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Genie S-40 TRAX, Service Manual

The Genie S-40 TRAX is an innovative aerial work platform designed for a smooth and efficient operation. To ensure safety and optimal performance, don't forget to download the Operator's Manual. It's available for free download at manualshive.com, providing comprehensive instructions and valuable insights for operating the Genie S-40 TRAX.

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Service Manual

Part No. 102521

Rev E

October 2013

Serial Number Range

from S40-7001 to

S4012-17231

S-40
S-45

TM

TM

Property of American Airlines

Summary of Contents for S-40 TRAX

Page 1: ...Service Manual Part No 102521 Rev E October 2013 Serial Number Range from S40 7001 to S4012 17231 S 40 S 45 TM TM P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 2: ...ng fault codes and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Complianc...

Page 3: ...6 150 6 151 6 153 D1 10 1012 2 Spec 2 1 2 2 3 Maint 3 9 3 33 to 3 34 4 Repair 4 59 to 4 60 D2 10 2013 4 Repair 4 3 6 Schem 6 19 6 29 6 33 6 93 REFERENCEEXAMPLES 2 1_Section 2_Specifications Page 3 3_Section3_MaintenanceProcedurePage 4 48_Section4_RepairProcedurePage Fault Codes_Section 5 6 5_Section 6_Schematic Page ElectronicVersion Click on any procedure or page number highlighted in blue to vie...

Page 4: ... REFERENCEEXAMPLES 2 1_Section 2_Specifications Page 3 3_Section3_MaintenanceProcedurePage 4 48_Section4_RepairProcedurePage Fault Codes_Section 5 6 5_Section 6_Schematic Page ElectronicVersion Click on any procedure or page number highlighted in blue to view the update P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 5: ...ated work load including occupants 500 lb 227 kg Maximum allowable inclination of the chassis 0 deg Gradeability N A Maximum allowable side force 150 lb 670 N Maximum number of platfrm occupants 2 Model year Manufacture date 01 05 06 2006 Maximum wind speed 28 mph 12 5 m s Maximum platform height 60 ft 6 in 18 3 m Maximum platform reach 34 ft 3 in 10 4 m Sequence number stamped on chassis Serial l...

Page 6: ...S 40 S 45 PartNo 102521 July 2007 iv This page intentionally left blank Section 1 Safety Rules P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 7: ...tor s manual are also safety hazards when maintenance andrepairproceduresareperformed 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 applicablegovernmentalregulations You have the appropriate tools lifting equipment and a...

Page 8: ...her protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire ext...

Page 9: ...ine Specifications 2 8 DeutzF3L 2011 DeutzD2011L03iEngineSpecifications 2 9 Perkins 704 30 Engine Specifications 2 10 Perkins 404 22 Engine Specifications 2 11 Machine Torque Specifications 2 12 Hydraulic Hose and Fitting Torque Specifications 2 13 SAE and Metric Fastener Torque Chart 2 14 Section 3 Rev ScheduledMaintenanceProcedures Introduction 3 1 Pre DeliveryPreparation 3 3 MaintenanceInspecti...

Page 10: ...ance Ford Models 3 15 ChecklistBProcedures B 1 Inspect the Battery 3 16 B 2 Inspect the Electrical Wiring 3 17 B 3 Inspect the Air Filter 3 18 B 4 Test the Key Switch 3 19 B 5 Perform Engine Maintenance Deutz and Perkins Models 3 19 B 6 Check the Exhaust System 3 20 B 7 Check the Oil Cooler and Cooling Fins Deutz Models 3 20 B 8 Inspect the Tires Wheels and Lug Nut Torque 3 21 B 9 Check the Drive ...

Page 11: ... Platform Overload Mechanism if equipped 3 36 C 4 Replace the Engine Air Filter Deutz and Perkins Models 3 39 C 5 Replace the Inline Fuel Strainer 3 39 C 6 Perform Engine Maintenance Ford Models 3 40 ChecklistDProcedures D 1 Check the Boom Wear Pads 3 41 D 2 Check the Turntable Rotation Bearing Bolts 3 42 D 3 ChecktheFree wheelConfiguration 3 43 D 4 Replace the Drive Hub Oil 3 45 D 5 Perform Engin...

Page 12: ... 1 ALC 500CircuitBoard 4 2 1 2 Joysticks 4 3 PlatformComponents 2 1 Platform Leveling Slave Cylinder 4 8 2 2 PlatformRotator 4 9 2 3 Platform Overload System 4 11 Jib Boom Components 3 1 Jib Boom 4 14 3 2 Jib Boom Lift Cylinder 4 15 BoomComponents 4 1 CableTrack 4 16 4 2 Boom 4 18 4 3 Boom Lift Cylinder 4 19 4 4 Boom Extension Cylinder 4 20 4 5 Platform Leveling Master Cylinder 4 21 Engines 5 1 RP...

Page 13: ...al number 7569 4 43 7 9 Traction Manifold Components 2WD after serial number 7568 4 44 7 10 Valve Adjustments 2WD Traction Manifold 4 45 7 11 Traction Manifold Components 4WD before serial number 7569 4 46 7 12 Traction Manifold Components 4WD from serial number 7568 to 15822 4 48 7 13 Traction Manifold Components 4WD from serial number 15823 4 50 7 14 Valve Adjustments 4WD Traction Manifold 4 52 ...

Page 14: ... Schematic Deutz F3L 1011 Models beforeserialnumber7544 6 8 GroundControlBoxWiringDiagram DeutzF3L 1011FModels 6 11 Platform Control Box Wiring Diagram DeutzF3L 1011FModels 6 14 Platform Control Box Switch Panel Wiring Diagram DeutzF3L 1011FModels 6 15 Electrical Schematic Perkins 704 30 Models beforeserialnumber7472 6 18 GroundControlBoxWiringDiagram Perkins 704 30 Models 6 21 Platform Control Bo...

Page 15: ...Perkins 404 22 Models from serial number 15663 to 16419 6 40 Electrical Schematic Deutz F3L 2011 Deutz D2011L03i Models CE Perkins 404 22 Models from serial number 15663 to 16419 6 44 Electrical Schematic Deutz F3L 2011 Deutz D2011L03i Models ANSI CSA AS Perkins 404 22 Models from serial number 16420 6 48 Electrical Schematic Deutz F3L 2011 Deutz D2011L03i Models CE Perkins 404 22 Models from seri...

Page 16: ...tzD2011L03iModels Perkins 404 22 Models from serial number 12510 6 65 Electrical Schematic Ford LRG 425 EFI Models before serial number 7597 6 68 GroundControlBoxWiringDiagram Ford LRG 425 EFI Models before serial number 7597 6 71 Platform Control Box Wiring Diagram Ford LRG 425 EFI Models before serial number 7597 6 74 Platform Control Box Switch Panel Wiring Diagram Ford LRG 425 EFI Models befor...

Page 17: ...19 6 104 Electrical Schematic Ford DSG 423 EFI Models ANSA CSA AS fromserialnumber16420 6 108 Electrical Schematic Ford DSG 423 EFI Models CE fromserialnumber16420 6 112 GroundControlBoxWiringDiagram Ford DSG 423 EFI Models before serial number 14832 6 116 GroundControlBoxWiringDiagram Ford DSG 423 EFI Models from serial number 14832 6 117 Platform Control Box Wiring Diagram Ford DSG 423 EFI Model...

Page 18: ...nWiringDiagram 6 138 HydraulicGeneratorWiringDiagram welderoption 6 139 Hydraulic Schematic 2WD Non oscillating S 40 Models beforeserialnumber7569 6 142 Hydraulic Schematic 2WD Non oscillating S 45 Models beforeserialnumber7569 6 143 Hydraulic Schematic 4WD Oscillating S 40 Models beforeserialnumber7569 6 146 Hydraulic Schematic 4WD Oscillating S 45 Models beforeserialnumber7569 6 147 Hydraulic Sc...

Page 19: ...lubricated 170 ft lbs 230 Nm Lug nut torque 8 bolt non drive spindles Lug nut dry 170 ft lbs 230 Nm Lug nut lubricated 130 ft lbs 176 Nm Track Components TRAX option Track material Rubber Weight assembly each 480 lbs 218 kg Fluid capacities Fuel tank 20 gallons 75 7 liters Fuel tank Option 30 gallons 114 liters LPG tank 33 5 pounds 15 2 kg Hydraulic tank 45 gallons 170 liters Hydraulic system 55 g...

Page 20: ...ib boom up S 45 models 35 to 45 seconds Jib boom down S 45 models 20 to 30 seconds Braking distance maximum High range on paved surface 3 to 4 ft 0 9 to 1 2 m Hydraulic Oil Specifications Hydraulic Oil Specifications Hydraulic oil type Chevron Rando HD MV equivalent Viscosity grade Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rando HD MV...

Page 21: ...fixed displacement Displacement 0 37 cu in 6 cc Flow rate 2500 rpm 2 8 gallons per minute 10 6 liters per minute Continued use of Chevron Aviation A hydraulic oil when ambient temperatures are consistently above 32 F 0 C may result in componentdamage Note Use Chevron Aviation A hydraulic oil when ambient temperatures are consistently below 0 F 18 C Note Use Shell Tellus S2 V 46 hydraulic oil when ...

Page 22: ...line filter 25 psi 1 7 bar bypass Auxiliary pump Type fixed displacement gear pump Displacement static 0 151 cu in 2 47 cc Displacement 1 75 gallons per minute 6 62 liters per minute Functionmanifold Function relief valve pressure S 40 2600 psi 179 bar S 45 2900 psi 200 bar Boom down 2200 psi relief valve pressure 152 bar Boom extend 1950 psi 134 bar Oscillate axle 950 psi 66 bar Steer regulator 2...

Page 23: ...n air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 2 position 3 way 10V DC 6 3 Ω schematic items AC and AE Solenoid valve 3 position 4 way 10V DC 6 3 Ω schematic item AT and AZ Solenoid valve 2 position 3 way 10V DC 6 3 Ω schematic items AU AV AX a...

Page 24: ...ting temperatures may require the use of alternative engine oils For oil requirements refer to the engine Operator s Manual on your machine Oil pressure switch specifications Torque 8 18 ft lbs 11 24 Nm Oil pressure switch point 3 5 psi 0 21 0 34 bar Starter motor Normal engine cranking speed 200 to 250 rpm Current draw normal load 140 200A Current draw maximum load 800A Current draw no load 70A B...

Page 25: ...ratures may require the use of alternative engine oils For oil requirements refer to the engine Operator s Manual on your machine Electronic fuel pump Fuel pressure static 64 psi 4 4 bar Fuel flow rate 0 43 gpm 1 6 L min Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Ignition system Spark plug type Motorcraft AGSF 32 FEC Spark plug gap 0 049 to 0 053 i...

Page 26: ...91 x 105 mm Horsepower 36 3000 rpm 26 8 kW 3000 rpm Firing order 1 2 3 Compression ratio 18 5 1 Compression pressure 362 to 435 psi 25 to 30 bar Low idle rpm 1500 rpm Frequency 313 Hz High idle rpm 2300 rpm Frequency 479 9 Hz Governor centrifugal mechanical Valve clearance cold Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure 26 to 87 psi 1 8 to 6 0 bar Oil capacity 8...

Page 27: ...cold Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure hot 2000 rpm 40 60 psi 2 8 to 4 1 bar Oil capacity 8 5 quarts including filter 8 liters Deutz F3L2011 Engine Oil capacity 9 5 quarts including filter 9 liters Deutz D2011L03i Engine Oil viscosity requirements Unit ships with 15 W40 oil Extreme operating temperatures may require the use of alternative engine oils Fo...

Page 28: ...fuel requirement refer to the engine Operator s Manual on your machine Starter motor Current draw normal load 140 200A Brush length new 0 72 in 18 5 mm Brush length minimum 0 27 in 7 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Alternator output 60A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm SPECIFICATIONS P r o p e r t y o f A...

Page 29: ...apacity 7 3 quarts including filter 8 3 liters Oil viscosity requirements below 68 F 20 C synthetic 5W 20 5 F to 104 F 15 C to 40 C 10W 30 above 14 F 10 C 15W 40 Engine oil should have properties of API classification CC SE API classification CD SE or CCMC D4 can be used but is not recommended during the first 50 hours nor for light load applications Injection system Injection pump make Zexel PFR ...

Page 30: ...psi at 2000 rpm 2 8 to 4 1 bar Oil capacity 9 4 quarts to 11 2 quarts including filter 8 9 liters to 10 6 liters Oil viscosity requirements Unit ships with 15 W40 oil Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the engine Operator s Manual on your machine Oil pressure sending unit Torque 8 18 ft lbs 11 24 Nm Oil pressure switch point ...

Page 31: ...und 217 Nm Drive motor and hubs Drive hub mounting bolts dry 210 ft lbs 284 Nm Drive hub mounting bolts lubricated 160 ft lbs use blue thread locking compound 217 Nm Drive motor mounting bolts dry 49 ft lbs 66 4 Nm Drive motor mounting bolts lubricated 37 ft lbs 50 Nm Turntable bearing Turntable bearing mounting bolts lubricated 180 ft lbs 244 Nm TRAX Torque Specifications Hub to drive sprocket fa...

Page 32: ...e and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque 4 14 ft lbs 18 9...

Page 33: ...TORQUE CHART Grade 5 DRY LUBED This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Black Oxide Bolts Grade 8 LUBED 1 4 LUBED DRY LUBED DRY 1 1 2 9 16 5 8 3 4 7 8 1 1 1 8 1 1 4 5 16 3 8 7 16 1 2 Size mm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm in lbs Nm 5 16 1 8 21 2 4 41 4 63 54 6 18 58 6 63 78 8 84 68 7 75 91 10 3 6 19 3 0...

Page 34: ...he boom between the non steer wheels Turntable secured with the turntable rotation lock Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety information and step by step instructi...

Page 35: ... for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly every six months annual and two years The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine w...

Page 36: ... box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and reinspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Fundamentals It is the responsibility of the dealer to perform the Pre deliveryPreparation The Pre delivery Preparation is...

Page 37: ...3 4 S 40 S 45 PartNo 102521 October2013 Section 3 Scheduled Maintenance Procedures This page intentionally left blank P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 38: ...nd control B 15 Directional valve linkage B 16 Platform self leveling B 17 Drive brakes B 18 Drive speed stowed position B 19 Drive speed raised position B 20 Hydraulic oil analysis B 21 Alarm package B 22 Fuel and hydraulic cap venting systems B 23 Check track tension TRAX option Perform every 400 hours B 24 Engine maintenance Ford models Maintenance Inspection Report Instructions Make copies of ...

Page 39: ...E 6 Engine maintenance Deutz models Perform every 6000 hours E 7 Engine maintenance Deutz and Perkins models Perform every 12 000 hours E 8 Engine maintenance Deutz models Perform every 4 years E 9 Engine maintenance Ford models Comments Instructions Make copies of both pages to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour In...

Page 40: ...ck to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals ...

Page 41: ...ure be performed daily Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the Operator s Manual ...

