Manual de Serviço 107846

Z-45/25 • Z-45/25J Part No. 107846

June 2012

ii

Introduction

Important

Read, understand and obey the safety rules andoperating instructions in the Genie Z-45/25 andGenie Z-45/25J Operator's Manual beforeattempting any maintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting faultcodes and repair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skillsare required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealer servicecenter.

Compliance

Machine ClassificationGroup B/Type 3 as defined by ISO 16368

Machine Design LifeUnrestricted with proper opeation, inspection andscheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest degreeof accuracy possible. However, continuousimprovement of our products is a Genie policy.Therefore, product specifications are subject tochange without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.

Contact Us:

http://www.genielift.come-mail: [email protected]

Serial Number Information

Genie Industries offers the following ServiceManuals for these models:

Title Part No.

Z-45/25 and Z-45/25J Service ManualBefore the following serial numbers:Deutz models: 23041Ford models: 23190Perkins models: 23009 ......................................... 77809

Copyright © 2011 Terex Corporation

107846 Rev C August 2006Third Edition, Third Printing

"Genie" and "Z" are registered trademarks ofTerex South Dakota, Inc. in the USA and manyother countries.

Printed on recycled paper

Printed in U.S.A.

Introduction

Part No. 107846 Z-45/25 • Z-45/25J

June 2012

Serial Number Legend

INTRODUCTION

iii

Z4525 06 - 12345

Model

Model year

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5CAN B.354.4

Serial number: Z452506-12345

Electrical schematic number: ES0274

Machine unladen weight:

Rated 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: 04/12/062006

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 45 ft 6 in/ 13.8 m

Maximum platform reach : 25 ft 3 in/ 7.7 m

Serial numberstamped on chassis

Serial label(located under cover)

Z-45/25 • Z-45/25J Part No. 107846

June 2012

This page intentionally left blank.

iv

Part No. 107846 Z-45/25 • Z-45/25J

June 2012

v

Safety Rules

Section 1 • Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie Z-45/25 andGenie Z-45/25J Operator's Manual will result indeath or serious injury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance on this machine.

You read, understand and obey:- manufacturer’s instructions and safety rules- employer’s safety rules and worksite

regulations- applicable governmental regulations

You have the appropriate tools, liftingequipment and a suitable workshop.

Z-45/25 • Z-45/25J Part No. 107846

June 2012

SAFETY RULES

vi

Section 1 • Safety Rules

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

Read each procedure thoroughly. Thismanual and the decals on the machineuse signal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.

With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.

Without safety alert symbol—usedto indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.

Used to indicate operation ormaintenance information.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammableand combustible materials like battery

gases and engine fuels. Always have an approvedfire extinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free

of debris that could get into machine componentsand cause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work areais properly ventilated and well lit.

Part No. 107846 Z-45/25 • Z-45/25J

June 2012

Table of Contents

vii

Introduction

Important Information .................................................................................................. ii

Serial Number Information ........................................................................................... ii

Serial Number Legend................................................................................................ iii

Section 1 Safety Rules

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

Section 2 Rev Specifications

H Machine Specifications .......................................................................................... 2 - 1

Performance Specifications ................................................................................... 2 - 2

Hydraulic Specifications ........................................................................................ 2 - 3

Manifold Component Specifications ....................................................................... 2 - 5

Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6

Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7

Deutz F3L-2011 / D2011 L03i Engine Specifications .............................................. 2 - 8

Perkins 404-22 Engine Specifications .................................................................. 2 - 10

Machine Torque Specifications ............................................................................ 2 - 12

Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 13

SAE and Metric Fastener Torque Chart ............................................................... 2 - 14

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Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-Delivery Preparation ........................................................................................ 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

D Checklist A Procedures

A-1 Perform Pre-operation Inspection ................................................................. 3 - 7

A-2 Perform Function Tests ................................................................................ 3 - 7

A-3 Perform Engine Maintenance ....................................................................... 3 - 8

A-4 Check the High Pressure Hydraulic Filter Condition Indicator ....................... 3 - 9

A-5 Test the Oscillate Axle (if equipped) ............................................................. 3 - 9

A-6 Perform 30 Day Service ............................................................................. 3 - 10

A-7 Perform Engine Maintenance - Ford Models ............................................... 3 - 10

A-8 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 11

A-9 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13

A-10 Perform Engine Maintenance - Ford Models ............................................... 3 - 13

C Checklist B Procedures

B-1 Inspect the Battery ..................................................................................... 3 - 14

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 15

B-3 Check the Exhaust System ....................................................................... 3 - 16

B-4 Inspect the Engine Air Filter ....................................................................... 3 - 17

B-5 Check the Oil Cooler and Cooling Fins - Deutz Models............................... 3 - 17

B-6 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 18

B-7 Confirm the Proper Brake Configuration...................................................... 3 - 19

B-8 Check the Oil Level in the Drive Hubs ........................................................ 3 - 19

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Section 3 Rev Scheduled Maintenance Procedures, continued

B-9 Check and Adjust the Engine RPM - All Models ........................................ 3 - 20

B-10 Test the Ground Control Override .............................................................. 3 - 22

B-11 Check the Directional Valve Linkage ......................................................... 3 - 23

B-12 Test the Platform Self-leveling ................................................................... 3 - 23

B-13 Test the Engine Idle Select ........................................................................ 3 - 24

B-14 Test the Fuel Select Operation - Ford Models ........................................... 3 - 25

B-15 Test the Drive Brakes ................................................................................ 3 - 26

B-16 Test the Drive Speed - Stowed Position .................................................... 3 - 26

B-17 Test the Drive Speed - Raised or Extended Position ................................. 3 - 27

B-18 Test the Alarm Package (if equipped) ........................................................ 3 - 28

B-19 Perform Hydraulic Oil Analysis .................................................................. 3 - 29

B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ...................... 3 - 29

B-21 Replace the Fuel Filter Element - Perkins Models ..................................... 3 - 30

B-22 Perform Engine Maintenance - Perkins Models ......................................... 3 - 32

B-23 Replace the Engine Air Filter Element - Ford Models ................................ 3 - 32

B-24 Perform Engine Maintenance - Ford Models .............................................. 3 - 33

D Checklist C Procedures

C-1 Perform Engine Maintenance - Deutz Models ............................................ 3 - 34

C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 34

C-3 Test the Platform Overload System (if equipped) ...................................... 3 - 35

C-4 Replace the Fuel Filter/Water Separator - Perkins Models ........................ 3 - 38

C-5 Replace the Engine Air Filter Element - Deutz and Perkins Models ........... 3 - 40

C-6 Perform Engine Maintenance - Perkins Models ......................................... 3 - 40

C-7 Perform Engine Maintenance - Ford Models .............................................. 3 - 41

Z-45/25 • Z-45/25J Part No. 107846

June 2012

Section 3 Rev Scheduled Maintenance Procedures, continued

D Checklist D Procedures

D-1 Check the Boom Wear Pads ...................................................................... 3 - 42

D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 42

D-3 Inspect for Turntable Bearing Wear ............................................................ 3 - 44

D-4 Replace the Drive Hub Oil .......................................................................... 3 - 46

D-5 Check the Free-wheel Configuration ........................................................... 3 - 46

D-6 Replace the Hydraulic Filters ...................................................................... 3 - 48

D-7 Perform Engine Maintenance - Deutz Models ............................................. 3 - 49

D Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 50

E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 52

E-3 Perform Engine Maintenance - Deutz Models ............................................. 3 - 53

E-4 Perform Engine Maintenance - Deutz Models ............................................. 3 - 54

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1

B Platform Controls

1-1 ALC-500 Circuit Board .................................................................................. 4 - 2

1-2 Joysticks ..................................................................................................... 4 - 3

C Platform Components

2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 7

2-2 Platform Rotator ........................................................................................... 4 - 8

2-3 Platform Overload System ......................................................................... 4 - 10

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Part No. 107846 Z-45/25 • Z-45/25J

June 2012

Section 4 Rev Repair Procedures, continued

B Jib Boom Components, Z-45/25J

3-1 Jib Boom.................................................................................................... 4 - 12

3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 13

B Primary Boom Components

4-1 Cable Track ................................................................................................ 4 - 15

4-2 Primary Boom ............................................................................................ 4 - 19

4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 21

4-4 Primary Boom Extension Cylinder .............................................................. 4 - 23

4-5 Platform Leveling Master Cylinder .............................................................. 4 - 24

B Secondary Boom Components

5-1 Secondary Boom........................................................................................ 4 - 27

5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 32

B Engines

6-1 RPM Adjustment - Ford and Deutz Models ................................................ 4 - 33

6-2 RPM Adjustment - Perkins Models............................................................. 4 - 33

6-3 Flex Plate................................................................................................... 4 - 33

6-4 Engine Fault Codes - Ford Models ............................................................. 4 - 37

B Hydraulic Pumps

7-1 Lift/Steer Pump .......................................................................................... 4 - 38

7-2 Drive Pump ................................................................................................ 4 - 39

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June 2012

TABLE OF CONTENTS


E Manifolds

8-1 Function Manifold Components(before serial number 27001) ..................................................................... 4 - 42

8-2 Valve Adjustments - Function Manifold(before serial number 27001) ..................................................................... 4 - 46

8-3 Function Manifold Components(after serial number 27000) ........................................................................ 4 - 48

8-4 Valve Adjustments - Function Manifold(after serial number 27000) ........................................................................ 4 - 52

8-5 Jib Boom / Platform Rotate Manifold Components(before serial number 27001) ..................................................................... 4 - 53

8-6 Jib Boom / Platform Rotate Manifold Components(after serial number 27000) ........................................................................ 4 - 54

8-7 Turntable Rotation Manifold Components(before serial number 27001) ..................................................................... 4 - 55

8-8 Turntable Rotation Manifold Components(after serial number 27000) ........................................................................ 4 - 56

8-9 Directional Valve Manifold Components .................................................... 4 - 57

8-10 Traction Manifold Components, 2WD(before serial number 27001) ..................................................................... 4 - 60

8-11 Traction Manifold Components, 2WD(after serial number 27000) ........................................................................ 4 - 62

8-12 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 64

8-13 Traction Manifold Components, 4WD(before serial number 27001) ..................................................................... 4 - 66

8-14 Traction Manifold Components, 4WD(after serial number 27000) ........................................................................ 4 - 68

8-15 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 70

8-16 Valve Coils ................................................................................................. 4 - 70

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Part No. 107846 Z-45/25 • Z-45/25J

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TABLE OF CONTENTS


C Turntable Rotation Components

9-1 Turntable Rotation Assembly ..................................................................... 4 - 72

C Axle Components

10-1 Hub and Bearings, 2WD Models ................................................................. 4 - 73

10-2 Oscillate Lock-out Cylinders ....................................................................... 4 - 74

Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1

A Fault Codes - Control System ................................................................................ 5 - 2

B Fault Codes - Ford LRG-425 EFI Models ............................................................... 5 - 6

A Fault Codes - Ford DSG-423 EFI Models ............................................................. 5 - 12

Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1

A Electrical Symbols Legend .................................................................................... 6 - 2

A Hydraulic Symbols Legend .................................................................................... 6 - 3

A Ford Engine Relay Layout ...................................................................................... 6 - 4

Ford models

A Ford LRG-425 EFI Engine Harness ........................................................................ 6 - 5

A Ford DSG-423 EFI Engine Harness ....................................................................... 6 - 6

C Electrical Schematic, Z-45/25Ford LRG-425 EFI (before serial number 30142) ........................................ 6 - 7

A Electrical Schematic, Z-45/25Ford DSG-423 EFI (after serial number 30141) ........................................... 6 - 9

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Section 6 Rev Schematics, continuedFord models, continued

A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 .............................. 6 - 11

B Ground Control Box Switch Panel Wiring Diagram, Z-45/25 ................................ 6 - 12

A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25 ............................. 6 - 13

A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 .............................. 6 - 14

C Electrical Schematic, Z-45/25JFord LRG-425 EFI (before serial number 30142) ...................................... 6 - 15

A Electrical Schematic, Z-45/25JFord DSG-423 EFI (after serial number 30141) ......................................... 6 - 17

A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J ............................ 6 - 19

B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J .............................. 6 - 20

A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J ........................... 6 - 21

A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J ............................ 6 - 22

Deutz F3L-2011 models

C Electrical Schematic, Z-45/25 .............................................................................. 6 - 23

C Electrical Schematic, Z-45/25CE models ........................................................................................................... 6 - 25

A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 .............................. 6 - 27

B Ground Control Box Switch Panel Wiring Diagram, Z-45/25 ................................ 6 - 28

A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25CE Models ........................................................................................................... 6 - 29

B Ground Control Box Switch Panel Wiring Diagram, Z-45/25CE Models ........................................................................................................... 6 - 30

A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25 ............................. 6 - 31

A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 .............................. 6 - 32

Part No. 107846 Z-45/25 • Z-45/25J

June 2012

Section 6 Rev Schematics, continuedDeutz F3L-2011 models, continued

C Electrical Schematic, Z-45/25J ............................................................................ 6 - 33

C Electrical Schematic, Z-45/25JCE models ........................................................................................................... 6 - 35

A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J ............................ 6 - 37

B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J .............................. 6 - 38

A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JCE Models ........................................................................................................... 6 - 39

B Ground Control Box Switch Panel Wiring Diagram, Z-45/25JCE Models ........................................................................................................... 6 - 40

A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J ........................... 6 - 41

A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J ............................ 6 - 42

Perkins 404-22 models

C Electrical Schematic, Z-45/25 .............................................................................. 6 - 44

A Ground Control Box Terminal Strip Wiring Diagram, Z-45/25 ................................ 6 - 48

B Ground Control Box Switch Panel Wiring Diagram, Z-45/25 ................................. 6 - 49

A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25 .............................. 6 - 52

A Platform Control Box Switch Panel Wiring Diagram, Z-45/25 ................................ 6 - 53

C Electrical Schematic, Z-45/25J ............................................................................ 6 - 56

B Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J .............................. 6 - 60

B Ground Control Box Switch Panel Wiring Diagram, Z-45/25J ................................ 6 - 61

A Platform Control Box Terminal Strip Wiring Diagram, Z-45/25J ............................ 6 - 63

A Platform Control Box Switch Panel Wiring Diagram, Z-45/25J .............................. 6 - 65

Hydraulic Schematics

D Hydraulic Schematic, 2WD Models (before serial number 27001) ......................... 6 - 67

B Hydraulic Schematic, 2WD Models (after serial number 27000) ........................... 6 - 69

C Hydraulic Schematic, 4WD Models (before serial number 27001) ......................... 6 - 71

B Hydraulic Schematic, 4WD Models (after serial number 27000) ........................... 6 - 73

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Part No. 107846 Z-45/25 • Z-45/25J 2 - 1

Section 2 • SpecificationsJanuary 2011

REV H Specifications

Machine Specifications

Tires and wheels Rough terrain Industrial

Tire size 355/55 D625 9-14.5 LT

Tire ply rating 14 Tread 8Sidewall 6

Tire weight,new foam-filled (minimum) 390 lbs 175 lbs

177 kg 79 kg

Overall tire diameter 36.9 in 28 in93.7 cm 71 cm

Wheel diameter 24.5 inches 14.5 inches62.2 cm 36.8 cm

Wheel width 11.75 inches 7 inches29.8 cm 17.8 cm

Wheel lugs 9 @ 5/8 -18 9 @ 5/8 -18

Lug nut torque(lubricated) 94 ft-lbs 94 ft-lbs

127.4 Nm 127.4 Nm(dry) 125 ft-lbs 125 ft-lbs

169.5 Nm 169.5 Nm

Tire pressure (air-filled tires) 50 psi 100 psi3.45 bar 6.9 bar

Tires and wheels Hi-flotation(option)

Tire size 33/16LL500

Tire ply rating 10

Overall tire diameter 33 in84 cm

Wheel diameter 19.5 inches49.5 cm

Wheel width 14 inches35.6 cm

Wheel lugs 9 @ 5/8 -18

Lug nut torque(lubricated) 94 ft-lbs

127.4 Nm(dry) 125 ft-lbs

169.5 Nm

Tire pressure 38 psi2.6 bar

For operational specifications, refer to theOperator's Manual.

Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.

2 - 2 Z-45/25 • Z-45/25J Part No. 107846

Section 2 • Specifications January 2011

REV H

Fluid capacities

LPG tank 33.5 pounds15.2 kg

Fuel tank 17 gallons64.4 liters

Hydraulic tank 24 gallons91 liters

Hydraulic system 30 gallons(including tank) 113.6 liters

Drive hubs, 2WD models 17 fl oz(before serial number 24690) 0.5 liters

Drive hubs, 2WD models 24 fl oz(after serial number 24689) 0.7 liters

Drive hubs - Steer end, 4WD models 17 fl oz0.5 liters

Drive hubs, 48:1, 17 fl ozNon-steer end, 4WD models 0.5 liters(before serial number 23812)

Drive hubs with brake, 57:1, 24 fl ozNon-steer end, 4WD models 0.7 liters(after serial number 23811)

Drive hub oil type:SAE 90 multipurpose hypoid gear oil API serviceclassification GL5

SPECIFICATIONS

Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.

Performance Specifications

Drive speed, maximum

Stowed position 4.8 mph7.7 km/h

40 ft / 5.7 sec12.2 m / 5.7 sec

Raised or extended position 0.6 mph0.98 km/h

40 ft / 45 sec12.2 m / 45 sec

Raised or extended position 0.38 mph(narrow models) 0.6 km/h

40 ft / 70 sec12.2 m / 70 sec

Gradeability See Operator's Manual

Braking distance, maximum

High range on paved surface 3 to 6 ft0.9 to 1.8 m

Boom function speeds, maximumfrom platform controls

Primary boom up 24 to 28 seconds

Primary boom down 24 to 28 seconds

Secondary boom up 24 to 28 seconds

Secondary boom down 38 to 42 seconds(before serial number 27001)

Secondary boom down 24 to 28 seconds(after serial number 27000)

Turntable rotate, 359° 62 to 68 secondsprimary boom retracted

Part No. 107846 Z-45/25 • Z-45/25J 2 - 3


REV H SPECIFICATIONS

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalentViscosity grade Multi-viscosityViscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and have a minimum viscosity indexgreater than 140. They should provide excellentantiwear, oxidation, corrosion inhibition, sealconditioning, and foam and aeration suppressionproperties.

Optional fluids

Biodegradable Petro Canada Environ MV46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A

Use Chevron Aviation A hydraulicoil when in ambient temperaturesconsistently below 0°F / -18°C.

Use Shell Tellus T46 hydraulic oilwhen oil temperatures consistentlyexceed 205°F / 96°C.

Genie specifications requireadditional equipment and specialinstallation instructions for theapproved optional fluids. Consultthe Genie Industries ServiceDepartment before use.

Drive pump

Type: bi-directional, variabledisplacement piston pump

Flow rate @ 2500 rpm 32 gpm121 L/min

Drive pressure, maximum 3500 psi241 bar

Charge pump

Type: gear

Displacement 0.84 cu in13.76 cc

Flow rate @ 2500 rpm 9.1 gpm34.4 L/min

Charge pressure @ 2500 rpm 315 psi21.7 bar

Function pump

Type: gear

Displacement 0.67 cu in11 cc

Flow rate @ 2500 rpm 7.25 gpm27.4 L/min

Auxiliary pump

Type: gear, fixed displacement

Displacement per revolution 0.067 cu in1.1 cc

Auxiliary pump relief pressure 3200 psi220.6 bar


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REV H

Function manifold

System relief valve pressure 3200 psi220.6 bar

Secondary boom down 2100 psirelief valve pressure 145 bar

Platform level relief valve pressure 2500 psi172 bar

Steer flow regulator 1.5 gpm5.7 L/min

Boom extend flow regulator 2 gpm7.6 L/min

Jib boom / platform rotate flow regulator 0.4 gpm1.5 L/min

Drive manifold

Hot oil relief pressure 250 psi17.2 bar

Steer end drive motors (4WD models)

Displacement 1.53 cu inper revolution 25 cc

Non-steer end drive motors

Displacement per revolution, variable 0.12 to 2.14 cu in4WD (2 speed motor) 1.97 to 35 cc(before serial number 23812)

Displacement per revolution, variable 0.01 to 1.83 cu in4WD (2 speed motor) 1.61 to 30 cc(after serial number 23811)

Displacement per revolution, variable 1.37 to 2.14 cu in2WD (before serial number 24690) 22.5 to 35 cc

Displacement per revolution, variable 0.99 to 1.83 cu in2WD (after serial number 24689) 16.2 to 30 cc

Hydraulic filters

High pressure filter Beta 3 ≥ 200

High pressure filter 100 psibypass pressure 6.89 bar

Medium pressure filter Beta 3 ≥ 200

Medium pressure filter 50 psibypass pressure 3.4 bar

Hydraulic return filter 10 micron with 25 psi / 1.7 bar bypass

SPECIFICATIONS


Part No. 107846 Z-45/25 • Z-45/25J 2 - 5



Manifold ComponentSpecifications

Plug torque

SAE No. 2 36 in-lbs / 4 Nm

SAE No. 4 10 ft-lbs / 13 Nm





Valve Coil Resistance Specification

Proportional directional solenoid valve, 10V DC 6 to 8Ω(schematic items A, C, D, BP, BU and BY)

3 position 4 way directional valve, 10V DC 6 to 8Ω(schematic items B, F, H, BF, BM, CG)

2 position 3 way solenoid valve, 10V DC 6 to 8Ω(schematic items E, G, CA, CC, AD, OO,XX, AF, AG, AI and AK)


2 - 6 Z-45/25 • Z-45/25J Part No. 107846


REV HSPECIFICATIONS

Ford LRG-425 EFI Engine

Displacement 153 cu in2.5 liters

Number of cylinders 4

Bore & stroke 3.78 x 3.4 inches96.01 x 86.36 mm

Horsepower 70 @ 2500 rpm52 kW @ 2500 rpm

Firing order 1 - 3 - 4 - 2

Low function idle (computer controlled) 1600 rpm27 Hz

High function idle (computer controlled) 2500 rpm42 Hz

Compression ratio 9.4:1

Compression pressure (approx.)Pressure (psi or bar) of lowest cylinder must beat least 75% of highest cylinder

Valve clearances - 0.035 to 0.055 inchescollapsed tappet 0.889 to 1.397 mm

Lubrication system

Oil pressure 40 to 60 psi(operating temperature @ 2500 rpm) 2.75 to 4.1 bar

Oil capacity 4.5 quarts(including filter) 4.3 liters

Oil pressure switch

Oil pressure switch point 7.5 psi0.51 bar

Oil viscosity requirements

Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.

Electronic fuel pump

Fuel pressure, static 63 psi4.3 bar

Fuel flow rate 0.58 gpm2.2 L/min

Fuel requirement

For fuel requirements, refer to the engine Operator'sManual on your machine.

Ignition system

Spark plug type Motorcraft AGSF-32-FM

Spark plug gap 0.042 to 0.046 inches1.07 to 1.17 mm

Engine coolant

Capacity 11.5 quarts10.9 liters

Coolant temperature switch

Temperature switch point 230°F110°C

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Current draw, maximum load 800A

Alternator

Output 95A, 14.5V DC

Battery

Type 12V DC, Group 34/78

Quantity 1

Cold cranking ampere @ 0°F 900A

Reserve capacity @ 25A rate 200 minutes


Part No. 107846 Z-45/25 • Z-45/25J 2 - 7



Ford DSG-423 EFI Engine

Displacement 140.4 cu in2.3 liters


Bore & stroke 3.44 x 3.7 inches87.5 x 94 mm



Low function idle (computer controlled) 1600 rpm27 Hz

High function idle (computer controlled) 2500 rpm42 Hz


Compression pressure (approx.)Pressure (psi or bar) of lowest cylinder must beat least 75% of highest cylinder

Lubrication system

Oil pressure 29 to 39 psi(at operating temperature @ 2500 rpm) 2 to 2.7 bar

Oil capacity 4 quarts(including filter) 3.8 liters

Oil pressure switch

Oil pressure switch point 7.5 psi0.51 bar

Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.

Electronic fuel pump

Fuel pressure, static 64 psi4.4 bar

Fuel flow rate 0.43 gpm1.6 L/min

Fuel requirement


Ignition system

Spark plug type Motorcraft AGSF-32-FEC

Spark plug gap 0.044 to 0.045 inches1.125 to 1.135 mm

Engine coolant

Capacity 10 quarts9.5 liters

Cylinder head temperature sending unit

Fault code set temperature 280°F138°C

Engine shut-down temperature 300°F149°C

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Current draw, maximum load 800A

Alternator

Output 95A, 13.8V DC

Battery


Quantity 1

Cold cranking ampere @ 0°F 900A



2 - 8 Z-45/25 • Z-45/25J Part No. 107846


REV HSPECIFICATIONS

Lubrication system

Oil pressure 20 to 44 psi1.4 to 3 bar

Oil capacity 8.5 quarts(including filter) 8 liters(Deutz F3L 2011 Engine)

Oil capacity 9.5 quarts(including filter) 9 liters(Deutz D2011L03i Engine)


-22° F to 86° F/ -30° C to 30° C 5W-30(synthetic)

-4° F to 90° F / -20° C to 32° C 10W-40

Above 23° F / -5° C 20W-50

Units ship with 15W-40.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.

Oil temperature switch

Temperature switch point 300°F149°C

Oil pressure switch

Oil pressure switch point 7 psi(Deutz F3L 2011 Engine) 0.5 bar

Oil pressure switch point 22 psi(Deutz D2011L03i Engine) 1.5 bar

Deutz F3L 2011 EngineDeutz D2011L03i



Bore and stroke 3.7 x 4.4 inches94 x 112 mm


Firing order 1 - 2 - 3

Low idle 1500 rpm25 Hz

High idle 2500 rpm42 Hz

Compression ratio 19:1

Compression pressure 362 to 435 psi25 to 30 bar

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in0.3 mm

Exhaust 0.020 in0.5 mm


Part No. 107846 Z-45/25 • Z-45/25J 2 - 9


REV H

Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum 15000 psi1034 bar

Injector opening pressure 3046 psi210 bar

Fuel requirement


Starter motor

Current draw, no load 90A

Brush length, new 0.72 in18.5 mm

Brush length, minimum 0.27 in7 mm

Battery


Quantity 1

Cold cranking ampere 900A


Alternator output 60A @ 14V DC

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

SPECIFICATIONS


2 - 10 Z-45/25 • Z-45/25J Part No. 107846


REV H

Lubrication system

Oil pressure, cold 60 psi(at 2500 rpm) 4.1 bar

Oil capacity 9.3 quarts(including filter) 8.8 liters


Below 86°F / 30°C 5W-20

-4°F to 104°F / -20°C to 40°C 10W-30

Above 14°F / -10°C 15W-40

Units ship with 15W-40.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.

Oil pressure sending unit

Oil pressure switch point 14.2 psi1 bar

Fuel injection system

Injection pump make Zexel

Injection pressure 2133 psi147 bar

Fuel requirement


Alternator output 55A @ 12V DC

Fan belt deflection 3/8 in10 mm

Starter motor

Current draw, no load 90A

Brush length, new 0.7480 in19 mm

Brush length, minimum 0.5 in12.7 mm


SPECIFICATIONS

Perkins 404-22 Engine



Bore and stroke 3.31 x 3.94 inches84 x 100 mm



Low idle 1300 rpm22 Hz

High idle 2500 rpm42 Hz


Compression pressure 426 psi29.4 bar

Pressure (psi) of lowest cylinder mustbe within 50 psi / 3.45 bar of highest cylinder

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.008 in0.2 mm

Exhaust 0.008 in0.2 mm

Part No. 107846 Z-45/25 • Z-45/25J 2 - 11


REV H

Battery


Quantity 1

Cold cranking ampere 900A


Engine coolant

Capacity 7.7 quarts7.3 liters

Coolant temperature sending unit

Temperature switch point 221° F 105° C

SPECIFICATIONS


2 - 12 Z-45/25 • Z-45/25J Part No. 107846


REV H

Machine Torque Specifications

Platform rotator

3/4 -10 center bolt, GR 8 380 ft-lbs515 Nm

3/8 -16 bolts, GR 8 44 ft-lbs60 Nm

Turntable rotate assembly

Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm

Drive motor/brake mounting bolts, dry 110 ft-lbs149 Nm

Drive motor/brake mounting bolts, lubricated 80 ft-lbs108 Nm

Drive motor and hubs

Drive hub mounting bolts, lubricated 180 ft-lbs244 Nm

Drive motor mounting bolts, lubricated 55 ft-lbs75 Nm

SPECIFICATIONS


Part No. 107846 Z-45/25 • Z-45/25J 2 - 13



Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 11 ft-lbs / 14.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 40 ft-lbs / 54.2 Nm

-10 69 ft-lbs / 93.6 Nm

-12 93 ft-lbs / 126.1 Nm

-16 139 ft-lbs / 188.5 Nm

-20 172 ft-lbs / 233.2 Nm

-24 208 ft-lbs / 282 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

Seal-Lok® Fittings(hose end)


-4 18 ft-lbs / 25 Nm

-6 30 ft-lbs / 40 Nm

-8 40 ft-lbs / 55 Nm

-10 60 ft-lbs / 80 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must bereplaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

The O-rings used in the ParkerSeal Lok® fittings and hose endsare custom-size O-rings. They arenot standard SAE size O-rings.They are available in the O-ringfield service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

2 - 14 Z-45/25 • Z-45/25J Part No. 107846


REV HSPECIFICATIONS

Size

(mm)in- lbs N m in-lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m

5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4

f t - lbs N m ft-lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m

8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.610 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6

DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8

DRY

SIZE THREAD

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

5/16

3/8

7/16

1/2

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

LUBED

1/4

LUBED DRY LUBED DRY

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5

DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8

10.9 12.98.84.6

Part No. 107846 Z-45/25 • Z-45/25J 3 - 1

August 2006 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every 2 years as specified on theMaintenance Inspection Report.

Failure to perform each procedureas presented and scheduled maycause death, serious injury orsubstantial damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Keep records on all inspections for three years.

Unless otherwise specified, perform eachmaintenance procedure with the machine in thefollowing configuration:

· Machine parked on a firm, level surface

· Boom in stowed position

· Turntable rotated with the boom betweenthe non-steer wheels

· Turntable secured with the turntablerotation lock

· Key switch in the off position with thekey removed

· Wheels chocked

· All external AC power disconnectedfrom the machine

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetyinformation and step-by-step instructions.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.



Indicates that a specific result is expected afterperforming a series of steps.

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

3 - 2 Z-45/25 • Z-45/25J Part No. 107846

August 2006Section 3 • Scheduled Maintenance Procedures

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold engine will berequired to perform this procedure.

Indicates that a warm engine will berequired to perform this procedure.

Indicates that dealer service is requiredto perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

Make copies of the Pre-delivery Preparation reportto use for each inspection. Store completed formsas required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, every six months, annual andtwo years. The Scheduled Maintenance ProceduresSection and the Maintenance Inspection Reporthave been divided into five subsections—A, B, C,D and E. Use the following chart to determine whichgroup(s) of procedures are required to perform ascheduled inspection.

Inspection Table or Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six months or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two years or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.

SCHEDULED MAINTENANCE PROCEDURES

Part No. 107846 Z-45/25 • Z-45/25J 3 - 3


Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.Rev B

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspection completed

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing thePre-operation Inspection, the Maintenance items and theFunction Tests.

Use this form to record the results. Place a check in theappropriate box after each part is completed. Follow theinstructions in the operator’s manual.

If any inspection receives an N, remove the machine fromservice, repair and re-inspect it. After repair, place a checkin the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover if anythingis apparently wrong with a machine before it is put intoservice.

A damaged or modified machine must never be used. Ifdamage or any variation from factory delivered condition isdiscovered, the machine must be tagged and removed fromservice.

Repairs to the machine may only be made by a qualifiedservice technician, according to the manufacturer'sspecifications.

Scheduled maintenance inspections shall be performed byqualified service technicians, according to themanufacturer's specifications and the requirements listed inthe responsibilities manual.

3 - 4 Z-45/25 • Z-45/25J Part No. 107846



Part No. 107846 Z-45/25 • Z-45/25J 3 - 5


Checklist A - Rev D Y N R

A-1 Pre-operationinspection

A-2 Functions tests

A-3 Engine maintenance

A-4 Filter condition indicator

A-5 Oscillate axle

Perform after 40 hours:

A-6 30 day service

Perform every 100 hours:

A-7 Engine maintenance -Ford models

A-8 Fuel filter/separator -Diesel models

A-9 Rotation bearing


A-10 Engine maintenance -Ford models

Instructions· Make copies of both pages to use

for each inspection.

· Select the appropriate checklist(s)for the type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the step-by-step procedures inthis section to learn how to performthese inspections.

· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Checklist B - Rev C Y N R

B-1 Battery

B-2 Electrical wiring

B-3 Exhaust system

B-4 Inspect air filter

B-5 Oil cooler and fins-Deutz models

B-6 Tires and wheels

B-7 Brake configuration

B-8 Drive hub oil level

B-9 Engine RPM -All models

B-10 Ground control override

B-11 Directional valve

B-12 Platform leveling

B-13 Engine idle select

B-14 Fuel select -Ford models

B-15 Drive brakes

B-16 Drive speed -stowed position

B-17 Drive speed -raised position

B-18 Alarm package

B-19 Hydraulic oil analysis

B-20 Fuel and hydraulictank cap venting

B-21 Replace fuel filter -Perkins models

B-22 Engine maintenance -Perkins models

B-23 Air filter - Ford models


B-24 Engine maintenance -Ford models

Maintenance Inspection Report

Comments

3 - 6 Z-45/25 • Z-45/25J Part No. 107846


Checklist C - Rev D Y N R

C-1 Engine maintenance -Deutz models

C-2 Grease platformoverload (if equipped)

C-3 Test platform overload(if equipped)

C-4 Fuel filter/separator -Perkins models

C-5 Air filter - Deutz andPerkins models


C-6 Engine maintenance -Perkins models


C-7 Engine maintenance -Ford models

MAINTENANCE INSPECTION REPORT

Checklist D - Rev D Y N R

D-1 Boom wear pads

D-2 Turntable bearing bolts

D-3 Turntable bearing wear

D-4 Drive hub oil

D-5 Free-wheelconfiguration

D-6 Hydraulic filters

D-7 Engine maintenance -Deutz models

Checklist E - Rev D Y N R

E-1 Hydraulic oil

E-2 Grease steer axlewheel bearings,2WD models


E-3 Engine maintenance -Deutz models

Perform every 12,000 hours:

E-4 Engine maintenance -Deutz models

Instructions· Make copies of both pages to use

for each inspection.

· Select the appropriate checklist(s)for the type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the step-by-step procedures inthis section to learn how to performthese inspections.

· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Comments

Part No. 107846 Z-45/25 • Z-45/25J 3 - 7


REV D

A-1Perform Pre-operationInspectionCompleting a pre-operation inspection is essentialto safe machine operation. The pre-operationinspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparently wrongwith a machine before the operator performs thefunction tests. The pre-operation inspection alsoserves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the appropriate operator's manual. Referto the Operator's Manual on your machine.

Checklist A Procedures

A-2Perform Function TestsCompleting the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the appropriate operator's manual. Referto the Operator's Manual on your machine.

3 - 8 Z-45/25 • Z-45/25J Part No. 107846


REV DCHECKLIST A PROCEDURES

A-3Perform Engine Maintenance

Engine specifications require thatthis procedure be performed dailyor every 8 hours, whichever comesfirst.

Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.

Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) OR theFord DSG-423 EFI Operator Handbook(EDI part number 1060020) OR theDeutz FL 2011 Operation Manual(Deutz part number 0297-9929) OR thePerkins 400 Series Operation Manual(Perkins part number TPD 1443S).

Ford LRG-425 EFI Operator HandbookGenie part number 84792

Ford DSG-423 EFI Operator HandbookGenie part number 119488

Deutz FL 2011 Operation ManualGenie part number 84794

Perkins 400 Series Operation ManualGenie part number 94890

To access the engine:

1 Remove the safety pin from the engine pivotplate latch.

The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.

2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.

Part No. 107846 Z-45/25 • Z-45/25J 3 - 9


REV D CHECKLIST A PROCEDURES

A-4Check the High PressureHydraulic Filter ConditionIndicator

Genie specifications require thatthis procedure be performed dailyor every 8 hours, whichever comesfirst.

Maintaining the high pressure hydraulic filter ingood condition is essential to good systemperformance and safe machine operation. The filtercondition indicator will show when the hydraulic flowis bypassing a clogged filter. If the filter is notfrequently checked and replaced, impurities willremain in the hydraulic system and causecomponent damage.

1 Open the engine side turntable cover.

2 Start the engine from the ground controls.

3 Change the engine idle to high rpm (rabbitsymbol).

4 Visually inspect the filter condition indicator.

Result: The filter condition indicator should beoperating with the plunger in the green area.

Result: If the indicator displays the plunger inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter should bereplaced. See D-6, Replace the HydraulicFilters.

A-5Test the Oscillate Axle(if equipped)

Genie specifications require thatthis procedure be performed dailyor every 8 hours, whichever comesfirst.

Proper axle oscillation is essential to safe machineoperation. If the axle oscillation system is notoperating correctly, the stability of the machine iscompromised and it may tip over.

1 Start the engine from the platform controls.

2 Drive the right steer tire up onto a6 inch / 15 cm block or curb.

Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.

3 Drive the left steer tire up onto a6 inch / 15 cm block or curb.

Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.

4 Drive both steer tires up onto a6 inch / 15 cm block or curb.

Result: The non-steer tires should stay in firmcontact with the ground.

If the chassis does not remainlevel during test, refer to RepairProcedure 8-9, How to Set Up theDirectional Valve Linkage.

3 - 10 Z-45/25 • Z-45/25J Part No. 107846


REV D

A-6Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage, whichevercomes first. After this interval, refer to themaintenance checklist for continued scheduledmaintenance.

1 Perform the following maintenance procedures:

• A-9 Grease the Turntable Rotation Bearingand Rotate Gear

• A-10 Perform Engine Maintenance -Ford Models

• B-6 Inspect the Tires, Wheels andLug Nut Torque

• B-8 Check the Oil Level in the Drive Hubs

• C-1 Perform Engine Maintenance -Deutz Models

• D-2 Check the Turnable Rotation BearingBolts

• D-6 Replace the Hydraulic Filters

A-7Perform Engine Maintenance -Ford Models

Engine specifications require thatthis procedure be performed every100 hours. Perform this proceduremore often if dusty conditions existor the machine is subjected toextended low idle operation.


Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302) OR theFord DSG-423 EFI Operator Handbook(EDI part number 1060020).



CHECKLIST A PROCEDURES

Part No. 107846 Z-45/25 • Z-45/25J 3 - 11


REV D

A-8Inspect the Fuel Filter/ WaterSeparator - Diesel Models

Genie specifications require thatthis procedure be performed every100 hours or monthly, whichevercomes first.

Proper maintenance of the fuel filter/water separatoris essential for good engine performance. Failure toperform this procedure can lead to poor engineperformance and/or hard starting, and continueduse may result in component damge. Extremelydirty conditions may require this procedure beperformed more often.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.

Perform this procedure with theengine off.

