Professional Documents
Culture Documents
from Z60-4001
Z-60/34
TM
Introduction
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Technical Publications
Genie has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All Copyright © 2011 by Terex Corporation
communications will be carefully considered for 75861 Rev E September 2013
future printings of this and all other manuals. Third Edition, Fifth Printing
Revision History
Revision Date Section Procedure / Schematic Page / Description
E 9/2013 New Printing
REFERENCE EXAMPLES:
REFERENCE EXAMPLES:
INTRODUCTION
Serial Number Legend
Model: Z-60/34
Serial number: Z6006-12345
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: ES0423
Machine unladen weight:
Serial number OR
(stamped on chassis)
(located on ground
control box)
PN - 77055
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie Z-60/34
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.
SAFETY RULES
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................. iii
Section 2 Specifications
Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Hydraulic Oil Specifications ................................................................................... 2 - 3
Hydraulic Component Specifications ...................................................................... 2 - 4
Manifold Component Specifications ....................................................................... 2 - 6
Valve Coil Resistance Specifications ..................................................................... 2 - 6
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 7
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 9
Ford MSG-425 EFI Engine Specifications .............................................................. 2 - 9
Deutz F4L-1011F Engine Specifications .............................................................. 2 - 10
Deutz F3L-1011F Engine Specifications .............................................................. 2 - 11
Deutz F3L-2011/Deutz D2011L03i Engine Specifications ..................................... 2 - 12
Perkins 404C-22 Engine Specifications ............................................................... 2 - 14
Machine Torque Specifications ............................................................................ 2 - 15
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 16
SAE and Metric Fasteners Torque Charts ............................................................ 2 - 17
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
Section 6 Schematics
Introduction ............................................................................................................ 6 - 1
Wire Connector Legend .......................................................................................... 6 - 2
Electrical Symbols Legend .................................................................................... 6 - 3
Hydraulic Symbols Legend .................................................................................... 6 - 4
Electrical Abbreviations Legend ............................................................................. 6 - 5
Ford DSG-423 EFI Engine Relay Layout ................................................................ 6 - 8
Ford MSG-425 EFI Engine Relay Layout ............................................................... 6 - 8
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
Specifications
Machine Specifications Lug nut torque (before serial number 4551)
Tires and wheels Flanged or tapered lug nut, dry 170 ft-lbs
230 Nm
Tire size
(Rough terrain) 385-19.5 Flanged or tapered lug nut, lubricated 130 ft-lbs
176 Nm
Tire size
(Hi-flotation) 41/18LL x 22.5 Lug nut torque (after serial number 4550)
Tire weight, new foam-filled (minimum) 425 lbs Tapered lug nut, dry 170 ft-lbs
(Rough terrain) 193 kg 230 Nm
Overall tire diameter 40.1 in Tapered lug nut, lubricated 130 ft-lbs
(Rough terrain) 102 cm 176 Nm
SPECIFICATIONS
SPECIFICATIONS
Optional fluids
SPECIFICATIONS
Drive pump (before serial number 4551) Displacement, 2WD models 0.37 cu in
6.1 cc
Type: bi-directional,
variable displacement piston pump Displacement, 4WD models 0.51 cu in
8.4 cc
Displacement per revolution, variable, 2WD models
0 to 1.70 cu in Flow rate @ 2500 rpm, 2WD models 4 gpm
0 to 28 cc 15.1 L/min
Displacement per revolution, variable, 4WD models Flow rate @ 2500 rpm, 4WD models 5.5 gpm
0 to 2.74 cu in 20.8 L/min
0 to 45 cc
Charge pressure @ 2500 rpm 250 psi
Flow rate @ 2500 rpm, 2WD models 0 to 18.5 gpm Neutral position 17.2 bar
0 to 70.0 L/min
Charge pump (after serial number 4550)
Flow rate @ 2500 rpm, 4WD models 0 to 30.1 gpm
0 to 113.9 L/min Type: gerotor pump
Drive pressure, maximum, 4WD models 3625 psi Flow rate @ 2500 rpm 9 gpm
250 bar 34.1 L/min
Drive pump (after serial number 4550) Charge pressure @ 2500 rpm 310 psi
Neutral position 21.4 bar
Type: bi-directional,
variable displacement piston pump Function pump (before serial number 4551)
Displacement per revolution, variable, 4WD models Type gear, pressure balanced
0 to 2.8 cu in Displacement 1.37 cu in
0 to 46 cc 22.5 cc
Flow rate @ 2500 rpm 0 to 28 gpm Flow rate @ 2500 rpm 14.8 gpm
106 L/min 56 L/min
Drive pressure, maximum 3625 psi Function pump (after serial number 4550)
250 bar
Type gear, pressure balanced
Displacement 1.04 cu in
17 cc
SPECIFICATIONS
SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SPECIFICATIONS
SPECIFICATIONS
Ignition System
Engine coolant
Alternator
SPECIFICATIONS
Bore & stroke 3.44 x 3.7 inches Spark plug type Motorcraft AGSF-32-FEC
87.5 x 94 mm Spark plug gap 0.049 to 0.053 inches
Horsepower 1.244 to 1.346 mm
Continuous horsepower 59 @ 2500 rpm Engine coolant
Peak horsepower 69 @ 2500 rpm
Continuous horsepower 44 kW @ 2500 rpm Capacity 10 quarts
Peak horsepower 51 kW @ 2500 rpm 9.5 liters
Firing order 1-3-4-2 Cylinder head temperature sending unit
Low function idle (computer controlled) 1600 rpm Fault code set temperature 280°F
Frequency 53.3 Hz 138°C
High function idle (computer controlled) 2500 rpm Engine shut-down temperature 300°F
Frequency 83.3 Hz 149°C
Compression ratio 9.7:1 Starter motor
Compression pressure (approx.) Normal engine cranking speed 200 to 250 rpm
Pressure (psi or bar) of lowest cylinder must be
at least 75% of highest cylinder Current draw, normal load 140-200A
SPECIFICATIONS
Lubrication system
SPECIFICATIONS
Starter motor
Alternator
Battery
Quantity 1
SPECIFICATIONS
Bore and stroke 3.58 x 4.13 inches Injector opening pressure 3626 psi
91 x 105 mm 250 bar
SPECIFICATIONS
Bore and stroke 3.58 x 4.13 inches Injector opening pressure 3626 psi
91 x 105 mm 250 bar
SPECIFICATIONS
Bore and stroke 3.7 x 4.4 inches Oil capacity 9.5 quarts
94 x 112 mm (including filter) 9 liters
(Deutz D2011Lo3i Engine)
Horsepower
Net intermittent 48.7 @ 2800 rpm Oil viscosity requirements
Net continuous 46.2 @ 2800 rpm
Unit ships with 15-W40 oil.
Net intermittent 36 kW @ 2800 rpm
Extreme operating temperatures may require the use of
Net continuous 34.5 kW @ 2800 rpm
alternative engine oils. For oil requirements, refer to the
Firing order 1-2-3 engine Operator's Manual on your machine.
SPECIFICATIONS
Fuel requirement
Starter motor
Battery
Quantity 1
SPECIFICATIONS
SPECIFICATIONS
Reserve capacity @ 25A rate 200 minutes 1-8 center bolt, Gr 5, lubricated 480 ft-lbs
651 Nm
Coolant temperature sending unit
3/8-16 bolts, Gr 8, lubricated 35 ft-lbs*
Torque 8-18 ft-lbs *(use blue thread-locking compound) 47 Nm
11-24 Nm
Drive motor and hubs
Temperature switch point 221° F
105° C Drive hub mounting bolts, lubricated 160 ft-lbs*
(before serial number 4569 and after 5572) 217Nm
*(use blue thread-locking compound)
Turntable bearing
SPECIFICATIONS
Torque Procedure
a
Seal-Lok™ fittings
c b
1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
cannot be re-used if the fitting or hose end has Figure 1
been tightened beyond finger tight.
a hex nut
Note: The O-rings used in the Parker Seal Lok™ b reference mark
fittings and hose ends are custom-size O-rings. c body hex fitting
They are not standard SAE size O-rings. They are 3 Working clockwise on the body hex fitting, make
available in the O-ring field service kit (Genie part a second mark with a permanent ink marker to
number 49612). indicate the proper tightening position. Refer to
2 Lubricate the O-ring before installation. Figure 2.
3 Be sure that the face seal O-ring is seated and Note: Use the JIC 37° Fittings table on the previous
retained properly. page to determine the correct number of flats for
the proper tightening position.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger Note: The marks indicate that the correct tightening
tight. positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
5 Tighten the nut or fitting to the appropriate joint after it has been loosened.
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to b
confirm that there are no leaks. a
c
b
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose of Figure 2
the fitting body (body hex fitting) and tighten the a body hex fitting
hex nut to the body hex fitting to hand-tight, b reference mark
approximately 30 in-lbs / 3.4 Nm. c second mark
2 Make a reference mark on one of the flats of the 4 Tighten the hex nut until the mark on the hex nut
hex nut, and continue it on to the body hex is aligned with the second mark on the body hex
fitting with a permanent ink marker. Refer to fitting.
Figure 1.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SPECIFICATIONS
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
Symbols Legend
Maintenance inspections shall be completed by
a person trained and qualified on the Safety alert symbol—used to alert
maintenance of this machine. personnel to potential personal
injury hazards. Obey all safety
Scheduled maintenance inspections shall be
messages that follow this symbol
completed daily, quarterly, six months, annually to avoid possible injury or death.
and every 2 years as specified on the
Maintenance Inspection Report. Used to indicate the presence of
an imminently hazardous situation
Failure to perform each procedure which, if not avoided, will result in
as presented and scheduled may death or serious injury.
cause death, serious injury or
substantial damage. Used to indicate the presence of a
potentially hazardous situation
Immediately tag and remove from service a which, if not avoided, could result
damaged or malfunctioning machine. in death or serious injury.
Repair any machine damage or malfunction With safety alert symbol—used to
before operating machine. indicate the presence of a
potentially hazardous situation
Use only Genie approved replacement parts.
which, if not avoided, may cause
Machines that have been out of service for a minor or moderate injury.
period longer than three months must complete Used to indicate the presence of a
the quarterly inspection. potentially hazardous situation
Unless otherwise specified, perform each which, if not avoided, may result in
maintenance procedure with the machine in the property damage.
following configuration: Note: Used to indicate operation or maintenance
· Machine parked on a firm, level surface information
· Boom in the stowed position Indicates that a specific result is expected after
· Turntable rotated with the boom between performing a series of steps.
the non-steer wheels
Indicates that an incorrect result has occurred
· Turntable secured with the turntable after performing a series of steps.
rotation lock
· Key switch in the off position with the
key removed
· Wheels chocked
· All external AC power supply disconnected
from the machine
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, every six months, annual and
two years. The Scheduled Maintenance
Indicates that new parts will be required
Procedures Section and the Maintenance
to perform this procedure.
Inspection Report have been divided into five
subsections—A, B, C, D and E. Use the following
chart to determine which group(s) of procedures
Indicates that a cold motor, pump or are required to perform a scheduled inspection.
engine will be required to perform this
procedure.
Inspection Checklist
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing the
The Pre-delivery Preparation is performed prior to each Pre-operation Inspection, the Maintenance items and the
delivery. The inspection is designed to discover if anything Function Tests.
is apparently wrong with a machine before it is put into
service. Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
A damaged or modified machine must never be used. If instructions in the operator’s manual.
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed If any inspection receives an N, remove the machine from
from service. service, repair and re-inspect it. After repair, place a check
in the R box.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's Legend
specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed by N = no, unable to complete
qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements listed Comments
in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Genie specifications require that this procedure be and damage.
performed daily. Result: The machine is equipped with all
Maintaining the operator’s and safety manuals in required decals, and all decals are legible and
good condition is essential to safe machine in good condition.
operation. Manuals are included with each Result: The machine is not equipped with all
machine and should be stored in the container required decals, or one or more decals are
provided in the platform. An illegible or missing illegible or in poor condition. Remove the
manual will not provide safety and operational machine from service until the decals are
information necessary for a safe operating replaced.
condition.
4 Always return the manuals to the storage
In addition, maintaining all of the safety and container after use.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators Note: Contact your authorized Genie distributor or
and personnel to the many possible hazards Genie Industries if replacement manuals or decals
associated with using this machine. They also are needed.
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
CHECKLIST A PROCEDURES
A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed daily. performed daily.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the Operator's Manual on your
Complete information to perform this procedure is machine.
available in the Operator's Manual on your
machine.
CHECKLIST A PROCEDURES
Deutz 1011F Operation Manual Ford DSG 423 EFI Operator Handbook
(Deutz part number 0297 9683) or the Genie part number 119488
Deutz 2011 Operation Manual
(Deutz part number 0297 9929). Ford MSG-425 EFI Operator Handbook
Genie part number 215322
To access the engine:
Deutz 1011F Operation Manual
Genie part number 52883 1 Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
Deutz 2011 Operation Manual fastener located at the platform end of the
Genie part number 84794 engine tray. Swing the engine tray out and
away from the machine and secure it from
moving
Perkins models Crushing hazard. Failure to secure
the engine pivot plate from moving
Required maintenance procedures and additional could result in death or serious
engine information are available in the injury.
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).
CHECKLIST A PROCEDURES
A-5 A-6
Perform 30 Day Service Check the High Pressure
Hydraulic Filter Condition
Indicator (if equipped)
The 30 day maintenance procedure is a one time Genie specifications require that this procedure be
sequence of procedures to be performed after the performed every 40 hours of operation.
first 30 days or 40 hours of usage, whichever
comes first. After this interval, refer to the Maintaining the hydraulic return filter in good
maintenance tables for continued scheduled condition is essential to good system performance
maintenance. and safe machine operation. The filter condition
indicator will show when the hydraulic flow is
1 Perform the following maintenance procedures: bypassing a clogged filter. If the filter is not
frequently checked and replaced, impurities will
remain in the hydraulic system and cause
• A-11 Grease the Turntable Bearing and
component damage.
Rotate Gear
• B-8 Inspect the Tires, Wheels and Lug Nut 1 Open the ground control side turntable cover.
Torque 2 Start the engine from the ground controls.
• B-9 Check the Drive Hub Oil Level and 3 Change the engine idle to high rpm (rabbit
Fastener Torque symbol).
• D-2 Check the Turnable Rotation Bearing 4 Visually inspect the filter condition indicator.
Bolts Result: The filter condition indicator should be
• D-6 Replace the Hydraulic Filter Elements operating with the plunger in the green area. If
the indicator displays the plunger in the red
area, this indicates that the hydraulic filter is
being bypassed and the filter should be
replaced. See D-6, Replace the Hydraulic Filter
Elements.
CHECKLIST A PROCEDURES
CHECKLIST A PROCEDURES
A-8 A-9
Perform Engine Maintenance - Inspect the Fuel Filter/Water
Perkins Models Separator - Deutz Models
Engine specifications require that this procedure Genie specifications require that this procedure be
be performed every 50 hours. performed every 100 hours or monthly, whichever
comes first.
Perkins models
Proper maintenance of the fuel filter/water
Required maintenance procedures and additional
separator is essential for good engine
engine information are available in the
performance. Failure to perform this procedure can
Perkins 404C-22 Operation Manual
lead to poor engine performance and/or hard
(Perkins part number TPD 1443S).
starting, and continued use may result in
component damge. Extremely dirty conditions may
Perkins 404C-22 Operation Manual require this procedure be performed more often.
Genie part number 94890
Explosion and fire hazard. Engine
To access the engine: fuels are combustible. Perform this
procedure in an open, well-
1 Remove the engine tray retaining fasteners ventilated area away from heaters,
located under the engine tray. Loosen the pivot sparks, flames and lighted
fastener located at the platform end of the tobacco. Always have an
engine tray. Swing the engine tray out and approved fire extinguisher within
away from the machine and secure it from easy reach.
moving
Note: Perform this procedure with the engine off.
Crushing hazard. Failure to secure
the engine pivot plate from moving 1 Loosen the drain plug located at the bottom of
could result in death or serious the filter. Allow the water to drain into a suitable
injury container until fuel starts to come out.
Immediately tighten the drain plug.
CHECKLIST A PROCEDURES
A-10
Perform Engine Maintenance -
Ford Models
a
CHECKLIST A PROCEDURES
A-11 A-12
Grease the Turntable Rotation Perform Engine Maintenance -
Bearing and Rotate Gear Deutz 1011F Models
Genie specifications require that this procedure be Engine specifications require that this procedure
performed every 100 hours of operation. Perform be performed after the first 125 hours.
this procedure more often if dusty conditions exist.
Deutz models
Frequent application of lubrication to the turntable
Required maintenance procedures and additional
bearing and rotate gear is essential to good
engine information are available in the
machine performance and service life. Continued
Deutz 1011F Operation Manual
use of an improperly greased bearing and gear will
(Deutz part number 0297 9683).
result in component damage.
1 Raise the boom enugh to access the turntable Deutz 1011F Operation Manual
gearing. Genie part number 52883
2 Locate the grease fitting on the platform end of
To access the engine:
the engine side bulkhead.
3 Pump grease into the turntable rotation bearing. 1 Remove the engine tray retaining fasteners
Rotate the turntable in increments of located under the engine tray. Loosen the pivot
4 to 5 inches / 10 to 13 cm at a time and repeat fastener located at the platform end of the
this step until the entire bearing has been engine tray. Swing the engine tray out and
greased. away from the machine and secure it from
moving
4 Apply grease to each tooth of the drive gear,
located under the turntable. Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
Grease type
injury
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
CHECKLIST A PROCEDURES
Before serial number 4551 6 Repeat steps 1 through 4 for all the other drive
hubs.
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point. a
a
2 Remove both plugs and drain the oil into a
suitable container.
b
3 Drive the machine until one plug is at the top b
and the other is at 90 degrees.
Illustration A Illustration B
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Refer to Section 2, Specifications.
5 Install the plugs. Use pipe thread sealant on
units with pipe plugs.
6 Repeat steps 1 through 5 for all the other drive
hubs.
CHECKLIST A PROCEDURES
A-14
Perform Engine Maintenance -
Ford Models
Checklist B Procedures
B-1 7 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
Inspect the Battery follows:
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
Genie specifications require that this procedure be • Subtract 0.004 from the reading of each cell for
performed every 250 hours or quarterly, whichever every 10° / 5.5° C below 80° F / 26.7° C.
comes first.
Result: All battery cells display an adjusted
Proper battery condition is essential to good specific gravity of 1.277 or higher. The battery
engine performance and operational safety. is fully charged. Proceed to step 11.
Improper fluid levels or damaged cables and
Result: One or more battery cells display a
connections can result in engine component
specific gravity of 1.217 or below. Proceed to
damage and hazardous conditions.
step 8.
Electrocution hazard. Contact with 8 Perform an equalizing charge OR fully charge
hot or live circuits could result in the battery(s) and allow the battery(s) to rest at
death or serious injury. Remove all least 6 hours.
rings, watches and other jewelry.
9 Remove the battery vent caps and check the
Bodily injury hazard. Batteries specific gravity of each battery cell with a
contain acid. Avoid spilling or hydrometer. Note the results.
contacting battery acid. Neutralize
battery acid spills with baking soda 10 Check the ambient air temperature and adjust
and water. the specific gravity reading for each cell as
follows:
1 Put on protective clothing and eye wear.
• Add 0.004 to the reading of each cell for
2 Be sure that the battery cable connections are every 10° / 5.5° C above 80° F / 26.7° C.
free of corrosion.
• Subtract 0.004 from the reading of each cell for
Note: Adding terminal protectors and a corrosion every 10° / 5.5° C below 80° F / 26.7° C.
preventative sealant will help eliminate corrosion
on the battery terminals and cables. Result: All battery cells display a specific gravity
of 1.277 or greater. The battery is fully charged.
3 Be sure that the battery hold downs and cable Proceed to step 13.
connections are tight.
Result: The difference in specific gravity
4 Be sure that the battery separator wire readings between cells is greater than 0.1 OR
connections are tight (if equipped). the specific gravity of one or more cells is less
5 Fully charge the battery(s) and allow the than 1.217. Replace the battery.
battery(s) to rest at least 6 hours. 11 Check the battery acid level. If needed,
6 Remove the battery vent caps and check the replenish with distilled water to 1/8 inch / 3 mm
specific gravity of each battery cell with a below the bottom of the battery fill tube. Do not
hydrometer. Note the results. overfill.
12 Install the vent caps and neutralize any
electrolyte that may have spilled using baking
soda.
CHECKLIST B PROCEDURES
1 Open the engine side turntable cover. 9 Lower the boom to the stowed position and turn
the engine off.
2 Remove the engine tray retaining fasteners
located under the engine tray. Swing the engine 10 Inspect the following areas for burnt, chafed,
tray out and away from the machine and secure corroded, pinched and loose wires:
it from moving. • Cable track on the primary boom
Crushing hazard. Failure to secure • Cables on the primary, and jib booms
the engine pivot plate from moving
• Jib boom/Platform rotate manifold
could result in death or serious
injury. • Inside of the platform control box
3 Inspect the following areas for burnt, chafed, 11 Inspect for a liberal coating of dielectric grease
corroded and loose wires: in all connections between the ECM and the
platform controls.
• Engine wiring harness
12 Swing the engine back to its original position
and install the engine pivot plate retaining
fasteners.
Crushing hazard. Failure to install
the fasteners into the engine tray
to secure it from moving could
result in death or serious injury.
CHECKLIST B PROCEDURES
a clamp
b canister end cap
c dust discharge valve
CHECKLIST B PROCEDURES
B-4 B-5
Test the Key Switch Perform Engine Maintenance -
Genie specifications require that this procedure be Deutz and Perkins Models
performed every 250 hours or quarterly, whichever
comes first.
CHECKLIST B PROCEDURES
B-6 B-7
Check the Exhaust System Check the Oil Cooler and Cooling
Fins - Deutz Models
CHECKLIST B PROCEDURES
a b c B-8
Inspect the Tires, Wheels
and Lug Nut Torque
CHECKLIST B PROCEDURES
B-9 2 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Check the Drive Hub Oil Level Refer to Section 2, Specifications.
and Fastener Torque 3 Apply pipe thread sealant to the plugs. Install
the plugs.
4 Check the torque of the drive hub mounting
fasteners. Refer to Section 2, Specifications.
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever 5 Repeat this procedure for each drive hub.
comes first.
Failure to maintain proper drive hub oil levels may a
a
cause the machine to perform poorly and
continued use may cause component damage.
CHECKLIST B PROCEDURES
d
Proper brake configuration is essential to safe
operation and good machine performance.
Hydrostatic brakes and hydraulically-released,
spring-applied individual wheel brakes can appear
a drive pump
to operate normally when they are actually not fully b screwdriver
operational. c lift pump
d free-wheel valve
1 Check each drive hub disconnect cap to be
sure it is in the engaged position. Note: The free-wheel valve should always remain
closed.
brake disengaged position
CHECKLIST B PROCEDURES
B-11 B-12
Test the Engine Idle Select Test the Fuel Select Operation -
Genie specifications require that this procedure be Ford Models
performed every 250 hours or quarterly, whichever
comes first.
CHECKLIST B PROCEDURES
CHECKLIST B PROCEDURES
B-14 B-15
Check the Directional Valve Test the Platform Self-leveling
Linkage
CHECKLIST B PROCEDURES
B-16 B-17
Test the Drive Brakes Test the Drive Speed -
Stowed Position
CHECKLIST B PROCEDURES
CHECKLIST B PROCEDURES
B-19 B-20
Perform Hydraulic Oil Analysis Test the Alarm Package
(if equipped) and the
Descent Alarm
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Replacement or testing of the hydraulic oil is Note: The descent alarm is standard, beginning
essential for good machine performance and with serial number 7270.
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and The alarm package includes:
continued use may cause component damage.
Extremely dirty conditions may require oil changes • Travel alarm
to be performed more often. • Flashing beacons
Note: Before replacing the hydraulic oil, the oil may Alarms and beacons are installed to alert operators
be tested by an oil distributor for specific levels of and ground personnel of machine proximity and
contamination to verify that changing the oil is motion. The alarm package is installed on the
necessary. If the hydraulic oil is not replaced at turntable rear cover. Beacons are installed on both
the two year inspection, test the oil quarterly. turntable covers.
Replace the oil when it fails the test.
See E-1, Test or Replace the Hydraulic Oil. The alarms and beacons will operate with the
engine running or not running.
CHECKLIST B PROCEDURES
CHECKLIST B PROCEDURES
8 Install the breather cap onto the hydraulic tank. Ford MSG-425 EFI Operator Handbook
Genie part number 215322
To access the engine:
1 Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury
Checklist C Procedures
C-1 Perkins models
Perform Engine Maintenance - Required maintenance procedures and additional
Deutz and Perkins Models engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).
CHECKLIST C PROCEDURES
C-2 C-3
Grease the Platform Overload Test the Platform Overload
Mechanism (if equipped) System (if equipped)
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 500 hours or 6 months, whichever performed every 500 hours or 6 months, whichever
comes first. Perform this procedure more often if comes first.
dusty conditions exist.
Testing the platform overload system regularly is
Application of lubrication to the platform overload essential to safe machine operation. Continued
mechanism is essential to safe machine operation. use of an improperly operating platform overload
Continued use of an improperly greased platform system could result in the system not sensing an
overload mechanism could result in the system not overloaded platform condition. Machine stablity
sensing an overloaded platform condition and will could be compromised resulting in the machine
result in component damage. tipping over.
1 Locate the grease fittings on each pivot pin of Note: Perform this procedure with the machine on
the platform overload assembly. a firm, level surface.
2 Thoroughly pump grease into each grease 1 Turn the key switch to platform control. Start the
fitting using a multi-purpose grease. engine and level the platform.
2 Determine the maximum platform capacity.
Grease type
Refer to the machine serial plate.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect test.
CHECKLIST C PROCEDURES
4 Using a suitable lifting device, place a test 6 Using a suitable lifting device, place an
weight equal to that of the available capacity additional 50 lbs / 23 kg of weight onto the
one of the locations shown. platform.
Refer to Illustration 1.
Result: The alarm should sound.
Result: The platform overload indicator lights The platform overload indicator lights should be
should be off at both the ground and platform flashing at both the ground and platform
controls and the alarm should not sound. controls.
Result: The platform overload indicator lights Result: The alarm does not sound and the
are on and the alarm is sounding. Calibrate the platform overload indicator lights are not
platform overload system. Refer to Repair flashing. Calibrate the platform overload
Procedure 2-4, How to Calibrate the Platform system. Refer to Repair Procedure 2-4, How to
Overload System (if equipped). Calibrate the Platform Overload System (if
equipped).
5 Carefully move the test weight to each
remaining location. Refer to Illustration 1. Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
Result: The platform overload indicator lights
sounds.
should be off at both the ground and platform
controls and the alarm should not sound. 7 Carefully move the test weights to each
remaining location on the platform.
Result: The platform overload indicator lights
Refer to Illustration 1.
are on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair Result: The alarm should sound.
Procedure 2-4, How to Calibrate the Platform The platform overload indicator lights should be
Overload System (if equipped). flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-4, How to
Calibrate the Platform Overload System (if
equipped).
Note: There may be a two second delay before the
overload indicator lights flash and the alarm
sounds.
Illustration 1
CHECKLIST C PROCEDURES
8 Test all machine functions from the platform 14 Start the engine and test all machine functions
controls. from the ground controls.
Result: All platform control functions should not Result: All ground control functions should
operate. operate normally.
9 Turn the key switch to ground control. 15 Turn the key switch to platform control.
10 Test all machine functions from the ground 16 Test all machine functions from the platform
controls. controls.
Result: All ground control functions should not Result: All platform control functions should
operate. operate.
11 Activate the auxiliary power toggle switch. Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-4,
Note: The engine will turn off when the auxiliary
How to Calibrate the Platform Overload System (if
power is activated.
equipped).
12 Using auxiliary power, test all machine functions
17 Using a suitable lifting device, remove the
from the ground controls.
remaining test weights from the platform.
Result: All ground control functions should
operate.
13 Using a suitable lifting device, lift the additional
test weight from the platform.
Result: The platform overload indicator lights
should turn off at both the ground and platform
controls and the alarm should not sound.
Note: There may be an two second delay before
the overload indicator lights and alarm turn off.
CHECKLIST C PROCEDURES
C-4 C-5
Replace the Engine Air Filter Replace the In-line Fuel Strainer -
Element - Deutz and Perkins Deutz Models
Models
CHECKLIST C PROCEDURES
C-6 C-7
Perform Engine Maintenance - Check and Adjust the
Ford Models Engine RPM
Engine specifications require that this procedure Genie specifications require that this procedure be
be performed every 800 hours. performed every 250 hours or quarterly, whichever
comes first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential Maintaining the engine rpm at the proper setting for
to good engine performance and service life. both low and high idle is essential to good engine
Failure to perform the maintenance procedures performance and service life. The machine will not
can lead to poor engine performance and operate properly if the rpm is incorrect and
component damage. continued use may cause component damage.
Required maintenance procedures and additional Note: This procedure will require two people.
engine information are available in the
Ford Models
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the Note: The engine rpm is controlled by the ECM
Ford DSG-423 EFI Operator Handbook and can only be adjusted by re-programming the
(EDI part number 1060020) or the ECM. If rpm adjustment or service is required,
Ford MSG-425 EFI Operator Handbook please contact Genie Industries Service
(Ford part number 1020010). Department OR your local Ford dealer.
Deutz Models
Ford LRG 425 EFI Operation Manual
Genie part number 84792 1 Connect a tachometer to the engine. Start the
engine from the ground controls. Refer to
Ford DSG 423 EFI Operator Handbook Section 2, Specifications.
Genie part number 119488
Skip to step 3 if the low idle rpm is correct.
Ford MSG-425 EFI Operator Handbook
Genie part number 215322 2 Loosen the low idle lock nut and turn the low
idle adjustment screw clockwise to increase the
To access the engine: rpm or counterclockwise to decrease the rpm.
1 Remove the engine tray retaining fasteners Tighten the low idle lock nut and re-check the
located under the engine tray. Loosen the pivot rpm.
fastener located at the platform end of the 3 Move the function enable/rpm select toggle
engine tray. Swing the engine tray out and switch to the high idle (rabbit symbol) position
away from the machine and secure it from at the ground controls. Refer to Section 2,
moving Specifications.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury
CHECKLIST C PROCEDURES
a b c d
a solenoid boot
b high idle adjustment nut
c yoke lock nut
d yoke
e low idle adjustment screw
f low idle lock nut
Note: Be sure the solenoid fully retracts when 3 Move the function enable toggle switch to the
activating high idle. high idle (rabbit symbol) position. Refer to
Section 2, Specifications.
Perkins Models
If high idle rpm is correct, disregard
1 Connect a tachometer to the engine. Start the
adjustment step 4.
engine from the ground controls. Refer to
Section 2, Specifications. 4 Loosen the yoke lock nut. Turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and re-check the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
CHECKLIST C PROCEDURES
Checklist D Procedures
D-1 Primary boom wear
pad specifications Minimum
Check the Boom Wear Pads
Top and side wear pads 3/8inch
(extension end of boom) 9.5 mm
Genie specifications requires that this procedure (extension end of boom) 12.7 mm
be performed every 1000 hours or annually, 1/2 inch
Top and bottom wear pads
whichever comes first. (pivot end of boom) 12.7 mm
Maintaining the boom wear pads in good condition Side wear pads 3/8 inch
is essential to safe machine operation. Wear pads (pivot end of boom) 9.5 mm
are placed on boom tube surfaces to provide a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued 4 Extend and retract the boom through the entire
use of extremely worn wear pads may result in range of motion to check for tight spots that
component damage and unsafe operating may cause binding or scraping of the boom.
conditions.
Note: Always maintain squareness between the
1 Measure each wear pad. Replace the wear pad outer and inner boom tubes.
once it reaches the minimum allowable
thickness. If the wear pad is still within
specification, shim as necessary to obtain
minimum clearance with zero binding.
2 Start the engine from the ground controls.
3 Raise the end of the primary boom to a
comfortable working height (chest high), then
extend the boom 1 foot / 30 cm.
The minimum shim clearance for primary boom
wear pads is 0.070 inch / 1.8 mm and the
maximum allowable shim clearance is
0.188 inch / 4.8 mm.
CHECKLIST D PROCEDURES
1
D-2 13
10 15
7
18
Bearing Bolts 12
3 4
11 17
CHECKLIST D PROCEDURES
13
10 15
7
D-3
6 19
Check the Free-wheel
18 12
Configuration
3 4
11 17
disengaged position
engaged position
CHECKLIST D PROCEDURES
CHECKLIST D PROCEDURES
4 Fill the hub with oil from the top hole until the oil
Illustration A Illustration B
level is even with the bottom of the side hole.
Refer to Section 2, Specifications.
5 Install the plugs. Use pipe thread sealant on Turntable Rotate Drive Hub:
units with pipe plugs. Note: When removing a hose assembly or fitting,
6 Repeat steps 1 through 5 for all the other drive the O-ring on the fitting and/or hose end must be
hubs. replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
a
Fitting Torque Specifications.
1 Raise the secondary boom until the platform
end of the lower secondary boom arm is
approximately 8 feet / 2.4 m off the ground.
CHECKLIST D PROCEDURES
2 Secure the turntable from rotating with the 4 Attach a suitable lifting device to the lifting eyes
turntable rotation lock pin. located near the drive motor.
5 Remove the drive hub mounting bolts. Carefully
remove the turntable rotate drive hub assembly
from the machine.
Crushing hazard. The turntable
rotate drive hub assembly could
become unbalanced and fall if not
properly supported by the lifting
unlocked locked device.
3 Tag, disconnect and plug the hydraulic hoses 6 Remove the plug from the side of the drive hub.
from the turntable rotate drive motor. Cap the Drain the oil from the hub into a suitable
fittings on the drive motor. container.
7 Install the drive hub assembly onto the
machine. Torque the drive hub mounting bolts
to specification. Refer to
Section 2, Specifications.
a 8 Fill the drive hub with oil from the side hole until
the oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plug. Install the
plug.
CHECKLIST D PROCEDURES
D-5 D-6
Perform Engine Maintenance - Replace the Hydraulic Filter
Deutz and Perkins Models Elements
Engine specifications require that this procedure Genie specifications require that this procedure be
be performed every 1000 hours. performed every 1000 hours or annually,
whichever comes first. Perform this procedure
Deutz models more often if dusty conditions exist.
Required maintenance procedures and additional Replacement of the hydraulic filters is essential for
engine information are available in the good machine performance and service life. A dirty
Deutz 1011F Operation Manual or clogged filter may cause the machine to perform
(Deutz part number 0297 9683) or the poorly and continued use may cause component
Deutz 2011 Operation Manual damage. Extremely dirty conditions may require
(Deutz part number 0297 9929). that the filters be replaced more often.
Perkins 404C-22 Operation Manual 3 Install the new filter element into the filter
Genie part number 94890 housing.
4 Use a permanent ink marker to write the date
To access the engine: and number of hours from the hour meter on
1 Remove the engine tray retaining fasteners the oil filter housing.
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury
CHECKLIST D PROCEDURES
12 Remove the filter housings by using a wrench Periodic inspection of turntable bearing wear is
on the nut provided on the bottom of the essential to safe machine operation, good machine
housings. performance and service life. Continued use of a
worn turntable bearing could create an unsafe
13 Remove the filter elements from the housings. operating condition, resulting in death or serious
14 Inspect the housing seals and replace them if injury and component damage.
necessary.
Note: Perform this procedure with the machine on
15 Install the new filter elements into the housings a firm, level surface and the boom in the stowed
and tighten them securely. position.
16 Clean up any oil that may have spilled during 1 Grease the turntable bearing. See A-12, Grease
the installation procedure. the Turntable Bearing and Rotate Gear.
17 Use a permanent ink marker to write the date 2 Torque the turntable bearing bolts to
and number of hours from the hour meter on specification. See D-2, Check the Turntable
the oil filter housings. Rotation Bearing Bolts.
18 Start the engine from the ground controls. 3 Start the machine from the ground controls and
raise the boom to full height. Do not extend the
19 Inspect the filter housings and related
boom.
components to be sure that there are no leaks.
CHECKLIST D PROCEDURES
4 Place a dial indicator between the drive chassis 7 Note the reading on the dial indicator.
and the turntable at a point that is directly
Result: The measurement is less than
under, or inline with, the boom and no more
0.047 inch / 1.2 mm. The bearing is good.
than 1 inch / 2.5 cm from the bearing.
Result: The measurement is more than
Note: To obtain an accurate measurement, place
0.047 inch / 1.2 mm. The bearing is worn and
the dial indicator no more than 1 inch /
needs to be replaced.
2.5 cm from the turntable rotation bearing.
8 Fully retract the boom and raise the boom to full
height. Visually inspect the the dial indicator to
a be sure the needle returns to the "zero"
position.
9 Remove the dial indicator and rotate the
turntable 90°.
b
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
c equally spaced areas 90° apart.
11 Lower the boom to the stowed position and turn
the machine off.
d
12 Remove the dial indicator from the machine.
a turntable
b dial indicator
c drive chassis
d turntable rotation bearing
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
CHECKLIST E PROCEDURES
10 Remove the hydraulic tank from the machine. 20 Models with hydraulic tank shut-off valves:
Open the two hydraulic tank valves at the
Crushing hazard. The hydraulic
hydraulic tank.
tank could become unbalanced
and fall if not properly supported 21 Fill the tank with hydraulic oil until the level is
when removed from the machine. within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
11 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic 22 Clean up any oil that may have spilled.
return filter housing from the hydraulic tank.
23 Prime the pump. Refer to Repair Procedure
12 Remove the suction strainers from the tank and 7-2, How to Prime the Pump.
clean them using a mild solvent.
Note: Always use pipe thread sealant when
13 Rinse out the inside of the tank using a mild installing the suction hose fittings and the drain
solvent. plug.
14 Install the suction strainers using a thread
sealant on the threads.
15 Install the drain plug using a thread sealant on
the threads.
16 Install the hydraulic return filter housing onto the
hydraulic tank.
17 Install the hydraulic tank onto the machine.
18 Install the two suction hoses to the suction
strainers.
19 Install the supply hose for the auxiliary power
unit and the return filter hose.
CHECKLIST E PROCEDURES
CHECKLIST E PROCEDURES
15 Place the large inner bearing into the rear of the E-3
hub.
Perform Engine Maintenance -
16 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is flush.
Deutz 1011F and Perkins Models
Note: Always replace the bearing grease seal
when removing the hub.
17 Slide the hub onto the yoke spindle. Engine specifications require that this procedure
be performed every 2000 hours.
Component damage hazard. Do
not apply excessive force or Proper engine maintenance, following the engine
damage to the lip of the seal may manufacturer's maintenance schedule, is essential
occur. to good engine performance and service life.
Failure to perform the maintenance procedures
18 Place the outer bearing into the hub. can lead to poor engine performance and
19 Install the washer and castle nut. component damage.
CHECKLIST E PROCEDURES
CHECKLIST E PROCEDURES
E-5 E-6
Perform Engine Maintenance - Perform Engine Maintenance -
Ford Models Deutz 2011 Models
Engine specifications require that this procedure Engine specifications require that this procedure
be performed every 4 years. be performed every 5000 hours.
Required maintenance procedures and additional Proper engine maintenance, following the engine
engine information are available in the manufacturer's maintenance schedule, is essential
Ford LRG-425 EFI Operator Handbook to good engine performance and service life.
(Ford part number FPP 194-302) or the Failure to perform the maintenance procedures
Ford DSG-423 EFI Operator Handbook can lead to poor engine performance and
(EDI part number 1060020) or the component damage.
Ford MSG-425 EFI Operator Handbook
(Ford part number 1020010). Required maintenance procedures and additional
engine information are available in the
Deutz 2011 Operation Manual
Ford LRG 425 EFI Operation Manual (Deutz part number 0297 9929).
