Service and Repair Manual

Serial Number Range

SX™-180
from SX18014-101
to SX18016-599
This manual includes:
Repair procedures
from SX180H-600 Fault Codes
to SX180H-744 Electrical and
Hydraulic Schematics

For detailed maintenance

procedures, refer to the
appropriate Maintenance
Manual for your machine.

Part No. 1268497GT

Rev B
December 2019
Service and Repair Manual December 2019

Introduction
Intr oducti on Intr oducti on

Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
procedure. Therefore, product specifications are subject to
change without notice.
This manual provides troubleshooting and repair
procedures for qualified service professionals. Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
Basic mechanical, hydraulic and electrical skills are communications will be carefully considered for
required to perform most procedures. However, future printings of this and all other manuals.
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an Contact Us:
authorized Genie dealer service center.
Internet: www.genielift.com
E-mail: awp.techpub@terex.com

Compliance
Find a Manual for this Model
Machine Classification Go to http://www.genielift.com
Group B/Type 3 as defined by ISO 16368 Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Machine Design Life Manuals, Parts Manuals and Operator's Manuals.
Unrestricted with proper operation, inspection and
scheduled maintenance.

Copyright © 2015 by Terex Corporation

1268497GT Rev B, December 2019

First Edition, Second Printing

Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.

"SX" is a trademark of Terex South Dakota, Inc.

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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 Hydraulic 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

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Introduction

Serial Number Legend

To August 31, 2016

1 Model 1 Sequence number

2 Model year 2 Serial number (stamped on chassis)
3 Facility code 3 Serial label (located under cover)
From September 1, 2016

1 Model 1 Serial number (stamped on chassis)

2 Facility code 2 Serial label (located under cover)
3 Sequence number

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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.

Do Not Perform Maintenance

Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.

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Safety Rules

Personal Safety Workplace Safety

Any person working on or around a machine must Any person working on or around a machine must
be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal
safety and the continued safe operation of the safety and the continued safe operation of the
machine should be your top priority. machine should be your top priority.

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.

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Table of Contents

Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Serial Number Legend .......................................................................................... iv

Section 1 Safety Rules .......................................................................................................... v

General Safety Rules ............................................................................................. v

Section 2 Specifications ....................................................................................................... 1

Machine Specifications ........................................................................................... 1
Performance Specifications .................................................................................... 2
Hydraulic Oil Specifications .................................................................................... 3
Hydraulic Component Specifications...................................................................... 6
Manifold Component Specifications ....................................................................... 7
Deutz TD2011L04i Engine Specifications .............................................................. 8
Deutz TD 2.9 Engine Specifications ....................................................................... 9
Perkins 1104D-44T Engine Specifications ........................................................... 10
Perkins 854F-34T Engine Specifications ............................................................. 12
Machine Torque Specifications ............................................................................ 13
Hydraulic Hose and Fitting Torque Specifications ............................................... 14
Torque Procedure ................................................................................................ 15

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Table of Contents

Section 3 Repair Procedures ..............................................................................................17

Introduction ...........................................................................................................17

Platform Controls ...............................................................................................19

1-1 Platform Circuit Board ....................................................................................19
How to Remove the LED Circuit Board ...........................................................20
1-2 Joysticks .........................................................................................................21
How to Reset a Proportional Valve Coil Default..............................................24
How to Set the Function Thresholds and Default Functions Speeds..............25
How to Adjust the Function Speeds ................................................................27
How to Adjust the Function Ramp Rate Setting ..............................................27

Platform Components ........................................................................................28

2-1 Platform ..........................................................................................................28
2-2 Platform Leveling Cylinder .............................................................................29
2-3 Platform Rotator .............................................................................................30
How to Bleed the Platform Rotator ..................................................................31
2-4 Platform Level Sensor ....................................................................................32
2-5 Platform Overload System (if equipped) ........................................................33
2-6 Platform Overload Recovery Message ..........................................................34

Jib Boom Components ......................................................................................36

3-1 Jib Boom.........................................................................................................37
3-2 Jib Boom Lift Cylinder ....................................................................................38
3-3 How to Remove the Jib Boom Bellcrank ........................................................39
3-4 Jib Boom Bellcrank Angle Sensor ..................................................................40

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Boom Components ............................................................................................ 42

4-1 Cable Track .................................................................................................... 43
4-2 Primary Boom................................................................................................. 45
4-3 Primary Boom Lift Cylinder ............................................................................ 52
4-4 Extension Cylinder ......................................................................................... 54
4-5 Boom Extend and Retract Cables .................................................................. 58
How to Replace the Boom Extend/Retract Cables ......................................... 62
4-6 Boom Internal Cable Track ............................................................................ 65
4-7 Primary Boom Angle Sensor .......................................................................... 67
4-8 Boom Length Sensor ..................................................................................... 70

Engines ................................................................................................................ 72
5-1 RPM Adjustment ............................................................................................ 72
5-2 Flex Plate ....................................................................................................... 72
How to Install the Flex Plate............................................................................ 73

Ground Controls ................................................................................................. 74

6-1 Bypass/Recovery Key Switch ........................................................................ 74
6-2 Circuit Boards ................................................................................................. 76
6-3 Membrane Decal ............................................................................................ 78
6-4 Full Machine Calibration................................................................................. 79

Display Module ................................................................................................... 80

Hydraulic Pumps ................................................................................................ 87

7-1 Function Pump ............................................................................................... 87
How to Prime the Function Pump ................................................................... 88
How to Adjust the Function Pump Standby Pressure ..................................... 88
How to Adjust the Function Pump Pressure Compensator ............................ 90
7-2 Drive Pump..................................................................................................... 91
How to Prime the Drive Pump ......................................................................... 93

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Table of Contents

Manifolds .............................................................................................................94
8-1 Function Manifold ...........................................................................................94
8-2 Valve Adjustments - Function Manifold ........................................................100
8-3 Platform Level and Rotation Manifold (to SX180H-612) ..............................102
8-3A Platform Level and Rotation Manifold (from SX180H-613) .......................103
8-4 Jib Boom Manifold (to SX180H-612) ............................................................104
8-4A Jib Boom Manifold (from SX180H-613) .....................................................105
8-5 Function Enable Manifold .............................................................................106
8-6 Steer and Axle Manifold Components, to SX180H-604 ...............................108
8-6A Steer and Axle Manifold Components, from SX180H-605 ........................112
8-7 Valve Adjustments - Steer and Axle Manifold ..............................................116
8-8 Traction Manifold Components ....................................................................118
8-9 Valve Adjustments - Traction Manifold .........................................................122
8-10 Generator Manifold Component .................................................................123
8-11 Valve Coils .................................................................................................124

Turntable Rotation Components.....................................................................126

9-1 Turntable Rotation Assembly .......................................................................126
How to Adjust the Turntable Rotation Gear Backlash ...................................127
9-2 Turntable Level Sensor ................................................................................128

Axle Components .............................................................................................131

10-1 Steer Sensors .............................................................................................131
How to Calibrate a Replacement Steer Sensor ............................................133
How to Calibrate All Steer Sensors ...............................................................133
10-2 Steer Cylinders ...........................................................................................136
10-3 Axle Extension Cylinders............................................................................136
10-4 Axle Angle Sensors ....................................................................................137

Generators.........................................................................................................140
11-1 Welder Generator .......................................................................................140

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Table of Contents

Section 4 Fault Codes ....................................................................................................... 141

Introduction ......................................................................................................... 141

Control System Fault Codes ........................................................................... 142

Fault Matrix ......................................................................................................... 161
Fault Code Source ............................................................................................. 162
Deutz TD 2.9 L4 Engine Fault Codes ................................................................ 165
Perkins 854F-34T Engine Fault Code ................................................................ 180

Section 5 Schematics........................................................................................................ 189

Introduction ......................................................................................................... 189
Wire Circuit Legend ............................................................................................ 190
Wire Color Legend ............................................................................................. 194
Limit Switches and Angle Sensors ..................................................................... 199
Circuit Connector Legend ................................................................................... 203
Connector Pin Legend ........................................................................................ 206
Engine Relay and Fuse Panel Legend - Deutz TD2011L04i and Perkins
1104D-44T Models ..................................................................................... 220
Engine Relay and Fuse Panel Legend - Deutz TD 2.9 L4 Models .................... 221
Engine Relay and Fuse Panel Legend - Perkins 854F-34T Models .................. 222
Electrical Symbols Legend ................................................................................. 223
Hydraulic Symbols Legend ................................................................................. 224

Electrical Schematics – Control Circuits ....................................................... 225

Control Circuits - Horn ........................................................................................ 226
Control Circuits - Power ..................................................................................... 227
Control Circuits - Can Bus .................................................................................. 230
Control Circuits - Deutz TD2011L04i Engine ..................................................... 231
Control Circuits - Deutz TD 2.9 L4Engine .......................................................... 234
Control Circuits - Perkins 1104D-44T Engine .................................................... 235
Control Circuits - Perkins 854F-34T Engine ....................................................... 238

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Table of Contents

Control Circuits - Axle Extend/Retract ................................................................239

Control Circuits - Steering ..................................................................................242
Control Circuits - Propel .....................................................................................243
Control Circuits - Turntable Rotate .....................................................................246
Control Circuits - Boom Up/Down.......................................................................247
Control Circuits - Boom Extend/Retract .............................................................250
Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate ........................251
Control Circuits - Platform Level and Jib Bellcrank Level...................................254
Control Circuits - Platform Load Sense ..............................................................255
Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights ............258
Control Circuits - Recovery PLD.........................................................................259
Control Circuits - Telematics ..............................................................................262
Generator Receptacle Wiring- ANSI/CSA ..........................................................263
Generator Receptacle Wiring- CE ......................................................................266
Perkins 1104D-44T Engine Electrical Schematic ...............................................267
Perkins 854F-34T Engine Electrical Schematic .................................................270
Perkins 854F-34T Engine Harness ....................................................................271
Deutz TD 2.9 L4 Engine Electrical Schematic ....................................................274
Deutz TD 2.9 L4 Engine Harness .......................................................................275

Hydraulic Schematics ......................................................................................277

Hydraulic Schematic, to SX180H-604 ................................................................278
Hydraulic Schematic, from SX180H-605 to SX180H-612 ..................................279
Hydraulic Schematic, from SX180H-613 ............................................................281
Electrical Schematic, to SX180H-318 ................................................................283
Electrical Schematic, from SX180H-319 to SX180H-612 ..................................284
Electrical Schematic, from SX180H-613 ............................................................285

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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

For operational specifications, refer to the

Operator's Manual.

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Specifications

Performance Specifications Boom function speeds, maximum from platform

controls
Drive speed, maximum Jib boom up/down 58 - 62 sec
Stowed position, high speed 2.3 mph Jib boom rotate CW/CCW 60° 28 - 32 sec
3.7 km/h
36ft / 8.9 sec Primary boom extend/retract 30 - 33 sec /
11 m / 8.9 sec 0 - 100 in / 254 cm
Raised or extended 0.4 mph Primary boom up/down (stowed) 80 - 88 sec / 82°
0.64 km/h Primary boom up/down 100 - 110 sec / 82°
36 ft / 62-68 sec (stringpot = 76 in / 193 cm)
11 m / 62-68 sec
Primary boom up/down 45 - 50 sec / 20°
Boom above 125 ft / 38.1 m 0.1 mph (stringpot = 158 in / 401 cm)
0.16 km/h
18 ft / 124-132 sec Primary boom up/down 71 - 80 sec / 20°
5.5 m / 124 - 132 sec (stringpot = 238 in / 605 cm)
Primary boom up/down 26 - 31 sec / 5°
Braking distance, maximum
(stringpot = 370 in / 940 cm)
High range on paved surface 6 ft / 2 m
Primary boom up/down 34 - 39 sec / 5°
Gradeability Refer to Operator's Manual (stringpot = 596 in / 1514 cm)
Turntable rotate, drive enable to 38 - 42 sec
drive enable (80°) fully stowed
Turntable rotate, drive enable to 63 - 70 sec
drive enable (80°)
stringpot = 36 in / 91.4 cm
Turntable rotate, drive enable to 109 - 120 sec
drive enable (80°)
stringpot = 76 in / 193 cm
(above 75 ft / 22.8 m)
Turntable rotate, drive enable to 155 - 175 sec
drive enable (80°)
stringpot = 258 in / 655 cm (above
125 ft / 38.1 m)
For operational specifications, refer to the
Operator's Manual.

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Specifications

Hydraulic Oil Specifications Do not top off with incompatible

hydraulic fluids. Hydraulic fluids
Hydraulic Fluid Specifications may be incompatible due to the
Genie specifications require hydraulic oils which are differences in base additive
designed to give maximum protection to hydraulic chemistry. When incompatible
systems, have the ability to perform over a wide fluids are mixed, insoluble
temperature range, and the viscosity index should materials may form and deposit
exceed 140. They should provide excellent antiwear, in the hydraulic system,
oxidation prevention, corrosion inhibition, seal plugging hydraulic lines, filters,
conditioning, and foam and aeration suppression control valves and may result in
properties. component damage.
Cleanliness level, ISO 15/13
minimum Note: Do not operate the machine when the
Water content, 250 ppm ambient air temperature is consistently above
maximum 120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic oil type Chevron Rando HD Premium Hydraulic Fluid Temperature
Viscosity grade 32 Range
Viscosity index 200
Optional Hydraulic Fluids
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable Petro Canada Environ MV 46
Fire resistant UCON Hydrolube HP-5046
Note: Genie specifications require additional
equipment and special installation instructions for Ambient air temperature
the approved optional fluids. Consult Genie
Product Support before use. 1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
Optional fluids may not have 3 UCON Hydrolube HP-5046D
the same hydraulic lifespan and 4 Chevron Rando HD premium oil MV
may result in component
damage.

Note: Extended machine operation can cause the

hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

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Specifications

Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

MV Fluid Properties Fluid Properties
ISO Grade 32 ISO Grade 15
Viscosity index 200 Viscosity index 300
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 7.5 cSt @ 200°F / 100°C 5.5
cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C 15.0
cSt @ -40°F / -40°C 510
Brookfield Viscosity
cP @ -4°F / -20°C 1040 Flash point 180°F / 82°C
cP @ -22°F / -30°C 3310
Pour point -81°F / -63°C
Flash point 375°F / 190°C
Maximum continuous operating 124°F / 51°C
Pour point -58°F / -50°C temperature
Maximum continuous operating 171°F / 77°C
temperature Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
Note: A hydraulic oil heating system is are consistently below 0°F / -17°C unless an oil
recommended when the ambient temperature is heating system is used.
consistently below 0°F / -18°C.
Continued use of Chevron
Note: Do not operate the machine when the 5606A hydraulic fluid, or
ambient temperature is below -20°F / -29°C with equivalent, when ambient
Rando HD Premium MV. temperatures are consistently
above 32°F / 0°C may result in
component damage

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Specifications

Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid

Fluid Properties Properties
ISO Grade 46 ISO Grade 46
Viscosity index 154 Viscosity index 192
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 8.0 cSt @ 149°F / 65°C 22
cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C 46
cSt @ 0°F / -18°C 1300
Flash point 482°F / 250°C
Flash point None
Pour point -49°F / -45°C
Maximum continuous operating 180°F / 82°C Pour point -81°F / -63°C
temperature Maximum continuous operating 189°F / 87°C
temperature

Shell Tellus S4 VX Fluid

Properties
ISO Grade 32
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C 9
cSt @ 104°F / 40°C 33.8
Brookfield Viscosity
cSt @ -4°F / -20°C 481
cSt @ -13°F / -25°C 702.4
cSt @ -40°F / -40°C 2624
Flash point >100
Pour point -76°F / -60°C
Maximum continuous operating 103°F / 75°C
temperature

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Specifications

Hydraulic Component Function Pump - End Pump

Specifications Type variable

displacement
Drive Pump piston pump

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 P TEST 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

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Specifications

Brakes Manifold Component

Brake relief pressure 160 psi
11 bar
Specifications
Drive Motors Plug torque
Displacement per revolution 1.19 cu in SAE No. 2 36 in-lbs / 4 Nm
high speed: 19,5 cc SAE No. 4 10 ft-lbs / 13 Nm
Displacement per revolution 2.7 cu in SAE No. 6 14 ft-lbs / 19 Nm
low speed 45 cc
SAE No. 8 38 ft-lbs / 51 Nm
Hydraulic Filters
SAE No. 10 41 ft-lbs / 55 Nm
High pressure filter: Beta 5 ≥1000
SAE No. 12 56 ft-lbs / 76 Nm
High pressure filter bypass pressure 102 psi
7 bar
Medium pressure filter Beta 3 ≥200
Medium pressure filter bypass 51 psi
pressure 3,5 bar
Hydraulic tank return filter 10 micron with
25 psi / 1,7 bar
bypass
Drive motor case drain return filter Beta 10 ≥2

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Specifications

Deutz TD2011L04i Engine Oil temperature switch

Installation torque 8 - 18 ft-lbs
Displacement 220.9 cu. in 11 - 24 Nm
3.62 liters
Temperature switch point 275°F
Number of cylinders 4 135°C
Bore and Stroke 3.78 x 4.92 inches Oil Pressure switch
96 x 125 mm
Installation torque 8 - 18 ft-lbs
Horsepower net intermittent @ 74 hp 11 - 24 Nm
2400 rpm 55 kW
Pressure switch point 22 psi
Induction system turbocharged 1.5 bar
Firing order 1-3-4-2 Fuel injection system Motorpal
Low idle 1300 rpm Injection pump pressure, maximum 15,000 psi
1034 bar
High idle 2450 rpm
Injector opening pressure 3046 psi
Compression ratio 17.5:1 210 bar
Compression pressure pressure (psi or bar) of the Fuel requirement
lowest cylinder must be at least 75% of the highest
cylinder For fuel requirements, refer to the engine Operator
Manual for your engine.
Governor centrifugal
mechanical Starter motor
Valve Clearance, cold Current draw, normal load 140 - 200A
Intake 0.012 in Cranking speed 250 - 350 rpm
0.3 mm Battery – Auxiliary power units
Exhaust 0.020 in Type 6V DC
0.5 mm
Quantity 2
Lubrication system
Battery capacity, maximum 285 AH
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Reserve capacity @ 25A rate 745 minutes
2.8 to 4.1 bar
Battery – Engine starting and control system
Oil capacity (including filter) 12.8 quarts
12.1 liters Type 12V DC, Group 31
Oil viscosity requirements Quantity 1
-22°F to 86°F / -30°C to 30°C 5W-30 Battery capacity, maximum 1000A
(synthetic) Reserve capacity @ 25A rate 200 Minutes
-4°F to 104°F / -20°C to 40°C 10W-40 Alternator output 80A @ 14V DC
Above 5°F / -15°C 15W-40 Fan belt deflection 3/8 to 1/2 inch
Unit ships with 15W-40. Extreme operating 9 to 12 mm
temperatures may require the use of alternative
engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.

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Specifications

Deutz TD 2.9 Engine Oil temperature switch

Installation torque 8 - 18 ft-lbs
Displacement 177 cu. in 11 - 24 Nm
2.9 liters
Temperature switch point 275°F
Number of cylinders 4 135°C
Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch
92 x 110 mm
Installation torque 8 - 18 ft-lbs
Horsepower net intermittent @ 74.2 hp 11 - 24 Nm
2600 rpm 55 kW
Pressure switch point 22 psi
Induction system turbocharged 1.5 bar
Firing order 1-3-4-2 Fuel injection system Motorpal
Low idle, standby 1000 rpm Injection pump pressure, maximum 15,000 psi
1034 bar
Low idle, function enable 1500 rpm
Injector opening pressure 3046 psi
High idle 2500 rpm 210 bar
Compression ratio 17.4:1 Fuel requirement
Compression pressure pressure (psi or bar) of the For fuel requirements, refer to the engine Operator
lowest cylinder must be at least 75% of the highest Manual for your engine.
cylinder
Starter motor
Governor electronic
Current draw, normal load 140 - 200A
Lubrication system Low ash oil required
Cranking speed 250 - 350 rpm
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar Battery – Engine starting and control system
Oil capacity (including filter) 9.4 quarts Type 12V DC, Group 31
8.9 liters Quantity 1
Oil viscosity requirements Battery capacity, maximum 1000A
-22°F to 86°F / -30°C to 30°C 5W-30 Reserve capacity @ 25A rate 200 Minutes
(synthetic) Alternator output 95A @ 14V DC
-4°F to 104°F / -20°C to 40°C 10W-40
Fan belt deflection 3/8 to 1/2 inch
Above 5°F / -15°C 15W-40 9 to 12 mm
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.

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Specifications

Perkins 1104D-44T Oil Pressure switch

Installation torque 8 - 18 ft-lbs
Displacement 268.5 cu. in 11 - 24 Nm
4.4 liters
Pressure switch point 8 psi
Number of cylinders 4 0.55 bar
Bore and Stroke 4.13 x 5 inches Oil Sensor Settings
105 x 127 mm
0 psi 10 ohms
Horsepower net intermittent @
2200 rpm 68 hp / 50.7 kW 50 psi 120 ohms
74 hp / 55.2 kW Fuel injection system
Induction system turbocharged Transfer pump pressure 10-12 psi /
0.69-0.83 bar
Firing order 1-3-4-2
Injection pressure (4264+116 psi) /
Low idle 1300 rpm
(294+8 bar)
High idle 2450 rpm
Fuel requirement
Compression ratio 18.2:1 For fuel requirements, refer to the engine Operator
Compression pressure pressure (psi or bar) of the Manual for your engine.
lowest cylinder must be at least 75% of the highest Starter motor
cylinder
Current draw, normal load 115A
Governor centrifugal
mechanical Cranking speed 200 - 250 rpm

Valve Clearance, cold Battery – Auxiliary power units

Intake 0.008 in Type 6V DC

0.2 mm Quantity 2
Exhaust 0.018 in Battery capacity, maximum 285 AH
0.45 mm Reserve capacity @ 25A rate 745 minutes
Lubrication system Battery – Engine starting and control system
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Type 12V DC, Group 31
2.8 to 4.1 bar
Quantity 1
Oil capacity (including filter) 10.4 quarts
9.8 liters Battery capacity, maximum 1000A
Reserve capacity @ 25A rate 200 Minutes
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C 5W-20
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 15W-40
Unit ships with 15W-40. Extreme operating
temperatures may require the use of alternative engine
oils. For oil requirements, refer to the Engine Operator
Manual for your engine.

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Specifications

Perkins 1104D-44T cont.

Engine coolant
Capacity 9.5 quarts
(engine only) 9 liters
Coolant temperature switch
Installation torque 8 - 18 ft-lbs
11 - 24 Nm
Temperature switch point 230°F
110°C
Temperature Sensor Settings
215°F 37 ohms
102°C
170°F 78 ohms
82°C
Alternator output 85A @ 12V DC
Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm

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Specifications

Perkins 854F-34T Oil Pressure switch

Installation torque 18.4 ft-lbs
Displacement 207 cu. in 25 Nm
3.4 liters
Pressure switch point 12 psi
Number of cylinders 4 0.82 bar
Bore and Stroke 3.89 x 4.33 inches Oil Sensor Settings
99 x 110 mm
0 psi 10 ohms
Horsepower net intermittent @
2500 rpm 50 psi 120 ohms
74 hp / 55.2 kW
Fuel injection system
Induction system turbocharged Transfer pump pressure 10-12 psi /
Firing order 1-3-4-2 0.69-0.83 bar

Standby speed 1000 rpm Injection pressure 23000 psi /

(1600 bar)
Low idle 1500 rpm
Fuel requirement
High idle 2450 rpm
For fuel requirements, refer to the engine Operator
Compression ratio 17.0:1 Manual for your engine.
Compression pressure pressure (psi or bar) of the Glow plugs
lowest cylinder must be at least 75% of the highest Initial load (0-10 sec) 80A
cylinder
Continuous load (>10 sec) 40A
Governor Electronic
Starter motor
Lubrication system
Current draw, normal load 68A
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
Cranking speed 130 - 200 rpm
2.8 to 4.1 bar
Battery – Auxiliary power units
Minimum oil pressure 12 psi
0.82 bar Type 6V DC
Oil capacity (including filter) 7.7 quarts Quantity 2
7.3 liters Battery capacity, maximum 285 AH
Oil viscosity requirements Reserve capacity @ 25A rate 745 minutes
-22°F to 86°F / -30°C to 30°C 5W-20 Battery – Engine starting and control system
-4°F to 104°F / -20°C to 40°C 10W-40 Type 12V DC, Group 31
Above 5°F / -15°C 15W-40 Quantity 1
Unit ships with 15W-40. Extreme operating Battery capacity, maximum 1000A
temperatures may require the use of alternative engine
Reserve capacity @ 25A rate 200 Minutes
oils. For oil requirements, refer to the Engine Operator
Manual for your engine.

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Specifications

Perkins 854F-34T cont. Machine Torque Specifications

Engine coolant
Platform Rotator
Capacity 16.5 quarts
(50/50 extended life) 15.6 liters 1-8 center bolt, GR 5, dry 615 ft-lbs
834 Nm
Coolant temperature switch
3/8-16 bolts, GR 8, dry 35 ft-lbs*
Installation torque 18.4 ft-lbs *use blue thread locking compound 47,5 Nm*
25 Nm
Jib Boom Rotator
Maximum continuous temperature 226°F
108°C Rotate bearing mounting bolts 200 ft-lbs
271 Nm
Temperature Sensor Settings
Turntable rotate assembly
215°F 37 ohms
102°C Rotate bearing mounting bolts, lubricated 455ft-lbs
(30w motor oil) 617 Nm
170°F 78 ohms
82°C Rotate drive hub mounting bolts, dry 70 ft-lbs
95 Nm
Alternator output 120A @ 12V DC
Backlash plate mounting bolts, lubricated 320 ft-lbs
Fan belt deflection 3/8 to 1/2 inch 434 Nm
9 to 12 mm
Drive motors and hubs
Drive hub mounting bolts, lubricated 205 ft-lbs
288 Nm
Drive motor mounting bolts, dry 165 ft-lbs
224 Nm
Engine vibration isolators
Compressed height >0.375 in
Compressed height <0.625 in

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Specifications

Hydraulic Hose and Fitting SAE O-ring Boss Port

Torque Specifications (tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be -4 14 ft-lbs / 19 Nm
torqued to specification when they are removed -6 23 ft-lbs / 31,2 Nm
and installed or when new hoses or fittings are -8 36 ft-lbs / 54,2 Nm
installed.
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
Seal-Lok™ Fittings -16 125 ft-lbs / 169,5 Nm
(hose end - ORFS)
-20 151 ft-lbs / 204,7 Nm
SAE Dash Size Torque
-24 184 ft-lbs / 249,5 Nm
-4 18 ft-lbs / 25 Nm
-6 30 ft-lbs / 41 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 81 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 150 ft-lbs / 205 Nm
Adjustable Fitting Non-adjustable fitting
-24 230 ft-lbs / 315 Nm
1 jam nut

JIC 37° Fittings

(swivel nut or hose connection)
SAE O-ring Boss Port
SAE Dash Size Thread Size Flats (tube fitting - installed into Steel)
-4 7/16-20 2 SAE Dash Size Torque
-6 9/16-18 1 1/2 -4 ORFS / 37° (Adj) 15 ft-lbs / 20,3 Nm
-8 3/4-16 1 1/2 ORFS (Non-adj) 26 ft-lbs / 35,3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-10 7/8-14 1 1/2
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47,5 Nm
-12 1 1/16-12 1 1/4
37° (Adj / Non-adj) 29 ft-lbs / 39,3 Nm
-16 1 5/16-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81,3 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70,5 Nm
-24 1 7/8-12 1 -10 ORFS (Adj / Non-adj) 100 ft-lbs / 135,6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115,3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271,2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413,5 Nm

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Specifications

Torque Procedure JIC 37° fittings

1 Align the tube flare (hex nut) against the nose
Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
1 Replace the O-ring. The O-ring must be
approximately 30 in-lbs / 3.4 Nm.
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or 2 Using a permanent ink marker, make a
hose end has been tightened beyond finger reference mark on one the flats of the hex nut
tight. and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut
finger tight. Illustration 1

5 Tighten the nut or fitting to the appropriate 1 hex nut

torque. Refer to the appropriate torque chart in 2 reference mark
this section. 3 body hex fitting

6 Operate all machine functions and inspect the

hose, fittings and related components to
confirm there are no leaks.

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Specifications

3 Working clockwise on the body hex fitting,

make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to
determine the correct number of flats, for the
proper tightening position.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.

Illustration 2
1 body hex fitting
2 reference mark
3 second mark

4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.

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Repair Procedures

Machine Configuration:
Section 3 Repair Pr oc edures

 Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Key switch in the off position with the key
Observe and Obey: removed
 Repair procedures shall be completed by a • The red Emergency Stop button in the off
person trained and qualified on the repair of position at both the ground and platform
this machine. controls
 Immediately tag and remove from service a • Wheels chocked
damaged or malfunctioning machine.
• All external AC power supply disconnected
 Repair any machine damage or malfunction from the machine
before operating the machine.
• Boom in the stowed position
• Turntable secured with the turntable rotation
Before Repairs Start: lock
 Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
 Be sure that all necessary tools and parts are
available and ready for use.
 Use only Genie approved replacement parts.
 Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.

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Repair Procedures

About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the appropriate
repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to
re-assemble, perform the disassembly steps in
reverse order.

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.

Indicates a imminently hazardous

situation which, if not avoided, will
result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,
could result in death or serious
injury.

Indicates a potentially hazardous

situation which, if not avoided,
may cause minor or moderate
injury.

Indicates a potentially hazardous

situation which, if not avoided,
may result in property damage.

Indicates that a specific result is expected

after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

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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.

Note: When the platform circuit board is replaced,

the joystick controllers will need to be calibrated.
Refer to Repair Procedure, How to Calibrate a
Joystick.

How to Remove the Circuit Board

1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Locate the cables that connect to the bottom
of the control box. Number each cable and its
location at the control box.
3 Disconnect the cables from the bottom of the
platform control box.
4 Remove the control cable receptacle retaining
fasteners from the bottom of the platform
control box.
5 Remove the platform control box lid retaining
fasteners. Open the control box lid.
6 Locate the circuit board mounted to the inside
of the platform control box.

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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.

4 Tag and carefully disconnect the ribbon cables

from the membrane circuit board.
5 Remove the circuit board mounting fasteners.
6 Carefully remove the LED circuit board from
the platform control box lid. Do not lose the
plastic spacers.
Note: When installing the LED circuit board, be
sure the plastic spacers are installed between the
circuit board and the control box lid.

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Platform Controls

1-2 Drive functions:

Joysticks 1 Turn the key switch to the off position.

2 Press and hold the enter button on the ground
How to Calibrate a Joystick control panel while turning the key switch to
platform controls. Hold the enter button for
The joystick controllers on this machine utilize
approximately 5 seconds.
digital Hall Effect technology for proportional
control. If a joystick controller is disconnected or 3 Press the minus button twice, then press the
replaced, it must be calibrated before that particular enter button twice.
machine function will operate.
4 Use the scroll button to scroll through the
Note: The joystick must be calibrated before the menu until DELETE DRIVE JOYSTICK
threshold, max-out or ramping can be set. DEFAULTS is displayed.

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.

Plus Minus Previous Enter

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Platform Controls

Steer functions: Primary boom extend/retract functions:

1 Turn the key switch to the off position. 1 Turn the key switch to the off position.
2 Press and hold the enter button on the ground 2 Press and hold the enter button on the ground
control panel while turning the key switch to control panel while turning the key switch to
platform controls. Hold the enter button for platform controls. Hold the enter button for
approximately 5 seconds. approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until DELETE STEER JOYSTICK menu until DELETE PRIMARY BOOM
DEFAULTS is displayed. EXTEND/RETRACT JOYSTICK DEFAULTS
is displayed.
5 Press the plus button to select YES, then
press the enter button. 5 Press the plus button to select YES, then
press the enter button.
6 Do not start the engine.
6 Do not start the engine.
7 Locate the drive/steer joystick.
7 Locate the thumb rocker switch on top of the
8 Move the drive/steer joystick or thumb rocker
primary boom/turntable rotate joystick.
switch (if equipped) full stroke in the left
direction and hold for 5 seconds, then return to 8 Move the primary boom extend/retract thumb
the center or neutral position. rocker switch full stroke in the extend direction
and hold for 5 seconds, then return to
9 Move the drive/steer joystick or thumb rocker
thecenter or neutral position.
switch (if equipped) full stroke in the right
direction and hold for 5 seconds, then return to 9 Move the primary boom extend/retract thumb
the center or neutral position. rocker switch full stroke in the retract direction
and hold for 5 seconds, then return to the
Result: The alarm at the ground controls
center or neutral position.
should sound for a successful calibration.
Result: The alarm at the ground controls
should sound for a successful calibration.

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Platform Controls

Primary boom up/down functions: Jib boom up/down functions:

1 Turn the key switch to the off position. 1 Turn the key switch to the off position.
2 Press and hold the enter button on the ground 2 Press and hold the enter button on the ground
control panel while turning the key switch to control panel while turning the key switch to
platform controls. Hold the enter button for platform controls. Hold the enter button for
approximately 5 seconds. approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until DELETE PRIMARY BOOM menu until RESET JIB BOOM UP/DOWN
UP/DOWN JOYSTICK DEFAULTS is JOYSTICK DEFAULTS is displayed.
displayed.
5 Press the plus button to select YES, then
5 Press the plus button to select YES, then press the enter button.
press the enter button.
6 Do not start the engine.
6 Do not start the engine.
7 Locate the jib boom joystick.
7 Locate the primary boom/turntable rotate
8 Move the jib boom joystick full stroke in the up
joystick.
direction and hold for 5 seconds, then return to
8 Move the boom/turntable rotate joystick full the center or neutral position.
stroke in the up direction and hold for
9 Move the jib boom joystick full stroke in the
5 seconds, then return to the center or neutral
down direction and hold for 5 seconds, then
position.
return to the center or neutral position.
9 Move the boom/turntable rotate joystick full
Result: The alarm at the ground controls
stroke in the down direction and hold for
should sound for a successful calibration.
5 seconds, then return to the center or neutral
position.
Result: The alarm at the ground controls
should sound for a successful calibration.

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Platform Controls
How to R es et a Proportional Valve Coil D efault

Turntable rotate functions: How to Reset a Proportional

1 Turn the key switch to the off position. Valve Coil Default
2 Press and hold the enter button on the ground Note: Use the following chart to identify the
control panel while turning the key switch to description of each LCD screen control button used
platform controls. Hold the enter button for in this procedure.
approximately 5 seconds.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through the
menu until DELETE TURNTABLE ROTATE Plus Minus Previous Enter
JOYSTICK DEFAULTS is displayed. Note: This procedure only needs to be performed if
5 Press the plus button to select YES, then a proportional valve has been replaced.
press the enter button.
Note: After the valve coil defaults have been set,
6 Do not start the engine. each machine function threshold and default
function speed must be set. Refer to Repair
7 Locate the primary boom/turntable rotate Procedure, How to Set the Function Thresholds
joystick. and Default Function Speeds.
8 Move the boom/turntable joystick full stroke in
1 Turn the key switch to the off position.
the left direction and hold for 5 seconds, then
return to the center or neutral position. 2 Press and hold the enter button on the ground
9 Move the boom/turntable joystick full stroke in control panel while turning the key switch to
the right direction and hold for 5 seconds, then platform controls. Hold the enter button for
return to the center or neutral position. approximately 5 seconds.

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.

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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.

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Platform Controls

Function speeds: 15 Once the function speeds have been set,

press and hold the engine start button until the
Note: Be sure the machine is in the stowed position engine shuts off. Do not press the red
and the boom is rotated between the circle end Emergency Stop button.
tires.
Note: Approximately 3 seconds after the engine
Note: Perform this procedure with the machine on shuts off, the alarm at the ground controls will
a firm, level surface that is free of obstructions. sound to indicate the settings are being saved in
memory.
12 Start the engine from the platform controls.
13 Select the function that needs the function 16 At the ground controls, turn the key switch to
speeds set. the off position, wait a moment and then turn
the key switch to platform controls.
14 Primary boom extend/retract functions:
Move the joystick full stroke in the extend 17 Check the display at the ground controls to be
direction. When the alarm sounds, move the sure there are no calibration faults.
joystick in the opposite direction full stroke Note: There should be no calibration faults shown
until the alarm sounds again. Return the on the display. If calibration faults exist, repeat this
joystick to center. procedure.
Turntable rotate functions: Move the
joystick full stroke in either the left or right
direction. When the drive enable indicator light
turns on, move the joystick in the opposite
direction full stroke until the alarm sounds.
Return the joystick to center.
Extend the boom approximately 4 ft / 1.2 m,
then again move the joystick full stroke in the
opposite direction until the alarm sounds.
Return the joystick to center.
Raise and extend the boom approximately
85 ft / 26 m, then again move the joystick full
stroke in the opposite direction until the alarm
sounds. Return the joystick to center.

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Platform Controls
How to Adj ust the Functi on Speeds How to Adj ust the Functi on R amp R ate Setti ng

How to Adjust the Function How to Adjust the Function Ramp

Speeds Rate Setting
Note: Perform this procedure with the boom in the The ramp rate setting of a joystick controls the time
stowed position. at which it takes for the joystick to reach maximum
output, when moved out of the neutral position. The
Note: Use the following chart to identify the ramp rate settings of a joystick can be changed to
description of each LCD screen control button used compensate for hydraulic pump wear to maintain
in this procedure. peak performance from the machine.
Note: Perform this procedure with the boom in the
stowed position.
Note: Use the following chart to identify the
description of each LCD screen control button used
Plus Minus Previous Enter
in this procedure.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for Plus Minus Previous Enter
approximately 5 seconds. 1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
3 Press the plus button twice, then press the
controls.
minus button twice.
2 Press and hold the enter button on the ground
4 Press the previous button until the function to
control panel while turning the key switch to
be adjusted is displayed.
platform controls. Hold the enter button for
5 Press the plus button to increase the speed or approximately 5 seconds.
press the minus button to decrease the
3 Press the plus button twice, then press the
speed.
previous button twice.
6 Press the enter button to save the setting in
memory. 4 Press the previous button until the function to
be adjusted is displayed.
7 Press the enter or previous button on the
5 Press the plus button to increase the ramp
LCD screen until EXIT is displayed.
rate or press the minus button to decrease the
8 Press the plus button or minus button to ramp rate.
select YES and then press the enter button.
6 Press the enter button to save the setting in
9 Continue to perform this procedure until the memory.
machine function speed meets specification.
Refer to Specifications, Performance 7 Press the enter or previous button on the
Specifications. LCD screen until EXIT is displayed.
8 Press the plus button or minus button to
select YES and then press the enter button.

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Platform Components

2-1 9 Remove the weld cable from the platform (if

equipped).
Platform
Electrocution/burn hazard.
How to Remove the Platform Contact with electrically charged
circuits could result in death or
1 Separate the foot switch quick disconnect serious injury. Remove all rings,
plug. watches and other jewelry.
2 Support the platform with an appropriate lifting
device. 10 Support the platform mounting weldment, but
do not apply any lifting pressure.
3 Locate the cables that connect to the bottom
of the control box. Number each cable and its 11 Remove the eight mounting bolts from the
location at the platform control box. platform mounting weldment.

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.

8 Remove the power to platform electrical outlet

box from the platform and lay it to the side.

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2-2 4 Remove the pin retaining fasteners from the

barrel-end pivot pin. Use a soft metal drift to
Platform Leveling Cylinder remove the barrel-end pivot pin.
The platform leveling cylinder keeps the platform 5 Support the rod end of the platform level
level through the entire range of boom motion. The cylinder.
platform is maintained level to the turntable. To
accomplish this, the ECM at the ground controls 6 Remove the pin retaining fasteners from the
compares the difference in readings between the platform leveling cylinder rod-end pivot pin.
platform angle sensor and the turntable level Use a soft metal drift to remove the barrel-end
sensor, which then sends a signal to the platform pivot pin.
controls to open or close the appropriate platform 7 Carefully pull the platform leveling cylinder out
level proportional valve on the platform manifold to of the boom to access the hydraulic hoses.
maintain a level platform. The platform leveling
cylinder is equipped with counterbalance valves to 8 Tag, disconnect and plug the hydraulic hoses
prevent movement in the event of a hydraulic line from the platform leveling cylinder. Cap the
failure. fittings on the cylinder.
Bodily injury hazard. Spraying
How to Remove the Platform hydraulic oil can penetrate and
Leveling Cylinder burn skin. Loosen hydraulic
connections very slowly to allow
Note: When removing a hose assembly or fitting, the oil pressure to dissipate
the O-ring (if equipped) on the fitting and/or hose gradually. Do not allow oil to
end must be replaced. All connections must be squirt or spray.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 9 Remove the platform leveling cylinder from the
Specifications. machine.
1 Raise the jib boom slightly and place blocks Crushing hazard. The platform
under the platform. leveling cylinder may fall if not
2 Lower the jib boom until the platform is resting properly supported when
on the blocks just enough to support the removed from the machine.
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
3 Secure the platform leveling cylinder to the jib
boom for support.