Perkins models:

1 Put on protective clothing and eye wear.




CHECKLIST A PROCEDURES


5 Locate the fuel filter/water separator mounted tothe rear engine mounting bracket.

6 Visually inspect the filter bowl for water buildup.

Result: If water is present in the filter bowl,continue with steps 7 through 11.

7 Loosen the vent plug located on the fuel filter/water separator head.

a vent plugb drain plugc filter bowld separator head

8 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

9 Tighten the vent plug.

If the fuel filter/water separator iscompletely drained, you mustprime the fuel filter/water separatorbefore starting the engine.See C-4, Replace The Fuel Filter/Water Separator Element - PerkinsModels, for instructions on how toprime the fuel filter/waterseparator.

b

d

a

c

3 - 12 Z-45/25 • Z-45/25J Part No. 107846


REV DCHECKLIST A PROCEDURES

10 Clean up any fuel that may have spilled.

11 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

12 Swing the engine back to its original positionand close the engine pivot plate latch.

13 Install the engine pivot plate safety pin.

Deutz models:





4 Locate the fuel filter/water separator next to theoil filter.

5 Loosen the drain plug located at the bottom ofthe filter. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

Do not completely drain the filter.

a fuel filter/water separatorb drain valve

6 Clean up any fuel that may have spilled.

7 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.



a

b

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REV D CHECKLIST A PROCEDURES

A-9Grease the Turntable RotationBearing and Rotate Gear

Genie specifications require thatthis procedure be performed every100 hours of operation. Performthis procedure more often if dustyconditions exist.

Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Before serial number 27001: Locate the greasefitting on the front turntable cover.

After serial number 27000: Locate the greasefitting near the ground control box.

2 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of 4 to 5inches / 10 to 13 cm at a time and repeat thisstep until the entire bearing has been greased.

3 Apply grease to each tooth of the drive gear,located under the turntable.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent

A-10Perform Engine Maintenance -Ford Models

Engine specifications require thatthis procedure be performed every200 hours.









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B-1Inspect the Battery

Genie specifications require thatthis procedure be performed every250 hours or quarterly, whichevercomes first.

Proper battery condition is essential to good engineperformance and operational safety. Improper fluidlevels or damaged cables and connections canresult in engine component damage and hazardousconditions.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.


2 Be sure that the battery cable connections arefree of corrosion.

Adding terminal protectors and acorrosion preventative sealant willhelp eliminate corrosion on thebattery terminals and cables.

3 Be sure that the battery hold downs and cableconnections are tight.

Checklist B Procedures

4 Be sure that the battery separator wireconnections are tight (if equipped).

5 Fully charge the battery(s) and allow thebattery(s) to rest at least 6 hours.

6 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

7 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjustedspecific gravity of 1.277 or higher. The batteryis fully charged. Proceed to step 11.

Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 8.

8 Perform an equalizing charge OR fully chargethe battery(s) and allow the battery(s) to rest atleast 6 hours.

9 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

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10 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specificgravity of 1.277 or greater. The battery is fullycharged. Proceed to step 13.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.177. Replace the battery.

11 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.

12 Install the vent caps and neutralize anyelectrolyte that may have spilled.

B-2Inspect the Electrical Wiring


Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.





4 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Engine wiring harness

· Hydraulic manifold wiring

CHECKLIST B PROCEDURES

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5 Open the ground controls side turntable cover.

6 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Ground control box wire harnesses

· Inside of the ground control box

· Hydraulic manifold wiring

7 Inspect for a liberal coating of dielectric greaseat the following location:

· All wire harnesses connectors to theground control box

8 Start the engine from the ground controls andraise the secondary boom above the turntablecovers.

9 Remove the center turntable cover retainingfasteners. Remove the center turntable coverfrom the machine.

10 Inspect the turntable area for burnt, chafed andpinched cables.

11 Lower the boom to the stowed position and turnthe engine off.

12 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· Cable track on the primary boom

· Cables on the primary, and jib booms

· Jib boom/Platform rotate manifold

· Inside of the platform control box

13 Inspect for a liberal coating of dielectric greaseat the following location:

· All wire harnesses connectors to theplatform control box



16 Install the center turntable cover and tighten theretaining fasteners.

B-3Check the Exhaust System

Engine specifications require thatthis procedure be performed every250 hours or quarterly, whichevercomes first.

Maintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.

Bodily injury hazard. Do notinspect while the engine is running.Remove the key to secure fromoperation.

Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.

Ford models:



2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine to access the exhaust system.

All models:

3 Be sure that all nuts and bolts are tight.

4 Inspect all welds for cracks.

5 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

Ford models:




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B-4Inspect the Engine Air Filter


Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Release the latches from the air cleaner canisterend cap. Remove the end cap.

2 Remove the filter element.

3 Clean the inside of the canister and the end capwith a damp cloth.

4 Inspect the air filter element. If needed, blowfrom the inside out using low pressure drycompressed air, or carefully tap out dust.Replace the filter if needed.

5 Install the filter element.

6 Install the air filter canister end cap and securethe end cap latches.

Be sure the discharge valve ispointing down when the cap isinstaled.

B-5Check the Oil Cooler andCooling Fins - Deutz Models


Maintaining the oil cooler in good condition isessential for good engine performance. Operating amachine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.

Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.

Oil cooler:




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3 Remove the fasteners from the engine sidecover, then remove the cover.

4 Inspect the oil cooler for leaks and physicaldamage.

a oil coolerb cylinder head cooling finsc fan blower fins

5 Clean the oil cooler of debris and foreignmaterial.

Cooling and fan blower fins:

6 Inspect the fan blower fins for physical damage.

7 Clean the fan blower fins of debris and foreignmaterial.

8 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.

9 Clean the cylinder head cooling passages ofdebris and foreign material.

10 Install the engine side cover.



B-6Inspect the Tires, Wheels andLug Nut Torque


Maintaining the tires and wheels, including properwheel fastener torque, is essential to safe operationand good performance. Tire and/or wheel failurecould result in a machine tip-over. Componentdamage may also result if problems are notdiscovered and repaired in a timely fashion.

Bodily injury hazard. An over-inflated tire can explode and couldcause death or serious injury.

Tip-over hazard. Do not usetemporary flat tire repair products.

The tires on some machines arefoam-filled and do not need airadded to them.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracked welds.

3 Check each lug nut for proper torque.Refer to Section 2, Specifications.

4 Check the pressure in each air-filled tire.Refer to Section 2, Specifications.


cba

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B-7Confirm the ProperBrake Configuration


Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

1 Check each drive hub disconnect cap to be sureit is in the engaged position.

B-8Check the Oil Levelin the Drive Hubs


Failure to maintain proper drive hub oil levels maycause the machine to perform poorly and continueduse may cause component damage.

1 Drive the machine to rotate the hub until theplugs are located one on top and the other at90 degrees.

a drive hub plugs

2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the side plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole.

4 Install the plug(s) into the drive hub.

5 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.

6 Repeat this procedure for each drive hub.


brake disengaged position

brake engaged position

a

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B-9Check and Adjust theEngine RPM - All Models


Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

Ford LRG-425 EFI models:

The engine rpm is controlled by theECM and can only be adjusted byre-programming the ECM. If rpmadjustment or service is required,please contact the GenieIndustries Service Department ORyour local Ford dealer.

Ford DSG-423 EFI models:

The engine rpm is controlled by theECM and can only be adjusted byre-programming the ECM. If rpmadjustment or service is required,please contact your local EDIdistributor. Refer to the engineoperator's handbook on yourmachine for EDI distributorlocations.

Deutz models:

This procedure will require twopeople.




3 Connect a tachometer to the engine, and thenstart the engine from the ground controls andcheck the rpm. Refer to Section 2,Specifications.

Skip to step 5 if the low idle rpm is correct.

4 Loosen the low idle lock nut, then turn the lowidle adjustment screw clockwise to increase therpm or counterclockwise to decrease the rpm.Tighten the low idle lock nut and recheck therpm.

a solenoid bootb high idle adjustment nutc yoke lock nutd yokee low idle adjustment screwf low idle lock nut


f

e

c dba

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5 Move the function enable/rpm select toggleswitch to the high idle (rabbit symbol) position atthe ground controls and check the rpm. Refer toSection 2, Specifications.

If high idle rpm is correct, disregard adjustmentstep 6.

6 Loosen the yoke lock nut, then turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Be sure the solenoid fully retractswhen activating high idle.



Perkins models:

This procedure will require twopeople.





4 Connect a tachometer to the engine. Start theengine from the ground controls. Refer toSection 2, Specifications.

Skip to step 6 if the low idle rpm is correct.

5 Loosen the low idle lock nut and turn the low idleadjustment screw clockwise to increase therpm, or counterclockwise to decrease the rpm.Tighten the low idle lock nut and confirm therpm.

a solenoid bootb high idle adjustment nutc yoked low idle lock nut and adjustment

screw

6 Move the function enable toggle switch to thehigh idle (rabbit symbol) position. Refer toSection 2, Specifications.

If high idle rpm is correct, disregard adjustmentstep 7.


a b c d

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7 Loosen the yoke lock nut, then turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Be sure the solenoid fully retractswhen activating high idle.



B-10Test the Ground ControlOverride


A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allow groundpersonnel to operate the machine from the groundcontrols whether or not the red Emergency Stopbutton on the platform controls is in the on or offposition. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.

1 Push in the platform red Emergency Stop buttonto the off position.


3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.


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B-11Check the Oscillate DirectionalValve Linkage


Perform this test only on modelsequipped with an oscillating axle.

Proper axle oscillation is essential to safe machineoperation. If the oscillate directional valve linkage isnot operating correctly, the stability of the machineis compromised and it may tip over.

1 Remove the drive chassis cover and the axlecovers from the non-steer end of the drivechassis.

2 Locate the oscillate directional valve inside ofthe non-steer axle and inspect the linkage forthe following:

· Lock nut is tight against yoke

· Yoke clevis pins are installed

· Cotter pins are installed through clevis pins

· Linkage is properly attached todirectional valve

B-12Test the Platform Self-leveling


Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom.A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.

1 Start the engine from the ground controls andlower the boom into the stowed position.

2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.

3 Raise and lower the primary boom througha full cycle.

Result: The platform should remain level atall times to within ±5 degrees.


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B-13Test the Engine Idle Select


A properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are two settings.

Foot switch activated low idle (turtle symbol)allows the operator to control individual boomfunctions. Drive functions will operate at low idle,but at reduced performance.

Foot switch activated high idle (rabbit symbol)should be used for normal machine operation. Thisselection activates high idle only when the footswitch is pressed down.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Start the engine from the ground controls thenmove the function enable toggle switch to thehigh idle (rabbit symbol) position and hold in theon position.

Result: The engine should change to high idle.

3 Release the function enable toggle switch.

Result: The engine should return to low idle.

4 Turn the key switch to platform controls.

5 Move the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

Result: The engine should not change tohigh idle.

6 Press down the foot switch.

Result: The engine should change to high idle.

7 Move the engine idle control switch to footswitch activated low idle (turtle symbol).

Result: The engine should change to low idle.


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B-14Test the Fuel Select Operation -Ford Models


The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade when the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicate fuelsystem problems that could develop into ahazardous situation.

Perform this test after checkingthe gasoline and LPG fuel levels,and warming the engine to normaloperating temperature.

1 At the platform controls, move the fuel selectswitch to gasoline and then move the engineidle control switch to foot switch activated highidle (rabbit and foot switch symbol).

2 Start the engine from the platform controls andallow it to run at low idle.

3 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

4 Release the foot switch and shut the engine offby pushing in the red Emergency Stop button into the off position.

5 Move the fuel select switch to LPG.

6 Restart the engine and allow it to run atlow idle.

7 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

The engine may hesitatemomentarily and then continueto run on the selected fuel if thefuel source is switched whilethe engine is running.


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B-15Test the Drive Brakes


Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydrostatic brakes and hydraulically-released individual wheel brakes can appear tooperate normally when they are actually not fullyoperational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.See B-7, Confirm the Proper BrakeConfiguration.

Select a test area that is firm, leveland free of obstructions.

1 Mark a test line on the ground for reference.


3 Move the engine idle control switch tofoot switch activated high idle (rabbit andfoot switch symbol), then lower the boom intothe stowed position.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

5 Bring the machine to top drive speed beforereaching the test line. Release the drive joystickwhen your reference point on the machinecrosses the test line.

6 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.

The brakes must be able to holdthe machine on any slope it is ableto climb.

B-16Test the Drive Speed -Stowed Position


Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.


1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


3 Move the engine idle control switch tofoot switch activated high idle (rabbit and footswitch symbol), then lower the boom into thestowed position.

4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

6 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.


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B-17Test the Drive Speed -Raised or Extended Position


Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.


1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


3 Move the engine idle select switch to foot switchactivated high idle (rabbit and foot switchsymbol).

4 Press down the foot switch and raise theprimary boom above horizontal.



7 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

8 Lower the boom to the stowed position andextend the boom 1 foot / 30 cm.



11 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.


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B-18Test the Alarm Package(if equipped)


The alarm package includes:

· Travel alarm

· Descent alarm

· Flashing beacon

Alarms and a beacon are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theturntable covers.

The alarms and beacon willoperate with the enginerunning or not running.

1 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

Result: The flashing beacon should be on andflashing.

2 Move the function enable switch to either sideand activate the primary boom toggle switch inthe down position, hold for a moment and thenrelease it.

Result: The descent alarm should sound whenthe switch is held down.

3 Move the function enable switch to either sideand activate the secondary boom toggle switchin the down position, hold for a moment andthen release it.


4 Z-45/25J: Move the function enable toggleswitch to either side and activate the jib boomtoggle switch in the down position, hold for amoment and then release it.


5 Turn the key switch to platform control.

Result: The flashing beacon should be onand flashing.

6 Press down the foot switch. Move the primaryboom control handle to the down position, holdfor a moment and then release it.

Result: The descent alarm should sound whenthe control handle is held down.

7 Press down the foot switch. Move thesecondary boom control handle to the downposition, hold for a moment and then release it.

Result: The descent alarm should sound whenthe control handle is held down.

8 Z-45/25J: Press down the foot switch. Activatethe jib boom toggle switch in the down position,hold for a moment and then release it.


9 Press down the foot switch. Move the drivecontrol handle off center, hold for a moment andthen release it. Move the drive control handle offcenter in the opposite direction, hold for amoment and then release it.

Result: The travel alarm should sound when thedrive control handle is moved off center in eitherdirection.


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B-19Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction strainermay cause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often. For hydraulic oilspecifications, refer to Section 2, Specifications.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.See E-1, Test or Replace theHydraulic Oil.

B-20Inspect the Fuel and HydraulicTank Cap Venting Systems

Genie requires that this procedurebe performed every 250 hours orquarterly, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Free-breathing fuel and hydraulic tank caps areessential for good machine performance andservice life. A dirty or clogged tank cap may causethe machine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the caps be inspectedmore often.



1 Remove the cap from the fuel tank.

2 Check for proper venting.

Result: Air passes through the fuel tank cap.Proceed to step 4.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.

When checking for positive tankcap venting, air should pass freelythrough the cap.


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3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 2.

4 Install the fuel tank cap onto the fuel tank.

5 Remove the breather cap from the hydraulictank.

6 Check for proper venting.

Result: Air passes through the fuel tank cap.Proceed to step 8.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 7.

When checking for positive tankcap venting, air should pass freelythrough the cap.

7 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 6.

8 Install the breather cap onto the hydraulic tank.

B-21Replace the Fuel Filter Element -Perkins Models


Replacing the diesel fuel filter element is essentialfor good engine performance and service life. Adirty or clogged filter may cause the engine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay required that the filter be replaced more often.







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3 Thoroughly clean the outside surfaces of thefuel filter assembly.

4 Place a suitable container under the fuel filterelement.

5 Disconnect and plug the fuel line from the fuelpump to the fuel filter element.

a fuel lineb filter headc fuel filter element

6 Remove the fuel filter element with a filterwrench.

7 Apply a thin layer of fuel to the new fuel filterelement O-ring.

8 Install the new fuel filter element and tighten itsecurely by hand. Clean up any fuel that mayhave spilled during the installation procedure.

9 Use a permanent ink marker to write the dateand number of hours from the hour meter on thefuel filter housing.


a

bc

Prime the fuel system:

10 Loosen the vent plug on top of the fuel injectionpump.

a vent plugb fuel injection pumpc fuel lift pump

11 Operate the priming lever or priming bulb (ifequipped) of the fuel lift pump until fuel, freefrom air, comes from the vent plug. Tighten thevent plug.

12 Clean up any fuel that may have spilled duringthis procedure.

13 Operate the starter motor for intervals of 15seconds until the engine starts.

It is important to allow the startermotor to cool for 30 secondsbetween each 15 second intervalof operation.

If the engine runs correctly for ashort time and then stops or runsroughly, check for air in the fuelsystem. If there is air in the fuelsystem, there is probably a leak inthe low pressure side of thesystem.

b

a

c

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B-22Perform Engine Maintenance -Perkins Models



Required maintenance procedures and additionalengine information are available in thePerkins 400 Series Operation Manual(Perkins part number TPD 1443S).


B-23Replace the Engine Air FilterElement - Ford Models




1 Locate the engine air filter assembly.


3 Remove and discard the filter element.


5 Install the new filter element.




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B-24Perform Engine Maintenance -Ford Models







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C-1Perform Engine Maintenance -Deutz Models

Deutz engine specifications requirethat this procedure be performedevery 500 hours.


Required maintenance procedures and additionalengine information are available in theDeutz FL 2011 Operation Manual(Deutz part number 0297-9929).






Checklist C Procedures

C-2Grease the Platform OverloadMechanism (if equipped)

Genie specifications requirethat this procedure be performedevery 500 hours or 6 months,whichever comes first. Performthis procedure more often if dustyconditions exist.

Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.

1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.

2 Thoroughly pump grease into each greasefitting.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent

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C-3Test the Platform OverloadSystem (if equipped)

Genie specifications require thatthis procedure be performed every500 hours or six months,whichever comes first.

Testing the platform overload system regularly isessential to safe machine operation. Continued useof an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.

The platform overload system is designed to detectan overloaded platform and prevent machineoperation anytime the machine is turned on. Whenactivated, the system halts all normal boomoperation, giving visual and audible warning to theoperator.

Models equipped with the platform overload optionare provided with additional machine components:an adjustable spring-loaded platform supportsubassembly, a limit switch, an electronic modulewhich receives the overload signal and interruptspower, and an audio/visual warning indication toalert the operator of the overload.

The platform support subassembly utilizes two loadsupport arms that are opposed in a fullparallelogram link. This isolates platform loads intoa shear or vertical state, which translates into acompressive load. A spring in the parallelogram linksupports this purely compressive load regardless ofwhere the load is placed in the platform.

As weight is added to the platform, the spring willcompress until, when the platform is overloaded,the lower arm contacts a limit switch and therebyactivating the overload signal. When adjustedcorrectly, the platform overload system willdeactivate normal boom operation at platformcapacity.

Perform this procedure with themachine on a firm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Failure to remove all weight, toolsand accessories from the platformwill result in an inaccurate test.

CHECKLIST C PROCEDURES

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4 Using a suitable lifting device, place a testweight equal to that of the available capacityone of the locations shown.Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lights areon and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProceedure 2-3, How to Calibrate the PlatformOverload System (if equipped).

5 Carefully move the test weight to eachremaining location. Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lights areon and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProceedure 2-3, How to Calibrate the PlatformOverload System (if equipped).

Illustration 1

6 Using a suitable lifting device, place anadditional 50 lbs / 23 kg of weight onto theplatform.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Proceedure 2-3,How to Calibrate the Platform Overload System(if equipped).

There may be a 2 second delaybefore the overload indicator lightsflash and the alarm sounds.

7 Carefully move the test weights to eachremaining location on the platform.Refer to Illustration 1.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Proceedure 2-3,How to Calibrate the Platform OverloadSystem (if equipped).

There may be a 2 second delaybefore the overload indicator lightsflash and the alarm sounds.


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REV D

8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.

9 Turn the key switch to ground control.

10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

11 Activate the auxiliary power toggle switch.

The engine will turn off when theauxiliary power is activated.

12 Using auxiliary power, test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate.

13 Using a suitable lifting device, lift the additionaltest weight from the platform.

Result: The platform overload indicator lightsshould turn off at both the ground and platformcontrols and the alarm should not sound.

There may be an 2 second delaybefore the overload indicator lightsand alarm turn off.

14 Start the engine and test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate normally.



Result: All platform control functions shouldoperate.

If the platform overload system isnot operating properly, Referto Repair Procedure 2-3, How toCalibrate the Platform OverloadSystem (if equipped).

17 Using a suitable lifting device, remove theremaining test weights from the platform.


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REV D

C-4Replace the Fuel Filter/WaterSeparator - Perkins Models


Regular replacement of the fuel filter/waterseparator is essential for good engine performance.Failure to perform this procedure can lead to poorengine performance and/or hard starting, andcontinued use may result in component damge.Extremely dirty conditions may require thisprocedure be performed more often.








5 Locate the fuel filter/water separator mounted tothe rear engine mounting bracket.

6 Disconnect and plug the fuel supply hose fromthe fuel tank to the fuel filter/water separator.

7 Loosen the vent plug located on the fuel filter/water separator head.

a vent plugb main fuel linec drain plugd filter bowle filter elementf separator head

8 Place a suitable container under the filter bowl.Loosen the drain plug located at the bottom ofthe bowl. Completely drain the fuel.

9 Rotate the filter bowl counterclockwise andremove it from the element.


d

c

f

e b

a

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REV D

10 Rotate the filter element counterclockwise andremove it from the filter head.

11 Install the bowl onto the new filter element.

12 Apply a thin layer of oil onto the element gasket.Install the filter/bowl assembly onto the filterhead. Tighten the drain plug and vent plug.

Component damage hazard. Thedrain plug and vent plug can bedamaged if they are overtightened.

13 Clean up any diesel fuel that may have spilledduring the installation procedure.

14 Install the fuel supply hose from the fuel tank tothe fuel filter/water separator. Tighten theclamp.

15 Use a permanent ink marker to write the dateand number of hours from the hour meter on thefilter element housing.

Prime the fuel system:

16 Loosen the vent plug on top of the fuel injectionpump.

a vent plugb fuel injection pumpc fuel lift pump


17 Operate the priming lever or priming bulb (ifequipped) of the fuel lift pump until fuel, freefrom air, comes from the vent plug. Tighten thevent plug.

18 Clean up any fuel that may have spilled duringthis procedure.

19 Operate the starter motor for intervals of 15seconds until the engine starts.

It is important to allow the startermotor to cool for 30 secondsbetween each 15 second intervalof operation.

If the engine runs correctly for ashort time and then stops or runsroughly, check for air in the fuelsystem. If there is air in the fuelsystem, there is probably a leak inthe low pressure side of thesystem.



a

bc

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REV D

C-5Replace the Engine Air FilterElement - Deutz and PerkinsModels




1 Locate the engine air filter assembly.


3 Remove and discard the filter element.


5 Install the new filter element.



C-6Perform Engine Maintenance -Perkins Models



Required maintenance procedures and additionalengine information are available in thePerkins 400 Series Operation Manual(Perkins part number TPD 1443S).







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REV D CHECKLIST C PROCEDURES

C-7Perform Engine Maintenance -Ford Models










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REV DChecklist D Procedures

D-1Check the Boom Wear Pads

Genie specifications require thatthis procedure be performed every1000 hours or annually, whichevercomes first.

Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of worn wear pads may result in componentdamage and unsafe operating conditions.

1 Measure each wear pad. Replace the wear padonce it reaches the minimum allowablethickness. If the wear pad is still withinspecification, shim as necessary to obtainminimum clearance with zero binding.

2 Extend and retract the primary boom through theentire range of motion to check for tight spotsthat may cause binding or scraping of the boom.

Always maintain squarenessbetween the outer and innerboom tubes.

Primary boom wearpad specifications Minimum

Top, bottom and side wear pads 5/8 inch(platform end of boom) 15.9 mm

Side and bottom wear pads 1/2 inch(pivot end of boom) 12.7 mm

Top wear pads 5/8 inch(pivot end of boom) 15.9 mm

D-2Check the Turntable RotationBearing Bolts


Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Raise the secondary boom and place a safetychock on the lift cylinder rods. Carefully lowerthe boom onto the lift cylinder safety chock.

Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering theboom.

The lift cylinder safety chock isavailable through the GenieService Parts Department.

2 Turn the engine off.



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REV D



6 Be sure that each turntable mounting bolt istorqued in sequence to specification. Refer toSection 2, Specifications.

Bolt torque sequence(before serial number 23332)

Bolt torque sequence(from serial number 23332 to 27000)

Bolt torque sequence(after serial number 27000)


8 Raise the secondary boom and remove thesafety chocks.

9 Lower the boom to the stowed position.

10 Remove drive chassis covers from both thesteer end and the non-steer end of the machine.

11 Remove the lower chassis cover mountingfasteners from inside of the drive chassis (ifequipped).

12 Remove the lower chassis cover to access thelower turntable bearing bolts under the drivechassis.

CHECKLIST D PROCEDURES

191510

136

18

3

11

8

2016 2 9

145

17

4

12

7

1

15

1013618

311

8

16

2

914 5 17

412

7

1

Counterweight

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REV D

13 Check to ensure that each lower bearingmounting bolt under the drive chassis is torquedin sequence to specification. Refer to Section 2,Specifications.

Bolt torque sequence(before serial number 23332)

Bolt torque sequence(after serial number 23331)

D-3Inspect for Turntable BearingWear


Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.

Perform this procedure with themachine on a firm, level surfaceand the boom in the stowedposition.

1 Grease the turntable bearing. See A-10, Greasethe Turntable Bearing and Rotate Gear.

2 Torque the turntable bearing bolts tospecification. See D-2, Check the TurntableRotation Bearing Bolts.

3 Start the machine from the ground controls andraise the primary and secondary booms to fullheight. Do not extend the primary boom.


115

7

12

4

5

14

9216

8

3

11

6

1310

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REV D

4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no more than1 inch / 2.5 cm from the bearing.

To obtain an accuratemeasurement, place the dialindicator no more than 1 inch /2.5 cm from the turntable rotationbearing.

a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 At the dial indicator, adjust it to "zero" theindicator.

6 Lower the secondary boom to the stowedposition and lower the primary boom to ahorizontal position. Fully extend the primaryboom.

7 Note the reading on the dial indicator.

Result: The measurement is less than0.055 inch / 1.4 mm. The bearing is good.

Result: The measurement is more than0.055 inch / 1.4 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the primary boom. Raise theprimary and secondary booms to full height.Visually inspect the the dial indicator to be surethe needle returns to the "zero" position.

9 Remove the dial indicator and rotate theturntable 90°.

10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.

11 Lower the primary and secondary booms to thestowed position and turn the machine off.

12 Remove the dial indicator from the machine.


a

b

c

d

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REV D

D-4Replace the Drive Hub Oil


Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly and continueduse may cause component damage.

1 Select the drive hub to be serviced. Then drivethe machine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

a drive hub plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Install the plugs.

5 Repeat steps 1 through 4 for all the other drivehubs.

6 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.

D-5Check the Free-wheelConfiguration


Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily for towing.A machine configured to free-wheel without operatorknowledge may cause death or serious injury andproperty damage.

Collision hazard. Select a work sitethat is firm and level.

Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.

Non-steer wheels: All models

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the non-steer tires.

3 Lift the wheels off the ground and then placejack stands under the drive chassis for support.


a

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REV D

4 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachnon-steer wheel hub.

5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate withminimum effort.

6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Raise the machine,remove the jack stands and lower the machine.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.

Steer wheels: 4WD models

7 Chock the non-steer wheels to prevent themachine from rolling.

8 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the steer tires.

9 Lift the wheels off the ground and then placejack stands under the drive chassis for support.


10 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachsteer wheel hub.

11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate withminimum effort.

12 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Raise the machine,remove the jack stands and lower the machine.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.

disengaged position

engaged position

disengaged position

engaged position

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REV DCHECKLIST D PROCEDURES

D-6Replace the Hydraulic Filters

Genie requires that this procedurebe performed yearly or every 1000hours, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filters be replaced more often.

Bodily injury hazard. Beware of hotoil. Contact with hot oil may causesevere burns.


Hydraulic return filter

1 Open the ground controls side turntable coverand locate the hydraulic return filter housing ontop of the hydraulic tank.

2 Remove the cap from the filter housing.

3 Lift the handle on the filter element and rotatethe element counterclockwise to release theelement from the housing.

4 Remove the filter element from the filterhousing.

5 Install the new filter element into the filterhousing.

6 Push the filter element down to be sure theO-ring on the element is fully seated into thehousing.

7 Rotate the filter element clockwise to lock it inplace.

8 Install the filter housing cap.

9 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housing.

Medium and high pressure filters

The medium pressure filter is forthe charge pump and the highpressure filter is for all machinefunctions except the drive circuitand oscillating axle circuit.

10 Open the engine side turntable cover and locatethe medium and high pressure filters.

The medium pressure filter ismounted near the pump. The highpressure filter, with filter conditionindicator, is mounted to thebulkhead.

11 Place a suitable container under each filter.

12 Remove the filter housings by using a wrench onthe nut provided on the bottom of the housings.

13 Remove the filter elements from the housings.

14 Inspect the housing seals and replace them ifnecessary.

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REV D CHECKLIST D PROCEDURES

15 Install the new filter elements into the housingsand tighten them securely.

The medium and high pressurefilters use the same elements.

16 Clean up any oil that may have spilled during theinstallation procedure.

17 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housings.


19 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.

D-7Perform Engine Maintenance -Deutz Models









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REV D

1 Ford models: Turn the valve on the LPG tankclockwise to the off position (if equipped). Thenslowly disconnect the hose from the LPG tank.

2 Ford models: Open the clamps from the LPGtank straps and remove the LPG tank from themachine (if equipped).

3 Models with hydraulic tank shut-off valves:Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.

Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

4 Remove the drain plug from the hydraulic tankand completely drain the tank into a container ofsuitable capacity. Refer to Section 2,Specifications.

E-1Test or Replace the Hydraulic Oil

Genie requires that this procedurebe performed every 2000 hours orevery two years, whichever comesfirst. Perform this procedure moreoften if dusty conditions exist.

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly and continueduse may cause component damage. Extremelydirty conditions may require oil changes to beperformed more often.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.

When removing a hose assemblyor fitting, the O-ring (if equipped)on the fitting and/or the hose endmust be replaced. All connectionsmust be torqued to specificationduring installation. Refer toSection 2, Hydraulic Hose andFitting Torque Specifications.

Perform this procedure with theboom in the stowed position.

Checklist E Procedures

open closed

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REV D

5 Tag, disconnect and plug the two suction hosesand supply hose for the auxiliary pump from thehydraulic tank. Cap the fittings on the tank.

The hoses can be accessedthrough the access hole under theturntable.

6 Disconnect and plug the return filter hydraulichose at the return filter. Cap the fitting on thefilter housing.

7 Remove the ground controls side turntablecover.

8 Support the hydraulic tank with an appropriatelifting device.

9 Remove the hydraulic tank mounting fasteners.

10 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if not properly supportedwhen removed from the machine.

11 Remove the hydraulic return filter housingmounting fasteners. Remove the hydraulicreturn filter housing from the hydraulic tank.

12 Remove the suction strainers from the tank andclean them using a mild solvent.

13 Rinse out the inside of the tank using a mildsolvent.

14 Install the suction strainers using a threadsealant on the threads.

15 Install the drain plug using a thread sealant onthe threads.

16 Install the hydraulic return filter housing onto thehydraulic tank.

17 Install the hydraulic tank onto the machine.

18 Install the two suction hoses to the suctionstrainers.

19 Install the supply hose for the auxiliary powerunit and the return filter hose.

20 Models with hydraulic tank shut-off valves:Open the two hydraulic tank valves at thehydraulic tank.

21 Fill the tank with the proper hydraulic oil for yourmachine until the level is within the top2 inches / 5 cm of the sight gauge. Do notoverfill. Refer to Section 2, Specifications.

22 Clean up any oil that may have spilled.

23 Prime the pump. Refer to Repair Procedure 7-2,How to Prime the Pump.

Always use pipe thread sealantwhen installing the suction hosefittings and the drain plug.

CHECKLIST E PROCEDURES

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REV D

E-2Grease the Steer AxleWheel Bearings, 2WD Models

Genie requires that this procedurebe performed every 2000 hours orevery two years, whichever comesfirst. Perform this procedure moreoften if dusty conditions exist.

Maintaining the steer axle wheel bearings isessential for safe machine operation and servicelife. Operating the machine with loose or wornwheel bearings may cause an unsafe operatingcondition and continued use may result incomponent damage. Extremely wet or dirtyconditions or regular steam cleaning and pressurewashing of the machine may require that thisprocedure be performed more often.

1 Loosen the wheel lug nuts. Do not remove them.

2 Block the non-steer wheels, then center a liftingjack under the steer axle.

3 Raise the machine 6 inches / 15 cm and placeblocks under the drive chassis for support.

4 Remove the lug nuts. Remove the tire and wheelassembly.

5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should be no side to side or upand down movement.

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

7 Tighten the castle nut to 35 ft-lbs / 47 Nm toseat the bearings.

8 Loosen the castle nut and re-tighten to8 ft-lbs / 11 Nm.

9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: If there is no side to side or up anddown movement, continue with step 11 andgrease the wheel bearings.

Result: If there is side to side or up and downmovement, continue to step 11 and replace thewheel bearings with new ones.

When replacing a wheel bearing,both the inner and outer bearings,including the pressed-in races,must be replaced.

10 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

11 Remove the castle nut.

12 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.

13 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove the rearbearing.

14 Pack both bearings with clean, fresh grease.

15 Place the large inner bearing into the rear of thehub.


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REV D

E-3Perform Engine Maintenance -Deutz Models









16 Install a new bearing grease seal into the hub bypressing it evenly into the hub until it is flush.

17 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.

20 Tighten the slotted nut to 35 ft-lbs / 47 Nm toseat the bearings.

21 Loosen the castle nut and re-tighten to8 ft-lbs / 11 Nm.

22 Install a new cotter pin. Bend the cotter pinto lock it in.

Always use a new cotter pin wheninstalling a castle nut.

23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.


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REV DCHECKLIST E PROCEDURES

E-4Perform Engine Maintenance -Deutz Models

Engine specifications require thatthis procedure be performed every12,000 hours.








Part No. 107846 Z-45/25 • Z-45/25J 4 - 1

August 2006 Section 4 • Repair Procedures

Repair Procedures

Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.


Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start:Read, understand and obey the safety rules andoperating instructions in the appropriateOperator's Manual on your machine.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

�Machine parked on a firm, level surface

�Boom in stowed position

�Turntable rotated with the boom betweenthe non-steer wheels

�Turntable secured with the turntablerotation lock

�Key switch in the off position with thekey removed

�Wheels chocked

�All external AC power disconnectedfrom the machine

About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. To re-assemble,perform the disassembly steps in reverse order.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.



Indicates that a specific result is expected afterperforming a series of steps.

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

4 - 2 Z-45/25 • Z-45/25J Part No. 107846

August 2006Section 4 • Repair Procedures

REV B

The platform control box contains one printedcircuit board. The ALC-500 circuit board inside theplatform control box controls all proportionalmachine functions from the platform. The joystickcontrollers at the platform controls utilize HallEffect technology and require no adjustment. Theoperating parameters of the joysticks are stored inmemory at the ECM circuit board at the platformcontrols. If a joystick error occurs or if a joystick isreplaced, it will need to be calibrated before thatparticular machine function will operate. See 1-2,How to Calibrate a Joystick.

Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

a ALC-500 circuit boardb drive/steer joystick controllerc secondary boom up/down

joystick controllerd primary boom up/down and

turntable rotate left/rightjoystick controller

1-1ALC-500 Circuit Board

Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

When the ALC-500 circuit board isreplaced, the joystick controllerswill need to be calibrated. See 1-2,How to Calibrate a Joystick.

How to Remove the ALC-500Circuit Board1 Push in the red Emergency Stop button to the

off position at both the ground and platformcontrols.

2 Remove the platform control box lid retainingfasteners. Open the control box lid.

3 Locate the ALC-500 circuit board mounted to theinside of the platform control box.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Platform Controls

bcd

a

Part No. 107846 Z-45/25 • Z-45/25J 4 - 3


REV B

1-2Joysticks

How to Calibrate a JoystickThe joysticks on this machine utilize digital HallEffect technology for proportional control. If ajoystick is disconnected or replaced, it must becalibrated before that particular machine functionwill operate.

The joystick must be calibratedbefore the threshold, max-out orramp rate can be set.


1 Open the platform control box.


3 Turn the key switch to platform control. Do notstart the engine.

4 Select a joystick to calibrate.

5 Disconnect the wire harness connector from thejoystick for approximately 10 seconds or untilthe alarm sounds. Connect the wire harnessconnector to the joystick.

6 Move the joystick full stroke in either directionand hold for 5 seconds.

7 Return the joystick to the neutral position, pausefor a moment, then move the joystick full strokein the opposite direction. Hold for 5 seconds andreturn the joystick to the neutral position.

Result: The alarm should sound indicatingsuccessful joystick calibration.

8 Repeat this procedure for each joystickcontrolled machine function including the thumbrocker steer switch.

No machine fuction should operatewhile performing the joystickcalibration procedure.

4 Attach a grounded wrist strap to the groundscrew inside the platform control box.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

5 Carefully disconnect the wire connectors fromthe circuit board.

6 Remove the ALC-500 circuit board mountingfasteners.

7 Carefully remove the ALC-500 circuit board fromthe platform control box.

PLATFORM CONTROLS

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REV BPLATFORM CONTROLS

How to Adjust the JoystickMax-out SettingThe max-out setting of a joystick controls themaximum speed of a joystick-controlled machinefunction. Whenever a hydraulic cylinder, drivemotor or hydraulic pump is replaced, the max-outsetting should be adjusted to maintain optimumperformance. The max-out settings on the joystickcan be changed to compensate for hydraulic pumpwear to maintain peak performance from themachine.




3 Push in the platform controls red EmergencyStop button to the off position.

4 Do not press down the foot switch.

5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.

6 When the alarm sounds, release the driveenable toggle switch.

7 Momentarily activate the drive enable toggleswitch in the right direction 4 times.

Result: There should be a pause and the alarmshould sound 4 times indicating that themachine is in max-out calibration mode.

8 Start the engine from the platform controls andpress down the foot switch.

9 Start a timer and activate the machine functionthat needs to be adjusted. Record the time ittakes for that function to complete a full cycle(ie; boom up).

10 Compare the machine function time with thefunction times listed in Section 2,Specifications. Determine whether the functiontime needs to increase or decrease.

11 While the joystick is activated, adjust the max-out setting to achieve the proper function cycletime. Momentarily move the drive enable toggleswitch in the right direction to increase thefunction speed or momentarily move the driveenable toggle switch in the left direction todecrease the function speed.

Each time the drive enable toggleswitch is momentarily moved, thefunction speed will change in 2%increments.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.

13 Return the joystick to the neutral position andwait for approximately 10 seconds to allow thesettings to be saved.

Result: The alarm should sound indicating thatthe settings have been saved in memory.

Do not operate any machinefunction during the 10 secondwaiting time.

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REV B PLATFORM CONTROLS

How to Adjust the JoystickRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.









