Genie S-40 Service Manual
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Genie S-40 Service Manual

Serial number range from s40-7001 to s4012-17231
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Download this manual See also: Service & Repair Manual, Maintenance Manual
Service Manual
S-40
TM
S-45
TM
Serial Number Range
from S40-7001 to
S4012-17231
Part No. 102521
Rev E
October 2013

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Summary of Contents for Genie S-40

  • Page 1 Service Manual Serial Number Range from S40-7001 to S-40 S4012-17231 S-45 Part No. 102521 Rev E October 2013...

  • Page 2: Introduction

    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.
  • Page 3 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. Click on any procedure or page number 4-48_Section 4_Repair Procedure Page #. highlighted in blue to view the update. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. Part No. 102521 S-40 • S-45...
  • Page 4 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. Click on any procedure or page number 4-48_Section 4_Repair Procedure Page #. highlighted in blue to view the update. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. S-40 • S-45 Part No. 102521...

  • Page 5: Serial Number Legend

    Country of manufacture: USA This machine complies with: ANSI A92.5 CAN B.354.4 Genie Industries 18340 NE 76th Street Redmond, WA 98052 Serial label Sequence number (located under cover) (stamped on chassis) PN - 77055 Part No. 102521 S-40 • S-45...
  • Page 6 Section 1 • Safety Rules July 2007 This page intentionally left blank. S-40 • S-45 Part No. 102521...

  • Page 7: Safety Rules

    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.
  • Page 8 Be sure to properly dispose of old oil or which, if not avoided, may result in other fluids. Use an approved container. property damage. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. S-40 • S-45 Part No. 102521...

  • Page 9: Table Of Contents

    Maintenance Inspection Report ................3 - 5 Checklist A Procedures Inspect the Decals and Manuals ..............3 - 7 Perform Pre-operation Inspection ..............3 - 8 Perform Function Tests ................3 - 8 Perform Engine Maintenance ............... 3 - 9 Part No. 102521 S-40 • S-45...
  • Page 10 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...
  • Page 11 Perform Engine Maintenance - Deutz and Perkins Models ......3 - 53 Perform Engine Maintenance - Ford Models ..........3 - 54 Perform Engine Maintenance - Deutz and Perkins Models ......3 - 54 Part No. 102521 S-40 • S-45...
  • Page 12 RPM Adjustment - Deutz Models ............... 4 - 24 RPM Adjustment - Perkins Models ............. 4 - 24 Flex Plate ....................4 - 24 Engine Fault Codes - Ford Models ............. 4 - 28 S-40 • S-45 Part No. 102521...
  • Page 13 Turntable Rotation Assembly ..............4 - 56 Axle Components Oscillate Axle Cylinders ................4 - 58 Track Components 10-1 Track Assembly - TRAX Option ..............4 - 59 Generators 10-1 Hydraulic Generator ..................4 - 61 Part No. 102521 S-40 • S-45...
  • Page 14 Ground Control Box Wiring Diagram Perkins 704-30 Models ................6 - 21 Platform Control Box Wiring Diagram Perkins 704-30 Models ................6 - 24 Platform Control Box Switch Panel Wiring Diagram Perkins 704-30 Models ................6 - 25 S-40 • S-45 Part No. 102521...
  • Page 15 Deutz F3L-2011/Deutz D2011L03i Models Perkins 404-22 Models (before serial number 14832) ......... 6 - 56 Ground Control Box Wiring Diagram, Deutz F3L-2011/Deutz D2011L03i Models Perkins 404-22 Models (from serial number 14832) ........6 - 57 xiii Part No. 102521 S-40 • S-45...
  • Page 16 Ground Control Box Wiring Diagram, Ford LRG-425 EFI Models (from serial number 7597 to 11066) ............6 - 81 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) ............6 - 84 S-40 • S-45 Part No. 102521...
  • Page 17 Platform Control Box Switch Panel Wiring Diagram, Ford DSG-423 EFI Models (from serial number 11067 to 12509) ....6 - 124 Platform Control Box Switch Panel Wiring Diagram Ford DSG-423 EFI Models (from serial number 12510) ......6 - 125 Part No. 102521 S-40 • S-45...
  • Page 18 MTE Hydraulic Generator Option Wiring Diagram ..........6 - 138 Hydraulic Generator Wiring Diagram (welder option) ..........6 - 139 Hydraulic Schematic, 2WD Non-oscillating S-40 Models (before serial number 7569) ............... 6 - 142 Hydraulic Schematic, 2WD Non-oscillating S-45 Models (before serial number 7569) ...............

  • Page 19: Machine Specifications

    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...

  • Page 20: Hydraulic Oil Specifications

    Shell Donax TG (Dexron III) oils. Drive speed, stowed 40 ft / 11 sec Genie specifications require hydraulic oils which are 12.2 m / 11 sec designed to give maximum protection to hydraulic Drive speed, raised or extended...
  • Page 21 0 to 28 gpm Note: Genie specifications require additional 106 L/min equipment and special installation instructions for Drive pressure, maximum 3625 psi the approved optional fluids. Consult the Genie 250 bar Industries Service Department before use. Charge pump Type: gerotor pump Displacement 0.85 cu in...
  • Page 22 Traction manifold, 2WD and 4WD (after serial number 7568) Hot oil relief pressure 280 psi 19.3 bar Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 S-40 • S-45 Part No. 102521...

  • Page 23: Manifold Component Specifications

    (schematic items DA) 4.8 Ω Solenoid valve, 2 position 3 way, 12V DC (schematic items CE) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 102521 S-40 • S-45 2 - 5...

  • Page 24: Ford Lrg-425 Efi Engine Specifications

    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...

  • Page 25: Ford Dsg-423 Efi Engine Specifications

    Quantity Cold cranking ampere @ 0°F 1000A Reserve capacity @ 25A rate 200 minutes Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 102521 S-40 • S-45 2 - 7...

  • Page 26: Deutz F3L-1011F Engine Specifications

    Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Continuous improvement of our products is a engine Operator's Manual on your machine. Genie policy. Product specifications are subject to change without notice. 2 - 8 S-40 • S-45...
  • Page 27 7 psi Valve clearance, cold (Deutz F3L2011 Engine) .5 bar Intake 0.012 in Oil pressure switch point 22 psi 0.3 mm (Deutz D2011L03i Engine) 1.5 bar Exhaust 0.020 in 0.5 mm Part No. 102521 S-40 • S-45 2 - 9...
  • Page 28 Battery Type 12V, Group 31 Quantity Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes Alternator output 60A @ 14V DC Fan belt deflection inch 9 to 12 mm 2 - 10 S-40 • S-45 Part No. 102521...

  • Page 29: Perkins 704-30 Engine Specifications

    41 psi Quantity (at 2600 rpm) 2.8 bar Cold cranking ampere 1000A Oil capacity 7.3 quarts Reserve capacity @ 25A rate 200 minutes (including filter) 8.3 liters Fan belt deflection 10 mm Part No. 102521 S-40 • S-45 2 - 11...

  • Page 30: Perkins 404-22 Engine Specifications

    (at 2000 rpm) 2.8 to 4.1 bar Fan belt deflection to ½ in Oil capacity 9.4 quarts to 11.2 quarts 9 to 12 mm (including filter) 8.9 liters to 10.6 liters 2 - 12 S-40 • S-45 Part No. 102521...

  • Page 31: Machine Torque Specifications

    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...

  • Page 32: Hydraulic Hose And Fitting Torque Specifications

    O-rings. or when new hoses or fittings are installed. 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.
  • Page 33 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4 18.9 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 Part No. 102521 S-40 • S-45 2 - 15...
  • Page 34 Repair any machine damage or malfunction indicate the presence of a before operating machine potentially hazardous situation 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...
  • Page 35 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...