Genie part number 84792
Ford DSG 423 EFI Operator Handbook Deutz 2011 Operation Manual
Genie part number 119488 Genie part number 84794
CHECKLIST E PROCEDURES
E-7 E-8
Perform Engine Maintenance - Perform Engine Maintenance -
2011 Deutz Models Deutz 2011 Models
Engine specifications require that this procedure Engine specifications require that this procedure
be performed every 6000 hours. be performed every 12,000 hours.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. to good engine performance and service life.
Failure to perform the maintenance procedures Failure to perform the maintenance procedures
can lead to poor engine performance and can lead to poor engine performance and
component damage. component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
Deutz 2011 Operation Manual Deutz 2011 Operation Manual
(Deutz part number 0297 9929). (Deutz part number 0297 9929).
CHECKLIST E PROCEDURES
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey: Perform disassembly procedures to the point
where repairs can be completed. To re-assemble,
Repair procedures shall be completed by a
perform the disassembly steps in reverse order.
person trained and qualified on the repair of this
machine. Symbols Legend
Immediately tag and remove from service a Safety alert symbol—used to alert
damaged or malfunctioning machine. personnel to potential personal
Repair any machine damage or malfunction injury hazards. Obey all safety
messages that follow this symbol
before operating the machine.
to avoid possible injury or death.
Before Repairs Start: Used to indicate the presence of
an imminently hazardous situation
Read, understand and obey the safety rules
which, if not avoided, will result in
and operating instructions in the Genie Z-60/34
death or serious injury.
Operator’s Manual on your machine.
Used to indicate the presence of a
Be sure that all necessary tools and parts are
potentially hazardous situation
available and ready for use. which, if not avoided, could result
Use only Genie approved replacement parts. in death or serious injury.
Read each procedure completely and adhere With safety alert symbol—used to
to the instructions. Attempting shortcuts may indicate the presence of a
produce hazardous conditions. potentially hazardous situation
which, if not avoided, may cause
Unless otherwise specified, perform each minor or moderate injury.
repair procedure with the machine in the
Used to indicate the presence of a
following configuration:
potentially hazardous situation
• Machine parked on a flat, level surface which, if not avoided, may result in
• Boom in the stowed position property damage.
• Turntable rotated with the boom between Indicates that a specific result is expected after
the non-steering wheels performing a series of steps.
• Turntable secured with the turntable Indicates that an incorrect result has occurred
rotation lock pin after performing a series of steps.
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Platform Controls
The platform control box contains one printed 1-1
circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional ALC-500 Circuit Board
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall Electrocution hazard. Contact
Effect technology and require no adjustment. The with electrically charged circuits
operating parameters of the joysticks are stored in could result in death or serious
memory at the ECM circuit board at the platform injury. Remove all rings, watches
controls. If a joystick error occurs or if a joystick is and other jewelry.
replaced, it will need to be calibrated before that Note: When the ALC-500 circuit board is replaced,
particular machine function will operate. See 1-2, the joystick controllers will need to be calibrated.
How to Calibrate a Joystick. See 1-2, How to Calibrate a Joystick.
Each joystick controller should operate smoothly
and provide proportional speed control over its How to Remove the ALC-500
entire range of motion. Circuit Board
1 Push in the red Emergency Stop button to the off
a
position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to the
inside of the platform control box.
d c b
PLATFORM CONTROLS
4 Attach a grounded wrist strap to the ground 2 Pull out the red Emergency Stop button to the
screw inside the platform control box. on position at both the ground and platform
controls.
Component damage hazard.
Electrostatic discharge (ESD) can 3 Turn the key switch to platform control. Do not
damage printed circuit board start the engine.
components. Maintain firm contact
4 Select a joystick to calibrate.
with a metal part of the machine
that is grounded at all times when 5 Disconnect the wire harness connector from the
handling printed circuit boards OR joystick for approximately 10 seconds or until
use a grounded wrist strap. the alarm sounds. Connect the wire harness
connector to the joystick.
5 Carefully disconnect the wire connectors from
the circuit board. 6 Move the joystick full stroke in either direction
and hold for 5 seconds.
6 Remove the ALC-500 circuit board mounting
fasteners. 7 Return the joystick to the neutral position, pause
for a moment, then move the joystick full stroke
7 Carefully remove the ALC-500 circuit board
in the opposite direction. Hold for 5 seconds.
from the platform control box.
Result: The alarm should sound indicating
successful joystick calibration.
1-2
Result: The alarm does not sound. Check the
Joysticks electrical connections or replace the joystick.
PLATFORM CONTROLS
How to Adjust the Joystick 8 Start the engine from the platform controls and
press down the foot switch.
Max-out Setting
9 Start a timer and activate the machine function
The max-out setting of a joystick controls the that needs to be adjusted. Record the time it
maximum speed of a joystick-controlled machine takes for that function to complete a full cycle
function. Whenever a hydraulic cylinder, drive (ie; boom up).
motor or hydraulic pump is replaced, the max-out
setting should be adjusted to maintain optimum 10 Compare the machine function time with the
performance. The max-out settings on the joystick times in Section 2, Specifications to determine
can be changed to compensate for hydraulic pump whether the function time needs to increase or
wear to maintain peak performance from the decrease.
machine. 11 While the joystick is activated, adjust the max-
Note: Perform this procedure with the boom in the out setting to achieve the proper function cycle
stowed position. time. Momentarily move the drive enable toggle
switch to the left to increase the time or
1 Pull out the red Emergency Stop button to the momentarily move the drive enable toggle
on position at both the ground and platform switch to the right to decrease the time.
controls.
Note: Each time the drive enable toggle switch is
2 Turn the key switch to platform control. Do not momentarily moved, the time will change 2%.
start the engine.
12 Repeat steps 9 through 11 for each joystick
3 Push in the red Emergency Stop button to the controlled machine function.
off position at the platform controls.
13 Return the joystick to the neutral position and
4 Do not press down the foot switch. wait for approximately 10 seconds.
5 Move and hold the drive enable toggle switch in Result: The alarm should sound indicating that
the right position and pull out the red the settings have been saved in memory.
Emergency Stop button to the on position.
Note: Do not operate any machine function during
6 When the alarm sounds, release the drive the 10 second waiting time.
enable toggle switch.
7 Momentarily activate the drive enable toggle
switch in the right direction 4 times.
Result: There should be a pause and the alarm
should sound 4 times indicating that the
machine is in max-out calibration mode.
PLATFORM CONTROLS
How to Adjust the Joystick 11 While the joystick is activated, set the ramp
rate. Momentarily move the drive enable toggle
Ramp Rate Setting switch in the right direction to increase the time
The ramp rate setting of a joystick controls the time or momentarily move the drive enable toggle
at which it takes for the joystick to reach maximum switch in the left direction to decrease the time.
output, when moved out of the neutral position. Note: Each time the drive enable toggle switch is
The ramp rate settings of a joystick can be momentarily moved, the time will change in 5%
changed to compensate for hydraulic pump wear increments.
to maintain peak performance from the machine.
12 Repeat steps 9 through 11 for each joystick
Note: Perform this procedure with the boom in the controlled machine function.
stowed position.
13 Return the joystick to the neutral position and
1 Pull out the red Emergency Stop button to the wait for approximately 10 seconds.
on position at both the ground and platform
controls. Result: The alarm should sound indicating that
the settings have been saved in memory.
2 Turn the key switch to platform control. Do not
start the engine. Note: Do not operate any machine function during
the 10 second waiting time.
3 Push in the red Emergency Stop button to the
off position at the platform controls. Ramp rate (factory settings)
4 Do not press down the foot switch.
Primary boom up/down
5 Move and hold the drive enable toggle switch in accelerate 3 seconds
the right position and pull out the red decelerate 1 second
Emergency Stop button to the on position. Secondary boom up/down
6 When the alarm sounds, release the drive accelerate 2 seconds
enable toggle switch. decelerate 1 second
PLATFORM CONTROLS
How to Adjust the Joystick 8 Start the engine from the platform controls and
press down the foot switch.
Threshold Setting
9 Select a boom function joystick to set the
The threshold setting of a joystick is the minimum threshold.
output at which a function proportional valve can
open and allow the function to operate. 10 Slowly move the joystick off center in either
direction just until the function begins to move.
Note: Perform this procedure with the boom in the
stowed position. 11 Slowly move the joystick back to the neutral
position. Just before the function stops moving,
1 Pull out the red Emergency Stop button to the move the drive enable toggle switch to either
on position at both the ground and platform side to set the threshold.
controls.
Result: The alarm should sound indicating a
2 Turn the key switch to platform control. Do not successful calibration.
start the engine.
12 Repeat steps 9 through 11 for each boom
3 Push in the red Emergency Stop button to the joystick-controlled machine function (boom up/
off position at the platform controls. down, boom extend/retract and turntable
rotate).
4 Do not press down the foot switch.
13 Return the joystick to the neutral position and
5 Move and hold the drive enable toggle switch in
wait for approximately 10 seconds.
the right position and pull out the red
Emergency Stop button to the on position. Result: The alarm should sound indicating that
the settings have been saved in memory.
6 When the alarm sounds, release the drive
enable toggle switch. Note: Do not operate any machine function during
the 10 second waiting time.
7 Momentarily activate the drive enable toggle
switch in the right direction 8 times.
Result: There should be a pause and the alarm
should sound 8 times indicating that the
machine is in threshold calibration mode.
Platform Components
2-1 8 Support and secure the platform to an
appropriate lifting device.
Platform
9 Remove the platform mounting fasteners and
remove the platform from the machine.
How to Remove the Platform
Crushing hazard. The platform
1 Remove the cable clamps from the top of the could become unstable and fall
platform mounting weldment. when it is removed from the
2 Remove the clamp from the platform mounting machine if not properly supported.
weldment that holds the power to platform
cable.
3 Remove the mounting fasteners from the power
to platform outlet box bracket. Lay the outlet
box and bracket assembly off to the side.
4 Remove the foot switch mounting fasteners.
5 Remove the cover plate from the bottom of the
foot switch to access the foot switch wire
terminals.
6 Tag and disconnect the foot switch wiring from
the foot switch. Remove the cable from the
back of the platform.
Electrocution hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
7 Remove the platform control box mounting
fasteners. Lower the control box and set it
aside.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
Note: If your machine is equipped with an airline to
platform option, the airline must be disconnected
from the platform before removal.
PLATFORM COMPONENTS
The slave cylinder and the rotator pivot are the Note: Do not rest the entire weight of the boom on
two primary supports for the platform. The slave the blocks.
cylinder keeps the platform level through the
4 Tag, disconnect and plug the hydraulic hoses
entire range of boom motion. It operates in a
from the slave cylinder and connect the hoses
closed-circuit hydraulic loop with the master
together using a connector. Cap the fittings on
cylinder. The slave cylinder is equipped with
the cylinder.
counterbalance valves to prevent movement in
the event of a hydraulic line failure. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove the Platform burn skin. Loosen hydraulic
Leveling Slave Cylinder connections very slowly to allow
the oil pressure to dissipate
Note: Before cylinder removal is considered, bleed gradually. Do not allow oil to
the slave cylinder to be sure there is no squirt or spray.
air in the closed loop.
5 Remove the pin retaining fasteners from the
Note: When removing a hose assembly or fitting, slave cylinder rod-end pivot pin. Do not remove
the O-ring (if equipped) on the fitting and/or the the pin.
hose end must be replaced. All connections must 6 Remove the pin retaining fastener from the
be torqued to specification during installation. slave cylinder barrel-end pivot pin. Do not
Refer to Section 2, Hydraulic Hose and Fitting remove the pin.
Torque Specifications.
7 Support the slave cylinder with a lifting device.
1 Adjust the platform to a level position. Protect the cylinder rod from damage.
2 Raise the jib boom slightly and place blocks 8 Use a soft metal drift to remove the rod-end
under the platform for support. pivot pin.
Crushing hazard. The platform will
fall, if not properly supported,
when the slave cylinder rod-end
pivot pin is removed.
Component damage hazard. The
slave cylinder rod may become
damaged if not properly supported
when the pin is removed.
a
9 Use a soft metal drift and remove the barrel-end
pin.
10 Carefully remove the cylinder from the platform
leveling assembly.
a platform slave cylinder
PLATFORM COMPONENTS
PLATFORM COMPONENTS
PLATFORM COMPONENTS
How to Calibrate the Platform 5 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
Overload System (if equipped) inches. Allow the platform to settle.
Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6.
Calibration of the platform overload system is Result: The overload indicator lights are
essential to safe machine operation. Continued flashing at the platform and ground controls,
use of an improperly calibrated platform overload and the alarm is sounding. Slowly tighten the
system could result in the system failing to sense load spring adjustment nut in a clockwise
an overloaded platform. The stability of the direction in 10° increments until the overload
machine is compromised and it could tip over. indicator light turns off, and the alarm does not
sound. Proceed to step 8.
Note: Perform this procedure with the machine on
a firm, level surface. Note: The platform will need to be moved up and
down and allowed to settle between each
1 Turn the key switch to platform control. Start the adjustment.
engine and level the platform.
Note: There may be a 2 second delay before the
2 Determine the maximum platform capacity. platform overload indicator light and alarm
Refer to the machine serial plate. responds.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
6 Move the platform up and down by hand, so it 8 Add an additional 10 lb / 4.5 kg test weight to
bounces approximately 2.5 to 5 cm / 1 to 2 the platform.
inches. Allow the platform to settle.
Result: The overload indicator light is flashing at
Result: The overload indicator lights are off at both the ground and platform controls, and the
the platform and ground controls, and the alarm alarm is sounding. Proceed to step 9.
does not sound. Slowly loosen the load spring
Result: The overload indicator light is off at both
adjustment nut in a counterclockwise direction
the ground and platform controls, and the alarm
in 10° increments until the overload indicator
does not sound. Remove the additional 10 lb /
light flashes at both the platform and ground
4.5 kg test weight. Repeat this procedure
controls, and the alarm sounds. Proceed to
beginning with step 6.
step 7.
Note: There may be a 2 second delay before the
Result: The overload indicator lights are
platform overload indicator light and alarm
flashing at the platform and ground controls,
responds.
and the alarm is sounding. Repeat this
procedure beginning with step 5. 9 Test all machine functions from the platform
Note: The platform will need to be moved up and controls.
down and allowed to settle between each Result: All platform control functions should not
adjustment. operate.
Note: There may be a 2 second delay before the 10 Turn the key switch to ground control.
platform overload indicator lights and alarm
responds. 11 Test all machine functions from the ground
controls.
7 Move the platform up and down by hand, so it
Result: All ground control functions should not
bounces approximately 2.5 to 5 cm / 1 to 2
operate.
inches. Allow the platform to settle.
12 Using a suitable lifting device, lift the test weight
Result: The overload indicator lights are off and
off the platform floor.
the alarm does not sound. Proceed to step 8.
Result: The platform overload indicator light
Result: The overload indicator lights are
should be off at both the ground and platform
flashing at the platform and ground controls,
controls and the alarm should not sound.
and the alarm is sounding. Repeat this
procedure beginning with step 5. Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm 13 Test all machine functions from the ground
responds. controls.
Result: All ground control functions should
operate normally.
14 Turn the key switch to platform control.
15 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate normally.
Boom Components
a b c d e d f
n m l k j i i h g
a jib boom
b extension boom
c primary boom
d lower tension link
e upper secondary boom
f upper pivot
g turntable bulkhead
h primary boom lift cylinder
i lower leveling link
j lower secondary boom
k secondary boom lift cylinder
l mid-pivot
m connecting link
n jib boom leveling link
1 Raise the jib boom slightly and place blocks 6 Tag and disconnect the wiring from the
under the platform mounting weldment. Then jib boom/platform rotate manifold.
lower the jib boom until the platform is resting 7 Remove the cable clamp from the platform
on the blocks just enough to support the rotator.
platform.
8 Remove the cable cover from the side of the jib
Note: Do not rest the entire weight of the boom on boom.
the blocks.
9 Tag, disconnect and plug the hydraulic hoses
2 Locate the cables from the primary boom cable from the jib boom/platform rotate manifold.
track to the platform control box. Number each Cap the fittings on the jib boom/platform rotate
cable and its entry location at the platform manifold.
control box.
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.
10 Remove the hose clamps from the top of the jib 18 Remove the cable track from the machine and
boom. place it on a structure capable of supporting it.
11 Remove the hose and cable clamp from the Crushing hazard. The cable track
primary boom at the pivot end. could become unbalanced and fall
if not properly attached to the
12 Remove the retaining fastener from the cable
overhead crane.
track tube at the platform end of the primary
extension boom. Component damage hazard.
Cables and hoses can be
13 Remove the fasteners from the side panel on
damaged if they are kinked or
the lower cable track, then remove the panel.
pinched.
Pull all of the cables out of the channel.
Component damage hazard.
14 Place blocks between the lower cable track and
The primary boom cable track
the upper cable track tube and secure them
can be damaged if it is twisted.
together.
Crushing hazard. If the lower
cable track and upper cable track
tube are not properly secured
together, the cable track could
become unbalanced and fall when
removed from the machine.
15 Attach a lifting strap from an overhead crane to
the cable track.
16 Remove the cable track guide fasteners from
the platform end of the primary boom.
17 Remove the cable track mounting fasteners that
attach the lower cable track to the primary
boom.
6 Remove the primary boom drive speed limit 13 Place a 24 inch / 60 cm long block of wood
switch from the upper pivot. Do not disconnect across the lower secondary boom leveling links
the wiring. to support the primary boom lift cylinder.
7 Remove the primary extension boom drive 14 Remove the pin retaining fasteners from the
speed limit switch mounted on the inside of the primary boom lift cylinder rod-end pivot pin.
pivot end of the primary boom. Do not
15 Use a soft metal drift to remove the pin.
disconnect the wiring.
Crushing hazard. The primary
8 At the engine side of the upper pivot, remove
boom lift cylinder and the primary
the retaining fasteners from the master cylinder
boom will fall if they are not
rod-end pivot pin. Use a slide hammer to
properly supported when the pin is
remove the pin.
removed.
9 Pull the master cylinder back and secure it from
16 Lower the rod end of the primary boom lift
moving.
cylinder onto the support block placed across
10 Tag, disconnect and plug the extension cylinder the lower secondary boom leveling links.
hydraulic hoses. Cap the fittings on the
17 Remove the pin retaining fasteners from the
cylinder.
primary boom pivot pin.
Bodily injury hazard. Spraying
18 Use a soft metal drift to remove the primary
hydraulic oil can penetrate and
boom pivot pin. Remove the primary boom and
burn skin. Loosen hydraulic
place it on a structure capable of supporting it.
connections very slowly to allow
the oil pressure to dissipate Crushing hazard. The boom could
gradually. Do not allow oil to become unbalanced and fall if not
squirt or spray. properly supported when the pin is
removed.
11 Attach a 5 ton / 5,000 kg overhead crane to the
center point of the primary boom. Lift the
primary boom enough to access the primary
boom lift cylinder rod-end pivot pin.
12 Attach a similar lifting device to the primary
boom lift cylinder.
How to Disassemble the 7 Remove the external snap rings from the
extension cylinder rod-end pivot pins.
Primary Boom
8 Use a soft metal drift to remove the pins.
Note: Complete disassembly of the primary boom
is only necessary if the primary tube must be 9 Support and slide the extension cylinder out
replaced. The extension cylinder can only be of the platform end of the extension boom.
removed after removing the extension boom from 10 Remove and label the wear pads from the
the primary boom. See 4-4, How to Remove the extension boom.
Primary Boom Extension Cylinder.
Note: Pay careful attention to the location and
1 Remove the primary boom. amount of shims used with each wear pad.
See How to Remove the Primary Boom.
2 Place blocks under the extension cylinder for
support.
3 Remove the cotter pin from the extension
cylinder barrel-end pivot pin.
4 Use a soft metal drift to remove the pin.
5 Remove and label the wear pads from the
platform end of the primary boom.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or the hydraulic oil can penetrate and
hose end must be replaced. All connections must burn skin. Loosen hydraulic
be torqued to specification during installation. connections very slowly to allow
Refer to Section 2, Hydraulic Hose and Fitting the oil pressure to dissipate
Torque Specifications. gradually. Do not allow oil to
squirt or spray.
1 Raise the primary boom enough to access the
11 Place another 24 inch / 60 cm long block of
primary boom lift cylinder rod-end pivot pin.
wood across the lower secondary boom
2 Attach a 5 ton / 5,000 kg overhead crane to the leveling links to support the primary boom lift
primary boom for support. Do not lift the boom. cylinder.
3 Place a 24 inch / 60 cm long block of wood
across the lower secondary boom leveling links
to support the primary boom lift cylinder.
4 Support the rod end of the primary boom lift
cylinder with an appropriate lifting device.
2 Remove the jib boom. 9 Support the extension boom at the primary
Refer to 3-1, How to Remove the Jib Boom. boom end with a suitable lifting device.
3 Extend the extension boom approximately Note: During removal, the overhead crane strap will
5 feet / 1.5 m. need to be carefully adjusted for proper balancing.
4 Tag, disconnect and plug the extension cylinder 10 Remove the extension boom from the primary
hydraulic hoses from the extension cylinder. boom.
Cap the fittings on the cylinder.
Crushing hazard. The extension
Bodily injury hazard. Spraying boom could become unbalanced
hydraulic oil can penetrate and and fall when removed from the
burn skin. Loosen hydraulic primary boom if not properly
connections very slowly to allow supported.
the oil pressure to dissipate
gradually. Do not allow oil to 11 Remove the external snap rings from the
squirt or spray. extension cylinder rod-end pivot pins.
5 Remove the cotter pin from the extension 12 Remove the pins using a soft metal drift.
cylinder barrel-end pivot pin. 13 Support and slide the extension cylinder out of
6 Remove the pin using a soft metal drift. the extension boom.
7 Support the extension boom and remove the Crushing hazard. The extension
wear pads from the primary boom. cylinder could become unbalanced
and fall when removed from the
Note: Pay careful attention to the location and extension boom if not properly
amount of shims used with each wear pad. supported.
8 Slide the extension boom out using a suitable Component damage hazard. Be
pulling device until the extension boom wear careful not to damage the
pads are just visible. counterbalance valves on the
primary boom extension cylinder
Crushing hazard. The extension
when removing the cylinder from
boom could become unbalanced
the primary boom.
and fall when removed from the
primary boom if not properly
supported.
How to Replace the Extension 8 Loosen the lock nut on the valve and bleed the
pressure from the counterbalance valve by
Cylinder Upper Counterbalance turning the external adjustment screw
Valve clockwise.
Note: This procedure will require two people. 9 Remove the counterbalance valve from the
cylinder.
Note: Adjust the primary boom to a horizontal
position before performing this procedure. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
1 Using auxiliary power, raise the secondary burn skin. Loosen hydraulic valve
boom until the counterweight end of the primary very slowly to allow the oil
boom is just above the counterweight. pressure to dissipate
gradually. Do not allow oil to
2 Using a suitable lifting device, support the
squirt or spray.
secondary boom assembly. Do not lift it.
10 Install the new counterbalance valve and torque
3 Extend the extension boom approximately
the valve to 35-40 ft-lbs / 47-54 Nm.
1 foot / 0.3 m. Turn the machine off.
11 Clean up any hydraulic oil that may have
4 Remove the cotter pin from the extension
spilled.
cylinder barrel-end pivot pin.
12 Support the barrel end of the extension cylinder
5 Use a soft metal drift and remove the pin.
with a pry bar or other suitable tool. Have
6 Support the barrel end of the extension cylinder another person use auxiliary power to extend
with a pry bar or other suitable tool. Have the extension cylinder until the pivot pin bore
another person use auxiliary power to retract aligns with the pin bore of the boom tube.
the extension cylinder until it clears the platform
13 Use a soft metal drift and install the pin.
leveling master cylinder (approximately
6 inches / 15 cm). 14 Install a new cotter pin into the extension
cylinder barrel-end pivot pin.
7 Allow the extension cylinder to rest on the
bottom of the boom tube.
4-5
Platform Leveling Master
Cylinder
The master cylinder acts as a pump for the slave
cylinder. It is part of the closed circuit hydraulic
loop that keeps the platform level through the
entire range of boom motion. The master cylinder
is located inside the upper mid-pivot at the base of
the primary boom.
9 Attach a 5 ton / 5,000 kg overhead crane to the 15 Remove the two engine pivot plate retaining
center of the upper secondary boom. bolts. Then swing the engine out away from the
machine and secure it from moving.
10 Remove the mounting fasteners from the
secondary boom lift cylinder rod-end pivot pin Crushing hazard. Failure to secure
mounting bracket. the engine pivot plate from moving
could result in death or serious
11 Remove the pin retaining fasteners from both
injury.
upper pivot to upper secondary boom pivot
pins. Use a soft metal drift to remove the pins. 16 Disconnect the battery cables.
Crushing hazard. The upper mid- Electrocution hazard. Contact with
pivot may fall when the pins are hot or live circuits could result in
removed if the upper mid-pivot is death or serious injury. Remove all
not properly secured. rings, watches and other jewelry.
12 Remove the pin retaining fasteners from the 17 Remove the battery hold down fasteners, and
lower mid-pivot to upper secondary boom pivot remove the battery.
pin.
Bodily injury hazard. Batteries
13 Remove the lower mid-pivot to upper secondary contain acid. Avoid spilling or
boom pivot pin using a soft metal drift, and contacting battery acid. Neutralize
remove the upper secondary boom from the battery acid spills with baking soda
machine. and water.
Crushing hazard. The upper 18 Gasoline/LPG models: Remove the mounting
secondary boom may become fasteners from the ECM mounted to the engine
unbalanced and fall if not properly side bulkhead cover.
supported when it is removed from
19 Remove the mounting fasteners from both of
the machine.
the turntable bulkhead covers, and remove both
14 Remove both turntable covers. turntable bulkhead covers.
20 Remove the hydraulic tank. 26 Remove the pin retaining fasteners from the
Refer to Section Three, E-1 Test or Replace secondary boom lift cylinder pivot pins.
the Hydraulic Oil.
Remove the pins using a slide hammer, and
21 Attach a lifting strap from an overhead crane to remove the secondary boom lift cylinder from
the lug on the primary boom lift cylinder, then lift the machine.
the primary boom lift cylinder to a vertical
Crushing hazard. The secondary
position.
boom lift cylinder could become
22 Tag, disconnect and plug the primary boom lift unbalanced and fall if not properly
cylinder hydraulic hoses. Cap the fittings on the supported when removed from the
cylinder. machine.
23 Remove the pin retaining fasteners from the 27 Attach a securing strap from the mid-pivot to the
primary boom lift cylinder barrel-end pivot pin. lower secondary boom, to prevent the mid-pivot
Use a soft metal drift to remove the pins, and from moving.
remove the primary boom lift cylinder from the
28 Number each electrical cable and its entry
machine.
location at the platform control box.
Crushing hazard. The primary
29 Disconnect the cables from the platform control
boom lift cylinder could become
box.
unbalanced and fall if not properly
supported when removed from the 30 Pull all of the electrical cables out of the cable
machine. track. Do not pull out the hydraulic hoses.
24 Tag, disconnect and plug the secondary boom 31 Tag, disconnect and plug the platform rotator
lift cylinder hydraulic hoses. Cap the fittings on and slave cylinder hydraulic hoses at the union,
the cylinder. located near the upper pivot.
Bodily injury hazard. Spraying Bodily injury hazard. Spraying
hydraulic oil can penetrate and hydraulic oil can penetrate and
burn skin. Loosen hydraulic burn skin. Loosen hydraulic
connections very slowly to allow connections very slowly to allow
the oil pressure to dissipate the oil pressure to dissipate
gradually. Do not allow oil to gradually. Do not allow oil to
squirt or spray. squirt or spray.
25 Attach a lifting strap from an overhead crane to 32 Remove the hose and cable covers from both of
the lug on the rod end of the secondary boom the lower secondary boom leveling links.
lift cylinder.
33 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
34 Attach a lifting strap from an overhead crane to 41 Place blocks under each of the lower leveling
the lug on the rod end of the master cylinder. links for support at the turntable bulkhead end.
35 Remove the pin retaining fasteners from the 42 Remove the pin retaining fasteners from both of
master cylinder barrel-end pivot pin. the upper pivot to lower leveling link pivot pins.
36 Remove the pin using a soft metal drift, and 43 Use a soft metal drift to remove the pins, and
remove the master cylinder from the machine. remove the upper pivot from the machine.
Crushing hazard. The master Crushing hazard. The upper pivot
cylinder could become unbalanced could become unbalanced and fall
and fall if not properly supported if not properly supported when
when removed from the machine. removed from the machine.
37 Attach a lifting strap from an overhead crane to 44 Attach a lifting strap from an overhead crane to
the upper pivot, and remove the securing strap the center of the engine side lower leveling link.
from the mid-pivot.
45 Remove the pin retaining fasteners from the
38 Pull all of the hoses and cables out of the upper engine side lower leveling link pivot pin at the
mid-pivot. mid-pivot.
Component damage hazard. 46 Use a soft metal drift to remove the pins, and
Cables and hoses can be remove the engine side lower leveling link from
damaged if they are kinked or the machine.
pinched.
Crushing hazard. The engine side
39 Remove the secondary boom drive limit switch lower leveling link could become
mounting fasteners from the lower secondary unbalanced and fall if not properly
boom. Do not disconnect the wiring. supported when removed from the
machine.
40 Pull all of the hoses and cables out of the
mid-pivot and lay them off to the side. 47 Attach a lifting strap from an overhead crane to
the center of the ground controls side lower
Component damage hazard.
leveling link.
Cables and hoses can be
damaged if they are kinked or
pinched.
48 Remove the pin retaining fasteners from the 55 Use a soft metal drift to remove the pins, and
ground controls side lower leveling link pivot pin remove the mid-pivot from the machine.
at the mid-pivot.
Crushing hazard. The mid-pivot
49 Remove the pin using a soft metal drift, and could become unbalanced and fall
remove the ground controls side lower leveling if not properly supported when
link from the machine. removed from the machine.
Crushing hazard. The ground 56 Remove the hose and cable covers from the
controls side lower leveling link lower secondary boom.
could become unbalanced and fall
57 Attach a 5 ton / 5,000 kg overhead crane to the
if not properly supported when
center point of the lower secondary boom.
removed from the machine.
58 Remove the pin retaining fasteners from the
50 Attach a lifting strap from an overhead crane to
lower secondary boom pivot pin at the turntable
the connecting link.
bulkhead.
51 Remove the pin retaining fasteners from the
59 Use a soft metal drift to remove the pins, and
connecting link pivot pin at the lower secondary
remove the lower secondary boom from the
boom.
machine.
52 Use a soft metal drift to remove the pins, and
Crushing hazard. The lower
remove the connecting link from the machine.
secondary boom could become
Crushing hazard. The connecting unbalanced and fall if not properly
link could become unbalanced and supported when removed from the
fall if not properly supported when machine.
removed from the machine.
53 Attach a 5 ton / 5,000 kg overhead crane to the
mid-pivot.
54 Remove the pin retaining fasteners from the
lower secondary boom pivot pin at the
mid-pivot.
The secondary boom lift cylinder raises and Bodily injury hazard. Spraying
lowers the secondary boom. The secondary hydraulic oil can penetrate and
boom lift cylinder is equipped with counterbalance burn skin. Loosen hydraulic
valves to prevent movement in the event of a connections very slowly to allow
hydraulic line failure. the oil pressure to dissipate
gradually. Do not allow oil to
How to Remove the squirt or spray.
Secondary Boom Lift Cylinder 3 Remove the mounting fasteners from
the secondary boom lift cylinder rod-end pivot
Bodily injury hazard. This pin mounting bracket.
procedure requires specific repair
skills, lifting equipment and a 4 Remove the retaining fasteners from the
suitable workshop. Attempting this secondary boom lift cylinder pivot pins.
procedure without these skills and 5 Remove the pins using a slide hammer, and
tools could result in death or remove the cylinder from the machine.
serious injury and significant
component damage. Crushing hazard. The secondary
boom lift cylinder could become
Note: When removing a hose assembly or fitting, unbalanced and fall if not properly
the O-ring (if equipped) on the fitting and/or the supported when removed from the
hose end must be replaced. All connections must machine.
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Attach a lifting strap from an overhead crane to
the lug on the rod end of the secondary boom
lift cylinder.
Engines
6-1 6-2
RPM Adjustment Flex Plate
Refer to Maintenance Procedure C-7, Check and The flex plate acts as a coupler between the
Adjust the Engine RPM. engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive the
pump.
a b c d e
f
a pump
b pump shaft
c pump coupler
d flex plate with raised spline
e engine flywheel
f 0.18 inch / 4.6 mm gap - Deutz Models
0.070 inch / 1.8 mm gap - Perkins Models
0.0625 inch / 1.5 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423
ENGINES
Ford LRG-425 EFI models: 12 Remove all of the engine bell housing fasteners.
1 Disconnect the electrical connector for the 13 Carefully pull the pump and bell housing
oxygen sensor at the tailpipe. Do not remove assembly away from the engine and secure it
the oxygen sensor. from moving.
2 Remove the engine oil dipstick fasteners from Component damage hazard.
the muffler bracket. Remove the dipstick from Hoses can be damaged if they are
the engine. kinked or pinched.
3 Remove the muffler retaining fasteners from the 14 Remove the flex plate mounting fasteners.
exhaust pipe. Remove the flex plate from the flywheel.
4 Support the muffler and bracket assembly with Ford DSG-423 and MSG-425 models:
an overhead crane or other suitable lifting
1 Disconnect the electrical connectors from both
device.
oxygen sensors at the tailpipe and exhaust
5 Remove the muffler bracket mounting manifold. Do not remove the oxygen sensors.
fasteners. Carefully remove the muffler and
2 Remove the exhaust pipe fasteners at the
bracket assembly from the engine.
muffler.
6 Support the engine with a suitable lifting device.
3 Support the muffler and bracket assembly with
Do not lift it.
a suitable lifting device.
7 Remove the engine plate to vibration isolator
4 Remove the muffler bracket mounting fasteners
fasteners.
from the bell housing. Carefully remove the
8 Remove the engine mounting plate to bell muffler and bracket assembly from the engine.
housing fasteners.
5 Support the engine with an overhead crane or
9 Raise the engine slightly to take the weight off other suitable lifting device. Do not lift it.
of the engine mounting plate.
6 Remove the engine mounting plate to bell
10 Slide the engine mounting plate towards the housing fasteners.
pump as far as it will go.
7 Raise the engine slightly using the overhead
11 Support the drive pump assembly with an crane and place a block of wood under the oil
appropriate lifting device. pan for support.
8 Support the drive pump assembly with an
overhead crane or other suitable lifting device.
Do not apply any lifting pressure.
ENGINES
9 Remove all of the engine bell housing retaining How to Install the Flex Plate
fasteners.
1 Install the flex plate onto the engine flywheel
10 Carefully pull the pump and bell housing with the raised spline towards the pump.
assembly away from the engine and secure it
from moving. 2 Apply Loctite® removable thread sealant to the
screws. Torque the flex plate in a star pattern
Component damage hazard. using the following values.
Hoses can be damaged if they are
kinked or pinched. Ford models:
Before serial number 7924: Torque the flex
11 Remove the flex plate mounting fasteners. plate mounting bolts in sequence to
Remove the flex plate from the flywheel. 24 ft-lbs / 32 Nm.
Perkins models: After serial number 7923: Torque the flex
plate mounting bolts in sequence to
1 Remove the fuel filter/water separator mounting 20 ft-lbs / 27 Nm.
fasteners.
Deutz models:
2 Remove the fuel filter/water separator and lay it Torque the flex plate mounting bolts in
to the side. Do not disconnect the hoses. sequence to 28 ft-lbs / 38 Nm.
3 Support the drive pump assembly with an Perkins models:
appropriate lifting device. Before serial number 8050: Torque the flex
4 Remove all of the engine bell housing fasteners. plate mounting bolts in sequence to
49 ft-lbs / 66 Nm.
5 Carefully pull the pump and bell housing After serial number 8049: Torque the flex
assembly away from the engine and secure it plate mounting bolts in sequence to
from moving. 14 ft-lbs / 19.1 Nm.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
6 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
ENGINES
3 Install the pump coupler onto the pump shaft 5 Install the pump and bell housing assembly.
with the set screw toward the pump. Leave the
Ford LRG-425 models:
appropriate gap between coupler and pump
Before serial number 4545: Torque the bell
end plate for your engine.
housing mounting bolts in sequence to
23 ft-lbs / 31 Nm.
a b c d e After serial number 4544: Torque the bell
housing mounting bolts labeled "C" in sequence
to 47 ft-lbs / 63 Nm. Torque the bell housing
mounting bolts labeled "B" in sequence to
61 ft-lbs / 83 Nm.
Ford DSG-423 and MSG-425 models:
Torque the bell housing mounting bolts labeled
f
"A" and "B" in sequence to 28 ft-lbs / 38 Nm
and the mounting bolts labeled "C" to 49 ft-lbs /
a pump
b pump shaft
66 Nm. Then torque the bell housing mounting
c pump coupler bolts labeled "A" and "B" in sequence to 40 ft-
d flex plate with raised spline lbs / 54 Nm and the mounting bolts labeled "C"
e engine flywheel to 70 ft-lbs / 95 Nm.
f 0.18 inch / 4.6 mm gap - Deutz Models
0.070 inch / 1.8 mm gap - Perkins Models Deutz models:
0.0625 inch / 1.5 mm gap - Ford LRG-425 Before serial number 4608: Torque the bell
0.080 inch / 2 mm gap - Ford DSG-423
housing mounting bolts in sequence to
4 Apply Loctite® removable thread sealant to the 28 ft-lbs / 38 Nm.
pump coupler set screw. Torque the set screw After serial number 4607: Torque the bell
to 61 ft-lbs / 83 Nm. housing mounting bolts in sequence to
47 ft-lbs / 63 Nm.
Perkins models:
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.
Component damage hazard.
When installing the pump, do not
force the pump coupler into the
flexplate or damage to the pump
shaft seal may occur.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
ENGINES
3 1 1 6
C C
6-3
5 8
7
C C
8 Engine Fault Codes - Ford
3 C
C 4 Models
7 6
C
How to Retrieve Engine Fault
9
C C
Codes
2 4 5 2
Ford models:
Ford LRG 425 models Ford LRG 425 models
(before serial number 4545) (after serial number 4544) The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel
6 1 6
injection and make constant and instantaneous
1
10 C C
changes to ignition timing, fuel delivery and throttle
8 10 8
C C
position to maintain the engine's running condition
4 3
at its highest efficiency while at the same time
4 3
C C keeping exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of
11 12 11 C C
12 set parameters, the ECM will store a fault code in
C C memory that relates to the appropriate sensor and
7 5 C C
7 5 will turn on the Check Engine Light.
2 9 9
2
Refer to Section 5, How to Retrieve Engine Fault
Deutz 1011 models Deutz 2011 models Codes. Use the Fault Code Chart within Section 5
(before serial number 4608) (after serial number 4607)
to aid in identifying the fault.
6 1
A A
6
1 B
B
3
A
9
B
B
4 A 4 5
B
B B
C C B 7
8 B
7 B 5
2 3
2
Hydraulic Pumps
7-1 2 Tag, disconnect and plug the function pump
hydraulic hoses. Cap the fittings on the pump.
Function Pump
Bodily injury hazard. Spraying
How to Remove the hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Function Pump connections very slowly to allow
Note: When removing a hose assembly or fitting, the oil pressure to dissipate
the O-ring (if equipped) on the fitting and/or the gradually. Do not allow oil to
hose end must be replaced. All connections must squirt or spray.
be torqued to specification during installation. 3 Remove the pump mounting bolts. Carefully
Refer to remove the pump.
