CONTROLS AND SWITCHES
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1 CONTROLS AND SWITCHES Power Relay Engine Start / Stop Lift / Drive Speed / Torque Emergency Stop Choke / Glow Plug Micro-Switches Steering Enable Switch Generator (Optional) Horn (Optional) Drive Enabled Indicator (Optional) Outrigger Extend/Retract (Optional) Reverse/Down Rocker Switch Forward/Up Rocker Switch Potentiometer Raise (Green) Lower (Green) Throttle (Green) Engine Stop (Red) Platform / Chassis Circuit Breaker Gasoline/Propane (Dual Fuel) Emergency Stop Hour Meter Engine Start (Green) Choke/Preheat (Black) March 008 Page - "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications
2 SECTION : SCHEMATICS SECTION : SCHEMATICS... - Hydraulic Schematic... - Main Hydraulic Manifold... - Optional Outriggers Hydraulic Manifold... - Electric Schematics... - Circuit Board Controls...-0 Engine...- Optional Outriggers...- Optional Generator...- "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications March 008 Page -
3 HYDRAULIC SCHEMATIC Callout CYL MA SV ORF CYL MA SV RV ORF CYL MA SV RV ORF LF LR RV RF RR RV P Description Lift Cylinder Components (07RT) Cylinder Manifold, Lift Cylinder Solenoid Valve - V Cable Attach Orifice Lift Cylinder Components (77RT) Cylinder, Upper Manifold, Lift Cylinder, Upper Solenoid Valve - V Dual Coil Relief Valve - 00 PSI Orifice Cylinder, Lower Manifold, Lift Cylinder, Lower Solenoid Valve - V Dual Coil Relief Valve - 00 PSI Orifice Wheel Motor Components Wheel Motor - Left Front Wheel Motor - Left Rear Relief Valve PSI - Cross Port Relief Wheel Motor - Right Front Wheel Motor - Right Rear Relief Valve PSI - Cross Port Relief Pump - Variable Displacement Pressure Compensated Callout MA SVD SV SV SV - SV SP RV RV PD - PD - PD EP - EP MP LS - LS - LS CBV - CBV CL CL CL HP FD - FD EC CV - CV OD OPL OPL - OPL ORF Description Manifold Components Manifold, Main Valve Block Spool Valve, Drive, Way - Position Spool Valve, Lift, Way Spool Valve, Steer, Way - Position Spool Valve, Series Parallel, Way - Position Proportional Valve - V Relief Valve, Lift - 00 PSI Relief Valve, Steer - 00 PSI Piloted Spool Valve, Way - Position Piloted Poppet Valve Manual Pull Valve Load Sense Shuttle Check Valve Counter Balance Valve Coil, Series 8 - V Coil, Series 0 - V Coil, Series 0 E-Coil - V Hand Pump, Brake Release Flow Divider / Combiner Pressure Compensator Check Valve, Load Sense Orifice Disc, Brake Orifice Plug, Steer Orifice Plug, Flow Divider Bleed Orifice, Decent Control FL Return Filter - 0 Micron CYL Cylinder, Steering CYL SV7 SV8 SV9 Optional Outriggers Components Outrigger Cylinder Solenoid Valve, Poppet N.C. Solenoid Valve, Poppet N.C. Spool Valve, Way - Position March 008 Page - "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications
4 MA- RV CYL UPPER LIFT CYLINDER MA- RV CYL LOWER LIFT CYLINDER CYL STEERING CYL FL P PUMP SV SV ORLS ORR ORS ø.07 ORF ø.07 ORF 77RT ONLY STR STL LFT CV CV SV S CL S CL RV OPL ø PSI SP EC GSTR MA- ø.07 ORF CYL LIFT CYLINDER ø.09 ORF MA- EP CL LS SV CL RV 00 PSI LS P GP LS GLS SV 07RT ONLY OPTIONAL OUTRIGGERS ORA ORB SV7 SV7 SV7 SV7 CYL CYL CYL SV8 SV8 SV8 SV8 SV9 ORS ORR ORLS RV RV B A A B RR LF RF LFA LFB RRB RRA RFB RRA LRA LRB LR PD PD ø.0 OPL OPL ø.0 EP FD PD FD CBV CBV LS OD ø.0 CL SV CL MP SV SVD a b HP B T CYL "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications March 008 Page -