  • Page 36: Pre-Delivery Preparation

    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...
  • Page 37 Section 3 • Scheduled Maintenance Procedures October 2013 This page intentionally left blank. 3 - 4 S-40 • S-45 Part No. 102521...

  • Page 38: Maintenance Inspection Report

    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...
  • Page 39 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...

  • Page 40: Checklist A Procedures

    Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed daily. Result: The machine is equipped with all required decals, and all decals are legible and Maintaining the operator’s and safety manuals in...

  • Page 41: Perform Pre-Operation Inspection

    Section 3 • Scheduled Maintenance Procedures October 2013 CHECKLIST A PROCEDURES 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...

  • Page 42: Inspect The Track Components, Trax Option

    TRAX option Perkins 404-22 Operation Manual (Perkins part number TPD 1443S). Perkins 404-22 Operation Manual Note: Genie specifications require that this Genie part number 94890 procedure be performed daily or every 8 hours, whichever comes first.

  • Page 43: Perform 30 Day Service

    Check the Turnable Rotation Bearing • (Deutz part number 0312 3547). Bolts Replace the Hydraulic Filter Elements • Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 3 - 10 S-40 • S-45 Part No. 102521...

  • Page 44: Replace The Drive Hub Oil

    6 Repeat steps 1 through 5 for all the other drive injury. hubs. models with pipe plugs drive hub plugs Part No. 102521 S-40 • S-45 3 - 11...

  • Page 45: Perform Engine Maintenance - Perkins Models

    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...

  • Page 46: Perform Engine Maintenance - Ford Models

    Swing the engine tray out and away from the machine and secure it from moving. Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. Part No. 102521 S-40 • S-45 3 - 13...

  • Page 47: Grease The Turntable Rotation Bearing And Rotate Gear

    Bearing and Rotate Gear Deutz 1011F Models Engine specifications require that this procedure Genie specifications require that this procedure be be performed after the first 125 hours. performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist.

  • Page 48: Perform Engine Maintenance - Ford Models

    (Ford part number 1020010) . Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG-425 EFI Operator Handbook Genie part number 215322 Part No. 102521 S-40 • S-45 3 - 15...

  • Page 49: Checklist B Procedures

    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.

  • Page 50: Inspect The Electrical Wiring

    • 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 5 Open the turntable cover at the ground control comes first.

  • Page 51: Inspect The Air Filter

    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.

  • Page 52: Test The Key Switch

    CHECKLIST B PROCEDURES Test the Key Switch Perform Engine Maintenance - Deutz and Perkins Models Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper key switch action and response is essential Engine specifications require that this procedure be to safe machine operation.

  • Page 53: Check The Exhaust System

    CHECKLIST B PROCEDURES Check the Exhaust System Check the Oil Cooler and Cooling Fins - Deutz Models Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first.

  • Page 54: Inspect The Tires, Wheels And Lug Nut Torque

    Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES Inspect the Tires, Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the tires and wheels in good condition including proper wheel fastener torque is essential to safe operation and good performance.

  • Page 55: Check The Drive Hub Oil Level And Fastener Torque

    Fastener Torque Result: The oil level should be even with the bottom of the plug hole. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage.

  • Page 56: Confirm The Proper Brake Configuration

    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 performed every 250 hours or quarterly, whichever comes first. Proper brake configuration is essential to safe operation and good machine performance.

  • Page 57: Check And Adjust The Engine Rpm

    CHECKLIST B PROCEDURES B-11 Check and Adjust the Engine RPM Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life.

  • Page 58: Test The Engine Idle Select

    Test the Engine Idle Select 2 Loosen the low idle lock nut. Turn the low idle adjustment screw clockwise to increase the Genie specifications require that this procedure be rpm, or counterclockwise to decrease the rpm. performed every 250 hours or quarterly, whichever comes first.

  • Page 59: Test The Fuel Select Operation - Ford Models

    3 Release the foot switch and shut the engine off by pushing the red Emergency Stop button in to the off position. Genie specifications require that this procedure be 4 Move the fuel select switch to LPG. performed every 250 hours or quarterly, whichever comes first.

  • Page 60: Test The Ground Control Override

    B-15 Test the Ground Control Override Check the Directional Valve Linkage Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly functioning ground control override is Genie specifications require that this procedure be essential to safe machine operation.

  • Page 61: Test The Platform Self-Leveling

    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.

  • Page 62: Test The Drive Speed - Stowed Position

    Test the Drive Speed - Test the Drive Speed - Stowed Position Raised or Extended Position 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.

  • Page 63: Perform Hydraulic Oil Analysis

    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 comes first.

  • Page 64: Test The Alarm Package (If Equipped) And The Descent Alarm

    Descent Alarm Result: The descent alarm should sound when the toggle switch is held down. Genie specifications require that this procedure be 4 Turn the key switch to platform controls. performed every 250 hours or quarterly, whichever comes first.

  • Page 65: Inspect The Fuel And Hydraulic Tank Cap Venting System

    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.

  • Page 66: Check The Track Tension And Fastener Torque, Trax Option

    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...

  • Page 67: Perform Engine Maintenance - Ford Models

    Swing the engine tray out and away from the machine and secure it from moving. Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. 3 - 34 S-40 • S-45 Part No. 102521...

  • Page 68: Checklist C Procedures

    ( Deutz part number 0297 9683) or the Deutz 2011 Operation Manual ( Deutz part number 0312 3547). Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 Part No. 102521 S-40 • S-45 3 - 35...

  • Page 69: Grease The Platform Overload Mechanism (If Equipped)

    Grease the Platform Overload Test the Platform Overload Mechanism (if equipped) System (if equipped) Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever performed every 500 hours or six months, comes first.
  • Page 70 Result: The platform overload indicator lights and the engine shuts off. should turn off at both the ground and platform controls and the alarm should not sound. Part No. 102521 S-40 • S-45 3 - 37...
  • Page 71 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.

  • Page 72: Replace The Engine Air Filter - Deutz And Perkins Models

    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.

  • Page 73: Replace The Inline Fuel Strainer

    Swing the engine tray out and away from the machine and secure it from moving. Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. 3 - 40 S-40 • S-45 Part No. 102521...

  • Page 74: Checklist D Procedures

    Check the Boom Wear Pads all wear pads 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.

  • Page 75: Check The Turntable Rotation Bearing Bolts

    Section 3 • Scheduled Maintenance Procedures October 2013 CHECKLIST D PROCEDURES Check the Turntable Rotation Bearing Bolts Genie specifications requires that this procedure be performed every 1000 hours or annually, whichever comes first. Maintaining proper torque on the turntable bearing Bolt torque sequence bolts is essential to safe machine operation.

  • Page 76: Check The Free-Wheel Configuration

    Refer to Check the Free-wheel Section 2, Specifications. Configuration Genie specifications requires that this procedure be performed every 1000 hours or annually, whichever comes first. Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing.
  • Page 77 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...

  • Page 78: Replace The Drive Hub Oil

    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.
  • Page 79 Swing the engine tray out and away from the machine and secure it from moving Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury 3 - 46 S-40 • S-45 Part No. 102521...

  • Page 80: Replace The Hydraulic Filters

    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, Note: The medium pressure filter is for the charge whichever comes first.

  • Page 81: Inspect For Turntable Bearing Wear

    October 2013 CHECKLIST D PROCEDURES Inspect for Turntable Bearing Wear Genie specifications requires that this procedure be performed every 1000 hours or annually, whichever comes first. Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life.
  • Page 82 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...

  • Page 83: Checklist E Procedures

    Test or Replace the Hydraulic Oil hydraulic tank through the access hole underneath the turntable. Close the valves. Genie specifications require that this procedure be performed every 2000 hours or 2 years, whichever comes first. Replacement or testing of the hydraulic oil is...
  • Page 84 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...