Section 2, Hydraulic Hose and Fitting Torque
Specifications. Models without hydraulic tank shut-off valves:
open closed
HYDRAULIC PUMPS
HYDRAULIC PUMPS
4 Support the pump with a lifting device and How to Prime the Pump
remove the two drive pump mounting fasteners.
1 Remove the engine tray retaining fasteners
5 Carefully pull the drive pump out until the pump located under the engine tray. Loosen the pivot
coupler separates from the flex plate. fastener located at the platform end of the
6 Remove the drive pump from the machine. engine tray.
Component damage hazard. The 2 Swing the engine tray out and away from the
hydraulic pump may become machine.
unbalanced and fall if not properly 3 Connect a 0 to 600 psi / 0 to 50 bar pressure
supported. gauge to the test port on the drive pump.
Component damage hazard. 4 Ford models: Close the valve on the LPG tank
When installing the pump, do not then disconnect the hose from the tank. Move
force the pump coupler into the the fuel select switch to the LPG position.
flexplate or damage to the pump
shaft seal may occur. Perkins models: Disconnect the engine wiring
harness from the fuel solenoid at the injector
Models without hydraulic tank shut-off valves: pump.
Component damage hazard. Be Deutz models: Hold the manual fuel shutoff
sure to fill the hydraulic tank to valve clockwise to the closed position.
specification and prime the pump
after installing the pump. a
HYDRAULIC PUMPS
Manifolds
8-1
Function Manifold Components - View 1
(before serial number 4461)
The function manifold is located behind the ground control box.
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 3 position 4 way ....... A ........... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm
2 Solenoid valve, 3 position 4 way ....... B ........... Secondary boom up/down ................ 26-30 ft-lbs / 35-41 Nm
3 Solenoid valve, 3 position 4 way ....... C ........... Primary boom up/down ..................... 26-30 ft-lbs / 35-41 Nm
4 Counterbalance valve,
500 psi / 34.4 bar ............................... D ........... Platform level up/down
and motion control ............................ 30-35 ft-lbs / 41-47 Nm
5 Counterbalance valve,
500 psi / 34.4 bar ............................... E ........... Platform level up/down
and motion control ............................ 30-35 ft-lbs / 41-47 Nm
6 Solenoid valve, 3 position 4 way ....... F ........... Platform level up/down .................... 26-30 ft-lbs / 35-41 Nm
7 Differential sensing valve,
150 psi / 10.3 bar ............................... G ........... Turntable rotate left/right ................... 30-35 ft-lbs / 41-47 Nm
8 Solenoid valve, 2 position 3 way ....... H ........... Boom extend ..................................... 30-35 ft-lbs / 41-47 Nm
9 Solenoid valve, 2 position 3 way ....... I ............ Boom retract ..................................... 30-35 ft-lbs / 41-47 Nm
10 Solenoid valve, 3 position 4 way ....... J ............ Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
11 Check valve ....................................... K ........... Boom extend ..................................... 10-12 ft-lbs / 14-16 Nm
12 Check valve ....................................... L ........... Jib boom select ................................. 20-25 ft-lbs / 27-34 Nm
13 Flow regulator valve,
0.1 gpm / 0.37 L/min .......................... M .......... Flow control ....................................... 26-30 ft-lbs / 35-41 Nm
14 Check valve ....................................... N ........... Turntable rotate left/right ................... 10-12 ft-lbs / 14-16 Nm
15 Check valve ....................................... O ........... Platform level up ............................... 10-12 ft-lbs / 14-16 Nm
16 Check valve ....................................... P ........... Platform level down .......................... 10-12 ft-lbs / 14-16 Nm
17 Check valve ....................................... Q ........... Primary boom up/down ..................... 10-12 ft-lbs / 14-16 Nm
18 Check valve ....................................... R ........... Secondary boom up/down ................ 10-12 ft-lbs / 14-16 Nm
19 Flow regulator valve,
3.5 gpm / 13.2 L/min .......................... S ........... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm
20 Relief valve, 2400 psi / 165.4 bar ...... T ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
21 Check valve, 50 psi / 3.45 bar ........... U ........... Pressure in from drive pump ............. 30-35 ft-lbs / 41-47 Nm
22 Differential sensing valve .................. V ........... Secondary boom up/down ................ 30-35 ft-lbs / 41-47 Nm
23 Differential sensing valve .................. W .......... Primary boom up/down ..................... 30-35 ft-lbs / 41-47 Nm
MANIFOLDS
1 2 3 4 5 6 7 8 9 10 11
H
C
J
A B
G
D E
W
23
V
22
12
M
13
U
21
1
N
14
T
20
O
15
P
16
Q
17
R
S
18
19
MANIFOLDS
8-2
Function Manifold Components - View 2
(before serial number 4461)
The function manifold is located behind the ground control box.
Index Schematic
No. Description Item Function Torque
1 Valve check ....................................... X ........... Boom retract ..................................... 10-12 ft-lbs / 14-16 Nm
2 Diagnostic nipple ............................... Y ........... Testing
3 Diagnostic nipple ............................... Z ........... Testing
4 Check valve, 30 psi / 2.1 bar ............. AA ......... To tank .............................................. 30-35 ft-lbs / 41-47 Nm
5 Proportional solenoid valve ............... AB ......... Secondary boom down ..................... 20-25 ft-lbs / 27-34 Nm
6 Proportional solenoid valve ............... AC ........ Primary boom down .......................... 20-25 ft-lbs / 27-34 Nm
7 Relief valve, 1600 psi / 110.3 bar ...... AD ........ Secondary boom up/down ................ 20-25 ft-lbs / 27-34 Nm
8 Relief valve, 1800 psi / 124.1 bar ...... AE ......... Primary boom up/down ..................... 20-25 ft-lbs / 27-34 Nm
9 Free flow needle valve ...................... AF ......... Platform level .................................... 20-25 ft-lbs / 27-34 Nm
10 Proportional solenoid valve ............... AG ........ Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
11 Differential sensing valve .................. AH ........ Function pressure control ................. 30-35 ft-lbs / 41-47 Nm
12 Flow regulator valve,
5 gpm / 18.9 L/min ............................. AI .......... Boom extend retract .......................... 30-35 ft-lbs / 41-47 Nm
13 Flow regulator valve,
1 gpm / 3.8 L/min ............................... AJ ......... Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
14 Solenoid valve, 3 position 4 way ....... AK ......... Jib up/down and platform
rotate left/right ................................... 26-30 ft-lbs / 35-41 Nm
15 Check valve ....................................... AL ......... Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
16 Check valve ....................................... AM ........ Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
MANIFOLDS
1
AA
Y
X
AB
AC
AE
AD
AF
AH
AI
AJ
AG
AK
AM
AL
MANIFOLDS
8-3
Function Manifold Components
from serial number 4461)
The function manifold is located behind the ground control box.
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 3 position 4 way ....... HA ........ Turntable rotate left/right ................... 33-37 ft-lbs / 45-50 Nm
2 Differential sensing valve,
150 psi / 10.3 bar ............................... HB ........ Turntable rotate left/right ................... 30-35 ft-lbs / 41-47 Nm
3 Solenoid valve, 3 position 4 way ....... HC ........ Platform level up/down ..................... 33-37 ft-lbs / 45-50 Nm
4 Solenoid valve, 3 position 4 way ....... HD ........ Primary boom up/down ..................... 33-37 ft-lbs / 45-50 Nm
5 Solenoid valve, 3 position 4 way ....... HE ........ Secondary boom up/down ................ 33-37 ft-lbs / 45-50 Nm
6 Solenoid valve, 3 position 4 way ....... HF ......... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm
7 Check valve, 50 psi / 3.45 bar ........... HG ........ Pressure in from drive pump ............. 30-35 ft-lbs / 41-47 Nm
8 Diagnostic nipple ............................... HH ........ Testing
9 Flow regulator valve,
3.5 gpm / 13.2 L/min .......................... HI .......... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm
10 Differential sensing valve .................. HJ ......... Secondary boom up/down ................ 30-35 ft-lbs / 41-47 Nm
11 Differential sensing valve .................. HK ........ Primary boom up/down ..................... 30-35 ft-lbs / 41-47 Nm
12 Counterbalance valve,
500 psi / 34.4 bar ............................... HL ......... Platform level up/down
and motion control ............................ 30-35 ft-lbs / 41-47 Nm
13 Proportional solenoid valve ............... HM ........ Secondary boom down ..................... 20-25 ft-lbs / 27-34 Nm
14 Counterbalance valve,
500 psi / 34.4 bar ............................... HN ........ Platform level up/down
and motion control ............................ 30-35 ft-lbs / 41-47 Nm
15 Proportional solenoid valve ............... HO ........ Primary boom down .......................... 20-25 ft-lbs / 27-34 Nm
16 Relief valve, 1800 psi / 124.1 bar ...... HP ........ Primary boom up/down ..................... 20-25 ft-lbs / 27-34 Nm
17 Free flow needle valve ...................... HQ ........ Platform level .................................... 30-35 ft-lbs / 41-47 Nm
18 Proportional solenoid valve ............... HR ........ Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm
19 Flow regulator valve,
0.1 gpm / 0.37 L/min .......................... HS ........ Flow control ....................................... 20-25 ft-lbs / 27-34 Nm
20 Differential sensing valve .................. HT ......... Function pressure control ................. 30-35 ft-lbs / 41-47 Nm
MANIFOLDS
1 2 3 4 5 6
HA HB HC HD HE HF
IM
39
HG
7
HH
8
HI
9
IL
38 HJ
10
IK
37 HK
11
IJ HL
36 12
HM 13
HN
14
HO
15
HP
16
iew
pV
To
II
35 HQ
17
IH HR
34 18
IG
33 HS
19
HT
20
w HU
Vie 21
nt
Fro
32 31 30 29 28 27 26
IF IE ID IC IB IA HZ
Shows valves
hidden from
above view
HY HX HW HV
25 24 23 22
MANIFOLDS
8-3
Function Manifold Components, continued
(from serial number 4461)
The function manifold is located behind the ground control box.
Index Schematic
No. Description Item Function Torque
21 Solenoid valve, 3 position 4 way ....... HU ........ Jib up/down and platform
rotate left/right ................................... 33-37 ft-lbs / 45-50 Nm
22 Check valve, 30 psi / 2.1 bar ............. HV ........ To tank .............................................. 30-35 ft-lbs / 41-47 Nm
23 Relief valve, 1600 psi / 110.3 bar ...... HW ....... Secondary boom up/down ................ 20-25 ft-lbs / 27-34 Nm
24 Flow regulator valve,
5 gpm / 18.9 L/min ............................. HX ........ Boom extend retract .......................... 30-35 ft-lbs / 41-47 Nm
25 Flow regulator valve,
1.5 gpm / 5.6 L/min ............................ HY ........ Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
26 Relief valve, 2600 psi / 180 bar ........ HZ ......... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
27 Check valve ....................................... IA .......... Secondary boom up/down ............... 8-10 ft-lbs / 11-14 Nm
28 Check valve ....................................... IB .......... Primary boom up/down .................... 8-10 ft-lbs / 11-14 Nm
29 Check valve ....................................... IC .......... Platform level down .......................... 8-10 ft-lbs / 11-14 Nm
30 Check valve ....................................... ID .......... Platform level up ............................... 8-10 ft-lbs / 11-14 Nm
31 Check valve ....................................... IE .......... Turntable rotate left/right .................. 8-10 ft-lbs / 11-14 Nm
32 Check valve ....................................... IF .......... Boom extend .................................... 8-10 ft-lbs / 11-14 Nm
33 Check valve ....................................... IG .......... Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
34 Check valve ....................................... IH .......... Jib select ........................................... 20-25 ft-lbs / 27-34 Nm
35 Valve check ....................................... II ............ Boom retract ..................................... 10-12 ft-lbs / 14-16 Nm
36 Solenoid valve, 2 position 3 way ...... IJ ........... Boom extend .................................... 30-35 ft-lbs / 41-47 Nm
37 Solenoid valve, 2 position 3 way ...... IK .......... Boom retract ..................................... 30-35 ft-lbs / 41-47 Nm
38 Diagnostic nipple .............................. IL .......... Testing
39 Check valve ....................................... IM ......... Jib boom select ................................. 20-25 ft-lbs / 27-34 Nm
MANIFOLDS
1 2 3 4 5 6
HA HB HC HD HE HF
IM
39
HG
7
HH
8
HI
9
IL
38 HJ
10
IK
37 HK
11
IJ HL
36 12
HM 13
HN
14
HO
15
HP
16
iew
pV
To
II
35 HQ
17
IH HR
34 18
IG
33 HS
19
HT
20
w HU
Vie 21
nt
Fro
32 31 30 29 28 27 26
IF IE ID IC IB IA HZ
Shows valves
hidden from
above view
HY HX HW HV
25 24 23 22
MANIFOLDS
MANIFOLDS
MANIFOLDS
8-5
Jib Boom / Platform Rotate Manifold Components
(before serial number 4461)
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 2 way ....... BA ......... Platform rotate .................................. 20-25 ft-lbs / 27-34 Nm
2 Solenoid valve, 2 position 2 way ....... BB ......... Jib boom up/down ............................. 20-25 ft-lbs / 27-34 Nm
3 Orifice, 0.031 inch / 0.787 mm .......... BC ........ Platform rotate circuit
4 Orifice, 0.031 inch / 0.787 mm .......... BD ........ Platform rotate circuit
1 2
BB
BA
BC
3
BD
4
MANIFOLDS
8-6
Jib Boom / Platform Rotate Manifold Components
(from serial number 4461 to serial number 10245)
Index Schematic
No. Description Item Function Torque
3 Counterbalance valve ....................... BH ........ Platform rotate left ............................. 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ....................... BJ ......... Platform rotate right .......................... 35-40 ft-lbs / 47-54 Nm
3 Solenoid valve, 2 position 2 way ...... BE ......... Platform rotate
Jib boom up/down ............................. 20-25 ft-lbs / 27-34 Nm
4 Orifice, 0.030 inch / 0.762 mm .......... BF ......... Platform rotate circuit
5 Orifice, 0.030 inch / 0.762 mm .......... BF ......... Platform rotate circuit
1
BH
Platform
Rotate Manifold
BJ
2
BE
3
Jib Manifold
BF
4
BG
5
MANIFOLDS
8-7
Jib Boom / Platform Rotate Manifold Components
(from serial number 10246 to serial number 11003)
Index Schematic
No. Description Item Function Torque
3 Counterbalance valve ....................... BH ........ Platform rotate left ............................. 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ....................... BJ ......... Platform rotate right .......................... 35-40 ft-lbs / 47-54 Nm
3 Solenoid valve, 2 position 2 way ...... BE ......... Platform rotate
Jib boom up/down ............................. 20-25 ft-lbs / 27-34 Nm
4 Orifice, 0.030 inch / 0.762 mm .......... BF ......... Platform rotate circuit
5 Orifice, 0.030 inch / 0.762 mm .......... BF ......... Platform rotate circuit
BN
2
BM
1
MANIFOLDS
8-8
Jib Boom / Platform Rotate Manifold Components
(from serial number 11004 to serial number 11477)
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 2 way ..... BP ......... Jib boom up/down ................... 19-21 ft-lbs / 25.8 - 28.6 Nm
2 Flow control valve ............................ BR ......... Platform rotate ......................... 19-21 ft-lbs / 25.8 - 28.6 Nm
3 Check valve ...................................... BS ......... One way flow ................................ 12-14 ft-lbs / 16.3-19 Nm
4 Load shuttle valve ............................ BT ......... Controls direction of flow ......... 19-21 ft-lbs / 25.8 - 28.6 Nm
5 Check valve ...................................... BU ......... One way flow ................................ 12-14 ft-lbs / 16.3-19 Nm
1 2
BP BR
BU
5
BT
4
BS
3
MANIFOLDS
8-9
Jib Boom / Platform Rotate Manifold Components
(from serial number 11478)
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 2 way ..... BW ......... Jib boom up/down ................... 19-21 ft-lbs / 25.8 - 28.6 Nm
2 Check valve ...................................... BV ......... One way flow ........................... 19-21 ft-lbs / 25.8 - 28.6 Nm
3 Check valve ...................................... BQ ......... One way flow ........................... 19-21 ft-lbs / 25.8 - 28.6 Nm
4 Flow control valve ............................ BO ......... Platform rotate ......................... 19-21 ft-lbs / 25.8 - 28.6 Nm
5 Flow control valve ............................ BK ......... Platform rotate ......................... 19-21 ft-lbs / 25.8 - 28.6 Nm
BW
1
BV
2
BQ
3
BO
4
BK
5
MANIFOLDS
MANIFOLDS
8-10
Brake / Two Speed Manifold Components
(before serial number 4461)
The brake / Two speed manifold is mounted on the engine side bulkhead..
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 3 way ... DA ........... Releases brakes ............................. 20-25 ft-lbs / 37-34 Nm
2 Solenoid valve, 2 position 3 way ... DB ........... 2 speed motor shift ........................... 20-25 ft-lbs / 37-34 Nm
3 Orifice, 0.042 inch / 1.066 mm ....... DC ........... Controls flow to tank
4 Check valve .................................... DD ........... One way flow .................................... 10-12 ft-lbs / 14-16 Nm
1 2
DA
4 DD
DB
DC
MANIFOLDS
8-11
Brake / Two Speed Manifold Components
(from serial number 4461)
The brake / Two speed manifold is mounted on the engine side bulkhead.
Index Schematic
No. Description Item Function Torque
1 Solenoid valve, 2 position 3 way .... EA ........... Releases brakes .............................. 47-52 ft-lbs / 64-70 Nm
2 Solenoid valve, 2 position 3 way .... EB ........... 2 speed motor shift .......................... 47-52 ft-lbs / 64-70 Nm
3 Check valve .................................... EC ........... One way flow ...................................... 8-10 ft-lbs / 11-14 Nm
4 Orifice, 0.042 inch / 1.066 mm ....... ED ........... Controls flow to tank
1 2
EA EB
ED
4
EC
3
MANIFOLDS
8-12
Traction Manifold Components, 2WD
(before serial number 4551)
The 2WD traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
No. Description Item Function Torque
1 Check valve ....................................... FA ......... Divider bypass circuit ........................ 30-35 ft-lbs / 41-47 Nm
2 Check valve ....................................... FB ......... Divider bypass circuit ........................ 30-35 ft-lbs / 41-47 Nm
3 Flow Divider / Combiner Valve .......... FC ......... Controls flow to drive motors in
forward and reverse .................... 90-100 ft-lbs / 120-133 Nm
4 Orifice, 0.079 in / 2.01 mm ................ FD ......... Drive circuit
5 Orifice, 0.079 in / 2.01 mm ................ FE ......... Drive circuit
6 Relief valve, 300 psi / 20.6 bar .......... FF ......... Charge pressure circuit ..................... 20-25 ft-lbs / 27-34 Nm
7 Diagnostic nipple ............................... FG ........ Testing
8 Shuttle valve, 3 position 3 way .......... FH ......... Charge pressure, hot oil shuttle ........ 30-35 ft-lbs / 41-47 Nm
9 Diagnostic nipple ............................... FI .......... Testing
MANIFOLDS
6 FI
FH FA
5 1
7 FB
1
FG
6 FC
FF 2
5
FE
4 FD
MANIFOLDS
8-13
Traction Manifold Components, 2WD
(from serial number 4551)
The 2WD traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
No. Description Item Function Torque
1 Relief Valve, 280 psi / 19.3 bar ......... TT ......... Charge pressure circuit ..................... 30-35 ft-lbs / 41-47 Nm
2 Flow Divider / Combiner Valve .......... WW ....... Controls flow to drive motors in
forward and reverse .................... 90-100 ft-lbs / 120-133 Nm
3 Check Valve, 5 psi / 0.34 bar ............ SS ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
4 Check Valve, 5 psi / 0.34 bar ............ XX ......... Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
5 Shuttle Valve, 3 position 3 way ......... UU ........ Controls flow to drive motors in
forward and reverse .......................... 50-55 ft-lbs / 67-73 Nm
6 Orifice Plug, 0.07 inch / 1.78 mm ...... VV ......... Equalizes flow across flow
divider/combiner valve C
MANIFOLDS
1
TT
WW
2
SS
3
XX
4
UU
5
VV
6
MANIFOLDS
8-14
Traction Manifold Components, 4WD
(before serial number 10154)
The 4WD traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
No. Description Item Function Torque
1 Diagnostic fitting ................................ GA ........ Testing
2 Relief valve, 250 psi / 17.2 bar .......... GB ........ Charge pressure circuit ..................... 20-25 ft-lbs / 27-34 Nm
3 Check valve, 5 psi / 0.34 bar ............. GC ........ Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
4 Flow divider/combiner valve .............. GD ........ Controls flow to flow
divider/combiner
valves GI and GO ....................... 90-100 ft-lbs / 120-133 Nm
5 Check valve, 5 psi / 0.34 bar ............. GE ........ Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
6 Check valve, 5 psi / 0.34 bar ............. GF ........ Drive motor anti-cavitation ................ 30-35 ft-lbs / 41-47 Nm
7 Shuttle valve ...................................... GG ........ Charge pressure circuit
that gets hot oil out of low pressure
side of drive pump ............................ 50-55 ft-lbs / 67-73 Nm
8 Check valve, 5 psi / 0.34 bar ............. GH ........ Drive motor anti-cavitation ................ 30-35 ft-lbs / 41-47 Nm
9 Flow divider/combiner valve .............. GI .......... Controls flow from steer end
drive motors in forward
and reverse ................................. 90-100 ft-lbs / 120-133 Nm
10 Check valve, 5 psi / 0.34 bar ............. GJ ......... Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
11 Flow regulator valve,
2 gpm / 7.6 L/min .............................. GK ........ Equalizes pressure on both sides
of flow divider/combiner valve GI ...... 30-35 ft-lbs / 41-47 Nm
12 Flow regulator valve,
2 gpm / 7.6 L/min .............................. GL ......... Equalizes pressure on both sides
of flow divider/combiner valve ........... 30-35 ft-lbs / 41-47 Nm
13 Flow regulator valve,
2 gpm / 7.6 L/min .............................. GM ........ Equalizes pressure on both sides
of flow divider/combiner valve GO .... 30-35 ft-lbs / 41-47 Nm
14 Check valve, 5 psi / 0.34 bar ............. GN ........ Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
15 Flow divider/combiner valve .............. GO ........ Controls flow from non-steer end
drive motors in forward
and reverse ................................. 90-100 ft-lbs / 120-133 Nm
MANIFOLDS
1 2 3 4
GA GB GC
GO
16
15
GN STEER END
GM
14
GL
13
GK
12
GJ
11
GI
10
GD
5
GE
6
GH GG GF
9 8 7 NON-STEER END
MANIFOLDS
8-15
Traction Manifold Components, 4WD
(from serial number 10154)
The 4WD traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
No. Description Item Function Torque
1 Relief valve, 280 psi / 19.3 bar ......... HA ........ Charge pressure circuit .................... 55-60 ft-lbs / 74-81 Nm
4 Check valve ....................................... HD ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 74-81 Nm
5 Check valve ....................................... HE ........ Non-steer end drive motor circuit . 80-90 ft-lbs / 108-122 Nm
10 Check valve ....................................... HJ ......... Steer end drive motor circuit ........ 80-90 ft-lbs / 108-122 Nm
MANIFOLDS
MANIFOLDS
MANIFOLDS
8-17
Directional Valve Manifold Components
The directional valve manifold is mounted inside the drive chassis at the non-steer end.
Index
No. Description Function Torque
1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm
2 Spool valve ....................................................... Directional control
MANIFOLDS
MANIFOLDS
a relief valve
MANIFOLDS
8-20
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index Schematic
No. Description Item Function Torque
1 Shuttle valve 2 position 3 way ........ CA ........... Turntable rotation brake release ...... 10-13 ft-lbs / 14-18 Nm
2 Counterbalance valve ..................... CB ........... Turntable rotate right ....................... 35-40 ft-lbs / 47-54 Nm
3 Counterbalance valve ..................... CC ........... Turntable rotate left .......................... 35-40 ft-lbs / 47-54 Nm
1 2 3
CB
123
12345
123
123
12345
12345
MM
12345 CC
123456
123456
123456
123456
NN
123456
CB
CA CC
123456
123456
123456
LL
123456
CA
MANIFOLDS
8-21
Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
No. Description Item Function Torque
MANIFOLDS
MANIFOLDS
+
interruption of electrical current to a coil. Faulty 10 W 9V
diodes can fail to protect the electrical system, RESISTOR BATTERY
resulting in a tripped circuit breaker or component
d
+
damage. c
-
Electrocution hazard. Contact with
electrically charged circuits could a multimeter or ammeter
b diode
result in death or serious injury.
c 9V DC battery
Remove all rings, watches and d 10ΩΩ resistor
other jewelry. e coil
1 Test the coil for resistance. See How to Test a Note: Dotted lines in illustration indicate a
Coil. reversed connection as specified in
step 6
2 Connect a 10Ω Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the 4 Connect the negative lead to the other terminal
other end of the resistor to a terminal on the on the coil.
coil. If testing a single-terminal coil,
connect the negative lead to the
Ω
Resistor, 10Ω internal metallic ring at either end
Genie part number 27287 of the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
Note: The battery should read 9V DC or more
battery. Note and record the current reading.
when measured across the terminals.
6 At the battery or coil terminals, reverse the
3 Set a multimeter to read DC current. connections. Note and record the current
The multimeter, when set to read reading.
DC current, should be capable of
Result: Both current readings are greater than
reading up to 800 mA.
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Axle Components
10-1 How to Install the Hub and
Hub and Bearings, 2WD Models Bearings, 2WD Models
Note: When replacing a wheel bearing, both the
How to Remove the inner and outer bearings including the pressed-in
Hub and Bearings, 2WD Models races must be replaced.
1 Loosen the wheel lug nuts. Do not remove 1 Be sure that both bearings are packed
them. with clean, fresh grease.
2 Block the non-steering wheels and place a 2 Place the large inner bearing into the rear
lifting jack of ample capacity under the steer of the hub.
axle.
3 Press the bearing seal evenly into the hub
3 Raise the machine 6 inches / 15 cm and place until it is flush.
blocks under the chassis for support.
4 Slide the hub onto the yoke spindle.
Crushing hazard. The machine
Component damage hazard. Do
may fall if not properly supported.
not apply excessive force or
4 Remove the lug nuts. Remove the tire and damage to the lip of the seal may
wheel assembly. occur.
5 Remove the dust cap, cotter pin and 5 Place the outer bearing into the hub.
castle nut.
6 Install the washer and castle nut.
Note: Always use a new cotter pin when installing
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to
a castle nut.
seat the bearing.
6 Pull the hub off the spindle. The washer and Note: Rotate the hub by hand while torquing the
outer bearing should fall loose from the hub. castle nut to make sure the bearings seat properly.
7 Place the hub on a flat surface and gently pry
8 Loosen the castle nut one turn, and then torque
the bearing seal out of the hub.
to 35 ft-lbs / 47 Nm.
8 Remove the rear bearing.
9 Install a new cotter pin. Bend the cotter pin
to secure the castle nut.
Note: Always use a new cotter pin when installing
a castle nut.
10 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
AXLE COMPONENTS
The oscillating axle cylinders extend and retract Bodily injury hazard. Spraying
between the drive chassis and the oscillating axle. hydraulic oil can penetrate and
The cylinders are equipped with counterbalance burn skin. Loosen hydraulic
valves to prevent movement in the event of a connections very slowly to allow
hydraulic line failure. The valves are not the oil pressure to dissipate
adjustable. gradually. Do not allow oil to squirt
or spray.
How to Remove an Oscillating 4 Remove the pin retaining fasteners from the
Axle Cylinder rod-end pivot pin.
Note: Perform this procedure on a firm, level 5 Use a soft metal drift to remove the pin.
surface with the boom in the stowed position. 6 Attach a lifting strap from an overhead crane to
Note: When removing a hose assembly or fitting, the barrel end of the oscillating cylinder.
the O-ring (if equipped) on the fitting and/or the 7 Remove the pin retaining fasteners from the
hose end must be replaced. All connections must barrel-end pivot pin.
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting 8 Use a soft metal drift to remove the pin.
Torque Specifications. Crushing hazard. The oscillate
1 Rotate the turntable until the boom is between cylinder may become unbalanced
the steer tires. and fall if not properly supported
when removed from the machine.
2 Remove the fasteners from drive chassis cover
at the steer end. Remove the cover. 9 Remove the oscillate cylinder from the machine.
Crushing hazard. The oscillate
cylinder could become unbalanced
and fall if not properly supported
when it is removed from the
machine.
Generators
11-1 5 Connect the positive and negative leads from a
multimeter of sufficient capacity to the electrical
Adjustments - Hydraulic outlet at the generator.
Generator Note: The multimeter, when set to read AC
voltage, should be capable of reading up to 125V
How to Adjust the 3000/3500W AC.
Generator Voltage (prior to serial Result: The reading on the multimeter should be
number 10283) 112 to 118V AC.
Bodily injury hazard. Spraying Result: If the reading on the multimeter is not
hydraulic oil can penetrate and 112 to 118V AC, proceed to step 6.
burn skin. Loosen hydraulic
6 Turn the key switch to the off position.
connections very slowly to allow
the oil pressure to dissipate 7 Use a wrench to loosen the jam nut and adjust
gradually. Do not allow oil to squirt the generator flow regulator valve (item AM).
or spray.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and a
other jewelry.
Note: Perform this procedure with the machine on
a firm, level surface.
1 Disconnect all electrical tools from the machine. a flow regulator
2 Start the engine from the platform controls. 8 Adjust the hex socket screw. Turn it clockwise
3 Press the generator select switch. to increase the voltage or counterclockwise to
decrease the voltage. Tighten the jam nut while
4 Connect an electrical tool, which does not draw holding the adjustment screw in place.
more than 15A, to the electrical outlet at the
platform controls and run the tool at full speed. Component damage hazard.
Failure to adjust the generator as
instructed may result in damage to
the generator or other electrical
equipment. Do not adjust the
generator to other than specified.
9 Repeat steps 2 through 5 to confirm the
generator AC voltage.
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Genie Z-60/34 Operator’s Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropiate fault code thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each
from movement.
repair procedure with the machine in the
following configuration: Electrocution hazard. Contact
· Machine parked on a firm, level surface with electrically charged circuits
could result in death or serious
· Boom in stowed position
injury. Remove all rings, watches
· Turntable rotated with the boom between and other jewelry.
the non-steer wheels
Bodily injury hazard. Spraying
· Turntable secured with the turntable hydraulic oil can penetrate and
rotation lock burn skin. Loosen hydraulic
· Key switch in the off position with the connections very slowly to allow
key removed the oil pressure to dissipate
· Wheels chocked gradually. Do not allow oil to
squirt or spray.
· All external AC power disconnected
from the machine Note: Perform all troubleshooting on a firm level
surface.
Note: Two persons will be required to safely
perform some troubleshooting procedures.
FAULT CODES
Fault Code Chart - 3 Determine the error source: The red LED
indicates the error source and will flash two
Control System separate codes. The first code will indicate the
first digit of the two digit code, flashing once per
How to Retrieve Control System second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Fault Codes
Note: When the red LED is flashing the code, the
Note: At least one fault code is present when the
yellow LED will be on solid.
alarm at the platform controls produces two short
beeps every 30 seconds for 10 minutes. 4 Determine the error type: The yellow LED
indidates the error type and will flash two
Note: Perform this procedure with the engine off,
separate codes. The first code will indicate the
the key switch turned to platform controls and the
first digit of the two digit code, flashing once per
red Emergency Stop button pulled out to the on
second. It will then pause for 1.5 seconds and
position at both the ground and platform controls.
flash the second digit once per 0.5 second.
1 Open the platform control box lid. Note: When the yellow LED is flashing the code,
Electrocution hazard. Contact the red LED will be on solid.
with electrically charged circuits
5 Use the fault code table on the following pages
could result in death or serious
to aid in troubleshooting the machine by
injury. Remove all rings, watches
pinpointing the area or component affected.
and other jewelry.
2 Locate the red and yellow fault LEDs on the
ALC-500 circuit board inside the platform control
box. Do not touch the circuit board.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. If the circuit board
does need to be handled, maintain
firm contact with a metal part of
the machine that is grounded at all
times when handling the printed
circuit board OR use a grounded
wrist strap.
FAULT CODES
FAULT CODES
FAULT CODES
Ford LRG-425 EFI Engine 5 Continue to hold the run/test toggle switch in the
test position and count the blinks.
How to Retrieve Ford Engine Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three times.
Fault Codes After the fault codes, the check engine light will
The ECM constantly monitors the engine by the blink a code 123 three times again indicating the
use of sensors on the engine. The ECM also uses end of the stored codes.
signals from the sensors to initiate sequential fuel
Note: If any fault codes are present, the ECM will
injection and make constant and instantaneous
blink a three digit code three times for each code
changes to ignition timing, fuel delivery and throttle
stored in memory. It will blink the first digit of a
position to maintain the engine's running condition
three digit code, pause, blink the second digit,
at its highest efficiency while at the same time
pause, and then blink the third digit. For example:
keeping exhaust emissions to a minimum. When a
the check engine light blinks 5 consecutive times,
sensor fails or returns signals that are outside of
blinks 3 times and then 1 time. That would indicate
set parameters, the ECM will store a fault code in
code 531.
memory that relates to the appropriate sensor and
will turn on the Check Engine Light. Note: Once a fault code has been retrieved and the
repair has been completed, the ECM memory must
Note: Perform this procedure with the key switch in
be reset to clear the fault code from the ECM. See
the off position.
How to Clear Engine Fault Codes from the ECM.
1 Open the ground controls side cover and locate
the run/test toggle switch on the side of the How to Clear Engine Fault
ground control box. Codes from the ECM
2 Pull out the red Emergency Stop button to the Note: Perform this procedure with the engine off
on position at both the ground and platform and the key switch in the off position.
controls.
1 Open the engine side turntable cover and locate
3 Quickly activate and release the start toggle
the battery.
switch/button. Do not start the engine.
2 Disconnect the negative battery cable from the
4 Move and hold the run/test toggle switch to the
battery for a minimum of 5 minutes.
test position.
Electrocution hazard. Contact with
Result: The check engine light should turn on.
electrically charged circuits could
The check engine light should begin to blink.
result in death or serious injury.
Remove all rings, watches and
other jewelry.
3 Connect the negative battery cable to the
battery.
112
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections
(Bank 1) open or shorted OR sensor is faulty.
Repair wiring and/or connections OR
replace sensor.
113
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections
(Bank 2) open or shorted OR sensor is faulty.
Heated Oxygen Sensor wiring and/or Repair wiring and/or connections OR replace
connections open or shorted OR sensor is sensor OR repair any vacuum and exhaust leaks
Closed Loop Multiplier
121 High (Gasoline)
faulty OR there are vacuum leaks or exhaust
leaks OR fuel pressure is low OR the fuel
OR test the fuel pressure OR clean or replace the
fuel injectors.
injectors need cleaning or replacing.
122
Closed Loop Multiplier or shorted OR sensor is faulty OR one or more Adjust or replace sensors OR clean or repair
Low (Gasoline) fuel injectors are stuck open OR there is fuel injectors.
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.
Engine wire harness may have an intermittent Repair short in engine wire harness
Adaptive Learn Low
144 (LPG)
short to 5V DC or 12V DC OR fuel system
components may be faulty.
OR test and repair the fuel system
components.
161
Battery is faulty OR alternator is not charging OR Replace battery OR repair alternator OR repair
System Voltage Low
battery supply wiring to ECM is open or shorted. battery supply wiring to ECM.
162
Alternator is overcharging the battery when
System Voltage High Repair or replace the alternator.
engine RPM is greater than 1500 rpm.
Faulty oil pressure sensor OR sensor wiring Replace oil pressure sensor OR repair sensor
215 Oil Pressure Low and/or connections open or shorted OR engine wiring and/or connections OR fill engine oil level
to specification.
oil level too low.
222 CHT/ECT Low Voltage overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
OR coolant level is low.
Coolant temperature at the cylinder head is 240° F. Repair engine cooling system problems OR
Engine cooling system is malfunctioning and
223
CHT Higher Than repair open or shorted wiring to sensor OR
Expected (1) overheating the engine OR sensor wires and/or replace sensor OR fill engine coolant level to
connections open or shorted OR sensor is faulty specification.
OR coolant level is low.
231
Open or shorted wiring and/or connections to MAP
MAP High Pressure
sensor OR sensor is faulty.
Repair wiring and/or connections to sensor OR
replace MAP sensor.
232
Open or shorted wiring and/or connections to MAP
MAP Low Voltage
sensor OR sensor is faulty.
Crankshaft position sensor wiring and/or Be sure system ground connections are in place
243 Never Crank Synced
At Start
connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.
and secure OR repair wiring and/or connections
to sensor OR replace sensor.
253
Knock sensor wiring and/or connections open or Repair wiring and/or connections to knock sensor
Knock Sensor Open
shorted OR sensor is faulty. OR replace knock sensor.
Knock sensor wiring and/or connections open or Check for excessive engine vibration OR repair
254 Excessive Knock Signal shorted OR there is excessive engine vibration
OR sensor is faulty.
wiring and/or connections to knock sensor OR
replace knock sensor.
311
Open wiring and/or connections to fuel injector #1
Injector Driver #1 Open
OR fuel injector #1 is faulty OR ECM is faulty. Repair wiring and/or connections to fuel injector #1
Wiring and/or connections to fuel injector #1 is OR replace fuel injector #1 OR replace the ECM.
312 Injector Driver #1 Shorted shorted OR fuel injector #1 is faulty OR
ECM is faulty.
313
Open wiring and/or connections to fuel injector #2
Injector Driver #2 Open
OR fuel injector #2 is faulty OR ECM is faulty. Repair wiring and/or connections to fuel injector #2
Wiring and/or connections to fuel injector #2 is OR replace fuel injector #2 OR replace the ECM.
314 Injector Driver #2 Shorted shorted OR fuel injector #2 is faulty OR
ECM is faulty.
315
Open wiring and/or connections to fuel injector #3
Injector Driver #3 Open
OR fuel injector #3 is faulty OR ECM is faulty. Repair wiring and/or connections to fuel injector #3
Wiring and/or connections to fuel injector #3 is OR replace fuel injector #3 OR replace the ECM.
316 Injector Driver #3 Shorted shorted OR fuel injector #3 is faulty OR
ECM is faulty.
321
Open wiring and/or connections to fuel injector #4
Injector Driver #4 Open
OR fuel injector #4 is faulty OR ECM is faulty. Repair wiring and/or connections to fuel injector #4
Wiring and/or connections to fuel injector #4 is OR replace fuel injector #4 OR replace the ECM.
322 Injector Driver #4 Shorted shorted OR fuel injector #4 is faulty OR
ECM is faulty.
The MegaJector detects voltage less than 9.5 volts Repair VBAT power or ground circuit to ECM and
362
MegaJector Voltage
for 5 seconds anytime the engine is cranking or MegaJector OR replace battery OR repair
Supply Low
running. charging system OR replace the MegaJector.
411
Open wiring and/or connections to ignition
Coil Driver #1 Open
coil #1 OR ignition coil #1 is faulty. Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
412
Wiring and/or connections to ignition coil #1
Coil Driver #1 Shorted
shorted OR ignition coil #1 is faulty
413
Open wiring and/or connections to ignition
Coil Driver #2 Open
coil #2 OR ignition coil #2 is faulty. Repair wiring and/or connections to ignition
coil #2 OR replace ignition coil #2.
414
Wiring and/or connections to ignition coil #2
Coil Driver #2 Shorted
shorted OR ignition coil #2 is faulty
531 TPS1 (Signal Voltage) High The #1 throttle position sensor wiring and/or
connections open or shorted OR there is a poor
Be sure system ground connections are in place
and secure OR repair wiring and/or connections
system ground connection OR throttle position
532 TPS1 (Signal Voltage) Low sensor #1 is faulty.
to sensor OR replace throttle position sensor #1.
