Professional Documents
Culture Documents
S-40
S-45
TM
from S40-7001
TM
Introduction
July 2009
Important
Title
Part No.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are
subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
http://www.genieindustries.com
e-mail: awp.techpub@terex.com
ii
S-40 S-45
July 2009
INTRODUCTION
Model: S-40
S4006-12345
Serial number:
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: ES0274
Machine unladen weight:
S40 06 - 12345
Sequence
number
Model
Model year
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
Sequence number
(stamped on chassis)
Serial label
(located under cover)
PN - 77055
S-40 S-45
iii
July 2007
iv
S-40 S-45
July 2007
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-40 and S-45
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
S-40 S-45
July 2007
SAFETY RULES
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable
and combustible materials like battery
gases and engine fuels. Always have an approved
fire extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
vi
S-40 S-45
July 2009
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................. iv
Section 1
Safety Rules
General Safety Rules .................................................................................................. v
Section 2
Rev
E
Specifications
Machine Specifications .......................................................................................... 2 - 1
Hydraulic Oil Specifications ................................................................................... 2 - 2
Manifold Component Specifications ....................................................................... 2 - 5
Valve Coil Resistance Specifications ..................................................................... 2 - 5
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7
Deutz F3L-1011F Engine Specifications ................................................................ 2 - 8
Deutz F3L-2011/Deutz D2011L03i Engine Specifications ....................................... 2 - 9
Perkins 704-30 Engine Specifications .................................................................. 2 - 10
Perkins 404-22 Engine Specifications .................................................................. 2 - 11
Machine Torque Specifications ............................................................................ 2 - 12
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 13
SAE and Metric Fastener Torque Chart ............................................................... 2 - 14
Section 3
Rev
Checklist A Procedures
A-1
A-2
A-3
A-4
S-40 S-45
vii
July 2009
TABLE OF CONTENTS
Section 3
Rev
A-6
A-7
A-8
A-9
A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13
A-11 Perform Engine Maintenance - Deutz 1011F Models .................................. 3 - 14
A-12 Replace the Drive Hub Oil .......................................................................... 3 - 14
A-13 Perform Engine Maintenance - Ford Models ............................................... 3 - 15
D
Checklist B Procedures
B-1
B-2
B-3
B-4
B-5
B-6
B-7
Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 21
B-8
B-9
Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 23
viii
S-40 S-45
July 2009
TABLE OF CONTENTS
Section 3
Rev
Checklist C Procedures
C-1
C-2
C-3
C-4
Replace the Engine Air Filter - Deutz and Perkins Models .......................... 3 - 39
C-5
C-6
Checklist D Procedures
D-1
D-2
D-3
D-4
D-5
D-6
D-7
Checklist E Procedures
E-1
E-2
E-3
E-4
E-5
S-40 S-45
ix
July 2009
TABLE OF CONTENTS
Section 3
Section 4
Rev
E-6
E-7
E-8
E-9
Repair Procedures
Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1
1-2
Joysticks ..................................................................................................... 4 - 3
Platform Components
2-1
2-2
2-3
3-2
Boom Components
4-1
4-2
Boom ......................................................................................................... 4 - 18
4-3
4-4
4-5
Engines
5-1
5-2
5-3
5-4
S-40 S-45
July 2009
TABLE OF CONTENTS
Section 4
Rev
A
6-2
Manifolds
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
7-9
Axle Components
9-1
Generators
10-1 Valve Adjustments - Hydraulic Generator .................................................. 4 - 57
S-40 S-45
xi
July 2009
TABLE OF CONTENTS
Section 5
Rev
Fault Codes
Introduction ............................................................................................................ 5 - 1
Section 6
Rev
Schematics
Introduction ............................................................................................................ 6 - 1
xii
Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models
(from serial number 7544 to 12509)
Perkins 404-22 Models
(from serial number7472 to 12509) ............................................................. 6 - 28
S-40 S-45
July 2009
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models (after serial number 12509) .................................... 6 - 32
Electrical Schematic,
Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 44
Electrical Schematic,
Ford LRG-425 EFI Models
(from serial number 7597 to 11066) ............................................................ 6 - 54
S-40 S-45
xiii
July 2009
TABLE OF CONTENTS
Section 6
xiv
Rev
Schematics, continued
S-40 S-45
July 2009
Section 2 Specifications
Specifications
REV E
Machine Specifications
S-40 and S-45 Models
Fluid capacities
12.5L-16SL
12-16.5 NHS
Tire size,
2WDRT & 4WD front & rear
12-16.5 NHS
12
88 sq in
568 sq cm
57 sq in
368 sq cm
33.7 in
85.6 cm
33.2 in
84.3 cm
45 psi
3.1 bar
45 psi
3.1 bar
Wheel diameter
16 in
40.6 cm
161/2 in
41.9 cm
Wheel width
10 in
25.4 cm
9 3/4 in
24.8 cm
8@ 5/8 -18
9@ 5/8 -18
Tire pressure
Wheel lugs
Lug nut torque, dry
Lug nut torque, lubricated
Fuel tank
20 gallons
75.7 liters
30 gallons
114 liters
LPG tank
33.5 pounds
15.2 kg
Hydraulic tank
45 gallons
170 liters
Hydraulic system
(including tank)
55 gallons
208 liters
Drive hub
(before serial number 7569)
17 fl oz
0.5 liters
Drive hub
(after serial number 7568)
24 fl oz
0.71 liters
Turntable rotation
drive hub
8 fl oz
0.24 liters
S-40 S-45
2-1
Section 2 Specifications
July 2009
SPECIFICATIONS
REV E
Performance Specifications
All Models
40 ft / 40 - 45 sec
12.2 m / 40 - 45 sec
See Operator's Manual
40 to 60 seconds
Boom down
50 to 80 seconds
Boom extend
30 to 60 seconds
Boom retract
15 to 35 seconds
70 to 100 seconds
25 to 50 seconds
15 to 35 seconds
35 to 45 seconds
20 to 30 seconds
15/13
200 ppm
Fire resistant
6 to 12 seconds
Platform level up
Mineral based
3 to 4 ft
0.9 to 1.2 m
2-2
S-40 S-45
July 2009
Section 2 Specifications
REV E
SPECIFICATIONS
Hydraulic Component
Specifications
Drive pump
Type:
bi-directional,
variable displacement piston pump
0 to 28 gpm
106 L/min
3625 psi
250 bar
Charge pump
Type:
Displacement
Flow rate @ 2500 rpm
Charge pressure @ 2500 rpm
Neutral position
gerotor pump
0.85 cu in
13.9 cc
9 gpm
34.1 L/min
310 psi
21.4 bar
Function pump
Type
Displacement
Flow rate @ 2500 rpm
Oscillation pump
Type
Displacement
Flow rate @ 2500 rpm
S-40 S-45
2-3
Section 2 Specifications
July 2009
SPECIFICATIONS
REV E
Auxiliary pump
0.151 cu in
2.47 cc
1.75 gallons per minute
6.62 liters per minute
Function manifold
Function relief valve pressure
S-40
S-45
1.52 cu in / 25 cc
2.13 cu in / 35 cc
0.99 cu in / 16.3 cc
Boom down
relief valve pressure
2200 psi
152 bar
1.83 cu in / 30 cc
Boom extend
1950 psi
134 bar
Hydraulic Filters
Oscillate axle
950 psi
66 bar
Steer regulator,
All models
Beta 3 200
51 psi
3.5 bar
10 micron with
25 psi / 1.7 bar bypass
210 psi
14.5 bar
280 psi
19.3 bar
2-4
S-40 S-45
July 2009
Section 2 Specifications
REV E
SPECIFICATIONS
Manifold Component
Specifications
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
SAE No. 8
38 ft-lbs / 51.5 Nm
SAE No. 10
41 ft-lbs / 55.6 Nm
Description
SAE No. 12
56 ft-lbs / 75.9 Nm
6.3
6.3
6.3
6.3
Specification
6.8
3.3
4.8
S-40 S-45
2-5
Section 2 Specifications
July 2009
SPECIFICATIONS
REV E
Displacement
Number of cylinders
3.78 x 3.4 in
96.01 x 86.36 mm
Starter motor
Normal engine cranking speed
Current draw, normal load
Current draw, maximum load
Current draw, no load
70 @ 2500 rpm
60 @ 2500 rpm
52 kW @ 2500 rpm
44.7 kW @ 2500 rpm
1-3-4-2
1600 rpm
396.8 Hz
2500 rpm
620 Hz
9.4:1
Compression ratio
Compression pressure (approx.)
Pressure (psi) of lowest cylinder must be
at least 75% of highest cylinder
Valve clearances collapsed tappet
Oil pressure
(operating temp. @ 2000 rpm)
Oil capacity
(including filter)
Type
70A
Quantity
Cold cranking ampere
Reserve capacity @ 25A rate
1
1000A
200 minutes
64 psi
4.4 bar
0.58 gpm
2.18 L/min
0.035 to 0.055 in
0.889 to 1.397 mm
40 to 60 psi
2.75 to 4.1 bar
4.5 quarts
4.3 liters
Motorcraft AWSF-52-C
Motorcraft AGSF-32-FM
Engine coolant
Capacity
8-18 ft-lbs
11-24 Nm
3-5 psi
0.21-0.34 bar
11.5 quarts
10.9 liters
2-6
800A
Ignition System
Lubrication system
140-200A
Battery
Firing order
Torque
8-18 ft-lbs
11-24 Nm
230 F
112 C
Alternator
S-40 S-45
July 2009
Section 2 Specifications
REV E
SPECIFICATIONS
Displacement
Number of cylinders
Bore & stroke
Horsepower
Continuous horsepower
Peak horsepower
Continuous horsepower
Peak horsepower
64 psi
4.4 bar
0.43 gpm
1.6 L/min
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Ignition system
Spark plug type
Motorcraft AGSF-32-FEC
1-3-4-2
1600 rpm
53.3 Hz
Engine coolant
2500 rpm
83.3 Hz
Firing order
9.7:1
Compression ratio
Compression pressure (approx.)
Pressure (psi or bar) of lowest cylinder must be
at least 75% of highest cylinder
Capacity
Cylinder head temperature sending unit
Fault code set temperature
280F
138C
300F
149C
Lubrication system
Oil pressure
(at operating temperature @ 2500 rpm)
29 to 39 psi
2 to 2.7 bar
Starter motor
Normal engine cranking speed
Oil capacity
(including filter)
4 quarts
3.8 liters
10 quarts
9.5 liters
Alternator
Output
95A, 13.8V DC
Battery
Type
Quantity
1000A
200 minutes
S-40 S-45
2-7
Section 2 Specifications
July 2009
SPECIFICATIONS
REV E
Injection system
125 cu in
2.05 liters
Displacement
Horsepower
Firing order
18.5:1
Compression ratio
Compression pressure
4351 psi
300 bar
3626 psi
250 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.
Starter motor
Current draw, no load
1500 rpm
313 Hz
2300 rpm
479.9 Hz
centrifugal mechanical
Exhaust
0.020 in
0.5 mm
Lubrication system
Oil pressure
0.7480 in
19 mm
0.5 in
12.7 mm
12V, Group 31
Quantity
1000A
200 minutes
3 /8
26 to 87 psi
1.8 to 6.0 bar
Oil capacity
(including filter)
90A
Battery
Type
Intake
55A, 14V
Alternator output
Governor
OMAP
Number of cylinders
Bore and stroke
to 1/2 inch
9 to 12 mm
8.5 quarts
8 liters
5W-30
10W-40
15W-40
2-8
S-40 S-45
July 2009
Section 2 Specifications
REV E
SPECIFICATIONS
Lubrication system
Oil pressure, hot @ 2000 rpm
142 cu in
2.33 liters
Oil capacity
(including filter)
(Deutz F3L2011 Engine)
8.5 quarts
8 liters
Oil capacity
(including filter)
(Deutz D2011L03i Engine)
9.5 quarts
9 liters
Horsepower
Net
Net
Net
Net
intermittent
continuous
intermittent
continuous
Firing order
1-2-3
1500 rpm
313 Hz
2500 rpm
521.7 Hz
Compression ratio
Compression pressure
Governor
19:1
362 to 435 psi
25 to 30 bar
Torque
Oil pressure switch point
(Deutz F3L2011 Engine)
Intake
0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
8-18 ft-lbs
11-24 Nm
220 F
104 C
centrifugal mechanical
40-60 psi
2.8 to 4.1 bar
S-40 S-45
8-18 ft-lbs
11-24 Nm
7 psi
.5 bar
22 psi
1.5 bar
2-9
Section 2 Specifications
July 2009
SPECIFICATIONS
REV E
Bosch
15000 psi
1034 bar
3046 psi
210 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.
Starter motor
Current draw, normal load
140-200A
0.72 in
18.5 mm
0.27 in
7 mm
Battery
Type
12V, Group 31
Quantity
2 - 10
1000A
200 minutes
60A @ 14V DC
3 /8
to 1/2 inch
9 to 12 mm
S-40 S-45
July 2009
Section 2 Specifications
REV E
SPECIFICATIONS
17.5:1
1600 rpm
246.7 Hz
2200 rpm
339.2 Hz
centrifugal mechanical
10W-30
15W-40
Injection system
Injection pump make
Intake
0.014 in
0.35 mm
Exhaust
0.014 in
0.35 mm
Lubrication system
2755 psi
3336 psi
190 bar
230 bar
3626 psi
250 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.
Capacity
Alternator output
Type
41 psi
2.8 bar
7.3 quarts
8.3 liters
65A, 12V
12V, Group 31
Quantity
111/2 quarts
10.9 liters
Battery
Zexel PFR-KX
Engine coolant
Oil pressure
(at 2600 rpm)
5W-20
1-3-4-2
Compression pressure
Governor
S-40 S-45
1
1000A
200 minutes
3 /8
in
10 mm
2 - 11
Section 2 Specifications
July 2009
SPECIFICATIONS
REV E
Displacement
Number of cylinders
Horsepower
gross intermittent
continuous
gross intermittent
continuous
50 @ 2800 rpm
41 @ 2800 rpm
37.3 kW @ 2800 rpm
31 kW @ 2800 rpm
Torque
1-3-4-2
1300 rpm
200.5 Hz
1500 rpm
231.3 Hz
2500 rpm
385.5 Hz
426 psi
29.4 bar
centrifugal mechanical
Exhaust
Injection pressure
0.008 in
0.2 mm
0.008 in
0.2 mm
8-18 ft-lbs
11-24 Nm
221 F
105 C
Zexel
2133 psi
147 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's
Manual on your machine.
Battery
Type
22.4:1
Compression pressure
14.2 psi
1 bar
Firing order
Compression ratio
8-18 ft-lbs
11-24 Nm
Quantity
Cold cranking ampere
Reserve capacity @ 25A rate
12V, Group 31
1
1000A
200 minutes
Starter motor
Lubrication system
Current draw, normal load
Oil pressure, hot
(at 2000 rpm)
Oil capacity
(including filter)
2 - 12
40 to 60 psi
2.8 to 4.1 bar
9.4 quarts to 11.2 quarts
8.9 liters to 10.6 liters
Alternator output
Fan belt deflection
S-40 S-45
140-200A
65A @ 13.8V DC
3/8 to in
9 to 12 mm
July 2009
Section 2 Specifications
REV E
SPECIFICATIONS
640 ft-lbs
868 Nm
480 ft-lbs
651 Nm
3/8
35 ft-lbs*
47.5 Nm
210 ft-lbs
284 Nm
160 ft-lbs
217 Nm
210 ft-lbs
284 Nm
160 ft-lbs*
217 Nm
49 ft-lbs
66.4 Nm
37 ft-lbs
50 Nm
Turntable bearing
Turntable bearing mounting bolts, lubricated 180 ft-lbs
244 Nm
S-40 S-45
2 - 13
Section 2 Specifications
July 2009
SPECIFICATIONS
REV E
Seal-Lok fittings
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
-20
-24
(hose end)
Torque
Torque
-4
15 ft-lbs / 20.3 Nm
-4
18 ft-lbs / 24.4 Nm
-6
35 ft-lbs / 47.5 Nm
-6
30 ft-lbs / 40.7 Nm
-8
60 ft-lbs / 81.3 Nm
-8
40 ft-lbs / 54.2 Nm
-10
-10
60 ft-lbs / 81.3 Nm
-12
-12
85 ft-lbs / 115 Nm
-16
-16
-20
-20
-24
-24
2 - 14
S-40 S-45
July 2009
Section 2 Specifications
REV E
SPECIFICATIONS
Grade 5
SIZE THREAD
LUBED
20
28
1/4
DRY
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
80
90
9
10.1
100
120
11.3
13.5
110
120
12.4
13.5
140
160
15.8
18
130
140
14.7
15.8
LUBED
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
Grade 8
DRY
LUBED
DRY
LUBED
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
Class 4.6
Size
(mm)
5
6
7
LUBED
LUBED
DRY
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
S-40 S-45
2 - 15
July 2007
Symbols Legend
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
S-40 S-45
3-1
July 2007
Checklist
A
A+B
A+B+C
A+B+C+D
A+B+C+D+E
3-2
S-40 S-45
Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals
Instructions
Pre-Delivery Preparation
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
(425) 881-1800
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
July 2007
3-4
S-40 S-45
Checklist A - Rev C
Y N R
Checklist B - Rev D
B-1 Battery
A-2 Pre-operation
inspection
Hour meter
Machine owner
Inspected by (print)
Serial number
Date
Inspector signature
Inspector title
Inspector company
Instructions
Make copies of this report to use for
each inspection.
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
A
A+B
Y N R
Comments
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
S-40 S-45
3-5
July 2007
Model
Checklist C - Rev B
Serial number
Date
Hour meter
Machine owner
Inspector signature
Inspector company
Instructions
Make copies of both pages to use for
each inspection.
Checklist D - Rev B
D-3 Free-wheel
configuration
Daily or 8 hour
Inspection:
A
A+B
Y N R
Inspector title
Checklist E - Rev B
E-1 Hydraulic oil
Inspected by (print)
Y N R
Comments
3-6
S-40 S-45
July 2007
REV C
Checklist A Procedures
A-1
Inspect the Manuals and Decals
Genie specifications require that this procedure be
performed daily.
Maintaining the operators and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
S-40 S-45
3-7
CHECKLIST A
July 2007
PROCEDURES
REV C
A-2
Perform Pre-operation Inspection
A-3
Perform Function Tests
3-8
S-40 S-45
July 2007
REV C
CHECKLIST A
Perkins models
A-4
Perform Engine Maintenance
52883
84794
94890
Ford models
PROCEDURES
84792
119488
S-40 S-45
3-9
CHECKLIST A
PROCEDURES
REV C
A-5
Perform 30 Day Service
A-6
Perform Engine Maintenance Deutz and Ford Models
A-10
B-8
B-9
D-2
D-6
3 - 10
July 2007
52883
84794
S-40 S-45
July 2007
REV C
CHECKLIST A
Ford models
Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).
Ford LRG 425 EFI Operation Manual
Genie part number
Ford DSG 423 EFI Operator Handbook
Genie part number
PROCEDURES
A-7
Perform Engine Maintenance Perkins Models
119488
94890
S-40 S-45
3 - 11
CHECKLIST A
July 2007
PROCEDURES
REV C
A-8
Inspect the Fuel Filter/Water
Separator - Deutz Models
a
a
b
fuel filter
drain plug
3 - 12
S-40 S-45
July 2007
REV C
CHECKLIST A
PROCEDURES
A-9
Perform Engine Maintenance Ford Models
A-10
Grease the Turntable Rotation
Bearing and Rotate Gear
84792
119488
Grease specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
S-40 S-45
3 - 13
CHECKLIST A
July 2007
PROCEDURES
REV C
A-11
Perform Engine Maintenance Deutz 1011F Models
A-12
Replace the Drive Hub Oil
52883
3 - 14
S-40 S-45
July 2007
REV C
CHECKLIST A
PROCEDURES
A-13
Perform Engine Maintenance Ford Models
84792
119488
S-40 S-45
3 - 15
CHECKLIST A
September
July 2007
PROCEDURES
3 - 16
S-40 S-45
September 2007
Checklist B Procedures
REV D
B-1
Inspect the Battery
S-40 S-45
3 - 17
CHECKLIST B
September 2007
PROCEDURES
REV D
B-2
Inspect the Electrical Wiring
Level sensor
3 - 18
S-40 S-45
September 2007
REV D
CHECKLIST B PROCEDURES
B-3
Inspect the Air Filter
a
b
c
clamp
canister end cap
dust discharge valve
S-40 S-45
3 - 19
CHECKLIST B
September 2007
PROCEDURES
REV D
B-4
Test the Key Switch
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
a hazardous operating situation.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to ground control, start the
engine and then turn the key switch to platform
control.
3 Check all machine function from the ground
controls.
Result: All machine functions should not
operate.
B-5
Perform Engine Maintenance Deutz and Perkins Models
52883
Perkins models
94890
3 - 20
S-40 S-45
September 2007
REV D
CHECKLIST B
B-6
Check the Exhaust System
B-7
Check the Oil Cooler and Cooling
Fins - Deutz Models
PROCEDURES
S-40 S-45
3 - 21
CHECKLIST B
September 2007
PROCEDURES
REV D
B-8
Inspect the Tires, Wheels
and Lug Nut Torque
a
b
c
oil cooler
cylinder head cooling fins
fan blower fins
3 - 22
S-40 S-45
September 2007
REV D
CHECKLIST B
PROCEDURES
B-9
Check the Drive Hub Oil Level
and Fastener Torque
S-40 S-45
3 - 23
CHECKLIST B
September 2007
PROCEDURES
REV D
B-10
Confirm the Proper
Brake Configuration
a
b
c
d
drive pump
screwdriver
lift pump
free-wheel valve
3 - 24
S-40 S-45
September 2007
REV D
CHECKLIST B
PROCEDURES
B-11
Check and Adjust the
Engine RPM
f
e
a
b
c
d
e
f
solenoid boot
high idle adjustment nut
yoke lock nut
yoke
low idle adjustment screw
low idle lock nut
S-40 S-45
3 - 25
CHECKLIST B
September 2007
PROCEDURES
REV D
B-12
Test the Engine Idle Select
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
A properly operating engine idle select switch
is essential to good engine performance and safe
machine operation. There are two settings.
Foot switch activated low idle (turtle symbol)
allows the operator to control individual boom
functions.
Foot switch activated high idle (rabbit symbol)
should be used for normal machine operation. This
selection activates high idle only when the foot
switch is pressed down.
solenoid boot
high idle adjustment nut
clevis
low idle lock nut and adjustment
screw
3 - 26
S-40 S-45
September 2007
REV D
CHECKLIST B
B-13
Test the Fuel Select Operation Ford Models
PROCEDURES
S-40 S-45
3 - 27
CHECKLIST B
PROCEDURES
REV D
B-14
Test the Ground Control Override
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
A properly functioning ground control override is
essential to safe machine operation. The ground
control override function is intended to allow
ground personnel to operate the machine from the
ground controls whether or not the red Emergency
Stop button on the platform controls is in the on or
off position. This function is particularly useful if the
operator at the platform controls cannot return the
boom to the stowed position.
1 Push in the platform red Emergency Stop
button to the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boom
function through a partial cycle.
Result: All boom functions should operate.
3 - 28
September 2007
B-15
Check the Directional Valve
Linkage
S-40 S-45
September 2007
REV D
CHECKLIST B
PROCEDURES
B-16
Test the Platform Self-leveling
B-17
Test the Drive Brakes
S-40 S-45
3 - 29
CHECKLIST B
September 2007
PROCEDURES
REV D
B-18
Test the Drive Speed Stowed Position
B-19
Test the Drive Speed Raised or Extended Position
3 - 30
S-40 S-45
September 2007
REV D
CHECKLIST B
PROCEDURES
B-20
Perform Hydraulic Oil Analysis
S-40 S-45
3 - 31
CHECKLIST B
September 2007
PROCEDURES
REV D
B-21
Test the Alarm Package
(if equipped) and the
Descent Alarm
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
The alarm package includes:
Travel alarm
Flashing beacons
3 - 32
S-40 S-45
September 2007
REV D
CHECKLIST B
PROCEDURES
B-22
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
S-40 S-45
3 - 33
CHECKLIST B
PROCEDURES
September 2007
REV D
B-23
Perform Engine Maintenance Ford Models
84792
119488
3 - 34
S-40 S-45
September
July
2007 2007
REV B
Checklist C Procedures
Perkins models
C-1
Perform Engine Maintenance Deutz and Perkins Models
52883
84794
94890
S-40 S-45
3 - 35
CHECKLIST
July 2007
PROCEDURES
REVB
C-2
Grease the Platform Overload
Mechanism (if equipped)
C-3
Test the Platform Overload
System (if equipped)
Grease type
3 - 36
S-40 S-45
July 2007
REV B
CHECKLIST
C PROCEDURES
Illustration 1
S-40 S-45
3 - 37
CHECKLIST
July 2007
PROCEDURES
REV B
3 - 38
S-40 S-45
July 2007
REV B
CHECKLIST
C-4
Replace the Engine Air Filter
Element - Deutz and Perkins
Models
C-5
Replace the In-line Fuel Strainer Deutz Models
C PROCEDURES
S-40 S-45
3 - 39
CHECKLIST
PROCEDURES
July 2007
REV B
C-6
Perform Engine Maintenance Ford Models
84792
119488
3 - 40
S-40 S-45
July 2007
REV B
Checklist D Procedures
D-1
Check the Boom Wear Pads
Wear pad
specifications
all wear pads
Minimum
9/16
inch
14.3 mm
S-40 S-45
3 - 41
CHECKLIST
July 2007
PROCEDURES
REV B
D-2
10
15
13
19
18
12
11
17
20
5
8
14
16
3 - 42
S-40 S-45
July 2007
REV B
CHECKLIST
D PROCEDURES
D-3
Check the Free-wheel
Configuration
15
13
19
18
12
11
17
20
5
8
14
16
engaged position
S-40 S-45
3 - 43
CHECKLIST
July 2007
REV B
PROCEDURES
All Models:
b
c
a
b
c
d
drive pump
screwdriver
lift pump
free-wheel valve
3 - 44
S-40 S-45
July 2007
REV B
CHECKLIST
D PROCEDURES
D-4
Replace the Drive Hub Oil
S-40 S-45
3 - 45
CHECKLIST
July 2007
PROCEDURES
REV B
D-5
Perform Engine Maintenance Deutz and Perkins Models
52883
84794
Perkins models
Required maintenance procedures and additional
engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).
Perkins 404C-22 Operation Manual
Genie part number
94890
3 - 46
S-40 S-45
July 2007
CHECKLIST
REV B
D PROCEDURES
D-6
Replace the Hydraulic Filter
Elements
S-40 S-45
3 - 47
CHECKLIST
July 2007
REV B
PROCEDURES
D-7
Inspect for Turntable Bearing
Wear
3 - 48
a
b
c
d
turntable
dial indicator
drive chassis
turntable rotation bearing
S-40 S-45
July 2007
REV B
CHECKLIST
D PROCEDURES
S-40 S-45
3 - 49
July 2007
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
REV B
open
closed
3 - 50
S-40 S-45
July 2007
REV B
CHECKLIST E
PROCEDURES
S-40 S-45
3 - 51
CHECKLIST E
July 2007
PROCEDURES
REV B
E-2
Grease the Steer Axle
Wheel Bearings, 2WD Models
3 - 52
S-40 S-45
July 2007
REV B
CHECKLIST E
PROCEDURES
E-3
Perform Engine Maintenance Deutz and Perkins Models
52883
Perkins models
Required maintenance procedures and additional
engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).
Perkins 404C-22 Operation Manual
Genie part number
94890
S-40 S-45
3 - 53
CHECKLIST E
July 2007
REV B
PROCEDURES
E-4
Perform Engine Maintenance Ford Models
E-5
Perform Engine Maintenance Deutz and Perkins Models
84792
119488
52883
84794
3 - 54
S-40 S-45
July 2007
REV B
CHECKLIST E
Perkins models
Required maintenance procedures and additional
engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).