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Platform Components

2-3 3 Remove the platform angle sensor retaining

fasteners. Remove the platform angle sensor
Platform Rotator from the platform rotator.
The platform rotator is a hydraulically activated Component damage hazard. The
helical gear assembly used to rotate the platform platform angle sensor is a very
160 degrees. sensitive instrument. It can be
damaged internally if is dropped
How to Remove the Platform or sustains any physical shock,
Rotator even if the damage is not visible.

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.

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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.

Component damage hazard. The

platform angle sensor is a very
sensitive instrument. It can be
damaged internally if is dropped
or sustains any physical shock,
even if the damage is not visible.

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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
Note: Perform this procedure with the machine on sequence: (plus)(enter)(enter)(plus).
a firm, level surface.
9 Press the enter or previous button on the
Note: Perform this procedure with the boom in the LCD screen until SET PLATFORM LEVEL
stowed position. SENSOR TO GRAVITY is displayed.

Note: Use the following chart to identify the 10 Press the plus button to select YES, then
description of each LCD screen control button used press the enter button to accept.
in this procedure. Note: The platform level sensor is calibrated at the
factory for the correct millivolt/degree and will not
need to be adjusted.

11 Press the enter or previous button on the

LCD screen until EXIT is displayed.
Plus Minus Previous Enter 12 Press the plus button or minus button to
1 Secure a digital level to one of the side railings select YES and then press the enter button.
of the platform. 13 Remove the fastener that was temporarily
2 Start the machine and level the platform to installed. Close the control box door and install
gravity. Turn the machine off. the door retaining fasteners.
3 Open the ground control box. Note: When the control box door is closed, the
calibration toggle switch is automatically activated
4 Locate the calibration toggle switch at the top to exit out of calibration mode.
of the ground control box. Activate calibration
mode by moving the toggle switch in the left
direction.
5 Temporarily install a control box door retaining
fastener between the door and the box to
prevent the control box door from moving the
toggle switch while calibrating the machine.

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2-5 Determine the limit switch trigger point:

Platform Overload System (if 4 Gently move the platform up and down by
equipped) hand, so it bounces approximately 1 to
2 inches / 2.5 to 5 cm. Allow the platform to
Proper calibration of the platform overload system settle.
is essential to safe machine operation. Continued Result: The overload indicator light and the
use of an improperly calibrated platform overload alarm is on. Slowly tighten the load spring
system could result in the system failing to sense adjustment nut by turning it clockwise just until
an overloaded platform. The stability of the the overload indicator light and alarm turns off.
machine is compromised and it could tip over.
Note: The platform will need to be moved up and
How to Calibrate the Platform down and allowed to settle in between
adjustments.
Overload System (if equipped)
Note: There may be a 2 second delay before the
Note: Perform this procedure with the machine on overload indicator lights flash and the alarm
a firm, level surface.
sounds.
1 Level the platform.
Result: The overload indicator light and
2 Determine the maximum platform capacity. alarm is off. Slowly loosen the load spring
Refer to the machine serial plate. adjustment nut by turning it counterclockwise
just until the overload indicator light and alarm
3 Using a suitable lifting device, place an
turn on.
appropriate test weight equal to that of the
maximum platform capacity at the center of Note: There may be a 2 second delay before the
the platform floor. overload indicator lights flash and the alarm
sounds.
Note: The platform will need to be moved up and
down and allowed to settle in between
adjustments.

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Platform Components

Confirm the setting: 2-6

5 Start the engine from the platform controls. Platform Overload Recovery
6 Lift the test weight off the platform floor using a Message (software V2.0 and later)
suitable lifting device.
If the ground controls LCD screen displays
7 Place the test weight back onto the center of OVERLOAD RECOVERY, the emergency lowering
the platform floor using a suitable lifting system has been used while the platform was
device. overloaded.
Result: The alarm should be off. The platform
overload indicator light should be off at the How to Clear the Platform
platform controls and there should be no error Overload Recovery Message
message on the LCD display at the ground
controls. Note: This message shall be cleared by a person
trained and qualified on the troubleshooting and
Note: There may be an 2 second delay before the repair of this machine.
overload indicator lights and alarm turn off.
Note: Use the following chart to identify the
8 Add an additional 15 lbs / 6.8 kg test weight to description of each LCD screen control button used
the original test weight to overload the in this procedure.
platform.
Result: The alarm should be sounding. The
platform overload indicator light should be
flashing at the platform controls and platform
overload should be displayed on the LCD
screen at the ground controls. Plus Minus Previous Enter

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.

Result: All platform control functions should

not operate.
10 Turn the key switch to ground controls.
11 Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.

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3 Press the buttons on the ground controls in the

following sequence:
(plus)(minus)(minus)(plus).
4 Press the enter or previous button on the
LCD screen until CLEAR OVERLOAD
RECOVERY is displayed.
5 Press the plus button or the minus button to
select YES. Then press the buttons in the
following sequence:
(plus)(plus)(plus)(minus). and press the
enter button to accept.
Note: The passcode buttons
(plus)(plus)(plus)(minus) must be entered in the
proper sequence before the enter button is
pressed.
6 Press the enter or previous button on the
LCD screen until EXIT is displayed.
7 Press the plus button or minus button to
select YES and then press the enter button.
8 Turn the key switch to the off position.

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Jib Boom Components

1 platform rotator 5 bellcrank

2 jib boom 6 jib boom lift cylinder
3 jib rotator 7 platform leveling cylinder
4 bellcrank leveling cylinder

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3-1 5 Support the barrel end of the cylinder with a

suitable lifting device.
Jib Boom
6 Remove the pin retaining fastener from the jib
How to Remove the Jib Boom boom lift cylinder barrel-end pivot pin.

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.

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Jib Boom Components

3-2 4 Remove the pin retaining fasteners from the

jib boom lift cylinder rod-end pivot pin. Use a
Jib Boom Lift Cylinder soft metal drift to remove the pin and let the
cylinder hang down.
How to Remove the Jib Boom Lift
5 Attach a lifting strap from an overhead crane
Cylinder to the barrel end of jib boom lift cylinder.
Note: Perform this procedure with the boom in the 6 Remove the pin retaining fasteners from the
stowed position. jib boom lift cylinder barrel-end pivot pin. Use
a soft metal drift to remove the pin.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose 7 Remove the jib boom lift cylinder from the
end must be replaced. All connections must be machine.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque Crushing hazard. The jib boom
Specifications. lift cylinder may become
unbalanced and fall when it is
1 Raise the jib boom slightly and place blocks removed from the machine if it is
under the platform mounting weldment. Lower not properly supported by the
the jib boom until the platform is resting on the overhead crane.
blocks just enough to support the platform.
Note: Do not rest the entire weight of the boom on
the blocks.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

3 Support the rod end of the jib boom lift cylinder

with a suitable lifting device.

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3-3 7 Use a soft metal drift to remove the bellcrank

leveling cylinder rod-end pivot pin.
How to Remove the Jib Boom
Bellcrank Crushing hazard. The bellcrank
leveling cylinder may be
Note: Perform this procedure with the boom in the damaged if it is not properly
stowed position. supported when the rod-end
pivot pin is removed.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose 8 Remove the pin retaining fastener from the jib
end must be replaced. All connections must be boom bellcrank pivot pin.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 9 Use a soft metal drift to remove the jib boom
Specifications. bellcrank pivot pin. Remove the jib boom
bellcrank from the machine.
1 Remove the platform. Refer to Repair
Procedure, How to Remove the Platform. Crushing hazard. The jib boom
bellcrank may become
2 Remove the platform mounting weldment and unbalanced and fall if it is not
the platform rotator. Refer to Repair properly supported when it is
Procedure, How to Remove the Platform removed from the machine.
Rotator.
3 Remove the jib boom. Refer to Repair
Procedure, How to Remove the Jib Boom.
4 Attach a lifting strap from an overhead crane
to the jib boom bellcrank.
5 Support the rod end of the bellcrank leveling
cylinder with a suitable lifting device. Protect
the cylinder rod from damage.
6 Remove the pin retaining fastener from the
bellcrank leveling cylinder rod-end pivot pin.

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Jib Boom Components

3-4 Note: Use the following chart to identify the

description of each LCD screen control button used
Jib Boom Bellcrank Angle Sensor in this procedure.
The jib boom bellcrank angle sensor is monitored
by the control system to keep the jib boom
bellcrank vertical and to help maintain a level
platform through boom range of motion. If a jib
boom bellcrank angle sensor is replaced, it must be
calibrated prior to machine operation. The jib boom Plus Minus Previous Enter
bellcrank angle sensor is mounted to the bellcrank 1 Place a digital level with a magnetic base, on
pivot pin on the engine side of the machine. the underside of the jib bellcrank as shown in
Illustration 1.
How to Calibrate the Jib Boom
Bellcrank Angle Sensor
Note: If the primary boom angle sensor has been
removed or replaced, it must to be calibrated
before the jib boom bellcrank angle sensor. Refer
to Repair Procedure, How to Calibrate the Primary
Boom Angle Sensor.
Note: Perform this procedure with the machine on
a firm, level surface and in the stowed position with
the axles extended.
Note: A digital level will be required to perform this
procedure.
Note: A kit is available through Genie Product Illustration 1
Support (Genie part number 58351GT). This kit 1 digital level
includes a digital level with a magnetic base and
cable harnesses. 2 Raise the jib boom to a slightly less than
horizontal position.
3 Push in the ground controls red Emergency
Stop button to the off position. Do not turn the
key switch to the off position.
4 Open the ground control box.
5 Locate the calibration toggle switch at the top
of the ground control box. Activate calibration
mode by moving the toggle switch in the left
direction.
6 Temporarily install a control box door retaining
fastener between the door and the box to
prevent the control box door from moving the
toggle switch while calibrating the machine.

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7 Remove the key from the main key switch. 14 Press and hold the engine start button for
Insert the key into the bypass/recovery key approximately 5 seconds to shut off the
switch and turn it to the bypass position. engine and to save the calibration settings.
Note: The angle sensor calibration values will not Note: Do not turn the engine off with the key switch
be saved correctly unless the key switch is in the or red Emergency Stop button or all calibration
bypass position and the calibration toggle switch is points or values will not be saved.
activated.
15 Press the enter or previous button on the
8 Press and hold the enter button on the ground LCD screen until EXIT is displayed.
control panel while pulling out the ground
16 Press the plus button to select YES, then
controls red Emergency Stop button to the on
press the enter button to accept.
position. Hold the enter button for
approximately 5 seconds and then release it. 17 Turn the key back to the run position and
remove the key from the bypass/recovery key
9 Enter sensor calibration mode by pressing the
switch. Insert the key into the main key switch
buttons at the ground controls in the following
and turn it to ground controls.
sequence: (plus)(enter)(enter)(plus).
18 Wait approximately 20 seconds and turn the
10 Press the enter or previous button on the
machine off by pressing the red Emergency
LCD screen until DELETE JIB LEVEL ANGLE
Stop button in.
SENSOR CALIBRATION is displayed.
19 Remove the fastener that was temporarily
11 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.
12 Adjust the jib bellcrank until it is level to
Note: When the control box door is closed, the
gravity.
calibration toggle switch is automatically activated
Note: While in the jib bellcrank level sensor to exit out of calibration mode.
calibration mode, the platform level up and platform
level down buttons on the TCON will activate the jib 20 Use the key to turn the bypass / recovery key
bellcrank level up and level down valves. switch to the run position.
Note: Be sure that the bypass/recovery key switch
13 At the JIB BELLCRANK LEVEL TO GRAVITY?
is in the run position before attempting to operate
screen, Press the plus button to select YES, the machine.
then press the enter button to accept.
21 Pull out the red Emergency Stop button. Start
Note: If the engine is started to adjust the jib
bellcrank, press and hold the engine start button for the engine and lower the boom to the stowed
position. Be sure there are no calibration faults
five seconds.
shown on the display.
Note: If the system exits out of calibration mode 22 Remove the digital level from jib bellcrank.
when the engine is started, repeat step 9 and
continue to step 12.

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Boom Components

1 boom tube #1 5 primary lift cylinder

2 boom tube #2 6 boom tube #0
3 boom tube #3 7 secondary extension cylinder
4 boom tube #4

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Boom Components

4-1 4 Pull the electrical cables out of the lower cable

track that lead to the primary boom.
Primary Boom Cable Track
Component damage hazard.
The primary boom cable track guides the cables Cables can be damaged if they
and hoses running up the boom. It can be repaired are kinked or pinched.
link by link without removing the cables and hoses
that run through it. Removing the entire primary 5 Tag and disconnect the electrical connectors
boom cable track is only necessary when from the jib boom manifold located at the
performing major repairs that involve removing the platform end of the primary boom.
primary boom.
6 Tag, disconnect and plug the two hydraulic
How to Remove the Primary hoses from the side of the jib boom manifold
that lead to the primary boom cable track. Cap
Boom Cable Track the fittings on the manifold.
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
Note: Perform this procedure with the machine on squirt or spray.
a firm, level surface.
7 Tag and disconnect the electrical connector
Note: Perform this procedure with the boom in the from the limit switches on the sides of the
stowed position. primary boom. Do not remove the limit
switches.
1 Tag and disconnect the electrical connectors
from the boom #0 cable track. 8 Remove the retaining fasteners from the cable
track guide at the platform end of the boom.
2 Disconnect the AC electrical wire and option Remove the cable track guide from the
wires and hoses. machine.
3 Tag and disconnect the ground box 9 Disconnect the platform box harness, the AC
harnesses. electrical cable and option wires and hoses
from the platform.
10 Pull the wires and hoses from the jib boom.

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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 6 Remove the upper rollers from the
damaged if they are kinked or replacement section of cable track.
pinched. 7 Lift up the hoses and cables and carefully
insert the new 4-link section of cable track.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.

8 Connect the ends of the replacement cable

track section to the existing cable track using
the pins and snap rings.
9 Install the rollers onto the new section of cable
track.
10 Operate the primary boom extend/retract
function through a full cycle to ensure smooth
operation of the new section of cable track.

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4-2 Pivot end upper wear pads

Primary Boom 10 Loosen the wear pad mounting fasteners.
11 Add shims by hand until snug.
How to Shim the Boom
Note: Do not use force when adding the shims.
1 Measure each upper, side and lower wear
pad. 12 Remove one shim from each upper wear pad
only.
Note: If a wear pad is not less than specification,
perform the following procedure. Note:The wear pad clearance should be 0.060 in /
1.52 mm.
Platform end wear pads
13 Tighten the mounting fasteners.
2 Extend the boom until the wear pads are
accessible at the platform end of the machine. 14 Replace the covers.

3 Loosen the wear pad mounting fasteners. 15 Extend and retract the boom through an entire
cycle. Check for tight spots that may cause
4 Add shims by hand until snug. binding of the boom.
Note: Do not use force when adding the shims.
Primary boom wear pad Minimum
5 Tighten the mounting fasteners. specifications
Platform end
6 Remove the boom end cover retaining
fasteners at the pivot end of the boom. Bottom and side wear pads 0.63 in
Remove the boom end cover from the 16 mm
machine. Top wear pads 0.35 in
(#0 to #1; #1 to #2; #2 to #3) 9 mm
Pivot end side wear pads
Top wear pads 0.47 in
7 Loosen the wear pad mounting fasteners. (#3 to #4) 12 mm
Pivot end
8 Add shims by hand until snug.
Top wear pads 0.63 in
Note: Do not use force when adding the shims. 16 mm
9 Tighten the mounting fasteners. Side wear pads 0.47 in
12 mm

Grease Specification
Lube a Boom grease
Genie part number 110147

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How to Remove the Primary 3 Attach a lifting strap from an overhead crane
to the rod end of the primary boom lift cylinder.
Boom
4 Remove the pin retaining fastener from the
Bodily injury hazard. This boom lift cylinder rod-end pivot pin. Use a soft
procedure requires specific repair metal drift to remove the pin. Protect the
skills, lifting equipment and a cylinder rod from damage.
suitable workshop. Attempting
this procedure without these skills Crushing hazard. The boom lift
and tools could result in death or cylinder may fall when the
serious injury and significant rod-end pivot pin is removed if
component damage. Dealer the boom lift cylinder is not
service is strongly recommended. properly supported by the
overhead crane.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Crushing hazard. The boom
end must be replaced. All connections must be may fall when the rod-end pivot
torqued to specification during installation. Refer to pin is removed if the boom is
Specifications, Hydraulic Hose and Fitting Torque not properly supported by the
Specifications. overhead crane.
Note: Perform this procedure with the boom in the
5 Place support blocks under the boom lift
stowed position.
cylinder.
Note: Most repair procedures to the boom 6 Remove the pin retaining fastener from the
assembly components can be performed with the boom lift cylinder rod-end pivot pin. Use a soft
boom attached. metal drift to remove the pin. Protect the
Note: The boom assembly may be removed with cylinder rod from damage.
the cable track attached. 7 Using the Auxiliary Power Unit, retract the
boom lift cylinder until the rod end will clear the
1 Attach an overhead 10 ton / 9071 kg crane to
boom weldment.
the platform end of the boom for support. Do
not lift the boom. 8 Carefully lower the rod end of the boom lift
cylinder down onto the support blocks.
2 Place a block under the rod end of the primary
boom lift cylinder. 9 Tag, disconnect and plug the boom lift cylinder
hydraulic hoses.

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10 Tag, disconnect and plug the secondary boom 17 Disconnect the electrical connector from the
extension cylinder hydraulic hoses. Cap the primary boom angle sensor.
fittings on the cylinder.
Note: The primary boom angle sensor is located on
Bodily injury hazard. Spraying the pivot pin on the tank side of the boom.
hydraulic oil can penetrate and
18 Remove the primary boom angle sensor
burn skin. Loosen hydraulic
bracket mounting fasteners and remove the
connections very slowly to allow
primary boom angle sensor from the primary
the oil pressure to dissipate
boom. Do not remove the angle sensor from
gradually. Do not allow oil to
the bracket.
squirt or spray.
Note: When the primary boom is installed, the
11 Remove the platform. Refer to Repair primary boom angle sensor will need to be
Procedure, How to Remove the Platform. calibrated. Refer to Repair Procedure, How to
Calibrate the Primary Boom Angle Sensor.
12 Remove the platform mounting weldment and
the platform rotator. Refer to Repair 19 Attach a 10 ton / 9071 kg overhead crane to
Procedure, How to Remove the Platform the pivot end of the primary boom. Do not
Rotator. apply any lifting pressure.
13 Remove the jib boom. Refer to Repair 20 Remove the pin retaining fasteners from the
Procedure, How to Remove the Jib Boom. primary boom pivot pins.
Note: When the jib boom is installed, the jib boom 21 Use a soft metal drift to remove the primary
angle sensor will need to be calibrated. Refer to boom pivot pins.
Repair Procedure, How to Calibrate the Jib Boom
Bellcrank Angle Sensor. 22 Carefully remove the primary boom from the
machine and place it on a structure capable of
14 Remove the primary boom cable track. Refer supporting it.
to Repair Procedure, How to Remove the
Cable Track. Crushing hazard. The primary
boom could become unbalanced
15 Remove the end cover from the pivot end of and fall when removed from the
the primary boom. machine if not properly attached
16 Remove the limit switch mounting fasteners to the overhead crane.
from the limit switch on the ground controls
side of the primary boom. Do not disconnect
the wiring. Remove the limit switch.

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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 removed 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.
2 Remove the platform. Refer to Repair Component damage hazard.
Procedure, How to Remove the Platform. Cables, hoses, boom cable
tube and cable track can be
3 Remove the platform mounting weldment and
damaged if they are kinked or
the platform rotator. Refer to Repair
pinched.
Procedure, How to Remove the Platform
Rotator.
4 Remove the jib boom. Refer to Repair
Procedure, How to Remove the Jib Boom.
5 Remove the jib boom lift cylinder. Refer to
Repair Procedure, How to Remove the Jib
Boom Lift Cylinder.

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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
3RS and 4EOS. Remove the bracket and limit #2 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 tube if it is not properly
#4 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
#0 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.

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Remove the #2 boom tube: 28 Remove the fasteners securing the lower wear
pads and remove the wear pads and
23 At the pivot end of the machine, remove the aluminum block between the #1 and #2 boom
shims from the wear pads between the #1 and tubes.
#2 boom tubes.
29 Back the wire cables from the opening below
Note: Pay careful attention to the location and the #1 boom tube into the tube and then push
amount of shims used with each wear pad. them out the end of the #1 boom tube.
24 At the platform end, remove the top wear pads Note: This will allow the retract cables to come out
between the #1 and #2 boom tubes. with the boom tubes. Remove the retract wire
Note: Pay careful attention to the location and cables with the #2 boom tube.
amount of shims used with each wear pad. 30 Begin pulling the #2 boom tube from the
25 At the platform end, remove the shims from #1 boom tube.
the upper side wear pad and lower side wear Note: Make sure the tube remains parallel to the
pads from the opposite side of the boom #1 boom tube while removing.
between the #1 and #2 boom tubes.
31 When approximately 10 feet of the #2 boom
Note: Pay careful attention to the location and tube remains in the #1 boom tube, attach a
amount of shims used with each wear pad. strap from a suitable overhead lifting device
26 Remove the bolts supporting the cable track and slightly lift the tube.
assembly from the #2 boom tube. Crushing hazard. The number
Note: You may have to lift the cable track assembly 2 boom tube may become
to clear the tab on the #2 boom tube when it is unbalanced and fall when it is
removed. removed from the number
1 boom tube if it is not properly
27 Attach the #2 boom tube to a forklift, and lift supported and attached to the
the tube enough to relieve the pressure from overhead crane.
the lower wear pads.
Note: During removal, the overhead crane strap will
Note: Remove the retract wire cables with the
need to be adjusted for proper balancing.
boom tube.
32 Remove the final two side wear pads from the
platform end of the machine.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
33 Support and slide the #2 boom tube from the
boom assembly.

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Remove the #1 boom tube: 41 Remove limit switches 2RO and 2RS and
bracket from boom tube #0.
34 Strap and secure the secondary boom
extension cylinder to the #0 boom tube. Tip-over hazard. Failure to
install the correct proximity
35 Remove the pin retaining fasteners from
and/or limit switches in the
barrel-end pin securing the cylinder to the
correct location will result in the
#1 boom tube. Remove the pin.
machine tipping over, resulting
Crushing hazard. The in death or serious injury.
secondary boom extension
cylinder may become 42 When approximately 10 feet of the #1 boom
unbalanced and fall if it is not tube remains in the #0 boom tube, attach a
properly supported. strap from a suitable overhead lifting device
and slightly lift the tube.
36 At the pivot end of the machine, remove the 43 Remove the lower wear pads between the
shims from the wear pads between the #0 and #0 and #1 boom tubes.
#1 boom tubes.
Note: Pay careful attention to the location and
Note: Pay careful attention to the location and amount of shims used with each wear pad.
amount of shims used with each wear pad.
44 Remove the final two side wear pads from the
37 At the platform end, remove the top wear pads platform end of the machine.
between the #0 and #1 boom tubes.
Note: Pay careful attention to the location and
Note: Pay careful attention to the location and amount of shims used with each wear pad.
amount of shims used with each wear pad.
45 Support and slide the #1 boom tube from the
38 Remove an upper side wear pad and the lower #0 boom tube.
side wear pad from the opposite side of the
boom between the #0 and #1 boom tubes. Crushing hazard. The #1 boom
tube may become unbalanced
Note: Pay careful attention to the location and
and fall when it is removed from
amount of shims used with each wear pad.
the #0 boom tube if it is not
39 Remove the bracket supporting the cable properly supported and
track assembly from the #1 boom tube. attached to the overhead crane.

40 Attach the #1 boom tube to a forklift, and lift Note: During removal, the overhead crane strap will
the tube enough to relieve the pressure from need to be adjusted for proper balancing.
the lower wear pads. Begin sliding the tube
from the boom assembly.
Note: Make sure the tube remains parallel to the
#0 boom tube while removing.

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4-3 3 Attach an overhead 10 ton / 9071 kg crane to

the platform end of the boom for support. Do
Primary Boom Lift Cylinder not lift the boom.
The primary boom lift cylinder raises and lowers Note: Place the lifting strap between the cable track
the primary boom. The primary boom lift cylinder is assembly and the boom.
equipped with a counterbalance valve to prevent
movement in the event of a hydraulic line failure. 4 Remove the boom storage area cover
retaining fasteners. Remove the cover from
How to Remove the Boom Lift the machine.

Cylinder 5 Remove the pin retaining fastener from the

boom lift cylinder rod-end pivot pin. Use a soft
Bodily injury hazard. This metal drift to remove the pin. Protect the
procedure requires specific repair cylinder rod from damage.
skills, lifting equipment and a
suitable workshop. Attempting Crushing hazard. The boom lift
this procedure without these skills cylinder may fall when the
and tools could result in death or rod-end pivot pin is removed if
serious injury and significant the boom lift cylinder is not
component damage. Dealer properly supported by the
service is strongly recommended. overhead crane.

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
cylinder.
4 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.

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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.

Component damage hazard. Be

careful not to damage the
proximity and/or limit switches
when removing the boom lift
cylinder.

Component damage hazard.

1 engine pivot plate anchor hole The cables and hydraulic hoses
2 engine pivot plate retaining fastener can be damaged if the boom lift
cylinder is pulled across them.
12 Locate the engine pivot plate anchor hole at
the pivot end of the engine pivot plate.
13 Install the bolt that was just removed into the
anchor hole to secure the engine pivot plate
from moving.
Crushing hazard. Failure to
install the bolt into the engine
pivot plate to secure it from
moving could result in death or
serious injury.

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4-4 3 Tag and disconnect the limit switch

harnesses. Remove the fasteners to the limit
Extension Cylinders switch harness mounting bracket and remove
the bracket.
The primary boom extension cylinder is located
inside the boom assembly and incorporates cables 4 Tag and disconnect limit switch 3RO (6).
and pulleys that are responsible for extending the Remove the mounting bracket with the limit
boom tubes. The secondary boom extension switch attached. (Illustration 1)
cylinder is located underneath the number 0 boom
tube and is responsible for extending the number 5 Disconnect and remove the string
1 boom tube. The extension cylinders are equipped potentiometer from boom tube #0. Remove
with counterbalance valves to prevent movement in the clevis from boom tube #2.
the event of a hydraulic line failure. 6 Tag and disconnect the harness from cable
tension limit switch 6S (4). Remove the
How to Remove the Primary bracket and limit switch. Remove cable
Boom Extension Cylinder tension limit switch 5S (5) from the mounting
bracket. (Illustration 1)
Bodily injury hazard. This Note: The mounting bracket must remain attached
procedure requires specific repair to the extend cylinder.
skills, lifting equipment and a
suitable workshop. Attempting 7 Tag, disconnect and plug the hydraulic hoses
this procedure without these skills from the primary boom extension cylinder.
and tools could result in death or Cap the fittings on the cylinder.
serious injury and significant
component damage. Dealer Bodily injury hazard. Spraying
service is strongly recommended. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Note: When removing a hose assembly or fitting, connections very slowly to allow
the O-ring (if equipped) on the fitting and/or hose the oil pressure to dissipate
end must be replaced. All connections must be gradually. Do not allow oil to
torqued to specification during installation. Refer to squirt or spray.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 8 Remove the fasteners from the inner cable
track mounting bracket at the primary boom
1 Raise the boom to a horizontal position and extension cylinder.
fully retract the primary extension cylinder.
2 Remove the retaining fasteners from the boom
end cover at the pivot end of the boom.
Remove the cover from the machine.

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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.

12 Loosen the #4 extend cable adjustment bolts.

13 Loosen the #3 extend cable adjustment bolts
10 turns (about 1 in / 2.54 cm).
Note: Do not over loosen the extend cables.
Note: When reassembling the extend cable
assembly, tighten the three extend cable
adjustment bolts so the cable mounting blocks (1)
line up with the weldment edge (2) as shown in
Illustration 2.

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

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14 Remove the locking plates securing the How to Remove the Secondary
extend cylinder to boom #1 (1). (Illustration 1)
Boom Extension Cylinder
15 Remove the cable guards (2) covering the
sheaves attached to the extend cylinder. Bodily injury hazard. This
(Illustration 1) procedure requires specific repair
skills, lifting equipment and a
16 Remove the locking plates (7) securing the suitable workshop. Attempting
extend cylinder sheaves to boom #2. this procedure without these skills
(Illustration 1) and tools could result in death or
17 Remove the locking plates (3) securing the serious injury and significant
retract cables to boom #3. (Illustration 1) component damage. Dealer
service is strongly recommended.
18 Remove the fasteners securing the three
#3 boom extend adjustment bolt mounting Note: When removing a hose assembly or fitting,
block. the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
19 Attach a suitable lifting device to the extend
torqued to specification during installation. Refer to
cylinder arms that will allow the cylinder to be
Specifications, Hydraulic Hose and Fitting Torque
lifted to clear the mounting plates on the
Specifications.
#1 boom and pulled from the boom assembly.
20 Attach a lifting strap from an overhead crane 1 Raise the boom until the secondary boom
to support the cylinder as it is removed from extension cylinder rod-end pivot pins are
the boom assembly. accessible.

21 Support and slide the primary boom extension 2 Remove the secondary boom extend cylinder
cylinder out of the boom assembly while cover retaining fasteners. Remove the covers.
guiding the cables out of the boom and place it Bodily injury hazard. Do not
on a structure capable of supporting it. operate the machine unless the
Crushing hazard. The primary secondary extend cylinder
boom extension cylinder may covers are properly installed.
become unbalanced and fall Operating the machine with the
when it is removed from the covers removed could result in
boom if it is not properly death or serious injury.
supported and attached to the
overhead crane.

Component damage hazard.

Cables can be damaged if they
are kinked, pinched or snagged
during removal.

Note: During removal, the overhead crane strap will

need to be adjusted for proper balancing.

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3 Loosen but do not remove the extension 7 Protect the boom lift cylinder rod from
cylinder support bracket and wear pad. damage.
Bodily injury hazard. Do not 8 Use a soft metal drift to remove both pivot
operate the machine unless the pins.
secondary extend cylinder 9 Remove the secondary boom extension
support bracket is properly cylinder from the machine while guiding the
installed. Operating the barrel end of the cylinder out of the boom.
machine with the bracket loose
could result in death or serious Crushing hazard. The
injury. secondary boom extension
cylinder may become
4 Tag, disconnect and plug the secondary boom unbalanced and fall if it is not
extension cylinder hydraulic hoses. Cap the properly supported when it is
fittings on the cylinder. removed from the machine.
Bodily injury hazard. Spraying
Component damage hazard.
hydraulic oil can penetrate and
The boom lift cylinder rod can
burn skin. Loosen hydraulic
become damaged if the barrel
connections very slowly to allow
end of the secondary boom
the oil pressure to dissipate
extension cylinder is allowed to
gradually. Do not allow oil to
come in contact with it.
squirt or spray.

5 Support the secondary boom extension

cylinder with an overhead crane or other
suitable lifting device.
Note: Place the strap between the boom tube and
the cable track to avoid any pressure on the track.
6 Remove the pin retaining fasteners from both
the rod-end and barrel-end pivot pins. Do not
remove the pins.

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4-5
Boom Extend and Retract Cables
How to Adjust the Boom
Extend/Retract Cables
Properly adjusted extend/retract cables are
essential to safe machine operation. Failure to
maintain proper adjustment of the cables could
result in unsafe operating conditions and may
cause component damage. The boom extend and
retract functions should operate smoothly and be
free of hesitation, jerking and unusual noise.
1 Start the engine from the ground controls.
2 Raise and extend the boom approximately
15 feet / 4.6 m.
3 Fully retract the boom and lower to the
horizontal position.
4 Stop the engine.
5 Measure the distance between boom tubes
#1 and #2, measuring from the points
identified as (11) and (12). (Illustration 1) This
is dimension "A".
Note: The distance should be approximately 1 in /
2.6 cm. The actual measurement will be a function Illustration 1
of the primary extend/retract cylinder.
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

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6 Measure the distance between boom tubes

#2 and #3 using points (9) and (10).
(Illustration 1) The gap should be 1 in / 2.6 cm
to 1.5 in / 3.8 cm greater than dimension "A".
Result: The measurement is between 1 in /
2.6 cm and 1.5 in / 3.8 cm more than
dimension "A". The gap is in tolerance.
Proceed to step 28.
Result: The measurement is more than 1.5 in /
3.8 cm greater than dimension "A". Proceed to
step 7.
Result: The measurement is less than 1 in /
2.6 cm greater than dimension "A". Proceed to
step 20.
7 Remove the boom end cover from the pivot
end of the machine.
8 Locate the red locking brackets (2) covering
the cable adjustment bolts at the pivot end of
the boom (Illustration 2).
9 Loosen each of the three extend cable
adjustment bolts (4) five turns. (Illustration 2) Illustration 2
1 #4 extend cable adjustment nuts
2 locking brackets
3 cable tension limit switch 6S
4 #3 extend cable adjustment bolts
5 cable tension limit switch 5S
6 limit switch actuator bracket

10 At the platform end of the boom, locate the

retract cable bolt under the # 1 boom tube (6).
(Illustration 1)
11 Loosen the jam nut on the cable tension
retract bracket. Do not remove the nuts.
12 Tighten the retract bolt using a torque wrench
until boom tube #3 begins to move.
Note: If the torque wrench reaches 105 ft-lbs / 142
Nm and boom tube #3 hasn't moved, loosen the
extend cable adjustment bolts 5 turns and continue
tightening the boom tube #1 retract bolt.

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13 Tighten the retract bolt until the gap between 23 Torque the three extend cable adjustment
boom tubes #2 and #3 is 1 to 1.5 in / 2.5 to bolts (4) to 35 ft-lbs / 47.5 Nm. Make small
3.8 cm greater than dimension "A". adjustments to the three bolts to insure the
cable tension limit switch arm (6) is centered in
14 Torque the three extend cable adjustment
the limit switch actuator bracket. (Illustration 1)
bolts to 35 ft-lbs / 47.5 Nm. Make small
adjustments to the three bolts to insure the 24 Start the engine and fully raise and extend the
cable break limit switch whisker is centered in boom approximately 15 ft / 4.6 m.
the limit switch actuator bracket (6).
25 Fully retract the boom and lower the boom to
(Illustration 2)
the horizontal position.
15 Torque the #1 retract bolt to 105 ft-lbs / 142
26 Stop the engine.
Nm.
27 Re-measure the gap between boom tubes
16 Start the engine and fully raise and extend the
#1 and #2 from points (11) and (12)
boom approximately 15 ft / 4.6 m.
(dimension “A”) and boom tubes #2 and
17 Fully retract the boom and lower the boom to #3 from points (9) and (10). (Illustration 1)
the horizontal position.
Result: The measurement is between 1 in /
18 Stop the engine. 2.6 cm and 1.5 in / 3.8 cm more than
dimension "A". The gap is in tolerance.
19 Re-measure the gap between boom tubes
Proceed to step 28.
#1 and #2 from points (11) and (12)
(dimension “A”) and boom tubes #2 and Result: The measurement is more than 1.5 in /
#3 from points (9) and (10). (Illustration 1) 3.8 cm greater than dimension "A". Repeat the
procedure beginning with step 9.
Result: The measurement is between 1 in /
2.6 cm and 1.5 in / 3.8 cm more than Result: The measurement is less than 1 in /
dimension "A". The gap is in tolerance. 2.6 cm greater than dimension "A". Repeat the
Proceed to step 28. procedure beginning with step 20.
Result: The measurement is more than 1.5 in / 28 Measure the gap between boom tubes #3 and
3.8 cm greater than dimension "A". Repeat the #4 using measuring points (7) and (8).
procedure beginning with step 9. (Illustration 1)
Result: The measurement is less than 1 in / Result: The measurement is between 1 in /
2.6 cm greater than dimension "A". Proceed to 2.6 cm and 1.5 in / 3.8 cm more than
step 20. dimension "A". The gap is in tolerance.
Proceed to step 48.
20 Loosen the retract cable retract bolt (6).
(Illustration 1) Result: The measurement is more than 1.5 in /
3.8 cm greater than dimension "A". Proceed to
21 Tighten the three extend cable adjustment
step 29.
bolts (4) (Illustration 2) until the gap between
boom tubes #2 and #3 is between 1 in / Result: The measurement is less than 1 in /
2.6 cm and 1.5 in / 3.8 cm plus dimension “A”. 2.6 cm greater than dimension "A". Proceed to
step 40.
22 Torque the retract cable retract bolt to
105 ft-lbs / 142 Nm.

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29 Loosen the two extend cable adjustment bolts 39 Re-measure the gap between boom tubes
(1) five turns. (Illustration 2) #1 and #2 from points (11) and (12)
(dimension “A”) and boom tubes #3 and
30 At the platform end of the boom, locate the
#4 from points (7) and (8). (Illustration 1)
#4 retract cable retract bolt attached to the
#2 boom tube (5). (Illustration 1) Result: The measurement is between 1 in /
2.6 cm and 1.5 in / 3.8 cm more than
31 Loosen the jam nut on the cable tension
dimension "A". The gap is in tolerance.
retract bracket. Do not remove the nuts.
Proceed to step 48.
32 Tighten the retract bolt using a torque wrench
Result: The measurement is more than 1.5 in /
until boom tube #4 begins to move.
3.8 cm greater than dimension "A". Repeat the
Note: If the torque wrench reaches 70 ft-lbs / 95 procedure beginning with step 29.
Nm and boom tube #4 has not moved, loosen the
Result: The measurement is less than 1 in /
#4 extend cable adjustment nuts 5 turns and
2.6 cm greater than dimension "A". Proceed to
continue tightening the boom tube #4 retract bolt.
step 40.
33 Tighten the retract bolt until the gap between 40 Loosen the retract cable retract bolt (5).
boom tubes #3 and #4 is 1.5 in / 3.8 cm (Illustration 1)
greater than dimension "A".
41 Tighten the two extend cable adjustment nuts
34 Torque the two extend cable adjustment nuts (1) (Illustration 2) until the gap between boom
(1) to 35 ft-lbs / 47.5 Nm. Make small tubes #3 and #4 is between 1” and 1.5” plus
adjustments to the two nuts to insure the cable dimension “A”.
tension limit switch arm (3) is centered in the
limit switch actuator bracket. (Illustration 2) 42 Torque the retract cable retract bolt to 70 ft-lbs
/ 95 Nm.
35 Torque the #4 retract bolt to 70 ft-lbs / 95 Nm.
43 Torque the two extend cable adjustment nuts
36 Start the engine and fully raise and extend the (1) to 35 ft-lbs / 47.5 Nm. Make small
boom approximately 15 ft / 4.6 m. adjustments to the bolts to insure the cable
37 Fully retract the boom and lower the boom to break limit switch arm (4) is centered in the
the horizontal position. limit switch bracket. (Illustration 1)

38 Stop the engine. 44 Start the engine and fully raise and extend the
boom approximately 15 ft / 4.6 m.

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How to R eplac e the Boom Extend/R etr act Cables

45 Fully retract the boom and lower the boom to How to Replace the Boom
the horizontal position.
Extend/Retract Cables
46 Stop the engine.
Note: The cable sheaves must be inspected when
47 Re-measure the gap between boom tubes replacing the cables.
#1 and #2 from points (11) and (12)
(dimension “A”) and boom tubes #3 and 1 Remove the primary boom extension cylinder.
#4 from points (7) and (8). (Illustration 1) Refer to Repair Procedure, How to Remove
the Primary Boom Extension Cylinder.
Result: The measurement is between 1 in /
2.6 cm and 1.5 in / 3.8 cm more than #3 Boom extend cables:
dimension "A". The gap is in tolerance.
2 The #3 boom extend cables remain attached
Proceed to step 48.
to the extension cylinder during removal.
Result: The measurement is more than 1.5 in /
#4 Boom extend cables:
3.8 cm greater than dimension "A". Repeat the
procedure beginning with step 29. 3 Remove the cable tension limit switch
Result: The measurement is less than 1 in / mounting bracket.
2.6 cm greater than dimension "A". Repeat the 4 Remove the nut (1) securing the extend cable
procedure beginning with step 40. to pivoting adjustment assembly (2).
48 Install the red locking brackets (2) over the (Illustration 1)
cable adjustment bolts. A flat edge of each bolt
head must be on top for the locking bracket to
secure the bolts (Illustration 2).
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.

