Professional Documents
Culture Documents
Genie Sx150
Genie Sx150
SX™-150
from SX15015H-101
to SX15016H-499
This manual includes:
Repair procedures
from SX150H-500 Fault Codes
to SX150H-611 Electrical and
Hydraulic Schematics
Introduction
Intr oducti on Intr oducti on
Introduction
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 9/2016 Introduction Serial Number Legend
A2 6/2017 Repair 8-3, 8-4, 8-5
Fault Codes Fault Code Source
A3 10/2018 Repair 8-3A, 8-4A
Schematics Electrical schematics
A4 12/2018 Specifications Machine Torque Specifications
B 12/2019 Cover Add ending serial break
Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
Introduction
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial number (stamped on chassis)
6 Serial label (located under cover)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)
Safety Rules
Section 1 Safety R ules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Safety Rules
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
Indicates a potentially hazardous
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation Be sure that your workshop or work area
warrants it. is properly ventilated and well lit.
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.
Table of Contents
Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Serial Number Legend .......................................................................................... iv
Table of Contents
Table of Contents
Engines ................................................................................................................ 69
5-1 RPM Adjustment ............................................................................................ 69
5-2 Flex Plate ....................................................................................................... 69
How to Install the Flex Plate............................................................................ 70
Table of Contents
Manifolds .............................................................................................................92
8-1 Function Manifold Components......................................................................92
8-2 Valve Adjustments - Function Manifold ..........................................................98
8-3 Platform Level and Rotation Manifold Components, to SX150H-518 ..........100
8-3A Platform Level and Rotation Manifold Components, from SX150H-519 ...101
8-4 Jib Boom Manifold Components, to SX150H-518 .......................................102
8-4A Jib Boom Manifold Components, from SX150H-519 .................................103
8-5 Function Enable Manifold .............................................................................104
8-6 Steer and Axle Manifold Components, to SX150H-507 ...............................106
8-6A Steer and Axle Manifold Components, from SX150H-508 ........................110
8-7 Valve Adjustments - Steer and Axle Manifold ..............................................114
8-8 Traction Manifold Components ....................................................................116
8-9 Valve Adjustments - Traction Manifold .........................................................120
8-10 Generator Manifold Component .................................................................121
8-11 Valve Coils .................................................................................................122
Generators.........................................................................................................138
11-1 Welder Generator .......................................................................................138
Table of Contents
Table of Contents
Specifications
Section 2 Specific ati ons
Machine Specifications
Tires and wheels
Tire size 445D50/710, FF
Tire ply rating 18
Tire weight, new foam-filled 850 lbs
(minimum) 386 kg
Overall tire diameter 45.47 in
115.5 cm
Wheel diameter 28 in
71.1 cm
Wheel width 15 in
38.1 cm
Wheel lugs 10 @ 3/4 - 16
Lug nut torque, dry 320 ft-lbs
434 Nm
Fluid capacities
Fuel tank 50 gal
189 liters
Hydraulic tank 110 gal
416 liters
Hydraulic system (including tank) 175 gal
663 liters
Drive hubs 67 fl oz
1981 cc
Turntable rotation drive hub 43 fl oz
1262 cc
Drive hub oil type: SAE 90 multipurpose hypoid
gear oil API service classification GL5
Specifications
Specifications
Specifications
Specifications
Specifications
Type: bi-directional variable displacement piston pump Displacement per revolution 0 to 1.8 cu in
0 to 30 cc
Displacement per revolution 2.8 cu in
46 cc Flow rate @ 2450 rpm 0 to 20 gpm
0 to 76.4 L/min
Flow rate @ 2450 rpm 30 gpm
114 L/min Pressure, maximum 2900 psi
200 bar
Drive pressure, maximum 3625 psi
250 bar Pressure compensator 2900 psi
200 bar
Charge Pump
Standby pressure 350 psi
Type gerotor 24 bar
Displacement per revolution 0.85 cu in Auxiliary Pump
13.9 cc
Type fixed displacement
Flow rate @ 2450 rpm 9 gpm gear pump
34 L/min
Displacement per revolution 0.15 cu in
Charge pressure @ 2450 rpm 315 psi 2.47 cc
Neutral position 21.7 bar
Function manifold
Function Pump - Middle Pump
System relief valve pressure, 3200 psi
Type: variable displacement piston pump maximum 221 bar
Displacement per revolution 0 to 1.8 cu in Primary boom extend relief pressure 2500 psi
0 to 30 cc (measured at PTEST port) 172 bar
Flow rate @ 2450 rpm 0 to 20 gpm Platform Manifold
0 to 76.4 L/min
Platform rotate and platform level 0.2 gpm
Pressure, maximum 2700 psi flow regulator 0.76 L/min
183 bar
Steer/Axle Manifold
Pressure compensator 2700 psi
183 bar Axle extend relief pressure 2400 psi
165 bar
Standby pressure 350 psi
24 bar Traction Manifold
Hot oil relief pressure 250 psi
17.2 bar
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
Repair Procedures
Machine Configuration:
Section 3 Repair Pr oc edures
Repair Procedures
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Platform Controls
1-1
Platform Circuit Board
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Platform Controls
How to R emove the LED Circui t Board
7 Attach a grounded wrist strap to the ground How to Remove the LED Circuit
screw inside the control box.
Board
Electrocution/burn hazard.
1 Push in the red Emergency Stop button to the
Contact with electrically charged
off position at both the ground and platform
circuits could result in death or
controls.
serious injury. Remove all rings,
watches and other jewelry. 2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
Component damage hazard. 3 Locate the circuit board mounted to the inside
Electrostatic discharge (ESD) of the platform control box.
can damage printed circuit board
components. Maintain firm Electrocution/burn hazard.
contact with a metal part of the Contact with electrically charged
machine that is grounded at all circuits could result in death or
times when handling printed serious injury. Remove all rings,
circuit boards OR use a watches and other jewelry.
grounded wrist strap.
Component damage hazard.
8 Tag and carefully disconnect the wire Electrostatic discharge (ESD)
connectors from the circuit board. can damage printed circuit board
9 Tag and disconnect the ribbon cable from the components. Maintain firm
LED circuit board. contact with a metal part of the
machine that is grounded at all
10 Remove the circuit board mounting fasteners. times when handling printed
11 Carefully remove the circuit board from the circuit boards OR use a
control box. grounded wrist strap.
Platform Controls
Note: After each joystick is calibrated, check the 5 Press the plus button to select YES, then
display at the ground control box. There should be press the enter button.
no calibration faults shown on the display. If 6 Do not start the engine.
calibration faults exist, repeat procedure for that
joystick controlled function. 7 Locate the drive/steer joystick.
Note: If Joystick Not Calibrated is displayed at the 8 Move the drive/steer joystick full stroke in the
ground control box, proceed to step 7 for that forward direction and hold for 5 seconds, then
joystick controlled function procedure. return to the center or neutral position.
9 Move the drive/steer joystick full stroke in the
Note: Perform this procedure with the engine off.
reverse direction and hold for 5 seconds, then
Note: Use the following chart to identify the return to the center or neutral position.
description of each LCD screen control button used Result: The alarm at the ground controls
in this procedure. should sound for a successful calibration.
Platform Controls
Platform Controls
Platform Controls
How to R es et a Proportional Valve Coil D efault
Result: The alarm at the ground controls 3 Press the minus button twice, then press the
should sound for a successful calibration. enter button twice.
4 Use the previous button to scroll through the
menu until the function valve that needs to be
reset is displayed. Press the plus button to
select yes, then press the enter button to save
the setting.
5 Press the enter or previous button on the
LCD screen until EXIT is displayed.
6 Press the plus button or minus button to
select YES and then press the enter button.
Platform Controls
How to Set the F unction T hresholds and D efault Func tions Speeds
How to Set the Function 6 Slowly move the joystick off center in the
opposite direction just until the machine
Thresholds and Default function starts to move, then move the joystick
Functions Speeds very slowly towards the neutral or center
position just before the machine function
Note: Before the threshold and default function stops. Do not let go of the joystick.
speeds can be set, the boom function proportional
valve coil defaults must be set first. Refer to Repair 7 While holding the joystick in position, press the
Procedure, How to Reset a Proportional Valve Coil engine start button at the platform controls to
Default. set the joystick controller threshold.
Note: If a boom function proportional valve coil has 8 Repeat steps for each joystick controlled
not been replaced and just want to reset the machine function:
function speed to original factory settings, proceed • turntable rotate left/right.
to Function speeds procedure.
• primary boom extend/retract.
1 Start the engine from the platform controls.
• drive forward/reverse.
2 Press down the foot switch.
9 Once the threshold has been set, press and
Note: Be sure the engine rpm is set to foot switch hold the engine start button until the engine
activated high idle. shuts off. Do not press the red Emergency
Function threshold: Stop button.
Note: Approximately 3 seconds after the engine
3 Select a joystick controlled function that needs shuts off, the alarm at the ground controls will
to have the threshold set. sound to indicate the settings are being saved in
4 Slowly move the joystick off center in either memory.
direction just until the machine function starts
to move, then move the joystick very slowly 10 At the ground controls, turn the key switch to
towards the neutral or center position just the off position, wait a moment and then turn
before the machine function stops. Do not let the key switch to platform controls.
go of the joystick. 11 Check the display at the ground controls to be
5 While holding the joystick in position, press the sure there are no calibration faults.
engine start button at the platform controls to Note: There should be no calibration faults shown
set the joystick controller threshold. on the display. If calibration faults exist, repeat this
procedure.
Platform Controls
Platform Controls
How to Adj ust the Functi on Speeds How to Adj ust the Functi on R amp R ate Setti ng
Platform Controls
Platform Components
4 Disconnect the cables from the bottom of the 12 Remove the center bolt and slide the platform
platform control box. mounting weldment off of the platform rotator.
5 Remove the platform control box mounting Crushing hazard. The platform
fasteners. Remove the platform control box mounting weldment may
and set it aside. become unbalanced and fall if it
is not properly supported.
6 Remove the air line to platform bracket
retaining fasteners (if equipped).
7 Remove the power to platform cover plate
from the electrical outlet box. Do not
disconnect the wiring.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Platform Components
Platform Components
Component damage hazard. 4 Tag, disconnect and plug the hydraulic hoses
Mark the platform mounting from the platform rotator manifold. Cap the
weldment and the rotator flange fittings on the manifold.
before removing the platform
mounting weldment. The Bodily injury hazard. Spraying
platform mounting weldment hydraulic oil can penetrate and
must be replaced in the exact burn skin. Loosen hydraulic
same position on the rotator connections very slowly to allow
flange as it was before removal. the oil pressure to dissipate
If a new rotator is installed or the gradually. Do not allow oil to
rotator is disassembled, proper squirt or spray.
alignment can be achieved by
5 Tag, disconnect and plug the hydraulic hoses
rotating the rotator all the way to
the left and then installing the from the platform manifold. Cap the fittings on
platform mounting weldment all the manifold.
the way in the left position. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Note: When removing a hose assembly or fitting, burn skin. Loosen hydraulic
the O-ring (if equipped) on the fitting and/or hose connections very slowly to allow
end must be replaced. All connections must be the oil pressure to dissipate
torqued to specification during installation. Refer to gradually. Do not allow oil to
Specifications, Hydraulic Hose and Fitting Torque squirt or spray.
Specifications.
1 Remove the platform. Refer to Repair 6 Remove the pin retaining fasteners from the
Procedure, How to Remove the Platform. jib boom and jib boom leveling arms to
platform rotator pivot pins. Do not remove the
2 Tag and disconnect the electrical connector pins.
from the platform angle sensor.
Platform Components
How to Bleed the Pl atform R otator
7 Support the jib boom leveling arms with a How to Bleed the Platform
suitable lifting device.
Rotator
8 Use a soft metal drift to remove both pins and
remove the platform rotator from the machine. Note: Do not start the engine. Use auxiliary power
for all machine functions in this procedure.
Crushing hazard. The jib boom
leveling arms may fall if they are 1 Rotate the platform full right, then full left until
not properly supported when the air is completely out of the rotator. Bleeding
jib boom leveling arm pivot pin is the valve is not necessary.
removed.
Platform Components
6 Insert the key into the bypass/recovery key
2-4 switch and turn it to the bypass position.
Platform Level Sensor
Note: The platform level calibration value will not
The platform level sensor is mounted to the side of be saved correctly unless the key switch is in the
the platform rotator. The platform level sensor is bypass position and the calibration toggle switch is
monitored by the control system to maintain a level activated.
platform through boom range of motion. If a
7 Press and hold the enter button on the ground
platform level sensor is replaced, it must be
control panel while turning the key switch to
calibrated prior to machine operation.
ground controls. Hold the enter button for
approximately 5 seconds.
How to Calibrate the Platform 8 Enter sensor calibration mode by pressing the
Level Sensor buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus).
Note: Perform this procedure with the machine on
a firm, level surface. 9 Press the enter or previous button on the
LCD screen until SET PLATFORM LEVEL
Note: Perform this procedure with the boom in the SENSOR TO GRAVITY is displayed.
stowed position.
10 Press the plus button to select YES, then
Note: Use the following chart to identify the press the enter button to accept.
description of each LCD screen control button used
Note: The platform level sensor is calibrated at the
in this procedure.
factory for the correct millivolt/degree and will not
need to be adjusted.
Platform Components
Platform Components
Note: There may be a 2 second delay before the 1 Turn the key switch to the off position.
overload indicator lights flash and the alarm 2 Press and hold the enter button on the ground
sounds. control panel while turning the key switch to
9 Test all machine functions from the platform ground controls. Hold the enter button for
controls. approximately 5 seconds.
Platform Components
Note: Perform this procedure with the boom in the 7 Use a soft metal drift to remove the pin and let
stowed position. the cylinder hang down.
8 Attach a lifting strap from an overhead crane
Note: When removing a hose assembly or fitting,
to the jib boom.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 9 Remove the pin retaining fastener from the jib
torqued to specification during installation. Refer to boom pivot pin.
Specifications, Hydraulic Hose and Fitting Torque
10 Use a soft metal drift to remove the pin and
Specifications.
remove the jib boom from the jib rotator.
1 Remove the platform. Refer to Repair
Crushing hazard. The jib boom
Procedure, How to Remove the Platform.
may become unbalanced and fall
2 Remove the platform mounting weldment and when it is removed from the
the platform rotator. Refer to Repair machine if it is not properly
Procedure, How to Remove the Platform supported by the overhead
Rotator. crane.
3 Support the jib boom with a suitable lifting 11 Remove the pin retaining fasteners from the
device. jib boom lift cylinder rod-end pivot pin. Do not
4 Tag, disconnect and plug the jib boom lift remove the pin.
cylinder hydraulic hoses. Cap the fittings on 12 Attach a lifting strap from an overhead crane
the cylinder. to the lug on the rod end of the jib boom lift
Bodily injury hazard. Spraying cylinder.
hydraulic oil can penetrate and 13 Use a soft metal drift to remove the jib boom
burn skin. Loosen hydraulic lift cylinder rod-end pivot pin. Remove the jib
connections very slowly to allow boom lift cylinder from the jib boom bellcrank.
the oil pressure to dissipate
gradually. Do not allow oil to Crushing hazard. The jib boom
squirt or spray. lift cylinder may become
unbalanced and fall when it is
removed from the machine if it is
not properly supported by the
overhead crane.
8 Press and hold the enter button on the ground 17 Turn the key back to the run position and
control panel while pulling out the ground remove the key from the bypass/recovery key
controls red Emergency Stop button to the on switch. Insert the key into the main key switch
and turn it to ground controls.
position. Hold the enter button for
approximately 5 seconds and then release it. 18 Wait approximately 20 seconds and turn the
machine off by pressing the red Emergency
9 Enter sensor calibration mode by pressing the
Stop button in.
buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus). 19 Remove the fastener that was temporarily
installed. Close the control box door and install
10 Press the enter or previous button on the
the door retaining fasteners.
LCD screen until DELETE JIB LEVEL ANGLE
SENSOR CALIBRATION is displayed. Note: When the control box door is closed, the
calibration toggle switch is automatically activated
11 Press the plus button to select YES, then
to exit out of calibration mode.
press the enter button to accept.
12 Adjust the jib bellcrank until it is level to 20 Use the key to turn the bypass / recovery key
gravity. switch to the run position.
Note: While in the jib bellcrank level sensor Note: Be sure that the bypass/recovery key switch
calibration mode, the platform level up and platform is in the run position before attempting to operate
level down buttons on the TCON will activate the jib the machine.
bellcrank level up and level down valves. 21 Pull out the red Emergency Stop button. Start
13 t the JIB BELLCRANK LEVEL TO GRAVITY? screen, the engine and lower the boom to the stowed
Press the plus button to select YES, then position. Be sure there are no calibration faults
shown on the display.
press the enter button to accept.
22 Remove the digital level from jib bellcrank.
Note: If the engine is started to adjust the jib
bellcrank, press and hold the engine start button for
five seconds.
Note: If the system exits out of calibration mode
when the engine is started, repeat step 9 and
continue to step 12.
Boom Components
Boom Components
Boom Components
11 Secure the upper and lower tracks together. How to Repair the Primary Boom
Crushing hazard. If the upper Cable Track
and lower cable tracks are not
Component damage hazard.
properly secured together, the
The boom cable track can be
cable track could become
damaged if it is twisted.
unbalanced and fall when
removed from the machine. Note: A cable track repair kit is available through
the Genie Service Parts Department.
12 Attach a lifting strap to each end of the cable
track from an overhead crane for support. Do 1 Visually inspect the cable track and determine
not apply any lifting pressure. which 4-link section needs to be replaced.
13 Remove the mounting fasteners that attach 2 Support the cable track assembly above the
the cable track to the primary boom. section to be replaced.
14 Carefully remove the cable track from the 3 Carefully remove the snap rings and pins from
machine and lay it on a structure capable of each end of the damaged section of cable
supporting it. track.
Crushing hazard. The primary 4 Remove the retaining fasteners from the
boom cable track could become upper black rollers from the 4-link section of
unbalanced and fall when cable track to be replaced. Remove the rollers.
removed from the primary boom
5 Lift up the hoses and cables and carefully
if not properly supported by the
remove the damaged 4-link section of cable
overhead crane.
track.
Component damage hazard. Component damage hazard.
The boom cable track can be Cables and hoses can be
damaged if it is twisted. damaged if they are kinked or
pinched.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
Boom Components
Boom Components
How to R emove the Primary Boom
Boom Components
4 Remove the pin retaining fastener from the 13 Remove the primary boom cable track. Refer
boom lift cylinder rod-end pivot pin. Use a soft to Repair Procedure, How to Remove the
metal drift to remove the pin. Protect the Cable Track.
cylinder rod from damage.
14 Remove the end cover from the pivot end of
Crushing hazard. The boom lift the primary boom.
cylinder may fall when the 15 Remove the limit switch mounting fasteners
rod-end pivot pin is removed if from the limit switch on the ground controls
the boom lift cylinder is not side of the primary boom. Do not disconnect
properly supported by the the wiring. Remove the limit switch.
overhead crane.
16 Disconnect the electrical connector from the
Crushing hazard. The boom primary boom angle sensor.
may fall when the rod-end pivot Note: The primary boom angle sensor is located on
pin is removed if the boom is the pivot pin on the tank side of the boom.
not properly supported by the
overhead crane. 17 Remove the primary boom angle sensor
bracket mounting fasteners and remove the
5 Place support blocks under the boom lift primary boom angle sensor from the primary
cylinder. boom. Do not remove the angle sensor from
the bracket.