5 Main Hydraulic Manifold RV RV SP CL PLG OPL PLG PLG LS PLG RRA OPL ORS P RFB LRB CV GSTR LFT CV LEFT BOTTOM SVD LS LS PLG EC EP FD PLG PLG PLG SV GP CL SV CL CL LS ORLS T HP FRONT SV CL EP PLG BACK SV CL PLG CBV OPL PLG PLG STL LFA LFB PD STR B RFA RRB GLS MP OD CBV ORR LRA PLG PD PLG FD PD RIGHT TOP March 008 Page - "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications
6 Optional Outriggers Hydraulic Manifold SV CL CL CAV PLG0 ORB ORS LEFT FRONT CV ORA ORR PLG ORLS CV RIGHT BOTTOM "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications March 008 Page -
7 ELECTRIC SCHEMATICS A B C D March 008 Page - "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications
8 A A B C C MAIN HARNESS - ANSI TILT SENSOR "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications March 008 Page -7
9 Circuit Board The Circuit Bard schematic is broken into two pages for clarity. The cable connections are shown on this page. Match the numbers to line-up the traces. March 008 Page -8 "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications
10 "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications March 008 Page -9
11 Controls ANSI UPPER CONTROLS WITHOUT OUTRIGGER OPTION JOYSTICK 0 E-STOP IN (H) IGN (L) CHOKE IN (L) THROTTLE INPUT (L) HI RANGE (H) STEER LEFT STEER RIGHT TORQUE SW (L) LIFT MODE FORWARD/DOWN REVERSE/UP PWM INPUT CONNECTORS ON MAIN CONTROL HARNESS TERMINAL STRIP HD CONN WIRE NUMBERS AND COLORS A E-STOP 0 /RED CHOKE/GLOW A YEL/WHT 0 YEL/WHT H H /GRN R X + A - DT0-SA UPPER STATION WHT/ 0 BLU/RED 8 PNK/WHT S REVERSE/UP S FORWARD/DOWN ENABLE ROCKER STEER L/R WHT WHT/RED /WHT GRN/WHT /GRN GRN WHT/ BLU/RED GRN/ BLU/ BLU WHT GRN/WHT A GRN YEL BLU PPL RED GRN/ BLU/ PPL 8 GRN 7 GRN/WHT 0A RED PLUG NUMBERS /RED 0 WHT/RED 0 WHT/RED GRN/WHT PPL LIFT/DRIVE GRN/WHT / SPEED/TORQUE PPL TIME DELAY RELAY PC BOARD / RED/ RED/ /RED /RED TORQUE SW () DE OUT (H) DE IN (H) PLATFORM DISABLE (H) START (L) GND R S T U V W X M N O P Q 0 WHT/RED /WHT GRN/WHT /GRN 8 GRN WHT/ 0 BLU/RED GRN/ BLU/ BLU PPL BLU DT0-S UPPER STATION # B D F H K L C E G A J / RED/GRN A RED/ /RED 0 /RED 7 BLU/WHT 7 /WHT/RED 7 WHT//RED 7 RED/WHT 7 RED/WHT/ DIODE BLOCK DB- RELAY UPPER STATION NOT USED KEY SWITCH DIODE BLOCK DB- GENERATOR SWITCH (OPTION) 7 RED/WHT March 008 Page -0 "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications
12 87 87A E-STOP 0 /RED CHOKE/GLOW H H /GRN R A YEL/WHT 0 YEL/WHT X + A - ANSI UPPER CONTROLS WITH OUTRIGGER OPTION JOYSTICK 0 E-STOP IN (H) IGN (L) CHOKE IN (L) THROTTLE INPUT (L) HI RANGE (H) STEER LEFT STEER RIGHT TORQUE SW (L) LIFT MODE FORWARD/DOWN REVERSE/UP PWM INPUT CONNECTORS ON MAIN CONTROL HARNESS TERMINAL STRIP HD CONN WIRE NUMBERS AND COLORS DT0-SA UPPER STATION WHT/ /RED /RED S REVERSE/UP S FORWARD/DOWN ENABLE ROCKER STEER L/R WHT WHT/RED /WHT GRN/WHT /GRN GRN WHT/ BLU/RED GRN/ BLU/ BLU WHT A GRN YEL BLU PPL RED PLUG NUMBERS GRN/ BLU/ PPL 8 GRN 7 GRN/WHT 0A RED 0 BLU/RED 8 PNK/WHT WHT GRN RETRACT EXTEND DIODE BLOCK DB- GRY (7) RED/BLU (0) GRN/WHT PPL / PNK/WHT (9) YEL (8) GRY (7) GRN/WHT LIFT/DRIVE GRN/WHT 0 