Perkins 404C-22 Operation Manual
Genie part number
94890
PROCEDURES
E-6
Perform Engine Maintenance Deutz and Perkins Models
52883
84794
S-40 S-45
3 - 55
CHECKLIST E
July 2007
PROCEDURES
REV B
E-7
Perform Engine Maintenance Deutz Models
E-8
Perform Engine Maintenance Deutz Models
52883
52883
84794
84794
3 - 56
S-40 S-45
July 2007
REV B
CHECKLIST E
PROCEDURES
E-9
Perform Engine Maintenance Ford Models
84792
119488
S-40 S-45
3 - 57
CHECKLIST E
July 2007
PROCEDURES
3 - 58
S-40 S-45
April 2009
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Wheels chocked
S-40 S-45
4-1
April 2009
Platform Controls
REV D
1-1
ALC-500 Circuit Board
d
a
b
c
d
4-2
S-40 S-45
April 2009
PLATFORM CONTROLS
REV D
1-2
Joysticks
S-40 S-45
4-3
April 2009
PLATFORM CONTROLS
REV D
4-4
S-40 S-45
April 2009
PLATFORM CONTROLS
REV D
3 second
1 seconds
Turntable rotate
accelerate
decelerate
2 seconds
1 second
Drive
accelerate
decelerate to neutral
decelerate, change of direction
decelerate, coasting
decelerate, braking
decelerate, shift from low to high speed
decelerate, shift from high to low speed
S-40 S-45
2 seconds
0.5 second
0.5 second
0.75 second
1 second
1 second
3 seconds
4-5
April 2009
PLATFORM CONTROLS
REV D
4-6
S-40 S-45
July 2007
Platform Components
REV B
2-1
Platform Leveling Slave Cylinder
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.
S-40 Models:
5 Tag, disconnect and plug the hydraulic hoses
from the slave cylinder at the union located
near the platform rotate counterbalance valve
manifold and connect them together using a
connector. Cap the fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
S-45 Models:
S-40 S-45
4-7
July 2007
PLATFORM COMPONENTS
REV B
S-40 Models:
2-2
Platform Rotator
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
160 degrees.
S-45 Models:
3 Tag and disconnect the hydraulic hoses from
the "V1" and "V2" ports on the counterbalance
valve manifold located on the platform rotator
and connect them together using a connector.
Cap the fittings on the manifold.
4 Support the platform leveling arms and platform
mounting weldment with an appropriate lifting
device, but do not apply any lifting pressure.
All Models:
5 Remove the six mounting bolts from the
platform mounting weldment. Remove the
center bolt and slide the platform mounting
weldment off of the platform rotator.
Crushing hazard. The platform
mounting weldment could become
unbalanced and fall if it is not
properly supported.
4-8
S-40 S-45
July 2007
REV B
PLATFORM COMPONENTS
d
a
b
c
d
S-40 S-45
4-9
July 2007
PLATFORM COMPONENTS
REV B
2-3
Platform Overload System
4 - 10
S-40 S-45
July 2007
REV B
PLATFORM COMPONENTS
S-40 S-45
4 - 11
July 2007
REV B
PLATFORM COMPONENTS
4 - 12
S-40 S-45
July 2007
PLATFORM COMPONENTS
S-40 S-45
4 - 13
July 2007
REV A
3-1
Jib Boom
4 - 14
S-40 S-45
July 2007
REV A
3-2
Jib Boom Lift Cylinder
How to Remove the Jib Boom
Lift Cylinder
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Then
lower the jib boom until the platform is resting
on the blocks just enough to support the
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
S-40 S-45
4 - 15
July 2007
Boom Components
4-1
Cable Track
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses
that run through it. Removing the entire primary
boom cable track is only necessary when
performing major repairs that involve removing the
primary boom.
REV A
4 - 16
S-40 S-45
July 2007
REV A
BOOM COMPONENTS
S-40 S-45
4 - 17
July 2007
BOOM COMPONENTS
REV A
4-2
Boom
4 - 18
S-40 S-45
July 2007
REV A
S-40 S-45
4 - 19
July 2007
REV A
4 - 20
S-40 S-45
July 2007
REV A
BOOM COMPONENTS
4-3
Boom Lift Cylinder
S-40 S-45
4 - 21
July 2007
BOOM COMPONENTS
REV A
4-4
Extension Cylinder
4 - 22
S-40 S-45
July 2007
REV A
BOOM COMPONENTS
4-5
Platform Leveling
Master Cylinder
7 Remove the pin retaining fastener from the rodend pivot pin.
8 Use a soft metal drift to remove the pin.
9 Remove the master cylinder from the machine.
S-40 S-45
4 - 23
September 2007
Engines
REV D
5-1
RPM Adjustment - Deutz Models
5-3
Flex Plate
5-2
RPM Adjustment - Perkins
Models
Refer to Maintenance Procedure B-11, Check and
Adjust the Engine RPM.
f
a
b
c
d
e
f
pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
0.18 inch / 4.6 mm gap - Deutz Models
0.070 inch / 1.8 mm gap - Perkins Models
0.0625 inch / 1.6 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423
4 - 24
S-40 S-45
September 2007
ENGINES
REV D
S-40 S-45
4 - 25
September 2007
ENGINES
REV D
f
a
b
c
d
e
f
4 - 26
pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
0.18 inch / 4.6 mm gap - Deutz Models
0.070 inch / 1.8 mm gap - Perkins Models
0.0625 inch / 1.6 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423
S-40 S-45
September 2007
ENGINES
REV D
1
A
10
Deutz models:
Before serial number 7544: Torque the bell
housing mounting bolts in sequence to
28 ft-lbs / 38 Nm.
After serial number 7543: Torque the bell
housing mounting bolts in sequence to
47 ft-lbs / 63 Nm.
Perkins models
(after serial number 7471)
10
10
1
C
11
12 11
5
2
12
C
C
8
C
Perkins models
(before serial number 7472)
Perkins models:
Before serial number 7472: Torque the bell
housing mounting bolts in sequence to
28 ft-lbs / 38 Nm.
After serial number 7471: Torque the bell
housing mounting bolts labeled "B" in sequence
to 28 ft-lbs / 38 Nm and the mounting bolts
labeled "A" to 49 ft-lbs / 66 Nm. Then torque the
bell housing mounting bolts labeled "B" in
sequence to 40 ft-lbs / 54 Nm and the mounting
bolts labeled "A" to 70 ft-lbs / 95 Nm.
12
11
5
9
S-40 S-45
4 - 27
September 2007
ENGINES
REV D
5-4
Engine Fault Codes Ford Models
How to Retrieve Engine Fault
Codes
When an engine malfunction is detected by the
Electronic Control Module (ECM), a fault code is
recorded and the check engine light will turn on at
the ground controls. Special equipment is required
to retrieve fault codes stored within the ECM.
Contact Genie Industries Service Department for
assistance in retrieving fault codes.
Note: Perform this procedure with the key switch in
the off position.
1 Open the ground controls side cover and locate
the run/test toggle switch on the side of the
ground control box.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
4 - 28
S-40 S-45
July 2007
Hydraulic Pumps
REV A
6-1
Function Pump
How to Remove the
Function Pump
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Models with hydraulic tank shut-off valves:
Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.
open
closed
S-40 S-45
4 - 29
July 2007
HYDRAULIC PUMPS
REV A
6-2
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electro-proportional controller,
located on the pump. The only adjustment that can
be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized Eaton
Hydraulics center. Call Genie Industries Service
Department to locate your local authorized service
center.
open
4 - 30
closed
S-40 S-45
July 2007
REV A
HYDRAULIC PUMPS
S-40 S-45
4 - 31
October 2007
Manifolds
REV C
7-1
Function Manifold Components
The function manifold is located underneath the ground controls side turntable cover.
Index
No.
Description
Schematic
Item
Function
Torque
Solenoid valve, 2 position 3 way ....... AC ........ Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
Solenoid valve, 2 position 3 way ....... AE ......... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
7
8
Relief valve, 2200 psi / 152 bar ........ AI .......... Boom down relief .............................. 20-25 ft-lbs / 27-34 Nm
10
11
12
Relief valve, 1950 psi / 134 bar ........ AL ......... Extend cylinder relief ........................ 20-25 ft-lbs / 27-34 Nm
13
14
15
16
4 - 32
S-40 S-45
October 2007
MANIFOLDS
REV C
AA AB AC AD AE AF AG AH
9
AI
10
11
AJ AK
12
13
14
AM
AL
AN
AO 15
AP 16
17
AQ 18
AR 19
AS 20
AT 21
AU 22
AV 23
AW 24
AX 25
BI
36
BH
35
BG
34
BF
33
BE BD BC BB
32
31
30
29
AY
26
AZ
27
BA
28
S-40 S-45
4 - 33
October 2007
MANIFOLDS
REV C
Description
Schematic
Item
Function
Torque
18
Relief valve,
2900 psi / 200 bar ............................. AQ ........ System relief (S-45) .......................... 30-35 ft-lbs / 41-47 Nm
18
Relief valve,
2600 psi / 179 bar ............................. AQ ........ System relief (S-40) .......................... 30-35 ft-lbs / 41-47 Nm
19
20
21
Solenoid valve, 3 position 4 way ...... AT ......... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm
22
Solenoid valve, 2 position 3 way ...... AU ........ Boom extend .................................... 30-35 ft-lbs / 41-47 Nm
23
Solenoid valve, 2 position 3 way ...... AV ......... Boom retract ..................................... 30-35 ft-lbs / 41-47 Nm
24
Proportional solenoid valve .............. AW ........ Boom up/down circuit ....................... 20-25 ft-lbs / 27-34 Nm
25
Solenoid valve, 2 position 3 way ...... AX ......... Boom up ........................................... 30-35 ft-lbs / 41-47 Nm
26
Solenoid valve, 2 position 3 way ...... AY ......... Boom down ....................................... 30-35 ft-lbs / 41-47 Nm
27
Solenoid valve, 3 position 4 way ...... AZ ......... Turntable rotate ................................ 20-25 ft-lbs / 27-34 Nm
28
Check valve ....................................... BA ......... Platform level down .......................... 10-12 ft-lbs / 14-16 Nm
29
Proportional solenoid valve .............. BB ......... Turntable rotate left/right .................. 20-25 ft-lbs / 27-34 Nm
30
Counterbalance valve ....................... BC ........ Platform level up ............................... 30-35 ft-lbs / 41-47 Nm
31
Needle Valve .................................... BD ........ Platform level circuit ......................... 20-25 ft-lbs / 27-34 Nm
32
Counterbalance valve ....................... BE ......... Platform level down .......................... 30-35 ft-lbs / 41-47 Nm
33
Solenoid valve, 3 position 4 way ...... BF ......... Platform rotate and jib boom
up/down (S-45) ................................. 20-25 ft-lbs / 27-34 Nm
34
35
36
4 - 34
S-40 S-45
October 2007
MANIFOLDS
REV C
AA AB AC AD AE AF AG AH
9
AI
10
11
AJ AK
12
13
14
AM
AL
AN
AO 15
AP 16
17
AQ 18
AR 19
AS 20
AT 21
AU 22
AV 23
AW 24
AX 25
BI
36
BH
35
BG
34
BF
33
BE BD BC BB
32
31
30
29
AY
26
AZ
27
BA
28
S-40 S-45
4 - 35
October 2007
MANIFOLDS
REV C
7-2
Valve Adjustments Function Manifold
How to Adjust the System
Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the PTEST port on the function
manifold.
2 Start the engine from the ground controls.
3 Hold the function enable/rpm select toggle
switch to the high idle position. Activate and
hold the boom retract toggle switch with the
boom fully retracted.
4 Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item AQ).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 5 and recheck relief
valve pressure.
8 Remove the pressure gauge.
4 - 36
S-40 S-45
October 2007
MANIFOLDS
REV C
7-3
Jib Select, Platform Rotate and Generator Manifold Components
Index
No.
Description
Counterbalance valve ........................ CA ........ Platform rotate right .......................... 30-35 ft-lbs / 41-47 Nm
Counterbalance valve ........................ CB ........ Platform rotate left ............................. 30-35 ft-lbs / 41-47 Nm
Relief valve ........................................ CD ........ Generator overload relief .................. 30-35 ft-lbs / 41-47 Nm
Solenoid valve ................................... CE ........ Controls generator on / off ................ 50-55 ft-lbs / 68-75 Nm
Solenoid valve, 2 position 3 way ....... CC ........ Platform rotate/jib boom select ......... 18-20 ft-lbs / 25-27 Nm
Schematic
Item
Function
Torque
CC
CE
CD
3
S-40 S-45
4 - 37
October 2007
MANIFOLDS
REV C
7-4
Brake Manifold Components (before serial number 7569)
Index
No.
Description
Solenoid valve, 2 position 3 way ... DA ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
Orifice, 0.025 inch / 0.635 mm ....... DB ........... Turntable rotation brake release
Schematic
Item
Function
Torque
DA
DB
4 - 38
S-40 S-45
October 2007
MANIFOLDS
REV C
7-5
Brake/Two-Speed Manifold Components (after serial number 7568)
Index
No.
Description
Orifice, 0.025 inch / 0.63 mm ......... EA ........... Turntable rotation brake release
Schematic
Item
Function
Torque
Solenoid valve, 2 position 3 way ... EB ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
Solenoid valve, 2 position 3 way ... EC ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm
Check valve .................................... ED ........... Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm
1
EA
2
EB
EC
ED
S-40 S-45
4 - 39
October 2007
MANIFOLDS
REV C
7-6
Oscillate Directional Valve Components
The oscillate directional valve is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
Function
Torque
4 - 40
S-40 S-45
October 2007
MANIFOLDS
REV C
4 Remove the drive chassis cover and the nonsteer axle covers.
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
6 To level the drive chassis, start the engine and
loosen the lock nuts on both sides of the
urethane cushions.
S-40 S-45
4 - 41
October 2007
MANIFOLDS
REV C
7-7
Valve Adjustments - Oscillate
Relief Valve
1 Remove the drive chassis cover from the nonsteer end of the machine.
950 psi
65.5 bar
4 - 42
S-40 S-45
October 2007
MANIFOLDS
REV C
7-8
Traction Manifold Components, 2WD (before serial number 7569)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
Schematic
Item
Relief valve, 210 psi / 14.5 bar ......... FA ......... Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
Orifice, 0.070 inch / 1.78 mm ............ FC ......... Equalizes flow across flow
divider/combiner valve (item FB)
Shuttle valve, 3 position 3 way .......... FD ......... Charge pressure, hot oil shuttle ........ 50-55 ft-lbs / 68-75 Nm
1
FA
Function
Torque
2
FB
FC
2WD
FD
FE
S-40 S-45
4 - 43
October 2007
MANIFOLDS
REV C
7-9
Traction Manifold Components, 2WD (after serial number 7568)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
Schematic
Item
Relief valve, 280 psi / 19.3 bar ......... GA ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
Check valve ....................................... GC ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
Check valve ....................................... GD ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
Orifice, 0.070 inch / 1.78 mm ............ GF ........ Equalizes flow across flow
divider/combiner valve (item GB)
Function
Torque
1
GA
GB
GC
4 - 44
S-40 S-45
GD
GE
GF
October 2007
MANIFOLDS
REV C
7-10
Valve Adjustments, 2WD
Drive Manifold
How to Adjust the Hot Oil Shuttle
Relief Valve
Note: The pressure differential between the charge
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the drive
manifold) is necessary to return hot oil from the
closed loop drive circuit to the hydraulic tank for
cooling. This pressure differential must be
maintained at 40 psi / 14.5 bar.
Note: The following procedure will require two
people.
S-40 S-45
4 - 45
October 2007
MANIFOLDS
REV C
7-11
Traction Manifold Components, 4WD (before serial number 7569)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
Schematic
Item
Function
Torque
Orifice, 0.070 inch / 1.778 mm .......... HC ........ Rear drive motor circuit
Orifice, 0.070 inch / 1.778 mm .......... HD ........ Equalizes pressure on both sides
of flow divider/combiner valve 7
Shuttle valve, 3 position 3 way .......... HE ........ Charge pressure, hot oil shuttle ........ 50-55 ft-lbs / 68-75 Nm
Relief valve, 210 psi / 14.5 bar .......... HH ........ Charge pressure circuit ..................... 30-35 ft-lbs / 41-47 Nm
Orifice, 0.052 inch / 1.32 mm ............ HI .......... Front drive motor circuit
4 - 46
S-40 S-45
October 2007
MANIFOLDS
REV C
HI
HA
HB
1
2
HH
HG
HC
HD
HE
HF
6
S-40 S-45
4 - 47
October 2007
MANIFOLDS
REV C
7-12
Traction Manifold Components, 4WD (after serial number 7568)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
Relief valve, 280 psi / 19.3 bar ......... JA ......... Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm
Check valve ....................................... JC ......... Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm
Check valve ....................................... JD ......... Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm
Check valve ....................................... JF ......... Non-steer end drive motor circuit ...... 60-70 ft-lbs / 81-95 Nm
10
Check valve ....................................... JJ .......... Steer end drive motor circuit ............. 60-70 ft-lbs / 81-95 Nm
11
Check valve ....................................... JK ......... Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm
12
Shuttle valve, 3 position 3 way .......... JL .......... Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
13
14
Check valve ....................................... JN ......... Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm
4 - 48
Schematic
Item
Function
S-40 S-45
Torque
October 2007
MANIFOLDS
REV C
14
13
12
11
10
JA
JB
JC
JD
JE
JF
JN
JM
JL
JK
JJ
JG
JH
JI
S-40 S-45
4 - 49
October 2007
MANIFOLDS
REV C
7-13
Valve Adjustments, 4WD
Drive Manifold
How to Adjust the Hot Oil Shuttle
Relief Valve
Note: The pressure differential between the charge
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the drive
manifold) is necessary to return hot oil from the
closed loop drive circuit to the hydraulic tank for
cooling. This pressure differential must be
maintained at 40 psi / 14.5 bar.
Note: The following procedure will require two
people.
4 - 50
S-40 S-45
October 2007
MANIFOLDS
REV C
7-14
Valve Coils
Description
Specification
6.3
6.3
6.3
6.3
6.8
3.3
4.8
S-40 S-45
4 - 51
October 2007
MANIFOLDS
REV C
a
d
10 W
RESISTOR
27287
9V
BATTERY
a
b
c
d
multimeter
9V DC battery
10 resistor
coil
Resistor, 10
Genie part number
AMMETER
COIL
4 - 52
S-40 S-45
October 2007
MANIFOLDS
REV C
7-15
Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index
No.
Description
Directional Valve ............................ CY ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm
Orifice disc ...................................... CW .......... Delays shift to drive ......................... 35-40 ft-lbs / 47-54 Nm
Solenoid valve ............................... CV ........... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
Relief valve .................................... CX ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm
Check valve .................................... CU ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm
Schematic
Item
Function
Torque
CU
CY
CW
CV
CX
S-40 S-45
4 - 53
July 2007
REV A
8-1
Turntable Rotation Assembly
d
Unlocked position
a
b
c
d
e
f
brake assembly
drive hub
backlash plate mounting bolts
backlash plate
manifold
motor
Locked position
4 - 54
S-40 S-45
July 2007
REV A
S-40 S-45
4 - 55
July 2007
Axle Components
REV A
9-1
Oscillate Cylinders
The oscillating axle cylinders extend and retract
between the drive chassis and the axle to maintain
a level chassis while driving over uneven terrain.
The cylinders are equipped with counterbalance
valves to prevent movement in the event of a
hydraulic hose failure.
4 - 56
S-40 S-45
July 2007
Generators
REV A
10-1
Valve Adjustments Hydraulic Generator
flow regulator
S-40 S-45
4 - 57
July 2007
GENERATORS
4 - 58
S-40 S-45
July 2007
Fault Codes
REV A
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Genie S-40 and S-45 Operators Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
S-40 S-45
5-1
July 2007
FAULT CODES
REV A
5-2
S-40 S-45
July 2007
FAULT CODES
REV A
Error Source
ID
21
22
23
31
32
Name
Boom 1 Joystick
(primary boom up/
down)
Boom 1 directional
valves
Boom 1 flow
control valve
Boom 2 Joystick
(secondary boom
up/down or
primary boom
extend/retract)
Boom 2 directional
valves
Error Type
ID
11
12
15
16
Name
17
Not calibrated
18
Just calibrated
21
Fault
12
15
17
Not calibrated
18
Just calibrated
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
Value at 5V
Value too high
Value too low
Value at 0V
Condition
Function is inoperative
until joystick is
calibrated. Alarm
sounds indicating
fault.
Function is inoperative
until joystick is
calibrated.
Initiate 1-second beep
of alarm.
Valve is operating
outside of operational
limits. Alarm sounds
indicating fault.
Valve is operating
outside of operational
limits. Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Joystick is operating
outside of operational
limits. Alarm sounds
indicating fault.
Function is inoperative
until joystick is
calibrated.
Initiate 1 second beep
of alarm.
Valve is operating
outside of operational
limits. Alarm sounds
indicating fault.
Solution
Cycle power off,
then on and
problem should be
corrected.
Calibrate joystick
Self-clearing.
(transient)
Cycle power off,
then on and
problem should be
corrected.
Cycle power off,
then on and
problem should be
corrected.
Calibrate valve
thresholds
Self-clearing.
(transient)
Cycle power off,
then on and
problem should be
corrected.
Calibrate joystick
Self-clearing.
(transient)
Cycle power off,
then on and
problem should be
corrected.
S-40 S-45
5-3
July 2007
REV A
FAULT CODES
Error Source
ID
33
41
42
43
44
5-4
Name
Boom 2 flow
control valve
Turntable rotate
joystick
Error Type
ID
Name
12
15
17
Not calibrated
18
Just calibrated
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
12
15
17
Not calibrated
18
Just calibrated
21
Fault
Turntable rotate
directional valves
Turntable rotate
flow control valve
Drive enable
override switches
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Solution
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
S-40 S-45
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
July 2007
FAULT CODES
REV A
Error Source
ID
51
53
54
55
61
62
Name
Drive joystick
Error Type
ID
11
12
15
16
Name
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
12
15
17
Not calibrated
18
Just calibrated
21
Fault
21
Fault
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
Steer joystick
Steer directional
valves
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Motor speed frozen in
the low state. Alarm
sounds indicating
fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
Initiate 1-second beep
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
S-40 S-45
Solution
Power up
controller with
problem corrected.
Calibrate joystick
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Calibrate valve
thresholds
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate Joystick
Self-clearing.
(transient)
Power up
controller with
problem corrected.
5-5
July 2007
FAULT CODES
REV A
5-6
S-40 S-45
July 2007
FAULT CODES
REV A
Code
Problem
Cause
Solution
111
112
HO2S Open/Inactive
(Bank 1)
113
HO2S Open/Inactive
(Bank 2)
114
Post-cat oxygen
sensor open
121
142
143
144
122
124
133
134
135
NG cat monitor
141
S-40 S-45
5-7
July 2007
FAULT CODES
Code
Problem
REV A
Cause
Solution
161
162
211
212
213
214
215
221
222
223
224
231
BP High Pressure
BP Low Pressure
242
243
244
232
234
235
5-8
S-40 S-45
July 2007
FAULT CODES
REV A
Code
Problem
Cause
245
253
254
311
312
313
314
315
316
321
322
351
352
353
MegaJector Delivery
Pressure Higher Than
Expected
354
MegaJector Delivery
Pressure Lower Than
Expected
355
MegaJector
Communication Lost
361
MegaJector Voltage
Supply High
362
MegaJector Voltage
Supply Low
S-40 S-45
Solution
5-9
July 2007
FAULT CODES
Code
REV A
Problem
Cause
363
MegaJector Internal
Actuator Fault Detection
364
MegaJector Internal
Circuitry Fault Detection
365
MegaJector Internal
Communication Fault
Detection
411
412
413
414
511
512
513
Not used.
514
521
522
531
532
533
534
535
536
537
538
545
5 - 10
Solution
S-40 S-45
July 2007
FAULT CODES
REV A
Code
Problem
551
552
553
611
COP Failure
612
Invalid Interrupt
613
A/D Loss
614
RTI 1 Loss
615
616
RAM Failure
631
External 5V DC Ref
Lower than Expected
632
External 5V DC Ref
Higher than Expected
655
RTI2 Loss
656
RTI3 Loss
Cause
Solution
S-40 S-45
5 - 11
July 2007
FAULT CODES
REV A
5 - 12
S-40 S-45
July 2007
FAULT CODES
REV A
Code
111
112
113
114
115
121
122
124
133
134
141
142
143
144
161
162
163
164
165
166
167
168
171
172
173
174
181
182
183
184
185
186
211
Description
CL (closed loop) high LPG
EGO open / lazy pre-cat 1
EGO open / lazy pre-cat 2/post-cat 1
EGO open / lazy post-cat 1
EGO open / lazy post-cat 2
CL (closed loop) high gasoline bank 1
CL (closed loop) low gasoline bank 1
CL (closed loop) low LPG
Gasoline catalyst monitor 1
LPG catalyst monitor
AL (adaptive learning) high gasoline bank 1
AL (adaptive learning) low gasoline bank 1
AL (adaptive learning) high LPG
AL (adaptive learning) low LPG
Battery voltage high
Battery voltage low
AUX analog PD1 high
AUX analog PD1 low
AUX analog PU3 high
AUX analog PU3 low
AUX analog PUD1 high
Code
212
213
214
215
221
222
223
224
225
226
231
232
234
235
242
243
244
245
246
253
254
Description
IAT (intake air temperature) low voltage
IAT (intake air temperature) higher than expected 1
IAT (intake air temperature) higher than expected 2
Oil pressure low
ECT/CHT (engine/cylinder head temp) high voltage
ECT/CHT (engine/cylinder head temp) low voltage
CHT higher than expected 1
CHT higher than expected 2
ECT higher than expected 1
ECT higher than expected 2
MAP (manifold absolute pressure) high pressure
MAP (manifold absolute pressure) low pressure
BP (barometric pressure) high pressure
BP (barometric pressure) low pressure
Crank sync noise
Never crank synced at start
Cam loss
Cam sync noise
Crank loss
Knock 1-2 sensor open 1
Knock 1-2 excessive signal 1
S-40 S-45
5 - 13
July 2007
FAULT CODES
Code
261
262
271
272
273
274
311
312
313
314
315
316
321
322
351
352
353
354
355
359
361
362
363
364
365
411
412
413
414
415
416
421
422
5 - 14
REV A
Description
Code
531
532
533
534
535
536
537
538
539
541
542
543
544
551
552
553
611
612
613
614
615
Description
TPS1 (throttle position sensor) high voltage
TPS1 (throttle position sensor) low voltage
TPS2 (throttle position sensor) high voltage
TPS2 (throttle position sensor) low voltage
TPS1 (throttle position sensor) higher than TPS2
TPS1 (throttle position sensor) lower than TPS2
Unable to reach higher TPS (throttle position sensor)
Unable to reach lower TPS (throttle position sensor)
TPS 1-2 simultaneous voltages
AUX analog PU1 high
AUX analog PU1 low
AUX analog PU2 high
AUX analog PU2 low
Max govern speed override
Fuel rev limit
Spark rev limit
COP failure
Invalid interrupt
A/D loss
RTI 1 loss
Flash checksum invalid
S-40 S-45
July 2007
FAULT CODES
REV A
Code
616
631
632
633
634
635
641
642
643
644
646
647
648
655
656
711
712
713
714
715
716
721
722
723
731
732
733
734
735
736
741
742
743
Description
RAM failure
5VE1 low voltage
5VE1 high voltage
5VE2 high voltage
5VE2 low voltage
5VE1-5VE2 simultaneous out-of-range
Rx inactive
Rx noise
Code
744
761
762
763
771
772
1629
1630
Description
PWM5 short to power
MIL (malfunction indicator light) control ground short
MIL (malfunction indicator light) open
MIL (malfunction indicator light) control short to power
Tach output ground short
Tach output short to power
J1939 TSC1 message receipt lost
J1939 ETC message receipt lost
S-40 S-45
119488
5 - 15
July 2007
5 - 16
S-40 S-45
July 2007
Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Hydraulic Schematics
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-40 & Genie S-45 Operator's Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
S-40 S-45
problem
solved
Inspect
and test
Perform
repair
6-1
Section 6 Schematics
July 2007
FS1
BLK
BLK
P3
WHT
Quick disconnect
terminal
N.O.H.C
Coil
solenoid or relay
N.C.H.O
Limit switch
Horn button
normally open
P1
KS1
TB21
WHT #21
Foot switch
LS3
PLATFORM
OTS2
N.O.
