

TS57

TS53

TS52

CB1

CB2

CB3

TS62

TS22

TS58

TS61

R2

G2

G1

L2

HM

G3

R1










OIL PRESSURE GAGE

CHECK ENGINE

WATER TEMP. GAGE

HOUR METER

CHECK ENGINE SWITCH


VOLT METER GAGE

ENGINE START SWITCH

FUNCTION ENABLE


LP/GAS SWITCH

AUXILIARY SWITCH TS51

U34LOAD SENSE TIME DELAY RELAY (10A)

134ARD-U34-2RD-H6+

GR/WH-35B

GR/WH-45B

KS1KEY SWITCH

RD

B

B1

1

24

3

GR

OU

ND

ST

UD

D2

D4

D10

D28D14

D13

LOAD SENSE OPTION - TIMER RELAY

WH-CR2#86

WH-ISM#9

RD-TB134(A)C

BR-GND

BK-C3B-10

44B-RD/BK-C6-19

SPARE

RD-CR23#30

&CR45#86 & CR23#86

WH/RD-C6-32


GR/BK-133B - C32-8

BK-C7-1 - C32-5BK-22C - C32-4

RD-TS55 - C32-7

RD-H6+ - C32-1

BR - GND - C32-12

RD-TS51 - C32-6

BL/WH-132D - C32-3

PLATFORM LOAD

U33 C32

GR/BK-133AGR/BK-L45-

RD-134BRD-C32-1

H6

85

30

86

87

85

30

86

87

CR45

RD-20C

WORK LIGHT OPTION RELAY

WH-W.L. CABLE

WH-21C

BR-GND

BN-GND

WH-21B

RD C4B-12

RD C4B-10


RD-24C

CR23

DIODE ADDED AT SERIAL NUMBER 164531

1

1


6 - 118

Ground Control Box Wiring DiagramFord DSG-423 EFI Models(from serial number 14832)

6 - 117


6 - 119

Platform Control Box Wiring DiagramFord DSG-423 EFI Models


6 - 120

1

2

3

4

5

6

7

8



6 - 120 S-40 • S-45 Part No. 102521

Platform Control Box Wiring DiagramFord DSG-423 EFI Models(before serial number 14832)

D4

0

GR/BK C4P-4

BATGND C7P-3

RE

D/B

LK

-28

TILT

ALALRM

H1

RE

D-T

ILT

BR

N

D3

9

19/18 CONTROL CABLE

C2

P(B

K)

C1

P(G

Y)

C4

P(B

R)

C3

P(G

R)

12V BATT

C7P

C3P

C4P

C7P

C1

3L

ED

BL

/RD

C28TTA RD/BK C1P-2

C2

9M

SR

D/W

H

RE

D-T

ILT

GR

/BK

L4

8

JC1

-2B

RN

JC2

-2B

RN

JC3

-4,6

WH

JC3

-2B

RN

DR

EB

BL

/BK

DR

EA

BL

/WH

C2

7A

UX

RD

C1

P-1

C3

4S

AB

K/W

HC

1P

-8

C3

3S

TR

BK

C1

P-7

C2

8T

TA

RD

/BK

C1

P-2

C1P

C2P

1

RD

/BK

L4

J1

9

C1

0S

BU

BL

C3

P-1

0

C1

3D

RE

BL

/RD

C4

P-1

C11

SB

DB

L/B

KC

3P

-1 1

C4

0L

S1

OR

C2

P-2

C1

2S

BF

BL

/WH

C3

P-1

2

C4

1R

PM

OR

/BK

C2

P-3

C3

0E

DC

+W

HC

1P

-4

C1

PB

UR

DC

3P

-1

C3

1E

DC

-W

H/B

KC

1P

-5

C2

PB

DR

D/B

KC

3P

-2

C3

7S

TC

CB

L/B

KC

1P

-1 1

C3

PB

FR

D/W

HC

3P

-3

C3

6S

TC

BL

C1

P-1

0

C4

TR

LW

HC

3P

-4

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C2

9M

SR

D/W

HC

1P

-3

C3

5R

PM

BK

/RD

C1

P-9

C1

34

PW

RR

DC

2P

-4

J2

JC2

-5B

K

JC2

-3O

R

JC3

-5B

L

JC3

-3O

R

JC1

-5Y

EL

JC2

-4R

D

JC1

-3O

R

ALC-500

P2

4F

SW

H

BR

N

P2

4F

SW

H

C3P

C9P

F.S.

F.S.

JIBLS18

BR

N

C1

9JS

VG

R/W

HC

4P

-7A

ND

TS

8

OPT.

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9P

-2

P2

5F

SR

DC

9P

-3

P2

6B

AT

BK

C9

P-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C4

3H

RN

GR

C2

P-5

JDA

LA

RM

GR

/BK

C2

P-6

DR

IVE

LTB

K/R

DC

3P

-9

C6

TR

FW

H/R

DC

3P

-6

1

11

1

C1

9JS

VG

R/W

HJIB

P2

3S

WB

AT

WH

C7

P-2

P2

2B

AT

BK

C7

P-1

C1

8JD

GR

/BK

C4

P-6

C1

32

PL

IB

KC

1P

-12

C1

5P

LD

OR

/BK

C4

P-3

C1

4P

LU

OR

C4

P- 2

C1

7JU

GR

C4

P-5

RD

H1

RD

P2

P2

6B

AT

BK

J3

3

HARNESS

PBOX WIRING

DL

ITE

BK

/RD

C3

P-9

TS

48

-WL

2R

DC

2P

-11

TS

48

-WL

1R

DC

2P

-12

C3

9L

PB

L/R

DC

2P

-1

ESO433

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 121


Platform Control Box Wiring DiagramFord DSG-423 EFI Models


TS

48

-WL1

RD

C2

P-1

2

TS

48

-WL2

RD

C2

P-1

1

C3

9LP

BL/R

DC

2P-1

BR

BR

B

RD

C1

CR14

GR/WH

P1

34

PW

RR

D

CR

13

-#8

6G

R/W

H

GR

/WH

RD

GR/WH

B

YY

B

RR

R

BR -

RD OUTPUT

GR/WH +

B

BK

JIB

R

B

BY Y

B

B

WH

B

B

3

J3

P2

6E

ST

PB

K

C1

7JU

GR

C4

P-5

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8JD

GR

/BK

C4

P-6

P2

2B

AT

BK

C7

P-1

P2

3B

AT

WH

C7

P-2

C1

9JS

VG

R/W

HC

4P-7

1

11

1

C6

TR

FW

H/R

DC

3P-6

JD

ALA

RM

GR

/BK

C2

P-6

C4

3H

RN

GR

C2

P-5

C8

PB

RB

K/W

HC

3P-8

C7

PB

EB

KC

3P-7

P2

6E

ST

PB

KC

9P-1

P2

5F

SR

DC

9P-3

P2

4F

SW

HC

9P-2

C4

5G

EN

GR

/WH

C2

P-7

F.S.

C9P

P2

4F

SW

H

BR

P2

4F

SW

HALC-500

J2

P1

34

PW

RR

DC

2P-4

C3

5R

PM

BK

/RD

C1

P-9

C2

9M

SR

D/W

HC

1P-3

C5

TR

RW

H/B

KC

3P-5

C3

2B

RK

WH

/RD

C1

P-6

C4

TR

LW

HC

3P-4

C3

6S

TC

BL

C1

P-1

0C

3P

BF

RD

/WH

C3

P-3

C3

7S

TC

CB

L/B

KC

1P-1

1

C2

PB

DR

D/B

KC

3P-2

C3

1E

DC

-W

H/B

KC

1P-5

C1

PB

UR

DC

3P-1

C3

0E

DC

+W

HC

1P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL/W

HC

3P-1

2C

40

LS

1O

RC

2P-2

C1

1S

BD

BL/B

KC

3P-1

1C

13

DR

EB

L/R

DC

4P-1

C1

0S

BU

BL

C3

P-1

0

9

J1

RD

/BK

L4

1

C2P

C1P

C2

8T

TA

RD

/BK

C1

P-2

C3

3S

TR

BK

C1

P-7

C3

4S

AB

K/W

HC

1P-8

C2

7A

UX

RD

C1

P-1

GR

/BK

L4

8

RD

-TILT

C28TTA RD/BK C1P-2

C7P

C4P

C3P

C7P

12V BATT

C3

P(G

R)

C4

P(B

R)

C1

P(G

Y)

C2

P(B

K)

