GS40 Service Manual PDF

Service Manual
Serial Number Range
from S40-7001 to
S-40
TM
S4012-17231
TM
S-45
Part No. 102521

Rev E
October 2013
Introduction October 2013
Important Serial Number Information

Read, understand and obey the safety rules and Genie offers the following Service Manuals for
operating instructions in the appropriate operator's these models:
manual on your machine before attempting any
maintenance or repair procedure. Title Part No.
This manual provides detailed scheduled
S-40 and S-45 Service Manual
maintenance information for the machine owner and
(before serial number 3804) ................................ 32222
user. It also provides troubleshooting fault codes
and repair procedures for qualified service S-40 and S-45 Service Manual
professionals. (from serial number 3804 to 4728) ....................... 52271
Basic mechanical, hydraulic and electrical skills are S-40 and S-45 Service Manual
required to perform most procedures. However, (from serial number 4729 to 7000) ....................... 72136
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life

Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
Copyright © 2011 by Terex Industries
and send in suggestions for improvement. All
communications will be carefully considered for 102521 Rev E October 2013
future printings of this and all other manuals. Fourth Edition, Fifth Printing
"Genie" and "S" are registered trademarks of

Terex South Dakota, Inc. in the USA and many
other countries.
Contact Us: Printed on recycled paper
Printed in U.S.A.
http://www.genielift.com
e-mail: awp.techpub@terex.com
ii S-40 • S-45 Part No. 102521

October 2013
Revision History
Revision Date Section Procedure / Schematic Page / Description
D 2/2012 2 - Spec. 2-1, 2-2, 2-13
3 - Maint. 3-1, 3-3, 3-9 to 3-15, 3-17, 3-35 to 3-38, 3-54
4 - Repair 4-4, 4-5, 4-6, 4-7, 4-48, 4-49, 4-50, 4-51, 4-60
6 - Schem. 6-4, 6-5, 6-32 to 6-64, 6-92 to 6-125, 6-138,
6-139, 6-150, 6-151, 6-153
D1 10/1012 2 - Spec. 2-1, 2-2
3 - Maint. 3-9, 3-33 to 3-34

4 - Repair 4-59 to 4-60
D2 10/2013 4- Repair 4-3
6 - Schem. 6-19, 6-29, 6-33, 6-93
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #. Electronic Version

3-3_Section 3_Maintenance Procedure Page #.
4-48_Section 4_Repair Procedure Page #. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-5_Section 6_Schematic Page #.
Part No. 102521 S-40 • S-45

October 2013
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #. Electronic Version

3-3_Section 3_Maintenance Procedure Page #.
4-48_Section 4_Repair Procedure Page #. Click on any procedure or page number
Fault Codes_Section 5. highlighted in blue to view the update.
6-5_Section 6_Schematic Page #.
S-40 • S-45 Part No. 102521

October 2013 Section 1 • Safety Rules
Serial Number Legend
Model: S-40
Serial number: S4006-12345
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: ES0274
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg

Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg S40 06 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 60 ft 6 in/ 18.3 m
Model Sequence
Maximum platform reach : 34 ft 3 in/ 10.4 m number
Gradeability: N/A
Country of manufacture: USA Model year
This machine complies with:
ANSI A92.5
CAN B.354.4
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
Sequence number Serial label

(stamped on chassis) (located under cover)
PN - 77055
iii
Part No. 102521 S-40 • S-45
Section 1 • Safety Rules July 2007
This page intentionally left blank.
iv
S-40 • S-45 Part No. 102521
July 2007 Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-40 and S-45
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's

manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting equipment
and a suitable workshop.
v
Part No. 102521 S-40 • S-45
Section 1 • Safety Rules July 2007
SAFETY RULES
Personal Safety Be sure to wear protective eye wear and

other protective clothing if the situation
Any person working on or around a machine must warrants it.
be aware of all known safety hazards. Personal
safety and the continued safe operation of the Be aware of potential crushing hazards
machine should be your top priority. such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Read each procedure thoroughly. This
manual and the decals on the machine use
signal words to identify the following:
Workplace Safety
Be sure to keep sparks, flames and
Safety alert symbol—used to alert
lighted tobacco away from flammable and
personnel to potential personal
combustible materials like battery gases
injury hazards. Obey all safety
and engine fuels. Always have an approved fire
messages that follow this symbol
extinguisher within easy reach.
to avoid possible injury or death.
Be sure that all tools and working areas
Used to indicate the presence of
are properly maintained and ready for
an imminently hazardous situation
use. Keep work surfaces clean and free
which, if not avoided, will result in
death or serious injury. of debris that could get into machine components
and cause damage.
Used to indicate the presence of a
potentially hazardous situation Be sure any forklift, overhead crane or
which, if not avoided, could result other lifting or supporting device is fully
in death or serious injury. capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
Used to indicate the presence of a are in good condition and of ample capacity.
potentially hazardous situation
which, if not avoided, may result in Be sure that fasteners intended for one
minor or moderate injury. time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
Used to indicate the presence of a may fail if they are used a second time.
which, if not avoided, may result in Be sure to properly dispose of old oil or
property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
vi
S-40 • S-45 Part No. 102521
October 2013
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................. iv
Section 1 Safety Rules

General Safety Rules .................................................................................................. v
Section 2 Rev Specifications

Machine Specifications .......................................................................................... 2 - 1
Hydraulic Oil Specifications ................................................................................... 2 - 2
Manifold Component Specifications ....................................................................... 2 - 5
Valve Coil Resistance Specifications ..................................................................... 2 - 5
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7
Deutz F3L-1011F Engine Specifications ................................................................ 2 - 8
Deutz F3L-2011/Deutz D2011L03i Engine Specifications ....................................... 2 - 9
Perkins 704-30 Engine Specifications .................................................................. 2 - 10
Perkins 404-22 Engine Specifications .................................................................. 2 - 11
Machine Torque Specifications ............................................................................ 2 - 12
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 13
SAE and Metric Fastener Torque Chart ............................................................... 2 - 14
Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
Checklist A Procedures
A-1 Inspect the Decals and Manuals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................. 3 - 8
A-3 Perform Function Tests ................................................................................ 3 - 8
A-4 Perform Engine Maintenance ....................................................................... 3 - 9
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Part No. 102521 S-40 • S-45
October 2013
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

A-5 Inspect the Track Components, TRAX option .............................................. 3 - 9
A-6 Perform 30 Day Service ............................................................................. 3 - 10
A-7 Perform Engine Maintenance - Deutz and Ford Models .............................. 3 - 10
A-8 Replace the Drive Hub Oil .......................................................................... 3 - 11
A-9 Perform Engine Maintenance - Perkins Models .......................................... 3 - 12
A-10 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12
A-11 Perform Engine Maintenance - Ford Models ............................................... 3 - 13
A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 14
A-13 Perform Engine Maintenance - Deutz 1011F Models .................................. 3 - 14
A-14 Perform Engine Maintenance - Ford Models ............................................... 3 - 15
Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 16
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 17
B-3 Inspect the Air Filter ................................................................................... 3 - 18
B-4 Test the Key Switch ................................................................................... 3 - 19
B-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 19
B-6 Check the Exhaust System ....................................................................... 3 - 20
B-7 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 20
B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 21
B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 22
B-10 Confirm the Proper Brake Configuration ...................................................... 3 - 23
B-11 Check and Adjust the Engine RPM ............................................................ 3 - 24
B-12 Test the Engine Idle Select ........................................................................ 3 - 25
B-13 Test the Fuel Select Operation - Ford Models ............................................ 3 - 26
B-14 Test the Ground Control Override ............................................................... 3 - 27
B-15 Check the Directional Valve Linkeage ........................................................ 3 - 27
B-16 Test the Platform Self-leveling ................................................................... 3 - 28
viii S-40 • S-45 Part No. 102521

October 2013
TABLE OF CONTENTS

B-17 Test the Drive Brakes ................................................................................ 3 - 28
B-18 Test the Drive Speed - Stowed Position ..................................................... 3 - 29
B-19 Test the Drive Speed - Raised or Extended Position .................................. 3 - 29
B-20 Perform Hydraulic Oil Analysis ................................................................... 3 - 30
B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 31
B-22 Inspect the Fuel and Hydraulic Tank Cap Venting System ......................... 3 - 32
B-23 Check the Track Tension and Fastener Torque - TRAX Option .................. 3 - 33
B-24 Perform Engine Maintenance - Ford Models ............................................... 3 - 34
Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 35
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 36
C-3 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 36
C-4 Replace the Engine Air Filter - Deutz and Perkins Models .......................... 3 - 39
C-5 Replace the Inline Fuel Strainer .................................................................. 3 - 39
C-6 Perform Engine Maintenance Ford Models ................................................. 3 - 40
Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 41
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 42
D-3 Check the Free-wheel Configuration ........................................................... 3 - 43
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 45
D-5 Perform Engine Maintenance - Deutz Models ............................................. 3 - 46
D-6 Replace the Hydraulic Filters ...................................................................... 3 - 47
D-7 Inspect for Turntable Bearing Wear ............................................................ 3 - 48
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 50
E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 52
E-3 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 53
E-4 Perform Engine Maintenance - Ford Models ............................................... 3 - 54
Part No. 102521 S-40 • S-45 ix

October 2013
TABLE OF CONTENTS

E-7 Perform Engine Maintenance - Deutz Models ............................................. 3 - 56
E-8 Perform Engine Maintenance - Deutz Models ............................................. 3 - 56
E-9 Perform Engine Maintenance - Ford Models ............................................... 3 - 57
Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1 ALC-500 Circuit Board .................................................................................. 4 - 2
1-2 Joysticks ..................................................................................................... 4 - 3
Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 8
2-2 Platform Rotator ........................................................................................... 4 - 9
2-3 Platform Overload System ......................................................................... 4 - 11
Jib Boom Components
3-1 Jib Boom .................................................................................................... 4 - 14
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 15
Boom Components
4-1 Cable Track ................................................................................................ 4 - 16
4-2 Boom ......................................................................................................... 4 - 18
4-3 Boom Lift Cylinder ...................................................................................... 4 - 19
4-4 Boom Extension Cylinder ........................................................................... 4 - 20
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 21
Engines
5-1 RPM Adjustment - Deutz Models ............................................................... 4 - 24
5-2 RPM Adjustment - Perkins Models ............................................................. 4 - 24
5-3 Flex Plate ................................................................................................... 4 - 24
5-4 Engine Fault Codes - Ford Models ............................................................. 4 - 28
x
S-40 • S-45 Part No. 102521
October 2013
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

Hydraulic Pumps
6-1 Function Pump ........................................................................................... 4 - 29
6-2 Drive Pump ................................................................................................ 4 - 30
Manifolds
7-1 Function Manifold Components .................................................................. 4 - 32
7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 36
7-3 Jib Select and Platform Rotate Manifold Components ................................ 4 - 37
7-4 Brake Manifold Components
(before serial number 7569) ........................................................................ 4 - 38
7-5 Brake/Two-Speed Manifold Components
(after serial number 7568) ........................................................................... 4 - 39
7-6 Oscillate Directional Valve Manifold Components ....................................... 4 - 40
7-7 Valve Adjustments, Oscillate Relief Valve ................................................. 4 - 42
7-8 Traction Manifold Components, 2WD (before serial number 7569) .............. 4 - 43
7-9 Traction Manifold Components, 2WD (after serial number 7568) ................. 4 - 44
7-10 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 45
7-11 Traction Manifold Components, 4WD (before serial number 7569) .............. 4 - 46
7-12 Traction Manifold Components, 4WD (from serial number 7568 to 15822) .. 4 - 48
7-13 Traction Manifold Components, 4WD (from serial number 15823) ............... 4 - 50
7-14 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 52
7-15 Valve Coils ................................................................................................. 4 - 53
7-16 Drive Oil Diverter Manifold Components (welder option) ............................. 4 - 55
Turntable Rotation Components
8-1 Turntable Rotation Assembly ..................................................................... 4 - 56
Axle Components
9-1 Oscillate Axle Cylinders ............................................................................. 4 - 58
Track Components
10-1 Track Assembly - TRAX Option ................................................................. 4 - 59
Generators
10-1 Hydraulic Generator .................................................................................... 4 - 61
xi
Part No. 102521 S-40 • S-45
October 2013
TABLE OF CONTENTS
Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1
Fault Codes - Control System ................................................................................ 5 - 2
Fault Codes - Ford LRG-425 Engine ....................................................................... 5 - 6
Fault Codes - Ford DSG-423 EFI Engine ............................................................. 5 - 12
Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend .................................................................................... 6 - 2
Hydraulic Symbols Legend .................................................................................... 6 - 3
Ford DSG-423 Engine Relay Layout ....................................................................... 6 - 4
Connector Pin Legend ............................................................................................ 6 - 5
Electrical Schematic, Deutz F3L 1011 Models
(before serial number 7544) .......................................................................... 6 - 8
Ground Control Box Wiring Diagram
Deutz F3L-1011F Models ........................................................................... 6 - 11
Platform Control Box Wiring Diagram
Deutz F3L-1011F Models ........................................................................... 6 - 14
Platform Control Box Switch Panel Wiring Diagram
Deutz F3L-1011F Models ........................................................................... 6 - 15
Electrical Schematic, Perkins 704-30 Models
(before serial number 7472) ........................................................................ 6 - 18
Perkins 704-30 Models ............................................................................... 6 - 21
Perkins 704-30 Models ............................................................................... 6 - 24
Perkins 704-30 Models ............................................................................... 6 - 25
xii
S-40 • S-45 Part No. 102521
October 2013
TABLE OF CONTENTS
Section 6 Rev Schematics, continued

Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models
(from serial number 7544 to 12509)
Perkins 404-22 Models
(from serial number7472 to 12509) ............................................................. 6 - 28
Perkins 404-22 Models (from serial number 12510 to 14831) ...................... 6 - 32
Deutz F3L-2011/Deutz D2011L03i Models - ANSI / CSA / AS
Deutz F3L-2011/Deutz D2011L03i Models - CE
Deutz F3L-2011/Deutz D2011L03i Models - ANSI / CSA / AS
Perkins 404-22 Models (from serial number 16420) .................................... 6 - 48
Deutz F3L-2011/Deutz D2011L03i Models - CE
Ground Control Box Wiring Diagram,
Perkins 404-22 Models (before serial number 14832) ................................. 6 - 56
xiii
Part No. 102521 S-40 • S-45
October 2013
TABLE OF CONTENTS

Perkins 404-22 Models (before serial number 14832) ................................. 6 - 60
(from serial number 7472 to 12509) ............................................................ 6 - 64
Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 68
Ford LRG-425 EFI Models
xiv
S-40 • S-45 Part No. 102521
October 2013
TABLE OF CONTENTS

Electrical Schematic, Ford DSG-423 EFI Models
(from serial number 11067 to 12509) .......................................................... 6 - 88
Electrical Schematic, Ford DSG-423 EFI Models - ANSA / CSA / AS
(from serial number 15663 to 16419) ......................................................... 6 - 100
Electrical Schematic, Ford DSG-423 EFI Models - CE
Electrical Schematic, Ford DSG-423 EFI Models - ANSA / CSA / AS
(from serial number 16420) ........................................................................ 6 - 108
Electrical Schematic, Ford DSG-423 EFI Models - CE
Ford DSG-423 EFI Models (before serial number 14832) ........................... 6 - 116
Ford DSG-423 EFI Models (from serial number 14832) .............................. 6 - 117
Ford DSG-423 EFI Models (before serial number 14832) ........................... 6 - 120
Platform Control Box Switch Panel Wiring Diagram,
Ford DSG-423 EFI Models (from serial number 11067 to 12509) ............... 6 - 124
Part No. 102521 S-40 • S-45

October 2013
TABLE OF CONTENTS

Engine Harness, Ford LRG-425 EFI Models
(before serial number 11067) ..................................................................... 6 - 128
Engine Harness, Ford DSG-423 EFI Models
Engine Harness, Ford DSG-423 EFI Models
Joystick Connector Diagram ............................................................................... 6 - 133
CTE Option Wiring Diagram ................................................................................ 6 - 136
MTE Hydraulic Generator Option Wiring Diagram ................................................ 6 - 138
Hydraulic Generator Wiring Diagram (welder option) ............................................ 6 - 139
Hydraulic Schematic, 2WD Non-oscillating S-40 Models
(before serial number 7569) ....................................................................... 6 - 142
Hydraulic Schematic, 2WD Non-oscillating S-45 Models
Hydraulic Schematic, 4WD Oscillating S-40 Models
Hydraulic Schematic, 4WD Oscillating S-45 Models
Hydraulic Schematic, 2WD (from serial number 7569) ........................................ 6 - 150
Hydraulic Schematic, 4WD (from serial number 7569) ........................................ 6 - 151
Generator Hydraulic Schematic (welder option) ................................................... 6 - 153
S-40 • S-45 Part No. 102521

October 2013 Section 2 • Specifications
Specifications
Machine Specifications Track Components, TRAX option
S-40 and S-45 Models Track material Rubber
Tires and wheels Weight, assembly (each) 480 lbs

218 kg
Tire size, 2WD
front tires only 12.5L-16SL Fluid capacities
rear tires only 12-16.5 NHS Fuel tank 20 gallons
Tire size, 75.7 liters
2WDRT & 4WD front & rear 12-16.5 NHS Fuel tank, Option 30 gallons
Tire weight, new foam-filled (minimum) 300 lbs 114 liters
(Rough terrain) 136 kg LPG tank 33.5 pounds
Tire ply rating 12 8 15.2 kg
Tire contact area 88 sq in 57 sq in Hydraulic tank 45 gallons

568 sq cm 368 sq cm 170 liters
Overall tire diameter 33.7 in 33.2 in Hydraulic system 55 gallons

85.6 cm 84.3 cm (including tank) 208 liters
Tire pressure 45 psi 45 psi Drive hub 17 fl oz

(Rough terrain) 3.1 bar 3.1 bar (before serial number 7569) 0.5 liters
Tire pressure 60 psi 60 psi Drive hub 24 fl oz

(Rough terrain) 4.1 bar 4.1 bar (from serial number 7569 to 15677) 0.71 liters
Wheel diameter 16 in 161/2 in Drive hub 20 fl oz

40.6 cm 41.9 cm (from serial number 15678) 0.6 liters
Wheel width 10 in 9 3/4 in Turntable rotation 8 fl oz

25.4 cm 24.8 cm drive hub 0.24 liters
Wheel lugs 8@ 5/8 -18 9@ 5/8 -18 Drive hub oil type:
SAE 90 multipurpose hypoid gear oil API service
Lug nut torque - Drive and 9-bolt non-drive hubs classification GL5
Lug nut, dry 230 ft-lbs

312 Nm For operational specifications, refer to the
Operator's Manual.
Lug nut, lubricated 170 ft-lbs
230 Nm
Lug nut torque - 8-bolt non-drive spindles
Lug nut, dry 170 ft-lbs

230 Nm
Lug nut, lubricated 130 ft-lbs

176 Nm
Continuous improvement of our products is a Genie

policy. Product specifications are subject to change
without notice.
Part No. 102521 S-40 • S-45 2-1

Section 2 • Specifications October 2013
SPECIFICATIONS
Performance Specifications Hydraulic Oil Specifications

All Models
Hydraulic Oil Specifications
Drive speeds, 2WD and 4WD Hydraulic oil type Chevron Rando HD MV equivalent
Viscosity grade Multi-viscosity
Drive speed, stowed 40 ft / 5.2 - 5.9 sec
Viscosity index 200
12.2 m / 5.2 - 5.9 sec
Drive speed, raised or extended 40 ft / 40 - 45 sec Cleanliness level, minimum 15/13
12.2 m / 40 - 45 sec Water content, maximum 200 ppm
Drive speed, TRAX option
Chevron Rando HD MV oil is fully compatible and
Drive speed, stowed 40 ft / 11 sec mixable with Shell Donax TG (Dexron III) oils.
12.2 m / 11 sec Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
Drive speed, raised or extended 40 ft / 40 sec systems, have the ability to perform over a wide
12.2 m / 40 sec temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
Gradeability See Operator's Manual
oxidation, corrosion inhibition, seal conditioning, and
Boom function speeds, maximum foam and aeration suppression properties.
from platform controls
Optional fluids
Boom up 50 to 60 seconds
Biodegradable Petro Canada Environ MV46
Boom down 45 to 60 seconds Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Boom extend 30 to 60 seconds
Fire resistant UCON Hydrolube HP-5046
Boom retract 15 to 35 seconds Quintolubric 822
Turntable rotate, 360° Mineral based Shell Tellus S2 V 32

boom fully stowed 70 to 100 seconds Shell Tellus S2 V 46
Chevron Aviation A
Turntable rotate, 360° Eni Arnica 32
boom fully extended 120 to 140 seconds
Platform level (10° range of motion)

ANSI 3 to 5 seconds
CE/Austrailia 20 to 22 seconds
Jib boom up, S-45 models 35 to 45 seconds
Jib boom down, S-45 models 20 to 30 seconds
Braking distance, maximum
High range on paved surface 3 to 4 ft

0.9 to 1.2 m
Continuous improvement of our products is a

Genie policy. Product specifications are subject
to change without notice.
2-2 S-40 • S-45 Part No. 102521

SPECIFICATIONS
Continued use of Chevron Aviation Hydraulic Component

A hydraulic oil when ambient
temperatures are consistently Specifications
above 32°F / 0°C may result in
component damage. Drive pump
Note: Use Chevron Aviation A hydraulic oil when Type: bi-directional,

ambient temperatures are consistently variable displacement piston pump
below 0°F / -18°C. Displacement per revolution, variable, 4WD models
0 to 2.8 cu in
Note: Use Shell Tellus S2 V 46 hydraulic oil when
0 to 46 cc
oil temperatures consistently exceed 205°F / 96°C.
Flow rate @ 2500 rpm 0 to 28 gpm
Note: Genie specifications require additional 106 L/min
equipment and special installation instructions for
the approved optional fluids. Consult the Genie Drive pressure, maximum 3625 psi
Industries Service Department before use. 250 bar
Charge pump
Type: gerotor pump
Displacement 0.85 cu in
13.9 cc
Flow rate @ 2500 rpm 9 gpm

34.1 L/min
Charge pressure @ 2500 rpm 310 psi

Neutral position 21.4 bar
Function pump
Type gear, pressure balanced
17 cc
Flow rate @ 2500 rpm 10.69 gpm

40.5 L/min
Oscillation pump
Type gear, fixed displacement
6 cc
Flow rate @ 2500 rpm 2.8 gallons per minute
10.6 liters per minute

Part No. 102521 S-40 • S-45 2-3

SPECIFICATIONS
Auxiliary pump Steer-end drive motors, 4WD

(before serial number 7569)
Type: fixed displacement gear pump
Displacement per revolution 1.52 cu in / 25 cc
Displacement - static 0.151 cu in
2.47 cc Non-steer end drive motors, 2WD and 4WD
Displacement 1.75 gallons per minute
6.62 liters per minute Displacement per revolution 2.13 cu in / 35 cc
Function manifold Two-speed drive motors, 2WD and 4WD

(after serial number 7568)
Function relief valve pressure
S-40 2600 psi / 179 bar Displacement per revolution 0.99 cu in / 16.3 cc
S-45 2900 psi / 200 bar low speed
Boom down 2200 psi Displacement per revolution 1.83 cu in / 30 cc

relief valve pressure 152 bar high speed
Boom extend 1950 psi Hydraulic Filters

134 bar
Medium pressure filter Beta 3 ≥ 200
Oscillate axle 950 psi
66 bar Medium pressure filter 51 psi
bypass pressure 3.5 bar
Steer regulator, 2 gallons per minute
All models 7.6 liters per minute Hydraulic tank circuit 10 micron with
return line filter 25 psi / 1.7 bar bypass
Traction manifold, 2WD and 4WD
Hot oil relief pressure 210 psi

14.5 bar
Traction manifold, 2WD and 4WD

Hot oil relief pressure 280 psi

19.3 bar

2-4 S-40 • S-45 Part No. 102521

SPECIFICATIONS
Manifold Component Valve Coil Resistance

Specifications Specifications
Plug torque Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
SAE No. 2 36 in-lbs / 4.1 Nm valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
SAE No. 4 10 ft-lbs / 13.6 Nm
increase or decrease by 4% for each 18°F / 20°C
SAE No. 6 14 ft-lbs / 19 Nm that your air temperature increases or decreases
from 68°F / 20°C.
SAE No. 8 38 ft-lbs / 51.5 Nm
SAE No. 10 41 ft-lbs / 55.6 Nm Description Specification
SAE No. 12 56 ft-lbs / 75.9 Nm Solenoid valve, 2 position 3 way, 10V DC 6.3 Ω
(schematic items AC and AE)
Solenoid valve, 3 position 4 way, 10V DC 6.3 Ω

(schematic item AT and AZ)

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

(schematic items AZ and BF)
Proportional solenoid valve, 12V DC 9Ω

(schematic items AW and BB)

(schematic item CC)

(schematic items DA)

(schematic items CE)

Part No. 102521 S-40 • S-45 2-5

SPECIFICATIONS
Ford LRG-425 EFI Engine Starter motor
Displacement 153 cu in Normal engine cranking speed 200 to 250 rpm

2.5 liters Current draw, normal load 140-200A
Number of cylinders 4 Current draw, maximum load 800A
Bore & stroke 3.78 x 3.4 in Current draw, no load 70A
96.01 x 86.36 mm
Battery
Horsepower
Gross intermittent 70 @ 2500 rpm Type 12V DC, Group 31
Continuous 60 @ 2500 rpm
Gross intermittent 52 kW @ 2500 rpm Quantity 1
Continuous 44.7 kW @ 2500 rpm
Cold cranking ampere 1000A
Firing order 1-3-4-2
Reserve capacity @ 25A rate 200 minutes
Low idle rpm 1600 rpm
Frequency 396.8 Hz Electronic fuel pump
High idle rpm 2500 rpm Fuel pressure, static 64 psi

Frequency 620 Hz 4.4 bar
Compression ratio 9.4:1 Fuel flow rate 0.58 gpm

2.18 L/min
Compression pressure (approx.)
Pressure (psi) of lowest cylinder must be Ignition System
at least 75% of highest cylinder Spark plug type Motorcraft AWSF-52-C
Valve clearances - 0.035 to 0.055 in (before serial number 4546)
collapsed tappet 0.889 to 1.397 mm Spark plug type Motorcraft AGSF-32-FM
Lubrication system (after serial number 4545)
Oil pressure 40 to 60 psi Spark plug gap 0.042 to 0.046 inches

(operating temp. @ 2000 rpm) 2.75 to 4.1 bar 1.07 to 1.17 mm
Oil capacity 4.5 quarts Spark plug torque 5-10 ft-lbs

(including filter) 4.3 liters 7-14 Nm
Oil viscosity requirements Engine coolant
Unit ships with 5W-30 oil. Capacity 11.5 quarts

Extreme operating temperatures may require the use of 10.9 liters
alternative engine oils. For oil requirements, refer to the Coolant temperature switch
engine Operator's Manual on your machine.
Torque 8-18 ft-lbs
Oil pressure switch specifications 11-24 Nm
Torque 8-18 ft-lbs Temperature switch point 230° F
11-24 Nm 112° C
Oil pressure switch point 3-5 psi Alternator
0.21-0.34 bar
2-6 S-40 • S-45 Part No. 102521

SPECIFICATIONS
Ford DSG-423 EFI Engine Electronic fuel pump
Displacement 140.4 cu in Fuel pressure, static 64 psi

2.3 liters 4.4 bar
Number of cylinders 4 Fuel flow rate 0.43 gpm

1.6 L/min
Bore & stroke 3.44 x 3.7 inches
87.5 x 94 mm Fuel requirement
Horsepower For fuel requirements, refer to the engine Operator's

Continuous horsepower 59 @ 2500 rpm Manual on your machine.
Peak horsepower 69 @ 2500 rpm Ignition system
Continuous horsepower 44 kW @ 2500 rpm
Peak horsepower 51 kW @ 2500 rpm Spark plug type Motorcraft AGSF-32-FEC
Firing order 1-3-4-2 Spark plug gap 0.049 to 0.053 inches
1.244 to 1.346 mm
Low function idle (computer controlled) 1600 rpm
Frequency 53.3 Hz Engine coolant
High function idle (computer controlled) 2500 rpm Capacity 10 quarts
Frequency 83.3 Hz 9.5 liters
Compression ratio 9.7:1 Cylinder head temperature sending unit
Compression pressure (approx.) Fault code set temperature 280°F
Pressure (psi or bar) of lowest cylinder must be 138°C
at least 75% of highest cylinder
Engine shut-down temperature 300°F
Lubrication system 149°C
Oil pressure 29 to 39 psi Starter motor
(at operating temperature @ 2500 rpm) 2 to 2.7 bar
Normal engine cranking speed 200 to 250 rpm
Oil capacity 4 quarts
(including filter) 3.8 liters Current draw, normal load 140-200A
Oil viscosity requirements Current draw, maximum load 800A
Unit ships with 5-W20 oil. Alternator

Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the Output 95A, 13.8V DC
engine Operator's Manual on your machine. Battery
Type 12V DC, Group 31
Quantity 1
Cold cranking ampere @ 0°F 1000A

Part No. 102521 S-40 • S-45 2-7

SPECIFICATIONS
Deutz F3L-1011F Engine Injection system
Displacement 125 cu in Injection pump make OMAP

2.05 liters Injection pump pressure 4351 psi
Number of cylinders 3 300 bar
Bore and stroke 3.58 x 4.13 inches Injector opening pressure 3626 psi
91 x 105 mm 250 bar
Horsepower 36 @ 3000 rpm Fuel requirement

26.8 kW @ 3000 rpm For fuel requirement, refer to the engine Operator's
Firing order 1-2-3 Manual on your machine.
Compression ratio 18.5:1 Alternator output 55A, 14V
Compression pressure 362 to 435 psi Starter motor

25 to 30 bar Current draw, no load 90A
Low idle rpm 1500 rpm Brush length, new 0.7480 in
Frequency 313 Hz 19 mm
High idle rpm 2300 rpm Brush length, minimum 0.5 in
Frequency 479.9 Hz 12.7 mm
Governor centrifugal mechanical Battery
Valve clearance, cold Type 12V, Group 31
Intake 0.012 in Quantity 1
0.3 mm
Exhaust 0.020 in
0.5 mm Reserve capacity @ 25A rate 200 minutes
Lubrication system Fan belt deflection 3 /8to 1/2 inch
9 to 12 mm
Oil pressure 26 to 87 psi
1.8 to 6.0 bar
Oil capacity 8.5 quarts

(including filter) 8 liters
Oil viscosity requirements
Temperature below 60°F / 15.5°C (synthetic) 5W-30
-10°F to 90°F / -23°C to 32°C 10W-40
Temperature above -4°F / -34°C 15W-40

alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine. Continuous improvement of our products is a
2-8 S-40 • S-45 Part No. 102521

SPECIFICATIONS
Deutz F3L-2011 Engine Lubrication system

Deutz D2011L03i Engine Oil pressure, hot @ 2000 rpm 40-60 psi
2.8 to 4.1 bar
Displacement 142 cu in
2.33 liters Oil capacity 8.5 quarts
(including filter) 8 liters
Number of cylinders 3 (Deutz F3L2011 Engine)
Bore and stroke 3.7 x 4.4 inches Oil capacity 9.5 quarts
94 x 112 mm (including filter) 9 liters
(Deutz D2011L03i 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
Net continuous 34.5 kW @ 2800 rpm
Firing order 1-2-3 engine Operator's Manual on your machine.
Low idle rpm 1500 rpm Oil temperature switch

Frequency 313 Hz
Torque 8-18 ft-lbs
High idle rpm 2500 rpm 11-24 Nm
Frequency 521.7 Hz
Temperature switch point 220° F
Compression ratio 19:1 104° C
Compression pressure 362 to 435 psi Oil pressure switch

25 to 30 bar
Torque 8-18 ft-lbs
Governor centrifugal mechanical 11-24 Nm
Valve clearance, cold Oil pressure switch point 7 psi

(Deutz F3L2011 Engine) .5 bar
Intake 0.012 in
0.3 mm Oil pressure switch point 22 psi
(Deutz D2011L03i Engine) 1.5 bar
Exhaust 0.020 in
0.5 mm
Part No. 102521 S-40 • S-45 2-9

SPECIFICATIONS
Fuel injection system
Injection pump make Bosch
Injection pump pressure, maximum 15000 psi

1034 bar
Injector opening pressure 3046 psi

210 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's

Manual on your machine.
Starter motor
Current draw, normal load 140-200A
Brush length, new 0.72 in

18.5 mm
Brush length, minimum 0.27 in

7 mm
Battery
Type 12V, Group 31
Quantity 1
Alternator output 60A @ 14V DC
Fan belt deflection 3 /8to 1/2 inch

9 to 12 mm
2 - 10 S-40 • S-45 Part No. 102521

SPECIFICATIONS
Perkins 704-30 Engine Oil viscosity requirements
Displacement 183 cu in below 68°F / 20°C (synthetic) 5W-20

2.9 liters 5°F to 104°F / -15°C to 40°C 10W-30
Number of cylinders 4 above 14°F / -10°C 15W-40
Bore and stroke 3.82 x 3.94 inches Engine oil should have properties of API classification
97 x 100 mm CC/SE. API classification CD/SE or CCMC D4 can be
Horsepower 63 @ 2600 rpm used, but is not recommended during the first 50 hours
47 kW @ 2600 rpm nor for light load applications.
Firing order 1-3-4-2
Compression ratio 17.5:1 Injection system
Compression pressure 300 to 500 psi Injection pump make Zexel PFR-KX
20.7 to 34.5 bar Injection pump pressure
Pressure (psi) of lowest cylinder must be within (stage one) 2755 psi 190 bar
50 psi (3.45 bar) of highest cylinder (stage two) 3336 psi 230 bar
Low idle rpm 1600 rpm Injector opening pressure 3626 psi 250 bar
Frequency 246.7 Hz
Fuel requirement
High idle rpm 2200 rpm
Frequency 339.2 Hz For fuel requirement, refer to the engine Operator's
Manual on your machine.
Governor centrifugal mechanical
Engine coolant
Valve clearance, cold
Capacity 111/2 quarts
Intake 0.014 in 10.9 liters
0.35 mm
Alternator output 65A, 12V
Exhaust 0.014 in
0.35 mm Battery
Lubrication system Type 12V, Group 31
Oil pressure 41 psi Quantity 1
(at 2600 rpm) 2.8 bar
Oil capacity 7.3 quarts
(including filter) 8.3 liters Reserve capacity @ 25A rate 200 minutes
Fan belt deflection 3 /8

in
10 mm
Part No. 102521 S-40 • S-45 2 - 11

SPECIFICATIONS
Perkins 404-22 Engine Oil viscosity requirements
Displacement 134 cu in Unit ships with 15-W40 oil.

2.2 liters Extreme operating temperatures may require the use of
Number of cylinders 4 engine Operator's Manual on your machine.
Bore and stroke 3.31 x 3.94 inches Oil pressure sending unit
84 x 100 mm
Torque 8-18 ft-lbs
Horsepower 11-24 Nm
gross intermittent 50 @ 2800 rpm Oil pressure switch point 14.2 psi
continuous 41 @ 2800 rpm 1 bar
gross intermittent 37.3 kW @ 2800 rpm
continuous 31 kW @ 2800 rpm Coolant temperature sending unit
Firing order 1-3-4-2 Torque 8-18 ft-lbs

11-24 Nm
Low idle rpm 1300 rpm
Frequency 200.5 Hz Temperature switch point 221° F
105° C
Low Idle rpm with generator option 1500 rpm
Frequency 231.3 Hz Fuel injection system
High idle rpm 2500 rpm Injection pump make Zexel

Frequency 385.5 Hz Injection pressure 2133 psi
Compression ratio 22.4:1 147 bar
Compression pressure 426 psi Fuel requirement

29.4 bar For fuel requirement, refer to the engine Operator's
Pressure (psi) of lowest cylinder must Manual on your machine.
be within 50 psi / 3.45 bar of highest cylinder
Battery
Governor centrifugal mechanical
Type 12V, Group 31
Valve clearance, cold
Quantity 1
Intake 0.008 in
0.2 mm Cold cranking ampere 1000A
Exhaust 0.008 in Reserve capacity @ 25A rate 200 minutes
0.2 mm
Starter motor
Lubrication system
Current draw, normal load 140-200A
Oil pressure, hot 40 to 60 psi
(at 2000 rpm) 2.8 to 4.1 bar Alternator output 65A @ 13.8V DC
Fan belt deflection 3/8 to ½ in

Oil capacity 9.4 quarts to 11.2 quarts
(including filter) 8.9 liters to 10.6 liters 9 to 12 mm
2 - 12 S-40 • S-45 Part No. 102521

SPECIFICATIONS
Machine Torque Specifications TRAX Torque Specifications

Platform rotator Hub to drive sprocket fasteners
1-8 center bolt, Gr 5, dry 640 ft-lbs Lug nut, dry 230 ft-lbs
868 Nm 312 Nm
1-8 center bolt, Gr 5, lubricated 480 ft-lbs Lug nut, lubricated 170 ft-lbs
651 Nm 230 Nm
3/8 -16 bolts, Gr 8, lubricated 35 ft-lbs* Idler and bogey wheel fasteners
*use blue thread-locking compound 47.5 Nm
3/4 -10 bolts, GR 8, dry 375 ft-lbs
Turntable rotator 508 Nm
Drive hub mounting bolts, dry 210 ft-lbs 3/4 -10 bolts, GR 8, lubricated 281 ft-lbs
284 Nm 381 N
Drive hub mounting bolts, lubricated* 160 ft-lbs

*use blue thread-locking compound 217 Nm
Drive motor and hubs
Drive hub mounting bolts, dry 210 ft-lbs

284 Nm
Drive hub mounting bolts, lubricated 160 ft-lbs*

*use blue thread-locking compound 217 Nm
Drive motor mounting bolts, dry 49 ft-lbs

66.4 Nm
Drive motor mounting bolts, lubricated 37 ft-lbs

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

244 Nm
Part No. 102521 S-40 • S-45 2 - 13

SPECIFICATIONS
Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
Your machine is equipped with Parker Seal-Lok® cannot be re-used if the fitting or hose end has
fittings and hose ends. Genie specifications require been tightened beyond finger tight.
that fittings and hose ends be torqued to
specification when they are removed and installed Note: The O-rings used in the Parker Seal Lok®
or when new hoses or fittings are installed. fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
SAE O-ring Boss Port number 49612).
(tube fitting - installed into Aluminum)
2 Lubricate the O-ring before installation.
SAE Dash size Torque
3 Be sure that the face seal O-ring is seated and
-4 14 ft-lbs / 18.9 Nm retained properly.
-6 23 ft-lbs / 31.2 Nm 4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
-8 36 ft-lbs / 48.8 Nm tight.
-10 62 ft-lbs / 84.1 Nm 5 Tighten the nut or fitting to the appropriate
-12 84 ft-lbs / 113.9 Nm torque per given size as shown in the table.
-16 125 ft-lbs / 169.5 Nm

6 Operate all machine functions and inspect the
hoses and fittings and related components to
-20 151 ft-lbs / 204.7 Nm confirm that there are no leaks.
-24 184 ft-lbs / 250 Nm
SAE O-ring Boss Port Seal-Lok Fittings (ORFS)

®
(tube fitting - installed into Steel) (hose end)
SAE Dash size Torque SAE Dash size Torque
-4 15 ft-lbs / 20.3 Nm -4 18 ft-lbs / 24.4 Nm
-6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40.7 Nm
-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 54.2 Nm
-10 100 ft-lbs / 135.6 Nm -10 60 ft-lbs / 81.3 Nm
-12 135 ft-lbs / 183 Nm -12 85 ft-lbs / 115 Nm
-16 200 ft-lbs / 271 Nm -16 110 ft-lbs / 149 Nm
-20 250 ft-lbs / 334 Nm -20 140 ft-lbs / 190 Nm
-24 305 ft-lbs / 414 Nm -24 180 ft-lbs / 244 Nm
2 - 14 S-40 • S-45 Part No. 102521

SPECIFICATIONS
SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8 Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4

24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
1 8 480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
1 1/8 7 590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 1/4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1/2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(mm) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
Part No. 102521 S-40 • S-45 2 - 15

October 2013 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Observe and Obey: Each procedure includes a description, safety
information and step-by-step instructions.
Maintenance inspections shall be completed by
a person trained and qualified on the Symbols Legend
maintenance of this machine.
Safety alert symbol—used to alert
Scheduled maintenance inspections shall be personnel to potential personal
completed daily, quarterly, six months, annually injury hazards. Obey all safety
and every 2 years as specified on the messages that follow this symbol
Maintenance Inspection Report. The frequency to avoid possible injury or death.
and extent of periodic examinations and tests
may also depend on national regulations.
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
Used to indicate the presence of a
substantial damage.
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
Use only Genie approved replacement parts. which, if not avoided, may cause
minor or moderate injury.
Machines that have been out of service for a
period longer than three months must complete Used to indicate the presence of a
the quarterly inspection. potentially hazardous situation
which, if not avoided, may result in
Unless otherwise specified, perform each property damage.
maintenance procedure with the machine in the
following configuration: Indicates that a specific result is expected after
• Machine parked on a firm, level surface performing a series of steps.
• Boom in the stowed position Indicates that an incorrect result has occurred
after performing a series of steps.
• Turntable rotated with the boom between
the non-steer wheels
• Turntable secured with the turntable
rotation lock
• Key switch in the off position with the
key removed
• Wheels chocked
• All external AC power supply disconnected
from the machine
Part No. 102521 S-40 • S-45 3-1

Section 3 • Scheduled Maintenance Procedures October 2013
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in The pre-delivery preparation report contains
this manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation
procedure, it conveys the meaning below. Report to use for each inspection. Store completed
forms as required.
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
Daily or every 8 hours A

Indicates that a warm motor or pump
will be required to perform this Quarterly or every 250 hours A+B
procedure.
Six months or every 500 hours A+B+C
Annual or every 1000 hours A+B+C+D

Indicates that dealer service is required
to perform this procedure. Two years or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and govermental regulations
and requirements.
3-2 S-40 • S-45 Part No. 102521

Pre-Deliver
Pre-Deliveryy Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to each the Pre-operation Inspection, the Maintenance items
delivery. The inspection is designed to discover if and the Function Tests.
anything 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.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and reinspect 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 Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed N = no, unable to complete
by qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements Comments
listed 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
Terex South Dakota, Inc USA Genie UK

500 Oak Wood Road The Maltings, Wharf Road
PO Box 1150 Grantham, Lincolnshire
Watertown, SD 57201-6150 NG31- 6BH England
(605) 882-4000 (44) 1476-584333
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc.
133192 Rev D
3-4 S-40 • S-45 Part No. 102521

Maintenance Inspection Report

Model Checklist A Y N R
A-1 Inspect the Decals Checklist B Y N R
Serial number
A-2 Pre-operation B-1 Battery
Date inspection B-2 Electrical wiring
A-3 Functions tests B-3 Air filter element
Hour meter A-4 Engine maintenance - B-4 Key switch
all models
Machine owner B-5 Engine maintenance -
A-5 Inspect tracks - Deutz and Perkins
TRAX option models
Inspected by (print)
Perform after 40 hours: B-6 Exhaust system
Inspector signature A-6 30 Day Service B-7 Oil cooler and fins-
Perform after first 50 hours: Deutz models
Inspector title A-7 Engine maintenance - B-8 Tires, wheels and lug
Deutz and Ford models nut torque
Inspector company
A-8 Drive Hub Oil B-9 Drive hub maintenance
Instructions Perform every 50 hours: B-10 Brake configuration
• Make copies of this report to use for A-9 Engine maintenance- B-11 Engine RPM
each inspection. Perkins models B-12 Engine idle select
• Select the appropriate checklist(s) for Perform every 100 hours: B-13 Fuel select -
the type of inspection to be A-10 Fuel filter/water Ford models
performed. separator - B-14 Ground control
Deutz models
Daily or 8 hour B-15 Directional
A-11 Engine maintenance - valve linkage
Inspection: A
Ford models
Quarterly or 250 hour B-16 Platform
A-12 Rotation bearing self-leveling
Inspection: A+B
Perform after first 125 hours: B-17 Drive brakes
Six Month or 500 hour
Inspection: A+B+C A-13 Engine maintenance - B-18 Drive speed -
Deutz 1011F models stowed position
Annual or 1000 hours
Perform every 200 hours: B-19 Drive speed -
Inspection: A+B+C+D
A-14 Engine maintenance - raised position
2 Year or 2000 hour
Ford models B-20 Hydraulic oil analysis
Inspection: A+B+C+D+E
B-21 Alarm package
• Place a check in the appropriate box
Comments B-22 Fuel and hydraulic cap
after each inspection procedure is
venting systems
completed.
• Use the step-by-step procedures in B-23 Check track tension -
this section to learn how to perform TRAX option
these inspections. Perform every 400 hours:
• If any inspection receives an “N”, tag B-24 Engine maintenance -
and remove the machine from service, Ford models
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Part No. 102521 S-40 • S-45 3-5

MAINTENANCE INSPECTION REPORT
Model Checklist C Y N R Checklist E Y N R

C-1 Engine maintenance - E-1 Hydraulic oil
Serial number Deutz and Perkins E-2 Steer axle
models wheel bearings,
Date
C-2 Platform overload 2WD models
Hour meter (if equipped) Perform every 2000 hours:
C-3 Platform overload E-3 Engine maintenance -
Machine owner (if equipped) Deutz and
C-4 Air filter element - Perkins models
Inspected by (print) Deutz and Perkins Perform every 2400 hours:
models
Inspector signature E-4 Engine maintenance -
C-5 Fuel inline strainer - Ford models
Deutz models
Inspector title Perform every 3000 hours:
Perform every 800 hours:
E-5 Engine maintenance -
Inspector company C-6 Engine maintenance - Deutz and
Ford models Perkins models
Instructions Checklist D Y N R Perform every 5000 hours:
• Make copies of both pages to use for D-1 Boom wear pads E-6 Engine maintenance -
each inspection. D-2 Turntable bearing bolts Deutz models
• Select the appropriate checklist(s) for D-3 Free-wheel Perform every 6000 hours:
the type of inspection to be configuration E-7 Engine maintenance -
performed.
D-4 Drive hub oil Deutz and
Daily or 8 hour D-5 Engine maintenance- Perkins models
Inspection: A Deutz and Perkins Perform every 12,000 hours:
models E-8 Engine maintenance -
Quarterly or 250 hour
Inspection: A+B D-6 Hydraulic filters Deutz models
Six Month or 500 hour D-7 Turntable bearing wear Perform every 4 years:
Inspection: A+B+C E-9 Engine maintenance -
Annual or 1000 hours Ford models
Inspection: A+B+C+D
Comments
2 Year or 2000 hour
Inspection: A+B+C+D+E
• Place a check in the appropriate box

after each inspection procedure is
completed.
• Use the step-by-step procedures in
this section to learn how to perform
these inspections.
• If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6 S-40 • S-45 Part No. 102521

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.
1 Check to make sure that the operator's and

safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove the
machine from service until the manual is
replaced.
Part No. 102521 S-40 • S-45 3-7

CHECKLIST A PROCEDURES
A-2 A-4
Perform Pre-operation Inspection Perform Engine Maintenance
Genie specifications require that this procedure be
performed daily.
Completing a Pre-operation Inspection is essential Engine specifications require that this procedure be
to safe machine operation. The Pre-operation performed every 8 hours or daily, whichever comes
Inspection is a visual inspection performed by the first.
operator prior to each work shift. The inspection is
designed to discover if anything is apparently Proper engine maintenance, following the engine
wrong with a machine before the operator performs manufacturer's maintenance schedule, is essential
the function tests. The Pre-operation Inspection to good engine performance and service life.
also serves to determine if routine maintenance Failure to perform the maintenance procedures
procedures are required. can lead to poor engine performance and
component damage.
Complete information to perform this procedure is
available in the Operator's Manual on your Deutz models
machine. Required maintenance procedures and additional
engine information are available in the
A-3 Deutz 1011F Operation Manual
Perform Function Tests (Deutz part number 0297 9683) or the
Deutz 2011 Operation Manual
Genie specifications require that this procedure be (Deutz part number 0312 3547).
performed daily.
Completing the function tests is essential to safe Deutz 1011F Operation Manual
Genie part number 52883
machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must Deutz 2011 Operation Manual
never be used. If malfunctions are discovered, the Genie part number 139320
machine must be tagged and removed from
service.
Complete information to perform this procedure is

available in the Operator's Manual on your
machine.
3-8 S-40 • S-45 Part No. 102521

Perkins models A-5

Required maintenance procedures and additional Inspect the Track Components,
engine information are available in the TRAX option
Perkins 404-22 Operation Manual
(Perkins part number TPD 1443S).
Perkins 404-22 Operation Manual Note: Genie specifications require that this
procedure be performed daily or every 8 hours,
whichever comes first.
Maintaining tracks and track assembly components

Ford models
is essential to safe operation and good
Required maintenance procedures and additional performance. A track assembly failure could result
engine information are available in the in a machine tip-over. Component damage may
Ford LRG-425 EFI Operator Handbook also result if problems are not discovered and
(Ford part number FPP 194-302) or the repaired in a timely fashion.
Ford DSG-423 EFI Operator Handbook
1 Thoroughly clean the track assembly of any dirt,
(EDI part number 1060020) or the
rocks, clay, etc.
Ford MSG-425 EFI Operator Handbook
(Ford part number 1020010). 2 Inspect the following areas for damaged,
cracked, loose or missing parts and fasteners:
Ford LRG 425 EFI Operation Manual • Track
• Idler wheels
Ford DSG 423 EFI Operator Handbook • Drive sprocket and hub
• Bogey wheels
Ford MSG-425 EFI Operator Handbook • Undercarriage
Genie part number 215322 • Kingpin and steering linkage bushings
To access the engine:

Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot
fastener located at the platform end of the
engine tray. Swing the engine tray out and
away from the machine and secure it from
moving.
Crushing hazard. Failure to secure
the engine pivot plate from moving
could result in death or serious
injury.
Part No. 102521 S-40 • S-45 3-9

A-6 A-7
Perform 30 Day Service Perform Engine Maintenance -
Deutz and Ford Models
The 30 day maintenance procedure is a one time

sequence of procedures to be performed after the
Engine specifications require that this procedure be
first 30 days or 40 hours of usage, whichever
performed after the first 50 hours of operation.
comes first. After this interval, refer to the
maintenance tables for continued scheduled Proper engine maintenance, following the engine
maintenance. manufacturer's maintenance schedule, is essential
to good engine performance and service life.
1 Perform the following maintenance procedures:
Failure to perform the maintenance procedures
can lead to poor engine performance and
• A-10 Grease the Turntable Bearing and component damage.
Rotate Gear
Deutz models
• B-8 Inspect the Tires, Wheels and Lug Nut
Required maintenance procedures and additional
Torque
• B-9 Check the Drive Hub Oil Level and
Deutz 1011F Operation Manual
Fastener Torque
(Deutz part number 0297 9683) or the
• D-2 Check the Turnable Rotation Bearing Deutz 2011 Operation Manual
Bolts (Deutz part number 0312 3547).
• D-6 Replace the Hydraulic Filter Elements Deutz 1011F Operation Manual

3 - 10 S-40 • S-45 Part No. 102521

Ford models A-8

Required maintenance procedures and additional Replace the Drive Hub Oil
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the
Manufacturer drive hub specifications require that
this one-time procedure be performed after the first
150 hours.
(Ford part number 1020010).
Replacing the drive hub oil is essential for good
Ford LRG 425 EFI Operation Manual machine performance and service life. Failure to
Genie part number 84792 replace the torque hub oil after the first 50 hours of
use may cause the machine to perform poorly and
Ford DSG 423 EFI Operator Handbook continued use may cause component damage.
1 Select the drive hub to be serviced. Drive the
Ford MSG-425 EFI Operator Handbook machine until one of the two plugs is at the
Genie part number 215322 lowest point.
2 Remove both plugs and drain the oil into a
To access the engine: suitable container.
Remove the engine tray retaining fasteners 3 Drive the machine until one plug is at the top
located under the engine tray. Loosen the pivot and the other is at 90 degrees.
engine tray. Swing the engine tray out and 4 Fill the hub with oil from the top hole until the oil
away from the machine and secure it from level is even with the bottom of the side hole.
moving. Refer to Section 2, Specifications.
Crushing hazard. Failure to secure 5 Install the plugs. Use pipe thread sealant on
the engine pivot plate from moving units with pipe plugs.
could result in death or serious 6 Repeat steps 1 through 5 for all the other drive
injury. hubs.
models with pipe plugs a drive hub plugs
Part No. 102521 S-40 • S-45 3 - 11

A-9 A-10
Perform Engine Maintenance - Inspect the Fuel Filter/Water
Perkins Models Separator - Deutz Models
Engine specifications require that this procedure be Genie specifications require that this procedure be
performed every 50 hours. performed every 100 hours or monthly, whichever
comes first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential Proper maintenance of the fuel filter/water
to good engine performance and service life. separator is essential for good engine
Failure to perform the maintenance procedures performance. Failure to perform this procedure can
can lead to poor engine performance and lead to poor engine performance and/or hard
component damage. starting, and continued use may result in
component damge. Extremely dirty conditions may
Perkins models require this procedure be performed more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, well-
ventilated area away from heaters,
sparks, flames and lighted
Perkins 404-22 Operation Manual tobacco. Always have an
Genie part number 94890 approved fire extinguisher within
easy reach.
Note: Perform this procedure with the engine off.
located under the engine tray. Loosen the pivot 1 Loosen the drain plug located at the bottom of
fastener located at the platform end of the the filter. Allow the water to drain into a suitable
engine tray. Swing the engine tray out and container until fuel starts to come out.
away from the machine and secure it from Immediately tighten the drain plug.
moving.
injury.
3 - 12 S-40 • S-45 Part No. 102521

A-11
Perform Engine Maintenance -
Ford Models
a

a fuel filter performed every 100 hours.
b drain plug
2 Clean up any fuel that may have spilled. manufacturer's maintenance schedule, is essential
3 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
Explosion and fire hazard. If a fuel component damage.
leak is discovered, keep any
additional personnel from entering Required maintenance procedures and additional
the area and do not operate the engine information are available in the
machine. Repair the leak Ford LRG-425 EFI Operator Handbook
immediately. (Ford part number FPP 194-302) or the
(Ford part number 1020010) .
Ford LRG 425 EFI Operation Manual

Ford DSG 423 EFI Operator Handbook



moving.
injury.
Part No. 102521 S-40 • S-45 3 - 13

A-12 A-13
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.
Frequent application of lubrication to the turntable manufacturer's maintenance schedule, is essential
bearing and rotate gear is essential to good to good engine performance and service life.
machine performance and service life. Continued Failure to perform the maintenance procedures
use of an improperly greased bearing and gear will can lead to poor engine performance and
result in component damage. component damage.
1 Raise the boom enugh to access the turntable Required maintenance procedures and additional
gearing. engine information are available in the
2 Locate the grease fitting on the platform end of (Deutz part number 0297 9683).
the engine side bulkhead.
3 Pump grease into the turntable rotation bearing. Deutz 1011F Operation Manual
Rotate the turntable in increments of Genie part number 52883
4 to 5 inches / 10 to 13 cm at a time and repeat
this step until the entire bearing has been To access the engine:
greased.
1 Remove the engine tray retaining fasteners
4 Apply grease to each tooth of the drive gear, located under the engine tray. Loosen the pivot
located under the turntable. fastener located at the platform end of the
Grease specification away from the machine and secure it from
moving.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent Crushing hazard. Failure to secure
injury.
3 - 14 S-40 • S-45 Part No. 102521

A-14 To access the engine:

Perform Engine Maintenance - Remove the engine tray retaining fasteners
Ford Models located under the engine tray. Loosen the pivot
moving.
performed every 200 hours. Crushing hazard. Failure to secure
Proper engine maintenance, following the engine could result in death or serious
manufacturer's maintenance schedule, is essential injury.
component damage.



Part No. 102521 S-40 • S-45 3 - 15

Checklist B Procedures
B-1 • Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
Inspect the Battery
• Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display an adjusted
Genie specifications require that this procedure be specific gravity of 1.277 or higher. The battery
performed every 250 hours or quarterly, whichever is fully charged. Proceed to step 11.
comes first.
Result: One or more battery cells display a
Proper battery condition is essential to good specific gravity of 1.217 or below. Proceed to
engine performance and operational safety. step 8.
Improper fluid levels or damaged cables and
7 Perform an equalizing charge, OR fully charge
connections can result in engine component
the batteries and allow the batteries to rest at
damage and hazardous conditions.
least 6 hours.
Electrocution/burn hazard. Contact 8 Remove the battery vent caps and check the
with hot or live circuits could result specific gravity of each battery cell with a
in death or serious injury. Remove hydrometer. Note the results.
all rings, watches and other
jewelry. 9 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
Bodily injury hazard. Batteries follows:
contain acid. Avoid spilling or
contacting battery acid. Neutralize • Add 0.004 to the reading of each cell for
battery acid spills with baking soda every 10° / 5.5° C above 80° F / 26.7° C.
and water. • Subtract 0.004 from the reading of each cell for
1 Put on protective clothing and eye wear. every 10° / 5.5° C below 80° F / 26.7° C.
2 Be sure that the battery cable connections are Result: All battery cells display a specific gravity
free of corrosion. of 1.277 or greater. The battery is fully charged.
Proceed to step 11.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion Result: The difference in specific gravity
on the battery terminals and cables. readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
3 Be sure that the battery hold downs and cable than 1.217. Replace the battery.
connections are tight.
10 Check the battery acid level. If needed,
4 Fully charge the batteries and allow the batteries replenish with distilled water to 1/8 inch / 3 mm
to rest at least 6 hours. below the bottom of the battery fill tube. Do not
5 Remove the battery vent caps and check the overfill.
specific gravity of each battery cell with a 11 Install the vent caps and neutralize any
hydrometer. Note the results. electrolyte that may have spilled with baking
6 Check the ambient air temperature and adjust soda.
the specific gravity reading for each cell as
follows:
3 - 16 S-40 • S-45 Part No. 102521

CHECKLIST B PROCEDURES
B-2 4 Inspect for a liberal coating of dielectric grease

in the following locations:
Inspect the Electrical Wiring
• Between the ground and platform controls
• Between the ground and drive controls
• All harness connectors
Genie specifications require that this procedure be • Level sensor
performed every 250 hours or quarterly, whichever
comes first. 5 Open the turntable cover at the ground control
side of the machine.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine 6 Inspect the following areas for burnt, chafed,
performance. Failure to find and replace burnt, corroded and loose wires:
chafed, corroded or pinched wires could result in • Inside of the ground control box
unsafe operating conditions and may cause
• Hydraulic manifold wiring
component damage.
7 Start the engine from the ground controls and
Electrocution/burn hazard. Contact raise the boom above the turntable covers.
with hot or live circuits could result
in death or serious injury. Remove 8 Inspect the turntable area for burnt, chafed and
all rings, watches and other pinched cables.
jewelry. 9 Lower the boom to the stowed position and turn
1 Open the engine side turntable cover. the engine off.
2 Remove the engine tray retaining fasteners 10 Inspect the following areas for burnt, chafed,
located under the engine tray. Swing the engine corroded, pinched and loose wires:
tray out and away from the machine and secure • Cable track on the primary boom
it from moving.
• Cables on the primary, and jib booms
• Jib boom/Platform rotate manifold
could result in death or serious • Inside of the platform control box
injury. 11 Inspect for a liberal coating of dielectric grease
3 Inspect the following areas for burnt, chafed, in all connections between the ECM and the
corroded and loose wires: platform controls.
• Engine wiring harness 12 Swing the engine back to its original position
and install the engine pivot plate retaining
• Hydraulic manifold wiring fasteners.
Crushing hazard. Failure to install
the fasteners into the engine tray
to secure it from moving could
result in death or serious injury.
Part No. 102521 S-40 • S-45 3 - 17

B-3 4 Remove the filter element.

Inspect the Air Filter 5 Clean the inside of the canister and the gasket
with a damp cloth.
6 Clean the filter using dry compressed air. Blow
out from inside to outside. Check filter gasket
Note: Genie specifications require that this for damage.
procedure be performed every 250 hours or
7 Re-install the filter element, or if there are any
quarterly, whichever comes first. Perform this
signs of loss of filtration, replace the element.
procedure more often if dusty conditions exist.
8 Install the end cap onto the canister. Secure the
Maintaining the engine air filter in good condition is clamps.
essential to good engine performance and service
life. Failure to perform this procedure can lead to Note: Be sure the dust discharge valve is pointing
poor engine performance and component damage. down.

