Service Manual First Edition Second Printing - Genie liftmanuals.gogenielift.com/Parts And Service Manuals/data/Service/Z... · First Edition Second Printing Part No. 52709 Service

First Edition

Second Printing

Part No. 52709

Service Manual

From Serial number 9998 to 21179

Genie Z-45/25 & Genie Z-45/25J Part No. 52709

First Edition • Second Printing

ii

Introduction

®

Copyright © 1998 by Genie Industries

First Edition: Second Printing, September 2000

"Genie" and "Z" are Registered Trademarksof Genie Industries in the USA and many othercountries.

These machines comply withANSI/SIA 92.5-1992.

Printed on recycled paper

Printed in U.S.A.

Important

Read, understand and obey the safety rules andoperating instructions in theGenie Z-45/25 & Genie Z-45/25J Operator'sManual before attempting any maintenance orrepair procedure.

This service manual covers the Genie Z-45/25 &Genie Z-45/25J 2WD and 4WD models introducedin 1998.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair 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 a Genie dealer service center.

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore product specifications are subjectto change 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 other manuals. Pleasewrite to the technical publications team in care ofGenie Industries, PO Box 97030, Redmond WA98073-9730 U.S.A.

If you have any questions, please call GenieIndustries.

Contact us:

http://www.genielift.com

e-mail: [email protected]

Part No. 52709 Genie Z-45/25 & Genie Z-45/25J


iii

Safety Rules

Section 1 • Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Genie Z-45/25 &Genie 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.



SAFETY RULES

iv

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 machine,use 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.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Green—used to indicate operationor maintenance 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 flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher 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 components andcause damage.

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

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 .



Table of Contents

v

Introduction

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

Section One Safety Rules

General Safety Rules..................................................................................................... iii

Section Two Specifications

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

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

Hydraulic Specifications ............................................................................................ 2 - 4

Ford LRG-425 EFI Engine Specifications ................................................................. 2 - 5

Deutz F3L 1011F Engine Specifications ................................................................... 2 - 7

Perkins 104-22 Engine Specifications....................................................................... 2 - 8

Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 9

Section Three Theory of Operation

Power Source ........................................................................................................... 3 - 1

Hydraulic System...................................................................................................... 3 - 1

Electrical System ...................................................................................................... 3 - 1

Limit Switches ........................................................................................................... 3 - 2

Machine Controls ...................................................................................................... 3 - 2



TABLE OF CONTENTS

vi

Section Four Scheduled Maintenance Procedures

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

Maintenance Inspection Report ................................................................................ 4 - 3

A-1 Inspect the Operator's and Safety Manuals .................................................... 4 - 5

A-2 Inspect the Decals and Placards ..................................................................... 4 - 5

A-3 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6

A-4 Check the Engine Oil Level ............................................................................. 4 - 7

A-5 Check the Engine Coolant Level - Liquid Cooled Models ................................ 4 - 8

A-6 Check for Fuel Leaks ...................................................................................... 4 - 8

A-7 Check the Hydraulic Oil Level ......................................................................... 4 - 9

A-8 Check for Hydraulic Leaks ............................................................................ 4 - 10

A-9 Check the Tire Pressure ............................................................................... 4 - 10

A-10 Test the Oscillate Axle (if equipped) .............................................................. 4 - 11

A-11 Test the Platform and Ground Controls ......................................................... 4 - 11

A-12 Test the Auxiliary Power Operation ............................................................... 4 - 12

A-13 Test the Tilt Sensor ....................................................................................... 4 - 13

A-14 Test the Limit Switches ................................................................................. 4 - 14

A-15 Check the Engine Belt - Perkins Diesel Models ............................................ 4 - 18

A-16 Inspect the Engine Air Filter Element ............................................................ 4 - 19

A-17 Replace the Fuel Filters - Ford Models ......................................................... 4 - 20

A-18 Inspect the Radiator - Perkins Models .......................................................... 4 - 21

A-19 Perform 30 Day Service ................................................................................ 4 - 22

A-20 Replace the Engine Oil and Filter - Ford and Perkins Diesel Models ............ 4 - 23

A-21 Inspect the Fuel Filter/Water Separator - Diesel Models ............................... 4 - 24

A-22 Check and Adjust the Engine RPM - Perkins Diesel Models ......................... 4 - 26

A-23 Check the Engine Belt - Ford Models ............................................................ 4 - 28



TABLE OF CONTENTS

vii

Section Four Scheduled Maintenance Procedures, continued

B-1 Check the Battery ......................................................................................... 4 - 29

B-2 Inspect the Electrical Wiring .......................................................................... 4 - 29

B-3 Check the Radiator - Ford Models ................................................................ 4 - 30

B-4 Check the Exhaust System ........................................................................... 4 - 31

B-5 Check the Hydraulic Return Filter Condition Indicator ................................... 4 - 32

B-6 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ...................... 4 - 32

B-7 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 33

B-8 Confirm the Proper Brake Configuration ....................................................... 4 - 34

B-9 Check the Oil Level in the Drive Hubs ........................................................... 4 - 34

B-10 Check and Adjust the Engine RPM - Ford and Deutz Diesel Models ............ 4 - 35

B-11 Test the Key Switch ...................................................................................... 4 - 37

B-12 Test the Emergency Stop Buttons ................................................................. 4 - 37

B-13 Test the Ground Control Override ................................................................. 4 - 38

B-14 Check the Directional Valve Linkage ............................................................. 4 - 38

B-15 Test the Platform Self-leveling ...................................................................... 4 - 39

B-16 Test the Horn ................................................................................................ 4 - 40

B-17 Test the Foot Switch ..................................................................................... 4 - 40

B-18 Test the Engine Idle Select ........................................................................... 4 - 41

B-19 Test the Fuel Select Operation - Ford Models ............................................... 4 - 42

B-20 Test the Drive Enable System ....................................................................... 4 - 43

B-21 Test the Drive Brakes ................................................................................... 4 - 44

B-22 Test the Drive Speed - Stowed Position ........................................................ 4 - 45

B-23 Test the Drive Speed - Raised or Extended Position .................................... 4 - 46




B-24 Test the Alarm Package - Optional Equipment .............................................. 4 - 47

B-25 Perform Hydraulic Oil Analysis ...................................................................... 4 - 48

B-26 Replace the Hydraulic Tank Return Filter ...................................................... 4 - 48

B-27 Replace the Fuel Filter/Water Separator Element - Perkins Diesel Models ... 4 - 49

B-28 Replace the Fuel Filter Element - Perkins Diesel Models .............................. 4 - 51

B-29 Replace the Spark Plugs - Ford Models ........................................................ 4 - 52

B-30 Replace the Engine Air Filter Element ........................................................... 4 - 53

C-1 Check the Engine Belt- Deutz Diesel Models ................................................ 4 - 55

C-2 Replace the Engine Oil and Filter - Deutz Diesel Models .............................. 4 - 57

C-3 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 57

C-4 Change or Recondition the Engine Coolant - Liquid Cooled Models ............. 4 - 58

C-5 Check the Engine Valve Clearances - Perkins Diesel Models ....................... 4 - 59

C-6 Replace the PCV Valve - Ford Models .......................................................... 4 - 60

D-1 Check the Boom Wear Pads ......................................................................... 4 - 61

D-2 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 62

D-3 Check the Free-wheel Configuration ............................................................. 4 - 63

D-4 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 4 - 65

D-5 Replace the Drive Hub Oil ............................................................................. 4 - 66

D-6 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 67

D-7 Check and Adjust the Air/LPG Mixture - Ford Models ................................... 4 - 68

D-8 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models......... 4 - 69

viii

TABLE OF CONTENTS




E-1 Test or Replace the Hydraulic Oil .................................................................. 4 - 70

E-2 Change or Recondition the Engine Coolant - Ford Models ........................... 4 - 72

E-3 Change the Fuel Hoses ................................................................................ 4 - 74

E-4 Check the Toothed Belt - Deutz Diesel Models ............................................. 4 - 77

E-5 Check the Engine Valve Clearance - Ford Models ........................................ 4 - 77

E-6 Check the Engine Cylinder Compression - Ford Models ............................... 4 - 77

E-7 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models ........... 4 - 77

E-8 Replace the Timing Belt - Ford Models ......................................................... 4 - 77

E-9 Grease the Steer Axle Wheel Bearings, 2WD Models .................................. 4 - 78

Section Five Troubleshooting Flow Charts

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

Fault Codes .............................................................................................................. 5 - 3

1 Engine Will Not Crank Over ............................................................................ 5 - 6

2 Engine Cranks Over But Will Not Start - Ford Models ..................................... 5 - 8

2A Engine Runs While Cranking Then Dies ....................................................... 5 - 10

3 Engine Cranks Over But Will Not Start - Diesel Models ................................ 5 - 11

4 Engine Will Not Start On LPG, But Will Start On Gasoline - Ford Models ..... 5 - 14

5 Engine Will Not Start On Gasoline, But Will Start On LPG - Ford Models ..... 5 - 16

6 Engine High Idle Inoperative - Ford Models .................................................. 5 - 17

7 Engine Low Idle Inoperative - Ford Models ................................................... 5 - 18

8 Engine High Idle Inoperative - Diesel Models ................................................ 5 - 19

9 Engine Low Idle Inoperative - Diesel Models................................................. 5 - 21

10 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 22

11 All Lift and Steer Functions Inoperative, Drive Functions Operational ........... 5 - 23

ix

TABLE OF CONTENTS



TABLE OF CONTENTS

Section Five Troubleshooting Flow Charts, continued

12 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 24

13 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 25

14 Primary Boom Up Function Inoperative ........................................................ 5 - 26

15 Primary Boom Down Function Inoperative (before serial number 13099) ..... 5 - 29

16 Primary Boom Down Function Inoperative (after serial number 13098) ........ 5 - 32

17 Secondary Boom Up Function Inoperative .................................................... 5 - 35

18 Secondary Boom Down Function Inoperative ............................................... 5 - 38

19 Primary Boom Extend Function Inoperative .................................................. 5 - 41

20 Primary Boom Retract Function Inoperative .................................................. 5 - 43

21 Turntable Rotate Left Function Inoperative ................................................... 5 - 45

22 Turntable Rotate Right Function Inoperative ................................................. 5 - 49

23 All Platform Leveling Functions Inoperative .................................................. 5 - 53

24 Platform Level Up Function Inoperative ........................................................ 5 - 54

25 Platform Level Down Function Inoperative .................................................... 5 - 56

26 Platform Rotate Left Function Inoperative ..................................................... 5 - 58

27 Platform Rotate Right Function Inoperative ................................................... 5 - 61

28 Jib Boom Up Function Inoperative, Z-45/25J Models .................................... 5 - 64

29 Jib Boom Down Function Inoperative, Z-45/25J Models ............................... 5 - 66

30 Steer Left Function Inoperative ..................................................................... 5 - 68

31 Steer Right Function Inoperative ................................................................... 5 - 69

32 Oscillate Function Inoperative ....................................................................... 5 - 70

33 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 71

34 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 74

35 Traction Function Inoperative ........................................................................ 5 - 75

36 Machine Will Not Drive At Full Speed............................................................ 5 - 76

37 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 77

38 Drive Enable System Is Malfunctioning ......................................................... 5 - 78

39 Auxiliary Functions Inoperative ..................................................................... 5 - 79

x



TABLE OF CONTENTS

Section Six Schematics

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

Electrical Components .............................................................................................. 6 - 2

Electrical Symbols Legend ....................................................................................... 6 - 4

Abbreviation Legend ................................................................................................. 6 - 5

Ford LRG-425 EFI Engine Harness (before serial number 13099) ........................... 6 - 7

Ford LRG-425 EFI Engine Harness (after serial number 13098) .............................. 6 - 8

Electrical Schematic - Z-45/25 Ford Models (before serial number 13099) ............. 6 - 10

Ground Control Box Wiring Diagram, Z-45/25 Ford Models (before serial number 13099) ............................................................................. 6 - 11

Platform Control Box Wiring Diagram, Z-45/25 Ford Models (before serial number 13099) ............................................................................. 6 - 12

Electrical Schematic, Z-45/25 Ford Models (from serial number 13098 to 16303) ................................................................. 6 - 14

Ground Control Box Wiring Diagram, Z-45/25 Ford Models (from serial number 13098 to 16303) ................................................................. 6 - 15

Platform Control Box Wiring Diagram, Z-45/25 Ford Models (from serial number 13098 to 16303) ................................................................. 6 - 16

Electrical Schematic, Z-45/25J Ford Models (before serial number 13099) ............................................................................. 6 - 18

Ground Control Box Wiring Diagram, Z-45/25J Ford Models (before serial number 13099) ............................................................................. 6 - 19

Platform Control Box Wiring Diagram, Z-45/25J Ford Models (before serial number 13099) ............................................................................. 6 - 20

Electrical Schematic, Z-45/25J Ford Models (from serial number 13098 to 16303) ................................................................. 6 - 22

Ground Control Box Wiring Diagram, Z-45/25J Ford Models (from serial number 13098 to 16303) ................................................................. 6 - 23

xi



TABLE OF CONTENTS

xii

Section Six Schematics, continued

Platform Control Box Wiring Diagram, Z-45/25J Ford Models (from serial number 13098 to 16303) ................................................................. 6 - 24

Electrical Schematic, Z-45/25 Ford Models (after serial number 16303) ................. 6 - 26

Ground Control Box Wiring Diagram, Z-45/25 Ford Models (after serial number 16303) ................................................................................ 6 - 27

Platform Control Box Wiring Diagram, Z-45/25 Ford Models (after serial number 16303) ................................................................................ 6 - 28

Electrical Schematic, Z-45/25J Ford Models (after serial number 16303) ............... 6 - 30

Ground Control Box Wiring Diagram, Z-45/25J Ford Models (after serial number 16303) ................................................................................ 6 - 31

Platform Control Box Wiring Diagram, Z-45/25J Ford Models (after serial number 16303) ................................................................................ 6 - 32

Electrical Schematic, Z-45/25 Deutz Models (before serial number 13099) ............ 6 - 34

Ground Control Box Wiring Diagram, Z-45/25 Deutz Models (before serial number 13099) ............................................................................. 6 - 35

Platform Control Box Wiring Diagram, Z-45/25 Deutz Models (before serial number 13099) ............................................................................. 6 - 36

Electrical Schematic, Z-45/25 Deutz Models (from serial number 13098 to 16303) ................................................................. 6 - 38

Ground Control Box Wiring Diagram, Z-45/25 Deutz Models (from serial number 13098 to 16303) ................................................................. 6 - 39

Platform Control Box Wiring Diagram, Z-45/25 Deutz Models (from serial number 13098 to 16303) ................................................................. 6 - 40

Electrical Schematic, Z-45/25J Deutz Models (before serial number 13099) .......... 6 - 42

Ground Control Box Wiring Diagram, Z-45/25J Deutz Models (before serial number 13099) ............................................................................. 6 - 43

Platform Control Box Wiring Diagram, Z-45/25J Deutz Models (before serial number 13099) ............................................................................. 6 - 44

Electrical Schematic, Z-45/25J Deutz Models (from serial number 13098 to 16303) ................................................................. 6 - 46

Ground Control Box Wiring Diagram, Z-45/25J Deutz Models (from serial number 13098 to 16303) ................................................................. 6 - 47



TABLE OF CONTENTS

xiii


Platform Control Box Wiring Diagram, Z-45/25J Deutz Models (from serial number 13098 to 16303) ................................................................. 6 - 48

Platform Control Box Wiring Diagram - Lift Drive Select Option,Z-45/25J Deutz Models (from serial number 13098 to 16303) ................................ 6 - 49

Electrical Schematic, Z-45/25 Deutz Models (after serial number 16303) ................................................................................ 6 - 51

Ground Control Box Wiring Diagram, Z-45/25 Deutz Models (after serial number 16303) ................................................................................ 6 - 52

Platform Control Box Wiring Diagram, Z-45/25 Deutz Models (after serial number 16303) ................................................................................ 6 - 53

Platform Control Box Wiring Diagram - Lift Drive Select Option,Z-45/25 Deutz Models (after serial number 16303) ................................................. 6 - 54

Electrical Schematic, Z-45/25J Deutz Models (after serial number 16303) ............. 6 - 56

Ground Control Box Wiring Diagram, Z-45/25J Deutz Models (after serial number 16303) ................................................................................ 6 - 57

Platform Control Box Wiring Diagram, Z-45/25J Deutz Models (after serial number 16303) ................................................................................ 6 - 58

Platform Control Box Wiring Diagram - Lift Drive Select Option,Z-45/25J Deutz Models (after serial number 16303) ............................................... 6 - 59

Electrical Schematic, Z-45/25 Perkins Models (before serial number 16304) ......... 6 - 61

Ground Control Box Wiring Diagram, Z-45/25 Perkins Models (before serial number 16304) ............................................................................. 6 - 62

Platform Control Box Wiring Diagram, Z-45/25 Perkins Models (before serial number 16304) ............................................................................. 6 - 63

Electrical Schematic, Z-45/25J Perkins Models (before serial number 16304) ....... 6 - 65

Ground Control Box Wiring Diagram, Z-45/25J Perkins Models (before serial number 16304) ............................................................................. 6 - 66



TABLE OF CONTENTS


Platform Control Box Wiring Diagram, Z-45/25J Perkins Models (before serial number 16304) ............................................................................. 6 - 67

Platform Control Box Wiring Diagram - Lift/Drive Select Option,Z-45/25J Perkins Models (before serial number 16304) ......................................... 6 - 68

Electrical Schematic, Z-45/25 Perkins Models (after serial number 16303) ............ 6 - 70

Ground Control Box Wiring Diagram, Z-45/25 Perkins Models (after serial number 16303) ................................................................................ 6 - 71

Platform Control Box Wiring Diagram, Z-45/25 Perkins Models (after serial number 16303) ................................................................................ 6 - 72

Electrical Schematic, Z-45/25J Perkins Models (after serial number 16303)) ......... 6 - 74

Ground Control Box Wiring Diagram, Z-45/25J Perkins Models (after serial number 16303) ................................................................................ 6 - 75

Platform Control Box Wiring Diagram, Z-45/25J Perkins Models (after serial number 16303) ................................................................................ 6 - 76

Platform Control Box Wiring Diagram - Lift/Drive Select Option,Z-45/25J Perkins Models (after serial number 16303) ............................................ 6 - 78

Platform Control Box Wiring Diagram- Load Sensor Option, All Models ................. 6 - 79

Hydraulic Symbols Legend ..................................................................................... 6 - 80

2WD Hydraulic Schematic ...................................................................................... 6 - 82

4WD Hydraulic Schematic ...................................................................................... 6 - 83

Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1

Platform Controls

1-1 Joystick Controllers ......................................................................................... 7 - 2

1-2 Horsepower Limiter Board .............................................................................. 7 - 8

xiv



Section Seven Repair Procedures, continued

1-3 Foot Switch ................................................................................................... 7 - 10

1-4 Toggle Switches ............................................................................................ 7 - 11

Platform Components

2-1 Platform ........................................................................................................ 7 - 13

2-2 Platform Leveling Slave Cylinder .................................................................. 7 - 14

2-3 Platform Rotator ............................................................................................ 7 - 15

Jib Boom Components, Z-45/25J Models

3-1 Jib Boom, Z-45/25J Models .......................................................................... 7 - 18

3-2 Jib Boom Lift Cylinder, Z-45/25J Models ....................................................... 7 - 19

3-3 Jib Boom / Platform Rotate Manifold Components, Z-45/25J Models ........... 7 - 21

Primary Boom Components

4-1 Plastic Cable Track ....................................................................................... 7 - 22

4-2 Primary Boom ............................................................................................... 7 - 27

4-3 Primary Boom Lift Cylinder ........................................................................... 7 - 30

4-4 Primary Boom Extension Cylinder ................................................................. 7 - 31

4-5 Platform Leveling Master Cylinder ................................................................ 7 - 32

Secondary Boom Components

5-1 Secondary Boom .......................................................................................... 7 - 34

5-2 Secondary Boom Lift Cylinders ..................................................................... 7 - 39

Turntable Covers

6-1 Turntable Covers .......................................................................................... 7 - 40

Deutz Engine F3L 1011F

7-1 RPM Adjustment ........................................................................................... 7 - 41

7-2 Flex Plate ...................................................................................................... 7 - 41

7-3 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 42

xv

TABLE OF CONTENTS




Perkins 104-22 Engine

8-1 RPM Adjustment ........................................................................................... 7 - 43

8-2 Flex Plate ...................................................................................................... 7 - 43

8-3 Coolant Temperature and Oil Pressure Gauages ......................................... 7 - 44

Ford LRG-425 EFI Engine

9-1 Timing Adjustment ........................................................................................ 7 - 45

9-2 RPM Adjustment ........................................................................................... 7 - 45

9-3 Flex Plate ...................................................................................................... 7 - 45

9-4 Water Temperature and Oil Pressure Gauges .............................................. 7 - 46

Ground Controls

10-1 Control Relays .............................................................................................. 7 - 48

10-2 Toggle Switches, See 1-4, Toggle Switches ................................................. 7 - 49

10-3 Wago® Components ...................................................................................... 7 - 49

10-4 Engine Fault Codes - Ford Models ................................................................ 7 - 50

Hydraulic Pumps

11-1 Lift/Steer Pump ............................................................................................. 7 - 52

11-2 Drive Pump ................................................................................................... 7 - 53

Manifolds

12-1 Function Manifold Components ..................................................................... 7 - 56

12-2 Valve Adjustments - Function Manifold ......................................................... 7 - 62

12-3 Turntable Rotation Manifold Components ..................................................... 7 - 63

12-4 Directional Valve Manifold Components ........................................................ 7 - 65

12-5 2WD Drive Manifold Components ................................................................. 7 - 68

12-6 Valve Adjustments, 2WD Drive Manifold ....................................................... 7 - 70

12-7 4WD Drive Manifold Components ................................................................. 7 - 72

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TABLE OF CONTENTS




12-8 Valve Adjustments, 4WD Drive Manifold ....................................................... 7 - 76

. Fuel and Hydraulic Tanks

13-1 Fuel Tank ...................................................................................................... 7 - 77

13-2 Hydraulic Tank .............................................................................................. 7 - 80

Turntable Rotation Components

14-1 Rotation Hydraulic Motor ............................................................................... 7 - 80

2WD Steering Axle Components

15-1 Yoke and Hub ............................................................................................... 7 - 84

15-2 Steering Cylinders ......................................................................................... 7 - 84

15-3 Tie Rod ......................................................................................................... 7 - 85


16-1 Yoke and Hub ............................................................................................... 7 - 86

16-2 Steering Cylinders, See 15-2, Steering Cylinders ......................................... 7 - 88

16-3 Tie Rod, See 15-3, Tie Rod .......................................................................... 7 - 88

Oscillating Axle Components

17-1 Oscillating Axle Lock-out Cylinders ............................................................... 7 - 89

Non-steering Axle Components

18-1 Drive Motor ................................................................................................... 7 - 90

18-2 Drive Hub ...................................................................................................... 7 - 91

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Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 2 - 1

Section 2 • SpecificationsFirst Edition • Second Printing

Specifications

Machine Specifications

Stowed dimensions Z-45/25 Z-45/25J(non jib) (jib)

Length 18 ft 22 ft 3 in5.5 m 6.8 m

WidthStandard Base Models 7 ft 4 in 7 ft 4 in

2.2 m 2.2 mNarrow Base Models 5 ft 9 in 5 ft 9 in

1.8 m 1.8 m

HeightStandard Base Models 6 ft 10 in 6 ft 10 in


2.05 m 2.05 m

WeightStandard Base Models 14,000 lbs 14,700 lbs

6350 kg 6668 kgNarrow Base Models 17,100 lbs 17,100 lbs

7756 kg 7756 kg

Ground clearanceStandard Base Models 10 in 10 in

25.4 cm 25.4 cmNarrow Base Models 7 in 7 in

17.7 cm 17.7 cm

Operational dimensions

Maximum platform heightStandard Base Models 45 ft 8 in 45 ft 6 in


13.9 m 13.9 m

Maximum horizontal reach 124 ft 6 in 25 ft 3 in17.5 m 7.7 m

Maximum turntable tailswing 0 in 0 in0 cm 0 cm

Wheelbase 6 ft 8 in 6 ft 8 in2 m 2 m

1 Outreach specification with platform rotated90 degrees.

Z-45/25 Z-45/25J(non jib) (jib)

Minimum turning radius, insideStandard Base Models 4 ft 6 in 4 ft 6 in

1.4 m 1.4 mNarrow Base Models 5 ft 5 ft

1.5 m 1.5 m

Minimum turning radius, outsideStandard Base Models 11 ft 6 in 11 ft 6 in

3.5 m 3.5 mNarrow Base Models 11 ft 11 ft

3.35 m 3.35 m

Turntable rotation 359° 359°

Platform rotation 180° 160°

Maximum capacity 500 lbs 500 lbs6 foot platform 227 kg 227 kg

Maximum allowableside force (ANSI and CSA) 150 lbs 150 lbs

68 kg 68 kg

Platform dimensions

Length 72 in183 cm

Width 30 in76 cm

2 - 2 Genie Z-45/25 & Genie Z-45/25J Part No. 52709

Section 2 • Specifications First Edition • Second Printing

SPECIFICATIONS

Tires and wheels Rough terrain Industrial

Wheel diameter 17.5 inches 14.5 inches

Wheel width 10.5 inches 7 inches

Wheel lugs, 4WD 9 @ 5/8 -18

Wheel lugs, 2WDFront 8 @ 5/8 -18 8 @ 5/8 -18Rear 9 @ 5/8 -18 9 @ 5/8 -18

Lug nut torque 125 ft-lbs 125 ft-lbs169.5 Nm 169.5 Nm

Tire size 14-17.5 NHS 9-14.5 LT

Tire ply rating 14 Tread 8Sidewall 6

Tire contact area 59 sq in 43.5 sq in149.9 sq cm 280 sq cm

Overall tire diameter 35.8 in 28 in90.9 cm 71 cm

Tire pressure 45 psi Foam filled2.76 bar

Fluid capacities

Fuel tank 17 gallons64.3 liters

LPG tank 33.5 pounds15.2 kg

Hydraulic tank 24 gallons91 liters

Hydraulic system 30 gallons(including tank) 113.6 liters

Drive torque hubs 17 fl oz0.51 liters

Continuous improvement of our products is a Geniepolicy. Product specifications are subject to changewithout notice.

Performance Specifications

Drive speeds, maximum

Drive speed, stowed 4.8 mphAll models 7.7 km/h

40 ft/5.7 sec12.2 m/5.7 sec

Drive speed, boom 0.6 mphraised or extended, 1 km/hStandard Base Models 40 ft/45 sec

12.2 m/45 sec

Drive speed, boom 0.36 mphraised or extended, 0.58 km/hNarrow Base Models 40 ft/79 sec

12.2 m/79 sec

Gradeability 2WD 4WD

Boom Stowed Position 30% 45%



SPECIFICATIONS

Boom function speeds, maximumfrom platform controls

Jib boom up 38 to 42 seconds

Jib boom down 24 to 27 seconds

Primary boom up 24 to 27 seconds

Primary boom down 32 to 37 seconds

Secondary boom up 23 to 27 seconds

Secondary boom down 23 to 27 seconds

Primary boom extend 10 to 14 seconds

Primary boom retract 18 to 22 seconds

Turntable rotate - 359° 73 to 78 secondsprimary boom retracted

Platform rotate - 180° 10 to 14 secondsZ-45/25 Models

Platform rotate - 160° 9 to 13 secondsZ-45/25J Models

Platform level up 35 to 39 seconds

Platform level down 26 to 32 seconds



SPECIFICATIONS

Hydraulic Specifications

Hydraulic fluid Dexron equivalent

Drive pump

Type: bi-directional variable displacement piston pump

Displacement @ 2500 rpm 0 to 30.3 gallons per minute0 to 114.7 liters per minute

Maximum drive pressure 3500 psi241.3 bar

Charge pressureneutral position 290 psi 20 bardrive position 250 psi 17 bar

Medium pressure filter 3 micron

Medium pressure filter 50 psibypass pressure 3.4 bar

Drive manifold

Brake 250 psirelief pressure 17.2 bar

Steer end drive motors 4WD models

Displacement 1.53 cu inper revolution 25 cc

Non-steer end drive motors

Displacement per revolution, variable 0.16 to 2.8 cu in4WD (2 speed motor) 2.62 to 45.9 cc

Displacement per revolution, variable 1.1 to 2.8 cu in2WD 18.4 to 45.9 cc

Function pump

Type: pressure balanced gear

Displacement - static 0.67 cu in11 cc

Displacement @ 2500 rpm 0 to 2.1 gallons per minute0 to 7.95 liters per minute

Hydraulic tank circuit 6 micron with 25 psireturn line filter (1.7 bar) bypass

Function manifold

Function relief valve pressure 3200 psi220.6 bar

Primary boom down 2300 psirelief valve pressure 158.6 bar

Secondary boom down 1800 psirelief valve pressure 124 bar

Steer flow regulator 1.5 gpm5.7 liters/min

Auxiliary pump

Type: fixed displacement gear pump

Displacement 1.75 gallons per minute2.8 liters per minute

Auxiliary pump 3200 psirelief pressure 220.6 bar



SPECIFICATIONS

Ford Engine LRG-425 EFI

Displacement 153 cu in2.5 liters

Number of cylinders 4

Bore & stroke 3.78 x 3.4 in96.01 x 86.36 mm

Horsepower

gross intermittent 97continuous 82horsepower @ 2500 rpm 70

Firing order 1 - 3 - 4 - 2

Low idle 1600 rpm

High idle 2500 rpm

Compression ratio 9.4:1

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

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

Lubrication system

Oil pressure 40 to 60 psi(operating temp. @ 2000 rpm) 2.75 to 4.1 bar

Oil capacity 5 quarts(including filter) 4.7 liters

Oil viscosity requirements

Temperature below 60°F / 15.5°C 5W-30

-10°F to 90°F / -23°C to 32°C 10W-30

Temperature above 10W-40 to 10W-50-10°F / -23°C

Temperature above 20W-40 or 20W-5020°F / -6.6°C

Use oils meeting API classification SG (labeled SG/CCor SG/CD) as they offer improved wear protection.Units ship with 10W-40 SG/CC.

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Current draw, maximum load 800A

Current draw, minimum 60-80A

Maximum circuit voltage drop 0.5V DCwhile starting (normal temperature)

Brush length, new 0.66 in16.8 mm

Brush length wear limit 0.25 in6.35 mm

Brush spring tension 64 ounces18 Newtons

Bolt torque 45 to 84 in-lbsthrough brush 5.08 to 9.5 Nm

Brush mounting 15 to 20 ft-lbsbolt torque 20 to 27 Nm

Maximum commutator 0.005 inrun-out 0.127 mm



SPECIFICATIONS

Battery

Type 12V, Group 34/78

Quantity 1

Cold cranking ampere 900A

Reserve capacity @ 25A rate 200 minutes

Electronic fuel pump

Fuel pressure, static 64 psi4.4 bar

Fuel flow rate 0.58 gpm2.18 L/min

Ignition System

Spark plug type Motorcraft AWSF-52C

Spark plug gap 0.042 to 0.046 in1.07 to 1.18 mm

Engine coolant

Capacity 111/2 quarts10.9 liters

Alternator

Output 95A, 14.5V



SPECIFICATIONS

Injection system

Injection pump make OMAP

Injection pump pressure 4351 psi300 bar

Injector opening pressure 3626 psi250 bar

Fuel requirement diesel number 2-D

Alternator output 55A, 14V

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



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




Bore and stroke 3.58 x 4.13 inches91 x 105 mm

Horsepower

gross intermittent 44continuous 40horsepower @ 3000 rpm 36

Firing order 1 - 2 - 3

Low idle 1400 rpm

High idle 2500 rpm

Compression ratio 18.5:1

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

Lubrication system

Oil pressure 26 to 87 psi1.8 to 6 bar

Oil capacity 6.5 quarts(including filter) 6 liters


Temperature below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

Temperature above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCC/SG or CD/SG grades.Units ship with 10W-40 SG/CC.



Perkins Engine 104-22(KR model)



Bore and stroke 3.31 x 3.94 inches84 x 100 mm

Horsepower

gross intermittent 50continuous 46.9horsepower @ 2800 rpm 41

Firing order 1 - 3 - 4 - 2

Low idle 1600 rpm

High idle 2500 rpm

Compression ratio 22:1

Compression pressure 300 to 500 psi20.7 to 34.5 bar

Pressure (psi) of lowest cylinder must be 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

Lubrication system

Oil pressure 41 psi(at 2600 rpm) 2.8 bar

Oil capacity 8.6 quarts(including filter) 8.2 liters


below 68°F / 20°C (synthetic) 5W-20

5°F to 104°F / -15°C to 40°C 10W-30

above 14°F / -10°C 15W-40

Engine oil should have properties of API classificationCC/SE. API classification CD/SE or CCMC D4 can beused, but is not recommended during the first 50 hoursnor for light load applications.

Injection system

Injection pump make Zexel

Injection pressure 2133 psi147 bar

Fuel requirement #2 Diesel

Alternator output 55A @ 13.8V

Starter motor

Current draw, no load 90A

Brush length, new 0.7480 in19 mm

Brush length, minimum 0.5 in12.7 mm

Battery


Quantity 1



Fan belt deflection 3/8 in10 mm

SPECIFICATIONS



Hydraulic Hose and Fitting Torque SpecificationsYour machine is equipped with Parker Seal-Lok® O-ring face seal fittings and hose ends. Machines thatutilize Parker Seal-Lok® O-ring face seal fittings and hose ends require that the fittings and hose ends betorqued to specification when they are removed and installed or when new hoses or fittings are installed.

Torque Procedure1 Replace the O-ring. The O-ring must be

replaced 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 arestandard SAE size O-rings. Theyare available in the O-ring fieldservice kit(Genie part number 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 tableabove.

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

Hydraulic Hose and Fitting Torque SpecificationsSAE O-ring Boss Port - tube fitting Seal-Lok® - hose end

SAE Dash Size

Installing into... ft. lbs. Nm

SAE Dash Size ft. lbs. Nm

-4 Aluminum 11 14.9 -4 18 24.4Steel 16 21.7 -6 27 36.6

-6 Aluminum 23 31.2 -8 40 54.2Steel 35 47.5 -10 63 85.4

-8 Aluminum 40 54.2 -12 90 122Steel 60 81.3 -16 120 162.7

-10 Aluminum 69 93.6 -20 140 190Steel 105 142.4 -24 165 223.7

-12 Aluminum 93 126.1Steel 140 190

-16 Aluminum 139 188.5Steel 210 284.7

-20 Aluminum 172 233.2Steel 260 352.5

-24 Aluminum 208 282Steel 315 427.1

SPECIFICATIONS





Section 3 • Theory of OperationFirst Edition • Second Printing

Theory of Operation

Power SourceThe Genie Z-45/25 and Genie Z-45/25J arepowered by either a gasoline/LPG engine or one oftwo diesel engines. The gasoline/LPG option usesa Ford LRG-425 EFI engine rated at 70horsepower @ 2500 rpm. The diesel optionsinclude a Deutz F3L 1011F engine rated at 36horsepower @ 3000 rpm, and a Perkins 104-22KR engine rated at 41 horsepower @ 2800 rpm.

Hydraulic SystemAll machine functions are performed by thehydraulic system. The hydraulic system can bedivided into two groups: Boom/Steer functions andDrive functions.

Boom/Steer functions are powered by a single-section gear pump, rated at 7 gpm (26.5 L/min).When the engine is running, this pump supplieshydraulic fluid under pressure to the functionmanifold, where the directional and flow controlvalves are located. To protect from over-pressurization of the Boom/Steer system, thepump is provided with a pressure relief valve, setat 3500 psi (241.3 bar).

Drive functions are powered by a bi-directional,variable output piston pump rated at 0 to 30.3 gpm(0 to 114.7 L/min) @ 2500 rpm. Two internal 3200psi (220.6 bar) relief valves are used to preventover-pressurization of the closed loop drivesystem.

The boom lift cylinder, boom extend cylinder,platform leveling slave cylinder, platform rotatorand jib boom cylinder (Z-45/25J models)incorporate counterbalance valves to preventmovement in the event of a hydraulic line failure.

Electrical SystemBoom/Steer functions are accomplished bymoving a toggle switch or a controller, which sendsvoltage to the appropriate directional control valve.These directional valves determine which directionthe hydraulic fluid will travel. The amount ofhydraulic fluid volume is determined by aproportional valve or flow regulator valve. Aproportional valve receives a variable voltagesignal and delivers more hydraulic fluid as thevoltage increases. A flow regulator valve is amechanical valve and delivers a predeterminedamount of hydraulic fluid.

Drive forward or reverse is accomplished bypressing down the foot switch in the platform andmoving the drive controller (joystick) in theappropriate direction. When activated, the drivecontroller completes a circuit to the electronicdisplacement controller (EDC). The EDC regulatesdrive pump displacement in direct relation to thedrive controller position. A horsepower limiterprinted circuit board (located in the platform controlbox) is provided to maintain engine RPM as drivesystem loads become greater. This is done bysensing engine RPM (via an AC tap on thealternator) and limiting the amount of currentsupplied to the drive controller/EDC, whichdestrokes the pump, reducing pump output.


Section 3 • Theory of Operation First Edition • Second Printing

THEORY OF OPERATION

Limit switches

There are two types of limit switches which arefound in various locations on the machine: drivespeed limit switches and a drive enable limitswitch. The function of a drive speed limit switch isto limit the raised or extended drive speed to 0.6miles per hour (1 km/h) when the primary boom israised more than 2 feet (0.6 m) OR when theprimary boom is extended more than18 inches (45.7 cm). The function of the driveenable limit switch is to limit the ability of themachine to drive when the boom is rotated beyondthe non-steer wheels.

Machine ControlsThe Genie Z-45/25 and Genie Z-45/25J machinesare equipped with operational controls which arefound in two locations: the ground controls, locatedon the engine side of the machine, and theplatform controls, located in the platform. All lift anddrive functions are available at the platformcontrols. Only boom functions are available at theground controls.

Ground controls are activated by holding thefunction enable toggle switch to either side, thenmoving a boom function toggle switch in thedirection indicated on the control panel decal.This will determine which boom function willoperate and its direction of travel.

Platform controls use toggle switches and boomfunction controllers (joysticks) to operate the boomfunctions. The drive controller (joystick) regulatesthe drive pump displacement through the EDC indirect relation to the drive controller position. Athumb rocker switch on the top of the drivecontroller is used for steering.

Washing electronic components isnot suggested. Instead, usecompressed air to remove debris.


First Edition • Second Printing Section 4 • 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 flat, level surface

· Boom in stowed position

· Turntable rotated with the boom betweenthe non-steering wheels

· Turntable secured with the turntablerotation lock

· Key switch in the OFF position with thekey removed

· Wheels chocked

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







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


First Edition • Second PrintingSection 4 • 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.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two years.The Scheduled Maintenance Procedures Sectionand the Maintenance Inspection Report have beendivided 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



Checklist A Y N RA-1 ManualsA-2 Decals and placards

A-3 Damage and loose ormissing parts

A-4 Engine oil level

A-5 Engine coolant-Liquid Cooled Models

A-6 Fuel leaks

A-7 Hydraulic oil level

A-8 Hydraulic leaks

A-9 Tire pressure

A-10 Oscillate axle

A-11 Platform andground controls

A-12 Auxiliary power

A-13 Tilt sensor

A-14 Limit switches

A-15 Check the engine belt-Perkins Models

A-16 Air filter

A-17 Fuel filter- Ford Models

A-18 Inspect the radiator-Perkins Models

A-19 Perform 30 day service

Perform every 100 hours:

A-20 Replace oil filter-Ford and Perkins Models

A-21 Inspect fuel filter/water separator-Diesel Models

A-22 Check engine RPM-Perkins Engine Models

Perform every 200 hours:A-23 Check the engine belt-Ford Models

Instructions· Make copies of both pages to use for

each inspection.

· Select the appropriate checklist(s) forthe 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.

· 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 service

R = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Checklist B Y N RB-1 Check the battery

B-2 Inspect electrical wiring

B-3 Check the radiator-Ford Models

B-4 Exhaust system

B-5 Hydraulic return filtercondition indicator

B-6 Check oil cooler and fins-Deutz Models

B-7 Tires and wheels

B-8 Brake configuration

B-9 Drive hub oil level

B-10 Engine RPM-Ford and Deutz Models

B-11 Key switch

B-12 Emergency Stop

B-13 Ground control override

B-14 Directional valve

B-15 Platform leveling

B-16 Horn

B-17 Foot switch

B-18 Engine idle select

B-19 Fuel select-Ford Models

B-20 Drive enable system

B-21 Drive brakes

B-22 Drive speed-stowed

B-23 Drive speed-raised

B-24 Alarm package

B-25 Hydraulic oil analysis

Perform every 250 hours:

B-26 Replace hydraulictank return filter

Perform every 400 hours:B-27 Replace fuel filter/waterseparator element-Perkins models

B-28 Replace the fuel filterelement - Perkins Models

B-29 Replace spark plugs-Ford Models

B-30 Replace engine air filter

Maintenance Inspection Report



Checklist C Y N RC-1 Engine belt-Deutz Models

C-2 Replace engine oiland filter-Deutz Models

C-3 Valves-Deutz Models

C-4 Check the coolant-Liquid Cooled Models

C-5 Check the valveclearance-Perkins Models

C-6 PCV valve-Ford Models

Checklist D Y N RD-1 Boom wear pads

D-2 Turntable bearing bolts

D-3 Free-wheel configuration

D-4 Grease rotation bearing

D-5 Drive hub oil

D-6 Drive loop hydraulic filter

D-7 Check Air/LPG mixture-Ford Models

D-8 Replace the diesel fuelfilter/water separator-Deutz Models

MAINTENANCE INSPECTION REPORT

Instructions· Make copies of both pages to use for

each inspection.

· Select the appropriate checklist(s) forthe 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.

· 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 service

R = repaired

Comments

Checklist E Y N RE-1 Hydraulic oil

E-2 Engine coolant-Ford Models

E-3 Fuel hoses

E-4 Check the toothed belt-Deutz Models

E-5 Check the engine valveclearance-Ford Models

E-6 Check cylindercompression-Ford Models

E-7 Check the fuel injectionpump-Deutz Models

E-8 Replace timing beltFord Models

E-9 Grease the steer axlewheel bearings, 2WD Models



A-1Inspect the Operator's andSafety ManualsMaintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

1 Check to be sure that the storage container ispresent and in good condition.

2 Check to make sure that the operator's,responsibilities and safety manuals are presentand complete in the storage container in theplatform.

3 Examine the pages of each manual to be surethat they are legible and in good condition.

4 Always return the manuals to the storagecontainer after use.

Contact your authorized Geniedistributor or Genie Industries ifreplacement manuals are needed.

Table A Procedures

A-2Inspect the Decalsand PlacardsMaintaining all of the safety and instructionaldecals and placards in good condition ismandatory for safe machine operation. Decalsalert operators and personnel to the many possiblehazards associated with using this machine. Theyalso provide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Refer to the Decals section in theGenie Z45/25 & Genie Z45/25J Operator'sManual and use the decal list and illustrationsto determine that all decals and placards are inplace.

2 Inspect all decals for legibility and damage.Replace any damaged or illegible decalimmediately.

Contact your authorized Geniedistributor or Genie Industries ifreplacement decals are needed.



TABLE A PROCEDURES

A-3Inspect for Damage and Loose orMissing Parts

Daily machine condition inspections are essentialto safe machine operation and good machineperformance. Failure to locate and repair damage,and discover loose or missing parts may result inan unsafe operating condition.

1 Inspect the entire machine for damage andimproperly installed or missing parts including:

· Electrical components, wiring and electrical cables

· Hydraulic hoses, fittings, cylinders and manifolds

· Fuel and hydraulic tanks

· Drive and turntable rotation motors and drive torque hubs

· Axle components

· Boom components and wear pads

· Platform entry mid-rail or gate

· Tires and wheels

· Engine and related components

· Limit switches

· Alarms, horn and beacon (if equipped)

· Nuts, bolts and other fasteners

Check entire machine for:

· Cracks in welds or structural components

· Dents or damage to machine

· Battery and connections

· Compartment covers and latches

Be sure that all structural and other criticalcomponents are present and all associatedfasteners and pins are in place and properlytightened.

After you complete each inspection, be sure that allcompartment covers are in place and secured.



TABLE A PROCEDURES

A-4Check the Engine Oil Level

Maintaining the proper engine oil level is essentialto good engine performance and service life.Operating the machine with an improper oil levelcan damage engine components.

Check the oil level with theengine off.

1 Check the oil dipstick. Add oil as needed.

Result: The oil level should be in the "safe"zone.

Ford LRG-425 EFI Engine 4.5 quartsOil capacity (including filter) 4.3 liters


below 60°F / 15.5°C 5W-30

-10° to 90°F / -23° to 32°C 5W-30

above -10°F / -23°C 5W-30

above 25°F / -4°C 10W-30

Use oils meeting API classification SH or SG.Units ship with 10-40 CC/SG.

Deutz Engine F3L 1011F 6.3 quartsOil capacity (including filter) 6 liters


below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCC/SE, CD/SE, SF/CC or SF/CD grades.Units ship with 10-40 CC/SG.

Perkins Engine 104-22 8.6 quartsOil capacity (including filter) 8.2 liters


below 60°F / 15.5°C 5W-20

-10° to 90°F / -23° to 32°C 10W-30

above -10°F / -23°C 15W-40

above 25°F / -4°C 20W-50

Engine oil should have properties of API classificationCC/SE, CD/SE, SF/CC or SF/CD grades.Units ship with 10-40 CC/SG.



TABLE A PROCEDURES

A-5Check the Engine Coolant Level -Liquid Cooled Models

Maintaining the engine coolant at the proper levelis essential to engine service life. Improper coolantlevel will affect the engine's cooling capability anddamage engine components. Daily checks willallow the inspector to identify changes in coolantlevel that might indicate cooling system problems.

Burn hazard. Beware of hotengine parts and coolant. Contactwith hot engine parts and/orcoolant may result in severeburns.

1 Check the fluid level in the coolant recoverytank. Add fluid as needed.

Result: The fluid level should be at theFULL mark.

Do not remove the radiator cap.

A-6Check for Fuel Leaks

Failure to detect and correct fuel leaks will result inan unsafe condition. An explosion or fuel fire maycause death or serious injury.

Explosion and fire hazard. Enginefuels are combustible. Inspect themachine in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

1 Open the shutoff valve on the liquid petroleumgas (LPG) tank by turning it counterclockwise(if equipped).

2 Perform a visual inspection around the followingareas.

Ford Models:

· LPG tank, hoses and fittings, solenoid shutoffvalve, LPG regulator and throttle body.

An LPG detector may benecessary to locate LPG leaks.

· Fuel tank, manual shutoff valve, fuelpump, fuel filters, fuel rail and fuel injectors,hoses and fittings and throttle body.



TABLE A PROCEDURES

Deutz and Perkins Models:

· Fuel tank, shutoff valve, hoses and fittings,fuel pump, fuel filter, fuel injection pumps andfuel injectors.

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

A-7Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level isessential to machine operation. Improper hydraulicoil levels can damage hydraulic components. Dailychecks allow the inspector to identify changes in oillevel that might indicate the presence of hydraulicsystem problems.

1 Be sure that the boom is in the stowed position,then visually inspect the sight gauge located onthe side of the hydraulic oil tank.

Result: The hydraulic oil level should be withinthe top 2 inches (5 cm) of the sight gauge.

2 Add oil as needed.

Hydraulic oil specifications

Hydraulic oil type Dexron equivalent

Tank capacity 24 gallons 90.8 liters

Hydraulic system(including tank) 30 gallons 113.6 liters



TABLE A PROCEDURES

A-8Check for Hydraulic Leaks

Detecting hydraulic fluid leaks is essential tooperational safety and good machine performance.Undiscovered leaks can develop into hazardoussituations, impair machine functions and damagemachine components.

1 Inspect for hydraulic oil puddles, dripping orresidue on or around the following areas:

· Hydraulic tank— fittings, hoses, auxiliarypower unit, filters, and turntable surface

· Engine compartment—hydraulic filters,fittings, hoses, pumps, filter and turntablesurface

· All hydraulic cylinders

· All hydraulic manifolds

· Primary and jib boom

· The underside of the turntable

· The underside of the drive chassis

· Ground area under the machine

A-9Check the Tire Pressure

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

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

This procedure does not needto be performed on machinesequipped with foam-filledtire.

To safeguard maximum stability, achieveoptimum machine handling and minimize tirewear, it is essential to maintain proper pressurein all air-filled tires.

1 Check each tire with an air pressure gauge andadd air as needed.

Tire specifications 2WD Models 4WD Models

Standard base modelsRough terrain tire 14-17.5 NHS 14-17.5 NHS

45 psi (3.1 bar) 45 psi (3.1 bar)

Narrow base modelsIndustrial tire Foam Filled Only N/A



TABLE A PROCEDURES

A-10Test the Oscillate Axle(if equipped)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 a 6 inch(15.2 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 a 6 inch(15.2 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 a 6 inch(15.2 cm) block or curb.

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

If the chassis does not remainlevel during test, see RepairProcedure 12-4, How to Set Upthe Directional Valve Linkage

A-11Test the Platform andGround ControlsTesting the machine functions and the EmergencyStop buttons for malfunctions is essential for safemachine operation. An unsafe working conditionexists if any function fails to operate properly oreither Emergency Stop button fails to stop all themachine functions and shut off the engine. Eachfunction should activate, operate smoothly and befree of hesitation, jerking and unusual noise.

1 Turn the key switch to ground control and pullout the Emergency Stop button to the ON

position.

2 Start the engine from the ground controls.

3 Do not hold the function enable switch to eitherside. Attempt to activate each boom andplatform function toggle switch.

Result: All boom and platform functions shouldnot operate.

4 Hold the function enable switch to either sideand activate each boom and platform functiontoggle switch.

Result: All boom and platform functions shouldoperate through a full cycle. Descent alarm (ifequipped) should sound while the boom islowering.

Machines equipped with PlatformLevel Control Disable Function:The platform level function will notoperate when the boom is raisedor extended past the drive speedlimit switches.



TABLE A PROCEDURES

5 Push in the Emergency Stop button to the OFF

position.

Result: No function should operate, the engineshould stop.

Deutz and Perkins Diesel models:All functions should stopimmediately. The engine willshut off after 2 to 3 seconds.


7 Do not press down on the foot switch.

8 Attempt to activate each machine function.

Result: All machine functions should notoperate.

9 Press down on the foot switch and activateeach machine function.

Machines equipped with PlatformLevel Control Disable Function:The platform level function will notoperate when the boom is raisedor extended past the drive speedlimit switches.

Result: All machine functions should operatethrough a full cycle.

10 Push in the Emergency Stop button to the OFF

position at the platform controls.

Result: No function should operate, the engineshould stop.

As a safety feature, selectingand operating the groundcontrols will override theplatform controls, includingthe Emergency Stop button.


