Manual de Service Genie S40 7645

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

Rev C3
July 2009
Introduction
July 2009
Important
Serial Number Information
Read, understand and obey the safety rules and

operating instructions in the Genie S-40 and S-45
Operator's Manual before attempting any
maintenance or repair procedure.
Genie Industries offers the following Service

Manuals for these models:
This manual provides detailed scheduled

maintenance information for the machine owner
and user. It also provides troubleshooting fault
codes and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, 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.
Title
Part No.
S-40 and S-45 Service Manual

(before serial number 3804) ................................ 32222
(from serial number 3804 to 4728) ....................... 52271
(from serial number 4729 to 7000) ....................... 72136
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications are
subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Copyright 1994 by Genie Industries
http://www.genieindustries.com
e-mail: awp.techpub@terex.com
102521 Rev C July 2007

Fourth Edition, Third Printing
"Genie" and "S" are registered trademarks of
Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.
ii
S-40 S-45
Part No. 102521
July 2009
Section 1 Safety Rules
INTRODUCTION
Serial Number Legend
Model: S-40
S4006-12345
Serial number:
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
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 60 ft 6 in/ 18.3 m
S40 06 - 12345
Sequence
number
Model
Maximum platform reach : 34 ft 3 in/ 10.4 m

Gradeability: N/A
Model year
Country of manufacture: USA

This machine complies with:
ANSI A92.5
CAN B.354.4
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
Sequence number
(stamped on chassis)
Serial label
(located under cover)
PN - 77055
Part No. 102521
S-40 S-45
iii
July 2007
This page intentionally left blank.
iv
S-40 S-45
Part No. 102521
July 2007
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-40 and S-45
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturers instructions and safety rules
- employers safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 102521
S-40 S-45
July 2007
SAFETY RULES
Be sure to wear protective eye wear and

other protective clothing if the situation
warrants it.
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This

manual and the decals on the machine
use signal words to identify the following:
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
which, if not avoided, may result in
minor or moderate injury.
property damage.
Be aware of potential crushing hazards

such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable
and combustible materials like battery
gases and engine fuels. Always have an approved
fire extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
vi
S-40 S-45
Part No. 102521
July 2009
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................. iv
Section 1
Safety Rules
General Safety Rules .................................................................................................. v
Section 2
Rev
E
Specifications
Machine Specifications .......................................................................................... 2 - 1
Hydraulic Oil Specifications ................................................................................... 2 - 2
Manifold Component Specifications ....................................................................... 2 - 5
Valve Coil Resistance Specifications ..................................................................... 2 - 5
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7
Deutz F3L-1011F Engine Specifications ................................................................ 2 - 8
Deutz F3L-2011/Deutz D2011L03i Engine Specifications ....................................... 2 - 9
Perkins 704-30 Engine Specifications .................................................................. 2 - 10
Perkins 404-22 Engine Specifications .................................................................. 2 - 11
Machine Torque Specifications ............................................................................ 2 - 12
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 13
SAE and Metric Fastener Torque Chart ............................................................... 2 - 14
Section 3
Rev
Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
Part No. 102521
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
S-40 S-45
vii
July 2009
TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures, continued

A-5
Perform 30 Day Service ............................................................................. 3 - 10
A-6
Perform Engine Maintenance - Deutz and Ford Models ............................ 3 - 10
A-7
Perform Engine Maintenance - Perkins Models ......................................... 3 - 11
A-8
Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12
A-9
Perform Engine Maintenance - Ford Models ............................................... 3 - 13
A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13
A-11 Perform Engine Maintenance - Deutz 1011F Models .................................. 3 - 14
A-12 Replace the Drive Hub Oil .......................................................................... 3 - 14
A-13 Perform Engine Maintenance - Ford Models ............................................... 3 - 15
D
Checklist B Procedures
B-1
Inspect the Battery ..................................................................................... 3 - 17
B-2
Inspect the Electrical Wiring ....................................................................... 3 - 18
B-3
Inspect the Air Filter ................................................................................... 3 - 19
B-4
Test the Key Switch ................................................................................... 3 - 20
B-5
Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 20
B-6
Check the Exhaust System ....................................................................... 3 - 20
B-7
Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 21
B-8
Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 22
B-9
Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 23
B-10 Confirm the Proper Brake Configuration ...................................................... 3 - 24

B-11 Check and Adjust the Engine RPM ............................................................ 3 - 25
B-12 Test the Engine Idle Select ........................................................................ 3 - 26
B-13 Test the Fuel Select Operation - Ford Models ............................................ 3 - 27
B-14 Test the Ground Control Override ............................................................... 3 - 28
B-15 Check the Directional Valve Linkeage ........................................................ 3 - 28
B-16 Test the Platform Self-leveling ................................................................... 3 - 29
viii
S-40 S-45
Part No. 102521
July 2009
TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures, continued

B-17 Test the Drive Brakes ................................................................................ 3 - 29
B-18 Test the Drive Speed - Stowed Position .................................................... 3 - 30
B-19 Test the Drive Speed - Raised or Extended Position ................................. 3 - 30
B-20 Perform Hydraulic Oil Analysis .................................................................. 3 - 31
B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 32
B-22 Inspect the Fuel and Hydraulic Tank Cap Venting System ......................... 3 - 33
B-23 Perform Engine Maintenance - Ford Models ............................................... 3 - 34
Part No. 102521
Checklist C Procedures
C-1
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
E-4
E-5
S-40 S-45
ix
July 2009
TABLE OF CONTENTS
Section 3
Section 4
Rev Scheduled Maintenance Procedures, continued
Rev
E-6
E-7
E-8
E-9
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 - 7
2-2
Platform Rotator ........................................................................................... 4 - 8
2-3
Platform Overload System ......................................................................... 4 - 10
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
S-40 S-45
Part No. 102521
July 2009
TABLE OF CONTENTS
Section 4
Rev
A
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 (after serial number 7568) ............... 4 - 48
7-13 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 50
7-14 Valve Coils ................................................................................................. 4 - 51
7-15 Drive Oil Diverter Manifold Components (welder option) ............................ 4 - 53
A
Turntable Rotation Components

8-1
Axle Components
9-1
Turntable Rotation Assembly ..................................................................... 4 - 54
Oscillate Axle Cylinders ............................................................................. 4 - 56
Generators
10-1 Valve Adjustments - Hydraulic Generator .................................................. 4 - 57
Part No. 102521
S-40 S-45
xi
July 2009
TABLE OF CONTENTS
Section 5
Rev
Fault Codes
Introduction ............................................................................................................ 5 - 1
Section 6
Fault Codes - Control System ................................................................................ 5 - 2
Fault Codes - Ford LRG-425 Engine ....................................................................... 5 - 6
Fault Codes - Ford DSG-423 EFI Engine ............................................................. 5 - 12
Rev
Schematics
Introduction ............................................................................................................ 6 - 1
xii
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
Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models
(from serial number 7544 to 12509)
Perkins 404-22 Models
(from serial number7472 to 12509) ............................................................. 6 - 28
S-40 S-45
Part No. 102521
July 2009
TABLE OF CONTENTS
Section 6
Rev
Schematics, continued
Perkins 404-22 Models (after serial number 12509) .................................... 6 - 32
Ground Control Box Wiring Diagram,

Perkins 404-22 Models ............................................................................... 6 - 35

Perkins 404-22 Models ............................................................................... 6 - 38

(from serial number 7472 to 12509) ............................................................ 6 - 39

Perkins 404-22 Models (after serial number 12509) .................................... 6 - 41
Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 44



Ford LRG-425 EFI Models



Part No. 102521
S-40 S-45
xiii
July 2009
TABLE OF CONTENTS
Section 6
xiv
Rev
Schematics, continued
Electrical Schematic, Ford DSG-423 EFI Models

(from serial number 11067 to 12509) .......................................................... 6 - 64
Electrical Schematic, Ford DSG-423 EFI Models

(after serial number 12509) ......................................................................... 6 - 68

Ford DSG-423 EFI Models ......................................................................... 6 - 71

Ford DSG-423 EFI Models ......................................................................... 6 - 74
Platform Control Box Switch Panel Wiring Diagram,

Ford DSG-423 EFI Models (from serial number 11067 to 12509) ................ 6 - 75

Ford DSG-423 EFI Models (after serial number 12509) ............................... 6 - 77
Engine Harness, Ford LRG-425 EFI Models

(before serial number 11067) ...................................................................... 6 - 80
Engine Harness, Ford DSG-423 EFI Models

(from serial number 11067 to 11784) .......................................................... 6 - 81
Engine Harness, Ford DSG-423 EFI Models

(after serial number 11784) ......................................................................... 6 - 83
Joystick Connector Diagram ................................................................................ 6 - 85
CTE Option Wiring Diagram ................................................................................. 6 - 88
Hydraulic Generator Wiring Diagram (welder option) ............................................. 6 - 89
Hydraulic Schematic, 2WD Non-oscillating S-40 Models

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 (after serial number 7568) ......................................... 6 - 99
Hydraulic Schematic, 4WD (after serial number 7568) ........................................ 6 - 101
Hydraulic Generator Schematic (welder option) ................................................... 6 - 103
S-40 S-45
Part No. 102521
July 2009
Section 2 Specifications
Specifications
REV E
Machine Specifications
S-40 and S-45 Models
Fluid capacities
Tires and wheels

Tire size, 2WD
front tires only
rear tires only
12.5L-16SL
12-16.5 NHS
Tire size,
2WDRT & 4WD front & rear
12-16.5 NHS
Tire ply rating

Tire contact area
Overall tire diameter
12
88 sq in
568 sq cm
57 sq in
368 sq cm
33.7 in
85.6 cm
33.2 in
84.3 cm
45 psi
3.1 bar
45 psi
3.1 bar
Wheel diameter
16 in
40.6 cm
161/2 in
41.9 cm
Wheel width
10 in
25.4 cm
9 3/4 in
24.8 cm
8@ 5/8 -18
9@ 5/8 -18
Tire pressure
Wheel lugs
Lug nut torque, dry
Lug nut torque, lubricated
170 ft-lbs / 230 Nm

130 ft-lbs / 176 Nm
Fuel tank
20 gallons
75.7 liters
Fuel tank, Option
30 gallons
114 liters
LPG tank
33.5 pounds
15.2 kg
Hydraulic tank
45 gallons
170 liters
Hydraulic system
(including tank)
55 gallons
208 liters
Drive hub
(before serial number 7569)
17 fl oz
0.5 liters
Drive hub
(after serial number 7568)
24 fl oz
0.71 liters
Turntable rotation
drive hub
8 fl oz
0.24 liters
Drive hub oil type:

SAE 90 multipurpose hypoid gear oil API service
classification GL5
For operational specifications, refer to the

Operator's Manual.
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
July 2009
SPECIFICATIONS
REV E
Performance Specifications
All Models
Hydraulic Oil Specifications
Drive speeds, 2WD and 4WD
Hydraulic oil type

Viscosity grade
Viscosity index
Drive speed, stowed
40 ft / 5.2 - 5.9 sec

12.2 m / 5.2 - 5.9 sec
Drive speed, raised or extended

Gradeability
Hydraulic Oil Specifications
40 ft / 40 - 45 sec
12.2 m / 40 - 45 sec
See Operator's Manual
Boom function speeds, maximum

from platform controls
Boom up
40 to 60 seconds
Boom down
50 to 80 seconds
Boom extend
30 to 60 seconds
Boom retract
15 to 35 seconds
Turntable rotate, 360

boom fully stowed
70 to 100 seconds
Turntable rotate, 360

boom fully extended
120 to 140 seconds
Platform rotate, 160
Cleanliness level, minimum

Water content, maximum
25 to 50 seconds
Platform level down
15 to 35 seconds
Jib boom up, S-45 models
35 to 45 seconds
Jib boom down, S-45 models
20 to 30 seconds
15/13
200 ppm
Chevron Rykon MV oil is fully compatible and

mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable
Fire resistant
6 to 12 seconds
Platform level up
Chevron Rykon MV equivalent

Multi-viscosity
200
Mineral based
Petro Canada Environ MV46

Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
UCON Hydrolube HP-5046
Quintolubric 822
Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
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
July 2009
REV E
SPECIFICATIONS
Continued use of Chevron Aviation

A hydraulic oil when ambient
temperatures are consistently
above 32F / 0C may result in
component damage.
Note: Use Chevron Aviation A hydraulic oil when
ambient temperatures are consistently
below 0F / -18C.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205F / 96C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Industries Service Department before use.
Hydraulic Component
Specifications
Drive pump
Type:
bi-directional,
variable displacement piston pump
Displacement per revolution, variable, 4WD models

0 to 2.8 cu in
0 to 46 cc
Flow rate @ 2500 rpm
Drive pressure, maximum
0 to 28 gpm
106 L/min
3625 psi
250 bar
Charge pump
Type:
Displacement
Charge pressure @ 2500 rpm
Neutral position
gerotor pump
0.85 cu in
13.9 cc
9 gpm
34.1 L/min
310 psi
21.4 bar
Function pump
Type
Displacement
gear, pressure balanced

1.04 cu in
17 cc
10.69 gpm
40.5 L/min
Oscillation pump
Type
Displacement
gear, fixed displacement

0.37 cu in
6 cc
2.8 gallons per minute
10.6 liters per minute

Part No. 102521
S-40 S-45
2-3
July 2009
SPECIFICATIONS
REV E
Auxiliary pump
Steer-end drive motors, 4WD

Type: fixed displacement gear pump

Displacement - static
Displacement
0.151 cu in
2.47 cc
1.75 gallons per minute
Function manifold
Function relief valve pressure
S-40
S-45
Displacement per revolution
1.52 cu in / 25 cc
Non-steer end drive motors, 2WD and 4WD

2.13 cu in / 35 cc
Two-speed drive motors, 2WD and 4WD

2600 psi / 179 bar
2900 psi / 200 bar

low speed
0.99 cu in / 16.3 cc
Boom down
relief valve pressure
2200 psi
152 bar

high speed
1.83 cu in / 30 cc
Boom extend
1950 psi
134 bar
Hydraulic Filters
Oscillate axle
950 psi
66 bar
Steer regulator,
All models
2 gallons per minute

Medium pressure filter
Beta 3 200
Medium pressure filter

bypass pressure
51 psi
3.5 bar
Hydraulic tank circuit

return line filter
10 micron with
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
July 2009
REV E
SPECIFICATIONS
Manifold Component
Specifications
Valve Coil Resistance

Specifications
Plug torque
Note: The following coil resistance specifications

are at an ambient temperature of 68F / 20C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18F / 20C
that your air temperature increases or decreases
from 68F / 20C.
SAE No. 2
36 in-lbs / 4.1 Nm
SAE No. 4
10 ft-lbs / 13.6 Nm
SAE No. 6
14 ft-lbs / 19 Nm
SAE No. 8
38 ft-lbs / 51.5 Nm
SAE No. 10
41 ft-lbs / 55.6 Nm
Description
SAE No. 12
56 ft-lbs / 75.9 Nm
Solenoid valve, 2 position 3 way, 10V DC

(schematic items AC and AE)
6.3

(schematic item AT and AZ)
6.3

(schematic items AU, AV, AX, and AY)
6.3

(schematic items AZ and BF)
6.3
Proportional solenoid valve, 12V DC

(schematic items AW and BB)
Specification

(schematic item CC)
6.8

(schematic items DA)
3.3

(schematic items CE)
4.8

Part No. 102521
S-40 S-45
2-5
July 2009
SPECIFICATIONS
REV E
Ford LRG-425 EFI Engine

153 cu in
2.5 liters
Displacement
Number of cylinders
3.78 x 3.4 in
96.01 x 86.36 mm
Bore & stroke

Horsepower
Gross intermittent
Continuous
Gross intermittent
Continuous
Starter motor
Normal engine cranking speed
Current draw, normal load
Current draw, maximum load
Current draw, no load
70 @ 2500 rpm
60 @ 2500 rpm
52 kW @ 2500 rpm
44.7 kW @ 2500 rpm
1-3-4-2
Low idle rpm

Frequency
1600 rpm
396.8 Hz
High idle rpm

Frequency
2500 rpm
620 Hz
9.4:1
Compression ratio
Compression pressure (approx.)
Pressure (psi) of lowest cylinder must be
at least 75% of highest cylinder
Valve clearances collapsed tappet
Oil pressure
(operating temp. @ 2000 rpm)
Oil capacity
(including filter)
Type
70A
12V DC, Group 31
Quantity
Cold cranking ampere
Reserve capacity @ 25A rate
1
1000A
200 minutes
Electronic fuel pump

Fuel pressure, static
Fuel flow rate
64 psi
4.4 bar
0.58 gpm
2.18 L/min
0.035 to 0.055 in
0.889 to 1.397 mm
40 to 60 psi
2.75 to 4.1 bar
4.5 quarts
4.3 liters
Spark plug type

Motorcraft AWSF-52-C
Spark plug type

Motorcraft AGSF-32-FM
Spark plug gap

Spark plug torque
Oil viscosity requirements
Engine coolant
Unit ships with 5W-30 oil.

Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
engine Operator's Manual on your machine.
Capacity
8-18 ft-lbs
11-24 Nm
3-5 psi
0.21-0.34 bar
0.042 to 0.046 inches

1.07 to 1.17 mm
5-10 ft-lbs
7-14 Nm
11.5 quarts
10.9 liters
Coolant temperature switch

Torque
Oil pressure switch specifications
2-6
800A
Ignition System
Lubrication system
Oil pressure switch point
140-200A
Battery
Firing order
Torque
200 to 250 rpm
Temperature switch point
8-18 ft-lbs
11-24 Nm
230 F
112 C
Alternator
S-40 S-45
Part No. 102521
July 2009
REV E
SPECIFICATIONS
Ford DSG-423 EFI Engine
Electronic fuel pump

140.4 cu in
2.3 liters
Displacement
Number of cylinders
Bore & stroke
Horsepower
Continuous horsepower
Peak horsepower
Continuous horsepower
Peak horsepower
3.44 x 3.7 inches

87.5 x 94 mm
59 @ 2500 rpm
69 @ 2500 rpm
44 kW @ 2500 rpm
51 kW @ 2500 rpm
Fuel pressure, static
64 psi
4.4 bar
Fuel flow rate
0.43 gpm
1.6 L/min
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Ignition system
Spark plug type
Motorcraft AGSF-32-FEC
1-3-4-2
Spark plug gap
Low function idle (computer controlled)

Frequency
1600 rpm
53.3 Hz
0.049 to 0.053 inches

1.244 to 1.346 mm
Engine coolant
High function idle (computer controlled)

Frequency
2500 rpm
83.3 Hz
Firing order
9.7:1
Compression ratio
Compression pressure (approx.)
Pressure (psi or bar) of lowest cylinder must be
at least 75% of highest cylinder
Capacity
Cylinder head temperature sending unit
Fault code set temperature
280F
138C
Engine shut-down temperature
300F
149C
Lubrication system
Oil pressure
(at operating temperature @ 2500 rpm)
29 to 39 psi
2 to 2.7 bar
Starter motor
Normal engine cranking speed
Oil capacity
(including filter)
4 quarts
3.8 liters
10 quarts
9.5 liters
Current draw, maximum load
Unit ships with 5-W20 oil.

Alternator
Output
200 to 250 rpm

140-200A
800A
95A, 13.8V DC
Battery
Type
Quantity
12V DC, Group 31

1
Cold cranking ampere @ 0F
1000A
200 minutes

Part No. 102521
S-40 S-45
2-7
July 2009
SPECIFICATIONS
REV E
Deutz F3L-1011F Engine
Injection system
125 cu in
2.05 liters
Displacement
Horsepower
3.58 x 4.13 inches

91 x 105 mm
36 @ 3000 rpm
26.8 kW @ 3000 rpm
1-2-3
Firing order
18.5:1
Compression ratio
Compression pressure
Injection pump pressure
4351 psi
300 bar
Injector opening pressure
3626 psi
250 bar
362 to 435 psi

25 to 30 bar
Fuel requirement
For fuel requirement, refer to the engine Operator's
Starter motor
Current draw, no load
1500 rpm
313 Hz
Brush length, new
High idle rpm

Frequency
2300 rpm
479.9 Hz
Brush length, minimum
centrifugal mechanical
Valve clearance, cold

0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
Lubrication system
Oil pressure
0.7480 in
19 mm
0.5 in
12.7 mm
12V, Group 31
Quantity
1000A
200 minutes
Fan belt deflection
3 /8
26 to 87 psi
1.8 to 6.0 bar
Oil capacity
(including filter)
90A
Battery
Type
Intake
55A, 14V
Alternator output
Low idle rpm

Frequency
Governor
OMAP
Number of cylinders
Bore and stroke
Injection pump make
to 1/2 inch
9 to 12 mm
8.5 quarts
8 liters

Temperature below 60F / 15.5C (synthetic)
5W-30
-10F to 90F / -23C to 32C
10W-40
Temperature above -4F / -34C
15W-40

2-8

S-40 S-45
Part No. 102521
July 2009
REV E
SPECIFICATIONS
Deutz F3L-2011 Engine

Deutz D2011L03i Engine
Displacement
Number of cylinders
Bore and stroke
Lubrication system
Oil pressure, hot @ 2000 rpm
142 cu in
2.33 liters
Oil capacity
(including filter)
(Deutz F3L2011 Engine)
8.5 quarts
8 liters
3.7 x 4.4 inches

94 x 112 mm
Oil capacity
(including filter)
(Deutz D2011L03i Engine)
9.5 quarts
9 liters
48.7 @ 2800 rpm

46.2 @ 2800 rpm
36 kW @ 2800 rpm
34.5 kW @ 2800 rpm
Horsepower
Net
Net
Net
Net
intermittent
continuous
intermittent
continuous
Firing order
1-2-3
Low idle rpm

Frequency
1500 rpm
313 Hz
High idle rpm

Frequency
2500 rpm
521.7 Hz
Compression ratio
Governor

Oil temperature switch
Torque
19:1
362 to 435 psi
25 to 30 bar
Torque
(Deutz F3L2011 Engine)
Intake
0.012 in
0.3 mm
Exhaust
0.020 in
0.5 mm
8-18 ft-lbs
11-24 Nm
220 F
104 C
Oil pressure switch
Part No. 102521
40-60 psi
2.8 to 4.1 bar

(Deutz D2011L03i Engine)
S-40 S-45
8-18 ft-lbs
11-24 Nm
7 psi
.5 bar
22 psi
1.5 bar
2-9
July 2009
SPECIFICATIONS
REV E
Fuel injection system

Injection pump make
Bosch
Injection pump pressure, maximum
15000 psi
1034 bar
3046 psi
210 bar
Fuel requirement
Starter motor
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

Alternator output
Fan belt deflection
2 - 10
1000A
200 minutes
60A @ 14V DC
3 /8
to 1/2 inch
9 to 12 mm
S-40 S-45
Part No. 102521
July 2009
REV E
SPECIFICATIONS
Perkins 704-30 Engine

Displacement
Number of cylinders
Bore and stroke
Horsepower
Firing order
Compression ratio

183 cu in
2.9 liters
4
3.82 x 3.94 inches

97 x 100 mm
63 @ 2600 rpm
47 kW @ 2600 rpm
17.5:1
300 to 500 psi

20.7 to 34.5 bar
Pressure (psi) of lowest cylinder must be within
50 psi (3.45 bar) of highest cylinder
Low idle rpm

Frequency
1600 rpm
246.7 Hz
High idle rpm

Frequency
2200 rpm
339.2 Hz
5F to 104F / -15C to 40C
10W-30
above 14F / -10C
15W-40
Engine oil should have properties of API classification

CC/SE. API classification CD/SE or CCMC D4 can be
used, but is not recommended during the first 50 hours
nor for light load applications.
Injection system
Injection pump make
Intake
0.014 in
0.35 mm
Exhaust
0.014 in
0.35 mm
Lubrication system
Injection pump pressure

(stage one)
(stage two)
2755 psi
3336 psi
190 bar
230 bar
3626 psi
250 bar
Fuel requirement
Capacity
Alternator output
Type
41 psi
2.8 bar
7.3 quarts
8.3 liters
65A, 12V
12V, Group 31
Quantity

Fan belt deflection
Part No. 102521
111/2 quarts
10.9 liters
Battery

Oil capacity
(including filter)
Zexel PFR-KX
Engine coolant
Oil pressure
(at 2600 rpm)
5W-20
1-3-4-2
Governor
below 68F / 20C (synthetic)
S-40 S-45
1
1000A
200 minutes
3 /8
in
10 mm
2 - 11
July 2009
SPECIFICATIONS
REV E
Perkins 404-22 Engine

134 cu in
2.2 liters
Displacement
Number of cylinders
3.31 x 3.94 inches

84 x 100 mm
Bore and stroke

Oil pressure sending unit
Torque
Horsepower
gross intermittent
continuous
gross intermittent
continuous
50 @ 2800 rpm
41 @ 2800 rpm
37.3 kW @ 2800 rpm
31 kW @ 2800 rpm
Torque
1-3-4-2
Low idle rpm

Frequency
1300 rpm
200.5 Hz
Low Idle rpm with generator option

Frequency
1500 rpm
231.3 Hz
Fuel injection system
High idle rpm

Frequency
2500 rpm
385.5 Hz
426 psi
29.4 bar
Pressure (psi) of lowest cylinder must

be within 50 psi / 3.45 bar of highest cylinder
Governor
Exhaust
Injection pressure
0.008 in
0.2 mm
0.008 in
0.2 mm
8-18 ft-lbs
11-24 Nm
221 F
105 C
Zexel
2133 psi
147 bar
Fuel requirement
Battery
Type

Intake
Injection pump make
22.4:1
14.2 psi
1 bar
Coolant temperature sending unit
Firing order
Compression ratio
8-18 ft-lbs
11-24 Nm
Quantity
12V, Group 31
1
1000A
200 minutes
Starter motor
Lubrication system
Oil pressure, hot
(at 2000 rpm)
Oil capacity
(including filter)
2 - 12
40 to 60 psi
2.8 to 4.1 bar
9.4 quarts to 11.2 quarts
8.9 liters to 10.6 liters
Alternator output
Fan belt deflection
S-40 S-45
140-200A
65A @ 13.8V DC
3/8 to in
9 to 12 mm
Part No. 102521
July 2009
REV E
SPECIFICATIONS
Machine Torque Specifications

Platform rotator
1-8 center bolt, Gr 5, dry
640 ft-lbs
868 Nm
1-8 center bolt, Gr 5, lubricated
480 ft-lbs
651 Nm
3/8
35 ft-lbs*
47.5 Nm
-16 bolts, Gr 8, lubricated

*use blue thread-locking compound
Turntable rotator
Drive hub mounting bolts, dry
210 ft-lbs
284 Nm
Drive hub mounting bolts, lubricated*

160 ft-lbs
217 Nm
Drive motor and hubs

Drive hub mounting bolts, dry
Drive hub mounting bolts, lubricated
210 ft-lbs
284 Nm
160 ft-lbs*
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
July 2009
SPECIFICATIONS
REV E
Seal-Lok fittings
Hydraulic Hose and Fitting

Torque Specifications
Your machine is equipped with Parker Seal-Lok
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
SAE O-ring Boss Port

(tube fitting - installed into Aluminum)
1 Replace the O-ring. The O-ring must be replaced

anytime the seal has been broken. The O-ring
cannot be re-used if the fitting or hose end has
been tightened beyond finger tight.
Note: The O-rings used in the Parker Seal Lok
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
number 49612).
2 Lubricate the O-ring before installation.
SAE Dash size
Torque
-4
14 ft-lbs / 18.9 Nm
-6
23 ft-lbs / 31.2 Nm
-8
36 ft-lbs / 48.8 Nm
-10
62 ft-lbs / 84.1 Nm
-12
84 ft-lbs / 113.9 Nm
-16
125 ft-lbs / 169.5 Nm
-20
151 ft-lbs / 204.7 Nm
-24
184 ft-lbs / 250 Nm
3 Be sure that the face seal O-ring is seated and

retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
tight.
5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
6 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
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
July 2009
REV E
SPECIFICATIONS
SAE FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual
Grade 5
SIZE THREAD
LUBED
20
28
1/4
DRY
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
80
90
9
10.1
100
120
11.3
13.5
110
120
12.4
13.5
140
160
15.8
18
130
140
14.7
15.8
LUBED
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
A574 High Strength

Black Oxide Bolts
LUBED
Grade 8
DRY
LUBED
DRY
LUBED
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
METRIC FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual
Class 4.6
Size
(mm)
5
6
7
LUBED
LUBED
DRY
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
ft-lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
Part No. 102521
S-40 S-45
2 - 15
July 2007
Section 3 Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
information and step-by-step instructions.
Observe and Obey:

Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Symbols Legend
Scheduled maintenance inspections shall be

completed daily, quarterly, six months, annually
and every 2 years as specified on the
Maintenance Inspection Report.

Failure to perform each procedure

as presented and scheduled may
cause death, serious injury or
substantial damage.

Immediately tag and remove from service a

damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine
With safety alert symbolused to

indicate the presence of a
which, if not avoided, may cause
Use only Genie approved replacement parts.

Machines that have been out of service for a
period longer than three months must complete
the quarterly inspection.
Unless otherwise specified, perform each
maintenance procedure with the machine in the
following configuration:
Machine parked on a firm, level surface
Boom in the stowed position

property damage.
Indicates that a specific result is expected after
performing a series of steps.
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
July 2007
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend
Pre-delivery Preparation Report
Note: The following symbols have been used in

this manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.
The pre-delivery preparation report contains

checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation
Report to use for each inspection. Store completed
forms as required.
Maintenance Schedule
Indicates that tools will be required to

perform this procedure.
Indicates that new parts will be required

to perform this procedure.
Indicates that a cold motor, pump or

engine 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
Procedures Section and the Maintenance
Inspection Report have been divided into five
subsectionsA, B, C, D and E. Use the following
chart to determine which group(s) of procedures
are required to perform a scheduled inspection.
Inspection
Checklist
Daily or every 8 hours
Indicates that a warm motor or pump

will be required to perform this
procedure.
Quarterly or every 250 hours

Six months or every 500 hours
Annual or every 1000 hours
Indicates that dealer service is required

to perform this procedure.
Two years or every 2000 hours
A
A+B
A+B+C
A+B+C+D
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

Pre-delivery Preparation.
Use the operators manual on your machine.
The Pre-delivery Preparation is performed prior to

each delivery. The inspection is designed to discover if
anything is apparently wrong with a machine before it
is put into service.
A damaged or modified machine must never be used.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged
and removed from service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer's specifications.
Scheduled maintenance inspections shall be
performed by qualified service technicians, according
to the manufacturer's specifications and the
requirements listed in the responsibilities manual.
The Pre-delivery Preparation consists of completing

the Pre-operation Inspection, the Maintenance items
and the Function Tests.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operators manual.
If any inspection receives an N, remove the machine
from service, repair and re-inspect it. After repair,
place a check in the R box.
Legend
Y = yes, completed
N = no, unable to complete
R = repaired
Comments
Pre-Delivery Preparation
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
(425) 881-1800
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
Copyright 2002 by Genie Industries. Genie is a registered trademark of Genie

Industries. Rev B
July 2007
3-4
S-40 S-45
Part No. 102521
July 2007 2007

September
Maintenance Inspection Report

Model
Checklist A - Rev C
Y N R
Checklist B - Rev D
A-1 Inspect the Decals
B-1 Battery
A-2 Pre-operation
inspection
B-2 Electrical wiring
A-3 Functions tests
B-4 Key switch
Hour meter
A-4 Engine maintenance all models
Machine owner
Perform after 40 hours:
B-5 Engine maintenance Deutz and Perkins

models
A-5 30 Day Service
B-6 Exhaust system
Perform after first 50 hours:
B-7 Oil cooler and finsDeutz models
Serial number
Date
B-3 Air filter element
Inspector signature
A-6 Engine maintenance Deutz and Ford models
Inspector title
Perform every 50 hours:
Inspector company
A-7 Engine maintenancePerkins models
B-9 Drive hub maintenance
Instructions
Make copies of this report to use for
each inspection.
B-11 Engine RPM
A-8 Fuel filter/water

separator Deutz models
B-12 Engine idle select
A-9 Engine maintenance Ford models
B-14 Ground control
Select the appropriate checklist(s) for

the type of inspection to be
performed.
A-10 Rotation bearing
Daily or 8 hour
Inspection:
Quarterly or 250 hour
Inspection:
A
A+B
Six Month or 500 hour

Inspection:
A+B+C
Annual or 1000 hours
Inspection:
A+B+C+D
2 Year or 2000 hour
Inspection:
A+B+C+D+E

A-11 Engine maintenance Deutz 1011F models
A-12 Drive hub oil
A-13 Engine maintenance Ford models
B-8 Tires, wheels and lug

nut torque
B-10 Brake configuration
B-13 Fuel select Ford models

B-15 Directional
valve linkage
B-16 Platform
self-leveling
B-17 Drive brakes
B-18 Drive speed stowed position
B-19 Drive speed raised position
B-20 Hydraulic oil analysis
B-21 Alarm package
B-22 Fuel and hydraulic cap
venting systems
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,
Y N R

B-23 Engine maintenance Ford models
Comments
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Part No. 102521
S-40 S-45
3-5
July 2007
MAINTENANCE INSPECTION REPORT
Model
Checklist C - Rev B
Serial number
C-1 Engine maintenance Deutz and Perkins

models
Date
Hour meter
C-2 Platform overload

(if equipped)
Machine owner
C-3 Platform overload

(if equipped)
Inspector signature

E-3 Engine maintenance Deutz and
Perkins models
E-4 Engine maintenance Ford models
Inspector company
C-6 Engine maintenance Ford models
Instructions
Make copies of both pages to use for
each inspection.
Checklist D - Rev B
Select the appropriate checklist(s) for

the type of inspection to be
performed.
D-3 Free-wheel
configuration
Daily or 8 hour
Inspection:
D-1 Boom wear pads

D-2 Turntable bearing bolts
A
A+B
Six Month or 500 hour

Inspection:
A+B+C
D-4 Drive hub oil

D-5 Engine maintenanceDeutz and Perkins
models

Perkins models
Y N R

E-6 Engine maintenance Deutz models
Perkins models
Perform every 12,000 hours:
D-6 Hydraulic filters
E-8 Engine maintenance Deutz models
D-7 Turntable bearing wear
Perform every 4 years:

E-9 Engine maintenance Ford models
Annual or 1000 hours

Inspection:
A+B+C+D
2 Year or 2000 hour
Inspection:
A+B+C+D+E
Y N R
E-2 Steer axle

wheel bearings,
2WD models
C-5 Fuel inline strainer Deutz models
Inspector title
Checklist E - Rev B
E-1 Hydraulic oil
C-4 Air filter element Deutz and Perkins

models
Quarterly or 250 hour

Inspection:
Y N R
Comments
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,
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
3-6
S-40 S-45
Part No. 102521
July 2007
REV C
Checklist A Procedures
A-1
Inspect the Manuals and Decals
Genie specifications require that this procedure be
performed daily.
Maintaining the operators and safety manuals in
good condition is essential to safe machine
operation. Manuals are included with each
machine and should be stored in the container
provided in the platform. An illegible or missing
manual will not provide safety and operational
information necessary for a safe operating
condition.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
3 Open the operator's manual to the decals

inspection section. Carefully and thoroughly
inspect all decals on the machine for legibility
and damage.
Result: The machine is equipped with all
required decals, and all decals are legible and
in good condition.
Result: The machine is not equipped with all
required decals, or one or more decals are
illegible or in poor condition. Remove the
machine from service until the decals are
replaced.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie Industries if replacement manuals or decals
are needed.
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
July 2007
PROCEDURES
REV C
A-2
Perform Pre-operation Inspection
A-3
Perform Function Tests

performed daily.

performed daily.
Completing a Pre-operation Inspection is essential

to safe machine operation. The Pre-operation
Inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently
wrong with a machine before the operator performs
the function tests. The Pre-operation Inspection
also serves to determine if routine maintenance
procedures are required.
Completing the function tests is essential to safe

machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
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
Complete information to perform this procedure is

available in the Operator's Manual on your
machine.
S-40 S-45
Part No. 102521
July 2007
REV C
CHECKLIST A
Perkins models
A-4
Perform Engine Maintenance
Required maintenance procedures and additional

engine information are available in the
Perkins 404C-22 Operation Manual
(Perkins part number TPD 1443S).
Engine specifications require that this procedure

be performed every 8 hours or daily, whichever
comes first.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Deutz models
Deutz 2011 Operation Manual

Genie part number

Genie part number

Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302) or the
Ford DSG-423 EFI Operator Handbook
(EDI part number 1060020).
Ford DSG 423 EFI Operator Handbook

Genie part number
52883
84794
94890
Ford models
Ford LRG 425 EFI Operation Manual

Genie part number
Deutz 1011F Operation Manual

(Deutz part number 0297 9683) or the
(Deutz part number 0297 9929).
Genie part number
PROCEDURES
84792
119488
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
CHECKLIST A
PROCEDURES
REV C
A-5
Perform 30 Day Service
A-6
Perform Engine Maintenance Deutz and Ford Models
The 30 day maintenance procedure is a one time

sequence of procedures to be performed after the
first 30 days or 40 hours of usage, whichever
comes first. After this interval, refer to the
maintenance tables for continued scheduled
maintenance.
1 Perform the following maintenance procedures:
A-10
Grease the Turntable Bearing and

Rotate Gear
B-8
Inspect the Tires, Wheels and Lug Nut

Torque
B-9
Check the Drive Hub Oil Level and

Fastener Torque
D-2
Check the Turnable Rotation Bearing

Bolts
D-6
Replace the Hydraulic Filter Elements
3 - 10
July 2007

be performed after the first 50 hours of operation.
component damage.
Deutz models

Genie part number
52883

Genie part number
84794
S-40 S-45
Part No. 102521
July 2007
REV C
CHECKLIST A
Ford models
Genie part number
Genie part number
PROCEDURES
A-7
Perform Engine Maintenance Perkins Models

be performed every 50 hours.
84792
119488

moving.
injury.

component damage.
Perkins models

Genie part number
94890

moving.
injury.
Part No. 102521
S-40 S-45
3 - 11
CHECKLIST A
July 2007
PROCEDURES
REV C
A-8
Inspect the Fuel Filter/Water
Separator - Deutz Models
a

performed every 100 hours or monthly, whichever
comes first.
Proper maintenance of the fuel filter/water
separator is essential for good engine
performance. Failure to perform this procedure can
lead to poor engine performance and/or hard
starting, and continued use may result in
component damge. Extremely dirty conditions may
require this procedure be performed more often.
a
b
fuel filter
drain plug
2 Clean up any fuel that may have spilled.

3 Start the engine from the ground controls and
check the fuel filter/water separator for leaks.
Explosion and fire hazard. Engine

fuels are combustible. Perform this
procedure in an open, wellventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Explosion and fire hazard. If a fuel

leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
Note: Perform this procedure with the engine off.

1 Loosen the drain plug located at the bottom of
the filter. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
3 - 12
S-40 S-45
Part No. 102521
July 2007
REV C
CHECKLIST A
PROCEDURES
A-9
Perform Engine Maintenance Ford Models
A-10
Grease the Turntable Rotation
Bearing and Rotate Gear


performed every 100 hours of operation. Perform
this procedure more often if dusty conditions exist.

component damage.
Genie part number
Genie part number
84792
119488
Frequent application of lubrication to the turntable

bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.
1 Raise the boom enugh to access the turntable
gearing.
2 Locate the grease fitting on the platform end of
the engine side bulkhead.
3 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of
4 to 5 inches / 10 to 13 cm at a time and repeat
this step until the entire bearing has been
greased.
4 Apply grease to each tooth of the drive gear,
located under the turntable.

moving.
Grease specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent

injury.
Part No. 102521
S-40 S-45
3 - 13
CHECKLIST A
July 2007
PROCEDURES
REV C
A-11
Perform Engine Maintenance Deutz 1011F Models
A-12
Replace the Drive Hub Oil

be performed after the first 125 hours.
component damage.
Genie part number
52883

1 Remove the engine tray retaining fasteners
moving.
Manufacturer drive hub specifications require that

this one-time procedure be performed after the first
150 hours.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the torque hub oil after the first 50 hours of
use may cause the machine to perform poorly and
continued use may cause component damage.
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
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.
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.

injury.
models with pipe plugs
3 - 14
S-40 S-45
drive hub plugs
Part No. 102521
July 2007
REV C
CHECKLIST A
PROCEDURES
A-13

component damage.
Genie part number
Genie part number
84792
119488

moving.
injury.
Part No. 102521
S-40 S-45
3 - 15
CHECKLIST A
September
July 2007
PROCEDURES
3 - 16
S-40 S-45
Part No. 102521
September 2007
Checklist B Procedures
REV D
7 Check the ambient air temperature and adjust

the specific gravity reading for each cell as
follows:
B-1
Inspect the Battery
Add 0.004 to the reading of each cell for

every 10 / 5.5 C above 80 F / 26.7 C.
performed every 250 hours or quarterly, whichever
comes first.
Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions.
Result: All battery cells display an adjusted

specific gravity of 1.277 or higher. The battery
is fully charged. Proceed to step 11.
Result: One or more battery cells display a
specific gravity of 1.217 or below. Proceed to
step 8.
Electrocution/burn hazard. Contact

with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
3 Be sure that the battery hold downs and cable
connections are tight.
4 Be sure that the battery separator wire
connections are tight.
5 Fully charge the batteries and allow the
batteries to rest at least 6 hours.
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
Part No. 102521
Subtract 0.004 from the reading of each cell for

every 10 / 5.5 C below 80 F / 26.7 C.
8 Perform an equalizing charge, OR fully charge

the batteries and allow the batteries to rest at
least 6 hours.
9 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
10 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
Add 0.004 to the reading of each cell for
every 10 / 5.5 C above 80 F / 26.7 C.
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 a specific gravity
of 1.277 or greater. The battery is fully charged.
Proceed to step 11.
Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
than 1.217. Replace the battery.
11 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
12 Install the vent caps and neutralize any
electrolyte that may have spilled with baking
soda.
S-40 S-45
3 - 17
CHECKLIST B
September 2007
PROCEDURES
REV D
4 Inspect for a liberal coating of dielectric grease

in the following locations:
B-2
Inspect the Electrical Wiring

comes first.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
1 Open the engine side turntable cover.
located under the engine tray. Swing the engine
tray out and away from the machine and secure
it from moving.
injury.
3 Inspect the following areas for burnt, chafed,
corroded and loose wires:
Engine wiring harness
Hydraulic manifold wiring
Between the ground and platform controls
Between the ground and drive controls
All harness connectors
Level sensor
5 Open the turntable cover at the ground control

side of the machine.
corroded and loose wires:
Inside of the ground control box
Hydraulic manifold wiring

raise the boom above the turntable covers.
8 Inspect the turntable area for burnt, chafed and
pinched cables.
9 Lower the boom to the stowed position and turn
the engine off.
corroded, pinched and loose wires:
Cable track on the primary boom
Cables on the primary, and jib booms
Jib boom/Platform rotate manifold
Inside of the platform control box
11 Inspect for a liberal coating of dielectric grease

in all connections between the ECM and the
platform controls.
12 Swing the engine back to its original position
and install the engine pivot plate retaining
fasteners.
Crushing hazard. Failure to install
the fasteners into the engine tray
to secure it from moving could
result in death or serious injury.
3 - 18
S-40 S-45
Part No. 102521
September 2007
REV D
CHECKLIST B PROCEDURES
4 Remove the filter element.
B-3
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
for damage.
Note: Genie specifications require that this

procedure be performed every 250 hours or
quarterly, whichever comes first. Perform this
procedure more often if dusty conditions exist.
7 Re-install the filter element, or if there are any

signs of loss of filtration, replace the element.
Maintaining the engine air filter in good condition is

essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.
8 Install the end cap onto the canister. Secure the

clamps.
Note: Be sure the dust discharge valve is pointing
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
b
c
clamp
canister end cap
dust discharge valve
3 Disconnect the latches and remove the end cap

of the air cleaner canister.
Part No. 102521
S-40 S-45
3 - 19
CHECKLIST B
September 2007
PROCEDURES
REV D
B-4
Test the Key Switch
comes first.
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
a hazardous operating situation.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to ground control, start the
engine and then turn the key switch to platform
control.
3 Check all machine function from the ground
controls.
Result: All machine functions should not
operate.
B-5
Perform Engine Maintenance Deutz and Perkins Models

be performed quarterly or every 250 hours,
whichever comes first.
Deutz models
Genie part number
52883
Perkins models

4 Turn the key switch to ground control.

5 Check all machine function from the platform
controls.
Result: All machine functions should not
operate.
6 Turn the key switch to the off position.
Result: The engine should stop and no
functions should operate.