Result: There should be a pause and the alarmshould sound 6 times indicating that themachine is in ramp rate calibration mode.


9 Start a timer and simultaneously move thejoystick in either direction full stroke. Note howlong it takes the function to reach maximumspeed. This is the ramp rate.

10 Compare the function ramp rate time with thetable below and determine whether the ramprate time needs to increase or decrease.

11 While the joystick is activated, set the ramprate. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.

Each time the drive enable toggleswitch is momentarily moved, thetime will change in 10%increments.

12 Repeat steps 9 through 11 for each joystickcontrolled machine function.




Ramp rate (factory settings)

Primary boom up/downaccelerate 4 secondsdecelerate 0.5 second

Secondary boom up/downaccelerate 2 secondsdecelerate 0.5 second

Turntable rotateaccelerate 2 secondsdecelerate 0.5 second

Driveaccelerate 3.3 secondsaccelerate (narrow models) 3.8 secondsdecelerate to neutral 0.5 seconddecelerate, change of direction 0.5 seconddecelerate, coasting 0.75 seconddecelerate, braking 1 seconddecelerate, shift from low to high speed 1 seconddecelerate, shift from high to low speed 2 seconds

4 - 6 Z-45/25 • Z-45/25J Part No. 107846


REV BPLATFORM CONTROLS

How to Adjust the JoystickThreshold SettingThe threshold setting of a joystick is the minimumoutput at which a function proportional valve canopen and allow the function to operate.









Result: There should be a pause and the alarmshould sound 8 times indicating that themachine is in threshold calibration mode.


9 Select a boom function joystick to set thethreshold.

10 Slowly move the joystick off center in eitherdirection just until the function begins to move.

11 Slowly move the joystick back to the neutralposition. Just before the function stops moving,move the drive enable toggle switch to eitherside to set the threshold.

Result: The alarm should sound indicating asuccessful calibration.

12 Repeat steps 9 through 11 for each boomjoystick controlled machine function (boom up/down, boom extend/retract and turntable rotate).




Part No. 107846 Z-45/25 • Z-45/25J 4 - 7


REV CPlatform Components

2-1Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.

How to Remove the PlatformLeveling Slave Cylinder

Before cylinder removal isconsidered, bleed the slavecylinder to be sure there is noair in the closed loop.

When removing a hose assemblyor fitting, the O-ring (if equipped)on the fitting and/or the hose endmust be replaced. All connectionsmust be torqued to specificationduring installation. Refer toSection 2, Hydraulic Hose andFitting Torque Specifications..

1 Z-45/25J: Extend the primary boom until theslave cylinder barrel-end pivot pin is accessible.

2 Raise the primary boom slightly and placeblocks under the platform for support.

3 Lower the primary boom until the platform isresting on the blocks just enough to support theplatform.

Do not rest the entire weight of theboom on the blocks.

4 Tag, disconnect and plug the hydraulic hosesfrom the slave cylinder at the unions andconnect them together using a connector.Connect the hoses from the cylinder togetherusing a connector.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

5 Remove the pin retaining fastener from the slavecylinder rod-end pivot pin. Do not remove thepin.

6 Z-45/25J: Remove the external snap rings fromthe slave cylinder barrel-end pivot pin. Do notremove the pin.

Z-45/25: Remove the pin retaining fastener fromthe slave cylinder barrel-end pivot pin. Do notremove the pin.

7 Place a block under the slave cylinder forsupport. Protect the cylinder rod from damage.

4 - 8 Z-45/25 • Z-45/25J Part No. 107846


REV CPLATFORM COMPONENTS

8 Z-45/25: Support the platform rotator with asuitable lifting device.

9 Use a soft metal drift to drive the rod-end pivotpin out.

Crushing hazard. The platformcould fall when the slave cylinderrod-end pivot pin is removed if notproperly supported.

Component damage hazard. Theslave cylinder rod may becomedamaged if it is allowed to fall ifnot properly supported by the liftingdevice.

10 Use a soft metal drift and drive the barrel-endpin out.

11 Carefully pull the cylinder out of the primaryboom.

How to Bleed the Slave Cylinder1 Simultaneously activate the boom up function

and the platform level up function until the boomis fully raised.

2 Simultaneously activate the boom down functionand the platform level down function until theboom is fully lowered.

2-2Platform Rotator

How to Bleed the PlatformRotator

This procedure will require twopeople. Do not start the engine.Use auxiliary power for thisprocedure.

1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right then the left through twoplatform rotation cycles, then hold the switch tothe right position until the platform is fullyrotated to the right.

Before serial number 24304:

2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a container tocollect any drainage. Secure the container tothe boom.

3 Open the top bleed valve on the rotator, but donot remove it.

a top bleed valveb bottom bleed valvec containerd clear hose

a

d c b

Part No. 107846 Z-45/25 • Z-45/25J 4 - 9


REV C PLATFORM COMPONENTS

4 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the left position until the platform is fullyrotated to the left. Continue holding the toggleswitch until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear of theplatform during rotation.

5 Connect the clear hose to the bottom bleedvalve and open the valve. Do not remove thebleed valve.

6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedvalve. Close the bleed valve.


7 Remove the hose from the bleed valve andclean up any hydraulic oil that may have spilled.

8 Rotate the platform fully in both directions andinspect the bleed valves for leaks.

After serial number 24303:

2 Place a suitable container underneath theplatform rotator.

3 Open the top bleed screw on the rotator, but donot remove it.


4 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the left position until the platform is fullyrotated to the left. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.


5 Open the bottom bleed screw on the rotator, butdo not remove it.


6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.


7 Clean up any hydraulic oil that may have spilled.

8 Rotate the platform fully in both directions andinspect the bleed screws for leaks.

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REV C

2-3Platform Overload System

How to Calibrate the PlatformOverload SystemCalibration of the platform overload system isessential to safe machine operation. Continued useof an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.

Perform this procedure with themachine on a firm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Failure to remove all weight, toolsand accessories from the platformwill result in an incorrectcalibration.

4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the center of the platform floor.

5 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.

Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 6.

Result: The overload indicator lights are flashingat the platform and ground controls, and thealarm is sounding. Slowly tighten the load springadjustment nut in a clockwise direction in 10°increments until the overload indicator lightturns off, and the alarm does not sound.Proceed to step 8.

The platform will need to be movedup and down and allowed to settlebetween each adjustment.

There may be a 2 second delaybefore the platform overloadindicator light and alarm responds.


Result: The overload indicator lights are off atthe platform and ground controls, and the alarmdoes not sound. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, and the alarm sounds.Proceed to step 7.

Result: The overload indicator lights are flashingat the platform and ground controls, and thealarm is sounding. Repeat this procedurebeginning with step 5.

The platform will need to be movedup and down and allowed to settlebetween each adjustment.

There may be a 2 second delaybefore the platform overloadindicator lights and alarmresponds.

PLATFORM COMPONENTS

Part No. 107846 Z-45/25 • Z-45/25J 4 - 11


REV C


Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 8.

Result: The overload indicator lights are flashingat the platform and ground controls, and thealarm is sounding. Repeat this procedurebeginning with step 5.


8 Add an additional 10 lb / 4.5 kg test weight tothe platform.

Result: The overload indicator light is flashing atboth the ground and platform controls, and thealarm is sounding. Proceed to step 9.

Result: The overload indicator light is off at boththe ground and platform controls, and the alarmdoes not sound. Remove the additional 10 lb /4.5 kg test weight. Repeat this procedurebeginning with step 6.



Result: All platform control functions should notoperate.

PLATFORM COMPONENTS

10 Turn the key switch to ground control.


Result: All ground control functions should notoperate.

12 Using a suitable lifting device, lift the test weightoff the platform floor.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.

There may be a 2 second delaybefore the overload indicator lightsand alarm turn off.


Result: All ground control functions shouldoperate normally.



Result: All platform control functions shouldoperate normally.

4 - 12 Z-45/25 • Z-45/25J Part No. 107846


REV B

3-1Jib Boom

How to Remove the Jib BoomPerform this procedure with theboom in the stowed position.


1 Remove the platform.

2 Disconnect the electrical connector from the jibboom/platform rotate select valve manifoldmounted to the platform support.

3 Tag, disconnect and plug all of the hydraulichoses from the jib boom/platform rotate selectvalve manifold. Cap the fittings on the manifoldand pull the hoses out through the platformrotator.


4 Remove the platform mounting weldment.

5 Attach a lifting strap from an overhead crane tothe platform rotator for support.

6 Remove the pin retaining fastener from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

7 Remove the pin retaining fasteners from bothplatform rotator pivot pins. Do not remove thepins.

8 Use a soft metal drift to remove the leveling armpivot pin and let the leveling arms hang down.

9 Use a soft metal drift to remove the platformrotator pivot pin and remove the platform rotatorfrom the machine.

10 Slide both of the jib boom leveling arms off ofthe jib boom cylinder rod-end pivot pin.

11 Remove the hose and cable cover from the sideof the jib boom. Remove the hose and cableseparators.

12 Attach a lifting strap from an overhead crane tothe jib boom.

13 Support the barrel end of the jib boom liftcylinder with a suitable lifting device.

14 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


Jib Boom Components, Z-45/25J

Part No. 107846 Z-45/25 • Z-45/25J 4 - 13


REV B JIB BOOM COMPONENTS, Z-45/25J

15 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin.

16 Use a soft metal drift to remove the pin and letthe cylinder hang down.

Crushing hazard. The jib boomcould fall when when the barrel-endpivot pin is removed if not properlysupported by the overhead crane.

17 Remove the pin retaining fastener from the jibboom pivot pin. Use a soft metal drift to removethe pin, then remove the jib boom from thebellcrank.

Crushing hazard. The jib boomcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.

18 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

19 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin, then remove the jibboom lift cylinder from the bellcrank.

Crushing hazard. The jib boom liftcylinder could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

3-2Jib Boom Lift Cylinder

How to Remove the Jib BoomLift Cylinder



1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.

Do not rest the entire weight of theboom on the blocks.

2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


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REV B

3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

4 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out. Thenlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.

5 Support the jib boom lift cylinder with a suitablelifting device.

6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pin andlet the cylinder hang down.

Crushing hazard. The jib boomcould fall when the barrel-end pivotpin is removed if not properlysupported by the overhead crane.

7 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

8 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the jib boom liftcylinder from the machine.

Crushing hazard. The jib boom liftcylinder could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

JIB BOOM COMPONENTS, Z-45/25J

Part No. 107846 Z-45/25 • Z-45/25J 4 - 15


REV B

4-1Cable Track

The primary boom cable track guides the cablesand hoses running up the boom. It can be repairedlink by link without removing the cables and hosesthat run through it. Removing the entire primaryboom cable track is only necessary whenperforming major repairs that involve removing theprimary boom.

How to Remove the Cable Track,Z-45/25


1 Locate the cables from the primary boom cabletrack to the platform control box. Number eachcable and its entry location at the platformcontrol box.

2 Disconnect the cables from the platform controlbox.

3 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.

4 Raise the primary boom to a horizontal position.

Primary Boom Components

5 Tag, disconnect and plug the platform rotatorhydraulic hoses at the union located above theprimary boom lift cylinder. Cap the fittings onthe unions.


6 Tag, disconnect and plug the hydraulic hosesfrom the "V1" and "V2" ports on thecounterbalance valve manifold located on theplatform rotator. Cap the fittings on themanifold.


7 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling master cylinder. Capthe fittings on the cylinder.


4 - 16 Z-45/25 • Z-45/25J Part No. 107846


REV BPRIMARY BOOM COMPONENTS

8 Tag and disconnect the hydraulic hoses fromthe platform leveling slave cylinder and connectthem together using a connector. Cap thefittings on the cylinder.


9 Pull the four hydraulic hoses toward the platformto clear the rod end of the primary boom liftcylinder.

10 Place blocks in between the upper and lowercable tracks and secure the upper and lowertracks together.

Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.

11 Remove all hose and cable clamps from theunderside of the primary boom.

12 Attach a strap from an overhead crane to thecable track.

13 Remove the mounting fasteners from the uppercable track at the platform end of the extensionboom.

14 Remove the cable track mounting fasteners thatattach the lower cable track to the primaryboom.

15 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.

Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.

How to Remove the Cable Track,Z-45/25J


1 Locate the cables from the primary boom cabletrack to the platform control box. Number eachcable and its entry location at the platformcontrol box.

2 Disconnect the cables from the platform controlbox.

3 Remove the hose and cable cover from the sideof the jib boom. Remove the hose and cableseparators.

4 Remove the hose clamp on the primary boombellcrank.

5 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.

Part No. 107846 Z-45/25 • Z-45/25J 4 - 17


REV B

6 Tag, disconnect and plug the hydraulic hosesfrom the "V1" and "V2" ports on thecounterbalance valve manifold located on theplatform rotator. Cap the fittings on themanifold.


7 Tag and disconnect the hydraulic hoses fromthe platform leveling slave cylinder at the unionand connect them together using a connector.Connect the hoses from the cylinder togetherusing a connector.


8 Tag, disconnect and plug the hydraulic hosesfrom the jib boom/platform rotate manifold. Capthe fittings on the manifold.


9 Tag, disconnect and plug the platform rotatorhydraulic hoses at the union located above theprimary boom lift cylinder. Cap the fittings onthe unions.


10 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling master cylinder. Capthe fittings on the cylinder.


11 Raise the boom to a horizontal position.

12 Place blocks between the upper and lower cabletracks and secure the upper and lower trackstogether.

Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.

13 Attach a lifting strap from an overhead 5 ton /5,000 kg capacity crane to the platform end ofthe primary boom for support. Do not lift it.

PRIMARY BOOM COMPONENTS

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REV B

a

b

14 Remove all hose and cable clamps from theunderside of the primary boom.

15 Support the rod end of the primary boom liftcylinder with a suitable lifting device.

16 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Donot remove the pin.

17 Raise the primary boom slightly with theoverhead crane to relieve the pressure on theprimary boom lift cylinder rod-end pivot pin.

18 Use a soft metal drift to remove the primaryboom lift cylinder rod-end pivot pin.

Crushing hazard. The primaryboom lift cylinder could becomeunbalanced and fall if not properlysupported by the lifting device.

19 Lower the rod end of the primary boom liftcylinder approximately 12 inches / 30 cm.

20 Pull all of the hoses and cables out and awayfrom the mounting ears for the rod end of theprimary boom lift cylinder.

21 Raise the rod end of the primary boom liftcylinder back into position and install the rod-end pivot pin. Install the pin retaining fasteners.

22 Attach a strap from an overhead crane to thecable track.

23 Remove the mounting fasteners from the uppercable track at the platform end of the extensionboom.

24 Remove the cable track mounting fasteners thatattach the lower cable track to the primaryboom.

25 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.

Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.

How to Repair the Primary BoomCable Track

Component damage hazard. Theprimary boom cable track can bedamaged if it is twisted.

A 7 link repair section of cabletrack is available throughthe Genie Industries Service PartsDepartment.

a link separation pointb lower clip

1 Use a slotted screwdriver to pry down on thelower clip.

2 To remove a single link, open the lower clipand then use a screw driver to pry the link to theside.

3 Repeat steps 1 and 2 for each link.


Part No. 107846 Z-45/25 • Z-45/25J 4 - 19


REV B PRIMARY BOOM COMPONENTS

4-2Primary Boom

How to Remove the PrimaryBoom

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.




2 Z-45/25: Remove the platform rotator andplatform mounting weldment.

Z-45/25J: Remove the jib boom.See 3-1, How to Remove the Jib Boom.

3 Remove the cable track. See 4-1, How toRemove the Cable Track.


5 Remove the hose and cable cover from theupper pivot.

6 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin. Use a softmetal drift to remove the pin. Then lower thecylinder and let it hang down.

Component damage hazard.When lowering the master cylinderdown, be sure not to damage themaster cylinder hoses or fittings.

7 Locate the primary boom drive speed limitswitch inside of the upper pivot.

8 Remove the primary boom drive speed limitswitch mounting fasteners. Do not disconnectthe wiring.

9 Locate the primary extension boom drive speedlimit switch inside of the extension boom.

10 Remove the primary extension boom drivespeed limit switch mounting fasteners. Do notdisconnect the wiring.

11 Pull the limit switch and the wiring out of theextension tube and move it out of the way.

12 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


4 - 20 Z-45/25 • Z-45/25J Part No. 107846


REV BPRIMARY BOOM COMPONENTS

13 Remove the hose clamp at the pivot end of theboom.

14 Attach a 5 ton / 5,000 kg overhead crane to thecenter point of the primary boom.

15 Attach a similar lifting device to the primaryboom lift cylinder.

16 Place support blocks under the primary boom liftcylinder.

17 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.

Crushing hazard. The boom liftcylinder and primary boom will fallif not properly supported.

18 Lower the rod end of the primary boom liftcylinder onto support blocks. Protect thecylinder rod from damage.

19 Remove the pin retaining fasteners from theprimary boom pivot pin.

20 Remove the primary boom pivot pin with a softmetal drift, then carefully remove the primaryboom from the machine and place it on astructure capable of supporting it.

Crushing hazard. The primaryboom could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

How to Disassemble the PrimaryBoom

Complete disassembly of theboom is only necessaryif the outer or inner boom tubemust be replaced. The extensioncylinder can be removed withoutcompletely disassembling theboom. See 4-4, How to Removethe Primary Boom ExtensionCylinder.

1 Remove the primary boom. See How to Removethe Primary Boom.

2 Place blocks under the barrel end of the primaryboom extension cylinder for support.

3 Remove the pin retaining fastener from theextension cylinder barrel-end pivot pin at thepivot end of the primary boom. Use a soft metaldrift to remove the pin.

4 Remove and label the location of the wear padsfrom the platform end of the primary boom.

Pay careful attention to thelocation and amount of shims usedwith each wear pad.

5 Support and slide the extension tube andextension cylinder assembly out of the boomtube.

Crushing hazard. The primaryboom extension tube couldbecome unbalanced and fall whenremoved from the primary boomtube if not properly supported.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

Part No. 107846 Z-45/25 • Z-45/25J 4 - 21


REV B PRIMARY BOOM COMPONENTS

6 Remove the external snap rings from theextension cylinder rod-end pivot pin at theplatform end of the extension tube. Use a softmetal drift to remove the pin.

7 Support and slide the extension cylinder out ofthe base end of the extension tube. Place theextension cylinder on blocks for support.

Crushing hazard. The extensioncylinder could become unbalancedand fall when removed fromprimary boom extension tube if notproperly supported.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

4-3Primary Boom Lift Cylinder

The primary boom lift cylinder raises and lowers theprimary boom. The primary boom lift cylinder isequipped with a counterbalance valve to preventmovement in the event of a hydraulic line failure.

How to Remove the PrimaryBoom Lift Cylinder




2 Raise the secondary boom until the primaryboom lift cylinder barrel-end pivot pin is abovethe turntable covers.

3 Attach a 5 ton / 5000 kg overhead crane to theprimary boom for support.

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REV B

4 Raise the primary boom with the overhead craneslightly to take the pressure off the primaryboom lift cylinder pivot pins.

5 Support the rod end and the barrel end of theprimary boom lift cylinder with a secondoverhead crane or similar lifting device.

6 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


7 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.

Crushing hazard. The primaryboom will fall if not properlysupported when the primary boomrod-end pivot pin is removed.

8 Place a support block across both turntablecovers under the primary boom lift cylinder.

9 Lower the rod end of the lift cylinder onto theblock. Protect the cylinder rod from damage.

Crushing hazard. The primaryboom lift cylinder could fall if notproperly supported.


10 Remove the primary boom lift cylinder barrel-endpivot pin retaining fasteners. Do not remove thepin.

11 Use a slide hammer to remove the barrel-endpivot pin. Carefully remove the primary boom liftcylinder from the machine.

Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported andsecured to the lifting device.

Part No. 107846 Z-45/25 • Z-45/25J 4 - 23


REV B

4-4Primary Boom ExtensionCylinder

The primary boom extension cylinder extends andretracts the primary boom extension tube.Theprimary boom extension cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the PrimaryBoom Extension Cylinder




2 Extend the primary boom until the primary boomextension cylinder rod-end pivot pin isaccessible in the primary boom extension tube.

3 Remove the hose and cable guard from theupper pivot.

4 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


5 At the platform end of the boom, remove theexternal snap rings from the extension cylinderrod-end pivot pin. Use a soft metal drift toremove the pin.

6 Remove the barrel-end pivot pin retainingfasteners.

7 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

8 Support and slide the extension cylinder out ofthe upper pivot.

Crushing hazard. The extensioncylinder could fall when removedfrom the extension boom if notproperly supported.

Component damage hazard. Becareful not to damage thecounterbalance valves on theprimary boom extension cylinderwhen removing the cylinder fromthe primary boom.

Component damage hazard. Hosesand cables can be damaged if theprimary boom extension cylinder isdragged across them.

Note the length of the cylinder afterremoval. The cylinder must be atthe same length for installation.


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REV B

4-5Platform LevelingMaster Cylinder

The master cylinder acts as a pump for the slavecylinder. It’s part of the closed circuit hydraulic loopthat keeps the platform level through the entirerange of boom motion. The master cylinder islocated at the base of the primary boom.

How to Remove the PlatformLeveling Master Cylinder


1 Raise the secondary boom until both the rod-endand barrel-end pivot pins on the master cylinderare accessible.

2 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on the cylinder.


3 Attach overhead crane or similar lifting device tothe master cylinder.


4 Remove the pin retaining fasteners from themaster cylinder barrel-end pivot pin.

5 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

6 Remove the pin retaining fastener from the rod-end pivot pin.

7 Place a rod through the rod-end pivot pin andtwist to remove the pin.

8 Remove the master cylinder from the machine.

Crushing hazard. The mastercylinder could become unbalancedand fall if not properly attached tothe overhead crane.

Part No. 107846 Z-45/25 • Z-45/25J 4 - 25



4 - 26 Z-45/25 • Z-45/25J Part No. 107846


REV BSecondary Boom Components

j

a b c

d

e

i

g

f

h

Secondary Boom components

a upper secondary boom(number 1 arm)

b upper tension link(number 2 arm)

c lower tension link(number 3 arm)

d mid-pivote compression linkf secondary boom lift cylinder (2)g lower secondary boom

(number 4 arm)h turntable pivoti boom restj upper pivot

Part No. 107846 Z-45/25 • Z-45/25J 4 - 27


REV B SECONDARY BOOM COMPONENTS

5-1Secondary Boom

How to Disassemble theSecondary Boom

Bodily injury hazard. Theprocedures in this section requirespecific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.

Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.



2 Z-45/25J: Remove the jib boom.See 3-1, How to Remove the Jib Boom.

3 Remove the primary boom. See 3-2, How toRemove the Primary Boom.

4 Remove the master cylinder. See 4-5, How toRemove the Master Cylinder.

5 Attach a lifting strap from an overhead crane toto the lug on the rod end of the primary boom liftcylinder. Then raise the primary boom liftcylinder with the crane, to a vertical position.

6 Tag, disconnect and plug the hydraulic hoses atthe primary boom lift cylinder. Cap the fittingson the cylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

7 Remove the pin retaining fastener from theprimary boom lift cylinder barrel-end pivot pin.

8 Use a slide hammer to remove the pin. Removethe primary boom lift cylinder from the machine.

Crushing hazard. The primaryboom lift cylinder could becomeunbalanced and fall if not properlysupported by the overhead crane.

9 Tag, disconnect and plug the hydraulic hoseson both of the secondary boom lift cylinders.Cap the fittings on the cylinders.


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REV B

10 Remove the pin retaining fasteners from bothsides of the secondary boom lift cylinder rod-end pivot pin and barrel-end pivot pin. Do notremove the pins.

11 Attach a strap from an overhead crane to the lugon the rod end of one of the secondary boom liftcylinders for support. Do not apply any liftingpressure.

12 Use a soft metal drift to drive the barrel-endpivot pin half way out. Lower the barrel end ofthe secondary boom lift cylinder and let it hangdown.

13 Use a soft metal drift to drive the rod-end pivotpin half way out.

14 Remove the secondary boom lift cylinder fromthe machine.

15 Repeat steps 11 through 14 for the othersecondary boom lift cylinder.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall when removedfrom the machine if not properlyattached to the overhead crane.

Component damage hazard. Whenremoving a secondary boom liftcylinder from the machine, becareful not to damage thecounterbalance valve at the barrelend of the cylinder.

16 Attach a lifting strap from an overhead crane tothe upper pivot for support. Do not lift it.

17 Attach a lifting strap from a second overheadcrane to the number 1 arm at the mid-pointbetween the upper pivot and mid-pivot.

18 Remove the pin retaining fasteners from thenumber 1 arm pivot pins at the mid-pivot andthe upper pivot. Do not remove the pins.

19 Use a soft metal drift to drive both pins out.

20 Remove the number 1 arm from the machine.

Crushing hazard. The number 1arm could become unbalanced andfall when removed from themachine if not properly attached tothe overhead crane.

Crushing hazard. The upper pivotcould fall when the number 1 armis removed from the machine if notproperly supported by the overheadcrane.

21 Using the overhead crane attached to the upperpivot, raise the secondary boom assemblyapproximately 30 inches / 76 cm.

22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm blockbetween the number 2 arm and the boom rest.Then lower the secondary boom assembly ontothe block.

Crushing hazard. The secondaryboom assembly could fall if notproperly supported by the4 x 4 x 11 inch / 10 x 10 x28 cm block.

SECONDARY BOOM COMPONENTS

Part No. 107846 Z-45/25 • Z-45/25J 4 - 29


REV B

23 Pull all of the cables and hoses out through theupper pivot.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

24 Remove the hose and cable covers from the topof the number 2 arm.

25 Pull all of the hoses and cables out of the upperpivot and out through the mid-pivot. Lay thehoses and cables on the ground.


26 Remove the pin retaining fastener from thenumber 2 arm pivot pin at the upper pivot. Use asoft metal drift to remove the pin.

27 Remove the upper pivot from the machine.

Crushing hazard. The upper pivotcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.

28 Attach the lifting strap from an overhead craneto the number 2 arm at the upper pivot end.

29 Raise the number 2 arm slightly and remove the4 x 4 x 11 inch / 10 x 10 x 28 cm block.

30 Lower the number 2 arm onto the boom rest pad.

31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cmblock between the number 3 arm and thenumber 4 arm at the mid-pivot end.

32 Attach a lifting strap from the overhead crane tothe mid-pivot for support. Do not lift it.

33 Remove the pin retaining fasteners from thenumber 2, 3 and 4 arm pivot pins at themid-pivot. Do not remove the pins.

34 Use a soft metal drift to drive each pin out. Thenremove the mid-pivot from the secondary boomassembly.

Crushing hazard. The mid-pivotcould become unbalanced and fallwhen removed from the secondaryboom assembly if not properlysupported by the overhead crane.

35 Attach the lifting strap from an overhead craneto the center point of the number 2 arm forsupport. Do not lift it.

36 Remove the pin retaining fasteners from bothcompression link pivot pins. Do not remove thepins.

37 Use a soft metal drift to remove the lowercompression link pivot pin at the number 3 arm.

38 Support the compression link with an appropriatelifting device.


4 - 30 Z-45/25 • Z-45/25J Part No. 107846


REV B

43 Open the ground controls side turntable cover.

44 Remove the fuel tank filler cap.

45 Using an approved hand-operated pump, drainthe fuel tank into a container of suitablecapacity. Refer to Section 2, Specifications.


Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

Be sure to only use a hand-operated pump suitable for usewith gasoline and diesel fuel.

46 Tag, disconnect and plug the fuel hoses fromthe fuel tank. Clean up any fuel that may havespilled.

47 Remove the fuel tank mounting fasteners.Carefully remove the fuel tank from themachine.

Component damage hazard. Thefuel tank is plastic and maybecome damaged if allowed to fall.

Clean the fuel tank and inspect forcracks and other damage beforeinstalling it onto the machine.

39 Use a soft metal drift to remove the uppercompression link pivot pin from the number 2arm. Remove the compression link from themachine.

Crushing hazard. The number 2arm could fall when thecompression link is disconnectedfrom the number 2 arm if notproperly supported by the overheadcrane.

Crushing hazard. The compressionlink may fall if not properlysupported when removed from thesecondary boom assembly.


Crushing hazard. The number 2arm could become unbalanced andfall when removed from thesecondary boom assembly if notproperly supported by the overheadcrane.

41 Remove the upper and lower hose and cablecovers from the number 3 arm.

42 Pull all of the cables and hoses from the number3 arm and lay them over the turntablecounterweight.



Part No. 107846 Z-45/25 • Z-45/25J 4 - 31


REV B

57 Remove the pin retaining fasteners from thenumber 4 arm at the turntable riser. Do notremove the pin.

58 Attach a lifting strap from the overhead crane tothe center point of the number 4 arm. Do notlift it.

59 Use a slide hammer to remove the number 4arm from the turntable riser through the groundcontrols side bulkhead.


Crushing hazard. The number 4arm could become unbalanced andfall when removed from themachine if not properly supportedby the overhead crane.


48 Remove the retaining fastener from the groundcontrol box and function manifold pivot plate.

49 Lower the ground control box and functionmanifold pivot plate to access the number 3 armpivot pin.

50 Attach the lifting strap from the overhead craneto the centerpoint of the number 3 arm forsupport. Do not lift it.

51 Remove the mounting fasteners from the coverlocated in the boom storage area to access thenumber 3 and number 4 arm pivot pin retainingfasteners at the turntable riser.

52 Remove the pin retaining fasteners from thenumber 3 arm at the turntable riser. Do notremove the pin.

53 Use a slide hammer to remove the number 3arm pivot pin from the turntable pivot throughthe access hole behind the ground control box.


Crushing hazard. The number 3arm could become unbalanced andfall when removed from themachine if not properly supportedby the overhead crane.

55 Remove the upper and lower hose and cablecovers from the number 3 arm.

56 Remove the secondary boom drive speed limitswitch mounting fasteners from the number 4arm at the mid-pivot end. Do not disconnect thewiring.

4 - 32 Z-45/25 • Z-45/25J Part No. 107846


REV B

5-2Secondary Boom Lift Cylinders

There are two secondary boom lift cylindersincorporated in the structure of the secondary boomassembly. These cylinders operate in parallel andrequire hydraulic pressure to extend and retract.Each secondary boom lift cylinder is equipped witha counterbalance valve to prevent movement in theevent of a hydraulic line failure.

How to Remove a SecondaryBoom Lift Cylinder



1 Lower the secondary boom to the stowedposition.

2 Raise the primary boom so that it is above thesecondary boom lift cylinder rod-end pivot pin.


3 Tag, disconnect and plug the hydraulic hoseson the secondary boom lift cylinder.


4 Remove the pin retaining fasteners from thesecondary boom lift cylinder rod-end pivot pinand barrel-end pivot pin. Do not remove thepins.

5 Attach a strap from an overhead crane to the lugon the rod end of the secondary boom liftcylinder for support. Do not apply any liftingpressure.

6 Use a soft metal drift to drive the barrel-endpivot pin half way out. Lower the barrel end ofthe secondary boom lift cylinder and let it hangdown.

7 Use a soft metal drift to drive the rod-end pivotpin half way out.

8 Remove the secondary boom lift cylinder fromthe machine.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall when removedfrom the machine if not properlyattached to the overhead crane.

Component damage hazard. Whenremoving a secondary boom liftcylinder from the machine, becareful not to damage thecounterbalance valve at the barrelend of the cylinder.

Part No. 107846 Z-45/25 • Z-45/25J 4 - 33


REV B

6-1RPM Adjustment - Ford andDeutz Models

Refer to Maintenance Procedure B-9, Check andAdjust the Engine RPM - All Models.

6-2RPM Adjustment - PerkinsModels

Refer to Maintenance Procedure B-9, Check andAdjust the Engine RPM - All Models.

6-3Flex Plate

The flex plate acts as a coupler between the engineand the pump. It is bolted to the engine flywheeland has a splined center to drive the pump.

How to Remove the Flex Plate1 Disconnect the positive battery cable from the

battery.


2 Disconnect the electrical connectors at theelectrical proportional controller, located on thedrive pump.

Ford LRG-425 EFI and Perkins models:

3 Remove the engine starter mounting fasteners.Remove the starter from the engine. Do notdisconnect the wiring.

4 Support the drive pump with an appropriatelifting device. Then remove all of the bellhousing to engine mounting bolts. Leave thepump connected to the bell housing.

Engines

4 - 34 Z-45/25 • Z-45/25J Part No. 107846


REV BENGINES

5 Carefully pull the pump and bell housing awayfrom the engine and secure it from moving.

Component damage hazard. Hosescan be damaged if they are kinkedor pinched.

6 Remove the flex plate mounting fasteners,then remove the flex plate from the engineflywheel.

Ford DSG-423 EFI models:

3 Support the drive pump assembly with anoverhead crane or other suitable lifting device.Do not apply any lifting pressure.

4 Remove the drive pump retaining fasteners.

5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

Component damage hazard. Hosescan be damaged if they are kinkedor pinched.

6 Disconnect the electrical connector from theoxygen sensor at the tailpipe. Do not removethe oxygen sensor.

7 Support the muffler and bracket assembly with asuitable lifting device.

8 Remove the exhaust pipe fasteners at themuffler.

9 Remove the muffler bracket mounting fastenersfrom the bell housing. Carefully remove themuffler and bracket assembly from the engine.

10 Support the engine with an overhead crane orother suitable lifting device. Do not lift it.

11 Remove the engine mounting plate to bellhousing fasteners.

12 Raise the engine slightly using the overheadcrane and place a block of wood under the oilpan for support.

13 Remove all of the engine bell housing retainingfasteners.

14 Carefully remove the bell housing from theengine.

15 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.

Part No. 107846 Z-45/25 • Z-45/25J 4 - 35


REV B ENGINES

How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump.

2 Ford models: Torque the flex plate mountingbolts in sequence to 14 ft-lbs / 19 Nm.Then torque the flex plate mounting bolts insequence to 20 ft-lbs / 27 Nm.

Deutz models: Torque the flex plate mountingbolts in sequence to 28 ft-lbs / 38 Nm.Then torque the flex plate mounting bolts insequence to 40 ft-lbs / 54 Nm.

Perkins models: Torque the flex plate mountingbolts in sequence to 49 ft-lbs / 66 Nm.Then torque the flex plate mounting bolts insequence to 70 ft-lbs / 95 Nm.

Ford and Deutz models

Perkins models

3 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pump endplate for your engine.

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 3/16 inch / 4.8 mm gap - Diesel Models

1/16 inch / 1.5 mm gap - Ford LRG-4250.080 inch / 2 mm gap - Ford DSG-423

4 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 61 ft-lbs / 83 Nm.

a b c d e

f

1

2

3

4 5

6

1

2 3

4 - 36 Z-45/25 • Z-45/25J Part No. 107846


REV B

5 Install the pump and bell housing assembly.

Ford LRG-425 and Deutz models: Torque thebell housing mounting bolts labeled "C" insequence to 28 ft-lbs / 38 Nm. Then torque thebell housing mounting bolts labeled "C" insequence to 40 ft-lbs / 54 Nm.

Ford DSG-423 models: Torque the bell housingmounting bolts labeled "A" and "B" in sequenceto 28 ft-lbs / 38 Nm and the mounting boltslabeled "C" to 49 ft-lbs / 66 Nm. Then torque thebell housing mounting bolts labeled "A" and "B"in sequence to 40 ft-lbs / 54 Nm and themounting bolts labeled "C" to 70 ft-lbs / 95 Nm.

Perkins models: Torque the bell housingmounting bolts labeled "B" in sequence to28 ft-lbs / 38 Nm and the mounting bolts labeled"A" to 49 ft-lbs / 66 Nm. Then torque the bellhousing mounting bolts labeled "B" in sequenceto 40 ft-lbs / 54 Nm and the mounting boltslabeled "A" to 70 ft-lbs / 95 Nm.

Component damage hazard. Wheninstalling the pump, do not forcethe pump coupler into the flexplateor damage to the pump shaft sealmay occur.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

Ford LRG-425 EFI models

ENGINES

10

6 1

8

4

11

7 5

92

12

3

C

C C

C

C

C

C

CC

C

C

C

6 1

9

5

7

32

8

4

A A

B

B

B

B

B

B

B

1 6

5 2

34

C C

CC

CC

CC

7 8

9

C

CC

BB

A

A

B

1

2

3

4

5

6

7

Ford DSG-423 EFI models

Deutz models

Perkins models

Part No. 107846 Z-45/25 • Z-45/25J 4 - 37


REV B ENGINES

6-4Engine Fault Codes -Ford Models

How to Retrieve Engine FaultCodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM also usessignals from the sensors to initiate sequential fuelinjection and make constant and instantaneouschanges to ignition timing, fuel delivery and throttleposition to maintain the engine's running conditionat its highest efficiency while at the same timekeeping exhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault code inmemory that relates to the appropriate sensor andwill turn on the Check Engine Light.

Refer to Section 5, How to Retrieve Engine FaultCodes for your specific model of engine. Use theFault Code Chart within Section 5 to aid inidentifying the fault.

4 - 38 Z-45/25 • Z-45/25J Part No. 107846


REV BHydraulic Pumps

7-1Lift/Steer Pump

How to Remove theLift/Steer Pump


1 Models without hydraulic tank shut-offvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a container of suitable capacity. Refer toSection 2, Specifications.

Models with hydraulic tank shut-off valves:Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.


2 Tag, disconnect and plug the lift/steer pumphydraulic hoses. Cap the fittings on the pump.


3 Remove the pump mounting bolts. Carefullyremove the pump.

Models without hydraulic tank shut-off valves:

Component damage hazard. Besure to fill the hydraulic tank tospecification and prime the pumpafter installing the pump.

Models with hydraulic tank shut-off valves:

Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.

open closed

Part No. 107846 Z-45/25 • Z-45/25J 4 - 39


REV B HYDRAULIC PUMPS

7-2Drive Pump

The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electro-proportional controller,located on the pump. The only adjustment that canbe made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorized EatonHydraulics center. Call Genie Industries ServiceDepartment to locate your local authorized servicecenter.

How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Disconnect the electrical connectors at theelectrical proportional controller located on thedrive pump.

2 Models without hydraulic tank shut-offvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. See capacityspecifications.

Models with hydraulic tank shut-off valves:Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.


3 Tag and disconnect and plug the hydraulichoses from the drive and lift/steer pumps. Capthe fittings on the pumps.


open closed

4 - 40 Z-45/25 • Z-45/25J Part No. 107846


REV B

a

4 Support the pump with a lifting device andremove the two drive pump mounting fasteners.

5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

6 Remove the drive pump from the machine.

Component damage hazard. Thehydraulic pump may becomeunbalanced and fall if not properlysupported.

Component damage hazard. Wheninstalling the pump, do not forcethe pump coupler into the flexplateor damage to the pump shaft sealmay occur.

Models without hydraulic tank shut-off valves:

Component damage hazard. Besure to fill the hydraulic tank tospecification and prime the pumpafter installing the pump.

Models with hydraulic tank shut-off valves:

Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.

HYDRAULIC PUMPS

How to Prime the Pump1 Connect a 0 to 600 psi / 0 to 41 bar pressure

gauge to the test port on the drive pump.

2 Remove the safety pin (if equipped) from theengine pivot plate latch.



4 Ford models: Close the valve on the LPG tankthen disconnect the hose from the tank. Thenmove the fuel select switch to the LPG position.