A-12Test the Auxiliary PowerOperationDetection of auxiliary power system malfunctions isessential for safe machine operation. An unsafeworking condition exists if the auxiliary poweredfunctions do not operate in the event of a mainpower loss. When operating the machine onengine power, selecting auxiliary power will stopthe engine immediately. Auxiliary power isdesigned for short term use only,and excessive use will result in battery drainand component damage.


position.

2 Lift the red auxiliarypower switch cover.

3 Simultaneously holdthe auxiliary powerswitch ON and activateeach boom functiontoggle switch.

To conserve battery power, testeach function through a partialcycle.

Result: All boom functions should operate.

4 Turn the key switch to platform control.

5 Pull out the Emergency Stop button to the ON

position at the platform controls.

6 Press down the foot switch.



7 Lift the red auxiliary power switch cover.

8 Simultaneously hold the auxiliary power switchON and activate each function control handle ortoggle switch.

Result: All boom and steer functions shouldoperate. Drive functions should not operate withauxiliary power.

To conserve battery power, testeach function through a partialcycle.

A-13Test the Tilt SensorThe tilt sensor sounds an alarm located in theplatform when the incline of the turntable exceedsthe rating on the serial plate.

Select a level test area. The tiltalarm should not be sounding priorto the test.

1 Open the engine side turntable cover.

2 Turn the key switch to platform controls and pullout the red Emergency Stop buttons out to theON position at both the ground and platformcontrols.

3 Locate the tilt sensor to the right of the hydraulicpump.

4 Press down on one side of the tilt sensor.

Result: The alarm, located in the platform,should sound.

Tip-over hazard. The alarm shouldbe heard at the ground controls. Ifyou can't hear the alarm at theground controls, replace the alarmin the platform.

TABLE A PROCEDURES



A-14Test the Limit Switches

Drive Limit Switches

Detecting limit switch malfunctions is essential tosafe machine operation. The drive limit switchesare used to restrict drive speed when the boom israised or extended. An improperly functioning drivelimit switch will allow the machine to operate at anunsafe drive speed.

1 Remove the hose and cable cover from the rearof the upper mid-pivot.

2 Locate the primary boom drive limit switchlocated on the inside of the upper mid-pivot.

3 Visually inspect primary boom drive limit switchfor the following:

· Broken or missing roller or arm

· Missing fasteners

· Loose wiring

4 Manually activate the primary boom drive limitswitch.

Result: The primary boom drive limit switch armshould move freely and spring return to center.A distinct click should be felt and heard.

a primary boom drive limit switch (LS2)

TABLE A PROCEDURES

5 Locate the secondary boom drive limit switchlocated at the platform end of the lowersecondary boom.

a secondary boom drivelimit switch (LS3)

6 Visually inspect secondary boom drive limitswitch for the following:



· Loose wiring

7 Manually activate the secondary boom drivelimit switch.

Result: The secondary boom drive limit switcharm should move freely and spring return tocenter. A distinct click should be felt and heard.

a

a



8 Locate the primary boom extend drive limitswitch located at the pivot end of the primaryboom.

a primary boom extend drive limitswitch (LS1)

9 Visually inspect the boom extend drive limitswitch located at the pivot end of the primaryboom. Inspect for the following:

· Broken or missing arm


· Loose wiring

10 Start the engine from the ground controls andextend the primary boom approximately 2 feet(61 cm).

11 Turn the engine off.

12 Manually activate the boom extend drive limitswitch.

Result: The boom extend drive limit switch armshould move freely and spring return to center.A distinct click should be felt and heard.

TABLE A PROCEDURES


14 Move the lift/drive select switch to the liftposition (if equipped).

15 Press down the foot switch. Fully retract theprimary boom.

16 Move the lift/drive select switch to the driveposition (if equipped).

17 Press down the foot switch and slowly move thedrive control handle off center.

Result: The machine should move at normaldrive speeds.


19 Press down the foot switch and raise theprimary boom approximately 2 feet (61 cm).



Result: The machine should move at a reduceddrive speed.


23 Press down the foot switch and lower theprimary boom to the stowed position, then raisethe secondary boom approximately2 feet (61 cm).

a







27 Press down the foot switch and lower thesecondary boom to the stowed position, thenextend the primary boom approximately 2 feet(0.6 m).




Drive speed, maximum,raised or extended

Drive speed, boom 0.6 mphraised or extended, 1.0 km/hStandard Base Models 40 ft/45 sec

12.2 m/45 sec


12.2 m/79 sec

Drive Enable Limit Switch

A properly functioning drive enable limit switch isessential for safe machine operation andworkplace safety. The drive enable limit switchstops the drive function when the boom is rotatedpast a non-steer tire and alerts the operator thatthe machine may drive in the opposite directionthat the drive and steer control handle is moved.

1 Start the engine from the ground controls androtate the boom between the steer andnon-steer tires. Turn the engine off.

2 Visually inspect the drive enable limit switch forthe following:



· Loose wiring

a turntableb drive enable limit switch (LS4)c turntable rotation bearing

a

bc

TABLE A PROCEDURES



3 Manually activate the drive enable limit switch.

Result: The drive enable limit switch rollershould move freely and spring return to center.A distinct click should be felt and heard.


Result: The drive enable indicator light shouldbe on.


6 Press down the foot switch. Then rotate theturntable until the primary boom is in betweenthe non-steer tires.

Result: The drive enable indicator light shouldbe off.



Result: The drive function should operate.


10 Press down the foot switch and rotate theturntable to the left until the boom is past theleft non-steer wheel.




Result: Drive function should not operate.

13 Move and hold the drive enable toggle switch toeither side and slowly move the drive controlhandle off center.

Result: Drive function should operate.


15 Press down the foot switch and rotate theturntable to the right until the boom is past theright non-steer wheel.


16 Rotate the turntable to the left until the boom ispast the left non-steer wheel.




Result: Drive function should not operate.

19 Move and hold the drive enable toggle switch toeither side and slowly move the drive controlhandle off center.

Result: Drive function should operate.

TABLE A PROCEDURES



A-15Check the Engine Belt -Perkins ModelsMaintaining the engine belt is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause componentdamage.

Bodily injury hazard. Do notinspect while the engine isrunning. Remove the key tosecure from operation.

Burn hazard. Beware of hotengine components. Contact withhot engine components may resultin severe burns.

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.

3 Inspect the engine belt for:

· Cracking

· Glazing

· Separation

· Breaks

4 Replace belt if any damage is found.

5 Check the engine belt for proper tension.

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

7 Install the engine pivot plate safety pin.

8 Replace the air baffle and install the air baffleretaining fasteners.

Belt deflection 3/8 in to 1/2 in9.5 mm to 12 mm

Engine belt - Genie part number 65537

TABLE A PROCEDURES



A-16Clean the Engine Air FilterElement

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.

Perform this procedure with theengine off.

All Models:

1 Remove the safety pin (if equipped) from theengine pivot plate latch.



TABLE A PROCEDURES

3 Remove the end cap from the air cleanercanister.

4 Remove the air filter retaining fastener. Removethe filter element.

5 Clean the inside of the canister and the gasketwith a damp cloth.

6 Inspect the filter element. If needed, blow outfrom inside out using low pressure drycompressed air, or tap out dust taking care notto damage the element.

7 Install the end cap onto the canister. Install andtighten the retaining ring.


9 Install the engine pivot plate safety pin(if equipped).



A-17Replace the FuelFilters - Ford Models

Replacing the gasoline fuel filter is essential togood engine performance and service life. A dirtyor clogged filter may cause the engine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel filter in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.


1 Locate the fuel system components mountedunderneath the engine pivot plate (viewed frombottom of engine pivot plate).

a hose from fuel pump to regulator/filterb hose from fuel pre-filter to fuel pumpc hose from fuel tank to fuel pre-filterd hose from regulator/filter to enginee hose from regulator/filter to tank

2 At the pre-filter, disconnect and plug the fuelhose that goes to the fuel tank.

3 Disconnect the fuel hose from the fuel pre-filterto the fuel pump, then remove the pre-filter.

4 Install the new fuel pre-filter (Genie part number52179) and connect the fuel hoses to the filter.

5 Clean up any fuel that may have spilled duringthe installation procedure.

TABLE A PROCEDURES

a b c

e d



6 Disconnect the hoses from the pressureregulator/filter.

Explosion and fire hazard.Electronic Fuel Injection (EFI)systems operate at a very highpressure. Fuel may be expelledunder pressure if the hoses areremoved too quickly. Loosen thefuel lines very slowly to allow thefuel pressure to dissipategradually. Wrap a cloth aroundfuel hoses to absorb leaking fuelbefore disconnecting them.

7 Remove the regulator/filter mounting fasteners.Then remove the regulator/filter from the enginepivot plate.

8 Install the new regulator/filter (Genie partnumber 58967) onto the engine pivot plate andinstall the hoses to the regulator/filter.

Component damage hazard. Besure the correct regulator/filter isinstalled or component damagemay occur.

9 Start the machine from the ground controls,then inspect the fuel filters and hoses for leaks.


Fuel filters - Genie part numbers

Fuel pre-filter 52179Fuel pressure regulator/filter 58967

A-18Inspect the Radiator -Perkins Models

Maintaining the radiator in good condition isessential for good engine performance. Operatinga machine with a damaged or leaking radiator mayresult in engine damage. Also, restricting air flowthrough the radiator (i.e., dirt or debris) will affectthe performance of the cooling system. A frequentcheck allows the inspector to identify changes inthe condition of the radiator that might indicatecooling system problems.

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





TABLE A PROCEDURES



3 Inspect the radiator for leaks and physicaldamage.

4 Clean the radiator fins of debris and foreignmaterials.

5 Inspect all radiator hoses and connections.


7 Install the engine pivot plate safety pin.

A-19Perform 30 Day Service

The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 50 hours of usage. After thisinterval, refer to the maintenance tables forcontinued scheduled maintenance.

1 Perform the following maintenance procedures: • Replace the Engine Oil and Filter -

Ford/Perkins Models ............................. A-19 Deutz Diesel Models .............................. C-2

• Inspect the Tires and Wheels (including lug nut torque) ......................... B-5

• Replace the Hydraulic Tank Return Filter ........................................................ B-24

• Check the Turnable Rotation Bearing Bolts ....................................................... D-2

TABLE A PROCEDURES



A-20Replace the Engine Oil andFilter - Ford and Perkins Models

Ford and Perkins enginespecifications require that thisprocedure be performed every 100hours. Perform this proceduremore often if dusty conditions existor the machine is subjected toextended low idle operation.

Periodic replacement of the engine oil and filteris essential to good engine performance. Operatingthe machine with an improper oil level orneglecting periodic oil and filter changes candamage engine components. A daily check ofmachine hours against the hours noted on the oilfilter will allow the inspector to anticipate andperform oil and filter changes at the 100 hourinterval.

Perform this procedure afterwarming the engine to normaloperating temperature.

Burn hazard. Beware of hotengine parts and oil. Contact withhot engine oil and/or engine partsmay result in severe burns.




3 Remove the oil filler cap located on thevalve cover.

4 Pull the oil drain hose out from underneath theengine.

5 Open the valve on the oil pan and allow all ofthe oil from the engine to drain into a suitablecontainer. See capacity specifications.

6 Close the valve on the oil pan.

7 Place a container under the oil filter.

8 Use an oil filter wrench and remove the filter.

9 Apply a thin layer of oil to the new oil filtergasket. Then install the filter and tighten itsecurely by hand.

Oil filters - Genie part numbersFord LRG-425 EFI Engine 28656Perkins 104-22 Engine 65540

10 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter.

11 Fill the engine with new oil per specificationsand install the filler cap. See capacityspecifications.

12 Start the engine from the ground controls.Allow the engine to run for 30 seconds, thenturn the engine off.

TABLE A PROCEDURES



13 Check the oil filter and the oil pan hose forleaks.



16 Check the engine oil level dipstick. Add oilif needed.

Ford LRG-425 EFI Engine 4.5 quartsOil capacity (including filter) 4.3 liters


below 60°F / 15.5°C 5W-30

-10° to 90°F / -23° to 32°C 5W-30

above -10°F / -23°C 5W-30

above 25°F / -4°C 10W-30

Use oils meeting API classification SH or SG.Units ship with 10-40 CC/SG

Perkins 104-22 Engine 8.6 quartsOil capacity (including filter) 8.2 liters


below 60°F / 15.5°C 15W-40

-10°F to 90°F / -23°C to 32°C 10W-30

above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCF4 grade.

A-21Inspect the Fuel Filter/ WaterSeparator - Diesel Models

Engine specifications require thatthis procedure be performed every100 hours.

Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and componentdamage.

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


Perkins Models:

1 Open the engine side turntable cover and locatethe fuel filter/water separator next to thehydraulic return filter on the bulkhead.

2 Inspect the filter bowl for water buildup.

Result: If water is present in the filter bowlcontinue with steps 3 through 7 for Perkinsmodels only.

TABLE A PROCEDURES



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

Fuel filter/water separatora vent plugb drain plugc filter bowld separator head

4 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.

5 Tighten the vent plug.

If the fuel filter/water separator iscompletely drained, you mustprime the fuel filter/waterseparator before starting theengine. Refer to B-27 in thissection, Replace The Fuel FilterElement - Perkins Diesel Models,for instructions on how to primethe fuel filter/water separator.

6 Clean up any fuel that may have spilled.

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


Deutz Models:

1 Open the engine side turntable cover and locatethe fuel filter/water separator.




4 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.

a fuel filter/water separatorb drain plug

TABLE A PROCEDURES

b

d

a

a

b

c



4 Clean up any fuel that may have spilled.

If the fuel filter is completelydrained, you must prime the fuelfilter/water separator beforestarting the engine. Refer to D-8 inthis section, Replace The DieselFuel Filter/Water Separator -Deutz Diesel Models, forinstructions on how to prime thefuel filter/water separator.

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




A-22Check and Adjust theEngine RPM - Perkins DieselModels

Perkins specifications require thatthis procedure be performed every100 hours.

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.

This procedure will require twopeople.

1 Connect a tachometer to the engine. Start theengine from the ground controls.

Result: Low idle should be 1600 rpm.

TABLE A PROCEDURES



Skip to step 3 if the low idle rpm is correct.

2 Loosen the low idle lock nut and turn the lowidle adjustment 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

3 Move the function enable toggle switch to thehigh idle (rabbit symbol) position.

Result: High idle should be 2500 rpm.

If high idle rpm is correct, disregardadjustment step 4.

TABLE A PROCEDURES

4 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 Diesel models

Low idle 1600 rpm

High idle 2500 rpm

a b c d



TABLE A PROCEDURES

A-23Check the Engine Belt -Ford Models


Maintaining the engine belt is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause componentdamage.







· Cracking

· Glazing

· Separation

· Breaks


Ford LRG-425 EFI engines areequipped with a serpentine beltand incorporate a self adjustingbelt tensioner. No adjustment isrequired.



Engine belt - Genie part numberFord Models 52580



B-1Check the Battery

Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions.

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.

1 Put on protective clothing and eye wear.

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

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

The battery is a maintenance freebattery and does not require thereplenishing of electrolyte.

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

Table B Procedures

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



TABLE B PROCEDURES

5 Open the ground controls side turntable cover.

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

· Inside of the ground control box

· Hydraulic manifold wiring

7 Start the engine from the ground controls andraise the boom above the turntable covers.

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

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

10 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



B-3Check the Radiator -Ford ModelsMaintaining the radiator in good condition isessential for good engine performance. Operatinga machine with a damaged or leaking radiator mayresult in engine damage. Also, restricting air flowthrough the radiator (i.e., dirt or debris) will affectthe performance of the cooling system. A frequentcheck allows the inspector to identify changes inthe condition of the radiator that might indicatecooling system problems.







TABLE B PROCEDURES


3 Inspect the radiator for leaks and physicaldamage.

4 Clean the radiator fins of debris and foreignmaterials.

5 Inspect all radiator hoses and connections.




B-4Check the Exhaust SystemMaintaining 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.



1 Ford models: Remove the safety pin (ifequipped) from the engine pivot plate latch.


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

3 All models: Be sure that all nuts and bolts aretight.

4 Inspect all welds for cracks.

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

6 Ford models: Swing the engine back to itsoriginal position and close the engine pivotplate latch.




TABLE B PROCEDURES

B-5Check the Hydraulic Return FilterCondition IndicatorMaintaining the hydraulic return filter in goodcondition is essential to good system performanceand safe machine operation. The filter conditionindicator will show when the hydraulic flow isbypassing a clogged filter. If the filter is notfrequently checked and replaced, impurities willremain in the hydraulic system and causecomponent damage.



3 Move the engine RPM toggle switch to themaintained high idle position (rabbit symbol).

4 Inspect the filter condition indicator gauge.

Result: The needle on the gauge should beoperating in the green area. If the needle is inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter should bereplaced.

The hydraulic filter conditionindicator gauge is mounted to thehydraulic return filter on the engineside bulkhead.

B-6Check the Oil Cooler and CoolingFins - Deutz Diesel Models

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



Oil Cooler




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



TABLE B PROCEDURES

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-7Inspect the Tires and Wheels(including lug nut torque)

Maintaining the tires and wheels in goodcondition is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired 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.

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.

4 Check the pressure in each air-filled tire.

Tire specifications Industrial Rough terrain

Tire size 9-14.5 LT 14-17.5 NHS

Inflation pressure Foam Filled 45 psi (3.1 bar)

Tire ply rating (minimum) 12 14

Wheel lugs, 4WD 8 @ 5/8 -18 9 @ 5/8 -18

Wheel lugs, 2WDFront 8 @ 5/8 -18 8 @ 5/8 -18Rear 9 @ 5/8 -18 9 @ 5/8 -18

Lug nut torque, dry 125 ft-lbs 125 ft-lbs169.5 Nm 169.5 Nm

Lug nut torque, lubricated 94 ft-lbs 94 ft-lbs127.4 Nm 127.4 Nm

cba



B-8Confirm 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 besure it is in the engaged position.

2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

The free-wheel valve is located onthe side of the drive pump.

a drive pumpb free-wheel valvec lift pumpd screwdriver

The free-wheel valve shouldalways remain closed.

TABLE B PROCEDURES

B-9Check the Oil Levelin the Drive Hubs

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

Drive Hubs

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

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

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

a

b

c

d

brake disengage position

brake engage position



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

4 Apply pipe thread sealant to the plug, and theninstall it in the drive hub.

5 Repeat this procedure for each drive hub.

Drive hub oil

Capacity 17 fl oz0.5 liters

Type: SAE 90 multipurpose hypoid gear oil - API serviceclassification GL5

TABLE B PROCEDURES

B-10Check and Adjust theEngine RPM - Ford and DeutzModels

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 Models:

The engine rpm is controlled bythe ECM and can only be adjustedby re-programming the ECM. Ifrpm adjustment or service isrequired, please contact GenieIndustries Service Department ORyour local Ford dealer.

Ford Models

Low idle 1600 rpm

High idle 2500 rpm

Deutz Diesel Models:

This procedure will require twopeople.





TABLE B PROCEDURES


3 Connect an rpm gauge to the engine, and thenstart the engine from the ground controls.

Result: Low idle should be 1400 rpm.

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

5 Move the function enable toggle switch to thehigh idle (rabbit symbol) position at the groundcontrols.

Result: High idle should be 2500 rpm.

If high idle rpm is correct, disregardadjustment step 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.

Deutz Diesel Models

Low idle 1400 rpm

High idle 2500 rpm

f

e

c dba



TABLE B PROCEDURES

B-11Test the Key SwitchProper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

1 Pull out the Emergency Stop button to the ON

position at both the ground and platformcontrols.

2 Turn the key switch to ground control, start theengine and then turn the key switch to platformcontrol.

3 Check any machine function from the groundcontrols.

Result: The machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check any machine function from the platformcontrols.


6 Turn the key switch to the OFF position.

Result: The engine should stop and nofunctions should operate.


B-12Test the EmergencyStop ButtonsProperly functioning Emergency Stop buttonsare essential for safe machine operation. Animproperly operating Emergency Stop buttonwill fail to shut off power and stop all machinefunctions, resulting in a hazardous situation forground and platform personnel.

As a safety feature, selectingand operating the ground controlswill override the platform controls,including the platform EmergencyStop button.


2 Push down the Emergency Stop button to theOFF position.

Result: The engine should shut off and nomachine functions should operate.



4 Push down the Emergency Stop button to theOFF position.

Result: The engine should shut off and nomachine functions should operate.

The ground Emergency Stopbutton will stop all machineoperation, even if the key switchis switched to platform control.



TABLE B PROCEDURES

B-13Test the Ground Control OverrideA properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether or not the EmergencyStop button on the platform controls is in the ON orOFF position. This function is particularly useful ifthe operator at the platform controls cannot returnthe boom to the stowed position.

1 Push in the platform Emergency Stop buttonto the OFF position.


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

Result: All boom functions should operate.

B-14Check the Directional ValveLinkage

Perform this test only on modelsequipped with a oscillating axle.

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

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



TABLE B PROCEDURES

2 Locate the directional valve inside of the non-steer axle and inspect the linkage for thefollowing:

· Lock nut is tight against yoke

· Yoke clevis pins are installed

· Cotter pins are installed through clevis pins

· Linkage is properly attached todirectional valve

a directional valveb clevis pin with cotter pin (hidden)c yoked lock nut

B-15Test 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 andground personnel.

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.

a

b

c

d



TABLE B PROCEDURES

B-16Test the HornA functional horn is essential to safe machineoperation. The horn is activated at the platformcontrols and sounds at the ground as a warning toground personnel. An improperly functioning hornwill prevent the operator from alerting groundpersonnel of hazards or unsafe conditions.

1 Turn the key switch to platform control andpull out the Emergency Stop button to theON position at both the ground andplatform controls.

2 Push down the horn button at the platformcontrols.

Result: The horn should sound.

If necessary, the horn can beadjusted to obtain the loudestvolume by turning the adjustmentscrew near the wire terminals onthe horn.

B-17Test the Foot SwitchA properly functioning foot switch is essential tosafe machine operation. Machine functions shouldactivate and operate smoothly as long as the footswitch is pressed down, and promptly stop whenthe foot switch is released. The foot switch will alsoshift the engine into high idle if the idle select isswitched to the rabbit and foot switch symbol. Animproperly functioning foot switch can cause anunsafe working condition and endanger platformand ground personnel.

The engine should not start if thefoot switch is pressed down.

1 Turn the key switch to platform controls and pullout the Emergency Stop button to the ON


2 Press down the foot switch and attempt to startthe engine by moving the start toggle switch toeither side.

Result: The engine should not start.

3 Do not press down the foot switch and attemptto start the engine.

Result: The engine should start.

4 Do not press down the foot switch. Check themachine functions.


5 Press down the foot switch and operate themachine functions.

Result: The machine functions should operate.



TABLE B PROCEDURES

B-18Test the Engine Idle SelectA properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are three settings.

Low idle (turtle symbol) allows the operator tocontrol individual boom functions only. Drivefunctions do not operate at low idle.

High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle and is usually selected onlywhen the generator option is being used.

Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This selection activates highidle only when the foot switch is pressed down.

1 Pull out the 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 At the platform controls, move the engine idlecontrol switch to high idle (rabbit symbol). Donot press down the footswitch.


6 Move the engine idle control switch to low idle(turtle symbol).

Result: The engine should change to low idle.

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

Result: The engine should not change tohigh idle.

8 Press down the foot switch.




TABLE B PROCEDURES

B-19Test the Fuel Select Operation -Ford ModelsThe 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 indicatefuel system 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 Move the fuel select switch to gasoline and thenmove the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

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 the Emergency Stop button in to theOFF 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.



TABLE B PROCEDURES

B-20Test the Drive Enable SystemProper drive enable system operation isessential to safe machine operation. When theboom is past the non-steering wheels, drivemovement is stopped and the indicator light turnson. The drive enable switch must be to either sideto reactivate the drive function and should informthe operator that the machine will move in theopposite direction that the drive and steer controlsare moved. An improperly functioning drive enablesystem may allow the machine to be moved intoan unsafe position.


2 Rotate the turntable to the right until the boom ispast the right non-steering wheel.

Result: The drive enable indicator light shouldturn on.

3 Slowly move the drive control handle off center.

Result: The drive function should not operate.

4 Hold the drive enable toggle switch to eitherside and slowly move the drive control handleoff center.

Collsion hazard. Always use thecolor-coded direction arrows onthe platform control panel and thedrive chassis to identify whichdirection the machine will travel.

Result: The drive function should operate.

5 Rotate the turntable to the left until the boom ispast the left non-steering wheel.

Result: The drive enable indicator light shouldcome on.

6 Repeat steps 3 and 4.



B-21Test 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.Refer to B-8 in this section,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), 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 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.

Braking:paved surface 4WD

Stopping distance 3 to 6 ft0.9 to 1.8 m

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

TABLE B PROCEDURES



B-22Test the Drive Speed -Stowed Position

Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet (12.2 m) apart.


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

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.

Drive speed, maximumstowed position

All models 40 ft / 5.7 sec12.2 m / 5.7 sec

TABLE B PROCEDURES



TABLE B PROCEDURES

B-23Test the Drive Speed -Raised or Extended Position

Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet (12.2 m) apart.



4 Move the engine idle select switch to foot switchactivated high idle (rabbit and foot switch).Press down the foot switch and raise the boomabove horizontal.




8 Continue at full speed and note the time whenthe machine reference point crosses the finishline.


10 Press down the foot switch and lower the boomto the stowed position.

11 Extend the boom 1 foot (30 cm).




15 Continue at top speed and note the time whenthe machine reference point crosses the finishline.


12.2 m/45 sec


12.2 m/79 sec



TABLE B PROCEDURES

B-24Test the Alarm Package -Optional EquipmentThe alarm package includes:

· Travel alarm

· Descent alarm

· Flashing beacon

Alarms and a beacon are installed to alertoperators and ground personnel of machineproximity and motion. The alarm package isinstalled on the turntable covers.

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



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.

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

4 Turn the key switch to platform control.

Result: The flashing beacon should be ON

and flashing.

5 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.

6 Press down the foot switch. Move thesecondary boom control handle to the DOWN

position, hold for 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 the drivecontrol handle off center, hold for a momentand then release it. Move the drive controlhandle off center in the opposite direction, holdfor a moment and then release it.

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



TABLE B PROCEDURES

B-26Replace the Hydraulic TankReturn Filter

Genie requires that this procedurebe performed quarterly or every250 hours, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Replacement of the hydraulic tank filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.

Burn hazard. Beware of hot oil.Contact with hot oil may result insevere burns.


1 Open the engine side turntable cover and locatethe hydraulic return filter on the bulkhead.

2 Remove the filter with an oil filter wrench.

3 Apply a thin layer of oil to the new oil filtergasket.

4 Install the new filter (Genie part number 65540)and tighten it securely by hand. Clean up anyoil that may have spilled during the installationprocedure.


6 Inspect the filter and related components tobe sure that there are no leaks.

B-25Perform Hydraulic Oil Analysis

See E-1, Test or Replace the Hydraulic Oil.



B-27Replace the Fuel Filter/ WaterSeparator Element -Perkins Diesel Models

Replacing the diesel fuel filter/water separatorelement is essential for good engine performanceand service life. A dirty or clogged filter may causethe engine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.



1 Open the engine side turntable cover and locatethe fuel filter/water separator next to thehydraulic return filter on the bulkhead.

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

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

Fuel filter/water separatora vent plugb main fuel linec drain plugd filter bowle filter elementf separator head

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

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

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

7 Install the bowl onto the new filter element(Genie part number 22942).

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

10 Tighten the vent plug.

TABLE B PROCEDURES

d

c

f

e b

a



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

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

Bleed the system:

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

a vent plugb fuel injection pumpc fuel lift pump

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

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

TABLE B PROCEDURES

16 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



B-28Replace the Fuel Filter Element -Perkins Diesel 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.





TABLE B PROCEDURES


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.

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 (Genie partnumber 65542) and tighten it securely by hand.Clean up any fuel that may have spilled duringthe installation procedure.

a fuel lineb filter headc fuel filter element

b

a

c



Bleed the system:

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

a vent plugb fuel injection pumpc fuel lift pump

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


12 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-29Replace the Spark Plugs -Ford Models

Engine specifications requires thatthis procedure be performed every400 hours.

Periodic replacement of the spark plugs isessential to good engine performance andservice life. Worn, loose or corroded spark plugswill cause the engine to perform poorly and mayresult in component damage.





3 Label, then disconnect the plug wires from thespark plugs by grasping the handle on thespark plug boot. Do not pull on the plug wire.

TABLE B PROCEDURES

a

bc



4 Blow out any debris around spark plugs.

5 Remove all the spark plugs from the engine.

6 Adjust the gap on each new spark plug.

7 Install the new spark plugs and torque tospecifications.

8 Connect the wires. Be sure that each spark plugwire is attached to the correct spark plug.



Spark plug specifications

Spark plug type Motorcraft AWSF-52C

Spark plug gap 0.042 to 0.046 inch1.07 to 1.18 mm

Spark plug torque 5 to 10 ft-lbs7 to 14 Nm

TABLE B PROCEDURES

B-30Replace the Engine Air FilterElement

Engine specifications requires thatthis procedure be performed every400 hours or annually, whichevercomes first. Perform thisprocedure more often if dustyconditions exist.

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.


All Models:




3 Open the engine side cover and remove theretaining ring from the end cap of the air filtercanister.



4 Remove the end cap from the air cleanercanister.

5 Remove the air filter retaining fastener. Removethe filter element.

6 Clean the inside of the canister and the gasketwith a damp cloth.

7 Install the new air filter element and install themounting fastener.

8 Install the end cap onto the canister. Install andtighten the retaining ring.



Air filters - Genie part numbersAll Models 27916

TABLE B PROCEDURES



C-1Check the Engine Belt -Deutz Diesel Models


Maintaining the engine belt is essential to goodengine performance and service life. The machinewill not operate properly with a loose or defectivebelt and continued use may cause componentdamage.



1 Remove the safety pin (if equipped) from theengine pivot plate latch .



3 Remove the air baffle retaining fasteners.Remove the air baffle.

Table C Procedures

4 Remove the front engine access covermounting fasteners.


· Cracking

· Glazing

· Separation

· Breaks


7 Check the engine belt for proper tension. Adjustas necessary.

Deutz Diesel engine

8 Install the front engine access cover.




Belt deflection - 3/8 inch to 1/2 inch9.5 mm to 12 mm

Engine belt - Genie part number 32698



cb

a

TABLE C PROCEDURES

C-2Replace the Engine Oil andFilter - Deutz Diesel Models

Engine specifications requirethat this procedure be performedevery 500 hours. Perform thisprocedure more often if dustyconditions exist or if the machineis operated in hot climates.

Periodic replacement of the engine oil andfilter is essential to good engine performance.Operating the machine with an improper oil level orneglecting periodic oil and filter changes candamage engine components. A frequent checkof elapsed machine hours against the hoursnoted on the oil filter will allow the inspector toanticipate and perform oil and filter changes atthe 500 hour interval.

Burn hazard. Beware of hotengine parts and oil. Contact withhot engine oil and/or engine partsmay result in severe burns.

Perform this procedure afterwarming the engine to normaloperating temperature.




3 Remove the oil filler cap located above thedipstick.

4 Pull the end of the oil drain hose out from underthe engine.

5 Remove the plug from the drain hose and allowall of the oil from the engine to drain into asuitable container. See capacity specifications.

6 Install the plug on the oil drain hose.

7 Place a pan under the oil filter.

8 Use an oil filter wrench and remove the oil filter.

a engine oil level dipstickb fuel filter/water separatorc oil filter

9 Apply a thin layer of oil to the new oil filtergasket (Genie part number 49924). Install thefilter and tighten it securely by hand.

10 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter.



TABLE C PROCEDURES

11 Fill the engine with new oil per specificationsand install the oil filler cap.

12 Start the engine from the ground controls. Allowthe engine to run for 30 seconds then turn theengine off.

13 Check the oil filter and oil drain hose for leaks.

14 Check the engine oil level dipstick. Add oil ifneeded.

Deutz Engine F3L 1011F 6.3 quartsOil capacity (including filter) 6 liters


Temperature below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

Temperature above -4°F / -34°C 15W-40

Engine oil should have properties of API classificationCC/SE, CD/SE, CC/SF or CD/SF grades.Units shipped with 10-40 CC/SG

Oil filter - Genie part number 49924

C-3Check the Engine ValveClearances -Deutz Diesel Models

Engine specifications requirethat this procedure be performedinitially at 500 hours, at 1000hours and every 1000 hoursthereafter.

Complete information to perform this procedure isavailable in the Deutz F3L 1011F OperationManual, Deutz part number 0297 7343(Genie part number 52883).





4 Disconnect the coolant return hose at theradiator and drain the coolant return tank into asuitable container.

5 Slowly remove the radiator cap from theradiator.

Bodily injury hazard. Allow anypressure to dissipate graduallybefore removing the radiator cap.

6 Open the drain valve on the radiator and allowall the coolant to drain into a suitable container.

7 After all the coolant has drained, close the drainvalve and connect the coolant return hose tothe radiator.

8 Open the drain valve on the engine block andallow the coolant to drain into a suitablecontainer. After the fluid is drained, close thedrain valve.

9 Replace all coolant hoses and clamps.

10 Fill the radiator with the proper coolant mixture(coolant and water) for your climate until it isfull.

11 Fill the coolant return tank to the NORMAL range.

TABLE C PROCEDURES

C-4Change or Recondition theEngine Coolant -Liquid Cooled Models

Engine specifications requirethat this procedure be performedevery 500 hours or 6 months,whichever comes first.

Replacing or reconditioning the engine coolant isessential to good engine performance and servicelife. Old or dirty coolant may cause the engine toperform poorly and continued use may causeengine damage. Extremely dirty conditions mayrequire coolant to be changed more frequently.


Perform this procedure with theengine off and cooled.





TABLE C PROCEDURES

12 Clean up any coolant that may have spilledduring this procedure.

13 Start the engine from the ground controls andlet it run for 30 seconds. Turn the engine offand inspect for leaks.

14 Check the coolant level in the coolant returntank. Add coolant if needed.



17 Start the engine from the ground controlsand let it run until it reaches normal operatingtemperature.

18 Turn the engine off. Allow the engine to cool.

19 Check the coolant level in the coolant returntank. Add coolant if needed.

Coolant capacityFord Gasoline/LPG Engine 11.5 quarts 10.9 litersPerkins 104-22 Engine 6.3 quarts 6 liters

C-5Check the Engine ValveClearances -Perkins Diesel Models

Engine specifications requirethat this procedure be performedevery 600 hours.

Complete information to perform this procedure isavailable in the Perkins Workshop Manual,Perkins part number TPD 1378(Genie part number 72352).



TABLE C PROCEDURES

C-6Replace the PCV Valve -Ford Models

Engine specifications requirethat this procedure be performedevery 800 hours.

Replacement of the PCV valve is essential to goodengine performance. A malfunctioning PCV valvecan impair crankcase ventilation and may causeengine damage.






4 Locate the PCV valve on the engine under theintake manifold. Detach the hose from the PCVvalve.

a PCV valveb PCV valve hose

5 Remove the PCV valve from the engine.Discard the valve.

6 Thoroughly clean the inside and outside of thehose, tubes and fittings.

7 Install the new PCV valve and connect thehose.



PCV Valve - Genie part number 33957

a

b



Table D Procedures

D-1Check the BoomWear Pads

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 out wear pads may result incomponent damage and unsafe operatingconditions.

If the wear pads are not wornbelow specification but are stillwithin tolerence, see RepairProcedure 4-2, How to Shim thePrimary Boom.


2 Raise the end of the primary boom to acomfortable working height (chest high), thenextend the boom 1 foot (30 cm).

3 Measure each wear pad. Replace the wear padif it is less than 9/16 inch. If the wear pad is notless than 9/16 inch, shim as necessary to obtainzero clearance and zero drag.

4 Extend and retract the primary boom throughthe entire range of motion to check for tightspots that may cause binding or scraping of theboom.

Always maintain squarenessbetween the outer and innerboom tubes.

Wear pad specifications

All wear pads 9/16 inch14.3 mm



TABLE D PROCEDURES

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 safetychocks on the lift cylinders rods. Carefully lowerthe boom onto the lift cylinders safety chocks.

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

The lift cylinder safety chock isavailable through(Genie part number 33484).





5 Be sure that each turntable mounting bolt istorqued in sequence to 210 ft-lbs (285 Nm).

Bolt torque sequence

6 Start the engine form the ground controls.

7 Rais the secondary boom and remove thesafety chocks.

8 Lower the boom to the stowed position.

9 Remove drive chassis covers from both thesteer end and the non-steer end of themachine.

10 Remove the lower chassis cover mountingfasteners from inside of the drive chassis.



TABLE D PROCEDURES

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

12 Check to ensure that each lower bearingmounting bolt under the drive chassis istorqued in sequence to 210 ft-lbs(285 Nm).

Bolt torque sequence

D-3Check the Free-wheelConfiguration

Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily fortowing. A machine configured to free-wheel withoutoperator knowledge may cause death or seriousinjury and property damage.

Collision hazard. Select a worksite that 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.



TABLE D PROCEDURES

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

5 Manually rotate each non-steering wheel.

Result: Each non-steering wheel should rotatewith minimum effort.

6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the jack stands.

Collision hazard. Failure tore-engage the drive hubs maycause 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.

disengage position

engage position

disengage position

engage position



TABLE D PROCEDURES

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

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

All Models:

13 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

The free-wheel valve is located onthe side of the drive pump.

a drive pumpb free-wheel valvec lift pumpd screwdriver

The free-wheel valve shouldalways remain closed.

D-4Grease the Turntable RotationBearing and Rotate Gear

Yearly 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 Locate the grease fitting on the front turntablecover.

a turntable bearing grease fittingb front turntable coverc power to platform plug

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 type Multipurpose grease

a b c

a b

c

d



TABLE D PROCEDURES

D-5Replace 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 andcontinued use may cause component damage.

Drive Hubs:

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.

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Apply pipe thread sealant to the plugs, and theninstall the plugs.

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

Oil capacity per hub 17 fl oz0.5 liters

Type: SAE 90 multipurpose hypoid gear oil - APIservice classification GL5



TABLE D PROCEDURES

D-6Replace the Drive LoopHydraulic Filter

Replacing the drive loop hydraulic filter is essentialto good machine performance and service life. Adirty or clogged filter may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require that the filter be replaced more often.

Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.


1 Open the engine side turntable cover and locatethe drive loop hydraulic filter mounted near thepump.

2 Remove the filter housing by using a wrench onthe nut provided on the bottom of the housing.

3 Remove the filter element from the housing.

4 Inspect the housing seal and replace it ifnecessary.

5 Install the new filter (Genie part number 20880)and tighten the housing onto the filter securlyhead by hand. Clean up any oil that may havespilled during the installation procedure.


7 Inspect the filter assembly to be sure that thereare no leaks.

8 Clean up any oil that may have spilled duringthe installation procedure.



D-7Check and Adjust the Air/LPGMixture - Ford Models

Maintaining the proper air-to-fuel mixture duringLPG operation is essential to good engineperformance.


The engine should be warmed tonormal operating temperaturebefore performing this procedure.

1 Move the fuel select toggle switch to LPG fueland start the engine from the ground controls.

2 Locate the high idle mixture adjustmentscrew on the throttle body elbow that attachesto the air cleaner.

3 Loosen the lock nut on the high idle mixtureadjustment screw.

4 Load the system by activating the primary boomretract function, then move the function enabletoggle switch to the high idle (rabbit symbol)position.

5 Adjust the high idle adjustment screw to obtainan air-to-fuel mixture ratio of 13.0:1 to 13.2:1,using an exhaust gas analyzer.

Preliminary setting is 1/4 inch(6.4mm) of threads showing.Measure from top of lock nut totop of adjustment screw.

If an exhaust gas analyzer is notavailable, adjust to obtain peak oroptimum rpm.

6 Hold the adjustment screw and tighten thelock nut.

7 Return the function enable toggle switch to thecenter position.

8 Locate the low idle mixture adjustment screw onthe LPG regulator.

9 Adjust the low idle mixture adjustment screw toobtain an air-to-fuel mixture ratio of 13.0:1 to13.2:1.

Preliminary setting: turn low idleadjustment screw clockwise all theway in. Turn low idle adjustmentscrew counterclockwise 2 3/4turns.

TABLE D PROCEDURES



D-8Replace the Diesel FuelFilter/Water Separator - DeutzDiesel Models

Replacing the diesel fuel filter/water separator isessential to good engine performance and servicelife. A dirty or clogged filter may cause the engineto perform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require that the filter be replaced more often.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel filter in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.





3 At the fuel pump, disconnect and plug the fuelhose that goes to the fuel tank.

4 Remove the fuel filter with a filter wrench.

a oil filterb fuel filter/water separator

Prime the Fuel Pump:

5 Fill the new filter (Genie part number 65541)with fresh diesel fuel and apply a thin layer of oilor diesel fuel to the new fuel filter gasket.

6 Install the new filter and tighten it securely byhand. Clean up any diesel fuel that might havespilled during the procedure.

7 Connect the fuel hose from the tank to the fuelpump.

8 Start the engine from the ground controls, theninspect the fuel filter for leaks.


TABLE D PROCEDURES

ab



3 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 withthe hydraulic tank shutoff 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 Place a suitable container underneath thehydraulic tank.

5 Remove the drain plug from the hydraulic tank.

6 Completely drain the tank into a suitablecontainer. See capacity specifications.

7 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tankshutoff valves.

8 Disconnect and plug the return filter hydraulichose at the hydraulic tank. Cap the fitting on thetank.

E-1Test or Replace the Hydraulic Oil

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 andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

The machine uses Dexronequivalent hydraulic oil. Beforereplacing the hydraulic oil, the oilmay be tested by an oil distributorfor specific levels of contaminationto verify that changing the oil isnecessary. If the hydraulic oil isnot replaced at the two yearinspection, test the oil quarterly.Replace the oil when it fails thetest.

Perform this procedure with theboom in the stowed position.

1 Ford models: Turn the valve on the LPG tankclockwise to the OFF position. Then slowlydisconnect the hose from the LPG tank.

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

Table E Procedures

open closed



9 Disconnect and plug the supply hose for theauxiliary power unit through the access holeunderneath the turntable. Cap the fitting on thehydraulic tank.

10 Remove the ground controls side turntablecover. See Repair Procedure 6-1, How toRemove a Turntable Cover.

11 Support the hydraulic tank with an appropriatelifting device.

12 Remove the hydraulic tank mounting fasteners.

13 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank may become unbalanced andfall if it is not properly supportedby the lifting device.

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

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

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

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

TABLE E PROCEDURES

18 Install the hydraulic tank onto the machine.

19 Install the two suction hoses to the suctionstrainers.

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

21 Fill the tank with hydraulic oil until the level iswithin the top 2 inches (5 cm) of the sightgauge. Do not overfill.

22 Clean up any oil that may have spilled and openthe hydraulic tank valves.



TABLE E PROCEDURES

23 Prime the pump. See Repair Procedure 11-2,How to Prime the Pump.

Component damage hazard. Besure that the hydraulic tank shutoffvalves are in the OPEN positionbefore priming the pump. Theengine must not be started withthe hydraulic tank shutoff 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.

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

Use only Dexron equivalenthydraulic fluid.

Hydraulic system

Hydraulic tank capacity 24 gallons91 liters

Hydraulic system 30 gallonscapacity (including tank) 114 liters

Hydraulic fluid Dexron equivalent

E-2Change or Recondition theEngine Coolant -Ford Models

Replacing or reconditioning the engine coolant isessential to good engine performance and servicelife. Old or dirty coolant may cause the engine toperform poorly and continued use may causeengine damage. Extremely dirty conditions mayrequire coolant to be changed more frequently.


Perform this procedure with theengine off and cooled.







TABLE E PROCEDURES



15 Start the engine from the ground controls,run it for 30 seconds, and then turn it off.

16 Inspect for leaks and then check the fluidlevel in the coolant return tank. Addwater if needed.

17 Start the engine from the ground controlsand let it run until it reaches normal operatingtemperature.


19 Allow engine to cool and check the fluid level inthe coolant retrun tank. Add water if needed.

Coolant capacity 11.5 quarts10.9 liters

4 Disconnect the coolant return hose at theradiator and drain the coolant return tank into asuitable container.

5 Slowly remove the radiator cap from theradiator.

Bodily injury hazard. Allow anypressure to dissipate graduallybefore removing the radiator cap.

6 Open the drain valve on the radiator and allowall the coolant to drain into a suitable container.

7 After all the coolant has drained, close the drainvalve. Connect the coolant return hose tothe radiator.

8 Open the drain valve on the engine block andallow the coolant to drain into a container.After the fluid is drained, close the drain valve.

9 Replace all coolant hoses and clamps.

10 Pour the proper coolant mixture (anti-freeze andwater) for your climate into the radiator until it isfull.

11 Fill the radiator and then fill the coolant returntank to the NORMAL range.

12 Clean up any coolant spilled during thisprocedure.



TABLE E PROCEDURES


3 Place a suitable container underneath theengine pivot plate.

4 Ford Models: At the pre-filter, disconnect thefuel hose to the fuel tank and drain the fueltank into the container.

a hose from fuel pump to regulator/filterb hose from fuel pre-filter to fuel pumpc hose from fuel tank to fuel pre-filterd hose from regulator/filter to enginee hose from regulator/filter to tank

E-3Change the Fuel Hoses

Maintaining the fuel hoses in good condition isessential to safe operation and good engineperformance. Failure to detect a worn, cracked orleaking fuel hose may cause an unsafe operatingcondition.

Explosion and fire hazard. Enginefuels are combustible. Replace thefuel hoses in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Component damage hazard. Besure the fuel hoses are routed thesame way the original hoses were.

Perform this procedure with theengine off and the key switch inthe OFF position.



a b c

e d



Deutz Diesel modelsa hose from the injector to

the fuel tankb hoses connecting injectorsc hose from the fuel shutoff valve

to the fuel pumpd hose from the fuel pump to

the fuel filtere hose from the fuel filter to the

injection pumpf hose from the injection pump

to the injectors

TABLE E PROCEDURES

Deutz Diesel Models: At the fuel pump,disconnect the fuel hose to the fuel tank anddrain the fuel tank into the container.

5 Remove and replace all of the fuel line hosesand clamps according to the followingillustrations:

Explosion and fire hazard. FuelInjection systems operate at avery high pressure. Fuel may beexpelled under pressure if thehoses are removed too quickly.Loosen the fuel lines very slowlyto allow the fuel pressure todissipate gradually. Wrap a clotharound fuel hoses to absorbleaking fuel before disconnectingthem.

b b b b b b

e d cf

ba






9 Start the engine from the ground controls, theninspect the fuel filter and hoses for leaks.


TABLE E PROCEDURES

Explosion and fire hazard.Electronic Fuel Injection (EFI)systems operate at a very highpressure. Fuel may be expelledunder pressure if the hoses areremoved too quickly. Loosen thefuel lines very slowly to allow thefuel pressure to dissipategradually. Wrap a cloth aroundfuel hoses to absorb leaking fuelbefore disconnecting them.

Ford modelsa high pressure hose from fuel pump to

regulator/filterb hose from fuel pre-filter to fuel pumpc hose from fuel tank to fuel pre-filterd high pressure hose from regulator/

filter to enginee hose from regulator/filter to tank

a b c

e d



TABLE E PROCEDURES

E-4Check the Toothed Belt -Deutz Diesel Models

Complete information to perform this procedure isavailable in the Deutz FL 1011F Operation ManualDeutz part number: 0297 4706 EN.(Genie part number 29790).

E-5Check the Engine ValveClearance - Ford Models

Complete information to perform this procedure isavailable in the Ford LRG-425 EFI 2.5 LiterIndustrial Engine Service ManualFord number: FPP-194-303.(Genie part number 52695).

E-6Check the Engine CylinderCompression - Ford Models

Complete information to perform this procedure isavailable in the Ford LRG-425 EFI 2.5 LiterIndustrial Engine Service ManualFord number: FPP-194-303.(Genie part number 52695).

E-7Check the Fuel Injection Pumpand Injectors - Deutz DieselModels

Complete information to perform this procedure isavailable in the Deutz FL 1011F Workshop ManualDeutz part number: 0297 7195.(Genie part number 52229).

E-8Replace the Timing Belt -Ford Models

Complete information to perform this procedure isavailable in the Ford LRG-425 EFI 2.5 LiterIndustrial Engine Service ManualFord part number: FPP-194-303.(Genie part number 52695).



E-9Grease the Steer AxleWheel Bearings, 2WD Models

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 removethem.

2 Block the non-steering wheels, then center alifting jack 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, then remove the tire andwheel assembly.

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, thenremove the cotter pin from the castle nut.

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

8 Loosen the castle nut, then 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 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.

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

10 Remove the dust cap from the hub, thenremove the cotter 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 therear bearing.

TABLE E PROCEDURES



14 Pack both bearings with clean, fresh grease.

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

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

Always replace the bearing greaseseal when removing the hub.

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.


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

23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts to125 ft-lbs (169.5 Nm).

TABLE E PROCEDURES





First Edition • Second Printing Section 5 • Troubleshooting Flow Charts

Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in theGenie Z-45/25 and Genie Z-45/25J Operator’sManual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate flow chart 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.

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

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.

Perform all troubleshooting on afirm level surface.

Two persons will be required tosafely perform sometroubleshooting procedures.

Troubleshooting Flow Charts

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.


Repair any machine damage or malfunctionbefore operating the machine.

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

· Machine parked on a flat level surface


· Turntable rotated with the boom between the non-steering wheels

· Turntable secured with the turntable rotation lock

· Key switch in the OFF position with the key removed

· Wheels chocked


First Edition • Second PrintingSection 5 • Troubleshooting Flow Charts

General Repair Process

TROUBLESHOOTING FLOW CHARTS

About This SectionWhen a malfunction is discovered, the flow chartsin this section will help a service professionalpinpoint the cause of the problem. To use thissection, basic hand tools and certain pieces of testequipment are required—voltmeter, ohmmeter,pressure gauges.

The location of terminals mentioned in this sectioncan be found on the appropriate electrical orhydraulic schematics provided in Section 6,Schematics.

Since various degrees of a particular functionloss may occur, selecting the appropriate flowchart may be troublesome. When a function will notoperate with the same speed or power as amachine in good working condition, refer to theflow chart which most closely describes theproblem.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

Fault codes

The ECM constantly monitors the engine by theuse of sensors on the engine. The ECM alsouses signals from the sensors to initiatesequential fuel injection and make constant andinstantaneous changes to ignition timing, fueldelivery and throttle position to maintain theengine's running condition at its highestefficiency while at the same time keepingexhaust emissions to a minimum. When asensor fails or returns signals that are outside ofset parameters, the ECM will store a fault codein memory that relates to the appropriate sensorand will turn on the Check Engine Light. SeeRepair Section, How to Retrieve Engine FaultCodes. Use the Fault Code Chart on thefollowing pages to aid in identifying the fault.



Fault Codes

FaultCode Problem Cause Solution

11 -- -- Normal operation.

12Throttle Position (TP)sensor low voltage.

Faulty TP sensor OR sensorwires shorted shorted to groundor poor terminal connection.