1 Open the engine side cover. Empty the dust
discharge valve by pressing together the sides
of the discharge slot. Clean the discharge slot
as needed.
2 Inspect the dust discharge valve. If the valve
shows any signs of damage, replace the valve.
a clamp
b canister end cap
c dust discharge valve
3 Disconnect the latches and remove the end cap

of the air cleaner canister.
3 - 18 S-40 • S-45 Part No. 102521

B-4 B-5
Test the Key Switch Perform Engine Maintenance -
Genie specifications require that this procedure be Deutz and Perkins Models
comes first.
Proper key switch action and response is essential

to safe machine operation. The machine can be
performed quarterly or every 250 hours, whichever
operated from the ground or platform controls and
comes first.
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to Deutz models
activate the appropriate control panel could cause
a hazardous operating situation. Required maintenance procedures and additional
1 Pull out the red Emergency Stop button to the Deutz 1011F Operation Manual
on position at both the ground and platform (Deutz part number 0297 9683).
controls.
2 Turn the key switch to ground control, start the Deutz 1011F Operation Manual
engine and then turn the key switch to platform Genie part number 52883
control.
Perkins models
3 Check all machine function from the ground
controls. Required maintenance procedures and additional
Result: All machine functions should not Perkins 404-22 Operation Manual
operate. (Perkins part number TPD 1443S).
4 Turn the key switch to ground control.
5 Check all machine function from the platform Genie part number 94890
controls.
Result: All machine functions should not To access the engine:
operate.
6 Turn the key switch to the off position. located under the engine tray. Loosen the pivot
Result: The engine should stop and no engine tray. Swing the engine tray out and
functions should operate. away from the machine and secure it from
moving.
injury.
Part No. 102521 S-40 • S-45 3 - 19

B-6 B-7
Check the Exhaust System Check the Oil Cooler and Cooling
Fins - Deutz Models

performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be
comes first. performed every 250 hours or quarterly, whichever
Maintaining the exhaust system is essential to comes first.
good engine performance and service life. Running Maintaining the oil cooler in good condition is
the engine with a damaged or leaking exhaust essential for good engine performance. Operating
system can cause component damage and unsafe a machine with a damaged oil cooler may result in
operating conditions. engine damage. Also, restricting air flow through
Bodily injury hazard. Do not the oil cooler will affect the performance of the
inspect while the engine is cooling system.
running. Remove the key to Bodily injury hazard. Do not
secure from operation. inspect while the engine
Burn hazard. Beware of hot is running. Remove the key to
engine components. Contact with secure from operation.
hot engine components may result Burn hazard. Beware of hot
in severe burns. engine components. Contact with
1 Remove the engine tray retaining fasteners hot engine components may result
located under the engine tray. Swing the engine in severe burns.
tray out and away from the machine and secure Oil cooler
it from moving.
injury.
2 Be sure that all nuts and bolts are tight. moving.
3 Inspect all welds for cracks. Crushing hazard. Failure to secure
4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
injury.
5 Swing the engine back to its original position
2 Remove the fasteners from the engine side
and install the engine pivot plate retaining
cover, and remove the cover.
fasteners.
3 Inspect the oil cooler for leaks and physical
Crushing hazard. Failure to install
damage.
to secure it from moving could 4 Clean the oil cooler of debris and foreign
result in death or serious injury. material.
3 - 20 S-40 • S-45 Part No. 102521

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

comes first.
Maintaining the tires and wheels in good

condition including proper wheel fastener torque is
a oil cooler essential to safe operation and good performance.
b cylinder head cooling fins Tire and/or wheel failure could result in a machine
c fan blower fins tip-over. Component damage may also result if
problems are not discovered and repaired in a
timely fashion.
Cooling and fan blower fins
Bodily injury hazard. An over-
5 Inspect the fan blower fins for physical damage. inflated tire can explode and could
cause death or serious injury.
6 Clean the fan blower fins of debris and foreign
material. Tip-over hazard. Do not use
temporary flat tire repair products.
7 Inspect the head cooling passages and fins for
physical damage or foreign material, using a Note: The tires on some machines are foam-filled
flashlight. and do not need air added to them.
8 Clean the cylinder head cooling passages of 1 Check all tire treads and sidewalls for cuts,
debris and foreign material. cracks, punctures and unusual wear.
9 Install the engine side cover. 2 Check each wheel for damage, bends and
cracks.
and install the engine pivot plate retaining 3 Check each lug nut for proper torque. Refer to
fasteners. Tighten the pivot fastener. Section 2, Specifications.
Crushing hazard. Failure to install Models with air-filled tires:
to secure it from moving could 4 Check pressure in each air-filled tire. Add air as
result in death or serious injury. necessary. Refer to Section 2, Specifications.
Part No. 102521 S-40 • S-45 3 - 21

B-9 Turntable rotate drive hub

Check the Drive Hub Oil Level 1 Remove the plug located on the side of the hub
and Fastener Torque and check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.

comes first.
Failure to maintain proper drive hub oil levels may
a
cause the machine to perform poorly and
continued use may cause component damage.
1 Drive the machine to rotate the hub until the

plugs are located one on top and the other
at 90 degrees.
2 Remove the plug located at 90 degrees and
check the oil level.
turntable drive hub
Result: The oil level should be even with the a plug
bottom of the side plug hole. 2 If necessary, add oil until the oil level is even
3 If necessary, remove the top plug and add oil with the bottom of the plug hole.
until the oil level is even with the bottom of the 3 Apply pipe thread sealant to the plug, and
side plug hole. Refer to Section 2, install the plug in the drive hub.
Specifications.
4 Check the torque of the turntable drive hub
4 Install the plug(s) in the drive hub. Use pipe mounting fasteners. Refer to Section 2,
thread sealant on units with pipe plugs. Specifications.
5 Check the torque of the drive hub mounting
fasteners. Refer to Section 2, Specifications.
6 Repeat this procedure for each drive hub.
3 - 22 S-40 • S-45 Part No. 102521

B-10 2 Be sure the free-wheel valve on the drive pump

is closed (clockwise).
Confirm the Proper
Note: The free-wheel valve is located on the
Brake Configuration bottom of the drive pump.
Genie specifications require that this procedure be b

comes first. a c
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
brake engaged position
Part No. 102521 S-40 • S-45 3 - 23

B-11
Check and Adjust the
Engine RPM
f

comes first.
Maintaining the engine rpm at the proper setting for a b c d

both low and high idle is essential to good engine
performance and service life. The machine will not
a solenoid boot
operate properly if the rpm is incorrect and b high idle adjustment nut
continued use may cause component damage. c yoke lock nut
d yoke
Note: This procedure will require two people. e low idle adjustment screw
f low idle lock nut
Ford Models
If high idle rpm is correct, disregard
Note: The engine rpm is controlled by the ECM adjustment step 4.
and can only be adjusted by re-programming the
ECM. If rpm adjustment or service is required, 4 Loosen the yoke lock nut. Turn the high idle
please contact Genie Industries Service adjustment nut and solenoid boot
Department OR your local Ford dealer. counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
Deutz Models yoke lock nut and re-check the rpm.
1 Connect a tachometer to the engine. Start the Note: Be sure the solenoid fully retracts when
engine from the ground controls. Refer to activating high idle.
Section 2, Specifications.
Perkins Models
Skip to step 3 if the low idle rpm is correct.
1 Connect a tachometer to the engine. Start the
2 Loosen the low idle lock nut and turn the low engine from the ground controls. Refer to
idle adjustment screw clockwise to increase the Section 2, Specifications.
rpm or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and re-check the
rpm.
3 Move the function enable/rpm select toggle
switch to the high idle (rabbit symbol) position
at the ground controls. Refer to Section 2,
Specifications.
3 - 24 S-40 • S-45 Part No. 102521

Skip to step 3 if the low idle rpm is correct. B-12

2 Loosen the low idle lock nut. Turn the low idle Test the Engine Idle Select
adjustment screw clockwise to increase the
rpm, or counterclockwise to decrease the rpm. Genie specifications require that this procedure be
comes first.
A properly operating engine idle select switch

is essential to good engine performance and safe
machine operation. There are two settings.
Foot switch activated low idle (turtle symbol)
allows the operator to control individual boom
functions.
Foot switch activated high idle (rabbit symbol)

should be used for normal machine operation. This
selection activates high idle only when the foot
switch is pressed down.
1 Pull out the red Emergency Stop button to the

a b c d on position at both the ground and platform
controls.
Tighten the low idle lock nut and confirm the
rpm. 2 Start the engine from the ground controls then
move and hold the function enable/rpm select
a solenoid boot
b high idle adjustment nut toggle switch to the high idle (rabbit symbol).
c clevis
d low idle lock nut and adjustment
Result: The engine should change to high idle.
screw
3 Release the function enable/rpm select toggle
3 Move the function enable toggle switch to the switch.
high idle (rabbit symbol) position. Refer to Result: The engine should return to low idle.
4 Turn the key switch to platform controls.
If high idle rpm is correct, disregard
adjustment step 4. 5 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
4 Loosen the yoke lock nut. Turn the high idle symbol).
adjustment nut and solenoid boot
counterclockwise to increase the rpm or Result: The engine should not change to
clockwise to decrease the rpm. Tighten the high idle.
yoke lock nut and re-check the rpm. 6 Press down the foot switch.
Note: Be sure the solenoid fully retracts when Result: The engine should change to high idle.
activating high idle.
7 Move the engine idle control switch to foot
switch activated low idle (turtle symbol).
Result: The engine should change to low idle.
Part No. 102521 S-40 • S-45 3 - 25

B-13 2 Start the engine from the platform controls and

allow it to run at low idle. Press down the foot
Test the Fuel Select Operation - switch to allow the engine to run at high idle.
Ford Models Result: The engine should start promptly and
operate smoothly in low and high idle.
3 Release the foot switch and shut the engine off
by pushing the red Emergency Stop button
in to the off position.
performed every 250 hours or quarterly, whichever 4 Move the fuel select switch to LPG.
comes first.
5 Start the engine and allow it to run at
The ability to select and switch between low idle. Press down the foot switch to allow the
gasoline and LPG fuels as needed is essential to engine to run at high idle.
safe machine operation. A fuel selection can be Result: The engine should start promptly and
made when the engine is running or not. operate smoothly in low and high idle.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel Note: The engine may hesitate momentarily and
modes and through all idle speeds can indicate then continue
fuel system problems that could develop into a to run on the selected fuel if switched while
hazardous situation. running.
Note: Perform this test after checking the gasoline

and LPG fuel levels, and warming the engine to
normal operating temperature.
1 Move the fuel select switch to gasoline and then
move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
symbol).
3 - 26 S-40 • S-45 Part No. 102521

B-14 B-15
Test the Ground Control Override Check the Directional Valve
Genie specifications require that this procedure be Linkage
comes first.
A properly functioning ground control override is

essential to safe machine operation. The ground
control override function is intended to allow
comes first.
ground personnel to operate the machine from the
ground controls whether or not the red Emergency Note: Perform this test only on models equipped
Stop button on the platform controls is in the on or with a oscillating axle.
off position. This function is particularly useful if the
operator at the platform controls cannot return the Proper axle oscillation is essential to safe machine
boom to the stowed position. operation. If the directional valve linkage is not
operating correctly, the stability of the machine is
1 Push in the platform red Emergency Stop compromised and it may tip over.
button to the off position.
1 Remove the drive chassis cover and the axle
2 Start the engine from the ground controls. covers from the non-steer end of the drive
3 At the ground controls, operate each boom chassis.
function through a partial cycle. 2 Locate the directional valve inside of the non-
Result: All boom functions should operate. steer axle and inspect the linkage for the
following:
• Lock nut is tight against yoke

• Yoke clevis pins are installed
• Cotter pins are installed through clevis
pins
• Linkage is properly attached to
directional valve
Part No. 102521 S-40 • S-45 3 - 27

B-16 B-17
Test the Platform Self-leveling Test the Drive Brakes
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.
Automatic platform self-leveling throughout Proper brake action is essential to safe machine
the full cycle of primary boom raising and lowering operation. The drive brake function should operate
is essential for safe machine operation. The smoothly, free of hesitation, jerking and unusual
platform is maintained at level by the platform noise. Hydrostatic brakes and hydraulically-
leveling slave cylinder which operates in a closed released individual wheel brakes can appear to
loop hydraulic circuit with the master cylinder operate normally when they are actually not fully
located at the base of the boom. operational.
A platform self-leveling failure creates an unsafe Collision hazard. Be sure that the
working condition for platform and ground machine is not in free-wheel or
personnel. partial free-wheel configuration.
See B-10, Confirm the Proper
1 Start the engine from the ground controls and Brake Configuration.
lower the boom to the stowed position.
Note: Select a test area that is firm, level and free
2 Hold the function enable toggle switch to either of obstructions.
side and adjust the platform to a level position
using the platform level toggle switch. 1 Mark a test line on the ground for reference.
3 Raise and lower the primary boom through a full 2 Start the engine from the platform controls.
cycle.
3 Move the engine idle control switch to
Result: The platform should remain level at foot switch activated high idle (rabbit and
all times to within ±5 degrees. foot switch symbol), then lower the boom into
the stowed position.
4 Choose a point on the machine; i.e., contact
patch of a tire, as a visual reference for use
when crossing the test line.
5 Bring the machine to top drive speed before
reaching the test line. Release the drive joystick
when your reference point on the machine
crosses the test line.
6 Measure the distance between the test line and
your machine reference point. Refer to
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
3 - 28 S-40 • S-45 Part No. 102521

B-18 B-19
Test the Drive Speed - Test the Drive Speed -
Stowed Position Raised or Extended Position
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Proper drive function movement is essential to Proper drive function movement is essential to
safe machine operation. The drive function should safe machine operation. The drive function should
respond quickly and smoothly to operator control. respond quickly and smoothly to operator control.
Drive performance should also be free of Drive performance should also be free of
hesitation, jerking and unusual noise over the hesitation, jerking and unusual noise over the
entire proportionally controlled speed range. entire proportionally controlled speed range.
Note: Select a test area that is firm, level and free Note: Select a test area that is firm, level and free
of obstructions. of obstructions.
1 Create start and finish lines by marking two 1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart. lines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls. 2 Start the engine from the platform controls.
3 Move the engine idle control switch to 3 Move the engine idle select switch to foot switch
foot switch activated high idle (rabbit and foot activated high idle (rabbit and foot switch
switch symbol), then lower the boom into the symbol).
stowed position.
4 Raise the boom above horizontal.
when crossing the start and finish lines.
when crossing the start and finish lines.
5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
6 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Specifications.
Part No. 102521 S-40 • S-45 3 - 29

6 Bring the machine to top drive speed before B-20

reaching the start line. Begin timing when your
reference point on the machine crosses the Perform Hydraulic Oil Analysis
start line.
7 Continue at full speed and note the time when
the machine reference point crosses the finish Genie specifications require that this procedure be
line. Refer to Section 2, Specifications. performed every 250 hours or quarterly, whichever
8 Lower the boom to the stowed position and comes first.
extend the boom 1 foot / 30 cm.
Replacement or testing of the hydraulic oil is
9 Choose a point on the machine; i.e., contact essential for good machine performance and
patch of a tire, as a visual reference for use service life. Dirty oil and a clogged suction strainer
when crossing the start and finish lines. may cause the machine to perform poorly and
10 Bring the machine to top drive speed before Extremely dirty conditions may require oil changes
reaching the start line. Begin timing when your to be performed more often.
reference point on the machine crosses the
start line. Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
11 Continue at top speed and note the time when
contamination to verify that changing the oil is
the machine reference point crosses the finish
necessary. If the hydraulic oil is not replaced at
line. Refer to Section 2, Specifications.
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
See E-1, Test or Replace the Hydraulic Oil.
3 - 30 S-40 • S-45 Part No. 102521

B-21 3 Move the function enable/rpm select toggle

switch to either side and activate the jib boom
Test the Alarm Package toggle switch in the down position, hold for a
(if equipped) and the moment and then release it.
Descent Alarm Result: The descent alarm should sound when
the toggle switch is held down.
performed every 250 hours or quarterly, whichever 4 Turn the key switch to platform controls.
comes first.
Result: The flashing beacons should be on
The alarm package includes: and flashing.
5 Press down the foot switch. Move the boom
• Travel alarm
controller to the down position, hold for a
• Flashing beacons moment and then release it.
Alarms and beacons are installed to alert operators Result: The descent alarm should sound when
and ground personnel of machine proximity and the controller is held down.
motion. The alarm package is installed on the
turntable rear cover. Beacons are installed on both 6 Press down the foot switch. Move the jib boom
turntable covers. toggle switch to the down position, hold for a
moment and then release it.
Note: The alarms and beacons will operate with
Result: The descent alarm should sound when
the engine running or not running.
the controller is held down.
Note: The descent alarm is standard equipment
7 Press down the foot switch. Move the drive
beginning with serial number 12602.
controller off center, hold for a moment and
1 Turn the key switch to ground controls and pull then release it. Move the drive controller off
out the red Emergency Stop button to the on center in the opposite direction, hold for a
position at both the ground and platform moment and then release it.
controls. Result: The travel alarm should sound when the
Result: Both flashing beacons should be on and drive controller is moved off center in either
flashing. direction.
2 Hold the function enable switch to either side

and activate the boom toggle switch in the
down position, hold for a moment and then
release it.
Result: The descent alarm should sound when
the toggle switch is held down.
Part No. 102521 S-40 • S-45 3 - 31

B-22 2 Check for proper venting.

Inspect the Fuel and Hydraulic Note: When checking for positive fuel tank cap
venting, air should pass freely through the cap.
Tank Cap Venting Systems
Result: Air should pass through the fuel tank
cap. Proceed to step 4.
Result: Air is not passing through the fuel tank
Genie specifications require that this procedure be cap. Clean or replace the cap.
performed quarterly or every 250 hours, whichever Proceed to step 3.
comes first. Perform this procedure more often if
dusty conditions exist. 3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
A free-breathing fuel and hydraulic tank cap is compressed air. Repeat this procedure
essential for good machine performance and beginning with step 2.
service life. A dirty or clogged cap may cause the
machine to perform poorly and continued use may 4 Install the fuel tank cap onto the fuel tank.
cause component damage. Extremely dirty All models:
conditions may require that the cap be inspected
more often. 5 Remove the breather cap from the hydraulic
tank.
Explosion and fire hazard. Engine
fuels are combustible. Perform this 6 Check for proper venting.
procedure in an open, well- Result: Air should pass through the breather
ventilated area away from heaters, cap. Proceed to step 8.
sparks, flames and lighted
tobacco. Always have an Result: If air does not pass through the breather
approved fire extinguisher within cap, clean or replace the cap.
easy reach. Proceed to step 7.
Gasoline/LPG models (before serial Note: When checking for positive tank cap venting,
number 13740) and Diesel models (all): air should pass freely through the cap.
Note: Perform this procedure with the engine off. 7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
Note: Gasoline/LPG models use a pressurized cap compressed air. Repeat this procedure
beginning with serial number 13740. beginning with step 6.
1 Remove the cap from the fuel tank. 8 Install the breather cap onto the hydraulic tank.
3 - 32 S-40 • S-45 Part No. 102521

B-23 5 Visually inspect the section of track under the

bogey wheels.
Check the Track Tension and
Result: There should be between 0.75 - 1 inch /
Fastener Torque, TRAX option 1.9 - 2.5 cm of gap between the bogey wheels
and the inside surface of the track. Proceed to
step 7.
Note: Manufacturer specifications require that this Result: There is 1 inch / 2.5 cm or more of gap
procedure be performed every 250 hours or between the bogey wheels and the inside
quarterly. surface of the track. Proceed to step 6.
Maintaining proper track tension and properly

torqued fasteners is essential to good machine
performance and service life. The machine will not
operate properly with a track that is incorrectly half sprocket
tensioned. Continued use of a machine with
incorrectly tensioned tracks may cause component
damage.
1 Thoroughly clean the track assembly of any dirt,
rocks, clay, etc.
2 Chock the tracks at one end of the machine to
prevent the machine from rolling.
3 Center a lifting jack of ample capacity idler wheel
(20,000 lbs / 10,000 kg) under the drive chassis tensioner bogey wheel
assembly
between the tracks at the other end of the
machine.
4 Lift the machine until the tracks are off the
ground and then place jack stands under the
drive chassis for support.
Part No. 102521 S-40 • S-45 3 - 33

6 Loosen the tensioner jam nut and idler axle bolts B-24
on both sides of the tensioner wheel and tighten
the tensioner nut until there is between 0.75 - 1 Perform Engine Maintenance -
inch / Ford Models
1.9 - 2.5 cm of gap between the bogey wheels
and the inside surface of the track.
Component damage hazard.
Do not over tighten the track. Engine specifications require that this procedure be
Overtightening the track will cause performed every 400 hours.
the machine to lose power during
operation. Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
7 Tighten the jam nut. to good engine performance and service life.
8 Check the torque of the track assembly
fasteners. Refer to Section 2, Specifications.
component damage.
9 Raise the machine, remove the jack stands and
lower the machine. Required maintenance procedures and additional
10 Repeat this procedure for each track assembly. Ford LRG-425 EFI Operator Handbook
FFord DSG-423 EFI Operator Handbook




moving.
injury.
3 - 34 S-40 • S-45 Part No. 102521

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

Engine specifications require that this procedure be Genie part number 94890
performed every 500 hours.
Proper engine maintenance, following the engine To access the engine:

manufacturer's maintenance schedule, is essential Remove the engine tray retaining fasteners
to good engine performance and service life. located under the engine tray. Loosen the pivot
Failure to perform the maintenance procedures fastener located at the platform end of the
can lead to poor engine performance and engine tray. Swing the engine tray out and
component damage. away from the machine and secure it from
Deutz models moving.
injury.
(Deutz part number 0312 3547).


Part No. 102521 S-40 • S-45 3 - 35

CHECKLIST C PROCEDURES
C-2 C-3
Grease the Platform Overload Test the Platform Overload
Mechanism (if equipped) System (if equipped)
performed every 500 hours or 6 months, whichever performed every 500 hours or six months,
comes first. Perform this procedure more often if whichever 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 use
mechanism is essential to safe machine operation. 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 a
the platform overload assembly. 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
inaccurate test.
4 Using a suitable lifting device, place a test

weight equal to that of the available capacity at
one of the locations shown.
Refer to Illustration 1.
Result: The platform overload indicator lights
should be off at both the ground and platform
controls and the alarm should not sound.
Result: The platform overload indicator lights are
on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Procedure 2-4, How to Calibrate the Platform
Overload System (if equipped).
3 - 36 S-40 • S-45 Part No. 102521

7 Using a suitable lifting device, remove the test

weights, restart the engine and carefully move
the test weights to each remaining location on
the platform. Refer to Illustration 1.
Result: The alarm should sound, the engine
should shut off and the platform overload
indicator lights should be flashing at both the
ground and platform controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
Illustration 1
flashing. Calibrate the platform overload
5 Carefully move the test weight to each system. Refer to Repair Procedure 2-4, How to
remaining location. Refer to Illustration 1. Calibrate the Platform Overload System (if
equipped).
Result: The platform overload indicator lights
should be off at both the ground and platform Note: There may be a 2 second delay before the
controls and the alarm should not sound. overload indicator lights flash, the alarm sounds
and the engine shuts off.
Result: The platform overload indicator lights are
on and the alarm is sounding. Calibrate the 8 Test all machine functions from the platform
platform overload system. Refer to Repair controls.
Procedure 2-4, How to Calibrate the Platform
Result: All platform control functions should not
operate.
6 Using a suitable lifting device, place an
9 Turn the key switch to ground control.
additional 50 lbs / 23 kg of weight onto the
platform. 10 Test all machine functions from the ground
controls.
Result: The alarm should sound and the engine
should shut off. The platform overload indicator Result: All ground control functions should not
lights should be flashing at both the ground and operate.
platform controls.
11 Activate the auxiliary power toggle switch.
Result: The alarm does not sound, the engine
12 Using auxiliary power, test all machine functions
does not shut off and the platform overload
from the ground controls.
indicator lights are not flashing. Calibrate the
platform overload system. Refer to Repair Result: All ground control functions should
Procedure 2-4, How to Calibrate the Platform operate.
13 Using a suitable lifting device, lift the additional
Note: There may be a 2 second delay before the test weight from the platform.
overload indicator lights flash, the alarm sounds
and the engine shuts off. Result: The platform overload indicator lights
should turn off at both the ground and platform
Part No. 102521 S-40 • S-45 3 - 37

14 Start the engine and test all machine functions 21 Using Illustration 3 as a guide, locate D31 Valve
from the ground controls. Power LED on the ALC500 printed circuit board.
Result: All ground control functions should
operate normally. Valve Power LED
15 Turn the key switch to platform control. ALC 500 Board
16 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate.
Note: If the platform overload system is not
operating properly, Refer to Repair Procedure 2-4,
How to Calibrate the Platform Overload System (if
equipped).
17 Push in the red Emergency stop button at the
platform to shut off engine.
Illustration 3
18 Using a suitable lifting device, remove all test
22 Step on the footswitch at the platform.
weights from the platform.
Result: The Valve Power LED should not
19 Pull out the red Emergency stop button to the on
illuminate.
position at the platform controls.
Result: The Valve Power LED is illuminated.
20 Remove the fasteners securing the lid to the
Remove the machine from service and contact
platform controls. Using Illustration 2 as a
the Genie Service Department.
guide, locate the timer relay inside the platform
control box. Tag and disconnect the red wire 23 Securely install the red wire, disconnected in
from terminal 5 on the timer relay. step 20, onto terminal 5 of the relay timer.
24 Step on the footswitch at the platform.
Result: The Valve Power LED should illuminate.
Result: The Valve Power LED is not illuminated.
Timer Relay Remove the machine from service and contact
the Genie Service Department.
weight equal to that of the available capacity at
Orange the center location shown in Illustration 1.
Wire
Terminal 5
Illustration 2
3 - 38 S-40 • S-45 Part No. 102521

26 Using a suitable lifting device, place an C-4

additional 50 lbs / 23 kg of weight onto the
platform. Replace the Engine Air Filter
Result: The alarm should sound and the Valve
Element - Deutz and Perkins
Power LED should not light. The platform Models
overload indicator lights should be flashing at
both the ground and platform controls.
27 Working from outside the platform and standing
next to the platform rotator, locate the orange Genie specifications requires that this procedure
wire, which enters into the base of the platform be performed every 500 hours or 6 months,
control box from the load sense switch and whichever comes first.
locate the wire terminal at the end of the wire.
Maintaining the engine air filter in good condition is
Tag and disconnect the connectors.
essential to good engine performance and service
Refer to Illustration 2.
life. Failure to perform this procedure can lead to
28 Using a multimeter set to read resistance poor engine performance and component damage.
(ohms), securely install a lead from the
1 Open the evacuator valve located on the air
multimeter to the connector on the orange wire,
cleaner cap by squeezing the sides together
and securely connect the other multimeter lead
with your fingers.
to a ground point in the control box.
2 Disconnect the latches on the air cleaner cap.
Result: The readout on the multimeter should
Remove the end cap from the air cleaner
indicate zero resistance.
canister.
Result: The readout on the multimeter shows
3 Remove the filter element.
resistance. Remove the machine from service
and contact the Genie Service Department. 4 Clean the inside of the canister and the gasket
with a damp cloth.
29 Using a suitable lifting device, remove all weight
from the platform. Note the result on the 5 Install the new filter element.
multimeter.
6 Install the end cap on the canister and re-
Result: The readout on the multimeter should connect the latches.
indicate infinite resistance.
Note: Be sure the evacuator valve is pointing
Result: The readout on the multimeter shows down.
zero resistance. Remove the machine from
service and contact the Genie Service
Department.
31 Turn off the multimeter and remove the leads
from the machine. Securely connect the wires
disconnected in step 27.
32 Close the platform control box. Install and
securely tighten the fasteners. Do not
overtighten.
Part No. 102521 S-40 • S-45 3 - 39

C-5 C-6
Replace the In-line Fuel Strainer - Perform Engine Maintenance -
Deutz Models Ford Models
Engine specifications require that this procedure Engine specifications require that this procedure be
be performed every 500 hours or 6 months, performed every 800 hours.
Replacing the diesel fuel strainer is essential for manufacturer's maintenance schedule, is essential
good engine performance and service life. A dirty to good engine performance and service life.
or clogged filter may cause the engine to perform Failure to perform the maintenance procedures
poorly and continued use may cause component can lead to poor engine performance and
damage. component damage.
Explosion and fire hazard. Engine Required maintenance procedures and additional
fuels are combustible. Perform this engine information are available in the
procedure in an open, well- Ford LRG-425 EFI Operator Handbook
ventilated area away from heaters, (Ford part number FPP 194-302) OR the
sparks, flames and lighted Ford DSG-423 EFI Operator Handbook
tobacco. Always have an (EDI part number 1060020) or the
approved fire extinguisher within Ford MSG-425 EFI Operator Handbook
easy reach. (Ford part number 1020010) .
1 Put on protective clothing and eye wear. Genie part number 84792
2 Locate the inline strainer above the throttle
actuator solenoid.
4 Place a suitable container under the filter.
5 Loosen the clamp holding the strainer to the
engine mount. Loosen the clamps securing the
fuel lines to the strainer. Remove and replace. To access the engine:

moving.
injury.
3 - 40 S-40 • S-45 Part No. 102521

Checklist D Procedures
D-1 Wear pad
specifications Minimum
Check the Boom Wear Pads
all wear pads 9/16
inch
14.3 mm
Genie specifications requires that this procedure 4 Extend and retract the boom through the entire
be performed every 1000 hours or annually, range of motion to check for tight spots that
whichever comes first. may cause binding or scraping of the boom.
Maintaining the boom wear pads in good condition Note: Always maintain squareness between the
is essential to safe machine operation. Wear pads outer and inner boom tubes.
are placed on boom tube surfaces to provide a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued
use of extremely worn wear pads may result in
component damage and unsafe operating
conditions.
1 Start the engine from the ground controls.

2 Raise the end of the primary boom to a
comfortable working height (chest high), then
extend the boom 1 foot / 30 cm.
3 Measure each wear pad. Replace the wear pad
once it reaches the minimum allowable
thickness. If the wear pad is still within
specification, shim as necessary to obtain
minimum clearance with zero binding.
Note: The minimum shim clearance for primary
boom wear pads is 0.070 inch / 1.8 mm and the
maximum allowable shim clearance is 0.188 inch /
4.8 mm.
Part No. 102521 S-40 • S-45 3 - 41

CHECKLIST D PROCEDURES
1
D-2 13
10 15
7
Check the Turntable Rotation 6 19
18
Bearing Bolts 12
3 4
11 17
Genie specifications requires that this procedure 20 5
be performed every 1000 hours or annually, 8 14

16 9
whichever comes first. 2
Maintaining proper torque on the turntable bearing Bolt torque sequence

bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe 4 Be sure that each turntable mounting bolt is
operating condition and component damage. torqued in sequence to specifications. Refer to
1 Raise the primary boom and place safety
chocks on the lift cylinders rods. Carefully lower 5 Start the engine form the ground controls.
the boom onto the lift cylinders safety chocks. 6 Raise the secondary boom and remove the
Crushing hazard. Keep hands safety chock.
away from cylinders and all 7 Lower the boom to the stowed position.
moving parts when lowering the
boom. 8 Remove drive chassis covers from both the
steer end and the non-steer end of the
Note: The lift cylinder safety chock is available machine.
through Genie (Genie part number 75097).
2 Turn the engine off.

located under the engine tray. Swing the engine
tray out and away from the machine and secure
it from moving.
injury.
3 - 42 S-40 • S-45 Part No. 102521

9 Check to ensure that each lower bearing D-3

mounting bolt under the drive chassis is
torqued in sequence to specifications. Refer to Check the Free-wheel
Configuration
1
10 15
13 7
6 19
18 12 Genie specifications requires that this procedure

be performed every 1000 hours or annually,
3 4
11 17
Proper use of the free-wheel configuration is
20 5 essential to safe machine operation. The
8 14 free-wheel configuration is used primarily for
16
2
9 towing. A machine configured to free-wheel without
operator knowledge may cause death or serious
Bolt torque sequence
injury and property damage.
and install the engine pivot plate retaining Collision hazard. Select a work
fasteners. site that is firm and level.
Crushing hazard. Failure to install Component damage hazard. If the

the fasteners into the engine tray machine must be towed, do not
to secure it from moving could exceed 2 mph / 3.2 km/h.
result in death or serious injury. Non-steer Wheels: All Models
1 Chock the steer wheels to prevent the machine

from rolling.
2 Center a lifting jack of sufficient capacity
(20,000 lbs / 10,000 kg) under the drive chassis
between the non-steer tires.
3 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
non-steer wheel hub.
disengaged position
engaged position
Part No. 102521 S-40 • S-45 3 - 43

5 Manually rotate each non-steer wheel. All Models:

Result: Each non-steer wheel should rotate with 13 Be sure the free-wheel valve on the drive pump
minimum effort. is closed (clockwise).
6 Re-engage the drive hubs by turning over Note: The free-wheel valve is located on the
the hub disconnect caps. Rotate each wheel to bottom of the drive pump.
check for engagement. Lift the machine and
remove the jack stands. Note: The free-wheel valve should always remain
closed.
Collision hazard. Failure to
re-engage the drive hubs may
cause death or serious injury and
property damage.
b
Steer Wheels: 4WD Models a c
7 Chock the non-steer wheels to prevent the d

machine from rolling.
8 Center a lifting jack of ample capacity
a drive pump
between the steer tires.
b screwdriver
9 Lift the wheels off the ground and then place c lift pump
d free-wheel valve
jack stands under the drive chassis for support.
10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
steer wheel hub.
11 Manually rotate each steer wheel.
Result: Each steer wheel should rotate with
minimum effort.
12 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Raise the machine and
remove the jack stands.
Collision hazard. Failure to
re-engage the drive hubs may
cause death or serious injury and
property damage.
3 - 44 S-40 • S-45 Part No. 102521

D-4 Turntable Rotate Drive Hub:

Replace the Drive Hub Oil Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section 2, Hydraulic Hose and Fitting
Genie specifications requires that this procedure
Torque Specifications.
be performed every 1000 hours or annually,
whichever comes first. 1 Raise the secondary boom until the platform
end of the lower secondary boom arm is
Replacing the drive hub oil is essential for good
approximately 8 feet / 2.4 m off the ground.
machine performance and service life. Failure to
replace the torque hub oil at yearly intervals may 2 Secure the turntable from rotating with the
cause the machine to perform poorly and turntable rotation lock pin.
3 Tag, disconnect and plug the hydraulic hoses
1 Select the drive hub to be serviced. Drive the from the turntable rotate drive motor. Cap the
machine until one of the two plugs is at the fittings on the drive motor.
lowest point.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
a
4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Refer to Section 2, Specifications.
5 Install the plugs. Use pipe thread sealant on
units with pipe plugs.
6 Repeat steps 1 through 5 for all the other drive
hubs.
turntable drive hub
a plug
a
4 Attach a suitable lifting device to the lifting eyes

located near the drive motor.
Part No. 102521 S-40 • S-45 3 - 45

5 Remove the drive hub mounting bolts. Carefully D-5

remove the turntable rotate drive hub assembly
from the machine. Perform Engine Maintenance -
Crushing hazard. The turntable
Deutz and Perkins Models
rotate drive hub assembly could
become unbalanced and fall if not
properly supported by the lifting
device. Engine specifications require that this procedure be
6 Remove the plug from the side of the drive hub.
Drain the oil from the hub into a suitable Deutz models
container.
7 Install the drive hub assembly onto the engine information are available in the
machine. Torque the drive hub mounting bolts Deutz 1011F Operation Manual
to specification. Refer to (Deutz part number 0297 9683) or the
Section 2, Specifications. Deutz 2011 Operation Manual
8 Fill the drive hub with oil from the side hole until (Deutz part number 0312 3547).
the oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plug. Install the Deutz 1011F Operation Manual
plug. Genie part number 52883

Perkins models


moving
injury
3 - 46 S-40 • S-45 Part No. 102521

D-6 7 Rotate the filter element clockwise to lock it in

place.
Replace the Hydraulic Filter
8 Install the filter housing cap.
Elements
9 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter housing.
Genie specifications require that this procedure be Medium and high pressure filter
performed every 1000 hours or annually,
whichever comes first. Perform this procedure Note: The medium pressure filter is for the charge
more often if dusty conditions exist. pump and the high pressure filter (if equipped) is
for all machine functions except the drive circuit
Replacement of the hydraulic filters is essential for and oscillating axle circuit.
good machine performance and service life. A dirty
or clogged filter may cause the machine to perform 10 Open the engine side turntable cover and
poorly and continued use may cause component locate the medium pressure filter mounted to
damage. Extremely dirty conditions may require the engine tray.
that the filters be replaced more often. 11 Place a suitable container under each filter.
Bodily injury hazard. Beware of 12 Remove the filter housings by using a wrench
hot oil. Contact with hot oil may on the nut provided on the bottom of the
cause severe burns. housings.
Note: Perform this procedure with the engine off. 13 Remove the filter elements from the housings.
Hydraulic return filter 14 Inspect the housing seals and replace them if
necessary.
1 Open the ground controls side turntable cover
and locate the hydraulic return filter housing on 15 Install the new filter elements into the housings
top of the hydraulic tank. and tighten them securely.
2 Remove the cap from the filter housing. 16 Clean up any oil that may have spilled during
the installation procedure.
3 Lift the handle on the filter element and rotate
the element counterclockwise to release the 17 Use a permanent ink marker to write the date
element from the housing. and number of hours from the hour meter on
the oil filter housings.
4 Remove the filter element from the filter
housing. 18 Start the engine from the ground controls.
5 Install the new filter element into the filter 19 Inspect the filter housings and related
housing. components to be sure that there are no leaks.
6 Push the filter element down to be sure the
o-ring on the element is fully seated into the
housing.
Part No. 102521 S-40 • S-45 3 - 47

D-7
a
Inspect for Turntable Bearing
Wear
b
Genie specifications requires that this procedure

be performed every 1000 hours or annually, c
Periodic inspection of turntable bearing wear is
d
essential to safe machine operation, good machine
performance and service life. Continued use of a a turntable
worn turntable bearing could create an unsafe b dial indicator
c drive chassis
operating condition, resulting in death or serious d turntable rotation bearing
injury and component damage.
5 At the dial indicator, adjust it to "zero" the
Note: Perform this procedure with the machine on indicator.
a firm, level surface and the boom in the stowed
position. 6 Fully extend the boom and lower to a horizontal
position.
3 Start the machine from the ground controls and
raise the boom to full height. Do not extend the 7 Note the reading on the dial indicator.
boom. Result: The measurement is less than
4 Place a dial indicator between the drive chassis 0.063 inch / 1.6 mm. The bearing is good.
and the turntable at a point that is directly Result: The measurement is more than
under, or inline with, the boom and no more 0.063 inch / 1.6 mm. The bearing is worn and
than 1 inch / 2.5 cm from the bearing. needs to be replaced.
Note: To obtain an accurate measurement, place 8 Fully retract the boom and raise the boom to full
the dial indicator no more than 1 inch / 2.5 cm from height. Visually inspect the the dial indicator to
the turntable rotation bearing. be sure the needle returns to the "zero"
position.
3 - 48 S-40 • S-45 Part No. 102521

9 Remove the dial indicator and rotate the

turntable 90°.
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90° apart.
11 Lower the boom to the stowed position and turn
the machine off.
12 Remove the dial indicator from the machine.
Part No. 102521 S-40 • S-45 3 - 49

Checklist E Procedures
E-1 3 Models with hydraulic tank shut-off valves:
Locate the two hydraulic tank valves at the
Test or Replace the Hydraulic Oil hydraulic tank through the access hole
underneath the turntable. Close the valves.

performed every 2000 hours or 2 years, whichever
comes first.
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may open closed
cause the machine to perform poorly and
continued use may cause component damage. Component damage hazard. The
Extremely dirty conditions may require oil changes engine must not be started with
to be performed more often. the hydraulic tank shut-off valves
in the closed position or
Note: Before replacing the hydraulic oil, the oil may component damage will occur. If
be tested by an oil distributor for specific levels of the tank valves are closed,
contamination to verify that changing the oil is remove the key from the key
necessary. If the hydraulic oil is not replaced at switch and tag the machine to
the two year inspection, test the oil quarterly. inform personnel of the condition.
Replace the oil when it fails the test.
4 Remove the drain plug and completely drain the
Note: Perform this procedure with the boom in the tank into a suitable container. Refer to
stowed position. Section 2, Specifications.
1 Ford models: Turn the valve on the LPG tank 5 Tag, disconnect and plug the two suction hoses
clockwise to the off position (if equipped). Then and supply hose for the auxiliary pump from the
slowly disconnect the hose from the LPG tank. hydraulic tank. Cap the fittings on the tank.
2 Ford models: Open the clamps from the LPG Note: The hoses can be accessed through the
tank straps and remove the LPG tank from the access hole under the turntable.
machine (if equipped).
6 Disconnect and plug the return filter hydraulic
hose at the return filter. Cap the fitting on the
filter housing.
7 Remove the ground controls side turntable
cover.
3 - 50 S-40 • S-45 Part No. 102521

CHECKLIST E PROCEDURES
8 Support the hydraulic tank with an appropriate 20 Models with hydraulic tank shut-off valves:
lifting device. Open the two hydraulic tank valves at the
hydraulic tank.
9 Remove the hydraulic tank mounting fasteners.
21 Fill the tank with hydraulic oil until the level is
10 Remove the hydraulic tank from the machine.
within the top 2 inches / 5 cm of the sight
Crushing hazard. The hydraulic gauge. Do not overfill.
tank could become unbalanced
22 Clean up any oil that may have spilled.
and fall if not properly supported
when removed from the machine. 23 Prime the pump. Refer to Repair Procedure
6-2, How to Prime the Pump.
11 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic Note: Always use pipe thread sealant when
return filter housing from the hydraulic tank. installing the suction hose fittings and the drain
plug.
12 Remove the suction strainers from the tank and
clean them using a mild solvent.
13 Rinse out the inside of the tank using a mild
solvent.
14 Install the suction strainers using a thread
sealant on the threads.
15 Install the drain plug using a thread sealant on
the threads.
16 Install the hydraulic return filter housing onto the
hydraulic tank.
17 Install the hydraulic tank onto the machine.
18 Install the two suction hoses to the suction
strainers.
19 Install the supply hose for the auxiliary power
unit and the return filter hose.
Part No. 102521 S-40 • S-45 3 - 51

E-2 6 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
Grease the Steer Axle
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to
Wheel Bearings, 2WD Models seat the bearings.
Note: Rotate the hub by hand while torqueing the
castle nut to make sure the bearings seat properly.
Genie specifications require that this procedure be 8 Loosen the castle nut one full turn and then
performed every 2000 hours or 2 years, whichever torque to 35 ft-lbs / 47 Nm.
comes first.
9 Check for wheel bearing wear by attempting to
Maintaining the steer axle wheel bearings is move the wheel hub side to side, then up and
essential for safe machine operation and service down.
life. Operating the machine with loose or worn
Result: If there is no side to side or up and
wheel bearings may cause an unsafe operating
down movement, continue to step 11 and
condition and continued use may result in
grease the wheel bearings.
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure Result: If there is side to side or up and down
washing of the machine may require that this movement, continue to step 11 and replace the
procedure be performed more often. wheel bearings with new ones.
1 Loosen the wheel lug nuts. Do not remove Note: When replacing a wheel bearing, both the
them. inner and outer bearings, including the pressed-in
races, must be replaced.
2 Block the non-steering wheels. Center a lifting
jack under the steer axle. 10 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
3 Raise the machine 6 inches / 15 cm Place
blocks under the drive chassis for support. 11 Remove the castle nut.
4 Remove the lug nuts. Remove the tire and 12 Pull the hub off of the spindle. The washer and
wheel assembly. outer bearing should fall loose from the hub.
5 Check for wheel bearing wear by attempting to 13 Place the hub on a flat surface and gently pry
move the wheel hub side to side, then up and the bearing seal out of the hub. Remove the
down. rear bearing.
Result: There should be no side to side or up
and down movement.
Skip to step 10 if there is no movement.
3 - 52 S-40 • S-45 Part No. 102521

14 Pack both bearings with clean, fresh grease. E-3

15 Place the large inner bearing into the rear of the Perform Engine Maintenance -
hub.
Deutz and Perkins Models
16 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is flush.
Note: Always replace the bearing grease seal
when removing the hub. Engine specifications require that this procedure be
17 Slide the hub onto the yoke spindle.
Component damage hazard. Do manufacturer's maintenance schedule, is essential
not apply excessive force or to good engine performance and service life.
damage to the lip of the seal may Failure to perform the maintenance procedures
occur. can lead to poor engine performance and
18 Place the outer bearing into the hub. component damage.
19 Install the washer and castle nut.

Deutz 1011F models
20 Tighten the slotted nut to 158 ft-lbs / 214 Nm to Required maintenance procedures and additional
seat the bearings. engine information is available in the
21 Loosen the castle nut one full turn and then Deutz 1011F Operation Manual
torque to 35 ft-lbs / 47 Nm. (Deutz part number 0297 9683).
22 Install a new cotter pin. Bend the cotter pin

to lock it in.
23 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to Perkins models
specification. Refer to Section 2, Specifications. Required maintenance procedures and additional


located under the engine tray. Swing the engine
tray out and away from the machine and secure
it from moving.
injury.
Part No. 102521 S-40 • S-45 3 - 53

E-4 E-5
Perform Engine Maintenance - Perform Engine Maintenance -
Ford Models Deutz and Perkins Models
Engine specifications require that this procedure Engine specifications require that this procedure be
be performed every 2400 hours. performed every 3000 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). component damage.
Ford LRG 425 EFI Operation Manual engine information are available in the
Genie part number 119488 Deutz 2011 Operation Manual
Remove the engine tray retaining fasteners Genie part number 52883
engine tray. Swing the engine tray out and Genie part number 139320
moving. To access the engine:
injury.
moving.
injury.
3 - 54 S-40 • S-45 Part No. 102521

Perkins models E-6

Required maintenance procedures and additional Perform Engine Maintenance -
engine information are available in the Deutz and Perkins Models

To access the engine: Proper engine maintenance, following the engine
Remove the engine tray retaining fasteners manufacturer's maintenance schedule, is essential
located under the engine tray. Loosen the pivot to good engine performance and service life.
fastener located at the platform end of the Failure to perform the maintenance procedures
engine tray. Swing the engine tray out and can lead to poor engine performance and
away from the machine and secure it from component damage.
moving. Required maintenance procedures and additional
Crushing hazard. Failure to secure engine information are available in the
the engine pivot plate from moving Deutz 1011F Operation Manual
could result in death or serious (Deutz part number 0297 9683) or the
injury. Deutz 2011 Operation Manual



moving.
injury.
Part No. 102521 S-40 • S-45 3 - 55

E-7 E-8
Perform Engine Maintenance - Perform Engine Maintenance -
Deutz Models Deutz Models
Engine specifications require that this procedure be Engine specifications require that this procedure be
performed every 6000 hours. 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 1011F Operation Manual Deutz 1011F Operation Manual
(Deutz part number 0297 9683) or the (Deutz part number 0297 9683) or the
Deutz 2011 Operation Manual Deutz 2011 Operation Manual
(Deutz part number 0312 3547). (Deutz part number 0312 3547).
Deutz 1011F Operation Manual Deutz 1011F Operation Manual

Genie part number 52883 Genie part number 52883
Deutz 2011 Operation Manual Deutz 2011 Operation Manual

Genie part number 139320 Genie part number 139320
To access the engine: To access the engine:

. Remove the engine tray retaining fasteners Remove the engine tray retaining fasteners
located under the engine tray. Loosen the pivot located under the engine tray. Loosen the pivot
fastener located at the platform end of the fastener located at the platform end of the
engine tray. Swing the engine tray out and engine tray. Swing the engine tray out and
away from the machine and secure it from away from the machine and secure it from
moving. moving.
Crushing hazard. Failure to secure Crushing hazard. Failure to secure
the engine pivot plate from moving the engine pivot plate from moving
could result in death or serious could result in death or serious
injury. injury.
3 - 56 S-40 • S-45 Part No. 102521

E-9
Perform Engine Maintenance -
Ford Models

performed every 4 years.





moving.
injury.
Part No. 102521 S-40 • S-45 3 - 57

3 - 58 S-40 • S-45 Part No. 102521

October 2013 Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:
Perform disassembly procedures to the point where
Repair procedures shall be completed by a repairs can be completed. To re-assemble, perform
person trained and qualified on the repair of this the disassembly steps in reverse order.
machine.
Symbols Legend
Immediately tag and remove from service a
damaged or malfunctioning machine. Safety alert symbol—used to alert
personnel to potential personal
Repair any machine damage or malfunction injury hazards. Obey all safety
before operating the machine. messages that follow this symbol
to avoid possible injury or death.
Before Repairs Start:
Read, understand and obey the safety rules and an imminently hazardous situation
operating instructions in the Genie S-40 and which, if not avoided, will result in
Genie S-45 Operator’s Manual on your machine. death or serious injury.
Be sure that all necessary tools and parts are Used to indicate the presence of a
available and ready for use. potentially hazardous situation
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
Unless otherwise specified, perform each which, if not avoided, may cause
repair procedure with the machine in the minor or moderate injury.
following configuration: Used to indicate the presence of a
• Machine parked on a flat, level surface potentially hazardous situation
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
rotation lock pin Indicates that an incorrect result has occurred
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
Part No. 102521 S-40 • S-45 4-1

Section 4 • Repair Procedures October 2013
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
a
off position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to
the inside of the platform control box.
d c b
a ALC-500 circuit board

b drive/steer joystick controller
c secondary boom up/down
joystick controller
d primary boom up/down and
turntable rotate left/right
joystick controller
4-2 S-40 • S-45 Part No. 102521

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.
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
1-2 successful joystick calibration.
Joysticks Result: The alarm does not sound. Check the
electrical connections or replace the joystick.
How to Calibrate a Joystick 8 Repeat this procedure for each joystick
The joysticks on this machine utilize digital Hall controlled machine function including the thumb
Effect technology for proportional control. If a rocker steer switch.
joystick is disconnected or replaced, it must be Note: No machine fuction should operate while
calibrated before that particular machine function performing the joystick calibration procedure.
will operate.
Note: The joystick must be calibrated before the

threshold, max-out or ramping can be set.
1 Open the platform control box.
Part No. 102521 S-40 • S-45 4-3

PLATFORM CONTROLS
How to Adjust the Joystick 7 Momentarily activate the drive enable toggle
switch in the right direction 4 times.
Max-out Setting
Result: There should be a pause and the alarm
The max-out setting of a joystick controls the should sound 4 times indicating that the
maximum speed of a joystick-controlled machine machine is in max-out calibration mode.
function. Whenever a hydraulic cylinder, drive
motor or hydraulic pump is replaced, the max-out Result: The alarm does not sound. Repeat steps
setting should be adjusted to maintain optimum 3 through 7.
performance. The max-out settings on the joystick 8 Start the engine from the platform controls and
can be changed to compensate for hydraulic pump press down the foot switch.
wear to maintain peak performance from the
machine. 9 Start a timer and activate the machine function
that needs to be adjusted. Record the time it
Note: Perform this procedure with the boom in the takes for that function to complete a full cycle
stowed position. (ie; boom up).
1 Pull out the red Emergency Stop button to the 10 Compare the machine function time with the
on position at both the ground and platform function times listed in Section 2,
controls. Specifications. Determine whether the function
time needs to increase or decrease.
2 Turn the key switch to platform control. Do not
start the engine. 11 While the joystick is activated, adjust the max-
out setting to achieve the proper function cycle
3 Push in the platform controls red Emergency
time. Momentarily move the drive enable toggle
Stop button to the off position.
switch in the right direction to increase the
4 Do not press down the foot switch. function speed or momentarily move the drive
enable toggle switch in the left direction to
5 Move and hold the drive enable toggle switch in decrease the function speed.
the right position and pull out the red
Emergency Stop button to the on position. Note: Each time the drive enable toggle switch is
momentarily moved, the function speed will change
6 When the alarm sounds, release the drive
in 2% increments.
enable toggle switch.
12 Repeat steps 9 through 11 for each joystick
controlled machine function.
4-4 S-40 • S-45 Part No. 102521

PLATFORM CONTROLS
13 Return the joystick to the neutral position and 2 Turn the key switch to platform control. Do not
wait for approximately 10 seconds to allow the start the engine.
settings to be saved.
3 Push in the platform controls red Emergency
Result: The alarm should sound indicating that Stop button to the off position.
the settings have been saved in memory.
4 Do not press down the foot switch.
Result: The alarm does not sound. The
5 Move and hold the drive enable toggle switch in
minimum or maximum adjustment has been
the right position and pull out the red
obtained. No changes can be saved.
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.
14 Cycle the red Emergency Stop button off, then 7 Momentarily activate the drive enable toggle
back on. switch in the right direction 6 times.
should sound 6 times indicating that the
How to Adjust the Joystick machine is in ramp rate calibration mode.
Ramp Rate Setting
Result: The alarm does not sound. Repeat steps
The ramp rate setting of a joystick controls the time 3 through 7.
at which it takes for the joystick to reach maximum
8 Start the engine from the platform controls and
output, when moved out of the neutral position. The
press down the foot switch.
ramp rate settings of a joystick can be changed to
compensate for hydraulic pump wear to maintain 9 Start a timer and simultaneously move the
peak performance from the machine. joystick in either direction full stroke. Note how
long it takes the function to reach maximum
Note: Perform this procedure with the boom in the speed. This is the ramp rate.
stowed position.
10 Compare the function ramp rate time with the
1 Pull out the red Emergency Stop button to the table below and determine whether the ramp
on position at both the ground and platform rate time needs to increase or decrease.
controls.
11 Release the foot switch.
Part No. 102521 S-40 • S-45 4-5

PLATFORM CONTROLS
12 While the joystick is activated, set the ramp Ramp rate (factory settings)
rate. Momentarily move the drive enable toggle
switch in the right direction to increase the time Boom up/down
or momentarily move the drive enable toggle accelerate 3 second
switch in the left direction to decrease the time. decelerate 1 seconds
Note: Each time the drive enable toggle switch is Turntable rotate
momentarily moved, the time will change in 5% accelerate 2 seconds
increments. decelerate 1 second
Drive
13 Repeat steps 9 through 11 for each joystick
accelerate 2 seconds
controlled machine function.
decelerate to neutral 0.5 second
14 Return the joystick to the neutral position and decelerate, change of direction 0.5 second
wait for approximately 10 seconds to allow the decelerate, coasting 0.75 second
settings to be saved. decelerate, braking 1 second
decelerate, shift from low to high speed 1 second
Result: The alarm should sound indicating that decelerate, shift from high to low speed 3 seconds
the settings have been saved in memory.
Note: Do not operate any machine function during
the 10 second waiting time.
15 Cycle the red Emergency Stop button off, then
back on.
4-6 S-40 • S-45 Part No. 102521

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
wait for approximately 10 seconds.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red Result: The alarm should sound indicating that
Emergency Stop button to the on position. the settings have been saved in memory.
6 When the alarm sounds, release the drive Note: Do not operate any machine function during
enable toggle switch. the 10 second waiting time.
7 Momentarily activate the drive enable toggle 14 Cycle the red Emergency Stop button off, then
switch in the right direction 8 times. back on.
should sound 8 times indicating that the
machine is in threshold calibration mode.
Result: The alarm does not sound. Repeat steps
3 through 7.
Part No. 102521 S-40 • S-45 4-7

Platform Components
2-1 S-40 Models:
Platform Leveling Slave Cylinder 5 Tag, disconnect and plug the hydraulic hoses
from the slave cylinder at the union located
The slave cylinder and the rotator pivot are the near the platform rotate counterbalance valve
two primary supports for the platform. The slave manifold and connect them together using a
cylinder keeps the platform level through the connector. Cap the fittings on the cylinder.
entire range of boom motion. It operates in a Bodily injury hazard. Spraying
closed-circuit hydraulic loop with the master hydraulic oil can penetrate and
cylinder. The slave cylinder is equipped with burn skin. Loosen hydraulic
counterbalance valves to prevent movement in connections very slowly to allow
the event of a hydraulic line failure. the oil pressure to dissipate
gradually. Do not allow oil to
How to Remove the Platform squirt or spray.
Leveling Slave Cylinder S-45 Models:
Note: Before cylinder removal is considered, bleed 6 Tag, disconnect and plug the slave cylinder
the slave cylinder to be sure there is no hoses at the union.
air in the closed loop.
7 Pull the slave cylinder hoses through the
Note: When removing a hose assembly or fitting, platform rotator.
replaced and then torqued to specification during 8 Remove the pin retaining fastener from
installation. the slave cylinder rod-end pivot pin. Do not
Refer to Section 2, Hydraulic Hose and Fitting remove the pin.
Torque Specifications. 9 Remove the external retaining fastener from the
1 Extend the primary boom until the slave cylinder barrel-end pivot pin.
barrel-end pivot pin is accessible. 10 Use a soft metal drift to drive the rod-end pivot
2 Raise the primary boom slightly and place pin out.
blocks under the platform for support. 11 Use a soft metal drift and drive the barrel-end
3 Lower the primary boom until the platform is pin out.
resting on the blocks just enough to support the 12 Carefully pull the cylinder out of the boom.
platform.
Component damage hazard. Hoses
Note: Do not rest the entire weight of the boom on can be damaged if they are kinked
the blocks. or pinched.
4 Protect the slave cylinder rod from damage. How to Bleed the Slave Cylinder
Note: Do not start the engine. Use auxiliary power
for this procedure.
1 Raise the primary boom to a horizontal position.
2 Move the platform level toggle switch up and
down through two platform leveling cycles to
remove any air that might be in the system.
4-8 S-40 • S-45 Part No. 102521

PLATFORM COMPONENTS
2-2 S-40 Models:

Platform Rotator 2 Tag, disconnect and plug the hydraulic hoses
from the platform rotator. Cap the fittings on the
The platform rotator is a hydraulically activated rotator.
helical gear assembly used to rotate the platform Bodily injury hazard. Spraying
160 degrees. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
How to Remove the connections very slowly to allow
Platform Rotator the oil pressure to dissipate
gradually. Do not allow oil to squirt
Component damage hazard. Mark or spray.
the platform mounting weldment
and the rotator flange before S-45 Models:
removing the platform mounting 3 Tag and disconnect the hydraulic hoses from
weldment. The platform mounting the "V1" and "V2" ports on the counterbalance
weldment must be replaced in the valve manifold located on the platform rotator
exact same position on the rotator and connect them together using a connector.
flange as it was before removal. If Cap the fittings on the manifold.
a new rotator is installed or the
rotator is disassembled, proper 4 Support the platform leveling arms and platform
alignment can be achieved by mounting weldment with an appropriate lifting
rotating the rotator all the way to device, but do not apply any lifting pressure.
the left and then installing the
All Models:
platform mounting weldment all
the way in the left position. 5 Remove the six mounting bolts from the
platform mounting weldment. Remove the
Note: When removing a hose assembly or fitting,
center bolt and slide the platform mounting
weldment off of the platform rotator.
installation. Refer to Section Two, Hydraulic Hose Crushing hazard. The platform
and Fitting Torque Specifications. mounting weldment could become
unbalanced and fall if it is not
1 Remove the platform and platform support. properly supported.
6 Support the platform rotator with an appropriate
lifting device. Do not apply any lifting pressure.
Part No. 102521 S-40 • S-45 4-9

PLATFORM COMPONENTS
7 Support the platform leveling slave cylinder. 3 Open the top bleed valve on the rotator, but do
Protect the cylinder rod from damage. not remove it.
a
8 Remove the pin retaining fasteners from both
the slave cylinder rod-end pivot pin, and the
rotator pivot pin.
9 Use a soft metal drift to drive both pins out, then
remove the platform rotator from the machine.
Crushing hazard. The platform
rotator could become unbalanced
and fall if it is not properly
supported.
How to Bleed the Platform

Rotator d c b
Note: This procedure will require two people. Do not a top bleed valve
b bottom bleed valve
start the engine. Use auxiliary power for this
c container
procedure. d clear hose
1 Move the function enable toggle switch to either 4 Move the function enable toggle switch to either
side and activate the platform rotate toggle side and hold the platform rotate toggle switch
switch to the right then the left through two to the left position until the platform is fully
platform rotation cycles, then hold the switch to rotated to the left. Continue holding the toggle
the right position until the platform is fully switch until air stops coming out of the bleed
rotated to the right. valve. Close the bleed valve.
2 Connect a clear hose to the top bleed valve. Crushing hazard. Keep clear of
Place the other end of the hose in a container the platform during rotation.
to collect any drainage. Secure the container to
the boom. 5 Connect the clear hose to the bottom bleed
valve and open the valve. Do not remove the
bleed valve.
6 Move the function enable toggle switch to either
side and hold the platform rotate toggle switch
to the right position until the platform is fully
rotated to the right. Continue holding the toggle
switch until air stops coming out of the bleed
valve. Close the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions and
inspect the bleed valves for leaks.
4 - 10 S-40 • S-45 Part No. 102521

PLATFORM COMPONENTS
2-3 How to Calibrate the Platform

Platform Overload System Overload System (if equipped)
The platform overload system is designed to
prevent the machine from continuing to operate
when the load in the platform exceeds maximum
Calibration of the platform overload system is
rated capacity. Refer to the machine serial label for
essential to safe machine operation. Continued use
maximum capacity information.
of an improperly calibrated platform overload
If maximum platform capacity is exceeded, the system could result in the system failing to sense
alarm will sound at the platform controls and the an overloaded platform. The stability of the
platform overload indicator lights will flash at both machine is compromised and it could tip over.
the ground and platform controls. The ground and
Note: Perform this procedure with the machine on a
platform controls will become disabled and the
firm, level surface.
engine will stop. Before normal machine operation
can continue, the excess load will need to be 1 Turn the key switch to platform control. Start the
removed from the platform. engine and level the platform.
If the excess load cannot be removed or if the 2 Determine the maximum platform capacity.
operator at the platform controls is unable to correct Refer to the machine serial plate.
the overloaded condition, another person at the
3 Remove all weight, tools and accessories from
ground controls can operate the machine using
the platform.
auxiliary power. There will be limited control of
boom functions from the ground controls when Note: Failure to remove all weight, tools and
using auxiliary power. Auxiliary power can be used accessories from the platform will result in an
to correct the overloaded platform condition in order incorrect calibration.
to resume normal, safe operation of the machine.
Note: When the engine is shut off in an overloaded weight equal to the maximum platform capacity
condition, it will not be possible to re-start the at the center of the platform floor.
engine until the overloaded condition is corrected.
Part No. 102521 S-40 • S-45 4 - 11

PLATFORM COMPONENTS
5 Move the platform up and down by hand, so it 7 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2 bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle. inches. Allow the platform to settle.
Result: The overload indicator lights are off and Result: The overload indicator lights are off and
the alarm does not sound. Proceed to step 6. the alarm does not sound. Proceed to step 8.
Result: The overload indicator lights are flashing Result: The overload indicator lights are flashing
at the platform and ground controls, the alarm is at the platform and ground controls, the alarm is
sounding, and the engine stops. Slowly tighten sounding, and the engine stops. Repeat this
the load spring adjustment nut in a clockwise procedure beginning with step 5.
direction in 10° increments until the overload
Note: There may be a 2 second delay before the
indicator light turns off, and the alarm does not
platform overload indicator light and alarm
sound. Proceed to step 8.
responds.
Note: The platform will need to be moved up and
down and allowed to settle between each 8 Add an additional 10 lb / 4.5 kg test weight to
adjustment. the platform.
Result: The overload indicator light is flashing at
both the ground and platform controls, the alarm
is sounding, and the engine stops. Proceed to
responds.
step 9.
6 Move the platform up and down by hand, so it
Result: The overload indicator light is off at both
bounces approximately 2.5 to 5 cm / 1 to 2
the ground and platform controls, and the alarm
inches. Allow the platform to settle.
does not sound. Remove the additional 10 lb /
Result: The overload indicator lights are off at 4.5 kg test weight. Repeat this procedure
the platform and ground controls, and the alarm beginning with step 6.
does not sound. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
overload indicator lights and alarm turn off.
in 10° increments until the overload indicator
light flashes at both the platform and ground 9 Test all machine functions from the platform
controls, the alarm sounds, and the engine controls.
stops. Proceed to step 7.
Result: All platform control functions should not
Result: The overload indicator lights are flashing operate.
at the platform and ground controls, the alarm is
sounding, and the engine stops. Repeat this 10 Turn the key switch to ground control.
procedure beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
responds.
4 - 12 S-40 • S-45 Part No. 102521

PLATFORM COMPONENTS
11 Test all machine functions from the ground

controls.
Result: All ground control functions utilizing
engine power should not operate. (Only limited
ground control functions utilizing APU power
should function).
12 Using a suitable lifting device, lift the test weight
off the platform floor.
Result: The platform overload indicator light
should be off at both the ground and platform
overload indicator lights and alarm turn off.