  • Page 85: Grease The Steer Axle Wheel Bearings, 2Wd Models

    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.

  • Page 86: Perform Engine Maintenance - Deutz And Perkins Models

    Swing the engine tray out and away from the machine and secure it from moving. Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. Part No. 102521 S-40 • S-45 3 - 53...

  • Page 87: Perform Engine Maintenance - Ford Models

    Swing the engine tray out and away from the machine and secure it from moving. Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. 3 - 54 S-40 • S-45 Part No. 102521...

  • Page 88: E-6 Perform Engine Maintenance - Deutz And Perkins Models

    Swing the engine tray out and away from the machine and secure it from moving. Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. Part No. 102521 S-40 • S-45 3 - 55...

  • Page 89: E-7 Perform Engine Maintenance - Deutz Models

    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...

  • Page 90: E-9 Perform Engine Maintenance - Ford Models

    Swing the engine tray out and away from the machine and secure it from moving. Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. Part No. 102521 S-40 • S-45 3 - 57...
  • Page 91 Section 3 • Scheduled Maintenance Procedures October 2013 CHECKLIST E PROCEDURES This page intentionally left blank. 3 - 58 S-40 • S-45 Part No. 102521...
  • Page 92 Used to indicate the presence of 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.

  • Page 93: Platform Controls

    3 Locate the ALC-500 circuit board mounted to the inside of the platform control box. ALC-500 circuit board drive/steer joystick controller secondary boom up/down joystick controller primary boom up/down and turntable rotate left/right joystick controller 4 - 2 S-40 • S-45 Part No. 102521...

  • Page 94: Joysticks

    Note: The joystick must be calibrated before the threshold, max-out or ramping can be set. Note: Perform this procedure with the engine off. 1 Open the platform control box. Part No. 102521 S-40 • S-45 4 - 3...
  • Page 95 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...
  • Page 96 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...
  • Page 97 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...
  • Page 98 Result: There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode. Result: The alarm does not sound. Repeat steps 3 through 7. Part No. 102521 S-40 • S-45 4 - 7...

  • Page 99: Platform Components

    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...

  • Page 100: Platform Rotator

    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...
  • Page 101 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...

  • Page 102: Platform Overload System

    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...
  • Page 103 Note: The platform will need to be moved up and down and allowed to settle between each adjustment. Note: There may be a 2 second delay before the platform overload indicator light and alarm responds. 4 - 12 S-40 • S-45 Part No. 102521...

  • Page 104: Part No. 102521 S-40 •

    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...

  • Page 105: Jib Boom Components

    6 Remove the hose cover, hoses and cables from the side of the jib boom and set them aside. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 4 - 14 S-40 • S-45 Part No. 102521...

  • Page 106: Jib Boom Lift Cylinder

    Do not allow oil to squirt or spray. 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. Part No. 102521 S-40 • S-45 4 - 15...

  • Page 107: Boom Components

    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...
  • Page 108 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.

  • Page 109: Boom

    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.
  • Page 110 Do not allow oil to 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...
  • Page 111 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...

  • Page 112: Boom Lift Cylinder

    Turn the machine off. Part No. 102521 S-40 • S-45 4 - 21...
  • Page 113 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...

  • Page 114: Platform Leveling Master Cylinder

    Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 102521 S-40 • S-45 4 - 23...

  • Page 115: Engines

    Component damage hazard. Hoses can be damaged if they are kinked or pinched. 5 Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel. 4 - 24 S-40 • S-45 Part No. 102521...
  • Page 116 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...
  • Page 117 Before serial number 13740: Torque the flex to 61 ft-lbs / 83 Nm. plate mounting bolts in sequence to 24 ft-lbs / 32 Nm. 5 Install the pump and bell housing assembly. 4 - 26 S-40 • S-45 Part No. 102521...
  • Page 118 Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. Ford DSG 423 models Part No. 102521 S-40 • S-45 4 - 27...

  • Page 119: Engine Fault Codes - Ford Models

    6 Refer to Section 5, Fault Codes , for definition of to retrieve fault codes stored within the ECM. engine fault codes. Contact Genie Industries Service Department for assistance in retrieving fault codes. Note: Once a fault code has been retrieved and the...

  • Page 120: Hydraulic Pumps

    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...

  • Page 121: Drive Pump

    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.
  • Page 122 3 Open the engine pivot plate latch and swing the valve. engine pivot plate out and away from the machine. 7 Start the engine from the ground controls and check for hydraulic leaks. Part No. 102521 S-40 • S-45 4 - 31...

  • Page 123: Manifolds

    (S-45) ......... 20-25 ft-lbs / 27-34 Nm Flow regulator valve, 0.6 gpm / 2.27 L/min ......AA ..platform rotate (S-40) ......20-25 ft-lbs / 27-34 Nm Check valve ........AB ..Differential sensing circuit, platform rotate right and jib boom down (S-45) ......
  • Page 124 October 2013 Section 4 • Repair Procedures MANIFOLDS AA AB AC AD AE AF AG AH AI AJ AK AL Part No. 102521 S-40 • S-45 4 - 33...
  • Page 125 2900 psi / 200 bar ......AQ ..System relief (S-45) ......30-35 ft-lbs / 41-47 Nm Relief valve, 2600 psi / 179 bar ......AQ ..System relief (S-40) ......30-35 ft-lbs / 41-47 Nm Flow regulator valve, 4.5 gpm / 17.03 L/min ......AR ..Boom extend/retract circuit ....30-35 ft-lbs / 41-47 Nm Check valve ........
  • Page 126 October 2013 Section 4 • Repair Procedures MANIFOLDS AA AB AC AD AE AF AG AH AI AJ AK AL Part No. 102521 S-40 • S-45 4 - 35...

  • Page 127: Valve Adjustments - Function Manifold

    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...
  • Page 128 Solenoid valve ........CE ..Controls generator on / off ....50-55 ft-lbs / 68-75 Nm Solenoid valve, 2 position 3 way ..CC ..Platform rotate/jib boom select ..18-20 ft-lbs / 25-27 Nm Jib Select Manifold Platform Rotate Manifold Generator Manifold Part No. 102521 S-40 • S-45 4 - 37...

  • Page 129: Brake Manifold Components (Before Serial Number 7569)

    Torque Solenoid valve, 2 position 3 way ... DA ... Brake release ........20-25 ft-lbs / 27-34 Nm Orifice, 0.025 inch / 0.635 mm ..DB ... Turntable rotation brake release 4 - 38 S-40 • S-45 Part No. 102521...

  • Page 130: Brake/Two-Speed Manifold Components (After Serial Number 7568)

    Solenoid valve, 2 position 3 way ... EC ... Two-speed motor shift ..... 20-25 ft-lbs / 27-34 Nm Check valve ........ED ... Brake release circuit ......20-25 ft-lbs / 27-34 Nm Part No. 102521 S-40 • S-45 4 - 39...
  • Page 131 The oscillate directional valve is mounted inside the drive chassis at the non-steer end. Index Description Function Torque Cap ..............Breather ..........20-25 ft-lbs / 27-33 Nm Spool valve ............Directional control Relief valve ............Pressure adjustment 4 - 40 S-40 • S-45 Part No. 102521...
  • Page 132 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.

  • Page 133: Valve Adjustments, Oscillate Relief Valve

    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...

  • Page 134: Traction Manifold Components, 2Wd (Before Serial Number 7569)

    Orifice, 0.070 inch / 1.78 mm .... FC ..Equalizes flow across flow divider/combiner valve (item FB) Shuttle valve, 3 position 3 way ..FD ..Charge pressure, hot oil shuttle ..50-55 ft-lbs / 68-75 Nm Diagnostic nipple ....... FE ..Testing Part No. 102521 S-40 • S-45 4 - 43...