49 Lower the boom to the stowed position.

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6 Remove the fasteners securing the idler pulley

holding the upper extend cables and remove
the pulley (3). (Illustration 1)
7 Remove the upper side wear pads (4) from the
#4 boom tube. (Illustration 1)
8 Remove the anti-rotation bolts from the extend
cable. Attach electrician's tape to the threaded
end of the extend cable.
9 At the platform end, loosen but do not remove
the fasteners labeled (1). (Illustration 2)

Illustration 1
1 #4 extend cable nut
2 #4 cable pivot assembly
3 idler pully
4 side wear pad
Illustration 2
5 #3 retract cable
6 cable retainer 1 wear pad fastener
7 #4 extend cable 2 sheave mounting fastener
8 #4 retract cable 3 sheave retaining bolt
4 side wear pad
5 Remove the cable pivot assembly (2).

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10 Remove the center mounting bolt securing the #3 Boom retract cables:
sheave to the cover plate (3).
21 Remove the fastener and the retract cable
11 Remove the remaining fasteners securing the guide between boom tubes #2 and #3.
cover plate to the #3 boom tube. Do not
remove the fasteners labeled (2) at this time. 22 Remove the retract bolt from the #3 boom
(Illustration 2) retract cables at the platform end of the
#1 boom.
12 Remove the side wear pad (4).
23 Remove the equalizing bracket from the
13 Loosen the fasteners (2) securing the sheave #3 boom retract cables.
mounting plate to the boom tube.
24 At the platform end, attach electrician's tape to
14 Remove the sheave from the bearing. the cable.
15 At the platform end, pull on the cable that was 25 At the pivot end of the boom, remove the
above the sheave and then feed the cable that guide bracket between the #1 and #2 boom
was below the sheave toward the pivot end. tubes.
16 Remove the cable retainer (6) securing the 26 At the pivot end, pull the retract cable out of
ends of #4 extend cable and #4 retract cable. the boom tubes.
(Illustration 1)
27 Repeat the procedure for the other retract
17 Attach electrician's tape to the lower end of the cable.
#4 extend cable.
28 Reverse the procedure to install the new
18 At the platform end, pull the upper end of the retract cable.
cable from the boom tube and then the lower
end. #4 Boom retract cables:

19 Perform the procedure on the other extend 29 Remove the #4 retaining sheave weldment
cable. from the #3 boom.
20 Reverse the procedure to install the new 30 Remove the #4 retract cable sheave pin and
extend cable beginning with the lower end of sheave.
the cable. 31 Remove the retract bolt from the #4 boom
retract cables at the platform end of the
#2 boom.

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32 Remove the equalizing bracket from the 4-6

#4 boom retract cables.
Boom Internal Cable Track
33 Attach electrician's tape to the #4 retract cable
at the pivot end of the machine. How to Remove the Boom
34 Attach a suitable device to pull the #3 and Internal Cable Track
#4 boom tubes approximately 2 feet / 0.6 m.
Using an suitable overhead lifting device, Note: When removing a hose assembly or fitting,
attach a strap to the #3 and #4 boom tubes the O-ring (if equipped) on the fitting and/or hose
and slightly lift the tubes. end must be replaced. All connections must be
torqued to specification during installation. Refer to
Note: This will relieve the pressure on the Specifications, Hydraulic Hose and Fitting Torque
aluminum spacers that guide the retract cables. Specifications.
35 Remove the aluminum spacers. 1 Raise the boom to a horizontal position and
36 At the platform end, pull the retract cable out fully retract the primary extension cylinder.
of the boom tube. 2 Remove the retaining fasteners from the boom
37 Repeat the procedure for the other retract end cover at the pivot end of the boom.
cable. Remove the cover from the machine.

38 Reverse the procedure to install the new 3 Remove the retaining fasteners from the
retract cable. bracket holding the string potentiometer and
set the assembly aside.
39 Adjust the boom extend/retract cables. Refer
to Repair Procedure, How to Adjust the Boom 4 Tag and disconnect the limit switch
Extend and Retract Cables. harnesses. Remove the fasteners to the limit
switch harness mounting bracket and remove
the bracket.
5 Tag and disconnect the harness to the chain
brake switch (5S).
6 Tag, disconnect and plug the hydraulic hoses
from the primary boom extension cylinder.
Cap the fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

7 Remove the fasteners from the internal cable

track mounting bracket at the primary boom
extension cylinder.

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8 Tag, disconnect and plug the hydraulic hoses 11 At the pivot end, note the position of the
from at the fittings just below the primary locating U notch on the cable tube. Pull the
boom. Cap the fittings. cable track and cable tube from the boom
Note: A crowfoot wrench will be necessary to approximately two inches so the U notch is at
remove the fittings. the alignment edge. At this point the two
fasteners can be removed from the boom and
Bodily injury hazard. Spraying cable track assembly.
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

9 At the weldment securing the rod end of the lift

cylinder to the boom, locate the two fasteners
securing the internal cable track assembly to
the boom, using Illustration 1 as a guide.

Illustration 2
1 Alignment edge
2 U notch (two inches)
3 V notch (6 inches)

12 Continue pulling the cable track assembly

from the boom. Secure the cable track and
cable tube using zip ties every 4 to 5 feet.

Illustration 1
1 Securing fasteners
2 Centering hole

10 Loosen, but do not remove the two nuts.

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13 Support the assembly as it is removed from 4-7

the boom.
Primary Boom Angle Sensor
Note: Reverse the procedure to install the
assembly. When installing the assembly, stop The primary boom angle sensor is used to limit the
when the locating V notch aligns with the edge of angle of the primary boom relative to the angle of
the mounting bracket, approximately 6 inches from the turntable and gravity.
the final installation position. At this point insert a
small bolt and hold it in the center locating hole How to Calibrate the Primary
identified in Illustration 1. This will provide a stop Boom Angle Sensor
and center the assembly as the cable track
continues to be inserted into the boom. Note: If the angle sensor is replaced, both the
sensor and magnet must be replaced as a set.
Note: When the U notch aligns with the edge of the
mounting bracket, approximately two inches from Note: Perform this procedure with the machine on
the installed position, the two carriage bolts can be a firm, level surface and in the stowed position with
inserted into the outer holes while the cable track the axles extended.
assembly is pushed into its final position.
Note: The turntable level sensor and platform load
Note: When the three smaller holes shown in sensor must be calibrated prior to calibrating the
Illustration 1 are centered in the positioning holes, primary boom angle sensor.
the assembly is in the proper position. Tighten the
fasteners and complete reassembly. Note: RSB1AO and RSB1AS are calibrated at the
same time.
Note: The turntable level sensor, platform load
sensor and primary boom angle sensor must be
calibrated before calibrating the boom length
sensor.
Note: If the calibration flags between SCON and
TCON do not agree after calibration, a crosscheck
fault is generated and recorded and the affected
boom function is inhibited.
Note: A digital level will be required to perform this
procedure.
Note: A kit is available through Genie Product
Support (Genie part number 58351GT). This kit
includes a digital level with a magnetic base and
cable harnesses.

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Note: Use the following chart to identify the 10 Press the plus button to select YES, then
description of each LCD screen control button used press the enter button to accept.
in this procedure. 11 Place the digital level on top of the primary
boom near the pivot and note the angle
displayed on the digital level.
12 Press the enter button until PRIMARY BOOM
ANGLE TO GRAVITY -2.6 DEG is displayed,
Plus Minus Previous Enter press the plus or minus button to adjust the
display to the exact value shown on the digital
1 Push in the ground controls red Emergency level, then press the enter button.
Stop button to the off position.
Note: If the measured angle already matches the
2 Turn the key switch to ground controls. angle shown on the display at the ground controls,
3 Open the ground control box. press the plus button or minus button to change
the angle and then change back to the measured
4 Locate the calibration toggle switch at the top value. The system must detect a change in
of the ground control box. Activate calibration displayed value to record the calibrated value.
mode by moving the toggle switch in the left
direction. Note: If the system exits out of calibration mode
when the engine is started, repeat step 8 and
5 Temporarily install a control box door retaining
continue to step 13.
fastener between the door and the box to
prevent the control box door from moving the 13 Start the engine from the ground controls.
toggle switch while calibrating the machine.
14 Press and hold a function enable/speed select
6 Remove the key from the main key switch. button and the primary boom up button until
Insert the key into the bypass/recovery key the digital level displays 15 degrees.
switch and turn it to the bypass position.
15 At the PRIMARY BOOM ANGLE TO
Note: The angle sensor calibration values will not GRAVITY 15 DEG screen, press the plus or
be saved correctly unless the key switch is in the minus button to adjust the display to the exact
bypass position and the calibration toggle switch is value shown on the digital level, then press the
activated. enter button.
7 Press and hold the enter button on the ground Note: If the measured angle already matches the
control panel while pulling out the ground angle shown on the display at the ground controls,
controls red Emergency Stop button to the on press the plus button or minus button to change
position. Hold the enter button for the angle and then change back to the measured
approximately 5 seconds and then release it. value. The system must detect a change in
displayed value to record the calibrated value.
8 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following 16 Press and hold a function enable/speed select
sequence: (plus)(enter)(enter)(plus). button and the primary boom up button until
9 Press the enter or previous button on the the digital level displays 32 degrees.
LCD screen until DELETE PRIMARY BOOM
ANGLE SENSOR is displayed.

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17 At the PRIMARY BOOM ANGLE TO 22 Press and hold a function enable/speed select
GRAVITY 32 DEG screen, press the plus or button and the primary boom button until the
minus button to adjust the display to the exact boom is fully raised.
value shown on the digital level, then press the
enter button. 23 At the PRIMARY BOOM ANGLE TO
GRAVITY 82 DEG screen, press the plus or
Note: If the measured angle already matches the minus button to adjust the display to the exact
angle shown on the display at the ground controls, value shown on the digital level, then press the
press the plus button or minus button to change enter button.
the angle and then change back to the measured
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,
press the plus button or minus button to change
18 Press and hold a function enable/speed select the angle and then change back to the measured
button and the primary boom up button until value. The system must detect a change in
the digital level displays 49 degrees. displayed value to record the calibrated value.
19 At the PRIMARY BOOM ANGLE TO 24 Press and hold the engine start button for
GRAVITY 49 DEG screen, press the plus or approximately 5 seconds to shut off the
minus button to adjust the display to the exact engine and to save the calibration settings.
value shown on the digital level, then press
the enter button. Note: Do not turn the engine off with the key switch
or red Emergency Stop button or all calibration
Note: If the measured angle already matches the points or values will not be saved.
angle shown on the display at the ground controls,
press the plus button or minus button to change 25 Press the enter or previous button on the
the angle and then change back to the measured LCD screen until EXIT is displayed.
value. The system must detect a change in
26 Press the plus button to select YES, then
displayed value to record the calibrated value.
press the enter button to accept.
20 Press and hold a function enable/speed select 27 Turn the key back to the run position and
button and the primary boom up button until remove the key from the bypass/recovery key
the digital level displays 66 degrees. switch. Insert the key into the main key switch
21 At the PRIMARY BOOM ANGLE TO and turn it to ground controls.
GRAVITY 66 DEG screen, press the plus or 28 Wait approximately 20 seconds and turn the
minus button to adjust the display to the exact machine off by pressing the red Emergency
value shown on the digital level, then press the Stop button in.
enter button.
29 Remove the fastener that was temporarily
Note: If the measured angle already matches the installed. Close the control box door and install
angle shown on the display at the ground controls, the door retaining fasteners.
press the plus button or minus button to change
the angle and then change back to the measured Note: When the control box door is closed, the
value. The system must detect a change in calibration toggle switch is automatically activated
displayed value to record the calibrated value. to exit out of calibration mode.
30 Pull out the red Emergency Stop button. Start
the engine and lower the boom to the stowed
position. Be sure there are no calibration faults
shown on the display.

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4-8 Note: Use the following chart to identify the

description of each LCD screen control button used
Boom Length Sensor in this procedure.

How to Calibrate the Primary

Boom Length Sensor
Note: Perform this procedure with the machine on
a firm, level surface with the axles extended. Plus Minus Previous Enter
Note: The turntable level sensor and platform load 1 With the boom in the stowed position, start the
sensor must be calibrated prior to calibrating the engine and fully raise the boom to its
primary boom angle sensor. maximum angle.

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: A kit is available through Genie Product mode by moving the toggle switch in the left
Support (Genie part number 58351GT). This kit direction.
includes a digital level with a magnetic base and
6 Temporarily install a control box door retaining
cable harnesses.
fastener between the door and the box to
Note: Platform leveling is set to default parameters prevent the control box door from moving the
to avoid platform out of level faults during toggle switch while calibrating the machine.
calibration. 7 Remove the key from the main key switch.
Note: If the calibration flags between SCON and Insert the key into the bypass/recovery key
TCON do not agree after calibration, a crosscheck switch and turn it to the bypass position.
fault is generated and recorded and the affected Note: The length sensor calibration values will not
boom function is inhibited. be saved correctly unless the key switch is in the
bypass / recovery position.

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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
controls red Emergency Stop button to the on engine 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.

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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.

How to Remove the Flex Plate

1 Disconnect the wiring plug at the electronic
displacement controller (EDC), located on the
drive pump.
2 Support the drive pump with an appropriate
lifting device. Then remove all of the pump
mounting plate to engine bell housing bolts.
3 Carefully pull the pump away from the engine
and secure it from moving.
4 Remove the flex plate mounting fasteners,
then remove the flex plate from the engine
flywheel.

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3 Perkins engines: Torque the pump plate
How to Ins tall the Fl ex Plate

How to Install the Flex Plate mounting bolts in sequence to 23 ft-lbs / 31

1 Install the flex plate onto the engine flywheel Nm. Then torque the pump plate mounting
with the rubber vibration isolators towards the bolts in sequence to 47 ft-lbs / 63 Nm.
pump.
2 Use blue thread locking compound and torque
the flex plate mounting bolts in sequence to
28 ft-lbs / 38 Nm. Then torque the flex plate
mounting bolts in sequence to 40 ft-lbs / 54
Nm.
3 Apply a high viscosity coupling grease (Genie
part number 128025) to the splines of the
pump shaft and flex plate.
4 Install the pump plate and pump assembly
onto the engine.
Grease Specification
Shell Alvania® Grease CG, NLGI 0/1 or equivalent.

Perkins 1104D pump plate

Perkins 854F pump plate

Deutz and Perkins models

How to Install the Pump Plate

1 Using a suitable lifting device, install the pump
plate and pump assembly onto the engine.
2 Deutz engines: Torque the pump plate
mounting bolts in sequence to 23 ft-lbs / 31
Nm. Then torque the pump plate mounting Deutz TD2011L04i pump plate
bolts in sequence to 47 ft-lbs / 63 Nm. Deutz TD2.9 pump plate

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Ground Controls

6-1 How to Use the Bypass Mode

Bypass/Recovery Key Switch Tip-over hazard. Operating the
machine outside of the operating
The turntable control box (TCON) is the envelope while in Bypass mode
communication and operations center for the will result in death or serious
machine. The turntable control box contains two injury if proper operating
key switches. The main key switch towards the top procedures and safety
of the control box is for selection of ground or precautions are not followed. Do
platform controls. The key switch at the bottom of not use this mode if you are not
the control box is the Bypass/Recovery key switch. trained and familiar with the
Bypass and Recovery modes are only intended for operating envelope of the
certain circumstances and are not part of normal machine.
machine operation. If either the Bypass or the
Recovery function is required, this indicates there Note: Before using the Bypass mode, make sure
may be faults with the machine. Contact trained you understand the fault code or issue affecting the
personnel immediately. operation of the machine to be sure the use of
bypass is required.
Bypass is used for a platform out-of-level condition
and calibrating certain machine parameters. The Bypass mode will allow the platform to be
manually leveled when an out-of-level condition
Recovery is only to be used as a last attempt to exists. In the event that the platform angle is
lower the platform when the operator in the greater than 10° from level, the boom angle and
platform is unable to do so, system failure or in platform level functions are disabled. Use of the
emergency situations. Bypass mode will allow the platform to be manually
adjusted to within the normal operating envelope,
±4.5°. Only auxiliary power can be used to correct
an out of level platform fault.
1 Turn the engine off.
2 Turn the main key switch to ground controls.
Remove the key from the main key switch and
insert the key into the bypass/recovery key
switch.
Note: The main key switch must remain in the
ground control position.

1 Run
2 Bypass / Recovery
3 Recovery

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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.

The recovery sequence will automatically retract

the primary boom and then lower the primary boom
using the auxiliary power unit to allow the operator
at the platform controls to exit the platform.
1 Turn the main key switch to ground controls.
Remove the key from the main key switch and
insert the key into the bypass/recovery key
switch.

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2 Turn and hold the bypass/recovery key switch 6-2

to the recovery position. The switch must be
held in the recovery position.
Circuit Boards
Result: The auxiliary power unit will turn on The ground control box contains a replaceable
and the boom will begin the following recovery membrane decal with touch sensitive buttons for
sequence. various machine functions. The ground control box
also contains two printed circuit boards:
• The primary boom will retract.
The LCD (Liquid Crystal Display) circuit board
• The primary boom will lower.
is mounted to the inside of the control box lid which
Note: The key switch must be held in the recovery controls the LCD display screen.
position until the recovery sequence is complete or
until the operator in the platform can safely exit the The ECM circuit board is the main circuit board
platform. for the machine. All operating parameters and
configuration of options for the machine are stored
Note: If any boom safety limit switches are faulty, in the ECM memory.
the boom will only retract and not lower and the
operator will need to be recovered from that point. Note: When the ECM circuit board is replaced, the
joysticks will need to be calibrated. Refer to Repair
Note: If the Recovery function has been used, this Procedure, How to Calibrate a Joystick.
will indicate there are faults with the machine. Tag
and remove the machine from service until the fault Note: When the ECM circuit board is replaced, all
has been corrected by trained personnel. the boom, platform and axle angle sensors will
need to be calibrated and in a specific order.
Contact Genie Product Support.

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Ground Controls

How to Remove the LCD Display How to Remove the ALC-1000

Screen Circuit Board Circuit Board
1 Push in the red Emergency Stop button to the 1 Push in the red Emergency Stop button to the
off position at both the ground and platform off position at both the ground and platform
controls. controls.
2 Remove the ground control box lid fasteners. 2 Remove the ground control box lid fasteners.
3 Open the ground control box. 3 Open the ground control box.
Electrocution/burn hazard. 4 Tag and disconnect the harnesses from the
Contact with electrically charged ground control box.
circuits could result in death or
5 Remove the control cable receptacle retaining
serious injury. Remove all rings,
fasteners from the side of the control box.
watches and other jewelry.
6 Attach a grounded wrist strap to the ground
Component damage hazard. screw inside the control box.
Electrostatic discharge (ESD)
Electrocution/burn hazard.
can damage printed circuit board
Contact with electrically charged
components. Maintain firm
circuits could result in death or
contact with a metal part of the
serious injury. Remove all rings,
machine that is grounded at all
watches and other jewelry.
times when handling printed
circuit boards OR use a
grounded wrist strap. Component damage hazard.
Electrostatic discharge (ESD)
4 Carefully disconnect the LCD circuit board can damage printed circuit board
ribbon cable from the ECM circuit board. components. Maintain firm
contact with a metal part of the
5 Remove the LCD display circuit board machine that is grounded at all
retaining fasteners. times when handling printed
6 Carefully remove the LCD display circuit board circuit boards OR use a
from the ground control box lid. grounded wrist strap.

7 Tag and carefully disconnect the wire

connectors from the circuit board.
8 Carefully disconnect the LCD circuit board
ribbon cable from the ECM circuit board.
9 Carefully disconnect the two ribbon cables
from the membrane decal at the ECM circuit
board.
10 Remove the circuit board mounting fasteners.
11 Carefully remove the circuit board from the
control box.

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6 Remove any decal adhesive from the control
6-3 box lid with a mild solvent.
Membrane Decal
Note: Do not allow any solvent to come in contact
The membrane decal is a special decal that with the LCD display screen.
consists of a decal with an electronic membrane on 7 Install the new membrane decal while guiding
the backside. The membrane contains touch the ribbon cables through the control box lid.
sensitive areas that, when pushed, activate the
machine functions. The membrane contains touch 8 Connect the ribbon cables to the ECM circuit
sensitive areas that activate the machine functions. board.
9 Close the control box lid and install the
How to Replace the Membrane retaining fasteners.
Decal
1 Turn the key switch to the off position and
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.

Component damage hazard.

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

5 Carefully remove the membrane decal from

the control box lid while guiding the ribbon
cables out of the control box lid.

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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
to Calibrate a Joystick.
How to Fully Calibrate the
Machine • Turntable level sensor. Refer to Repair
Procedure, How to Calibrate the Turntable
Calibration procedures shall only be completed by Level Sensor.
qualified technicians that have Genie factory
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 • Axle angle sensors. Refer to Repair
proper sequence could cause Procedure, How to Calibrate the Axle Angle
the machine to tip over resulting Sensors.
in death or serious injury.
• Steer sensors. Refer to Repair Procedure,
Note: A digital level will be required to perform this How to Calibrate All Steer Sensors.
procedure.
• Primary boom angle sensor. Refer to Repair
Note: A kit is available through Genie Product Procedure, How to Calibrate the Primary
Support (Genie part number 58351GT). This kit Boom Angle Sensor.
includes a digital level with a magnetic base and
• Primary boom length sensor. Refer to
cable harnesses.
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 • Jib boom bellcrank angle sensor. Refer to
in this procedure. Repair Procedure, How to Calibrate the Jib
Boom Bellcrank Sensor.
• Select option configuration. Refer to Repair
Section, Display Module, Options.

Plus Minus Previous Enter

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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.

Tip-over hazard. Calibration and parameter settings must be completed by a person

trained and qualified on the repair of this machine. Failure to properly calibrate or set
parameters could cause the machine to tip over resulting in death or serious injury.

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.

Plus Minus Previous Enter

Activation of the enter or previous buttons scrolls through the screens. To change parameter values or
select a setting, use the plus button (to increase or scroll forward) and the minus button (to decrease or
scroll backwards). Then press the enter button to save the new value to memory. An audible beep will
indicate a save to memory. Use the enter and previous buttons to scroll to the EXIT menu. Use the plus
button to change to YES and use the enter button to exit.

Screen or Menu Procedure Description Range or Selection

Operator Default Hourmeter (on power up)
Engine speed

Engine oil pressure PSI (English)

Engine oil pressure kPa (metric)

Engine temperature °F (Engiish) engine temp will not display

until temp is >100°F
Engine temperature °C (metric) engine temp will not display
until temp is >38°C
Primary boom angle to gravity

Turntable level sensor X° direction

Turntable level sensor Y° direction

Platform level sensor degree

Battery volts

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Display Module

Screen or Menu Procedure Description Range or Selection

Machine Status With key switch on, press the Hydraulic pressure PSI 0-4500 PSI
(plus)(minus) buttons at the same (English)
time. Hydraulic pressure kPa (metric) 0-31000 kPa

Primary angle degrees -2° to +83°

Length sensor extension inches 0in to 682in

Length sensor extension 0cm to 1732cm

centimeters
Axles fully extended YES/NO

Jib bellcrank angle -10° to +10°

DPF regeneration mode Auto/Force/Inhibit

Unit of Measure With key switch OFF, press and hold Metric/English (measurement English, German,
and Language the enter button and turn key switch to units) French, Spanish,
on position. Portuguese, Italian,
Release the enter button and press Dutch, and Swedish.
(plus)(minus)(minus)(plus) Deutz 2.9L Turbo
(D2.9T)
Set engine Deutz TD2011L04i
(DL04i)
Perkins 1104D-44T
(P1104)
Perkins 854F (P854T)
Overload With key switch OFF, press and hold Clear Overload Recovery A passcode is required
Recovery the enter button and turn key switch to to clear message
(software V2.0 on position.
and later) Release the enter buton and press
(plus)(minus)(minus)(plus)
Default Reset With key switch OFF, press and hold Delete drive functions
the enter button and turn key switch to
on position.
Release the enter button and press
Delete boom function speeds
(minus)(minus)(previous)(previous)

Delete lift function ramps

Delete all (Contact Genie

Product Support before using
this option)

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Display Module

Screen or Menu Procedure Description Range or Selection

Drive Functions With key switch OFF, press Forward extended drive speed % 120% (max) 100% (default)
and hold the enter button 50% (min)
and turn key switch to on Forward not stowed drive 120% (max) 100% (default)
position. speed % 50% (min)
Release the enter button
and press Forward low drive speed % 120% (max) 100% (default)
(plus)(plus)(enter)(enter). 50% (min)
Forward high drive speed % 120% (max) 100% (default)
50% (min)
Reverse extended drive speed % 120% (max) 100% (default)
50% (min)
Reverse not stowed drive 120% (max) 100% (default)
speed % 50% (min)
Reverse low drive speed % 120% (max) 100% (default)
50% (min)
Reverse high drive speed % 120% (max) 100% (default)
50% (min)
Drive acceleration % 125% (max) 100% (default)
25% (min)
Drive deceleration % 125% (max) 100% (default)
25% (min)
Speed limit on steer angle 100% (max) 50% (default)
0%

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Display Module

Screen or Menu Procedure Description Range or Selection

Boom Function With key switch OFF, press Primary boom up speed stowed
Speeds and hold the enter button
and turn key switch to on
position. Primary boom up speed <80ft
Release the enter button
and press Primary boom up speed >80ft
(plus)(plus)(minus)(minus)
Primary boom up speed <120ft

Primary boom up speed <150ft

Primary boom up speed <170ft

Primary boom down speed stowed

Primary boom down speed <80ft

Primary boom down speed >80ft 120% max, 50% min,

Primary boom down speed >120ft 100% (default)

Primary boom down speed >150ft

Primary boom down speed >170ft

Primary boom extend speed

Primary boom retract speed

Jib up speed

Jib down speed

Jib rotate CW speed

Jib rotate CCW speed

Turntable rotate speed retracted

Turntable rotate speed not

retracted
Turntable rotate speed > 75'

Turntable rotate speed > 125'

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Display Module

Screen or Menu Procedure Description Range or Selection

Lift Functions With key switch OFF, press and Primary boom up/down ramp
Ramps hold the enter button and turn key acceleration %
switch to on position.
Primary boom up/down ramp
Release the enter button and deceleration %
press
(plus)(plus)(previous)(previous). Primary boom extend/retract
ramp acceleration %
Primary boom extend/retract 150% max and 50% min
ramp deceleration % 100% (default),
Turntable rotate ramp 5% increment
acceleration %
Turntable rotate ramp
deceleration %
Jib up/down ramp
acceleration %
Jib up/down ramp
deceleration %
Jib rotate ramp
acceleration %
Jib rotate ramp
deceleration %

Screen or Menu Procedure Description Range or Selection

Valve Calibration With key switchOFF, press and Delete drive valve calibration
hold the enter button and turn
Delete boom extend/retract valve
key switch to on position.
calibration
Release the enter button and
press Delete turntable rotate valve
(minus)(minus)(enter)(enter). calibration
Allow turntable rotate speed YES/NO
calibration
Delete drive joystick calibration

Delete boom up/down joystick

calibration
Delete boom extend/retract
joystick calibration
Delete turntable rotate joystick
calibration
Delete steer joystick calibration

Delete jib up/down joystick

calibration
Delete jib rotate joystick
calibration

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Display Module

Screen or Menu Procedure Description Range or Selection

Sensor Calibration With key switch OFF, press Set unit X-axis to gravity
and hold the enter button Set unit Y-axis to gravity
and turn key switch to on
position. Set platform level to gravity (YES/NO)
Release the enter button Platform level sensor millivolts/degree
and press
(plus)(enter)(enter)(plus). Delete axles angle sensors calibration?
(YES/NO)
Axle angle fully retracted (YES/NO)
Axle angle fully extended (YES/NO)
Delete all steer sensors calibrations?
(YES/NO)
Delete blue end blue side steer sensor
(LF) calibration? (YES/NO)
Delete yellow end blue side steer
sensor (LR) calibration? (YES/NO)
Delete blue end yellow side steer
sensor (RF) calibration? (YES/NO)
Delete yellow end yellow side steer Use +/- buttons to adjust
sensor (RR) calibration? (YES/NO)
Delete primary boom angle sensor
calibration? (YES/NO)
primary boom angle to gravity -2.6°
primary boom angle to gravity 15°
primary boom angle to gravity 32°
primary boom angle to gravity 49°
primary boom angle to gravity 66°
primary boom angle to gravity 82°
Delete boom length sensor calibration?
(YES/NO)
Boom fully retracted (YES/NO)
Boom fully extended (YES/NO)
Delete jib level angle sensor
calibration? (YES/NO)
Set jib level to gravity (YES/NO)

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Display Module

Screen or Menu Procedure Description Range or Selection

Options With key switch OFF, press AC Generator (NONE/7.5KW/12.5KW)
and hold the enter button
and turn key switch to on
position.
Release the enter button
and press
(minus)(minus)(plus)(plus).
Allow platform functions with AC (NO/YES)
generator ON?
Alarm options No (NO AL)/Motion (MO AL)/
Travel (TR AL)/ Descent (DE
AL)/ Travel and Descent (TD
AL)
Lift/Drive No (NO CO)/ Drive cut out
while not stowed (DCONS)/
Lifting or driving (LORDR)
Proximity Kill Switch? (NONE/PROX)

Platform Overload sensing? (NONE/PLFTS)

Flashing Beacon? (NO/YES)

Disable Steer Mode Change

while Driving? (NO/YES)
Rocker Switch steering? (NO/YES)

Foot Switch Lockout 30.0 max and 0.0 min, 10.0

(0-30 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 Gravity? (NO/YES)

Axle Motion Only While Driving? (NO/YES)

Chassis Tilt Options (CODRV/COALL)

Boom Length Limit (NONE/150FT/135FT/120FT)

(SX180)
(NONE/135FT/120FT/100FT)
(SX150)

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Hydraulic Pumps

2 Tag, disconnect and plug the function pump

7-1 hydraulic hoses. Cap the fittings on the pump.
Function Pump Bodily injury hazard. Spraying
hydraulic oil can penetrate and
The function pump is a pressure compensated, burn skin. Loosen hydraulic
variable displacement piston pump. Any internal connections very slowly to allow
service to the pump should be performed at an the oil pressure to dissipate
authorized Sauer-Danfoss service center. Contact gradually. Do not allow oil to
Genie Product Support to locate your local squirt or spray.
authorized service center.
3 Support the pump with a suitable lifting device.
How to Remove the Function
4 Remove the two pump mounting fasteners.
Pump Carefully remove the pump.
Note: When removing a hose assembly or fitting, Component damage hazard. Be
the O-ring (if equipped) on the fitting and/or hose sure to open the two hydraulic
end must be replaced. All connections must be tank valves and prime the pump
torqued to specification during installation. Refer to after installing the pump.
Specifications, Hydraulic Hose and Fitting Torque
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 open closed
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the
condition.

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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.

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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 /
clockwise (higher pressure). If the pressure 25 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.

1 standby pressure set screw

2 standby pressure adjustment screw

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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 /
gauge. 200 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.

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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.

How to Remove the Drive Pump

1 pressure compensator set screw
Component damage hazard. The
2 pressure compensator adjustment screw work area and surfaces where
this procedure will be performed
8 Adjust the pressure compensator pressure.
must be clean and free of debris
Turn the adjustment screw clockwise to
that could get into the hydraulic
increase the pressure or counterclockwise to
system and cause severe
decrease the pressure. Tighten the set screw.
component damage. Dealer
Component damage hazard. service is recommended.
Do not adjust the pressure
compensator higher than Note: When removing a hose assembly or fitting,
specified. the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
9 Verify that the wire connectors to both torqued to specification during installation. Refer to
solenoids are securely connected. Specifications, Hydraulic Hose and Fitting Torque
Specifications.
10 Turn the engine off and remove the pressure
gauge. 1 Disconnect the wiring plug at the electronic
displacement controller (EDC), located on the
drive pump.

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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.

Component damage hazard.

The engine must not be started
open closed
with the hydraulic tank shut-off
Component damage hazard. valves in the closed position or
The engine must not be started component damage will occur. If
with the hydraulic tank shut-off the tank valves are closed,
valves in the closed position or remove the key from the key
component damage will occur. If switch and tag the machine to
the tank valves are closed, inform personnel of the
remove the key from the key condition.
switch and tag the machine to
inform personnel of the
condition.

3 Tag, disconnect and plug the hydraulic hoses

from the drive and function pumps. Cap the
fittings on the pumps.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

4 Support the pumps with a suitable lifting

device and remove the two drive pump
mounting fasteners.

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How to Prime the Driv e Pum p

How to Prime the Drive Pump

Component damage hazard. Be
sure to open the two hydraulic
tank valves before performing
this procedure.

1 Connect a 0 to 600 psi / 0 to 50 bar pressure

gauge to either the "A" or "B" test port on the
drive pump.
2 Perkins models: Disconnect the engine
wiring harness from the fuel shutoff solenoid at
the injector pump.
Deutz models: Hold the manual fuel shutoff
valve clockwise to the closed position.
3 Have another person crank the engine with
the starter motor for 15 seconds, wait
15 seconds, then crank the engine an
additional 15 seconds or until the pressure
reaches approximately 250 psi / 17 bar.
4 Perkins models: Connect the engine wiring
harness to the fuel solenoid.
Deutz models: Release the manual fuel
shutoff valve.
5 Start the engine from the ground controls.
6 Check for hydraulic leaks.

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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
Solenoid operated 2 position 2 way 33-37 ft-lbs /
1 T Primary boom cylinder retract
directional valve 45-50 Nm
2 Orifice, 0.025 in / 0.635 mm X
3 Orifice, 0.025 in / 0.635 mm Z
Solenoid operated 2 position 2 way 33-37 ft-lbs /
4 U Secondary boom cylinder extend
directional valve 45-50 Nm
Primary boom extend/retract
circuit, regulates pressure drop 33-37 ft-lbs /
5 Differential sensing valve, 150 psi / 10.3 bar I
across secondary boom 45-50 Nm
extend/retract proportional valve
Proportional solenoid operated 2 position Primary boom extend/retract, 33-37 ft-lbs /
6 J
2 way directional valve normally closed proportional speed control 45-50 Nm
Solenoid operated 3 position 4 way 19-21 ft-lbs /
7 W Primary boom extend/retract
directional valve 25.7-28.5 Nm
Solenoid operated 3 position 4 way 33-37 ft-lbs /
8 X Primary boom lift/ cylinder up/down
directional valve 45-50 Nm
Proportional solenoid operated 2 position Primary lift cylinder up/down high 33-37 ft-lbs /
9 L
2 way directional valve normally closed speed control 45-50 Nm
Proportional solenoid operated 2 position Primary lift cylinder up/down low 19-21 ft-lbs /
10 K
2 way directional valve normally closed speed control 25.7-28.5 Nm
Prevents the draining of hydraulic
19-21 ft-lbs /
11 Check valve, 5 psi / 0.34 bar V oil from the jib manifold and
25.7-28.5 Nm
platform manifold
19-21 ft-lbs /
12 Check valve, 5 psi / 0.34 bar A Pressure Circuit #2
25.7-28.5 Nm
19-21 ft-lbs /
13 Check valve, 5 psi / 0.34 bar B Pressure Circuit #1
25.7-28.5 Nm
Prevents hydraulic pressure from 19-21 ft-lbs /
14 Check valve, 5 psi / 0.34 bar D
flowing back into auxiliary pump #2 25.7-28.5 Nm

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Manifolds

8-1
Function Manifold Components, continued
Schematic
Index No. Description Function Torque
Item
Prevents hydraulic pressure from 19-21 ft-lbs /
15 Check valve, 5 psi / 0.34 bar C
flowing back into auxiliary pump #1 25.7-28.5 Nm
24-26 ft-lbs /
16 Relief valve, 3200 psi / 221 bar E System relief
32.6-35.4 Nm
17 Orifice, 0.025 in / 0.635 mm Y
Primary extend thermal pressure 19-21 ft-lbs /
18 Relief valve, 3000 psi / 207 bar S
limit 25.7-28.5 Nm
Primary and secondary retract 46-54 ft-lbs /
19 Relief valve, 2500 psi / 172.4 bar H
pressure limit 62.6-73.4 Nm

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Function Manifold Components – View 2

Schematic
Index No. Description Function Torque
Item
Pilot operated 3 position, 4 way, Boom cylinder extend / retract 46-54 ft-lbs /
20 R
directional valve circuit 62.6-73.4 Nm
Pilot operated 3 position, 4 way, Boom lift cylinder up/down 46-54 ft-lbs /
21 P
directional valve circuit 62.6-73.4 Nm
Turntable rotate circuit,
Differential sensing valve, 150 psi / regulates pressure drop across 19-21 ft-lbs /
22 F
10.3 bar turntable rotate proportional 25.7-28.5 Nm
valve
19-21 ft-lbs /
23 Solenoid operated proportional valve M Turntable rotate, speed control
25.7-28.5 Nm
Solenoid operated 3 position 4 way 24-26 ft-lbs /
24 N Turntable rotate circuit
directional valve 32.6-35.4 Nm
Holds hydraulic oil in boom 33-37 ft-lbs /
25 Check valve, 100 psi / 6.9 bar Q
extend circuit 45-50 Nm

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8-2 How to Adjust the Primary Boom

Valve Adjustments - Extend Relief Valve
Function Manifold Note: Perform this procedure with the axles
extended.
How to Adjust the Function 1 Locate limit switch LSB4EO/S on the cable
Manifold Relief Valve track side of boom #2.
Note: Perform this procedure with the boom in the 2 Disconnect the wire connector from the limit
stowed position. switch and connect a jumper wire to pin 1 and
pin 2 of the deutsch connector on the upper
Note: Refer to Function Manifold Component list to limit switch cable.
locate the system relief valve.
Note: The correct wire connector will be a 4 pin
1 Connect a 0 to 5000 psi / 0 to 350 bar connector with a red and blue marker on the cable.
pressure gauge to the test port on the function
manifold 3 Start the engine and fully extend the primary
boom. Turn the engine off.
2 Start the engine and raise the boom slightly
and completely lower the jib boom. Turn off 4 Connect a 0 to 5000 psi / 0 to 350 bar
the engine. pressure gauge to the ptest port on the
function manifold.
3 Push and hold the auxiliary button and the jib
down button and observe the pressure 5 Start the engine from the ground controls and
reading on the pressure gauge. Refer to press and release the rpm select button until
Specifications, Hydraulic Component the engine changes to high idle.
Specifications.
4 Use a wrench to hold the relief valve and
remove the cap.
5 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.

6 Repeat step 3 to confirm relief valve pressure.

7 Remove the pressure gauge.

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6 Simultaneously push and hold the function

enable/high speed button and the primary
boom extend button with the primary boom
fully extended. Observe the pressure reading
on the pressure gauge. Refer to
Specifications, Hydraulic Component
Specifications.
Note: The pressure at the ptest port on the function
manifold is a combination of pressures produced
by the differential valve and relief valve. Setting the
valve to the combined pressure will insure the relief
valve is set to the correct pressure.
7 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap.
8 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.

9 Repeat step 6 to confirm relief valve pressure.

10 Connect the limit switch connector that was
disconnected in step 2.
11 Remove the pressure gauge.
12 Start the engine and fully retract the primary
boom. Turn the engine off.

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8-3
Platform Level and Rotation Manifold Components
to SX180H-612
The platform manifold is mounted under the jib boom.