Page 42: ...ted under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury CHECKLIST A PROCEDURES A 5 Inspect the Track Components TRAX option Note Genie specifications require that this pr...

Page 43: ...peration Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 A 6 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage whichever comes first After t...

Page 44: ...ing could result in death or serious injury CHECKLIST A PROCEDURES A 8 Replace the Drive Hub Oil Manufacturer drive hub specifications require that this one time procedure be performed after the first 150 hours Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the torque hub oil after the first 50 hours of use may cause the machine to perform...

Page 45: ...filter Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug A 9 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 50 hours Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to pe...

Page 46: ...425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure i...

Page 47: ...chine and secure it from moving Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury A 12 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turnta...

Page 48: ...dbook Ford part number FPP 194 302 or the FordDSG 423EFIOperatorHandbook EDI part number 1060020 or the FordMSG 425EFIOperatorHandbook Fordpartnumber1020010 Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 CHECKLIST A PROCEDURES To access the engine Remove the engine tra...

Page 49: ...specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity of 1...

Page 50: ...manifold wiring 4 Inspect for a liberal coating of dielectric grease in the following locations Between the ground and platform controls Between the ground and drive controls All harness connectors Level sensor 5 Open the turntable cover at the ground control side of the machine 6 Inspect the following areas for burnt chafed corroded and loose wires Inside of the ground control box Hydraulic manif...

Page 51: ...he dust discharge valve by pressing together the sides of the discharge slot Clean the discharge slot as needed 2 Inspect the dust discharge valve If the valve shows any signs of damage replace the valve a clamp b canister end cap c dust discharge valve 3 Disconnect the latches and remove the end cap of the air cleaner canister 4 Remove the filter element 5 Clean the inside of the canister and the...

Page 52: ...ine pivot plate from moving could result in death or serious injury B 4 Test the Key Switch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplishe...

Page 53: ...Inspect the oil cooler for leaks and physical damage 4 Clean the oil cooler of debris and foreign material B 6 Check the Exhaust System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can...

Page 54: ...cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Check each lug nut for proper torque Refer to Section 2 Specifications Models with air filled tires 4 Check pressure in each air filled tire Add air as necessary Refer to Section 2 Specifications a oil cooler b cylinder head cooling fins c fan blower fins Cooling and fan blower fins 5 Inspect the fan blower fins for...

Page 55: ...ery 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bott...

Page 56: ...ce Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure it is in the engaged position 2 Be sure the free wheel valve on the drive pump is closed clockwise Note The free wheel valve is located on the bottom of the drive pump a drive pump b scre...

Page 57: ... proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Note This procedure will require two people Ford Models Note The engine rpm is controlled by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is required ...

Page 58: ... Turn the key switch to platform controls 5 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Result The engine should not change to high idle 6 Press down the foot switch Result The engine should change to high idle 7 Move the engine idle control switch to foot switch activated low idle turtle symbol Result The engine should change to low idle Sk...

Page 59: ...ontinue to run on the selected fuel if switched while running B 13 Test the Fuel Select Operation Ford Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made when the engine is running or not S...

Page 60: ...d controls 3 At the ground controls operate each boom function through a partial cycle Result All boom functions should operate B 15 Check the Directional Valve Linkage Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Note Perform this test only on models equipped with a oscillating axle Proper axle oscillation is essential to safe ma...

Page 61: ...ing the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications Note The brakes must be able to hold the machine on any slope it is able to climb B 16 Test the Platform Self leveling Genie specific...

Page 62: ...sition Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Not...

Page 63: ...replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Sect...

Page 64: ...it Result The travel alarm should sound when the drive controller is moved off center in either direction B 21 Test the Alarm Package if equipped and the Descent Alarm Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The alarm package includes Travel alarm Flashing beacons Alarms and beacons are installed to alert operators and ground...

Page 65: ... system Dry using low pressure compressed air Repeat this procedure beginning with step 6 8 Install the breather cap onto the hydraulic tank B 22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie specifications require that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing fuel and...

Page 66: ...med every 250 hours or quarterly Maintaining proper track tension and properly torqued fasteners is essential to good machine performance and service life The machine will not operate properly with a track that is incorrectly tensioned Continued use of a machine with incorrectly tensioned tracks may cause component damage 1 Thoroughly clean the track assembly of any dirt rocks clay etc 2 Chock the...

Page 67: ...I Operator Handbook Genie part number 215322 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury 6...

Page 68: ...utz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 Perkins models Requiredmaintenanceproceduresandadditional engine information are available in the Perkins404 22OperationManual Perkins part number TPD 1443S Perkins 404 22 Operation Manual Genie part numbe...

Page 69: ...e platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stablity could be compromised resulting in the machine tipping over Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control...

Page 70: ...lt All ground control functions should operate 13 Using a suitable lifting device lift the additional test weight from the platform Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound Illustration 1 5 Carefully move the test weight to each remaining location Refer to Illustration 1 Result The platform overload indica...

Page 71: ...ols Using Illustration 2 as a guide locate the timer relay inside the platform control box Tag and disconnect the red wire from terminal 5 on the timer relay Illustration 2 Timer Relay Orange Wire Terminal 5 21 Using Illustration 3 as a guide locate D31 Valve Power LED on the ALC500 printed circuit board Illustration 3 22 Step on the footswitch at the platform Result The Valve Power LED should not...

Page 72: ...ts should be flashing at both the ground and platform controls 27 Working from outside the platform and standing next to the platform rotator locate the orange wire which enters into the base of the platform control box from the load sense switch and locate the wire terminal at the end of the wire Tag and disconnect the connectors Refer to Illustration 2 28 Using a multimeter set to read resistanc...

Page 73: ...t the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury CHECKLIST C PROCEDURES C 5 Replace the In line Fuel Strainer Deutz Models Engine specifications require that this procedure be performed every 500 hours or 6 months whichever ...

Page 74: ...s 2 Raise the end of the primary boom to a comfortable working height chest high then extend the boom 1 foot 30 cm 3 Measure each wear pad Replace the wear pad once it reaches the minimum allowable thickness If the wear pad is still within specification shim as necessary to obtain minimum clearance with zero binding Note The minimum shim clearance for primary boom wear pads is 0 070 inch 1 8 mm an...

Page 75: ...ally whichever comes first Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the primary boom and place safety chocks on the lift cylinders rods Carefully lower the boom onto the lift cylinders safety chocks Crushing hazard Keep hands away from cylinders and...

Page 76: ...r annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed...

Page 77: ...the drive hubs may cause death or serious injury and property damage Steer Wheels 4WD Models 7 Chock the non steer wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 lbs 10 000 kg under the drive chassis between the steer tires 9 Lift the wheels off the ground and then place jack stands under the drive chassis for support 10 Disengage the drive hubs by turn...

Page 78: ...bottom of the side hole Refer to Section 2 Specifications 5 Install the plugs Use pipe thread sealant on units with pipe plugs 6 Repeat steps 1 through 5 for all the other drive hubs models with pipe plugs a drive hub plugs a Turntable Rotate Drive Hub Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during i...

Page 79: ...models Requiredmaintenanceproceduresandadditional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2011 Operation Manual Deutz part number 0312 3547 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 139320 5 Remove the drive hub mounting bolts Carefully remove the turntable rotate drive hu...

Page 80: ...he filter element down to be sure the o ring on the element is fully seated into the housing CHECKLIST D PROCEDURES 7 Rotate the filter element clockwise to lock it in place 8 Install the filter housing cap 9 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housing Medium and high pressure filter Note The medium pressure filter is for the charg...

Page 81: ...ns requires that this procedure be performed every 1000 hours or annually whichever comes first Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with t...

Page 82: ... the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the boom to the stowed position and turn the machine off 12 Remove the dial indicator from the machine CHECKLIST D PROCEDURES P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 83: ... the ground controls side turntable cover E 1 Test or Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 2000 hours or 2 years whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause compo...

Page 84: ...ll the suction strainers using a thread sealant on the threads 15 Install the drain plug using a thread sealant on the threads 16 Install the hydraulic return filter housing onto the hydraulic tank 17 Install the hydraulic tank onto the machine 18 Install the two suction hoses to the suction strainers 19 Install the supply hose for the auxiliary power unit and the return filter hose 20 Models with...

Page 85: ...down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement 6 Remove the dust cap from the hub Remove the cotter pin from the castle nut 7 Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings Note Rotate the hub by hand while torqueing the castle nut to make sure the bearings seat properly 8 Loosen the castle nut one full turn and then to...

Page 86: ...nance Deutz and Perkins Models Engine specifications require that this procedure be performedevery2000hours Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Deutz 1011F models Required maintenance procedures an...

Page 87: ...astener located at the platform end of the engine tray Swing the engine tray out and away from the machine and secure it from moving Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury E 4 Perform Engine Maintenance Ford Models Engine specifications require that this procedure be performed every 2400 hours Required maintenance procedures and...

Page 88: ...rs Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information are available in the Deutz 1011F Operation Manual Deutz part number 0297 9683 or the Deutz 2...

Page 89: ...ecure it from moving Crushing hazard Failure to secure the engine pivot plate from moving could result in death or serious injury E 7 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performedevery6000hours Properenginemaintenance followingtheengine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to pe...

Page 90: ...torHandbook Fordpartnumber1020010 Ford LRG 425 EFI Operation Manual Genie part number 84792 Ford DSG 423 EFI Operator Handbook Genie part number 119488 Ford MSG 425 EFI Operator Handbook Genie part number 215322 To access the engine Remove the engine tray retaining fasteners located under the engine tray Loosen the pivot fastener located at the platform end of the engine tray Swing the engine tray...

Page 91: ...3 58 S 40 S 45 PartNo 102521 October2013 Section 3 Scheduled Maintenance Procedures This page intentionally left blank CHECKLIST E PROCEDURES P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 92: ...oided may result in propertydamage 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 Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damagedormalfunctioningmachine Repair any ...

Page 93: ...speed control over its entire range of motion a ALC 500 circuit board b drive steer joystick controller c secondary boom up down joystick controller d primary boom up down and turntable rotate left right joystick controller 1 1 ALC 500 Circuit Board Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Not...

Page 94: ...oard mounting fasteners 7 Carefully remove the ALC 500 circuit board from the platform control box PLATFORM CONTROLS 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Turn the key switch to platform control Do not start the engine 4 Select a joystick to calibrate 5 Disconnect the wire harness connector from the joystick for approximately 10 seco...

Page 95: ...enable toggle switch 7 Momentarily activate the drive enable toggle switch in the right direction 4 times Result There should be a pause and the alarm should sound 4 times indicating that the machine is in max out calibration mode Result The alarm does not sound Repeat steps 3 through 7 8 Start the engine from the platform controls and press down the foot switch 9 Start a timer and activate the ma...

Page 96: ...button to the on position at both the ground and platform controls 2 Turn the key switch to platform control Do not start the engine 3 Push in the platform controls red Emergency Stop button to the off position 4 Do not press down the foot switch 5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position 6 When the alarm sound...

Page 97: ...sition and wait for approximately 10 seconds to allow the settings to be saved Result The alarm should sound indicating that the settings have been saved in memory Note Do not operate any machine function during the 10 second waiting time 15 Cycle the red Emergency Stop button off then back on Ramp rate factory settings Boomup down accelerate 3 second decelerate 1 seconds Turntable rotate accelera...

Page 98: ...nd the alarm should sound 8 times indicating that the machine is in threshold calibration mode Result The alarm does not sound Repeat steps 3 through 7 8 Start the engine from the platform controls and press down the foot switch 9 Select a boom function joystick to set the threshold 10 Slowly move the joystick off center in either direction just until the function begins to move 11 Slowly move the...

Page 99: ... of the boom on the blocks 4 Protect the slave cylinder rod from damage S 40Models 5 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the platform rotate counterbalance valve manifold and connect them together using a connector Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic conne...

Page 100: ...ns 1 Remove the platform and platform support S 40Models 2 Tag disconnect and plug the hydraulic hoses from the platform rotator Cap the fittings on the rotator Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray S 45 Models 3 Tag and disconnect the hydr...

Page 101: ...e Secure the container to the boom 3 Open the top bleed valve on the rotator but do not remove it a top bleed valve b bottom bleed valve c container d clear hose 4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the b...

Page 102: ...er can be used to correct the overloaded platform condition in order to resume normal safe operation of the machine Note When the engine is shut off in an overloaded condition it will not be possible to re start the engine until the overloaded condition is corrected How to Calibrate the Platform Overload System if equipped Calibration of the platform overload system is essential to safe machine op...

Page 103: ...latform to settle Result The overload indicator lights are off and the alarm does not sound Proceed to step 6 Result The overload indicator lights are flashing at the platform and ground controls the alarm is sounding and the engine stops Slowly tighten the load spring adjustment nut in a clockwise direction in 10 increments until the overload indicator light turns off and the alarm does not sound...

Page 104: ... indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Start the engine from the ground controls 14 Test all machine functions from the ground controls Result All ground control functions should operatenormally 15 Turn the key switch to platform control 16 T...

Page 105: ...nd cables from the side of the jib boom and set them aside Componentdamagehazard Hoses and cables can be damaged if they are kinked or pinched 7 Place blocks under the platform leveling cylinder for support Protect the cylinder rod from damage 8 Remove the pin retaining fasteners from the jib boom lift cylinder barrel end pivot pin Do not remove the pin 9 Attach a lifting strap from an overhead cr...

Page 106: ... spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 5 Support the jib boom lift cylinder with a lifting de...

Page 107: ...p from the platform support Boom Components 6 Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold 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 Tag di...

Page 108: ...rd The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Industries Service Parts Department part no 81007 The kit includes a 4 link section of cable track 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Remove the snap on cable track spacers 3 Carefully remove the external snap rings from the ...

Page 109: ... platform end of the cable track Remove the clevis pin Note Always replace the cotter pin with a new one when removing a clevis pin 11 Remove the fasteners from the side panel on the cable track to access the cable track mountingfasteners 4 2 Boom How to Remove the Boom Consult the Genie Industries Service Department for instructions on how to safely remove the boom assembly from the machine Failu...

Page 110: ...azard 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 17 Attach an overhead 5 ton 4500 kg crane to the center point of the boom 18 Attach a similar lifting device to the boom lift cylinder 19 Use the overhead crane to lift the boom to a horizontalposition 20 Place suppor...

Page 111: ...d become unbalanced and fall when removed from the primary boom tube if not properlysupported Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing 7 Remove and label the wear pads from the top side of the secondary boom tube at the platform end of the boom 8 Remove the trunnion pin retaining fasteners at the base end of the secondary boom tube Use a ...

Page 112: ...ting device 5 Tag disconnect and plug the 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 6 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft...

Page 113: ...ssible in the extension tube 2 Remove the master cylinder See 4 5 How to Remove the Master Cylinder 3 Raise the boom to a horizontal position 4 Remove the external snap rings from the extension cylinder rod end pins at the platform end Use a soft metal drift to remove the pins 5 Remove the turntable end cover 6 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the ...