Genie part number
94890

moving.
injury.
3 - 20
S-40 S-45
Part No. 102521
September 2007
REV D
CHECKLIST B
B-6
Check the Exhaust System
B-7
Check the Oil Cooler and Cooling
Fins - Deutz Models

comes first.
Maintaining the exhaust system is essential to
good engine performance and service life. Running
the engine with a damaged or leaking exhaust
system can cause component damage and unsafe
operating conditions.
Bodily injury hazard. Do not
inspect while the engine is
running. Remove the key to
secure from operation.

comes first.
Maintaining the oil cooler in good condition is
essential for good engine performance. Operating
a machine with a damaged oil cooler may result in
engine damage. Also, restricting air flow through
the oil cooler will affect the performance of the
cooling system.
Bodily injury hazard. Do not
inspect while the engine
is running. Remove the key to
secure from operation.
Burn hazard. Beware of hot

engine components. Contact with
hot engine components may result
in severe burns.
it from moving.
injury.
2 Be sure that all nuts and bolts are tight.
Burn hazard. Beware of hot

engine components. Contact with
hot engine components may result
in severe burns.
Oil cooler
moving.
injury.
3 Inspect all welds for cracks.

4 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.
fasteners.
Part No. 102521
PROCEDURES
2 Remove the fasteners from the engine side

cover, and remove the cover.
3 Inspect the oil cooler for leaks and physical
damage.
4 Clean the oil cooler of debris and foreign
material.
S-40 S-45
3 - 21
CHECKLIST B
September 2007
PROCEDURES
REV D
B-8
Inspect the Tires, Wheels
and Lug Nut Torque

comes first.
a
b
c
Maintaining the tires and wheels in good

condition including proper wheel fastener torque is
essential to safe operation and good performance.
Tire and/or wheel failure could result in a machine
tip-over. Component damage may also result if
problems are not discovered and repaired in a
timely fashion.
oil cooler
cylinder head cooling fins
fan blower fins
Cooling and fan blower fins
Bodily injury hazard. An overinflated tire can explode and could

cause death or serious injury.
5 Inspect the fan blower fins for physical damage.

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
flashlight.
Note: The tires on some machines are foam-filled

and do not need air added to them.
8 Clean the cylinder head cooling passages of

debris and foreign material.
1 Check all tire treads and sidewalls for cuts,

cracks, punctures and unusual wear.
9 Install the engine side cover.
2 Check each wheel for damage, bends and

cracks.

fasteners. Tighten the pivot fastener.
3 - 22
3 Check each lug nut for proper torque. Refer to

Section 2, Specifications.
Models with air-filled tires:
4 Check pressure in each air-filled tire. Add air as
necessary. Refer to Section 2, Specifications.
S-40 S-45
Part No. 102521
September 2007
REV D
CHECKLIST B
PROCEDURES
Turntable rotate drive hub
B-9
Check the Drive Hub Oil Level
and Fastener Torque
1 Remove the plug located on the side of the hub

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
cause the machine to perform poorly and
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

a plug
Result: The oil level should be even with the

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

with the bottom of the plug hole.
3 If necessary, remove the top plug and add oil

until the oil level is even with the bottom of the
side plug hole. Refer to Section 2,
Specifications.
3 Apply pipe thread sealant to the plug, and

install the plug in the drive hub.
4 Check the torque of the turntable drive hub
mounting fasteners. Refer to Section 2,
Specifications.
4 Install the plug(s) in the drive hub. Use pipe

thread sealant on units with pipe plugs.
5 Check the torque of the drive hub mounting
fasteners. Refer to Section 2, Specifications.
6 Repeat this procedure for each drive hub.
a
Part No. 102521
drive hub plugs
S-40 S-45
3 - 23
CHECKLIST B
September 2007
PROCEDURES
REV D
2 Be sure the free-wheel valve on the drive pump

is closed (clockwise).
B-10
Confirm the Proper
Brake Configuration
Note: The free-wheel valve is located on the

bottom of the drive pump.

comes first.
Proper brake configuration is essential to safe

operation and good machine performance.
Hydrostatic brakes and hydraulically-released,
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully
operational.
1 Check each drive hub disconnect cap to be
sure it is in the engaged position.
a
b
c
d
drive pump
screwdriver
lift pump
free-wheel valve
Note: The free-wheel valve should always remain

closed.
brake disengaged position
brake engaged position
3 - 24
S-40 S-45
Part No. 102521
September 2007
REV D
CHECKLIST B
PROCEDURES
B-11
Check and Adjust the
Engine RPM
f
e

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. The machine will not
operate properly if the rpmaais incorrect and
a
b
c
d
e
f
Note: This procedure will require two people.

Ford Models
Note: The engine rpm is controlled by the ECM
and can only be adjusted by re-programming the
ECM. If rpm adjustment or service is required,
please contact Genie Industries Service
Department OR your local Ford dealer.
Deutz Models
1 Connect a tachometer to the engine. Start the
engine from the ground controls. Refer to
solenoid boot
high idle adjustment nut
yoke lock nut
yoke
low idle adjustment screw
low idle lock nut
If high idle rpm is correct, disregard

adjustment step 4.
4 Loosen the yoke lock nut. Turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and re-check the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
Perkins Models
Skip to step 3 if the low idle rpm is correct.

2 Loosen the low idle lock nut and turn the low
idle adjustment screw clockwise to increase the
rpm or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and re-check the
rpm.
1 Connect a tachometer to the engine. Start the

engine from the ground controls. Refer to
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.
Part No. 102521
S-40 S-45
3 - 25
CHECKLIST B
September 2007
PROCEDURES
REV D
Skip to step 3 if the low idle rpm is correct.

2 Loosen the low idle lock nut. Turn the low idle
adjustment screw clockwise to increase the
rpm, or counterclockwise to decrease the rpm.
B-12
Test the Engine Idle Select
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.

controls.
Tighten the low idle lock nut and confirm the

rpm.
a
b
c
d
2 Start the engine from the ground controls then

move and hold the function enable/rpm select
toggle switch to the high idle (rabbit symbol).
solenoid boot
high idle adjustment nut
clevis
low idle lock nut and adjustment
screw
Result: The engine should change to high idle.
3 Move the function enable toggle switch to the

high idle (rabbit symbol) position. Refer to
If high idle rpm is correct, disregard
adjustment step 4.
4 Loosen the yoke lock nut. Turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and re-check the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.
3 Release the function enable/rpm select toggle

switch.
Result: The engine should return to low idle.
4 Turn the key switch to platform controls.
5 Move the engine idle control switch to foot
switch activated high idle (rabbit and foot switch
symbol).
Result: The engine should not change to
high idle.
6 Press down the foot switch.
Result: The engine should change to 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.
3 - 26
S-40 S-45
Part No. 102521
September 2007
REV D
CHECKLIST B
B-13
Test the Fuel Select Operation Ford Models

comes first.
The ability to select and switch between
gasoline and LPG fuels as needed is essential to
safe machine operation. A fuel selection can be
made when the engine is running or not.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate
fuel system problems that could develop into a
hazardous situation.
PROCEDURES
2 Start the engine from the platform controls and

allow it to run at low idle. Press down the foot
switch to allow the engine to run at high idle.
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.
4 Move the fuel select switch to LPG.
5 Start the engine and allow it to run at
low idle. Press down the foot switch to allow the
engine to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
Note: The engine may hesitate momentarily and
then continue
to run on the selected fuel if switched while
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).
Part No. 102521
S-40 S-45
3 - 27
CHECKLIST B
PROCEDURES
REV D
B-14
Test the Ground Control Override
comes first.
A properly functioning ground control override is
essential to safe machine operation. The ground
control override function is intended to allow
ground personnel to operate the machine from the
ground controls whether or not the red Emergency
Stop button on the platform controls is in the on or
off position. This function is particularly useful if the
operator at the platform controls cannot return the
boom to the stowed position.
1 Push in the platform red Emergency Stop
button to the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boom
function through a partial cycle.
Result: All boom functions should operate.
3 - 28
September 2007
B-15
Check the Directional Valve
Linkage

comes first.
Note: Perform this test only on models equipped
with a oscillating axle.
Proper axle oscillation is essential to safe machine
operation. If the directional valve linkage is not
operating correctly, the stability of the machine is
compromised and it may tip over.
1 Remove the drive chassis cover and the axle
covers from the non-steer end of the drive
chassis.
2 Locate the directional valve inside of the nonsteer axle and inspect the linkage for the
following:
S-40 S-45
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
September 2007
REV D
CHECKLIST B
PROCEDURES
B-16
Test the Platform Self-leveling
B-17
Test the Drive Brakes

comes first.

comes first.
Automatic platform self-leveling throughout

the full cycle of primary boom raising and lowering
is essential for safe machine operation. The
platform is maintained at level by the platform
leveling slave cylinder which operates in a closed
loop hydraulic circuit with the master cylinder
located at the base of the boom.
Proper brake action is essential to safe machine

operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear to
operate normally when they are actually not fully
operational.
A platform self-leveling failure creates an unsafe

working condition for platform and ground
personnel.
Collision hazard. Be sure that the

machine is not in free-wheel or
partial free-wheel configuration.
See B-10, Confirm the Proper
Brake Configuration.

lower the boom to the stowed position.
2 Hold the function enable toggle switch to either
side and adjust the platform to a level position
using the platform level toggle switch.
3 Raise and lower the primary boom through a full
cycle.
Result: The platform should remain level at
all times to within 5 degrees.
Note: Select a test area that is firm, level and free

of obstructions.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls.
3 Move the engine idle control switch to
foot switch activated high idle (rabbit and
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.
Part No. 102521
S-40 S-45
3 - 29
CHECKLIST B
September 2007
PROCEDURES
REV D
B-18
Test the Drive Speed Stowed Position
B-19
Test the Drive Speed Raised or Extended Position

comes first.

comes first.
Proper drive function movement is essential to

safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
Proper drive function movement is essential to

safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.

of obstructions.

of obstructions.
1 Create start and finish lines by marking two

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

lines on the ground 40 feet / 12.2 m apart.
3 Move the engine idle control switch to

foot switch activated high idle (rabbit and foot
switch symbol), then lower the boom into the
stowed position.
3 Move the engine idle select switch to foot switch

activated high idle (rabbit and foot switch
symbol).

when crossing the start and finish lines.
4 Raise the boom above horizontal.


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.
3 - 30
S-40 S-45
Part No. 102521
September 2007
REV D
CHECKLIST B

start line.
7 Continue at full speed and note the time when
8 Lower the boom to the stowed position and
extend the boom 1 foot / 30 cm.
start line.
11 Continue at top speed and note the time when
Part No. 102521
PROCEDURES
B-20
Perform Hydraulic Oil Analysis

comes first.
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and
Extremely dirty conditions may require oil changes
to be performed more often.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
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.
S-40 S-45
3 - 31
CHECKLIST B
September 2007
PROCEDURES
REV D
3 Move the function enable/rpm select toggle

switch to either side and activate the jib boom
toggle switch in the down position, hold for a
moment and then release it.
B-21
Test the Alarm Package
(if equipped) and the
Descent Alarm
comes first.
The alarm package includes:
Travel alarm
Flashing beacons
Result: The descent alarm should sound when

the toggle switch is held down.
4 Turn the key switch to platform controls.
Result: The flashing beacons should be on
and flashing.
5 Press down the foot switch. Move the boom
controller to the down position, hold for a
Alarms and beacons are installed to alert operators

and ground personnel of machine proximity and
motion. The alarm package is installed on the
turntable rear cover. Beacons are installed on both
turntable covers.
Note: The alarms and beacons will operate with
the engine running or not running.
Note: The descent alarm is standard equipment
beginning with serial number 12602.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
Result: Both flashing beacons should be on and
flashing.

the controller is held down.
6 Press down the foot switch. Move the jib boom
toggle switch to the down position, hold for a
the controller is held down.
7 Press down the foot switch. Move the drive
controller off center, hold for a moment and
then release it. Move the drive controller off
center in the opposite direction, hold for a
Result: The travel alarm should sound when the
drive controller is moved off center in either
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.
the toggle switch is held down.
3 - 32
S-40 S-45
Part No. 102521
September 2007
REV D
CHECKLIST B
PROCEDURES
2 Check for proper venting.
B-22
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
Note: When checking for positive fuel tank cap

venting, air should pass freely through the cap.
Result: Air should pass through the fuel tank
cap. Proceed to step 4.

performed quarterly or every 250 hours, whichever
comes first. Perform this procedure more often if
dusty conditions exist.
A free-breathing fuel and hydraulic tank cap is
service life. A dirty or clogged cap may cause the
machine to perform poorly and continued use may
cause component damage. Extremely dirty
conditions may require that the cap be inspected
more often.
easy reach.
Result: Air is not passing through the fuel tank

cap. Clean or replace the cap.
Proceed to step 3.
3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
All models:
5 Remove the breather cap from the hydraulic
tank.
6 Check for proper venting.
Result: Air should pass through the breather
cap. Proceed to step 8.
Result: If air does not pass through the breather
cap, clean or replace the cap.
Proceed to step 7.
Gasoline/LPG models (before serial

number 13740) and Diesel models (all):
Note: When checking for positive tank cap venting,

air should pass freely through the cap.

Note: Gasoline/LPG models use a pressurized cap
beginning with serial number 13740.
7 Using a mild solvent, carefully wash the cap

venting system. Dry using low pressure
compressed air. Repeat this procedure
1 Remove the cap from the fuel tank.
8 Install the breather cap onto the hydraulic tank.
Part No. 102521
S-40 S-45
3 - 33
CHECKLIST B
PROCEDURES
September 2007
REV D
B-23

component damage.
Genie part number
Genie part number
84792
119488

moving.
injury.
3 - 34
S-40 S-45
Part No. 102521
September
July
2007 2007
REV B
Checklist C Procedures
Perkins models
C-1


component damage.
Deutz models

Genie part number

moving.

Genie part number
52883

Genie part number
84794
Part No. 102521
94890
S-40 S-45

injury.
3 - 35
CHECKLIST
July 2007
PROCEDURES
REVB
C-2
Grease the Platform Overload
Mechanism (if equipped)
C-3
Test the Platform Overload
System (if equipped)

performed every 500 hours or 6 months, whichever
comes first. Perform this procedure more often if
dusty conditions exist.

performed every 500 hours or 6 months, whichever
comes first.
Application of lubrication to the platform overload

mechanism is essential to safe machine operation.
Continued use of an improperly greased platform
overload mechanism could result in the system not
sensing an overloaded platform condition and will
result in component damage.
Testing the platform overload system regularly is

essential to safe machine operation. Continued
use of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stablity
could be compromised resulting in the machine
tipping over.
1 Locate the grease fittings on each pivot pin of

the platform overload assembly.
Note: Perform this procedure with the machine on

a firm, level surface.
2 Thoroughly pump grease into each grease

fitting using a multi-purpose grease.
1 Turn the key switch to platform control. Start the

engine and level the platform.
Grease type
2 Determine the maximum platform capacity.

Refer to the machine serial plate.
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent
3 Remove all weight, tools and accessories from

the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect test.
3 - 36
S-40 S-45
Part No. 102521
July 2007
REV B
CHECKLIST
4 Using a suitable lifting device, place a test

weight equal to that of the available capacity
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.
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).
5 Carefully move the test weight to each
remaining location. Refer to Illustration 1.
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).
C PROCEDURES
6 Using a suitable lifting device, place an

additional 50 lbs / 23 kg of weight onto the
platform.
Result: The alarm should sound.
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
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-4, How to
Calibrate the Platform Overload System (if
equipped).
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
7 Carefully move the test weights to each
remaining location on the platform.
Refer to Illustration 1.
Result: The alarm should sound.
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
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-4, How to
Calibrate the Platform Overload System (if
equipped).
Note: There may be a two second delay before the
overload indicator lights flash and the alarm
sounds.
Illustration 1
Part No. 102521
S-40 S-45
3 - 37
CHECKLIST
July 2007
PROCEDURES
REV B
8 Test all machine functions from the platform

controls.
14 Start the engine and test all machine functions

from the ground controls.
Result: All platform control functions should not

operate.
Result: All ground control functions should

operate normally.
15 Turn the key switch to platform control.
10 Test all machine functions from the ground

controls.

controls.
Result: All ground control functions should not

operate.
11 Activate the auxiliary power toggle switch.
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).
Note: The engine will turn off when the auxiliary

power is activated.
12 Using auxiliary power, test all machine functions
from the ground controls.
17 Using a suitable lifting device, remove the

remaining test weights from the platform.

operate.
13 Using a suitable lifting device, lift the additional
test weight from the platform.
should turn off at both the ground and platform
Note: There may be an two second delay before
the overload indicator lights and alarm turn off.
3 - 38
S-40 S-45
Part No. 102521
July 2007
REV B
CHECKLIST
C-4
Replace the Engine Air Filter
Element - Deutz and Perkins
Models
C-5
Replace the In-line Fuel Strainer Deutz Models
Genie specifications requires that this procedure

be performed every 500 hours or 6 months,
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component damage.

be performed every 500 hours or 6 months,
Replacing the diesel fuel strainer is essential for
good engine performance and service life. A dirty
or clogged filter may cause the engine to perform
poorly and continued use may cause component
damage.
easy reach.
1 Open the evacuator valve located on the air

cleaner cap by squeezing the sides together
with your fingers.
2 Disconnect the latches on the air cleaner cap.
Remove the end cap from the air cleaner
canister.
3 Remove the filter element.
4 Clean the inside of the canister and the gasket
with a damp cloth.
5 Install the new filter element.
6 Install the end cap on the canister and reconnect the latches.
Note: Be sure the evacuator valve is pointing
down.
Part No. 102521
C PROCEDURES

1 Put on protective clothing and eye wear.
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.
S-40 S-45
3 - 39
CHECKLIST
PROCEDURES
July 2007
REV B
C-6

component damage.
(Ford part number FPP 194-302) OR the
Genie part number
Genie part number
84792
119488

moving.
injury.
3 - 40
S-40 S-45
Part No. 102521
July 2007
REV B
Checklist D Procedures
D-1
Check the Boom Wear Pads
Wear pad
specifications
all wear pads
Minimum
9/16
inch
14.3 mm

be performed every 1000 hours or annually,
4 Extend and retract the boom through the entire

range of motion to check for tight spots that
may cause binding or scraping of the boom.
Maintaining the boom wear pads in good condition

is essential to safe machine operation. Wear pads
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.
Note: Always maintain squareness between the

outer and inner boom tubes.

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
July 2007
PROCEDURES
REV B
D-2
10
15
13
Check the Turntable Rotation

Bearing Bolts
19
18
12
11

Maintaining proper torque on the turntable bearing
bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe
operating condition and component damage.
1 Raise the primary boom and place safety
chocks on the lift cylinders rods. Carefully lower
the boom onto the lift cylinders safety chocks.
Crushing hazard. Keep hands
away from cylinders and all
moving parts when lowering the
boom.
Note: The lift cylinder safety chock is available
through Genie (Genie part number 75097).
17
20
5
8
14
16
Bolt torque sequence
4 Be sure that each turntable mounting bolt is

torqued in sequence to specifications. Refer to
5 Start the engine form the ground controls.
6 Raise the secondary boom and remove the
safety chock.
7 Lower the boom to the stowed position.
8 Remove drive chassis covers from both the
steer end and the non-steer end of the
machine.
2 Turn the engine off.

it from moving.
injury.
3 - 42
S-40 S-45
Part No. 102521
July 2007
REV B
CHECKLIST
9 Check to ensure that each lower bearing

mounting bolt under the drive chassis is
torqued in sequence to specifications. Refer to
10
D PROCEDURES
D-3
Check the Free-wheel
Configuration
15
13
19
18

12
11
17
20
Proper use of the free-wheel configuration is

essential to safe machine operation. The
free-wheel configuration is used primarily for
towing. A machine configured to free-wheel without
operator knowledge may cause death or serious
injury and property damage.
5
8
14
16
Bolt torque sequence

fasteners.
Collision hazard. Select a work

site that is firm and level.
Component damage hazard. If the
machine must be towed, do not
exceed 2 mph / 3.2 km/h.
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
CHECKLIST
July 2007
REV B
PROCEDURES
5 Manually rotate each non-steer wheel.
All Models:
Result: Each non-steer wheel should rotate with

minimum effort.
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift 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.
Steer Wheels: 4WD Models
13 Be sure the free-wheel valve on the drive pump

is closed (clockwise).
Note: The free-wheel valve is located on the
bottom of the drive pump.
Note: The free-wheel valve should always remain
closed.
b
c
7 Chock the non-steer wheels to prevent the

machine from rolling.
8 Center a lifting jack of ample capacity

(20,000 lbs / 10,000 kg) under the drive chassis
between the steer tires.
9 Lift the wheels off the ground and then place
jack stands under the drive chassis for support.
a
b
c
d
drive pump
screwdriver
lift pump
free-wheel valve
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
July 2007
REV B
CHECKLIST
D PROCEDURES
Turntable Rotate Drive Hub:
D-4
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
Torque Specifications.

1 Raise the secondary boom until the platform

end of the lower secondary boom arm is
approximately 8 feet / 2.4 m off the ground.
Replacing the drive hub oil is essential for good

machine performance and service life. Failure to
replace the torque hub oil at yearly intervals may
2 Secure the turntable from rotating with the

turntable rotation lock pin.
3 Tag, disconnect and plug the hydraulic hoses
from the turntable rotate drive motor. Cap the
fittings on the drive motor.
1 Select the drive hub to be serviced. Drive the

machine until one of the two plugs is at the
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.
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
drive hub plugs
S-40 S-45
3 - 45
CHECKLIST
July 2007
PROCEDURES
REV B
5 Remove the drive hub mounting bolts. Carefully

remove the turntable rotate drive hub assembly
from the machine.
Crushing hazard. The turntable
rotate drive hub assembly could
become unbalanced and fall if not
properly supported by the lifting
device.
6 Remove the plug from the side of the drive hub.
Drain the oil from the hub into a suitable
container.
7 Install the drive hub assembly onto the
machine. Torque the drive hub mounting bolts
to specification. Refer to
8 Fill the drive hub with oil from the side hole until
the oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plug. Install the
plug.
D-5

Deutz models
Genie part number
52883

Genie part number
84794
Perkins models
Genie part number
94890

moving
injury
3 - 46
S-40 S-45
Part No. 102521
July 2007
CHECKLIST
REV B
D PROCEDURES
7 Rotate the filter element clockwise to lock it in

place.
D-6
Replace the Hydraulic Filter
Elements

performed every 1000 hours or annually,
whichever comes first. Perform this procedure
more often if dusty conditions exist.
Replacement of the hydraulic filters is essential for
good machine performance and service life. A dirty
or clogged filter may cause the machine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filters be replaced more often.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
Install the filter housing cap.
Use a permanent ink marker to write the date

and number of hours from the hour meter on
the oil filter housing.
Medium and high pressure filter

Note: The medium pressure filter is for the charge
pump and the high pressure filter (if equipped) is
for all machine functions except the drive circuit
and oscillating axle circuit.
10 Open the engine side turntable cover and
locate the medium pressure filter mounted to
the engine tray.
11 Place a suitable container under each filter.
12 Remove the filter housings by using a wrench
on the nut provided on the bottom of the
housings.
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
top of the hydraulic tank.
2 Remove the cap from the filter housing.
3 Lift the handle on the filter element and rotate
the element counterclockwise to release the
element from the housing.
4 Remove the filter element from the filter
housing.
5 Install the new filter element into the filter
housing.
15 Install the new filter elements into the housings

and tighten them securely.
16 Clean up any oil that may have spilled during
the installation procedure.
17 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter housings.
19 Inspect the filter housings and related
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
CHECKLIST
July 2007
REV B
PROCEDURES
D-7
Inspect for Turntable Bearing
Wear

Periodic inspection of turntable bearing wear is
essential to safe machine operation, good machine
performance and service life. Continued use of a
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious
injury and component damage.
Note: Perform this procedure with the machine on
a firm, level surface and the boom in the stowed
position.
3 Start the machine from the ground controls and
raise the boom to full height. Do not extend the
boom.
4 Place a dial indicator between the drive chassis
and the turntable at a point that is directly
under, or inline with, the boom and no more
than 1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, place
the dial indicator no more than 1 inch / 2.5 cm from
the turntable rotation bearing.
3 - 48
a
b
c
d
turntable
dial indicator
drive chassis
turntable rotation bearing
5 At the dial indicator, adjust it to "zero" the

indicator.
6 Fully extend the boom and lower to a horizontal
position.
7 Note the reading on the dial indicator.
Result: The measurement is less than
0.063 inch / 1.6 mm. The bearing is good.
Result: The measurement is more than
0.063 inch / 1.6 mm. The bearing is worn and
needs to be replaced.
8 Fully retract the boom and raise the boom to full
height. Visually inspect the the dial indicator to
be sure the needle returns to the "zero"
position.
S-40 S-45
Part No. 102521
July 2007
REV B
CHECKLIST
D PROCEDURES
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
July 2007
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
REV B
3 Models with hydraulic tank shut-off valves:

Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.

performed every 2000 hours or 2 years, whichever
comes first.
Replacement or testing of the hydraulic oil is
service life. Dirty oil and suction strainers may
Extremely dirty conditions may require oil changes
to be performed more often.
open
closed
Component damage hazard. The

engine must not be started with
the 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.
Note: Before replacing the hydraulic oil, the oil may

be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
Note: Perform this procedure with the boom in the
stowed position.
4 Remove the drain plug and completely drain the

tank into a suitable container. Refer to
1 Ford models: Turn the valve on the LPG tank

clockwise to the off position (if equipped). Then
slowly disconnect the hose from the LPG tank.
5 Tag, disconnect and plug the two suction hoses

and supply hose for the auxiliary pump from the
hydraulic tank. Cap the fittings on the tank.
2 Ford models: Open the clamps from the LPG

tank straps and remove the LPG tank from the
machine (if equipped).
Note: The hoses can be accessed through the

access hole under the turntable.
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
July 2007
REV B
CHECKLIST E
8 Support the hydraulic tank with an appropriate

lifting device.
9 Remove the hydraulic tank mounting fasteners.
10 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulic
tank could become unbalanced
and fall if not properly supported
when removed from the machine.
11 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic
return filter housing from the hydraulic tank.
12 Remove the suction strainers from the tank and
clean them using a mild solvent.
PROCEDURES

Open the two hydraulic tank valves at the
hydraulic tank.
21 Fill the tank with hydraulic oil until the level is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
22 Clean up any oil that may have spilled.
23 Prime the pump. Refer to Repair Procedure
6-2, How to Prime the Pump.
Note: Always use pipe thread sealant when
installing the suction hose fittings and the drain
plug.
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
CHECKLIST E
July 2007
PROCEDURES
REV B
6 Remove the dust cap from the hub. Remove the

cotter pin from the castle nut.
E-2
Grease the Steer Axle
Wheel Bearings, 2WD Models
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to

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

performed every 2000 hours or 2 years, whichever
comes first.
Maintaining the steer axle wheel bearings is
essential for safe machine operation and service
life. Operating the machine with loose or worn
wheel bearings may cause an unsafe operating
condition and continued use may result in
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
washing of the machine may require that this
procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove
them.
2 Block the non-steering wheels. Center a lifting
jack under the steer axle.
3 Raise the machine 6 inches / 15 cm Place
blocks under the drive chassis for support.
8 Loosen the castle nut one full turn and then

torque to 35 ft-lbs / 47 Nm.
9 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: If there is no side to side or up and
down movement, continue to step 11 and
grease the wheel bearings.
Result: If there is side to side or up and down
movement, continue to step 11 and replace the
wheel bearings with new ones.
Note: When replacing a wheel bearing, both the
inner and outer bearings, including the pressed-in
races, must be replaced.
10 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
11 Remove the castle nut.
4 Remove the lug nuts. Remove the tire and

wheel assembly.
12 Pull the hub off of the spindle. The washer and

outer bearing should fall loose from the hub.
5 Check for wheel bearing wear by attempting to

move the wheel hub side to side, then up and
down.
13 Place the hub on a flat surface and gently pry

the bearing seal out of the hub. Remove the
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
July 2007
REV B
CHECKLIST E
14 Pack both bearings with clean, fresh grease.

15 Place the large inner bearing into the rear of the
hub.
PROCEDURES
E-3
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.

17 Slide the hub onto the yoke spindle.

Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
18 Place the outer bearing into the hub.
19 Install the washer and castle nut.

component damage.
Deutz 1011F models
20 Tighten the slotted nut to 158 ft-lbs / 214 Nm to

seat the bearings.
21 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
22 Install a new cotter pin. Bend the cotter pin
to lock it in.

engine information is available in the
Genie part number
23 Install the dust cap, then the tire and wheel

assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
52883
Perkins models
Genie part number
94890

it from moving.
injury.
Part No. 102521
S-40 S-45
3 - 53
CHECKLIST E
July 2007
REV B
PROCEDURES
E-4
E-5




component damage.

Genie part number
Genie part number
84792
119488


moving.
injury.

Genie part number
52883

Genie part number
84794

moving.
injury.
3 - 54
S-40 S-45
Part No. 102521
July 2007
REV B
CHECKLIST E
Perkins models
Genie part number
94890

moving.
injury.
PROCEDURES
E-6

component damage.
Genie part number
52883

Genie part number
84794

moving.
injury.
Part No. 102521
S-40 S-45
3 - 55
CHECKLIST E
July 2007
PROCEDURES
REV B
E-7
Perform Engine Maintenance Deutz Models
E-8
Perform Engine Maintenance Deutz Models


be performed every 12,000 hours.

component damage.

component damage.



Genie part number
52883

Genie part number
52883

Genie part number
84794

Genie part number
84794

.

moving.

moving.

injury.
3 - 56
S-40 S-45

injury.
Part No. 102521
July 2007
REV B
CHECKLIST E
PROCEDURES
E-9

be performed every 4 years.
Genie part number
Genie part number
84792
119488

moving.
injury.
Part No. 102521
S-40 S-45
3 - 57
CHECKLIST E
July 2007
PROCEDURES
3 - 58
S-40 S-45
Part No. 102521
April 2009
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:

Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
Perform disassembly procedures to the point where

repairs can be completed. To re-assemble, perform
the disassembly steps in reverse order.
Symbols Legend



before operating the machine.
Before Repairs Start:


operating instructions in the Genie S-40 and
Genie S-45 Operators Manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use.

Use only Genie approved replacement parts.

Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
With safety alert symbolused to

indicate the presence of a
which, if not avoided, may cause

repair procedure with the machine in the
Machine parked on a flat, level surface
Boom in the stowed position

the non-steering wheels

rotation lock pin

key removed
Wheels chocked
All external AC power supply disconnected

from the machine
Part No. 102521

property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
S-40 S-45
4-1
April 2009
Platform Controls
REV D
The platform control box contains one printed

circuit board. The ALC-500 circuit board inside the
platform control box controls all proportional
machine functions from the platform. The joystick
controllers at the platform controls utilize Hall
Effect technology and require no adjustment. The
operating parameters of the joysticks are stored in
memory at the ECM circuit board at the platform
controls. If a joystick error occurs or if a joystick is
replaced, it will need to be calibrated before that
particular machine function will operate. See 1-2,
How to Calibrate a Joystick.
1-1
ALC-500 Circuit Board
Each joystick controller should operate smoothly

and provide proportional speed control over its
entire range of motion.
How to Remove the ALC-500

Circuit Board
Electrocution hazard. Contact

with electrically charged circuits
injury. Remove all rings, watches
and other jewelry.
Note: When the ALC-500 circuit board is replaced,
the joystick controllers will need to be calibrated.
See 1-2, How to Calibrate a Joystick.
1 Push in the red Emergency Stop button to the

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
a
b
c
d
4-2
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
S-40 S-45
Part No. 102521
April 2009
PLATFORM CONTROLS
REV D
4 Attach a grounded wrist strap to the ground

screw inside the platform control box.
1-2
Joysticks
Component damage hazard.

Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
How to Calibrate a Joystick

The joysticks on this machine utilize digital Hall
Effect technology for proportional control. If a
joystick is disconnected or replaced, it must be
calibrated before that particular machine function
will operate.
5 Carefully disconnect the wire connectors from

the circuit board.
Note: The joystick must be calibrated before the

threshold, max-out or ramping can be set.
6 Remove the ALC-500 circuit board mounting

fasteners.
7 Carefully remove the ALC-500 circuit board

from the platform control box.

controls.
2 Turn the key switch to platform control. Do not
start the engine.
3 Select a joystick to calibrate.
4 Move the joystick full stroke in either direction
and hold for 5 seconds.
5 Return the joystick to the neutral position,
pause for a moment, then move the joystick full
stroke in the opposite direction. Hold for 5
seconds and return the joystick to the neutral
position.
Result: The alarm should sound indicating
successful joystick calibration.
6 Repeat this procedure for each joystick
controlled machine function including the thumb
rocker steer switch.
Note: No machine fuction should operate while
performing the joystick calibration procedure.
Part No. 102521
S-40 S-45
4-3
April 2009
PLATFORM CONTROLS
REV D

press down the foot switch.
How to Adjust the Function

Speeds
The max-out setting of a joystick controls the
maximum speed of a joystick-controlled machine
function. Whenever a hydraulic cylinder, drive
motor or hydraulic pump is replaced, the max-out
setting should be adjusted to maintain optimum
performance. The max-out settings on the joystick
can be changed to compensate for hydraulic pump
wear to maintain peak performance from the
machine.
stowed position.
controls.
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch in
the right position and pull out the red
Emergency Stop button to the on position.
9 Start a timer and activate the machine function

that needs to be adjusted. Record the time it
takes for that function to complete a full cycle
(ie; boom up).
10 Compare the machine function time with the
function times listed in Section 2,
Specifications. Determine whether the function
time needs to increase or decrease.
11 While the joystick is activated, adjust the maxout setting to achieve the proper function cycle
time. Momentarily move the drive enable toggle
switch in the right direction to increase the
function speed or momentarily move the drive
enable toggle switch in the left direction to
decrease the function speed.
Note: Each time the drive enable toggle switch is
momentarily moved, the function speed will change
in 2% increments.
12 Repeat steps 9 through 11 for each joystick
controlled machine function.
13 Return the joystick to the neutral position and
wait for approximately 10 seconds to allow the
settings to be saved.
Result: The alarm should sound indicating that
the settings have been saved in memory.
6 When the alarm sounds, release the drive

enable toggle switch.
Note: Do not operate any machine function during

the 10 second waiting time.
7 Momentarily activate the drive enable toggle

switch in the right direction 4 times.
Result: There should be a pause and the alarm
should sound 4 times indicating that the
machine is in max-out calibration mode.
4-4
S-40 S-45
Part No. 102521
April 2009
PLATFORM CONTROLS
REV D
How to Adjust the Joystick

Ramp Rate Setting
10 Compare the function ramp rate time with the

table below and determine whether the ramp
rate time needs to increase or decrease.
The ramp rate setting of a joystick controls the time

at which it takes for the joystick to reach maximum
output, when moved out of the neutral position.
The ramp rate settings of a joystick can be
changed to compensate for hydraulic pump wear
to maintain peak performance from the machine.
11 While the joystick is activated, set the ramp

rate. Momentarily move the drive enable toggle
switch in the right direction to increase the time
or momentarily move the drive enable toggle
switch in the left direction to decrease the time.

stowed position.
controls.
start the engine.
3 Push in the platform controls red Emergency
Stop button to the off position.
machine is in ramp rate calibration mode.
9 Start a timer and simultaneously move the
joystick in either direction full stroke. Note how
long it takes the function to reach maximum
speed. This is the ramp rate.
Part No. 102521
Note: Each time the drive enable toggle switch is

momentarily moved, the time will change in 5%
increments.
12 Repeat steps 9 through 11 for each joystick
controlled machine function.
wait for approximately 10 seconds to allow the
settings to be saved.
Ramp rate (factory settings)
Boom up/down
accelerate
decelerate
3 second
1 seconds
Turntable rotate
accelerate
decelerate
2 seconds
1 second
Drive
accelerate
decelerate to neutral
decelerate, change of direction
decelerate, coasting
decelerate, braking
decelerate, shift from low to high speed
decelerate, shift from high to low speed
S-40 S-45
2 seconds
0.5 second
0.5 second
0.75 second
1 second
1 second
3 seconds
4-5
April 2009
PLATFORM CONTROLS
REV D

How to Adjust the Joystick

Threshold Setting
The threshold setting of a joystick is the minimum
output at which a function proportional valve can
open and allow the function to operate.
stowed position.
controls.
start the engine.
3 Push in the red Emergency Stop button to the
off position at the platform controls.
9 Select a boom function joystick to set the

threshold.
10 Slowly move the joystick off center in either
direction just until the function begins to move.
11 Slowly move the joystick back to the neutral
position. Just before the function stops moving,
move the drive enable toggle switch to either
side to set the threshold.
Result: The alarm should sound indicating a
successful calibration.
12 Repeat steps 9 through 11 for each boom
joystick-controlled machine function (boom up/
down, boom extend/retract and turntable rotate).
wait for approximately 10 seconds.

machine is in threshold calibration mode.
4-6
S-40 S-45
Part No. 102521
July 2007
Platform Components
REV B
2-1
Platform Leveling Slave Cylinder
The slave cylinder and the rotator pivot are the
two primary supports for the platform. The slave
cylinder keeps the platform level through the
entire range of boom motion. It operates in a
closed-circuit hydraulic loop with the master
cylinder. The slave cylinder is equipped with
counterbalance valves to prevent movement in
the event of a hydraulic line failure.
How to Remove the Platform

Leveling Slave Cylinder
S-40 Models:
from the slave cylinder at the union located
near the platform rotate counterbalance valve
manifold and connect them together using a
connector. Cap the fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
S-45 Models:
Note: Before cylinder removal is considered, bleed

the slave cylinder to be sure there is no
air in the closed loop.
installation.
1 Extend the primary boom until the slave cylinder
barrel-end pivot pin is accessible.
2 Raise the primary boom slightly and place
blocks under the platform for support.
3 Lower the primary boom until the platform is
resting on the blocks just enough to support the
platform.
6 Tag, disconnect and plug the slave cylinder

hoses at the union.
7 Pull the slave cylinder hoses through the
platform rotator.
8 Remove the pin retaining fastener from
the slave cylinder rod-end pivot pin. Do not
remove the pin.
9 Remove the external retaining fastener from the
barrel-end pivot pin.
10 Use a soft metal drift to drive the rod-end pivot
pin out.
11 Use a soft metal drift and drive the barrel-end
pin out.
12 Carefully pull the cylinder out of the boom.
Component damage hazard. Hoses
can be damaged if they are kinked
or pinched.
Note: Do not rest the entire weight of the boom on

the blocks.
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.
Part No. 102521
S-40 S-45
4-7
July 2007
PLATFORM COMPONENTS
REV B
S-40 Models:
2-2
Platform Rotator
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
160 degrees.

from the platform rotator. Cap the fittings on the
rotator.
gradually. Do not allow oil to squirt
or spray.
How to Remove the

Platform Rotator
Component damage hazard. Mark
the platform mounting weldment
and the rotator flange before
removing the platform mounting
weldment. The platform mounting
weldment must be replaced in the
exact same position on the rotator
flange as it was before removal. If
a new rotator is installed or the
rotator is disassembled, proper
alignment can be achieved by
rotating the rotator all the way to
the left and then installing the
platform mounting weldment all
the way in the left position.
installation. Refer to Section Two, Hydraulic Hose
and Fitting Torque Specifications.
S-45 Models:
3 Tag and disconnect the hydraulic hoses from
the "V1" and "V2" ports on the counterbalance
valve manifold located on the platform rotator
and connect them together using a connector.
Cap the fittings on the manifold.
4 Support the platform leveling arms and platform
mounting weldment with an appropriate lifting
device, but do not apply any lifting pressure.
All Models:
5 Remove the six mounting bolts from the
platform mounting weldment. Remove the
center bolt and slide the platform mounting
weldment off of the platform rotator.
Crushing hazard. The platform
mounting weldment could become
unbalanced and fall if it is not
properly supported.
1 Remove the platform and platform support.
6 Support the platform rotator with an appropriate

lifting device. Do not apply any lifting pressure.
4-8
S-40 S-45
Part No. 102521
July 2007
REV B
PLATFORM COMPONENTS
7 Support the platform leveling slave cylinder.

Protect the cylinder rod from damage.
3 Open the top bleed valve on the rotator, but do

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.
rotator could become unbalanced
and fall if it is not properly
supported.
How to Bleed the Platform

Rotator
d
a
b
c
d
Note: This procedure will require two people. Do not

start the engine. Use auxiliary power for this
procedure.
1 Move the function enable toggle switch to either
side and activate the platform rotate toggle
switch to the right then the left through two
platform rotation cycles, then hold the switch to
the right position until the platform is fully
rotated to the right.
2 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container
to collect any drainage. Secure the container to
the boom.
top bleed valve

bottom bleed valve
container
clear hose

side and hold the platform rotate toggle switch
to the left position until the platform is fully
rotated to the left. 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.
5 Connect the clear hose to the bottom bleed
valve and open the valve. Do not remove the
bleed valve.
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.
Part No. 102521
S-40 S-45
4-9
July 2007
PLATFORM COMPONENTS
REV B
2-3
Platform Overload System
How to Calibrate the Platform

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
rated capacity. Refer to the machine serial label for
maximum capacity information.
If maximum platform capacity is exceeded, the
alarm will sound at the platform controls and the
platform overload indicator lights will flash at both
the ground and platform controls. The ground and
platform controls will become disabled. Before
normal machine operation can continue, the excess
load will need to be removed from the platform.
If the excess load cannot be removed or if the
operator at the platform controls is unable to correct
the overloaded condition, another person at the
ground controls can operate the machine using
auxiliary power. There will be limited control of
boom functions from the ground controls when
using auxiliary power. Auxiliary power can be used
to correct the overloaded platform condition in order
to resume normal, safe operation of the machine.
Note: Even though platform and ground controls are
disabled when an overloaded condition is detected,
the engine will continue to run. If the engine is shut
off in an overloaded condition, it will not be possible
to re-start the engine until the overloaded condition
is corrected.
4 - 10
Calibration of the platform overload system is

essential to safe machine operation. Continued use
of an improperly calibrated platform overload
system could result in the system failing to sense
an overloaded platform. The stability of the
machine is compromised and it could tip over.
Note: Perform this procedure with the machine on a
firm, level surface.
1 Turn the key switch to platform control. Start the
engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform capacity
at the center of the platform floor.
S-40 S-45
Part No. 102521
July 2007
REV B
PLATFORM COMPONENTS
5 Move the platform up and down by hand, so it

bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.