19/18 CONTROL CABLE

BR

RD

-TILT

H1

ALALRMTILT

RD

/BK

-28

BATGND C7P-3

GR/BK C4P-4

DR

EA

BL/W

H

DR

EB

BL/B

KC

13

LE

DB

L/R

DC

29

MS

RD

/WH

JC

3-1

BR

JC

3-3

,5B

L/W

H

JC

2-1

BR

JC

1-1

BR

JC

1-4

WH

/BK

JC

3-2

OR

JC

3-4

WH

/RD

JC

2-4

RD

/WH

JC

2-2

OR

JC

1-2

OR

JC

2-3

WH

/RD

C1

9JS

VG

R/W

HT

S7

C1

9JS

VG

R/W

HC

4P-7

BR

GN

DB

RJC

3

RD

-E-S

TO

PP

13

4P

WR

RD

-H1

+

OPT.LS18

OPTION

RD LS18 CABLE

COM

32NO

5

P2

6E

ST

PB

KE

-ST

OP

BR

GN

D

RD

-H1

+P

13

4P

WR

RD

R2

6E

ST

PB

KC

9P-1

U35

JIB

C132PLI1 BK C1P-12

C132PLI2 BK C3P-10

D89

D88

D3

9

D4

0

47

00

R2

0LOAD SENSE

OPTION

TILT ALARMH1

COMPONENT INDEX

CR14 JIB DELAY RELAY

C1 JIB TIME DELAY

LOAD SENSE TIME DELAY RELAY (30A)U35

PLAT CONTHARNESS

(TO SWITCHPANEL)


6 - 1226 - 121

Platform Control Box Wiring DiagramFord DSG-423 EFI Models(from serial number 14832)


6 - 123

Platform Control Box Switch Panel Wiring DiagramFord DSG-423 EFI Models


6 - 124

1

2

3

4

5

6

7

8



6 - 124 S-40 • S-45 Part No. 102521

Platform Control Box Switch Panel Wiring DiagramFord DSG-423 EFI Models(from serial number 11067 to 12509)


+

4

2

1

3

5

6

7

C2

9M

SR

D/W

HJ1

-8

C2

7A

UX

RD

C1

P-1

C1

7JU

GR

C4

P-5

C1

9JS

VG

R/W

HJIB

C1

8JD

GR

/BK

C4

P-6

ROTATEPLATFORM

TS9

PLATFORMP3

HORN

LEVEL

WH

TS7

CE SEE DETAIL A

WH

PUMP

AUXILIARY

WH

TS1

START

TS2

5

GR

-43

RD

OR

/BK

-15

OR

-14

RD

J1

-1

BK

J1

-2

BR

NJ1

-12

OR

J1

-11

3

2

4

JC2

1

7

6

BL

/BK

-DE

2J1

-7BK

-7

BK

/WH

-8

DR

IVE

LTB

K/R

D-C

3P

-9

WH

-24

TS13

RETRACT

EXTEND/

BOOM

PRIMARY

BK

-22

WH

-24

BL

/WH

-DE

1J1

-6

BL

/RD

-DE

3J1

-16

WH

-24

L1

RD

-25

BK

-33

+

DRV.ENATS15

P2

2B

AT

BK

C7

P-1

P2

6B

AT

BK

C9

P-1

HIGH/LOW

TS4

RPM

P2EMERGENCY STOP

OPTION WIRES

DASHED LINES INDICATENOTE:

CR30

TS49

TS2

TS7

TS3

TS8

TS15

TS4

TS13

TS47

L4

RD

-TILT

RD

/BK

H1

WH

-24

BK

/RD

-35

JC3

WH

J1

-5

WH

J1

-5

BL

J1

- 4

BR

NJ1

-14

OR

J1

- 13

WH

- 23

RD

-TILT

BK

-22

TS9

L4

PBOX WIRING

HARNESS

JC2

P3

TS1

P2

L1

JC3


CR27





DRIVE ENABLE SWITCH

HI/L0 RPM SWITCH

JIB UP/DOWN SWITCH



START ENGINE SWITCH

56457

2737827378

13037

16397

13037

13037

13037

56457

56457

13037

PART NUMBER




HORN SWITCH


AUXILIARY SWITCH

DRIVE ENABLE LED

COMPONENT INDEX

62390

56298

42730

66813, 66816

66812, 95406

75565

C1

9JS

VG

R/W

H

JD

AL

AR

MG

R/B

K-4

4C

2P

-6

GR/BK

GR

JIB

TS8

WH

-JIB

WH

-JIB

BR

N

WH

-24

CR13

DRIVE LITE

TS49

DL

ITE

/

10 AMP FUSE

(OPTION)

GENERATOR

TS47

RD

GR

/WH

-45

WH

-TS

4

WH

-24

WH

-TS

47

HIGH/LOWSPEEDDRIVE

TS14

TS14 DRIVE SPEED SWITCH

RD

WL

1

WORK /

RD

WL

2

FUEL SELECT

TS3

RD

BL

/RD

-39

RD

CHASSIS TILT LED 56298

OR R40LS1

(SPLICE TO C32BRK)

(SPLICE TO R40LS1)

WH TS7

WH/RD C32BRK


(GND STUD)

WH TS1

BRN BATGND

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 125


Platform Control Box Switch Panel Wiring DiagramFord DSG-423 EFI Models


TS15DRIVE ENABLE

PRIMARYBOOMEXTEND/RETRACT

DRIVE/STEER

6

1JC3

TT ROTATE

UP/DOWN

1

6JC2

PRI. BOOM

+

TS13L48

+

+CR13

WH

-24

12 NC

12 NC12 NC

34

NO

J1

-2R

D/W

HJC

2-4

J1

-1W

H/R

DJC

2-3

J1

-12

BR

NJC

2-1

J1

-11

OR

JC

2-2

BK

-22

RD

-TILT

WH

-23

BK

/RD

-35

WH

-24

NOTE:

EMERGENCY STOP

P2RPM

TS4

HIGH/LOW

P2

6E

ST

PB

KC

9P-1

P2

2B

AT

BK

C7

P-1

BK

-33

RD

-25

L1

WH

-24

BL/R

D-D

E3

J1

-16

BL/W

H-D

E1

J1

-6

WH

-24

BK

-22

BK

/WH

-8

BK

-7

BL/B

K-D

E2

J1

-7

OR

-14

OR

/BK

-15

RD

GR

-43

TS2

START

TS1

AUXILIARYPUMP

WH

CE SEE DETAIL A

TS7

WHLEVEL

HORNP3 PLATFORM

TS9

PLATFORMROTATE

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HJIB

C1

7JU

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

C2

9M

SR

D/W

HJ1

-8

J1

-5B

L/W

HJC

3-5

J1

-5B

L/W

HJC

3-3

J1

-4W

H/R

DJC

3-4

J1

-14

BR

JC

3-1

J1

-13

OR

JC

3-2

RD

-P2

L4

GR

/BK

H1

RD

/BK

H1

D12

BR

WH

-JIB

TS8

JIB

GR

GR/BKJD

ALA

RM

GR

/BK

-44

C2

P-6

C1

9JS

VG

R/W

H

D27

RD

BL/R

D-3

9

RD

TS3

FUEL SELECT

D11

GR

/WH

-45

RD

TS47

GENERATOR(OPTION)

TS14

DRIVESPEEDHIGH/LOW

WH

-24


OPTION WIRES

CR27


CR30

BR BATGND

WH TS1

(GND STUD)


WH/RD C32BRK

WH TS7

(SPLICE TO C32BRK)

(SPLICE TO R40LS1)

OR R40LS1

JC3

L1

P2

TS1

P3

JC2

L4

TS9

TS47

TS13

TS4

TS15

TS8

TS3

TS7

TS2

TS49

TS14

COMPONENT INDEX

DRIVE ENABLE LED

AUXILIARY SWITCH


HORN SWITCH




START ENGINE SWITCH



JIB UP/DOWN SWITCH

HI/L0 RPM SWITCH

DRIVE ENABLE SWITCH

DRIVE SPEED SWITCH





CHASSIS TILT LED

10 AMP FUSE

BK

/WH

-8

DR

IVE

LTB

K/R

D-C

3P

-9

DRIVE LITE

TS49

DL

ITE

/

RD

WL

1

WORK /

RD

WL

2

DRIVE/WORK LIGHT OPTION CHANGED AT SERIAL NUMBER 1642021

21

85

86

3087A

85

86

3087A

85

86

3087

HARNESSPBOX

WIRING


6 - 126

Platform Control Box Switch Panel Wiring DiagramFord DSG-423 EFI Models(from serial number 12510)