14 Test all machine functions from the ground
controls.
Result: All ground control functions should
operate normally.
15 Turn the key switch to platform control.
16 Test all machine functions from the platform
controls.
Result: All platform control functions should
operate normally.
Part No. 102521 S-40 • S-45 4 - 13

Jib Boom Components, S-45

3-1 7 Place blocks under the platform leveling cylinder
for support. Protect the cylinder rod from
Jib Boom damage.
8 Remove the pin retaining fasteners from the jib
How to Remove the Jib Boom boom lift cylinder barrel-end pivot pin. Do not
Note: Perform this procedure with the boom in the remove the pin.
stowed position. 9 Attach a lifting strap from an overhead crane to
Note: When removing a hose assembly or fitting, the lug on the rod end of the jib boom lift
the O-ring on the fitting and/or hose end must be cylinder.
replaced and then torqued to specification during 10 Use a soft metal drift to remove the jib boom lift
installation. cylinder rod-end pivot pin.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications. 11 Use a soft metal drift to remove the jib boom lift
cylinder barrel-end pivot pin, then remove the
1 Remove the platform. jib boom cylinder.
2 Remove the platform mounting weldment, Crushing hazard. The jib boom
and the platform rotator. See 2-2, How to lift cylinder could become
Remove the Platform Rotator. unbalanced and fall when it is
removed from the machine if it is
3 From the ground controls, raise the jib boom to
not properly attached to the
a horizontal position.
overhead crane.
4 Support the jib boom with a strap from an
overhead crane.
boom pivot pin. Use a soft metal drift to remove
5 Tag, disconnect and plug the hydraulic hoses the pin, then remove the jib boom from the
from the jib boom lift cylinder. Cap the fittings bellcrank.
on the cylinder.
Crushing hazard. The jib boom
Bodily injury hazard. Spraying could become unbalanced and fall
hydraulic oil can penetrate and when it is removed from the
burn skin. Loosen hydraulic machine if it is not properly
connections very slowly to allow attached to the overhead crane.
the oil pressure to dissipate
squirt or spray.
6 Remove the hose cover, hoses and cables from
the side of the jib boom and set them aside.
and cables can be damaged if they
are kinked or pinched.
4 - 14 S-40 • S-45 Part No. 102521

JIB BOOM COMPONENTS, S-45
3-2 4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
Jib Boom Lift Cylinder lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
How to Remove the Jib Boom opposite leveling arm. Do not remove the pin.
Lift Cylinder 5 Support the jib boom lift cylinder with a lifting
device.
stowed position. 6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
Note: When removing a hose assembly or fitting, soft metal drift to remove the barrel-end pin and
the O-ring on the fitting and/or hose end must be let the cylinder hang down.
installation. Refer to Section 2, Hydraulic Hose and Crushing hazard. The platform
Fitting Torque Specifications. and jib boom could become
unbalanced and fall when the jib
1 Raise the jib boom slightly and place blocks boom barrel-end pivot pin is
under the platform mounting weldment. Then removed if not properly supported.
lower the jib boom until the platform is resting
on the blocks just enough to support the 7 Attach a lifting strap from an overhead crane to
platform. the lug on the rod end of the jib boom lift
cylinder.
Note: Do not rest the entire weight of the boom on
the blocks. 8 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pin. Remove the cylinder from
2 Tag, disconnect and plug the jib boom lift the machine.
cylinder hydraulic hoses. Cap the fittings on the
cylinder. Crushing hazard. The jib boom lift
cylinder could become unbalanced
Bodily injury hazard. Spraying and fall when removed from the
hydraulic oil can penetrate and machine if not properly attached to
burn skin. Loosen hydraulic the overhead crane.
connections very slowly to allow
squirt or spray.
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
Part No. 102521 S-40 • S-45 4 - 15

Boom Components
4-1 6 Tag, disconnect and plug the hydraulic hoses
from the counterbalance valve manifold located
Cable Track on the platform rotator. Cap the fittings on the
manifold.
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire primary burn skin. Loosen hydraulic
boom cable track is only necessary when connections very slowly to allow
performing major repairs that involve removing the the oil pressure to dissipate
primary boom. gradually. Do not allow oil to
squirt or spray.
How to Remove the Cable Track 7 Tag, disconnect and plug the hydraulic hoses
Note: When removing a hose assembly or fitting, from the platform leveling cylinder at the union
the O-ring on the fitting and/or hose end must be and connect the hoses from the cylinder
replaced and then torqued to specification during together using a connector.
installation. Refer to Section 2, Hydraulic Hose and Bodily injury hazard. Spraying
Fitting Torque Specifications. hydraulic oil can penetrate and
1 Raise the primary boom to a horizontal position.
2 Locate the cables from the cable track to the the oil pressure to dissipate
platform control box. Number each cable and gradually. Do not allow oil to
its entry location at the platform control box. squirt or spray.
3 Disconnect the cables from the platform control 8 Locate all electrical cables that enter the cable
box. track.
4 Remove the electrical outlet box bracket 9 Tag and disconnect the electrical connectors for
mounting fasteners. Remove the outlet box and all cables that enter the cable track.
lay it to the side.
10 Remove the retaining fasteners from the
5 Remove the hose and cable clamp from the electrical connector receptacles for the cables
platform support. that enter the cable track.
11 Remove the fasteners from the drive speed limit
switch mounted on the side of the cable track at
the pivot end of the boom. Do not disconnect
the wiring.
4 - 16 S-40 • S-45 Part No. 102521

BOOM COMPONENTS
12 Remove the fasteners from the side panel on How to Repair the Cable Track
the lower cable track, then remove the panel.
Pull all of the cables out of the channel. Component damage hazard.
The boom cable track can be
13 Remove the cable cover on the side of the damaged if it is twisted.
boom.
Note: A cable track repair kit is available through
14 Place blocks in between the upper and lower the Genie Industries Service Parts Department,
cable tracks and secure the upper and lower part no. 81007. The kit includes a 4 link section of
tracks together. cable track.
Crushing hazard. If the upper and
1 Visually inspect the cable track and determine
lower cable tracks are not properly
which 4 link section needs to be replaced.
secured together, the cable track
could become unbalanced and fall 2 Remove the snap-on cable track spacers.
when it is removed from the
machine. 3 Carefully remove the external snap rings from
the pivot pins at each end of the 4-link section
15 Attach a lifting strap from an overhead crane to to be removed.
the cable track.
4 Lift up the hoses and cables and carefully
16 Remove the mounting fasteners from the upper remove the damaged 4 link section of cable
cable track at the platform end of the extension track.
boom.
17 Remove the cable track mounting fasteners that and cables can be damaged if they
attach the lower cable track to the boom. are kinked or pinched.
18 Remove the cable track from the machine and 5 Remove the snap-on spacers from the
place it on a structure capable of supporting it. replacement section of the cable track.
Crushing hazard. The cable track 6 Lift up the hoses and cables and carefully insert
could become unbalanced and fall the new 4 link section of cable track.
if it is not properly attached to the
overhead crane. Component damage hazard.
Hoses and cables can be
Component damage hazard. damaged if they are kinked or
Hoses and cables can be pinched.
damaged if they are kinked or
pinched. 7 Connect the ends of the replacement cable
track section to the existing cable track using
the pivot pins and external snap rings.
Note: Be sure the pivot pins are installed from the
inside out so the external snap rings are on the
outside of the cable track.
8 Operate the boom extend/retract function

through a full cycle to ensure smooth operation
of the new section of cable track.
Part No. 102521 S-40 • S-45 4 - 17

BOOM COMPONENTS
4-2 1 Remove the platform. See 2-1, How to Remove

the Platform.
Boom
2 Remove the platform rotator and leveling slave
cylinder. See 2-3, How to Remove the Platform
How to Remove the Boom Rotator.
Consult the Genie Industries Service Department 3 S-45 Models: Remove the jib boom. See 3-1,
for instructions on how to safely remove the boom How to Remove the Jib Boom.
assembly from the machine. Failure to read and
follow the warnings listed below could result in 4 Remove the mounting fasteners from the jib
death or serious injury. boom/platform rotate valve manifold on the end
of the boom. Remove the manifold and set it
Bodily injury hazard. This aside.
procedure requires specific repair
skills, lifting equipment and a 5 Remove the fasteners from the limit switch
suitable workshop. Attempting this mounted on the side of the cable track. Do not
procedure without these skills and disconnect the wiring.
tools could result in death or 6 Support the cable track with an overhead crane.
serious injury and significant
component damage. Dealer 7 Remove the hose/cable clamp from the pivot
service is strongly recommended. end of the boom.
Note: Perform this procedure with the boom in the 8 Remove the hose/cable clamp at the platform
stowed position. end of the cable track.
Note: When removing a hose assembly or fitting, 9 Remove the fasteners from the large cable track
the O-ring on the fitting and/or hose end must be guide at the platform end of the cable track.
replaced and then torqued to specification during Remove the guide.
installation. 10 Remove the cotter pin from the clevis pin at the
Refer to Section 2, Hydraulic Hose and Fitting platform end of the cable track. Remove the
Torque Specifications. clevis pin.
Note: Always replace the cotter pin with a new one
when removing a clevis pin.
11 Remove the fasteners from the side panel on

the cable track to access the cable track
mounting fasteners.
4 - 18 S-40 • S-45 Part No. 102521

12 Remove the cable track mounting fasteners, 18 Attach a similar lifting device to the boom lift
then remove the cable track from the boom and cylinder.
lay it off to the side.
19 Use the overhead crane to lift the boom to a
Component damage hazard. horizontal position.
The boom cable track can be
20 Place support blocks under the boom lift
damaged if it is twisted.
cylinder, across the turntable.
21 Remove the pin retaining fastener from the
Hoses can be damaged if they are
boom lift cylinder rod-end pin. Use a soft metal
kinked or pinched.
drift to remove the pin.
13 Remove the turntable end cover.
Crushing hazard. The boom lift
14 Remove the retaining fastener from the master cylinder will fall if not properly
cylinder rod-end pivot pin. Use a soft metal drift supported.
to remove the pin. Pull the cylinder back and
22 Lower the rod end of the lift cylinder onto
secure it from moving.
support blocks. Protect the cylinder rod from
Component damage hazard. damage.
When pulling the master cylinder
23 Remove the pin retaining fastener from the
back, be sure not to damage the
boom pivot pin.
master cylinder hoses or fittings.
24 Use a soft metal drift to remove the boom pivot
15 Remove the fasteners from the limit switch
pin, then carefully remove the boom from the
mounted to the turntable riser at the pivot end of
machine.
the boom. Do not disconnect the wiring.
Crushing hazard. The primary
16 Tag, disconnect and plug the extension cylinder
boom could become unbalanced
hydraulic hoses. Cap the fittings on the cylinder.
and fall when removed from the
Bodily injury hazard. Spraying machine if not properly attached to
hydraulic oil can penetrate and the overhead crane.
squirt or spray.
17 Attach an overhead 5 ton / 4500 kg crane to the
center point of the boom.
Part No. 102521 S-40 • S-45 4 - 19

8 Remove the trunnion pin retaining fasteners at

How to Disassemble the Boom the base end of the secondary boom tube. Use
Note: Complete disassembly of the boom is only a slide hammer to remove the trunnion pins.
necessary if the secondary boom tube must be 9 Carefully rotate the base end of the extension
replaced. The extension cylinder can be removed cylinder until the pin mounting bore is in a
without completely disassembling the boom. See 4- vertical position.
4, How to Remove the Extension Cylinder.
10 Remove the external snap rings from the
1 Remove the boom. See 4-2, How to Remove the extension cylinder rod-end pivot pin at the
Boom. platform end of the secondary boom tube. Use a
2 Place blocks under the extension cylinder for soft metal drift to remove the pin.
support. 11 Support and slide the extension cylinder out of
3 Remove the external snap rings from the the base end of the secondary boom tube.
extension cylinder barrel-end pivot pin at the Place the extension cylinder on blocks for
pivot end of the primary boom tube. Use a soft suppport.
metal drift to remove the pin. Crushing hazard. The extension
4 Remove and label the wear pads from the top cylinder may become unbalanced
side of the primary boom tube at the platform and fall when removed from the
end of the boom. secondary boom tube if not
properly supported.
Note: Pay careful attention to the location and
amount of shims used with each wear pad. Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.
5 Attach a lifting strap from an overhead crane to
the secondary boom tube at the platform end of 12 Remove the label the wear pads from the
the boom for support. extension cylinder.
6 Support and slide the secondary boom tube out Note: Pay careful attention to the location of each
of the primary boom tube. Place the secondary wear pad.
boom tube on blocks for support.
Crushing hazard. The secondary
boom tube could become
unbalanced and fall when removed
from the primary boom tube if not
properly supported.
Note: During removal, the overhead crane strap will
need to be carefully adjusted for proper balancing.
7 Remove and label the wear pads from the top
side of the secondary boom tube at the platform
end of the boom.
4 - 20 S-40 • S-45 Part No. 102521

BOOM COMPONENTS
4-3 5 Tag, disconnect and plug the boom lift cylinder

hydraulic hoses. Cap the fittings on the cylinder.
Boom Lift Cylinder
Bodily injury hazard. Spraying
The boom lift cylinder raises and lowers the boom. hydraulic oil can penetrate and
The boom lift cylinder is equipped with burn skin. Loosen hydraulic
counterbalance valves to prevent movement in the connections very slowly to allow
event of a hydraulic line failure. the oil pressure to dissipate
How to Remove the Boom squirt or spray.
Lift Cylinder 6 Remove the pin retaining fastener from the
boom lift cylinder rod-end pivot pin. Use a soft
Bodily injury hazard. This metal drift to remove the pin. Lower the lift
procedure requires specific repair cylinder onto the blocks. Protect the cylinder
skills, lifting equipment and a rod from damage.
suitable workshop. Attempting this
procedure without these skills and Crushing hazard. The lift cylinder
tools could result in death or could become unbalanced and fall
serious injury and significant if it is not properly supported.
component damage. Dealer 7 Remove the four mounting fasteners from the
service is strongly recommended. lift cylinder barrel-end pivot pin mounting plate.
Note: When removing a hose assembly or fitting, 8 With the lift cylinder being supported by the
the O-ring on the fitting and/or hose end must be overhead crane, pull the cylinder toward the
replaced and then torqued to specification during platform to remove it from the machine.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications. Crushing hazard. The lift cylinder
could become unbalanced and fall
1 Raise the boom to a horizontal position. if it is not properly supported.
2 Place support blocks across the turntable under Component damage hazard. The
the boom lift cylinder. cables and hydraulic hoses can be
3 Attach a 5 ton / 5000 kg overhead crane to the damaged if the lift cylinder is
boom at the platform end for support. Do not lift pulled across them.
the boom. 9 Using auxiliary power, activate the boom down
4 Support and secure both ends of the boom lift function so the cylinder will retract. Retract the
cylinder to a second overhead crane or similar cylinder just enough until the rod end of the
lifting device. cylinder will clear the mounting bracket on the
boom. Turn the machine off.
Part No. 102521 S-40 • S-45 4 - 21

BOOM COMPONENTS
4-4 4 Remove the external snap rings from the

extension cylinder rod-end pins (at the platform
Extension Cylinder end). Use a soft metal drift to remove the pins.
The extension cylinder extends and retracts the 5 Remove the turntable end cover.
boom extension tube. The extension cylinder is 6 Tag, disconnect and plug the extension cylinder
equipped with counterbalance valves to prevent hydraulic hoses. Cap the fittings on the
movement in the event of a hydraulic line failure. cylinder.
How to Remove the Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Extension Cylinder burn skin. Loosen hydraulic
This procedure requires specific connections very slowly to allow
repair skills, lifting equipment and the oil pressure to dissipate
a suitable workshop. Attempting gradually. Do not allow oil to
this procedure without these skills squirt or spray.
and tools could cause death or 7 Remove the barrel-end pivot pin retaining
serious injury and significant fasteners.
component damage. Dealer
service is strongly recommended. 8 Place a rod through the barrel-end pivot pin and
twist to remove the pin.
installation. Refer to Section Two, Hydraulic Hose
and Fitting Torque Specifications.
1 Extend the boom until the extension cylinder
rod-end pivot pins are accessible in the
extension tube.
2 Remove the master cylinder. See 4-5, How to
Remove the Master Cylinder. 9 Support and slide the extension cylinder out of
the pivot end of the boom.
3 Raise the boom to a horizontal position.
Crushing hazard. The extension
cylinder will fall when it is removed
from the extension boom if it is not
properly supported.
Note: Note the length of the cylinder after removal.
The cylinder must be at the same length for
installation.
4 - 22 S-40 • S-45 Part No. 102521

BOOM COMPONENTS
4-5 4 Attach a lifting strap from an overhead crane to

the lug on the rod end of the master cylinder.
Platform Leveling
5 Remove the pin retaining fasteners from the
Master Cylinder master cylinder barrel-end pivot pin.
The master cylinder acts as a pump for the slave 6 Place a rod through the barrel-end pivot pin and
cylinder. It is part of the closed circuit hydraulic twist to remove the pin.
loop that keeps the platform level through the
entire range of boom motion. The master cylinder
is located at the base of the boom.
How to Remove the Platform

Leveling Master Cylinder
installation. Refer to Section Two, Hydraulic Hose 7 Remove the pin retaining fastener from the rod-
and Fitting Torque Specifications. end pivot pin.
8 Use a soft metal drift to remove the pin.
1 Remove the turntable end cover to access the
master cylinder. 9 Remove the master cylinder from the machine.
2 Raise the boom until the master cylinder Crushing hazard. The master
rod-end pivot pin is accessible. cylinder could become unbalanced
and fall if it is not properly attached
3 Tag, disconnect and plug the master cylinder
to the overhead crane.
hydraulic hoses. Cap the fittings on the
cylinder.
hydraulic oil can penetrate and
squirt or spray.
Part No. 102521 S-40 • S-45 4 - 23

Engines
5-1 5-3
RPM Adjustment - Deutz Models Flex Plate
Refer to Maintenance Procedure B-11, Check and The flex plate acts as a coupler between the engine
Adjust the Engine RPM. and the pump. It is bolted to the engine flywheel
and has a splined center to drive the pump.
a b c d e
5-2
RPM Adjustment - Perkins
Models
Refer to Maintenance Procedure B-11, Check and
Adjust the Engine RPM. f
a 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 / 1.6 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423
How to Remove the Flex Plate

Deutz models:
1 Remove the tailpipe bracket mounting fasteners

from the engine bell housing.
2 Support the drive pump assembly with an
appropriate lifting device.
3 Remove all of the engine bell housing fasteners.
4 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
can be damaged if they are kinked
or pinched.
5 Remove the flex plate mounting fasteners.
Remove the flex plate from the flywheel.
4 - 24 S-40 • S-45 Part No. 102521

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. Hoses
the muffler bracket. Remove the dipstick from can be damaged if they are kinked
the engine. 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 EFI 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 fasteners. manifold. Do not remove the oxygen sensors.
Carefully remove the muffler and bracket
2 Remove the exhaust pipe fasteners at the
assembly from the engine.
muffler.
6 Support the engine with a suitable lifting device.
3 Support the muffler and bracket assembly with a
Do not lift it.
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.
Part No. 102521 S-40 • S-45 4 - 25

ENGINES
9 Remove all of the engine bell housing retaining After serial number 13739: Torque the flex
fasteners. plate mounting bolts in sequence to
20 ft-lbs / 27 Nm.
assembly away from the engine and secure it Deutz models:
from moving. Torque the flex plate mounting bolts in
sequence to
28 ft-lbs / 38 Nm.
or pinched. Perkins models:
Before serial number 7472: Torque the flex
plate mounting bolts in sequence to
Remove the flex plate from the flywheel.
28 ft-lbs / 38 Nm.
Perkins models: From serial number 7472 to 13773: Torque the
flex plate mounting bolts in sequence to
1 Remove the fuel filter/water separator mounting 49 ft-lbs / 66 Nm.
fasteners. After serial number 13773: Torque the flex
2 Remove the fuel filter/water separator and lay it plate mounting bolts in sequence to
to the side. Do not disconnect the hoses. 14 ft-lbs / 19.1 Nm.
3 Support the drive pump assembly with an 3 Install the pump coupler onto the pump shaft
appropriate lifting device. with the set screw toward the pump. Leave the
appropriate gap between coupler and pump end
4 Remove all of the engine bell housing fasteners. plate for your engine.
a b c d e
assembly away from the engine and secure it
from moving.
or pinched.
Remove the flex plate from the flywheel. f
a pump
How to Install the Flex Plate b pump shaft
c pump coupler
1 Install the flex plate onto the engine flywheel d flex plate with raised spline
with the raised spline towards the pump. e engine flywheel
f 0.18 inch / 4.6 mm gap - Deutz Models
2 Apply Loctite® removable thread sealant to the 0.070 inch / 1.8 mm gap - Perkins Models
screws. Torque the flex plate in a star pattern 0.0625 inch / 1.6 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423
using the following values.
Ford models: 4 Apply Loctite® removable thread sealant to the
Before serial number 13740: Torque the flex pump coupler set screw. Torque the set screw
plate mounting bolts in sequence to to 61 ft-lbs / 83 Nm.
24 ft-lbs / 32 Nm. 5 Install the pump and bell housing assembly.
4 - 26 S-40 • S-45 Part No. 102521

ENGINES
3 1 1 6
Ford LRG-425 models: C C
Before serial number 7597: Torque the bell

7 8
housing mounting bolts in sequence to 5 8 C C
23 ft-lbs / 31 Nm. C
C 4
3
After serial number 7596: Torque the bell
housing mounting bolts labeled "C" in sequence 7 6
C
to 47 ft-lbs / 63 Nm. Torque the bell housing 9
C C
mounting bolts labeled "B" in sequence to 2 4 5 2

61 ft-lbs / 83 Nm.
Ford LRG 425 models Ford LRG 425 models
Ford DSG-423 models: (after serial number 7596)
Torque the bell housing mounting bolts labeled
"A" and "B" in sequence to 28 ft-lbs / 38 Nm 6 1
6 1 A A
and the mounting bolts labeled "C" to 49 ft-lbs /
10 8
66 Nm. Then torque the bell housing mounting
bolts labeled "A" and "B" in sequence to 40 ft-
4 3 9
lbs / 54 Nm and the mounting bolts labeled "C" B
B
to 70 ft-lbs / 95 Nm. 4 5
11 12 B
Deutz models: B B
Before serial number 7544: Torque the bell 8 B B 7

7 5
housing mounting bolts in sequence to 2 9 2 3
28 ft-lbs / 38 Nm.
Perkins models Perkins models
After serial number 7543: Torque the bell (after serial number 7471)
housing mounting bolts in sequence to
47 ft-lbs / 63 Nm.
6 1 6 1
Perkins models: 10 8 C C
10 8
Before serial number 7472: Torque the bell C C
housing mounting bolts in sequence to 4 3 4
C
3
28 ft-lbs / 38 Nm. C
After serial number 7471: Torque the bell

11 12 11 C C
housing mounting bolts labeled "B" in sequence 12
to 28 ft-lbs / 38 Nm and the mounting bolts C C

7 5 C C
labeled "A" to 49 ft-lbs / 66 Nm. Then torque the 7 5
2 9
bell housing mounting bolts labeled "B" in 2 9
sequence to 40 ft-lbs / 54 Nm and the mounting
Deutz 1011 models Deutz 2011 models
bolts labeled "A" to 70 ft-lbs / 95 Nm. (before serial number 7544) (after serial number 7543)
Component damage hazard. When
installing the pump, do not force 6
1 B
the pump coupler into the flexplate B
3
A
or damage to the pump shaft seal
may occur.
A
4
Component damage hazard. Do
not force the drive pump during
C C
installation or the flex plate teeth 7 B 5
may become damaged. 2
Ford DSG 423 models
Part No. 102521 S-40 • S-45 4 - 27

ENGINES
5-4 5 Continue to hold the run/test toggle switch in the

test position and count the blinks.
Engine Fault Codes -
Note: If any fault codes are present, the ECM will
Ford Models use the check engine light to blink a three digit
code.
How to Retrieve Engine Fault It will blink the first digit of a three digit code,
Codes pause, blink the second digit, pause, and then blink
the third digit. For example: the check engine light
When an engine malfunction is detected by the blinks 5 consecutive times, blinks 3 times and then
Electronic Control Module (ECM), a fault code is 1 time. That would indicate code 531. There will be
recorded and the check engine light will turn on at a longer pause between codes.
the ground controls. Special equipment is required
to retrieve fault codes stored within the ECM. 6 Refer to Section 5, Fault Codes, for definition of
Contact Genie Industries Service Department for engine fault codes.
assistance in retrieving fault codes. 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.
(before serial no. 7597) 2 Disconnect the negative battery cable from the
battery for a minimum of 5 minutes.
4 Move and hold the run/test toggle switch to the
test position. Electrocution/burn hazard. Contact
with electrically charged circuits
Result: The check engine light should turn on.
The check engine light should begin to blink.
injury. Remove all rings, watches
and other jewelry.
3 Connect the negative battery cable to the
battery.
4 - 28 S-40 • S-45 Part No. 102521

Hydraulic Pumps
6-1 Models without hydraulic tank shut-off
valves: Remove the drain plug from the
Function Pump hydraulic tank and completely drain the tank
into a suitable container. See capacity
How to Remove the specifications.
Function Pump 2 Tag, disconnect and plug the function pump
hydraulic hoses. Cap the fittings on the pump.
the O-ring on the fitting and/or hose end must be Bodily injury hazard. Spraying
replaced and then torqued to specification during hydraulic oil can penetrate and
installation. burn skin. Loosen hydraulic
Refer to Section 2, Hydraulic Hose and Fitting connections very slowly to allow
Torque Specifications. the oil pressure to dissipate
1 Models with hydraulic tank shut-off valves: squirt or spray.
hydraulic tank through the access hole 3 Remove the pump mounting bolts. Carefully
underneath the turntable. Close the valves. remove the pump.
Models with hydraulic tank shut-off valves:
Component damage hazard. Be

sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
Models without hydraulic tank shut-off valves:

open closed
sure to fill the hydraulic tank to
Component damage hazard. The
specification and prime the pump
engine must not be started with the
after installing the pump.
hydraulic tank shut-off valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
Part No. 102521 S-40 • S-45 4 - 29

HYDRAULIC PUMPS
6-2 2 Models with hydraulic tank shut-off valves:

Drive Pump hydraulic tank through the access hole
underneath the turntable. Close the valves.
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electro-proportional controller,
located on the pump. The only adjustment that can
be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized Eaton
Hydraulics center. Call Genie Industries Service
Department to locate your local authorized service open closed
center.
How to Remove the Drive Pump engine must not be started with the
hydraulic tank shut-off valves in
Component damage hazard. The the closed position or component
work area and surfaces where this damage will occur. If the tank
procedure will be performed must valves are closed, remove the key
be clean and free of debris that from the key switch and tag the
could get into the hydraulic system machine to inform personnel of the
and cause severe component condition.
damage. Dealer service is
recommended. Models without hydraulic tank shut-off
valves: Remove the drain plug from the
Note: When removing a hose assembly or fitting, hydraulic tank and completely drain the tank
the O-ring on the fitting and/or hose end must be into a suitable container. See capacity
replaced and then torqued to specification during specifications.
installation.
Refer to Section 2, Hydraulic Hose and Fitting 3 Tag and disconnect and plug the hydraulic
Torque Specifications. hoses from the drive and function pumps.
Cap the fittings on the pumps.
1 Disconnect the electrical connection at the
electro-proportional controller located on the Bodily injury hazard. Spraying
drive pump. hydraulic oil can penetrate and
squirt or spray.
4 - 30 S-40 • S-45 Part No. 102521

HYDRAULIC PUMPS
4 Support the pump with a lifting device and 4 Ford models: Close the valve on the LPG tank
remove the two drive pump mounting fasteners. then disconnect the hose from the tank. Move
the fuel select switch to the LPG position.
5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate. Perkins models: Disconnect the engine wiring
harness from the fuel solenoid at the injector
6 Remove the drive pump from the machine.
pump.
Deutz models: Hold the manual fuel shutoff
hydraulic pump may become
valve clockwise to the closed position.
unbalanced and fall if not properly
supported.
a
Models with hydraulic tank shut-off valves:

sure to open the two hydraulic tank
valves and prime the pump after
installing the pump.
Models without hydraulic tank shut-off valves:

sure to fill the hydraulic tank to
specification and prime the pump
after installing the pump.
a manual fuel shutoff valve
5 Have another person crank the engine with the

How to Prime the Pump starter motor for 15 seconds, wait 15 seconds,
1 Connect a 0 to 600 psi / 0 to 50 bar pressure then crank the engine an additional 15 seconds
gauge to the test port on the drive pump. or until the pressure reaches 320 psi / 22 bar.
2 Remove the safety pin (if equipped) from the 6 Ford models: Connect the LPG hose to the
engine pivot plate latch. LPG tank and open the valve on the tank. Move
the fuel select switch to the gasoline position.
Note: The engine pivot plate latch is located under
the engine turntable pivot plate at the counterweight Perkins models: Connect the engine wiring
end of the machine. harness to the fuel solenoid.
3 Open the engine pivot plate latch and swing the Deutz models: Release the manual fuel shutoff
engine pivot plate out and away from the valve.
machine. 7 Start the engine from the ground controls and
check for hydraulic leaks.
Part No. 102521 S-40 • S-45 4 - 31

Manifolds
7-1
Function Manifold Components
The function manifold is located underneath the ground controls side turntable cover.
Index Schematic
No. Description Item Function Torque
1 Flow regulator valve,

0.8 gpm / 3.03 L/min .......................... AA ......... platform rotate and
jib boom (S-45) ................................. 20-25 ft-lbs / 27-34 Nm
0.6 gpm / 2.27 L/min .......................... AA ......... platform rotate (S-40) ........................ 20-25 ft-lbs / 27-34 Nm
2 Check valve ....................................... AB ......... Differential sensing circuit,

platform rotate right and
jib boom down (S-45) ........................ 10-12 ft-lbs / 14-16 Nm
3 Solenoid valve, 2 position 3 way ....... AC ........ Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
4 Check valve ....................................... AD ........ Differential sensing circuit,

platform level up ............................... 10-12 ft-lbs / 14-16 Nm
5 Solenoid valve, 2 position 3 way ....... AE ......... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
6 Check valve ....................................... AF ......... Differential sensing circuit,
boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
7 Differential sensing valve,
150 psi / 10.3 bar ............................... AG ........ Turntable rotate circuit ...................... 30-35 ft-lbs / 41-47 Nm
150 psi / 10.3 bar ............................... AH ........ Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
9 Relief valve, 2200 psi / 152 bar ........ AI .......... Boom down relief .............................. 20-25 ft-lbs / 27-34 Nm
0.1 gpm / 0.38 L/min .......................... AJ ......... Bleeds off differential sensing
valves to tank .................................... 20-25 ft-lbs / 27-34 Nm
11 Check valve ....................................... AK ......... Differential sensing circuit,
boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
12 Relief valve, 1950 psi / 134 bar ........ AL ......... Extend cylinder relief ........................ 20-25 ft-lbs / 27-34 Nm
13 Check valve ....................................... AM ........ Differential sensing circuit,
boom extend/retract .......................... 10-12 ft-lbs / 14-16 Nm
2.0 gpm / 7.6 L/min ............................ AN ........ Steer left/right circuit ......................... 30-35 ft-lbs / 41-47 Nm
15 Check valve ....................................... AO ........ Platform level up .......................................... 14 ft-lbs / 19 Nm

16 Diagnostic nipple ............................... AP ......... Testing
This list continues. Please turn the page
4 - 32 S-40 • S-45 Part No. 102521

MANIFOLDS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
AA AB AC AD AE AF AG AH AI AJ AK AL AM AN
AO 15
AP 16
17
AQ 18
AR 19
AS 20
AT 21
AU 22
AV 23
AW 24
AX 25
AY
26
AZ
27
BI BH BG BF BE BD BC BB BA
36 35 34 33 32 31 30 29 28
Part No. 102521 S-40 • S-45 4 - 33

MANIFOLDS
Function Manifold Components, continued

Index Schematic
18 Relief valve,
2900 psi / 200 bar ............................. AQ ........ System relief (S-45) .......................... 30-35 ft-lbs / 41-47 Nm
18 Relief valve,
2600 psi / 179 bar ............................. AQ ........ System relief (S-40) .......................... 30-35 ft-lbs / 41-47 Nm
4.5 gpm / 17.03 L/min ........................ AR ........ Boom extend/retract circuit ............... 30-35 ft-lbs / 41-47 Nm
20 Check valve ....................................... AS ......... Blocks flow from auxiliary pump
to function pump ............................... 30-35 ft-lbs / 41-47 Nm
21 Solenoid valve, 3 position 4 way ...... AT ......... Steer left/right .................................... 30-35 ft-lbs / 41-47 Nm
22 Solenoid valve, 2 position 3 way ...... AU ........ Boom extend .................................... 30-35 ft-lbs / 41-47 Nm
23 Solenoid valve, 2 position 3 way ...... AV ......... Boom retract ..................................... 30-35 ft-lbs / 41-47 Nm
24 Proportional solenoid valve .............. AW ........ Boom up/down circuit ....................... 20-25 ft-lbs / 27-34 Nm
25 Solenoid valve, 2 position 3 way ...... AX ......... Boom up ........................................... 30-35 ft-lbs / 41-47 Nm
26 Solenoid valve, 2 position 3 way ...... AY ......... Boom down ....................................... 30-35 ft-lbs / 41-47 Nm
27 Solenoid valve, 3 position 4 way ...... AZ ......... Turntable rotate ................................ 20-25 ft-lbs / 27-34 Nm
28 Check valve ....................................... BA ......... Platform level down .......................... 10-12 ft-lbs / 14-16 Nm
29 Proportional solenoid valve .............. BB ......... Turntable rotate left/right .................. 20-25 ft-lbs / 27-34 Nm
30 Counterbalance valve ....................... BC ........ Platform level up ............................... 30-35 ft-lbs / 41-47 Nm
31 Needle Valve .................................... BD ........ Platform level circuit ......................... 20-25 ft-lbs / 27-34 Nm
32 Counterbalance valve ....................... BE ......... Platform level down .......................... 30-35 ft-lbs / 41-47 Nm
33 Solenoid valve, 3 position 4 way ...... BF ......... Platform rotate and jib boom
up/down (S-45) ................................. 20-25 ft-lbs / 27-34 Nm
150 psi / 10.3 bar ............................... BG ........ Differential sensing circuit,
meters flow to functions .................... 30-35 ft-lbs / 41-47 Nm
35 Check valve ....................................... BH ........ Differential sensing circuit,
platform rotate left and
jib boom up (S-45) ............................ 10-12 ft-lbs / 14-16 Nm
36 Diagnostic nipple .............................. BI .......... Testing
4 - 34 S-40 • S-45 Part No. 102521

MANIFOLDS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
AA AB AC AD AE AF AG AH AI AJ AK AL AM AN
AO 15
AP 16
17
AQ 18
AR 19
AS 20
AT 21
AU 22
AV 23
AW 24
AX 25
AY
26
AZ
27
BI BH BG BF BE BD BC BB BA
36 35 34 33 32 31 30 29 28
Part No. 102521 S-40 • S-45 4 - 35

MANIFOLDS
7-2
Valve Adjustments -
Function Manifold
How to Adjust the System

Relief Valve
stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the PTEST port on the function
manifold.
3 Hold the function enable/rpm select toggle
switch to the high idle position. Activate and
hold the boom retract toggle switch with the
boom fully retracted.
4 Observe the pressure reading on the pressure
gauge. Refer to Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item AQ).
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 2 through 5 and recheck relief
valve pressure.
8 Remove the pressure gauge.
4 - 36 S-40 • S-45 Part No. 102521

MANIFOLDS
7-3
Jib Select, Platform Rotate and Generator Manifold Components
Index Schematic
1 Counterbalance valve ........................ CA ........ Platform rotate right .......................... 30-35 ft-lbs / 41-47 Nm
2 Counterbalance valve ........................ CB ........ Platform rotate left ............................. 30-35 ft-lbs / 41-47 Nm
3 Relief valve ........................................ CD ........ Generator overload relief .................. 30-35 ft-lbs / 41-47 Nm
4 Solenoid valve ................................... CE ........ Controls generator on / off ................ 50-55 ft-lbs / 68-75 Nm
5 Solenoid valve, 2 position 3 way ....... CC ........ Platform rotate/jib boom select ......... 18-20 ft-lbs / 25-27 Nm
CC
5
Jib Select Manifold

CA
1
CE
4
Platform Rotate Manifold
Generator Manifold
CB
2
CD
3
Part No. 102521 S-40 • S-45 4 - 37

MANIFOLDS
7-4
Brake Manifold Components (before serial number 7569)
Index Schematic
1 Solenoid valve, 2 position 3 way ... DA ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
2 Orifice, 0.025 inch / 0.635 mm ....... DB ........... Turntable rotation brake release
DA
1
DB
2
4 - 38 S-40 • S-45 Part No. 102521

MANIFOLDS
7-5
Brake/Two-Speed Manifold Components (after serial number 7568)
Index Schematic
1 Orifice, 0.025 inch / 0.63 mm ......... EA ........... Turntable rotation brake release
2 Solenoid valve, 2 position 3 way ... EB ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
3 Solenoid valve, 2 position 3 way ... EC ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm
4 Check valve .................................... ED ........... Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm
1 2 3
EA EB EC
ED
4
Part No. 102521 S-40 • S-45 4 - 39

MANIFOLDS
7-6
Oscillate Directional Valve Components
The oscillate directional valve is mounted inside the drive chassis at the non-steer end.
Index
No. Description Function Torque
1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm
2 Spool valve ....................................................... Directional control
2 Relief valve ....................................................... Pressure adjustment
4 - 40 S-40 • S-45 Part No. 102521

MANIFOLDS
How to Set Up the Oscillate 7 Push up or pull down on the threaded rod until
the machine is completely level.
Directional Valve
8 Verify that the ground and drive chassis are
Note: Adjustment of the oscillate directional valve completely level.
linkage is only necessary when the linkage or valve
has been replaced. 9 Tighten the nuts on both sides of the urethane
cushions until they are snug. Tighten the
1 Lower the boom to the stowed position. locknuts.
2 Use a "bubble type" level to be sure the floor is 10 Verify that the ground and drive chassis are
completely level. completely level.
Tip-over hazard. Failure to 11 Measure the distance between the drive
perform this procedure on a level chassis and the non-steer axle on both sides
floor could compromise the (from the inside of the drive chassis).
stability of the machine resulting in
the machine tipping over. Note: If the distance is not equal and the
adjustment to the linkage was completed with the
3 Check the tire pressure in all four tires and add ground and drive chassis level, repeat steps 6
air if needed to meet specification. through 11 OR consult Genie Industries Service
Department.
Note: The tires on some machines are foam-filled
and do not need air added to them.
4 Remove the drive chassis cover and the non-

steer axle covers.
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
6 To level the drive chassis, start the engine and
loosen the lock nuts on both sides of the
urethane cushions.
Part No. 102521 S-40 • S-45 4 - 41

MANIFOLDS
7-7 8 Adjust the internal screw. Turn it clockwise to

increase the pressure or counterclockwise to
Valve Adjustments - Oscillate decrease the pressure. Install the valve cap.
Relief Valve Tip-over hazard. Do not adjust the
relief valve higher than specified.
How to Adjust the Oscillate Relief
9 Repeat steps 4 through 7 and manually activate
Valve Pressure the valve to confirm the valve pressure.
1 Remove the drive chassis cover from the non- 10 Turn the engine off, remove the pressure gauge
steer end of the machine. and assemble the directional valve linkage.
2 Connect a 0 to 2000 psi / 0 to 150 bar pressure 11 Install the cover on the non-steer end of the
gauge to the diagnostic nipple located near the drive chassis.
oscillate directional valve.
3 Disconnect the directional valve linkage, by
removing the heim joint and retaining fastener
from the axle.
4 Start the engine from the platform controls.
5 With the engine running, manually activate the
valve and observe the pressure reading on the
pressure gauge.
Oscillate relief valve specification
Pressure 950 psi

65.5 bar
6 Turn the engine off.

7 Locate the relief valve on the directional valve
and remove the cap.
4 - 42 S-40 • S-45 Part No. 102521

MANIFOLDS
7-8
Traction Manifold Components, 2WD (before serial number 7569)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
1 Relief valve, 210 psi / 14.5 bar ......... FA ......... Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
2 Flow divider/combiner valve ............. FB ......... Controls flow to drive motors
in forward and reverse ................ 90-100 ft-lbs / 122-136 Nm
3 Orifice, 0.070 inch / 1.78 mm ............ FC ......... Equalizes flow across flow
divider/combiner valve (item FB)
4 Shuttle valve, 3 position 3 way .......... FD ......... Charge pressure, hot oil shuttle ........ 50-55 ft-lbs / 68-75 Nm
5 Diagnostic nipple ............................... FE ......... Testing
1 2
FA FB
FC
3
2WD
FD
4
FE
5
Part No. 102521 S-40 • S-45 4 - 43

MANIFOLDS
7-9
Traction Manifold Components, 2WD (after serial number 7568)
Index Schematic
1 Relief valve, 280 psi / 19.3 bar ......... GA ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
2 Flow divider/combiner valve ............. GB ........ Controls flow to drive motors
in forward and reverse ................ 90-100 ft-lbs / 122-136 Nm
3 Check valve ....................................... GC ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
4 Check valve ....................................... GD ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
5 Flow divider/combiner valve .............. GE ........ Controls flow to drive motors
in forward and reverse ...................... 50-55 ft-lbs / 68-75 Nm
6 Orifice, 0.070 inch / 1.78 mm ............ GF ........ Equalizes flow across flow
divider/combiner valve (item GB)
1
GA
GB
2
GC
3
GD
4
GE
5
GF
6
4 - 44 S-40 • S-45 Part No. 102521

MANIFOLDS
7-10 4 Start the engine from the platform controls and

drive the machine slowly in the forward
Valve Adjustments, 2WD direction. Note the pressure reading on the
Drive Manifold pressure gauge.
5 Turn the engine off, and remove the hot oil
How to Adjust the Hot Oil Shuttle shuttle relief valve cap (item FA). Adjust the
Relief Valve internal hex socket clockwise to increase the
pressure or counterclockwise to decrease the
Note: The pressure differential between the charge pressure. Install the valve cap.
pump relief valve (located in the drive pump) and (before serial no. 7569)
the hot oil shuttle relief valve (located in the drive
manifold) is necessary to return hot oil from the
shuttle relief valve cap (item GA). Adjust the
closed loop drive circuit to the hydraulic tank for
internal hex socket clockwise to increase the
cooling. This pressure differential must be
maintained at 40 psi / 14.5 bar.
pressure. Install the valve cap.
Note: The following procedure will require two (after serial no. 7568)
people.
1 Open the engine side turntable cover and 6 Repeat steps 4 and 5 until the pressure reading
connect a 0 to 600 psi / 0 to 41 bar pressure on the guage is 40 psi / 2.8 bar less than the
gauge to the diagnostic nipple on the drive pressure reading at the pump.
pump.
allow the engine to run at high idle. Note the
pressure reading on the pressure gauge.
3 Turn the engine off and connect a
0 to 600 psi / 0 to 41 bar pressure gauge to the
diagnostic nipple located on the drive manifold.
Part No. 102521 S-40 • S-45 4 - 45

MANIFOLDS
7-11
Traction Manifold Components, 4WD (before serial number 7569)
Index Schematic
1 Flow divider/combiner valve ............. HA ........ Controls flow to steer
end drive motors in
forward/reverse ........................... 90-100 ft-lbs / 122-136 Nm
2 Flow divider/combiner valve .............. HB ........ Controls flow to non-steer
end drive motors in
forward/reverse ........................... 90-100 ft-lbs / 122-136 Nm
3 Orifice, 0.070 inch / 1.778 mm .......... HC ........ Rear drive motor circuit
4 Orifice, 0.070 inch / 1.778 mm .......... HD ........ Equalizes pressure on both sides
of flow divider/combiner valve 7
5 Shuttle valve, 3 position 3 way .......... HE ........ Charge pressure, hot oil shuttle ........ 50-55 ft-lbs / 68-75 Nm
6 Diagnostic nipple ............................... HF ......... Testing

7 Flow divider/combiner valve .............. HG ........ Controls flow to flow
divider/combiner valves
1 and 2 ........................................ 90-100 ft-lbs / 122-136 Nm
8 Relief valve, 210 psi / 14.5 bar .......... HH ........ Charge pressure circuit ..................... 30-35 ft-lbs / 41-47 Nm
9 Orifice, 0.052 inch / 1.32 mm ............ HI .......... Front drive motor circuit
4 - 46 S-40 • S-45 Part No. 102521

MANIFOLDS
HI
9
HA
1
HB
2
HH
8
HG
7
HC
3
HD
4
HE
5
HF
6
Part No. 102521 S-40 • S-45 4 - 47

MANIFOLDS
7-12
Traction Manifold Components, 4WD (from serial number 7568 to 15822)
Index Schematic
1 Relief valve, 280 psi / 19.3 bar ......... JA ......... Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm
2 Flow divider/combiner valve .............. JB ......... Controls flow to non-steer end

drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
3 Check valve ....................................... JC ......... Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm
4 Check valve ....................................... JD ......... Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm
5 Flow divider/combiner valve .............. JE ......... Controls flow to flow

2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
6 Check valve ....................................... JF ......... Non-steer end drive motor circuit ...... 60-70 ft-lbs / 81-95 Nm
7 Orifice, 0.040 inch / 1 mm ................. JG ......... Equalizes pressure on both sides

8 Orifice, 0.040 inch / 1 mm ................. JH ......... Equalizes pressure on both sides
9 Orifice, 0.040 inch / 1 mm ................. JI ........... Equalizes pressure on both sides
10 Check valve ....................................... JJ .......... Steer end drive motor circuit ............. 60-70 ft-lbs / 81-95 Nm
11 Check valve ....................................... JK ......... Steer end drive motor circuit ............. 35-40 ft-lbs / 48-54 Nm
12 Shuttle valve, 3 position 3 way .......... JL .......... Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ........................ 80-90 ft-lbs / 108-122 Nm
13 Flow divider/combiner valve .............. JM ......... Controls flow to steer end
14 Check valve ....................................... JN ......... Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm
4 - 48 S-40 • S-45 Part No. 102521

MANIFOLDS
JA
1
JB
2
JC
3
JN
14
JD
4
JM
13
JE
5
JF
6
JL
12
JK
11
JJ
10
JI JH JG
9 8 7
Part No. 102521 S-40 • S-45 4 - 49

MANIFOLDS
7-13
Traction Manifold Components, 4WD (from serial number 15823)
Index Schematic
1 Relief valve, 280 psi / 19.3 bar ......... KA ......... Charge pressure circuit .................... 55-60 ft-lbs / 74-81 Nm
2 Flow divider/combiner valve ............. KB ......... Controls flow to non-steer end

3 Check valve ....................................... KC ........ Steer end drive motor circuit ............ 55-60 ft-lbs / 74-81 Nm
4 Check valve ....................................... KD ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 74-81 Nm
5 Check valve ....................................... KE ......... Non-steer end drive motor circuit ... 70-75 ft-lbs / 95-100 Nm
6 Flow divider/combiner valve ............. KF ......... Controls flow to flow

2 and 13 ........................................ 80-90 ft-lbs / 108-122 Nm
7 Orifice, 0.040 inch / 1 mm .................. KG ........ Equalizes pressure on both sides

8 Orifice, 0.040 inch / 1 mm .................. KH ........ Equalizes pressure on both sides
9 Orifice, 0.040 inch / 1 mm .................. KI .......... Equalizes pressure on both sides
11 Shuttle valve, 3 position 3 way ......... KJ ......... Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ............................ 35-40 ft-lbs / 48-54 Nm
10 Check valve ....................................... KK ......... Steer end drive motor circuit .......... 55-60 ft-lbs / 95-100 Nm
12 Check valve ....................................... KL ......... Steer end drive motor circuit .......... 70-75 ft-lbs / 95-100 Nm
13 Flow divider/combiner valve ............. KM ........ Controls flow to steer end

14 Check valve ....................................... KN ........ Non-steer end drive motor circuit ..... 55-60 ft-lbs / 74-81 Nm
4 - 50 S-40 • S-45 Part No. 102521

MANIFOLDS
KA
1
KB
2
KC
3
KN
14 KD
4
KM KE
13 5
KF
6
KL
12
KK
11 4WD
KJ
10
KI KH KG
9 8 7
Part No. 102521 S-40 • S-45 4 - 51

MANIFOLDS
7-14 4 Start the engine from the platform controls and

drive the machine slowly in the forward
Valve Adjustments, 4WD direction. Note the pressure reading on the
Drive Manifold pressure gauge.
How to Adjust the Hot Oil Shuttle shuttle relief valve cap (item HH). Adjust the
Relief Valve internal hex socket clockwise to increase the
Note: The pressure differential between the charge pressure. Install the valve cap.
pump relief valve (located in the drive pump) and (before serial no. 7569)
the hot oil shuttle relief valve (located in the drive
manifold) is necessary to return hot oil from the
shuttle relief valve cap (item JA). Adjust the
closed loop drive circuit to the hydraulic tank for
internal hex socket clockwise to increase the
cooling. This pressure differential must be
maintained at 40 psi / 14.5 bar.
pressure. Install the valve cap.
Note: The following procedure will require two (from serial no. 7569 to 15822)
people.
1 Open the engine side turntable cover and shuttle relief valve cap (item KA). Adjust the
connect a 0 to 600 psi / 0 to 41 bar pressure internal hex socket clockwise to increase the
gauge to the diagnostic nipple on the drive pressure or counterclockwise to decrease the
pump. pressure. Install the valve cap.
(from serial no. 15823)
allow the engine to run at high idle. Note the
pressure reading on the pressure gauge. 6 Repeat steps 4 and 5 until the pressure reading
on the guage is 40 psi / 2.8 bar less than the
3 Turn the engine off and connect a pressure reading at the pump.
0 to 600 psi / 0 to 41 bar pressure gauge to the
diagnostic nipple located on the drive manifold.
4 - 52 S-40 • S-45 Part No. 102521

MANIFOLDS
7-15 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromagnetic force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / 10°C
within the coil. Zero resistance or infinite that your air temperature increases or decreases
resistance indicates the coil has failed. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Description Specification

resistance values outside specification can produce
erratic operation. When coil resistance decreases Solenoid valve, 2 position 3 way, 10V DC 6.3 Ω
below specification, amperage increases. As (schematic items AC and AE)
resistance rises above specification, voltage Solenoid valve, 3 position 4 way, 10V DC 6.3 Ω
increases. (schematic item AT and AZ)
While valves may operate when coil resistance is Solenoid valve, 2 position 3 way, 10V DC 6.3 Ω
outside specification, maintaining coils within (schematic items AU, AV, AX, and AY)
specification will help ensure proper valve function
over a wide range of operating temperatures. Solenoid valve, 3 position 4 way, 10V DC 6.3 Ω
(schematic items AZ and BF)
Electrocution/burn hazard. Contact
Proportional solenoid valve, 12V DC 9Ω
(schematic items AW and BB)
injury. Remove all rings, watches Solenoid valve, 2 position 3 way, 10V DC 6.8 Ω
and other jewelry. (schematic item CC)
Note: If the machine has been in operation, allow Solenoid valve, 2 position 3 way, 10V DC 3.3 Ω
the coil to cool at least 3 hours before performing (schematic items DA)
this test.
1 Tag and disconnect the wiring from the coil to be (schematic items CE)
tested.
2 Test the coil resistance using a multimeter set
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
Part No. 102521 S-40 • S-45 4 - 53

MANIFOLDS
How to Test a Coil Diode

a
Genie incorporates spike suppressing diodes in all COIL AMMETER
of its directional valve coils except proportional d

valves and those coils with a metal case. Properly
functioning coil diodes protect the electrical circuit
by suppressing voltage spikes. Voltage spikes c - b
naturally occur within a function circuit following the
+
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
c
damage.
+
b
Electrocution/burn hazard. Contact -

with electrically charged circuits a multimeter
could result in death or serious b 9V DC battery
injury. Remove all rings, watches c 10Ω resistor
and other jewelry. d coil
Note: Dotted lines in illustration indicate a

1 Test the coil for resistance. See, How to Test a
reversed connection as specified in
Coil. step 6
2 Connect a 10Ω resistor to the negative terminal 4 Connect the negative lead to the other terminal
of a known good 9V DC battery. Connect the on the coil.
other end of the resistor to a terminal on the
coil. Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
Resistor, 10ΩΩ end of the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
Note: The battery should read 9V DC or more when
measured across the terminals. 6 At the battery or coil terminals, reverse the
connections. Note and record the current
3 Set a multimeter to read DC current.
reading.
Note: The multimeter, when set to read DC current,
Result: Both current readings are greater than
should be capable of 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.
4 - 54 S-40 • S-45 Part No. 102521

MANIFOLDS
7-16
Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
1 Directional Valve ............................ CY ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm
2 Orifice disc ...................................... CW .......... Delays shift to drive ......................... 35-40 ft-lbs / 47-54 Nm
3 Solenoid valve ............................... CV ........... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
4 Relief valve .................................... CX ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm
5 Check valve .................................... CU ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm
CU
5
CY
1
CW
2
CV
3
CX
4
Part No. 102521 S-40 • S-45 4 - 55

Turntable Rotation Components

8-1 2 Tag, disconnect and plug the hydraulic hoses
from the motor, brake and manifold. Cap the
Turntable Rotation Assembly fittings on the motor, brake and manifold.
How to Remove the Turntable hydraulic oil can penetrate and
Rotation Assembly burn skin. Loosen hydraulic
gradually. Do not
allow oil to squirt or spray.
installation.
Refer to Section 2, Hydraulic Hose and Fitting 3 Attach a suitable lifting device to the turntable
Torque Specifications. rotator assembly.

firm and level surface.
f
1 Secure the turntable from rotating with the
turntable rotation lock pin.
e
d c b a
Unlocked position
a brake assembly
b drive hub
c backlash plate mounting bolts
d backlash plate
e manifold
f motor
Locked position
4 - 56 S-40 • S-45 Part No. 102521

TURNTABLE ROTATION COMPONENTS
4 Remove the turntable rotation assembly

mounting fasteners.
5 Carefully remove the turntable rotation assembly
from the machine.
could rotate unexpectedly when
the rotation drive hub assembly is
removed if the turntable is not
secured with the turntable rotation
lock pin.
rotation drive hub assembly could
become unbalanced and fall when
removed from the machine if not
properly supported.
When installing the drive hub assembly:
6 Install the drive hub. Apply Loctite® removable

thread sealant and torque the backlash plate
mounting fasteners to 160 ft-lbs / 217 Nm.
Part No. 102521 S-40 • S-45 4 - 57

Axle Components
9-1 2 Remove the fasteners from drive chassis cover
at the steer end. Remove the cover.
Oscillate Cylinders
3 Tag, disconnect and plug the oscillating axle
The oscillating axle cylinders extend and retract cylinder hydraulic hoses. Cap the fittings on the
between the drive chassis and the axle to maintain oscillate cylinder.
a level chassis while driving over uneven terrain. Bodily injury hazard. Spraying
The cylinders are equipped with counterbalance hydraulic oil can penetrate and
valves to prevent movement in the event of a burn skin. Loosen hydraulic
hydraulic hose failure. connections very slowly to allow
How to Remove an Oscillating gradually. Do not allow oil to squirt
Axle Cylinder or spray.
Bodily injury hazard. This 4 Remove the pin retaining fasteners from the
procedure requires specific repair rod-end pivot pin. Use a soft metal drift to
skills and a suitable workshop. remove the pin.
Attempting this procedure without 5 Attach a lifting strap from an overhead crane to
these skills and tools could result the barrel end of the oscillating cylinder.
in death or serious injury and
significant component damage. 6 Remove the pin retaining fasteners from the
Dealer service is strongly barrel-end pivot pin. Use a soft metal drift to
recommended. remove the pin.
Note: Perform this procedure on a firm, level 7 Remove the cylinder from the machine.
surface with the boom in
Crushing hazard. The oscillate
the stowed position.
cylinder could become unbalanced
Note: When removing a hose assembly or fitting, and fall when it is removed from
the O-ring on the fitting and/or hose end must be the machine if it is not properly
replaced and then torqued to specification during attached to the overhead crane.
installation.
Refer to Section Two, Hydraulic Hose and Fitting
Torque Specifications.
1 Rotate the turntable until the boom is between
the steer tires.
4 - 58 S-40 • S-45 Part No. 102521

Track Components
10-1 How to Replace the Track
Track Assembly - TRAX option Note: The sprocket is comprised of two halves.
1 Center a lifting jack of ample capacity

How to Remove a Track (20,000 lbs / 10,000 kg) under the drive chassis
Assembly between the tracks.
Note: Perform this procedure on a firm, level 2 Refer to illustration 1 and place the drive hub
surface with the boom in the stowed position. disconnect cap in the brake disengaged
position.
1 Chock the tracks at the opposite end of the
machine to prevent the machine from rolling. 3 Lift the machine until the tracks are off the
2 Center a lifting jack of ample capacity drive chassis for support.
between the tracks. 4 Loosen the idler axle bolt, tensioner jam nut and
tension nut on both sides of the assembly to
3 Lift the machine until the tracks are off the allow maximum play in the tensioner wheel.
drive chassis for support. 5 Remove the lug nut bolts holding each half
sprocket on the drive hub. Rotate the sprockets
4 Remove the lug nut bolts holding each half until only one sprocket is contacting the track.
sprocket on the drive hub. Rotate the sprockets Remove the lower half sprocket from the track
until only one sprocket is contacting the track. assembly.
Remove the lower half sprocket from the track
assembly. 6 Rotate the remaining half sprocket 180° so that
it is free of the track.
5 Rotate the remaining half sprocket 180° so that
it is free of the track. 7 Carefully remove the track from the
undercarriage.
6 Attach a lifting strap from an overhead crane to
the center-point of the track assembly, above
the sprocket. brake disengaged position
7 Remove the fasteners holding the TRAX

mounting pin located underneath the axle.
Remove the pin supporting the TRAX assembly.
brake engaged position
8 Carefully remove the track assembly from the
drive hub and set aside. Illustration 1
Crushing hazard. The track
assembly could become
unbalanced and fall when removed
from the machine if not properly
supported by the overhead crane.
Part No. 102521 S-40 • S-45 4 - 59