Result: The overload indicator lights are off and

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

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

at the platform and ground controls, and the
alarm is sounding. Slowly tighten the load spring
adjustment nut in a clockwise direction in 10
increments until the overload indicator light
turns off, and the alarm does not sound.
Proceed to step 8.

alarm is sounding. Repeat this procedure
Note: The platform will need to be moved up and

down and allowed to settle between each
adjustment.
platform overload indicator light and alarm
responds.
Result: The overload indicator lights are off at
the platform and ground controls, and the alarm
does not sound. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
in 10 increments until the overload indicator
light flashes at both the platform and ground
controls, and the alarm sounds.
Proceed to step 7.
alarm is sounding. Repeat this procedure

responds.
8 Add an additional 10 lb / 4.5 kg test weight to
the platform.
Result: The overload indicator light is flashing at
both the ground and platform controls, and the
alarm is sounding. Proceed to step 9.
Result: The overload indicator light is off at both
the ground and platform controls, and the alarm
does not sound. Remove the additional 10 lb /
4.5 kg test weight. Repeat this procedure
overload indicator lights and alarm turn off.
controls.
Result: All platform control functions should not
operate.
Note: The platform will need to be moved up and

down and allowed to settle between each
adjustment.
responds.
Part No. 102521
S-40 S-45
4 - 11
July 2007
REV B
PLATFORM COMPONENTS

controls.
Result: All ground control functions should not
operate.
12 Using a suitable lifting device, lift the test weight
off the platform floor.
Result: The platform overload indicator light
overload indicator lights and alarm turn off.
controls.
operate normally.
14 Turn the key switch to platform control.
controls.
Result: All platform control functions should
operate normally.
4 - 12
S-40 S-45
Part No. 102521
July 2007
PLATFORM COMPONENTS
Part No. 102521
S-40 S-45
4 - 13
July 2007
Jib Boom Components, S-45
REV A
3-1
Jib Boom
7 Place blocks under the platform leveling cylinder

for support. Protect the cylinder rod from
damage.
How to Remove the Jib Boom
8 Remove the pin retaining fasteners from the jib

boom lift cylinder barrel-end pivot pin. Do not
remove the pin.

stowed position.
installation.
1 Remove the platform.
9 Attach a lifting strap from an overhead crane to

the lug on the rod end of the jib boom lift
cylinder.
10 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin.
cylinder barrel-end pivot pin, then remove the
jib boom cylinder.
2 Remove the platform mounting weldment,

and the platform rotator. See 2-2, How to
Remove the Platform Rotator.
Crushing hazard. The jib boom

lift cylinder could become
unbalanced and fall when it is
removed from the machine if it is
not properly attached to the
overhead crane.
3 From the ground controls, raise the jib boom to

a horizontal position.
4 Support the jib boom with a strap from an
overhead crane.
from the jib boom lift cylinder. Cap the fittings
on the cylinder.

boom pivot pin. Use a soft metal drift to remove
the pin, then remove the jib boom from the
bellcrank.

squirt or spray.
Crushing hazard. The jib boom

could become unbalanced and fall
when it is removed from the
machine if it is not properly
attached to the overhead crane.
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
July 2007
REV A
JIB BOOM COMPONENTS, S-45
4 Use a soft metal drift to tap the jib boom lift

cylinder rod-end pivot pin half way out. Then
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
3-2
Jib Boom Lift Cylinder
How to Remove the Jib Boom
Lift Cylinder
stowed position.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Then
lower the jib boom until the platform is resting
on the blocks just enough to support the
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
5 Support the jib boom lift cylinder with a lifting

device.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pin and
let the cylinder hang down.
and jib boom could become
unbalanced and fall when the jib
boom barrel-end pivot pin is
removed if not properly supported.
the lug on the rod end of the jib boom lift
cylinder.
cylinder rod-end pin. Remove the cylinder from
the machine.

squirt or spray.
Crushing hazard. The jib boom lift

cylinder could become unbalanced
and fall when removed from the
machine if not properly attached to
the overhead crane.

boom lift cylinder rod-end pivot pin. Do not
remove the pin.
Part No. 102521
S-40 S-45
4 - 15
July 2007
Boom Components
4-1
Cable Track
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses
that run through it. Removing the entire primary
boom cable track is only necessary when
performing major repairs that involve removing the
primary boom.
How to Remove the Cable Track

REV A

from the counterbalance valve manifold located
on the platform rotator. Cap the fittings on the
manifold.
squirt or spray.
from the platform leveling cylinder at the union
and connect the hoses from the cylinder
together using a connector.
squirt or spray.
1 Raise the primary boom to a horizontal position.

2 Locate the cables from the cable track to the
platform control box. Number each cable and
its entry location at the platform control box.
3 Disconnect the cables from the platform control
box.
8 Locate all electrical cables that enter the cable

track.
4 Remove the electrical outlet box bracket

mounting fasteners. Remove the outlet box and
lay it to the side.
9 Tag and disconnect the electrical connectors for

all cables that enter the cable track.
5 Remove the hose and cable clamp from the

platform support.
10 Remove the retaining fasteners from the

electrical connector receptacles for the cables
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
July 2007
REV A
BOOM COMPONENTS
12 Remove the fasteners from the side panel on

the lower cable track, then remove the panel.
Pull all of the cables out of the channel.
How to Repair the Cable Track

The boom cable track can be
damaged if it is twisted.
13 Remove the cable cover on the side of the

boom.
14 Place blocks in between the upper and lower
cable tracks and secure the upper and lower
tracks together.
Crushing hazard. If the upper and
lower cable tracks are not properly
secured together, the cable track
when it is removed from the
machine.
the cable track.
16 Remove the mounting fasteners from the upper
cable track at the platform end of the extension
boom.
Note: A cable track repair kit is available through

the Genie Industries Service Parts Department,
part no. 81007. The kit includes a 4 link section of
cable track.
1 Visually inspect the cable track and determine
which 4 link section needs to be replaced.
2 Remove the snap-on cable track spacers.
3 Carefully remove the external snap rings from
the pivot pins at each end of the 4-link section
to be removed.
4 Lift up the hoses and cables and carefully
remove the damaged 4 link section of cable
track.
and cables can be damaged if they
are kinked or pinched.
17 Remove the cable track mounting fasteners that

attach the lower cable track to the boom.
18 Remove the cable track from the machine and
place it on a structure capable of supporting it.
Crushing hazard. The cable track
if it is not properly attached to the
overhead crane.
Hoses and cables can be
damaged if they are kinked or
pinched.
5 Remove the snap-on spacers from the

replacement section of the cable track.
6 Lift up the hoses and cables and carefully insert
the new 4 link section of cable track.
Hoses and cables can be
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
July 2007
BOOM COMPONENTS
REV A
1 Remove the platform. See 2-1, How to Remove

the Platform.
4-2
Boom
2 Remove the platform rotator and leveling slave

cylinder. See 2-3, How to Remove the Platform
Rotator.
How to Remove the Boom

Consult the Genie Industries Service Department
for instructions on how to safely remove the boom
assembly from the machine. Failure to read and
follow the warnings listed below could result in
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
3 S-45 Models: Remove the jib boom. See 3-1,

How to Remove the Jib Boom.
4 Remove the mounting fasteners from the jib
boom/platform rotate valve manifold on the end
of the boom. Remove the manifold and set it
aside.
5 Remove the fasteners from the limit switch
mounted on the side of the cable track. Do not
disconnect the wiring.
6 Support the cable track with an overhead crane.
7 Remove the hose/cable clamp from the pivot
end of the boom.

stowed position.
8 Remove the hose/cable clamp at the platform

end of the cable track.

installation.
9 Remove the fasteners from the large cable track

guide at the platform end of the cable track.
Remove the guide.
10 Remove the cotter pin from the clevis pin at the
platform end of the cable track. Remove the
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
July 2007
REV A
12 Remove the cable track mounting fasteners,

then remove the cable track from the boom and
lay it off to the side.
The boom cable track can be
damaged if it is twisted.
18 Attach a similar lifting device to the boom lift

cylinder.
19 Use the overhead crane to lift the boom to a
horizontal position.
20 Place support blocks under the boom lift
cylinder, across the turntable.

Hoses can be damaged if they are
kinked or pinched.
21 Remove the pin retaining fastener from the

boom lift cylinder rod-end pin. Use a soft metal
drift to remove the pin.
13 Remove the turntable end cover.

14 Remove the retaining fastener from the master
cylinder rod-end pivot pin. Use a soft metal drift
to remove the pin. Pull the cylinder back and
secure it from moving.
When pulling the master cylinder
back, be sure not to damage the
master cylinder hoses or fittings.
15 Remove the fasteners from the limit switch
mounted to the turntable riser at the pivot end of
the boom. Do not disconnect the wiring.
Crushing hazard. The boom lift

cylinder will fall if not properly
supported.
22 Lower the rod end of the lift cylinder onto
support blocks. Protect the cylinder rod from
damage.
boom pivot pin.
24 Use a soft metal drift to remove the boom pivot
pin, then carefully remove the boom from the
machine.
16 Tag, disconnect and plug the extension cylinder

hydraulic hoses. Cap the fittings on the cylinder.
squirt or spray.
Crushing hazard. The primary

boom could become unbalanced
machine if not properly attached to
the overhead crane.
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
July 2007
REV A
How to Disassemble the Boom

Note: Complete disassembly of the boom is only
necessary if the secondary boom tube must be
replaced. The extension cylinder can be removed
without completely disassembling the boom. See 44, How to Remove the Extension Cylinder.
1 Remove the boom. See 4-2, How to Remove the
Boom.
2 Place blocks under the extension cylinder for
support.
3 Remove the external snap rings from the
extension cylinder barrel-end pivot pin at the
pivot end of the primary boom tube. Use a soft
metal drift to remove the pin.
8 Remove the trunnion pin retaining fasteners at

the base end of the secondary boom tube. Use
a slide hammer to remove the trunnion pins.
9 Carefully rotate the base end of the extension
cylinder until the pin mounting bore is in a
vertical position.
extension cylinder rod-end pivot pin at the
platform end of the secondary boom tube. Use a
soft metal drift to remove the pin.
11 Support and slide the extension cylinder out of
the base end of the secondary boom tube.
Place the extension cylinder on blocks for
suppport.
Crushing hazard. The extension
cylinder may become unbalanced
secondary boom tube if not
properly supported.
4 Remove and label the wear pads from the top

side of the primary boom tube at the platform
end of the boom.
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.

the secondary boom tube at the platform end of
the boom for support.
6 Support and slide the secondary boom tube out
of the primary boom tube. Place the secondary
boom tube on blocks for support.
12 Remove the label the wear pads from the

extension cylinder.
Note: Pay careful attention to the location of each
wear pad.
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
July 2007
REV A
BOOM COMPONENTS
5 Tag, disconnect and plug the boom lift cylinder

hydraulic hoses. Cap the fittings on the cylinder.
4-3
Boom Lift Cylinder

squirt or spray.
The boom lift cylinder raises and lowers the boom.

The boom lift cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.
How to Remove the Boom

Lift Cylinder
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or

boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin. Lower the lift
cylinder onto the blocks. Protect the cylinder
rod from damage.
Crushing hazard. The lift cylinder
if it is not properly supported.
7 Remove the four mounting fasteners from the
lift cylinder barrel-end pivot pin mounting plate.
8 With the lift cylinder being supported by the
overhead crane, pull the cylinder toward the
platform to remove it from the machine.
Crushing hazard. The lift cylinder
if it is not properly supported.
1 Raise the boom to a horizontal position.

2 Place support blocks across the turntable under
the boom lift cylinder.
3 Attach a 5 ton / 5000 kg overhead crane to the
boom at the platform end for support. Do not lift
the boom.
4 Support and secure both ends of the boom lift
cylinder to a second overhead crane or similar
lifting device.
Part No. 102521

cables and hydraulic hoses can be
damaged if the lift cylinder is
pulled across them.
9 Using auxiliary power, activate the boom down
function so the cylinder will retract. Retract the
cylinder just enough until the rod end of the
cylinder will clear the mounting bracket on the
boom. Turn the machine off.
S-40 S-45
4 - 21
July 2007
BOOM COMPONENTS
REV A
4-4
Extension Cylinder

extension cylinder rod-end pins (at the platform
end). Use a soft metal drift to remove the pins.
The extension cylinder extends and retracts the

boom extension tube. The extension cylinder is
equipped with counterbalance valves to prevent
movement in the event of a hydraulic line failure.
5 Remove the turntable end cover.

6 Tag, disconnect and plug the extension cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
How to Remove the

Extension Cylinder
This procedure requires specific
repair skills, lifting equipment and
a suitable workshop. Attempting
this procedure without these skills
and tools could cause death or

squirt or spray.
7 Remove the barrel-end pivot pin retaining
fasteners.
8 Place a rod through the barrel-end pivot pin and
twist to remove the pin.
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.
3 Raise the boom to a horizontal position.
9 Support and slide the extension cylinder out of

the pivot end of the boom.
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
July 2007
REV A
BOOM COMPONENTS
4-5
Platform Leveling
Master Cylinder

the lug on the rod end of the master cylinder.
The master cylinder acts as a pump for the slave

cylinder. It is part of the closed circuit hydraulic
loop that keeps the platform level through the
entire range of boom motion. The master cylinder
is located at the base of the boom.
6 Place a rod through the barrel-end pivot pin and

twist to remove the pin.
5 Remove the pin retaining fasteners from the

master cylinder barrel-end pivot pin.
How to Remove the Platform

Leveling Master Cylinder
1 Remove the turntable end cover to access the
master cylinder.
7 Remove the pin retaining fastener from the rodend pivot pin.
8 Use a soft metal drift to remove the pin.
9 Remove the master cylinder from the machine.
2 Raise the boom until the master cylinder

rod-end pivot pin is accessible.
3 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
Crushing hazard. The master

and fall if it is not properly attached
to the overhead crane.

squirt or spray.
Part No. 102521
S-40 S-45
4 - 23
September 2007
Engines
REV D
5-1
RPM Adjustment - Deutz Models
5-3
Flex Plate
Refer to Maintenance Procedure B-11, Check and

Adjust the Engine RPM.
The flex plate acts as a coupler between the engine

and the pump. It is bolted to the engine flywheel
and has a splined center to drive the pump.
a
5-2
RPM Adjustment - Perkins
Models
Refer to Maintenance Procedure B-11, Check and
Adjust the Engine RPM.
f
a
b
c
d
e
f
pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
0.18 inch / 4.6 mm gap - Deutz Models
0.070 inch / 1.8 mm gap - Perkins Models
0.0625 inch / 1.6 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423
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.
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
September 2007
ENGINES
REV D
Ford LRG-425 EFI models:
1 Disconnect the electrical connector for the

oxygen sensor at the tailpipe. Do not remove
the oxygen sensor.

from moving.
or pinched.
2 Remove the engine oil dipstick fasteners from

the muffler bracket. Remove the dipstick from
the engine.
3 Remove the muffler retaining fasteners from the
exhaust pipe.

4 Support the muffler and bracket assembly with

an overhead crane or other suitable lifting
device.
Ford DSG-423 EFI models:
5 Remove the muffler bracket mounting fasteners.

Carefully remove the muffler and bracket
assembly from the engine.
6 Support the engine with a suitable lifting device.
Do not lift it.
7 Remove the engine plate to vibration isolator
fasteners.
9 Raise the engine slightly to take the weight off

of the engine mounting plate.

2 Remove the exhaust pipe fasteners at the

muffler.
3 Support the muffler and bracket assembly with a
suitable lifting device.
4 Remove the muffler bracket mounting fasteners
from the bell housing. Carefully remove the
muffler and bracket assembly from the engine.
8 Remove the engine mounting plate to bell

housing fasteners.
10 Slide the engine mounting plate towards the

pump as far as it will go.
1 Disconnect the electrical connectors from both

oxygen sensors at the tailpipe and exhaust
manifold. Do not remove the oxygen sensors.
5 Support the engine with an overhead crane or

other suitable lifting device. Do not lift it.
6 Remove the engine mounting plate to bell
housing fasteners.
7 Raise the engine slightly using the overhead
crane and place a block of wood under the oil
pan for support.
overhead crane or other suitable lifting device.
Do not apply any lifting pressure.
Part No. 102521
S-40 S-45
4 - 25
September 2007
ENGINES
REV D
9 Remove all of the engine bell housing retaining

fasteners.
from moving.
or pinched.
Perkins models:
1 Remove the fuel filter/water separator mounting
fasteners.
2 Remove the fuel filter/water separator and lay it
to the side. Do not disconnect the hoses.
After serial number 13739: Torque the flex

plate mounting bolts in sequence to
20 ft-lbs / 27 Nm.
Deutz models:
Torque the flex plate mounting bolts in
sequence to
28 ft-lbs / 38 Nm.
Perkins models:
Before serial number 7472: Torque the flex
28 ft-lbs / 38 Nm.
From serial number 7472 to 13773: Torque the
flex plate mounting bolts in sequence to
49 ft-lbs / 66 Nm.
After serial number 13773: Torque the flex
14 ft-lbs / 19.1 Nm.
3 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
appropriate gap between coupler and pump end
plate for your engine.

from moving.

or pinched.
f
a
b
c
d
e
f
How to Install the Flex Plate

1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
2 Apply Loctite removable thread sealant to the
screws. Torque the flex plate in a star pattern
using the following values.
Ford models:
Before serial number 13740: Torque the flex
24 ft-lbs / 32 Nm.
4 - 26
pump
pump shaft
pump coupler
flex plate with raised spline
engine flywheel
0.18 inch / 4.6 mm gap - Deutz Models
0.070 inch / 1.8 mm gap - Perkins Models
0.0625 inch / 1.6 mm gap - Ford LRG-425
0.080 inch / 2 mm gap - Ford DSG-423
4 Apply Loctite removable thread sealant to the

pump coupler set screw. Torque the set screw
to 61 ft-lbs / 83 Nm.
5 Install the pump and bell housing assembly.
S-40 S-45
Part No. 102521
September 2007
ENGINES
REV D
Ford LRG-425 models:

Before serial number 7597: Torque the bell
housing mounting bolts in sequence to
23 ft-lbs / 31 Nm.
After serial number 7596: Torque the bell
housing mounting bolts labeled "C" in sequence
to 47 ft-lbs / 63 Nm. Torque the bell housing
mounting bolts labeled "B" in sequence to
61 ft-lbs / 83 Nm.
Ford LRG 425 models

6
1
A
10
Ford LRG 425 models

Ford DSG-423 models:

Torque the bell housing mounting bolts labeled
"A" and "B" in sequence to 28 ft-lbs / 38 Nm
and the mounting bolts labeled "C" to 49 ft-lbs /
66 Nm. Then torque the bell housing mounting
bolts labeled "A" and "B" in sequence to 40 ftlbs / 54 Nm and the mounting bolts labeled "C"
to 70 ft-lbs / 95 Nm.
Deutz models:
28 ft-lbs / 38 Nm.
47 ft-lbs / 63 Nm.
Perkins models
10
10
1
C
11
12 11
5
2
Component damage hazard. When

installing the pump, do not force
the pump coupler into the flexplate
or damage to the pump shaft seal
may occur.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
12
C
C
Deutz 1011 models

8
C
Perkins models
Perkins models:
28 ft-lbs / 38 Nm.
housing mounting bolts labeled "B" in sequence
to 28 ft-lbs / 38 Nm and the mounting bolts
labeled "A" to 49 ft-lbs / 66 Nm. Then torque the
bell housing mounting bolts labeled "B" in
sequence to 40 ft-lbs / 54 Nm and the mounting
bolts labeled "A" to 70 ft-lbs / 95 Nm.
12
11
5
9
Deutz 2011 models

6
Ford DSG 423 models
Part No. 102521
S-40 S-45
4 - 27
September 2007
ENGINES
REV D
5 Continue to hold the run/test toggle switch in the

test position and count the blinks.
5-4
Engine Fault Codes Ford Models
How to Retrieve Engine Fault
Codes
When an engine malfunction is detected by the
Electronic Control Module (ECM), a fault code is
recorded and the check engine light will turn on at
the ground controls. Special equipment is required
to retrieve fault codes stored within the ECM.
Contact Genie Industries Service Department for
assistance in retrieving fault codes.
Note: Perform this procedure with the key switch in
the off position.
1 Open the ground controls side cover and locate
the run/test toggle switch on the side of the
ground control box.
controls.
Note: If any fault codes are present, the ECM will

use the check engine light to blink a three digit
code.
It will blink the first digit of a three digit code,
pause, blink the second digit, pause, and then blink
the third digit. For example: the check engine light
blinks 5 consecutive times, blinks 3 times and then
1 time. That would indicate code 531. There will be
a longer pause between codes.
6 Refer to Section 5, Fault Codes, for definition of
engine fault codes.
Note: Once a fault code has been retrieved and the
repair has been completed, the ECM memory must
be reset to clear the fault code from the ECM. See
How to Clear Engine Fault Codes from the ECM.
How to Clear Engine Fault

Codes from the ECM
Note: Perform this procedure with the engine off
and the key switch in the off position.
1 Open the engine side turntable cover and locate
the battery.
3 Quickly activate and release the start toggle

switch/button. Do not start the engine.
(before serial no. 7597)
4 Move and hold the run/test toggle switch to the
test position.
2 Disconnect the negative battery cable from the

battery for a minimum of 5 minutes.
and other jewelry.
Result: The check engine light should turn on.

The check engine light should begin to blink.
3 Connect the negative battery cable to the

battery.
4 - 28
S-40 S-45
Part No. 102521
July 2007
Hydraulic Pumps
REV A
Models without hydraulic tank shut-off

valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a suitable container. See capacity
specifications.
6-1
Function Pump
How to Remove the
Function Pump
installation.
2 Tag, disconnect and plug the function pump

hydraulic hoses. Cap the fittings on the pump.
squirt or spray.
3 Remove the pump mounting bolts. Carefully
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

engine must not be started with the
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

sure to fill the hydraulic tank to
specification and prime the pump
after installing the pump.
4 - 29
July 2007
HYDRAULIC PUMPS
REV A
6-2
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electro-proportional controller,
located on the pump. The only adjustment that can
be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should only be performed at an authorized Eaton
Hydraulics center. Call Genie Industries Service
Department to locate your local authorized service
center.

open

engine must not be started with the
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.
How to Remove the Drive Pump

work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
installation.
1 Disconnect the electrical connection at the
electro-proportional controller located on the
drive pump.
4 - 30
closed
Models without hydraulic tank shut-off

valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a suitable container. See capacity
specifications.
3 Tag and disconnect and plug the hydraulic
hoses from the drive and function pumps.
Cap the fittings on the pumps.
squirt or spray.
S-40 S-45
Part No. 102521
July 2007
REV A
HYDRAULIC PUMPS
4 Support the pump with a lifting device and

remove the two drive pump mounting fasteners.
5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
6 Remove the drive pump from the machine.
hydraulic pump may become
unbalanced and fall if not properly
supported.
4 Ford models: Close the valve on the LPG tank

then disconnect the hose from the tank. Move
the fuel select switch to the LPG position.
Perkins models: Disconnect the engine wiring
harness from the fuel solenoid at the injector
pump.
Deutz models: Hold the manual fuel shutoff
valve clockwise to the closed position.
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
5 Have another person crank the engine with the

starter motor for 15 seconds, wait 15 seconds,
then crank the engine an additional 15 seconds
or until the pressure reaches 320 psi / 22 bar.
How to Prime the Pump

1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the test port on the drive pump.
2 Remove the safety pin (if equipped) from the
engine pivot plate latch.
Note: The engine pivot plate latch is located under
the engine turntable pivot plate at the counterweight
end of the machine.
3 Open the engine pivot plate latch and swing the
engine pivot plate out and away from the
machine.
Part No. 102521
manual fuel shutoff valve
6 Ford models: Connect the LPG hose to the

LPG tank and open the valve on the tank. Move
the fuel select switch to the gasoline position.
Perkins models: Connect the engine wiring
harness to the fuel solenoid.
Deutz models: Release the manual fuel shutoff
valve.
check for hydraulic leaks.
S-40 S-45
4 - 31
October 2007
Manifolds
REV C
7-1
Function Manifold Components
The function manifold is located underneath the ground controls side turntable cover.
Index
No.
Description
Schematic
Item
Function
Torque
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
Check valve ....................................... AB ......... Differential sensing circuit,

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

platform level up ............................... 10-12 ft-lbs / 14-16 Nm
Solenoid valve, 2 position 3 way ....... AE ......... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm
Check valve ....................................... AF ......... Differential sensing circuit,

boom up/down .................................. 10-12 ft-lbs / 14-16 Nm
Differential sensing valve,
150 psi / 10.3 bar ............................... AG ........ Turntable rotate circuit ...................... 30-35 ft-lbs / 41-47 Nm
7
8

150 psi / 10.3 bar ............................... AH ........ Boom up/down circuit ....................... 30-35 ft-lbs / 41-47 Nm
Relief valve, 2200 psi / 152 bar ........ AI .......... Boom down relief .............................. 20-25 ft-lbs / 27-34 Nm
10

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
14
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
October 2007
MANIFOLDS
REV C
AA AB AC AD AE AF AG AH
9
AI
10
11
AJ AK
12
13
14
AM
AL
AN
AO 15
AP 16
17
AQ 18
AR 19
AS 20
AT 21
AU 22
AV 23
AW 24
AX 25
BI
36
BH
35
Part No. 102521
BG
34
BF
33
BE BD BC BB
32
31
30
29
AY
26
AZ
27
BA
28
S-40 S-45
4 - 33
October 2007
MANIFOLDS
REV C
Function Manifold Components, continued

Index
No.
Description
Schematic
Item
Function
Torque
18
Relief valve,
2900 psi / 200 bar ............................. AQ ........ System relief (S-45) .......................... 30-35 ft-lbs / 41-47 Nm
18
Relief valve,
2600 psi / 179 bar ............................. AQ ........ System relief (S-40) .......................... 30-35 ft-lbs / 41-47 Nm
19

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
34

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
October 2007
MANIFOLDS
REV C
AA AB AC AD AE AF AG AH
9
AI
10
11
AJ AK
12
13
14
AM
AL
AN
AO 15
AP 16
17
AQ 18
AR 19
AS 20
AT 21
AU 22
AV 23
AW 24
AX 25
BI
36
BH
35
Part No. 102521
BG
34
BF
33
BE BD BC BB
32
31
30
29
AY
26
AZ
27
BA
28
S-40 S-45
4 - 35
October 2007
MANIFOLDS
REV C
7-2
Valve Adjustments Function Manifold
How to Adjust the System
Relief Valve
stowed position.
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
October 2007
MANIFOLDS
REV C
7-3
Jib Select, Platform Rotate and Generator Manifold Components
Index
No.
Description
Counterbalance valve ........................ CA ........ Platform rotate right .......................... 30-35 ft-lbs / 41-47 Nm
Counterbalance valve ........................ CB ........ Platform rotate left ............................. 30-35 ft-lbs / 41-47 Nm
Relief valve ........................................ CD ........ Generator overload relief .................. 30-35 ft-lbs / 41-47 Nm
Solenoid valve ................................... CE ........ Controls generator on / off ................ 50-55 ft-lbs / 68-75 Nm
Solenoid valve, 2 position 3 way ....... CC ........ Platform rotate/jib boom select ......... 18-20 ft-lbs / 25-27 Nm
Schematic
Item
Function
Torque
CC
Jib Select Manifold

CA
CE
Platform Rotate Manifold

Generator Manifold
CB
CD
3
Part No. 102521
S-40 S-45
4 - 37
October 2007
MANIFOLDS
REV C
7-4
Brake Manifold Components (before serial number 7569)
Index
No.
Description
Solenoid valve, 2 position 3 way ... DA ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
Orifice, 0.025 inch / 0.635 mm ....... DB ........... Turntable rotation brake release
Schematic
Item
Function
Torque
DA
DB
4 - 38
S-40 S-45
Part No. 102521
October 2007
MANIFOLDS
REV C
7-5
Brake/Two-Speed Manifold Components (after serial number 7568)
Index
No.
Description
Orifice, 0.025 inch / 0.63 mm ......... EA ........... Turntable rotation brake release
Schematic
Item
Function
Torque
Solenoid valve, 2 position 3 way ... EB ........... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
Solenoid valve, 2 position 3 way ... EC ........... Two-speed motor shift ..................... 20-25 ft-lbs / 27-34 Nm
Check valve .................................... ED ........... Brake release circuit ......................... 20-25 ft-lbs / 27-34 Nm
1
EA
2
EB
EC
ED
Part No. 102521
S-40 S-45
4 - 39
October 2007
MANIFOLDS
REV C
7-6
Oscillate Directional Valve Components
The oscillate directional valve is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
Function
Torque
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
October 2007
MANIFOLDS
REV C
7 Push up or pull down on the threaded rod until

the machine is completely level.
How to Set Up the Oscillate

Directional Valve
Note: Adjustment of the oscillate directional valve
linkage is only necessary when the linkage or valve
has been replaced.
8 Verify that the ground and drive chassis are

completely level.
1 Lower the boom to the stowed position.
9 Tighten the nuts on both sides of the urethane

cushions until they are snug. Tighten the
locknuts.
2 Use a "bubble type" level to be sure the floor is

completely level.
10 Verify that the ground and drive chassis are

completely level.
Tip-over hazard. Failure to

perform this procedure on a level
floor could compromise the
stability of the machine resulting in
the machine tipping over.
3 Check the tire pressure in all four tires and add
air if needed to meet specification.
Note: The tires on some machines are foam-filled
and do not need air added to them.
11 Measure the distance between the drive

chassis and the non-steer axle on both sides
(from the inside of the drive chassis).
Note: If the distance is not equal and the
adjustment to the linkage was completed with the
ground and drive chassis level, repeat steps 6
through 11 OR consult Genie Industries Service
Department.
4 Remove the drive chassis cover and the nonsteer axle covers.
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
6 To level the drive chassis, start the engine and
loosen the lock nuts on both sides of the
urethane cushions.
Part No. 102521
S-40 S-45
4 - 41
October 2007
MANIFOLDS
REV C
8 Adjust the internal screw. Turn it clockwise to

increase the pressure or counterclockwise to
decrease the pressure. Install the valve cap.
7-7
Valve Adjustments - Oscillate
Relief Valve
Tip-over hazard. Do not adjust the

relief valve higher than specified.
How to Adjust the Oscillate Relief

Valve Pressure
9 Repeat steps 4 through 7 and manually activate

the valve to confirm the valve pressure.
1 Remove the drive chassis cover from the nonsteer end of the machine.
10 Turn the engine off, remove the pressure gauge

and assemble the directional valve linkage.

gauge to the diagnostic nipple located near the
oscillate directional valve.
11 Install the cover on the non-steer end of the

drive chassis.
3 Disconnect the directional valve linkage, by

removing the heim joint and retaining fastener
from the axle.
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
October 2007
MANIFOLDS
REV C
7-8
Traction Manifold Components, 2WD (before serial number 7569)
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index
No.
Description
Schematic
Item
Relief valve, 210 psi / 14.5 bar ......... FA ......... Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
Flow divider/combiner valve ............. FB ......... Controls flow to drive motors

in forward and reverse ................ 90-100 ft-lbs / 122-136 Nm
Orifice, 0.070 inch / 1.78 mm ............ FC ......... Equalizes flow across flow
divider/combiner valve (item FB)
Shuttle valve, 3 position 3 way .......... FD ......... Charge pressure, hot oil shuttle ........ 50-55 ft-lbs / 68-75 Nm
Diagnostic nipple ............................... FE ......... Testing
1
FA
Function
Torque
2
FB
FC
2WD
FD
FE
Part No. 102521
S-40 S-45
4 - 43
October 2007
MANIFOLDS
REV C
7-9
Traction Manifold Components, 2WD (after serial number 7568)
Index
No.
Description
Schematic
Item
Relief valve, 280 psi / 19.3 bar ......... GA ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
Flow divider/combiner valve ............. GB ........ Controls flow to drive motors

in forward and reverse ................ 90-100 ft-lbs / 122-136 Nm
Check valve ....................................... GC ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
Check valve ....................................... GD ........ Drive circuit ....................................... 30-35 ft-lbs / 41-47 Nm
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)
Function
Torque
1
GA
GB
GC
4 - 44
S-40 S-45
GD
GE
GF
Part No. 102521
October 2007
MANIFOLDS
REV C

drive the machine slowly in the forward
direction. Note the pressure reading on the
pressure gauge.
7-10
Valve Adjustments, 2WD
Drive Manifold
How to Adjust the Hot Oil Shuttle
Relief Valve
Note: The pressure differential between the charge
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the drive
manifold) is necessary to return hot oil from the
closed loop drive circuit to the hydraulic tank for
cooling. This pressure differential must be
maintained at 40 psi / 14.5 bar.
Note: The following procedure will require two
people.
5 Turn the engine off, and remove the hot oil

shuttle relief valve cap (item FA). Adjust the
internal hex socket clockwise to increase the
pressure or counterclockwise to decrease the
pressure. Install the valve cap.
shuttle relief valve cap (item GA). Adjust the
(after serial no. 7568)
6 Repeat steps 4 and 5 until the pressure reading
on the guage is 40 psi / 2.8 bar less than the
pressure reading at the pump.

connect a 0 to 600 psi / 0 to 41 bar pressure
gauge to the diagnostic nipple on the drive
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
October 2007
MANIFOLDS
REV C
7-11
Traction Manifold Components, 4WD (before serial number 7569)
Index
No.
Description
Schematic
Item
Function
Torque
Flow divider/combiner valve ............. HA ........ Controls flow to steer

end drive motors in
forward/reverse ........................... 90-100 ft-lbs / 122-136 Nm
Flow divider/combiner valve .............. HB ........ Controls flow to non-steer

end drive motors in
forward/reverse ........................... 90-100 ft-lbs / 122-136 Nm
Orifice, 0.070 inch / 1.778 mm .......... HC ........ Rear drive motor circuit
Orifice, 0.070 inch / 1.778 mm .......... HD ........ Equalizes pressure on both sides
of flow divider/combiner valve 7
Shuttle valve, 3 position 3 way .......... HE ........ Charge pressure, hot oil shuttle ........ 50-55 ft-lbs / 68-75 Nm
Diagnostic nipple ............................... HF ......... Testing
Flow divider/combiner valve .............. HG ........ Controls flow to flow

divider/combiner valves
1 and 2 ........................................ 90-100 ft-lbs / 122-136 Nm
Relief valve, 210 psi / 14.5 bar .......... HH ........ Charge pressure circuit ..................... 30-35 ft-lbs / 41-47 Nm
Orifice, 0.052 inch / 1.32 mm ............ HI .......... Front drive motor circuit
4 - 46
S-40 S-45
Part No. 102521
October 2007
MANIFOLDS
REV C
HI
HA
HB
1
2
HH
HG
HC
HD
HE
HF
6
Part No. 102521
S-40 S-45
4 - 47
October 2007
MANIFOLDS
REV C
7-12
Traction Manifold Components, 4WD (after serial number 7568)
Index
No.
Description
Relief valve, 280 psi / 19.3 bar ......... JA ......... Charge pressure circuit .................... 35-40 ft-lbs / 48-54 Nm
Flow divider/combiner valve .............. JB ......... Controls flow to non-steer end

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

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

Orifice, 0.040 inch / 1 mm ................. JH ......... Equalizes pressure on both sides

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

drive motors in forward
and reverse ................................... 80-90 ft-lbs / 108-122 Nm
14
Check valve ....................................... JN ......... Non-steer end drive motor circuit ...... 35-40 ft-lbs / 48-54 Nm
4 - 48
Schematic
Item
Function
S-40 S-45
Torque
Part No. 102521
October 2007
MANIFOLDS
REV C
14
13
12
11
10
JA
JB
JC
JD
JE
JF
JN
JM
JL
JK
JJ
Part No. 102521
JG
JH
JI
S-40 S-45
4 - 49
October 2007
MANIFOLDS
REV C

drive the machine slowly in the forward
direction. Note the pressure reading on the
pressure gauge.
7-13
Valve Adjustments, 4WD
Drive Manifold
How to Adjust the Hot Oil Shuttle
Relief Valve
Note: The pressure differential between the charge
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the drive
manifold) is necessary to return hot oil from the
closed loop drive circuit to the hydraulic tank for
cooling. This pressure differential must be
maintained at 40 psi / 14.5 bar.
Note: The following procedure will require two
people.

shuttle relief valve cap (item HH). Adjust the
shuttle relief valve cap (item JA). Adjust the
(after serial no. 7568)
6 Repeat steps 4 and 5 until the pressure reading
on the guage is 40 psi / 2.8 bar less than the
pressure reading at the pump.

connect a 0 to 600 psi / 0 to 41 bar pressure
gauge to the diagnostic nipple on the drive
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.
4 - 50
S-40 S-45
Part No. 102521
October 2007
MANIFOLDS
REV C
7-14
Valve Coils
Valve Coil Resistance

Specification
How to Test a Coil

A properly functioning coil provides an
electromagnetic force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil. Zero resistance or infinite
resistance indicates the coil has failed.
Note: The following coil resistance specifications

are at an ambient temperature of 68F / 20C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18F / 20C
that your air temperature increases or decreases
from 68F / 20C.
Since coil resistance is sensitive to temperature,

resistance values outside specification can produce
erratic operation. When coil resistance decreases
below specification, amperage increases. As
resistance rises above specification, voltage
increases.
Description
While valves may operate when coil resistance is

outside specification, maintaining coils within
specification will help ensure proper valve function
over a wide range of operating temperatures.
and other jewelry.
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to be
tested.
Specification

(schematic items AC and AE)
6.3

(schematic item AT and AZ)
6.3

(schematic items AU, AV, AX, and AY)
6.3

(schematic items AZ and BF)
6.3
Proportional solenoid valve, 12V DC

(schematic items AW and BB)

(schematic item CC)
6.8

(schematic items DA)
3.3

(schematic items CE)
4.8
2 Test the coil resistance using a multimeter set

to resistance (). 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 - 51
October 2007
MANIFOLDS
REV C
How to Test a Coil Diode
a
d
10 W
RESISTOR
27287
Note: The battery should read 9V DC or more when

measured across the terminals.
3 Set a multimeter to read DC current.
Note: The multimeter, when set to read DC current,
should be capable of reading up to 800 mA.
9V
BATTERY
a
b
c
d
multimeter
9V DC battery
10 resistor
coil
Note: Dotted lines in illustration indicate a

reversed connection as specified in
step 6
1 Test the coil for resistance. See, How to Test a

Coil.
Resistor, 10
Genie part number

and other jewelry.
2 Connect a 10 resistor to the negative terminal

of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.
AMMETER
COIL
Genie incorporates spike suppressing diodes in all

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. Voltage spikes
naturally occur within a function circuit following the
interruption of electrical current to a coil. Faulty
diodes can fail to protect the electrical system,
resulting in a tripped circuit breaker or component
damage.
4 Connect the negative lead to the other terminal

on the coil.
Note: If testing a single-terminal coil, connect the
negative lead to the internal metallic ring at either
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.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
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 - 52
S-40 S-45
Part No. 102521
October 2007
MANIFOLDS
REV C
7-15
Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index
No.
Description
Directional Valve ............................ CY ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm
Orifice disc ...................................... CW .......... Delays shift to drive ......................... 35-40 ft-lbs / 47-54 Nm
Solenoid valve ............................... CV ........... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
Relief valve .................................... CX ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm
Check valve .................................... CU ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm
Schematic
Item
Function
Torque
CU
CY
CW
CV
CX
Part No. 102521
S-40 S-45
4 - 53
July 2007
Turntable Rotation Components
REV A

from the motor, brake and manifold. Cap the
fittings on the motor, brake and manifold.
8-1
Turntable Rotation Assembly

gradually. Do not
allow oil to squirt or spray.
How to Remove the Turntable

Rotation Assembly
installation.
3 Attach a suitable lifting device to the turntable

rotator assembly.

firm and level surface.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
d
Unlocked position
a
b
c
d
e
f
brake assembly
drive hub
backlash plate mounting bolts
backlash plate
manifold
motor
Locked position
4 - 54
S-40 S-45
Part No. 102521
July 2007
REV A
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 - 55
July 2007
Axle Components
REV A
2 Remove the fasteners from drive chassis cover

at the steer end. Remove the cover.
9-1
Oscillate Cylinders
The oscillating axle cylinders extend and retract
between the drive chassis and the axle to maintain
a level chassis while driving over uneven terrain.
The cylinders are equipped with counterbalance
valves to prevent movement in the event of a
hydraulic hose failure.
3 Tag, disconnect and plug the oscillating axle

cylinder hydraulic hoses. Cap the fittings on the
oscillate cylinder.
or spray.
How to Remove an Oscillating

Axle Cylinder
skills and a suitable workshop.
Attempting this procedure without
these skills and tools could result
in death or serious injury and
significant component damage.
Dealer service is strongly
recommended.

rod-end pivot pin. Use a soft metal drift to
remove the pin.
the barrel end of the oscillating cylinder.
barrel-end pivot pin. Use a soft metal drift to
remove the pin.
7 Remove the cylinder from the machine.
Note: Perform this procedure on a firm, level

surface with the boom in
the stowed position.
installation.
Refer to Section Two, Hydraulic Hose and Fitting
Crushing hazard. The oscillate

and fall when it is removed from
the machine if it is not properly
attached to the overhead crane.
1 Rotate the turntable until the boom is between

the steer tires.
4 - 56
S-40 S-45
Part No. 102521
July 2007
Generators
REV A
5 Connect the positive and negative leads from a

multimeter of sufficient capacity to the electrical
outlet at the generator.
10-1
Valve Adjustments Hydraulic Generator
Result: The reading on the multimeter should be

112 to 118V AC.
How to Adjust the Generator

Voltage
Result: If the reading on the multimeter is not

112 to 118V AC, proceed to step 6.

or spray.
6 Turn the key switch to the off position.

7 Use a wrench to hold the generator flow
regulator valve (item AM) and remove the cap.

and other jewelry.
Note: Be sure that the hydraulic oil level is within

the top 2 inches / 5 cm of the sight gauge.
firm, level surface.
1 Disconnect all electrical tools from the machine.
flow regulator
8 Adjust the internal hex socket. Turn it clockwise

to increase the AC voltage or counterclockwise
to decrease the AC voltage. Install the flow
regulator valve cap.
Failure to adjust the generator as
instructed may result in damage to
the generator or other electrical
equipment. Do not adjust the
generator to other than specified.