Check for poor terminalconnections or shorted wiresfrom the TP sensor to the ECMOR replace the TP sensor.

14Manifold AbsolutePressure (MAP) sensorlow voltage.

Faulty MAP sensor OR sensorwires shorted to ground or poorterminal connection.

Check for poor terminalconnections OR wires shorted toground OR replace MAP sensor.

21Engine speed exceeded4000 RPM.

Obstruction in throttle body ORfaulty ECM.

Check for obstructions in thethrottle body that could causebinding of the throttle assemblyOR replace ECM.

22Throttle Position (TP)sensor high voltage.

The ECM senses a signal fromthe TP sensor that is greaterthan 4.9V DC OR the TPsensor wiring is shorted toground OR there is a poorterminal connection OR the TPsensor is bad.

Check for poor terminalconnections or shorted wiresfrom the TP sensor to the ECMOR replace the TP sensor.

24Manifold AbsolutePressure (MAP) sensorhigh voltage.

Faulty MAP sensor OR sensorwires shorted to ground or poorterminal connection.

Check for poor terminalconnections or shorted wiresfrom the MAP sensor to theECM to ground OR replace MAPsensor.

31 Fuel pump low voltage.Voltage to fuel pump is greaterthan or equal to2V DC below ignition voltage.

Test the fuel pump relay, see theRepair Section OR check forpoor terminal connection fromthe fuel pump relay to fuel pumpOR replace the fuel pump.

32Heated Oxygen (HO2)sensor low voltage.

Water in the fuel, misfiringcylinder, plugged fuel filter ORthe HO2 sensor wiring isshorted to ground OR there is apoor terminal connection ORthe HO2 sensor is bad.

Check for water in the fuel,misfiring cylinder or pugged fuelfilter OR check for poor terminalconnections or shorted wiresfrom the HO2 sensor to the ECMto ground OR replace HO2

sensor.

33Engine CoolantTemperature (ECT)sensor high voltage.

Engine is overheating ORsensor wires shorted to groundor poor terminal connectionsOR ECT sensor is bad

Check engine coolant level ORcheck for shorted wires or poorterminal connections from theECT sensor to the ECM ORreplace the ECT sensor.



FaultCode

Problem Cause Solution

FAULT CODES

35Intake Air Temperature(IAT) sensor high voltage.

IAT sensor signal is greaterthan or equal to4.93V DC for at least 3seconds.

Check for poor terminalconnections or shorted wiresfrom the IAT sensor to the ECMto ground OR replace IATsensor.

41 Fuel pump high voltage.

Fuel pump is receiving voltagewhen the ECM is not sendingthe signal to the fuel pump toturn ON.

Test the fuel pump relay, see theRepair Section OR check forpoor terminal connections fromthe fuel pump relay to fuel pumpOR replace the ECM.

42Heated Oxygen (HO2)sensor high voltage.

A leaking or malfunctioning fuelinjector, misfiring cylinder, faultyTP sensor or contaminationfrom fuel OR use of improperthread sealant on sensorthreads OR sensor wiresshorted to ground or poorterminal connections OR HO2

sensor is bad.

Test for a leaking ormalfunctioning fuel injector,misfiring cylinder or bad TPsensor. Remove HO2 sensor andcheck condition of sensor forcontamination OR check for poorterminal connections or shortedwires from the HO2 sensor to theECM to ground OR replace HO2

sensor.

43Engine CoolantTemperature (ECT)sensor low voltage.

ECM detects a excessively lowsignal voltage from the ECTsensor.

Check engine coolant level ORcheck for shorted wires or poorterminal connections from theECT sensor to the ECM ORreplace the ECT sensor.

45Intake Air Temperature(IAT) sensor low voltage.

ECM detects a excessively lowsignal voltage from the IATsensor.

The IAT sensor shares the sameground wire as the ECT andMAP sensors. Check for shortedwires or poor terminalconnections from the IAT sensorto the ECT and MAP sensors tothe ECM OR replace the IATsensor.

51 Low oil pressure.Bad oil pressure switch, wiresshorted to ground or notenough engine oil.

Check engine oil level OR checkfor shorted wires or poorterminal connections from the oilpressure switch to the ECM ORreplace the oil pressure switch.



FaultCode

Problem Cause Solution

FAULT CODES

52Crankshaft Position (CKP)sensor senses extra ormissing pulses.

The CKP and CMP sensorswork together; if one is bad, theother one won’t work correctlyand causes the ECM to detecta fault. The ECM uses thesignal pulses from the CKP andCMP sensors to initiatesequential fuel injection.

Check for shorted wires or poorterminal connections from theCKP and CMP sensors to theECM OR replace the CKP orCMP sensor.

53Camshaft Position (CMP)sensor senses unknownpattern.

The CMP and CKP sensorswork together; if one is bad, theother one won’t work correctlyand causes the ECM to detecta fault. The ECM uses thesignal pulses from the CKP andCMP sensors to initiatesequential fuel injection.

Check for shorted wires or poorterminal connections from theCKP and CMP sensors to theECM OR replace the CKP orCMP sensor.

54ECM Fault - IllegalOperation.

The ECM received an illegalinstruction signal from one ormore of the sensors and hasgone into a default programand then return to normaloperation.

Replace the ECM.

55 ECM - Illegal Interuption.

The ECM received an illegalinterruption signal from one ormore engine sensors and hasgone into a default programand then return to normaloperation.

Replace the ECM.

56ECM - ComputerOperating Properly (COP)failure

Under normal operation theECM will store numbers intomemory. If this does nothappen, it will reset itself andset fault code 56.

Replace the ECM.

61 System voltage low.Battery supply voltage to theECM is 8V DC or less.

Check battery and/or alternatorcondition OR check for shortedwires or poor terminalconnections from the battery tothe ECM.

62 System voltage high.Battery supply voltage to theECM is 18V DC or more.

Check battery and/or alternatorcondition OR check for shortedwires or poor terminalconnections from the battery tothe ECM.



Engine Will NotCrank OverBe sure the key switchis in the appropriateposition.

Be sure that bothEmergency Stopbuttons are pulled out tothe ON position.

Be sure the circuitbreakers are nottripped.

Be sure the battery isfully charged.

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Be sure to check fuellevels and the enginecoolant level.

Be sure that the radiatoroverflow tank is at theFULL mark.

Perform following testsin gasoline mode only.

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Be sure to checkfuel level.

Be sure that the batteryis fully charged.

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Be sure the valve on theLPG tank is fullyopened.

Be sure to checkLPG fuel level.

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Engine WillNot Start OnGasoline,But Will StartOn LPG -Ford ModelsBe sure fuel selectswitch is switchedto gasoline.

Be sure to checkgasoline fuel level.

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EngineHigh IdleInoperative -Diesel ModelsBe sure mechanicallinkage is not bindingor defective.

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"&

) !"(" ##*) $

%&

(+ ("$

"&

%&

, (+ +"$

- .$

*) !"("*) / 0 # $

- $

"& )

+"("$

%&

, 121 (+$

"&

%& ) +"3(+*) (+$

)45 ) *) (+*) / 0 # $



CHART 15

! "# $% && ' %

"!

"!

() *+ + ,

% % + +,

-. % ,%



PrimaryBoom DownFunctionInoperative(after serialnumber13098)Be sure all otherfunctions operatenormally.

Chart 16

!!"

#$

%$

& '("

%$

) '( !!*) "

#$

'+ +("

, -"

%$ )

+('("

#$

. /0/ '+"

%$

#$ ) +%1'+*) '+"

)23 ) *) '+*) 4 5 6 "



CHART 16

!" ##$

%&

"&

' ("$

"&

) !"(" ##*) $

%&

(+ ("$

"&

%&

, (+ +"$

- .$

*) !"("*) / 0 # $

- $

"& )

+"("$

%&

, 121 (+$

"&

%& ) +"3(+*) (+$

)45 ) *) (+*) / 0 # $



CHART 16

! "# $% && ' %

"(!

"(!

)* +, , -

% % , ,-

./ % -%



Chart 17

SecondaryBoom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

!"

#

$%#

& !$%"

$$$%#

' !$% !(' "

#

!)% )$%"

* +"

$$$%# '

)$%!$%"

#

, -.- !)%"

$%#

# ' )%/!)%(' !)%"

'01 ' (' !)%(' 2 3 4 "



CHART 17

! " ##$

%

!&%

' (!$

!&%

) !(! ##*) $

%

(+& (!$

!&%

%

, (+& +!$

- .$

*) !(!*) / # 0 $

- $

!&% )

+!(!$

%

, 121 (+&$

!&%

% ) +&3(+&*) (+&$

)45 ) *) (+&*) / # 0 $



CHART 17

!"#$%&&' %

"(!

"(!

)* +, ,-

%% , ,-

+.%-%



SecondaryBoom DownFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 18

!"

#

$%#

& !$%"

$$$%#

' !$% !(' "

#

!)% )$%"

* +"

$$$%# '

)$%!$%"

#

, -.- !)%"

$%#

#' )%/!)%(' !)%"

'01 ' (' !)%(' 2 3 4 "



CHART 18

!! " ##$

%

!&%

' (!!$

!&%

) " !!(!! ##*) $

%

(+& (!!$

!&%

%

, (+& +!!$

- .$

*) " !!(!!*) / # 0 $

- $

!&% )

+!!(!!$

%

, 121 (+&$

!&%

% ) +&3(+&*) (+&$

)45 ) *) (+&*) / # 0 $



CHART 18

!"#$%&&' %

"(!

"(!

)* +, ,-

%% , ,-

+.%-%



Chart 19

Primary BoomExtendFunctionInoperativeBe sure all otherfunctions operatenormally.

!"# #"$ #!""%&# "#"%&!'# "#()* #"###&

+

!"##"$ #!""%#&"#!'# "#(*#"###& #!'# "#

+

"!##),# "#"

-"##"!#&&#(.*"""#&&##

+"

/"

#!#&&#(.*

0"+/+++0(1/*"" 2#"### #" 3&# "# "! "# #"###""

++0

""++0

###"#" ! ,#!#!##&&",#"40""&#-



CHART 19

!

"#$ %

"



Chart 20

Primary BoomRetractFunctionInoperativeBe sure all otherfunctions operatenormally.

!"#$ $#% $"##&'$ #$#&'"$ #$()* $#$$$$'

+

!"#$$#% $"##&$'#$"$ #$(*$#$$$$' $"$ #$

+

#"$$),$ #$#

-#$$#"$$''$(.*###$''$$

+#

/0#

$"$$''$(.*

1#+/+++1(2/*## 3$#$$$ $# 4'$#$ #"$ #$ $#$$$$##

++1

##++1

$$$#$# "$ ,$"$"$$''#,$#51##'$-



CHART 20

,-!.*/./0!!0 ()*+

.1/ !

!



Chart 21

TurntableRotate LeftFunctionInoperativeBe sure all otherfunctions operatenormally.

!"

#$

%$

& '"

%#%$

( ' !)( "

#$

'*% *"

+ ,"

( *'"

#$

! -.- '*%"

%$

#$ ( */'*%)( '*%"

(01 ( )( '*%)( 2 3 4 "

%#%$



CHART 21

!! "

#$

%$

& '("

%$

) '( !! *) "

#$

'+% '("

%$

#$

, '+% +("

- ."

*) '(*) / 0 1 "

- "

%$ )

+('("

#$

, 232 '+%"

%$

#$ ) +4'+%*) '+%"

)56 ) *) '+%*) / 0 1 "



CHART 21

! "# $% & %

'(!

'(!

)*

+,*% %

-

,



CHART 21

!"!!!!#$" %

&"!

&"!

'( )) *

+

, !!#!-+



Chart 22

TurntableRotate RightFunctionInoperativeBe sure all otherfunctions operatenormally.

!"

#$

%$

& '"

%#%$

( ' !)( "

#$

'*% *"

+ ,"

( *'"

#$

! -.- '*%"

%$

#$ ( */'*%)( '*%"

(01 ( )( '*%)( 2 3 4 "

%#%$



CHART 22

!! "

#$

%$

& '("

%$

) '( !! *) "

#$

'+% '("

%$

#$

, '+% +("

- ."

*) '(*) / 0 1 "

- "

%$ )

+('("

#$

, 232 '+%"

%$

#$ ) +('+%*) '+%"

)45 ) *) '+%*) / 0 1 "



CHART 22

! "# $% & %

'(!

'(!

)*

+,*% %

-

,



CHART 22

!"!!!!#$" %

&"!

&"!

'( )) *

+

, !!#!-+



Chart 23

All PlatformLevelingFunctionsInoperativeBe sure all otherfunctions operatenormally.

!"!!!!#$" % &

!!!'(

(!"!!!!#$" % ) * +"!!'(

!!!'(

,

!!!'(

) -

!!!'(



Chart 24

Platform LevelUp FunctionInoperativeBe sure all otherfunctions operatenormally.

!"

# $%&

!"

$%&

' $%& ('

%)"

!"

(' (' $%&(' * + ,

%)"

(' (' $%&(' * + , %)"

- .



CHART 24

! "

!

#$%!&'

$

$

' ' ( ( !()#

*( +$( !( )#



Chart 25

Platform LevelDown FunctionInoperativeBe sure all otherfunctions operatenormally.

!

"#

$ %&!

"#

%&!

' %& (' !

&)#

"#

(' (' %&(' * + , !

&)#

(' (' %&(' * + , !&)#

- .!



CHART 25

! "

!

#$%!&'

$

$

' ' ( ( !()#

*( ++( !( )#



Chart 26

Platform RotateLeft FunctionInoperativeBe sure all otherfunctions operatenormally.

! "

#$

%"

&$

' !%"

( )"

' * ! !+'"' "

#$

&$

!"

&$

#$

"' +'"

, "

&$

#$

' !"

( "

#$

&$

' "



CHART 26

!

"#!

$ %$

& '()$"*

$ $"*

& '($"*

"#!

!

$ $"*%$ +#$"*%$ $"*

!

"#!

& , -&!.

"#!

!

/

$

$ $"*,

0



CHART 26

!

"##$#% "&'()

**!

+,

#

-*+. **!

"



Chart 27

Platform RotateRight FunctionInoperativeBe sure all otherfunctions operatenormally.

! "

#$

%"

&$

' !%"

( )"

' * ! !+'"' "

#$

&$

!"

&$

#$

"' +'"

, "

&$

#$

' !"

( "

#$

&$

' "



CHART 27

!

"#!

$ %$

& '()$"*

$ $"*

& '($"*

"#!

!

$ $"*%$ +#$"*%$ $"*

!

"#!

& , -&!.

"#!

!

/

$

$ $"*,

0



CHART 27

!

"##$#% "&'()

**!

+,

#

-*+. ))!

"



Chart 28

Jib Boom UpFunctionInoperative,Z-45/25JModelsBe sure all otherfunctions operatenormally.

!"

#$

%&$

' %("

%&$

#$

) %( *) "

) *)"

%("

%&$

#$

+ ,%("

) ,%( %("

%&$

#$

"

- ./# -)%/"

#$

%&$) ,%(*)"

#$

%&$

) ,%-)%/*) -)%/"

- .( -)%/"

%&$

#$)-)%/"

) .( -)%/*) 0 1 2 "

- 3"



CHART 28

!

"#$ $"%

&'

%#!!

%#!!

(!)!!! !%*) +

$ ,

-$ ,-$ -$!!%!., -$ -$/(0

&'

$ ,

/(0



Chart 29

Jib Boom DownFunctionInoperative,Z-45/25JModelsBe sure all otherfunctions operatenormally.

!!"#

$%

&'%

( !&#

&'%

$%

) !& *) #

) *)#

!&#

&'%

$%

+ ,&#

) ,&!&#

&'%

$%

#

- ./$ -)&/#

$%

&'%) ,&*)#

$%

&'%

) !,&-)&/*) -)&/#

- .0 -)&/#

&'%

$%)-)&/#

) .0 -)&/*) 1 2 3 #

- 4#



CHART 29

!

"#$ $"%

&'

%#!!

%#!!

(!)!!! !%*) +

$ ,

-$ ,-$ -$!!%!., -$ -$/(0

&'

$ ,

/(0



Chart 30

Steer LeftFunctionInoperativeBe sure all otherfunctions operatenormally.

!"#$

%&

'&

( $

'&

) *"# "# !"#$

%&

) $+ , - $

( *"# ,, $

'&

%&

) *"# !"# $

,, $

%

) ,,.) $

/0

- %/%%%-%"1/2 $

"'%%-

"'%%-

) .) $+ , - $

+ .) .)3.) , - $



Chart 31

Steer RightFunctionInoperativeBe sure all otherfunctions operatenormally.

!"#$

%&

'&

( )$

'&

* +"# "# !"#$

%&

* $, - . $

( )+"# -- $

'&

%&

* )+"# !"# $

-- $

%

* --/* $

0#

. %0%%%.%"102 $

"'%%.

"'%%.

* /* $, - . $

, /* /*3/* - . $



Chart 32

OscillateFunctionInoperativeBe sure all otherfunction operatenormally.

!" #$

%

& '('')'*(%+,

('

-. -/, #0/ 1 & "

('

1 & "



All DriveFunctionsInoperative,All OtherFunctionsOperateNormallyBe sure the rpm toggleswitch is in thefootswitch activatedhigh idle position.

Be sure the hydraulictank shut off valves arein the OPEN position.

Be sure machine isnot in the free wheelconfiguration.

Chart 33

!"

# $ %&'(

) *' + %&'(

! ,&'

) &'

-

) *' +

!

)

)

- ,

./

- 0+

./

)

)0+ *1+*'+,



CHART 33

!"

#$ #$

"

!"

%&'()

"

*

*

$# $#

"

%&'()

*

*

!"

+



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!

"#

#

$ %&'%(%)

* +,%&'- !

#

"#

$ .%&'%("%)",/&.-%) !0

' +,%&'-%&'

#

"#

$ %&'

"#

#

$ .!(,%&'-1$ 1$23&!

% 1$ 1$23&!

' +,%&'-



Chart 34

Drive ForwardOr ReverseFunctionInoperativeBe sure all otherfunctions operatenormally includingdrive in oppositedirection ofmalfunction.

!"#

$% ! #&' (

)*( ( + *

*

,% %* - &' (

.

./



Chart 35

TractionFunctionInoperativeBe sure all otherfunctions operatenormally.



Chart 36

Machine WillNot Drive AtFull SpeedBe sure all otherfunctions operatenormally.

Be sure the machineis not raised above orextended beyond thedrive limit switches.

Be sure the primaryboom drive limitswitch is clear of anydebris and is notactivated when theboom is in the stowedposition.

Be sure thesecondary boom drivelimit switch is clear ofany debris and is notactivated when theboom is in the stowedposition.

Be sure that theprimary boom extenddrive limit switch armis being activatedwhen the boom isfully retracted.

Be sure the wiring tolimit switches is intactand show no sign ofdamage or corrosion.

Be sure the free-wheel valve is closedon the drive pump.

! " #$% && '

()

*()

+, % ! " #$%-. &/



Chart 37

Machine DrivesAt Full SpeedWith PlatformRaised orExtendedBe sure primary boomdrive limit switch isbeing activated by thecam on the primaryboom when the primaryboom is raised.

Be sure secondaryboom drive limit switchis being activated by thecam on thecompression link whenthe secondary boom israised.

Be sure that the primaryboom extend drive limitswitch is not being helddown or being activatedwhen the primary boomis extended.

Be sure the wiring tolimit switches is intactand show no sign ofdamage or corrosion.

! "

! #$%&'$%($%)*'

%+,&-%

! .!

! .!,/ .! 01 %2



Chart 38

Drive EnableSystem IsMalfunctioningBe sure the boom is inthe stowed position.

!"#$% &%'( )*"( +,#

%-

&$-"

. /&%'0&$%1&2%1( /&%'0

3 !- /#$%0

4 /&%'0

& , +,#

)&2*&2%1

( /5"0

3 &2*&2%1

&2*5"5"&2%1

$ ( +,#



Chart 39

AuxiliaryFunctionsInoperativeBe sure all otherfunctions operatenormally.

Be sure key switchis in the appropriateposition and bothEmergency Stopbuttons are pulledout to the ON

position.

Be sure engine isnot running whenusing auxiliarypower.

Note: Operatingauxiliary power withthe engine runningshould immediatelykill the engine.

!

"

#$#%&'(

"

#)! *! ! !

+) !, '! )!

%)!! !- )

!

#

."-

-/ )*0"1

."-

-

#*0"12#.$#!2#.$#2#.

/ )*'.

-# ) 3'. *'.

."-

#4"1*'.*0"1$#*'.

%)

! #!

#




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 rulesand operating instructions printed in theGenie Z-45/25 & Genie Z-45/25JOperator's Manual.

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

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

Hydraulic Schematics

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.

General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test


Section 6 • SchematicsFirst Edition • Second Printing

Item Description Genie Manufacturer Manufacturer QtyPart Number Part Number

BAT ................ Battery, 900 CCA, 12V DC .... 36872 ........... Delco .................................... 34DT78 .......................... 1

BP1 ................ Joystick controller, Dual axis . 53073 ........... OEM Controls ...................... EJS5DM11179 ............... 1

CB1, CB2 ....... Circuit breaker ....................... 24018 ........... ETA ...................................... 45-700-IG1-P10 ............. 2

CR1,2,4,5,7,8CR7, 8,(Gas/LPG) ...... Relay, SPDT, 12V DC ........... 34052 ........... Potter-Brumfield .................. VF4-15F11-CO5 ............ 6

CR1through 5,CR7, 8,(Diesel) ........... Relay, SPDT, 12V DC ........... 34052 ........... Potter-Brumfield .................. VF4-15F11-CO5 ............ 7

CR7,12,13 and 14(Diesel) ........... Relay, SPDT, 12V DC ........... 19274 ........... Potter-Brumfield .................. VF4-15F11-CO5 ............ 2

Diode(Gas/LPG) ...... Diode, 6 amp, 200 PIV .......... 45782 ........... Motorola ............................... MOTMR752 ................. 25

Diode(Diesel) ........... Diode, 6 amp, 200 PIV .......... 45782 ........... Motorola ............................... MOTMR752 ................. 25

DP1 ................ Joystick controller - Drive ...... 20424 ........... OEM Controls ...................... MCH1159AD1386 .......... 1

FB .................. Flashing beacon .................... 20189 ........... ECCO Electronic Controls ... 6400A-GEN ................... 1

FS1 ................ Footswitch .............................. 13482 ........... Linemaster Switch Corp. ..... 632-S ............................. 1

H1 .................. Alarm, Warble tone ................ 19270 ........... Floyd Bell Inc. ...................... MW-09-616-Q ................ 1

H2 .................. Horn, 12V DC, 130 dB ........... 56264 ........... Wolo Industries. ................... 300ST - 12 GEN ............ 1

H3 .................. Alarm, intermittent ................. 18963 ........... Floyd Bell Inc. ...................... XB-09-630-Q .................. 1

H4 .................. Alarm, chime tone ................. 45462 ........... Floyd Bell Inc. ...................... CH-09-525-Q ................. 1

HM ................. Hourmeter .............................. 56100 ........... Curtis Instruments ............... 17305666 ....................... 1

KS1 ................ Contact - Keyswitch, N.O. ..... 45081 ........... Telemecanique .................... ZB2-BE101 .................... 2

L1,2,3,4(Gas/LPG) ...... LED - Red, 12V DC ............... 32335 ........... Arctolectric Corp. ................. LE177C39007 ................ 4

L1,2,3(Diesel) ........... LED - Red, 12V DC ............... 32335 ........... Arctolectric Corp. ................. LE177C39007 ................ 3

LS1, 2, 3 ........ Contact - Limit switch,N.C.H.O. ................................ 19491 ........... Telemecanique .................... XESP2051 ..................... 3

This list continues on the next page.

First Edition • Second PrintingSection 6 • Schematics

Electrical Components



First Edition • Second Printing Section 6 • Schematics

ELECTRICAL COMPONENTS

Item Description Genie Manufacturer Manufacturer QtyPart Number Part Number

Level sensor .. Level sensor, 4.5° .................. 44586 ........... Power Comp. of Midwest .... LS36 ............................... 1

P1, P2 ............ Contact, N.C. ......................... 29732 ........... Telemecanique .................... ZB2-BE102 .................... 4

P3 ................... Contact, N.O. ......................... 45081 ........... Telemecanique .................... ZB2-BE101 .................... 1

PR1 ................ Relay, 12V DC continuous .... 27155 ........... Stancor ................................ 70-902 ............................ 1

R1 .................. Resistor, 50Ω 5 watt .............. 49866 ........... Dale ..................................... RH5- 50R-1% ................ 1

R2 .................. Resistor, 100Ω 25 watt .......... 27116 ........... Dale ..................................... RH25-100R-1% ............. 1

R3 .................. Resistor, 250Ω 5 watt ............ 27117 ........... Dale ..................................... RH5- 250R-1% .............. 1

R4, (before serial number 13099)Resistor, 15Ω 25 watt ............ 45836 ........... Dale ..................................... RH25-15R-1% ............... 1

R4, (after serial number 13098)Resistor, 10Ω 25 watt ............ 54516 ........... Dale ..................................... D25K10R ....................... 1

R5 .................. Resistor, 10Ω 25 watt ............ 27287 ........... Dale ..................................... RH25-10R-1% ............... 1

TS1, TS51, TS64(Gas/LPG) ...... Toggle switch, DPST

2 position momentary ............ 13480 ........... Microswitch Control Inc. ...... 2NT1-8 ........................... 3

TS1, TS51(Diesel) ........... Toggle switch, DPST


TS2, 3, 9,13,15, 52,54 58, 59, 63(Gas/LPG) ...... Toggle switch, SPDT


TS2,8, 9,13,15,52,54,58,59, 63(Diesel) ........... Toggle switch, SPDT

3 position momentary ............ 13037 ........... Microswitch Control Inc. ...... 1NT1-7 ......................... 10

TS14 .............. Toggle switch, DPST2 position maintained ............ 27378 ........... Microswitch Control Inc. ...... 2NT1-3 ........................... 1

TS4 ................ Toggle switch, DPDT3 position maintained ............ 13038 ........... Microswitch Control Inc. ...... 2NT1-1 ........................... 1

TS7, 57,60, 61, 62, ...... Toggle switch, DPDT




Electrical Symbols Legend

LABEL DESCRIPTION

BAT ............. Battery

BP ............... Boom Proportional controller

CB ............... Circuit breaker

CR ............... Control relay

DP ............... Drive proportional controller

FB................Flashing beacon

FS................Foot switch

H.................. Horn or Alarm

HM............... Hour meter

KS ............... Keyswitch

L .................. LED

LS ................ Limit switch

P .................. Power switch

PR ............... Power relay

R.................. Resistor

TB................Terminal base location

TP................Terminal platform location

TS................Toggle switch



Abbreviation Legend



Ford LRG-425 EFI Engine Wire Harness(before serial number 13099)


Service ManualSection 6 • Schematics

Ford LRG-425 EFI Engine Wire Harness(before serial number 13099)

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N


CR

AN

KS

HA

FT

PO

SIT

ION

G

IGN

ITIO

N

SY

ST

EM

COIL

WATER TEMP.SWITCH (NO)

Y3

K1

X1F1

G1A3

F2H1

C1F3

H2J1

X3

S3W3

S1S2

T1A2

B3R2

X2C2

J2

C3W2W1

G2E3

G3M1

L1A1

H3

P1

K3R3K2

N2M2

P3L2

B2M3

N3N1

Y1

D2B1D1

L3T2

E1R1

J3D3

P2T3

Y2

E2

NOT USED

VPWR

IGNITION COIL 1NOT USED

CRANKSHAFT SENSOR RETURN (-)CRANKSHAFT SENSOR RETURN (+)NOT USED

KEEP ALIVE PWRNOT USED

THROTTLE POSITION SENSOR INPUTFUEL PUMP MONITOR

CAMSHAFT SENSOR FEED (+)

NOT USED

NOT USED

VREFDRY FUEL MODULATOR

FUEL INJECTOR #1NOT USED

FUEL INJECTOR #2

NOT USED

FUEL INJECTOR #3FUEL INJECTOR #4

NOT USED

NOT USEDNOT USED

POWER GROUNDPOWER GROUNDNOT USED

POWER GROUNDPOWER GROUND

DATA LINK CONNECTOR (+)FUEL SELECTMALFUNCTION INDICATOR LAMPGOVERNOR SELECT #2

DATA LINKDRIVE BY WIRE

SELF TEST INPUTGOVERNOR SELECT #1

AUXILLARY INPUT

NOT USED

INTAKE AIR TEMP SENSOR

DATA LINK CONNECTOR (-)FUEL PUMP RELAY CONTROLNOT USEDNOT USEDSINGLE RETURN

NOT USED

NOT USED

IDLE AIR CONTROL

OIL PRESSUREDRY FUEL SENSOR

ECT SENSORMAP SENSOR INPUT

STARTER LOCKOUTNO USAGE

NOT USED

GROUNDDRYFUEL LOCKOFFIGNITION COIL 2HO2S SENSOR SIDE

42

13

2524

6

1533

34

8

2

7

POWER

5

PO

SIT

ION

CA

MS

HA

FT

G

DIAGNOSTIC

CONNECTOR

87

86

85

30 8

7A

SWITCH (NC)OIL PRESSURE

HEATED

18

16

1422

9

37

31

1

113

26

FUEL INJECTOR VALVES

THROTTLE ACTUATOR/POSITION SENSOR

SE

NS

OR

#4 #3 #2 #1

95TW18

361LR1837BY18

350GY18282DB/O18355GY/W18

238ADG/Y18

555T18556W18

557BR/Y18558BR/LB18

351BR/W1877DB/Y18

349DB18

570BK/W18570ABK/W18570BBK/W18570HBK/W18

107P20151LB/BK20198DG/O20209W/P20

306T/LB20307BK/Y20

658PK/LG20674BR/W20

914T/O20915PK/LB20926ALB/O16

359FGY/R20

743GY20358LG/BK20

354LG/R18

342LG/P16

264W/LB18225BK/Y20

253BDG/W2057BK18

242DG1896T/O18

74GY/LB18

570EBK/W12

16AR/LG1637BY18

39RW2037Y12

767PK/BK16351DBR/W20570CBK/W12

107P20151LB/BK20

11T/Y20

914T/O20

32ADKBL16915PK/LB20

359LGY/Y2032R/LB16

209W/P20306T/LB20307BK/Y20

658PK/LG20674BR/W20

198DG/O20

253DG/W20

26

4W

/LB

18

16

R/L

G1

6

36

1JR

14

32

AD

KB

L1

63

42

LG

/P1

6

32

R/L

B1

6

36

1E

R1

6

78

7A

PK

/BK

16

92

6A

LB

/O1

6

37

CY

16

16

BR

/LG

18

36

1R

12

57

0D

BK

/W1

8

37

AY

12

35

5G

Y/W

18

35

9C

GY

/R1

8

55

5T

18

36

1A

R1

4

55

6W

18

36

1B

R1

4

55

7B

R/Y

18

36

1C

R1

4

55

8B

R/L

B1

83

61

DR

14

39

RW

20

57

0B

K/W

12

35

1B

BR

/W1

8

89

AO

18

57

0N

BK

/W1

8

74

GY

/LB

18

34

LB

/O1

8

57

BK

18

25

3A

DG

/W2

0

34

9D

B1

83

50

GY

18

16

CR

/LG

16

95

AT

/W1

8

96

T/O

18

35

9D

GY

/Y2

03

54

LG

/R1

8

35

1C

BR

/W2

0

35

9K

GY

/Y2

03

58

LG

/BK

20

36

1P

R1

82

42

DG

18

77

DB

/Y1

83

61

NR

18

35

9M

GY

/Y2

02

25

BK

/Y2

0

28

2D

B/O

18

35

9A

GY

/R1

8

35

9JG

Y/R

18

74

3G

Y2

0

57

0B

K/W

20

10

7P

20

91

5P

K/L

B2

0

65

8P

K/L

G2

0

91

4T

/O2

02

09

W/P

20

1 2 3

L

M

N

P

R

S

T

W

X

Y

321

B

A

E

C

D

H

F

G

J

K

SHOWNMATING FACE

1

9 42

34

SHOWNMATING FACE

SHOWNMATING FACE

87

86

85

30

87

A

86

87

87

A

85

30

85

86

87

87

A

30

OXYGEN

SENSOR

(CK

P)

CR4

(LOCATED INSIDE THE

GROUND CONTROL BOX)

SE

NS

OR

(CM

P)

SENSOR

(IAT)

INTAKE AIR

TEMPERATURE

(HO2S)

CR-FA CR-FB

FUEL PUMP

CR-FC

STARTER

FORD 42 PIN QUICK DISCONNECT

(SEE PAGE 1)

ENGINE HARNESS #2

NOTE: * SHOWS USED WIRES

PINK/BLK 16awg FUEL PUMP OUTPUT

WHT/PUR 18awg SELF TEST INPUT *

YELLOW 10awg KEEP ALIVE PWR *

DRIVE BY WIRE SIGNAL RETURN

BLK/Y 18awg GOV. SPD. CONT.TAN/LB 18awg GOV. SPD. CONT.

BLK/WHT 10awg BATT. -BLK/WHT 10awg BATT. -

PINK/LG 18awg FAULT LT. *

DB/BL 16awg STARTER INPUT

RED/LB 16awg STARTER OUTPUT

BRN/WHT 20awg FUEL SELECT *

WATER TEMP. SWITCH

DRIVE BY WIRE SIGNAL INPUTDATA LINK

AUXILARY INPUT

DATA LINK CONNECTOR (+)DATA LINK CONNECTOR (-)

OIL PRESSURE SWITCH *

VREF

VPWR *

TACH LEADRED 10awg KEEP ALIVE PWR *

LPG LOCKOUT RELAY

AND VALVE

SENSOR

PRESSURE

ABSOLUTE

MANIFOLD

(MAP)

SENSOR

(ECT)

TEMPERATURE

COOLANT

ENGINE

(TO ECM)

QUICK DISCONNECTS

FORD ENGINE CONTROL MODULE (ECM)

NOTES:

1. WIRES ARE LABELLED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GUAGE

2. INTERNAL SPLICES ARE NOT SHOWN

EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GREY WIRE WITH LIGHT BLUE STRIPE, 18 GUAGE WIRE

FORD WIRING HARNESS WIRE COLOR CODE

CODE

BL

COLOR

BLUE GY GREY

COLORCODE

P PURPLE

COLORCODE

BK BLACK LB LIGHT BLUE R RED

BR BROWN LG LIGHT GREEN T TAN

DB DARK BLUE N NATURAL W WHITE

DG DARK GREEN O ORANGE Y YELLOW

GN GREEN PK PINK

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A


Ford LRG-425 EFI Engine Wire Harness(after serial number 13098)

G

IGNITION

SYSTEM

COIL

WATER TEMP.SWITCH (NO)

Y3

K1

X1F1

G1A3

F2H1

C1F3

H2J1

X3

S3W3

S1S2

T1A2

B3R2

X2C2

J2

C3W2W1

G2E3

G3M1

L1A1

H3

P1

K3R3K2

N2M2

P3L2

B2M3

N3N1

Y1

D2B1D1

L3T2

E1R1

J3D3

P2T3

Y2

E2

NOT USED

VPWR

IGNITION COIL 1NOT USED

CRANKSHAFT SENSOR RETURN (-)CRANKSHAFT SENSOR RETURN (+)NOT USED

KEEP ALIVE PWRNOT USED

THROTTLE POSITION SENSOR INPUTFUEL PUMP MONITOR

CAMSHAFT SENSOR FEED (+)

NOT USED

NOT USED

VREFDRY FUEL MODULATOR

FUEL INJECTOR #1NOT USED

FUEL INJECTOR #2

NOT USED

FUEL INJECTOR #3FUEL INJECTOR #4

NOT USED

NOT USEDNOT USED

POWER GROUNDPOWER GROUNDNOT USED

POWER GROUNDPOWER GROUND

DATA LINK CONNECTOR (+)FUEL SELECTMALFUNCTION INDICATOR LAMPGOVERNOR SELECT #2

DATA LINKDRIVE BY WIRE

SELF TEST INPUTGOVERNOR SELECT #1

AUXILLARY INPUT

NOT USED

INTAKE AIR TEMP SENSOR

DATA LINK CONNECTOR (-)FUEL PUMP RELAY CONTROLNOT USEDNOT USEDSINGLE RETURN

NOT USED

NOT USED

IDLE AIR CONTROL

OIL PRESSUREDRY FUEL SENSOR

ECT SENSORMAP SENSOR INPUT

STARTER LOCKOUTNO USAGE

NOT USED

GROUNDDRY FUEL LOCKOFFIGNITION COIL 2HO2S SENSOR SIDE

42

13

2524

6

1533

34

8

2

7

POWER

5

G

DIAGNOSTIC

CONNECTOR

87

86

85

30

87

ASWITCH (NC)

OIL PRESSURE

HEATED

18

16

1422

9

37

31

1

113

26

FUEL INJECTOR VALVES

THROTTLE ACTUATOR/POSITION SENSOR

#4 #3 #2 #1

95TW18

361LR1837BY18

350GY18282DB/O18355GY/W18

238ADG/Y18

555T18556W18

557BR/Y18558BR/LB18351BR/W18

77DB/Y18

349DB18

570BK/W18570ABK/W18570BBK/W18570HBK/W18

107P20151LB/BK20198DG/O20

209W/P20306T/LB20307BK/Y20

658PK/LG20674BR/W20

914T/O20915PK/LB20926ALB/O16

359FGY/R20

743GY20358LG/BK20

354LG/R18

342LG/P16

264W/LB18225BK/Y20

253BDG/W2057BK18

242DG1896T/O18

74GY/LB18

570EBK/W12

16AR/LG1637BY18

39RW2037Y12

787PK/BK16351DBR/W20570CBK/W12

107P20151LB/BK20

11T/Y20

914T/O20

32ADKBL16915PK/LB20

359LG/Y2032R/LB16

209W/P20306T/LB20307BK/Y20

658PK/LG20674Y/BK20

198DG/O20

253DG/W20

26

4W

/LB

18

16

R/L

G1

6

36

1JR

14

32

AD

KB

L1

63

42

LG

/P1

6

32

R/L

B1

6

36

1E

R1

6

78

7A

PK

/BK

16

92

6A

LB

/O1

6

37

CY

16

16

BR

/LG

18

36

1R

12

57

0D

BK

/W1

8

37

AY

12

35

5G

Y/W

18

35

9C

GY

/R1

8

55

5T

18

36

1A

R1

4

55

6W

18

36

1B

R1

4

55

7B

R/Y

18

36

1C

R1

4

55

8B

R/L

B1

83

61

DR

14

39

RW

20

57

0B

K/W

12

35

1B

BR

/W1

8

89

AO

18

57

0N

BK

/W1

8

74

GY

/LB

18

34

LB

/O1

8

57

BK

18

25

3A

DG

/W2

0

34

9D

B1

83

50

GY

18

16

CR

/LG

16

95

AT

/W1

8

96

T/O

18

35

9D

GY

/Y2

03

54

LG

/R1

8

35

1C

BR

/W2

0

35

9K

GY

/Y2

03

58

LG

/BK

20

36

1P

R1

82

42

DG

18

77

DB

/Y1

83

61

NR

18

35

9M

GY

/Y2

02

25

BK

/Y2

0

28

2D

B/O

18

35

9A

GY

/R1

8

35

9JG

Y/R

18

74

3G

Y2

0

57

0B

K/W

20

10

7P

20

91

5P

K/L

B2

0

65

8P

K/L

G2

0

91

4T

/O2

02

09

W/P

20

1 2 3

L

M

N

P

R

S

T

W

X

Y

321

B

A

E

C

D

H

F

G

J

K

SHOWNMATING FACE

1

9 42

34

SHOWNMATING FACE

SHOWNMATING FACE

87

86

85

30

87

A

86

87

87

A

85

30

85

86

87

87

A

30

OXYGEN

SENSOR

CRANKSHAFT

POSITION

SENSOR

(CKP)

CR4

(LOCATED INSIDE THE

GROUND CONTROL BOX)

POSITION

CAMSHAFT

SENSOR

(CMP)

SENSOR

(IAT)

INTAKE AIR

TEMPERATURE

(HO2S)

CR-FA CR-FB

FUEL PUMP

CR-FC

STARTER


ENGINE HARNESS #2

NOTE: * SHOWS USED WIRES

PK/BK FUEL PUMP OUTPUT *

W/P SELF TEST INPUT *

Y KEEP ALIVE PWR *

GY/R DRIVE BY WIRE SIGNAL RETURN

BK/Y GOV. SPD. CONT.T/LB GOV. SPD. CONT. *

BK/W BATT. - *BK/W BATT. - *

PK/LG FAULT LT. *

BL STARTER INPUT

R/LB STARTER OUTPUT

Y/BK FUEL SELECT *

R/W WATER TEMP. SWITCH

DB/BK DRIVE BY WIRE SIGNAL INPUTP DATA LINK

GN/O AUXILARY INPUT

T/O DATA LINK CONNECTOR (+)PK/LB DATA LINK CONNECTOR (-)

GN/W OIL PRESSURE SWITCH

VREF

Y VPWR *

T/Y TACH LEADR/GN KEEP ALIVE PWR *

LPG LOCKOUT RELAY

AND VALVE

SENSOR

PRESSURE

ABSOLUTE

MANIFOLD

(MAP)

SENSOR

(ECT)

TEMPERATURE

COOLANT

ENGINE

(TO ECM)

QUICK DISCONNECTS

FORD ENGINE CONTROL MODULE (ECM)

NOTES:

1. WIRES ARE LABELED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GUAGE

2. INTERNAL SPLICES ARE NOT SHOWN

EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GREY WIRE WITH LIGHT BLUE STRIPE, 18 GUAGE WIRE

FORD WIRING HARNESS WIRE COLOR CODE

CODE

BL

COLOR

BLUE GY GREY

COLORCODE

P PURPLE

COLORCODE

BK BLACK LB LIGHT BLUE R RED

BR BROWN LG LIGHT GREEN T TAN

DB DARK BLUE N NATURAL W WHITE

DG DARK GREEN O ORANGE Y YELLOW

GN GREEN PK PINK


Section 6 • SchematicsFirst Edition • Second Printing

Ford LRG-425 EFI Engine Wire Harness(after serial number 13908)


Electrical Schematic, Z-45/25 Ford Models(before serial number 13099)

1

2

3

4

5

6

7

8



WH

T-2

RE

D/W

HT

#2

3-C

.H.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

STA.

A

I

S

FLD.

REGULATOR

+

-

RED

RE

D#

20

-C.H

.

TB20

GRD.

BAT.

ALTERNATOR

LINK

FUSE

50

0

RE

LA

Y

BL

K/R

ED

#R

5-C

.H.

WH

T#

21

-E.H

.#1

OR

G/B

LK

#4

1-C

.H.

RE

D-E

.H.#

1

CR5CR5

BL

K/R

ED

#9

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLKBLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

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


TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER

IGN./FUEL ONENG. FAULT

KEY BYPASS

START INPUT

START RELAY

STA

RT

EN

GIN

E

TS64

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D#

27

-C.H

.

PR1

NO

RE

D/B

LK

#2

8-C

.H.

CR1NO

CR1

BL

K#

R1

-E.H

.#1

RD

/LG

FE

H(1

6A

)P

IN1

BR

/WT

FE

H(6

74

)P

IN7

BR

N/B

LU

FE

H(2

53

)P

IN2

4

YF

EH

(37

B)

PIN

8

YF

EH

(37

)P

IN9

(GN

D)

BL

K/W

TF

EH

(57

0E

)P

IN4

2

PIN

K/L

GF

EH

(65

8)

PIN

6

WT

/PU

RF

EH

(20

9)

PIN

18

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

TB27TB28

RE

D

TS1

WH

T

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

#2

3-E

.H.#

1

IGN./START

HM

TB38

MODULE

L2

TE

ST

TE

ST

RU

N

BL

U/W

HT

#3

8

WH

T#

21

GR

N/W

HT

#4

5-E

.H.#

1

FB

TS53

BL

K-1

BL

U/R

ED

-1

TB39

TP33 TP39TP38

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

WHT

TP25

TP24

REDFS1 REDBLK

BR

N/B

LU

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

L3

BL

U/W

HT

-1

ON

OF

FGE

NE

RA

TO

R

(GN

D)

BL

K/W

TF

EH

(57

0C

)P

IN3

4

LP

GA

SF

UE

L

FU

EL

GA

S

LP

BRN

RED

RED

WHT

WHT

ORG/BLK

DRIVE

SELECTOR

OPTIONTS3

TS50

CH

EC

KE

NG

INE

LE

D

TP41

12 V

DC

TP21

CHECK

ENGINE

ENGINE

CHECK

OP

TIO

N

LIF

T/D

RIV

ES

EL

EC

TO

R

OP

TIO

N(R

EQ

UIR

ED

LO

WR

PM

HIG

HR

PM

LO

WR

PM

FO

OT

SW

.H

/L

ENGINESPEED

ENGINE HARNESS #2

CE

MO

DE

LS

)

TILT

AL

AR

M

13

2

LIFT/


1

2

3

4

5

6

7

8



LS2

DR

IVE

LIMIT

SW

ITC

HW

HT

#40-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

BRN

DE

SC

EN

T A

LAR

M O

PT

ION

RED

RED

WHT

ORG/BLK

WHT

BRN

TP3

OR

G/B

LK-3

UP

DO

WN

OR

G/B

LK#15-M

.H.

OR

G#14-M

.H.

PLAT

FO

RM

RO

TATE

LEF

T

PLAT

FO

RM

RO

TATE

RIG

HT

PLAT

LEV

EL U

P

PLAT

LEV

EL D

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP17

RIG

HT

LEF

TP

LAT R

OTAT

E

RIG

HT

LEF

TP

LAT R

OTAT

E

TP18

TS7

GR

N-3

TS57

TB18

TB17

GR

N/B

LK-3

GR

N#17-M

.H.

GR

N/B

LK#18-M

.H.

NCCR8

TS9

TP15

TS59

UP

DO

WN

PLAT

FO

RM

LEV

EL

PLAT

FO

RM

LEV

EL

TB14

TB15

SE

CO

ND

AR

Y B

OO

MF

LOW

CO

NT

RO

L

SE

CO

ND

AR

YB

OO

M D

OW

N

SE

CO

ND

AR

Y B

OO

M U

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BLU

/WH

T#12-M

.H.

BP2

PWMA+-X

R

TS60

TB11

BLU

/BLK

BLU

/BLK

#11-M.H

.

TP14

OR

G-3

BLU

/WH

T

BLU

/WH

T-3

TP12

RE

D/W

HT-3

TP11

BLU

-3

BLU

/BLK

-3

BLU

TB10

BLU

#10-M.H

.

TP4

WH

T#4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FLO

W C

ON

TR

OL

PR

IMA

RY

BO

OM

TU

RN

TAB

LE R

OTAT

E LE

FT

TU

RN

TAB

LE R

OTAT

E R

IGH

T

TU

RN

TAB

LE R

OTAT

E

PR

IMA

RY

BO

OM

UP

FLO

W C

ON

TR

OL

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

10

R5

PWMA+-X

R

TP1

TS61

TP2

RE

D/B

LK-3

RE

D-3

TB3

RE

D/B

LK#2-M

.H.

RE

D/W

HT

#3-M.H

.

-+A

PWM

BP1

15

R4

R

X

TS62

WH

T/B

LK#5-M

.H.

TB1

TB6

WH

T/R

ED

#6-M.H

.

TB5

RIG

HT

LEF

TT

UR

NTA

BLE

RO

TATE

RE

D#1-M

.H.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK-3

TS63

BLK

/WH

T#8-M

.H.

TB8

WH

T-3

TB4

BOARD

POWER

TS13

TP7

BLK

-3

TP8

BLK

/WH

T-3

BLK

#7-M.H

.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

E R

ELE

AS

EV

ALV

E

RE

D/W

HT-1

MO

TOR

ST

RO

KE

SE

CO

ND

AR

Y B

OO

M U

PB

RN

-4

BR

N-6

DR

IVE

LIMIT

SW

ITC

H

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIMIT

SW

ITC

H

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

CR12

12

4

65

7

98

3

TP40

OR

G-1

50

R1

LS3

WH

T#40-4

WH

T#40-6

TB40

NONO

R2

TS14

LOW

(4WD

)R

ED

HIG

H (2W

D)

RED

BLK

R3

250

100

DRIVERANGE

RE

D/W

HT

#29-C.H

.

TR

AV

EL A

LAR

M O

PT

ION

ST

EE

R LE

FT

ST

EE

R R

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BLU

-1

BLU

/BLK

-1

TB37TB36

BLU

/BLK

#37-M.H

.

BLU

#36-M.H

. OR

G/R

ED

#16-C.H

.LIM

IT S

WIT

CH

DR

IVE

EN

AB

LE S

WIT

CH

TB16

DR

IVE

ED

C

WHT#12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK-1

WH

T/R

ED

-1

NOHC

WH

T#30-C

.H.

TB31

WH

T/B

LK#31-C

.H.

WH

T/R

ED

#32-C.H

.

TB32

LS4

TP13

L1

BLU

/RE

D-3

BR

N-2

TB13

NCHO

BLU

/RE

D#13-C

.H.

BR

N

MODELS ONLY)

(2WD/4WD)

CE MODELS ONLY




Ground Control Box Wiring Diagram-Z-45/25 Ford Models (before serial number 13099)


Ground Control Box Wiring Diagram-Z-45/25 Ford Models (before serial number 13099)

1

2

3

4

5

6

7

8




GROUND CONTROL SWITCH PANEL

STACKED CONTACTS

TS53

31WT/BK-C.H.. WHT/BLK-1

TS64

BR

N-G

RD

.

RU

N/T

ES

T

WHT#40-R7

CH+EH1

WHT-PRIM.#5

EH2

WHT-EXT.#6

BLK-S.P.

BLACK-SEC.#4 42ORG/RED-1

GRN/BLK-1

GRN-1

GRN/WHT-1GRN/WHT-C.H

43

44

45

BLU/RED-1

ORG-1

ORG/BLK-1

WHT/RED-1

BLK-1

BLK/WHT-1

BLK/RED-1

BLU-1

BLU/BLK-1

BLU/WHT-1

BU/BK-M.H.

OG/BK-C.H.

PK/GR-EH#2

BRN/WHT-EH2

BLU-M.H.

WT/RD-C.H.

BR/BLU-EH2

41

38

39

40

37

36

34

35

32

33

SPARE

SPARE

SPARE

GEN. OPTION

L.P. (FUEL SELECT)

RPM

BRAKE

START

TEST LIGHT

PULSE PICKUP

LIMIT SWITCH SIG.

STEER RIGHT

GLOW PLUG

STEER LEFT

WHT-SEC.#4

BU/RD-S.P.

BU/WT-S.P.

OG/BK-ISM#2

BLK-ISM#3

BK/RD-S.P.

HIGH/LOW RPM

RED TO EH2

RED-R1

BLU/BLK #11

BLK #33

BLU #10

RED #20

SEC.#4

BLK 25B

BR

NIS

M5

1

WHT ISM7

WHT 23B

WHT/PRP EH2

2

3

PRIM.#5

EXT#6

M.H.BLK-33D

MODULE

BLK/RED-C.H

BLK-TEST SW

WHT-TEST SW

RED-ISM#6

R/W-1

WHT-1

RED-1

BLK-2

WHT-2

RED/BLK-1

RD/WT-C.H.