Perkins models: Disconnect the engine wiringharness from the fuel solenoid at the injectorpump.

Deutz models: Hold the manual fuel shutoffvalve clockwise to the closed position.

a manual fuel shutoff valve

Part No. 107846 Z-45/25 • Z-45/25J 4 - 41


REV B

5 Have another person crank the engine with thestarter motor for 15 seconds, wait 15 seconds,then crank the engine an additional 15 secondsor until the pressure reaches 320 psi / 22 bar.

6 Ford models: Connect the LPG hose to theLPG tank and open the valve on the tank.

Perkins models: Connect the engine wiringharness to the fuel solenoid.

7 Start the engine from the ground controls andcheck for hydraulic leaks.

HYDRAULIC PUMPS

4 - 42 Z-45/25 • Z-45/25J Part No. 107846

June 2012Section 4 • Repair Procedures

REV E

8-1Function Manifold Components (before serial number 27001)

The function manifold is located next to the hydraulic tank underneath the ground controls side cover.

Index SchematicNo. Description Item Function Torque

1 Proportional directionalsolenoid valve, 3 position 4 way ....... A ........... Secondary boom up/down ............... 16-20 ft-lbs / 22-27 Nm

2 Solenoid valve, 3 position 4 way ...... B ........... Steer left/right ............................................... 25 ft-lbs / 34 Nm

3 Proportional directionalsolenoid valve, 3 position 4 way ....... C ........... Turntable rotate left/right .................. 16-20 ft-lbs / 22-27 Nm

4 Proportional directionalsolenoid valve, 3 position 4 way ....... D ........... Primary boom up/down .................... 16-20 ft-lbs / 22-27 Nm

5 Solenoid valve, 2 position 3 way ...... E ........... Primary boom extend .................................. 20 ft-lbs / 27 Nm

6 Solenoid valve, 3 position 4 way ...... F ........... Platform rotate left/right andjib boom up/down (Z-45/25J) ...................... 25 ft-lbs / 34 Nm

7 Solenoid valve, 2 position 3 way ...... G ........... Primary boom retract ................................... 20 ft-lbs / 27 Nm

8 Solenoid valve, 3 position 4 way ...... H ........... Platform level up/down ................................ 25 ft-lbs / 34 Nm

9 Check valve, dual pilot operated ...... I ............ Platform level circuit .................................... 20 ft-lbs / 27 Nm

10 Check valve ....................................... J ............ Differential sensing circuit,platform rotate right andjib boom up (Z-45/25J) ..................... 12-14 ft-lbs / 16-19 Nm

11 Check valve ....................................... K ........... Differential sensing circuit,platform rotate left andjib boom down (Z-45/25J) ................ 12-14 ft-lbs / 16-19 Nm

12 Differential sensing valve .................. L ........... Meters flow to functions ............................... 25 ft-lbs / 34 Nm

13 Check valve ....................................... M .......... Differential sensing circuit,secondary boom down ..................... 12-14 ft-lbs / 16-19 Nm

14 Check valve ....................................... N ........... Differential sensing circuit,secondary boom up .......................... 12-14 ft-lbs / 16-19 Nm

15 Priority flow regulator valve,1.5 gpm / 5.7 L/min ............................ O ........... Steer circuit .................................................. 25 ft-lbs / 34 Nm

16 Relief valve, 3200 psi / 220.6 bar ..... P ........... System relief ................................................ 20 ft-lbs / 27 Nm

17 Flow regulator valve,0.1 gpm / 0.38 L/min .......................... Q ........... Primary boom load sense circuit ................. 20 ft-lbs / 27 Nm

18 Shuttle valve ...................................... R ........... Primary boom circuit ..................................4-5 ft-lbs / 5-7 Nm

19 Flow regulator valve,2 gpm / 7.6 L/min ............................... S ........... Boom extend/retract circuit .......................... 20 ft-lbs / 27 Nm

20 Flow regulator valve,0.4 gpm / 1.5 L/min ............................ T ........... Jib boom and platform

rotate circuit ................................................. 20 ft-lbs / 27 Nm

This list continues. Please turn the page.

Manifolds

Part No. 107846 Z-45/25 • Z-45/25J 4 - 43

June 2012 Section 4 • Repair Procedures

REV E

A B C D E F G

H

I

J

K

L

M

N

OPQRSTU

V

W

X

Y

Z

AA

AB

AC

1 2 3 4 5 6 7

2021 19 18 17 16 15

8

9

12

10

11

13

14

22

24

25

23

27

26

28

29

MANIFOLDS

4 - 44 Z-45/25 • Z-45/25J Part No. 107846


REV E

Function Manifold Components(before serial number 27001), continued


21 Needle valve ..................................... U ........... Platform level flow control ........................... 20 ft-lbs / 27 Nm

22 Relief valve, 2500 psi / 172 bar ........ V ........... Platform level circuit .................................... 25 ft-lbs / 34 Nm

23 Check valve ....................................... W .......... Differential sensing circuit,platform level up ............................... 12-14 ft-lbs / 16-19 Nm

24 Check valve ....................................... X ........... Differential sensing circuit,platform level down .......................... 12-14 ft-lbs / 16-19 Nm

25 Shuttle valve ...................................... Y ........... Platform level circuit ..................................4-5 ft-lbs / 5-7 Nm

26 Check valve ....................................... Z ........... Differential sensing circuit,boom retract ...................................... 12-14 ft-lbs / 16-19 Nm

27 Check valve ....................................... AA ......... Differential sensing circuit,turntable rotate right ......................... 12-14 ft-lbs / 16-19 Nm

28 Check valve ....................................... AB ......... Differential sensing circuit,turntable rotate left ............................ 12-14 ft-lbs / 16-19 Nm

29 Relief valve, 2100 psi / 145 bar ........ AC ........ Secondary boom down ............................... 25 ft-lbs / 34 Nm

MANIFOLDS

Part No. 107846 Z-45/25 • Z-45/25J 4 - 45


REV E

A B C D E F G

H

I

J

K

L

M

N

OPQRSTU

V

W

X

Y

Z

AA

AB

AC

1 2 3 4 5 6 7

2021 19 18 17 16 15

8

9

12

10

11

13

14

22

24

25

23

27

26

28

29

MANIFOLDS

4 - 46 Z-45/25 • Z-45/25J Part No. 107846


REV EMANIFOLDS

8-2Valve Adjustments -Function Manifold(before serial number 27001)

How to Adjust the SystemRelief Valve


1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST1 port on the function manifold.


3 Hold the function enable switch to the high rpmposition and activate and hold the primary boomretract switch with the boom fully retracted.

4 Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item P).

6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.

Tip-over hazard. Do not adjustthe relief valve higher thanspecified.

7 Repeat steps 2 through 5 and recheck reliefvalve pressure.

8 Remove the pressure gauge.

How to Adjust the SecondaryBoom Down Relief Valve




3 Hold the function enable switch to the high rpmposition and activate and hold the secondaryboom down switch with the secondary boomfully lowered.


5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item AC).





Part No. 107846 Z-45/25 • Z-45/25J 4 - 47


REV E


MANIFOLDS

4 - 48 Z-45/25 • Z-45/25J Part No. 107846


REV E

8-3Function Manifold Components (after serial number 27000)

The function manifold is located next to the hydraulic tank underneath the ground controls side cover.


1 Solenoid valve, 3 position 4 way ...... BM ........ Platform level up/down ................................ 25 ft-lbs / 34 Nm

2 Solenoid valve, 3 position 4 way ...... CG ........ Platform rotate left/right andjib boom up/down ........................................ 25 ft-lbs / 34 Nm

3 Flow regulator valve,2 gpm / 7.6 L/min ............................... BZ ......... Boom extend/retract circuit .......................... 20 ft-lbs / 27 Nm

4 Solenoid valve, 2 position 3 way ...... CA ........ Primary boom extend .................................. 20 ft-lbs / 27 Nm

5 Proportional directionalsolenoid valve, 3 position 4 way ....... BY ......... Primary boom up/down .................... 16-20 ft-lbs / 22-27 Nm

6 Differential sensing valve160 psi / 11 bar ................................. BG ........ Meters flow to functions ............................... 25 ft-lbs / 34 Nm

7 Proportional directionalsolenoid valve, 3 position 4 way ....... BP ......... Turntable rotate left/right .................. 16-20 ft-lbs / 22-27 Nm

8 Proportional directionalsolenoid valve, 3 position 4 way ....... BU ........ Secondary boom up/down ............... 16-20 ft-lbs / 22-27 Nm

9 Solenoid valve, 3 position 4 way ...... BF ......... Steer left/right ............................................... 25 ft-lbs / 34 Nm

10 Relief valve, 2100 psi / 145 bar ........ BV ......... Secondary boom down ............................... 20 ft-lbs / 27 Nm

11 Orifice, 0.046 inch / 1.17 mm ............ CF ......... Secondary boom down circuit

12 Check valve, 5psi / 0.3 bar ................ BT ......... Differential sensing circuit,secondary boom down ..................... 12-14 ft-lbs / 16-19 Nm

13 Check valve, 5psi / 0.3 bar ................ BW ........ Secondary boom circuit ............................... 25 ft-lbs / 34 Nm

14 Check valve, 5psi / 0.3 bar ................ BS ......... Differential sensing circuit,secondary boom up .......................... 12-14 ft-lbs / 16-19 Nm

15 Priority flow regulator valve,1.5 gpm / 5.7 L/min ............................ BB ......... Steer circuit .................................................. 25 ft-lbs / 34 Nm

16 Relief valve, 3200 psi / 220.6 bar ..... BA ......... System relief ................................................ 20 ft-lbs / 27 Nm

17 Shuttle valve ...................................... BO ........ Turntable rotate circuit ...................... 12-14 ft-lbs / 16-19 Nm

18 Check valve, 5psi / 0.3 bar ................ BQ ........ Differential sensing circuit,turntable rotate ................................. 12-14 ft-lbs / 16-19 Nm

19 Check valve, 5psi / 0.3 bar ................ CB ........ Differential sensing circuit,primary boom retract ........................ 12-14 ft-lbs / 16-19 Nm

20 Check valve, 5psi / 0.3 bar ................ BC ........ Differential sensing circuit,platform rotate left andjib boom up .................................................. 25 ft-lbs / 34 Nm

This list continues. Please turn the page.

MANIFOLDS

Part No. 107846 Z-45/25 • Z-45/25J 4 - 49


REV E

BM CG BZ CA BY BG BP BU

BF

BV

CF

BT

BW

BSBBBABOBQCBBCBD

BX

CD

BR

CE

BE

BN

BH

BK

BL

CC

BI

BJ

29

9

15

1 2 4 7

11

13

161821 20 19

24

26

27

28

30

32

33

25

23

10

22

31

3

17

12

14

865

MANIFOLDS

4 - 50 Z-45/25 • Z-45/25J Part No. 107846


REV E

Function Manifold Components(after serial number 27000), continued


21 Check valve, 5 psi / 0.3 bar ............... BD ........ Differential sensing circuit,platform rotate right andjib boom down ............................................. 25 ft-lbs / 34 Nm

22 Flow regulator valve,0.1 gpm / 0.38 L/min .......................... BX ......... Primary boom load sense circuit ................. 20 ft-lbs / 27 Nm

23 Counterbalance valve,3000 psi / 207 bar ............................. CD ........ Primary boom down circuit ............... 30-35 ft-lbs / 45-50 Nm

24 Pressure compensator valve,80 psi / 5.5 bar ................................... BR ........ Turntable rotate circuit ................................. 25 ft-lbs / 34 Nm

25 Shuttle valve ...................................... CE ........ Differential sensing circuit,primary boom up/down ..................... 12-14 ft-lbs / 16-19 Nm

26 Flow regulator valve,0.4 gpm / 1.5 L/min ............................ BE ......... Jib boom and platform

rotate circuit ................................................. 20 ft-lbs / 27 Nm

27 Needle valve ..................................... BN ........ Platform level flow control ........................... 20 ft-lbs / 27 Nm

28 Relief valve, 2500 psi / 172 bar ........ BH ........ Platform level circuit .................................... 20 ft-lbs / 27 Nm

29 Check valve, 5psi / 0.3 bar ................ BK ......... Differential sensing circuit,platform level up ............................... 12-14 ft-lbs / 16-19 Nm

30 Check valve, 5psi / 0.3 bar ................ BL ......... Differential sensing circuit,platform level down .......................... 12-14 ft-lbs / 16-19 Nm

31 Solenoid valve, 2 position 3 way ...... CC ........ Primary boom retract ................................... 20 ft-lbs / 27 Nm

32 Shuttle valve ...................................... BI .......... Platform level circuit ......................... 12-14 ft-lbs / 16-19 Nm

33 Check valve, dual pilot operated,135 psi / 9.3 bar ................................. BJ ......... Platform level circuit .................................... 20 ft-lbs / 27 Nm

MANIFOLDS

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BM CG BZ CA BY BG BP BU

BF

BV

CF

BT

BW

BSBBBABOBQCBBCBD

BX

CD

BR

CE

BE

BN

BH

BK

BL

CC

BI

BJ

29

9

15

1 2 4 7

11

13

161821 20 19

24

26

27

28

30

32

33

25

23

10

22

31

3

17

12

14

865

MANIFOLDS

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8-4Valve Adjustments -Function Manifold(after serial number 27000)

How to Adjust the SystemRelief Valve




3 Hold the function enable switch to the high rpmposition and activate and hold the primary boomretract switch with the boom fully retracted.


5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item BA).





How to Adjust the SecondaryBoom Down Relief Valve




3 Hold the function enable switch to the high rpmposition and activate and hold the secondaryboom down switch with the secondary boomfully lowered.


5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item BV).





Part No. 107846 Z-45/25 • Z-45/25J 4 - 53


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8-5Jib Boom / Platform Rotate Manifold Components(before serial number 27001)

The jib boom / platform rotate manifold is mounted to the platform support.


1 Solenoid valve, 2 position 3 way ..... AD ........ Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm

MANIFOLDS

AD

1

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8-6Jib Boom / Platform Rotate Manifold Components(after serial number 27000)

The jib boom / platform rotate manifold is mounted to the platform support.


1 Solenoid valve, 2 position 3 way ..... G ........... Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm

G

1

MANIFOLDS

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8-7Turntable Rotation Manifold Components(before serial number 27001)

The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storagecompartment.

Index SchematicNo. Description Item Function

1 Counterbalance valve .................... MM .......... Turntable rotate right

2 Counterbalance valve .................... NN ........... Turntable rotate left

MANIFOLDS

1 2

MM NN

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8-8Turntable Rotation Manifold Components(after serial number 27000)

The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storagecompartment.

Index SchematicNo. Description Item Function

1 Counterbalance valve ...................... L ............ Turntable rotate right

2 Counterbalance valve ...................... J ............ Turntable rotate left

1 2

L J

MANIFOLDS

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8-9Directional Valve Manifold Components

The directional valve manifold is mounted inside the drive chassis at the non-steer end.

IndexNo. Description Function Torque

1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm

2 Spool valve ...................................................... Directional control

MANIFOLDS

1

2

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How to Set Up the DirectionalValve Linkage

Adjustment of the directional valvelinkage is only necessary when thelinkage or valve has beenreplaced.

1 Lower the boom to the stowed position.

2 Use a "bubble type" level to be sure the floor iscompletely level.

Tip-over hazard. Failure to performthis procedure on a level floorcould compromise the stability ofthe machine resulting in themachine tipping over.

3 Check the tire pressure in all four tires and addair if needed to meet specification.

4 Remove the drive chassis cover and the non-steer axle covers.

5 Place a "bubble type" level across the drivechassis non-steer end. Check to be sure thedrive chassis is completely level.

6 To level the drive chassis, start the engine andloosen the lock nuts on both sides of theurethane cushions.

7 Push up or pull down on the threaded rod untilthe machine is completely level.

MANIFOLDS

8 Verify that the ground and drive chassis arecompletely level.

9 Tighten the nuts on both sides of the urethanecushions until they are snug. Tighten thelocknuts.

10 Check to be sure the drive chassis iscompletely level.

11 Measure the distance between the drive chassisand the non-steer axle on both sides (from theinside of the drive chassis).

If the distance is not equal and theadjustment to the linkage wascompleted with the ground anddrive chassis level, repeat steps 6through 10 OR consult GenieIndustries Service Department.

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MANIFOLDS

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8-10Traction Manifold Components, 2WD (before serial number 27001)

The traction manifold is mounted inside the drive chassis at the non-steer end of the machine.


1 Solenoid valve, 2 position 3 way ...... XX ......... Braking .............................................10-12 ft-lbs / 14-16 Nm

2 Relief valve, 250 psi / 17.2 bar ......... PP ......... Charge pressure circuit ....................10-12 ft-lbs / 14-16 Nm

3 Flow divider/combiner valve ............. QQ ........ Controls flow to drive motorsin forward and reverse .....................25-30 ft-lbs / 34-41 Nm

4 Orifice, 0.070 in / 1.78 mm ................ RR ........ Drive circuit

5 Check valve ....................................... SS ......... Drive circuit .......................................25-30 ft-lbs / 34-41 Nm

6 Check valve ....................................... TT ......... Drive circuit .......................................25-30 ft-lbs / 34-41 Nm

7 Shuttle valve, 3 position 3 way ......... UU ........ Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump and allowslow pressure flow path forbrake release and 2-speedmotor shift .........................................15-18 ft-lbs / 20-24 Nm

8 Diagnostic fitting ................................ VV ......... Testing

9 Orifice, 0.030 in / 0.76 mm ................ WW ....... Brake circuit

10 Solenoid valve, 2 position 3 way ...... OO ........ 2-speed motor shift ...........................10-12 ft-lbs / 14-16 Nm

MANIFOLDS

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78

1 2 3

9

10

5

4

6

XX PP QQ

RR

SS

TT

UUVV

WW

OO

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8-11Traction Manifold Components, 2WD (after serial number 27000)



1 Solenoid valve, 2 position 3 way ...... AF ......... Braking .............................................10-12 ft-lbs / 14-16 Nm

2 Relief valve, 250 psi / 17.2 bar ......... AD ........ Charge pressure circuit ....................10-12 ft-lbs / 14-16 Nm

3 Flow divider/combiner valve ............. U ........... Controls flow to drive motorsin forward and reverse .....................25-30 ft-lbs / 34-41 Nm

4 Orifice, 0.070 in / 1.78 mm ................ AL ......... Drive circuit

5 Check valve ....................................... S ........... Drive circuit .......................................25-30 ft-lbs / 34-41 Nm

6 Check valve ....................................... AA ......... Drive circuit .......................................25-30 ft-lbs / 34-41 Nm

7 Shuttle valve, 3 position 3 way ......... R ........... Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump and allowslow pressure flow path forbrake release and 2-speedmotor shift .........................................15-18 ft-lbs / 20-24 Nm

8 Diagnostic fitting ............................................... Testing

9 Orifice, 0.030 in / 0.76 mm ................ AE ......... Brake circuit

10 Solenoid valve, 2 position 3 way ...... AG ........ 2-speed motor shift ...........................10-12 ft-lbs / 14-16 Nm

MANIFOLDS

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78

1 2 3

9

10

5

4

6

AF AD U

AL

S

AA

R

AE

AG

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8-12Valve Adjustments, 2WDTraction Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi / 0 to 50 bar pressure


2 Hold the charge pressure relief valve andremove the cap (item PP or AD).

3 Turn the internal hex socket clockwise fully untilit stops. Install the cap.

4 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position. Note the reading on thepressure gauge.


6 Remove the pressure gauge from the drivepump. Connect the gauge to the test portlocated on the traction manifold.

7 Hold the charge pressure relief valve andremove the cap (item PP or AD).

8 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position.

9 Adjust the internal hex socket until the pressurereading on the gauge is 40 psi / 2.8 bar lessthan the pressure reading on the pump. Turn itclockwise to increase the pressure orcounterclockwise to decrease the pressure.Install the valve cap.

10 Turn the engine off and remove the pressuregauge.

MANIFOLDS

Part No. 107846 Z-45/25 • Z-45/25J 4 - 65


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8-13Traction Manifold Components, 4WD (before serial number 27001)



1 Flow divider/combiner valve .............. AB ......... Controls flow to non-steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm

2 Bi-directional flow control valve,2 gpm / 7.6 L/min ............................... AC ........ Non-steer end drive motor circuit ..... 25-30 ft-lbs / 34-41 Nm

3 Bi-directional flow control valve,1 gpm / 3.8 L/min ............................... AD ........ Steer end drive motor circuit ............ 25-30 ft-lbs / 34-41 Nm

4 Directional control valve ................... AE ......... 2 speed motor shift circuit/High speed bypass ........................... 10-12 ft-lbs / 14-16 Nm

5 Diagnostic fitting ................................ AF ......... Testing

6 Shuttle valve, 3 position 3 way ......... AG ........ Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump and allowslow pressure flow path forbrake release and 2-speedmotor shift ......................................... 15-18 ft-lbs / 20-24 Nm

7 Relief valve, 250 psi / 17.2 bar ......... AH ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm

8 Solenoid valve, 2 position 3 way ...... AI .......... 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm

9 Orifice, 0.030 inch / 0.76 mm ............ AJ ......... Brake and 2-speed motor shift circuit

10 Solenoid valve, 2 position 3 way ...... AK ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm

11 Check valve ....................................... AL ......... 2 speed motor shift circuit ................. 10-12 ft-lbs / 14-16 Nm

12 Orifice, 0.025 inch / 0.64 mm ............ AM ........ 2 speed motor shift circuit

13 Flow divider/combiner valve ............. AN ........ Controls flow to flowdivider/combiner valves 1 and 17 .... 25-30 ft-lbs / 34-41 Nm

14 Check valve ....................................... AO ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm

15 Orifice, 0.052 in / 1.32 mm ................ AP ......... Drive circuit

16 Check valve ....................................... AQ ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm

17 Flow divider/combiner valve ............. AR ........ Controls flow to steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm

18 Check valve ....................................... AS ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm

19 Check valve ....................................... AT ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm

MANIFOLDS

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1 32 4 5 6 7 8 9

17

18

19

10

11

12

13

14

15

16

AB AC AD AE AF AG AH AI AJ

AK

AL

AM

AN

AO

AP

AQ

AR

AS

AT

MANIFOLDS

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8-14Traction Manifold Components, 4WD (after serial number 27000)

The traction manifold is mounted inside the drive chassis at the non-steer end.


1 Flow divider/combiner valve ............. U ........... Controls flow to non-steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm

2 Bi-directional flow control valve,2 gpm / 7.6 L/min ............................... Z ........... Non-steer end drive motor circuit ..... 25-30 ft-lbs / 34-41 Nm

3 Bi-directional flow control valve,1 gpm / 3.8 L/min ............................... X ........... Steer end drive motor circuit ............ 25-30 ft-lbs / 34-41 Nm

4 Directional control valve ................... AV ......... 2 speed motor shift circuit/High speed bypass ........................... 10-12 ft-lbs / 14-16 Nm

5 Diagnostic fitting ............................................... Testing

6 Shuttle valve, 3 position 3 way ......... R ........... Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump and allowslow pressure flow path forbrake release and 2-speedmotor shift ......................................... 15-18 ft-lbs / 20-24 Nm

7 Relief valve, 250 psi / 17.2 bar ......... AD ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm

8 Solenoid valve, 2 position 3 way ...... AG ........ 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm

9 Orifice, 0.030 inch / 0.76 mm ............ AE ......... Brake and 2-speed motor shift circuit

10 Solenoid valve, 2 position 3 way ...... AF ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm

11 Check valve ....................................... AH ........ 2 speed motor shift circuit ................. 10-12 ft-lbs / 14-16 Nm

12 Orifice, 0.025 inch / 0.64 mm ............ AI .......... 2 speed motor shift circuit

13 Flow divider/combiner valve ............. V ........... Controls flow to flowdivider/combiner valves 1 and 17 .... 25-30 ft-lbs / 34-41 Nm

14 Check valve ....................................... AC ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm

15 Orifice, 0.052 in / 1.32 mm ................ Y ........... Drive circuit

16 Check valve ....................................... T ........... Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm

17 Flow divider/combiner valve ............. W .......... Controls flow to steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm

18 Check valve ....................................... S ........... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm

19 Check valve ....................................... AA ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm

MANIFOLDS

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1 32 4 5 6 7 8 9

17

18

19

10

11

12

13

14

15

16

U Z X AV R AD AG AE

AF

AH

AI

V

AC

Y

T

W

S

AA

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REV EMANIFOLDS

8-15Valve Adjustments, 4WDTraction Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi / 0 to 50 bar pressure


2 Hold the charge pressure relief valve andremove the cap (item AH or AD).

3 Turn the internal hex socket clockwise fully untilit stops. Install the cap.

4 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position. Note the reading on thepressure gauge.


6 Remove the pressure gauge from the drivepump. Connect the gauge to the test portlocated on the traction manifold.

7 Hold the charge pressure relief valve andremove the cap (item AH or AD).

8 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position.

9 Adjust the internal hex socket until the pressurereading on the gauge is 40 psi / 2.8 bar lessthan the pressure reading on the pump. Turn itclockwise to increase the pressure orcounterclockwise to decrease the pressure.Install the valve cap.

10 Turn the engine off and remove the pressuregauge.

8-16Valve Coils

How to Test a CoilA properly functioning coil provides anelectromotive force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil that provides this force field.


1 Tag and disconnect the wiring from the coil to betested.

2 Test the coil resistance.

Result: The resistance should be withinspecification, plus or minus 30%.

Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.

Valve Coil Resistance Specification(before serial number 27001)

Proportional directional solenoid valve, 10V DC 6 to 8Ω(schematic items A, C and D)

3 position 4 way directional valve, 10V DC 6 to 8Ω(schematic items B, F and H)

2 position 3 way solenoid valve, 10V DC 6 to 8Ω(schematic items E, G, AD, OO, XX, AI and AK)

Valve Coil Resistance Specification(after serial number 27000)

Proportional directional solenoid valve, 10V DC 6 to 8Ω(schematic items BP, BU and BY)

3 position 4 way directional valve, 10V DC 6 to 8Ω(schematic items BF, BM and CG)

2 position 3 way solenoid valve, 10V DC 6 to 8Ω(schematic items CA, CC, AF and AG)

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How to Test a Coil DiodeProperly functioning coil diodes protect theelectrical circuit by suppressing voltage spikes.Voltage spikes naturally occur within a functioncircuit following the interruption of electrical currentto a coil. Faulty diodes can fail to protect theelectrical system, resulting in a tripped circuitbreaker or component damage.


1 Test the coil for resistance. See, How to Test aCoil.

2 Connect a 10Ω resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.

Resistor, 10ΩΩΩΩΩGenie part number 27287

The battery should read 9V DC ormore when measured across theterminals.

a multimeterb 9V DC batteryc 10Ω resistord coil

Note: Dotted lines in illustration indicate areversed connection as specified instep 6

3 Set a multimeter to read DC current.

The multimeter, when set to readDC current, should be capable ofreading up to 800 mA.

4 Connect the negative lead to the other terminalon the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current reading.

6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.

Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.

Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.

9VBATTERY

10

RESISTOR

�

MULTIMETER

COIL

+

-

+

-

d

b

b

a

c

c

MANIFOLDS

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REV C





6 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor manifold. Capthe fittings on the manifold.


7 Attach a lifting strap from and overhead crane orother suitable lifting device to the turntablerotator assembly.

8 Remove the turntable rotation assemblymounting fasteners.

9 Carefully remove the turntable rotation assemblyfrom the machine.

Tip-over hazard. The machinecould tip over when the turntablerotation assembly is removed if theturntable rotation lock is not in thelocked position.

Crushing hazard. The turntablerotation assembly could becomeunbalanced and fall when removedfrom the machine if not properlysupported by the overhead crane.

Turntable Rotation Components

9-1Turntable Rotation Assembly

How to Remove the TurntableRotation Assembly


1 Raise the secondary boom until the upper pivotis above the turntable covers. Turn the machineoff.

2 Secure the turntable from rotating with theturntable rotation lock.

Tip-over hazard. The machinecould tip over when the turntablerotation assembly is removed if theturntable rotation lock is not in thelocked position.

Unlocked position

Locked position

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How to Install the Hub andBearings, 2WD Models

When replacing a wheel bearing,both the inner and outer bearingsincluding the pressed-in racesmust be replaced.

1 Be sure that both bearings are packedwith clean, fresh grease.

2 Place the large inner bearing into the rearof the hub.

3 Press the bearing seal evenly into the hubuntil it is flush.

4 Slide the hub onto the yoke spindle.

Component damage. Do notapply excessive force or damageto the lip of the seal may occur.

5 Place the outer bearing into the hub.

6 Install the washer and castle nut.

7 Tighten the castle nut to 35 ft-lbs / 47 Nm toseat the bearing.

8 Fully loosen the castle nut, then re-tighten to8 ft-lbs / 11 Nm.

9 Install a new cotter pin. Bend the cotter pinto secure the castle nut.


10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

Axle Components

10-1Hub and Bearings, 2WD Models

How to Remove theHub and Bearings, 2WD Models1 Loosen the wheel lug nuts. Do not remove them.

2 Block the non-steer wheels and place a liftingjack of ample capacity under the steer axle.

3 Raise the machine 6 inches / 15 cm and placeblocks under the chassis for support.

Crushing hazard. The machinemay fall if not properly supported.

4 Remove the lug nuts. Remove the tire and wheelassembly.

5 Remove the dust cap, cotter pin andcastle nut.


6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently prythe bearing seal out of the hub.

8 Remove the rear bearing.

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REV C

10-2Oscillating AxleLock-out Cylinders

The oscillating axle cylinders extend and retractbetween the drive chassis and the oscillating axle.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure. The valves are not adjustable.

How to Remove an OscillatingAxle Cylinder

Perform this procedure on a firm,level surface with the boom inthe stowed position.


1 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on theoscillate cylinder.


2 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.

3 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.

4 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pin.

Crushing hazard. The oscillatecylinder may become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.

5 Remove the oscillate cylinder from the machine.

AXLE COMPONENTS

Part No. 107846 Z-45/25 • Z-45/25J 5 - 1

August 2006 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theGenie Z-45/25 and Genie Z-45/25J Operator’sManual on your machine.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.



Perform all troubleshooting on afirm level surface.

Two persons will be required tosafely perform sometroubleshooting procedures.

Fault Codes

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:

· Machine parked on a firm, level surface

· Boom in stowed position

· Turntable rotated with the boom betweenthe non-steer wheels

· Turntable secured with the turntablerotation lock

· Key switch in the off position with thekey removed

· Wheels chocked

· All external AC power disconnectedfrom the machine

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August 2006Section 5 • Fault Codes

REV AFAULT CODES

Control System

How to Retrieve Control SystemFault Codes

At least one fault code is presentwhen the alarm at the platformcontrols produces two short beepsevery 30 seconds for 10 minutes.

Perform this procedure with theengine off, the key switch turned toplatform controls and the redEmergency Stop button pulled outto the on position at both theground and platform controls.

1 Open the platform control box lid.


2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platform controlbox. Do not touch the circuit board.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. If the circuit boarddoes need to be handled, maintainfirm contact with a metal part ofthe machine that is grounded at alltimes when handling the printedcircuit board OR use a groundedwrist strap.

3 Determine the error source: The red LEDindicates the error source and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

When the red LED is flashing thecode, the yellow LED will be onsolid.

4 Determine the error type: The yellow LEDindidates the error type and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.

When the yellow LED is flashingthe code, the red LED will be onsolid.

5 Use the fault code table on the following pagesto aid in troubleshooting the machine bypinpointing the area or component affected.

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REV A

Error Source Error TypeID Name ID Name

Condition Solution11121516

Value at 5VValue too highValue too lowValue at 0V

Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.

Power upcontroller withproblem corrected.

17 Not calibratedJoystick speed anddirection frozen atzero and neutral.

Calibrate joystick.

21 Boom 1 Joystick(primary boom up/down)

18 Just calibratedInitiate 1-second beepof alarm.

Self-clearing.(transient)

22 Boom 1 directionalvalves

21 Fault



1215

Value too highValue too low



17 Not calibratedCalibrate valvethresholds.

23 Boom 1 flowcontrol valve

18 Just calibrated

Normal functionexcept threshold forone or both directionsis zero.


11121516





Calibrate joystick.

31 Boom 2 Joystick(secondary boomup/down orprimary boomextend/retract)

18 Just calibratedInitiate 1 second beepof alarm.


32 Boom 2 directionalvalves

21 Fault



Continued on next page

FAULT CODES

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REV A


Condition Solution

1215





33 Boom 2 flowcontrol valve

18 Just calibrated



11121516





Calibrate joystick.

41 Turntable rotatejoystick



42 Turntable rotatedirectional valves

21 Fault



1215





43 Turntable rotateflow control valve

18 Just calibrated



44 Drive enableoverride switches 21 Fault

Enable overridedirection is frozen atneutral.


FAULT CODES

Part No. 107846 Z-45/25 • Z-45/25J 5 - 5


REV A


Condition Solution11121516





Calibrate joystick

51 Drive joystick



1215




17 Not calibratedCalibrate valvethresholds

53 Drive flow valve(EDC)

18 Just calibrated



54 Drive brake valve

21 Fault



55 High speed drivemotor Valve 21 Fault

Motor speed frozen inthe low state. Alarmsounds indicatingfault.


11121516





Calibrate Joystick

61 Steer joystick



62 Steer directionalvalves

21 Fault



FAULT CODES

5 - 6 Z-45/25 • Z-45/25J Part No. 107846


REV BFAULT CODES

Ford LRG-425 EFI Engine

How to Retrieve Ford EngineFault CodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM also usessignals from the sensors to initiate sequential fuelinjection and make constant and instantaneouschanges to ignition timing, fuel delivery and throttleposition to maintain the engine's running conditionat its highest efficiency while at the same timekeeping exhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault code inmemory that relates to the appropriate sensor andwill turn on the Check Engine Light.

Perform this procedure with thekey switch in the off position.

1 Locate the run/test toggle switch on the side ofthe ground control box.


3 Quickly activate and release the start toggleswitch/button. Do not start the engine.

4 Move and hold the run/test toggle switch to thetest position.

Result: The check engine light should turn on.The check engine light should begin to blink.

5 Continue to hold the run/test toggle switch in thetest position and count the blinks.

Before the fault codes aredisplayed, the check engine lightwill blink a code 123 three times.After the fault codes, the checkengine light will blink a code 123three times again indicating theend of the stored codes.

If any fault codes are present, theECM will blink a three digit codethree times for each code stored inmemory. It will blink the first digitof a three digit code, pause, blinkthe second digit, pause, and thenblink the third digit. For example:the check engine light blinks 5consecutive times, blinks 3 timesand then 1 time. That wouldindicate code 531.

Once a fault code has beenretrieved and the repair has beencompleted, the ECM memory mustbe reset to clear the fault codefrom the ECM. See How to ClearEngine Fault Codes from the ECM.

How to Clear Engine FaultCodes from the ECM

Perform this procedure with theengine off and the key switch inthe off position.

1 Open the engine side turntable cover and locatethe battery.

2 Disconnect the negative battery cable from thebattery for a minimum of 5 minutes.


3 Connect the negative battery cable to thebattery.

Part No. 107846 Z-45/25 • Z-45/25J 5 - 7


REV B FAULT CODES

Code Problem Cause Solution

111 Closed loop multiplier high (LPG)

Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks.

Repair wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks.

112 HO2S open/inactive (bank 1)

Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty.

Repair wiring and/or connections OR replace sensor.

113 HO2S open/inactive (bank 2)

Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty.

Repair wiring and/or connections OR replace sensor.

114 Post-cat oxygen sensor open

The post cat heated oxygen sensor wiring and/or connections are open or shorted OR sensor is cold, non-responsive or inactive for 60 seconds or longer.

Repair wiring and/or connections OR replace the post cat oxygen sensor.

121 Closed loop multiplier high (gasoline)

Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing.

Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors.

122 Closed loop multiplier low (gasoline)

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 open OR there is electro-magnetic interference from a faulty crankshaft and/or camshaft position sensor.

Adjust or replace sensors OR clean or repair fuel injectors.

124 Closed loop multiplier low (LPG)

Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty OR fuel quality is poor OR fuel system components may be faulty.

Repair wiring and/or connections OR replace sensor OR replace fuel OR test and repair the fuel system components.

133 Gasoline cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level.

Repair exhaust leaks OR there is an emissions compliance issue. Contact Ford Power Products for assistance.

134 LPG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level.


135 NG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level.


141 Adaptive lean fault - High limit (Gasoline)

Heated oxygen sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum or exhaust leaks OR one or more fuel injectors faulty or stuck closed OR fuel quality is poor OR fuel pressure is too low.

Repair heated oxygen sensor wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors.

142 Adaptive rich fault - Low limit (Gasoline)

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.

Adjust or replace sensors OR clean or repair fuel injectors.

143 Adaptive learn high (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel quality is poor OR fuel system components may be faulty.

Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR replace fuel OR test and repair the fuel system components.

144 Adaptive learn low (LPG) Engine wire harness may have an intermittent short to 5V DC or 12V DC OR fuel system components may be faulty.

Repair short in engine wire harness OR test and repair the fuel system components.

161 System voltage low Battery is faulty OR alternator is not charging OR battery supply wiring to ECM is open or shorted.

Replace battery OR repair alternator OR repair battery supply wiring to ECM.

162 System voltage high Alternator is overcharging the battery when engine RPM is greater than 1500 rpm.

Repair or replace the alternator.

211 IAT high voltage IAT sensor wiring and/or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too cold.

Repair wiring and/or connections OR replace sensor OR direct warmer air into air intake.

212 IAT low voltage IAT sensor wiring and/or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too hot.

Repair wiring and/or connections OR replace sensor OR direct cooler air into air intake.


5 - 8 Z-45/25 • Z-45/25J Part No. 107846


REV BFAULT CODES


213 IAT higher than expected (1)

Air intake temperature is greater than 200° F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty.

Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor.

214 IAT higher than expected (2)

Air intake temperature is greater than 210° F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty.

Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor.

215 Oil pressure low Faulty oil pressure sensor OR sensor wiring and/or connections open or shorted OR engine oil level too low.

Replace oil pressure sensor OR repair sensor wiring and/or connections OR fill engine oil level to specification.

221 CHT/ECT high voltage Engine cooling system is malfunctioning OR sensor wires and/or connections open or shorted OR sensor is faulty.

Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor.

222 CHT/ECT low voltage

Engine cooling system is malfunctioning and overheating 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.

223 CHT higher than expected (1)

Coolant temperature at the cylinder head is 240° F. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.


224 CHT higher than expected (2)

Coolant temperature at the cylinder head is 250° F. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.


231 MAP high pressure Open or shorted wiring and/or connections to MAP sensor OR sensor is faulty.

Repair wiring and/or connections to sensor OR replace MAP sensor.

232 MAP low voltage Open or shorted wiring and/or connections to MAP sensor OR sensor is faulty.

Repair wiring and/or connections to sensor OR replace MAP sensor.

234 BP high pressure MAP sensor is faulty OR ECM is faulty. Replace MAP sensor OR replace the ECM.

235 BP low pressure MAP sensor is faulty OR ECM is faulty. Replace MAP sensor OR replace the ECM.

242 Crank sync noise Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.

Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace sensor.