Index Schematic
Description Function Torque
No. Item
Proportional Directional Control valve, 25-30 ft-lbs /
1 DC Jib level up/down
3 position 5 way 33.9-40.7 Nm
Jib boom up/down circuit, regulates
Pressure compensator valve, 150 psi / 19-21 ft-lbs /
2 DD pressure drop across jib boom
10.3 bar 25.8-28.6 Nm
up/down proportional. valve
19-21 ft-lbs /
3 Proportional solenoid valve, 3 position 4 way DE Platform level up/down 25.8-28.6 Nm
19-21 ft-lbs /
4 Solenoid valve, 3 position 4 way DF Platform rotate left/right 25.8-28.6 Nm
19-21 ft-lbs /
5 Flow control valve, 0.2 gpm / 0.76 L/min DG Platform rotate left/right circuit 25.8-28.6 Nm
19-21 ft-lbs /
6 Flow control valve, 0.2 gpm / 0.76 L/min DH Platform rotate left/right circuit 25.8-28.6 Nm

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8-3A
Platform Level and Rotation Manifold Components
from SX180H-613
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 25.8-28.6 Nm
19-21 ft-lbs /
2 Solenoid valve, 3 position 4 way DB Platform rotate left/right circuit 25.8-28.6 Nm
19-21 ft-lbs /
3 Solenoid valve, 3 position 4 way DF Jib level up/down 25.8-28.6 Nm
19-21 ft-lbs /
4 Proportional solenoid valve DD Platform level up/down 25.8-28.6 Nm
19-21 ft-lbs /
5 Solenoid valve, 2 position 2 way DH Platform level up/down 25.8-28.6 Nm
19-21 ft-lbs /
6 Flow control valve, 0.2 gpm / 0.76 L/min DA Platform rotate left/right circuit 25.8-28.6 Nm
19-21 ft-lbs /
7 Flow control valve, 0.2 gpm / 0.76 L/min DC Platform rotate left/right circuit 25.8-28.6 Nm

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8-4
Jib Boom Manifold Components
to SX180H-612
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
25.8-28.6 Nm
Jib boom rotate circuit, regulates
Pressure sensing valve, 150 psi / 19-21 ft-lbs /
2 EC pressure drop across jib boom rotate
10.3 bar 25.8-28.6 Nm
proportional. valve
Proportional solenoid valve, 3 position 25-30 ft-lbs /
3 ED Jib bellcrank level
4 way 33.9-40.7 Nm
Proportional Directional Control valve, 19-21 ft-lbs /
4 EB Jib rotate left/right
3 position 5 way 25.8-28.6 Nm

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8-4A
Jib Boom Manifold Components
from SX180H-613
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 19-21 ft-lbs /
1 EF Jib level up/down
2 way 25.8-28.6 Nm
19-21 ft-lbs /
2 Solenoid Valve EH Jib rotate left/right
25.8-28.6 Nm
Jib boom rotate circuit, regulates
Pressure sensing valve, 150 psi / 19-21 ft-lbs /
3 EC pressure drop across jib boom rotate
10.3 bar 25.8-28.6 Nm
proportional. valve
19-21 ft-lbs /
4 Check valve, 25 psi / 1.7 bar EE Holds oil in jib boom manifold
25.8-28.6 Nm
Proportional Directional Control valve, 19-21 ft-lbs /
5 EB Jib rotate left/right
3 position 5 way 25.8-28.6 Nm
19-21 ft-lbs /
6 Solenoid Valve EG Jib rotate left/right
25.8-28.6 Nm
Proportional solenoid valve, 3 position 25-30 ft-lbs /
7 ED Jib bellcrank level
4 way 33.9-40.7 Nm

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8-5
Function Enable Manifold Components
The function enable manifold is located on the engine side below the hydraulic pumps.

Index No. Description Schematic Item Function Torque

Enables function pumps to provide
20-25 ft-lbs
1 Solenoid valve, 2 position 2 way A hydraulic pressure for all boom and
27-34 Nm
steer/axle functions

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8-6
Steer and Axle Manifold Components, to SX180H-604
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

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Steer and Axle Manifold Components, continued (to SX180H-604)

Schematic
Index No. Description Function Torque
Item
Pressure reducing valve, 2400 psi / 30-35 ft-lbs
15 BR Axle extend/retract circuit
165 bar 41-47 Nm
Prevents left rear steer cylinder 20-25 ft-lbs
16 Check valve BD
from moving when not steering 27-34 Nm
Left rear steer cylinder retract 20-25 ft-lbs
17 Flow control valve, 1.5 gpm / 5,7 L/min BK
circuit 27-34 Nm
Prevents right rear steer cylinder 20-25 ft-lbs
18 Check valve BE
from moving when not steering 27-34 Nm
Right rear steer cylinder retract 20-25 ft-lbs
19 Flow control valve, 1.5 gpm / 5,7 L/min BM
circuit 27-34 Nm
Left front steer cylinder retract 20-25 ft-lbs
20 Flow control valve, 1.5 gpm / 5,7 L/min BG
circuit 27-34 Nm
Left front steer cylinder extend 20-25 ft-lbs
21 Flow control valve, 2.1 gpm / 8 L/min BF
circuit 27-34 Nm
Right front steer cylinder extend 20-25 ft-lbs
22 Flow control valve, 2.1 gpm / 8 L/min BH
circuit 27-34 Nm
Steer left/right, left front steer 20-25 ft-lbs
23 Solenoid valve, 3 position 4 way BN
cylinder 27-34 Nm
Steer left/right, right front steer 20-25 ft-lbs
24 Solenoid valve, 3 position 4 way B0
cylinder 27-34 Nm
25 Pilot operated piston (not shown) A

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8-6A
Steer and Axle Manifold Components, from SX180H-605
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

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Steer and Axle Manifold Components, continued (from SX180H-605)

Schematic
Index No. Description Function Torque
Item
33-37 ft-lbs
15 Solenoid valve, 2 position 2 way CA Axle retract
45-50 Nm
Pressure reducing valve, 2400 psi / 30-35 ft-lbs
16 BY Axle extend/retract circuit
165 bar 41-47 Nm
Prevents left rear steer cylinder 20-25 ft-lbs
17 Check valve BF
from moving when not steering 27-34 Nm
Prevents right rear steer cylinder 20-25 ft-lbs
18 Check valve BH
from moving when not steering 27-34 Nm
Left front steer cylinder extend 20-25 ft-lbs
19 Flow control valve, 2.1 gpm / 8 L/min BJ
circuit 27-34 Nm
Steer left/right, left front steer 20-25 ft-lbs
20 Solenoid valve, 3 position 4 way BR
cylinder 27-34 Nm
Prevents left rear steer cylinder 20-25 ft-lbs
21 Check valve BG
from moving when not steering 27-34 Nm
Prevents right rear steer cylinder 20-25 ft-lbs
22 Check valve BI
from moving when not steering 27-34 Nm
Steer left/right, right front steer 20-25 ft-lbs
23 Solenoid valve, 3 position 4 way BS
cylinder 27-34 Nm
Prevents left front steer cylinder 20-25 ft-lbs
24 Check valve BC
from moving when not steering 27-34 Nm
Prevents right front steer cylinder 20-25 ft-lbs
25 Check valve BE
from moving when not steering 27-34 Nm
26 Pilot operated piston (not shown) BV

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8-7 4 Turn the engine off.

Valve Adjustments - Steer and 5 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
Axle Manifold counterclockwise to decrease the pressure.
Install the relief valve cap.
How to Adjust the Axle Relief
Component damage hazard. Do
Valve not adjust the relief valve
Note: Perform this procedure with the machine on pressures higher than
a firm, level surface and in the stowed position with specifications.
the axles extended.
6 Repeat steps 3 through 5 to confirm relief
Note: Refer to Steer and Axle Manifold list to locate valve pressure.
the axle relief valve.
7 Remove the pressure gauge.
Note: Two people will be required to perform this
procedure.
1 Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the test port on the steer
and axle manifold.
2 Locate the axle relief valve on the steer and
axle manifold. Hold the relief valve with a
wrench and remove the cap.
3 Start the engine from the platform controls and
press down the foot switch. Press and hold the
axle extend button at the platform controls.
Observe the pressure reading on the pressure
gauge. Refer to Specifications, Hydraulic
Component Specifications.

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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

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Traction Manifold Components, continued

Index Schematic
Description Function Torque
No. Item
Equalizes pressure on both sides of 30-35 ft-lbs
13 Orifice, 3 gpm / 11,4 L/min AQ
divider/combiner valve AP 40,7-47,5 Nm
Equalizes pressure on both sides of 30-35 ft-lbs
14 Orifice, 3 gpm / 11,4 L/min AL
divider/combiner valve AM 40,7-47,5 Nm
20-25 ft-lbs
15 Check valve AJ Anti-cavitation
27,1-33,9 Nm
Controls flow to circle end drive motors in 90-100 ft-lbs
16 Flow divider/combiner valve AM
forward and reverse 122-135,6 Nm
Controls flow to divider/combiner valves AM 90-100 ft-lbs
17 Flow divider/combiner valve AP
and AR 122-135,6 Nm
20-25 ft-lbs
18 Check valve AT Anti-cavitation
27,1-33,9 Nm

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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 /
Note: The hydraulic oil temperature must be 100°F 2.8 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.

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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
26-28 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
33-35 Nm
Solenoid valve, 2 position 2 way 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
9-11 Nm
45-50 ft-lbs
6 Needle valve FF Charge pressure circuit
61-68 Nm
Counterbalance valve, 4.5:1 2000 psi / 45-50 ft-lbs
7 FG Adds backpressure to generator circuit
138 bar 61-68 Nm

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8-11 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromotive force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / 10°C
within the coil that provides this force field. that your air temperature increases or decreases
from 68°F / 20°C.
Since coil resistance is sensitive to temperature,
resistance values outside specification can Valve Coil Resistance Specification
produce erratic operation. When coil resistance Function Manifold
decreases below specification, amperage
schematic item L 4.5Ω@12v
increases. As resistance rises above specification,
voltage increases. schematic item K 5.4Ω@12v
schematic item J, N, T, U 7.1Ω@12v
While valves may operate when coil resistance is
outside specification, maintaining coils within schematic item W, X 6.2Ω@12v
specification will help ensure proper valve function schematic Item M 8.8Ω@12v
over a wide range of operating temperatures. Steer Manifold
Electrocution/burn hazard. schematic item BT, BU 5.6Ω@12v
Contact with electrically charged schematic item BF, BH, BJ, BL 7.2@12v
circuits could result in death or Traction Manifold
serious injury. Remove all rings,
watches and other jewelry. schematic item AX, AY 7.2Ω@12v
Jib Manifold
1 Tag and disconnect the wiring from the coil to schematic item EB, ED 6.2Ω@10v
be tested.
Platform Manifold
2 Test the coil resistance.
schematic item DB, DD, DG 6.2Ω@10v
Result: The resistance should be within Function Enable Manifold
specification, plus or minus 30%.
schematic item A 7.2Ω@12v
Result: If the resistance is not within Generator Manifold
specification, plus or minus 30%, replace the
schematic item FB, FD 7.1Ω@12v
coil.

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How to Test a Coil Diode

Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.

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,
should be capable of reading up to 800 mA.
Note: The battery should read 9V DC or more when
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.

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5 Remove the drive hub mounting bolts and

9-1 remove the turntable rotation assembly from
the machine.
Turntable Rotation Assembly
6 Repeat steps 3 through 5 for the other
How to Remove a Turntable turntable rotation assembly.
Rotation Assembly Tip-over hazard. If the turntable
rotation lock pin is not properly
Note: When removing a hose assembly or fitting, installed, machine stability is
the O-ring (if equipped) on the fitting and/or hose compromised and the machine
end must be replaced. All connections must be could tip over when the drive hub
torqued to specification during installation. Refer to is removed from the machine,
Specifications, Hydraulic Hose and Fitting Torque which could result in death or
Specifications. serious injury.
Note: Perform this procedure with the primary
boom between the circle-end tires and with the Crushing hazard. The drive hub
machine on a firm, level surface. could become unbalanced and
fall if not properly supported by
1 Secure the turntable from rotating with the an overhead crane or lifting
turntable rotation lock pin. device when removed from the
2 Remove the ground controls side fixed machine.
turntable cover.
Note: When installing a turntable rotation assembly,
3 Tag, disconnect the hydraulic hoses from the the rotation gear backlash must be adjusted. Refer
turntable rotation motor. Cap the fittings on the to Repair Procedure, Adjust the Turntable Rotation
motor. Gear Backlash.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

4 Attach a lifting strap from an overhead crane

or other suitable lifting device to the lifting eye
on the turntable rotation assembly.

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7 Turn the adjustment bolt 1/2 to 3/4 turn
How to Adj ust the Tur ntabl e R otati on Gear Backlash

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.

1 backlash pivot plate

2 adjustment bolt with lock nut
3 backlash pivot plate mounting bolts

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9-2 1 Push in the ground controls red Emergency

Stop button to the off position.
Turntable Level Sensor
2 Open the ground control box.
How to Calibrate the Turntable 3 Locate the calibration toggle switch at the top
Level Sensor of the ground control box. Activate calibration
mode by moving the toggle switch in the left
Note: If the Safety Controller (SCON) has been direction.
replaced, the entire machine needs to be calibrated
in a specific order. Refer to Repair Procedure, How 4 Temporarily install a control box door retaining
to Fully Calibrate the Machine. fastener between the door and the box to
prevent the control box door from moving the
Note: Perform this procedure with the boom fully toggle switch while calibrating the machine.
retracted and in the stowed position and with the
5 Turn the key switch to ground controls.
machine on a firm, level surface.
6 Remove the key from the main key switch.
Note: A digital level will be required to perform this Insert the key into the bypass/recovery key
procedure. switch and turn it to the bypass position.
Note: A kit is available through Genie Product Note: The angle sensor calibration values will not
Support (Genie part number 58351GT). This kit be saved correctly unless the key switch is in the
includes a digital level with a magnetic base and bypass position and the calibration toggle switch is
cable harnesses. activated.
Note: Use the following chart to identify the 7 Press and hold the enter button on the ground
description of each LCD screen control button used control panel while pulling out the ground
in this procedure. controls red Emergency Stop button to the on
position. Hold the enter button for
approximately 5 seconds and then release it.

Plus Minus Previous Enter

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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.

12 Press the enter or previous button on the

LCD screen,until SET UNIT Y AXIS LEVEL
TO GRAVITY is displayed.Place the digital
level along the Y axis of the turntable.

1 + Y Axis
2 - Y Axis

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13 Press the plus button or minus button to

adjust the display to the exact value shown on
the digital level and press the enter button.
Note: If the measured angle already matches the
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.
14 Press the enter or previous button on the
LCD screen until EXIT is displayed.
15 Press the plus button to select YES, then
press the enter button to accept.
16 Wait approximately 20 seconds and turn the
machine off by pressing the red Emergency
Stop button in.
17 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.
18 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.
19 Start the engine. Be sure there are no
calibration faults shown on the display.

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10-1 3 Remove the steer sensor cover retaining

fasteners. Remove the steer sensor assembly.
Steer Sensors
Note: If the sensor activator pin needs to be
The steer sensors measure steer angle and replaced, install the new activator pin per
communicates that information to the ground Illustration 1.
controls ECM. The steer sensor on the ground
controls side of the machine at the square-end acts
as the lead sensor when in front wheel steer mode.
In rear wheel steer mode, the steer sensor on the
ground controls side of the machine at the
circle-end acts as the lead sensor. The other three
sensors follow the position, or steer angle, of the
lead sensor. There is a steer sensor mounted to
the top of each steer yoke upper pivot pin.

How to Replace a Steer Sensor

Note: When the steer sensor is replaced, both the
sensor and magnet must be replaced as a set.
Note: Perform this procedure with the axles fully Illustration 1
retracted and the boom in the stowed position. (square end, yellow side and circle end, blue side shown)
1 Align the remaining wheels on the machine so Left front (square-end, blue side) and right rear
they are visually parallel to the chassis as (circle-end, yellow side) angle sensors:
close as possible.
2 Disconnect the steer sensor assembly cable
from the main harness to be replaced.

Illustration 2
1 installed position
2 starting position
3 sensor cover
4 rotation arrow

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4 Position the new steer sensor assembly over 10 Position the new steer sensor assembly over
the sensor activator pin with the sensor cable the sensor activator pin with the sensor cable
angled towards the tire. Refer to Illustration 2. angled away from the tire. Refer to Illustration
5 Align the sensor with the pin and install the 3.
sensor on to the pin. 11 Align the sensor with the pin and install the
Note: Be sure the sensor activator pin is engaged sensor on to the pin.
into the sensor. Note: Be sure the sensor activator pin is engaged
6 Rotate the sensor housing in a clockwise into the sensor.
direction until the sensor cable is pointing 12 Rotate the sensor housing in a clockwise
away from the machine. Refer to Illustration 2. direction until the sensor cable is pointing
7 Install the steer sensor cover retaining away from the machine. Refer to Illustration 2.
fasteners. Do not tighten the cover retaining 13 Install the steer sensor cover retaining
fasteners. fasteners. Do not tighten the cover retaining
8 Connect the steer sensor assembly cable to fasteners.
the main harness. 14 Connect the steer sensor assembly cable to
9 Calibrate the steer sensor. Refer to Repair the main harness.
Procedure, How to Calibrate a Replacement 15 Calibrate the steer sensor. Refer to Repair
Steer Sensor. Procedure, How to Calibrate a Replacement
Note: Be sure the yoke pivot pin retaining plate is Steer Sensor.
fully engaged into the pivot pin and that the Note: Be sure the yoke pivot pin retaining plate is
fasteners are securely tightened. fully engaged into the pivot pin and that the
Right front (square-end, yellow side) and left fasteners are securely tightened.
rear (circle-end, blue side) angle sensors:

Illustration 3
1 starting position
2 installed position
3 sensor cover
4 rotation arrow

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How to C alibr ate a R epl acem ent Steer Sens or How to C alibr ate All Steer Sensors

How to Calibrate a Replacement How to Calibrate All Steer

Steer Sensor Sensors
Note: If a steer angle sensor has been removed or Note: This procedure will only need to be
replaced, the steer angle sensors will need to be performed if the ground controls circuit board
calibrated. (TCON) has been replaced.
Note: Perform this procedure with the axles Note: Perform this procedure with the axles
retracted and the tires straightened. retracted and the tires straightened.
Note: Two people will be required to perform this Note: Use the following chart to identify the
procedure. description of each LCD screen control button used
in this procedure.
Note: Be sure the yoke pivot pin retaining plate is
fully engaged into the pivot pin and that the
fasteners are securely tightened.
1 Start the engine from the platform controls.
2 Select the proper steer mode. If a front Plus Minus Previous Enter
(square-end) steer angle sensor has been
replaced, select rear steer mode. If a rear 1 Locate the calibration toggle switch at the top
(circle-end) steer angle sensor has been of the ground control box. Activate calibration
replaced, select front steer mode. mode by moving the toggle switch in the left
direction.
3 Have another person press down the foot
switch. 2 Temporarily install a control box door retaining
fastener between the door and the box to
4 At the new steer angle sensor, loosen the prevent the control box door from moving the
steer angle sensor cover retaining fasteners. toggle switch while calibrating the machine.
Do not remove the fasteners or the sensor
cover. 3 Turn the key switch to ground controls and pull
out the ground controls red Emergency Stop
5 Rotate the sensor cover clockwise or button to the on position.
counterclockwise until the tire is straight in
relation with the other tires. Tighten the sensor 4 Loosen the steer angle sensor cover retaining
cover fasteners. fasteners. Do not remove the fasteners or the
sensor cover.
Note: If available, WebGPI can also be used for
this procedure. 5 Using a voltmeter set to DC voltage, probe the
back of the electrical connector at pins B and
6 Push in the red Emergency Stop button to the C.
off position.

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6 Left front (square-end, blue side) and right 9 Press and hold the enter button on the ground
rear (circle-end, yellow side) angle control panel while pulling out the ground
sensors: Rotate the sensor cover clockwise controls red Emergency Stop button to the on
or counterclockwise until the voltage reading position. Hold the enter button for
is between 1.4 to 1.6V DC. Tighten the sensor approximately 5 seconds and then release it.
cover fasteners.
Right front (square-end, yellow side) and
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
this procedure.
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 angle sensor calibration values will not
be saved correctly unless the key switch is in the
bypass position and the calibration toggle switch is
activated. 1 Run
2 Bypass / Recovery
8 Push in the red Emergency Stop button to the 3 Recovery
off position.
10 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus).

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Delete all Steer Sensor Calibrations Delete a Single Steer Sensor Calibration

11 Press the enter or previous button on the 15 To calibrate a single steer sensor, delete the
LCD screen until DELETE ALL STEER specific steer sensor calibration
SENSORS CALIBRATION is displayed. Press 16 Press the enter or previous button on the
the plus button to select YES, then press the LCD screen until DELETE _____ STEER
enter button to accept. SENSORS CALIBRATION is displayed.
12 Press the enter or previous button on the Example: DELETE BLUE END BLUE SIDE
LCD screen until EXIT is displayed. STEER SENSORS CALIBRATION (FL).

13 Press the plus button to select YES, then 17 Press the plus button to select YES, then
press the enter button to accept. press the enter button to accept.

14 Proceed to step 21. 18 Press the enter or previous button on the

LCD screen until EXIT is displayed.
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.

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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.

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4 Connect the hydraulic hoses from a portable 10-4

hydraulic power unit to the axle extension
cylinder.
Axle Angle Sensors
Note: Connect the pressure hose from the power The axle angle sensors measure the axle angle
unit to the "R" port of the cylinder and the return and communicates that information to the ground
hose from the power unit to the "E" port on the controls ECM. There are two axle angle sensors.
cylinder. They are located on opposite axle pivot pins at
each end of the chassis.
5 Support the axle extension cylinder with a
suitable lifting device. Protect the cylinder rod How to Calibrate the Axle Angle
from damage.
Sensors
6 Remove the pin retaining fasteners from both
axle extension cylinder pivot pins. Note: Use the following chart to identify the
description of each LCD screen control button used
7 Use a soft metal drift to remove the pin. in this procedure.
8 Using the portable hydraulic power unit,
retract the axle extension cylinder until the
ends of the cylinder clear the axles.
9 Remove the axle extension cylinder from the
machine. Plus Minus Previous Enter
Crushing hazard. The axle Note: If an axle angle sensor has been removed or
extension cylinder may become replaced, the axle angle sensors will need to be
unbalanced and fall if not calibrated.
properly supported by the lifting
device. Note: Perform this procedure with the axles fully
retracted and the boom in the stowed position.
Note: Two people will be required to perform this
procedure.
1 Push in the ground controls red Emergency
Stop button to the off position.
2 Turn the key switch to ground controls.
3 Locate the calibration toggle switch at the top
of the ground control box. Activate calibration
mode by moving the toggle switch in the left
direction.

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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.

12 Press the plus button to select YES, then

press the enter button to accept.
13 Press the enter or previous button on the
1 Run
LCD screen until EXIT is displayed.
2 Bypass / Recovery 14 Press the plus button to select YES, then
3 Recovery press the enter button to accept.
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
bypass position and the calibration toggle switch is engine and to save the calibration settings.
activated. Note: Do not turn the engine off with the key switch
6 Press and hold the enter button on the ground or red Emergency Stop button or all calibration
control panel while pulling out the ground points or values will not be saved.
controls red Emergency Stop button to the on
position. Hold the enter button for
approximately 5 seconds and then release it.

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16 Wait approximately 20 seconds and turn the

machine off by pressing the red Emergency
Stop button in.
17 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.
18 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.

1 Run
2 Bypass / Recovery
3 Recovery

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Generators

4 Start the engine from the platform controls.

11-1 5 Turn on the generator from the platform
Welder Generator controls and let the generator run for at least
three minutes.
How to Set the Welder Generator 6 Insert the leads from a multimeter set to
Frequency register frequency (HZ) and turn the needle
valve until the frequency is 2 Hz above the
Note: Perform this procedure with the machine on normal frequency.
a firm, level surface.
Note: The normal frequency will be either 50 Hz or
Note: Perform this procedure with the boom in the 60 Hz, depending on the country.
stowed position.
7 While holding the adjusting screw, tighten the
1 Plug a 1000 watt load into the generator outlet retaining nut on the needle valve.
like a portable work light or heater.
8 Turn off the generator and then turn off the
2 Loosen the retaining nut on the needle valve engine.
and screw the adjustment screw clockwise
until it stops.

1 Needle valve

3 Turn the adjusting screw counterclockwise two

turns.

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Fault Codes

Before Troubleshooting:
Section 4 Faul t Codes

 Read, understand and obey the safety rules

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.
Observe and Obey:  Read each appropriate fault code thoroughly.
Attempting short cuts may produce hazardous
 Troubleshooting and repair procedures shall
conditions.
be completed by a person trained and qualified
on the repair of this machine  Be aware of the following hazards and follow
generally accepted safe workshop practices.
 Immediately tag and remove from service a
damaged or malfunctioning machine. Electrocution/burn hazard.
 Repair any machine damage or malfunction Contact with electrically charged
before operating the machine. circuits could result in death or
serious injury. Remove all rings,
 Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Machine parked on a firm, level surface
• Key switch in the off position with the key
removed
• The red Emergency Stop button in the off
position at both the ground and platform
controls
• Wheels chocked
• All external AC power supply disconnected
from the machine
• Boom in the stowed position
• Turntable secured with the turntable rotation
lock
• Welder disconnected from the machine (if
equipped with the weld cable to platform
option)

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Primary Ext/Ret Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
zero and neutral, Alarm sounds. joystick. Check the connections to
Value Too High
ensure the connector terminals have
Value Too Low not backed out. Substitute a known
good joystick. If necessary replace and
Value at 0 V recalibrate joystick.
Not Calibrated Joystick Speed and Direction frozen at Calibrate Joystick.
zero and neutral.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Primary Up/Down Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
zero and neutral, Alarm sounds. joystick. Check the connections to
Value Too High
ensure the connector terminals have
Value Too Low not backed out. Substitute a known
good joystick. If necessary replace and
Value at 0 V recalibrate joystick.
Not Calibrated Joystick Speed and Direction frozen at Calibrate Joystick.
zero and neutral.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Steer Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
zero and neutral, Alarm sounds. joystick. Check the connections to
Value Too High
ensure the connector terminals have
Value Too Low not backed out. Substitute a known
good joystick. If necessary replace and
Value at 0 V recalibrate joystick.
Not Calibrated Joystick Speed and Direction frozen at Calibrate Joystick.
zero and neutral.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Primary Boom Up/Down Fault Check (both Primary Boom Up/Down disabled, Check ribbon and connector from
buttons on TCON buttons pressed) display message on LCD membrane switch. If necessary replace
membrane switch.
Primary Boom Ext/Ret Fault Check (both Primary Boom Ext/Retract disabled, Check ribbon and connector from
buttons on TCON buttons pressed) display message on LCD membrane switch. If necessary replace
membrane switch.
Primary Extend/Retract Not Calibrated Display message on LCD and allow Perform auto calibrate procedure.
Speed operation at default speed
Operational Primary Boom Value at 5.0 V Disable Boom Up, Extend Down, TT Power up controller with problem
Length Sensor Rotate, and Propel. Boom Retract corrected.
allowed and Boom Down allowed if
Value Too High
fully retracted as sensed by LSB3RO.
Value Too Low Propel allowed once boom is fully
stowed. Display message on LCD.
Value at 0 V Alarm sounds
Not Calibrated Primary Up only active from TCON Calibrate Sensor
activate alarm
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Safety Primary Boom Length Value at 5.0 V Disable Boom Up, Extend Down, TT Power up controller with problem
Sensor Rotate, and Propel. Boom Retract corrected.
allowed and Boom Down allowed if
Value Too High
fully retracted as sensed by LSB3RO.
Value Too Low Propel allowed once boom is fully
stowed. Display message on LCD.
Value at 0 V Alarm sounds
Not Calibrated Primary up only active from TCON, Calibrate Sensor
activate alarm
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

RSB1AO/RSB1AS Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Cross-check Rotate, and Propel powers in SCON. corrected.
Boom Retract allowed and Boom
Down allowed if fully retracted as
sensed by LSB3RS. Alarm sounds.
Propel allowed once boom is fully
stowed. Display message on LCD:
BOOM ANGLE SENSORS CROSS
CHECK FAULT.
LTB1LO/LTB1LS Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Cross-check Rotate, and Propel powers in SCON. corrected.
Boom Retract allowed and Boom
Down allowed if fully retracted as
sensed by LSB3RS. Alarm sounds.
Display message on LCD: BOOM
LENGTH SENSORS CROSS CHECK
FAULT.
RSB1AO (boom angle) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Active Cross-check Rotate, and Propel powers in SCON. corrected.
Boom Retract allowed and Boom
Down allowed if fully retracted as
sensed by LSB3RO. Alarm sounds.
Display message on LCD: RSB1AO
ACTIVE CROSS CHECK FAULT.
LTB1LO (boom length) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Active Cross-check Rotate, and Propel powers in SCON. corrected.
Boom Retract allowed and Boom
Down allowed if fully retracted as
sensed by LSB3RO. Alarm sounds.
Display message on LCD: LTB1AO
ACTIVE CROSS CHECK FAULT.

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

RSB1AO/LSB1DO (10°) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Cross-check Rotate, and Propel powers in SCON. corrected.
Boom Retract allowed and Boom
Down allowed if fully retracted as
sensed by LSB3RO. Alarm sounds.
Display message on LCD: LTB1AO
ACTIVE CROSS CHECK FAULT.
LTB1LO/LSB3RO (3 ft) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Cross-check Rotate, and Propel powers in SCON. corrected.
Boom Retract allowed and Boom
Down allowed if fully retracted as
sensed by LSB3RS. Alarm sounds.
Display message on LCD:
LTB1LO/LSB4RO CROSS CHECK
FAULT.
LSB2RO (151ft)/LSB4EO Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
(150 ft) Cross-check Rotate, and Propel powers in SCON. corrected.
Boom Retract allowed and Boom
Down allowed if fully retracted as
sensed by LSB3RO. Alarm sounds.
Display message on LCD:
LSB2RO/LSB4EO CROSS CHECK
FAULT.

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

LSB2RS (151ft)/LSB4ES Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
(150 ft) Cross-check Rotate, and Propel powers in SCON. corrected.
Boom Retract allowed and Boom
Down allowed if fully retracted as
sensed by LSB3RO. Alarm sounds.
Display message on LCD:
LSB2RS/LSB4ES CROSS CHECK
FAULT.
Primary Boom Extend Valve Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
zero and neutral, Alarm sounds. Check for an open or shorted valve
coil. Repair or replace as necessary.
Primary Boom Retract Valve
Primary Boom Up Valve
Primary Boom Down Valve
Primary Lock-Out Valve #1
Primary Lock-Out Valve #2
Engine Speed Range Check Display message on LCD Engine is running below 50 RPM.
(underspeed) Check fuel system.
Oil Pressure Range Check (low Display message on LCD Oil pressure is low. Check sender and
oil pressure) oil level.
Water/Oil Temperature Range Check Display message on LCD Engine is overheating. Check sender,
(high temp) water or oil level or radiator/heat
exchanger.
Oil Pressure Sender Fault Check Display message on LCD Check wiring to senders for opens or
shorts. Repair or replace senders.
Water/Oil Temp Sender

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Axle Extend/Retract Fault Check Axle extend/retract disabled. Display Check for defective or damaged wiring
Switches message on LCD or switches. Power up controller with
problem corrected.
Axle Valves Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
zero and neutral, Alarm sounds. Check for an open or shorted valve
coil. Repair or replace as necessary.
DCON CAN Bus Fault Check Display message on LCD Disable Check CAN bus wiring from TCON to
propel DCON through rotator. Repair or
replace wiring or DCON.
CAN Bus Fault Check Display message on LCD Check CAN bus wiring from TCON to
SCON/PCON. Repair or replace wiring
or SCON/PCON.
Tether Power P3 Fault Check Display message on LCD TETHER Power up controller with problem
POWER P3 FAULT corrected.
Valve Power P6R1 Fault Check Display message on LCD VALVE Power up controller with problem
POWER P6R1 FAULT corrected.
Engine Power P6R2 Fault Check Display message on LCD ENGINE Power up controller with problem
POWER P3 FAULT corrected.
Enable Input P7 Fault Check Display message on LCD ENABLE Power up controller with problem
INPUT P7 FAULT corrected.
Enable Output P7R Fault Check Display message on LCD ENABLE Power up controller with problem
OUTPUT P7R FAULT corrected.
DCON Valve Power P7R Fault Check Display message on LCD DCON Power up controller with problem
VALVE POWER P7R FAULT corrected.
Primary Down Power P9A Fault Check Display message on LCD PRI DOWN Power up controller with problem
POWER P9A FAULT corrected.
Ignition/Fuel Power P9B Fault Check Display message on LCD IGN/FUEL Power up controller with problem
POWER P9B FAULT corrected.

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Primary Extend Power P10 Fault Check Display message on LCD PRI Power up controller with problem
EXTEND POWER P10 FAULT corrected.
Primary Up Power P11 Fault Check Display message on LCD PRI UP Power up controller with problem
POWER P11 FAULT corrected.
Axle Retract Power P12 Fault Check Display message on LCD AXLE Power up controller with problem
RETRACT POWER P12 FAULT corrected.
Test Point P14 (not currently Fault Check Display message on LCD TEST Power up controller with problem
used) POINT P14 FAULT corrected.
Test Point P18 (not currently Fault Check Display message on LCD TEST Power up controller with problem
used) POINT P18 FAULT corrected.
Platform Level Valve P22 Fault Check Display message on LCD PLAT Power up controller with problem
LEVEL VALVE P22 FAULT corrected.
Primary Up/Down Valve Fault Check Display message on LCD PRI UP/DN Power up controller with problem
Power P22R VLV PWR P22R FAULT corrected.
Propel Power P38 Fault Check Display message on LCD PROPEL Power up controller with problem
PWR P38 FAULT corrected.
Turntable Rotate Power P39 Fault Check Display message on LCD Power up controller with problem
TURNTABLE ROTATE P39 FAULT corrected.
Secondary Up/Ext Power Fault Check Display message on LCD SEC Power up controller with problem
P30 (not currently used) UP/EXT POWER P30 FAULT corrected.
Platform Overload Fault Check Display message on LCD Power up controller with problem
(if active) corrected.
Platform Overload Switches
Inconsistent

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Turntable Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
zero and neutral, Alarm sounds. joystick. Check the connections to
ensure the connector terminals have
Value Too High
not backed out. Substitute a known
Value Too Low good joystick. If necessary replace and
recalibrate joystick.
Value at 0 V
Not Calibrated Joystick Speed and Direction frozen at Calibrate Joystick.
zero and neutral.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Turntable Rotate Buttons on Fault Check (both Turntable rotate disabled Display Check ribbon and connector from
TCON buttons pressed) message on LCD membrane switch. If necessary replace
membrane switch.
Turntable Rotate Speed Not Calibrated Display message on LCD and allow Perform auto calibrate procedure.
operation at default speed
Turntable Rotate Flow Valve Not Calibrated Normal function except threshold for Perform calibration procedure
one or the other direction is zero.
Display message on LCD.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad
zero and neutral, Alarm sounds. ground. Replace coil if necessary
Value Too Low Check for shorts to ground in the
wiring. Replace coil if necessary

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Turntable Rotate Clockwise Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
Valve zero and neutral, Alarm sounds. Check for an open or shorted valve
coil. Repair or replace as necessary.
Turntable Rotate
Counterclockwise Valve
Operational Turntable Level Value at 5.0 V Flash unit out of level icon and LED Check that SCON is grounded
Sensor X Direction and activate alarm
Value Too High Replace SCON
Value Too Low
Value at 0 V
Out of Tolerance
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Safety Turntable Level Value at 5.0 V Flash unit out of level icon and LED Check that SCON is grounded
Sensor X Direction and activate alarm
Value Too High Replace SCON
Value Too Low
Value at 0 V
Out of Tolerance
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Operational Turntable Level Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded
Sensor Y Direction sounds
Value Too High Replace SCON
Value Too Low
Value at 0 V
Out of Tolerance
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Safety Turntable Level Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded
Sensor Y Direction sounds
Value Too High Replace SCON
Value Too Low
Value at 0 V
Out of Tolerance
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Primary Boom Up/Down Not Calibrated Normal function except threshold for Calibrate Thresholds.
Flow Valve(s) (#1 and #2) one or the other direction is zero.
Display message on LCD.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad
zero and neutral, Alarm sounds. ground. Replace coil if necessary
Value Too Low
Primary Boom Not Calibrated Normal function except threshold for Calibrate Thresholds.
Extend/Retract Flow Valve one or the other direction is zero.
Display message on LCD.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad
zero and neutral, Alarm sounds. ground. Replace coil if necessary
Value Too Low

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Operational Primary Boom Value at 5.0 V Disable Boom Up, Extend, Down, TT Power up controller with problem
Angle Sensor Rotate, and Propel. Boom Retract corrected.
allowed and Boom Down allowed if
fully retracted as sensed by LSB3RO.
Propel allow once boom is fully stowed.
Display message on LCD. Alarm
sounds.
Value Too High
Value Too Low
Value at 0 V
Not Calibrated Primary up only active from TCON, Calibrate Sensor
activate alarm
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Safety Primary Boom Angle Value at 5.0 V Disable Boom Up, Extend, Down, TT Power up controller with problem
Sensor Rotate, and Propel. Boom Retract corrected.
allowed and Boom Down allowed if
fully retracted as sensed by LSB3RO.
Propel allow once boom is fully stowed.
Display message on LCD. Alarm
sounds.
Value Too High
Value Too Low
Value at 0 V
Not Calibrated Primary up only active from TCON, Calibrate Sensor
activate alarm
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Platform Level Sensor Y Value at 5.0 V Primary up and extend disabled, Alarm Power up controller with problem
Direction sounds corrected.
Value Too High
Value Too Low
Value at 0 V
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Platform Rotate Clockwise Fault Check Fault Check Check for defective or damaged wiring.
Valve Check for an open or shorted valve
coil. Repair or replace as necessary.
Platform Rotate
Counterclockwise Valve
Jib Up/Down Flow Valve(s) Not Calibrated Normal function except threshold for Perform calibration procedure
one or the other direction is zero.
Display message on LCD.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad
zero and neutral, Alarm sounds. ground. Replace coil if necessary
Value Too Low

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Jib Level (Bellcrank) Not Calibrated Normal function except threshold for Perform calibration procedure
Up/Down Flow Valve(s) one or the other direction is zero.
Display message on LCD.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad
zero and neutral, Alarm sounds. ground. Replace coil if necessary
Value Too Low
Jib Rotate CW/CCW Flow Not Calibrated Normal function except threshold for Perform calibration procedure
Valve(s) one or the other direction is zero.
Display message on LCD.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad
zero and neutral, Alarm sounds. ground. Replace coil if necessary
Value Too Low
Platform Level Up / Platform Not Calibrated Normal function except threshold for Perform calibration procedure
Level Down Flow Valve one or the other direction is zero.
Display message on LCD.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad
zero and neutral, Alarm sounds. ground. Replace coil if necessary
Value Too Low Limited Speed and Direction frozen at Check for shorts to ground in the
zero and neutral, Alarm sounds. wiring. Replace coil if necessary

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Platform Rotate Switches Fault Check (both Primary Boom Up/Down disabled. Power up controller with problem
buttons pressed) Display message on LCD corrected.
Platform Level Switches Fault Check (both Primary Boom Ext/Ret disabled. Display Power up controller with problem
buttons pressed) message on LCD corrected.
Jib Up/Down Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
zero and neutral, Alarm sounds. joystick. Check the connections to
ensure the connector terminals have
Value Too High
not backed out. Substitute a known
Value Too Low good joystick. If necessary replace
and recalibrate joystick.
Value at 0 V
Not Calibrated Joystick Speed and Direction frozen at
zero and neutral.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Jib Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
zero and neutral, Alarm sounds. joystick. Check the connections to
ensure the connector terminals have
Value Too High
not backed out. Substitute a known
Value Too Low good joystick. If necessary replace
and recalibrate joystick.
Value at 0 V
Not Calibrated Joystick Speed and Direction frozen at Calibrate Joystick.
zero and neutral.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Front Axle Angle Sensor Value at 5.0 V Primary up and Extend disabled, axle Check for an open ground circuit
extend and retract LED flash going to the sensor
Value Too High Primary up and Extend disabled, axle Sensor is out of range. Check sensor
extend and retract LED flash and actuating pin for proper
installation. Repair or replace sensor
Value Too Low
and recalibrate.
Value at 0 V Primary up and Extend disabled, axle Check for 5.0 VDC at the sensor.
extend and retract LED flash Check for damaged wiring going to
the sensor. Check that the % .0 VDC
LED is lit on the TCON board. Repair
or replace as necessary
Not Calibrated Primary up only active from TCON, Perform calibration procedure
activate alarm
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Rear Axle Angle Sensor Value at 5.0 V Primary up and Extend disabled, axle Check for an open ground circuit
extend and retract LED flash going to the sensor
Value Too High Primary up and Extend disabled, axle Sensor is out of range. Check sensor
extend and retract LED flash and actuating pin for proper
installation. Repair or replace sensor
Value Too Low
and recalibrate.
Value at 0 V Primary up and Extend disabled, axle Check for 5.0 VDC at the sensor.
extend and retract LED flash Check for damaged wiring going to
the sensor. Check that the % .0 VDC
LED is lit on the TCON board. Repair
or replace as necessary
Not Calibrated Primary up only active from TCON, Perform calibration procedure
activate alarm
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Propel Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
zero and neutral, Alarm sounds. joystick. Check the connections to
ensure the connector terminals have
Value Too High
not backed out. Substitute a known
Value Too Low good joystick. If necessary replace
and recalibrate joystick.
Value at 0 V
Not Calibrated Joystick Speed and Direction frozen at Calibrate Thresholds.
zero and neutral.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Propel Valves Not Calibrated Joystick Speed and Direction frozen at Calibrate Thresholds.
Forward/Reverse zero and neutral.
Propel EDC Just calibrated Initiate one second beep of audible Self-clearing (transient)
Forward/Reverse warning device
Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad
zero and neutral, Alarm sounds. ground. Replace coil if necessary
Value Too Low Check for shorts to ground in the
wiring. Replace coil if necessary
Motor Valve Speed Fault Check Limited Speed and Direction frozen at Check for defective or damaged
zero and neutral, Alarm sounds. wiring. Check for an open or shorted
valve coil. Repair or replace as
Brake Valve
necessary.

