Parts and Service Manual Supplement

Transcription

1 Parts and Service Manual Supplement Part No. 0 Rev A November 00

2 November 00 Important Read, understand and obey the safety rules and operating instructions in the TMZ0/0 Operator's Manual before attempting any maintenance or repair procedure. This manual provides detailed parts and service information 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. This Parts and Service Manual Supplement provides service parts information and electrical schematics for the recently released TMZ0/0 Control System, which are not included in your parts or service manuals. Please add this parts information and electrical schematics to the parts and service manuals for your machine. Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Contact Us: PO Box 00 Redmond, WA 00 USA techsup@genieind.com Copyright by Genie Industries 0 Rev A November 00 First Edition, First Printing "Genie" is a registered trademark of Genie Industries in the USA and many other countries. "TMZ" is a trademark of Genie Industries. Printed on recycled paper Printed in U.S.A. TMZ0/0 Part No. 0

3 November 00 Table of Contents Introduction Important Information... Section Rev Service Parts A Decals... A Platform Controls... A Ground Controls... A Drive Controls, View... A Drive Controls, View... Section Rev Schematics A Introduction... A Wiring Diagram Ground Controls, View AA... 0 A Wiring Diagram Ground Controls, View BB... A Wiring Diagram Ground Controls, View CC... A Wiring Diagram Platform Controls, View DD... A Wiring Diagram Platform Controls, View EE... A Wiring Diagram Platform Controls, View FF... A Wiring Diagram Drive Controls, View GG... A Wiring Diagram Drive Controls, View HH... A Wiring Diagram Drive Controls, View JJ... Part No. 0 TMZ0/0

4 November 00 Section Rev Schematics, continued A Electrical Schematic Platform Controls (all models)... 0 A Electrical Schematic Drive Controls (all models)... A Electrical Schematic DC Models (before serial number T000)... A Electrical Schematic DC Models (from serial number T000 to T00)... A Electrical Schematic DC Models (from serial number T00 to TMZ00)... A Electrical Schematic DC Models (after serial number TMZ00)... A Electrical Schematic Gasoline Models (before serial number T000)... 0 A Electrical Schematic Gasoline Models (from serial number T000 to T00)... A Electrical Schematic Gasoline Models (from serial number T00 to TMZ00)... A Electrical Schematic Gasoline Models (after serial number TMZ00)... A Electrical Schematic Gasoline BiFuel Models (before serial number T000)... A Electrical Schematic Gasoline BiFuel Models (from serial number T000 to T00)... 0 A Electrical Schematic Gasoline BiFuel Models (from serial number T00 to TMZ00) A Electrical Schematic Gasoline BiFuel Models (after serial number TMZ00)... TMZ0/0 Part No. 0

5 November 00 Section Rev Schematics, continued A Electrical Schematic Diesel Models (before serial number T000)... A Electrical Schematic Diesel Models (from serial number T000 to T00)... A Electrical Schematic Diesel Models (from serial number T00 to TMZ00)... 0 A Electrical Schematic Diesel Models (after serial number TMZ00)... A Electrical Schematic Diesel BiFuel Models (before serial number T000)... A Electrical Schematic Diesel BiFuel Models (from serial number T000 to T00)... A Electrical Schematic Diesel BiFuel Models (from serial number T00 to TMZ00)... A Electrical Schematic Diesel BiFuel Models (after serial number TMZ00)... 0 Part No. 0 TMZ0/0

6 Parts Information November 00 Decals or 0 or ** or 0 or 0 Safety Tape ** or 0 0 or *** 0 or or Shading indicates that the decal is hidden from view. or ** ** or *Not on DC Models **Not on Gas and Diesel (All decals appear on BiFuel Models) ***Not on units with english decals Power Unit Side Ground Controls Side 0 or *** 0 SafetyTape or 0 or 0 or 0 0 or Safety Tape or * or Safety tape 0 Safety tape or 0 or * 0 TMZ0/0 Part No. 0

7 November 00 Parts Information DECALS Index Part No. Description Quantity Danger Electrocution Hazard... Label Dexron... Label Unleaded... * Label Diesel... Warning Crushing Hand... Notice Hazardous Materials... Label No Smoking... Power to Platform, 0V AC... Caution Compartment Access... 0 Notice Missing Manuals... Power to Platform, V AC... Warning Failure To Read Danger, Do not alter limit switch... Notice Max Cap, Hook, 00 lbs / kg... 0 Notice Max Cap, 00 lbs / kg... 0 Label Lanyard Anchorage Point... Notice Power to Battery Charger, 0V AC... Notice Max Capacity, 0 lbs / 00 kg... 0 Notice Power to Battery Charger, V AC... 0 Airline to Platform... Notice Side Force 0 lbs / 00N, CE... Danger General Safety, Platform... Label Parking Brake (surge)... ** Notice Battery Charger Operating Instructions... ** Danger Battery/Charger Safety... ** Danger Tipover (batteries)... This list continues on the next page. Part No. 0 TMZ0/0

8 Parts Information November 00 DECALS or 0 or ** or 0 or 0 Safety Tape ** or 0 0 or *** 0 or or Shading indicates that the decal is hidden from view. or ** ** or *Not on DC Models **Not on Gas and Diesel (All decals appear on BiFuel Models) ***Not on units with english decals Power Unit Side Ground Controls Side 0 or *** 0 SafetyTape or 0 or 0 or 0 0 or Safety Tape or * or Safety tape 0 Safety tape or 0 or * 0 TMZ0/0 Part No. 0

9 November 00 Parts Information DECALS Index Part No. Description Quantity 00 Danger General Safety, Ground... Label Transport Tiedown... Ground Control Panel... 0 Cosmetic Genie TMZ0/0 Large... 0 Cosmetic Genie TMZ/0 Large... Platform Control Panel... Cosmetic Genie TMZ0/0 Small... Cosmetic Genie TMZ/0 Small Notice Operating Instructions, Ground... 0 Notice Operating Instructions, Platform... 0 Danger/Notice Drive System... 0 Warning Towing Hazard... 0 Label Manual Lowering Valves Notice Material Lifting Operation... Notice Honda Engine Specifications... Notice Hatz Engine Specifications... Label Arrow... Notice Max Capacity, 0 lbs / 00 kg... *** Patch, Ground Control Panel... *** Patch, Platform Control Panel... Notice Battery Connection Diagram, DC... 0 Label Waterline to Platform... 0 Notice Battery Connection Diagram, Bifuel Notice Side Force, 0 lbs / 00N, ANSI and CSA... Notice Tire specification, ANSI and CSA... This list continues on the next page. Part No. 0 TMZ0/0

10 Parts Information November 00 DECALS or ** ** Shading indicates or that the decal is hidden from view. or 0 or ** or 0 or 0 Safety Tape ** or 0 0 or *** 0 or or *Not on DC Models **Not on Gas and Diesel (All decals appear on BiFuel Models) ***Not on units with english decals Power Unit Side Ground Controls Side 0 or *** 0 SafetyTape or 0 or 0 or 0 0 or Safety Tape or * or Safety tape 0 Safety tape or 0 or * 0 0 TMZ0/0 Part No. 0

11 November 00 Parts Information DECALS Index Part No. Description Quantity Decal Notice, Transport Instructions... 0 Notice Tire specification, CE... Label Transport to Canada... 0 Ground Control Panel... 0 Platform Control Panel... 0 Drive Control Panel... 0 Serial Label... Ground Control Panel... 0 Platform Control Panel... 0 Danger/Notice Drive System... Label Fault Codes... ** Notice Battery Connection Diagram, DC Models with Drive... Label LED Diagnostic Readout... Notice Operating Instructions, Ground... Notice Operating Instructions, Platform... Part No. 0 TMZ0/0

12 Parts Information November 00 Platform Controls TMZ0/0 Part No. 0

13 November 00 Parts Information PLATFORM S Item Part No. Description Quantity This Figure Platform Control Box Assembly, IC Complete... Platform Control Box Assembly, DC Complete... Platform Control Box Assembly, BiFuel Complete... Resistor, 0k ohms, Watt... 0 Resistor, k ohms, Watt... Screw HHC, / 0 x inch, GR... Button Joystick Mount... Low Profile Nylock Nut, / Screw PHPM, x 0. inch, GR... Draw Latch Over Center (includes keeper and latch)... Keeper Over Center Latch... Nylock Nut,... Platform Control Box... Dual Pulse Width Modulation Controller... Push Button Black with Seal (horn)... Base with N.O Contact... N.O. Contact... 0 Push Button Red Mushroom Head... Base Push Button (includes N.C. contact)... N.C. Contact... 0 Toggle Switch DPDT, position (power connection)... Boot Rubber... Push Button Black with Seal (engine start) (IC and Bifuel models)... Base with N.O Contact... N.O. Contact... Plug Nylon, Black Domed (DC models)... Push Button Black with Seal (choke/preheat) (IC and Bifuel models)... Base with N.O Contact... N.O. Contact... Plug Nylon, Black Domed (DC models)... Platform Control Box Lid... Screw PHPM, 0 x 0. inch, GR... 0 Internal Star Washer, #0... This list continues on the next page. Part No. 0 TMZ0/0