6 - 125


6 - 127

Engine Wire HarnessFord LRG-425 EFI Models


6 - 128

1

2

3

4

5

6

7

8



6 - 128 S-40 • S-45 Part No. 102521

351 BR-W 18

359 GY-R 18

358 LG-BK 18

TWR

B

A

C

MAP_CONN

361 R 16 361 R 16 361 R 16

INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2

ACT

151 LB-BK

307 BK-Y 18

570 BK-W 12570 BK-W 12

570 BK-W 16

570 BK-W 16

570 BK-W 16

34 GROUND

25 IVS

14 FPP1

39 R-W 18570 BK-W 1616 WATER TEMP

WATERTEMP

30AF1

16 R-LG 181 VSW

5AF216 R-LG 18

20AF3

ECT

361 R 12361 R 14361 R 14

351 BR-W 18

359 GY-R 18

351 BR-W 18

359 GY-R 1833 ANA RTN

31 VREF

9 VBATT

360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

198 DG-O 18

18 O-Y 1838 EGR ANA IN

32 ANA AUX PD1

37 ANA AUX PU1

12 FPP2

40 EGR PWM

41 EGR REC360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

198 DG-O 18

18 O-Y 18

361 R 16

16 R-LG 18

307 BK-Y 18

351 BR-W 18

359 GY-R 18

570 BK-W 16

570 BK-W 16

360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

354 LG-R 18

151 LB-BK 18

198 DG-O 18

18 O-Y 18

555 T 16

556 W 16

557 BR-Y 16

558 BR-LB 16

358 LG-BK 18

743 GY 18

145 VOLT REF

3VSW

23EGR RECIRC

22EGR PWM

2POWER GROUND

1POWER GROUND

21EGR

20MAP

27IAT

16FPP 2

15FPP 1

11INJ 5

6INJ +

7INJ 1

12INJ 6

28ECT

17IVS

13ANA_RTN

18AUX ANA PU1

19AUX ANA PD1

31AUX OUT 2

8INJ 3

9INJ 4

10INJ 2

J1 BLACK

74 GY-LB 1824EGO 1

452 GY-R 18

282 DB-O 18

349 DB 18

350 GY 18

34CAM +

35CAM -

32CRANK +

33CRANK -

30KNK -

29KNK +

26EGO 3

570 BK-W 16

570 BK-W 16

351 BR-W 18

359 GY-R 18

354 LG-R 18

358 LG-BK 18

361 R 16

555 T 16

556 W 16

557 BR-Y 16

558 BR-LB 16

359 GY-R 18

743 GY 18

16 R-LG 18

151 LB-BK

570 BK-W 16

CRANK361 R 14361 R 16

361 R 16

5VBAT

VBAT4

392 R-LG 1825EGO 2

570 BK-W 16

359 GY-R 18

74 GY-LB 18

361A R 16

392 R-LG 18

361A R 16

359 GY-R 18

570 BK-W 16

O2 SENSOR

O2SENSOR

361 R 14

CAM

307 BK-Y 18

359 GY-R 18

361A R 16

851 Y-R 18

850 Y-BK 18

LOCKOFF SOLENOID

361A R 16

242 DG 18

361A R 16

77 DB-Y 18

TRIM VALVE

361A R 16

172 LB-R 18

169 LG-BK 18

148 Y-R 18

317 GY-O 18

15 R-Y 18

458 O-BK 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

77 DB-Y 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

238 DG-Y 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18

926A LB-O 18

242 DG 18

342 LG-P 18

570 BK-W 16

TWR

B

A

WPTWR2_GY

TWR

A

B

J2 GREY

33OVERSPEED

5AUX OUT 1

13COIL 4

3COIL 3

2COIL 2

1COIL 1

4SPK PWR GROUND

35RS 232 RX

34RS 232 TX

21RS 485 -

20RS 485 +

19CAN -

18CAN +

12ROAD SPEED -

11ROAD SPEED +

17GOV SELECT 2

16GOV SELECT 1

10FUEL PUMP MON

8TACH

7OIL PRESSURE

6BRAKE SWITCH

31TPS2

30TPS1

23FUEL LOCKOFF

22STARTER LOCKOUT

14FUEL SELECT

15AUX ANA PU2

27MIL

26GASEOUS TRIM

29DBW -

28DBW +

24COIL 5

25COIL 6

32RELAY CONTROL

9FUEL PUMP

COIL 2

VBAT

COIL 11

12

2

3

3

15 R-Y 18

926A LB-O 18

172 LB-R 18

169 LG-BK 18

148 Y-R 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 18

238 DG-Y 18

317 GY-O 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18SHDA

E

F

B

C

D

MTRSHD6TWR

D

C

B

F

E

A

MTRTWR6

2

3

1

4

5

6

THROTTLE

317 GY-O 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18

351 BR-W 18

359 GY-R 18351 BR-W 18

359 GY-R 18

FPP_COMMD

C

A

TWR

RTN

5V

RX

BTX

351 BR-W 18

359 GY-R 18

458 O-BK 18

669 DG-W 18

87A85

86 30

87

458 O-BK 18

342 LG-P 18

15 STARTER IN (INTERUPT)

13 STARTER CONTROL

39 STARTER IN (AUTOCRANK)32 R-LB 16

32 R-LB 16

32 R-LB 16

5 FUEL PUMP787A PK-BK 16

87A85

86 30

87

16 R-LG 18

342 LG-P 18

361 R 14

87A85

86 30

87

15AF4

FUEL PUMPRELAY

787A PK-BK 16

361 R 1615AF5

21 AUX OUT1

20 RS 232+

18 RS 232-

3 RS 485-

11 RS 485+

172 LB-R 18

169 LG-BK 18

148 Y-R 18

458 O-BK 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 184 BRAKE

26 OIL PRES

2 TACH

6 MIL

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 -

570 BK-W 16

361A R 16

459 O-LG 18

662 DG-P 18

MTRSHD4

TWR

D

C

B

A

MTRTWR4

PLUG (GROUND)

PLUG (RELAY POWER)

PLUG (CAN +)

PLUG (CAN -)

SHD

D

B

A

C

253 DG-W 18OIL PRESSURE

361 R 16

STARTERRELAY

POWERRELAY

FORD42 PIN

CONNECTOR

Engine Wire HarnessFord LRG-425 EFI Models(before serial number 11067)

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 129


R/W 18

W/BK 18

PK/LG 18

BR/Y 16

BK/LG 18

O 18

LB/BK 18

GY/W 18

R/LG 18

W/LB 18

LG/W

DG/W 18

DG/BK

DBL 18

LG/BK 18

GY/R 18

DG/P

W/PK 18

W/PK 18

GY/R 18

(FPP2)

T/GN 18

R/BK 18

BK/R 16

GY/O 18

R/T 16

R/Y 18

BK/W 16

BK/R 16

LB/O 18

W 16

T 16

BK/LB 18

R/T 16

BR/LB 16

BK/W 16

DG 18

Y/W 18

Y/R 18

LB/Y 18

P/LB 18

T/Y 18

BK/O 18

LG/R 18

GY 18

W/R 18

BK/Y 18

DB/W 18

T/LB 18

GY 18

GY/R 18

LB/R 18

GY/Y 18

BR/W 18

W/LG 18

GY/LB 18

BK/W 16

Y/BK 18

Y/RD 18

RD/T 14

DG 18

O 18

GY/R 18

GY 18

BR/W 18

FP REC

LB/DG 18

DG/P 18

R/LG 18

Y/BK 18

O/LG 18

FUEL PUMP

LG/P 18

(FUEL PUMP)