  • Page 135: Traction Manifold Components, 2Wd (After Serial Number 7568)

    Flow divider/combiner valve ....GE ..Controls flow to drive motors in forward and reverse ...... 50-55 ft-lbs / 68-75 Nm Orifice, 0.070 inch / 1.78 mm .... GF ..Equalizes flow across flow divider/combiner valve (item GB) 4 - 44 S-40 • S-45 Part No. 102521...
  • Page 136 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...

  • Page 137: Traction Manifold Components, 4Wd (Before Serial Number 7569)

    Relief valve, 210 psi / 14.5 bar ..HH ..Charge pressure circuit ..... 30-35 ft-lbs / 41-47 Nm Orifice, 0.052 inch / 1.32 mm .... HI ..Front drive motor circuit 4 - 46 S-40 • S-45 Part No. 102521...
  • Page 138 October 2013 Section 4 • Repair Procedures MANIFOLDS Part No. 102521 S-40 • S-45 4 - 47...

  • Page 139: Traction Manifold Components, 4Wd (From Serial Number 7568 To 15822)

    Flow divider/combiner valve ....JM ..Controls flow to steer end drive motors in forward and reverse ........80-90 ft-lbs / 108-122 Nm 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...
  • Page 140 October 2013 Section 4 • Repair Procedures MANIFOLDS Part No. 102521 S-40 • S-45 4 - 49...

  • Page 141: Traction Manifold Components, 4Wd (From Serial Number 15823)

    Flow divider/combiner valve ..... KM ..Controls flow to steer end drive motors in forward and reverse ........80-90 ft-lbs / 108-122 Nm 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...
  • Page 142 October 2013 Section 4 • Repair Procedures MANIFOLDS Part No. 102521 S-40 • S-45 4 - 51...
  • Page 143 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...

  • Page 144: Valve Coils

    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...
  • Page 145 October 2013 MANIFOLDS How to Test a Coil Diode AMMETER Genie incorporates spike suppressing diodes in all COIL of its directional valve coils except proportional valves and those coils with a metal case. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes.

  • Page 146: Drive Oil Diverter Manifold Components (Welder Option)

    Solenoid valve ....... CV ... Pilot valve to diverter ....... 35-40 ft-lbs / 47-54 Nm Relief valve ........CX ... Charge pressure circuit ....35-40 ft-lbs / 47-54 Nm Check valve ........CU ... Prevents oil to generator ....35-40 ft-lbs / 47-54 Nm Part No. 102521 S-40 • S-45 4 - 55...

  • Page 147: Turntable Rotation Components

    1 Secure the turntable from rotating with the turntable rotation lock pin. Unlocked position brake assembly drive hub backlash plate mounting bolts backlash plate manifold motor Locked position 4 - 56 S-40 • S-45 Part No. 102521...
  • Page 148 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...

  • Page 149: Axle Components

    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...

  • Page 150: Track Components

    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...
  • Page 151 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...

  • Page 152: Generators

    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...
  • Page 153 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...
  • Page 154 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.
  • Page 155 OR use a grounded wrist strap. 5 - 2 S-40 • S-45 Part No. 102521...
  • Page 156 Boom 2 directional Valve is operating Cycle power off, valves outside of operational then on and Fault limits. Alarm sounds problem should be indicating fault. corrected. Continued on next page Part No. 102521 S-40 • S-45 5 - 3...
  • Page 157 Calibrate valve Not calibrated one or both directions thresholds. is zero. Drive enable Drive enable function Cycle power off, toggle switch is inoperative. then on and Fault problem should be corrected. 5 - 4 S-40 • S-45 Part No. 102521...
  • Page 158 Calibrate Joystick calibrated. Steer directional Valve is operating Cycle power off, valves outside of operational then on and Fault limits. Alarm sounds problem should be indicating fault. corrected. Part No. 102521 S-40 • S-45 5 - 5...
  • Page 159 123 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...
  • Page 160 Repair short in engine wire harness Adaptive Learn Low short to 5V DC or 12V DC OR fuel system OR test and repair the fuel system (LPG) components may be faulty. components. Part No. 102521 S-40 • S-45 5 - 7...
  • Page 161 OR sensor is faulty. to sensor OR replace sensor. Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor Camshaft Sensor Loss system ground connection OR sensor is faulty. 5 - 8 S-40 • S-45 Part No. 102521...
  • Page 162 Repair VBAT power or ground circuit to ECM and 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...
  • Page 163 FPP1 Low Voltage FPP1 Higher than IVS Limit If this fault appears on your machine, contact Not used. the Genie Industries Service Department. FPP1 Lower than IVS Limit FPP2 High Voltage FPP2 High Voltage The #1 throttle position sensor wiring and/or...
  • Page 164 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 secure OR replace ECM. RTI3 Loss Part No. 102521 S-40 • S-45 5 - 11...
  • Page 165 123 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...
  • Page 166 AUX analog PUD3 high AUX analog PUD3 low AUX DIG1 high AUX DIG1 low AUX DIG2 high AUX DIG2 low AUX DIG3 high AUX DIG3 low IAT (intake air temperature) high voltage Part No. 102521 S-40 • S-45 5 - 13...
  • Page 167 Primary loop open OR low-side short to ground 2 Primary coil shorted 2 Primary loop open OR low-side short to ground 3 Primary coil shorted 3 Primary loop open OR low-side short to ground 4 Primary coil shorted 4 5 - 14 S-40 • S-45 Part No. 102521...
  • Page 168 Ford DSG-423 PWM3-gauge3 short to power EFI Service Manual (EDI part number 1060040). PWM4 open / ground short Genie part number 119494. PWM4 short to power Ford DSG 423 EFI Operator Handbook PWM5 open / ground short...
  • Page 169 Section 5 • Fault Codes October 2013 This page intentionally left blank. 5 - 16 S-40 • S-45 Part No. 102521...
  • Page 170 Read, understand and obey the safety rules or spray. and operating instructions printed in the 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.

  • Page 171: Electrical Symbols Legend

    Fuse with amperage Key switch N.O. (after serial number 22050) Circuit breaker with amperage Fuel or RPM Control relay contact solenoid normally open Starting aid: glow plug or flame ignitor Coil 6 - 2 S-40 • S-45 Part No. 102521...

  • Page 172: Hydraulic Symbols Legend

    2 position, 2 way solenoid valve 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...

  • Page 173: Ford Dsg-423 Engine Relay Layout

    Section 6 • Schematics October 2013 Ford DSG-423 Engine Relay Layout Starter Empty Relay F1-10A F2-5A Fuel Power Pump F3-10A F4-15A Relay Relay F5-15A F6-10A F6-10A 6 - 4 S-40 • S-45 Part No. 102521...

  • Page 174: Connector Pin Legend

    BL/RD C13DRE R21IGN C14PLU OR/BK C15PLD C36STC C36STC GR/BK C133PLA BROWN C37STCC BL/BK C37STCC BL/BK C17JU GR/BK C18JD C45GEN GR/WH C45GEN GR/WH GR/WH C19JSV C40LS1 C40LS1 PLUG PLUG PLUG PLUG PLUG Part No. 102521 S-40 • S-45 6 - 5...
  • Page 175 October 2013 Section 6 • Schematics Connector Pin Legend 6 - 5 6 - 6...
  • Page 176 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L 1011F Models (before serial number 7544) 6 - 8 6 - 7...