14 Parts Information November 00 PLATFORM S TMZ0/0 Part No. 0

15 November 00 Parts Information PLATFORM S Item Part No. Description Quantity This Figure 0 Nutsert, 0... Indicator Battery Discharge (DC and Bifuel models)... 0 Plug (IC models)... 0 Potentiometer Assembly... 0 Toggle Switch SPDT, position, Momentary (turntable rotate)... Boot Rubber... Toggle Switch SPDT, position, Momentary (platform level)... Boot Rubber... Toggle Switch SPDT, position, Momentary (secondary boom up/down)... Boot Rubber... Toggle Switch SPDT, position, Momentary (primary boom up/down)... Boot Rubber... Toggle Switch SPDT, position, Momentary (jib boom up/down)... Boot Rubber... Toggle Switch SPDT, position, Momentary (primary boom extend/retract)... Boot Rubber... Push Button Black with Seal (boom function enable)... Base with N.O Contact... N.O. Contact... Connector Receptacle with Flange, way... 0 Terminal Pin, Gauge... Alarm Warble Tone, 0V DC... Nut Retainer... 0 Holder Relay Relay V DC (DC and Bifuel models)... 0 Relay V DC (IC models)... 0 Bracket Relay Mount... Part No. 0 TMZ0/0

16 Parts Information November 00 Ground Controls TMZ0/0 Part No. 0

17 November 00 Parts Information GROUND S Item Part No. Description Quantity This Figure Ground Control Box Assembly, IC Complete... Ground Control Box Assembly, DC Complete... 0 Ground Control Box Assembly, BiFuel Complete... Screw HHC, / 0 x inch, GR... Button Joystick Mount... 0 Nutsert, / 0... Ground Control Box... 0 Nutsert, Internal Star Washer, #0... Screw PHPM, 0 x 0. inch, GR... Printed Circuit Board CPU (DC & Bifuel models)... Printed Circuit Board CPU (IC mocels)... Connector Plug, 0 way... Socket Terminal, Gauge... 0 Seal Plug Screw PHPM, 0 x 0. inch... Coupling Nut, 0 x 0. inch... Alarm Warble Tone, 00V DC... Retainer Nut... Wire Harness Assembly Drive... Receptacle Connector, way... 0 Terminal Pin, Gauge... Panel Washer Shell, Size... 0 Panel Nut Plastic, Size... 0 Toggle Switch DPDT, position (power connection)... Boot Rubber... Push Button Black with Seal (engine start) (IC and Bifuel models)... Base with N.O Contact... N.O. Contact... Plug Nylon, Black Domed (DC models)... This list continues on the next page. Part No. 0 TMZ0/0

18 Parts Information November 00 GROUND S TMZ0/0 Part No. 0

19 November 00 Parts Information GROUND S Item Part No. Description Quantity This Figure Push Button Black with Seal (choke/preheat) (IC and Bifuel models)... Base with N.O Contact... N.O. Contact... Plug Nylon, Black Domed (DC models) Key Switch, Position (includes pair of keys)... 0 Key (single)... Key, Package of Rubber Washer Push Button, Green (outrigger right/rear) Base with N.O. Contact and Green LED... Push Button Black with Seal (horn)... Base with N.O Contact... N.O. Contact Push Button, Green (outrigger right/front) Base with N.O. Contact and Green LED... Toggle Switch SPDT, position, Momentary (turntable rotate)... Boot Rubber... Toggle Switch SPDT, position, Momentary (platform level)... Boot Rubber Push Button, Green (outrigger left/rear) Base with N.O. Contact and Green LED... Toggle Switch SPDT, position, Momentary (jib up/down)... Boot Rubber... Toggle Switch SPDT, position, Momentary (secondary boom up/down)... Boot Rubber... 0 Ground Control Lid Push Button, Green (outrigger left/front) Base with N.O. Contact and Green LED... Toggle Switch SPDT, position, Momentary (primary boom up/down)... Boot Rubber... Push Button Black with Seal (autolevel)... Base with N.O Contact... N.O. Contact... This list continues on the next page. Part No. 0 TMZ0/0

20 Parts Information November 00 GROUND S TMZ0/0 Part No. 0

21 November 00 Parts Information GROUND S Item Part No. Description Quantity This Figure Toggle Switch SPDT, position, Momentary (primary boom extend/retract)... Boot Rubber... Push Button Black with Seal (outrigger enable)... Base with N.O Contact... N.O. Contact... Push Button Black with Seal (outrigger extend)... Base with N.O Contact... N.O. Contact... Push Button Black with Seal (outrigger retract)... Base with N.O Contact... N.O. Contact... Push Button Red Mushroom Head... Base with N.C. Contact... N.C. Contact... Nylock Nut,... 0 Screw PHPM, x 0. inch, GR Screw PHM, 0 x 0. inch, GR... PCB Mount... Wire Harness Assembly Power... 0 Receptacle Connector, Position, Flanged... 0 Terminal Pin, Gauge Circuit Breaker, A, 0V AC... Wire Harness Assembly Autolevel... Receptacle Connector, way, Flanged, Gauge... 0 Receptacle Lock, way, Gauge... 0 Terminal Pin, Gauge... Part No. 0 TMZ0/0

22 Parts Information November 00 Drive Controls, View TMZ0/0 Part No. 0

23 November 00 Parts Information DRIVE S, VIEW Item Part No. Description Quantity This Figure Drive Control Box Assembly, IC Complete... Drive Control Box Assembly, DC and BiFuel Complete... 0 Diode, A... Resistor,. ohms, Watt... Screw HHC, / 0 x inch, GR... Button Joystick Mount... Low Profile Nylock Nut, / Screw PHPM, x 0. inch, GR... Draw Latch Over Center (includes keeper and latch)... Keeper Over Center Latch... Nylock Nut,... Holder Relay... 0 Relay V DC (DC and Bifuel models)... 0 Relay V DC (IC models)... Bracket Relay Mount... 0 Screw PHPM, 0 x 0. inch, GR... 0 Nutsert, 0... Dual Pulse Width Modulation Controller... 0 Internal Star Washer, #0... Joystick Dual Axis... Push Button Red Mushroom Head... Base with N.C. Contact... N.C. Contact... Push Button Black with Seal (horn)... Base with N.O Contacts... N.O. Contact... Push Button Black with Seal (outrigger extend)... Base with N.O Contacts... N.O. Contact... Push Button Black with Seal (autolevel)... Base with N.O Contact... N.O. Contact... This list continues on the next page. Part No. 0 TMZ0/0

24 Parts Information November 00 DRIVE S, VIEW TMZ0/0 Part No. 0

25 November 00 Parts Information DRIVE S, VIEW Item Part No. Description Quantity This Figure Push Button Black with Seal (outrigger retract)... Base with N.O Contacts... N.O. Contact... 0 Drive Controls Box Lid... Screw PHPM, x 0. inch... Drive Controls Box... Receptacle Connector, way... 0 Terminal Pin, Gauge... Panel Washer Shell, Size... 0 Panel Nut Plastic, Size... Part No. 0 TMZ0/0

26 Parts Information November 00 Drive Controls, View 0 TMZ0/0 Part No. 0

27 November 00 Parts Information DRIVE S, VIEW Item Part No. Description Quantity This Figure 0 Drive Mount Arm Kit... 0 Mount Drive Control... Screw HHC, / x. inches... Nut Nylock, /... Screw HHC, / 0 x inch, GR... Button Joystick Mount... Low Profile Nylock Nut, / 0... Ref. Drive Control Box (refer to Drive Controls, View )... 0 Nut Nylock,... Draw Latch Over Center (includes keeper and latch)... Keeper Over Center Latch Screw PHPM, x 0. inch, GR... 0 Drive Guard, Right Screw PHPM, / 0 x 0. inch, GR... 0 Nut Nylock, / Drive Guard, Left... Nut Low Profile Nylock, / 0... Screw HHC, / 0 x 0. inch, GR... Part No. 0 TMZ0/0