11 Install the other sprocket half, removed in step

4.
half sprocket
12 Install the lug nuts onto the wheel hub and
torque to specification. Refer to Section 2,
Specifications.
13 Adjust the track tension. Tighten the tensioner
nut on both sides of the idler wheel until there is
about 0.75 - 1.0 inch / 19 - 25 mm of droop
between the inside of the rubber track and the
bottom surface of the bogey wheels.
idler wheel Note: Make sure that both sides of the track have
tensioner bogey wheel the same amount of clearance between the rollers
assembly and the track.
Illustration 2
14 Tighten the jam nuts and idler axle bolts on both
tensioner assemblies.
8 Install the new track onto the undercarriage.
Note: Be sure the idler and bogey wheels are
aligned with the inside surface of the track.
9 Using a suitable lifting device, lift up on the
rubber track and rotate the half sprocket until
one of the sprocket teeth is engaging the track.
10 Continue rotating the half sprocket until it is fully
engaging the track.
4 - 60 S-40 • S-45 Part No. 102521

Generators
11-1 outlet at the generator.
Hydraulic Generator Result: The reading on the multimeter should be
112 to 118V AC.
How to Adjust the Generator Result: If the reading on the multimeter is not
Voltage 112 to 118V AC, proceed to step 6.
Bodily injury hazard. Spraying 6 Turn the key switch to the off position.
hydraulic oil can penetrate and 7 Use a wrench to hold the generator flow
burn skin. Loosen hydraulic regulator valve (item AM) and remove the cap.
the oil pressure to dissipate a flow regulator
gradually. Do not allow oil to squirt
or spray.
Electrocution/burn hazard. Contact
could result in death or serious a
and other jewelry.
Note: Be sure that the hydraulic oil level is within
the top 2 inches / 5 cm of the sight gauge.
8 Adjust the internal hex socket. Turn it clockwise
Note: Perform this procedure with the machine on a to increase the AC voltage or counterclockwise
firm, level surface. to decrease the AC voltage. Install the flow
regulator valve cap.
1 Disconnect all electrical tools from the machine.
2 Start the engine from the platform controls.
Failure to adjust the generator as
3 Press the generator select switch. instructed may result in damage to
the generator or other electrical
4 Connect an electrical tool, which does not draw equipment. Do not adjust the
more than 15A, to the electrical outlet at the generator to other than specified.
platform controls and run the tool at full speed.
9 Repeat steps 2 through 5 to confirm the
5 Connect the positive and negative leads from a generator AC voltage.
multimeter of sufficient capacity to the electrical
Part No. 102521 S-40 • S-45 4 - 61

GENERATORS
How to Purge the Hydraulic Line

on the MTE Generator
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Note: This procedure should be performed if the
hydaulic line to the generator has been removed.

firm, level surface.
1 Locate the blue purge wire with the male spade
connector from the MTE generator harness.
2 Connect a jumper wire of sufficient length from
the positive battery terminal to the spade
connector on the purge wire.
3 Start the engine and turn on the generator. Allow
the generator to run for three minutes.
4 Turn off the generator and turn off the engine.
5 Remove the jumper wire from the positive
battery terminal and disconnect from the purge
wire.
6 Start the engine and turn on the generator. Using
a digital multimeter check the voltage at the
outlet.
Result: The generator produces a voltage ±10%
of rated output. The generator is ready for use.
Result: The generator output voltage is outside
the ±10% voltage range. Repeat the procedure
beginning with step 2.
4 - 62 S-40 • S-45 Part No. 102521

October 2013 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Genie S-40 and S-45 Operator’s Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
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/burn hazard. Contact
• Machine parked on a firm, level surface with electrically charged circuits
• Boom in stowed position
• Turntable rotated with the boom between and other jewelry.
the non-steer wheels
• 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.
Part No. 102521 S-40 • S-45 5-1

Section 5 • Fault Codes October 2013
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/burn hazard. Contact the red LED will be on solid.
5 Use the fault code table on the following pages
to aid in troubleshooting the machine by
pinpointing the area or component affected.
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.
Electrostatic discharge (ESD) can
damage printed circuit board
components. If the circuit board
does need to be handled, maintain
firm contact with a metal part of
the machine that is grounded at all
times when handling the printed
circuit board OR use a grounded
wrist strap.
5-2 S-40 • S-45 Part No. 102521

FAULT CODES
Error Source Error Type Condition Solution

ID Name ID Name
21 Boom 1 Joystick 11 Function is inoperative
Value at 5V Cycle power off,
(primary boom up/ 12 until joystick is
Value too high then on and
down) 15 calibrated. Alarm
Value too low problem should be
16 sounds indicating
Value at 0V corrected.
fault.
Function is inoperative
17 Not calibrated until joystick is Calibrate joystick
calibrated.
22 Boom 1 directional Valve is operating Cycle power off,
valves outside of operational then on and
21 Fault
limits. Alarm sounds problem should be
indicating fault. corrected.
23 Boom 1 flow Valve is operating
control valve outside of operational
Cycle power off,
limits. Alarm sounds
12 Value too high then on and
indicating fault.
15 Value too low problem should be
corrected.
Normal function except Calibrate valve

17 Not calibrated threshold for one or both thresholds
directions is zero.
24 Boom 1 angle 11 Value at 5V Reduced speed. Cycle power off,
sensor 12 Value too high then on and
15 Value too low problem should be
16 Value at 0V corrected.
Initiate 1 second beep Calibrate angle
31 Invalid setup
of alarm. sensor.
31 Boom 2 Joystick 11 Value at 5V
Joystick is operating Cycle power off,
(secondary boom 12 Value too high
outside of operational then on and
up/down or 15 Value too low
primary boom 16 Value at 0V
extend/retract)
calibrated.
32 Boom 2 directional Valve is operating Cycle power off,
21 Fault
Continued on next page
Part No. 102521 S-40 • S-45 5-3

FAULT CODES

ID Name ID Name
33 Boom 2 flow Valve is operating Cycle power off,
control valve 12 Value too high outside of operational then on and
15 Value too low limits. Alarm sounds problem should be
Normal function
except threshold for Calibrate valve
17 Not calibrated
one or both directions thresholds
is zero.
41 Turntable rotate 11 Value at 5V Joystick is operating Cycle power off,
joystick 12 Value too high outside of operational then on and
16 Value at 0V indicating fault. corrected.
calibrated.
42 Turntable rotate Valve is operating Cycle power off,
directional valves outside of operational then on and
21 Fault
43 Turntable rotate Valve is operating Cycle power off,
flow control valve 12 Value too high outside of operational then on and
Normal function
17 Not calibrated
one or both directions thresholds.
is zero.
44 Drive enable Drive enable function Cycle power off,
toggle switch is inoperative. then on and
21 Fault
problem should be
corrected.
5-4 S-40 • S-45 Part No. 102521

FAULT CODES

ID Name ID Name
51 Drive joystick 11 Value at 5V Joystick is operating Cycle power off,
12 Value too high outside of operational then on and
calibrated.
53 Drive flow valve Valve is operating Cycle power off,
(EDC) 12 Value too high outside of operational then on and
Normal function
17 Not calibrated
one or both directions thresholds
is zero.
54 Drive brake valve Valve is operating Cycle power off,
outside of operational then on and
21 Fault
55 High speed drive Motor speed frozen in Cycle power off,
motor Valve the low state. Alarm then on and
21 Fault
sounds indicating problem should be
fault. corrected.
61 Steer joystick 11 Value at 5V Joystick is operating Cycle power off,
12 Value too high outside of operational then on and
17 Not calibrated until joystick is Calibrate Joystick
calibrated.
62 Steer directional Valve is operating Cycle power off,
21 Fault
Part No. 102521 S-40 • S-45 5-5

FAULT CODES
Ford LRG-425 EFI Engine Note: If any fault codes are present, the ECM will
blink a three digit code three times for each code
stored in memory. It will blink the first digit of a
How to Retrieve Ford Engine three digit code, pause, blink the second digit,
Fault Codes pause, and then blink the third digit. For example:
the check engine light blinks 5 consecutive times,
The ECM constantly monitors the engine by the blinks 3 times and then 1 time. That would indicate
use of sensors on the engine. The ECM also uses code 531.
signals from the sensors to initiate sequential fuel
injection and make constant and instantaneous Note: Once a fault code has been retrieved and the
changes to ignition timing, fuel delivery and throttle repair has been completed, the ECM memory must
position to maintain the engine's running condition be reset to clear the fault code from the ECM. See
at its highest efficiency while at the same time How to Clear Engine Fault Codes from the ECM.
keeping exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of How to Clear Engine Fault
set parameters, the ECM will store a fault code in Codes from the ECM
memory that relates to the appropriate sensor and
will turn on the Check Engine Light. Note: Perform this procedure with the engine off
and the key switch in the off position.
Note: Perform this procedure with the key switch in
the off position. 1 Open the engine side turntable cover and locate
the battery.
1 Open the ground controls side cover and locate
the run/test toggle switch on the side of the 2 Disconnect the negative battery cable from the
ground control box. battery for a minimum of 5 minutes.
2 Pull out the red Emergency Stop button to the Electrocution/burn hazard. Contact
on position at both the ground and platform with electrically charged circuits
controls. could result in death or serious
3 Quickly activate and release the start toggle and other jewelry.
4 Move and hold the run/test toggle switch to the battery.
test position.
5 Continue to hold the run/test toggle switch in the
test position and count the blinks.
Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three times.
After the fault codes, the check engine light will
blink a code 123 three times again indicating the
end of the stored codes.
5-6 S-40 • S-45 Part No. 102521

FAULT CODES
Code Problem Cause Solution
Closed Loop Multiplier Heated Oxygen Sensor wiring and/or

111
Repair wiring and/or connections OR replace
High (LPG) connections open or shorted OR sensor is faulty sensor OR repair vacuum and exhaust leaks.
OR there are vacuum leaks or exhaust leaks.
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.
The post cat Heated Oxygen Sensor wiring

and/or connections are open or shorted OR Repair wiring and/or connections OR replace
114
Post-cat oxygen
sensor open sensor is cold, non-responsive or inactive for the post cat oxygen sensor.
60 seconds or longer.
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.
MAP, IAT or ECT sensors not in correct position

OR wiring and/or connections for sensors open
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.
Heated Oxygen Sensor wiring and/or

124
Closed Loop Multiplier connections open or shorted OR sensor is
sensor OR replace fuel OR test and repair the
Low (LPG) faulty OR fuel quality is poor OR fuel system
fuel system components.
components may be faulty.
133 Gasoline cat monitor
Repair exhaust leaks OR there is an emissions

134
There are exhaust leaks OR the catalyst system
LPG cat monitor efficiency is below the acceptable level. compliance issue. Contact Ford Power Products
for assistance.
135 NG cat monitor

connections open or shorted OR sensor is Repair heated oxygen sensor wiring and/or
Adaptive Lean Fault -
141
faulty OR there are vacuum or exhaust leaks connections OR replace sensor OR repair
High Limit (Gasoline) OR one or more fuel injectors faulty or stuck vacuum and exhaust leaks OR test the fuel
closed OR fuel quality is poor OR fuel pressure OR clean or replace the fuel injectors.
pressure is too low.
MAP, IAT or ECT sensors not in correct position

OR wiring and/or connections for sensors open
Adaptive Rich Fault -
142
or shorted OR sensor is faulty OR one or more Adjust or replace sensors OR clean or repair
Low Limit (Gasoline) fuel injectors are stuck closed OR there is fuel injectors.
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.

connections open or shorted OR sensor is
143
Adaptive Learn High sensor OR repair any vacuum and exhaust
faulty OR there are vacuum leaks or exhaust
(LPG) leaks OR replace fuel OR test and repair the
leaks OR fuel quality is poor OR fuel system
fuel system components.
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
OR test and repair the fuel system
components.
Part No. 102521 S-40 • S-45 5-7

FAULT CODES
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.
IAT sensor wiring and/or connections are open or

211 IAT High Voltage shorted OR sensor is faulty OR engine intake air
temperature is too cold.
sensor OR direct warmer air into air intake.
IAT sensor wiring and/or connections are open or

212 IAT Low Voltage shorted OR sensor is faulty OR engine intake air
temperature is too hot.
sensor OR direct cooler air into air intake.
Air intake temperature is greater than 200° F with

213
IAT Higher Than
the engine greater than 1000 rpm OR air intake
Expected (1)
system has leaks OR IAT sensor is faulty. Check air intake system for damage and proper
routing of air intake components OR replace the
Air intake temperature is greater than 210° F with IAT sensor.
IAT Higher Than
214 Expected (2)
the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.
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.
Engine cooling system is malfunctioning OR Repair engine cooling system problems OR

221 CHT/ECT High Voltage sensor wires and/or connections open or shorted
OR sensor is faulty.
repair open or shorted wiring to sensor OR
replace sensor.
Engine cooling system is malfunctioning and
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
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.
Coolant temperature at the cylinder head is 250° F.

224
CHT Higher Than
Expected (2) overheating the engine OR sensor wires and/or
connections open or shorted OR sensor is faulty
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.
234 BP High Pressure MAP sensor is faulty OR ECM is faulty.

Replace MAP sensor OR replace the ECM.
235 BP Low Pressure MAP sensor is faulty OR ECM is faulty.
Crankshaft position sensor wiring and/or

242 Crank Sync Noise connections open or shorted OR there is a poor
system ground connection 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
and secure OR repair wiring and/or connections
to sensor OR replace sensor.
Crankshaft position sensor wiring and/or

244 Camshaft Sensor Loss connections open or shorted OR there is a poor
5-8 S-40 • S-45 Part No. 102521

FAULT CODES

Camshaft position sensor wiring and/or Be sure system ground connections are in place
245 Camshaft Sensor Noise connections open or shorted OR there is a poor and secure OR repair wiring and/or connections
system ground connection OR sensor is faulty. 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
ECM is faulty.
315
ECM is faulty.
321
ECM is faulty.
Open wiring and/or connections to fuel pump OR

351
Fuel Pump Loop Open or
fuel pump power shorted to ground OR fuel pump
High Side Short to Ground
is faulty. Repair wiring and/or connections to fuel pump OR
replace fuel pump.
352
Fuel Pump High Side Wiring and/or connections to fuel pump shorted to
Shorted to Power power OR fuel pump is faulty.
Fuel pressure too high OR LPG lockoff not opening

MegaJector Delivery completely OR the line between the MegaJector
353 Pressure Higher Than
Expected
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly Check fuel pressure OR repair LPG lockoff OR
OR MegaJector is faulty. repair the line between the MegaJector and
Fuel pressure too low OR LPG lockoff not opening carburetor OR repair engine cooling system OR
MegaJector Delivery completely OR the line between the MegaJector replace the MegaJector.
354 Pressure Lower Than
Expected
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly
OR MegaJector is faulty.
The ECM doesn't get any response from the Check CAN circuits for continuity and shorts to
355 MegaJector
Communication Lost
MegaJector, or an incorrect response for 500ms
period or longer.
power or ground and for continuity and repair as
necessary OR replace the MegaJector.
The MegaJector detects voltage greater than 18
361 MegaJector Voltage
Supply High
volts for 5 seconds anytime the engine is cranking
Repair charging system OR replace the
MegaJector.
or running.
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.
Part No. 102521 S-40 • S-45 5-9

FAULT CODES
363 MegaJector Internal The MegaJector detects an internal fault. Open or

Actuator Fault Detection short in power, ground or CAN circuits.
Check Power, Ground and CAN circuits at
MegaJector and all connections and repair as
364 MegaJector Internal The MegaJector detects an internal circuitry failure.
Circuitry Fault Detection Open or short in power, ground or CAN circuits. necessary OR MegaJector has an internal fault.
Contact Ford Power Products for assistance.
MegaJector Internal The MegaJector detects an internal
365 Communication Fault communications failure. Open or short in power,
ground or CAN circuits.
Detection
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
511 FPP1 High Voltage
512 FPP1 Low Voltage
513 FPP1 Higher than IVS Limit

If this fault appears on your machine, contact
Not used.
the Genie Industries Service Department.
514 FPP1 Lower than IVS Limit
531 TPS1 (Signal Voltage) High The #1 throttle position sensor wiring and/or
Be sure system ground connections are in place
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
Be sure system ground connections are in place
system ground connection OR throttle position
534 TPS2 (Signal Voltage) Low sensor #2 is faulty.
to sensor OR replace throttle position sensor #2.
The throttle position sensor wiring and/or

535 TPS1 Higher than TPS2 connections for either TPS1 or TPS2 open or
Be sure engine harness wiring and connections
are in place and secure OR repair wiring and/or
shorted OR there is a poor system ground
connections to one or both TPS sensors OR
536 TPS1 Lower than TPS2 connection OR one or both throttle position
sensors are faulty.
replace one or both TPS sensors.
Governor actuator is stuck closed OR wiring

537 Throttle Unable to Open and/or connections open or shorted OR
governor actuator is faulty. Repair wiring and/or connections to governor
actuator OR replace the governor actuator.
Governor actuator is stuck open OR wiring
538 Throttle Unable to Close and/or connections open or shorted OR
governor actuator is faulty.
Engine harness wiring and/or connections open

545
Repair wiring and/or connections in engine
Governor Interlock Failure or shorted OR there is a poor system ground
harness OR replace the ECM.
connection OR ECM is faulty.
5 - 10 S-40 • S-45 Part No. 102521

FAULT CODES
551 Max Governor Speed

Override
ECM needs to be re-programmed OR throttle is Re-program ECM OR repair binding throttle
552 FPP1 Low Voltage sticking open OR there are air leaks between the
throttle body and cylinder head.
operation OR repair any air leaks between the
throttle body and cylinder head.
553 FPP1 Higher than IVS Limit
611 COP Failure
612 Invalid Interrupt
613 A/D 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
614 RTI 1 Loss secure OR replace ECM.
615 Flash Checksum Invalid
616 RAM Failure
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.
Part No. 102521 S-40 • S-45 5 - 11

FAULT CODES
Ford DSG-423 EFI Engine Note: If any fault codes are present, the ECM will
blink a three digit code three times for each code
stored in memory. It will blink the first digit of a
How to Retrieve Ford Engine three digit code, pause, blink the second digit,
Fault Codes pause, and then blink the third digit. For example:
the check engine light blinks 5 consecutive
The ECM constantly monitors the engine by the times, blinks 3 times and then 1 time. That would
use of sensors on the engine. The ECM also indicate code 531.
uses signals from the sensors to initiate
sequential fuel injection and make constant and Note: Once a fault code has been retrieved and
instantaneous changes to ignition timing, fuel the repair has been completed, the ECM memory
delivery and throttle position to maintain the must be reset to clear the fault code from the
engine's running condition at its highest efficiency ECM. See How to Clear Engine Fault Codes from
while at the same time keeping exhaust the ECM.
emissions to a minimum. When a sensor fails or
returns signals that are outside of set How to Clear Engine Fault
parameters, the ECM will store a fault code in Codes from the ECM
memory that relates to the appropriate sensor
and will turn on the Check Engine Light. Note: Perform this procedure with the engine off
and the key switch in the off position.
Note: Perform this procedure with the key switch
in the off position. 1 Open the engine side turntable cover and
locate the battery.
1 Open the ground controls side cover and
locate the run/test toggle switch on the side of 2 Disconnect the negative battery cable from
the ground control box. the battery for a minimum of 5 minutes.
2 Pull out the red Emergency Stop button to the Electrocution/burn hazard.
on position at both the ground and platform Contact with electrically charged
controls. circuits could result in death or
serious injury. Remove all rings,
3 Quickly activate and release the start toggle watches and other jewelry.
4 Move and hold the run/test toggle switch to battery.
the test position.
5 Continue to hold the run/test toggle switch in
the test position and count the blinks.
Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three
times. After the fault codes, the check engine
light will blink a code 123 three times again
indicating the end of the stored codes.
5 - 12 S-40 • S-45 Part No. 102521

FAULT CODES
Code Description Code Description
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
114 EGO open / lazy post-cat 1 215 Oil pressure low
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
133 Gasoline catalyst monitor 1 225 ECT higher than expected 1
134 LPG catalyst monitor 226 ECT 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
161 Battery voltage high 242 Crank sync noise
162 Battery voltage low 243 Never crank synced at start
163 AUX analog PD1 high 244 Cam loss
164 AUX analog PD1 low 245 Cam sync noise
165 AUX analog PU3 high 246 Crank loss
166 AUX analog PU3 low 253 Knock 1-2 sensor open 1
167 AUX analog PUD1 high 254 Knock 1-2 excessive signal 1
168 AUX analog PUD1 low
171 AUX analog PUD2 high
173 AUX analog PUD3 high
181 AUX DIG1 high
182 AUX DIG1 low
183 AUX DIG2 high
184 AUX DIG2 low
185 AUX DIG3 high
186 AUX DIG3 low
211 IAT (intake air temperature) high voltage
Part No. 102521 S-40 • S-45 5 - 13

FAULT CODES
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
314 Injector coil shorted 2 541 AUX analog PU1 high
315 Injector loop open OR low-side short to ground 3 542 AUX analog PU1 low
316 Injector coil shorted 3 543 AUX analog PU2 high
321 Injector loop open OR low-side short to ground 4 544 AUX analog PU2 low
322 Injector coil shorted 4 551 Max govern speed override
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
355 EPR comm lost 613 A/D loss
359 Fuel run-out longer than expected 614 RTI 1 loss
361 EPR voltage supply high 615 Flash checksum invalid
362 EPR voltage supply low
363 EPR internal actuator fault detection
364 EPR internal circuitry fault detection
365 EPR internal comm fault detection
411 Primary loop open OR low-side short to ground 1
412 Primary coil shorted 1
5 - 14 S-40 • S-45 Part No. 102521

FAULT CODES
616 RAM failure 744 PWM5 short to power
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
634 5VE2 low voltage 771 Tach output ground short
635 5VE1-5VE2 simultaneous out-of-range 772 Tach output short to power
641 Rx inactive 1629 J1939 TSC1 message receipt lost
642 Rx noise 1630 J1939 ETC message receipt lost
643 Invalid packet format
644 Shutdown request
646 CAN Tx failure
647 CAN Rx failure
648 CAN address conflict failure
655 RTI 2 loss
656 RTI 3 loss
711 Relay control ground short
712 Relay coil open
713 Relay coil short to power
714 Fpump relay control ground short
715 Fpump relay coil open
716 Fpump relay coil short to power
721 Start relay control ground short
722 Start relay coil open
723 Start relay coil short to power
731 PWM1-gauge1 open / ground short
732 PWM1-gauge1 short to power
733 PWM2-gauge2 open / ground short
735 PWM3-gauge3 open / ground short For further engine fault code troubleshooting and
diagnostic information, refer to the Ford DSG-423
EFI Service Manual (EDI part number 1060040).
741 PWM4 open / ground short Genie part number 119494.
742 PWM4 short to power
743 PWM5 open / ground short
Part No. 102521 S-40 • S-45 5 - 15

5 - 16 S-40 • S-45 Part No. 102521

October 2013 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey: Electrocution/burn hazard. Contact

Troubleshooting and repair procedures shall be could result in death or serious
completed by a person trained and qualified on injury. Remove all rings, watches
the repair of this machine. and other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules gradually. Do not allow oil to squirt
and operating instructions printed in the or spray.
Genie S-40 & Genie S-45 Operator's Manual. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 102521 S-40 • S-45 6-1

Section 6 • Schematics October 2013
Electrical Symbols Legend
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
Gauge Auxiliary pump

OPS1
Circuits crossing N.C.
no connection
510
HM Toggle switch SPDT Oil pressure switch
normally closed Resistor with
ohm value
Diode Hour meter

TS6
DOWN
UP
L3
PLATFORM LEVEL
-
Gauge sending unit Tilt sensor
LED
Battery
Toggle switch DPDT
F1
KS1
25A A B C
CB1
PULL IN
Fuse
HOLD
CR4
15A with amperage N.O. Key switch
Circuit breaker
with amperage
Control relay contact Fuel or RPM
normally open solenoid
Starting aid:
glow plug or
flame ignitor
Coil
6-2 S-40 • S-45 Part No. 102521

Hydraulic Symbols Legend
25 psi
(1.7 bar) .035"
(0.89 mm)
Orifice with size
Solenoid operated
Solenoid operated 3 position, 3 position, 4 way,
Filter with 4 way, directional valve proportional directional valve
bypass valve
relief setting
Check valve
200 psi
(13.8 bar)
2 position, 3 way, shuttle valve
Pump
fixed displacement Relief valve Priority
with pressure setting flow regulator valve
o
Brake
Pump Solenoid operated 2 position,

bi-directional, 3 way, directional valve
variable displacement Directional valve
(mechanically activated)
3000 psi
(206.8 bar)
3:1
Needle valve
50% 50%
Flow divider/combiner valve

Motor with pressure balancing orifice
bi-directional Counterbalance valve
and flow percentages with pressure and pilot ratio
Pilot operated 3 position,

3 way, shuttle valve
Motor
2-speed,
bi-directional
2 position, 2 way
solenoid valve
E
Pump prime mover
(engine or motor)
Differential
sensing valve
Directional valve
pilot operated
2 position, 2 way
Double acting
cylinder
Solenoid operated
proportional valve
Part No. 102521 S-40 • S-45 6-3

Ford DSG-423 Engine Relay Layout
Starter Empty
Relay
F1-10A F2-5A
Fuel Power
Pump Relay F3-10A F4-15A
Relay
F5-15A F6-10A
F6-10A
6-4 S-40 • S-45 Part No. 102521

Connector Pin Legend
N M L K J I H G F E D C B A
1
C1P DT06-12SA C1 C7: DTP06-4S C7
COLOR CKT # PIN # COLOR CKT # PIN #
RD C27AUX 1 BK P22BAT 1
C7 C5-GBOX
RD/BK C28TTA 2 WH P23BAT 2
RD/WH C29MS 3 BRN BATGND 3 2
WH C30EDC+ 4 C1 N/A PLUG 4 C5-ENGINE HARNESS
PIN# CKT# COLOR
WH/BK C31EDC- 5
GRAY
WH/RD C32BRK 6 * NOTE: WIRE ONLY IN C7B CONNECTOR.
BK C33STR 7 PIN# COLOR CKT#
BK/WH C34SA 8
1 1
BK/RD C35RPM 9 2 C41RPM OR/BK 2 OR/BK C41RPM
BL C36STC 10 3 C107AF WH 3 WH C107AF
BL/BK C37STCC 11 4 4
BL/WH C132PLI 12
5 5 BK R33STR 3
6 6 RD R27AUX
7 7
C2P DT06-12SB C2 C6 C6-GBOX C6-FUNCTION HARNESS 8 8 WH R21IGN
9 9 BK/RD C35RPM
10 C39LP BL/RD 10 BL/RD C39LP
COLOR CKT # PIN # WH
CIRCUIT # COLOR 11 TB23 11 WH(12) VSW
CIRCUIT # COLOR
12 12 GR C127TST
BL/RD C39LP 1 BL/WH
1 C1PBU RD C1PBU RD 13 C38ESL 13 BL/WH C38ESL
OR C40LS1 2 14 14 WH/RD C26TSR
2 C2PBD RD/BK C2PBD RD/BK
OR/BK C41RPM 3 RD/WH 15 15
OR/RD C134PWR 4
C2 3 C3PBF RD/WH C3PBF
16 16 WH/BK C25PSR 4
4 C4TRL WH C4TRL WH 17 C21IGN WH 17 WH C21IGN
GR C43HRN 5 BLACK 18
5 C5TRR WH/BK C5TRR WH/BK 18
GR/BK JDALARM 6 C6TRF WH/RD 19 19
6 C6TRF WH/RD WH/BK
GR/WH C45GEN 7 20 C31EDC 20 WH/BK C31EDC
7 C7PBE BK C7PBE BK C30EDC WH
21 21 WH C30EDC
PLUG 8 C8PBR BK/WH BK/WH
8 C8PBR BK/WH 22 C34SA 22
PLUG 9 23 C32BRK WH/RD 23 WH/RD C32BRK
9
PLUG 10 24 C29MS RD/WH 24 RD/WH C29MS
10
PLUG 11 11
PLUG 12
12 5
13 C13DRE BL/RD C13DRE BL/RD
C3P DT06-12SC C3 14 C14PLU OR C14PLU OR
15 C15PLD OR/BK C15PLD OR/BK
COLOR CKT # PIN # R43HRN BK
16 R43HRN BK
RD C1PBU 1 17 C17JU GR C17JU GR
18 C18JD GR/BK C18JD GR/BK
RD/BK C2PBD 2 C9
19 C2DA RD/BK C2DA RD/BK
RD/WH C3PBF 3 C3
20
WH C4TRL 4
GREEN 21
6
WH/BK C5TRR 5
22
WH/RD C6TRF 6
23 C134PWR RD C23BAT RD
BK C7PBE 7
24
BK/WH C8PBR 8 A C9 FS DT04-4P
25 C116HYD BK
GR/BK JALARM 9
BL C10SBU 26 GND BR COLOR CKT # PIN #
10
C11SBD 27 C27AUX RD C27AUX RD
BL/BK 11
28 C28TTA RD/BK C28TTA RD/BK BK P22ESTOP 1
BL/WH C12SBF 12
29 WH P24FS 2 7
C4P DT06-12SD C4 30 P46PWR BL/WH P46PWR BL/WH RD P25BAT 3
N/C 4
31
COLOR CKT # PIN # 32 C32TA WH/RD C32TA WH/RD
BL/RD 1 33 R116HYD OR
C13DRE
OR C14PLU 2 34 R21IGN WH
OR/BK C15PLD 3 35
C4 C36STC BL
GR/BK C133PLA 4 36 C36STC BL
GR C17JU 5 BROWN 37 C37STCC BL/BK C37STCC BL/BK 8
GR/BK C18JD 6 38
GR/WH C19JSV 7 39 C45GEN GR/WH C45GEN GR/WH
PLUG 8 40 C40LS1 OR C40LS1 OR
PLUG 9
PLUG 10
PLUG 11
PLUG 12
Part No. 102521 S-40 • S-45 6-5

Connector Pin Legend
6-5
6-6
Electrical Schematic
Deutz F3L 1011F Models (before serial number 7544)
6-8
6-7
A B C D E F G H I J K L M N
1
RD/BK
TB41
C2-3 OR/BK
P26ESTP BK BK
LS18
P2 FS1
RD-(FS) C9-3 P25FS RD
C9-1 BK BK-(FS)
2 WH-(FS) C9-2 P24FS WH WH
RD C28TTA RD/BK
P22BAT BK
C134PWR OR/RD
C41RPM OR/BK
C132PLI BL/WH
TS2 TS6
SEE NOTE 2
TS17
ON GLOW
TS4
START
L4
H1 TS1
PLUG
HIGH RPM(FS)
P3 L48
GENERATOR
HORN D39 D40
PUMP AUXILIARY
TB 134 IS WAGO TERMINAL BLOCK 42
TB 133 IS WAGO TERMINAL BLOCK 16 SEE NOTE 2
ENGINE
L24
3 C7-1
C2-5
C1-12
C2-4
C1-7
C1-8
C2-7
C4-4
C1-2
C1-1
C7-2
CB2 TB134 TB132
P1 RD
15AMP. RD RD RD
C1-9
TB43
1 3 RD
KS1 TB22
C43HRN GR
C45GEN GR/WH
4
C28TTA RD/BK
C27AUX RD
C35ESPD BK/RD
P23BAT WH
C33STR BK
C34SA BK/WH
C133PLA OR/RD
5 TS51 TS52 TS56 TS55
PLAT
GRD
6 U33
ENGINE
ON GLOW
LOW RPM
HIGH RPM
START BK
FUNCTION ENA.
4
PUMP
AUXILARY
RD
PLUG BK
7
12 8 TB45
TB27 TB33
CB1
RD
1 START RELAY
TB20 15AMP. H6 L45 TB23 2 TACHOMETER
TB34
D6 3 START INPUT
TB133 4 AUX. ON IGN./START
TB28 TB24 5 GROUND TB35
RD MODULE
6 BATTERY L5
5 CB3 CR2
7 KEY PWR.
C6-39
BK/RD
CR1 8 KEY BYPASS
C6-28
C6-23
20AMP. CR5
CR5 CR1 CR2 9 IGN./FUEL ON
NO NO 10 ENG. FAULT
NO
TB21
C6-34
NO CR3
RD/BK-28
RD-134
C5-3
C6-16
C6-27
C5-2
C5-5
C5-22
GR/WH-45
OTS
C5-15
NO TB25 TB26
6 G2 G3
RD-27
BK-43
BK-33
C6-25
WH-21
OR/BK-41
NO CR4
PR2
ALTERNATOR PR2
CR17 NO
NO
WH
EXCT. PR1
WH-24
BK/RD-C5-8
C5-16
C5-14
RD
CR17 PR1
12 V NO
C6-33
BAT. BAT.
WH/BK
DC + -
+
STA.
FB +
FAN AUX STARTER OPS OTS
HM G1
BK
REGULATOR H2 PUMP _ NC
7 NO
C6-26
-
IND.
BRN
BRN
STARTER MOTOR
IGN./START RELAY
SERVICE HORN
RELAY
SERVICE HORN
OPTION
FLASHING BEACONS
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
AUXILIARY PUMP
(OPTION)
COOLING FAN
SWITCH
HOUR METER
SWITCH
HIGH IDLE RELAY

HIGH RPM SOLENOID
FUEL RELAY
GLOW PLUG OPTION
OPTION
GENERATOR
OIL PRESSURE
TEMP. SWITCH
HYDRAULIC OIL
OIL PRESSURE GAUGE

VOLT METER
WATER TEMP GAUGE

WATER TEMP
8
NOTE:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
IN THE STOWED POSITION AND KEYSWITCH "OFF".
2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.
6-8 S-40 • S-45 Part No. 102521

Section 6 • Schematics
6-9
1
BRN-2
GROUND
A
C41RPM OR/BK
C2P-3
5
15
TB30
B
C30EDC+ WH
S-40 • S-45
C1P-4 C30EDC+ WH C5-21 A B

8 15 DRIVE EDC FORWARD
L1
J1
C1P-5 C31EDC- WH/BK C5-20 C31EDC- WH/BK D C

DRE LED BL/RD
16
16 DRIVE EDC REVERSE
TB31
H4
TS15
DRE B BL/BK C6-32

7 TRAVEL ALARM OPTION
6 C1P-6 C32BRK WH/RD C5-23 C32BRK WH/RD
DRE A BL/WH 19 BRAKE RELEASE VALVE
TB32
DRIVE & STEERING
7 20
C
RKOUT 6 WH 5
TB37
YOUT 5 BL 4
JC3
C1P-11 C37STCC BL/BK C6-37 C37STCC BL/BK

J1
4 18 STEER RIGHT
PWR 3 OR 13
GND 2 BRN 14 C1P-10 C36STC BL C6-36 C36STC BL
17 STEER LEFT
TB36
1
11
C3P-6 C6TRF WH/RD
9
C3P-5 C5TRR WH/BK
D
C3P-4 C4TRL WH
10
C6-4 C4TRL WH
LEFT
TURNTABLE ROTATE LEFT
TB4
TROTATE
TS62
RIGHT C6-5 C5TRR WH/BK

TURNTABLE ROTATE RIGHT
TB5
PRI UP/DN & TT ROTATE
7 C6TRF WH/RD TURNTABLE ROTATE

Part No. 102521
C6-6
R2
6 FLOW CONTROL
TB3 TB2 TB6
TB1
October 2013
YOUT 5 BK 2 7.5
JC2
XOUT 4 RD 1 C6-1 C1PBU RD

PRIMARY BOOM UP
E
J1
PWR 3 OR 11 UP PRIMARY
DOWN BOOM C6-2 C2PBD RD/BK
J2
TS61
GND 2 BRN 12 PRIMARY BOOM DOWN

1
C6-3 C3PBF RD/WH PRIMARY BOOM
R1
5
FLOW CONTROL
C3P-1
6
C1PBU RD
C3P-2
7
C2PBD RD/BK
C3P-3
F
8
C3PBF RD/WH
C6-19 RD/BK
DESCENT ALARM OPTION
H3
14
13
12
WH
NONC
LS2-PRIMARY BOOM UP
BK DRIVE LIMIT SWITCH
SJ1-WH
G
JOYSTICK CONTROL CARD
WH
NOHC
BRN
1
LS1-PRIMARY BOOM EXTEND
BK
TB13
P24FS WH DRIVE LIMIT SWITCH

2
J3
P24FS WH C4P-1 C13DRE BL/RD C6-13 C13DRE BL/RD WH

4
NOHC
3 DRIVE ENABLE
P26ESTP BK BK
3 LIMIT SWITCH
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED

C6-30
C2P-2 C40LS1 OR C6-40 C40LS1 OR

4
TB40
H
TB22
TB7
POSITION EXCEPT AS NOTED.

TS63
CR27
OPTION
NC
C6-7 C7PBE BK
CR30
DRIVE
BOOM EXTEND
NO
LIFT/
EXTEND
TB8
I
BOOM
CE
RETRACT C6-8 C8PBR BK/WH

BOOM RETRACT
C3P-7 C7PBE BK
EXTEND BOOM
C3P-8 C8PBR BK/WH
TS13
RETRACT
C4P-2 C14PLU OR
NOTE:
UP PLATFORM
TB14
DOWN LEVEL C4P-3 C15PLD OR/BK
TS9
C14PLU OR
J
C6-14
UP PLAT LEVEL UP
PLATFORM
DOWN LEVEL C15PLD OR/BK
TS59
C6-15
PLAT LEVEL DOWN
TB15
TB44
GR/BK-44 C2P-6 JDALARM GR/BK
CR13
WH
NC
K
C4P-6 C18JD GR/BK

DOWN JIB
TB18
UP BOOM C4P-5 C17JU GR
TS8
TS58
C6-18 C18JD GR/BK
DOWN
PLATFORM ROTATE RIGHT / JIB DOWN
UP JIB BOOM C6-17 C17JU GR
PLATFORM ROTATE LEFT / JIB UP
TB17
TS57
RIGHT PLAT RIGHT
JIB BOOM
LEFT ROTATE LEFT
TS7
WH
L
AMP
7
6
5
3
4
2
1
C4P-7
C19JSV GR/WH
TB19
Joystick Adaptor Harness

Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin1
CR13
C19JSV GR/WH
JIB VALVES
RKOUT
XOUT
YOUT
PWR
GND
BRN
M
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
JIB VALVE
Deutsch
1
3
OR/BK
RD/BK
5
6
BRN
WH
RD
RD
BK
N
6-9
6 - 10

Deutz F3L 1011F Models
1
RD-H6+ - C23-1 DRIVE LIGHT OPTION RELAY

BL/WH-38D - C23-3 RD-C23-1
U33 C23
BK-22C - C23-4 RD-42B RD-CB3 SP
PLATFORM LOAD BK-C7-1 - C23-5
GN/BK-L45-
H6
RD-TS51 - C23-6 CR23
RD-TS55 - C23-7 GN/BK-16A G1 G2 G3
GN/BK-16B - C23-8 BK/RD-9B
BR - GND - C23-12 WH-21A RD C4B-11 2
BR (GROUND) RD C4B-12
46 LIMIT SWITCH POWER
GR/WH-C6-39 GR/WH-C2B-7 45 GEN. OPTION BRN GND
GR/BK-C2B-6 44 GR/BK-2B GR/BK-S.P. JDALARM JIB
GR-C2B-5 43 GR-CR5#86 HORN
RD-C6-23 OR/RD-C2B-4 42 RD-H6+ RD-KS1-2 S.P. C134PWR
OR/BK-C5-2 OR/BK-C2B-3 41 OR/BK-ISM#2 PULSE PICKUP
OR-C6-40 OR-C2B-2 40 LIMIT SWITCH SIG.
WH/BK-25A
BK/WH-C5-10 BL/RD-C2B-1 39 BL/RD-S.P. L.P.
WH/RD-26A
BL/WH-C23-3 BL/WH-C1B-12 38 C132PLI
BL/BK-C6-37 BL/BK-C1B-11 37 STEER LEFT BK-22A
BL-C6-36 BL-C1B-10 36 STEER RIGHT KEY SWITCH
BK/RD-C1B-9 35 BK/RD CR3-#30 BK/RD-S.P. RPM P1 KS1
TS51
3
BK/WH-C5-22 BK/WH-C1B-8 34 BK/WH-S.P. GLOW PLUG B
33 RD-CB2
BK-C1B-7 BK-ISM#3 BK-S.P. START NC
LABEL PART #
RD
WH/RD-C5-23 WH/RD-C1B-6 32 WH/RD-C6-32 BRAKE/TRAVEL ALARM 1
DESCRIPTION
3
WH/BK-C5-20 WH/BK-C1B-5 31 E.D.C.- NC B1
WH-C5-21 WH-C1B-4 30 E.D.C.+ WH-23A 2
EMERGENCY STOP BUTTON P1 P1
4
RD/WH-C1B-3 29 SPARE RD-42A KEY SWITCH KS1 KS1
RD/BK-C6-28 RD/BK-C1B-2 28 TILT ALARM RD-27A
RD-C6-27 RD-C1B-1 27 RD-ISM#4 D6 RD-S.P. AUX. PWR. RD-C23-6 AUXILIARY SWITCH TS51 42730
WH/RD-C5-14 26 WH/RD-S.P. WATER TEMP. SENDER 13037
25
ENGINE START SWITCH TS52
WH/BK-C5-16 WH/BK-S.P. OIL PRESSURE SENDER
RD-C5-1 24 RED-CR1#30 RD-S.P. ENGINE POWER RD-H6+
WH-C7B-2 RD-C5-19 23 WH-ISM #7 WH-S.P. KEYSWITCH PWR/FB OR/RD-H6-
BL/WH-C6-30 BK-C23-4 22 BK-CR5#30 BK-S.P. PWR. TO PLAT. FUNCTION ENABLE TS55 13037 4
WH-C5-3+C5-11 WH-C6-34 21 WH-CR2#87 WH-S.P. IGNITION PWR. PLATFORM ROTATE SWITCH TS57 16397
WH-21A
RD- 12VOLT CB3-SP 20 CB2-SP CB1 - SP 12 VOLT BATTERY POWER
GR/WH-C4B-7 19 GR/WH-SP JIB VALVE PLATFORM LEVEL SWITCH TS59 13037
GR/BK-C6-18 GR/BK-C4B-6 18 GR/BK-S.P. PLAT. ROT. R. HM
17 GR-S.P. PLAT. ROT. L. BR (GROUND) L45 BOOM EXTEND/RETRACT SWITCH TS63 13037
GR-C6-17 GR-C4B-5
OR/RD-C4B-4 16 GN/BK-C23-8 GN/BK-H6- C133PLA L2 PRIMARY BOOM UP/DOWN SWITCH TS61 16397
OR/BK-C4B-3 15 PLAT. LEVEL DN.
12 V
OR/BK-C6-15 OR/BK-S.P. BL/WH-C5-15

OR-C6-14 OR-C4B-2 14 OR-S.P. PLAT. LEVEL. UP TURNTABLE ROTATE SWITCH TS62 16397
BL/WH-ISM#10
BL/RD-C6-13 BL/RD-C4B-1 13 DRV. ENA. LT. RD/WH-3A TS61 JIB BOOM UP/DOWN SWITCH TS58 13037
12V TO PLAT
BL/WH-C3B-12 12 RD/BK-2A
BR-GND BL/BK-C3B-11 11 CIRCUIT BREAKER, CONTROLS, 15A CB1 CB1
RD-1A
3 STUD BL-C3B-10 10
CIRCUIT BREAKER, ENGINE, 15A CB2 CB2 5
C7B
BK-C23-5 BK/RD-C3B-9 9 BK/RD-CR23#87 DRIVE LIGHT OPTION

1 BK/WH-C6-8 BK/WH-C3B-8 8 BK/WH-S.P. BOOM RETRACT CIRCUIT BREAKER, OPTIONS, 20A CB3 CB3
2 WH-23C BK-C6-7 BK-C3B-7 7 BK-S.P. BOOM EXTEND TS63
WH/RD-S.P. TURN. ROT. F.C. BK/WH-8A RESISTOR, 5 OHM, BOOM FUNCTION R1 R1
WH/RD-C6-6 WH/RD-C3B-6 6
BK-7A
WH/BK-C6-5 WH/BK-C3B-5 5 WH/BK-S.P. TURN. ROT. L RESISTOR, 7.5 OHM,TURNTABLE FUNCTION R2 R2
GR/BK-44A
WH-C6-4 WH-C3B-4 4 WH-S.P. TURN. ROT. R TS62
C1B C2B C3B C4B
BK-33A
RD/WH-C6-3 RD/WH-C3B-3 3 RD/WH-S.P. PRI. BOOM F.C. TS52 CB3 VOLT METER GAGE G1 G1
44B+RD/BK-C6-19 RD/BK-S.P. PRI. BOOM DOWN
19/18 CABLES
RD/BK-C6-2 RD/BK-C3B-2 2
RD-C6-1 RD-C3B-1 1 RD-S.P. PRI. BOOM UP BK/WH-34A OIL PRESSURE GAGE G2 G2
D C B A OIL TEMP. GAGE G3 G3
RD- 20C TS56
BK-CR1#86 TS58 STARTER AID L28 56298
1 START RELAY RD-CR17#30
R1
OR/BK-41B IGN./START
BK-33D
2 TACHOMETER
3 START INPUT MODULE
WH-4
WH/RD-6 HOUR METER HM HM 6
RD-27B WH/BK-5 IGN. START RELAY CR1 CR1
4 AUX. ON
BR-GND.
5 GROUND IGN. POWER RELAY CR2 CR2
RD-CR2#30 R2
WH-23B
6 BATTERY
7 KEY PWR. HIGH IDLE (RPM) CUTOUT RELAY CR3 CR3
D14 CB1 CB2
WH-CR2#86
8 KEY BYPASS RPM RELAY CR4 CR4
FUNCTIONS
BL/WH-L2
9 IGN./FUEL ON TS57
10 ENG. FAULT COOLING FAN RELAY CR17 CR17
RD-C23-7
BK-22B TS55 PLATFORM OVERLOAD ALARM H6
RD-ISM#6 TS59
C6
RD-CB3 SP GR-43D D13

WH-ISM#9 PLAT OVERLOAD MODULE U33
RD-24B BK-C6-25 BK/RD-35A
CR1 CR2 CR17 CR5 RD- 20A
PLAT OVERLOAD LED L45 7
BK-ISM#1 RD- 24A
RD- 20B
BK-C5-5 RD- P1 E-STOP
ENGINE
WH-21B OR-C6-33
BK-C6-16 OR/BK-15A
BR-GND+C6-26
C5
OR-14A
BK/RD-35B
GR-17A
CR3 CR4 GR/WH-19A
GR/BK-18A
8
GROUND STUD
BK/RD-C5-9
GROUND STUD WIRING

BR HARNESS:
TO BASE
ALL BR WIRES
Part No. 102521 S-40 • S-45 6 - 11


6 - 11
6 - 12
Platform Control Box Wiring Diagram- ALC-500

6 - 14
6 - 13
N
PART NUMBER
45383
89353
M
PBOX WIRING
HARNESS
COMPONENT INDEX
L
OPT.
TILT ALARM
ALC-500
H1
K
RD P2
LS18
RD H1
C132PLI BK C1P-12
P23SWBAT WH C7P-2
J
P22BAT BK C7P-1
JIB
C19JSV GR/WH
C19JSV GR/WH JIB C4P-7 AND TS8
C18JD GR/BK C4P-6 BRN
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C43 HRN GR C2P-5
I
C8PBR BK/WH C3P-8

C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
JDALARM GR/BK C2P-6
DRIVE LT BK/RD C3P-9
C3P
C45GEN GR/WH C2P-7

C9P
TS48-WL1 RD C2P-12 F.S.

H
F.S.
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE GR/BK C2P-6
P26BAT BK
11
1
1
3
G
C6TRF WH/RD C3P-6

J3
C10SBU BL C3P-10
C13DRE BL/RD C4P-1
12V BATT
C11SBD BL/BK C3P-11
C7P
P24FS WH C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
P24FS WH C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
BRN C1PBU RD C3P-1
C7P
F
C31EDC- WH/BK C1P-5

C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C4P
C37STC BL/BK C1P-11
Part No. 102521

C5TRR WH/BK C3P-5

ALC-500
C32BRK WH/RD C1P-6

C4P(BR)
C4TRL WH C3P-4
J2
C29MS RD/WH C1P-3
C3P
E
19/18 CONTROL CABLE

C134PWR RD C2P-4
C3P(GR)
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
C2P(BK)
D
C1P
J1
1
9
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
C1P(GY)
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
S-40 • S-45
JC3-3 OR
C
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH C28TTA RD/BK C1P-2
C28TTA RD/BK C1P-2

DRE B BL/BK
BATGND C7P-3
C13LED BL/RD
GN/BK C4P-4
C29MS RD/WH
D40
H1
RED/BLK-28
ALALRM
D39
GN/BK L48
TILT
RED-TILT RED-TILT
A
October 2013
BRN
6 - 14
1
8

1
HARNESS
PBOX WIRING
7 7 COMPONENT INDEX PART NUMBER
TS48/ TS49 BOOM PROPORTIONAL JOYSTICK:
2
JC2 62390
6 6 PRIMARY UP/DN , TURNTABLE ROTATE
WORK/ DRIVE LITE
5 TS15 TS47
5 JC3 DRIVE PROPORTIONAL JOYSTICK 75565
DRV.ENA GENERATOR L1 DRIVE ENABLE LED 56298
EMERGENCY STOP BUTTON
4 (OPTION) 4 P2
P3 HORN SWITCH
66812, 73805
66813, 66816
TS1 AUXILIARY SWITCH 42730
3 3 TS2 START ENGINE SWITCH 13037
TS13
TS4 HI/L0 RPM SWITCH 27378 3
2 PRIMARY 2 TS6 GLOW PLUG OPTION 56298
JC2 BOOM JC3 TS7 PLATFORM ROTATE SWITCH 16397
1 1 TS8 JIB UP/DOWN SWITCH 13037
EXTEND/ TS9 PLATFORM LEVEL SWITCH 13037
DLITE/ RD WL2
TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH 13037
RETRACT
TS15 DRIVE ENABLE SWITCH 13037
TS47 GENERATOR SWITCH ( OPTION ) 27378
TS48-9 WORK/DRIVE LIGHT ( OPTION ) 27378
+
4
+
CR13 L4
WH-24
L1 +
DETAIL A: LIFT/DRIVE OPTION
L48
DRIVE LT BK/RD-C3P-9
RD WL1
REPLACE WIRE WITH THIS WIRING DIAGRAM
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
BRN BATGND
GR/WH-45
BRN J1-14
BRN J1-12
(GND STUD) 5
GN/BK H1
RD/BK H1
OR J1-13
BK/WH-8
OR J1-11
WH J1-5
WH J1-5
BK J1-2
RD J1-1
WH-JIB
BL J1-4
WH-24
WH-24
BK-22
BK-7
BRN
CR27
RD
WH TS7 WH TS1
WH/RD C32BRK
RD P3
RD-25
RD
RD LS18
RD P2
P22BAT BK C7P-1
BK-22
BK-33
BK/RD-35
P26BAT BK C9P-1
GR-43
C18JD GR/BK C4P-6
C17JU GR C4P-5
C27AUX RD C1P-1
C19JSV GR/WH JIB
OR/BK-15
OR-14
WH-24
C34SA BK/WH C1P-8
WH-24
WH-23
C19JSV GR/WH
JDALARM GR/BK-44 C2P-6
WH-JIB
(SPLICE TO C32BRK)
CR30
6
OR R40LS1
NC
1
(SPLICE TO R40LS1)
WH
NC
RD
1
GR
TS4
NO
4
WH RD
HIGH/LOW
TS6 TS2 RPM RD 7
P3 TS9
WH
TS8 TS1
GR/BK GLOW PLUG START P2
HORN PLATFORM JIB AUXILIARY PUMP
TS7 REMOVE FOR GENERATOR OPTION EMERGENCY STOP
LEVEL PLATFORM
ROTATE CE SEE DETAIL A
NOTE:
1) DASHED LINES INDICATE OPTION WIRES. 8
Part No. 102521 S-40 • S-45 6 - 15


6 - 15
6 - 16
Perkins 704-30 Models (before serial number 7472)
6 - 18
6 - 17
1
C28TTA RD/BK RD/BK
TB41
C2-3 OR/BK
P26ESTP BK BK
LS18 P2 FS1 RD-(FS) C9-3 P25FS RD
C9-1 BK BK-(FS)
WH-(FS) C9-2 P24FS WH WH
RD
P22BAT BK
C41RPM OR/BK
C134PWR OR/RD C2-4
C132PLI BL/WH
2 SEE NOTE 2
C1-12
TS1 TS17
P3 TS4
HORN L4 L48
HIGH RPM(FS)
PUMP
AUXILIARY
TB 132 IS WAGO TERMINAL BLOCK 38 H1 TS2
L24 SEE NOTE 2
C1-12
GENERATOR
TB34
C7-1
C2-5
START
D39 D40
CB2 TB134
ENGINE
P1 RD
TB132 TB43
C4-4
C1-1
C1-2
C7-2
15AMP.
C1-7
C2-7
C1-9
RD RD
3 L28
KS1 TB22 1 3
C43HRN GR
RD
4 5 RD
PLAT
GRD TS52
P23BAT WH
C28TTA RD/BK
C27AUX RD
C33STR BK
C45GEN GR/WH
C35ESPD BK/RD
6
C133PLA OR/RD
U33 TS51 TS55
START
LOW RPM
HIGH RPM
7
PUMP
AUXILIARY
12 8
RD
ENGINE
RD
BK
4 TB27
TB33
D6
TB45
H6 L45 TB23 1 START RELAY
CB1 2 TACHOMETER
TB133 3 START INPUT
TB20 15AMP. RD TB28 4 AUX. ON IGN./START TB35
TB24 5 GROUND MODULE L5
C6-39
6 BATTERY
C6-28
C6-23
CB3 CR5 CR5 7 KEY PWR.
BK/RD
NO 8 KEY BYPASS
20AMP. CR1 CR2 9
NO CR1 CR2 IGN./FUEL ON
NO
5 TB21
10 ENG. FAULT
C6-34
NO CR3
RD-P134
RD/BK-28
C5-3
C6-16
C6-27
C5-5
C5-2
OTS TB25 TB26

NO
G2 G3
GR/WH-45
BK-43
RD-27
BK-33
OR/BK-41
WH-21
7 3
CONTROLLER
6 ALTERNATOR 4
C6-25
NO CR4
C5-14
C5-15
C5-16
5
EXCT. PR1 PR1
CR17 6
RD
WH
NO
BK/RD-C5-8
12 V BAT. BAT. NO
+ -
WH/RD
WH/BK
DC CR17
WH-24
WH-24
C6-33
+
STA. 1
H2 FB +
AUX
PUMP STARTER HM G1
REGULATOR _ OPS OTS
FAN
BK
- IND.
NC
7 NO
C6-26
BRN
BRN
HIGH RPM SOLENOID
HIGH IDLE RELAY

FUEL RELAY
FLASHING BEACONS
HOUR METER
LEVEL SENSOR
RELAY
IGN./START RELAY
(OPTION)
HYDRAULIC OIL
SWITCH
OPTION
RELAY
SERVICE HORN
STARTER MOTOR
SWITCH
CONTROLLER
OPTION
GENERATOR
OIL TEMP GAUGE
OIL PRESSURE
SERVICE HORN
OIL PRESSURE GAUGE
OIL TEMP
GLOW PLUG
GLOW PLUG
VOLT METER
COOLING FAN
TILT ALARM
AUXILIARY PUMP
TEMP. SWITCH
AUXILIARY POWER
8
NOTE:

6 - 18 S-40 • S-45 Part No. 102521

6 - 19
BRN-2
GROUND
C41RPM OR/BK
A
C2P-3
5
15
TS14
TB30
Y51
C29MS C1P-4 C30EDC+ WH C5-21 C30EDC+ WH A B

B
S-40 • S-45
L1
J1

DRE LED BL/RD 16 DRIVE EDC REVERSE
16
TB31
H4
C6-32
TS15
DRE B BL/BK TRAVEL ALARM OPTION

7
DRIVE ENABLE
Y2

TB32
Y27
7
DRIVE & STEERING
C1P-3 C29MS RD/WH C5-19 C29MS RD/WH

20 MOTOR STROKE
RKOUT 6 WH 5
TB29
TB37
YOUT 5 BL 4
JC3
C
Y3

J1
4 18 STEER RIGHT
PWR 3 OR 13
Y4

17 STEER LEFT
1
TB36
C3P-6 C6TRF WH/RD

11
C3P-5 C5TRR WH/BK
9
C3P-4 C4TRL WH
10
Y23
D
C6-4 C4TRL WH
LEFT TURNTABLE ROTATE LEFT
TROTATE
TB4
Y29

TS62

TB5
Y13
7 C6-6 C6TRF WH/RD TURNTABLE ROTATE

6 FLOW CONTROL
R2
TB6
7.5
TB1
YOUT 5 BK 2
Part No. 102521
Y21 Y22
JC2

PRIMARY BOOM UP
J1
October 2013
UP
TB2
PWR 3 OR 11 BOOM
GND 2 BRN 12 DOWN C6-2 C2PBD RD/BK
TS61
J2
PRIMARY BOOM DOWN

E
1
TB3
Y12

R1
FLOW CONTROL
5
6
C3P-1 C1PBU RD
7
C3P-2 C2PBD RD/BK
8
C3P-3 C3PBF RD/WH
C6-19 RD/BK
H4
F
14
13 WH
NCHO
LS2-PRIMARY BOOM UP
12 DRIVE LIMIT SWITCH
BK
SJ1-WH
BRN WH
NOHC
1 LS1-PRIMARY BOOM EXTEND

P24FS WH BK DRIVE LIMIT SWITCH
2
TB13
J3
P24FS WH
G
4 C4P-1 C13DRE BL/RD C6-13 C13DRE BL/RD WH

NOHC
3 DRIVE ENABLE
P26ESTP BK
3 BK LIMIT SWITCH

4
TB40
WH
C6-30
TB22
H

CR27
CR30
NC
CE NO
OPTION
TB7
Y25
DRIVE
TS63
C6-7
LIFT/
C7PBE BK
BOOM EXTEND
EXTEND
TB8
BOOM
Y26
BOOM RETRACT
I
C3P-7 C7PBE BK
EXTEND
BOOM
RETRACT C3P-8 C8PBR BK/WH
TS13
NOTE:
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
TB14
DOWN C4P-3 C15PLD OR/BK
TS9
Y20
TS59
C6-14 C14PLU OR
PLAT LEVEL UP
J
UP
PLAT LEVEL
Y19
DOWN C6-15 C15PLD OR/BK
PLAT LEVEL DOWN
TB15
TB44
K
CR13
C4P-6 C18JD GR/BK

NC
DOWN
JIB BOOM
TB18
UP C4P-5 C17JU GR
TS8
Y16
TS58
C6-18 C18JD GR/BK
DOWN
Y17
TB17
TS57
RIGHT RIGHT
AMP
PLAT ROTATE PLAT ROTATE
7
L
6
5
3
4
2
1
LEFT LEFT
TS7
WH

Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin1
C4P-7
C19JSV GR/WH
TB19
C19JSV GR/WH
JIB VALVES
CR13
RKOUT
XOUT
YOUT
PWR
GND
BRN
M
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
JIB VALVE
BL/WH
OR/BK
RD/BK
Deutsch
BRN
WH
3
RD
RD
BK
5
6
4
N
6 - 19
6 - 20