DG/P 18

Y/DB 18

DB/O 18

DG/O 18

O/LG 18

W/BK 18

R 16

Y/RD 18

GY/R 18

8CAN -

5UNUSED

25V REF

1ANA RTN

3PC TX

4PC RX

6UNUSED

7CAN +

DIAGNOSTIC CONNECTOR

82DBW -

79VBAT

73RELAY

70INJ6 LS

67INJ4 LS

64INJ1 LS

61EGOH 2

55PC TX

52KNOCK -

43TACH

37ECT

34GOV 1

315V EXT 2

28CAM -

25CRANK +

22EGO2

195V EXT 1

16CAN2 -

10UEGOP

81GROUND

80DBW +

69GROUND

68INJ5 LS

72STARTER

74MIL

75UEGO H

77LOCKOFF

60VBAT

56PC RX

62EGOH 1

63INJ HS

65INJ2 LS

44VSW

47TPS 1

48TPS 2

51KNOCK +

53FPP1

325V RTN 2

33PULSE IN

36IAT

205V RTN

21EGO1

23MAP

26CRANK -

29SPEED +

27CAM +

17CAN2 +

14CAN1 +

15CAN1 -

9UEGOC

8UEGOS

11UEGPR

30SPEED -

66INJ3 LS

88AUX PWM4 REC

85AUX PWM1

76AUX PWM7

58KNOCK 2-

49(FUELSELECT)AUX DIG1

46AUX ANA PUD1

40(IVS) AUX ANA PU3

13(FRP) AUX ANA PD2

7SPK_COIL3B

4SPK_GND

1SPK_COIL1A

87AUX PWM2

83AUX PWM5 REC

84AUX PWM5

86AUX PWM4

89AUX PWM3 REC

71AUX PWM8

59VBAT PROT

57KNOCK 2+

45AUX ANA PUD2

50AUX DIG 2

35OIL PRESS

38(FRT) AUX ANA PU1

39(LPTEMP) AUX ANA PU2

41(BRAKE) AUX DIG 3

24AUX ANA PUD3

12AUX ANA PD1

2SPK_COIL1B

3SPARK_COIL2A

5SPK_COIL2B

78AUX PWM6

90AUX PWM3

54FPP2-IVS

42(GOV2) AUX DIG 4

6SPK_COIL3A

18AUX ANA PD3

O/LG 18

BR/W 18

BR/W 18

LG/BK 18

DG/P 18

B

A

LPG

TEMPERATURE

A

B

TWR

LPG

LOCKOFF

BOSCHTMAP

R 16

W/R 18

GY/R 18

DG/P 18

Y/R 18

KNOCK

SENSOR

GY 18

DBL 18

CRANK

DB/O 18

GY/R 18

CAM

CYL #2

DG/P 18

4

3

2

1

BK/W 16

PK/BK 16

GY/LB 18

R 16

GY/Y 18

W/LG 18

DG/P 18

O/LG 18

BR/W 18

LG/R 18

GY/R 18

R/LG 18

GY/R 18

Y/W 18

GY/O 18

GY/W 18

LB/DG 18

BR/W 18

R/LG 18

R/T 14

LB/O 18

O 18

DG 18

W/LB 18

T/GN 18

P/LB 18

Y/DB 18

O/LG 18

BK/R 16

PK/LG 18

T/Y 18

DG/W 18

BK/O 18

R/W 18

R/BK 18

R/Y 18

LG/P 18

GY/R 18

BR/W 18

BK/LG 18

LB/Y 18

DB/W 18

DG/O 18

BK/Y 18

BK/LB 18

LB/BK 18

BK/W 16

BK/W 16

BK/W 16

T/LB 18

LB/R 18

DG/BK

LG/W

R 16

T 16R 16

R 16

R 16

W 16

INJECTOR CYL #2

R 16

BN/LB 16

BR/Y 16

R 16

IGNITION COILS

CYL #3 CYL #4 CYL #1

INJECTOR CYL #4

INJECTOR CYL #3

INJECTOR CYL #1

ENGINE ECM

CONNECTOR

ES0400A

GY/R 18

Y/W 18

R 14

31 VREF

23 GOV SELECT 2

1 VSW

36 ROADSPEED -

R/LB 16

GY/O 18

GY/W 18

LB/DG 18

BR/W 18

R 16

R 16R 16

87A

RING

BATT(+)

LB/PK 16

W/PK 16

R/LB 16

R 14

33 ANA RTN

32 ANA AUX PD1

12 FPP2

37 AUX ANA PU2B

14 FPP1

35 ROADSPEED +

24 GOV SELECT 1

BK/W 18

W 18 W 18

R/T 18

R/Y 18

LB/PK 16

PK/BK 16

LG/P 18

R/LG 18

R 16

R 12

R/T 14

R/LG 18

O/LG 18

RELAYED POWER

F5

15A

EPR

F1

10A

R16

PK/BK 16 PK/BK 16

F2

VSW5A

GROUND

RING

DG/P 18

RING

STARTER

SOLENOID

3

2

6

5

1

4

BOSCH THROTTLE

FUEL PUMP

F4

15A

DG/W 18

87

30

85

86RELAY

OMRON

FPP

STARTER RELAY

ECM

F3

10A

SHD

R/LG 18

CAN

TERMINATION

CONNECTOR

BR/W 18

BK/Y 18

R/LG 18

LB/R 18

87A

85

86

87

30

POWER RELAY

GY/R 18

LB/Y 18

DG/O 18

DB/W 18

LB/BK 18

T/LB 18

LG/BK 18

TWR

2

1

3

ALTERNATOR

6GROUND

3CAN +

4UNUSED

5UNUSED

7POWER

8UNUSED

1CAN -

CAN + TERM

EPR

CONNECTOR

18 FUEL PUMP -

3 RS 232-

4 BRAKE

7 FUEL SELECT

6 MIL

25 IVS

5 FUEL PUMP +

29 CAN -

28 CAN +

11 RS 232+

26 OIL PRES

39 AUX OUT1

27 AUX OUT 2

2 TACH

10 AUX ANA PD1B

15 START IN INTERUPT

19 START IN AUTOCRANK

O 18

BK/R 16

LB/PK 16

W/PK 16

W/LB 18

Y/DB 18

PK/LG 18

BK/O 18

PK/BK 16

DG 18

DG/P 18

O/LG 18

T/GN 18

T/Y 18

DG/W 18

P/LB 18

O/LG 18

21 AUX PWM 5

16 AUX PWM 4

R/BK 18

R/W 18

R 16

PK/BK 16

LB/O 18

R/LG 18

R 16

87A

85

86

87

30

FUEL PUMP RELAY

BK/LG 18

HO2S #2

GY/LB 18

GY/R 18

R 16

GY/R 18

BR/W 18

R 16

LG/R 18

W/LG 18

BK/LB 18

LG/W 18

GY/YL 18

GY/R 18

MTRTWR4

CHT

D

B

A

C

SHD

HO2S #1

GASOLINE

SENSOR

INTERFACE

A

B

C

D

TWRGY/R 18

R 12

2

OIL PRESSURE

GROUND

RING

BK/W 12

FORD

42 PIN

CONNECTOR

BR 16 BR 1634 GND

Engine Wire HarnessFord DSG-423 EFI Models (from serial number 11067 to 11784)


6 - 130

Engine Wire HarnessFord DSG-423 EFI Models (from serial number 11101 to 11784)

6 - 129


6 - 131

Engine Wire HarnessFord DSG-423 EFI Models (from serial number 11785)

6 - 132

1

2

3

4

5

6

7

8



6 - 132 S-40 • S-45 Part No. 102521

Engine Wire HarnessFord DSG-423 EFI Models (from serial number 11785)

R/W 18

W/BK 18

PK/LG 18

BR/Y 16

BK/LG 18

O 18

LB/BK 18

GY/W 18

R/LG 18

W/LB 18

LG/W

DG/W 18

DG/BK

DBL 18

LG/BK 18

GY/R 18

DG/P

W/PK 18

W/PK 18

GY/R 18

(FPP2)

T/GN 18

R/BK 18

BK/R 16

GY/O 18

R/T 16

R/Y 18

BK/W 16

BK/R 16

LB/O 18

W 16

T 16

BK/LB 18

R/T 16

BR/LB 16

BK/W 16

DG 18

Y/W 18

Y/R 18

LB/Y 18

P/LB 18

T/Y 18

BK/O 18

LG/R 18

GY 18

W/R 18

BK/Y 18

DB/W 18

T/LB 18

GY 18

GY/R 18

LB/R 18

GY/Y 18

BR/W 18

W/LG 18

GY/LB 18

BK/W 16

Y/BK 18

Y/RD 18

RD/T 14

DG 18

O 18

GY/R 18

GY 18

BR/W 18

FP REC

LB/DG 18

DG/P 18

R/LG 18

Y/BK 18

O/LG 18

FUEL PUMP

LG/P 18

(FUEL PUMP)