GROUND
T-circuits connect
at terminal
H1
Horn or alarm
T-circuits
connect
Key switch
Oil temperature
switch
normally open
Emergency Stop
button normally
closed
FAN
FB
PR1
CTS1
N.O.
Flashing beacon
Power relay
Coolant temperature
switch
normally open
Connection
no terminal
G1
TS2
START
ENGINE
Gauge
Aux
Pump
Auxiliary pump
OPS1
N.C.
Circuits crossing
no connection
510
HM
Diode
Hydraulic oil
cooling fan
Resistor with
ohm value
Hour meter
TS6
PLATFORM LEVEL
LED
KS1
25A
CB1
15A
Fuse
with amperage
CR4
N.O.
Circuit breaker
with amperage
Control relay contact
normally open
Starting aid:
glow plug or
flame ignitor
6-2
Tilt sensor
C
HOLD
F1
PULL IN
Battery
UP
DOWN
L3
Key switch
Fuel or RPM
solenoid
Coil
S-40 S-45
July 2007
Section 6 Schematics
25 psi
(1.7 bar)
.035"
(0.89 mm)
Filter with
bypass valve
relief setting
Solenoid operated
3 position, 4 way,
proportional directional valve
Check valve
200 psi
(13.8 bar)
Pump
fixed displacement
Relief valve
with pressure setting
Priority
flow regulator valve
o
Brake
Pump
bi-directional,
variable displacement
Directional valve
(mechanically activated)
Needle valve
50%
Motor
bi-directional
Motor
2-speed,
bi-directional
50%
Counterbalance valve
with pressure and pilot ratio
E
Pump prime mover
(engine or motor)
Differential
sensing valve
Directional valve
pilot operated
2 position, 2 way
Double acting
cylinder
Solenoid operated
proportional valve
S-40 S-45
6-3
Section 6 Schematics
July 2007
REV A
Starter
Relay
Fuel
Pump
Relay
Power
Relay
Empty
F1-10A
F2-5A
F3-10A
F4-15A
F5-15A
6-4
S-40 S-45
July 2007
Section 6 Schematics
REV A
C1P DT06-12SA
C7: DTP06-4S
C1
CKT #
PIN #
1
BK
P22BAT
RD/BK
C28TTA
WH
P23SWBAT
RD/WH
C29MS
BRN
BATGND
WH
C30EDC+
N/A
PLUG
WH/BK
C31EDC-
WH/RD
C32BRK
BK
C33STR
BK/WH
C34SA
BK/RD
C35ESPD
BL
C36STC
10
BL/BK
C37STCC
C132PLI
11
BL/WH
CKT #
OR
C40LS1
OR/BK
C41RPM
3
4
GR
C134PWR
C43HRN
GR/BK
JDALARM
GR/WH
C45GEN
PLUG
PLUG
PLUG
10
PLUG
11
PLUG
12
CKT #
C1PBU
C2PBD
RD/WH
C3PBF
WH
C4TRL
WH/BK
C5TRR
WH/RD
C6TRF
BK
C7PBE
BK/WH
C8PBR
BK/RD
BL/BK
DRVLT
PLUG
PLUG
BL/WH
PLUG
GREEN
COLOR
CIRCUIT #
COLOR
RD
C1PBU
C2PBD
RD
3
4
C3PBF
C4TRL
RD/WH
RD/WH
WH
C3PBF
C4TRL
C5TRR
WH/BK
C5TRR
WH/BK
C6TRF
WH/RD
C6TRF
WH/RD
C7PBE
BK
C7PBE
BK
8
9
C8PBR
BK/WH
C8PBR
BK/WH
RD/BK
RD/BK
WH
10
C13DRE
C14PLU
BL/RD
OR
C13DRE
C14PLU
C15PLD
OR/BK
C15PLD
OR/BK
R43HRN
BK
R43HRN
BK
C17JU
C18JD
C2DA
GR
GR/BK
RD/BK
C17JU
C18JD
C2DA
GR
GR/BK
RD/BK
CKT #
C134PWR
RD
C134PWR
RD
25
C116HYD
BK
26
GND
C27AUX
BR
RD
C27AUX
RD
RD/BK
C28TTA
RD/BK
C28TTA
30
P46PWR
BL/WH
P46PWR
BL/WH
C32TA
WH/RD
32
C32TA
WH/RD
33
R116HYD
OR
OR
34
R21IGN
WH
OR/BK
C15PLD
35
OR/RD
C133PLA
GR
C17JU
GR/BK
C18JD
38
GR/WH
C19JSV
PLUG
PLUG
PLUG
10
PLUG
11
PLUG
12
C39LP
TB23
BL/RD
WH
C38ESL
BL/WH
C21IGN
WH
C31EDC
C30EDC
C34SA
C32BRK
C29MS
WH/BK
WH
BK/WH
WH/RD
RD/WH
COLOR
FORD
COLOR
PERKINS
COLOR
C4
BROWN
DEUTZ
OR/BK
WH
C41RPM
C107AF
OR/BK
WH
C41RPM
C107AF
OR/BK
WH
C41RPM
C107AF
BK
RD
R33STR
R27AUX
BK
R33STR
BK
R33STR
WH
BK/RD
BL/RD
WH(12)
GR
BL/WH
WH/RD
R21IGN
C35RPM
C39LP
VSW
C127TST
C38ESL
C26TSR
BK/RD
C35RPM
BK/RD
C35RPM
WH/RD
TSWITCH
WH/RD
TSWITCH
WH/BK
WH
C25PSR
C21IGN
WH/BK
PSWITCH
WH/BK
PSWITCH
WH/BK
WH
C31EDC
C30EDC
WH/RD
RD/WH
C32BRK
C29MS
WH/BK
WH
BK/WH
WH/RD
RD/WH
C31EDC
C30EDC
C34SA
C32BRK
C29MS
WH/BK
WH
BK/WH
WH/RD
RD/WH
C31EDC
C30EDC
C34SA
C32BRK
C29MS
C9 FS DT04-4P
29
C13DRE
C14PLU
BL/RD
OR/BK
WH
C41RPM
C107AF
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
C9
24
28
C4
PIN #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
21
22
31
COLOR
BL/RD
OR
16
17
18
19
20
27
12
15
23
11
C4P DT06-12SD
CIRCUIT #
13
14
C3
COLOR
12
PIN #
RD
C6-FUNCTION HARNESS
10
11
C3
RD/BK
BL
BLACK
C6-GBOX
C1PBU
C2PBD
1
2
C3P DT06-12SC
COLOR
C6
C2
PIN #
C39LP
C5-ENGINE HARNESS
CKT#
PIN#
C2
C5-GBOX
PIN#
12
BL/RD
OR/RD
GRAY
C7
C2P DT06-12SB
COLOR
C1
C7
C27AUX
COLOR
CKT # PIN #
RD
COLOR
36
C36STC
BL
C36STC
BL
37
C37STCC
BL/BK
C37STCC
BL/BK
39
C45GEN
GR/WH
C45GEN
GR/WH
40
C40LS1
OR
C40LS1
OR
COLOR
CKT #
PIN #
BK
P26BAT
WH
P24BAT
RD
P25BAT
N/C
S-40 S-45
6-5
July 2007
Section 6 Schematics
6-5
6-6
Section 6 Schematics
July 2007
Electrical Schematic
Deutz F3L 1011F Models (before serial number 7544)
6-8
6-7
July 2007
Section 6 Schematics
REV B
Electrical Schematic
Deutz F3L 1011F Models (before serial number 7544)
A
1
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
LS18
P2
FS1
BK-(FS)
C9-1 BK
C9-3 P25FS RD
C9-2 P24FS WH
RD-(FS)
WH-(FS)
TS2
SEE NOTE 2
TS17
ON GLOW
PLUG
TS4
SEE NOTE 2
C2-7
C1-8
C1-9
TB43
TB45
RD
RD
C35ESPD BK/RD
LOW RPM
FUNCTION ENA.
HIGH RPM
TB34
TB35
L5
BK/RD
8
9
10
TS55
C6-39
CR2
NO
START RELAY
TACHOMETER
START INPUT
IGN./START
AUX. ON
GROUND
MODULE
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
C45GEN GR/WH
CR2
CR1
CR1
NO
1
2
3
4
5
6
C34SA BK/WH
CR5
TB24
C6-28
CR5
NO
20AMP.
C6-23
CB3
ON GLOW
PLUG BK
RD
D6
TB28
TS56
TB33
TB23
TB133
START BK
L45
H6
15AMP.
ENGINE
RD
CB1
TB20
PUMP
AUXILARY
TB27
TS52
C33STR BK
TS51
RD
7
8
12
C27AUX RD
U33
P23BAT WH
C28TTA RD/BK
PLAT
GRD
C133PLA OR/RD
C43HRN GR
KS1 TB22
HIGH RPM(FS)
L24
C1-7
ENGINE
C1-1
C7-2
C1-2
C4-4
C2-5
C7-1
GENERATOR
TS1
L48
D40
TS6
START
D39
PUMP AUXILIARY
P3
HORN
L4
H1
TB132
TB134
RD
P22BAT BK
C2-4
RD
C1-12
P1
RD
C132PLI BL/WH
CB2
15AMP.
C134PWR OR/RD
C41RPM OR/BK
WH
C28TTA RD/BK
RD
BK
TB21
OPS
OTS
NC
NO
CR3
NO CR4
BK/RD-C5-8
G1
GR/WH-45
C5-22
HM
NO
PR2
C5-14
G3
WH-24
C5-16
WH/BK
STARTER
TB26
PR2
NO
PR1
PR1
NO
AUX
PUMP
BK
BRN
C6-26
BRN
HIGH IDLE RELAY
GENERATOR
OPTION
S-40 S-45
WATER TEMP
SWITCH
+
-
OIL PRESSURE
SWITCH
NOTE:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
IN THE STOWED POSITION AND KEYSWITCH "OFF".
FUEL RELAY
VOLT METER
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
SERVICE HORN
RELAY
HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)
6-8
C5-15
G2
WH-21
BK-33
RD-27
FB
H2
REGULATOR
C5-5
C6-27
WH
RD
STA.
IND.
TB25
BK-43
CR17
FAN
RD/BK-28
RD-134
C6-16
C6-25
BAT.
-
CR17
NO
C6-33
BAT.
+
C6-34
EXCT.
12 V
DC
OR/BK-41
ALTERNATOR
C5-2
C5-3
OTS
NO
DRE A BL/WH
12
13
14
10
11
17
18
20
19
16
15
C41RPM OR/BK
15
8
16
7
WH
RKOUT 6
2
1
11
12
14
13
OR
BRN
BL
4
PWR 3
GND 2
RD
OR
BK
YOUT 5
XOUT 4
BRN
GND 2
PWR 3
BRN
P24FS WH
C1P-6
C1P-5
C1P-4
C37STCC BL/BK
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
BRN-2
C1P-11
C36STC BL
C2P-3
C1P-10
LEFT
TROTATE
RIGHT
C4TRL WH
C5TRR WH/BK
7.5
C6TRF WH/RD
RD
C3P-6
RD
C3P-5
C3P-4
C3P-1
C3P-2
C3P-3
C4P-1
UP
PRIMARY
DOWN BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
C40LS1 OR
C5-21
C5-20
C6-32
C5-23
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C30EDC+ WH
A
C31EDC- WH/BK D
C32BRK WH/RD
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
C6-19 RD/BK
C6-13
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
C40LS1 OR
C6-40
C6-7
C6-8
C6-14
C6-15
7
BK
WH
BK
WH
BK
WH
H3
GROUND
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
STEER RIGHT
STEER LEFT
DRIVE ENABLE
LIMIT SWITCH
BOOM EXTEND
BOOM RETRACT
PLAT LEVEL UP
PLAT LEVEL DOWN
JIB VALVES
6-9
S-40 S-45
Part No. 102521
H4
SJ1-WH
C18JD GR/BK
NOTE:
P24FS WH
3
C2P-2
EXTEND
BOOM
PLATFORM
LEVEL
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
RETRACT
UP
DOWN
C6-18
C17JU GR
NONC
C3P-7
C3P-8
JDALARM GR/BK
C18JD GR/BK
C17JU GR
C6-17
NOHC
P26ESTP BK
RETRACT
EXTEND BOOM
C4P-2
C2P-6
PLATFORM
UP
DOWN LEVEL C4P-3
GR/BK-44
C4P-6
DOWN JIB
BOOM C4P-5
UP
DOWN
UP JIB BOOM
JIB BOOM
TB7
8
NOHC
BRN
6
5
C6-30
TB22
1
Deutsch
LEFT
RIGHT
RIGHT PLAT
LEFT ROTATE
3
2
TB31
TB32
TB36
TB30
TB37
TB5
C19JSV GR/WH
2
5
AMP
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
1
5
TB8
TB14
TB15
TB18
TB17
TS62
TS61
TB4
TB1
TB13
3
C4P-7
TS57
J2
4
TS63
TS59
TS58
TB40
R2
R1
YOUT 5
J1
J1
J1
J3
CR30
NO
JIB VALVE
C19JSV GR/WH
TS13
JC3
JC2
WH
2
CR27
NC
CR13
NC
CR13
CE
LIFT/
DRIVE
OPTION
L1
TS15
WH
WH
TS9
TS8
TS7
TB44
TB19
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
6
Electrical Schematic
REV B
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 Schematics
July 2007
RD/BK
OR/BK
BK
BRN
July 2007
Section 6 Schematics
Electrical Schematic
Deutz F3L 1011F Models (before serial number 7544)
6-9
6 - 10
July 2007
Section 6 Schematics
REV A
K
RD-H6+ - C23-1
BL/WH-38D - C23-3
BK-22C - C23-4
BK-C7-1 - C23-5
RD-TS51 - C23-6
RD-TS55 - C23-7
GN/BK-16B - C23-8
BR - GND - C23-12
12 V
C7B
C1B C2B C3B C4B
BK-CR1#86
OR/BK-41B
BK-33D
RD-27B
BR-GND.
RD-CR2#30
WH-23B
RD-KS1-2 S.P.
BK/RD-S.P.
BK/WH-S.P.
BK-S.P.
BK/RD CR3-#30
BK-ISM#3
WH/RD-C6-32
D6
RD-ISM#4
RED-CR1#30
WH-ISM #7
BK-CR5#30
WH-CR2#87
CB2-SP
GN/BK-C23-8
RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
CB1 - SP
GR/WH-SP
GR/BK-S.P.
GR-S.P.
GN/BK-H6OR/BK-S.P.
OR-S.P.
BK/RD-CR23#87
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
44B+RD/BK-C6-19 RD/BK-S.P.
RD-S.P.
B
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
5 GROUND
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
IGN./START
MODULE
CR2
RD C4B-11
BR (GROUND)
RD C4B-12
BRN GND
BK-22A
P1
RD-CB2
KEY SWITCH
KS1
NC
WH-23A
RD-42A
RD-27A
RD-C23-6
TS51
NC
LABEL
DESCRIPTION
1
B1
KEY SWITCH
AUXILIARY SWITCH
ENGINE START SWITCH
RD-H6+
OR/RD-H6-
FUNCTION ENABLE
PLATFORM ROTATE SWITCH
WH-21A
HM
BR (GROUND)
L45
L2
BL/WH-C5-15
BL/WH-ISM#10
RD/WH-3A
RD/BK-2A
RD-1A
TS61
TS63
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
TS52
CB3
BK/WH-34A
TS58
CB1
CB2
TS55
RD- 20A
P1
KS1
TS51
TS52
P1
KS1
42730
13037
TS55
13037
16397
13037
13037
16397
16397
13037
TS57
TS59
TS63
TS61
TS62
TS58
CB1
CB2
CB3
R1
R2
G1
G2
G3
R2
G1
G2
G3
STARTER AID
L28
56298
HOUR METER
IGN. START RELAY
IGN. POWER RELAY
HIGH IDLE (RPM) CUTOUT RELAY
HM
CR1
CR2
CR3
HM
CR1
CR2
CR3
RPM RELAY
CR4
CR4
CR17
CR17
TS59
PART #
CB1
CB2
CB3
R1
TS62
TS56
RD- 20C
RD-CR17#30
WH-4
WH/RD-6
WH/BK-5
D13
BK-ISM#1
WH/BK-25A
WH/RD-26A
BK/RD-35A
CR5
BK/RD-9B
WH-21A
TS57
CR17
CR23
RD-C23-7
BK-C6-25
G3
G2
G1
R2
BK-22B
GR-43D
RD-CB3 SP
D14
RD-CB3 SP
CR1
H6
GN/BK-16A
BL/RD-S.P.
RD-ISM#6
WH-ISM#9
RD-24B
C6
GN/BK-L45-
GR/BK-S.P.
GR/BK-2B
GR-CR5#86
RD-H6+
OR/BK-ISM#2
WH-CR2#86
BL/WH-L2
H6
U33
L45
RD- 24A
BK-C5-5
C5
19/18 CABLES
FUNCTIONS
ENGINE
RD-C23-1
RD-42B
R1
GROUND STUD
46
GR/WH-C2B-7 45
GR/WH-C6-39
GR/BK-C2B-6 44
43
GR-C2B-5
OR/RD-C2B-4 42
RD-C6-23
OR/BK-C2B-3 41
OR/BK-C5-2
40
OR-C2B-2
OR-C6-40
BK/WH-C5-10
BL/RD-C2B-1 39
BL/WH-C23-3
BL/WH-C1B-12 38
BL/BK-C6-37
BL/BK-C1B-11 37
36
BL-C6-36
BL-C1B-10
BK/RD-C1B-9 35
BK/WH-C5-22
BK/WH-C1B-8 34
33
BK-C1B-7
WH/RD-C5-23
WH/RD-C1B-6 32
WH/BK-C5-20
WH/BK-C1B-5 31
30
WH-C5-21
WH-C1B-4
RD/WH-C1B-3 29
RD/BK-C6-28
RD/BK-C1B-2 28
27
RD-C6-27
RD-C1B-1
26
WH/RD-C5-14
25
WH/BK-C5-16
24
RD-C5-1
23
RD-C5-19
WH-C7B-2
22
BL/WH-C6-30
BK-C23-4
21
WH-C5-3+C5-11 WH-C6-34
20
CB3-SP
RD- 12VOLT
GR/WH-C4B-7 19
GR/BK-C6-18
GR/BK-C4B-6 18
17
GR-C6-17
GR-C4B-5
OR/RD-C4B-4 16
OR/BK-C6-15
OR/BK-C4B-3 15
14
OR-C6-14
OR-C4B-2
BL/RD-C6-13
BL/RD-C4B-1 13
BL/WH-C3B-12 12
BL/BK-C3B-11 11
BL-C3B-10
10
BK/RD-C3B-9 9
BK/WH-C6-8
BK/WH-C3B-8 8
7
BK-C6-7
BK-C3B-7
WH/RD-C6-6
WH/RD-C3B-6 6
WH/BK-C6-5
WH/BK-C3B-5 5
4
WH-C6-4
WH-C3B-4
RD/WH-C6-3
RD/WH-C3B-3 3
RD/BK-C3B-2 2
RD/BK-C6-2
RD-C6-1
1
RD-C3B-1
RD
12V TO PLAT
C23
U33
PLATFORM LOAD
BR-GND
3 STUD
BK-C23-5
1
2 WH-23C
WH-21B
BK/RD-35B
CR3
OR-C6-33
BR-GND+C6-26
BK-C6-16
RD- 20B
RD- P1 E-STOP
OR/BK-15A
OR-14A
GR-17A
CR4
GR/WH-19A
GR/BK-18A
BK/RD-C5-9
GROUND STUD
BR
WIRING
HARNESS:
TO BASE
ALL BR WIRES
S-40 S-45
6 - 11
July 2007
Section 6 Schematics
6 - 11
6 - 12
Section 6 Schematics
July 2007
6 - 14
6 - 13
P26BAT BK
P24FS WH
P24FS WH
11
1
C132PLI BK C1P-12
RD P2
RD H1
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH
C4P-7 AND TS8
BRN
C4P(BR)
C3P(GR)
C2P(BK)
F.S.
OPT.
LS18
C1P(GY)
RED/BLK-28
H1
D39
F.S.
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
JIB
C9P
RED-TILT
BRN
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
C3P
C3P
D40
C7P
BATGND C7P-3
BRN
C4P
GN/BK C4P-4
12V BATT
19/18 CONTROL CABLE
TILT
ALALRM
C1P
C28TTA RD/BK C1P-2
HARNESS
PBOX WIRING
J2
J1
J3
GN/BK L48
ALC-500
RED-TILT
45383
89353
TILT ALARM
ALC-500
H1
C2P
PART NUMBER
COMPONENT INDEX
N
M
L
K
J
I
H
G
F
E
D
C
B
A
C7P
Section 6 Schematics
July 2007
REV A
July 2007
REV B
Section 6 Schematics
HARNESS
PBOX WIRING
7
TS48/ TS49
WORK/ DRIVE LITE
6
TS47
GENERATOR
(OPTION)
TS15
DRV.ENA
5
4
5
4
2
JC2
JC3
DLITE/ RD WL2
TS13
PRIMARY
BOOM
EXTEND/
RETRACT
2
1
75565
56298
66812, 73805
66813, 66816
42730
13037
TS4
TS6
TS7
TS8
TS9
TS13
27378
56298
16397
13037
13037
13037
WH-24
DRIVE LT BK/RD-C3P-9
13037
27378
27378
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BK-22
BRN BATGND
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
RD/BK H1
GN/BK H1
WH-24
RD
GR/WH-45
WH-24
BRN
WH-JIB
BK-7
BK/WH-8
BL/BK-DE2 J1-7
RD WL1
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
RD P3
WH TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
OR R40LS1
(SPLICE TO R40LS1)
NC
TS2
START
CR27
WH TS7
P22BAT BK C7P-1
TS6
TS1
GLOW PLUG
AUXILIARY PUMP
NC
NO
TS4
HIGH/LOW
RPM
(GND STUD)
RD LS18
WH-23
BK-22
P26BAT BK C9P-1
BK/RD-35
WH-24
BK-33
RD
RD-25
WH-24
C27AUX RD C1P-1
WH-JIB
C19JSV GR/WH
C17JU GR C4P-5
OR-14
OR/BK-15
RD P2
GR-43
TS8
JIB
WH
TS7
PLATFORM
ROTATE
L48
GR
GR/BK
JC3
L1
P2
P3
TS1
TS2
L4
L1
WH
62390
+
+
CR13
RD
TS9
PLATFORM
LEVEL
PART NUMBER
WH
P3
HORN
COMPONENT INDEX
JC2
RD
RD
P2
EMERGENCY STOP
CE SEE DETAIL A
NOTE:
S-40 S-45
6 - 15
July 2007
Section 6 Schematics
6 - 15
6 - 16
Section 6 Schematics
July 2007
Electrical Schematic
Perkins 704-30 Models (before serial number 7472)
6 - 18
6 - 17
July 2007
Section 6 Schematics
REV B
Electrical Schematic
Perkins 704-30 Models (before serial number 7472)
A
C28TTA RD/BK
TB41
RD/BK
C2-3
OR/BK
P26ESTP BK
P2
LS18
C9-1 BK
FS1
BK-(FS)
RD
P24FS WH
WH
C1-12
C1-9
8
9
10
CR2
C6-34
C5-14
3
5
HM
G1
CR3
NO CR4
BK/RD-C5-8
WH/RD
WH-24
WH-24
C5-15
WH/BK
STARTER
OTS
OPS
NC
NO
BRN
BRN
HIGH IDLE RELAY
GENERATOR
OPTION
GLOW PLUG
CONTROLLER
GLOW PLUG
OIL TEMP
SWITCH
S-40 S-45
OIL PRESSURE
SWITCH
+
-
NOTE:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
IN THE STOWED POSITION AND KEYSWITCH "OFF".
FUEL RELAY
VOLT METER
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER
RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
FLASHING BEACONS
OPTION
SERVICE HORN
SERVICE HORN
RELAY
HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)
6 - 18
AUX
PUMP
BK
FAN
C5-16
WH-21
FB
GR/WH-45
BK-33
CR17
H2
G3
G2
PR1
NO
TB26
TB25
CONTROLLER
C5-5
RD-27
WH
RD
PR1
NO
C6-27
RD/BK-28
RD-P134
BK-43
REGULATOR
IND.
C6-16
STA.
C6-26
BAT.
-
C6-25
BAT.
+
CR17
NO
C6-33
12 V
DC
OR/BK-41
EXCT.
C5-2
C5-3
ALTERNATOR
C35ESPD BK/RD
CR2
NO
TB21
OTS
NO
HIGH RPM(FS)
CR1
TB35
L5
BK/RD
CR1
NO
HIGH RPM
TB45
START RELAY
TACHOMETER
START INPUT
IGN./START
AUX. ON
GROUND
MODULE
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
C6-39
1
2
3
4
5
6
TB24
C6-28
C6-23
CR5 CR5
NO
TS55
LOW RPM
TB28
RD
C45GEN GR/WH
TB133
CB3
C2-7
GENERATOR
ENGINE
TB23
L45
20AMP.
SEE NOTE 2
TB33
D6
15AMP.
L28
C33STR BK
START
BK
AUXILIARY
PUMP
RD
TB27
TB20
L24
TB34
C1-7
ENGINE
C27AUX RD
P23BAT WH
TS52
TS51
4
CB1
TS4
TS2
C1-1
C7-2
RD
C28TTA RD/BK
H6
TS17
RD
RD
C133PLA OR/RD
U33
D40
C1-2
12
C9-2
START
D39
L48
C4-4
L4
H1
TB43
PLAT
GRD
P3
HORN
TB132
1
TB22
WH-(FS)
BK
SEE NOTE 2
C43HRN GR
KS1
P25FS RD
AUXILIARY
PUMP
C7-1
TB134
RD
RD
RD
C9-3
TS1
C2-5
P22BAT BK
C1-12
P1
C132PLI BL/WH
CB2
15AMP.