WHT#30-C.H.

RED-C.H.

RD/BK-C.H.

RED-EXT.#6

RD/WT-C.H.

29

30

27

26

28

RED-ISM#4

24

25

22

23

21 WHT-E.H.#1

BLU/RED-3

BLU/WHT-3

GRN-3

ORG-3

ORG/BLK-3

ORG/RED-3

GRN/BLK-3

BLU-3

BLU/BLK-3

GRN/WHT-3

ORG/RED-CH

RED-C.H.

GRN-M.H

GRN/BLK-M.H

BLU/WHT-M.H

BL/RED#13-C.H.

BLU-M.H

BLU/BLK-M.H

15

19

20

17

18

16

12

13

10

11

14

E.D.C.

E.D.C.

2WD/4WD (DRIVE RANGE)

AUX. PWR.

WATER TEMP. SENDER

OIL PRESSURE SENDER

PWR. TO PLAT.

KEYSWITCH PWR.

IGNITION PWR.

TILT ALARM

RED-S.P.

BLK-S.P.

WHT-S.P.

WHT-S.P.

SEC. BOOM F.C.

JIB VALVE

DRV. ENA. LT. SW.

PLAT. ROT. R.

PLAT. ROT. L.

PLAT. LEVEL DN.

PLAT. LEVEL. UP

DRV. ENA.

SEC. BOOM DN

12V BATT. SUPPLY

SEC. BOOM UP

OG/BK-S.P

GR/WT-S.P.

RED-S.P.

GRN-S.P.

GR/BK-S.P.

WHT#12-C.H.

BLU/WT-S.P.

BLU-S.P.

BU/BK-S.P.

ORG-S.P

10

BLK/WHT-3

WHT/RED-3

RED/BLK-3

RED-3

WHT-3

WHT/BLK-3

RED/WHT-3

BLK-3

BLK/RED-3

WHT-M.H

W/R-M.H

BLK/WHT-M.H

WHT/BLK-M.H

BLK-M.H

BLOCK

R/W-M.H

RED/BLK-M.H

RED-M.H

D C

4

8

5

6

7

9

3

1

2

B

BASE TERMINATION

RED-20C

BRN-GRD. TST. SW.

RED-27B

WHT-R2#86

WHT-TST. SW.7

9

8

3

4

6

5

ENG. FAULT

HORN

BOOM RETRACT

TURN. ROT. R

TURN. ROT. L

PRI. BOOM F.C.

PRI. BOOM DOWN

TURN. ROT. F.C.

BOOM EXTEND

PRI. BOOM UP

WHT-S.P.

BK/WT-S.P.

BLK-S.P.

WT/RD-S.P.

WT/BLK-S.P.

BK/RD-R5

RD/WT-S.P.

RED-S.P.

RD/BK-S.P.

A

IGN./FUEL ON

KEY BYPASS

KEY PWR.

START INPUT

AUX. ON

BATTERY

GROUND

WHT#21TO R2CHECK

HOUR METER

TS54

R5

BLK/RED #35

R4

BLU/WHT #12

CB1

TS52

STARTSEC. BOOM

CB2

2

3

1

TS60

ENGINE

LIGHT

BRN TO R4BRN TO GRD

RED #27

WHT #21

BLK #22

WHT #23

L2

RE

D

ORG/BLK-41A

BLK-R1#861

2

IGN./START

START RELAY

TACHOMETER

NO

NO

NO

NO

NC

STOP

P1

NC

KS1

GROUND CONTROL BOX

KS1

CR7 CR8

PLATFORM LEVEL CUTOUT

ENGINE HARNESS # 2, FORD EFI,42 PIN INTERCHANGE

PIN/#: TO:RED/GRN #1 - 25DPNK/GRN #6 - 38DBRN/WHT #7 - 39DYEL (18GA) #8 - CB2YEL (12GA) #9 - CB2

BRN/BLU #26 - 35DWHT/PRP #18 - TST SW

LEVEL

PLAT.PLATFORM

ROTATE

TS57

ORG/BLK #15

GRN #17

ORG #14

(CE MODLES ONLY)

BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMS

TS63 PRIMARY BOOM EXTEND/RETRACT SWITCH

CR8

CR7

CR5

CR1

CR4

CR2

R5

TS64

TS61

CB1

TS62

TS60

R4

HM

CB2

TURNTABLEROTATE

TS62

TS59

BOOM EXTEND/

TS63

UP/DOWN

PRIMARYBOOM

TS61

FUEL SELECT

RETRACT

PRIMARY

WHT/BLK #5

GRN/WHT #19

GRN/BLK #18

WHT/RED #6

BLK/WHT #8

WHT #4

RED/BLK #2

RED #1

BLK #7

BLU/WHT #38

TS51

AUXILIARY PUMP

BLU/RED #39

RED/WHT #3

L2

PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

CR1 CR2 CR5 CR4

PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)

CIRCUIT BREAKER, ENGINE, 15A

PRIMARY BOOM UP/DOWN SWITCH

CIRCUIT BREAKER, CONTROLS, 15A

SECONDARY BOOM UP/DOWN SWITCH

TURNTABLE ROTATE SPEED LIMITING RESISTOR, 15 OHMS

CHECK ENGINE LED

HORN RELAY

LPG LOCKOUT RELAY

INGITION POWER RELAY

IGNITION / START RELAY

RUN/TEST SWITCH

HOUR METER

TURNTABLE ROTATE SWITCH

LABEL

TS51

KS1

TS53

TS55

TS59

TS57

TS52

P1

FUEL SELECT SWITCH

PLATFORM ROTATE SWITCH

PLATFORM LEVEL SWITCH

START ENGINE SWITCH

FUNCTION ENABLE SWITCH

AUXILIARY SWITCH

EMERGENCY STOP BUTTON

KEY SWITCH

DESCRIPTION

TO BASECONTROL BOXCONNECTIONS

GROUND STUD

(-12 VOLTS)

HARNESS:WIRING

SPLICE

ORG-M.H.

OR/BK-M.H.

WHT-40

ORG ORG/BLK

ORG/BLK-15

ORG-14

BLK-R4

RED-R4

GREEN-R4

BLK/RED-R5WHT-21

BLK-R1 TO E.H.#1

BLK-R1 TO ISM#1

RED-CB1

WHT-R2

BLK-22

BLK/RED-9

BRN TO H.M.

RD/GRN-EH#1

RED-R4

BLK-R4

BLK-1

BLK/RED-R5

ORG-R7

ORG/BLK-R8

GRN-R4

RED-E.H.#1

ORG/BLK-M.H.

BLK/RED-E.H.#1

GRN-E.H.#1

BLK-E.H.#1

BLK-E.H.#1

ORANGE-M.H.

M.H.

R or CR

S.P.

MANIFOLD HARNESS

RELAY

SWITCH PANEL

EH#2

C.H.

EH#1

ENGINE HARNESS #2 (FORD EFI HARNESS)

ENGINE HARNESS #1

CHASSIS HARNESS

WIRE CONNECTION ABBREVIATION KEY:

IGNITION/START MODULE

H.M. HOUR METER

ISM

Platform Control Box Wiring Diagram-Z-45/25 Ford Models (before serial number 13099)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24

PLATFORM CONTROL SWITCH PANEL

PLATFORM CONTROL BOX

14

23

PW

R.

FR

MP

LA

T.

PW

R.

TO

PL

AT.

DR

V.

EN

A.

LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.

(OP

TIO

N)

ST

EE

RR

IGH

T

GL

OW

PL

G.

OP

T.

DR

V.

EN

A.

SE

C.

BO

OM

DN

.

SE

C.B

OO

MU

P

PW

R.

TO

F.S

.

PW

R.

(STA

RT

)

PW

R.

(CO

NT.)

PL

AT.

RO

T.

R.

PL

AT.

RO

T.

L.

PL

AT.

LVL

.D

N.

PL

AT.

LVL

.U

P

SW

ING

F.C

.

SW

ING

RIG

HT

SW

ING

LE

FT

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DN

.

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

F.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

EX

TE

ND

HO

RN

RE

TR

AC

T

SE

C.

BO

OM

F.C

.

JIB

VA

LVE

L.P

.

BR

AK

E

AU

X.

PW

R.

E.D

.C.

E.D

.C.

2W

D/4

WD

RP

M

STA

RT

EN

GIN

EF

AU

LT

SP

AR

E

SP

AR

E

SP

AR

E

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

OG/BK-41

ORG-40

RED-10

BL

U/R

ED

-39

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

RE

D/W

HT

-3

BL

U/W

HT

-38

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

GEN.

EFI RELAY

FUEL SELECTHIGH/LOW

START

DRIVE

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

PRIMARY

PLATFORM

PLATFORM

PRIMARY BOOM

P2

TS3TS4

TS2

TS15

L3

CHECKENGINE

RPM

L1

DRIVESPEED

TS1

TS14

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13

TURNTABLEUP/DOWNROTATE

LEVEL

TS9P3

BP1

BP2

50

CR12

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

OPT.

BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN , TURNTABLE ROTATEBP1

CR12

H.P.L.

H1

BP2

TILT ALARM

HORSEPOWER LIMITER BOARD

EFI RELAY

BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN

DESCRIPTIONLABEL

TS2

TS7

TS9

TS3

P3

TS1

R3

L1

L3

TS10

TS12

R2

TS11

R1

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR

PRIMARY BOOM EXTEND/RETRACT SWITCH

EFI RESISTOR

DRIVE ENABLE LED




FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH

R1

R2 R3

LIFT/DRIVE SELECT SWITCHTS50

+_


Platform Control Box Wiring Diagram-Z-45/25 Ford Models (before serial number 13099)


1

2

3

4

5

6

7

8




Electrical Schematic, Z-45/25 Ford Models(from serial number 13099 to 16303)

WH

T-2

RE

D/W

HT

#2

3-C

.H.

HO

RN

RE

LA

Y

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

STA.

A

I

S

FLD.

REGULATOR

+

-

RED

RE

D#

20

-C.H

.

TB20

GRD.

BAT.

ALTERNATOR

LINK

FUSE

50

0A

MP

BL

K/R

ED

#R

5-C

.H.

WH

T#

21

-E.H

.#1

OR

G/B

LK

#4

1-C

.H.

RE

D-E

.H.#

1

CR5CR5

BL

K/R

ED

#9

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

AU

XIL

IAR

YP

OW

ER

AU

XIL

IAR

YP

OW

ER

TP26BLKBLK

TP22P2

GE

NE

RA

TO

RO

PT

ION

FL

AS

HIN

GB

EA

CO

NO

PT

ION

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

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


TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

EN

GIN

E

OF

FG

EN

ER

AT

OR

ON

TS64

4

STARTERAUXPUMP

PR1

RE

D#

27

-C.H

.

PR1

NO

RE

D/B

LK

#2

8-C

.H.

CR1NO

CR1

BL

K#

R1

-E.H

.#1

RD

/LG

FE

H(1

6A

)P

IN1

YE

L/B

LK

FE

H(6

74

)P

IN7

TA

N/B

LU

FE

H(3

06

)P

IN2

4

YF

EH

(37

B)

PIN

8

YF

EH

(37

)P

IN9

(GN

D)

BL

K/W

TF

EH

(57

0E

)P

IN4

2

PIN

K/L

GF

EH

(65

8)

PIN

6

WT

/PU

RF

EH

(20

9)

PIN

18

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

#2

3-E

.H.#

1

IGN./STARTMODULE

HM

TB38

L2

TE

ST

TE

ST

RU

N

BL

U/W

HT

#3

8

WH

T#

21

GR

N/W

HT

#4

5-E

.H.#

1

FB

TS53

BL

K-1

BL

U/R

ED

-1

TB39

TP33 TP39TP38

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

WHT

TP25

TP24

REDFS1 REDBLK

TA

N/B

LU

TS54

BL

K/R

ED

-1

HIG

HR

PMF

UN

CT

ION

EN

A.

TS4

TP35

NOTE:

L3

BL

U/W

HT

-1

(GN

D)

BL

K/W

TF

EH

(57

0C

)P

IN3

4

LP

GA

SF

UE

L

FU

EL

GA

S

LP

BRN

RED

RED

WHT

WHT

ORG/BLK

TS3

TS50

CH

EC

KE

NG

INE

LE

D

TP41

12 VDC

TP21

SEE NOTE 1

1) The connection to TP24 is for units without generator option.

CHECK

ENGINE

CHECKENGINE

LIF

T/D

RIV

ES

EL

EC

TO

R

OP

TIO

N(R

EQ

UIR

ED

FO

R

LO

WR

PM

HIG

HR

PM

LO

WR

PM

FO

OT

SW

.H

/LENGINESPEED

ENGINE HARNESS #2

SEE NOTE 2

2) The foot switch power is connected to both white wires without the lift/drive selector option.

CE

MO

DE

LS

)

3) All switches and contacts are shown with the boom in the stowed position and the key switch off.

TILT

AL

AR

M

1

3

2

LIFT/DRIVESELECTOROPTION

BL

K#

22

WH

T

RE

D

WH

T

BR

NB

LK

PIN

K/B

LK

FE

H(7

87

)P

IN5

FUELPUMP

PK

/BL

KB

LK

FU

EL

PU

MP


1

2

3

4

5

6

7

8



LS2

WH

T#

40

-5

BO

OM

RE

TR

AC

T

10

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

WHT

ORG/BLK

WHT

BRN

TP3

OR

G/B

LK

-3

UP

DO

WN

OR

G/B

LK

#1

5-M

.H.

OR

G#

14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TETP17

TS7

GR

N-3

TS57

TB17

TB18

GR

N/B

LK

-3

GR

N#

17

-M.H

.

GR

N/B

LK

#1

8-M

.H.

NC

CR8

TS9

TP15

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

L

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BL

U/W

HT

#1

2-M

.H.

BP2

PWM

A+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

#11

-M.H

.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U#

10

-M.H

.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

#2

-M.H

.

RE

D/W

HT

#3

-M.H

.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

#5

-M.H

.

TB1

TB6

WH

T/R

ED

#6

-M.H

.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D#

1-M

.H.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

#8

-M.H

.

TB8

WH

T-3

TB5

HORSE-

LIMITER

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K#

7-M

.H.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PD

RIV

EL

IMIT

SW

ITC

HB

RN

-4

BR

N-6

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

DR

IVE

LIM

ITS

WIT

CH

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T#

40

-4

WH

T#

40

-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

RE

D/W

HT

#2

9-C

.H.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

#3

7-M

.H.

BL

U#

36

-M.H

. RE

D-7

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT#12-C.H.

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

#3

1-C

.H.

WH

T/R

ED

#3

2-C

.H.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

DRIVERANGE

(2WD/4WD)

10

R1

CR12

50

R4

CE MODELS ONLY




Ground Control Box Wiring Diagram-Z-45/25 Ford Models (from serial number 13099 to 16303)


Ground Control Box Wiring Diagram-Z-45/25 Ford Models (from serial number 13099 to 16303)

1

2

3

4

5

6

7

8




BASE CONTROL SWITCH PANEL

STACKED CONTACTS

TS53


TS64

BR

N-G

RD

.

RU

N/T

ES

T

WHT#40-R7

CH+EH1

WHT-PRIM.#5

EH2

WHT-EXT.#6

BLK-S.P.

42ORG/RED-1

GRN/BLK-1

GRN-1


43

44

45

BLU/RED-1

ORG-1

ORG/BLK-1

WHT/RED-1

BLK-1

BLK/WHT-1

BLK/RED-1

BLU-1

BLU/BLK-1

BLU/WHT-1

BU/BK-M.H.

OG/BK-C.H.

PK/GR-EH#2

YEL/BLK-EH2

BLU-M.H.

WT/RD-C.H.

BR/BLU-EH2

41

38

39

40

37

36

34

35

32

33

(SPARE)

(SPARE)

(SPARE)

GENERATOR OPTION

LIQUID PROPANE FUEL

HIGH/LOW RPM

BRAKE

START ENGINE

(SPARE)

ALTERNATOR PULSE PICKUP

OFF-LIMIT SPEED

STEER LEFT

GLOW PLUG

STEER RIGHT

WHT-SEC.#4

BU/RD-S.P.

BU/WT-S.P.

OG/BK-ISM#2

BLK-ISM#3

BK/RD-S.P. HIGH/LOW RPM

RED TO EH2

RED-R1

BLU/BLK #11

BLK #33

BLU #10

RED #20

SEC.#4

BLK 25B

BR

NIS

M5

1

WHT ISM7

WHT 23B

WHT/PRP EH2

2

3

PRIM.#5

EXT#6

M.H.BLK-33D

MODULE

BLK/RED-C.H

BLK-TEST SW

WHT-TEST SW

RED-ISM#6

R/W-1

WHT-1

RED-1

BLK-2

WHT-2

RED/BLK-1

RD/WT-C.H.

WHT-ENA.

RED-C.H.

RD/BK-C.H.

RED-EXT.#6

RD/WT-C.H.

29

30

27

26

28

RED-ISM#4

24

25

22

23

21 WHT-E.H.#1

BLU/RED-3

BLU/WHT-3

GRN-3

ORG-3

ORG/BLK-3

ORG/RED-3

GRN/BLK-3

BLU-3

BLU/BLK-3

GRN/WHT-3

OR/BK-M.H

RED-ENA.

RED-C.H.

GRN-M.H

GRN/BLK-M.H

BLK-ENA.

BLU-M.H

BLU/BLK-M.H

15

19

20

17

18

16

12

13

10

11

14

E.D.C.

E.D.C.

2WD/4WD

AUXILIARY PUMP SELECT

(UNUSED)

ECM KEEP ALIVE POWER

+12 V TO PLATFORM

KEYSWITCH POWER

IGNITION POWER

TILT ALARM

RED-S.P.

BLK-S.P.

WHT-S.P.

WHT-S.P.

SECONDARY BOOM FUNCTION CTRL

JIB VALVE

DRIVE ENABLE LIGHT

PLATFORM ROTATE RIGHT

PLATFORM ROTATE LEFT

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

DRIVE ENABLE RELAY COIL

SECONDARY BOOM DOWN

+12 V POWER

SECONDARY BOOM UP

OG/BK-S.P

GR/WT-S.P.

RED-S.P.

GRN-S.P.

GR/BK-S.P.

WHT#12-C.H.

BLU/WT-S.P.

BLU-S.P.

BU/BK-S.P.

ORG-S.P

10

BLK/WHT-3

WHT/RED-3

RED/BLK-3

RED-3

WHT-3

WHT/BLK-3

RED/WHT-3

BLK-3

BLK/RED-3

WHT-M.H

W/R-M.H

BLK/WHT-M.H

WHT/BLK-M.H

BLK-M.H

BLOCK

R/W-M.H

RED/BLK-M.H

RED-M.H

D C

4

8

5

6

7

9

3

1

2

B

BASE TERMINATION

RED-20C

BRN-GRD. TST. SW.

RED-27B

WHT-R2#86

WHT-TST. SW.7

9

8

3

4

6

5

ENG. FAULT

HORN

PRIMARY BOOM RETRACT

TURNTABLE ROTATE LEFT

TURNTABLE ROTATE RIGHT

PRIMARY BOOM FUNTION CONTROL

PRIMARY BOOM DOWN

TURNTABLE ROTATE FUNCTION CTRL

PRIMARY BOOM EXTEND

PRIMARY BOOM UP

WHT-S.P.

BK/WT-S.P.

BLK-S.P.

WT/RD-S.P.

WT/BLK-S.P.

BK/RD-R5

RD/WT-S.P.

RED-S.P.

RD/BK-S.P.

A

IGN./FUEL ON

KEY BYPASS

KEY PWR.

START INPUT

AUX. ON

BATTERY

GROUND

WHT#21TO R2

CHECK

HOUR METER

TS54

BLK/RED #35

BLU/WHT #12

CB1

TS52

START

SECONDARYBOOM

CB2

2

3

1

TS60

ENGINE

BRN TO R4

BRN TO GRD

RED #27

WHT #21

BLK #22

WHT #23

L2 LE

D

ORG/BLK-41A

BLK-R1#861

2

IGN./START

START RELAY

TACHOMETER NO

NO

NO

NO

NC

STOP

P1

NC

KS1

BASE CONTROL BOX

KS1

CR7 CR8



PIN/#: TO:RED/GRN #1 - 25DPNK/GRN #6 - 38DYEL/BLK #7 - 39DYEL (18GA) #8 - CB2YEL (12GA) #9 - CB2

TAN/BLU #24 - 35DWHT/PRP #18 - TST SW

LEVEL

PLATFORM

PLATFORM

ROTATE

TS57

ORG/BLK #15

GRN #17

ORG #14

(CE MODELS ONLY)

WHT-40

SPEED LIMITING VARIABLE RESISTOR 10 OHMS


CR8

CR7

CR5

CR1

CR4

CR2

TS64

TS61

CB1

TS62

TS60

R4

HM

CB2

TURNTABLEROTATE

TS62

TS59

BOOM EXTEND/

TS63

UP/DOWNPRI. BOOM

TS61

FUEL SELECT

RETRACT

PRIMARY

WHT/BLK #5

GRN/WHT #19

GRN/BLK #18

WHT/RED #6

BLK/WHT #8

WHT #4

RED/BLK #2

RED #1

BLK #7

BLU/WHT #38

TS51

AUXILIARY PUMP

BLU/RED #39

RED/WHT #3

L2


CR1 CR2 CR5 CR4






CHECK ENGINE LED

HORN RELAY

LPG LOCKOUT RELAY



RUN/TEST SWITCH

HOUR METER


LABEL

TS51

KS1

TS53

TS55

TS59

TS57

TS52

P1

FUEL SELECT SWITCH



START ENGINE SWITCH


AUXILIARY SWITCH


KEY SWITCH

DESCRIPTION


GROUND STUD

(-12 VOLTS)

M.H.

R or CR

S.P.

MANIFOLD HARNESS

RELAY

SWITCH PANEL

EH#2

C.H.

EH#1


ENGINE HARNESS #1

CHASSIS HARNESS


HARNESS:WIRING

SPLICE

ORG-M.H.

ORG ORG/BLK

ORG/BLK-15

ORG-14

BLK-R4

RED-R4

GREEN-R4

BLK/RED-R5WHT-21

BLK-R1 TO E.H.#1

BLK-R1 TO ISM#1

RED-CB1

WHT-R2

BLK-22

BLK/RED-9

BRN TO H.M.

RD/GRN-EH#1

RED-R4

BLK-R4

BLK-1

BLK/RED-R5

ORG-R7

ORG/BLK-R8

GRN-R4

RED-E.H.#1

ORG/BLK-M.H.

BLK/RED-E.H.#1

GRN-E.H.#1

BLK-E.H.#1

BLK-E.H.#1

ORANGE-M.H.


H.M. HOUR METER

ISM

R4

+

(UNUSED)

Platform Control Box Wiring Diagram-Z-45/25 Ford Models (from serial number 13099 to 16303)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARM

TILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.

PW

R.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.

LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.

(OP

TIO

N)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.

BO

OM

DN

.

SE

C.

BO

OM

UP

PW

R.

TO

F.S

.

F.S

.U

PP

OW

ER

PW

R.

(CO

NT.)

PL

AT.

RO

T.

R.

PL

AT.

RO

T.

L.

PL

AT.

LE

VE

LD

N.

PL

AT.

LE

VE

LU

P

TU

RN

.R

OT.

F.C

.

TU

RN

RO

T.

R.

TU

RN

RO

T.

L.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

F.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.

BO

OM

F.C

.

JIB

VA

LVE

L.P

.G

AS

BR

AK

E

AU

X.

PU

MP

SE

L.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

BL

U/R

ED

-39

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

RE

D/W

HT

-3

BL

U/W

HT

-38

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6GEN.

LIMITING RELAY

FUEL SELECTHIGH/LOW

START

DRIVEDP1

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

P2

TS3TS4

TS2

TS15

L3

CHECKENGINE

RPM

L1

DRIVESPEED

TS1

TS14

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



BP1

BP2

50

CR12

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

OPT.


CR12

H.P.L.

H1

T1

BP2

TIME DELAY ( JIB ONLY )

TILT ALARM


EFI RELAY


DESCRIPTIONLABEL

TS2

TS7

TS9

TS3

P3

TS1

R3

L1

L3

TS10

TS12

R2

TS11

R1

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR


EFI RESISTOR ( FORD AND PERKINS ONLY )

DRIVE ENABLE LED




FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH

R1

R2 R3


(UN

US

ED

)

RED-10

ORG-40

WHT-24

RED-10

+_


Platform Control Box Wiring Diagram-Z-45/25 Ford Models (from serial number 13099 to 16303)


Electrical Schematic, Z-45/25J Ford Models(before serial number 13099)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

#2

3-C

.H.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

STA.

A

I

S

FLD.

REGULATOR

+

-

RED

RE

D#

20

-C.H

.

TB20

GRD.

BAT.

ALTERNATOR

LINK

FUSE

50

0

RE

LA

Y

BL

K/R

ED

#R

5-C

.H.

WH

T#

21

-E.H

.#1

OR

G/B

LK

#4

1-C

.H.

RE

D-E

.H.#

1

CR5CR5

BL

K/R

ED

#9

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLKBLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

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


TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

EN

GIN

E

TS64

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D#

27

-C.H

.

PR1

NO

RE

D/B

LK

#2

8-C

.H.

CR1NO

CR1

BL

K#

R1

-E.H

.#1

RD

/LG

FE

H(1

6A

)P

IN1

BR

/WT

FE

H(6

74

)P

IN7

BR

N/B

LU

FE

H(2

53

)P

IN2

4

YF

EH

(37

B)

PIN

8

YF

EH

(37

)P

IN9

(GN

D)

BL

K/W

TF

EH

(57

0E

)P

IN4

2

PIN

K/L

GF

EH

(65

8)

PIN

6

WT

/PU

RF

EH

(20

9)

PIN

18

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

#2

3-E

.H.#

1

IGN./START

HM

TB38

MODULE

L2

TE

ST

TE

ST

RU

N

BL

U/W

HT

#3

8

WH

T#

21

GR

N/W

HT

#4

5-E

.H.#

1

FB

TS53

BL

K-1

BL

U/R

ED

-1

TB39

TP33 TP39TP38

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

WHT

TP25

TP24

REDFS1 REDBLK

BR

N/B

LU

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

L3

BL

U/W

HT

-1

(GN

D)

BL

K/W

TF

EH

(57

0C

)P

IN3

4

RE

D

CR13

CR14

LP

GA

SF

UE

L

FU

EL

GA

S

LP

BRN

RED

RED

WHT

BRN

WHT

ORG/BLK

DRIVE

SELECTOR

OPTION

RED

TS3

TS50

CH

EC

KE

NG

INE

LE

D

TP41

12 V

DC

TP21

SEE NOTE 1

CHECK

ENGINE

ENGINE

CHECK

OP

TIO

N

CR14NO

LIF

T/D

RIV

ES

EL

EC

TO

R

OP

TIO

N(R

EQ

UIR

ED

FO

R

JIB

CU

TO

UT

RE

LA

Y(C

R1

3)

JIB

CU

TO

UT

RE

LA

Y

JIB

VA

LV

ER

EL

AY

(CR

-14

)JIB

VA

LV

ER

EL

AY

JIB

VA

LV

ES

LO

WR

PM

JIB

VA

LV

ES

HIG

HR

PM

LO

WR

PM

FO

OT

SW

.H

/L

OF

F

ON

GE

NE

RA

TO

R

ENGINESPEED

ENGINE HARNESS #2

SEE NOTE 2

CE

MO

DE

LS

)

TIL

TA

LA

RM

1

3

2

LIFT/

BL

K#

22

WH

T


1

2

3

4

5

6

7

8



LS2

DR

IVE

LIMIT

SW

ITC

HW

HT

#40-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

RIG

HT

LEF

TP

LAT R

OTAT

ER

IGH

T

LEF

TP

LAT R

OTAT

E

TS57

BRN

DE

SC

EN

T A

LAR

M O

PT

ION

RED

RED

RED

WHT

ORG/BLK

WHT

BRN

CR9 NCCR9

TS7+

BR

N

TB19

GR

N/W

HT-3

TP19TP3

OR

G/B

LK-3

UP

DO

WN

PLAT

FO

RM

LEV

EL

OR

G/B

LK#15-M

.H.

OR

G#14-M

.H.

PLAT

FO

RM

RO

TATE

LEF

T/

JIB B

OO

M U

P

PLAT

FO

RM

RO

TATE

RIG

HT

/JIB

BO

OM

DO

WN

PLAT

FO

RM

LEV

EL U

P

PLAT

FO

RM

LEV

EL D

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP17

LEF

T

LEF

T

UP

JIB B

OO

M

UP

JIB B

OO

M

TP18

TS8

NCCR13

GR

N-3

TS58

TB18

TB17

GR

N/B

LK-3

GR

N#17-M

.H.

GR

N/B

LK#18-M

.H.

NCCR8

TS9

TP15

TS59

UP

DO

WN

PLAT

FO

RM

LEV

EL

TB14

TB15

SE

CO

ND

AR

Y B

OO

MF

LOW

CO

NT

RO

L

SE

CO

ND

AR

Y B

OO

M D

OW

N

SE

CO

ND

AR

Y B

OO

M U

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BLU

/WH

T#12-M

.H.

BP2

PWMA+-X

R

TS60

TB11

BLU

/BLK

BLU

/BLK

#11-M.H

.

TP14

OR

G-3

BLU

/WH

T

BLU

/WH

T-3

TP12

RE

D/W

HT-3

TP11

BLU

-3

BLU

/BLK

-3

BLU

TB10

BLU

#10-M.H

.

TP4

WH

T#4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FLO

W C

ON

TR

OL

PR

IMA

RY

BO

OM

TU

RN

TAB

LE R

OTAT

E LE

FT

TU

RN

TAB

LE R

OTAT

E R

IGH

T

TU

RN

TAB

LE R

OTAT

E

PR

IMA

RY

BO

OM

UP

FLO

W C

ON

TR

OL

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

10

R5

PWMA+-X

R

TP1

TS61

TP2

RE

D/B

LK-3

RE

D-3

TB3

RE

D/B

LK#2-M

.H.

RE

D/W

HT

#3-M.H

.

-+A

PWM

BP1

15

R4

R

X

TS62

WH

T/B

LK#5-M

.H.

TB1

TB6

WH

T/R

ED

#6-M.H

.

TB5

RIG

HT

LEF

TT

UR

NTA

BLE

RO

TATE

RE

D#1-M

.H.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK-3

TS63

BLK

/WH

T#8-M

.H.

TB8

WH

T-3

TB4

BOARD

POWER

TS13

TP7

BLK

-3

TP8

BLK

/WH

T-3

BLK

#7-M.H

.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

E R

ELE

AS

EV

ALV

E

RE

D/W

HT-1

MO

TOR

ST

RO

KE

SE

CO

ND

AR

Y B

OO

M U

PB

RN

-4

BR

N-6

DR

IVE

LIMIT

SW

ITC

H

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIMIT

SW

ITC

H

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

CR12

12

4

65

7

98

3

TP40

OR

G-1

50

R1

LS3

WH

T#40-4

WH

T#40-6

TB40

NONO

R2

TS14

LOW

(4WD

)R

ED

HIG

H (2W

D)

RED

BLK

R3

250

100

DRIVERANGE

RE

D/W

HT

#29-C.H

.

TR

AV

EL A

LAR

M O

PT

ION

ST

EE

R LE

FT

ST

EE

R R

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BLU

-1

BLU

/BLK

-1

TB37TB36

BLU

/BLK

#37-M.H

.

BLU

#36-M.H

. OR

G/R

ED

#16-C.H

.LIM

IT S

WIT

CH

DR

IVE

EN

AB

LE S

WIT

CH

TB16

DR

IVE

ED

C

WHT#12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK-1

WH

T/R

ED

-1

NOHC

WH

T#30-C

.H.

TB31

WH

T/B

LK#31-C

.H.

WH

T/R

ED

#32-C.H

.

TB32

LS4

TP13

L1

BLU

/RE

D-3

BR

N-2

TB13

NCHO

BLU

/RE

D#13-C

.H.

BR

N

MODELS ONLY)

(2WD/4WD)

TI

CE MODELS ONLY




Ground Control Box Wiring Diagram-Z-45/25J Ford Models (before serial number 13099)


Ground Control Box Wiring Diagram-Z-45/25J Ford Models (before serial number 13099)

1

2

3

4

5

6

7

8





STACKED CONTACTS

TS53


BR

N-G

RD

.

WHT#40-R7

CH+EH1

WHT-PRIM.#5

EH2

WHT-EXT.#6

BLK-S.P.

BLACK-SEC.#4 42ORG/RED-1

GRN/BLK-1

GRN-1


43

44

45

BLU/RED-1

ORG-1

ORG/BLK-1

WHT/RED-1

BLK-1

BLK/WHT-1

BLK/RED-1

BLU-1

BLU/BLK-1

BLU/WHT-1

BU/BK-M.H.

OG/BK-C.H.

PK/GR-EH#2

BRN/WHT-EH2

BLU-M.H.

WT/RD-C.H.

BR/BLU-EH2

41

38

39

40

37

36

34

35

32

33

SPARE

SPARE

SPARE

GEN. OPTION

L.P. (FUEL SELECT)

RPM

BRAKE

START

TEST LIGHT

PULSE PICKUP

LIMIT SWITCH SIG.

STEER RIGHT

GLOW PLUG

STEER LEFT

WHT-SEC.#4

BU/RD-S.P.

BU/WT-S.P.

OG/BK-ISM#2

BLK-ISM#3

BK/RD-S.P.

HIGH/LOW RPM

RED TO EH2

RED-R1

BLU/BLK #11

BLK #33

BLU #10

RED #20

SEC.#4

BLK 25B

BR

NIS

M5

1

WHT ISM7

WHT 23B

WHT/PRP EH2

2

3

PRIM.#5

EXT#6

M.H.BLK-33D

MODULE

BLK/RED-C.H

BLK-TEST SW

WHT-TEST SW

RED-ISM#6

R/W-1

WHT-1

RED-1

BLK-2

WHT-2

RED/BLK-1

RD/WT-C.H.

WHT#30-C.H.

RED-C.H.

RD/BK-C.H.

RED-EXT.#6

RD/WT-C.H.

29

30

27

26

28

RED-ISM#4

24

25

22

23

21 WHT-E.H.#1

BLU/RED-3

BLU/WHT-3

GRN-3

ORG-3

ORG/BLK-3

ORG/RED-3

GRN/BLK-3

BLU-3

BLU/BLK-3

GRN/WHT-3

ORG/RED-CH

RED-C.H.

GRN-M.H

GRN/BLK-M.H

BLU/WHT-M.H

BL/RED#13-C.H.

BLU-M.H

BLU/BLK-M.H

15

19

20

17

18

16

12

13

10

11

14

E.D.C.

E.D.C.

2WD/4WD (DRIVE RANGE)

AUX. PWR.

WATER TEMP. SENDER

OIL PRESSURE SENDER

PWR. TO PLAT.

KEYSWITCH PWR.

IGNITION PWR.

TILT ALARM

RED-S.P.

BLK-S.P.

WHT-S.P.

WHT-S.P.

SEC. BOOM F.C.

JIB VALVE

DRV. ENA. LT. SW.

PLAT. ROT. R.

PLAT. ROT. L.

PLAT. LEVEL DN.

PLAT. LEVEL. UP

DRV. ENA.

SEC. BOOM DN

12V BATT. SUPPLY

SEC. BOOM UP

OG/BK-S.P

GR/WT-S.P.

RED-S.P.

GRN-S.P.

GR/BK-S.P.

WHT#12-C.H.

BLU/WT-S.P.

BLU-S.P.

BU/BK-S.P.

ORG-S.P

10

BLK/WHT-3

WHT/RED-3

RED/BLK-3

RED-3

WHT-3

WHT/BLK-3

RED/WHT-3

BLK-3

BLK/RED-3

WHT-M.H

W/R-M.H

BLK/WHT-M.H

WHT/BLK-M.H

BLK-M.H

BLOCK

R/W-M.H

RED/BLK-M.H

RED-M.H

D C

4

8

5

6

7

9

3

1

2

B

BASE TERMINATION

RED-20C

BRN-GRD. TST. SW.

RED-27B

WHT-R2#86

WHT-TST. SW.7

9

8

3

4

6

5

ENG. FAULT

HORN

BOOM RETRACT

TURN. ROT. R

TURN. ROT. L

PRI. BOOM F.C.

PRI. BOOM DOWN

TURN. ROT. F.C.

BOOM EXTEND

PRI. BOOM UP

WHT-S.P.

BK/WT-S.P.

BLK-S.P.

WT/RD-S.P.

WT/BLK-S.P.

BK/RD-R5

RD/WT-S.P.

RED-S.P.

RD/BK-S.P.

A

IGN./FUEL ON

KEY BYPASS

KEY PWR.

START INPUT

AUX. ON

BATTERY

GROUND

WHT#21TO R2CHECK

HOUR METER

TS54

R5

BLK/RED #35

R4

BLU/WHT #12

CB1

TS52

STARTSEC. BOOM

CB2

2

3

1

TS60

ENGINE

LIGHT

BRN TO R4BRN TO GRD

RED #27

WHT #21

BLK #22

WHT #23

L2

RE

D

ORG/BLK-41A

BLK-R1#861

2

IGN./START

START RELAY

TACHOMETER

NO

NO

NO

NO

NC

STOP

P1

NC

KS1

GROUND CONTROL BOX

KS1

CR7 CR8



PIN/#: TO:RED/GRN #1 - 25DPNK/GRN #6 - 38DBRN/WHT #7 - 39DYEL (18GA) #8 - CB2YEL (12GA) #9 - CB2

BRN/BLU #26 - 35DWHT/PRP #18 - TST SW

LEVEL

PLAT.PLATFORM

ROTATE

TS57

ORG/BLK #15

GRN #17

ORG #14

(CE MODELS ONLY)

BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMS


CR8

CR7

CR5

CR1

CR4

CR2

R5

TS64

TS61

CB1

TS62

TS60

R4

HM

CB2

TURNTABLEROTATE

TS62

JIB

TS59

TS58

BOOM EXTEND/

TS63

UP/DOWNPRI. BOOM

TS61

FUEL SELECT

RETRACT

PRIMARY

WHT/BLK #5

GRN/WHT #19

GRN/BLK #18

WHT/RED #6

BLK/WHT #8

WHT #4

RED/BLK #2

RED #1

BLK #7

BLU/WHT #38

TS51

AUXILIARY PUMP

BLU/RED #39

RED/WHT #3

L2


CR1 CR2 CR5 CR4







CHECK ENGINE LED

HORN RELAY

LPG LOCKOUT RELAY



RUN/TEST SWITCH

HOUR METER


TS58

LABEL

TS51

KS1

TS53

TS55

TS59

TS57

TS52

P1

JIB BOOM UP/DOWN

FUEL SELECT SWITCH



START ENGINE SWITCH


AUXILIARY SWITCH


KEY SWITCH

DESCRIPTION


GROUND STUD

(-12 VOLTS)

M.H.

R or CR

S.P.

MANIFOLD HARNESS

RELAY

SWITCH PANEL

EH#2

C.H.

EH#1


ENGINE HARNESS #1

CHASSIS HARNESS


HARNESS:WIRING

SPLICE

ORG-M.H.

OR/BK-M.H.

WHT-40

ORG ORG/BLK

ORG/BLK-15

ORG-14

BLK-R4

RED-R4

GREEN-R4

BLK/RED-R5WHT-21

BLK-R1 TO E.H.#1

BLK-R1 TO ISM#1

RED-CB1

WHT-R2

BLK-22

BLK/RED-9

BRN TO H.M.

RD/GRN-EH#1

RED-R4

BLK-R4

BLK-1

BLK/RED-R5

ORG-R7

ORG/BLK-R8

GRN-R4

RED-E.H.#1

ORG/BLK-M.H.

BLK/RED-E.H.#1

GRN-E.H.#1

BLK-E.H.#1

BLK-E.H.#1

ORANGE-M.H.


H.M. HOUR METER

ISM

Platform Control Box Wiring Diagram-Z-45/25J Ford Models (before serial number 13099)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24



14

23

PW

R.F

RM

PL

AT.

PW

R.T

OP

LA

T.

DR

V.

EN

A.

LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.

(OP

TIO

N)

ST

EE

RR

IGH

T

GL

OW

PL

G.O

PT.

DR

V.

EN

A.

SE

C.

BO

OM

DN

.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

PW

R.(S

TA

RT

)

PW

R.(C

ON

T.)

PL

AT.

RO

T.

R.

PL

AT.

RO

T.

L.

PL

AT.LV

L.D

N.

PL

AT.LV

L.U

P

SW

ING

F.C

.

SW

ING

RIG

HT

SW

ING

LE

FT

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DN

.

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

EX

TE

ND

HO

RN

RE

TR

AC

T

SE

C.

BO

OM

F.C

.

JIB

VA

LV

E

L.P

.

BR

AK

E

AU

X.

PW

R.

E.D

.C.

E.D

.C.

2W

D/4

WD

RP

M

STA

RT

EN

GIN

EF

AU

LT

SP

AR

E

SP

AR

E

SP

AR

E

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TIL

TA

LA

RM

RE

D/B

LK

-1

25

0

10

0

EMERGENCY STOP

HORN

OG/BK-41

ORG-40

RED-10

BL

U/R

ED

-39

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

BL

U/W

HT

-38

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

GEN.

TIME DELAY

EFI RELAY

FUEL SELECTHIGH/LOW

START

DRIVE

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORM

PLATFORM

PRIMARY BOOM

RE

DT

ILT

AL

.

RE

DT

OS

TO

PS

W

P2

T1

TS3TS4

TS2

TS15

L3

CHECKENGINE

RPM

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9P3

WHT JIB CABLE

BP1

BP2

50

CR12

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

JIB

OPT.

RE

DF

RO

MC

R1

4


CR13

CR14

CR12

H.P.L.

T1

H1

BP2

TIME DELAY

TILT ALARM


EFI RELAY

JIB CUTOUT RELAY

JIB VALVE RELAY


DESCRIPTIONLABEL

TS2

TS7

TS9

TS3

P3

TS1

TS8

R3

L1

L3

TS10

TS12

R2

TS11

R1

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR


EFI RESISTOR

DRIVE ENABLE LED


JIB BOOM UP/DOWN



FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH

R1

R2 R3


+ _


Platform Control Box Wiring Diagram-Z-45/25J Ford Models (before serial number 13099)


Electrical Schematic, Z-45/25J Ford Models(from serial number 13099 to 16303)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

#2

3-C

.H.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

STA.

A

I

S

FLD.

REGULATOR

+

-

RED

RE

D#

20

-C.H

.

TB20

GRD.

BAT.

ALTERNATOR

LINK

FUSE

50

0

RE

LA

Y

BL

K/R

ED

#R

5-C

.H.

WH

T#

21

-E.H

.#1

OR

G/B

LK

#4

1-C

.H.

RE

D-E

.H.#

1

CR5CR5

BL

K/R

ED

#9

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1 RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLKBLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

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


TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

EN

GIN

E

TS64

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D#

27

-C.H

.

PR1

NO

RE

D/B

LK

#2

8-C

.H.

CR1NO

CR1

BL

K#

R1

-E.H

.#1

RD

/LG

FE

H(1

6A

)P

IN1

YE

L/B

LK

FE

H(6

74

)P

IN7

TA

N/B

LU

FE

H(3

06

)P

IN2

4

YF

EH

(37

B)

PIN

8

YF

EH

(37

)P

IN9

(GN

D)

BL

K/W

TF

EH

(57

0E

)P

IN4

2

PIN

K/L

GF

EH

(65

8)

PIN

6

WT

/PU

RF

EH

(20

9)

PIN

18

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

#2

3-E

.H.#

1

IGN./START

HM

TB38

MODULE

L2

TE

ST

TE

ST

RU

N

BL

U/W

HT

#3

8

WH

T#

21

GR

N/W

HT

#4

5-E

.H.#

1

FB

TS53

BL

K-1

BL

U/R

ED

-1

TB39

TP33 TP39TP38

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

WHT

TP25

TP24

REDFS1 REDBLK

TA

N/B

LU

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

NOTE:

L3

BL

U/W

HT

-1

(GN

D)

BL

K/W

TF

EH

(57

0C

)P

IN3

4

RE

D

CR13

CR14

LP

ONG

AS

OF

FG

EN

ER

AT

OR

FU

EL

FU

EL

GA

S

LP

BRN

RED

RED

WHT

BRN

WHT

ORG/BLK

DRIVE

SELECTOR

OPTION

RED

TS3

TS50

CH

EC

KE

NG

INE

LE

D

TP41

12 V

DC

TP21

SEE NOTE 1

1) The connection to TP24 is for units without generator option.

CHECK

ENGINE

ENGINE

CHECK

OP

TIO

N

CR14NO

LIF

T/D

RIV

ES

EL

EC

TO

R

OP

TIO

N(R

EQ

UIR

ED

FO

R

JIB

BO

OM

CU

TO

UT

RE

LA

Y(C

R1

3)

JIB

CU

TO

UT

RE

LA

Y

JIB

BO

OM

VA

LVE

RE

LA

Y(C

R-1

4)

JIB

VA

LVE

RE

LA

Y

JIB

BO

OM

VA

LVE

S

LO

WR

PM

JIB

VA

LVE

S

HIG

HR

PM

LO

WR

PM

FO

OT

SW

.H

/L

ENGINESPEED

ENGINE HARNESS #2

SEE NOTE 2


CE

MO

DE

LS

)


TILT

AL

AR

M

1

3

2

LIFT/

BL

K#

22

WH

T

RE

D

WH

T

BR

NB

LK

PIN

K/B

LK

FE

H(7

87

)P

IN5

PUMPFUEL

PK

/BL

KB

LK

FU

EL

PU

MP


1

2

3

4

5

6

7

8



LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T#

40

-5

BO

OM

RE

TR

AC

T

10

RIG

HT

LE

FT

PL

AT

RO

TA

TE

RIG

HT

LE

FT

PL

AT

RO

TA

TE

TS57

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

RED

WHT

ORG/BLK

WHT

BRN

CR9 NCCR9

TS7+

BR

N

TB19

GR

N/W

HT

-3

TP19 TP3

OR

G/B

LK

-3

UP

DO

WN

OR

G/B

LK

#1

5-M

.H.

OR

G#

14

-M.H

.

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

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

DO

WN

UP

JIB

BO

OM

DO

WN

UP

JIB

BO

OM

TP17

NCCR13

GR

N-3

TB17

TB18

GR

N/B

LK

-3

GR

N#

17

-M.H

.

GR

N/B

LK

#1

8-M

.H.

NC

CR8

TS9

TP15

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

L

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BL

U/W

HT

#1

2-M

.H.

BP2

PWM

A

+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

#11

-M.H

.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U#

10

-M.H

.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

#2

-M.H

.

RE

D/W

HT

#3

-M.H

.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

#5

-M.H

.

TB1

TB6

WH

T/R

ED

#6

-M.H

.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D#

1-M

.H.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

#8

-M.H

.

TB8

WH

T-3

TB5

HORSE-

LIMITER

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K#

7-M

.H.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T#

40

-4

WH

T#

40

-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

#2

9-C

.H.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

#3

7-M

.H.

BL

U#

36

-M.H

. RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT#12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

#3

1-C

.H.

WH

T/R

ED

#3

2-C

.H.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

TI

R4

TS8

TS58

R1

CR12

50

10

CE MODELS ONLY




Ground Control Box Wiring Diagram-Z-45/25J Ford Models (from serial number 13099 to 16303)


Ground Control Box Wiring Diagram-Z-45/25J Ford Models (from serial number 13099 to 16303)

1

2

3

4

5

6

7

8





STACKED CONTACTS

TS53


TS64

BR

N-G

RD

.

RU

N/T

ES

T

WHT#40-R7

CH+EH1

WHT-PRIM.#5

EH2

WHT-EXT.#6

BLK-S.P.

42ORG/RED-1

GRN/BLK-1

GRN-1


43

44

45

BLU/RED-1

ORG-1

ORG/BLK-1

WHT/RED-1

BLK-1

BLK/WHT-1

BLK/RED-1

BLU-1

BLU/BLK-1

BLU/WHT-1

BU/BK-M.H.

OG/BK-C.H.

PK/GR-EH#2

YEL/BLK-EH2

BLU-M.H.

WT/RD-C.H.

BR/BLU-EH2

41

38

39

40

37

36

34

35

32

33

(SPARE)

(SPARE)

(SPARE)

GENERATOR OPTION

LIQUID PROPANE FUEL

HIGH/LOW RPM

BRAKE

START ENGINE

(SPARE)


OFF-LIMIT SPEED

STEER LEFT

GLOW PLUG

STEER RIGHT

WHT-SEC.#4

BU/RD-S.P.

BU/WT-S.P.

OG/BK-ISM#2

BLK-ISM#3


RED TO EH2

RED-R1

BLU/BLK #11

BLK #33

BLU #10

RED #20

SEC.#4

BLK 25B

BR

NIS

M5

1

WHT ISM7

WHT 23B

WHT/PRP EH2

2

3

PRIM.#5

EXT#6

M.H.BLK-33D

MODULE

BLK/RED-C.H

BLK-TEST SW

WHT-TEST SW

RED-ISM#6

R/W-1

WHT-1

RED-1

BLK-2

WHT-2

RED/BLK-1

RD/WT-C.H.

WHT-ENA.

RED-C.H.

RD/BK-C.H.

RED-EXT.#6

RD/WT-C.H.

29

30

27

26

28

RED-ISM#4

24

25

22

23

21 WHT-E.H.#1

BLU/RED-3

BLU/WHT-3

GRN-3

ORG-3

ORG/BLK-3

ORG/RED-3

GRN/BLK-3

BLU-3

BLU/BLK-3

GRN/WHT-3

OR/BK-M.H

RED-ENA.

RED-C.H.

GRN-M.H

GRN/BLK-M.H

BLK-ENA.

BLU-M.H

BLU/BLK-M.H

15

19

20

17

18

16

12

13

10

11

14

E.D.C.

E.D.C.

2WD/4WD


(SPARE)


+12 V TO PLATFORM

KEYSWITCH POWER

IGNITION POWER

TILT ALARM

RED-S.P.

BLK-S.P.

WHT-S.P.

WHT-S.P.


JIB VALVE

DRIVE ENABLE LIGHT

PLATFORM ROTATE RIGHT/JIB DOWN

PLATFORM ROTATE LEFT/JIB UP

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP


SECONDARY BOOM DOWN

+12 V POWER

SECONDARY BOOM UP

OG/BK-S.P

GR/WT-S.P.

RED-S.P.

GRN-S.P.

GR/BK-S.P.

WHT#12-C.H.

BLU/WT-S.P.

BLU-S.P.

BU/BK-S.P.