Page 114: ...he master cylinder rod end pivot pin is accessible 3 Tag disconnect and plug the master 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 4 Attach a lifting strap from an overhead crane to the l...

Page 115: ...gine flywheel f 0 18 inch 4 6 mm gap Deutz Models 0 070 inch 1 8 mm gap Perkins Models 0 0625 inch 1 6 mm gap Ford LRG 425 0 080 inch 2 mm gap Ford DSG 423 How to Remove the Flex Plate Deutzmodels 1 Remove the tailpipe bracket mounting fasteners from the engine bell housing 2 Support the drive pump assembly with an appropriate lifting device 3 Remove all of the engine bell housing fasteners 4 Care...

Page 116: ...te lifting device 12 Remove all of the engine bell housing fasteners 13 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Componentdamagehazard Hoses can be damaged if they are kinked orpinched 14 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Ford DSG 423 EFI models 1 Disconnect the electrical connectors from both ox...

Page 117: ...mbly 9 Remove all of the engine bell housing retaining fasteners 10 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Componentdamagehazard Hoses can be damaged if they are kinked orpinched 11 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Perkinsmodels 1 Remove the fuel filter water separator mounting fasteners 2 Rem...

Page 118: ...mounting bolts in sequence to 28 ft lbs 38 Nm After serial number 7543 Torque the bell housing mounting bolts in sequence to 47 ft lbs 63 Nm Perkinsmodels Before serial number 7472 Torque the bell housing mounting bolts in sequence to 28 ft lbs 38 Nm After serial number 7471 Torque the bell housing mounting bolts labeled B in sequence to 28 ft lbs 38 Nm and the mounting bolts labeled A to 49 ft lb...

Page 119: ...oggle switch in the test position and count the blinks Note If any fault codes are present the ECM will use the check engine light to blink a three digit code It will blink the first digit of a three digit code pause blink the second digit pause and then blink the third digit For example the check engine light blinks 5 consecutive times blinks 3 times and then 1 time That would indicate code 531 T...

Page 120: ... the machine to inform personnel of the condition Models without hydraulic tank shut off valves Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container See capacity specifications 2 Tag disconnect and plug the function pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydrau...

Page 121: ...Section 2 Hydraulic Hose and Fitting TorqueSpecifications 1 Disconnect the electrical connection at the electro proportional controller located on the drive pump 2 Models with hydraulic tank shut off valves Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valves Componentdamagehazard The engine must not be started with the hydrau...

Page 122: ...atch is located under the engine turntable pivot plate at the counterweight end of the machine 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine 4 Ford models Close the valve on the LPG tank then disconnect the hose from the tank Move the fuel select switch to the LPG position Perkins models Disconnect the engine wiring harness from the fuel solenoi...

Page 123: ...bs 27 34 Nm 6 Check valve AF Differential sensing circuit boom up down 10 12 ft lbs 14 16 Nm 7 Differential sensing valve 150 psi 10 3 bar AG Turntable rotate circuit 30 35 ft lbs 41 47 Nm 8 Differential sensing valve 150 psi 10 3 bar AH Boom up down circuit 30 35 ft lbs 41 47 Nm 9 Relief valve 2200 psi 152 bar AI Boom down relief 20 25 ft lbs 27 34 Nm 10 Flow regulator valve 0 1 gpm 0 38 L min AJ...

Page 124: ...es AA AB AC AD AE AF AG AH AI AJ AK AL AM AN AO AP AQ AR AS AT AU AV AW AX AY AZ BA BB BC BD BE BF BG BH BI 35 34 33 32 31 30 29 28 15 27 18 17 19 21 20 16 22 23 24 25 26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 36 MANIFOLDS P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 125: ...4 Nm 25 Solenoid valve 2 position 3 way AX Boom up 30 35 ft lbs 41 47 Nm 26 Solenoid valve 2 position 3 way AY Boom down 30 35 ft lbs 41 47 Nm 27 Solenoid valve 3 position 4 way AZ Turntable rotate 20 25 ft lbs 27 34 Nm 28 Check valve BA Platform level down 10 12 ft lbs 14 16 Nm 29 Proportional solenoid valve BB Turntable rotate left right 20 25 ft lbs 27 34 Nm 30 Counterbalance valve BC Platform ...

Page 126: ...es MANIFOLDS AA AB AC AD AE AF AG AH AI AJ AK AL AM AN AO AP AQ AR AS AT AU AV AW AX AY AZ BA BB BC BD BE BF BG BH BI 35 34 33 32 31 30 29 28 15 27 18 17 19 21 20 16 22 23 24 25 26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 36 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 127: ... idle position Activate and hold the boom retract toggle switch with the boom fully retracted 4 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the engine off Use a wrench to hold the relief valve and remove the cap item AQ 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the...

Page 128: ... ft lbs 41 47 Nm 2 Counterbalance valve CB Platform rotate left 30 35 ft lbs 41 47 Nm 3 Relief valve CD Generator overload relief 30 35 ft lbs 41 47 Nm 4 Solenoid valve CE Controls generator on off 50 55 ft lbs 68 75 Nm 5 Solenoid valve 2 position 3 way CC Platform rotate jib boom select 18 20 ft lbs 25 27 Nm CA CB CC CD CE 1 2 3 4 5 Jib Select Manifold Generator Manifold Platform Rotate Manifold ...

Page 129: ...fold Components before serial number 7569 Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way DA Brake release 20 25 ft lbs 27 34 Nm 2 Orifice 0 025 inch 0 635 mm DB Turntable rotation brake release DA DB 1 2 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 130: ...n Item Function Torque 1 Orifice 0 025 inch 0 63 mm EA Turntable rotation brake release 2 Solenoid valve 2 position 3 way EB Brake release 20 25 ft lbs 27 34 Nm 3 Solenoid valve 2 position 3 way EC Two speed motor shift 20 25 ft lbs 27 34 Nm 4 Check valve ED Brake release circuit 20 25 ft lbs 27 34 Nm EA EB EC ED 1 3 2 4 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 131: ...onents The oscillate directional valve is mounted inside the drive chassis at the non steer end Index No Description Function Torque 1 Cap Breather 20 25 ft lbs 27 33 Nm 2 Spool valve Directional control 2 Relief valve Pressure adjustment 1 2 MANIFOLDS 3 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 132: ...r axle covers 5 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 6 To level the drive chassis start the engine and loosen the lock nuts on both sides of the urethane cushions 7 Push up or pull down on the threaded rod until the machine is completely level 8 Verify that the ground and drive chassis are completely level 9 Tighten...

Page 133: ...lly activate the valve and observe the pressure reading on the pressure gauge Oscillate relief valve specification Pressure 950 psi 65 5 bar 6 Turn the engine off 7 Locate the relief valve on the directional valve and remove the cap 8 Adjust the internal screw Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap Tip over hazard Do not adjust...

Page 134: ...lief valve 210 psi 14 5 bar FA Charge pressure circuit 30 35 ft lbs 41 47 Nm 2 Flow divider combiner valve FB Controls flow to drive motors in forward and reverse 90 100 ft lbs 122 136 Nm 3 Orifice 0 070 inch 1 78 mm FC Equalizes flow across flow divider combiner valve item FB 4 Shuttle valve 3 position 3 way FD Charge pressure hot oil shuttle 50 55 ft lbs 68 75 Nm 5 Diagnostic nipple FE Testing 2...

Page 135: ...ircuit 30 35 ft lbs 41 47 Nm 2 Flow divider combiner valve GB Controls flow to drive motors in forward and reverse 90 100 ft lbs 122 136 Nm 3 Check valve GC Drive circuit 30 35 ft lbs 41 47 Nm 4 Check valve GD Drive circuit 30 35 ft lbs 41 47 Nm 5 Flow divider combiner valve GE Controls flow to drive motors in forward and reverse 50 55 ft lbs 68 75 Nm 6 Orifice 0 070 inch 1 78 mm GF Equalizes flow...

Page 136: ...e Note the pressure reading on the pressure gauge 3 Turn the engine off and connect a 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple located on the drive manifold 4 Start the engine from the platform controls and drive the machine slowly in the forward direction Note the pressure reading on the pressure gauge 5 Turn the engine off and remove the hot oil shuttle relief valve cap i...

Page 137: ...drive motors in forward reverse 90 100 ft lbs 122 136 Nm 3 Orifice 0 070 inch 1 778 mm HC Rear drive motor circuit 4 Orifice 0 070 inch 1 778 mm HD Equalizes pressure on both sides of flow divider combiner valve 7 5 Shuttle valve 3 position 3 way HE Charge pressure hot oil shuttle 50 55 ft lbs 68 75 Nm 6 Diagnostic nipple HF Testing 7 Flow divider combiner valve HG Controls flow to flow divider co...

Page 138: ...PartNo 102521 S 40 S 45 4 47 October2013 Section 4 Repair Procedures MANIFOLDS HA HB HC HD HE HF HG HH HI 1 7 2 3 4 5 6 9 8 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 139: ... lbs 108 122 Nm 6 Check valve JF Non steer end drive motor circuit 60 70 ft lbs 81 95 Nm 7 Orifice 0 040 inch 1 mm JG Equalizes pressure on both sides of flow divider combiner valve 5 8 Orifice 0 040 inch 1 mm JH Equalizes pressure on both sides of flow divider combiner valve 2 9 Orifice 0 040 inch 1 mm JI Equalizes pressure on both sides of flow divider combiner valve 13 10 Check valve JJ Steer e...

Page 140: ...rtNo 102521 S 40 S 45 4 49 October2013 Section 4 Repair Procedures MANIFOLDS JA JB JC JD JE JF JN JM JI JL JK JJ JH JG 10 11 13 4 5 3 2 1 14 12 6 7 8 9 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 141: ...ve KF Controls flow to flow divider combiner valves 2 and 13 80 90 ft lbs 108 122 Nm 7 Orifice 0 040 inch 1 mm KG Equalizes pressure on both sides of flow divider combiner valve 5 8 Orifice 0 040 inch 1 mm KH Equalizes pressure on both sides of flow divider combiner valve 2 9 Orifice 0 040 inch 1 mm KI Equalizes pressure on both sides of flow divider combiner valve 13 11 Shuttle valve 3 position 3...

Page 142: ...No 102521 S 40 S 45 4 51 October2013 Section 4 Repair Procedures KA KB KC KD KE KF KG KH KI KJ KK KL KM KN 4WD 9 8 7 10 11 13 6 5 3 2 4 1 14 12 MANIFOLDS P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 143: ...gauge to the diagnostic nipple located on the drive manifold 4 Start the engine from the platform controls and drive the machine slowly in the forward direction Note the pressure reading on the pressure gauge 5 Turn the engine off and remove the hot oil shuttle relief valve cap item HH Adjust the internal hex socket clockwise to increase the pressure or counterclockwise to decrease the pressure In...

Page 144: ...1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance using a multimeter set to resistance Ω Refer to the Valve Coil Resistance Specification table Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 6...

Page 145: ...attery should read 9V DC or more when measured across the terminals 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA a multimeter b 9V DC battery c 10Ω resistor d coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 4 Connect the negative lead to the other terminal on the coil Not...

Page 146: ... No Description Item Function Torque 1 Directional Valve CY Diverter valve 80 90 ft lbs 108 122 Nm 2 Orifice disc CW Delays shift to drive 35 40 ft lbs 47 54 Nm 3 Solenoid valve CV Pilot valve to diverter 35 40 ft lbs 47 54 Nm 4 Relief valve CX Charge pressure circuit 35 40 ft lbs 47 54 Nm 5 Check valve CU Prevents oil to generator 35 40 ft lbs 47 54 Nm MANIFOLDS CU CX CY CW CV 1 3 4 5 2 P r o p e...

Page 147: ...ake assembly b drive hub c backlash plate mounting bolts d backlash plate e manifold f motor 8 1 Turntable Rotation Assembly How to Remove the Turntable Rotation Assembly Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting TorqueSpecifications Not...

Page 148: ...mbly is removed if the turntable is not secured with the turntable rotation lock pin Crushing hazard The turntable rotation drive hub assembly could become unbalanced and fall when removed from the machine if not properly supported When installing the drive hub assembly 6 Install the drive hub Apply Loctite removable thread sealant and torque the backlash plate mounting fasteners to 160 ft lbs 217...

Page 149: ...tion Refer to Section Two Hydraulic Hose and Fitting TorqueSpecifications 1 Rotate the turntable until the boom is between the steer tires 2 Remove the fasteners from drive chassis cover at the steer end Remove the cover 3 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and bu...

Page 150: ...the pin supporting the TRAX assembly 8 Carefully remove the track assembly from the drive hub and set aside Crushing hazard The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane How to Replace the Track Note The sprocket is comprised of two halves 1 Center a lifting jack of ample capacity 20 000 lbs 10 000 kg under the dri...

Page 151: ... idler wheel half sprocket Illustration 2 11 Install the other sprocket half removed in step 4 12 Install the lug nuts onto the wheel hub and torque to specification Refer to Section 2 Specifications 13 Adjust the track tension Tighten the tensioner nut on both sides of the idler wheel until there is about 0 75 1 0 inch 19 25 mm of droop between the inside of the rubber track and the bottom surfac...

Page 152: ...trical tool which does not draw more than 15A to the electrical outlet at the platform controls and run the tool at full speed 5 Connect the positive and negative leads from a multimeter of sufficient capacity to the electrical outlet at the generator Result The reading on the multimeter should be 112 to 118V AC Result If the reading on the multimeter is not 112 to 118V AC proceed to step 6 6 Turn...

Page 153: ...tor harness 2 Connect a jumper wire of sufficient length from the positive battery terminal to the spade connector on the purge wire 3 Start the engine and turn on the generator Allow the generator to run for three minutes 4 Turn off the generator and turn off the engine 5 Remove the jumper wire from the positive battery terminal and disconnect from the purge wire 6 Start the engine and turn on th...

Page 154: ...nd burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Note Perform all troubleshooting on a firm level surface Note Two persons will be required to safely performsometroubleshootingprocedures Fault Codes Observe and Obey Troubleshootingandrepairproceduresshallbe completed by a person trained and qualified on the r...

Page 155: ...nts If the circuit board does need to be handled maintain firm contact with a metal part of the machine that is grounded at all times when handling the printed circuit board OR use a grounded wrist strap 3 Determine the error source The red LED indicates the error source and will flash two separate codes The first code will indicate the first digit of the two digit code flashing once per second It...

Page 156: ...ng fault Cycle power off then on and problem should be corrected 17 Not calibrated Normal function except threshold for one or both directions is zero Calibrate valve thresholds 24 Boom 1 angle sensor 11 12 15 16 Value at 5V Value too high Value too low Value at 0V Reduced speed Cycle power off then on and problem should be corrected 31 Invalid setup Initiate 1 second beep of alarm Calibrate angle...

Page 157: ... should be corrected 41 Turntable rotate joystick 17 Not calibrated Function is inoperative until joystick is calibrated Calibrate joystick 42 Turntable rotate directional valves 21 Fault Valve is operating outside of operational limits Alarm sounds indicating fault Cycle power off then on and problem should be corrected 12 15 Value too high Value too low Valve is operating outside of operational ...