3 Press the generator select switch.
4 Connect an electrical tool, which does not draw
more than 15A, to the electrical outlet at the
platform controls and run the tool at full speed.
9 Repeat steps 2 through 5 to confirm the

generator AC voltage.
Part No. 102521
S-40 S-45
4 - 57
July 2007
GENERATORS
4 - 58
S-40 S-45
Part No. 102521
July 2007
Section 5 Fault Codes
Fault Codes
REV A
Before Troubleshooting:
operating instructions printed in the
Genie S-40 and S-45 Operators Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:

Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Read each appropiate fault code thoroughly.

Attempting shortcuts may produce hazardous
conditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.

repair procedure with the machine in the

and other jewelry.
Machine parked on a firm, level surface

Boom in stowed position
the non-steer wheels

squirt or spray.

rotation lock
key removed
Wheels chocked
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
July 2007
FAULT CODES
REV A
Fault Code Chart Control System

How to Retrieve Control System
Fault Codes
Note: At least one fault code is present when the
alarm at the platform controls produces two short
beeps every 30 seconds for 10 minutes.
Note: Perform this procedure with the engine off,
the key switch turned to platform controls and the
red Emergency Stop button pulled out to the on
position at both the ground and platform controls.
1 Open the platform control box lid.
and other jewelry.
3 Determine the error source: The red LED

indicates the error source and will flash two
separate codes. The first code will indicate the
first digit of the two digit code, flashing once per
second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Note: When the red LED is flashing the code, the
yellow LED will be on solid.
4 Determine the error type: The yellow LED
indidates the error type and will flash two
separate codes. The first code will indicate the
first digit of the two digit code, flashing once per
second. It will then pause for 1.5 seconds and
flash the second digit once per 0.5 second.
Note: When the yellow LED is flashing the code,
the red LED will be on solid.
5 Use the fault code table on the following pages
to aid in troubleshooting the machine by
pinpointing the area or component affected.
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
July 2007
FAULT CODES
REV A
Error Source
ID
21
22
23
31
32
Name
Boom 1 Joystick
(primary boom up/
down)
Boom 1 directional
valves
Boom 1 flow
control valve
Boom 2 Joystick
(secondary boom
up/down or
primary boom
extend/retract)
Boom 2 directional
valves
Error Type
ID
11
12
15
16
Name
17
Not calibrated
18
Just calibrated
21
Fault
12
15
Value too high

Value too low
17
Not calibrated
18
Just calibrated
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
Value at 5V
Value too high
Value too low
Value at 0V
Condition
Function is inoperative
until joystick is
calibrated. Alarm
sounds indicating
fault.
until joystick is
calibrated.
Initiate 1-second beep
of alarm.
Valve is operating
outside of operational
limits. Alarm sounds
indicating fault.
Valve is operating
indicating fault.
Normal function
except threshold for
one or both directions
is zero.
Joystick is operating
indicating fault.
until joystick is
calibrated.
Initiate 1 second beep
of alarm.
Valve is operating
indicating fault.
Solution
Cycle power off,
then on and
problem should be
corrected.
Calibrate joystick
Self-clearing.
(transient)
Cycle power off,
then on and
problem should be
corrected.
Cycle power off,
then on and
problem should be
corrected.
Calibrate valve
thresholds
Self-clearing.
(transient)
Cycle power off,
then on and
problem should be
corrected.
Calibrate joystick
Self-clearing.
(transient)
Cycle power off,
then on and
problem should be
corrected.
Continued on next page
Part No. 102521
S-40 S-45
5-3
July 2007
REV A
FAULT CODES
Error Source
ID
33
41
42
43
44
5-4
Name
Boom 2 flow
control valve
Turntable rotate
joystick
Error Type
ID
Name
12
15
Value too high

Value too low
17
Not calibrated
18
Just calibrated
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
12
15
Value too high

Value too low
17
Not calibrated
18
Just calibrated
21
Fault
Turntable rotate
directional valves
Turntable rotate
flow control valve
Drive enable
override switches
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
is zero.
Solution
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Limited speed and

direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
is zero.
Enable override
direction is frozen at
neutral.
S-40 S-45
Power up
controller with
problem corrected.
Calibrate joystick.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate valve
thresholds.
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Part No. 102521
July 2007
FAULT CODES
REV A
Error Source
ID
51
53
54
55
61
62
Name
Drive joystick
Drive flow valve

(EDC)
Error Type
ID
11
12
15
16
Name
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
12
15
Value too high

Value too low
17
Not calibrated
18
Just calibrated
21
Fault
21
Fault
11
12
15
16
Value at 5V
Value too high
Value too low
Value at 0V
17
Not calibrated
18
Just calibrated
21
Fault
Drive brake valve
High speed drive

motor Valve
Steer joystick
Steer directional
valves
Part No. 102521
Condition
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Normal function
is zero.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Motor speed frozen in
the low state. Alarm
sounds indicating
fault.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
Joystick speed and
direction frozen at
zero and neutral.
of alarm.
Limited speed and
direction frozen at
zero and neutral.
Alarm sounds
indicating fault.
S-40 S-45
Solution
Power up
controller with
problem corrected.
Calibrate joystick
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Calibrate valve
thresholds
Self-clearing.
(transient)
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Power up
controller with
problem corrected.
Calibrate Joystick
Self-clearing.
(transient)
Power up
controller with
problem corrected.
5-5
July 2007
FAULT CODES
REV A
Ford LRG-425 EFI Engine

How to Retrieve Ford Engine
Fault Codes
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel
injection and make constant and instantaneous
changes to ignition timing, fuel delivery and throttle
position to maintain the engine's running condition
at its highest efficiency while at the same time
keeping exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of
set parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor and
will turn on the Check Engine Light.
Note: Perform this procedure with the key switch in
the off position.
1 Open the ground controls side cover and locate
the run/test toggle switch on the side of the
ground control box.

blink a three digit code three times for each code
stored in memory. It will blink the first digit of a
three digit code, pause, blink the second digit,
pause, and then blink the third digit. For example:
the check engine light blinks 5 consecutive times,
blinks 3 times and then 1 time. That would indicate
code 531.
Note: Once a fault code has been retrieved and the
repair has been completed, the ECM memory must
be reset to clear the fault code from the ECM. See
How to Clear Engine Fault Codes from the ECM.

Codes from the ECM
1 Open the engine side turntable cover and locate
the battery.
2 Disconnect the negative battery cable from the
battery for a minimum of 5 minutes.
and other jewelry.

controls.
4 Move and hold the run/test toggle switch to the
test position.

battery.

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
July 2007
FAULT CODES
REV A
Code
Problem
Cause
Solution
111
Closed Loop Multiplier

High (LPG)
Heated Oxygen Sensor wiring and/or

connections open or shorted OR sensor is faulty
OR there are vacuum leaks or exhaust leaks.
Repair wiring and/or connections OR replace

sensor OR repair vacuum and exhaust leaks.
112
HO2S Open/Inactive
(Bank 1)
Heated Oxygen Sensor wiring and/or connections

open or shorted OR sensor is faulty.
113
HO2S Open/Inactive
(Bank 2)
Heated Oxygen Sensor wiring and/or connections

open or shorted OR sensor is faulty.
114
Post-cat oxygen
sensor open
The post cat Heated Oxygen Sensor wiring

and/or connections are open or shorted OR
sensor is cold, non-responsive or inactive for
60 seconds or longer.

the post cat oxygen sensor.
121

High (Gasoline)

connections open or shorted OR sensor is
faulty OR there are vacuum leaks or exhaust
leaks OR fuel pressure is low OR the fuel
injectors need cleaning or replacing.

sensor OR repair any vacuum and exhaust leaks
OR test the fuel pressure OR clean or replace the
fuel injectors.

Low (Gasoline)
MAP, IAT or ECT sensors not in correct position

OR wiring and/or connections for sensors open
or shorted OR sensor is faulty OR one or more
fuel injectors are stuck open OR there is
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.
Adjust or replace sensors OR clean or repair

fuel injectors.

faulty OR fuel quality is poor OR fuel system
components may be faulty.

sensor OR replace fuel OR test and repair the
fuel system components.
There are exhaust leaks OR the catalyst system

efficiency is below the acceptable level.
Repair exhaust leaks OR there is an emissions

compliance issue. Contact Ford Power Products
for assistance.
Adaptive Lean Fault High Limit (Gasoline)

faulty OR there are vacuum or exhaust leaks
OR one or more fuel injectors faulty or stuck
closed OR fuel quality is poor OR fuel
pressure is too low.
Repair heated oxygen sensor wiring and/or

connections OR replace sensor OR repair
vacuum and exhaust leaks OR test the fuel
pressure OR clean or replace the fuel injectors.
142
Adaptive Rich Fault Low Limit (Gasoline)
MAP, IAT or ECT sensors not in correct position

OR wiring and/or connections for sensors open
or shorted OR sensor is faulty OR one or more
fuel injectors are stuck closed OR there is
electro-magnetic interference from a faulty
crankshaft and/or camshaft position sensor.
Adjust or replace sensors OR clean or repair

fuel injectors.
143
Adaptive Learn High

(LPG)

faulty OR there are vacuum leaks or exhaust
leaks OR fuel quality is poor OR fuel system

sensor OR repair any vacuum and exhaust
leaks OR replace fuel OR test and repair the
fuel system components.
144
Adaptive Learn Low

(LPG)
Engine wire harness may have an intermittent

short to 5V DC or 12V DC OR fuel system
Repair short in engine wire harness

OR test and repair the fuel system
components.
122
124

Low (LPG)
133
Gasoline cat monitor
134
LPG cat monitor
135
NG cat monitor
141
Part No. 102521
S-40 S-45
Repair wiring and/or connections OR

replace sensor.
5-7
July 2007
FAULT CODES
Code
Problem
REV A
Cause
Solution
161
System Voltage Low
Battery is faulty OR alternator is not charging OR

battery supply wiring to ECM is open or shorted.
Replace battery OR repair alternator OR repair

battery supply wiring to ECM.
162
System Voltage High
Alternator is overcharging the battery when

engine RPM is greater than 1500 rpm.
Repair or replace the alternator.
211
IAT High Voltage
IAT sensor wiring and/or connections are open or

shorted OR sensor is faulty OR engine intake air
temperature is too cold.

sensor OR direct warmer air into air intake.
212
IAT Low Voltage
IAT sensor wiring and/or connections are open or

shorted OR sensor is faulty OR engine intake air
temperature is too hot.

sensor OR direct cooler air into air intake.
213
IAT Higher Than

Expected (1)
Air intake temperature is greater than 200 F with

the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.
214
IAT Higher Than

Expected (2)
Air intake temperature is greater than 210 F with

the engine greater than 1000 rpm OR air intake
system has leaks OR IAT sensor is faulty.
215
Oil Pressure Low
Faulty oil pressure sensor OR sensor wiring

and/or connections open or shorted OR engine
oil level too low.
Replace oil pressure sensor OR repair sensor

wiring and/or connections OR fill engine oil level
to specification.
221
CHT/ECT High Voltage
Engine cooling system is malfunctioning OR

sensor wires and/or connections open or shorted
OR sensor is faulty.
Repair engine cooling system problems OR

repair open or shorted wiring to sensor OR
replace sensor.
222
CHT/ECT Low Voltage
Engine cooling system is malfunctioning and

overheating the engine OR sensor wires and/or
OR coolant level is low.
223
CHT Higher Than

Expected (1)
Coolant temperature at the cylinder head is 240 F.

224
CHT Higher Than

Expected (2)
Coolant temperature at the cylinder head is 250 F.

231
MAP High Pressure
Open or shorted wiring and/or connections to MAP

sensor OR sensor is faulty.
MAP Low Voltage
Open or shorted wiring and/or connections to MAP

sensor OR sensor is faulty.
BP High Pressure
MAP sensor is faulty OR ECM is faulty.
BP Low Pressure
MAP sensor is faulty OR ECM is faulty.
242
Crank Sync Noise
Crankshaft position sensor wiring and/or

connections open or shorted OR there is a poor
system ground connection OR sensor is faulty.
243
Never Crank Synced

At Start

244
Camshaft Sensor Loss

232
234
235
5-8
Check air intake system for damage and proper

routing of air intake components OR replace the
IAT sensor.
Repair engine cooling system problems OR

repair open or shorted wiring to sensor OR
replace sensor OR fill engine coolant level to
specification.
Repair wiring and/or connections to sensor OR

replace MAP sensor.
Replace MAP sensor OR replace the ECM.
S-40 S-45
Be sure system ground connections are in place

and secure OR repair wiring and/or connections
to sensor OR replace sensor.
Part No. 102521
July 2007
FAULT CODES
REV A
Code
Problem
Cause
245
Camshaft Sensor Noise
Camshaft position sensor wiring and/or


to sensor OR replace sensor.
253
Knock Sensor Open
Knock sensor wiring and/or connections open or

shorted OR sensor is faulty.
Repair wiring and/or connections to knock sensor

OR replace knock sensor.
254
Excessive Knock Signal
Knock sensor wiring and/or connections open or

shorted OR there is excessive engine vibration
OR sensor is faulty.
Check for excessive engine vibration OR repair

wiring and/or connections to knock sensor OR
replace knock sensor.
311
Injector Driver #1 Open
Open wiring and/or connections to fuel injector #1

OR fuel injector #1 is faulty OR ECM is faulty.
312
Injector Driver #1 Shorted
Wiring and/or connections to fuel injector #1 is

shorted OR fuel injector #1 is faulty OR
ECM is faulty.
313

314

ECM is faulty.
315

316

ECM is faulty.
321

322

ECM is faulty.
351
Fuel Pump Loop Open or

High Side Short to Ground
Open wiring and/or connections to fuel pump OR

fuel pump power shorted to ground OR fuel pump
is faulty.
352
Fuel Pump High Side

Shorted to Power
Wiring and/or connections to fuel pump shorted to

power OR fuel pump is faulty.
353
MegaJector Delivery
Pressure Higher Than
Expected
Fuel pressure too high OR LPG lockoff not opening

completely OR the line between the MegaJector
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly
OR MegaJector is faulty.
354
MegaJector Delivery
Pressure Lower Than
Expected
Fuel pressure too low OR LPG lockoff not opening

completely OR the line between the MegaJector
and carburetor is kinked or restricted or is leaking
OR engine cooling system is not operating properly
OR MegaJector is faulty.
355
MegaJector
Communication Lost
The ECM doesn't get any response from the

MegaJector, or an incorrect response for 500ms
period or longer.
Check CAN circuits for continuity and shorts to

power or ground and for continuity and repair as
necessary OR replace the MegaJector.
361
MegaJector Voltage
Supply High
The MegaJector detects voltage greater than 18

volts for 5 seconds anytime the engine is cranking
or running.
Repair charging system OR replace the

MegaJector.
362
MegaJector Voltage
Supply Low
The MegaJector detects voltage less than 9.5 volts

for 5 seconds anytime the engine is cranking or
running.
Repair VBAT power or ground circuit to ECM and

MegaJector OR replace battery OR repair
charging system OR replace the MegaJector.
Part No. 102521
S-40 S-45
Solution
Repair wiring and/or connections to fuel injector #1

OR replace fuel injector #1 OR replace the ECM.



Repair wiring and/or connections to fuel pump OR

replace fuel pump.
Check fuel pressure OR repair LPG lockoff OR

repair the line between the MegaJector and
carburetor OR repair engine cooling system OR
replace the MegaJector.
5-9
July 2007
FAULT CODES
Code
REV A
Problem
Cause
363
MegaJector Internal
Actuator Fault Detection
The MegaJector detects an internal fault. Open or

short in power, ground or CAN circuits.
364
MegaJector Internal
Circuitry Fault Detection
The MegaJector detects an internal circuitry failure.

Open or short in power, ground or CAN circuits.
365
MegaJector Internal
Communication Fault
Detection
The MegaJector detects an internal

communications failure. Open or short in power,
ground or CAN circuits.
411
Coil Driver #1 Open
Open wiring and/or connections to ignition

coil #1 OR ignition coil #1 is faulty.
412
Coil Driver #1 Shorted
Wiring and/or connections to ignition coil #1

shorted OR ignition coil #1 is faulty
413
Coil Driver #2 Open
Open wiring and/or connections to ignition

coil #2 OR ignition coil #2 is faulty.
414
Coil Driver #2 Shorted
Wiring and/or connections to ignition coil #2

shorted OR ignition coil #2 is faulty
511
FPP1 High Voltage
512
FPP1 Low Voltage
513
FPP1 Higher than IVS Limit
Check Power, Ground and CAN circuits at

MegaJector and all connections and repair as
necessary OR MegaJector has an internal fault.
Contact Ford Power Products for assistance.
Repair wiring and/or connections to ignition

coil #1 OR replace ignition coil #1.
Repair wiring and/or connections to ignition

coil #2 OR replace ignition coil #2.
Not used.
If this fault appears on your machine, contact

the Genie Industries Service Department.
The #1 throttle position sensor wiring and/or

system ground connection OR throttle position
sensor #1 is faulty.

to sensor OR replace throttle position sensor #1.
The #2 throttle position sensor wiring and/or

system ground connection OR throttle position
sensor #2 is faulty.

to sensor OR replace throttle position sensor #2.
The throttle position sensor wiring and/or

connections for either TPS1 or TPS2 open or
shorted OR there is a poor system ground
connection OR one or both throttle position
sensors are faulty.
Be sure engine harness wiring and connections

are in place and secure OR repair wiring and/or
connections to one or both TPS sensors OR
replace one or both TPS sensors.
514
FPP1 Lower than IVS Limit
521
FPP2 High Voltage
522
FPP2 High Voltage
531
TPS1 (Signal Voltage) High
532
TPS1 (Signal Voltage) Low
533
TPS2 (Signal Voltage) High
534
TPS2 (Signal Voltage) Low
535
TPS1 Higher than TPS2
536
TPS1 Lower than TPS2
537
Throttle Unable to Open
Governor actuator is stuck closed OR wiring

and/or connections open or shorted OR
governor actuator is faulty.
538
Throttle Unable to Close
Governor actuator is stuck open OR wiring

and/or connections open or shorted OR
governor actuator is faulty.
545
Governor Interlock Failure
Engine harness wiring and/or connections open

or shorted OR there is a poor system ground
connection OR ECM is faulty.
5 - 10
Solution
S-40 S-45
Repair wiring and/or connections to governor

actuator OR replace the governor actuator.
Repair wiring and/or connections in engine

harness OR replace the ECM.
Part No. 102521
July 2007
FAULT CODES
REV A
Code
Problem
551
Max Governor Speed

Override
552
FPP1 Low Voltage
553
FPP1 Higher than IVS Limit
611
COP Failure
612
Invalid Interrupt
613
A/D Loss
614
RTI 1 Loss
615
Flash Checksum Invalid
616
RAM Failure
631
External 5V DC Ref
Lower than Expected
632
External 5V DC Ref
Higher than Expected
655
RTI2 Loss
656
RTI3 Loss
Part No. 102521
Cause
Solution
ECM needs to be re-programmed OR throttle is

sticking open OR there are air leaks between the
throttle body and cylinder head.
Re-program ECM OR repair binding throttle

operation OR repair any air leaks between the
throttle body and cylinder head.
Loose wire connections to ECM OR ECM is faulty.
Locate and repair any engine harness wiring

damage or shorts to ECM to be sure they are
secure OR replace ECM.
Engine harness wiring and/or connections open

or shorted to ground OR there is a faulty engine
sensor OR ECM is faulty.

damage or shorts OR locate and troubleshoot or
repair faulty engine sensor OR replace ECM.
Loose wire connections to ECM OR ECM is faulty.

damage or shorts to ECM to be sure they are
secure OR replace ECM.
S-40 S-45
5 - 11
July 2007
FAULT CODES
REV A
Ford DSG-423 EFI Engine

How to Retrieve Ford Engine
Fault Codes
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also
uses signals from the sensors to initiate
sequential fuel injection and make constant and
instantaneous changes to ignition timing, fuel
delivery and throttle position to maintain the
engine's running condition at its highest efficiency
while at the same time keeping exhaust
emissions to a minimum. When a sensor fails or
returns signals that are outside of set
parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor
and will turn on the Check Engine Light.
Note: Perform this procedure with the key switch
in the off position.
1 Open the ground controls side cover and
locate the run/test toggle switch on the side of
the ground control box.

blink a three digit code three times for each code
stored in memory. It will blink the first digit of a
three digit code, pause, blink the second digit,
pause, and then blink the third digit. For example:
the check engine light blinks 5 consecutive
times, blinks 3 times and then 1 time. That would
indicate code 531.
Note: Once a fault code has been retrieved and
the repair has been completed, the ECM memory
must be reset to clear the fault code from the
ECM. See How to Clear Engine Fault Codes from
the ECM.

Codes from the ECM
locate the battery.
2 Disconnect the negative battery cable from
the battery for a minimum of 5 minutes.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

controls.

battery.
4 Move and hold the run/test toggle switch to

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
July 2007
FAULT CODES
REV A
Code
111
112
113
114
115
121
122
124
133
134
141
142
143
144
161
162
163
164
165
166
167
168
171
172
173
174
181
182
183
184
185
186
211
Description
CL (closed loop) high LPG
EGO open / lazy pre-cat 1
EGO open / lazy pre-cat 2/post-cat 1
EGO open / lazy post-cat 1
EGO open / lazy post-cat 2
CL (closed loop) high gasoline bank 1
CL (closed loop) low gasoline bank 1
CL (closed loop) low LPG
Gasoline catalyst monitor 1
LPG catalyst monitor
AL (adaptive learning) high gasoline bank 1
AL (adaptive learning) low gasoline bank 1
AL (adaptive learning) high LPG
AL (adaptive learning) low LPG
Battery voltage high
Battery voltage low
AUX analog PD1 high
AUX analog PD1 low
AUX analog PU3 high
AUX analog PU3 low
AUX analog PUD1 high
Code
212
213
214
215
221
222
223
224
225
226
231
232
234
235
242
243
244
245
246
253
254
Description
IAT (intake air temperature) low voltage
IAT (intake air temperature) higher than expected 1
IAT (intake air temperature) higher than expected 2
Oil pressure low
ECT/CHT (engine/cylinder head temp) high voltage
ECT/CHT (engine/cylinder head temp) low voltage
CHT higher than expected 1
CHT higher than expected 2
ECT higher than expected 1
ECT higher than expected 2
MAP (manifold absolute pressure) high pressure
MAP (manifold absolute pressure) low pressure
BP (barometric pressure) high pressure
BP (barometric pressure) low pressure
Crank sync noise
Never crank synced at start
Cam loss
Cam sync noise
Crank loss
Knock 1-2 sensor open 1
Knock 1-2 excessive signal 1
AUX analog PUD1 low

AUX analog PUD2 low
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
July 2007
FAULT CODES
Code
261
262
271
272
273
274
311
312
313
314
315
316
321
322
351
352
353
354
355
359
361
362
363
364
365
411
412
413
414
415
416
421
422
5 - 14
REV A
Description
Code
FP (fuel pressure) high voltage

FP (fuel pressure) low voltage
FT (fuel temperature) gasoline high voltage
FT (fuel temperature) gasoline low voltage
FT (fuel temperature) gaseous fuel high voltage
FT (fuel temperature) gaseous fuel low voltage
Injector loop open OR low-side short to ground 1
Injector coil shorted 1
FPump motor loop open OR high-side shorted to ground
Fpump motor high-side shorted to power
EPR delivery pressure higher than expected
EPR delivery pressure lower than expected
EPR comm lost
Fuel run-out longer than expected
EPR voltage supply high
531
532
533
534
535
536
537
538
539
541
542
543
544
551
552
553
611
612
613
614
615
Description
TPS1 (throttle position sensor) high voltage
TPS1 (throttle position sensor) low voltage
TPS2 (throttle position sensor) high voltage
TPS2 (throttle position sensor) low voltage
TPS1 (throttle position sensor) higher than TPS2
TPS1 (throttle position sensor) lower than TPS2
Unable to reach higher TPS (throttle position sensor)
Unable to reach lower TPS (throttle position sensor)
TPS 1-2 simultaneous voltages
AUX analog PU1 high
AUX analog PU1 low
AUX analog PU2 high
AUX analog PU2 low
Max govern speed override
Fuel rev limit
Spark rev limit
COP failure
Invalid interrupt
A/D loss
RTI 1 loss
Flash checksum invalid
EPR voltage supply low

EPR internal actuator fault detection
EPR internal circuitry fault detection
EPR internal comm fault detection
Primary loop open OR low-side short to ground 1
Primary coil shorted 1
S-40 S-45
Part No. 102521
July 2007
FAULT CODES
REV A
Code
616
631
632
633
634
635
641
642
643
644
646
647
648
655
656
711
712
713
714
715
716
721
722
723
731
732
733
734
735
736
741
742
743
Description
RAM failure
5VE1 low voltage
5VE1 high voltage
5VE2 high voltage
5VE2 low voltage
5VE1-5VE2 simultaneous out-of-range
Rx inactive
Rx noise
Code
744
761
762
763
771
772
1629
1630
Description
PWM5 short to power
MIL (malfunction indicator light) control ground short
MIL (malfunction indicator light) open
MIL (malfunction indicator light) control short to power
Tach output ground short
Tach output short to power
J1939 TSC1 message receipt lost
J1939 ETC message receipt lost
Invalid packet format

Shutdown request
CAN Tx failure
CAN Rx failure
CAN address conflict failure
RTI 2 loss
RTI 3 loss
Relay control ground short
Relay coil open
Relay coil short to power
Fpump relay control ground short
Fpump relay coil open
Fpump relay coil short to power
Start relay control ground short
Start relay coil open
Start relay coil short to power
PWM1-gauge1 open / ground short
PWM1-gauge1 short to power
PWM4 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).
Genie part number 119494.
PWM4 short to power

PWM5 open / ground short
Part No. 102521

Genie part number
S-40 S-45
119488
5 - 15
July 2007
5 - 16
S-40 S-45
Part No. 102521
July 2007
Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
Observe and Obey:

and other jewelry.
Troubleshooting and repair procedures shall be

completed by a person trained and qualified on
the repair of this machine.
Hydraulic Schematics
or spray.

Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-40 & Genie S-45 Operator's Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
General Repair Process
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
Part No. 102521
S-40 S-45
problem
solved
Inspect
and test
Perform
repair
6-1
July 2007
Electrical Symbols Legend

REV A
FS1
BLK
BLK
P3
WHT
Quick disconnect
terminal
N.O.H.C
Coil
solenoid or relay
N.C.H.O
Limit switch
Horn button
normally open
P1
KS1
TB21
WHT #21
Foot switch
LS3
PLATFORM
OTS2
N.O.
GROUND
T-circuits connect
at terminal
H1
Horn or alarm
T-circuits
connect
Key switch
Oil temperature
switch
normally open
Emergency Stop
button normally
closed
FAN
FB
PR1
CTS1
N.O.
Flashing beacon
Power relay
Coolant temperature
switch
normally open
Connection
no terminal
G1
TS2
START
ENGINE
Gauge
Aux
Pump
Auxiliary pump
OPS1
N.C.
Circuits crossing
no connection
510
HM
Diode
Hydraulic oil
cooling fan
Toggle switch SPDT
Oil pressure switch

normally closed
Resistor with
ohm value
Hour meter
TS6
PLATFORM LEVEL
LED
KS1
25A
CB1
15A
Fuse
with amperage
CR4
N.O.
Circuit breaker
with amperage
Control relay contact
normally open
Starting aid:
glow plug or
flame ignitor
6-2
Tilt sensor
Toggle switch DPDT

B
C
HOLD
F1
Gauge sending unit
PULL IN
Battery
UP
DOWN
L3
Key switch
Fuel or RPM
solenoid
Coil
S-40 S-45
Part No. 102521
July 2007
Hydraulic Symbols Legend

REV A
25 psi
(1.7 bar)
.035"
(0.89 mm)
Orifice with size

Solenoid operated 3 position,
4 way, directional valve
Filter with
bypass valve
relief setting
Solenoid operated
3 position, 4 way,
proportional directional valve
Check valve
200 psi
(13.8 bar)
Pump
fixed displacement
Relief valve
with pressure setting
2 position, 3 way, shuttle valve
Priority
flow regulator valve
o
Brake
Pump
bi-directional,
variable displacement
Directional valve
(mechanically activated)
Solenoid operated 2 position,

3 way, directional valve
3000 psi
(206.8 bar)
3:1
Needle valve
50%
Motor
bi-directional
Motor
2-speed,
bi-directional
50%
Flow divider/combiner valve

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

3 way, shuttle valve
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
July 2007
REV A
Ford DSG-423 Engine Relay Layout
Starter
Relay
Fuel
Pump
Relay
Power
Relay
Empty
F1-10A
F2-5A
F3-10A
F4-15A
F5-15A
6-4
S-40 S-45
Part No. 102521
July 2007
REV A
Connector Pin Legend
C1P DT06-12SA
C7: DTP06-4S
C1
CKT #
PIN #
1
BK
P22BAT
RD/BK
C28TTA
WH
P23SWBAT
RD/WH
C29MS
BRN
BATGND
WH
C30EDC+
N/A
PLUG
WH/BK
C31EDC-
WH/RD
C32BRK
BK
C33STR
BK/WH
C34SA
BK/RD
C35ESPD
BL
C36STC
10
BL/BK
C37STCC
C132PLI
11
BL/WH
CKT #
OR
C40LS1
OR/BK
C41RPM
3
4
GR
C134PWR
C43HRN
GR/BK
JDALARM
GR/WH
C45GEN
PLUG
PLUG
PLUG
10
PLUG
11
PLUG
12
CKT #
C1PBU
C2PBD
RD/WH
C3PBF
WH
C4TRL
WH/BK
C5TRR
WH/RD
C6TRF
BK
C7PBE
BK/WH
C8PBR
BK/RD
BL/BK
DRVLT
PLUG
PLUG
BL/WH
PLUG
GREEN
COLOR
CIRCUIT #
COLOR
RD
C1PBU
C2PBD
RD
3
4
C3PBF
C4TRL
RD/WH
RD/WH
WH
C3PBF
C4TRL
C5TRR
WH/BK
C5TRR
WH/BK
C6TRF
WH/RD
C6TRF
WH/RD
C7PBE
BK
C7PBE
BK
8
9
C8PBR
BK/WH
C8PBR
BK/WH
RD/BK
RD/BK
WH
10
C13DRE
C14PLU
BL/RD
OR
C13DRE
C14PLU
C15PLD
OR/BK
C15PLD
OR/BK
R43HRN
BK
R43HRN
BK
C17JU
C18JD
C2DA
GR
GR/BK
RD/BK
C17JU
C18JD
C2DA
GR
GR/BK
RD/BK
CKT #
C134PWR
RD
C134PWR
RD
25
C116HYD
BK
26
GND
C27AUX
BR
RD
C27AUX
RD
RD/BK
C28TTA
RD/BK
C28TTA
30
P46PWR
BL/WH
P46PWR
BL/WH
C32TA
WH/RD
32
C32TA
WH/RD
33
R116HYD
OR
OR
34
R21IGN
WH
OR/BK
C15PLD
35
OR/RD
C133PLA
GR
C17JU
GR/BK
C18JD
38
GR/WH
C19JSV
PLUG
PLUG
PLUG
10
PLUG
11
PLUG
12
C39LP
TB23
BL/RD
WH
C38ESL
BL/WH
C21IGN
WH
C31EDC
C30EDC
C34SA
C32BRK
C29MS
WH/BK
WH
BK/WH
WH/RD
RD/WH
COLOR
FORD
COLOR
PERKINS
COLOR
C4
BROWN
DEUTZ
OR/BK
WH
C41RPM
C107AF
OR/BK
WH
C41RPM
C107AF
OR/BK
WH
C41RPM
C107AF
BK
RD
R33STR
R27AUX
BK
R33STR
BK
R33STR
WH
BK/RD
BL/RD
WH(12)
GR
BL/WH
WH/RD
R21IGN
C35RPM
C39LP
VSW
C127TST
C38ESL
C26TSR
BK/RD
C35RPM
BK/RD
C35RPM
WH/RD
TSWITCH
WH/RD
TSWITCH
WH/BK
WH
C25PSR
C21IGN
WH/BK
PSWITCH
WH/BK
PSWITCH
WH/BK
WH
C31EDC
C30EDC
WH/RD
RD/WH
C32BRK
C29MS
WH/BK
WH
BK/WH
WH/RD
RD/WH
C31EDC
C30EDC
C34SA
C32BRK
C29MS
WH/BK
WH
BK/WH
WH/RD
RD/WH
C31EDC
C30EDC
C34SA
C32BRK
C29MS
C9 FS DT04-4P
29
C13DRE
C14PLU
BL/RD
OR/BK
WH
C41RPM
C107AF
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
C9
24
28
C4
PIN #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
21
22
31
COLOR
BL/RD
OR
16
17
18
19
20
27
12
15
23
11
C4P DT06-12SD
CIRCUIT #
13
14
C3
COLOR
12
PIN #
RD
C6-FUNCTION HARNESS
10
11
C3
RD/BK
BL
BLACK
C6-GBOX
C1PBU
C2PBD
1
2
C3P DT06-12SC
COLOR
C6
C2
* NOTE: WIRE ONLY IN C7B CONNECTOR.
PIN #
C39LP
C5-ENGINE HARNESS
CKT#
PIN#
C2
C5-GBOX
PIN#
12
BL/RD
OR/RD
GRAY
C7
C2P DT06-12SB
COLOR
C1
C7
C27AUX
COLOR
CKT # PIN #
RD
COLOR
36
C36STC
BL
C36STC
BL
37
C37STCC
BL/BK
C37STCC
BL/BK
39
C45GEN
GR/WH
C45GEN
GR/WH
40
C40LS1
OR
C40LS1
OR
COLOR
CKT #
PIN #
BK
P26BAT
WH
P24BAT
RD
P25BAT
N/C
Part No. 102521
S-40 S-45
6-5
July 2007
Connector Pin Legend
6-5
6-6
July 2007
Electrical Schematic
Deutz F3L 1011F Models (before serial number 7544)
6-8
6-7
July 2007
REV B
A
1
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
LS18
P2
FS1
BK-(FS)
C9-1 BK
C9-3 P25FS RD
C9-2 P24FS WH
RD-(FS)
WH-(FS)
TS2
SEE NOTE 2
TS17
ON GLOW
PLUG
TS4
SEE NOTE 2
C2-7
C1-8
C1-9
TB43
TB45
RD
RD
C35ESPD BK/RD
LOW RPM
FUNCTION ENA.
HIGH RPM
TB34
TB35
L5
BK/RD
8
9
10
TS55
C6-39
CR2
NO
START RELAY
TACHOMETER
START INPUT
IGN./START
AUX. ON
GROUND
MODULE
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
C45GEN GR/WH
CR2
CR1
CR1
NO
1
2
3
4
5
6
C34SA BK/WH
CR5
TB24
C6-28
CR5
NO
20AMP.
C6-23
CB3
ON GLOW
PLUG BK
RD
D6
TB28
TS56
TB33
TB23
TB133
START BK
L45
H6
15AMP.
ENGINE
RD
CB1
TB20
PUMP
AUXILARY
TB27
TS52
C33STR BK
TS51
RD
7
8
12
C27AUX RD
U33
P23BAT WH
C28TTA RD/BK
PLAT
GRD
C133PLA OR/RD
C43HRN GR
KS1 TB22
HIGH RPM(FS)
L24
C1-7
ENGINE
C1-1
C7-2
C1-2
C4-4
C2-5
C7-1
GENERATOR
TS1
L48
D40
TS6
START
D39
PUMP AUXILIARY
P3
HORN
L4
H1
TB132
TB134
RD
P22BAT BK
C2-4
RD
C1-12
P1
RD
C132PLI BL/WH
CB2
15AMP.
C134PWR OR/RD
C41RPM OR/BK
WH
C28TTA RD/BK
RD
TB 134 IS WAGO TERMINAL BLOCK 42

BK
TB21
OPS
OTS
NC
NO
CR3
NO CR4
BK/RD-C5-8
G1
GR/WH-45
C5-22
HM
NO
PR2
C5-14
G3
WH-24
C5-16
WH/BK
STARTER
TB26
PR2
NO
PR1
PR1
NO
AUX
PUMP
BK
BRN
C6-26
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR
OPTION
GLOW PLUG OPTION
Part No. 102521
WATER TEMP GAUGE
S-40 S-45
WATER TEMP
SWITCH
+
-
2) THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.
OIL PRESSURE
SWITCH
NOTE:
1) ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM
IN THE STOWED POSITION AND KEYSWITCH "OFF".
OIL PRESSURE GAUGE
FUEL RELAY
VOLT METER
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
SERVICE HORN
RELAY
HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)
6-8
C5-15
G2
WH-21
BK-33
RD-27
FB
H2
REGULATOR
C5-5
C6-27
WH
RD
STA.
IND.
TB25
BK-43
CR17
FAN
RD/BK-28
RD-134
C6-16
C6-25
BAT.
-
CR17
NO
C6-33
BAT.
+
C6-34
EXCT.
12 V
DC
OR/BK-41
ALTERNATOR
C5-2
C5-3
OTS
NO
DRE LED BL/RD

DRE B BL/BK
DRE A BL/WH
12
13
14
10
11
17
18
20
19
16
15
C41RPM OR/BK
15
8
16
7
WH
RKOUT 6
2
1
11
12
14
13
OR
BRN
BL
4
PWR 3
GND 2
RD
OR
BK
YOUT 5
XOUT 4
BRN
GND 2
PWR 3
BRN
P24FS WH
C1P-6
C1P-5
C1P-4
C37STCC BL/BK
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
BRN-2
C1P-11
C36STC BL
C2P-3
C1P-10
LEFT
TROTATE
RIGHT
C4TRL WH
C5TRR WH/BK
7.5
C6TRF WH/RD
RD
C3P-6
RD
C3P-5
C3P-4
C3P-1
C3P-2
C3P-3
C4P-1
UP
PRIMARY
DOWN BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
C40LS1 OR
C5-21
C5-20
C6-32
C5-23
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C30EDC+ WH
A
C31EDC- WH/BK D
C32BRK WH/RD
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
C6-19 RD/BK
C6-13
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
C40LS1 OR
C6-40
C6-7
C6-8
C6-14
C6-15
7
BK
WH
BK
WH
BK
WH
H3
GROUND
DRIVE EDC FORWARD
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
BRAKE RELEASE VALVE
STEER RIGHT
STEER LEFT
TURNTABLE ROTATE LEFT

TURNTABLE ROTATE RIGHT
TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM
FLOW CONTROL
LS1-PRIMARY BOOM EXTEND

DRIVE LIMIT SWITCH
DESCENT ALARM OPTION
DRIVE ENABLE
LIMIT SWITCH
BOOM EXTEND
BOOM RETRACT
PLAT LEVEL UP
PLAT LEVEL DOWN
PLATFORM ROTATE RIGHT / JIB DOWN

PLATFORM ROTATE LEFT / JIB UP
JIB VALVES
6-9
S-40 S-45
Part No. 102521
H4
SJ1-WH
C18JD GR/BK
NOTE:
P24FS WH
3
C2P-2
EXTEND
BOOM
PLATFORM
LEVEL
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
RETRACT
UP
DOWN
C6-18
C17JU GR
NONC
1) ALL LIMIT SWITCHES SHOWN WITH THE BOOM IN STOWED
C3P-7
C3P-8
JDALARM GR/BK
C18JD GR/BK
C17JU GR
C6-17
NOHC
POSITION EXCEPT AS NOTED.
P26ESTP BK
RETRACT
EXTEND BOOM
C4P-2
C2P-6
PLATFORM
UP
DOWN LEVEL C4P-3
GR/BK-44
C4P-6
DOWN JIB
BOOM C4P-5
UP
DOWN
UP JIB BOOM
JIB BOOM
TB7
8
NOHC
BRN
6
5
C6-30
TB22
1
Deutsch
LEFT
RIGHT
RIGHT PLAT
LEFT ROTATE
3
2
TB3 TB2 TB6
TB31
TB32
TB36
TB30
TB37
TB5
C19JSV GR/WH
2
5
AMP
Joystick Adaptor Harness
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
1
5
TB8
TB14
TB15
TB18
TB17
TS62
TS61
TB4
TB1
TB13
3
C4P-7
TS57
J2
4
TS63
TS59
TS58
TB40
R2
R1
YOUT 5
PRI UP/DN & TT ROTATE
J1
J1
J1
J3
CR30
NO
JIB VALVE
C19JSV GR/WH
TS13
JOYSTICK CONTROL CARD
DRIVE & STEERING
JC3
JC2
WH
2
CR27
NC
CR13
NC
CR13
CE
LIFT/
DRIVE
OPTION
L1
TS15
WH
WH
TS9
TS8
TS7
TB44
TB19
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
6
REV B
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
July 2007
RD/BK
OR/BK
BK
BRN
July 2007
6-9
6 - 10
July 2007
REV A

Deutz F3L 1011F Models
K
RD-H6+ - C23-1
BL/WH-38D - C23-3
BK-22C - C23-4
BK-C7-1 - C23-5
RD-TS51 - C23-6
RD-TS55 - C23-7
GN/BK-16B - C23-8
BR - GND - C23-12
12 V
C7B
C1B C2B C3B C4B
BK-CR1#86
OR/BK-41B
BK-33D
RD-27B
BR-GND.
RD-CR2#30
WH-23B
RD-KS1-2 S.P.
BK/RD-S.P.
BK/WH-S.P.
BK-S.P.
BK/RD CR3-#30
BK-ISM#3
WH/RD-C6-32
D6
RD-ISM#4
RED-CR1#30
WH-ISM #7
BK-CR5#30
WH-CR2#87
CB2-SP
GN/BK-C23-8
RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
CB1 - SP
GR/WH-SP
GR/BK-S.P.
GR-S.P.
GN/BK-H6OR/BK-S.P.
OR-S.P.
BK/RD-CR23#87
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
44B+RD/BK-C6-19 RD/BK-S.P.
RD-S.P.
B
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
5 GROUND
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
IGN./START
MODULE
CR2
RD C4B-11
BR (GROUND)
RD C4B-12
BRN GND
BK-22A
P1
RD-CB2
KEY SWITCH
KS1
NC
WH-23A
RD-42A
RD-27A
RD-C23-6
TS51
NC
LABEL
DESCRIPTION
1
B1
EMERGENCY STOP BUTTON
KEY SWITCH
AUXILIARY SWITCH
ENGINE START SWITCH
RD-H6+
OR/RD-H6-
FUNCTION ENABLE
PLATFORM ROTATE SWITCH
WH-21A
HM
BR (GROUND)
PLATFORM LEVEL SWITCH

BOOM EXTEND/RETRACT SWITCH
PRIMARY BOOM UP/DOWN SWITCH
TURNTABLE ROTATE SWITCH
JIB BOOM UP/DOWN SWITCH
CIRCUIT BREAKER, CONTROLS, 15A
CIRCUIT BREAKER, ENGINE, 15A
CIRCUIT BREAKER, OPTIONS, 20A
RESISTOR, 5 OHM, BOOM FUNCTION
L45
L2
BL/WH-C5-15
BL/WH-ISM#10
RD/WH-3A
RD/BK-2A
RD-1A
TS61
TS63
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
TS52
CB3
BK/WH-34A
TS58
CB1
CB2
TS55
RD- 20A
P1
KS1
TS51
TS52
P1
KS1
42730
13037
TS55
13037
16397
13037
13037
16397
16397
13037
TS57
TS59
TS63
TS61
TS62
TS58
CB1
CB2
CB3
R1
VOLT METER GAGE