C41RPM OR/BK
RD-(FS)
DRE A BL/WH
14
2
1
11
12
9
10
11
17
18
20
19
16
15
C1P-10
C1P-11
C1P-6
C1P-5
C1P-4
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
BRN-2
C3P-6
LEFT
TROTATE
RIGHT
C3P-5
C3P-4
C3P-1
C3P-2
C3P-3
7.5
C5TRR WH/BK
C4TRL WH
C2P-3
C41RPM OR/BK
15
16
WH
RKOUT 6
RD
13
BL
OR
BRN
YOUT 5
GND 2
PWR 3
OR
6
YOUT 5
XOUT 4
BRN
6
7
8
14
13
12
C4P-1
UP
PRIMARY
DOWN BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
C5-21
C5-20
C6-32
C5-23
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C30EDC+ WHA
C31EDC- WH/BK
C32BRK WH/RD
WH
BK
WH
BK
BK
WH
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
C6-3
C6-13
C40LS1 OR
C6-19 RD/BK
C6-40
GROUND
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
C
TRAVEL ALARM OPTION
BRAKE RELEASE VALVE
STEER RIGHT
STEER LEFT
PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM
FLOW CONTROL
DRIVE ENABLE
LIMIT SWITCH
BOOM EXTEND
BOOM RETRACT
PLAT LEVEL UP
PLAT LEVEL DOWN
6 - 19
S-40 S-45
Part No. 102521
BK
PWR 3
1
GND 2
BRN
1
2
3
C40LS1 OR
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
C6-7
C6-8
C6-14
C6-15
JIB VALVES
NOTE:
P24FS WH
P24FS WH
4
C2P-2
JIB BOOM
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
EXTEND
BOOM
RETRACT
UP
DOWN
C18JD GR/BK
C17JU GR
7
H3
2
P26ESTP BK
C18JD GR/BK
JDALARM GR/BK
C4P-6
C6-18
C6-17
NONC
R2
C17JU GR
PLAT
ROTATE
NOHC
H4
SJ1-WH
C6-30
8
NOHC
BRN
C3P-7
C3P-8
EXTEND BOOM
C4P-2
UP
PLATFORM
DOWN LEVEL C4P-3
RETRACT
RD
RD
C4P-5
GR/BK-44 C2P-6
DOWN
UP JIB BOOM
TB30
TB31
TB37
TB32
TB5
DOWN
UP JIB BOOM
RIGHT
TB8
TB14
TB18
TB22
AMP
Deutsch
LEFT
RIGHT PLAT
ROTATE
2
4
LEFT
TB19
C19JSV GR/WH
3
2
TB44
5
TB7
TB15
TB17
TS62
TS61
TB36
TB4
TB1
TB13
TB40
3
C4P-7
TS57
J2
J1
JIB VALVE
JC2
BRN
J1
J1
CR30
NO
R1
JC3
DRIVE & STEERING
PRI UP/DN & TT ROTATE
WH
4
TS63
TS59
TS58
TS13
TS9
TS8
TS7
J3
JOYSTICK CONTROL CARD
C19JSV GR/WH
CR27
NC
CR13
NC
CR13
CE
LIFT/
DRIVE
OPTION
L1
TS15
WH
WH
6
4
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
1
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
6
Electrical Schematic
REV B
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 Schematics
July 2007
RD/BK
OR/BK
BK
July 2007
Section 6 Schematics
Electrical Schematic
Perkins 704-30 Models (before serial number 7472)
6 - 19
6 - 20
July 2007
Section 6 Schematics
REV A
RD/BK-C6-28
RD-C6-27
WH/RD-C5-14
WH/BK-C5-16
WH-C7B-2
BL/WH-C6-30
WH-C5-3+C5-11
RD- 12VOLT
12 V
C7B
C1B C2B C3B C4B
BK/WH-C6-8
BK-C6-7
WH/RD-C6-6
WH/BK-C6-5
WH-C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1
WH-CR2#86
BL/WH-L2
BK/RD CR3-#30
BK-ISM#3
WH/RD-C6-32
C6
D6
RD-ISM#4
RED-CR1#30
BK-CR5#30
WH-CR2#87
CB2-SP
GR/BK-C23-8
BK/RD-CR23#87
44B+RD/BK-C6-19
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.
IGN./START
MODULE
BK-22A
P1
RD-CB2
KEY SWITCH
KS1
TS51
NC
3
NC
WH-23A
RD-42A
RD-27A
RD-C23-6
1
B1
WH-21A
HM
BR (GROUND)
L45
FUNCTION ENABLE
PLATFORM ROTATE SWITCH
L2
BL/WH-C5-15
BL/WH-ISM#10
RD/WH-3A
RD/BK-2A
RD-1A
TS61
TS63
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
BK/WH-34A
TS52
+
-
RD- 20C
RD-CR17#30
WH-4
WH/RD-6
WH/BK-5
TS62
CB3
L28
TS58
TS55
D13
CR3
BK-C6-16
LABEL
DESCRIPTION
RD-H6+
OR/RD-H6-
CB1
CB2
TS59
RD- 20A
P1
KS1
42730
13037
TS55
13037
16397
13037
13037
16397
16397
13037
TS57
TS59
TS63
TS61
TS62
TS58
CB1
CB2
CB3
R1
R2
G1
G2
G3
R2
G1
G2
G3
STARTER AID
L28
56298
HOUR METER
IGN. START RELAY
IGN. POWER RELAY
HIGH IDLE (RPM) CUTOUT RELAY
HM
CR1
CR2
CR3
HM
CR1
CR2
CR3
RPM RELAY
CR4
CR4
CR17
CR17
RD- 20B
RD- P1 E-STOP
OR/BK-15A
PART #
P1
KS1
TS51
TS52
CB1
CB2
CB3
R1
RD- 24A
OR-C6-33
BR-GND+C6-26
RD C4B-12
BRN GND
WH/BK-25A
WH/RD-26A
BK/RD-35A
CR5
CR23
TS57
CR17
BK/RD-9B
BK-22B
GR-43D
BK-ISM#1
BK/RD-35B
RD C4B-11
RD-C23-7
CR2
WH-21B
RD-CB3 SP
R2
BK-C6-25
BK-C5-5
BR (GROUND)
D14
RD-CB3 SP
CR1
G3
G2
G1
WH-21A
BR-GND
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
5 GROUND
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
RD-ISM#6
WH-ISM#9
RD-24B
H6
BK-CR1#86
OR/BK-41B
BK-33D
RD-27B
BR-GND.
RD-CR2#30
WH-23B
GR/BK-S.P.
GR/BK-2B
GR-CR5#86
RD-H6+
OR/BK-ISM#2
C5
12V TO PLAT
19/18 CABLES
FUNCTIONS
ENGINE
3 BR-GND STUD
1 BK-C23-5
2 WH-23C
R1
GROUND STUD
OR/BK-C6-15
OR-C6-14
BL/RD-C6-13
RD
BK/WH-C5-22
BK-ISM#3
WH/RD-C5-23
WH/BK-C5-20
WH-C5-21
GR/BK-C6-18
GR-C6-17
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
RD-C5-1
RD- C5-19
23
22
BK-C23-4
21
WH-C6-34
CB3-SP
20
GR/WH-C4B-7 19
GR/BK-C4B-6 18
17
GR-C4B-5
OR/RD-C4B-4 16
OR/BK-C4B-3 15
OR-C4B-2
14
BL/RD-C4B-1
13
BL/WH-C3B-12 12
BL/BK-C3B-11 11
BL-C3B-10
10
9
BK/RD-C3B-9
BK/WH-C3B-8 8
7
BK-C3B-7
WH/RD-C3B-6 6
WH/BK-C3B-5 5
4
WH-C3B-4
RD/WH-C3B-3 3
2
RD/BK-C3B-2
1
RD-C3B-1
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1
RD-C6-23
OR/BK-C5-2
OR-C6-40
BK/WH-C5-10
BL/WH-C23-3
BL/BK-C6-37
BL-C6-36
RD-H6+ - C23-1
BL/WH-38D - C23-3
BK-22C - C23-4
RD-C23-1
BK-C7-1 - C23-5
RD-42B
RD-TS51 - C23-6 GN/BK-L45RD-TS55 - C23-7 GN/BK-16A
GN/BK-16B - C23-8
BR - GND - C23-12
U33
C23
PLATFORM
LOAD
GR/WH-C6-39
H6
U33
L45
OR-14A
GR-17A
CR4
GR/WH-19A
GR/BK-18A
BK/RD-C5-9
GROUND STUD
BR
WIRING
HARNESS:
TO BASE
ALL BR WIRES
S-40 S-45
6 - 21
July 2007
Section 6 Schematics
6 - 21
6 - 22
Section 6 Schematics
July 2007
6 - 24
6 - 23
P26BAT BK
P24FS WH
C132PLI BK C1P-12
RD P2
RD H1
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C19JSV GR/WH
C4P-7 AND TS8
BRN
C4P(BR)
C3P(GR)
C2P(BK)
F.S.
OPT.
LS18
C1P(GY)
RED/BLK-28
H1
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
C3P
C3P
D40
F.S.
D39
P24FS WH
C9P
C7P
RED-TILT
BRN
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
GN/BK L48
C7P
BATGND C7P-3
12V BATT
19/18 CONTROL CABLE
TILT
ALALRM
11
JIB
C4P
GN/BK C4P-4
BRN
C1P
C28TTA RD/BK C1P-2
J3
RED-TILT
HARNESS
PBOX WIRING
J2
J1
ALC-500
45383
89353
TILT ALARM
ALC-500
H1
C2P
PART NUMBER
COMPONENT INDEX
N
M
L
K
J
I
H
G
F
E
D
C
B
A
S-40 S-45
6 - 24
Section 6 Schematics
July 2007
REV A
July 2007
Section 6 Schematics
REV B
HARNESS
PBOX WIRING
7
TS48/ TS49
WORK/ DRIVE LITE
6
TS47
GENERATOR
(OPTION)
TS15
DRV.ENA
5
4
5
4
2
JC2
JC3
DLITE/ RD WL2
TS13
PRIMARY
BOOM
EXTEND/
RETRACT
2
1
WH-24
CR13
DRIVE LT BK/RD-C3P-9
75565
56298
66812, 73805
66813, 66816
42730
13037
TS4
L24
TS7
TS8
TS9
TS13
27378
56298
16397
13037
13037
13037
13037
27378
27378
4
DETAIL A: LIFT/DRIVE OPTION
REPLACE WIRE WITH THIS WIRING DIAGRAM
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BK-22
BRN BATGND
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
RD/BK H1
GN/BK H1
WH-24
RD
GR/WH-45
WH-24
BRN
WH-JIB
BK-7
BK/WH-8
BL/BK-DE2 J1-7
RD WL1
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
WH TS1
RD P3
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
OR R40LS1
(SPLICE TO R40LS1)
1
TS2
START
TS1
AUXILIARY PUMP
NC
TS8
JIB
TS4
HIGH/LOW
RPM
CR27
WH TS7
P22BAT BK C7P-1
NO
L24
GLOW PLUG
NC
(GND STUD)
RD LS18
BK-22
P26BAT BK C9P-1
WH-23
RD-TILT
BK/RD-35
WH-24
BK-33
RD
RD-25
BRN
WH-24
C27AUX RD C1P-1
WH-JIB
C17JU GR C4P-5
C19JSV GR/WH
OR-14
OR/BK-15
RD P2
GR-43
TS7
PLATFORM
ROTATE
L48
WH
GR/BK
JC3
L1
P2
P3
TS1
TS2
L4
L1
WH
62390
+
+
GR
TS9
PLATFORM
LEVEL
PART NUMBER
WH
P3
HORN
COMPONENT INDEX
JC2
RD
RD
P2
EMERGENCY STOP
CE SEE DETAIL A
NOTE:
1) DASHED LINES INDICATE OPTION WIRES.
S-40 S-45
6 - 25
July 2007
Section 6 Schematics
6 - 25
6 - 26
Section 6 Schematics
July 2007
Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)
Perkins 404-22 Models (from serial number 7472 to 12509)
6 - 28
6 - 27
July 2007
Section 6 Schematics
REV A
Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)
Perkins 404-22 Models (from serial number 7472 to 12509)
A
BL/WH
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
BK
F18
FS1
BK-(FS)
C9-1 BK
HIGH RPM(FS)
C3P-9
GENERATOR
WH
WH
DRIVE LIGHT
TS4
C2-7
BK
BK
C1-9
RD
LOW RPM
FUNCTION ENA.
HIGH RPM
BK/RD
C6-39
C2B-4
GR/WH-45
CR3
CR4
BK/RD-C5-8
C4B-11
C5-11
RD
RD
S1
Y29
G1
L29
NO
L29
BRN
C6-26
NC
BRN
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
WATER TEMP
SWITCH
OIL PRESSURE
SWITCH
NOTE:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
IN THE STOWED POSITION AND KEYSWITCH "OFF".
RPM FILTER
VOLT METER
FUEL RELAY
HOUR METER
IGN./START RELAY
STARTER MOTOR
EMISSION CONTROL
AUXILIARY PUMP
AUXILIARY POWER
RELAY
TILT ALARM
LEVEL SENSOR
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
+
-
COOLING FAN
(OPTION)
S-40 S-45
C35ESPD BK/RD
C45GEN GR/WH
DLITE OR/RD
C21IGN2
C5-22
CR23
CR23
NO
NO
NO
PR3
WH/RD
HM
_
PR3
NO
C5-14
J144-4
WH/BK
J1 44-6
BK
G6
M2 PUMP
TB35
L2
G3
S2
STARTER
AUX
C34SA BK/WH
TB34
TB26
C5-16
PR2
S7
H2
C5-13 WH
WH-21
BK-33
RD-27
WH
RD
3MF
PR2
TS55
TB45
PBOX GND
C5-5
C6-27
G2
PR1
FB
M1
REGULATOR
IND.
TB21
CR2
NO
TB25
PR1
NO
STA.
FAN
RD/BK-28
RD-134
CR17
C6-33
BAT.
-
CR17
NO
CR2
CR1
CR1
NO
BK-43
EXCT.
C6-25
OR/BK-41
ALTERNATOR
CR5
C6-16
C6-34
C5-2
C5-3
OTS
NO
C6-23
CR5
NO
TB24
C6-28
CB3
BK
TB28
RD
20AMP.
1 START RELAY
2 TACHOMETER
3 START INPUT
IGN./START
4 AUX. ON
MODULE
5 GROUND
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
D6
TB133
6 - 28
TS17
L30
TB33
TB23
L45
ON GLOW
PLUG
H6
15AMP.
C33STR BK
RD
CB1
TS56
ENGINE
TB27
BK
TS52
START
RD
TS51
PUMP AUXILIARY
U33
12
C27AUX RD
P23BAT WH
C28TTA RD/BK
C43HRN GR
GRD
BAT.
+
TS48
RD
C133PLA OR/RD
L30
C1-8
C1-7
PUMP AUXILIARY
C1-1
C7-2
C1-2
C4-4
TB43
WORK LIGHT
TS1
L48
D40
D39
TS6
START ENGINE
H1
C2-5
C7-1
C1-12
TB22
PLAT
12 V
DC
TS49
WH
ON GLOW
PLUG
P22BAT BK
C132PLI BL/WH
L4
TB132
KS1
FUSE 10A
RD
RD
TB20
P24FS WH
TS2
TB134
RD
P1
P25FS RD
C9-2
HORN
C2-4
CB2
15AMP.
C9-3
WH-(FS)
C28TTA RD/BK
P3
NOTE:
TB132 IS WAGO TERMINAL BLOCK 42
TB TB133
134 ISISWAGO
BLOCK 16
42
WAGO TERMINAL
TERMINAL BLOCK
TB TB134
133 ISISWAGO
BLOCK 38
16
WAGO TERMINAL
TERMINAL BLOCK
TB 132 IS WAGO TERMINAL BLOCK 38
RD-(FS)
RD
C134PWR RD
C41RPM OR/BK
P2
LS18
Electrical Schematic
REV A
C29MS
DRE A BL/WH
BL
WH
14
13
OR
RD
BK
12
11
15
16
19
20
18
17
11
10
6
7
8
14
13
12
C2P-3
C1P-4
C1P-5
C1P-6
C1P-3
C1P-11
C1P-10
C3P-6
C3P-5
C3P-4
7.5
BRN-2
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C37STCC BL/BK
C36STC BL
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
TROTATE
RIGHT
LEFT
C4P-1
C3P-3
C3P-2
C3P-1
C40LS1 OR
C13DRE BL/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
PRIMARY BOOM
DOWN
UP
C2P-2
C8PBR BK/WH
C7PBE BK
EXTEND
JIB BOOM
RETRACT
C3P-8
C14PLU OR
C3P-7
C4P-2
C15PLD OR/BK
C5-21
C5-20
C6-32
C5-23
C5-19
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C13DRE BL/RD
C6-3
C6-13
C6-15
C6-14
C6-8
C6-7
C40LS1 OR
6
C6-40
C6-18
C6-17
C30EDC+ WH
C6-30
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C6-19 RD/BK
C7PBE BK
C8PBR BK/WH
C14PLU OR
C15PLD OR/BK
C18JD GR/BK
C17JU GR
7
WH
BK
WH
BK
WH
BK
GROUND
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
MOTOR STROKE
STEER RIGHT
STEER LEFT
TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM UP
PRIMARY BOOM
FLOW CONTROL
DRIVE ENABLE
LIMIT SWITCH
BOOM EXTEND
BOOM RETRACT
PLAT LEVEL UP
PLAT LEVEL DOWN
JIB VALVES
6 - 29
S-40 S-45
C41RPM OR/BK
15
16
7
RKOUT 6
OR
7
YOUT 5
BRN
5
4
4
PWR 3
1
GND 2
XOUT 4
YOUT 5
BRN
GND 2
PWR 3
BRN
P24FS WH
P24FS WH
P26ESTP BK
3
4
BOOM
C4P-3
JDALARM GR/BK
PLATFORM LEVEL
RETRACT
EXTEND
UP
DOWN
C2P-6
C18JD GR/BK
DOWN
UP JIB BOOM
C4P-6
C17JU GR
DOWN
UP JIB BOOM
NOTE:
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
POSITION EXCEPT AS NOTED.
NCHO
8
NOHC
BRN
NOHC
Y51
Y2
Y27
Y3
Y4
Y29 Y23
Y13
Y21 Y22
Y12
H4
Y25
Y26
Y19 Y20
Y17 Y16
H4
SJ1-WH
TB22
TB30
TB31
TB32
TB37
TB36
TB4
4
C4P-5
RD
5
TB6
TB14
R2
R1
TB29
TB3
TB8
TB17
TB5
TB2
TB13
TB40
TB7
TB15
TB1
RIGHT
PLAT ROTATE
LEFT
TB44
C19JSV GR/WH
TB18
GR/BK-44
DOWN
JIB BOOM
UP
C4P-7
TS58
TB19
RIGHT
PLAT ROTATE
LEFT
JIB VALVE
RD
J1
J1
J1
J3
2
TS14
L1
TS15
JC3
3
J2
TS62
TS61
TS63
TS59
TS57
TS13
TS9
TS8
TS7
CR27
NC
CR13
NC
CR13
CR30
CE NO
LIFT/
DRIVE
OPTION
C19JSV GR/WH
WH
WH
JC2
WH
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 Schematics
July 2007
RD/BK
BL/WH
BK
OR/BK
BRN
July 2007
Section 6 Schematics
Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)
Perkins 404-22 Models (from serial number 7472 to 12509)
6 - 29
6 - 30
Section 6 Schematics
July 2007
Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models
(after serial number 12509)
6 - 32
6 - 31
July 2007
Section 6 Schematics
REV B
Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models
(after serial number 12509)
A
N
BL/WH
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
BK
F18
LS18
P2
FUSE 10A
FS1
C9-1 BK
BK-(FS)
RD-(FS)
C9-3
P25FS RD
WH-(FS)
C9-2
P24FS WH
TS6
DRIVE LIGHT
TS17
TS4
HIGH RPM(FS)
C3P-9
GENERATOR
WH
GLOW
PLUG
L30
L30
C2-7
C1-8
C1-7
C1-1
C7-2
C1-2
C4-4
C2-5
C7-1
C2-4
PUMP AUXILIARY
ENGINE
D39
WH
TS1
L48
H1
ON
START
L4
WORK LIGHT
P3
HORN
C1-12
TB132
BK
BK
TB134
RD
P1
RD
RD
C1-9
15AMP.
P22BAT BK
C134PWR OR/RD
C132PLI BL/WH
C41RPM OR/BK
CB2
TS2
D40
WH
C28TTA RD/BK
RD
Note:
TB132 is WAGO terminal block 42
TB133 is WAGO terminal block 16
TB134 is WAGO terminal block 38
TS48
TB43
2
C35ESPD BK/RD
GR/WH-45
CR4
RD
L29
BK/RD-C5-8
RD
S1
NO
C4B-9
C4B-11
3
4
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
OIL TEMPERATURE
SWITCH
OIL PRESSURE
SWITCH
RPM FILTER
C6-39
C4B-12
C4B-10
S2
FUEL RELAY
VOLT METER
S-40 S-45
HOUR METER
IGN./START RELAY
STARTER MOTOR
EMISSION CONTROL
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
+
-
COOLING FAN
(OPTION)
NOTE:
6 - 32
G1
NC
1.
L29
CR3
Y29
HM
BRN
BR
PR3
+
_
NO
NO
PR3
NO
C5-14 WH/RD
H2
FAN
G3
J144-4
IND.
CR23
CR23
NO
TB26
G6
STARTER
M2 PUMP
BK
REGULATOR
J144-6
RD
NO
M1
C5-16 WH/BK
PR2
PR2
S7
FB
STA.
WH-21
BK-33
RD-27
RD
WH
NO
C5-13 WH
C5-5
RD/BK-28
RD-134
BK-43
BK
OR/BK-41
3MF
PR1
PR1
BAT.
-
BAT.
+
12 V
DC
CR17
TB25
G2
TB35
FUSE 70A
WH
C5-22
WH
C5-2
C5-3
EXCT.
CR17
NO
L2
3
NO
ALTERNATOR
TB21
CR2
NO
BL/WH
OTS
CR2
CR1
CR1
NO
CR5
TB34
C2B-4
CR5
NO
RD
BK/RD
CB3
20AMP.
LOW RPM
FUNCTION ENA.
HIGH RPM
TB24
DLITE OR/RD
RD
C34SA BK/WH
TB28
TB45
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
IGN./START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS U1
9 IGN./FUEL ON
10ENG. FAULT
D6
TB133
PBOX GND
TS55
RD
TB33
TB23
L45
H6
ON GLOW
PLUG
15AMP.
TS56
BK
RD
CB1
TB20
C33STR BK
TB27
D3
D2
BK
TS52
START ENGINE
12
RD
U33
TS51
PUMP AUXILIARY
C27AUX RD
P23BAT WH
GRD
C28TTA RD/BK
PLAT
C133PLA OR/RD
C45GEN GR/WH
TB22
C43HRN GR
KS1
BRN
Electrical Schematic
REV B
BL/WH
OR
BL/WH
WH/RD
14
5
13
12
13
14
10
11
17
18
20
19
16
15
C41RPM OR/BK
15
16
BRN
11
RD/WH
12
DRE A BL/WH
GND 1
WH/RD
OR
BRN
1
2
4
3
4
BOOM
C2P-3
BRN-2
C1P-3
C1P-6
C37STCC BL/BK
C29MS RD/WH
C32BRK WH/RD
C31EDC- WH/BK
C1P-11
C36STC BL
C30EDC+ WH
C1P-10
C6TRF WH/RD
C1P-5
C3P-6
C5TRR WH/BK
C1P-4
C3P-5
C4TRL WH
PRI BOOM
LEFT TT ROTATE
RIGHT
C3P-4
7.5
DOWN
UP
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
BOOM
C40LS1 OR
EXTEND
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
RETRACT
JDALARM GR/BK
C3P-1
C3P-2
C3P-3
C4P-1
C2P-2
C3P-8
C3P-7
C2P-6
C18JD GR/BK
C5-21
C31EDC- WH/BK
C30EDC+ WH
D
C6-5
C6-4
C6-36
C6-37
C5-19
C5-23
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
C36STC BL
C37STCC BL/BK
C29MS RD/WH
C32BRK WH/RD
C2PBD RD/BK
C1PBU RD
C6-2
C3PBF RD/WH
C6-13
C13DRE BL/RD
C6-17
C6-18
C17JU GR
C18JD GR/BK
C15PLD OR/BK
C14PLU OR
WH
BK
BK
WH
BK
WH
C7PBE BK
C40LS1 OR
C6-30
C6-7
C6-8
C6-14
C6-15
C8PBR BK/WH
C6-40
C6-19 RD/BK
C6-3
C6-1
C6-6
C6-32
C5-20
5
TB18
B
C
GROUND
PLAT LEVEL UP
BOOM RETRACT
BOOM EXTEND
DRIVE ENABLE
LIMIT SWITCH
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
STEER LEFT
STEER RIGHT
MOTOR STROKE
7
JIB VALVES
6 - 33
S-40 S-45
Part No. 102521
RKOUT 5
YOUT 4
XOUT 3
PWR 2
6
5
YOUT 4
XOUT 3
PWR 2
GND 1
BRN
P24FS WH
P24FS WH
P26ESTP BK
EXTEND
RETRACT
C4P-2
C4P-3
C4P-6
C17JU GR
JIB BOOM
DOWN
UP
PLAT ROTATE
8
NOTE:
NCHO
NOHC
NOHC
BRN
Y51
Y2
Y27
Y3
Y4
Y23
Y29
Y13
Y22
Y21
Y12
H4
Y25
TB6
TB3
TB30
TB31
TB32
TB37
DOWN
PLAT LEVEL
UP
C4P-5
DOWN
PLAT LEVEL
UP
GR/BK-44
JIB BOOM
RIGHT
LEFT
SJ1-WH
TB29
TB14
TB5
TB2
TB36
TB4
TB1
C19JSV GR/WH
TB8
TB17
R2
R1
H4
Y26
Y20
TS63
TB13
TB40
TB7
TB15
TS61
TS59
3
C4P-7
TB44
Y19
Y16
Y17
DOWN
UP
PLAT ROTATE
RD
TS15
4
TS58
TB19
RIGHT
LEFT
JIB VALVE
RD
J1
J1
J1
J3
TS62
TS57
J2
CR30
NO
CE
LIFT/
DRIVE
OPTION
C19JSV GR/WH
TS9
TS8
TS7
CR27
NC
CR13
NC
CR13
TS13
TS14
L1
DRIVE & STEERING
2
WH
WH
JC3
JC2 PRI UP/DN & TT ROTATE
WH
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 Schematics
July 2007
OR/BK
BK
BL/WH
RD/BK
BRN
July 2007
Section 6 Schematics
Electrical Schematic
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models
(after serial number 12509)
6 - 33
6 - 34
July 2007
Section 6 Schematics
REV A
PLATFORM LOAD
RD-C6-23
OR/BK-C5-2
OR-C6-40
BK/WH-C5-10
BL/WH-C23-3
BL/BK-C6-37
BL-C6-36
BK/WH-C5-22
WH/RD-C5-23
WH/BK-C5-20
WH-C5-21
RD/WH-C5-24
RD/BK-C6-28
RD-C6-27
RD-C5-1
BL/WH-C6-30
WH-C5-3+C5-11
RD- 12VOLT
GR/BK-C6-18
GR-C6-17
BR-GND STUD
C7B
3
1
BK-C32-5
2 WH-23C
C2B
12V TO PLAT
12 V
OR/BK-C6-15
OR-C6-14
BL/RD-C6-13
BK/WH-C6-8
BK-C6-7
WH/RD-C6-6
WH/BK-C6-5
WH-C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1
WH-C7B-2
BK-C32-4
WH-C6-34
CB3-SP
GR/WH-C4B-7
GR/BK-C4B-6
GR-C4B-5
OR/RD-C4B-4
OR/BK-C4B-3
OR-C4B-2
BL/RD-C4B-1
BL/WH-C3B-12
BL/BK-C3B-11
BL-C3B-10
BK/RD-C3B-9
BK/WH-C3B-8
BK-C3B-7
WH/RD-C3B-6
WH/BK-C3B-5
WH-C3B-4
RD/WH-C3B-3
RD/BK-C3B-2
RD-C3B-1
C1B
C4B
19/18 CABLES
C3B
WH-23B
WH-CR2#86
WH-L2 DIODE
G2
BK/RD-9B
G3
BK/RD-S.P.
BK/WH-S.P.
BK-S.P.
D6
RD-ISM#4
RED-CR1#30
WH-ISM #7
BK-CR5#30
WH-CR2#87
CB2-SP
GR/BK-C32-8
RD C4B-12
BR (GROUND)
RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
CB1 - SP
GR/WH-SP
GR/BK-S.P.
GR-S.P.
GR/BK-H6OR/BK-S.P.
OR-S.P.
WH/BK-25A
WH/RD-26A
BK-22A
KS1
RD-CB2
TS51
NC
3
NC
WH-23A
RD-42A
RD-27A
RD-C23-6
1
B1
BK/RD-CR23#86
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.