6 Remove the pin retaining fastener from the
boom lift cylinder rod-end pivot pin. Use a soft Note: When the primary boom is installed, the
metal drift to remove the pin. Protect the primary boom angle sensor will need to be
cylinder rod from damage. calibrated. Refer to Repair Procedure, How to
Calibrate the Primary Boom Angle Sensor.
7 Using the Auxiliary Power Unit, retract the
boom lift cylinder until the rod end will clear the 18 Attach a 10 ton / 9071 kg overhead crane to
boom weldment. the pivot end of the primary boom. Do not
8 Carefully lower the rod end of the boom lift apply any lifting pressure.
cylinder down onto the support blocks. 19 Remove the pin retaining fasteners from the
9 Tag, disconnect and plug the boom lift cylinder primary boom pivot pins.
hydraulic hoses. 20 Use a soft metal drift to remove the primary
10 Remove the platform. Refer to Repair boom pivot pins.
Procedure, How to Remove the Platform. 21 Carefully remove the primary boom from the
11 Remove the platform mounting weldment and machine and place it on a structure capable of
the platform rotator. Refer to Repair supporting it.
Procedure, How to Remove the Platform Crushing hazard. The primary
Rotator. boom could become unbalanced
12 Remove the jib boom. Refer to Repair and fall when removed from the
Procedure, How to Remove the Jib Boom. machine if not properly attached
to the overhead crane.
Note: When the jib boom is installed, the jib boom
angle sensor will need to be calibrated. Refer to
Repair Procedure, How to Calibrate the Jib Boom
Bellcrank Angle Sensor.
Boom Components
How to Dis ass embl e the Primary Boom
How to Disassemble the Primary 6 Remove the jib boom bellcrank. Refer to
Repair Procedure, How to Remove the Jib
Boom Boom Bellcrank.
Bodily injury hazard. This 7 Remove the boom primary extension cylinder.
procedure requires specific repair Refer to Repair Procedure, How to Remove
skills, lifting equipment and a the Boom Primary Extension Cylinder.
suitable workshop. Attempting
this procedure without these skills 8 The boom tubes can be disassembled without
and tools could result in death or removing the cable track assembly. If you
serious injury and significant choose to remove the cable track assembly,
component damage. Dealer Refer to Repair Procedure, How to Remove
service is strongly recommended. the Cable Track.
9 Remove the brackets supporting the cable
Note: When removing a hose assembly or fitting, track assembly from the #3 and #4 boom
the O-ring (if equipped) on the fitting and/or hose tubes
end must be replaced. All connections must be
torqued to specification during installation. Refer to 10 Place blocks between the cable tracks and
Specifications, Hydraulic Hose and Fitting Torque cable tubes for support.
Specifications.
11 Strap together the boom cable tubes, blocks of
1 Level the boom. wood, and the cable track.
Boom Components
Remove the #3 and #4 boom tubes: 19 Attach the #3 boom tube to a forklift, and lift
12 At the platform end, remove the #4 boom the tube enough to relieve the pressure from
retract bolt and secure the retract cables to the the lower wear pads, begin sliding the tube
#4 boom tube. from the boom assembly.
13 Tag and disconnect the harness to limit switch Note: Make sure the tube remains parallel to the #2
3RS and 4EOS. Remove the bracket and limit boom tube while removing.
switch from the #2 boom tube. 20 When approximately 10 feet of the #3 boom
Tip-over hazard. Failure to tube remains in the #2 boom tube, attach a
install the correct proximity strap from a suitable overhead lifting device
and/or limit switches in the and slightly lift the tube.
correct location will result in the Crushing hazard. The #3 and
machine tipping over, resulting #4 boom tubes may become
in death or serious injury. unbalanced and fall when they
are removed from the # 2 boom
14 Remove the red locking brackets from the #4 tube if it is not properly
extend cable pivot assembly. supported and attached to the
15 Remove the nuts on the #4 extend cables and overhead crane.
remove the #4 pivot assembly.
Note: During removal, the overhead crane strap will
16 At the pivot end of the machine, remove the need to be adjusted for proper balancing.
shims from the wear pads between the #2 and
#3 boom tubes. 21 Remove the fasteners securing the lower wear
pads between the #2 and #3 boom tubes.
Note: Pay careful attention to the location and
amount of shims used with each wear pad. Note: This will allow the retract cables to come out
with the boom tubes.
17 Using a strap, secure the #2 tube to the #1
tube. 22 Support and slide the #4 boom and #3 boom
tubes from the boom assembly.
18 At the platform end, remove the shims from
the lower channel and upper side wear pads
between the #2 and #3 boom tubes.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
Boom Components
Remove the #2 boom tube: 30 Begin pulling the #2 boom tube from the #1
boom tube.
23 At the pivot end of the machine, remove the
Note: Make sure the tube remains parallel to the #1
shims from the wear pads between the #1 and
boom tube while removing.
#2 boom tubes.
Note: Pay careful attention to the location and 31 When approximately 10 feet of the #2 boom
amount of shims used with each wear pad. tube remains in the #1 boom tube, attach a
strap from a suitable overhead lifting device
24 At the platform end, remove the top wear pads and slightly lift the tube.
between the #1 and #2 boom tubes.
Crushing hazard. The number 2
Note: Pay careful attention to the location and boom tube may become
amount of shims used with each wear pad. unbalanced and fall when it is
removed from the number 1
25 At the platform end, remove the shims from
boom tube if it is not properly
the upper side wear pad and lower side wear
supported and attached to the
pads from the opposite side of the boom
overhead crane.
between the #1 and #2 boom tubes.
Note: Pay careful attention to the location and Note: During removal, the overhead crane strap will
amount of shims used with each wear pad. need to be adjusted for proper balancing.
26 Remove the bolts supporting the cable track 32 Remove the final two side wear pads from the
assembly from the #2 boom tube. platform end of the machine.
Note: You may have to lift the cable track assembly Note: Pay careful attention to the location and
to clear the tab on the #2 boom tube when it is amount of shims used with each wear pad.
removed.
33 Support and slide the #2 boom tube from the
27 Attach the #2 boom tube to a forklift, and lift boom assembly.
the tube enough to relieve the pressure from
the lower wear pads.
Note: Remove the retract wire cables with the
boom tube.
28 Remove the fasteners securing the lower wear
pads and remove the wear pads and
aluminum block between the #1 and #2 boom
tubes.
29 Back the wire cables from the opening below
the #1 boom tube into the tube and then push
them out the end of the #1 boom tube.
Note: This will allow the retract cables to come out
with the boom tubes. Remove the retract wire
cables with the #2 boom tube
Boom Components
Note: When removing a hose assembly or fitting, Crushing hazard. The boom
the O-ring (if equipped) on the fitting and/or hose may fall when the rod-end pivot
end must be replaced. All connections must be pin is removed if the boom is
torqued to specification during installation. Refer to not properly supported by the
Specifications, Hydraulic Hose and Fitting Torque overhead crane.
Specifications.
6 Place support blocks under the boom lift
1 Raise the boom until there is approximately 4
cylinder.
feet / 1.2 m between the turntable and boom
rest pad. 7 Using the Auxiliary Power Unit, retract the
boom lift cylinder until the rod end will clear the
2 Attach a lifting strap from an overhead crane
boom weldment.
or other suitable lifting device to the rod end of
the the boom lift cylinder. 8 Carefully lower the rod end of the boom lift
cylinder down onto the support blocks.
Boom Components
9 Tag, disconnect and plug the boom lift cylinder 14 Remove the pin retaining fastener from the
hydraulic hoses. barrel-end pivot pin. Do not remove the pin.
Bodily injury hazard. Spraying 15 Support the boom lift cylinder with an
hydraulic oil can penetrate and overhead crane.
burn skin. Loosen hydraulic 16 Use a slide hammer to remove the boom lift
connections very slowly to allow cylinder barrel-end pivot pin through the
the oil pressure to dissipate access hole in the engine side turntable riser.
gradually. Do not allow oil to
squirt or spray. 17 With the boom lift cylinder being supported by
the overhead crane, pull the boom lift cylinder
10 Carefully raise the boom with the overhead toward the platform until it is out.
crane until the barrel end of the boom lift
cylinder is accessible. Crushing hazard. The boom lift
cylinder may become
11 Remove the engine pivot plate retaining unbalanced and fall if it is not
fastener. Swing the engine pivot plate out properly supported when it is
away from the machine. removed from the machine.
Boom Components
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or hose hydraulic oil can penetrate and
end must be replaced. All connections must be burn skin. Loosen hydraulic
torqued to specification during installation. Refer to connections very slowly to allow
Specifications, Hydraulic Hose and Fitting Torque the oil pressure to dissipate
Specifications. gradually. Do not allow oil to
squirt or spray.
1 Raise the boom to a horizontal position and
fully retract the primary extension cylinder. 8 Remove the fasteners from the inner cable
2 Remove the retaining fasteners from the boom track mounting bracket at the primary boom
end cover at the pivot end of the boom. extension cylinder.
Remove the cover from the machine.
Boom Components
9 Lay the inner cable track and hoses down and 10 At the platform end of the machine, loosen the
out of the way. retract cable equalizer bolts at the #1 and #2
boom tubes.
11 Remove the retaining fasteners from the red
cable adjustment locking brackets. Remove
the red locking brackets.
Bodily injury hazard. Failure to
install the red cable adjustment
locking bracket would allow the
cable mounting bolts to loosen
and fall out which could result in
death or serious injury.
llustration 1
1 #4 extend cable nut Illustration 2
2 6S limit switch 1 extend cable block
3 #3 extend cable adjusting bolt 2 weldment alignment edge
4 5S limit switch actuator bracket
5 #2 extend cylinder mounting plate
6 3RO limit switch
7 #1 extend cylinder mounting plate
Boom Components
19 Attach a suitable lifting device to the extend 1 Start the engine from the ground controls.
cylinder arms that will allow the cylinder to be
2 Raise and extend the boom approximately 15
lifted to clear the mounting plates on the #1
feet / 4.6 m.
boom and pulled from the boom assembly.
3 Fully retract the boom and lower to the
20 Attach a lifting strap from an overhead crane
horizontal position.
to support the cylinder as it is removed from
the boom assembly. 4 Stop the engine.
21 Support and slide the primary boom extension 5 Measure the distance between boom tubes #1
cylinder out of the boom assembly while and #2, measuring from the points identified
guiding the cables out of the boom and place it as (11) and (12). (Illustration 1) This is
on a structure capable of supporting it. dimension "A".
Crushing hazard. The primary Note: The distance should be approximately 1 in /
boom extension cylinder may 2.6 cm. The actual measurement will be a function
become unbalanced and fall of the primary extend/retract cylinder.
when it is removed from the
boom if it is not properly
supported and attached to the
overhead crane.
Boom Components
Illustration 1
1 Boom tube #1
2 Boom tube #2
3 Boom tube #3
4 Boom tube #4
5 Boom #4 retract bolt
6 Boom #3 retract bolt
7 Boom #4 measuring edge
8 Boom #3 measuring surface
9 Boom #3 measuring edge
10 Boom #2 measuring surface
11 Boom #1 measuring edge
12 Boom #2 measuring edge
Boom Components
Boom Components
20 Loosen the retract cable retract bolt (6). 28 Measure the gap between boom tubes #3 and
(Illustration 1) #4 using measuring points (7) and (8).
(Illustration 1)
21 Tighten the three extend cable adjustment
bolts (4) (Illustration 2) until the gap between Result: The measurement is between 1 in / 2.6
boom tubes #2 and #3 is between 1 in / 2.6 cm cm and 1.5 in / 3.8 cm more than dimension
and 1.5 in / 3.8 cm plus dimension “A”. "A". The gap is in tolerance. Proceed to step
48.
22 Torque the retract cable retract bolt to 105
ft-lbs / 142 Nm. Result: The measurement is more than 1.5 in /
3.8 cm greater than dimension "A". Proceed to
23 Torque the three extend cable adjustment
step 29.
bolts (4) to 35 ft-lbs / 47.5 Nm. Make small
adjustments to the three bolts to insure the Result: The measurement is less than 1 in /
cable tension limit switch arm (6) is centered in 2.6 cm greater than dimension "A". Proceed to
the limit switch actuator bracket. (Illustration 1) step 40.
24 Start the engine and fully raise and extend the 29 Loosen the two extend cable adjustment bolts
boom approximately 15 ft / 4.6 m. (1) five turns. (Illustration 2)
25 Fully retract the boom and lower the boom to 30 At the platform end of the boom, locate the #4
the horizontal position. retract cable retract bolt attached to the #2
boom tube (5). (Illustration 1)
26 Stop the engine.
31 Loosen the jam nut on the cable tension
27 Re-measure the gap between boom tubes #1
retract bracket. Do not remove the nuts.
and #2 from points (11) and (12) (dimension
“A”) and boom tubes #2 and #3 from points (9) 32 Tighten the retract bolt using a torque wrench
and (10). (Illustration 1) until boom tube #4 begins to move.
Result: The measurement is between 1 in / 2.6 Note: If the torque wrench reaches 70 ft-lbs / 95
cm and 1.5 in / 3.8 cm more than dimension Nm and boom tube #4 has not moved, loosen the
"A". The gap is in tolerance. Proceed to step #4 extend cable adjustment nuts 5 turns and
28. continue tightening the boom tube #4 retract bolt.
Result: The measurement is more than 1.5 in / 33 Tighten the retract bolt until the gap between
3.8 cm greater than dimension "A". Repeat the boom tubes #3 and #4 is 1.5 in / 3.8 cm
procedure beginning with step 9. greater than dimension "A".
Result: The measurement is less than 1 in / 34 Torque the two extend cable adjustment nuts
2.6 cm greater than dimension "A". Repeat the (1) to 35 ft-lbs / 47.5 Nm. Make small
procedure beginning with step 20. adjustments to the two nuts to insure the cable
tension limit switch arm (3) is centered in the
limit switch actuator bracket. (Illustration 2)
Boom Components
35 Torque the #4 retract bolt to 70 ft-lbs / 95 Nm. 45 Fully retract the boom and lower the boom to
36 Start the engine and fully raise and extend the the horizontal position.
boom approximately 15 ft / 4.6 m. 46 Stop the engine.
37 Fully retract the boom and lower the boom to 47 Re-measure the gap between boom tubes #1
the horizontal position. and #2 from points (11) and (12) (dimension
38 Stop the engine. “A”) and boom tubes #3 and #4 from points (7)
and (8). (Illustration 1)
39 Re-measure the gap between boom tubes #1
and #2 from points (11) and (12) (dimension Result: The measurement is between 1 in / 2.6
“A”) and boom tubes #3 and #4 from points (7) cm and 1.5 in / 3.8 cm more than dimension
and (8). (Illustration 1) "A". The gap is in tolerance. Proceed to step
48.
Result: The measurement is between 1 in / 2.6
cm and 1.5 in / 3.8 cm more than dimension Result: The measurement is more than 1.5 in /
"A". The gap is in tolerance. Proceed to step 3.8 cm greater than dimension "A". Repeat the
48. procedure beginning with step 29.
Result: The measurement is more than 1.5 in / Result: The measurement is less than 1 in /
3.8 cm greater than dimension "A". Repeat the 2.6 cm greater than dimension "A". Repeat the
procedure beginning with step 29. procedure beginning with step 40.
Result: The measurement is less than 1 in / 48 Install the red locking brackets (2) over the
2.6 cm greater than dimension "A". Proceed to cable adjustment bolts. A flat edge of each bolt
step 40. head must be on top for the locking bracket to
secure the bolts (Illustration 2).
40 Loosen the retract cable retract bolt (5).
(Illustration 1) Bodily injury hazard. Failure to
install the red cable adjustment
41 Tighten the two extend cable adjustment nuts
locking bracket would allow the
(1) (Illustration 2) until the gap between boom
cable mounting bolts to loosen
tubes #3 and #4 is between 1” and 1.5” plus
and fall out which could result in
dimension “A”.
death or serious injury.
42 Torque the retract cable retract bolt to 70 ft-lbs
/ 95 Nm. 49 Lower the boom to the stowed position.
43 Torque the two extend cable adjustment nuts
(1) to 35 ft-lbs / 47.5 Nm. Make small
adjustments to the bolts to insure the cable
break limit switch arm (4) is centered in the
limit switch bracket. (Illustration 1)
44 Start the engine and fully raise and extend the
boom approximately 15 ft / 4.6 m.
Boom Components
How to R eplac e the Boom Extend/R etr act Cables
Illustration 1
1 #4 extend cable nut
2 #4 cable pivot assembly
3 idler pully
4 side wear pad
5 #3 retract cable
6 cable retainer
7 #4 extend cable
8 #4 retract cable
Boom Components
6 Remove the fasteners securing the idler pulley 10 Remove the center mounting bolt securing the
holding the upper extend cables and remove sheave to the cover plate (3).
the pulley (3). (Illustration 1)
11 Remove the remaining fasteners securing the
7 Remove the upper side wear pads (4) from the cover plate to the #3 boom tube. Do not
#4 boom tube. (Illustration 1) remove the fasteners labeled (2) at this time.
(Illustration 2)
8 Remove the anti-rotation bolts from the extend
cable. Attach electrician's tape to the threaded 12 Remove the side wear pad (4).
end of the extend cable.
13 Loosen the fasteners (2) securing the sheave
9 At the platform end, loosen but do not remove mounting plate to the boom tube.
the fasteners labeled (1). (Illustration 2)
14 Remove the sheave from the bearing.
15 At the platform end, pull on the cable that was
above the sheave and then feed the cable that
was below the sheave toward the pivot end.
16 Remove the cable retainer (6) securing the
ends of #4 extend cable and #4 retract cable.
(Illustration 1)
17 Attach electrician's tape to the lower end of the
#4 extend cable.
18 At the platform end, pull the upper end of the
cable from the boom tube and then the lower
end.
19 Perform the procedure on the other extend
cable.
20 Reverse the procedure to install the new
extend cable beginning with the lower end of
the cable.
Illustration 2
1 wear pad fastener
2 sheave mounting fastener
3 sheave retaining bolt
4 side wear pad
Boom Components
Boom Components
Note: If the calibration flags between SCON and Note: The angle sensor calibration values will not
TCON do not agree after calibration, a crosscheck be saved correctly unless the key switch is in the
fault is generated and recorded and the affected bypass position and the calibration toggle switch is
boom function is inhibited. activated.
Note: A digital level will be required to perform this 7 Press and hold the enter button on the ground
procedure. control panel while pulling out the ground
controls red Emergency Stop button to the on
Note: A kit is available through Genie Product position. Hold the enter button for
Support (Genie part number 58351GT). This kit approximately 5 seconds and then release it.
includes a digital level with a magnetic base and
8 Enter sensor calibration mode by pressing the
cable harnesses.
buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus).
9 Press the enter or previous button on the
LCD screen until DELETE PRIMARY BOOM
ANGLE SENSOR is displayed.
Boom Components
10 Press the plus button to select YES, then 17 At the PRIMARY BOOM ANGLE TO
press the enter button to accept. GRAVITY 32 DEG screen, press the plus or
minus button to adjust the display to the exact
11 Place the digital level on top of the primary
value shown on the digital level, then press the
boom near the pivot and note the angle
enter button.
displayed on the digital level.
Note: If the measured angle already matches the
12 Press the enter button until PRIMARY BOOM
angle shown on the display at the ground controls,
ANGLE TO GRAVITY -2.6 DEG is displayed,
press the plus button or minus button to change
press the plus or minus button to adjust the
the angle and then change back to the measured
display to the exact value shown on the digital
value. The system must detect a change in
level, then press the enter button.
displayed value to record the calibrated value.