533 TPS2 (Signal Voltage) High The #2 throttle position sensor wiring and/or
connections open or shorted OR there is a poor
Be sure system ground connections are in place
and secure OR repair wiring and/or connections
system ground connection OR throttle position
534 TPS2 (Signal Voltage) Low sensor #2 is faulty.
to sensor OR replace throttle position sensor #2.
631
External 5V DC Ref
Lower than Expected Engine harness wiring and/or connections open Locate and repair any engine harness wiring
or shorted to ground OR there is a faulty engine damage or shorts OR locate and troubleshoot or
632
External 5V DC Ref sensor OR ECM is faulty. repair faulty engine sensor OR replace ECM.
Higher than Expected
655 RTI2 Loss Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is faulty. damage or shorts to ECM to be sure they are
656 RTI3 Loss
secure OR replace ECM.
Ford DSG-423 EFI Engine 5 Continue to hold the run/test toggle switch in the
test position and count the blinks.
How to Retrieve Ford Engine Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three times.
Fault Codes After the fault codes, the check engine light will
The ECM constantly monitors the engine by the blink a code 123 three times again indicating the
use of sensors on the engine. The ECM also uses end of the stored codes.
signals from the sensors to initiate sequential fuel
Note: If any fault codes are present, the ECM will
injection and make constant and instantaneous
blink a three digit code three times for each code
changes to ignition timing, fuel delivery and throttle
stored in memory. It will blink the first digit of a
position to maintain the engine's running condition
three digit code, pause, blink the second digit,
at its highest efficiency while at the same time
pause, and then blink the third digit. For example:
keeping exhaust emissions to a minimum. When a
the check engine light blinks 5 consecutive times,
sensor fails or returns signals that are outside of
blinks 3 times and then 1 time. That would indicate
set parameters, the ECM will store a fault code in
code 531.
memory that relates to the appropriate sensor and
will turn on the Check Engine Light. Note: Once a fault code has been retrieved and the
repair has been completed, the ECM memory must
Note: Perform this procedure with the key switch in
be reset to clear the fault code from the ECM. See
the off position.
How to Clear Engine Fault Codes from the ECM.
1 Open the ground controls side cover and locate
the run/test toggle switch on the side of the How to Clear Engine Fault
ground control box. Codes from the ECM
2 Pull out the red Emergency Stop button to the Note: Perform this procedure with the engine off
on position at both the ground and platform and the key switch in the off position.
controls.
1 Open the engine side turntable cover and locate
3 Quickly activate and release the start toggle
the battery.
switch/button. Do not start the engine.
2 Disconnect the negative battery cable from the
4 Move and hold the run/test toggle switch to the
battery for a minimum of 5 minutes.
test position.
Electrocution hazard. Contact with
Result: The check engine light should turn on.
electrically charged circuits could
The check engine light should begin to blink.
result in death or serious injury.
Remove all rings, watches and
other jewelry.
3 Connect the negative battery cable to the
battery.
111 CL (closed loop) high LPG 212 IAT (intake air temperature) low voltage
112 EGO open / lazy pre-cat 1 213 IAT (intake air temperature) higher than expected 1
113 EGO open / lazy pre-cat 2/post-cat 1 214 IAT (intake air temperature) higher than expected 2
115 EGO open / lazy post-cat 2 221 ECT/CHT (engine/cylinder head temp) high voltage
121 CL (closed loop) high gasoline bank 1 222 ECT/CHT (engine/cylinder head temp) low voltage
122 CL (closed loop) low gasoline bank 1 223 CHT higher than expected 1
124 CL (closed loop) low LPG 224 CHT higher than expected 2
141 AL (adaptive learning) high gasoline bank 1 231 MAP (manifold absolute pressure) high pressure
142 AL (adaptive learning) low gasoline bank 1 232 MAP (manifold absolute pressure) low pressure
143 AL (adaptive learning) high LPG 234 BP (barometric pressure) high pressure
144 AL (adaptive learning) low LPG 235 BP (barometric pressure) low pressure
166 AUX analog PU3 low 253 Knock 1-2 sensor open 1
167 AUX analog PUD1 high 254 Knock 1-2 excessive signal 1
261 FP (fuel pressure) high voltage 531 TPS1 (throttle position sensor) high voltage
262 FP (fuel pressure) low voltage 532 TPS1 (throttle position sensor) low voltage
271 FT (fuel temperature) gasoline high voltage 533 TPS2 (throttle position sensor) high voltage
272 FT (fuel temperature) gasoline low voltage 534 TPS2 (throttle position sensor) low voltage
273 FT (fuel temperature) gaseous fuel high voltage 535 TPS1 (throttle position sensor) higher than TPS2
274 FT (fuel temperature) gaseous fuel low voltage 536 TPS1 (throttle position sensor) lower than TPS2
311 Injector loop open OR low-side short to ground 1 537 Unable to reach higher TPS (throttle position sensor)
312 Injector coil shorted 1 538 Unable to reach lower TPS (throttle position sensor)
313 Injector loop open OR low-side short to ground 2 539 TPS 1-2 simultaneous voltages
315 Injector loop open OR low-side short to ground 3 542 AUX analog PU1 low
321 Injector loop open OR low-side short to ground 4 544 AUX analog PU2 low
351 FPump motor loop open OR high-side shorted to ground 552 Fuel rev limit
352 Fpump motor high-side shorted to power 553 Spark rev limit
353 EPR delivery pressure higher than expected 611 COP failure
354 EPR delivery pressure lower than expected 612 Invalid interrupt
631 5VE1 low voltage 761 MIL (malfunction indicator light) control ground short
632 5VE1 high voltage 762 MIL (malfunction indicator light) open
633 5VE2 high voltage 763 MIL (malfunction indicator light) control short to power
735 PWM3-gauge3 open / ground short For further engine fault code troubleshooting and
diagnostic information, refer to the Ford DSG-423
736 PWM3-gauge3 short to power
EFI Service Manual (EDI part number 1060040).
741 PWM4 open / ground short Genie part number 119494.
742 PWM4 short to power
Ford DSG 423 EFI Operator Handbook
743 PWM5 open / ground short
Genie part number 119488
Ford MSG-425 Engine Fault 5 Continue to hold the run/test toggle switch in the
test position and count the blinks.
Codes
Note: Before the fault codes are displayed, the
check engine light will blink a code 1-6-5-4 three
How to Retrieve Ford Engine times. After the fault codes, the check engine light
Fault Codes will blink a code 1-6-5-4 three times again indicating
the end of the stored codes.
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also uses Note: If any fault codes are present, the ECM will
signals from the sensors to initiate sequential fuel blink a three digit code three times for each code
injection and make constant and instantaneous stored in memory. It will blink the first digit of a
changes to ignition timing, fuel delivery and throttle three digit code, pause, blink the second digit,
position to maintain the engine's running condition pause, and then blink the third digit. For example:
at its highest efficiency while at the same time the check engine light blinks 5 consecutive times,
keeping exhaust emissions to a minimum. When a blinks 3 times and then 1 time. That would indicate
sensor fails or returns signals that are outside of code 531.
set parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor and Note: Once a fault code has been retrieved and the
will turn on the Check Engine Light. repair has been completed, the ECM memory must
be reset to clear the fault code from the ECM. See
Note: Perform this procedure with the key switch in How to Clear Engine Fault Codes from the ECM.
the off position.
How to Clear Engine Fault
1 Locate the run/test toggle switch on the side of
the ground control box. Codes from the ECM
2 Pull out the red Emergency Stop button to the Note: Perform this procedure with the engine off
on position at both the ground and platform and the key switch in the off position.
controls.
1 Open the engine side turntable cover and locate
3 Quickly activate and release the start toggle the battery.
switch/button. Do not start the engine.
2 Disconnect the negative battery cable from the
4 Move and hold the run/test toggle switch to the battery for a minimum of 5 minutes.
test position.
Electrocution/burn hazard. Contact
Result: The check engine light should turn on. with electrically charged circuits
The check engine light should begin to blink. could result in death or serious
injury. Remove all rings, watches
and other jewelry.
3 Connect the negative battery cable to the
battery.
Code Description
2309 Primary Loop Open or Low-side
Short to Ground
2310 Primary Coil Shorted
2312 Primary Loop Open or Low-side
Short to Ground
2313 Primary Coil Shorted
2315 Primary Loop Open or Low-side
Short to Ground
2316 Primary Coil Shorted
2318 Primary Loop Open or Low-side
Short to Ground
2319 Primary Coil Shorted
2321 Primary Loop Open or Low-side
Short to Ground
2322 Primary Coil Shorted
2618 Tach output ground short
2619 Tach output short to power
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
Electrocution hazard. Contact with
electrically charged circuits could
Observe and Obey: result in death or serious injury.
Remove all rings, watches and
Troubleshooting and repair procedures shall be other jewelry.
completed by a person trained and qualified on
the repair of this machine. Hydraulic Schematics
Immediately tag and remove from service a Bodily injury hazard. Spraying
damaged or malfunctioning machine. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
gradually. Do not allow oil to squirt
Before Troubleshooting: or spray.
Read, understand and obey the safety rules General Repair Process
and operating instructions printed in your
Operator's Manual.
Be sure that all necessary tools and test Malfunction Identify Troubleshoot
discovered symptoms
equipment are available and ready for use.
problem
still exists
BL/WH C132PLI 12
C5-GROUND BOX
C2 DT06-12SD PIN
CIRCUIT NO. FORD DEUTZ PERKINS
COLOR CIRCUIT NO. PIN NO. C2 FUNCTION HARNESS NO. ENGINE ENGINE ENGINE
BL/RD OPTION 1
1
OR C40LS1 2
CIRCUIT NO. COLOR 2 C41RPM OR/BK OR/BK OR/BK
OR/BK C41RPM 3 WH
3 C107AF WH WH
OR/RD P134PWR 4 C1PBU RD-3 GR/WH
4 C45GEN GR/WH GR/WH
GR C46HRN 5 C129DA RD/BK-3
5 R33STR BK BK(14) BK(14)
GR/BK JDALARM 6 C3PBF RD/WH-3
C2 6 C27AUX RD
GR/WH C45GEN 7 C2PBD RD/BK
NC 8 BLACK C5TRR WH/BK-3 -
7 - -
NC 9 C6TRF WH/RD-3
C7PBE BK-3 8 C21IGN-FEH16A WH
NC 10
NC 11 C8PBR BK/WH-3 BK/RD
9 C128RPM-FEH306 BK/RD BK/RD
NC 12 LS PWR BL/WH-3
10 C39LP-FEH674 BL/RD
C13DRE BL/WH-3
C134PWR RD-3 11 VSW WH
C3 DT06-12SA
C14PLU OR-3 12 C127TST GR
COLOR CIRCUIT NO. PIN NO. C15PLD OR/BK-3
C3 13 C108ESL-C24TSPS BL/WH WH WH
RD C1PBU 1
C17JU GR-3 WH/RD WH/RD WH/RD
RD/BK C2PBD 2 14 C26TSR
RD/WH C3PBF 3 C18JD GR/BK-3
15
WH C4TRL 4 P23BATSR RD
16 C25PS WH/BK WH/BK WH/BK
WH/BK C5TRR 5 C27AUX RD-1
WH/RD C6TRF 6 C28TTA RD/BK 17 C21IGN-FEH16A WH
BK C7PBE 7 C3 18
BK/WH C8PBR 8 GREEN
CABLE #3
BK/RD DLITE 9 19
C36STCC BL-1
BL C10SBU 10 WH/BK
C37STC BL/BK-1 20 C31REV WH/BK WH/BK
BL/BK C11SBD 11
A C40LS1 OR-1 21 C30FWD WH WH WH
BL/WH C12SBF 12
22 C34SA BK/WH BK/WH
FS1
BLK
BLK
P3
WHT LS3 Foot switch
N.O.H.C N.C.H.O
Quick disconnect
terminal Limit switch Horn button
Coil normally open
solenoid or relay
P1
KS1
WHT #21 TB21
PLATFORM
OTS2
GROUND N.O.
T-circuits connect H1 Emergency Stop
at terminal button normally
Oil temperature
switch closed
Horn or alarm Key switch normally open
T-circuits
connect FAN
FB PR1
CTS1
N.O.
Hydraulic oil
Flashing beacon Power relay cooling fan
Connection Coolant temperature
no terminal switch
normally open Aux
G1 TS2 Pump
ENGINE
START
L3
PLATFORM LEVEL
-
Gauge sending unit Tilt sensor
LED
Battery
Toggle switch DPDT
F1
25A A B C
PULL IN
Fuse
HOLD
AUX MAIN
CR4
with amperage N.O.
CB1
15A
Starting aid:
glow plug or
Circuit breaker flame ignitor
with amperage Coil
25 psi
(1.7 bar) .035"
(0.89 mm)
Orifice with size
200 psi
(13.8 bar)
Hydraulic oil cooler
Pump
fixed displacement Relief valve Priority
with pressure setting flow regulator valve
o
Brake
50% 50%
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
Ford DSG-423
Starter Empty
Relay
F1-10A F2-5A
Fuel Power
Pump Relay F3-10A F4-15A
Relay
F5-15A
F6-10A
Power Fuel
Empty
Relay Pump
Relay
Starter
20A F1-10A F2-5A
F4 Fuel pump
F6 Alternator
6 - 10
6-9
Section 6 • Schematics September 2013
1
RD/BK
P26ESTP BK BK
LS18
P2 FS1
RD-(FS) C9-3 P25FS RD
2 C9-1 BK BK-(FS)
WH-(FS) C9-2 P24FS WH WH
RD C28TTA RD/BK
TS2 TS6
C134PWR OR/RD
C132PLI BL/WH
P22BAT BK
SEE NOTE 2
TS17
C41RPM OR/BK
ON GLOW
START
L4 TS4
H1 L48 TS1
P3
GENERATOR
HIGH RPM(FS)
PLUG
HORN D39
AUXILIARY
SEE NOTE 2
PUMP
ENGINE
D40
3
C1-12
C2-4
C2-7
C1-7
C1-8
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
CB2 TB134
P1 RD TB132
15AMP. RD RD RD
C1-9
TB43
1 3 RD
KS1 TB22
C43HRN GR
C45GEN GR/WH
4 5 TS51 TS52 TS56 TS55
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
P23BAT WH
PLAT
GRD
HIGH RPM
LOW RPM
6
START ENGINE
ON GLOW
FUNCTION ENA.
4
AUXILIARY
U33
PUMP
RD
7
PLUG
BK
BK
12 8 TB45
TB27
TB33
CB1
RD
BK/RD
20AMP. CR1 CR2
8 KEY BYPASS
NO CR5 NO
9 IGN./FUEL ON
NO 10 ENG. FAULT
TB21
NO CR3
GR/WH-45
OTS
RD-23
RD/BK-28
NO TB25 TB26
G2 G3
6
BK-43
NO CR4
OR/BK-41
RD-27
BK-33
WH-21
PR3
ALTERNATOR CR17 NO PR3
EXCT. NO
RD
WH
CR17 PR1
BK/RD-R4-E.H.
WH-24
WH-24
PR1
12 V BAT. BAT. NO
- PR2 PR2
WH/RD
WH/BK
DC +
NO
+
FB S7
STA.
+
AUX
M2 PUMP STARTER OPS S2 S1 OTS
HM G1 Y29
H2 G6
BK
REGULATOR FAN M1
IND. _ NC NO
7 -
BRN
BRN
FUEL RELAY
RELAY
SERVICE HORN
SWITCH
WATER TEMP
OPTION
FLASHING BEACONS
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
IGN./START RELAY
HOUR METER
VOLT METER
OPTION
GENERATOR
AUXILIARY PUMP
NOTE:
8
September 2013
6 - 11
Diesel Electrical Schematic - View 2
BRN-2
GROUND
C41RPM OR/BK
A
C2P-3
5
15
TB31 TB30
J1
7 20
RKOUT 6 WH 5
TB36 TB37
YOUT 5 BL 4
JC3
4 18 STEER RIGHT
PWR 3 OR 13
GND 2 BRN 14 C1P-10 C36STC BL C36STC BL
STEER LEFT
17
1
C3P-6 C6TRF WH/RD
11
C3P-5 C5TRR WH/BK
9
TB4
C3P-4 C4TRL WH
10
C4TRL WH
TURNTABLE ROTATE LEFT
D
.5 R5
C5TRR WH/BK
TS62
6 FLOW CONTROL
TB6
TB1
R4
YOUT 5 BK 2
7.5
JC2
XOUT 4 RD 1 C1PBU RD
PRIMARY BOOM UP
J1
UP
TB2
GND 2 12
J2
1
TB3
C3P-12
SECONDARY BOOM UP/DWN
14
7
F
C3P-11
6 13 C105BU BL
SECONDARY BOOM UP
OUT 5 YEL 3 C3P-10
12
JC1
TB10
4
J1
C115BD BL/BK
PWR 3 OR 9 SECONDARY BOOM DOWN
UP
GND 2 BRN 10 SECONDARY BOOM
DOWN C125BF BL/WH SECONDARY BOOM
TS60
1
TB11
FLOW CONTROL
TB12
G
BRN
1 CABLE #6 4 WH
NCHO
SECONDARY BOOM
TB13
P24FS WH
2 CABLE #6 3 BK OPERATION
3
TB40
P26ESTP BK
3 CABLE #7 4 WH
C2P-2 C40LS1 OR C40LS1 OR NCHO PRIMARY BOOM
4 CABLE #7 3 BK OPERATION
H
TB44
CABLE #8 4 WH
NOHC
BOOM RETRACTED
TB46
C46PWR WH 3 BK OPERATION
CR27
CR30
NO
2
DRIVE
CABLE #5 WH
NOHC
LIFT/
LS3
TB46
CE
TB8
C3P-7
TS63
C8PBR BK/WH
RETRACT
BOOM RETRACT
BOOM
EXTEND
WH
C7PBE BK
NOTE:
BOOM EXTEND
TB7
C4P-2 C14PLU OR
J
UPPLATFORM LEVEL
DOWN C15PLD OR/BK TB14
TS9
TS59
C4P-3
C14PLU OR
PLAT LEVEL UP
UP PLATFORM LEVEL
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
GR/BK-44 C2P-6 JDALARM GR/BK
K
CR13
DOWN
TB18
JIB BOOM
UP C4P-5 C17JU GR
TS8
C18JD GR/BK
PLATFORM ROTATE RIGHT / JIB DOWN
TS58
DOWN
JIB BOOM
UP C17JU GR
PLATFORM ROTATE LEFT / JIB UP
TS57
TB17
RIGHT
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
TS7
LEFT
L
WH
C4P-7
C19JSV GR/WH
TB19
C19JSV GR/WH
CR13
AMP
7
6
5
3
4
2
1
Y18
BRN
M
RKOUT
XOUT
YOUT
PWR
GND
RD/BK
OR/BK
BRN
WH
RD
RD
BK
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
N
Deutsch
3
1
2
5
6
4
Section 6 • Schematics September 2013
6 - 11
6 - 12
Section 6 • Schematics September 2013
6 - 14
6 - 13
Section 6 • Schematics September 2013
1
BL/WH
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
BK
F18
LS18
P2 FUSE 10A
2 C9-1 BK BK-(FS)
FS1
RD-(FS) C9-3 P25FS RD
TS48
C132PLI BL/WH
TS6
P22BAT BK
1
2
WORK LIGHT
WHEN C.E. OPTION IS NOT
DRIVE LIGHT
C41RPM OR/BK
START
ON GLOW
L4 TS4
CONNECTS PIN 4 TO PIN 5
WH
WH
AND PIN 6 TO PIN 7 TS1
L48
PLUG
HIGH RPM(FS)
P3 H1
GENERATOR
LS18 - PLATFORM OVERLOAD
SWITCH HORN D39
ENGINE
PUMP AUXILIARY
C3P-9
D40
3 L30 L30
C1-12
C2-4
C2-7
C1-7
C1-8
TB133 IS WAGO TERMINAL BLOCK 16
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
TB 134 IS WAGO TERMINAL BLOCK 42
CB2 TB134
BK
BK
P1 RD TB132
15AMP. RD
RD
C1-9
TB43 RD
2 1 3
KS1 TB22
C43HRN GR
RD
C45GEN GR/WH
4 5
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
P23BAT WH
PLAT
BK/RD
GRD
4 6
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
FUNCTION ENA.
U33
RD
PLUG
7 D3 PBOX GND
BK
ENGINE
D2
BK
12 8
TB45
TB27
TB33
RD
CB1
TB23
15AMP. L45 1 START RELAY
TB20 H6 TB35
2 TACHOMETER
D6 3 START INPUT
TB133 TB34
TB28 4 AUX. ON IGN./START
5 RD
TB24 5 GROUND
6 BATTERY
MODULE
7 KEY PWR. L2
CB3 CR2 8 KEY BYPASS U1
BK/RD
CR1 9 IGN./FUEL ON
20AMP. CR5 CR1
NO CR5 NO CR2 10 ENG. FAULT
TB21 NO
WH
CR3
NO
C5-3
C5-2
C5-22
D33
C21IGN2 WH
GR/WH-45
RD-134
RD/BK-28
C5-5
OTS CR23
6 NO
TB25 TB26 CR23
NO
G2 G3
C5-13 WH
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1 S1
BK/RD-C5-8
C5-11
NO
RD
RD
S7
+
FB
STA. G6
M1 NC
+ Y29
AUX STARTER
7 M2 PUMP HM G1 S2
S1
BK
REGULATOR H2
FAN _
- IND. L29 L29
NC C4B-9 C4B-11
NO
BRN
BR
BRN
VOLT METER
STARTER MOTOR
FUEL RELAY
SERVICE HORN
RELAY
SERVICE HORN
HOUR METER
SWITCH PERKINS
WATER TEMPERATURE
OPTION
WORK LIGHTS
OPTION
DRIVE LIGHT
TILT ALARM
OPTION
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
EMISSION CONTROL DEUTZ
DEUTZ SHUTDOWN
OIL PRESSURE GAUGE
AUXILIARY PUMP
OIL PRESSURE
SWITCH PERKINS
DEUTZ ONLY
8
September 2013
6 - 15
A
BRN
GROUND
C41RPM OR/BK
ES0434
C2P-3
5
B
15
TS14
LO
TB31 TB30
Y51
DRIVE MODE
C1P-4 C30EDC+ WH C5-21 C30EDC+ WH
HI
J1
DRIVE ENABLE
Y2
Y3
RKOUT 6 WH 5
Y4
XOUT 4
J1
D
PWR 3 OR 13
C3P-6 C6TRF WH/RD
GND 2 BRN 14 11
1 C5TRR WH/BK
9 C3P-5
Section 6 • Schematics
C3P-4 C4TRL WH
TB4
10
Y23
C4TRL WH
LEFT TURNTABLE ROTATE CW
TTROTATE
Y29
7 TURNTABLE ROTATE
E
C6TRF WH/RD
6 FLOW CONTROL
TB6
R5
YOUT 5 BK 2
TB1
5
Y22
JC2
XOUT 4 RD 1 C1PBU RD
PRIMARY BOOM UP
J1
OR UP
TB2
GND 2 BRN 12
J2
Y12
6 C3P-12
14
OUT 5 YEL 3 C3P-11
JC1
4 13
J1
PWR 3 OR 9 C3P-10
12
Y53
1 UP
TB11 TB10
SECONDARY BOOM
Y52
BRN
1 WH
NCHO SECONDARY BOOM
P24FS WH
TB13
2 BK OPERATION
H
C4P-1
SJ2 WH
4 3
P26ESTP BK 3 WH
NCHO
C2P-2 C40LS1 OR PRIMARY BOOM
4 OPERATION
TB40
BK
SJ1 WH
NOHC
BOOM RETRACTED
BK OPERATION
I
CR30
CR27
NO
NC
OPTION
WH
DRIVE
NOHC
LIFT/
LS3
CE
NOTE:
C3P-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3P-7
Y25
J
C8PBR BK/WH
TS63
BOOM RETRACT
RETRACT
BOOM
Y26
EXTEND
WH
TB7
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TB14
TS9
Y20
C4P-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
Y19
PLATFORM LEVEL
DOWN C15PLD OR/BK
K
TB15
GR/BK TB44
C2P-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
C4P-5
TB18
UP C17JU GR
TS8
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
L
DOWN
JIB BOOM
Y17
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
RIGHT
TS57
TB17
PLAT ROTATE RIGHT
LEFT
PLAT ROTATE
TS7
LEFT
WH
AMP
7
6
5
3
4
2
1
C4P-7
Pin1
TB19
C19JSV GR/WH
M
CR13
RKOUT
XOUT
YOUT
Y18
PWR
GND
BRN
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
JIB VALVE
JIB VALVE
Deutsch
N
3
1
2
BL/WH
RD/BK
OR/BK
BRN
5
6
4
RD
RD
WH
BK
Section 6 • Schematics September 2013
6 - 15
6 - 16
Section 6 • Schematics September 2013
6 - 17 6 - 18
Section 6 • Schematics September 2013
1
BL/WH
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
BK
F18
LS18
FUSE 10A
2 P2
C9-1 BK BK-(FS)
FS1
RD-(FS) C9-3 P25FS RD
TS48
C132PLI BL/WH
TS6
P22BAT BK
2
WORK LIGHT
WHEN C.E. OPTION IS NOT
DRIVE LIGHT
C41RPM OR/BK
START
ON GLOW
L4 TS4
CONNECTS PIN 4 TO PIN 5
WH
WH
AND PIN 6 TO PIN 7 TS1
GENERATOR
L48
PLUG
HIGH RPM(FS)
LS18 - PLATFORM OVERLOAD P3 H1
SWITCH HORN D39
ENGINE
PUMP AUXILIARY
C3P-9
3 D40
L30 L30
C1-12
C2-4
C2-7
C1-7
C1-8
TB133 IS WAGO TERMINAL BLOCK 16
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
TB 134 IS WAGO TERMINAL BLOCK 42
CB2 TB134
BK
BK
P1 RD TB132
15AMP. RD
RD
C1-9
TB43 RD
2 1 3
KS1 TB22
C43HRN GR
RD
C45GEN GR/WH
4 5
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
P23BAT WH
PLAT
BK/RD
4 GRD
6
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
FUNCTION ENA.
U33
RD
PLUG
7 D3 4 PBOX GND
BK
D64
ENGINE
D2
BK
12 8
TB45
TB27
TB33
RD
CB1
TB23
15AMP. L45 1 START RELAY
TB20 H6 TB35
2 TACHOMETER
D6 3 START INPUT
TB133 TB34 TB9
4 AUX. ON IGN./START
5 RD
TB28 TB24 5 GROUND
6 BATTERY
MODULE
7 KEY PWR. L2
CB3 CR2 8 KEY BYPASS U1
BK/RD
CR1 9 IGN./FUEL ON
20AMP. CR5 CR1
NO CR5 NO CR2 10 ENG. FAULT FUSE 10A
TB21 NO
FUSE 70A
CR3
NO
C5-3
C5-2
C5-22
C21IGN2 WH
GR/WH-45
3
RD-134
RD/BK-28
C5-5
OTS CR23
6
C5-13 WH
TB25 TB26 CR23
NO NO
G2 G3
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1
BK/RD-C5-8
C5-11
J144-6
J144-4
DC D52 NO
RD
NO
RD
RD
S7
+
FB
STA. G6 5
M1
+ Y29
STARTER
7 AUX
M2 PUMP HM G1 S2
BK
REGULATOR H2
FAN _ S1
IND. L29 L29
NO
-
NC C4B-9 C4B-11
BRN
BR
BRN
VOLT METER
STARTER MOTOR
RELAY
SERVICE HORN
HOUR METER
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
TILT ALARM
OPTION
WORK LIGHTS
OPTION
DRIVE LIGHT
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
EMISSION CONTROL DEUTZ
AUXILIARY PUMP
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
SECOND GLOW PLUG OPTION
GLOW PLUG OPTION
8
September 2013
6 - 19
A
BR-2
GROUND
C41RPM OR/BK
C2-3
5
B
15
TS14
Y51
TB30
J1
7
C
TB32
RKOUT 5 BL/WH
Y3
DRIVE & STEERING
TB36
XOUT 3 BL/WH 4
J1
Y4
GND 1 BR 14
11
C3-6 C6TRF WH/RD
8
9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
TURNTABLE ROTATE LEFT
Y29
C5TRR WH/BK
R4
TS62
7.5
TURNTABLE ROTATE RIGHT
Part No. 75861
TB5
E
Y13
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
GND 1 BR 12
PRIMARY BOOM DOWN
TB3
Y12
FLOW CONTROL
C3-1 C1PBU RD
D30
6
F
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
C3-10
J1
D29
PWR 2 OR 9 12
Y53
GND 1 BR 10 C10SBU BL
G
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
C11SBD BL/BK
8
DOWN
SECONDARY BOOM DOWN
TS60
TB11
BR
1
NO
NC
13
WH
22 21
43
TB13
2 OPERATION
14
3
P26ESTP BK
3
NO
NC
22 21
21
C2-2 C40LS1 OR BK PRIMARY BOOM
14
4 OPERATION
TB40
SJ1 WH
14
21
BK
I
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
Y25
J
C8PBR BK/WH
TS63
BOOM RETRACT
8
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
K
TB15
TB44
GR/BK-44 C2-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
L
DOWN
Y17
JIB BOOM
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
AMP
7
6
5
3
4
2
1
BR
C4-7
C19JSV GR/WH
TB19
M
+
_
RKOUT
XOUT
YOUT
PWR
GND
Y18
JIB VALVE
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
6
Deutsch
3
1
2
N
BL/WH
RD/BK
OR/BK
5
6
4
RD
RD
BR
WH
RD
BK
Section 6 • Schematics September 2013
6 - 19 6 - 20
Section 6 • Schematics September 2013
6 - 22
6 - 21
Section 6 • Schematics September 2013
1
RD
BL/WH
RD/BK
TB41
C2-3
OR/BK OR/BK
P26ESTP BK
2 F18
BK
P2 FUSE 10A
FS1 TS48
RD-(FS) C9-3 P25FS RD
C9-1 BK BK-(FS)
WH-(FS) C9-2 P24FS WH
WH
RD
TS2
C134PWR OR/RD
TS6
P22BAT BK
WORK LIGHT
DRIVE LIGHT
C41RPM OR/BK
TS17
START
ON GLOW
C132PLI BL/WH
TS4
WH
WH
TS1
GENERATOR
PLUG
3
HIGH RPM(FS)
P3
HORN L48
H1
ENGINE
PUMP AUXILIARY
D39
C3P-9
D40 L30 L30
C1-12
C2-4
C2-7
C1-7
C1-8
TB133 IS WAGO TERMINAL BLOCK 16
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
TB 134 IS WAGO TERMINAL BLOCK 42
CB2 TB134 D12
BK
BK
P1 RD TB132 C28TTA RD/BK
15AMP. RD
RD
C1-9
TB43 RD
KS1 1 3
4 TB22
C43HRN GR
RD
C45GEN GR/WH
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
P23BAT WH
PLAT
4 5
BK/RD
GRD
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
6
FUNCTION ENA.
RD
PLUG
RD
D3 PBOX GND
BK
C32 7 D64
ENGINE
TB133 D4
BK
CONN. TB45
12 PLUG 8
GBOX
GND TB27
TB33
D13 D14
CB1
D2 TB23
5 TB20 15AMP. 1 START RELAY 2
GR/BK
2 TACHOMETER TB35
D6 3 START INPUT TB34 TB9
TB28 4 AUX. ON IGN./START
TB24 5 GROUND MODULE
RD
6 BATTERY
7 KEY PWR. L2
CB3 CR2 8 KEY BYPASS U1
BK/RD
CR1 9 IGN./FUEL ON
20AMP. CR5 CR1
NO CR5 NO CR2 10 ENG. FAULT FUSE 10A
TB21 NO
FUSE 70A
CR3
6 NO
C5-3
C5-2
C5-22
C21IGN2 WH
GR/WH-45
RD-134
RD/BK-28
C5-5
OTS CR23
C5-13 WH
TB25 TB26 CR23
NO NO
D22 G2 G3
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
BK/RD
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1
C5-11
J144-6
J144-4
DC D52 NO CB7
RD
S7 NO 10A
RD
RD
7
+
FB
STA. G6
M1
C5-8
+ Y29
AUX STARTER
M2 PUMP HM G1 S2
BK
REGULATOR H2
FAN _ S1
IND. L29 L29
NO
-
NC C4B-9 C4B-11
BR
BR
BRN
VOLT METER
STARTER MOTOR
RELAY
SERVICE HORN
HOUR METER
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
TILT ALARM
OPTION
WORK LIGHTS
OPTION
DRIVE LIGHT
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
EMISSION CONTROL DEUTZ
AUXILIARY PUMP
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
SECOND GLOW PLUG OPTION
GLOW PLUG OPTION
NOTE:
8
September 2013
6 - 23
A
BR-2
GROUND
C41RPM OR/BK
C2-3
5
B
15
TS14
Y51
TB30
C29MS RD/WH
TB31
L1
J1
7
TB32
RKOUT 5 BL/WH
Y3
DRIVE & STEERING
TB36
XOUT 3 BL/WH 4
J1
Y4
GND 1 BR 14
11
C3-6 C6TRF WH/RD
C3-5 C5TRR WH/BK
Section 6 • Schematics
9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
TURNTABLE ROTATE LEFT
Y29
C5TRR WH/BK
R4
TS62
7.5
TURNTABLE ROTATE RIGHT
Part No. 75861
TB5
E
Y13
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
GND 1 BR 12
PRIMARY BOOM DOWN
TB3
Y12
D30
6
C3-2 C2PBD RD/BK
7
C3-3 RD/BK
C3PBF RD/WH DESCENT ALARMN
8
6
SECONDARY BOOM UP/DN
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
C3-10
J1
D29
PWR 2 OR 9 12
Y53
G
GND 1 BR 10 C10SBU BL
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
TB11
BR
1
NO
NC
14 13
WH
22 21
43
TB13
2 OPERATION
3
P26ESTP BK
3
NO
NC
22 21
C2-2 C40LS1 OR 21
BK PRIMARY BOOM
4 OPERATION
TB40
SJ1 WH
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
Y25
J
C8PBR BK/WH
TS63
BOOM RETRACT
7
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
K
TB15
TB44
GR/BK-44 C2-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
L
DOWN
Y17
JIB BOOM
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
M
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
6
N
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
Section 6 • Schematics September 2013
6 - 23
6 - 24
Section 6 • Schematics September 2013
6 - 26
6 - 25
Section 6 • Schematics September 2013
1
RD
BL/WH
RD/BK
TB41
C2-3
OR/BK OR/BK
P26ESTP BK
BK
2
P2 FS1
RD-(FS) C9-3 P25FS RD
C9-1 BK BK-(FS)
WH-(FS) C9-2 P24FS WH
WH
RD
TS2
C134PWR OR/RD
TS6
P22BAT BK
C41RPM OR/BK
TS17
START
ON GLOW
C132PLI BL/WH
GENERATOR
PLUG
HIGH RPM(FS)
P3
3 HORN
H1
L48
ENGINE
PUMP AUXILIARY
D39
BK
BK
D40
C1-12
C2-4
C2-7
C1-7
C1-8
TB133 IS WAGO TERMINAL BLOCK 16
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
TB 134 IS WAGO TERMINAL BLOCK 42
CB2 TB134 D12
P1 RD TB132 C28TTA RD/BK
15AMP. RD
RD
C1-9
TB43 RD
KS1 1 3
TB22
C43HRN GR
RD
4
C45GEN GR/WH
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
P23BAT WH
PLAT
4 5
GRD
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
6
FUNCTION ENA.
RD
PLUG
RD
D3
BK
C32 7 D64
BR
ENGINE
TB133 D4
BK
CONN. TB45
12 PLUG 8
GBOX
GND TB27
TB33
D13 D14
CB1
D2 TB23
1 START RELAY 2
5 TB20 15AMP.
GR/BK
2 TACHOMETER TB35
D6 3 START INPUT TB34
TB28 4 AUX. ON IGN./START
TB24 5 GROUND MODULE
RD
6 BATTERY
7 KEY PWR. L2
CR2 8 KEY BYPASS U1
BK/RD
CB3 CR45 CR1 9 IGN./FUEL ON
CR45 CR1
NO NO CR2 10 ENG. FAULT FUSE 10A
20AMP.
TB21 NO
FUSE 70A
CR3
NO
6 CR5
C5-3
C5-2
C5-22
CR5
C21IGN2 WH
GR/WH-45
NO
RD-134
RD/BK-28
C5-5
OTS
C5-13 WH
CR23 CR23
TB25 TB26
NO NO
D22 G2 G3
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
BK/RD
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1
C5-11
J144-6
J144-4
DC D52 NO CB7
RD
S7 NO 10A
RD
RD
+
FB
7 STA.
M1
G6
C5-8
+ Y29
AUX STARTER
M2 PUMP HM G1 S2
BK
REGULATOR H2
FAN _ S1
IND. L29 L29
NO
-
NC C4B-9 C4B-11
BR
BR
BRN
WORK LIGHTS
VOLT METER
STARTER MOTOR
RELAY
SERVICE HORN
HOUR METER
WORK LIGHTS RELAY (OPTION)
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
OPTION
DRIVE LIGHT
TILT ALARM
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
EMISSION CONTROL DEUTZ
AUXILIARY PUMP
OPTION
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
SECOND GLOW PLUG OPTION
GLOW PLUG OPTION
NOTE:
8
September 2013
6 - 27
C7-3 BR-2
GROUND
A
C41RPM OR/BK
RETURN
C2-3
5
EDC
TB9
C3-9 C5-7
15
TS14
Y51
TB30
B
J1
Z-60/34
7
TB32
20 MOTOR STROKE
6
TB37
DRIVE & STEERING
RKOUT 5 BL/WH
Y3
TB36
XOUT 3 BL/WH 4
J1
C36STC BL
Y4
C1-10 C36STC BL
PWR 2 OR 13 17 STEER CW
GND 1 BR 14
C3-6 C6TRF WH/RD
11
8
D
10
Y23
C4TRL WH
TURNTABLE ROTATE LEFT
Section 6 • Schematics
Y29
C5TRR WH/BK
R4
TS62
Y13
TURNTABLE ROTATE
PRI UP/DN & TT ROTATE
6 C6TRF WH/RD
5 FLOW CONTROL
TB6
TB1
5
Y22
YOUT 4 RD/WH
JC2
2
E
C1PBU RD
J1
Y12
FLOW CONTROL
C3-1 C1PBU RD
6
D30
C3-3 RD/BK
C3PBF RD/WH DESCENT ALARMN
8
SECONDARY BOOM UP/DN
6
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
J1
D29
C3-10
PWR 2 OR 9 12
Y53
GND 1 BR 10 C10SBU BL
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
TB11
Y14
BR
1
NO
NC
13
WH
22 21
JOYSTICK CONTROL CARD
SECONDARY BOOM
43
P24FS WH BK
2
TB13
OPERATION
3
H
P26ESTP BK
3
BK
14
OPERATION
TB40
SJ1 WH
NO
NC
22 21
13
BOOM RETRACTED
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
DRIVE
13
LS3
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
C3-8 C8PBR BK/WH
RETRACT
NOTE:
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
9
6
RETRACT
1.