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Left Front Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit
Sensor zero and neutral, Alarm sounds. going to the sensor
Value Too High Limited Speed and Direction frozen at Sensor is out of range. Check sensor
zero and neutral, Alarm sounds. and actuating pin for proper
installation. Repair or replace sensor
and recalibrate.
Value Too Low
Value at 0 V Limited Speed and Direction frozen at Check for 5.0 VDC at the sensor.
zero and neutral, Alarm sounds. Check for damaged wiring going to
the sensor. Check that the % .0 VDC
LED is lit on the TCON board. Repair
or replace as necessary
Right Front Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit
Sensor zero and neutral, Alarm sounds. going to the sensor
Value Too High Limited Speed and Direction frozen at Sensor is out of range. Check sensor
zero and neutral, Alarm sounds. and actuating pin for proper
installation. Repair or replace sensor
and recalibrate.
Value Too Low
Value at 0 V Limited Speed and Direction frozen at Check for 5.0 VDC at the sensor.
zero and neutral, Alarm sounds. Check for damaged wiring going to
the sensor. Check that the % .0 VDC
LED is lit on the TCON board. Repair
or replace as necessary
Left Rear Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit
Sensor zero and neutral, Alarm sounds. going to the sensor
Value Too High Limited Speed and Direction frozen at Sensor is out of range. Check sensor
zero and neutral, Alarm sounds. and actuating pin for proper
installation. Repair or replace sensor
and recalibrate.
Value Too Low
Value at 0 V Limited Speed and Direction frozen at Check for 5.0 VDC at the sensor.
zero and neutral, Alarm sounds. Check for damaged wiring going to
the sensor. Check that the % .0 VDC
LED is lit on the TCON board. Repair
or replace as necessary

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

Right Rear Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit
Sensor zero and neutral, Alarm sounds. going to the sensor
Value Too High Limited Speed and Direction frozen at Sensor is out of range. Check sensor
zero and neutral, Alarm sounds. and actuating pin for proper
installation. Repair or replace sensor
and recalibrate.
Value Too Low
Value at 0 V Limited Speed and Direction frozen at Check for 5.0 VDC at the sensor.
zero and neutral, Alarm sounds. Check for damaged wiring going to
the sensor. Check that the % .0 VDC
LED is lit on the TCON board. Repair
or replace as necessary
Steer Valves - LF, RF, LR, Fault Check Limited Speed and Direction frozen at Check for defective or damaged
RR zero and neutral, Alarm sounds. wiring. Check for an open or shorted
valve coil. Repair or replace as
necessary.
Jib Bellcrank Sensor Value at 5.0 V Primary up and extend disabled, Alarm Power up controller with problem
sounds corrected.
Value Too High
Value Too Low
Value at 0 V
SCON Tilt Sensor Calibration check Display X direction and Y direction not Re-power after entering tilt x axis and
calibrated y axis matrix information
Footswitch Timeout Calibration check Display message on LCD Recycle power
LSJ2RS/LSJ3RO Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Cross-check Rotate, Jib Rotate CCW, Up, Down, corrected.
Platform Up, Down, Rotate and Propel.
Boom Retract and Jib Rotate CW
allowed. Alarm sounds. Display
message on LCD: LSJ2RS/LSJ3RO
CROSS-CHECK FAULT
Jib Bellcrank Loop Valve Fault Check Limited Speed and Direction frozen at Power up controller with problem
zero and neutral, Alarm sounds. corrected.
Platform Level Loop Valve Fault Check Limited Speed and Direction frozen at Power up controller with problem
zero and neutral, Alarm sounds. corrected.
Axle Retract Enable Valve Fault Check Limited Speed and Direction frozen at Power up controller with problem
zero and neutral, Alarm sounds. corrected.
Fuel Level Sensor Value at 5.0 V Display message on LCD Power up controller with problem
corrected.
Value Too High
Value Too Low

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Control System Fault Codes

Error Source Error Type Effects Recovery Actions

PBMAS Safety Envelope Position Check Disable Boom Up, TT Rotate, Propel Return Boom back inside Operational
and Ignition/Fuel. Boom Down and Envelope
Retract allowed. All functions allowed
once boom is lowered back into
envelope. Alarm Sounds. Display
message on LCD PRIMARY BOOM
PBMAS SAFETY ENVELOPE
PBMLS Safety Envelope Position Check Disable Boom Up, Down, Extend, TT Return Boom back inside Operational
Rotate, Propel and Ignition/Fuel. Boom Envelope
Retract allowed. All functions allowed
once boom is lowered back into
envelope. Alarm Sounds. Display
message on LCD PRIMARY BOOM
PBMLS SAFETY ENVELOPE
Boom Envelope Safety Position Check Disable Boom Down, Extend, and Return Boom back inside Operational
Ignition/Fuel. Boom Retract and Up Envelope
allowed. All functions allowed once
boom is lowered back into envelope.
Alarm Sounds. Display message on
LCD PRIMARY BOOM SAFETY
ENVELOPE

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Control System Fault 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)

P_38 P_39 P_10 P_11 P_9A P_9B P_22 P_22R P_12

Turntable tilt Y axis (+5°, secondary OFF OFF OFF

boom not stowed)
Primary Boom Angle (crosscheck) OFF OFF OFF OFF OFF*
Primary Boom Length (crosscheck) OFF OFF OFF OFF OFF*
Primary 2 Cylinder (crosscheck) OFF OFF OFF*
Boom Envelope Safety Interlock OFF OFF OFF
Axle Safety Not Stowed OFF OFF
Axles crosscheck Angle sensor vs. OFF OFF OFF OFF
safety switch(es)
Axle (not fully extended) and TT OFF OFF
Rotate (stowed and in drive disable
zone)
Turntable Tilt Angle (crosscheck OFF OFF OFF OFF OFF
SCON internal sensors 3 in a delta
configuration)
Loss of CAN OFF OFF OFF OFF OFF* OFF
Platform Overload (SCON pin #1) OFF
Platform Out of Level (>10°) OFF
Jib Bellcrank Out of Level (>10°) OFF
Boom Safety (max angle) OFF OFF OFF OFF
Boom Safety (max length) OFF OFF OFF OFF OFF OFF
Axle Retract Safety OFF
Cable Tension (#1 or #2) OFF

* P-9A and P-10 energized if boom is fully retracted as indicated by LSB3RS and LSB2RS

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Control System Fault Codes

Fault Source and Type will display as: Fault Source

Source Type ID Description

“ ID XXX_xx FAULT “ 3 SCON Controller Area Network

4 Primary Boom Angle Zone
Where XXX is the one to three digit Fault Source 5 Primary Boom Length Switches Cross-Check
and xx is the two digit Fault Type. 8 PCON Controller Area Network
TCON - Turntable Controller 9 Engine
18 DCON Controller Area Network
PCON - Platform Controller
20 Boom Extend/Retract Joystick
SCON - Safety Controller 21 Boom Up/Down Joystick
DCON - Drive Controller 26 Boom Extend/Retract Buttons
27 Boom Up/Down Buttons
Fault Type
28 Boom Angle Sensors Cross-Check (SCON)
ID Description
29 LSB2RS/LSB4ES Cross-Check (SCON)
11 Value at 5V
30 Propel Joystick
12 Value too High
35 Propel Valve
13 No Response
40 Turntable Rotate Joystick
15 Value too Low
43 Footswitch Timeout
16 Value at 0V
44 Jib Up/Down Joystick
17 Not Calibrated
48 PBMAS Safety Envelope (SCON)
21 Fault
49 Jib Up/Down Buttons
26 Timeout
50 Jib Up/Down Flow Valve
31 Invalid Setup
52 Steer Joystick
32 Min Cal Too Low
53 Left Front Steer Sensor
33 Min Cal Too High
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

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Control System Fault Codes

Fault Source Fault Source

ID Description ID Description
65 Turntable Level Sensor X-Direction 124 Enable Output Power P7R
66 Turntable Level Snesor Y-Direction 125 Primary Down Power P9A
67 Boom Length Sensors Cross-Check (SCON) 126 IGN/Fuel Power P9B
68 Boom Safety Envelope (SCON) 127 Primary Extend Power P10
70 Turntable Controller - Platform Controller 128 Primary Up Power P11
Software Version
129 Axle Retract Power P12
73 Engine Pressure Sensor 132 Platform Level Power P22
74 Engine Temperature Sensor 133 Primary Up/Down Valve Power P22R
75 LSB2RO/LSB4EO Cross-Check
134 DCON Valve Power P7R
80 TCON/SCON Calibration Inconsistent
142 Turntable Rotate CW Valve
81 Boom Up/Down Flow Valve (Fine) 143 Turntable Rotate CCW Valve
82 Boom Extend/Retract Flow Valve 144 Axle Safety Not Stowed (SCON)
83 Boom Extend/Retract Speed
145 Boom Up Valve
85 Boom Up/Down Speed
146 Boom Down Valve
86 Boom Angle Sensor 147 Platform Overload Switches Inconsistent
90 Jib Rotate Flow Valve (SCON)
91 Turntable Rotate Buttons 148 Boom Extend Valve
92 Turntable Rotate Flow Valve 149 Boom Retract Valve
93 Turntable Rotate Speed 150 Overload Recovery
94 Boom Length Sensor 152 Boom Up/Down Flow Valve (Gross)
95 Jib Rotate Joystick 153 Primary Lockout P1 Valve
98 Platform Level Sensor 154 Primary Lockout P2 Valve
99 Platform Level Buttons 157 Axles Fully Extended Cross-Check (SCON)
110 Platform Rotate Buttons 158 Drive Disable Zone and Axles Not Fully
Extended (SCON)
113 Jib Rotate Buttons
160 Left Front Steer Valve
117 Propel Power P38
118 Turntable Rotate Power P39 161 Right Front Steer Valve

121 Valve Power P6R1 162 Left Rear Steer Valve

163 Right Rear Steer Valve
122 Engine Power P6R2
164 Axle Valve
123 Enable Input Power P7
165 Boom Not Retracted and Chassis Tilted (SCON)

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Control System Fault Codes

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

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description
FMI = Failure Mode Identifier
KWP = Keyword Protocol 51 6 1022 Actuator error EGR-Valve; signal
range check high
SPN FMI KWP Description
51 6 1224 Actuator EGR-Valve; over
51 3 1019 EGR-Valve, short circuit to current
battery
51 6 1230 Actuator error EGR-Valve;
51 3 1024 Position sensor error of actuator Overload by short-circuit
EGR-Valve; signal range check
high 51 7 1016 Actuator position for EGR-Valve
not plausible
51 3 1226 EGR-Valve; short circuit to
battery (A02) 51 11 1231 Actuator error EGR-Valve; Power
stage over temp due to high
51 3 1227 EGR-Valve; short circuit to current
battery (A67)
51 12 1018 Actuator EGR-Valve; powerstage
51 4 1020 EGR-Valve; short circuit to over temperature
ground
51 12 1021 Mechanical actuator defect
51 4 1025 Position sensor error actuator EGR-Valve
EGR-Valve; signal range check
low 51 12 1225 Actuator EGR-Valve; over
temperature
51 4 1228 EGR-Valve; short circuit to
ground (A02) 94 1 474 Low fuel pressure; warning
threshold exceeded
51 4 1229 EGR-Valve; short circuit to
ground (A67) 94 1 475 Low fuel pressure; shut off
threshold exceeded
1 4 1232 Actuator error EGR-Valve;
Voltage below threshold 94 3 472 Sensor error low fuel pressure;
signal range check high
51 5 1015 Actuator error EGR-Valve; signal
range check low 94 4 473 Sensor error low fuel pressure;
signal range check low
51 5 1017 Actuator EGR-Valve; open load
97 3 464 Sensor error water in fuel; signal
51 5 1023 Actuator error EGR-Valve; signal range check high
range check low
97 4 465 Sensor error water in fuel; signal
51 5 1223 Actuator EGR-Valve; open load range check low
51 6 1014 Actuator error EGR-Valve; signal 97 12 1157 Water in fuel level prefilter;
range check high maximum value exceeded

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 108 3 412 Sensor error ambient air press.;
KWP = Keyword Protocol signal range check high
SPN FMI KWP Description 108 4 413 Sensor error ambient air press.;
100 0 734 High oil pressure; warning signal range check low
threshold exceeded 110 0 98 High coolant temperature;
100 0 735 High oil pressure; shut off warning threshold exceeded
threshold exceeded 110 0 99 High coolant temperature; shut
100 1 736 Low oil pressure; warning off threshold exceeded
threshold exceeded 110 3 96 Sensor error coolant temp.;
100 1 737 Low oil pressure; shut off signal range check high
threshold exceeded 110 4 97 Sensor error coolant temp.;
100 3 732 Sensor error oil pressure; signal signal range check low
range check high 111 1 101 Coolant level too low
100 4 733 Sensor error oil pressure sensor; 132 11 1 Air flow sensor load correction
signal range check low factor exceeding the maximum
102 2 88 Charged air pressure above drift limit; plausibility error
warning threshold 132 11 2 Air flow sensor load correction
102 2 89 Charged air pressure above shut factor exceeding drift limit;
off threshold plausibility error

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

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 174 0 481 High low fuel temperature;
KWP = Keyword Protocol warning threshold exceeded
SPN FMI KWP Description 174 0 482 High Low fuel temperature; shut
168 0 1180 Physical range check high for off threshold exceeded
battery voltage 175 0 740 Physical range check high for oil
168 1 1181 Physical range check low for temperature
battery voltage 175 0 745 High oil temperature; warning
168 2 47 High battery voltage; warning threshold exceeded
threshold exceeded 175 0 746 High oil temperature; shut off
168 2 48 Low battery voltage; warning threshold exceeded
threshold exceeded 175 1 741 Physical range check low for oil
168 3 45 Sensor error battery voltage; temperature
signal range check high 175 2 738 Sensor oil temperature;
168 4 46 Sensor error battery voltage; plausibility error
signal range check low 175 2 739 Sensor oil temperature;
171 3 417 Sensor error environment plausibility error oil temperature
temperature; signal range check too high
high 175 3 743 Sensor error oil temperature;
171 4 418 Sensor error environment signal range check high
temperature; signal range check 175 4 744 Sensor error oil temperature;
low signal range check low
172 0 1182 Physical range check high for 190 0 389 Engine speed above warning
intake air temperature threshold (FOC-Level 1)
172 1 1183 Physical range check low for 190 2 421 Offset angle between crank- and
intake air temperature camshaft sensor is too large
172 2 9 Sensor ambient air temperature; 190 8 419 Sensor camshaft speed;
plausibility error disturbed signal
172 2 983 Intake air sensor; plausibility
error
172 3 981 Sensor error intake air; signal
range check high
172 4 982 Sensor error intake air sensor;
signal range check low

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 412 3 1007 Sensor error EGR cooler
KWP = Keyword Protocol downstream temperature; signal
SPN FMI KWP Description range check high

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

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 677 3 956 Starter relay high side; short
KWP = Keyword Protocol circuit to battery
SPN FMI KWP Description 677 3 960 Starter relay low side; short
651 5 568 Injector 1 (in firing order); circuit to battery
interruption of electric connection 677 4 957 Starter relay high side; short
652 3 581 Injector 2 (in firing order); short circuit to ground
circuit 677 4 961 Starter relay low side; short
652 4 587 High side to low side short circuit circuit to ground
in the injector 2 (in firing order) 677 5 958 Starter relay; no load error
652 5 569 Injector 2 (in firing order); 677 12 959 Starter relay; powerstage over
interruption of electric connection temperature
653 3 582 Injector 3 (in firing order); short 703 3 426 Engine running lamp; short circuit
circuit to battery
653 4 588 High side to low side short circuit 703 4 427 Engine running lamp; short circuit
in the injector 3 (in firing order) to ground
653 5 570 Injector 3 (in firing order); 703 5 424 Engine running lamp; open load
interruption of electric connection
703 12 425 Engine running lamp;
654 3 583 Injector 4 (in firing order); short powerstage over temperature
circuit
729 5 545 Cold start aid relay open load
654 4 589 High side to low side short circuit
729 12 547 Cold start aid relay; over
in the injector 4 (in firing order)
temperature error
654 5 571 Injector 4 (in firing order);
898 9 305 Timeout Error of
interruption of electric connection
CAN-Receive-Frame TSC1TE;
676 11 543 Cold start aid relay error. Setpoint
676 11 544 Cold start aid relay open load 1079 13 946 Sensor supply voltage monitor
1 error (ECU)
1080 13 947 Sensor supply voltage monitor
2 error (ECU)

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 1180 1 1463 Exhaust gas temperature
KWP = Keyword Protocol upstream turbine; shut off
SPN FMI KWP Description threshold exceeded

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

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 2798 4 1338 Injector diagnostics; timeout error
KWP = Keyword Protocol of short circuit to ground
SPN FMI KWP Description measurement cyl. Bank 1

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)

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 523008 2 649 Timeout error in Manipulation
KWP = Keyword Protocol control
SPN FMI KWP Description 523009 9 825 Pressure Relief Valve (PRV)
4766 0 1029 Physical range check high for reached maximun allowed
exhaust gas temperature opening count
downstream (DOC) 523009 10 833 Pressure relief valve (PRV)
4766 1 1032 Physical range check low for reached maximun allowed open
exhaust gas temperature time
downstream (DOC) 523212 9 171 Timeout Error of
4768 2 1036 Sensor exhaust gas temperature CAN-Receive-Frame
upstream (DOC); plausibility ComEngPrt; Engine Protection
error 523216 9 198 Timeout Error of
4768 3 1044 Sensor error exhaust gas CAN-Receive-Frame
temperature upstream (DOC); PrHtEnCmd; pre-heat command,
signal range check high engine command

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

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier
523612 12 613 Internal ECU monitoring
KWP = Keyword Protocol
detection reported error
SPN FMI KWP Description
523612 12 614 Internal ECU monitoring
523470 7 876 Maximum rail pressure in limp detection reported error
home mode exceeded (PRV)
523612 12 615 Internal ECU monitoring
523470 11 831 The PRV can not be opened at detection reported error
this operating point with a
523612 12 616 Internal ECU monitoring
pressure shock detection reported error
523470 11 832 Rail pressure out of tolerance 523612 12 617 Internal ECU monitoring
range detection reported error
523470 12 828 Open Pressure Relief Valve 523612 12 618 Internal ECU monitoring
(PRV); shut off condition detection reported error
523470 12 829 Open Pressure Relief Valve 523612 12 619 Internal ECU monitoring
(PRV); warning condition
detection reported error
523470 14 830 Pressure Relief Valve (PRV) is 523612 12 620 Internal ECU monitoring
open
detection reported error
523550 12 980 T50 start switch active for too 523612 12 621 Internal ECU monitoring
long
detection reported error
523601 13 948 Sensor supply voltage monitor 523612 12 623 Internal ECU monitoring
3 error (ECU)
detection reported error
523603 9 126 Timeout Error of 523612 12 624 Internal ECU monitoring
CAN-Receive-Frame AMB; detection reported error
Ambient Temperature Sensor
523612 12 625 Internal ECU monitoring
523605 9 300 Timeout Error of detection reported error
CAN-Receive-Frame TSC1AE;
Traction Control 523612 12 627 Internal ECU monitoring
detection reported error
523606 9 301 Timeout Error of
CAN-Receive-Frame TSC1AR; 523612 12 628 Internal ECU monitoring
Retarder detection reported error
523612 12 387 Internal software error ECU;
injection cut off
523612 12 612 Internal ECU monitoring
detection reported error

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier
523615 3 596 Metering unit (Fuel-System);
KWP = Keyword Protocol
short circuit to battery low side
SPN FMI KWP Description
523615 4 595 Metering unit (Fuel-System);
523612 12 637 Internal ECU monitoring short circuit to ground high side
detection reported error
523615 4 597 Metering Unit (Fuel-System);
523612 12 1170 Internal software error ECU short circuit to ground low side
523612 14 973 Softwarereset CPU SWReset_0 523615 5 592 Metering unit (Fuel-System);
open load
523612 14 974 Softwarereset CPU SWReset_1
523615 12 593 Metering unit (Fuel-System);
523612 14 975 Softwarereset CPU SWReset_2
powerstage over temperature
523613 0 856 Maximum positive deviation of
523619 2 488 Physical range check high for
rail pressure exceeded
exhaust gas temperature
(RailMeUn0)
upstrem (SCR-CAT)
523613 0 857 Maximum positive deviation of
rail pressure in metering unit 523698 11 122 Shut off request from supervisory
monitoring function
exceeded (RailMeUn1)
523717 12 125 Timeout Error of
523613 0 858 Railsystem leakage detected
CAN-Transmit-Frame AmbCon;
(RailMeUn10)
Weather environments
523613 0 859 Maximum negative deviation of
rail pressure in metering unit 523718 3 1488 SCR mainrelay; short circuit to
battery (only CV56B)
exceeded (RailMeUn2)
523613 0 860 Negative deviation of rail 523718 4 1489 SCR mainrelay; short circuit to
ground (only CV56B)
pressure second stage
(RailMeUn22) 523718 5 1486 SCR mainrelay; open load (only
CV56B)
523613 0 862 Maximum rail pressure exceeded
(RailMeUn4) 523718 12 1487 SCR mainrelay; powerstage over
temperature (only CV56B)
523613 1 861 Minimum rail pressure exceeded
(RailMeUn3) 523766 9 281 Timeout Error of
CAN-Receive-Frame Active
523613 2 864 Setpoint of metering unit in
TSC1AE
overrun mode not plausible
523767 9 282 Timeout Error of
523615 3 594 Metering unit (Fuel-System);
CAN-Receive-Frame Passive
short circuit to battery highside
TSC1AE

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 523897 13 561 check of missing injector
KWP = Keyword Protocol adjustment value programming
SPN FMI KWP Description (IMA) injector 3 (in firing order)

523768 9 283 Timeout Error of 523898 13 562 check of missing injector

CAN-Receive-Frame Active adjustment value programming
TSC1AR (IMA) injector 4 (in firing order)

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)

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier
523936 12 169 Timeout Error of
KWP = Keyword Protocol
CAN-Transmit-Frame
SPN FMI KWP Description EEC3VOL2; Engine send
messages
523922 7 1262 Burner Shut Off Valve; blocked
closed 523946 0 1158 Zerofuel calibration injector 1 (in
firing order); maximum value
523922 7 1264 Burner Shut Off Valve; blocked
exceeded
closed
523929 0 109 Fuel Balance Control integrator 523946 1 1164 Zerofuel calibration injector 1 (in
firing order); minimum value
injector 1 (in firing order);
exceeded
maximum value exceeded
523947 0 1159 Zerofuel calibration injector 2 (in
523929 1 115 Fuel Balance Control integrator
firing order); maximum value
injector 1 (in firing order);
exceeded
minimum value exceeded
523947 1 1165 Zerofuel calibration injector 2 (in
523930 0 110 Fuel Balance Control integrator
firing order); minimum value
injector 2 (in firing order);
exceeded
maximum value exceeded
523930 1 116 Fuel Balance Control integrator 523948 0 1160 Zerofuel calibration injector 3 (in
firing order); maximum value
injector 2 (in firing order);
exceeded
minimum value exceeded
523948 1 1166 Zerofuel calibration injector 3 (in
523931 0 111 Fuel Balance Control integrator
injector 3 (in firing order); firing order); minimum value
exceeded
maximum value exceeded
523949 0 1161 Zerofuel calibration injector 4 (in
523931 1 117 Fuel Balance Control integrator
firing order); maximum value
injector 3 (in firing order);
exceeded
minimum value exceeded
523932 0 112 Fuel Balance Control integrator 523949 1 1167 Zerofuel calibration injector 4 (in
firing order); minimum value
injector 4 (in firing order);
exceeded
maximum value exceeded
523960 0 1011 Physical range check high for
523932 1 118 Fuel Balance Control integrator
injector 4 (in firing order); EGR cooler downstream temp.
minimum value exceeded
523935 12 168 Timeout Error of
CAN-Transmit-Frame
EEC3VOL1; Engine send
messages

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier
524016 2 1259 Amount of air is not plausible to
KWP = Keyword Protocol
pump speed
SPN FMI KWP Description
524016 2 1260 Calculated amount of air is not
523960 0 1458 High exhaust gas temperature plausible to HFM reading
EGR cooler downstream;
524016 11 1258 HFM sensor; electrical fault
warning threshold exceeded
524021 11 1263 Burner fuel line pipe leak behind
523960 1 1012 Physical range check low for Shut Off Valve
EGR cooler downstream temp.
524024 11 1302 Deviation of the exhaust gas
523960 1 1459 High exhaust gas temperature temp. setpoint to actual value
EGR cooler downstream; shut off downstream (DOC) too high
threshold exceeded
524028 2 1431 CAN message PROEGRActr;
523980 14 1187 Bad quality of reduction agent plausibility error
detected
524029 2 1432 Timeout Error of
523981 11 918 Urea-tank without heating CAN-Receive-Frame
function (heating phase) ComEGRActr - exhaust gas
523982 0 360 Powerstage diagnosis disabled; recirculation positioner
high battery voltage
524030 7 1440 EGR actuator; internal error
523982 1 361 Powerstage diagnosis disabled; 524031 13 1441 EGR actuator; calibration error
low battery voltage
524032 2 1442 EGR actuator; status message
523988 3 1245 Charging lamp; short circuit to EGRCust is missing
battery
524033 7 1443 EGR actuator; due to overload in
523988 4 1246 Charging lamp; short circuit to Save Mode
ground
524034 3 1438 Disc separator; short circuit to
523988 5 1243 Charging lamp; open load battery
523988 12 1244 Charging lamp; over temp. 524034 4 1439 Disc separator; short circuit to
523998 4 1327 Injector cylinder bank 2 slave; ground
short circuit
524034 5 1436 Disc Separator; open load
523999 12 1328 Injector powerstage output Slave 524034 12 1437 Disc Separator; powerstage over
defect temperature
524014 1 1254 Air pressure glow plug flush line;
below limit

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Control System Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier
524108 9 1669 Timeout error of
KWP = Keyword Protocol
CAN-Transmit-Frame
SPN FMI KWP Description ComEGRTVActr
524035 12 1341 Injector diagnostics; time out 524109 9 1679 Timeout error of
error in the SPI communication CAN-Receive-Frame
ComRxEGRTVActr
524057 2 1505 Electric fuel pump; fuel pressure
build up error 524110 9 1670 Timeout error of
CAN-Transmit-Frame
524097 9 1663 Timeout error of
ComETVActr
CAN-Transmit-Frame
DPFBrnAirPmpCtl 524111 9 1680 Timeout error of
CAN-Receive-Frame
524098 9 1664 Timeout error of
ComRxETVActr
CAN-Transmit-Frame
ComDPFBrnPT 524112 9 1671 Timeout ComITVActr
524099 9 1665 Timeout error of 524113 9 1681 Timeout error of
CAN-Transmit-Frame CAN-Receive-Frame
ComDPFC1 ComRxITVActr
524100 9 1666 Timeout error of 524114 9 1659 Timeout error of
CAN-Transmit-Frame CAN-Transmit-Frame A1DOC
ComDPFHisDat 524115 9 1660 Timeout error of
524101 9 1667 Timeout error of CAN-Transmit-Frame AT1S
CAN-Transmit-Frame
524116 9 1661 Timeout error of
ComDPFTstMon CAN-Transmit-Frame SCR2
524102 9 1674 Timeout error of 524117 9 1662 Timeout error of
CAN-Receive-Frame CAN-Transmit-Frame SCR3
ComRxDPFBrnAirPmpCtl
524118 9 1672 Timeout error of
524103 9 1675 Timeout error of CAN-Receive-Frame
CAN-Receive-Frame ComRxCM1
ComRxDPFBrnAirPmp
524119 9 1673 Timeout error of
524104 9 1676 Timeout error of CAN-Receive-Frame
CAN-Receive-Frame
ComRxCustSCR3
ComRxDPFCtl
524105 9 1668 Timeout error of
CAN-Transmit-Frame
ComEGRMsFlw
524106 9 1677 Timeout error of
CAN-Receive-Frame
ComRxEGRMsFlw1
524107 9 1678 Timeout error of
CAN-Receive-Frame
ComRxEGRMsFlw2

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Control System Fault Codes

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
KWP = Keyword Protocol
SPN FMI KWP Description
524120 9 1682 Timeout error of
CAN-Receive-Frame
ComRxSCRHtDiag
524121 9 1683 Timeout error of
CAN-Receive-Frame
ComRxTrbChActr
524122 9 1684 Timeout error of
CAN-Receive-Frame
ComRxUQSens
524123 9 1685 Timeout error of
CAN-Receive-Frame
ComSCRHtCtl
524124 9 1686 Timeout error of
CAN-Receive-Frame
ComTxAT1IMG
524125 9 1687 Timeout error of
CAN-Receive-Frame
ComTxTrbChActr

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Control System Fault Codes

SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
SPN FMI Description Refer to Engine Manual
27 3 Engine Exhaust Gas Recirculation Valve Valve Position Sensor- Test
Position :Voltage Above Normal
27 4 Engine Exhaust Gas Recirculation Valve Valve Position Sensor - Test
Position :Voltage Be- low Normal
29 3 Accelerator Pedal Position 2 :Voltage Above Analog Throttle Position Sensor Circuit - Test
Normal
29 4 Accelerator Pedal Position 2 :Voltage Below Analog Throttle Position Sensor Circuit - Test
Normal
51 3 Engine Throttle Valve 1Position :Voltage Above Valve Position Sensor - Test
Normal
51 4 Engine Throttle Valve 1 Position :Voltage Below Valve Position Sensor - Test
Normal
91 3 Accelerator Pedal Position 1 :Voltage Above Analog Throttle Position Sensor Circuit - Test
Normal
91 4 Accelerator Pedal Position 1: Voltage Below Analog Throttle Position Sensor Circuit - Test
Normal
97 15 Water In Fuel Indicator :High - least severe Fuel Contains Water
100 2 Engine Oil Pressure :Erratic,Intermittent,or Switch Circuits - Test
Incorrect
100 17 Engine Oil Pressure :Low - least severe (1) Oil Pressure Is Low
102 3 Engine Intake Manifold #1 Pressure:Voltage Engine Pressure Sensor Open or Short Circuit - Test
Above Normal
102 4 Engine Intake Manifold #1 Pressure :Voltage Engine Pressure Sensor Open or Short Circuit - Test
Below Normal
102 20 Engine Intake Manifold #1Pressure :Data Engine Pressure Sensor Open or Short Circuit - Test
Drifted High
102 21 Engine Intake Manifold #1Pressure :Data Engine Pressure Sensor Open or Short Circuit - Test
Drifted Low
105 3 Engine Intake Manifold #1 Engine Temperature Sensor Open or Short Circuit -
Temperature :Voltage Above Normal Test
105 4 Engine Intake Manifold #1 Engine Temperature Sensor Open or Short Circuit-
Temperature :Voltage Below Normal Test
107 2 Engine Air Filter 1Differential Pressure : Switch Circuits - Test
Erratic,Intermittent,or Incorrect
107 15 Engine Air Filter 1Differential Pressure :High - Inlet Air Is Restricted
least severe (1)
107 16 Engine Air Filter 1Differential Pressure :High - Inlet Air Is Restricted
moderate severity(2)

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Control System Fault Codes

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
SPN FMI Description Refer to Engine Manual
108 3 Barometric Pressure :Voltage Above Normal Engine Pressure Sensor Open or Short Circuit -
Test
108 4 Barometric Pressure :Voltage Below Normal Engine Pressure Sensor Open or Short Circuit -
Test
110 3 Engine Coolant Temperature :Voltage Above Engine Temperature Sensor Open or Short Circuit -
Normal Test
110 4 Engine Coolant Temperature :Voltage Below Engine Temperature Sensor Open or Short Circuit -
Normal Test
110 15 Engine Coolant Temperature :High - least Coolant Temperature Is High
severe (1)
110 16 Engine Coolant Temperature:High - moderate Coolant Temperature Is High
severity (2)
152 2 Number Of ECU Resets :Erratic,Intermittent,or ECM Memory - Test
Incorrect
157 0 Engine Injector Metering Rail#1Pressure : High - Fuel Rail Pressure Problem
most severe (3)
157 2 Engine Injector Metering Rail #1 Pressure : Fuel Rail Pressure Problem
Erratic, Intermittent, or Incorrect
157 3 Engine Injector Metering Rail#1 Pressure : Engine Pressure Sensor Open or Short Circuit -
Voltage Above Normal Test
157 4 Engine Injector Metering Rail #1 Engine Pressure Sensor Open or Short Circuit -
Pressure :Voltage Below Normal Test
157 10 Engine Injector Metering Rail#1 Pressure : Engine Pressure Sensor Open or Short Circuit -
Abnormal Rate of Change Test
157 16 Engine Injector Metering Rail#1 Pressure : High - Fuel Rail Pressure Problem
moderate severity (2)
157 17 Engine Injector Metering Rail#1Pressure :Low - Fuel Rail Pressure Problem
least severe (1)
157 18 Engine Injector Metering Rail#1Pressure :Low - Fuel Rail Pressure Problem
moderate severity (2)
168 3 Battery Potential/ Power Input 1 :Voltage Above Ignition Keyswitch Circuit and Battery Supply Circuit
Normal - Test
166 2 Engine Rated Power :Erratic, Intermittent or ECM Memory- Test
Incorrect
166 14 Engine Rated Power :Special Instruction ECM Memory - Test
168 4 Battery Potential/ Power Input 1 :Voltage Below Ignition Keyswitch Circuit and Battery Supply Circuit
Normal - Test

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Control System Fault Codes

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
SPN FMI Description Refer to Engine Manual
172 3 Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit-
Above Normal Test
172 4 Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit -
Below Normal Test
173 3 Engine Exhaust Gas Temperature : Voltage Engine Temperature Sensor Open or Short Circuit -
Above Normal Test
173 4 Engine Exhaust Gas Temperature :Voltage Engine Temperature Sensor Open or Short Circuit-
Below Normal Test
174 3 Engine Fuel Temperature1 :Voltage Above Engine Temperature Sensor Open or Short Circuit -
Normal Test
174 4 Engine Fuel Temperature 1 :Voltage Below Engine Temperature Sensor Open or Short Circuit -
Normal Test
190 8 Engine Speed :Abnormal Frequency,Pulse Engine Speed/Timing Sensor Circuit - Test
Width,or Period
190 15 Engine Speed :High - least severe (1) Engine Over speeds
558 2 Accelerator Pedal1Low Idle Switch :Erratic, Idle Validation Switch Circuit- Test
Intermittent, or Incorrect
593 31 Engine Idle Shutdown has Shutdown Engine This code indicates that an engine idle shutdown is
about to occur. This code does not represent a fault.
If equipped, the warning lamp will come on.
594 31 Engine Idle Shutdown Driver Alert Mode This code indicates that an engine idle shut down has
occurred.This code does not represent a fault. If
equipped,the warning lamp will flash and the
shutdown lamp will come on.
623 6 Red Stop Lamp :Current Above Normal Indicator Lamp Circuit- Test
624 6 Amber Warning Lamp :Current Above Normal Indicator Lamp Circuit - Test
630 2 Calibration Memory :Erratic, Intermittent, or Injector Data Incorrect- Test
Incorrect
637 11 Engine Timing Sensor :Other Failure Mode Engine Speed/Timing Sensor Circuit- Test
639 9 J1939 Network #1 :Abnormal Update Rate CAN Data Link Circuit - Test
639 14 J1939 Network #1:Special Instruction CAN Data Link Circuit - Test
651 5 Engine Injector Cylinder #01 : Current Below Injector Solenoid Circuit - Test
Normal
651 6 Engine Injector Cylinder #01 : Current Above Injector Solenoid Circuit- Test
Normal
651 20 Engine Injector Cylinder#01 :Data Drifted High Injector Data Incorrect- Test
651 21 Engine Injector Cylinder#01 :Data Drifted Low Injector Data Incorrect - Test

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Control System Fault Codes

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
SPN FMI Description Refer to Engine Manual
652 5 Engine Injector Cylinder #02 :Current Below Normal Injector Solenoid Circuit - Test
652 6 Engine Injector Cylinder #02 :Current Above Normal Injector Solenoid Circuit - Test
652 20 Engine Injector Cylinder #02 :Data Drifted High Injector Data Incorrect- Test
652 21 Engine Injector Cylinder #02 :Data Drifted Low Injector Data Incorrect- Test

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

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Control System Fault Codes

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
SPN FMI Description Refer to Engine Manual
1076 2 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test
Valve :Erratic, Intermittent, or Incorrect
1076 5 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test
Valve :Current Below Normal
1076 6 Engine Fuel Injection Pump Fuel Control Solenoid Valve- Test
Valve :Current Above Normal
1081 5 Engine Wait to Start Lamp :Current Below Indicator Lamp Circuit - Test
Normal
1081 6 Engine Wait to Start Lamp :Current Above Indicator Lamp Circuit- Test
Normal
1127 16 Engine Turbocharger 1 Boost Pressure : High - Intake Manifold Air Pressure Is High
moderate severity (2)
1127 18 Engine Turbocharger 1 Boost Pressure :Low - Intake Manifold Air Pressure Is Low
moderate severity (2)
1188 5 Engine Turbocharger Wastegate Actuator 1 Solenoid Valve - Test
Position :Current Below Normal
1188 6 Engine Turbocharger Wastegate Actuator 1 Solenoid Valve - Test
Position :Current Above Normal
1209 3 Engine Exhaust Gas Pressure :Voltage Above Engine Pressure Sensor Open or Short Circuit - Test
Normal
1209 4 Engine Exhaust Gas Pressure :Voltage Below Engine Pressure Sensor Open or Short Circuit- Test
Normal
1221 2 Continuously Monitored Systems ECM Memory- Test
Support/Status ;Erratic,Intermittent,or Incorrect
1221 14 Continuously Monitored Systems Another diagnostic code has requested engine speed
Support/Status : Special Instruction limitation. The warning lamp will flash.The engine
speed is limited to 1200rpm. Troubleshoot all other
diagnostic codes.No troubleshooting is required for
this diagnostic code.
1239 0 Engine Fuel Leakage 1 :High- most severe (3) Fuel Rail Pressure Problem
1485 7 ECM Main Relay :Not Responding Properly Electrical Power Supply- Test
1485 14 ECM Main Relay :Special Instruction Electrical Power Supply- Test