ORG-S.P

10

BLK/WHT-3

WHT/RED-3

RED/BLK-3

RED-3

WHT-3

WHT/BLK-3

RED/WHT-3

BLK-3

BLK/RED-3

WHT-M.H

W/R-M.H

BLK/WHT-M.H

WHT/BLK-M.H

BLK-M.H

BLOCK

R/W-M.H

RED/BLK-M.H

RED-M.H

D C

4

8

5

6

7

9

3

1

2

B

BASE TERMINATION

RED-20C

BRN-GRD. TST. SW.

RED-27B

WHT-R2#86

WHT-TST. SW.7

9

8

3

4

6

5

ENG. FAULT

HORN





PRIMARY BOOM DOWN


PRIMARY BOOM EXTEND

PRIMARY BOOM UP

WHT-S.P.

BK/WT-S.P.

BLK-S.P.

WT/RD-S.P.

WT/BLK-S.P.

BK/RD-R5

RD/WT-S.P.

RED-S.P.

RD/BK-S.P.

A

IGN./FUEL ON

KEY BYPASS

KEY PWR.

START INPUT

AUX. ON

BATTERY

GROUND

WHT#21TO R2

CHECK

HOUR METER

TS54

BLK/RED #35

BLU/WHT #12

CB1

TS52

START

SECONDARYBOOM

CB2

2

3

1

TS60

ENGINE

BRN TO R4

BRN TO GRD

RED #27

WHT #21

BLK #22

WHT #23

L2 LE

D

ORG/BLK-41A

BLK-R1#861

2

IGN./START

START RELAY

TACHOMETER NO

NO

NO

NO

NC

STOP

P1

NC

KS1

GROUND CONTROL BOX

KS1

CR7 CR8





LEVEL

PLAT.

PLATFORM

ROTATE

TS57

ORG/BLK #15

GRN #17

ORG #14

(CE VERSION ONLY)

WHT-40



CR8

CR7

CR5

CR1

CR4

CR2

TS64

TS61

CB1

TS62

TS60

R4

HM

CB2

TURNTABLEROTATE

TS62

JIB

TS59

TS58

BOOM EXTEND/

TS63

UP/DOWNPRI. BOOM

TS61

FUEL SELECT

RETRACT

PRIMARY

WHT/BLK #5

GRN/WHT #19

GRN/BLK #18

WHT/RED #6

BLK/WHT #8

WHT #4

RED/BLK #2

RED #1

BLK #7

BLU/WHT #38

TS51

AUXILIARY PUMP

BLU/RED #39

RED/WHT #3

L2


CR1 CR2 CR5 CR4






CHECK ENGINE LED

SERVICE HORN RELAY

LPG LOCKOUT RELAY



RUN/TEST SWITCH

HOUR METER


TS58

LABEL

TS51

KS1

TS53

TS55

TS59

TS57

TS52

P1

JIB BOOM UP/DOWN

FUEL SELECT SWITCH



START ENGINE SWITCH


AUXILIARY SWITCH


KEY SWITCH

DESCRIPTION


GROUND STUD

(-12 VOLTS)

M.H.

R or CR

S.P.

MANIFOLD HARNESS

RELAY

SWITCH PANEL

EH#2

C.H.

EH#1


ENGINE HARNESS #1

CHASSIS HARNESS


HARNESS:WIRING

SPLICE

ORG-M.H.

ORG ORG/BLK

ORG/BLK-15

ORG-14

BLK-R4

RED-R4

GREEN-R4

BLK/RED-R5WHT-21

BLK-R1 TO E.H.#1

BLK-R1 TO ISM#1

RED-CB1

WHT-R2

BLK-22

BLK/RED-9

BRN TO H.M.

RD/GRN-EH#1

RED-R4

BLK-R4

BLK-1

BLK/RED-R5

ORG-R7

ORG/BLK-R8

GRN-R4

RED-E.H.#1

ORG/BLK-M.H.

BLK/RED-E.H.#1

GRN-E.H.#1

BLK-E.H.#1

BLK-E.H.#1

ORANGE-M.H.


H.M. HOUR METER

ISM

R4

+

(UNUSED)

Platform Control Box Wiring Diagram-Z-45/25J Ford Models (from serial number 13099 to 16303)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARM

TILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LV

E

L.P

.G

AS

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TIL

TA

LA

RM

RE

D/B

LK

-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

BL

U/R

ED

-39

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

BL

U/W

HT

-38

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

GEN.

TIME DELAY

LIMITING RELAY

FUEL SELECTHIGH/LOW

START

DRIVE

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

RE

DT

ILT

AL

.

RE

DT

OS

TO

PS

W

P2

T1

TS3TS4

TS2

TS15

L3

CHECKENGINE

RPM

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



WHT JIB CABLE

BP1

BP2

50

CR12

NO

NC

NONC

NC

NO

HORSE-POWERLIMITERBOARD

JIB

OPT.

RE

DF

RO

MC

R1

4

BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN, TURNTABLE ROTATEBP1

CR13

CR14

CR12

H.P.L.

T1

H1

BP2

TIME DELAY

TILT ALARM


EFI RELAY

JIB CUTOUT RELAY

JIB VALVE RELAY

BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN

DESCRIPTIONLABEL

TS2

TS7

TS9

TS3

P3

TS1

TS8

R3

L1

L3

TS10

TS12

R2

TS11

R1

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR


EFI RESISTOR

DRIVE ENABLE LED


JIBBOOM UP/DOWN



FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH

R1

R2 R3


(UN

US

ED

)

RED-10

ORG-40

WHT-24

RED-10

+ _


Platform Control Box Wiring Diagram-Z-45/25J Ford Models (from serial number 13099 to 16303)



Electrical Schematic, Z-45/25 Ford Models(after serial number 16303)

1

2

3

4

5

6

7

8



WH

T-2

RE

D/W

HT

-23

-C.H

.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

STA.

A

I

S

FLD.

REGULATOR

+

-

RED

RE

D#

20

-C.H

.

TB20

GRD.

BAT.

ALTERNATOR

LINK

FUSE

50

0

RE

LA

Y

BL

K/R

ED

-R5

-C.H

.

WH

T-2

1-E

.H.#

1

OR

G/B

LK

-41

-C.H

.

RE

D-E

.H.#

1

CR5CR5

BL

K/R

ED

-9

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLK-(FS)BLK

TP22

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

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


TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

EN

GIN

E

TS64

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D-2

7-C

.H.

PR1

NO

RE

D/B

LK

-28

-C.H

.

CR1NO

CR1

BL

K-R

1-E

.H.#

1

RD

/LG

FE

H(1

6A

)P

IN1

YE

L/B

LK

FE

H(6

74

)P

IN7

TA

N/B

LU

FE

H(3

06

)P

IN2

4

YF

EH

(37

B)

PIN

8

YF

EH

(37

)P

IN9

(GN

D)

BL

K/W

TF

EH

(57

0E

)P

IN4

2

PIN

K/L

GF

EH

(65

8)

PIN

6

WT

/PU

RF

EH

(20

9)

PIN

18

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T

PU

MP

PU

MP

AU

XIL

IAR

Y

AU

XIL

IAR

Y

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

-23

-E.H

.#1

IGN./START

HM

TB38

MODULE

L2

TE

ST

TE

ST

RU

N

BL

U/W

HT

-38

WH

T-2

1

GR

N/W

HT

-45

-E.H

.#1

FB

TS53

BL

K-1

BL

U/R

ED

-1

TB39

TP33 TP39TP38

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

TP25RED-(FS)FS1

TA

N/B

LU

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

L3

BL

U/W

HT

-1

(GN

D)

BL

K/W

TF

EH

(57

0C

)P

IN3

4

LP

OF

F

ON

GE

NE

RA

TO

R

GA

SF

UE

L

FU

EL

GA

S

LP

BRN

RED

RED

WHT

ORG/BLK

TS3

CH

EC

KE

NG

INE

LE

D

TP41

12 V

DC

TP24

CHECK

ENGINE

ENGINE

CHECK

OP

TIO

N

LO

WR

PM

HIG

HR

PM

LO

WR

PM

FO

OT

SW

.H

/L

ENGINESPEED

ENGINE HARNESS #2

(SEE PAGE 6)

TIL

TA

LA

RM

13

2

BL

K-2

2

WH

T

RE

D

WH

T

BR

NB

LK

PIN

K/B

LK

FE

H(7

87

)P

IN5

PUMPFUEL

PK

/BL

KB

LK

FU

EL

PU

MP

P2 RED

WHT

LOAD SENSE OPTION (SEE DETAIL)

WHT-(FS)

LOAD SENSE OPTION

8GND

OR

G-L

OA

D

TP22 FS1

BLK-(FS)

P2RED-(FS)

BLK-26 LOAD

WHT-(FS)

LOADSENSOR

B+

C

BOXWHT-LOAD WHT-24

TP24

BLK-26

TP26


1

2

3

4

5

6

7

8




LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T-4

0-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

LE

FT

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

ORG/BLK

WHT

BRN

TP3

OR

G/B

LK

-3

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

OR

G/B

LK

-15

-M.H

.

OR

G-1

4-M

.H.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

RIG

HT

LE

FT

PL

AT

RO

TA

TE

RIG

HT

PL

AT

RO

TA

TE

TP17

TS7

GR

N-3

TS57

TB17

TB18

GR

N/B

LK

-3

GR

N-1

7-M

.H.

GR

N/B

LK

-18

-M.H

.

NC

CR8

TS9

TP15

TS59

UP

DO

WN P

LA

TF

OR

ML

EV

EL

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BL

U/W

HT

-12

-M.H

.

BP2

PWM

A+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

-11-M

.H.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U-1

0-M

.H.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

-2-M

.H.

RE

D/W

HT

-3-M

.H.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

-5-M

.H.

TB1

TB6

WH

T/R

ED

-6-M

.H.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D-1

-M.H

.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

-8-M

.H.

TB8

WH

T-3

TB5

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K-7

-M.H

.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T-4

0-4

WH

T-4

0-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

-29

-C.H

.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

-37

-M.H

.

BL

U-3

6-M

.H.

RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT-12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

-31

-C.H

.

WH

T/R

ED

-32

-C.H

.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

R4

R1

CR12

50

10

REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY)

WHT

CE MODELS ONLY



Ground Control Box Wiring Diagram-Z-45/25 Ford Models (after serial number 16303)


Ground Control Box Wiring Diagram-Z-45/25 Ford Models (after serial number 16303)

1

2

3

4

5

6

7

8





STACKED CONTACTS

TS53


TS64

BR

N-G

RD

.

RU

N/T

ES

T

WHT#40-R7

CH+EH1

WHT-PRIM.#5

EH2

WHT-EXT.#6

BLK-S.P.

42ORG/RED-1

GRN/BLK-1

GRN-1


43

44

45

BLU/RED-1

ORG-1

ORG/BLK-1

WHT/RED-1

BLK-1

BLK/WHT-1

BLK/RED-1

BLU-1

BLU/BLK-1

BLU/WHT-1

BU/BK-M.H.

OG/BK-C.H.

PK/GR-EH#2

YEL/BLK-EH2

BLU-M.H.

WT/RD-C.H.

BR/BLU-EH2

41

38

39

40

37

36

34

35

32

33

(SPARE)

(SPARE)

(SPARE)

GENERATOR OPTION

LIQUID PROPANE FUEL

HIGH/LOW RPM

BRAKE

START ENGINE

(SPARE)


OFF-LIMIT SPEED

STEER LEFT

GLOW PLUG

STEER RIGHT

WHT-SEC.#4

BU/RD-S.P.

BU/WT-S.P.

OG/BK-ISM#2

BLK-ISM#3


RED TO EH2

RED-R1

BLU/BLK-11

BLK-33

BLU-10

RED-20

SEC.#4

BLK 25B

BR

NIS

M5

1

WHT ISM7

WHT 23B

WHT/PRP EH2

2

3

PRIM.#5

EXT#6

M.H.BLK-33D

MODULE

BLK/RED-C.H

BLK-TEST SW

WHT-TEST SW

RED-ISM#6

R/W-1

WHT-1

RED-1

BLK-2

WHT-2

RED/BLK-1

RD/WT-C.H.

WHT-ENA.

RED-C.H.

RD/BK-C.H.

RED-EXT.#6

RD/WT-C.H.

29

30

27

26

28

RED-ISM#4

24

25

22

23

21 WHT-E.H.#1

BLU/RED-3

BLU/WHT-3

GRN-3

ORG-3

ORG/BLK-3

ORG/RED-3

GRN/BLK-3

BLU-3

BLU/BLK-3

GRN/WHT-3

OR/BK-M.H

RED-ENA.

RED-C.H.

GRN-M.H

GRN/BLK-M.H

BLK-ENA.

BLU-M.H

BLU/BLK-M.H

15

19

20

17

18

16

12

13

10

11

14

E.D.C.

E.D.C.

2WD/4WD


(SPARE)


+12 V TO PLATFORM

KEYSWITCH POWER

IGNITION POWER

TILT ALARM

RED-S.P.

BLK-S.P.

WHT-S.P.

WHT-S.P.


JIB VALVE

DRIVE ENABLE LIGHT



PLATFORM LEVEL DOWN

PLATFORM LEVEL UP


SECONDARY BOOM DOWN

+12 V POWER

SECONDARY BOOM UP

OG/BK-S.P

GR/WT-S.P.

RED-S.P.

GRN-S.P.

GR/BK-S.P.

WHT#12-C.H.

BLU/WT-S.P.

BLU-S.P.

BU/BK-S.P.

ORG-S.P

10

BLK/WHT-3

WHT/RED-3

RED/BLK-3

RED-3

WHT-3

WHT/BLK-3

RED/WHT-3

BLK-3

BLK/RED-3

WHT-M.H

W/R-M.H

BLK/WHT-M.H

WHT/BLK-M.H

BLK-M.H

BLOCK

R/W-M.H

RED/BLK-M.H

RED-M.H

D C

4

8

5

6

7

9

3

1

2

B

BASE TERMINATION

RED-20C

BRN-GRD. TST. SW.

RED-27B

WHT-R2#86

WHT-TST. SW.7

9

8

3

4

6

5

ENG. FAULT

HORN





PRIMARY BOOM DOWN


PRIMARY BOOM EXTEND

PRIMARY BOOM UP

WHT-S.P.

BK/WT-S.P.

BLK-S.P.

WT/RD-S.P.

WT/BLK-S.P.

BK/RD-R5

RD/WT-S.P.

RED-S.P.

RD/BK-S.P.

A

IGN./FUEL ON

KEY BYPASS

KEY PWR.

START INPUT

AUX. ON

BATTERY

GROUND

WHT-21TO R2

CHECK

HOUR METER

TS54

BLK/RED-35

BLU/WHT-12

CB1

TS52

START

SECONDARYBOOM

CB2

2

3

1

TS60

ENGINE

BRN TO R4

BRN TO GRD

RED-27

WHT-21

BLK-22

WHT-23

L2 LE

D

ORG/BLK-41A

BLK-R1#861

2

IGN./START

START RELAY

TACHOMETER NO

NO

NO

NO

NC

STOP

P1

NC

KS1

GROUND CONTROL BOX

KS1

CR7 CR8





LEVEL

PLAT.

PLATFORM

ROTATE

TS57

ORG/BLK-15

GRN-17

ORG-14

(CE VERSION ONLY)

WHT-40



CR8

CR7

CR5

CR1

CR4

CR2

TS64

TS61

CB1

TS62

TS60

R4

HM

CB2

TURNTABLEROTATE

TS62

TS59

BOOM EXTEND/

TS63

UP/DOWNPRIMARY BOOM

TS61

FUEL SELECT

RETRACT

PRIMARY

WHT/BLK-5

GRN/WHT-19

GRN/BLK-18

WHT/RED-6

BLK/WHT-8

WHT-4

RED/BLK-2

RED-1

BLK-7

BLU/WHT-38

TS51

AUXILIARY PUMP

BLU/RED-39

RED/WHT-3

L2


CR1 CR2 CR5 CR4






CHECK ENGINE LED

HORN RELAY

LPG LOCKOUT RELAY



RUN/TEST SWITCH

HOUR METER


LABEL

TS51

KS1

TS53

TS55

TS59

TS57

TS52

P1

FUEL SELECT SWITCH



START ENGINE SWITCH


AUXILIARY SWITCH


KEY SWITCH

DESCRIPTION


GROUND STUD

(-12 VOLTS)

M.H.

R or CR

S.P.

MANIFOLD HARNESS

RELAY

SWITCH PANEL

EH#2

C.H.

EH#1


ENGINE HARNESS #1

CHASSIS HARNESS


HARNESS:WIRING

SPLICE

ORG-M.H.

ORG ORG/BLK

ORG/BLK-15

ORG-14

BLK-R4

RED-R4

GREEN-R4

BLK/RED-R5WHT-21

BLK-R1 TO E.H.#1

BLK-R1 TO ISM#1

RED-R1

WHT-R2

BLK-22

BLK/RED-9

BRN TO H.M.

RD/GRN-EH#1

RED-R4

BLK-R4

BLK-1

BLK/RED-R5

ORG-R7

ORG/BLK-R8

GRN-R4

RED-E.H.#1

ORG/BLK-M.H.

BLK/RED-E.H.#1

GRN-E.H.#1

BLK-E.H.#1

BLK-E.H.#1

ORANGE-M.H.


H.M. HOUR METER

ISM

R4

+

(UNUSED)

BLK/RED-35GEN

BLK/RED-35GEN

Platform Control Box Wiring Diagram-Z-45/25 Ford Models (after serial number 16303)




5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARM

TILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.

PW

R.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.

LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.

(OP

TIO

N)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.

BO

OM

DN

.

SE

C.

BO

OM

UP

PW

R.

TO

F.S

.

F.S

.U

PP

OW

ER

PW

R.

(CO

NT.)

PL

AT.

RO

T.

R.

PL

AT.

RO

T.

L.

PL

AT.

LE

VE

LD

N.

PL

AT.

LE

VE

LU

P

TU

RN

.R

OT.

F.C

.

TU

RN

RO

T.

R.

TU

RN

RO

T.

L.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

F.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.

BO

OM

F.C

.

JIB

VA

LVE

L.P

.G

AS

BR

AK

E

AU

X.

PU

MP

SE

L.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

BL

U/R

ED

-39

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

RE

D/W

HT

-3

BL

U/W

HT

-38

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

GEN.

LIMITING RELAY

FUEL SELECTHIGH/LOW

START

DRIVE

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

P2

TS3TS4

TS2

TS15

L3

CHECKENGINE

RPM

L1

DRIVESPEED

TS1

TS14

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



BP1

BP2

50

CR12

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

OPT.

BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN ,TURNTABLE ROTATEBP1

CR12

H.P.L.

H1

BP2

TILT ALARM


EFI RELAY


COMPONENT INDEX

TS2

TS7

TS9

TS3

P3

TS1

R3

L1

L3

TS10

TS12

R2

TS11

R1

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR


EFI RESISTOR

DRIVE ENABLE LED




FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH

R1

R2 R3

(UN

US

ED

)

RE

D-G

EN

GR

N/W

HT

-45

ORG-40

RED-10

RED-10

WHT-24

DP1 DRIVE PROPORTIONAL JOYSTICK

DP1

TS47

TS47 GENERATOR SWITCH ( OPTION )

8

7

6

54

3

21

WHT TO PLATFORM ROTATE

SEESIDE VIEW

DP1

SIDE VIEW OF DP1

RE

D-T

ILT

RE

D-T

ILT

+ _

1

2

3

4

5

6

7

8

Platform Control Box Wiring Diagram-Z-45/25 Ford Models (after serial number 16303)



Electrical Schematic, Z-45/25J Ford Models(after serial number 16303)

1

2

3

4

5

6

7

8



WH

T-2

RE

D/W

HT

-23

-C.H

.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

STA.

A

I

S

FLD.

REGULATOR

+

-

RED

RE

D#

20

-C.H

.

TB20

GRD.

BAT.

ALTERNATOR

LINK

FUSE

50

0

RE

LA

Y

BL

K/R

ED

-R5

-C.H

.

WH

T-2

1-E

.H.#

1

OR

G/B

LK

-41

-C.H

.

RE

D-E

.H.#

1

CR5CR5

BL

K/R

ED

-9

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLK-(FS)BLK

TP22

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

N

HO

UR

ME

TE

R

RU

N/T

ES

TS

WIT

CH

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


TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

EN

GIN

E

TS64

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D-2

7-C

.H.

PR1

NO

RE

D/B

LK

-28

-C.H

.

CR1NO

CR1

BL

K-R

1-E

.H.#

1

RD

/LG

FE

H(1

6A

)P

IN1

YE

L/B

LK

FE

H(6

74

)P

IN7

TA

N/B

LU

FE

H(3

06

)P

IN2

4

YF

EH

(37

B)

PIN

8

YF

EH

(37

)P

IN9

(GN

D)

BL

K/W

TF

EH

(57

0E

)P

IN4

2

PIN

K/L

GF

EH

(65

8)

PIN

6

WT

/PU

RF

EH

(20

9)

PIN

18

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T

PU

MP

PU

MP

AU

XIL

IAR

Y

AU

XIL

IAR

Y

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

-23

-E.H

.#1

IGN./START

HM

TB38

MODULE

L2

TE

ST

TE

ST

RU

N

BL

U/W

HT

-38

WH

T-2

1

GR

N/W

HT

-45

-E.H

.#1

FB

TS53

BL

K-1

BL

U/R

ED

-1

TB39

TP33 TP39TP38

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

TP25RED-(FS)FS1

TA

N/B

LU

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

.

TS4

TP35

L3

BL

U/W

HT

-1

(GN

D)

BL

K/W

TF

EH

(57

0C

)P

IN3

4

RE

D

CR13

CR14

LP

GA

SF

UE

L

ON

OF

FG

EN

ER

AT

OR

FU

EL

GA

S

LP

BRN

RED

RED

BRN

WHT

ORG/BLK

RED

TS3

CH

EC

KE

NG

INE

LE

D

TP41

12 V

DC

TP24

CHECK

ENGINE

ENGINE

CHECK

OP

TIO

N

CR14NO

JIB

BO

OM

CU

TO

UT

RE

LA

Y(C

R1

3)

JIB

CU

TO

UT

RE

LA

Y

JIB

BO

OM

VA

LVE

RE

LA

Y(C

R-1

4)

JIB

VA

LVE

RE

LA

Y

JIB

BO

OM

VA

LVE

S

LO

WR

PM

JIB

VA

LVE

S

HIG

HR

PM

LO

WR

PM

FO

OT

SW

.H

/L

ENGINESPEED

ENGINE HARNESS #2

(SEE PAGE 6)

TIL

TA

LA

RM

13

2

BL

K-2

2

WH

T

RE

D

WH

T

BR

NB

LK

PIN

K/B

LK

FE

H(7

87

)P

IN5

PUMPFUEL

PK

/BL

KB

LK

FU

EL

PU

MP

P2 RED

WHT

LOAD SENSE OPTION (SEE DETAIL)

WHT-(FS)

LOAD SENSE OPTION

8GND

OR

G-L

OA

D

TP22FS1

BLK-(FS)

P2RED-(FS)

BLK-26 LOAD

WHT-(FS)

B+

C

LOADSENSORBOX

WHT-LOAD WHT-24TP24

BLK-26

TP26





LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T-4

0-5

BO

OM

RE

TR

AC

T

10

RIG

HT

LE

FT

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

PL

AT

FO

RM

RO

TA

TE

TS57

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

RED

WHT

ORG/BLK

WHT

BRN

CR9NC

CR9

TS7+

BR

N

TB19

GR

N/W

HT

-3

TP19TP3

OR

G/B

LK

-3

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

OR

G/B

LK

-15

-M.H

.

OR

G-1

4-M

.H.

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

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

DO

WN

UP

JIB

BO

OM

DO

WN

UP

JIB

BO

OM

TP17

NCCR13

GR

N-3

TB17

TB18

GR

N/B

LK

-3

GR

N-1

7-M

.H.

GR

N/B

LK

-18

-M.H

.

NC

CR8

TS9

TP15

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BL

U/W

HT

-12

-M.H

.

BP2

PWM

A+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

-11-M

.H.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U-1

0-M

.H.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

-2-M

.H.

RE

D/W

HT

-3-M

.H.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

-5-M

.H.

TB1

TB6

WH

T/R

ED

-6-M

.H.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D-1

-M.H

.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

-8-M

.H.

TB8

WH

T-3

TB5

HORSE-

LIMITER

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K-7

-M.H

.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T-4

0-4

WH

T-4

0-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

-29

-C.H

.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

-37

-M.H

.

BL

U-3

6-M

.H.

RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT-12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

-31

-C.H

.

WH

T/R

ED

-32

-C.H

.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

TI

R4

TS8

TS58

R1

CR12

50

10


WHT

CE MODELS ONLY

1

2

3

4

5

6

7

8



Ground Control Box Wiring Diagram-Z-45/25J Ford Models (after serial number 16303)


Ground Control Box Wiring Diagram-Z-45/25J Ford Models (after serial number 16303)

1

2

3

4

5

6

7

8





STACKED CONTACTS

TS53


TS64

BR

N-G

RD

.

RU

N/T

ES

T

WHT#40-R7

CH+EH1

WHT-PRIM.#5

EH2

WHT-EXT.#6

BLK-S.P.

42ORG/RED-1

GRN/BLK-1

GRN-1


43

44

45

BLU/RED-1

ORG-1

ORG/BLK-1

WHT/RED-1

BLK-1

BLK/WHT-1

BLK/RED-1

BLU-1

BLU/BLK-1

BLU/WHT-1

BU/BK-M.H.

OG/BK-C.H.

PK/GR-EH#2

YEL/BLK-EH2

BLU-M.H.

WT/RD-C.H.

BR/BLU-EH2

41

38

39

40

37

36

34

35

32

33

(SPARE)

(SPARE)

(SPARE)

GENERATOR OPTION

LIQUID PROPANE FUEL

HIGH/LOW RPM

BRAKE

START ENGINE

(SPARE)


OFF-LIMIT SPEED

STEER LEFT

GLOW PLUG

STEER RIGHT

WHT-SEC.#4

BU/RD-S.P.

BU/WT-S.P.

OG/BK-ISM#2

BLK-ISM#3


RED TO EH2

RED-R1

BLU/BLK-11

BLK-33

BLU-10

RED-20

SEC.#4

BLK 25B

BR

NIS

M5

1

WHT ISM7

WHT 23B

WHT/PRP EH2

2

3

PRIM.#5

EXT#6

M.H.BLK-33D

MODULE

BLK/RED-C.H

BLK-TEST SW

WHT-TEST SW

RED-ISM#6

R/W-1

WHT-1

RED-1

BLK-2

WHT-2

RED/BLK-1

RD/WT-C.H.

WHT-ENA.

RED-C.H.

RD/BK-C.H.

RED-EXT.#6

RD/WT-C.H.

29

30

27

26

28

RED-ISM#4

24

25

22

23

21 WHT-E.H.#1

BLU/RED-3

BLU/WHT-3

GRN-3

ORG-3

ORG/BLK-3

ORG/RED-3

GRN/BLK-3

BLU-3

BLU/BLK-3

GRN/WHT-3

OR/BK-M.H

RED-ENA.

RED-C.H.

GRN-M.H

GRN/BLK-M.H

BLK-ENA.

BLU-M.H

BLU/BLK-M.H

15

19

20

17

18

16

12

13

10

11

14

E.D.C.

E.D.C.

2WD/4WD


(SPARE)


+12 V TO PLATFORM

KEYSWITCH POWER

IGNITION POWER

TILT ALARM

RED-S.P.

BLK-S.P.

WHT-S.P.

WHT-S.P.


JIB VALVE

DRIVE ENABLE LIGHT



PLATFORM LEVEL DOWN

PLATFORM LEVEL UP


SECONDARY BOOM DOWN

+12 V POWER

SECONDARY BOOM UP

OG/BK-S.P

GR/WT-S.P.

RED-S.P.

GRN-S.P.

GR/BK-S.P.

WHT#12-C.H.

BLU/WT-S.P.

BLU-S.P.

BU/BK-S.P.

ORG-S.P

10

BLK/WHT-3

WHT/RED-3

RED/BLK-3

RED-3

WHT-3

WHT/BLK-3

RED/WHT-3

BLK-3

BLK/RED-3

WHT-M.H

W/R-M.H

BLK/WHT-M.H

WHT/BLK-M.H

BLK-M.H

BLOCK

R/W-M.H

RED/BLK-M.H

RED-M.H

D C

4

8

5

6

7

9

3

1

2

B

BASE TERMINATION

RED-20C

BRN-GRD. TST. SW.

RED-27B

WHT-R2#86

WHT-TST. SW.7

9

8

3

4

6

5

ENG. FAULT

HORN





PRIMARY BOOM DOWN


PRIMARY BOOM EXTEND

PRIMARY BOOM UP

WHT-S.P.

BK/WT-S.P.

BLK-S.P.

WT/RD-S.P.

WT/BLK-S.P.

BK/RD-R5

RD/WT-S.P.

RED-S.P.

RD/BK-S.P.

A

IGN./FUEL ON

KEY BYPASS

KEY PWR.

START INPUT

AUX. ON

BATTERY

GROUND

WHT-21TO R2

CHECK

HOUR METER

TS54

BLK/RED-35

BLU/WHT-12

CB1

TS52

START

SECONDARYBOOM

CB2

2

3

1

TS60

ENGINE

BRN TO R4

BRN TO GRD

RED-27

WHT-21

BLK-22

WHT-23

L2 LE

D

ORG/BLK-41A

BLK-R1#861

2

IGN./START

START RELAY

TACHOMETER NO

NO

NO

NO

NC

STOP

P1

NC

KS1

GROUND CONTROL BOX

KS1

CR7 CR8





LEVEL

PLAT.

PLATFORM

ROTATE

TS57

ORG/BLK-15

GRN-17

ORG-14

(CE MODELS ONLY)

WHT-40



CR8

CR7

CR5

CR1

CR4

CR2

TS64

TS61

CB1

TS62

TS60

R4

HM

CB2

TURNTABLEROTATE

TS62

JIB

TS59

TS58

BOOM EXTEND/

TS63

UP/DOWNPRI. BOOM

TS61

FUEL SELECT

RETRACT

PRIMARY

WHT/BLK-5

GRN/WHT-19

GRN/BLK-18

WHT/RED-6

BLK/WHT-8

WHT-4

RED/BLK-2

RED-1

BLK-7

BLU/WHT-38

TS51

AUXILIARY PUMP

BLU/RED-39

RED/WHT-3

L2


CR1 CR2 CR5 CR4






CHECK ENGINE LED

HORN RELAY

LPG LOCKOUT RELAY



RUN/TEST SWITCH

HOUR METER


TS58

LABEL

TS51

KS1

TS53

TS55

TS59

TS57

TS52

P1

JIB BOOM UP/DOWN

FUEL SELECT SWITCH



START ENGINE SWITCH


AUXILIARY SWITCH


KEY SWITCH

DESCRIPTION


GROUND STUD

(-12 VOLTS)

M.H.

R or CR

S.P.

MANIFOLD HARNESS

RELAY

SWITCH PANEL

EH#2

C.H.

EH#1


ENGINE HARNESS #1

CHASSIS HARNESS


HARNESS:WIRING

SPLICE

ORG-M.H.

ORG ORG/BLK

ORG/BLK-15

ORG-14

BLK-R4

RED-R4

GREEN-R4

BLK/RED-R5WHT-21

BLK-R1 TO E.H.#1

BLK-R1 TO ISM#1

RED-R1

WHT-R2

BLK-22

BLK/RED-9

BRN TO H.M.

RD/GRN-EH#1

RED-R4

BLK-R4

BLK-1

BLK/RED-R5

ORG-R7

ORG/BLK-R8

GRN-R4

RED-E.H.#1

ORG/BLK-M.H.

BLK/RED-E.H.#1

GRN-E.H.#1

BLK-E.H.#1

BLK-E.H.#1

ORANGE-M.H.


H.M. HOUR METER

ISM

R4

+

(UNUSED)

BLK/RED-35GEN

BLK/RED-35GEN

Platform Control Box Wiring Diagram-Z-45/25J Ford Models (after serial number 16303)




1

2

3

4

5

6

7

8

5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.

PW

R.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.

LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.

(OP

TIO

N)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.

BO

OM

DN

.

SE

C.

BO

OM

UP

PW

R.

TO

F.S

.

F.S

.U

PP

OW

ER

PW

R.

(CO

NT.)

PL

AT.

RO

T.

R.

PL

AT.

RO

T.

L.

PL

AT.

LE

VE

LD

N.

PL

AT.

LE

VE

LU

P

TU

RN

.R

OT.

F.C

.

TU

RN

RO

T.

R.

TU

RN

RO

T.

L.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.

BO

OM

F.C

.

JIB

VA

LVE

L.P

.G

AS

BR

AK

E

AU

X.

PU

MP

SE

L.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

BL

U/R

ED

-39

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

BL

U/W

HT

-38

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

GEN.

TIME DELAY

LIMITING RELAY

FUEL SELECTHIGH/LOW

START

DRIVE

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

RE

D-T

ILT

RE

D-S

TP

P2

T1

TS3TS4

TS2

TS15

L3

CHECKENGINE

RPM

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



WHT JIB CABLE

BP1

BP2

50

CR12

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

JIB

OPT.

RE

DF

RO

MC

R1

4

BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN ,TURNTABLE ROTATEBP1

CR13

CR14

CR12

H.P.L.

T1

H1

BP2

TIME DELAY

TILT ALARM


EFI RELAY

JIB CUTOUT RELAY

JIB VALVE RELAY


COMPONENT INDEX

TS2

TS7

TS9

TS3

P3

TS1

TS8

R3

L1

L3

TS10

TS12

R2

TS11

R1

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR


EFI RESISTOR

DRIVE ENABLE LED


JIB BOOM UP/DOWN



FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH

R1

R2 R3

(UN

US

ED

)

RE

D-G

EN

GR

N/W

HT

-45

ORG-40

RED-10

RED-10

WHT-24


DP1

TS47


8

7

6

54

3

21


SEE SIDEVIEW DP1

SIDE VIEW FOR DP1

RE

D-T

ILT

RE

D-S

TP

+ _

Platform Control Box Wiring Diagram-Z-45/25J Ford Models (after serial number


Electrical Schematic, Z-45/25 Deutz Models(before serial number 13099)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

#2

3-E

.H.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

+

-

RED

RE

D#

20

-E.H

.

TB20

RE

LA

Y

BL

K/R

ED

#R

5-E

.H.

WH

T#

21

-E.H

.

OR

G/B

LK

#4

1-E

.H. CR5

CR5

BL

K/R

ED

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLKBLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

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

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

PUMP

RE

LA

Y

PR1

RE

D#

27

-E.H

.

PR1

NO

RE

D/B

LK

#2

8-E

.H.

CR1

NO

CR1

BL

K#

R1

-E.H

.

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

TP27TP28

TS52

BL

K

12

TB33

3 RE

D/W

HT

#2

3-E

.H.

IGN./STARTMODULE

WH

T#

21

GR

N/W

HT

#4

5-E

.H.

FB

BL

K-1

TP33

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

WHT

TP25

TP24

REDFS1 REDBLK

BL

K/R

ED

TS54

BL

K/R

ED

-1

HIG

HR

PM

FO

OT

SW

.H

/LH

IGH

RP

M

TS4

TP35

BRN

RED

RED

WHT

WHT

ORG/BLK

DRIVE

SELECTOR

OPTION

TS50

OIL

TE

MP

ER

AT

UR

EL

ED

TP41

12 V

DC

TP21

REG.IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

WH

T/R

ED

WH

T/B

LK

L2

L3

OIL

PRES.

OIL

TEMP.

WH

T/B

LK

#2

5E

.H.

WH

T/R

ED

#2

6E

.H.

OPS

NCOTS

NO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

BL

K

TB34

TS56

BL

K-1

GL

OW

PL

UG

OF

F

ON

GE

NE

RA

TO

R

GL

OW

PL

UG

TP34

TS6

GL

OW

PL

UG

OP

TIO

N

PR2

NO

CR4CR4

CR3

CR3NO

BL

K/R

ED

#R

4-E

.H.

PR2

NO

BL

K/W

HT

#3

4-E

.H.

OP

TIO

N

RP

MS

OL

EN

OID

HIG

HID

LE

RE

LA

Y

HIG

HID

LE

CU

TO

UT

RE

LA

Y

ENGINE

SPEED

LO

WR

PM

LO

WR

PM

LIF

T/D

RIV

ES

EL

EC

TO

R

OP

TIO

N(R

EQ

UIR

ED

FO

R

CE

MO

DE

LS

)

TIL

TA

LA

RM

LIFT/

BL

K#

22

WH

T

STA

RT

EN

GIN

E

STARTERAUX

STA

RT

EN

GIN

E

FU

NC

TIO

NE

NA

BL

E

HM

1

2

3


1

2

3

4

5

6

7

8



LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T#

40

-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

WHT

ORG/BLK

WHT

BRN

TP3

OR

G/B

LK

-3

OR

G/B

LK

#1

5-M

.H.

OR

G#

14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP17TP18

TS8

GR

N-3

TS58

TB18

TB17

GR

N/B

LK

-3

GR

N#

17

-M.H

.

GR

N/B

LK

#1

8-M

.H.

NC

CR8

TS9

TP15

TS59

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

CR7NC

TB12

BL

U/W

HT

#1

2-M

.H.

BP2

PWM

A+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

#11

-M.H

.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U#

10

-M.H

.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

10

R5

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

#2

-M.H

.

RE

D/W

HT

#3

-M.H

.

-+A

PWM

BP1

15

R4

R

X

TS62

WH

T/B

LK

#5

-M.H

.

TB1

TB6

WH

T/R

ED

#6

-M.H

.

TB5

RE

D#

1-M

.H.

BO

OM

EX

TE

ND

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

#8

-M.H

.

TB8

WH

T-3

TB4

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K#

7-M

.H.

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T#

40

-4

WH

T#

40

-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

#2

9-C

.H.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

#3

7-M

.H.

BL

U#

36

-M.H

. OR

G/R

ED

#1

6-C

.H.

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT#12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T#

30

-C.H

.

TB31

WH

T/B

LK

#3

1-C

.H.

WH

T/R

ED

#3

2-C

.H.

TB32

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

U/R

ED

#1

3-C

.H.

BR

N

MODELS ONLY)

(2WD/4WD)

LS4

UP

DO

WN P

LA

TF

OR

ML

EV

EL

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

UP

DO

WN

PR

IMA

RY

BO

OM

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

EX

TE

ND

RE

TR

AC

TB

OO

M

EX

TE

ND

RE

TR

AC

T BO

OM

DR

IVE

EN

AB

LE

CE MODELS ONLY




Ground Control Box Wiring Diagram- Z-45/25 Deutz Models (before serial number 13099)


Ground Control Box Wiring Diagram-Z-45/25 Deutz Models (before serial number 13099)

1

2

3

4

5

6

7

8




AUXILIARY

TS63

PLAT.BLU/BLK #11

RED-R1

RED #20

R5

LEVEL

BLU #10

BLK/RED #35

BLK #33

BRN TO GRD

WHT #21

WHT #23

BLK #22

RED #27

TS60TS62

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS59

CB2

SEC. BOOM

OIL PRESS

TS57

PRIMARY BOOM

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1 KS1

ROTATE

ORG/BLK #15

ORG #14

PLATFORM

ROTATETURNTABLE

EXTENDRETRACT

GRN #17

GRN/BLK #18

WHT/RED #6

WHT/BLK #5

WHT #4

BLK/WHT #8

RED/BLK #2

RED/WHT #3

BLK #7

RED #1

WHT/BLK # 25

9 BK/RD-R5BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

CD

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4

RED/BLK-4

R/W-4

WHT-4

WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1#86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2 # 30

PRI. BOOM UP

BOOM EXTEND

TURN. ROT. F.C.

PRI. BOOM DOWN

PRI. BOOM F.C.

TURN. ROT. L

TURN. ROT. R

BOOM RETRACT

AB

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM#7

RED-ISM#4

28RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3

BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

BLU/WHT-4

GRN/BLK-4

ORG/BLK-4/R8

WHT#12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.#6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1

GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SEC. BOOM UP

12V BATT. SUPPLY

SEC. BOOM DN

DRV. ENA.

PLAT. LEVEL. UP

PLAT. LEVEL DN.

PLAT. ROT. L.

PLAT. ROT. R.

DRV. ENA. LT.

IGNITION PWR.

KEYSWITCH PWR.

PWR. TO PLAT.

OIL PRESSURE SENDER

WATER TEMP. SENDER

GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE

AUX. PWR.

STEER LEFT

GLOW PLUG

STEER RIGHT

LIMIT SWITCH SIG.

PULSE PICKUP

GEN. OPTION

BK/RD-R3#35

BLK-S.P.BLK-ISM#3

TEST LIGHT

START

2WD/4WD

E.D.C.

E.D.C.

BRAKE

RPM

L.P.

SPARE

SPARE

SPARE

BLU/WHT #12

SEC. BOOM F.C.

RE

D

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED#R4-EH

WHT-40B

BRN GRND H.M

CR4CR3

BLK/RED#35B

WHT#21

CR2

BLK#R1-E.H

CR1

BLK-ISM#1

RED-CB1

WHT-ISM#9

ORG-4

CR7


BRN TO R4

GRN/WHT #19BLK/RED#R5-AH

BLK#22

BLK/RED-9A

RED-ISM#6

WHT#21TO R2

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

BLK-SEC#4R

ED

WHT/RED #26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM#10

BLU/RED-C.H

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-30 C.H

WHT/RED-C.H

WHT-24D

WHT-E.H.1

BLK/RED-EH BLK/RED-R4


BLK-E.H BLK-R1

ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

R4

WHT-EXT.#6

ORG/RED-C.H

2

ORG-M.H

ORG/BLK-M.H

ORG-R7

ORG/BLK-R8

BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMSR5

CR2

CR3

CR1

CR4

CR7

CR8

L2



RPM SOLENOID RELAY


POWER RELAY

HIGH IDLE CUTOUT RELAY

OIL PRESSURE LED

DESCRIPTIONLABEL

TS52

TS57

TS59

TS54

KS1

TS51

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1







HOUR METER





KEY SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH

OIL TEMPERATURE LEDL3

HORN RELAYCR5

ENGINE HARNESSEH

HOUR METER


CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR RELAY

C.H.

S.P.

M.H.


ENGINE FAULT

(CE MODELS ONLY)

GROUND CONTROL SWITCH PANELGROUND CONTROL BOX

BASE TERMINATION BLOCK

CR5

Platform Control Box Wiring Diagram- Z-45/25 Deutz Models (before serial number 13099)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24


14

23

PW

R.F

RM

PL

AT.

PW

R.T

OP

LA

T.

DR

V.E

NA

.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

G.O

PT.

DR

V.E

NA

.

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

PW

R.(S

TA

RT

)

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.LV

L.D

N.

PL

AT.LV

L.U

P

SW

ING

F.C

.

SW

ING

RIG

HT

SW

ING

LE

FT

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DN

.

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

F.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

EX

TE

ND

HO

RN

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LVE

L.P

.

BR

AK

E

AU

X.P

WR

.

E.D

.C.

E.D

.C.

2W

D/4

WD

RP

M

STA

RT

EN

GIN

EF

AU

LT

SP

AR

E

SP

AR

E

SP

AR

E

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

OG/BK-41

ORG-40

RED-10

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6GEN.

HIGH/LOW

START

DRIVEDP1

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)


AUXILIARY PUMP

PRIMARY

PLATFORM

PLATFORM

PRIMARY BOOM

P2

TS4

TS2

TS15

RPM

L1

DRIVESPEED

TS1

R2 R3

TS14

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9P3

BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

OPT.


CR12

H.P.L.

T1

H1

BP2

TIME DELAY

TILT ALARM


EFI RELAY


DESCRIPTIONLABEL

TS2

TS7

TS9

TS6

P3

TS1

R3

L1

TS10

TS12

R2

TS11

TS13

P2


LOW SPEED RESISTOR


LOW SPEED RESISTOR


DRIVE ENABLE LED


GLOW PLUG OPTION



HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


+ _


Platform Control Box Wiring Diagram- Z-45/25 Deutz Models (before serial number 13099)


Electrical Schematic, Z-45/25 Deutz Models(from serial number 13099 to 16303)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

#2

3-E

.H.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

+

-

RED

RE

D#

20

-E.H

.

TB20

RE

LA

Y

BL

K/R

ED

#R

5-E

.H.

WH

T#

21

-E.H

.

OR

G/B

LK

#4

1-E

.H. CR5

CR5

BL

K/R

ED

N.O.

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLKBLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

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

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

GL

OW

PL

UG

GL

OW

PL

UG

EN

GIN

E

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D#

27

-E.H

.

PR1

N.O.

RE

D/B

LK

#2

8-E

.H.

CR1

N.O.

CR1

BL

K#

R1

-E.H

.

TB21

TB25

N.O.

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

TB27TB28

RE

D

TS1

WH

T

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

#2

3-E

.H.

IGN./STARTMODULE

WH

T#

21

GR

N/W

HT

#4

5-E

.H.

FB

BL

K-1

TP33

TB45

GR

N/W

HT

-1G

EN

ER

AT

OR

ON

OF

F

TS47

TP45

RED

WHT

WHT

TP25

TP24

REDFS1 REDBLK

BL

K/R

ED

TS54

BL

K/R

ED

-1

HIG

HR

PM

HIG

HR

PM

FO

OT

SW

.H

/L

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

NOTE:

BRN

RED

RED

WHT

WHT

ORG/BLK

DRIVE

SELECTOR

OPTION

TS50

OIL

TE

MP

ER

AT

UR

EL

ED

TP41

12 VDC

TP21

SEE NOTE 1

1) The connection to TP24 is for units without the generator option.

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

WH

T/R

ED

WH

T/B

LK

L2

L3

OIL

PRES.

OIL

TEMP.

WH

T/B

LK

#2

5E

.H.

WH

T/R

ED

#2

6E

.H.

OPS

N.C. OILTEMPERATURE

SWITCHN.O.

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

BL

K

TB34

TS56

BL

K-1

TP34

TS6

PR2

.NO.CR4

CR4

CR3

CR3N.O.

BL

K/R

ED

#R

4-E

.H.

PR2

N.O.

BL

K/W

HT

#3

4-E

.H.

OP

TIO

N

RP

MS

OL

EN

OID

HIG

HID

LE

RE

LA

Y

HIG

HID

LE

CU

TO

UT

RE

LA

Y

ENGINE

SPEED

LO

WR

PM

LO

WR

PM

SEE NOTE 2


LIF

T/D

RIV

ES

EL

EC

TO

R

OP

TIO

N(R

EQ

UIR

ED

FO

R

CE

MO

DE

LS

)

TIL

TA

LA

RM

HM

1

2

3


LIFT/

BL

K#

22

WH

T

RE

D

WH

T

BR

NB

LK

GL

OW

PL

UG


1

2

3

4

5

6

7

8



LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T#

40

-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

WHT

ORG/BLK

WHT

BRN

TP3

OR

G/B

LK

-3

UP

DO

WN

OR

G/B

LK

#1

5-M

.H.

OR

G#

14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

RIG

HT

LE

FT

PL

AT

RO

TA

TE

RIG

HT

LE

FT

PL

AT

RO

TA

TE

TP17

TS7

GR

N-3

TS57

TB17

TB18

GR

N/B

LK

-3

GR

N#

17

-M.H

.

GR

N/B

LK

#1

8-M

.H.

NC

CR8

TS9

TP15

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

L

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BL

U/W

HT

#1

2-M

.H.

BP2

PWM

A

+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

#11

-M.H

.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U#

10

-M.H

.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

#2

-M.H

.

RE

D/W

HT

#3

-M.H

.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

#5

-M.H

.

TB1

TB6

WH

T/R

ED

#6

-M.H

.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D#

1-M

.H.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

#8

-M.H

.

TB8

WH

T-3

TB5

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K#

7-M

.H.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

N.C.H.O.

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T#

40

-4

WH

T#

40

-6

TB40

N.O.N.O.

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

#2

9-C

.H.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

#3

7-M

.H.

BL

U#

36

-M.H

. RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT#12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

N.O.H.C.

WH

T-7

TB31

WH

T/B

LK

#3

1-C

.H.

WH

T/R

ED

#3

2-C

.H.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

N.C.H.O.

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

10

R4

CE MODELS ONLY




Ground Control Box Wiring Diagram- Z-45/25 Deutz Models (from serial number 13099 to 16303)


Ground Control Box Wiring Diagram-Z-45/25 Deutz Models (from serial number 13099 to 16303)

1

2

3

4

5

6

7

8




AUXILIARY

TS63

PLAT.

BLU/BLK #11

RED-R1

RED #20

LEVELBLU #10

BLK/RED #35

BLK #33

BRN TO GRDWHT #21

WHT #23

BLK #22RED #27

TS60

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS59CB2

SEC. BOOM

OIL PRESS

TS57

TS62

PRIMARYBOOM

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1 KS1

ROTATE

ORG/BLK #15

ORG #14

PLAT.

ROTATETURNTABLE

EXTENDRETRACT

GRN #17

GRN/BLK #18

WHT/RED #6

WHT/BLK #5

WHT #4

BLK/WHT #8

RED/BLK #2

RED/WHT #3

BLK #7

RED #1

WHT/BLK # 25

9 BK/RD-R5BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

CD

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4

RED/BLK-4

R/W-4

WHT-4

WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1#86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2 # 30

PRIMARY BOOM UP

PRIMARY BOOM EXTEND


PRIMARY BOOM DOWN

PRIMARY BOOM FUNCTION CONTROL




AB

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM#7

RED-ISM#4

28RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3

BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

GRN/BLK-4

ORG/BLK-4/R8

WHT#12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.#6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1

GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SECONDARY BOOM UP

+12 V POWER

SECONDARY BOOM DOWN


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN



DRIVE ENABLE LIGHT

IGNITION POWER

KEYSWITCH POWER

+12 V TO PLATFORM

OIL PRESSURE SWITCH

OIL TEMPERATURE SWITCH

GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE

AUXILARY PUMP SELECT

STEER RIGHT

GLOW PLUG

STEER LEFT

OFF-LIMIT SPEED


GENERATOR OPTION

BK/RD-R3#35

BLK-S.P.BLK-ISM#3

(SPARE)

START ENGINE

2WD/4WD

E.D.C.

E.D.C.

BRAKE

HIGH/LOW RPM

(SPARE)

(SPARE)

(SPARE)

(SPARE)

BLU/WHT #12


LE

D

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED#R4-EH

WHT-40B

BRN GRND H.M

CR4CR3

BLK/RED#35B

WHT#21

CR2

BLK#R1-E.H.

CR1

BLK-ISM#1

RED-CB1

WHT-ISM#9

ORG-4

CR7

PLATFORM LEVELCUTOUT

BRN TO R4

GRN/WHT #19BLK/RED#R5-AH.

BLK#22

BLK/RED-9A

RED-ISM#6

WHT#21TO R2

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

RE

D

WHT/RED #26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM#10

BLK-ENA.

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-ENA.

WHT/RED-C.H

WHT-24D

WHT-E.H.1

BLK/RED-EH-r.male r.fem-BLK/RED-R4

BLK/RED-EH-r.fem r.male-BLK/RED-R5

BLK-E.H-r.fem r.male-BLK-R1

ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

WHT-EXT.#6

RED-ENA.