Page 158: ...irections is zero Calibrate valve thresholds 54 Drive brake valve 21 Fault Valve is operating outside of operational limits Alarm sounds indicating fault Cycle power off then on and problem should be corrected 55 High speed drive motor Valve 21 Fault Motor speed frozen in the low state Alarm sounds indicating fault Cycle power off then on and problem should be corrected 11 12 15 16 Value at 5V Val...

Page 159: ...ght should begin to blink 5 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 123 three times After the fault codes the check engine light will blink a code 123 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a three ...

Page 160: ...t leaks OR one or more fuel injectors faulty or stuck closed OR fuel quality is poor OR fuel pressure is too low MAP IAT or ECT sensors not in correct position OR wiring and or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck closed OR there is electro magnetic interference from a faulty crankshaft and or camshaft position sensor Heated Oxygen Sen...

Page 161: ...eating the engine OR sensor wires and or connections open or shorted OR sensor is faulty OR coolant level is low Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification 222 CHT ECT Low Voltage Engine cooling system is malfunctioning and overheating the engine OR sensor wires and or connections open or shorted ...

Page 162: ...jector 4 OR fuel injector 4 is faulty OR ECM is faulty 321 Repair wiring and or connections to fuel injector 4 OR replace fuel injector 4 OR replace the ECM Injector Driver 4 Shorted Wiring and or connections to fuel injector 4 is shorted OR fuel injector 4 is faulty OR ECM is faulty 322 Fuel Pump Loop Open or High Side Short to Ground Open wiring and or connections to fuel pump OR fuel pump power...

Page 163: ...hrottle position sensor wiring and or connections open or shorted OR there is a poor system ground connection OR throttle position sensor 1 is faulty 531 TPS1 Signal Voltage High Be sure system ground connections are in place and secure OR repair wiring and or connections to sensor OR replace throttle position sensor 1 532 TPS1 Signal Voltage Low The 2 throttle position sensor wiring and or connec...

Page 164: ...ng damage or shorts to ECM to be sure they are secure OR replace ECM 612 Invalid Interrupt 613 A D Loss 614 615 Flash Checksum Invalid RTI 1 Loss 616 RAM Failure Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM External 5V DC Ref Lower than Expected Engine harness wiring and or connections open or shorted to groun...

Page 165: ...ght should begin to blink 5 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 123 three times After the fault codes the check engine light will blink a code 123 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a three ...

Page 166: ... 1 2 excessive signal 1 Code Description 111 CL closed loop high LPG 112 EGO open lazy pre cat 1 113 114 EGO open lazy post cat 1 EGO open lazy pre cat 2 post cat 1 115 121 122 124 EGO open lazy post cat 2 CL closed loop high gasoline bank 1 CL closed loop low gasoline bank 1 CL closed loop low LPG 133 134 141 142 Gasoline catalyst monitor 1 LPG catalyst monitor AL adaptive learning high gasoline ...

Page 167: ...l shorted 1 Primary loop open OR low side short to ground 2 414 415 416 421 422 Primary coil shorted 4 Primary coil shorted 2 Primary loop open OR low side short to ground 3 Primary coil shorted 3 Primary loop open OR low side short to ground 4 FP fuel pressure low voltage FT fuel temperature gasoline low voltage FT fuel temperature gaseous fuel high voltage FT fuel temperature gaseous fuel low vo...

Page 168: ... voltage 634 635 641 642 Rx inactive 643 644 646 647 Invalid packet format Shutdown request CAN Tx failure CAN Rx failure 648 655 656 711 RTI 3 loss CAN address conflict failure RTI 2 loss Relay control ground short 712 713 714 715 Relay coil open Relay coil short to power Fpump relay control ground short Fpump relay coil open 716 721 722 723 Fpump relay coil short to power Start relay control gro...

Page 169: ...5 16 S 40 S 45 PartNo 102521 October2013 Section 5 Fault Codes This page intentionally left blank P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 170: ...on There are two groups of schematics in this section An illustration legend precedes each group of drawings ElectricalSchematics Electrocution burnhazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry HydraulicSchematics Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connection...

Page 171: ...itch DPDT TS6 UP DOWN PLATFORM LEVEL Gauge sending unit HM Hour meter N O OTS2 Oil temperature switch normally open N O CTS1 Coolant temperature switch normally open Oil pressure switch normally closed N C OPS1 BLK FS1 Foot switch Pump Aux Auxiliary pump FAN Hydraulic oil cooling fan G1 Gauge Tilt sensor LED L3 Limit switch N C H O N O H C LS3 Fuse with amperage 25A F1 510 Resistor with ohm value ...

Page 172: ...le displacement E Pump prime mover engine or motor Directional valve mechanically activated o Relief valve with pressure setting 200 psi 13 8 bar Orifice with size 035 0 89 mm Solenoid operated 3 position 4 way directional valve Directional valve pilot operated 2 position 2 way Flow divider combiner valve with pressure balancing orifice and flow percentages 50 50 Counterbalance valve with pressure...

Page 173: ... 102521 October2013 Section 6 Schematics Power Relay Starter Relay Fuel Pump Relay F5 15A F4 15A F3 10A F2 5A F1 10A Empty Ford DSG 423 Engine Relay Layout F6 10A F6 10A P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 174: ...GND BK BR RD RD C18JD C17JU C2DA GR 11 14 15 16 13 12 10 9 7 8 C14PLU C13DRE C15PLD R43HRN OR BK C8PBR C7PBE BK 3 5 4 2 1 C3PBF C4TRL C5TRR C2PBD C1PBU WH RD CIRCUIT CIRCUIT COLOR C1PBU C2PBD C5TRR C4TRL C3PBF C7PBE C8PBR C6TRF WH RD BK WH BK RD WH WH BK RD BK WH RD R43HRN C15PLD C13DRE C14PLU C2DA C17JU C18JD RD BK GR BK OR BK BL RD BK GR OR RD C23BAT C27AUX C28TTA RD BK RD WH RD C32TA P46PWR BL ...

Page 175: ...October2013 Section 6 Schematics 6 6 Connector Pin Legend 6 5 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 176: ...October2013 Section 6 Schematics 6 7 Electrical Schematic Deutz F3L 1011F Models before serial number 7544 6 8 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 177: ...6 C1 8 C2 7 TS2 P24FS WH P25FS RD P26ESTP BK TS6 BRN BK RD C35ESPD BK RD HIGH RPM LOW RPM TB35 TS55 RD RD WH BK OR BK C1 9 GENERATOR G2 G3 G1 VOLT METER OIL PRESSURE GAUGE WATER TEMP GAUGE L24 TB24 C5 15 C5 16 C5 14 C5 5 C6 27 C6 28 C6 23 TB43 C6 16 C5 2 C5 3 FAN OPTION COOLING FAN TEMP SWITCH HYDRAULIC OIL NO OTS CR17 NO CR17 CB3 20AMP C6 33 C6 34 C6 25 TB134 P1 RD TB22 PLAT GRD KS1 RD H6 L45 6 U...

Page 178: ...BK 3 J3 1 3 4 2 8 7 C41RPM OR BK 16 15 19 20 17 18 11 10 C30EDC WH C32BRK WH RD C6TRF WH RD C36STC BL C37STCC BL BK C31EDC WH BK C5TRR WH BK TB6 TB3 C6 1 C6 5 TB1 TB2 TB5 TB4 TB32 TB37 TB36 TB31 TB30 C1PBU RD TS61 C4TRL WH TS62 C3P 1 C3P 6 C3P 4 C3P 5 C1P 6 C1P 11 C1P 10 C1P 4 C1P 5 BRN 2 C2P 3 RD BK BRN OR J2 6 J1 12 1 11 2 9 7 PRI UP DN TT ROTATE YOUT XOUT GND 1 2 4 3 5 6 PWR JC2 DRE A BL WH DRE...

Page 179: ...October2013 Section 6 Schematics 6 10 Electrical Schematic Deutz F3L 1011F Models before serial number 7544 6 9 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 180: ...RD CR2 30 BR GND CR2 KEY BYPASS ENG FAULT IGN FUEL ON 10 8 9 6 7 5 BATTERY KEY PWR GROUND RD 27B BK 33D OR BK 41B BK CR1 86 TACHOMETER START INPUT START RELAY 3 2 1 BK C6 16 CR5 BK 22B BL C6 36 BL BK C6 37 RD BK C6 28 OR C6 14 OR BK C6 15 LIMIT SWITCH POWER 46 SPARE WH BK C5 20 WH C5 21 WH RD C5 23 BL WH C6 30 WH RD C6 32 GR 43D BL WH L2 CR17 OR C6 33 RD CB3 SP BK C6 25 BR GND C6 26 GR C2B 5 GR CR...

Page 181: ...October2013 Section 6 Schematics 6 12 Ground Control Box Wiring Diagram DeutzF3L1011FModels 6 11 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 182: ...October2013 Section 6 Schematics 6 13 Platform Control Box Wiring Diagram ALC 500 DeutzF3L1011FModels 6 14 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 183: ... C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C37STC BL BK C1P 11 C3PBF RD WH C3P 3 C36STCC BL C1P 10 C4TRL WH C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C2P J2 11 1 JC1 5 YEL JC3 5 BL JC3 3 OR JC2 4 RD JC1 3 OR JC2 3 OR JC2 5 BK ALC 500 BRN P24FS WH P24FS WH J3 1 3 C3P OPT BRN F S C9P F S LS18 JIB C19JSV GR WH C4P 7 AND TS8 C39LP BL RD C2P 1 C45GEN G...

Page 184: ...IFT DRIVE OPTION REPLACE WIRE WITH THIS WIRING DIAGRAM GND STUD BRN BATGND CE SEE DETAIL A RD WL1 DLITE RD WL2 WH J1 5 C34SA BK WH C1P 8 GLOW PLUG TS6 RD L4 L48 4 2 1 3 5 6 7 RD BK H1 GN BK H1 RD P3 RD RD 1 DASHED LINES INDICATE OPTION WIRES NOTE DRIVE LT BK RD C3P 9 OPTION TS47 GENERATOR GR WH 45 RD RD WH 24 REMOVE FOR GENERATOR OPTION BK RD 35 TS4 WH 24 HIGH LOW RPM TS47 JC3 L1 JC2 TS1 TS13 TS4 ...

Page 185: ...October2013 Section 6 Schematics 6 16 Platform Control Box Switch Panel Wiring Diagram DeutzF3L1011FModels 6 15 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 186: ...October2013 Section 6 Schematics 6 17 Electrical Schematic Perkins 704 30 Models before serial number 7472 6 18 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 187: ...L28 TB24 C6 39 C5 15 C5 16 C5 14 C5 5 C6 27 C6 28 C6 23 TB43 C6 16 C5 2 C5 3 FAN OPTION COOLING FAN TEMP SWITCH HYDRAULIC OIL NO OTS CR17 NO CR17 CB3 20AMP C6 33 C6 34 C6 25 C1 12 NO CR4 NO CR3 BK RD C5 8 HIGH IDLE RELAY HIGH RPM SOLENOID TB134 P1 RD TB22 PLAT GRD KS1 RD H6 L45 6 U33 12 8 7 1 4 3 5 TB132 C132PLI BL WH C134PWR OR RD C1 12 C2 4 P22BAT BK HORN C7 1 H1 P3 LS18 RD L4 P2 C28TTA RD BK RD...

Page 188: ...S9 BRN JIB VALVE WH CR13 TS8 TS7 GR BK 44 WH NC CR13 WH BK OR BK JOYSTICK CONTROL CARD TS13 CE OPTION LIFT DRIVE 4 NO CR30 CR27 NC BRN P24FS WH P24FS WH P26ESTP BK 3 J3 1 3 4 2 8 7 C41RPM OR BK 16 15 19 20 17 18 11 10 C30EDC WH C32BRK WH RD C6TRF WH RD C36STC BL C37STCC BL BK C31EDC WH BK C5TRR WH BK TB6 TB3 C6 1 C6 5 TB1 TB2 TB5 TB4 TB32 TB37 TB36 TB31 TB30 C1PBU RD TS61 C4TRL WH TS62 C3P 1 C3P 6...

Page 189: ...October2013 Section 6 Schematics 6 20 Electrical Schematic Perkins 704 30 Models before serial number 7472 6 19 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 190: ...BL WH C6 30 WH RD C6 32 GR C2B 5 GR CR5 86 BK WH C5 22 BK RD CR23 87 DRIVE LIGHT OPTION C133PLA GR BK 2B BL WH C23 3 RD H6 RD KS1 2 S P RD C6 23 GR BK C23 8 GR BK H6 RD 12VOLT CB3 SP CB2 SP CB1 SP 12 VOLT BATTERY POWER GR BK S P BK RD CR3 30 WH SP 46A WH LIMIT SWITCH POWER HARNESS TO BASE WIRING KS1 B B1 1 2 4 3 RD KEY SWITCH WH RD 26A BR GROUND WH 21A WH BK 25A G3 G2 G1 WH 21A BR GROUND BK WH 34A...

Page 191: ...October2013 Section 6 Schematics 6 22 Ground Control Box Wiring Diagram Perkins704 30Models 6 21 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 192: ...October2013 Section 6 Schematics 6 23 Platform Control Box Wiring Diagram Perkins704 30Models 6 24 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 193: ... C3P 11 C40LS1 OR C2P 2 C12SBF BL WH C3P 12 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C37STC BL BK C1P 11 C3PBF RD WH C3P 3 C36STCC BL C1P 10 C4TRL WH C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C2P J2 11 1 JC1 5 YEL JC3 5 BL JC3 3 OR JC2 4 RD JC1 3 OR JC2 3 OR JC2 5 BK ALC 500 BRN P24FS WH P24FS WH J3 1 3 C3P OPT BRN F S C9P F S LS18 J...

Page 194: ...IVE OPTION REPLACE WIRE WITH THIS WIRING DIAGRAM GND STUD BRN BATGND CE SEE DETAIL A RD WL1 DLITE RD WL2 WH J1 5 C34SA BK WH C1P 8 GLOW PLUG L24 L4 L48 4 2 1 3 5 6 7 RD BK H1 GN BK H1 RD P3 RD RD 1 DASHED LINES INDICATE OPTION WIRES NOTE DRIVE LT BK RD C3P 9 OPTION TS47 GENERATOR GR WH 45 RD RD WH 24 REMOVE FOR GENERATOR OPTION BK RD 35 TS4 WH 24 HIGH LOW RPM TS47 JC3 L1 JC2 TS1 TS13 TS4 TS15 TS8 ...