A
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
KEY SWITCH
KS1
KS1
AUXILIARY SWITCH
TS51
42730
TS52
13037
STARTER AID
TS56
13037
TS55
13037
16397
TS57
TS59
13037
WH-21A
TS63
13037
HM
BR (GROUND)
L2
L45
WH-C5-13
PRIMARY BOOM
UP/DOWN
TS61
RD/WH-3A
RD/BK-2A
RD-1A
BOOM
EXTEND/RETRACT
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
TS63
TURNTABLE
ROTATE
TS52
ENGINE
START
TS56
D14
FUNCTION
ENABLE
CB1
TS61
16397
TS62
16397
TS58
13037
CB1
CB1
CB2
CB2
CB3
CB3
R1
R1
R2
R2
G1
G1
G2
G2
G3
G3
HM
CB3
TS58
JIB BOOM
UP/DOWN
TS62
R2
CB2
TS57
BK/RD-35B
P1
RD- 20C
RD-CR17#30
WH/BK-5A
WH/RD-6A
WH-4A
MODULE
PART #
P1
RD
STARTER AID
IGN./START
LABEL
GR/BK-H6-
BK/WH-34A
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
DESCRIPTION
AUXILIARY
KEY SWITCH
P1
BL/WH-ISM#10
44B+RD/BK-C6-19
RD C4B-11
BRN GND
HORN
C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
3MF
C132PLI
STEER LEFT
STEER RIGHT
GND
RPM
GLOW PLUG
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
MOTOR SPEED
TILT ALARM
AUX. PWR.
WATER TEMP. SENDER
OIL PRESSURE SENDER
ENGINE POWER
KEYSWITCH PWR/FB
PWR. TO PLAT.
IGNITION PWR.
12 VOLT BATTERY POWER
JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.
C133PLA
PLAT. LEVEL DN.
PLAT. LEVEL. UP
DRV. ENA. LT.
BL/RD-S.P.
BK/RD CR3-#30
RD-CB3 SP
WH-21A
RD-KS1-2 S.P.
BR -3MF CAP
BK-ISM#3
WH/RD-C6-32
CR23
GR/BK-S.P.
GR/BK-2B
GR-CR5#85
RD-H6+
OR/BK-ISM#2
RD-ISM#6
WH-ISM#9
RD-24B
C6
H6
G1
B
1
2
3
4
5
R1
BK-CR1#86
OR/BK-41B
BK-33B
RD-27B
BR-GND.
RD-CR2#30
RD-C32-1
RD-42B
GR/BK-L45GR/BK-16A
SPARE
GEN. OPTION
FUNCTIONS
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RD
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1
RD-H6+ - C32-1
BL/WH-38D - C32-3
BK-22C - C32-4
BK-C7-1 - C32-5
RD-TS51 - C32-6
RD-TS55 - C32-7
GR/BK-16B - C32-8
BR - GND - C32-12
C32
U33
GR/WH-C6-39
RD-C32-7
HOUR METER
HM
CR1
CR1
CR2
CR2
CR3
CR3
RPM RELAY
CR4
CR4
CR17
CR17
H6
U33
L45
TS55
CR1
CR2
CR4
CR3
D13
BK/RD-35A
BK-ISM#1
TS59
PLATFORM
LEVEL
PLATFORM
ROTATE
RD- 20A
BK-C5-5
RD- 24A
WH-21B
RD- 20B
C5
ENGINE
BK/RD-C5-9
BK-C6-16
RD- P1 E-STOP
OR-C6-33
OR/BK-15A
OR-14A
GR-17A
GR/WH-19A
GR/BK-18A
CR5
GR-43D
GROUND STUD
BK-22B
GROUND STUD
BR
CR17
BK-C6-25
RD-CB3 SP
WIRING
HARNESS:
TO BASE
ALL BR WIRES
S-40 S-45
6 - 35
July 2007
Section 6 Schematics
6 - 35
6 - 36
Section 6 Schematics
July 2007
6 - 38
6 - 37
11
1
P26BAT BK
P24FS WH
P24FS WH
BRN
PART NUMBER
45383
94771
COMPONENT INDEX
TILT ALARM
ALC-500
H1
RD P2
RD H1
C132PLI BK C1P-12
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C19JSV GR/WH
C4P-7 AND TS8
BRN
OPT.
LS18
JIB
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
F.S.
RD/BK-28
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH
C9P
C7P
J3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
C7P
BATGND C7P-3
12V BATT
19/18 CONTROL CABLE
TILT
ALALRM
C3P
C3P
D40
D39
H1
S-40 S-45
6 - 38
RED-TILT
C4P
GR/BK C4P-4
C1P
C28TTA RD/BK C1P-2
J2
J1
GR/BK L4
HARNESS
PBOX WIRING
REV A
C2P
N
M
L
K
J
I
H
G
F
E
D
C
B
A
ALC-500
RED-TILT
Section 6 Schematics
July 2007
July 2007
REV A
Section 6 Schematics
HARNESS
PBOX WIRING
10 AMP FUSE
TS48
JC2
TS15
DRV.ENA
JC2
PRIMARY
BOOM
EXTEND/
RETRACT
56298
75565
56298
66812, 95406
66813, 66815
42730
13037
TS4
TS6
TS7
TS8
RD WL2
TS13
WH-24
L1
TS9
TS13
TS14
TS15
TS47
TS48
DRIVE LT BK/RD-C3P-9
L48
(GND STUD)
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
CR27
WH TS7
RD
RD P3
P22BAT BK C7P-1
RD LS18
WH-23
BK-22
P26BAT BK C9P-1
GR/WH-45
WH-24
BK/RD-35
WH-24
C33STR BK C1P-7
RD TS47
RD-25
WH-24
C29MS RD/WH J1-8
WH-24
C27AUX RD C1P-1
WH-JIB
C19JSV GR/WH
C17JU GR C4P-5
WH TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
REMOVE FOR
GENERATOR OPTION
OR R40LS1
1
(SPLICE TO R40LS1)
1 1
GENERATOR
(OPTION)
NC NC NC
TS47
2 2
NO
PLATFORM
LEVEL
BRN BATGND
RD/BK H1
GR/BK H1
WH-24
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BK-22
BRN
WH-JIB
BK-7
BK/WH-8
BL/BK-DE2 J1-7
RD WL1
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
OR-14
OR/BK-15
RD P2
GR-43
HORN
13037
27378
27378
P2
EMERGENCY STOP
WH
PLATFORM
ROTATE
GR/BK
13037
13037
56457
GR
WH
16397
13037
RD
WH
TS9
56457
13037
L4
P3
56298
CE PLATFORM LED
HI/L0 RPM SWITCH
CR13
TS7
62390
JC3
L1
L4
JC3
L48
P2
P3
TS1
TS2
PART NUMBER
COMPONENT INDEX
TS8
JIB
TS1
AUXILIARY PUMP
TS14
TS6
TS4
HIGH/LOW
DRIVE
SPEED
GLOW PLUG
HIGH/LOW
RPM
RD
NOTE:
1) DASHED LINES INDICATE OPTION WIRES.
CE SEE DETAIL A
S-40 S-45
6 - 39
July 2007
Section 6 Schematics
6 - 39
6 - 40
July 2007
REV A
Section 6 Schematics
HARNESS
PBOX WIRING
10 AMP FUSE
WORK/ DRIVE LITE
TS48
PRIMARY BOOM
UP/DOWN
DRIVE/STEER
DRIVE ENABLE
TS15
JC2
JC3
TURNTABLE ROTATE
RD WL2
RD WL1
PRIMARY
BOOM
EXTEND/
RETRACT
4
WH-24
TS13
J1-13 OR JC3-2
GR/BK H1
RD/BK H1
WH-24
BRN BATGND
(GND STUD)
WH TS7
CR27
WH TS1
RD
RD LS18
RD P3
BK-22
P22BAT BK C7P-1
WH-23
P26BAT BK C9P-1
GR/WH-45
BK/RD-35
WH-24
C33STR BK C1P-7
RD-25
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
(SPLICE TO R40LS1)
TS1
TS14
TS6
TS4
TS2
DRIVE
SPEED
JIB
L48
WH-24
C29MS RD/WH J1-8
PLATFORM
ROTATE
GR/BK
BL/RD-DE3 J1-16
WH
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7
PLATFORM
LEVEL
OR R40LS1
GR
HORN
P3
RD
L4
WH-24
C27AUX RD C1P-1
WH-JIB
C17JU GR C4P-5
C19JSV GR/WH
TS8
L1
DRIVE LT BK/RD-C3P-9
BRN
BK-7
BK/WH-8
J1-11 OR JC2-2
WH
OR-14
OR/BK-15
RD P2
GR-43
WH
TS7
TS9
CR13
HIGH/LOW
AUXILIARY PUMP
EMERGENCY STOP
P2
TS17
GLOW PLUG
RD
START
HIGH/LOW
RPM
RD
7
NOTE:
GENERATOR
(OPTION)
CE SEE DETAIL A
S-40 S-45
6 - 41
July 2007
Section 6 Schematics
6 - 41
6 - 42
Section 6 Schematics
July 2007
Electrical Schematic
Ford LRG-425 EFI Models
(before serial number 7597)
6 - 44
6 - 43
C9-1 BK
HIGH RPM(FS)
GENERATOR
LP
FUEL
GAS
C2-7
C2-1
C1-7
ENGINE
C2-5
C7-1
C4-4
C1-2
C7-2
C1-1
PUMP AUXILIARY
START
P22BAT BK
C2-4
RD
C1-9
C35ESPD BK/RD
C45GEN GR/WH
BK
ENGINE
LP FUEL
GAS
C33STR BK
START
TB45
AUXILIARY
PUMP
RD
C27AUX RD
P23BAT WH
C28TTA RD/BK
C133PLA OR/RD
BK/RD
C6-39
TEST
RUN
C6-28
C6-23
GR/WH-45
C5-13
C5-12
C5-17
C5-10
C5-9
C5-15
C5-5
C6-27
BRN
OR/BK-41
C5-14
WH/RD-24
WH/BK-24
C5-16
BK
C6-26
BRN
RD (FEH 361A)
C6-33
NOTE:
FUEL PUMP
FORD
42 PIN PLUG
GENERATOR
OPTION
FUEL RELAY
OIL PRESSURE
SWITCH
WATER TEMP
SWITCH
RD
WH
WH-21
BK-33
RD-27
C6-25
BK-43
RD/BK-28
RD-P134
C6-16
C6-34
C5-2
C5-3
OTS
NC
G1
HM
_
REGULATOR
PR1
G3
G2
P24BAT
TB24
TB26
TB25
FUEL
PUMP
OPS
+
STARTER
AUX
PUMP
H2
FAN
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)
NO
IND.
C134PWR OR/RD
C41RPM OR/BK
RD
STA.
CR17
BAT.
BAT.
12 V
DC
CB3
PR1
NO
EXCT.
8
9
10
CR2
CR2
NO
CR1
CR1
NO
CR5 CR5
NO
20AMP.
FB
CR17
NO
ALTERNATOR
S-40 S-45
6 - 44
TB24
OTS
NO
TB35
TS22
L2
START RELAY
TACHOMETER
START INPUT
IGN./START
AUX. ON
GROUND
MODULE
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
1
2
3
4
5
6
TB23
RD
TB20 15AMP.
TB33
D6
TB27
TB39
TB28
TB133
CB1
TS53
PLAT
GRD
SEE NOTE 2
TS17
TS3
TS2
TS1
OR/BK
C2-3
TB41
TS55
TS52
TS51
TB22
KS1
TB134
RD
P1
CB2
D40
D39
TS4
L4
RD-(FS)
WH-(FS)
FS1
BK-(FS)
P2
RD/BK
C28TTA RD/BK
RD
TB43
RD
RD
15AMP.
L48
H1
P3
HORN
WH
P25FS RD
P24FS WH
C9-3
C9-2
RD
REV B
Electrical Schematic
N
M
L
K
J
I
H
G
F
E
D
C
B
A
FORD
ENGINE
HARNESS
Section 6 Schematics
July 2007
P26ESTP BK
BK
TB21
WH
DRE A BL/WH
WH
RKOUT 6
10
11
17
18
20
19
16
15
C41RPM OR/BK
15
8
16
7
6
5
4
13
14
BL
OR
BRN
YOUT 5
GND 2
PWR 3
RD
6
7
8
14
13
12
C1P-10
C1P-11
C1P-6
C1P-5
C1P-4
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
BRN-2
C3P-6
C5TRR WH/BK
C2P-3
C3P-5
C2PBD RD/BK
C1PBU RD
UP
PRIMARY
DOWN BOOM
LEFT
TROTATE
RIGHT
C4TRL WH
7.5
C3P-4
C3P-1
C3P-2
C3P-3
C13DRE BL/RD
C3PBF RD/WH
C4P-1
C40LS1 OR
BOOM
C7PBE BK
C8PBR BK/WH
C14PLU OR
C15PLD OR/BK
PLAT
DOWN LEVEL
UP
RETRACT
EXTEND
C2P-2
C3P-7
EXTEND BOOM
C3P-8
RETRACT
C4P-2
UP
PLAT
DOWN LEVEL C4P-3
JDALARM GR/BK
C18JD GR/BK
C2P-6
C4P-6
C5-21
C5-20
C6-32
C5-23
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-13
C6-40
C6-7
C6-8
C6-14
C6-15
C6-18
C30EDC+ WH
C32BRK WH/RD
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C6-19 RD/BK
C13DRE BL/RD
C40LS1 OR
C7PBE BK
C8PBR BK/WH
C14PLU OR
C15PLD OR/BK
C18JD GR/BK
BK
WH
BK
WH
BK
WH
C31EDC- WH/BK D
7
H3
PLAT LEVEL UP
BOOM RETRACT
BOOM EXTEND
DRIVE ENABLE
LIMIT SWITCH
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
STEER LEFT
STEER RIGHT
GROUND
8
JIB VALVES
6 - 45
S-40 S-45
Part No. 102521
OR
BK
YOUT 5
XOUT 4
BRN
2
1
11
12
PWR 3
1
GND 2
BRN
2
4
4
RD
C17JU GR
C17JU GR
NOTE:
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
POSITION EXCEPT AS NOTED.
P24FS WH
P24FS WH
P26ESTP BK
RD
C4P-5
C6-17
AMP
GR/BK-44
DOWN JIB
BOOM
UP
RIGHT JIB
BOOM
LEFT
RIGHT PLAT
LEFT ROTATE
H4
SJ1-WH
C6-30
TB22
1
Deutsch
C19JSV GR/WH
TB36
3
RIGHT PLAT
LEFT ROTATE
C4P-7
2
4
TB6
TB8
TB14
TB18
TB5
TB2
TB30
TB1
TB32
TB37
TB13
TB40
5
TB3
TB7
TB15
TB17
TB31
TB4
4
TS62
TS61
J1
J1
J1
JIB VALVE
4
1
TB44
TB19
TS63
TS59
TS58
TS57
J2
C19JSV GR/WH
CR27
NC
TS13
TS9
TS8
TS7
J3
JOYSTICK CONTROL CARD
2
CR13
NC
CR13
CR30
NO
CE
LIFT/
DRIVE
OPTION
L1
JC3
TS15
JC2
WH
WH
6
6
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
6
Electrical Schematic
REV B
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 Schematics
July 2007
RD/BK
OR/BK
BK
BRN
July 2007
Section 6 Schematics
Electrical Schematic
Ford LRG-425 EFI Models
(before serial number 7597)
6 - 45
6 - 46
July 2007
Section 6 Schematics
REV A
GR/WH-C6-39
OR/BK-C5-2
OR- C6-40
BK/WH-C5-10
BL C5-13
BL/BK-C6-37
BL- C6-36
BK/RD-C5-9
BK-ISM#3
WH/RD-C5-23
WH/BK-C5-20
WH- C5-21
RD- C6-23
BL/WH-C6-30
WH-C5-3+C6-34
GR/BK-C6-18
GR- C6-17
12 V
C2B
C1B
GR/WH-SP
GR/BK-S.P.
GR-S.P.
JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.
OR/BK-S.P.
OR-S.P.
GR/BK-SP
BL/RD-S.P.
BL/WT-S.P.
BL/WH-ISM#10
BK/RD-S.P.
BK/WH-S.P.
BK-S.P.
D6
RD-ISM#4
RED-CR1#30
WH-TS22#5
BK-CR5#30
WH-CR2#87
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.
44B-RD/BK-C6-19
3 BR-GND STUD
1 BK-22C
2 WH-23C
G1
1
2
3
4
5
6
7
8
9
10
WH-CR2#86
BK/WH-38B
RD-ISM#6
WH-ISM#9
RD-24B
CR17
CR2
P1
RD-CB2
C6
OR-C6-33
BR-GND+C6-26
TS22
36
25
14
KS1
KEY SWITCH
NC
1
B1
WH-23A
RD-42A
RD-27A
BL/RD-39A
RD-C23-6
RD-H6+
TS51
B
3
OR/RD-H6-
WH-21A
TS53
L2
L45
BL/WH-C5-13
BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP
BL/WH-ISM#10
DESCRIPTION
TS61
RD/WH-3A
RD/BK-2A
RD-1A
TS63
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
START RELAY
TACHOMETER
START INPUT IGN./START
AUX. ON
MODULE
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
TS62
TS52
CB3
RD- 20C
RD-CR17#30
GR-17A
GR/WH-19A
GR/BK-18A
RD-CB3 SP
TS58
CR23
GR/BK C2B-6
R2
D14
CB1
RD C4B-11
TS57
CB2
RD C4B-12
BRN GND
CR5
TS55
TS59
P1
PART #
P1
KEY SWITCH
KS1
KS1
AUXILIARY SWITCH
TS51
42730
TS52
13037
LP/GAS SWITCH
TS53
56457
13037
FUNCTION ENABLE
TS55
TS57
16397
TS59
13037
TS63
13037
TS61
16397
TS62
16397
TS58
13037
42730
TS22
CB1
CB1
CB2
CB2
CB3
CB3
R1
R1
R2
R2
G1
G1
G2
G2
RD- 24A
G3
G3
RD- 20B
CHECK ENGINE
L2
56298
HOUR METER
HM
HM
RD- P1 E-STOP
WH-ISM#7
WH-23B
BLK-33B
WH CR2#87
WH-C5-17
LABEL
RD- 20A
BK/RD-35A
BK-C6-16
G3
G2
NC
D13
WH-21B
WH-TS22#4
WH/BK-25A
WH/RD-26A
BK-22A
BK-ISM#1
BK-C5-5
BK-22B
GR-43D
RD-CB3 SP
BK-C6-25
BR (GROUND)
A
BK-CR1#86
OR/BK-41B
BK-33B
RD-27B
BR-GND.
RD-CR2#30
WH-TS22#6
WH-21A
HM
CR1
BR (GROUND)
C3B C4B
C7B
C5
FUNCTIONS
ENGINE
GROUND STUD
BK/WH-C6-8
BK- C6-7
WH/RD-C6-6
WH/BK-C6-5
WH- C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1
RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
GR/BK-2B
GR-CR5#85
BK-CR1#85 D5
WH/RD-C6-32
R1
19/18 CABLES
12V TO PLAT
OR/BK-C6-15
OR- C6-14
BL/RD-C6-13
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
RD- C5-1
24
23
WH-C7B
22
BK-C7B
WH-C5-11
21
20
GR/WH-C4B-7 19
GR/BK-C4B-6 18
GR-C4B-5
17
OR/RD-C4B-4 16
OR/BK-C4B-3 15
OR-C4B-2
14
13
BL/RD-C4B-1
BL/WH-C3B-12 12
BL/BK-C3B-11 11
10
BL-C3B-10
9
BK/RD-C3B-9
BK/WH-C3B-8 8
7
BK-C3B-7
WH/RD-C3B-6 6
WH/BK-C3B-5 5
4
WH-C3B-4
RD/WH-C3B-3 3
RD/BK-C3B-2
2
1
RD-C3B-1
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1
RD
RD/BK-C6-28
RD- C6-27
WH/RD-C5-14
WH/BK-C5-16
OR/BK-15A
OR-14A
GR-17A
GR/WH-19A
GR/BK-18A
WIRING
HARNESS:
TO BASE
GROUND STUD
BR
ALL BR WIRES
S-40 S-45
6 - 47
July 2007
Section 6 Schematics
6 - 47
6 - 48
Section 6 Schematics
July 2007
6 - 50
6 - 49
11
1
P26BAT BK
P24FS WH
P24FS WH
BRN
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH
C132PLI BK C1P-12
RD P2
RD H1
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C19JSV GR/WH
C4P-7 AND TS8
BRN
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
RED/BLK-28
H1
COMPONENT INDEX
PART NUMBER
TILT ALARM
ALC-500
45383
89353
H1
J2
OPT.
LS18
JIB
C9P
F.S.
D39
RED-TILT
F.S.
12V BATT
1
J3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
C3P
C3P
D40
C4P
GR/BK C4P-4
BRN
C7P
BATGND C7P-3
C1P
C28TTA RD/BK C1P-2
GR/BK L48
HARNESS
PBOX WIRING
J1
ALC-500
RED-TILT
REV A
C2P
N
M
L
K
J
I
H
G
F
E
D
C
B
A
C7P
Section 6 Schematics
July 2007
July 2007
Section 6 Schematics
REV A
HARNESS
PBOX WIRING
COMPONENT INDEX
TS48 / TS49
WORK / DRIVE LITE
TS15
DRV.ENA
3
2
JC2
5
4
DLITE/ RD WL2
RD WL1
TS13
PRIMARY
BOOM
EXTEND/
RETRACT
3
2
JC3
1
+
62390
JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L3
TS7
TS8
TS9
TS13
75565
56298
66812, 73805
66813, 66816
42730
13037
56457
56457
56298
16397
13037
13037
13037
L4
BL/RD-DE3 J1-16
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
RD-TILT
RD/BK H1
WH-24
BRN BATGND
(GND STUD)
CR27
P22BAT BK C7P-1
RD-TILT
WH-23
BK-22
P26BAT BK C9P-1
RD
BL/RD-39
RD
WH-24
BK/RD-35
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
(SPLICE TO R40LS1)
1
1
TS3
FUEL SELECT
RD
TS2
START
TS47
GENERATOR
(OPTION)
TS1
AUXILIARY
PUMP
TS4
HIGH/LOW
RPM
NC NC NC
NO
TS7
PLATFORM
ROTATE
TS8
JIB
WH-TS47
RD-25
BK-33
WH-24
WH-TS4
GR/WH-45
WH-24
C27AUX RD C1P-1
WH-JIB
C19JSV GR/WH
C17JU GR C4P-5
OR-14
OR/BK-15
RD
GR-43
WH
WH TS1
OR R40LS1
GR
TS9
PLATFORM
LEVEL
WH
P3
HORN
13037
27378
27378
WH TS7
WH
L1
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7
BRN
WH-JIB
BK-7
BK/WH-8
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
DRIVE LT BK/RD-C3P-9
WH-24
CR13
PART NUMBER
JC2
NOTE:
P2
EMERGENCY STOP
CE SEE DETAIL A
S-40 S-45
6 - 51
July 2007
Section 6 Schematics
6 - 51
6 - 52
Section 6 Schematics
July 2007
Electrical Schematic
Ford LRG-425 EFI Models
(from serial number 7597 to 11066)
6 - 54
6 - 53
P22BAT BK
C3-9
GENERATOR
C2-7
HIGH RPM(FS)
WH
WH
C1-7
ENGINE
REV B
Electrical Schematic
BL/WH
BK
P26ESTP BK
RD
C1-9
BK
BK
C35ESPD BK/RD
FUNCTION ENA.
LOW RPM
HIGH RPM
C45GEN GR/WH
DLITE BK/RD
C33STR BK
BK
ENGINE
START
C6-39
C6-28
GR/WH-45
C5-12
C5-17
C5-9
C5-13
C5-5
C5-10
C5-8
C5-11
C4B-12
C4B-11
WH-21
RD
RD
C5-14 WH/RD
C5-16 WH/BK
RD (FEH 361A)
DGRN (FEH 242)
C21IGN
C127TST
WH PIN 21
GR PIN 18
BK/RD PIN 23
BL/WH PIN 6
BK PIN 15
C38ESL
WH PIN 24
C35RPM
R33STR
BL/RD PIN 7
WH PIN 1
BK PIN 13
BK
BRN
BR PIN34
C39LP
R21IGN
RD PIN 9
BL/WH PIN 5
VBATT
VSW
C33STR
BK-33
WH
RD-27
RD/BK-28
RD
C6-27
RD-134
BK-43
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
VOLT METER
HOUR METER
TEMP GAUGE
FORD
42 PIN PLUG
FUEL PUMP
START RELAY
STARTER MOTOR
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)
START
C2-1
RD
C27AUX RD
P23BAT WH
C28TTA RD/BK
C6-23
C6-16
C6-25
C6-26
OR/BK PIN 2
PBOX GND
C133PLA OR/RD
C43HRN GR
C6-34
C6-33
C41RPM
PUMP AUXILIARY
LP FUEL
GAS
C1-2
C7-2
C1-1
PUMP AUXILIARY
C2-5
C7-1
C2-4
C5-2
510 OHM
L29
L29
TS4
C134PWR RD
TS22
C5-3
L30
TS17
C41RPM OR/BK
RD
OTS
STARTER
FORD
ENGINE
HARNESS
Y29
G1
HM
G6
H2
M1
CR23
CR23
NO
G3
TB26
G2
OPS
IND.
S7
TB21
CR39
TB35
CR1
L2
CR1
NO
CR2
TB24
FUEL
PUMP
FB
FAN
AUX
M2 PUMP
REGULATOR
CR17
EXCT.
TB33
D6
TB45
CB1
BRN
PR2 PR2
12 V DC
STA.
PR1
PR1
NO
BAT.
BAT.
+
CR17
NO
ALTERNATOR
C28TTA RD/BK
TS55
TS52
TB25
OTS
NO
NC
CR5
NO
TS1
L48
CR2
NO
CR5
20AMP.
TB23
RD
TB39
D40
TS53
TS51
PLAT
GRD
CR39
CB3
RD
KS1
TB22
TB27
TB28
15AMP.
TB20
TB43
TB134
RD
P1
CB2
RD
RD
15AMP.
NOTE:
C9-1 BK
TS2
TS3
H1
P3
HORN
P24FS WH
WH
P25FS RD
C9-2
FUSE 10A
C9-3
WH-(FS)
BK-(FS)
RD-(FS)
FS1
P2
TS49
RD
OR/BK
C2-3
TB41
N
M
L
K
J
I
H
G
F
E
D
C
B
A
L30
Section 6 Schematics
July 2007
RD/BK
F18
DRE B BL/BK
DRE A BL/WH
WH
RKOUT 6
BL
14
13
16
15
19
20
17
18
11
9
10
6
7
8
14
13
12
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C29MS RD/WH
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
BRN-2
C3P-6
C5TRR WH/BK
C2P-3
C3P-5
C4TRL WH
C40LS1 OR
RETRACT
EXTEND
UP PLATFORM LEVEL
DOWN
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
BOOM
C13DRE BL/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
UP
PRIMARY
DOWN BOOM
LEFT TROTATE
RIGHT
C3P-4
7.5
5
C3P-1
C3P-2
C3P-3
C4P-1
C2P-2
C3P-7
C3P-8
C4P-2
C4P-3
JDALARM GR/BK
C18JD GR/BK
C17JU GR
C5-21
C5-20
C6-32
C5-23
C5-19
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C31EDC- WH/BK
C30EDC+ WH
C32BRK WH/RD
C29MS RD/WH
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
C6-19 RD/BK
C6-13
C6-30
C6-7
C6-8
C6-14
C6-15
C17JU GR
C18JD GR/BK
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
C40LS1 OR
C6-40
C6-18
C6-17
WH
BK
WH
BK
BK
WH
GROUND
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
MOTOR STROKE
STEER RIGHT
STEER LEFT
DRIVE ENABLE
LIMIT SWITCH
BOOM EXTEND
BOOM RETRACT
PLAT LEVEL UP
PLAT LEVEL DOWN
NOTE:
JIB VALVES
6 - 55
S-40 S-45
C41RPM OR/BK
15
16
OR
5
4
BRN
YOUT 5
PWR 3
1
GND 2
BK
RD
OR
BRN
2
1
11
12
7
6
YOUT 5
XOUT 4
PWR 3
GND 2
1
P24FS WH
BRN
P24FS WH
P26ESTP BK
C4P-5
C4P-6
C2P-6
UP
PLATFORM LEVEL
DOWN
GR/BK-44
DOWN
UP JIB BOOM
DOWN
UP JIB BOOM
NCHO
TB30
RIGHT
LEFT PLAT ROTATE
TB18
NOHC
7
NOHC
BRN
Y51
Y2
Y27
Y3
Y4
Y23
Y29
Y13
Y22
Y21
Y12
H4
Y25
Y26
Y20
Y19
Y16
Y17
SJ1-WH
TB6
TB3
TB14
H4
1
Deutsch
5
TB8
TB17
TB13
TB40
TB7
TB32
TB37
TB36
TB4
TB1
TB29
TB5
TB2
TB15
R2
R1
TB31
C19JSV GR/WH
RIGHT
LEFT PLAT ROTATE
RD
J1
J1
J1
3
C4P-7
2
4
AMP
TB44
TS62
TS61
TS63
J2
6
4
1
WH
WH
4
TS58
TB19
TS59
TS57
CR27
NC
TS7
JIB VALVE
RD
TS13
TS9
TS8
TS14
L1
JC3
TS15
JC2
WH
2
CR13
NC
CR13
CR30
CE NO
LIFT/
DRIVE
OPTION
C19JSV GR/WH
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
6
Electrical Schematic
REV B
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 Schematics
July 2007
OR/BK
BL/WH
RD/BK
BK
BRN
July 2007
Section 6 Schematics
Electrical Schematic
Ford LRG-425 EFI Models
(from serial number 7597 to 11066)
6 - 55
6 - 56
July 2007
Section 6 Schematics
REV A
GR/WH-C6-39
OR/BK-C5-2
OR- C6-40
BL/RD-C5-10
BL/WH-C23-3
BL/BK-C6-37
BL- C6-36
BK/RD-C5-9
RD- C6-23
BL/WH-C6-30
WH-C5-3+C5-8
RD- 12 VOLT
GR/BK-C6-18
GR- C6-17
12 V
RD-CR39#85
RED-CR1#30
CR39 #30
BK-CR5#30
WH-CR2#87
RD-S.P.(CB2)
GR/BK-C23-8
44B-RD/BK-C6-19
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.