2

ORG-M.H.-r.male

ORG/BLK-M.H.-r.male

r.fem-ORG-R7

r.fem-ORG/BLK-R8


CR2

CR3

CR1

CR4

CR7

CR8

L2



RPM SOLENOID RELAY


POWER RELAY


OIL PRESSURE LED

DESCRIPTIONLABEL

TS52

TS57

TS59

TS55

KS1

TS51

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1






HOUR METER





KEY SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


SERVICE HORN RELAYCR5

ENGINE HARNESSEH

HOUR METER


CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR RELAY

C.H.

S.P.

M.H.


ENGINE FAULT

(CE VERSION ONLY)



CR5

R4

+

TS56

GLOW PLUG

BLK/WHT-34

BLK/WHT-34

TS56 GLOW PLUG

Platform Control Box Wiring Diagram- Z-45/25 Deutz Models (from serial number 13099 to 16303)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARM

TILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

F.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LVE

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

RED-10

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6GENERATOR

OPTION

HIGH/LOW

START

DRIVE

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

P2

TS4

TS2

TS15

RPM

L1

DRIVESPEED

TS1

TS14

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-


H.P.L.

H1

BP2

TILT ALARM



DESCRIPTIONLABEL

TS2

TS7

TS9

TS6

TS3

P3

TS1

R3

L1

L3

TS10

TS12

R2

TS11

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR


DRIVE ENABLE LED




FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


(UN

US

ED

)

(SP

AR

E)

GLOW PLUG

TS6

R3R2

BL

K/W

HT

-34

GLOW PLUG

+_


Platform Control Box Wiring Diagram- Z-45/25 Deutz Models (from serial number 13099 to 16303)


Electrical Schematic, Z-45/25J Deutz Models(before serial number 13099)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

#2

3-E

.H.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

+

-

RED

RE

D#

20

-E.H

.

TB20

RE

LA

Y

BL

K/R

ED

#R

5-E

.H.

WH

T#

21

-E.H

.

OR

G/B

LK

#4

1-E

.H. CR5

CR5

BL

K/R

ED

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLKBLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

RG

EN

ER

AT

OR

OF

F

ON

FL

AS

HIN

GB

EA

CO

NS

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

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

4

PUMP

RE

LA

Y

PR1

RE

D#

27

-E.H

.

PR1

NO

RE

D/B

LK

#2

8-E

.H.

CR1

NO

CR1

BL

K#

R1

-E.H

.

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T PU

MP

PU

MP A

UX

ILIA

RY

AU

XIL

IAR

Y

TP27TP28

TS52

BL

K

12

TB33

3 RE

D/W

HT

#2

3-E

.H.

IGN./STARTMODULE

WH

T#

21

GR

N/W

HT

#4

5-E

.H.

FB

BL

K-1

TP33

TB45G

RN

/WH

T-1

TS47

TP45

RED

WHT

WHT

TP25

TP24

REDFS1 REDBLK

BL

K/R

ED

TS54

BL

K/R

ED

-1

HIG

HR

PM

TS4

TP35

BRN

RED

RED

WHT

WHT

ORG/BLK

DRIVE

SELECTOR

OPTION

TS50

OIL

TE

MP

ER

AT

UR

EL

ED

TP41

12 V

DC

TP21

REG.IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

WH

T/R

ED

WH

T/B

LK

L2

L3

OIL

PRES.

OIL

TEMP.

WH

T/B

LK

#2

5E

.H.

WH

T/R

ED

#2

6E

.H.

OPS

NCOTS

NO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

BL

K

TB34

TS56

BL

K-1

TP34

TS6

GL

OW

PL

UG

OP

TIO

N

PR2

NO

CR4CR4

CR3

CR3NO

BL

K/R

ED

#R

4-E

.H.

PR2

NO

BL

K/W

HT

#3

4-E

.H.

OP

TIO

N

RP

MS

OL

EN

OID

HIG

HID

LE

RE

LA

Y

HIG

HID

LE

CU

TO

UT

RE

LA

Y

ENGINE

SPEED

LO

WR

PM

LIF

T/D

RIV

ES

EL

EC

TO

R

OP

TIO

N(R

EQ

UIR

ED

FO

R

JIB

BO

OM

VA

LVE

S

JIB

BO

OM

VA

LVE

RE

LA

Y(C

R-1

4)

JIB

BO

OM

CU

TO

UT

RE

LA

Y(C

R-1

3)

CE

MO

DE

LS

)

TILT

AL

AR

M

LIFT/

BL

K#

22

WH

T

STA

RT

EN

GIN

E

STARTERAUX

STA

RT

EN

GIN

E

FU

NC

TIO

NE

NA

BL

E

HM

1

2

3

JIB

VA

LVE

S

RE

D

CR13

CR14

BRN

RED

HIG

HR

PM

LO

WR

PM

FO

OT

SW

.H

/L

GL

OW

PL

UG

S

GL

OW

PL

UG

S

CR14NO


1

2

3

4

5

6

7

8



LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T#

40

-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

WHT

ORG/BLK

WHT

BRN

TP3

OR

G/B

LK

-3

OR

G/B

LK

#1

5-M

.H.

OR

G#

14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

UP

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP17TP18

TS8

GR

N-3

TS58

TB18

TB17

GR

N/B

LK

-3

GR

N#

17

-M.H

.

GR

N/B

LK

#1

8-M

.H.

NC

CR8

TS9

TP15

TS59

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OM

UP

TP10

CR7NC

TB12

BL

U/W

HT

#1

2-M

.H.

BP2

PWM

A+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

#11

-M.H

.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U#

10

-M.H

.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

10

R5

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

#2

-M.H

.

RE

D/W

HT

#3

-M.H

.

-+A

PWM

BP1

15

R4

R

X

TS62

WH

T/B

LK

#5

-M.H

.

TB1

TB6

WH

T/R

ED

#6

-M.H

.

TB5

RE

D#

1-M

.H.

BO

OM

EX

TE

ND

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

#8

-M.H

.

TB8

WH

T-3

TB4

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K#

7-M

.H.

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T#

40

-4

WH

T#

40

-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

#2

9-C

.H.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

#3

7-M

.H.

BL

U#

36

-M.H

. OR

G/R

ED

#1

6-C

.H.

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT#12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T#

30

-C.H

.

TB31

WH

T/B

LK

#3

1-C

.H.

WH

T/R

ED

#3

2-C

.H.

TB32

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

U/R

ED

#1

3-C

.H.

BR

N

MODELS ONLY)

(2WD/4WD)

LS4

RIG

HT

LE

FT

PL

AT

RO

TA

TE

RIG

HT

LE

FT

PL

AT

RO

TA

TE

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

DO

WN

JIB

BO

OM

UP

DO

WN

JIB

BO

OM

UP

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

UP

DO

WN

PR

IMA

RY

BO

OM

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

EX

TE

ND

RE

TR

AC

TB

OO

M

EX

TE

ND

RE

TR

AC

TB

OO

M

DR

IVE

EN

AB

LE

TS57

RED

CR9 NCCR9

TS7+

BR

N

TB19

GR

N/W

HT

-3

TP19

NCCR13TI

CE MODELS ONLY




Ground Control Box Wiring Diagram- Z-45/25J Deutz Models (before serial number 13099)


Ground Control Box Wiring Diagram-Z-45/25J Deutz Models (before serial number 13099)

1

2

3

4

5

6

7

8




AUXILIARY

TS63

PLAT.BLU/BLK #11

RED-R1

RED #20

R5

LEVEL

BLU #10

BLK/RED #35

BLK #33

BRN TO GRD

WHT #21

WHT #23

BLK #22

RED #27

TS60

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS59

CB2

SEC. BOOM

OIL PRESS

TS57

TS62

PRIMARYBOOM

TS58

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1 KS1

ROTATE

ORG/BLK #15

ORG #14

PLATFORM

ROTATETURNTABLE

EXTENDRETRACT

GRN #17

GRN/BLK #18

WHT/RED #6

WHT/BLK #5

WHT #4

BLK/WHT #8

RED/BLK #2

RED/WHT #3

BLK #7

RED #1

WHT/BLK # 25

9 BK/RD-R5BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

CD

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4

RED/BLK-4

R/W-4

WHT-4

WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1#86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2 # 30

PRI. BOOM UP

BOOM EXTEND

TURN. ROT. F.C.

PRI. BOOM DOWN

PRI. BOOM F.C.

TURN. ROT. L

TURN. ROT. R

BOOM RETRACT

AB

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM#7

RED-ISM#4

28RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3

BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

BLU/WHT-4

GRN/BLK-4

ORG/BLK-4/R8

WHT#12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.#6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1

GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SEC. BOOM UP

12V BATT. SUPPLY

SEC. BOOM DN

DRV. ENA.

PLAT. LEVEL. UP

PLAT. LEVEL DN.

PLAT. ROT. L.

PLAT. ROT. R.

DRV. ENA. LT.

IGNITION PWR.

KEYSWITCH PWR.

PWR. TO PLAT.

OIL PRESSURE SENDER

WATER TEMP. SENDER

GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE

AUX. PWR.

STEER LEFT

GLOW PLUG

STEER RIGHT

LIMIT SWITCH SIG.

PULSE PICKUP

GEN. OPTION

BK/RD-R3#35

BLK-S.P.BLK-ISM#3

TEST LIGHT

START

2WD/4WD

E.D.C.

E.D.C.

BRAKE

RPM

L.P.

SPARE

SPARE

SPARE

BLU/WHT #12

SEC. BOOM F.C.

RE

D

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED#R4-EH

WHT-40B

BRN GRND H.M

CR4CR3

BLK/RED#35B

WHT#21

CR2

BLK#R1-E.H

CR1

BLK-ISM#1

RED-CB1

WHT-ISM#9

ORG-4

CR7

PLATFORM LEVELCUTOUT

BRN TO R4

GRN/WHT #19

JIB

BLK/RED#R5-AH

BLK#22

BLK/RED-9A

RED-ISM#

WHT#21TO R2

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

BLK-SEC#4

RE

D

WHT/RED #26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM#10

BLU/RED-C.H

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-30 C.H

WHT/RED-C.H

WHT-24D

WHT-E.H.1


BLK/RED-EHBLK/RED-R5

BLK-E.H BLK-R1

ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

R4

WHT-EXT.#6

ORG/RED-C.H

2

ORG-M.H.

ORG/BLK-M.H.

ORG-R7

ORG/BLK-R8

BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMSR5

CR2

CR3

CR1

CR4

CR7

CR8

L2



RPM SOLENOID RELAY


POWER RELAY


OIL PRESSURE LED

DESCRIPTIONLABEL

TS52

TS57

TS59

TS54

KS1

TS51

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1







HOUR METER





KEY SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


HORN RELAYCR5

ENGINE HARNESSEH

HOUR METER


CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR RELAY

C.H.

S.P.

M.H.


ENGINE FAULT

(CE MODELS ONLY)



CR5

Platform Control Box Wiring Diagram- Z-45/25J Deutz Models (before serial number 13099)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24



14

23

PW

R.F

RM

PL

AT.

PW

R.T

OP

LA

T.

DR

V.E

NA

.LT

.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

G.O

PT.

DR

V.E

NA

.

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

PW

R.(S

TA

RT

)

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.LV

L.D

N.

PL

AT.LV

L.U

P

SW

ING

F.C

.

SW

ING

RIG

HT

SW

ING

LE

FT

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DN

.

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

EX

TE

ND

HO

RN

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LVE

L.P

.

BR

AK

E

AU

X.P

WR

.

E.D

.C.

E.D

.C.

2W

D/4

WD

RP

M

STA

RT

EN

GIN

EF

AU

LT

SP

AR

E

SP

AR

E

SP

AR

E

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

OG/BK-41

ORG-40

RED-10

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

GEN.

TIME DELAY

HIGH/LOW

START

DRIVEDP1

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORM

PLATFORM

PRIMARY BOOM

RE

DT

ILTA

L.

RE

DT

OS

TO

PS

W

P2

T1

TS4

TS2

R2 R3TS15

RPM

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9P3

WHT JIB CABLE

BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

JIB

OPT.

RE

DF

RO

MC

R1

4


CR13

CR14

CR12

H.P.L.

T1

H1

BP2

TIME DELAY

TILT ALARM


EFI RELAY

JIB CUTOUT RELAY

JIB VALVE RELAY


DESCRIPTIONLABEL

TS2

TS7

TS9

TS6

P3

TS1

TS8

R3

L1

TS10

TS12

R2

TS11

TS13

P2


LOW SPEED RESISTOR


LOW SPEED RESISTOR


DRIVE ENABLE LED


JIB BOOM UP/DOWN

GLOW PLUG OPTION



HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


_+


Platform Control Box Wiring Diagram- Z-45/25J Deutz Models (before serial number 13099)


Electrical Schematic, Z-45/25J Deutz Models(from serial number 13099 to 16303)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

#2

3-E

.H.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

+

-

RED

RE

D#

20

-E.H

.

TB20

RE

LA

Y

BL

K/R

ED

#R

5-E

.H.

WH

T#

21

-E.H

.

OR

G/B

LK

#4

1-E

.H. CR5

CR5

BL

K/R

ED

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLKBLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

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

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

EN

GIN

E

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D#

27

-E.H

.

PR1

NO

RE

D/B

LK

#2

8-E

.H.

CR1

NO

CR1

BL

K#

R1

-E.H

.

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

#2

3-E

.H.

IGN./START

MODULE

WH

T#

21

GR

N/W

HT

#4

5-E

.H.

FB

BL

K-1

TP33

TB45

GR

N/W

HT

-1G

EN

ER

AT

OR

GL

OW

PL

UG

GL

OW

PL

UG

TS47

TP45

RED

WHT

WHT

TP25

TP24

REDFS1 REDBLK

BL

K/R

ED

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

NOTE:

BRN

RED

RED

WHT

WHT

ORG/BLK

DRIVE

SELECTOR

OPTION

TS50

OIL

TE

MP

ER

AT

UR

EL

ED

TP41

12 VDC

TP21

SEE NOTE 1


REGULATORIND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

WH

T/R

ED

WH

T/B

LK

L2

L3

OIL

PRES.

OIL

TEMP.

WH

T/B

LK

#2

5E

.H.

WH

T/R

ED

#2

6E

.H.

OPS

NC OILTEMPERATURE

SWITCH

NO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

BL

K

TB34

TS56

BL

K-1

TP34

TS6

PR2

NO

CR4CR4

CR3

CR3NO

BL

K/R

ED

#R

4-E

.H.

PR2

NO

BL

K/W

HT

#3

4-E

.H.

OP

TIO

N

RP

MS

OL

EN

OID

HIG

HID

LE

RE

LA

Y

HIG

HID

LE

CU

TO

UT

RE

LA

Y

ENGINE

SPEEDL

OW

RP

M

SEE NOTE 2


LIF

T/D

RIV

ES

EL

EC

TO

R

OP

TIO

N(R

EQ

UIR

ED

FO

R

CE

MO

DE

LS

)

TILT

AL

AR

M

HM

1

2

3


LIFT/

BL

K#

22

WH

T

RE

D

WH

T

BR

NB

LK

GL

OW

PL

UG


1

2

3

4

5

6

7

8



LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T#

40

-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

RIG

HT

LE

FT

PL

AT

RO

TA

TE

RIG

HT

LE

FT

PL

AT

RO

TA

TE

TS57

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

RED

WHT

ORG/BLK

WHT

BRN

CR9 NCCR9

TS7+

BR

N

TB19

GR

N/W

HT

-3

TP19 TP3

OR

G/B

LK

-3

UP

DO

WN

OR

G/B

LK

#1

5-M

.H.

OR

G#

14

-M.H

.

JIB

BO

OM

DO

WN

JIB

BO

OM

UP

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

DO

WN

UP

JIB

BO

OM

DO

WN

UP

JIB

BO

OM

TP17

NCCR13

GR

N-3

TB17

TB18

GR

N/B

LK

-3

GR

N#

17

-M.H

.

GR

N/B

LK

#1

8-M

.H.

NC

CR8

TS9

TP15

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

L

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BL

U/W

HT

#1

2-M

.H.

BP2

PWM

A

+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

#11

-M.H

.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U#

10

-M.H

.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

#2

-M.H

.

RE

D/W

HT

#3

-M.H

.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

#5

-M.H

.

TB1

TB6

WH

T/R

ED

#6

-M.H

.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D#

1-M

.H.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

#8

-M.H

.

TB8

WH

T-3

TB5

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K#

7-M

.H.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T#

40

-4

WH

T#

40

-6TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

#2

9-C

.H.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

#3

7-M

.H.

BL

U#

36

-M.H

. RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT#12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

#3

1-C

.H.

WH

T/R

ED

#3

2-C

.H.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

TI

10

TS8

TS58

R4

CE MODELS ONLY




Ground Control Box Wiring Diagram- Z-45/25J Deutz Models (from serial number 13099 to 16303)


Ground Control Box Wiring Diagram-Z-45/25J Deutz Models (from serial number 13099 to 16303)

1

2

3

4

5

6

7

8




AUXILIARY

TS63

TS62

PLAT.

BLU/BLK #11

RED-R1

RED #20

LEVELBLU #10

BLK/RED #35

BLK #33

BRN TO GRDWHT #21

WHT #23

BLK #22RED #27

TS60

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS59CB2

SEC. BOOM

OIL PRESS

TS57

PRIMARYBOOM

TS58

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1 KS1

ORG/BLK #15

ORG #14

PLATFORMROTATE

ROTATETURNTABLE

EXTENDRETRACT

GRN #17

GRN/BLK #18

WHT/RED #6

WHT/BLK #5

WHT #4

BLK/WHT #8

RED/BLK #2

RED/WHT #3

BLK #7

RED #1

WHT/BLK # 25

9 BK/RD-R5BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

CD

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4

RED/BLK-4

R/W-4

WHT-4

WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1#86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2 # 30

PRIMARY BOOM UP

PRIMARY BOOM EXTEND


PRIMARY BOOM DOWN





AB

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM#7

RED-ISM#4

28RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3

BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

GRN/BLK-4

ORG/BLK-4/R8

WHT#12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.#6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1

GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SECONDARY BOOM UP

+12 V POWER

SECONDARY BOOM DOWN


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN



DRIVE ENABLE LIGHT

IGNITION POWER

KEYSWITCH POWER

+12 V TO PLATFORM

OIL PRESSURE SWITCH


GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE


STEER RIGHT

GLOW PLUG

STEER LEFT

OFF-LIMIT SPEED


GENERATOR OPTION

BK/RD-R3#35

BLK-S.P.BLK-ISM#3

(SPARE)

START ENGINE

2WD/4WD

E.D.C.

E.D.C.

BRAKE

HIGH/LOW RPM

(SPARE)

(SPARE)

(SPARE)

(SPARE)

BLU/WHT #12


LE

D

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED#R4-EH

WHT-40B

BRN GRND H.M

CR4CR3

BLK/RED#35B

WHT#21

CR2

BLK#R1-E.H.

CR1

BLK-ISM#1

RED-CB1

WHT-ISM#9

ORG-4

CR7

PLATFORM LEVELCUTOUT(CE MODELS ONLY)

BRN TO R4

GRN/WHT #19

JIB

BLK/RED#R5-AH.

BLK#22

BLK/RED-9A

RED-ISM#6

WHT#21TO R2

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

RE

D

WHT/RED #26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM#10

BLK-ENA.

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-ENA.

WHT/RED-C.H

WHT-24D

WHT-E.H.1




ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

WHT-EXT.#6

RED-ENA.

2

ORG-M.H.-r.male

ORG/BLK-M.H.-r.male

r.fem-ORG-R7

r.fem-ORG/BLK-R8


CR2

CR3

CR1

CR4

CR7

CR8

L2



RPM SOLENOID RELAY


POWER RELAY


OIL PRESSURE LED

DESCRIPTIONLABEL

TS52

TS57

TS59

TS54

KS1

TS51

TS58

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1






HOUR METER





JIB BOOM UP/DOWN

KEY SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH

HORN RELAYCR5

ENGINE HARNESSEH

HOUR METER


CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR RELAY

C.H.

S.P.

M.H.


ENGINE FAULT



CR5

R4

+

BLK/WHT-34

TS56

GLOW PLUG

BLK/WHT-34

GLOW PLUGTS56

Platform Control Box Wiring Diagram- Z-45/25J Deutz Models (from serial number 13099 to 16303)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.

PW

R.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.

LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.

(OP

TIO

N)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.

BO

OM

DN

.

SE

C.

BO

OM

UP

PW

R.

TO

F.S

.

F.S

.U

PP

OW

ER

PW

R.

(CO

NT.)

PL

AT.

RO

T.

R.

PL

AT.

RO

T.

L.

PL

AT.

LE

VE

LD

N.

PL

AT.

LE

VE

LU

P

TU

RN

.R

OT.

F.C

.

TU

RN

RO

T.

R.

TU

RN

RO

T.

L.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.

BO

OM

F.C

.

JIB

VA

LVE

BR

AK

E

AU

X.

PU

MP

SE

L.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

RED-10

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

GEN.

TIME DELAY

HIGH/LOW

START

DRIVE

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

RE

DT

ILTA

L.

RE

DT

OS

TO

PS

W

P2

T1

TS4

TS2

TS15

RPM

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



WHT JIB CABLE

BP1

BP2

NO

NC

NONC

NC

NO

HORSE-POWERLIMITER|BOARD

JIB

OPT.

RE

DF

RO

MC

R1

4


CR13

CR14

H.P.L.

T1

H1

BP2

TIME DELAY

TILT ALARM


JIB CUTOUT RELAY

JIB VALVE RELAY


DESCRIPTIONLABEL

TS2

TS7

TS9

TS6

P3

TS1

TS8

R3

L1

TS10

TS12

R2

TS11

TS13

P2


LOW SPEED RESISTOR


LOW SPEED RESISTOR


DRIVE ENABLE LED


JIB UP/DOWN



HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


(UN

US

ED

)

(SP

AR

E)

BL

K/W

HT

-34

GLOW PLUG

TS6

R3R2

GLOW PLUG

+ _


Platform Control Box Wiring Diagram- Z-45/25J Deutz Models (from serial number 13099 to 16303)


Platform Control Box Wiring Diagram- Lift/Drive SelectOption,Z-45/25J Deutz Models (from serial number 13099 to 16303)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARM

TILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LVE

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

RED-10

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

LIFT/

GEN.

TIME DELAY

HIGH/LOW

START

DRIVE

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

RE

DT

ILTA

L.

RE

DT

OS

TO

PS

W

P2

T1

TS4

TS2

TS15

RPM

SEL.

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



WHT JIB CABLE

BP1

BP2

NO

NC

NONC

NC

NO

HORSE-POWERLIMITERBOARD

DRIVE

TS50W

HT

-21

JIB

OPT.

RE

DF

RO

MC

R1

4


CR13

CR14

H.P.L.

T1H1

BP2

TIME DELAY

TILT ALARM


JIB CUTOUT RELAY

JIB VALVE RELAY


DESCRIPTIONLABEL

TS2

TS7

TS9

TS6

P3

TS1

TS8

R3

L1

L3

TS10

TS12

R2

TS11

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR


DRIVE ENABLE LED


JIB UP/DOWN



HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


(UN

US

ED

)

(SP

AR

E)

BL

K/W

HT

-34

GLOW PLUG

TS6

R3R2

GLOW PLUG

+ _


Platform Control Box Wiring Diagram- Lift/Drive Select Option,Z-45/25J Deutz Models (from serial number 13099 to 16303)


Electrical Schematic, Z-45/25 Deutz Models(after serial number 16303)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

-23

-E.H

.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

+

-

RED

RE

D-2

0-E

.H.

TB20

RE

LA

Y

BL

K/R

ED

-R5

-E.H

.

WH

T-2

1-E

.H.

OR

G/B

LK

-41

-E.H

. CR5CR5

BL

K/R

ED

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1

RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLK-(FS)BLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

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

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

EN

GIN

E

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D-2

7-E

.H.

PR1

NO

RE

D/B

LK

-28

-E.H

.

CR1

NO

CR1

BL

K-R

1-E

.H.

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T PU

MP

PU

MP

AU

AX

ILIA

RY

AU

AX

ILIA

RY

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

-23

-E.H

.

IGN./STARTMODULE

WH

T-2

1

GR

N/W

HT

-45

-E.H

.

FB

BL

K-1

TP33

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

WHT

TP25RED-(FS)FS1

BL

K/R

ED

TS54

BL

K/R

ED

-1

HIG

HR

PM

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

BRN

RED

RED

WHT

ORG/BLK

OIL

TE

MP

ER

AT

UR

EL

ED

TP41

12 V

DC

TP24

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

WH

T/R

ED

WH

T/B

LK

L2

L3

OIL

PRES.

OIL

TEMP.

WH

T/B

LK

-25

E.H

.

WH

T/R

ED

-26

E.H

.OPSNC

OTSNO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

BL

K

TB34

TS56

BL

K-1

TP34

TS6

PR2

NO

CR4CR4

CR3

CR3NO

BL

K/R

ED

-R4

-E.H

.

PR2

NO

BL

K/W

HT

-34

-E.H

.

OP

TIO

N

RP

MS

OL

EN

OID

HIG

HID

LE

RE

LA

Y

HIG

HID

LE

CU

TO

UT

RE

LA

Y

ENGINE

SPEEDL

OW

RP

M

ON

OF

FGE

NE

RA

TO

R

GL

OW

PL

UG

GL

OW

PL

UG

LO

WR

PM

FO

OT

SW

H/L

TILT

AL

AR

M

HM

1

2

3

BL

K-2

2

WH

T

RE

D

WH

T

BR

NB

LK

GL

OW

PL

UG

OP

TIO

N

LOAD SENSE OPTION (SEE DETAIL BELOW)

WHT-(FS)

LOAD SENSE OPTION

8GND

OR

G-L

OA

D

TP22FS1

BLK-(FS)

P2RED-(FS)

BLK-26 LOAD

WHT-(FS)

B+

C

LOADSENSORBOX

WHT-LOAD WHT-24TP24

BLK-26

TP26

Electrical Schematic, Z-45/25 Deutz Models(after serial number 16303)




1

2

3

4

5

6

7

8

LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T-4

0-5

BO

OM

RE

TR

AC

T

10

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

PL

AT

FO

RM

RO

TA

TE

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

ORG/BLK

WHT

BRN

TP3

OR

G/B

LK

-3

UP

DO

WN

OR

G/B

LK

-15

-M.H

.

OR

G-1

4-M

.H.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

RIG

HT

LE

FT

TP17

TS7

GR

N-3

TS57

TB17

TB18

GR

N/B

LK

-3

GR

N-1

7-M

.H.

GR

N/B

LK

-18

-M.H

.

NC

CR8

TS9

TP15

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

L

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7

NC

TB12

BL

U/W

HT

-12

-M.H

.

BP2

PWM

A+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

-11-M

.H.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U-1

0-M

.H.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

-2-M

.H.

RE

D/W

HT

-3-M

.H.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

-5-M

.H.

TB1

TB6

WH

T/R

ED

-6-M

.H.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D-1

-M.H

.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

-8-M

.H.

TB8

WH

T-3

TB5

HORSE-

LIMITER

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K-7

-M.H

.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T-4

0-4

WH

T-4

0-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

-29

-C.H

.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

-37

-M.H

.

BL

U-3

6-M

.H.

RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT-12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

-31

-C.H

.

WH

T/R

ED

-32

-C.H

.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

R4

10


WHT

CE MODELS ONLY

Electrical Schematic- Z-45/25 Deutz Models(after serial number 16303)


Ground Control Box Wiring Diagram-Z-45/25 Deutz Models (after serial number 16303)


Ground Control Box Wiring Diagram-Z-45/25 Deutz Models (after serial number 16303)

1

2

3

4

5

6

7

8




AUXILIARY

TS63

PLAT.

BLU/BLK-11

RED-R1

RED-20

LEVELBLU-10

BLK/RED-35

BLK-33

BRN-(GRND)WHT-21

WHT-23

BLK-22RED-27

TS60

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS59CB2

SEC. BOOM

OIL PRESS

TS57

TS62

PRIMARYBOOM

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1 KS1

ROTATE

ORG/BLK-15

ORG-14

PLATFORM

ROTATETURNTABLE

EXTENDRETRACT

GRN-17

GRN/BLK-18

WHT/RED-6

WHT/BLK-5

WHT-4

BLK/WHT-8

RED/BLK-2

RED/WHT-3

BLK-7

RED-1

WHT/BLK-25

9 BK/RD-R5BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

CD

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4

RED/BLK-4

R/W-4

WHT-4

WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1-86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2#30

PRIMARY BOOM UP

PRIMARY BOOM EXTEND


PRIMARY BOOM DOWN





AB

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM-7

RED-ISM-4

28RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3

BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

GRN/BLK-4

ORG/BLK-4/R8

WHT-12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.-6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1

GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SECONDARY BOOM UP

+12 V POWER

SECONDARY BOOM DOWN


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN



DRIVE ENABLE LIGHT

IGNITION POWER

KEYSWITCH POWER

+12 V TO PLATFORM

OIL PRESSURE SWITCH


GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE


STEER RIGHT

GLOW PLUG

STEER LEFT

OFF-LIMIT SPEED


GENERATOR OPTION

BK/RD-R3#35

BLK-S.P.BLK-ISM-3

(SPARE)

START ENGINE

2WD/4WD

E.D.C.

E.D.C.

BRAKE

HIGH/LOW RPM

(SPARE)

(SPARE)

(SPARE)

(SPARE)

BLU/WHT-12


LE

D

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED-R4

WHT-40B

BRN-(GRND H.M)

CR4CR3

BLK/RED-35B

WHT-21

CR2

BLK-R1-E.H.

CR1

BLK-R1

RED-R1

WHT-R2

ORG-4

CR7


BRN-(R5)

GRN/WHT-19BLK/RED-R5

BLK-22

BLK/RED-9A

RED-R2

WHT-21 (R2)

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

RE

D

WHT/RED-26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM-10

BLK-ENA.

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-ENA.

WHT/RED-C.H

WHT-24D

WHT-E.H.1




ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

WHT-EXT.#6

RED-ENA.

2

ORG-M.H.-r.male

ORG/BLK-M.H.-r.male

r.fem-ORG-R7

r.fem-ORG/BLK-R8


CR2

CR3

CR1

CR4

CR7

CR8

L2



RPM SOLENOID RELAY


POWER RELAY


OIL PRESSURE LED

DESCRIPTIONLABEL

TS52

TS57

TS59

TS54

KS1

TS51

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1






HOUR METER





KEY SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


SERVICE HORN RELAYCR5

ENGINE HARNESSEH

HOUR METER


CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR RELAY

C.H.

S.P.

M.H.


ENGINE FAULT



CR5

R4

+

BLK/RED-35GEN

BLK/RED-35GEN

BLK/WHT-34

TS56

GLOW PLUG

TS56 GLOW PLUG

Platform Control Box Wiring Diagram-Z-45/25 Deutz Models (after serial number 16303)




1

2

3

4

5

6

7

8

5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

F.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

BL

K/W

HT

-3

4

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LV

E

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

-

+A

X

+A

RX

- 42

31

56

78

TIL

TA

LA

RM

RE

D/B

LK

-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

RED-10

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

GENERATOROPTION

HIGH/LOW

START

DRIVE

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

P2

TS4

TS2TS6

TS15

RPM

L1

DRIVESPEED

TS1

TS14

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATEBP1

CR13

CR14

CR12

H.P.L.

T1

BP2


TILT ALARM


EFI RELAY ( FORD AND PERKINS ONLY )

JIB CUTOUT RELAY ( JIB ONLY )

JIB VALVE RELAY ( JIB ONLY )


COMPONENT INDEX

TS2

TS7

TS9

TS6

TS3

P3

TS1

TS8

R3

L1

L3

TS10

TS12

R2

TS11

R1

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR



DRIVE ENABLE LED


JIB UP/DOWN (JIB OPTION ONLY)

GLOW PLUG OPTION (DIESEL ONLY)



FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH(UN

US

ED

)

(UN

US

ED

)

RE

D-G

EN

GR

N/W

HT

-45

GLOW PLUG


DP1

TS47


8

7

6

54

3

21


SEESIDE VIEW

DP1

SIDE VIEW DP1

RE

D-T

ILT

RE

D-T

ILT

Platform Control Box Wiring Diagram-Z-45/25 Deutz Models (after serial number 16303)


Platform Control Box Wiring Diagram- Lift/Drive SelectOption,Z-45/25 Deutz Models (after serial number 16303)

1

2

3

4

5

6

7

8




5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

F.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

BL

K/W

HT

-3

4

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LVE

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

-

+A

X

+A

RX

- 42

31

56

78

TIL

TA

LA

RM

RE

D/B

LK

-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

RED-10

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6GENERATOROPTION

HIGH/LOW

START

DRIVE

SEC.BOOM

DRIVEENABLE

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

P2

TS4

TS2

TS6

R3R2

TS15

RPM

L1

DRIVESPEED

TS1

TS14

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-


H.P.L.

H1

BP2

TILT ALARM



COMPONENT INDEX

TS2

TS7

TS9

TS6

P3

TS1

R3

L1

L3

TS10

TS12

R2

TS11

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR


DRIVE ENABLE LED


GLOW PLUG



HORN SWITCH


AUXILIARY SWITCH


US

ED

)

(UN

US

ED

)

RE

D-G

EN

GR

N/W

HT

-45

GLOW PLUG


DP1

TS47


8

7

6

54

3

21


SEESIDE VIEW

DP1

SIDE VIEW FOR DP1

RE

D-T

ILT

RE

D-T

ILT

+ -

Platform Control Box Wiring Diagram- Lift/Drive Select Option,Z-45/25 Deutz Models (after serial number 16303)


Electrical Schematic, Z-45/25J Deutz Models(after serial number 16303)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

-23

-E.H

.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

+

-

RED

RE

D-2

0-E

.H.

TB20

RE

LA

Y

BL

K/R

ED

-R5

-E.H

.

WH

T-2

1-E

.H.

OR

G/B

LK

-41

-E.H

. CR5CR5

BL

K/R

ED

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1

RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLK-(FS)BLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

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

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

GL

OW

PL

UG

GL

OW

PL

UG

EN

GIN

E

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D-2

7-E

.H.

PR1

NO

RE

D/B

LK

-28

-E.H

.

CR1

NO

CR1

BL

K-R

1-E

.H.

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

-23

-E.H

.IGN./STARTMODULE

WH

T-2

1

GR

N/W

HT

-45

-E.H

.

FB

BL

K-1

TP33

TB45G

RN

/WH

T-1

TS47

TP45

RED

WHT

WHT

TP25RED-(FS)FS1

BL

K/R

ED

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

JIB

VA

LVE

S

RE

D

CR13

CR14

BRN

RED

RED

BRN

WHT

ORG/BLK

RED

OIL

TE

MP

ER

AT

UR

EL

ED

TP41

12 V

DC

TP24

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

WH

T/R

ED

WH

T/B

LK

L2

L3

OIL

PRES.

OIL

TEMP.

WH

T/B

LK

-25

E.H

.

WH

T/R

ED

-26

E.H

.

OPSNC

OTSNO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

BL

K

TB34

TS56

BL

K-1

TP34

TS6

PR2

NO

CR4CR4

CR3

CR3NO

BL

K/R

ED

-R4

-E.H

.

PR2

NO

BL

K/W

HT

-34

-E.H

.

OP

TIO

N

RP

MS

OL

EN

OID

HIG

HID

LE

RE

LA

Y

HIG

HID

LE

CU

TO

UT

RE

LA

Y

ENGINE

SPEED

HIG

HR

PM

ON

OF

FG

EN

ER

AT

OR

LO

WR

PM

FO

OT

SW

.H

/L

LO

WR

PM

CR14NO

JIB

BO

OM

VA

LVE

S

JIB

BO

OM

VA

LVE

RE

LA

Y(C

R-1

4)

JIB

VA

LVE

RE

LA

Y

JIB

BO

OM

CU

TO

UT

RE

LA

Y

JIB

CU

TO

UT

RE

LA

Y(C

R-1

3)

TIL

TA

LA

RM

HM

1

2

3

BL

K-2

2

WH

T

RE

D

WH

T

BR

NB

LK

GL

OW

PL

UG

OP

TIO

N


LOAD SENSE OPTION

8GND

OR

G-L

OA

D

TP22FS1

BLK-(FS)

P2RED-(FS)

BLK-26 LOAD

WHT-(FS)LOAD

SENSOR

B+

C

BOXWHT-LOAD WHT-24

TP24

BLK-26

TP26

WHT-(FS)

Electrical Schematic, Z-45/25J Deutz Models(after serial number 16303)




1

2

3

4

5

6

7

8

LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T-4

0-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

RIG

HT

LE

FT

PL

AT

RO

TA

TE

RIG

HT

LE

FT

PL

AT

RO

TA

TE

TS57

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

RED

WHT

ORG/BLK

WHT

BRN

CR9 NCCR9

TS7+

BR

N

TB19

GR

N/W

HT

-3

TP19TP3

OR

G/B

LK

-3

UP

DO

WN

OR

G/B

LK

-15

-M.H

.

OR

G-1

4-M

.H.

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

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

DO

WN

UP

JIB

BO

OM

DO

WN

UP

JIB

BO

OM

TP17

NCCR13

GR

N-3

TB17

TB18

GR

N/B

LK

-3

GR

N-1

7-M

.H.

GR

N/B

LK

-18

-M.H

.

NC

CR8

TS9

TP15

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

L

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BL

U/W

HT

-12

-M.H

.

BP2

PWM

A+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

-11

-M.H

.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U-1

0-M

.H.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

-2-M

.H.

RE

D/W

HT

-3-M

.H.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

-5-M

.H.

TB1

TB6

WH

T/R

ED

-6-M

.H.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D-1

-M.H

.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

-8-M

.H.

TB8

WH

T-3

TB5

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K-7

-M.H

.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T-4

0-4

WH

T-4

0-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

-29

-C.H

.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

-37

-M.H

.

BL

U-3

6-M

.H.

RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT-12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

-31

-C.H

.

WH

T/R

ED

-32

-C.H

.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

TI

R4

TS8

TS58

10


WHT

CE MODELS ONLY

Electrical Schematic- Z-45/25J Deutz Models(after serial number 16303)


Ground Control Box Wiring Diagram-Z-45/25J Deutz Models (after serial number 16303)


Ground Control Box Wiring Diagram-Z-45/25J Deutz Models (after serial number 16303)

1

2

3

4

5

6

7

8




AUXILIARY

TS63

PLAT.

BLU/BLK-11

RED-R1

RED-20

LEVELBLU-10

BLK/RED-35

BLK-33

BRN-(GRND)WHT-21

WHT-23

BLK-22RED-27

TS60

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS59CB2

SEC. BOOM

OIL PRESS

TS57

PRIMARYBOOM

TS58

TS62

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1 KS1

ORG/BLK-15

ORG-14

PLATFORMROTATE

ROTATETURNTABLE

EXTENDRETRACT

GRN-17

GRN/BLK-18

WHT/RED-6

WHT/BLK-5

WHT-4

BLK/WHT-8

RED/BLK-2

RED/WHT-3

BLK-7

RED-1

WHT/BLK-25

9 BK/RD-R5BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

CD

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4

RED/BLK-4

R/W-4

WHT-4

WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1-86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2#30

PRIMARY BOOM UP

PRIMARY BOOM EXTEND


PRIMARY BOOM DOWN





AB

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM-7

RED-ISM-4

28RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3

BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

GRN/BLK-4

ORG/BLK-4/R8

WHT-12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.-6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1

GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SECONDARY BOOM UP

+12 V POWER

SECONDARY BOOM DOWN


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN



DRIVE ENABLE LIGHT

IGNITION POWER

KEYSWITCH POWER

+12 V TO PLATFORM

OIL PRESSURE SWITCH


GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE


STEER RIGHT

GLOW PLUG

STEER LEFT

OFF-LIMIT SPEED


GENERATOR OPTION

BK/RD-R3#35

BLK-S.P.BLK-ISM-3

(SPARE)

START ENGINE

2WD/4WD

E.D.C.

E.D.C.

BRAKE

HIGH/LOW RPM

(SPARE)

(SPARE)

(SPARE)

(SPARE)

BLU/WHT-12


LE

D

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED-R4

WHT-40B

BRN-(GRND H.M)

CR4CR3

BLK/RED-35B

WHT-21

CR2

BLK-R1-E.H.

CR1

BLK-R1

RED-R1

WHT-R2

ORG-4

CR7


BRN-(R5)

GRN/WHT-19

JIB

BLK/RED-R5

BLK-22

BLK/RED-9A

RED-R2

WHT-21 (R2)

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

RE

D

WHT/RED-26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM-10

BLK-ENA.

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-ENA.

WHT/RED-C.H

WHT-24D

WHT-E.H.1




ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

WHT-EXT.#6

RED-ENA.

2

ORG-M.H.-r.male

ORG/BLK-M.H.-r.male

r.fem-ORG-R7

r.fem-ORG/BLK-R8


CR2

CR3

CR1

CR4

CR7

CR8

L2



RPM SOLENOID RELAY


POWER RELAY


OIL PRESSURE LED

DESCRIPTIONLABEL

TS52

TS57

TS59

TS54

KS1

TS51

TS58

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1






HOUR METER





JIB UP/DOWN

KEY SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


HORN RELAYCR5

ENGINE HARNESSEH

HOUR METER


CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR RELAY

C.H.

S.P.

M.H.


ENGINE FAULT



CR5

R4

+

BLK/RED-35GEN

BLK/RED-35GEN

BLK/WHT-34

TS56

GLOW PLUG

TS56 GLOW PLUG

Platform Control Box Wiring Diagram-Z-45/25J Deutz Models (after serial number 16303)




5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

K/W

HT

-34

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LV

E

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TIL

TA

LA

RM

RE

D/B

LK

-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

RED-10

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

GEN.

TIME DELAY

HIGH/LOW

START

DRIVE

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

RE

D-T

ILT

RE

D-S

TP

P2

T1

TS4

TS2

TS6TS15

RPM

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



WHT JIB CABLE

BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

JIB

OPT.

RE

DF

RO

MC

R1

4

BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATEBP1

CR13

CR14

CR12

H.P.L.

T1

BP2


TILT ALARM



JIB CUTOUT RELAY ( JIB ONLY )

JIB VALVE RELAY ( JIB ONLY )


COMPONENT INDEX

TS2

TS7

TS9

TS6

TS3

P3

TS1

TS8

R3

L1

L3

TS10

TS12

R2

TS11

R1

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR



DRIVE ENABLE LED


JIB UP/DOWN (JIB OPTION ONLY)




FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH


US

ED

)

(UN

US

ED

)

RE

D-G

EN

GR

N/W

HT

-45

GLOW PLUG


DP1

TS47


8

7

6

54

3

21


SEESIDE VIEW

DP1

SIDE VIEW DP1

RE

D-T

ILT

RE

D-S

TP

1

2

3

4

5

6

7

8

Platform Control Box Wiring Diagram-Z-45/25J Deutz Models (after serial number 16303)


Platform Control Box Wiring Diagram- Lift/Drive SelectOption,Z-45/25J Deutz Models (after serial number 16303)




5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

K/W

HT

-34

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LVE

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TIL

TA

LA

RM

RE

D/B

LK

-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

RED-10

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

GEN.

TIME DELAY

HIGH/LOW

START

DRIVE

VALVE

JIB CUTOUT

SEC.BOOM

DRIVEENABLE

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

RE

D-T

ILT

RE

D-S

TP

P2

T1

TS4

TS2

TS6

R2 R3

TS15

RPM

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



WHT JIB CABLE

BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

JIB

OPT.

RE

DF

RO

MC

R1

4

BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN,TURNTABLE ROTATEBP1

CR13

CR14

H.P.L.

T1

H1

BP2

TIME DELAY

TILT ALARM


JIB CUTOUT RELAY

JIB VALVE RELAY


COMPONENT INDEX

TS2

TS7

TS9

TS6

TS3

P3

TS1

TS8

R3

L1

L3

TS10

TS12

R2

TS11

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR


DRIVE ENABLE LED


JIB BOOM UP/DOWN

GLOW PLUG



FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH


US

ED

)

(UN

US

ED

)

RE

D-G

EN

GR

N/W

HT

-45

GLOW PLUG


DP1

TS47


8

7

6

54

3

21


SEESIDE VIEW

DP1

SIDE VIEW FOR DP1

RE

D-T

ILT

RE

D-S

TP

+ -

1

2

3

4

5

6

7

8

Platform Control Box Wiring Diagram- Lift/Drive Select Option,Z-45/25J Deutz Models (after serial number 16303)


Electrical Schematic, Z-45/25 Perkins Models(before serial number 16304)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

#2

3-E

.H.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

+

-

RED

RE

D#

20

-E.H

.

TB20

RE

LA

Y

BL

K/R

ED

#R

5-E

.H.

WH

T#

21

-E.H

.

OR

G/B

LK

#4

1-E

.H. CR5

CR5

BL

K/R

ED

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLKBLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

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

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

ON

ON

OF

F

HIG

HR

PM

GE

NE

RA

TO

R

ON

GL

OW

PL

UG

GL

OW

PL

UG

EN

GIN

E

4

STARTER

PUMP

AUX

RE

LA

Y

PR1

RE

D#

27

-E.H

.

PR1

NO

RE

D/B

LK

#2

8-E

.H.

CR1

NO

CR1

BL

K#

R1

-E.H

.

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T PU

MP

PU

MP

AU

XIL

IAR

Y

AU

XIL

IAR

Y

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

#2

3-E

.H.

IGN./STARTMODULE

WH

T#

21

GR

N/W

HT

#4

5-E

.H.

FB

BL

K-1

TP33

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

WHT

TP25

TP24

REDFS1 REDBLK

BL

K/R

ED

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

NOTE:1) The connection to TP24 is for units without the generator option2) The foot switch power is connected to both white wires without the lift/drive selector option.3) All switches and contacts are shown with the boom in the stowed position and the key switch off

BRN

RED

RED

WHT

WHT

ORG/BLK

DRIVE

SELECTOR

OPTION

TS50

OIL

TE

MP

ER

AT

UR

EL

ED

TP41

12 VDC

TP21

SEE NOTE 1

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

WH

T/R

ED

WH

T/B

LK

L2

L3

OIL

PRES.

OIL

TEMP.

WH

T/B

LK

#2

5E

.H.

WH

T/R

ED

#2

6E

.H.

OILPRESSURE

SWITCHNC

OILTEMPERATURE

SWITCH

NO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

BL

K

TB34

TS56

BL

K-1

TP34

TS6

GL

OW

PL

UG

PR2

NO

CR4CR4

CR3

CR3NO

BL

K/R

ED

#R

4-E

.H.

PR2

NO

BL

K/W

HT

#3

4-E

.H.

OP

TIO

N

RP

MS

OL

EN

OID

HIG

HID

LE

RE

LA

Y

HIG

HID

LE

CU

TO

UT

RE

LA

Y

ENGINE

SPEED

LO

WR

PM

LO

WR

PM

FO

OT

SW

.H

/L

SEE NOTE 2

LIF

T/D

RIV

ES

EL

EC

TO

R

OP

TIO

N(R

EQ

UIR

ED

FO

R

CE

MO

DE

LS

)

TIL

TA

LA

RM

HM

1

2

3

LIFT/

BL

K#

22

WH

T

W

WH

T

RE

DB

LK

BR

N


1

2

3

4

5

6

7

8



LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T#

40

-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

BRN

DE

SC

EN

TA

LA

RM

(OP

TIO

N)

RED

RED

WHT

ORG/BLK

WHT

BRN

TP3

OR

G/B

LK

-3

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

OR

G/B

LK

#1

5-M

.H.

OR

G#

14

-M.H

.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

TP17

TS7

GR

N-3

TS57

TB17

TB18

GR

N/B

LK

-3

GR

N#

17

-M.H

.

GR

N/B

LK

#1

8-M

.H.

NC

CR8

TS9

TP15

TS59

UP

DO

WN P

LA

TF

OR

ML

EV

EL

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN S

EC

ON

DA

RY

BO

OM

CR7NC

TB12

BL

U/W

HT

#1

2-M

.H.

BP2

PWM

A+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

#11

-M.H

.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U#

10

-M.H

.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

FL

OW

CO

NT

RO

L

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

#2

-M.H

.

RE

D/W

HT

#3

-M.H

.

PWM

BP1

-+A

R

X

TS62

WH

T/B

LK

#5

-M.H

.

TB1

TB6

WH

T/R

ED

#6

-M.H

.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D#

1-M

.H.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

#8

-M.H

.

TB8

WH

T-3

TB5

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K#

7-M

.H.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LV

E

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T#

40

-4

WH

T#

40

-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

#2

9-C

.H.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

#3

7-M

.H.

BL

U#

36

-M.H

. RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT#12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

#3

1-C

.H.

WH

T/R

ED

#3

2-C

.H.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

R4

CE MODELS ONLY

50

R1

CR12




Ground Control Box Wiring Diagram, Z-45/25 Perkins Models(before serial number 16304)


Ground Control Box Wiring Diagram, Z-45/25 Perkins Models(before serial number 16304)

1

2

3

4

5

6

7

8




AUXILIARY

TS63

PLAT.

BLU/BLK #11

RED-R1

RED #20

LEVELBLU #10

BLK/RED #35

BLK #33

BRN TO GRDWHT #21

WHT #23

BLK #22RED #27

TS60

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS62

TS59CB2

SEC. BOOM

OIL PRESS

TS57

PRIMARYBOOM

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1 KS1

ORG/BLK #15

ORG #14

PLATFORMROTATE

ROTATETURNTABLE

EXTENDRETRACT

GRN #17

GRN/BLK #18

WHT/RED #6

WHT/BLK #5

WHT #4

BLK/WHT #8

RED/BLK #2

RED/WHT #3

BLK #7

RED #1

WHT/BLK # 25

9 BK/RD-R5BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

CD

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4

RED/BLK-4

R/W-4

WHT-4

WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1#86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2 # 30

PRIMARY BOOM UP

PRIMARY BOOM EXTEND


PRIMARY BOOM DOWN





AB

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM#7

RED-ISM#4

28RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3

BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

GRN/BLK-4

ORG/BLK-4/R8

WHT#12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.#6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1

GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SECONDARY BOOM UP

+12 V POWER

SECONDARY BOOM DOWN


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN

PLATFORM ROTATE LEFT

PLATFORM ROTATE RIGHT

DRIVE ENABLE LIGHT

IGNITION POWER

KEYSWITCH POWER

+12 V TO PLATFORM

OIL PRESSURE SWITCH


GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE


STEER RIGHT

GLOW PLUG

STEER LEFT

OFF-LIMIT SPEED


GENERATOR OPTION

BK/RD-R3#35

BLK-S.P.BLK-ISM#3

(SPARE)

START ENGINE

2WD/4WD

E.D.C.

E.D.C.

BRAKE

HIGH/LOW RPM

(SPARE)

(SPARE)

(SPARE)

(SPARE)

BLU/WHT #12


LE

D

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED#R4-EH

WHT-40B

BRN GRND H.M

CR4CR3

BLK/RED#35B

WHT#21

CR2

BLK#R1-E.H.