DG/P 18

Y/DB 18

DB/O 18

DG/O 18

O/LG 18

W/BK 18

R 16

Y/RD 18

GY/R 18

8CAN -

5UNUSED

25V REF

1ANA RTN

3PC TX

4PC RX

6UNUSED

7CAN +

DIAGNOSTIC CONNECTOR

82DBW -

79VBAT

73RELAY

70INJ6 LS

67INJ4 LS

64INJ1 LS

61EGOH 2

55PC TX

52KNOCK -

43TACH

37ECT

34GOV 1

315V EXT 2

28CAM -

25CRANK +

22EGO2

195V EXT 1

16CAN2 -

10UEGOP

81GROUND

80DBW +

69GROUND

68INJ5 LS

72STARTER

74MIL

75UEGO H

77LOCKOFF

60VBAT

56PC RX

62EGOH 1

63INJ HS

65INJ2 LS

44VSW

47TPS 1

48TPS 2

51KNOCK +

53FPP1

325V RTN 2

33PULSE IN

36IAT

205V RTN

21EGO1

23MAP

26CRANK -

29SPEED +

27CAM +

17CAN2 +

14CAN1 +

15CAN1 -

9UEGOC

8UEGOS

11UEGPR

30SPEED -

66INJ3 LS

88AUX PWM4 REC

85AUX PWM1

76AUX PWM7

58KNOCK 2-

49(FUELSELECT)AUX DIG1

46AUX ANA PUD1

40(IVS) AUX ANA PU3

13(FRP) AUX ANA PD2

7SPK_COIL3B

4SPK_GND

1SPK_COIL1A

87AUX PWM2

83AUX PWM5 REC

84AUX PWM5

86AUX PWM4

89AUX PWM3 REC

71AUX PWM8

59VBAT PROT

57KNOCK 2+

45AUX ANA PUD2

50AUX DIG 2

35OIL PRESS

38(FRT) AUX ANA PU1

39(LPTEMP) AUX ANA PU2

41(BRAKE) AUX DIG 3

24AUX ANA PUD3

12AUX ANA PD1

2SPK_COIL1B

3SPARK_COIL2A

5SPK_COIL2B

78AUX PWM6

90AUX PWM3

54FPP2-IVS

42(GOV2) AUX DIG 4

6SPK_COIL3A

18AUX ANA PD3

O/LG 18

BR/W 18

BR/W 18

LG/BK 18

DG/P 18

B

A

LPG

TEMPERATURE

A

B

TWR

LPG

LOCKOFF

BOSCHTMAP

R 16

W/R 18

GY/R 18

DG/P 18

Y/R 18

KNOCK

SENSOR

GY 18

DBL 18

CRANK

DB/O 18

GY/R 18

CAM

CYL #2

DG/P 18

4

3

2

1

BK/W 16

PK/BK 16

GY/LB 18

R 16

GY/Y 18

W/LG 18

DG/P 18

O/LG 18

BR/W 18

LG/R 18

GY/R 18

R/LG 18

GY/R 18

Y/W 18

GY/O 18

GY/W 18

LB/DG 18

BR/W 18

R/LG 18

R/T 14

LB/O 18

O 18

DG 18

W/LB 18

T/GN 18

P/LB 18

Y/DB 18

O/LG 18

BK/R 16

PK/LG 18

T/Y 18

DG/W 18

BK/O 18

R/W 18

R/BK 18

R/Y 18

LG/P 18

GY/R 18

BR/W 18

BK/LG 18

LB/Y 18

DB/W 18

DG/O 18

BK/Y 18

BK/LB 18

LB/BK 18

BK/W 16

BK/W 16

BK/W 16

T/LB 18

LB/R 18

DG/BK

LG/W

R 16

T 16R 16

R 16

R 16

W 16

INJECTOR CYL #2

R 16

BN/LB 16

BR/Y 16

R 16

IGNITION COILS

CYL #3 CYL #4 CYL #1

INJECTOR CYL #4

INJECTOR CYL #3

INJECTOR CYL #1

ENGINE ECM

CONNECTOR

ES0400A

GY/R 18

Y/W 18

R 14

31 VREF

23 GOV SELECT 2

1 VSW

36 ROADSPEED -

R/LB 16

GY/O 18

GY/W 18

LB/DG 18

BR/W 18

R 16

R 16R 16

87A

RING

BATT(+)

LB/PK 16

W/PK 16

R/LB 16

R 14

33 ANA RTN

32 ANA AUX PD1

12 FPP2

37 AUX ANA PU2B

14 FPP1

35 ROADSPEED +

24 GOV SELECT 1

BK/W 18

W 18 W 18

R/T 18

R/Y 18

LB/PK 16

PK/BK 16

LG/P 18

R/LG 18

R 16

R 12

R/T 14

R/LG 18

O/LG 18

RELAYED POWER

F5

15A

EPR

F1

10A

R16

PK/BK 16 PK/BK 16

R/LG 18

F2

VSW5A

GROUND

RING

DG/P 18

RING

STARTER

SOLENOID

3

2

6

5

1

4

BOSCH THROTTLE

FUEL PUMP

F4

15A

DG/W 18

87

30

85

86RELAY

OMRON

FPP

STARTER RELAY

ECM

F3

10A

SHD

R/LG 18

CAN

TERMINATION

CONNECTOR

BR/W 18

BK/Y 18

R/LG 18

LB/R 18

87A

85

86

87

30

POWER RELAY

GY/R 18

LB/Y 18

DG/O 18

DB/W 18

LB/BK 18

T/LB 18

LG/BK 18

TWR

2

1

3

ALTERNATOR

6GROUND

3CAN +

4UNUSED

5UNUSED

7POWER

8UNUSED

1CAN -

CAN + TERM

EPR

CONNECTOR

18 FUEL PUMP -

3 RS 232-

4 BRAKE

7 FUEL SELECT

6 MIL

25 IVS

5 FUEL PUMP +

29 CAN -

28 CAN +

11 RS 232+

26 OIL PRES

39 AUX OUT1

27 AUX OUT 2

2 TACH

10 AUX ANA PD1B

15 START IN INTERUPT

19 START IN AUTOCRANK

O 18

BK/R 16

LB/PK 16

W/PK 16

W/LB 18

Y/DB 18

PK/LG 18

BK/O 18

PK/BK 16

DG 18

DG/P 18

O/LG 18

T/GN 18

T/Y 18

DG/W 18

P/LB 18

O/LG 18

21 AUX PWM 5

16 AUX PWM 4

R/BK 18

R/W 18

R 16

PK/BK 16

LB/O 18

R/LG 18

R 16

87A

85

86

87

30

FUEL PUMP RELAY

BK/LG 18

HO2S #2

GY/LB 18

GY/R 18

R 16

GY/R 18

BR/W 18

R 16

LG/R 18

W/LG 18

BK/LB 18

LG/W 18

GY/YL 18

GY/R 18

MTRTWR4

CHT

D

B

A

C

SHD

HO2S #1

GASOLINE

SENSOR

INTERFACE

A

B

C

D

TWRGY/R 18

R 12

2

OIL PRESSURE

GROUND

RING

BK/W 12

FORD

42 PIN

CONNECTOR

BR 16 BR 1634 GND

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 133


Joystick Connector Diagram


RD

BK

BR

N

OR

J1

12 1

11 2

7


YO

UT

XO

UT

GN

D

1 2 43 5 6

PW

R

JC2

BR

N

OR

BL

WH

J1

13

14 54

RK

OU

T

YO

UT

31 2 4 5

PW

R

GN

D

76

DRIVE & STEERING

JC3 4

2

1

3

5

6

7

5

RD

J1

-1B

KJ1

-2

BR

NJ1

-12

OR

J1

-11

3

2

4

JC2

1

7

6

JC3

WH

J1

-5

WH

J1

-5B

LJ1

-4

BR

NJ1

-14

OR

J1

-13

631 2 4 5

DRIVE & STEERING

BR

N

OR

WH

/RD

BL

/WH

5 4

13

14

RK

OU

T

YO

UT

PW

R

GN

D

JC3

BL

/WH

XO

UT

WH

/RD

RD

/WH

BR

N1

2 11 21

OR


1G

ND

JC2

432 65

YO

UT

XO

UT

PW

R

J1J1


J1

-5B

L/W

HJC

3-5

J1

-4W

H/R

DJC

3-4

J1

-5B

L/W

HJC

3-3

J1

-13

OR

JC

3-2

J1

-14

BR

NJC

3-1

JC3

DRIVE/STEER

J1

-11

OR

JC

2-2

J1

-12

BR

NJC

2-1

J1

-1W

H/R

DJC

2-3

J1

-2R

D/W

HJC

2-4

JC2

TURNTABLE ROTATE

UP/DOWN

PRIMARY BOOM

Deutsch - 6 Pin Connector

AMP - 7 Pin Connector

DRIVE/STEER

TURNTABLE ROTATE

UP/DOWN

PRIMARY BOOM

Note: Production changedfrom 7 pin to 6 pin Joysticksat Serial Number 12510

1

2

34

5

6

1

2

3

4

5

6

7

Deutsch

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7


1

2

34

5

6

7

6

5

4

3

2

1

Deutsch

AMP

Pin1

Pin 1 GND Pin 2

Pin 2 PWR Pin 3

Pin 3 XOUT Pin 4

Pin 4 YOUT Pin 5

Pin 5 RKOUT Pin 6

Pin 6 Pin 7



6 - 134

Joystick Connector Diagram

6 - 133


6 - 135

CTE Option Wiring Diagram

6 - 136

1

2

3

4

5

6

7

8


February 2012 Section 6 • Schematics

6 - 136 S-40 • S-45 Part No. 102521

CTE Option Wiring Diagram

C2

0-1

C2

1-1

PLA

TLE

VE

LD

OW

N

C2

1-2

PLA

TLE

VE

LU

P

GROUND

C2

0-2

PLA

TLE

VE

L

UP

RE

LA

Y

CR

20

CR21

C1

5P

LD

OR

/BK

TB15

TB134

TB22

LIM

ITS

WIT

CH

ES

TB40

R1

4P

LU

OR

R1

5P

LD

OR

/BK

CR20

C1

4P

LU

OR

TB14

PLA

TLE

VE

L

DO

WN

RE

LA

Y

CR

21

P1

34

PW

R

BO

OM

ST

OW

ED

PLA

TF

OR

MLE

VE

LD

OW

N

PLA

TF

OR

MLE

VE

LU

P

WIRING DIAGRAM RD

-C6

-23

+LS

PW

R-C

6-3

0

C1

5P

LD

OR

/BK

CR

21

#8

6

OR

/RD

-C2

B-4

OR

C6

-40

OR

C2

B-2

13

4

40

C1

4P

LU

OR

CR

20

#8

6

C1

5P

LD

OR

/ BK

C4

B-3

C1

4P

LU

OR

C4

B-2

14

15

GR

OU

ND

BO

LT

C1

5P

LD

OR

/BK

C6

-15

C1

4P

LU

OR

C6

-14

C1

5P

LD

OR

/BK

15

-D

13

4

40

15

14

C4

0LS

1O

RC

R2

0#

30

RD

-KS

1-2

S. P

.