1
RD-H6+ - C23-1
BL/WH-38D - C23-3
U33 C23 BK-22C - C23-4 RD-C23-1
PLATFORM BK-C7-1 - C23-5 RD-42B
LOAD RD-TS51 - C23-6 GN/BK-L45- H6
RD-TS55 - C23-7 GN/BK-16A G1 G2 G3 DRIVE LIGHT OPTION RELAY
GN/BK-16B - C23-8
WH-21A RD-CB3 SP
2
BR - GND - C23-12
BR (GROUND)
46 LIMIT SWITCH POWER CR23
GR/WH-C6-39 GR/WH-C2B-7 45 GEN. OPTION
GR/BK-C2B-6 44 GR/BK-2B GR/BK-S.P. JDALARM JIB BK/RD-9B
RD-H6+ RD-KS1-2 S.P. C134PWR
RD C4B-11
RD-C6-23 OR/RD-C2B-4 42
OR/BK-C5-2 OR/BK-C2B-3 41 OR/BK-ISM#2 PULSE PICKUP RD C4B-12
OR-C6-40 OR-C2B-2 40 LIMIT SWITCH SIG. WH/BK-25A
WH/RD-26A
BRN GND
BL/BK-C6-37
BL-C6-36
BL/BK-C1B-11
BL-C1B-10
37
36
STEER LEFT
STEER RIGHT
BK-22A KEY SWITCH 3
BK/RD-C1B-9 35 BK/RD CR3-#30 BK/RD-S.P. RPM P1 KS1
BK/WH-C5-22 BK/WH-C1B-8 34 BK/WH-S.P. GLOW PLUG B
TS51
RD-CB2
BK-ISM#3 BK-C1B-7 33 BK-ISM#3 BK-S.P. START NC
RD
WH/RD-C5-23 WH/RD-C1B-6 32 WH/RD-C6-32 BRAKE/TRAVEL ALARM 3 1
WH/BK-C5-20 WH/BK-C1B-5 31 E.D.C.- NC B1
WH-C5-21 WH-C1B-4 30 E.D.C.+ WH-23A 4 2
RD/WH-C1B-3 29 SPARE RD-42A
RD/BK-C6-28 RD/BK-C1B-2 28 TILT ALARM RD-27A
RD-C6-27 RD-C1B-1 27 RD-ISM#4 D6 RD-S.P. AUX. PWR. RD-C23-6
WH/RD-C5-14 26 WH/RD-S.P. WATER TEMP. SENDER DESCRIPTION LABEL PART #
WH/BK-C5-16 25 WH/BK-S.P. OIL PRESSURE SENDER
RD-C5-1 24 RED-CR1#30 RD-S.P. ENGINE POWER RD-H6+ EMERGENCY STOP BUTTON P1 P1
WH-C7B-2 RD- C5-19 23 WH-SP.+WH46A KEYSWITCH PWR/FB OR/RD-H6- KEY SWITCH KS1 KS1 4
BL/WH-C6-30 BK-C23-4 22 BK-CR5#30 BK-S.P. PWR. TO PLAT.
WH-C5-3+C5-11 WH-C6-34 21 WH-CR2#87 WH-S.P. IGNITION PWR. AUXILIARY SWITCH TS51 42730
RD- 12VOLT CB3-SP 20 CB2-SP CB1 - SP 12 VOLT BATTERY POWER
WH-21A
GR/WH-C4B-7 19 GR/WH-SP
ENGINE START SWITCH TS52 13037
JIB VALVE
GR/BK-C6-18 GR/BK-C4B-6 18 GR/BK-S.P. PLAT. ROT. R. HM
GR-C6-17 GR-C4B-5 17 GR-S.P. PLAT. ROT. L. BR (GROUND) L45
OR/RD-C4B-4 16 GR/BK-C23-8 GR/BK-H6- C133PLA L2 FUNCTION ENABLE TS55 13037
12V TO PLAT
OR/BK-C6-15 OR/BK-C4B-3 15 OR/BK-S.P. PLAT. LEVEL DN. PLATFORM ROTATE SWITCH 16397
12 V
OR-C4B-2
BL/WH-C5-15 TS57
OR-C6-14 14 OR-S.P. PLAT. LEVEL. UP
BL/WH-ISM#10 13037
BL/RD-C6-13 BL/RD-C4B-1 13 DRV. ENA. LT.
RD/WH-3A TS61 PLATFORM LEVEL SWITCH TS59
BL/WH-C3B-12 12
BL/BK-C3B-11 11 RD/BK-2A BOOM EXTEND/RETRACT SWITCH TS63 13037
3 BR-GND STUD
BL-C3B-10 10 RD-1A
PRIMARY BOOM UP/DOWN SWITCH TS61 16397 5
C7B
BK/RD-C3B-9 9 BK/RD-CR23#87 DRIVE LIGHT OPTION

1 BK-C23-5 BK/WH-C6-8 BK/WH-C3B-8 8 BK/WH-S.P. BOOM RETRACT TURNTABLE ROTATE SWITCH TS62 16397
2 WH-23C BK-C6-7 BK-C3B-7 7 BK-S.P. BOOM EXTEND
TS63 JIB BOOM UP/DOWN SWITCH TS58 13037
WH/RD-C6-6 WH/RD-C3B-6 6 WH/RD-S.P. TURN. ROT. F.C. BK/WH-8A
WH/BK-C6-5 WH/BK-C3B-5 5 WH/BK-S.P. TURN. ROT. L BK-7A CIRCUIT BREAKER, CONTROLS, 15A CB1 CB1
WH-C6-4 WH-C3B-4 4 WH-S.P. TURN. ROT. R GR/BK-44A
TS62
C1B C2B C3B C4B
RD/WH-C6-3 RD/WH-C3B-3 3 RD/WH-S.P. PRI. BOOM F.C. BK-33A CIRCUIT BREAKER, ENGINE, 15A CB2 CB2
2 44B+RD/BK-C6-19
TS52 CB3
RD/BK-C6-2 RD/BK-C3B-2 RD/BK-S.P. PRI. BOOM DOWN BK/WH-34A + CIRCUIT BREAKER, OPTIONS, 20A CB3 CB3
19/18 CABLES
RD-C6-1 RD-C3B-1 1 RD-S.P. PRI. BOOM UP

D C B A BR-GND L28 RESISTOR, 5 OHM, BOOM FUNCTION R1 R1
RD- 20C - RESISTOR, 7.5 OHM,TURNTABLE FUNCTION R2 R2
TS58
BK-CR1#86
1 START RELAY RD-CR17#30
VOLT METER GAGE G1 G1 6
R1
OR/BK-41B IGN./START WH-4
2 TACHOMETER
BK-33D WH/RD-6 OIL PRESSURE GAGE G2 G2
3 START INPUT MODULE WH/BK-5
RD-27B
4 AUX. ON OIL TEMP. GAGE G3 G3
BR-GND.
5 GROUND
RD-CR2#30 R2 STARTER AID L28 56298
WH-23B
6 BATTERY
7 KEY PWR. D14 CB1 CB2 HOUR METER HM HM
WH-CR2#86
8 KEY BYPASS
FUNCTIONS
9 IGN./FUEL ON TS57 IGN. START RELAY CR1 CR1

BL/WH-L2
10 ENG. FAULT RD-C23-7 IGN. POWER RELAY CR2 CR2
BK-22B TS55
RD-ISM#6 TS59
C6
RD-CB3 SP GR-43D D13 HIGH IDLE (RPM) CUTOUT RELAY CR3 CR3
WH-ISM#9
RD-24B BK-C6-25 BK/RD-35A RPM RELAY CR4 CR4
7
CR2 CR17 CR5 RD- 20A
CR1 COOLING FAN RELAY CR17 CR17
BK-ISM#1 RD- 24A
PLATFORM OVERLOAD ALARM H6
RD- 20B
RD- P1 E-STOP
PLAT OVERLOAD MODULE U33
ENGINE
BK-C5-5 WH-21B OR-C6-33

BK-C6-16 OR/BK-15A PLAT OVERLOAD LED L45
BR-GND+C6-26
C5
OR-14A
BK/RD-35B GR-17A
CR3 CR4 GR/WH-19A
GR/BK-18A 8
GROUND STUD
BK/RD-C5-9
GROUND STUD WIRING

BR HARNESS:
TO BASE
ALL BR WIRES
Part No. 102521 S-40 • S-45 6 - 21


6 - 21
6 - 22

6 - 24
6 - 23
N
PART NUMBER
45383
89353
M
PBOX WIRING
HARNESS
COMPONENT INDEX
L
OPT.
TILT ALARM
ALC-500
H1
K
RD P2
LS18
RD H1
C132PLI BK C1P-12
P23SWBAT WH C7P-2
J
P22BAT BK C7P-1
JIB
C19JSV GR/WH
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C43 HRN GR C2P-5
I
C8PBR BK/WH C3P-8

C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
JDALARM GR/BK C2P-6
C3P
C45GEN GR/WH C2P-7

C9P
F.S.
TS48-WL1 RD C2P-12
H
F.S.
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE GR/BK C2P-6
P26BAT BK
11
1
1
3
C6TRF WH/RD C3P-6

G
J3
C10SBU BL C3P-10
C13DRE BL/RD C4P-1
12V BATT
C11SBD BL/BK C3P-11
C7P
C12SBF BL/WH C3P-12
C30EDC+ WH C1P-4
BRN C1PBU RD C3P-1
C7P
F
C31EDC- WH/BK C1P-5

C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C4P
C37STC BL/BK C1P-11
Part No. 102521

C5TRR WH/BK C3P-5

ALC-500
C32BRK WH/RD C1P-6

C4P(BR)
C4TRL WH C3P-4
J2
C29MS RD/WH C1P-3
C3P
19/18 CONTROL CABLE

E
C134PWR RD C2P-4
C3P(GR)
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
C2P(BK)
C1P
D
J1
1
9
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
C1P(GY)
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
S-40 • S-45
JC3-3 OR
JC3-4,6 WH
C
JC3-2 BRN
C28TTA RD/BK C1P-2

DRE B BL/BK
BATGND C7P-3
C13LED BL/RD
GN/BK C4P-4
C29MS RD/WH
B
D40
H1
RED/BLK-28
ALALRM
D39
GN/BK L48
TILT
A RED-TILT RED-TILT
BRN
October 2013
6 - 24
1
8

1
HARNESS
PBOX WIRING
7 7 COMPONENT INDEX PART NUMBER
TS48/ TS49 JC2
BOOM PROPORTIONAL JOYSTICK:
62390
6 6 PRIMARY UP/DN , TURNTABLE ROTATE
2
WORK/ DRIVE LITE
5 TS15 TS47
5 JC3 DRIVE PROPORTIONAL JOYSTICK 75565
DRV.ENA GENERATOR L1 DRIVE ENABLE LED 56298
EMERGENCY STOP BUTTON
4 (OPTION) 4 P2
P3 HORN SWITCH
66812, 73805
66813, 66816
TS13 27378
TS4 HI/L0 RPM SWITCH
2 PRIMARY 2 L24 GLOW PLUG INDICATOR 56298
JC2 BOOM JC3 TS7 PLATFORM ROTATE SWITCH 16397 3
1 1 TS8 JIB UP/DOWN SWITCH 13037
EXTEND/ TS9 PLATFORM LEVEL SWITCH 13037
DLITE/ RD WL2
RETRACT
TS48-9 WORK/DRIVE LIGHT ( OPTION ) 27378
+
+
CR13 L4 4
WH-24
L1 +
L48
RD WL1
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
BRN BATGND
GR/WH-45
BRN J1-14
BRN J1-12
(GND STUD)
GN/BK H1
RD/BK H1
OR J1-13
BK/WH-8
OR J1-11
WH J1-5
WH J1-5
BK J1-2
RD J1-1
WH-JIB
BL J1-4
WH-24
WH-24
BK-22
BK-7
5
BRN
CR27
RD
WH TS7 WH TS1
WH/RD C32BRK
RD P3
RD-25
RD
RD LS18
RD P2
P22BAT BK C7P-1
BK-22
BK-33
BK/RD-35
P26BAT BK C9P-1
GR-43
C18JD GR/BK C4P-6
C17JU GR C4P-5
C27AUX RD C1P-1
C19JSV GR/WH JIB
OR/BK-15
OR-14
WH-24
WH-24
RD-TILT
WH-23
C19JSV GR/WH
WH-JIB
C34SA BK/WH C1P-8

BRN
(SPLICE TO C32BRK)
CR30
6
OR R40LS1
NC
1
+ (SPLICE TO R40LS1)
WH
NC
2
1
GR L24 TS4
NO
4
WH RD
GLOW PLUG HIGH/LOW
RPM RD
P3 WH TS2
TS9 GR/BK TS8 TS1 START P2 7
HORN PLATFORM JIB AUXILIARY PUMP
TS7 REMOVE FOR GENERATOR OPTION EMERGENCY STOP
LEVEL PLATFORM
NOTE:
1) DASHED LINES INDICATE OPTION WIRES.
Part No. 102521 S-40 • S-45 6 - 25


6 - 25
6 - 26
Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)
Perkins 404-22 Models (from serial number 7472 to 12509)
6 - 28
6 - 27
1 BL/WH
RD/BK
TB41 C2-3 OR/BK
P26ESTP BK BK
F18
LS18 P2 FS1 FUSE 10A

RD-(FS) C9-3 P25FS RD TS49 TS48
2 C9-1 BK BK-(FS)
WH-(FS) C9-2 P24FS WH WH
RD
C28TTA RD/BK
C134PWR RD
C132PLI BL/WH
C41RPM OR/BK
P22BAT BK
3
TS2
TS6
WORK LIGHT
DRIVE LIGHT
2
TS17
ON GLOW
START ENGINE
L4 H1 TS4
P3 TS1
PLUG
HIGH RPM(FS)
NOTE: L48
GENERATOR
HORN
WH
WH
TB132 IS WAGO TERMINAL BLOCK 42 D39 D40
PUMP AUXILIARY
TB TB133
134 ISISWAGO
WAGO TERMINAL BLOCK 16
TERMINAL BLOCK 42
C2-5
C1-12
C2-4
C7-1
C3P-9
TB TB134
133 ISISWAGO
WAGO TERMINAL BLOCK 38
TERMINAL BLOCK 16
3 TB 132 IS WAGO TERMINAL BLOCK 38
L30 L30
C2-7
C1-7
C4-4
C1-2
C1-8
C1-1
C7-2
TB134
CB2 RD
P1 TB132 TB43
BK
15AMP.
BK
RD RD
RD
C1-9
3 RD
TB22 1 3
P23BAT WH
C28TTA RD/BK
C27AUX RD
C33STR BK
C35ESPD BK/RD
C133PLA OR/RD
C45GEN GR/WH
KS1
C43HRN GR
C34SA BK/WH
4 5 TS51 TS52 TS55
PLAT TS56
GRD
6
PUMP AUXILIARY
START
HIGH RPM
LOW RPM
ON GLOW
U33
FUNCTION ENA.
4 7
RD
PLUG
12 8
ENGINE
BK
BK
TB45
PBOX GND
TB27
TB33
DLITE OR/RD
CB1
RD
TB20 15AMP. H6 TB23 1 START RELAY

L45 2 TACHOMETER TB34
D6 3 START INPUT TB35
TB28 TB24 5 GROUND MODULE
RD
6 BATTERY L2
5 CB3 CR2
7 KEY PWR.
8 KEY BYPASS
BK/RD
C2B-4
C6-39
CR5 CR1 CR1 9 IGN./FUEL ON
C6-28
C6-23
20AMP. CR5 CR2

NO NO 10 ENG. FAULT
NO
TB21
C6-34
NO CR3
C5-2
RD-134
RD/BK-28
C6-27
C5-3
GR/WH-45
C6-16
C5-5
C21IGN2
C5-22
OTS CR23
C5-13 WH
NO CR23
TB25 TB26
NO
OR/BK-41
C6-25
G2 G3
6 CR4
WH-21
NO
RD-27
BK-33
BK-43
PR3
PR3
C4B-11
ALTERNATOR
CR17 NO
RD
C5-14
BK/RD-C5-8
C5-16
WH
EXCT. NO CR17
PR1 PR1 3MF
C5-11
12 V BAT. BAT. NO PR2
J1 44-6
J144-4
+ - PR2
C6-33
DC
WH/BK
WH/RD
RD
RD
+
S7
STA.
FB S2 S1
FAN M1 STARTER +
AUX Y29
M2 PUMP G6 HM G1
BK
REGULATOR H2 _
IND. NC
C6-26
- NO L29 L29
7
BRN
BRN
IGN./START RELAY
(OPTION)
SWITCH
HYDRAULIC OIL
SERVICE HORN
RELAY
SERVICE HORN
HIGH IDLE RELAY

LEVEL SENSOR
RELAY
STARTER MOTOR
HOUR METER
SWITCH
HIGH RPM SOLENOID

FLASHING BEACONS
FUEL RELAY
RPM FILTER
GENERATOR
COOLING FAN
OIL PRESSURE
OIL PRESSURE GAUGE
OPTION
GLOW PLUG OPTION
OPTION
OPTION
OPTION
DRIVE LIGHT
AUXILIARY POWER
AUXILIARY PUMP
WATER TEMP GAUGE
FUEL SOLENOID RELAY

TEMP. SWITCH
TILT ALARM
EMISSION CONTROL
VOLT METER
WORK LIGHTS
WATER TEMP
8 NOTE:
2 THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.
3 C.E. OPTION ONLY
6 - 28 S-40 • S-45 Part No. 102521

6 - 29
1
BRN-2
GROUND
C41RPM OR/BK
A
C2P-3
5
15
TS14
TB30
Y51
C29MS C1P-4 C30EDC+ WH C5-21 C30EDC+ WH A B

B

S-40 • S-45
L1
J1

16
TB31
H4
C6-32
TS15

7
DRIVE ENABLE
Y2

TB32
Y27
7
DRIVE & STEERING

20 MOTOR STROKE
RKOUT 6 WH 5
C
TB29
TB37
YOUT 5 BL 4
JC3
Y3

J1
4 18 STEER RIGHT
PWR 3 OR 13
Y4

17 STEER LEFT
1
TB36
C3P-6 C6TRF WH/RD

11
C3P-5 C5TRR WH/BK
9
D
C3P-4 C4TRL WH
10
Y23
C6-4 C4TRL WH
LEFT TURNTABLE ROTATE LEFT
TROTATE
TB4
Y29

TS62

TB5
Y13

Part No. 102521
6 FLOW CONTROL
R2
TB6
7.5
TB1
YOUT 5 BK 2
Y21 Y22
JC2
October 2013

PRIMARY BOOM UP
J1
UP
TB2
PWR 3 OR 11 BOOM
E
GND 2 BRN 12 DOWN C6-2 C2PBD RD/BK

TS61
J2
PRIMARY BOOM DOWN

1
TB3
Y12

R1
FLOW CONTROL
5
6
C3P-1 C1PBU RD
7
C3P-2 C2PBD RD/BK
8
C3P-3 C3PBF RD/WH
C6-19 RD/BK
F

H4
14
13 WH
NCHO
LS2-PRIMARY BOOM UP
BK
SJ1-WH
BRN WH
NOHC

2
G
TB13
J3
P24FS WH
NOHC
3 DRIVE ENABLE
P26ESTP BK
3 BK LIMIT SWITCH

4
TB40
WH
C6-30
H
TB22

CR27
CR30
NC
CE NO
OPTION
TB7
Y25
DRIVE
TS63
C6-7
LIFT/
C7PBE BK
BOOM EXTEND
EXTEND
TB8
BOOM
Y26
I

BOOM RETRACT
C3P-7 C7PBE BK
EXTEND
BOOM
TS13
NOTE:
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
DOWN C4P-3 C15PLD OR/BK TB14
TS9
Y20
J
TS59
C6-14 C14PLU OR
PLAT LEVEL UP
UP
PLAT LEVEL
Y19
PLAT LEVEL DOWN
TB15
TB44
K
CR13
C4P-6 C18JD GR/BK

NC
DOWN
JIB BOOM
TB18
UP C4P-5 C17JU GR
TS8
Y16
TS58
C6-18 C18JD GR/BK
DOWN
Y17
TB17
TS57
L
RIGHT RIGHT
LEFT LEFT
TS7
WH
C4P-7
C19JSV GR/WH
TB19
C19JSV GR/WH
JIB VALVES
CR13
M
BRN
JIB VALVE
BL/WH
OR/BK
RD/BK
BRN
WH
RD
RD
BK
N
6 - 29
6 - 30
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models
6 - 32
6 - 31
1
BL/WH
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
BK
F18
LS18
P2 FUSE 10A
FS1 TS48
2 C9-1 BK BK-(FS)
WH-(FS) C9-2 P24FS WH
WH
RD C28TTA RD/BK
C134PWR OR/RD
C132PLI BL/WH
TS2
P22BAT BK
TS6
2
4
DRIVE LIGHT
C41RPM OR/BK
WORK LIGHT
TS17
ON
START
L4 TS4
Note:
WH
TS1
WH
GENERATOR
TB132 is WAGO terminal block 42 L48
PLUG
GLOW
HIGH RPM(FS)
P3 H1
TB133 is WAGO terminal block 16 HORN D39
ENGINE
PUMP AUXILIARY
TB134 is WAGO terminal block 38
C3P-9
D40
3 L30 L30
C1-12
C2-4
C2-7
C1-7
C1-8
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
BK
CB2 TB134
BK
P1 RD TB132
15AMP. RD
RD
C1-9
TB43 RD
2 1 3
KS1
C43HRN GR
TB22
C45GEN GR/WH
RD
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
4
C133PLA OR/RD
P23BAT WH
PLAT TS51 TS52 TS56 TS55
GRD
6
HIGH RPM
LOW RPM
ON GLOW
START ENGINE
PUMP AUXILIARY
4
FUNCTION ENA.
RD
U33
PLUG
7 D3 PBOX GND
D2
BK
BK
12 8
TB45
TB27
TB33
RD
CB1
TB23
DLITE OR/RD
15AMP. L45 1 START RELAY
TB20 H6 TB35
2 TACHOMETER
D6 3 START INPUT
TB133 TB34
TB24 5 GROUND
RD MODULE
5 CB3
6 BATTERY
7 KEY PWR. L2
CR2 8 KEY BYPASS U1
BK/RD
CR1 9 IGN./FUEL ON
20AMP. CR5 CR1
CR5 CR2 10ENG. FAULT
C2B-4
C6-39
NO NO
TB21 NO
FUSE 70A
WH
BL/WH WH CR3
NO
C5-3
C5-2
C5-22
3
GR/WH-45
RD-134
RD/BK-28
C5-5
OTS
C5-13 WH
CR23
TB25 TB26 CR23
6 NO
G2 G3
NO
BK-43
OR/BK-41
BK
WH-21
CR4
RD-27
NO
BK-33
PR3
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
C5-14 WH/RD
RD
WH
C5-16 WH/BK
EXCT. NO PR1 3MF
PR1
BK/RD-C5-8
12 V BAT. BAT. NO PR2
+ - PR2
J144-6
J144-4
DC
RD
S7 NO
RD
RD
+
STA. FB
G6
M1
STARTER + Y29
M2 PUMP HM G1
BK
S2
7 -
REGULATOR
IND. FAN
H2
_ S1
L29 L29
NC NO
C4B-9 C4B-11
BRN
BR
STARTER MOTOR
OIL PRESSURE GAUGE

FUEL RELAY
WATER TEMP GAUGE

HOUR METER
SERVICE HORN
RELAY
SERVICE HORN
BRN
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
RPM FILTER
OPTION
FLASHING BEACONS
OPTION
WORK LIGHTS
OPTION
DRIVE LIGHT
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
IGN./START RELAY
VOLT METER
OPTION
GENERATOR
EMISSION CONTROL
AUXILIARY PUMP
HIGH RPM SOLENOID

(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
GLOW PLUG OPTION
HIGH IDLE RELAY

8 NOTE:
1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM 3 70A FUSE ADDED AT SERIAL NUMBER 12978
4 C.E. OPTION ONLY
2 THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION
WHEN C.E. OPTION IS NOT INSTALLED A JUMPER HARNESS
CONNECTS PIN 4 TO PIN 5 AND PIN 6 TO PIN 7
LS18 - PLATFORM OVERLOAD SWITCH
6 - 32 S-40 • S-45 Part No. 102521

6 - 33
1
BRN-2 GROUND
C41RPM OR/BK
A
C2P-3
5
15
TS14
TB30
Y51
B
S-40 • S-45
C1P-4 C30EDC+ WH C5-21 C30EDC+ WH A B

L1
J1

16
TB31
H4
C6-32
TS15
DRE B BL/BK 7 TRAVEL ALARM OPTION

Y2

TB32
Y27

20 MOTOR STROKE
C
TB29
TB37
Y3
DRIVE & STEERING
6 C1P-11 C37STCC BL/BK C6-37 C37STCC BL/BK

18 STEER RIGHT
RKOUT 5 BL/WH
Y4
YOUT 4 WH/RD 4 C1P-10 C36STC BL C6-36 C36STC BL

17 STEER LEFT
XOUT 3 BL/WH 5
TB36
J1
PWR 2 OR 13
GND 1 BRN 14
C3P-6 C6TRF WH/RD
11
JC3
C3P-5 C5TRR WH/BK

9
D
C3P-4 C4TRL WH
Y23
10
C6-4 C4TRL WH
LEFT TT ROTATE
Y29
TB4

TS62

TB5
Y13
C6-6 C6TRF WH/RD TURNTABLE ROTATE

Part No. 102521
FLOW CONTROL
R2
TB6
7.5
Y22
TB1
October 2013
6 C1PBU RD
C6-1 PRIMARY BOOM UP
5 UP PRI BOOM
TB2
E
Y21
YOUT 4 RD/WH 2 DOWN C6-2 C2PBD RD/BK

TS61
J2
PRIMARY BOOM DOWN

XOUT 3 WH/RD 1
J1
TB3
PWR 2 OR 11
Y12
GND 1 BRN 12 C6-3 C3PBF RD/WH PRIMARY BOOM

R1
FLOW CONTROL
5
6
JC2
C3P-1 C1PBU RD
7
C3P-2 C2PBD RD/BK
8
C3P-3 C3PBF RD/WH
C6-19 RD/BK
F
DESCENT ALARM
H4
14
13 WH
LS2-PRIMARY BOOM UP
NCHO

SJ1-WH
BK
BRN WH
NOHC

2
TB13
G
J3
P24FS WH
NOHC
3 DRIVE ENABLE
P26ESTP BK 3

BK LIMIT SWITCH
4
TB40
WH
C6-30
H

CR27
CR30
OPTION
NO
NC
DRIVE
TB7
LIFT/
Y25
TS63
C7PBE BK
CE
C6-7
BOOM EXTEND
EXTEND
TB8
BOOM
Y26
I
BOOM RETRACT
C3P-7 C7PBE BK
EXTEND
BOOM
C8PBR BK/WH
TS13
RETRACT C3P-8
NOTE:
C4P-2 C14PLU OR
UP
PLAT LEVEL
TB14

TS9
Y20
C14PLU OR
TS59
C6-14 PLAT LEVEL UP

J
UP
Y19
PLAT LEVEL
PLAT LEVEL DOWN
TB15
GR/BK-44 C2P-6 JDALARM GR/BK TB44
K
CR13
NC
C4P-6 C18JD GR/BK

DOWN
TB18
Y16
UP C4P-5
TS8
C17JU GR
TS58
JIB BOOM C6-18 C18JD GR/BK
DOWN
Y17
TB17
TS57
PLAT ROTATE
RIGHT RIGHT
PLAT ROTATE
L
LEFT LEFT
TS7
WH
C4P-7
C19JSV GR/WH
TB19
C19JSV GR/WH
CR13 JIB VALVES
BRN
M
JIB VALVE
BL/WH
RD/BK
OR/BK
BRN
WH
RD
RD
BK
N
6 - 33
6 - 34
6 - 36
6 - 35
(from serial number 14832 to serial 15662)
1
BL/WH
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
BK
F18
LS18
P2 FUSE 10A
FS1 TS48
2 C9-1 BK BK-(FS)
WH
RD C28TTA RD/BK
C134PWR OR/RD
C132PLI BL/WH
TS2
P22BAT BK
TS6
6
DRIVE LIGHT
TS17
C41RPM OR/BK
WORK LIGHT
ON
START
L4 TS4
WH
TS1
WH
L48
PLUG
GLOW
HIGH RPM(FS)
P3 H1
GENERATOR
HORN D39
ENGINE
PUMP AUXILIARY
C3P-9
D40
3 L30 L30
C1-12
C2-4
C2-7
C1-7
C1-8
C2-5
C7-1
C4-4
C1-2
C1-1
C7-2
BK
CB2 TB42
BK
P1 RD TB132
15AMP. RD
RD
C1-9
TB43 RD
6 1 3
KS1
C43HRN GR
TB22
C45GEN GR/WH
RD
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
4
C133PLA OR/RD
5
P23BAT WH
GRD
6
HIGH RPM
LOW RPM
ON GLOW
START ENGINE
PUMP AUXILIARY
4
FUNCTION ENA.
RD
U33
PLUG
7 PBOX GND
BK
D2 D64
BK
12 8
TB45
TB27
TB33
RD
CB1
TB23
DLITE OR/RD
15AMP. L45 1 START RELAY
TB20 H6 TB35
2 TACHOMETER
D6 3 START INPUT
TB133 TB34
TB24 5 GROUND
RD MODULE
6 BATTERY
5 CB3 CR2
7 KEY PWR.
8 KEY BYPASS U1
L2
BK/RD
CR1 9 IGN./FUEL ON
20AMP. CR5 CR1
CR5 CR2 10ENG. FAULT
C2B-4
C6-39
NO NO
TB21 NO
FUSE 10A
FUSE 70A 5
WH
BL/WH WH CR3
NO
C5-3
C5-2
C5-22
GR/WH-45
FUSE 70A
RD-134
RD/BK-28
C5-5
OTS
C5-13 WH
CR23
TB25 TB26 CR23
NO
R21IGN
NO
6 G2 G3
BK-43
OR/BK-41
BK
WH-21
CR4
RD-27
NO
BK-33
PR3
ALTERNATOR PR3
C4B-10
C4B-12
CR17 CR17 NO
BK/RD
C5-14 WH/RD
RD
WH
C5-16 WH/BK
EXCT. NO PR1 3MF
PR1
BAT. BAT. NO PR7
12 V
WH
+ - PR2 PR2
J144-6
J144-4
DC NO PR7
3 CB7
RD
S7 NO
RD
RD
+
FB 10A
STA. G6 4
C5-8
M1
STARTER + Y29
M2 PUMP HM G1
BK
REGULATOR H2 S2
FAN _ S1
IND. L29 L29
7 -
NC NO
C4B-9 C4B-11
BRN
BR
STARTER MOTOR
OIL PRESSURE GAUGE

FUEL RELAY
WATER TEMP GAUGE

HOUR METER
SERVICE HORN
RELAY
SERVICE HORN
OPTION
BRN
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
RPM FILTER (DEUTZ ONLY)
OPTION
FLASHING BEACONS
WORK LIGHTS
DRIVE LIGHT
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
IGN./START RELAY
VOLT METER
FUEL SOLENOID
OPTION
GENERATOR
OPTION
EMISSION CONTROL
AUXILIARY PUMP
HIGH RPM SOLENOID

(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
GLOW PLUG OPTION
HIGH IDLE RELAY

(DEUTZ ONLY)
SECOND GLOW PLUG OPTION
2
8 NOTE:
1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
2 SECOND GLOW PLUG OPTION ADDED AT SERIAL NUMBER 15151 6 C.E. OPTION ONLY
WHEN C.E. OPTION IS NOT INSTALLED A JUMPER HARNESS
3 CB7 10A FUSE ADDED AT SERIAL NUMBER 15573 CONNECTS PIN 4 TO PIN 5 AND PIN 6 TO PIN 7
4 FUEL SOLENOID ADDED AT SERIAL NUMBER 15574 LS18 - PLATFORM OVERLOAD SWITCH
5 10A FUSE ADDED AT SERIAL NUMBER 15574
6 - 36 S-40 • S-45 Part No. 102521

6 - 37
1
BR-2 GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
TB30
Y51
DRIVE MODE
C1-4 C5-21 A B
C29MS RD/WH 8 15 C30EDC+ WH C30EDC+ WH DRIVE EDC FORWARD
B
S-40 • S-45
L1
J1
C1-5 C5-20 D C
16 C31EDC- WH/BK C31EDC- WH/BK DRIVE EDC REVERSE
LED BL/RD 16
TB31
H4
C6-32
TS15

7
DRIVE ENABLE
Y2
DRE A BL/WH 6 C1-6 C5-23

19 C32BRK WH/RD C32BRK WH/RD BRAKE RELEASE VALVE
TB32
Y27
C1-3 C5-19
20 C29MS RD/WH C29MS RD/WH MOTOR STROKE
TB29
TB37
C
Y3
C1-11 C6-37 STEER CCW

DRIVE & STEERING
6 18 C37STCC BL/BK C37STCC BL/BK

RKOUT 5 BL/WH
Y4
YOUT 4 WH/RD 4 C1-10 C6-36 STEER CW

17 C36STC BL C36STC BL
XOUT 3 BL/WH
TB36
5
J1
PWR 2 OR 13
GND 1 BR 14
C3-6
11 C6TRF WH/RD
JC3
C3-5
9 C5TRR WH/BK
C3-4
Y23
D
10 C4TRL WH
C6-4 C4TRL WH TURNTABLE ROTATE CW
Y29
TB4
C6-5
TS62
C5TRR WH/BK TURNTABLE ROTATE CCW

TB5
Y13

R2
FLOW CONTROL
TB6
Part No. 102521

7.5
Y22
TB1
6
October 2013
C6-1 C1PBU RD PRIMARY BOOM UP

5 UP
TB2
Y21
YOUT 4 RD/WH 2 DOWN

E
C6-2
TS61
J2
C2PBD RD/BK PRIMARY BOOM DOWN

XOUT 3 WH/RD 1
J1
TB3
PWR 2 OR 11
Y12
GND 1 BR 12 C6-3 PRIMARY BOOM

C3PBF RD/WH
R1
FLOW CONTROL
5
D30
JC2
6 C1PBU RD
C3-1
7 C2PBD RD/BK
C3-2
8 C3PBF RD/WH
C3-3
C6-19
F
RD/BK
H4
14
D29
13
NO
1
NC
14 13
22 21
WH LS2-PRIMARY BOOM UP
BK
DRIVE LIMIT SWITCH
2
12
SJ1-WH
NO
NC
14 13
22 21

GND BR 1
DRIVE LIMIT SWITCH
1
WH
BK
P24FS WH 2
2
G
J3
TB13
NO
P24FS WH 4
NC
14 13
22 21
DRIVE ENABLE
3
P26ESTP BK C4-1 C6-13 WH LIMIT SWITCH

3 3 C13DRE BL/RD C13DRE BL/RD BK
4

C2-2 C6-40
4 C40LS1 OR C40LS1 OR
WH

C6-30
H
CR27
CR30
OPTION
NO
NC
TB7
DRIVE
Y26
LIFT/
TS63
C6-7
CE
C7PBE BK BOOM EXTEND

EXTEND
TB8
BOOM
I
Y25
RETRACT C6-8 C8PBR BK/WH BOOM RETRACT
C3-7
C7PBE BK
EXTEND
BOOM
NOTE:
RETRACT
TS13
C3-8
C8PBR BK/WH
C4-2
C14PLU OR
UP
PLATFORM LEVEL
DOWN TB14
TS9
C4-3
Y20
C15PLD OR/BK
J
TS59
C6-14 C14PLU OR PLAT LEVEL UP

UP PLATFORM LEVEL
Y19
DOWN C6-15 C15PLD OR/BK PLAT LEVEL DOWN
TB15
TB44
C2-6
GR/BK-44 JDALARM GR/BK
K
D27
CR13
NC
C4-6
C18JD GR/BK
DOWN
JIB BOOM
TB18
Y16
UP
TS8
C4-5
C17JU GR
D28
TS58
C6-18
C18JD GR/BK PLATFORM ROTATE CCW / JIB DOWN
DOWN
Y17
UP JIB BOOM C6-17
C17JU GR PLATFORM ROTATE CW / JIB UP
TB17
L
TS57
CCW CCW
PLAT ROTATE
CW PLAT ROTATE CW
TS7
WH
BR
C4-7
CR13 C19JSV GR/WH
TB19
GR/WH
M
JIB TIME DELAY CIRCUIT

+
-
JIB VALVES
CR14
NO
BL/WH
RD/BK
OR/BK
JIB VALVE
WH
BK
RD
RD
BR
N
P134PWR RD
6 - 37
6 - 38
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS
6 -40
6 - 39
1
RD
BL/WH
RD/BK
TB41
C2-3
OR/BK OR/BK
2 P26ESTP BK
BK
F18
P2 FUSE 10A
FS1 TS48
C9-1 BK BK-(FS)
WH
RD
C134PWR OR/RD
TS2
P22BAT BK
TS6
WORK LIGHT
DRIVE LIGHT
C41RPM OR/BK
TS17
START
ON GLOW
C132PLI BL/WH
TS4
WH
3
WH
TS1
GENERATOR
PLUG
HIGH RPM(FS)
P3
HORN L48
ENGINE
H1
PUMP AUXILIARY
D39
C3P-9
D40 L30 L30
C1-12
C2-4
TB132 IS WAGO TERMINAL BLOCK 36
C2-7
C1-7
C1-8
C2-5
C7-1
TB133 IS WAGO TERMINAL BLOCK 16
C4-4
C1-2
C1-1
C7-2
CB2 D12
BK
TB134
BK
P1 RD TB132 C28TTA RD/BK
15AMP. RD
RD
C1-9
TB43 RD
4 KS1 1 3
C43HRN GR
TB22
C45GEN GR/WH
RD
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
P23BAT WH
4 5
BK/RD
GRD
ON GLOW
HIGH RPM
LOW RPM
START
PUMP AUXILIARY
6
FUNCTION ENA.
RD
PLUG
RD
D3 PBOX GND
BK
7
ENGINE
C32 TB133 D4 D64
BK
CONN. TB45
12 PLUG 8
GBOX
GND TB27
TB33
D13 D14
CB1
5 D2 TB23
1 START RELAY
GR/BK
TB20 15AMP. TB35

2 TACHOMETER
D6 3 START INPUT TB34 TB9
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
TB21 NO
FUSE 10A
FUSE 70A
WH
BL/WH WH
6 NO
CR3
C5-3
C5-2
C5-22
C21IGN2 WH
GR/WH-45
FUSE 70A
RD-134
RD/BK-28
C5-5
OTS
C5-13 WH
CR23
TB25 TB26 CR23
NO NO
G2 G3
BK-43
D22
OR/BK-41
BK
CR4
WH-21
RD-27
NO
BK-33
PR3
ALTERNATOR PR3
C4B-10
C4B-12
NO
BK/RD
CR17 CR17
C5-14 WH/RD
RD
WH
C5-16 WH/BK
EXCT. NO PR1 3MF
PR1
C5-11
12 V BAT. BAT. NO PR2 PR7

+ - PR2
J144-6
J144-4
DC D52 PR7
NO CB7
RD
S7 NO 10A
RD
RD
+
7 STA.
M1
FB
G6
C5-8
+ Y29
AUX STARTER
M2 PUMP HM G1
BK
REGULATOR H2 S2
FAN _ S1
- IND. L29 L29
NC NO
C4B-9 C4B-11
BR
BR
VOLT METER
STARTER MOTOR
OIL PRESSURE GAUGE

FUEL RELAY
WATER TEMP GAUGE

SERVICE HORN
RELAY
SERVICE HORN
HOUR METER
BRN
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
RPM FILTER DEUTZ

FLASHING BEACONS
TILT ALARM
OPTION
WORK LIGHTS
OPTION
DRIVE LIGHT
LEVEL SENSOR
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
EMISSION CONTROL DEUTZ
AUXILIARY PUMP
HIGH RPM SOLENOID

FUEL SOLENOID
(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
GLOW PLUG OPTION
HIGH IDLE RELAY

8
NOTE:
6 - 40 S-40 • S-45 Part No. 102521

6 - 41
1
BR-2 GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
TB30
Y51
DRIVE MODE
C1-4 C5-21 A B
B
S-40 • S-45
L1
J1
C1-5 C5-20 D C
LED BL/RD 16
TB31
H4
C6-32
TS15

7
DRIVE ENABLE
Y2

TB32
Y27
C1-3 C5-19
TB29
TB37
C
Y3

DRIVE & STEERING

RKOUT 5 BL/WH
Y4

XOUT 3 BL/WH
TB36
5
J1
PWR 2 OR 13
GND 1 BR 14
C3-6
11 C6TRF WH/RD
JC3
C3-5
9 C5TRR WH/BK
D
C3-4
Y23
10 C4TRL WH
Y29
TB4
C6-5
TS62

TB5
Y13

R2
FLOW CONTROL
Part No. 102521
TB6
7.5
Y22
TB1
6
October 2013

5 UP
TB2
Y21
E
YOUT 4 RD/WH 2 DOWN C6-2

TS61
J2

XOUT 3 WH/RD 1
J1
TB3
PWR 2 OR 11
Y12

C3PBF RD/WH
R1
FLOW CONTROL
5
D30
JC2
6 C1PBU RD
C3-1
7 C2PBD RD/BK
C3-2
8 C3PBF RD/WH
C3-3
C6-19
F
RD/BK DESCENT ALARM OPTION

H4
14
D29
13
NO
1
NC
14 13
22 21
BK
DRIVE LIMIT SWITCH
2
12
SJ1-WH
NO
NC
14 13
22 21

GND BR 1
DRIVE LIMIT SWITCH
1
WH
BK
P24FS WH 2
2
G
J3
TB13
NO
P24FS WH 4
NC
14 13
22 21
DRIVE ENABLE
3

4

C2-2 C6-40
WH

C6-30
H
CR27
CR30
OPTION
NO
NC
TB7
DRIVE
Y26
LIFT/
TS63
C6-7
CE

EXTEND
TB8
BOOM
I
Y25
C3-7
C7PBE BK
EXTEND
BOOM
NOTE:
RETRACT
TS13
C3-8
C8PBR BK/WH
C4-2
C14PLU OR
UP
PLATFORM LEVEL
DOWN
TB14
TS9
C4-3
Y20
C15PLD OR/BK
J
TS59

UP PLATFORM LEVEL
Y19
TB15
TB44
C2-6
K
D27
CR13
NC
C4-6
C18JD GR/BK
DOWN
JIB BOOM
TB18
Y16
UP
TS8
C4-5
C17JU GR
D28
TS58
C6-18
DOWN
Y17
UP JIB BOOM C6-17
TB17
TS57
L
CCW CCW
PLAT ROTATE
CW PLAT ROTATE CW
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
GR/WH
M

+
-
JIB VALVES
CR14
NO
BL/WH
RD/BK
OR/BK
JIB VALVE
WH
BK
RD
RD
BR
N P134PWR RD
6 - 41
6 - 42
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE
6 - 44
6 - 43
1
RD
BL/WH
C132PLI2 BK
RD/BK
TB41
C2-3
OR/BK OR/BK
D89
P26ESTP BK
BK
LS18A F18
2 FUSE 10A
LS18 P2 FS1 TS48
PBOX C9-1 BK BK
GND D88
WH
C134PWR OR/RD RD
TS2
P22BAT BK
TS6
R20
WORK LIGHT
DRIVE LIGHT
C41RPM OR/BK
4.7 K
BK
TS1 TS17
START
ON GLOW
C132PLI BL/WH
TS4
WH
WH
C4-10
PUMP AUXILIARY
2 SEC
GENERATOR
PLUG
HIGH RPM(FS)
P3 NO
HORN H1 30A
ENGINE
3 L48
D39
C3P-9
U35
C1-1
L30 L30
C1-12
C2-4
TB132 IS WAGO TERMINAL BLOCK 36 D40

PBOX
C2-7
C1-7
C1-8
TB133 IS WAGO TERMINAL BLOCK 16 C2-5
C7-1
C4-4
C1-2
C7-2
GND
CB2 D12
BK
BK
P1 RD TB134
TB132 C28TTA RD/BK
15AMP. RD
RD
C1-9
TB43 RD
1 3
KS1
C43HRN GR
TB22
C45GEN GR/WH
RD
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
C35ESPD BK/RD
C133PLA OR/RD
P23BAT WH
TS51 TS52 TS56 TS55
C21IGN WH
PLAT
4 4 5
BK/RD
GRD
ON GLOW
HIGH RPM
LOW RPM
START
2 SEC
PUMP AUXILIARY
6 NO
FUNCTION ENA.
LOAD
RD
10A
PLUG
RD
SENSE D3 PBOX GND
BK
MODULE 7
ENGINE
TB133 D4 D64
BK
U34 TB45
GBOX 12 8
GND TB27
D2 TB23 TB33 D14
CB1 D13
1 START RELAY
GR/BK
TB20 15AMP.
H6 2 TACHOMETER
D6 3 START INPUT
5 RD
L45
TB28 TB24
4 AUX. ON
5 GROUND
IGN./START
MODULE
TB34 TB9 TB35
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
TB21 NO
FUSE 10A
FUSE 70A
WH
BL/WH WH CR3
NO
C5-3
C5-2
C5-22
C21IGN2 WH
GR/WH-45
FUSE 70A
RD/BK-28
C5-5
6 OTS
C5-13 WH
CR23
TB25 TB26 CR23
NO NO
G2 G3
BK-43
D22
OR/BK-41
BK
CR4
WH-21
RD-27
NO
BK-33
PR3
ALTERNATOR PR3
C4B-10
C4B-12
NO
BK/RD
CR17 CR17
C5-14 WH/RD
RD
WH
C5-16 WH/BK
EXCT. NO PR1 3MF
PR1
C5-11
12 V BAT. BAT. NO PR2 PR7

+ - PR2
J144-6
J144-4
DC D52 PR7
NO CB7
RD
S7 NO 10A
RD
RD
+
FB
STA. G6
M1
C5-8
+ Y29
STARTER
7 AUX
M2 PUMP HM G1
BK
REGULATOR H2 S2
FAN _ S1
- IND. L29 L29
NC NO
C4B-9 C4B-11
BR
BR
VOLT METER
STARTER MOTOR
OIL PRESSURE GAUGE

FUEL RELAY
WATER TEMP GAUGE

SERVICE HORN
RELAY
SERVICE HORN
HOUR METER
BRN
SWITCH
OIL PRESSURE
SWITCH
OIL TEMPERATURE
OPTION
RPM FILTER DEUTZ

FLASHING BEACONS
OPTION
WORK LIGHTS
OPTION
DRIVE LIGHT
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
IGN./START RELAY
OPTION
GENERATOR
EMISSION CONTROL DEUTZ
AUXILIARY PUMP
HIGH RPM SOLENOID

FUEL SOLENOID
(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
GLOW PLUG OPTION
HIGH IDLE RELAY

8
NOTE:
6 - 44 S-40 • S-45 Part No. 102521

6 - 45
BR-2 GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
TB30
Y51
DRIVE MODE
C1-4 C5-21 A B
B
S-40 • S-45
L1
J1
C1-5 C5-20 D C
LED BL/RD 16
TB31
H4
C6-32
TS15

7
DRIVE ENABLE
Y2

TB32
Y27
C1-3 C5-19
TB29
TB37
C
Y3

DRIVE & STEERING

RKOUT 5 BL/WH
Y4

XOUT 3 BL/WH
TB36
5
J1
PWR 2 OR 13
GND 1 BR 14
C3-6
11 C6TRF WH/RD
JC3
C3-5
9 C5TRR WH/BK
D
C3-4
Y23
10 C4TRL WH
Y29
TB4
C6-5
TS62

TB5
Y13

R2
FLOW CONTROL
Part No. 102521
TB6
7.5
Y22
TB1
6
October 2013

5 UP
TB2
Y21
E

TS61
J2

XOUT 3 WH/RD 1
J1
TB3
PWR 2 OR 11
Y12

C3PBF RD/WH
R1
FLOW CONTROL
5
D30
JC2
6 C1PBU RD
C3-1
7 C2PBD RD/BK
C3-2
8 C3PBF RD/WH
C3-3
C6-19
F

H4
14
D29
13
NO
1
NC
14 13
22 21
BK
DRIVE LIMIT SWITCH
2
12
SJ1-WH
NO
NC
14 13
22 21

GND BR 1
DRIVE LIMIT SWITCH
1
WH
BK
P24FS WH 2
2
G
J3
TB13
NO
P24FS WH 4
NC
14 13
22 21
DRIVE ENABLE
3

4

C2-2 C6-40
WH

C6-30
H
CR27
CR30
OPTION
NO
NC
TB7
DRIVE
Y26
LIFT/
TS63
C6-7
CE

EXTEND
TB8
BOOM
I
Y25
C3-7
C7PBE BK
EXTEND
BOOM
NOTE:
RETRACT
TS13
C3-8
C8PBR BK/WH
C4-2
C14PLU OR
UP
PLATFORM LEVEL
DOWN TB14
TS9
C4-3
Y20
C15PLD OR/BK
J
TS59

UP PLATFORM LEVEL
Y19
TB15
TB44
C2-6
K
D27
CR13
NC
C4-6
C18JD GR/BK
DOWN
JIB BOOM
TB18
Y16
UP
TS8
C4-5
C17JU GR
D28
TS58
C6-18
DOWN
Y17
UP JIB BOOM C6-17
TB17
TS57
L
CCW CCW
PLAT ROTATE
CW PLAT ROTATE CW
TS7
WH
BR
C4-7
CR13 C19JSV GR/WH
TB19
GR/WH
M

+
-
JIB VALVES
CR14
NO
BL/WH
RD/BK
OR/BK
JIB VALVE
WH
BK
RD
RD
BR
N P134PWR RD
6 - 45
6 - 46
(from serial number 16420)
6 - 48
6 - 47
1
RD
BL/WH
RD/BK
TB41 C2-3
OR/BK
BK
P26ESTP BK
WH
2 P2
C9-1
FS1 C9-3
P25FS RD
BK
C9-2 P24FS WH
RD
P134PWR RD
C132PLI1 BL/WH
P22BAT BK
TS17
C41RPM OR/BK
TS6 TS4
P3
WH
TS2
WH
C28TTA RD/BK
HORN + TS1
GENERATOR
HIGH RPM(FS)
H1 L48
ENG SPEED
-
D39
C7-1
C1-12
C2-5
C2-4
3 D40
L30 L30
C2-7
C1-7
C1-8
C1-2
C1-1
C7-2
C4-4
CB2 TB134
P1 RD TB132 TB43 D12
15AMP.
BK
BK
RD
C1-9
1 3
C43HRN GR
C133PLA OR/RD
KS1 TB22 RD
C28TTA RD/BK
C27AUX RD
C33STR BK
C34SA BK/WH
TS51 TS52 TS56 TS55
P23BAT WH
C35RPM BK/RD
C45GEN GR/WH
PLAT
4 5
GRD
4
START
HIGH RPM
LOW RPM
6
FUNCTION ENA.
RD
C32 7 TB133
D64
ENGINE
D4
RD
12 CONN. 8
PLUG
GBOX GND TB28
TB27 TB33
GR/BK
D14
CB1 D13
D2 TB23 1 START RELAY
TB20 15AMP. TB34 TB45
D6 2 TACHOMETER
3 START INPUT TB35
4 AUX. ON 2
TB24 5 GROUND IGN./START
5 CB3
RD 6 BATTERY
7 KEY PWR.
MODULE L2
CR45 CR2 8 KEY BYPASS
C6-39
CR45 CR1
BK/RD
20AMP. NO CR1 9 IGN./FUEL ON
CR2 10 ENG. FAULT FUSE 10A
NO
TB21 NO
BR
NO CR3
C6-34
FUSE 70A
C5-3
C5-2
C6-28
C6-23
C6-27
CR5
C5-5
C45GEN GR/WH
OTS NO CR5 NO CR4
C5-22
CR23
C5-13
FUSE 70A CR23
NO TB25 TB26
6 NO
R21IGN WH
G2
C6-25
D22
WH
PR3
ALTERNATOR PR3
C4B-10
NO
C4B-12
CR17
WH
NO
RD
EXCT.
C5-14
C5-16
PR1 PR1 3MF CB7
BAT. BAT. CR17 NO 10A
12 V
C6-16
C6-33
+ - PR2 PR2
J144-6
J144-4
DC
WH/RD
PR7
WH/BK
NO PR7
C5-8
+ S7 NO
RD
RD
STA.
FB
FAN M1 STARTER + Y29
AUX G6 G1 S2
H2 M2 PUMP HM
REGULATOR
BK
_ S1
7 IND.
NO L29 L29
C6-26
-
NC C4B-11
C4B-9
BR
OIL PRESSURE
SWITCH
SWITCH
OIL TEMPERATURE
WORK LIGHTS RELAY (OPTION)
OIL PRESSURE GAUGE

STARTER MOTOR
IGNITION RELAY
WATER TEMP GAUGE

RELAY
SERVICE HORN
SERVICE HORN
OPTION
FLASHING BEACONS
FUEL SOLENOID
AUXILIARY POWER
LEVEL SENSOR
TILT ALARM
RELAY
START RELAY
HOUR METER
VOLT METER
OPTION
GENERATOR
AUXILIARY PUMP
WORK LIGHTS
OPTION
DRIVE LIGHT
OPTION
EMISSION CONTROL
HIGH RPM SOLENOID

(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
GLOW PLUG OPTION
GLOW PLUG OPTION
HIGH IDLE RELAY

SECOND
LIGHTS PACKAGE
8
NOTE:

2 DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453
6 - 48 S-40 • S-45 Part No. 102521

6 - 49
1
BR-2 GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
TB30
Y51
DRIVE MODE
C1-4 C5-21 A B
B
S-40 • S-45
L1
J1
C1-5 C5-20 D C
LED BL/RD 16
TB31
H4
C6-32
TS15

7
DRIVE ENABLE
Y2

TB32
Y27
C1-3 C5-19
TB29
TB37
C
Y3

DRIVE & STEERING

RKOUT 5 BL/WH
Y4

XOUT 3 BL/WH
TB36
5
J1
PWR 2 OR 13
GND 1 BR 14
C3-6
11 C6TRF WH/RD
JC3
C3-5
9 C5TRR WH/BK
C3-4
Y23
D
10 C4TRL WH
Y29
TB4
C6-5
TS62

TB5
Y13

R2
FLOW CONTROL
TB6
Part No. 102521

7.5
Y22
TB1
6 C6-1
October 2013
C1PBU RD PRIMARY BOOM UP

5 UP
TB2
Y21

E
TS61
J2

XOUT 3 WH/RD 1
J1
TB3
PWR 2 OR 11
Y12

C3PBF RD/WH
R1
FLOW CONTROL
5
D30
JC2
6 C1PBU RD
C3-1
7 C2PBD RD/BK
C3-2
8 C3PBF RD/WH
C3-3
C6-19
F
H4
14
D29
13
NO
1
NC
14 13
22 21
BK
DRIVE LIMIT SWITCH
2
12
SJ1-WH
NO
NC
14 13
22 21

GND BR 1
DRIVE LIMIT SWITCH
1
WH
BK
P24FS WH 2
2
G
J3
TB13
NO
P24FS WH 4
NC
14 13
22 21
DRIVE ENABLE
3

4

C2-2 C6-40
WH

C6-30
H
CR27
CR30
OPTION
NO
NC
TB7
DRIVE
Y26
LIFT/
TS63
C6-7
CE

EXTEND
TB8
BOOM
Y25
I

C3-7
C7PBE BK
EXTEND
BOOM
NOTE:
RETRACT
TS13
C3-8
C8PBR BK/WH
C4-2
C14PLU OR
UP
PLATFORM LEVEL
DOWN
TB14
TS9
C4-3
Y20
C15PLD OR/BK
J
TS59

UP PLATFORM LEVEL
Y19
TB15
TB44
C2-6
K
D27
CR13
NC
C4-6
C18JD GR/BK
DOWN
JIB BOOM
TB18
Y16
UP
TS8
C4-5
C17JU GR
D28
TS58
C6-18
DOWN
Y17
UP JIB BOOM C6-17
TB17
TS57
L
CCW CCW
PLAT ROTATE
CW PLAT ROTATE CW
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
GR/WH
M

+
-
JIB VALVES
CR14
NO
BL/WH
RD/BK
OR/BK
JIB VALVE
WH
BK
RD
RD
BR
N P134PWR RD
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI /CSA / AS
6 - 49
6 - 50
6 - 52
6 - 51
1 RD
BL/WH
RD/BK
C132PLI2 BK
TB41 C2-3
OR/BK
D89
LS18A BK
P26ESTP BK
P2
LS18
WH
D88 FS1 C9-3
PBOX GND C9-1
RD P25FS RD-(FS)
2 BK
C9-2
P24FS WH-(FS)
R20
C3-10
4.7K
P134PWR RD
C28TTA RD/BK
P22BAT BK
C132PLI1 BL/WH
BK
TS17
C41RPM OR/BK
TS6 TS4
P3 TS2
WH
WH
HORN + 2 SEC TS1
GENERATOR
HIGH RPM(FS)
L4 H1
NO
ENG SPEED
D39 - 30A
C1-12
C2-5
C7-1
C2-4
C1-1
D40
GR/BK C4-4
U35
3 L30 L30
C2-7
C1-7
C1-8
C1-2
C7-2
CB2 TB134 PBOX GND
P1 RD TB132 TB43 D12
15AMP.
BK
RD
C1-9
3
C133PLA OR/RD
1
C43HRN GR
KS1 TB22 RD
C45GEN GR/WH
C27AUX RD
C28TTA RD/BK
C34SA BK/WH
TS51 TS52 TS55
C33STR BK
C35RPM BK/RD
PLAT TS56
P23BAT WH
4 5
C21IGN WH
GRD 2 SEC
START
FUNCTION ENA.
HIGH RPM
LOW RPM
6 LOAD NO
4
RD
SENSE 7 TB133 10A
MODULE D64
ENGINE
D4
RD
12 U33 8 U34
GBOX GND TB28
TB27 TB33
GR/BK
D2 TB23 D14
CB1 D13
TB20 15AMP. H6 L45 1 START RELAY
TB34
2 TACHOMETER TB45
D6 3 START INPUT TB35
4 AUX. ON IGN./START 2
TB24 5 GROUND
RD 6 BATTERY MODULE
7 KEY PWR. L2
CB3 CR45
5 8 KEY BYPASS
C6-39
CR45 CR1
BK/RD
NO CR1 CR2 9 IGN./FUEL ON
20AMP. CR2 10 ENG. FAULT FUSE 10A
NO
TB21 NO
BR
NO CR3
C6-34
FUSE 70A
C5-3
C5-2
CR5
C6-28
C6-23
C6-27
C45GEN GR/WH
NO CR5
C5-5
OTS NO CR4
C5-22
CR23
C5-13
TB25 FUSE 70A CR23
NO TB26
NO
BK/RD
R21IGN WH
G2 G3
C6-25
D22
6
WH
PR3
ALTERNATOR PR3
C4B-10
NO
C4B-12
CR17
C5-16
C5-14
NO
WH
RD
EXCT. PR1 3MF

CR17 PR1
CB7
C6-16
12 V BAT. BAT. NO
C6-33
+ - PR2 PR2 10A
WH/RD
J144-6
J144-4
WH/BK
DC NO PR7
S7 PR7
+ NO
RD
RD
C5-8
STA.
FB
FAN M1 AUX STARTER + Y29
H2 M2 PUMP G6 HM G1 S2 S1
REGULATOR
BK
IND. _
L29 L29
NO
C6-26
-
NC
C4B-9 C4B-11
7
BR
SWITCH
SWITCH
OIL TEMPERATURE
OIL PRESSURE
OIL PRESSURE GAUGE
STARTER MOTOR
IGNITION RELAY
COOLANT TEMP GAUGE

SERVICE HORN
RELAY
SERVICE HORN
OPTION
FLASHING BEACONS
FUEL SOLENOID
LEVEL SENSOR
TILT ALARM
RELAY
AUXILIARY POWER
START RELAY
HOUR METER
VOLT METER
OPTION
GENERATOR
OPTION
AUXILIARY PUMP
DRIVE LIGHT
OPTION
WORK LIGHTS
EMISSION CONTROL
HIGH RPM SOLENOID

(OPTION)
COOLING FAN
TEMP. SWITCH
HYDRAULIC OIL
(DEUTZ ONLY)
GLOW PLUG OPTION
GLOW PLUG OPTION
HIGH IDLE RELAY

SECOND
LIGHTS PACKAGE
8 NOTE:

2 DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453
6 - 52 S-40 • S-45 Part No. 102521

6 - 53
BR-2 GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
TB30
Y51
DRIVE MODE
C1-4 C5-21 A B
B
S-40 • S-45
L1
J1
C1-5 C5-20 D C
LED BL/RD 16
TB31
H4
C6-32
TS15

7
DRIVE ENABLE
Y2

TB32
Y27
C1-3 C5-19
TB29
TB37
C
Y3

DRIVE & STEERING

RKOUT 5 BL/WH
Y4

XOUT 3 BL/WH
TB36
5
J1
PWR 2 OR 13
GND 1 BR 14
C3-6
11 C6TRF WH/RD
JC3
C3-5
9 C5TRR WH/BK
C3-4
Y23
D
10 C4TRL WH
Y29
TB4
C6-5
TS62

TB5
Y13

R2
FLOW CONTROL
TB6
Part No. 102521

7.5
Y22
TB1
6 C6-1
October 2013
C1PBU RD PRIMARY BOOM UP

5 UP
TB2
Y21

E
TS61
J2

XOUT 3 WH/RD 1
J1
TB3
PWR 2 OR 11
Y12

C3PBF RD/WH
R1
FLOW CONTROL
5
D30
JC2
6 C1PBU RD
C3-1
7 C2PBD RD/BK
C3-2
8 C3PBF RD/WH
C3-3
C6-19
F
H4
14
D29
13
NO
1
NC
14 13
22 21
BK
DRIVE LIMIT SWITCH
2
12
SJ1-WH
NO
NC
14 13
22 21

GND BR 1
DRIVE LIMIT SWITCH
1
WH
BK
P24FS WH 2
2
G
J3
TB13
NO
P24FS WH 4
NC
14 13
22 21
DRIVE ENABLE
3

4

C2-2 C6-40
WH

C6-30
H
CR27
CR30
OPTION
NO
NC
TB7
DRIVE
Y26
LIFT/
TS63
C6-7
CE

EXTEND
TB8
BOOM
Y25
I

C3-7
C7PBE BK
EXTEND
BOOM
NOTE:
RETRACT
TS13
C3-8
C8PBR BK/WH
C4-2
C14PLU OR
UP
PLATFORM LEVEL
DOWN
TB14
TS9
C4-3
Y20
C15PLD OR/BK
J
TS59