Note: If the measured angle already matches the
angle shown on the display at the ground controls, 18 Press and hold a function enable/speed select
press the plus button or minus button to change button and the primary boom up button until
the angle and then change back to the measured the digital level displays 49 degrees.
value. The system must detect a change in 19 At the PRIMARY BOOM ANGLE TO
displayed value to record the calibrated value. GRAVITY 49 DEG screen, press the plus or
minus button to adjust the display to the exact
Note: If the system exits out of calibration mode
value shown on the digital level, then press
when the engine is started, repeat step 8 and
the enter button.
continue to step 13.
Note: If the measured angle already matches the
13 Start the engine from the ground controls. angle shown on the display at the ground controls,
14 Press and hold a function enable/speed select press the plus button or minus button to change
button and the primary boom up button until the angle and then change back to the measured
the digital level displays 15 degrees. value. The system must detect a change in
displayed value to record the calibrated value.
15 At the PRIMARY BOOM ANGLE TO
GRAVITY 15 DEG screen, press the plus or 20 Press and hold a function enable/speed select
minus button to adjust the display to the exact button and the primary boom up button until
value shown on the digital level, then press the the digital level displays 66 degrees.
enter button.
21 At the PRIMARY BOOM ANGLE TO
Note: If the measured angle already matches the GRAVITY 66 DEG screen, press the plus or
angle shown on the display at the ground controls, minus button to adjust the display to the exact
press the plus button or minus button to change value shown on the digital level, then press the
the angle and then change back to the measured enter button.
value. The system must detect a change in
Note: If the measured angle already matches the
displayed value to record the calibrated value.
angle shown on the display at the ground controls,
16 Press and hold a function enable/speed select press the plus button or minus button to change
button and the primary boom up button until the angle and then change back to the measured
the digital level displays 32 degrees. value. The system must detect a change in
displayed value to record the calibrated value.
Boom Components
22 Press and hold a function enable/speed select 28 Wait approximately 20 seconds and turn the
button and the primary boom button until the machine off by pressing the red Emergency
boom is fully raised. Stop button in.
23 At the PRIMARY BOOM ANGLE TO 29 Remove the fastener that was temporarily
GRAVITY 82 DEG screen, press the plus or installed. Close the control box door and install
minus button to adjust the display to the exact the door retaining fasteners.
value shown on the digital level, then press the
Note: When the control box door is closed, the
enter button. calibration toggle switch is automatically activated
Note: If the measured angle already matches the to exit out of calibration mode.
angle shown on the display at the ground controls,
press the plus button or minus button to change 30 Pull out the red Emergency Stop button. Start
the angle and then change back to the measured the engine and lower the boom to the stowed
value. The system must detect a change in position. Be sure there are no calibration faults
displayed value to record the calibrated value. shown on the display.
Boom Components
Note: LTB1LO and LTB1LS are calibrated at the 2 Push in the ground controls red Emergency
same time. Stop button to the off position.
Note: The turntable level sensor, platform load 3 Turn the key switch to ground controls.
sensor and primary boom angle sensor must be 4 Open the ground control box.
calibrated before calibrating the boom length
sensor. 5 Locate the calibration toggle switch at the top
of the ground control box. Activate calibration
Note: Platform leveling is set to default parameters mode by moving the toggle switch in the left
to avoid platform out of level faults during direction.
calibration.
6 Temporarily install a control box door retaining
Note: If the calibration flags between SCON and fastener between the door and the box to
TCON do not agree after calibration, a crosscheck prevent the control box door from moving the
fault is generated and recorded and the affected toggle switch while calibrating the machine.
boom function is inhibited. 7 Remove the key from the main key switch.
Insert the key into the bypass/recovery key
switch and turn it to the bypass position.
Note: The length sensor calibration values will not
be saved correctly unless the key switch is in the
bypass / recovery position.
Boom Components
8 Press and hold the enter button on the ground 18 Press and hold the engine start button for
control panel while pulling out the ground approximately 5 seconds to shut off the engine
controls red Emergency Stop button to the on and to save the calibration settings.
position. Hold the enter button for
Result: An audible alarm sounds for 1 second.
approximately 5 seconds and then release it.
Calibration has been stored.
9 Enter sensor calibration mode by pressing the
Note: Do not turn the engine off with the key switch
buttons at the ground controls in the following
or red Emergency Stop button or all calibration
sequence: (plus)(enter)(enter)(plus).
points or values will not be saved.
10 Press the enter or previous button on the
LCD screen until DELETE PRIMARY BOOM 19 Press the enter or previous button on the
LENGTH CALIBRATION is displayed. LCD screen until EXIT is displayed.
11 Press the plus button to select YES, then 20 Press the plus button to select YES, then
press the enter button to accept. press the enter button to accept.
12 Start the engine and attempt to retract the 21 Turn the bypass/recovery key switch to the run
boom to insure it is fully retracted. position.
13 Press the enter or previous button on the 22 Remove the key from the bypass/recovery key
LCD screen until BOOM FULLY switch and insert the key into the main key
RETRACTED? is displayed. switch.
23 Remove the fastener that was temporarily
14 Press the plus button to select YES, then
installed. Close the control box door and install
press the enter button to accept.
the door retaining fasteners.
15 Fully extend the boom.
Note: When the control box door is closed, the
16 Press the enter or previous button on the calibration toggle switch is automatically activated
LCD screen until BOOM FULLY EXTENDED? to exit out of calibration mode.
is displayed.
24 Start the engine and retract the boom to the
17 Press the plus button to select YES, then stowed position.Verify there are no primary
press the enter button to accept. boom length sensor calibration faults shown
on the display.
Engines
5-1 5-2
RPM Adjustment Flex Plate
Refer to Maintenance Procedure in the appropriate The flex plate acts as a coupler between the engine
Service or Maintenance Manual for your machine, and the pump. It is bolted to the engine flywheel
Check and Adjust the Engine RPM. and has a splined center to drive the pump.
Engines
3 Perkins engines: Torque the pump plate
How to Ins tall the Fl ex Plate
Ground Controls
1 Run
2 Bypass / Recovery
3 Recovery
Ground Controls
How to Us e the R ec ov ery Mode
3 Turn the bypass/recovery key switch to the How to Use the Recovery Mode
bypass position.
Recovery is only to be used as a last attempt to
4 Using auxiliary power, operate the ground lower the platform when the operator in the
control buttons to level the platform. platform is unable to do so, system failure or in
Note: Only the auxiliary power unit can be used to emergency situations.
correct an out of level platform fault.
Bodily injury hazard. When using
5 Turn the bypass/recovery key switch to the run recovery mode, the platform may
position. not fully lower to the ground when
the recovery mode is completed.
6 Remove the key from the bypass/recovery key Failure to use only suitable
switch and insert the key into the main key equipment and/or practices to
switch. allow the operator to safely exit
Note: If the Bypass function has been used, there the platform could result in death
may be faults with the machine. Check the LCD or serious injury.
screen on the ground control box for machine faults,
then contact trained service personnel. Bodily injury hazard. Platform
leveling is not active when using
recovery mode. The platform
could reach high out-of-level
conditions when using this mode.
The operator will need to secure
themself to the platform to
prevent falling injury.
Ground Controls
Ground Controls
Ground Controls
5 Carefully remove the membrane decal from
6-3 the control box lid while guiding the ribbon
Membrane Decal cables out of the control box lid.
The membrane decal is a special decal that 6 Remove any decal adhesive from the control
consists of a decal with an electronic membrane on box lid with a mild solvent.
the backside. The membrane contains touch Note: Do not allow any solvent to come in contact
sensitive areas that, when pushed, activate the with the LCD display screen.
machine functions. The membrane contains touch
sensitive areas that activate the machine functions. 7 Install the new membrane decal while guiding
the ribbon cables through the control box lid.
How to Replace the Membrane 8 Connect the ribbon cables to the ECM circuit
board.
Decal
9 Close the control box lid and install the
1 Turn the key switch to the off position and retaining fasteners.
push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Remove the ground control box lid fasteners.
3 Open the ground control box.
4 Carefully disconnect the two ribbon cables
from the membrane decal at the ECM circuit
board.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Ground Controls
Note: Start this procedure with the booms in the
6-4 fully stowed position and the axle retracted.
Full Machine Calibration
Full machine calibration must be completed in the
Full machine calibration must be completed in the following sequence:
proper sequence when the ALC-1000 circuit board
(TCON) in the ground control box has been • Select engine configuration. Refer to Repair
replaced or the turntable level sensor (SCON) has Section Display Module. Unit of Measure
been replaced. and Language.
• Joysticks. Refer to Repair Procedure, How
How to Fully Calibrate the to Calibrate a Joystick.
Machine • Turntable level sensor. Refer to Repair
Calibration procedures shall only be completed by Procedure, How to Calibrate the Turntable
qualified technicians that have Genie factory Level Sensor.
service training. • Platform level sensor. Refer to Repair
Procedure, How to Calibrate the Platform
Tip-over hazard. Failure to Level Sensor.
calibrate the machine in the
proper sequence could cause • Axle angle sensors. Refer to Repair
the machine to tip over resulting Procedure, How to Calibrate the Axle Angle
in death or serious injury. Sensors.
Note: A digital level will be required to perform this • Steer sensors. Refer to Repair Procedure,
procedure. How to Calibrate All Steer Sensors.
Note: A kit is available through Genie Product • Primary boom angle sensor. Refer to Repair
Support (Genie part number 58351GT). This kit Procedure, How to Calibrate the Primary
includes a digital level with a magnetic base and Boom Angle Sensor.
cable harnesses. • Primary boom length sensor. Refer to
Repair Procedure, How to Calibrate the
Note: Use the following chart to identify the
Primary Boom Length Sensor.
description of each LCD screen control button used
in this procedure. • Jib boom bellcrank angle sensor. Refer to
Repair Procedure, How to Calibrate the Jib
Boom Bellcrank Sensor.
• Select option configuration. Refer to Repair
Section, Display Module, Options.
Plus Minus Previous Enter
Display Module
This table lists the various screens and menu options of the operating software. Some display menus are
for informational purpose only, while others can be used to change the machine operating parameters.
Note: The key switch must be in the off position before entering the programming mode.
Note: Use the following chart to identify the description of each LCD screen control button used in this
procedure.
Battery volts
Display Module
Display Module
Display Module
Jib up speed
Display Module
Display Module
Display Module
Foot Switch Lockout (0-30 30.0 max and 0.0 min, 10.0
minutes) (default) Holding +/- button
will cause display to scroll
through options or increment
number settings
automatically at 0.2 min
increase/decrease
Platform Always Level to (NO/YES)
Gravity?
Axle Motion Only While Driving? (NO/YES)
Hydraulic Pumps
How to Remove the Function 3 Support the pump with a suitable lifting device.
Pump 4 Remove the two pump mounting fasteners.
Carefully remove the pump.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Component damage hazard. Be
end must be replaced. All connections must be sure to open the two hydraulic
torqued to specification during installation. Refer to tank valves and prime the pump
Specifications, Hydraulic Hose and Fitting Torque after installing the pump.
Specifications.
1 Locate the two hydraulic tank valves at the
hydraulic tank. Close the valves.
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, open closed
remove the key from the key
switch and tag the machine to
inform personnel of the
condition.
Hydraulic Pumps
How to Prime the F uncti on Pump How to Adj ust the Functi on Pum p Standby Pr ess ure
How to Prime the Function Pump How to Adjust the Function Pump
Note: When removing a hose assembly or fitting, Standby Pressure
the O-ring (if equipped) on the fitting and/or hose
1 Connect a 0 to 5000 psi / 0 to 350 bar
end must be replaced. All connections must be
pressure gauge to the test port on the function
torqued to specification during installation. Refer to
manifold
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 2 Start the engine from the ground controls and
allow the engine to run at low idle.
1 Remove the case drain hydraulic hose from
the top of the function pump. 3 Observe the pressure reading on the pressure
gauge.
Note: The case drain hose is the smaller of the two
hoses on top of the function pump and closest to Result: The pressure gauge shows 350 psi /
the drive pump. 25 bar. One or both of the functions pumps are
correctly set. Proceed to step 4.
2 Locate and open the hydraulic tank shut-off
valve at the hydraulic tank that supplies Result: If the gauge shows a reading lower
hydraulic oil to the function pump. Do not open than 350 psi / 25 bar, both the function pumps
the valve for the drive pump. need to be adjusted higher Proceed to step 6.
3 When hydraulic fluid begins to come out of the Result: If the gauge shows a reading higher
case drain port of the function pump, install the than 350 psi / 25 bar, one or both of the
function pump case drain hose. function pumps need to be adjusted lower.
Proceed to step 8.
4 Clean up any oil that may have spilled.
Properly discard the used oil. Note: The reading will show the higher pressure of
the two function pumps.
5 Start the engine from the ground controls.
6 Check for hydraulic leaks.
Hydraulic Pumps
Pressure reads 350 psi / 25 bar Pressure reads less than 350 psi / 25 bar
4 One or both of the function pumps may be at 6 Loosen the set screw for the standby pressure
the correct pressure. Loosen the set screw for adjustment screw on the rear function pump.
the standby pressure adjustment on the rear Turn the adjustment screw clockwise (higher
function pump and turn the adjustment screw pressure) until the pressure reads 350 psi / 25
clockwise (higher pressure). If the pressure bar. Tighten the set screw.
increases above 350 psi / 25 bar, turn the
7 Loosen the set screw for the standby pressure
screw counterclockwise (lower pressure) until
adjustment screw on the mid function pump.
the gauge shows 350 psi / 25 bar. Tighten the
Turn the adjustment screw clockwise (higher
set screw.
pressure) until the pressure reads greater than
5 Loosen the set screw for the standby pressure 350 psi / 25 bar, then turn the adjustment
adjustment on the middle function pump and screw counterclockwise (lower pressure) until
turn the adjustment screw clockwise until the the pressure reads 350 psi / 25 bar. Tighten
pressure reads higher than 350 psi / 25 bar. the set screw. Proceed to step 11.
Once the gauge reads higher than 350 psi / 25
bar, turn the adjustment screw
counterclockwise until the gauge reads 350
psi / 25 bar. Tighten the set screw. Proceed to
step 11.
Hydraulic Pumps
How to Adj ust the Functi on Pum p Press ure Com pens ator
Pressure reads more than 350 psi / 25 bar How to Adjust the Function Pump
8 Loosen the set screw for the standby pressure Pressure Compensator
adjustment screw on the rear function pump.
Note: Two people will be required to perform this
Turn the adjustment screw counterclockwise
procedure.
(lower pressure) and note if the pressure
drops. If so turn the adjust screw 1 Confirm the system relief pressure is set to
counterclockwise (higher pressure) until the specification. Refer to Repair Procedure,
pressure reads 350 psi / 25 bar. If the Valve Adjustments - Function Manifold.
pressure does not drop, turn the screw slightly
counterclockwise to lower the pressure and 2 Connect a 0 to 5000 psi / 0 to 350 bar
proceed to step 7. pressure gauge to the test port on the function
manifold
9 Loosen the set screw for the standby pressure
adjustment screw on the mid function pump. 3 Start the engine from the ground controls and
Turn the adjustment screw counterclockwise change the rpm to high idle.
until the pressure reads 350 psi / 25 bar. 4 Push and hold the high speed function enable
Tighten the set screw. Proceed to step 8. button (rabbit symbol). Do not activate any
10 Turn the adjustment screw on the rear function boom functions.
pump clockwise until the pressure reads 5 Locate the function enable solenoids below
greater than 350 psi / 25 bar, then turn the the function pumps on the engine tray.
screw counterclockwise until the gauge reads Disconnect the wire connector from the inside
350 psi / 25 bar. Tighten the adjustment solenoid and observe the pressure reading on
screw. the pressure gauge.
11 Turn the engine off and remove the pressure Result: The gauge should show 2900 psi / 200
gauge. bar on the end pump.
Result: If the gauge does not show 2900 psi /
200 bar, proceed to step 7 to adjust the
function pump pressure compensator.
6 Reconnect the wire connector to the inside
solenoid and disconnect the wire connector
from the outer solenoid.
Result: The gauge should show 2700 psi / 186
bar on the middle pump.
Result: If the gauge does not show 2700 psi /
186 bar, proceed to step 7 to adjust the
function pump pressure compensator.
Hydraulic Pumps
7 Loosen the set screw for the pressure
compensator adjustment screw.
7-2
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), 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 be performed at an authorized
Sauer-Danfoss service center. Contact Genie
Product Support to locate your local authorized
service center.
Hydraulic Pumps
2 Locate the two hydraulic tank valves at the 5 Carefully pull the drive pump out until the
hydraulic tank. Close the valves. pump coupler separates from the flex plate.
6 Remove the drive pump from the machine.
Component damage hazard.
The pump(s) may become
unbalanced and fall if not
properly supported.
Hydraulic Pumps
How to Prime the Driv e Pum p
Manifolds
8-1
Function Manifold Components – View 1
The function manifold is mounted next to the hydraulic tank on the ground control side of the machine.
Index Schematic
Description Function Torque
No. Item
1 Orifice, 0.025 in / 0,635 mm G
2 Orifice, 0.025 in / 0,635 mm S
Primary boom extend/retract
circuit, regulates pressure drop 33-37 ft-lbs
3 Differential sensing valve, 160 psi / 11 bar I
across secondary boom 45-50 Nm
extend/retract proportional valve
Proportional solenoid operated 2 position 2 Primary boom extend/retract, 33-37 ft-lbs
4 J
way directional valve normally closed proportional speed control 45-50 Nm
Solenoid operated 3 position 4 way 19-21 ft-lbs
5 W Primary boom extend/retract
directional valve 26-28 Nm
Solenoid operated 3 position 4 way 33-37 ft-lbs
6 X Primary boom lift/ cylinder up/down
directional valve 45-50 Nm
Proportional solenoid operated 2 position 2 Primary lift cylinder up/down high 33-37 ft-lbs
7 L
way directional valve normally closed speed control 45-50 Nm
Proportional solenoid operated 2 position 2 Primary lift cylinder up/down low 19-21 ft-lbs
8 K
way directional valve normally closed speed control 26-28 Nm
Prevents the draining of hydraulic
19-21 ft-lbs
9 Check valve, 5 psi / 0,34 bar V oil from the jib manifold and
26-28 Nm
platform manifold
19-21 ft-lbs
10 Check valve, 5 psi / 0,34 bar A Pressure Circuit #2
26-28 Nm
19-21 ft-lbs
11 Check valve, 5 psi / 0,34 bar B Pressure Circuit #1
26-28 Nm
Prevents hydraulic pressure from 19-21 ft-lbs
12 Check valve, 5 psi / 0,34 bar D
flowing back into auxiliary pump #2 26-28 Nm
Manifolds
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Manifolds
Manifolds
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Manifolds
8-3
Platform Level and Rotation Manifold Components, to SX150H-518
The platform manifold is mounted under the jib boom.
Index Schematic
Description Function Torque
No. Item
Proportional Directional Control valve, 3 25-30 ft-lbs
1 DC Jib level up/down
position 5 way 34-41 Nm
Jib boom up/down circuit, regulates
Pressure compensator valve, 150 psi / 10,3 19-21 ft-lbs
2 DD pressure drop across jib boom
bar 26-29 Nm
up/down proportional. valve
19-21 ft-lbs
3 Proportional solenoid valve, 3 position 4 way DE Platform level up/down 26-29 Nm
19-21 ft-lbs
4 Solenoid valve, 3 position 4 way DF Platform rotate left/right 26-29 Nm
19-21 ft-lbs
5 Flow control valve, 0.2 gpm / 0,76 L/min DG Platform rotate left/right circuit 26-29 Nm
19-21 ft-lbs
6 Flow control valve, 0.2 gpm / 0,76 L/min DH Platform rotate left/right circuit 26-29 Nm
Manifolds
8-3A
Platform Level and Rotation Manifold Components, from SX150H-519
The platform manifold is mounted under the jib boom.