RD

-H6

+

OR

/BK

-TS

59

OR

-TS

59

BR

BR

-GN

DS

TU

D

C4

0LS

1O

R4

0-A

BR C

14

PLU

OR

14

-D

FUNCTIONHARNESS

85

85

86

30

87

86

30

87

February 2012Section 6 • Schematics

6 - 137

MTE Hydraulic Generator Option Wiring Diagram

6 - 138

1

2

3

4

5

6

7

8



6 - 138 S-40 • S-45 Part No. 102521

MTE Hydraulic Generator Option Wiring Diagram

SCHEMATIC - MTE HYDRUALIC GENERATOR OPTIONS

C4

5G

EN

-GR

/WH

-4

C4

5G

EN

-GR

/WH

-4

T2

T1

YELLOW

RED

WHITE

GREEN

T3

T4

8

5

BLACK

BLACK

BLACK

WHITE

BLACK

WHITE

WHITE

BLACK

GREEN

WHITE

BLACK L1

L2

GND

C4

5G

EN

-GR

/WH

-4B

AT

GN

D-B

R-4

1 2 43

3 421

GR

/WH BR

BL

PLU

G

PURGE-BL

DTP04-4P

GREEN

REDBLACK

BLUEYELLOW

WHITE

BLACK BLACKWHITE

YELLOW

BLUE

BLACKRED

GREEN

DTP04-4P

PURGE-BL

PLU

G

BL

BR

GR

/WH

1 2 43

3 421

BA

TG

ND

-BR

GND

L2

L1BLACK

WHITE

GREEN

BLACK

WHITE

WHITE

BLACK

WHITE

BLACK

RED

RED

5

8

T4

T3

BLACK

WHITE

BLACK

WHITE

T1

T2

T2

T1

YELLOW

RED

WHITE

GREEN

T3

T4

8

5

BLACK

BLACK

BLACK

WHITE

BLACK

WHITE

WHITE

BLACK

GREEN

L2

L1

BA

TG

ND

-BR

-4

1 2 43

3 421

GR

/WH

BR

BL

PLU

G

PURGE-BL

DTP04-4P

BLACKRED

GREEN

WHITE

BLACK

BLUE

YELLOW

WHITE

BLACK

GND

GENERATORJUMPER HARNESS

ACGENERATOR

ACGENERATOR


120VAC, 50Hz, 1 PH120VAC, 60Hz, 1 PH

240VAC, 50Hz, 1 PH


ACGENERATOR

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 139


Hydraulic Generator Wiring Diagram- Welder Option

C57

TB41

C5

-6

C6

-39

C4

1R

PM

OR

/BK

C5

-21

C5

-20

C1

B-5

C1

B-4

TB21

19

CR66OMRON RELAY

PS4

U36

NC

N.O.

P2

C32BRK WH/RD

753

18

642

PILOT PRESSURE SIGNALFROM GENERATOR MANIFOLD

TB24TIME DELAY MODULE4 SECOND

8 N.C.

2 COM

1 N.O.

3 GND 5 SW INPUT

DR

IVE

ED

C-

DR

IVE

ED

C+

B C

U4

AD

C5

-21

C5

-20

C1

B-5

C1

B-4

C3

1E

DC

WH

/BK

C3

0E

DC

WH

C1

P-5

C1

P-4

16

15

ALC-500C

2P

-7C

2B

-7C

45

GE

NG

R/W

H

TB45

P25FS-RD

P24FS-WH

TS4RPM

SELECT

TB35

C3

5R

PM

BK

/RD

C1

B-9

C1

P-9

RP

MH

I

RP

ML

O

FOOTSWITCH

2 4

6

81 3

5 7

RS232RxD

A1 BATTERY +A2 SENSOR POWER +5 VDCA3 BATTERY-

B1 VALVE 0 FWD COIL)B2 VALVE 1 NCB3 DIGITAL OUTPUT BYPASS

C1 TxD (YLW)C2 RxD (GRN)

C3 /BOOT

D1 ANALOG 0 JOYSTICKD2 ANALOG 1 NCD3 DIG IN 3 NC

E1 NOT USEDE2 NOT USEDE3 NOT USED

F1 DIG IN 0F2 DIG IN 1 GENERATOR ON

F3 DIG IN 2

RS232TxD

CR

4H

IGH

IDL

ER

EL

AY

C4

5G

EN

GR

/WH

V151HG GR

V150HG GR/BK

1k ohms124 ohms

124 ohms

ABC

20

P26ESTP-BK

TB29

2

1

3

C1

B-3

C1

P-3

C2

9M

SR

D/W

H

BY

PA

SS

CO

IL

MO

TO

RS

TR

OK

EV

ALV

E

SX Controller

CR50OMRONRELAY

C5

-18

C5

-24

C5

-1W

H

C5

-12

P22PWR-BK

D65D98

DIVERTER MANIFOLD

PR

ES

SU

RE

SW

ITC

H2

00

PS

I

D99

BK

-2

TS47GENERATOR

ON

C57

Y75

Y75-2

TB32

C3

2B

RK

WH

/RD

C1

P-6

BR

AK

ER

EL

EA

SE

C5

-23

BK 16-2J129

BR-2(16-2)

RD

-1


6 - 140

Hydraulic Generator Wiring Diagram- Welder Option

6 - 139


6 - 141

2WD Non-Oscillating Hydraulic Schematic S-40 Models (before serial number 7569)

6 - 142

1

2

3

4

5

6

7

8



6 - 142 S-40 • S-45 Part No. 102521

2WD Non-Oscillating Hydraulic SchematicS-40 Models (before serial number 7569)

HYDRAULIC

xx

D

E

C

B

A

F

3300 PSI

3:1

3:1

3500 PSI

COUNTERBALANCE VALVE

3:1

3:1

3:1

RATIO

1000 PSI

3000 PSI

2000 PSI

PRESS

5:1 3500 PSI

79

BC

A A

C C

F F

EE

D D

7

7

7

x

x xx x

x

xx

REAR

RIGHT

REARLEFT

M1

T

M3

50%

.070

50%

M4

M2

T1

210 psi14.5 bar

TESTBA

68 3 1 2 54

E

3625 psi250 bar

3 psi0.2 bar

3 psi0.2 bar

TEST

A

B

TEST315 psi21.7 bar

51 psi3.5 bar

T2

CP

25 psi1.7 bar

BRAKE

LS TEST

T1

PRESS

PL2PL1

PR2

.030

T2

PR1P2

2200 psi151.7 bar

P1

TANK

V1V2

SW1 SW2

1950 psi134 bar

S1

RET

ST2ST1

PTESTAUX EXT

2600 psi179 bar

1.7M

2.0 gpm7.6 L/min

FLB FLR

2A 2B138B 6C 6B6B8C8A 2C

0.1 gpm0.4 L/min

54

FRBFRR

17 L/min4.5 gpm 0.6 gpm

2.3 L/min

AUX

T2

TANK

PRESS

T1RESERVOIR

HYDRAULIC ROTARY COUPLER

BRAKE MANIFOLD

DRIVE PUMP

PUMPFUNCTION

RETURNFILTER

MANIFOLD

TRACTION

PLATFORM

SLAVE

MASTER

ROTATE

TURNTABLEROTATE2 gpm

7.6 L/min

3 gpm11.4 bar

EXTEND RETRACT CYL4 gpm

15.1 L/min

FUNCTION

MANIFOLD

PUMP

AUXILIARY

MEDIUM

PRESSUREFILTER

CYLINDERS

PLATFORM LEVEL

PRIMARY LIFTCYLINDER

STEERINGRIGHT LEFT

165.5 bars2400 psi

OPTIONAL

MANIFOLD

GENERATOR

OPTIONAL

GENERATOR

FUNCTION

MANIFOLD

TO HYD ROTARY COUPLER

FUNCTION

PUMP

COOLEROPTION

185 psi12.7 bar

RELEASE

185 psi12.7 bar

RELEASE

CA CB

BH AB

BF

0.6 gpm2 L/min(S-40)

AABD

AJ

ACAE

BAAD

BEBG

AI

AW

AH

AK

AZ

AG

BB

AFAM

AV

AL

AU

AR

BG

AP

AO

AS

AN

AQ

AT

BI

DA

.025 DB

FE

FA

FDFB

FC

AYAX

Note: 'alpha' callouts refer tocomponents shown in themanifold illustrations.Refer to the Repair Section.