J
BOOM
Y26
EXTEND C7PBE BK
WH
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
K
TB15
TB44
GR/BK-44 C2-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
DOWN
JIB BOOM
Y17
L
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
RIGHT
TB17
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
M
+
_
Y18
JIB VALVE
JIB TIME
JIB VALVE
CIRCUIT
CR14
DELAY
6
N
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
Section 6 • Schematics September 2013
6 - 27
6 - 28
Section 6 • Schematics September 2013
6 - 30
6 - 29
Section 6 • Schematics September 2013
1
RD
BL/WH
C132PLI2 BK
RD/BK
TB41
C2-3
OR/BK OR/BK
D89
P26ESTP BK
2 LS18A F18
BK
P2 FUSE 10A
LS18 FS1 TS48
RD-(FS) C9-3 P25FS RD
PBOX C9-1 BK BK
WH-(FS) C9-2 P24FS WH
GND D88
WH
RD
TS2
C134PWR OR/RD
TS6
P22BAT BK
R20
WORK LIGHT
DRIVE LIGHT
4.7 K
C41RPM OR/BK
BK
TS1 TS17
START
ON GLOW
C132PLI BL/WH
TS4
WH
WH
C4-10
PUMP AUXILIARY
2 SEC
GENERATOR
3
PLUG
NO
HIGH RPM(FS)
P3
HORN H1 30A
ENGINE
L48
D39
C3P-9
U35
C1-1
L30 L30
C1-12
C2-4
C2-7
C1-7
C1-8
TB133 IS WAGO TERMINAL BLOCK 16
C2-5
C7-1
C4-4 GND
C1-2
C7-2
TB 134 IS WAGO TERMINAL BLOCK 42
CB2 D12
BK
TB134
BK
P1 RD TB132 C28TTA RD/BK
15AMP. RD
RD
C1-9
TB43 RD
1 3
4 KS1 TB22
C43HRN GR
RD
C45GEN GR/WH
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
P23BAT WH
PLAT
C21IGN WH
4 5
BK/RD
GRD
ON GLOW
2 SEC
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
6 NO
FUNCTION ENA.
LOAD
RD
10A
PLUG
RD
BK
MODULE 7 D4 D64
ENGINE
TB133 U34 TB45
BK
GBOX 12 8
GND TB27
D2 TB23 TB33 D14
CB1 D13
5 TB20 15AMP. 1 START RELAY 2
GR/BK
H6 2 TACHOMETER
D6 3 START INPUT
L45 TB34 TB9 TB35
TB28 4 AUX. ON IGN./START
TB24 5 GROUND MODULE
RD
6 BATTERY
7 KEY PWR. L2
CB3 8 KEY BYPASS U1
BK/RD
CR1 CR2 9 IGN./FUEL ON
20AMP. CR5 CR1
NO CR5 NO CR2 10 ENG. FAULT FUSE 10A
TB21 NO
FUSE 70A
BL/WH WH
6 FUSE 70A
WH
CR3
NO
C5-3
C5-2
C5-22
C21IGN2 WH
GR/WH-45
RD/BK-28
C5-5
OTS CR23
C5-13 WH
TB25 TB26 CR23
NO NO
D22 G2 G3
BK-43
OR/BK-41
CR4
BK
WH-21
NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
BK/RD
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1
C5-11
J144-6
J144-4
DC D52 NO CB7
RD
S7 NO 10A
7
RD
RD
+
FB
STA. G6
M1
C5-8
+ Y29
AUX STARTER
M2 PUMP HM G1 S2
BK
REGULATOR H2
FAN _ S1
IND. L29 L29
NO
-
NC C4B-9 C4B-11
BR
BR
BRN
VOLT METER
STARTER MOTOR
RELAY
SERVICE HORN
HOUR METER
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
TILT ALARM
OPTION
WORK LIGHTS
OPTION
DRIVE LIGHT
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
EMISSION CONTROL DEUTZ
AUXILIARY PUMP
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
SECOND GLOW PLUG OPTION
GLOW PLUG OPTION
NOTE:
8
(from serial number 9799 to serial number 10387)
September 2013
6 - 31
A
BR-2
GROUND
C41RPM OR/BK
C2-3
5
B
15
TS14
Y51
TB30
J1
DRE B BL/BK
C
7
TB32
RKOUT 5 BL/WH
Y3
DRIVE & STEERING
TB36
XOUT 3 BL/WH 4
J1
Y4
PWR 2 OR 13 17
GND 1 BR 14
11
C3-6 C6TRF WH/RD
Section 6 • Schematics
10
Y23
C4TRL WH
TURNTABLE ROTATE LEFT
Y29
C5TRR WH/BK
R4
TS62
7.5
TB5
E
Y13
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
GND 1 BR 12
PRIMARY BOOM DOWN
TB3
Y12
C1PBU RD
D30
6
C3-2 C2PBD RD/BK
7
C3-3 RD/BK
C3PBF RD/WH DESCENT ALARMN
8
6
SECONDARY BOOM UP/DN
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
C3-10
J1
D29
PWR 2 OR 9 12
Y53
G
GND 1 BR 10 C10SBU BL
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
TB11
BR
1
NO
NC
14 13
WH 22 21
H
43
TB13
2 OPERATION
3
P26ESTP BK
3
NO
NC
22 21
21
C2-2 C40LS1 OR BK PRIMARY BOOM
4 OPERATION
TB40
SJ1 WH
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
J
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
7
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
K
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
GR/BK-44 C2-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
L
DOWN
Y17
JIB BOOM
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
C19JSV GR/WH
M
CR13
TB19
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
6
N
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
Section 6 • Schematics September 2013
6 - 31
6 - 32
Section 6 • Schematics September 2013
6 - 34
6 - 33
Section 6 • Schematics September 2013
RD
BL/WH
C132PLI BK
RD/BK
TB41
C2-3
OR/BK OR/BK
2 D89 P26ESTP BK
BK
LS18A
P2 FS1
LS18 BK-(FS) RD-(FS) C9-3 P25FS RD
PBOX C9-1 BK
WH-(FS) C9-2 P24FS WH
GND D88
WH
RD
TS2
C134PWR OR/RD
TS6
P22BAT BK
R20
4.7 K
C41RPM OR/BK
TS17
START
ON GLOW
C132PLI BL/WH
GENERATOR
PLUG
NO
HIGH RPM(FS)
P3
HORN H1 30A
C4-10
ENGINE
L48
PUMP AUXILIARY
D39
BK
BK
U35
C1-12
C2-4
C2-7
C1-7
C1-8
TB133 IS WAGO TERMINAL BLOCK 16
C2-5
C7-1
GND
C4-4
C1-2
C1-1
C7-2
TB 134 IS WAGO TERMINAL BLOCK 42
CB2 TB134 D12
P1 RD TB132 C28TTA RD/BK
15AMP. RD
RD
C1-9
TB43 RD
4 KS1 TB22
1 3
C43HRN GR
RD
C45GEN GR/WH
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
P23BAT WH
PLAT
C21IGN WH
4 5
GRD
2 SEC
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
6 NO
LOAD
FUNCTION ENA.
10A
RD
SENSE
PLUG
RD
D3
MODULE
BK
7
ENGINE
D64
BR
TB133 D4 U34
TB45
BK
GBOX 12 8
GND TB27
D2 TB23 TB33 D14
D13
5 CB1
1 START RELAY 2
TB20 15AMP.
GR/BK
2 TACHOMETER TB35
H6 D6 3 START INPUT
L45 TB34
TB28 4 AUX. ON IGN./START
TB24 5 GROUND MODULE
RD
6 BATTERY
7 KEY PWR. L2
8 KEY BYPASS U1
BK/RD
CB3 CR45 CR1 CR2 9 IGN./FUEL ON
CR45 CR1
NO NO CR2 10 ENG. FAULT FUSE 10A
20AMP.
TB21 NO
FUSE 70A
CR3
CR5 NO
CR5
C5-3
C5-2
C5-22
NO C21IGN2 WH
GR/WH-45
RD-134
RD/BK-28
C5-5
OTS
C5-13 WH
CR23 CR23
TB25 TB26
NO NO
D22 G2 G3
BK-43
OR/BK-41
CR4
BK
WH-21 NO
RD-27
PR3
BK-33
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
BK/RD
C5-14 WH/RD
RD
WH
NO
C5-16 WH/BK
EXCT. PR1 3MF
PR1
C5-11
J144-6
J144-4
DC D52 NO CB7
7
RD
S7 NO 10A
RD
RD
+
FB
STA. G6
M1
C5-8
+ Y29
AUX STARTER
M2 PUMP HM G1 S2
BK
REGULATOR H2
FAN _ S1
IND. L29 L29
NO
-
NC C4B-9 C4B-11
BR
BR
BRN
WORK LIGHTS
VOLT METER
STARTER MOTOR
RELAY
SERVICE HORN
HOUR METER
WORK LIGHTS RELAY (OPTION)
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
OPTION
TILT ALARM
DRIVE LIGHT
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
EMISSION CONTROL DEUTZ
AUXILIARY PUMP
OPTION
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
SECOND GLOW PLUG OPTION
GLOW PLUG OPTION
NOTE:
8
September 2013
6 - 35
C7-3 BR-2
GROUND
A
C41RPM OR/BK
RETURN
C2-3
5
EDC
TB9
C3-9 C5-7
15
TS14
Y51
B
TB30
J1
Z-60/34
7
TB32
C1-3
20 MOTOR STROKE
6
TB37
DRIVE & STEERING
RKOUT 5 BL/WH
Y3
TB36
XOUT 3 BL/WH 4
J1
C36STC BL
Y4
C1-10 C36STC BL
PWR 2 OR 13 17 STEER CW
GND 1 BR 14
C3-6 C6TRF WH/RD
11
8
D
10
Y23
C4TRL WH
TURNTABLE ROTATE LEFT
Section 6 • Schematics
Y29
C5TRR WH/BK
R4
TS62
Y13
TURNTABLE ROTATE
PRI UP/DN & TT ROTATE
6 C6TRF WH/RD
5 FLOW CONTROL
TB6
TB1
5
E
Y22
YOUT 4 RD/WH
JC2
2
C1PBU RD
J1
Y12
FLOW CONTROL
C3-1 C1PBU RD
6
D30
C3-3 RD/BK
C3PBF RD/WH DESCENT ALARMN
8
SECONDARY BOOM UP/DN
6
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
J1
D29
C3-10
PWR 2 OR 9 12
Y53
GND 1 BR 10 C10SBU BL
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
TS60
TB11
Y14
BR
1
NO
NC
13
WH
22 21
JOYSTICK CONTROL CARD
SECONDARY BOOM
43
P24FS WH BK
2
TB13
OPERATION
3
H
P26ESTP BK
3
BK
14
OPERATION
TB40
SJ1 WH
NO
NC
22 21
13
BOOM RETRACTED
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
DRIVE
13
LS3
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
C3-8 C8PBR BK/WH
RETRACT
NOTE:
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
9
6
RETRACT
J
1.
BOOM
Y26
EXTEND C7PBE BK
WH
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
K
TB15
TB44
GR/BK-44 C2-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
DOWN
L
JIB BOOM
Y17
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
RIGHT
TB17
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
M
+
_
Y18
JIB VALVE
JIB TIME
JIB VALVE
CIRCUIT
CR14
DELAY
6
N
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
Section 6 • Schematics September 2013
6 - 35
6 - 36
Section 6 • Schematics September 2013
6 - 38
6 - 37
Section 6 • Schematics September 2013
1
VOLT METER OIL PRESSURE OIL TEMP
H6 U33
RD-H6+ - C23-1
RD-C23-1 BL/WH-38D - C23-3
PLATFORM LOAD
RD-42B
C23
BK-22C - C23-4
BK-C7-1 - C23-5
GN/BK-L45 RD-TS11 - C23-6
GN/BK-16A RD-TS14 - C23-7 G1 G2 G3
WHT-21A GN/BK-16B - C23-8
BRN-GROUND BR-GND - C23-12
BLK-22A
2 P2 WHT-23A
46 WH -5 WH-23A LIMIT SWITCH POWER
ENGINE WH -8
NC RD 42A
STARTER GR/WH-4 GR/WH-1 45 GENERATOR OPTION
C23-6
NC WH -7 44 BK -8 LIMIT SWITCH J1
KS1 WH -6 43 BK -7 LIMIT SWITCH J2
KEY OR/RD-1 42 RD H6
RD-4 RD KS1 C134PWR
SWITCH BRN-GROUND
OR/BK-E.H. OR/BK-1 41 OR/BK-ISM#2 PULSE PICKUP
B BK -6 OR-1 40 C40LS1 STOWED +
3 1 3 MFD WT/BK-25A WT/RD-26A
RD
TS58 TURNTABLE RD/WH-4 RD/WH-3 3 RD/WH S.P. PRIMARY BOOM F.C. R4 RESISTOR, 7.5 OHM, TURN. ROT. FUNC.
R4
JIB BOOM ROTATE RD/BK-4 RD/BK-3 2 RD/BK S.P. PRIMARY BOOM DOWN
RD-4 RD-3 1 RD S.P.
DRIVE LIGHT OPTION RELAY R5 RESISTOR, 5 OHM, TURN. AUX. FUNC.
PRIMARY BOOM UP
D3 G1 VOLT METER GAGE
WH/RD S.P. CABLE D C B A
#2 RD-CB3 SP G2 OIL PRESSURE GAGE
BK-CR1#86 START RELAY
1
CR23 G3 WATER TEMP. GAGE
OR/BK-41B TACHOMETER
6 TS56
GLOW PLUG
TS52
ENGINE START
TS57
GRN-17A BK-33D
2
START INPUT
3
H2 SERVICE HORN
RD-27B H3 TRAVEL BUZZER
PLATFORM AUXILIARY ONIGN./START
4 BK/RD-9B
ROTATE GRN/BLK-18A BR-GROUND GROUND5
MODULE H4 DESCENT BUZZER
RD-CR1#30 BATTERY
GRN/WHT-19A 6 CR1 IGN/START RELAY
WH-23B
TS59 KEY POWER
7
PLATFORM RD TO LIGHT CR2 IGN./POWER RELAY
KEY BYPASS
8
LEVEL WH-CR2#86 IGN./FUEL ON CR3 HIGH IDLE (RPM) CUTOUT RELAY
ORG/BLK-15A CABLE BL/WHT-L2-
9 RD-C4B-12
ORG-14A #3 ENGINE FAULT
10 CR4 RPM RELAY
WARNING SENDER BRN GND
TS55 CR5 SERVICE HORN RELAY
FUNCTION RD-S.P. (CB3)
ENABLE RD-24B
CR17 HYDRAULIC COOLER FAN RELAY
7 CB1 CB2
CB3
OIL COOLER/
CABLE
#4
WH-ISM#9
WH-H.C.
GR-1 CR CR18 CE PLATFORM LEVEL RELAY
OPTION, 20A RD-ISM#6 BK-22B RELAY
ENGINE, 15A CONTROL, 15A
LEGEND H6 PLATFORM OVERLOAD ALARM
CR1 CR2 CR17 CR5
BK-ISM#1 L45 PLATFORM OVERLOAD LED
87 V33 PLATFORM OVERLOAD MODULE
CR17 #30 BK-E.H. 87A LS1 (CABLE#6) PRIMARY BOOM STOWED LIMIT SWITCH
WH-21D RD-H.C. BK-4
RED-20C BR-GROUND LS2 (CABLE#5) DRIVE ENABLE LIMIT SWITCH
HYDRAULIC 86 85
BLK-33A COOLER
30
BK/RD-35B LS3 (CABLE#7) BOOM RETRACTED LIMIT SWITCH
BLK/RED-35A
LS4 (CABLE#8) SECONDARY BOOM STOWED LIMIT SWITCH
RD C23-7 CR4
CR3 (CABLE#1) TO PLATFORM C-BOX, TERMINAL 27-46
RED-20A
8 RED-20B 1 RPM FILTER ADDED AT SERIAL NUMBER 4461
(CABLE#2) TO PLATFORM C-BOX, TERMINAL 22-23
BK/WH-34A (CABLE#3) TO PLATFORM C-BOX, TERMINAL 1-19
RED-24A ENGINE BK/RD-E.H. (CABLE#4) TO FUNCTION MANIFOLD
HARNESS
GROUND STUD PR1 AUXILARY POWER RELAY
BR BR PR2 GLOW PLUG POWER RELAY
BK-H.C. + BR-H.C.
BR-2
1
RD-H6+ - C32-1 WH-21A G1 G2 G3
BL/WH-38D - C32-3
BK-22C - C32-4
U33 C32 BK-C7B-1 - C32-5 RD-C32-1
PLATFORM LOAD RD-TS51 - C32-6 RD-42B
RD-TS55 - C32-7 GR/BK-L45 H6
GR/BK-16B - C32-8 GR/BK-16A BR (GROUND)
BR - GND - C32-12 LOAD SENSE OPTION - TIMER RELAY LABEL DESCRIPTION
46 SPARE
GR/WH-4 GR/WH-C2B-7 45 GENERATOR OPTION WH/BK-25A P1 EMERGENCY STOP BUTTON
GR/BK-C2B-6 44 GR/BK-11B GR/BK S.P. JDALARM WH/RD-26A KS1 KEY SWITCH
GR-C2B-5 43 GR-CR5#86 HORN DEUTZ TS51 AUXILIARY SWITCH
2
RD-C23-6 WH-CR2#86
RD-4 OR/RD-C2B-4 42 RD H6 RD KS1
OR/BK-C5-2 OR/BK-C2B-3 41 OR/BK-ISM#2 BR- 3MF CAP
C134PWR ONLY WH-ISM#9 TS52 ENGINE START SWITCH
PULSE PICKUP KEY SWITCH
OR-4 OR-C2B-2 40 C40LS1 STOWED KS1 TS56 GLOW PLUG SWITCH
P1 TS51
BL/RD-C2B-1 39 BL/RD S.P. L.P./GAS B TS55 FUNCTION ENABLE SWITCH
RD-CB2 RD-TB134(A)C
BL/WH - C23-3 BL/WH-C1B-12 38 C132PLI 3MF NC 1
TS57 PLATFORM ROTATE SWITCH
RD
BL/BK-4 BL/BK-C1B-11 37 STEER LEFT 3
NC B1 TS58 JIB BOOM SWITCH
BL-4 BL-C1B-10 36 STEER RIGHT BR-GND
35 GND WH-23A 4 2 TS59 PLATFORM LEVEL SWITCH
BK/RD-C1B-9 BK/RD-CR3#30 BK/RD S.P. RPM RD-42A
BK/WH-C5-22 BK/WH-C1B-8 34 BK/WH S.P. GLOW PLUG TS60 SECONDARY BOOM UP/DOWN SWITCH
BK-C1B-7 33 BK-ISM#3 BK S.P. START BK-22A
BK-C3B-10 TS61 PRIMARY BOOM UP/DOWN SWITCH
32 WH/RD -4
WH/RD -C5-23
WH/BK -C5-20
WH/RD-C1B-6
WH/BK-C1B-5 31
BRAKE
E.D.C.-
RD-27A
TS62 TURNTABLE ROTATE SWITCH 3
WH -C5-21 WH-C1B-4 30 E.D.C.+ TS63 BOOM EXTEND/RETRACT SWITCH
GR/BK-H6- REPLACE WIRE WITH THIS WIRING DIAGRAM
RD/WH -C5-24 RD/WH-C1B-3 29 MOTOR SPEED
RD/BK -4 RD/BK-C1B-2 28 TILT ALARM
RD -4 RD-C1B-1 27 RD-ISM#4 RD S.P. AUXILIARY POWER WH-21A CB1 CIRCUIT BREAKER, ENGINE, 15A
WH/RD-C5-14 26 WH/RD S.P. OIL TEMP. SENDER CB2 CIRCUIT BREAKER, CONTROL, 15A
WH/BK-C5-16 25 WH/BK S.P. OIL PRESSURE SENDER HM CB3 CIRCUIT BREAKER, OPTION, 20A
24 RD-CR1#30 RD CB1 ENGINE POWER BR (GROUND) L2
L45 HM HOUR METER
WH-C7B-2 23 WH-ISM#7 WH S.P. KEYSWITCH POWER
BL/WH-4 BK - C23-4 22 BK-CR5#30 BK S.P. POWER TO PLATFORM BL/WH-ISM-10
WH-C5-3+C5-11 WH - H.C. 21 WH-CR2#87 WH-SP IGNITION POWER R4 RESISTOR, 7.5 OHM, TURN. ROT. FUNC.
WL
WH-C5-13
RD-4 (12V) RD-S.P.(CB3)
GR/WH-C4B-7
20
19
RD-S.P.(CB2) RD-S.P.(CB1)
GR/WH S.P.
12V BATTERY SUPPLY
JIB VALVE RD/WH-3A
R5 RESISTOR, 5 OHM, TURN. AUX. FUNC. 4
RD/BK-2A G1 VOLT METER GAGE
GR/BK-4 GR/BK-C4B-6 18 GR/BK S.P. PLATFORM ROTATE R
GR-4 GR-C4B-5 17 GR S.P. PLATFORM ROTATE L G2 OIL PRESSURE GAGE
BL/BK-11A
OR/RD-C4B-4 16 GR/BK C23-8 GR/BK-H6- C133PLT G3 WATER TEMP. GAGE
OR/BK-4 OR/BK-C4B-3 15 OR/BK S.P. PLATFORM LEVEL DOWN H2 SERVICE HORN
HC
BL/WH-4 BL/WH-C3B-12 12 BL/WH S.P. SECONDARY BOOM F.C. TS63 H4 DESCENT BUZZER
BL/WH-12A TS60 TS61
3 BR-GND STUD BL/BK-4 BL/BK-C3B-11 11 44B-GR/BK+2B-BL/BK BL/BK S.P. SECONDARY BOOM DOWN CR1 IGN/START RELAY
1 BK-C32-5 BL-4 BL-C3B-10 10 BL S.P. SECONDARY BOOM UP BK/WH-8A DRIVE LIGHT OPTION RELAY
C7B
5
RD/WH-4 RD/WH-C3B-3 3 RD/WH S.P. PRIMARY BOOM F.C. 87A CR17 HYDRAULIC COOLER FAN RELAY
19/18 CABLES
2 11B-RD/BK-4 86 85 BR-C4B-11
RD/BK-4 RD/BK-C3B-2 RD/BK S.P. PRIMARY BOOM DOWN BK-33A
(BK)
CR23
C2B
WH/BK-5A
C3B
BK-CR1#86 BK/RD-9B
1 START RELAY WH/RD-6A U33 PLATFORM OVERLOAD MODULE
OR/BK-41B WH-4A
2 TACHOMETER
BK-33B L2 CHECK ENGINE LED
3 START INPUT IGN./START 6
(BR)
RD-27B
C4B
4 AUX. ON MODULE R4
BR-GND. GROUND
5 7.5 C1B TO PLATFORM C-BOX, TERMINAL 27-38
RD-CR2#30 BATTERY
6
WH-23B KEY PWR. TS57 C2B TO PLATFORM C-BOX, TERMINAL 39-45
7 D14 CB1 CB2 HYDRAULIC OIL COOLER OPTION RELAY
FUNCTIONS
BK-C5-5
OR-14A BRN GND
WH-21B BK/RD-C5-8
CR5 GR-17A
87 86 BK-4 GR/WH-19A
85
87A GR/BK-18A
30 GR-43B
1
8
BK-22B DIODE D64 ADDED AT SERIAL NUMBER 9066
GROUND STUD
6 - 39
6 - 40
Section 6 • Schematics September 2013
6 - 42
6 - 41
Section 6 • Schematics September 2013
RD
BL/WH - C23-3 BL/WH-C1B-12 132 C132PLI 3
NC B1 TS58 JIB BOOM SWITCH
BL/BK-4 BL/BK-C1B-11 37 STEER LEFT BR-GND
BL-4 36 WH-23A 4 2 TS59 PLATFORM LEVEL SWITCH
BL-C1B-10 STEER RIGHT RD-42A
BK/RD-C1B-9 35 BK/RD-CR3#30 GR/WH 45B BK/RD S.P. RPM D4 TS60 SECONDARY BOOM UP/DOWN SWITCH
BK/WH-C5-22 BK/WH-C1B-8 34 BK/WH S.P. GLOW PLUG BK-22A
BK-C3B-10 TS61 PRIMARY BOOM UP/DOWN SWITCH
BK-C1B-7 33 BK-ISM#3 BK S.P. START RD-27A
WH/RD -C5-23 WH/RD-C1B-6 32 WH/RD -4 TS62 TURNTABLE ROTATE SWITCH
BRAKE
3 WH/BK -C5-20 WH/BK-C1B-5 31 E.D.C.- REPLACE WIRE WITH THIS WIRING DIAGRAM
TS63 BOOM EXTEND/RETRACT SWITCH
WH -C5-21 WH-C1B-4 30 GR/BK-H6-
E.D.C.+
RD/WH -C5-24 RD/WH-C1B-3 29 MOTOR SPEED
RD/BK -4 RD/BK-C1B-2 28 TILT ALARM WH-21A CB1 CIRCUIT BREAKER, ENGINE, 15A
RD -4 RD-C1B-1 27 RD-ISM#4 RD S.P. AUXILIARY POWER CB2 CIRCUIT BREAKER, CONTROL, 15A
WH/RD-C5-14 26 WH/RD S.P. OIL TEMP. SENDER HM CB3 CIRCUIT BREAKER, OPTION, 20A
WH/BK-C5-16 25 WH/BK S.P. OIL PRESSURE SENDER BR (GROUND) L2
L45 HM HOUR METER
RD-D.L.CR23#30 24 RD-CR1#30 RD CB1 ENGINE POWER
WH-C7B-2 23 WH-ISM#7 WH S.P. KEYSWITCH POWER BL/WH-ISM-10 DRIVE LIGHT OPTION RELAY
1 BL/WH-4 BK - C23-4 22 BK-CR5#30 BK S.P. POWER TO PLATFORM R4 RESISTOR, 7.5 OHM, TURN. ROT. FUNC.
WL
5
WH-4 WH-C3B-4 4 WH S.P. TURNTABLE ROTATE R CR17 HYDRAULIC COOLER FAN RELAY
19/18 CABLES
RD-H.C. CR23
C2B
D C B A WH/BK-5A 85 86
C3B
TACHOMETER
C4B
WH-23B BR GND
7 KEY PWR. C3B TO PLATFORM C-BOX, TERMINAL 1-12
8 KEY BYPASS
WH-CR2#86 TS55 C4B TO PLATFORM C-BOX, TERMINAL 13-19
9 IGN./FUEL ON
4
86 85 86 85 86 85 86 87A
87 87 87 87
OR-14A
BK-C5-5
GR-17A 30
WH-21B BK/RD-C5-8 GR/WH-19A
CR5
87 86 BK-4 GR/BK-18A RD-CB3 SP
85
87A
BR GND
30 GR-43B
8 BK-22B
WIRING
GROUND STUD HARNESS:
TO BASE
BR ALL BR WIRES
6 - 44
6 - 43
Section 6 • Schematics September 2013
P24FS WH
P26BAT BK
GR/BK L48
RED-TILT
P24FS WH
BRN
C29MS RD/WH
DRE B BL/BK
DRE A BL/WH
JC3-4,6 WH
JC3-5 BL
JC1-5 YEL
JC2-5 BK
JC2-4 RD
C13LED BL/RD
JC3-2 BRN
JC3-3 OR
JC2-2 BRN
JC2-3 OR
JC1-2 BRN
JC1-3 OR
ALC-500
3
J3
1
J1 J2
9 11
2 1 1
RD/BK L4
C27AUX RD C1P-1
C33STR BK C1P-7
P24FS WH C9P-2
P25FS RD C9P-3
P26BAT BK C9P-1
C7PBE BK C3P-7
C8PBR BK/WH C3P-8
C43 HRN GR C2P-5
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C17JU GR C4P-5
C18JD GR/BK C4P-6
C19JSV GR/WH JIB
P22BAT BK C7P-1
P23SWBAT WH C7P-2
C5TRR WH/BK C3P-5
C37STCC BL/BK C1P-11
C36STC BL C1P-10
C132PLI BK C1P-12
RD H1
RD P2
TS48-WL2 RD C2P-11
TS48-WL1 RD C2P-12
JDALARM GR/BK C2P-6
3 JC2
COMPONENT INDEX
BOOM PROPORTIONAL JOYSTICK:
PRIMARY UP/DN , TURNTABLE ROTATE
C28TTA RD/BK C1P-2 C1P
JC1 BOOM SECONDARY JOYSTICK:
C2P
JC3 DRIVE PROPORTIONAL JOYSTICK
D40
L1 DRIVE ENABLE LED C3P C3P
L4 C.E. PLATFORM LED
GR/BK C4P-4 C4P
L48 TILT ALARM LED
BRN
P2 EMERGENCY STOP BUTTON BATGND C7P-3 C7P
P3 HORN SWITCH
TS1 AUXILIARY SWITCH
TS2 START ENGINE SWITCH
D39
4 TS3 FUEL SELECT SWITCH (FORD EFI ONLY) RED-TILT
F.S.
RED/BLK-28
TS4 HI/L0 RPM SWITCH
TS6 GLOW PLUG OPTION
C2P(BK)
C3P(GR)
C4P(BR)
C1P(GY)
TS7 PLATFORM ROTATE SWITCH
TS8 JIB UP/DOWN SWITCH
TS9 PLATFORM LEVEL SWITCH C7P C9P LS18 OPT.
JIB
TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH
TS14 DRIVE SPEED SWITCH
TS15 DRIVE ENABLE SWITCH
H1
TS17 GENERATOR OPTION
TS48 WORK/DRIVE LIGHT ( OPTION )
TILT
ALARM 19/18 CONTROL CABLE 12V BATT F.S.
5
DETAIL A: LIFT/DRIVE OPTION
REPLACE WIRE WITH THIS WIRING DIAGRAM 1 10A FUSE ADDED AT SERIAL NUMBER 4496.
10 AMP FUSE 7
BRN BATGND TS48
WORK/DRIVE LIGHT
6
(GND STUD) TS15
7 7 DRIVE ENABLE
5
6 6
CR27 4
WH TS7
WH TS1
5 5
3
RD WL2
6 WH/RD C32BRK
4
BOOM
4
2
DLITE/ RD WL2
(SPLICE TO C32BRK) 3 EXTEND/ 3 JC3
1
RETRACT
2 2
+
JC2 JC1
CR30 1 1
L48
TS13
CR13 L1
WH-24
+
L4
CP2-2 OR R40LS1
RD WL1
BL/RD-DE3 J1-16
BL/BK-DE2 J1-7
BL/WH-DE1 J1-6
(SPLICE TO R40LS1)
BRN J1-14
BRN J1-10
BRN J1-12
GR/BK H1
RD/BK H1
BK/WH-8
OR J1-13
YEL J1-3
OR J1-11
WH J1-5
WH J1-5
OR J1-9
WH-JIB
BK J1-2
RD J1-1
BL J1-4
WH-24
BK-22
BK-7
BRN
RD-P2
WH-24
GR/WH-45
WH-24
BK/RD-35
GR/WH-45
P26BAT BK C9P-1
P22BAT BK C7P-1
RD L48
BK-33
RD-25
GR-43
OR-14
RD LS18
RD L4
WH-24
BK/RD-35
WH-23
OR/BK-15
WH-24
WH-JIB
C27AUX RD C1P-1
C19JSV GR/WH
C17JU GR C4P-5
C18JD GR/BK C4P-6
REMOVE FOR
GENERATOR OPTION
D12
CE SEE DETAIL A D12
8 TS4
TS4
NC
1
2
TS2 TS9 TS7 WH TS1 RD
TS14 TS2 1
HIGH/LOW GR TS8
NC
DRIVE HIGH/LOW
NO
RPM
3
4
SPEED RPM
1
WH
NC
START
RD TS6 START
1
GENERATOR WH HIGH/LOW RD
HORN JIB AUXILIARY GLOW PLUG GENERATOR P2
NOTE: (OPTION) PLATFORM PLATFORM
P3 PUMP NOTE: (OPTION) EMERGENCY STOP
DASHED LINES INDICATE OPTION WIRES TS17 LEVEL ROTATE
GR/BK DASHED LINES INDICATE OPTION WIRES TS17
8
September 2013
6 - 45
A
RD L48
EMERGENCY STOP
RD LS18
1 1 1
P22BAT BK C7P-1
B
NC NC
P2
Z-60/34
6
RD-P2
DRIVE/STEER
C
RD P2
RD H1
LS18
GENERATOR
GR/WH-45
(OPTION)
C132PLI BK C1P-12
TS17
+
+
L48
L4
P23SWBAT WH C7P-2
P22BAT BK C7P-1
D12
C17JU GR C4P-5
D
GR/BK H1
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
RD
P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
DRIVE LT BK/RD C3P-9
NOTE:
C3P
TS2
TS48-WL1 RD C2P-12
Part No. 75861
BK-33
F.S.
TS48-WL2 RD C2P-11
E
P26BAT BK
RD
+
L1
TS15
GLOW PLUG
11
BK-22
TS6
HIGH/LOW
1
10 AMP FUSE
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C4P
C4P(BR)
ALC-500
C4TRL WH C3P-4
TS1
WH
WH-JIB
C3P
WH-JIB
C134PWR RD C2P-4 JDALARM GR/BK-44 C3P-9
C3P(GR)
C35RPM BK/RD C1P-9
BRN TS8
G
JIB
C2P
C33STR BK C1P-7
19/18 CONTROL CABLE
GR/BK
C2P(BK)
EXTEND/
RETRACT
WH
GR
BK-7
BOOM
C1P
TS13
J1
PLATFORM
9
WORK/DRIVE LIGHT
JC1-3 OR WH-24
ROTATE
C17JU GR C4P-5
JC2-4 RD RD WL2
JC1-2 BRN C19JSV GR/WH
C1P(GY) RD WL1
D27
JC2-5 BK
TS48
TS7
JC2-2 BRN
C18JD GR/BK C4P-6
JC3-5 BL J1-11 OR JC2-2
JC2
WH
JC3-3 OR J1-12 BR JC2-1
H
JC3-4,6 WH
JC3-2 BRN
C28TTA RD/BK C1P-2
PLATFORM
C28TTA RD/BK C1P-2
6
DRE A BL/WH
TS9
LEVEL
OR-14
DRE B BL/BK
BATGND C7P-3
C13LED BL/RD
GR/BK C4P-4
C29MS RD/WH
TURNTABLE ROTATE
OR/BK-15
RD L4 3
D40
HORN
GR-43 NO
P3
H1
RED/BLK-28 4
D39
ALARM
GR/BK L48
I
TILT
RED-TILT RED-TILT
BRN
J
BRN BATGND
(GND STUD)
WH TS1
REPLACE WIRE WITH THIS WIRING DIAGRAM
PRIMARY BOOM EXTEND/RETRACT SWITCH
FUEL SELECT SWITCH (FORD EFI ONLY)
PRIMARY UP/DN , TURNTABLE ROTATE
BOOM PROPORTIONAL JOYSTICK:
CR27
CR30
DETAIL A: LIFT/DRIVE OPTION
PLATFORM ROTATE SWITCH
EMERGENCY STOP BUTTON
GENERATOR OPTION
GLOW PLUG OPTION
COMPONENT INDEX
AUXILIARY SWITCH
HORN SWITCH
(SPLICE TO C32BRK)
(SPLICE TO R40LS1)
TILT ALARM
CP2-2 OR R40LS1
WH/RD C32BRK
WH TS7
CR14
TS13
TS15
TS48
TS17
TS14
JC1
TS6
TS1
TS2
TS3
TS4
TS7
TS8
TS9
JC2
JC1
JC3
L48
C1
P3
P2
L1
L4
L
M
N
Section 6 • Schematics September 2013
6 - 45
6 - 46
Section 6 • Schematics September 2013
6 - 48
6 - 47
N
M
L
WH
C19JSV GR/WH TS7
C19JSV GR/WH C4P-7 RD L48
BR BK
BR JC3
EMERGENCY STOP
CR13-#86 GR/WH BR
NC NC
P2
GR/WH
P134PWR RD
Jc3
BR -
JIB
OPT.
GR/WH RD
6
RD-P2
DRIVE/STEER
J
GENERATOR
LS18
GR/WH-45
(OPTION)
TS17
BK C1P-12
+
+
L48
L4
P23SWBAT WH C7P-2
P22BAT BK C7P-1
D12
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
I
TS4
GR/BK H1
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
RD
NOTE:
C3P
TS48-WL1 RD C2P-12
BK-33
F.S.
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1 RD-25
START
H
P26BAT BK
RD
+
L1
TS15
GLOW PLUG
11
BK-22
TS6
C10SBU BL C3P-10 BL/BK-DE2 J1-7
C13DRE BL/RD C4P-1
12V BATT
HIGH/LOW
C12SBF BL/WH C3P-12
TS14
C41RPM OR/BK C2P-3 J1-9 OR JC1-2
P24FS WH
C30EDC+ WH C1P-4 WH-24
Jc1
C7P
DRIVE
SPEED
6
1
10 AMP FUSE
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C4P
AUXILIARY
C5TRR WH/BK C3P-5
PUMP
C4P(BR)
ALC-500
C4TRL WH C3P-4
TS1
C29MS RD/WH C1P-3
UP/DOWN
J2
WH
WH-JIB
C3P
WH-JIB
C134PWR RD C2P-4 JDALARM GR/BK-44 C3P-9
C3P(GR)
C35RPM BK/RD C1P-9
BRN
TS8
C34SA BK/WH C1P-8
CE SEE DETAIL A
CR13
JIB
C2P
C33STR BK C1P-7
19/18 CONTROL CABLE
F
GR/BK
C2P(BK)
EXTEND/
RETRACT
WH
GR
BK-7
BOOM
C1P
TS13
J1
PLATFORM
9
WORK/DRIVE LIGHT
JC1-3 OR WH-24
ROTATE
C17JU GR C4P-5
JC2-4 RD RD WL2
JC1-2 BRN C19JSV GR/WH
September 2013
D27
JC2-5 BK
TS48
JC2-3 OR C19JSV GR/WH JIB
J1-2 RD/WH JC2-4
JC1-5 YEL J1-1 WH/RD JC2-3
TS7
JC2-2 BRN
C18JD GR/BK C4P-6
JC3-5 BL J1-11 OR JC2-2
JC2
WH
JC3-3 OR J1-12 BR JC2-1
JC3-4,6 WH
JC3-2 BRN
E
PLATFORM
C28TTA RD/BK C1P-2
1
DRE A BL/WH
TS9
LEVEL
OR-14
DRE B BL/BK
BATGND C7P-3
C13LED BL/RD
GR/BK C4P-4
C29MS RD/WH
TURNTABLE ROTATE
OR/BK-15
RD L4 3
D40
HORN
NO
(from serial number 9066 to serial number 9696)
GR-43
P3
H1
RED/BLK-28 4
D39
Diesel Platform Control Box Wiring Diagram
ALARM
GR/BK L48
TILT
D
RED-TILT RED-TILT
BRN
C
BRN BATGND
(GND STUD)
WH TS1
PRIMARY BOOM EXTEND/RETRACT SWITCH
Z-60/34
FUEL SELECT SWITCH (FORD EFI ONLY)
PRIMARY UP/DN , TURNTABLE ROTATE
BOOM PROPORTIONAL JOYSTICK:
GENERATOR OPTION
GLOW PLUG OPTION
COMPONENT INDEX
AUXILIARY SWITCH
CR27
CR30
JIB DELAY RELAY
HORN SWITCH
B
TILT ALARM
(SPLICE TO C32BRK)
(SPLICE TO R40LS1)
CP2-2 OR R40LS1
WH/RD C32BRK
CR14
TS13
TS15
TS48
TS17
TS14
TS6
JC1
TS1
TS2
TS3
TS4
TS7
TS8
TS9
JC2
JC1
JC3
L48
Section 6 • Schematics
C1
P3
P2
L1
L4
WH TS7
A
6 - 48
1
8
(from serial number 9697)
Diesel Platform Control Box Wiring Diagram
8
September 2013
6 - 49
A
WH
PBOX WIRING
BR GND RD RD LS18
B
RD-E-STOP 1 1 1
P134PWR RD-H1+ P22BAT BK C7P-1
GR/WH
CR13-#86 GR/WH BR
NC NC
P2
GR/WH
JC3
P134PWR RD
BR -
Z-60/34
JIB
OPT.