Index Schematic
Description Function Torque
No. Item
19-21 ft-lbs
1 Proportional solenoid valve, 3 position 4 way DG Jib level up/down 26-29 Nm
19-21 ft-lbs
2 Solenoid valve, 3 position 4 way DB Platform rotate left/right circuit 26-29 Nm
Jib boom up/down circuit, regulates
Pressure compensator valve, 150 psi / 10,3 19-21 ft-lbs
3 DF pressure drop across jib boom
bar 26-29 Nm
up/down proportional. valve
19-21 ft-lbs
4 Proportional solenoid valve DD Platform level up/down 26-29 Nm
19-21 ft-lbs
5 Solenoid valve, 2 position 2 way DH Platform level up/down 26-29 Nm
19-21 ft-lbs
6 Flow control valve, 0.2 gpm / 0,76 L/min DA Platform rotate left/right circuit 26-29 Nm
19-21 ft-lbs
7 Flow control valve, 0.2 gpm / 0,76 L/min DC Platform rotate left/right circuit 26-29 Nm
Manifolds
8-4
Jib Boom Manifold Components, to SX150H-518
The jib boom manifold is mounted on the primary extension boom at the platform end.
Schematic
Index No. Description Function Torque
Item
19-21 ft-lbs
1 Check valve, 25 psi / 1,7 bar EE Holds oil in jib boom manifold
26-28 Nm
Jib boom rotate circuit, regulates
Pressure compensator valve, 150 psi / 19-21 ft-lbs
2 EC pressure drop across jib boom rotate
10,3 bar 26-28 Nm
proportional. valve
Proportional solenoid valve, 3 position 4 25-30 ft-lbs
3 ED Jib bellcrank level
way 34-41 Nm
Proportional Directional Control valve, 3 19-21 ft-lbs
4 EB Jib rotate left/right
position 5 way 26-28 Nm
Manifolds
8-4A
Jib Boom Manifold Components, from SX150H-519
The jib boom manifold is mounted on the primary extension boom at the platform end.
Schematic
Index No. Description Function Torque
Item
Proportional solenoid valve, 2 position 2 19-21 ft-lbs
1 EF Jib level up/down
way 26-28 Nm
Counterbalance valve, 3:1 3300 psi / 30-35 ft-lbs
2 EH Jib rotate left
228 bar 41-47 Nm
Jib boom rotate circuit, regulates
Pressure compensator valve, 150 psi / 19-21 ft-lbs
3 EC pressure drop across jib boom rotate
10,3 bar 26-28 Nm
proportional. valve
19-21 ft-lbs
4 Check valve, 25 psi / 1,7 bar EE Holds oil in jib boom manifold
26-28 Nm
Proportional Directional Control valve, 3 19-21 ft-lbs
5 EB Jib rotate left/right
position 5 way 26-28 Nm
Counterbalance valve, 3:1 3300 psi / 30-35 ft-lbs
6 EG Jib rotate right
228 bar 41-47 Nm
Proportional solenoid valve, 3 position 4 25-30 ft-lbs
7 ED Jib bellcrank level
way 34-41 Nm
Manifolds
8-5
Function Enable Manifold Components
The function enable manifold is located on the engine side below the hydraulic pumps.
8-6
Steer and Axle Manifold Components, to SX150H-507
The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine.
Index Schematic
Description Function Torque
No. Item
Right front steer cylinder retract 20-25 ft-lbs
1 Flow control valve, 1.5 gpm / 5,7 L/min BI
circuit 27-34 Nm
Prevents right front steer cylinder 20-25 ft-lbs
2 Check valve BC
from moving when not steering 27-34 NM
Prevents left front steer cylinder 20-25 ft-lbs
3 Check valve BB
from moving when not steering 27-34 Nm
Prevents right front steer cylinder 20-25 ft-lbs
4 Check valve BW
from moving when not steering 27-34 Nm
Prevents left front steer cylinder 20-25 ft-lbs
5 Check valve BV
from moving when not steering 27-34 Nm
Right rear steer cylinder extend 20-25 ft-lbs
6 Flow control valve, 2.1 gpm / 8 L/min BL
circuit 27-34 Nm
Steer left/right, right rear steer 20-25 ft-lbs
7 Solenoid valve, 3 position 4 way BQ
cylinder 27-34 Nm
Prevents right rear steer cylinder 20-25 ft-lbs
8 Check valve BY
from moving when not steering 27-34 Nm
Prevents left rear steer cylinder from 20-25 ft-lbs
9 Check valve BX
moving when not steering 27-34 Nm
Steer left/right, left rear steer 20-25 ft-lbs
10 Solenoid valve, 3 position 4 way BP
cylinder 27-34 Nm
20-25 ft-lbs
11 Flow control valve, 2.1 gpm / 8 L/min BJ Left rear steer cylinder extend circuit
27-34 Nm
50-55 ft-lbs
12 Flow control valve, 9 gpm / 34 L/min BS Axle extend/retract circuit
68-75 Nm
50-55 ft-lbs
13 Solenoid Valve, 2 position 3 way BU Axle retract
68-75 Nm
50-55 ft-lbs
14 Solenoid Valve, 2 position 3 way BT Axle extend
68-75 Nm
8-6A
Steer and Axle Manifold Components, from SX150H-508
The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine.
Index Schematic
Description Function Torque
No. Item
Right front steer cylinder extend 20-25 ft-lbs
1 Flow control valve, 2.1 gpm / 8 L/min BL
circuit 27-34 Nm
Right front steer cylinder retract 20-25 ft-lbs
2 Flow control valve, 1.5 gpm / 5,7 L/min BM
circuit 27-34 NM
Prevents right front steer cylinder 20-25 ft-lbs
3 Check valve BD
from moving when not steering 27-34 Nm
Prevents left front steer cylinder 20-25 ft-lbs
4 Check valve BB
from moving when not steering 27-34 Nm
20-25 ft-lbs
5 Flow control valve, 1.5 gpm / 5,7 L/min BK Left front steer cylinder retract circuit
27-34 Nm
Steer left/right, right rear steer 20-25 ft-lbs
6 Solenoid valve, 3 position 4 way BU
cylinder 27-34 Nm
Steer left/right, left rear steer 20-25 ft-lbs
7 Solenoid valve, 3 position 4 way BT
cylinder 27-34 Nm
Right rear steer cylinder extend 20-25 ft-lbs
8 Flow control valve, 2.1 gpm / 8 L/min BP
circuit 27-34 Nm
Right front steer cylinder retract 20-25 ft-lbs
9 Flow control valve, 1.5 gpm / 5,7 L/min BQ
circuit 27-34 Nm
20-25 ft-lbs
10 Flow control valve, 2.1 gpm / 8 L/min BN Left rear steer cylinder extend circuit
27-34 Nm
20-25 ft-lbs
11 Flow control valve, 1.5 gpm / 5,7 L/min BO Left rear steer cylinder retract circuit
27-34 Nm
50-55 ft-lbs
12 Solenoid Valve, 2 position 3 way BX Axle retract
68-75 Nm
50-55 ft-lbs
13 Solenoid Valve, 2 position 3 way BW Axle extend
68-75 Nm
50-55 ft-lbs
14 Flow control valve, 9 gpm / 34L/mon BZ Axle extend/retract circuit
68-75 Nm
Manifolds
Manifolds
8-8
Traction Manifold Components
The traction manifold is mounted inside the drive chassis at the circle end of the machine
Index Schematic
Description Function Torque
No. Item
30-35 ft-lbs
1 Check valve AZ Anti-cavitation
40,7-47,5 Nm
26-30 ft-lbs
2 Solenoid Valve, 2 position 3 way AX Two-speed drive motor shift
35,3-40,7 Nm
26-30 ft-lbs
3 Solenoid Valve, 2 position 3 way AY Brake release
35,3-40,7 Nm
Keeps brakes released if temporary loss of 20-25 ft-lbs
4 Check valve AW
charge pressure 27,1-33,9 Nm
Charge pressure circuit that directs hot oil 50-55 ft-lbs
5 Shuttle Valve, 3 position 3 way AO
out of low pressure side of drive pumpp 67,8-74,6 Nm
20-25 ft-lbs
6 Relief valve, 250 psi / 17,23 bar AN Charge pressure circuit
27,1-33,9 Nm
20-25 ft-lbs
7 Orifice Plug, 0.030 inch / 0,762 mm AV Brake and two-speed circuit
27,1-33,9 Nm
20-25 ft-lbs
8 Check valve AU Anti-cavitation
27,1-33,9 Nm
30-35 ft-lbs
9 Check valve BA Anti-cavitation
40,7-47,5 Nm
Controls flow to square end drive motors in 90-100 ft-lbs
10 Flow divider/combiner valve AR
forward and reverse 122-135,6 Nm
20-25 ft-lbs
11 Check valve AK Anti-cavitation
27,1-33,9 Nm
Equalizes pressure on both sides of 30-35 ft-lbs
12 Orifice, 3 gpm / 11,4 L/min AS
divider/combiner valve 40,7-47,5 Nm
Manifolds
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8-9 8 Hold the hot oil relief valve and remove the
cap.
Valve Adjustments - Traction
9 Start the engine from the ground controls.
Manifold
10 Press and hold the function enable/high rpm
How to Adjust the Hot Oil Relief select button (rabbit symbol) position.
Valve 11 Adjust the internal hex socket until the
pressure reading on the gauge is 40 psi / 2.8
Note: The hydraulic oil temperature must be 100°F bar less than the pressure reading on the
to 150°F / 38°C to 65.5°C before performing this pump. Turn it clockwise to increase the
procedure. pressure or counterclockwise to decrease the
1 Connect a 0 to 600 psi / 0 to 50 bar pressure pressure. Install the relief valve cap.
gauge to either the "A" or "B" test port on the 12 Turn the engine off.
drive pump.
13 Remove the pressure gauge.
2 Locate the hot oil relief valve on the traction
manifold. Hold the relief valve and remove the
cap.
3 Turn the internal hex socket clockwise fully
until it stops. Install the cap.
4 Start the engine from the ground controls.
5 Press and hold the function enable/high rpm
select button (rabbit symbol) position. Note the
reading on the pressure gauge.
6 Turn the engine off.
7 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the traction manifold.
Manifolds
8-10
Generator Manifold Components
The oil diverter manifold is mounted near the hydraulic generator located in the engine compartment.
Index Schematic
Description Function Torque
No. Item
19-21 ft-lbs /
1 Check valve FA Controls flow to diverter valve
25.7-28.5 Nm
Solenoid Valve, 2 position 2 way valve 33-37 ft-lbs /
2 FB Pilot valve to diverter valve
(normally closed) 45-50 Nm
24-26 ft-lbs /
3 Relief valve, 3200 psi / 221 bar FC Generator relief valve
32.6-35.4 Nm
Solenoid Valve, 2 position 2 way valve 33-37 ft-lbs /
4 FD Charge pressure circuit
(normally open) 45-50 Nm
7-8 ft-lbs /
5 Check valve FE Prevents oil to generator
9.5-10.8 Nm
45-50 ft-lbs /
6 Needle valve FF Charge pressure circuit
61-68 Nm
Counterbalance valve 4.5:1 2000 psi / Adds backpressure to generator 45-50 ft-lbs /
7 FG
138 bar circuit 61-68 Nm
Manifolds
Manifolds
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
1 multimeter
1 Test the coil for resistance. Refer to Repair
Procedure, How to Test a Coil. 2 9v DC battery
3 10Ω resistor
2 Connect a 10W resistor to the negative 4 coil
terminal of a known good 9V DC battery.
Connect the other end of the resistor to a Note: Dotted lines in illustration indicate a reversed
terminal on the coil. connection as specified in step 6.
Resistor 10Ω 3 Set a multimeter to read DC current.
Genie part number 27287 Note: The multimeter, when set to read DC current,
Note: The battery should read 9V DC or more when should be capable of reading up to 800 mA.
measured across the terminals.
4 Connect the negative lead to the other
terminal on 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.
How to Adjust the Turntable counterclockwise. Tighten the lock nut on the
Rotation Gear Backlash adjustment bolt.
1 Secure the turntable from rotating with the 8 Pull the backlash pivot plate away from the
turntable rotation lock pin. turntable until it contacts the adjustment bolt.
Then lubricate the mounting fasteners on the
2 Remove the fixed turntable cover at the
backlash pivot plate and torque to
ground controls side of the machine.
specification. Refer to Specifications, Machine
3 Loosen the backlash pivot plate mounting Torque Specifications.
bolts.
9 Rotate the turntable through an entire rotation.
4 Push the backlash pivot plate towards the Check for tight spots that could cause binding.
turntable as far as possible (this will push the Readjust if necessary.
rotation pinion gears into the turntable bearing
ring gear).
5 Loosen the lock nut on the adjustment bolt.
6 Turn the adjustment bolt clockwise until it
contacts the backlash pivot plate.
8 Enter sensor calibration mode by pressing the 10 Place the digital level along the X axis of the
buttons at the ground controls in the following turntable.
sequence: (plus)(enter)(enter)(plus).
1 -X Axis
2 +X Axis
3 Platform end
1 Run
2 Bypass / Recovery 11 Press the plus button or minus button to
3 Recovery adjust the display to the exact value shown on
the digital level and press the enter button.
9 Press the enter or previous button on the
LCD screen until SET UNIT X AXIS LEVEL Note: If the measured angle already matches the
TO GRAVITY is displayed. angle shown on the display at the ground controls,
press the plus button or minus button to change
the angle and then change back to the measured
value. The system must detect a change in
displayed value to record the calibrated value.
1 + Y Axis
2 - Y Axis
Axle Components
Axle Components
Left front (square-end, blue side) and right rear 6 Rotate the sensor housing in a clockwise
(circle-end, yellow side) angle sensors: direction until the sensor cable is pointing
away from the machine. Refer to Illustration 2.
7 Install the steer sensor cover retaining
fasteners. Do not tighten the cover retaining
fasteners.
8 Connect the steer sensor assembly cable to
the main harness.
9 Calibrate the steer sensor. Refer to Repair
Procedure, How to Calibrate a Replacement
Steer Sensor.
Note: Be sure the yoke pivot pin retaining plate is
fully engaged into the pivot pin and that the
fasteners are securely tightened.
Illustration 3
1 starting position
2 installed position
3 sensor cover
4 rotation arrow
Axle Components
How to C alibr ate a R epl acem ent Steer Sens or
10 Position the new steer sensor assembly over How to Calibrate a Replacement
the sensor activator pin with the sensor cable
angled away from the tire. Refer to Illustration
Steer Sensor
3. Note: If a steer angle sensor has been removed or
11 Align the sensor with the pin and install the replaced, the steer angle sensors will need to be
sensor on to the pin. calibrated.
Note: Be sure the sensor activator pin is engaged Note: Perform this procedure with the axles
into the sensor. retracted and the tires straightened.
12 Rotate the sensor housing in a clockwise Note: Two people will be required to perform this
direction until the sensor cable is pointing procedure.
away from the machine. Refer to Illustration 2.
Note: Be sure the yoke pivot pin retaining plate is
13 Install the steer sensor cover retaining fully engaged into the pivot pin and that the
fasteners. Do not tighten the cover retaining fasteners are securely tightened.
fasteners.
1 Start the engine from the platform controls.
14 Connect the steer sensor assembly cable to
the main harness. 2 Select the proper steer mode. If a front
(square-end) steer angle sensor has been
15 Calibrate the steer sensor. Refer to Repair replaced, select rear steer mode. If a rear
Procedure, How to Calibrate a Replacement (circle-end) steer angle sensor has been
Steer Sensor. replaced, select front steer mode.
Note: Be sure the yoke pivot pin retaining plate is 3 Have another person press down the foot
fully engaged into the pivot pin and that the switch.
fasteners are securely tightened.
4 At the new steer angle sensor, loosen the
steer angle sensor cover retaining fasteners.
Do not remove the fasteners or the sensor
cover.
5 Rotate the sensor cover clockwise or
counterclockwise until the tire is straight in
relation with the other tires. Tighten the sensor
cover fasteners.
Note: If available, WebGPI can also be used for
this procedure.
6 Push in the red Emergency Stop button to the
off position.
Axle Components
How to C alibr ate All Steer Sensors
How to Calibrate All Steer 5 Using a voltmeter set to DC voltage, probe the
back of the electrical connector at pins B and
Sensors C.
Note: This procedure will only need to be 6 Left front (square-end, blue side) and right
performed if the ground controls circuit board
rear (circle-end, yellow side) angle
(TCON) has been replaced.
sensors: Rotate the sensor cover clockwise
Note: Perform this procedure with the axles or counterclockwise until the voltage reading
retracted and the tires straightened. is between 1.4 to 1.6V DC. Tighten the sensor
cover fasteners.
Note: Use the following chart to identify the
description of each LCD screen control button used Right front (square-end, yellow side) and
in this procedure. left rear (circle-end, blue side) angle
sensors: Rotate the sensor cover clockwise
or counterclockwise until the voltage reading
is between 3.4 to 3.6V DC. Tighten the sensor
cover fasteners.
Note: If available, WebGPI can also be used for
Plus Minus Previous Enter this procedure.
1 Locate the calibration toggle switch at the top 7 Remove the key from the main key switch.
of the ground control box. Activate calibration Insert the key into the bypass/recovery key
mode by moving the toggle switch in the left switch and turn it to the bypass position.
direction.
Note: The angle sensor calibration values will not
2 Temporarily install a control box door retaining be saved correctly unless the key switch is in the
fastener between the door and the box to bypass position and the calibration toggle switch is
prevent the control box door from moving the activated.
toggle switch while calibrating the machine.
8 Push in the red Emergency Stop button to the
3 Turn the key switch to ground controls and pull
off position.
out the ground controls red Emergency Stop
button to the on position.
4 Loosen the steer angle sensor cover retaining
fasteners. Do not remove the fasteners or the
sensor cover.
Axle Components
9 Press and hold the enter button on the ground Delete all Steer Sensor Calibrations
control panel while pulling out the ground
controls red Emergency Stop button to the on 11 Press the enter or previous button on the
position. Hold the enter button for LCD screen until DELETE ALL STEER
approximately 5 seconds and then release it. SENSORS CALIBRATION is displayed. Press
the plus button to select YES, then press the
enter button to accept.
12 Press the enter or previous button on the
LCD screen until EXIT is displayed.
13 Press the plus button to select YES, then
press the enter button to accept.
14 Proceed to step 21.
Delete a Single Steer Sensor Calibration
15 To calibrate a single steer sensor, delete the
specific steer sensor calibration
16 Press the enter or previous button on the
LCD screen until DELETE _____ STEER
SENSORS CALIBRATION is displayed.
Example: DELETE BLUE END BLUE SIDE
1 Run STEER SENSORS CALIBRATION (FL).
2 Bypass / Recovery 17 Press the plus button to select YES, then
3 Recovery press the enter button to accept.
10 Enter sensor calibration mode by pressing the 18 Press the enter or previous button on the
buttons at the ground controls in the following LCD screen until EXIT is displayed.
sequence: (plus)(enter)(enter)(plus).
19 Press the plus button to select YES, then
press the enter button to accept.
20 Push in the red Emergency Stop button to the
off position.
21 Remove the fastener that was temporarily
installed. Close the control box door and install
the door retaining fasteners.