P1
RD-CB2
KS1
KEY SWITCH
3
NC
4
WH-21A
TS53
L2
BL/WH-C5-13
DESCRIPTION
TS61
RD/WH-3A
RD/BK-2A
RD-1A
KEY SWITCH
AUXILIARY SWITCH
TS63
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
TS62
CB3
RD-CB3 SP
TS58
CR2
CR23
R2
D14
CB1
RD C4B-11
TS57
CB2
RD C4B-12
BRN GND
WH-21B
WH-C5-17
TS55
D13
WH-C5-11
TS59
CR39
BK-C6-25
RD-CB3 SP
KS1
TS51
PART #
P1
KS1
13480
TS52
13037
LP/GAS SWITCH
TS53
56457
FUNCTION ENABLE
TS55
13037
TS57
16397
TS59
13037
TS63
13037
TS61
16397
TS62
16397
TS58
13037
42730
TS22
CB1
CB1
CB2
CB2
CB3
CB3
R1
R1
R2
R2
G1
G1
G2
G2
RD- 24A
G3
G3
RD- 20B
CHECK ENGINE
L2
56298
HOUR METER
HM
HM
OR/BK-15A
CR17
P1
RD- P1 E-STOP
RD-27B
LABEL
RD- 20A
BK/RD-35A
OR-C6-33
OR-14A
GR-17A
WH-23B
C5
1
B1
WH-23A
RD-42A
RD-27A
BL/RD-39A
BK-33B
CR5
TS51
NC
BK/RD-9B
BK-C6-16
WH/BK-25A
WH/RD-26A
BK-22A
RD-24B
TS22
RD- 20C
RD-CR17#30
WH/BK-5A
WH/RD-6A
WH-4A
BK-C5-5
BR (GROUND)
TS52
CR1
G3
G2
BR (GROUND)
BK/RD-CR23#86
GR-C5-12
ENGINE
G1
HM
GR-43B
BK-22B
GROUND STUD
WH-21A
3 BR-GND STUD
1 BK-22C
2 WH-23C
C2B
C1B
BK-CR1#85 D5
WH/RD-C6-32
C3B C4B
C7B
SPARE
GEN. OPTION
JDALARM JIB
HORN
RD-KS1-2 S.P. C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
BL/RD-S.P.
L.P.
C132PLI
STEER LEFT
STEER RIGHT
BK/RD-S.P.
RPM
BK/WH-S.P.
GLOW PLUG
START
BK-S.P.
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
MOTOR SPEED
TILT ALARM
AUX. PWR.
RD-S.P.
WH/RD-S.P. WATER TEMP. SENDER
WH/BK-S.P. OIL PRESSURE SENDER
RD-S.P.
ENGINE POWER
KEYSWITCH PWR/FB
WH-S.P.
PWR. TO PLAT.
BK-S.P.
WH-S.P.
IGNITION PWR.
RD-S.P.(CB1) 12V BATTERY SUPPLY
GR/WH-SP
JIB VALVE
GR/BK-S.P.
PLAT. ROT. R.
GR-S.P.
PLAT. ROT. L.
GR/BK-H6C133PLT
OR/BK-S.P.
PLAT. LEVEL DN.
OR-S.P.
PLAT. LEVEL. UP
DRV. ENA. LT.
GR/BK-SP
C6
FUNCTIONS
BK/WH-C6-8
BK- C6-7
WH/RD-C6-6
WH/BK-C6-5
WH- C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1
R1
19/18 CABLES
12V TO PLAT
OR/BK-C6-15
OR- C6-14
BL/RD-C6-13
GR/BK-2B
GR-CR5#85
RD-H6+
RD
WH/RD-C5-23
WH/BK-C5-20
WH- C5-21
RD/WH-C5-24
RD/BK-C6-28
RD- C6-27
WH/RD-C5-14
WH/BK-C5-16
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
WH-C7B-2
22
BK-C7B-1
WH-C6-34
21
RD-S.P.(CB3)
20
GR/WH-C4B-7 19
GR/BK-C4B-6 18
GR-C4B-5
17
OR/RD-C4B-4 16
OR/BK-C4B-3 15
OR-C4B-2
14
13
BL/RD-C4B-1
BL/WH-C3B-12 12
BL/BK-C3B-11 11
10
BL-C3B-10
9
BK/RD-C3B-9
BK/WH-C3B-8 8
7
BK-C3B-7
WH/RD-C3B-6 6
WH/BK-C3B-5 5
4
WH-C3B-4
RD/WH-C3B-3 3
RD/BK-C3B-2
2
1
RD-C3B-1
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1
GR/WH-19A
GR/BK-18A
WIRING
HARNESS:
TO BASE
GROUND STUD
BR
ALL BR WIRES
S-40 S-45
6 - 57
July 2007
Section 6 Schematics
6 - 57
6 - 58
Section 6 Schematics
July 2007
6 - 60
6 - 59
11
1
P26BAT BK
P24FS WH
P24FS WH
C132PLI BK C1P-12
RD P2
RD H1
P23SWBAT WH C7P-2
P22BAT BK C7P-1
F.S.
C19JSV GR/WH
C4P-7 AND TS8
BRN
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
RED/BLK-28
H1
PART NUMBER
TILT ALARM
45383
H1
COMPONENT INDEX
J2
OPT.
LS18
JIB
C9P
F.S.
D39
RED-TILT
BRN
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH
BRN
C3P
C3P
D40
C4P
GR/BK C4P-4
12V BATT
19/18 CONTROL CABLE
TILT
ALALRM
C7P
BATGND C7P-3
C7P
C1P
C28TTA RD/BK C1P-2
1
J3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
GR/BK L48
RED-TILT
HARNESS
PBOX WIRING
J1
ALC-500
REV A
C2P
N
M
L
K
J
I
H
G
F
E
D
C
B
A
S-40 S-45
6 - 60
Section 6 Schematics
July 2007
July 2007
Section 6 Schematics
REV B
10 AMP FUSE
5
4
DLITE/ RD WL2
RD WL1
TS13
PRIMARY
BOOM
EXTEND/
RETRACT
2
JC2
JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L4
TS7
TS8
TS9
TS13
TS14
TS15
TS47
TS48-9
3
2
JC3
1
+
62390
75565
56298
66812, 94506
66813, 66816
42730
13037
56457
56457
56298
16397
13037
13037
13037
56457
13037
27378
27378
L4
BL/RD-DE3 J1-16
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
RD-TILT
RD/BK H1
WH-24
BRN BATGND
(GND STUD)
P22BAT BK C7P-1
RD-TILT
WH-23
BK-22
P26BAT BK C9P-1
RD
BL/RD-39
RD
WH-24
BK/RD-35
WH-TS47
RD-25
BK-33
WH-24
WH-TS4
GR/WH-45
WH-24
WH-24
C27AUX RD C1P-1
WH-JIB
C17JU GR C4P-5
C19JSV GR/WH
OR-14
OR/BK-15
RD
GR-43
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
1
1
RD
TS3
FUEL SELECT
TS2
START
TS47
GENERATOR
(OPTION)
TS14
DRIVE
SPEED
HIGH/LOW
TS1
AUXILIARY
PUMP
TS4
HIGH/LOW
RPM
NC NC NC
NO
TS7
PLATFORM
ROTATE
TS8
JIB
WH TS1
(SPLICE TO R40LS1)
WH
WH
CR27
OR R40LS1
GR
TS9
PLATFORM
LEVEL
PART NUMBER
L1
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7
BRN
WH-JIB
BK-7
BK/WH-8
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
DRIVE LT BK/RD-C3P-9
WH-24
CR13
WH
WH TS7
P3
HORN
COMPONENT INDEX
JC2
TS15
DRV.ENA
HARNESS
PBOX WIRING
TS48 / TS49
WORK / DRIVE LITE
NOTE:
P2
EMERGENCY STOP
CE SEE DETAIL A
S-40 S-45
6 - 61
July 2007
Section 6 Schematics
6 - 61
6 - 62
Section 6 Schematics
July 2007
Electrical Schematic
Ford DSG-423 EFI Models
(from serial number 11067 to 12509)
6 - 64
6 - 63
BL/WH
HIGH RPM(FS)
C3-9
C2-7
GENERATOR
WH
C1-9
C35ESPD BK/RD
LOW RPM
FUNCTION ENA.
HIGH RPM
C45GEN GR/WH
DLITE BK/RD
C6-39
GR/WH
1K
C6-27
C4B-12
C4B-11
B
C
RD
RD
500
GR PIN 3
WH PIN 16
WH/RD PIN 39
C21IGN
BK PIN 15
BK/RD PIN 23
C26TSR
C35RPM
BL/WH PIN 5
BL/RD PIN 7
BL PIN 18
WH PIN 24
C135RET
C135FP
WH PIN 1
R21IGN
VSW
BL/WH PIN 6
BK
BRN
C38ESL
C39LP
R33STR
C127TSW
C107AF WH
WH/BK
RD/GN
BK/BL
RD
GY/YL
GY/RD
C5-16 WH/BK
R21IGN WH
C5-3
C5-14
C5-12
C5-17
C5-9
C5-5
C5-8
C5-10
C5-11
C5-13
WH
C27AUX RD
RD/BK
RD
C6-26
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
VOLT METER
HOUR METER
GASOLINE SENSOR
LPG LOCKOUT
TO ALTERNATOR FIELD
TEMP GAUGE
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)
DRIVELIGHT
ENGINE
C6-28
RD
C6-33
FORD ENGINEHARNESS
BK
BK
C33STR BK
START
LP
FUEL
GAS
AUXILIARY
PUMP
RD
C27AUX RD
P23BAT WH
C28TTA RD/BK
C6-23
R43HRN BK
C6-25
BRN
OR/BK PIN 2
BLUE/PINK
STARTER RELAY
STARTER MOTOR
ESO433B
2
WORKLIGHT
WH
C1-7
ENGINE
C2-1
C1-1
C7-2
C1-2
C133PLA OR/RD
C43HRN GR
C6-16
C6-34
PR2
C41RPM
PR2
START
FUEL
GAS
LP
AUXILIARY
PUMP
C2-5
C7-1
C2-4
P22BAT BK
C134PWR RD
C5-2
P20BAT RD
6 - 64
NOTE:
L29
L29
OPS
FORD ENGINE
HARNESS
TB45
TB9
TB23
C2-3
15AMP.
G1
HM
TB25
TS22
DIAGNOSTIC
Y29
+
FAN M1
CR23
CR23
NO
G2
FUEL
PUMP
G6
AUX
PUMP
H2
M2
FB
FUEL PUMP
3
S7
12 V
DC
TB21
TB41
R4
NO
CR17
PR1
PR1
CR17
NO
RD
L2
R3
TB26
OTS
CR5
CR5
NO
CB3
20AMP.
PBOX GND
TB33
L30
L30
TS55
TS53
CR1
CR1
NO
CR2
CR2
NO
CR39
CR39
NC
TS49
C28TTA RD/BK
TS17
TS2
TS3
TB35
RD
TB24
CB1
15AMP.
TB20
G3
NO
TB27
TB28
TB39
B
BK
P26ESTP BK
RD
B1
TS52
CB2
TB43
RD
2
REV B
Electrical Schematic
RD
TB22
4
1
RD
TB42
TS51
PLAT
GRD
KS1
P1
TS1
L48
WH
C9-2
BK(FS)
C9-1 BK
TS4
H1
P3
HORN
FUSE 10A
P25FS RD
P24FS WH
C9-3
RD(FS)
WH(FS)
FS1
P2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
RD
C41RPM OR/BK
TB 134 IS WAGO
TERMINAL BLOCK 42
Section 6 Schematics
July 2007
RD/BK
OR/BK
F18
Electrical Schematic
REV B
DRIVE SPEED
C29MS RD/WH
DRE A BL/WH
PWR 3
RD
BK
BRN
OR
12
11
14
13
7
6
12
13
14
10
11
17
18
20
19
16
15
C41RPM OR/BK
15
16
WH
4
7
RKOUT 6
BL
GND 2
OR
YOUT 5
XOUT 4
YOUT 5
BRN
GND 2
PWR 3
1
BRN
P24FS WH
P24FS WH
P26ESTP BK
3
4
EXTEND
BOOM
RETRACT
C2P-3
C1P-4
C1P-5
C1P-6
C1P-3
C1P-11
C1P-10
C3P-5
C3P-6
C3P-4
7.5
BRN-2
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C37STCC BL/BK
C36STC BL
C5TRR WH/BK
C6TRF WH/RD
C4TRL WH
LEFT
TT ROTATE
RIGHT
C4P-1
C3P-3
C3P-2
C3P-1
C40LS1 OR
C13DRE BL/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
UP
PRIMARY BOOM
DOWN
C2P-2
C3P-8
C14PLU OR
C8PBR BK/WH
C7PBE BK
EXTEND
BOOM
RETRACT
C4P-2
C15PLD OR/BK
C3P-7
C4P-3
JDALARM GR/BK
UP
PLATFORM LEVEL
DOWN
C2P-6
C18JD GR/BK
C5-21
C5-20
C6-32
C5-23
C5-24
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C31EDC- WH/BK
C30EDC+ WH
C37STCC BL/BK
C29MS RD/WH
C32BRK WH/RD
C36STC BL
C4TRL WH
C1PBU RD
C5TRR WH/BK
C2PBD RD/BK
C6TRF WH/RD
C3PBF RD/WH
C6-19 RD/BK
C13DRE BL/RD
WH
BK
BK
WH
BK
WH
C15PLD OR/BK
C14PLU OR
C7PBE BK
C6-13
C6-30
C6-7
C6-8
C6-14
C6-15
C17JU GR
C18JD GR/BK
C8PBR BK/WH
C40LS1 OR
6
C6-40
C6-18
C6-17
GROUND
MOTOR STROKE
STEER RIGHT
STEER LEFT
TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM UP
PRIMARY BOOM
FLOW CONTROL
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
PLAT LEVEL UP
BOOM RETRACT
BOOM EXTEND
DRIVE ENABLE
LIMIT SWITCH
8
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
JIB VALVES
ESO433
POSITION EXCEPT AS NOTED.
6 - 65
S-40 S-45
Part No. 102521
Y2
TB30
TB31
DOWN
JIB BOOM
UP
NOTE:
NCHO
TB32
UP
PLATFORM LEVEL
DOWN
C4P-6
C17JU GR
C19JSV GR/WH
BRN
NOHC
Y27
Y25
NOHC
Y3
Y4
Y23
Y22
Y29
Y21
Y13
Y12
7
H4
Y26
Y20
TB13
5
TB40
TB7
TB15
H4
Y19
TB5
TB2
TB37
TB4
TB1
TB29
TB36
TB6
TB3
TB14
SJ1-WH
Y16
Y17
TB44
RIGHT
PLAT ROTATE
LEFT
TS58
TB8
TB17
TS61
TS63
TS59
R2
R1
C4P-5
RD
TS15
Y51
4
TS62
TS57
GR/BK-44
DOWN
JIB BOOM
UP
C4P-7
TB19
RIGHT
PLAT ROTATE
LEFT
JIB VALVE
RD
J1
J1
J1
J3
CR30
NO
J2
JOYSTICK CONTROL CARD
TS14
LO
HI
L1
DRIVE & STEERING
PRI UP/DN & TT ROTATE
3
C19JSV GR/WH
TS13
TS9
TS8
TS7
CR27
NC
CR13
NC
CR13
CE
LIFT/
DRIVE
OPTION
2
WH
WH
JC3
JC2
WH
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 Schematics
July 2007
RD/BK
BL/WH
OR/BK
BK
BRN
TB18
July 2007
Section 6 Schematics
Electrical Schematic
Ford DSG-423 EFI Models
(from serial number 11067 to 12509)
6 - 65
6 - 66
Section 6 Schematics
March 2007
Electrical Schematic
Ford DSG-423 EFI Models
(after serial number 12509)
6 - 68
6 - 67
BL/WH
HIGH RPM(FS)
C2-7
GENERATOR
C1-9
C35ESPD BK/RD
LOW RPM
FUNCTION ENA.
HIGH RPM
C45GEN GR/WH
DLITE BK/RD
C6-39
GR/WH
C4B-12
C4B-11
B
C
RD
RD
C5-14
C127TSW
C26TSR
BK/RD PIN 23
WH PIN 16
GR PIN 3
WH/RD PIN 39
WH/BK
RD/GN
BK/BL
RD
GY/YL
GY/RD
C5-16 WH/BK
R21IGN WH
C5-3
C5-12
C35RPM
C21IGN
BK PIN 15
C5-17
R33STR
C5-9
C5-5
BL/RD PIN 7
WH PIN 24
BL/WH PIN 5
R21IGN
BL PIN 18
C5-8
C135RET
C135FP
WH PIN 1
C39LP
VSW
BL/WH PIN 6
C5-10
C5-11
C38ESL
BRN
C5-13
C27AUX RD
WH
BK
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
VOLT METER
HOUR METER
FORD
42 PIN PLUG
GASOLINE SENSOR
LPG LOCKOUT
TEMP GAUGE
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
NOTE:
STARTER MOTOR
STARTER RELAY
FORD ENGINEHARNESS
COOLING FAN
(OPTION)
C3-9
1K
C6-27
RD/BK
RD
C6-26
WH
ENGINE
C6-28
RD
BRN
OR/BK PIN 2
BLUE/PINK
BK
BK
C33STR BK
START
LP
FUEL
GAS
AUXILIARY
PUMP
RD
C27AUX RD
P23BAT WH
C28TTA RD/BK
C6-23
R43HRN BK
C6-25
C6-33
PR2
C41RPM
PR2
DRIVELIGHT
C1-7
ENGINE
C2-1
C1-1
C7-2
C1-2
C133PLA OR/RD
C6-16
C5-2
P20BAT RD
L29
L29
OPS
FORD ENGINE
HARNESS
ESO433C
1.
G1
HM
Y29
+
TB45
TB9
TB23
C43HRN GR
R3
C6-34
TB25
WORKLIGHT
WH
START
LP
FUEL
GAS
AUXILIARY
PUMP
C2-5
C7-1
C2-4
P22BAT BK
C134PWR RD
C2-3
PR1
CR23
CR23
NO
G2
FUEL
PUMP
TB26
FUEL PUMP
L2
G6
AUX
PUMP
H2
M2
FB
6 - 68
TB21
TB41
CR1
CR1
NO
CR2
CR2
NO
CR39
PBOX GND
TB33
15AMP.
S7
12 V
DC
FAN M1
NO
CR17
TB27
TB35
RD
TB24
TS52
TB39
TS22
DIAGNOSTIC
G3
NO
PR1
CR17
NO
RD
CR5
3
OTS
BK
P26ESTP BK
RD
TB22
TB28
TS55
4
1
REV B
Electrical Schematic
RD
RD
L30
L30
2
TS17
TS2
TS3
C41RPM OR/BK
CR39
NC
CR5
NO
CB3
20AMP.
TB43
B1
TS49
C28TTA RD/BK
RD
TS53
PLAT
GRD
B
CB2
TB42
2
RD
CB1
15AMP.
TB20
KS1
P1
TS1
L48
WH
C9-2
BK(FS)
C9-1 BK
TS4
H1
P3
HORN
FUSE 10A
P25FS RD
P24FS WH
C9-3
RD(FS)
WH(FS)
FS1
P2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TS51
Section 6 Schematics
July 2007
RD/BK
OR/BK
F18
Electrical Schematic
REV B
DRIVE SPEED
C29MS RD/WH
DRE B BL/BK
DRE A BL/WH
YOUT 4
OR
WH/RD
RD/WH
12
11
15
16
19
20
12
13
14
10
11
17
18
C41RPM OR/BK
15
16
BL/WH
6
RKOUT 5
5
13
OR
BL/WH
WH/RD
PWR 2
14
YOUT 4
BRN
XOUT 3
GND 1
XOUT 3
BRN
GND 1
PWR 2
BRN
P24FS WH
P24FS WH
P26ESTP BK
3
EXTEND
RETRACT
BOOM
C2P-3
C1P-4
C1P-5
C1P-6
C1P-3
C1P-11
C1P-10
C3P-6
C3P-5
C3P-4
7.5
BRN-2
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C37STCC BL/BK
C36STC BL
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
LEFT
TT ROTATE
RIGHT
C3P-2
C3P-1
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
PRI BOOM
C3P-3
C13DRE BL/RD
UP
DOWN
C4P-1
C40LS1 OR
BOOM
C2P-2
EXTEND
C3P-8
C14PLU OR
C8PBR BK/WH
C7PBE BK
RETRACT
C4P-2
C15PLD OR/BK
C3P-7
C4P-3
JDALARM GR/BK
DOWN
PLAT LEVEL
UP
C2P-6
C18JD GR/BK
C5-21
C5-20
C6-32
C5-23
C5-24
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C31EDC- WH/BK
C30EDC+ WH
C37STCC BL/BK
C29MS RD/WH
C32BRK WH/RD
C36STC BL
C4TRL WH
C1PBU RD
C5TRR WH/BK
C2PBD RD/BK
C6TRF WH/RD
C3PBF RD/WH
C6-19 RD/BK
C13DRE BL/RD
WH
BK
BK
WH
BK
WH
C14PLU OR
C7PBE BK
C15PLD OR/BK
C17JU GR
C18JD GR/BK
C8PBR BK/WH
C6-13
C6-30
C6-7
C6-8
C6-14
C6-15
C6-17
C40LS1 OR
6
C6-40
C6-18
Y2
7
Y51
GROUND
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
MOTOR STROKE
STEER RIGHT
STEER LEFT
TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM
FLOW CONTROL
DRIVE ENABLE
LIMIT SWITCH
BOOM EXTEND
BOOM RETRACT
PLAT LEVEL UP
PLAT LEVEL DOWN
JIB VALVES
6 - 69
S-40 S-45
Part No. 102521
Y27
TB30
TB31
8
NCHO
NOTE:
NOHC
TB32
TB37
DOWN
PLAT LEVEL
UP
C4P-6
C17JU GR
C19JSV GR/WH
BRN
NOHC
Y3
Y4
Y23
Y22
Y29
Y21
Y13
Y12
Y25
TB13
TB40
TB7
TB15
H4
Y26
Y20
TB36
TB5
TB2
H4
Y19
5
TB29
TB6
TB3
TB14
SJ1-WH
Y16
Y17
TS63
TB4
TB1
RIGHT
PLAT ROTATE
LEFT
TB44
TB8
TB17
TS62
TS61
TS59
R2
R1
C4P-5
C4P-7
TS58
GR/BK-44
DOWN
UP
JIB BOOM
PLAT ROTATE
RD
3
RIGHT
LEFT
RD
2
TS14
LO
HI
L1
TS15
DRIVE & STEERING
JC3
J1
J1
J1
J3
CR30
NO
4
TS57
TS13
J2
JOYSTICK CONTROL CARD
CE
LIFT/
DRIVE
OPTION
C19JSV GR/WH
CR27
NC
CR13
NC
CR13
TS9
TS8
TS7
JIB VALVE
TB19
WH
WH
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Section 6 Schematics
July 2007
BL/WH
OR/BK
RD/BK
BK
BRN
TB18
July 2007
Section 6 Schematics
Electrical Schematic
Ford DSG-423 EFI Models
(after serial number 12509)
6 - 69
6 - 70
July 2007
Section 6 Schematics
REV B
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
GR/WH-C6-39
OR/BK-C5-2
OR- C6-40
BL/RD-C5-10
BL/BK-C6-37
BL- C6-36
BK/RD-C5-9
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1
WH/RD-C5-23
WH/BK-C5-20
WH- C5-21
RD/WH-C5-24
WH-C5-3+C5-8
RD- 12 VOLT
OR/BK-C6-15
OR- C6-14
BL/RD-C6-13
BK/RD-C3B-9
BK/WH-C3B-8
BK-C3B-7
WH/RD-C3B-6
WH/BK-C3B-5
WH-C3B-4
RD/WH-C3B-3
RD/BK-C3B-2
RD- C6-1
RD-C3B-1
12 V
BK/WH-C6-8
BK- C6-7
WH/RD-C6-6
WH/BK-C6-5
WH- C6-4
RD/WH-C6-3
RD/BK-C6-2
D
C7B
GR/BK-S.P.
RD-KS1-2 S.P.
BL/RD-S.P.
BK/RD-S.P.
BK/WH-S.P.
BK-S.P.
D5
BK-CR1#85
WH/RD-C6-32
RD-CR39#85
RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
RD-S.P.(CB1)
RED-CR1#30
CR39 #30
BK-CR5#30
WH-CR2#87
RD-S.P.(CB2)
HORN
C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
C132PLI
STEER LEFT
STEER RIGHT
RPM
GLOW PLUG
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
MOTOR SPEED
TILT ALARM
AUX. PWR.
WATER TEMP. SENDER
OIL PRESSURE SENDER
ENGINE POWER
KEYSWITCH PWR/FB
PWR. TO PLAT.
IGNITION PWR.
12V BATTERY SUPPLY
GR/WH-SP
GR/BK-S.P.
GR-S.P.
JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.
C133PLT
OR/BK-S.P.
OR-S.P.
G2
G1
WH/BK-25A
WH/RD-26A
BK-22A
KEY SWITCH
KS1
P1
NC
TS51
RD-CB2
NC
B1
WH-23A
RD-42A
RD-27A
BL/RD-39A
44B-RD/BK-C6-19
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
WH-23A
RD-S.P.
L2
TS53
BL/WH-C5-13
TS61
RD/WH-3A
RD/BK-2A
RD-1A
TS63
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
TS62
CB3
TS52
TS58
(BR)
RD-CR17/CR23 #30
WH/BK-5A
WH/RD-6A
WH-4A
RD-24B
CR2
CR1
R2
C2B
(BK)
CB1
C1B
RD-CB3 S.P.