  • Page 177: Electrical Schematic, Deutz F3L 1011 Models

    STA. STARTER PUMP REGULATOR IND. 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...
  • Page 178 Pin 6 Pin 6 Pin 7 Deutsch TB22 C6-30 SJ1-WH Joystick Adaptor Harness NOHC NOHC NONC NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 S-40 • S-45 6 - 9...
  • Page 179 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L 1011F Models (before serial number 7544) 6 - 9 6 - 10...

  • Page 180: Ground Control Box Wiring Diagram

    RD- 20A BK-ISM#1 RD- 24A RD- 20B RD- P1 E-STOP BK-C5-5 WH-21B OR-C6-33 OR/BK-15A BK-C6-16 BR-GND+C6-26 OR-14A BK/RD-35B GR-17A GR/WH-19A GR/BK-18A BK/RD-C5-9 WIRING GROUND STUD HARNESS: TO BASE ALL BR WIRES Part No. 102521 S-40 • S-45 6 - 11...
  • Page 181 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Deutz F3L 1011F Models 6 - 11 6 - 12...
  • Page 182 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram- ALC-500 Deutz F3L 1011F Models 6 - 14 6 - 13...

  • Page 183: Platform Control Box Wiring Diagram

    COMPONENT INDEX PART NUMBER TILT ALARM 45383 ALC-500 89353 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GN/BK C4P-4 BATGND C7P-3 F.S. LS18 OPT. TILT ALALRM 19/18 CONTROL CABLE 12V BATT F.S. 6 - 14 S-40 • S-45 Part No. 102521...

  • Page 184: Platform Control Box Switch Panel Wiring Diagram

    (SPLICE TO R40LS1) HIGH/LOW START GR/BK GLOW PLUG HORN PLATFORM AUXILIARY PUMP EMERGENCY STOP REMOVE FOR GENERATOR OPTION LEVEL PLATFORM ROTATE CE SEE DETAIL A NOTE: 1) DASHED LINES INDICATE OPTION WIRES. Part No. 102521 S-40 • S-45 6 - 15...
  • Page 185 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Deutz F3L 1011F Models 6 - 15 6 - 16...
  • Page 186 Section 6 • Schematics October 2013 Electrical Schematic Perkins 704-30 Models (before serial number 7472) 6 - 18 6 - 17...

  • Page 187: Electrical Schematic, Perkins 704-30 Models

    STA. STARTER PUMP REGULATOR IND. 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 - 18 S-40 • S-45 Part No. 102521...
  • Page 188 TB22 Joystick Adaptor Harness C6-30 Y17 Y16 Y19 Y20 Y21 Y22 Y29 Y23 NOHC NOHC NCHO NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 S-40 • S-45 6 - 19...
  • Page 189 October 2013 Section 6 • Schematics Electrical Schematic Perkins 704-30 Models (before serial number 7472) 6 - 19 6 - 20...
  • Page 190 RD- 20B PLAT OVERLOAD MODULE RD- P1 E-STOP BK-C5-5 WH-21B OR-C6-33 PLAT OVERLOAD LED OR/BK-15A BK-C6-16 BR-GND+C6-26 OR-14A BK/RD-35B GR-17A GR/WH-19A GR/BK-18A BK/RD-C5-9 WIRING GROUND STUD HARNESS: TO BASE ALL BR WIRES Part No. 102521 S-40 • S-45 6 - 21...

  • Page 191: Ground Control Box Wiring Diagram

    October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Perkins 704-30 Models 6 - 21 6 - 22...

  • Page 192: Platform Control Box Wiring Diagram

    Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Perkins 704-30 Models 6 - 24 6 - 23...

  • Page 193: Perkins 704-30 Models

    COMPONENT INDEX PART NUMBER TILT ALARM 45383 ALC-500 89353 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GN/BK C4P-4 BATGND C7P-3 F.S. LS18 OPT. TILT ALALRM 19/18 CONTROL CABLE 12V BATT F.S. 6 - 24 S-40 • S-45 Part No. 102521...

  • Page 194: Platform Control Box Switch Panel Wiring Diagram Perkins 704-30 Models

    (SPLICE TO R40LS1) GLOW PLUG HIGH/LOW START GR/BK HORN PLATFORM AUXILIARY PUMP EMERGENCY STOP REMOVE FOR GENERATOR OPTION LEVEL PLATFORM ROTATE CE SEE DETAIL A NOTE: 1) DASHED LINES INDICATE OPTION WIRES. Part No. 102521 S-40 • S-45 6 - 25...
  • Page 195 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Perkins 704-30 Models 6 - 25 6 - 26...
  • Page 196 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509) Perkins 404-22 Models (from serial number 7472 to 12509) 6 - 28 6 - 27...
  • Page 197 REGULATOR PUMP IND. NOTE: 1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. C.E. OPTION ONLY 6 - 28 S-40 • S-45 Part No. 102521...
  • Page 198 TB17 TB18 SJ1-WH TB22 C6-30 Y17 Y16 Y19 Y20 Y21 Y22 Y29 Y23 NOHC NOHC NCHO NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 S-40 • S-45 6 - 29...
  • Page 199 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509) Perkins 404-22 Models (from serial number 7472 to 12509) 6 - 29 6 - 30...
  • Page 200 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510 to 14831) 6 - 32 6 - 31...
  • Page 201 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...
  • Page 202 TB36 TB30 TB37 TB32 TB31 TB15 TB13 TB40 TB29 TB14 TB17 TB18 SJ1-WH NOHC NCHO NOHC NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 S-40 • S-45 6 - 33...
  • Page 203 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510 to 14831) 6 - 33 6 - 34...
  • Page 204 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832 to 15662) 6 - 36 6 - 35...
  • Page 205 CONNECTS PIN 4 TO PIN 5 AND PIN 6 TO PIN 7 LS18 - PLATFORM OVERLOAD SWITCH FUEL SOLENOID ADDED AT SERIAL NUMBER 15574 10A FUSE ADDED AT SERIAL NUMBER 15574 6 - 36 S-40 • S-45 Part No. 102521...
  • Page 206 Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832 to 15662) NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 S-40 • S-45 6 - 37...
  • Page 207 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832 to 15662) 6 - 37 6 - 38...
  • Page 208 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 15663 to 16419) 6 -40 6 - 39...
  • Page 209 Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 15663 to 16419) OR/BK CONN. PLUG STARTER REGULATOR NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 40 S-40 • S-45 Part No. 102521...
  • Page 210 Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 15663 to 16419) NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 S-40 • S-45 6 - 41...
  • Page 211 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 15663 to 16419) 6 - 41 6 - 42...
  • Page 212 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 15663 to 16419) 6 - 44 6 - 43...
  • Page 213 OR/BK LS18A LS18 4.7 K 2 SEC 2 SEC LOAD SENSE MODULE STARTER REGULATOR NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 44 S-40 • S-45 Part No. 102521...
  • Page 214 Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 15663 to 16419) NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 S-40 • S-45 6 - 45...
  • Page 215 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 15663 to 16419) 6 - 45 6 - 46...
  • Page 216 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 16420) 6 - 48 6 - 47...
  • Page 217 PLUG REGULATOR NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". DIODE BETWEEN T 35 AND TB45 ADDED AT SERIAL NUMBER 16453 6 - 48 S-40 • S-45 Part No. 102521...
  • Page 218 Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI / CSA / AS (from serial number 16420) NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 S-40 • S-45 6 - 49...
  • Page 219 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - ANSI /CSA / AS (from serial number 16420) 6 - 49 6 - 50...
  • Page 220 Section 6 • Schematics October 2013 Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 16420) 6 - 52 6 - 51...
  • Page 221 MODULE REGULATOR NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". DIODE BETWEEN T 35 AND TB45 ADDED AT SERIAL NUMBER 16453 6 - 52 S-40 • S-45 Part No. 102521...
  • Page 222 Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 16420) NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 S-40 • S-45 6 - 53...
  • Page 223 October 2013 Section 6 • Schematics Electrical Schematic Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models - CE (from serial number 16420) 6 - 53 6 - 54...
  • Page 224 Section 6 • Schematics October 2013 Ground Control Box Wiring Diagram Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (before serial number 14832) 6 - 56 6 - 55...
  • Page 225 RD- 24A BK-C5-5 WH-21B RD- 20B BK/RD-C5-9 RD- P1 E-STOP OR/BK-15A BK-C6-16 OR-C6-33 OR-14A GR-17A GR/WH-19A GR/BK-18A GR-43D CR17 BK-C6-25 BK-22B RD-CB3 SP GROUND STUD WIRING HARNESS: TO BASE ALL BR WIRES 6 - 56 S-40 • S-45 Part No. 102521...
  • Page 226 Section 6 • Schematics Ground Control Box Wiring Diagram Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832) KEY SWITCH CR17 DIODE BETWEEN T 35 AND TB45 ADDED AT SERIAL NUMBER 16453 Part No. 102521 S-40 • S-45 6 - 57...
  • Page 227 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832) 6 - 57 6 - 58...
  • Page 228 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (before serial number 14832) 6 - 60 6 - 59...