GR/WH RD
6
R20
P134PWR RD RD-P2
4700
LOAD SENSE OPTION
C
RD-H1+
DRIVE/STEER
U35
COM
GENERATOR
LS18
NO
GR/WH-45
(OPTION)
2
5
3
D88
TS17
+
+
L48
L4
P23SWBAT WH C7P-2
P22BAT BK C7P-1
D12
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
TS4
GR/BK H1
C43 HRN GR C2P-5
Section 6 • Schematics
TS2
TS48-WL1 RD C2P-12
E
BK-33
F.S.
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1 RD-25
START
P26BAT BK
RD
+
L1
TS15
GLOW PLUG
11
BK-22
TS6
HIGH/LOW
1
10 AMP FUSE
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C4P
C4TRL WH C3P-4
TS1
WH-JIB WH
C3P
WH-JIB
C134PWR RD C2P-4 JDALARM GR/BK-44 C3P-9
C3P(GR)
G
TS8
C34SA BK/WH C1P-8
CE SEE DETAIL A
CR13
JIB
C2P
C33STR BK C1P-7
19/18 CONTROL CABLE
GR/BK
C2P(BK)
EXTEND/
RETRACT
WH
GR
BK-7
BOOM
C1P
TS13
J1
PLATFORM
9
WORK/DRIVE LIGHT
JC1-3 OR WH-24
ROTATE
C17JU GR C4P-5
JC2-4 RD RD WL2
JC1-2 BRN C19JSV GR/WH
C1P(GY) RD WL1
D27
JC2-5 BK
TS48
TS7
JC2-2 BRN
C18JD GR/BK C4P-6
H
WH
1
PLATFORM
C28TTA RD/BK C1P-2
6
DRE A BL/WH
TS9
LEVEL
OR-14
DRE B BL/BK
BATGND C7P-3
C13LED BL/RD
GR/BK C4P-4
C29MS RD/WH
TURNTABLE ROTATE
OR/BK-15
RD L4 3
D40
HORN
GR-43 NO
P3
H1
RED/BLK-28 4
I
D39
ALARM
GR/BK L48
TILT
RED-TILT RED-TILT
BRN
BRN BATGND
(GND STUD)
BOOM PROPORTIONAL JOYSTICK:
WH TS1
PLATFORM ROTATE SWITCH
EMERGENCY STOP BUTTON
GENERATOR OPTION
GLOW PLUG OPTION
COMPONENT INDEX
AUXILIARY SWITCH
HORN SWITCH
TILT ALARM
K
CR27
CR30
DETAIL A: LIFT/DRIVE OPTION
1
CR14
TS13
TS15
TS48
TS17
TS14
JC1
TS6
TS1
TS2
TS3
TS4
TS7
TS8
TS9
JC2
JC1
JC3
L48
C1
P3
P2
L1
L4
(SPLICE TO C32BRK)
(SPLICE TO R40LS1)
WH/RD C32BRK
CP2-2 OR R40LS1
WH TS7
L
M
N
Section 6 • Schematics September 2013
6 - 48
6 - 50
Section 6 • Schematics September 2013
6 - 52
6 - 51
Section 6 • Schematics September 2013
December 2011
P26ESTP BK BK
P2 FS1 RD-(FS)
BK-(FS) C9-3 P25FS RD
C9-1 BK
WH-(FS) C9-2 P24FS WH WH
2 RD C28TTA RD/BK
TS2
C134PWR OR/RD
P22BAT BK
SEE NOTE 2
GENERATOR
TS17
C41RPM OR/BK
L4 TS4
TS3
H1 L48 TS1
P3
HIGH RPM(FS)
HORN D39
TB 132 IS WAGO TERMINAL BLOCK 38
C1-7
TB 133 IS WAGO TERMINAL BLOCK 16 D40 SEE NOTE 2
C2-7
C2-1
TB 134 IS WAGO TERMINAL BLOCK 42
C2-4
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
3 RD
CB2 P1
TB134
C1-9
RD
15AMP. RD RD
RD
TB43
TS51
C35ESPD BK/RD
KS1 TB22 TS52 TS55
C45GEN GR/WH
C27AUX RD
C133PLA OR/RD
C28TTA RD/BK
P23BAT WH
TS53
C33STR BK
PLAT
FUNCTION ENA.
LOW RPM
HIGH RPM
START
GRD TB39
RD
ENGINE
C43HRN GR
BK
4
TB27
TB33
TEST
RUN
8 KEY BYPASS
CB3 CR5 9 IGN./FUEL ON
CR1 CR2 10 ENG. FAULT
NO CR1
5 20AMP.
CR5 NO NO
CR2
TB21
P24BAT
GR/WH-45
OTS
RD-23
RD/BK-28
NO TB24
TB25
C35RPM2
C211GN2
G2 TB26 G3
BK-43
C38ESL
OR/BK-41
RD-27
BK-33
WH-21
C39LP
TSW
6 ALTERNATOR CR17 CR17
NO
RD
WH
EXCT. PR1
WH/BK
WH-24
WH-24
WH/RD
PR1
NO
STA.
PUMP
RD (FEH 361A)
M1 + OPS S2 S1 OTS
AUX Y29
M2 PUMP HM G1 NO
H2
BK
REGULATOR STARTER
- IND.
FAN _ NC
BRN
7 BRN
(OPTION)
TEMP. SWITCH
HYDRAULIC OIL
STARTER MOTOR
RELAY
IGN./START RELAY
GENERATOR
SERVICE HORN
RELAY
SWITCH
COOLING FAN
FUEL PUMP
OPTION
HOUR METER
SWITCH
LEVEL SENSOR
FLASHING BEACONS
TILT ALARM
OIL PRESSURE
FUEL RELAY
OPTION
WATER TEMP
VOLT METER
AUXILIARY POWER
AUXILIARY PUMP
FORD
ENGINE
HARNESS
LOCKOUT
LPG
SOLENOID
FORD
42 PIN PLUG
8
NOTE:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
IN THE STOWED POSITION AND KEYSWITCH "OFF".
8
September 2013
6 - 53
BRN-2
GROUND
C41RPM OR/BK
A
C2P-3
5
15
TB30
Y51
L1
J1
H3
TS15
Z-60/34
7 20
DRIVE & STEERING
RKOUT 6 WH 5
C
TB37
YOUT 5 BL 4
Y3
JC3
4 18 STEER RIGHT
PWR 3 OR 13
Y4
1
C3P-6 C6TRF WH/RD
11
C3P-5 C5TRR WH/BK
9
D
C3P-4 C4TRL WH
Y23
10
C4TRL WH
TURNTABLE ROTATE LEFT
TB4
Y29
5 R5
C5TRR WH/BK
TS62
TB5
PRI UP/DN & TT ROTATE
Y13
TB1
YOUT 5 BK
7.5
Y22
2
JC2
XOUT 4 RD C1PBU RD
Part No. 75861
1 PRIMARY BOOM UP
J1
E
TB2
Y12
C6-19 RD/BK
F
14
7
Y53
C3P-11
6 13 C105BU BL
SECONDARY BOOM UP
OUT 5 YEL 3 C3P-10
JC1
Y52
12
4
J1
1 SECONDARY BOOM
FLOW CONTROL
TB11
G
TB12
BRN
NCHO
1 CABLE #6 WH
JOYSTICK CONTROL CARD
SECONDARY BOOM
TB13
P24FS WH
2 BK OPERATION
J3
4 3
P26ESTP BK
H
3
NCHO
CABLE #7 WH
C2P-2 C40LS1 OR C40LS1 OR PRIMARY BOOM
4 BK OPERATION
TB40
CABLE #7
TB44
NOHC
CABLE #8 WH
BOOM RETRACTED
TB46
C46PWR WH BK OPERATION
CR30
CR27
CE NO
NC
I
OPTION
NOHC
WH
DRIVE
LS3
LIFT/
TB46
C46PWR WH BK DRIVE ENABLE
C3P-8 C8PBR BK/WH
RETRACT
BOOM
TS13
EXTEND C7PBE BK
Y25
C3P-7
TS63
C8PBR BK/WH
BOOM RETRACT
RETRACT
TB8
Y26
BOOM
J
WH
Y19 Y20
C4P-3
TS59
C14PLU OR
PLAT LEVEL UP
TB14
UP PLATFORM LEVEL
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
K
TB44
GR/BK-44 C2P-6 JDALARM GR/BK
CR13
NC
C4P-5 C17JU GR
Y16
C18JD GR/BK
TS58
PLATFORM ROTATE RIGHT / JIB DOWN
TB18
DOWN
Y17
JIB BOOM
L
UP C17JU GR
PLATFORM ROTATE LEFT / JIB UP
TS57
TB17
RIGHT
PLAT ROTATE RIGHT
LEFT PLAT ROTATE
TS7
LEFT
WH
AMP
7
6
5
3
4
2
1
C4P-7
C19JSV GR/WH
C19JSV GR/WH
RKOUT
XOUT
YOUT
PWR
GND
Y18
BRN
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
JIB VALVES JIB VALVES
Deutsch
3
1
2
N
RD/BK
OR/BK
5
6
BRN
WH
RD
RD
BK
Section 6 • Schematics September 2013
6 - 53
6 - 54
Section 6 • Schematics September 2013
6 - 56
6 - 55
N
BRN
RD
RD
WH
BL/WH
BK
RD/BK
OR/BK
LOW RPM
M
FUNCTION ENA.
HIGH RPM
TS4
TB35
TS17
TB45
Y29
L29
RD DRIVE LIGHT
TS49
WH C4B-12 OPTION
PBOX GND
L29
BK
L30
RD WORK LIGHTS
K
FUSE 10A
C4B-11 OPTION
CR23
NO
WH BK
L30
F18
RD (FEH 361A)
HARNESS
LPG
ENGINE
FORD
LOCKOUT
DGRN (FEH 242) SOLENOID
J
G1
VOLT METER
WH-21
HM
HOUR METER
+
G6
_
G3
TB26
C5-14 WH/RD
OTS
L2
OPS
TB25
C5-16 WH/BK
C1-7 C33STR BK
TS2
G2
TS52
H
TS22
CR1
ENGINE
START
BK
TB33
CR1
NO
42 PIN PLUG
C5-9 C35RPM BK/RD PIN 23
G
CR2
BK PIN 15
NO
C5-5 R33STR
FORD
TB21
C2-1 BR PIN34
TB41
TB24
C5-8 R21IGN
TB39
WH PIN 24
TS3
VBATT RD PIN 9
3
CR39
BL/WH PIN 5
P24FS WH
P25FS RD
P26ESTP BK
PUMP
FUEL
FUEL PUMP
C5-11 VSW WH PIN 1
C9-3
C9-2
BK-33
PR2
TB27
TS1
STARTER
STARTER MOTOR
PR2
E
NO
RD
FS1
BK-(FS)
PR1
PUMP
NOTE:
AUXILIARY PUMP
AUX
C9-1 BK
PR1
NO
3
C7-2 P23BAT WH
TB23
P2
L48
TB28
D
S7
RD/BK-28 WH TILT ALARM
M2
C1-2 C28TTA RD/BK
D40
RD-23 RD BK BRN
LEVEL SENSOR
(from serial number 4546 to serial number 5715)
FLASHING BEACONS
FB
OPTION
Ford Electrical Schematic - View 1
CR5
HORN
P3
C2-5 C43HRN GR SERVICE HORN
C
RELAY
CR5
NO
RD
TB43
BK-43
SERVICE HORN
Z-60/34
H2
P22BAT BK C7-1
CR17
OTS
NO
C134PWR OR/RD C2-4
HYDRAULIC OIL
TEMP. SWITCH
CR17
NO
M1
COOLING FAN
FAN
TB134
(OPTION)
RD
C41RPM OR/BK
B
TB22
EXCT.
STA.
BAT.
IND.
-
Section 6 • Schematics
PLAT
GRD
ALTERNATOR
OHM
RD
REGULATOR
510
KS1
RD
20AMP.
15AMP.
A
BAT.
+
CB3
CB1
P1
RD
TB20
-
15AMP.
CB2
12 V
DC
RD
6 - 56
1
8
Ford Electrical Schematic - View 2
(from serial number 4546 to serial number 5715)
8
September 2013
6 - 57
A
BRN
GROUND
C41RPM OR/BK
B
C2P-3
5
15
TS14
LO
TB31 TB30
Z-60/34
Y51
DRIVE MODE
C1P-4 C30EDC+ WH C5-21 C30EDC+ WH
HI
J1
H3
TS15
DRIVE ENABLE
Y2
Y3
RKOUT 6 WH 5
D
Y4
XOUT 4
J1
PWR 3 OR 13
C3P-6 C6TRF WH/RD
GND 2 BRN 14 11
Section 6 • Schematics
1 C5TRR WH/BK
9 C3P-5
C3P-4 C4TRL WH
TB4
10
Y23
C4TRL WH
LEFT TURNTABLE ROTATE CW
TTROTATE
Y29
7.5
TB5
Y13
PRI UP/DN & TT ROTATE
7 TURNTABLE ROTATE
C6TRF WH/RD
6 FLOW CONTROL
TB6
R5
YOUT 5 BK 2
TB1
Y22
5
JC2
XOUT 4 RD 1 C1PBU RD
PRIMARY BOOM UP
J1
OR UP
TB2
GND 2 BRN 12
J2
Y12
FLOW CONTROL
C3P-1 C1PBU RD
6
C3P-2 C2PBD RD/BK
7
RD/BK
SECONDARY BOOM UP/DN
6 C3P-12
14
OUT 5 YEL 3 C3P-11
JC1
4 13
J1
PWR 3 OR 9 C3P-10
12
G
Y53
SECONDARY BOOM
Y52
BRN
JOYSTICK CONTROL CARD
1 WH
H
NCHO
2 BK OPERATION
P24FS WH C13DRE BL/RD
J3
C4P-1
SJ2 WH
4 3
P26ESTP BK 3 WH
NCHO
C2P-2 C40LS1 OR PRIMARY BOOM
4 OPERATION
TB40
BK
SJ1 WH
NOHC
BOOM RETRACTED
I
BK OPERATION
CR30
CR27
NO
NC
OPTION
WH
DRIVE
NOHC
LIFT/
LS3
CE
NOTE:
C3P-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
J
TB8
C3P-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
RETRACT
BOOM
Y26
EXTEND
WH
TB7
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TB14
TS9
Y20
C4P-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
Y19
PLATFORM LEVEL
K
TB15
GR/BK TB44
C2P-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
C4P-5
TB18
UP C17JU GR
TS8
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
L
DOWN
JIB BOOM
Y17
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
RIGHT
TS57
TB17
PLAT ROTATE RIGHT
LEFT
PLAT ROTATE
TS7
LEFT
WH
C4P-7
C19JSV GR/WH
TB19
M
C19JSV GR/WH
CR13
Y18
BRN
JIB VALVE
JIB VALVE
N
BL/WH
RD/BK
OR/BK
BRN
RD
RD
WH
BK
Section 6 • Schematics September 2013
6 - 57
6 - 58
Section 6 • Schematics September 2013
6 - 60
6 - 59
N
BRN
RD
RD
WH
BL/WH
BK
RD/BK
OR/BK
LOW RPM
FUNCTION ENA.
M
HIGH RPM
TS4
TB35
TS17
TB45
Y29
L29
RD DRIVE LIGHT
TS49
WH C4B-12 OPTION
PBOX GND
L29
BK
L30
RD WORK LIGHTS
K
FUSE 10A
C4B-11 OPTION
CR23
NO
WH BK
FUSE 10A
L30
F18
RD (FEH 361A)
HARNESS
LPG
ENGINE
FORD
LOCKOUT
DGRN (FEH 242) SOLENOID
J
G1
VOLT METER
WH-21
HM
HOUR METER
+
G6
_
G3
TB26
C5-14 WH/RD
OTS
L2
OPS
TB25
C5-16 WH/BK
C1-7 C33STR BK
TS2
G2
TS52
H
TS22
CR1
ENGINE
START
BK
TB33
CR1
NO
42 PIN PLUG
C5-9 C35RPM BK/RD PIN 23
G
CR2
BK PIN 15
NO
C5-5 R33STR
FORD
TB21
C2-1 BR PIN34
TB41
TB24
C5-8 R21IGN
TB39
WH PIN 24
TS3
VBATT RD PIN 9
CR39
BL/WH PIN 5
P24FS WH
P25FS RD
P26ESTP BK
C28TTA RD/BK
PUMP
FUEL
FUEL PUMP
F
C33STR BK PIN 13
CR39
NC
TS51
START RELAY
September 2013
BK-33
PR2
TB27
TS1
STARTER
STARTER MOTOR
PR2
NO
E
RD
FS1
BK-(FS)
PR1
PUMP
AUXILIARY PUMP
AUX
C9-1 BK
PR1
NO
C7-2 P23BAT WH
TB23
P2
L48
TB28
S7
TILT ALARM
D
RD/BK-28 WH
M2
C1-2 C28TTA RD/BK
D40
RD-23 RD BK BRN
LEVEL SENSOR
(from serial number 5716 to serial number 6315)
FLASHING BEACONS
FB
OPTION
Ford Electrical Schematic - View 1
CR5
HORN
P3
C2-5 C43HRN GR SERVICE HORN
RELAY
CR5
C
NO
RD
TB43
BK-43
SERVICE HORN
H2
P22BAT BK C7-1
Z-60/34
CR17
OTS
NO
C134PWR OR/RD C2-4
HYDRAULIC OIL
TEMP. SWITCH
CR17
NO
M1
COOLING FAN
FAN
TB134
(OPTION)
RD
C41RPM OR/BK
B
TB22
EXCT.
STA.
BAT.
IND.
-
PLAT
GRD
Section 6 • Schematics
ALTERNATOR
OHM
RD
REGULATOR
510
KS1
RD
20AMP.
15AMP.
BAT.
+
CB3
CB1
P1
A
RD
TB20
-
15AMP.
CB2
12 V
DC
RD
6 - 60
1
8
Ford Electrical Schematic - View 2
(from serial number 5716 to serial number 6315)
8
September 2013
6 - 61
A
BRN
GROUND
C41RPM OR/BK
C2P-3
B
5
15
TS14
LO
TB31 TB30
Y51
DRIVE MODE
Z-60/34
J1
H3
TS15
DRIVE ENABLE
Y2
Y3
RKOUT 6 WH 5
Y4
D
XOUT 4
J1
PWR 3 OR 13
C3P-6 C6TRF WH/RD
GND 2 BRN 14 11
Section 6 • Schematics
1 C5TRR WH/BK
9 C3P-5
C3P-4 C4TRL WH
TB4
10
Y23
C4TRL WH
LEFT TURNTABLE ROTATE CW
TTROTATE
Y29
TB5
Y13
PRI UP/DN & TT ROTATE
7 TURNTABLE ROTATE
C6TRF WH/RD
6 FLOW CONTROL
TB6
R5
YOUT 5 BK 2
TB1
Y22
5
JC2
XOUT 4 RD 1 C1PBU RD
PRIMARY BOOM UP
J1
OR UP
TB2
GND 2 BRN 12
J2
Y12
C3P-1 C1PBU RD
6
C3P-2 C2PBD RD/BK
7
RD/BK
SECONDARY BOOM UP/DN
6 C3P-12
14
OUT 5 YEL 3 C3P-11
JC1
4 13
J1
PWR 3 OR 9 C3P-10
12
Y53
G
SECONDARY BOOM
Y52
BRN
JOYSTICK CONTROL CARD
1 WH NCHO
P24FS WH
TB13
2 BK OPERATION
P24FS WH C13DRE BL/RD
J3
C4P-1
SJ2 WH
4 3
P26ESTP BK 3 WH
NCHO
C2P-2 C40LS1 OR PRIMARY BOOM
4 OPERATION
TB40
BK
SJ1 WH
NOHC
BOOM RETRACTED
BK OPERATION
I
CR30
CR27
NO
NC
OPTION
WH
DRIVE
NOHC
LIFT/
LS3
CE
NOTE:
C3P-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3P-7
Y25
J
C8PBR BK/WH
TS63
BOOM RETRACT
RETRACT
BOOM
Y26
EXTEND
WH
TB7
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TB14
TS9
Y20
C4P-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
Y19
PLATFORM LEVEL
DOWN C15PLD OR/BK
K
TB15
GR/BK TB44
C2P-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
C4P-5
TB18
UP C17JU GR
TS8
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
DOWN
L
JIB BOOM
Y17
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
RIGHT
TS57
TB17
PLAT ROTATE RIGHT
LEFT
PLAT ROTATE
TS7
LEFT
WH
C4P-7
C19JSV GR/WH
TB19
C19JSV GR/WH
CR13
M
Y18
BRN
JIB VALVE
JIB VALVE
BL/WH
RD/BK
OR/BK
N
BRN
RD
RD
WH
BK
Section 6 • Schematics September 2013
6 - 61
6 - 62
Section 6 • Schematics September 2013
6 - 64
6 - 63
N
BL/WH
BRN
RD
RD
WH
RD/BK
OR/BK
BK
TS55
LOW RPM
FUNCTION ENA.
M
HIGH RPM
TB35
TS17
TB45
Y29
CR23
DRIVELIGHT
TB9
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
TS48
WH BK
L29
PBOX GND
RD WORK LIGHTS
WORKLIGHT
FUSE 10A
C4B-10 OPTION
CR23
FUSE 10A
C4-9
NO
K
WH BK
F18
L30
G1
VOLT METER
J
R21IGN WH
HM
HOUR METER
G6
+
_ OPS
TB25
C5-16 WH/BK
G2
TB33
CR1
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START GY/RD
A
GY/YL
B
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
DIAGNOSTIC
CR1
NO
D BK/BL
H
RD/GN
TS22
LPG LOCKOUT
WH/BK
C5-14
C2-1
G
P25FS RD
C28TTA RD/BK
TB24
CR39
WH-(FS)
C135RET BL PIN 18
TS1
PUMP
FUEL
RD-(FS)
TS51
AUXILIARY
PUMP AUXILIARY C5-11 VSW WH PIN 1
PUMP
NOTE:
CR39
C9-3
C9-2
NC
September 2013
L2
RD
FS1
1K
R2
C1-1 C27AUX RD RD AUXILIARY POWER
E
C9-1
RELAY
PR1
PUMP
AUXILIARY PUMP
BK-(FS)
PR1
TB23
NO
C7-2 P23BAT WH
P2
TB28
L48
M2
C1-2 C28TTA RD/BK
S7
RD RD BK BRN LEVEL SENSOR
D
FLASHING BEACONS
FB
OPTION
CR5
(from serial number 6316 to serial number 7226)
HORN
P3
TB43
CR5
NO
R34HRN BK
Ford Electrical Schematic - View 1
SERVICE HORN
P22BAT BK C7-1
H2
CR17
OTS
NO
C
CR17
M1
Z-60/34
NO
BR COOLING FAN
TB134
RD
FAN
(OPTION)
RD
C41RPM OR/BK C2-3 C5-2 C41RPM OR/BK PIN 2
42 PIN FORD CONNECTOR
TB41
BLUE/PINK
FORD ENGINE HARNESS
B
TB22
START RELAY
PLAT
GRD
CB1
CB3
STARTER MOTOR
KS1
1
2
15AMP.
20AMP.
B1
TB 132 IS WAGO TERMINAL BLOCK 38
TB 133 IS WAGO TERMINAL BLOCK 16
TB 134 IS WAGO TERMINAL BLOCK 42
B
Section 6 • Schematics
RD
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
A
6 - 64
1
8
1
8
September 2013
6 - 65
Ford Electrical Schematic - View 2
(from serial number 6316 to serial number 7226)
A
BRN
GROUND
C41RPM OR/BK
C2P-3
5
B
15
TS14
LO
TB31 TB30
Y51
DRIVE MODE
C1P-4 C30EDC+ WH C5-21 C30EDC+ WH
HI
Z-60/34
J1
DRIVE ENABLE
C
Y2
Y3
RKOUT 6 WH 5
Y4
XOUT 4
J1
D
PWR 3 OR 13
C3P-6 C6TRF WH/RD
GND 2 BRN 14 11
1 C5TRR WH/BK
9 C3P-5
Section 6 • Schematics
C3P-4 C4TRL WH
TB4
10
Y23
C4TRL WH
LEFT TURNTABLE ROTATE CW
TTROTATE
Y29
7 TURNTABLE ROTATE
E
C6TRF WH/RD
6 FLOW CONTROL
TB6
R5
YOUT 5 BK 2
TB1
Y22
5
JC2
XOUT 4 RD 1 C1PBU RD
PRIMARY BOOM UP
J1
OR UP
TB2
GND 2 BRN 12
J2
Y12
6 C3P-12
14
OUT 5 YEL 3 C3P-11
JC1
4 13
J1
PWR 3 OR 9 C3P-10
12
Y53
1 UP
TB11 TB10
SECONDARY BOOM
Y52
BRN
JOYSTICK CONTROL CARD
1 WH NCHO
2 BK OPERATION
H
C4P-1
SJ2 WH
4 3
P26ESTP BK 3 WH
NCHO
C2P-2 C40LS1 OR PRIMARY BOOM
4 OPERATION
TB40
BK
SJ1 WH
NOHC
BOOM RETRACTED
BK OPERATION
I
CR30
CR27
NO
NC
OPTION
WH
DRIVE
NOHC
LIFT/
LS3
CE
NOTE:
C3P-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3P-7
Y25
C8PBR BK/WH
J
TS63
BOOM RETRACT
RETRACT
BOOM
Y26
EXTEND
WH
TB7
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TB14
TS9
Y20
C4P-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
Y19
PLATFORM LEVEL
DOWN C15PLD OR/BK
K
TB15
GR/BK TB44
C2P-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
C4P-5
TB18
UP C17JU GR
TS8
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
DOWN
L
JIB BOOM
Y17
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
RIGHT
TS57
TB17
PLAT ROTATE RIGHT
LEFT
PLAT ROTATE
TS7
LEFT
WH
AMP
7
6
5
3
4
2
1
Pin1
C19JSV GR/WH
TB19
C19JSV GR/WH
M
CR13
RKOUT
XOUT
YOUT
PWR
GND
Y18
BRN
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
JIB VALVE
JIB VALVE
Deutsch
3
1
2
N
5
6
4
BL/WH
RD/BK
OR/BK
BRN
RD
RD
WH
BK
Section 6 • Schematics September 2013
6 - 65
6 - 66
Section 6 • Schematics September 2013
6 - 68
6 - 67
N
BL/WH
BRN
RD
RD
WH
RD/BK
OR/BK
BK
RD
TS55
M
LOW RPM
FUNCTION ENA.
HIGH RPM
TB35
TS17
TB45
Y29
GENERATOR
CR23
DRIVELIGHT
TB9
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
TS48
WH BK
L29
PBOX GND
RD WORK LIGHTS
WORKLIGHT
FUSE 10A
C4B-10
K
OPTION
CR23
C4-9
FUSE 10A
NO
WH BK
F18
L30
G1
VOLT METER
J
R21IGN WH
HM
HOUR METER
G6
+
_ OPS
TB25
C5-16 WH/BK
I
G2
CR1
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START GY/RD
A
GY/YL
B
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
DIAGNOSTIC
CR1
NO
H
D BK/BL
LPG LOCKOUT
WH/BK
C5-14
P25FS RD
C28TTA RD/BK
TB24
CR39
WH-(FS)
C135RET BL PIN 18
TS1
PUMP
FUEL
RD-(FS)
TS51
AUXILIARY
PUMP AUXILIARY C5-11 VSW WH PIN 1
PUMP
NOTE:
CR39
C9-3
C9-2
NC
4
September 2013
L2
RD
FS1
1K
R2
1
C1-1 C27AUX RD RD AUXILIARY POWER
C9-1
RELAY
PR1
E
PUMP
AUXILIARY PUMP
BK-(FS)
PR1
TB23
NO
C7-2 P23BAT WH
P2
TB28
L48
M2
C1-2 C28TTA RD/BK
S7
RD RD BK BRN LEVEL SENSOR
D
FLASHING BEACONS
FB
OPTION
(from serial number 7227 to serial number 10387)
CR5
HORN
P3
TB43
CR5
NO
R34HRN BK
SERVICE HORN
P22BAT BK
Ford Electrical Schematic - View 1
C7-1
H2
CR17
OTS
NO
C134PWR RD C2-4 WH BK
C
HYDRAULIC OIL
TEMP. SWITCH
CR17
M1
NO
BR COOLING FAN
Z-60/34
RD
FAN
TB42
3
(OPTION)
RD
C41RPM OR/BK C2-3 C5-2 C41RPM OR/BK PIN 2
42 PIN FORD CONNECTOR
TB41
GND BR
BLUE/PINK
FORD ENGINE HARNESS
PR8
NO
TB22
4
START RELAY
B
PLAT
RD
GRD
CB1
CB3
STARTER MOTOR
KS1
1
2
15AMP.
20AMP.
B1
B
RD
Section 6 • Schematics
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
A
6 - 68
1
8
Ford Electrical Schematic - View 2
(from serial number 7227 to serial number 10387)
8
September 2013
6 - 69
A
BR-2
GROUND
C41RPM OR/BK
B
C2-3
5
15
TS14
Z-60/34
Y51
TB30
J1
16
H3
7
TB32
RKOUT 5 BL/WH
Y3
DRIVE & STEERING
TB36
XOUT 3 BL/WH 4
J1
Y4
11
C3-5 C5TRR WH/BK
9
C3-4 C4TRL WH
TB4
10
Y23
C4TRL WH
TURNTABLE ROTATE LEFT
Part No. 75861
Y29
C5TRR WH/BK
E
R4
TS62
7.5
TURNTABLE ROTATE RIGHT
TB5
Y13
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
GND 1 BR 12
PRIMARY BOOM DOWN
TB3
Y12
FLOW CONTROL
C3-1 C1PBU RD
D30
6
C3-2 C2PBD RD/BK
7
C3-3 RD/BK
C3PBF RD/WH DESCENT ALARMN
8
6
SECONDARY BOOM UP/DN
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
C3-10
J1
D29
G
PWR 2 OR 9 12
Y53
GND 1 BR 10 C10SBU BL
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
TB11
BR
H
1
NO
NC
14 13
WH
22 21
43
TB13
2 OPERATION
3
P26ESTP BK
3
NO
NC
SJ1 WH
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
J
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
7
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
K
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
GR/BK-44 C2-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
L
DOWN
Y17
JIB BOOM
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
M
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
6
N
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
Section 6 • Schematics September 2013
6 - 69
6 - 70
Section 6 • Schematics September 2013
6 - 72
6 - 71
N
BL/WH
BRN
RD
RD
WH
RD/BK
OR/BK
BK
RD
D12
ENGINE SPEED
TS55
D14
M
LOW RPM
FUNCTION ENA.
HIGH RPM
TB35
D13
TS17
TB45
Y29
WORK LIGHTS
OPTION
CR23
L29
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
WH BK WORKLIGHT
L29
RD
C4B-10
CR23
K
C4-9
FUSE 10A
NO
WH BK
L30
G1
VOLT METER
J
R21IGN WH
HM
HOUR METER
G6
+
_ OPS
TB25
C5-16 WH/BK
G2
TB33
CR1
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START GY/RD
A
GY/YL
B
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
DIAGNOSTIC
CR1
NO
BK/BL
H
D
RD/GN
LPG LOCKOUT
WH/BK
C5-3
FUEL
GAS C5-5 R33STR BK PIN 15
TB21
CR2
NO
P24FS WH
P26ESTP BK
P25FS RD
C28TTA RD/BK
CR39
WH-(FS)
C135RET BL PIN 18
TS1
PUMP
D4
FUEL
RD-(FS)
NOTE:
TS51
AUXILIARY
PUMP AUXILIARY C5-11 VSW WH PIN 1
PUMP
CR39
C9-3
C9-2
NC
September 2013
L2
RD
FS1
RELAY
PR1
E
CR45
PUMP
AUXILIARY PUMP
BK-(FS)
PR1
TB23
CR45
NO
NO
C7-2 P23BAT WH
WORK LIGHTS RELAY (OPTION)
P2
TB28
L48
Ford Electrical Schematic, ANSI / CSA - View 1
M2
C1-2 C28TTA RD/BK
S7
D40
RD RD BK BRN
D2
LEVEL SENSOR
D
D39
FLASHING BEACONS
FB
OPTION
CR5
HORN
P3
TB43
CR5
NO
R34HRN BK
TB133
P22BAT BK SERVICE HORN
H2
CR17
OTS
NO
TB132
WH BK HYDRAULIC OIL
C
8
7
5
TEMP. SWITCH
CR17
M1
C132PLI1 BL/WH C1-12
NO
CONN.
3
BR COOLING FAN
PLUG
RD
Z-60/34
FAN
C32
(from serial number 10388 to 11788)
RD
12
6
4
C41RPM OR/BK C2-3 C5-2 C41RPM OR/BK PIN 2
42 PIN FORD CONNECTOR
TB41
GND BR
BLUE/PINK
TB134
FORD ENGINE HARNESS
PR8
NO
TB22
START RELAY
B
PLAT
RD
GRD
CB1
CB3
GBOX GND
STARTER MOTOR
KS1
1
2
15AMP.
20AMP.
B1
B
RD
Section 6 • Schematics
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
A
6 - 72
1
8
1
8
September 2013
6 - 73
A
BR-2
GROUND
C41RPM OR/BK
B
C2-3
5
15
TS14
Y51
Z-60/34
TB30
J1
H3
7
TB32
RKOUT 5 BL/WH
Y3
DRIVE & STEERING
TB36
D
XOUT 3 BL/WH 4
J1
Y4
10
Y23
C4TRL WH
TURNTABLE ROTATE LEFT
Y29
C5TRR WH/BK
R4
TS62
7.5
TB5
Y13
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
GND 1 BR 12
PRIMARY BOOM DOWN
TB3
Y12
C3-1 C1PBU RD
D30
6
C3-2 C2PBD RD/BK
7
C3-3 RD/BK
C3PBF RD/WH DESCENT ALARMN
8
6
SECONDARY BOOM UP/DN
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
C3-10
J1
D29
PWR 2 OR 9 12
G
Y53
GND 1 BR 10 C10SBU BL
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
TB11
BR
1 NO
NC
14 13
WH
22 21
H
43
TB13
2 OPERATION
3
P26ESTP BK
3
NO
NC
22 21
C40LS1 OR 21
BK PRIMARY BOOM
C2-2
4 OPERATION
TB40
SJ1 WH
WH OPERATION
14
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
J
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
7
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
K
TB15
TB44
GR/BK-44 C2-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
DOWN
L
Y17
JIB BOOM
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
TB17
RIGHT
TS57
PLAT ROTATE
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
M
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
6
N
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
Section 6 • Schematics September 2013
6 - 73
6 - 74
Section 6 • Schematics September 2013
6 -76
6 - 75
BL/WH
BRN
WH
RD
RD
RD/BK
OR/BK
BK
RD
N
D12
ENGINE SPEED
TS55
D14
LOW RPM
FUNCTION ENA.
HIGH RPM
TB35
D13
M
TS17
TB45
Y29
WORK LIGHTS
OPTION
L29
CR23
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
WH BK WORKLIGHT
L29
RD
C4B-10
CR23
C4-9
NO
FUSE 10A
WH BK
L30
K
VOLT METER
G1
R21IGN WH
HM
HOUR METER
J
G6
+
_ OPS
TB25
C5-16 WH/BK
G2
TB33
CR1
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START GY/RD
A
GY/YL
B
FORD ENGINE
RD GASOLINE SENSOR
HARNESS
C
CR1
DIAGNOSTIC
NO
D BK/BL
H
RD/GN
TS22
C5-14
C2-1
G
FUEL
GAS C5-5 R33STR BK PIN 15
TB21
CR2
NO
P24FS WH
P26ESTP BK
C28TTA RD/BK
P25FS RD
CR39
C135RET BL PIN 18
WH-(FS)
TS1
PUMP
D4
FUEL
RD-(FS)
NOTE:
TS51
AUXILIARY
PUMP AUXILIARY C5-11 VSW WH PIN 1
PUMP
CR39
C9-3
September 2013
C9-2
L2
RD
FS1
E
RELAY
PR1
CR45
PUMP
AUXILIARY PUMP
BK-(FS)
PR1
TB23
NO
CR45
NO
C7-2 P23BAT WH
WORK LIGHTS RELAY (OPTION)
Ford Electrical Schematic, ANSI / CSA - View 1
P2
TB28
L48
M2
C1-2 C28TTA RD/BK
S7
D40
D
RD RD BK BRN
D2
LEVEL SENSOR
D39
FLASHING BEACONS
FB
OPTION
CR5
HORN
P3
TB43
CR5
NO
R34HRN BK
TB133
P22BAT BK SERVICE HORN
C
H2
OTS
CR17
NO
Z-60/34
TB132
WH BK HYDRAULIC OIL
8
7
5
TEMP. SWITCH
M1
CR17
C132PLI1 BL/WH C1-12
NO
CONN.
3
BR COOLING FAN
PLUG
RD
FAN
C32
P134PWR RD C2-4 (OPTION)
RD
12
6
4
C41RPM OR/BK C2-3 C5-2 C41RPM OR/BK PIN 2
42 PIN FORD CONNECTOR
(from serial number 11789)
TB41
B
BLUE/PINK
TB134
FORD ENGINE HARNESS
TB22
START RELAY
PLAT
GRD
CB1
CB3
GBOX GND
Section 6 • Schematics
STARTER MOTOR
KS1
1
2
15AMP.
20AMP.
B1
B
RD
A
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
6 - 76
1
8
(from serial number 11789)
Ford Electrical Schematic, ANSI / CSA - View 2
8
September 2013
6 - 77
C7-3 BR-2
GROUND
A
C41RPM OR/BK
RETURN
C2-3
5
EDC
TB9
C3-9 C5-7
15
TS14
Y51
TB30
B
J1
MOTOR STROKE
6
DRIVE & STEERING
TB36 TB37
RKOUT 5BL/WH
Y3
XOUT 3BL/WH 4
J1
C36STC BL
Y4
10
Y23
C4TRL WH
TURNTABLE ROTATE LEFT
Section 6 • Schematics
Y29
C5TRR WH/BK
R4
TS62
Y13
5
R5
Y22
YOUT 4 RD/WH
JC2
2 PRIMARY BOOM
E
C1PBU RD
J1
PWR 2 OR 11
Y21
Y12
6
C3-2 C2PBD RD/BK
7
F
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
D29
J1
C3-10
PWR 2 OR 9 12
Y53
Y52
TB11
Y14
BR
JOYSTICK CONTROL CARD
1
NO
NC
14 13
WH
22 21
P24FS WH BK
TB13
2 OPERATION
J3
4 3
P26ESTP BK 3
NO
NC
14 13
WH
22 21
21
C2-2 C40LS1 OR BK PRIMARY BOOM
4 OPERATION
TB40
SJ1 WH
NO
NC
22 21
14 13
BOOM RETRACTED
WH OPERATION
21
BK
CR27
CR30
NO
NC
OPTION
NO
NC
DRIVE
22 21
14 13
LS3
LIFT/
WH
43
BK
C3-8 C8PBR BK/WH
RETRACT
NOTE:
EXTEND
TS13
C7PBE BK TB8
C3-7
Y25
BOOM BOOM C8PBR BK/WH
TS63
BOOM RETRACT
8
7
6
RETRACT
1.
J
Y26
EXTEND
WH
TB7
C4-2 C14PLU OR
UP
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3 PLATFORM LEVEL C14PLU OR
TS59
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
K
TB15
GR/BK-44 TB44
C2-6 JDALARM GR/BK
CR13
DOWN
UP
TB18
C4-5 C17JU GR
TS8
Y16
JIB BOOM C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
DOWN
Y17
JIB BOOM
L
UP C17JU GR
PLAT ROTATE PLATFORM ROTATE CW / JIB UP
TS7
PLAT ROTATE
TB17
RIGHT
TS57
LEFT RIGHT
LEFT
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
M
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
JIB VALVE
CR14
DELAY
6
N
BL/WH
RD/BK
OR/BK
RD
RD
WH
BR
RD
BK
Section 6 • Schematics September 2013
6 - 77
6 - 78
Section 6 • Schematics September 2013
6 - 80
6 - 79
N
BL/WH
BRN
RD
RD
WH
RD/BK
OR/BK
BK
RD
D12
TS4
ENGINE SPEED
TS55
D14
LOW RPM
FUNCTION ENA.