CB2
TS57
WH-21B
WH-C5-17
CR23
TS55
OR-C6-33
WH-C5-11
C6
4
DESCRIPTION
L2
LABEL
PART#
P1
P1
KEY SWITCH
KS1
KS1
AUXILIARY SWITCH
TS51
13480
TS52
13037
LP/GAS SWITCH
TS53
56457
FUNCTION ENABLE
TS55
13037
TS57
16397
TS59
13037
TS63
13037
TS61
16397
TS62
16397
TS58
13037
TS22
42730
CB1
CB1
CB2
CB2
CB3
CB3
R1
R1
R2
R2
G1
G1
G2
G2
G3
G3
L2
110395
L2
119870
HOUR METER
HM
HM
R3
104333
BK/RD-9B
TS59
BK-C6-16
BL/WH-C5-13
BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. R
TURN. ROT. L
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP
1
B1
HM
BK/RD-CR23#86
B
3
WH-21A
TS22
BK/RD-35A
RD C4B-11
RD- 20A
RD C4B-12
RD- 24A
BRN GND
RD- 20B
RD- P1 E-STOP
CR5
GR-43B
BK-22B
RD-27B
CR39
BK-C6-25
OR/BK-15A
CR17
OR-14A
RD-CB3 SP
GR-C5-12
GR-17A
WH-23B
GR/WH-19A
GR/BK-18A
C5
ENGINE
2 WH-23C
(GY)
BR (GROUND)
BK-33B
FUNCTIONS
G3
BR (GROUND)
BK-C5-5
WH-21A
BK-22C
(GR)
C4B
R1
C3B
GEN. OPTION
JDALARM JIB
RD- 20C
19/18 CABLES
SPARE
GR/BK-2B
GR-CR5#85
BR-GND STUD
12V TO PLAT
OR/BK-C4B-3
OR-C4B-2
BL/RD-C4B-1
BL/WH-C3B-12
BL/BK-C3B-11
BL-C3B-10
R3
GR/WH-C4B-7
GR/BK-C4B-6
GR-C4B-5
OR/RD-C4B-4
GR/BK-C6-18
GR- C6-17
RD
WH-C7B-2
BK-C7B-1
WH-C6-34
RD-S.P.(CB3)
RD- C6-23
BL/WH-C6-30
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
RD
RD/BK-C6-28
RD- C6-27
WH/RD-C5-14
WH/BK-C5-16
GROUND STUD
WIRING
HARNESS:
TO BASE
ESO433
GROUND STUD
BR
ALL BR WIRES
S-40 S-45
6 - 71
July 2007
Section 6 Schematics
6 - 71
6 - 72
Section 6 Schematics
July 2007
6 - 74
6 - 73
11
1
C132PLI BK C1P-12
RD P2
RD H1
P22BAT BK C7P-1
BRN
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
RED/BLK-28
C19JSV GR/WH
C4P-7 AND TS8
OPT.
LS18
C9P
P23SWBAT WH C7P-2
C17JU GR C4P-5
C14PLU OR C4P-2
P26BAT BK C9P-1
C7PBE BK C3P-7
P24FS WH C9P-2
P25FS RD C9P-3
TS48-WL2 RD C2P-11
TS48-WL1 RD C2P-12
C40LS1 OR C2P-2
F.S.
D39
RED-TILT
F.S.
TILT
P26BAT BK
P24FS WH
C1PBU RD C3P-1
C30EDC+ WH C1P-4
C36STC BL C1P-10
BATGND C7P-3
C134PWR RD C2P-4
C33STR BK C1P-7
RD/BK L4
C27AUX RD C1P-1
C7P
BRN
C3P
C3P
D40
C4P
GR/BK C4P-4
P24FS WH
BRN
DRE A BL/WH
JC3-4,6 WH
JC3-2 BRN
JC3-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC2-3 OR
JC1-2 BRN
JC2-5 BK
JC2-4 RD
JC1-3 OR
DRE B BL/BK
C13LED BL/RD
J2
J1
12V BATT
19/18 CONTROL CABLE
ALALRM
JIB
C7P
C1P
C28TTA RD/BK C1P-2
J3
C29MS RD/WH
GR/BK L48
HARNESS
PBOX WIRING
ALC-500
RED-TILT
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
S-40 S-45
6 - 74
Section 6 Schematics
July 2007
C2P
H1
ESO433
July 2007
Section 6 Schematics
REV A
10 AMP FUSE
DRV.ENA
TS15
DLITE/ RD WL2
RD WL1
JC2
JC3
1
1
TS13
WH-24
CR13
+
2
PART NUMBER
62390
JC2
COMPONENT INDEX
BOOM PROPORTIONAL JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE
JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L4
TS7
TS8
TS9
TS13
TS14
TS15
TS47
TS49
PRIMARY
BOOM
EXTEND/
RETRACT
HARNESS
PBOX WIRING
75565
56298
66812, 95406
66813, 66816
42730
13037
56457
56457
56298
16397
13037
13037
13037
56457
13037
27378
27378
BL/RD-DE3 J1-16
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
RD-TILT
RD/BK H1
WH-24
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7
BRN
WH-JIB
BK/WH-8
BK-7
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
DRIVE LT BK/RD-C3P-9
L4
L1
BRN BATGND
(GND STUD)
P22BAT BK C7P-1
RD-TILT
BK-22
RD
P26BAT BK C9P-1
WH-23
RD
BL/RD-39
WH-24
BK/RD-35
WH-TS47
BK-33
RD-25
WH-24
WH-TS4
GR/WH-45
WH-24
WH-24
C27AUX RD C1P-1
WH-JIB
C19JSV GR/WH
C17JU GR C4P-5
OR-14
OR/BK-15
RD
GR-43
CR27
WH TS7
WH TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
WH
TS9
TS7
TS8
TS1
GR
TS47
WH
HORN
P3
PLATFORM
LEVEL
WH
PLATFORM
ROTATE
GR/BK
JIB
AUXILIARY
PUMP
DRIVE
SPEED
HIGH/LOW
OR R40LS1
TS2
TS14
START
HIGH/LOW
RPM
TS4
TS3
(SPLICE TO R40LS1)
FUEL SELECT
GENERATOR
(OPTION)
EMERGENCY STOP
P2
RD
CE SEE DETAIL A
S-40 S-45
6 - 75
July 2007
Section 6 Schematics
6 - 75
6 - 76
July 2007
Section 6 Schematics
REV A
10 AMP FUSE
PRI. BOOM
WORK /
UP/DOWN
DRIVE LITE
TS49
JC2
JC3
DLITE/ RD WL2
RD WL1
JC2
COMPONENT INDEX
BOOM PROPORTIONAL JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE
JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L4
TS7
TS8
TS9
TS13
TS14
TS15
TS47
TS49
75565
DRIVE PROPORTIONAL JOYSTICK
DRIVE ENABLE LED
56298
66812, 95406
EMERGENCY STOP BUTTON
66813, 66816
HORN SWITCH
AUXILIARY SWITCH
42730
START ENGINE SWITCH
13037
56457
FUEL SELECT SWITCH (FORD EFI ONLY)
HI/L0 RPM SWITCH
56457
CHASSIS TILT LED
56298
PLATFORM ROTATE SWITCH
16397
JIB UP/DOWN SWITCH
13037
PLATFORM LEVEL SWITCH
13037
PRIMARY BOOM EXTEND/RETRACT SWITCH13037
DRIVE SPEED SWITCH
56457
DRIVE ENABLE SWITCH
13037
GENERATOR SWITCH ( OPTION )
27378
WORK/DRIVE LIGHT ( OPTION )
27378
DRIVE/STEER
PRIMARY
BOOM
EXTEND/
RETRACT
HARNESS
PBOX WIRING
DRV.ENA
TS15
TT ROTATE
PART NUMBER
62390
TS13
WH-24
+
L4
J1-13 OR JC3-2
(GND STUD)
P22BAT BK C7P-1
JIB
CR27
WH TS7
RD-TILT
BK-22
P26BAT BK C9P-1
WH-23
RD
BL/RD-39
RD
TS8
PLATFORM
ROTATE GR/BK
BK/RD-35
WH-24
BK-33
RD-25
WH-24
WH-TS4
GR/WH-45
WH-24
WH-24
C27AUX RD C1P-1
WH
RD-TILT
RD/BK H1
WH-24
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7
BRN
WH-JIB
PLATFORM
LEVEL
BRN BATGND
WH TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
6
TS4
TS1
AUXILIARY
PUMP
OR R40LS1
TS47
(SPLICE TO R40LS1)
TS2
TS14
HIGH/LOW
RPM
WH
HORN
P3
CR30
WH
GR
L1
DRIVE LT BK/RD-C3P-9
WH-JIB
BK-7
BK/WH-8
C19JSV GR/WH
C17JU GR C4P-5
OR-14
NO
J1-11 OR JC2-2
OR/BK-15
RD
GR-43
TS7
TS9
4
CR13
DRIVE
SPEED
HIGH/LOW
TS3
START
GENERATOR
(OPTION)
FUEL SELECT
RD
NC
NC
NC
EMERGENCY STOP
P2
NOTE:
DASHED LINES INDICATE
CE SEE DETAIL A
OPTION WIRES
S-40 S-45
6 - 77
July 2007
Section 6 Schematics
6 - 77
6 - 78
Section 6 Schematics
July 2007
6 - 80
6 - 79
July 2007
Section 6 Schematics
REV A
1
INJ +
INJ 1
INJ 3
INJ 4
INJ 2
INJ 5
INJ 6
AUX OUT 2
EGR
POWER GROUND
ANA_RTN
5 VOLT REF
VSW
CRANK CRANK +
CAM CAM +
VBAT
VBAT
EGO 2
EGO 1
EGO 3
KNK +
KNK -
361 R 16
361 R 16
555 T 16
557 BR-Y 16
557 BR-Y 16
558 BR-LB 16
558 BR-LB 16
10
556 W 16
361 R 16
743 GY 18
12
359 GY-R 18
INJECTOR #1
21
18 O-Y 18
19
198 DG-O 18
20
358 LG-BK 18
15
151 LB-BK 18
27
743 GY 18
307 BK-Y 18
28
354 LG-R 18
354 LG-R 18
COIL 4
COIL 5
COIL 6
STARTER LOCKOUT
FUEL LOCKOFF
FUEL PUMP
RELAY CONTROL
TPS1
TPS2
DBW +
DBW BRAKE SWITCH
OIL PRESSURE
TACH
MIL
FUEL PUMP MON
AUX OUT 1
FUEL SELECT
AUX ANA PU2
GOV SELECT 1
GOV SELECT 2
ROAD SPEED +
ROAD SPEED GASEOUS TRIM
OVERSPEED
CAN +
CAN -
RS 485 +
RS 485 RS 232 TX
RS 232 RX
17
307 BK-Y 18
A
B
18
150 DG-W 18
16
114 LB-Y 18
22
352 BR-LG 18
23
360 BR-PK 18
570 BK-W 16
570 BK-W 16
570 BK-W 16
570 BK-W 16
151 LB-BK
307 BK-Y 18
570 BK-W 16
ECT
16 WATER TEMP
570 BK-W 12
F1 30A
F2
570 BK-W 12
5A
16 R-LG 18
MAP_CONN
F3 20A
13
359 GY-R 18
570 BK-W 16
14
351 BR-W 18
351 BR-W 18
16 R-LG 18
33
350 GY 18
358 LG-BK 18
358 LG-BK 18
32
349 DB 18
359 GY-R 18
359 GY-R 18
35
452 GY-R 18
18 O-Y 18
34
282 DB-O 18
198 DG-O 18
198 DG-O 18
361 R 16
150 DG-W 18
150 DG-W 18
361 R 16
114 LB-Y 18
114 LB-Y 18
25
392 R-LG 18
352 BR-LG 18
352 BR-LG 18
24
74 GY-LB 18
360 BR-PK 18
360 BR-PK 18
361 R 14
361 R 14
CRANK
O2 SENSOR
26
361 R 14
30
18 O-Y 18
359 GY-R 18
351 BR-W 18
361A R 16
361A R 16
570 BK-W 16
570 BK-W 16
74 GY-LB 18
392 R-LG 18
O2
SENSOR
MTRTWR6 MTRSHD6
355 GY-W 18
151 LB-BK 18
359 GY-R 18
317 GY-O 18
351 BR-W 18
850 Y-BK 18
851 Y-R 18
TWR
361A R 16
1 COIL 1
2 VBAT
A
B
242 DG 18
361A R 16
LOCKOFF SOLENOID
24
25
SHD
TWR
A
16 R-LG 18
THROTTLE
355 GY-W 18
357 Y-W 18
151 LB-BK 18
317 GY-O 18
351 BR-W 18
359 GY-R 18
FUEL PUMP
RELAY
6
5
4
1
32 R-LB 16
86
86
87
38 EGR ANA IN
32 ANA AUX PD1
37 ANA AUX PU1
12 FPP2
40 EGR PWM
41 EGR REC
30
32 R-LB 16
32 R-LB 16
3
2
85
87
87A
359 GY-R 18
351 BR-W 18
C
B
458 O-BK 18
RTN
FPP_COMM
787A PK-BK 16
F4 15A
787A PK-BK 16
RX
TWR
86
926A LB-O 18
32
15 R-Y 18
30
355 GY-W 18
31
357 Y-W 18
28
151 LB-BK 18
29
317 GY-O 18
511 LG-R 18
511 LG-R 18
511 LG-R 18
253 DG-W 18
253 DG-W 18
253 DG-W 18
11 T-Y 18
11 T-Y 18
11 T-Y 18
27
658 PK-LG 18
658 PK-LG 18
658 PK-LG 18
10
238 DG-Y 18
238 DG-Y 18
71 O-LG 18
71 O-LG 18
71 O-LG 18
14
72 Y-BK 18
72 Y-BK 18
72 Y-BK 18
15
148 Y-R 18
148 Y-R 18
148 Y-R 18
16
306 T-LB 18
306 T-LB 18
306 T-LB 18
17
307 BK-Y 18
307 BK-Y 18
307 BK-Y 18
11
169 LG-BK 18
169 LG-BK 18
169 LG-BK 18
12
172 LB-R 18
172 LB-R 18
172 LB-R 18
26
33
77 DB-Y 18
349A DB 18
349A DB 18
349A DB 18
18
662 DG-P 18
662 DG-P 18
662 DG-P 18
19
459 O-LG 18
459 O-LG 18
459 O-LG 18
20
642 DG-O 18
642 DG-O 18
642 DG-O 18
21
461 O 18
461 O 18
461 O 18
34
669 DG-W 18
669 DG-W 18
35
458 O-BK 18
458 O-BK 18
669 DG-W 18
458 O-BK 18
85
926A LB-O 18
15 R-Y 18
87
87A
361 R 16
OIL PRESSURE
5 FUEL PUMP
POWER
RELAY
30
242 DG 18
F5 15A
361 R 16
253 DG-W 18
570 BK-W 16
361A R 16
459 O-LG 18
662 DG-P 18
MTRTWR4
39 STARTER IN (AUTOCRANK)
TX
23
361A R 16
15 STARTER IN (INTERUPT)
5V
342 LG-P 18
361A R 16
31 VREF
13 STARTER CONTROL
342 LG-P 18
669 DG-W 18
77 DB-Y 18
33 ANA RTN
87A
22
S-40 S-45
9 VBATT
STARTER
RELAY
30
85
342 LG-P 18
3 COIL 2
13
1 VSW
351 BR-W 18
34 GROUND
361 R 14
359 GY-R 18
570 BK-W 16
25 IVS
361 R 14
29
361 R 12
TWR
351 BR-W 18
16 R-LG 18
CAM
14 FPP1
570 BK-W 16
16 R-LG 18
WPTWR2_GY
6 - 80
39 R-W 18
359 GY-R 18
570 BK-W 16
TRIM VALVE
TWR
570 BK-W 16
151 LB-BK
J2 GREY
COIL 3
INJECTOR #2
WATER
TEMP
359 GY-R 18
COIL 1
INJECTOR #4
ACT
359 GY-R 18
COIL 2
INJECTOR #3
FORD
42 PIN
CONNECTOR
31
357 Y-W 18
361 R 16
556 W 16
11
J1 BLACK
361 R 16
555 T 16
TWR
4 BRAKE
26 OIL PRES
2 TACH
6 MIL
21 AUX OUT1
7 FUEL SELECT
10 AUX ANA PU2
24 GOV SELECT 1
23 GOV SELECT 2
35 ROADSPEED +
36 ROADSPEED 30 OVERSPEED
28 CAN +
29 CAN 11 RS 485+
3 RS 48520 RS 232+
18 RS 232-
SHD
PLUG (GROUND)
PLUG (CAN -)
PLUG (CAN +)
MTRSHD4
July 2007
Section 6 Schematics
REV A
R 16
ENGINE ECM
CONNECTOR
SPK_COIL1A
SPK_COIL1B
SPARK_COIL2A
SPK_GND
SPK_COIL2B
SPK_COIL3A
SPK_COIL3B
UEGOS
UEGOC
UEGOP
UEGPR
AUX ANA PD1
(FRP) AUX ANA PD2
CAN1 +
CAN1 CAN2 CAN2 +
AUX ANA PD3
5V EXT 1
5V RTN
EGO1
EGO2
MAP
AUX ANA PUD3
CRANK +
CRANK CAM +
CAM SPEED +
SPEED 5V EXT 2
5V RTN 2
PULSE IN
GOV 1
OIL PRESS
IAT
ECT
(FRT) AUX ANA PU1
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
(BRAKE) AUX DIG 3
(GOV2) AUX DIG 4
TACH
VSW
AUX ANA PUD2
AUX ANA PUD1
TPS 1
TPS 2
(FUELSELECT)AUX DIG1
AUX DIG 2
KNOCK +
KNOCK FPP1
FPP2-IVS
(FPP2)
PC TX
PC RX
KNOCK 2+
KNOCK 2VBAT PROT
VBAT
EGOH 2
EGOH 1
INJ HS
INJ1 LS
INJ2 LS
INJ3 LS
INJ4 LS
INJ5 LS
GROUND
INJ6 LS
AUX PWM8
STARTER
RELAY
MIL
UEGO H
AUX PWM7
LOCKOFF
AUX PWM6
(FUEL PUMP)
VBAT
DBW +
GROUND
DBW AUX PWM5 REC
AUX PWM5
AUX PWM1
AUX PWM4
AUX PWM2
AUX PWM4 REC
AUX PWM3 REC
FP REC
AUX PWM3
FUEL PUMP
Y/BK 18
W/PK 18
Y/RD 18
BK/W 16
DG/P
6
7
8
9
10
11
12
13
14
15
DG/O 18
W/LG 18
DG/P 18
O/LG 18
R 16
GY/LB 18
DG/P 18
DB/O 18
GY/R 18
CYL #2
CYL #3
CYL #4
HO2S #1
IGNITION COILS
Y/BK 18
W/PK 18
Y/RD 18
1
2
3
4
5
GY/R 18
GY/YL 18
R 16
BK/LB 18
CYL #1
DG/P 18
O/LG 18
LG/BK 18
BR/W 18
GY 18
GY/R 18
GASOLINE
SENSOR
INTERFACE
FORD
42 PIN
CONNECTOR
LG/R 18
GY/R 18
GY/R 18
GROUND
BR 16
BR 16
34 GND
RING
4
3
2
1
CHT
LG/W
DG/BK
LB/R 18
T/LB 18
BK/W 16
BK/W 16
BK/W 16
LB/BK 18
BK/LB 18
LB/R 18
LG/BK 18
T/LB 18
36 ROADSPEED 35 ROADSPEED +
24 GOV SELECT 1
LB/BK 18
R/LG 18
BK/Y 18
R/LG 18
R/T 14
R/T 14
F2
14 FPP1
R/LG 18
R/LG 18
1 VSW
VSW
5A
F3
R 14
ECM
10A
BK/Y 18
GY 18
DBL 18
23 GOV SELECT 2
O/LG 18
DG/P 18
CRANK
29 CAN 28 CAN +
DG/O 18
DG/O 18
DB/W 18
LB/Y 18
DB/W 18
GY/R 18
BR/W 18
GY/R 18
BR/W 18
33 ANA RTN
31 VREF
R/BK 18
R/W 18
R/BK 18
R/W 18
21 AUX PWM 5
16 AUX PWM 4
BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18
BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18
25 IVS
26 OIL PRES
2 TACH
6 MIL
18 FUEL PUMP 39 AUX OUT1
7 FUEL SELECT
10 AUX ANA PD1B
27 AUX OUT 2
4 BRAKE
11 RS 232+
3 RS 232-
LB/PK 16
W/PK 16
15 START IN INTERUPT
19 START IN AUTOCRANK
PK/BK 16
5 FUEL PUMP +
LB/Y 18
12 FPP2
RD/T 14
R/T 16
BK/LB 18
BK/LG 18
GY/R 18
BR/W 18
T 16
BR/Y 16
BR/LB 16
W 16
BK/W 16
BK/W 16
LG/P 18
R/Y 18
PK/LG 18
BK/R 16
W/BK 18
LB/O 18
R/T 16
LB/DG 18
BK/W 16
GY/O 18
BK/LG 18
BOSCH THROTTLE
GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18
GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18
BATT(+)
R 12
RING
6
5
4
3
2
1
R 14
R 12
R 16
3
2
1
ALTERNATOR
DG/W 18
LG/P 18
R/Y 18
OIL PRESSURE
R/BK 18
O/LG 18
R/W 18
T/GN 18
BK/R 16
W 16
W/R 18
INJECTOR CYL #2
GY/R 18
FUEL PUMP
F4
LPG
TEMPERATURE
BN/LB 16
PK/BK 16
GY/R 18
BR/W 18
DG 18
O 18
TWR
INJECTOR CYL #4
W/BK 18
R/LG 18
A
B
LPG
LOCKOFF
BR/Y 16
DG/P 18
Y/R 18
KNOCK
SENSOR
DG/P 18
O/LG 18
1
2
3
4
5
6
7
8
ANA RTN
5V REF
PC TX
PC RX
UNUSED
UNUSED
CAN +
CAN -
DIAGNOSTIC CONNECTOR
PK/BK 16
LB/O 18
85
R 16
PK/BK 16
30
R/LG 18
STARTER
SOLENOID
87
RING
87A
LB/PK 16
87
W/PK 16
30
86
87A
R/LG 18
CAN
TERMINATION
CONNECTOR
STARTER RELAY
LB/PK 16
R/LG 18
LG/P 18
INJECTOR CYL #3
T 16
15A
86
R 16
85
W 18
SHD
RELAY
OMRON
FPP
PK/BK 16
TWR
W 18
DG/P 18
O/LG 18
BK/W 18
3
1
6
4
5
8
PK/BK 16
F1
R16
R/Y 18
INJECTOR CYL #1
R 16
BK/W 12
Y/R 18
DG/P 18
LB/BK 18
LB/Y 18
DG 18
O 18
R 16
SHD
A
B
C
D
MTRTWR4
BR/W 18
LG/R 18
BOSCH
TMAP
T/LB 18
DG/W 18
GY 18
LG/R 18
LG/W
W/R 18
BK/O 18
W/LB 18
BK/Y 18
T/Y 18
R/LG 18
DB/W 18
P/LB 18
GY/W 18
Y/W 18
Y/DB 18
R 16
TWR
A
B
C
D
GY/R 18
LG/W 18
BR/W 18
W/LG 18
W/LG 18
GY 18
DBL 18
GY/R 18
DB/O 18
DG/BK
LB/R 18
R 16
GY/Y 18
BR/W 18
GY/R 18
GY/LB 18
GY/Y 18
LG/BK 18
R 16
HO2S #2
R 16
BK/LG 18
GY/LB 18
GY/R 18
CAM
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
R 16
POWER RELAY
R 16
30
R 16
87
R/T 18
86
87A
R/LB 16
R/LB 16
10A
85
EPR
R 16
15A
RELAYED POWER
CAN +
CAN GROUND
UNUSED
UNUSED
UNUSED
POWER
EPR
CONNECTOR
F5
R 16
CAN + TERM
ES0400A
S-40 S-45
6 - 81
July 2007
Section 6 Schematics
6 - 81
6 - 82
July 2007
Section 6 Schematics
REV A
J
R 16
ENGINE ECM
CONNECTOR
SPK_COIL1A
SPK_COIL1B
SPARK_COIL2A
SPK_GND
SPK_COIL2B
SPK_COIL3A
SPK_COIL3B
UEGOS
UEGOC
UEGOP
UEGPR
AUX ANA PD1
(FRP) AUX ANA PD2
CAN1 +
CAN1 CAN2 CAN2 +
AUX ANA PD3
5V EXT 1
5V RTN
EGO1
EGO2
MAP
AUX ANA PUD3
CRANK +
CRANK CAM +
CAM SPEED +
SPEED 5V EXT 2
5V RTN 2
PULSE IN
GOV 1
OIL PRESS
IAT
ECT
(FRT) AUX ANA PU1
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
(BRAKE) AUX DIG 3
(GOV2) AUX DIG 4
TACH
VSW
AUX ANA PUD2
AUX ANA PUD1
TPS 1
TPS 2
(FUELSELECT)AUX DIG1
AUX DIG 2
KNOCK +
KNOCK FPP1
FPP2-IVS
(FPP2)
PC TX
PC RX
KNOCK 2+
KNOCK 2VBAT PROT
VBAT
EGOH 2
EGOH 1
INJ HS
INJ1 LS
INJ2 LS
INJ3 LS
INJ4 LS
INJ5 LS
GROUND
INJ6 LS
AUX PWM8
STARTER
RELAY
MIL
UEGO H
AUX PWM7
LOCKOFF
AUX PWM6
(FUEL PUMP)
VBAT
DBW +
GROUND
DBW AUX PWM5 REC
AUX PWM5
AUX PWM1
AUX PWM4
AUX PWM2
AUX PWM4 REC
AUX PWM3 REC
FP REC
AUX PWM3
FUEL PUMP
Y/BK 18
W/PK 18
Y/RD 18
BK/W 16
DG/P
6
7
8
9
10
11
12
13
14
15
R 16
GY/LB 18
DG/P 18
DB/O 18
GY/R 18
CYL #2
CYL #3
CYL #4
GY/R 18
GY/YL 18
R 16
BK/LB 18
CYL #1
DG/P 18
O/LG 18
LG/BK 18
BR/W 18
GY 18
GY/R 18
GASOLINE
SENSOR
INTERFACE
FORD
42 PIN
CONNECTOR
LG/R 18
GY/R 18
GY/R 18
GROUND
BR 16
BR 16
34 GND
RING
4
3
2
1
CHT
LG/W
DG/BK
LB/R 18
T/LB 18
BK/W 16
BK/W 16
BK/W 16
LB/BK 18
BK/LB 18
LB/R 18
LG/BK 18
T/LB 18
36 ROADSPEED 35 ROADSPEED +
24 GOV SELECT 1
LB/BK 18
R/LG 18
BK/Y 18
R/LG 18
R/T 14
R/T 14
F2
14 FPP1
R/LG 18
R/LG 18
1 VSW
VSW
5A
F3
R 14
ECM
10A
Y/R 18
DG/P 18
LB/BK 18
LB/Y 18
DG 18
O 18
BK/Y 18
GY 18
DBL 18
23 GOV SELECT 2
O/LG 18
DG/P 18
CRANK
29 CAN 28 CAN +
DG/O 18
DG/O 18
DB/W 18
LB/Y 18
DB/W 18
GY/R 18
BR/W 18
GY/R 18
BR/W 18
33 ANA RTN
31 VREF
R/BK 18
R/W 18
R/BK 18
R/W 18
21 AUX PWM 5
16 AUX PWM 4
BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18
BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18
25 IVS
26 OIL PRES
2 TACH
6 MIL
18 FUEL PUMP 39 AUX OUT1
7 FUEL SELECT
10 AUX ANA PD1B
27 AUX OUT 2
4 BRAKE
11 RS 232+
3 RS 232-
LB/PK 16
W/PK 16
15 START IN INTERUPT
19 START IN AUTOCRANK
PK/BK 16
5 FUEL PUMP +
LB/Y 18
12 FPP2
RD/T 14
R/T 16
BK/LB 18
BK/LG 18
GY/R 18
BR/W 18
T 16
BR/Y 16
BR/LB 16
W 16
BK/W 16
BK/W 16
LG/P 18
R/Y 18
PK/LG 18
BK/R 16
W/BK 18
LB/O 18
R/T 16
LB/DG 18
BK/W 16
GY/O 18
BK/LG 18
BOSCH THROTTLE
GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18
GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18
BATT(+)
R 12
R 12
RING
6
5
4
3
2
1
R 14
R 16
3
2
1
R/LG 18
ALTERNATOR
DG/W 18
LG/P 18
R/Y 18
OIL PRESSURE
R/BK 18
O/LG 18
R/W 18
T/GN 18
BK/R 16
W 16
W/R 18
INJECTOR CYL #2
GY/R 18
FUEL PUMP
F4
LPG
TEMPERATURE
BN/LB 16
PK/BK 16
GY/R 18
BR/W 18
DG 18
O 18
TWR
INJECTOR CYL #4
W/BK 18
R/LG 18
A
B
LPG
LOCKOFF
BR/Y 16
DG/P 18
Y/R 18
KNOCK
SENSOR
DG/P 18
O/LG 18
1
2
3
4
5
6
7
8
ANA RTN
5V REF
PC TX
PC RX
UNUSED
UNUSED
CAN +
CAN -
DIAGNOSTIC CONNECTOR
PK/BK 16
LB/O 18
LB/O 18
85
R 16
PK/BK 16
30
R/LG 18
STARTER
SOLENOID
87
RING
87A
LB/PK 16
87
W/PK 16
30
86
87A
R/LG 18
CAN
TERMINATION
CONNECTOR
STARTER RELAY
LB/PK 16
INJECTOR CYL #3
T 16
15A
FUEL PUMP RELAY
R/LG 18
86
LG/P 18
85
R 16
W 18
SHD
RELAY
OMRON
FPP
PK/BK 16
TWR
W 18
DG/P 18
O/LG 18
BK/W 18
3
1
6
4
5
8
PK/BK 16
F1
R16
R/Y 18
INJECTOR CYL #1
R 16
SHD
A
B
C
D
MTRTWR4
BR/W 18
LG/R 18
BOSCH
TMAP
T/LB 18
DG/W 18
GY 18
LG/R 18
LG/W
W/R 18
BK/O 18
W/LB 18
BK/Y 18
T/Y 18
R/LG 18
DB/W 18
P/LB 18
GY/W 18
Y/W 18
Y/DB 18
R 16
BK/W 12
GY 18
DBL 18
GY/R 18
DB/O 18
DG/BK
LB/R 18
R 16
TWR
A
B
C
D
GY/R 18
LG/W 18
BR/W 18
W/LG 18
W/LG 18
BR/W 18
GY/R 18
GY/LB 18
GY/Y 18
LG/BK 18
R 16
GY/Y 18
DG/O 18
W/LG 18
DG/P 18
O/LG 18
R 16
HO2S #2
R 16
BK/LG 18
GY/LB 18
GY/R 18
CAM
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
HO2S #1
IGNITION COILS
Y/BK 18
W/PK 18
Y/RD 18
1
2
3
4
5
R 16
POWER RELAY
R 16
30
R 16
87
R/T 18
86
R/LB 16
R/LB 16
10A
85
EPR
87A
R 16
15A
RELAYED POWER
POWER
EPR
CONNECTOR
F5
R 16
CAN + TERM
CAN +
CAN GROUND
UNUSED
UNUSED
UNUSED
ES0400A
S-40 S-45
6 - 83
July 2007
Section 6 Schematics
6 - 83
6 - 84
July 2007
Section 6 Schematics
REV A
PRIMARY BOOM
UP/DOWN
DRIVE/STEER
JC2
YOUT 5
PWR 3
GND 2
YOUT 5
XOUT 4
PWR 3
GND 2
RKOUT 6
BL
WH
13
BK
OR
RD
11
14
OR
12
BRN
BRN
J1
JC3
JC3
TURNTABLE ROTATE
J1
4
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
PRIMARY BOOM
UP/DOWN
6
6
1
1
5
5
2
2
4
4
3
3
Deutsch
DRIVE/STEER
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
GND
PWR
XOUT
YOUT
RKOUT
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
JC2
JC3
JC2
7
1
6
2
5
3
4
4
3
5
2
6
1
7
AMP
JC3
YOUT 4
RKOUT 5
OR
BL/WH
WH/RD
BL/WH
XOUT 3
BRN
RD/WH
GND 1
WH/RD
PWR 2
YOUT 4
OR
XOUT 3
BRN
GND 1
PWR 2
TURNTABLE ROTATE
7
5
13
14
11
12
J1
J1
J1-5 BL/WH JC3-5
J1-13 OR JC3-2
J1-11 OR JC2-2
S-40 S-45
6 - 85
July 2007
Section 6 Schematics
6 - 85
6 - 86
Section 6 Schematics
July 2007
6 - 88
6 - 87
6 - 88
GROUND
S-40 S-45
Part No. 102521
14"
WIRING DIAGRAM
OR C2B-2
OR-TS59
OR/BK-TS59
K
L
GROUND BOLT
14
14 PLATFORM LEVEL UP
14"
15
C40LS1 OR CR20#30
TB40
40
RD-H6+
RD-KS1-2 S.P.