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Control System Fault Codes

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
SPN FMI Description Refer to Engine Manual
2791 5 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve- Test
Control:Current Below Normal
2791 6 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve - Test
Control :Current Above Normal
2791 7 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve- Test
Control :Not Responding Properly
2797 6 Engine Injector Group 1 :Current Above Normal Injector Solenoid Circuit- Test
2797 7 Engine Injector Group 1 :Not Responding Injector Solenoid Circuit - Test
Property
2798 6 Engine Injector Group 2 :Current Above Normal Injector Solenoid Circuit- Test
2840 12 ECU Instance :Failure ECM Memory- Test
2840 14 ECU Instance :Special Instruction Electrical Power Supply- Test
2880 2 Engine Operator Primary Intermediate Speed Throttle Switch Circuit - Test
Select :Erratic, Intermittent,or Incorrect
2880 3 Engine Operator Primary Intermediate Speed Throttle Switch Circuit - Test
Select :Voltage Above Normal
2880 4 Engine Operator Primary Intermediate Speed Throttle Switch Circuit - Test
Select : Voltage Below Normal
2970 2 Accelerator Pedal 2 Low Idle Switch :Erratic, Idle Validation Switch Circuit- Test
Intermittent, or Incorrect
3217 3 After treatment #1 Intake 02 :Voltage Above Oxygen Level- Test
Normal
3217 4 After treatment #1 Intake 02 :Voltage Below Oxygen Level - Test
Normal
3217 5 After treatment #1 Intake 02 :Current Below Oxygen Level- Test
Normal
3217 6 After treatment #1 Intake 02 :Current Above Oxygen Level- Test
Normal
3217 12 After treatment #1 Intake 02 :Failure Oxygen Level- Test
3217 13 After treatment #1 Intake 02 : Out of Calibration Oxygen Level- Test
3217 15 After treatment #1 Intake 02 : High - least Oxygen Level- Test
severe (1)

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Control System Fault Codes

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
SPN FMI Description Refer to Engine Manual
3219 15 After treatment #1 Intake Gas Sensor at Oxygen Level- Test
Temperature : High- least severe (1)
3219 17 After treatment #1 Intake Gas Sensor at Oxygen Level- Test
Temperature : Low - least severe (1)
3222 3 After treatment #1 Intake Gas Sensor Heater : Oxygen Level- Test
Voltage Above Normal
3222 4 After treatment #1 Intake Gas Sensor Oxygen Level- Test
Heater :Voltage Below Normal
3222 5 After treatment #1 Intake Gas Sensor Oxygen Level- Test
Heater :Current Below Normal
3242 3 Particulate Trap Intake Gas Engine Temperature Sensor Open or Short Circuit-
Temperature :Voltage Above Normal Test
3242 4 Particulate Trap Intake Gas Engine Temperature Sensor Open or Short Circuit-
Temperature :Voltage Below Normal Test
3251 0 Particulate Trap Differential Pressure : High- Diesel Particulate Filter Collects Excessive Soot
most severe (3)
3251 3 Particulate Trap Differential Pressure:Voltage Engine Pressure Sensor Open or Short Circuit - Test
Above Normal
3251 4 Particulate Trap Differential Pressure :Voltage Engine Pressure Sensor Open or Short Circuit- Test
Below Normal
3251 7 Particulate Trap Differential Pressure :Not Diesel Particulate Filter Has Differential Pressure
Responding Properly Problem
3251 10 Particulate Trap Differential Diesel Particulate Filter Has Differential Pressure
Pressure :Abnormal Rate of Change Problem
3251 16 Particulate Trap Differential Diesel Particulate Filter Collects Excessive Soot
Pressure :High-moderate severity (2)
3251 17 Particulate Trap Differential Pressure : Low - Diesel Particulate Filter Has Differential Pressure
least severe (1) Problem
3509 2 Sensor Supply Voltage 1: Erratic,Intermittent,or 5 Volt Sensor Supply Circuit- Test
Incorrect
3510 2 Sensor Supply Voltage 2 : Erratic,Intermittent, 5 Volt Sensor Supply Circuit- Test
or Incorrect
3511 2 Sensor Supply Voltage 3 : Erratic,Intermittent,or 5 Volt Sensor Supply Circuit - Test
Incorrect
3697 6 Particulate Trap Lamp Command :Current Indicator Lamp Circuit- Test
Above Normal
3698 6 Exhaust System High Temperature Lamp Indicator Lamp Circuit- Test
Command :Current Below Normal

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Control System Fault Codes

SPN = Suspect Parameter Number

FMI = Failure Mode Identifier
SPN FMI Description Refer to Engine Manual
3702 6 Diesel Particulate Filter Active Regeneration Indicator Lamp Circuit- Test
Inhibited Status : Current Above Normal
4765 3 After treatment #1 Diesel Oxidation Catalyst Engine Temperature Sensor Open or Short Circuit -
Intake Gas Temperature :Voltage Above Test
Normal
4765 4 After treatment #1 Diesel Oxidation Catalyst Engine Temperature Sensor Open or Short Circuit-
Intake Gas Temperature :Voltage Below Test
Normal
5055 17 Engine Oil Viscosity : Low - least severe (1) Oil Contains Fuel
5055 18 Engine Oil Viscosity : Low - moderate severity Oil Contains Fuel
(2)
5099 6 Engine Oil Pressure Low Lamp Data : Current Indicator Lamp Circuit- Test
Above Normal
5319 31 After treatment Diesel Particulate Filter Diesel Particulate Filter Active Regeneration Was
Incomplete Regeneration Interrupted
5324 7 Engine Glow Plug 1: Not Responding Properly Glow Plug Starting Aid - Test
5325 7 Engine Glow Plug 2 :Not Responding Properly Glow Plug Starting Aid - Test
5326 7 Engine Glow Plug 3 :Not Responding Properly Glow Plug Starting Aid - Test
5327 7 Engine Glow Plug 4 :Not Responding Properly Glow Plug Starting Aid - Test
5419 5 Engine Throttle Actuator #1 :Current Below Motorized Valve- Test
Normal
5419 6 Engine Throttle Actuator #1 :Current Above Motorized Valve - Test
Normal
5419 7 Engine Throttle Actuator #1 :Not Responding Motorized Valve- Test
Properly
5571 2 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem
Relief Valve :Erratic, Intermittent, or Incorrect
5571 7 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem
Relief Valve :Not Responding Properly
5571 10 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem
Relief Valve : Abnormal Rate of Change
5571 14 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem
Relief Valve : Special Instruction
5571 16 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem
Relief Valve :High - moderate severity (2)
5826 16 Emission Control System Operator Inducement Refer to "Operator Inducement Codes".
Severity :High - moderate severity (2)

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Schematics

About This Section

Section 5 Schem atics

There are two groups of schematics in this section.

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.

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Wire Circuit Legend

Circuit numbering Circuit prefix

1 Circuit numbers consist of three parts: the C Control
circuit prefix, circuit number and circuit suffix. D Data
The circuit prefix indicates the type of circuit.
The circuit number describes the function of E Engine
the circuit. The circuit suffix provides an G Gauges
abbreviation for the number or may be used to N Neutral
further define the function of this portion of the
P Power
circuit. It also may be used to indicate the final
end of the circuit, i.e., LS or limit sw. R Relay Output
S Safety
2 The circuit number may be used more than
once in a circuit. V Valve

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.

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Wire Circuit Legend

Suffix Definition Suffix Definition

ABV Auxiliary Boom Valve ESP Engine Speed Select
AF Alternator Field FAP Axle Front Position
AFV Auxiliary Forward Valve FB Flashing Beacon
AH Auxiliary Hydraulic Pump FE Function Enable
ANG Angle FL Fuel Select (gas/LP)
APV Auxiliary Platform Valve FLR Filter Restricted
ARV Auxiliary Reverse Valve FLT Filter Switch
ASV Auxiliary Steer/Drive Valve FP Fuel Pump
AXE Axle Extend Valve FS Float Switch
AXO Axle Oscillate FSL Fuel Solenoid
AXR Axle Retract Valve FTS Foot switch Signal
BAT Battery FWD Forward
BEX Boom Extended GEN AC Generator
BRK Brake GND Ground
BST Boom Stowed HG Hydraulic Generator
BV Bypass Valves HRN Horn
CAL Calibrate HS High RPM
CAN CAN Signal IGN Ignition
CAT CATS Module JBD Jib Bellcrank Down
CNK Chain Break JBE Jib Extend
DCN Drive Chassis Controller JBR Jib Retract
DE Drive Enable JBS Jib Sensor
DEL Drive Enable Left JBU Jib Bellcrank Up
DER Drive Enable Right JD Jib Down
DTH Data High JER Jib Extend/Retract Control
DTL Data Low JFC Jib Up/Down Flow Control
EDC Electrical Displacement Control JPL Propel Signal
ENL Envelope Lockout JPW Joystick 5V DC Power
ENV Envelope Light JRL Jib Rotate Left (CCW)
ERL Extend/Retract Lockout JRR Jib Rotate Right (CW)
ESL Engine Status Lamp

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Wire Circuit Legend

Suffix Definition Suffix Definition

JSV Jib Select Valve PLF Platform Level Flow Control
JU Jib Up PLL Propel Lockout
JUD Jib Up/Down Control PLS Primary Boom Extend/Retract Signal
LDS Load Sensor PLU Platform Level Up
LF Left Front PRC Platform Rotate Control
LFS Left Front Steer Sensor PRF Platform Rotate Flow Control
LO Lockout PRL Platform Rotate Left (CCW)
LOF Low fuel PRR Platform Rotate Right (CW)
LPS Lamps PRV Proportional Valve
LR Left Rear PS Pressure Switches
LRS Left Rear Steer Sensor PSE Program Setup Enable
LS Limit Switch PSL Power to Length Sensor
LS Low RPM PSR Pressure Sender
LSR Lift Speed Reduction PTA Platform Tilt Alarm
MFV Multi Function Valve PTS Platform Tilt Sensor
MS Motor Shift (Speed) PUD Primary Boom Up/Down Flow Control
PBD Primary Boom Down PWR Power
PBE Primary Boom Extend PXS Proximity Sensor
PBL Primary Boom Extend/Retract Lockout RAP Axle Rear Position
Valve RCV Recovery
PBR Primary Boom Retract REC Receptacle
PBS Primary Boom Angle Sensor RET Return
PBU Primary Boom Up REV Reverse
PCE Pressure Comp Enable RF Right Front
PCN Platform Control RFS Right Front Steer Sensor
PEL Primary Ext/Ret Lockout RL Retract Lockout
PER Primary Boom Extend/Retract Flow Control RPM RPM
PES Primary Boom Up/Down Signal RR Right Rear
PL Primary Lockout
PLD Platform Level Down

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Wire Circuit Legend

Suffix Definition Suffix Definition

RRS Right Rear Steer Sensor STR Starter
RS Rotary Sensor SUD Sec Boom Up/Down Flow Control
SA Start Aid (Glow Plug or choke) TAX Tilt Alarm X axis
SB Secondary Boom TAY Tilt Alarm Y axis
SBD Sec Boom Down TCN Ground Control
SBE Sec Boom Extend TCN Ground Control Panel
SBL Sec Boom Elevated TET Tether
SBR Sec Boom Retract TRF Turntable Rotate Flow Control
SBS Sec Boom Angle Sensor TRR Turntable Rotate Right (CW)
SBU Sec Boom Up TS Temp Switches
SCC Steering Valve (CCW) TSR Temp Sender
SCW Steering Valve (CW) TSW Test Switch
SEN Sensor TTA Turntable Tilt Alarm
SER Sec Boom Extend/Retract Flow Control TTS Turntable Tilt Sensor
SHD CAN Shield
SLD Secondary Boom Lockout Valve (riser
down)
SLE Secondary Boom Lockout Valve (extend)
SP Spare
SS Speed Sensor
STC Steer Control Signal

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Wire Color Legend

Wire Coloring Power Circuits

1 All cylinder extension colors are solid and all P9A Primary up valve
retract functions are striped black. When using P9B Ignition/Fuel
black wire, the stripe shall be white.
P10 Primary boom extend valve
2 All rotations that are LEFT or CW are solid, P11 Primary boom up valve
RIGHT or CCW are striped and black. When
P12 Axle Retract
the wire is black, the stripe is white.
P22 Jib, Jib Level, Platform Level
3 All proportional valve wiring is striped.
P38 Propel (drive) valves
P39 Turntable rotate flow control valve
Wire Color Legend
BL Blue
BL/BK Blue/Black
BL/RD Blue/Red
BL/WH Blue/White
BK Black
BK/RD Black/Red
BK/WH Black/White
BK/YL Black/Yellow
BR Brown
GR Green
GR/BK Green/Black
GR/WH Green/White
RD Red
RD/BK Red/Black
RD/WH Red/White
OR Orange
OR/BK Orange/Black
OR/RD Orange/Red
WH White
WH/BK White/Black
WH/RD White/Red
YL Yellow

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Wire Color Legend

Color Circuit # Primary Function Color Circuit # Primary Function

RD 1 Primary boom up driver WH/RD 26 Power to temp sender
RD/BK 2 Primary boom down driver RD 27 Auxiliary Power
RD/WH 3 Primary boom up/down flow RD/BK 28 Platform level alarm
control proportional valve driver RD/WH 29 Drive Motor shift (speed)
WH 4 Turntable rotate left valve driver WH 30 Forward/EDC-A
WH/BK 5 Turntable rotate right valve WH/BK 31 Reverse/EDC-B
driver
WH/RD 32 Brake
WH/RD 6 Turntable rotate flow control
proportional valve driver BK 33 Start
BK 7 Primary boom extend BK/WH 34 Start Aid (glow plug or choke)
BK/WH 8 Primary boom retract BK/RD 35 High Engine speed select
BK/RD 9 Primary boom Extend/Retract BL 36 Steer clockwise
proportional valve driver BL/BK 37 Steer counterclockwise
BL 10 Secondary boom up valve driver BL/WH 38 Gasoline
BL/BK 11 Secondary boom down valve BL/RD 39 LPG
driver
OR 40 Limit switch signal stowed
BL/WH 12 Secondary boom up/down flow
OR/BK 41 RPM signal
control proportional valve driver
OR/RD 42 Boom retracted signal
BL/RD 13 Drive enable
GR 43 Jib Up
OR 14 Platform level up valve
GR/BK 44 Jib Down
OR/BK 15 Platform level down valve
GR/WH 45 AC Generator
OR/RD 16 Platform up/down flow control
proportional valve driver WH 46 Horn
GR 17 Platform rotate left valve driver WH/BK 47 Output Power Enable
GR/BK 18 Platform rotate right valve driver WH/RD 48 Work Lamp
GR/WH 19 Jib select valve driver circuit WH/BK 49 Motion Lamp
RD 20 12V DC battery supply BL 50 Auxiliary Boom
WH 21 12V DC ignition supply BL/WH 51 Auxiliary Steer
BK 22 Key switch power to platform BL/RD 52 Auxiliary Platform
WH 23 Power to platform WH/BK 53 Boom envelope safety valve
cutoff
RD 24 Power to warning senders
BK/WH 54 Power to safety interlock switches
WH/BK 25 Power to oil pressure sender
(engine)

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Wire Color Legend

Color Circuit # Primary Function Color Circuit # Primary Function

GR/BK 55 Axle oscillation OR 86 Hydraulic Filter restricted
RD 56 Foot switch/TCON estop power RD 87 Platform Level Safety Power
RD/WH 57 Boom down safety interlock RD/BK 88 Platform Level Safety Output
RD/BK 58 Safety interlock to engine BR 89 Platform Level Safety Ground
GR/WH 59 Chain break circuit RD/BK 90 Proximity Kill
GR/WH 60 Axle extend RD/WH 91 Gate Interlock
GR 61 Axle retract WH/BK 92 Motor Speed (LO/HI)
OR 62 Boom stowed (safety) WH/RD 93 Motor Bypass
OR/RD 63 Power to boom envelope safety WH 94 Load Sensor
switch OR 95 Tether ESTOP return
OR/BK 64 Power for operational switches RD 96 Tether Power
BL/WH 65 Low fuel indication BK 97 Tether ESTOP Power
BL 66 Drive Enable WH 98 J1708 + (high)
BL 67 Secondary boom not stowed BK 99 J1708- (low)
RD 68 Primary Boom lowered WH/RD 100 Outrigger lowered
(operational)
WH/BK 101 Outrigger raised
BL 69 Primary boom #1 extended
OR 102 Pothole protector up
BL/WH 70 Primary boom #2 retracted
OR/RD 103 Pothole protector down
BL/BK 71 Primary boom #2 extended
BK/WH 104 Proprietary Data buss - (I.e. ITT
BL/WH 72 Secondary boom extended or AP)
BL/RD 73 Secondary boom retracted BK/RD 105 Proprietary Data buss + (I.e. ITT
RD 74 Primary #1 Lockout or AP)
RD/WH 75 Primary #2 Lockout GR 106 Spare
BL 76 Primary boom #3 extended RD 107 Alternator Field
WH 77 Lower Angle #1 operational BL/WH 108 Engine Status
WH/BK 78 Upper Angle #2 operational GR/WH 109 Sensor Power
BK 79 Power from TCON ESTOP BK 110 Sensor Return
N/A 80 Can 2.0/J1939 Shield OR 111 Steer Signal
GR 81 Can 2.0/J1939 Low RD 112 Steer Signal to Solenoid Valve
YL 82 Can 2.0/J1939 High OR/RD 113 Multi-function Valve
GR/WH 83 Tilt signal X axis BK/RD 114 Load Moment Overweight
GR/BK 84 Tilt signal Y axis RD/BK 115 Load Moment Underweight
GR 85 Tilt sensor power OR 116 Hydraulic Oil Cooler

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Wire Color Legend

Color Circuit # Primary Function Color Circuit # Primary Function

RD 117 Flashing Beacon RD 141 Primary Boom Angle Signal
OR 118 Lift Speed Reduction Safety

BL 119 Hydraulic Pressure Sensor OR 142 Secondary Boom Angle Signal

Output Safety

OR 120 Oil Cooler Fan BL/RD 143 Drive Enable Left

GR 121 Axle Oscillate Left BL/WH 144 Drive Enable Right

GR/BK 122 Axle Oscillate Right RD/WH 145 Calibrate

RD/BK 123 Primary Boom Angle Signal BL 146 Jib Bellcrank Up Flow Control
Operational BL/BK 147 Jib Bellcrank Down Flow Control
RD/WH 124 Secondary Boom Angle Signal BL/WH 148 Jib Bellcrank Sensor
Operational GR/WH 149 Jib Up/Down Flow Control
WH/RD 125 Secondary Boom Lockout GR/BK 150 Hydraulic Generator Bypass
(Extend Enable)
GR 151 Hydraulic EDC Output
WH/BK 126 Secondary Boom Lockout (Riser
Down Enable) BK 152 Injector Retard
GR 127 ECU Test Switch BK 153 Jib Extend
OR/RD 128 Low Engine Speed BK/WH 154 Jib Retract
RD/BK 129 Descent Alarm OR/RD 155 Pressure Comp. Enable
WH/RD 130 Travel Alarm GR/WH 156 Jib Up/Down
BL 131 Motion Alarm BK/RD 157 Jib Extend/Retract
GR 132 Platform Load Input BL/RD 158 Steer Signal Rocker
GR/WH 133 Platform Load Alarm BL/WH 159 Steer Joystick Signal
GR/BK 134 Key Switch power WH/RD 160 Propel Joystick Signal
BL/WH 135 Fuel Pump WH/BK 161 Secondary Boom Joystick Signal
RD 136 Power to Safety Module OR 162 Joystick 5V DC power
RD/WH 137 Drive Power (P_38) BL/WH 163 Primary Extend/Retract Signal
RD/BK 138 Primary Boom Up/Secondary RD/WH 164 Primary Up/Down Signal
Boom Down-Extend (P_11/30) WH/RD 165 TT Rotate Signal
WH/RD 139 Turntable Rotate Flow Control
Safety (P_39)
OR/RD 140 Boom Envelope Safety

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Wire Color Legend

Color Circuit # Primary Function Color Circuit # Primary Function

OR 166 Boom Length Signal Safety GR 188 Safety cross check
OR/BK 167 Boom Length Signal Operational BK 189 Data Receive
BL/RD 168 Primary Boom Hydraulic Valve BK/WH 190 Data Transmit
Lockout WH/RD 191 Multi-Function Pressure Relief
GR 169 Envelope Active LED WH/BK 192 Jib Rotate Left
WH/RD 170 Load Sense Relay Source WH/RD 193 Jib Rotate Right
WH/BK 171 Load Sense Relay Sink WH/RD 194 Speed Select Input
BL 172 UP/DN Flow Control Ground OR/RD 195 Electric Brake Source
BK 173 Ext/Ret Flow Control Ground YL 196 2.5V Sensor Power
WH 174 Key Switch Power, Ground WH 197 Hour Meter
Position
RD 198 +12V Sensor Power
WH/BK 175 Load Sensor Signal Operational
WH/RD 199 Thermal Switch
GR/WH 176 Secondary Extend/Retract FC
BL 226 Telematics Remote Disable
BL/RD 177 Extend/Retract Lockout
GR 227 Engine Control
BK 178 Control Module Status Light CAN 2.0 / J1939 Low
GR 179 Drive Power Relay YL 228 Engine Control
BK 180 Lift Power Relay CAN 2.0 / J1939 High
OR 181 48 Volt Alternator field (or Battery) BR N/A Ground or Return
RD 182 24 Volt Battery
BL 183 Envelope or Load Sense
Recovery
WH 184 Program setup Enable
WH 185 Encode A
BL 186 Encode B
BL 187 Bootstrap or Program Enable

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Limit Switches and Angle Sensors

Types of Limit Switches Numbering Legend

LS FA 1 L O
There are two types of limit switches, found in LS Limit FA Front Circuit L Load O Operational
various locations throughout the machine: Switch Axle Number moment
mechanical-type operational/safety switches and LT Stringpot RA Rear
Axle
A Angle S Safety

rotation or angle sensors. As in aircraft, which RS Rotary LF Left D Down

features redundant safety systems, each Sensor Front
LR Left Rear E Extend
mechanical operational switch is backed up with a
RF Right R Retract
separate, independently functioning safety switch. Front
RR Right
The mechanical-type operational or safety Rear
J Jib Boom
switches are used to sense a positive displacement
or movement of the limit switch actuator, or arm, as P Boom

the machine moves through its range of operational T Turntable

functions. The rotation or angle sensors utilize

Hall Effect technology and must be calibrated when
replaced. Included in this group are envelope limit
switches which sense the extended length and
angle of the booms and rotational position of the
turntable.
An example is the drive enable limit switch, which
disables the drive function anytime the boom is
rotated past the rear tires, indicated by the 'circle'
end of the drive chassis.In some cases, the engine
will be stopped if safety parameters are exceeded.

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Limit Switches and Angle Sensors

Switches and Sensors - Primary Boom

Index Description Schematic Item Function Controlled Switch Type and
Operation
1 Boom #0 - 151ft (boom fully LSB2RO Activates P1 lockout valve Normally open switch
retracted) Operational Limit Switch during retract.
2 Boom #0 - 151 ft (boom fully LSB2RS Cross-checked with .
retracted) Safety Limit Switch LSB4ES.
3 Jib Rotated CCW Safety Limit Switch LSJ2RS . Normally closed
switch;contacts open
when jib boom is in
stowed position.
4 Jib Rotated CCW Operational Limit LSJ3RO
Switch
5 Boom #2 - 150 ft (boom #2, #3, LSB4EO/S
#4 fully extended)
Operational/Safety Limit Switch
6 Boom #2 - 2. ft' (boom fully retracted) LSB3RS Out of stowed safety
Safety Limit Switch
7 Boom Angle Operational/Safety RSB1AO/S .
Rotary Sensor
8 Boom Angle - 10°Operational Limit LSB1DO
Switch
9 Cable Tension #1Safety Limit Switch LSB5S
10 Cable Tension #2Safety Limit Switch LSB6S
11 Boom Length Operational/Safety LTB1LO/S .
Stringpot
12 Boom #0 - 2 ft (boom fully retracted) LSB3RO Out of stowed. Normally open
Operational Limit Switch switch;contacts close
when primary boom is
fully retracted.

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Limit Switches and Angle Sensors

Switches and Sensors - Turntable

Index Description Schematic Item Function Controlled Switch Type and
Operation
1 Turntable #1 Operational Limit LST1O Activates the drive enable Normally closed
Switch zone when the turntable is switch;contacts open
rotated in the right direction. when turntable is
rotated in the right
direction.
2 Turntable #1 Safety Limit Switch LST1S Prevents the turntable from Normally closed
rotating past either rear tire switch;contacts open
when the axles are when turntable is
retracted. rotated past either
rear tire with the axles
retracted.
3 Turntable #2 Operational Limit LST2O Activates the drive enable Normally closed
Switch zone when the turntable is switch;contacts open
rotated in the left direction. when turntable is
rotated in the left
direction.

counterweight end platform end

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Limit Switches and Angle Sensors

Switches and Sensors - Drive Chassis

Index Description Schematic Item Function Controlled Switch Type and
Operation
1 Front Axle #1Extended Safety Limit LSFA1ES Disables boom functions when Normally open
Switch. axles are retracted. switch;contacts close
when axle is fully
extended.
2 Rear Axle #1Extended Safety Limit LSRA1ES Disables boom functions when Normally open
Switch axles are retracted. switch;contacts close
when axle is fully
extended
3 Front Axle #1 Angle Operational Rotary RSFA1SO Provides front axle positioning
Sensor information for adjusting
steering neutral setting during
axle extension.
4 Rear Axle #1 Angle Operational Rotary RSRA1SO Provides rear axle positioning
Sensor information for adjusting
steering neutral setting during
axle extension.
5 Left Front #1 Steer Operational Rotary RSLF1SO Provides wheel position
Sensor information during steering.
Master wheel in all steer modes
except rear steer.
6 Right Front #1 Steer Operational Rotary RSRF1SO Provides wheel position
Sensor information during steering.
7 Left Rear #1 Steer Operational Rotary RSLR1SO Provides wheel position
Sensor information during steering.
Master wheel when in rear
steer mode.
8 Right Rear #1 Steer Operational Rotary RSRR1SO Provides wheel position
Sensor information during steering.

Blue side

Blue end Yellow end

Front Rear
Square end Circle end
Platform end

Yellow side

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Circuit Connector Legend

Number Description Number Description
J1 Molex connector on toggle/LED pcb J37 2 pin Deutsch DTP connector (swivel-lower)
J9 Ribbon connector from TCON to membrane J38 6 pin Deutsch DTP connector (swivel-lower)
#1 J55 6 pin Deutsch DT connector for platform tilt
J10 Ribbon connector from TCON to membrane sensor (S6)
#2 J57 4 pin Deutsch DTP connector for throttle
J11 Black 23 pin AMP connector on TCON solenoid
J12 Black 35 pin AMP connector on TCON J58 2 pin Deutsch DT pri boom up/dwn F.C. valve
J13 White 23 pin AMP connector on TCON #1 (Y45)

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)

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Circuit Connector Legend

Number Description Number Description

J87 2 pin Deutsch DT two speed motor stroke J135 2 pin Deutsch DT jib bellcrank up valve (Y85)
valve (Y27) J136 2 pin Deutsch DT jib bellcrank down valve
J91 2 pin Deutsch DT RR steer right valve (Y55) (Y86)
J92 2 pin Deutsch DT RR steer left valve (Y56) J137 4 pin Deutsch DT front axle safety switch
J93 2 pin Deutsch DT LR steer right valve (Y57) (LSFA1ES)

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

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Circuit Connector Legend

Number Description Number Description

J160 6 pin Deutsch DT front axle sensor (RSFA10) J210 2 pin Deutsch DT 10 deg angle oper
J161 6 pin Deutsch DT rear axle sensor (RSRA10) (LSB1DO)

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

J202 2 pin Deutsch DT jib rotate CW valve (Y89)

J203 2 pin Deutsch DT jib rotate CCW valve (Y90)
J205 4 pin Deutsch DT jib rotated CW (LSJ2RO)
J206 2 pin Deutsch DT jib rotated CCW (LSJ3RO)
J207 4 pin Deutsch DT 3.5ft extend safety
(LSB3RS)
J208 12 pin Deutsch DT lower limit to zero tube
cable
J209 4 pin Deutsch DT 151ft retract safety
(LSB2RS)

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Connector Pin Legend

Pin location - 4 pin Pin location - 23 pin Pin location - 35 pin connector
connector connector

Pin location - 12 pin

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

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Connector Pin Legend

J11 Black 23 Pin Connector
Pin NO. Type* Signal Name Circuit NO. Signal Description
P11-01 REF P CON G ND GNDPCON-BR PCON ground
P11-02 PWR P CON P OWE R P 52PCON-WH Power output to PCON. Unregulate d 12V auto motive
power.
P11-03 RLY HORN RELAY COIL C46HRN-WH Power to service horn relay
P11-04 CONT OUT PWR ENBL C47OUT-WH/BK Bi -directional relay control signal. Normally low,
switched to 12V PWR-PCON ESTOP is high and the
emergency stop switch is closed.
P11-05 PWR PWR-PCON ESTOP P 23PCO N-BK Output signal to PCON. Provides 12V power to the
emergency stop switch.
P11-06 CONT P _7 S 56PRV -RD Bi -directional relay control signal. Normally low,
switched to 12V when PCON POWER & OUT PWR
ENBL are active and the foot-switch is closed.
P11-07 CONT P _22 P 56PRV -RD/WH Relay control signal or power signal o f PCON, normally
controlled by the platform tilt safety switch output, but
may be over-ridden in bypass / recovery mode.
P11-08 RLY SPARE RLY OUT Power relay coil
P11-09 RLY FLASHING BEACON RLY C117FB-RD Flashing beacon relay
P11-10 COM CAN SHIELD Termination for CA N cable shield
P11-11 CONT S ERV /CAL MODE C145CAL-RD/WH 12V calibration mode signal for SCON
P11-12 NOT USED No connection
P11-13 !BOOT !BOOT
P11-14 FAC CAL FREQ 1 Calibration frequency 1
P11-15 NOT USED No connection
P11-16 FAC CAL FREQ 2 Calibration frequency 2
P11-17 COM CAN LO W D81CAN(-)-G R CAN bus connection
P11-18 COM CAN HIGH D82CAN(+ )-YL CAN bus connection
P11-19 NOT USED No connection
P11-20 NOT USED No connection
P11-21 REF DIAG GND Ground
P11-22 PWR DIAG PWR (12V ) 12V power for TCON, DCON, and SCON
P11-23 NOT USED No connection

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Connector Pin Legend

J12 Black 35 Pin Connector
Pin No. Type Signal Name Circuit No. Signal Description
P12-01 REF SCON ECU GND SCONGND-BR Ground for SCON ECU
P12-02 PWR DCON ECU PWR P21DCON-WH 12V power for ECU power
P12-03 PWR P_6R1 P53LS-WH/BK Safety circuit power (to DCON, SCON)
P12-04 PWR P_6R2 P54ENG-BK/WH Safety circuit power (to SCON)
P12-05 PWR P_7R S56PRV-RD Safety circuit power (to DCON, SCON)
P12-06 PWR P_9A P57PBD-RD/WH Safety circuit for boom down (power)
P12-07 PWR P_9B P58LS-RD/BK Safety circuit for fuel/ignition (power)
P12-08 PWR P_10 S59CNBK-GR/WH Safety circuit for boom extend - cable break (power)
P12-09 PWR P_11 S140ENL-OR/RD Safety circuit for boom up (power)
P12-10 PWR P_12 C61AXRT-GR Safety circuit for axle retract (signal)
P12-11 DI P_14 Monitoring circuit
P12-12 DI P_18 Monitoring circuit
P12-13 PWR OPER SW PWR C64LS-OR/BK Power for Operational Limit Switches
P12-14 DI LOW FUEL - FST1S C65LOFL-BL/WH Low fuel float switch
P12-15 DI DRV ENBL R - LST1O C144DER-BL/WH Turntable stowed switch 1 (drive enable right)
P12-16 DI LSB1DO C68PBD-BL Input - primary boom lowered (10 deg operational)
P12-17 DI 12V SIG TO PLD C64LS-OR/BK Tied high (12V) for proper operation of PLD
P12-18 PWR OPER SW PWR C64LS-OR/BK Power for Operational Limit Switches
P12-19 DI LSB3RO C70PBE-BL/WH Input - primary boom fully retracted for PLD (3ft retracted
operational)
P12-20 DI LSB4EO C71PBE-BL/BK Input - primary boom sections 2-4 extended (150ft extended
operational)
P12-21 DI LSB2RS S69PBE-BK/WH Input - primary boom section #1 retracted (151ft retracted
safety)
P12-22 DI SPARE DI Spare
P12-23 OM P1 SEQ SX-180 only
P12-24 OM P2 SEQ SX-180 only
P12-25 REF SNSR GND SNSR GND-BR Ground to angle sensor
P12-26 SNSR SNSR PWR (5V) P109ANG-GR/WH Power to angle sensor (5.0VDC)
P12-27 AI AUX HYD PRESSURE IN Signal from auxiliary hydraulic pressure sensor
P12-28 DI DRV ENBL L - LST2O C143DEL-BL/RD Turntable stowed switched 2 (drive enable left)
P12-29 DI SPARE DI Spare
P12-30 DI SPARE DI Spare
P12-31 DI BOOM STOWED Override for boom transport
P12-32 AI RSB1AO (BOOM ANGLE)C123PBS-RD/BK Primary angle sensor input to TCON
P12-33 AI LTB1LO (BOOM C167PRS-OR/BK Primary length sensor input to TCON
LENGTH)
P12-34 PWR P_30 Safety power feed to P_30
P12-35 REF VALVE RETURN VLVRET-BR Valve return

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Connector Pin Legend

J13 White 23 Pin Connector
Pin NO. Type Signal Name Circuit NO. Signal Description
P13-01 REF VALVE_RETURN_1 Valve ground return (return for throttle RPM
solenoid)
P13-02 RLY THROTTLE C35RPM-BK/RD Provides power to throttle actuator relay
P13-03 RLY FUEL/IGNITION C21IGN-WH Provides power to engine shutdown actuator relay
coil
P13-04 RLY START AID RLY C34SA-BK/WH Provides power to choke/glow plug relay
P13-05 PM FWD PWM Forward proportional PWM valve drive
P13-06 PM REV PWM Reverse proportional PWM valve drive
P13-07 RLY SERVICE HORN C46HRN-WH Output to service horn
P13-08 OM KEYSWITCH PWR ON/OFF valve drive to LP selector on throttle body
P13-09 RLY STARTER RELAY C33STR-BK Tier IV engines only
P13-10 EDC EDC FWD C30EDC(+)-WH Electrical displacement control (forward)
P13-11 EDC EDC REV C31EDC(-)-WH/BK Electrical displacement control (reverse)
P13-12 AI OIL_PRESSURE C25PSR-WH/BK Input from oil pressure sender
P13-13 AI OIL/WATER_TEMP C26TSR-WH/RD Input from oil/water temperature sender
P13-14 REF TT_TILT_SNSR_GND Ground for turntable tilt sensor
P13-15 SNSR TT_TILT_SNSR_PWR Supply voltage for turntable tilt sensor
(SNSR_5V)
P13-16 REF VALVE_RETURN_2 Valve ground return (return for glow plugs)
P13-17 PWR P_38 PWR TO PROPEL S137PLL-RD/WH Safety power feed to propel drivers from SCON
P13-18 FAC ALTERNATOR RPM C41RPM-OR/BK Input from alternator indicating engine RPM
P13-19 PWR P_39 PWR TO TTROT S139TRF-WH/RD Safety power feed to turntable rotate flow control
FC valve
P13-20 AI TT_TILT_X_AXIS Analog input from tilt sensor (spare)
P13-21 AI TT_TILT_Y_AXIS Analog input from tilt sensor (spare)
P13-22 OM AC GENERATOR V45HG-GR/WH Output to ON/ OFF generator valve
P13-23 REF VALVE_RETURN_3 Valve ground return

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Connector Pin Legend

J14 White 35 Pin Connector
Pin NO. Type Signal Name Circuit NO. Signal Description
P14-01 REF VALVE_RETURN_4 VLVRET4-BR Valve ground return
P14-02 PM PRI BM U/D FC VLV #2 V03PUD2-GR/WH Proportional PWM valve drive (primary boom up/down
valve #2 -GROSS-)
P14-03 PM PRI BM E/R FC VLV V09PER-BK/RD Proportional PWM valve drive (primary boom
extend/retract)
P14-04 PM TT ROT FC VLV V06TRF-WH/RD Proportional PWM valve drive (turntable rotate)
P14-05 PM PRI BM U/D FC VLV #1 V03PUD1-RD/WH Proportional PWM valve drive (primary boom up/down
valve #1 -FINE-)
P14-06 PM SPARE PM Proportional PWM valve drive
P14-07 OM PRI_UP_VLV V01PBU-RD ON/OFF valve drive (primary boom up)
P14-08 OM PRI_DOWN_VLV V02PBD-RD/BK ON/OFF valve drive (primary boom down)
P14-09 OM PRI_EXTEND_VLV V07PBE-BK ON/OFF valve drive (primary boom extend)
P14-10 OM PRI_RETRACT_VLV V08PBR-BK/WH ON/OFF valve drive (primary boom retract)
P14-11 NOT USED No connection
P14-12 OM SPARE OM ON/OFF valve drive
P14-13 RLY DRIVE LIGHT RELAY C49LP-WH/BK Feeds power to drive light relay
P14-14 REF VALVE_RETURN_5 Valve ground return
P14-15 DI HYD_FILTER1 DI Grounding switch input from hydraulic filter #1
P14-16 DI HYD_FILTER2 DI Grounding switch input from hydraulic filter #2
P14-17 DI BOOM REVERSE LOAD DI Grounding switch input from boom reverse proximity
switch
P14-18 DI BOOM OVERLOAD DI Grounding switch input from boom overload switch
P14-19 OH SPARE OM ON/OFF valve drive
P14-20 OH SPARE OM ON/OFF valve drive
P14-21 OM SPARE OM ON/OFF valve drive
P14-22 NOT USED No connection
P14-23 OM MULTI_FUNCT_VLV ON/OFF valve drive
P14-24 NOT USED No connection
P14-25 OM ROTATE_CW_VLV V04TRL-WH ON/OFF valve drive (rotate clockwise)
P14-26 OM ROTATE_CCW_VLV V05TRR-WH/BK ON/OFF valve drive (rotate counter-clockwise)
P14-27 REF VALVE_RETURN_7 VLVRET7-BR Valve ground return
P14-28 NOT USED No connection
P14-29 NOT USED No connection
P14-30 REF VALVE_RETURN_6 VLVRET6-BR Valve ground return
P14-31 NOT USED No connection
P14-32 OM AUX_RELAY C27AUX-RD Relay coil feed
P14-33 OM PRESS COMP ENBL VLV #2 V155PCE2-OR/BL ON/OFF valve drive (Activate Pressure Comp Valve on
pump)
P14-34 OM PRESS COMP ENBL VLV #1 V155PCE1-OR/RD ON/OFF valve drive (Activate Pressure Comp Valve on
pump)
P14-35 OM AC GENERATOR BYPASS V150BV-GR/BK Output to ON/OFF Generator Bypass
VALVE

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Connector Pin Legend

J17 - 16 Pin Connector
Pin NO. Type Signal Name Circuit NO. Signal Description
J17-1 PWR PWR TO TCON ESTOP BL/BK Power to TCON E-Stop (P1)
J17-2 NOT USED
J17-3 PWR SERV/CAL MODE WH Service/calibration mode signal
J17-4 CONT ECU POWER C47OUT-WH/BK Power to TCON ECU
J17-5 PWR PCON MODE P23PCON-BK Output signal to PCON. Provides 12V power to the
emergency stop switch.
J17-6 CONT OUTPUT PWR ENABLE C47OUT-WH/BK Function enable
J17-7 PWR P_6R1 P53LS-BK/WH Safety circuit power
J17-8 PWR P_7R S56PRV-RD/BK Safety circuit power
J17-9 CONT SERV. OR OPER. REC. SRV REC-WH Service/recovery mode signal
J17-10 PWR P_22 P56PRV-RD Safety circuit power (platform level bypass)
J17-11 CONT OPER. REC. P_15-OR/BK Power to PLD while in recovery mode
J17-12 CONT P_7 P_7 PLAT-GR/WH Power for function enable while in recovery mode
J17-13 PWR P_11 S140ENL-OR/RD Power for boom up in service mode
J17-14 CONT TCON MODE RD/WH TCON mode power
J17-15 CONT ALARM PWR ALM PWR-BL TCON alarm signal
J17-16 REF ALARM GND ALM GND-BR TCON alarm ground