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29 November 00 Service Information Schematics About This Section Electrical Schematics Observe and Obey: Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. General Repair Process Malfunction discovered Return to service problem solved Identify symptoms problem still exists Inspect and test Troubleshoot Perform repair Part No. 0 TMZ0/0

30 X X X X X X X X Service Information November 00 Wiring Diagram Ground Controls, View AA GROUND BOX VIEW AA (INSIDE LID SURFACE) VIEW BB VIEW CC VIEW AA VIEW AA VIEW AA VIEW BB VIEW CC ROUTE THESE WIRES TO GROUND BOX PRINTED BOARD (VIEW BB) WH/RD J GN GN/BK J J BN J RD J RD/BK RD/WH BK/WH J J J BK J GN/WH BL/BK J J BL BL/WH J J GN/YL J YL J OR J OR/BK J WH WH/BK J0 J YL J OR/RD J WH/RD WH/RD TS EXT/RET WH/RD TS TS0 TS TS UP/DN UP/DN UP/DN UP/DN WH/RD WH/RD WH/RD WH/RD TS BN BOOM FUNCTION ENABLE PRIMARY BOOM PRIMARY BOOM SECONDARY BOOM JIB PLATFORM TURNTABLE ROTATE WH/RD BN EXTEND BN WH BN0 AUTO WH BN LEFT FRONT BN BK BK WH WH WH BN0 LEFT REAR BN BK BK BN HORN WH/RD WH/RD RETRACT WH/RD RIGHT FRONT RIGHT REAR WH/RD KEY SWITCH KS P TS RD BN BN0 B B EMERGENCY STOP IC/DC/AUX START (MODELS WITH ) CHOKE/PREHEAT (MODELS WITH ) RD CB ROUTE THIS WIRE TO GROUND BOX FRONT SURFACE (VIEW CC) RD/BK RD/BK J J RD J0 OR/WH J BL/RD J OR/WH RD/WH S0 S BK/RD GN/WH WH BL/WH J S J S ROUTE THESE WIRES TO GROUND BOX PRINTED BOARD (VIEW BB) BL/RD J RD/WH J GN/YL J BK U() ROUTE THIS WIRE TO GROUND BOX FRONT SURFACE (VIEW CC) 0 TMZ0/0 Part No. 0

31 November 00 Service Information Wiring Diagram Ground Controls, View BB GROUND BOX VIEW BB (INSIDE BOX ASSEMBLY) VIEW BB VIEW CC VIEW AA VIEW AA VIEW BB VIEW BB VIEW CC WIRES ROUTED FROM GROUND BOX INSIDE LID SURFACE (VIEW BB) S S S0 S S S GROUND JUMPERS S AUTO S S S S S S S S JUMPER INSTALLATION ALL MODELS (S S) AND (S S0) IC/DC MODELS (S S) IC ONLY MODELS (S S) MODELS WITH MOTION ALARM (S S) MODELS WITHOUT DRIVE JUMPER (S S) BEFORE S/N T000 (S S) AFTER S/N T0000 (S S) DRIVE S S S S0 S S S S S0 S S S S S S S S S S J S S S S BN # BN # BN0 # BN # GN/WH OR/WH BL/WH RD/WH J RD/WH J BL/WH J OR/WH J J J J JA JH JG JE JD JK JB JC JJ JL JM JN JF JP GN/WH BK WH RD BK/WH OR GN/WH RD/WH GN/BK OR/BK RD RD/BK BL/BK WH/BK BL GN WH BK J J RD BK S S S0 S (UNUSED) (UNUSED) (UNUSED) (UNUSED) (UNUSED) J J J J J J J J J J0 J J J BL RD/BK YL GN/YL BK BK/WH BL BL/BK WH/BK WH OR OR/BK GN GN/BK BL/RD WH/RD BK/RD YL BL/RD RD WH GN/WH BL/WH OR/WH RD/WH BN GN/YL RD/WH RD/BK RD/BK OR/RD J H () BK RD H() CB # RD CB # J J J J J J0 J J J J J J J J J0 J J J J J J J0 WIRES ROUTED FROM VIEW CC WIRES ROUTED FROM VIEW AA WIRES ROUTED FROM VIEW CC WIRES ROUTED FROM NOTE: S AND S0 ARE ONLY FOR DC AND BIFUEL VIEW CC MODELS BEFORE SERIAL NUMBER T000; REFER TO THE CORRECT ELECTRICAL SCHEMATIC FOR DETAILS Part No. 0 TMZ0/0

32 Service Information November 00 Wiring Diagram Ground Controls, View CC GROUND BOX VIEW CC (FRONT INSIDE SURFACE) VIEW BB VIEW CC VIEW AA VIEW AA VIEW CC VIEW BB VIEW CC J CB A BREAKER J H ALARM P E N F D M A C G B L H K J J ROUTE THESE WIRES TO INSIDE LID SURFACE (VIEW AA) RD P # BK BN #X ROUTE THIS WIRE TO INSIDE BOX ASSEMBLY (VIEW BB) BK J S S S S S0 S BK RD (UNUSED) WH RD/WH OR/WH BL/WH J J J J J J J S GN/WH J J J RD RD S BK S J S S S S S RD BL BK/WH RD RD/BK GN/BK RD/WH JA JB JC JD JE S WH JF S0 S S S S S S GN/WH OR BL/BK OR/BK WH/BK BL GN JG JH JJ JK JL JM JN S BK JP ROUTE THESE WIRES TO GROUND BOX PRINTED BOARD (VIEW BB) TMZ0/0 Part No. 0

33 November 00 Service Information Wiring Diagram Platform Controls, View DD PLATFORM BOX VIEW DD (INSIDE LID SURFACE) VIEW EE VIEW DD VIEW DD VIEW DD VIEW FF VIEW EE VIEW FF ROUTE THESE WIRES TO PLATFORM BOX FRONT INSIDE SURFACE (VIEW FF) BL H () RD/BK J RD J BK J BK/WH J BL J BL/BK J WH/BK J WH J0 BK H () OR/WH J0 WH/RD BN BOOM FUNCTION ENABLE BN HORN WH/RD WH/RD TS TS TS0 (SW) (SW) (SW) EXT/RET PRIMARY BOOM WH/RD UP/DN PRIMARY BOOM PLATFORM WH/RD UP/DN SECONDARY BOOM TS TS TS (SW) UP/DN JIB (SW) UP/DN WH/RD (SW) TURNTABLE ROTATE BK BK POTENTIOMETER 0K OHM CCW R R VO R CW RESISTOR 0K OHM, W N P G BATTERY CHARGE INDICATOR OR RD WH/RD P TS0 IC/DC/AUX BN WH/RD BN EMERGENCY STOP START (MODELS WITH ) CHOKE/PREHEAT (MODELS WITH ) RD J RD J J J RD/BK GN/YL YL J OR/BK J J J J OR RD BL/RD BK/RD CR CR0 WH/RD RD/BK J J BK OR/WH OR CRA WH CR ROUTE THESE WIRES TO PLATFORM BOX FRONT INSIDE SURFACE (VIEW FF) ROUTE THESE WIRES TO PLATFORM BOX INSIDE BOX ASSEMBLY (VIEW EE) Part No. 0 TMZ0/0

34 Service Information November 00 Wiring Diagram Platform Controls, View EE PLATFORM BOX VIEW EE (INSIDE BOX ASSEMBLY) VIEW EE VIEW DD VIEW DD VIEW EE VIEW FF VIEW EE VIEW FF RESISTOR K OHM, W CR SPEED BK BL/WH OR U ELECTRONIC MODULE 0 A 0 A GN/BK CR CHOKE/PREHEAT J J (BLACK) 0 0 BL/WH BK RD WH OR J (REFER TO VIEW FF) P # RD/BK BK G () GN J J GN/BK BN # WH/RD OR/WH G () RD/WH J H () WH/RD R VO WH R OR CW BL/WH J ROUTE THESE WIRES TO PLATFORM BOX INSIDE LID SURFACE (VIEW DD) ROUTE THESE WIRES TO PLATFORM BOX FRONT INSIDE SURFACE (VIEW FF) TMZ0/0 Part No. 0