243 Never crank synced at start Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.


244 Camshaft sensor loss Camshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.


245 Camshaft sensor noise Camshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.


253 Knock sensor open Knock sensor wiring and/or connections open or shorted OR sensor is faulty.

Repair wiring and/or connections to knock sensor OR replace knock sensor.

254 Excessive knock signal Knock sensor wiring and/or connections open or shorted OR there is excessive engine vibration OR sensor is faulty.

Check for excessive engine vibration OR repair wiring and/or connections to knock sensor OR replace knock sensor.

311 Injector driver #1 open Open wiring and/or connections to fuel injector #1 OR fuel injector #1 is faulty OR ECM is faulty.

Repair wiring and/or connections to fuel injector #1 OR replace fuel injector #1 OR replace the ECM.

312 Injector driver #1 shorted Wiring and/or connections to fuel injector #1 shorted OR fuel injector #1 is faulty OR ECM is faulty.






Part No. 107846 Z-45/25 • Z-45/25J 5 - 9


REV B FAULT CODES











351 Fuel pump loop open or high side short to ground

Open wiring and/or connections to fuel pump OR fuel pump power shorted to ground OR fuel pump is faulty.

Repair wiring and/or connections to fuel pump OR replace fuel pump.

352 Fuel pump high side shorted to power

Wiring and/or connections to fuel pump shorted to power OR fuel pump is faulty.

Repair wiring and/or connections to fuel pump OR replace fuel pump.

353 MegaJector delivery pressure higher than expected

Fuel pressure too high OR LPG lockoff not sealing correctly OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty.

Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace MegaJector.

354 Megajector delivery pressure lower than expected

Fuel pressure too low OR LPG lockoff not opening completely OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty.

Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace the MegaJector.

355 MegaJector communication lost

The ECM doesn’t get any response from the MegaJector, or an incorrect response for 500ms period or longer.

Check CAN circuits for continuity and shorts to power or ground and for continuity and repair as necessary OR replace the MegaJector.

361 MegaJector voltage supply high

The MegaJector detects voltage greater than 18 volts for 5 seconds anytime the engine is cranking or running.

Repair charging system OR replace the MegaJector.

362 MegaJector voltage supply low

The MegaJector detects voltage less than 9.5 volts for 5 seconds anytime the engine is cranking or running.

Repair VBAT power or ground circuit to ECM and MegaJector OR replace battery OR repair charging system OR replace the MegaJector.

363 Megajector internal actuator fault detection

The MegaJector detects an internal fault. Open or short in power, ground or CAN circuits.s

Check power, ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault. Contact Ford Power Products for assistance.

364 Megajector internal circuitry fault detection

The MegaJector detects an internal circuitry failure. Open or short in power, ground or CAN circuits.

Check power, ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault. Contact Ford Power Products for assistance.

365 MegaJector internal communication fault detection

The MegaJector detects an internal communications failure. Open or short in power, ground or CAN circuits.

Check Power, Ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault. Contact Ford Power Products for assistance.

411 Coil driver #1 open Open wiring and/or connections to ignition coil #1 OR ignition coil #1 is faulty.

Repair wiring and/or connections to ignition coil #1 OR replace ignition coil #1.

412 Coil driver #1 shorted Wiring and/or connections to ignition coil #1 shorted OR ignition coil #1 is faulty.


413 Coil driver #2 open Open wiring and/or connections to ignition coil #2 OR ignition coil #2 is faulty.


414 Coil driver #2 shorted Wiring and/or connections to ignition coil #2 shorted OR ignition coil #2 is faulty.


5 - 10 Z-45/25 • Z-45/25J Part No. 107846


REV BFAULT CODES


511 FPP1 high voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

512 FPP1 low voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

513 FPP1 higher than IVS Limit Not used. If this fault appears on your machine, contact Genie Industries Service Department.

514 FPP1 lower than IVS Limit Not used. If this fault appears on your machine, contact Genie Industries Service Department.

521 FPP2 high voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

522 FPP2 low voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

531 TPS1 (signal voltage) high

The #1 throttle position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR throttle position sensor #1 is faulty.

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



533 TPS2 (signal voltage) high



534 TPS2 (signal voltage) low



535 TPS1 higher than TPS2

The throttle position sensor wiring and/or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty.

Be sure engine harness wiring and connections are in place and secure OR repair wiring and/or connections to one or both TPS sensors OR replace one or both TPS sensors.

536 TPS1 lower than TPS2

The throttle position sensor wiring and/or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty.

Be sure engine harness wiring and connections are in place and secure OR repair wiring and/or connections to one or both TPS sensors OR replace one or both TPS sensors.

537 Throttle unable to open Governor actuator is stuck closed OR wiring and/or connections open or shorted OR governor actuator is faulty.

Repair wiring and/or connections to governor actuator OR replace the governor actuator.

538 Throttle unable to close Governor actuator is stuck open OR wiring and/or connections open or shorted OR governor actuator is faulty.

Repair wiring and/or connections to governor actuator OR replace the governor actuator.

545 Governor interlock failure Engine harness wiring and/or connections open or shorted OR there is a poor system ground connection OR ECM is faulty.

Repair wiring and/or connections in engine harness OR replace the ECM.

551 Max governor speed override

ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head.

Re-program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head.

552 Fuel rev limit ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head.


553 Spark rev limit ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head.


611 COP failure Loose wire connections to ECM OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM.

612 Invalid interrupt Loose wire connections to ECM OR ECM is faulty.


613 A/D loss Loose wire connections to ECM OR ECM is faulty.


Part No. 107846 Z-45/25 • Z-45/25J 5 - 11


REV B FAULT CODES


614 RTI 1 loss Loose wire connections to ECM OR ECM is faulty.


615 Flash checksum invalid Loose wire connections to ECM OR ECM is faulty.


616 RAM failure Loose wire connections to ECM OR ECM is faulty.


631 External 5V DC ref lower than expected

Engine harness wiring and/or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM.

632 External 5V DC ref higher than expected

Engine harness wiring and/or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM.





5 - 12 Z-45/25 • Z-45/25J Part No. 107846


REV A

Ford DSG-423 EFI Engine

How to Retrieve Ford EngineFault CodesThe ECM constantly monitors the engine by theuse of sensors on the engine. The ECM also usessignals from the sensors to initiate sequential fuelinjection and make constant and instantaneouschanges to ignition timing, fuel delivery and throttleposition to maintain the engine's running conditionat its highest efficiency while at the same timekeeping exhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault code inmemory that relates to the appropriate sensor andwill turn on the Check Engine Light.

Perform this procedure with thekey switch in the off position.

1 Locate the run/test toggle switch on the side ofthe ground control box.


3 Quickly activate and release the start toggleswitch/button. Do not start the engine.

4 Move and hold the run/test toggle switch to thetest position.

Result: The check engine light should turn on.The check engine light should begin to blink.

5 Continue to hold the run/test toggle switch in thetest position and count the blinks.

Before the fault codes aredisplayed, the check engine lightwill blink a code 123 three times.After the fault codes, the checkengine light will blink a code 123three times again indicating theend of the stored codes.

If any fault codes are present, theECM will blink a three digit codethree times for each code stored inmemory. It will blink the first digitof a three digit code, pause, blinkthe second digit, pause, and thenblink the third digit. For example:the check engine light blinks 5consecutive times, blinks 3 timesand then 1 time. That wouldindicate code 531.

Once a fault code has beenretrieved and the repair has beencompleted, the ECM memory mustbe reset to clear the fault codefrom the ECM. See How to ClearEngine Fault Codes from the ECM.

How to Clear Engine FaultCodes from the ECM

Perform this procedure with theengine off and the key switch inthe off position.

1 Open the engine side turntable cover and locatethe battery.

2 Disconnect the negative battery cable from thebattery for a minimum of 5 minutes.


3 Connect the negative battery cable to thebattery.

FAULT CODES

Part No. 107846 Z-45/25 • Z-45/25J 5 - 13


REV A

Code DescriptionCode Description111 CL (Closed Loop) high LPG

112 EGO open / lazy pre-cat 1

113 EGO open / lazy pre-cat 2/post-cat 1

114 EGO open / lazy post-cat 1

115 EGO open / lazy post-cat 2

121 CL (Closed Loop) high gasoline bank 1

122 CL (Closed Loop) low gasoline bank 1

124 CL (Closed Loop) low LPG

133 Gasoline catalyst monitor 1

134 LPG catalyst monitor

141 AL (Adaptive Learn) high gasoline bank1

142 AL (Adaptive Learn) low gasoline bank 1

143 AL (Adaptive Learn) high LPG

144 AL (Adaptive Learn) low LPG

161 Battery Voltage high

162 Battery Voltage low

163 AUX analog PD1 high

164 AUX analog PD1 low

165 AUX analog PU3 high

166 AUX analog PU3 low

167 AUX analog PUD1 high

168 AUX analog PUD1 low





181 AUX DIG1 high

182 AUX DIG1 low

183 AUX DIG2 high

184 AUX DIG2 low

185 AUX DIG3 high

186 AUX DIG3 low

For further engine fault code troubleshooting anddiagnostic information, refer to the Ford DSG-423EFI Service Manual (EDI part number 1060040).

Ford DSG 423 EFI Service ManualGenie part number 119494

211 IAT (Intake Air Temperature) high voltage

212 IAT (Intake Air Temperature) low voltage

213 IAT (Intake Air Temperature) higher than expected 1

214 IAT (Intake Air Temperature) higher than expected 2

215 Oil pressure low

221 ECT / CHT (Engine/Cylinder Head Coolant Temperature) high voltage

222 ECT / CHT (Engine/Cylinder Head Coolant Temperature) low voltage

223 CHT higher than expected 1

224 CHT higher than expected 2

225 ECT higher than expected 1

226 ECT higher than expected 2

231 MAP (Manifold Absolute Pressure) high pressure

232 MAP (Manifold Absolute Pressure) low voltage

234 BP (Barometric Pressure) high pressure

235 BP (Barometric Pressure) low pressure

242 Crank sync noise

243 Never crank synced at start

244 Cam loss

245 Cam sync noise

246 Crank loss

253 Knock1/2 sensor open 1

254 Knock1/2 excessive signal 1

FAULT CODES

5 - 14 Z-45/25 • Z-45/25J Part No. 107846


REV A

Code DescriptionCode Description



261 FP (Fuel Pressure) high voltage

262 FP (Fuel Pressure) low voltage

271 FT (Fuel Temperature) gasoline high voltage

272 FT (Fuel Temperature) gasoline low voltage

273 FT (Fuel Temperature) gaseous fuel high voltage

274 FT (Fuel Temperature) gaseous fuel low voltage

311 Injector Loop Open or Low-Side Short to Ground 1

312 Injector Coil Shorted 1







351 FPump motor loop open or high-side shorted to ground

352 FPump motor high-side shorted to power

353 EPR delivery pressure higher than expected

354 EPR delivery pressure lower than expected

355 EPR comm lost

359 Fuel run-out longer than expected

361 EPR voltage supply high

362 EPR voltage supply low

363 EPR internal actuator fault detection

364 EPR internal circuitry fault detection

365 EPR internal comm fault detection

411 Primary Loop Open or Low-Side Short to Ground 1

412 Primary Coil Shorted 1







531 TPS1 (Throttle Position Sensor) high voltage

532 TPS1 (Throttle Position Sensor) Low voltage

533 TPS2 (Throttle Position Sensor) high voltage

534 TPS2 (Throttle Position Sensor) low voltage

535 TPS1 (Throttle Position Sensor) higher than TPS2

536 TPS1 (Throttle Position Sensor) lower than TPS2

537 Unable to reach higher TPS (Throttle Position Sensor)

538 Unable to reach lower TPS (Throttle Position Sensor)

539 TPS1/2 simultaneous voltages





551 Max govern speed override

552 Fuel rev limit

553 Spark rev limit

FAULT CODES

Part No. 107846 Z-45/25 • Z-45/25J 5 - 15


REV A

Code DescriptionCode Description611 COP failure

612 Invalid interrupt

613 A/D loss

614 RTI 1 loss

615 Flash checksum invalid

616 RAM failure

631 5VE1 low voltage

632 5VE1 high voltage

633 5VE2 high voltage

634 5VE2 low voltage

635 5VE1/2 simultaneous out-of-range

641 Rx Inactive

642 Rx Noise

643 Invalid Packet Format

644 Shutdown Request

646 CAN Tx failure

647 CAN Rx failure

648 CAN address conflict failure

655 RTI 2 loss

656 RTI 3 loss

711 Relay control ground short

712 Relay coil open

713 Relay coil short to power

714 FPump relay control ground short

715 Fpump relay coil open

716 Fpump relay coil short to power

721 Start relay control ground short

722 Start relay coil open

723 Start relay coil short to power

731 PWM1-Gauge1 open / ground short

732 PWM1-Gauge1 short to power





741 PWM4 open / ground short

742 PWM4 short to power

743 PWM5 open / ground short

744 PWM5 short to power

761 MIL (Malfunction Indicator Light) control ground short

762 MIL (Malfunction Indicator Light) open

763 MIL (Malfunction Indicator Light) control short to power

771 Tach output ground short

772 Tach output short to power

1629 J1939 TSC1 message receipt lost

1630 J1939 ETC message receipt lost



FAULT CODES

5 - 16 Z-45/25 • Z-45/25J Part No. 107846



Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions in the appropriateOperator's Manual on your machine.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

Part No. 107846 Z-45/25 • Z-45/25J 6 - 1

Section 6 • SchematicsAugust 2006

August 2006Section 6 • Schematics

6 - 2 Z-45/25 • Z-45/25J Part No. 107846

Electrical Symbols Legend

Connectionno terminal

P3

Horn buttonnormally open

T-circuitsconnect

FB

Flashing beacon

Diode

Circuits crossingno connection

Quick disconnectterminal

BLK

WHT

T-circuits connectat terminal

WHT #21 TB21

Battery

+

-

Circuit breakerwith amperage

15A

CB1

Horn or alarm

H1 Emergency Stopbutton normally

closed

P1

Coilsolenoid or relay

Key switch(before serial number 22051)

KS1

GROUND

PLATFORM

Power relay

PR1

Toggle switch SPDT

TS2

START

ENG

INE

Toggle switch DPDT

TS6

UP

DO

WN

PLATFOR

MLEVEL

Gauge sending unit

HM

Hour meter

N.O.OTS2

Oil temperatureswitch

normally open

N.O.CTS1

Coolant temperatureswitch

normally open

Oil pressure switchnormally closed

N.C.OPS1

BLK

FS1

Foot switch

PumpAux

Auxiliary pump

FAN

Hydraulic oilcooling fan

G1

Gauge

Tilt sensorLED

L3

Limit switch

N.C.H.ON.O.H.C

LS3

Fusewith amperage

25A

F1

510

Resistor withohm value

Starting aid:glow plug orflame ignitor

Control relay contactnormally open

CR4N.O.

Coil

Fuel or RPMsolenoid

PU

LL

IN

HO

LD

CA B

Key switch(after serial number 22050)

KS1

REV A

August 2006 Section 6 • Schematics

Hydraulic Symbols Legend

Part No. 107846 Z-45/25 • Z-45/25J 6 - 3

Pumpfixed displacement

Motorbi-directional

Check valve

2 position, 3 way, shuttle valve

Double actingcylinder

Priorityflow regulator valve

Differentialsensing valve

Solenoid operatedproportional valve

Brake

Pilot operated 3 position,3 way, shuttle valve

Filter withbypass valverelief setting

25 psi(1.7 bar)

Motor2-speed,

bi-directional

Pumpbi-directional,

variable displacement

E

Pump prime mover(engine or motor)

Directional valve(mechanically activated)

o

Relief valvewith pressure setting

200 psi(13.8 bar)

Orifice with size

.035"(0.89 mm)

Solenoid operated 3 position,4 way, directional valve

Directional valvepilot operated

2 position, 2 way

Flow divider/combiner valvewith pressure balancing orifice

and flow percentages

50% 50%

Counterbalance valvewith pressure and pilot ratio

(206.8 bar)3000 psi

3:1

Solenoid operated 2 position,3 way, directional valve

2 position, 2 waysolenoid valve

Solenoid operated3 position, 4 way,

proportional directional valve

Shut off valve

REV A


6 - 4 Z-45/25 • Z-45/25J Part No. 107846

PowerRelay

StarterRelay

Fuel PumpRelay

F5-15A

F4-15A F3-20A

F2-5A F1-30A

PowerRelay

StarterRelay

FuelPumpRelay

F5-15A

F4-15AF3-10A

F2-5AF1-10A

Empty

Ford LRG-425 EFI (before serial number 30142)

Ford DSG-423 EFI (after serial number 30141)

Ford Engine Relay LayoutREV A

Ford LRG-425 EFI Engine Wire Harness


351 BR-W 18

359 GY-R 18

358 LG-BK 18

TWR

B

A

C

MAP_CONN

361 R 16 361 R 16 361 R 16

INJECTOR #1 INJECTOR #3 INJECTOR #4 INJECTOR #2

ACT

151 LB-BK

307 BK-Y 18

570 BK-W 12570 BK-W 12

570 BK-W 16

570 BK-W 16

570 BK-W 16

34 GROUND

25 IVS

14 FPP1

39 R-W 18570 BK-W 1616 WATER TEMP

WATERTEMP

30AF1

16 R-LG 181 VSW

5AF216 R-LG 18

20AF3

ECT

361 R 12361 R 14361 R 14

351 BR-W 18

359 GY-R 18

351 BR-W 18

359 GY-R 1833 ANA RTN

31 VREF

9 VBATT

360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

198 DG-O 18

18 O-Y 1838 EGR ANA IN

32 ANA AUX PD1

37 ANA AUX PU1

12 FPP2

40 EGR PWM

41 EGR REC360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

198 DG-O 18

18 O-Y 18

361 R 16

16 R-LG 18

307 BK-Y 18

351 BR-W 18

359 GY-R 18

570 BK-W 16

570 BK-W 16

360 BR-PK 18

352 BR-LG 18

114 LB-Y 18

150 DG-W 18

354 LG-R 18

151 LB-BK 18

198 DG-O 18

18 O-Y 18

555 T 16

556 W 16

557 BR-Y 16

558 BR-LB 16

358 LG-BK 18

743 GY 18

145 VOLT REF

3VSW

23EGR RECIRC

22EGR PWM

2POWER GROUND

1POWER GROUND

21EGR

20MAP

27IAT

16FPP 2

15FPP 1

11INJ 5

6INJ +

7INJ 1

12INJ 6

28ECT

17IVS

13ANA_RTN

18AUX ANA PU1

19AUX ANA PD1

31AUX OUT 2

8INJ 3

9INJ 4

10INJ 2

J1 BLACK

74 GY-LB 1824EGO 1

452 GY-R 18

282 DB-O 18

349 DB 18

350 GY 18

34CAM +

35CAM -

32CRANK +

33CRANK -

30KNK -

29KNK +

26EGO 3

570 BK-W 16

570 BK-W 16

351 BR-W 18

359 GY-R 18

354 LG-R 18

358 LG-BK 18

361 R 16

555 T 16

556 W 16

557 BR-Y 16

558 BR-LB 16

359 GY-R 18

743 GY 18

16 R-LG 18

151 LB-BK

570 BK-W 16

CRANK361 R 14361 R 16

361 R 16

5VBAT

VBAT4

392 R-LG 1825EGO 2

570 BK-W 16

359 GY-R 18

74 GY-LB 18

361A R 16

392 R-LG 18

361A R 16

359 GY-R 18

570 BK-W 16

O2 SENSOR

O2SENSOR

361 R 14

CAM

307 BK-Y 18

359 GY-R 18

361A R 16

851 Y-R 18

850 Y-BK 18

LOCKOFF SOLENOID

361A R 16

242 DG 18

361A R 16

77 DB-Y 18

TRIM VALVE

361A R 16

172 LB-R 18

169 LG-BK 18

148 Y-R 18

317 GY-O 18

15 R-Y 18

458 O-BK 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

77 DB-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

33OVERSPEED

5AUX OUT 1

13COIL 4

3COIL 3

2COIL 2

1COIL 1

4SPK PWR GROUND

35RS 232 RX

34RS 232 TX

21RS 485 -

20RS 485 +

19CAN -

18CAN +

12ROAD SPEED -

11ROAD SPEED +

17GOV SELECT 2

16GOV SELECT 1

10FUEL PUMP MON

8TACH

7OIL PRESSURE

6BRAKE SWITCH

31TPS2

30TPS1

23FUEL LOCKOFF

22STARTER LOCKOUT

14FUEL SELECT

15AUX ANA PU2

27MIL

26GASEOUS TRIM

29DBW -

28DBW +

24COIL 5

25COIL 6

32RELAY CONTROL

9FUEL PUMP

COIL 2

VBAT

COIL 11

12

2

3

3

15 R-Y 18

926A LB-O 18

172 LB-R 18

169 LG-BK 18

148 Y-R 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 18

238 DG-Y 18

317 GY-O 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18SHDA

E

F

B

C

D

MTRSHD6TWR

D

C

B

F

E

A

MTRTWR6

2

3

1

4

5

6

THROTTLE

317 GY-O 18

151 LB-BK 18

357 Y-W 18

355 GY-W 18

351 BR-W 18

359 GY-R 18351 BR-W 18

359 GY-R 18

FPP_COMMD

C

A

TWR

RTN

5V

RX

BTX

351 BR-W 18

359 GY-R 18

458 O-BK 18

669 DG-W 18

87A85

86 30

87

458 O-BK 18

342 LG-P 18

15 STARTER IN (INTERUPT)

13 STARTER CONTROL

39 STARTER IN (AUTOCRANK)32 R-LB 16

32 R-LB 16

32 R-LB 16

5 FUEL PUMP787A PK-BK 16

87A85

86 30

87

16 R-LG 18

342 LG-P 18

361 R 14

87A85

86 30

87

15AF4

FUEL PUMPRELAY

787A PK-BK 16

361 R 1615AF5

21 AUX OUT1

20 RS 232+

18 RS 232-

3 RS 485-

11 RS 485+

172 LB-R 18

169 LG-BK 18

148 Y-R 18

458 O-BK 18

669 DG-W 18

461 O 18

642 DG-O 18

459 O-LG 18

662 DG-P 18

349A DB 18

307 BK-Y 18

306 T-LB 18

72 Y-BK 18

71 O-LG 18

658 PK-LG 18

11 T-Y 18

253 DG-W 18

511 LG-R 184 BRAKE

26 OIL PRES

2 TACH

6 MIL

7 FUEL SELECT

10 AUX ANA PU2

24 GOV SELECT 1

23 GOV SELECT 2

35 ROADSPEED +

36 ROADSPEED -

30 OVERSPEED

28 CAN +

29 CAN -

570 BK-W 16

361A R 16

459 O-LG 18

662 DG-P 18

MTRSHD4

TWR

D

C

B

A

MTRTWR4

PLUG (GROUND)

PLUG (RELAY POWER)

PLUG (CAN +)

PLUG (CAN -)

SHD

D

B

A

C

253 DG-W 18OIL PRESSURE

361 R 16

STARTERRELAY

POWERRELAY

FORD42 PIN

CONNECTOR


Ford LRG-425 EFI Engine Wire Harness

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N

6 - 5 Z-45/25 • Z-45/25J Part No. 107846

REV A

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A

Part No. 107846 Z-45/25 • Z-45/25J 6 - 6

Ford DSG-423 EFI Engine Wire Harness


REV A

GY/R 18

Y/W 18

R 14

31 VREF

23 GOV SELECT 2

1 VSW

36 ROADSPEED -

R/LB 16

GY/O 18

GY/W 18

LB/DG 18

BR/W 18

R 16

R 16R 16

87A

RING

BATT(+)

LB/PK 16

W/PK 16

R/LB 16

R 14

33 ANA RTN

32 ANA AUX PD1

12 FPP2

37 AUX ANA PU2B

14 FPP1

35 ROADSPEED +

24 GOV SELECT 1

BK/W 18

W 18 W 18

R/T 18

R/Y 18

LB/PK 16

PK/BK 16

LG/P 18

R/LG 18

R 16

R 12

R/T 14

R/LG 18

O/LG 18

RELAYED POWER

F5

15A

EPR

F1

10A

R16

PK/BK 16 PK/BK 16

R/LG 18

F2

VSW5A

GROUND

RING

BK/W 12

DG/P 18

FORD42 PIN

CONNECTOR

RING

STARTERSOLENOID

3

2

6

5

1

4

BOSCH THROTTLE

FUEL PUMP

F4

15A

DG/W 18

87

30

85

86RELAYOMRONFPP

STARTER RELAY

ECM

F3

10A

SHD

R/LG 18

CANTERMINATIONCONNECTOR

BR/W 18

BK/Y 18

R/LG 18

LB/R 18

87A

85

86

87

30

POWER RELAY

GY/R 18

LB/Y 18

DG/O 18

DB/W 18

LB/BK 18

T/LB 18

LG/BK 18

TWR

2

1

3

ALTERNATOR

6GROUND

3CAN +

4UNUSED

5UNUSED

7POWER

8UNUSED

1CAN -

CAN + TERM

EPRCONNECTOR

18 FUEL PUMP -

3 RS 232-

4 BRAKE

7 FUEL SELECT

6 MIL

25 IVS

5 FUEL PUMP +

29 CAN -

28 CAN +

11 RS 232+

26 OIL PRES

39 AUX OUT1

27 AUX OUT 2

2 TACH

10 AUX ANA PD1B

15 START IN INTERUPT

19 START IN AUTOCRANK

O 18

BK/R 16

LB/PK 16

W/PK 16

W/LB 18

Y/DB 18

PK/LG 18

BK/O 18

PK/BK 16

DG 18

DG/P 18

O/LG 18

T/GN 18

T/Y 18

DG/W 18

P/LB 18

O/LG 18

21 AUX PWM 5

16 AUX PWM 4

R/BK 18

R/W 18

R 16

PK/BK 16

LB/O 18

R/LG 18

R 16

87A

85

86

87

30

FUEL PUMP RELAY

BK/LG 18

HO2S #2

GY/LB 18

GY/R 18

R 16

GY/R 18

BR/W 18

R 16

LG/R 18

W/LG 18

BK/LB 18

LG/W 18

GY/YL 18

GY/R 18

MTRTWR4

CHT

D

B

A

C

SHD

HO2S #1

GASOLINESENSORINTERFACE

A

B

C

D

TWRGY/R 18

R 12

2

OIL PRESSURE

R/W 18

W/BK 18

PK/LG 18

BR/Y 16

BK/LG 18

O 18

LB/BK 18

GY/W 18

R/LG 18

W/LB 18

LG/W

DG/W 18

DG/BK

DBL 18

LG/BK 18

GY/R 18

DG/P

W/PK 18

W/PK 18

GY/R 18

(FPP2)

T/GN 18

R/BK 18

BK/R 16

GY/O 18

R/T 16

R/Y 18

BK/W 16

BK/R 16

LB/O 18

W 16

T 16

BK/LB 18

R/T 16

BR/LB 16

BK/W 16

DG 18

Y/W 18

Y/R 18

LB/Y 18

P/LB 18

T/Y 18

BK/O 18

LG/R 18

GY 18

W/R 18

BK/Y 18

DB/W 18

T/LB 18

GY 18

GY/R 18

LB/R 18

GY/Y 18

BR/W 18

W/LG 18

GY/LB 18

BK/W 16

Y/BK 18

Y/RD 18

RD/T 14

DG 18

O 18

GY/R 18

GY 18

BR/W 18

FP REC

LB/DG 18

DG/P 18

R/LG 18

Y/BK 18

O/LG 18

FUEL PUMP

LG/P 18

(FUEL PUMP)

DG/P 18

Y/DB 18

DB/O 18

DG/O 18

O/LG 18

W/BK 18

R 16

Y/RD 18

GY/R 18

8CAN -

5UNUSED

25V REF

1ANA RTN

3PC TX

4PC RX

6UNUSED

7CAN +

DIAGNOSTIC CONNECTOR

82DBW -

79VBAT

73RELAY

70INJ6 LS

67INJ4 LS

64INJ1 LS

61EGOH 2

55PC TX

52KNOCK -

43TACH

37ECT

34GOV 1

315V EXT 2

28CAM -

25CRANK +

22EGO2

195V EXT 1

16CAN2 -

10UEGOP

81GROUND

80DBW +

69GROUND

68INJ5 LS

72STARTER

74MIL

75UEGO H

77LOCKOFF

60VBAT

56PC RX

62EGOH 1

63INJ HS

65INJ2 LS

44VSW

47TPS 1

48TPS 2

51KNOCK +

53FPP1

325V RTN 2

33PULSE IN

36IAT

205V RTN

21EGO1

23MAP

26CRANK -

29SPEED +

27CAM +

17CAN2 +

14CAN1 +

15CAN1 -

9UEGOC

8UEGOS

11UEGPR

30SPEED -

66INJ3 LS

88AUX PWM4 REC

85AUX PWM1

76AUX PWM7

58KNOCK 2-

49(FUELSELECT)AUX DIG1

46AUX ANA PUD1

40(IVS) AUX ANA PU3

13(FRP) AUX ANA PD2

7SPK_COIL3B

4SPK_GND

1SPK_COIL1A

87AUX PWM2

83AUX PWM5 REC

84AUX PWM5

86AUX PWM4

89AUX PWM3 REC

71AUX PWM8

59VBAT PROT

57KNOCK 2+

45AUX ANA PUD2

50AUX DIG 2

35OIL PRESS

38(FRT) AUX ANA PU1

39(LPTEMP) AUX ANA PU2

41(BRAKE) AUX DIG 3

24AUX ANA PUD3

12AUX ANA PD1

2SPK_COIL1B

3SPARK_COIL2A

5SPK_COIL2B

78AUX PWM6

90AUX PWM3

54FPP2-IVS

42(GOV2) AUX DIG 4

6SPK_COIL3A

18AUX ANA PD3

O/LG 18

BR/W 18

BR/W 18

LG/BK 18

DG/P 18

B

A

LPGTEMPERATURE

A

B

TWR

LPGLOCKOFF

BOSCHTMAP

R 16

W/R 18

GY/R 18

DG/P 18

Y/R 18

KNOCKSENSOR

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/O 18

BK/Y 18

BK/LB 18

LB/BK 18

BK/W 16

BK/W 16

T/LB 18

LB/R 18

DG/BK

LG/W

R 16

T 16R 16

R 16

R 16

W 16

INJECTOR CYL #2

R 16

BN/LB 16

BR/Y 16

R 16

IGNITION COILS

CYL #3 CYL #4 CYL #1

INJECTOR CYL #4

INJECTOR CYL #3

INJECTOR CYL #1

ENGINE ECMCONNECTOR

BR 16 BR 1634 GND

P23 BAT

C35 RPM

C128 RPM

C41 RPM

C10 BESL

C21 IGN

C135 FP

C39 LP

C127 TSW

R33 STR

C135 FP+

Section 6 • SchematicsAugust 2006

Ford DSG-423 EFI Engine Wire Harness


Electrical Schematic, Z-45/25Ford LRG-425 EFI Models (before serial number 30142)

1

2

3

4

5

6

7

8


6 - 7 Z-45/25 • Z-45/25J Part No. 107846

REV C

P1

34

TT

SR

D

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

STA.

A

I

S

FLD.

REGULATOR

+

-

RD

P2

0B

AT

RD

TB20

GND.

BAT.

ALTERNATOR

LINK

FUSE

51

0

R4

6H

RN

BK

/RD

C1

07

AF

WH

C41RPM OR/BK

BA

T-R

D

CR5CR5

C4

6H

RN

BK

/RD

NO

CB1

RD

CB2

15A

TB41

TB23

KS1

PLAT

GRND

P1RD

P3

HORN

BK

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BK

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

AU

XIL

LA

RY

PO

WE

RR

EL

AYIG

NIT

ION

/STA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

FORD 42 PIN QUICK DISCONNECTENGINE HARNESS #2

TB35

TS2

TS64

STARTERAUX

PUMP

RE

LA

Y

PR1

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

CR1

NO

CR1

C3

3S

TR

BK

P2

3B

AT

WH

FE

H(1

6)

PIN

1

BL

/RD

FE

H(7

2)

PIN

7

BK

/RD

FE

H(3

07

A)

PIN

23

P2

0B

AT

RD

FE

H(3

61

)P

IN9

BL

/WH

FE

H(6

58

)P

IN6

GR

FE

H(4

58

)P

IN1

8

TB21

NO

CR2 CR2

TS51

TB27

TS1

WH

TS52

TB33

P1

34

BA

TR

D

HM

C5-13

L2T

ES

T

C1

08

ES

LB

L/W

H

C2

1IG

NW

H

C4

5G

EN

GR

/WH

FB1

TS53

TB39

TS47

RD-(FS)FS1

NOTE:1) All switches and contacts are shown with the boomin the stowed position and the keyswitch off.

(GN

D)

BR

FE

H(5

70

)P

IN3

4

TS3

CH

EC

KE

NG

INE

LE

D

12 V

DC

CHECK

ENGINE

TILT

AL

AR

M

+

_

P2

2H

RN

BK

RD

WH

BR

NB

K

BL

/WH

FE

H(7

87

A)

PIN

5

FUELPUMP

BL

/WH

BK

FU

EL

PU

MP

P2RD

WHWH-(FS)

H2

H1

C2

P-4

C1

P-9

C3

5R

PM

BK

/RD

TS54

ENGINE

SPEED

TS4

P24FS WH

P26ESTP BK

C41RPM OR/BK

C22LS RD

RD

RD

BRN

C1

28

RP

MO

R/R

D

C4

5G

EN

GR

/WH

C2

P-7

C2

P-1

C3

9L

PB

L/R

D

C1

P-7

C3

3S

TR

BK

C1

P-1

C2

7A

UX

RD

C1

P-2

C2

8T

TA

RD

/BK

C7

P-2

P2

3B

AT

WH

C3

P-9

C4

6H

RN

BK

/RD

C4

1R

PM

OR

/BK

OR

/RD

FE

H(3

06

)P

IN2

4

TB42

P26ESTP BK

P25FS RD

P24FS WHC9P-2

C9P-3

C7

P-1

C28TTA RD/BK C28TTA RD/BK

FO

OT

SW

.H

IGH

FO

OT

SW

.L

OW

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

.

C1

28

RP

MO

R/R

D

C35RPM BK/RD

C1

B-9

C2

B-4

C5-9

C5

-12

LP

GA

S

LP

FU

EL

SE

LE

CT

GA

S

C2

B-7

C2

B-1

C5

-10

EN

GIN

ES

TA

RT

C1

B-7

C6

-34

C5-8

C7

B-4

C2

B-3

C2

8T

TA

RD

/BK

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

C5

-5

C6

-9

C5

-17

C5

-24

C6

-27

C1

P-1

C1

P-2

C7

B-2

C3

B-9

C5-3

C5

-19

C39LP BL/RD

C7

B-1

TB38

B1

D1

R16

M3

M2

S8

M4

C5

-18

FUSE 10A (ONLY ON WORKLIGHTS)

TS48

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30

C2

P-1

2

C2

P-11

C3

P-4

RD

RD

L30

CR23

L29

RD

C4

B-1

2

C3

B-4

DL

ITE

WH

C2

P-1

0

PBOX GND

C2

P-9

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

RD

C4

B-11

CR23

NO

C127TSW GR

TB24

BL/RD

C1

34

PW

RG

RC

2B

-5R

DC

2P

-5

L4

TB134

FUSE 10A

C2

1IG

NW

HF

EH

(71

)P

IN2

1

C4

1R

PM

OR

/BK

FE

H(11

)P

IN2

CR39NC CR39

BR

P24BAT RD

R3

3S

TR

BK

FE

H(3

2)

PIN

15

C3

3S

TR

BK

FE

H(3

2)

PIN

13

C5

-2

WH

P134BAT RD

C5

-11

BA

T-R

D

BA

T-R

D

C1

35

FP

EN

GIN

ES

TA

RT

FU

EL

SE

LE

CT

A C

B


1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 8


REV C

NOTES:1. ALL LIMIT SWITCHES SHOWNWITH BOOM IN STOWED POSITIONEXCEPT AS NOTED.

SWITCH SHOWN WITH BOOMROTATED PAST EITHER NON-STEERWHEEL.

2

C1B & C1P - GRAYC2B & C2P - BLACKC3B & C3P - GREENC4B & C4P - BROWN

WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

H3

C2

2-2C

5-2

5

C2

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AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

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C2

1-2

C2

0-2

C1

6-2

C1

7-2

C1

29

DA

BK

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

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OR

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C1

4P

LU

OR

C2

1-1

C2

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C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

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BK

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LS

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SE

CO

ND

AR

YB

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MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

1-

PR

IMA

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BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

LS

2-

PR

IMA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

3-

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6

RD

C11

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K-7

C1

0-2

14

R11

SB

DB

L/B

K

R1

0S

BU

BL

C1

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C1

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LS2

22

21

C1

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WH

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BK

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13

2

8587a 87

8630

CR37

R4

TR

LW

H

R5

TR

RW

H/B

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R2

PB

DR

D/B

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C1

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C1

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C1

2-1

C1

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R1

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D

8587a 87

8630

C6

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C6

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C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

CW

BL

/BK

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6S

CC

BL

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

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C3

2TA

WH

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C2

8-1

C2

6-1

H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

J3 J1 J1

C1

5P

LD

OR

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C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

P2

2L

SB

K

TB18

TB17

C4

B-5

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C1

7JU

GR

TS58

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C3

P-8

C3

P-7

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

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SB

DB

L/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LS1

C1

0-3

WH

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21

WH

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22

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C11

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C6

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C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-11

C11

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21

OR BK

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C6

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TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60

U13 JOYSTICK CONTROL CARD

C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

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12

13

TS61 TS62

6R14

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

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10

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6

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H

P2

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ST

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3 4

CR27NC

P2

4F

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BR

N

BR

N OR

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L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

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SECONDARY BOOM UP/DOWN

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11 1

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PW

R

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C3

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WH

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TG

ND

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C1

B-1

0

C1

B-11

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

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B-3

C3

P-6

C1

P-1

0

C1

P-11

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RK

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T

L1

7

WH

BR

N

OR

BL

BL

14

5

13 4

GN

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PW

R

YO

UT

DR

IVE

MO

DE

CD

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BL

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CD

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BL

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16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3

TS15

15

TS14

RD

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HT

LE

FT

DR

IVE

EN

AB

LE

LE

FT

RIG

HT

BO

OM

EX

TE

ND

RE

TR

AC

T

PL

AT

FO

RM

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VE

LD

OW

N

UP

PL

AT

FO

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TA

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FT

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UP

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AC

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CO

ND

AR

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RY

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UP

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WN

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ER

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FT

D314

20R4

7.5


Electrical Schematic, Z-45/25Ford DSG-423 EFI Models (after serial number 30141)

1

2

3

4

5

6

7

8


6 - 9 Z-45/25 • Z-45/25J Part No. 107846

REV A

P1

34

TT

SR

D

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

STA.

A

I

S

FLD.

REGULATOR

+

-

RD

P2

0B

AT

RD

TB20

GND.

BAT.