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Connector Pin Legend

J21 Black 23 Pin Connector
Pin NO. Type* Signal Name Circuit NO. Signal Description
P21-01 REF PCON GND GNDPCON-BR PCON ground
P21-02 PWR PCON PWR P52PCON-WH Power for PCON
P21-03 NOT USED
P21-04 CONT P_7 S56PRV-RD 12V when footswitch is pressed
P21-05 NOT USED
P21-06 NOT USED
P21-07 PWR P_22 P56PRV-RD/WH Power for platform level up/down, jib up/down,
and jib bellcrank up/down in TCON mode
P21-08 NOT USED
P21-09 NOT USED
P21-10 COM CAN SHIELD Termination for CAN cable shield
P21-11 NOT USED
P21-12 NOT USED
P21-13 !BOOT !Boot
P21-14 NOT USED
P21-15 CONT OUT PWR ENBL C47OUT-WH/BK 12V when platform E-Stop is pulled out
P21-16 CONT HRN RLY CNTRL C46HRN-WH Output from horn membrane switch on PCON
P21-17 COM CAN LOW D81CAN(-)-GR CAN bus connection
P21-18 COM CAN HIGH D82CAN(+)-YL CAN bus connection
P21-19 NOT USED
P21-20 NOT USED
P21-21 NOT USED
P21-22 NOT USED
P21-23 PWR PWR-PCON P23PCON-BK Power to PCON E-Stop
ESTOP

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Connector Pin Legend

J22 White 35 Pin Connector
Pin NO. Type* Signal Name Circuit NO. Signal Description
P22-01 REF VALVE_RETURN_1 VLVRET1-BR Valve ground return
P22-02 OM SPARE OM ON/OFF valve drive
P22-03 OM PLAT ROT CCW V18PRR-GR/BK ON/OFF valve drive (platform rotate CCW - right)
P22-04 OM PLAT ROT CW V17PRL-GR ON/OFF valve drive (platform rotate CW - left)
P22-05 PM JIB UP V43JU-GR Proportional PWM valve drive (jib up)
P22-06 PM JIB DOWN V44JD-GR/BK Proportional PWM valve drive (jib down)
P22-07 PM PLAT LEVEL UP V14PLU-OR Proportional PWM valve drive (platform level up)
P22-08 PM PLAT LEVEL DOWN V15PLD-OR/BK Proportional PWM valve drive (platform level down)
P22-09 OM SPARE OM ON/OFF valve drive
P22-10 REF PROX KILL GND
P22-11 DI PROX Kill IN C90PXS-RD/BK Jib Stowed signal (from LSJ4SO)
P22-12 REF LOAD SNSR GND GR/YL Ground return for load sense switch
P22-13 DI LOAD SNSR IN OR Digital signal input for load sense switch (CE)
P22-14 PWR LOAD SNSR PWR BK 12V Power for load sense switch
P22-15 PWR SAFE PL TILT OUT C88PJTS-RD/BK Power for platform level up/down, jib up/down, and jib
bellcrank up/down in PCON mode (platform and Jib
bellcrank tilt sensor - safety)
P22-16 PWR LIMIT SWITCH PWR C64LS-OR/BK Power for footswitch, prox sensor, and limit switches
P22-17 CONT FOOT SW RTN C56FTS-RD Power from footswitch (P_7 circuit)
P22-18 DI JIB ROTATED CCW C215JRO-WH/RD Jib rotated CCW operational signal (from LSJ3RO)
P22-19 REF PL TILT SNSR GND P85RET-BR Ground for platform tilt sensor (operational)
P22-20 AI PL TILT SNSR C84TAY-GR/BK Analog signal input for platform tilt sensor
(operational)
P22-21 SNSR PL TILT SNSR PWR P85PTS-RD 5V Supply voltage for platform tilt sensor (operational)
P22-22 REF SAFE PL TILT GND P89RET-BR Ground for platform tilt sensor (safety)
P22-23 PWR SAFE PL TILT PWR P87PTS-RD 12V Supply voltage for platform tilt sensor (safety)
P22-24 PM JIB ROTATE CW V192JRL-WH Proportional PWM valve drive (jib rotate CW - left)
P22-25 OM SPARE OM ON/OFF valve drive
P22-26 OM SPARE OM ON/OFF valve drive
P22-27 PM JIB ROTATE CCW V193JRR-WH/BK Proportional PWM valve drive (jib rotate CCW - right)
P22-28 PM JIB BELLCRANK LEVEL UP V146JBU-BL Proportional PWM valve drive (jib bellcrank up)
P22-29 PM JIB BELLCRANK LEVEL V147JBD-BL/BK Proportional PWM valve drive (jib bellcrank down)
DOWN
P22-30 SNSR JIB SNSR PWR P109JBS-GR/WH 5V Supply voltage for jib bellcrank level sensor
P22-31 REF JIB SNSR GND P110JBS-BK Ground for jib bellcrank level sensor
P22-32 AI JIB SNSR IN C148JBS-BL/WH Analog signal input for jib bellcrank level sensor
P22-33 DI JIB ROTATED CCW C214JRS-RD/WH Jib rotated CCW signal (from LSJ2RS)
P22-34 REF VALVE_RETURN_2 VLVRET2-BR Valve ground return
P22-35 NOT USED No Connection

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Connector Pin Legend

Circuit Board Connector
Pin NO. Type* Signal Name Circuit NO. Signal Description
J29-1 REF JOYSTICK_GND_2 JSGND2-BR Joystick signal ground (JC8)
J29-2 REF JOYSTICK_GND_3 JSGND3-BR Joystick signal ground (JC2)
J29-3 SNSR JOYSTICK_PWR_2 P162JPW2-OR Joystick power (JC8)
J29-4 SNSR JOYSTICK_PWR_3 P162JPW3-OR Joystick power (JC2)
J29-5 NOT USED
J29-6 AI STEER - ROCKER C158STC-BL/RD Rocker steer signal from propel joystick (JC3)
J29-7 AI STEER - DUAL C159STC-BL/WH Dual axis steer signal from propel joystick (JC3)
AXIS
J29-8 AI PROPEL C160JPL-WH/RD Propel signal from propel joystick (JC3)
J29-9 AI SPARE AI
J29-10 AI PRIMARY EXT/RET C163PES-BL/WH Boom extend/retract signal from boom joystick (JC2)
J29-11 AI PRIMARY C164PLS-RD/WH Boom up/down signal from boom joystick (JC7)
UP/DOWN
J29-12 AI TT ROTATE C165TRS-WH/RD Turntable rotate CW/CCW signal from boom joystick
(JC7)
J29-13 SNSR JOYSTICK_PWR_4 P162JPW4-OR Joystick power (JC7)
J29-14 SNSR JOYSTICK_PWR_1 P162JPW1-OR Joystick power (JC3)
J29-15 REF JOYSTICK_GND_4 JSGND4-BR Joystick signal ground (JC7)
J29-16 REF JOYSTICK_GND_1 JSGND1-BR Joystick signal ground (JC3)

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Connector Pin Legend

Circuit Board Connector

Pin NO. Type* Signal Name Circuit NO. Signal Description
J169-1 AI JIB ROTATE C213JRS-RD/BK Jib rotate CW/CCW signal from jib joystick
(JC8)
J169-2 REF GND GND4-BR Joystick case ground (JC7)
J169-3 AI JIB UP/DOWN C156JUD-GR/WH Jib up/down signal from jib joystick (JC8)
J169-4 AI SPARE AI
J169-5 REF GND GND3-BR Joystick case ground (JC2)
J169-6 REF GND GND6-BR Return from platform level toggle switch (TS9)
J169-7 DI PLAT LVL UP PLAT LVL UP-OR Platform level up signal (TS9)
J169-8 DI PLAT LVL DOWN PLAT LVL DN-OR/BK Platform level down signal (TS9)
J169-9 REF GND GND2-BR Joystick case ground (JC8)
J169-10 PWR OUT PWR ENBL ESTOP RET-BK Return from PCON E-Stop (P2) - output
power enable circuit
J169-11 !BOOT
J169-12 REF GND GND12-BR PCON alarm ground
J169-13 REF GND GND1-BR Joystick case ground (JC3)
J169-14 DI SPARE DI
J169-15 DI SPARE DI
J169-16 REF GND
J169-17 DI PLAT ROT CCW PLAT ROT Platform Rotate CCW signal (TS7)
CCW-GR/BK
J169-18 DI PLAT ROT CW PLAT ROT CW-GR Platform Rotate CW signal (TS7)
J169-19 CONT ALARM ALARM(+)-RD/BK PCON alarm signal
J169-20 PWR PWR-PCON ESTOP PWR-RD/BK Power to PCON E-Stop (P2)
ESTOP

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Connector Pin Legend

Circuit Board Connector

Pin NO. Type* Signal Name Circuit NO. Signal Description
J1-1 DI PWR-HORN HORN PWR-RD Power for Service Horn button
J1-2 REF RET-HORN HORN RET-GR Return for Service Horn button
J1-3 DI GENERATOR ON/OFF GEN ON/OFF-GR/WH Generator toggle switch input
J1-4 DI AUXILIARY PUMP AUX PUMP-RD Auxiliary Pump toggle switch input
J1-5 DI START ASSIST START ASST-BK/WH Start Assist (Glow Plug) toggle switch input
J1-6 DI ENGINE START ENG START-BK Engine Start toggle switch input
J1-7 DI DRIVE ENABLE DRV ENBL-BL/WH Drive Enable toggle switch input
J1-8 NOT USED
J1-9 DI AXLE RETRACT AXLE RET-GR Axle Retract toggle switch input
J1-10 REF GND1 GND1-BR Ground for toggle switch inputs
J1-11 DI ENGINE SPEED ENG SPEED-BK/RD Engine Speed toggle switch input
SELECT
J1-12 DI AXLE EXTEND AXLE EXT-GR/WH Axle Extend toggle switch input
J1-13 DI DRIVE SPEED SELECT DRV SPEED-RD/WH Drive Speed toggle switch input
J1-14 DI STEER MODE SELECT STR MODE L-OR Steer Mode Select - Left toggle switch input
LEFT
J1-15 NOT USED
J1-16 NOT USED
J1-17 DI STEER MODE SELECT STR MODE R-OR/BK Steer Mode Select - Right toggle switch input
RIGHT
J1-18 DI SPARE Spare (option) toggle switch input
J1-19 NOT USED
J1-20 REF GND2 GND2-BR Ground for toggle switch inputs

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Connector Pin Legend

J31 Black 23 Pin Connector
Pin NO. Type* Signal Name Circuit NO. Signal Description
P31-01 REF DCON ECU GND GNDDCON-BR DCON ground
P31-02 PWR DCON ECU PWR P21DCON-WH Power for DCON
P31-03 PWR P_6R1 P53LS-WH/BK Power for motor speed and brake valves
P31-04 NOT USED
P31-05 PWR P_7R S56PRV-RD Power for axle extend and steer valves
P31-06 PWR P_12 C61AXRT-GR Power for axle retract valve
P31-07 NOT USED
P31-08 REF AXLE NOT RET GND Not used
P31-09 DI AXLE NOT RET RTN Not used (active low)
P31-10 COM CAN SHIELD Not used
P31-11 COM RS232 RXD Not used
P31-12 COM RS232 TXD Not used
P31-13 !BOOT !BOOT
P31-14 NOT USED
P31-15 DI AXLE NOT EXT RTN Not used (active high)
P31-16 NOT USED
P31-17 COM CAN LOW D81CAN(-)-GR CAN bus connection
P31-18 COM CAN HIGH D82CAN(+)-YL CAN bus connection
P31-19 COM RS232GND Not used
P31-20 AI FRONT AXLE C60FAP-GR/WH Analog signal input for front axle position sensor
POSITION SENSOR (RSFA1O)
P31-21 AI REAR AXLE POSITION C60RAP-GR/WH Analog signal input for rear axle position sensor
SENSOR (RSRA1O)
P31-22 AI SPARE Not used (0-5V Analog Input - Biased to 2.5V)
P31-23 PWR AXLE NOT EXT PWR P61LSA-GR Power to axle safety switches (LSFA1ES and
LSRA1ES)

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Connector Pin Legend

J32 White 23 Pin Connector
Pin NO. Type* Signal Name Circuit NO. Signal Description
P32-01 REF VALVE_RETURN_1 VLVRET1-BR Valve ground return
P32-02 OM AXLE RETRACT V61AXRT-GR ON/OFF valve drive (axle retract)
P32-03 OM AXLE EXTEND V60AXEX-GR/WH ON/OFF valve drive (axle extend)
P32-04 OM MOTOR SPEED V29MS-RD/WH ON/OFF valve drive (motor speed)
P32-05 OM SPARE Not used
P32-06 OH SPARE Not used (paired with P32-07)
P32-07 OH SPARE Not used (paired with P32-06)
P32-08 OM RR STEER RIGHT V36RRS-BL ON/OFF valve drive (right rear steer right)
P32-09 OM RR STEER LEFT V37RRS-BL/BK ON/OFF valve drive (right rear steer left)
P32-10 AI RR STEER SNSR C111RRS-OR Analog signal input for right rear steer sensor
P32-11 AI LR STEER SNSR C111LRS-OR Analog signal input for left rear steer sensor
P32-12 AI RF STEER SNSR C111RFS-OR Analog signal input for right front steer sensor
P32-13 AI LF STEER SNSR C111LFS-OR Analog signal input for left front steer sensor
P32-14 REF VALVE_RETURN_2 VLVRET2-BR Valve ground return
P32-15 OM BRAKE V32BRK-WH/RD ON/OFF valve drive (brake)
P32-16 OM LR STEER RIGHT V36LRS-BL ON/OFF valve drive (left rear steer right)
P32-17 OM LR STEER LEFT V37LRS-BL/BK ON/OFF valve drive (left rear steer left)
P32-18 OM RF STEER RIGHT V36RFS-BL ON/OFF valve drive (right front steer right)
P32-19 REF STEER SNSR GND P110RT-BK Ground to steer sensors
P32-20 SNSR STEER SNSR PWR (5.0 P109ANG-GR/WH Power to steer sensors (5.0VDC)
VDC)
P32-21 OM RF STEER LEFT V37RFS-BL/BK ON/OFF valve drive (right front steer left)
P32-22 OM LF STEER RIGHT V36LFS-BL ON/OFF valve drive (left front steer right)
P32-23 OM LF STEER LEFT V37LFS-BL/BK ON/OFF valve drive (left front steer left)

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Connector Pin Legend

J121 Gray 12 Pin Connector
Pin NO. Type* Signal Name Circuit NO. Signal Description
P121-01 DI LOAD SENSE S132LDS-BL/WH Digital input from load sense switch
P121-02 DI LSB3RS+LSB2RS S42BRT-OR/RD Digital input from LSB3RS+LSB2RS limit
(FULLY RETRACTED) switches
P121-03 COM RS232 TXD RS232 serial - connected through tee harness
P121-04 DI CALIBRATION IN C145CAL-RD/WH Digital input from calibration switch in TCON
P121-05 COM RS232 RXD RS232 serial - connected through tee harness
P121-06 COM CAN HIGH D82CAN(+)-YL CAN bus connection
P121-07 COM CAN LOW D81CAN(-)-GR CAN bus connection
P121-08 OM P_12 C61AXRT-GR Safety circuit for axle retract (power)
P121-09 PWR P_7R S56PRV-RD Safety circuit power (from TCON)
P121-10 OM P_38 S137PLL-RD/WH Safety circuit for propel (power)
P121-11 OM P_39 S139TRF-WH/RD Safety circuit for turntable rotate (power)
P121-12 REF GND SCONGND-BR Ground for SCON ECU

J122 Black 12 Pin Connector

Pin NO. Type* Signal Name Circuit NO. Signal Description
P122-01 PWR ECU PWR P21DCON-WH Power for SCON/DCON ECU
P122-02 AI LTB1LS (BOOM C166PRS-OR Analog signal input for boom length (safety)
LENGTH)
P122-03 AI RSB1AS (BOOM C141PBS-RD Analog signal input for boom angle (safety)
ANGLE)
P122-04 DI AXLES EXTENDED C60AXEX-GR/WH Digital input from LSFA1ES and LSRA1ES
(power from DCON)
P122-05 DI LSB4ES (150FT S76BEX-BL Digital input from LSB4ES
EXTENDED)
P122-06 DI LST1S (DRIVE ENABLE) S13DE-BL/RD Digital input from LST1S limit switch
P122-07 PWR P_6R1 P53LS-WH/BK Safety circuit power (from TCON)
P122-08 OM P_11 S140ENL-OR/RD Safety circuit for boom up (power)
P122-09 PWR P_6R2 P54ENG-BK/WH Safety circuit power (from TCON)
P122-10 OM P_9B P58LS-RD/BK Safety circuit for fuel/ignition (power)
P122-11 PWR P_6R1 P53LS-WH/BK Safety circuit power (from TCON)
P122-12 OM P_9A+P_10 P57PBD-RD/WH Safety circuit for boom down and extend (power)

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Engine Relay and Fuse Panel Legend - Deutz TD2011L04i

and Perkins 1104D-44T Models

Number Component Description

1 CR77A PCE#1
2 CR28 Engine / Fuel Relay
3 CR17 Hydraulic Oil Cooler Fan Relay
4 CR77B PCE#2
5 CR41 Flashing Beacon Relay
6 CR5 Horn Relay
7 F20 Fuse, 20A, RPM Solenoid
8 F23 Fuse, 30A, Eng / Start / Alt
9 F22 Fuse, 60A, Glow Plug
10 F7 Fuse, 20A, Hydraulic Oil Cooler / Horn
11 B3BAT Fused Power from B1
12 B1BAT Power from Battery
13 R21PIGN Ignition
14 02PGND Ground
15 CR1 Start Relay
16 CR15 Glow Plug Relay

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Engine Relay and Fuse Panel Legend - Deutz TD 2.9 L4

Models

Number Component Description

1 CR39 Engine Shutdown
2 CR77A PCE #1
3 CR2 Engine Alt. Relay
4 CR17 Hydraulic Oil Cooler / Fan Relay
5 CR28 Fuel Pump
6 CR77B PCE #2
7 CR41 Flashing Beacon Relay
8 CR5 Horn Relay
9 F27 Fuse, 20A, RPM Solenoid
10 F23 Fuse, 30A, Eng / Start/ Alt
11 F22 Fuse 60A, Glow Plug
12 F7 Fuse, 20A, Hydraulic Oil Cooler / Horn
13 B3BAT Fused Power from B1
14 B1BAT Power from Battery
15 R21PIGN Ignition
16 02PGND Ground
17 CR17 Glow Plug Relay

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Engine Relay and Fuse Panel Legend - Perkins 854F-34T

Models

Number Component Description

1 CR77A PCE#1
2 CR2 Engine Alt
3 CR17 Hydraulic Oil Cooler Fan Relay
4 CR77B PCE#2
5 FX1 Fuse, 30A, ECU Power
6 FX2 Fuse, 20A, Key Switch Power
7 CR41 Flashing Beacon Relay
8 CR5 Horn Relay
9 F27 Fuse, 20A, RPM Solenoid
10 F23 Fuse, 30A, Eng / Start / Alt
11 F22 Fuse, 60A, Glow Plug
12 F7 Fuse, 20A, Hydraulic Oil Cooler / Horn
13 B3BAT Fused Power from B1
14 B1BAT Power from Battery
15 R21PIGN Ignition
16 02PGND Ground
17 CR1 Engine Starter
18 CR81 ECU Power

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Electrical Symbols Legend

Battery Motor Horn or alarm Flashing beacon Gauge

Diode Hour meter LED Fuse with amperage Foot switch

Circuit connection Limit Switch Power relay Coil with suppression Fuel or RPM solenoid

Connection - no Circuits crossing no Quick disconnect Circuit breaker with

Battery separator
terminal connection terminal amperage

Service Bypass Key

Main Key switch Steer sensor Auxiliary Pump Tilt sensor
switch

Emergency Stop Hydraulic oil cooling

Relay Power relay Gauge sending unit
button fan

Coolant temperature Diode starting aid,

Oil temperature Oil pressure switch Control relay contact
switch - normally glow plug or flame
switch normally open normally closed normally open
open ignitor

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Hydraulic Symbols Legend

Orifice with size Check valve Shut off valve Brake

Pump, bi-directional Motor, 2 speed

Pump, fixed displacement Motor, bi-directional
variable displacement bi-directional

Pump, prime mover (engine Shuttle valve. 2 position,

Cylinder, double acting Differential sensing valve
or motor) 3 way

Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator
valve setting proportional valve

Solenoid operated
Pilot operated 3 position,
Pressure reducing valve Flow divider/combiner valve 2 position, 3 way directional
3 way shuttle valve
valve

Solenoid operated
Counterbalance valve with Pilot operated 2 position, 2 position, 2 way solenoid
3 position 4 way directional
pressure and pilot ratio 2 way directional valve valve
valve

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Control Circuits - Horn

225
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Control Circuits - Horn

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Control Circuits - Power

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Control Circuits - Power

228
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Control Circuits - Can Bus

229
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Control Circuits - Can Bus

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Control Circuits - Deutz TD2011L04i Engine

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Control Circuits - Deutz TD2011L04i Engine

232
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Control Circuits - Deutz TD 2.9 L4Engine

233
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Control Circuits - Deutz TD 2.9 L4 Engine

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Control Circuits - Perkins 1104D-44T Engine

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Control Circuits - Perkins 1104D-44T Engine

236
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Control Circuits - Perkins 854F-34T Engine

237
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Control Circuits - Perkins 854F-34T Engine

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Control Circuits - Axle Extend/Retract

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Control Circuits - Axle Extend/Retract

240
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Control Circuits - Steering

241
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Control Circuits - Steering

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Control Circuits - Propel

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Control Circuits - Propel

244
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Control Circuits - Turntable Rotate

245
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Control Circuits - Turntable Rotate

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Control Circuits - Boom Up/Down

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Control Circuits - Boom Up/Down

248
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Control Circuits - Boom Extend/Retract

249
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Control Circuits - Boom Extend/Retract

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Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate

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Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate

252
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Control Circuits - Platform Level and Jib Bellcrank Level

253
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Control Circuits - Platform Level and Jib Bellcrank Level

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Control Circuits - Platform Load Sense

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Control Circuits - Platform Load Sense

256
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Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights

257
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Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights

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Control Circuits - Recovery PLD

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Control Circuits - Recovery PLD

260
 December 2019 Service and Repair Manual

Control Circuits - Telematics

261
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Control Circuits - Telematics

262 SX™-180 Part No. 1268497GT

December 2019 Service and Repair Manual

Generator Receptacle Wiring- ANSI/CSA

Part No. 1268497GT SX™-180 263

Service and Repair Manual December 2019

Generator Receptacle Wiring - ANSI/CSA

264
 December 2019 Service and Repair Manual

Generator Receptacle Wiring - CE

265
Service and Repair Manual December 2019

Generator Receptacle Wiring - CE

266 SX™-180 Part No. 1268497GT

December 2019 Service and Repair Manual

Perkins 1104D-44T Engine Electrical Schematic

Part No. 1268497GT SX™-180 267

Service and Repair Manual December 2019

Perkins 1104D-44T Engine Electrical Schematic

268
 December 2019 Service and Repair Manual

Perkins 854F-34T Engine Electrical Schematic

269
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Perkins 854F-34T Engine Electrical Schematic

270 SX™-180 Part No. 1268497GT

December 2019 Service and Repair Manual

Perkins 854F-34T Engine Harness

Part No. 1268497GT SX™-180 271

Service and Repair Manual December 2019

Perkins 854F-34T Engine Harness

272
 December 2019 Service and Repair Manual

Deutz TD 2.9 L4 Engine Electrical Schematic

273
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Deutz TD 2.9 L4 Engine Electrical Schematic

274 SX™-180 Part No. 1268497GT

December 2019 Service and Repair Manual

Deutz TD 2.9 L4 Engine Harness

Part No. 1268497GT SX™-180 275

Service and Repair Manual December 2019

Deutz TD 2.9 L4 Engine Harness

276
 December 2019 Service and Repair Manual

Hydraulic Schematic, to SX180H-604

277
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Hydraulic Schematic, to SX180H-604

278 SX™-180 Part No. 1268497GT

December 2019 Service and Repair Manual

Hydraulic Schematic, from SX180H-605 to SX180H-612

Part No. 1268497GT SX™-180 279

Service and Repair Manual December 2019

Hydraulic Schematic, from SX180H-605 to SX180H-612

280
December 2019 Service and Repair Manual

Hydraulic Schematic, from SX180H-613

Part No. 1268497GT SX™-180 281

Service and Repair Manual December 2019

Hydraulic Schematic, from SX180H-613

282
 TCON MEMBRANE PANEL (MS2)

1
TO
uP

AC GENERATOR BYPASS VALVE P14-35 V150BV-GR/BK

2 PRESS COMP ENABLE VLV #1 P14-34 C155PCE1-OR/RD
TO
uP

TT ROTATE CW PRESS COMP ENABLE VLV #2 P14-33 C155PCE2-OR/BL

3 AUX RELAY P14-32 C27AUX-RD
PLAT ROT CW NOT USED P14-31
TO
uP

4 VALVE_RETURN_6 P14-30 VLVRET6-BR

JIB DOWN TO PLD NOT USED P14-29
5 NOT USED P14-28
Z

PLAT LVL DOWN VALVE_RETURN_7 P14-27 VLVRET7-BR

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

ROTATE CW VLV P14-25 V04TRL-WH Y52 TT ROT CW VLV (J70) VLVRET6-BR

TO
uP

7
2

NOT USED P14-24

1

V45HG-GR/WH Y91 AC GENERATOR VLV (J216)

JIB UP MULTI FUNCT VLV P14-23 VLVRET3-BR
8
TO

NOT USED P14-22

uP
TO
uP

PLAT ROT CCW SPARE OM P14-21

9 TO PLD
SPARE OM P14-20
C155PCE1-OR/RD
C155PCE2-OR/BK
TO
uP

V150BV-GR/BK

TT ROTATE CCW SPARE OM P14-19

VLVRET6-BR

VLVRET6-BR
TO

10
uP

V45HG-GR/WH

BOOM OVERLOAD DI P14-18

VLVRET8-BR

TURTLE
86

87 85

TO PLD BOOM REVERSE LOAD DI P14-17 C155PCE1-OR/RD

11 TO PLD
2
FUNCTION

HYD_FILTER2 DI P14-16
1
30

R155PCE1-OR/RD Y74 FUNCTION ENABLE VALVE #1 (J166)

JIB ROT CCW
ENABLE
TO
uP

HYD_FILTER1 DI P14-15
87a
TO

CR77B
uP

12
P_30

VALVE_RETURN_5 P14-14
#1

RABBIT DRIVE LIGHT RELAY P14-13

TO
uP

13
SPARE OM P14-12
86

87 85

BOOM EXT C155PCE2-OR/BK

Y

TO PLD NOT USED P14-11

2
1

14 R155PCE2-OR/BK Y74A FUNCTION ENABLE VALVE #2 (J166A)

30
2
1

FUNCTION

PRI RETRACT VLV P14-10 V08PBR-BK/WH Y80 PRI RET VLV (J63)
87a

BOOM DOWN
ENABLE
2

TO PLD
1
TO

V07PBE-BK Y79 PRI EXT VLV (J62)

uP

PRI EXTEND VLV P14-09

CR77A

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

C25PSR-WH/BK OIL PRESSURE

1

TT ROT FC VLV P14-04 V06TRF-WH/RD Y77 TT ROT CW/CCW F.C. (J69)

J144-5
TO
uP

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

VALVE_RETURN_4 P14-01 VLVRET4-BR

uP

1
R21IGN-WH 06GND-BR
30

FUEL SOLENOID
FUNCTION HARNESS

J144-7

J144-8

VLVRET8-BR B1ENG-RD
87a
ENG FUEL
2

TO PLD
1
J14 WHITE 35 PIN

2 V75PRLO-RD/WH Y88 PRI LOCKOUT VLV #2 (J220)

2

C21IGN-WH

RELAY
1

V74PRLO-RD Y87 PRI LOCKOUT VLV #1 (J219)

CR28
TO
uP

FUNCTION

3
HARNESS

J153

NOT USED
J172-2

TO PLD
HYDRAULIC
4
J172-1
87 87a

FAN

03GND-BR
4
X

NOT USED OIL COOLER FAN

30
3

COOLER
R116HYD-OR
J146 4
3
2
1

LOWER LS

5
HARNESS

RELAY
1 2
MULTI FUNCTION VLV RECOVERY SIGNAL
SEC BOOM EXT/RET FC RECOVERY SIGNAL

BOOM UP C116HYD-OR 03GND-BR

OTS1
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

AUXILIARY BK GLOW PLUGS

BK IN CYLINDER HEADS
8
J224 GREY 8 PIN

ENG SPEED CAN LOW (-) P224-08 D227CAN- GR

BK
8
TELEMATICS

CAN HIGH (+) P224-07 D22CAN+ YL P34SA-BK/WH R34SA-BK/WH

GLOW 86 30
85 87

9
7

NOT USED REMOTE DISABLE P224-06 C226TEL-BL C34SA-BK/WH 01GND-BR GLOW PLUG
TO CAN GATEWAY
ENGINE CAN BUS
6

FOOTSWITCH STATUS P224-05 RELAY

S56PRV-RD
RELAY

10
5

PLUG
CR15

+ BUTTON KEYSWITCH POWER P224-04 P23PCON-BK

J120
4

(TIER IV)

IGNITION STATUS P224-03 C21TEL-WH

11
A B C D
3

C31EDC(-)-WH/BK
P_11

- BUTTON GROUND P224-02 GND-BR DUAL

2
P_6R1

SYS_POWER P224-01 B1BAT-RD COIL

12
P_9A

EDC
1
W

B1ENG-RD

SCRL FWD/ENTER C30EDC(+)-WH

P_39

VALVE_RETURN_3 P13-23 VLVRET3-BR

13 AC GENERATOR VALVE P13-22 V45HG-GR/WH 02GND-BR
SCROLL R
TT_TILT_Y_AXIS P13-21
P34SA-BK/WH
TO

B3BAT/14-RD
uP

BK-GND BK
TT_TILT_X_AXIS
6 AMP

14 PULL IN
3

P13-20 HI/LO SPEED

V75PRLO-RD/WH

STRT ASST WH-PULL IN WH

P_39 PWR TO TT ROT FC P13-19 S139TRF-WH/RD HOLD SOLENOID
1 2
VLVRET8-BR

V74PRLO-RD

CB9

RD-HOLD RD
P_22R

C21TEL-WH

C226TEL-BL
P_7R
P_10

15
J57

ALTERNATOR RPM P13-18 C41RPM-OR/BK

P_30

START P_38 PWR TO PROPEL P13-17 S137PLL-RD/WH

RELAY
HORN
TO

J10
uP

D22

VALVE_RETURN_2 P13-16
CR5
TO

TO
uP

uP

TT_TILT_SNSR_PWR P13-15 SERVICE

H2

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

OIL PRESSURE P13-12 C25PSR-WH/BK B3BAT/14-RD RELAY

87a

OTHER ENGINE SCHEMATICS

EDC REV P13-11 C31EDC(-)-WH/BK BAT GND-BR

SEE SCHEMATIC PAGES FOR

(P15)+(ECU POWER)
EDC FWD P13-10 C30EDC(+)-WH C41RPM-OR/BK
TO HORN
J144-1
TO
uP

WH-PULL IN

BUTTON STARTER RELAY P13-09 C33STR-BK C107AF-RD

J144-2
RD-HOLD
5V

LP P13-08
IND.
EXCT.

SERVICE HORN P13-07 C46HRN-WH

BAT.

STA.
ALTERNATOR

-
V

P_7R REV PWM P13-06

REGULATOR
TO uP

CB7

15A

P_7 FWD PWM P13-05 ALTERNATOR

~SLP MODE (~SM)

P_6R1 START AID RLY P13-04 C34SA-BK/WH

AUX HYD (AH)

FUEL/IGNITION P13-03 C21IGN-WH C21IGN-WH

FUNC ENABLE (FE)

BAT.
P_7

P34SA-BK/WH

C
B3BAT/14-RD

THROTTLE P13-02 C35RPM-BK/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

(ACTIVE HIGH SHOWN)

TO

(~SM)+(AH)
uP

AUX+
BAT+

GND-
(~SM)+(AH)

PUMP
F23 ENG/START/ALT

AUX.
CR80
TELEMATICS
RELAY
5V 12V

BY DEUTZ
C229TEL-BL/BK

F19 DRIVE LIGHTS

GND
(OE)

F20 HI/LO SPEED

S137PLL-RD/WH

F22 GLOW PLUG

F7 OIL COOLER

AUX HYD
S139TRF-WH/RD

C35RPM-BK/RD PUMP
5 VOLT PR1
13

74HC08 10
12
(~SM)+(AH)

SOLENOID
4

74HC08 1
9

2
74HC08 5

(OPTION)
74HC08

PUMP
AUX.
FUSES
7
((~SM)+(AH))(OE) 6
((~SM)+(AH))(P_7) 8

3
14

05GND-BR
14

86

87 85
((~SM)+(AH))(P_22)
OUT PWR ENABLE (OE)

C33STR-BK
74HC08

STARTER
TO
(TM)(FE)

uP
P_6R1
P_22R
P_22

B1ENG-RD
P_7R

R33STR-BK
30

P16-04
STARTER

B1ENG-RD RELAY
U

BATECU GND P16-03 GND-BR F23

3

W/BAT CBL

30A
STARTER

INTEGRAL

SYS BAT GND P16-02 GND-BR

2

F20 STARTER
POWER
RELAY

P_7 SYS BAT PWR P16-01 B1BAT-RD B1BAT-RD

HARN

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
IN2 OUT 1

IN1 OUT 1
ST OUT 2

POWER HARN

POWER

ENGINE BLOCK
BTS650
BTS650

IN OUT

OUT
BTS650

F22
IN OUT

P_1
P_6R2

HARN
HARN

ENG

-
GND
GND

GND

60A
B1
Vbb

Vbb
IN1

IN2
Vbb

AUX MAIN
IN

IS
IS
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

TWO 6 VOLT
BATTERIES
SEPARATE
4 GA WIRE

AUX HYD
(BM STOWED)

BATTERY
(~SM)+(AH)
U95

S139TRF-WH/RD
S137PLL-RD/WH
74HC08 10
T

HARNESS
8

ENGINE
((~SM)+(AH))(BM STOWED)
SEC BOOM EXT/RET FC RECOVERY SIGNAL

MULTI FUNCTION VLV RECOVERY SIGNAL

VLVRET8-BR
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
SEC BOOM RET RECOVERY SIGNAL

J215
AUXILIARY HYD RECOVERY SIGNAL

BOOM DWN RECOVERY SIGNAL

V75PRLO-RD/WH
BOOM RET RECOVERY SIGNAL

2
Vbb BTS621

LOWER LS
IN1 OUT 1
ST OUT 2

HARNESS

V74PRLO-RD
TO HORN BUTTON

GND
PWR TO TCON ESTOP

OUT PWR ENABLE

(P15)+(ECU POWER)

IN2
P_30

P_22
P_9B

P23PCON-BK
S56PRV-RD

B3BAT/14-RD
GND-BR

22 21

11

BK/WH
4321

LSB2RS
4

NC

RED NC

S69PBR-BK/WH S69PBR-BK/WH BR BK
RD/WH 151FT RET SAFETY
12
J20A 3

ORN

S42BRT-OR RD RD J209
BOOM STOWED
S

5 VOLT

NO
13
21

BK/WH
P_6R1

LSB2RO
P_11

4321
P_9A

NC
PCON POWER

BK
12

C64LS-OR/BK BK BL 151FT RET OPER

P_6R2

P_10
P_7

22

14
P_7R

ORN
TCON MODE

BLU

C69PBR-BK C69PBR-BK WH BR J214

LSB4EO/S
NO
13
21

BK/WH
4321

150FT EXT OPER/SAFETY

J20 1 2 3

NC

S76BEX-BL BL BK
C64LS-OR/BK WH/BK BL J213
22

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

OR/BK BL 3FT EXT OPER

22

14
BLU

C70PBE-BL/WH C70PBE-BL/WH GR/BK BR

AUXILIARY HYD RECOVERY SIGNAL

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

C64LS-OR/BK RD/BK BL 10 DEG ANGLE OPER

2 1

22

14
OUT PWR ENABLE
PWR TO TCON ESTOP

C68PBD-BL C68PBD-BL WH/BK BR

J210
7
TO HORN BUTTON
(P15)+(ECU POWER)

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

BK DRV ENABLE LEFT

22

14
ORN
YEL

WH J125
ORN NO
13
21

C64LS-OR/BK RD LST1O
21

NC

C144DER-BL/WH C144DER-BL/WH BR DRV ENABLE RIGHT

BK
22

14

WH J124
C64LS-OR/BK FST1S
C65LOFL-BL/WH C65LOFL-BL/WH LOW FUEL FS
VLVRET BR VLVRET-BR
LST1S
ORN NO
13
21

C64LS-OR/BK C64LS-OR/BK RD DRV ENABLE

4 321

NC

S13DE-BL/RD BR
BK SAFETY
22

14

RED

WH J126
VALVE_RETURN_8 P12-35 VLVRET8-BR
J208

6 J199

P_30 P_30 P12-34

LTB1LO (BOOM LENGTH) P12-33 C167PRS-OR/BK C167PRS-OR/BK C167PRS-OR/BK BL YL LTB1LO
6

RSB1AO (BOOM ANGLE) P12-32 C123PBS-RD/BK P109ANG-GR/WH P109ANG-GR/WH GR BR BOOM LENGTH

4

OPER
BOOM STOWED P12-31 SNSRGND-BR SNSRGND-BR OR
Q

OR
5

SPARE DI P12-30 C166PRS-OR RD BL

3

SPARE DI P12-29 P109ANG-GR/WH BK BK LTB1LS

1

DRV ENBL L - LST2O P12-28 C143DEL-BL/RD SNSRGND-BR WH RD BOOM LENGTH

2

SAFETY
TO
uP

AUX HYD PRESSURE IN P12-27

SNSR PWR (5V) P12-26 P109ANG-GR/WH
B3BAT/14-RD
S139TRF-WH/RD
S137PLL-RD/WH

4567

21

11

P57PBD-RD/WH RD BK/WH LSB3RS

4321

NC

NC

SNSR GND P12-25 SNSRGND-BR P63LS-OR/RD WH BK

TO

3.5FT EXT SAFETY

uP

S42BRT-OR OR RD/WH
RED
22

12

P2 SEQ VLV P12-24 V75PRLO-RD/WH S42BRT-OR GR RD J207

LOCKOUT VALVE #1 SIG
J20

TO PLD P1 SEQ VLV P12-23 V74PRLO-RD

6 J114

SPARE DI P12-22
P109ANG-GR/WH P109ANG-GR/WH BL
LSB2RS P12-21 S69PBR-BK/WH RSB1A0
SNSRGND-BR SNSRGND-BR GR
TO
uP

LSB4EO P12-20 C71PBE-BL/BK BOOM ANGLE

C123PBS-RD/BK C123PBS-RD/BK WH OPER
LSB3RO P12-19 C70PBE-BL/WH
4

PRI BOOM LENGTH 3' STATUS TO PLD C141PBS-RD YL

LSB2RO P12-18 C69PBR-BK
3

SNSRGND-BR BK RSB1AS
TO
uP

12V SIG TO PLD P12-17 C64LS-OR/BK BOOM ANGLE

P109ANG-GR/WH RD SAFETY
PRI BOOM LENGTH 151' STATUS LSB1DO P12-16
1

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

OPER SW PWR P12-13 C64LS-OR/BK

J20B
P_22
P_9B

P_18 P12-12
P_14 P12-11
2 1

2 1

S59CNBK-GR/WH S59CNBK-GR/WH GR/BK

P_12 P12-10 C61AXRT-GR SJ2-OR/BK RD/BK
11 12

P_11 P12-09 S140ENL-OR/RD

4 3 2 1

BK/WH
P_10 P_10 P12-08 S59CNBK-GR/WH P63LS-OR/RD BL/BK
J208

J222A

P_9B P_9B P12-07 P58LS-RD/BK

J122-BLACK 12
S59CNBK-GR/WH

P_9A P12-06 P57PBD-RD/WH

MULTI FUNCTION VLV RECOVERY SIGNAL

U32 PIN SCON

SEC BOOM EXT/RET FC RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL

P_7R P_7R P12-05 S56PRV-RD MODULE

P63LS-OR/RD

U31
SJ2-OR/BK
AUXILIARY HYD RECOVERY SIGNAL

SJ2-OR/BK

P_6R2 P_6R2 P12-04 P54ENG-BK/WH P57PBD-RD/WH P57PBD-RD/WH P122-12 P_9A+P_10

U30
BOOM DWN RECOVERY SIGNAL

SEC BOOM RET RECOVERY SIGNAL

P_6R1
BOOM RET RECOVERY SIGNAL

P_6R1 P12-03 P53LS-WH/BK P53LS-WH/BK P122-11

DCON/SCON ECU PWR P12-02 P21DCON-WH P58LS-RD/BK P58LS-RD/BK P122-10 P_9B
PRI BOOM LENGTH 151' STATUS
PRI BOOM LENGTH 3' STATUS