Page 195: ...October2013 Section 6 Schematics 6 26 Platform Control Box Switch Panel Wiring Diagram Perkins704 30Models 6 25 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 196: ...ion 6 Schematics 6 27 Electrical Schematic Deutz F3L 2011 Deutz D2011L03i from serial number 7544 to 12509 Perkins 404 22 Models from serial number 7472 to 12509 6 28 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 197: ...5 RD RD WH BK OR BK C1 9 GENERATOR G2 G3 G1 VOLT METER OIL PRESSURE GAUGE WATER TEMP GAUGE TB24 C5 13 C5 5 C6 27 C6 28 C6 23 TB43 C6 16 C5 2 C5 3 FAN OPTION COOLING FAN TEMP SWITCH HYDRAULIC OIL NO OTS CR17 NO CR17 CB3 20AMP C6 33 C6 34 C6 25 TB134 P1 RD TB22 PLAT GRD KS1 RD H6 L45 6 U33 12 8 7 1 4 3 5 TB132 C132PLI BL WH C134PWR RD C1 12 C2 4 P22BAT BK HORN C7 1 H1 P3 LS18 RD L4 P2 C28TTA RD BK R...

Page 198: ...WH BK OR BK JOYSTICK CONTROL CARD TS13 CE OPTION LIFT DRIVE 4 NO CR30 CR27 NC BRN P24FS WH P24FS WH P26ESTP BK 3 J3 1 3 4 2 8 7 C41RPM OR BK 16 15 19 20 17 18 11 10 C30EDC WH C32BRK WH RD C6TRF WH RD C36STC BL C37STCC BL BK C31EDC WH BK C5TRR WH BK TB6 TB3 C6 1 C6 5 TB1 TB2 TB5 TB4 TB32 TB37 TB36 TB31 TB30 C1PBU RD TS61 C4TRL WH TS62 C3P 1 C3P 6 C3P 4 C3P 5 C1P 6 C1P 11 C1P 10 C1P 4 C1P 5 BRN 2 C2...

Page 199: ...13 Section 6 Schematics 6 30 Electrical Schematic DeutzF3L 2011 DeutzD2011L03i fromserialnumber7544to12509 Perkins404 22Models fromserialnumber7472to12509 6 29 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 200: ...October2013 Section 6 Schematics 6 31 Electrical Schematic DeutzF3L 2011 DeutzD2011L03iandPerkins404 22Models fromserialnumber12510to14831 6 32 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 201: ... G1 VOLT METER OIL PRESSURE GAUGE WATER TEMP GAUGE TB24 TB43 OPTION COOLING FAN TEMP SWITCH HYDRAULIC OIL NO OTS CR17 NO CR17 CB3 20AMP TB134 P1 RD TB22 PLAT GRD KS1 RD H6 L45 6 U33 12 8 7 1 4 3 5 TB132 C132PLI BL WH C134PWR OR RD C1 12 C2 4 P22BAT BK HORN C7 1 H1 P3 LS18 RD L4 P2 C28TTA RD BK RD BK C133PLA OR RD C4 4 C2 3 TB133 L48 D40 D39 FUNCTION ENA L2 M1 S7 M2 PR2 PR2 NO U1 Y29 G6 3MF RPM FIL...

Page 202: ...4 TB5 TB2 TB1 C6 5 C6 1 TB3 TB6 C5TRR WH BK C31EDC WH BK C37STCC BL BK C36STC BL C6TRF WH RD C32BRK WH RD C30EDC WH 10 11 18 17 20 19 15 16 C41RPM OR BK 7 8 2 4 3 1 J3 3 P26ESTP BK P24FS WH P24FS WH NC CR27 CR30 NO 4 DRIVE LIFT OPTION CE TS13 JOYSTICK CONTROL CARD OR BK BK WH TS7 WH TS9 C3P 3 C3P 2 C4P 1 TS63 C13DRE BL RD C2P 2 C3P 8 C3P 7 C4P 3 C4P 2 C40LS1 OR C8PBR BK WH C7PBE BK TB40 TB13 TB7 T...

Page 203: ...October2013 Section 6 Schematics 6 34 Electrical Schematic DeutzF3L 2011 DeutzD2011L03iandPerkins404 22Models fromserialnumber12510to14831 6 33 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 204: ...October2013 Section 6 Schematics 6 35 Electrical Schematic DeutzF3L 2011 DeutzD2011L03iandPerkins404 22Models fromserialnumber14832to15662 6 36 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 205: ...B22 PLAT GRD KS1 RD H6 L45 6 U33 12 8 7 1 4 3 5 TB132 C132PLI BL WH C134PWR OR RD C1 12 C2 4 P22BAT BK HORN C7 1 H1 P3 LS18 RD L4 P2 C28TTA RD BK RD BK C133PLA OR RD C4 4 C2 3 TB133 L48 D40 D39 FUNCTION ENA L2 M1 S7 M2 PR2 PR2 NO U1 Y29 G6 3MF RPM FILTER DEUTZ ONLY D6 D2 C5 5 C5 2 C5 3 EMISSION CONTROL C5 14 WH RD C5 16 WH BK C5 13 WH NC S2 SWITCH SWITCH OIL TEMPERATURE OIL PRESSURE NO S1 BR RD WH...

Page 206: ... C13DRE BL RD TS63 C4 1 C3 2 C3 3 TS9 WH TS7 WH BK OR BK JOYSTICK CONTROL CARD TS13 CE OPTION LIFT DRIVE 4 NO CR30 CR27 NC P24FS WH P24FS WH P26ESTP BK 3 J3 1 3 4 2 8 7 C41RPM OR BK 16 15 19 20 17 18 11 10 C30EDC WH C32BRK WH RD C6TRF WH RD C36STC BL C37STCC BL BK C31EDC WH BK C5TRR WH BK TB6 TB3 C6 1 C6 5 TB1 TB2 TB5 TB4 TB32 TB37 TB36 TB31 TB30 C1PBU RD TS61 C4TRL WH TS62 C3 1 C3 6 C3 4 C3 5 C1 ...

Page 207: ...October2013 Section 6 Schematics 6 38 Electrical Schematic DeutzF3L 2011 DeutzD2011L03iandPerkins404 22Models fromserialnumber14832to15662 6 37 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 208: ...ber2013 Section 6 Schematics 6 39 Electrical Schematic DeutzF3L 2011 Deutz D2011L03i andPerkins404 22Models ANSI CSA AS fromserialnumber15663to16419 6 40 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 209: ...GE TB24 TB43 OPTION COOLING FAN TEMP SWITCH HYDRAULIC OIL NO OTS CR17 NO CR17 CB3 20AMP TB134 P1 RD TB22 PLAT GRD KS1 RD 6 C32 CONN PLUG 12 8 7 1 4 3 5 TB132 C132PLI BL WH C134PWR OR RD C1 12 C2 4 P22BAT BK HORN C7 1 H1 P3 RD P2 C28TTA RD BK RD BK C133PLA OR RD C4 4 C2 3 TB133 L48 D40 D39 FUNCTION ENA L2 M1 S7 M2 PR2 PR2 NO U1 Y29 G6 3MF RPM FILTER DEUTZ D6 D3 D4 C5 5 C5 2 C5 3 FUEL SOLENOID D52 C...

Page 210: ... 8 C2 2 C13DRE BL RD TS63 C4 1 C3 2 C3 3 TS9 WH TS7 WH BK OR BK JOYSTICK CONTROL CARD TS13 CE OPTION LIFT DRIVE 4 NO CR30 CR27 NC P24FS WH P24FS WH P26ESTP BK 3 J3 1 3 4 2 8 7 C41RPM OR BK 16 15 19 20 17 18 11 10 C30EDC WH C32BRK WH RD C6TRF WH RD C36STC BL C37STCC BL BK C31EDC WH BK C5TRR WH BK TB6 TB3 C6 1 C6 5 TB1 TB2 TB5 TB4 TB32 TB37 TB36 TB31 TB30 C1PBU RD TS61 C4TRL WH TS62 C3 1 C3 6 C3 4 C...

Page 211: ...ber2013 Section 6 Schematics 6 42 Electrical Schematic DeutzF3L 2011 Deutz D2011L03i andPerkins404 22Models ANSI CSA AS fromserialnumber15663to16419 6 41 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 212: ...October2013 Section 6 Schematics 6 43 Electrical Schematic DeutzF3L 2011 Deutz D2011L03iandPerkins404 22Models CE fromserialnumber15663to16419 6 44 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 213: ... CR17 CB3 20AMP TB134 P1 RD TB22 PLAT GRD KS1 RD 6 LOAD SENSE MODULE 12 8 7 1 4 3 5 TB132 C132PLI BL WH C134PWR OR RD C1 12 C2 4 P22BAT BK HORN C7 1 H1 P3 RD P2 C28TTA RD BK RD BK C133PLA OR RD C4 4 C2 3 TB133 L48 D40 D39 FUNCTION ENA L2 M1 S7 M2 PR2 PR2 NO U1 Y29 G6 3MF RPM FILTER DEUTZ D6 D3 D4 C5 5 C5 2 C5 3 FUEL SOLENOID D52 C5 11 C21IGN2 WH BL WH EMISSION CONTROL DEUTZ C5 14 WH RD C5 16 WH BK...

Page 214: ... 2 C13DRE BL RD TS63 C4 1 C3 2 C3 3 TS9 WH TS7 WH BK OR BK JOYSTICK CONTROL CARD TS13 CE OPTION LIFT DRIVE 4 NO CR30 CR27 NC P24FS WH P24FS WH P26ESTP BK 3 J3 1 3 4 2 8 7 C41RPM OR BK 16 15 19 20 17 18 11 10 C30EDC WH C32BRK WH RD C6TRF WH RD C36STC BL C37STCC BL BK C31EDC WH BK C5TRR WH BK TB6 TB3 C6 1 C6 5 TB1 TB2 TB5 TB4 TB32 TB37 TB36 TB31 TB30 C1PBU RD TS61 C4TRL WH TS62 C3 1 C3 6 C3 4 C3 5 C...

Page 215: ...October2013 Section 6 Schematics 6 46 Electrical Schematic DeutzF3L 2011 Deutz D2011L03iandPerkins404 22Models CE fromserialnumber15663to16419 6 45 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 216: ...October2013 Section 6 Schematics 6 47 Electrical Schematic DeutzF3L 2011 Deutz D2011L03i andPerkins404 22Models ANSI CSA AS fromserialnumber16420 6 48 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 217: ...TB132 RD KS1 GRD PLAT TB22 P1 TB134 C6 25 C6 34 C6 33 20AMP CB3 CR17 NO CR17 OTS NO HYDRAULIC OIL TEMP SWITCH COOLING FAN OPTION C5 3 C5 2 C6 16 TB43 C6 23 C6 28 C6 27 C5 5 TB24 WATER TEMP GAUGE OIL PRESSURE GAUGE VOLT METER G1 G2 GENERATOR C1 9 OR BK BK WH RD RD TS55 LOW RPM HIGH RPM C35RPM BK RD BR P26ESTP BK P25FS RD P24FS WH TS2 C2 7 C45GEN GR WH C1 7 TS52 START RELAY MODULE IGN START START IN...

Page 218: ...C2 2 C13DRE BL RD TS63 C4 1 C3 2 C3 3 TS9 WH TS7 WH BK OR BK JOYSTICK CONTROL CARD TS13 CE OPTION LIFT DRIVE 4 NO CR30 CR27 NC P24FS WH P24FS WH P26ESTP BK 3 J3 1 3 4 2 8 7 C41RPM OR BK 16 15 19 20 17 18 11 10 C30EDC WH C32BRK WH RD C6TRF WH RD C36STC BL C37STCC BL BK C31EDC WH BK C5TRR WH BK TB6 TB3 C6 1 C6 5 TB1 TB2 TB5 TB4 TB32 TB37 TB36 TB31 TB30 C1PBU RD TS61 C4TRL WH TS62 C3 1 C3 6 C3 4 C3 5...

Page 219: ...October2013 Section 6 Schematics 6 50 Electrical Schematic DeutzF3L 2011 Deutz D2011L03i andPerkins404 22Models ANSI CSA AS fromserialnumber16420 6 49 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 220: ...October2013 Section 6 Schematics 6 51 Electrical Schematic DeutzF3L 2011 Deutz D2011L03iandPerkins404 22Models CE fromserialnumber16420 6 52 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 221: ...B2 RD 15AMP CB1 P23BAT WH C28TTA RD BK C27AUX RD C43HRN GR TB23 TB28 TB27 C2 5 TS51 C1 2 C7 2 C1 1 C9 1 BK FS1 C9 2 C9 3 C33STR BK TB33 4 3 5 2 1 AUX ON GROUND TACHOMETER START INPUT IGN START MODULE START RELAY TS52 C1 7 C45GEN GR WH C2 7 TS2 P24FS WH FS P25FS RD FS P26ESTP BK C35RPM BK RD HIGH RPM LOW RPM TS55 C1 9 GENERATOR G2 G3 G1 VOLT METER OIL PRESSURE GAUGE COOLANT TEMP GAUGE TB24 C5 5 C6 ...

Page 222: ...C13DRE BL RD TS63 C4 1 C3 2 C3 3 TS9 WH TS7 WH BK OR BK JOYSTICK CONTROL CARD TS13 CE OPTION LIFT DRIVE 4 NO CR30 CR27 NC P24FS WH P24FS WH P26ESTP BK 3 J3 1 3 4 2 8 7 C41RPM OR BK 16 15 19 20 17 18 11 10 C30EDC WH C32BRK WH RD C6TRF WH RD C36STC BL C37STCC BL BK C31EDC WH BK C5TRR WH BK TB6 TB3 C6 1 C6 5 TB1 TB2 TB5 TB4 TB32 TB37 TB36 TB31 TB30 C1PBU RD TS61 C4TRL WH TS62 C3 1 C3 6 C3 4 C3 5 C1 6...

Page 223: ...October2013 Section 6 Schematics 6 54 Electrical Schematic DeutzF3L 2011 Deutz D2011L03iandPerkins404 22Models CE fromserialnumber16420 6 53 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 224: ...ctober2013 Section 6 Schematics 6 55 Ground Control Box Wiring Diagram DeutzF3L 2011 DeutzD2011L03iandPerkins404 22Models beforeserialnumber14832 6 56 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 225: ...K 33B OR BK 41B BK CR1 86 TACHOMETER START INPUT START RELAY 3 2 1 BL C6 36 BL BK C6 37 RD BK C6 28 OR C6 14 OR BK C6 15 46 MOTOR SPEED WH BK C5 20 WH C5 21 WH RD C5 23 BL WH C6 30 WH RD C6 32 WH L2 DIODE GR C2B 5 GR CR5 85 BK WH C5 22 BK RD C5 9 BK RD 35B CR3 CR4 BK RD CR23 86 DRIVE LIGHT OPTION C133PLA GR BK 2B H6 U33 PLATFORM LOAD C32 BL WH C23 3 BL WH 38D C32 3 RD C32 1 RD H6 RD 42B RD KS1 2 S...