5
40 BOOM STOWED
42
OR C6-40
14"
42 P134PWR
14"
C14PLU OR C6-14
OR/RD-C2B-4
CR20
C15PLD OR/BK C6-15
26"
C15PLD OR/BK 15-D
BRN 7.5"
CR21
DOWN RELAY
RD-C6-23 + LS PWR-C6-30
7.5"
PLAT LEVEL
C14PLU OR 14-D
CR20
UP RELAY
TB22
LIMIT SWITCHES
P22LS BK
PLAT LEVEL
CR21
11"
TB15
C40LS1 OR 40-A
6
BRN
C14PLU OR
BR-GND STUD
C20-1
4
R14PLU OR
R15PLD OR/BK
TB134
C20-2
C21-1
3
B
PLAT LEVEL UP
C21-2
C15PLD OR/BK
July 2007
Section 6 Schematics
REV A
M
N
TB14
July 2007
REV A
Section 6 Schematics
P25FS-RD
P26FS-BK
P24FS-WH
RPM HI
RPM LO
20
15
16
TS47
GENERATOR ON
TS4
FOOTSWITCH
ALC-500
D12
1 N.O.
2 COM
C45GEN GR/WH
8 N.C.
C35RPM BK/RD
C2P-7
C1P-9
C29MS RD/WH
L3
C30EDC WH
C31EDC WH/BK
L2
L1
C1P-3
C1P-4
C1P-5
NEMA 4 CONTROL BOX
TB29
124 ohms
1
V151HG GR
V150HG GR/BK
GROUND
STUD ON
PANEL
APBPC
RS232TxD
RS232RxD
A1 BATTERY +
A2 SENSOR POWER +5 VDC
A3 BATTERYB1 VALVE 0 FWD COIL
B2 VALVE 1 NC
B3 DIGITAL OUTPUT BYPASS/OMRON
C1 TxD
C2 RxD
C3 /BOOT
8 GA 5 CONDUCTOR
BRASS
E1 NOT USED
E2 NOT USED
E3 NOT USED
GREEN 12GA
CR4PHIGH IDLE
RELAY
8 GA 4 CONDUCTOR
MOTOR STROKE
VALVE
D1 ANALOG 0 JOYSTICK
D2 ANALOG 1 NC
D3 DIG IN 3 NC
BLACK 12GA
SILVER
C45GEN GR/WH
124 ohms
20 AMP CIRCUIT
BREAKER
F1 DIG IN 0
F2 DIG IN 1 GENERATOR ON
F3 DIG IN 2
U4
SX Controller
BYPASS PCOIL
110 VAC
GFI
DRIVE EDC +
DRIVE EDC -
12 GA 3 CONDUCTOR
ENCLOSURE
3
1k ohms
OMRON
RELAY
GREEN
BLACK 12GA
C5-12
L1
C5-18
C5-24
BLACK
GREEN
TB45
WHITE
BLACK
TB35
C2B-7
4
2
TB22
C5-1
5
1
C5-21
L3
RED
5 SW INPUT
TIME DELAY
MODULE 4S
C5-20
ORANGE
N
3 GND
C1B-9
RED
TB24
C1B-3
L2
C1B-4
C1B-5
208 VAC
OUTLET
7
SILVER
BRASS
WHITE
GREEN
GREEN
BLACK
12 GA 3 CONDUCTOR
Inside
Enclosure
Harness
PIN#
1
2
3
4
5
6
7
8
9
10
11
12
COLOR
BR
WH
WH/BK
BR
BR
WH
WH/BK
BR
GR/WH
GR/BK
WH
BR
S-40 S-45
CKT#
GND
C30EDC+
C31EDCGND
GND
C30EDC+(A)
C31EDC-(A)
GND
C45GEN
V150HG
C22PWR
GND
COLOR
WH/RD
WH
WH/BK
BK/RD
BL/RD
RD
RD/BK
OR/RD
GR/WH
GR/BK
RD/WH
GR
6 - 89
July 2007
Section 6 Schematics
6 - 89
6 - 90
July 2007
Section 6 Schematics
REV C
.025
DB
2 gpm
7.6 L/min
MEDIUM
PRESSURE
FILTER
BRAKE MANIFOLD
T2
CP
SLAVE
PLATFORM LEVEL
CYLINDERS
D
PLATFORM
ROTATE
TEST
3 gpm
11.4 bar
BRAKE
PRIMARY LIFT
CYLINDER
DA
TURNTABLE
ROTATE
4 gpm
15.1 L/min
51 psi
3.5 bar
CB
CA
MASTER
.030
S1
AUXILIARY
PUMP
1.7
V2
AUX
TEST
HYDRAULIC
COOLER
OPTION
315 psi
21.7 bar
SW2
BG
P2
P1
PL2
BE
E
AD
AV
AU
3625 psi
250 bar
AE
AG
AS
COUNTERBALANCE VALVE
RATIO
AC
AH
AA
BD
4.5 gpm
17 L/min
AR
FUNCTION
PUMP
9 7
AB
BF
PRESS
BH
BA
AY
AX
AZ
PR2
PR1
AI
AL
1950 psi
134 bar
T1
PL1
V1
SW1
2200 psi
151.7 bar
FUNCTION
MANIFOLD
AO
RET
EXT
PTEST
AP
AM
AF
0.6 gpm
2.3 L/min
AK
AW
BB
0.6 gpm
2 L/min
(S-40)
AN
RETURN
FILTER
DRIVE PUMP
AQ
2.0 gpm
7.6 L/min
25 psi
1.7 bar
AJ
BG
3:1
1000 PSI
3:1
2000 PSI
3:1
3000 PSI
3:1
3300 PSI
3:1
3500 PSI
5:1
3500 PSI
0.1 gpm
0.4 L/min
AT
2600 psi
179 bar
TANK
3 psi
0.2 bar
3 psi
0.2 bar
PRESS
AUX
T2
ST1
BI
ST2
FUNCTION
MANIFOLD
LS TEST
RESERVOIR
T1
PRESS
OPTIONAL
GENERATOR
MANIFOLD
2400 psi
165.5 bars
8A
8B
x x
8C
6B
6C
6B
2A
2C
2B
5
FUNCTION
PUMP
A
REAR
RIGHT
TANK
TEST
M3
RELEASE
T2
FE
185 psi
12.7 bar
FRR
FRB
FLB
OPTIONAL
GENERATOR
FLR
M1
RIGHT
STEERING
LEFT
210 psi
14.5 bar
50%
FC
.070
50%
FB
FA
FD
M4
T1
REAR
LEFT
185 psi
12.7 bar M2
RELEASE
TRACTION
MANIFOLD
S-40 S-45
6 - 91
July 2007
Section 6 Schematics
6 - 91
6 - 92
July 2007
Section 6 Schematics
REV C
BRAKE MANIFOLD
.025
DB
2 gpm
7.6 L/min
MEDIUM
PRESSURE
FILTER
T2
CP
TURNTABLE
ROTATE
4 GPM
15.1 L/min
50 psi
3.5 bar
PRIMARY LIFT
CYLINDER
SLAVE
PLATFORM LEVEL
CYLINDERS
J2
3 GPM
11.4 L/min
V1
J1
C
DA
TEST
BRAKE
CC
MASTER
V2
.030
CA
PR1
S1
AUXILIARY
PUMP
1.7
V2
PL1
V1
PL2
PR2
AUX
HYDRAULIC
COOLER
OPTION
TEST
315 psi
21.7 bars
FUNCTION
MANIFOLD
AO
RET
EXT
PTEST
AP
P2
P1
SW2
2200 psi
151.7 bar
BE
BH
AD
AV
AG
AC
AH
BD
4.5 gpm
17 L/min
FUNCTION
PUMP
AM
AF
0.6 gpm
2.27 L/min
AK
BB
AW
AA
0.8 gpm
3 L/min
AN
RETURN
FILTER
25 psi
1.7 bar
AQ
AJ
BG
2.0 gpm
7.6 L/min
0.1 gpm
0.38 L/min
AT
2900 psi
200 bar
TANK
3 psi
0.2 bar
3 psi
0.2 bar
PLATFORM
ROTATE
AB
BF
AR
DRIVE PUMP
CB
BA
AE
AU
AS
9 7
JIB SELECT
MANIFOLD
AY
AX
AZ
PR2
PRESS
3625 psi
249.9 bar
PR1
AI
AL
1950 psi
134.4 bar
T1
SW1
BG
AUX
T2
ST1
BI
ST2
FUNCTION
MANIFOLD
LS TEST
RESERVOIR
T1
PRESS
OPTIONAL
GENERATOR
MANIFOLD
COUNTERBALANCE VALVE
RATIO
8A
8B
x x
8C
6C
6B
6B
A
REAR
RIGHT
2A
2C
2B
TEST
FE
M3
PRESS
3:1
1000 PSI
3:1
2000 PSI
3:1
3000 PSI
3:1
3300 PSI
3:1
3500 PSI
5:1
3500 PSI
2400 psi
165.5 bar
FUNCTION
PUMP
TANK
T2
185 psi
12.7 bar
RELEASE
FRR
FRB
FLB
OPTIONAL
GENERATOR
FLR
M1
RIGHT
STEERING
LEFT
50%
FC
.070
FA
50%
FB
FD
M4
T1
REAR
LEFT
M2
185 psi
12.7 bar
RELEASE
TRACTION
MANIFOLD
S-40 S-45
6 - 93
July 2007
Section 6 Schematics
6 - 93
6 - 94
July 2007
Section 6 Schematics
REV C
BRAKE MANIFOLD
.025
DB
2 gpm
7.6 L/min
MEDIUM
PRESSURE
FILTER
TURNTABLE
ROTATE
4 gpm
15.1 L/min
50 psi
3.4 bar
3 gpm
11.4 L/min
T2
PLATFORM LEVEL
CYLINDERS
SLAVE
PRIMARY LIFT
CYLINDER
CA
CP
DA
MASTER
TEST
BRAKE
.030
CB
S1
V2
B
M
TEST
1.7
AUXILIARY
PUMP
315 psi
21.7 bar
AUX
HYDRAULIC
COOLER
OPTION
PTEST
AP
FUNCTION
MANIFOLD
AO
RET
EXT
PL1
SW1 SW2
P1
BG
P2
2200 psi
151.7 bar
AL
AE
AG
AC
AH
BD
4.5 gpm
17 L/min
AR
FUNCTION
PUMP
RATIO
AM
AA
0.6 gpm
2.27 L/min
AF
BB
AK
AW
0.6 gpm
2 L/min
AN
RETURN
FILTER
DRIVE PUMP
AQ
25 psi
1.7 bar
3 psi
0.2 bar
0.1 gpm
0.38 L/min
AT
2600 psi
179.3 bar
TANK
3:1
1000 PSI
3:1
2000 PSI
3:1
3000 PSI
3:1
3300 PSI
3:1
3500 PSI
5:1
3500 PSI
1.5:1
3000 PSI
AJ
BG
2.0 gpm
7.6 L/min
PRESS
AY
AX
AU
AS
COUNTERBALANCE VALVE
AB
BA
BF
3625 psi
249.9 bar
9
PR2
PR1
BH
PRESS
PLATFORM
ROTATE
BE
E
AD
AV
AZ
PL2
AI
1950 psi
134.4 bar
T1
V1
3 psi
0.2 bar
AUX
T2
ST1
BI
ST2
LS TEST
FUNCTION
MANIFOLD
RESERVOIR
T1
PRESS
OPTIONAL
GENERATOR
MANIFOLD
2400 psi
165.5 bar
x
8B
x x
8C 6B
x
6C 6A
2A
2C
2B
FUNCTION
PUMP
HF
REAR
LEFT
TEST
TANK
T2
M4
M7
FRONT
LEFT
M5
210 psi
14.5 bar
FRR
M2
HH
50%
RIGHT
HE
FRB
FLB
STEERING
67% 33%
LEFT
HA
TEST
.052
HG
50%
.070
HD
HI
IN
50%
FRONT
RIGHT
T1
M6
M1
B
A
OUT
M8
M3
950 psi
65.5 bar
RIGHT
LEFT
OSCILLATE VALVE
TRACTION
MANIFOLD
OPTIONAL
GENERATOR
FLR
50%
.070
HC
REAR
RIGHT
OSCILLATE CYLINDERS
S-40 S-45
6 - 95
July 2007
Section 6 Schematics
6 - 95
6 - 96
July 2007
Section 6 Schematics
REV C
TURNTABLE
ROTATE
4 gpm
15.1 L/min
50 psi
3.4 bar
BRAKE MANIFOLD
.025
DB
2 gpm
7.6 L/min
MEDIUM
PRESSURE
FILTER
J2
3 gpm
11.4 L/min
T2
PLATFORM LEVEL
CYLINDERS
SLAVE
PRIMARY LIFT
CYLINDER
V1
J1
CP
DA
TEST
BRAKE
CC
MASTER
V2
.030
CA
PR1
S1
V2
B
M
TEST
1.7
AUXILIARY
PUMP
315 psi
21.7 bar
AUX
HYDRAULIC
COOLER
OPTION
PTEST
AP
AO
RET
EXT
FUNCTION
MANIFOLD
SW1
PL1
SW2
BG
P2
P1
2200 psi
151.7 bar
AD
BA
AE
AG
AR
4.5 gpm
17 L/min
FUNCTION
PUMP
RETURN
FILTER
AQ
25 PSI
AC
BD
AM
0.6 gpm
2.27 L/min
AK
AF
BB
AW
AA
0.8 gpm
3 L/min
COUNTERBALANCE VALVE
BG
2.0 gpm
7.5 L/min
0.1 gpm
0.3 L/min
AT
3 psi
0.2 bar
T2
ST1
BI
ST2
PRESS
RATIO
AJ
2900 psi
200 bar
TANK
3 psi
0.2 bar
AH
AN
DRIVE PUMP
PLATFORM
ROTATE
AY
AX
AU
AS
CB
AB
BH
PRESS
JIB SELECT
MANIFOLD
BF
3625 psi
249.9 bar
E
PR2
PR2
PR1
AV
AZ
PL2
BE
AI
AL
1950 psi
134.5 bar
T1
V1
LS TEST
RESERVOIR
3:1
1000 PSI
3:1
2000 PSI
3:1
3000 PSI
3:1
3300 PSI
3:1
3500 PSI
5:1
3500 PSI
1.5:1
3000 PSI
AUX
FUNCTION
MANIFOLD
x
8B
x x
8C 6B
x
6C 6A
HF
REAR
LEFT
TEST
T1
2C
2B
2400 psi
165.5 bar
M4
FRONT
LEFT
210 psi
14.5 bar
RIGHT
HE
FRB
FLB
STEERING
FLR
67% 33%
TANK
HA
TEST
.052
HB
HG
50%
.070
HD
T2
HI
IN
50%
FRONT
RIGHT
T1
M6
M1
B
A
OUT
M8
M3
950 psi
65.5 bar
OPTIONAL
GENERATOR
RIGHT
LEFT
OSCILLATE VALVE
TRACTION
MANIFOLD
FUNCTION
PUMP
LEFT
50%
.070
HC
FRR
M2
HH
50%
PRESS
OPTIONAL
GENERATOR
MANIFOLD
M7
M5
REAR
RIGHT
2A
OSCILLATE CYLINDERS
S-40 S-45
6 - 97
July 2007
Section 6 Schematics
6 - 97
6 - 98
September
July 2007 2007
Section 6 Schematics
REV D
BRAKE/2 SPEED
MANIFOLD EA
TURNTABLE
ROTATE
(2 gpm / 7.5 L/min)
A
V1
CC
.030
V2
S1
M 1.7 AUXILIARY
PUMP
V2
AUX
HYDRAULIC
COOLER
OPTION
TEST
315 psi
21.7 bar
PTEST
AP
AO
SW1 SW2
RET
EXT
BC
P2
P1
FUNCTION
MANIFOLD
2200 psi
151.6 bar
1950 psi
134.5 bar
T1
E
AD
BA
AE
AU
AS
4.5 gpm
17 L/m
AR
FUNCTION
PUMP
AM
AF
AX
AY
AW
COUNTERBALANCE VALVE
AA
0.8 gpm
3 L/min
(S-45)
0.6 gpm
2.2 L/min
0.6 gpm
2 L/min
(S-40)
AQ
25 psi
1.7 bar
TANK
3 psi
0.20 bar
3 psi
0.20 bar
2.0 gpm
7.5 L/m
RETURN
FILTER
0.1 gpm
0.3 L/min
2600 psi
179 bar
(S-40)
T2
AJ
BG
AT
2900 psi
200 bar
(S-45)
E
F
G
ST1
ST2
BI
AUX
FUNCTION
MANIFOLD
-8
X
X
8B 6B 6C 6A
8A
2A
2C
2B
RIGHT
REAR
FRR
M4
RIGHT
CDR
GC
M2
LEFT
REAR
M3
T2
LEFT
STEERING
OPTIONAL
GENERATOR
MTR A
-12
-12
LEFT
RIGHT
-12
T
OSCILLATE VALVE
G
TANK
21CC
G2
G1
950 psi
65.5 bar
GD
12.5 KW GENERATOR
B
A
IN
OUT
TRACTION
MANIFOLD
G1
MTR B
-12
TEST
GB
FLR
-8
280 psi
19.3 bar
.070
50%
CU
GA
GF
M1
CDL
FLB
GE
50%
FRB
CY
270 PSI @
3.5 GPM
G2
TANK
A
B
0.031
CW
CX
FUNCTION
PUMP
TEST A
CV
2400 psi
165.4 bar
PMP A
CLR
PMP B
WELDER
MANIFOLD
2400 psi
165.4 bar
OPTIONAL
GENERATOR
MANIFOLD
DRIVE
PUMP
-12
3.5 GPM
21 GPM
-12
PRESS
OIL
COOLER
T1
PRESS
1000 PSI
2000 PSI
3000 PSI
3300 PSI
3500 PSI
3500 PSI
3000 PSI
LS TEST
RESERVOIR
RATIO
3:1
3:1
3:1
3:1
3:1
5:1
1.5:1
AN
DRIVE PUMP
X X
PLATFORM
ROTATE
AC
AK
BB
CB
AH
AG
BD
JIB SELECT
MANIFOLD
BF
3625 psi
249.9 bar
AB
AY
AX
AZ
PR2
BH
AI
AV
PR2
PR1
AL
PRESS
BE
CA
PR1
PL2
PL1
V1
TEST
MASTER
8C
J2
J1
EC
BRAKE 2SPEED
PLATFORM LEVEL
CYLINDERS
SLAVE
PRIMARY LIFT
CYLINDER
(3 gpm / 11.3 L/min)
T2
CP
ED
EB
025.
MEDIUM
PRESSURE
FILTER
HYDRAULIC
ROTARY
COUPLER
OSCILLATE CYLINDERS
S-40 S-45
6 - 99
July 2007
Section 6 Schematics
6 - 99
6 - 100
September
July 2007 2007
Section 6 Schematics
REV D
TURNTABLE
ROTATE
(2 gpm / 7.5 L/min)
A
EA
V1
T2
CP
C
TEST
BRAKE 2SPEED
CC
V2
S1
A
M 1.7
TEST
AUXILIARY
PUMP
AUX
HYDRAULIC
COOLER
OPTION
315 psi
21.7 bar
V1
V2
AP
AO
RET
EXT
PTEST
PL1
SW1 SW2
BC
P2
2200 psi
E
151.6 bar
P1
FUNCTION
MANIFOLD
T1
1950 psi
134.5 bar
PR1
AZ
FUNCTION
PUMP
BF
4.5 gpm
17 L/min
AA
0.6 gpm
2.2 L/min
AK
AF
BB
AW
0.8 gpm
3 L/min
(S-45)
0.6 gpm
2 L/min
(S-40)
COUNTERBALANCE VALVE
3 psi
0.20 bar
RETURN
FILTER
2600 psi
179 bar
(S-40)
B
C
D
E
ST1
T2
ST2
BI
LS TEST
RESERVOIR
AUX
FUNCTION
MANIFOLD
PRESS
8B 6B 6C 6A
8A
2A 2C
TEST A
JD
M7
M8
A
FRR
RIGHT
FRONT
FRB
M6
JA
CY
270 PSI @
3.5 GPM
G2
CU
OPTIONAL
GENERATOR
LEFT
RIGHT
0.031
CW
CX
JL
M5
6
CV
T2
FLR
FLB
PMP A
CLR
PMP B
TANK
STEERING
CDR
DRIVE
PUMP
G1
MTR B
-12
MTR A
-12
1
JC
-12
WELDER
MANIFOLD
2400 psi
165.4 bar
FUNCTION
PUMP
RIGHT
REAR
3.5 GPM
OPTIONAL
GENERATOR
MANIFOLD
2B
-12
-8
21 GPM
PRESS
1000 PSI
2000 PSI
3000 PSI
3300 PSI
3500 PSI
3500 PSI
3000 PSI
OIL
COOLER
T1
RATIO
3:1
3:1
3:1
3:1
3:1
5:1
1.5:1
0.1 gpm
0.3 L/min
AT
2900 psi
200 bar
(S-45)
TANK
AJ
BG
2.0 gpm
7.5 L/min
AQ
25 psi
1.7 bar
3 psi
0.20 bar
AM
50%
50%
280 psi
19.3 bar
.040
JH
LEFT
REAR
M3
CDL
M1
JN
JK
TEST
.040
JI
JE
JB
50%
50% 50%
.040
JG
PLATFORM
ROTATE
AN
DRIVE PUMP
X
CB
AC
BD
JIB SELECT
MANIFOLD
AH
AG
AR
AB
BA
AE
AS
PR2
BH
AD
AU
3625 psi
249.9 bar
PR2
AY
AX
BE
AI
AV
CA
PR1
PL2
AL
PRESS
8C
2
C
MASTER
EC
0.030
J1
-8
B
A
IN
OUT
JM
50%
950 psi
65.5 bar
M4
-12
TANK
21CC
G2
G1
-12
12.5 KW GENERATOR
RIGHT
LEFT
ED
EB
J2
.025
PRIMARY LIFT
CYLINDER
(3 gpm / 11.3 L/min)
PLATFORM LEVEL
CYLINDERS
SLAVE
HYDRAULIC
ROTARY
COUPLER
BRAKE/2 SPEED
MANIFOLD
MEDIUM
PRESSURE
FILTER
50 psi
3.5 bar
B
JF
JJ
TRACTION
MANIFOLD
M2
LEFT
FRONT
OSCILLATE VALVE
G
OSCILLATE CYLINDERS
S-40 S-45
6 - 101
July 2007
Section 6 Schematics
6 - 101
6 - 102
July 2007
Section 6 Schematics
REV A
1
1
OIL
COOLER
3.5 GPM
DRIVE
PUMP
A
3
PMP B
CLR
PMP A
WELDER
MANIFOLD
CV
4
4
0.031
CW
CY
CX
5
5
270 PSI @
3.5 GPM
G2
CU
G1
MTR B
MTR A
6
3
TANK
21CC
G2
HYDRAULIC
ROTARY
COUPLER
7
7
G1
8
8
12.5 KW GENERATOR
S-40 S-45
6 - 103
July 2007
Section 6 Schematics
6 - 103
6 - 104
California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
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