35 November 00 Service Information Wiring Diagram Platform Controls, View FF PLATFORM BOX VIEW FF (FRONT INSIDE SURFACE) VIEW EE VIEW DD VIEW DD VIEW FF VIEW FF VIEW EE VIEW FF BL BK BK H ALARM J PLATFORM BL J BK J BK CR ROUTE THESE WIRES TO J RD/WH J J GN J CR GN/BK J CR0 BL/WH J PLATFORM BOX INSIDE BOX ASSEMBLY (VIEW EE) J RD/BK P # P # RD J BN # J BN # J BL/RD RD J J J J RD SW RD/BK SW YL SW GN/YL SW SW J SW J SW J SW J SW J SW WH J0 SW J SW J G () J0 BK BK/WH BL BL/BK WH/BK OR OR/BK OR/WH ROUTE THESE WIRES TO PLATFORM BOX INSIDE LID SURFACE (VIEW DD) J BK/RD BN # BK BL G () BN # Part No. 0 TMZ0/0

36 Service Information November 00 Wiring Diagram Drive Controls, View GG DRIVE BOX VIEW GG (INSIDE LID SURFACE) VIEW HH VIEW GG VIEW GG VIEW JJ VIEW GG VIEW JJ VIEW HH ROUTE THESE WIRES TO DRIVE BOX FRONT INSIDE SURFACE (VIEW JJ) GN/BK JD JF WH RD/WH JE HORN EXTEND BL/WH BL/WH BL/WH BN BN GN/WH JG BL/RD JH JM JN WH/BK OR BL GN B A SIG VE Vs THROTTLE BOARD WH/BK JL JC JOYSTICK STEER BOARD WH/BK WH/BK WH/BK JB RD RD/BK JC B A SIG VE Vs AUTO BN BL/RD RETRACT WH/BK BN0 RESISTOR.K OHM, W R R BL/WH GN WH BK OR/WH YL BN RD/BK CR RESISTOR.K OHM, W BK CRA P CRB CRA CRB CRA CRA0 CR0 EMERGENCY STOP ROUTE THESE WIRES TO DRIVE BOX INSIDE BOX ASSEMBLY (VIEW HH) CRA J TMZ0/0 Part No. 0

37 November 00 Service Information Wiring Diagram Drive Controls, View HH DRIVE BOX VIEW HH (INSIDE BOX ASSEMBLY) VIEW HH VIEW GG VIEW HH VIEW JJ VIEW GG VIEW JJ VIEW HH ROUTE THESE WIRES TO DRIVE BOX FRONT INSIDE SURFACE (VIEW JJ) U ELECTRONIC MODULE OR/BK JK JJ BL/BK BK/WH JA JP BK U J (GREY) J (BLACK) BK BL/WH 0 BK 0 CR RETRACT CRA RESISTOR R CRB RESISTOR R A A A BN GN WH BK RD WH DIODE, A BL/WH BN0 # GN R YL JC STEER A JC BN JC STEER VE WH R WH/BK JC RD/BK P # BK THROTTLE VE BN JC STEER SIG OR/WH JC STEER B ROUTE THESE WIRES TO DRIVE BOX INSIDE LID SURFACE (VIEW GG) Part No. 0 TMZ0/0

38 Service Information November 00 Wiring Diagram Drive Controls, View JJ DRIVE BOX VIEW JJ (FRONT INSIDE SURFACE) VIEW HH VIEW GG VIEW JJ VIEW JJ VIEW GG VIEW JJ VIEW HH ROUTE THESE WIRES TO DRIVE BOX INSIDE BOX ASSEMBLY (VIEW HH) BL/BK ECM J JJ OR/BK ECM J JK BK/WH CR JA BK CRB JP P E N F D M A C G B L H K J J RD P # RD/BK P # GN/BK BN0 # JC RD/WH BN # WH BN # JB JC JD JE JF JG JH JL JM JN GN/WH BN # OR JC THROTTLE SIG WH/BK BL JC THROTTLE A GN JC THROTTLE B ROUTE THESE WIRES TO DRIVE BOX INSIDE LID SURFACE (VIEW GG) TMZ0/0 Part No. 0

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40 Service Information November 00 Electrical Schematic Platform Controls (all models) PLATFORM BOX R K OHM RESISTOR CR SPEED J J J J0 J J J J J BN START TS TURNTABLE ROTATE TS PRI BOOM EXT/RET 0 A R U ECM TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN CCW CW VO TS PLAT J PIN CONNECTOR R0A 0K OHM RESISTOR G BCI N P R0B0K OHM RESISTOR P EMERGENCY STOP CR CHOKE/ PREHEAT 0 TS0 POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN HORN ALARM BN0 CHOKE/PREHEAT TS JIB UP/DN H J J J J0 J J J J J J J J J J J J J J J J J J0 J J 0 TMZ0/0 Part No. 0

41 November 00 Service Information Electrical Schematic Drive Controls (all models) DRIVE BOX J PIN CONNECTOR JJ JK JN JM JH JC JOYSTICK JL J B A SIG VE Vs B A SIG VE Vs THROTTLE BOARD STEER BOARD J J J U ECM J J J J BN HORN R.k OHM RESISTOR R.k OHM RESISTOR J J BN EXTEND BN0 RETRACT JF JD JE JG JB JC JA BN AUTO P EMERGENCY STOP CR RETRACT 0 CRA RESISTOR R 0 CRB RESISTOR R 0 JP Part No. 0 TMZ0/0

42 Service Information November 00 Electrical Schematic DC Models (before serial number T000) Part of B B PLATFORM BN START GROUND KS KEY SWITCH P EMERGENCY STOP CB A BREAKER BN HORN TS POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN EXTEND BN RETRACT BN0 CHOKE/PREHEAT GROUND BOX TS TURNTABLE ROTATE TS PRI BOOM EXT/RET TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN TS PLAT TS JIB UP/DN BN LF X BN RF BN0 LR X X BN RR BN0 AUTO X X X X H ALARM J J0 J J J S0 S J J J POWER CONNECTOR J J J S S J J J J V V U V/V VOLTAGE DIVIDER CONNECTOR PC BOARD U J J J J J J J J J J J J J J J0 P V PUMP ENABLE PUMP SPEED J S J S0 J S J S J J 0 P LS LS 0 J CR0 0 B FOUR V BATTERIES (MODELS WITHOUT DRIVE) B EIGHT V BATTERIES QD ( ) U BATTERY CHARGER F A FUSE M MOTOR D M A PROPORTIONAL DRIVE COIL PROPORTIONAL DRIVE COIL LEFT REAR COIL LEFT REAR COIL LEFT REAR COM LEFT REAR N.C. RIGHT REAR N.C. RIGHT REAR COM RIGHT REAR COIL RIGHT REAR COIL AC INPUT QD () T M B V B 0V U MOTOR LER G Y FOR DRIVE FUNCTIONS Y LS LS Y NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 00A ES0C ES00A TMZ0/0 Part No. 0

43 November 00 Service Information Electrical Schematic DC Models (before serial number T000) Part of LEFT FRONT COIL LEFT FRONT COIL Y LEFT FRONT COM LEFT FRONT N.C. LS LS LS RIGHT FRONT N.C. RIGHT FRONT COM LS RIGHT FRONT COIL RIGHT FRONT COIL P Y FLASHING BEACONS (OPTION) FLASHING BEACONS FB 0 LS N.O.H.C. LIMIT SWITCH COM JIB BOOM N.O.H.C. PRIMARY BOOM UP N.O.H.C. LS LS LS N.O.H.C. 0 PROPORTIONAL VALVE COIL Y PROPORTIONAL VALVE COIL S AUTO GROUND BOX TO DRIVE BOX S J S J (UNUSED) J S J S J S0 J S J S J S JA S JB S JC S JD S JE S JF S0 JG S JH S JJ S JK S JL S JM S JN S JP J PIN CONNECTOR TO PLATFORM BOX S S S S NOTE S S S S S S S MODELS WITH MOTION ALARM: CONNECT S TO S MODELS WITHOUT DRIVE: CONNECT S TO S S S S0 S CONNECTOR PC BOARD U GROUP A GROUND Y UP (RETRACT) COIL (EXTEND) COIL REGEN COIL Y0 Y PLATFORM UP (FWD) COIL PLATFORM DN (REV) COIL Y0 Y ROTATE RIGHT COIL ROTATE LEFT COIL LIFT/DRIVE SELECT COIL GROUP B GROUND LOWER LIFT CYL UP COIL Y Y Y P PLATFORM Y P LIFT / DRIVE 0 LOWER LIFT CYL DN COIL UPPER LIFT CYL UP COIL Y Y UPPER LIFT CYL DN COIL JIB EXTEND (UP) COIL Y Y JIB RETRACT (DN) COIL BOOM EXTEND COIL Y0 Y 0 0 BOOM RETRACT COIL Y RD N.O. BOARD WH BK S GROUP C GROUND DRIVE COIL Y 0 RIGHT FORWARD COIL RIGHT REVERSE COIL Y0A YA DRIVE (OPTION) LEFT FORWARD COIL LEFT REVERSE COIL Y0 Y 00A ES0C ES00A FOR DRIVE FUNCTIONS NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 0 TMZ0/0