HIGH RPM
TB35
D13
TS17
TB45
Y29
L
L29
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
WH BK WORKLIGHT
K
L29
RD
C4B-10
CR23
C4-9
FUSE 10A
NO
WH BK
L30
J
G1
VOLT METER
R21IGN WH
HM
HOUR METER
G6
+
_ OPS
TB25
C5-16 WH/BK
I
G2
CR1
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START A GY/RD
GY/YL
B
FORD ENGINE
H
RD GASOLINE SENSOR
HARNESS
C
DIAGNOSTIC
CR1
NO
P24PWR D BK/BL
RD/GN
10A
TS22
U34
C4-10
TB39
FUEL
GAS C5-5 R33STR BK PIN 15
TB21
CR2
C28TTA RD/BK
NO
P24FS WH
P26ESTP BK
P25FS RD
C28TTA RD/BK
FUEL PUMP
C135FP BL/WH PIN 5
D3
CR39
C135RET BL PIN 18
TS1
PUMP
D4
FUEL
NOTE:
TS51
AUXILIARY
PUMP AUXILIARY
C9-2
C9-3
L2
BK
RD
C1-1 C27AUX RD
E
RD AUXILIARY POWER
C9-1
RELAY
PR1
CR45
U35
PUMP
30A
AUXILIARY PUMP
NO
PBOX
2 SEC
GND
PR1
TB23
CR45
NO
NO
C7-2 P23BAT WH
WORK LIGHTS RELAY (OPTION)
P2
TB28
C1-2
RD/BK WH TILT ALARM
M2
C28TTA RD/BK
D40
H1
S7
D39
RD RD BK
D
BRN
D2
LEVEL SENSOR
4.7 K
R20
C132PLI2 BK
L4
(from serial number 10388 to serial number 11788)
FB
OPTION
C133PLA OR/RD
CR5
HORN
P3
C43HRN GR
LS18A
RELAY
TB43
CR5
NO
R34HRN BK
TB133
P22BAT BK SERVICE HORN
H2
GN/BK
C
CR17
OTS
NO
TB132
WH BK HYDRAULIC OIL
8
7
5
L45
TEMP. SWITCH
Z-60/34
CR17
M1
C132PLI1 BL/WH C1-12
NO
CONN.
3
BR COOLING FAN
PLUG
RD
FAN
D89
D88
C32
P134PWR RD C2-4 (OPTION)
1
PBOX
GND
12
6
H6
4
C41RPM OR/BK C2-3 C5-2 C41RPM OR/BK PIN 2
42 PIN FORD CONNECTOR
TB41
GND BR
BLUE/PINK
TB134
FORD ENGINE HARNESS
B
PR8
NO
TB22
START RELAY
PLAT
RD
GRD
CB1
CB3
GBOX GND
STARTER MOTOR
KS1
1
2
15AMP.
20AMP.
B1
B
Section 6 • Schematics
RD
CB2
-
TB20
P1
15AMP.
P20BAT RD
RD
DC
12 V
A
6 - 80
1
8
1
8
September 2013
6 - 81
(from serial number 10388 to serial number 11788)
Ford Electrical Schematic, CE - View 2
BR-2
GROUND
C41RPM OR/BK
C2-3
5
B
15
TS14
Y51
TB30
Z-60/34
J1
7
TB32
C
RKOUT 5 BL/WH
Y3
DRIVE & STEERING
TB36
XOUT 3 BL/WH 4
J1
Y4
10
Y23
C4TRL WH
TURNTABLE ROTATE LEFT
Y29
C5TRR WH/BK
R4
TS62
7.5
TURNTABLE ROTATE RIGHT
TB5
Y13
6
PRI UP/DN & TT ROTATE
E
FLOW CONTROL
TB6
5
R5
TB1
Y22
5
JC2
YOUT 4 RD/WH 2
C1PBU RD
J1
PRIMARY BOOM
Y21
PWR 2 OR 11
DOWN C2PBD RD/BK
TS61
J2
GND 1 BR 12
PRIMARY BOOM DOWN
TB3
Y12
6
C3-2 C2PBD RD/BK
F
7
C3-3 RD/BK
C3PBF RD/WH DESCENT ALARMN
8
6
SECONDARY BOOM UP/DN
H4
C3-12
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
C3-10
J1
D29
PWR 2 OR 9 12
Y53
GND 1 BR 10 C10SBU BL
SECONDARY BOOM UP
UP
TB10
SECONDARY BOOM
Y52
TB11
BR
1
NO
NC
14 13
WH
22 21
43
TB13
2 OPERATION
3
H
P26ESTP BK
3
NO
NC
SJ1 WH
14
21
BK
CR27
CR30
NO
NC
I
OPTION
NO
NC
22 21
13
LS3
DRIVE
LIFT/
P23PWR RD
DRIVE ENABLE
CE
WH
14
43
BK
NOTE:
C3-8 C8PBR BK/WH
RETRACT
BOOM
EXTEND C7PBE BK
TS13
TB8
C3-7
Y25
C8PBR BK/WH
TS63
BOOM RETRACT
7
6
1.
RETRACT
BOOM
Y26
EXTEND C7PBE BK
WH
BOOM EXTEND
J
TB7
C4-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3
C14PLU OR
TS59
PLAT LEVEL UP
UP
PLATFORM LEVEL
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
K
TB44
GR/BK-44 C2-6 JDALARM GR/BK
CR13
DOWN
JIB BOOM
UP C4-5 C17JU GR
TS8
TB18
Y16
C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
DOWN
Y17
JIB BOOM
UP C17JU GR
PLATFORM ROTATE CW / JIB UP
TB17
RIGHT
TS57
PLAT ROTATE
L
LEFT RIGHT
PLAT ROTATE
LEFT
TS7
WH
BR
C4-7
CR13 C19JSV GR/WH
TB19
+
_
M
Y18
JIB VALVE
JIB TIME
CIRCUIT
CR14
JIB VALVE
DELAY
6
BL/WH
RD/BK
OR/BK
RD
RD
BR
WH
RD
BK
N
Section 6 • Schematics September 2013
6 - 81
6 - 82
Section 6 • Schematics September 2013
6 - 84
6 - 83
BRN
BL/WH
RD
RD
WH
BK
RD/BK
OR/BK
RD
D12
C35RPM BK/RD
TS4
ENGINE SPEED
TS55
D14
LOW RPM
FUNCTION ENA.
HIGH RPM
TB35
D13
M
TS17
TB45
Y29
L29
CR23
RD DRIVE LIGHT
L30
C4B-12 OPTION
C4-11
WH BK WORKLIGHT
L29
RD
C4B-10
C4-9
CR23
NO
FUSE 10A
WH BK
L30
K
VOLT METER
G1
R21IGN WH
HM
HOUR METER
G6
+
_
J
OPS
TB25
C5-16 WH/BK
G2
CR1
I
C1-7 C33STR BK
TS2
TS52
ENGINE
START
ENGINE
START A GY/RD
GY/YL
B
FORD ENGINE
C RD GASOLINE SENSOR
HARNESS
CR1
NO
DIAGNOSTIC
P24PWR D BK/BL
RD/GN
10A
NO
TS22
U34
C4-10
WATER TEMP GAUGE
G3
C2-1
C5-12 C127TSW GR PIN 3
CR2
TS3
FUEL
TS53
D10
FUEL
GAS C5-5 R33STR BK PIN 15
TB21
CR2
NO
C28TTA RD/BK
P24FS WH
P26ESTP BK
P25FS RD
C28TTA RD/BK
PUMP
CR39
C135RET BL PIN 18
FUEL
TS1
D4
NOTE:
F
TS51
AUXILIARY
PUMP AUXILIARY VSW
C9-2
C5-11
C9-3
WH PIN 1
PUMP
CR39
NC
FS1
September 2013
L2
BK
RD
C1-1 C27AUX RD
RD AUXILIARY POWER
C9-1
RELAY
PR1
E
CR45
U35
PUMP
30A
AUXILIARY PUMP
NO
2 SEC
PBOX
GND
PR1
TB23
NO
CR45
NO
C7-2 P23BAT WH
WORK LIGHTS RELAY (OPTION)
P2
TB28
C1-2
RD/BK WH TILT ALARM
M2
C28TTA RD/BK
D40
H1
S7
D39
RD RD BK BRN
D2
LEVEL SENSOR
4.7 K
D
R20
C132PLI2 BK
L4
FB
OPTION
Ford Electrical Schematic, CE - View 1
C133PLA OR/RD
CR5
HORN
P3
LS18A
RELAY
TB43
CR5
NO
R34HRN BK
TB133
P22BAT BK SERVICE HORN
H2
GN/BK
C
OTS
CR17
NO
TB132
WH BK HYDRAULIC OIL
L45
7
5
Z-60/34
TEMP. SWITCH
FAN M1
CR17
C132PLI1 BL/WH C1-12
NO
CONN.
3
BR COOLING FAN
PLUG
RD
D89
D88
C32
P134PWR RD C2-4 (OPTION)
1
PBOX
GND
12
H6
6
4
C41RPM OR/BK C2-3 C5-2 C41RPM OR/BK PIN 2
42 PIN FORD CONNECTOR
TB41
(from serial number 11789)
BLUE/PINK
B
TB134
FORD ENGINE HARNESS
TB22
START RELAY
PLAT
GRD
CB1
CB3
GBOX GND
STARTER MOTOR
KS1
1
Section 6 • Schematics
15AMP.
20AMP.
B1
B
RD
CB2
-
TB20
P1
A
15AMP.
P20BAT RD
RD
DC
12 V
6 - 84
1
8
1
8
September 2013
6 - 85
(from serial number 11789)
Ford Electrical Schematic, CE - View 2
C7-3 BR-2
GROUND
C41RPM OR/BK
B
RETURN
C2-3
5
EDC
TB9
C3-9 C5-7
15
TS14
Y51
Z-60/34
TB30
J1
TB36 TB37
RKOUT 5BL/WH
Y3
C1-11
YOUT 4WH/RD 5 18 STEER CCW
JC3
XOUT 3BL/WH 4
J1
C36STC BL
Y4
10
Y23
C4TRL WH
E
C5TRR WH/BK
R4
TS62
Y13
5
R5
TB1
5
Y22
YOUT 4 RD/WH
JC2
PWR 2 OR 11
Y21
GND 1 BR 12
TB3
Y12
6
C3-2 C2PBD RD/BK
7
SECONDARY BOOM UP/DN
C3-12
G
5 14
OUT 4 WH/BK 3 C3-11
JC1
13
3
D29
J1
C3-10
PWR 2 OR 9 12
Y53
Y52
FLOW CONTROL
TB12
BR
JOYSTICK CONTROL CARD
NO
NC
14 13
WH
22 21
43
P24FS WH BK
TB13
2 OPERATION
J3
NO
NC
14 13
WH
22 21
21
C2-2 C40LS1 OR BK PRIMARY BOOM
I
4 OPERATION
TB40
SJ1 WH
NO
NC
22 21
14 13
BOOM RETRACTED
WH OPERATION
21
BK
CR30
NO
NC
OPTION
NO
NC
DRIVE
22 21
14 13
LS3
LIFT/
P23PWR RD
J
DRIVE ENABLE
CE
WH
43
BK
C3-8 C8PBR BK/WH
RETRACT
NOTE:
EXTEND
TS13
C7PBE BK
TB8
C3-7
Y25
BOOM BOOM C8PBR BK/WH
TS63
BOOM RETRACT
8
7
6
RETRACT
1.
Y26
EXTEND
WH
TB7
C4-2 C14PLU OR
UP
DOWN C15PLD OR/BK
TS9
TB14
Y20
C4-3 PLATFORM LEVEL C14PLU OR
TS59
PLATFORM LEVEL PLAT LEVEL UP
UP
Y19
DOWN C15PLD OR/BK
PLAT LEVEL DOWN
TB15
L
GR/BK-44 TB44
C2-6 JDALARM GR/BK
CR13
DOWN
UP
TB18
C4-5 C17JU GR
TS8
Y16
JIB BOOM C18JD GR/BK
PLATFORM ROTATE CCW / JIB DOWN
TS58
DOWN
Y17
JIB BOOM
UP C17JU GR
PLAT ROTATE PLATFORM ROTATE CW / JIB UP
TS7
M
PLAT ROTATE
TB17
RIGHT
TS57
LEFT RIGHT
LEFT
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
N
+
_
Y18
JIB VALVE
JIB TIME
CIRCUIT
JIB VALVE
CR14
DELAY
6
BL/WH
RD/BK
OR/BK
RD
RD
WH
BR
RD
BK
Section 6 • Schematics September 2013
6 - 85
6 - 86
Section 6 • Schematics September 2013
6 - 88
6 - 87
Section 6 • Schematics September 2013
A B C D E F G H I J K L M N
1
VOLT METER OIL PRESSURE OIL TEMP
H6 U33
RD-H6+ - C23-1
RD-C23-1 BL/WH-38D - C23-3
PLATFORM LOAD
RD-42B
C23
BK-22C - C23-4
BK-C7-1 - C23-5
GN/BK-L45 RD-TS11 - C23-6
GN/BK-16A RD-TS14 - C23-7 G1 G2 G3
WHT-21A GN/BK-16B - C23-8
BRN-GROUND BR-GND - C23-12
2 P2 BLK-22A
WHT-23A
ENGINE WH -8 46 WH -5 WH-23A LIMIT SWITCH POWER
NC RD 42A
STARTER GR/WH-4 GR/WH-1 45 GENERATOR OPTION
C23-6
NC WH -7 44 BK -8 LIMIT SWITCH J1
KS1 WH -6 43 BK -7 LIMIT SWITCH J2
KEY OR/RD-1 42 RD H6
RD-4 RD KS1 C134PWR
SWITCH BRN-GROUND
OR/BK-E.H. OR/BK-1 41 OR/BK-ISM#2 PULSE PICKUP
B BK -6 OR-1 40 C40LS1 STOWED +
3 1 3 MFD WT/BK-25A WT/RD-26A
RD
TS58 TURNTABLE RD/WH-4 RD/WH-3 3 RD/WH S.P. PRIMARY BOOM F.C. R4 RESISTOR, 7.5 OHM, TURN. ROT. FUNC.
R4
JIB BOOM ROTATE RD/BK-4 RD/BK-3 2 RD/BK S.P. PRIMARY BOOM DOWN
RD-4 RD-3 1 RD S.P.
DRIVE LIGHT OPTION RELAY R5 RESISTOR, 5 OHM, TURN. AUX. FUNC.
PRIMARY BOOM UP
D3 G1 VOLT METER GAGE
WH/RD S.P. CABLE D C B A
#2 RD-CB3 SP G2 OIL PRESSURE GAGE
BK-CR1#86 START RELAY
1
CR23 G3 WATER TEMP. GAGE
6 TS56 TS52 GRN-17A
OR/BK-41B
BK-33D
TACHOMETER
2 H2 SERVICE HORN
GLOW PLUG ENGINE START
TS57 START INPUT
3
RD-27B H3 TRAVEL BUZZER
PLATFORM AUXILIARY ONIGN./START
4 BK/RD-9B
ROTATE GRN/BLK-18A BR-GROUND GROUND5
MODULE H4 DESCENT BUZZER
RD-CR1#30 BATTERY
GRN/WHT-19A 6 CR1 IGN/START RELAY
WH-23B
TS59 KEY POWER
7
PLATFORM RD TO LIGHT CR2 IGN./POWER RELAY
KEY BYPASS
8
LEVEL WH-CR2#86 IGN./FUEL ON CR3 HIGH IDLE (RPM) CUTOUT RELAY
ORG/BLK-15A CABLE BL/WHT-L2-
9 RD-C4B-12
ORG-14A #3 ENGINE FAULT
10 CR4 RPM RELAY
WARNING SENDER BRN GND
TS55 CR5 SERVICE HORN RELAY
FUNCTION RD-S.P. (CB3)
ENABLE RD-24B
7 CB3 CABLE WH-ISM#9 GR-1 CR
CR17 HYDRAULIC COOLER FAN RELAY
CB1 CB2 OIL COOLER/ #4 WH-H.C. CR18 CE PLATFORM LEVEL RELAY
OPTION, 20A RD-ISM#6 BK-22B RELAY
ENGINE, 15A CONTROL, 15A
LEGEND H6 PLATFORM OVERLOAD ALARM
CR1 CR2 CR17 CR5
BK-ISM#1 L45 PLATFORM OVERLOAD LED
87 V33 PLATFORM OVERLOAD MODULE
CR17 #30 BK-E.H. 87A LS1 (CABLE#6) PRIMARY BOOM STOWED LIMIT SWITCH
WH-21D RD-H.C. BK-4
RED-20C BR-GROUND LS2 (CABLE#5) DRIVE ENABLE LIMIT SWITCH
HYDRAULIC 86 85
BLK-33A COOLER
30
BK/RD-35B LS3 (CABLE#7) BOOM RETRACTED LIMIT SWITCH
BLK/RED-35A
LS4 (CABLE#8) SECONDARY BOOM STOWED LIMIT SWITCH
RD C23-7 CR4
CR3
8 RED-20A (CABLE#1) TO PLATFORM C-BOX, TERMINAL 27-46
RED-20B (CABLE#2) TO PLATFORM C-BOX, TERMINAL 22-23
1 RPM FILTER ADDED AT SERIAL NUMBER 4461
BK/WH-34A (CABLE#3) TO PLATFORM C-BOX, TERMINAL 1-19
RED-24A ENGINE BK/RD-E.H. (CABLE#4) TO FUNCTION MANIFOLD
HARNESS
GROUND STUD PR1 AUXILARY POWER RELAY
BR BR PR2 GLOW PLUG POWER RELAY
BK-H.C. + BR-H.C.
BR-2
N M L K J I H G F E D C B A
1
G2 G3
WHT-21A 46 SPARE G1
BRN-GROUND GR/WH-4 GR/WH-1 45 GENERATOR OPTION
GR/BK-1 44 GR/BK-11B JDALARM
BLK-22A
WHT-23A
GR-1 43 GR-CR5#85 HORN 2
RD-4 OR/RD-1 42 RD H6 RD KS1 C134PWR
RD 42A OR/BK-C5-2 OR/BK-1 41 PULSE PICKUP
OR-4 OR-1 40 C40LS1 STOWED BRN-GROUND
BL/RD-C5-10 BL/RD-1 39 BL/RD S.P. L.P./GAS
KEY WT/BK-25A WT/RD-26A
BL/WH C23-3 BL/WH-1 38 C132PLI WHT-21A
SWITCH BL/BK-4 BL/BK-1 37 STEER LEFT
KS1 BL-4 BL-1 36 STEER RIGHT
B BK/RD-C5-9 BK/RD-1 35 BK/RD S.P. RPM
1 TS51
BK/WH-1 34 BK/WH S.P. GLOW PLUG/CHECK ENGINE
RD
3 BK-1 33 BK-CR1#85 D5 BK S.P. LABEL DESCRIPTION
START
B1 WH/RD-C5-23 WH/RD-1 32 WH/RD-4 BRAKE
4 2 AUXILIARY SWITCH P1 EMERGENCY STOP BUTTON
WH/BK-C5-20 WH/BK-1 31 E.D.C.-
P2 WH- C5-21 30 KS1 KEY SWITCH
WH-1 E.D.C.+
NC RD/WH-C5-24 RD/WH-1 29 MOTOR SPEED
NC
RD/BK -4
RD -4
RD/BK-1
RD-1
28
27 RD-CR39#85 RD S.P.
TILT ALARM
AUXILIARY POWER
TS51
TS52
AUXILIARY SWITCH
ENGINE START SWITCH
3
WH/RD-C5-14 26 WT/RD S.P. OIL TEMP. SENDER
D3 TS53 LP/GAS SWITCH
D2 WH/BK-C5-16 25 WT/BK S.P. OIL PRESSURE SENDER
24 RD-CR2#30 RD CB1 ENGINE POWER TS55 FUNCTION ENABLESWITCH
WH-2 23 WH-CR39#30 WH S.P. KEYSWITCH POWER TS57 PLATFORM ROTATE SWITCH
BL/WH-4 C23-4 22 BK-CR5#30 BK S.P. POWER TO PLATFORM
BL/RD-39A WH-C5-3+C5-8 21 WH-CR2#87 WH-SP IGNITION POWER TS58 JIB BOOM SWITCH
RED-27A RD- 12 VOLT RD-S.P.(CB3) 20 RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY TS59 PLATFORM LEVEL SWITCH
BLU-10A GR/WH-3 19 GR/WH S.P. JIB VALVE
BLU/BLK-11A GR/BK-4 GR/BK-3 18 GR/BK S.P. PLATFORM ROTATE R TS60 SECONDARY BOOM UP/DOWN SWITCH
BLK/WHT-8A GR-4 GR-3 17 GR S.P. PLATFORM ROTATE L TS61 PRIMARY BOOM UP/DOWN SWITCH
TS53 BLK-7A OR/RD-3 16 GR/BK C23-8 GN/BK-H6 C133PLT
OR/BK-4 OR/BK-3 15 OR/BK S.P. PLATFORM LEVEL DOWN TS62 TURNTABLE ROTATE SWITCH
L2
OPTION OR-4 OR-3 14 OR S.P. PLATFORM LEVEL UP TS63 BOOM EXTEND/RETRACT SWITCH
LP/GAS
SWITCH
BL/WH-C5-13
BL/RD-4
BL/WH-4
BL/RD-3
BL/WH-3
13
12 BL/WH S.P.
DRIVE ENABLE
SECONDARY BOOM F.C. TS22 RUN/TEST SWITCH 4
BL/BK-4 BL/BK-3 11 44B-GR/BK+2B-BL/BK BL/BK S.P. SECONDARY BOOM DOWN CB1 CIRCUIT BREAKER, ENGINE, 15A
BL-4 BL-3 10 BL S.P. SECONDARY BOOM UP
RED-1A BK/RD-3 9 BK/RD-CR23#86 DRIVE LIGHT OPTION CB2 CIRCUIT BREAKER, CONTROL, 15A
RED/BLK-2A BK/WH-4 BK/WH-3 8 BK/WH S.P. BOOM RETRACT CB3 CIRCUIT BREAKER, HYD COOLER, 20A
BK-4 BK-3 7 BK S.P. BOOM EXTEND
+
WH/RD-4 WH/RD-3 6 WH/RD S.P. TURNTABLE ROTATE F.C. HM HOUR METER
HYDRAULIC WH/BK-4 WH/BK-3 5 WH/BK S.P. TURNTABLE ROTATE R
HM RED/WHT-3A COOLER
WH-4 WH-3 4 WH S.P. TURNTABLE ROTATE L
TS60 RD/WH-4 RD/WH-3 3 RD/WH S.P. PRIMARY BOOM F.C. R4 RESISTOR, 7.5 OHM, TURN. ROT. FUNC.
TS63 SECONDARY BOOM RD/BK-4 RD/BK-3 2 11B-RD/BK-4 RD/BK S.P. PRIMARY BOOM DOWN
- R5 RESISTOR, 5 OHM, TURN. AUX. FUNC.
BOOM UP/DOWN SWITCH RD-4 RD-3 1 RD S.P. PRIMARY BOOM UP
TS61 EXTEND/RETRACT G1 VOLT METER GAGE
PRIMARY BOOM D C B A
SWITCH BL/WH -12A G2 OIL PRESSURE GAGE
UP/DOWN SWITCH WHT/BLK-5A
WHT-4A
CABLE
G3 WATER TEMP. GAGE 5
H2 SERVICE HORN
#1 DRIVE LIGHT OPTION RELAY
TURNTABLE H3 TRAVEL BUZZER
ROTATE
R4 SWITCH RD-CB3 SP H4 DESCENT BUZZER
TS62
7.5 CR1 IGN/START RELAY
5
BK/RD-9B
RD-24B
WH/RD-6A RD TO LIGHT
CABLE CR5 SERVICE HORN RELAY
JIB BOOM SWITCH #2
TS58 GR/BK-44A CR1 CR2 RD TO LIGHT CR39 AUX FUNCTION
PLATFORM GRN-17A
BK-33B BRN GND CR17 HYDRAULIC COOLER FAN RELAY 6
LEVEL SWITCH
TS59 PLATFORM H6 PLATFORM OVERLOAD ALARM
TS52 ROTATE GRN/BLK-18A BK-C5-5 WH-21B
SWITCH L45 PLATFORM OVERLOAD LED
CB3 TS57 GRN/WHT-19A WH-C5-17
U33 PLATFORM OVERLOAD MODULE
ENGINE HYD COOLER, CR
START 20A CABLE
SWITCH #3 RELAY
ORG/BLK-15A
OR-H.C. LEGEND
ORG-14A BK-4 WH-C5-11
CR17 #30
RED-20C
(CABLE#1) TO PLATFORM C-BOX, TERMINAL 27-46
87
FUNCTION
TS22 (CABLE#2)
(CABLE#3)
TO PLATFORM C-BOX, TERMINAL 22-23
TO PLATFORM C-BOX, TERMINAL 1-19
7
ENABLESWITCH CR5 CR39 CR17 87A
GR-43B RD-27B (CABLE#4) TO FUNCTION MANIFOLD
TS55 CABLE BK-H.C.
#4 BK-22B
CB1 CB2 PR1 AUXILARY POWER RELAY
WH-23B RD-CB3 SP 86 85
ENGINE, 15A CONTROL, 15A 30 PR2 GLOW PLUG POWER RELAY
GR-C5-12
BLK-33A
BLK/RED-35A
C5
BR
RED-20B BR
ENGINE
RED-20A HARNESS
BR-H.C.
8
RED-24A BR-2
GROUND STUD
6 - 89
6 - 90
Section 6 • Schematics September 2013
6 - 92
6 - 91
Section 6 • Schematics September 2013
1
WH-21A G1 G2 G3
46 SPARE
GR/WH-4 GR/WH-C2B-7 45 GENERATOR OPTION
GR/BK-C2B-6 44 GR/BK-11B GR/BK S.P. JDALARM
GR-C2B-5 43 GR-CR5#85 HORN
RD-4 RD-C2B-4 42 RD KS1 C134PWR BR (GROUND)
OR/BK -C5-2 OR/BK-C2B-3 41 PULSE PICKUP
OR-4 OR-C2B-2 40 C40LS1 STOWED
DESCRIPTION LABEL
BL/RD -C5-10 BL/RD-C2B-1 39 BL/RD S.P. L.P./GAS WH/BK-25A
BL/WH-C1B-12 38 C132PLI EMERGENCY STOP BUTTON P1
WH/RD-26A
2 BL/BK-4
BL-4
BL/BK-C1B-11
BL-C1B-10
37
36
STEER LEFT
STEER RIGHT
KEY SWITCH
AUXILIARY SWITCH
KS1
TS51
BK/RD -C5-9 BK/RD-C1B-9 35 BK/RD S.P. RPM ENGINE START SWITCH TS52
BK/WH-C1B-8 34 BK/WH S.P. GLOW PLUG KEY SWITCH AUXILIARY
P1 KS1 LP/GAS SWITCH TS53
BK-C1B-7 33 BK-CR1#86 D5 BK S.P. START TS51
B FUNCTION ENABLE SWITCH TS55
WH/RD -C5-23 WH/RD-C1B-6 32 WH/RD-4 BRAKE RD-CB2
NC 1
WH/BK -C5-20 WH/BK-C1B-5 31 PLATFORM ROTATE SWITCH TS57
RD
E.D.C.- 3
WH -C5-21 WH-C1B-4 30 E.D.C.+ NC B1 JIB BOOM SWITCH TS58
RD/WH -C5-24 RD/WH-C1B-3 29 MOTOR SPEED WH-23A 4 2 PLATFORM LEVEL SWITCH TS59
RD/BK -4 RD/BK-C1B-2 28 TILT ALARM RD-42A
SECONDARY BOOM UP/DOWN SWITCH TS60
RD -4 RD-C1B-1 27 RD-CR39#85 RD S.P. AUXILIARY POWER BK-22A PRIMARY BOOM UP/DOWN SWITCH TS61
WH/RD -C5-14 26 WH/RD S.P. OIL TEMP. SENDER
RD-27A TURNTABLE ROTATE SWITCH TS62
3 WH/BK -C5-16 25
24
WH/BK S.P.
RD CB1
OIL PRESSURE SENDER
BL/RD-39A BOOM EXTEND/RETRACT SWITCH TS63
RD-CR1#30 ENGINE POWER
RUN/TEST WH-C7B-2 23 WH-CR39#30 WH S.P. KEYSWITCH POWER RUN/TEST SWITCH TS22
TS22 BL/WH-4 22 CIRCUIT BREAKER, ENGINE, 15A CB1
BK-C7B-1 BK-CR5#30 BK S.P. POWER TO PLATFORM
WH-C5-3+C5-8 21 WH-CR2#87 WH-SP IGNITION POWER WH-21A CIRCUIT BREAKER, CONTROL, 15A CB2
RD-4 (12V) RD-S.P.(CB3) 20 RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY LP/GAS CIRCUIT BREAKER, OPTION, 20A CB3
L2 TS53
GR/WH-C4B-7 19 GR/WH S.P. JIB VALVE HM HOUR METER HM
GR/BK-4 GR/BK-C4B-6 18 GR/BK S.P. PLATFORM ROTATE R BR (GROUND) RESISTOR, 1K OHM/2W, #104333 R3
GR-4 GR-C4B-5 17 GR S.P. PLATFORM ROTATE L
GR-C5-12 16 RESISTOR, 7.5 OHM, TURN. ROT. FUNC. R4
OR/RD-C4B-4 C133PLT BL/WH-C5-13
OR/BK-4 OR/BK-C4B-3 15 OR/BK S.P. PLATFORM LEVEL DOWN R3 RESISTOR, 5 OHM, TURN. AUX. FUNC. R5
14 DRIVE LIGHT OPTION RELAY VOLT METER GAGE G1
OR-4 OR-C4B-2 OR S.P. PLATFORM LEVEL UP 1 1K
4 BL/RD-4 BL/RD-C4B-1 13 DRIVE ENABLE RD/WH-3A
RD/BK-2A
RD-24D
CR23
OIL PRESSURE GAGE G2
BL/WH-4 BL/WH-C3B-12 12 BL/WH S.P. SECONDARY BOOM F.C.
PRIMARY FUSE 10A WATER TEMP. GAGE G3
BL/BK-4 BL/BK-C3B-11 11 44B-GR/BK+2B-BL/BK BL/BK S.P. SECONDARY BOOM DOWN BOOM
BL/BK-11A BOOM SERVICE HORN H2
BL-4 BL-C3B-10 10 BL S.P. SECONDARY BOOM UP UP/DOWN 30
EXTEND/RETRACT BR-C4B-9 TRAVEL BUZZER H3
BK/RD-C3B-9 9 BK/RD-CR23#86 DRIVE LIGHT OPTION BR
GND
HC
4
1 BK-22C WH-4 WH-C3B-4 WH S.P. TURNTABLE ROTATE R BK/WH-8A BK/RD-9B
C7B
5
TS52 HYDRAULIC OIL COOLER OPTION RELAY
TO PLATFORM C-BOX, TERMINAL 27-38 C1B
BK-33A CB3
(BK)
C2B
87
WH/RD-6A 85 86 BK-H.C. ENGINE HARNESS C5
WH-4A 87A
RD-24B TO PLATFORM C-BOX, TERMINAL 22-23 C7B
(BR)
TS55
BK-C5-5 FUNCTION
4
WH-21B
ENABLE D13 TS59
WH-C5-17
BK/RD-35A PLATFORM
LEVEL
BK-4 RD-27B RD- 20A
CR5
RD- 24A
7 85
87
86
GR-43B
RD- 20B
87A RD- P1 E-STOP
ENGINE
OR/BK-15A
C5
30
OR-14A
GR-17A
BK-22B GR/WH-19A
GR/BK-18A
8 GROUND STUD
WIRING
HARNESS:
TO BASE
BR ALL BR WIRES
GROUND STUD
1
WH-21A G1 G2 G3
46 SPARE
GR/WH-4 GR/WH-C2B-7 45 GENERATOR OPTION
GR/BK-C2B-6 44 GR/BK-11B GR/BK S.P. JDALARM
GR-C2B-5 43 GR-CR5#85 HORN
LOAD SENSE OPTION - TIMER RELAY
RD-4 RD-C2B-4 42 RD KS1 C134PWR BR (GROUND)
OR/BK -C5-2 OR/BK-C2B-3 41 PULSE PICKUP
OR-4 OR-C2B-2 40 C40LS1 STOWED
DESCRIPTION LABEL
BL/RD -C5-10 BL/RD-C2B-1 39 BL/RD S.P. L.P./GAS WH/BK-25A WH-CR2#86 EMERGENCY STOP BUTTON P1
BL/BK-4
BL/WH-C1B-12
BL/BK-C1B-11
38
37
C132PLI
STEER LEFT
WH/RD-26A
WH-ISM#9 KEY SWITCH KS1
2
BL-4 BL-C1B-10 36 STEER RIGHT AUXILIARY SWITCH TS51
BK/RD -C5-9 BK/RD-C1B-9 35 BK/RD S.P. RPM ENGINE START SWITCH TS52
BK/WH-C1B-8 34 BK/WH S.P. KEY SWITCH
RD-TB134(A)C
GLOW PLUG AUXILIARY
P1 KS1 LP/GAS SWITCH TS53
BK-C1B-7 33 BK-CR1#86 D5 BK S.P. START TS51
B FUNCTION ENABLE SWITCH TS55
WH/RD -C5-23 WH/RD-C1B-6 32 WH/RD-4 BRAKE RD-CB2 BR-GND
NC 1
WH/BK -C5-20 WH/BK-C1B-5 31 PLATFORM ROTATE SWITCH TS57
RD
E.D.C.- 3
WH -C5-21 WH-C1B-4 30 E.D.C.+ NC B1 U34 JIB BOOM SWITCH TS58
RD/WH -C5-24 RD/WH-C1B-3 29 MOTOR SPEED WH-23A 4 2 PLATFORM LEVEL SWITCH TS59
RD/BK -4 RD/BK-C1B-2 28 TILT ALARM RD-42A BK-C3B-10
SECONDARY BOOM UP/DOWN SWITCH TS60
RD -4 RD-C1B-1 27 RD-CR39#85 RD S.P. AUXILIARY POWER BK-22A PRIMARY BOOM UP/DOWN SWITCH TS61
WH/RD -C5-14
WH/BK -C5-16
26
25
WH/RD S.P.
WH/BK S.P.
OIL TEMP. SENDER
OIL PRESSURE SENDER
RD-27A REPLACE WIRE WITH THIS WIRING DIAGRAM TURNTABLE ROTATE SWITCH TS62 3
BL/RD-39A BOOM EXTEND/RETRACT SWITCH TS63
24 RD-CR1#30 RD CB1 ENGINE POWER
RUN/TEST WH-C7B-2 23 WH-CR39#30 WH S.P. KEYSWITCH POWER RUN/TEST SWITCH TS22
TS22 BL/WH-4 BK-C7B-1 22 BK-CR5#30 BK S.P. POWER TO PLATFORM 1 CIRCUIT BREAKER, ENGINE, 15A CB1
WH-C5-3+C5-8 21 R3 2
WH-CR2#87 WH-SP IGNITION POWER WH-21A CIRCUIT BREAKER, CONTROL, 15A CB2
RD-S.P.(CB3) 20 LP/GAS
1K
RD-4 (12V) RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY CIRCUIT BREAKER, OPTION, 20A CB3
L2 TS53
GR/WH-C4B-7 19 GR/WH S.P. JIB VALVE HM HOUR METER HM
GR/BK-4 GR/BK-C4B-6 18 GR/BK S.P. PLATFORM ROTATE R BR (GROUND) RESISTOR, 1K OHM/2W, #104333 R3
GR-4 GR-C4B-5 17 GR S.P. PLATFORM ROTATE L
GR-C5-12 16 DRIVE LIGHT OPTION RELAY RESISTOR, 7.5 OHM, TURN. ROT. FUNC. R4
OR/RD-C4B-4 C133PLT BL/WH-C5-13
OR/BK-4 OR/BK-C4B-3 15 OR/BK S.P. PLATFORM LEVEL DOWN RD-24D RESISTOR, 5 OHM, TURN. AUX. FUNC. R5
OR-4
BL/RD-4
OR-C4B-2
BL/RD-C4B-1
14 OR S.P. PLATFORM LEVEL UP
DRIVE ENABLE RD/WH-3A
FUSE 10A
CR23
VOLT METER GAGE G1 4
13
WL
4
1 BK-22C WH-4 WH-C3B-4 WH S.P. TURNTABLE ROTATE R BK/WH-8A
C7B
5
TS52
RD-24D TO PLATFORM C-BOX, TERMINAL 27-38 C1B
BK-33A CB3
(BK)
CR23
C2B
BR
C3B
87
TS55
BK-C5-5 FUNCTION
4
WH-21B
ENABLE D13
WH-C5-17 TS59
BK/RD-35A PLATFORM HYDRAULIC OIL COOLER OPTION RELAY
LEVEL
BK-4 RD-27B RD- 20A
CR5
RD- 24A
RD-H.C.
CR17
7
87 GR-43B
85 86 RD- 20B
87A 87
RD- P1 E-STOP 85 86 BK-H.C.
ENGINE
87A
OR/BK-15A
C5
30
OR-14A 30
GR-17A
BK-22B GR/WH-19A
RD-CB3 SP
GR/BK-18A
BRN GND
8
WIRING
GROUND STUD HARNESS:
TO BASE 1 RESISTOR R3 REMOVED AT SERIAL NUMBER 7924
GROUND STUD
6 - 93
6 - 94
Section 6 • Schematics September 2013
6 - 96
6 - 95
Section 6 • Schematics September 2013
RD
D2 3
BL/BK-4 BL/BK-C1B-11 37 STEER LEFT NC B1 JIB BOOM SWITCH TS58
REPLACE WIRE WITH THIS WIRING DIAGRAM
BL-4 BL-C1B-10 36 STEER RIGHT WH-23A 4 2 PLATFORM LEVEL SWITCH TS59
BK/RD -C5-9 BK/RD-C1B-9 35 BK/RD S.P. RPM RD-42A SECONDARY BOOM UP/DOWN SWITCH TS60
D4 D3
BK/WH-C1B-8 34 BK/WH S.P. GLOW PLUG BK-22A PRIMARY BOOM UP/DOWN SWITCH TS61
BK-C1B-7 33 BK-CR1#86 D5 BK S.P. START RD-27A TURNTABLE ROTATE SWITCH TS62
WH/RD -C5-23 WH/RD-C1B-6 32 WH/RD-4 BRAKE
3 WH/BK -C5-20 WH/BK-C1B-5 31 E.D.C.-
BL/RD-39A BOOM EXTEND/RETRACT SWITCH TS63
RUN/TEST WH -C5-21 WH-C1B-4 30 E.D.C.+ RUN/TEST SWITCH TS22
TS22 RD/WH -C5-24 RD/WH-C1B-3 29 MOTOR SPEED CIRCUIT BREAKER, ENGINE, 15A CB1
RD/BK -4 RD/BK-C1B-2 28 TILT ALARM WH-21A CIRCUIT BREAKER, CONTROL, 15A CB2
RD -4 RD-C1B-1 27 RD-CR39#85 RD S.P. AUXILIARY POWER LP/GAS DRIVE LIGHT OPTION RELAY
L2 CIRCUIT BREAKER, OPTION, 20A CB3
WH/RD -C5-14 26 WH/RD S.P. OIL TEMP. SENDER TS53 RD-24D
HM HOUR METER HM
25 WH/BK S.P. OIL PRESSURE SENDER CR23
WH/BK -C5-16 BR (GROUND) FUSE 10A
RESISTOR, 1K OHM/2W, #104333 R3
24 RD-CR1#30 RD CB1 ENGINE POWER
GR-C5-12 23 WH-CR39#30 D10 30 RESISTOR, 7.5 OHM, TURN. ROT. FUNC. R4
WH-C7B-2 WH S.P. KEYSWITCH POWER BL/WH-C5-13 BR-C4B-9
BL/WH-4 22 BK-CR5#30 BR RESISTOR, 5 OHM, TURN. AUX. FUNC. R5
BK-C7B-1 BK S.P. POWER TO PLATFORM GND
WH-C5-3+C5-8 21 WH-CR2#87 87A VOLT METER GAGE G1
WH-SP IGNITION POWER 86 85 BR-C4B-11
4 1
WL
RD-4 (12V) RD-S.P.(CB3) 20 RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY RD/WH-3A 87 OIL PRESSURE GAGE G2
RD/BK-2A RD-C4B-10
GR/WH-C4B-7 19 GR/WH S.P. JIB VALVE WATER TEMP. GAGE G3
PRIMARY RD-C4B-12
GR/BK-4 GR/BK-C4B-6 18 GR/BK S.P. PLATFORM ROTATE R BOOM
BL/BK-11A BOOM SERVICE HORN H2
GR-4 GR-C4B-5 17 GR S.P. PLATFORM ROTATE L BK/RD-9B
UP/DOWN TRAVEL BUZZER H3
OR/RD-C4B-4 16 C133PLT EXTEND/RETRACT
HC
85 86 BK-H.C.