Note: When the control box door is closed, the
calibration toggle switch is automatically activated
to exit out of calibration mode.
22 Use the key to turn the bypass / recovery key
switch to the run position.
Note: Be sure that the bypass/recovery key switch
is in the run position before attempting to operate
the machine.
Axle Components
10-2 10-3
Steer Cylinders Axle Extension Cylinders
How to Remove a Steer Cylinder How to Remove an Axle
Note: When removing a hose assembly or fitting, Extension Cylinder
the O-ring (if equipped) on the fitting and/or hose
Note: When removing a hose assembly or fitting,
end must be replaced. All connections must be
the O-ring (if equipped) on the fitting and/or hose
torqued to specification during installation. Refer to
end must be replaced. All connections must be
Specifications, Hydraulic Hose and Fitting Torque
torqued to specification during installation. Refer to
Specifications.
Specifications, Hydraulic Hose and Fitting Torque
Note: Perform this procedure with the axles Specifications.
extended.
Note: Perform this procedure with the machine on
1 Tag, disconnect and plug the hydraulic hoses a firm, level surface and in the stowed position with
from the steer cylinder. Cap the fittings on the the axles extended.
cylinder.
Note: This procedure will require the use of a
Bodily injury hazard. Spraying portable hydraulic power unit.
hydraulic oil can penetrate and
1 Tag, disconnect and plug the hydraulic hoses
burn skin. Loosen hydraulic
from the axle extension cylinder. Cap the
connections very slowly to allow
fittings on the cylinder.
the oil pressure to dissipate
gradually. Do not allow oil to Bodily injury hazard. Spraying
squirt or spray. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
2 Support the steer cylinder with a suitable lifting connections very slowly to allow
device. Protect the cylinder rod from damage. the oil pressure to dissipate
3 Remove the pin retaining fasteners from both gradually. Do not allow oil to
steer cylinder pivot pins. squirt or spray.
4 Use a soft metal drift to remove the pin. 2 Remove the axle extension limit switch cover
fasteners. Remove the cover.
5 Remove the steering cylinder from the
machine. 3 Remove the limit switch mounting fasteners
and remove the limit switch. Do not disconnect
Crushing hazard. The steer the wiring.
cylinder may become
unbalanced and fall if not
properly supported by the lifting
device when removed from the
machine.
Axle Components
Axle Components
4 Temporarily install a control box door retaining 7 Enter sensor calibration mode by pressing the
fastener between the door and the box to buttons at the ground controls in the following
prevent the control box door from moving the sequence: (plus)(enter)(enter)(plus).
toggle switch while calibrating the machine.
8 Press the enter or previous button on the
5 Remove the key from the main key switch. LCD screen until DELETE AXLE ANGLE
Insert the key into the bypass/recovery key SENSORS CALIBRATION is displayed.
switch and turn it to the bypass position.
9 Press the plus button to select YES, then
press the enter button to accept.
10 At the AXLE ANGLES FULLY RETRACTED
screen, press the plus button to select YES,
then press the enter button to accept.
11 When the AXLE ANGLES FULLY EXTENDED
screen is displayed, turn the main key switch
to platform controls, start the engine and fully
extend the axles.
Note: If the system exits out of calibration mode
when the engine is started, repeat step 10.
Note: The angle sensor calibration values will not 15 Press and hold the engine start button for
be saved correctly unless the key switch is in the approximately 5 seconds to shut off the engine
bypass position and the calibration toggle switch is and to save the calibration settings.
activated. Note: Do not turn the engine off with the key switch
or red Emergency Stop button or all calibration
6 Press and hold the enter button on the ground
points or values will not be saved.
control panel while pulling out the ground
controls red Emergency Stop button to the on
position. Hold the enter button for
approximately 5 seconds and then release it.
Axle Components
1 Run
2 Bypass / Recovery
3 Recovery
Generators
1 Plug a 1000 watt load into the generator outlet 7 While holding the adjusting screw, tighten the
like a portable work light or heater. retaining nut on the needle valve.
2 Loosen the retaining nut on the needle valve 8 Turn off the generator and then turn off the
and screw the adjustment screw clockwise engine.
until it stops.
1 Needle valve
Fault Codes
Before Troubleshooting:
Section 4 Faul t Codes
P_38 - Propel P_39 - Turntable P_10 - Primary P_11 - Primary P_9A - Primary P_9B -
(P13-17 TCON) Rotate (P13-19 Boom Extend Up (P12-09 Down (P12-06 Ignition/Fuel
TCON) (P12-08 TCON) TCON) TCON) (P12-07 TCON)
P_22 - Jib Jib Lvl P_22R - Primary P_12 - Axle
Pwr Up/Down FC Retract (P121-08
SCON)
Where XXX is the one to three digit Fault Source 4 Primary Boom Angle Zone
and xx is the two digit Fault Type. 5 Primary Boom Length Switches Cross-Check
8 PCON Controller Area Network
TCON - Turntable Controller
9 Engine
PCON - Platform Controller 18 DCON Controller Area Network
SCON - Safety Controller 20 Boom Extend/Retract Joystick
21 Boom Up/Down Joystick
DCON - Drive Controller
26 Boom Extend/Retract Buttons
Fault Type 27 Boom Up/Down Buttons
ID Description 28 Boom Angle Sensors Cross-Check (SCON)
11 Value at 5V 29 LSB2RS/LSB4ES Cross-Check (SCON)
12 Value too High 30 Propel Joystick
13 No Response 35 Propel Valve
15 Value too Low 40 Turntable Rotate Joystick
16 Value at 0V 43 Footswitch Timeout
17 Not Calibrated 44 Jib Up/Down Joystick
21 Fault 48 PBMAS Safety Envelope (SCON)
26 Timeout 49 Jib Up/Down Buttons
31 Invalid Setup 50 Jib Up/Down Flow Valve
32 Min Cal Too Low 52 Steer Joystick
33 Min Cal Too High 53 Left Front Steer Sensor
54 Right Front Steer Sensor
55 Left Rear Steer Sensor
56 Right Rear Steer Sensor
59 Rocker Steer Joystick
61 PBMLS Safety Envelope (SCON)
63 Front Axle Sensor
64 Rear Axle Sensor
Fault Source
ID Description
166 Brake Valve
167 Motor Shift Valve
168 Chassis Tilt Sensors Cross-Check (SCON)
170 Jib Bellcrank Level Sensor
171 Jib Bellcrank Level Flow Valve
172 AUX Relay
173 Platform Level Toggle Switch
174 Platform Rotate Toggle Switch
175 Platform Level Flow Valve
176 Platform Rotate Valve
180 Boom Length Sensor
195 Safety Platform Overload (SCON)
220 RSB1AO Active Cross-Check
221 LTB1LO Active Cross-Check
222 Axle Extend/Retract Toggle Switch
235 RSB1AO/LSB1DO Cross-Check
236 LTB1LO/LSB3RO Cross-Check
237 LTB1LO/LSB4EO Cross-Check
238 Pressure Comp Enable #1 Valve
239 Pressure Comp Enable #2/Generator Valve
245 Check Machine Software Type at TCON
246 Check Machine Software Type at SCON
247 TCON/SCON Software Inconsistent
102 4 777 Sensor error charged air press.; 132 11 3 Air flow sensor low idle correction
signal range check low factor exceeding the maximum
drift limit
105 0 996 High charged air cooler
temperature; warning threshold 132 11 4 Air flow sensor load correction
exceeded factor exceeding the maximum
drift limit
105 0 997 High charged air cooler
temperature; shut off threshold 157 3 877 Sesnor error rail pressure; signal
exceeded range check high
105 3 994 Sensor error charged air 157 4 878 Sensor error rail pressure; signal
temperature; signal range check range check low
high
105 4 995 Sensor error charged air
temperature; signal range check
low
190 8 422 Sensor crankshaft speed; 412 4 1008 Sensor error EGR cooler
disturbed signal downstream temperature; signal
range check low
190 11 390 Engine speed above warning
threshold (FOC-Level 2) 520 9 306 Timeout Error of
CAN-Receive-Frame TSC1TR;
190 12 420 Sensor camshaft speed; no Setpoint
signal
597 2 49 Break lever mainswitch and
190 12 423 Sensor crankshaft speed; no break lever redundancy switch
signal status not plausible
190 14 391 Engine speed above warning 624 3 971 SVS lamp; short circuit to batt.
threshold (Overrun Mode)
624 4 972 SVS lamp; short circuit to grd.
190 14 1222 Camshaft- and Crankshaft speed
sensor signal not available on 624 5 969 SVS lamp; open load
CAN 624 12 970 SVS lamp; powerstage over
411 0 791 Physical range check high for temperature
differential pressure Venturiunit 630 12 376 Access error EEPROM memory
(EGR) (delete)
411 1 792 Physical range check low for 630 12 377 Access error EEPROM memory
differential pressure Venturiunit (read)
(EGR)
630 12 378 Access error EEPROM memory
411 3 795 Sensor error differential pressure (write)
Venturiunit (EGR); signal range
639 14 84 CAN-Bus 0 "BusOff-Status"
check high
651 3 580 Injector 1 (in firing order); short
411 4 381 Physical range check low for
circuit
EGR differential pressure
651 4 586 High side to low side short circuit
411 4 796 Sensor error differential pressure
in the injector 1 (in firing order)
Venturiunit (EGR); signal range
check low
1109 2 121 Engine shut off demand ignored 1180 3 1067 Sensor error exhaust gas
temperature upstream turbine;
1136 0 1398 Physikal range check high for signal range check high
ECU temperature
1180 11 1066 Sensor exhaust gas temperature
1136 1 1399 Physikal range check low for upstream turbine; plausibility
ECU temperature error
1136 3 1400 Sensor error ECU temperature; 1188 2 1414 Wastegate; status message from
signal range check high ECU missing
1136 4 1401 Sensor error ECU temperature; 1188 7 1415 Wastegate actuator; blocked
signal range check low
1188 11 1411 Wastegate actuator; internal
1176 3 849 Sensor error pressure sensor error
upstream turbine; signal range
check high 1188 11 1412 Wastegate actuator; EOL
calibration not performed
1176 4 850 Sensor error pressure sensor correctly
downstream turbine; signal range
check high 1188 11 1416 Wastegate actuator; over
temperature (> 145øC)
1180 0 1193 Physical range check high for
exhaust gas temperature 1188 11 1417 Wastegate actuator; over
upstream turbine temperature (> 135øC)
1180 0 1460 Turbocharger Wastegate CAN 1188 11 1418 Wastegate actuator; operating
feedback; warning threshold voltage error
exceeded 1188 13 1413 Wastegate actuator calibration
1180 0 1462 Exhaust gas temperature deviation too large, recalibration
upstream turbine; warning required
threshold exceeded 1231 14 85 CAN-Bus 1 "BusOff-Status"
1180 1 1194 Physical range check low for 1235 14 86 CAN-Bus 2 "BusOff-Status"
exhaust gas temperature
upstream turbine
1180 1 1461 Turbocharger Wastegate CAN
feedback; shut off threshold
exceeded
1237 2 747 Override switch; plausibility error 2798 4 1339 Injector diagnostics; short circuit
to ground monitoring Test in Cyl.
1322 12 610 Too many recognized misfires in Bank 0
more than one cylinder
2798 4 1340 Injector diagnostics; short circuit
1323 12 604 Too many recognized misfires in to ground monitoring Test in Cyl.
cylinder 1 (in firing order) Bank 1
1324 12 605 Too many recognized misfires in 3224 2 127 DLC Error of
cylinder 2 (in firing order) CAN-Receive-Frame AT1IG1
1325 12 606 Too many recognized misfires in NOX Sensor (SCR-system
cylinder 3 (in firing order) upstream cat; DPF-system
downstream cat); length of frame
1326 12 607 Too many recognized misfires in incorrect
cylinder 4 (in firing order)
3224 9 128 Timeout Error of
2659 0 1524 Physical range check high for CAN-Receive-Frame AT1IG1;
EGR exhaust gas mass flow NOX sensor upstream
2659 1 1525 Physical range check low for 3248 4 1047 Sensor error particle filter
EGR exhaust gas mass flow downstream temperature; signal
2659 2 1523 Exhaust gas recirculation AGS range check low
sensor; plausibility error 3699 2 1616 DPF differential pressure sensor
2659 2 1527 AGS sensor temperature and a further sensor or actuator
exhaust gas mass flow; CRT system defective
plausibility error 3699 2 1617 Temperature sensor us. and ds.
2659 12 1526 Exhaust gas recirculation; AGS DOC simultaneously defect
sensor has "burn off" not 3699 14 1615 Maximum stand-still-duration
performed reached; oil exchange required
2797 4 1337 Injector diagnostics; timeout error 4765 0 1039 Physical range check high for
of short circuit to ground exhaust gas temperature
measurement cyl. Bank 0 upstream (DOC)
4765 1 1042 Physical range check low for
exhaust gas temperature
upstream (DOC)
4768 4 1045 Sensor error exhaust gas 523240 9 179 Timeout CAN-message
temperature upstream (DOC) FunModCtl; Function Mode
signal range check low Control
4769 2 1026 Sensor exhaust gas temperature 523350 4 565 Injector cylinder-bank 1; short
downstream (DOC); plausibility circuit
error 523352 4 566 Injector cylinder-bank 2; short
4769 3 1034 Sensor error exhaust gas circuit
temperature downstream (DOC); 523354 12 567 Injector powerstage output defect
signal range check high
523470 2 826 Pressure Relief Valve (PRV)
4769 4 1035 Sensor error exhaust gas forced to open; performed by
temperature downstream (DOC); pressure increase
signal range check low
523470 2 827 Pressure Relief Valve (PRV)
523006 3 34 Controller mode switch; short forced to open; performed by
circuit to battery pressure shock
523006 4 35 Controller mode switch; short
circuit to ground
523008 1 648 Manipulation control was
triggered
523769 9 284 Timeout Error of 523910 6 1261 Air Pump; over current
CAN-Receive-Frame Passive 523913 3 74 Sensor error glow plug control
TSC1AR diagnostic line voltage; signal
523770 9 285 Timeout Error of range check high
CAN-Receive-Frame Passive 523913 4 75 Sensor error glow plug control
TSC1DE diagnostic line voltage; signal
523776 9 291 Timeout Error of range check low
CAN-Receive-Frame TSC1TE - 523914 3 78 Glow plug control; short circuit to
active battery
523777 9 292 Passive Timeout Error of 523914 4 79 Glow plug control; short circuit to
CAN-Receive-Frame TSC1TE; ground
Setpoint
523914 5 76 Glow plug control; open load
523778 9 293 Active Timeout Errorof
523914 5 1216 Glow plug control release line;
CAN-Receive-Frame TSC1TR
short circuit error
523779 9 294 Passive Timeout Error of
523914 11 1217 Glow plug control; internal error
CAN-Receive-Frame TSC1TR
523914 12 77 Glow plug control; powerstage
523788 12 299 Timeout Error of
over temperature
CAN-Transmit-Frame TrbCH;
Status Wastegate 523919 2 1378 Sensor air pump airpressure;
plausibility error
523793 9 202 Timeout Error of
CAN-Receive-Frame UAA10; 523920 2 1379 Sensor exhaust gas back
AGS sensor service message pressure burner; plausibility error
523794 9 203 Timeout Error of
CAN-Receive-Frame UAA11;
AGS sensor data
523895 13 559 Check of missing injector
adjustment value programming
(IMA) injector 1 (in firing order)
523896 13 560 check of missing injector
adjustment value programming
(IMA) injector 2 (in firing order)
653 5 Engine Injector Cylinder #03 :Current Below Normal Injector Solenoid Circuit - Test
653 6 Engine Injector Cylinder #03 :Current Above Normal Injector Solenoid Circuit - Test
653 20 Engine Injector Cylinder #03 :Data Drifted High Injector Data Incorrect- Test
653 21 Engine Injector Cylinder #03 :Data Drifted Low Injector Data Incorrect - Test
654 5 Engine Injector Cylinder #04 :Current Below Normal Injector Solenoid Circuit - Test
654 6 Engine Injector Cylinder #04 :Current Above Normal Injector Solenoid Circuit - Test
654 20 Engine Injector Cylinder #04 :Data Drifted High Injector Data Incorrect- Test
654 21 Engine Injector Cylinder #04 :Data Drifted Low Injector Data Incorrect - Test
676 5 Engine GloW Plug Relay : Current Below Normal Glow Plug Starting Aid - Test
676 6 Engine Glow Plug Relay :Current Above Normal Glow Plug Starting Aid - Test
676 19 Engine Glow Plug Relay :Data Error Glow Plug Starting Aid- Test
677 3 Engine Starter Motor Relay :Voltage Above Normal Start Relay Circuit - Test
677 5 Engine Starter Motor Relay :Current Below Normal Start Relay Circuit - Test
677 6 Engine Starter Motor Relay :Current Above Normal Start Relay Cricuit - Test
723 8 Engine Speed Sensor #2 :Abnormal Engine Speed/liming Sensor Circuit - Test
Frequency,Pulse Width, or Period
976 2 PTO Governor State : Erratic,Intermittent, or PTO Switch Circuit - Test
Incorrect
1041 2 Start Signal Indicator :Erratic,Intermittent,or Start Relay Circuit- Test
Incorrect
Schematics
Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and qualified
on the repair of this machine
Hydraulic Schematics
Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Repair any machine damage or malfunction
burn skin. Loosen hydraulic
before operating the machine.
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
gradually. Do not allow oil to
Read, understand and obey the safety rules squirt or spray.
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
For Example:
C 74 PL – This is the circuit for the lockout valve #1.
C stands for control, 74 is the number of the circuit
for the primary #1 lock out valve. PL stands for
Primary Lockout.
S 62 BST – This is the circuit that communicates to
the onboard computers of the machine that the
boom is fully stowed. S stands for safety, 62 is the
number of the circuit for boom stowed and BST
stands for Boom Stowed.
P 48 LP – P stands for power. 48 is the circuit
number for work lamps and LP stands for Lamp.
R 48 LP – R stands for relay. In this case it is the
wire that feeds the relay coil for the work lamp. All
other numbers remain the same.
V61AXR – V stands for valve power. Number 61
stands for axle retracted circuit; AXR stands for
Axle retracted.
R46HRN – R stands for Relay output, supplying
power to the horn (HRN). Number 46 is the circuit
number for the horn.