  • Page 229: Perkins 404-22 Models (Before Serial Number 14832)

    (before serial number 14832) COMPONENT INDEX PART NUMBER TILT ALARM 45383 ALC-500 94771 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GR/BK C4P-4 BATGND C7P-3 OPT. LS18 TILT ALALRM 19/18 CONTROL CABLE 12V BATT F.S. 6 - 60 S-40 • S-45 Part No. 102521...
  • Page 230 (from serial number 14832) LOAD SENSE OPTION CR14 GR/WH GR/WH + RD OUTPUT BR - C28TTA RD/BK C1P-2 GR/BK C4P-4 GR/WH BATGND C7P-3 C132PLI1 BK C1P-12 C132PLI2 BK C3P-10 RD LS18 CABLE TILT ALALRM Part No. 102521 S-40 • S-45 6 - 61...
  • Page 231 October 2013 Section 6 • Schematics Platform Control Box Wiring Diagram- ALC-500 Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832) 6 - 61 6 - 62...
  • Page 232 Section 6 • Schematics October 2013 Platform Control Box Switch Panel Wiring Diagram Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509) Perkins 404-22 Models (from serial number 7472 to 12509) 6 - 64 6 - 63...
  • Page 233 TS47 GENERATOR (OPTION) EMERGENCY STOP NOTE: 1) DASHED LINES INDICATE OPTION WIRES. TS14 PLATFORM HIGH/LOW GLOW PLUG HIGH/LOW HORN ROTATE AUXILIARY PUMP PLATFORM DRIVE GR/BK LEVEL SPEED CE SEE DETAIL A 6 - 64 S-40 • S-45 Part No. 102521...
  • Page 234 GLOW PLUG NOTE: PLATFORM PLATFORM AUXILIARY PUMP ROTATE LEVEL GN/BK GENERATOR 1) DASHED LINES INDICATE OPTION WIRES. (OPTION) CE SEE DETAIL A T 48 REMOVED FROM PLATFORM BOX AT SERIAL NUMBER 16420 Part No. 102521 S-40 • S-45 6 - 65...
  • Page 235 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510) 6 - 65 6 - 66...
  • Page 236 Section 6 • Schematics October 2013 Electrical Schematic Ford LRG-425 EFI Models (before serial number 7597) 6 - 68 6 - 67...

  • Page 237: Electrical Schematic Ford Lrg-425 Efi Models (Before Serial Number 7597)

    REGULATOR IND. FORD ENGINE HARNESS 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 - 68 S-40 • S-45 Part No. 102521...
  • Page 238 Pin 6 Pin 6 Pin 7 Deutsch TB22 C6-30 SJ1-WH Joystick Adaptor Harness NOHC NOHC NONC NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 S-40 • S-45 6 - 69...
  • Page 239 October 2013 Section 6 • Schematics Electrical Schematic Ford LRG-425 EFI Models (before serial number 7597) 6 - 69 6 - 70...

  • Page 240: Ground Control Box Wiring Diagram Ford Lrg-425 Efi Models (Before Serial Number 7597)

    CHECK ENGINE RD- P1 E-STOP WH-ISM#7 HOUR METER OR/BK-15A BR-R1 WH-23B BR-GND BLK-33B OR-14A BK/RD-C5-12 WH CR2#87 GR-17A WH-C5-17 TS22 GR/WH-19A GR/BK-18A WIRING HARNESS: TO BASE GROUND STUD ALL BR WIRES Part No. 102521 S-40 • S-45 6 - 71...
  • Page 241 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) 6 - 71 6 - 72...
  • Page 242 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) 6 - 74 6 - 73...

  • Page 243: Platform Control Box Wiring Diagram Ford Lrg-425 Efi Models (Before Serial Number 7597)

    COMPONENT INDEX PART NUMBER TILT ALARM 45383 ALC-500 89353 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GR/BK C4P-4 BATGND C7P-3 F.S. LS18 OPT. TILT 19/18 CONTROL CABLE 12V BATT F.S. ALALRM 6 - 74 S-40 • S-45 Part No. 102521...
  • Page 244 (SPLICE TO R40LS1) HIGH/LOW NOTE: TS47 START FUEL SELECT DASHED LINES INDICATE HORN AUXILIARY GENERATOR PLATFORM EMERGENCY STOP OPTION WIRES (OPTION) PUMP LEVEL PLATFORM CE SEE DETAIL A ROTATE REMOVE FOR GENERATOR OPTION Part No. 102521 S-40 • S-45 6 - 75...

  • Page 245: Platform Control Box Switch Panel Wiring Diagram Ford Lrg-425 Efi Models (Before Serial Number 7597)