P54ENG-BK/WH
LOCKOUT VALVE #1 SIGNAL

SCON ECU GND P12-01 GNDSCON-BR P54ENG-BK/WH P122-09 P_6R2

OUT PWR ENABLE
PRI BOOM DOWN STATUS

PWR TO TCON ESTOP

S140ENL-OR/RD S140ENL-OR/RD P122-08 P_11 4 32 1 21

(P15)+(ECU POWER)

TO HORN BUTTON

BK
BK

BR
BR

BK/WH

BL
BL

BK/WH

P53LS-WH/BK P122-07 P_6R1

S13DE-BL/RD P122-06 LST1S (DRIVE ENABLE)
LIMIT SWITCH HARN
P_22

S76BEX-BL P122-05 LSB4ES (150FT EXTENDED)

J12 BLACK 35 PIN
O

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

GNDSCON-BR GNDSCON-BR P121-12 SCON GND

S139TRF-WH/RD P121-11 P_39
S137PLL-RD/WH P121-10 P_38
S56PRV-RD S56PRV-RD P121-09 P_7R
C61AXRT-GR P121-08 P_12
D81CAN(-)-GR P121-07 CAN LOW
D82CAN(+)-YL P121-06 CAN HIGH
P121-05 RS232 RxD
C145CAL-RD/WH P121-04 CALIBRATION IN
P121-03 RS232 TxD
TO MICRO

S42BRT-OR P121-02 LSB3RS+LSB2RS (FULLY RETRACTED)

S132LDS-BL/WH LOAD SENSE
P121-01
SCON
N

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

BM E/R FC O PLD MODULE

BM DWN O
P_15

BM RET O SEC BM E/R FC O

MLT FNC VLV O SEC BM RET O
AUX HYD O
OPER. REC.
BM DWN ST I SERV. OR OPER. REC.
BM 100' I PWR IN SERV OR
BM 3' I RECOVERY SERVICE OR
PROVIDES PWR TO RECOVERY MODE
PRI LO#1 O MINIMAL HARDWARE
OUT PWR ENABLE
PWR TO TCON ESTOP
TO HORN BUTTON

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
SERVICE/RECOVERY KEYSWITCH TRUTH-TABLE

GNDDCON-BR

P21DCON-WH
M

P53LS-WH/BK
P63LS-OR/RD
C61AXRT-GR
GROUND/PLATFORM KEYSWITCH TRUTH-TABLE

S56PRV-RD
KEYSWITCH POSITION
GROUND PLATFORM

CLOSED CLOSED
CLOSED CLOSED
CLOSED CLOSED

RECOVERY
CLOSED CLOSED OPEN
CLOSED CLOSED OPEN
KEY SWITCH

KEYSWITCH POSITION
2
E 1
NC

OPEN
OPEN
OPEN
3
1

J155/6C
W

Z
1

3
NC

NC

NO
NC 2

NO 4
NC 2 V

Y
1
NC D

3
NO 4
U
2
B 1

2
X

1
NC

OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
RUN
NC C

P117FB-RD

D81CAN(-)-GR
PANEL

D82CAN(+)-YL
01GND-BR
FLASHING BEACON
OPEN
OPEN
OPEN
OFF
A

CONTACT

PANEL
W
U

J152B
V

X
Y
Z
CONTACT

85
30
C
D
A
B

RELAY
CR41

86
TO FLASHING BEACONS 87a

87

BC BC
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

TCON E-STOP (P1)

L

PANEL
BOOM LOWER LS
CABLE HARNESS
J11 BLACK 23 PIN
BOOM HARNESS

BL/BK
CALIBRATION

CALIBRATE)
SWITCH TO

AC
AA
AB
J142
1 SWITCH
(CLOSE

G/P MODE-WH/BK
1

2
J17

WH/BK BA
J152A
1

1
C

D
E

BB
3

1 PWR TO TCON ESTOP

C145CAL-RD/WH
S132LDS-BL/WH

NOT USED BA
2 NOT USED P11-23
PLAT

PLAT

PLAT

PLAT

2
PLAT
OFF

OFF

OFF

OFF
2

2
GROUND

OFF
GRND
GROUND

GRND
GRND

WH 3 SERV/CAL MODE DIAG PWR (12V) P11-22

BC
BA
BB
J173-1

C47OUT WH/BK C47OUT-WH/BK 4 ECU POWER DIAG GND P11-21

P23PCON-BK P23PCON-BK 5 PCON MODE NOT USED P11-20
BL/WH

TCON MODE C47OUT-WH/BK 6 OUTPUT PWR ENABLE NOT USED P11-19

P53LS-BK/WH 7 P_6R1 CAN HIGH P11-18 D82CAN(+)-YL
NOTE: J152C
TIER IV ENGINES
ONLY

S56PRV-RD/BK 8 P_7R CAN LOW P11-17 D81CAN(-)-GR

SRV REC-WH 9 SERV OR OPER RECOVERY CAL FREQ 2 P11-16
AC
AA
AB
C117FB-RD

P56PRV-RD 10 P_22 NOT USED P11-15

K

OR/BK 11 OPER RECOVERY CAL FREQ 1 P11-14

BA
J152C

GR/WH 12 P_7 !BOOT P11-13

BB
OR/RD 13 P_11 NOT USED P11-12
BA
W
1

RD/WH 14 TCON MODE SERV/CAL MODE P11-11 C145CAL-RD/WH

U

V
Z

BL 15 ALARM PWR CAN SHIELD (1939-11) P11-10

BC
BA
BB

16 ALARM GND FLASHING BEACON RLY P11-09

2

C117FB-RD
RECOVERY
SERV BYPASS
RUN

SPARE RLY OUT P11-08

S140ENL-OR/RD P_22 P11-07 P56PRV-RD/WH
J4 ON CIRCUIT BOARD

U30
P_7 PLAT-GR/WH P_7 P11-06 S56PRV-RD
RS232_GND
DB9 CONNECTOR

RS232_RXD
RS232_TXD

C47OUT-WH/BK PWR-PCON ESTOP P11-05 P23PCON-BK

P_15-OR/BK OUT PWR ENBL P11-04 C47OUT-WH/BK
CKT #

HORN RELAY COIL P11-03 C46HRN-WH

ALARM
TCON

ALARM PWR-BL
H5

PCON ECU POWER P11-02 P52PCON-WH

ALARM GND-BR
PIN

PCON ECU GND P11-01 GNDPCON-BR

MOLEX

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

CAN SHIELD P223-02

J155/6B-1
J155/6B-2

J148A-1
J147A-1
& TCON LCD

ENGINE CAN HIGH P223-03 D228CAN+ YL

J150-4

J150-1
J150-2

ENGINE CAN BUS

J149-1
J149-2
J150-3

J228-1
D227CAN- GR TO ENGINE HARNESS
ENGINE CAN LOW P223-04 J228-2

C60AXEX-GR/WH
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

C61AXRT-GR
S132LDS-BL/WH

C47OUT-WH/BK
P56PRV-RD/WH

J155/6A
S56PRV-RD
GNDPCON-BR

P223-06 D81CAN- -GR

D81CAN(-)-GR
D82CAN(+)-YL

MACHINE CAN LOW

P52PCON-WH
P23PCON-BK

J228-4
GND-OR/WH

C46HRN-WH

1
S56PRV-RD
P20BAT-OR

DIGITAL IN 1 P223-07 P20BAT-OR

TO WORKLIGHT OPTION
DIGITAL IN 2 P223-08 GND-OR/WH
2
PWR-PCON ESTOP P21-23 P23PCON-BK
SPARE

NOT USED P21-22

TSx

#1

NOT USED P21-21

TIER IV ENG OPT

SPARE-WH
LED/TOGGLE SWITCH INTERFACE BOARD

NOT USED P21-20

STEER MODE

GBOX HARN

STR MODE R-OR/BK NOT USED P21-19 P23PCON-BK

SELECT
TS22

CAN HIGH P21-18 D82CAN(+)-YL D82CAN(+)-YL

STR MODE L-OR CAN LOW P21-17 D81CAN(-)-GR D81CAN(-)-GR
HRN RLY CNTRL P21-16 C46HRN-WH C46HRN-WH
SPEED

OUT PWR ENBL P21-15 C47OUT-WH/BK C47OUT-WH/BK

DRIVE
I

TS5

NOT USED P21-14

DRV SPEED-RD/WH
!BOOT P21-13
NOT USED P21-12
S132LDS-BL/WH
ENGINE
SPEED

NOT USED P21-11

TS4

GND2-BR 20 CAN SHIELD P21-10

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

STR MODE R-OR/BK 17 P_22 P21-07 P56PRV-RD/WH P56PRV-RD/WH

Vbb BTS621

ST OUT 2
IN1 OUT 1

BTS650
OUT

AXLE RET-GR 16 NOT USED P21-06

P_7R

NOT USED
P_6

GND

NOT USED P21-05

IN2

NOT USED 15
Vbb
IN
IS
ENABLE

STR MODE L-OR 14 P_7 P21-04 S56PRV-RD S56PRV-RD

DRIVE

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

DB9 CONNECTOR PIN

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

J38-DRIVE CHASSIS HARN

J37-DRIVE CHASSIS HARN
P_7R
ECU

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

BELLCRANK
HORN PWR-RD C88PTS-RD/BK

ASSEMBLY
5

- -
P89RET-BR 10 DEG
+ 10 DEG
MANIFOLD

+
4
J22 35 PIN

HARNESS

P109JBS-GR/WH SAFETY CUTOUT

WH

0-20 DEG Y AXIS

3
WHITE

S21
PCON

JIB
C148JBS-BL/WH
DRIVE & STEERING

2
+
6 P110JBS-BK PLAT TILT SNSR
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)

JSGND4-BR 15 JOYSTICK_GND_4 JIB BELLCRANK LEVEL UP P22-28 V146JBU-BL

5

CCW SAFETY
JIB ROTATED
JIB ROTATE

P162JPW1-OR 14 JOYSTICK_PWR_1 JIB ROTATE CCW P22-27

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)
POWER FET

JIB ROTATED
J218 SAFE PL/JB TILT PWR P22-23 P87PTS-RD

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)

6 GND3-BR C160JPL-WH/RD 8 PROPEL SAFETY CUTOUT

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

3 JIB ROTATED CCW P22-18 C215JRR-WH/RD C215JRR-WH/RD

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
P90PXS-RD/BK
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

PROXIMITY
AND TURNTABLE

LSP1PROX
PRIMARY BOOM

OPTIONAL
J29
JOYSTICK (JC7)

LOAD SNSR IN P22-13 OR OR

NC
5

SWITCH
4
2

(NOHC)
WH
4 C164PLS-RD/WH LOAD SNSR GND P22-12 GR/YL

3 P
UP/DOWN

KILL
1
PROX KILL IN P22-11 C90PXS-RD/BK C90PXS-RD/BK
ROTATE

3 C165TRS-WH/RD

J82
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

J1-OR/BK BK FRONT AXLE

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

PLAT ROT CCW-GR/BK 11 !BOOT GR

NOT USED

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

FRONT AXLE POSITION SENSOR P31-20 C60FAP-GR/WH C60FAP-GR/WH

PLAT LVL UP-OR GND3-BR 5 GND RS232 GND P31-19
4 SPARE AI
CAN HIGH P31-18 D82CAN(+)-YL
C156JUD-GR/WH 3 JIB UP/DOWN
CAN LOW P31-17 D81CAN(-)-GR
GND4-BR 2 GND
NOT USED P31-16
C213JRS-RD/BK 1 JIB ROTATE
AXLE NOT EXT RTN P31-15
ALARM

J169
PCON

ALARM(+)-RD/BK NOT USED P31-14

H8

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-180 ELECTRICAL SCHEMATIC

NOT USED P31-07

P_12 P31-06 C61AXRT-GR
P_7R P31-05 S56PRV-RD
with Deutz TD2011L04i Engine

NOT USED P31-04

C

P_6R1 P31-03 P53LS-WH/BK

DCON PWR P31-02 P21DCON-WH
from SX180H-101 to SX180H-318

DCON GND P31-01 GNDDCON-BR

J31 23 PIN BLACK

DRIVE CHASSIS
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
ES0555D

V37RRS-BL/BK Y56-RR STEER LEFT (J92)

2
V36RRS-BL Y55-RR STEER RIGHT (J91)
LF STEER LEFT P32-23 V37LFS-BL/BK
V36LFS-BL BK
B

LF STEER RIGHT P32-22

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

AC GENERATOR BYPASS VALVE P14-35 V150BV-GR/BK

2 PRESS COMP ENABLE VLV #1 P14-34 C155PCE1-OR/RD
TO
uP

TT ROTATE CW PRESS COMP ENABLE VLV #2 P14-33 C155PCE2-OR/BL

3 AUX RELAY P14-32 C27AUX-RD
PLAT ROT CW NOT USED P14-31
TO
uP

4 VALVE_RETURN_6 P14-30 VLVRET6-BR

JIB DOWN TO PLD NOT USED P14-29
5 NOT USED P14-28
Z

PLAT LVL DOWN VALVE_RETURN_7 P14-27 VLVRET7-BR

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

ROTATE CW VLV P14-25 V04TRL-WH Y52 TT ROT CW VLV (J70) VLVRET6-BR

TO
uP

7
2

NOT USED P14-24

1

V45HG-GR/WH Y91 AC GENERATOR VLV (J216)

JIB UP MULTI FUNCT VLV P14-23 VLVRET3-BR
8
TO

NOT USED P14-22

uP
TO
uP

PLAT ROT CCW SPARE OM P14-21

9 TO PLD
SPARE OM P14-20
C155PCE1-OR/RD
C155PCE2-OR/BK
TO
uP

V150BV-GR/BK

TT ROTATE CCW SPARE OM P14-19

VLVRET6-BR

VLVRET6-BR
TO

10
uP

V45HG-GR/WH

BOOM OVERLOAD DI P14-18

VLVRET8-BR

TURTLE
86

87 85

TO PLD BOOM REVERSE LOAD DI P14-17 C155PCE1-OR/RD

11 TO PLD
2
FUNCTION

HYD_FILTER2 DI P14-16
1
30

R155PCE1-OR/RD Y74 FUNCTION ENABLE VALVE #1 (J166)

JIB ROT CCW
ENABLE
TO
uP

HYD_FILTER1 DI P14-15
87a
TO

CR77B
uP

12
P_30

VALVE_RETURN_5 P14-14
#1

RABBIT DRIVE LIGHT RELAY P14-13

TO
uP

13
SPARE OM P14-12
86

87 85

BOOM EXT C155PCE2-OR/BK

Y

TO PLD NOT USED P14-11

2
1

14 R155PCE2-OR/BK Y74A FUNCTION ENABLE VALVE #2 (J166A)

30
2
1

FUNCTION

PRI RETRACT VLV P14-10 V08PBR-BK/WH Y80 PRI RET VLV (J63)
87a

BOOM DOWN
ENABLE
2

TO PLD
1
TO

V07PBE-BK Y79 PRI EXT VLV (J62)

uP

PRI EXTEND VLV P14-09

CR77A

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

C25PSR-WH/BK OIL PRESSURE

1

TT ROT FC VLV P14-04 V06TRF-WH/RD Y77 TT ROT CW/CCW F.C. (J69)

J144-5
TO
uP

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

VALVE_RETURN_4 P14-01 VLVRET4-BR

uP

1
R21IGN-WH 06GND-BR
30

FUEL SOLENOID
FUNCTION HARNESS

J144-7

J144-8

VLVRET8-BR B1ENG-RD
87a
ENG FUEL
2

TO PLD
1
J14 WHITE 35 PIN

2 V75PRLO-RD/WH Y88 PRI LOCKOUT VLV #2 (J220)

2

C21IGN-WH

RELAY
1

V74PRLO-RD Y87 PRI LOCKOUT VLV #1 (J219)

CR28
TO
uP

FUNCTION

3
HARNESS

J153

NOT USED
J172-2

TO PLD
HYDRAULIC
4
J172-1
87 87a

FAN

03GND-BR
4
X

NOT USED OIL COOLER FAN

30
3

COOLER
R116HYD-OR
J146 4
3
2
1

LOWER LS

5
HARNESS

RELAY
1 2
MULTI FUNCTION VLV RECOVERY SIGNAL
SEC BOOM EXT/RET FC RECOVERY SIGNAL

BOOM UP C116HYD-OR 03GND-BR

OTS1
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

AUXILIARY BK GLOW PLUGS

BK IN CYLINDER HEADS
8
J224 GREY 8 PIN

ENG SPEED CAN LOW (-) P224-08 D227CAN- GR

BK
8
TELEMATICS

CAN HIGH (+) P224-07 D22CAN+ YL P34SA-BK/WH R34SA-BK/WH

GLOW 86 30
85 87

9
7

NOT USED REMOTE DISABLE P224-06 C226TEL-BL C34SA-BK/WH 01GND-BR GLOW PLUG
TO CAN GATEWAY
ENGINE CAN BUS
6

FOOTSWITCH STATUS P224-05 RELAY

S56PRV-RD
RELAY

10
5

PLUG
CR15

+ BUTTON KEYSWITCH POWER P224-04 P23PCON-BK

J120
4

(TIER IV)

IGNITION STATUS P224-03 C21TEL-WH

11
A B C D
3

C31EDC(-)-WH/BK
P_11

- BUTTON GROUND P224-02 GND-BR DUAL

2
P_6R1

SYS_POWER P224-01 B1BAT-RD COIL

12
P_9A

EDC
1
W

B1ENG-RD

SCRL FWD/ENTER C30EDC(+)-WH

P_39

VALVE_RETURN_3 P13-23 VLVRET3-BR

13 AC GENERATOR VALVE P13-22 V45HG-GR/WH 02GND-BR
SCROLL R
TT_TILT_Y_AXIS P13-21
P34SA-BK/WH
TO

B3BAT/14-RD
uP

BK-GND BK
TT_TILT_X_AXIS
6 AMP

14 PULL IN
3

P13-20 HI/LO SPEED

V75PRLO-RD/WH

STRT ASST WH-PULL IN WH

P_39 PWR TO TT ROT FC P13-19 S139TRF-WH/RD HOLD SOLENOID
1 2
VLVRET8-BR

V74PRLO-RD

CB9

RD-HOLD RD
P_22R

C21TEL-WH

C226TEL-BL
P_7R
P_10

15
J57

ALTERNATOR RPM P13-18 C41RPM-OR/BK

P_30

START P_38 PWR TO PROPEL P13-17 S137PLL-RD/WH

RELAY
HORN
TO

J10
uP

D22

VALVE_RETURN_2 P13-16
CR5
TO

TO
uP

uP

TT_TILT_SNSR_PWR P13-15 SERVICE

H2

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

OIL PRESSURE P13-12 C25PSR-WH/BK B3BAT/14-RD RELAY

87a

OTHER ENGINE SCHEMATICS

EDC REV P13-11 C31EDC(-)-WH/BK BAT GND-BR

SEE SCHEMATIC PAGES FOR

(P15)+(ECU POWER)
EDC FWD P13-10 C30EDC(+)-WH C41RPM-OR/BK
TO HORN
J144-1
TO
uP

WH-PULL IN

BUTTON STARTER RELAY P13-09 C33STR-BK C107AF-RD

J144-2
RD-HOLD
5V

LP P13-08
IND.
EXCT.

SERVICE HORN P13-07 C46HRN-WH

BAT.

STA.
ALTERNATOR

-
V

P_7R REV PWM P13-06

REGULATOR
TO uP

CB7

15A

P_7 FWD PWM P13-05 ALTERNATOR

~SLP MODE (~SM)

P_6R1 START AID RLY P13-04 C34SA-BK/WH

AUX HYD (AH)

FUEL/IGNITION P13-03 C21IGN-WH C21IGN-WH

FUNC ENABLE (FE)

BAT.
P_7

P34SA-BK/WH

C
B3BAT/14-RD

THROTTLE P13-02 C35RPM-BK/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

(ACTIVE HIGH SHOWN)

TO

(~SM)+(AH)
uP

AUX+
BAT+

GND-
(~SM)+(AH)

PUMP
F23 ENG/START/ALT

AUX.
CR80
TELEMATICS
RELAY
5V 12V

BY DEUTZ
C229TEL-BL/BK

F19 DRIVE LIGHTS

GND
(OE)

F20 HI/LO SPEED

S137PLL-RD/WH

F22 GLOW PLUG

F7 OIL COOLER

AUX HYD
S139TRF-WH/RD

C35RPM-BK/RD PUMP
5 VOLT PR1
13

74HC08 10
12
(~SM)+(AH)

SOLENOID
4

74HC08 1
9

2
74HC08 5

(OPTION)
74HC08

PUMP
AUX.
FUSES
7
((~SM)+(AH))(OE) 6
((~SM)+(AH))(P_7) 8

3
14

05GND-BR
14

86

87 85
((~SM)+(AH))(P_22)
OUT PWR ENABLE (OE)

C33STR-BK
74HC08

STARTER
TO
(TM)(FE)

uP
P_6R1
P_22R
P_22

B1ENG-RD
P_7R

R33STR-BK
30

P16-04
STARTER

B1ENG-RD RELAY
U

BATECU GND P16-03 GND-BR F23

3

W/BAT CBL

30A
STARTER

INTEGRAL

SYS BAT GND P16-02 GND-BR

2

F20 STARTER
POWER
RELAY

P_7 SYS BAT PWR P16-01 B1BAT-RD B1BAT-RD

HARN

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
IN2 OUT 1

IN1 OUT 1
ST OUT 2

POWER HARN

POWER

ENGINE BLOCK
BTS650
BTS650

IN OUT

OUT
BTS650

F22
IN OUT

P_1
P_6R2

HARN
HARN

ENG

-
GND
GND

GND

60A
B1
Vbb

Vbb
IN1

IN2
Vbb

AUX MAIN
IN

IS
IS
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

TWO 6 VOLT
BATTERIES
SEPARATE
4 GA WIRE

AUX HYD
(BM STOWED)

BATTERY
(~SM)+(AH)
U95

S139TRF-WH/RD
S137PLL-RD/WH
74HC08 10
T

HARNESS
8

ENGINE
((~SM)+(AH))(BM STOWED)
SEC BOOM EXT/RET FC RECOVERY SIGNAL

MULTI FUNCTION VLV RECOVERY SIGNAL

FUEL LEVEL SNSR

VLVRET8-BR
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL

AT SX18016H-360
SEC BOOM RET RECOVERY SIGNAL

J215
AUXILIARY HYD RECOVERY SIGNAL

BOOM DWN RECOVERY SIGNAL

V75PRLO-RD/WH
BOOM RET RECOVERY SIGNAL

C A B J237

LOW FUEL FS
1

VALVE_RETURN_B P12-35
2
Vbb BTS621

LOWER LS
IN1 OUT 1
ST OUT 2

HARNESS

V74PRLO-RD
REPLACED

FUEL LEVEL SENSOR P12-27 C65LOFL-BL/WH YL/WH

FUEL
12V SIGNAOL TO PLD P12-17
TO HORN BUTTON

C64LS-OR/BK RD/WH
GND
PWR TO TCON ESTOP

LEVEL
OUT PWR ENABLE
(P15)+(ECU POWER)

IN2

VLVRET BR BK/WH SENSOR

P_30

P_22
P_9B

P23PCON-BK
S56PRV-RD

B3BAT/14-RD
GND-BR

22 21

11

BK/WH
4321

LSB2RS
4

NC

RED NC

S69PBR-BK/WH S69PBR-BK/WH BR BK
RD/WH 151FT RET SAFETY
12
J20A 3

ORN

S42BRT-OR RD RD J209
BOOM STOWED
S

5 VOLT

NO
13
21

BK/WH
P_6R1

LSB2RO
P_11

4321
P_9A

NC
PCON POWER

BK
12

C64LS-OR/BK BK BL 151FT RET OPER

P_6R2

P_10
P_7

22

14
P_7R

ORN
TCON MODE

BLU

C69PBR-BK C69PBR-BK WH BR J214

LSB4EO/S
NO
13
21

BK/WH
4321

150FT EXT OPER/SAFETY

J20 1 2 3

NC

S76BEX-BL BL BK
C64LS-OR/BK WH/BK BL J213
22

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

OR/BK BL 3FT EXT OPER

22

14
BLU

C70PBE-BL/WH C70PBE-BL/WH GR/BK BR

AUXILIARY HYD RECOVERY SIGNAL

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

C64LS-OR/BK RD/BK BL 10 DEG ANGLE OPER

2 1

22

14
OUT PWR ENABLE
PWR TO TCON ESTOP

C68PBD-BL C68PBD-BL WH/BK BR

J210
7
TO HORN BUTTON
(P15)+(ECU POWER)

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

BK DRV ENABLE LEFT

22

14
ORN
YEL

WH J125
ORN NO
13
21

C64LS-OR/BK RD LST1O
21

NC

C144DER-BL/WH C144DER-BL/WH BR DRV ENABLE RIGHT

BK
22

14

WH J124
C64LS-OR/BK FST1S
C65LOFL-BL/WH C65LOFL-BL/WH LOW FUEL FS
VLVRET BR VLVRET-BR
LST1S
ORN NO
13
21

C64LS-OR/BK C64LS-OR/BK RD DRV ENABLE

4 321

NC

S13DE-BL/RD BR
BK SAFETY
22

14

RED

WH J126
VALVE_RETURN_8 P12-35 VLVRET8-BR
J208

6 J199

P_30 P_30 P12-34

LTB1LO (BOOM LENGTH) P12-33 C167PRS-OR/BK C167PRS-OR/BK C167PRS-OR/BK BL YL LTB1LO
6

RSB1AO (BOOM ANGLE) P12-32 C123PBS-RD/BK P109ANG-GR/WH P109ANG-GR/WH GR BR BOOM LENGTH

4

OPER
BOOM STOWED P12-31 SNSRGND-BR SNSRGND-BR OR
Q

OR
5

SPARE DI P12-30 C166PRS-OR RD BL

3

SPARE DI P12-29 P109ANG-GR/WH BK BK LTB1LS

1

DRV ENBL L - LST2O P12-28 C143DEL-BL/RD SNSRGND-BR WH RD BOOM LENGTH

2

SAFETY
TO
uP

AUX HYD PRESSURE IN P12-27

SNSR PWR (5V) P12-26 P109ANG-GR/WH
B3BAT/14-RD
S139TRF-WH/RD
S137PLL-RD/WH

4567

21

11

P57PBD-RD/WH RD BK/WH LSB3RS

4321

NC

NC

SNSR GND P12-25 SNSRGND-BR P63LS-OR/RD WH BK

TO

3.5FT EXT SAFETY

uP

S42BRT-OR OR RD/WH
RED
22

12

P2 SEQ VLV P12-24 V75PRLO-RD/WH S42BRT-OR GR RD J207

LOCKOUT VALVE #1 SIG
J20

TO PLD P1 SEQ VLV P12-23 V74PRLO-RD

6 J114

SPARE DI P12-22
P109ANG-GR/WH P109ANG-GR/WH BL
LSB2RS P12-21 S69PBR-BK/WH RSB1A0
SNSRGND-BR SNSRGND-BR GR
TO
uP

LSB4EO P12-20 C71PBE-BL/BK BOOM ANGLE

C123PBS-RD/BK C123PBS-RD/BK WH OPER
LSB3RO P12-19 C70PBE-BL/WH
4

PRI BOOM LENGTH 3' STATUS TO PLD C141PBS-RD YL

LSB2RO P12-18 C69PBR-BK
3

SNSRGND-BR BK RSB1AS
TO
uP

12V SIG TO PLD P12-17 C64LS-OR/BK BOOM ANGLE

P109ANG-GR/WH RD SAFETY
PRI BOOM LENGTH 151' STATUS LSB1DO P12-16
1

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

OPER SW PWR P12-13 C64LS-OR/BK

J20B
P_22
P_9B

P_18 P12-12
P_14 P12-11
2 1

2 1

S59CNBK-GR/WH S59CNBK-GR/WH GR/BK

P_12 P12-10 C61AXRT-GR SJ2-OR/BK RD/BK
11 12

P_11 P12-09 S140ENL-OR/RD

4 3 2 1

BK/WH
P_10 P_10 P12-08 S59CNBK-GR/WH P63LS-OR/RD BL/BK
J208

J222A

P_9B P_9B P12-07 P58LS-RD/BK

J122-BLACK 12
S59CNBK-GR/WH

P_9A P12-06 P57PBD-RD/WH

MULTI FUNCTION VLV RECOVERY SIGNAL

U32 PIN SCON

SEC BOOM EXT/RET FC RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL

P_7R P_7R P12-05 S56PRV-RD MODULE

P63LS-OR/RD

U31
SJ2-OR/BK
AUXILIARY HYD RECOVERY SIGNAL

SJ2-OR/BK

P_6R2 P_6R2 P12-04 P54ENG-BK/WH P57PBD-RD/WH P57PBD-RD/WH P122-12 P_9A+P_10

U30
BOOM DWN RECOVERY SIGNAL

SEC BOOM RET RECOVERY SIGNAL

P_6R1
BOOM RET RECOVERY SIGNAL

P_6R1 P12-03 P53LS-WH/BK P53LS-WH/BK P122-11

DCON/SCON ECU PWR P12-02 P21DCON-WH P58LS-RD/BK P58LS-RD/BK P122-10 P_9B
PRI BOOM LENGTH 151' STATUS
PRI BOOM LENGTH 3' STATUS

P54ENG-BK/WH
LOCKOUT VALVE #1 SIGNAL

SCON ECU GND P12-01 GNDSCON-BR P54ENG-BK/WH P122-09 P_6R2

OUT PWR ENABLE
PRI BOOM DOWN STATUS

PWR TO TCON ESTOP

S140ENL-OR/RD S140ENL-OR/RD P122-08 P_11 4 32 1 21

(P15)+(ECU POWER)

TO HORN BUTTON

BK
BK

BR
BR

BK/WH

BL
BL

BK/WH

P53LS-WH/BK P122-07 P_6R1

S13DE-BL/RD P122-06 LST1S (DRIVE ENABLE)
LIMIT SWITCH HARN
P_22

S76BEX-BL P122-05 LSB4ES (150FT EXTENDED)

J12 BLACK 35 PIN
O

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

GNDSCON-BR GNDSCON-BR P121-12 SCON GND

S139TRF-WH/RD P121-11 P_39
S137PLL-RD/WH P121-10 P_38
S56PRV-RD S56PRV-RD P121-09 P_7R
C61AXRT-GR P121-08 P_12
D81CAN(-)-GR P121-07 CAN LOW
D82CAN(+)-YL P121-06 CAN HIGH
P121-05 RS232 RxD
C145CAL-RD/WH P121-04 CALIBRATION IN
P121-03 RS232 TxD
TO MICRO

S42BRT-OR P121-02 LSB3RS+LSB2RS (FULLY RETRACTED)

S132LDS-BL/WH LOAD SENSE
P121-01
SCON
N

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

BM E/R FC O PLD MODULE

BM DWN O
P_15

BM RET O SEC BM E/R FC O

MLT FNC VLV O SEC BM RET O
AUX HYD O
OPER. REC.
BM DWN ST I SERV. OR OPER. REC.
BM 100' I PWR IN SERV OR
BM 3' I RECOVERY SERVICE OR
PROVIDES PWR TO RECOVERY MODE
PRI LO#1 O MINIMAL HARDWARE
OUT PWR ENABLE
PWR TO TCON ESTOP
TO HORN BUTTON

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
SERVICE/RECOVERY KEYSWITCH TRUTH-TABLE

GNDDCON-BR

P21DCON-WH
M

P53LS-WH/BK
P63LS-OR/RD
C61AXRT-GR
GROUND/PLATFORM KEYSWITCH TRUTH-TABLE

S56PRV-RD
KEYSWITCH POSITION
GROUND PLATFORM

CLOSED CLOSED
CLOSED CLOSED
CLOSED CLOSED

RECOVERY
CLOSED CLOSED OPEN
CLOSED CLOSED OPEN
KEY SWITCH

KEYSWITCH POSITION
2
E 1
NC

OPEN
OPEN
OPEN
3
1

J155/6C
W

Z
1

3
NC

NC

NO
NC 2

NO 4
NC 2 V

Y
1
NC D

3
NO 4
U
2
B 1

2
X

1
NC

OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
RUN
NC C

P117FB-RD

D81CAN(-)-GR
PANEL

D82CAN(+)-YL
01GND-BR
FLASHING BEACON
OPEN
OPEN
OPEN
OFF
A

CONTACT

PANEL
W
U

J152B
V

X
Y
Z
CONTACT

85
30
C
D
A
B

RELAY
CR41

86
TO FLASHING BEACONS 87a

87

BC BC
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

TCON E-STOP (P1)

L

PANEL
BOOM LOWER LS
CABLE HARNESS
J11 BLACK 23 PIN
BOOM HARNESS

BL/BK
CALIBRATION

CALIBRATE)
SWITCH TO

AC
AA
AB
J142
1 SWITCH
(CLOSE

G/P MODE-WH/BK
1

2
J17

WH/BK BA
J152A
1

1
C

D
E

BB
3

1 PWR TO TCON ESTOP

C145CAL-RD/WH
S132LDS-BL/WH

NOT USED BA
2 NOT USED P11-23
PLAT

PLAT

PLAT

PLAT

2
PLAT
OFF

OFF

OFF

OFF
2

2
GROUND

OFF
GRND
GROUND

GRND
GRND

WH 3 SERV/CAL MODE DIAG PWR (12V) P11-22

BC
BA
BB
J173-1

C47OUT WH/BK C47OUT-WH/BK 4 ECU POWER DIAG GND P11-21

P23PCON-BK P23PCON-BK 5 PCON MODE NOT USED P11-20
WH/BK

TCON MODE C47OUT-WH/BK 6 OUTPUT PWR ENABLE NOT USED P11-19

P53LS-BK/WH 7 P_6R1 CAN HIGH P11-18 D82CAN(+)-YL
NOTE: J152C
TIER IV ENGINES
ONLY

S56PRV-RD/BK 8 P_7R CAN LOW P11-17 D81CAN(-)-GR

SRV REC-WH 9 SERV OR OPER RECOVERY CAL FREQ 2 P11-16
AC
AA
AB
C117FB-RD

P56PRV-RD 10 P_22 NOT USED P11-15

K

OR/BK 11 OPER RECOVERY CAL FREQ 1 P11-14

BA
J152C

GR/WH 12 P_7 !BOOT P11-13

BB
OR/RD 13 P_11 NOT USED P11-12
BA
W
1

RD/WH 14 TCON MODE SERV/CAL MODE P11-11 C145CAL-RD/WH

U

V
Z

BL 15 ALARM PWR CAN SHIELD (1939-11) P11-10

BC
BA
BB

16 ALARM GND FLASHING BEACON RLY P11-09

2

C117FB-RD
RECOVERY
SERV BYPASS
RUN

SPARE RLY OUT P11-08

S140ENL-OR/RD P_22 P11-07 P56PRV-RD/WH
J4 ON CIRCUIT BOARD

U30
P_7 PLAT-GR/WH P_7 P11-06 S56PRV-RD
RS232_GND
DB9 CONNECTOR

RS232_RXD
RS232_TXD

C47OUT-WH/BK PWR-PCON ESTOP P11-05 P23PCON-BK

P_15-OR/BK OUT PWR ENBL P11-04 C47OUT-WH/BK
CKT #

HORN RELAY COIL P11-03 C46HRN-WH

ALARM
TCON

ALARM PWR-BL
H5

PCON ECU POWER P11-02 P52PCON-WH

ALARM GND-BR
PIN

PCON ECU GND P11-01 GNDPCON-BR

MOLEX

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

CAN SHIELD P223-02

J155/6B-1
J155/6B-2

J148A-1
J147A-1
& TCON LCD

ENGINE CAN HIGH P223-03 D228CAN+ YL

J150-4

J150-1
J150-2
J149-1
J149-2
J150-3

J228-1 ENGINE CAN BUS

D227CAN- GR TO ENGINE HARNESS
ENGINE CAN LOW P223-04

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

C61AXRT-GR
S132LDS-BL/WH

C47OUT-WH/BK
P56PRV-RD/WH

J155/6A
S56PRV-RD
GNDPCON-BR

D81CAN(-)-GR

P223-06 D81CAN- -GR

D82CAN(+)-YL
P52PCON-WH

MACHINE CAN LOW

P23PCON-BK

J228-4
GND-OR/WH

C46HRN-WH

1
S56PRV-RD
P20BAT-OR

DIGITAL IN 1 P223-07 P20BAT-OR

TO WORKLIGHT OPTION
DIGITAL IN 2 P223-08 GND-OR/WH
2
PWR-PCON ESTOP P21-23 P23PCON-BK
SPARE

NOT USED P21-22

TSx

#1

NOT USED P21-21

TIER IV ENG OPT

SPARE-WH
LED/TOGGLE SWITCH INTERFACE BOARD

NOT USED P21-20

STEER MODE

GBOX HARN

STR MODE R-OR/BK NOT USED P21-19 P23PCON-BK

SELECT
TS22

CAN HIGH P21-18 D82CAN(+)-YL D82CAN(+)-YL

STR MODE L-OR CAN LOW P21-17 D81CAN(-)-GR D81CAN(-)-GR
HRN RLY CNTRL P21-16 C46HRN-WH C46HRN-WH
SPEED

OUT PWR ENBL P21-15 C47OUT-WH/BK C47OUT-WH/BK

DRIVE
I

TS5

NOT USED P21-14

DRV SPEED-RD/WH
!BOOT P21-13
NOT USED P21-12
S132LDS-BL/WH
ENGINE
SPEED

NOT USED P21-11

TS4

GND2-BR 20 CAN SHIELD P21-10

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

STR MODE R-OR/BK 17 P_22 P21-07 P56PRV-RD/WH P56PRV-RD/WH

Vbb BTS621

ST OUT 2
IN1 OUT 1

BTS650
OUT

AXLE RET-GR 16 NOT USED P21-06

P_7R

NOT USED
P_6

GND

NOT USED P21-05

IN2

NOT USED 15
Vbb
IN
IS
ENABLE

STR MODE L-OR 14 P_7 P21-04 S56PRV-RD S56PRV-RD

DRIVE

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

DB9 CONNECTOR PIN

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

J38-DRIVE CHASSIS HARN

J37-DRIVE CHASSIS HARN
P_7R
ECU

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

BELLCRANK
HORN PWR-RD C88PTS-RD/BK

ASSEMBLY
5

- -
P89RET-BR 10 DEG
+ 10 DEG
MANIFOLD

+
4
J22 35 PIN

HARNESS

P109JBS-GR/WH SAFETY CUTOUT

WH

0-20 DEG Y AXIS

3
WHITE

S21
PCON

JIB
C148JBS-BL/WH
DRIVE & STEERING

2
+
6 P110JBS-BK PLAT TILT SNSR
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)

JSGND4-BR 15 JOYSTICK_GND_4 JIB BELLCRANK LEVEL UP P22-28 V146JBU-BL

5

CCW SAFETY
JIB ROTATED
JIB ROTATE

P162JPW1-OR 14 JOYSTICK_PWR_1 JIB ROTATE CCW P22-27

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)
POWER FET

JIB ROTATED
J218 SAFE PL/JB TILT PWR P22-23 P87PTS-RD

NO
13