CR1

BLK-ISM#1

RED-CB1

WHT-ISM#9

ORG-4

CR7

PLATFORM LEVELCUTOUT(CE VERSION ONLY)

BRN TO R4

GRN/WHT #19BLK/RED#R5-AH.

BLK#22

BLK/RED-9A

RED-ISM#6

WHT#21TO R2

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

RE

D

WHT/RED #26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM#10

BLK-ENA.

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-ENA.

WHT/RED-C.H

WHT-24D

WHT-E.H.1




ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

WHT-EXT.#6

RED-ENA.

2

ORG-M.H.-r.male

ORG/BLK-M.H.-r.male

r.fem-ORG-R7

r.fem-ORG/BLK-R8


CR2

CR3

CR1

CR4

CR7

CR8

L2



RPM SOLENOID RELAY


POWER RELAY


OIL PRESSURE LED

DESCRIPTIONLABEL

TS52

TS57

TS59

TS54

KS1

TS51

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1




CIRCUIT BREAKER, ENGINE, 15APRIMARY BOOM EXTEND/RETRACT SWITCH

HOUR METER





KEY SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


HORN RELAYCR5

ENGINE HARNESSEH

HOUR METER


CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR RELAY

C.H.

S.P.

M.H.


ENGINE FAULT



CR5

R4

+

BLK/WHT-34

TS56

GLOW PLUG

BLK/WHT-34

GLOW PLUGTS56

Platform Control Box Wiring Diagram-Z-45/25 Perkins Models (before serial number 16304)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.

PW

R.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.

LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.

(OP

TIO

N)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.

BO

OM

DN

.

SE

C.

BO

OM

UP

PW

R.

TO

F.S

.

F.S

.U

PP

OW

ER

PW

R.

(CO

NT.)

PL

AT.

RO

T.

R.

PL

AT.

RO

T.

L.

PL

AT.

LE

VE

LD

N.

PL

AT.

LE

VE

LU

P

TU

RN

.R

OT.

F.C

.

TU

RN

RO

T.

R.

TU

RN

RO

T.

L.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

F.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.

BO

OM

F.C

.

JIB

VA

LVE

BR

AK

E

AU

X.

PU

MP

SE

L.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

H1 #3

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

GENERATOROPTION

HIGH/LOW

START

DRIVE

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

P2

TS4

TS2

TS15

RPM

L1

DRIVESPEED

TS1

TS14

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



BP1

BP2

NO

NC

NONC

NC

NO

BOARDLIMITERPOWERHORSE-

BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN, TURNTABLE ROTATEBP1

CR12

H1

H.P.L.

BP2

TILT ALARM


EFI RELAY


DESCRIPTIONLABEL

TS2

TS7

TS9

TS6

P3

TS1

R3

L1

TS10

TS12

R2

TS11

TS13

P2


LOW SPEED RESISTOR


LOW SPEED RESISTOR


DRIVE ENABLE LED


GLOW PLUG



HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


(UN

US

ED

)

(SP

AR

E)

LIMITING RELAY

ORG-40

RED-10

WHT-24

CR12

R150

RED-10

BL

K/W

HT

-34

GLOW PLUG

TS6

R2 R3

+_


Platform Control Box Wiring Diagram- Z-45/25 Perkins Models (before serial number 16304)


Electrical Schematic, Z-45/25J Perkins Models(before serial number 16304)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

#2

3-E

.H.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

+

-

RED

RE

D#

20

-E.H

.

TB20

RE

LA

Y

BL

K/R

ED

#R

5-E

.H.

WH

T#

21

-E.H

.

OR

G/B

LK

#4

1-E

.H. CR5

CR5

BL

K/R

ED

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1RED

P3

TP23

HORN

BL

K

AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

TP9TB22

BL

K-2

TP26BLKBLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

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

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

GL

OW

PL

UG

S GE

NE

RA

TO

RO

FF

ON

GL

OW

PL

UG

S

EN

GIN

E

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D#

27

-E.H

.

PR1

NO

RE

D/B

LK

#2

8-E

.H.

CR1

NO

CR1

BL

K#

R1

-E.H

.

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

#2

3-E

.H.

IGN./STARTMODULE

WH

T#

21

GR

N/W

HT

#4

5-E

.H.

FB

BL

K-1

TP33

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

WHT

TP25

TP24

REDFS1 REDBLK

BL

K/R

ED

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

NOTE:

JIB

VA

LV

ES

RE

D

CR13

CR14

BRN

RED

RED

WHT

BRN

WHT

ORG/BLK

DRIVE

SELECTOR

OPTION

RED

TS50

OIL

TE

MP

ER

AT

UR

EL

ED

TP41

12 VDC

TP21

SEE NOTE 1


REGULATORIND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

WH

T/R

ED

WH

T/B

LK

L2

L3

OIL

PRES.

OIL

TEMP.

WH

T/B

LK

#2

5E

.H.

WH

T/R

ED

#2

6E

.H.

OPS

NC OILTEMPERATURE

SWITCH

NO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

BL

K

TB34

TS56

BL

K-1

TP34

TS6

GL

OW

PL

UG

S

PR2

NO

CR4CR4

CR3

CR3NO

BL

K/R

ED

#R

4-E

.H.

PR2

NO

BL

K/W

HT

#3

4-E

.H.

OP

TIO

N

RP

MS

OL

EN

OID

HIG

HID

LE

RE

LA

Y

HIG

HID

LE

CU

TO

UT

RE

LA

Y

ENGINE

SPEED

HIG

HR

PM

LO

WR

PM

FO

OT

SW

.H

/LL

OW

RP

M

SEE NOTE 2


CR14NO

LIF

T/D

RIV

ES

EL

EC

TO

R

OP

TIO

N(R

EQ

UIR

ED

FO

R

JIB

BO

OM

VA

LV

ES

JIB

BO

OM

VA

LV

ER

EL

AY

(CR

-14

)JIB

VA

LV

ER

EL

AY

JIB

BO

OM

CU

TO

UT

RE

LA

YJIB

CU

TO

UT

RE

LA

Y(C

R-1

3)

CE

MO

DE

LS

)

TIL

TA

LA

RM

HM

1

2

3


LIFT/

BL

K#

22

WH

T

W

RE

D

WH

T

BR

NB

LK


1

2

3

4

5

6

7

8



LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T#

40

-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

RIG

HT

LE

FT

PL

AT

RO

TA

TE

RIG

HT

LE

FT

PL

AT

RO

TA

TE

TS57

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

RED

WHT

ORG/BLK

WHT

BRN

CR9 NCCR9

TS7+

BR

N

TB19

GR

N/W

HT

-3

TP19 TP3

OR

G/B

LK

-3

UP

DO

WN

OR

G/B

LK

#1

5-M

.H.

OR

G#

14

-M.H

.

JIB

BO

OM

DO

WN

JIB

BO

OM

UP

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

DO

WN

UP

JIB

BO

OM

DO

WN

UP

JIB

BO

OM

TP17

NCCR13

GR

N-3

TB17

TB18

GR

N/B

LK

-3

GR

N#

17

-M.H

.

GR

N/B

LK

#1

8-M

.H.

NC

CR8

TS9

TP15

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

L

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BL

U/W

HT

#1

2-M

.H.

BP2

PWM

A

+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

#11

-M.H

.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U#

10

-M.H

.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

#2

-M.H

.

RE

D/W

HT

#3

-M.H

.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

#5

-M.H

.

TB1

TB6

WH

T/R

ED

#6

-M.H

.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D#

1-M

.H.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

#8

-M.H

.

TB8

WH

T-3

TB5

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K#

7-M

.H.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T#

40

-4

WH

T#

40

-6TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

#2

9-C

.H.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

#3

7-M

.H.

BL

U#

36

-M.H

. RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT#12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

#3

1-C

.H.

WH

T/R

ED

#3

2-C

.H.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

TI

R4

50

R1

CR12

TS8

TS58

10

CE OPTION ONLY




Ground Control Box Wiring Diagram- Z-45/25J Perkins Models (before serial number 16304)


Ground Control Box Wiring Diagram- Z-45/25J Perkins Models (before serial number 16304)

1

2

3

4

5

6

7

8




AUXILIARY

TS63

TS62

PLAT.

BLU/BLK #11

RED-R1

RED #20

LEVELBLU #10

BLK/RED #35

BLK #33

BRN TO GRDWHT #21

WHT #23

BLK #22RED #27

TS60

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS59CB2

SEC. BOOM

OIL PRESS

TS57

PRIMARYBOOM

TS58

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1 KS1

ROTATE

ORG/BLK #15

ORG #14

PLATFORM

ROTATETURNTABLE

EXTENDRETRACT

GRN #17

GRN/BLK #18

WHT/RED #6

WHT/BLK #5

WHT #4

BLK/WHT #8

RED/BLK #2

RED/WHT #3

BLK #7

RED #1

WHT/BLK # 25

9 BK/RD-R5BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

CD

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4

RED/BLK-4

R/W-4

WHT-4

WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1#86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2 # 30

PRIMARY BOOM UP

PRIMARY BOOM EXTEND


PRIMARY BOOM DOWN





AB

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM#7

RED-ISM#4

28RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3

BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

GRN/BLK-4

ORG/BLK-4/R8

WHT#12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.#6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1

GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SECONDARY BOOM UP

+12 V POWER

SECONDARY BOOM DOWN


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN



DRIVE ENABLE LIGHT

IGNITION POWER

KEYSWITCH POWER

+12 V TO PLATFORM

OIL PRESSURE SWITCH


GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE


STEER RIGHT

GLOW PLUG

STEER LEFT

OFF-LIMIT SPEED


GENERATOR OPTION

BK/RD-R3#35

BLK-S.P.BLK-ISM#3

(SPARE)

START ENGINE

2WD/4WD

E.D.C.

E.D.C.

BRAKE

HIGH/LOW RPM

(SPARE)

(SPARE)

(SPARE)

(SPARE)

BLU/WHT #12


LE

D

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED#R4-EH

WHT-40B

BRN GRND H.M

CR4CR3

BLK/RED#35B

WHT#21

CR2

BLK#R1-E.H.

CR1

BLK-ISM#1

RED-CB1

WHT-ISM#9

ORG-4

CR7


BRN TO R4

GRN/WHT #19

JIB

BLK/RED#R5-AH.

BLK#22

BLK/RED-9A

RED-ISM#6

WHT#21TO R2

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

RE

D

WHT/RED #26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM#10

BLK-ENA.

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-ENA.

WHT/RED-C.H

WHT-24D

WHT-E.H.1




ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

WHT-EXT.#6

RED-ENA.

2

ORG-M.H.-r.male

ORG/BLK-M.H.-r.male

r.fem-ORG-R7

r.fem-ORG/BLK-R8


CR2

CR3

CR1

CR4

CR7

CR8

L2



RPM SOLENOID RELAY


POWER RELAY


OIL PRESSURE LED

DESCRIPTIONLABEL

TS52

TS57

TS59

TS54

KS1

TS51

TS58

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1






HOUR METER





JIB BOOM UP/DOWN

KEY SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


HORN RELAYCR5

ENGINE HARNESSEH

HOUR METER


CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR RELAY

C.H.

S.P.

M.H.


ENGINE FAULT



CR5

R4

+

GLOW PLUG

BLK/WHT-34

TS56

BLK/WHT-34

TS56 GLOW PLUG

Platform Control Box Wiring Diagram- Z-45/25J Perkins Models (before serial number 16304)

1

2

3

4

5

6

7

8



5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LV

E

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TIL

TA

LA

RM

RE

D/B

LK

-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

H1 #3

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

GENERATOR

TIME DELAY

HIGH/LOW

START

DRIVEDP1

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

RE

DT

ILT

AL

.

RE

DT

OS

TO

PS

W

P2

T1

TS4

TS2

TS15

RPM

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



WHT JIB CABLE

BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

JIB

OPTION

RE

DF

RO

MC

R1

4

BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN , TURNTABLE ROTATEBP1

CR13

CR14

CR12

H.P.L.

T1

H1

BP2

TIME DELAY

TILT ALARM



JIB CUTOUT RELAY

JIB VALVE RELAY


DESCRIPTIONLABEL

TS2

TS7

TS9

TS6

TS3

P3

TS1

TS8

R3

L1

L3

TS10

TS12

R2

TS11

R1

TS13

P2

CHECK ENGINE LED


LOW SPEED RESISTOR


LOW SPEED RESISTOR



DRIVE ENABLE LED


JIB BOOM UP/DOWN



FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


(UN

US

ED

)

(SP

AR

E)

LIMITING RELAY

ORG-40

RED-10

WHT-24

CR12

R150

RED-10

BL

K/W

HT

-34

TS6

R2 R3

GLOW PLUG

GLOW PLUG

+ _


Platform Control Box Wiring Diagram-Z-45/25J Perkins Models (before serial number 16304)


Platform Control Box Wiring Diagram- Lift/Drive SelectOption,Z-45/25J Perkins Models (before serial number 16304)

1

2

3

4

5

6

7

8




5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.

PW

R.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.

LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.

(OP

TIO

N)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.

BO

OM

DN

.

SE

C.

BO

OM

UP

PW

R.

TO

F.S

.

F.S

.U

PP

OW

ER

PW

R.

(CO

NT.)

PL

AT.

RO

T.

R.

PL

AT.

RO

T.

L.

PL

AT.

LE

VE

LD

N.

PL

AT.

LE

VE

LU

P

TU

RN

.R

OT.

F.C

.

TU

RN

RO

T.

R.

TU

RN

RO

T.

L.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.

BO

OM

F.C

.

JIB

VA

LVE

BR

AK

E

AU

X.

PU

MP

SE

L.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

LIFT/

GEN.

TIME DELAY

HIGH/LOW

START

DRIVEDP1

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

RE

DT

ILTA

L.

RE

DT

OS

TO

PS

W

P2

T1

TS4

TS2

TS15

RPM

SEL.

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



WHT JIB CABLE

BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

DRIVE

TS50

WH

T-2

1

JIB

OPT.

RE

DF

RO

MC

R1

4

(UN

US

ED

)

(SP

AR

E)

LIMITING RELAY

ORG-40

RED-10

WHT-24

CR12

R150

RED-10

BL

K/W

HT

-34

TS6R3R2

GLOW PLUG

BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN , TURNTABLE ROTATEBP1

CR13

CR14

CR12

H.P.L.

T1

H1

BP2

TIME DELAY

TILT ALARM



JIB CUTOUT RELAY

JIB VALVE RELAY


DESCRIPTIONLABEL

TS2

TS7

TS9

TS6

TS3

P3

TS1

TS8

R3

L1

TS10

TS12

R2

TS11

R1

TS13

P2


LOW SPEED RESISTOR


LOW SPEED RESISTOR



DRIVE ENABLE LED


JIB BOOM UP/DOWN



FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


GLOW PLUG

+ _

Platform Control Box Wiring Diagram- Lift/Drive Select Option,Z-45/25J Perkins Models (before serial number 16304)


Electrical Schematic, Z-45/25 Perkins Models(after serial number 16303)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

-23

-E.H

.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

+

-

RED

RE

D-2

0-E

.H.

TB20

RE

LA

Y

BL

K/R

ED

-R5

-E.H

.

WH

T-2

1-E

.H.

OR

G/B

LK

-41

-E.H

. CR5CR5

BL

K/R

ED

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1

RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLK-(FS)BLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

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

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

EN

GIN

E

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D-2

7-E

.H.

PR1

NO

RE

D/B

LK

-28

-E.H

.

CR1

NO

CR1

BL

K-R

1-E

.H.

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T AU

XIL

IAR

YP

UM

P

AU

XIL

IAR

YP

UM

P

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

-23

-E.H

.

IGN./STARTMODULE

WH

T-2

1

GR

N/W

HT

-45

-E.H

.

FB

BL

K-1

TP33

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

WHT

TP25RED-(FS)FS1

BL

K/R

ED

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

BRN

RED

RED

WHT

ORG/BLK

OIL

TE

MP

ER

AT

UR

EL

ED

TP41

12 V

DC

TP24

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

WH

T/R

ED

WH

T/B

LK

L2

L3

OIL

PRES.

OIL

TEMP.

WH

T/B

LK

-25

E.H

.

WH

T/R

ED

-26

E.H

.OPS

NCOTS

NO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

BL

K

TB34

TS56

BL

K-1

TP34

TS6

GL

OW

PL

UG

SG

LO

WP

LU

GS

GE

NE

RA

TO

RO

FF

HIG

HR

PM

LO

WR

PM

FO

OT

SW

.H

/L

ON

GL

OW

PL

UG

S

PR2

NO

CR4CR4

CR3

CR3NO

BL

K/R

ED

-R4

-E.H

.

PR2

NO

BL

K/W

HT

-34

-E.H

.

OP

TIO

N

RP

MS

OL

EN

OID

HIG

HID

LE

RE

LA

Y

HIG

HID

LE

CU

TO

UT

RE

LA

Y

ENGINE

SPEEDL

OW

RP

M

TIL

TA

LA

RM

HM

1

2

3

BL

K-2

2

WH

T

W

RE

D

WH

T

BR

NB

LK


LOAD SENSE OPTION

8GND

OR

G-L

OA

D

TP22FS1

BLK-(FS)

P2RED-(FS)

BLK-26 LOAD

WHT-(FS)LOAD

SENSOR

B+

C

BOXWHT-LOAD WHT-24

TP24

BLK-26

TP26

WHT-(FS)





1

2

3

4

5

6

7

8

LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T-4

0-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

PL

AT

RO

TA

TE

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

ORG/BLK

WHT

BRN

TP3

OR

G/B

LK

-3

UP

DO

WN

OR

G/B

LK

-15

-M.H

.

OR

G-1

4-M

.H.

PL

AT

FO

RM

RO

TA

TE

RIG

HT

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

RIG

HT

LE

FT

RIG

HT

LE

FT

PL

AT

RO

TA

TE

TP17

TS7

GR

N-3

TS57

TB17

TB18

GR

N/B

LK

-3

GR

N-1

7-M

.H.

GR

N/B

LK

-18

-M.H

.

NC

CR8

TS9

TP15

TS59

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

L

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BL

U/W

HT

-12

-M.H

.

BP2

PWM

A+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

-11

-M.H

.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U-1

0-M

.H.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

-2-M

.H.

RE

D/W

HT

-3-M

.H.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

-5-M

.H.

TB1

TB6

WH

T/R

ED

-6-M

.H.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D-1

-M.H

.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

-8-M

.H.

TB8

WH

T-3

TB5

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K-7

-M.H

.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T-4

0-4

WH

T-4

0-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

-29

-C.H

.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

-37

-M.H

.

BL

U-3

6-M

.H.

RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT-12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

-31

-C.H

.

WH

T/R

ED

-32

-C.H

.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

R4

50

R1

CR12

10


WHT

CE MODELS ONLY



Ground Control Box Wiring Diagram-Z-45/25 Perkins Models (after serial number 16303)


Ground Control Box Wiring Diagram-Z-45/25 Perkins Models (after serial number 16303)

1

2

3

4

5

6

7

8




AUXILIARY

TS63

TS62

PLAT.

BLU/BLK-11

RED-R1

RED-20

LEVELBLU-10

BLK/RED-35

BLK-33

BRN-(GRND)WHT-21

WHT-23

BLK-22RED-27

TS60

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS59CB2

SEC. BOOM

OIL PRESS

TS57

PRIMARYBOOM

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1 KS1

ORG/BLK-15

ORG-14

PLATFORMROTATE

ROTATETURNTABLE

EXTENDRETRACT

GRN-17

GRN/BLK-18

WHT/RED-6

WHT/BLK-5

WHT-4

BLK/WHT-8

RED/BLK-2

RED/WHT-3

BLK-7

RED-1

WHT/BLK-25

9 BK/RD-R5BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

CD

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4

RED/BLK-4

R/W-4

WHT-4

WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1-86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2#30

PRIMARY BOOM UP

PRIMARY BOOM EXTEND


PRIMARY BOOM DOWN





AB

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM-7

RED-ISM-4

28RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3

BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

GRN/BLK-4

ORG/BLK-4/R8

WHT-12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.-6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1

GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SECONDARY BOOM UP

+12 V POWER

SECONDARY BOOM DOWN


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN



DRIVE ENABLE LIGHT

IGNITION POWER

KEYSWITCH POWER

+12 V TO PLATFORM

OIL PRESSURE SWITCH


GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE


STEER RIGHT

GLOW PLUG

STEER LEFT

OFF-LIMIT SPEED


GENERATOR OPTION

BK/RD-R3#35

BLK-S.P.BLK-ISM-3

(SPARE)

START ENGINE

2WD/4WD

E.D.C.

E.D.C.

BRAKE

HIGH/LOW RPM

(SPARE)

(SPARE)

(SPARE)

(SPARE)

BLU/WHT-12


LE

D

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED-R4

WHT-40B

BRN-(GRND H.M)

CR4CR3

BLK/RED-35B

WHT-21

CR2

BLK-R1-E.H.

CR1

BLK-R1

RED-R1

WHT-R2

ORG-4

CR7


BRN-(R5)

GRN/WHT-19BLK/RED-R5

BLK-22

BLK/RED-9A

RED-R2

WHT-21 (R2)

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

RE

D

WHT/RED-26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM-10

BLK-ENA.

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-ENA.

WHT/RED-C.H

WHT-24D

WHT-E.H.1




ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

WHT-EXT.#6

RED-ENA.

2

ORG-M.H.-r.male

ORG/BLK-M.H.-r.male

r.fem-ORG-R7

r.fem-ORG/BLK-R8


CR2

CR3

CR1

CR4

CR7

CR8

L2

PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY)PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

RPM SOLENOID RELAY


POWER RELAY


OIL PRESSURE LED

DESCRIPTIONLABEL

TS52

TS57

TS59

TS54

KS1

TS51

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1






HOUR METER





KEY SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


HORN RELAYCR5

ENGINE HARNESSEH

HOUR METER


CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR RELAY

C.H.

S.P.

M.H.


ENGINE FAULT



CR5

R4

+

BLK/RED-35GEN

BLK/RED-35GEN

BLK/WHT-34

TS56

GLOW PLUG

GLOW PLUGTS56

Platform Control Box Wiring Diagram-Z-45/25 Perkins Models (after serial number 16303)




1

2

3

4

5

6

7

8

5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

F.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LVE

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6GENERATOR

HIGH/LOW

START

DRIVE

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

P2

TS4

TS2

TS6

R2 R3TS15

RPM

L1

DRIVESPEED

TS1

TS14

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

OPTION

BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN,TURNTABLE ROTATEBP1

CR12

H.P.L.

H1

BP2

TILT ALARM




COMPONENT INDEX

TS2

TS7

TS9

TS6

TS3

P3

TS1

R3

L1

TS10

TS12

R2

TS11

R1

TS13

P2


LOW SPEED RESISTOR


LOW SPEED RESISTOR



DRIVE ENABLE LED


GLOW PLUG OPTION



FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH


US

ED

)

(SP

AR

E)

RE

D-G

EN

GR

N/W

HT

-45

LIMITING RELAY

RED-10

R1

50

CR12

WHT-24

RED-10

ORG-40

BL

K/W

HT

-34

GLOW PLUG


DP1

TS47


8

7

6

54

3

21


SEESIDE VIEW

DP1

SIDE VIEW FOR DP1

RE

D-T

ILT

REMOVE FOR LIFT/DRIVE SELECT VERSION

RE

D-T

ILT

+ _

Platform Control Box Wiring Diagram-Z-45/25 Perkins Models (after serial number 16303)


Platform Control Box Wiring Diagram- Lift/Drive SelectOption,Z-45/25 Perkins Models (after serial number 16303)




5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

F.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LVE

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6GENERATOR

OPTION

HIGH/LOW

START

DRIVE

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

P2

TS4

TS2

TS6

R2 R3TS15

RPM

L1

DRIVESPEED

TS1

TS14

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



BP1

BP2

NO

NC

NONC

NC

NO

POWER

LIMITER

BOARD

HORSE-

BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DN,TURNTABLE ROTATEBP1

CR12

H.P.L.

H1

BP2

TILT ALARM




COMPONENT INDEX

TS2

TS7

TS9

TS6

TS3

P3

TS1

R3

L1

TS10

TS12

R2

TS11

R1

TS13

P2


LOW SPEED RESISTOR


LOW SPEED RESISTOR



DRIVE ENABLE LED





FUEL SELECT SWITCH

HORN SWITCH


AUXILIARY SWITCH


US

ED

)

(SP

AR

E)

RE

D-G

EN

GR

N/W

HT

-45

LIMITING RELAY

RED-10

R1

50

CR12

WHT-24

RED-10

ORG-40

BL

K/W

HT

-34

GLOW PLUG


DP1

TS47


8

7

6

54

3

21


SEESIDE VIEW

DP1

SIDE VIEW FOR DP1

RE

D-T

ILT

RE

D-T

ILT

+ _

1

2

3

4

5

6

7

8

Platform Control Box Wiring Diagram- Lift/Drive Select Option,Z-45/25 Perkins Models (after serial number 16303)


Electrical Schematic, Z-45/25J Perkins Models(after serial number 16303)

1

2

3

4

5

6

7

8




WH

T-2

RE

D/W

HT

-23

-E.H

.

HO

RN

LE

VE

LS

EN

SO

R

HO

RN

15AMP.

+

-

RED

RE

D-2

0-E

.H.

TB20

RE

LA

Y

BL

K/R

ED

-R5

-E.H

.

WH

T-2

1-E

.H.

OR

G/B

LK

-41

-E.H

. CR5CR5

BL

K/R

ED

NO

CB2

RE

D

RED

CB1

15AMP.

OR

G/B

LK

-1

TB41

BL

K/R

ED

-3

TB23TB9

KS1

PLAT

GRND

P1

RED

P3

TP23

HORN

BL

K

TP9TB22

BL

K-2

TP26BLK-(FS)BLK

TP22P2

OP

TIO

N

GE

NE

RA

TO

R

FL

AS

HIN

GB

EA

CO

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

TB35

TS2

GROUNDAUX. ON

KEY PWR.BATTERY

TACHOMETER


KEY BYPASS

START INPUT

START RELAY

STA

RT

GL

OW

PL

UG

GL

OW

PL

UG

EN

GIN

E

4

STARTER

PUMPAUX

RE

LA

Y

PR1

RE

D-2

7-E

.H.

PR1

NO

RE

D/B

LK

-28

-E.H

.

CR1

NO

CR1

BL

K-R

1-E

.H.

TB21

TB25

NO

CR2

8765

109

CR2

TS51

RE

D-1

RE

D/B

LK

-1

TB27TB28

RE

D

TS1

WH

T PU

MP

PU

MP

AU

XIL

IAR

Y

AU

XIL

IAR

Y

TP27TP28

TS52

BL

K

1

2

TB33

3

STA

RT

EN

GIN

E

RE

D/W

HT

-23

-E.H

.

IGN./STARTMODULE

WH

T-2

1

GR

N/W

HT

-45

-E.H

.

FB

BL

K-1

TP33

TB45

GR

N/W

HT

-1

TS47

TP45

RED

WHT

WHT

TP25RED-(FS)FS1

BL

K/R

ED

TS54

BL

K/R

ED

-1

HIG

HR

PM

FU

NC

TIO

NE

NA

BL

E

TS4

TP35

JIB

VA

LV

ES

RE

D

CR13

CR14

BRN

RED

RED

BRN

WHT

ORG/BLK

RED

OIL

TE

MP

ER

AT

UR

EL

ED

TP41

12 V

DC

TP24

REGULATOR

IND.

ALTERNATOR

BAT.+

STA.

BAT.-

EXCT.

FU

EL

SO

LE

NO

ID

TB24

TB26

WH

T/R

ED

WH

T/B

LK

L2

L3

OIL

PRES.

OIL

TEMP.

WH

T/B

LK

-25

E.H

.

WH

T/R

ED

-26

E.H

.OPS

NCOTS

NO

OIL

PR

ES

SU

RE

OIL

TE

MP

ER

AT

UR

E

SW

ITC

H

SW

ITC

H

OIL

PR

ES

SU

RE

LE

D

BL

K

TB34

TS56

BL

K-1

TP34

TS6

GL

OW

PL

UG

S

PR2

NO

CR4CR4

CR3

CR3NO

BL

K/R

ED

-R4

-E.H

.

PR2

NO

BL

K/W

HT

-34

-E.H

.

OP

TIO

N

RP

MS

OL

EN

OID

HIG

HID

LE

RE

LA

Y

HIG

HID

LE

CU

TO

UT

RE

LA

Y

ENGINE

SPEEDH

IGH

RP

M

ON

OF

FG

EN

ER

AT

OR

LO

WR

PM

FO

OT

SW

.H

/L

LO

WR

PM

CR14NO

JIB

BO

OM

VA

LV

ES

JIB

BO

OM

VA

LV

ER

EL

AY

(CR

-14

)

JIB

VA

LV

ER

EL

AY

JIB

BO

OM

CU

TO

UT

RE

LA

Y

JIB

CU

TO

UT

RE

LA

Y(C

R-1

3)

TIL

TA

LA

RM

HM

1

2

3

BL

K-2

2

WH

T

W

RE

D

WH

T

BR

NB

LK


LOAD SENSE OPTION

8GND

OR

G-L

OA

D

TP22FS1

BLK-(FS)

P2RED-(FS)

BLK-26 LOAD

WHT-(FS)LOAD

SENSOR

B+

C

BOXWHT-LOAD WHT-24

TP24

BLK-26

TP26

WHT-(FS)





1

2

3

4

5

6

7

8

LS2

DR

IVE

LIM

ITS

WIT

CH

WH

T-4

0-5

BO

OM

RE

TR

AC

T

HORSE-

LIMITER

10

RIG

HT

LE

FT

RIG

HT

LE

FT

PL

AT

FO

RM

RO

TA

TE

PL

AT

FO

RM

RO

TA

TE

TS57

BRN

DE

SC

EN

TA

LA

RM

OP

TIO

N

RED

RED

RED

WHT

ORG/BLK

WHT

BRN

CR9 NCCR9

TS7+

BR

N

TB19

GR

N/W

HT

-3

TP19TP3

OR

G/B

LK

-3

UP

DO

WN

PL

AT

FO

RM

LE

VE

L

PL

AT

FO

RM

LE

VE

LO

RG

/BL

K-1

5-M

.H.

OR

G-1

4-M

.H.

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

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LD

OW

N

CUTOUT (CE

PLATFORM LEVEL

TP18

DO

WN

UP

JIB

BO

OM

DO

WN

UP

JIB

BO

OM

TP17

NCCR13

GR

N-3

TB17

TB18

GR

N/B

LK

-3

GR

N-1

7-M

.H.

GR

N/B

LK

-18

-M.H

.

NC

CR8

TS9

TP15

TS59

UP

DO

WN

TB14

TB15

SE

CO

ND

AR

YB

OO

MF

LO

WC

ON

TR

OL

SE

CO

ND

AR

YB

OO

MD

OW

N

SE

CO

ND

AR

YB

OO

MU

P

TP10

UP

DO

WN

SE

CO

ND

AR

YB

OO

M

CR7NC

TB12

BL

U/W

HT

-12

-M.H

.

BP2

PWM

A+-X

R

TS60

TB11

BL

U/B

LK

BL

U/B

LK

-11-M

.H.

TP14

OR

G-3

BL

U/W

HT

BL

U/W

HT

-3

TP12

RE

D/W

HT

-3

TP11

BL

U-3

BL

U/B

LK

-3

BL

U

TB10

BL

U-1

0-M

.H.

TP4

WH

T#

4-M

.H.

PR

IMA

RY

BO

OM

DO

WN

FL

OW

CO

NT

RO

LP

RIM

AR

YB

OO

M

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

TU

RN

TA

BL

ER

OTA

TE

PR

IMA

RY

BO

OM

UP

FL

OW

CO

NT

RO

L

TB2

UP

DO

WN

PR

IMA

RY

BO

OM

PWM

A+-X

R

TP1

TS61

TP2

RE

D/B

LK

-3

RE

D-3

TB3

RE

D/B

LK

-2-M

.H.

RE

D/W

HT

-3-M

.H.

-+A

PWM

BP1

R

X

TS62

WH

T/B

LK

-5-M

.H.

TB1

TB6

WH

T/R

ED

-6-M

.H.

TB4

RIG

HT

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RE

D-1

-M.H

.

BO

OM

EX

TE

ND

EX

TE

ND

RE

TR

AC

TB

OO

M

TB7

TP5 TP6

WH

T/R

ED

-3

WH

T/B

LK

-3

TS63

BL

K/W

HT

-8-M

.H.

TB8

WH

T-3

TB5

BOARD

POWER

TS13

TP7

BL

K-3

TP8

BL

K/W

HT

-3

BL

K-7

-M.H

.

EX

TE

ND

RE

TR

AC

TB

OO

M

BR

AK

ER

EL

EA

SE

VA

LVE

RE

D/W

HT

-1M

OT

OR

ST

RO

KE

SE

CO

ND

AR

YB

OO

MU

PB

RN

-4

BR

N-6

DR

IVE

LIM

ITS

WIT

CH

PR

IMA

RY

BO

OM

EX

TE

ND

DR

IVE

LIM

ITS

WIT

CH

BR

N-5

PR

IMA

RY

BO

OM

UP

LS1

NCHO

12

4

65

7

98

3

TP40

OR

G-1

LS3

WH

T-4

0-4

WH

T-4

0-6

TB40

NONO

R2

TS14

LO

W(4

WD

)R

ED

HIG

H(2

WD

)

RED

BL

K

R3

25

0

10

0

DRIVERANGE

RE

D/W

HT

-29

-C.H

.

TR

AV

EL

AL

AR

MO

PT

ION

ST

EE

RL

EF

T

ST

EE

RR

IGH

T

1

3

54

6

87

2

DP1

TP29

RED

TB29

TP37TP36

BL

U-1

BL

U/B

LK

-1

TB37TB36

BL

U/B

LK

-37

-M.H

.

BL

U-3

6-M

.H.

RE

D-7

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

SW

ITC

H

TB16

DR

IVE

ED

C

WHT-12-C.H.

DR

IVE

EN

AB

LE

GR

OU

ND

TP30

TB30

TS15

TP31 TP16

DR

IVE

EN

AB

LE

TP32

WH

T-1

OR

G/R

ED

-3

WH

T/B

LK

-1

WH

T/R

ED

-1

NOHC

WH

T-7

TB31

WH

T/B

LK

-31

-C.H

.

WH

T/R

ED

-32

-C.H

.

TB32

LS4

TP13

L1

BL

U/R

ED

-3

BR

N-2

TB13

NCHO

BL

K-7

BR

N-7

MODELS ONLY)

(2WD/4WD)

TI

R4

50

R1

CR12

TS8

TS58

10


WHT

CE MODELS ONLY



Ground Control Box Wiring Diagram-Z-45/25J Perkins Models (after serial number 16303)


Ground Control Box Wiring Diagram-Z-45/25J Perkins Models (after serial number 16303)

1

2

3

4

5

6

7

8




AUXILIARY

TS63

PLAT.

BLU/BLK-11

RED-R1

RED-20

LEVELBLU-10

BLK/RED-35

BLK-33

BRN-(GRND)WHT-21

WHT-23

BLK-22RED-27

TS60

FUNCTION ENABLE

TS54

START

CB1

TS52

HOUR METER

3

1

L2

TS61

TS59CB2

SEC. BOOM

OIL PRESS

TS57

PRIMARYBOOM

TS58

TS62

TS51

KS1

STACKED CONTACTS

NO

NO

NC

STOP

NC

NO

NO

P1 KS1

ROTATE

ORG/BLK-15

ORG-14

PLATFORM

ROTATETURNTABLE

EXTENDRETRACT

GRN-17

GRN/BLK-18

WHT/RED-6

WHT/BLK-5

WHT-4

BLK/WHT-8

RED/BLK-2

RED/WHT-3

BLK-7

RED-1

WHT/BLK-25

9 BK/RD-R5BLK/RED-3

TACHOMETER

START INPUT

START RELAY

ENG. FAULT

KEY BYPASS

IGN./FUEL ON

CD

IGN./START

MODULE

BLK-3

RED/WHT-3

WHT/BLK-3

WHT-3

RED-3

RED/BLK-3

WHT/RED-3

BLK/WHT-3

RED-4

RED/BLK-4

R/W-4

WHT-4

WHT/BLK-4

BLK/WHT-4

BLK-4

W/R-4

2

1

4

3

7

6

5

8

WHT-23A

WHT-R2#86

10

KEY PWR.

8

9

7

BLK-R1-86

RED-27B

BLK-33D

BRN-GRD.

ORG/BLK-41A

RED-R2#30

PRIMARY BOOM UP

PRIMARY BOOM EXTEND


PRIMARY BOOM DOWN





AB

GROUND

BATTERY

AUX. ON

5

6

4

2

3

1

WT/BK-S.P.

WT/RD-S.P.

WHT-S.P.

BLK-S.P.

RD/BK-S.P.

RED-S.P.

RD/WT-S.P.

BK/WT-S.P.

HORN

OG/BK-IM2

WHT-ISM-7

RED-ISM-4

28RED/BLK-1

GRN/WHT-3

BLU/BLK-3

BLU-3

GRN/BLK-3

ORG/RED-3

ORG/BLK-3

ORG-3

GRN-3

BLU/WHT-3

BLU/RED-3

ORG-4/R7

BLU/BLK-4

BLU-4

GRN/BLK-4

ORG/BLK-4/R8

WHT-12-E.H.1

GRN-4

14

11

10

13

12

16

15

18

17

WHT-2

BLK-2

RED-1

RED-C.H.

RD/WT-C.H.

RED-EXT.-6

WT/RD-E.H.1

21

20

19

23

22

26

25

24

27

BLU/WHT-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

R/W-1

WHT/RED-1

WT/BK-E.H.1

BU/BK-M.H.

BLU-M.H.

33

30

29

32

31

35

34

37

36

GRN/WHT-1

ORG/RED-1

ORG/BLK-1

ORG-1

BLU/RED-1

GRN-1

GRN/BLK-1

WHT#40-R7

OG/BK-E.H.1

40

39

38

42

41

45

44

43

TILT ALARM

SECONDARY BOOM UP

+12 V POWER

SECONDARY BOOM DOWN


PLATFORM LEVEL UP

PLATFORM LEVEL DOWN



DRIVE ENABLE LIGHT

IGNITION POWER

KEYSWITCH POWER

+12 V TO PLATFORM

OIL PRESSURE SWITCH


GR/BK-S.P.

OG/BK-SP

ORG-SP

GRN-S.P.

BU/BK-S.P.

BLU-S.P.

BLU/WT-S.P.

WHT/BLK-SP

WHT-S.P.

RED-S.P.

WHT-S.P.

BLK-S.P.

RED-S.P.

JIB VALVE


STEER RIGHT

GLOW PLUG

STEER LEFT

OFF-LIMIT SPEED


GENERATOR OPTION

BK/RD-R3#35

BLK-S.P.BLK-ISM-3

(SPARE)

START ENGINE

2WD/4WD

E.D.C.

E.D.C.

BRAKE

HIGH/LOW RPM

(SPARE)

(SPARE)

(SPARE)

(SPARE)

BLU/WHT-12


LE

D

GR/WT-S.P.

ORG/BLK-4

CR8

ORG/BLK-15

BLK/RED-R4

WHT-40B

BRN-(GRND H.M)

CR4CR3

BLK/RED-35B

WHT-21

CR2

BLK-R1-E.H.

CR1

BLK-R1

RED-R1

WHT-R2

ORG-4

CR7


BRN-(R5)

GRN/WHT-19

JIB

BLK/RED-R5

BLK-22

BLK/RED-9A

RED-R2

WHT-21 (R2)

WHT/RED-SP

WHT/BLK-EH.1

BK/RD-SP

BLK/WHT-E.H.1

WHT-SEC#4

WHT-PRIM.#5

RE

D

WHT/RED-26

OIL TEMP.

L3

GR/WT-C.H

WHT-ISM-10

BLK-ENA.

RED-C.H

RED/BLK-C.H

RED/WHT-C.H

WHT-ENA.

WHT/RED-C.H

WHT-24D

WHT-E.H.1




ORG-14

CH+EH1

M.H.

PRIM.5

SECON.4

1

2

3

EXT.6

GRD-HOLE

WHT-EXT.#6

RED-ENA.

2

ORG-M.H.-r.male

ORG/BLK-M.H.-r.male

r.fem-ORG-R7

r.fem-ORG/BLK-R8


CR2

CR3

CR1

CR4

CR7

CR8

L2



RPM SOLENOID RELAY


POWER RELAY


OIL PRESSURE LED

DESCRIPTIONLABEL

TS52

TS57

TS59

TS54

KS1

TS51

TS58

CB2

HM

R4

TS60

TS62

CB1

TS61

TS63

P1






HOUR METER





JIB BOOM UP/DOWN (JIB OPTION ONLY)

KEY SWITCH


AUXILIARY SWITCH

START ENGINE SWITCH


HORN RELAYCR5

ENGINE HARNESSEH

HOUR METER


CHASSIS HARNESS

SWITCH PANEL

MANIFOLD HARNESS

H.M.

ISM

R or CR RELAY

C.H.

S.P.

M.H.


ENGINE FAULT



CR5

R4

+

BLK/RED-35GEN

BLK/RED-35GEN

BLK/WHT-34

TS56

GLOW PLUG

GLOW PLUGTS56

Platform Control Box Wiring Diagram-Z-45/25J Perkins Models (after serial number 16303)




1

2

3

4

5

6

7

8

5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.

PW

R.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.

LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.

(OP

TIO

N)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.

BO

OM

DN

.

SE

C.

BO

OM

UP

PW

R.

TO

F.S

.

F.S

.U

PP

OW

ER

PW

R.

(CO

NT.)

PL

AT.

RO

T.

R.

PL

AT.

RO

T.

L.

PL

AT.

LE

VE

LD

N.

PL

AT.

LE

VE

LU

P

TU

RN

.R

OT.

F.C

.

TU

RN

RO

T.

R.

TU

RN

RO

T.

L.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.

BO

OM

F.C

.

JIB

VA

LVE

BR

AK

E

AU

X.

PU

MP

SE

L.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

GEN.

TIME DELAY

HIGH/LOW

START

DRIVE

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

RE

D-T

ILT

RE

D-S

TP

P2

T1

TS4

TS2

TS6

R3R2TS15

RPM

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



WHT JIB CABLE

BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

JIB

OPT.

RE

DF

RO

MC

R1

4

BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOMUP/DOWN,TURNTABLE ROTATEBP1

CR13

CR14

CR12

H.P.L.

T1

BP2

TIME DELAY

TILT ALARM



JIB CUTOUT RELAY

JIB VALVE RELAY


COMPONENT INDEX

TS2

TS7

TS9

TS6

P3

TS1

TS8

R3

L1

TS10

TS12

R2

TS11

R1

TS13

P2


LOW SPEED RESISTOR


LOW SPEED RESISTOR



DRIVE ENABLE LED


JIB UP/DOWN

GLOW PLUG OPTION



HORN SWITCH


AUXILIARY SWITCH


US

ED

)

(SP

AR

E)

RE

D-G

EN

GR

N/W

HT

-45

LIMITING RELAY

RED-10

R1

50

CR12

WHT-24

RED-10

ORG-40

BL

K/W

HT

-34

GLOW PLUG


DP1

TS47


8

7

6

54

3

21


SEESIDE VIEW

DP1

SIDE VIEW FOR DP1

RE

D-T

ILT

REMOVE FOR LIFT/DRIVE SELECT VERSION

RE

D-S

TP

+ -

Platform Control Box Wiring Diagram-Z-45/25J Perkins Models (after serial number 16303)


Platform Control Box Wiring Diagram- Lift/Drive SelectOption,Z-45/25J Perkins Models (after serial number 16303)




5

WH

T/R

ED

-6

OR

G-1

4

OR

G/B

LK

-15

BL

K/R

ED

-9

NO

RE

D/B

LK

-28

ALARMTILT

STUDGRD.

76

81

09

WHT-24 14

23

KE

YS

W.

PW

R.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.

LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.

(OP

TIO

N)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.

BO

OM

DN

.

SE

C.

BO

OM

UP

PW

R.

TO

F.S

.

F.S

.U

PP

OW

ER

PW

R.

(CO

NT.)

PL

AT.

RO

T.

R.

PL

AT.

RO

T.

L.

PL

AT.

LE

VE

LD

N.

PL

AT.

LE

VE

LU

P

TU

RN

.R

OT.

F.C

.

TU

RN

RO

T.

R.

TU

RN

RO

T.

L.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/W

HT

-12

RE

D-2

7

GR

N/B

LK

-18

GR

N-1

7

BL

K/W

HT

-8

BL

K-7

RE

D-1

RE

D/B

LK

-2

WH

T/B

LK

-5

WH

T-4

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

BL

U/B

LK

-37

RE

DT

IM.D

EL

.

WH

T-3

0

WH

T/R

ED

-32

BL

K/R

ED

-35

BL

U/R

ED

-13

RE

D-2

5

BL

K-3

3

OR

G/R

ED

-16

RE

D-1

0T

OH

.P.L

.

RE

D/W

HT

-29

BL

U/B

LK

-11

BL

U-1

0

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.

BO

OM

F.C

.

JIB

VA

LVE

BR

AK

E

AU

X.

PU

MP

SE

L.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

WH

T-2

4T

OH

.P.L

.

BL

K-2

6

BR

NT

OG

RD

.

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TIL

TA

LA

RM

RE

D/B

LK

-1

25

0

10

0

EMERGENCY STOP

HORN

ORG/BLK-41

ORG-40

OP

TIO

NW

IRE

WH

T

GR

N/W

HT

-19

CABLE

#3H1

BLK JIB CABLE

GRN/WHT +

RED OUTPUT

BRN

RE

D/W

HT

-3

WH

T/B

LK

-31

WH

T-2

3

BL

K-2

2

BL

U-3

6

RE

DJU

MP

RE

DT

OJIB

CA

BL

E

GEN.

TIME DELAY

HIGH/LOW

START

DRIVE

VALVE

JIB CUTOUT

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMP

JIB

PRIMARY

PLATFORMPLATFORM

PRIMARY BOOM

RE

D-T

ILT

RE

D-S

TP

P2

T1

TS4

TS2

TS6

R2 R3TS15

RPM

RELAY

RELAY

L1

CR14

CR13

DRIVESPEED

TS1

TS14

TS8

ROTATE

TS7

BOOMEXTEND/RETRACT

TS13


LEVEL

TS9

P3



WHT JIB CABLE

BP1

BP2

NO

NC

NONC

NC

NO

POWERLIMITERBOARD

HORSE-

JIB

OPT.

RE

DF

RO

MC

R1

4

BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOMUP/DOWN,TURNTABLE ROTATEBP1

CR13

CR14

CR12

H.P.L.

T1

H1

BP2

TIME DELAY

TILT ALARM



JIB CUTOUT RELAY

JIB VALVE RELAY


COMPONENT INDEX

TS2

TS7

TS9

TS6

P3

TS1

TS8

R3

L1

TS10

TS12

R2

TS11

R1

TS13

P2


LOW SPEED RESISTOR


LOW SPEED RESISTOR



DRIVE ENABLE LED


JIB BOOMUP/DOWN




HORN SWITCH


AUXILIARY SWITCH


US

ED

)

(SP

AR

E)

RE

D-G

EN

GR

N/W

HT

-45

LIMITING RELAYRED-10

R1

50

CR12

WHT-24

RED-10

ORG-40

BL

K/W

HT

-34

GLOW PLUG


DP1

TS47


8

7

6

54

3

21


SEESIDE VIEW

DP1

SIDE VIEW FOR DP1

RE

D-T

ILT

RE

D-S

TP

+ -

1

2

3

4

5

6

7

8

Platform Control Box Wiring Diagram- Lift/Drive Select Option,Z-45/25J Perkins Models (after serial number 16303)


Platform Control Box Wiring Diagram- Load Sensor Option,All Models (after serial number 16303)


1

2

3

4

5

6

7

8



Platform Control Box Wiring Diagram- Load Sensor Option,All Models (after serial number 16303)


5

NO

ALARM

TILT

76

81

09

14

23

KE

YS

W.P

WR

.

+1

2V

TO

PL

AT.

DR

IVE

EN

A.LT.

LIM

ITS

WIT

CH

PU

LS

EP

ICK

UP

GE

N.(O

PT

ION

)

ST

EE

RR

IGH

T

GL

OW

PL

UG

DR

IVE

EN

AB

LE

SE

C.B

OO

MD

N.

SE

C.B

OO

MU

P

PW

R.T

OF.S

.

F.S

.U

PP

OW

ER

PW

R.(C

ON

T.)

PL

AT.R

OT.R

.

PL

AT.R

OT.L

.

PL

AT.L

EV

EL

DN

.

PL

AT.L

EV

EL

UP

TU

RN

.R

OT.F.C

.

TU

RN

RO

T.R

.

TU

RN

RO

T.L

.

PR

IMA

RY

F.C

.

PR

IMA

RY

UP

PR

IMA

RY

DO

WN

ST

EE

RL

EF

T

110

25

RE

D(F

.S.)

BL

U/B

LK

-3

#2

CABLE

#1

CABLE

RE

D-3

RE

D/B

LK

-3

RE

D/W

HT

-3

21 3

BL

U-3

BL

K-3

BL

K/R

ED

-3

BL

K/W

HT

-3

WH

T-3

WH

T/R

ED

-3

WH

T/B

LK

-3

764 5 1098

JIB

CABLEF.S.

GR

N/B

LK

-3

BL

U/R

ED

-3

GR

N-3

OR

G/R

ED

-3

OR

G-3

BL

U/W

HT

-3

OR

G/B

LK

-3

14

1311

12

17

15

16

WH

T-2

BL

K-2

WH

T(F

.S.)

GR

N/W

HT

-3

20 21

19

18

24

23

22

39

BL

U/R

ED

-1

32

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

RE

D-1

BL

K(F

.S.)

RE

D/W

HT

-1

27

28

26 31

29

30

BL

U/B

LK

-1

BL

U/W

HT

-1

BL

K/W

HT

-1

BL

K/R

ED

-1

BL

K-1

BL

U-1

35

33

34

37

38

36

GR

N/B

LK

-1

GR

N/W

HT

-1

GR

N-1

OR

G/R

ED

-1

OR

G/B

LK

-1

OR

G-1

42

40 41

45

44

43

BO

OM

EX

TE

ND

HO

RN

BO

OM

RE

TR

AC

T

SE

C.B

OO

MF.C

.

JIB

VA

LVE

BR

AK

E

AU

X.P

UM

PS

EL

.

E.D

.C.

E.D

.C.