    October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG-425 EFI Models (before serial number 7597) 6 - 75 6 - 76...
  • Page 246 Section 6 • Schematics October 2013 Electrical Schematic Ford LRG-425 EFI Models (from serial number 7597 to 11066) 6 - 78 6 - 77...
  • Page 247 HARNESS NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. REFER TO E0375 FOR FORD HARNSS 6 - 78 S-40 • S-45 Part No. 102521...
  • Page 248 Pin 5 RKOUT Pin 6 Pin 6 Pin 7 Deutsch SJ1-WH Joystick Adaptor Harness NOHC NOHC NCHO NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 S-40 • S-45 6 - 79...
  • Page 249 October 2013 Section 6 • Schematics Electrical Schematic Ford LRG-425 EFI Models (from serial number 7597 to 11066) 6 - 79 6 - 80...
  • Page 250 CHECK ENGINE 56298 RD- P1 E-STOP HOUR METER RD-27B CR39 CR17 OR/BK-15A GR-43B BK-C6-25 BK-22B OR-14A RD-CB3 SP GR-C5-12 GR-17A WH-23B GR/WH-19A GR/BK-18A WIRING HARNESS: TO BASE GROUND STUD ALL BR WIRES Part No. 102521 S-40 • S-45 6 - 81...
  • Page 251 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) 6 - 81 6 - 82...
  • Page 252 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) 6 - 84 6 - 83...
  • Page 253 (from serial number 7597 to 11066) COMPONENT INDEX PART NUMBER TILT ALARM 45383 ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GR/BK C4P-4 BATGND C7P-3 F.S. LS18 OPT. TILT 19/18 CONTROL CABLE 12V BATT F.S. ALALRM 6 - 84 S-40 • S-45 Part No. 102521...
  • Page 254 TS47 DRIVE START FUEL SELECT DASHED LINES INDICATE HORN AUXILIARY GENERATOR PLATFORM SPEED EMERGENCY STOP OPTION WIRES (OPTION) PUMP LEVEL HIGH/LOW PLATFORM CE SEE DETAIL A ROTATE REMOVE FOR GENERATOR OPTION Part No. 102521 S-40 • S-45 6 - 85...
  • Page 255 October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford LRG-425 EFI Models (from serial number 7597 to 11066) 6 - 85 6 - 86...
  • Page 256 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models (from serial number 11067 to 12509) 6 - 88 6 - 87...
  • Page 257 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. ESO433B RESISTOR R4 REMOVED AT SERIAL NUMBER 11785 . 6 - 88 S-40 • S-45 Part No. 102521...
  • Page 258 TB30 TB37 TB32 TB15 TB13 TB36 TB29 TB40 TB14 TB17 TB18 SJ1-WH NCHO NOHC NOHC NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. ESO433 Part No. 102521 S-40 • S-45 6 - 89...
  • Page 259 October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models (from serial number 11067 to 12509) 6 - 89 6 - 90...
  • Page 260 Section 6 • Schematics February 2012 Electrical Schematic Ford DSG-423 EFI Models (from serial number 12510 to 14831) 6 - 92 6 - 91...
  • Page 261 ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION. RESISTOR R3 REMOVED AT SERIAL NUMBER 13740. ESO433C CHECK ENGINE LAMP L2 CHANGED TO INCANDESCENT. 6 - 92 S-40 • S-45 Part No. 102521...
  • Page 262 TB36 TB37 TB32 TB31 TB30 TB15 TB40 TB13 TB29 TB14 TB17 TB18 SJ1-WH NOHC NOHC NCHO NOTE: 1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED POSITION EXCEPT AS NOTED. Part No. 102521 S-40 • S-45 6 - 93...
  • Page 263 October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models (from serial number 12510 to 14831) 6 - 93 6 - 94...
  • Page 264 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models (from serial number 14832 to 15662) 6 - 96 6 - 95...
  • Page 265 (from serial number 14832 to 15662) FUSE 10A TS49 PBOX GND CR23 CR23 C4-9 C4-11 NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 96 S-40 • S-45 Part No. 102521...
  • Page 266 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models (from serial number 14832 to 15662) NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 S-40 • S-45 6 - 97...
  • Page 267 October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models (from serial number 14832 to 15662) 6 - 97 6 - 98...
  • Page 268 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 15663 to 16419) 6 - 100 6 - 99...
  • Page 269 SENSE MODULE CR23 CR23 C4-9 C4-11 NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". STARTER RELAY PR8 ADDED AT SERIAL NUMBER 15703 6 - 100 S-40 • S-45 Part No. 102521...
  • Page 270 Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 15663 to 16419) NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 S-40 • S-45 6 - 101...
  • Page 271 October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 15663 to 16419) 6 - 101 6 - 102...
  • Page 272 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 15663 to 16419) 6 - 104 6 - 103...
  • Page 273 SENSE MODULE CR23 CR23 C4-9 C4-11 NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". STARTER RELAY PR8 ADDED AT SERIAL NUMBER 15703 6 - 104 S-40 • S-45 Part No. 102521...
  • Page 274 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 15663 to 16419) NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 S-40 • S-45 6 - 105...
  • Page 275 October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 15663 to 16419) 6 - 105 6 - 106...
  • Page 276 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 16420) 6 - 108 6 - 107...
  • Page 277 CONN. PLUG NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". ES0433K DIODE BETWEEN T 35 AND TB45 ADDED AT SERIAL NUMBER 16453 6 - 108 S-40 • S-45 Part No. 102521...
  • Page 278 Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 16420) NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 S-40 • S-45 6 - 109...
  • Page 279 October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 16420) 6 - 109 6 - 110...
  • Page 280 Section 6 • Schematics October 2013 Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 16420) 6 - 112 6 - 111...
  • Page 281 LOAD SENSE MODULE NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". DIODE BETWEEN T 35 AND TB45 ADDED AT SERIAL NUMBER 16453 6 - 112 S-40 • S-45 Part No. 102521...
  • Page 282 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 16420) NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 102521 S-40 • S-45 6 - 113...
  • Page 283 October 2013 Section 6 • Schematics Electrical Schematic Ford DSG-423 EFI Models- CE (from serial number 16420) 6 - 113 6 - 114...
  • Page 284 Section 6 • Schematics October 2013 Ground Control Box Wiring Diagram Ford DSG-423 EFI Models (before serial number 14832) 6 - 116 6 - 115...

  • Page 285: Ground Control Box Wiring Diagram Ford Dsg-423 Efi Models (Before Serial Number 14832)

    RD- P1 E-STOP DRIVE LIGHT OPTION RELAY OR/BK-15A RD-27B GR-43B CR39 CR17 BK-C6-25 OR-14A BK-22B RD-CB3 SP GR-C5-12 GR-17A WH-23B GR/WH-19A GR/BK-18A WIRING HARNESS: TO BASE ESO433 GROUND STUD ALL BR WIRES 6 - 116 S-40 • S-45 Part No. 102521...
  • Page 286 October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford DSG-423 EFI Models (from serial number 14832) KEY SWITCH DIODE ADDED AT SERIAL NUMBER 16453 Part No. 102521 S-40 • S-45 6 - 117...

  • Page 287: Ground Control Box Wiring Diagram Ford Dsg-423 Efi Models (From Serial Number 14832)

    October 2013 Section 6 • Schematics Ground Control Box Wiring Diagram Ford DSG-423 EFI Models (from serial number 14832) 6 - 117 6 - 118...
  • Page 288 Section 6 • Schematics October 2013 Platform Control Box Wiring Diagram Ford DSG-423 EFI Models (before serial number 14832) 6 - 120 6 - 119...

  • Page 289: Platform Control Box Wiring Diagram Ford Dsg-423 Efi Models (Before Serial Number 14832)

    Ford DSG-423 EFI Models (before serial number 14832) ALC-500 HARNESS PBOX WIRING C28TTA RD/BK C1P-2 GR/BK C4P-4 BATGND C7P-3 F.S. OPT. LS18 TILT F.S. 19/18 CONTROL CABLE 12V BATT ALALRM ESO433 6 - 120 S-40 • S-45 Part No. 102521...

  • Page 290: Platform Control Box Wiring Diagram Ford Dsg-423 Efi Models (From Serial Number 14832)

    HARNESS (TO SWITCH PANEL) CR14 GR/WH GR/WH + RD OUTPUT BR - C28TTA RD/BK C1P-2 GR/BK C4P-4 GR/WH BATGND C7P-3 C132PLI1 BK C1P-12 C132PLI2 BK C3P-10 RD LS18 CABLE TILT ALALRM Part No. 102521 S-40 • S-45 6 - 121...
  • Page 291 October 2013 Section 6 • Schematics Platform Control Box Wiring Diagram Ford DSG-423 EFI Models (from serial number 14832) 6 - 121 6 - 122...
  • Page 292 Section 6 • Schematics October 2013 Platform Control Box Switch Panel Wiring Diagram Ford DSG-423 EFI Models (from serial number 11067 to 12509) 6 - 124 6 - 123...

  • Page 293: Platform Control Box Switch Panel Wiring Diagram Ford Dsg-423 Efi Models (From Serial Number 11067 To 12509)

    START FUEL SELECT HORN SPEED PLATFORM PLATFORM AUXILIARY GENERATOR HIGH/LOW PUMP LEVEL ROTATE GR/BK (OPTION) NOTE: DASHED LINES INDICATE EMERGENCY STOP OPTION WIRES CE SEE DETAIL A REMOVE FOR GENERATOR OPTION 6 - 124 S-40 • S-45 Part No. 102521...
  • Page 294 HIGH/LOW GENERATOR DRIVE START HORN (OPTION) SPEED PLATFORM PLATFORM AUXILIARY EMERGENCY STOP HIGH/LOW ROTATE LEVEL PUMP FUEL SELECT GR/BK CE SEE DETAIL A DRIVE/WORK LIGHT OPTION CHANGED AT SERIAL NUMBER 16420 Part No. 102521 S-40 • S-45 6 - 125...