44 Service Information November 00 Electrical Schematic DC Models (from serial number T000 to T00) Part of B B PLATFORM BN START GROUND KS KEY SWITCH P EMERGENCY STOP CB A BREAKER BN HORN TS POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN EXTEND BN RETRACT BN0 CHOKE/PREHEAT GROUND BOX TS TURNTABLE ROTATE TS PRI BOOM EXT/RET TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN TS PLAT TS JIB UP/DN BN LF X BN RF BN0 LR X X BN RR BN0 AUTO X X X X H ALARM J J0 J J J J J J J J J J CONNECTOR PC BOARD U J J J J J J J J J J J J J J J0 J S J S0 J S J S J J J S J # J POWER S J # P V PUMP ENABLE PUMP SPEED 0 P LS LS 0 B FOUR V BATTERIES (MODELS WITHOUT DRIVE) B EIGHT V BATTERIES QD ( ) U BATTERY CHARGER F A FUSE M MOTOR D M A PROPORTIONAL DRIVE COIL PROPORTIONAL DRIVE COIL LEFT REAR COIL LEFT REAR COIL LEFT REAR COM LEFT REAR N.C. RIGHT REAR N.C. RIGHT REAR COM RIGHT REAR COIL RIGHT REAR COIL AC INPUT QD () T M B V B 0V U MOTOR LER G Y FOR DRIVE FUNCTIONS Y LS LS Y NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 00A ES0B ES00B TMZ0/0 Part No. 0

45 November 00 Service Information Electrical Schematic DC Models (from serial number T000 to T00) Part of LEFT FRONT COIL LEFT FRONT COIL Y LEFT FRONT COM LEFT FRONT N.C. LS LS LS RIGHT FRONT N.C. RIGHT FRONT COM LS RIGHT FRONT COIL RIGHT FRONT COIL P Y FLASHING BEACONS (OPTION) FLASHING BEACONS FB 0 LS N.O.H.C. LIMIT SWITCH COM JIB BOOM N.O.H.C. PRIMARY BOOM UP N.O.H.C. LS LS LS N.O.H.C. 0 PROPORTIONAL VALVE COIL Y PROPORTIONAL VALVE COIL S AUTO GROUND BOX TO DRIVE BOX S J S J (UNUSED) J S J S J S0 J S J S J S JA S JB S JC S JD S JE S JF S0 JG S JH S JJ S JK S JL S JM S JN S JP J PIN CONNECTOR TO PLATFORM BOX S S S S NOTE S S S S S S S MODELS WITH MOTION ALARM: CONNECT S TO S MODELS WITHOUT DRIVE: CONNECT S TO S S S S0 S CONNECTOR PC BOARD U GROUP A GROUND Y UP (RETRACT) COIL (EXTEND) COIL REGEN COIL Y0 Y PLATFORM UP (FWD) COIL PLATFORM DN (REV) COIL Y0 Y ROTATE RIGHT COIL ROTATE LEFT COIL LIFT/DRIVE SELECT COIL GROUP B GROUND LOWER LIFT CYL UP COIL Y Y Y P PLATFORM Y P LIFT / DRIVE 0 LOWER LIFT CYL DN COIL UPPER LIFT CYL UP COIL Y Y UPPER LIFT CYL DN COIL JIB EXTEND (UP) COIL Y Y JIB RETRACT (DN) COIL BOOM EXTEND COIL Y0 Y 0 0 BOOM RETRACT COIL Y RD N.O. BOARD WH BK S GROUP C GROUND DRIVE COIL Y 0 RIGHT FORWARD COIL RIGHT REVERSE COIL Y0A YA DRIVE (OPTION) LEFT FORWARD COIL LEFT REVERSE COIL Y0 Y 00A ES0B ES00B FOR DRIVE FUNCTIONS NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 0 TMZ0/0

46 Service Information November 00 Electrical Schematic DC Models (from serial number T00 to TMZ00) Part of B B PLATFORM BN START GROUND KS KEY SWITCH P EMERGENCY STOP CB A BREAKER BN HORN TS POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN EXTEND BN RETRACT BN0 CHOKE/PREHEAT GROUND BOX TS TURNTABLE ROTATE TS PRI BOOM EXT/RET TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN TS PLAT TS JIB UP/DN BN LF X BN RF BN0 LR X X BN RR BN0 AUTO X X X X H ALARM J J0 J J J J J J J J J J CONNECTOR PC BOARD U J J J J J J J J J J J J J J J0 J S J S0 J S J S J J J S J # J POWER S J # P V PUMP ENABLE PUMP SPEED 0 P LS LS 0 B FOUR V BATTERIES (MODELS WITHOUT DRIVE) B EIGHT V BATTERIES QD ( ) U BATTERY CHARGER F A FUSE M MOTOR D M A PROPORTIONAL DRIVE COIL PROPORTIONAL DRIVE COIL LEFT REAR COIL LEFT REAR COIL LEFT REAR COM LEFT REAR N.C. RIGHT REAR N.C. RIGHT REAR COM RIGHT REAR COIL RIGHT REAR COIL AC INPUT QD () T M B V B 0V U MOTOR LER G Y FOR DRIVE FUNCTIONS Y LS LS Y NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 00A ES00A ES0A TMZ0/0 Part No. 0

47 November 00 Service Information Electrical Schematic DC Models (from serial number T00 to TMZ00) Part of LEFT FRONT COIL LEFT FRONT COIL Y LEFT FRONT COM LEFT FRONT N.C. LS LS LS RIGHT FRONT N.C. RIGHT FRONT COM LS RIGHT FRONT COIL RIGHT FRONT COIL P Y FLASHING BEACONS (OPTION) FLASHING BEACONS FB 0 LS N.O.H.C. LS N.O.H.C. LIMIT SWITCH COM JIB BOOM N.O.H.C. PRIMARY BOOM UP N.O.H.C. TURNTABLE N.C. LS LS Ls LS N.C. 0 PROPORTIONAL VALVE COIL Y PROPORTIONAL VALVE COIL S AUTO GROUND BOX TO DRIVE BOX S J S J (UNUSED) J S J S J S0 J S J S J S JA S JB S JC S JD S JE S JF S0 JG S JH S JJ S JK S JL S JM S JN S JP J PIN CONNECTOR TO PLATFORM BOX S S S S NOTE S S S S S S S MODELS WITH MOTION ALARM: CONNECT S TO S MODELS WITHOUT DRIVE: CONNECT S TO S S S S0 S CONNECTOR PC BOARD U GROUP A GROUND Y UP (RETRACT) COIL (EXTEND) COIL REGEN COIL Y0 Y PLATFORM UP (FWD) COIL PLATFORM DN (REV) COIL Y0 Y ROTATE RIGHT COIL ROTATE LEFT COIL LIFT/DRIVE SELECT COIL GROUP B GROUND LOWER LIFT CYL UP COIL Y Y Y P PLATFORM Y P LIFT / DRIVE 0 LOWER LIFT CYL DN COIL UPPER LIFT CYL UP COIL Y Y UPPER LIFT CYL DN COIL JIB EXTEND (UP) COIL Y Y JIB RETRACT (DN) COIL BOOM EXTEND COIL Y0 Y 0 0 BOOM RETRACT COIL Y RD N.O. BOARD WH BK S GROUP C GROUND DRIVE COIL Y 0 RIGHT FORWARD COIL RIGHT REVERSE COIL Y0A YA DRIVE (OPTION) LEFT FORWARD COIL LEFT REVERSE COIL Y0 Y 00A ES00A ES0A FOR DRIVE FUNCTIONS NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 0 TMZ0/0

48 Service Information November 00 Electrical Schematic DC Models (after serial number TMZ00) Part of B B PLATFORM BN START GROUND KS KEY SWITCH P EMERGENCY STOP CB A BREAKER BN HORN TS POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN EXTEND BN RETRACT BN0 CHOKE/PREHEAT GROUND BOX TS TURNTABLE ROTATE TS PRI BOOM EXT/RET TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN TS PLAT TS JIB UP/DN BN LF X BN RF BN0 LR X X BN RR BN0 AUTO X X X X H ALARM J J0 J J J J J J J J J J CONNECTOR PC BOARD U J J J J J J J J J J J J J J J0 J S J S0 J S J S J J J S J # J POWER S J # P V PUMP ENABLE PUMP SPEED 0 P LS LS 0 B FOUR V BATTERIES (MODELS WITHOUT DRIVE) B EIGHT V BATTERIES QD ( ) U BATTERY CHARGER F A FUSE M MOTOR D M A PROPORTIONAL DRIVE COIL PROPORTIONAL DRIVE COIL LEFT REAR COIL LEFT REAR COIL LEFT REAR COM LEFT REAR N.C. RIGHT REAR N.C. RIGHT REAR COM RIGHT REAR COIL RIGHT REAR COIL AC INPUT QD () T M B V B 0V U MOTOR LER G Y FOR DRIVE FUNCTIONS Y LS LS Y NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 00A ES00B ES0B TMZ0/0 Part No. 0