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 143



HYDRAULIC

xx

D

E

C

B

A

F

3300 PSI

3:1

3:1

3500 PSI


3:1

3:1

3:1

RATIO

1000 PSI

3000 PSI

2000 PSI

PRESS

5:1 3500 PSI

79

BC

A A

C C

F F

EE

7

7

7

x

x xx x

x

xx

REAR

RIGHT

REARLEFT

M1

T

M3

50%

.070

50%

M4

M2

T1

TESTBA

68 3 1 2 54

E

3625 psi249.9 bar

3 psi 3 psi

0.2 bar 0.2 bar

TEST

A

B

TEST

315 psi21.7 bars

3.5 bar50 psi

T2

CP

25 psi1.7 bar

BRAKE

LS TEST

T1

PRESS

PL2PL1

PR2

.030

T2

PR1P2

2200 psi151.7 bar

P1

TANK

V1V2

SW1 SW2

1950 psi134.4 bar

S1

RET

ST2ST1

PTESTAUX EXT

1.7M

2.0 gpm7.6 L/min

FLB FLR

2A 2B138B 6C 6B6B8C8A 2C

0.1 gpm0.38 L/min

54

FRBFRR

4.5 gpm17 L/min

0.6 gpm2.27 L/min

AUX

T2

TANK

PRESS

T1RESERVOIR


BRAKE MANIFOLD

DRIVE PUMP

PUMPFUNCTION

RETURNFILTER

MANIFOLDTRACTION

SLAVE

MASTER

TURNTABLEROTATE

7.6 L/min

2 gpm

11.4 L/min3 GPM

EXTEND RETRACT CYL4 GPM15.1 L/min

FUNCTION

MANIFOLD

PUMP

AUXILIARY

MEDIUM

PRESSUREFILTER

CYLINDERS

PLATFORM LEVEL


STEERINGRIGHT LEFT

2400 psi165.5 bar

OPTIONAL

MANIFOLDGENERATOR

OPTIONALGENERATOR

FUNCTIONMANIFOLD


FUNCTIONPUMP

COOLEROPTION

C

V2

PR2

PR1

V1J1

J2

PLATFORMROTATE

S45 JIB BOOM

MANIFOLDJIB SELECT

C

D

D

185 psi12.7 bar

RELEASE

185 psi12.7 bar

RELEASE

CC

CA

CB

BH AB

BF

AA

0.8 gpm3 L/min

BG BE

AD BA

ACAE

BD

AJ

AI

AYAX

AH

AK

AW

AZ

AG

BB

AFAM

AV

AL

AU

AR

BG

BI

AT

AN

2900 psi200 bar

AQ

AS

AO

AP

FD

FC

FA

FB

FE

DB.025

DA



6 - 144


6 - 143


6 - 145

4WD Oscillating Hydraulic SchematicS-40 Models (before serial number 7569)

6 - 146

1

2

3

4

5

6

7

8



6 - 146 S-40 • S-45 Part No. 102521


79

BC

A A

C C

F F

EE

D

D

7

7

2

7 2

x

x xx xx

REARRIGHT

REARLEFT

M1

T1

T

M2

LEFTFRONT

M3

50%

.070

50%

M7

M5

67%

210 psi14.5 bar

.070

33%

TEST BA

68 3 1

M4

50%

50%

FRONTRIGHT

M8

M6

2 54

E

249.9 bar3625 psi

3 psi 3 psi0.2 bar 0.2 bar

TEST

A

B

TEST315 psi21.7 bar

50 psi3.4 bar

T2

CP

25 psi1.7 bar

BRAKE

LS TEST

T1

PRESS

PL2PL1

PR2

.030

T2

PR1

TANK

SW2

V1

SW1

1950 psi134.4 bar

V2

S1

RET

ST2ST1

PTESTAUX EXT

2600 psi179.3 bar

1.7M

2.0 gpm7.6 L/min

FLB FLR

2A 2B138A 6A6B8B 2C

0.6 gpm

2.27 L/min

0.38 L/min

0.1 gpm

54

FRBFRR

950 psi65.5 bar

A

B

OUT

IN

TEST.052

4.5 gpm17 L/min

AUX

T2

TANK

PRESS

T1

6C8C

RESERVOIR


BRAKE MANIFOLD

DRIVE PUMP

PUMPFUNCTION

RETURNFILTER

MANIFOLDTRACTION

PLATFORM

SLAVE

MASTER

ROTATE

3 gpm11.4 L/min

TURNTABLEROTATE

7.6 L/min2 gpm

EXTEND RETRACT CYL4 gpm15.1 L/min

FUNCTION

MANIFOLDPUMPAUXILIARY

MEDIUMPRESSUREFILTER

CYLINDERSPLATFORM LEVEL


STEERINGRIGHT LEFT

OSCILLATE VALVE

OSCILLATE CYLINDERS

LEFT RIGHT

2400 psi165.5 bar

OPTIONAL

MANIFOLDGENERATOR

OPTIONALGENERATOR

FUNCTIONMANIFOLD


FUNCTIONPUMP

HYDRAULICCOOLEROPTION

G G

D

E

C

B

A

F

3300 PSI

3:1

3:1

3500 PSI


3:1

3:1

3:1

RATIO

1000 PSI

3000 PSI

2000 PSI

PRESS

5:1 3500 PSI

G 1.5:1 3000 PSI

DB.025

DA

HF

HI

HA

HD

HH

HE

HCHG

CA

CB

BH AB

BF

AA

0.6 gpm2 L/min

BG BE

AD BA

AE AC

BD

AJ

BI

AZ

AG

BB

AFAM

BG

AR

AU

AV

AL

AP

AO

AS

AN

AT

AQ

P2

2200 psi151.7 bar

P1

AI

AW

AH

AK

AYAX


1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 147



79

BC

A A

C C

F F

EE

7

7

2

7 2

x

x xx xx

REARRIGHT

REARLEFT

M1

T1

T

M2

LEFTFRONT

M3

50%

.070

50%

M7

M5

67%

210 psi14.5 bar

.070

33%

TEST BA

68 3 1

M4

50%

50%

FRONTRIGHT

M8

M6

2 54

E

3625 psi249.9 bar

3 psi 3 psi0.2 bar 0.2 bar

TEST

A

B

TEST315 psi21.7 bar

50 psi3.4 bar

T2

CP

25 PSI

BRAKE

LS TEST

T1

PRESS

PL2PL1

PR2

.030

T2

PR1P2

2200 psi151.7 bar

P1

TANK

SW2

V1

SW1

1950 psi134.5 bar

V2

S1

RET

ST2ST1

PTESTAUX EXT

1.7M

2.0 gpm7.5 L/min

FLB FLR

2A 2B138A 6A6B8B 2C

0.1 gpm0.3 L/min

54

FRBFRR

950 psi65.5 bar

A

B

OUT

IN

TEST.052

4.5 gpm17 L/min

0.6 gpm

2.27 L/min

AUX

T2

TANK

PRESS

T1

6C8C

RESERVOIR


BRAKE MANIFOLD

DRIVE PUMP

PUMPFUNCTION

RETURNFILTER

MANIFOLDTRACTION

SLAVE

MASTER

3 gpm11.4 L/min

TURNTABLEROTATE2 gpm7.6 L/min

EXTEND RETRACT CYL4 gpm15.1 L/min

FUNCTION

MANIFOLDPUMPAUXILIARY




STEERINGRIGHT LEFT

OSCILLATE VALVE

OSCILLATE CYLINDERS

LEFT RIGHT

2400 psi165.5 bar

OPTIONAL

MANIFOLDGENERATOR

OPTIONALGENERATOR

FUNCTIONMANIFOLD


FUNCTIONPUMP


D

E

C

B

A

F

3300 PSI

3:1

3:1

3500 PSI


3:1

3:1

3:1

RATIO

1000 PSI

3000 PSI

2000 PSI

PRESS

5:1 3500 PSI

G G

G 1.5:1 3000 PSI

C

V2

PR2

PR1

V1J1

J2

PLATFORMROTATE

S45 JIB BOOM

MANIFOLDJIB SELECT

C

D

D

ABBH

BF

0.8 gpm3 L/min

AA

BG BE

AD BA

ACAE

BD

AJ

AI

AX AY

AH

AK

AW

AZ

AG

BB

AFAM

AV

AL

AU

AR

BG

AT

AN

AQ

2900 psi200 bar

AS

AO

.025

DA

DB

HD

AP

BI

HE

HH

HI

HF

HC

HA

HB HG

CC

CA

CB



6 - 148


6 - 147


6 - 149

2WD Hydraulic Schematic (from serial number 7569)

6 - 150

1

2

3

4

5

6

7

8



6 - 150 S-40 • S-45 Part No. 102521



RESERVOIR

6 8 3 1


2 54

DRIVE PUMP

E

3625 psi

249.9 bar

3 psi

0.20 bar

PUMPFUNCTION

79

TEST

A

B

TEST315 psi

21.7 bar

50 psi

3.5 bar

RETURNFILTER

LS TEST

T1

PRESS

PL2PL1

PR2

PLATFORM

SLAVE

MASTER

V2

ROTATE

PR2

PR1

T2

PR1P2

2200 psi

151.6 bar

P1

TANK

SW2

V1

SW1

1950 psi

134.5 bar

V2

S1

RET

V1(3 gpm / 11.3 L/min)