Blue side
Yellow side
J14 White 35 pin AMP connector on TCON J58A 2 pin Deutsch DT pri boom up/dwn F.C. valve
#2 (Y45A)
J15 Black 4 pin DTP connector on PCON
J59 2 pin Deutsch DT primary boom up valve
J17 16 pin Molex mini fit circuit board to key (Y22)
switch
J60 2 pin Deutsch DT primary boom down valve
J20 8 pin Deutsch DT lower/upper LS harness (Y21)
J20B 2 pin Deutsch DT cable tension #2 harness J61 2 pin Deutsch DT pri boom extend/retract
J21 Black 23 pin AMP connector on PCON F.C. valve (Y76)
J22 White 35 pin AMP connector on PCON J62 2 pin Deutsch DT pri boom extend valve
(Y79)
J24 10 pin connector PCON PCB to toggle/LED
driver PCB J63 2 pin Deutsch DT pri boom retract valve
(Y80)
J25 6 pin Deutsch DTM conn on drive/steer
joystick (JC3) J69 2 pin Deutsch DT TT rotate CW/CCW F.C.
valve (Y77)
J26 6 pin Deutsch DTM conn on extend/retract
joystick (JC2) J70 2 pin Deutsch DT turntable rotate CW valve
(Y52)
J29 16 pin Molex conn on PCON PCB
J71 2 pin Deutsch DT turntable rotate CCW valve
J31 Black 23 pin AMP connector on DCON
(Y53)
J32 White 23 pin AMP connector on DCON
J76 2 pin Deutsch DT platform rotate CW valve
J33 3 pin Deutsch SAE DT connector (Y70)
(swivel-upper)
J77 2 pin Deutsch DT platform rotate CCW valve
J34 2 pin Deutsch DTP connector (swivel-upper) (Y71)
J35 6 pin Deutsch DT connector (swivel-upper) J78 2 pin Deutsch DT jib up valve (Y72)
J36 3 pin Deutsch SAE DT connector J79 2 pin Deutsch DT jib down valve (Y73)
(swivel-upper)
J80 2 pin Deutsch DT platform level up valve
(Y20)
J81 2 pin Deutsch DT platform level down valve
(Y19)
J82 4 pin Deutsch DT proximity kill (LSP1PROX)
J84 2 pin Deutsch DT footswitch (FS1)
J94 2 pin Deutsch DT LR steer left valve (Y58) J138 4 pin Deutsch DT rear axle safety switch
(LSRA1ES)
J95 2 pin Deutsch DT RF steer right valve (Y59)
J142 2 pin Deutsch DT boom cable to lower LS
J96 2 pin Deutsch DT RF steer left valve (Y60) harness
J97 2 pin Deutsch DT LF steer right valve (Y61) J144 10 pin AMP connector to Deutz engine
J98 2 pin Deutsch DT LF steer left valve (Y62) J146 2 pin Deutsch DT lower LS to function
J99 2 pin Deutsch DT axle extend valve (Y99) harness
J100 2 pin Deutsch DT axle retract valve (Y100) J147A 1 way Deutsch DTHD upper to lower boom
cable
J106 2 pin Deutsch DT brake release valve (Y2)
J147B 3/8 in stud term TCON to lower boom cable
J107 3 pin Deutsch DT RR steer sensor
(P52PCON)
(RSRR1SO)
J148A 1 way Deutsch DTHD upper to lower boom
J108 3 pin Deutsch DT LR steer sensor
cable
(RSLR1SO)
J148B 3/8 in stud term TCON to lower boom cable
J109 3 pin Deutsch DT RF steer sensor
(GNDPCON)
(RSRF1SO)
J149 2 pin Deutsch DTP upper to lower boom
J110 3 pin Deutsch DT LF steer sensor
cable
(RSLF1SO)
J150 4 pin Deutsch DT upper to lower boom cable
J114 6 pin Deutsch DT pri boom angle sensor
(RSB1AO/S) J151 3 pin Deutsch SAE DT upper to lower boom
cable
J120 4 pin Packard weatherpack EDC connection
J152A 3 pin Deutsch SAE tee harness
J121 12 pin Deutsch DTM gray SCON module #1
J152B 3 pin Deutsch SAE tee harness
J122 12 pin Deutsch DTM green SCON module #2
J153 4 pin Deutsch DT engine to function harness
J124 2 pin Deutsch DT drive enable right (LST1O)
J155A 2 way Deutsch DTP plat to upper boom cable
J125 4 pin Deutsch DT drive enable left (LST2O)
J155B 2 way Deutsch DTP upper to lower boom
J126 4 pin Deutsch DT drive enable safety
cable
(LST1S)
J155C 2 way Deutsch DTP lower boom cable to
J127 6 pin Deutsch DTM pri boom up/dwn/TT rot
swing
joystick (JC7)
J157 2 pin Deutsch DT plat harness to upper boom
cable
J162 6 pin Deutsch DT jib bellcrank tilt sensor J211 4 pin Deutsch DT 3ft extend oper (LSB3RO)
(S21) J213 4 pin Deutsch DT 150ft extend oper/safety
J166 2 pin Deutsch DT function enable valve #1 (LSB4EO/S)
(Y74) J215 2 pin Deutsch DT lower LS to engine harness
J166A 2 pin Deutsch DT function enable valve #2 J216 2 pin Deutsch DT hyd generator valve (Y91)
(Y74A) J217 2 pin Deutsch DT hyd generator bypass valve
J169 20 pin Molex conn on PCON PCB (Y92)
J171 2 pin Deutsch DT hydraulic oil cooler sensor J218 6 pin Deutsch DTM jib up/dwn/jib rot joystick
J172 2 pin Deutsch DT hydraulic oil cooler fan (JC8)
J173 2 pin Deutsch DT boom cable to engine J219 2 pin Deutsch DT primary lockout valve #1
harness (Y87)
J192A 4 pin Deutsch DT cable break safety #1 J220 2 pin Deutsch DT primary lockout valve #2
(LSB5S) (Y88)
J192B 2 pin Deutsch DT cable break safety #2 J222A 4 pin Deutsch DT zero tube limit to cable
(LSB6S) tension cable #1
J199 6 pin Deutsch DT pri boom length sensor J222B 2 pin Deutsch DTP upper limit to cable
(LTB1LO/S) tension cable #2
Pin location - 4 pin Pin location - 23 pin Pin location - 35 pin connector
connector connector
Abbreviation
OH High Current On/Off Solenoid Output (3 < x < 6 Amps)
OM Medium Current On/Off Solenoid Output (0.5 < x < 3 Amps)
OL Low Current On/Off Solenoid Output (0.1 < x < 3 Amps)
PM Prop. Medium Current Proportional Solenoid Output (0.5 < x < 3 Amps)
LED LED Output LED Output Driver
RLY Relay Output Relay Output Driver (0.1 < x < 0.3 Amps)
EDC EDC Output Linear Current Control (propel)
AI Analog Input (0 to +5 Vdc)
DI Digital Input (0 or 'Vbat' Voltage)
FAC Frequency AC Input (0 to 1 kHZ / 0 to 13.8 Vptop)
RDF Ground Ref signal power / GND to external sensors, input power(s) and ground
PWR 12V Power (x > 6 Amps)
CONT 12V Power (x < 1 Amp)
SNSR Sensor Power 5.0 Vdc Supply for sensors
Circuit connection Limit Switch Power relay Coil with suppression Fuel or RPM solenoid
Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator
valve setting proportional valve
Solenoid operated 2
Pilot operated 3 position, 3
Pressure reducing valve Flow divider/combiner valve position, 3 way directional
way shuttle valve
valve
Solenoid operated 3
Counterbalance valve with Pilot operated 2 position, 2 2 position, 2 way solenoid
position 4 way directional
pressure and pilot ratio way directional valve valve
valve
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TCON MEMBRANE PANEL (MS2)
1
TO
uP
6
2
1
ROTATE CCW VLV P14-26 V05TRR-WH/BK Y53 TT ROT CCW VLV (J71) V150BV-GR/BK Y92 AC GENERATOR BYPASS VLV (J217)
2
PLAT LVL UP
1
7
2
V150BV-GR/BK
VLVRET6-BR
TO
10
uP
V45HG-GR/WH
TURTLE
86
87 85
HYD_FILTER2 DI P14-16
1
30
HYD_FILTER1 DI P14-15
87a
TO
CR77B
uP
12
P_30
VALVE_RETURN_5 P14-14
#1
13
SPARE OM P14-12
86
87 85
FUNCTION
PRI RETRACT VLV P14-10 V08PBR-BK/WH Y80 PRI RET VLV (J63)
87a
BOOM DOWN
ENABLE
2
TO PLD
1
TO
15
2
1
PRI DOWN VLV P14-08 V02PBD-RD/BK Y21 PRI DWN VLV (J60)
TO
uP
#2
BOOM RET
2
1
J9 PRI UP VLV P14-07 V01PBU-RD Y22 PRI UP VLV (J59) C26TSR-WH/RD OIL TEMP SENDER
TO
uP
J144-3
SPARE PM P14-06
R21IGN-WH
2
P P P P
1
PRI BM U/D FC VLV #1 P14-05 V03PUD1-RD/WH Y45 PRI BM UP/DWN F.C. #1 (J58)
2
2
1
PRI BM E/R FC VLV P14-03 V09PER-BK/RD Y76 PRI BM EXT/RET F.C. (J61)
TO
uP
2
1
PRI BM U/D FC VLV #2 P14-02 V03PUD2-GR/WH Y45A PRI BM UP/DWN F.C. #2 (J58A)
86
87 85
01GND-BR
TO
1
R21IGN-WH 06GND-BR
30
FUEL SOLENOID
FUNCTION HARNESS
J144-7
J144-8
B1ENG-RD
87a
ENG FUEL
TO PLD
J14 WHITE 35 PIN
2
C21IGN-WH
RELAY
CR28
TO
uP
3
J153
NOT USED
J172-2
TO PLD
HYDRAULIC
4
J172-1
87 87a
FAN
03GND-BR
4
X
COOLER
5 R116HYD-OR
RELAY
1 2
MULTI FUNCTION VLV RECOVERY SIGNAL
SEC BOOM EXT/RET FC RECOVERY SIGNAL
TEMP
86
BOOM UP/DWN FC RECOVERY SIGNAL
J171-2
85
N.O.
J171-1
FUNCTION ENGINE
SW
AUXILIARY HYD RECOVERY SIGNAL
6
COOLER
HARNESS HARNESS
SEC BOOM RET RECOVERY SIGNAL
JIB ROT CW
BOOM DWN RECOVERY SIGNAL
RELAY
BOOM RET RECOVERY SIGNAL
CR17
R21IGN-WH
C21IGN-WH
BK
OIL
7
C26TSR-WH/RD
C25PSR-WH/BK
9
7
NOT USED REMOTE DISABLE P224-06 C226TEL-BL C34SA-BK/WH 01GND-BR GLOW PLUG
TO CAN GATEWAY
ENGINE CAN BUS
6
10
5
PLUG
CR15
(TIER IV)
C31EDC(-)-WH/BK
P_11
EDC
1
W
B1ENG-RD
B3BAT/14-RD
uP
BK-GND BK
TT_TILT_X_AXIS
6 AMP
14 PULL IN
3
RD-HOLD RD
P_22R
C21TEL-WH
C226TEL-BL
P_7R
P_10
15
J57
J10
uP
D22
VALVE_RETURN_2 P13-16
CR5
TO
TO
uP
uP
HORN
DEUTZ TD2011L04i ENGINE SHOWN
86
TT_TILT_SNSR_GND P13-14
87 85
01GND-BR
OIL/WATER TEMP P13-13 C26TSR-WH/RD HORN
R46HRN-WH 01GND-BR
30
TO
uP
(P15)+(ECU POWER)
EDC FWD P13-10 C30EDC(+)-WH C41RPM-OR/BK
TO HORN
J144-1
TO
uP
WH-PULL IN
LP P13-08
IND.
EXCT.
STA.
ALTERNATOR
V
CB7
15A
BAT.
P34SA-BK/WH
C
B3BAT/14-RD
TROMBETTA
TIME DELAY
100 OHM PULL UP
VALVE_RETURN_1 P13-01
B3BAT+ STUD ON RELAY BLOCK
SUPPLIED S-500-A6
MOM N.O.
87a
82 OHM PULL UP
C27AUX-RD
30
NC
J13 WHITE 23 PIN
5
C229TEL IS CONNECTED TO
B1BAT-RD
NOTE: FOR ACTIVE LOW
85
86
ENGINE HARN
B1BAT-RD
PR1
B1ENG-RD
TELEMATICS SYSTEMS
(~SM)+(AH)
AUX+
BAT+
GND-
PUMP
F23 ENG/START/ALT
AUX.
CR80
TELEMATICS
RELAY
5V 12V
BY DEUTZ
C229TEL-BL/BK
(~SM)+(AH)
AUX HYD
S139TRF-WH/RD
C35RPM-BK/RD PUMP
5 VOLT PR1
13
74HC08 10
12
SOLENOID
4
74HC08 1
9
2
74HC08 5
(OPTION)
74HC08
(~SM)+(AH)
PUMP
AUX.
FUSES
7
6
8
3
14
05GND-BR
14
86
87 85
((~SM)+(AH))(P_22)
OUT PWR ENABLE (OE)
C33STR-BK
74HC08
((~SM)+(AH))(P_7)
((~SM)+(AH))(OE)
STARTER
TO
uP
P_6R1
P_22R
P_22
B1ENG-RD
P_7R
R33STR-BK
30
(TM)(FE)
P16-04
STARTER
B1ENG-RD RELAY
U
W/BAT CBL
30A
STARTER
INTEGRAL
F20 STARTER
POWER
RELAY
20A P35RPM-BK/RD
W/BAT CBL
CR1
INTEGRAL
1
J16 BLACK 4 PIN
20A
J15
CB
Vbb BTS621
Vbb BTS621
01GND-BR
ST OUT 2
IN1 OUT 1
IN1 OUT 1
ST OUT 2
POWER HARN
POWER
ENGINE BLOCK
BTS650
BTS650
BTS650
F22
OUT
OUT
P_1
OUT
P_6R2
HARN
HARN
ENG
-
GND
GND
GND
60A
B1
Vbb
Vbb
IN2
IN2
Vbb
AUX MAIN
IN
IN
IS
IS
IN
IS
F7
B1BAT-RD
20A
01GND-BR
B1BAT-RD START/CONT
B1BAT-RD B1BAT-RD ROL SYS
-
+
-
U32
B2
BATTERY
B2BAT-RD
SEPARATE
4 GA WIRE
S139TRF-WH/RD
S137PLL-RD/WH
74HC08 10
T
HARNESS
8
ENGINE
SEC BOOM EXT/RET FC RECOVERY SIGNAL
((~SM)+(AH))(BM STOWED)
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
SEC BOOM RET RECOVERY SIGNAL
J215
AUXILIARY HYD RECOVERY SIGNAL
2
Vbb BTS621
LOWER LS
ST OUT 2
IN1 OUT 1
HARNESS
TO HORN BUTTON
GND
OUT PWR ENABLE
(P15)+(ECU POWER)
IN2
P_30
P_22
P_9B
P23PCON-BK
S56PRV-RD
B3BAT/14-RD
GND-BR
BOOM STOWED
S
5 VOLT
P_6R1
P_11
P_9A
PCON POWER
P_6R2
P_10
P_7
P_7R
TCON MODE
LSB4EO
NO
13
21
BK/WH
4321
BK
J20 1 2
14
C71PBE-BL/BK
RED
C71PBE-BL/BK
BLU
BK BR
NO
13
21
BK/WH
432 1
MULTI FUNCTION VLV RECOVERY SIGNAL
NC
LSB3RO
SEC BOOM EXT/RET FC RECOVERY SIGNAL
10
BK
BOOM EXT/RET FC RECOVERY SIGNAL
C64LS-OR/BK
BOOM UP/DWN FC RECOVERY SIGNAL
14
BLU
J211
8 J208 9
SEC BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
WHT NO
13
21
BK/WH
NC
BK LSB1DO
ALL LIMIT SWITCHES SHOWN IN "STOWED" STATE
22
14
OUT PWR ENABLE
PWR TO TCON ESTOP
NO
13
21
P_22
P_9B
C64LS-OR/BK RD
4 32 1
LST2O
NC
C143DEL-BL/RD C143DEL-BL/RD
P_30
BR
R
14
ORN
YEL
WH J125
ORN NO
13
21
C64LS-OR/BK RD LST1O
21
NC
14
WH J124
A B J53
LST1S
ORN NO
13
21
NC
S13DE-BL/RD BR
BK SAFETY
22
14
RED
WH J126
VALVE_RETURN_8 P12-35 VLVRET8-BR
J208
6 J199
OPER
BOOM STOWED P12-31 SNSRGND-BR SNSRGND-BR OR
Q
OR
5
SAFETY
TO
uP
4567
21
11
NC
NC
C64LS-OR/BK OR RD/WH
RED
22
12
SPARE DI P12-22
P109ANG-GR/WH P109ANG-GR/WH BL
SPARE DI P12-21 RSB1A0
SNSRGND-BR SNSRGND-BR GR
TO
uP
SNSRGND-BR BK RSB1AS
TO
uP
TO PLD C68PBD-BL
PRI BOOM DOWN STATUS DRV ENBL R - LST1O P12-15 C144DER-BL/WH
TO PLD
LOW FUEL - FST1S P12-14 C65LOFL-BL/WH
P
TO
uP
OUT PWR ENABLE
J222B
P_18 P12-12
P_14 P12-11
2 1
2 1
BK/WH
P_10 P_10 P12-08 S59CNBK-GR/WH P63LS-OR/RD BL/BK
J208
J222A
U31
SJ2-OR/BK
AUXILIARY HYD RECOVERY SIGNAL
SJ2-OR/BK
P_6R1
BOOM RET RECOVERY SIGNAL
P54ENG-BK/WH
LOCKOUT VALVE #1 SIGNAL
TO HORN BUTTON
BK
BK
BR
BR
BK/WH
BL
BL
BK/WH
22 21 22 21
C60AXEX-GR/WH P122-04 LSFA1ES & LSRA1ES (AXLES EXTENDED)
NC NC
P53LS-WH/BK C141PBS-RD P122-03 RSB1AS (BOOM ANGLE) 14 13 14 13
PUR
GRN
NO NO
B3BAT/14-RD C166PRS-OR P122-02 LTB1LS (BOOM LENGTH)
P21DCON-WH P21DCON-WH P122-01 SCON PWR
LSB5S
CABLE
TENSION #1
J192A
LSB6S
CABLE
TENSION #2
J192B
C60AXEX-GR/WH
P53LS-WH/BK
C61AXRT-GR
C145CAL-RD/WH
S132LDS-BL/WH
P57PBD-RD/WH
J121-GRAY 12
S56PRV-RD
D81CAN(-)-GR
P117FB-RD
D82CAN(+)-YL
P63LS-OR/RD
BM U/D FC O
C61AXRT-GR
PIN SCON
ECU POWER
GND-BR
PCON POWER
ECU POWER
OPER. REC.