49 November 00 Service Information Electrical Schematic DC Models (after serial number TMZ00) Part of LEFT FRONT COIL LEFT FRONT COIL Y LEFT FRONT COM LEFT FRONT N.C. LS LS LS RIGHT FRONT N.C. RIGHT FRONT COM LS RIGHT FRONT COIL RIGHT FRONT COIL P Y FLASHING BEACONS (OPTION) FLASHING BEACONS FB 0 LS N.O.H.C. LS N.O.H.C. LIMIT SWITCH COM JIB BOOM N.O.H.C. PRIMARY BOOM UP N.O.H.C. TURNTABLE N.C. LS LS Ls LS N.C. 0 PROPORTIONAL VALVE COIL Y PROPORTIONAL VALVE COIL S AUTO GROUND BOX TO DRIVE BOX S J S J (UNUSED) J S J S J S0 J S J S J S JA S JB S JC S JD S JE S JF S0 JG S JH S JJ S JK S JL S JM S JN S JP J PIN CONNECTOR TO PLATFORM BOX S S S S NOTE S S S S S S S MODELS WITH MOTION ALARM: CONNECT S TO S MODELS WITHOUT DRIVE: CONNECT S TO S S S S0 S CONNECTOR PC BOARD U GROUP A GROUND Y UP (RETRACT) COIL (EXTEND) COIL REGEN COIL Y0 Y PLATFORM UP (FWD) COIL PLATFORM DN (REV) COIL Y0 Y ROTATE RIGHT COIL ROTATE LEFT COIL LIFT/DRIVE SELECT COIL GROUP B GROUND LOWER LIFT CYL UP COIL Y Y Y P PLATFORM Y P LIFT / DRIVE 0 LOWER LIFT CYL DN COIL UPPER LIFT CYL UP COIL Y Y UPPER LIFT CYL DN COIL JIB EXTEND (UP) COIL Y Y JIB RETRACT (DN) COIL BOOM EXTEND COIL Y0 Y 0 0 BOOM RETRACT COIL Y RD N.O. BOARD WH BK S GROUP C GROUND DRIVE COIL Y 0 RIGHT FORWARD COIL RIGHT REVERSE COIL Y0A YA DRIVE (OPTION) LEFT FORWARD COIL LEFT REVERSE COIL Y0 Y 00A ES00B ES0B FOR DRIVE FUNCTIONS NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 0 TMZ0/0

50 Service Information November 00 Electrical Schematic Gasoline Models (before serial number T000) Part of B B PLATFORM BN START GROUND KS KEY SWITCH P EMERGENCY STOP CB A BREAKER BN HORN TS POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN EXTEND BN RETRACT BN0 CHOKE/PREHEAT GROUND BOX TS TURNTABLE ROTATE TS PRI BOOM EXT/RET TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN TS PLAT TS JIB UP/DN BN LF X BN RF BN0 LR X X BN RR BN0 AUTO X X X X H ALARM J J0 J J J B ONE V BATTERY J J QD ( ) QD () J J S J J POWER CONNECTOR S J J J J F A FUSE CONNECTOR PC BOARD U AUX PUMP ENABLE M P KS KEY SWITCH WH WH RD/BK F A FUSE STARTER M BK/WH CR START 0 J J J J J J J J J J J J J J J0 BK CR HIGH IDLE 0 THROTTLE START SW OIL Q HIGH IDLE SOLENOID BK/YL BK/YL U VOLTAGE REGULATOR GY GY BK J GY RUN U IGNITION COIL S J S0 J S J S G STOP GROUND CR STOP 0 A U0 SPARK PLUG PROPORTIONAL DRIVE COIL PROPORTIONAL DRIVE COIL Y FOR DRIVE FUNCTIONS J J LEFT REAR COIL LEFT REAR COIL Y 0 P LEFT REAR COM LEFT REAR N.C. LS LS LS 0 RIGHT REAR N.C. RIGHT REAR COM LS J RIGHT REAR COIL RIGHT REAR COIL Y NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 00A ES0B ES0B 0 TMZ0/0 Part No. 0

51 November 00 Service Information Electrical Schematic Gasoline Models (before serial number T000) Part of LEFT FRONT COIL LEFT FRONT COIL Y LEFT FRONT COM LEFT FRONT N.C. LS LS LS RIGHT FRONT N.C. RIGHT FRONT COM LS RIGHT FRONT COIL RIGHT FRONT COIL P Y FLASHING BEACONS (OPTION) FLASHING BEACONS FB 0 LS N.O.H.C. LIMIT SWITCH COM JIB BOOM N.O.H.C. PRIMARY BOOM UP N.O.H.C. LS LS LS N.O.H.C. 0 PROPORTIONAL VALVE COIL Y PROPORTIONAL VALVE COIL S AUTO GROUND BOX TO DRIVE BOX S J S J (UNUSED) J S J S J S0 J S J S J S JA S JB S JC S JD S JE S JF S0 JG S JH S JJ S JK S JL S JM S JN S JP J PIN CONNECTOR TO PLATFORM BOX S S S S NOTE S S S S S S S MODELS WITH MOTION ALARM: CONNECT S TO S MODELS WITHOUT DRIVE: CONNECT S TO S S S S0 S CONNECTOR PC BOARD U GROUP A GROUND Y UP (RETRACT) COIL (EXTEND) COIL REGEN COIL Y0 Y PLATFORM UP (FWD) COIL PLATFORM DN (REV) COIL Y0 Y ROTATE RIGHT COIL ROTATE LEFT COIL LIFT/DRIVE SELECT COIL GROUP B GROUND LOWER LIFT CYL UP COIL Y Y Y P PLATFORM Y P LIFT / DRIVE 0 LOWER LIFT CYL DN COIL UPPER LIFT CYL UP COIL Y Y UPPER LIFT CYL DN COIL JIB EXTEND (UP) COIL Y Y JIB RETRACT (DN) COIL BOOM EXTEND COIL Y0 Y 0 0 BOOM RETRACT COIL Y RD N.O. BOARD WH BK S GROUP C GROUND DRIVE COIL Y 0 RIGHT FORWARD COIL RIGHT REVERSE COIL Y0A YA DRIVE (OPTION) LEFT FORWARD COIL LEFT REVERSE COIL Y0 Y 00A ES0B ES0B FOR BOOM FUNCTIONS (MODELS WITHOUT DRIVE) AND FOR BOOM AND DRIVE FUNCTIONS NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 0 TMZ0/0

52 Service Information November 00 Electrical Schematic Gasoline Models (from serial number T000 to T00) Part of B B PLATFORM BN START GROUND KS KEY SWITCH P EMERGENCY STOP CB A BREAKER BN HORN TS POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN EXTEND BN RETRACT BN0 CHOKE/PREHEAT GROUND BOX TS TURNTABLE ROTATE TS PRI BOOM EXT/RET TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN TS PLAT TS JIB UP/DN BN LF X BN RF BN0 LR X X BN RR BN0 AUTO X X X X H ALARM J J0 J J J B ONE V BATTERY J J QD ( ) QD () J J S J J POWER CONNECTOR S J J J J F A FUSE CONNECTOR PC BOARD U AUX PUMP ENABLE M P KS KEY SWITCH WH WH RD/BK F A FUSE STARTER M BK/WH CR START 0 J J J J J J J J J J J J J J J0 BK CR HIGH IDLE 0 THROTTLE START SW OIL Q HIGH IDLE SOLENOID BK/YL BK/YL U VOLTAGE REGULATOR GY GY BK J GY RUN U IGNITION COIL S J S0 J S J S G STOP GROUND CR STOP 0 A U0 SPARK PLUG PROPORTIONAL DRIVE COIL PROPORTIONAL DRIVE COIL Y FOR DRIVE FUNCTIONS J J LEFT REAR COIL LEFT REAR COIL Y 0 P LEFT REAR COM LEFT REAR N.C. LS LS LS 0 RIGHT REAR N.C. RIGHT REAR COM LS J RIGHT REAR COIL RIGHT REAR COIL Y NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 00A ES0C ES0C TMZ0/0 Part No. 0