UP PLATFORM LEVEL
Y19
TB15
TB44
C2-6
K
D27
CR13
NC
C4-6
C18JD GR/BK
DOWN
JIB BOOM
TB18
Y16
UP
TS8
C4-5
C17JU GR
D28
TS58
C6-18
DOWN
Y17
UP JIB BOOM C6-17
TB17
TS57
L
CCW CCW
PLAT ROTATE
CW PLAT ROTATE CW
TS7
WH
BR
C4-7
C19JSV GR/WH
CR13
TB19
GR/WH
M

+
-
JIB VALVES
CR14
NO
BL/WH
RD/BK
OR/BK
JIB VALVE
WH
BK
RD
RD
BR
N P134PWR RD
6 - 53
6 - 54

6 - 56
6 - 55

1
DRIVE LIGHT OPTION RELAY
C32 RD-H6+ - C32-1
U33 BL/WH-38D - C32-3
RD-C32-1 RD-CB3 SP
BK-22C - C32-4
RD-42B
PLATFORM LOAD BK-C7-1 - C32-5
H6
RD-TS51 - C32-6 GR/BK-L45- CR23
GR/BK-16A
RD-TS55 - C32-7
BK/RD-9B
GR/BK-16B - C32-8 G1 G2 G3
BR - GND - C32-12 RD C4B-11
WH-21A
2 46 SPARE
RD C4B-12
GR/WH-C6-39 GR/WH-C2B-7 45 GEN. OPTION BR (GROUND)
GR/BK-C2B-6 44 GR/BK-2B GR/BK-S.P. BRN GND
RD-C6-23 OR/RD-C2B-4 42 RD-H6+ RD-KS1-2 S.P. C134PWR
OR/BK-C5-2 OR/BK-C2B-3 41 OR/BK-ISM#2 BR -3MF CAP PULSE PICKUP
OR-C6-40 OR-C2B-2 40 LIMIT SWITCH SIG.
3MF
BL/WH-C23-3 BL/WH-C1B-12 38 C132PLI WH/BK-25A
BL/BK-C6-37 BL/BK-C1B-11 37 STEER LEFT WH/RD-26A
BL-C6-36 BL-C1B-10 36 STEER RIGHT GND BK-22A
BK/RD-C1B-9 35 BK/RD CR3-#30 BK/RD-S.P. RPM KS1 DESCRIPTION LABEL PART #
BK/WH-C5-22 BK/WH-C1B-8 34 BK/WH-S.P. GLOW PLUG AUXILIARY
3 WH/RD-C5-23
BK-C1B-7 33 BK-ISM#3
WH/RD-C6-32
BK-S.P. START P1
KEY SWITCH
B TS51 EMERGENCY STOP BUTTON P1 P1
WH/RD-C1B-6 32 BRAKE/TRAVEL ALARM RD-CB2
NC 1
RD
WH/BK-C5-20 WH/BK-C1B-5 31 E.D.C.- KEY SWITCH KS1 KS1
WH-C5-21 WH-C1B-4 30 E.D.C.+ 3
29 NC B1 AUXILIARY SWITCH TS51 42730
RD/WH-C5-24 RD/WH-C1B-3 MOTOR SPEED
RD/BK-C6-28 WH-23A 4 2
RD/BK-C1B-2 28 TILT ALARM ENGINE START SWITCH TS52 13037
RD-C6-27 RD-C1B-1 27 RD-ISM#4 D6 RD-S.P. AUX. PWR. RD-42A
RD-27A STARTER AID TS56 13037
26 WH/RD-S.P. WATER TEMP. SENDER
RD-C23-6
25 WH/BK-S.P. OIL PRESSURE SENDER
FUNCTION ENABLE SWITCH TS55 13037
RD-C5-1 24 RED-CR1#30 RD-S.P. ENGINE POWER
WH-C7B-2 23 WH-ISM #7 WH-S.P. KEYSWITCH PWR/FB PLATFORM ROTATE SWITCH TS57 16397
RD
BL/WH-C6-30 BK-C32-4 22 BK-CR5#30 BK-S.P. PWR. TO PLAT.
WH-S.P. GR/BK-H6- PLATFORM LEVEL SWITCH TS59 13037
WH-C5-3+C5-11 WH-C6-34 21 WH-CR2#87 IGNITION PWR.
4 RD- 12VOLT CB3-SP
GR/WH-C4B-7
20
19
CB2-SP CB1 - SP
GR/WH-SP
12 VOLT BATTERY POWER
JIB VALVE
WH-21A BOOM EXTEND/RETRACT SWITCH TS63 13037
GR/BK-C6-18 GR/BK-C4B-6 18 GR/BK-S.P. PLAT. ROT. R. PRIMARY BOOM UP/DOWN SWITCH TS61 16397
HM
GR-C6-17 GR-C4B-5 17 GR-S.P. PLAT. ROT. L. BR (GROUND) L2
TURNTABLE ROTATE SWITCH TS62 16397
OR/RD-C4B-4 16 GR/BK-C32-8 GR/BK-H6- C133PLA
OR/BK-C6-15 OR/BK-C4B-3 15 OR/BK-S.P. PLAT. LEVEL DN. JIB BOOM UP/DOWN SWITCH TS58 13037
L45
OR-C6-14 OR-C4B-2 14 OR-S.P. PLAT. LEVEL. UP WH-C5-13
BL/RD-C6-13 BL/RD-C4B-1 13 DRV. ENA. LT. CIRCUIT BREAKER, CONTROLS, 15A CB1 CB1
12 V
BL/WH-C3B-12 12 BL/WH-ISM#10 PRIMARY BOOM CIRCUIT BREAKER, ENGINE, 15A CB2 CB2
BL/BK-C3B-11 11 UP/DOWN
BL-C3B-10 10 RD/WH-3A TS61 CIRCUIT BREAKER, OPTIONS, 20A CB3 CB3
BK/RD-C3B-9 9 BK/RD-CR23#86 DRIVE LIGHT OPTION RD/BK-2A
BR-GND STUD RESISTOR, 5 OHM, BOOM FUNCTION R1 R1
3 BK/WH-C6-8 BK/WH-C3B-8 8 BK/WH-S.P. BOOM RETRACT RD-1A
5
12V TO PLAT
BK-C32-5 BK-C6-7 7 BK-S.P. BOOM EXTEND

C7B
1 BK-C3B-7 RESISTOR, 7.5 OHM,TURNTABLE FUNCT R2 R2

2 WH-23C WH/RD-C6-6 WH/RD-C3B-6 6 WH/RD-S.P. TURN. ROT. F.C.
BOOM
WH/BK-C6-5 WH/BK-C3B-5 5 WH/BK-S.P. TURN. ROT. L VOLT METER GAGE G1 G1
EXTEND/RETRACT
WH-C6-4 WH-C3B-4 4 WH-S.P. TURN. ROT. R TS63
BK/WH-8A OIL PRESSURE GAGE G2 G2
RD/WH-C6-3 RD/WH-C3B-3 3 RD/WH-S.P. PRI. BOOM F.C. BK-7A
RD/BK-C6-2 RD/BK-C3B-2 2 44B+RD/BK-C6-19 RD/BK-S.P. PRI. BOOM DOWN GR/BK-44A TURNTABLE OIL TEMP. GAGE G3 G3
C2B
RD-C6-1 RD-C3B-1 1 RD-S.P. PRI. BOOM UP BK-33A ROTATE

TS52
D C B A CB3
BK/WH-34A HOUR METER HM HM
BK-CR1#86
C1B
1 START RELAY STARTER AID

19/18 CABLES
OR/BK-41B ENGINE TS58 IGN. START RELAY CR1 CR1

2 TACHOMETER TS56 START
RD- 20C
BK-33B IGN./START JIB BOOM
3 START INPUT RD-CR17#30 IGN. POWER RELAY CR2 CR2
UP/DOWN TS62
R1
C4B
RD-27B
6 BR-GND.
4
5
AUX. ON
GROUND
MODULE WH/BK-5A
WH/RD-6A
HIGH IDLE (RPM) CUTOUT RELAY CR3 CR3
RD-CR2#30 WH-4A
6 BATTERY RPM RELAY CR4 CR4
WH-23B
C3B
7 KEY PWR.
COOLING FAN RELAY CR17 CR17
8 KEY BYPASS R2
WH-CR2#86
9 IGN./FUEL ON PLATFORM OVERLOAD ALARM H6
WH-L2 DIODE FUNCTION D14 CB2
10 ENG. FAULT CB1
ENABLE PLAT OVERLOAD MODULE U33
RD-ISM#6 BK/RD-35B TS57
PLAT OVERLOAD LED L45
WH-ISM#9 RD-C32-7
FUNCTIONS
RD-24B TS55
C6
CR4 TS59
CR1 CR2 CR3 D13 PLATFORM
PLATFORM ROTATE
BK/RD-35A
7 BK-ISM#1
RD- 20A
LEVEL
RD- 24A
BK-C5-5 WH-21B
RD- 20B
BK/RD-C5-9
RD- P1 E-STOP
OR/BK-15A
ENGINE
C5
BK-C6-16 OR-C6-33
OR-14A
GR-17A
GR/WH-19A
GR/BK-18A
8 CR5 GR-43D CR17 BK-C6-25
BK-22B RD-CB3 SP
WIRING
GROUND STUD
GROUND STUD
BR HARNESS:
TO BASE
ALL BR WIRES
6 - 56 S-40 • S-45 Part No. 102521


Deutz D2011L03i and Perkins 404-22 Models
1
LOAD SENSE OPTION - TIMER RELAY
RD-H6+ - C32-1
BL/WH-132D - C32-3
U33 C32 RD-C32-1
BK-22C - C32-4
PLATFORM LOAD BK-C7-1 - C32-5 RD-134B
RD-TS51 - C32-6 GR/BK-L45- H6 WH-CR2#86
8
RD-TS55 - C32-7 GR/BK-133A WH-ISM#9
GR/BK-133B - C32-8 9
G1 G2 G3
BR - GND - C32-12
46 SPARE RD-TB134(A)C
2
WH-21A 2
GR/WH-C6-39 GR/WH-C2B-7 45 GR/WH-35B 2 GEN. OPTION BR (GROUND)
GR-C2B-5 43 GR-CR5#85 HORN BR-GND
3
RD-U34-2 134A 5
RD-C6-23 OR/RD-C2B-4 134 RD-H6+ RD-KS1-2 S.P. P134PWR U34
OR/BK-C5-2 OR/BK-C2B-3 41 OR/BK-ISM#2 BR -3MF CAP PULSE PICKUP (DEUTZ ONLY)
OR-C6-40 OR-C2B-2 40 LIMIT SWITCH SIG. BK-C3B-10
37 WH/BK-25A
BL/BK-C6-37 BL/BK-C1B-11 STEER CCW
2 WH/RD-26A
BL-C6-36 BL-C1B-10 36 STEER CW BK-22A
BK/WH-C5-22
BK/RD-C1B-9
BK/WH-C1B-8
35 BK/RD CR3-#30 GR/WH-45B
34
BK/RD-S.P.
BK/WH-S.P.
RPM
GLOW PLUG
KEY SWITCH
REPLACE WIRE WITH THIS WIRING DIAGRAM 3
P1 KS1
BK-C1B-7 33 BK-ISM#3 BK-S.P. START TS51
WH/RD-C5-23 32 WH/RD-C6-32 B
WH/RD-C1B-6 BRAKE/TRAVEL ALARM
WH/BK-C5-20 31 RD-CB2 NC 1
WH/BK-C1B-5 E.D.C.-
RD
WH-C5-21 D2 3
WH-C1B-4 30 E.D.C.+
RD/WH-C5-24 29 MOTOR SPEED NC B1
RD/WH-C1B-3 DESCRIPTION LABEL
28 TILT ALARM 4 2
RD/BK-C6-28 RD/BK-C1B-2 WH-23A
RD-C6-27 RD-C1B-1 27 RD-ISM#4 D6 RD-S.P. AUX. PWR. RD-134A
EMERGENCY STOP BUTTON P1
26 WH/RD-S.P. WATER TEMP. SENDER RD-27A D4
25 WH/BK-S.P. OIL PRESSURE SENDER RD-C32-6 DRIVE LIGHT OPTION RELAY KEY SWITCH KS1
RD-C5-1 RD-CR23#30 24 RED-CR1#30 RD-S.P. ENGINE POWER
AUXILIARY SWITCH TS51
WH-C7B-2 23 WH-ISM #7 WH-S.P. KEYSWITCH PWR/FB RD-24C
BL/WH-C6-30
WH-C5-3+C5-11
BK-C32-4
C634&CR45#86
22 BK-CR5#30
21 WH-CR2#87&CR23#86
BK-S.P.
WH-S.P.
PWR. TO PLAT.
IGNITION PWR. GR/BK-H6-
RD
ENGINE START SWITCH TS52 4
RD- 12VOLT CB3-SP 20 CB2-SP CB1 - SP 12 VOLT BATTERY POWER CR23 30 STARTER AID TS56
GR/WH-C4B-7 19 GR/WH-SP JIB VALVE WH-21A 85
86 BN-GND FUNCTION ENABLE TS55
GR/BK-C6-18 GR/BK-C4B-6 18 GR/BK-S.P. PLAT. ROT. CCW CHECK ENG
HM
GR-C6-17 GR-C4B-5 17 GR-S.P. PLAT. ROT. CW LED L2 87 PLATFORM ROTATE SWITCH TS57
RD C4B-10
OR/RD-C4B-4 133 GR/BK-C32-8 GR/BK-H6- C133PLA BR (GROUND)
OR/BK-C6-15 15 OR/BK-S.P. PLAT. LEVEL DN. PLATFORM LEVEL SWITCH TS59
OR/BK-C4B-3
L45 RD C4B-12
OR-C6-14 OR-C4B-2 14 OR-S.P. PLAT. LEVEL. UP BOOM EXTEND/RETRACT SWITCH TS63
13 WH-C5-13 WH-21B
BL/RD-C6-13 BL/RD-C4B-1 DRV. ENA. LT.
12 V
BL/WH-C3B-12 12 PRIMARY BOOM UP/DOWN SWITCH TS61

11 BL/WH-ISM#10
BL/BK-C3B-11
TURNTABLE ROTATE SWITCH TS62
BL-C3B-10 10 TS61
9 SPARE RD/WH-3A
JIB BOOM UP/DOWN SWITCH TS58 5
12V TO PLAT
3 BR-GND STUD BK/WH-C6-8 8 BK/WH-S.P. BOOM RETRACT RD/BK-2A

BK/WH-C3B-8
RD-1A CB1
C7B
1 BK-C32-5 BK-C6-7 BK-C3B-7 7 BK-S.P. BOOM EXTEND CIRCUIT BREAKER, CONTROLS, 15A
WH/RD-C6-6 WH/RD-C3B-6 6 WH/RD-S.P. TURN. ROT. F.C.
2 WH-23C CIRCUIT BREAKER, ENGINE, 15A CB2
WH/BK-C6-5 WH/BK-C3B-5 5 WH/BK-S.P. TURN. ROT. CCW WORK LIGHT OPTION RELAY
WH-C6-4 WH-C3B-4 4 WH-S.P. TURN. ROT. CW TS63 CIRCUIT BREAKER, OPTIONS, 20A CB3
RD/WH-C6-3 RD/WH-C3B-3 3 RD/WH-S.P. PRI. BOOM F.C. BK/WH-8A RD-20C
RD/BK-C6-2 2 44B+RD/BK-C6-19 RD/BK-S.P. PRI. BOOM DOWN BK-7A RESISTOR, 5 OHM, BOOM FUNCTION R1
RD/BK-C3B-2
C2B
RD-C6-1 RD-C3B-1 1 RD-S.P. PRI. BOOM UP GR/BK-44A TS62

CR45 RESISTOR, 7.5 OHM,TURNTABLE FUNCT R2
BK-33A TS52 30
D C B A CB3
D64 VOLT METER GAGE G1
86 85 BR-GND
BK-CR1#86 BK/WH-34A
19/18 CABLES
1 START RELAY
C1B
OR/BK-41B 87 OIL PRESSURE GAGE G2

2 TACHOMETER
BK-33B
RD-27B
3 START INPUT
IGN./START RD-20C
TS56
TS58
OIL TEMP. GAGE G3 6
R1
4 AUX. ON WH-W.L. CABLE
C4B
MODULE RD-CR17#30 L2
BR-GND. 5 GROUND CHECK ENG LED
WH/BK-5A WH-21C
RD-CR2#30 6 BATTERY WH/RD-6A HOUR METER HM
WH-23B 7 KEY PWR. WH-4A
C3B
IGN. START RELAY CR1

8 KEY BYPASS
WH-CR2#86 R2
9 IGN./FUEL ON IGN. POWER RELAY CR2
WH-L2 DIODE D27
10 ENG. FAULT
D14 CB1 CB2 HIGH IDLE (RPM) CUTOUT RELAY CR3
RD-ISM#6 TS57 RPM RELAY CR4

BK/RD-35B
FUNCTIONS
WH-ISM#9
RD-24B RD-C32-7 TS55 HORN RELAY CR5
7
C6
CR4 TS59
CR1 CR2 CR3 D13 COOLING FAN RELAY CR17
BK-ISM#1 BK/RD-35A PLATFORM OVERLOAD ALARM H6
RD-20A PLAT OVERLOAD MODULE U33

BK-C5-5 WH-21B RD-24A LOAD SENSE TIME DELAY RELAY (10A) U34
BK/RD-C5-9 RD-20B
PLAT OVERLOAD LED L45
RD-P1 E-STOP
ENGINE
OR/BK-15A
C5
BK-C6-16 OR-C6-33
OR-14A
GR-17A
GR/WH-19A
8
GR/BK-18A
CR5 GR-43D CR17 BK-C6-25
BK-22B RD-CB3 SP
WIRING
GROUND STUD
GROUND STUD HARNESS:

BR TO BASE
ALL BR WIRES 2 DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453
Part No. 102521 S-40 • S-45 6 - 57


6 - 57
6 - 58

6 - 60
6 - 59
N
PART NUMBER
PBOX WIRING
HARNESS
45383
94771
M
OPT.
COMPONENT INDEX
L
TILT ALARM
RD P2
ALC-500
LS18
RD H1
C132PLI BK C1P-12
H1
K
P23SWBAT WH C7P-2
P22BAT BK C7P-1
JIB
C19JSV GR/WH
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
J
C43 HRN GR C2P-5

C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
JDALARM GR/BK C2P-6
I
C3P
C9P
C45GEN GR/WH C2P-7

F.S.
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
P26BAT BK
H
11
1
3
C6TRF WH/RD C3P-6

J3
C10SBU BL C3P-10
12V BATT
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C7P
G
C12SBF BL/WH C3P-12

C30EDC+ WH C1P-4
BRN C1PBU RD C3P-1
C31EDC- WH/BK C1P-5 C7P
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C4P
C37STC BL/BK C1P-11
ALC-500
F
C5TRR WH/BK C3P-5 C4P(BR)

C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
19/18 CONTROL CABLE

J2
C3P
Part No. 102521

C134PWR RD C2P-4
C3P(GR)
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C2P
E
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L48
C2P(BK)
C1P
J1
9
JC1-3 OR
JC2-4 RD
JC1-2 BRN
D
JC2-5 BK
C1P(GY)
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
S-40 • S-45
C28TTA RD/BK C1P-2
C
DRE B BL/BK
BATGND C7P-3
C13LED BL/RD
GR/BK C4P-4
C29MS RD/WH
D40
B
H1
RD/BK-28
ALALRM
GR/BK L4 D39
TILT
RED-TILT RED-TILT
A
October 2013
6 - 60
1
8
6 - 61
1
WH
B
B
A
C19JSV GR/WH TS7

B
C19JSV GR/WH C4P-7

BR JC3 BR BK
B
Y
BR GND
RD
B
RD-E-STOP
Y
P134PWR RD-H1+
GR/WH
RD LS18 CABLE
BR
CR13-#86 GR/WH
B
R
S-40 • S-45
C1
87
86
RD OUTPUT
GR/WH +
OPT.
GR/WH
CR14
85
R
P134PWR RD
30
BR -
JIB
GR/WH RD
B
R
LOAD SENSE OPTION
C
R20
P134PWR RD 4700
B
RD-H1+
OPTION
U35
LS18
COM
NO
2
5
3
D88
D
P26ESTP BK E-STOP R26ESTP BK C9P-1

BR GND
D89
P23BAT WH C7P-2
P22BAT BK C7P-1
Part No. 102521
C19JSV GR/WH C4P-7

October 2013
C18JD GR/BK C4P-6

C17JU GR C4P-5
E
JIB
C15PLD OR/BK C4P-3

C14PLU OR C4P-2
C43HRN GR C2P-5
C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26ESTP BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
F
JDALARM GR/BK C2P-6

C45GEN GR/WH C2P-7
C9P
F.S.
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
C132PLI1 BK C1P-12
C132PLI2 BK C3P-10
G
P26ESTP BK
11
3
1
J3
12V BATT
C6TRF WH/RD C3P-6
C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
H
C7P
C12SBF BL/WH C3P-12
C30EDC+ WH C1P-4
C7P
BR C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C4P
C3PBF RD/WH C3P-3

C37STC BL/BK C1P-11
I

ALC-500
C32BRK WH/RD C1P-6

C4TRL WH C3P-4
J2
C29MS RD/WH C1P-3

C3P
19/18 CONTROL CABLE

P134PWR RD C2P-4 C3P(GR)
C35RPM BK/RD C1P-9
C2P
C34SA BK/WH C1P-8
J
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L48 C2P(BK)
C1P
J1
9
JC1-2 OR
JC2-3 WH/RD
JC1-1 BR C1P(GY)
K
JC2-4 RD/WH
JC2-2 OR
JC1-4 WH/BK
JC2-1 BR
JC3-4 WH/RD
JC3-2 OR
JC3-3,5 BL/WH
JC3-1 BR
C28TTA RD/BK C1P-2

L
DRE B BL/BK
BATGND C7P-3
LOAD SENSE TIME DELAY RELAY (30A)

C13LED BL/RD
GR/BK C4P-4
C29MS RD/WH
D40
H1
COMPONENT INDEX
JIB DELAY RELAY

ALALRM
RD/BK-28
JIB TIME DELAY

M
D39
TILT
GR/BK L4
TILT ALARM
RD-TILT RD-TILT
BR
CR14
U35
H1
C1
N

6 - 61
6 - 62

6 - 64
6 - 63

1
HARNESS
PBOX WIRING
2 7
10 AMP FUSE
7
COMPONENT INDEX PART NUMBER
6 TS48 6 JC2
PRIMARY UP/DN , TURNTABLE ROTATE
62390
WORK/ DRIVE LITE L48 CHASSIS TILT LED 56298
5 5 JC3 DRIVE PROPORTIONAL JOYSTICK 75565
TS15 L1 DRIVE ENABLE LED 56298
DRV.ENA P2 EMERGENCY STOP BUTTON 66812, 95406
4 4 P3 HORN SWITCH 66813, 66815
TS2 START ENGINE SWITCH 13037
3 3 L4 CE PLATFORM LED 56298
3 TS4 HI/L0 RPM SWITCH 56457
TS6 GLOW PLUG OPTION 13037
2 PRIMARY JC3 2 TS7 PLATFORM ROTATE SWITCH 16397
JC2 BOOM TS8 JIB UP/DOWN SWITCH 13037
1 EXTEND/ 1 TS9 PLATFORM LEVEL SWITCH 13037
RD WL2
RETRACT TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH 13037

TS14 DRIVE SPEED SWITCH 56457
TS13 TS48 WORK/DRIVE LIGHT ( OPTION ) 27378
4
WH-24
+
CR13
+ RD
L1
L4 DETAIL A: LIFT/DRIVE OPTION
RD WL1

+
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
L48
BL/BK-DE2 J1-7
BRN BATGND
5 (GND STUD)
BRN J1-14
BRN J1-12
GR/BK H1
RD/BK H1
OR J1-13
BK/WH-8
OR J1-11
WH J1-5
WH J1-5
BK J1-2
RD J1-1
WH-JIB
BL J1-4
WH-24
BK-22
BK-7
BRN
CR27
WH TS7
WH TS1
RD TS47
RD-25
RD P2
C19JSV GR/WH JIB
P26BAT BK C9P-1
RD LS18
RD P3
RD
C33STR BK C1P-7
P22BAT BK C7P-1
OR-14
BK-22
GR-43
C18JD GR/BK C4P-6
C17JU GR C4P-5
C29MS RD/WH J1-8
C34SA BK/WH C1P-8

WH-JIB
C27AUX RD C1P-1
GR/WH-45
OR/BK-15
C19JSV GR/WH
WH-24
BK/RD-35
WH-24
WH-23
WH-24
WH-24
WH/RD C32BRK
(SPLICE TO C32BRK)
6 CR30
REMOVE FOR
GENERATOR OPTION
OR R40LS1
2 2
NC NC NC
1
TS47 (SPLICE TO R40LS1)
WH
1 1
GENERATOR
2
(OPTION)
GR
P2
NO
4
WH EMERGENCY STOP
7 NOTE:
TS7 TS8 TS14 TS6 TS4 1) DASHED LINES INDICATE OPTION WIRES.
P3 WH
TS9 PLATFORM JIB TS1 HIGH/LOW GLOW PLUG HIGH/LOW
HORN
PLATFORM ROTATE GR/BK AUXILIARY PUMP DRIVE RPM
RD
LEVEL SPEED
CE SEE DETAIL A
6 - 64 S-40 • S-45 Part No. 102521


1
HARNESS
PBOX WIRING
2
10 AMP FUSE
COMPONENT INDEX
WORK/ DRIVE LITE JC2 BOOM PROPORTIONAL JOYSTICK:
PRIMARY BOOM
TS48 PRIMARY UP/DN , TURNTABLE ROTATE
UP/DOWN DRIVE/STEER
1 DRIVE ENABLE JC3 DRIVE PROPORTIONAL JOYSTICK
TS15 L48 CHASSIS TILT LED
L1 DRIVE ENABLE LED
P2 EMERGENCY STOP BUTTON
JC2 JC3 P3 HORN SWITCH
TS2 START ENGINE SWITCH
TS3 FUEL SELECT SWITCH (FORD EFI ONLY)
TS4 HI/L0 RPM SWITCH
TURNTABLE ROTATE L4 CE PLATFORM LED
PRIMARY TS7 PLATFORM ROTATE SWITCH
BOOM TS8 JIB UP/DOWN SWITCH
EXTEND/ TS9 PLATFORM LEVEL SWITCH
RD WL1
RETRACT RD WL2 TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH

TS14 DRIVE SPEED SWITCH
TS15 DRIVE ENABLE SWITCH
TS47 GENERATOR SWITCH ( OPTION )
TS49 WORK/DRIVE LIGHT ( OPTION ) 4
TS13
WH-24
CR13 +
86 +
RD
87A L1
30
L4 DETAIL A: LIFT/DRIVE OPTION
J1-2 RD/WH JC2-4
J1-1 WH/RD JC2-3
J1-4 WH/RD JC3-4

J1-5 BL/WH JC3-3
J1-5 BL/WH JC3-5

J1-12 BR JC2-1
BL/RD-DE3 J1-16
J1-14 BR JC3-1
+
J1-11 OR JC2-2
85
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
J1-13 OR JC3-2
L48
WH/RD C32BRK BRN BATGND
5
RD/BK H1
GN/BK H1
BK/WH-8
(SPLICE TO C32BRK) (GND STUD)
WH-24
BK-22
CR27
BK-7
86
BR
87A
WH TS7 30
WH TS1
85
C19JSV GN/WH
P22BAT BK C7P-1
P26BAT BK C9P-1
WH-23
RD-25
C29MS RD/WH J1-8
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
GN/WH-45
WH-24
WH-24
C19JSV GN/WH JIB
BK-22
RD P3
RD
OR/BK-15
C18JD GN/BK C4P-6

GN-43
BK/RD-35
RD LS18
OR-14
RD P2
WH-24
C17JU GN C4P-5
WH
WH-JIB
CR30
86
87 6
30
85
OR R40LS1
NC NC NC
(SPLICE TO R40LS1)
WH TS1
TS9 TS7 TS8
TS14 TS6 TS2 TS4 EMERGENCY STOP
NO GR P2
DRIVE TS17
SPEED 7
HIGH/LOW RD START HIGH/LOW
HORN PLATFORM JIB GLOW PLUG NOTE:
PLATFORM AUXILIARY PUMP RPM
P3 ROTATE
LEVEL
GN/BK GENERATOR 1) DASHED LINES INDICATE OPTION WIRES.
D27 RD (OPTION)
CE SEE DETAIL A
1 TS48 REMOVED FROM PLATFORM BOX AT SERIAL NUMBER 16420
Part No. 102521 S-40 • S-45 6 - 65


6 - 65
6 - 66
6 - 68
6 - 67
N
OR/BK
RD/BK
WH
BK
RD
RD

BRN
SEE NOTE 2
M
HIGH RPM(FS) C1-9

C35ESPD BK/RD
TS55
TS4
LOW RPM FUNCTION

L
HIGH RPM ENA. BK/RD

TB35
NOTE:
TB45
TS17
C2-7 C45GEN GR/WH C6-39 GR/WH-45 GENERATOR

K
OPTION
GENERATOR
C5-13 C38ESL BL (FEH 658) PIN6
C5-12 TSW BK/RD (FEH 458) PIN3
TEST C211GN2 WH (FEH 306) PIN24
J
C5-17
FORD
TS22
C5-10 C39LP BK/WH (FEH 72) PIN7 42 PIN PLUG

TB39
RUN C5-9 C35RPM2 OR/RD (FEH 307A) PIN23

C5-11 WH (FEH 16A) PIN1
C2-1
TS53
TS3
BL/WH (FEH 787) PIN5

P24BAT
LP LP FUEL
TB24
FUEL
GAS BR (FEH 570C) PIN34
GAS
PUMP
FUEL
L2
FUEL PUMP
I
G3
WATER TEMP GAUGE

TB26
C5-14
IGN./START
C2-3
MODULE
OTS
NO
WH/RD-24 WATER TEMP

SWITCH
TACHOMETER
START RELAY
IGN./FUEL ON
START INPUT
C28TTA RD/BK
KEY BYPASS
ENG. FAULT
C5-15 WH/BK-24 OIL PRESSURE

KEY PWR.
BATTERY
TS2
GROUND
AUX. ON
C1-7 C33STR BK SWITCH

OPS
NC
H
TS52
TB25
ENGINE C5-16
START
7
5
10
4
9
3
8
2
1
ENGINE
G2
START OIL PRESSURE GAUGE

BK
TB33
TB41
CR2
P26ESTP BK
FUEL RELAY
P24FS WH
P25FS RD
HARNESS
RD (FEH 361A)
ENGINE
G
FORD
TB21
CR2
DGRN (FEH 242)

NO
LPG LOCKOUT SOLENOID

C9-3
C9-2
D6
G1
VOLT METER
WH-21
HM
CR1
HOUR METER
_
WH-(FS)
RD-(FS)
IGN./START RELAY
F
TB24
C5-5 BK-33
CR1
NO
STARTER
Part No. 102521

FS1
STARTER MOTOR
TS51
BK-(FS)
TB27
TS1
AUXILIARY
PUMP AUXILIARY PUMP C6-27 RD-27 AUXILIARY POWER
E
RELAY
PR1
RD
C9-1 BK
C1-1 C27AUX RD
PUMP
AUX
TB23
C7-2 P23BAT WH AUXILIARY PUMP
PR1
TB28
NO
L48
P2
C1-2 C28TTA RD/BK C6-28 RD/BK-28 WH

TILT ALARM
TB133
D40
C6-23 RD-P134 RD BK BRN

LEVEL SENSOR
C4-4 C133PLA OR/RD
D39
H1
D
L4
FLASHING BEACONS
FB
OPTION
TB43
HORN
CR5 CR5
P3
C2-5
SERVICE HORN
RELAY
NO
C6-16 BK-43
SERVICE HORN
C7-1
H2
P22BAT BK
S-40 • S-45
CR17
OTS
NO
RD
C
C6-34 C6-25
HYDRAULIC OIL
CR17
TEMP. SWITCH
NO
C6-33 C6-26
COOLING FAN
FAN
C134PWR OR/RD
(OPTION)
C2-4
TB134
RD
C41RPM OR/BK C5-2 OR/BK-41
TB22
EXCT.
B
IND.
BAT.
STA.
C5-3
REGULATOR
PLAT
-
GRD
ALTERNATOR
RD
KS1
CB3
CB1
20AMP.
TB20 15AMP.
RD
BAT.
P1
+
RD
A
-
CB2
15AMP.
12 V
October 2013
DC
RD
6 - 68
1
8
6 - 69
1
BRN-2 GROUND
C41RPM OR/BK
A
C2P-3
5
15
TB30

B
L1
S-40 • S-45
J1

DRE LED BL/RD
16 16 DRIVE EDC REVERSE
TB31
H4
TS15
DRE B BL/BK C6-32

TRAVEL ALARM OPTION
TB32
7
20
DRIVE & STEERING
7
TB37
RKOUT 6 WH 5
C
YOUT 5 BL 4
JC3
J1

18 STEER RIGHT
PWR 3 OR 13
17 STEER LEFT
TB36
1
C3P-6 C6TRF WH/RD
11
C3P-5 C5TRR WH/BK
9
TB4
C3P-4 C4TRL WH
10
C4TRL WH
D
C6-4
TB5
LEFT
TROTATE
TS62

TB6

6 FLOW CONTROL
TB1
YOUT 5 BK 2 7.5
Part No. 102521
JC2

J1
PRIMARY BOOM UP
TB2
UP
October 2013
PWR 3 OR 11 PRIMARY
TS61
J2
GND 2 BRN 12 DOWN BOOM C6-2 C2PBD RD/BK

PRIMARY BOOM DOWN
E
TB3
1
5
FLOW CONTROL
C3P-1
6
C1PBU RD
C3P-2
7 C2PBD RD/BK
C3P-3
8 C3PBF RD/WH
C6-19 RD/BK
F
H3
14
13
12
NOHC NOHC NONC
WH
LS2-PRIMARY BOOM UP
BK DRIVE LIMIT SWITCH

SJ1-WH
WH
BRN LS1-PRIMARY BOOM EXTEND
1 BK
G
TB13
P24FS WH DRIVE LIMIT SWITCH

2
J3
P24FS WH

C4P-1 C13DRE BL/RD C6-13 C13DRE BL/RD WH
4 3 DRIVE ENABLE
P26ESTP BK BK
3 LIMIT SWITCH
C40LS1 OR
C6-30
C2P-2 C40LS1 OR C6-40

4
TB40
TB22
H
TB7

TS63
CR27
OPTION
CR30
NC
NO
DRIVE
C6-7 C7PBE BK
LIFT/
BOOM EXTEND
CE
TB8
EXTEND
BOOM
BOOM RETRACT
C3P-7 C7PBE BK
I
EXTEND BOOM
TS13
C4P-2 C14PLU OR
UP PLAT
TB14
DOWN LEVEL C4P-3 C15PLD OR/BK

TS9
NOTE:
C6-14 C14PLU OR
UP PLAT LEVEL UP
PLAT
DOWN LEVEL C6-15 C15PLD OR/BK
TS59
TB15 PLAT LEVEL DOWN

J
TB44

CR13
NC
WH
C4P-6 C18JD GR/BK

DOWN JIB
TB18
UP BOOM C4P-5 C17JU GR TS58
TS8
C6-18 C18JD GR/BK

K
RIGHT JIB PLATFORM ROTATE RIGHT / JIB DOWN

LEFT BOOM C6-17 C17JU GR
TB17
TS57
RIGHT PLAT RIGHT PLAT
LEFT ROTATE LEFT ROTATE
TS7
WH
C4P-7
AMP
C19JSV GR/WH
7
6
5
3
4
2
1
L
TB19
C19JSV GR/WH
CR13
JIB VALVES

Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin1
BRN
RKOUT
XOUT
YOUT
PWR
GND
JIB VALVE
M
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
OR/BK
RD/BK
BRN
WH
RD
RD
BK
Deutsch
1
3
5
6
4
N
6 - 69
6 - 70

1
46 LIMIT SWITCH POWER

GR/BK-C2B-6 44 GR/BK-2B GR/BK-SP SPARE
OR/RD-C2B-4 42 SPARE
OR/BK-C5-2 OR/BK-C2B-3 41 PULSE PICKUP G1 G2 G3
OR- C6-40 OR-C2B-2 40 LIMIT SWITCH SIG. WH-21A
BL - C5-13 BL/WH-C1B-12 38 BL/WH-ISM#10 BL/WT-S.P. CHECK ENGINE BR (GROUND) 2
BL/BK-C6-37 BL/BK-C1B-11 37 STEER LEFT
BL- C6-36 BL-C1B-10 36 STEER RIGHT
BK/RD-C5-9 BK/RD-C1B-9 35 BK/RD-S.P. RPM
BK/WH-C1B-8 34 BK/WH-S.P. GLOW PLUG
BK-ISM#3 BK-C1B-7 33 BK-CR1#85 D5 BK-S.P. START
WH/RD-C5-23 WH/RD-C1B-6 32 WH/RD-C6-32 BRAKE/TRAVEL ALARM
WH/BK-C5-20 WH/BK-C1B-5 31 E.D.C.- WH/BK-25A
WH- C5-21 WH/RD-26A
WH-C1B-4 30 E.D.C.+
BK-22A
RD/WH-C1B-3 29 SPARE
RD/BK-C6-28 RD/BK-C1B-2 28 TILT ALARM KS1
RD- C6-27 RD-C1B-1 27 RD-ISM#4 D6 RD-S.P. AUX. PWR. KEY SWITCH
P1 TS51
WH/RD-C5-14 26 WH/RD-S.P. WATER TEMP. SENDER RD-CB2
B 3
WH/BK-C5-16 25 WH/BK-S.P. OIL PRESSURE SENDER NC 1
RD
RD- C5-1 RED-CR1#30 3
24 RD-S.P. ENGINE POWER
RD- C6-23 23 WH-TS22#5 KEYSWITCH PWR/FB NC B1
WH-C7B WH-S.P.
WH-23A 4 2
BL/WH-C6-30 BK-C7B 22 BK-CR5#30 BK-S.P. PWR. TO PLAT.
RD-42A
WH-C5-3+C6-34 WH-C5-11 21 WH-CR2#87 WH-S.P. IGNITION PWR. RD-27A
20 BL/RD-39A
GR/WH-C4B-7 19 GR/WH-SP JIB VALVE RD-C23-6
GR/BK-C6-18 GR/BK-C4B-6 18 GR/BK-S.P. PLAT. ROT. R. RD-H6+
GR- C6-17 GR-C4B-5 17 GR-S.P. PLAT. ROT. L. OR/RD-H6-
OR/RD-C4B-4 16
OR/BK-C6-15 OR/BK-C4B-3 15 OR/BK-S.P. PLAT. LEVEL DN.
OR- C6-14 OR-C4B-2 14 OR-S.P. PLAT. LEVEL. UP WH-21A 4
BL/WH-C3B-12 12 TS53
HM
BL/BK-C3B-11 11 BR (GROUND) L2
BL-C3B-10 10
BK/RD-C3B-9 9
BL/WH-C5-13
L45
BK/WH-C6-8 BK/WH-C3B-8 8 BK/WH-S.P. BOOM RETRACT
BL/WH-ISM#10
BK- C6-7 BK-C3B-7 7 BK-S.P. BOOM EXTEND
DESCRIPTION LABEL PART #
WH/BK-C6-5 WH/BK-C3B-5 5 WH/BK-S.P. TURN. ROT. L RD/WH-3A TS61
WH- C6-4 WH-C3B-4 4 WH-S.P. TURN. ROT. R RD/BK-2A EMERGENCY STOP BUTTON P1 P1
RD/WH-C6-3 RD/WH-C3B-3 3 RD/WH-S.P. PRI. BOOM F.C. RD-1A
RD/BK-C6-2 RD/BK-C3B-2 2 44B-RD/BK-C6-19 RD/BK-S.P. PRI. BOOM DOWN
KEY SWITCH KS1 KS1 5
RD-C6-1 RD-C3B-1 1 RD-S.P. PRI. BOOM UP AUXILIARY SWITCH TS51 42730
12 V
D C B A BK/WH-8A TS63 ENGINE START SWITCH TS52 13037

12V TO PLAT
BK-7A LP/GAS SWITCH TS53 56457

GR/BK-44A
3 BR-GND STUD BK-CR1#86 BK-33A TS62 FUNCTION ENABLE TS55 13037
1 START RELAY
C7B
1 BK-22C OR/BK-41B 16397

2 TACHOMETER TS52 CB3
PLATFORM ROTATE SWITCH TS57
2 WH-23C BK-33B
3 START INPUT IGN./START PLATFORM LEVEL SWITCH TS59 13037
RD-27B
4 AUX. ON MODULE
BR-GND. 5 BOOM EXTEND/RETRACT SWITCH TS63 13037
GROUND RD- 20C
RD-CR2#30 TS58 RD-CB3 SP
C3B C4B
6 BATTERY RD-CR17#30 PRIMARY BOOM UP/DOWN SWITCH TS61 16397

WH-TS22#6
6
R1
7 KEY PWR. GR-17A
TURNTABLE ROTATE SWITCH TS62 16397
8 GR/WH-19A CR23
19/18 CABLES
KEY BYPASS
WH-CR2#86 GR/BK-18A JIB BOOM UP/DOWN SWITCH TS58 13037
9 IGN./FUEL ON
BK/WH-38B GR/BK C2B-6
10 ENG. FAULT CHECK ENGINE SWITCH TS22 42730
R2 RD C4B-11
BK-22B CIRCUIT BREAKER, CONTROLS, 15A CB1 CB1
C2B
RD-ISM#6
WH-ISM#9
RD-CB3 SP GR-43D D14 CB1 CB2 TS57 RD C4B-12 CIRCUIT BREAKER, ENGINE, 15A CB2 CB2
RD-24B BK-C6-25
BRN GND CIRCUIT BREAKER, OPTIONS, 20A CB3 CB3
CR1 CR2 CR17 CR5
C1B
TS55 RESISTOR, 5 OHM, BOOM FUNCTION R1 R1

BK-ISM#1 DRIVE LIGHT OPTION RELAY
TS59 RESISTOR, 7.5 OHM,TURNTABLE FUNCT R2 R2
D13
BK/RD-35A VOLT METER GAGE G1 G1 7
FUNCTIONS
BK-C5-5 WH-21B OR-C6-33

WH-TS22#4 BK-C6-16 RD- 20A OIL PRESSURE GAGE G2 G2
BR-GND+C6-26
RD- 24A WATER TEMP. GAGE G3 G3
C6
CHECK ENGINE TOGGLE SWITCH RD- 20B

CHECK ENGINE L2 56298
RD- P1 E-STOP
WH-ISM#7
36 WH-23B OR/BK-15A HOUR METER HM HM
BR-R1
BR-GND 25 BLK-33B
14 OR-14A
BK/RD-C5-12 WH CR2#87
WH-C5-17 GR-17A
ENGINE
TS22
GR/WH-19A
C5
GR/BK-18A
WIRING 8
HARNESS:
TO BASE
GROUND STUD
GROUND STUD
BR
ALL BR WIRES
Part No. 102521 S-40 • S-45 6 - 71


6 - 71
6 - 72

6 - 74
6 - 73
N
PART NUMBER
45383
89353
PBOX WIRING
HARNESS
M
OPT.
COMPONENT INDEX
L
TILT ALARM
ALC-500
RD P2
LS18
RD H1
H1
C132PLI BK C1P-12
K
P23SWBAT WH C7P-2
P22BAT BK C7P-1
JIB
C19JSV GR/WH
J
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
P24FS WH C9P-2
I
JDALARM GR/BK C2P-6

C3P
C45GEN GR/WH C2P-7

F.S.
C9P
TS48-WL1 RD C2P-12
F.S.
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE GR/BK C2P-6
H
P26BAT BK
11
3
C6TRF WH/RD C3P-6

J3
C10SBU BL C3P-10
C13DRE BL/RD C4P-1
12V BATT
C11SBD BL/BK C3P-11
G
C7P
C12SBF BL/WH C3P-12
C30EDC+ WH C1P-4
C7P
BRN C1PBU RD C3P-1

C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STCC BL C1P-10
C3PBF RD/WH C3P-3
C37STC BL/BK C1P-11 C4P
F
ALC-500
C5TRR WH/BK C3P-5

C32BRK WH/RD C1P-6
C4P(BR)
C4TRL WH C3P-4
19/18 CONTROL CABLE

J2
C29MS RD/WH C1P-3
C3P
Part No. 102521

C134PWR RD C2P-4
C3P(GR)
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C2P
E
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
C2P(BK)
C1P
J1
9
JC1-3 OR
JC2-4 RD
JC1-2 BRN
C1P(GY)
D
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
C28TTA RD/BK C1P-2

S-40 • S-45
DRE B BL/BK
C
BATGND C7P-3
C13LED BL/RD
GR/BK C4P-4
C29MS RD/WH
D40
H1
RED/BLK-28
B
ALALRM
D39
GR/BK L48
TILT
RED-TILT RED-TILT
A
BRN
October 2013
6 - 74
1
8

1
HARNESS
PBOX WIRING

TS48 / TS49
WORK / DRIVE LITE JC2
PRIMARY UP/DN , TURNTABLE ROTATE 62390
TS15
7 DRV.ENA 7 JC3 DRIVE PROPORTIONAL JOYSTICK 75565
2
L1 DRIVE ENABLE LED 56298
6 6 P2 EMERGENCY STOP BUTTON 66812, 73805
P3 HORN SWITCH 66813, 66816
TS13 TS3 FUEL SELECT SWITCH (FORD EFI ONLY) 56457
TS4 HI/L0 RPM SWITCH 56457
4 PRIMARY 4
DLITE/ RD WL2
L3 CHECK ENGINE LIGHT 56298
RD WL1
BOOM TS7 PLATFORM ROTATE SWITCH 16397
3 EXTEND/ 3 TS8 JIB UP/DOWN SWITCH 13037
RETRACT
TS9 PLATFORM LEVEL SWITCH 13037 3
2 2
JC2 JC3 TS47 GENERATOR SWITCH ( OPTION ) 27378
1 1 TS48-9 WORK/DRIVE LIGHT ( OPTION ) 27378
CR13
WH-24
+ +
L1 L4
4
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
BRN J1-12
BRN J1-14
BRN BATGND
RD/BK H1
OR J1-13
BK/WH-8
OR J1-11
WH J1-5
WH J1-5
RD-TILT
(GND STUD)
BK J1-2
RD J1-1
WH-JIB
BL J1-4
WH-24
BK-22
BK-7
BRN
CR27
WH TS7
WH TS1 5
P26BAT BK C9P-1
BK-33
BK/RD-35
RD
RD
BK-22
RD-TILT
P22BAT BK C7P-1
RD
C17JU GR C4P-5
BL/RD-39
OR-14
C19JSV GR/WH
RD-25
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C27AUX RD C1P-1
GR/WH-45
GR-43
OR/BK-15
WH-24
WH-TS47
WH-JIB
WH-23
WH-TS4
WH-24
WH-24
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
OR R40LS1 6
WH (SPLICE TO R40LS1)
GR TS4
NC NC NC
2
NO
1
3
4
2
WH HIGH/LOW
1
2
RPM
1
TS2 TS3 NOTE:
P3 WH TS47
TS9 TS8 TS1 START FUEL SELECT P2
HORN DASHED LINES INDICATE
PLATFORM JIB AUXILIARY GENERATOR RD EMERGENCY STOP OPTION WIRES
LEVEL TS7 PUMP (OPTION) 7
PLATFORM
REMOVE FOR GENERATOR OPTION
Part No. 102521 S-40 • S-45 6 - 75


6 - 75
6 - 76
6 - 78
6 - 77
N
RD
RD
BRN
BL/WH
WH
BK
RD/BK
OR/BK
HIGH RPM(FS) C1-9

C35ESPD BK/RD
2
TS55
LOW RPM
M
FUNCTION ENA.
HIGH RPM
TS4
TB35
TS17
TB45
Y29
C2-7 C45GEN GR/WH C6-39 GR/WH-45 GENERATOR

GENERATOR OPTION
L
CR23
C3-9 DLITE BK/RD

L29
TS49
RD DRIVE LIGHT
WH C4B-12 OPTION
L29
K
L30
FUSE 10A
PBOX GND
RD WORK LIGHTS
BK C4B-11 OPTION
CR23
NO
F18
WH BK
LPG LOCKOUT SOLENOID
L30
HARNESS
RD (FEH 361A)
ENGINE
FORD
DGRN (FEH 242)

J
G1
VOLT METER
WH-21
HM
HOUR METER
+
_
G6
G3
TEMP GAUGE
TB26
C5-14 WH/RD
OTS
L2
I
OPS
TB25
C5-16 WH/BK
G2
OIL PRESSURE GAUGE

TS22
CR1
C2-3
TB33
TS2
C1-7 C33STR BK
CR1
NO
TS52
START ENGINE ENGINE

H
START C5-12 C127TST GR PIN 18

PUMP AUXILIARY
CR2
BK
C5-17 C21IGN WH PIN 21
C5-13 C38ESL BL/WH PIN 6
C2-1
C5-9 C35RPM BK/RD PIN 23
TB41
TS3
CR2
NO
LP FUEL
GAS C5-5 R33STR BK PIN 15
FORD
TB24
BR PIN34
TB21
42 PIN PLUG
TB39
G
C5-8 R21IGN WH PIN 24

C5-10 C39LP BL/RD PIN 7
TS53
P25FS RD
P24FS WH
P26ESTP BK
C28TTA RD/BK
VBATT RD PIN 9
3
C9-3
BL/WH PIN 5
C9-2
PUMP
FUEL
CR39
FUEL PUMP
C5-11 VSW WH PIN 1
F
WH-(FS)
RD-(FS)
ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

C33STR BK PIN 13
CR39
TS51
NC
THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.

D6
BK-33
Part No. 102521

START RELAY

FS1
TS1
PR2 PR2
STARTER
PUMP AUXILIARY
BK-(FS)
RD STARTER MOTOR
TB27
REFER TO E0375 FOR FORD HARNSS

C1-1 C27AUX RD C6-27 RD-27 AUXILIARY POWER
E
PR1
RELAY
C9-1 BK
M2 PUMP
AUX
AUXILIARY PUMP
TB23
PR1
C7-2 P23BAT WH
NO
TB28
P2
S7
L48
C1-2 C28TTA RD/BK C6-28 RD/BK-28 WH

TILT ALARM
D40
NOTE:
C6-23 RD-134 RD BK BRN
LEVEL SENSOR
1.
3
2
H1
D
C133PLA OR/RD
FLASHING BEACONS
FB
HORN
OPTION
CR5
P3
C2-5 TB43 C43HRN GR SERVICE HORN

RELAY
CR5
NO
P22BAT BK C7-1
C6-16 BK-43
SERVICE HORN
H2
S-40 • S-45
CR17
C
RD
OTS
NO
C6-34 C6-25
HYDRAULIC OIL
TEMP. SWITCH
CR17
M1
C134PWR RD C2-4
NO
C6-33 C6-26
COOLING FAN
FAN
(OPTION)
TB134
RD
C41RPM OR/BK C5-2 C41RPM OR/BK PIN 2
42 PIN FORD CONNECTOR
IND.
EXCT.
BAT.
STA.
C5-3
-
PLAT
TB22
KS1
REGULATOR
GRD
ALTERNATOR
RD
510 OHM
RD
CB1
CB3
20AMP.
15AMP.
BAT.
P1
+
RD
TB20
-
CB2
A
15AMP.
12 V DC
October 2013
RD
6 - 78
1
8
6 - 79
1
BRN-2
GROUND
C41RPM OR/BK
A
C2P-3
5
15
TS14
TB30
Y51
B
S-40 • S-45

L1
J1

16
TB31
H4
TS15
C6-32
DRE B BL/BK
7 TRAVEL ALARM OPTION
Y2

TB32
Y27
C
7 C1P-3 C29MS RD/WH C5-19 C29MS RD/WH

DRIVE & STEERING
20 MOTOR STROKE
RKOUT 6 WH 5
TB29
TB37
4
Y3
YOUT 5 BL
JC3

J1
4 18 STEER RIGHT
PWR 3 OR 13
Y4
GND 2 C1P-10 C36STC BL C6-36 C36STC BL

BRN 14 17 STEER LEFT
TB36
1
C3P-6 C6TRF WH/RD
11
D
C3P-5 C5TRR WH/BK

9
Y23
C3P-4 C4TRL WH
10
C6-4 C4TRL WH
LEFT TROTATE
Y29
TB4
RIGHT
TS62
C6-5 C5TRR WH/BK

TB5
Y13
Part No. 102521


R2
6 FLOW CONTROL
October 2013
TB6
Y22
TB1
YOUT 5 BK 2 7.5
JC2
E

PRIMARY BOOM UP
J1
TB2
UP
Y21
PWR 3 OR 11 PRIMARY
DOWN BOOM C6-2 C2PBD RD/BK
J2
TS61

1
TB3
Y12

R1
FLOW CONTROL
5
6
C3P-1 C1PBU RD
7
C3P-2 C2PBD RD/BK
F
8
C3P-3 C3PBF RD/WH
C6-19 RD/BK
H4
14
13 WH
NCHO
LS2-PRIMARY BOOM UP
BK
SJ1-WH
WH

BRN
NOHC
1
G

2
TB13
J3
P24FS WH
NOHC
P26ESTP BK
3 DRIVE ENABLE
3 BK LIMIT SWITCH
4
TB40
WH

H
C6-30
NOTE:
CR27
CR30
NC
CE NO
OPTION
TB7
Y25
DRIVE
TS63
LIFT/
I
C6-7 C7PBE BK
BOOM EXTEND
EXTEND
TB8
BOOM
Y26
BOOM RETRACT
C3P-7 C7PBE BK
EXTEND PLATFORM LEVEL
RETRACT C8PBR BK/WH
TS13
C3P-8
C4P-2 C14PLU OR
UP
J
PLATFORM LEVEL
DOWN TB14
TS9
C4P-3 C15PLD OR/BK
Y20
TS59
C6-14 C14PLU OR
PLAT LEVEL UP
UP PLATFORM LEVEL
Y19
PLAT LEVEL DOWN
TB15
TB44
K
CR13
NC
C4P-6 C18JD GR/BK

DOWN
TB18
Y16
UP JIB BOOM
TS8
C4P-5 C17JU GR
TS58
C6-18 C18JD GR/BK
DOWN
Y17
TB17
L
TS57
AMP
RIGHT RIGHT
7
6
5
3
4
2
1
LEFT PLAT ROTATE LEFT PLAT ROTATE
TS7
WH

Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin1
C4P-7
C19JSV GR/WH
TB19
RKOUT
JIB VALVES
XOUT
YOUT
CR13
PWR
GND
C19JSV GR/WH
M
BRN
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
JIB VALVE
Deutsch
1
3
BL/WH
RD/BK
OR/BK
BRN
WH
RD
RD
N
5
6
4
BK
6 - 79
6 - 80

1
46 SPARE
GR/BK-C2B-6 44 GR/BK-2B GR/BK-SP JDALARM JIB
OR/RD-C2B-4 42 RD-H6+ RD-KS1-2 S.P. C134PWR
OR/BK-C5-2 OR/BK-C2B-3 41 PULSE PICKUP G1 G2 G3
BL/RD-C5-10 BL/RD-C2B-1 39 BL/RD-S.P. L.P.
BL/BK-C6-37 BL/BK-C1B-11 37 STEER LEFT
BR (GROUND)
2
BK-C1B-7 33 BK-CR1#85 D5 BK-S.P. START
WH/BK-C5-20 WH/BK-C1B-5 31 E.D.C.- WH/BK-25A
WH- C5-21 WH/RD-26A
WH-C1B-4 30 E.D.C.+
BK-22A
RD/WH-C5-24 RD/WH-C1B-3 29 MOTOR SPEED
RD/BK-C6-28 RD/BK-C1B-2 28 TILT ALARM KS1
RD- C6-27 RD-C1B-1 27 RD-CR39#85 RD-S.P. AUX. PWR. KEY SWITCH
P1 TS51
WH/RD-C5-14 26 WH/RD-S.P. WATER TEMP. SENDER B
RD-CB2
NC 1 3
RD
RED-CR1#30 3
24 RD-S.P. ENGINE POWER
RD- C6-23 23 CR39 #30 KEYSWITCH PWR/FB NC B1
WH-C7B-2 WH-S.P.
WH-23A 4 2
BL/WH-C6-30 BK-C7B-1 22 BK-CR5#30 BK-S.P. PWR. TO PLAT.
RD-42A
WH-C5-3+C5-8 WH-C6-34 21 WH-CR2#87 WH-S.P. IGNITION PWR. RD-27A
RD- 12 VOLT RD-S.P.(CB3) 20 RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY BL/RD-39A
GR/WH-C4B-7 19 GR/WH-SP JIB VALVE
GR/BK-C6-18 GR/BK-C4B-6 18 GR/BK-S.P. PLAT. ROT. R.
GR- C6-17 GR-C4B-5 17 GR-S.P. PLAT. ROT. L.
OR/RD-C4B-4 16 GR/BK-C23-8 GR/BK-H6- C133PLT
OR- C6-14 OR-C4B-2 14 OR-S.P. PLAT. LEVEL. UP
WH-21A
4
BL/WH-C3B-12 12 TS53
HM
BL/BK-C3B-11 11 BR (GROUND) L2
BL-C3B-10 10
BK/RD-C3B-9 9 BK/RD-CR23#86 DRIVE LIGHT OPTION
BL/WH-C5-13
BK/WH-C6-8 BK/WH-C3B-8 8 BK/WH-S.P. BOOM RETRACT
DESCRIPTION LABEL PART #
WH/BK-C6-5 WH/BK-C3B-5 5 WH/BK-S.P. TURN. ROT. L RD/WH-3A TS61
WH- C6-4 WH-C3B-4 4 WH-S.P. TURN. ROT. R RD/BK-2A EMERGENCY STOP BUTTON P1 P1
RD/WH-C6-3 RD/WH-C3B-3 3 RD/WH-S.P. PRI. BOOM F.C. RD-1A
KEY SWITCH KS1 KS1
RD/BK-C6-2
RD-C6-1
RD/BK-C3B-2
RD-C3B-1
2
1
44B-RD/BK-C6-19 RD/BK-S.P.
RD-S.P.
PRI. BOOM DOWN
PRI. BOOM UP AUXILIARY SWITCH TS51 13480 5
12 V
D C B A BK/WH-8A TS63 ENGINE START SWITCH TS52 13037

12V TO PLAT
BK-7A LP/GAS SWITCH TS53 56457

GR/BK-44A
3 BR-GND STUD BK-33A TS62 FUNCTION ENABLE TS55 13037
C7B
1 BK-22C 16397
TS52 CB3
PLATFORM ROTATE SWITCH TS57
2 WH-23C
PLATFORM LEVEL SWITCH TS59 13037
BOOM EXTEND/RETRACT SWITCH TS63 13037
RD- 20C RD-CB3 SP
TS58
C3B C4B
RD-CR17#30 PRIMARY BOOM UP/DOWN SWITCH TS61 16397
R1
WH/BK-5A
WH/RD-6A CR23 TURNTABLE ROTATE SWITCH TS62 16397 6
19/18 CABLES
RD-24B WH-4A JIB BOOM UP/DOWN SWITCH TS58 13037

BK/RD-9B
CR1 CR2 CHECK ENGINE SWITCH TS22 42730
R2 RD C4B-11
BK-33B CIRCUIT BREAKER, CONTROLS, 15A CB1 CB1
C2B
D14 CB1 CB2 TS57 RD C4B-12 CIRCUIT BREAKER, ENGINE, 15A CB2 CB2
BK-C5-5 BRN GND CIRCUIT BREAKER, OPTIONS, 20A CB3 CB3
WH-21B
C1B
WH-C5-17 TS55 RESISTOR, 5 OHM, BOOM FUNCTION R1 R1

TS59 DRIVE LIGHT OPTION RELAY
D13 RESISTOR, 7.5 OHM,TURNTABLE FUNCT R2 R2
WH-C5-11 OR-C6-33 BK/RD-35A VOLT METER GAGE G1 G1

7
FUNCTIONS
BK-C6-16
TS22 RD- 20A OIL PRESSURE GAGE G2 G2
RD- 24A WATER TEMP. GAGE G3 G3
C6
RD- 20B
CHECK ENGINE L2 56298
RD- P1 E-STOP
CR5 OR/BK-15A HOUR METER HM HM
GR-43B RD-27B CR39 CR17
BK-C6-25
BK-22B OR-14A
GR-C5-12 RD-CB3 SP
GR-17A
ENGINE
WH-23B
GR/WH-19A
C5
GR/BK-18A
WIRING 8
HARNESS:
TO BASE
GROUND STUD
GROUND STUD
BR
ALL BR WIRES
Part No. 102521 S-40 • S-45 6 - 81


6 - 81
6 - 82

6 - 84
6 - 83
N
PART NUMBER
45383
PBOX WIRING
HARNESS
M
OPT.
COMPONENT INDEX
L
TILT ALARM
RD P2
LS18
RD H1
H1
C132PLI BK C1P-12
K
P23SWBAT WH C7P-2
P22BAT BK C7P-1
JIB
C19JSV GR/WH
J
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
I
P24FS WH C9P-2
JDALARM GR/BK C2P-6
C3P
C45GEN GR/WH C2P-7

F.S.
C9P
TS48-WL1 RD C2P-12
F.S.
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE BK/RD C3P-9
H
P26BAT BK
11
3
C6TRF WH/RD C3P-6

J3
C10SBU BL C3P-10
C13DRE BL/RD C4P-1
12V BATT
C11SBD BL/BK C3P-11
G
C7P
C12SBF BL/WH C3P-12
C30EDC+ WH C1P-4
C7P
BRN C1PBU RD C3P-1

C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C4P
F
C37STCC BL/BK C1P-11

ALC-500
C5TRR WH/BK C3P-5

C32BRK WH/RD C1P-6
C4P(BR)
C4TRL WH C3P-4
19/18 CONTROL CABLE

J2
C29MS RD/WH C1P-3

C3P
Part No. 102521

C134PWR RD C2P-4
C3P(GR)
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C2P
E
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
C2P(BK)
C1P
J1
9
JC1-3 OR
JC2-4 RD
JC1-2 BRN
C1P(GY)
D
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
C28TTA RD/BK C1P-2

S-40 • S-45
DRE B BL/BK
C
BATGND C7P-3
C13LED BL/RD
GR/BK C4P-4
C29MS RD/WH
D40
H1
RED/BLK-28
B
ALALRM
D39
GR/BK L48
TILT
RED-TILT RED-TILT
A
BRN
October 2013
6 - 84
1
8

(from serial number 7597 to11066)
1
10 AMP FUSE HARNESS

PBOX WIRING

TS48 / TS49
WORK / DRIVE LITE JC2
PRIMARY UP/DN , TURNTABLE ROTATE 62390
2
TS15
7 DRV.ENA 7 JC3 DRIVE PROPORTIONAL JOYSTICK 75565
6 6 P2 EMERGENCY STOP BUTTON 66812, 94506
P3 HORN SWITCH 66813, 66816
TS13 TS3 FUEL SELECT SWITCH (FORD EFI ONLY) 56457
4 PRIMARY 4
DLITE/ RD WL2
RD WL1 L4 CHASSIS TILT LED 56298
BOOM TS7 PLATFORM ROTATE SWITCH 16397 3
3 EXTEND/ 3 TS8 JIB UP/DOWN SWITCH 13037
TS9 PLATFORM LEVEL SWITCH 13037
RETRACT TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH 13037
2 2 TS14 DRIVE SPEED SWITCH 56457
JC2 JC3 TS47 GENERATOR SWITCH ( OPTION ) 27378
1 1 TS48-9 WORK/DRIVE LIGHT ( OPTION ) 27378
CR13
WH-24
+ + 4
L1 L4
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
BRN J1-12
BRN J1-14
BRN BATGND
RD/BK H1
OR J1-13
BK/WH-8
OR J1-11
WH J1-5
WH J1-5
RD-TILT
(GND STUD)
BK J1-2
RD J1-1
WH-JIB
BL J1-4
WH-24
BK-22
BK-7
BRN
CR27
5
WH TS7
WH TS1
P26BAT BK C9P-1
BK-33
BK/RD-35
RD
RD
BK-22
RD-TILT
P22BAT BK C7P-1
RD
C17JU GR C4P-5
BL/RD-39
C29MS RD/WH J1-8
OR-14
C19JSV GR/WH
RD-25
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C27AUX RD C1P-1
GR/WH-45
GR-43
OR/BK-15
WH-24
WH-24
WH-TS47
WH-JIB
WH-23
WH-TS4
WH-24
WH-24
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
6
OR R40LS1
GR TS4
NC NC NC
NO
1
2
3
4
2
WH HIGH/LOW
1
2
RPM
1
TS14 TS2 TS3 NOTE:
P3 WH TS47
TS9 TS8 TS1
HORN
DRIVE
GENERATOR
START FUEL SELECT P2 DASHED LINES INDICATE 7
PLATFORM JIB AUXILIARY SPEED RD EMERGENCY STOP
TS7 (OPTION) OPTION WIRES
LEVEL PUMP HIGH/LOW
PLATFORM
Part No. 102521 S-40 • S-45 6 - 85


6 - 85
6 - 86
Ford DSG-423 EFI Models
6 - 88
6 - 87
BRN
N
RD
RD
WH
BK
BL/WH
OR/BK
RD/BK
ESO433B
HIGH RPM(FS) C1-9

C35ESPD BK/RD
2
TS55
LOW RPM
M
FUNCTION ENA.
HIGH RPM
TS4
TB35
TS17
TB45
GENERATOR
Y29
GENERATOR
C2-7 C45GEN GR/WH C6-39 GR/WH
OPTION
L
CR23
TB9
C3-9 DLITE BK/RD

DRIVELIGHT
L29
F18
DRIVE LIGHT
FUSE 10A
RD
TS49
WH
C4B-12 OPTION
K
L29
L30
WORKLIGHT
PBOX GND
RD WORK LIGHTS
BK C4B-11 OPTION
CR23
NO
WH BK
L30
G1
VOLT METER
R21IGN WH
HM
HOUR METER
J
_
G6
OPS
TB25
C5-16 WH/BK
G2
OIL PRESSURE GAUGE

I
RESISTOR R4 REMOVED AT SERIAL NUMBER 11785 .