TCON MODE
P_22
P_15
P_6R1
P_7
P_7R
P_11
TO WORKLIGHT OPTION
C60AXEX-GR/WH
P57PBD-RD/WH
CLOSED CLOSED
CLOSED CLOSED
CLOSED CLOSED
CLOSED
CLOSED
CLOSED
SERVICE RECOVERY
GNDDCON-BR
P21DCON-WH
M
P53LS-WH/BK
P63LS-OR/RD
C61AXRT-GR
GROUND/PLATFORM KEYSWITCH TRUTH-TABLE
S56PRV-RD
KEYSWITCH POSITION
RECOVERY KEYSWITCH TRUTH-TABLE
GROUND PLATFORM
CLOSED CLOSED
CLOSED CLOSED
CLOSED CLOSED
RECOVERY
CLOSED CLOSED OPEN
CLOSED CLOSED OPEN
KEY SWITCH
KEYSWITCH POSITION
2
E 1
OPEN
OPEN
OPEN
1
3
NC
J155/6C
W
Z
1
X 3 3
2
NC
4
NC
NO
V
Y
D
4
U
2
B 1
NO
NC
2
1
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
RUN
NC
NC
C
D81CAN(-)-GR
4
P117FB-RD
D82CAN(+)-YL
NC
NO
PANEL
01GND-BR
FLASHING BEACON
NC
OPEN
OPEN
OPEN
OFF
A
CONTACT
PANEL
J152B
W
U
V
X
Y
Z
CONTACT
85
30
C
D
A
B
RELAY
CR41
BC BC
86
TO FLASHING BEACONS 87a
87
GND-OR/WH
P20BAT-OR
BB BB
R117FB-RD
ESTOP
BA BA
C145CAL-RD/WH
S132LDS-BL/WH
C117FB-RD
GNDDCON-BR
NC 1
2
AC
AA
AB
GND-BR
PANEL
BOOM LOWER LS
CABLE HARNESS
J11 BLACK 23 PIN
BOOM HARNESS
BL/BK
CALIBRATION
CALIBRATE)
SWITCH TO
J142
1 SWITCH
(CLOSE
G/P MODE-WH/BK
1
2
J17
WH/BK
AC
AA
AB
1
1
C
D
E
PLAT
PLAT
PLAT
2
PLAT
OFF
OFF
OFF
OFF
2
2
GROUND
OFF
GRND
GROUND
GRND
BA
GRND
J152A
AC
AA
AB
V
Z
C117FB-RD
RECOVERY
SERV BYPASS
RUN
U30
P_7 PLAT-GR/WH P_7 P11-06 S56PRV-RD
RS232_GND
DB9 CONNECTOR
RS232_RXD
RS232_TXD
ALARM PWR-BL
H5
J147B-1
2
3
5
8PIN
J223
GNDDCON-BR
ENGINE CAN
TCON J147B-1
120Ω GNDPCON-BR
GROUND P223-01 ALM-GND-BR BUS TO
J
CAN GATEWAY
TELEMATICS
J151-C
J151-A
J151-B
C
B
A
J148A-1
J147A-1
& TCON LCD
J150-1
J150-2
J149-1
J149-2
J150-3
C60AXEX-GR/WH
J228-2
P57PBD-RD/WH
D82CAN+ -YL
GNDDCON-BR
P53LS-WH/BK
MACHINE CAN HIGH P223-05
P63LS-OR/RD
P21DCON-WH
D81CAN(-)-GR
D82CAN(+)-YL
J228-3 J155/6A
C61AXRT-GR
S132LDS-BL/WH
C47OUT-WH/BK
P56PRV-RD/WH
S56PRV-RD
GNDPCON-BR
D81CAN(-)-GR
J228-4
GND-OR/WH
C46HRN-WH
S56PRV-RD
P20BAT-OR
GND-OR/WH
OPT GBOX
DIGITAL IN 2 P223-08 2
HARN
#1
TS5
J34-LIMIT SW HARN
J35-LIMIT SW HARN
ENG SPEED-BK/RD
J1 20PIN
J33-BOOM HARN
NOT USED 19 NOT USED P21-09
AXLE EXT-GR/WH NOT USED P21-08
EXT/RET
SPARE-WH 18
AXLE
TS23
U21
U22
ST OUT 2
IN1 OUT 1
BTS650
OUT
NOT USED
P_6
GND
NOT USED 15
Vbb
IN
IS
ENABLE
6
2
3
5
TS15
4
C
1
2
A
B
DRV SPEED-RD/WH 13 NOT USED P21-03
DRV ENBL-BL/WH
6
2
3
5
4
PCON PWR P21-02 P52PCON-WH P52PCON-WH
C
AXLE EXT-GR/WH 12
A
B
1
2
ENG SPEED-BK/RD 11 PCON GND P21-01 GNDPCON-BR GNDPCON-BR
ENGINE
J24 10PIN
GR
START
YL
WH
OR
GR
DCON PWR RD
BR
10
BK
GND1-BR
TS2
BL
YL
AXLE RET-GR 9
J21 23 PIN
HARNESS
H
ENG START-BK
P_9A+P_10
DCON GND
SLIP RING
C60AXEX
CAN HIGH
CAN LOW
NOT USED 8
BLACK
RS232_GND
BOOM
RS232_RXD
RS232_TXD
P_6R1
P_10
P_12
P_7R
DRV ENBL-BL/WH 7
ASSIST
START
TS6
6
CKT #
ENG START-BK
START ASST-BK/WH START ASST-BK/WH 5
88
88
88
88
88
88
88
88
88
88
88
AUX PUMP-RD 4
74HC08
74HC08
GENERATOR AUXILIARY
GEN ON/OFF-GR/WH 3
PUMP
TS1
2
3
5
WH
GR
RD
OR
BR
BK
BL
YL
HORN RET-GR
ON CIRCUIT BOARD
GR
YL
2
1
5
AUX PUMP-RD
4
1
S132LDS-BL/WH
HORN PWR-RD
6
2
3
5
4
1
2
B
A
C
ON/OFF
6
2
3
5
4
TS17
B
J36-DRIVE CHASSIS HARN A
1
2
SLP_MODE
GEN ON/OFF-GR/WH
P_22
J157-1
P_6
HORN RTN-GR
P_7
J162
SERVICE
HORN
BN5
C88PJTS-RD/WH
6
G
TILT SENSOR
POWER FET POWER FET
HORN PWR-RD C88PTS-RD/BK
BELLCRANK
5
ASSEMBLY
- -
P89RET-BR + 10 DEG 10 DEG
MANIFOLD
+
4
J22 35 PIN
HARNESS
SAFETY CUTOUT
P109JBS-GR/WH
WH
3
0-20 DEG Y AXIS
WHITE
-
PCON
S21
C148JBS-BL/WH
JIB
DRIVE & STEERING
2
+
P110JBS-BK PLAT TILT SNSR
6
JOYSTICK (JC3)
1
GND1-BR
5 C158STC-BL/RD NOT USED P22-35
4 C160JPL-WH/RD VALVE_RETURN_2 P22-34 VLVRET2-BR VLVRET2-BR
3 C159STC-BL/WH JIB ROTATED CW P22-33 C214JRL-RD/WH
2 P
1
2
2 P162JPW1-OR V147JBD-BL/BK Y86 JIB BELLCRANK DOWN (J136)
JIB TILT SNSR IN P22-32 C148JBS-BL/WH
P
1
1 JSGND1-BR V146JBU-BL Y85 JIB BELLCRANK UP (J135)
JIB TILT SNSR GND P22-31 P110JBS-BK
J25
2 P
1
2
JIB TILT SNSR PWR P22-30 P109JBS-GR/WH V193JRR-WH/BK Y90 JIB ROTATE CCW (J203)
P
JIB UP/DOWN AND
1
JSGND1-BR 16 JOYSTICK_GND_1 JIB BELLCRANK LEVEL DOWN P22-29 V147JBD-BL/BK V192JRL-WH Y89 JIB ROTATE CW (J202)
6 GND2-BR
JOYSTICK (JC8)
CCW SAFETY
JIB ROTATED
JIB ROTATE
NO
V193JRR-WH/BK
13
21
4 C156JUD-GR/WH BK/WH
43 2 1
NC
P162JPW4-OR 13 JOYSTICK_PWR_4 SPARE OM P22-26 BK
LSJ2RS
3 C213JRS-RD/BK BL
14
TT ROTATE
22
C165TRS-WH/RD 12
GRN
SPARE OM P22-25 C214JRL-RD/WH
BLU
BR
J55
2 P162JPW2-OR
J205
C164PLS-RD/WH 11 PRIMARY UP/DOWN
PLATFORM
ASSEMBLY
1 JSGND2-BR JIB ROTATE CW P22-24 V192JRL-WH
6
F
SENSOR
C163PES-BL/WH 10 PRIMARY EXT/RET POWER FET
CCW (RIGHT)
JIB ROTATED
J218 SAFE PL/JB TILT PWR P22-23 P87PTS-RD POWER FET
NO
13
21
BK/WH
5
EXTEND/RETRACT
9
-
SPARE AI SAFE PL/JB TILT GND P22-22 10 DEG
-
10 DEG
NC
U20 P89RET-BR BK
TILT
+
LSJ3RO
4 +
PRIMARY BOOM
BL
S6
JOYSTICK (JC2)
14
22
PL TILT SNSR PWR P22-21
21
GRN
P85PTS-GR
RED
BR
3
-
STEER - DUAL AXIS
J206
5 C159STC-BL/WH 7 PL TILT SNSR IN P22-20 C84TAY-GR/BK + 0-20 DEG Y AXIS
2
4 C163PES-BL/WH C158STC-BL/RD 6 STEER - ROCKER PL TILT SNSR GND P22-19 P85RET-BR PLAT TILT SNSR
1
P_7R
P_22
5
P_6
FOOTSW (FS1)
2 P162JPW3-OR P162JPW3-OR 4 JOYSTICK_PWR_3
2
FOOT SW RTN P22-17 C56FTS-RD C56FTS-RD
C60AXEX-GR/WH
1 JSGND3-BR P162JPW2-OR 3 JOYSTICK_PWR_2 LIMIT SWITCH PWR P22-16 C64LS-OR/BK C64LS-OR/BK
P57PBD-RD/WH
D81CAN(-)-GR
D82CAN(+)-YL
GNDDCON-BR
P21DCON-WH
J26
P53LS-WH/BK
P63LS-OR/RD
C61AXRT-GR
JSGND3-BR 2 JOYSTICK_GND_3
OVERLOAD
SAFE PL/JB TILT OUT P22-15 C88PJTS-RD/WH
S56PRV-RD
1
RD
LIMIT SW
J84
JSGND2-BR 1 JOYSTICK_GND_2 LOAD SNSR PWR P22-14 BK BK BK
LSP1LS
6
NO
GND4-BR
AND TURNTABLE
PRIMARY BOOM
J29
JOYSTICK (JC7)
NC
5
WH
4 C164PLS-RD/WH LOAD SNSR GND P22-12 GR/YL
UP/DOWN
3 C165TRS-WH/RD
PROX GND P22-10
2 P162JPW4-OR
1 JSGND4-BR SPARE OM P22-09 P57PBD-RD/WH
2 P
1
2
J127 PLAT LEVEL DOWN P22-08 V15PLD-OR/BK Y19 PLAT LEVEL DOWN (J81) P63LS-OR/RD
1 P
1
PLAT LEVEL UP P22-07 V14PLU-OR Y20 PLAT LEVEL UP (J80)
C60AXEX-GR/WH
E
2 P
2
JIB DOWN P22-06 V44JD-GR/BK Y73 JIB DOWN (J79)
P
1
JIB UP P22-05 V43JU-GR Y72 JIB UP(J78)
13
23
C60AXEX-GR/WH RD
NO
NO
4 3 2 1
LSRA1ES
2
PLAT ROT CW P22-04 V17PRL-GR Y70 PLAT ROTATE CW (J76) J2-GR/BK BR
P63LS-OR/RD BK REAR AXLE SAFETY
24
14
1
2
ESTOP PWR-RD/BK 20 PWR-PCON ESTOP PLAT ROT CCW P22-03 V18PRR-GR/BK Y71 PLAT ROTATE CCW (J77) J1-OR/BK WH SW
ALARM(+)-RD/BK 19 ALARM SPARE OM P22-02 J138
PLAT ROT CW-GR 18 PLAT ROT CW VALVE_RETURN_1 P22-01 VLVRET1-BR
ESTOP PWR-RD
PLAT ROT CCW-GR/BK 17 PLAT ROT CCW
13
E-STOP
23
J2-GR/BK RD
NO
NO
PCON
4 3 2 1
GND5-BR 16 GND P61LSA-GR BR LSFA1ES
P2
24
14
15 SPARE DI SAFETY SW
P57PBD-RD/WH WH
14 SPARE DI J137
ESTOP RET-BK
GND1-BR 13 GND
PLATFORM PLATFORM
GND12-BR 12 GND BL
ROTATE
6
TS7
5
GND5-BR ESTOP RET-BK 10 OUT PWR ENBL WH
4
PLAT ROT CW-GR GND2-BR 9 GND AXLE NOT EXT PWR P31-23 P61LSA-GR P61LSA-GR YL RSRA1O
3
PLAT LVL DN-OR/BK 8 PLAT LVL DOWN SPARE AI (BIASED TO 2.5V) P31-22 BK REAR AXLE SENSOR
2
(S16)
PLAT LVL DN-OR/BK PLAT LVL UP-OR 7 PLAT LVL UP PCON REAR AXLE POSITION SENSOR P31-21 C60RAP-GR/WH C60RAP-GR/WH RD
LEVEL
J161
1
GND6-BR
TS9
GND6-BR 6 GND
D
J169
PCON
GND12-BR BL
!BOOT P31-13
6
GR NOT USED
RS232 TxD P31-12
5
RS232 RxD P31-11 WH
4
YL RSFA1O
CAN SHIELD P31-10
3
BK FRONT AXLE SENSOR
AXLE NOT RET RTN P31-09
2
(S15)
RD J160
AXLE NOT RET GND P31-08
1
SX-150 ELECTRICAL SCHEMATIC
HARNESS
VLVRET2-BR
2
V37LFS-BL/BK Y62-LF STEER LEFT (J98)
2
V36LFS-BL Y61-LF STEER RIGHT (J97)
2
V37RFS-BL/BK Y60-RF STEER LEFT (J96)
2
J32 23 PIN WHITE
V36RFS-BL Y59-RF STEER RIGHT (J95)
DRIVE CHASSIS
P_6R1
P_12
P_7R
2
V37LRS-BL/BK Y58-LR STEER LEFT (J94)
2
V36LRS-BL Y57-LR STEER RIGHT (J93)
HARNESS
2
ES0554D
2
V36RRS-BL Y55-RR STEER RIGHT (J91)
LF STEER LEFT P32-23 V37LFS-BL/BK
V36LFS-BL BK
B
C
RF STEER LEFT P32-21 V37RFS-BL/BK C111LFS-OR BL RSLF1SO
B
LF STEER
STEER SNSR PWR (5.0 VDC) P32-20 P109ANG-GR/WH P109ANG-GR/WH RD
SNSR (S14)
A
STEER SNSR GND P32-19 P110RT-BK P110RT-BK J110
RF STEER RIGHT P32-18 V36RFS-BL
LR STEER LEFT P32-17 V37LRS-BL/BK BK
C
LR STEER RIGHT P32-16 V36LRS-BL C111RFS-OR BL RSRF1SO
B
RF STEER
BRAKE P32-15 V32BRK-WH/RD RD
SNSR (S13)
A
VALVE_RETURN_2 P32-14 VLVRET2-BR J109
LF STEER SNSR P32-13 C111LFS-OR
RF STEER SNSR P32-12 C111RFS-OR BK
C
LR STEER SNSR P32-11 C111LRS-OR C111LRS-OR BL RSLR1SO
B
LR STEER
RR STEER SNSR P32-10 C111RRS-OR RD
SNSR (S12)
A
RR STEER LEFT P32-09 V37RRS-BL/BK J108
RR STEER RIGHT P32-08 V36RRS-BL
SPARE OM P32-07 BK
C
SPARE OM P32-06 C111RRS-OR BL RSRR1SO
B
A
RR STEER SNSR
SPARE OM P32-05 RD
(S11)
A
MOTOR SPEED P32-04 V29MS-RD/WH J107
AXLE EXTEND P32-03 V60AXEX-GR/WH
AXLE RETRACT P32-02 V61AXRT-GR
VALVE_RETURN_1 P32-01 VLVRET1-BR
DCON
2
V32BRK-WH/RD Y2-BRAKE RELEASE (J106)
2
V29MS-RD/WH Y27-TWO SPEED MOTOR STROKE (J87)
2
V60AXEX-GR/WH Y99-AXLE EXTEND (J99)
2
V61AXRT-GR Y100-AXLE RETRACT (J100)
VLVRET1-BR
10
12
13
14
15
16
11
1
9
TCON MEMBRANE PANEL (MS2)
1
TO
uP
6
2
1
ROTATE CCW VLV P14-26 V05TRR-WH/BK Y53 TT ROT CCW VLV (J71) V150BV-GR/BK Y92 AC GENERATOR BYPASS VLV (J217)
2
PLAT LVL UP
1
7
2
V150BV-GR/BK
VLVRET6-BR
TO
10
uP
V45HG-GR/WH
TURTLE
86
87 85
HYD_FILTER2 DI P14-16
1
30
HYD_FILTER1 DI P14-15
87a
TO
CR77B
uP
12
P_30
VALVE_RETURN_5 P14-14
#1
13
SPARE OM P14-12
86
87 85
FUNCTION
PRI RETRACT VLV P14-10 V08PBR-BK/WH Y80 PRI RET VLV (J63)
87a
BOOM DOWN
ENABLE
2
TO PLD
1
TO
15
2
1
PRI DOWN VLV P14-08 V02PBD-RD/BK Y21 PRI DWN VLV (J60)
TO
uP
#2
BOOM RET
2
1
J9 PRI UP VLV P14-07 V01PBU-RD Y22 PRI UP VLV (J59) C26TSR-WH/RD OIL TEMP SENDER
TO
uP
J144-3
SPARE PM P14-06
R21IGN-WH
2
P P P P
1
PRI BM U/D FC VLV #1 P14-05 V03PUD1-RD/WH Y45 PRI BM UP/DWN F.C. #1 (J58)
2
2
1
PRI BM E/R FC VLV P14-03 V09PER-BK/RD Y76 PRI BM EXT/RET F.C. (J61)
TO
uP
2
1
PRI BM U/D FC VLV #2 P14-02 V03PUD2-GR/WH Y45A PRI BM UP/DWN F.C. #2 (J58A)
86
87 85
01GND-BR
TO
1
R21IGN-WH 06GND-BR
30
FUEL SOLENOID
FUNCTION HARNESS
J144-7
J144-8
B1ENG-RD
87a
ENG FUEL
TO PLD
J14 WHITE 35 PIN
2
C21IGN-WH
RELAY
CR28
TO
uP
3
J153
NOT USED
J172-2
TO PLD
HYDRAULIC
4
J172-1
87 87a
FAN
03GND-BR
4
X
COOLER
5 R116HYD-OR
RELAY
1 2
MULTI FUNCTION VLV RECOVERY SIGNAL
SEC BOOM EXT/RET FC RECOVERY SIGNAL
TEMP
86
BOOM UP/DWN FC RECOVERY SIGNAL
J171-2
85
N.O.
J171-1
FUNCTION ENGINE
SW
AUXILIARY HYD RECOVERY SIGNAL
6
COOLER
HARNESS HARNESS
SEC BOOM RET RECOVERY SIGNAL
JIB ROT CW
BOOM DWN RECOVERY SIGNAL
RELAY
BOOM RET RECOVERY SIGNAL
CR17
R21IGN-WH
C21IGN-WH
BK
OIL
7
C26TSR-WH/RD
C25PSR-WH/BK
9
7
NOT USED REMOTE DISABLE P224-06 C226TEL-BL C34SA-BK/WH 01GND-BR GLOW PLUG
TO CAN GATEWAY
ENGINE CAN BUS
6
10
5
PLUG
CR15
(TIER IV)
C31EDC(-)-WH/BK
P_11
EDC
1
W
B1ENG-RD
B3BAT/14-RD
uP
BK-GND BK
TT_TILT_X_AXIS
6 AMP
14 PULL IN
3
RD-HOLD RD
P_22R
C21TEL-WH
C226TEL-BL
P_7R
P_10
15
J57
J10
uP
D22
VALVE_RETURN_2 P13-16
CR5
TO
TO
uP
uP
HORN
DEUTZ TD2011L04i ENGINE SHOWN
86
TT_TILT_SNSR_GND P13-14
87 85
01GND-BR
OIL/WATER TEMP P13-13 C26TSR-WH/RD HORN
R46HRN-WH 01GND-BR
30
TO
uP
(P15)+(ECU POWER)
EDC FWD P13-10 C30EDC(+)-WH C41RPM-OR/BK
TO HORN
J144-1
TO
uP
WH-PULL IN
LP P13-08
IND.
EXCT.
STA.
ALTERNATOR
V
CB7
15A
BAT.
P34SA-BK/WH
C
B3BAT/14-RD
TROMBETTA
TIME DELAY
100 OHM PULL UP
VALVE_RETURN_1 P13-01
B3BAT+ STUD ON RELAY BLOCK
SUPPLIED S-500-A6
MOM N.O.