Page 226: ... C TURN ROT CCW PRI BOOM F C PRI BOOM DOWN TURN ROT CW MODULE IGN START BK S P WH S P RD BK S P WH BK S P RD WH S P WH RD S P RD S P B A RD P1 E STOP OR BK 15A GR WH 19A GR 17A OR 14A RD 24A RD 20B RD 20A BK RD 35A D13 TS55 D14 CB1 CB2 WH RD 6A WH 4A WH BK 5A RD CR17 30 RD 20C BK 7A GR BK 44A BK 33A BK WH 8A R2 TS52 CB3 OR BK ISM 2 RED CR1 30 45 GR WH C6 39 GR WH C2B 7 26 WH C5 3 C5 11 GR C6 17 BK...

Page 227: ...October2013 Section 6 Schematics 6 58 6 57 Ground Control Box Wiring Diagram DeutzD2011L03iandPerkins404 22Models from serial number 14832 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 228: ...tober2013 Section 6 Schematics 6 59 Platform Control Box Wiring Diagram DeutzF3L 2011 DeutzD2011L03iandPerkins404 22Models beforeserialnumber14832 6 60 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 229: ... C3P 10 C13DRE BL RD C4P 1 C11SBD BL BK C3P 11 C40LS1 OR C2P 2 C12SBF BL WH C3P 12 C41RPM OR BK C2P 3 C30EDC WH C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C37STC BL BK C1P 11 C3PBF RD WH C3P 3 C36STCC BL C1P 10 C4TRL WH C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C2P J2 11 1 JC1 5 YEL JC3 5 BL JC3 3 OR JC2 4 RD JC1 3 OR JC2 3 OR JC2 5 BK ALC 500 BRN P24FS WH P24FS W...

Page 230: ...C BL C1P 10 C3PBF RD WH C3P 3 C37STC BL BK C1P 11 C2PBD RD BK C3P 2 C31EDC WH BK C1P 5 C1PBU RD C3P 1 C30EDC WH C1P 4 C41RPM OR BK C2P 3 C12SBF BL WH C3P 12 C40LS1 OR C2P 2 C11SBD BL BK C3P 11 C13DRE BL RD C4P 1 C10SBU BL C3P 10 C6TRF WH RD C3P 6 J2 1 11 1 JC1 4 WH BK JC3 2 OR JC3 4 WH RD JC2 4 RD WH JC2 2 OR JC1 2 OR JC2 3 WH RD ALC 500 BR P24FS WH P24FS WH J3 3 F S C9P COMPONENT INDEX TILT ALARM...

Page 231: ...October2013 Section 6 Schematics 6 62 Platform Control Box Wiring Diagram ALC 500 DeutzD2011L03iandPerkins404 22Models from serial number 14832 6 61 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 232: ...chematics 6 63 Platform Control Box Switch Panel Wiring Diagram DeutzF3L 2011 DeutzD2011L03i fromserialnumber7544to12509 Perkins404 22Models fromserialnumber7472to12509 6 64 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 233: ...27AUX RD C1P 1 RD 25 C33STR BK C1P 7 WH 23 P26BAT BK C9P 1 P22BAT BK C7P 1 BK 22 RD LS18 RD P2 WH BK WH 8 BL RD DE3 J1 16 BL WH DE1 J1 6 BK 7 WH JDALARM GR BK 44 C2P 6 HARNESS PBOX WIRING BL BK DE2 J1 7 OR J1 13 BRN J1 14 BL J1 4 WH J1 5 OR J1 11 BRN J1 12 BK J1 2 RD J1 1 JC3 JC2 CR13 WH JIB C19JSV GR WH WH 24 BRN WH JIB 4 2 1 3 5 6 7 WH 24 BK 22 WH 24 SPLICE TO R40LS1 SPLICE TO C32BRK OR R40LS1 W...

Page 234: ...RNESS L4 RD BK H1 GN BK H1 WH 24 L48 J1 5 BL WH JC3 5 J1 5 BL WH JC3 3 J1 4 WH RD JC3 4 J1 14 BR JC3 1 J1 13 OR JC3 2 WH 23 BK 22 RD LS18 RD P3 RD DRIVE STEER JC3 DETAIL A LIFT DRIVE OPTION CR27 C34SA BK WH C1P 8 GLOW PLUG TS6 RD RD WL1 TS48 WORK RD WL2 10 AMP FUSE DRIVE LITE 1 DASHED LINES INDICATE OPTION WIRES NOTE OR R40LS1 SPLICE TO R40LS1 REPLACE WIRE WITH THIS WIRING DIAGRAM WH TS7 WH TS1 BR...

Page 235: ...October2013 Section 6 Schematics 6 66 Platform Control Box Switch Panel Wiring Diagram DeutzD2011L03iandPerkins404 22Models fromserialnumber12510 6 65 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 236: ...October2013 Section 6 Schematics 6 67 Electrical Schematic FordLRG 425EFIModels beforeserialnumber7597 6 68 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 237: ...GINE FORD 42 PIN PLUG FUEL PUMP FORD BK WH FEH 72 PIN7 BL WH FEH 787 PIN5 OR RD FEH 307A PIN23 WH FEH 16A PIN1 BR FEH 570C PIN34 PUMP FUEL BK RD FEH 458 PIN3 WH FEH 306 PIN24 BL FEH 658 PIN6 TB24 TB24 TS3 TS53 TB39 TEST RUN TS22 P24BAT C35RPM2 C39LP C211GN2 TSW C38ESL C6 39 C5 13 C5 12 C5 17 C5 10 C5 9 C5 11 C5 15 C5 16 C5 14 C5 5 C6 27 C6 28 C6 23 TB43 C6 16 C5 2 C5 3 C2 1 FAN OPTION COOLING FAN ...

Page 238: ...OR BK C30EDC WH C32BRK WH RD C6TRF WH RD C36STC BL C37STCC BL BK C31EDC WH BK C5TRR WH BK C6 1 C6 5 TB1 TB36 TB30 C1PBU RD TS61 C4TRL WH TS62 C3P 1 BRN 2 C2P 3 J2 J1 DRE A BL WH DRE B BL BK DRE LED BL RD J1 6 J1 7 16 8 15 TS15 L1 C6 32 C6 13 C6 40 C6 15 C6 14 C31EDC WH BK C30EDC WH C32BRK WH RD C37STCC BL BK C36STC BL C6TRF WH RD C5TRR WH BK C4TRL WH C1PBU RD C2PBD RD BK C3PBF RD WH C7PBE BK C8PBR...

Page 239: ...October2013 Section 6 Schematics 6 70 Electrical Schematic FordLRG 425EFIModels beforeserialnumber7597 6 69 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 240: ...C BOOM EXTEND BOOM RETRACT PRI BOOM UP WH RD S P RD WH S P WH BK S P RD BK S P WH S P BK WH S P BK S P JIB VALVE PLAT LEVEL UP PLAT LEVEL DN PLAT ROT L PLAT ROT R DRV ENA LT IGNITION PWR OR BK S P OR S P GR WH SP GR BK S P GR S P TILT ALARM E D C E D C AUX PWR KEYSWITCH PWR FB PWR TO PLAT ENGINE POWER WH BK S P WH RD S P RD S P WH S P BK S P RD S P SPARE LIMIT SWITCH SIG GLOW PLUG STEER LEFT RPM S...

Page 241: ...October2013 Section 6 Schematics 6 72 Ground Control Box Wiring Diagram FordLRG 425EFIModels beforeserialnumber7597 6 71 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 242: ...October2013 Section 6 Schematics 6 73 Platform Control Box Wiring Diagram FordLRG 425EFIModels beforeserialnumber7597 6 74 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 243: ...C3P 4 C36STCC BL C1P 10 C3PBF RD WH C3P 3 C37STC BL BK C1P 11 C2PBD RD BK C3P 2 C31EDC WH BK C1P 5 C1PBU RD C3P 1 C30EDC WH C1P 4 C41RPM OR BK C2P 3 C12SBF BL WH C3P 12 C40LS1 OR C2P 2 C11SBD BL BK C3P 11 C13DRE BL RD C4P 1 C10SBU BL C3P 10 C6TRF WH RD C3P 6 J2 1 11 1 JC1 5 YEL JC3 3 OR JC3 5 BL JC2 5 BK JC2 3 OR JC1 3 OR JC2 4 RD ALC 500 BRN P24FS WH P24FS WH J3 3 C3P OPT F S C9P F S LS18 JIB C4P...

Page 244: ...3037 13037 13037 13037 27378 56298 62390 75565 GR 43 OR 14 OR BK 15 C18JD GR BK C4P 6 C19JSV GR WH JIB C17JU GR C4P 5 C27AUX RD C1P 1 BL RD 39 WH 23 P26BAT BK C9P 1 P22BAT BK C7P 1 BK 22 RD WH GR RD TS3 BK WH 8 BL RD DE3 J1 16 BL WH DE1 J1 6 BK 7 WH WH JDALARM GR BK 44 C2P 6 HARNESS PBOX WIRING DASHED LINES INDICATE OPTION WIRES NOTE RD TILT BL BK DE2 J1 7 4 2 1 3 5 6 7 OR J1 13 BRN J1 14 BL J1 4 ...

Page 245: ...October2013 Section 6 Schematics 6 76 Platform Control Box Switch Panel Wiring Diagram FordLRG 425EFIModels beforeserialnumber7597 6 75 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 246: ...October2013 Section 6 Schematics 6 77 Electrical Schematic FordLRG 425EFIModels from serial number 7597 to 11066 6 78 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 247: ...YDRAULIC OIL NO OTS CR17 NO CR17 CB3 20AMP C6 33 C6 34 C6 25 TB134 P1 RD TB22 PLAT GRD KS1 RD C134PWR RD C2 4 P22BAT BK C7 1 H1 RD P2 C28TTA RD BK RD BK C133PLA OR RD C2 3 L48 D40 FUNCTION ENA THIS WIRE FOR UNITS WITHOUT GENERATOR OPTION IN THE STOWED POSITION AND KEYSWITCH OFF ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM NOTE WH BK WH RD C6 39 L2 D6 C6 26 TS17 TS4 HIGH RPM FS F18 BK BK WH WH...

Page 248: ...E TS13 JOYSTICK CONTROL CARD OR BK BK WH CR13 NC WH GR BK 44 TS7 TS8 CR13 WH JIB VALVE BRN TS9 C3P 3 C3P 2 C4P 1 TS63 C13DRE BL RD C2P 2 C3P 8 C3P 7 C4P 3 C4P 2 C40LS1 OR C8PBR BK WH C7PBE BK TB40 TB13 TB7 TB8 C6 7 TB14 C15PLD OR BK C14PLU OR C2PBD RD BK C3PBF RD WH C4P 6 C2P 6 C4P 5 TB44 TS58 TS57 C18JD GR BK C17JU GR JDALARM GR BK C4P 7 RD RD C19JSV GR WH TB15 C6 17 TB18 TB17 TB19 TS59 C19JSV GR...

Page 249: ...October2013 Section 6 Schematics 6 80 Electrical Schematic FordLRG 425EFIModels from serial number 7597 to 11066 6 79 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 250: ... 2 GR WH C6 39 42 BK CR1 85 37 34 33 35 36 39 38 40 41 D5 44 43 45 RD S P TURN ROT R PRI BOOM DOWN PRI BOOM F C TURN ROT L TURN ROT F C BOOM EXTEND BOOM RETRACT PRI BOOM UP WH RD S P RD WH S P WH BK S P RD BK S P WH S P BK WH S P BK S P JIB VALVE PLAT LEVEL UP PLAT LEVEL DN PLAT ROT L PLAT ROT R DRV ENA LT IGNITION PWR OR BK S P OR S P GR WH SP GR BK S P GR S P TILT ALARM E D C E D C AUX PWR KEYSW...

Page 251: ...October2013 Section 6 Schematics 6 82 Ground Control Box Wiring Diagram FordLRG 425EFIModels from serial number 7597 to 11066 6 81 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 252: ...October2013 Section 6 Schematics 6 83 Platform Control Box Wiring Diagram FordLRG 425EFIModels from serial number 7597 to 11066 6 84 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 253: ... 6 C4TRL WH C3P 4 C36STC BL C1P 10 C3PBF RD WH C3P 3 C37STCC BL BK C1P 11 C2PBD RD BK C3P 2 C31EDC WH BK C1P 5 C1PBU RD C3P 1 C30EDC WH C1P 4 C41RPM OR BK C2P 3 C12SBF BL WH C3P 12 C40LS1 OR C2P 2 C11SBD BL BK C3P 11 C13DRE BL RD C4P 1 C10SBU BL C3P 10 C6TRF WH RD C3P 6 J2 1 11 1 JC1 5 YEL JC3 3 OR JC3 5 BL JC2 5 BK JC2 3 OR JC1 3 OR JC2 4 RD ALC 500 BRN P24FS WH P24FS WH J3 3 C3P OPT F S C9P F S ...

Page 254: ...5565 GR 43 OR 14 OR BK 15 C18JD GR BK C4P 6 C19JSV GR WH JIB C17JU GR C4P 5 C27AUX RD C1P 1 BL RD 39 WH 23 P26BAT BK C9P 1 P22BAT BK C7P 1 BK 22 RD WH GR RD TS3 BK WH 8 BL RD DE3 J1 16 BL WH DE1 J1 6 BK 7 WH WH JDALARM GR BK 44 C2P 6 HARNESS PBOX WIRING DASHED LINES INDICATE OPTION WIRES NOTE RD TILT BL BK DE2 J1 7 4 2 1 3 5 6 7 OR J1 13 BRN J1 14 BL J1 4 WH J1 5 OR J1 11 BRN J1 12 BK J1 2 RD J1 1...

Page 255: ...October2013 Section 6 Schematics 6 86 Platform Control Box Switch Panel Wiring Diagram FordLRG 425EFIModels from serial number 7597 to 11066 6 85 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 256: ...October2013 Section 6 Schematics 6 87 Electrical Schematic FordDSG 423EFIModels from serial number 11067 to 12509 6 88 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 257: ... FLASHING BEACONS _ HOUR METER PR1 NO WH RD PR1 CR5 NO CR5 R43HRN BK RD BK RD DC 12 V BK PUMP TILT ALARM LEVEL SENSOR RELAY SERVICE HORN SERVICE HORN RELAY AUXILIARY POWER AUXILIARY PUMP H2 STARTER MOTOR 1K R3 WH RD PIN 39 DIAGNOSTIC BLUE PINK HARNESS ENGINE FORD C135RET C135FP BL PIN 18 GASOLINE SENSOR GY RD GY YL RD BK BL D C B A C5 8 WH PIN 24 R21IGN 42 PIN FORD CONNECTOR OR BK PIN 2 C41RPM C5 ...

Page 258: ...STP BK 3 J3 1 3 4 2 8 7 C41RPM OR BK 16 15 19 20 17 18 11 10 C30EDC WH C32BRK WH RD C6TRF WH RD C36STC BL C37STCC BL BK C31EDC WH BK C5TRR WH BK TB6 TB3 C6 1 C6 5 TB1 TB2 TB5 TB4 TB32 TB37 TB36 TB31 TB30 C1PBU RD TS61 C4TRL WH TS62 C3P 1 C3P 6 C3P 4 C3P 5 C1P 6 C1P 11 C1P 10 C1P 4 C1P 5 BRN 2 C2P 3 RD BK BRN OR J2 6 J1 12 1 11 2 9 7 PRI UP DN TT ROTATE YOUT XOUT GND 1 2 4 3 5 6 PWR JC2 DRE A BL WH...