J1

J2

S45 JIB BOOMTURNTABLE

ROTATE(2 gpm / 7.5 L/min)

ST2ST1

PTESTAUX EXT

EXTEND RETRACT CYLINDER(4 gpm / 15.1 L/min)

3300 PSI3:1D

E 3:1 3500 PSI


3:1

C

B

3:1

3:1

RATIO1000 PSI

3000 PSI

2000 PSI

PRESS

1.7M

2.0 gpm

7.5 L/m

MANIFOLDJIB SELECT

FUNCTIONMANIFOLD

FLB FLR

2A 2B138B 6A6C 8A 2C

0.1 gpm

0.3 L/min

PUMPAUXILIARY

54



PRIMARY LIFT

CYLINDER

STEERINGRIGHT LEFT

A

F 5:1 3500 PSI

FRBFRR

OSCILLATE VALVE

950 psi

65.5 bar

OSCILLATE CYLINDERS

LEFT RIGHT

A

B

OUTIN

TEST

7

7

2

4.5 gpm

17 L/m

0.6 gpm

2.2 L/min

2400 psi

165.4 bar

OPTIONALGENERATOR

AUX

T2

TANK

PRESS

T1

FUNCTIONMANIFOLD


FUNCTION7PUMP 2


8C 6B

L

R

1.5:1 3000 PSI

A

B

B

A

TRACTIONMANIFOLD

A BTEST

280 psi

19.3 bar

CDR

M2

M4

50%

50%

M1

TCDL

M3LEFTREAR

RIGHTREAR

.025

BRAKE 2SPEED

CPT2

MANIFOLD

BRAKE/2 SPEED

X X

OSCILLATE CYLINDERS OPTION

XXXXX

3 psi

0.20 bar

G G

25 psi

1.7 bar

BC

AA

.030

C C

F F

EE

C

C

D

D

2400 psi

165.4 bar

G

OPTIONAL

MANIFOLDGENERATOR

.070

EA

ED

EB EC

BH AB

BF

AA

BC BE

AD BA

AE AC

BD

AJ

AW

AK

AH

AI

AZ

AG

AM

BB

AF

AU

AV

AL

AR

BG

AS

AO

AN

2900 psi

200 bar

(S-45)

2600 psi

179 bar

(S-40)

AT

AQ

0.8 gpm

3 L/min

(S-45)

0.6 gpm

2 L/min

(S-40)

CC

CA

CB

GAGC

GE

GB

GF

GD

AP

BI

AX AY

0.030

.030 orifice added after serial number 8445

removed at serial number 16791

T

PMP

TO OC

PORT ON

SIDE OF MOTOR

F

P

CD (PORT ON

TOP OF MOTOR)

RELIEF VALVE

SET @ 2700 PSI

MTE HYDRAULIC GENERATOR OPTION

from serial number 16453

HYDRAULIC GENERATOR OPTION

OILCOOLER

TO

OC

PUMPFUNCTION

FUNCTIONMANIFOLD

HYDRAULIC GENERATOR

OPTION

to serial number 16452

Valve BD changed

to 0.2 gpm at

serial number 16791

Valve AA changed

to 0.4 gpm at

serial number 16791

S45 valve AA changed to

0.6 gpm at serial number 18302

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 151


4WD Hydraulic Schematic(from serial number 7569)


RESERVOIR

6 8 3 1


2 54

DRIVE PUMP

EPUMPFUNCTION79

TEST

A

B

TEST

RETURNFILTER

LS TEST

T1

PRESS

PL2PL1

PR2

PLATFORM

SLAVE

MASTER

V2

ROTATE

PR2

PR1

T2

PR1P2P1

TANK

SW2

V1

SW1

V2

S1

RET

V1

J1

J2

S45 JIB BOOM

ST2ST1

PTESTAUX EXT

2900 psi

200 bar

(S-45)

1.7M

2.0 gpm

7.5 L/min

MANIFOLDJIB SELECT

FUNCTIONMANIFOLD

FLB FLR

2A 2B138B 6A6C 8A 2C

0.8 gpm

3 L/min

(S-45)

0.1 gpm

0.3 L/min

PUMPAUXILIARY

54



STEERINGRIGHT LEFT

FRBFRR

OSCILLATE VALVE

OSCILLATE CYLINDERS

LEFT RIGHT

A

B

OUT

IN

TEST

7

7

2

4.5 gpm

17 L/min

0.6 gpm

2.2 L/min


8C 6B

L

R

B

A

B

A

B

A

B

A

TRACTIONMANIFOLD

M6

M8RIGHTFRONT

M4

A BTEST

50%50%

CDR

M5

M7

M3

FRONTLEFTM2

T

CDL

M1LEFTREAR

RIGHTREAR

BRAKE 2SPEED

CP

T2

MANIFOLDBRAKE/2 SPEED

X X

OSCILLATE CYLINDERS OPTION

(3 gpm / 11.3 L/min)


TURNTABLEROTATE(2 gpm / 7.5 L/min)

.025

50 psi

3.5 bar

1950 psi

134.5 bar

AA

C C

2200 psi

151.6 barEE

C

C

3300 PSI3:1D

E 3:1 3500 PSI


3:1

C

B

3:1

3:1

RATIO1000 PSI

3000 PSI

2000 PSI

PRESS

A

F 5:1 3500 PSI

1.5:1 3000 PSIG

50%

50%

.040

.040 50%

50%

.040280 psi

19.3 bar

950 psi

65.5 bar

G G

FF

D

D

25 psi

1.7 bar

3 psi

0.20 bar3 psi

0.20 bar

3625 psi

249.9 bar

315 psi

21.7 bar

BC

EXTEND RETRACT CYLINDER(4 gpm / 15.1 L/min)

0.6 gpm

2 L/min

(S-40)

AA

AC

AJ

2600 psi

179 bar

(S-40)

BA

BC

BD

BF

BH

AK

ADAI

AHAG

AL

AM

AN

AO

AQ

AR

AS

AT

AU

AV

AZ

BB

BE

BG

AW

JA

JD

JE

JGJN

JH

JB

JI

JM

EA

ED

EB

JL

AE

AF

AB

JC

JK

JJJF

ECCC

CA

CB

AP

BI

AX AY

0.030

.030 orifice added after serial number 8445

removed at serial number 16791

2400 psi

165.4 bar

OPTIONALGENERATOR

AUX

T2

TANK

PRESS

T1

FUNCTIONMANIFOLD


FUNCTION7PUMP 2

2400 psi

165.4 barOPTIONAL

MANIFOLDGENERATOR

T

PMP

TO OC

PORT ON

SIDE OF MOTOR

F

P

CD (PORT ON

TOP OF MOTOR)

RELIEF VALVE

SET @ 2700 PSI

MTE HYDRAULIC GENERATOR OPTION

from serial number 16453

HYDRAULIC GENERATOR OPTION

OILCOOLER

TO

OC

PUMPFUNCTION

FUNCTIONMANIFOLD

HYDRAULIC GENERATOR

OPTION

to serial number 16452

Valve BD changed

to 0.2 gpm at

serial number 16791

Valve AA changed

to 0.4 gpm at

serial number 16791

S45 valve AA changed to

0.6 gpm at serial number 18302


6 - 152


6 - 151

1

2

3

4

5

6

7

8


Part No. 102521 S-40 • S-45 6 - 153


Generator Hydraulic Schematic- Welder Option


AH

AI

AM

AJ AK

AN

AL

TANK

13

Ø.031

13

A

B

HYDRAULIC WELDER OPTION

MANIFOLD

21

GP

M

G2 G1

12.5 KW GENERATOR

MTR B

G2 3.5 GPM

270 PSI @

MTR A

G1

CO

UP

LE

R

RO

TA

RY

HY

DR

AU

LIC

PMP B

WELDER

COOLER

OIL

CLR

3.5 GPM

PMP A

NO PRESS SW200 PSI

21CC

DRIVEPUMP


6 - 154

Generator Hydraulic Schematic- Welder Option

6 - 153

Dis

trib

ute

d B

y:

Genie North AmericaPhone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

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Fax +61 7 3375 1002

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Fax +86 21 53852569

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Fax +81 3 5445 1231

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Fax +33 2 37 26 09 98

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Phone +49 4221 491 810

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Fax +44 1476 584334

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Fax +52 55 5666 3241

California Proposition 65

WarningThe exhaust from this product

contains chemicals known to

the State of California to

cause cancer, birth defects

or other reproductive harm.

Se

rvic

e M

an

ua

lS

-40

• S

-45

Rev E

Part No.102521

(from

se

rial n

um

be

r S40-7

001)

102521 rev c - manuals - genie liftmanuals.gogenielift.com/parts and service...

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