ALTERNATOR

LINK

FUSE

R4

6H

RN

BK

/RD

C41RPM OR/BK

BA

T-R

D

CR5CR5

C4

6H

RN

BK

/RD

NO

CB1

RD

CB2

15A

TB41

TB23

KS1

PLAT

GRND

P1RD

P3

HORN

BK

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BK

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

AU

XIL

LA

RY

PO

WE

RR

EL

AYIG

NIT

ION

/STA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER


TB35

TS2

TS64

STARTERAUX

PUMP

RE

LA

Y

PR1

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

CR1

NO

CR1

P2

3B

AT

WH

FE

H(1

6)

PIN

1

BL

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FE

H(7

2)

PIN

7

BK

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FE

H(3

07

A)

PIN

23

BL

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H(6

58

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FE

H(4

58

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IN3

TB21

NO

CR2 CR2

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TB27

TS1

WH

TS52

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34

BA

TR

D

HM

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L2T

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T

C1

08

ES

LB

L/W

H

C2

1IG

NW

H

C4

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EN

GR

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TS53

TB39

TS47

RD-(FS)FS1


(GN

D)

BR

FE

H(5

70

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4

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EC

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INE

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D

12 V

DC

CHECK

ENGINE

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MP

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C3

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ENGINE

SPEED

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P24FS WH

P26ESTP BK

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RD

RD

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C1

28

RP

MO

R/R

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C4

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GR

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P-7

C2

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C3

9L

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C1

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C3

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TR

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UX

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C1

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TA

RD

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P-2

P2

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AT

WH

C3

P-9

C4

6H

RN

BK

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C4

1R

PM

OR

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OR

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FE

H(3

06

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IN2

4

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P25FS RD

P24FS WHC9P-2

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FO

OT

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FO

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HR

PM

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PM

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.

C1

28

RP

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B-4

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C5

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LP

GA

S

LP

FU

EL

SE

LE

CT

GA

S

C2

B-7

C2

B-1

C5

-10

EN

GIN

ES

TA

RT

C1

B-7

C6

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C5-8

C7

B-4

C2

B-3

C2

8T

TA

RD

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AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

C5

-5

C6

-9

C5

-17

C5

-24

C6

-27

C1

P-1

C1

P-2

C7

B-2

C3

B-9

C5

-19

C39LP BL/RD

C7

B-1

TB38

B1

D1

M3

M2

S8

M4

C5

-18


TS48

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30

C2

P-1

2

C2

P-11

C3

P-4

RD

RD

L30

CR23

L29

RD

C4

B-1

2

C3

B-4

DL

ITE

WH

C2

P-1

0

PBOX GND

C2

P-9

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

RD

C4

B-11

CR23

NO

C127TSW GR

TB24

BL/RD

C1

34

PW

RG

RC

2B

-5R

DC

2P

-5

L4

TB134

FUSE 10A

C2

1IG

NW

HF

EH

(71

)P

IN1

6

C4

1R

PM

OR

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FE

H(11

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IN2

CR39NC CR39

BR

P24BAT RD

R3

3S

TR

BK

FE

H(3

2)

PIN

15

C5

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WH

P134BAT RD

C5

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BA

T-R

D

BA

T-R

D

C1

35

FP

EN

GIN

ES

TA

RT

FU

EL

SE

LE

CT

ALT

ER

NA

TO

RF

IEL

D(F

EH

)

STA

RT

(FE

H)

A

B

C

ABCD

GY

/RD

GY

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RD

BK

/BL

FORD ENGINEHARNESS

WH

/BK

RD

/GN

GA

SO

LIN

ES

EN

SO

R

LP

GL

OC

KO

UT


1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 10


REV A



2


WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

H3

C2

2-2C

5-2

5

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C1

29

DA

BK

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5 C6

-13

LS

4-

SE

CO

ND

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

1-

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

LS

2-

PR

IMA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

3-

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6

RD

C11

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K-7

C1

0-2

14

R11

SB

DB

L/B

K

R1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

R4

TR

LW

H

R5

TR

RW

H/B

K

R2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

R1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

CW

BL

/BK

C3

6S

CC

BL

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1

H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

J3 J1 J1

C1

5P

LD

OR

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C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

P2

2L

SB

K

TB18

TB17

C4

B-5

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C1

7JU

GR

TS58

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C3

P-8

C3

P-7

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-11

C11

-4

21

OR BK

-6

C6

-40 C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-11

12

13

TS61 TS62

6R14

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

TS8TS9 TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

2

11 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1

C3

7S

CW

BL

/BK

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

CC

BL

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-11

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-11

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14

5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3

TS15

15

TS14R

D/W

H

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

LE

FT

RIG

HT

BO

OM

EX

TE

ND

RE

TR

AC

T

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

BO

OM

EX

TE

ND

RE

TR

AC

T SE

CO

ND

AR

YB

OO

MU

P

DO

WN

PR

IMA

RY

BO

OM

UP

DO

WN

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LE

FT

D314

20R4

7.5

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Ford Models


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Ford Models

1

2

3

4

5

6

7

8



6 - 11 Z-45/25 • Z-45/25J Part No. 107846

REV A

NOTE: DASHED LINES INDICATE OPTION WIRES

30

85

87

86

87A

30 = COMMON (12V DC IN)87A = NC87 = NO85 = COIL NEGATIVE86 = COIL POSITIVE

DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011 15

17

18

14

12

AU

XIL

IAR

YP

UM

P

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

(UN

US

ED

)

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C3

2-4

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C5

-18

BK

/RD

C5

-10

BL

/RD

C2

B-3

OR

/BK

C5

-2O

R/B

K

C5

-9O

R/R

D

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

GROUND CONTROL HARNESS

E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11 15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41

GROUNDCONTROLHARNESS(TO SWITCHPANEL)

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

C5

-5B

K

C7B3 BRN

C6

C4B

C5

C7B

WH

/RD

-AL

AR

MC

6-3

3

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT

FUNCTIONS ENGINE19/18 CABLES

C5C6 C2B C1BC3BC4B

12V DCTO PLAT

C7B

CB

1P

OW

ER

(UN

US

ED

)

C3BC3B C3B C3B C3B

C2B

C5

-13

BL

/WH

C2

B-1

BL

/RD

CH

EC

KE

NG

INE

LE

D

LIQ

UID

PR

OP

AN

EF

UE

LB

L/R

D-T

S5

3

BL

/WH

-L2

(-)

(UN

US

ED

)

CR2POWERRELAY

CR1IGNITIONSTART RELAY

BR

N

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

C16DRE OR/RDC6-16 C4B-4

C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C3B-4

C4B C4BC4B

C36STCC BLC6-36 C1B-10

C37STC BL/BKC6-37 C1B-11

C30FWD WHC1B-4 C5-21

C31REV WH/BKC1B-5 C5-20

C28TTA RD/BK C5-24C1B-2C29MS RD/WHC6-29 C1B-3

C40LS1 ORC6-40 C2B-2

C1

B-8

BK

/WH

C1

B-9

BK

/RD

C6

-20

BK

BRN-TS

GR

TS64RUN/TESTSWITCH

BK

/WH

-TS

56

BK

-KS

I

OR

/RD

-TS

54

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C4

3D

LIT

EG

R

C5-8 C127TSW

C2

B-4

OR

/RD

C45 GEN GR/WH C5-12C2B-7

RD

-CR

2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-CR

2

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

BRN

CR23DRIVE LIGHTOPTION RELAY

F1910A FUSE

C6-13 BK

BK-22B

RD

CR32PRIMARYBOOMRELAY

CR33TURNTABLEROTATERELAY

BRN

BRN

BR

N

RD

/WH

-3B

RD

-1B

C6

-2R

D/B

K

C6

-1R

D

C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

-6B

WH

/BK

-5B

BL

/WH

-12

BBL-10BBR

N

BRN

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-1

7W

H

C3

B-4

WH

C6

-34

RD

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

C6

-9B

K/R

D

CR37

BOOMRELAY

SECONDARY

BK

-CR

1

BK-33B

C5-11 WH

CR39AUXILLARYRELAY

RD

-CR

39

RD-27B

BRN

BRN-GND

BRN

BRN

C6 C6

R27AUX C5-6 RD

BK

-CR

5

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Ford Models

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 12


REV B


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

RD

C3

2-7

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRD

RD

RD

BRN

WH-CR2

WH

-21

A

BR

N

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

D3

RD

WH

/RD

-6A

WH

/BK

-5A

WH

/RD

-6A

WH

/BK

-5A

RD

RD

RD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8A

BK-7A

RD

RD

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

LT

S5

7P

LA

TF

OR

MR

OTA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1B

RE

AK

ER

EN

GIN

E1

5A

CIR

CU

IT

TS

54

FU

NC

TIO

NE

NA

BL

E

EN

GIN

E

SW

ITC

H

STA

RT

TS

52

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

T

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R,

20

TS

51

AU

XIL

IAR

YP

OW

ER

P1

ST

OP

SW

ITC

H

P1 RED EMERGENCY STOP BUTTON

KS1 KEY SWITCH

TS51 AUXILIARY TOGGLE SWITCH

TS52 ENGINE START TOGGLE SWITCH

TS53 FUEL SELECT TOGGLE SWITCH

TS54 FUNCTION ENABLE TOGGLE SWITCH

TS57 PLATFORM ROTATE TOGGLE SWITCH

TS59 PLATFORM LEVEL TOGGLE SWITCH

TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH

TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH

TS62 TURNTABLE ROTATE TOGGLE SWITCH

LABEL DESCRIPTION

TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH

CB1 CIRCUIT BREAKER, ENGINE, 15A

CB2 CIRCUIT BREAKER, CONTROLS, 15A

HM HOUR METER

R14 UP/DOWN SPEED RESISTER 7.5 OHMS

L2 CHECK ENGINE LED

CR1 IGNITION / START RELAY

CR2 INGITION POWER RELAY

CR4 HIGH IDLE RELAY

CR5 HORN RELAY

RD

RD

RD

RD

TS64 RUN/TEST TOGGLE SWITCH

RD

RD

BL

/RD

-39

A

TS

53

FU

EL

SE

LE

CT

BL

/WH

-38

-+

RD

-24

A

OR

/RD

-42

A

BK-22A

WH

-23

A

RD

KS

1

RD

RD

C2

3-7

L2

CH

EC

KE

NG

INE

LE

D

D2

P-BOX

G-BOX

R1

4

14 6

RD

RD

RD

RD

RD

R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS

D4

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Ford Models


Platform Control Box Wiring Diagram, Z-45/25Ford Models


Platform Box Wiring Diagram, Z-45/25Ford Models

1

2

3

4

5

6

7

8



6 - 13 Z-45/25 • Z-45/25J Part No. 107846

REV A

TILTALARM

RE

D-T

ILTR

ED

-TILT

C2

P-5

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P

PLATFORM CONTROLHARNESS

(TO SWITCH PANEL)

H1

12V DC BATTERYSUPPY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

9L

PB

L/R

DC

2P

-1

C4P

C1

28

LS

OR

/RD

C2

P-4

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4

CE LIFT/DRIVE OPTION

TS

7

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Y

RD

-P2

RD

-H1

RE

D-

LS

18

LS18CE OPTION

ONLYOPT.

H1

J3

J2

J1

U13

C1P - C4P

C7P

ALC-500 CONTROL BOARD

CONTROL BOARD POWER CONNECTOR

CONTROL BOARD OUTPUT CONNECTOR

CONTROL BOARD INPUT CONNECTOR

TILT ALARM

12V DC PLATFORM POWER CONNECTOR

48 PIN CONNECTOR BLOCK

DESCRIPTIONITEM

FOOT SWITCH CONNECTORC9

CR27 CONTROL RELAY (CE OPTION)


LS18 LOAD SENSE LIMIT SWITCH

RD

/BK

-L4

8(-)

GR

/BK

C4

P-1

GR

/BK

-L4

TS

1W

H

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Ford Models

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 14


REV A

P2EMERGENCY

STOPTS4

HIGH/LOWRPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED

TS14HIGH/LOW(2WD/4WD)

TS13PRIMARY

BOOMEXTEND/RETRACT

TS7PLATFORM

ROTATETS9

PLATFORMLEVEL

P3HORN

TS1AUXILIARY PUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

C3

9L

PB

L/R

DC

2P

-1

BK

C9

P-1

WH

C7

P-2

RD

WH

RD RD

WH-24

RD

BK

RD RD

TS3FUEL

SELECT

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

WHWH


C3

5R

PM

BK

/RD

C1

P-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE

FORWARD/REVERSE& STEER LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

JC2PRIMARY BOOM

UP/DOWN& TURNTABLE ROTATE

LEFT/RIGHT

C1

28

LS

OR

/RD

C2

P-4

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+

TS48DRIVE LIGHTS/WORK LIGHTS

(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

C3

P-4

DL

ITE

WH

2

1

3

5

4

6

7

2

1

3

5

4

6

7

GE

NE

RA

TO

RO

PT

ION

BK

BK

BK

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

BK

RD

RD

RD

RD

/BK

H1

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Ford Models


Electrical Schematic, Z-45/25JFord LRG-425 EFI Models (before serial number 30142)

1

2

3

4

5

6

7

8



6 - 15 Z-45/25 • Z-45/25J Part No. 107846

REV C

NOTE:1) All switches and contacts are shown with theboom in the stowed position and the keyswitch off.


P1

34

TT

SR

D

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

STA.

A

I

S

FLD.

REGULATOR

+

-

RD

P2

0B

AT

RD

TB20

GND.

BAT.

ALTERNATOR

LINK

FUSE

51

0

R4

6H

RN

BK

/RD

C1

07

AF

WH

C41RPM OR/BK

BA

T-R

D

CR5

CR5

C4

6H

RN

BK

/RD

NO

CB1

RD

CB2

15AMP.

TB41

TB23

KS1

PLAT

GRND

P1

RD

P3

HORN

BK

TB22

P2

2B

AT

BK

BK-(FS)C9P-1 BK

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

AU

XIL

LA

RY

RE

LA

Y

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

FORD 42 PIN QUICK DISCONNECT

TB35

TS2

TS64

AUXPUMP

PR1

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

CR1

NO

CR1

C3

3S

TR

BK

P2

3B

AT

WH

FE

H(1

6)

PIN

1

BL

/RD

FE

H(7

2)

PIN

7

BK

/RD

FE

H(3

07

A)

PIN

23

P2

0B

AT

RD

FE

H(3

61

)P

IN9

BL

/WH

FE

H(6

58

)P

IN6

GR

FE

H(4

58

)P

IN1

8

TB21

NO

CR2 CR2

TS51

TB27

TS1

WH

TS52

TB33P

13

4B

AT

RD

C5-13

L2

TE

ST

C1

08

ES

LB

L/W

H

C2

1IG

NW

H

C4

5G

EN

GR

/WH

FB1

TS53

TB39

TS47

RD-(FS)

FS1

(GN

D)

BR

FE

H(5

70

)P

IN3

4

TS3

CH

EC

KE

NG

INE

LE

D

CHECK

ENGINE

ENGINE HARNESS #2

TILT

AL

AR

M

+

_

P2

2H

RN

BK

RD

WH

BR

NB

K

BL

/WH

FE

H(7

87

A)

PIN

5

FUELPUMP

BL

/WH

BK

FU

EL

PU

MP

P2

RD

WHWH-(FS)

H2

H1

C2

P-4

C1

P-9

C3

5R

PM

BK

/RD

TS54

EN

GIN

ES

PE

ED

TS4

P24FS WH

P26ESTP BK

C41RPM OR/BK

C22LS RD

RD

RD

BRN

C1

28

RP

MO

R/R

D

C4

5G

EN

GR

/WH

C2

P-7

C2

P-1

C3

9L

PB

L/R

D

C1

P-7

C3

3S

TR

BK

C1

P-1

C2

7A

UX

RD

C1

P-2

C2

8T

TA

RD

/BK

C7

P-2

P2

3B

AT

WH

C3

P-9

C4

6H

RN

BK

/RD

C4

1R

PM

OR

/BK

OR

/RD

FE

H(3

06

)P

IN2

4

TB42

P26ESTP BK

P25FS RD

P24FS WHC9P-2

C9P-3

C7

P-1


C1

28

RP

MO

R/R

D

C35RPM BK/RD

C1

B-9

C2

B-4

C5-9

C5

-12

C2

B-7

C2

B-1

C5

-10

C1

B-7

C6

-34

C5-8

C7

B-4

C2

B-3

C2

8T

TA

RD

/BK

C5

-5

C6

-9

C5

-17

C5

-24

C6

-27

C1

P-1

C1

P-2

C7

B-2

C3

B-9

C5-3

C5

-19

C39LP BL/RD

C7

B-1

TB38

B112V DC

D1

R16

M3

M2

S8

M4

C5

-18


TS48

L30

C2

P-1

2

C2

P-11

C3

P-4

RD

RD

L30

CR23

L29

RD

C4

B-1

2

C3

B-4

DL

ITE

WH

C2

P-1

0

PBOX GNDC

2P

-9

WO

RK

LIG

HT

OP

TIO

N

DR

IVE

LIG

HT

OP

TIO

N

L29

RD

C4

B-11

CR23

NO

C127TSW GR

TB24

BL/RD

C1

34

PW

RG

RC

2B

-5R

DC

2P

-5

L4

TB134

FUSE 10A

C2

1IG

NW

HF

EH

(71

)P

IN2

1

C4

1R

PM

OR

/BK

FE

H(1 1

)P

IN2

CR39

NCCR39

BR

P24BAT RD

R3

3S

TR

BK

FE

H(3

2)

PIN

15

C3

3S

TR

BK

FE

H(3

2)

PIN

13

C5

-2

WH

P134BAT RD

C5

-11

BA

T-R

D

BA

T-R

D

C1

35

FP

ALT

ER

NA

TO

R

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

DR

IVE

LIG

HT

S

WO

RK

LIG

HT

S

GE

NE

RA

TO

R

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

LO

WR

PM

HIG

HR

PM

FU

EL

SE

LE

CT

LP

GA

S

FU

EL

SE

LE

CT

LP

GA

S

A C

B


1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 16


REV C



2


WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

VA

LVE

H3

C2

2-2C

5-2

5

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C1

29

DA

BK

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5 C6

-13

LS

4-

SE

CO

ND

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

1-

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

LS

2-

PR

IMA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

3-

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6

RD

C11

-3B

K-7

C1

0-2

14

R11

SB

DB

L/B

K

R1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

R4

TR

LW

H

R5

TR

RW

H/B

K

R2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

R1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

CW

BL

/BK

C3

6S

CC

BL

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1

H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

JIB

BO

OM

VA

LVE GR

/BK

-44

J3 J1 J1

C1

29

DA

GR

/BK

C1

9JS

VG

R/W

H

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

P2

2L

SB

K

TB18

TB17

C4

B-5

C4

B-7

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C2

B-6

TB44

C1

7JU

GR

TS57

TS58

C4

P-7

C19JSV GR/WH

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C2

P-6

C3

P-8

C3

P-7

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-11

C11

-4

21

OR BK

-6

C6

-40 C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-11

12

13

TS61 TS62

6R14

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

WH

CR13

TS7TS8

BRN

TS9

CR13

NC

TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

2

11 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1

C3

7S

CW

BL

/BK

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

CC

BL

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-11

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-11

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14

5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3

TS15

15

TS14

WH

BK

RD

/WH

DO

WN

UP

JIB

BO

OM

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

LE

FT

RIG

HT

BO

OM

EX

TE

ND

RE

TR

AC

T

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

DO

WN

UP

JIB

BO

OM

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

BO

OM

EX

TE

ND

RE

TR

AC

T SE

CO

ND

AR

YB

OO

MU

P

DO

WN

PR

IMA

RY

BO

OM

UP

DO

WN

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LE

FT

D314

20R4

7.5


Electrical Schematic, Z-45/25JFord DSG-423 EFI Models (after serial number 30141)

1

2

3

4

5

6

7

8


6 - 17 Z-45/25 • Z-45/25J Part No. 107846

REV A

P1

34

TT

SR

D

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

STA.

A

I

S

FLD.

REGULATOR

+

-

RD

P2

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AT

RD

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GND.

BAT.

ALTERNATOR

LINK

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T-R

D

CR5CR5

C4

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RD

CB2

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TB23

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RA

TO

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ION

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AS

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NS

OP

TIO

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HO

UR

ME

TE

R

RU

N/T

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TS

WIT

CH

AU

XIL

LA

RY

PO

WE

RR

EL

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ION

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RE

LA

Y

STA

RT

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MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER


TB35

TS2

TS64

STARTERAUX

PUMP

RE

LA

Y

PR1

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

CR1

NO

CR1

P2

3B

AT

WH

FE

H(1

6)

PIN

1

BL

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FE

H(7

2)

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7

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07

A)

PIN

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H(6

58

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58

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CR2 CR2

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TB27

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WH

TS52

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TR

D

HM

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L2T

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T

C1

08

ES

LB

L/W

H

C2

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C4

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GR

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TB39

TS47

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(GN

D)

BR

FE

H(5

70

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EC

KE

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INE

LE

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DC

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MP

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C3

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PM

BK

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SPEED

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P26ESTP BK

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RD

RD

BRN

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BK

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C2

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WH

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06

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OT

SW

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IGH

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OT

SW

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HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

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C1

28

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MO

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D

C35RPM BK/RD

C1

B-9

C2

B-4

C5-9

C5

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LP

GA

S

LP

FU

EL

SE

LE

CT

GA

S

C2

B-7

C2

B-1

C5

-10

EN

GIN

ES

TA

RT

C1

B-7

C6

-34

C5-8

C7

B-4

C2

B-3

C2

8T

TA

RD

/BK

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

C5

-5

C6

-9

C5

-17

C5

-24

C6

-27

C1

P-1

C1

P-2

C7

B-2

C3

B-9

C5

-19

C39LP BL/RD

C7

B-1

TB38

B1

D1

M3

M2

S8

M4

C5

-18


TS48

WO

RK

LIG

HT

DR

IVE

LIG

HT

LIG

HT

S

L30

C2

P-1

2

C2

P-11

C3

P-4

RD

RD

L30

CR23

L29

RD

C4

B-1

2

C3

B-4

DL

ITE

WH

C2

P-1

0

PBOX GND

C2

P-9

WO

RK

LIG

HT

SO

PT

ION

DR

IVE

LIG

HT

OP

TIO

N

L29

RD

C4

B-11

CR23

NO

C127TSW GR

TB24

BL/RD

C1

34

PW

RG

RC

2B

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DC

2P

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L4

TB134

FUSE 10A

C2

1IG

NW

HF

EH

(71

)P

IN1

6

C4

1R

PM

OR

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FE

H(11

)P

IN2

CR39NC CR39

BR

P24BAT RD

R3

3S

TR

BK

FE

H(3

2)

PIN

15

C5

-2

WH

P134BAT RD

C5

-11

BA

T-R

D

BA

T-R

D

C1

35

FP

EN

GIN

ES

TA

RT

FU

EL

SE

LE

CT

ALT

ER

NA

TO

RF

IEL

D(F

EH

)

STA

RT

(FE

H)

A

B

C

ABCD

GY

/RD

GY

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RD

BK

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RD

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GA

SO

LIN

ES

EN

SO

R

LP

GL

OC

KO

UT

Electrical Schematic, Z-45/25JFord DSG-423 EFI Models (after serial number 30141)

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 18


REV A



2


WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

VA

LVE

H3

C2

2-2C

5-2

5

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C1

29

DA

BK

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5 C6

-13

LS

4-

SE

CO

ND

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

1-

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

LS

2-

PR

IMA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

3-

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

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C6

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C1

0-1

WH

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RD

C11

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K-7

C1

0-2

14

R11

SB

DB

L/B

K

R1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

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BK

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13

2

8587a 87

8630

CR37

R4

TR

LW

H

R5

TR

RW

H/B

K

R2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

R1

PB

UR

D

8587a 87

8630

C6

-2

C6

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C6

-4

C6

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CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

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SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

CW

BL

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C3

6S

CC

BL

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

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C3

2TA

WH

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C2

8-1

C2

6-1

H4

C6

-37

C6

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C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

JIB

BO

OM

VA

LVE GR

/BK

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J3 J1 J1

C1

29

DA

GR

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C1

9JS

VG

R/W

H

C1

5P

LD

OR

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C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

P2

2L

SB

K

TB18

TB17

C4

B-5

C4

B-7

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C2

B-6

TB44

C1

7JU

GR

TS57

TS58

C4

P-7

C19JSV GR/WH

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C2

P-6

C3

P-8

C3

P-7

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

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C11

SB

DB

L/B

K

C3

PB

FR

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C1

0S

BU

BL

C2

PB

DR

D/B

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C1

PB

UR

D

LS1

C1

0-3

WH

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21

WH

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22

LS4

C11

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C6

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C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-11

C11

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21

OR BK

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C6

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TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-11

12

13

TS61 TS62

6R14

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

WH

CR13

TS7TS8

BRN

TS9

CR13

NC

TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

2

11 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1

C3

7S

CW

BL

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C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

CC

BL

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-11

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-11

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14

5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3

TS15

15

TS14

WH

BK

RD

/WH

DO

WN

UP

JIB

BO

OM

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

LE

FT

RIG

HT

BO

OM

EX

TE

ND

RE

TR

AC

T

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

DO

WN

UP

JIB

BO

OM

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

BO

OM

EX

TE

ND

RE

TR

AC

T SE

CO

ND

AR

YB

OO

MU

P

DO

WN

PR

IMA

RY

BO

OM

UP

DO

WN

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LE

FT

D314

20R4

7.5

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JFord Models


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JFord Models

1

2

3

4

5

6

7

8



6 - 19 Z-45/25 • Z-45/25J Part No. 107846

REV A


30

85

87

86

87A


DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011 15

17

18

14

12

AU

XIL

IAR

YP

UM

P

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

(UN

US

ED

)

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

LO

WR

PM

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C3

2-4

BK

C7

B-2

WH

C1

B-6

WH

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C6

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WH

/RD

C1

B-7

BK

C5

-18

BK

/RD

C5

-10

BL

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C2

B-3

OR

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C5

-2O

R/B

K

C5

-9O

R/R

D

C2

B-6

GR

/BK

RD

-TS

61

RD

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61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11 15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-KS

RD

-TS

51

BK

-33

TS

52

C5

-5B

K

C7B3 BRN

C6

C4B

C5

C7B

WH

/RD

-AL

AR

MC

6-3

3

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT


C5C6 C2B C1BC3BC4B

12V DCTO PLAT

C7B

CB

1P

OW

ER

(UN

US

ED

)

C3BC3B C3B C3B C3B

C2B

C5

-13

BL

/WH

C2

B-1

BL

/RD

CH

EC

KE

NG

INE

LE

D

LIQ

UID

PR

OP

AN

EF

UE

LB

L/R

D-T

S5

3

BL

/WH

-L2

(-)

(UN

US

ED

)

CR2POWERRELAY

CR1IGNITIONSTART RELAY

BR

NWH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C3B-4

C4B C4BC4B







C1

B-8

BK

/WH

C1

B-9

BK

/RD

C6

-20

BK

BRN-TS

GR

TS64RUN/TESTSWITCH

BK

/WH

-TS

56

BK

-KS

I

OR

/RD

-TS

54

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C4

3D

LIT

EG

R

C5-8 C127TSW

C2

B-4

OR

/RD


RD

-CR

2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-CR

2

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

BRN


F1910A FUSE

C6-13 BK

BK-22B

RD



BRN

BRN

BR

N

RD

/WH

-3B

RD

-1B

C6

-2R

D/B

K

C6

-1R

D

C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

-6B

WH

/BK

-5B

BL

/WH

-12

BBL-10BBR

N

BRN

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-1

7W

H

C3

B-4

WH

C6

-34

RD

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

C6

-9B

K/R

D

CR37

BOOMRELAY

SECONDARY

BK

-CR

1

BK-33B

C5-11 WH

CR39AUXILLARYRELAY

RD

-CR

39

RD-27B

BRN

BRN-GND

BRN

BRN

C6 C6

R27AUX C5-6 RD

BK

-CR

5

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JFord Models

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 20


REV B


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

RD

C3

2-7

RD

RD

-20

A

BK

-33

A

RD

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRD

RD

RD

BRN

WH-CR2

WH

-21

A

BR

N

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

GRGR

GR/BK

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

RD

GR/BK

RD

GR/BK

RD

GR

/BK

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

D3

RD

WH

/RD

-6A

WH

/BK

-5A

WH

/RD

-6A

WH

/BK

-5A

RD

RD

RD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8A

BK-7A

RD

RD

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

LT

S5

7P

LA

TF

OR

MR

OTA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1B

RE

AK

ER

EN

GIN

E1

5A

CIR

CU

IT

TS

54

FU

NC

TIO

NE

NA

BL

E

EN

GIN

E

SW

ITC

H

STA

RT

TS

52

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

58

JIB

BO

OM

UP

/DO

WN

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/RE

TR

AC

T

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R,

20

TS

51

AU

XIL

IAR

YP

OW

ER

P1

ST

OP

SW

ITC

H

GR

/BK

-44

A


KS1 KEY SWITCH

TS51 AUXILIARY TOGGLE SWITCH


TS53 FUEL SELECT TOGGLE SWITCH



TS58 JIB BOOM UP/DOWN TOGGLE SWITCH





LABEL DESCRIPTION




HM HOUR METER

R14 UP/DOWN SPEED RESISTER 7.5 OHMS

L2 CHECK ENGINE LED


CR2 INGITION POWER RELAY

CR4 HIGH IDLE RELAY

CR5 HORN RELAY

RD

RD

RD

RD

TS64 RUN/TEST TOGGLE SWITCH

RD

RD

BL

/RD

-39

A

TS

53

FU

EL

SE

LE

CT

BL

/WH

-38

-+

RD

-24

A

OR

/RD

-42

A

BK-22A

WH

-23

A

RD

KS

1

RD

RD

C2

3-7

L2

CH

EC

KE

NG

INE

LE

D

D2

P-BOX

G-BOX

R1

4

14 6

RD

RD

RD

RD

RD


D4

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JFord Models


Platform Control Box Wiring Diagram, Z-45/25JFord Models


Platform Control Box Wiring Diagram, Z-45/25JFord Models

1

2

3

4

5

6

7

8



6 - 21 Z-45/25 • Z-45/25J Part No. 107846

REV A

TILTALARM

WH

C1

9JS

V

RE

D-T

ILTR

ED

-TILT

C2

P-5

BR

NB

RN

C3P

JIB

F.S.

C7P

JIB BK JIB BK JIB

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

H1

12V DC BATTERYSUPPY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C3

9L

PB

L/R

DC

2P

-1

C4P

C1

28

LS

OR

/RD

C2

P-4

C4

4JD

AL

AR

MG

R/B

KC

2P

-6

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

7JU

GR

C4

P-5

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


TS

7

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Y

RD

-P2

RD

-H1

RE

D-

LS

18

LS18CE OPTION

ONLYOPT.

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM





RD

/BK

-L4

8(-)

GR

/BK

C4

P-1

GR

/BK

-L4

TS

1W

H

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JFord Models

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 22


REV A

P2EMERGENCY

STOPTS4

HIGH/LOWRPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED


TS13PRIMARY

BOOMEXTEND/RETRACT

CR13JIB BOOM

RELAY

TS8JIB

BOOM

TS7PLATFORM

ROTATETS9

PLATFORMLEVEL

P3HORN

TS1AUXILIARY PUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

C3

9L

PB

L/R

DC

2P

-1

BK

C9

P-1

WH

C7

P-2

RD

WH

GR/BK

RD

GR

RD

WH-24

RD

BK

RD RD

TS3FUEL

SELECT

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

WHWH

GR

/BK

-44

C2

P-6


C3

5R

PM

BK

/RD

C1

P-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7O

RJ1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE

FORWARD/REVERSE& STEER LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

JC2PRIMARY BOOM

UP/DOWN& TURNTABLE ROTATE

LEFT/RIGHT

C1

28

LS

OR

/RD

C2

P-4

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

C3

P-4

DL

ITE

WH

2

1

3

5

4

6

7

2

1

3

5

4

6

7

GE

NE

RA

TO

RO

PT

ION

BK

BK

BK

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

BK

RD

RD

RD

RD

/BK

H1

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JFord Models


Electrical Schematic, Z-45/25Deutz F3L-2011 Models

1

2

3

4

5

6

7

8



6 - 23 Z-45/25 • Z-45/25J Part No. 107846

REV C

C1B & C1P = GRAYC2B & C2P = BLACKC3B & C3P = GREENC4B & C4P = BROWN

NOTE:

1. All switches and contacts are shown with the boomin the stowed position and the keyswitch off.

5 Add D40 only if unit has L4 and L48.

ANSI/CSA (Domestic machine) add L48.6

C1

33

PL

AB

L/R

DP

13

4T

TS

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

+

-

RD

P2

0B

AT

RD

TB20

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

C4

6H

RN

BK

/RD

NO

CB1

RD

RD

CB2

15A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GND

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BK

P2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUND

AUX. ON

KEY PWR.

BATTERY

TACHOMETER

IGN./FUEL ON

ENG. FAULT

KEY BYPASS

START INPUT

START RELAY

4

PUMP

PR1

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

CR1CR1NO

R3

3S

TR

BK

TB21

TB25

CR2NO

8

7

6

5

10

9

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1

RD

TS52

BK

1

2

TB33

3IGNITION/STARTMODULE

C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L42

L43

OIL

PRES.

OIL

TEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

NO

CR4

CR4

NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TILT

AL

AR

M

P2

2B

AT

BK

W

GL

OW

PL

UG

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

C1

P-9

C3

5R

PM

BK

/RD

C4

1R

PM

OR

/BK

C28TTA RD/BKC28TTA RD/BK

C28TTA RD/BK

C41RPM OR/BK

EN

GIN

ES

PE

ED

C1

B-9

C5

-18

C1

B-8

C5

-12

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-17

C2

B-7

B112V DC

D1

C33MF

+

M2

M3

PR2PR2

NO

Q3

S8

U1

U32

C3

5R

PM

BK

/RD

BK

/RD

C6

-34

P1

34

FB

RD

C2

B-3

L30 L30

L29L29

FUSE 10A (ONLY FOR WORKLIGHTS)

C3

P-4

C3

B-4

DL

ITE

WH

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

NO

CR23CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

OP

TIO

N

C6

-38

C6

-39

TS48

RD

RD

C7

B-1

FUSE 10A

P20BAT RD

A C

B

HIG

HR

PM

SU

PR

ES

SIO

ND

IOD

E

4

6

12 8

7

5

C1

B-1

L48

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D40

1 3

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RG

NC

2B

-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

P134 RD

6

5

BR

N

C32

L48

PR3

L48L48

C5

-23 C

6-2

7

TB35

GR/BK

ALT

ER

NA

TO

R

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

GL

OW

PL

UG

GL

OW

PL

UG

LO

WR

PM

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

GE

NE

RA

TO

R

WO

RK

LIG

HT

S

DR

IVE

LIG

HT

S


1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 24


REV C



2


WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

H3

C2

2-2C

5-2

5

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C1

29

DA

BK

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

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C6

-18

C6

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C1

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OR

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C1

4P

LU

OR

C2

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PB

RB

K/W

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C1

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C1

7-1

C7

PB

EB

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C6

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C6

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C6

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LE

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SE

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ND

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SE

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ND

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MS

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EC

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SE

CO

ND

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N

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8-2

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PR

IMA

RY

BO

OM

UP

PR

IMA

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BO

OM

SE

LE

CT

RE

LA

Y

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2

8587a 87

8630

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8587a 87

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8630

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CF

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N

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B-2

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TB8

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C3

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C1

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TS58

C4

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119 17

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D314

20R4

7.5

Electrical Schematic, Z-45/25, CE ModelsDeutz F3L-2011 Models

1

2

3

4

5

6

7

8



6 - 25 Z-45/25 • Z-45/25J Part No. 107846

REV C

C1

33

PL

AB

L/R

DP

13

4T

TS

WH

HO

RN

RE

LA

Y

LE

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LS

EN

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HO

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+

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07

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OR

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BK

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NO

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RD

CB2

15A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

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GND

P1

RD

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TB134

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BK

BK-(FS)C9P-1 BK

P2

GE

NE

RA

TO

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ION

FL

AS

HIN

GB

EA

CO

NS

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N

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MO

TO

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AU

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YP

UM

P

AU

XIL

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ER

RE

LA

Y

TS2

GROUND

AUX. ON

KEY PWR.

BATTERY

TACHOMETER

IGN./FUEL ON

ENG. FAULT

KEY BYPASS

START INPUT

START RELAY

4

PUMP

PR1

C2

7A

UX

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NO

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TA

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CR1CR1NO

R3

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BK

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TB25

CR2NO

8

7

6

5

10

9

CR2

TS51

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RD

TS1

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TS52

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1

2

TB33


C2

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NW

H

FB1

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3S

TR

BK

C4

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GR

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TS47

P24FS WH

C9P-3RD-(FS)

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P26ESTP BK

OIL

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MP

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EL

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C9P-2

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TB26

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C5

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C5

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C5

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C5

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C2

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C5

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C5-3

C7

B-4

C5

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C2

B-7

B112V DC

D1

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+

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M3

PR2PR2

NO

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PM

BK

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BK

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C6

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P1

34

FB

RD

C2

B-3

L30 L30

L29L29


C3

P-4

C3

B-4

DL

ITE

WH

C2

P-11

C2

P-1

2C

2P

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C2

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RD

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NO

CR23CR23

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IVE

LIG

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OP

TIO

N

WO

RK

LIG

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OP

TIO

N

C6

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C6

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RD

RD

C7

B-1

FUSE 10A

P20BAT RD

A C

B

HIG

HR

PM

SU

PR

ES

SIO

ND

IOD

E

4

6

12 8

7

5

C1

B-1

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D40

1 3

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RG

NC

2B

-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

P134 RD

5

BR

N

U33

PR3

C5

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6-2

7

TB35

GR/BK

ALT

ER

NA

TO

R

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

GL

OW

PL

UG

GL

OW

PL

UG

LO

WR

PM

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NA

BL

E

GE

NE

RA

TO

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WO

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LIG

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S

DR

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LIG

HT

S


NOTE:



4 CE and platform overload option

H6 L45

L4

D39

4

LS18

C1

P-1

2

LO

AD

SE

NS

EM

OD

UL

E


1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 26


REV C



2


WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

H3

C2

2-2C

5-2

5

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C1

29

DA

BK

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5 C6

-13

LS

4-

SE

CO

ND

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

1-

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

LS

2-

PR

IMA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

3-

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6

RD

C11

-3B

K-7

C1

0-2

14

R11

SB

DB

L/B

K

R1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

R4

TR

LW

H

R5

TR

RW

H/B

K

R2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

R1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

CW

BL

/BK

C3

6S

CC

BL

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1

H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

J3 J1 J1

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

P2

2L

SB

K

TB18

TB17

C4

B-5

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C1

7JU

GR

TS58

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C3

P-8

C3

P-7

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-11

C11

-4

21

OR BK

-6

C6

-40 C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-11

12

13

TS61 TS62

6R14

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

TS8TS9 TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

2

11 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1

C3

7S

CW

BL

/BK

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

CC

BL

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-11

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-11

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14

5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3

TS15

15

TS14

RD

/WH

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

LE

FT

RIG

HT

BO

OM

EX

TE

ND

RE

TR

AC

T

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

BO

OM

EX

TE

ND

RE

TR

AC

T SE

CO

ND

AR

YB

OO

MU

P

DO

WN

PR

IMA

RY

BO

OM

UP

DO

WN

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LE

FT

D314

20R4

7.5

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Deutz F3L-2011 Models


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Deutz F3L-2011 Models

1

2

3

4

5

6

7

8



6 - 27 Z-45/25 • Z-45/25J Part No. 107846

REV A

NOTE: DASHED LINES INDICATE OPTION WIRES30

85

87

86

87A


DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011 15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C3

2-4

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C5

-22

BK

/WH

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

WH

-23

B

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11 15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

(SP

AR

E)

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-IS

7

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

WH

-IS

7

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN

I.S.M. I.S.M. I.S.M. I.S.M.