  • Page 295: Platform Control Box Switch Panel Wiring Diagram Ford Dsg-423 Efi Models (From Serial Number 12510)

    October 2013 Section 6 • Schematics Platform Control Box Switch Panel Wiring Diagram Ford DSG-423 EFI Models (from serial number 12510) 6 - 125 6 - 126...

  • Page 296: Engine Harness, Ford Lrg-425 Efi Models

    Section 6 • Schematics October 2013 Engine Wire Harness Ford LRG-425 EFI Models (before serial number 11067) 6 - 128 6 - 127...
  • Page 297 PLUG (GROUND) 361A R 16 77 DB-Y 18 PLUG (RELAY POWER) 459 O-LG 18 PLUG (CAN -) 361A R 16 361A R 16 662 DG-P 18 PLUG (CAN +) WPTWR2_GY MTRTWR4 MTRSHD4 6 - 128 S-40 • S-45 Part No. 102521...
  • Page 298 UNUSED R/LB 16 R/LB 16 POWER POWER RELAY R/Y 18 INJECTOR CYL #1 R 16 CONNECTOR R 16 R 16 R 16 R 16 R 16 R/T 18 ES0400A RELAYED POWER Part No. 102521 S-40 • S-45 6 - 129...
  • Page 299 October 2013 Section 6 • Schematics Engine Wire Harness Ford DSG-423 EFI Models (from serial number 11101 to 11784) 6 - 129 6 - 130...
  • Page 300 Section 6 • Schematics October 2013 Engine Wire Harness Ford DSG-423 EFI Models (from serial number 11785) 6 - 132 6 - 131...
  • Page 301 UNUSED R/LB 16 R/LB 16 POWER POWER RELAY R/Y 18 INJECTOR CYL #1 R 16 CONNECTOR R 16 R 16 R 16 R 16 R 16 ES0400A R/T 18 RELAYED POWER 6 - 132 S-40 • S-45 Part No. 102521...
  • Page 302 PRI UP/DN & TT ROTATE DRIVE & STEERING TURNTABLE ROTATE JOYSTICK CONTROL CARD 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...

  • Page 303: Joystick Connector Diagram

    October 2013 Section 6 • Schematics Joystick Connector Diagram 6 - 133 6 - 134...

  • Page 304: Cte Option Wiring Diagram

    Section 6 • Schematics October 2013 CTE Option Wiring Diagram 6 - 136 6 - 135...
  • Page 305 February 2012 Section 6 • Schematics CTE Option Wiring Diagram FUNCTION HARNESS WIRING DIAGRAM 6 - 136 S-40 • S-45 Part No. 102521...

  • Page 306: Mte Hydraulic Generator Option Wiring Diagram

    Section 6 • Schematics February 2012 MTE Hydraulic Generator Option Wiring Diagram 6 - 138 6 - 137...
  • Page 307 October 2013 Section 6 • Schematics MTE Hydraulic Generator Option Wiring Diagram SCHEMATIC - MTE HYDRUALIC GENERATOR OPTIONS 6 - 138 S-40 • S-45 Part No. 102521...

  • Page 308: Hydraulic Generator Wiring Diagram- Welder Option

    E3 NOT USED F1 DIG IN 0 F2 DIG IN 1 GENERATOR ON N.O. F3 DIG IN 2 SX Controller Y75-2 PILOT PRESSURE SIGNAL FROM GENERATOR MANIFOLD BR-2 (16-2) DIVERTER MANIFOLD Part No. 102521 S-40 • S-45 6 - 139...
  • Page 309 October 2013 Section 6 • Schematics Hydraulic Generator Wiring Diagram- Welder Option 6 - 139 6 - 140...

  • Page 310: (Before Serial Number 7569)

    Section 6 • Schematics October 2013 2WD Non-Oscillating Hydraulic Schematic S-40 Models (before serial number 7569) 6 - 142 6 - 141...

  • Page 311: (Before Serial Number 7569)

    STEERING 210 psi 14.5 bar .070 Note: 'alpha' callouts refer to components shown in the 185 psi REAR 12.7 bar manifold illustrations. LEFT RELEASE Refer to the Repair Section. TRACTION MANIFOLD 6 - 142 S-40 • S-45 Part No. 102521...

  • Page 312: (Before Serial Number 7569)

    RELEASE GENERATOR RIGHT LEFT STEERING .070 Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. REAR 185 psi LEFT 12.7 bar RELEASE TRACTION MANIFOLD Part No. 102521 S-40 • S-45 6 - 143...

  • Page 313: (Before Serial Number 7569)

    October 2013 Section 6 • Schematics 2WD Non-Oscillating Hydraulic Schematic S-45 Models (before serial number 7569) 6 - 143 6 - 144...
  • Page 314 Section 6 • Schematics October 2013 4WD Oscillating Hydraulic Schematic S-40 Models (before serial number 7569) 6 - 146 6 - 145...
  • Page 315 950 psi REAR 65.5 bar LEFT RIGHT RIGHT FRONT RIGHT Note: 'alpha' callouts refer to components shown in the OSCILLATE VALVE manifold illustrations. Refer to the Repair Section. TRACTION MANIFOLD OSCILLATE CYLINDERS 6 - 146 S-40 • S-45 Part No. 102521...
  • Page 316 TO HYD ROTARY COUPLER REAR 65.5 bar LEFT RIGHT RIGHT FRONT RIGHT Note: 'alpha' callouts refer to components shown in the OSCILLATE VALVE manifold illustrations. Refer to the Repair Section. TRACTION MANIFOLD OSCILLATE CYLINDERS Part No. 102521 S-40 • S-45 6 - 147...
  • Page 317 October 2013 Section 6 • Schematics 4WD Oscillating Hydraulic Schematic S-45 Models (before serial number 7569) 6 - 147 6 - 148...
  • Page 318 Section 6 • Schematics October 2013 2WD Hydraulic Schematic (from serial number 7569) 6 - 150 6 - 149...
  • Page 319 65.5 bar LEFT RIGHT Note: 'alpha' callouts refer to TRACTION components shown in the OSCILLATE VALVE MANIFOLD manifold illustrations. LEFT Refer to the Repair Section. REAR OSCILLATE CYLINDERS OPTION OSCILLATE CYLINDERS 6 - 150 S-40 • S-45 Part No. 102521...
  • Page 320 LEFT RIGHT Note: 'alpha' callouts refer to TRACTION components shown in the OSCILLATE VALVE MANIFOLD manifold illustrations. LEFT LEFT FRONT Refer to the Repair Section. REAR OSCILLATE CYLINDERS OPTION OSCILLATE CYLINDERS Part No. 102521 S-40 • S-45 6 - 151...
  • Page 321 October 2013 Section 6 • Schematics 4WD Hydraulic Schematic (from serial number 7569) 6 - 151 6 - 152...

  • Page 322: Generator Hydraulic Schematic- Welder Option

    Section 6 • Schematics Generator Hydraulic Schematic- Welder Option AJ AK NO PRESS SW 200 PSI Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. Part No. 102521 S-40 • S-45 6 - 153...
  • Page 323 October 2013 Section 6 • Schematics Generator Hydraulic Schematic- Welder Option 6 - 153 6 - 154...
  • Page 324 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie Scandinavia Genie China Phone +46 31 57 51 00...
  • Page 325 Part No. 102521 Rev E...

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