53 November 00 Service Information Electrical Schematic Gasoline Models (from serial number T000 to T00) Part of LEFT FRONT COIL LEFT FRONT COIL Y LEFT FRONT COM LEFT FRONT N.C. LS LS LS RIGHT FRONT N.C. RIGHT FRONT COM LS RIGHT FRONT COIL RIGHT FRONT COIL P Y FLASHING BEACONS (OPTION) FLASHING BEACONS FB 0 LS N.O.H.C. LIMIT SWITCH COM JIB BOOM N.O.H.C. PRIMARY BOOM UP N.O.H.C. LS LS LS N.O.H.C. 0 PROPORTIONAL VALVE COIL Y PROPORTIONAL VALVE COIL S AUTO GROUND BOX TO DRIVE BOX S J S J (UNUSED) J S J S J S0 J S J S J S JA S JB S JC S JD S JE S JF S0 JG S JH S JJ S JK S JL S JM S JN S JP J PIN CONNECTOR TO PLATFORM BOX S S S S NOTE S S S S S S S MODELS WITH MOTION ALARM: CONNECT S TO S MODELS WITHOUT DRIVE: CONNECT S TO S S S S0 S CONNECTOR PC BOARD U GROUP A GROUND Y UP (RETRACT) COIL (EXTEND) COIL REGEN COIL Y0 Y PLATFORM UP (FWD) COIL PLATFORM DN (REV) COIL Y0 Y ROTATE RIGHT COIL ROTATE LEFT COIL LIFT/DRIVE SELECT COIL GROUP B GROUND LOWER LIFT CYL UP COIL Y Y Y P PLATFORM Y P LIFT / DRIVE 0 LOWER LIFT CYL DN COIL UPPER LIFT CYL UP COIL Y Y UPPER LIFT CYL DN COIL JIB EXTEND (UP) COIL Y Y JIB RETRACT (DN) COIL BOOM EXTEND COIL Y0 Y 0 0 BOOM RETRACT COIL Y RD N.O. BOARD WH BK S GROUP C GROUND DRIVE COIL Y 0 RIGHT FORWARD COIL RIGHT REVERSE COIL Y0A YA DRIVE (OPTION) LEFT FORWARD COIL LEFT REVERSE COIL Y0 Y 00A ES0C ES0C FOR BOOM FUNCTIONS (MODELS WITHOUT DRIVE) AND FOR BOOM AND DRIVE FUNCTIONS NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 0 TMZ0/0

54 Service Information November 00 Electrical Schematic Gasoline Models (from serial number T00 to TMZ00) Part of B B PLATFORM BN START GROUND KS KEY SWITCH P EMERGENCY STOP CB A BREAKER BN HORN TS POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN EXTEND BN RETRACT BN0 CHOKE/PREHEAT GROUND BOX TS TURNTABLE ROTATE TS PRI BOOM EXT/RET TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN TS PLAT TS JIB UP/DN BN LF X BN RF BN0 LR X X BN RR BN0 AUTO X X X X H ALARM J J0 J J J B ONE V BATTERY J J QD ( ) QD () J J S J J POWER CONNECTOR S J J J J F A FUSE CONNECTOR PC BOARD U AUX PUMP ENABLE M P KS KEY SWITCH WH WH RD/BK F A FUSE STARTER M BK/WH CR START 0 J J J J J J J J J J J J J J J0 BK 0 CHOKE THROTTLE START CR HIGH IDLE SW OIL Q HIGH IDLE SOLENOID BK/YL BK/YL U VOLTAGE REGULATOR GY GY BK CR CHOKE 0 Q CHOKE J GY RUN U IGNITION COIL S J S0 J S J S G STOP GROUND CR STOP 0 A U0 SPARK PLUG PROPORTIONAL DRIVE COIL PROPORTIONAL DRIVE COIL Y FOR DRIVE FUNCTIONS J J LEFT REAR COIL LEFT REAR COIL Y 0 P LEFT REAR COM LEFT REAR N.C. LS LS LS 0 RIGHT REAR N.C. RIGHT REAR COM LS J RIGHT REAR COIL RIGHT REAR COIL Y NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 00A ES0A ES0A TMZ0/0 Part No. 0

55 November 00 Service Information Electrical Schematic Gasoline Models (from serial number T00 to TMZ00) Part of LEFT FRONT COIL LEFT FRONT COIL Y LEFT FRONT COM LEFT FRONT N.C. LS LS LS RIGHT FRONT N.C. RIGHT FRONT COM LS RIGHT FRONT COIL RIGHT FRONT COIL P Y FLASHING BEACONS (OPTION) FLASHING BEACONS FB 0 LS N.O.H.C. LS N.O.H.C. LIMIT SWITCH COM JIB BOOM N.O.H.C. PRIMARY BOOM UP N.O.H.C. TURNTABLE N.C. LS LS LS LS N.C. 0 PROPORTIONAL VALVE COIL Y PROPORTIONAL VALVE COIL S AUTO GROUND BOX TO DRIVE BOX S J S J (UNUSED) J S J S J S0 J S J S J S JA S JB S JC S JD S JE S JF S0 JG S JH S JJ S JK S JL S JM S JN S JP J PIN CONNECTOR TO PLATFORM BOX S S S S NOTE S S S S S S S MODELS WITH MOTION ALARM: CONNECT S TO S MODELS WITHOUT DRIVE: CONNECT S TO S S S S0 S CONNECTOR PC BOARD U GROUP A GROUND Y UP (RETRACT) COIL (EXTEND) COIL REGEN COIL Y0 Y PLATFORM UP (FWD) COIL PLATFORM DN (REV) COIL Y0 Y ROTATE RIGHT COIL ROTATE LEFT COIL LIFT/DRIVE SELECT COIL GROUP B GROUND LOWER LIFT CYL UP COIL Y Y Y P PLATFORM Y P LIFT / DRIVE 0 LOWER LIFT CYL DN COIL UPPER LIFT CYL UP COIL Y Y UPPER LIFT CYL DN COIL JIB EXTEND (UP) COIL Y Y JIB RETRACT (DN) COIL BOOM EXTEND COIL Y0 Y 0 0 BOOM RETRACT COIL Y RD N.O. BOARD WH BK S GROUP C GROUND DRIVE COIL Y 0 RIGHT FORWARD COIL RIGHT REVERSE COIL Y0A YA DRIVE (OPTION) LEFT FORWARD COIL LEFT REVERSE COIL Y0 Y 00A ES0A ES0A FOR BOOM FUNCTIONS (MODELS WITHOUT DRIVE) AND FOR BOOM AND DRIVE FUNCTIONS NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 0 TMZ0/0

56 Service Information November 00 Electrical Schematic Gasoline Models (after serial number TMZ00) Part of B B PLATFORM BN START GROUND KS KEY SWITCH P EMERGENCY STOP CB A BREAKER BN HORN TS POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN EXTEND BN RETRACT BN0 CHOKE/PREHEAT GROUND BOX TS TURNTABLE ROTATE TS PRI BOOM EXT/RET TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN TS PLAT TS JIB UP/DN BN LF X BN RF BN0 LR X X BN RR BN0 AUTO X X X X H ALARM J J0 J J J B ONE V BATTERY J J QD ( ) QD () J J S J J POWER CONNECTOR S J J J J F A FUSE CONNECTOR PC BOARD U AUX PUMP ENABLE M P KS KEY SWITCH WH WH RD/BK F A FUSE STARTER M BK/WH CR START 0 J J J J J J J J J J J J J J J0 BK 0 CHOKE THROTTLE START CR HIGH IDLE SW OIL Q HIGH IDLE SOLENOID BK/YL BK/YL U VOLTAGE REGULATOR GY GY BK CR CHOKE 0 Q CHOKE J GY RUN U IGNITION COIL S J S0 J S J S G STOP GROUND CR STOP 0 A U0 SPARK PLUG PROPORTIONAL DRIVE COIL PROPORTIONAL DRIVE COIL Y FOR DRIVE FUNCTIONS J J LEFT REAR COIL LEFT REAR COIL Y 0 P LEFT REAR COM LEFT REAR N.C. LS LS LS 0 RIGHT REAR N.C. RIGHT REAR COM LS J RIGHT REAR COIL RIGHT REAR COIL Y NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 00A ES0B ES0B TMZ0/0 Part No. 0