Page 259: ...October2013 Section 6 Schematics 6 90 Electrical Schematic FordDSG 423EFIModels from serial number 11067 to 12509 6 89 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 260: ...February2012 Section 6 Schematics 6 91 Electrical Schematic FordDSG 423EFIModels from serial number 12510 to 14831 6 92 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 261: ...B20 15AMP C41RPM OR BK TB41 FB GR WH TB21 R21IGN WH TB26 TB25 OPS GENERATOR OPTION OPTION FLASHING BEACONS _ HOUR METER PR1 NO WH RD PR1 CR5 NO CR5 R43HRN BK RD BK RD DC 12 V BK PUMP TILT ALARM LEVEL SENSOR RELAY SERVICE HORN SERVICE HORN RELAY AUXILIARY POWER AUXILIARY PUMP H2 STARTER MOTOR 1K R3 WH RD PIN 39 DIAGNOSTIC BLUE PINK HARNESS ENGINE FORD C135RET C135FP BL PIN 18 GASOLINE SENSOR GY RD ...

Page 262: ...6 5 C6 1 TB3 TB6 C5TRR WH BK C31EDC WH BK C37STCC BL BK C36STC BL C6TRF WH RD C32BRK WH RD C30EDC WH 10 11 18 17 20 19 15 16 C41RPM OR BK 7 8 2 4 3 1 J3 3 P26ESTP BK P24FS WH P24FS WH NC CR27 CR30 NO 4 DRIVE LIFT OPTION CE TS13 JOYSTICK CONTROL CARD OR BK BK WH TS7 WH TS9 C3P 3 C3P 2 C4P 1 TS63 C13DRE BL RD C2P 2 C3P 8 C3P 7 C4P 3 C4P 2 C40LS1 OR C8PBR BK WH C7PBE BK TB40 TB13 TB7 TB8 C6 7 TB14 C1...

Page 263: ...October2013 Section 6 Schematics 6 94 Electrical Schematic FordDSG 423EFIModels from serial number 12510 to 14831 6 93 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 264: ...October2013 Section 6 Schematics 6 95 Electrical Schematic FordDSG 423EFIModels from serial number 14832 to 15662 6 96 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 265: ...B C6 25 C6 34 C6 33 20AMP CB3 CR17 NO CR17 OTS NO HYDRAULIC OIL TEMP SWITCH COOLING FAN OPTION C5 2 C6 16 TB43 C6 23 C6 28 C6 27 C5 16 TEMP GAUGE OIL PRESSURE GAUGE VOLT METER G1 G3 G2 GENERATOR C1 9 TS55 LOW RPM HIGH RPM C35RPM BK RD P26ESTP BK P25FS RD P24FS WH TS2 C2 7 C45GEN GR WH C1 7 TS52 TB33 C33STR BK TS1 C1 1 C7 2 C1 2 TS51 C2 5 TB27 RD TB28 TB23 C43HRN GR C27AUX RD C28TTA RD BK P23BAT WH...

Page 266: ...K P24FS WH P24FS WH 4 DRIVE LIFT OPTION CE TS13 JOYSTICK CONTROL CARD WH TS7 TS9 C3 3 C3 2 C4 1 TS63 C13DRE BL RD C2 2 C3 8 C3 7 C4 3 C4 2 C40LS1 OR C8PBR BK WH C7PBE BK TB40 TB13 TB7 TB8 C6 7 TB14 C15PLD OR BK C14PLU OR C2PBD RD BK C3PBF RD WH C4 6 C4 5 TS57 C4 7 C19JSV GR WH TB15 C6 17 TB18 TB17 TB19 TS59 12 13 14 H4 C5 23 C5 20 C6 37 C6 36 C5 21 STEER CCW STEER CW FLOW CONTROL PRIMARY BOOM UP P...

Page 267: ...October2013 Section 6 Schematics 6 98 Electrical Schematic FordDSG 423EFIModels from serial number 14832 to 15662 6 97 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 268: ...October2013 Section 6 Schematics 6 99 Electrical Schematic Ford DSG 423 EFI Models ANSI CSA AS from serial number 15663 to 16419 6 100 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 269: ... C28TTA RD BK C27AUX RD C43HRN GR TB23 TB28 RD TB27 C2 5 TS51 C1 2 C7 2 TS1 C33STR BK TB33 TS52 C1 7 C45GEN GR WH C2 7 TS2 P24FS WH P25FS RD P26ESTP BK C35RPM BK RD HIGH RPM LOW RPM TS55 C1 9 GENERATOR G2 G3 G1 VOLT METER OIL PRESSURE GAUGE TEMP GAUGE C5 16 C6 27 C6 28 C6 23 TB43 C6 16 C5 2 OPTION COOLING FAN TEMP SWITCH HYDRAULIC OIL NO OTS CR17 NO CR17 CB3 20AMP C6 33 C6 34 C6 25 TB134 P1 RD TB2...

Page 270: ...26ESTP BK P24FS WH P24FS WH 4 DRIVE LIFT OPTION CE TS13 JOYSTICK CONTROL CARD WH TS7 TS9 C3 3 C3 2 C4 1 TS63 C13DRE BL RD C2 2 C3 8 C3 7 C4 3 C4 2 C40LS1 OR C8PBR BK WH C7PBE BK TB40 TB13 TB7 TB8 C6 7 TB14 C15PLD OR BK C14PLU OR C2PBD RD BK C3PBF RD WH C4 6 C4 5 TS57 C4 7 C19JSV GR WH TB15 C6 17 TB18 TB17 TB19 TS59 12 13 14 H4 C5 23 C5 20 C6 37 C6 36 C5 21 STEER CCW STEER CW FLOW CONTROL PRIMARY B...

Page 271: ...October2013 Section 6 Schematics 6 102 Electrical Schematic Ford DSG 423 EFI Models ANSI CSA AS from serial number 15663 to 16419 6 101 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 272: ...October2013 Section 6 Schematics 6 103 Electrical Schematic Ford DSG 423 EFI Models CE from serial number 15663 to 16419 6 104 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 273: ...TA RD BK C27AUX RD C43HRN GR TB23 TB28 RD TB27 C2 5 TS51 C1 2 C7 2 TS1 C33STR BK TB33 TS52 C1 7 C45GEN GR WH C2 7 TS2 P24FS WH P25FS RD P26ESTP BK C35RPM BK RD HIGH RPM LOW RPM TS55 C1 9 GENERATOR G2 G3 G1 VOLT METER OIL PRESSURE GAUGE TEMP GAUGE C5 16 C6 27 C6 28 C6 23 TB43 C6 16 C5 2 OPTION COOLING FAN TEMP SWITCH HYDRAULIC OIL NO OTS CR17 NO CR17 CB3 20AMP C6 33 C6 34 C6 25 TB134 P1 RD TB22 PLA...

Page 274: ...P BK P24FS WH P24FS WH 4 DRIVE LIFT OPTION CE TS13 JOYSTICK CONTROL CARD WH TS7 TS9 C3 3 C3 2 C4 1 TS63 C13DRE BL RD C2 2 C3 8 C3 7 C4 3 C4 2 C40LS1 OR C8PBR BK WH C7PBE BK TB40 TB13 TB7 TB8 C6 7 TB14 C15PLD OR BK C14PLU OR C2PBD RD BK C3PBF RD WH C4 6 C4 5 TS57 C4 7 C19JSV GR WH TB15 C6 17 TB18 TB17 TB19 TS59 12 13 14 H4 C5 23 C5 20 C6 37 C6 36 C5 21 STEER CCW STEER CW FLOW CONTROL PRIMARY BOOM U...

Page 275: ...October2013 Section 6 Schematics 6 106 Electrical Schematic Ford DSG 423 EFI Models CE from serial number 15663 to 16419 6 105 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 276: ...October2013 Section 6 Schematics 6 107 Electrical Schematic Ford DSG 423 EFI Models ANSI CSA AS from serial number 16420 6 108 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 277: ... C7 1 HORN P22BAT BK C2 4 P134PWR RD RD KS1 GRD PLAT TB22 RD P1 TB134 C6 25 C6 34 C6 33 20AMP CB3 CR17 NO CR17 OTS NO HYDRAULIC OIL TEMP SWITCH COOLING FAN OPTION C5 2 C6 16 TB43 C6 23 C6 28 C6 27 C5 16 TEMP GAUGE OIL PRESSURE GAUGE VOLT METER G1 G3 G2 GENERATOR C1 9 TS55 LOW RPM HIGH RPM C35RPM BK RD P26ESTP BK P25FS RD P24FS WH TS2 C2 7 C45GEN GR WH C1 7 TS52 TB33 C33STR BK TS1 C1 1 C7 2 C1 2 TS...

Page 278: ...P BK P24FS WH P24FS WH 4 DRIVE LIFT OPTION CE TS13 JOYSTICK CONTROL CARD WH TS7 TS9 C3 3 C3 2 C4 1 TS63 C13DRE BL RD C2 2 C3 8 C3 7 C4 3 C4 2 C40LS1 OR C8PBR BK WH C7PBE BK TB40 TB13 TB7 TB8 C6 7 TB14 C15PLD OR BK C14PLU OR C2PBD RD BK C3PBF RD WH C4 6 C4 5 TS57 C4 7 C19JSV GR WH TB15 C6 17 TB18 TB17 TB19 TS59 12 13 14 H4 C5 23 C5 20 C6 37 C6 36 C5 21 STEER CCW STEER CW FLOW CONTROL PRIMARY BOOM U...

Page 279: ...October2013 Section 6 Schematics 6 110 Electrical Schematic Ford DSG 423 EFI Models ANSI CSA AS from serial number 16420 6 109 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 280: ...October2013 Section 6 Schematics 6 111 Electrical Schematic Ford DSG 423 EFI Models CE from serial number 16420 6 112 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 281: ...OUR METER _ FLASHING BEACONS OPTION OPTION GENERATOR OPS TB25 TB26 R21IGN WH TB21 FB TB41 C41RPM OR BK 15AMP TB20 CB2 RD 15AMP CB1 P23BAT WH C28TTA RD BK C27AUX RD C43HRN GR TB23 TB28 RD TB27 C2 5 TS51 C1 2 C7 2 TS1 C33STR BK TB33 TS52 C1 7 C45GEN GR WH C2 7 TS2 P24FS WH P25FS RD P26ESTP BK C35RPM BK RD HIGH RPM LOW RPM TS55 C1 9 GENERATOR G2 G3 G1 VOLT METER OIL PRESSURE GAUGE TEMP GAUGE C5 16 C6...

Page 282: ... P24FS WH P24FS WH 4 DRIVE LIFT OPTION CE TS13 JOYSTICK CONTROL CARD WH TS7 TS9 C3 3 C3 2 C4 1 TS63 C13DRE BL RD C2 2 C3 8 C3 7 C4 3 C4 2 C40LS1 OR C8PBR BK WH C7PBE BK TB40 TB13 TB7 TB8 C6 7 TB14 C15PLD OR BK C14PLU OR C2PBD RD BK C3PBF RD WH C4 6 C4 5 TS57 C4 7 C19JSV GR WH TB15 C6 17 TB18 TB17 TB19 TS59 12 13 14 H4 C5 23 C5 20 C6 37 C6 36 C5 21 STEER CCW STEER CW FLOW CONTROL PRIMARY BOOM UP PR...

Page 283: ...October2013 Section 6 Schematics 6 114 Electrical Schematic Ford DSG 423 EFI Models CE from serial number 16420 6 113 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 284: ...October2013 Section 6 Schematics 6 115 Ground Control Box Wiring Diagram FordDSG 423EFIModels beforeserialnumber14832 6 116 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 285: ...N ROT R PRI BOOM F C PRI BOOM DOWN TURN ROT L BK S P BK WH S P WH S P RD BK S P WH BK S P RD WH S P WH RD S P RD S P GR S P OR S P OR BK S P C133PLT 12V BATTERY SUPPLY MOTOR SPEED WATER TEMP SENDER OIL PRESSURE SENDER BRAKE TRAVEL ALARM GLOW PLUG ENGINE POWER PWR TO PLAT KEYSWITCH PWR FB AUX PWR TILT ALARM IGNITION PWR PLAT ROT R JIB VALVE WH RD S P RD S P CB1 BK S P WH S P WH BK S P GR WH SP WH S...

Page 286: ...S P CB3 133 17 15 14 12 10 11 13 8 7 6 5 3 4 2 1 9 GR C6 17 BL RD C6 13 OR C6 14 OR BK C6 15 RD C6 1 BK WH C6 8 WH BK C6 5 RD WH C6 3 WH C6 4 WH RD C6 6 BK C6 7 RD BK C6 2 BL BK C3B 11 BL C3B 10 BK WH C3B 8 RD WH C3B 3 WH C3B 4 WH BK C3B 5 WH RD C3B 6 BK C3B 7 RD C3B 1 RD BK C3B 2 GR C4B 5 OR RD C4B 4 OR C4B 2 OR BK C4B 3 BL RD C4B 1 BL WH C3B 12 GR BK C4B 6 GR BK C6 18 BK RD C1B 9 BK RD C5 9 35 D...

Page 287: ...October2013 Section 6 Schematics 6 118 Ground Control Box Wiring Diagram FordDSG 423EFIModels from serial number 14832 6 117 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 288: ...October2013 Section 6 Schematics 6 119 Platform Control Box Wiring Diagram FordDSG 423EFIModels beforeserialnumber14832 6 120 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 289: ... C1P 4 C1PBU RD C3P 1 C31EDC WH BK C1P 5 C2PBD RD BK C3P 2 C37STCC BL BK C1P 11 C3PBF RD WH C3P 3 C36STC BL C1P 10 C4TRL WH C3P 4 C32BRK WH RD C1P 6 C5TRR WH BK C3P 5 C29MS RD WH C1P 3 C35RPM BK RD C1P 9 C134PWR RD C2P 4 J2 JC2 5 BK JC2 3 OR JC3 5 BL JC3 3 OR JC1 5 YEL JC2 4 RD JC1 3 OR ALC 500 P24FS WH BRN P24FS WH C3P C9P F S F S JIB LS18 BRN C19JSV GR WH C4P 7 AND TS8 OPT C45GEN GR WH C2P 7 P24...

Page 290: ...P 11 C2PBD RD BK C3P 2 C31EDC WH BK C1P 5 C1PBU RD C3P 1 C30EDC WH C1P 4 C41RPM OR BK C2P 3 C12SBF BL WH C3P 12 C40LS1 OR C2P 2 C11SBD BL BK C3P 11 C13DRE BL RD C4P 1 C10SBU BL C3P 10 9 J1 RD BK L4 1 C2P C1P C28TTA RD BK C1P 2 C33STR BK C1P 7 C34SA BK WH C1P 8 C27AUX RD C1P 1 GR BK L48 RD TILT C28TTA RD BK C1P 2 C7P C4P C3P C7P 12V BATT C3P GR C4P BR C1P GY C2P BK 19 18 CONTROL CABLE BR RD TILT H1...