WH/BK-4 WH/BK-C3B-5 5 WH/BK S.P. TURNTABLE ROTATE L START WORK LIGHTS OPTION RELAY Cr45
87A
5
4 TS52
WH-4 WH-C3B-4 WH S.P. TURNTABLE ROTATE R CHECK ENGINE LIGHT L2
RD/WH-4 RD/WH-C3B-3 3 BK-33A CB3
(BK)
RD/WH S.P. PRIMARY BOOM F.C. TO PLATFORM C-BOX, TERMINAL 27-38 C1B
C2B
30
RD- 20C TS58
19/18 CABLES
RD-CB3 SP
C3B
30 30 30
FUNCTIONS
OR/BK-15A
C5
87 GR-43B
85 86 RD-CB3 SP
OR-14A
87A
GR-17A
BR GND
30 GR/WH-19A
GR/BK-18A
8 BK-22B
WIRING
GROUND STUD HARNESS:
TERMINAL 9 BEFORE SERIAL NUMBER 10388 BK/RD-C3B-9 9 BK/RD-CR23#86 DRIVE LIGHT OPTION
TO BASE 1
TERMINAL 9 NOT USED FROM SERIAL NUMBER 10388 TO SERIAL NUMBER 11903 9 SPARE
TERMINAL 9 FROM SERIAL NUMBER 11904 BR C5-7 BR C3B-9 9 EDC RETURN
BR ALL BR WIRES
GROUND STUD
P24FS WH
P26BAT BK
GR/BK L48
RED-TILT
P24FS WH
BRN
ALC-500
C29MS RD/WH
DRE B BL/BK
DRE A BL/WH
JC3-4,6 WH
JC3-5 BL
JC1-5 YEL
JC2-5 BK
JC2-4 RD
C13LED BL/RD
JC3-2 BRN
JC3-3 OR
JC2-2 BRN
JC2-3 OR
JC1-2 BRN
JC1-3 OR
3
COMPONENT INDEX PART NUMBER J3
1
JC2 BOOM PROPORTIONAL JOYSTICK: 62390
PRIMARY UP/DN , TURNTABLE ROTATE
C132PLI BK C1P-12
RD H1
RD P2
P3 HORN SWITCH 66813, 66816
RD/BK L4
C27AUX RD C1P-1
C33STR BK C1P-7
P24FS WH C9P-2
P25FS RD C9P-3
P26BAT BK C9P-1
C7PBE BK C3P-7
C8PBR BK/WH C3P-8
C43 HRN GR C2P-5
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C17JU GR C4P-5
C18JD GR/BK C4P-6
C19JSV GR/WH JIB
P22BAT BK C7P-1
P23SWBAT WH C7P-2
C5TRR WH/BK C3P-5
C37STCC BL/BK C1P-11
C36STC BL C1P-10
TS48-WL2 RD C2P-11
TS48-WL1 RD C2P-12
DLITE BK/RD C3P-9
TS1 AUXILIARY SWITCH 42730
TS2 START ENGINE SWITCH 13037
TS3 FUEL SELECT SWITCH (FORD EFI ONLY) 56457
TS4 HI/L0 RPM SWITCH 13038
L4 CHASSIS TILT LED 56298
TS7 PLATFORM ROTATE SWITCH 16397
TS8 JIB UP/DOWN SWITCH 13037
TS9 PLATFORM LEVEL SWITCH 13037
TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH 13037
3
TS15 DRIVE ENABLE SWITCH 13037
TS17 SWITCH TOGGLE SPDT 2POS MNT 56457 C28TTA RD/BK C1P-2 C1P
TS48-9 WORK/DRIVE LIGHT ( OPTION ) 27378
C2P
D40
C3P C3P
BRN
DETAIL A: LIFT/DRIVE OPTION BATGND C7P-3 C7P
REPLACE WIRE WITH THIS WIRING DIAGRAM
C19JSV GR/WH
C4P-7 AND TS8
BRN
BRN BATGND
D39
F.S.
4
RED-TILT
RED/BLK-28
(GND STUD)
C2P(BK)
C3P(GR)
C4P(BR)
C1P(GY)
CR27
WH TS7
WH TS1 C7P C9P
JIB LS18 OPT.
WH/RD C32BRK
H1
(SPLICE TO C32BRK)
TILT
ALALRM 19/18 CONTROL CABLE 12V BATT F.S.
CR30 5
10 AMP FUSE
OR R40LS1 WORK /DRIVE LITE
(SPLICE TO R40LS1) TS48 DRV.ENA
PRIMARY BOOM 7 7 7
TS15
UP / DOWN DRIVE / STEER
6 6 6
5 5 5
PRIMARY
BOOM
4
4 EXTEND/
RETRACT
4
6
JC2
RD WL2
3 3 3
2 2 2
TURNTABLE JC1 + JC3
ROTATE 1 1 1
TS13 L1
CR13
WH-24
DRIVE LT BK/RD-C3P-9
+
RD WL1
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
L4
7
BRN J1-10
BRN J1-14
BRN J1-12
GND
RD/BK H1
OR J1-13
YEL J1-3
OR J1-11
BK/WH-8
WH J1-5
WH J1-5
OR J1-9
BK J1-2
BL J1-4
RD J1-1
WH-JIB
WH-24
BK-22
BK-7
BRN
RD
GR/WH-45
OR-14
BK/RD-35
WH-24
C17JU GR C4P-5
WH-JIB
C27AUX RD C1P-1
WH-23
P26BAT BK C9P-1
C19JSV GR/WH
WH-24
BK-22
WH-24
RD-TILT
P22BAT BK C7P-1
JDALARM GR/BK-44 C2P-6
RD
BL/RD-39
GR-43
RD
WH-24
GR/WH-45
WH-TS4
WH-TS47
TS2
WH
8
TS17 RD START TS9 TS7 TS8 TS1
TS14 TS2 TS4
GR
GENERATOR HIGH/LOW
(OPTION) WH RPM TS3
P3 START P2
DRIVE TS17 RD FUEL SELECT
HORN PLATFORM
1 GENERATOR OPTION CHANGED PLATFORM WH
ROTATE GR/BK
JIB AUXILIARY SPEED
1 GENERATOR REMOVE FOR EMERGENCY STOP
AT SERIAL NUMBER 5716 LEVEL PUMP HIGH/LOW (OPTION) GENERATOR OPTION
CE SEE DETAIL A
6 - 97
6 - 98
Section 6 • Schematics September 2013
6 - 100
6 - 99
N
M
L
K
EMERGENCY STOP
RD-TILT
P2
OPT.
P22BAT BK C7P-1
BK-22
P26BAT BK C9P-1
WH-23
J
FUEL SELECT
TS3
RD P2
RD H1
LS18
BL/RD-39
C132PLI BK C1P-12 RD
P23SWBAT WH C7P-2
P22BAT BK C7P-1 RD
TS4
HIGH/LOW
C19JSV GR/WH
JIB
WH-24
L4
C14PLU OR C4P-2
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
TS2
C7PBE BK C3P-7
START
P26BAT BK C9P-1
1
6
P25FS RD C9P-3
P24FS WH C9P-2
JDALARM GR/BK C2P-6 BL/WH J1-5 JC3-5
JC3-4
RD
DRIVE LT BK/RD C3P-9 WH/RD J1-4
JC3-3
GENERATOR
BL/WH J1-5
DRIVE / STEER
C3P
(OPTION)
OR J1-13 JC3-2
F.S.
C9P
TS48-WL1 RD C2P-12
BRN J1-14 JC3-1
TS17
F.S.
JC3
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
H
WH-24
C6TRF WH/RD C3P-6
J3
L1
C10SBU BL C3P-10
DRV.ENA
BL/RD-DE3 J1-16
C11SBD BL/BK C3P-11
BL/WH-DE1 J1-6
TS15
HIGH/LOW
BK-22
TS14
C12SBF BL/WH C3P-12
SPEED
DRIVE
P24FS WH C41RPM OR/BK C2P-3 BL/BK-DE2 J1-7 WH-24
C30EDC+ WH C1P-4 C29MS RD/WH J1-8
WH/BK J1-3 JC1-4
BRN C1PBU RD C3P-1
C7P
G
CE SEE DETAIL A
C31EDC- WH/BK C1P-5 OR J1-9 JC1-2
C2PBD RD/BK C3P-2
C36STC BL C1P-10
JC1
AUXILIARY
ALC-500
WH-24
C4P
PUMP
C5TRR WH/BK C3P-5
6
TS1
C4TRL WH C3P-4 BRN
WH
C29MS RD/WH C1P-3
J2
C3P
JC1
C34SA BK/WH C1P-8
19/18 CONTROL CABLE
C2P
C33STR BK C1P-7
CR13
C27AUX RD C1P-1
JIB
F
TS8
RD/BK L4
C2P(BK)
BK/WH-8
RETRACT
ROTATE GR/BK
PRIMARY
EXTEND/
C1P
WH
GR
PLATFORM
BOOM
J1
BK-7
9
JC1-3 OR
TS13
WORK /DRIVE LITE
JC2-4 RD C17JU GR C4P-5
JC1-2 BRN WH-24
C1P(GY)
TS48
JC2-5 BK
September 2013
TS7
RD J1-1 JC2-3
JC3-3 OR
JC3-4,6 WH C18JD GR/BK C4P-6
OR J1-11 JC2-2
WH
JC2
JC3-2 BRN BRN J1-12 JC2-1
C28TTA RD/BK C1P-2
PLATFORM
DRE B BL/BK
1
BATGND C7P-3
TS9
LEVEL
C13LED BL/RD
GR/BK C4P-4
OR-14
C29MS RD/WH
PRIMARY BOOM
OR/BK-15
TURNTABLE
UP / DOWN
ROTATE
D40
H1
P3
RED/BLK-28
ALALRM
D39 RD
HORN
GR/BK L48
TILT
GR-43
RED-TILT RED-TILT
JC2
D
Ford Platform Control Box Wiring Diagram
BRN
(from serial number 7227 to serial number 9065)
PART NUMBER
66812, 94506
66813, 66816
C
62390
62391
75565
56298
42730
13037
13038
16397
13037
13037
13037
13037
56457
56457
56298
27378
Z-60/34
BRN BATGND
(GND STUD)
WH TS1
REPLACE WIRE WITH THIS WIRING DIAGRAM
PRIMARY BOOM EXTEND/RETRACT SWITCH
FUEL SELECT SWITCH (FORD EFI ONLY)
PRIMARY UP/DN , TURNTABLE ROTATE
CR27
CR30
PLATFORM ROTATE SWITCH
EMERGENCY STOP BUTTON
AUXILIARY SWITCH
(SPLICE TO R40LS1)
(SPLICE TO C32BRK)
Section 6 • Schematics
WH/RD C32BRK
OR R40LS1
WH TS7
TS48-9
TS13
TS15
TS17
A
TS1
TS2
TS3
TS4
TS7
TS8
TS9
JC2
JC1
JC3
L4
P2
P3
L1
6 - 100
1
8
Section 6 • Schematics September 2013
1
COMPONENT INDEX
P24FS WH
P26BAT BK
GR/BK L48
RED-TILT
H1 TILT ALARM
P24FS WH
BRN
C29MS RD/WH
DRE B BL/BK
DRE A BL/WH
JC3-4,6 WH
JC3-5 BL
JC1-5 YEL
JC2-5 BK
JC2-4 RD
C13LED BL/RD
JC3-2 BRN
JC3-3 OR
JC2-2 BRN
JC2-3 OR
JC1-2 BRN
JC1-3 OR
CR13-#86 GR/WH
C1 JIB TIME DELAY ALC-500
BR GND
RD-E-STOP
BR JC3
CR14 JIB TIME DELAY RELAY 3
J3
1
J1 J2
COMPONENT INDEX PART NUMBER 9 11
JC2 BOOM PROPORTIONAL JOYSTICK: 62390 2
GR/WH
PRIMARY UP/DN , TURNTABLE ROTATE 1 1 CR14
GR/WH
JC1 BOOM SECONDARY JOYSTICK: 62391
RD/BK L4
C27AUX RD C1P-1
C33STR BK C1P-7
P24FS WH C9P-2
P25FS RD C9P-3
P26BAT BK C9P-1
C7PBE BK C3P-7
C8PBR BK/WH C3P-8
C43 HRN GR C2P-5
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
C17JU GR C4P-5
C18JD GR/BK C4P-6
C19JSV GR/WH JIB
P22BAT BK C7P-1
P23SWBAT WH C7P-2
C5TRR WH/BK C3P-5
C37STCC BL/BK C1P-11
C36STC BL C1P-10
TS48-WL2 RD C2P-11
TS48-WL1 RD C2P-12
JDALARM GR/BK C2P-6
JC3 DRIVE PROPORTIONAL JOYSTICK 75565
P134PWR RD
L1 DRIVE ENABLE LED 56298
P2 EMERGENCY STOP BUTTON 66812, 94506
P3 HORN SWITCH 66813, 66816
TS1 AUXILIARY SWITCH 42730
RD
TS2 START ENGINE SWITCH 13037
TS3 FUEL SELECT SWITCH (FORD EFI ONLY) 56457
GR/WH +
TS4 HI/L0 RPM SWITCH 13038
RD
RD OUTPUT
BR
BR
L4 CHASSIS TILT LED 56298 BR -
TS7 PLATFORM ROTATE SWITCH 16397
C1
3
TS8 JIB UP/DOWN SWITCH 13037
TS9 PLATFORM LEVEL SWITCH 13037 C28TTA RD/BK C1P-2 C1P
TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH 13037
C2P
D40
TS15 DRIVE ENABLE SWITCH 13037 C3P C3P
WH
TS17 SWITCH TOGGLE SPDT 2POS MNT 56457
BK
GR/BK C4P-4 C4P
TS48-9 WORK/DRIVE LIGHT ( OPTION ) 27378
BRN
GR/WH
BATGND C7P-3 C7P
BK C1P-12
JIB
D39
F.S.
RD LS18 CABLE
4
C134PWR RD LS18
RED-TILT
RED/BLK-28
DETAIL A: LIFT/DRIVE OPTION BEFORE SERIAL NUMBER 9697
REPLACE WIRE WITH THIS WIRING DIAGRAM
C2P(BK)
C3P(GR)
C4P(BR)
C1P(GY)
BRN BATGND
C7P C9P JIB LS18 OPT.
(GND STUD)
H1
CR27
WH TS7
WH TS1 TILT
ALARM 19/18 CONTROL CABLE 12V BATT F.S.
WH/RD C32BRK 5
(SPLICE TO C32BRK)
10 AMP FUSE
WORK /DRIVE LITE
CR30 TS48
PRIMARY BOOM DRV.ENA
TS15
UP / DOWN DRIVE / STEER
CP2-2 OR R40LS1
(SPLICE TO R40LS1) 6
PRIMARY 6 6
BOOM
JC2 EXTEND/ JC1
1 1
JC2
RETRACT 1
6
RD WL2
TURNTABLE JC1 + JC3
ROTATE
TS13 L1
DETAIL A: LIFT/DRIVE OPTION FROM SERIAL NUMBER 9697 CR13
BRN J1-10
OR J1-9
WH/BK J1-3
WH-24
REPLACE WIRE WITH THIS WIRING DIAGRAM
DRIVE LT BK/RD-C3P-9
BL/WH J1-5
BRN J1-14
BRN J1-12
BRN BATGND
OR J1-11
WH/RD C32BRK
OR J1-13
RD J1-1
+
BK J1-2
RD WL1
WH/RD J1-4
BL/WH J1-5
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
(SPLICE TO C32BRK) (GND STUD) L4
RD/BK H1
BK/WH-8
WH-JIB
WH-24
BK-22
JC2-2
JC2-1
JC2-3
JC2-4
JC1-1
CR27
BK-7
JC1-2
JC1-4
JC3-1
JC3-2
JC3-3
JC3-5
JC3-4
WH TS7
BRN
RD
WH TS1
OR-14
BK/RD-35
WH-24
C17JU GR C4P-5
WH-JIB
C27AUX RD C1P-1
WH-23
P26BAT BK C9P-1
C19JSV GR/WH
WH-24
BK-22
WH-24
RD-TILT
P22BAT BK C7P-1
JDALARM GR/BK-44 C2P-6
RD
BL/RD-39
GR-43
RD
GR/WH-45
OR R40LS1
(SPLICE TO R40LS1)
CR30
TS9 TS7
WH
TS8 TS1 TS4
8
GR TS14 TS2
TS17 HIGH/LOW
WH RPM TS3
P3 START P2
DRIVE RD FUEL SELECT
HORN WH PLATFORM JIB AUXILIARY
PLATFORM SPEED GENERATOR EMERGENCY STOP
LEVEL ROTATE GR/BK PUMP HIGH/LOW (OPTION)
CE SEE DETAIL A
6 - 101
6 - 102
Section 6 • Schematics September 2013
6 - 104
6 - 103
N
M
L
WH
PBOX WIRING
CR13-#86 GR/WH BR
RD LS18 CABLE
C1
GR/WH
RD OUTPUT
GR/WH +
CR14
EMERGENCY STOP
P134PWR RD
K
BR -
RD-TILT
P2
JIB
P22BAT BK C7P-1
OPT.
GR/WH RD
BK-22
P26BAT BK C9P-1
R20
P134PWR RD
4700 WH-23
LOAD SENSE OPTION
RD-H1+
U35
FUEL SELECT
TS3
COM
LS18
NO
BL/RD-39
2
5
3
D88
RD
P26ESTP BK E-STOP R26ESTP BK C9P-1
BR GND
J
D89
P23SWBAT WH C7P-2
P22BAT BK C7P-1 RD
TS4
HIGH/LOW
+
WH-24
L4
BK/RD-35
C17JU GR C4P-5
C15PLD OR/BK C4P-3 RD/BK H1
C14PLU OR C4P-2
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
TS2
C7PBE BK C3P-7
START
P26BAT BK C9P-1
1
6
I
P25FS RD C9P-3
P24FS WH C9P-2
BL/WH J1-5 JC3-5
JC3-4
RD
TS48-WL1 RD C2P-12
C3P
JC3
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
JDALARM GR/BK C2P-6
GR/WH-45
P26BAT BK
DRIVE LT BK/RD-C3P-9
11
3
WH-24
H
L1
C10SBU BL C3P-10
DRV.ENA
HIGH/LOW
BK-22
TS14
C12SBF BL/WH C3P-12
SPEED
DRIVE
P24FS WH C41RPM OR/BK C2P-3 BL/BK-DE2 J1-7 WH-24
C30EDC+ WH C1P-4 C29MS RD/WH J1-8
WH/BK J1-3 JC1-4
BRN C1PBU RD C3P-1
C7P
CE SEE DETAIL A
C31EDC- WH/BK C1P-5 OR J1-9 JC1-2
C2PBD RD/BK C3P-2
C36STC BL C1P-10
JC1
AUXILIARY
WH-24
C4P
PUMP
C5TRR WH/BK C3P-5
6
10 AMP FUSE
G
TS1
C4TRL WH C3P-4 BRN
WH
C29MS RD/WH C1P-3
J2
C3P
C33STR BK C1P-7
19/18 CONTROL CABLE
CR13
C27AUX RD C1P-1
JIB
TS8
RD/BK L4
C2P(BK)
BK/WH-8
RETRACT
ROTATE GR/BK
PRIMARY
EXTEND/
C1P
WH
GR
PLATFORM
BOOM
J1
BK-7
9
JC1-3 OR
TS13
WORK /DRIVE LITE
JC2-5 BK
JC2-3 OR RD WL2 C19JSV GR/WH
JC1-5 YEL RD WL1
JC2-2 BRN C19JSV GR/WH JIB
BK J1-2 JC2-4
JC3-5 BL
TS7
RD J1-1 JC2-3
JC3-3 OR
JC3-4,6 WH 1 OR J1-11 JC2-2
C18JD GR/BK C4P-6
September 2013
WH
JC2
JC3-2 BRN
PLATFORM
DRE B BL/BK
1
BATGND C7P-3
TS9
LEVEL
C13LED BL/RD
GR/BK C4P-4
OR-14
C29MS RD/WH
E
PRIMARY BOOM
OR/BK-15
TURNTABLE
UP / DOWN
ROTATE
D40
H1
P3
RED/BLK-28
D39 RD
HORN
ALARM
GR/BK L48
TILT
GR-43
RED-TILT RED-TILT
JC2
BRN
D
Ford PlatformControl Box Wiring Diagram
PART NUMBER
66812, 94506
66813, 66816
62390
62391
75565
56298
42730
13037
13038
16397
13037
13037
13037
13037
56457
56457
56298
27378
BRN BATGND
(GND STUD)
WH TS1
C
CR14
Z-60/34
PRIMARY BOOM EXTEND/RETRACT SWITCH
(from serial number 9799 to 11788)
CR27
CR30
PLATFORM ROTATE SWITCH
EMERGENCY STOP BUTTON
1
DRIVE ENABLE SWITCH
START ENGINE SWITCH
AUXILIARY SWITCH
HORN SWITCH
(SPLICE TO R40LS1)
(SPLICE TO C32BRK)
WH/RD C32BRK
OR R40LS1
WH TS7
TS48-9
Section 6 • Schematics
TS13
TS15
TS17
TS1
TS2
TS3
TS4
TS7
TS8
TS9
JC2
JC1
JC3
L4
P2
P3
L1
A
6 - 104
6 - 93
1
8
1
6 - 105
September 2013
A
B
WH
PBOX WIRING
BR BK
BR JC3
BR GND RD-TILT
P2
Z-60/34
RD
RD-E-STOP
P134PWR RD-H1+
P22BAT BK C7P-1
GR/WH
BR
CR13-#86 GR/WH BK-22
RD LS18 CABLE
P26BAT BK C9P-1
C1
GR/WH
WH-23
RD OUTPUT
C
GR/WH +
CR14
P134PWR RD
BR -
FUEL SELECT
OPT.
RD-P2
TS3
JIB
GR/WH RD BL/RD-39
RD
D11
R20
P134PWR RD
4700
LOAD SENSE OPTION
RD-H1+
LS18
U35
COM
NO
D
2
5
3
D88
BR GND
D89
RPM
WH-24
Section 6 • Schematics
BK/RD-35
+
+
P23SWBAT WH C7P-2
L48
D12
P22BAT BK C7P-1
L4
C14PLU OR C4P-2
E
C7PBE BK C3P-7
START
P26BAT BK C9P-1
1
6
P25FS RD C9P-3
P24FS WH C9P-2
BL/WH J1-5JC3-5
DRIVE / STEER
WH/RD J1-4JC3-4
RD
F.S.
OR J1-13 JC3-2
C3P
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
F
WH-24
C6TRF WH/RD C3P-6
12V BATT
J3
+
DRV.ENA
L1
C10SBU BL C3P-10
C13DRE BL/RD C4P-1 BL/RD-DE3 J1-16
C7P
HIGH/LOW
TS14
BK-22
C12SBF BL/WH C3P-12
SPEED
DRIVE
P24FS WH C41RPM OR/BK C2P-3 BL/BK-DE2 J1-7 WH-24
G
CE SEE DETAIL A
C36STC BL C1P-10
JC1
AUXILIARY
C4P
PUMP
C5TRR WH/BK C3P-5
C4P(BR)
ALC-500
C27AUX RD C1P-1
6
TS1
C4TRL WH C3P-4 BRN
WH
C29MS RD/WH C1P-3
J2
C3P
C33STR BK C1P-7
CR13
C27AUX RD C1P-1
JIB
TS8
RD/BK L4
C2P(BK)
ROTATE GR/BK
BK/WH-8
PRIMARY
RETRACT
BOOM
EXTEND/
C1P
WH
GR
J1
BK-7
PLATFORM
9
1
JC1-3 OR
JC2-4 RD C17JU GR C4P-5
WH-24
C1P(GY) TS13
JC1-2 BRN
JC2-5 BK
JC2-3 OR C19JSV GR/WH
JC1-5 YEL RD WL1
I
TS7
RD J1-1 JC2-3
JC3-3 OR
JC3-4,6 WH C18JD GR/BK C4P-6
OR J1-11 JC2-2
C28TTA RD/BK C1P-2
WH
JC3-2 BRN
JC2
BRN J1-12 JC2-1
DRE A BL/WH C28TTA RD/BK C1P-2
BATGND C7P-3
DRE B BL/BK
TS9
GR/BK C4P-4
C13LED BL/RD
PLATFORM
LEVEL
OR-14
C29MS RD/WH PRIMARY BOOM
TURNTABLE
UP / DOWN
OR/BK-15
ROTATE
D40
J
H1
P3
RED/BLK-28
D39 RD
ALARM
HORN
GR/BK L48
TILT
GR-43
RED-TILT RED-TILT
JC2
BRN
K
BRN BATGND
(GND STUD)
WH TS1
JIB TIME DELAY
TILT ALARM
COMPONENT INDEX
CR27
CR30
START ENGINE SWITCH
AUXILIARY SWITCH
(SPLICE TO R40LS1)
(SPLICE TO C32BRK)
WH/RD C32BRK
OR R40LS1
M
WH TS7
TS48-9
TS13
TS15
TS17
JC2
JC1
JC3
TS1
TS2
TS3
TS4
TS7
TS8
TS9
L4
P2
P3
L1
N
Section 6 • Schematics September 2013
6 - 105
6 - 106
Section 6 • Schematics September 2013
6 - 108
6 - 107
Section 6 • Schematics September 2013
1
6 361 R 16 361 R 16 361 R 16 361 R 16 361 R 16
INJ +
INJ 1
7 555 T 16 555 T 16 FORD
8 557 BR-Y 16 557 BR-Y 16
INJ 3
INJ 4
9 558 BR-LB 16 558 BR-LB 16 42 PIN
10 556 W 16 556 W 16
INJ 2
INJ 5
11 743 GY 18 INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2
570 BK-W 16 39 R-W 18
CONNECTOR
12 359 GY-R 18 16 WATER TEMP
INJ 6
31
AUX OUT 2
EGR
21 18 O-Y 18 WATER
19 198 DG-O 18 ACT TEMP
2 AUX ANA PD1
MAP
20 358 LG-BK 18
15 151 LB-BK 18 151 LB-BK 151 LB-BK
FPP 1 14 FPP1
27 743 GY 18 307 BK-Y 18 307 BK-Y 18
IAT 25 IVS
28 354 LG-R 18 354 LG-R 18 359 GY-R 18
ECT
17 307 BK-Y 18 570 BK-W 16
IVS F1 30A
18 150 DG-W 18 570 BK-W 16 570 BK-W 12 570 BK-W 12 34 GROUND
AUX ANA PU1
16 114 LB-Y 18
ECT 570 BK-W 16
FPP 2
22 352 BR-LG 18 F2 5A
EGR PWM 16 R-LG 18 16 R-LG 18
23 360 BR-PK 18 1 VSW
EGR RECIRC
1 570 BK-W 16 570 BK-W 16
POWER GROUND
2 570 BK-W 16 570 BK-W 16
3 POWER GROUND
13 359 GY-R 18 570 BK-W 16
MAP_CONN
361 R 14
F3 20A
361 R 14 361 R 12
ANA_RTN 9 VBATT
14 351 BR-W 18 351 BR-W 18 351 BR-W 18 TWR
5 VOLT REF C
3 16 R-LG 18 16 R-LG 18 361 R 14
VSW
33 350 GY 18 358 LG-BK 18 358 LG-BK 18
CRANK - B
32 349 DB 18 359 GY-R 18 359 GY-R 18
CRANK + A
35 452 GY-R 18 18 O-Y 18 18 O-Y 18
CAM - 38 EGR ANA IN
34 282 DB-O 18 198 DG-O 18 198 DG-O 18
CAM + 32 ANA AUX PD1
4 361 R 16 150 DG-W 18 150 DG-W 18
VBAT CAM CRANK 37 ANA AUX PU1
5 361 R 16 361 R 14 114 LB-Y 18 114 LB-Y 18
VBAT 12 FPP2
25 392 R-LG 18 352 BR-LG 18 352 BR-LG 18
EGO 2 40 EGR PWM
24 74 GY-LB 18
4 EGO 1
26 O2 SENSOR
360 BR-PK 18
361 R 14
360 BR-PK 18
41 EGR REC
EGO 3
29
KNK + 359 GY-R 18 359 GY-R 18
30 33 ANA RTN
KNK - 351 BR-W 18 351 BR-W 18
31 VREF
342 LG-P 18
4 570 BK-W 16 242 DG 18
SPK PWR GROUND A
1 850 Y-BK 18 1 2 3
COIL 1 1 COIL 1
2 851 Y-R 18 361A R 16
2 VBAT 361A R 16 FPP_COMM F4 15A
COIL 2 B 359 GY-R 18 D 787A PK-BK 16 787A PK-BK 16
3 RTN 5 FUEL PUMP
COIL 3 3 COIL 2 351 BR-W 18 C
13 5V
COIL 4 LOCKOFF SOLENOID 669 DG-W 18 B
24 TX
COIL 5 458 O-BK 18 A
25 RX 86 30 POWER
COIL 6 TWR
STARTER LOCKOUT
22 342 LG-P 18 RELAY
23 242 DG 18
FUEL LOCKOFF 85 87 87A
9 926A LB-O 18 926A LB-O 18
6 FUEL PUMP F5 15A
32 15 R-Y 18 15 R-Y 18 361 R 16 361 R 16
RELAY CONTROL
30 355 GY-W 18
TPS1
31 357 Y-W 18
TPS2 253 DG-W 18
28 151 LB-BK 18 OIL PRESSURE
DBW +
29 317 GY-O 18
DBW -
6 511 LG-R 18 511 LG-R 18 511 LG-R 18
BRAKE SWITCH 4 BRAKE
7 253 DG-W 18 253 DG-W 18 253 DG-W 18
OIL PRESSURE 26 OIL PRES
8 11 T-Y 18 11 T-Y 18 11 T-Y 18
TACH 2 TACH
27 658 PK-LG 18 658 PK-LG 18 658 PK-LG 18
MIL 6 MIL
10 238 DG-Y 18 238 DG-Y 18
FUEL PUMP MON
5 71 O-LG 18 71 O-LG 18
7 AUX OUT 1
FUEL SELECT
14 72 Y-BK 18 72 Y-BK 18
71 O-LG 18
72 Y-BK 18
21 AUX OUT1
7 FUEL SELECT
15 148 Y-R 18 148 Y-R 18 148 Y-R 18
AUX ANA PU2 10 AUX ANA PU2
16 306 T-LB 18 306 T-LB 18 306 T-LB 18
GOV SELECT 1 24 GOV SELECT 1
17 307 BK-Y 18 307 BK-Y 18 307 BK-Y 18
GOV SELECT 2 23 GOV SELECT 2
11 169 LG-BK 18 169 LG-BK 18 169 LG-BK 18
ROAD SPEED + 35 ROADSPEED +
12 172 LB-R 18 172 LB-R 18 172 LB-R 18
ROAD SPEED - 36 ROADSPEED -
26 77 DB-Y 18
GASEOUS TRIM
33 349A DB 18 349A DB 18 349A DB 18
OVERSPEED 30 OVERSPEED
18 662 DG-P 18 662 DG-P 18 662 DG-P 18
CAN + 28 CAN +
19 459 O-LG 18 459 O-LG 18 459 O-LG 18
CAN - 29 CAN -
8 RS 485 +
20
21
642 DG-O 18
461 O 18
642 DG-O 18
461 O 18
642 DG-O 18
461 O 18
11 RS 485+
RS 485 - 3 RS 485-
34 669 DG-W 18 669 DG-W 18 669 DG-W 18
RS 232 TX 20 RS 232+
35 458 O-BK 18 458 O-BK 18 458 O-BK 18
RS 232 RX 18 RS 232-
TWR SHD
570 BK-W 16
TRIM VALVE A A PLUG (GROUND)
TWR 361A R 16
77 DB-Y 18 B B PLUG (RELAY POWER)
A 459 O-LG 18
361A R 16 361A R 16 C C PLUG (CAN -)
B 662 DG-P 18
D D PLUG (CAN +)
WPTWR2_GY MTRTWR4 MTRSHD4
R 16
IGNITION COILS
R 16
HO2S #1
R 16 HO2S #2
1
ENGINE ECM Y/BK 18
CONNECTOR W/PK 18 BK/LG 18 GY/R 18 SHD
Y/RD 18 GY/LB 18 GY/YL 18 A
GY/LB 18
Y/BK 18 R 16 B
1 DG/P 18 GY/R 18
SPK_COIL1A W/PK 18 DB/O 18 BK/LB 18 C
2
SPK_COIL1B D
3 Y/RD 18
SPARK_COIL2A GY/R 18 GY/Y 18
4 BK/W 16
SPK_GND DG/P
5
SPK_COIL2B
6
SPK_COIL3A
7
SPK_COIL3B
UEGOS
8 CYL #2 CYL #3 CYL #4 CYL #1 GY/R 18 TWR GASOLINE
9 A
UEGOC
10 CAM
LG/W 18
B SENSOR
UEGOP BR/W 18
UEGPR
11
W/LG 18 W/LG 18 C INTERFACE
12 DG/O 18 D
AUX ANA PD1
(FRP) AUX ANA PD2
CAN1 +
13
14
15
W/LG 18
DG/P 18
O/LG 18
DG/P 18
O/LG 18
MTRTWR4 FORD 2
CAN1 - 42 PIN
16
CAN2 -
17 BR/W 18 CONNECTOR
CAN2 + LG/R 18 LG/R 18
18
AUX ANA PD3 BR/W 18
5V EXT 1
19
GY/R 18 GY/R 18 GY/R 18
GROUND BR 16 BR 16
20 34 GND
5V RTN GY/LB 18
21
EGO1 GY/Y 18 BK/W 12
22
EGO2
23 LG/BK 18 BOSCH RING
MAP
AUX ANA PUD3
24 TMAP
25 GY 18
CRANK + DBL 18
26 LG/BK 18
CRANK - GY/R 18 BR/W 18 4
27
CAM +
28 DB/O 18 GY 18
3 CHT
CAM - DG/BK GY/R 18 2
29
SPEED + LB/R 18 1
30
SPEED -
5V EXT 2
5V RTN 2
31
32
33
LG/W
DG/BK
LB/R 18
LB/R 18
LG/BK 18
36 ROADSPEED - 3
PULSE IN 35 ROADSPEED +
34 T/LB 18 T/LB 18 T/LB 18
GOV 1 24 GOV SELECT 1
35 DG/W 18 BK/W 16
OIL PRESS GY 18 BK/W 16
36
IAT LG/R 18 BK/W 16
37
ECT LG/W LB/BK 18 LB/BK 18
38 14 FPP1
(FRT) AUX ANA PU1 W/R 18 BK/LB 18
39
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
40 BK/O 18
F2
41 W/LB 18 R/LG 18 R/LG 18 R/LG 18 R/LG 18
(BRAKE) AUX DIG 3 1 VSW
42 BK/Y 18 BK/Y 18
(GOV2) AUX DIG 4
43 T/Y 18 5A VSW
TACH R/LG 18
44
VSW DB/W 18
45
AUX ANA PUD2
46 P/LB 18 F3
AUX ANA PUD1 GY/W 18 R/T 14
47 R/T 14 R 14
TPS 1 Y/W 18
48
TPS 2 ECM
(FUELSELECT)AUX DIG1
AUX DIG 2
49
50
51
Y/DB 18
Y/R 18
10A
BK/Y 18
23 GOV SELECT 2
4
KNOCK + GY 18
52 DG/P 18
KNOCK - DBL 18 O/LG 18
LB/BK 18 29 CAN -
53 DG/P 18
FPP1 28 CAN +
54 LB/Y 18
(FPP2) FPP2-IVS DG/O 18 DG/O 18
55 DG 18 32 ANA AUX PD1
PC TX
56 O 18
PC RX DB/W 18 DB/W 18
57 37 AUX ANA PU2B
KNOCK 2+
KNOCK 2-
58 CRANK LB/Y 18 LB/Y 18
12 FPP2
59
VBAT PROT R/T 16 RD/T 14
60
VBAT BK/LB 18 GY/R 18 GY/R 18 GY/R 18
61 33 ANA RTN
EGOH 2 BK/LG 18 BR/W 18 BR/W 18 BR/W 18
62 31 VREF
EGOH 1
63
INJ HS T 16
64
INJ1 LS
65 BR/Y 16 BK/LG 18 BOSCH THROTTLE
INJ2 LS
66 BR/LB 16 BATT(+) R 12 R 12 R 14
5
INJ3 LS W 16 GY/W 18 GY/W 18
67
INJ4 LS
68 Y/W 18 Y/W 18 6 RING R 16
INJ5 LS BK/W 16 LB/DG 18 LB/DG 18 5 3
69
GROUND BR/W 18 BR/W 18 4 2
70
INJ6 LS BK/W 16 GY/R 18 GY/R 18 3 1
71
AUX PWM8 LG/P 18 GY/O 18 GY/O 18 2
72
STARTER 1
RELAY
73 R/Y 18 ALTERNATOR
74 PK/LG 18
MIL BK/R 16
75
UEGO H
76
AUX PWM7 W/BK 18
77
LOCKOFF LB/O 18 LG/P 18 DG/W 18
78
(FUEL PUMP) AUX PWM6 R/T 16 R/Y 18
79
VBAT LB/DG 18
80
DBW +
81 BK/W 16 OIL PRESSURE
GROUND GY/O 18
82
DBW - R/BK 18
83 R/BK 18 21 AUX PWM 5
AUX PWM5 REC R/W 18
84 R/BK 18 R/W 18 16 AUX PWM 4
AUX PWM5
AUX PWM1
AUX PWM4
85
86
O/LG 18
R/W 18
T/GN 18
BK/O 18
DG/W 18
BK/O 18
DG/W 18
25 IVS
6
87 26 OIL PRES
AUX PWM2 T/Y 18
88 T/Y 18 2 TACH
AUX PWM4 REC
89 PK/LG 18 PK/LG 18 6 MIL
FP REC AUX PWM3 REC BK/R 16 BK/R 16
90 BK/R 16 18 FUEL PUMP -
FUEL PUMP AUX PWM3 O/LG 18 O/LG 18
39 AUX OUT1
R 16 W 16 Y/DB 18 Y/DB 18