57 November 00 Service Information Electrical Schematic Gasoline Models (after serial number TMZ00) Part of LEFT FRONT COIL LEFT FRONT COIL Y LEFT FRONT COM LEFT FRONT N.C. LS LS LS RIGHT FRONT N.C. RIGHT FRONT COM LS RIGHT FRONT COIL RIGHT FRONT COIL P Y FLASHING BEACONS (OPTION) FLASHING BEACONS FB 0 LS N.O.H.C. LS N.O.H.C. LIMIT SWITCH COM JIB BOOM N.O.H.C. PRIMARY BOOM UP N.O.H.C. TURNTABLE N.C. LS LS LS LS N.C. 0 PROPORTIONAL VALVE COIL Y PROPORTIONAL VALVE COIL S AUTO GROUND BOX TO DRIVE BOX S J S J (UNUSED) J S J S J S0 J S J S J S JA S JB S JC S JD S JE S JF S0 JG S JH S JJ S JK S JL S JM S JN S JP J PIN CONNECTOR TO PLATFORM BOX S S S S NOTE S S S S S S S MODELS WITH MOTION ALARM: CONNECT S TO S MODELS WITHOUT DRIVE: CONNECT S TO S S S S0 S CONNECTOR PC BOARD U GROUP A GROUND Y UP (RETRACT) COIL (EXTEND) COIL REGEN COIL Y0 Y PLATFORM UP (FWD) COIL PLATFORM DN (REV) COIL Y0 Y ROTATE RIGHT COIL ROTATE LEFT COIL LIFT/DRIVE SELECT COIL GROUP B GROUND LOWER LIFT CYL UP COIL Y Y Y P PLATFORM Y P LIFT / DRIVE 0 LOWER LIFT CYL DN COIL UPPER LIFT CYL UP COIL Y Y UPPER LIFT CYL DN COIL JIB EXTEND (UP) COIL Y Y JIB RETRACT (DN) COIL BOOM EXTEND COIL Y0 Y 0 0 BOOM RETRACT COIL Y RD N.O. BOARD WH BK S GROUP C GROUND DRIVE COIL Y 0 RIGHT FORWARD COIL RIGHT REVERSE COIL Y0A YA DRIVE (OPTION) LEFT FORWARD COIL LEFT REVERSE COIL Y0 Y 00A ES0B ES0B FOR BOOM FUNCTIONS (MODELS WITHOUT DRIVE) AND FOR BOOM AND DRIVE FUNCTIONS NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 0 TMZ0/0

58 Service Information November 00 Electrical Schematic Gasoline BiFuel Models (before serial number T000) Part of B B PLATFORM BN START GROUND KS KEY SWITCH P EMERGENCY STOP CB A BREAKER BN HORN TS POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN EXTEND BN RETRACT BN0 CHOKE/PREHEAT GROUND BOX TS TURNTABLE ROTATE TS PRI BOOM EXT/RET TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN TS PLAT TS JIB UP/DN BN LF X BN RF BN0 LR X X BN RR BN0 AUTO X X X X H ALARM B V BATTERY J J0 J J J S0 S QD ( ) J J U BATTERY CHARGER F A FUSE AC INPUT QD J J S J J POWER CONNECTOR S ( ) QD () QD ( ) J J J J V V U V/V VOLTAGE DIVIDER M MOTOR CR0 D M A T M CONNECTOR PC BOARD U B 0 V B 0V U MOTOR LER F A FUSE V PUMP ENABLE PUMP SPEED P KS KEY SWITCH WH WH RD/BK F A FUSE STARTER M BK/WH CR START 0 J J J J J J J J J J J J J J J0 BK CR HIGH IDLE 0 THROTTLE START SW OIL Q HIGH IDLE SOLENOID BK/YL BK/YL U VOLTAGE REGULATOR GY GY BK J GY RUN U IGNITION COIL S J S0 J S J S G STOP GROUND CR STOP 0 A U0 SPARK PLUG PROPORTIONAL DRIVE COIL PROPORTIONAL DRIVE COIL Y FOR DRIVE FUNCTIONS J J LEFT REAR COIL LEFT REAR COIL Y 0 P LEFT REAR COM LEFT REAR N.C. LS LS LS 0 RIGHT REAR N.C. RIGHT REAR COM LS J RIGHT REAR COIL RIGHT REAR COIL Y NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 00A ES0B ES0B TMZ0/0 Part No. 0

59 November 00 Service Information Electrical Schematic Gasoline BiFuel Models (before serial number T000) Part of LEFT FRONT COIL LEFT FRONT COIL Y LEFT FRONT COM LEFT FRONT N.C. LS S AUTO GROUND BOX TO DRIVE BOX S J S J (UNUSED) J S J S J S0 J S J S J S JA S JB S JC S JD S JE S JF S0 JG S JH S JJ S JK S JL S JM S JN S JP J PIN CONNECTOR TO PLATFORM BOX S S S S NOTE S S S S S S S MODELS WITH MOTION ALARM: CONNECT S TO S MODELS WITHOUT DRIVE: CONNECT S TO S S S S0 S LS LS RIGHT FRONT N.C. RIGHT FRONT COM LS RIGHT FRONT COIL RIGHT FRONT COIL P Y FLASHING BEACONS (OPTION) FLASHING BEACONS FB 0 CONNECTOR PC BOARD U LS N.O.H.C. LIMIT SWITCH COM JIB BOOM N.O.H.C. PRIMARY BOOM UP N.O.H.C. LS LS LS N.O.H.C. 0 Y PROPORTIONAL VALVE COIL PROPORTIONAL VALVE COIL GROUP A GROUND Y UP (RETRACT) COIL (EXTEND) COIL REGEN COIL Y0 Y PLATFORM UP (FWD) COIL PLATFORM DN (REV) COIL Y0 Y ROTATE RIGHT COIL ROTATE LEFT COIL LIFT/DRIVE SELECT COIL GROUP B GROUND LOWER LIFT CYL UP COIL Y Y Y P PLATFORM Y P LIFT / DRIVE 0 LOWER LIFT CYL DN COIL UPPER LIFT CYL UP COIL Y Y UPPER LIFT CYL DN COIL JIB EXTEND (UP) COIL Y Y JIB RETRACT (DN) COIL BOOM EXTEND COIL Y0 Y 0 0 BOOM RETRACT COIL Y V V V XAXIS (0V) YAXIS (0V) S RD N.O. BOARD WH BK S GROUP C GROUND DRIVE COIL Y 0 RIGHT FORWARD COIL RIGHT REVERSE COIL Y0A YA DRIVE (OPTION) LEFT FORWARD COIL LEFT REVERSE COIL Y0 Y 00A ES0B ES0B FOR BOOM FUNCTIONS (MODELS WITHOUT DRIVE) AND FOR BOOM AND DRIVE FUNCTIONS NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 0 TMZ0/0

60 Service Information November 00 Electrical Schematic Gasoline BiFuel Models (from serial number T000 to T00) Part of B B PLATFORM BN START GROUND KS KEY SWITCH P EMERGENCY STOP CB A BREAKER BN HORN TS POWER SELECT(IC/DC/AUX) BN BOOM FUNCTION ENABLE BN EXTEND BN RETRACT BN0 CHOKE/PREHEAT GROUND BOX TS TURNTABLE ROTATE TS PRI BOOM EXT/RET TS PRI BOOM UP/DN TS0 SEC BOOM UP/DN TS PLAT TS JIB UP/DN BN LF X BN RF BN0 LR X X BN RR BN0 AUTO X X X X H ALARM B V BATTERY J J0 J J J QD ( ) J J U BATTERY CHARGER F A FUSE AC INPUT QD J J ( ) QD () QD ( ) J J J M MOTOR S S J # J # D M A T M CONNECTOR PC BOARD U J POWER B V B 0V U MOTOR LER F A FUSE P V PUMP ENABLE PUMP SPEED KS KEY SWITCH WH WH RD/BK F A FUSE STARTER M BK/WH CR START 0 J J J J J J J J J J J J J J J0 BK CR HIGH IDLE 0 THROTTLE START SW OIL Q HIGH IDLE SOLENOID BK/YL BK/YL U VOLTAGE REGULATOR GY GY BK J GY RUN U IGNITION COIL S J S0 J S J S G STOP GROUND CR STOP 0 A U0 SPARK PLUG PROPORTIONAL DRIVE COIL PROPORTIONAL DRIVE COIL Y FOR DRIVE FUNCTIONS J J LEFT REAR COIL LEFT REAR COIL Y 0 P LEFT REAR COM LEFT REAR N.C. LS LS LS 0 RIGHT REAR N.C. RIGHT REAR COM LS J RIGHT REAR COIL RIGHT REAR COIL Y NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 00A ES0C ES0C 0 TMZ0/0 Part No. 0