C6

C4B

C5

C7BW

H/R

D-A

LA

RM

C6

-33

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT

RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TO PLAT

C7B

CB

1P

OW

ER

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

WH

/RD

-L4

3(-

)

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

(-)

OIL

PR

ES

SU

RE

SW

ITC

H

BK

/RD

-CR

4

CR2POWERRELAY

CR1IGNITIONSTARTRELAY

BR

N

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

C5-18 BK/RD

WH

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C3B-4

C4B C4BC4B







GL

OW

PL

UG

GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L4

2(-

)

C5-11 WH

BK

-KS

I

CR4HIGH RPMSOLENOIDRELAY

BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C4

3D

LIT

EG

R

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD

C5

-14

WH

/RD


RD

-CR

2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-CR

2

WH

-IS

7

C5

-16

WH

/RD

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

WH

-23

B

BK

-33

BB

K-I

S3

BK

-IS

3


F1910A FUSE

C6-13 BK

BK-22B

RD



CR37SECONDARYBOOMRELAY

BRN

BRN

BR

N

RD

/WH

-3B

RD

-1B

C6

-2R

D/B

K

C6

-1R

D

C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

-6B

WH

/BK

-5B

BL

/WH

-12

BBL-10BBR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-1

7W

H

C3

B-4

WH

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7B-1

BK 22B

RD H6

C3

2

13

45

67

81

2

RD

H6

H6

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

C6

-9B

K/R

D

C3

+

BR

NB

RN

C3

+

RD

H6

(CE OPTION ONLY)

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN GND

GR/BK H6

RD TS52

RD TS51

BK 22B

BK/WH C1B-12

RD H6

C3

2

13

45

67

81

2

45

67

45

67

45

67

45

67

WH

-25

D&

26

D

WH

-IS

10

WH

/RD

-L4

3-

WH

/BK

-L4

2-

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1

I.S.M. I.S.M. I.S.M. I.S.M.I.S.M.

BK

-IS

1

RD

-IS

6

RD

-27

B

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-33

BB

K-I

S3

BK

-IS

3

RD

-IS

4

BRN

BRN-GND

C6 C6

(SP

AR

E)

(SP

AR

E)

BK

-CR

5

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-2011 Models

1

2

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5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 28


REV B


KS1 KEY SWITCH

TS51 AUXILIARY POWER TOGGLE SWITCH



TS56 GLOW PLUG TOGGLE SWITCH (OPTION)






LABEL DESCRIPTION




HM HOUR METER


L42 OIL PRESSURE LED


CR2 IG ITION POWER RELAYN

CR4 HIGH IDLE RELAY

CR5 HORN RELAY

L43 OIL TEMPERATURE LED

HIGH IDLE RELAY

L45 PLATFORM OVERLOAD

HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD R

DR

D

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

A

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3O

ILT

EM

PL

ED

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R,2

0�

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

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WH

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A

GR

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RD

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RD

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LA

TF

OR

MO

VE

RL

OA

DL

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(CE

mo

de

ls)

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KS

1G-BOX

P-BOX

RD

14

�

6�

DA

LE

RH

-25

25

W7

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hm

1%

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4S

EC

ON

DA

RY

BO

OM

UP

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WN

SP

EE

DR

ES

IST

OR

R14 SECONDARY BOOM SPEED RESISTOR 7.5 OHMS

Ground Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-2011 Models


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25CE Models Deutz F3L-2011 Models


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25, CE ModelsDeutz F3L-2011 Models

1

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6 - 29 Z-45/25 • Z-45/25J Part No. 107846

REV A


85

87

86

87A


DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

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NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

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HT

TU

RN

TA

BL

ER

OTA

TE

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NC

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NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

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RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

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PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

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UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

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P

SE

CO

ND

AR

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MF

UN

CT

ION

CT

RL

SE

CO

ND

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OW

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2011 15

17

18

14

12

AU

XIL

IAR

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P

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MP

ER

AT

UR

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CH

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SW

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KE

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25

27

26

23

24

HIG

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PM

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RT

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GIN

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35

38

33

34

32

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NA

TO

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SE

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44

42

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CR

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GR

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62

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63

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BL

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BL

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GR

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OR

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LB

AS

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17

18

14

12

20

24

26

27

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39

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35

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nie

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ustr

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:

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sh

ge

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(SP

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BR

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RD

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CB

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MP

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CH

WH

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C2B

C2

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(SP

AR

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(SP

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(SP

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53

BL

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(-)

OIL

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ES

SU

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N

WH-21C

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BRN

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OW

PL

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GL

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PL

UG

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D&

26

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WH

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I


BRN

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C4

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LIT

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WH

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OR

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WH

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RD

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RD

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CD

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WH

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WH

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C5

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WH

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GR

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BK

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AR

M

RELAY HARNESS

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BRN

WH

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BW

H-I

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WH

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BK

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BB

K-I

S3

BK

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RD




BRN

BRN

BR

N

RD

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RD

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D/B

K

C6

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C6

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C6

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BL

C6

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C6

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BL

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WH

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BL

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N

13

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SP

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13

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PO

WE

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RD

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H

C3

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WH

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GR/BK H6

RD TS52

RD TS51

BK C7B-1

BK 22B

RD H6

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C3

2

13

45

67

81

2

RD

H6

H6

RD

C3

2-1

RD

13

4B

GR

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C3

2-8

GR

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5

GR

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C4

B-1

C6

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C6

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CR5HORNRELAY

C3

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BK

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13

4A

13

4

C6

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K/R

D

C3

+

BR

NB

RN

C3

+

RD

H6

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

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L4

5

GR

/BK

C4

B-1

BRN GND

GR/BK H6

RD TS52

RD TS51

BK 22B

BK/WH C1B-12

RD H6

C3

2

13

45

67

81

2

U33

WH

-25

D&

26

D

WH

-IS

10

WH

/RD

-L4

3-

WH

/BK

-L4

2-

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY)

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OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

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Vo

ltIG

NIT

ON

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RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

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OR

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A

BK

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B

RD

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B

BR

N-I

S5

WH

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RD

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1


BK

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1

RD

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6

RD

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B

OR

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A

RD

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4

OR

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2

BK

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BB

K-I

S3

BK

-IS

3

RD

-IS

4

BRN

BRN-GND

C6 C6

(SP

AR

E)

(SP

AR

E)

BK

-CR

5

Ground Control Box Switch Panel Wiring Diagram, Z-45/25, CE ModelsDeutz F3L-2011 Models

1

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Part No. 107846 Z-45/25 • Z-45/25J 6 - 30


REV B


KS1 KEY SWITCH










LABEL DESCRIPTION




HM HOUR METER





CR4 HIGH IDLE RELAY

CR5 HORN RELAY


HIGH IDLE RELAY


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD R

DR

D

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

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-8A

BK

-7A

RD

-1A

RD

RD

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-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

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A

WH

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A

WH-23

RD

13

4A

RD

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RD

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A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

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CB

1C

IRC

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BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

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NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

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RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

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WN

L4

3O

ILT

EM

PL

ED

R4

FU

NC

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NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R,2

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TS

51

AU

XIL

IAR

YP

OW

ER

P1

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GE

NC

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TO

PS

WIT

CH

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ILP

RE

SS

UR

EL

ED

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

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A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C3

2-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

mo

de

ls)

-+

KS

1

G-BOX

P-BOX

RD

14

�

6�

DA

LE

RH

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25

W7

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hm

1%

R1

4S

EC

ON

DA

RY

BO

OM

UP

/DO

WN

SP

EE

DR

ES

IST

OR


Ground Control Box Switch Panel Wiring Diagram, Z-45/25CE Models Deutz F3L-2011 Models


Platform Control Box Wiring Diagram, Z-45/25Deutz F3L-2011 Models


Platform Control Box Wiring Diagram, Z-45/25Deutz F3L-2011 Models

1

2

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5

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8



6 - 31 Z-45/25 • Z-45/25J Part No. 107846

REV A

TILTALARM

RE

D-T

ILTR

ED

-TILT

C2

P-5

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

H1

12V DC BATTERYSUPPY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

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C3

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RK

WH

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C1

P-6

C5

TR

RW

H/B

KC

3P

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C3

6S

TC

CB

KC

1P

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C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

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C1

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C2

PB

DR

D/B

KC

3P

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C1

P-5

C1

PB

UR

DC

3P

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WD

WH

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C4

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PM

OR

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C2

P-3

C1

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BF

BL

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P-1

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C4

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SS

OR

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P-2

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SB

DB

L/B

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OR

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C4

P-4

C1

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BU

BL

C3

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0

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TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

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H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

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C4P

C4

5G

EN

GR

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C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

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C8

PB

RB

K/W

HC

3P

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C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

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C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

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C1

P-6

C3

2B

RK

WH

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J2

-19

C4

0L

SS

OR

J2

-4


TS

7

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Y

RD

-P2

RD

-H1

RE

D-

LS

18

LS18CE OPTION

ONLYOPT.

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM





RD

/BK

-L4

8(-)

GR

/BK

C4

P-1

GR

/BK

-L4

TS

1W

H

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-2011 Models

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 32


REV A

P2EMERGENCY

STOPTS4HIGH/LOW

RPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED


TS13PRIMARY BOOM

EXTEND/RETRACT

TS8JIB BOOM

TS7PLATFORMROTATE

TS9PLATFORM

LEVEL

P3HORN TS1

AUXILIARYPUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

BK

C9

P-1

WH

C7

P-2

RD

WH

GR/BK

RD

GR

RD

WH-24

RD RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

TS6GLOWPLUG

(OPTION)

C3

4S

AB

K/W

HC

1P

-8WHWH

White wire replacedby CR27 and CR30on CE models

GR

/BK

-44

C2

P-6

RD

NOTE:DASHED LINES INDICATE OPTION WIRES

C3

5R

PM

BK

/RD

C1

P-9

2

1

NC

2

1

NCB

L/B

K-D

E2

J1

-7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE

FORWARD/REVERSE& STEER

LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

CR13JIB BOOMRELAY

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

C3

P-4

DL

ITE

WH

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2

PRIMARY BOOM UP/DOWN& TURNTABLE ROTATE

LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

L4PLATFORMOVERLOAD

LED

+

GR

/BK

H1

(D3

9)

BK

RD

RD

RD

RD

RD

/BK

H1

Platform Control Box Switch Panel Wiring Diagram, Z-45/25Deutz F3L-2011 Models


Electrical Schematic, Z-45/25JDeutz F3L-2011 Models

1

2

3

4

5

6

7

8



6 - 33 Z-45/25 • Z-45/25J Part No. 107846

REV C


NOTE:




C1

33

PL

AB

L/R

DP

13

4T

TS

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

+

-

RD

P2

0B

AT

RD

TB20

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

C4

6H

RN

BK

/RD

NO

CB1

RD

RD

CB2

15A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GND

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BK

P2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUND

AUX. ON

KEY PWR.

BATTERY

TACHOMETER

IGN./FUEL ON

ENG. FAULT

KEY BYPASS

START INPUT

START RELAY

4

PUMP

PR1

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

CR1CR1NO

R3

3S

TR

BK

TB21

TB25

CR2NO

8

7

6

5

10

9

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1

RD

TS52

BK

1

2

TB33


C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

OIL

TE

MP

ER

AT

UR

EL

ED

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L42

L43

OIL

PRES.

OIL

TEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

NO

CR4

CR4

NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TILT

AL

AR

M

P2

2B

AT

BK

W

GL

OW

PL

UG

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

C1

P-9

C3

5R

PM

BK

/RD

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BK

EN

GIN

ES

PE

ED

C1

B-9

C5

-18

C1

B-8

C5

-12

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-17

C2

B-7

B112V DC

D1

C33MF

+

M2

M3

PR2PR2

NO

Q3

S8

U1

U32

C3

5R

PM

BK

/RD

BK

/RD

C6

-34

P1

34

FB

RD

C2

B-3

L30 L30

L29L29


C3

P-4

C3

B-4

DL

ITE

WH

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

NO

CR23CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

OP

TIO

N

C6

-38

C6

-39

TS48

RD

RD

C7

B-1

FUSE 10A

P20BAT RD

A C

B

HIG

HR

PM

SU

PR

ES

SIO

ND

IOD

E

4

6

12 8

7

5

C1

B-1

L48

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D40

1 3

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RG

NC

2B

-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

P134 RD

6

5

BR

N

C32

L48

PR3

L48L48

C5

-23 C

6-2

7

TB35

GR/BK

ALT

ER

NA

TO

R

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

GL

OW

PL

UG

GL

OW

PL

UG

LO

WR

PM

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

GE

NE

RA

TO

R

WO

RK

LIG

HT

S

DR

IVE

LIG

HT

S


1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 34


REV C



2


WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

VA

LVE

H3

C2

2-2C

5-2

5

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C1

29

DA

BK

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5 C6

-13

LS

4-

SE

CO

ND

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

1-

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

LS

2-

PR

IMA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

3-

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6

RD

C11

-3B

K-7

C1

0-2

14

R11

SB

DB

L/B

K

R1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

R4

TR

LW

H

R5

TR

RW

H/B

K

R2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

R1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

CW

BL

/BK

C3

6S

CC

BL

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1

H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

JIB

BO

OM

VA

LVE GR

/BK

-44

J3 J1 J1

C1

29

DA

GR

/BK

C1

9JS

VG

R/W

H

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

P2

2L

SB

K

TB18

TB17

C4

B-5

C4

B-7

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C2

B-6

TB44

C1

7JU

GR

TS57

TS58

C4

P-7

C19JSV GR/WH

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C2

P-6

C3

P-8

C3

P-7

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-11

C11

-4

21

OR BK

-6

C6

-40 C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-11

12

13

TS61 TS62

6R14

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

WH

CR13

TS7TS8

BRN

TS9

CR13

NC

TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

2

11 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1

C3

7S

CW

BL

/BK

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

CC

BL

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-11

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-11

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14

5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3

TS15

15

TS14

WH

BK

RD

/WH

DO

WN

UP

JIB

BO

OM

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

LE

FT

RIG

HT

BO

OM

EX

TE

ND

RE

TR

AC

T

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

DO

WN

UP

JIB

BO

OM

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

BO

OM

EX

TE

ND

RE

TR

AC

T SE

CO

ND

AR

YB

OO

MU

P

DO

WN

PR

IMA

RY

BO

OM

UP

DO

WN

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LE

FT

D314

20R4

7.5

Electrical Schematic, Z-45/25J, CE ModelsDeutz F3L-2011 Models

1

2

3

4

5

6

7

8



6 - 35 Z-45/25 • Z-45/25J Part No. 107846

REV C

C1

33

PL

AB

L/R

DP

13

4T

TS

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

+

-

RD

P2

0B

AT

RD

TB20

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

C4

6H

RN

BK

/RD

NO

CB1

RD

RD

CB2

15A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GND

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BK

P2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

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GROUND

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BATTERY

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ENG. FAULT

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START INPUT

START RELAY

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4

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12 8

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5

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5

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N

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6-2

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AU

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EN

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TA

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PL

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NOTE:



4 CE and platform overload option

H6 L45

L4

D39

4

LS18

C1

P-1

2

LO

AD

SE

NS

EM

OD

UL

E


1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 36


REV C



2


WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

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WH

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BO

OM

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AC

T

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OM

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WN

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TA

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LE

FT

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BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

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N

JIB

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OM

VA

LVE

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2-2C

5-2

5

C2

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AT

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VE

LD

OW

N

PL

AT

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VE

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EX

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PB

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6-1

C1

7-1

C7

PB

EB

K

C6

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C6

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C6

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C6

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C6

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SE

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ND

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EC

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N

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BO

OM

SE

LE

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LA

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PR

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BO

OM

DO

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TU

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TA

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OTA

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SE

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CT

RE

LA

Y

TU

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TA

BL

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C1

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C1

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WH

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C1

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C1

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C6

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C6

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8587a 87

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EA

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C6

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C6

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C6

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C6

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C3

1R

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0F

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RD

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U4

C5

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C5

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TB5

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H/B

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TB17

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B-5

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B-7

TB14

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B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C2

B-6

TB44

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TS58

C4

P-7

C19JSV GR/WH

C4

P-5

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GR

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C4

P-2

C4

P-3

TS59 TS63

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P-6

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P-8

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P-7

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TB12

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B-2

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B-1

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P-2

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D314

20R4

7.5

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JDeutz F3L-2011 Models


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JDeutz F3L-2011 Models

1

2

3

4

5

6

7

8



6 - 37 Z-45/25 • Z-45/25J Part No. 107846

REV A


85

87

86

87A


DC

PR

IMA

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BO

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UP

1 2 3 4 5 6 7 8 10

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1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

MC

6-3

3

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT

RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TO PLAT

C7B

CB

1P

OW

ER

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

WH

/RD

-L4

3(-

)

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

(-)

OIL

PR

ES

SU

RE

SW

ITC

H

BK

/RD

-CR

4

CR2POWERRELAY


BR

N

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

C5-18 BK/RD

WH

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C3B-4

C4B C4BC4B







GL

OW

PL

UG

GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L4

2(-

)

C5-11 WH

BK

-KS

I


BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C4

3D

LIT

EG

R

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD

C5

-14

WH

/RD


RD

-CR

2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-CR

2

WH

-IS

7

C5

-16

WH

/RD

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

WH

-23

B

BK

-33

BB

K-I

S3

BK

-IS

3


F1910A FUSE

C6-13 BK

BK-22B

RD




BRN

BRN

BR

N

RD

/WH

-3B

RD

-1B

C6

-2R

D/B

K

C6

-1R

D

C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

-6B

WH

/BK

-5B

BL

/WH

-12

BBL-10BBR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-1

7W

H

C3

B-4

WH

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7B-1

BK 22B

RD H6

C3

2

13

45

67

81

2

RD

H6

H6

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

C6

-9B

K/R

D

C3

+

BR

NB

RN

C3

+

RD

H6

(CE OPTION ONLY)

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN GND

GR/BK H6

RD TS52

RD TS51

BK 22B

BK/WH C1B-12

RD H6

C3

2

13

45

67

81

2

45

67

45

67

45

67

45

67

WH

-25

D&

26

D

WH

-IS

10

WH

/RD

-L4

3-

WH

/BK

-L4

2-

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1


BK

-IS

1

RD

-IS

6

RD

-27

B

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-33

BB

K-I

S3

BK

-IS

3

RD

-IS

4

BRN

BRN-GND

C6 C6

(SP

AR

E)

(SP

AR

E)

BK

-CR

5

Ground Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-2011 Models

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8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 38


REV B


KS1 KEY SWITCH











LABEL DESCRIPTION




HM HOUR METER





CR4 HIGH IDLE RELAY

CR5 HORN RELAY


HIGH IDLE RELAY


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD R

DR

D

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

GRGR

GR/BK

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

RD

GR/BK

RD

GR/BK

RD

GR

/BK

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

A

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

58

JIB

BO

OM

UP

/DO

WN

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3O

ILT

EM

PL

ED

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R,2

0�

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

GR

/BK

-44

A

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C3

2-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

mo

de

ls)

-+

KS

1G-BOX

P-BOX

RD

14

�

6�

DA

LE

RH

-25

25

W7

.5o

hm

1%

R1

4S

EC

ON

DA

RY

BO

OM

UP

/DO

WN

SP

EE

DR

ES

IST

OR


Ground Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-2011 Models


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JCE Models Deutz F3L-2011 Models


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25J, CE ModelsDeutz F3L-2011 Models

1

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6 - 39 Z-45/25 • Z-45/25J Part No. 107846

REV A


85

87

86

87A


DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011 15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C3

2-4

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C5

-22

BK

/WH

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

WH

-23

B

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11 15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

(SP

AR

E)

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-IS

7

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

WH

-IS

7

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

MC

6-3

3

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT

RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TO PLAT

C7B

CB

1P

OW

ER

OIL

TE

MP

ER

AT

UR

ES

WIT

CH

WH

/RD

-L4

3(-

)

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

(-)

OIL

PR

ES

SU

RE

SW

ITC

H

BK

/RD

-CR

4

CR2POWERRELAY


BR

N

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

C5-18 BK/RD

WH

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C3B-4

C4B C4BC4B







GL

OW

PL

UG

GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L4

2(-

)

C5-11 WH

BK

-KS

I


BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C4

3D

LIT

EG

R

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD

C5

-14

WH

/RD


RD

-CR

2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-CR

2

WH

-IS

7

C5

-16

WH

/RD

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

WH

-23

B

BK

-33

BB

K-I

S3

BK

-IS

3


F1910A FUSE

C6-13 BK

BK-22B

RD




BRN

BRN

BR

N

RD

/WH

-3B

RD

-1B

C6

-2R

D/B

K

C6

-1R

D

C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

-6B

WH

/BK

-5B

BL

/WH

-12

BBL-10BBR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-1

7W

H

C3

B-4

WH

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7B-1

BK 22B

RD H6

U33

C3

2

13

45

67

81

2

RD

H6

H6

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

C6

-9B

K/R

D

C3

+

BR

NB

RN

C3

+

RD

H6

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN GND

GR/BK H6

RD TS52

RD TS51

BK 22B

BK/WH C1B-12

RD H6

C3

2

13

45

67

81

2

U33W

H-2

5D

&2

6D

WH

-IS

10

WH

/RD

-L4

3-

WH

/BK

-L4

2-

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1


BK

-IS

1

RD

-IS

6

RD

-27

B

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-33

BB

K-I

S3

BK

-IS

3

RD

-IS

4

BRN

BRN-GND

C6 C6

(SP

AR

E)

(SP

AR

E)

BK

-CR

5

Ground Control Box Switch Panel Wiring Diagram, Z-45/25J, CE ModelsDeutz F3L-2011 Models

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 40


REV B


KS1 KEY SWITCH











LABEL DESCRIPTION




HM HOUR METER





CR4 HIGH IDLE RELAY

CR5 HORN RELAY


HIGH IDLE RELAY


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD R

DR

D

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

GRGR

GR/BK

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

RD

GR/BK

RD

GR/BK

RD

GR

/BK

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

A

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

58

JIB

BO

OM

UP

/DO

WN

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3O

ILT

EM

PL

ED

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R,2

0�

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

GR

/BK

-44

A

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C3

2-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

mo

de

ls)

-+

KS

1

G-BOX

P-BOX

RD

14

�

6�

DA

LE

RH

-25

25

W7

.5o

hm

1%

R1

4S

EC

ON

DA

RY

BO

OM

UP

/DO

WN

SP

EE

DR

ES

IST

OR


Ground Control Box Switch Panel Wiring Diagram, Z-45/25JCE Models Deutz F3L-2011 Models


Platform Control Box Wiring Diagram, Z-45/25JDeutz F3L-2011 Models


Platform Control Box Wiring Diagram, Z-45/25JDeutz F3L-2011 Models

1

2

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5

6

7

8



6 - 41 Z-45/25 • Z-45/25J Part No. 107846

REV A

TILTALARM

WH

C1

9JS

V

RE

D-T

ILTR

ED

-TILT

C2

P-5

BR

NB

RN

C3P

JIB

F.S.

C7P

JIB BK JIB BK JIB

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

H1

12V DC BATTERYSUPPY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C4P

C4

4JD

AL

AR

MG

R/B

KC

2P

-6

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

7JU

GR

C4

P-5

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


TS

7

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Y

RD

-P2

RD

-H1

RE

D-

LS

18

LS18CE OPTION

ONLYOPT.

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM





RD

/BK

-L4

8(-)

GR

/BK

C4

P-1

GR

/BK

-L4

TS

1W

H

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-2011 Models

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6 - 42


REV A

P2EMERGENCY

STOPTS4HIGH/LOW

RPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED


TS13PRIMARY BOOM

EXTEND/RETRACT

TS8JIB BOOM

TS7PLATFORMROTATE

TS9PLATFORM

LEVEL

P3HORN TS1

AUXILIARYPUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

BK

C9

P-1

WH

C7

P-2

RD

WH

GR/BK

RD

GR

RD

WH-24

RD RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

TS6GLOWPLUG

(OPTION)

C3

4S

AB

K/W

HC

1P

-8WHWH

White wire replacedby CR27 and CR30on CE models

GR

/BK

-44

C2

P-6

RD


C3

5R

PM

BK

/RD

C1

P-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

CR13JIB BOOMRELAY

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

C3

P-4

DL

ITE

WH

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2


LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

L4PLATFORMOVERLOAD

LED

+

GR

/BK

H1

(D3

9)

BK

RD

RD

RD

RD

RD

/BK

H1

Platform Control Box Switch Panel Wiring Diagram, Z-45/25JDeutz F3L-2011 Models



Electrical Schematic, Z-45/25Perkins 404-22 Models

1

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8



6-44 Z-45/25 • Z-45/25J Part No. 107846


REV C


NOTE:




C1

33

PL

AB

L/R

DP

13

4T

TS

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

+

-

RD

P2

0B

AT

RD

TB20

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

C4

6H

RN

BK

/RD

NO

CB1

RD

RD

CB2

15A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GND

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BK

P2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUND

AUX. ON

KEY PWR.

BATTERY

TACHOMETER

IGN./FUEL ON

ENG. FAULT

KEY BYPASS

START INPUT

START RELAY

4

PUMP

PR1

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

CR1CR1NO

R3

3S

TR

BK

TB21

TB25

CR2NO

8

7

6

5

10

9

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1

RD

TS52

BK

1

2

TB33


C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

CO

OL

AN

TT

EM

PE

RA

TU

RE

LE

D

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L42

L43

OIL

PRES.

OIL

TEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

CO

OL

AN

TT

EM

PE

RA

TU

RE

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

NO

CR4

CR4

NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TILT

AL

AR

M

P2

2B

AT

BK

W

GL

OW

PL

UG

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

C1

P-9

C3

5R

PM

BK

/RD

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BK

EN

GIN

ES

PE

ED

C1

B-9

C5

-18

C1

B-8

C5

-12

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-17

C2

B-7

B112V DC

D1

C33MF

+

M2

M3

PR2PR2

NO

Q3

S8

U1

U32

C3

5R

PM

BK

/RD

BK

/RD

C6

-34

P1

34

FB

RD

C2

B-3

L30 L30

L29L29


C3

P-4

C3

B-4

DL

ITE

WH

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

NO

CR23CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

OP

TIO

N

C6

-38

C6

-39

TS48

RD

RD

C7

B-1

FUSE 10A

P20BAT RD

A C

B

HIG

HR

PM

SU

PR

ES

SIO

ND

IOD

E

4

6

12 8

7

5

C1

B-1

L48

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D40

1 3

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RG

NC

2B

-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

P134 RD

6

5

BR

N

C32

L48

PR3

L48L48

C5

-23 C

6-2

7

TB35

GR/BK

ALT

ER

NA

TO

R

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

GL

OW

PL

UG

GL

OW

PL

UG

LO

WR

PM

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

GE

NE

RA

TO

R

WO

RK

LIG

HT

S

DR

IVE

LIG

HT

S

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6-45



REV C



2


WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

H3

C2

2-2C

5-2

5

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C1

29

DA

BK

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5 C6

-13

LS

4-

SE

CO

ND

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

1-

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

LS

2-

PR

IMA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

3-

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6

RD

C11

-3B

K-7

C1

0-2

14

R11

SB

DB

L/B

K

R1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

R4

TR

LW

H

R5

TR

RW

H/B

K

R2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

R1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

CW

BL

/BK

C3

6S

CC

BL

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1

H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

J3 J1 J1

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

P2

2L

SB

K

TB18

TB17

C4

B-5

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C1

7JU

GR

TS58

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C3

P-8

C3

P-7

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-11

C11

-4

21

OR BK

-6

C6

-40 C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-11

12

13

TS61 TS62

6R14

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

TS8TS9 TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

2

11 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1

C3

7S

CW

BL

/BK

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

CC

BL

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-11

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-11

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14

5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3

TS15

15

TS14

RD

/WH

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

LE

FT

RIG

HT

BO

OM

EX

TE

ND

RE

TR

AC

T

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

BO

OM

EX

TE

ND

RE

TR

AC

T SE

CO

ND

AR

YB

OO

MU

P

DO

WN

PR

IMA

RY

BO

OM

UP

DO

WN

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LE

FT

D314

20R4

7.5


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Perkins 404-22 Models

1

2

3

4

5

6

7

8



6-48 Z-45/25 • Z-45/25J Part No. 107846

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25Perkins 404-22 Models

REV A


85

87

86

87A


DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011 15

17

18

14

12

AU

XIL

IAR

YP

UM

P

CO

OL

AN

TT

EM

PE

RA

TU

RE

SW

ITC

H

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C3

2-4

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C5

-22

BK

/WH

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

WH

-23

B

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11 15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

(SP

AR

E)

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-IS

7

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

WH

-IS

7

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

MC

6-3

3

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT

RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TO PLAT

C7B

CB

1P

OW

ER

WH

/RD

-L4

3(-

)

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

(-)

OIL

PR

ES

SU

RE

SW

ITC

H

BK

/RD

-R4

CR2POWERRELAY


BR

N

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

C5-18 BK/RD

WH

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C3B-4

C4B C4BC4B







GL

OW

PL

UG

GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L4

2(-

)

C5-11 WH

BK

-KS

I


BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C4

3D

LIT

EG

R

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD

C5

-14

WH

/RD


RD

-CR

2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-CR

2

WH

-IS

7

C5

-16

WH

/RD

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

WH

-23

B

BK

-33

BB

K-I

S3

BK

-IS

3


F1910A FUSE

C6-13 BK

BK-22B

RD




BRN

BRN

BR

N

RD

/WH

-3B

RD

-1B

C6

-2R

D/B

K

C6

-1R

D

C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

-6B

WH

/BK

-5B

BL

/WH

-12

BBL-10BBR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-1

7W

H

C3

B-4

WH

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK 22B

RD H6

C3

2

13

45

67

81

2

RD

H6

H6

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

C6

-9B

K/R

D

C3

+

BR

NB

RN

C3

+

RD

H6

(CE OPTION ONLY)

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7-1

BK 22B

BK/WH C1-12

RD H6

C3

2

13

45

67

81

2

45

67

45

67

45

67

45

67

WH

-25

D&

26

D

WH

-IS

10

WH

/RD

-L4

3-

WH

/BK

-L4

2-

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1


BK

-IS

1

RD

-IS

6

RD

-27

B

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-33

BB

K-I

S3

BK

-IS

3

RD

-IS

4

BRN

BRN-GND

C6 C6

(SP

AR

E)

(SP

AR

E)

BK

-CR

5

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6-49


Ground Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 404-22 Models

REV B


KS1 KEY SWITCH










LABEL DESCRIPTION




HM HOUR METER





CR4 HIGH IDLE RELAY

CR5 HORN RELAY

L43 COOLANT TEMPERATURE LED

HIGH IDLE RELAY


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD R

DR

D

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

A

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3C

OO

LA

NT

TE

MP

LE

D

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R,2

0�

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C3

2-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

mo

de

ls)

-+

KS

1

G-BOX

P-BOX

RD

14

�

6�

DA

LE

RH

-25

25

W7

.5o

hm

1%

R1

4S

EC

ON

DA

RY

BO

OM

UP

/DO

WN

SP

EE

DR

ES

IST

OR



Ground Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 404-22 Models


Platform Control Box Wiring Diagram, Z-45/25Perkins 404-22 Models

1

2

3

4

5

6

7

8



6-52 Z-45/25 • Z-45/25J Part No. 107846

Platform Control Box Wiring Diagram, Z-45/25Perkins 404-22 Models

REV A

TILTALARM

RE

D-T

ILTR

ED

-TILT

C2

P-5

BR

NB

RN

C3P

F.S.

C7P

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

H1

12V DC BATTERYSUPPY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C4P

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


TS

7

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Y

RD

-P2

RD

-H1

RE

D-

LS

18

LS18CE OPTION

ONLYOPT.

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM





RD

/BK

-L4

8(-)

GR

/BK

C4

P-1

GR

/BK

-L4

TS

1W

H

C3

4S

AB

K/W

HC

1P

-8

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6-53


Platform Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 404-22 Models

REV A

P2EMERGENCY

STOPTS4HIGH/LOW

RPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED


TS13PRIMARY BOOM

EXTEND/RETRACT

TS7PLATFORMROTATE

TS9PLATFORM

LEVEL

P3HORN TS1

AUXILIARYPUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

BK

C9

P-1

WH

C7

P-2

RD

WH

RD RD

WH-24

RD RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

TS6GLOWPLUG

C3

4S

AB

K/W

HC

1P

-8WHWH

RD


C3

5R

PM

BK

/RD

C1

P-9

2

1

NC

2

1

NCB

L/B

K-D

E2

J1

-7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

C1

9JS

VG

R/W

H

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

CD

LIT

EG

R

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2


LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

L4PLATFORMOVERLOAD

LED

+

GR

/BK

H1

(D3

9)

BK

RD

RD

RD

RD

RD

/BK

H1


Platform Control Box Switch Panel Wiring Diagram, Z-45/25Perkins 404-22 Models


Electrical Schematic, Z-45/25JPerkins 404-22 Models

1

2

3

4

5

6

7

8



6-56 Z-45/25 • Z-45/25J Part No. 107846


REV C


NOTE:




C1

33

PL

AB

L/R

DP

13

4T

TS

WH

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15A

+

-

RD

P2

0B

AT

RD

TB20

C1

07

AF

WH

C4

1R

PM

OR

/BK

CR5

C4

6H

RN

BK

/RD

NO

CB1

RD

RD

CB2

15A

TB41

C4

6H

RN

BK

/RD

TB23

KS1

PLAT

GND

P1

RD

P3

HORN

TB134

P2

2B

AT

BK

BK-(FS)C9P-1 BK

P2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NS

OP

TIO

N

HO

UR

ME

TE

R

PO

WE

RR

EL

AY

IGN

ITIO

N/S

TA

RT

RE

LA

Y

STA

RT

ER

MO

TO

R

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

OW

ER

RE

LA

Y

TS2

GROUND

AUX. ON

KEY PWR.

BATTERY

TACHOMETER

IGN./FUEL ON

ENG. FAULT

KEY BYPASS

START INPUT

START RELAY

4

PUMP

PR1

C2

7A

UX

RD

PR1

NO

C2

8T

TA

RD

/BK

CR1CR1NO

R3

3S

TR

BK

TB21

TB25

CR2NO

8

7

6

5

10

9

CR2

TS51

C2

8T

TA

RD

/BK

TB27

RD

TS1

RD

TS52

BK

1

2

TB33


C2

1IG

NW

H

FB1

C3

3S

TR

BK

C4

5G

EN

GR

/WH

TS47

P24FS WH

C9P-3RD-(FS)

FS1

BR

N

TS54

TS4

BRN

RD

BK

P24FS WH

P26ESTP BK

CO

OL

AN

TT

EM

PE

RA

TU

RE

LE

D

C9P-2

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

C2

6T

SR

WH

/RD

C2

5P

SR

WH

/BK

L42

L43

OIL

PRES.

OIL

TEMP.