A GY/RD IN THE STOWED POSITION AND KEYSWITCH "OFF".
GY/YL
FORD ENGINE
DIAGNOSTIC
B
HARNESS
C RD
TB33
CR1
BK/BL GASOLINE SENSOR

D
TS22
C1-7 C33STR BK
TS2
RD/GN
ENGINE
START WH/BK
H
CR1
NO
LPG LOCKOUT
ENGINE
3
START
TS52
C5-3 C107AF WH
500 TO ALTERNATOR FIELD
R4
G3
TEMP GAUGE
RD
TB26
C2-1 C5-14 C26TSR WH/RD PIN 39

TB39
TS3
C5-12 C127TSW GR PIN 3

LP
CR2
NOTE:
FUEL
GAS C5-17 C21IGN WH PIN 16
1.
3
G
BK/RD PIN 23
TS53
C5-9 C35RPM
LP
CR2
FUEL
NO
C5-5 R33STR BK PIN 15

P24FS WH
P25FS RD
TB21
GAS
C28TTA RD/BK
C5-8 R21IGN WH PIN 24 FORD

P26ESTP BK
42 PIN PLUG
C135FP BL/WH PIN 5
FUEL PUMP
CR39
AUXILIARY
PUMP
FUEL
PUMP C135RET BL PIN 18
TS51
F
TS1
C5-11 VSW WH PIN 1

C9-2
CR39
C9-3
AUXILIARY
NC
PUMP
WH(FS)
RD(FS)
L2
Part No. 102521

1K
R3
FS1
C6-27 C27AUX RD AUXILIARY POWER

BK(FS)
RELAY
TB27
RD
PR1
E
PUMP
AUX
AUXILIARY PUMP
PR1
C1-1 C27AUX RD
NO
M2
C9-1 BK
TB23
TB24
C7-2 P23BAT WH
P2
TB28
L48
S7
C1-2 C28TTA RD/BK C6-28 RD/BK WH
TILT ALARM
D
C6-23 RD RD BK BRN
LEVEL SENSOR
H1
C133PLA OR/RD
FLASHING BEACONS
FB
OPTION
HORN
TB43
CR5
P3
C2-5 C43HRN GR SERVICE HORN

RELAY
S-40 • S-45
CR5
NO
P22BAT BK C7-1 C6-16 R43HRN BK
C
SERVICE HORN
H2
RD
OTS
CR17
NO
C6-25
HYDRAULIC OIL
TEMP. SWITCH
CR17
FAN M1
C6-34
NO
C6-33 C6-26 COOLING FAN
(OPTION)
TB42
C134PWR RD C2-4
C41RPM OR/BK C2-3 C5-2 C41RPM OR/BK PIN 2

TB41
TB22
RD
BLUE/PINK
FORD ENGINEHARNESS
CB1
CB3
PLAT
GRD
PR2 STARTER RELAY
TB 134 IS WAGO
TERMINAL BLOCK 42
KS1
20AMP.
15AMP.
1
2
3
STARTER MOTOR
PR2
B1
A
RD
RD
October 2013
P1
TB20
CB2
-
15AMP.
P20BAT RD
12 V
DC
6 - 88
1
8
6 - 89
1
BRN-2
GROUND
C41RPM OR/BK
ESO433
A
C2P-3
5
15
TS14
LO
Y51
TB30
DRIVE SPEED C1P-4 C30EDC+ WH C5-21 C30EDC+ WH A B

15 DRIVE EDC FORWARD
HI
8
C29MS RD/WH
B
L1
S-40 • S-45
J1

TB31
16
H4
C6-32
TS15

7
Y2

TB32
Y27
7 C1P-3 C29MS RD/WH C5-24 C29MS RD/WH

20 MOTOR STROKE
DRIVE & STEERING
RKOUT 6 WH 5
TB29
YOUT 5 BL 4
C
Y3
JC3

J1
4 18 STEER RIGHT
PWR 3 OR
TB37
13
GND 2 BRN 14
Y4
C1P-10 C36STC BL C6-36 C36STC BL

1 17 STEER LEFT
TB36
C3P-6 C6TRF WH/RD

11
C3P-5 C5TRR WH/BK
9
C3P-4 C4TRL WH
D
10
Y23
C6-4 C4TRL WH
LEFT
TB4
Y29
TT ROTATE
TS62

TB5
Y13
7 C6TRF WH/RD
C6-6 TURNTABLE ROTATE

R2
6 FLOW CONTROL
TB6
Part No. 102521
7.5
TB1
YOUT 5 BK 2
Y22
JC2
C1PBU RD
October 2013
XOUT 4 RD 1 C6-1
PRIMARY BOOM UP
J1
UP
TB2
PWR 3 OR 11
Y21
PRIMARY BOOM
E
DOWN C6-2 C2PBD RD/BK

TS61
J2

1
TB3
Y12

R1
FLOW CONTROL
5
6
C3P-1 C1PBU RD
7
C3P-2 C2PBD RD/BK
8
C3P-3 C3PBF RD/WH
C6-19 RD/BK
F

H4
14
13 WH
NCHO
LS2-PRIMARY BOOM UP
BK
SJ1-WH
BRN WH
NOHC

DRIVE LIMIT SWITCH
P24FS WH BK
G
2
TB13
J3
P24FS WH
NOHC
3 DRIVE ENABLE
P26ESTP BK
3 BK LIMIT SWITCH
4

TB40
WH
H
C6-30

CR27
CR30
NO
NC
OPTION
TB7
DRIVE
Y25
LIFT/
TS63
C6-7 C7PBE BK
CE
BOOM EXTEND
I
EXTEND
TB8
BOOM
Y26
RETRACT C8PBR BK/WH
NOTE:
C6-8 BOOM RETRACT
C3P-7 C7PBE BK
EXTEND
BOOM
C8PBR BK/WH
TS13
RETRACT C3P-8
C4P-2 C14PLU OR
UP
PLATFORM LEVEL
J
TS9
TB14
Y20
C14PLU OR
TS59
C6-14 PLAT LEVEL UP

UP
PLATFORM LEVEL
Y19
PLAT LEVEL DOWN
TB15
TB44
K
CR13
NC
C4P-6 C18JD GR/BK

DOWN
JIB BOOM
TB18
TS8
UP C4P-5 C17JU GR
Y16
TS58
C6-18 C18JD GR/BK
DOWN
Y17
JIB BOOM
UP C6-17 C17JU GR
TB17
L
TS57
RIGHT RIGHT
LEFT LEFT
TS7
WH
C4P-7
C19JSV GR/WH
TB19
JIB VALVES
CR13
C19JSV GR/WH
M
BRN
JIB VALVE
BL/WH
RD/BK
OR/BK
BRN
WH
RD
RD
N
BK
6 - 89
6 - 90
Section 6 • Schematics February 2012
6 - 92
6 - 91
BRN
N
RD
RD
WH
BK
BL/WH
OR/BK
RD/BK
ESO433C
HIGH RPM(FS) C1-9

C35ESPD BK/RD
2
TS55
LOW RPM
M
FUNCTION ENA.
HIGH RPM
TS4
TB35
TS17
TB45
GENERATOR
Y29
GENERATOR
C2-7 C45GEN GR/WH C6-39 GR/WH
OPTION
L
CR23
TB9
C3-9 DLITE BK/RD

DRIVELIGHT
L29
F18
DRIVE LIGHT
FUSE 10A
RD
TS49
WH
C4B-12 OPTION
K
L29
L30
WORKLIGHT
PBOX GND
RD WORK LIGHTS
BK C4B-11 OPTION
CR23
NO
WH BK
L30
G1
VOLT METER
R21IGN WH
HM
HOUR METER
J
_
G6
OPS
TB25
C5-16 WH/BK
G2
OIL PRESSURE GAUGE

CHECK ENGINE LAMP L2 CHANGED TO INCANDESCENT.

I
RESISTOR R3 REMOVED AT SERIAL NUMBER 13740.

GY/RD IN THE STOWED POSITION AND KEYSWITCH "OFF".
A
GY/YL
FORD ENGINE
DIAGNOSTIC
B
HARNESS
C RD
TB33
CR1
BK/BL GASOLINE SENSOR

D
TS22
C1-7 C33STR BK
TS2
RD/GN
ENGINE
START WH/BK
H
CR1
NO
LPG LOCKOUT
ENGINE
START
TS52
C5-3
G3
TEMP GAUGE
RD
TB26
C2-1 C5-14 C26TSR WH/RD PIN 39

TB39
TS3
C5-12 C127TSW GR PIN 3

LP
CR2
NOTE:
FUEL
GAS C5-17 C21IGN WH PIN 16
3
1.
G
BK/RD PIN 23
TS53
C5-9 C35RPM
LP
CR2
FUEL
NO
C5-5 R33STR BK PIN 15

P24FS WH
P25FS RD
TB21
GAS
C28TTA RD/BK
C5-8 R21IGN WH PIN 24 FORD

P26ESTP BK
42 PIN PLUG
C135FP BL/WH PIN 5
FUEL PUMP
CR39
AUXILIARY
PUMP
FUEL
PUMP C135RET BL PIN 18
TS51
F
TS1
C5-11 VSW WH PIN 1

C9-2
CR39
C9-3
AUXILIARY
NC
PUMP
L2
WH(FS)
RD(FS)
Part No. 102521

3
1K
R3
FS1
C6-27 C27AUX RD AUXILIARY POWER

BK(FS)
RELAY
TB27
RD
PR1
E
PUMP
AUX
AUXILIARY PUMP
PR1
C1-1 C27AUX RD
NO
M2
C9-1 BK
TB23
TB24
C7-2 P23BAT WH
P2
TB28
L48
S7
C1-2 C28TTA RD/BK C6-28 RD/BK WH
TILT ALARM
D
C6-23 RD RD BK BRN
LEVEL SENSOR
H1
C133PLA OR/RD
FLASHING BEACONS
FB
OPTION
HORN
TB43
CR5
P3

RELAY
S-40 • S-45
CR5
NO
P22BAT BK C7-1 C6-16 R43HRN BK
C
SERVICE HORN
H2
RD
OTS
CR17
NO
C6-25
HYDRAULIC OIL
TEMP. SWITCH
CR17
FAN M1
C6-34
NO
(OPTION)
TB42
C134PWR RD
C2-4
B
C41RPM OR/BK C2-3 C5-2 C41RPM OR/BK PIN 2

TB41
TB22
RD
BLUE/PINK
FORD ENGINEHARNESS
CB1
CB3
PLAT
GRD
PR2 STARTER RELAY
KS1
20AMP.
15AMP.
1
2
3
STARTER MOTOR
PR2
B1
RD
October 2013
RD
P1
TB20
CB2
-
15AMP.
P20BAT RD
12 V
6 - 92
DC
1
8
6 - 93
1
BRN-2 GROUND
C41RPM OR/BK
A
C2P-3
5
15
TS14
TB30
Y51
B
S-40 • S-45

L1
J1

16
TB31
H4
C6-32
TS15

Y2

TB32
Y27

20 MOTOR STROKE
C
TB29
TB37
Y3
DRIVE & STEERING

18 STEER RIGHT
RKOUT 5 BL/WH
Y4
YOUT 4 WH/RD 4 C1P-10 C36STC BL C6-36 C36STC BL

17 STEER LEFT
XOUT 3 BL/WH 5
TB36
J1
PWR 2 OR 13
GND 1 BRN 14
C3P-6 C6TRF WH/RD
11
JC3
C3P-5 C5TRR WH/BK

9
D
C3P-4 C4TRL WH
Y23
10
C6-4 C4TRL WH
LEFT TT ROTATE
Y29
TB4

TS62

TB5
Y13

Part No. 102521
FLOW CONTROL
R2
TB6
7.5
Y22
TB1
October 2013
6 C1PBU RD
C6-1 PRIMARY BOOM UP
5 UP PRI BOOM
TB2
E
Y21
YOUT 4 RD/WH 2 DOWN C6-2 C2PBD RD/BK

TS61
J2
PRIMARY BOOM DOWN

XOUT 3 WH/RD 1
J1
TB3
PWR 2 OR 11
Y12
GND 1 BRN 12 C6-3 C3PBF RD/WH PRIMARY BOOM

R1
FLOW CONTROL
5
6
JC2
C3P-1 C1PBU RD
7
C3P-2 C2PBD RD/BK
8
C3P-3 C3PBF RD/WH
C6-19 RD/BK
F
DESCENT ALARM
H4
14
13 WH
LS2-PRIMARY BOOM UP
NCHO

SJ1-WH
BK
BRN WH
NOHC

2
TB13
G
J3
P24FS WH
NOHC
3 DRIVE ENABLE
P26ESTP BK 3

BK LIMIT SWITCH
4
TB40
WH
C6-30
H

CR27
CR30
OPTION
NO
NC
DRIVE
TB7
LIFT/
Y25
TS63
C7PBE BK
CE
C6-7
BOOM EXTEND
EXTEND
TB8
BOOM
Y26
I
BOOM RETRACT
C3P-7 C7PBE BK
EXTEND
BOOM
C8PBR BK/WH
TS13
RETRACT C3P-8
NOTE:
C4P-2 C14PLU OR
UP
PLAT LEVEL
TB14

TS9
Y20
C14PLU OR
TS59
C6-14 PLAT LEVEL UP

J
UP
Y19
PLAT LEVEL
PLAT LEVEL DOWN
TB15
GR/BK-44 C2P-6 JDALARM GR/BK TB44
K
CR13
NC
C4P-6 C18JD GR/BK

DOWN
TB18
Y16
UP C4P-5
TS8
C17JU GR
TS58
JIB BOOM C6-18 C18JD GR/BK
DOWN
Y17
TB17
TS57
PLAT ROTATE
RIGHT RIGHT
PLAT ROTATE
L
LEFT LEFT
TS7
WH
C4P-7
C19JSV GR/WH
TB19
C19JSV GR/WH
CR13 JIB VALVES
BRN
M
JIB VALVE
BL/WH
RD/BK
OR/BK
BRN
WH
RD
RD
BK
N
6 - 93
6 - 94
6 - 96
6 - 95
N
BL/WH
RD/BK
OR/BK
WH
RD
BK
RD
RD
BR
D12
HIGH RPM(FS) C1-9

M
C35RPM BK/RD
TS55
LOW RPM
D14
FUNCTION ENA.
ENG SPEED HIGH RPM
TS4
TB35
D13
L
TS17
TB45
GENERATOR
Y29
C6-39 GENERATOR
C2-7
C45GEN GR/WH C45GEN GR/WH OPTION
C3-9
DLITE BK/RD
L29
CR23
TB9
RD DRIVE LIGHT
L30
PBOX GND
K
C4-11
OPTION
FUSE 10A
C4B-12
TS49
WH BK
L29
RD WORK LIGHTS
F18
C4B-10
CR23
C4-9
OPTION
NO
WH BK
L30
VOLT METER
G1
J
HM
R21IGN WH HOUR METER

+
_
G6
OPS
C5-16
TB25
WH/BK
I
G2
OIL PRESSURE GAUGE

A GY/RD
FORD ENGINE
B GY/YL
DIAGNOSTIC
HARNESS
GASOLINE SENSOR
C RD
TB33
CR1
C1-7 D BK/BL
TS22
TS2
C33STR BK
H
RD/GR
LPG LOCKOUT
WH/BK
ENGINE
CR1
NO
START
TS52
G3
TEMP GAUGE
RD
TB26
C2-1 C5-14
C26TSR WH/RD PIN 39
TB39
D11
C5-12
TS3
C127TSW GR PIN 3
G
CR2
C5-17
C21IGN WH PIN 16
C5-9
TS53
D10
C35RPM BK/RD PIN 23

CR2
NO
C5-5
R33STR BK PIN 15
TB21
C5-8 FORD
P24FS WH
C28TTA RD/BK
P25FS RD
P26ESTP BK
R21IGN WH PIN 24 42 PIN PLUG

C5-10
C39LP BL/RD PIN 7
TS51
D4
FUEL PUMP
C135FP BL/WH PIN 5

CR39
F
PUMP
FUEL
C135RET BL PIN 18
TS1
THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF".

C5-11
VSW WH PIN 1
CR39
FS1 C9-3
C9-2
NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH

NC
C5-13
Part No. 102521

C38ESL BL/WH PIN 6
L2
BK
C9-1
E
C6-27 AUXILIARY POWER

RD C27AUX RD RELAY
PR1
TB27
M2 PUMP
AUX
AUXILIARY PUMP
C1-1
PR1
NO
C27AUX RD
TB23
TB24
C7-2
P23BAT WH
P2
TB28
L48
S7
D
C1-2 C6-28
C28TTA RD/BK RD/BK WH TILT ALARM
C6-23
D40
RD RD BK BR LEVEL SENSOR
D2
H1
FLASHING BEACONS
FB
OPTION
HORN
TB43
CR5 CR5
P3
C2-5 SERVICE HORN
S-40 • S-45
C43HRN GR
RELAY
NO
C6-16
C
P22BAT BK C7-1
R43HRN BK SERVICE HORN
H2
OTS
CR17
NO
RD
C6-25
HYDRAULIC OIL
TEMP. SWITCH
CR17
FAN M1
C6-34
NO
TB42
C2-4 (OPTION)
P134PWR RD
C2-3 C5-2
C41RPM OR/BK C41RPM OR/BK PIN 2 42 PIN FORD CONNECTOR
TB41
TB22
RD
BLUE/PINK FORD ENGINE
CB1
CB3
PLAT
PR2
GRD
STARTER RELAY
STARTER
KS1
20AMP.
15AMP.
STARTER MOTOR
1
2
3
PR2
B1
RD
RD
October 2013
P1
TB20
CB2
-
15AMP.
P20BAT RD
12 V
6 - 96
DC
1
8
6 - 97
1
BR-2 GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
LO
Y51
TB30
DRIVE SPEED C1-4 C5-21 A B

15 C30EDC+ WH C30EDC+ WH DRIVE EDC FORWARD
L1 HI
C29MS RD/WH 8
B
J1
S-40 • S-45
C1-5 C5-20 D C
DRE LED BL/RD 16
TB31
H4
C6-32
TS15

DRIVE ENABLE
Y2
C1-6 C5-23
DRE A BL/WH 6 19 C32BRK WH/RD C32BRK WH/RD BRAKE RELEASE VALVE
TB32
Y27
C1-3 C5-24
TB29
Y3
C
C1-11 C6-37
18 C37STCC BL/BK C37STCC BL/BK STEER CCW
TB37
Y4
C1-10 C6-36 STEER CW

TB36
6
DRIVE & STEERING
RKOUT 5 BL/WH
C3-6
YOUT 4 WH/RD 4 11 C6TRF WH/RD
XOUT 3 BL/WH 5
J1
PWR 2 OR 13 C3-5
9 C5TRR WH/BK
GND1 BRN 14 C3-4
10 C4TRL WH
Y23
D

JC3
TB4
Y29
C6-5
TS62

TB5
Y13

R2
FLOW CONTROL
TB6
TB1
7.5
Part No. 102521
Y21 Y22
PRIMARY BOOM C6-1 C1PBU RD PRIMARY BOOM UP

UP
October 2013
TB2
DOWN C6-2
TS61
J2

E
TB3
6
Y12
5 C6-3 PRIMARY BOOM

C3PBF RD/WH
R1
FLOW CONTROL
YOUT 4 RD/WH 2 5
XOUT 3 1
D30
WH/RD
J1
PWR 2 6 C1PBU RD
OR 11 C3-1
GND 1 BRN 12 7 C2PBD RD/BK
C3-2
8 C3PBF RD/WH
C3-3
JC2
C6-19
RD/BK DESCENT ALARM
H4
F
14
D29
13
NO
NC
WH
14 13
22 21
LS2-PRIMARY BOOM UP
2 1
BK
SJ1-WH
NO
NC
14 13
22 21

BR 1
WH DRIVE LIMIT SWITCH
2 1
BK
P24FS WH 2
J3
TB13
NO
4
G
P24FS WH
NC
13
22 21

DRIVE ENABLE
3 C4-1 C6-13 WH LIMIT SWITCH
P26ESTP BK 3
4 3
14
C13DRE BL/RD C13DRE BL/RD BK

C2-2 C6-40
TB40
WH
C6-30
H
CR27
CR30
NO
NC
OPTION
TB7
DRIVE
Y25
LIFT/
TS63
C6-7
CE

EXTEND
TB8
BOOM
Y26
RETRACT C6-8
C8PBR BK/WH BOOM RETRACT
I
C3-7
C7PBE BK
EXTEND
BOOM
RETRACT C3-8
TS13
C8PBR BK/WH
C4-2
C14PLU OR
UP PLATFORM LEVEL
DOWN
TB14
C4-3
TS9
C15PLD OR/BK
Y19 Y20
TS59
C6-14
C14PLU OR PLAT LEVEL UP
J
UP PLATFORM LEVEL
DOWN C6-15
C15PLD OR/BK PLAT LEVEL DOWN
TB15
TB44
C2-6
K
CR13
D27
NC
C4-6
C18JD GR/BK
DOWN
TB18
UP JIB BOOM C4-5
TS8
C17JU GR
Y16
D28
TS58
C6-18
DOWN
Y17
UP JIB BOOM C6-17
TB17
TS57
PLAT ROTATE
CCW CCW
L
CW CW PLAT ROTATE
TS7
WH
C4-7
C19JSV GR/WH
CR13
TB19
+
M
-
BR JIB VALVES
GR/WH
CR14
NO
JIB VALVE
BR
RD
RD
BL/WH
RD/BK
OR/BK
WH
RD
BK
N
6 - 97
6 - 98
Ford DSG-423 EFI Models- ANSI / CSA / AS
6 - 100
6 - 99
N
BL/WH
RD/BK
OR/BK
WH
RD
BK
RD
RD
BR
D12
M
HIGH RPM(FS) C1-9

C35RPM BK/RD
TS55
LOW RPM
D14
FUNCTION ENA.
ENG SPEED HIGH RPM
TS4
D13
TB35
L
TS17
TB45
GENERATOR
Y29
C6-39 GENERATOR
C2-7
C3-9
DLITE BK/RD
L29
CR23
TB9
RD DRIVE LIGHT
K
L30
PBOX GND
C4-11
OPTION
FUSE 10A
C4B-12
TS49
WH BK
L29
RD WORK LIGHTS
F18
C4B-10
CR23
C4-9
OPTION
NO
WH BK
L30
G1
VOLT METER
J
HM

+
_
G6
OPS
C5-16
TB25
WH/BK
10A
NO
G2
I
OIL PRESSURE GAUGE

2 SEC
U34
P24PWR
C3-10
R24PWR
A GY/RD
FORDENGINE
B GY/YL
DIAGNOSTIC
HARNESS
GASOLINE SENSOR
C RD
TB33
CR1
D BK/BL
TS22
C1-7
TS2
C33STR BK
RD/GR
H
LPG LOCKOUT
WH/BK
ENGINE
CR1
NO
START
TS52

G3

TEMP GAUGE
STARTER RELAY PR8 ADDED AT SERIAL NUMBER 15703

C132PLI2 BK
RD
TB26
C2-1 C5-14
C26TSR WH/RD PIN 39
TB39
D11
C5-12
TS3
C127TSW GR PIN 3
CR2
G
C5-17
C21IGN WH PIN 16
C5-9
TS53
D10
C35RPM BK/RD PIN 23

P26ESTP BK
CR2
NO
C5-5
42 PIN PLUG
P24FS WH
P25FS RD
R33STR BK PIN 15
TB21
C5-8
R21IGN WH PIN 24
FORD
C5-10
C39LP BL/RD PIN 7
TS51
D4
C28TTA RD/BK
FUEL PUMP
C135FP BL/WH PIN 5

CR39
PUMP
FUEL
C135RET BL PIN 18
F
TS1
C5-11
VSW WH PIN 1
CR39
FS1 C9-3
C9-2
NC
C1-1
C5-13
C38ESL BL/WH PIN 6
Part No. 102521

L2
1
2
BK

RD C27AUX RD
C9-1
RELAY
TB27
PR1
BK
PUMP
M2 AUX
AUXILIARY PUMP
30A
E
NO
PR1
NO
PBOX GND
2 SEC
C27AUX RD WORK LIGHT RELAY (OPTION)

U35
C7-2
P23BAT WH
TB23
P2
S7
C6-28
C1-2 WH
C28TTA RD/BK RD/BK TILT ALARM
+
D
D40
TB28
H1
C6-23
RD BK BR LEVEL SENSOR
D2
D39
4.7K
R20
GR/BK C4-4 FLASHING BEACONS
TB24
C133PLA OR/RD
L4
FB
OPTION
HORN
TB43
CR5 CR5
P3

RELAY
NO
S-40 • S-45
C6-16
RD
LS18A

LS18
C
H2
GN/BK
C7-1
TB133
P22BAT BK
OTS
RD
CR17
NO
L45
C6-25
TB132
HYDRAULIC OIL
D89
D88
TEMP. SWITCH
U33 8
5
CR17
FAN M1
C6-34
3
C1-12
NO
MODULE
C132PLI1 BL/WH C6-33 C6-26 COOLING FAN
SENSE
6 LOAD
(OPTION)
1
P134PWR RD C2-4
PBOX
GND
H6
4
12
B
C2-3 C5-2
TB134
GND BR
TB41
BLUE/PINK FORDENGINE
TB22
RD
PR8
NO
CB1
CB3
RD 12
PLAT
PR2
GRD
STARTER RELAY
STARTER
GBOX GND
KS1
20AMP.
15AMP.
STARTER MOTOR
1
2
3
PR2
B1
RD
RD
P1
TB20
CB2
-
October 2013
15AMP.
P20BAT RD
12 V
DC
6 - 100
1
8
6 - 101
1
BR-2 GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
LO
Y51
TB30

L1 HI
C29MS RD/WH 8
B
J1
S-40 • S-45
C1-5 C5-20 D C
DRE LED BL/RD 16
TB31
H4
C6-32
TS15

DRIVE ENABLE
Y2
C1-6 C5-23
TB32
Y27
C1-3 C5-24
TB29
C
Y3
C1-11 C6-37
TB37
Y4

TB36
6
DRIVE & STEERING
RKOUT 5 BL/WH
C3-6
XOUT 3 BL/WH 5
J1
PWR 2 OR 13 C3-5
9 C5TRR WH/BK
GND1 BRN 14 C3-4
10 C4TRL WH
Y23
D

JC3
TB4
Y29
C6-5
TS62

TB5
Y13

R2
FLOW CONTROL
TB6
TB1
7.5
Part No. 102521
Y21 Y22

October 2013
UP
TB2
DOWN C6-2
TS61
J2

E
TB3
6
Y12
5 C6-3 PRIMARY BOOM

C3PBF RD/WH
R1
FLOW CONTROL
YOUT 4 RD/WH 2 5
XOUT 3 1
D30
WH/RD
J1
PWR 2 6 C1PBU RD
OR 11 C3-1
C3-2
8 C3PBF RD/WH
C3-3
JC2
C6-19
RD/BK DESCENT ALARM
H4
F
14
D29
13
NO
NC
WH
14 13
22 21
LS2-PRIMARY BOOM UP
2 1
BK
SJ1-WH
NO
NC
14 13
22 21

BR 1
2 1
BK
P24FS WH 2
J3
TB13
NO
G
P24FS WH 4
NC
13
22 21

DRIVE ENABLE
P26ESTP BK 3
4 3
14

C2-2 C6-40
TB40
WH
C6-30
H
CR27
CR30
NO
NC
OPTION
TB7
DRIVE
Y25
LIFT/
TS63
C6-7
CE

EXTEND
TB8
BOOM
Y26
RETRACT C6-8 BOOM RETRACT
I
C8PBR BK/WH
C3-7
C7PBE BK
EXTEND
BOOM
RETRACT C3-8
TS13
C8PBR BK/WH
C4-2
C14PLU OR
UP PLATFORM LEVEL
DOWN
TB14
C4-3
TS9
C15PLD OR/BK
Y19 Y20
TS59
C6-14
J
UP PLATFORM LEVEL
DOWN C6-15
TB15
TB44
C2-6
K
CR13
D27
NC
C4-6
C18JD GR/BK
DOWN
TB18
UP JIB BOOM C4-5
TS8
C17JU GR
Y16
D28
TS58
C6-18
DOWN
Y17
UP JIB BOOM C6-17
TB17
TS57
PLAT ROTATE
CCW CCW
L
CW CW PLAT ROTATE
TS7
WH
C4-7
C19JSV GR/WH
CR13
TB19
+
M
-
BR JIB VALVES
GR/WH
CR14
NO
JIB VALVE
BR
RD
RD
BL/WH
RD/BK
OR/BK
WH
RD
BK
N
6 - 101
6 - 102
Ford DSG-423 EFI Models- CE
6 - 104
6 - 103
N
BL/WH
RD/BK
OR/BK
WH
RD
BK
RD
RD
BR
D12
M
HIGH RPM(FS) C1-9

C35RPM BK/RD
TS55
LOW RPM
D14
FUNCTION ENA.
ENG SPEED HIGH RPM
TS4
D13
TB35
L
TS17
TB45
GENERATOR
Y29
C6-39 GENERATOR
C2-7
C3-9
DLITE BK/RD
L29
CR23
TB9
RD DRIVE LIGHT
K
L30
PBOX GND
C4-11
OPTION
FUSE 10A
C4B-12
TS49
WH BK
L29
RD WORK LIGHTS
F18
C4B-10
CR23
C4-9
OPTION
NO
WH BK
L30
G1
VOLT METER
J
HM

+
_
G6
OPS
C5-16
TB25
WH/BK
10A
NO
I
G2
OIL PRESSURE GAUGE

2 SEC
U34
P24PWR
C3-10
R24PWR
A GY/RD
FORDENGINE
B GY/YL
DIAGNOSTIC
HARNESS
GASOLINE SENSOR
C RD
TB33
CR1
D BK/BL
TS22
C1-7
TS2
C33STR BK
H
RD/GR
LPG LOCKOUT
WH/BK
ENGINE
CR1
NO
START
TS52

G3

TEMP GAUGE
STARTER RELAY PR8 ADDED AT SERIAL NUMBER 15703

C132PLI2 BK
RD
TB26
C2-1 C5-14
C26TSR WH/RD PIN 39
TB39
D11
C5-12
TS3
C127TSW GR PIN 3
CR2
G
C5-17
C21IGN WH PIN 16
C5-9
TS53
D10
C35RPM BK/RD PIN 23

P26ESTP BK
CR2
NO
C5-5
42 PIN PLUG
P24FS WH
P25FS RD
R33STR BK PIN 15
TB21
C5-8
R21IGN WH PIN 24
FORD
C5-10
C39LP BL/RD PIN 7
TS51
D4
C28TTA RD/BK
FUEL PUMP
C135FP BL/WH PIN 5
CR39
PUMP
FUEL
F
C135RET BL PIN 18
TS1
C5-11
VSW WH PIN 1
CR39
FS1 C9-3
C9-2
NC
C1-1
C5-13
Part No. 102521

C38ESL BL/WH PIN 6
L2
1
2
BK

RD C27AUX RD
C9-1
RELAY
TB27
PR1
BK
E
PUMP
M2 AUX
AUXILIARY PUMP
30A
NO
PR1
NO
PBOX GND
2 SEC

U35
C7-2
P23BAT WH
TB23
P2
S7
C6-28
C1-2
D

+
D40
TB28
H1
C6-23
D2
D39
4.7K
R20
TB24
C133PLA OR/RD
L4
FB
OPTION
HORN
TB43
CR5 CR5
P3
RELAY
S-40 • S-45
NO
C6-16
RD
LS18A
C

LS18
H2
GN/BK
C7-1
TB133
P22BAT BK
OTS
RD
CR17
NO
L45
C6-25
TB132
HYDRAULIC OIL
D89
D88 TEMP. SWITCH
U33 8
5
CR17
FAN M1
C6-34
3
C1-12
NO
MODULE
SENSE
6 LOAD
(OPTION)
1
P134PWR RD C2-4
PBOX
GND
H6
B
12
C2-3 C5-2
TB134
GND BR
TB41
TB22
RD
PR8
NO
CB1
CB3
RD 12
PLAT
PR2
GRD
STARTER RELAY
STARTER
GBOX GND
KS1
20AMP.
15AMP.
STARTER MOTOR
1
2
3
PR2
B1
B
A
RD
RD
October 2013
P1
TB20
CB2
-
15AMP.
P20BAT RD
12 V
DC
6 - 104
1
8
6 - 105
1
BR-2 GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
LO
Y51
TB30

L1 HI
C29MS RD/WH 8
B
S-40 • S-45
J1
C1-5 C5-20 D C
DRE LED BL/RD 16
TB31
H4
C6-32
TS15

DRIVE ENABLE
Y2
C1-6 C5-23
TB32
Y27
C1-3 C5-24
TB29
C
Y3
C1-11 C6-37
TB37
Y4

TB36
6
DRIVE & STEERING
RKOUT 5 BL/WH
C3-6
XOUT 3 BL/WH 5
J1
PWR 2 OR 13 C3-5
9 C5TRR WH/BK
GND1 BRN 14 C3-4
10 C4TRL WH
D
Y23

JC3
TB4
Y29
C6-5
TS62

TB5
Y13

R2
FLOW CONTROL
TB6
Part No. 102521

TB1
7.5
Y21 Y22

October 2013
UP
TB2
DOWN C6-2
TS61
J2
PRIMARY BOOM DOWN

E
C2PBD RD/BK
TB3
6
Y12
5 C6-3 PRIMARY BOOM

C3PBF RD/WH
R1
FLOW CONTROL
YOUT 4 RD/WH 2 5
XOUT 3 1
D30
WH/RD
J1
PWR 2 6 C1PBU RD
OR 11 C3-1
C3-2
8 C3PBF RD/WH
C3-3
JC2
C6-19
RD/BK DESCENT ALARM
F
H4
14
D29
13
NO
NC
WH
14 13
22 21
LS2-PRIMARY BOOM UP
2 1
BK
SJ1-WH
NO
NC
14 13
22 21

BR 1
2 1
BK
P24FS WH 2
J3
G
TB13
NO
P24FS WH 4
NC
14 13
22 21

DRIVE ENABLE
P26ESTP BK 3
4 3

C2-2 C6-40
TB40
WH
C6-30
H
CR27
CR30
NO
NC
OPTION
TB7
DRIVE
Y25
LIFT/
TS63
C6-7
CE

EXTEND
TB8
BOOM
Y26
RETRACT C6-8
I

C3-7
C7PBE BK
EXTEND
BOOM
RETRACT C3-8
TS13
C8PBR BK/WH
C4-2
C14PLU OR
UP PLATFORM LEVEL
DOWN C4-3 TB14
TS9
C15PLD OR/BK
Y19 Y20
TS59
C6-14
J

UP PLATFORM LEVEL
DOWN C6-15
TB15
TB44
C2-6
K
CR13
D27
NC
C4-6
C18JD GR/BK
DOWN
TB18
UP JIB BOOM C4-5
TS8
C17JU GR
Y16
D28
TS58
C6-18
DOWN
Y17
UP JIB BOOM C6-17
TB17
TS57
PLAT ROTATE
L
CCW CCW
CW CW PLAT ROTATE
TS7
WH
C4-7
CR13 C19JSV GR/WH
TB19
+
M
-
BR
JIB VALVES
GR/WH
CR14
NO
JIB VALVE
BR
RD
RD
BL/WH
RD/BK
OR/BK
WH
RD
BK
N
6 - 105
6 - 106
6 - 108
6 - 107
N
BL/WH
RD/BK
OR/BK
WH
RD
BK
RD
RD
BR
D12
M
HIGH RPM(FS) C1-9

C35RPM BK/RD
ES0433K
TS55
LOW RPM
D14
FUNCTION ENA.
ENG SPEED HIGH RPM
TS4
TB35
D13
L
TS17
TB45
GENERATOR
1
2
Y29
C6-39 GENERATOR
C2-7
WORK LIGHTS
WH BK BR
OPTION
L30
LIGHTS PACKAGE
L29
CR23
WH BK DRIVE LIGHT
K
RD
C4B-12 OPTION
C4B-11
L30
L29
RD
C4B-10
FUSE 10A
CR23
NO
C4B-9
J
VOLT METER
HM G1

+
_
G6
OPS
C5-16
TB25
WH/BK
I
G2
OIL PRESSURE GAUGE

A GY/RD
FORD ENGINE
B GY/YL
DIAGNOSTIC
HARNESS
GASOLINE SENSOR
C RD
TB33
CR1
C1-7 D BK/BL
H
TS22
TS2
C33STR BK
RD/GR
LPG LOCKOUT
WH/BK
ENGINE
CR1
DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453

NO
START
TS52

G3
TEMP GAUGE
RD
TB26
C2-1 C5-14
C26TSR WH/RD PIN 39
TB39
D11
G
C5-12
TS3
C127TSW GR PIN 3
CR2
C5-17
C21IGN WH PIN 16
C5-9
TS53
D10
C35RPM BK/RD PIN 23

CR2
NO
C5-5
42 PIN PLUG
R33STR BK PIN 15
TB21
C5-8
P24FS WH
C28TTA RD/BK
P25FS RD
P26ESTP BK
R21IGN WH PIN 24
FORD
C5-10
C39LP BL/RD PIN 7
TS51
D4
FUEL PUMP
C135FP BL/WH PIN 5

F
CR39
PUMP
FUEL
C135RET BL PIN 18
TS1
RD C5-11
VSW WH PIN 1
CR39
FS1 C9-3
C9-2
Part No. 102521

NC
C5-13
C38ESL BL/WH PIN 6
L2
1
2
CR45
BK
E
WORK LIGHTS RELAY (OPTION)

C9-1
CR45
NO
C1-1 C6-27 AUXILIARY POWER
C27AUX RD C27AUX RD
TB27 RELAY
PR1
M2 PUMP
TB23
TB24
AUX
AUXILIARY PUMP
PR1
C7-2
NO
P23BAT WH
P2
TB28
D
L48
S7
C1-2 C6-28
C6-23
D40
RD RD BK BR LEVEL SENSOR
D2
H1
D39
C4-4 FLASHING BEACONS
FB
C133PLA OR/RD OPTION
HORN
TB43
CR5 CR5
S-40 • S-45
P3
C2-5 SERVICE HORN
C43HRN GR RELAY
C
NO
RD
C7-1 C6-16
P22BAT BK
TB133
GR/BK
H2
OTS
CR17
NO
RD
TB132
C6-25
HYDRAULIC OIL
8
5
7
TEMP. SWITCH
CR17
FAN M1
3
C1-12 C6-34
C132PLI1 BL/WH
NO
CONN.
C6-33 C6-26
PLUG
COOLING FAN
C32
1
C2-4 (OPTION)
P134PWR RD
TB134
12
6
C2-3 C5-2
GND BR
TB41
TB22
RD
PR8
NO
CB1
CB3
PLAT
PR2
GRD
STARTER
STARTER RELAY
RD
GBOX GND
A
KS1
20AMP.
15AMP.
STARTER MOTOR
1
2
3
PR2
B1
B
October 2013
RD
RD
P1
TB20
CB2
-
15AMP.
P20BAT RD
6 - 108
12 V
DC
1
8
6 - 109
1
BR-2 GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
LO
Y51
TB30

L1 HI
C29MS RD/WH 8
B
S-40 • S-45
J1
C1-5 C5-20 D C
DRE LED BL/RD 16
TB31
H4
C6-32
TS15

DRIVE ENABLE
Y2
C1-6 C5-23
TB32
Y27
C1-3 C5-24
TB29
C
Y3
C1-11 C6-37
TB37
Y4

TB36
6
DRIVE & STEERING
RKOUT 5 BL/WH
C3-6
XOUT 3 BL/WH 5
J1
PWR 2 OR 13 C3-5
9 C5TRR WH/BK
GND1 14 C3-4
D
BRN
10 C4TRL WH
Y23

JC3
TB4
Y29
C6-5
TS62

TB5
Y13

R2
FLOW CONTROL
TB6
Part No. 102521

TB1
7.5
Y21 Y22
PRIMARY BOOM
October 2013

UP
TB2
DOWN
E
C6-2
TS61
J2

TB3
6
Y12
5 C6-3 PRIMARY BOOM

C3PBF RD/WH
R1
FLOW CONTROL
YOUT 4 RD/WH 2 5
XOUT 3 1
D30
WH/RD
J1
PWR 2 6 C1PBU RD
OR 11 C3-1
C3-2
8 C3PBF RD/WH
C3-3
JC2
C6-19
RD/BK DESCENT ALARM
F
H4
14
D29
13
NO
NC
WH
14 13
22 21
LS2-PRIMARY BOOM UP
2 1
BK
SJ1-WH
NO
NC
14 13
22 21

BR 1
2 1
BK
P24FS WH 2
G
J3
TB13
NO
P24FS WH 4
NC
13
22 21

DRIVE ENABLE
P26ESTP BK 3
4 3
14

C2-2 C6-40
TB40
WH
C6-30
H
CR27
CR30
NO
NC
OPTION
TB7
DRIVE
Y25
LIFT/
TS63
C6-7
CE

EXTEND
TB8
BOOM
Y26
I
RETRACT C6-8
C3-7
C7PBE BK
EXTEND
BOOM
RETRACT C3-8
TS13
C8PBR BK/WH
C4-2
C14PLU OR
UP PLATFORM LEVEL
DOWN
TB14
C4-3
TS9
C15PLD OR/BK
Y19 Y20
J
TS59
C6-14
UP PLATFORM LEVEL
DOWN C6-15
TB15
TB44
C2-6
K
CR13
D27
NC
C4-6
C18JD GR/BK
DOWN
TB18
UP JIB BOOM C4-5
TS8
C17JU GR
Y16
D28
TS58
C6-18
DOWN
Y17
UP JIB BOOM C6-17
TB17
TS57
PLAT ROTATE
L
CCW CCW
CW CW PLAT ROTATE
TS7
WH
C4-7
C19JSV GR/WH
CR13
TB19
M
+
-
BR
JIB VALVES
GR/WH
CR14
NO
JIB VALVE
BR
RD
RD
BL/WH
RD/BK
OR/BK
WH
RD
BK
N
6 - 109
6 - 110
6 - 112
6 - 111
N
BL/WH
RD/BK
OR/BK
WH
RD
BK
RD
RD
BR
D12
C1-9
M
HIGH RPM(FS)
C35RPM BK/RD
TS55
LOW RPM
D14
FUNCTION ENA.
ENG SPEED HIGH RPM
TS4
D13
TB35
L
TS17
TB45
1
2
GENERATOR
Y29
C6-39 GENERATOR
C2-7
WORK LIGHTS
WH BK BR
OPTION
L30
LIGHTS PACKAGE
L29
CR23
WH BK DRIVE LIGHT
RD
K
C4B-12 OPTION
C4B-11
L30
L29
RD
FUSE 10A
C4B-10
CR23
NO
C4B-9
G1
VOLT METER
J
HM

+
_
G6
OPS
C5-16
TB25
WH/BK
10A
NO
G2
OIL PRESSURE GAUGE

I
2 SEC
U34
P24PWR
C3-10
R24PWR
A GY/RD
FORDENGINE
B GY/YL
DIAGNOSTIC
HARNESS
GASOLINE SENSOR
C RD
TB33
CR1
D BK/BL
TS22
C1-7
TS2
C33STR BK
RD/GR
H
LPG LOCKOUT
WH/BK
DIODE BETWEEN TB35 AND TB45 ADDED AT SERIAL NUMBER 16453

ENGINE
CR1
NO
START
TS52

G3

TEMP GAUGE
C132PLI2 BK
RD
TB26
C2-1 C5-14
C26TSR WH/RD PIN 39
TB39
D11
C5-12
TS3
C127TSW GR PIN 3
CR2
G
C5-17
C21IGN WH PIN 16
C5-9
TS53
D10
C35RPM BK/RD PIN 23

P26ESTP BK
CR2
NO
C5-5
42 PIN PLUG
P24FS WH
P25FS RD
R33STR BK PIN 15
TB21
C5-8
R21IGN WH PIN 24
FORD
C5-10
C39LP BL/RD PIN 7
TS51
D4
C28TTA RD/BK
FUEL PUMP
C135FP BL/WH PIN 5
CR39
PUMP
FUEL
C135RET BL PIN 18
F
TS1
C5-11
VSW WH PIN 1
CR39
FS1 C9-3
C9-2
NC
C1-1
C5-13
C38ESL BL/WH PIN 6
Part No. 102521

L2
1
2
BK

RD C27AUX RD
C9-1
RELAY
TB27
PR1
BK
PUMP
M2 AUX
E
AUXILIARY PUMP
30A
NO
PR1
NO
CR45
PBOX GND
2 SEC

U35
CR45
C7-2
NO
P23BAT WH
TB23
P2
S7
C6-28
C1-2 WH
C28TTA RD/BK RD/BK TILT ALARM
D
D40
TB28
H1
C6-23
D2
D39
4.7K
R20
TB24
C133PLA OR/RD
L4
FB
OPTION
HORN
TB43
CR5 CR5
P3

RELAY
NO
S-40 • S-45
C6-16
RD
LS18A

LS18
C
H2
GN/BK
C7-1
TB133
P22BAT BK
OTS
RD
CR17
NO
L45
C6-25
TB132
HYDRAULIC OIL
D89
D88
TEMP. SWITCH
U33 8
5
7
CR17
FAN M1
C6-34
3
C1-12
NO
MODULE
SENSE
6 LOAD
(OPTION)
1
P134PWR RD C2-4
PBOX
GND
H6
4
12
C2-3 C5-2
TB134
GND BR
TB41
TB22
RD
PR8
NO
CB1
CB3
PLAT
PR2
GRD
STARTER RELAY
RD
STARTER
GBOX GND
KS1
20AMP.
15AMP.
STARTER MOTOR
1
2
3
PR2
B1
RD
A
RD
P1
TB20
CB2
October 2013
-
15AMP.
P20BAT RD
12 V
DC
6 - 112
1
8
6 - 113
1
BR-2 GROUND
C41RPM OR/BK
A
C2-3
5
15
TS14
LO
Y51
TB30

L1 HI
C29MS RD/WH 8
B
J1
S-40 • S-45
C1-5 C5-20 D C
DRE LED BL/RD 16
TB31
H4
C6-32
TS15

DRIVE ENABLE
Y2
C1-6 C5-23
TB32
Y27
C1-3 C5-24
TB29
C
Y3
C1-11 C6-37
TB37
Y4

TB36
6
DRIVE & STEERING
RKOUT 5 BL/WH
C3-6
XOUT 3 BL/WH 5
J1
PWR 2 OR 13 C3-5
9 C5TRR WH/BK
GND1 BRN 14 C3-4
10 C4TRL WH
Y23
D

JC3
TB4
Y29
C6-5
TS62

TB5
Y13

R2
FLOW CONTROL
TB6
TB1
7.5
Part No. 102521
Y21 Y22

October 2013
UP
TB2
DOWN C6-2
TS61
J2

E
TB3
6
Y12
5 C6-3 PRIMARY BOOM

C3PBF RD/WH
R1
FLOW CONTROL
YOUT 4 RD/WH 2 5
XOUT 3 1
D30
WH/RD
J1
PWR 2 6 C1PBU RD
OR 11 C3-1
C3-2
8 C3PBF RD/WH
C3-3
JC2
C6-19
RD/BK DESCENT ALARM
H4
F
14
D29
13
NO
NC
WH
14 13
22 21
LS2-PRIMARY BOOM UP
2 1
BK
SJ1-WH
NO
NC
14 13
22 21

BR 1
2 1
BK
P24FS WH 2
J3
TB13
NO
G
P24FS WH 4
NC
14 13
22 21

DRIVE ENABLE
P26ESTP BK 3
4 3

C2-2 C6-40
TB40
WH
C6-30
H
CR27
CR30
NO
NC
OPTION
TB7
DRIVE
Y25
LIFT/
TS63
C6-7
CE

EXTEND
TB8
BOOM
Y26
RETRACT C6-8 BOOM RETRACT
I
C8PBR BK/WH
C3-7
C7PBE BK
EXTEND
BOOM
RETRACT C3-8
TS13
C8PBR BK/WH
C4-2
C14PLU OR
UP PLATFORM LEVEL
DOWN
TB14
C4-3
TS9
C15PLD OR/BK
Y19 Y20
TS59
C6-14
J
UP PLATFORM LEVEL
DOWN C6-15
TB15
TB44
C2-6
K
CR13
D27
NC
C4-6
C18JD GR/BK
DOWN
TB18
UP JIB BOOM C4-5
TS8
C17JU GR
Y16
D28
TS58
C6-18
DOWN
Y17
UP JIB BOOM C6-17
TB17
TS57
PLAT ROTATE
CCW CCW
L
CW CW PLAT ROTATE
TS7
WH
C4-7
C19JSV GR/WH
CR13
TB19
+
M
-
BR
JIB VALVES
GR/WH
CR14
NO
JIB VALVE
BR
RD
RD
BL/WH
RD/BK
OR/BK
WH
RD
BK
N
6 - 113
6 - 114

6 - 116
6 - 115

1
46 SPARE
RD-C2B-4 42 RD-KS1-2 S.P. C134PWR
G1 G2 G3
OR/BK-C5-2 OR/BK-C2B-3 41 PULSE PICKUP
BL/RD-C5-10 BL/RD-C2B-1 39 BL/RD-S.P. L.P.
2 BL/BK-C6-37
BL/WH-C1B-12
BL/BK-C1B-11
38
37
C132PLI
STEER LEFT
BR (GROUND)

BK-C1B-7 33 BK-CR1#85 D5 BK-S.P. START
WH/BK-C5-20 WH/BK-C1B-5 31 WH/BK-25A
E.D.C.-
WH/RD-26A
WH- C5-21 WH-C1B-4 30 E.D.C.+
BK-22A
RD/WH-C5-24 RD/WH-C1B-3 29 MOTOR SPEED
RD/BK-C6-28 RD/BK-C1B-2 28 TILT ALARM KEY SWITCH
RD- C6-27 RD-C1B-1 27 RD-CR39#85 RD-S.P. AUX. PWR. P1 KS1
TS51
WH/RD-C5-14 26 WH/RD-S.P. WATER TEMP. SENDER B
3 WH/BK-C5-16 25 WH/BK-S.P. OIL PRESSURE SENDER
RD-CB2
NC 1
RD
24 RED-CR1#30 RD-S.P. 3
ENGINE POWER
23 NC B1 KEY SWITCH KS1
RD- C6-23 WH-C7B-2 CR39 #30 WH-S.P. KEYSWITCH PWR/FB B
WH-23A 4 2
BL/WH-C6-30 BK-C7B-1 22 BK-CR5#30 BK-S.P. PWR. TO PLAT. 1
RD-42A
RD
WH-C5-3+C5-8 WH-C6-34 21 WH-CR2#87 WH-S.P. IGNITION PWR. 3
RD-27A
RD- 12 VOLT RD-S.P.(CB3) 20 RD-S.P.(CB2) RD-S.P.(CB1) 12V BATTERY SUPPLY BL/RD-39A B1
19 WH-23A 4 2
GR/WH-C4B-7 GR/WH-SP JIB VALVE
GR/BK-C6-18 GR/BK-C4B-6 18 GR/BK-S.P. PLAT. ROT. R.
GR- C6-17 GR-C4B-5 17 GR-S.P. PLAT. ROT. L.
OR/RD-C4B-4 16 C133PLT
Check Engine Light
R3
OR- C6-14 OR-C4B-2 14 OR-S.P. PLAT. LEVEL. UP WH-21A (after serial number 13739)
4 BL/RD-C6-13 BL/RD-C4B-1 13
12
DRV. ENA. LT.
L2 TS53
Note: Removed resistor R3 and DESCRIPTION LABEL PART#
BL/WH-C3B-12 HM changed L2 to incandescent L2
EMERGENCY STOP BUTTON P1 P1
BL/BK-C3B-11 11
BR (GROUND)
BL-C3B-10 10 KEY SWITCH KS1 KS1
BK/RD-C3B-9 9 BK/RD-CR23#86 DRIVE LIGHT OPTION AUXILIARY SWITCH TS51 13480
BL/WH-C5-13
BK/WH-C6-8 BK/WH-C3B-8 8 BK/WH-S.P. BOOM RETRACT BL/WH-C5-13 ENGINE START SWITCH TS52 13037
LP/GAS SWITCH TS53 56457
WH/BK-C6-5 WH/BK-C3B-5 5 WH/BK-S.P. TURN. ROT. R RD/WH-3A TS61 FUNCTION ENABLE TS55 13037
WH- C6-4 WH-C3B-4 4 WH-S.P. TURN. ROT. L RD/BK-2A PLATFORM ROTATE SWITCH TS57 16397
RD/WH-C6-3 RD/WH-C3B-3 3 RD/WH-S.P. PRI. BOOM F.C. RD-1A PLATFORM LEVEL SWITCH TS59 13037
RD/BK-C6-2 RD/BK-C3B-2 2 44B-RD/BK-C6-19 RD/BK-S.P. PRI. BOOM DOWN
BOOM EXTEND/RETRACT SWITCH TS63 13037
5 RD- C6-1 RD-C3B-1 1 RD-S.P. PRI. BOOM UP
PRIMARY BOOM UP/DOWN SWITCH TS61 16397
12 V
D C B A TS63
BK/WH-8A TURNTABLE ROTATE SWITCH TS62 16397
BK-7A JIB BOOM UP/DOWN SWITCH TS58 13037
GR/BK-44A
BR-GND STUD TS62 CHECK ENGINE SWITCH TS22 42730
3
12V TO PLAT
BK-33A
BK-22C
C7B
1 CIRCUIT BREAKER, CONTROLS, 15A CB1 CB1

CB3
2 WH-23C CIRCUIT BREAKER, ENGINE, 15A CB2 CB2
TS52
CIRCUIT BREAKER, OPTIONS, 20A CB3 CB3
RD- 20C RESISTOR, 5 OHM, BOOM FUNCTION R1 R1
TS58
RD-CR17/CR23 #30
C4B
(BR)
RESISTOR, 7.5 OHM,TURNTABLE FUNCT R2 R2
R1
WH/BK-5A
WH/RD-6A VOLT METER GAGE G1 G1
6 RD-24B WH-4A OIL PRESSURE GAGE G2 G2
(GR)
C3B
CR1 CR2 WATER TEMP. GAGE G3 G3

19/18 CABLES
R2
BK-33B CHECK ENGINE (before serial number 13740) L2 110395
RD-CB3 S.P. CHECK ENGINE (after serial number 13739) L2 119870
C2B
(BK)
CB1 CB2
HOUR METER HM HM
BK-C5-5 TS57
WH-21B CR23 RESISTOR, 1K OHM/2W, CHECK ENGINE R3 104333
WH-C5-17 TS55
(GY)
C1B
BK/RD-9B
TS59
BK/RD-35A RD C4B-11
BK-C6-16 WH-C5-11 OR-C6-33
TS22 RD- 20A RD C4B-12
7
FUNCTIONS
RD- 24A BRN GND

C6
RD- 20B
RD- P1 E-STOP DRIVE LIGHT OPTION RELAY
CR5
RD-27B OR/BK-15A
GR-43B CR39 CR17
BK-C6-25
BK-22B OR-14A
GR-C5-12 RD-CB3 SP
GR-17A
WH-23B
GR/WH-19A
ENGINE
GR/BK-18A
C5
WIRING
HARNESS:
8 TO BASE
GROUND STUD
ESO433
GROUND STUD
BR
ALL BR WIRES
6 - 116 S-40 • S-45 Part No. 102521