87a
82 OHM PULL UP
C27AUX-RD
30
NC
J13 WHITE 23 PIN
5
C229TEL IS CONNECTED TO
B1BAT-RD
NOTE: FOR ACTIVE LOW
85
86
ENGINE HARN
B1BAT-RD
PR1
B1ENG-RD
TELEMATICS SYSTEMS
(~SM)+(AH)
AUX+
BAT+
GND-
PUMP
F23 ENG/START/ALT
AUX.
CR80
TELEMATICS
RELAY
5V 12V
BY DEUTZ
C229TEL-BL/BK
(~SM)+(AH)
AUX HYD
S139TRF-WH/RD
C35RPM-BK/RD PUMP
5 VOLT PR1
13
74HC08 10
12
SOLENOID
4
74HC08 1
9
2
74HC08 5
(OPTION)
74HC08
(~SM)+(AH)
PUMP
AUX.
FUSES
7
6
8
3
14
05GND-BR
14
86
87 85
((~SM)+(AH))(P_22)
OUT PWR ENABLE (OE)
C33STR-BK
74HC08
((~SM)+(AH))(P_7)
((~SM)+(AH))(OE)
STARTER
TO
uP
P_6R1
P_22R
P_22
B1ENG-RD
P_7R
R33STR-BK
30
(TM)(FE)
P16-04
STARTER
B1ENG-RD RELAY
U
W/BAT CBL
30A
STARTER
INTEGRAL
F20 STARTER
POWER
RELAY
20A P35RPM-BK/RD
W/BAT CBL
CR1
INTEGRAL
1
J16 BLACK 4 PIN
20A
J15
CB
Vbb BTS621
Vbb BTS621
01GND-BR
ST OUT 2
IN1 OUT 1
IN1 OUT 1
ST OUT 2
POWER HARN
POWER
ENGINE BLOCK
BTS650
BTS650
BTS650
F22
OUT
OUT
P_1
OUT
P_6R2
HARN
HARN
ENG
-
GND
GND
GND
60A
B1
Vbb
Vbb
IN2
IN2
Vbb
AUX MAIN
IN
IN
IS
IS
IN
IS
F7
B1BAT-RD
20A
01GND-BR
B1BAT-RD START/CONT
B1BAT-RD B1BAT-RD ROL SYS
-
+
-
U32
B2
BATTERY
B2BAT-RD
SEPARATE
4 GA WIRE
S139TRF-WH/RD
S137PLL-RD/WH
74HC08 10
T
HARNESS
8
ENGINE
SEC BOOM EXT/RET FC RECOVERY SIGNAL
((~SM)+(AH))(BM STOWED)
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
SEC BOOM RET RECOVERY SIGNAL
J215
AUXILIARY HYD RECOVERY SIGNAL
2
Vbb BTS621
LOWER LS
ST OUT 2
IN1 OUT 1
HARNESS
TO HORN BUTTON
GND
OUT PWR ENABLE
(P15)+(ECU POWER)
IN2
P_30
P_22
P_9B
P23PCON-BK
S56PRV-RD
B3BAT/14-RD
GND-BR
BOOM STOWED
S
5 VOLT
P_6R1
P_11
P_9A
PCON POWER
P_6R2
P_10
P_7
P_7R
TCON MODE
LSB4EO
NO
13
21
BK/WH
4321
BK
J20 1 2
14
C71PBE-BL/BK
RED
C71PBE-BL/BK
BLU
BK BR
NO
13
21
BK/WH
432 1
MULTI FUNCTION VLV RECOVERY SIGNAL
NC
LSB3RO
SEC BOOM EXT/RET FC RECOVERY SIGNAL
10
BK
BOOM EXT/RET FC RECOVERY SIGNAL
C64LS-OR/BK
BOOM UP/DWN FC RECOVERY SIGNAL
14
BLU
J211
8 J208 9
SEC BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
WHT NO
13
21
BK/WH
NC
BK LSB1DO
ALL LIMIT SWITCHES SHOWN IN "STOWED" STATE
22
14
OUT PWR ENABLE
PWR TO TCON ESTOP
NO
13
21
P_22
P_9B
C64LS-OR/BK RD
4 32 1
LST2O
NC
C143DEL-BL/RD C143DEL-BL/RD
P_30
BR
R
14
ORN
YEL
WH J125
ORN NO
13
21
C64LS-OR/BK RD LST1O
21
NC
14
WH J124
LST1S
ORN NO
13
21
NC
S13DE-BL/RD BR
BK SAFETY
22
14
RED
WH J126
VALVE_RETURN_8 P12-35 VLVRET8-BR
J208
6 J199
OPER
BOOM STOWED P12-31 SNSRGND-BR SNSRGND-BR OR
Q
OR
5
SAFETY
TO
uP
4567
21
11
NC
NC
C64LS-OR/BK OR RD/WH
RED
22
12
SPARE DI P12-22
P109ANG-GR/WH P109ANG-GR/WH BL
LSB2RS P12-21 RSB1A0
SNSRGND-BR SNSRGND-BR GR
TO
uP
SNSRGND-BR BK RSB1AS
TO
uP
TO PLD C68PBD-BL
PRI BOOM DOWN STATUS DRV ENBL R - LST1O P12-15 C144DER-BL/WH
TO PLD
LOW FUEL - FST1S P12-14 C65LOFL-BL/WH
P
TO
uP
OUT PWR ENABLE
J222B
P_18 P12-12
P_14 P12-11
2 1
2 1
BK/WH
P_10 P_10 P12-08 S59CNBK-GR/WH P63LS-OR/RD BL/BK
J208
J222A
U31
SJ2-OR/BK
AUXILIARY HYD RECOVERY SIGNAL
SJ2-OR/BK
P_6R1
BOOM RET RECOVERY SIGNAL
P54ENG-BK/WH
LOCKOUT VALVE #1 SIGNAL
TO HORN BUTTON
BK
BK
BR
BR
BK/WH
BL
BL
BK/WH
22 21 22 21
C60AXEX-GR/WH P122-04 LSFA1ES & LSRA1ES (AXLES EXTENDED)
NC NC
P53LS-WH/BK C141PBS-RD P122-03 RSB1AS (BOOM ANGLE) 14 13 14 13
PUR
GRN
NO NO
B3BAT/14-RD C166PRS-OR P122-02 LTB1LS (BOOM LENGTH)
P21DCON-WH P21DCON-WH P122-01 SCON PWR
LSB5S
CABLE
TENSION #1
J192A
LSB6S
CABLE
TENSION #2
J192B
C60AXEX-GR/WH
P53LS-WH/BK
C61AXRT-GR
C145CAL-RD/WH
S132LDS-BL/WH
P57PBD-RD/WH
J121-GRAY 12
S56PRV-RD
D81CAN(-)-GR
P117FB-RD
D82CAN(+)-YL
P63LS-OR/RD
BM U/D FC O
C61AXRT-GR
PIN SCON
ECU POWER
GND-BR
PCON POWER
ECU POWER
OPER. REC.
TCON MODE
P_22
P_15
P_6R1
P_7
P_7R
P_11
TO WORKLIGHT OPTION
C60AXEX-GR/WH
P57PBD-RD/WH
CLOSED CLOSED
CLOSED CLOSED
CLOSED CLOSED
CLOSED
CLOSED
CLOSED
SERVICE RECOVERY
GNDDCON-BR
P21DCON-WH
M
P53LS-WH/BK
P63LS-OR/RD
C61AXRT-GR
GROUND/PLATFORM KEYSWITCH TRUTH-TABLE
S56PRV-RD
KEYSWITCH POSITION
RECOVERY KEYSWITCH TRUTH-TABLE
GROUND PLATFORM
CLOSED CLOSED
CLOSED CLOSED
CLOSED CLOSED
RECOVERY
CLOSED CLOSED OPEN
CLOSED CLOSED OPEN
KEY SWITCH
KEYSWITCH POSITION
2
E 1
OPEN
OPEN
OPEN
1
3
NC
J155/6C
W
Z
1
X 3 3
2
NC
4
NC
NO
V
Y
D
4
U
2
B 1
NO
NC
2
1
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
RUN
NC
NC
C
D81CAN(-)-GR
4
P117FB-RD
D82CAN(+)-YL
NC
NO
PANEL
01GND-BR
FLASHING BEACON
NC
OPEN
OPEN
OPEN
OFF
A
CONTACT
PANEL
J152B
W
U
V
X
Y
Z
CONTACT
85
30
C
D
A
B
RELAY
CR41
BC BC
86
TO FLASHING BEACONS 87a
87
GND-OR/WH
P20BAT-OR
BB BB
R117FB-RD
ESTOP
BA BA
C145CAL-RD/WH
S132LDS-BL/WH
C117FB-RD
GNDDCON-BR
NC 1
2
AC
AA
AB
GND-BR
PANEL
BOOM LOWER LS
CABLE HARNESS
J11 BLACK 23 PIN
BOOM HARNESS
BL/BK
CALIBRATION
CALIBRATE)
SWITCH TO
J142
1 SWITCH
(CLOSE
G/P MODE-WH/BK
1
2
J17
WH/BK
AC
AA
AB
1
1
C
D
E
PLAT
PLAT
PLAT
2
PLAT
OFF
OFF
OFF
OFF
2
2
GROUND
OFF
GRND
GROUND
GRND
BA
GRND
J152A
AC
AA
AB
V
Z
C117FB-RD
RECOVERY
SERV BYPASS
RUN
U30
P_7 PLAT-GR/WH P_7 P11-06 S56PRV-RD
RS232_GND
DB9 CONNECTOR
RS232_RXD
RS232_TXD
ALARM PWR-BL
H5
J147B-1
2
3
5
8PIN
J223
GNDDCON-BR
ENGINE CAN
TCON J147B-1
120Ω GNDPCON-BR
GROUND P223-01 ALM-GND-BR BUS TO
J
CAN GATEWAY
TELEMATICS
J151-C
J151-A
J151-B
C
B
A
J148A-1
J147A-1
& TCON LCD
J150-1
J150-2
J149-1
J149-2
J150-3
C60AXEX-GR/WH
J228-2
P57PBD-RD/WH
D82CAN+ -YL
GNDDCON-BR
P53LS-WH/BK
MACHINE CAN HIGH P223-05
P63LS-OR/RD
P21DCON-WH
D81CAN(-)-GR
D82CAN(+)-YL
J228-3 J155/6A
C61AXRT-GR
S132LDS-BL/WH
C47OUT-WH/BK
P56PRV-RD/WH
S56PRV-RD
GNDPCON-BR
D81CAN(-)-GR
J228-4
GND-OR/WH
C46HRN-WH
S56PRV-RD
P20BAT-OR
GND-OR/WH
OPT GBOX
DIGITAL IN 2 P223-08 2
HARN
#1
TS5
J34-LIMIT SW HARN
J35-LIMIT SW HARN
ENG SPEED-BK/RD
J1 20PIN
J33-BOOM HARN
NOT USED 19 NOT USED P21-09
AXLE EXT-GR/WH NOT USED P21-08
EXT/RET
SPARE-WH 18
AXLE
TS23
U21
U22
ST OUT 2
IN1 OUT 1
BTS650
OUT
NOT USED
P_6
GND
NOT USED 15
Vbb
IN
IS
ENABLE
6
2
3
5
TS15
4
C
1
2
A
B
DRV SPEED-RD/WH 13 NOT USED P21-03
DRV ENBL-BL/WH
6
2
3
5
4
PCON PWR P21-02 P52PCON-WH P52PCON-WH
C
AXLE EXT-GR/WH 12
A
B
1
2
ENG SPEED-BK/RD 11 PCON GND P21-01 GNDPCON-BR GNDPCON-BR
ENGINE
J24 10PIN
GR
START
YL
WH
OR
GR
DCON PWR RD
BR
10
BK
GND1-BR
TS2
BL
YL
AXLE RET-GR 9
J21 23 PIN
HARNESS
H
ENG START-BK
P_9A+P_10
DCON GND
SLIP RING
C60AXEX
CAN HIGH
CAN LOW
NOT USED 8
BLACK
RS232_GND
BOOM
RS232_RXD
RS232_TXD
P_6R1
P_10
P_12
P_7R
DRV ENBL-BL/WH 7
ASSIST
START
TS6
6
CKT #
ENG START-BK
START ASST-BK/WH START ASST-BK/WH 5
88
88
88
88
88
88
88
88
88
88
88
AUX PUMP-RD 4
74HC08
74HC08
GENERATOR AUXILIARY
GEN ON/OFF-GR/WH 3
PUMP
TS1
2
3
5
WH
GR
RD
OR
BR
BK
BL
YL
HORN RET-GR
ON CIRCUIT BOARD
GR
YL
2
1
5
AUX PUMP-RD
4
1
S132LDS-BL/WH
HORN PWR-RD
6
2
3
5
4
1
2
B
A
C
ON/OFF
6
2
3
5
4
TS17
B
J36-DRIVE CHASSIS HARN A
1
2
SLP_MODE
GEN ON/OFF-GR/WH
P_22
J157-1
P_6
HORN RTN-GR
P_7
J162
SERVICE
HORN
WH
BN5
C88PJTS-RD/WH
6
G
TILT SENSOR
POWER FET POWER FET
HORN PWR-RD C88PTS-RD/BK
BELLCRANK
5
ASSEMBLY
- -
P89RET-BR + 10 DEG 10 DEG
MANIFOLD
+
4
J22 35 PIN
HARNESS
SAFETY CUTOUT
P109JBS-GR/WH
3
0-20 DEG Y AXIS
WHITE
-
PCON
S21
C148JBS-BL/WH
JIB
DRIVE & STEERING
2
+
P110JBS-BK PLAT TILT SNSR
6
JOYSTICK (JC3)
1
GND1-BR
5 C158STC-BL/RD NOT USED P22-35 VLVRET2-BR
4 C160JPL-WH/RD VALVE_RETURN_2 P22-34 VLVRET2-BR
2
3 C159STC-BL/WH V238JLV-WH/RD Y102 JIB BELLCRANK LOOP VLV (J235)
JIB ROTATED CW P22-33 C214JRL-RD/WH
2 P
1
2
2 P162JPW1-OR V147JBD-BL/BK Y86 JIB BELLCRANK DOWN (J136)
JIB TILT SNSR IN P22-32 C148JBS-BL/WH
P
1
1 JSGND1-BR V146JBU-BL Y85 JIB BELLCRANK UP (J135)
JIB TILT SNSR GND P22-31 P110JBS-BK
J25
2 P
1
2
JIB TILT SNSR PWR P22-30 P109JBS-GR/WH V193JRR-WH/BK Y90 JIB ROTATE CCW (J203)
P
JIB UP/DOWN AND
1
JSGND1-BR 16 JOYSTICK_GND_1 JIB BELLCRANK LEVEL DOWN P22-29 V147JBD-BL/BK V192JRL-WH Y89 JIB ROTATE CW (J202)
6 GND2-BR
JOYSTICK (JC8)
CCW SAFETY
JIB ROTATED
JIB ROTATE
NO
V193JRR-WH/BK
13
21
4 C156JUD-GR/WH BK/WH
43 2 1
NC
P162JPW4-OR 13 JOYSTICK_PWR_4 PLAT LEVEL LOOP P22-26 BK
LSJ2RS
3 C213JRS-RD/BK BL
14
TT ROTATE
22
C165TRS-WH/RD 12
GRN
SPARE OM P22-25 C214JRL-RD/WH
BLU
BR
J55
2 P162JPW2-OR
J205
C164PLS-RD/WH 11 PRIMARY UP/DOWN JIB ROTATE CW P22-24 V192JRL-WH
PLATFORM
ASSEMBLY
1 JSGND2-BR
6
F
CCW (RIGHT)
JIB ROTATED
SENSOR
J218 SAFE PL/JB TILT PWR P22-23 P87PTS-RD POWER FET
NO
13
21
BK/WH
5
EXTEND/RETRACT
9
-
SPARE AI SAFE PL/JB TILT GND P22-22 10 DEG
-
10 DEG
NC
U20 P89RET-BR + BK
LSJ3RO
4 +
TILT
PRIMARY BOOM
BL
JOYSTICK (JC2)
14
22
S6
PL TILT SNSR PWR P22-21
21
GRN
P85PTS-GR
RED
BR
3
-
STEER - DUAL AXIS
J206
5 C159STC-BL/WH 7 PL TILT SNSR IN P22-20 C84TAY-GR/BK + 0-20 DEG Y AXIS
2
4 C163PES-BL/WH C158STC-BL/RD 6 STEER - ROCKER PL TILT SNSR GND P22-19 P85RET-BR PLAT TILT SNSR
1
P_7R
P_22
5
P_6
FOOTSW (FS1)
2 P162JPW3-OR P162JPW3-OR 4 JOYSTICK_PWR_3
2
FOOT SW RTN P22-17 C56FTS-RD C56FTS-RD
C60AXEX-GR/WH
1 JSGND3-BR P162JPW2-OR 3 JOYSTICK_PWR_2 LIMIT SWITCH PWR P22-16 C64LS-OR/BK C64LS-OR/BK
P57PBD-RD/WH
D81CAN(-)-GR
D82CAN(+)-YL
GNDDCON-BR
P21DCON-WH
J26
P53LS-WH/BK
P63LS-OR/RD
C61AXRT-GR
JSGND3-BR 2 JOYSTICK_GND_3
OVERLOAD
SAFE PL/JB TILT OUT P22-15 C88PJTS-RD/WH
S56PRV-RD
1
RD
LIMIT SW
J84
JSGND2-BR 1 JOYSTICK_GND_2 LOAD SNSR PWR P22-14 BK BK BK
LSP1LS
6
NO
GND4-BR
AND TURNTABLE
PRIMARY BOOM
J29
JOYSTICK (JC7)
NC
5
WH
4 C164PLS-RD/WH LOAD SNSR GND P22-12 GR/YL
UP/DOWN
3 C165TRS-WH/RD
PROX GND P22-10
2 P162JPW4-OR
P
1
2 P 2
1 JSGND4-BR JIB BELLCRANK LOOP P22-09 V238JLV-WH/RD Y101 PLAT LEVEL LOOP VLV (J236) P57PBD-RD/WH
2
J127 PLAT LEVEL DOWN P22-08 V15PLD-OR/BK Y19 PLAT LEVEL DOWN (J81) P63LS-OR/RD
1 P
1
PLAT LEVEL UP P22-07 V14PLU-OR Y20 PLAT LEVEL UP (J80)
C60AXEX-GR/WH
E
2 P
2
JIB DOWN P22-06 V44JD-GR/BK Y73 JIB DOWN (J79)
P
1
JIB UP P22-05 V43JU-GR Y72 JIB UP(J78)
13
23
C60AXEX-GR/WH RD
NO
NO
4 3 2 1
LSRA1ES
2
PLAT ROT CW P22-04 V17PRL-GR Y70 PLAT ROTATE CW (J76) J2-GR/BK BR
P63LS-OR/RD BK REAR AXLE SAFETY
24
14
1
2
ESTOP PWR-RD/BK 20 PWR-PCON ESTOP PLAT ROT CCW P22-03 V18PRR-GR/BK Y71 PLAT ROTATE CCW (J77) J1-OR/BK WH SW
ALARM(+)-RD/BK 19 ALARM SPARE OM P22-02 J138
PLAT ROT CW-GR 18 PLAT ROT CW VALVE_RETURN_1 P22-01 VLVRET1-BR
ESTOP PWR-RD
PLAT ROT CCW-GR/BK 17 PLAT ROT CCW
13