SW2NC

SW3NO

OIL

PR

ES

SU

RE

SW

ITC

H

CO

OL

AN

TT

EM

PE

RA

TU

RE

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

TB34

TS56

C3

4S

AB

K/W

H

TS6

PR3

NO

CR4

CR4

NO

HIG

HR

PM

SO

LE

NO

ID

HIG

HID

LE

RE

LA

Y

TILT

AL

AR

M

P2

2B

AT

BK

W

GL

OW

PL

UG

WH-(FS)

H1

RD

WH

BR

NB

K

BK

C3

P-9

H2+

_

C41RPM OR/BK

RD

P25FS RD

P26ESTP BK

C1

P-2

C1

P-1

C2

7A

UX

RD

C7

P-1

C1

P-7

C1

P-8

C2

P-7

C1

P-9

C3

5R

PM

BK

/RD

C4

1R

PM

OR

/BK


C28TTA RD/BK

C41RPM OR/BK

EN

GIN

ES

PE

ED

C1

B-9

C5

-18

C1

B-8

C5

-12

C1

B-7

C4

5G

EN

GR

/WH

C5

-22

C5

-14

C5

-16

C5

-11C6

-9

C3

4S

AB

K/W

H

C5

-5

C21IGN WH

C2

1IG

N2

WH

C3

B-9

C5

-2

C5-3

C7

B-4

C5

-17

C2

B-7

B112V DC

D1

C33MF

+

M2

M3

PR2PR2

NO

Q3

S8

U1

U32

C3

5R

PM

BK

/RD

BK

/RD

C6

-34

P1

34

FB

RD

C2

B-3

L30 L30

L29L29


C3

P-4

C3

B-4

DL

ITE

WH

C2

P-11

C2

P-1

2C

2P

-10

C2

P-9

PBOX GND

RD

RD

NO

CR23CR23

DR

IVE

LIG

HT

OP

TIO

N

WO

RK

LIG

HT

OP

TIO

N

C6

-38

C6

-39

TS48

RD

RD

C7

B-1

FUSE 10A

P20BAT RD

A C

B

HIG

HR

PM

SU

PR

ES

SIO

ND

IOD

E

4

6

12 8

7

5

C1

B-1

L48

D3

D4

C7

P-2

P2

3B

AT

WH

C7

B-2

D2

D40

1 3

C2

P-5

C1

32

PL

IB

L/W

H

C1

34

PW

RG

NC

2B

-5

C1

B-1

2

TB22

C4

B-1

C1

B-2

P134 RD

6

5

BR

N

C32

L48

PR3

L48L48

C5

-23 C

6-2

7

TB35

GR/BK

ALT

ER

NA

TO

R

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

EN

GIN

ES

TA

RT

EN

GIN

ES

TA

RT

GL

OW

PL

UG

GL

OW

PL

UG

LO

WR

PM

HIG

HR

PM

LO

WR

PM

FU

NC

TIO

NE

NA

BL

E

GE

NE

RA

TO

R

WO

RK

LIG

HT

S

DR

IVE

LIG

HT

S

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6-57



REV C



2


WH

P26ESTP BK

C41RPM OR/BK

C28TTA RD/BK

BRN

RD

RD

BK

P24FS WH

WH

-4

BO

OM

RE

TR

AC

T

CR33

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

C6

-19

DE

SC

EN

TA

LA

RM

OP

TIO

N

JIB

BO

OM

VA

LVE

H3

C2

2-2C

5-2

5

C2

3-2

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BO

OM

EX

TE

ND

C2

1-2

C2

0-2

C1

6-2

C1

7-2

C1

29

DA

BK

C1

8JD

GR

/BK

C2

2-1

C2

3-1

C1

7JU

GR

C6

-18

C6

-17

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C2

1-1

C2

0-1

C8

PB

RB

K/W

H

C1

6-1

C1

7-1

C7

PB

EB

K

C6

-15

C6

-14

C6

-8

C6

-7

C6

-20

BK

-5 C6

-13

LS

4-

SE

CO

ND

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

H

LS

1-

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

LS

2-

PR

IMA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS

3-

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P

SE

CO

ND

AR

YB

OO

MS

EL

EC

TR

EL

AY

SE

CO

ND

AR

YB

OO

MD

OW

N

C1

8-2

C1

9-2

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

SE

LE

CT

RE

LA

Y

PR

IMA

RY

BO

OM

DO

WN

TU

RN

TA

BL

ER

OTA

TE

SE

LE

CT

RE

LA

Y

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

LE

FT

C1

3-2

C1

4-2

C1

2-2

C1

5-2

BK LS3

C6

-10

C6

-11

C1

0-1

WH

-6

RD

C11

-3B

K-7

C1

0-2

14

R11

SB

DB

L/B

K

R1

0S

BU

BL

C1

8-1

C1

9-1

LS2

22

21

C1

0-4

WH

-5

BK

-6

13

2

8587a 87

8630

CR37

R4

TR

LW

H

R5

TR

RW

H/B

K

R2

PB

DR

D/B

K

C1

3-1

C1

4-1

C1

2-1

C1

5-1

R1

PB

UR

D

8587a 87

8630

C6

-2

C6

-5

C6

-4

C6

-1

CR32

8587a 87

8630

BR

AK

ER

EL

EA

SE

VA

LVE

TR

AV

EL

AL

AR

MO

PT

ION

MO

TO

RS

TR

OK

E

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

C2

4-2

C2

5-2

C2

8-2

C2

6-2

DR

IVE

ED

CR

EV

ER

SE

DR

IVE

ED

CF

OR

WA

RD

GR

OU

ND

BR

N

BR

N

BK

RD

C3

7S

CW

BL

/BK

C3

6S

CC

BL

C2

4-1

C2

5-1

C2

9M

SR

D/W

H

C3

2B

RK

WH

/RD

C3

2TA

WH

/RD

C2

8-1

C2

6-1

H4

C6

-37

C6

-36

C6

-29

C6

-32

C6

-33

C3

1R

EV

WH

/BK

C3

0F

WD

WH

RD

BK

U4

C5

-20

C5

-21

TB5

C5

TR

RW

H/B

K

JIB

BO

OM

VA

LVE GR

/BK

-44

J3 J1 J1

C1

29

DA

GR

/BK

C1

9JS

VG

R/W

H

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C8

PB

RB

K/W

H

C7

PB

EB

K

P2

2L

SB

K

TB18

TB17

C4

B-5

C4

B-7

TB14

C4

B-6

TB15

C4

B-2

C4

B-3

TB7

TB8

C3

B-8

C3

B-7

C2

B-6

TB44

C1

7JU

GR

TS57

TS58

C4

P-7

C19JSV GR/WH

C4

P-5

C1

8JD

GR

/BK

C4

P-2

C4

P-3

TS59 TS63

C4

P-6

C2

P-6

C3

P-8

C3

P-7

C1

6P

DR

EO

R/R

D

C1

2S

BF

BL

/WH

C11

SB

DB

L/B

K

C3

PB

FR

D/W

H

C1

0S

BU

BL

C2

PB

DR

D/B

K

C1

PB

UR

D

LS1

C1

0-3

WH

-6

21

WH

-7

22

LS4

C11

-2

C6

-16

22BK

-4

C4

B-4

TB10

TB12

TB11

C3

B-1

0

C3

B-11

C11

-4

21

OR BK

-6

C6

-40 C11

-1

TB3

C3

B-1

2

C3

B-3

C3

B-2

C3

B-1

TB2

TB6

TB1

C3

B-5

14

BK

C2

B-2

C40LSS OR

TS60


C2

P-2

C4

P-4

CELIFT/DRIVEOPTION

4 3

C3

P-1

0

C3

P-11

12

13

TS61 TS62

6R14

J2

C3

P-1

2

C3

P-2

C3

P-3

C3

P-1

8 7 6

C3

P-5

10

WH

CR13

TS7TS8

BRN

TS9

CR13

NC

TS13

6

P2

4F

SW

H

P2

6E

ST

PB

K

CR30NO

3 4

CR27NC

P2

4F

SW

H

BR

N

BR

N OR

YE

L

12

10 9 3

1 2 3 4 5

PW

R

GN

D

OU

T

JC1


P26ESTP BK

BR

N1

2

7 21

GN

D

RD

OR

BK

2

11 1

543 6 7

PW

R

XO

UT

YO

UT


JC2

J1

C4

1R

PM

OR

/BK

J1

C3

7S

CW

BL

/BK

C2

9M

SR

D/W

H

C6

TR

FW

H/R

D

C3

6S

CC

BL

C3

1R

EV

WH

/BK

C3

2B

RK

WH

/RD

C3

0F

WD

WH

BA

TG

ND

C3

B-6

C1

B-1

0

C1

B-11

TB32

C1

B-3

C1

B-6

C1

B-5

C1

B-4

C7

B-3

C3

P-6

C1

P-1

0

C1

P-11

18

119 17

C1

P-3

C1

P-6

20

19

C1

P-5

C2

P-3

C1

P-4

C7

P-3

15

16 5

C28TTA RD/BK

RK

OU

T

L1

7

WH

BR

N

OR

BL

BL

14

5

13 4

GN

D21 3 4 5 6

PW

R

YO

UT

DR

IVE

MO

DE

CD

E3

BL

/RD

CD

E2

BL

/BK

6 7

16 8

CD

E1

BL

P24FS WH

P26ESTP BK

DRIVE & STEERING

JC3

TS15

15

TS14

WH

BK

RD

/WH

DO

WN

UP

JIB

BO

OM

RIG

HT

LE

FT

DR

IVE

EN

AB

LE

LE

FT

RIG

HT

BO

OM

EX

TE

ND

RE

TR

AC

T

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

DO

WN

UP

JIB

BO

OM

PL

AT

FO

RM

LE

VE

LD

OW

N

UP

BO

OM

EX

TE

ND

RE

TR

AC

T SE

CO

ND

AR

YB

OO

MU

P

DO

WN

PR

IMA

RY

BO

OM

UP

DO

WN

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

LE

FT

D314

20R4

7.5


Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JPerkins 404-22 Models

1

2

3

4

5

6

7

8



6-60 Z-45/25 • Z-45/25J Part No. 107846

Ground Control Box Terminal Strip Wiring Diagram, Z-45/25JPerkins 404-22 Models

REV B


85

87

86

87A


DC

PR

IMA

RY

BO

OM

UP

1 2 3 4 5 6 7 8 10

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FU

NC

TIO

NC

ON

TR

OL

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

FU

NC

TIO

NC

TR

L

PR

IMA

RY

BO

OM

EX

TE

ND

PR

IMA

RY

BO

OM

RE

TR

AC

T

SE

CO

ND

AR

YB

OO

MU

P

+1

2V

OLT

PO

WE

R

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

DO

WN

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

UP

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

SE

CO

ND

AR

YB

OO

MF

UN

CT

ION

CT

RL

SE

CO

ND

AR

YB

OO

MD

OW

N

2011 15

17

18

14

12

AU

XIL

IAR

YP

UM

P

OIL

PR

ES

SU

RE

SW

ITC

H

KE

YS

WIT

CH

PO

WE

R

IGN

ITIO

NP

OW

ER

21

25

27

26

23

24

HIG

HR

PM

STA

RT

EN

GIN

E

BR

AK

E

39

35

38

33

34

32

ALT

ER

NA

TO

RP

UL

SE

PIC

KU

P4

1

44

42

BA

CR

32

#8

6R

D

C3

B-1

RD

C3

B-2

RD

/BK

C3

B-3

RD

/WH

CR

33

#8

6W

H/B

K

C3

B-5

WH

/BK

C3

B-6

WH

/RD

C6

-7B

K

C3

B-7

BK

C6

-8B

K/W

H

C3

B-8

BK

/WH

CR

37

#8

6B

L

C3

B-1

0B

L

C3

B-1

1B

L/B

K

CR

37

#3

0B

L/W

H

C3

B-1

2B

L/W

H

C6

-14

OR

C6

-15

OR

/BK

C6

-17

GR

C4

B-5

GR

C6

-18

GR

/BK

C4

B-6

GR

/BK

C1

B-1

RD

C7

B-4

RD

C5

-3W

H

C3

2-4

BK

C7

B-2

WH

C1

B-6

WH

/RD

C6

-32

WH

/RD

C1

B-7

BK

C5

-22

BK

/WH

C2

B-3

OR

/BK

C5

-2O

R/B

K

C2

B-6

GR

/BK

RD

-TS

61

RD

/BK

-TS

61

WH

/BK

-TS

62

BK

-TS

63

BK

/WH

-TS

63

BL

-TS

60

BL

/BK

-TS

60

BL

/WH

-TS

60

OR

-TS

59

OR

/BK

-TS

59

GR

-TS

57

GR

/BK

-TS

57

RD

-CB

1

BK

/RD

-TS

54

RD

/WH

-TS

61

WH

/RD

-TS

62

CR

33

#3

0W

H/R

D

C1B

C4B

C5

BATGND BRN

ENGINE HARNESS

FUNCTION HARNESS

WH

-23

B

RD

-27

B


E.H.

F.H.

OR

/BK

-IS

2

TE

RM

INA

LB

AS

E(T

B)

1 2 3 4 5 6 7 8 10

11 15

17

18

14

12

20

24

26

27

25

23

21

38

39

34

35

32

33

44

42

41


1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

(SP

AR

E)

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-23

B

WH

-R2

RD

-CR

1

CR

32

#3

0R

D/W

H

C4

B-2

OR

C4

B-3

OR

/BK

C6

-27

RD

WH

-IS

7

WH

-KS

RD

-TS

51

BK

-33

TS

52

OR

/BK

-41

A

WH

-IS

7

RD

-IS

4

OR

/BK

-IS

2

BK

-IS

1

WH

-IS

9

C5

-5B

K

C7B3 BRN


C6

C4B

C5

C7B

WH

/RD

-AL

AR

MC

6-3

3

BK-ALARMBK-ALARMBK

C6

-33

WH

/RD

-AL

AR

M

C5

-19

BK

-AL

AR

M

WH

/RD

-32

A

BK

-AL

AR

M

BK

BK

WH/RD-ALARM

JIB

DO

WN

DE

SC

EN

TA

LA

RM

BR

NB

RN

GROUND BOLT

RD

-IS

6

RD

-IS

4


C5C6 C2B C1BC3BC4B

12V DC TO PLAT

C7B

CB

1P

OW

ER

CO

OL

AN

TT

EM

PE

RA

TU

RE

SW

ITC

HW

H/R

D-L

43

(-)

C3BC3B C3B C3B C3B

C2B

C2

B-1

BL

/RD

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

BL

/RD

-TS

53

BL

/WH

-L2

(-)

OIL

PR

ES

SU

RE

SW

ITC

H

BK

/RD

-R4

CR2POWERRELAY


BR

N

WH-21C

RD

-24

B

BRN

C3B

+1

2V

OLT

TO

PL

AT

FO

RM

22

22

C7B-3

C5-18 BK/RD

WH

BK/RD-35C


C1

9JS

VG

R/W

HT

S5

7C

4B

-7G

R/W

H

C3B-4

C4B C4BC4B







GL

OW

PL

UG

GL

OW

PL

UG

C5

-22

BK

/WH

C1

B-8

BK

/WH

WH

-25

D&

26

D

C1

B-9

BK

/RD

C6

-20

BK

BK

/WH

-TS

56

WH

/BK

-L4

2(-

)

C5-11 WH

BK

-KS

I


BRN

R4

3D

LIT

E1

RD

R4

3D

LIT

E2

RD

P20DLITE RD

C4

3D

LIT

EG

R

WH

-IS

10

C2

B-4

OR

/RD

C5

-14

WH

/RD

C5

-14

WH

/RD


RD

-CR

2

RD

-CB

1

RD

-CB

2C

R2

3R

D

RD

-20

CD

RIV

EL

IGH

TS

WH

-HM

WH

-CR

2

WH

-IS

7

C5

-16

WH

/RD

C5

-16

WH

/RD

GR

/BK

-TS

58

BK

-AL

AR

M

RELAY HARNESS

I.S.M.

BRN

WH

-23

BW

H-I

S7

WH

-23

B

BK

-33

BB

K-I

S3

BK

-IS

3


F1910A FUSE

C6-13 BK

BK-22B

RD




BRN

BRN

BR

N

RD

/WH

-3B

RD

-1B

C6

-2R

D/B

K

C6

-1R

D

C6

-5W

H/B

K

C6

-10

BL

C6

-4W

H

C6

-11

BL

/BK

WH

/RD

-6B

WH

/BK

-5B

BL

/WH

-12

BBL-10BBR

N

13

4K

SP

OW

ER

13

4A

KS

PO

WE

R

RD

KS

1C

5-1

7W

H

C3

B-4

WH

C6

-34

RD

BRN GND

GR/BK H6

RD TS52

RD TS51

BK 22B

RD H6

C3

2

13

45

67

81

2

RD

H6

H6

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

C6

-38

C6

-39

CR5HORNRELAY

C3

B-9

BK

/RD

13

4A

13

4

C6

-9B

K/R

D

C3

+

BR

NB

RN

C3

+

RD

H6

(CE OPTION ONLY)

RD

C3

2-1

RD

13

4B

GR

/BK

C3

2-8

GR

/BK

L4

5

GR

/BK

C4

B-1

BRN GND

GR/BK H6

RD TS52

RD TS51

BK C7-1

BK 22B

BK/WH C1-12

RD H6

C3

2

13

45

67

81

2

45

67

45

67

45

67

45

67

WH

-25

D&

26

D

WH

-IS

10

WH

/RD

-L4

3-

WH

/BK

-L4

2-

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 9 10

STA

RT

RE

LA

Y

TA

CH

OM

ET

ER

STA

RT

INP

UT

AU

XP

WR

UN

IT

GR

OU

ND

BA

TT

ER

Y

TO

KE

YS

W(D

IES

EL

ON

LY)

JU

MP

TO

7(G

AS

ON

LY

)

IGN

OR

FU

EL

ON

TE

MP

OR

PR

ES

SF

AU

LT

13

47

10

92

12

/24

Vo

ltIG

NIT

ON

/STA

RT

MO

DU

LE

P/N

56

05

7

Ge

nie

Ind

ustr

ies

TO

RE

MO

VE

:

Pu

sh

ge

ntly

an

dlif

t

BK

-R1

OR

/BK

-41

A

BK

-33

B

RD

-27

B

BR

N-I

S5

WH

-R2

RD

-CR

1


BK

-IS

1

RD

-IS

6

RD

-27

B

OR

/BK

-41

A

RD

-IS

4

OR

/BK

-IS

2

BK

-33

BB

K-I

S3

BK

-IS

3

RD

-IS

4

BRN

BRN-GND

C6 C6

(SP

AR

E)

(SP

AR

E)

BK

-CR

5

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6-61


Ground Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 404-22 Models

1

2

3

4

5

6

7

8


REV B


KS1 KEY SWITCH











LABEL DESCRIPTION




HM HOUR METER





CR4 HIGH IDLE RELAY

CR5 HORN RELAY

L43 COOLANT TEMPERATURE LED

HIGH IDLE RELAY


HO

UR

ME

TE

R

BA

SE

BO

XH

AR

NE

SS

(TO

TE

RM

INA

LS

TR

IP)

BK

/RD

-35

A

RD

-20

B

RD

RD

C2

3-7

RD

RD

-20

A

BK

-33

A

RD R

DR

D

RD

RD

RD

RD

RD

RD

RD

RDRD

RDRDRD

RDRDRD

RD

RDRD

BRN

WH

-21

BR

N

RD

RD

RD

RD

GR

/BK

-18

GR

/BK

-18

A

RD

RD

GR

GR

GRGR

GR/BK

GR

-17

GR

-17

A

C1

9JS

VG

R/W

HC

4B

-7G

R/W

H

RD

GR/BK

RD

GR/BK

RD

GR

/BK

OR

-14

A

RD

OR

/BK

-15

A

RDRD

BL

/WH

-12

A

BL

/BK

-11

A

RD

BL

-10

A

RD

RD

RDRD

RD

WH

/RD

-6

WH

-4

WH

/BK

-5

WH

/RD

-6A

WH

-4A

WH

/BK

-5A

RDRD

RDRD

RDRD

RDRD RD

RD

RD

RD

RD

BK

/WH

-8A

BK

-7A

RD

-1A

RD

RD

/WH

-3A

RD

/BK

-2A

RD

BK/WH-8

BK-7

RD

RD

WH-23WH-23

WH

/RD

-26

A

WH

/BK

-25

A

WH-23

RD

13

4A

RD

-27

RD

-27

A

WH

TS

59

PL

AT

FO

RM

LE

VE

L

TS

57

PL

AT

FO

RM

RO

TA

TE

CB

2C

IRC

UIT

BR

EA

KE

RC

ON

TR

OL

S1

5A

CB

1C

IRC

UIT

BR

EA

KE

RE

NG

INE

15

A

TS

54

FU

NC

TIO

NE

NA

BL

E

TS

52

STA

RT

EN

GIN

E

TS

60

SE

CO

ND

AR

YB

OO

MU

P/D

OW

N

TS

58

JIB

BO

OM

UP

/DO

WN

TS

62

TU

RN

TA

BL

ER

OTA

TE

TS

63

PR

IMA

RY

BO

OM

EX

TE

ND

/R

ET

RA

CT

TS

61

PR

IMA

RY

BO

OM

UP

/DO

WN

L4

3C

OO

LA

NT

TE

MP

LE

D

R4

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LV

AR

IAB

LE

RE

SIS

TE

R,2

0�

TS

51

AU

XIL

IAR

YP

OW

ER

P1

EM

ER

GE

NC

YS

TO

PS

WIT

CH

L4

2O

ILP

RE

SS

UR

EL

ED

GR

/BK

-44

A

RD

RD

RD

1

2

NC

1

2

NC

-+

RD

-24

A

TS

56

GL

OW

PL

UG

(OP

TIO

N)

-+

BK

/WH

-34

A

RD

WH-CR4

BK-22A

WH

-23

A

GR

/BK

H6

RD

C3

2-6

RD

L4

5P

LA

TF

OR

MO

VE

RL

OA

DL

ED

(CE

mo

de

ls)

-+

KS

1

G-BOX

P-BOX

RD

14

�

6�

DA

LE

RH

-25

25

W7

.5o

hm

1%

R1

4S

EC

ON

DA

RY

BO

OM

UP

/DO

WN

SP

EE

DR

ES

IST

OR



Ground Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 404-22 Models


Platform Control Box Wiring Diagram, Z-45/25JPerkins 404-22 Models

1

2

3

4

5

6

7

8



6-64 Z-45/25 • Z-45/25J Part No. 107846

Platform Control Box Wiring Diagram, Z-45/25JPerkins 404-22 Models

REV A

TILTALARM

WH

C1

9JS

V

RE

D-T

ILTR

ED

-TILT

C2

P-5

BR

NB

RN

C3P

JIB

F.S.

C7P

JIB BK JIB BK JIB

C3P

C7PBATGRN C7P-3

C1P


(TO SWITCH PANEL)

H1

12V DC BATTERYSUPPY

C1

P(G

Y)

19/18 CONTROL CABLE

C7P C9

FOOT SWITCH

JIB

9

1

J1

JC

3-3

OR

DR

EA

BL

/WH

JC

3-2

BR

N

DR

EB

BL

/BK

C1

3L

ED

BL

/RD

C2

9M

SR

D/W

H

JC

2-5

BK

JC

1-5

YE

L

JC

2-3

OR

JC

3-4

BL

*

JC

2-2

BR

N

JC

3-5

WH

JC

1-3

OR

JC

2-4

RD

JC

1-2

BR

N

J2

1

11

1

P2

4F

SW

H

P24FS WH

P2

6E

ST

PB

K

J3

3

C2

P(B

K)

C3

P(G

R)

C4

P(B

R)

C28TTA RD/BK C1P-2

BR

N

C2

9M

SR

D/W

HC

1P

-3

C3

2B

RK

WH

/RD

C1

P-6

C5

TR

RW

H/B

KC

3P

-5

C3

6S

TC

CB

KC

1P

-10

C3

PB

FR

D/W

HC

3P

-3

C3

7S

TC

BL

/BK

C1

P-11

C2

PB

DR

D/B

KC

3P

-2

C3

1R

EV

WH

/BK

C1

P-5

C1

PB

UR

DC

3P

-1

C3

0F

WD

WH

C1

P-4

C4

1R

PM

OR

/BK

C2

P-3

C1

2S

BF

BL

/WH

C3

P-1

2

C4

0L

SS

OR

C2

P-2

C11

SB

DB

L/B

KC

3P

-11

C1

6D

RE

OR

/RD

C4

P-4

C1

0S

BU

BL

C3

P-1

0

C6

TR

FW

H/R

DC

3P

-6

C2

8T

TA

RD

/BK

H1

C2P

C2

7A

UX

RD

C1

P-1

C3

3S

TR

BK

C1

P-7

C3

5H

SB

K/R

DC

1P

-9

C4P

C4

4JD

AL

AR

MG

R/B

KC

2P

-6

C4

5G

EN

GR

/WH

C2

P-7

P2

4F

SW

HC

9-2

P2

5F

SR

DC

9-3

P2

6B

AT

BK

C9

-1

C7

PB

EB

KC

3P

-7

C8

PB

RB

K/W

HC

3P

-8

C9

HR

NB

K/R

DC

3P

-9

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

7JU

GR

C4

P-5

C1

8JD

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

P2

2B

AT

BK

C7

P-1

P2

3S

WB

AT

WH

C7

P-2

U13ALC-500

CR30 CR27

P2

4F

SW

HC

9P

-2

C4

0L

SS

OR

C2

P-2

C3

2B

RK

WH

/RD

C1

P-6

C3

2B

RK

WH

/RD

J2

-19

C4

0L

SS

OR

J2

-4


TS

7

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

CD

LIT

EG

R

WLITE BRN C2P-10

WLITE BRN C2P-9

BRN

BRNBRN

BR

N

Y

RD

-P2

RD

-H1

RE

D-

LS

18

LS18CE OPTION

ONLYOPT.

H1

J3

J2

J1

U13

C1P - C4P

C7P





TILT ALARM



DESCRIPTIONITEM





RD

/BK

-L4

8(-)

GR

/BK

C4

P-1

GR

/BK

-L4

TS

1W

H

C3

4S

AB

K/W

HC

1P

-8

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6-65


Platform Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 404-22 Models

REV A

P2EMERGENCY

STOPTS4HIGH/LOW

RPM

TS2ENGINESTART

TS15DRIVE

ENABLE

L1DRIVE

ENABLELED

DRIVESPEED


TS13PRIMARY BOOM

EXTEND/RETRACT

TS8JIB BOOM

TS7PLATFORMROTATE

TS9PLATFORM

LEVEL

P3HORN TS1

AUXILIARYPUMP

C9

HR

NB

K/R

DC

3P

-9

RD

C1

4P

LU

OR

C4

P-2

C1

5P

LD

OR

/BK

C4

P-3

C1

8P

RR

GR

/BK

C4

P-6

C1

9JS

VG

R/W

HC

4P

-7

C1

7P

RL

GR

C4

P-5

C2

7A

UX

RD

C1

P-1

P2

5F

SR

DC

9-3

C3

3S

TR

BK

C1

P-7

BK

C9

P-1

WH

C7

P-2

RD

WH

GR/BK

RD

GR

RD

WH-24

RD RD RD

TS47GENERATOR

(OPTION)

C8

PB

RB

K/W

HC

3P

-8

BL

/RD

-DE

3J1

-16

C4

5G

EN

GR

/WH

C2

P-7

RD

BL

-DE

1J1

-6

GR/WH

RD

C7

PB

EB

KC

3P

-7

GR

/WH

RD

C2

9M

SR

D/W

HJ1

-8

TS6GLOWPLUG

C3

4S

AB

K/W

HC

1P

-8WHWH

GR

/BK

-44

C2

P-6

RD


C3

5R

PM

BK

/RD

C1

P-9

2

1

NC

2

1

NC

BL

/BK

-DE

2J1

-7

4

2

1

3

5

6

7

OR

J1

-13

BR

NJ1

-14

WH

J1

-4

BL

J1

-5

OR

J1

-9

BR

NJ1

-10

YE

LJ1

-3

OR

J1

-11

BR

NJ1

-12

BK

J1

-2

RD

J1

-1

JC3DRIVE


LEFT/RIGHT

JC1SECONDARY BOOM

UP/DOWN

CR13JIB BOOMRELAY

WH

-JIB

C1

9JS

VG

R/W

H

P2

4F

SW

H

BR

N

WH

-JIB

P2

4F

SW

HC

9-2

RD

BK

BK

BK

BK

BK

BK

34 NO


(TO CONTROL BOX)

BL

J1

-5

+


(OPTION)

RD

RD

PD

LIT

ER

D

CW

LIT

ER

DC

2P

-11

CW

LIT

ER

DC

2P

-12

F18FUSE 10A

CD

LIT

EG

R

2

1

3

5

4

6

7

2

1

3

5

4

6

7JC2


LEFT/RIGHT

GE

NE

RA

TO

RO

PT

ION

2

1

NC

BK

J3

-3

BK

C7

P-1

RD

LS

18

L48TILT ALARM LED

+

L4PLATFORMOVERLOAD

LED

+

GR

/BK

H1

(D3

9)

BK

RD

RD

RD

RD

RD

/BK

H1


Platform Control Box Switch Panel Wiring Diagram, Z-45/25JPerkins 404-22 Models

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6-67

June 2012 Section 6 • Schematics

Hydraulic Schematic, 2WD Models(before serial number 27001)

REV D

X

LA

LB

RB

50%

50%

PB

RA PA

2SPD

BRK

T2

TT1

REARRIGHT

REARLEFT

DRIVE MANIFOLD

0.030 inch0.76 mm

0.070 inch1.78 mm

250 psi17.2 bar

E

M

CHARGEFILTER

DRIVE PUMP

FUNCTION PUMP7 gpm / 26.5 L/min

TANK AUXILIARYPOWER UNIT

FUNCTION MANIFOLD

GENERATOR SELECT

OPTIONALMOTOR/GEN

STEER CYLINDERS

JIB BOOM0.6 gpm / 2.27 L/min

MASTER CYLINDER

PLATFORM ROTATE0.25 gpm / 0.95 L/min

SLAVE CYLINDER

SECONDARY BOOMCYLINDERS

TURNTABLE ROTATE

PRIMARY BOOMEXTENSION

PRIMARY BOOM

3:13800 psi262 bar

4.5:1ATMOS.3500 psi241 bar

4.25:13625 psi250 bar

V2

0.030 inch0.76 mm

V1

315 psi21.7 bar

50 psi3.4 bar

100 psi6.9 bar

3500 psi241 bar

1.5:13800 psi262 bar

3:13300 psi228 bar

EXTEN RETRACT

5:1ATMOS

1000 psi / 69 bar

ST1 ST2 PR1 PR2 PL1 PL2 SW1 SW2 S1 S2 P1 P2

AUX

T

TP2

25 psi1.7 bar

3200 psi220.6 bar

OSCILLATECYLINDERS(OPTION)

3:13500 psi241 bar

TP1

0.025 inch0.64 mm

3:11000 psi69 bar

3:1ATMOS.1500 psi103 bar

HIGHPRESSURE

FILTER

PRESS

T1/GEN

1.5 gpm5.7 L/min

0.4 gpm1.5 L/min

3200 psi220.6 bar (set at 7 gpm /26.5 L/min at TP1)

2500 psi / 172 bar(set at 0.6 gpm /

2.27 L/min at TP2)

0.037 inch0.9 mm

2100 psi144.8 bar(set at 2.5 gpm /9.5 L/min at TP2)

J1 J2 PR1PR2

V2 V1

OPTIONAL OSCILLATEDIRECTIONAL VALVE

JIB BOOM MANIFOLD

A

MN

F

O

P

JK

D

R

Q

E

Z

G

S

C

AA

AC

AB

LL

MMNN

AD

OO

WW

XX

QQ

UU

RR

SS

TT

PP

H

Y

W X

U

V

T

L

I

B

Orifice removedafter serial number 22449

2 gpm7.6 L/min

0.1 gpm0.38 L/min

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6-69


Hydraulic Schematic, 2WD Models(after serial number 27000)

REV B

2.0 gpm7.6 L/min

0.1 gpm0.4 L/min

PR2 PR1

PR1PR2

L R

RE

FUNCTION MANIFOLD

JIB SELECT

MANIFOLD

LEFTREAR

RIGHTREAR

TRACTION MANIFOLDRB

OSC

TEST250 psi17.2 bar

0.030 inch0.76 mm

RA

LB

LA

2SPD

BRK

50%

50%

2100 psi / 145 barSET @2.5 GPMAT TEST

0.046 inch

2500 / 172.4 barPSI SET.6 GPM@ TEST2

3200 psi / 221 barSET @ 7 GPM@ TEST1

0.4 gpm1.5 L/min

1.5 gpm5.7 L/min

GEN

PRESS

102 psi7 bar

TEST1

3200 psi221 bar

25 PSI

TEST 2

T1

AUX P2P1S2S1SW2SW1PL2PL1PR2PR1 RETEXT

V1V2

J1 J2

3750 psi259 bar

51 psi3.5 bar

310 psi21.4 bar

V1

0.030 inch

V2

PRIMARY BOOMLIFT CYLINDER

TURNTABLE ROTATE

SLAVE

PLATFORM ROTATE

0.4 GPM

MASTER

0.4 GPM

JIB BOOM

STEER CYLINDERS

OSCILLATE AXLE CYLINDERS

APU

TANK

7

FUNCTIONPUMP

DRIVE PUMP

M

E

PRIMARY BOOMEXTENSION CYLINDER

ST1 ST2

AB

PLATFORM LEVEL

MEDIUMPRESSURE

FILTER

7

E R

E R

E R

E R E R

B

A

SECONDARY BOOMELEVATE CYLINDERS

1.0 GPM

0.60 GPM

HIGHPRESSURE

FILTER

BZ

BX

CA

CB

CC

CD

CE

BY

BW

BU

BS BT

CFBV

BO

BP

BQ BRBN

BM

BLBK

BJ

BI

BH

BDBC

CG

BEBB

BF

BG

BA

R

AD

AA

U

S

AF AG

AE

C D

G

E F

H I

J L

K

M

NO

P Q

AKAJ

3.2 / 2.4 GPM 4.1 (regen) / 2.1 GPM

LEFT RIGHT

A

B

P

T

E R E R

A

B

B

A

Z-45/25J MODELS

1.3 / 0.7 GPM

T1

0.0

67

in

ch

1.7

mm

T

GENERATOR SELECT

MANIFOLD

GENERATOR OPTION

B

A

1COUNTERBALANCE VALVE CD CHANGED FROM3000 PSI TO 1000 PSI AFTER SERIAL NUMBER 31414.

T

TEST

HS0081D

RATIO PRESSURE

1000 psi / 69 bar

3300 psi / 228 bar

3800 psi / 262 bar

3:1

3626 psi / 250 bar

3:1

3:1

4.25:1

4.5:1 3500 psi / 241 bar

3:1 3500 psi / 241 bar

3:1 1500 psi / 103 bar

COUNTERBALANCE VALVES

5.0:1 1000 psi / 69 bar

1.5:1 3800 psi / 262 bar

AJ AK

Q

P CD

E F

H I

J L

M N

C D

O

1

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6-71



REV C

E

M

CHARGEFILTER

DRIVE PUMP

FUNCTION PUMP7 gpm / 26.5 L/min

TANK AUXILIARYPOWER UNIT

FUNCTION MANIFOLD

GENERATOR SELECT

OPTIONALMOTOR/GEN

STEER CYLINDERS

JIB BOOM0.6 gpm / 2.27 L/min

MASTER CYLINDER

PLATFORM ROTATE0.25 gpm / 0.95 L/min

SLAVE CYLINDER

SECONDARY BOOMCYLINDERS

TURNTABLE ROTATE

PRIMARY BOOMEXTENSION

PRIMARY BOOM

3:13800 psi262 bar

4.5:1ATMOS.3500 psi241 bar

4.25:13625 psi250 bar

V2

0.030 inch0.76 mm

BA

V1

315 psi21.7 bar

50 psi3.4 bar

100 psi6.9 bar

3500 psi241 bar

1.5:13800 psi262 bar

3:13300 psi228 bar

Orifice removedafter serial number 22449

EXTEN RETRACT

5:1ATMOS

1000 psi / 69 bar

ST1 ST2 PR1 PR2 PL1 PL2 SW1 SW2 S1 S2 P1 P2

AUX

T

TP2

25 psi1.7 bar

3200 psi220.6 bar

OSCILLATECYLINDERS(OPTION)

3:13500 psi241 bar

TP1

0.025 inch0.64 mm

3:11000 psi69 bar

3:1ATMOS.1500 psi103 bar

HIGHPRESSURE

FILTER

PRESS

T1/GEN

1.5 gpm5.7 L/min

0.4 gpm1.5 L/min

3200 psi220.6 bar (set at 7 gpm /26.5 L/min at TP1)

2500 psi / 172 bar(set at 0.6 gpm /

2.27 L/min at TP2)

0.037 inch0.9 mm

2100 psi144.8 bar(set at 2.5 gpm /9.5 L/min at TP2)

0.025 inch0.64 mm

1 gpm3.8 L/min

2 gpm7.6 L/min

50%

50%

2SPD

BRK

LA

LB

RA

50%

50%

0.030 inch0.76 mm

250 psi17.2 bar

0.052 inch1.3 mm

33%67%

TANK

T

T2

TEST

LFA

LFB

RFA

RFB

A

BRB

X

DRIVE MANIFOLD

FRONTRIGHT

FRONTLEFT

REARRIGHT

REARLEFT

J1 J2 PR2 PR1

V2 V1

OPTIONAL OSCILLATEDIRECTIONAL VALVE

JIB BOOM MANIFOLD

AQ

AO

AT

AB

AC

AE

AN

AS

AP

AL

AM

AIAK

AJ

AH

AD

AR

AG

A

MN

F

O

P

JK

D

R

Q

E

Z

G

S

C

AA

AC

AB

AD

H

Y

W X

U

V

T

L

I

B

2 gpm7.6 L/min

0.1 gpm0.38 L/min

LL

MMNN

1

2

3

4

5

6

7

8


Part No. 107846 Z-45/25 • Z-45/25J 6-73



REV B

OSC

2.0 gpm7.6 L/min

0.1 gpm0.4 L/min

PR2 PR1

PR1PR2

L R

RE

FUNCTION MANIFOLD

JIB SELECT

MANIFOLD

LEFTREAR

RIGHTREAR

LEFTFRONT

RIGHTFRONT

TRACTION MANIFOLDRB

RFB

RFA

LFB

LFA

TEST

T2

T

67% 33%

0.052 inch1.32 mm

250 psi17.2 bar

0.030 inch0.76 mm

50%

50%

RA

LB

LA

2SPD

BRK

50%

50%

2.0

gp

m7

.6 L

/min

1.0

gp

m3

.8 L

/min

0.025 inch / 0.64 mm

2100 PSI / 145 barSET @2.5 GPMAT TEST

0.046 inch

2500 / 172.4 barPSI SET.6 GPM@ TEST2

3200 PSI / 221 barSET @ 7 GPM@ TEST1

0.4 gpm1.5 L/min

1.5 gpm5.7 L/min

T1

PRESS

102 psi7 bar

TEST1

3200 psi221 bar

25 PSI

TEST 2

T

AUX P2P1S2S1SW2SW1PL2PL1PR2PR1 RETEXT

V1V2

J1 J2

51 psi3.5 bar

V1

0.030 inch

V2

PRIMARY BOOMLIFT CYLINDER

TURNTABLE ROTATE

SLAVE

PLATFORM ROTATE

0.4 GPM

MASTER

0.4 GPM

JIB BOOM

STEER CYLINDERS

OSCILLATE AXLE CYLINDERS

APU

TANK

FUNCTIONPUMP

M

PRIMARY BOOMEXTENSION CYLINDER

ST1 ST2

RATIO PRESSURE

1000 psi / 69 bar

3300 psi / 228 bar

3800 psi / 262 bar

3:1

3626 psi / 250 bar

3:1

3:1

4.25:1

4.5:1 3500 psi / 241 bar

3:1 3500 psi / 241 bar

3:1 1500 psi / 103 bar

COUNTERBALANCE VALVES

AB

PLATFORM LEVEL

MEDIUMPRESSURE

FILTER

5.0:1 1000 psi / 69 bar

1.5:1 3800 psi / 262 bar

E R

E R

E R

E R E R

SECONDARY BOOMELEVATE CYLINDERS

1.0 GPM

0.60 GPM

HIGHPRESSURE

FILTER

BZ

BX

CA

CB

CC

CD

CE

BY

BW

BU

BS BT

CFBV

BO

BP

BQ BRBN

BM

BLBK

BJ

BI

BH

BDBC

CG

BEBB

BF

BG

BA

AJ AK

Q

P CD

E F

H I

J L

M N

C D

O

R

W

T

V

Y

X

AC

AD

ABAI

AH

AA

Z

U

S

AF AG

AE

C D

G

E F

H I

J L

K

M

NO

P Q

AKAJ

3.2 / 2.4 GPM 4.1 (regen) / 2.1 GPM

LEFT RIGHT

A

B

P

T

E R E R

B

A

A

BA

B

A

B

Z-45/25J MODELS

1.3 / 0.7 GPMGENERATOR SELECT

MANIFOLD

GENERATOR OPTION

B

A

1

1COUNTERBALANCE VALVE CD CHANGED FROM3000 PSI TO 1000 PSI AFTER SERIAL NUMBER 31414.

HS0081D

3750 psi259 bar

310 psi21.4 bar

7

DRIVE PUMP

E 7

B

A

TEST

Dis

trib

ute

d B

y:

California Proposition 65

WARNINGThe exhaust from this product contains chemicals

known to the State of California to cause cancer,

birth defects or other reproductive harm.

Genie North America

Genie Australia Pty Ltd.

Genie China

Genie Malaysia

Genie Japan

Genie Korea

Genie Brasil

Genie Holland

Phone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Phone +61 7 3375 1660

Fax +61 7 3375 1002

Phone +86 21 53852570

Fax +86 21 53852569

Phone +65 98 480 775

Fax +65 67 533 544

Phone +81 3 3453 6082

Fax +81 3 3453 6083

Phone +82 25 587 267

Fax +82 25 583 910

Phone +55 11 41 665 755

Fax +55 11 41 665 754

Phone +31 183 581 102

Fax +31 183 581 566

Genie Scandinavia

Genie France

Genie Iberica

Genie Germany

Genie U.K.

Genie Mexico City

Phone +46 31 575100

Fax +

Phone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Phone +34 93 579 5042

Fax +34 93 579 5059

Phone 0800 180 9017

Fax +49 422 149 1820

Phone +44 (0)1476 584333

Fax +44 (0)1476 584334

Phone +52 55 5666 5242

Fax +52 55 5666 3241

46 31 579020

Phone +49 422 149 1818

Manual de Serviço 107846

Documents

Transcript of Manual de Serviço 107846