OIL PRESSURE GAGE
OIL TEMP. GAGE
R2
G1
G2
G3
R2
G1
G2
G3
STARTER AID
L28
56298
HOUR METER
IGN. START RELAY
IGN. POWER RELAY
HIGH IDLE (RPM) CUTOUT RELAY
HM
CR1
CR2
CR3
HM
CR1
CR2
CR3
RPM RELAY
CR4
CR4
CR17
CR17
COOLING FAN RELAY

PLATFORM OVERLOAD ALARM
PLAT OVERLOAD MODULE
PLAT OVERLOAD LED
TS59
PART #
CB1
CB2
CB3
R1
RESISTOR, 7.5 OHM,TURNTABLE FUNCTION
TS62
TS56
RD- 20C
RD-CR17#30
WH-4
WH/RD-6
WH/BK-5
D13
BK-ISM#1
WH/BK-25A
WH/RD-26A
BK/RD-35A
CR5
BK/RD-9B
WH-21A
TS57
CR17
CR23
RD-C23-7
BK-C6-25
G3
G2
G1
R2
BK-22B
GR-43D
RD-CB3 SP
D14
RD-CB3 SP
CR1
H6
LIMIT SWITCH POWER

GEN. OPTION
JDALARM JIB
HORN
C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
C132PLI
STEER LEFT
STEER RIGHT
RPM
GLOW PLUG
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
SPARE
TILT ALARM
AUX. PWR.
WATER TEMP. SENDER
OIL PRESSURE SENDER
ENGINE POWER
KEYSWITCH PWR/FB
PWR. TO PLAT.
IGNITION PWR.
12 VOLT BATTERY POWER
JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.
C133PLA
PLAT. LEVEL DN.
PLAT. LEVEL. UP
DRV. ENA. LT.
DRIVE LIGHT OPTION

BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP
DRIVE LIGHT OPTION RELAY
GN/BK-16A
BL/RD-S.P.
RD-ISM#6
WH-ISM#9
RD-24B
C6
GN/BK-L45-
GR/BK-S.P.
GR/BK-2B
GR-CR5#86
RD-H6+
OR/BK-ISM#2
WH-CR2#86
BL/WH-L2
H6
U33
L45
RD- 24A
BK-C5-5
C5
19/18 CABLES
FUNCTIONS
ENGINE
RD-C23-1
RD-42B
R1
GROUND STUD
46
GR/WH-C2B-7 45
GR/WH-C6-39
GR/BK-C2B-6 44
43
GR-C2B-5
OR/RD-C2B-4 42
RD-C6-23
OR/BK-C2B-3 41
OR/BK-C5-2
40
OR-C2B-2
OR-C6-40
BK/WH-C5-10
BL/RD-C2B-1 39
BL/WH-C23-3
BL/WH-C1B-12 38
BL/BK-C6-37
BL/BK-C1B-11 37
36
BL-C6-36
BL-C1B-10
BK/RD-C1B-9 35
BK/WH-C5-22
BK/WH-C1B-8 34
33
BK-C1B-7
WH/RD-C5-23
WH/RD-C1B-6 32
WH/BK-C5-20
WH/BK-C1B-5 31
30
WH-C5-21
WH-C1B-4
RD/WH-C1B-3 29
RD/BK-C6-28
RD/BK-C1B-2 28
27
RD-C6-27
RD-C1B-1
26
WH/RD-C5-14
25
WH/BK-C5-16
24
RD-C5-1
23
RD-C5-19
WH-C7B-2
22
BL/WH-C6-30
BK-C23-4
21
WH-C5-3+C5-11 WH-C6-34
20
CB3-SP
RD- 12VOLT
GR/WH-C4B-7 19
GR/BK-C6-18
GR/BK-C4B-6 18
17
GR-C6-17
GR-C4B-5
OR/RD-C4B-4 16
OR/BK-C6-15
OR/BK-C4B-3 15
14
OR-C6-14
OR-C4B-2
BL/RD-C6-13
BL/RD-C4B-1 13
BL/WH-C3B-12 12
BL/BK-C3B-11 11
BL-C3B-10
10
BK/RD-C3B-9 9
BK/WH-C6-8
BK/WH-C3B-8 8
7
BK-C6-7
BK-C3B-7
WH/RD-C6-6
WH/RD-C3B-6 6
WH/BK-C6-5
WH/BK-C3B-5 5
4
WH-C6-4
WH-C3B-4
RD/WH-C6-3
RD/WH-C3B-3 3
RD/BK-C3B-2 2
RD/BK-C6-2
RD-C6-1
1
RD-C3B-1
RD
12V TO PLAT
C23
U33
PLATFORM LOAD
BR-GND
3 STUD
BK-C23-5
1
2 WH-23C
WH-21B
BK/RD-35B
CR3
OR-C6-33
BR-GND+C6-26
BK-C6-16
RD- 20B
RD- P1 E-STOP
OR/BK-15A
OR-14A
GR-17A
CR4
GR/WH-19A
GR/BK-18A
BK/RD-C5-9
GROUND STUD
BR
WIRING
HARNESS:
TO BASE
ALL BR WIRES
Part No. 102521
S-40 S-45
6 - 11
July 2007

6 - 11
6 - 12
July 2007
Platform Control Box Wiring Diagram- ALC-500

6 - 14
6 - 13
P26BAT BK
P24FS WH
P24FS WH
11
1
C132PLI BK C1P-12
RD P2
RD H1
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH
C4P-7 AND TS8
BRN
C4P(BR)
C3P(GR)
C2P(BK)
F.S.
OPT.
LS18
C1P(GY)
RED/BLK-28
H1
C19JSV GR/WH JIB

C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
D39
F.S.
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
DRIVE LT BK/RD C3P-9
C45GEN GR/WH C2P-7
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE GR/BK C2P-6
C6TRF WH/RD C3P-6

C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
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
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
C28TTA RD/BK C1P-2
JIB
C9P
RED-TILT
BRN
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
C3P
C3P
D40
C7P
BATGND C7P-3
BRN
Part No. 102521

S-40 S-45
6 - 14
C4P
GN/BK C4P-4
12V BATT
19/18 CONTROL CABLE
TILT
ALALRM
C1P
C28TTA RD/BK C1P-2
HARNESS
PBOX WIRING
J2
J1
J3
GN/BK L48
ALC-500
RED-TILT
45383
89353
TILT ALARM
ALC-500
H1
C2P
PART NUMBER
COMPONENT INDEX
N
M
L
K
J
I
H
G
F
E
D
C
B
A
C7P
July 2007
REV A

July 2007
REV B

HARNESS
PBOX WIRING
7
TS48/ TS49
WORK/ DRIVE LITE
6
TS47
GENERATOR
(OPTION)
TS15
DRV.ENA
5
4
5
4
2
JC2
JC3
DLITE/ RD WL2
TS13
PRIMARY
BOOM
EXTEND/
RETRACT
2
1
75565
56298
66812, 73805
66813, 66816
42730
13037
TS4
TS6
TS7
TS8
TS9
TS13
HI/L0 RPM SWITCH

GLOW PLUG OPTION
JIB UP/DOWN SWITCH
PRIMARY BOOM EXTEND/RETRACT SWITCH
27378
56298
16397
13037
13037
13037
WH-24
DRIVE LT BK/RD-C3P-9
13037
27378
27378
DETAIL A: LIFT/DRIVE OPTION

REPLACE WIRE WITH THIS WIRING DIAGRAM
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BK-22
BRN BATGND
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
RD/BK H1
GN/BK H1
WH-24
RD
GR/WH-45
WH-24
BRN
WH-JIB
BK-7
BK/WH-8
BL/BK-DE2 J1-7
RD WL1
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
RD P3
WH TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
OR R40LS1
(SPLICE TO R40LS1)
NC
TS2
START
CR27
WH TS7
P22BAT BK C7P-1
TS6
TS1
GLOW PLUG
AUXILIARY PUMP
NC
NO
TS4
HIGH/LOW
RPM
(GND STUD)
RD LS18
WH-23
BK-22
P26BAT BK C9P-1
BK/RD-35
WH-24
BK-33
RD
RD-25
C34SA BK/WH C1P-8
WH-24
C27AUX RD C1P-1
WH-JIB
JDALARM GR/BK-44 C2P-6
C19JSV GR/WH
C17JU GR C4P-5
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
OR-14
OR/BK-15
RD P2
GR-43
TS8
JIB
WH
TS7
PLATFORM
ROTATE
DRIVE PROPORTIONAL JOYSTICK

DRIVE ENABLE LED
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH
L48
GR
GR/BK
JC3
L1
P2
P3
TS1
TS2
L4
L1
WH
62390
+
+
CR13
RD
TS9
PLATFORM
LEVEL
PART NUMBER
BOOM PROPORTIONAL JOYSTICK:

PRIMARY UP/DN , TURNTABLE ROTATE
TS15 DRIVE ENABLE SWITCH

TS47 GENERATOR SWITCH ( OPTION )
TS48-9 WORK/DRIVE LIGHT ( OPTION )
WH
P3
HORN
COMPONENT INDEX
JC2
RD
RD
REMOVE FOR GENERATOR OPTION
P2
EMERGENCY STOP
CE SEE DETAIL A
NOTE:
1) DASHED LINES INDICATE OPTION WIRES.
Part No. 102521
S-40 S-45
6 - 15
July 2007

6 - 15
6 - 16
July 2007
Perkins 704-30 Models (before serial number 7472)
6 - 18
6 - 17
July 2007
REV B
A
C28TTA RD/BK
TB41
RD/BK
C2-3
OR/BK
P26ESTP BK
P2
LS18
C9-1 BK
FS1
BK-(FS)
RD
P24FS WH
WH
C1-12
C1-9
8
9
10
CR2
C6-34
C5-14
3
5
HM
G1
CR3
NO CR4
BK/RD-C5-8
WH/RD
WH-24
WH-24
C5-15
WH/BK
STARTER
OTS
OPS
NC
NO
BRN
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR
OPTION
GLOW PLUG
CONTROLLER
GLOW PLUG
OIL TEMP GAUGE
Part No. 102521
OIL TEMP
SWITCH
S-40 S-45
OIL PRESSURE
SWITCH
+
-
OIL PRESSURE GAUGE
NOTE:
FUEL RELAY
VOLT METER
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER
RELAY
AUXILIARY PUMP
TILT ALARM
LEVEL SENSOR
FLASHING BEACONS
OPTION
SERVICE HORN
SERVICE HORN
RELAY
HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)
6 - 18
AUX
PUMP
BK
FAN
C5-16
WH-21
FB
GR/WH-45
BK-33
CR17
H2
G3
G2
PR1
NO
TB26
TB25
CONTROLLER
C5-5
RD-27
WH
RD
PR1
NO
C6-27
RD/BK-28
RD-P134
BK-43
REGULATOR
IND.
C6-16
STA.
C6-26
BAT.
-
C6-25
BAT.
+
CR17
NO
C6-33
12 V
DC
OR/BK-41
EXCT.
C5-2
C5-3
ALTERNATOR
C35ESPD BK/RD
CR2
NO
TB21
OTS
NO
HIGH RPM(FS)
CR1
TB35
L5
BK/RD
CR1
NO
HIGH RPM
TB45
START RELAY
TACHOMETER
START INPUT
IGN./START
AUX. ON
GROUND
MODULE
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
C6-39
1
2
3
4
5
6
TB24
C6-28
C6-23
CR5 CR5
NO
TS55
LOW RPM
TB28
RD
C45GEN GR/WH
TB133
CB3
C2-7
GENERATOR
ENGINE
TB23
L45
20AMP.
SEE NOTE 2
TB33
D6
15AMP.
L28
C33STR BK
START
BK
AUXILIARY
PUMP
RD
TB27
TB20
L24
TB34
C1-7
ENGINE
C27AUX RD
P23BAT WH
TS52
TS51
4
CB1
TS4
TS2
C1-1
C7-2
RD
C28TTA RD/BK
H6
TS17
RD
RD
C133PLA OR/RD
U33
D40
C1-2
12
C9-2
START
D39
L48
C4-4
L4
H1
TB43
PLAT
GRD
P3
HORN
TB132
1
TB22
WH-(FS)
BK
SEE NOTE 2
C43HRN GR
KS1
P25FS RD
AUXILIARY
PUMP
C7-1
TB134
RD
RD
RD
C9-3
TS1
C2-5
P22BAT BK
C1-12
P1
C132PLI BL/WH
CB2
15AMP.
C134PWR OR/RD C2-4

C41RPM OR/BK
RD-(FS)
DRE LED BL/RD

DRE B BL/BK
DRE A BL/WH
14
2
1
11
12
9
10
11
17
18
20
19
16
15
C1P-10
C1P-11
C1P-6
C1P-5
C1P-4
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
BRN-2
C3P-6
LEFT
TROTATE
RIGHT
C3P-5
C3P-4
C3P-1
C3P-2
C3P-3
7.5
C5TRR WH/BK
C4TRL WH
C2P-3
C41RPM OR/BK
15
16
WH
RKOUT 6
RD
13
BL
OR
BRN
YOUT 5
GND 2
PWR 3
OR
6
YOUT 5
XOUT 4
BRN
6
7
8
14
13
12
C4P-1
UP
PRIMARY
DOWN BOOM
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
C5-21
C5-20
C6-32
C5-23
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C30EDC+ WHA
C31EDC- WH/BK
C32BRK WH/RD
WH
BK
WH
BK
BK
WH
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
C6-3
C6-13
C40LS1 OR
C6-19 RD/BK
C6-40
GROUND
DRIVE EDC FORWARD

DRIVE EDC REVERSE
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
C
TRAVEL ALARM OPTION
BRAKE RELEASE VALVE
STEER RIGHT
STEER LEFT

TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM
FLOW CONTROL

DRIVE LIMIT SWITCH
DRIVE ENABLE
LIMIT SWITCH
BOOM EXTEND
BOOM RETRACT
PLAT LEVEL UP
PLAT LEVEL DOWN
6 - 19
S-40 S-45
Part No. 102521
BK
PWR 3
1
GND 2
BRN
1
2
3
C40LS1 OR
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
C6-7
C6-8
C6-14
C6-15
JIB VALVES
NOTE:
P24FS WH
P24FS WH
4
C2P-2
JIB BOOM
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
EXTEND
BOOM
RETRACT
UP
DOWN
C18JD GR/BK
C17JU GR

7
H3
2
P26ESTP BK
C18JD GR/BK
JDALARM GR/BK
C4P-6
C6-18
C6-17
NONC
R2
C17JU GR
PLAT
ROTATE
NOHC
H4
SJ1-WH
C6-30
8
NOHC
BRN
C3P-7
C3P-8
EXTEND BOOM
C4P-2
UP
PLATFORM
DOWN LEVEL C4P-3
RETRACT
RD
RD
C4P-5
GR/BK-44 C2P-6
DOWN
UP JIB BOOM
TB3 TB2 TB6
TB30
TB31
TB37
TB32
TB5
DOWN
UP JIB BOOM
RIGHT
TB8
TB14
TB18
TB22
AMP
Deutsch
LEFT
RIGHT PLAT
ROTATE
2
4
LEFT
TB19
C19JSV GR/WH
3
2
TB44
5
TB7
TB15
TB17
TS62
TS61
TB36
TB4
TB1
TB13
TB40
3
C4P-7
TS57
J2
J1
JIB VALVE
JC2
BRN
J1
J1
CR30
NO
R1
JC3
DRIVE & STEERING
WH
4
TS63
TS59
TS58
TS13
TS9
TS8
TS7
J3
C19JSV GR/WH
CR27
NC
CR13
NC
CR13
CE
LIFT/
DRIVE
OPTION
L1
TS15
WH
WH
6
4
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
1
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
6
REV B
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
July 2007
RD/BK
OR/BK
BK
July 2007
6 - 19
6 - 20
July 2007
REV A

RD/BK-C6-28
RD-C6-27
WH/RD-C5-14
WH/BK-C5-16
WH-C7B-2
BL/WH-C6-30
WH-C5-3+C5-11
RD- 12VOLT
12 V
C7B
C1B C2B C3B C4B
BK/WH-C6-8
BK-C6-7
WH/RD-C6-6
WH/BK-C6-5
WH-C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1
WH-CR2#86
BL/WH-L2
BK/RD CR3-#30
BK-ISM#3
WH/RD-C6-32
C6
D6
RD-ISM#4
RED-CR1#30
BK-CR5#30
WH-CR2#87
CB2-SP
GR/BK-C23-8
BK/RD-CR23#87
44B+RD/BK-C6-19
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.
DRIVE LIGHT OPTION

BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP
IGN./START
MODULE
BK-22A
P1
RD-CB2
KEY SWITCH
KS1
TS51
NC
3
NC
WH-23A
RD-42A
RD-27A
RD-C23-6
1
B1

KEY SWITCH
AUXILIARY SWITCH
ENGINE START SWITCH
WH-21A
HM
BR (GROUND)
L45
FUNCTION ENABLE
L2
BL/WH-C5-15
BL/WH-ISM#10
RD/WH-3A
RD/BK-2A
RD-1A

TS61
TS63
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
BK/WH-34A
TS52
+
-
RD- 20C
RD-CR17#30
WH-4
WH/RD-6
WH/BK-5
TS62
CB3
L28
TS58
TS55
D13
CR3
BK-C6-16
LABEL
DESCRIPTION
RD-H6+
OR/RD-H6-
CB1
CB2
TS59
RD- 20A
P1
KS1
42730
13037
TS55
13037
16397
13037
13037
16397
16397
13037
TS57
TS59
TS63
TS61
TS62
TS58
CB1
CB2
CB3
R1
VOLT METER GAGE

OIL PRESSURE GAGE
OIL TEMP. GAGE
R2
G1
G2
G3
R2
G1
G2
G3
STARTER AID
L28
56298
HOUR METER
IGN. START RELAY
IGN. POWER RELAY
HM
CR1
CR2
CR3
HM
CR1
CR2
CR3
RPM RELAY
CR4
CR4
CR17
CR17
COOLING FAN RELAY

PLAT OVERLOAD LED
RD- 20B
RD- P1 E-STOP
OR/BK-15A
PART #
P1
KS1
TS51
TS52
CB1
CB2
CB3
R1
RESISTOR, 7.5 OHM,TURNTABLE FUNCTION
RD- 24A
OR-C6-33
BR-GND+C6-26
RD C4B-12
BRN GND
WH/BK-25A
WH/RD-26A
BK/RD-35A
CR5
CR23
TS57
CR17
BK/RD-9B
BK-22B
GR-43D
BK-ISM#1
BK/RD-35B
RD C4B-11
RD-C23-7
CR2
WH-21B
RD-CB3 SP
R2
BK-C6-25
BK-C5-5
BR (GROUND)
D14
RD-CB3 SP
CR1
G3
G2
G1
WH-21A
BR-GND
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
5 GROUND
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
RD-ISM#6
WH-ISM#9
RD-24B
H6
LIMIT SWITCH POWER

GEN. OPTION
JDALARM JIB
HORN
RD-KS1-2 S.P.
C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
BL/RD-S.P.
C132PLI
STEER LEFT
STEER RIGHT
BK/RD-S.P.
RPM
BK/WH-S.P.
GLOW PLUG
BK-S.P.
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
SPARE
TILT ALARM
RD-S.P.
AUX. PWR.
WH/RD-S.P.
WATER TEMP. SENDER
OIL PRESSURE SENDER
WH/BK-S.P.
RD-S.P.
ENGINE POWER
WH-SP.+WH46A KEYSWITCH PWR/FB
BK-S.P.
PWR. TO PLAT.
WH-S.P.
IGNITION PWR.
CB1 - SP
GR/WH-SP
JIB VALVE
GR/BK-S.P.
PLAT. ROT. R.
GR-S.P.
PLAT. ROT. L.
C133PLA
GR/BK-H6OR/BK-S.P.
PLAT. LEVEL DN.
OR-S.P.
PLAT. LEVEL. UP
DRV. ENA. LT.
BK-CR1#86
OR/BK-41B
BK-33D
RD-27B
BR-GND.
RD-CR2#30
WH-23B
GR/BK-S.P.
GR/BK-2B
GR-CR5#86
RD-H6+
OR/BK-ISM#2
C5
12V TO PLAT
19/18 CABLES
FUNCTIONS
ENGINE
3 BR-GND STUD
1 BK-C23-5
2 WH-23C
R1
GROUND STUD
OR/BK-C6-15
OR-C6-14
BL/RD-C6-13
RD
BK/WH-C5-22
BK-ISM#3
WH/RD-C5-23
WH/BK-C5-20
WH-C5-21
GR/BK-C6-18
GR-C6-17
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
RD-C5-1
RD- C5-19
23
22
BK-C23-4
21
WH-C6-34
CB3-SP
20
GR/WH-C4B-7 19
GR/BK-C4B-6 18
17
GR-C4B-5
OR/RD-C4B-4 16
OR/BK-C4B-3 15
OR-C4B-2
14
BL/RD-C4B-1
13
BL/WH-C3B-12 12
BL/BK-C3B-11 11
BL-C3B-10
10
9
BK/RD-C3B-9
BK/WH-C3B-8 8
7
BK-C3B-7
WH/RD-C3B-6 6
WH/BK-C3B-5 5
4
WH-C3B-4
RD/WH-C3B-3 3
2
RD/BK-C3B-2
1
RD-C3B-1
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1
RD-C6-23
OR/BK-C5-2
OR-C6-40
BK/WH-C5-10
BL/WH-C23-3
BL/BK-C6-37
BL-C6-36
RD-H6+ - C23-1
BL/WH-38D - C23-3
BK-22C - C23-4
RD-C23-1
BK-C7-1 - C23-5
RD-42B
RD-TS51 - C23-6 GN/BK-L45RD-TS55 - C23-7 GN/BK-16A
GN/BK-16B - C23-8
BR - GND - C23-12
U33
C23
PLATFORM
LOAD
GR/WH-C6-39
H6
U33
L45
OR-14A
GR-17A
CR4
GR/WH-19A
GR/BK-18A
BK/RD-C5-9
GROUND STUD
BR
WIRING
HARNESS:
TO BASE
ALL BR WIRES
Part No. 102521
S-40 S-45
6 - 21
July 2007

6 - 21
6 - 22
July 2007

6 - 24
6 - 23
P26BAT BK
P24FS WH
C132PLI BK C1P-12
RD P2
RD H1
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C19JSV GR/WH
C4P-7 AND TS8
BRN
C4P(BR)
C3P(GR)
C2P(BK)
F.S.
OPT.
LS18
C1P(GY)
RED/BLK-28
H1
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
C45GEN GR/WH C2P-7
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE GR/BK C2P-6
C6TRF WH/RD C3P-6

C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
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
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
C28TTA RD/BK C1P-2
C3P
C3P
D40
F.S.
D39
Part No. 102521
P24FS WH
C9P
C7P
RED-TILT
BRN
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
GN/BK L48
C7P
BATGND C7P-3
12V BATT
19/18 CONTROL CABLE
TILT
ALALRM
11
JIB
C4P
GN/BK C4P-4
BRN
C1P
C28TTA RD/BK C1P-2
J3
RED-TILT
HARNESS
PBOX WIRING
J2
J1
ALC-500
45383
89353
TILT ALARM
ALC-500
H1
C2P
PART NUMBER
COMPONENT INDEX
N
M
L
K
J
I
H
G
F
E
D
C
B
A
S-40 S-45
6 - 24
July 2007
REV A

July 2007
REV B

HARNESS
PBOX WIRING
7
TS48/ TS49
WORK/ DRIVE LITE
6
TS47
GENERATOR
(OPTION)
TS15
DRV.ENA
5
4
5
4
2
JC2
JC3
DLITE/ RD WL2
TS13
PRIMARY
BOOM
EXTEND/
RETRACT
2
1
WH-24
CR13
75565
56298
66812, 73805
66813, 66816
42730
13037
TS4
L24
TS7
TS8
TS9
TS13
HI/L0 RPM SWITCH

GLOW PLUG INDICATOR
JIB UP/DOWN SWITCH
27378
56298
16397
13037
13037
13037
13037
27378
27378
4
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BK-22
BRN BATGND
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
RD/BK H1
GN/BK H1
WH-24
RD
GR/WH-45
WH-24
BRN
WH-JIB
BK-7
BK/WH-8
BL/BK-DE2 J1-7
RD WL1
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
WH TS1
RD P3
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
OR R40LS1
(SPLICE TO R40LS1)
1
TS2
START
TS1
AUXILIARY PUMP
NC
TS8
JIB
TS4
HIGH/LOW
RPM
CR27
WH TS7
P22BAT BK C7P-1
NO
L24
GLOW PLUG
NC
(GND STUD)
RD LS18
BK-22
P26BAT BK C9P-1
WH-23
RD-TILT
BK/RD-35
WH-24
BK-33
RD
RD-25
C34SA BK/WH C1P-8
BRN
WH-24
C27AUX RD C1P-1
WH-JIB
C17JU GR C4P-5
C19JSV GR/WH
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
OR-14
OR/BK-15
RD P2
GR-43
TS7
PLATFORM
ROTATE

DRIVE ENABLE LED
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH
L48
WH
GR/BK
JC3
L1
P2
P3
TS1
TS2
L4
L1
WH
62390
+
+
GR
TS9
PLATFORM
LEVEL
PART NUMBER


WH
P3
HORN
COMPONENT INDEX
JC2
RD
RD
P2
EMERGENCY STOP
CE SEE DETAIL A
NOTE:
Part No. 102521
S-40 S-45
6 - 25
July 2007

6 - 25
6 - 26
July 2007
Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)
Perkins 404-22 Models (from serial number 7472 to 12509)
6 - 28
6 - 27
July 2007
REV A
A
BL/WH
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
BK
F18
FS1
BK-(FS)
C9-1 BK
HIGH RPM(FS)
C3P-9
GENERATOR
WH
WH
DRIVE LIGHT
TS4
C2-7
BK
BK
C1-9
RD
LOW RPM
FUNCTION ENA.
HIGH RPM
BK/RD
C6-39
C2B-4
GR/WH-45
CR3
CR4
BK/RD-C5-8
C4B-11
C5-11
RD
RD
S1
Y29
G1
L29
NO
L29
BRN
C6-26
NC
BRN
HIGH IDLE RELAY
HIGH RPM SOLENOID
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
Part No. 102521
FUEL SOLENOID RELAY
C.E. OPTION ONLY
GLOW PLUG OPTION
WATER TEMP GAUGE
THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION.
WATER TEMP
SWITCH
OIL PRESSURE
SWITCH
NOTE:
OIL PRESSURE GAUGE
RPM FILTER
VOLT METER
FUEL RELAY
HOUR METER
IGN./START RELAY
STARTER MOTOR
EMISSION CONTROL
AUXILIARY PUMP
AUXILIARY POWER
RELAY
TILT ALARM
LEVEL SENSOR
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
+
-
COOLING FAN
(OPTION)
S-40 S-45
C35ESPD BK/RD
C45GEN GR/WH
DLITE OR/RD
C21IGN2
C5-22
CR23
CR23
NO
NO
NO
PR3
WH/RD
HM
_
PR3
NO
C5-14
J144-4
WH/BK
J1 44-6
BK
G6
M2 PUMP
TB35
L2
G3
S2
STARTER
AUX
C34SA BK/WH
TB34
TB26
C5-16
PR2
S7
H2
C5-13 WH
WH-21
BK-33
RD-27
WH
RD
3MF
PR2
TS55
TB45
PBOX GND
C5-5
C6-27
G2
PR1
FB
M1
REGULATOR
IND.
TB21
CR2
NO
TB25
PR1
NO
STA.
FAN
RD/BK-28
RD-134
CR17
C6-33
BAT.
-
CR17
NO
CR2
CR1
CR1
NO
BK-43
EXCT.
C6-25
OR/BK-41
ALTERNATOR
CR5
C6-16
C6-34
C5-2
C5-3
OTS
NO
C6-23
CR5
NO
TB24
C6-28
CB3
BK
TB28
RD
20AMP.
1 START RELAY
2 TACHOMETER
3 START INPUT
IGN./START
4 AUX. ON
MODULE
5 GROUND
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
D6
TB133
6 - 28
TS17
L30
TB33
TB23
L45
ON GLOW
PLUG
H6
15AMP.
C33STR BK
RD
CB1
TS56
ENGINE
TB27
BK
TS52
START
RD
TS51
PUMP AUXILIARY
U33
12
C27AUX RD
P23BAT WH
C28TTA RD/BK
C43HRN GR
GRD
BAT.
+
TS48
RD
C133PLA OR/RD
L30
C1-8
C1-7
PUMP AUXILIARY
C1-1
C7-2
C1-2
C4-4
TB43
WORK LIGHT
TS1
L48
D40
D39
TS6
START ENGINE
H1
C2-5
C7-1
C1-12
TB22
PLAT
12 V
DC
TS49
WH
ON GLOW
PLUG
P22BAT BK
C132PLI BL/WH
L4
TB132
KS1
FUSE 10A
RD
RD
TB20
P24FS WH
TS2
TB134
RD
P1
P25FS RD
C9-2
HORN
C2-4
CB2
15AMP.
C9-3
WH-(FS)
C28TTA RD/BK
P3
NOTE:
TB132 IS WAGO TERMINAL BLOCK 42
TB TB133
134 ISISWAGO
BLOCK 16
42
WAGO TERMINAL
TERMINAL BLOCK
TB TB134
133 ISISWAGO
BLOCK 38
16
WAGO TERMINAL
TERMINAL BLOCK
RD-(FS)
RD
C134PWR RD
C41RPM OR/BK
P2
LS18
REV A
C29MS
DRE LED BL/RD

DRE B BL/BK
DRIVE ENABLE
DRE A BL/WH
BL
WH
14
13
OR
RD
BK
12
11
15
16
19
20
18
17
11
10
6
7
8
14
13
12
C2P-3
C1P-4
C1P-5
C1P-6
C1P-3
C1P-11
C1P-10
C3P-6
C3P-5
C3P-4
7.5
BRN-2
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C37STCC BL/BK
C36STC BL
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
TROTATE
RIGHT
LEFT
C4P-1
C3P-3
C3P-2
C3P-1
C40LS1 OR
C13DRE BL/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
PRIMARY BOOM
DOWN
UP
C2P-2
C8PBR BK/WH
C7PBE BK
EXTEND
JIB BOOM
RETRACT
C3P-8
C14PLU OR
C3P-7
C4P-2
C15PLD OR/BK
C5-21
C5-20
C6-32
C5-23
C5-19
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C13DRE BL/RD
C6-3
C6-13
C6-15
C6-14
C6-8
C6-7
C40LS1 OR
6
C6-40
C6-18
C6-17
C30EDC+ WH
C6-30
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C6-19 RD/BK
C7PBE BK
C8PBR BK/WH
C14PLU OR
C15PLD OR/BK
C18JD GR/BK
C17JU GR
7
WH
BK
WH
BK
WH
BK
GROUND
DRIVE EDC FORWARD
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
BRAKE RELEASE VALVE
MOTOR STROKE
STEER RIGHT
STEER LEFT
TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
PRIMARY BOOM
FLOW CONTROL

DRIVE LIMIT SWITCH
DRIVE ENABLE
LIMIT SWITCH
BOOM EXTEND
BOOM RETRACT
PLAT LEVEL UP
PLAT LEVEL DOWN

JIB VALVES
6 - 29
S-40 S-45
C41RPM OR/BK
15
16
7
RKOUT 6
OR
7
YOUT 5
BRN
5
4
4
PWR 3
1
GND 2
XOUT 4
YOUT 5
BRN
GND 2
PWR 3
BRN
P24FS WH
P24FS WH
P26ESTP BK
3
4
BOOM
C4P-3
JDALARM GR/BK
PLATFORM LEVEL
RETRACT
EXTEND
UP
DOWN
C2P-6
C18JD GR/BK
DOWN
UP JIB BOOM
C4P-6
C17JU GR
DOWN
UP JIB BOOM
NOTE:
NCHO
Part No. 102521
8
NOHC
BRN
NOHC
Y51
Y2
Y27
Y3
Y4
Y29 Y23
Y13
Y21 Y22
Y12
H4
Y25
Y26
Y19 Y20
Y17 Y16
H4
SJ1-WH
TB22
TB30
TB31
TB32
TB37
TB36
TB4
4
C4P-5
RD
5
TB6
TB14
R2
R1
TB29
TB3
TB8
TB17
TB5
TB2
TB13
TB40
TB7
TB15
TB1
RIGHT
PLAT ROTATE
LEFT
TB44
C19JSV GR/WH
TB18
GR/BK-44
DOWN
JIB BOOM
UP
C4P-7
TS58
TB19
RIGHT
PLAT ROTATE
LEFT
JIB VALVE
RD
J1
J1
J1
J3
2
TS14
L1
TS15
JC3
DRIVE & STEERING
3
J2
TS62
TS61
TS63
TS59
TS57
TS13
TS9
TS8
TS7
CR27
NC
CR13
NC
CR13
CR30
CE NO
LIFT/
DRIVE
OPTION
C19JSV GR/WH
WH
WH
JC2
WH
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
July 2007

RD/BK
BL/WH
BK
OR/BK
BRN
July 2007
6 - 29
6 - 30
July 2007
Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models
6 - 32
6 - 31
July 2007
REV B
A
N
BL/WH
RD/BK
TB41
C2-3
OR/BK
P26ESTP BK
BK
F18
LS18
P2
FUSE 10A
FS1
C9-1 BK
BK-(FS)
RD-(FS)
C9-3
P25FS RD
WH-(FS)
C9-2
P24FS WH
TS6
DRIVE LIGHT
TS17
TS4
HIGH RPM(FS)
C3P-9
GENERATOR
WH
GLOW
PLUG
L30
L30
C2-7
C1-8
C1-7
C1-1
C7-2
C1-2
C4-4
C2-5
C7-1
C2-4
PUMP AUXILIARY
ENGINE
D39
WH
TS1
L48
H1
ON
START
L4
WORK LIGHT
P3
HORN
C1-12
TB132
BK
BK
TB134
RD
P1
RD
RD
C1-9
15AMP.
P22BAT BK
C134PWR OR/RD
C132PLI BL/WH
C41RPM OR/BK
CB2
TS2
D40
WH
C28TTA RD/BK
RD
Note:
TB132 is WAGO terminal block 42
TS48
TB43
2
C35ESPD BK/RD
GR/WH-45
CR4
RD
L29
BK/RD-C5-8
RD
S1
NO
C4B-9
C4B-11
HIGH IDLE RELAY
70A FUSE ADDED AT SERIAL NUMBER 12978

C.E. OPTION ONLY
WHEN C.E. OPTION IS NOT INSTALLED A JUMPER HARNESS
CONNECTS PIN 4 TO PIN 5 AND PIN 6 TO PIN 7
LS18 - PLATFORM OVERLOAD SWITCH
HIGH RPM SOLENOID
3
4
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
GLOW PLUG OPTION
WATER TEMP GAUGE
OIL TEMPERATURE
SWITCH
THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION
OIL PRESSURE
SWITCH
OIL PRESSURE GAUGE
RPM FILTER
ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM

Part No. 102521
C6-39
C4B-12
C4B-10
S2
FUEL RELAY
VOLT METER
S-40 S-45
HOUR METER
IGN./START RELAY
STARTER MOTOR
EMISSION CONTROL
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
+
-
COOLING FAN
(OPTION)
NOTE:
6 - 32
G1
NC
1.
L29
CR3
Y29
HM
BRN
BR
PR3
+
_
NO
NO
PR3
NO
C5-14 WH/RD
H2
FAN
G3
J144-4
IND.
CR23
CR23
NO
TB26
G6
STARTER
M2 PUMP
BK
REGULATOR
J144-6
RD
NO
M1
C5-16 WH/BK
PR2
PR2
S7
FB
STA.
WH-21
BK-33
RD-27
RD
WH
NO
C5-13 WH
C5-5
RD/BK-28
RD-134
BK-43
BK
OR/BK-41
3MF
PR1
PR1
BAT.
-
BAT.
+
12 V
DC
CR17
TB25
G2
TB35
FUSE 70A
WH
C5-22
WH
C5-2
C5-3
EXCT.
CR17
NO
L2
3
NO
ALTERNATOR
TB21
CR2
NO
BL/WH
OTS
CR2
CR1
CR1
NO
CR5
TB34
C2B-4
CR5
NO
RD
BK/RD
CB3
20AMP.
LOW RPM
FUNCTION ENA.
HIGH RPM
TB24
DLITE OR/RD
RD
C34SA BK/WH
TB28
TB45
1 START RELAY
2 TACHOMETER
3 START INPUT
4 AUX. ON
IGN./START
5 GROUND
MODULE
6 BATTERY
7 KEY PWR.
8 KEY BYPASS U1
9 IGN./FUEL ON
10ENG. FAULT
D6
TB133
PBOX GND
TS55
RD
TB33
TB23
L45
H6
ON GLOW
PLUG
15AMP.
TS56
BK
RD
CB1
TB20
C33STR BK
TB27
D3
D2
BK
TS52
START ENGINE
12
RD
U33
TS51
PUMP AUXILIARY
C27AUX RD
P23BAT WH
GRD
C28TTA RD/BK
PLAT
C133PLA OR/RD
C45GEN GR/WH
TB22
C43HRN GR
KS1
BRN
REV B
DRE LED BL/RD

DRE B BL/BK
BL/WH
OR
BL/WH
WH/RD
14
5
13
12
13
14
10
11
17
18
20
19
16
15
C41RPM OR/BK
15
16
BRN
11
RD/WH
12
DRE A BL/WH
GND 1
WH/RD
OR
BRN
1
2
4
3
4
BOOM
C2P-3
BRN-2
C1P-3
C1P-6
C37STCC BL/BK
C29MS RD/WH
C32BRK WH/RD
C31EDC- WH/BK
C1P-11
C36STC BL
C30EDC+ WH
C1P-10
C6TRF WH/RD
C1P-5
C3P-6
C5TRR WH/BK
C1P-4
C3P-5
C4TRL WH
PRI BOOM
LEFT TT ROTATE
RIGHT
C3P-4
7.5
DOWN
UP
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
BOOM
C40LS1 OR
EXTEND
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
RETRACT
JDALARM GR/BK
C3P-1
C3P-2
C3P-3
C4P-1
C2P-2
C3P-8
C3P-7
C2P-6
C18JD GR/BK
C5-21
C31EDC- WH/BK
C30EDC+ WH
D
C6-5
C6-4
C6-36
C6-37
C5-19
C5-23
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
C36STC BL
C37STCC BL/BK
C29MS RD/WH
C32BRK WH/RD
C2PBD RD/BK
C1PBU RD
C6-2
C3PBF RD/WH
C6-13
C13DRE BL/RD
C6-17
C6-18
C17JU GR
C18JD GR/BK
C15PLD OR/BK
C14PLU OR
WH
BK
BK
WH
BK
WH
C7PBE BK
C40LS1 OR
C6-30
C6-7
C6-8
C6-14
C6-15
C8PBR BK/WH
C6-40
C6-19 RD/BK
C6-3
C6-1
C6-6
C6-32
C5-20
5
TB18
B
C
GROUND

PLAT LEVEL DOWN
PLAT LEVEL UP
BOOM RETRACT
BOOM EXTEND
DRIVE ENABLE
LIMIT SWITCH

DRIVE LIMIT SWITCH
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
STEER LEFT
STEER RIGHT
MOTOR STROKE
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
7
JIB VALVES
6 - 33
S-40 S-45
Part No. 102521
RKOUT 5
YOUT 4
XOUT 3
PWR 2
6
5
YOUT 4
XOUT 3
PWR 2
GND 1
BRN
P24FS WH
P24FS WH
P26ESTP BK
EXTEND
RETRACT
C4P-2
C4P-3
C4P-6
C17JU GR
JIB BOOM
DOWN
UP
PLAT ROTATE
8
NOTE:
NCHO
NOHC
NOHC
BRN
Y51
Y2
Y27
Y3
Y4
Y23
Y29
Y13
Y22
Y21
Y12
H4
Y25
TB6
TB3
TB30
TB31
TB32
TB37
DOWN
PLAT LEVEL
UP
C4P-5
DOWN
PLAT LEVEL
UP
GR/BK-44
JIB BOOM
RIGHT
LEFT
SJ1-WH
TB29
TB14
TB5
TB2
TB36
TB4
TB1
C19JSV GR/WH
TB8
TB17
R2
R1
H4
Y26
Y20
TS63
TB13
TB40
TB7
TB15
TS61
TS59
3
C4P-7
TB44
Y19
Y16
Y17
DOWN
UP
PLAT ROTATE
RD
TS15
4
TS58
TB19
RIGHT
LEFT
JIB VALVE
RD
J1
J1
J1
J3
TS62
TS57
J2
CR30
NO
CE
LIFT/
DRIVE
OPTION
C19JSV GR/WH
TS9
TS8
TS7
CR27
NC
CR13
NC
CR13
TS13
TS14
L1
DRIVE & STEERING
2
WH
WH
JC3
JC2 PRI UP/DN & TT ROTATE
WH
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
July 2007

OR/BK
BK
BL/WH
RD/BK
BRN
July 2007
6 - 33
6 - 34
July 2007
REV A

PLATFORM LOAD
RD-C6-23
OR/BK-C5-2
OR-C6-40
BK/WH-C5-10
BL/WH-C23-3
BL/BK-C6-37
BL-C6-36
BK/WH-C5-22
WH/RD-C5-23
WH/BK-C5-20
WH-C5-21
RD/WH-C5-24
RD/BK-C6-28
RD-C6-27
RD-C5-1
BL/WH-C6-30
WH-C5-3+C5-11
RD- 12VOLT
GR/BK-C6-18
GR-C6-17
BR-GND STUD
C7B
3
1
BK-C32-5
2 WH-23C
C2B
12V TO PLAT
12 V
OR/BK-C6-15
OR-C6-14
BL/RD-C6-13
BK/WH-C6-8
BK-C6-7
WH/RD-C6-6
WH/BK-C6-5
WH-C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1
WH-C7B-2
BK-C32-4
WH-C6-34
CB3-SP
GR/WH-C4B-7
GR/BK-C4B-6
GR-C4B-5
OR/RD-C4B-4
OR/BK-C4B-3
OR-C4B-2
BL/RD-C4B-1
BL/WH-C3B-12
BL/BK-C3B-11
BL-C3B-10
BK/RD-C3B-9
BK/WH-C3B-8
BK-C3B-7
WH/RD-C3B-6
WH/BK-C3B-5
WH-C3B-4
RD/WH-C3B-3
RD/BK-C3B-2
RD-C3B-1
C1B
C4B
19/18 CABLES
C3B
WH-23B
WH-CR2#86
WH-L2 DIODE
G2
BK/RD-9B
G3
BK/RD-S.P.
BK/WH-S.P.
BK-S.P.
D6
RD-ISM#4
RED-CR1#30
WH-ISM #7
BK-CR5#30
WH-CR2#87
CB2-SP
GR/BK-C32-8
RD C4B-12
BR (GROUND)
RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
CB1 - SP
GR/WH-SP
GR/BK-S.P.
GR-S.P.
GR/BK-H6OR/BK-S.P.
OR-S.P.
WH/BK-25A
WH/RD-26A
BK-22A
KS1
RD-CB2
TS51
NC
3
NC
WH-23A
RD-42A
RD-27A
RD-C23-6
1
B1
BK/RD-CR23#86
DRIVE LIGHT OPTION

BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.
A
6 BATTERY
7 KEY PWR.
8 KEY BYPASS
9 IGN./FUEL ON
10 ENG. FAULT
KEY SWITCH
KS1
KS1
AUXILIARY SWITCH
TS51
42730
ENGINE START SWITCH
TS52
13037
STARTER AID
TS56
13037
FUNCTION ENABLE SWITCH
TS55
13037
16397
TS57
TS59
13037
WH-21A
TS63
13037
HM
BR (GROUND)
L2
L45
WH-C5-13
PRIMARY BOOM
UP/DOWN
TS61
RD/WH-3A
RD/BK-2A
RD-1A
BOOM
EXTEND/RETRACT
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
TS63
TURNTABLE
ROTATE
TS52
ENGINE
START
TS56
D14
FUNCTION
ENABLE
CB1
TS61
16397
TS62
16397
TS58
13037
CB1
CB1
CB2
CB2
CB3
CB3
R1
R1
RESISTOR, 7.5 OHM,TURNTABLE FUNCT
R2
R2
VOLT METER GAGE
G1
G1
OIL PRESSURE GAGE
G2
G2
OIL TEMP. GAGE
G3
G3
HM
CB3
TS58
JIB BOOM
UP/DOWN
TS62
R2
CB2
TS57
BK/RD-35B
P1
RD- 20C
RD-CR17#30
WH/BK-5A
WH/RD-6A
WH-4A
MODULE
PART #
P1
RD
STARTER AID
IGN./START
LABEL
GR/BK-H6-
BK/WH-34A
START RELAY
TACHOMETER
START INPUT
AUX. ON
GROUND
DESCRIPTION
AUXILIARY
KEY SWITCH
P1
BL/WH-ISM#10
44B+RD/BK-C6-19
RD C4B-11
BRN GND
HORN
C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
3MF
C132PLI
STEER LEFT
STEER RIGHT
GND
RPM
GLOW PLUG
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
MOTOR SPEED
TILT ALARM
AUX. PWR.
WATER TEMP. SENDER
OIL PRESSURE SENDER
ENGINE POWER
KEYSWITCH PWR/FB
PWR. TO PLAT.
IGNITION PWR.
JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.
C133PLA
PLAT. LEVEL DN.
PLAT. LEVEL. UP
DRV. ENA. LT.
BL/RD-S.P.
BK/RD CR3-#30
RD-CB3 SP
WH-21A
RD-KS1-2 S.P.
BR -3MF CAP
BK-ISM#3
WH/RD-C6-32
CR23
GR/BK-S.P.
GR/BK-2B
GR-CR5#85
RD-H6+
OR/BK-ISM#2
RD-ISM#6
WH-ISM#9
RD-24B
C6
H6
G1
B
1
2
3
4
5
R1
BK-CR1#86
OR/BK-41B
BK-33B
RD-27B
BR-GND.
RD-CR2#30
RD-C32-1
RD-42B
GR/BK-L45GR/BK-16A
SPARE
GEN. OPTION
FUNCTIONS
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
RD
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1
RD-H6+ - C32-1
BL/WH-38D - C32-3
BK-22C - C32-4
BK-C7-1 - C32-5
RD-TS51 - C32-6
RD-TS55 - C32-7
GR/BK-16B - C32-8
BR - GND - C32-12
C32
U33
GR/WH-C6-39
RD-C32-7
HOUR METER
HM
IGN. START RELAY
CR1
CR1
IGN. POWER RELAY
CR2
CR2
CR3
CR3
RPM RELAY
CR4
CR4
COOLING FAN RELAY
CR17
CR17
H6
U33
PLAT OVERLOAD LED
L45
TS55
CR1
CR2
CR4
CR3
D13
BK/RD-35A
BK-ISM#1
TS59
PLATFORM
LEVEL
PLATFORM
ROTATE
RD- 20A
BK-C5-5
RD- 24A
WH-21B
RD- 20B
C5
ENGINE
BK/RD-C5-9
BK-C6-16
RD- P1 E-STOP
OR-C6-33
OR/BK-15A
OR-14A
GR-17A
GR/WH-19A
GR/BK-18A
CR5
GR-43D
GROUND STUD
BK-22B
GROUND STUD
BR
CR17
BK-C6-25
RD-CB3 SP
WIRING
HARNESS:
TO BASE
ALL BR WIRES
Part No. 102521
S-40 S-45
6 - 35
July 2007

6 - 35
6 - 36
July 2007

6 - 38
6 - 37
11
1
P26BAT BK
P24FS WH
P24FS WH
BRN
PART NUMBER
45383
94771
COMPONENT INDEX
TILT ALARM
ALC-500
H1
RD P2
RD H1
C132PLI BK C1P-12
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C19JSV GR/WH
C4P-7 AND TS8
BRN
OPT.
LS18
JIB
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
F.S.
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
C45GEN GR/WH C2P-7
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
C6TRF WH/RD C3P-6

C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
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
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L48
C28TTA RD/BK C1P-2
RD/BK-28
Part No. 102521
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH
C9P
C7P
J3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
C7P
BATGND C7P-3
12V BATT
19/18 CONTROL CABLE
TILT
ALALRM
C3P
C3P
D40
D39
H1
S-40 S-45
6 - 38
RED-TILT
C4P
GR/BK C4P-4
C1P
C28TTA RD/BK C1P-2
J2
J1
GR/BK L4
HARNESS
PBOX WIRING
REV A
Platform Control Box Wiring Diagram- ALC-500
C2P
N
M
L
K
J
I
H
G
F
E
D
C
B
A
ALC-500
RED-TILT
July 2007
July 2007
REV A

HARNESS
PBOX WIRING
10 AMP FUSE
TS48
JC2
WORK/ DRIVE LITE
TS15
DRV.ENA
JC2
PRIMARY
BOOM
EXTEND/
RETRACT
56298
75565
56298
66812, 95406
66813, 66815
42730
13037
TS4
TS6
TS7
TS8
RD WL2
TS13
DRIVE ENABLE LED

HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH
WH-24
L1
TS9
TS13
TS14
JIB UP/DOWN SWITCH

DRIVE SPEED SWITCH
TS15
TS47
TS48
DRIVE ENABLE SWITCH

GENERATOR SWITCH ( OPTION )
WORK/DRIVE LIGHT ( OPTION )
L48
(GND STUD)
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
CR27
WH TS7
RD
RD P3
P22BAT BK C7P-1
RD LS18
WH-23
BK-22
P26BAT BK C9P-1
GR/WH-45
WH-24
BK/RD-35
WH-24
C33STR BK C1P-7
RD TS47
RD-25
C34SA BK/WH C1P-8
WH-24
C29MS RD/WH J1-8
WH-24
C27AUX RD C1P-1
WH-JIB
C19JSV GR/WH
C17JU GR C4P-5
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
WH TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
REMOVE FOR
GENERATOR OPTION
OR R40LS1
1
(SPLICE TO R40LS1)
1 1
GENERATOR
(OPTION)
NC NC NC
TS47
2 2
NO
PLATFORM
LEVEL
BRN BATGND
RD/BK H1
GR/BK H1
WH-24
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BK-22
BRN
WH-JIB
BK-7
BK/WH-8
BL/BK-DE2 J1-7
RD WL1
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
OR-14
OR/BK-15
RD P2
GR-43
HORN
13037
27378
27378
P2
EMERGENCY STOP
WH
PLATFORM
ROTATE
GR/BK
13037
13037
56457
GR
WH
16397
13037
RD
WH
TS9
56457
13037
GLOW PLUG OPTION
L4
P3
56298
CE PLATFORM LED
HI/L0 RPM SWITCH
CR13
TS7
62390
CHASSIS TILT LED
JC3
L1
L4
JC3

L48
P2
P3
TS1
TS2
PART NUMBER
COMPONENT INDEX
TS8
JIB
TS1
AUXILIARY PUMP
TS14
TS6
TS4
HIGH/LOW
DRIVE
SPEED
GLOW PLUG
HIGH/LOW
RPM
RD
NOTE:
CE SEE DETAIL A
Part No. 102521
S-40 S-45
6 - 39
July 2007

6 - 39
6 - 40
July 2007
REV A

HARNESS
PBOX WIRING
10 AMP FUSE
WORK/ DRIVE LITE
TS48
PRIMARY BOOM
UP/DOWN
DRIVE/STEER
DRIVE ENABLE
TS15
JC2
JC3
TURNTABLE ROTATE
RD WL2
RD WL1
PRIMARY
BOOM
EXTEND/
RETRACT
4
WH-24
TS13
J1-5 BL/WH JC3-5
J1-4 WH/RD JC3-4
J1-13 OR JC3-2
GR/BK H1
RD/BK H1
WH-24
J1-5 BL/WH JC3-3

BRN BATGND
(GND STUD)
WH TS7
CR27
WH TS1
RD
RD LS18
RD P3
BK-22
P22BAT BK C7P-1
WH-23
P26BAT BK C9P-1
GR/WH-45
BK/RD-35
WH-24
C33STR BK C1P-7
RD-25
C34SA BK/WH C1P-8
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
(SPLICE TO R40LS1)
TS1
TS14
TS6
TS4
TS2
DRIVE
SPEED
JIB
J1-14 BRN JC3-1
L48
WH-24
C29MS RD/WH J1-8
PLATFORM
ROTATE
GR/BK
BL/RD-DE3 J1-16
WH
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7
PLATFORM
LEVEL
OR R40LS1
GR
HORN
P3
RD
L4
WH-24
C27AUX RD C1P-1
WH-JIB
C17JU GR C4P-5
C19JSV GR/WH JIB
C19JSV GR/WH
C18JD GR/BK C4P-6
TS8
L1
BRN
BK-7
BK/WH-8
J1-2 RD/WH JC2-4
J1-11 OR JC2-2
J1-1 WH/RD JC2-3
J1-12 BRN JC2-1
WH
OR-14
OR/BK-15
RD P2
GR-43
WH
TS7
TS9
CR13
HIGH/LOW
AUXILIARY PUMP
EMERGENCY STOP
P2
TS17
GLOW PLUG
RD
START
HIGH/LOW
RPM
RD
7
NOTE:
GENERATOR
(OPTION)
CE SEE DETAIL A
Part No. 102521
S-40 S-45
6 - 41
July 2007

Deutz F3L-2011Deutz D2011L03i and Perkins 404-22 Models
6 - 41
6 - 42
July 2007
6 - 44
6 - 43
C9-1 BK
HIGH RPM(FS)
GENERATOR
LP
FUEL
GAS
C2-7
C2-1
C1-7
ENGINE
C2-5
C7-1
C4-4
C1-2
C7-2
C1-1
PUMP AUXILIARY
START
P22BAT BK
C2-4
RD
C1-9
C35ESPD BK/RD
LOW RPM FUNCTION

HIGH RPM ENA.
C45GEN GR/WH
BK
ENGINE
LP FUEL
GAS
C33STR BK
START
TB45
AUXILIARY
PUMP
RD
C27AUX RD
P23BAT WH
C28TTA RD/BK
C133PLA OR/RD
BK/RD
C6-39
TEST
RUN
C6-28
C6-23
GR/WH-45
C5-13
C5-12
C5-17
C5-10
C5-9
C5-15
C5-5
C6-27
BRN
OR/BK-41
BL/WH (FEH 787) PIN5

BR (FEH 570C) PIN34
C5-14
WH/RD-24
WH/BK-24
C5-16
BK
C6-26
BRN
DGRN (FEH 242)
RD (FEH 361A)
C6-33
NOTE:
FUEL PUMP
FORD
42 PIN PLUG
GENERATOR
OPTION

FUEL RELAY
OIL PRESSURE GAUGE
OIL PRESSURE
SWITCH
WATER TEMP
SWITCH
WATER TEMP GAUGE
C38ESL BL (FEH 658) PIN6

BK/RD (FEH 458) PIN3
TSW
C211GN2 WH (FEH 306) PIN24
BK/WH (FEH 72) PIN7
C39LP
C35RPM2 OR/RD (FEH 307A) PIN23
WH (FEH 16A) PIN1
C5-11
RD
WH
WH-21
BK-33
RD-27
C6-25
BK-43
RD/BK-28
RD-P134
C6-16
C6-34
C5-2
C5-3
OTS
NC
G1
HM
_
REGULATOR
PR1
G3
G2
P24BAT
TB24
TB26
TB25
FUEL
PUMP
OPS
+
STARTER
AUX
PUMP
H2
FAN
LPG LOCKOUT SOLENOID

VOLT METER
HOUR METER
IGN./START RELAY
STARTER MOTOR
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)
Part No. 102521
NO
IND.
C134PWR OR/RD
C41RPM OR/BK
RD
STA.
CR17
BAT.
BAT.
12 V
DC
CB3
PR1
NO
EXCT.
8
9
10
CR2
CR2
NO
CR1
CR1
NO
CR5 CR5
NO
20AMP.
FB
CR17
NO
ALTERNATOR
S-40 S-45
6 - 44
TB24
OTS
NO
TB35
TS22
L2
START RELAY
TACHOMETER
START INPUT
IGN./START
AUX. ON
GROUND
MODULE
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
1
2
3
4
5
6
TB23
RD
TB20 15AMP.
TB33
D6
TB27
TB39
TB28
TB133
CB1
TS53
PLAT
GRD
SEE NOTE 2
TS17
TS3
TS2
TS1
OR/BK
C2-3
TB41
TS55
TS52
TS51
TB22
KS1
TB134
RD
P1
CB2
D40
D39
TS4
L4
RD-(FS)
WH-(FS)
FS1
BK-(FS)
P2
RD/BK
C28TTA RD/BK
RD
TB43
RD
RD
15AMP.
L48
H1
P3
HORN
WH
P25FS RD
P24FS WH
C9-3
C9-2
RD
REV B
N
M
L
K
J
I
H
G
F
E
D
C
B
A
FORD
ENGINE
HARNESS
July 2007

P26ESTP BK
BK
TB21
WH
DRE LED BL/RD

DRE B BL/BK
DRE A BL/WH
WH
RKOUT 6
10
11
17
18
20
19
16
15
C41RPM OR/BK
15
8
16
7
6
5
4
13
14
BL
OR
BRN
YOUT 5
GND 2
PWR 3
RD
6
7
8
14
13
12
C1P-10
C1P-11
C1P-6
C1P-5
C1P-4
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
BRN-2
C3P-6
C5TRR WH/BK
C2P-3
C3P-5
C2PBD RD/BK
C1PBU RD
UP
PRIMARY
DOWN BOOM
LEFT
TROTATE
RIGHT
C4TRL WH
7.5
C3P-4
C3P-1
C3P-2
C3P-3
C13DRE BL/RD
C3PBF RD/WH
C4P-1
C40LS1 OR
BOOM
C7PBE BK
C8PBR BK/WH
C14PLU OR
C15PLD OR/BK
PLAT
DOWN LEVEL
UP
RETRACT
EXTEND
C2P-2
C3P-7
EXTEND BOOM
C3P-8
RETRACT
C4P-2
UP
PLAT
DOWN LEVEL C4P-3
JDALARM GR/BK
C18JD GR/BK
C2P-6
C4P-6
C5-21
C5-20
C6-32
C5-23
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C6-13
C6-40
C6-7
C6-8
C6-14
C6-15
C6-18
C30EDC+ WH
C32BRK WH/RD
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C6-19 RD/BK
C13DRE BL/RD
C40LS1 OR
C7PBE BK
C8PBR BK/WH
C14PLU OR
C15PLD OR/BK
C18JD GR/BK
BK
WH
BK
WH
BK
WH
C31EDC- WH/BK D
7
H3
PLAT LEVEL DOWN
PLAT LEVEL UP
BOOM RETRACT
BOOM EXTEND
DRIVE ENABLE
LIMIT SWITCH

DRIVE LIMIT SWITCH
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
PRIMARY BOOM
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
TURNTABLE ROTATE
FLOW CONTROL
STEER LEFT
STEER RIGHT
BRAKE RELEASE VALVE
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
DRIVE EDC FORWARD
GROUND
8
JIB VALVES
6 - 45
S-40 S-45
Part No. 102521
OR
BK
YOUT 5
XOUT 4
BRN
2
1
11
12
PWR 3
1
GND 2
BRN
2
4
4
RD
C17JU GR
C17JU GR
NOTE:
P24FS WH
P24FS WH
P26ESTP BK
RD
C4P-5
C6-17
AMP
GR/BK-44
DOWN JIB
BOOM
UP
RIGHT JIB
BOOM
LEFT
RIGHT PLAT
LEFT ROTATE
NOHC NOHC NONC

BRN
H4
SJ1-WH
C6-30
TB22
1
Deutsch
C19JSV GR/WH
TB36
3
RIGHT PLAT
LEFT ROTATE
C4P-7
2
4
TB6
TB8
TB14
TB18
TB5
TB2
TB30
TB1
TB32
TB37
TB13
TB40
5
TB3
TB7
TB15
TB17
TB31
TB4
4
TS62
TS61
J1
J1
J1
JIB VALVE
4
1
TB44
TB19
TS63
TS59
TS58
TS57
J2
C19JSV GR/WH
CR27
NC
TS13
TS9
TS8
TS7
J3
2
CR13
NC
CR13
CR30
NO
CE
LIFT/
DRIVE
OPTION
L1
JC3
DRIVE & STEERING
TS15
JC2
WH
WH
6
6
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
6
REV B
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
July 2007

RD/BK
OR/BK
BK
BRN
July 2007
6 - 45
6 - 46
July 2007
REV A

GR/WH-C6-39
OR/BK-C5-2
OR- C6-40
BK/WH-C5-10
BL C5-13
BL/BK-C6-37
BL- C6-36
BK/RD-C5-9
BK-ISM#3
WH/RD-C5-23
WH/BK-C5-20
WH- C5-21
RD- C6-23
BL/WH-C6-30
WH-C5-3+C6-34
GR/BK-C6-18
GR- C6-17
12 V
C2B
C1B
GR/WH-SP
GR/BK-S.P.
GR-S.P.
JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.
OR/BK-S.P.
OR-S.P.
PLAT. LEVEL DN.

PLAT. LEVEL. UP
DRV. ENA. LT.
GR/BK-SP
BL/RD-S.P.
BL/WT-S.P.
BL/WH-ISM#10
BK/RD-S.P.
BK/WH-S.P.
BK-S.P.
D6
RD-ISM#4
RED-CR1#30
WH-TS22#5
BK-CR5#30
WH-CR2#87
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.
44B-RD/BK-C6-19
3 BR-GND STUD
1 BK-22C
2 WH-23C
G1
1
2
3
4
5
6
7
8
9
10
WH-CR2#86
BK/WH-38B
RD-ISM#6
WH-ISM#9
RD-24B
CR17
CR2
P1
RD-CB2
C6
OR-C6-33
BR-GND+C6-26
TS22
36
25
14
KS1
KEY SWITCH
NC
1
B1
WH-23A
RD-42A
RD-27A
BL/RD-39A
RD-C23-6
RD-H6+
TS51
B
3
OR/RD-H6-
WH-21A
TS53
L2
L45
BL/WH-C5-13
BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP
BL/WH-ISM#10
DESCRIPTION
TS61
RD/WH-3A
RD/BK-2A
RD-1A
TS63
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
START RELAY
TACHOMETER
START INPUT IGN./START
AUX. ON
MODULE
GROUND
BATTERY
KEY PWR.
KEY BYPASS
IGN./FUEL ON
ENG. FAULT
TS62
TS52
CB3
RD- 20C
RD-CR17#30
GR-17A
GR/WH-19A
GR/BK-18A
RD-CB3 SP
TS58
CR23
GR/BK C2B-6
R2
D14
CB1
RD C4B-11
TS57
CB2
RD C4B-12
BRN GND
CR5
TS55
TS59
P1
PART #
P1
KEY SWITCH
KS1
KS1
AUXILIARY SWITCH
TS51
42730
ENGINE START SWITCH
TS52
13037
LP/GAS SWITCH
TS53
56457
13037
FUNCTION ENABLE
TS55
TS57
16397
TS59
13037
TS63
13037
TS61
16397
TS62
16397
TS58
13037
42730
CHECK ENGINE SWITCH
TS22
CB1
CB1
CB2
CB2
CB3
CB3
R1
R1
R2
R2
VOLT METER GAGE
G1
G1
OIL PRESSURE GAGE
G2
G2
RD- 24A
WATER TEMP. GAGE
G3
G3
RD- 20B
CHECK ENGINE
L2
56298
HOUR METER
HM
HM
RD- P1 E-STOP
WH-ISM#7
WH-23B
BLK-33B
WH CR2#87
WH-C5-17
LABEL
RD- 20A
BK/RD-35A
BK-C6-16
CHECK ENGINE TOGGLE SWITCH

BR-R1
BR-GND
BK/RD-C5-12
G3
G2
NC
D13
WH-21B
WH-TS22#4
WH/BK-25A
WH/RD-26A
BK-22A
BK-ISM#1
BK-C5-5
BK-22B
GR-43D
RD-CB3 SP
BK-C6-25
BR (GROUND)
A
BK-CR1#86
OR/BK-41B
BK-33B
RD-27B
BR-GND.
RD-CR2#30
WH-TS22#6
WH-21A
HM
CR1
BR (GROUND)
C3B C4B
C7B
C5
FUNCTIONS
ENGINE
GROUND STUD
BK/WH-C6-8
BK- C6-7
WH/RD-C6-6
WH/BK-C6-5
WH- C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1
RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
LIMIT SWITCH POWER

GEN. OPTION
SPARE
HORN
SPARE
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
CHECK ENGINE
STEER LEFT
STEER RIGHT
RPM
GLOW PLUG
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
SPARE
TILT ALARM
AUX. PWR.
WATER TEMP. SENDER
OIL PRESSURE SENDER
ENGINE POWER
KEYSWITCH PWR/FB
PWR. TO PLAT.
IGNITION PWR.
GR/BK-2B
GR-CR5#85
BK-CR1#85 D5
WH/RD-C6-32
R1
19/18 CABLES
12V TO PLAT
OR/BK-C6-15
OR- C6-14
BL/RD-C6-13
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
RD- C5-1
24
23
WH-C7B
22
BK-C7B
WH-C5-11
21
20
GR/WH-C4B-7 19
GR/BK-C4B-6 18
GR-C4B-5
17
OR/RD-C4B-4 16
OR/BK-C4B-3 15
OR-C4B-2
14
13
BL/RD-C4B-1
BL/WH-C3B-12 12
BL/BK-C3B-11 11
10
BL-C3B-10
9
BK/RD-C3B-9
BK/WH-C3B-8 8
7
BK-C3B-7
WH/RD-C3B-6 6
WH/BK-C3B-5 5
4
WH-C3B-4
RD/WH-C3B-3 3
RD/BK-C3B-2
2
1
RD-C3B-1
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1
RD
RD/BK-C6-28
RD- C6-27
WH/RD-C5-14
WH/BK-C5-16
OR/BK-15A
OR-14A
GR-17A
GR/WH-19A
GR/BK-18A
WIRING
HARNESS:
TO BASE
GROUND STUD
BR
ALL BR WIRES
Part No. 102521
S-40 S-45
6 - 47
July 2007

6 - 47
6 - 48
July 2007

6 - 50
6 - 49
11
1
P26BAT BK
P24FS WH
P24FS WH
BRN
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH
C132PLI BK C1P-12
RD P2
RD H1
P23SWBAT WH C7P-2
P22BAT BK C7P-1
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
C17JU GR C4P-5
C15PLD OR/BK C4P-3
C14PLU OR C4P-2
C19JSV GR/WH
C4P-7 AND TS8
BRN
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
RED/BLK-28
H1
COMPONENT INDEX
PART NUMBER
TILT ALARM
ALC-500
45383
89353
H1
J2
OPT.
LS18
JIB
C9P
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
C45GEN GR/WH C2P-7
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE GR/BK C2P-6
C6TRF WH/RD C3P-6

C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
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
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
C28TTA RD/BK C1P-2
F.S.
D39
RED-TILT
F.S.
12V BATT
1
J3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
C3P
C3P
D40
C4P
GR/BK C4P-4
BRN
Part No. 102521

S-40 S-45
6 - 50
C7P
BATGND C7P-3
C1P
C28TTA RD/BK C1P-2
19/18 CONTROL CABLE

TILT
ALALRM
GR/BK L48
HARNESS
PBOX WIRING
J1
ALC-500
RED-TILT
REV A
C2P
N
M
L
K
J
I
H
G
F
E
D
C
B
A
C7P
July 2007

July 2007
REV A

N
HARNESS
PBOX WIRING
COMPONENT INDEX
TS48 / TS49
WORK / DRIVE LITE
TS15
DRV.ENA
3
2
JC2
5
4
DLITE/ RD WL2
RD WL1
TS13
PRIMARY
BOOM
EXTEND/
RETRACT
3
2
JC3
1
+
62390
JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L3
TS7
TS8
TS9
TS13

DRIVE ENABLE LED
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH
FUEL SELECT SWITCH (FORD EFI ONLY)
HI/L0 RPM SWITCH
CHECK ENGINE LIGHT
JIB UP/DOWN SWITCH
75565
56298
66812, 73805
66813, 66816
42730
13037
56457
56457
56298
16397
13037
13037
13037
L4
BL/RD-DE3 J1-16
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
RD-TILT
RD/BK H1
WH-24
BRN BATGND
(GND STUD)
CR27
P22BAT BK C7P-1
RD-TILT
WH-23
BK-22
P26BAT BK C9P-1
RD
BL/RD-39
RD
WH-24
BK/RD-35
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
(SPLICE TO R40LS1)
1
1
TS3
FUEL SELECT
RD
TS2
START
TS47
GENERATOR
(OPTION)
TS1
AUXILIARY
PUMP
TS4
HIGH/LOW
RPM
NC NC NC
NO
TS7
PLATFORM
ROTATE
TS8
JIB
WH-TS47
RD-25
BK-33
WH-24
WH-TS4
GR/WH-45
WH-24
C27AUX RD C1P-1
WH-JIB
C19JSV GR/WH
C17JU GR C4P-5
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
OR-14
OR/BK-15
RD
GR-43
WH
WH TS1
OR R40LS1
GR
TS9
PLATFORM
LEVEL
WH
P3
HORN
13037
27378
27378
WH TS7
WH
L1
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7
BRN
WH-JIB
BK-7
BK/WH-8
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
WH-24
CR13


PART NUMBER
JC2
NOTE:
P2
EMERGENCY STOP
DASHED LINES INDICATE

OPTION WIRES
CE SEE DETAIL A
Part No. 102521
S-40 S-45
6 - 51
July 2007

6 - 51
6 - 52
July 2007
6 - 54
6 - 53
P22BAT BK
C3-9
GENERATOR
C2-7
HIGH RPM(FS)
WH
WH
C1-7
ENGINE
REV B
BL/WH
BK
P26ESTP BK
RD
C1-9
BK
BK
C35ESPD BK/RD
FUNCTION ENA.
LOW RPM
HIGH RPM
C45GEN GR/WH
DLITE BK/RD
C33STR BK
BK
ENGINE
START
C6-39
C6-28
GR/WH-45
C5-12
C5-17
C5-9
C5-13
C5-5
C5-10
C5-8
C5-11
C4B-12
C4B-11
WH-21
RD
RD
C5-14 WH/RD
C5-16 WH/BK
RD (FEH 361A)
DGRN (FEH 242)
C21IGN
C127TST
WH PIN 21
GR PIN 18
BK/RD PIN 23
BL/WH PIN 6
BK PIN 15
C38ESL
WH PIN 24
C35RPM
R33STR
BL/RD PIN 7
WH PIN 1
BK PIN 13
BK
BRN
BR PIN34
C39LP
R21IGN
RD PIN 9
BL/WH PIN 5
VBATT
VSW
C33STR
BK-33
WH
RD-27
RD/BK-28
RD
C6-27
RD-134
BK-43
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
LPG LOCKOUT SOLENOID
VOLT METER
HOUR METER
TEMP GAUGE
FORD
42 PIN PLUG
OIL PRESSURE GAUGE
FUEL PUMP
START RELAY
STARTER MOTOR
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)
42 PIN FORD CONNECTOR
REFER TO E0375 FOR FORD HARNSS
START
C2-1
RD
C27AUX RD
P23BAT WH
C28TTA RD/BK
C6-23
C6-16
C6-25
C6-26
OR/BK PIN 2
PBOX GND
C133PLA OR/RD
C43HRN GR
C6-34
C6-33
C41RPM
PUMP AUXILIARY
LP FUEL
GAS
C1-2
C7-2
C1-1
PUMP AUXILIARY
C2-5
C7-1
C2-4
C5-2
510 OHM
L29
L29
TS4
C134PWR RD
TS22
C5-3
L30
TS17
C41RPM OR/BK
RD

1.
OTS
STARTER
FORD
ENGINE
HARNESS
Y29
G1
HM
G6
H2
Part No. 102521

S-40 S-45
6 - 54
M1
CR23
CR23
NO
G3
TB26
G2
OPS
IND.
S7
TB21
CR39
TB35
CR1
L2
CR1
NO
CR2
TB24
FUEL
PUMP
FB
FAN
AUX
M2 PUMP
REGULATOR
CR17
EXCT.
TB33
D6
TB45
CB1
BRN
PR2 PR2
12 V DC
STA.
PR1
PR1
NO
BAT.
BAT.
+
CR17
NO
ALTERNATOR
C28TTA RD/BK
TS55
TS52
TB25
OTS
NO
NC
CR5
NO
TS1
L48
CR2
NO
CR5
20AMP.
TB23
RD
TB39
D40
TS53
TS51
PLAT
GRD
CR39
CB3
RD
KS1
TB22
TB27
TB28
15AMP.
TB20
TB43
TB134
RD
P1
CB2
RD
RD
15AMP.
NOTE:
C9-1 BK
TS2
TS3
H1
P3
HORN
P24FS WH
WH
P25FS RD
C9-2
FUSE 10A
C9-3
WH-(FS)
BK-(FS)
RD-(FS)
FS1
P2
TS49
RD
OR/BK
C2-3
TB41
N
M
L
K
J
I
H
G
F
E
D
C
B
A
L30
July 2007

RD/BK
F18
DRE B BL/BK
DRE LED BL/RD
DRE A BL/WH
WH
RKOUT 6
BL
14
13
16
15
19
20
17
18
11
9
10
6
7
8
14
13
12
C1P-10
C1P-11
C1P-3
C1P-6
C1P-5
C1P-4
C6TRF WH/RD
C36STC BL
C37STCC BL/BK
C29MS RD/WH
C32BRK WH/RD
C31EDC- WH/BK
C30EDC+ WH
BRN-2
C3P-6
C5TRR WH/BK
C2P-3
C3P-5
C4TRL WH
C40LS1 OR
RETRACT
EXTEND
UP PLATFORM LEVEL
DOWN
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
BOOM
C13DRE BL/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
UP
PRIMARY
DOWN BOOM
LEFT TROTATE
RIGHT
C3P-4
7.5
5
C3P-1
C3P-2
C3P-3
C4P-1
C2P-2
C3P-7
C3P-8
C4P-2
C4P-3
JDALARM GR/BK
C18JD GR/BK
C17JU GR
C5-21
C5-20
C6-32
C5-23
C5-19
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C31EDC- WH/BK
C30EDC+ WH
C32BRK WH/RD
C29MS RD/WH
C37STCC BL/BK
C36STC BL
C4TRL WH
C5TRR WH/BK
C6TRF WH/RD
C1PBU RD
C2PBD RD/BK
C3PBF RD/WH
C13DRE BL/RD
C6-19 RD/BK
C6-13
C6-30
C6-7
C6-8
C6-14
C6-15
C17JU GR
C18JD GR/BK
C15PLD OR/BK
C14PLU OR
C8PBR BK/WH
C7PBE BK
C40LS1 OR
C6-40
C6-18
C6-17
WH
BK
WH
BK
BK
WH
GROUND
DRIVE EDC FORWARD
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
BRAKE RELEASE VALVE
MOTOR STROKE
STEER RIGHT
STEER LEFT

TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM
FLOW CONTROL

DRIVE LIMIT SWITCH
DRIVE ENABLE
LIMIT SWITCH
BOOM EXTEND
BOOM RETRACT
PLAT LEVEL UP
PLAT LEVEL DOWN

NOTE:
JIB VALVES
6 - 55
S-40 S-45
C41RPM OR/BK
15
16
OR
5
4
BRN
YOUT 5
PWR 3
1
GND 2
BK
RD
OR
BRN
2
1
11
12
7
6
YOUT 5
XOUT 4
PWR 3
GND 2
1
P24FS WH
BRN
P24FS WH
P26ESTP BK
EXTEND PLATFORM LEVEL

RETRACT
C4P-5
C4P-6
C2P-6
UP
PLATFORM LEVEL
DOWN
GR/BK-44
DOWN
UP JIB BOOM
DOWN
UP JIB BOOM
NCHO
TB30
RIGHT
LEFT PLAT ROTATE
TB18
NOHC
Part No. 102521
7
NOHC
BRN
Y51
Y2
Y27
Y3
Y4
Y23
Y29
Y13
Y22
Y21
Y12
H4
Y25
Y26
Y20
Y19
Y16
Y17
SJ1-WH
TB6
TB3
TB14
H4
1
Deutsch
5
TB8
TB17
TB13
TB40
TB7
TB32
TB37
TB36
TB4
TB1
TB29
TB5
TB2
TB15
R2
R1
TB31
C19JSV GR/WH
RIGHT
LEFT PLAT ROTATE
RD
J1
J1
J1
3
C4P-7
2
4
AMP
TB44
TS62
TS61
TS63
J2

J3
6
4
1
WH
WH
4
TS58
TB19
TS59
TS57
CR27
NC
TS7
JIB VALVE
RD
TS13
TS9
TS8
TS14
L1
JC3
DRIVE & STEERING
TS15
JC2
WH
2
CR13
NC
CR13
CR30
CE NO
LIFT/
DRIVE
OPTION
C19JSV GR/WH
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
GND
PWR
XOUT
YOUT
RKOUT
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
6
REV B
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
July 2007

OR/BK
BL/WH
RD/BK
BK
BRN
July 2007
6 - 55
6 - 56
July 2007
REV A

GR/WH-C6-39
OR/BK-C5-2
OR- C6-40
BL/RD-C5-10
BL/WH-C23-3
BL/BK-C6-37
BL- C6-36
BK/RD-C5-9
RD- C6-23
BL/WH-C6-30
WH-C5-3+C5-8
RD- 12 VOLT
GR/BK-C6-18
GR- C6-17
12 V
RD-CR39#85
RED-CR1#30
CR39 #30
BK-CR5#30
WH-CR2#87
RD-S.P.(CB2)
GR/BK-C23-8
44B-RD/BK-C6-19
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
RD-S.P.
P1
RD-CB2
KS1
KEY SWITCH
3
NC
4
WH-21A
DRIVE LIGHT OPTION

BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. L
TURN. ROT. R
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP
TS53
L2
BL/WH-C5-13
DESCRIPTION
TS61
RD/WH-3A
RD/BK-2A
RD-1A
KEY SWITCH
AUXILIARY SWITCH
ENGINE START SWITCH
TS63
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
TS62
CB3
RD-CB3 SP
TS58
CR2
CR23
R2
D14
CB1
RD C4B-11
TS57
CB2
RD C4B-12
BRN GND
WH-21B
WH-C5-17
TS55
D13
WH-C5-11
TS59
CR39
BK-C6-25
RD-CB3 SP
KS1
TS51
PART #
P1
KS1
13480
TS52
13037
LP/GAS SWITCH
TS53
56457
FUNCTION ENABLE
TS55
13037
TS57
16397
TS59
13037
TS63
13037
TS61
16397
TS62
16397
TS58
13037
42730
CHECK ENGINE SWITCH
TS22
CB1
CB1
CB2
CB2
CB3
CB3
R1
R1
R2
R2
VOLT METER GAGE
G1
G1
G2
G2
RD- 24A
WATER TEMP. GAGE
G3
G3
RD- 20B
CHECK ENGINE
L2
56298
HOUR METER
HM
HM
OR/BK-15A
CR17
P1
OIL PRESSURE GAGE
RD- P1 E-STOP
RD-27B
LABEL
RD- 20A
BK/RD-35A
OR-C6-33
OR-14A
GR-17A
WH-23B
C5
1
B1
WH-23A
RD-42A
RD-27A
BL/RD-39A
BK-33B
CR5
TS51
NC
BK/RD-9B
BK-C6-16
WH/BK-25A
WH/RD-26A
BK-22A
RD-24B
TS22
RD- 20C
RD-CR17#30
WH/BK-5A
WH/RD-6A
WH-4A
BK-C5-5
BR (GROUND)
TS52
CR1
G3
G2
BR (GROUND)
BK/RD-CR23#86
GR-C5-12
ENGINE
G1
HM
GR-43B
BK-22B
GROUND STUD
WH-21A
3 BR-GND STUD
1 BK-22C
2 WH-23C
C2B
C1B
BK-CR1#85 D5
WH/RD-C6-32
C3B C4B
C7B
SPARE
GEN. OPTION
JDALARM JIB
HORN
RD-KS1-2 S.P. C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
BL/RD-S.P.
L.P.
C132PLI
STEER LEFT
STEER RIGHT
BK/RD-S.P.
RPM
BK/WH-S.P.
GLOW PLUG
START
BK-S.P.
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
MOTOR SPEED
TILT ALARM
AUX. PWR.
RD-S.P.
WH/RD-S.P. WATER TEMP. SENDER
WH/BK-S.P. OIL PRESSURE SENDER
RD-S.P.
ENGINE POWER
KEYSWITCH PWR/FB
WH-S.P.
PWR. TO PLAT.
BK-S.P.
WH-S.P.
IGNITION PWR.
RD-S.P.(CB1) 12V BATTERY SUPPLY
GR/WH-SP
JIB VALVE
GR/BK-S.P.
PLAT. ROT. R.
GR-S.P.
PLAT. ROT. L.
GR/BK-H6C133PLT
OR/BK-S.P.
PLAT. LEVEL DN.
OR-S.P.
PLAT. LEVEL. UP
DRV. ENA. LT.
GR/BK-SP
C6
FUNCTIONS
BK/WH-C6-8
BK- C6-7
WH/RD-C6-6
WH/BK-C6-5
WH- C6-4
RD/WH-C6-3
RD/BK-C6-2
RD-C6-1
R1
19/18 CABLES
12V TO PLAT
OR/BK-C6-15
OR- C6-14
BL/RD-C6-13
GR/BK-2B
GR-CR5#85
RD-H6+
RD
WH/RD-C5-23
WH/BK-C5-20
WH- C5-21
RD/WH-C5-24
RD/BK-C6-28
RD- C6-27
WH/RD-C5-14
WH/BK-C5-16
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
WH-C7B-2
22
BK-C7B-1
WH-C6-34
21
RD-S.P.(CB3)
20
GR/WH-C4B-7 19
GR/BK-C4B-6 18
GR-C4B-5
17
OR/RD-C4B-4 16
OR/BK-C4B-3 15
OR-C4B-2
14
13
BL/RD-C4B-1
BL/WH-C3B-12 12
BL/BK-C3B-11 11
10
BL-C3B-10
9
BK/RD-C3B-9
BK/WH-C3B-8 8
7
BK-C3B-7
WH/RD-C3B-6 6
WH/BK-C3B-5 5
4
WH-C3B-4
RD/WH-C3B-3 3
RD/BK-C3B-2
2
1
RD-C3B-1
GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
OR/RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1
GR/WH-19A
GR/BK-18A
WIRING
HARNESS:
TO BASE
GROUND STUD
BR
ALL BR WIRES
Part No. 102521
S-40 S-45
6 - 57
July 2007

6 - 57
6 - 58
July 2007

6 - 60
6 - 59
11
1
P26BAT BK
P24FS WH
P24FS WH
C132PLI BK C1P-12
RD P2
RD H1
P23SWBAT WH C7P-2
P22BAT BK C7P-1
F.S.
C19JSV GR/WH
C4P-7 AND TS8
BRN
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
RED/BLK-28
H1
PART NUMBER
TILT ALARM
45383
H1
COMPONENT INDEX
J2
OPT.
LS18
JIB
C9P
C19JSV GR/WH JIB

C18JD GR/BK C4P-6
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
JDALARM GR/BK C2P-6
C45GEN GR/WH C2P-7
TS48-WL1 RD C2P-12
TS48-WL2 RD C2P-11
C39LP BL/RD C2P-1
DLITE BK/RD C3P-9
C6TRF WH/RD C3P-6

C10SBU BL C3P-10
C13DRE BL/RD C4P-1
C11SBD BL/BK C3P-11
C40LS1 OR C2P-2
C12SBF BL/WH C3P-12
C41RPM OR/BK C2P-3
C30EDC+ WH C1P-4
C1PBU RD C3P-1
C31EDC- WH/BK C1P-5
C2PBD RD/BK C3P-2
C36STC BL C1P-10
C3PBF RD/WH C3P-3
C37STCC BL/BK C1P-11
C5TRR WH/BK C3P-5
C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C134PWR RD C2P-4
C35RPM BK/RD C1P-9
C34SA BK/WH C1P-8
C33STR BK C1P-7
C27AUX RD C1P-1
RD/BK L4
C28TTA RD/BK C1P-2
F.S.
D39
RED-TILT
Part No. 102521
BRN
JC1-3 OR
JC2-4 RD
JC1-2 BRN
JC2-5 BK
JC2-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC3-3 OR
JC3-4,6 WH
JC3-2 BRN
DRE A BL/WH
BRN
C3P
C3P
D40
C4P
GR/BK C4P-4
12V BATT
19/18 CONTROL CABLE
TILT
ALALRM
C7P
BATGND C7P-3
C7P
C1P
C28TTA RD/BK C1P-2
1
J3
DRE B BL/BK
C13LED BL/RD
C29MS RD/WH
GR/BK L48
RED-TILT
HARNESS
PBOX WIRING
J1
ALC-500
REV A
C2P
N
M
L
K
J
I
H
G
F
E
D
C
B
A
S-40 S-45
6 - 60
July 2007

July 2007
REV B

(from serial number 7597 to11066)
N
10 AMP FUSE
5
4
DLITE/ RD WL2
RD WL1
TS13
PRIMARY
BOOM
EXTEND/
RETRACT
2
JC2
JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L4
TS7
TS8
TS9
TS13
TS14
TS15
TS47
TS48-9
3
2
JC3
1
+
62390