WHT/RED 0 WHT/RED SPEED/TORQUE DRIVE ENABLE LIGHT TIME DELAY RELAY PPL PPL BLU TO BASE, CONNECTS TO OUTRIGGER HARNESS PC BOARD / RED/ RED/ /RED /RED TORQUE SW () DE OUT (H) DE IN (H) PLATFORM DISABLE (H) START (L) GND DT0-S UPPER STATION # 7 RED/WHT B D F H K L C E G A J / RED/GRN A RED/ /RED 0 /RED 7 BLU/WHT 7 /WHT/RED 7 WHT//RED 7 RED/WHT 7 RED/WHT/ V W X M N O P Q R S T U 0 WHT/RED /WHT GRN/WHT /GRN 8 GRN WHT/ 0 BLU/RED GRN/ BLU/ BLU DIODE BLOCK DB- DIODE BLOCK DB- RELAY UPPER STATION KEY SWITCH "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications March 008 Page -
13 March 008 Page - "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications
14 Engine CONTROL MODULE POWER MODULE BATTERY CABLE RED BATTERY CABLE GA RED 00 0 GA RED 00 GA RED 00 ENGINE RUN SOLENOID "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications March 008 Page -
15 CONTROL MODULE POWER MODULE BATTERY CABLE RED BATTERY CABLE GA RED 00 0 GA RED 00 RED/GRN LIQUID PROPANE GASOLINE March 008 Page - "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications
16 Optional Outriggers UPPER CONTROL STATION RETRACT EXTEND PLATFORM DOWN SWITCH RED/WHT PPL PPL PPL LR RR RF LF OUTRIGGER PRESSURE SWITCHES PPL YEL 8 PNK/WHT 9 GRN PLATFORM POWER RELAY /RED GRY 7 WHT RED/BLU 0 INSIDE UPPER CONTROL BOX CABLE ASSEMBLIES PPL RED/BLU 0 RED/WHT 0 GRN/RED 7 GRY/WHT GRY/RED GRY/ BRN/YEL BRN/RED GRN BRN/ 0 OUTRIGGER CYLINDERS RETRAC LR EXTEND LR RETRACT RR EXTEND RR RETRACT RF EXTEND RF RETRACT LF EXTEND LF / / / LR RR RF LF OUTRIGGER STOWED SWITCHES RED/BLU 0 PNK/WHT 9 YEL 8 GRY 7 INSIDE LOWER CONTROLS P-9 P- P- P- GRY/WHT P- P- GRY/ P- BRN/RED P- P- BRN/ 0 P- P- GRN/RED 7 P- P- GRY/RED P-7 BRN/YEL P- P-8 GRN GP0 P-0 EXTEND OUTPUT P-7 RETRACT OUTPUT P-8 ALL LEGS DOWN OUTPUT P-9 THROTTLE UP OUTPUT P- / YEL/ 8 PPL/WHR 9 BRN /BLU 8 OUTRIGGER MANIFOLD EXTEND VALVE RETRACT VALVE PCB TERMINAL S7 B+ (VCC) ALARM TERMINAL YEL/WHT 0 RED/WHT 0 87 LIFT ENABLE RELAY 0 87 THROTTLE SWITCH TERMINAL /BLU PCB TERMINAL S / LOWER CONTROL BOX "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications March 008 Page -
17 Optional Generator Generator Option, RT Publication Art #: ART_9 RED/WHT DUAL FUEL EXISTING UPPER CONTROL CABLE RED/WHT 7 UPPER CONTROLS GENERATOR TOGGLE SWITCH WHT/RED TO: CIRCUIT BOARD RED/WHT GENERATOR VALVE 87 N.O. 87a /GRN VDC BATTERY ALT STARTER RED 0 GA RED INTERMEDIATE PIN HARNESS PIN PIN PIN PIN PIN GA RED YEL/RED THROTTLE RELAY 87 / 0 87a N.C. 8 8 /GRN ENGINE HARNESS THROTTLE SOLENOID GEN THROTTLE SOLENOID POWER MODULE CONTROL MODULE TO: GENERATOR WHT GRN RED/WHT DIESEL EXISTING UPPER CONTROL CABLE RED/WHT 7 UPPER CONTROLS GENERATOR TOGGLE SWITCH WHT/RED RED/WHT GENERATOR VALVE 87 N.O. 87a /GRN VDC BATTERY ALT STARTER RED 0 GA RED GA RED GA RED YEL/RED THROTTLE RELAY 87 / 0 87a N.C. 8 8 PREHEAT RELAY 87 /BLU 0 87a N.C. 8 8 /WHT THROTTLE SOLENOID TO: GLOW PLUGS GEN THROTTLE RELAY ENGINE RUN SOLENOID /GRN a 8 8 N.C. /GRN GEN THROTTLE SOLENOID TO: CIRCUIT BOARD INTERMEDIATE PIN HARNESS PIN PIN PIN PIN PIN PIN /WHT ENGINE HARNESS POWER MODULE CONTROL MODULE TO: GENERATOR WHT GRN March 008 Page - "07RT / 77RT / 77RT HD" Service & Parts Manual - ANSI Specifications
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