1
LOAD SENSE OPTION - TIMER RELAY
RD-H6+ - C32-1
BL/WH-132D - C32-3
U33 C32 RD-C32-1
BK-22C - C32-4
PLATFORM LOAD BK-C7-1 - C32-5 RD-134B
RD-TS51 - C32-6 GR/BK-L45- H6 G1 G2 WH-CR2#86
G3 8
RD-TS55 - C32-7 GR/BK-133A WH-ISM#9
GR/BK-133B - C32-8 9
BR - GND - C32-12
WH-21A
BR (GROUND)
2
RD-TB134(A)C
46 SPARE 2
GR/WH-C6-39 GR/WH-C2B-7 45 GR/WH-35B 1 GEN. OPTION
GR/BK-C2B-6 44 GR/BK-2B GR/BK-S.P. JDALARM JIB BR-GND
3 5
RD-U34-2 134A U34
RD-C2B-4 134 RD-H6+ RD-KS1-2 S.P. P134PWR
OR/BK-C5-2 OR/BK-C2B-3 41 PULSE PICKUP WH/BK-25A BK-C3B-10
OR- C6-40 OR-C2B-2 40 LIMIT SWITCH SIG. WH/RD-26A
BL/RD-C5-10 BL/RD-C2B-1 39 BL/RD-S.P. L.P. BK-22A
BL/WH-C1B-12 132 C132PLI KEY SWITCH
BL/BK-C6-37 BL/BK-C1B-11 37 STEER CW P1 KS1
BL- C6-36 BL-C1B-10 36 STEER CCW B
TS51
3
BK/RD-C5-9 BK/RD-C1B-9 35 GR/WH-45B 1 BK/RD-S.P. RPM RD-CB2 NC 1
RD
BK/WH-C1B-8 34 BK/WH-S.P. GLOW PLUG 3
D2
BK-C1B-7 33 BK-CR1#85 D5 BK-S.P. START NC B1
WH/RD-C5-23 WH/RD-C1B-6 32 WH/RD-C6-32 BRAKE/TRAVEL ALARM 4 2
WH-23A
WH/BK-C5-20 WH/BK-C1B-5 31 E.D.C.- RD-42A
WH- C5-21 WH-C1B-4 30 E.D.C.+ RD-27A
RD/WH-C5-24 RD/WH-C1B-3 29 MOTOR SPEED BL/RD-39A D4
RD/BK-C6-28 RD/BK-C1B-2 28 TILT ALARM
RD- C6-27 RD-C1B-1 27 RD-CR39#85 RD-S.P. AUX. PWR. DRIVE LIGHT OPTION RELAY
WH/RD-C5-14 26 WH/RD-S.P. WATER TEMP. SENDER
RD-CR23#30 24 RED-CR1#30 RD-S.P. ENGINE POWER RD-24C
RD- C6-23 WH-C7B-2 23 CR39 #30 WH-S.P. KEYSWITCH PWR/FB WH-21A
L2 4
BL/WH-C6-30 BK-C7B-1 22 BK-CR5#30 BK-S.P. PWR. TO PLAT. CR23 30
WH-C5-3+C5-8 C6-34 &CR45#86 21 WH-CR2#87& CR23#86 WH-S.P. IGNITION PWR. HM TS53
RD- 12 VOLT RD-S.P.(CB1) 86 85 BN-GND
RD-S.P.(CB3) 20 RD-S.P.(CB2) 12V BATTERY SUPPLY
GR/WH-C4B-7 19 GR/WH-SP JIB VALVE BR (GROUND) 87
GR/BK-C6-18 GR/BK-C4B-6 18 GR/BK-S.P. PLAT. ROT. CCW RD C4B-10
GR- C6-17 GR-C4B-5 17 GR-S.P. PLAT. ROT. CW BL/WH-C5-13 D10
OR/RD-C4B-4 133 C133PLA RD C4B-12
OR/BK-C6-15 OR/BK-C4B-3 15 OR/BK-S.P. PLAT. LEVEL DN. WH-21B
OR- C6-14 OR-C4B-2 14 OR-S.P. PLAT. LEVEL. UP TS61
BL/RD-C6-13 BL/RD-C4B-1 13 DRV. ENA. LT. RD/WH-3A
BL/WH-C3B-12 12 RD/BK-2A
BL/BK-C3B-11 11 RD-1A
BL-C3B-10 10 WORK LIGHT OPTION RELAY 5
9 SPARE
12 V
BK/WH-C6-8 BK/WH-C3B-8 8 BK/WH-S.P. BOOM RETRACT TS63 RD-20C

BK- C6-7 BK-C3B-7 7 BK-S.P. BOOM EXTEND BK/WH-8A
12V TO PLAT
WH/RD-C6-6 WH/RD-C3B-6 6 WH/RD-S.P. TURN. ROT. F.C. BK-7A

5 TURN. ROT. CCW GR/BK-44A CR45 30
3 BR-GND STUD WH/BK-C6-5 WH/BK-C3B-5 WH/BK-S.P. TS62
BK-33A
C7B
1 BK-22C WH- C6-4 WH-C3B-4 4 WH-S.P. TURN. ROT. CW 86 85 BR-GND

RD/WH-C6-3 RD/WH-C3B-3 3 RD/WH-S.P. PRI. BOOM F.C. CB3
2 WH-23C 2 87
RD/BK-C6-2 RD/BK-C3B-2 44B-RD/BK-C6-19 RD/BK-S.P. PRI. BOOM DOWN TS52
RD- C6-1 RD-C3B-1 1 RD-S.P. PRI. BOOM UP
RD-20C TS58 WH-W.L. CABLE
D C B A
(BR)
C4B
RD-CR17/CR23 #30 WH-21C
R1
WH/BK-5A
RD-24B
WH/RD-6A
WH-4A
6
19/18 CABLES
(GR)
C3B
CR1 CR2
R2
BK-33B D28 DESCRIPTION LABEL
(BK)
D14
C2B
CB1 CB2 TS57

EMERGENCY STOP BUTTON P1
BK-C5-5 WH-21B KEY SWITCH KS1
AUXILIARY SWITCH TS51
C1B
(GY)
WH-C5-17 TS55
TS59 ENGINE START SWITCH TS52
D13
LP/GAS SWITCH TS53
BK-C6-16 WH-C5-11 OR-C6-33 BK/RD-35A FUNCTION ENABLE TS55
FUNCTIONS
TS22
RD-20A PLATFORM ROTATE SWITCH TS57 7
RD-24A PLATFORM LEVEL SWITCH TS59
C6
RD-20B BOOM EXTEND/RETRACT SWITCH TS63

CR5 CR39 CR17 RD- P1 E-STOP PRIMARY BOOM UP/DOWN SWITCH TS61
GR-43B RD-27B OR/BK-15A TURNTABLE ROTATE SWITCH TS62
BK-C6-25
BK-22B JIB BOOM UP/DOWN SWITCH TS58
RD-CB3 SP OR-14A
GR-C5-12
WH-23B GR-17A CHECK ENGINE SWITCH TS22
CIRCUIT BREAKER, CONTROLS, 15A CB1
ENGINE
GR/WH-19A
C5
GR/BK-18A CIRCUIT BREAKER, ENGINE, 15A CB2

WIRING CIRCUIT BREAKER, OPTIONS, 20A CB3
HARNESS:
TO BASE RESISTOR, 5 OHM, BOOM FUNCTION R1 8
RESISTOR, 7.5 OHM,TURNTABLE FUNCT R2
VOLT METER GAGE G1
GROUND STUD
GROUND STUD 1 DIODE ADDED AT SERIAL NUMBER 16453 OIL PRESSURE GAGE G2
BR WATER TEMP. GAGE G3
CHECK ENGINE L2
ALL BR WIRES HOUR METER HM
LOAD SENSE TIME DELAY RELAY (10A) U34
Part No. 102521 S-40 • S-45 6 - 117


6 - 117
6 - 118

6 - 120
6 - 119
N
ESO433
M
PBOX WIRING
HARNESS
OPT.
L
RD P2
LS18
RD H1
C132PLI BK C1P-12
K
P23SWBAT WH C7P-2
P22BAT BK C7P-1
JIB
C19JSV GR/WH
C18JD GR/BK C4P-6
J
BRN
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C43 HRN GR C2P-5
C8PBR BK/WH C3P-8
C7PBE BK C3P-7
P26BAT BK C9P-1
P25FS RD C9P-3
I
P24FS WH C9P-2
JDALARM GR/BK C2P-6
C3P
C45GEN GR/WH C2P-7

C9P
TS48-WL1 RD C2P-12
F.S.
TS48-WL2 RD C2P-11
F.S.
C39LP BL/RD C2P-1

DLITE BK/RD C3P-9
H
P26BAT BK
11
3
C6TRF WH/RD C3P-6

J3
C10SBU BL C3P-10
C13DRE BL/RD C4P-1
G
C11SBD BL/BK C3P-11

C7P
C12SBF BL/WH C3P-12
12V BATT
C30EDC+ WH C1P-4
BRN C1PBU RD C3P-1
C7P
C31EDC- WH/BK C1P-5

C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
F
C4P
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4P(BR)
ALC-500
C4TRL WH C3P-4
C29MS RD/WH C1P-3
J2
Part No. 102521

C3P
C134PWR RD C2P-4
C3P(GR)
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
E
C2P
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
19/18 CONTROL CABLE

C2P(BK)
C1P
J1
9
JC1-3 OR
JC2-4 RD
JC1-2 BRN
C1P(GY)
D
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
S-40 • S-45
C28TTA RD/BK C1P-2
C
DRE B BL/BK
C13LED BL/RD
BATGND C7P-3
C29MS RD/WH
GR/BK C4P-4
D40
H1
RED/BLK-28
B
D39
GR/BK L48
ALALRM
TILT
RED-TILT RED-TILT
A
BRN
October 2013
6 - 120
1
8
6 - 121
8
(TO SWITCH
PLAT CONT
HARNESS
PANEL)
WH
B
B
A
C19JSV GR/WH TS7

B
C19JSV GR/WH C4P-7

BR JC3 BR BK
B
Y
BR GND
RD
B
RD-E-STOP
Y
P134PWR RD-H1+
GR/WH
RD LS18 CABLE
BR
CR13-#86 GR/WH
R
C1
RD OUTPUT
B
S-40 • S-45
GR/WH +
OPT.
GR/WH
CR14
R
P134PWR RD
BR -
JIB
GR/WH RD
B
R20
P134PWR RD
B
4700
B
RD-H1+
OPTION
C
LOAD SENSE
U35
OPTION
COM
LS18
NO
2
5
3
D88
P26ESTP BK E-STOP R26ESTP BK C9P-1

BR GND
D89
P23BAT WH C7P-2
D
P22BAT BK C7P-1
C19JSV GR/WH C4P-7
C18JD GR/BK C4P-6
C17JU GR C4P-5
JIB
C15PLD OR/BK C4P-3

C14PLU OR C4P-2
Part No. 102521
C43HRN GR C2P-5
C8PBR BK/WH C3P-8
October 2013
C7PBE BK C3P-7
P26ESTP BK C9P-1
E
P25FS RD C9P-3
P24FS WH C9P-2
JDALARM GR/BK C2P-6
C45GEN GR/WH C2P-7
C9P
F.S.
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
C132PLI2 BK C3P-10
C132PLI1 BK C1P-12
F
P26ESTP BK
11
3
1
J3
12V BATT
C6TRF WH/RD C3P-6

C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C7P

G
C12SBF BL/WH C3P-12

C30EDC+ WH C1P-4
C7P
BR C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
19/18 CONTROL CABLE
C36STC BL C1P-10
C4P
C3PBF RD/WH C3P-3

ALC-500
C32BRK WH/RD C1P-6

C4TRL WH C3P-4
H
J2
C29MS RD/WH C1P-3

C3P
P134PWR RD C2P-4 C3P(GR)

C35RPM BK/RD C1P-9
C2P
C34SA BK/WH C1P-8

C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4 C2P(BK)
I
C1P
J1
9
JC1-2 OR
JC2-3 WH/RD
JC1-1 BR C1P(GY)
JC2-4 RD/WH
JC2-2 OR
JC1-4 WH/BK
JC2-1 BR
JC3-4 WH/RD
JC3-2 OR
JC3-3,5 BL/WH
J
JC3-1 BR
C28TTA RD/BK C1P-2
C28TTA RD/BK C1P-2

DRE A BL/WH
DRE B BL/BK
BATGND C7P-3
GR/BK C4P-4
C13LED BL/RD
C29MS RD/WH
D40
K
H1
ALALRM
RD/BK-28
D39
TILT
GR/BK L48
RD-TILT RD-TILT
BR
L
LOAD SENSE TIME DELAY RELAY (30A)

COMPONENT INDEX
JIB DELAY RELAY

JIB TIME DELAY
M
TILT ALARM
CR14
U35
H1
C1
N

6 - 121
6 - 122

6 - 124
6 - 123

1
10 AMP FUSE HARNESS

PBOX WIRING
2
WORK / DRIVE LITE
TS49
JC2 BOOM PROPORTIONAL JOYSTICK: 62390
DRV.ENA PRIMARY UP/DN , TURNTABLE ROTATE
7 TS15 7
6 6 JC3 DRIVE PROPORTIONAL JOYSTICK 75565

P2 EMERGENCY STOP BUTTON 66812, 95406
5 5 P3 HORN SWITCH 66813, 66816
3 TS2 START ENGINE SWITCH 13037
DLITE/ RD WL2
4 PRIMARY 4
RD WL1
TS3 FUEL SELECT SWITCH (FORD EFI ONLY) 56457

BOOM
EXTEND/
3 L4 CHASSIS TILT LED 56298
3 RETRACT
TS7 PLATFORM ROTATE SWITCH 16397
TS8 JIB UP/DOWN SWITCH 13037
2 2 TS9 PLATFORM LEVEL SWITCH 13037
JC2 JC3 TS14 DRIVE SPEED SWITCH 56457
1 1 TS15 DRIVE ENABLE SWITCH 13037
TS13 TS47 GENERATOR SWITCH ( OPTION ) 27378
CR13
4
WH-24
+ +
L4
L1
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
BRN J1-14
BRN J1-12
RD/BK H1
OR J1-13
OR J1-11
BK/WH-8
WH J1-5
WH J1-5
BK J1-2
BL J1-4
RD J1-1
RD-TILT
WH-JIB
WH-24
BK-22
BK-7
5
BRN
BRN BATGND
(GND STUD)
C19JSV GR/WH JIB
WH-TS4
WH-24
OR/BK-15
OR-14
C18JD GR/BK C4P-6
RD-25
BK-33
BK/RD-35
WH-24
RD
C17JU GR C4P-5
WH-JIB
C27AUX RD C1P-1
BL/RD-39
WH-23
P26BAT BK C9P-1
C29MS RD/WH J1-8
GR/WH-45
C19JSV GR/WH
WH-24
WH-24
BK-22
RD-TILT
P22BAT BK C7P-1
GR-43
RD
WH-TS47
CR27
WH TS7
WH TS1
RD
WH/RD C32BRK
(SPLICE TO C32BRK)
6
CR30
WH
TS9 TS7 TS8 TS47
TS1
GR TS14 TS2 OR R40LS1
HIGH/LOW TS3
RPM
TS4
DRIVE START FUEL SELECT
HORN PLATFORM WH JIB AUXILIARY SPEED
PLATFORM GENERATOR
P3 HIGH/LOW
ROTATE PUMP
7 LEVEL GR/BK (OPTION)
RD EMERGENCY STOP
NOTE: DASHED LINES INDICATE
OPTION WIRES
P2
CE SEE DETAIL A
6 - 124 S-40 • S-45 Part No. 102521


1
10 AMP FUSE HARNESS

PBOX
WIRING
2
WORK / DRIVE LITE
PRI. BOOM TS49
UP/DOWN 1
2 DRIVE/STEER
DRIVE ENABLE
COMPONENT INDEX TS15
JC2 BOOM PROPORTIONAL JOYSTICK: 6 6
PRIMARY UP/DN , TURNTABLE ROTATE JC2 JC3
1 1
JC3 DRIVE PROPORTIONAL JOYSTICK
L1 DRIVE ENABLE LED
3
P2 EMERGENCY STOP BUTTON
DLITE/ RD WL2
RD WL1
P3 HORN SWITCH
TS1 AUXILIARY SWITCH TT ROTATE PRIMARY
TS2 START ENGINE SWITCH BOOM
TS3 FUEL SELECT SWITCH (FORD EFI ONLY) EXTEND/
TS4 HI/L0 RPM SWITCH RETRACT
L4 CHASSIS TILT LED
TS7 PLATFORM ROTATE SWITCH +
TS8 JIB UP/DOWN SWITCH
TS9 PLATFORM LEVEL SWITCH L48
4
TS13 PRIMARY BOOM EXTEND/RETRACT SWITCH TS13
WH-24
TS14 DRIVE SPEED SWITCH CR13
TS15 DRIVE ENABLE SWITCH 85 + +
TS47 GENERATOR SWITCH ( OPTION ) 87A L4
J1-5 BL/WH JC3-3

L1
J1-5 BL/WH JC3-5

J1-4 WH/RD JC3-4
J1-14 BR JC3-1
J1-1 WH/RD JC2-3
J1-2 RD/WH JC2-4
J1-13 OR JC3-2
BL/RD-DE3 J1-16
J1-12 BRN JC2-1
J1-11 OR JC2-2
BL/WH-DE1 J1-6
BL/BK-DE2 J1-7
86
GR/BK H1
RD/BK H1
5
BK/WH-8
RD-P2
BK/WH-8
BK-22
WH-24
BK-7
BR
BR BATGND
C18JD GR/BK C4P-6
C19JSV GR/WH JIB
P26ESTP BK C9P-1
C19JSV GR/WH
WH-23
OR/BK-15
BL/RD-39
C27AUX RD C1P-1
BK-22
P22BAT BK C7P-1
RD
WH-JIB
C17JU GR C4P-5
WH-24
C29MS RD/WH J1-8
OR-14
(GND STUD)
WH-24
BK-33
RD-25
BK/RD-35
WH-24
GR/WH-45
RD-TILT
GR-43
RD
CR27
RD
85
87A
WH TS7 30
WH TS1
6
86 D11
D12
WH/RD C32BRK
(SPLICE TO C32BRK) TS4

CR30
TS9 WH TS47
85
87 TS7 TS8 TS1
30 TS14 TS2
NO GR
NCNCNC
HIGH/LOW
4
2 2 2
1 1 1
3
RPM TS3 7
86 GENERATOR P2
DRIVE START
HORN JIB SPEED (OPTION)
OR R40LS1 P3 PLATFORM PLATFORM AUXILIARY
WH ROTATE HIGH/LOW EMERGENCY STOP
LEVEL PUMP FUEL SELECT
(SPLICE TO R40LS1) GR/BK
D27 RD
CE SEE DETAIL A
NOTE:
DASHED LINES INDICATE
1
2 DRIVE/WORK LIGHT OPTION CHANGED AT SERIAL NUMBER 16420 OPTION WIRES
8
Part No. 102521 S-40 • S-45 6 - 125


6 - 125
6 - 126
Engine Wire Harness

6 - 128
6 - 127
Engine Wire Harness

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
2 AUX ANA PD1
19
20
198 DG-O 18
358 LG-BK 18
ACT TEMP
MAP
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
3 POWER GROUND
2
13
570 BK-W 16
359 GY-R 18
570 BK-W 16
570 BK-W 16
MAP_CONN F3 20A
ANA_RTN 361 R 14 361 R 14 361 R 12
TWR
9 VBATT
14 351 BR-W 18 351 BR-W 18 351 BR-W 18
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
4 EGO 1
24
26
74 GY-LB 18
O2 SENSOR
360 BR-PK 18 360 BR-PK 18
41 EGR REC
EGO 3 361 R 14
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
J1 BLACK 361A R 16 361A R 16 O2 MTRTWR6 MTRSHD6

TWR SHD
THROTTLE
FUEL PUMP
16 R-LG 18 32 R-LB 16
13 STARTER CONTROL
570 BK-W 16 570 BK-W 16 SENSOR 355 GY-W 18
A A
355 GY-W 18
6
86 30 STARTER
357 Y-W 18 357 Y-W 18 RELAY RELAY
74 GY-LB 18 392 R-LG 18 B B 5
151 LB-BK 18 151 LB-BK 18
C C 4 85 87 87A
359 GY-R 18 359 GY-R 18 317 GY-O 18 317 GY-O 18 86 30 32 R-LB 16
D D 1 15 STARTER IN (INTERUPT)
359 GY-R 18 351 BR-W 18 32 R-LB 16
E E 3
5 J2 GREY 351 BR-W 18
F F
359 GY-R 18
2
85 87 87A
39 STARTER IN (AUTOCRANK)
TWR 342 LG-P 18 342 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
926A LB-O 18
6 FUEL PUMP
9
32
926A LB-O 18
15 R-Y 18 15 R-Y 18 361 R 16
F5 15A
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
71 O-LG 18
7 AUX OUT 1
5
14
71 O-LG 18
72 Y-BK 18 72 Y-BK 18
71 O-LG 18
72 Y-BK 18
21 AUX OUT1
FUEL SELECT 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 -
642 DG-O 18
8 RS 485 +
20
21
642 DG-O 18
461 O 18 461 O 18
642 DG-O 18
461 O 18
11 RS 485+
3 RS 485-
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
6 - 128 S-40 • S-45 Part No. 102521

Engine Wire Harness

Ford DSG-423 EFI Models (from serial number 11067 to 11784)
1
IGNITION COILS HO2S #1

R 16 R 16 R 16 HO2S #2
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
UEGOC
8
9
CYL #2 CYL #3 CYL #4 CYL #1 GY/R 18
LG/W 18
TWR
A
GASOLINE
SENSOR
2
UEGOP
10 CAM BR/W 18 B
UEGPR
11
W/LG 18 W/LG 18 C INTERFACE
12 DG/O 18 D
AUX ANA PD1 W/LG 18
13
(FRP) AUX ANA PD2
CAN1 +
14 DG/P 18 DG/P 18
MTRTWR4 FORD
15 O/LG 18 O/LG 18
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 +
CRANK -
CAM +
26
27
DBL 18
GY/R 18
LG/BK 18
BR/W 18 4
3 CHT
3
28 DB/O 18 GY 18
CAM - DG/BK GY/R 18 2
29
SPEED + LB/R 18 1
30
SPEED -
31 LG/W
5V EXT 2 DG/BK
32 LB/R 18 36 ROADSPEED -
5V RTN 2
33 LB/R 18 LG/BK 18
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
VSW
44
45
R/LG 18
DB/W 18 4
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
49 Y/DB 18 10A ECM
(FUELSELECT)AUX DIG1
50
AUX DIG 2 BK/Y 18
51 Y/R 18 23 GOV SELECT 2
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
EGOH 2
EGOH 1
INJ HS
62
63
BK/LG 18 BR/W 18 BR/W 18 BR/W 18
33 ANA RTN
31 VREF 5
64 T 16
INJ1 LS
65 BR/Y 16 BK/LG 18 BOSCH THROTTLE
INJ2 LS
66 BR/LB 16 BATT(+) R 12 R 12 R 14
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
DBW +
GROUND
80
81
LB/DG 18
BK/W 16 OIL PRESSURE 6
82 GY/O 18
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 O/LG 18
85
AUX PWM1 R/W 18 BK/O 18
86 BK/O 18 25 IVS
AUX PWM4 T/GN 18 DG/W 18
87 DG/W 18 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
7 FUEL SELECT
P/LB 18 P/LB 18
10 AUX ANA PD1B
T/GN 18 T/GN 18
27 AUX OUT 2
W/LB 18 W/LB 18
4 BRAKE
DG 18 DG 18 11 RS 232+
O 18 O 18
INJECTOR CYL #2
W/R 18
GY/R 18
A
FUEL PUMP
3 RS 232-
7
B LB/PK 16
F4 15 START IN INTERUPT
R 16 BN/LB 16 LPG PK/BK 16 PK/BK 16
W/PK 16 19 START IN AUTOCRANK
PK/BK 16
TEMPERATURE 5 FUEL PUMP +
GY/R 18 1
ANA RTN 15A
BR/W 18 2
TWR 5V REF
DG 18 3
PC TX
W/BK 18 O 18 4
PC RX
FUEL PUMP RELAY
INJECTOR CYL #4 R/LG 18 A
B
DG/P 18 5
6
UNUSED
LB/O 18 LB/O 18
STARTER STARTER RELAY CAN
85
LPG
Y/R 18
DG/P 18 7
UNUSED
R 16 30 SOLENOID 87A
TERMINATION
CAN + LB/PK 16
R 16 BR/Y 16
LOCKOFF O/LG 18 8 PK/BK 16 30 CONNECTOR
KNOCK CAN -
R/LG 18
87 LB/PK 16
87 W/PK 16
86
SENSOR DIAGNOSTIC CONNECTOR 87A RING W 18
SHD TWR
W 18 2
R/LG 18 R/LG 18 86 CAN + TERM
R 16 RELAY
INJECTOR CYL #3
LG/P 18 85
OMRON
FPP
DG/P 18
O/LG 18
3
1
CAN +
CAN -
8
BK/W 18 6
GROUND
PK/BK 16 PK/BK 16 4
R 16 T 16 UNUSED
5
UNUSED
8
UNUSED
F1
R16 R/LB 16 R/LB 16 7
POWER
POWER RELAY
R/Y 18 85 10A EPR EPR
INJECTOR CYL #1 R 16
R 16 R 16 R 16
30
F5 CONNECTOR
87
R 16 R 16
ES0400A
R/T 18 86
87A
15A RELAYED POWER
Part No. 102521 S-40 • S-45 6 - 129

Engine Wire Harness

Ford DSG-423 EFI Models (from serial number 11101 to 11784)
6 - 129
6 - 130
Engine Wire Harness

Ford DSG-423 EFI Models (from serial number 11785)
6 - 132
6 - 131
Engine Wire Harness

Ford DSG-423 EFI Models (from serial number 11785)
1 IGNITION COILS HO2S #1
R 16 R 16 R 16 HO2S #2
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
2 AUX ANA PD1
(FRP) AUX ANA PD2
12
13
14
DG/O 18
W/LG 18
DG/P 18 DG/P 18
D
FORD
CAN1 +
15 O/LG 18 O/LG 18
MTRTWR4
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 + 1
3 SPEED -
5V EXT 2
30
31
32
LB/R 18
LG/W
DG/BK LB/R 18
5V RTN 2 36 ROADSPEED -
33 LB/R 18 LG/BK 18
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
4 (FUELSELECT)AUX DIG1
TPS 2
48
49
50
Y/W 18
Y/DB 18 10A ECM
AUX DIG 2 BK/Y 18
51 Y/R 18 23 GOV SELECT 2
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 BATT(+) R 12 R 12 R 14
5 INJ3 LS
INJ4 LS
66
67
68
BR/LB 16
W 16 GY/W 18
Y/W 18
GY/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 R/LG 18
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
6 AUX PWM5
AUX PWM1
84
85
86
R/BK 18
O/LG 18
R/W 18
R/W 18
BK/O 18
R/W 18
BK/O 18
16 AUX PWM 4
AUX PWM4 25 IVS

87 T/GN 18 DG/W 18 DG/W 18
AUX PWM2 26 OIL PRES
88 T/Y 18 T/Y 18
AUX PWM4 REC 2 TACH
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
7 FUEL SELECT
P/LB 18 P/LB 18
10 AUX ANA PD1B
T/GN 18 T/GN 18
27 AUX OUT 2
W/LB 18 W/LB 18
4 BRAKE
DG 18 DG 18 11 RS 232+
W/R 18 O 18 O 18 3 RS 232-
A
INJECTOR CYL #2 GY/R 18
FUEL PUMP
B LB/PK 16
F4 15 START IN INTERUPT
R 16 BN/LB 16 LPG W/PK 16 19 START IN AUTOCRANK
7 TEMPERATURE
GY/R 18 1
ANA RTN
PK/BK 16
15A
PK/BK 16 PK/BK 16 5 FUEL PUMP +
BR/W 18 2
TWR 5V REF
DG 18 3
PC TX
W/BK 18 O 18 4
PC RX
FUEL PUMP RELAY
INJECTOR CYL #4 R/LG 18 A
B
DG/P 18 5
6
UNUSED
LB/O 18 LB/O 18
STARTER STARTER RELAY CAN
85
LPG
Y/R 18
DG/P 18 7
UNUSED
R 16 30 SOLENOID 87A
TERMINATION
CAN + LB/PK 16
R 16 BR/Y 16
LOCKOFF O/LG 18 8 PK/BK 16 30 CONNECTOR
KNOCK CAN -
R/LG 18
87 LB/PK 16
87 W/PK 16
86
SENSOR DIAGNOSTIC CONNECTOR 87A RING W 18
SHD TWR
W 18 2
R/LG 18 R/LG 18 86 CAN + TERM
R 16 RELAY
OMRON DG/P 18 3
CAN +
INJECTOR CYL #3
LG/P 18 85
FPP O/LG 18 1
CAN -
BK/W 18 6
GROUND
PK/BK 16 4
8 R 16 T 16 PK/BK 16
5
8
UNUSED
UNUSED
UNUSED
F1
R16 R/LB 16 R/LB 16 7
POWER
POWER RELAY
R/Y 18 85 10A EPR EPR
INJECTOR CYL #1 R 16
R 16 R 16 R 16
30
F5 CONNECTOR
87
R 16 R 16
ES0400A
R/T 18 86
87A
15A RELAYED POWER
6 - 132 S-40 • S-45 Part No. 102521

Joystick Connector Diagram
1
PRIMARY BOOM 7 7 2
DRIVE/STEER
UP/DOWN
6 6
JC2 JC3
5 5
JC2 JC3 4 4
PRI UP/DN & TT ROTATE DRIVE & STEERING

3 3
RKOUT 6
XOUT 4
YOUT 5
YOUT 5
PWR 3
PWR 3
GND 2
GND 2
2 2 3
TURNTABLE ROTATE
4
7
6
7
1
1 1
BRN
BRN
WH
RD
OR
BK
OR
BL
14
12
13
11
4
2
5
1
J1 J1
4
BRN J1-14
BRN J1-12
OR J1-13
OR J1-11
WH J1-5
WH J1-5
BK J1-2
BL J1-4
RD J1-1
7
1
Pin1 6
AMP - 7 Pin Connector
2
Pin 1 GND Pin 2 5
3
6
6 1
1 Pin 2 PWR Pin 3
4
4
5
5 2
2 Pin 3 XOUT Pin 4 5
3
5
4
4 3
3
Pin 4 YOUT Pin 5
2
6
Pin 5 RKOUT Pin 6
1
7
PRIMARY BOOM
DRIVE/STEER Deutsch Pin 6 Pin 7
UP/DOWN
AMP
JC2 JC3
JC2 PRI UP/DN & TT ROTATE JC3 DRIVE & STEERING 6

RKOUT 5
YOUT 4
XOUT 3
XOUT 3
YOUT 4
PWR 2
PWR 2
GND 1
GND 1
TURNTABLE ROTATE
5
6
6
WH/RD
BL/WH
BL/WH
BRN
WH/RD
RD/WH
BRN
OR
OR
7
14
13
12
11
4
1
5
2
J1 J1
J1-2 RD/WH JC2-4

J1-12 BRN JC2-1
J1-1 WH/RD JC2-3

J1-4 WH/RD JC3-4

J1-5 BL/WH JC3-3
J1-5 BL/WH JC3-5

J1-14 BRN JC3-1
J1-11 OR JC2-2
J1-13 OR JC3-2
8
Note: Production changed
from 7 pin to 6 pin Joysticks
at Serial Number 12510
Deutsch - 6 Pin Connector
Part No. 102521 S-40 • S-45 6 - 133

Joystick Connector Diagram
6 - 133
6 - 134
CTE Option Wiring Diagram
6 - 136
6 - 135
8
7
6
5
4
3
2
1
6 - 136
TB22
February 2012
TB134
A
TB15
C15PLD OR/BK
CR21
B
C21-2 C21-1
PLAT LEVEL DOWN R15PLD OR/BK

CTE Option Wiring Diagram
C14PLU OR
C
S-40 • S-45
TB14
CR20
PLAT LEVEL UP R14PLU OR
C20-2 C20-1
D
GROUND
TB40
E
LIMIT SWITCHES
Part No. 102521

BR-GND STUD BR
F
C40LS1 OR 40-A
PLAT LEVEL PLAT LEVEL

UP RELAY DOWN RELAY
30
CR20 CR21
30
85
86
G
85
86
87
87
BR
C15PLD OR/BK 15-D
C15PLD OR/BK C6-15

WIRING DIAGRAM
H
C14PLU OR C6-14
C14PLU OR 14-D
I
OR/RD-C2B-4 RD-H6+
RD-C6-23 + LS PWR-C6-30 134 P134PWR 134 RD-KS1-2 S.P.
J
OR C2B-2
OR C6-40 40 BOOM STOWED 40 C40LS1 OR CR20#30
K
C15PLD OR/BK C4B-3

C15PLD OR/BK CR21#86 15 PLATFORM LEVEL DOWN 15 OR/BK-TS59
C14PLU OR C4B-2
C14PLU OR CR20#86 14 PLATFORM LEVEL UP 14 OR-TS59
L
HARNESS
FUNCTION
M
GROUND BOLT
N
Section 6 • Schematics February 2012
MTE Hydraulic Generator Option Wiring Diagram
6 - 138
6 - 137
MTE Hydraulic Generator Option Wiring Diagram
1
BLACK BLACK
WHITE WHITE
RED BLACK BLACK GREEN BLACK BLACK BLACK GREEN
T1 RED T1 RED
AC AC
BLACK BLACK
GENERATOR
BLUE BLUE GENERATOR
WHITE YELLOW WHITE YELLOW
T2 YELLOW WHITE BLACK L1 T2 WHITE WHITE BLACK L1

2
WHITE WHITE WHITE WHITE 1 2 3 4
T3 GREEN GND T3 GREEN GND DTP04-4P
1 2 3 4
DTP04-4P
1 2 3 4 GENERATOR
JUMPER HARNESS
1 2 3 4 GENERATOR
WHITE L2 JUMPER HARNESS WHITE L2
PLUG
T4 GREEN BLACK T4 BLACK BLACK
PLUG
BLACK RED
5 5
BL
BR
3
GR/WH
BL
BR
GR/WH
PURGE-BL
8 BLACK 8 RED
120VAC, 60Hz, 1 PH PURGE-BL

120VAC, 50Hz, 1 PH
4
C45GEN-GR/WH-4
BATGND-BR-4
C45GEN-GR/WH-4
C45GEN-GR/WH-4
BATGND-BR
BATGND-BR-4
PURGE-BL
6 RED BLACK WHITE L2

GR/WH
T1 GENERATOR SCHEMATIC - MTE HYDRUALIC GENERATOR OPTIONS

PLUG
JUMPER HARNESS
BR
BL
1 2 3 4
GREEN GND DTP04-4P

T2 YELLOW WHITE 1 2 3 4
WHITE WHITE
T3
7
T4 GREEN BLACK BLACK L1
YELLOW
BLACK
5 WHITE BLUE
BLACK
AC
RED
GENERATOR
BLACK GREEN
WHITE
8 8 BLACK BLACK
240VAC, 50Hz, 1 PH
6 - 138 S-40 • S-45 Part No. 102521

Hydraulic Generator Wiring Diagram- Welder Option
1
FOOTSWITCH
P2
P25FS-RD
P26ESTP-BK
P22PWR-BK
P24FS-WH
ALC-500
TS4
16
19
20
15
RPM TS47
SELECT GENERATOR
2
ON
RPM LO
RPM HI
C32BRK WH/RD
C1P-5
C1P-4
C1P-6
C2P-7
C1P-9
C1P-3
3
C45GEN GR/WH
C32BRK WH/RD
C31EDC WH/BK
C30EDC WH
C35RPM BK/RD
C29MS RD/WH
4
C1B-9
8 N.C. U36
C1B-3
C1B-5
C1B-4
1 N.O.
2 COM
CR66
3 GND 5 SW INPUT OMRON RELAY
C2B-7
C5-1 WH
7
TIME DELAY MODULE
C5-20
C5-21
TB24 4 SECOND 5
C1B-5
C1B-4
D99
4 2
6
TB35 TB32
3 TB21 TB45 TB41
TB29
1k ohms D98 D65
124 ohms
5
A1 BATTERY +
C5-20
C5-21
2 A2 SENSOR POWER +5 VDC 6
1
1 A3 BATTERY-
124 ohms
B1 VALVE 0 FWD COIL)
C5-24
V151HG GR
C5-23
C5-6
B2 VALVE 1 NC
C5-18
C5-12
V150HG GR/BK B3 DIGITAL OUTPUT BYPASS
1 3 2 4 8 BK 16-2 A RS232TxD C1 TxD (YLW)
C45GEN GR/WH
J129 B RS232RxD C2 RxD (GRN)
C41RPM OR/BK
CR50 C57
OMRON NC C57 C C3 /BOOT
RELAY 7
Y75
BK-2
D1 ANALOG 0 JOYSTICK
RD-1
5 6 7
D2 ANALOG 1 NC
D3 DIG IN 3 NC
VALVE
STROKE
MOTOR
RELAY
HIGH IDLE
CR4
RELEASE
BRAKE
E1 NOT USED
BYPASS COIL
PRESSURE SWITCH
E2 NOT USED
PS4
D
E3 NOT USED
C6-39
200 PSI
F1 DIG IN 0
U4 N.O.
F2 DIG IN 1 GENERATOR ON 8
F3 DIG IN 2
SX Controller
DRIVE EDC -
DRIVE EDC +
Y75-2 PILOT PRESSURE SIGNAL

FROM GENERATOR MANIFOLD
BR-2
(16-2)
DIVERTER MANIFOLD
Part No. 102521 S-40 • S-45 6 - 139

Hydraulic Generator Wiring Diagram- Welder Option
6 - 139
6 - 140
2WD Non-Oscillating Hydraulic Schematic

S-40 Models (before serial number 7569)
6 - 142
6 - 141

1 TURNTABLE
EXTEND RETRACT CYL
4 gpm ROTATE
15.1 L/min 2 gpm PLATFORM LEVEL
7.6 L/min CYLINDERS
51 psi PRIMARY LIFT SLAVE
3.5 bar MEDIUM F F
CYLINDER D
BRAKE MANIFOLD PRESSURE
A D
A 3 gpm
FILTER 11.4 bar
.025 DB T2 PLATFORM CA CB
ROTATE
CP
2 DA
C B C C
MASTER
BRAKE TEST .030
S1
A AUXILIARY
M V2 V1 PL1 PL2
1.7
B PUMP
BG BE
AUX AP PTEST EXT RET SW1 SW2 P1 P2 PR1 PR2
HYDRAULIC 2200 psi
COOLER AO FUNCTION 151.7 bar E E
TEST
315 psi OPTION MANIFOLD AI
BH AB
21.7 bar
AL
COUNTERBALANCE VALVE
3 T1 1950 psi
134 bar
AV
AZ
AX AY
AD BA
BF
RATIO PRESS
PRESS
AU AE AC
3625 psi AS AG AH A 3:1 1000 PSI
250 bar
AA
BD
B 3:1 2000 PSI
4.5 gpm 0.6 gpm
AR
17 L/min AM AF AK 0.6 gpm
FUNCTION 2.3 L/min 3:1 3000 PSI
E
2 L/min C
9 7 PUMP BB
AW
(S-40)
AN D 3:1 3300 PSI
RETURN AJ E 3:1 3500 PSI
4 DRIVE PUMP
FILTER
AQ
2.0 gpm
7.6 L/min
BG
0.1 gpm
25 psi
AT 0.4 L/min F 5:1 3500 PSI
1.7 bar
2600 psi
TANK
179 bar
3 psi 3 psi
0.2 bar 0.2 bar AUX
T2 ST1 ST2
BI
LS TEST FUNCTION
MANIFOLD
RESERVOIR
T1
5 PRESS
OPTIONAL
GENERATOR
MANIFOLD
8 6 3 1 2 4 5
x x
7
2400 psi
HYDRAULIC ROTARY COUPLER 165.5 bars
6 x x x x x x x x
8A 8B 8C 6B 6C 6B 3 1 2A 2C 2B 7 4 5
FUNCTION TANK
7
PUMP
A B TEST
M3 T2
REAR FE
RELEASE
RIGHT
185 psi
12.7 bar OPTIONAL
FRR FRB FLB FLR TO HYD ROTARY COUPLER
GENERATOR
7 M1
RIGHT STEERING LEFT
50% 210 psi
14.5 bar
FC
.070
FA
FB FD
50%
M4
8
T1 Note: 'alpha' callouts refer to
185 psi T components shown in the
REAR
12.7 bar M2
LEFT manifold illustrations.
RELEASE
Refer to the Repair Section.
TRACTION
MANIFOLD
6 - 142 S-40 • S-45 Part No. 102521


1
EXTEND RETRACT CYL TURNTABLE
4 GPM ROTATE PLATFORM LEVEL S45 JIB BOOM
15.1 L/min 2 gpm C
50 psi 7.6 L/min SLAVE CYLINDERS J2
3.5 bar MEDIUM PRIMARY LIFT F F
BRAKE MANIFOLD PRESSURE CYLINDER
A A 3 GPM
V1
FILTER 11.4 L/min
.025 DB
T2 J1
CP C
DA
C B C C CC
2
MASTER
V2 D
BRAKE TEST .030 CA
PR1
S1
A AUXILIARY
M V2 V1 PL1 PL2
1.7
PUMP PR2
B BG BE
AUX AP PTEST EXT RET SW1 SW2 P1 P2 PR1 PR2 JIB SELECT CB
D
HYDRAULIC MANIFOLD
COOLER AO FUNCTION 2200 psi
E E
TEST 151.7 bar PLATFORM
315 psi OPTION MANIFOLD AL AI
AD BA
BH AB
ROTATE
3
21.7 bars T1 1950 psi AV
134.4 bar AZ
AX AY
BF
PRESS
AU AE AC
3625 psi AS AG AH
249.9 bar
BD AA
AR 4.5 gpm 0.6 gpm
AM AF AK 0.8 gpm
17 L/min 2.27 L/min
FUNCTION BB
3 L/min
E 9 7 AW
PUMP
RETURN AN
4
DRIVE PUMP FILTER 2.0 gpm
BG AJ
25 psi 7.6 L/min 0.1 gpm

AQ
1.7 bar AT 0.38 L/min
2900 psi
200 bar
TANK
3 psi 3 psi
0.2 bar AUX
0.2 bar
BI
T2 ST1 ST2 LS TEST FUNCTION
MANIFOLD
RESERVOIR
5
T1
PRESS
OPTIONAL
COUNTERBALANCE VALVE GENERATOR
MANIFOLD
8 6 3 1 2 4 5 RATIO PRESS
x x
7
2400 psi
HYDRAULIC ROTARY COUPLER A 3:1 1000 PSI 165.5 bar
6
x x x x x x x x B 3:1 2000 PSI
8A 8B 8C 6B 6C 6B 3 1 2A 2C 2B 7 4 5
C 3:1 3000 PSI
FUNCTION TANK
3:1 3300 PSI 7
D PUMP
E 3:1 3500 PSI
A B TEST
F 5:1 3500 PSI T2
REAR M3
FE
RIGHT 185 psi 7

12.7 bar OPTIONAL
RELEASE FRR FRB FLB FLR TO HYD ROTARY COUPLER
GENERATOR
M1
RIGHT STEERING LEFT
50%
FC
.070
FA
FB
50%
FD
Note: 'alpha' callouts refer to 8
components shown in the
M4
manifold illustrations.
T1
M2 T
REAR 185 psi
LEFT 12.7 bar
RELEASE
TRACTION
MANIFOLD
Part No. 102521 S-40 • S-45 6 - 143


6 - 143
6 - 144
4WD Oscillating Hydraulic Schematic

6 - 146
6 - 145

1 4 gpm ROTATE
15.1 L/min 2 gpm SLAVE
PLATFORM LEVEL
50 psi 7.6 L/min PRIMARY LIFT CYLINDERS
3.4 bar MEDIUM CYLINDER
F F
BRAKE MANIFOLD PRESSURE 3 gpm
A A D
FILTER 11.4 L/min CA
.025 DB
T2
CP
DA
C B C C
MASTER
2 BRAKE
TEST .030 CB
S1 D
A V2 V1 PL1 PL2 PLATFORM
B ROTATE
AUX AP PTEST EXT RET SW1 SW2 P1 P2
BG BE
PR1 PR2
M 1.7
AUXILIARY
PUMP HYDRAULIC FUNCTION 2200 psi E E
TEST COOLER AO
151.7 bar COUNTERBALANCE VALVE
MANIFOLD AL
BH AB
315 psi OPTION AI AD BA
21.7 bar T1 1950 psi AV RATIO PRESS
134.4 bar AZ AX AY
3 PRESS
AU AE AC
BF
A 3:1 1000 PSI
AS
3625 psi
AG
AH B 3:1 2000 PSI
AA
249.9 bar BD
AR
4.5 gpm 0.6 gpm 0.6 gpm C 3:1 3000 PSI
AM AF
FUNCTION 17 L/min AK 2.27 L/min 2 L/min
BB
E 9 7 2
PUMP
AW
D 3:1 3300 PSI
AN
E 3:1 3500 PSI
RETURN AJ
DRIVE PUMP FILTER AQ
2.0 gpm
BG
F 5:1 3500 PSI
25 psi 7.6 L/min 0.1 gpm
4 1.7 bar AT 0.38 L/min
G 1.5:1 3000 PSI
2600 psi
TANK 179.3 bar
3 psi 3 psi
0.2 bar 0.2 bar AUX
BI
T2 ST1 ST2 LS TEST FUNCTION
MANIFOLD
RESERVOIR
T1
5 PRESS
OPTIONAL
GENERATOR
8 6 3 1 2 7 4 5
MANIFOLD
x 2400 psi
165.5 bar
HYDRAULIC ROTARY COUPLER
x x x x x
8A 8B 8C 6B 6C 6A 3 1 2A 2C 2B 7 4 5
6
FUNCTION TANK
7 2
PUMP
HF TEST A B
T2
REAR M7 M4
LEFT
FRONT
LEFT OPTIONAL
FRR FRB FLB FLR TO HYD ROTARY COUPLER
GENERATOR
7 M5 HH
M2
RIGHT
STEERING LEFT
210 psi HE
50% 14.5 bar

50%
HA
67% 33% TEST
.070 .052
HC HI
HG
.070 IN B
50% 50%
HD OUT A
M8 950 psi
REAR M3 65.5 bar LEFT RIGHT
RIGHT FRONT
8 RIGHT
Note: 'alpha' callouts refer to
T1
OSCILLATE VALVE components shown in the
M1 M6 manifold illustrations.
G G Refer to the Repair Section.
TRACTION T
MANIFOLD
OSCILLATE CYLINDERS
6 - 146 S-40 • S-45 Part No. 102521


1
4 gpm S45 JIB BOOM
ROTATE PLATFORM LEVEL
15.1 L/min SLAVE C
2 gpm CYLINDERS
50 psi J2
MEDIUM
7.6 L/min PRIMARY LIFT F F
3.4 bar
BRAKE MANIFOLD PRESSURE CYLINDER
A A 3 gpm V1
FILTER 11.4 L/min
.025 DB
T2 J1
CP C
DA
C B C C CC 2
MASTER
TEST V2 D
BRAKE .030 CA
PR1
S1
A V2 V1 PL1 PL2
B PR2
BG BE
AUX AP PTEST EXT RET SW1 SW2 P1 P2 PR1 PR2 JIB SELECT CB
M
AUXILIARY MANIFOLD D
1.7
PUMP HYDRAULIC AO
FUNCTION 2200 psi E E
TEST COOLER MANIFOLD
151.7 bar
BH AB PLATFORM
315 psi
21.7 bar
OPTION
T1 1950 psi
AL
AV
AI
AD BA ROTATE 3
134.5 bar AZ
AX AY
PRESS BF
AU AE AC
AS AG
AH
3625 psi
249.9 bar BD
AA
AR
4.5 gpm 0.8 gpm
AM AF AK 0.6 gpm
FUNCTION 17 L/min 3 L/min
E 9 7 2 BB AW 2.27 L/min
PUMP
AN
DRIVE PUMP RETURN AQ

2.0 gpm
BG AJ RATIO PRESS 4
FILTER 7.5 L/min 0.1 gpm
25 PSI AT
0.3 L/min A 3:1 1000 PSI
2900 psi
200 bar
TANK B 3:1 2000 PSI
3 psi 3 psi C 3:1 3000 PSI
0.2 bar 0.2 bar
ST2 BI D 3:1 3300 PSI

T2 ST1 LS TEST
E 3:1 3500 PSI
RESERVOIR
F 5:1 3500 PSI 5
G 1.5:1 3000 PSI
AUX
8 6 3 1 2 7 4 5
x FUNCTION
HYDRAULIC ROTARY COUPLER MANIFOLD
T1
x x x x x
6
8A 8B 8C 6B 6C 6A 3 1 2A 2C 2B 7 4 5 PRESS
OPTIONAL
GENERATOR
HF TEST A B MANIFOLD
M4 2400 psi
REAR M7 165.5 bar
LEFT
FRONT
LEFT
FRR FRB FLB FLR 7
M5 M2
HH
RIGHT LEFT FUNCTION
STEERING 7 2 TANK
210 psi HE
PUMP
50% 14.5 bar
50%
HA
67% 33% TEST
.070 .052 T2
HC HB HI
HG
.070 IN B
50% 50%
OUT A
HD
OPTIONAL
REAR M3 M8 950 psi
65.5 bar LEFT RIGHT
GENERATOR TO HYD ROTARY COUPLER 8
RIGHT FRONT
RIGHT
T1
OSCILLATE VALVE
M1 M6 manifold illustrations.
G G Refer to the Repair Section.
TRACTION T
MANIFOLD
OSCILLATE CYLINDERS
Part No. 102521 S-40 • S-45 6 - 147


6 - 147
6 - 148
2WD Hydraulic Schematic

6 - 150
6 - 149

1 .030 orifice added after serial number 8445
removed at serial number 16791
EXTEND RETRACT CYLINDER TURNTABLE

(4 gpm / 15.1 L/min) ROTATE PLATFORM LEVEL S45 JIB BOOM
(2 gpm / 7.5 L/min) SLAVE CYLINDERS C
50 psi J2
3.5 bar MEDIUM PRIMARY LIFT F F
BRAKE/2 SPEED PRESSURE
A A CYLINDER
MANIFOLD EA FILTER (3 gpm / 11.3 L/min) V1
025. T2 0.030
J1
ED CP
2 C B C C C
EB EC
MASTER
CC
.030
BRAKE 2SPEED TEST
S1 V2
CA D
A PR1
M 1.7 AUXILIARY V2 V1 PL1 PL2 R
PUMP
B PTEST BC BE
AUX AP
EXT RET SW1 SW2 P1 P2 PR1 PR2
HYDRAULIC
COOLER FUNCTION 2200 psi E E L
TEST
AO
151.6 bar PR2
MANIFOLD
3 315 psi
OPTION AL
AD BA
BH AB
JIB SELECT CB
21.7 bar 1950 psi AV AI

MANIFOLD D
T1 AX AY
134.5 bar AZ
PRESS BF PLATFORM
AU AE AC
ROTATE
3625 psi AS
AG AH
249.9 bar
BD
AA
AR
4.5 gpm 0.6 gpm 0.8 gpm 0.6 gpm
AM AF AK
2.2 L/min 3 L/min 2 L/min RATIO PRESS
FUNCTION 17 L/m (S-45) (S-40)
E 9 7 2 PUMP
BB AW
A 3:1 1000 PSI
AN B 3:1 2000 PSI
4 DRIVE PUMP AQ BG Valve BD changed AJ Valve AA changed
C 3:1 3000 PSI
2.0 gpm to 0.2 gpm at D 3:1 3300 PSI
7.5 L/m 0.1 gpm to 0.4 gpm at
25 psi
AT
serial number 16791
0.3 L/min serial number 16791 E 3:1 3500 PSI
X X 1.7 bar 2900 psi 2600 psi
200 bar
S45 valve AA changed to F 5:1 3500 PSI
179 bar
TANK 0.6 gpm at serial number 18302
(S-45) (S-40) G 1.5:1 3000 PSI
3 psi 3 psi
0.20 bar 0.20 bar RETURN
FILTER
T2 ST1 ST2 BI
LS TEST
5 RESERVOIR
AUX
HYDRAULIC GENERATOR FUNCTION
MTE HYDRAULIC GENERATOR OPTION
OPTION MANIFOLD from serial number 16453
to serial number 16452 T1
PRESS FUNCTION
6 8 3 1 7 2 4 5 PUMP
HYDRAULIC ROTARY COUPLER 2400 psi HYDRAULIC GENERATOR OPTION

OPTIONAL 165.4 bar
6 GENERATOR PORT ON
X X X X X MANIFOLD
8B 6B 6C 6A 8A 3 1 2A 2B 7 5 RELIEF VALVE SIDE OF MOTOR
8C 2C 4 2400 psi
165.4 bar SET @ 2700 PSI
TO OC
F
FUNCTION
TEST A B PUMP 7 2 TANK
FRR FRB FLB FLR
RIGHT M4
REAR
7 A RIGHT LEFT T2 P
STEERING
GE
CDR
B OPTIONAL
GC
M2 GA
GENERATOR TO HYD ROTARY COUPLER
50%
280 psi TEST CD (PORT ON T
.070
19.3 bar TOP OF MOTOR)
GF
GB
IN B
OUT A PMP
8 50%
GD
950 psi FUNCTION TO OC OIL
M1 65.5 bar LEFT RIGHT MANIFOLD COOLER
CDL T
A Note: 'alpha' callouts refer to
TRACTION components shown in the
MANIFOLD OSCILLATE VALVE
B M3 manifold illustrations.
LEFT G G
REAR Refer to the Repair Section.
OSCILLATE CYLINDERS OPTION OSCILLATE CYLINDERS
6 - 150 S-40 • S-45 Part No. 102521


.030 orifice added after serial number 8445 1
removed at serial number 16791
EXTEND RETRACT CYLINDER TURNTABLE S45 JIB BOOM

(4 gpm / 15.1 L/min) ROTATE PLATFORM LEVEL
50 psi MEDIUM (2 gpm / 7.5 L/min) SLAVE CYLINDERS C
BRAKE/2 SPEED 3.5 bar PRESSURE F F
J2
FILTER PRIMARY LIFT
MANIFOLD A A CYLINDER
EA
(3 gpm / 11.3 L/min) V1
.025 T2 0.030
ED CP
J1 2
C B C C C
MASTER
EB EC
TEST CC
BRAKE 2SPEED
S1 V2
A PR1
CA D
AUXILIARY V2 V1 PL1 PL2
M 1.7 PUMP R
B BC BE
AUX AP PTEST EXT RET SW1 SW2 P1 P2 PR1 PR2
HYDRAULIC
COOLER FUNCTION 2200 psi L
E E PR2
TEST
315 psi
OPTION
AO
MANIFOLD 151.6 bar BH AB 3
AL
AI AD BA
JIB SELECT CB
D
21.7 bar T1 1950 psi AV
AY
MANIFOLD
AX
AZ
PRESS
134.5 bar BF
AU AE AC
PLATFORM
3625 psi AS AG AH
ROTATE
249.9 bar AA
BD
AR
4.5 gpm AK
0.6 gpm 0.8 gpm 0.6 gpm
17 L/min
AM AF
2.2 L/min 3 L/min 2 L/min COUNTERBALANCE VALVE
E 9 7 2 FUNCTION BB AW (S-45) (S-40)
PUMP RATIO PRESS
AN
A 3:1 1000 PSI 4
DRIVE PUMP 2.0 gpm BG Valve BD changed AJ Valve AA changed
3:1 2000 PSI
AQ
to 0.2 gpm at 0.1 gpm to 0.4 gpm at B
25 psi 7.5 L/min
X X 1.7 bar 2900 psi
AT serial number 16791
0.3 L/min serial number 16791 C 3:1 3000 PSI
2600 psi
S45 valve AA changed to
200 bar 179 bar
0.6 gpm at serial number 18302 D 3:1 3300 PSI
TANK (S-45) (S-40)
3 psi 3 psi E 3:1 3500 PSI
0.20 bar 0.20 bar
RETURN F 5:1 3500 PSI
FILTER
T2 ST1 ST2 BI G 1.5:1 3000 PSI
LS TEST
RESERVOIR 5
AUX
HYDRAULIC GENERATOR FUNCTION
MTE HYDRAULIC GENERATOR OPTION
OPTION MANIFOLD from serial number 16453
to serial number 16452 T1
PRESS FUNCTION
6 8 3 1 2 7 4 5 PUMP
2400 psi HYDRAULIC GENERATOR OPTION
HYDRAULIC ROTARY COUPLER OPTIONAL 165.4 bar 6
GENERATOR PORT ON
MANIFOLD
4 5 RELIEF VALVE SIDE OF MOTOR
8C 8B 6B 6C 6A 8A 3 1 2A 2C 2B 7 2400 psi
165.4 bar SET @ 2700 PSI
TO OC
F
FUNCTION
TEST A B PUMP 7 2 TANK
RIGHT FRR FRB FLB FLR
RIGHT M7
JD JC
M8
REAR
A A
FRONT
RIGHT LEFT P 7
T2
STEERING
CDR JL
B M6 B OPTIONAL
M5 JA
GENERATOR TO HYD ROTARY COUPLER
50% 50%
TEST CD (PORT ON T
.040 280 psi .040
19.3 bar TOP OF MOTOR)
JH JI
JE 50% 50% IN B
JB JM
OUT A PMP
50% .040 JG
50% 950 psi FUNCTION TO OC OIL
8
JN JK
M3 M4 65.5 bar LEFT RIGHT MANIFOLD COOLER
CDL
B B
TRACTION components shown in the
JF JJ MANIFOLD A OSCILLATE VALVE
A M1 M2 LEFT manifold illustrations.
LEFT
REAR FRONT G G Refer to the Repair Section.
T
OSCILLATE CYLINDERS OPTION
OSCILLATE CYLINDERS
Part No. 102521 S-40 • S-45 6 - 151


6 - 151
6 - 152
Generator Hydraulic Schematic- Welder Option
1
HYDRAULIC WELDER OPTION

2
B
OIL 3.5 GPM DRIVE

COOLER PUMP
A
3
PMP B CLR PMP A
WELDER
MANIFOLD
AJ AK AL
4
NO PRESS SW
200 PSI
AM
Ø.031
AN
AI
270 PSI @ 5
G2 3.5 GPM
AH
G1
MTR B MTR A
21 GPM
6
3
1
1
HYDRAULIC
COUPLER
ROTARY
TANK
7
21CC
G2 G1
12.5 KW GENERATOR

8
manifold illustrations.
Part No. 102521 S-40 • S-45 6 - 153

Generator Hydraulic Schematic- Welder Option
6 - 153
6 - 154
California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
Genie North America

Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia
Phone +46 31 57 51 00 Genie China
Fax +46 31 57 51 04 Phone +86 21 53853768
Fax +86 21 53852569
Genie France
Phone +33 2 37 26 09 99 Genie Singapore
Fax +33 2 37 26 09 98 Phone +65 67533544
Fax +65 67533544
Genie Iberica
Phone +34 93 572 5090 Genie Japan
Fax +34 93 572 5091 Phone +81 3 6436 2020
Fax +81 3 5445 1231
Genie Germany
Phone 0800 180 9017 Genie Korea
Phone +49 4221 491 810 Phone +82 2 558 7267
Fax +49 4221 491 820 Fax +82 2 558 3910
Genie U.K. Genie Brasil

Phone +44 1476 584333 Phone +55 11 4082 5600
Fax +44 1476 584334 Fax +55 22 4082 5630
Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566
Part No.
102521
Service Manual
Rev E
(from serial number S40-7001)
S-40 • S-45

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Service Manual

Serial Number Range

Part No. 102521

Important Serial Number Information

Machine Design Life

"Genie" and "S" are registered trademarks of

ii S-40 • S-45 Part No. 102521

3 - Maint. 3-1, 3-3, 3-9 to 3-15, 3-17, 3-35 to 3-38, 3-54

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

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

D2 10/2013 4- Repair 4-3

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

2-1_Section 2_Specifications Page #. Electronic Version

Part No. 102521 S-40 • S-45

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

2-1_Section 2_Specifications Page #. Electronic Version

S-40 • S-45 Part No. 102521

Serial Number Legend

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

Sequence number Serial label

This page intentionally left blank.

Many of the hazards identified in the operator's

Do Not Perform Maintenance

Personal Safety Be sure to wear protective eye wear and

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Section 3 Rev Scheduled Maintenance Procedures, continued

viii S-40 • S-45 Part No. 102521

Section 3 Rev Scheduled Maintenance Procedures, continued

Part No. 102521 S-40 • S-45 ix

Section 3 Rev Scheduled Maintenance Procedures, continued

Section 4 Rev Repair Procedures

Section 4 Rev Repair Procedures, continued

Section 5 Rev Fault Codes

Section 6 Rev Schematics

Section 6 Rev Schematics, continued

Section 6 Rev Schematics, continued

Section 6 Rev Schematics, continued

Part No. 102521 S-40 • S-45

Section 6 Rev Schematics, continued

S-40 • S-45 Part No. 102521

Tires and wheels Weight, assembly (each) 480 lbs

Tire contact area 88 sq in 57 sq in Hydraulic tank 45 gallons

Overall tire diameter 33.7 in 33.2 in Hydraulic system 55 gallons

Tire pressure 45 psi 45 psi Drive hub 17 fl oz

Tire pressure 60 psi 60 psi Drive hub 24 fl oz

Wheel diameter 16 in 161/2 in Drive hub 20 fl oz

Wheel width 10 in 9 3/4 in Turntable rotation 8 fl oz

Lug nut, dry 230 ft-lbs

Lug nut torque - 8-bolt non-drive spindles

Lug nut, dry 170 ft-lbs

Lug nut, lubricated 130 ft-lbs

Continuous improvement of our products is a Genie

Part No. 102521 S-40 • S-45 2-1

Performance Specifications Hydraulic Oil Specifications

Turntable rotate, 360° Mineral based Shell Tellus S2 V 32

Platform level (10° range of motion)

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

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

Braking distance, maximum

High range on paved surface 3 to 4 ft