Page 291: ...October2013 Section 6 Schematics 6 122 6 121 Platform Control Box Wiring Diagram FordDSG 423EFIModels from serial number 14832 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 292: ...October2013 Section 6 Schematics 6 123 Platform Control Box Switch Panel Wiring Diagram FordDSG 423EFIModels from serial number 11067 to 12509 6 124 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 293: ... 13 WH 23 RD TILT BK 22 TS9 L4 PBOX WIRING HARNESS JC2 P3 TS1 P2 L1 JC3 DETAIL A LIFT DRIVE OPTION CR27 WORK DRIVE LIGHT OPTION FUEL SELECT SWITCH FORD EFI ONLY PRIMARY BOOM EXTEND RETRACT SWITCH GENERATOR SWITCH OPTION DRIVE ENABLE SWITCH HI L0 RPM SWITCH JIB UP DOWN SWITCH PLATFORM LEVEL SWITCH PLATFORM ROTATE SWITCH START ENGINE SWITCH 56457 27378 27378 13037 16397 13037 13037 13037 56457 56457...

Page 294: ... WH JIB TS8 JIB GR GR BK JDALARM GR BK 44 C2P 6 C19JSV GR WH D27 RD BL RD 39 RD TS3 FUEL SELECT D11 GR WH 45 RD TS47 GENERATOR OPTION TS14 DRIVE SPEED HIGH LOW WH 24 DASHED LINES INDICATE OPTION WIRES CR27 DETAIL A LIFT DRIVE OPTION CR30 BR BATGND WH TS1 GND STUD REPLACE WIRE WITH THIS WIRING DIAGRAM WH RD C32BRK WH TS7 SPLICE TO C32BRK SPLICE TO R40LS1 OR R40LS1 JC3 L1 P2 TS1 P3 JC2 L4 TS9 TS47 T...

Page 295: ...October2013 Section 6 Schematics 6 126 Platform Control Box Switch Panel Wiring Diagram FordDSG 423EFIModels from serial number 12510 6 125 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 296: ...October2013 Section 6 Schematics 6 127 Engine Wire Harness FordLRG 425EFIModels beforeserialnumber11067 6 128 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 297: ...B Y 18 307 BK Y 18 306 T LB 18 72 Y BK 18 71 O LG 18 238 DG Y 18 658 PK LG 18 11 T Y 18 253 DG W 18 511 LG R 18 151 LB BK 18 357 Y W 18 355 GY W 18 926A LB O 18 242 DG 18 342 LG P 18 570 BK W 16 TWR B A WPTWR2_GY TWR A B J2 GREY 33 OVERSPEED 5 AUX OUT 1 13 COIL 4 3 COIL 3 2 COIL 2 1 COIL 1 4 SPK PWR GROUND 35 RS 232 RX 34 RS 232 TX 21 RS 485 20 RS 485 19 CAN 18 CAN 12 ROAD SPEED 11 ROAD SPEED 17 G...

Page 298: ...BK W 16 PK BK 16 GY LB 18 R 16 GY Y 18 W LG 18 DG P 18 O LG 18 BR W 18 LG R 18 GY R 18 R LG 18 GY R 18 Y W 18 GY O 18 GY W 18 LB DG 18 BR W 18 R LG 18 R T 14 LB O 18 O 18 DG 18 W LB 18 T GN 18 P LB 18 Y DB 18 O LG 18 BK R 16 PK LG 18 T Y 18 DG W 18 BK O 18 R W 18 R BK 18 R Y 18 LG P 18 GY R 18 BR W 18 BK LG 18 LB Y 18 DB W 18 DG O 18 BK Y 18 BK LB 18 LB BK 18 BK W 16 BK W 16 BK W 16 T LB 18 LB R 1...

Page 299: ...October2013 Section 6 Schematics 6 130 Engine Wire Harness Ford DSG 423 EFI Models from serial number 11101 to 11784 6 129 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 300: ...October2013 Section 6 Schematics 6 131 Engine Wire Harness Ford DSG 423 EFI Models from serial number 11785 6 132 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 301: ... SENSOR GY 18 DBL 18 CRANK DB O 18 GY R 18 CAM CYL 2 DG P 18 4 3 2 1 BK W 16 PK BK 16 GY LB 18 R 16 GY Y 18 W LG 18 DG P 18 O LG 18 BR W 18 LG R 18 GY R 18 R LG 18 GY R 18 Y W 18 GY O 18 GY W 18 LB DG 18 BR W 18 R LG 18 R T 14 LB O 18 O 18 DG 18 W LB 18 T GN 18 P LB 18 Y DB 18 O LG 18 BK R 16 PK LG 18 T Y 18 DG W 18 BK O 18 R W 18 R BK 18 R Y 18 LG P 18 GY R 18 BR W 18 BK LG 18 LB Y 18 DB W 18 DG ...

Page 302: ...T XOUT PWR J1 J1 JOYSTICK CONTROL CARD J1 5 BL WH JC3 5 J1 4 WH RD JC3 4 J1 5 BL WH JC3 3 J1 13 OR JC3 2 J1 14 BRN JC3 1 JC3 DRIVE STEER J1 11 OR JC2 2 J1 12 BRN JC2 1 J1 1 WH RD JC2 3 J1 2 RD WH JC2 4 JC2 TURNTABLE ROTATE UP DOWN PRIMARY BOOM Deutsch 6 Pin Connector AMP 7 Pin Connector DRIVE STEER TURNTABLE ROTATE UP DOWN PRIMARY BOOM Note Production changed from 7 pin to 6 pin Joysticks at Seria...

Page 303: ...October2013 Section 6 Schematics 6 134 Joystick Connector Diagram 6 133 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 304: ...October2013 Section 6 Schematics 6 135 CTE Option Wiring Diagram 6 136 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 305: ...14 PLAT LEVEL DOWN RELAY CR21 P134PWR BOOM STOWED PLATFORM LEVEL DOWN PLATFORM LEVEL UP WIRING DIAGRAM RD C6 23 LS PWR C6 30 C15PLD OR BK CR21 86 OR RD C2B 4 OR C6 40 OR C2B 2 134 40 C14PLU OR CR20 86 C15PLD OR BK C4B 3 C14PLU OR C4B 2 14 15 GROUND BOLT C15PLD OR BK C6 15 C14PLU OR C6 14 C15PLD OR BK 15 D 134 40 15 14 C40LS1 OR CR20 30 RD KS1 2 S P RD H6 OR BK TS59 OR TS59 BR BR GND STUD C40LS1 OR...

Page 306: ...February2012 Section 6 Schematics 6 137 MTE Hydraulic Generator Option Wiring Diagram 6 138 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 307: ...BLACK BLACK WHITE YELLOW BLUE BLACK RED GREEN DTP04 4P PURGE BL PLUG BL BR GR WH 1 2 4 3 3 4 2 1 BATGND BR GND L2 L1 BLACK WHITE GREEN BLACK WHITE WHITE BLACK WHITE BLACK RED RED 5 8 T4 T3 BLACK WHITE BLACK WHITE T1 T2 T2 T1 YELLOW RED WHITE GREEN T3 T4 8 5 BLACK BLACK BLACK WHITE BLACK WHITE WHITE BLACK GREEN L2 L1 BATGND BR 4 1 2 4 3 3 4 2 1 GR WH BR BL PLUG PURGE BL DTP04 4P BLACK RED GREEN WHI...

Page 308: ...B 9 C1P 9 RPM HI RPM LO FOOTSWITCH 2 4 6 8 1 3 5 7 RS232RxD A1 BATTERY A2 SENSOR POWER 5 VDC A3 BATTERY B1 VALVE 0 FWD COIL B2 VALVE 1 NC B3 DIGITAL OUTPUT BYPASS C1 TxD YLW C2 RxD GRN C3 BOOT D1 ANALOG 0 JOYSTICK D2 ANALOG 1 NC D3 DIG IN 3 NC E1 NOT USED E2 NOT USED E3 NOT USED F1 DIG IN 0 F2 DIG IN 1 GENERATOR ON F3 DIG IN 2 RS232TxD CR4 HIGH IDLE RELAY C45GEN GR WH V151HG GR V150HG GR BK 1k ohm...

Page 309: ...October2013 Section 6 Schematics 6 140 Hydraulic Generator Wiring Diagram Welder Option 6 139 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 310: ...October2013 Section 6 Schematics 6 141 2WD Non Oscillating Hydraulic Schematic S 40 Models before serial number 7569 6 142 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 311: ...R 2A 2B 1 3 8B 6C 6B 6B 8C 8A 2C 0 1 gpm 0 4 L min 5 4 FRB FRR 17 L min 4 5 gpm 0 6 gpm 2 3 L min AUX T2 TANK PRESS T1 RESERVOIR HYDRAULIC ROTARY COUPLER BRAKE MANIFOLD DRIVE PUMP PUMP FUNCTION RETURN FILTER MANIFOLD TRACTION PLATFORM SLAVE MASTER ROTATE TURNTABLE ROTATE 2 gpm 7 6 L min 3 gpm 11 4 bar EXTEND RETRACT CYL 4 gpm 15 1 L min FUNCTION MANIFOLD PUMP AUXILIARY MEDIUM PRESSURE FILTER CYLIN...

Page 312: ...FRB FRR 4 5 gpm 17 L min 0 6 gpm 2 27 L min AUX T2 TANK PRESS T1 RESERVOIR HYDRAULIC ROTARY COUPLER BRAKE MANIFOLD DRIVE PUMP PUMP FUNCTION RETURN FILTER MANIFOLD TRACTION SLAVE MASTER TURNTABLE ROTATE 7 6 L min 2 gpm 11 4 L min 3 GPM EXTEND RETRACT CYL 4 GPM 15 1 L min FUNCTION MANIFOLD PUMP AUXILIARY MEDIUM PRESSURE FILTER CYLINDERS PLATFORM LEVEL PRIMARY LIFT CYLINDER STEERING RIGHT LEFT 2400 p...

Page 313: ...October2013 Section 6 Schematics 6 144 2WD Non Oscillating Hydraulic Schematic S 45 Models before serial number 7569 6 143 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 314: ...October2013 Section 6 Schematics 6 145 4WD Oscillating Hydraulic Schematic S 40 Models before serial number 7569 6 146 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 315: ...IR HYDRAULIC ROTARY COUPLER BRAKE MANIFOLD DRIVE PUMP PUMP FUNCTION RETURN FILTER MANIFOLD TRACTION PLATFORM SLAVE MASTER ROTATE 3 gpm 11 4 L min TURNTABLE ROTATE 7 6 L min 2 gpm EXTEND RETRACT CYL 4 gpm 15 1 L min FUNCTION MANIFOLD PUMP AUXILIARY MEDIUM PRESSURE FILTER CYLINDERS PLATFORM LEVEL PRIMARY LIFT CYLINDER STEERING RIGHT LEFT OSCILLATE VALVE OSCILLATE CYLINDERS LEFT RIGHT 2400 psi 165 5 ...

Page 316: ... MANIFOLD DRIVE PUMP PUMP FUNCTION RETURN FILTER MANIFOLD TRACTION SLAVE MASTER 3 gpm 11 4 L min TURNTABLE ROTATE 2 gpm 7 6 L min EXTEND RETRACT CYL 4 gpm 15 1 L min FUNCTION MANIFOLD PUMP AUXILIARY MEDIUM PRESSURE FILTER CYLINDERS PLATFORM LEVEL PRIMARY LIFT CYLINDER STEERING RIGHT LEFT OSCILLATE VALVE OSCILLATE CYLINDERS LEFT RIGHT 2400 psi 165 5 bar OPTIONAL MANIFOLD GENERATOR OPTIONAL GENERATO...

Page 317: ...October2013 Section 6 Schematics 6 148 4WD Oscillating Hydraulic Schematic S 45 Models before serial number 7569 6 147 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 318: ...October2013 Section 6 Schematics 6 149 2WD Hydraulic Schematic from serial number 7569 6 150 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 319: ... RIGHT A B OUT IN TEST 7 7 2 4 5 gpm 17 L m 0 6 gpm 2 2 L min 2400 psi 165 4 bar OPTIONAL GENERATOR AUX T2 TANK PRESS T1 FUNCTION MANIFOLD TO HYD ROTARY COUPLER FUNCTION 7 PUMP 2 HYDRAULIC COOLER OPTION 8C 6B L R 1 5 1 3000 PSI A B B A TRACTION MANIFOLD A B TEST 280 psi 19 3 bar CDR M2 M4 50 50 M1 T CDL M3 LEFT REAR RIGHT REAR 025 BRAKE 2SPEED CP T2 MANIFOLD BRAKE 2 SPEED X X OSCILLATE CYLINDERS O...

Page 320: ...ATE 2 gpm 7 5 L min 025 50 psi 3 5 bar 1950 psi 134 5 bar A A C C 2200 psi 151 6 bar E E C C 3300 PSI 3 1 D E 3 1 3500 PSI COUNTERBALANCE VALVE 3 1 C B 3 1 3 1 RATIO 1000 PSI 3000 PSI 2000 PSI PRESS A F 5 1 3500 PSI 1 5 1 3000 PSI G 50 50 040 040 50 50 040 280 psi 19 3 bar 950 psi 65 5 bar G G F F D D 25 psi 1 7 bar 3 psi 0 20 bar 3 psi 0 20 bar 3625 psi 249 9 bar 315 psi 21 7 bar B C EXTEND RETRA...

Page 321: ...October2013 Section 6 Schematics 6 152 4WD Hydraulic Schematic from serial number 7569 6 151 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 322: ...r to components shown in the manifold illustrations Refer to the Repair Section AH AI AM AJ AK AN AL TANK 1 3 Ø 031 1 3 A B HYDRAULIC WELDER OPTION MANIFOLD 21 GPM G2 G1 12 5 KW GENERATOR MTR B G2 3 5 GPM 270 PSI MTR A G1 COUPLER ROTARY HYDRAULIC PMP B WELDER COOLER OIL CLR 3 5 GPM PMP A NO PRESS SW 200 PSI 21CC DRIVE PUMP P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 323: ...October2013 Section 6 Schematics 6 154 Generator Hydraulic Schematic Welder Option 6 153 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 324: ...Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Genie Scandinavia Phone 46 31 57 51 00 Fax 46 31 57 51 04 Genie France Phone 33 2 37 26 09 99 Fax 33 2 37 26 09 98 Genie Iberica Phone 34 93 572 5090 Fax 34 93 572 5091 Genie Germany Phone 0800 180 9017 Phone 49 4221 491 810 Fax 49 4221 491 820 Genie U K Phone 44 1476 584333 Fax 44 1476 584334 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5...

Page 325: ...Service Manual S 40 S 45 Rev E Part No 102521 from serial number S40 7001 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

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