DRIVE ENABLE LED
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH
HI/L0 RPM SWITCH
CHASSIS TILT LED
JIB UP/DOWN SWITCH
DRIVE SPEED SWITCH
DRIVE ENABLE SWITCH
75565
56298
66812, 94506
66813, 66816
42730
13037
56457
56457
56298
16397
13037
13037
13037
56457
13037
27378
27378
L4
BL/RD-DE3 J1-16
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
RD-TILT
RD/BK H1
WH-24
BRN BATGND
(GND STUD)
P22BAT BK C7P-1
RD-TILT
WH-23
BK-22
P26BAT BK C9P-1
RD
BL/RD-39
RD
WH-24
BK/RD-35
WH-TS47
RD-25
BK-33
WH-24
WH-TS4
GR/WH-45
WH-24
WH-24
C29MS RD/WH J1-8
C27AUX RD C1P-1
WH-JIB
C17JU GR C4P-5
C19JSV GR/WH JIB
C19JSV GR/WH
C18JD GR/BK C4P-6
OR-14
OR/BK-15
RD
GR-43
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
1
1
RD
TS3
FUEL SELECT
TS2
START
TS47
GENERATOR
(OPTION)
TS14
DRIVE
SPEED
HIGH/LOW
TS1
AUXILIARY
PUMP
TS4
HIGH/LOW
RPM
NC NC NC
NO
TS7
PLATFORM
ROTATE
TS8
JIB
WH TS1
(SPLICE TO R40LS1)
WH
WH
CR27
OR R40LS1
GR
TS9
PLATFORM
LEVEL
PART NUMBER
L1
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7
BRN
WH-JIB
BK-7
BK/WH-8
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
WH-24
CR13
WH

WH TS7
P3
HORN
COMPONENT INDEX
JC2
TS15
DRV.ENA
HARNESS
PBOX WIRING
TS48 / TS49
WORK / DRIVE LITE
NOTE:
P2
EMERGENCY STOP

OPTION WIRES
CE SEE DETAIL A
Part No. 102521
S-40 S-45
6 - 61
July 2007

6 - 61
6 - 62
July 2007
Ford DSG-423 EFI Models
6 - 64
6 - 63
BL/WH
HIGH RPM(FS)
C3-9
C2-7
GENERATOR
WH
C1-9
C35ESPD BK/RD
LOW RPM
FUNCTION ENA.
HIGH RPM
C45GEN GR/WH
DLITE BK/RD
C6-39
GR/WH
1K
C6-27
C4B-12
C4B-11
B
C
RD
RD
500
GR PIN 3
WH PIN 16
WH/RD PIN 39
C21IGN
BK PIN 15
BK/RD PIN 23
C26TSR
C35RPM
BL/WH PIN 5
BL/RD PIN 7
BL PIN 18
WH PIN 24
C135RET
C135FP
WH PIN 1
R21IGN
VSW
BL/WH PIN 6
BK
BRN
C38ESL
C39LP
R33STR
C127TSW
C107AF WH
WH/BK
RD/GN
BK/BL
RD
GY/YL
GY/RD
C5-16 WH/BK
R21IGN WH
C5-3
C5-14
C5-12
C5-17
C5-9
C5-5
C5-8
C5-10
C5-11
C5-13
WH
C27AUX RD
RD/BK
RD
C6-26
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
VOLT METER
HOUR METER
OIL PRESSURE GAUGE
GASOLINE SENSOR
LPG LOCKOUT
TO ALTERNATOR FIELD
TEMP GAUGE
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM

FORD
42 PIN PLUG
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
COOLING FAN
(OPTION)
RESISTOR R4 REMOVED AT SERIAL NUMBER 11785 .
DRIVELIGHT
ENGINE
C6-28
RD
C6-33
FORD ENGINEHARNESS
BK
BK
C33STR BK
START
LP
FUEL
GAS
AUXILIARY
PUMP
RD
C27AUX RD
P23BAT WH
C28TTA RD/BK
C6-23
R43HRN BK
C6-25
BRN
OR/BK PIN 2
BLUE/PINK
STARTER RELAY
STARTER MOTOR
ESO433B
2
WORKLIGHT
WH
C1-7
ENGINE
C2-1
C1-1
C7-2
C1-2
C133PLA OR/RD
C43HRN GR
C6-16
C6-34
PR2
C41RPM
PR2

1.
START
FUEL
GAS
LP
AUXILIARY
PUMP
C2-5
C7-1
C2-4
P22BAT BK
C134PWR RD
C5-2
P20BAT RD
Part No. 102521

S-40 S-45
+
6 - 64
NOTE:
L29
L29
OPS
FORD ENGINE
HARNESS
TB45
TB9
TB23
C2-3
15AMP.
G1
HM
TB25
TS22
DIAGNOSTIC
Y29
+
FAN M1
CR23
CR23
NO
G2
FUEL
PUMP
G6
AUX
PUMP
H2
M2
FB
FUEL PUMP
3
S7
12 V
DC
TB21
TB41
R4
NO
CR17
PR1
PR1
CR17
NO
RD
L2
R3
TB26
OTS
CR5
CR5
NO
CB3
20AMP.
PBOX GND
TB33
L30
L30
TS55
TS53
CR1
CR1
NO
CR2
CR2
NO
CR39
CR39
NC
TS49
C28TTA RD/BK
TS17
TS2
TS3
TB35
RD
TB24
CB1
15AMP.
TB20
G3
NO
TB27
TB28
TB39
B
BK
P26ESTP BK
RD
B1
TS52
CB2
TB43
RD
2
REV B
RD
TB22
4
1
RD
TB42
TS51
PLAT
GRD
KS1
P1
TS1
L48
WH
C9-2
BK(FS)
C9-1 BK
TS4
H1
P3
HORN
FUSE 10A
P25FS RD
P24FS WH
C9-3
RD(FS)
WH(FS)
FS1
P2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
RD
C41RPM OR/BK
TB 134 IS WAGO
TERMINAL BLOCK 42
July 2007

RD/BK
OR/BK
F18
REV B
DRIVE SPEED
C29MS RD/WH
DRE LED BL/RD

DRE B BL/BK
DRE A BL/WH
PWR 3
RD
BK
BRN
OR
12
11
14
13
7
6
12
13
14
10
11
17
18
20
19
16
15
C41RPM OR/BK
15
16
WH
4
7
RKOUT 6
BL
GND 2
OR
YOUT 5
XOUT 4
YOUT 5
BRN
GND 2
PWR 3
1
BRN
P24FS WH
P24FS WH
P26ESTP BK
3
4
EXTEND
BOOM
RETRACT
C2P-3
C1P-4
C1P-5
C1P-6
C1P-3
C1P-11
C1P-10
C3P-5
C3P-6
C3P-4
7.5
BRN-2
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C37STCC BL/BK
C36STC BL
C5TRR WH/BK
C6TRF WH/RD
C4TRL WH
LEFT
TT ROTATE
RIGHT
C4P-1
C3P-3
C3P-2
C3P-1
C40LS1 OR
C13DRE BL/RD
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
UP
PRIMARY BOOM
DOWN
C2P-2
C3P-8
C14PLU OR
C8PBR BK/WH
C7PBE BK
EXTEND
BOOM
RETRACT
C4P-2
C15PLD OR/BK
C3P-7
C4P-3
JDALARM GR/BK
UP
PLATFORM LEVEL
DOWN
C2P-6
C18JD GR/BK
C5-21
C5-20
C6-32
C5-23
C5-24
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C31EDC- WH/BK
C30EDC+ WH
C37STCC BL/BK
C29MS RD/WH
C32BRK WH/RD
C36STC BL
C4TRL WH
C1PBU RD
C5TRR WH/BK
C2PBD RD/BK
C6TRF WH/RD
C3PBF RD/WH
C6-19 RD/BK
C13DRE BL/RD
WH
BK
BK
WH
BK
WH
C15PLD OR/BK
C14PLU OR
C7PBE BK
C6-13
C6-30
C6-7
C6-8
C6-14
C6-15
C17JU GR
C18JD GR/BK
C8PBR BK/WH
C40LS1 OR
6
C6-40
C6-18
C6-17
GROUND
DRIVE EDC FORWARD
DRIVE EDC REVERSE

TRAVEL ALARM OPTION
BRAKE RELEASE VALVE
MOTOR STROKE
STEER RIGHT
STEER LEFT
TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM DOWN
PRIMARY BOOM UP
PRIMARY BOOM
FLOW CONTROL
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH

DRIVE LIMIT SWITCH
PLAT LEVEL UP
BOOM RETRACT
BOOM EXTEND
DRIVE ENABLE
LIMIT SWITCH
8
JIB VALVES
PLAT LEVEL DOWN
ESO433
6 - 65
S-40 S-45
Part No. 102521
Y2
TB30
TB31
DOWN
JIB BOOM
UP
NOTE:
NCHO
TB32
UP
PLATFORM LEVEL
DOWN
C4P-6
C17JU GR
C19JSV GR/WH
BRN
NOHC
Y27
Y25
NOHC
Y3
Y4
Y23
Y22
Y29
Y21
Y13
Y12
7
H4
Y26
Y20
TB13
5
TB40
TB7
TB15
H4
Y19
TB5
TB2
TB37
TB4
TB1
TB29
TB36
TB6
TB3
TB14
SJ1-WH
Y16
Y17
TB44
RIGHT
PLAT ROTATE
LEFT
TS58
TB8
TB17
TS61
TS63
TS59
R2
R1
C4P-5
RD
TS15
Y51
4
TS62
TS57
GR/BK-44
DOWN
JIB BOOM
UP
C4P-7
TB19
RIGHT
PLAT ROTATE
LEFT
JIB VALVE
RD
J1
J1
J1
J3
CR30
NO
J2
TS14
LO
HI
L1
DRIVE & STEERING
3
C19JSV GR/WH
TS13
TS9
TS8
TS7
CR27
NC
CR13
NC
CR13
CE
LIFT/
DRIVE
OPTION
2
WH
WH
JC3
JC2
WH
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
July 2007

RD/BK
BL/WH
OR/BK
BK
BRN
TB18
July 2007
6 - 65
6 - 66
March 2007
6 - 68
6 - 67
BL/WH
HIGH RPM(FS)
C2-7
GENERATOR
C1-9
C35ESPD BK/RD
LOW RPM
FUNCTION ENA.
HIGH RPM
C45GEN GR/WH
DLITE BK/RD
C6-39
GR/WH
C4B-12
C4B-11
B
C
RD
RD
C5-14
C127TSW
C26TSR
BK/RD PIN 23
WH PIN 16
GR PIN 3
WH/RD PIN 39
WH/BK
RD/GN
BK/BL
RD
GY/YL
GY/RD
C5-16 WH/BK
R21IGN WH
C5-3
C5-12
C35RPM
C21IGN
BK PIN 15
C5-17
R33STR
C5-9
C5-5
BL/RD PIN 7
WH PIN 24
BL/WH PIN 5
R21IGN
BL PIN 18
C5-8
C135RET
C135FP
WH PIN 1
C39LP
VSW
BL/WH PIN 6
C5-10
C5-11
C38ESL
BRN
C5-13
C27AUX RD
WH
BK
GENERATOR
OPTION
DRIVE LIGHT
OPTION
WORK LIGHTS
OPTION
VOLT METER
HOUR METER
OIL PRESSURE GAUGE
FORD
42 PIN PLUG
GASOLINE SENSOR
LPG LOCKOUT
TEMP GAUGE
AUXILIARY POWER
RELAY
AUXILIARY PUMP
LEVEL SENSOR
TILT ALARM
FLASHING BEACONS
OPTION
SERVICE HORN
RELAY
SERVICE HORN
HYDRAULIC OIL
TEMP. SWITCH
NOTE:
STARTER MOTOR
STARTER RELAY
FORD ENGINEHARNESS
COOLING FAN
(OPTION)
RESISTOR R3 REMOVED AT SERIAL NUMBER 13740.

CHECK ENGINE LAMP L2 CHANGED TO INCANDESCENT.
C3-9
1K
C6-27
RD/BK
RD
C6-26
WH
ENGINE
C6-28
RD
BRN
OR/BK PIN 2
BLUE/PINK
BK
BK
C33STR BK
START
LP
FUEL
GAS
AUXILIARY
PUMP
RD
C27AUX RD
P23BAT WH
C28TTA RD/BK
C6-23
R43HRN BK
C6-25
C6-33
PR2
C41RPM
PR2
DRIVELIGHT
C1-7
ENGINE
C2-1
C1-1
C7-2
C1-2
C133PLA OR/RD
C6-16
C5-2
P20BAT RD

L29
L29
OPS
FORD ENGINE
HARNESS
ESO433C
1.
G1
HM
Y29
+
TB45
TB9
TB23
C43HRN GR
R3
C6-34
TB25
WORKLIGHT
WH
START
LP
FUEL
GAS
AUXILIARY
PUMP
C2-5
C7-1
C2-4
P22BAT BK
C134PWR RD
C2-3
PR1
CR23
CR23
NO
G2
FUEL
PUMP
TB26
FUEL PUMP
L2
G6
AUX
PUMP
H2
M2
FB
Part No. 102521

S-40 S-45
+
6 - 68
TB21
TB41
CR1
CR1
NO
CR2
CR2
NO
CR39
PBOX GND
TB33
15AMP.
S7
12 V
DC
FAN M1
NO
CR17
TB27
TB35
RD
TB24
TS52
TB39
TS22
DIAGNOSTIC
G3
NO
PR1
CR17
NO
RD
CR5
3
OTS
BK
P26ESTP BK
RD
TB22
TB28
TS55
4
1
REV B
RD
RD
L30
L30
2
TS17
TS2
TS3
C41RPM OR/BK
CR39
NC
CR5
NO
CB3
20AMP.
TB43
B1
TS49
C28TTA RD/BK
RD
TS53
PLAT
GRD
B
CB2
TB42
2
RD
CB1
15AMP.
TB20
KS1
P1
TS1
L48
WH
C9-2
BK(FS)
C9-1 BK
TS4
H1
P3
HORN
FUSE 10A
P25FS RD
P24FS WH
C9-3
RD(FS)
WH(FS)
FS1
P2
N
M
L
K
J
I
H
G
F
E
D
C
B
A
TS51
July 2007

RD/BK
OR/BK
F18
REV B
DRIVE SPEED
C29MS RD/WH
DRE B BL/BK
DRE LED BL/RD
DRE A BL/WH
YOUT 4
OR
WH/RD
RD/WH
12
11
15
16
19
20
12
13
14
10
11
17
18
C41RPM OR/BK
15
16
BL/WH
6
RKOUT 5
5
13
OR
BL/WH
WH/RD
PWR 2
14
YOUT 4
BRN
XOUT 3
GND 1
XOUT 3
BRN
GND 1
PWR 2
BRN
P24FS WH
P24FS WH
P26ESTP BK
3
EXTEND
RETRACT
BOOM
C2P-3
C1P-4
C1P-5
C1P-6
C1P-3
C1P-11
C1P-10
C3P-6
C3P-5
C3P-4
7.5
BRN-2
C30EDC+ WH
C31EDC- WH/BK
C32BRK WH/RD
C29MS RD/WH
C37STCC BL/BK
C36STC BL
C6TRF WH/RD
C5TRR WH/BK
C4TRL WH
LEFT
TT ROTATE
RIGHT
C3P-2
C3P-1
C3PBF RD/WH
C2PBD RD/BK
C1PBU RD
PRI BOOM
C3P-3
C13DRE BL/RD
UP
DOWN
C4P-1
C40LS1 OR
BOOM
C2P-2
EXTEND
C3P-8
C14PLU OR
C8PBR BK/WH
C7PBE BK
RETRACT
C4P-2
C15PLD OR/BK
C3P-7
C4P-3
JDALARM GR/BK
DOWN
PLAT LEVEL
UP
C2P-6
C18JD GR/BK
C5-21
C5-20
C6-32
C5-23
C5-24
C6-37
C6-36
C6-4
C6-5
C6-6
C6-1
C6-2
C6-3
C31EDC- WH/BK
C30EDC+ WH
C37STCC BL/BK
C29MS RD/WH
C32BRK WH/RD
C36STC BL
C4TRL WH
C1PBU RD
C5TRR WH/BK
C2PBD RD/BK
C6TRF WH/RD
C3PBF RD/WH
C6-19 RD/BK
C13DRE BL/RD
WH
BK
BK
WH
BK
WH
C14PLU OR
C7PBE BK
C15PLD OR/BK
C17JU GR
C18JD GR/BK
C8PBR BK/WH
C6-13
C6-30
C6-7
C6-8
C6-14
C6-15
C6-17
C40LS1 OR
6
C6-40
C6-18
Y2
7
Y51
GROUND
DRIVE EDC FORWARD
LS2-PRIMARY BOOM UP
DRIVE LIMIT SWITCH
TRAVEL ALARM OPTION
DRIVE EDC REVERSE
BRAKE RELEASE VALVE
MOTOR STROKE
STEER RIGHT
STEER LEFT

TURNTABLE ROTATE
FLOW CONTROL
PRIMARY BOOM UP
PRIMARY BOOM DOWN
PRIMARY BOOM
FLOW CONTROL

DRIVE LIMIT SWITCH
DRIVE ENABLE
LIMIT SWITCH
BOOM EXTEND
BOOM RETRACT
PLAT LEVEL UP
PLAT LEVEL DOWN


JIB VALVES
6 - 69
S-40 S-45
Part No. 102521
Y27
TB30
TB31
8
NCHO
NOTE:
NOHC
TB32
TB37
DOWN
PLAT LEVEL
UP
C4P-6
C17JU GR
C19JSV GR/WH
BRN
NOHC
Y3
Y4
Y23
Y22
Y29
Y21
Y13
Y12
Y25
TB13
TB40
TB7
TB15
H4
Y26
Y20
TB36
TB5
TB2
H4
Y19
5
TB29
TB6
TB3
TB14
SJ1-WH
Y16
Y17
TS63
TB4
TB1
RIGHT
PLAT ROTATE
LEFT
TB44
TB8
TB17
TS62
TS61
TS59
R2
R1
C4P-5
C4P-7
TS58
GR/BK-44
DOWN
UP
JIB BOOM
PLAT ROTATE
RD
3
RIGHT
LEFT
RD
2
TS14
LO
HI
L1
TS15
DRIVE & STEERING
JC3
J1
J1
J1
J3
CR30
NO
4
TS57
TS13
J2
CE
LIFT/
DRIVE
OPTION
C19JSV GR/WH
CR27
NC
CR13
NC
CR13
TS9
TS8
TS7
JIB VALVE
TB19
WH
WH

JC2
WH
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
July 2007

BL/WH
OR/BK
RD/BK
BK
BRN
TB18
July 2007
6 - 69
6 - 70
July 2007
REV B

GR/WH-C2B-7
GR/BK-C2B-6
GR-C2B-5
RD-C2B-4
OR/BK-C2B-3
OR-C2B-2
BL/RD-C2B-1
BL/WH-C1B-12
BL/BK-C1B-11
BL-C1B-10
BK/RD-C1B-9
BK/WH-C1B-8
GR/WH-C6-39
OR/BK-C5-2
OR- C6-40
BL/RD-C5-10
BL/BK-C6-37
BL- C6-36
BK/RD-C5-9
BK-C1B-7
WH/RD-C1B-6
WH/BK-C1B-5
WH-C1B-4
RD/WH-C1B-3
RD/BK-C1B-2
RD-C1B-1
WH/RD-C5-23
WH/BK-C5-20
WH- C5-21
RD/WH-C5-24
WH-C5-3+C5-8
RD- 12 VOLT
OR/BK-C6-15
OR- C6-14
BL/RD-C6-13
BK/RD-C3B-9
BK/WH-C3B-8
BK-C3B-7
WH/RD-C3B-6
WH/BK-C3B-5
WH-C3B-4
RD/WH-C3B-3
RD/BK-C3B-2
RD- C6-1
RD-C3B-1
12 V
BK/WH-C6-8
BK- C6-7
WH/RD-C6-6
WH/BK-C6-5
WH- C6-4
RD/WH-C6-3
RD/BK-C6-2
D
C7B
GR/BK-S.P.
RD-KS1-2 S.P.
BL/RD-S.P.
BK/RD-S.P.
BK/WH-S.P.
BK-S.P.
D5
BK-CR1#85
WH/RD-C6-32
RD-CR39#85
RD-S.P.
WH/RD-S.P.
WH/BK-S.P.
RD-S.P.
WH-S.P.
BK-S.P.
WH-S.P.
RD-S.P.(CB1)
RED-CR1#30
CR39 #30
BK-CR5#30
WH-CR2#87
RD-S.P.(CB2)
HORN
C134PWR
PULSE PICKUP
LIMIT SWITCH SIG.
L.P.
C132PLI
STEER LEFT
STEER RIGHT
RPM
GLOW PLUG
START
BRAKE/TRAVEL ALARM
E.D.C.E.D.C.+
MOTOR SPEED
TILT ALARM
AUX. PWR.
WATER TEMP. SENDER
OIL PRESSURE SENDER
ENGINE POWER
KEYSWITCH PWR/FB
PWR. TO PLAT.
IGNITION PWR.
12V BATTERY SUPPLY
GR/WH-SP
GR/BK-S.P.
GR-S.P.
JIB VALVE
PLAT. ROT. R.
PLAT. ROT. L.
C133PLT
OR/BK-S.P.
OR-S.P.
PLAT. LEVEL DN.

PLAT. LEVEL. UP
DRV. ENA. LT.
G2
G1
WH/BK-25A
WH/RD-26A
BK-22A
KEY SWITCH
KS1
P1
NC
TS51
RD-CB2
NC
B1
WH-23A
RD-42A
RD-27A
BL/RD-39A
KEY SWITCH KS1
DRIVE LIGHT OPTION
44B-RD/BK-C6-19
BK/WH-S.P.
BK-S.P.
WH/RD-S.P.
WH/BK-S.P.
WH-S.P.
RD/WH-S.P.
RD/BK-S.P.
WH-23A
RD-S.P.
L2
Note: Removed resistor R3 and

changed L2 to incandescent
TS53
BL/WH-C5-13
TS61
RD/WH-3A
RD/BK-2A
RD-1A
TS63
BK/WH-8A
BK-7A
GR/BK-44A
BK-33A
TS62
CB3
TS52
TS58
(BR)
RD-CR17/CR23 #30
WH/BK-5A
WH/RD-6A
WH-4A
RD-24B
CR2
CR1
R2
C2B
(BK)
CB1
C1B
RD-CB3 S.P.
CB2
TS57
WH-21B
WH-C5-17
CR23
TS55
OR-C6-33
WH-C5-11
C6
4
DESCRIPTION
L2
LABEL
PART#
P1
P1
KEY SWITCH
KS1
KS1
AUXILIARY SWITCH
TS51
13480
ENGINE START SWITCH
TS52
13037
LP/GAS SWITCH
TS53
56457
FUNCTION ENABLE
TS55
13037
TS57
16397
TS59
13037
TS63
13037
TS61
16397
TS62
16397
TS58
13037
CHECK ENGINE SWITCH
TS22
42730
CB1
CB1
CB2
CB2
CB3
CB3
R1
R1
R2
R2
VOLT METER GAGE
G1
G1
OIL PRESSURE GAGE
G2
G2
WATER TEMP. GAGE
G3
G3
CHECK ENGINE (before serial number 13740)
L2
110395
CHECK ENGINE (after serial number 13739)
L2
119870
HOUR METER
HM
HM
RESISTOR, 1K OHM/2W, CHECK ENGINE
R3
104333
BK/RD-9B
TS59
BK-C6-16
Check Engine Light

BL/WH-C5-13
BOOM RETRACT
BOOM EXTEND
TURN. ROT. F.C.
TURN. ROT. R
TURN. ROT. L
PRI. BOOM F.C.
PRI. BOOM DOWN
PRI. BOOM UP
1
B1
HM
BK/RD-CR23#86
B
3
WH-21A
TS22
BK/RD-35A
RD C4B-11
RD- 20A
RD C4B-12
RD- 24A
BRN GND
RD- 20B
RD- P1 E-STOP
CR5
GR-43B
BK-22B
RD-27B
CR39
BK-C6-25
OR/BK-15A
CR17
OR-14A
RD-CB3 SP
GR-C5-12
GR-17A
WH-23B
GR/WH-19A
GR/BK-18A
C5
ENGINE
2 WH-23C
(GY)
BR (GROUND)
BK-33B
FUNCTIONS
G3
BR (GROUND)
BK-C5-5
WH-21A
BK-22C
(GR)
C4B
R1
C3B
GEN. OPTION
JDALARM JIB
RD- 20C
19/18 CABLES
SPARE
GR/BK-2B
GR-CR5#85
BR-GND STUD
12V TO PLAT
OR/BK-C4B-3
OR-C4B-2
BL/RD-C4B-1
BL/WH-C3B-12
BL/BK-C3B-11
BL-C3B-10
R3
GR/WH-C4B-7
GR/BK-C4B-6
GR-C4B-5
OR/RD-C4B-4
GR/BK-C6-18
GR- C6-17
RD
WH-C7B-2
BK-C7B-1
WH-C6-34
RD-S.P.(CB3)
RD- C6-23
BL/WH-C6-30
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
RD
RD/BK-C6-28
RD- C6-27
WH/RD-C5-14
WH/BK-C5-16
GROUND STUD
WIRING
HARNESS:
TO BASE
ESO433
GROUND STUD
BR
ALL BR WIRES
Part No. 102521
S-40 S-45
6 - 71
July 2007

6 - 71
6 - 72
July 2007

6 - 74
6 - 73
11
1
C132PLI BK C1P-12
RD P2
RD H1
P22BAT BK C7P-1
BRN
C4P(BR)
C3P(GR)
C2P(BK)
C1P(GY)
RED/BLK-28
C19JSV GR/WH
C4P-7 AND TS8
OPT.
LS18
C9P
P23SWBAT WH C7P-2
C17JU GR C4P-5
C19JSV GR/WH JIB

C18JD GR/BK C4P-6
C14PLU OR C4P-2
C15PLD OR/BK C4P-3
P26BAT BK C9P-1
C7PBE BK C3P-7
C43 HRN GR C2P-5

C8PBR BK/WH C3P-8
P24FS WH C9P-2
P25FS RD C9P-3
JDALARM GR/BK C2P-6
C45GEN GR/WH C2P-7
TS48-WL2 RD C2P-11
TS48-WL1 RD C2P-12
DLITE BK/RD C3P-9
C39LP BL/RD C2P-1
C6TRF WH/RD C3P-6

C10SBU BL C3P-10
C11SBD BL/BK C3P-11
C13DRE BL/RD C4P-1
C41RPM OR/BK C2P-3
C12SBF BL/WH C3P-12
C40LS1 OR C2P-2
F.S.
D39
RED-TILT
F.S.
TILT
P26BAT BK
P24FS WH
C1PBU RD C3P-1
C30EDC+ WH C1P-4
C36STC BL C1P-10
C2PBD RD/BK C3P-2
C31EDC- WH/BK C1P-5
C3PBF RD/WH C3P-3

C5TRR WH/BK C3P-5
BATGND C7P-3
C37STCC BL/BK C1P-11

C32BRK WH/RD C1P-6
C4TRL WH C3P-4
C29MS RD/WH C1P-3
C35RPM BK/RD C1P-9
C134PWR RD C2P-4
C33STR BK C1P-7
C34SA BK/WH C1P-8
RD/BK L4
C27AUX RD C1P-1
C28TTA RD/BK C1P-2
C7P
BRN
Part No. 102521
C3P
C3P
D40
C4P
GR/BK C4P-4
P24FS WH
BRN
DRE A BL/WH
JC3-4,6 WH
JC3-2 BRN
JC3-3 OR
JC1-5 YEL
JC2-2 BRN
JC3-5 BL
JC2-3 OR
JC1-2 BRN
JC2-5 BK
JC2-4 RD
JC1-3 OR
DRE B BL/BK
C13LED BL/RD
J2
J1
12V BATT
19/18 CONTROL CABLE
ALALRM
JIB
C7P
C1P
C28TTA RD/BK C1P-2
J3
C29MS RD/WH
GR/BK L48
HARNESS
PBOX WIRING
ALC-500
RED-TILT
REV A
N
M
L
K
J
I
H
G
F
E
D
C
B
A
S-40 S-45
6 - 74
July 2007
C2P
H1
ESO433
July 2007
REV A

10 AMP FUSE
DRV.ENA
TS15
DLITE/ RD WL2
RD WL1
JC2
JC3
1
1
TS13
WH-24
CR13
+
2
PART NUMBER
62390
JC2
COMPONENT INDEX
JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L4
TS7
TS8
TS9
TS13
TS14
TS15
TS47
TS49

DRIVE ENABLE LED
HORN SWITCH
AUXILIARY SWITCH
START ENGINE SWITCH
HI/L0 RPM SWITCH
CHASSIS TILT LED
JIB UP/DOWN SWITCH
DRIVE SPEED SWITCH
DRIVE ENABLE SWITCH
PRIMARY
BOOM
EXTEND/
RETRACT
HARNESS
PBOX WIRING
WORK / DRIVE LITE

TS49
75565
56298
66812, 95406
66813, 66816
42730
13037
56457
56457
56298
16397
13037
13037
13037
56457
13037
27378
27378
BL/RD-DE3 J1-16
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
RD-TILT
RD/BK H1
WH-24
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7
BRN
WH-JIB
BK/WH-8
BK-7
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
L4
L1
BRN BATGND
(GND STUD)
P22BAT BK C7P-1
RD-TILT
BK-22
RD
P26BAT BK C9P-1
WH-23
RD
BL/RD-39
WH-24
BK/RD-35
WH-TS47
BK-33
RD-25
WH-24
WH-TS4
GR/WH-45
WH-24
WH-24
C29MS RD/WH J1-8
C27AUX RD C1P-1
WH-JIB
C19JSV GR/WH
C17JU GR C4P-5
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
OR-14
OR/BK-15
RD
GR-43
CR27
WH TS7
WH TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
CR30
WH
TS9
TS7
TS8
TS1
GR
TS47
WH
HORN
P3
PLATFORM
LEVEL
WH
PLATFORM
ROTATE
GR/BK
JIB
AUXILIARY
PUMP
DRIVE
SPEED
HIGH/LOW
OR R40LS1
TS2
TS14
START
HIGH/LOW
RPM
TS4
TS3
(SPLICE TO R40LS1)
FUEL SELECT
GENERATOR
(OPTION)
EMERGENCY STOP
P2
RD
NOTE: DASHED LINES INDICATE

OPTION WIRES
CE SEE DETAIL A
Part No. 102521
S-40 S-45
6 - 75
July 2007

6 - 75
6 - 76
July 2007
REV A

N
10 AMP FUSE
PRI. BOOM
WORK /
UP/DOWN
DRIVE LITE
TS49
JC2
JC3
DLITE/ RD WL2
RD WL1
JC2
COMPONENT INDEX
JC3
L1
P2
P3
TS1
TS2
TS3
TS4
L4
TS7
TS8
TS9
TS13
TS14
TS15
TS47
TS49
75565
DRIVE ENABLE LED
56298
66812, 95406
66813, 66816
HORN SWITCH
AUXILIARY SWITCH
42730
START ENGINE SWITCH
13037
56457
HI/L0 RPM SWITCH
56457
CHASSIS TILT LED
56298
16397
JIB UP/DOWN SWITCH
13037
13037
PRIMARY BOOM EXTEND/RETRACT SWITCH13037
DRIVE SPEED SWITCH
56457
DRIVE ENABLE SWITCH
13037
27378
27378
DRIVE/STEER
PRIMARY
BOOM
EXTEND/
RETRACT
HARNESS
PBOX WIRING
DRV.ENA
TS15
TT ROTATE
PART NUMBER
62390
TS13
WH-24
+
L4
J1-5 BL/WH JC3-5
J1-4 WH/RD JC3-4
J1-13 OR JC3-2
J1-5 BL/WH JC3-3
J1-14 BRN JC3-1
(GND STUD)
P22BAT BK C7P-1
JIB
CR27
WH TS7
RD-TILT
BK-22
P26BAT BK C9P-1
WH-23
RD
BL/RD-39
RD
TS8
PLATFORM
ROTATE GR/BK
BK/RD-35
WH-24
BK-33
RD-25
WH-24
WH-TS4
GR/WH-45
WH-24
WH-24
C29MS RD/WH J1-8
C27AUX RD C1P-1
WH
RD-TILT
RD/BK H1
WH-24
BL/RD-DE3 J1-16
BL/WH-DE1 J1-6
BK-22
BL/BK-DE2 J1-7
BRN
WH-JIB
PLATFORM
LEVEL
BRN BATGND
WH TS1
WH/RD C32BRK
(SPLICE TO C32BRK)
6
TS4
TS1
AUXILIARY
PUMP
OR R40LS1
TS47
(SPLICE TO R40LS1)
TS2
TS14
HIGH/LOW
RPM
WH
HORN
P3

CR30
WH
GR
L1
WH-JIB
BK-7
BK/WH-8
C19JSV GR/WH
C17JU GR C4P-5
C19JSV GR/WH JIB
C18JD GR/BK C4P-6
OR-14
NO
J1-2 RD/WH JC2-4
J1-11 OR JC2-2
J1-1 WH/RD JC2-3
J1-12 BRN JC2-1
OR/BK-15
RD
GR-43
TS7
TS9
4
CR13
DRIVE
SPEED
HIGH/LOW
TS3
START
GENERATOR
(OPTION)
FUEL SELECT
RD
NC
NC
NC
EMERGENCY STOP
P2
NOTE:
CE SEE DETAIL A
OPTION WIRES
Part No. 102521
S-40 S-45
6 - 77
July 2007

6 - 77
6 - 78
July 2007
Engine Wire Harness

6 - 80
6 - 79
July 2007
REV A
Engine Wire Harness

A
1
INJ +
INJ 1
INJ 3
INJ 4
INJ 2
INJ 5
INJ 6
AUX OUT 2
EGR
AUX ANA PD1

MAP
FPP 1
IAT
ECT
IVS
AUX ANA PU1
FPP 2
EGR PWM
EGR RECIRC
POWER GROUND
POWER GROUND
ANA_RTN
5 VOLT REF
VSW
CRANK CRANK +
CAM CAM +
VBAT
VBAT
EGO 2
EGO 1
EGO 3
KNK +
KNK -
361 R 16
361 R 16
555 T 16
557 BR-Y 16
557 BR-Y 16
558 BR-LB 16
558 BR-LB 16
10
556 W 16
361 R 16
743 GY 18
12
359 GY-R 18
INJECTOR #1
21
18 O-Y 18
19
198 DG-O 18
20
358 LG-BK 18
15
151 LB-BK 18
27
743 GY 18
307 BK-Y 18
28
354 LG-R 18
354 LG-R 18
COIL 4
COIL 5
COIL 6
STARTER LOCKOUT
FUEL LOCKOFF
FUEL PUMP
RELAY CONTROL
TPS1
TPS2
DBW +
DBW BRAKE SWITCH
OIL PRESSURE
TACH
MIL
FUEL PUMP MON
AUX OUT 1
FUEL SELECT
AUX ANA PU2
GOV SELECT 1
GOV SELECT 2
ROAD SPEED +
ROAD SPEED GASEOUS TRIM
OVERSPEED
CAN +
CAN -
RS 485 +
RS 485 RS 232 TX
RS 232 RX
17
307 BK-Y 18
A
B
18
150 DG-W 18
16
114 LB-Y 18
22
352 BR-LG 18
23
360 BR-PK 18
570 BK-W 16
570 BK-W 16
570 BK-W 16
570 BK-W 16
151 LB-BK
307 BK-Y 18
570 BK-W 16
ECT
16 WATER TEMP
570 BK-W 12
F1 30A
F2
570 BK-W 12
5A
16 R-LG 18
MAP_CONN
F3 20A
13
359 GY-R 18
570 BK-W 16
14
351 BR-W 18
351 BR-W 18
16 R-LG 18
33
350 GY 18
358 LG-BK 18
358 LG-BK 18
32
349 DB 18
359 GY-R 18
359 GY-R 18
35
452 GY-R 18
18 O-Y 18
34
282 DB-O 18
198 DG-O 18
198 DG-O 18
361 R 16
150 DG-W 18
150 DG-W 18
361 R 16
114 LB-Y 18
114 LB-Y 18
25
392 R-LG 18
352 BR-LG 18
352 BR-LG 18
24
74 GY-LB 18
360 BR-PK 18
360 BR-PK 18
361 R 14
361 R 14
CRANK
O2 SENSOR
26
361 R 14
30
18 O-Y 18
359 GY-R 18
351 BR-W 18
361A R 16
361A R 16
570 BK-W 16
570 BK-W 16
74 GY-LB 18
392 R-LG 18
O2
SENSOR
MTRTWR6 MTRSHD6
355 GY-W 18
151 LB-BK 18
359 GY-R 18
317 GY-O 18
351 BR-W 18
850 Y-BK 18
851 Y-R 18
TWR
361A R 16
1 COIL 1
2 VBAT
A
B
242 DG 18
361A R 16
LOCKOFF SOLENOID
24
25
SHD
TWR
A
16 R-LG 18
THROTTLE
355 GY-W 18
357 Y-W 18
151 LB-BK 18
317 GY-O 18
351 BR-W 18
359 GY-R 18
FUEL PUMP
RELAY
6
5
4
1
32 R-LB 16
86
86
87
38 EGR ANA IN
32 ANA AUX PD1
37 ANA AUX PU1
12 FPP2
40 EGR PWM
41 EGR REC
30
32 R-LB 16
32 R-LB 16
3
2
85
87
87A
359 GY-R 18
351 BR-W 18
C
B
458 O-BK 18
RTN
FPP_COMM
787A PK-BK 16
F4 15A
787A PK-BK 16
RX
TWR
86
926A LB-O 18
32
15 R-Y 18
30
355 GY-W 18
31
357 Y-W 18
28
151 LB-BK 18
29
317 GY-O 18
511 LG-R 18
511 LG-R 18
511 LG-R 18
253 DG-W 18
253 DG-W 18
253 DG-W 18
11 T-Y 18
11 T-Y 18
11 T-Y 18
27
658 PK-LG 18
658 PK-LG 18
658 PK-LG 18
10
238 DG-Y 18
238 DG-Y 18
71 O-LG 18
71 O-LG 18
71 O-LG 18
14
72 Y-BK 18
72 Y-BK 18
72 Y-BK 18
15
148 Y-R 18
148 Y-R 18
148 Y-R 18
16
306 T-LB 18
306 T-LB 18
306 T-LB 18
17
307 BK-Y 18
307 BK-Y 18
307 BK-Y 18
11
169 LG-BK 18
169 LG-BK 18
169 LG-BK 18
12
172 LB-R 18
172 LB-R 18
172 LB-R 18
26
33
77 DB-Y 18
349A DB 18
349A DB 18
349A DB 18
18
662 DG-P 18
662 DG-P 18
662 DG-P 18
19
459 O-LG 18
459 O-LG 18
459 O-LG 18
20
642 DG-O 18
642 DG-O 18
642 DG-O 18
21
461 O 18
461 O 18
461 O 18
34
669 DG-W 18
669 DG-W 18
35
458 O-BK 18
458 O-BK 18
669 DG-W 18
458 O-BK 18
85
926A LB-O 18
15 R-Y 18
87
87A
361 R 16
OIL PRESSURE
5 FUEL PUMP
POWER
RELAY
30
242 DG 18
F5 15A
361 R 16
253 DG-W 18
570 BK-W 16
361A R 16
459 O-LG 18
662 DG-P 18
MTRTWR4
Part No. 102521
39 STARTER IN (AUTOCRANK)
TX
23
361A R 16
15 STARTER IN (INTERUPT)
5V
342 LG-P 18
361A R 16
31 VREF
13 STARTER CONTROL
342 LG-P 18
669 DG-W 18
77 DB-Y 18
33 ANA RTN
87A
22
S-40 S-45
9 VBATT
STARTER
RELAY
30
85
342 LG-P 18
3 COIL 2
13
1 VSW
351 BR-W 18
34 GROUND
361 R 14
359 GY-R 18
570 BK-W 16
25 IVS
361 R 14
29
361 R 12
TWR
351 BR-W 18
16 R-LG 18
CAM
14 FPP1
570 BK-W 16
16 R-LG 18
WPTWR2_GY
6 - 80
39 R-W 18
359 GY-R 18
570 BK-W 16
TRIM VALVE
TWR
570 BK-W 16
151 LB-BK
J2 GREY
COIL 3
INJECTOR #2
WATER
TEMP
359 GY-R 18
COIL 1
INJECTOR #4
ACT
359 GY-R 18
COIL 2
INJECTOR #3
FORD
42 PIN
CONNECTOR
31
357 Y-W 18
SPK PWR GROUND
361 R 16
556 W 16
11
J1 BLACK
361 R 16
555 T 16
TWR
4 BRAKE
26 OIL PRES
2 TACH
6 MIL
21 AUX OUT1
7 FUEL SELECT
10 AUX ANA PU2
24 GOV SELECT 1
23 GOV SELECT 2
35 ROADSPEED +
36 ROADSPEED 30 OVERSPEED
28 CAN +
29 CAN 11 RS 485+
3 RS 48520 RS 232+
18 RS 232-
SHD
PLUG (GROUND)
PLUG (RELAY POWER)
PLUG (CAN -)
PLUG (CAN +)
MTRSHD4
July 2007
Engine Wire Harness
REV A
Ford DSG-423 EFI Models (from serial number 11067 to 11784)

N
R 16
ENGINE ECM
CONNECTOR
SPK_COIL1A
SPK_COIL1B
SPARK_COIL2A
SPK_GND
SPK_COIL2B
SPK_COIL3A
SPK_COIL3B
UEGOS
UEGOC
UEGOP
UEGPR
AUX ANA PD1
(FRP) AUX ANA PD2
CAN1 +
CAN1 CAN2 CAN2 +
AUX ANA PD3
5V EXT 1
5V RTN
EGO1
EGO2
MAP
AUX ANA PUD3
CRANK +
CRANK CAM +
CAM SPEED +
SPEED 5V EXT 2
5V RTN 2
PULSE IN
GOV 1
OIL PRESS
IAT
ECT
(FRT) AUX ANA PU1
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
(BRAKE) AUX DIG 3
(GOV2) AUX DIG 4
TACH
VSW
AUX ANA PUD2
AUX ANA PUD1
TPS 1
TPS 2
(FUELSELECT)AUX DIG1
AUX DIG 2
KNOCK +
KNOCK FPP1
FPP2-IVS
(FPP2)
PC TX
PC RX
KNOCK 2+
KNOCK 2VBAT PROT
VBAT
EGOH 2
EGOH 1
INJ HS
INJ1 LS
INJ2 LS
INJ3 LS
INJ4 LS
INJ5 LS
GROUND
INJ6 LS
AUX PWM8
STARTER
RELAY
MIL
UEGO H
AUX PWM7
LOCKOFF
AUX PWM6
(FUEL PUMP)
VBAT
DBW +
GROUND
DBW AUX PWM5 REC
AUX PWM5
AUX PWM1
AUX PWM4
AUX PWM2
AUX PWM4 REC
AUX PWM3 REC
FP REC
AUX PWM3
FUEL PUMP
Y/BK 18
W/PK 18
Y/RD 18
BK/W 16
DG/P
6
7
8
9
10
11
12
13
14
15
DG/O 18
W/LG 18
DG/P 18
O/LG 18
R 16
GY/LB 18
DG/P 18
DB/O 18
GY/R 18
CYL #2
CYL #3
CYL #4
HO2S #1
IGNITION COILS
Y/BK 18
W/PK 18
Y/RD 18
1
2
3
4
5
GY/R 18
GY/YL 18
R 16
BK/LB 18
CYL #1
DG/P 18
O/LG 18
LG/BK 18
BR/W 18
GY 18
GY/R 18
GASOLINE
SENSOR
INTERFACE
FORD
42 PIN
CONNECTOR
LG/R 18
GY/R 18
GY/R 18
GROUND
BR 16
BR 16
34 GND
RING
4
3
2
1
CHT
LG/W
DG/BK
LB/R 18
T/LB 18
BK/W 16
BK/W 16
BK/W 16
LB/BK 18
BK/LB 18
LB/R 18
LG/BK 18
T/LB 18
36 ROADSPEED 35 ROADSPEED +
24 GOV SELECT 1
LB/BK 18
R/LG 18
BK/Y 18
R/LG 18
R/T 14
R/T 14
F2
14 FPP1
R/LG 18
R/LG 18
1 VSW
VSW
5A
F3
R 14
ECM
10A
BK/Y 18
GY 18
DBL 18
23 GOV SELECT 2
O/LG 18
DG/P 18
CRANK
29 CAN 28 CAN +
DG/O 18
DG/O 18
DB/W 18
LB/Y 18
DB/W 18
GY/R 18
BR/W 18
GY/R 18
BR/W 18
33 ANA RTN
31 VREF
R/BK 18
R/W 18
R/BK 18
R/W 18
21 AUX PWM 5
16 AUX PWM 4
BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18
BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18
25 IVS
26 OIL PRES
2 TACH
6 MIL
18 FUEL PUMP 39 AUX OUT1
7 FUEL SELECT
10 AUX ANA PD1B
27 AUX OUT 2
4 BRAKE
11 RS 232+
3 RS 232-
LB/PK 16
W/PK 16
15 START IN INTERUPT
19 START IN AUTOCRANK
PK/BK 16
5 FUEL PUMP +
32 ANA AUX PD1

37 AUX ANA PU2B
LB/Y 18
12 FPP2
RD/T 14
R/T 16
BK/LB 18
BK/LG 18
GY/R 18
BR/W 18
T 16
BR/Y 16
BR/LB 16
W 16
BK/W 16
BK/W 16
LG/P 18
R/Y 18
PK/LG 18
BK/R 16
W/BK 18
LB/O 18
R/T 16
LB/DG 18
BK/W 16
GY/O 18
BK/LG 18
BOSCH THROTTLE
GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18
GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18
BATT(+)
R 12
RING
6
5
4
3
2
1
R 14
R 12
R 16
3
2
1
ALTERNATOR
DG/W 18
LG/P 18
R/Y 18
OIL PRESSURE
R/BK 18
O/LG 18
R/W 18
T/GN 18
BK/R 16
W 16
W/R 18
INJECTOR CYL #2
GY/R 18
FUEL PUMP
F4
LPG
TEMPERATURE
BN/LB 16
PK/BK 16
GY/R 18
BR/W 18
DG 18
O 18
TWR
INJECTOR CYL #4
W/BK 18
R/LG 18
A
B
LPG
LOCKOFF
BR/Y 16
DG/P 18
Y/R 18
KNOCK
SENSOR
DG/P 18
O/LG 18
1
2
3
4
5
6
7
8
ANA RTN
5V REF
PC TX
PC RX
UNUSED
UNUSED
CAN +
CAN -
DIAGNOSTIC CONNECTOR
PK/BK 16
FUEL PUMP RELAY

LB/O 18
LB/O 18
85
R 16
PK/BK 16
30
R/LG 18
STARTER
SOLENOID
87
RING
87A
LB/PK 16
87
W/PK 16
30
86
87A
R/LG 18
CAN
TERMINATION
CONNECTOR
STARTER RELAY
LB/PK 16
R/LG 18
LG/P 18
INJECTOR CYL #3
T 16
15A
86
R 16
85
W 18
SHD
RELAY
OMRON
FPP
PK/BK 16
TWR
W 18
DG/P 18
O/LG 18
BK/W 18
3
1
6
4
5
8
PK/BK 16
F1
R16
R/Y 18
INJECTOR CYL #1
R 16
BK/W 12
Y/R 18
DG/P 18
LB/BK 18
LB/Y 18
DG 18
O 18
R 16
SHD
A
B
C
D
MTRTWR4
BR/W 18
LG/R 18
BOSCH
TMAP
T/LB 18
DG/W 18
GY 18
LG/R 18
LG/W
W/R 18
BK/O 18
W/LB 18
BK/Y 18
T/Y 18
R/LG 18
DB/W 18
P/LB 18
GY/W 18
Y/W 18
Y/DB 18
R 16
TWR
A
B
C
D
GY/R 18
LG/W 18
BR/W 18
W/LG 18
W/LG 18
GY 18
DBL 18
GY/R 18
DB/O 18
DG/BK
LB/R 18
R 16
GY/Y 18
BR/W 18
GY/R 18
GY/LB 18
GY/Y 18
LG/BK 18
R 16
HO2S #2
R 16
BK/LG 18
GY/LB 18
GY/R 18
CAM
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
R 16
POWER RELAY
R 16
30
R 16
87
R/T 18
86
87A
R/LB 16
R/LB 16
10A
85
EPR
R 16
15A
RELAYED POWER
Part No. 102521
CAN +
CAN GROUND
UNUSED
UNUSED
UNUSED
POWER
EPR
CONNECTOR
F5
R 16
CAN + TERM
ES0400A
S-40 S-45
6 - 81
July 2007
Engine Wire Harness

Ford DSG-423 EFI Models (from serial number 11101 to 11784)
6 - 81
6 - 82
July 2007
Engine Wire Harness
REV A
Ford DSG-423 EFI Models (after serial number 11784)

N
J
R 16
ENGINE ECM
CONNECTOR
SPK_COIL1A
SPK_COIL1B
SPARK_COIL2A
SPK_GND
SPK_COIL2B
SPK_COIL3A
SPK_COIL3B
UEGOS
UEGOC
UEGOP
UEGPR
AUX ANA PD1
(FRP) AUX ANA PD2
CAN1 +
CAN1 CAN2 CAN2 +
AUX ANA PD3
5V EXT 1
5V RTN
EGO1
EGO2
MAP
AUX ANA PUD3
CRANK +
CRANK CAM +
CAM SPEED +
SPEED 5V EXT 2
5V RTN 2
PULSE IN
GOV 1
OIL PRESS
IAT
ECT
(FRT) AUX ANA PU1
(LPTEMP) AUX ANA PU2
(IVS) AUX ANA PU3
(BRAKE) AUX DIG 3
(GOV2) AUX DIG 4
TACH
VSW
AUX ANA PUD2
AUX ANA PUD1
TPS 1
TPS 2
(FUELSELECT)AUX DIG1
AUX DIG 2
KNOCK +
KNOCK FPP1
FPP2-IVS
(FPP2)
PC TX
PC RX
KNOCK 2+
KNOCK 2VBAT PROT
VBAT
EGOH 2
EGOH 1
INJ HS
INJ1 LS
INJ2 LS
INJ3 LS
INJ4 LS
INJ5 LS
GROUND
INJ6 LS
AUX PWM8
STARTER
RELAY
MIL
UEGO H
AUX PWM7
LOCKOFF
AUX PWM6
(FUEL PUMP)
VBAT
DBW +
GROUND
DBW AUX PWM5 REC
AUX PWM5
AUX PWM1
AUX PWM4
AUX PWM2
AUX PWM4 REC
AUX PWM3 REC
FP REC
AUX PWM3
FUEL PUMP
Y/BK 18
W/PK 18
Y/RD 18
BK/W 16
DG/P
6
7
8
9
10
11
12
13
14
15
R 16
GY/LB 18
DG/P 18
DB/O 18
GY/R 18
CYL #2
CYL #3
CYL #4
GY/R 18
GY/YL 18
R 16
BK/LB 18
CYL #1
DG/P 18
O/LG 18
LG/BK 18
BR/W 18
GY 18
GY/R 18
GASOLINE
SENSOR
INTERFACE
FORD
42 PIN
CONNECTOR
LG/R 18
GY/R 18
GY/R 18
GROUND
BR 16
BR 16
34 GND
RING
4
3
2
1
CHT
LG/W
DG/BK
LB/R 18
T/LB 18
BK/W 16
BK/W 16
BK/W 16
LB/BK 18
BK/LB 18
LB/R 18
LG/BK 18
T/LB 18
36 ROADSPEED 35 ROADSPEED +
24 GOV SELECT 1
LB/BK 18
R/LG 18
BK/Y 18
R/LG 18
R/T 14
R/T 14
F2
14 FPP1
R/LG 18
R/LG 18
1 VSW
VSW
5A
F3
R 14
ECM
10A
Y/R 18
DG/P 18
LB/BK 18
LB/Y 18
DG 18
O 18
BK/Y 18
GY 18
DBL 18
23 GOV SELECT 2
O/LG 18
DG/P 18
CRANK
29 CAN 28 CAN +
DG/O 18
DG/O 18
DB/W 18
LB/Y 18
DB/W 18
GY/R 18
BR/W 18
GY/R 18
BR/W 18
33 ANA RTN
31 VREF
R/BK 18
R/W 18
R/BK 18
R/W 18
21 AUX PWM 5
16 AUX PWM 4
BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18
BK/O 18
DG/W 18
T/Y 18
PK/LG 18
BK/R 16
O/LG 18
Y/DB 18
P/LB 18
T/GN 18
W/LB 18
DG 18
O 18
25 IVS
26 OIL PRES
2 TACH
6 MIL
18 FUEL PUMP 39 AUX OUT1
7 FUEL SELECT
10 AUX ANA PD1B
27 AUX OUT 2
4 BRAKE
11 RS 232+
3 RS 232-
LB/PK 16
W/PK 16
15 START IN INTERUPT
19 START IN AUTOCRANK
PK/BK 16
5 FUEL PUMP +
32 ANA AUX PD1

37 AUX ANA PU2B
LB/Y 18
12 FPP2
RD/T 14
R/T 16
BK/LB 18
BK/LG 18
GY/R 18
BR/W 18
T 16
BR/Y 16
BR/LB 16
W 16
BK/W 16
BK/W 16
LG/P 18
R/Y 18
PK/LG 18
BK/R 16
W/BK 18
LB/O 18
R/T 16
LB/DG 18
BK/W 16
GY/O 18
BK/LG 18
BOSCH THROTTLE
GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18
GY/W 18
Y/W 18
LB/DG 18
BR/W 18
GY/R 18
GY/O 18
BATT(+)
R 12
R 12
RING
6
5
4
3
2
1
R 14
R 16
3
2
1
R/LG 18
ALTERNATOR
DG/W 18
LG/P 18
R/Y 18
OIL PRESSURE
R/BK 18
O/LG 18
R/W 18
T/GN 18
BK/R 16
W 16
W/R 18
INJECTOR CYL #2
GY/R 18
FUEL PUMP
F4
LPG
TEMPERATURE
BN/LB 16
PK/BK 16
GY/R 18
BR/W 18
DG 18
O 18
TWR
INJECTOR CYL #4
W/BK 18
R/LG 18
A
B
LPG
LOCKOFF
BR/Y 16
DG/P 18
Y/R 18
KNOCK
SENSOR
DG/P 18
O/LG 18
1
2
3
4
5
6
7
8
ANA RTN
5V REF
PC TX
PC RX
UNUSED
UNUSED
CAN +
CAN -
DIAGNOSTIC CONNECTOR
PK/BK 16
LB/O 18
LB/O 18
85
R 16
PK/BK 16
30
R/LG 18
STARTER
SOLENOID
87
RING
87A
LB/PK 16
87
W/PK 16
30
86
87A
R/LG 18
CAN
TERMINATION
CONNECTOR
STARTER RELAY
LB/PK 16
INJECTOR CYL #3
T 16
15A
FUEL PUMP RELAY
R/LG 18
86
LG/P 18
85
R 16
W 18
SHD
RELAY
OMRON
FPP
PK/BK 16
TWR
W 18
DG/P 18
O/LG 18
BK/W 18
3
1
6
4
5
8
PK/BK 16
F1
R16
R/Y 18
INJECTOR CYL #1
R 16
SHD
A
B
C
D
MTRTWR4
BR/W 18
LG/R 18
BOSCH
TMAP
T/LB 18
DG/W 18
GY 18
LG/R 18
LG/W
W/R 18
BK/O 18
W/LB 18
BK/Y 18
T/Y 18
R/LG 18
DB/W 18
P/LB 18
GY/W 18
Y/W 18
Y/DB 18
R 16
BK/W 12
GY 18
DBL 18
GY/R 18
DB/O 18
DG/BK
LB/R 18
R 16
TWR
A
B
C
D
GY/R 18
LG/W 18
BR/W 18
W/LG 18
W/LG 18
BR/W 18
GY/R 18
GY/LB 18
GY/Y 18
LG/BK 18
R 16
GY/Y 18
DG/O 18
W/LG 18
DG/P 18
O/LG 18
R 16
HO2S #2
R 16
BK/LG 18
GY/LB 18
GY/R 18
CAM
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
HO2S #1
IGNITION COILS
Y/BK 18
W/PK 18
Y/RD 18
1
2
3
4
5
R 16
POWER RELAY
R 16
30
R 16
87
R/T 18
86
R/LB 16
R/LB 16
10A
85
EPR
87A
Part No. 102521
R 16
15A
RELAYED POWER
POWER
EPR
CONNECTOR
F5
R 16
CAN + TERM
CAN +
CAN GROUND
UNUSED
UNUSED
UNUSED
ES0400A
S-40 S-45
6 - 83
July 2007
Engine Wire Harness

Ford DSG-423 EFI Models (after serial number 11784)
6 - 83
6 - 84
July 2007
REV A
Joystick Connector Diagram
PRIMARY BOOM
UP/DOWN
DRIVE/STEER
JC2
YOUT 5
PWR 3
GND 2
YOUT 5
XOUT 4
PWR 3
GND 2
RKOUT 6
DRIVE & STEERING
BL
WH
13
BK
OR
RD
11
14
OR
12
BRN
BRN
J1
JC3
JC3
TURNTABLE ROTATE
J1
4
WH J1-5
BL J1-4
WH J1-5
OR J1-13
BRN J1-14
BK J1-2
RD J1-1
OR J1-11
BRN J1-12
AMP - 7 Pin Connector
PRIMARY BOOM
UP/DOWN
6
6
1
1
5
5
2
2
4
4
3
3
Deutsch
DRIVE/STEER
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
GND
PWR
XOUT
YOUT
RKOUT
Pin1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7

JC2
JC2
JC3
JC2
7
1
6
2
5
3
4
4
3
5
2
6
1
7
AMP
JC3
DRIVE & STEERING
YOUT 4
RKOUT 5
OR
BL/WH
WH/RD
BL/WH
XOUT 3
BRN
RD/WH
GND 1
WH/RD
PWR 2
YOUT 4
OR
XOUT 3
BRN
GND 1
PWR 2
TURNTABLE ROTATE
7
5
13
14
11
12
J1
J1
J1-5 BL/WH JC3-5
J1-4 WH/RD JC3-4
J1-13 OR JC3-2
J1-5 BL/WH JC3-3
J1-14 BRN JC3-1
J1-2 RD/WH JC2-4
J1-11 OR JC2-2
Note: Production changed

from 7 pin to 6 pin Joysticks
at Serial Number 12510
J1-1 WH/RD JC2-3
J1-12 BRN JC2-1
Deutsch - 6 Pin Connector
Part No. 102521
S-40 S-45
6 - 85
July 2007
Joystick Connector Diagram
6 - 85
6 - 86
July 2007
CTE Option Wiring Diagram
6 - 88
6 - 87
6 - 88
GROUND
SCHEMATIC - PLATFORM LEVEL CUTOUT
S-40 S-45
Part No. 102521
14"
WIRING DIAGRAM
OR C2B-2
OR-TS59
OR/BK-TS59
CTE Option Wiring Diagram
K
L
GROUND BOLT
14
14 PLATFORM LEVEL UP
14"
15
C40LS1 OR CR20#30
TB40
15 PLATFORM LEVEL DOWN
40
RD-H6+
RD-KS1-2 S.P.
C15PLD OR/BK C4B-3

C15PLD OR/BK CR21#86
C14PLU OR C4B-2
C14PLU OR CR20#86
5
40 BOOM STOWED
42
OR C6-40
14"
42 P134PWR
14"
C14PLU OR C6-14
OR/RD-C2B-4
CR20
C15PLD OR/BK C6-15
26"
C15PLD OR/BK 15-D
BRN 7.5"
CR21
DOWN RELAY
RD-C6-23 + LS PWR-C6-30
7.5"
PLAT LEVEL
C14PLU OR 14-D
CR20
UP RELAY
TB22
LIMIT SWITCHES
P22LS BK
PLAT LEVEL
CR21
11"
TB15
C40LS1 OR 40-A
6
BRN
C14PLU OR
BR-GND STUD
C20-1
4
R14PLU OR
R15PLD OR/BK
TB134
C20-2
C21-1
3
B
PLAT LEVEL UP
C21-2
PLAT LEVEL DOWN
C15PLD OR/BK
July 2007
REV A
M
N
TB14
July 2007
REV A
Hydraulic Generator Wiring Diagram- Welder Option
P25FS-RD
P26FS-BK
P24FS-WH
RPM HI
RPM LO
20
15
16
12.5 KW HYDRAULIC GENERATOR
TS47
GENERATOR ON
TS4
FOOTSWITCH
ALC-500
D12
NEUTRAL BUSS BAR
1 N.O.
2 COM
C45GEN GR/WH
8 N.C.
C35RPM BK/RD
C2P-7
C1P-9
C29MS RD/WH
L3
C30EDC WH
C31EDC WH/BK
L2
L1
C1P-3
C1P-4
C1P-5
NEMA 4 CONTROL BOX
50 AMP 3 POLE CIRCUIT BREAKER WITH INTEGRAL GFI
TB29
124 ohms
1
V151HG GR
V150HG GR/BK
GROUND
STUD ON
PANEL
APBPC
RS232TxD
RS232RxD
A1 BATTERY +
A2 SENSOR POWER +5 VDC
A3 BATTERYB1 VALVE 0 FWD COIL
B2 VALVE 1 NC
B3 DIGITAL OUTPUT BYPASS/OMRON
C1 TxD
C2 RxD
C3 /BOOT
8 GA 5 CONDUCTOR
BRASS
E1 NOT USED
E2 NOT USED
E3 NOT USED
GREEN 12GA
120 VAC GFI
CR4PHIGH IDLE
RELAY
8 GA 4 CONDUCTOR
MOTOR STROKE
VALVE
D1 ANALOG 0 JOYSTICK
D2 ANALOG 1 NC
D3 DIG IN 3 NC
BLACK 12GA
SILVER
C45GEN GR/WH
124 ohms
20 AMP CIRCUIT
BREAKER
F1 DIG IN 0
F2 DIG IN 1 GENERATOR ON
F3 DIG IN 2
U4
SX Controller
BYPASS PCOIL
110 VAC
GFI
DRIVE EDC +
DRIVE EDC -
12 GA 3 CONDUCTOR
ENCLOSURE
3
1k ohms
OMRON
RELAY
GREEN
BLACK 12GA
C5-12
L1
C5-18
C5-24
BLACK
GREEN
TB45
WHITE
BLACK
TB35
C2B-7
4
2
TB22
C5-1
5
1
C5-21
L3
RED
5 SW INPUT
TIME DELAY
MODULE 4S
C5-20
ORANGE
N
3 GND
C1B-9
RED
TB24
C1B-3
L2
C1B-4
C1B-5
208 VAC
OUTLET
7
SILVER
BRASS
WHITE
GREEN
GREEN
BLACK
1. Turning on the Generator supplies current

to the high idle relay through the diode
switching the engine to high RPM. In addition
the diode between TB45 and TB29 supplies
power to the motor stroke valve switching
the motors to high speed/low torque mode.
3. When the AC generator is turned OFF the

SX module will ramp the output to the EDC to
threshold preventing cavitation to the hydraulic
motor powering the generator. When threshold
is reached the bypass valve is turned OFF.
12 GA 3 CONDUCTOR
2. The SX controller is turned ON supplying

power to bypass valve and the change over
relay. The EDC valve is switched over to the
output of the SX controller.
Part No. 102521
Inside
Enclosure
Harness
PIN#
1
2
3
4
5
6
7
8
9
10
11
12
COLOR
BR
WH
WH/BK
BR
BR
WH
WH/BK
BR
GR/WH
GR/BK
WH
BR
S-40 S-45
CKT#
GND
C30EDC+
C31EDCGND
GND
C30EDC+(A)
C31EDC-(A)
GND
C45GEN
V150HG
C22PWR
GND
COLOR
WH/RD
WH
WH/BK
BK/RD
BL/RD
RD
RD/BK
OR/RD
GR/WH
GR/BK
RD/WH
GR
6 - 89
July 2007
Hydraulic Generator Wiring Diagram- Welder Option
6 - 89
6 - 90
July 2007
REV C
2WD Non-Oscillating Hydraulic Schematic

S-40 Models (before serial number 7569)
EXTEND RETRACT CYL
.025
DB
2 gpm
7.6 L/min
MEDIUM
PRESSURE
FILTER
BRAKE MANIFOLD
T2
CP
SLAVE
PLATFORM LEVEL
CYLINDERS
D
PLATFORM
ROTATE
TEST
3 gpm
11.4 bar
BRAKE
PRIMARY LIFT
CYLINDER
DA
TURNTABLE
ROTATE
4 gpm
15.1 L/min
51 psi
3.5 bar
CB
CA
MASTER
.030
S1
AUXILIARY
PUMP
1.7
V2
AUX
TEST
HYDRAULIC
COOLER
OPTION
315 psi
21.7 bar
SW2
BG
P2
P1
PL2
BE
E
AD
AV
AU
3625 psi
250 bar
AE
AG
AS
COUNTERBALANCE VALVE
RATIO
AC
AH
AA
BD
4.5 gpm
17 L/min
AR
FUNCTION
PUMP
9 7
AB
BF
PRESS
BH
BA
AY
AX
AZ
PR2
PR1
AI
AL
1950 psi
134 bar
T1
PL1
V1
SW1
2200 psi
151.7 bar
FUNCTION
MANIFOLD
AO
RET
EXT
PTEST
AP
AM
AF
0.6 gpm
2.3 L/min
AK
AW
BB
0.6 gpm
2 L/min
(S-40)
AN
RETURN
FILTER
DRIVE PUMP
AQ
2.0 gpm
7.6 L/min
25 psi
1.7 bar
AJ
BG
3:1
1000 PSI
3:1
2000 PSI
3:1
3000 PSI
3:1
3300 PSI
3:1
3500 PSI
5:1
3500 PSI
0.1 gpm
0.4 L/min
AT
2600 psi
179 bar
TANK
3 psi
0.2 bar
3 psi
0.2 bar
PRESS
AUX
T2
ST1
BI
ST2
FUNCTION
MANIFOLD
LS TEST
RESERVOIR
T1
PRESS
OPTIONAL
GENERATOR
MANIFOLD
2400 psi
165.5 bars
HYDRAULIC ROTARY COUPLER
8A
8B
x x
8C
6B
6C
6B
2A
2C
2B
5
FUNCTION
PUMP
A
REAR
RIGHT
TANK
TEST
M3
RELEASE
T2
FE
185 psi
12.7 bar
FRR
FRB
FLB
OPTIONAL
GENERATOR
FLR
M1
RIGHT
STEERING
TO HYD ROTARY COUPLER
LEFT
210 psi
14.5 bar
50%
FC
.070
50%
FB
FA
Note: 'alpha' callouts refer to

components shown in the
manifold illustrations.
Refer to the Repair Section.
FD
M4
T1
REAR
LEFT
185 psi
12.7 bar M2
RELEASE
TRACTION
MANIFOLD
Part No. 102521
S-40 S-45
6 - 91
July 2007

6 - 91
6 - 92
July 2007
REV C

EXTEND RETRACT CYL
BRAKE MANIFOLD
.025
DB
2 gpm
7.6 L/min
MEDIUM
PRESSURE
FILTER
T2
CP
TURNTABLE
ROTATE
4 GPM
15.1 L/min
50 psi
3.5 bar
PRIMARY LIFT
CYLINDER
SLAVE
S45 JIB BOOM
PLATFORM LEVEL
CYLINDERS
J2
3 GPM
11.4 L/min
V1
J1
C
DA
TEST
BRAKE
CC
MASTER
V2
.030
CA
PR1
S1
AUXILIARY
PUMP
1.7
V2
PL1
V1
PL2
PR2
AUX
HYDRAULIC
COOLER
OPTION
TEST
315 psi
21.7 bars
FUNCTION
MANIFOLD
AO
RET
EXT
PTEST
AP
P2
P1
SW2
2200 psi
151.7 bar
BE
BH
AD
AV
AG
AC
AH
BD
4.5 gpm
17 L/min
FUNCTION
PUMP
AM
AF
0.6 gpm
2.27 L/min
AK
BB
AW
AA
0.8 gpm
3 L/min
AN
RETURN
FILTER
25 psi
1.7 bar
AQ
AJ
BG
2.0 gpm
7.6 L/min
0.1 gpm
0.38 L/min
AT
2900 psi
200 bar
TANK
3 psi
0.2 bar
3 psi
0.2 bar
PLATFORM
ROTATE
AB
BF
AR
DRIVE PUMP
CB
BA
AE
AU
AS
9 7
JIB SELECT
MANIFOLD
AY
AX
AZ
PR2
PRESS
3625 psi
249.9 bar
PR1
AI
AL
1950 psi
134.4 bar
T1
SW1
BG
AUX
T2
ST1
BI
ST2
FUNCTION
MANIFOLD
LS TEST
RESERVOIR
T1
PRESS
OPTIONAL
GENERATOR
MANIFOLD
RATIO
8A
8B
x x
8C
6C
6B
6B
A
REAR
RIGHT
2A
2C
2B
TEST
FE
M3
PRESS
3:1
1000 PSI
3:1
2000 PSI
3:1
3000 PSI
3:1
3300 PSI
3:1
3500 PSI
5:1
3500 PSI
2400 psi
165.5 bar
FUNCTION
PUMP
TANK
T2
185 psi
12.7 bar
RELEASE
FRR
FRB
FLB
OPTIONAL
GENERATOR
FLR
M1
RIGHT
STEERING
LEFT
50%
FC
.070
FA
50%
FB
FD

M4
T1
REAR
LEFT
M2
185 psi
12.7 bar
RELEASE
TRACTION
MANIFOLD
Part No. 102521
S-40 S-45
6 - 93
July 2007

6 - 93
6 - 94
July 2007
REV C
4WD Oscillating Hydraulic Schematic

EXTEND RETRACT CYL
BRAKE MANIFOLD
.025
DB
2 gpm
7.6 L/min
MEDIUM
PRESSURE
FILTER
TURNTABLE
ROTATE
4 gpm
15.1 L/min
50 psi
3.4 bar
3 gpm
11.4 L/min
T2
PLATFORM LEVEL
CYLINDERS
SLAVE
PRIMARY LIFT
CYLINDER
CA
CP
DA
MASTER
TEST
BRAKE
.030
CB
S1
V2
B
M
TEST
1.7
AUXILIARY
PUMP
315 psi
21.7 bar
AUX
HYDRAULIC
COOLER
OPTION
PTEST
AP
FUNCTION
MANIFOLD
AO
RET
EXT
PL1
SW1 SW2
P1
BG
P2
2200 psi
151.7 bar
AL
AE
AG
AC
AH
BD
4.5 gpm
17 L/min
AR
FUNCTION
PUMP
RATIO
AM
AA
0.6 gpm
2.27 L/min
AF
BB
AK
AW
0.6 gpm
2 L/min
AN
RETURN
FILTER
DRIVE PUMP
AQ
25 psi
1.7 bar
3 psi
0.2 bar
0.1 gpm
0.38 L/min
AT
2600 psi
179.3 bar
TANK
3:1
1000 PSI
3:1
2000 PSI
3:1
3000 PSI
3:1
3300 PSI
3:1
3500 PSI
5:1
3500 PSI
1.5:1
3000 PSI
AJ
BG
2.0 gpm
7.6 L/min
PRESS
AY
AX
AU
AS
AB
BA
BF
3625 psi
249.9 bar
9
PR2
PR1
BH
PRESS
PLATFORM
ROTATE
BE
E
AD
AV
AZ
PL2
AI
1950 psi
134.4 bar
T1
V1
3 psi
0.2 bar
AUX
T2
ST1
BI
ST2
LS TEST
FUNCTION
MANIFOLD
RESERVOIR
T1
PRESS
OPTIONAL
GENERATOR
MANIFOLD
2400 psi
165.5 bar

x
8A
x
8B
x x
8C 6B
x
6C 6A
2A
2C
2B
FUNCTION
PUMP
HF
REAR
LEFT
TEST
TANK
T2
M4
M7
FRONT
LEFT
M5
210 psi
14.5 bar
FRR
M2
HH
50%
RIGHT
HE
FRB
FLB
STEERING
67% 33%
LEFT
HA
TEST
.052
HG
50%
.070
HD
HI
IN
50%
FRONT
RIGHT
T1
M6
M1
B
A
OUT
M8
M3
950 psi
65.5 bar
RIGHT
LEFT
OSCILLATE VALVE
TRACTION
MANIFOLD
OPTIONAL
GENERATOR
FLR
50%
.070
HC
REAR
RIGHT

OSCILLATE CYLINDERS
Part No. 102521
S-40 S-45
6 - 95
July 2007

6 - 95
6 - 96
July 2007
REV C

EXTEND RETRACT CYL
TURNTABLE
ROTATE
4 gpm
15.1 L/min
50 psi
3.4 bar
BRAKE MANIFOLD
.025
DB
2 gpm
7.6 L/min
MEDIUM
PRESSURE
FILTER
J2
3 gpm
11.4 L/min
T2
S45 JIB BOOM
PLATFORM LEVEL
CYLINDERS
SLAVE
PRIMARY LIFT
CYLINDER
V1
J1
CP
DA
TEST
BRAKE
CC
MASTER
V2
.030
CA
PR1
S1
V2
B
M
TEST
1.7
AUXILIARY
PUMP
315 psi
21.7 bar
AUX
HYDRAULIC
COOLER
OPTION
PTEST
AP
AO
RET
EXT
FUNCTION
MANIFOLD
SW1
PL1
SW2
BG
P2
P1
2200 psi
151.7 bar
AD
BA
AE
AG
AR
4.5 gpm
17 L/min
FUNCTION
PUMP
RETURN
FILTER
AQ
25 PSI
AC
BD
AM
0.6 gpm
2.27 L/min
AK
AF
BB
AW
AA
0.8 gpm
3 L/min
BG
2.0 gpm
7.5 L/min
0.1 gpm
0.3 L/min
AT
3 psi
0.2 bar
T2
ST1
BI
ST2
PRESS
RATIO
AJ
2900 psi
200 bar
TANK
3 psi
0.2 bar
AH
AN
DRIVE PUMP
PLATFORM
ROTATE
AY
AX
AU
AS
CB
AB
BH
PRESS
JIB SELECT
MANIFOLD
BF
3625 psi
249.9 bar
E
PR2
PR2
PR1
AV
AZ
PL2
BE
AI
AL
1950 psi
134.5 bar
T1
V1
LS TEST
RESERVOIR
3:1
1000 PSI
3:1
2000 PSI
3:1
3000 PSI
3:1
3300 PSI
3:1
3500 PSI
5:1
3500 PSI
1.5:1
3000 PSI
AUX
FUNCTION
MANIFOLD

x
8A
x
8B
x x
8C 6B
x
6C 6A
HF
REAR
LEFT
TEST
T1
2C
2B
2400 psi
165.5 bar
M4
FRONT
LEFT
210 psi
14.5 bar
RIGHT
HE
FRB
FLB
STEERING
FLR
67% 33%
TANK
HA
TEST
.052
HB
HG
50%
.070
HD
T2
HI
IN
50%
FRONT
RIGHT
T1
M6
M1
B
A
OUT
M8
M3
950 psi
65.5 bar
OPTIONAL
GENERATOR
RIGHT
LEFT
OSCILLATE VALVE
TRACTION
MANIFOLD
FUNCTION
PUMP
LEFT
50%
.070
HC
FRR
M2
HH
50%
PRESS
OPTIONAL
GENERATOR
MANIFOLD
M7
M5
REAR
RIGHT
2A

OSCILLATE CYLINDERS
Part No. 102521
S-40 S-45
6 - 97
July 2007

6 - 97
6 - 98
September
July 2007 2007
REV D
2WD Hydraulic Schematic

M
EXTEND RETRACT CYLINDER

(4 gpm / 15.1 L/min)
50 psi
3.5 bar
BRAKE/2 SPEED
MANIFOLD EA
TURNTABLE
ROTATE
(2 gpm / 7.5 L/min)
A
V1
CC
.030
V2
S1
M 1.7 AUXILIARY
PUMP
V2
AUX
HYDRAULIC
COOLER
OPTION
TEST
315 psi
21.7 bar
PTEST
AP
AO
SW1 SW2
RET
EXT
BC
P2
P1
FUNCTION
MANIFOLD
2200 psi
151.6 bar
1950 psi
134.5 bar
T1
E
AD
BA
AE
AU
AS
4.5 gpm
17 L/m
AR
FUNCTION
PUMP
AM
AF
AX
AY
AW
AA
0.8 gpm
3 L/min
(S-45)
0.6 gpm
2.2 L/min
0.6 gpm
2 L/min
(S-40)
AQ
25 psi
1.7 bar
TANK
3 psi
0.20 bar
3 psi
0.20 bar
2.0 gpm
7.5 L/m
RETURN
FILTER
0.1 gpm
0.3 L/min
2600 psi
179 bar
(S-40)
T2
AJ
BG
AT
2900 psi
200 bar
(S-45)
E
F
G
ST1
ST2
BI
AUX
FUNCTION
MANIFOLD
-8
X
X
8B 6B 6C 6A
8A
2A
2C
2B
RIGHT
REAR
FRR
M4
RIGHT
CDR
GC
M2
LEFT
REAR
M3
T2
LEFT
STEERING
OPTIONAL
GENERATOR
MTR A
-12
-12
LEFT
RIGHT
-12

T
OSCILLATE VALVE
G
OSCILLATE CYLINDERS OPTION
TANK
21CC
G2
G1
950 psi
65.5 bar
GD
12.5 KW GENERATOR
B
A
IN
OUT
TRACTION
MANIFOLD
G1
MTR B
-12
TEST
GB
FLR
-8
280 psi
19.3 bar
.070
50%
CU
GA
GF
M1
CDL
FLB
GE
50%
FRB
CY
270 PSI @
3.5 GPM
G2
TANK
A
B
0.031
CW
CX
FUNCTION
PUMP
TEST A
CV
2400 psi
165.4 bar
PMP A
CLR
PMP B
WELDER
MANIFOLD
2400 psi
165.4 bar
OPTIONAL
GENERATOR
MANIFOLD
DRIVE
PUMP
-12
3.5 GPM
21 GPM
-12
PRESS
HYDRAULIC WELDER OPTION
OIL
COOLER
T1
PRESS
1000 PSI
2000 PSI
3000 PSI
3300 PSI
3500 PSI
3500 PSI
3000 PSI
LS TEST
RESERVOIR
RATIO
3:1
3:1
3:1
3:1
3:1
5:1
1.5:1
AN
DRIVE PUMP
X X
PLATFORM
ROTATE
AC
AK
BB
CB
AH
AG
BD
JIB SELECT
MANIFOLD
BF
3625 psi
249.9 bar
AB
AY
AX
AZ
PR2
BH
AI
AV
PR2
PR1
AL
PRESS
BE
CA
PR1
PL2
PL1
V1
TEST
MASTER
8C
J2
J1
EC
BRAKE 2SPEED
S45 JIB BOOM
PLATFORM LEVEL
CYLINDERS
SLAVE
PRIMARY LIFT
CYLINDER
(3 gpm / 11.3 L/min)
T2
CP
ED
EB
025.
MEDIUM
PRESSURE
FILTER
HYDRAULIC
ROTARY
COUPLER
OSCILLATE CYLINDERS
Part No. 102521
S-40 S-45
6 - 99
July 2007

6 - 99
6 - 100
September
July 2007 2007
REV D

.030 orifice added after serial number 8445
TURNTABLE
ROTATE
(2 gpm / 7.5 L/min)
A
EA
V1
T2
CP
C
TEST
BRAKE 2SPEED
CC
V2
S1
A
M 1.7
TEST
AUXILIARY
PUMP
AUX
HYDRAULIC
COOLER
OPTION
315 psi
21.7 bar
V1
V2
AP
AO
RET
EXT
PTEST
PL1
SW1 SW2
BC
P2
2200 psi
E
151.6 bar
P1
FUNCTION
MANIFOLD
T1
1950 psi
134.5 bar
PR1
AZ
FUNCTION
PUMP
BF
4.5 gpm
17 L/min
AA
0.6 gpm
2.2 L/min
AK
AF
BB
AW
0.8 gpm
3 L/min
(S-45)
0.6 gpm
2 L/min
(S-40)
3 psi
0.20 bar
RETURN
FILTER
2600 psi
179 bar
(S-40)
B
C
D
E
ST1
T2
ST2
BI
LS TEST
RESERVOIR
AUX
FUNCTION
MANIFOLD
PRESS
8B 6B 6C 6A
8A
2A 2C
TEST A
JD
M7
M8
A
FRR
RIGHT
FRONT
FRB
M6
JA
CY
270 PSI @
3.5 GPM
G2
CU
OPTIONAL
GENERATOR
LEFT
RIGHT
0.031
CW
CX
JL
M5
6
CV
T2
FLR
FLB
PMP A
CLR
PMP B
TANK
STEERING
CDR
DRIVE
PUMP
G1
MTR B
-12
MTR A
-12
1
JC
-12
WELDER
MANIFOLD
2400 psi
165.4 bar
FUNCTION
PUMP
RIGHT
REAR
3.5 GPM
OPTIONAL
GENERATOR
MANIFOLD
2B

3
-12
-8
21 GPM
PRESS
1000 PSI
2000 PSI
3000 PSI
3300 PSI
3500 PSI
3500 PSI
3000 PSI
HYDRAULIC WELDER OPTION
OIL
COOLER
T1
RATIO
3:1
3:1
3:1
3:1
3:1
5:1
1.5:1
0.1 gpm
0.3 L/min
AT
2900 psi
200 bar
(S-45)
TANK
AJ
BG
2.0 gpm
7.5 L/min
AQ
25 psi
1.7 bar
3 psi
0.20 bar
AM
50%
50%
280 psi
19.3 bar
.040
JH
LEFT
REAR
M3
CDL
M1
JN
JK
TEST
.040
JI
JE
JB
50%
50% 50%
.040
JG
PLATFORM
ROTATE
AN
DRIVE PUMP
X
CB
AC
BD
JIB SELECT
MANIFOLD
AH
AG
AR
AB
BA
AE
AS
PR2
BH
AD
AU
3625 psi
249.9 bar
PR2
AY
AX
BE
AI
AV
CA
PR1
PL2
AL
PRESS
8C
2
C
MASTER
EC
0.030
J1
-8
B
A
IN
OUT
JM
50%
950 psi
65.5 bar
M4
-12
TANK
21CC
G2
G1
-12
12.5 KW GENERATOR
RIGHT
LEFT
ED
EB
J2
.025
PRIMARY LIFT
CYLINDER
(3 gpm / 11.3 L/min)
S45 JIB BOOM
PLATFORM LEVEL
CYLINDERS
SLAVE
HYDRAULIC
ROTARY
COUPLER
BRAKE/2 SPEED
MANIFOLD
EXTEND RETRACT CYLINDER

(4 gpm / 15.1 L/min)
MEDIUM
PRESSURE
FILTER
50 psi
3.5 bar
B
JF
JJ
TRACTION
MANIFOLD
M2
LEFT
FRONT
OSCILLATE VALVE
G
OSCILLATE CYLINDERS OPTION

OSCILLATE CYLINDERS
Part No. 102521
S-40 S-45
6 - 101
July 2007

6 - 101
6 - 102
July 2007
REV A
1
1
OIL
COOLER
3.5 GPM
DRIVE
PUMP
A
3
PMP B
CLR
PMP A
WELDER
MANIFOLD
CV
4
4
0.031
CW
CY
CX
5
5
270 PSI @
3.5 GPM
G2
CU
G1
MTR B
MTR A
6
3
TANK
21CC
G2

HYDRAULIC
ROTARY
COUPLER
Hydraulic Generator Schematic- Welder Option
7
7
G1
8
8
12.5 KW GENERATOR
Part No. 102521
S-40 S-45
6 - 103
July 2007
Hydraulic Generator Schematic- Welder Option
6 - 103
6 - 104
California Proposition 65
Warning
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
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
Phone +46 31 575100
Fax +46 31 579020
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Germany
Phone
Phone
Fax
0800 180 9017

+49 422 149 1818
+49 422 149 1820
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Mexico City

Phone +52 55 5666 5242
Fax +52 55 5666 3241
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Distributed By:
Genie North America

Manual de Service Genie S40 7645

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Manual de Service Genie S40 7645

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Service Manual

Serial Number Range

Part No. 102521

Serial Number Information

Read, understand and obey the safety rules and

Genie Industries offers the following Service

This manual provides detailed scheduled

S-40 and S-45 Service Manual

Copyright 1994 by Genie Industries

102521 Rev C July 2007

Part No. 102521

Section 1 Safety Rules

Serial Number Legend

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

Maximum platform reach : 34 ft 3 in/ 10.4 m

Country of manufacture: USA

Part No. 102521

Section 1 Safety Rules

This page intentionally left blank.

Part No. 102521

Section 1 Safety Rules

Do Not Perform Maintenance

Part No. 102521

Section 1 Safety Rules

Be sure to wear protective eye wear and

Read each procedure thoroughly. This

Be aware of potential crushing hazards

Part No. 102521

Scheduled Maintenance Procedures

Part No. 102521

Inspect the Decals and Manuals .................................................................. 3 - 7

Perform Pre-operation Inspection ................................................................. 3 - 8

Perform Function Tests ................................................................................ 3 - 8

Perform Engine Maintenance ....................................................................... 3 - 9

Scheduled Maintenance Procedures, continued

Perform 30 Day Service ............................................................................. 3 - 10

Perform Engine Maintenance - Deutz and Ford Models ............................ 3 - 10

Perform Engine Maintenance - Perkins Models ......................................... 3 - 11

Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12

Perform Engine Maintenance - Ford Models ............................................... 3 - 13

Inspect the Battery ..................................................................................... 3 - 17

Inspect the Electrical Wiring ....................................................................... 3 - 18

Inspect the Air Filter ................................................................................... 3 - 19

Test the Key Switch ................................................................................... 3 - 20

Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 20

Check the Exhaust System ....................................................................... 3 - 20

Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 22

B-10 Confirm the Proper Brake Configuration ...................................................... 3 - 24

Part No. 102521

Scheduled Maintenance Procedures, continued

Part No. 102521

Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 35

Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 36

Test the Platform Overload Mechanism (if equipped) ................................. 3 - 36

Replace the Inline Fuel Strainer .................................................................. 3 - 39

Perform Engine Maintenance Ford Models ................................................. 3 - 40

Check the Boom Wear Pads ...................................................................... 3 - 41

Check the Turntable Rotation Bearing Bolts ............................................... 3 - 42

Check the Free-wheel Configuration ........................................................... 3 - 43

Replace the Drive Hub Oil .......................................................................... 3 - 45

Perform Engine Maintenance - Deutz Models ............................................. 3 - 46

Replace the Hydraulic Filters ...................................................................... 3 - 47

Inspect for Turntable Bearing Wear ............................................................ 3 - 48

Test or Replace the Hydraulic Oil ............................................................... 3 - 50