2W

D/4

WD

HIG

H/L

OW

RP

M

STA

RT

EN

GIN

E

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

(SP

AR

E)

NC NC

R+

AX

R

-

+A

X-

+A

RX

- 42

31

56

78

TILT

AL

AR

MR

ED

/BL

K-1

EMERGENCY STOP

HORN

OP

TIO

NW

IRE

WH

T

CABLE

#3

HIGH/LOW

START

DRIVE

SEC.BOOM

DRV.ENA

HIGH/LOW (2WD/4WD)

AUXILIARY PUMPJIBPLATFORMPLATFORM

PRIMARY BOOM

P2

TS4TS2

TS15

RPM

L1

DRIVESPEED

TS1

TS14TS8

ROTATE

TS7

PRIMARYBOOM

EXTEND/RETRACT

TS13

TURNTABLE

UP/DOWNROTATE

LEVEL

TS9P3



BP1

BP2NONC

NC

NO

BILL OF MATERIALS

54907

32335

56765

54909

54908

54905

54906

48716

56766

PART NUMBER

MODULE,LOAD SENSE,1/12V RELAY

DECAL, LABEL, LOAD SENSOR

WIRE ASSY LDSENSE, BROWN, GROUND

LOAD CELL BENDING TYPE

LED,RED 12V LARGE

WIRE ASSY LDSENS/FS, WHITE JUMP

WIRE ASSY LOADSENSE, ORANGE LED

DESCRIPTION

WIRE ASSY FTSWTCH/LDSENSOR, PWR

WIRE ASSY, LDSENSE, LED, GROUND

(UN

US

ED

)

GLOW PLUG

DP1

TS47

GROUND

BOLT

YELLOW LEDPREALARM(NOT USED)

OVER LOAD ADJUST

FUSE, 500 mA

RELAY

12

VO

LT

S

C.

N.C.

N.O.

+-

PREALARM ADJUST(NOT USED)

RED

OVER LOADLED

9

8

7

6

1

5

4

3

2

NP

N

R

V

B

WHT-LOAD (P/N 54908)

WHT-(F.S.) (P/N 54904)

OR

G-L

OA

D(P

/N5

49

05

)

BR

N-L

OA

DB

LK

-26

LO

AD

(P/N

54

90

6)

WHTGRNREDBLK

BR

N-L

OA

D(P

/N5

49

09

)

BL

K-2

6L

OA

D(P

/N5

49

06

)

BL

K-2

6(P

/N5

49

06

)

OR

G-L

OA

D(P

/N5

49

05

)

BRN

BRN (P/N 54907)

LOAD SENSOR MODULE (COVER REMOVED)

OPTIONGENERATOR

L4

TS6

DRV.ENA LED

CABLE TO LOAD CELL (P/N 56765)

(P/N 56766)

OVER LOAD LED(P/N 32335)

+

+

HO

RS

EP

OW

ER

LIM

ITE

RB

OA

RD

54904 WIRE ASSY FOOTSWITCH, SERV LOOP


Hydraulic Symbols Legend




1

2

3

4

5

6

7

8


2WD Hydraulic Schematic



REARLEFT

REARRIGHT

DRIVEMANIFOLD

X

LA

LB

RB

0.070”(1.18 mm) 50%

50%

0.030”(0.76 mm)

TEST

PB

RA PA

2 SPEED

BRAKE

T2

T

VV

WW

QQ

XX

PPYY

RR

UU

TTE

M

HIGHPRESSURE

FILTER

DRIVE PUMP

FUNCTIONPUMP7 GPM

(26.5 L/min)

TANK APU

LIFT FUNCTION MANIFOLD

GENERATORSELECT

OPTIONALMOTOR/

GENERATOR

X

OPTIONAL OSCILLATE

DIRECTIONAL VALVE

STEERINGCYLINDERS

JIB BOOM CYLINDER

JIB BOOMMANIFOLD

MASTERCYLINDER

X

PLATFORM ROTATE CYLINDER

SLAVECYLINDER

X SECONDARYBOOM CYLINDERS

EXTENSIONCYLINDER

PRIMARYBOOM CYLINDER

1.5:13800 PSI(262 bar)

semi restricted

1:1ATMOS

3000 PSI.(206.8 bar)

5:1ATMOS.

1500 PSI(103.4 bar)

3:1ATMOS.

1000 PSI(68.9 bar)

360 PSI(24.8 bar)

50 PSI(3.4 bar)

NOTE #1: 250 PSI (17.2 bar) before serial number280 PSI (19.3 bar) after serial number 12603

12604

3500 PSI(241.3 bar)

1.5:13800 PSI(262 bar)

semi restricted

J2 J1 V2 V1

R2

R1

V2 V1

3:12000 PSI

(137.9 bar)

1800 PSI(124.1 bar)

2 GPM(7.6 L/min)

EXTEND RETRACT

2300 PSI(159 bar)

This valve wasremoved afterserial number

12603

4.5:11000 PSI(67 bar)

ST1 ST2 PR1 PR2 PL1 PL2 SW1 SW2

4.5:13500 PSI

(241.3 bar)

S1 S2 P1 P2

TEST

PRESSURE

TANK

3200 PSI(220.6 bar)

0.6 GPM(2.3 L/min)

0.1 GPM(0.4 L/min)

1 GPM(3.8 L/min)

T2

1.5 GPM(5.7 L/min)

25 PSI(1.7 bar)

3200 PSI(220.6 bar)

0.040”(1 mm)

OPTIONALOSCILLATECLYINDERS

3:1SEMI RESTRICTIVE

SEALED PILOT3000 PSI.

(206.8 bar)

LLB

D

A

G

Z

N

AA

OEE

CC

TURNTABLE ROTATE

3:11500 PSI

(103.4 bar)

V2

S1

V1

OO NN

MM

N

KK

GG

F

BB

VU

S

P

QR

TFF

I

DD

Y

M

K

W

L

JEHHJJ

II

C

X

0.030”(0.76 mm)

0.030”(.76 mm)

0.030”(0.76 mm)

See Note #1

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

l

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

David.Reichel

Typewritten Text

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1

2

3

4

5

6

7

8





E

M

HIGHPRESSURE

FILTER

DRIVE PUMP

FUNCTIONPUMP7 GPM

(26.5 L/min)

TANK APU

LIFT FUNCTION MANIFOLD

REARLEFT

REARRIGHT

FRONTLEFT

FRONTRIGHT

GENERATORSELECT

OPTIONALMOTOR/

GENERATOR

DRIVEMANIFOLD

X

X

OPTIONAL OSCILLATE

DIRECTIONAL VALVE

STEERINGCYLINDERS

RB

JIB BOOM CYLINDER

JIB BOOMMANIFOLD

MASTERCYLINDER

X

PLATFORM ROTATE CYLINDER

SLAVECYLINDER

X SECONDARYBOOM CYLINDERS

EXTENSIONCYLINDER

PRIMARYBOOM CYLINDER

1.5:13800 PSI(262 bar)

semi restricted

1:1ATMOS

3000 PSI.(206.8 bar)

5:1ATMOS.

1500 PSI(103.4 bar)

3:1ATMOS.

1000 PSI(68.9 bar)

360 PSI(24.8 bar)

50 PSI(3.4 bar)

B

A

RFB

RFA

LFB

LFA

TEST

T2 TANK

67% 33%

0.052”(1.32 mm)

0.025”(0.64 mm)

0.030”(0.76 mm)

50%

50%

NOTE #1: 2 GPM (7.6 L/min) before serial number0.8 GPM after serial number 14774

14775(3.02 L/min)

NOTE #2: 250 PSI (17.2 bar) before serial number280 PSI (19.3 bar) after serial number 12603

12604

RA

LB

BRAKE

2 SPEED

50%

50%

3500 PSI(241.3 bar)

1.5:13800 PSI(262 bar)

semi restricted

J2 J1 V2 V1

R2

R1

V2 V1

3:12000 PSI

(137.9 bar)

1800 PSI(124.1 bar)

2 GPM(7.6 L/min)

EXTEND RETRACT

2300 PSI(159 bar)

This valve wasremoved afterserial number

12603

4.5:11000 PSI(67 bar)

ST1 ST2 PR1 PR2 PL1 PL2 SW1 SW2

4.5:13500 PSI

(241.3 bar)

S1 S2 P1 P2

TEST

PRESSURE

TANK

3200 PSI(220.6 bar)

0.6 GPM(2.3 L/min)

0.1 GPM(0.4 L/min)

1 GPM(3.8 L/min)

T2

1.5 GPM(5.7 L/min)

25 PSI(1.7 bar)

3200 PSI(220.6 bar)

0.2 GPM(0.76 L/min)

0.040”(1 mm)

OPTIONALOSCILLATECLYINDERS

3:1SEMI RESTRICTIVE

SEALED PILOT3000 PSI.

(206.8 bar)

LLB

D

A

G

Z

N

AA

OEE

CC

TURNTABLE ROTATE

3:11500 PSI

(103.4 bar)

V2

S1

V1

OO NN

MM

N

KK

GG

AK AI

AJ

AHAF

AL

AM

AE

ACAT

AP

AO

AD

AG

AR

AQAS

AB

F

BB

VU

S

P

QR

TFF

I

DD

YM

K

W

L

JEHHJJ

II

C

X

See Note #1

See Note #2

0.030”(0.76 mm)

0.030”(.76 mm)

0.030”(0.76 mm)

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First Edition • Second Printing Section 7 • Repair Procedures

Repair Procedures

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



Before Repairs Start:Read, understand and obey the safety rulesand operating instructions in the Genie Z-45/25& Genie Z-45/25J Operator’s Manual.

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 flat, level surface


· Turntable rotated with the boom between the non-steering wheels

· Turntable secured with the turntable rotation lock

· Key switch in the OFF position with the key removed

· Wheels chocked

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. Then tore-assemble, perform the disassembly steps inreverse order.

Symbols Legend







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


First Edition • Second PrintingSection 7 • Repair Procedures

1-1Joystick Controllers

Maintaining joystick controllers at the propersettings is essential to safe machine operation.Every joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

Platform control boxa horsepower limiter boardb terminal stripc drive proportional controllerd secondary boom proportional

controllere primary boom proportional controllerf turntable rotate proportional controller

Primary Boom Up/DownController Adjustments

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

Do not adjust the joystickcontrollers unless the static batteryvoltage is above 12V DC and thealternator is operating properly with13.6 to 14.5V DC output.

Individual trim potentiometers(trimpots) are used to adjustvarious output signals from thedrive and boom functioncontrollers. The trimpots will beidentified as the following.

• Max out trim potentiameter (max out trimpot)

• High range trim potentiameter (max out trimpot)

• Lo range trim potentiometer (lo range trimpot)

• Dual range trim potentiometer (lo range trimpot)

• Threshold trim potentiometer (threshold trimpot)

• Ramp rate trim potentiometer (ramp rate rimpot)

1 Turn the key switch to platform control andpull out the Emergency Stop button to theON position at both the ground and platformcontrols. Do not start the engine.

Platform Controls

b

c

a

def



6 Set the hi range: Press down the foot switch,then move the control handle all the way tothe UP position. Adjust the voltage to 6.5V DC.Turn the hi range trimpot adjustment screwclockwise to increase the voltage orcounterclockwise to decrease the voltage.

7 Set the lo range: Press down the foot switch,then move the control handle all the way to theDOWN position. Adjust the voltage to 5.5V DC.Turn the lo range trimpot adjustment screwclockwise to increase the voltage orcounterclockwise to decrease the voltage.

8 Start the engine and move the engine idlecontrol switch to foot switch activated highidle (rabbit and foot switch symbol).

9 Start a timer and record how long it takes forthe primary boom to fully raise. Adjust thehi range trimpot to achieve a 24 to 27 secondcycle time. Turn the hi range trimpot adjustmentscrew clockwise to increase the speed orcounterclockwise to decrease the speed.

10 Start a timer and record how long it takes forthe boom to fully lower. Adjust the lo rangetrimpot to achieve an 32 to 37 second cycletime. Turn the lo range trimpot adjustmentscrew clockwise to increase the speed orcounterclockwise to decrease the speed.

If the function cycle time is notachievable, check the relief valvepressure. See 12-2, ValveAdjustments - Function Manifold.

11 Turn the engine OFF.

12 Pull out the Emergency Stop button tothe ON position.

2 Open the platform control box lid and locatethe primary boom up/down controller.

a ramp rate adjustable trimpotb lo range adjustable trimpotc terminal "R" activates hi ranged (not used)e terminal "X" (not used)f terminal "-" groundg terminal "+" positiveh terminal "A" proportional outputi threshold adjustable trimpotj hi range adjustable trimpot

3 Set the preliminary ramp rate: Turn the ramprate trimpot adjustment screw counterclockwise15 turns or until you hear a repeated click.

4 Connect the red (+) lead from a volt meter tothe “A” terminal on the controller printed circuitboard. Connect the black (-) lead to ground.

5 Set the threshold: Press down the foot switch,then slowly move the control handle off centeruntil the moment a voltage reading appears.Adjust the voltage to 2.85V DC. Turn thethreshold trimpot adjustment screw clockwise toincrease the voltage or counterclockwise todecrease the voltage.

PLATFORM CONTROLS

a b c d e f g h i j



13 Press down the foot switch and then move thecontrol handle all the way to the UP position.Record the maximum voltage reading.

14 Start a timer and simultaneously move thecontrol handle all the way to the UP position.Note how long it takes to reach the maximumvoltage recorded in step 14. This is theramp rate.

15 Set the ramp rate: turn the ramp rate trimpot toobtain a 3 to 4 second ramp speed. Turn thetrimpot clockwise to increase the time orcounterclockwise to decrease the time.

Boom up/down specifications

Threshold 2.85V DC

Primary boom up - hi range 6.5V DCCycle time 24 to 27 seconds

Primary boom down - lo range 5.5V DCCycle time 32 to 37 seconds

Ramp rate 3 to 4 seconds

Secondary Boom Up/DownController Adjustments


Do not adjust the joystickcontrollers unless the static batteryvoltage is above 12V DC and thealternator is operating properlywith 13.6 to 14.5V DC output.

1 Turn the key switch to platform control andpull out the Emergency Stop button to theON position at both the ground and platformcontrols. Do not start the engine.

PLATFORM CONTROLS



2 Open the platform control box lid and locatethe secondary boom up/down controller.

a ramp rate adjustable trimpotb lo range adjustable trimpotc terminal "R" activates hi ranged (not used)e terminal "X" (not used)f terminal "-" groundg terminal "+" positiveh terminal "A" proportional outputi threshold adjustable trimpotj hi range adjustable trimpot



5 Set the threshold: Press down the foot switch,then slowly move the control handle off centeruntil the moment a voltage reading appears.Adjust the voltage to 2.85V DC. Turn thethreshold trimpot adjustment screw clockwise toincrease the voltage or counterclockwise todecrease the voltage.

6 Set the hi range: Press down the foot switch,then move the control handle all the way tothe UP position. Adjust the voltage to 6.5V DC.Turn the hi range trimpot adjustment screwclockwise to increase the voltage orcounterclockwise to decrease the voltage.

7 Set the lo range: Press down the foot switch,then move the control handle all the way to theDOWN position. Adjust the voltageto 5.5V DC.Turn the lo range trimpot adjustment screwclockwise to increase the voltage orcounterclockwise to decrease the voltage.

8 Start the engine and move the engine idlecontrol switch to foot switch activated highidle (rabbit and foot switch symbol).

9 Start a timer and record how long it takes forthe secondary boom to fully raise. Adjust themax-out trimpot to achieve a 23 to 27 secondcycle time. Turn the hi range trimpot adjustmentscrew clockwise to increase the speed orcounterclockwise to decrease the speed.

10 Start a timer and record how long it takes forthe secondary boom to fully lower. Adjust thedual range trimpot to achieve an 23 to 27second cycle time. Turn the hi range trimpotadjustment screw clockwise to increase thespeed or counterclockwise to decrease thespeed.

If the function cycle time is notachievable, check the relief valvepressure. See 12-2, ValveAdjustments - Function Manifold.


12 Pull out the Emergency Stop button tothe ON position.

PLATFORM CONTROLS

a b c d e f g h i j



PLATFORM CONTROLS

13 Press down the foot switch and then move thecontrol handle all the way to the UP position.Record the maximum voltage reading.

14 Start a timer and simultaneously move thecontrol handle all the way to the UP position.Note how long it takes to reach the maximumvoltage recorded in step 14. This is theramp rate.


Secondary boom up/down specifications

Threshold 2.85V DC

Secondary boom up - hi range 6.5V DCCycle time 23 to 27 seconds

Secondary boom down - lo range 5.5V DCCycle time 40 seconds

Ramp rate 3 to 4 seconds

Turntable Rotation ControllerAdjustments


Do not adjust the joystickcontrollers unless the static batteryvoltage is above 12V DC and thealternator is operating properlywith 13.6 to 14.5V DC output.

1 Turn the key switch to platform control andpull out the Emergency Stop button tothe ON position at both the ground andplatform controls. Do not start the engine.



PLATFORM CONTROLS

2 Open the platform control box lid and locatethe turntable rotation controller. Refer to theplatform control box illustration, page 7-2.

a ramp rate adjustable trimpotb lo range adjustable trimpotc terminal "R" (not used)d (not used)e terminal "X" (not used)f terminal "-" groundg terminal "+" positiveh terminal "A" proportional outputi threshold adjustable trimpotj hi range adjustable trimpot



5 Set the threshold: Press down the foot switch,then slowly move the control handle off centeruntil the moment a voltage reading appears.Adjust the voltage to 2.85V DC. Turn thethreshold trimpot adjustment screw clockwise toincrease the voltage or counterclockwiseto decrease the voltage.

6 Set the hi range: Press down the foot switch,fully retract the boom, then move the controlhandle all the way to the left or right. Adjust thevoltage to 5.5V DC. Turn the hi range trimpotadjustment screw clockwise to increase thevoltage or counterclockwise to decrease thevoltage.

7 Start the engine and move the engine idlecontrol switch to foot switch activated high idle(rabbit and foot switch symbol). Rotate theturntable to the FULL RIGHT position.

8 Start a timer and record how long it takes theturntable to rotate to the FULL LEFT position.Adjust the max-out trimpot to achieve a 73 to 78second cycle time. Turn the hi range trimpotadjustment screw clockwise to increase thespeed or counterclockwise to decrease thespeed.


Turntable rotation specifications

Threshold 2.85V DC

Turntable rotation -hi range 5.5V DCCycle time 73 to 78 seconds

Ramp rate 5 seconds

a b c d e f g h i j



PLATFORM CONTROLS

1-2Horsepower Limiter Board

The horsepower limiter board is responsible forgoverning drive pump output. It senses engine rpmfrom the alternator. The horsepower limiter boardsenses drops in rpm normally due to increaseddrive resistance (rough terrain or incline), anddecreases voltage to the drive controller which inturn decreases voltage to the drive pump, therebyreducing pump output to maintain optimum enginerpm and horsepower. Three adjustments arerequired for optimum performance.

How to Adjust the HorsepowerLimiter Board

The engine rpm must becorrect before performing thisprocedure. See MaintenanceProcedure A-22, Check andAdjust the Engine RPM, forPerkins Diesel Models, OR seeB-10 for Ford and Deutz EngineModels.

Do not adjust the horsepowerlimiter board unless the staticbattery voltage is above 12V DCand the alternator is operatingproperly with 12.5 to 14.5V DCoutput.

Ford models: Perform thisprocedure in gasoline mode.

1 Remove the fasteners from the platformcontrol box lid.

2 Open the control box lid and locate thehorsepower limiter board.

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

Platform control box

a horsepower limiter board

a



PLATFORM CONTROLS

3 Connect the black (-) lead from a DC volt meterto the number 2 terminal, and the red (+) lead tothe number 10 terminal.

Horsepower limiter board

a "A" potentiometer maximum voltageoutput to the controller in the stowedposition

b "B" potentiometer maximum voltageoutput to the drive controller in theboom raised or extended position

c "C" potentiometer reaction rate orhow fast the voltage output reacts tothe change in engine rpm



6 Press down the foot switch and adjust the"A" potentiometer counterclockwise to increasevoltage or clockwise to decrease voltage.

"A" potentiometer specifications - all models

Voltage setting 9 to 10V DC

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

8 Press down the foot switch and then adjustthe "C" potentiometer to obtain a0.1V DC to 0.5V DC voltage reading.


10 Press down the foot switch and re-adjust the"A" potentiometer to the previous voltagesetting in step 6.

11 Be sure that the boom is in the stowed position,then drive the machine and observe how theengine rpm reacts to drive control handlemovement. If the engine surges or hunts, adjustthe "C" potentiometer counterclockwise untilsurging is minimized.

Under an extreme load, anexcessive counterclockwiseadjustment to the "C"potentiometer will cause theengine to stall. The "C"potentiometer adjustment is acompromise between enginestability (surging) and enginerpm drop.

12 Disconnect the volt meter.

13 Raise the primary boom above horizontal.

12V DC or greatergroundengine rpm sensornot usednot usedlow drive speed limit switchnot usednot usednot usedoutput to drive controller

b

a

c



14 Drive the machine for 40 feet (12 m) andrecord the elapsed time. Repeat this step inthe opposite drive direction.

15 Adjust the "B" potentiometer to obtain thecorrect raised drive speed (see specificationsbelow). Turn the "B" potentiometercounterclockwise to decrease voltage orclockwise to increase voltage.

16 Close the platform control box lid and installthe fasteners.

Drive speed specifications

Stowed position drive speed: distance: 40 ft/12.2 mAll models 40 ft/5.7 sec

12.2 m/5.7 sec


12.2 m/45 sec


12.2 m/79 sec

1-3Foot Switch

How to Test the Foot SwitchPerform this procedure with thekeyswitch in the OFF position.

1 Remove the foot switch cover plate fastenersfrom the platform.

2 Remove the foot switch guard mountingfasteners from the platform.

3 Remove the foot switch mounting fasteners thatattach the foot switch to the foot switch guard.

4 Remove the cover plate from the bottom of thefoot switch to access the foot switch wireterminals.

5 Do not press down the foot switch. Connect theleads from an ohmmeter or continuity tester toeach terminal combination listed and check forcontinuity.

PLATFORM CONTROLS



Test Desired result

N.C. to C continuity(zero Ω)

N.C. to N.O. no continuity(infinite Ω)

C to N.O. no continuity(infinite Ω)

6 Press down the foot switch. Connect the leadsfrom an ohmmeter or continuity tester to eachterminal combination listed below and check forcontinuity.

Test Desired result

N.C. to C no continuity(infinite Ω)

N.C. to N.O. no continuity(infinite Ω)

C to N.O. continuity(zero Ω)

1-4Toggle Switches

Toggle switches used for single function switchingare single pole double throw (SPDT) switches.Dual function switching requires a double poledouble throw (DPDT) switch.

How to Test a Toggle SwitchContinuity is the equivalent of 0 to3 ohms. A simple continuity testermay not accurately test the switch.

This procedure covers fundamental switch testingand does not specifically apply to all varieties oftoggle switches.

1 Turn the key switch to the OFF position. Tagand disconnect all wiring from the toggle switchto be tested.

PLATFORM CONTROLS



2 Connect the leads of an ohmmeter to the switchterminals in the following combinations listed tocheck for continuity.

PLATFORM CONTROLS

1

2

3

4 5 6

1 2 3

1

2

3 1

2

3

1 2 3 1 2 3

1 2 3 1 2 3 1 2 3

4 5 6 4 5 6

CenterLeft Right

Single poledouble throw(SPDT)

Double poledouble throw(DPDT)

Test Desired result

Left position

terminal 1 to 2, 3, 4, 5 & 6 no continuity(infinite )

terminal 2 to 3 continuity(zero )

terminal 2 to 4, 5 & 6 no continuity(infinite )


terminal 4 to 5 & 6 no continuity(infinite )


Center position There are no terminal combinationsthat will produce continuity

(infinite )

Right position


terminal 1 to 3, 4, 5 & 6 no continuity(infinite )

terminal 2 to 3, 4, 5 & 6 no continuity(infinite )



terminal 4 to 6 no continuity(infinite )

terminal 5 to 6 no continuity(infinite )



Platform Components

2-1Platform

How to Remove the Platform1 Remove the foot switch cover plate from the

platform.

2 Remove the foot switch guard mountingfasteners from the platform.

3 Remove the footswitch and guard through theback of the platform through the access holeand set it aside.

4 Remove the platform control box mountingfasteners. Then lower the control box and set itaside.

If your machine is equipped withan airline to platform option, theairline must be disconnected fromthe platform before removal.

5 Raise the primary boom slightly and placeblocks under the platform. Then lower theprimary boom until the platform is resting on theblocks just enough to support the platform.

Do not rest the entire weight of theboom on the blocks.

6 Remove the platform mounting fasteners andremove the platform from the machine.

Crushing hazard. The platformmay become unstable and fall if itis not properly supported.



PLATFORM COMPONENTS

2-2Platform 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 on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section Two, HydraulicHose and Fitting TorqueSpecifications.

1 Z-45/25J Models: Extend the primary boomuntil the slave cylinder barrel-end pivot pin isaccessible.

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.


4 Z-45/25J Models: Tag, disconnect and plug thehydraulic hoses from the slave cylinder at theunion located near the jib/rotate manifold andconnect them together using a connector.Connect the hoses from the cylinder togetherusing a connector.


Z-45/25 Models: Tag, disconnect and plug thehydraulic hoses from the slave cylinder andconnect the hoses together using a connector.Cap the fittings on the cylinder. Then pull theslave cylinder hoses out through the primaryextension boom.


5 Remove the pin retaining fastener from theslave cylinder rod-end pivot pin. Do not removethe pin.

6 Z-45/25J Models: Remove the external snaprings from the barrel-end pivot pin.

Z-45/25 Models: Remove the pin retainingfastener from the slave cylinder barrel-end pivotpin. Do not remove the pin.



PLATFORM COMPONENTS

7 Support the slave cylinder with a lifting device.

8 Z-45/25J Models: Support the jib boom bellcrank with a suitable lifting device.

9 Use a soft metal drift to drive the rod-end pivotpin out.

Crushing hazard. The jib boombell crank may fall when the slavecylinder rod-end pivot pin isremoved if it is not properlysupported.

Component damage hazard. Theslave cylinder rod may becomedamaged if it is allowed to fall if itis not properly supported by thelifting device.

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 CylinderDo not start the engine. Useauxiliary power for all machinefunctions in this procedure.

1 Raise the primary boom to a horizontal position.

2 Move the platform level switch up and downthrough two platform leveling cycles to removeany air that might be in the system.

2-3Platform Rotator

The platform rotator is a hydraulically-activated,helical gear assembly used to rotate the platform160 degrees.

How to Remove thePlatform Rotator

Component damage hazard. Markthe platform mounting weldmentand the rotator flange beforeremoving the platform mountingweldment. The platform mountingweldment must be replaced in theexact same position on the rotatorflange as it was before removal. Ifa new rotator is installed or therotator is disassembled, properalignment can be achieved byrotating the rotator all the way tothe left and then installing theplatform mounting weldment allthe way in the left position.


1 Remove the platform. See 2-1,How to Remove the Platform.



2 Tag and disconnect the hydraulic hoses fromthe "V1" and "V2" ports on the counterbalancevalve manifold located on the platform rotatorand connect them together using a connector.Cap the fittings on the manifold.


3 Support the platform mounting weldment with alifting device, but do not apply any liftingpressure.

4 Remove the six mounting bolts from theplatform mounting weldment, then remove thecenter bolt and slide the platform mountingweldment off of the platform rotator.

Crushing hazard. The platformmounting weldment may becomeunbalanced and fall if it is notproperly supported.

5 Support the platform rotator with a lifting device.Do not apply any lifting pressure.

Z-45/25J Models:

6 Remove the pin retaining fasteners from the jibboom and jib boom leveling arms to platformrotator pivot pins. Do not remove the pins.

7 Support the jib boom and jib boom levelingarms with a overhead crane.

8 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Crushing hazard. The platformrotator may become unbalancedand fall if it is not properlysupported.

Z-45/25 Models:

6 Support the rod end of the platform levelingslave cylinder.

7 Remove the pin retaining fasteners from theslave cylinder rod-end pivot pin and the rotatorpivot pin.

8 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Crushing hazard. The platformrotator may become unbalancedand fall if it is not properlysupported.

PLATFORM COMPONENTS



a

d c b

How to Bleed the PlatformRotator

This procedure will require twopeople. Do not start the engine.Use auxiliary power for allmachine functions in thisprocedure.

1 Move the function enable toggle switch to eitherside and activate the platform rotate switch tothe right then the left through two platformrotation cycles, then hold the switch to the RIGHT

position until the platform is fully rotated to theright.

2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a containerto collect 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

4 Move the function enable toggle switch to eitherside and hold the platform rotate switch to theLEFT position until the platform is fully rotated.Continue holding the switch until air stopscoming out of the bleed valve. Then close thebleed valve.

Crushing hazard. Keep clear ofthe platform 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 switch to theRIGHT position until the platform is fully rotated.Continue holding the switch until air stopscoming out of the bleed valve. Then close thebleed valve.

Crushing hazard. Keep clear ofthe platform during rotation.

7 Remove the hose from the bleed valve andclean up any hydraulic oil that may have spilled.

8 Rotate the platform full right then left andinspect the bleed valves for leaks.

PLATFORM COMPONENTS



3-1Jib Boom, Z-45/25J Models

How to Remove the Jib BoomPerform this procedure with theboom in the stowed position.

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.


2 Remove the platform mounting weldmentand the platform rotator. See 2-3, How toRemove the Platform Rotator.

3 Remove the hose and cable cover from the sideof the jib boom.

4 Attach a lifting strap from an overhead crane tothe jib boom.

5 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


6 Support the barrel end of the cylinder with asuitable lifting device.

7 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin.

8 Use a soft metal drift to remove the pin and letthe cylinder hang down.

9 Remove the pin retaining fastener from the jibboom pivot pin. Use a soft metal drift to removethe pin, then remove the jib boom from theprimary boom bellcrank.

Crushing hazard. The jib boommay become unbalanced and fallwhen it is removed from themachine if it is not properlyattached to the overhead crane.

10 Remove the pin retaining fastener from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

Jib Boom Components, Z-45/25J Models



JIB BOOM COMPONENTS, Z-45/25J MODELS

11 Slide both of the jib boom leveling arms off ofthe jib boom cylinder rod-end pivot pin.

12 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

13 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin, then remove the jibboom lift cylinder from the primary boombellcrank.

Crushing hazard. The jib boom liftcylinder may become unbalancedand fall when it is removed fromthe machine if it is not properlyattached to the overhead crane.

3-2Jib Boom Lift Cylinder,Z-45/25J Models

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.




2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


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 liftingdevice.

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.

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 cylinder fromthe machine.

Crushing hazard. The jib boom liftcylinder may become unbalancedand fall when it is removed fromthe machine if it is not properlyattached to the overhead crane.





3-3Jib Boom / Platform Rotate Manifold Components, Z-45/25J Models

1 Orifice, 0.030 inch (0.76 mm) ............ AU ........ Platform rotate circuit2 Solenoid valve, 2 position 3 way ...... AV ......... Platform rotate/jib boom select .......... 8-10 ft-lbs (11-14 Nm)

Plug Torque Specifications

Description Hex Size Torque

SAE No. 2 1/8 50 in-lbs / 6 Nm

SAE No. 4 3/16 13 ft-lbs / 18 Nm

2 2

AU

AV

11

AV

AU

Valve Coil ResistanceSpecifications

Valve coil specification

2 position 3 way valve 5 to 7Ω(schematic item AV)



4-1Plastic Cable 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 Models


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 Open the platform control box.

Primary Boom Components

3 Label and disconnect each wire of the cablesthat enter the platform control box.

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

4 Pull all of the cables out of the platform controlbox.

5 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.


7 Tag, disconnect and plug the platform rotatorhydraulic hoses at the union located above theprimary boom lift cylinder. Cap the fittings onthe unions.




PRIMARY BOOM COMPONENTS

8 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.


9 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling master cylinder. Capthe fittings on the cylinder.


10 Tag and disconnect the hydraulic hoses fromthe platform leveling slave cylinder and connectthem together using a connector. Cap thefittings on the cylinder.


11 Pull the four hydraulic hoses toward theplatform to clear the rod end of the primaryboom lift cylinder.

12 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 trackmay become unbalanced and fallwhen it is removed from themachine.

13 Remove all hose and cable clamps from theunderside of the primary boom.

14 Attach a strap from an overhead crane to thecable track.

15 Remove the mounting fasteners from the uppercable track at the platform end of the extensionboom.

16 Remove the cable track mounting fasteners thatattach the lower cable track to the primaryboom.

17 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackmay become unbalanced and fallif it is not properly attached to theoverhead crane.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.



How to Remove the Cable Track,Z-45/25J Models


1 Remove the platform control box mountingfasteners.

2 Remove the foot switch access hole cover platefasteners. Remove the cover plate.

3 Remove the foot switch mounting fastenersfrom the platform.

4 Remove the foot switch through the back of theplatform through the access hole and set itaside.

5 Remove the platform control box and set itaside.

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 Remove the hose and cable cover from the sideof the jib boom.

13 Remove the hose clamp on the primary boombellcrank.

14 Place blocks 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 trackmay become unbalanced and fallwhen it is removed from themachine.

15 Attach a lifting strap from an overhead 5 ton(4,536 kg) capacity crane to the platform end ofthe primary boom for support. Do not lift it.

16 Remove all hose and cable clamps from theunderside of the primary boom.

17 Support the rod end of the primary boom liftcylinder with a lifting device.

18 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Donot remove the pin.

19 Raise the primary boom slightly with theoverhead crane to relieve the pressure on theprimary boom lift cylinder rod-end pivot pin.

20 Use a soft metal drift to remove the primaryboom lift cylinder rod-end pivot pin.

Crushing hazard. The primaryboom lift cylinder may becomeunbalanced and fall if it is notproperly supported by the liftingdevice.





21 Lower the rod end of the primary boom liftcylinder approximately 12 inches (30.5 cm).

22 Pull all of the hoses and cables out and awayfrom the mounting ears for the rod end of theprimary boom lift cylinder.

23 Raise the rod end of the primary boom liftcylinder back into position and install the rod-end pivot pin. Then install the pin retainingfastener.

24 Attach a strap from an overhead crane to thecable track.

25 Remove the mounting fasteners from the uppercable track at the platform end of the extensionboom.

26 Remove the cable track mounting fasteners thatattach the lower cable track to the primaryboom.

27 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackmay become unbalanced and fallif it is not properly attached to theoverhead crane.


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 IndustriesService Parts Department(Genie part number 58919).

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 tothe side.

3 Repeat steps 1 and 2 for each link.

a

b




4-2Primary Boom

How to Shim the Primary Boom1 Extend the primary boom until the wear pads

are accessible.

2 Measure each wear pad.

Replace the pad if it is less than9/16 inch (14.3 mm) thick. If thepad is more than 9/16 inch(14.3 mm) thick, shim asnecessary.

3 Loosen the wear pad mounting fasteners.

4 Install the new shims under the wear pad toobtain zero clearance and zero drag.

5 Tighten the mounting fasteners.

6 Extend and retract the primary boom through anentire cycle. Check for tight spots that maycause binding or scraping of the boom.

Always maintain squarenessbetween the outer and inner boomtubes.

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 Remove the platform rotator and platformmounting weldment. See 2-3, How to Removethe Platform Rotator.




3 Z-45/25 Models: Remove the platform levelingslave cylinder. See 2-2, How to Remove thePlatform Leveling Slave Cylinder.

Z-45/25J Models: Remove the jib boom.See 3-1, How to Remove the Jib Boom.

4 Remove the cable track. See 4-1, How toRemove the Cable Track.


6 Remove the hose and cable cover from theupper mid-pivot.

7 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.

8 Locate the primary boom drive speed limitswitch inside of the upper mid-pivot.

9 Remove the primary boom drive speed limitswitch mounting fasteners. Do not disconnectthe wiring.

10 Locate the primary boom extension drive speedlimit switch inside of the extension boom.

11 Remove the primary boom extension drivespeed limit switch mounting fasteners. Do notdisconnect the wiring.

12 Pull the limit switch and the wiring out of theextension tube and move it out of the way.

13 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


14 Remove the hose clamp at the pivot end of theboom.

15 Attach a 5 ton (4,536 kg) overhead crane to thecenter point of the primary boom.

16 Attach a similar lifting device to the primaryboom lift cylinder.

17 Place support blocks under the primary boomlift cylinder.

18 Remove the pin retaining fastener 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 fallunless they are properlysupported.

19 Lower the rod end of the primary boom liftcylinder onto support blocks. Protect thecylinder rod from damage.

20 Remove the pin retaining fastener from theprimary boom pivot pin.



21 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. If the overheadcrane is not properly attached,the boom and may becomeunbalanced and fall when it isremoved from the machine.

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 4-2, How toRemove the 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 shimsused with each wear pad.

5 Support and slide the extension tube out of theboom tube.

Crushing hazard. The primaryboom extension tube may becomeunbalanced and fall when it isremoved from the primary boomtube if it is not properly supported.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

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 may become unbalancedand fall when it is removed fromprimary boom extension tube if itis not properly 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 lowersthe primary 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



1 Raise the primary boom until the primary boomis horizontal.

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. Do not lift the boom.

4 Support the rod end and the barrel end of theprimary boom lift cylinder with a secondoverhead crane or similar lifting device.

5 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


6 Remove the pin retaining fastener from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.

The primary boom will fall if it isnot properly supported when theprimary boom rod-end pivot pin isremoved.

7 Place a support block across both turntablecovers under the primary boom lift cylinder.

8 Z-45/25J Models: Lower the lift cylinder ontothe block. Protect the cylinder rod fromdamage.

Crushing hazard. The primaryboom lift cylinder may fall if it is notproperly supported.

9 Remove the primary boom lift cylinder barrel-end pivot pin retaining fasteners. Do notremove the pin.

10 Use a slide hammer to remove the barrel-endpivot pin. Carefully remove the primary boom liftcylinder from the machine.

Crushing hazard. The lift cylindermay become unbalanced and fallif it is not properly supported andsecured to the lifting device.




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 primaryboom extension 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 Remove the external snap rings from theextension cylinder rod-end pivot pin (at theplatform end). Use a soft metal drift to removethe 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 will fall when it is removedfrom the extension boom if it is 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.Hoses and cables can bedamaged if the primary boomextension cylinder is draggedacross them.

Note the length of the cylinderafter removal. The cylinder mustbe at the same length forinstallation.

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-end and barrel-end pivot pins on the mastercylinder are accessible.

2 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.





3 Attach overhead crane or similar lifting device tothe master cylinder.

4 Remove the pin retaining fasteners from themaster cylinder barrel-end pivot pin. Do notremove the 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 may become unbalancedand fall if it is not properly attachedto the overhead crane.



Secondary Boom Components

j

a b c

d

e

i

g

f

h

5-1Secondary Boom

How to Disassemble theSecondary Boom

The procedures in this sectionrequire specific 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.

Secondary Boom componentsa upper secondary boom

(number 1 arm)b upper tension link

(number 2 arm)c lower tension link

(number 3 arm)d lower mid-pivote compression linkf secondary boom lift cylinder (2)g lower secondary boom

(number 4 arm)h turntable pivoti boom restj upper mid-pivot



SECONDARY BOOM COMPONENTS

1 Remove the platform. See 2-1, How to Removethe Platform.

2 Z-45/25J Models: 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 boomlift cylinder. 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.

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 may becomeunbalanced and fall if it is notproperly supported by theoverhead crane.

9 Tag, disconnect and plug the hydraulic hoseson both of the secondary boom lift cylinders.


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 thelug on the rod end of one of the secondaryboom lift cylinders for support. Do not apply anylifting pressure.

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 10 through 13 for the othersecondary boom lift cylinder.

Crushing hazard. The secondaryboom lift cylinder may becomeunbalanced and fall when it isremoved from the machine if it isnot properly attached to theoverhead crane.

Component damage hazard.When removing a secondaryboom lift cylinder from themachine, be careful not to damagethe counterbalance valve at thebarrel end of the cylinder.

16 Attach a lifting strap from an overhead crane tothe upper mid-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 and lower mid-pivots.



18 Remove the pin retaining fasteners from thenumber 1 arm pivot pins at the lower mid-pivotand the upper mid-pivot. Do not remove thepins.

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 may become unbalanced andfall when it is removed from themachine if it is not properlyattached to the overhead crane.

Crushing hazard. The upper mid-pivot may fall when the number 1arm is removed from the machineif it is not properly supported bythe overhead crane.

21 Using the overhead crane attached to uppermid-pivot, raise the secondary boom assemblyapproximately 30 inches (76 cm).

22 Insert a 4 x 4 x 11 inch (10.2 x 10.2 x 28 cm)block between the number 2 arm and the boomrest. Then lower the secondary boom assemblyonto the block.

Crushing hazard. The secondaryboom assembly may fall if it is notproperly supported by the4 x 4 x 11 inch (10.2 x 10.2 x28cm) block.

23 Locate the 4 cables that enter the platformcontrol box. Number each cable and its entrylocation at the platform control box.

24 Open the platform control box.

25 Label and disconnect each wire of the cablesthat enter the platform control box.


26 Pull all of the cables out of the platform controlbox.

27 Pull all of the cables and hoses out through theupper mid-pivot.


28 Remove the hose and cable covers from the topof the number 2 arm.

29 Pull all of the hoses and cables out of the uppermid-pivot and out through the lower mid-pivot.Lay the hoses and cables on the ground.


30 Remove the pin retaining fastener from thenumber 2 arm pivot pin at the upper mid-pivot.Use a soft metal drift to remove the pin.

31 Remove the upper mid-pivot from the machine.

Crushing hazard. The upper mid-pivot may become unbalancedand fall when it is removed fromthe machine if it is not properlyattached to the overhead crane.




32 Attach the lifting strap from an overhead craneto the number 2 arm at the upper mid-pivot end.

33 Raise the number 2 arm slightly and remove the4 x 4 x 11 inch (10.2 x 10.2 x 28 cm) block.

34 Lower the number 2 arm onto the boom restpad.

35 Insert a 4 x 4 x 81/2 inch (10.2 x 10.2 x 21.6 cm)block between the number 3 arm and thenumber 4 arm at the lower mid-pivot end.

36 Attach a lifting strap from the overhead crane tothe lower mid-pivot for support. Do not lift it.

37 Remove the pin retaining fasteners from thenumber 2, 3 and 4 arm pivot pins at the lowermid-pivot. Do not remove the pins.

38 Use a soft metal drift to drive each pin out. Thenremove the lower mid-pivot from the secondaryboom assembly.

Crushing hazard. The lower mid-pivot may become unbalancedand fall when it is removed fromthe secondary boom assembly if itis not properly supported by theoverhead crane.

39 Attach the lifting strap from an overhead craneto the center point of the number 2 arm forsupport. Do not lift it.

40 Remove the pin retaining fasteners from bothcompression link pivot pins. Do not remove thepins.

41 Use a soft metal drift to remove the lowercompression link pivot pin at the number 3 arm.

42 Support the compression link with anappropriate lifting device.

43 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 may fall when thecompression link is disconnectedfrom the number 2 arm if it is notproperly supported by theoverhead crane.

Crushing hazard. Thecompression link may fall if it is notproperly supported when it isremoved from the secondaryboom assembly.


Crushing hazard. The number 2arm may become unbalanced andfall when it is removed from thesecondary boom assembly if it isnot properly supported by theoverhead crane.

45 Remove the upper and lower hose and cablecovers from the number 3 arm.

46 Pull all of the cables and hoses from thenumber 3 arm and lay them over the turntablecounterweight.






48 Remove the fuel tank. See 13-1, How toRemove the Fuel Tank.

49 Remove the retaining fastener from the groundcontrol box and function manifold pivot plate.

50 Lower the ground control box and functionmanifold pivot plate to access the number 3arm pivot pin.

51 Attach the lifting strap from the overhead craneto the centerpoint of the number 3 arm forsupport. Do not lift it.

52 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 pivot.

53 Remove the pin retaining fasteners from thenumber 3 arm at the turntable pivot. Do notremove the pin.

54 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 may become unbalanced andfall when it is removed from themachine if it is not properlysupported by the overhead crane.

56 Remove the secondary boom drive speed limitswitch mounting fasteners from the number 4arm at the mid-pivot end. Do not disconnect thewiring.

57 Remove the pin retaining fasteners from thenumber 4 arm at the turntable pivot. 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 pivot through the groundcontrols side bulkhead.


Crushing hazard. The number 4arm may become unbalanced andfall when it is removed from themachine if it is not properlysupported by the overhead crane.




5-2Secondary Boom Lift Cylinders

There are two secondary boom lift cylindersincorporated in the structure of the secondaryboom assembly. These cylinders operate inparallel and require hydraulic pressure to extendand retract. Each secondary boom lift cylinder isequipped with a counterbalance valve to preventmovement in the event of a hydraulic line failure.

How to Remove a SecondaryBoom Lift Cylinder

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

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 thelug on 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 may becomeunbalanced and fall when it isremoved from the machine if it isnot properly attached to theoverhead crane.

Component damage hazard.When removing a secondaryboom lift cylinder from themachine, be careful not to damagethe counterbalance valve at thebarrel end of the cylinder.




6-1Turntable Covers

How to Remove aTurntable Cover1 Raise the turntable cover. Support and secure

the open cover to an overhead crane or forklift.Do not lift it.

Component damage hazard.Protect the cover from damage byusing carpet or padding on thecrane or fork lift forks.

2 Engine side cover: Remove the upper andlower retaining clips from the gas strut.

3 Engine side cover: Gently pry the strut pivotsockets off of the ball studs and remove thestrut. Protect the strut cylinder rod fromdamage.

4 Engine side cover: Mark the location of thehinge on the support bracket on the cover toensure proper cover alignment duringinstallation.

Ground controls side cover: Mark the locationof the hinge on the cover to ensure propercover alignment during installation.

5 Engine side cover: Remove the cover hingefasteners that fasten the hinge to the supportbracket on the cover.

Ground controls side cover: Remove thecover hinge fasteners that fasten the hinge tothe cover.

Turntable Covers

6 Carefully lift and remove the cover fromthe machine.

Crushing hazard. The turntablecover may become unbalancedand fall if it is not properlysupported and secured to aappropriate lifting device.

Bodily injury hazard. If a turntablecover must be replaced, be surethat all appropriate safety andinstructional decals areapplied to the new cover.

Alignment adjustments may benecessary when a new coveris installed.



7-1RPM Adjustment

Refer to Maintenance Procedures, B-10,Check and Adjust the Engine RPM- Ford andDeutz Diesel Models.

7-2Flex Plate

The flex plate acts as a coupler between theengine and the pump. It is bolted to the engineflywheel and has a splined center to drivethe pump.

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 7/16 inch gap


How to Remove the Flex Plate1 Disconnect the wiring plug at the electronic

displacement controller (EDC), located onthe drive pump.

2 Support the drive pump with an appropriatelifting device. Then remove all of the pumpmounting plate to engine bell housing bolts.

3 Carefully pull the pump away from the engineand secure it from moving.

4 Remove the flex plate mounting fasteners,then remove the flex plate from the engineflywheel.

How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump.Torque the flex plate mounting bolts to 34 ft-lbs(46 Nm).

2 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave a7/16 inch (11 mm) gap between the pumpcoupler and pump end plate.

3 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 45 ft-lbs (61 Nm).

4 Install the pump and torque the pump mountingplate fasteners to 34 ft-lbs (46 Nm).

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

a b c d e

f



7-3Oil Temperature and Oil PressureSwitches

The oil temperature switch is a normally openswitch that closes at approximately 220° F(104° C). When the switch closes, the engine willshut off to prevent damage and will not start untilthe temperature drops below the switch point. Anover-temperature indicator light at the groundcontrols should turn on when the switch closes.

Component damage hazard.Do not crank the engine withthe over-temperature light on.

The oil pressure switch is a normally closed switchthat opens at approximately 15 psi (1 bar). If the oilpressure drops below the switch point, the switchopens and shuts off the engine to prevent damage.A low oil pressure indicator light at the groundcontrols should turn on when the switch opens.

Component damage hazard.Do not crank the engine with thelow oil pressure light on.

How to Remove the OilTemperature and Oil PressureSwitches




DEUTZ ENGINE F3L 1011F


3 Oil temperature switch: Remove the fastenersfrom the engine side cover, then remove thecover.

4 Disconnect the wiring from the desired switch.

5 Remove the switch from the engine block, andthen install the new switch. Do not over tighten.

Burn hazard. Contact with hotengine fluids or components mayresult in severe burns

Always use pipe thread sealantwhen installing a switch.

Oil temperature switch specifications

Torque 8-18 ft-lbs 11-24 Nm

Hex size 13/16 inch

Temperature switch point 220° F (104° C)

Oil pressure switch specifications


Hex size 1-1/16 inch

Oil pressure switch point 15 psi 1 bar



8-1RPM Adjustment

Refer to Maintenance Procedures, A-22,Check and Adjust the Engine RPM.

8-2Flex Plate


a pumpb pump shaftc couplerd flex plate with raised splinee flywheelf 1/16 inch (1.5 mm) gap

How to Remove the Flex Plate1 Disconnect the wiring plug at the electronic



3 Carefully pull the pump away from the engineand secure it from moving.

4 Remove the flex plate mounting fasteners,then remove the flex plate from the engineflywheel.



2 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave a1/16 inch (1.5 mm) gap between the pumpcoupler and pump end plate.




a b c d e

f

Perkins 104-22 Engine



8-3Coolant Temperature and OilPressure Gauges

The engine coolant temperature gauge is anelectrical gauge. The engine coolant temperaturesending unit has limit contacts that are factory set.The contacts will close at approximately 221o F(105o C). When the contacts close, the engine willshut off to prevent damage and will not start untilthe temperature drops below the contact point.Engine coolant temperature will be indicated on thegauge when the key is ON and the Emergency StopButton is pulled out to the ON position.

Component damage hazard.Do not crank the engine withthe over-temperature light on.

The engine oil pressure gauge is an electricalgauge. The engine oil presure sending unit haslimit contacts that are factory set. The contacts willclose at approximately 4.2 psi (0.3 bar). When thecontacts close, the engine will shut off to preventdamage. Engine oil pressure will be indicated onthe gauge when the engine is running.

Component damage hazard.Do not crank the engine with thelow oil pressure light on.

How to Remove the CoolantTemperature and Oil PressureGauge Sending Units


1 Tag and disconnect the wiring from the desiredsending unit. Remove the sending unit from theengine block.

2 Install the new sending unit. Do not over tighten.

3 Connect the wires to the new sending unit.

Burn hazard. Contact with hotengine fluids or components mayresult in severe burns.

Always use pipe thread sealantwhen installing a sending unit.

Water temperature sending unit specifications


Hex size 7/8 inch


Oil pressure sending unit specifications


Hex size 7/8 inch

Oil pressure switch point 4.2 psi 0.3 bar

PERKINS 104-22 ENGINE



Ford LRG-425 EFI Engine

9-1Timing Adjustment

The ignition timing is controlled bythe ECM and can only be adjustedby re-programming the ECM. Iftiming adjustment or service isrequired, please contact GenieIndustries Service Department ORyour local Ford dealer.

9-2RPM Adjustment

Refer to Maintenance Procedures, B-10,Check and Adjust the Engine RPM- Ford andDeutz Diesel Models.

9-3Flex Plate


a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 1/16 inch (1.5 mm) gap

Flex Plate Removal1 Disconnect the wiring plug at the electronic



a b c d e

f



FORD LRG-425 EFI ENGINE

3 Carefully pull the pump away from theengine and secure it from moving.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

4 Remove the flex plate mounting fasteners,then remove the flex plate from the engine flywheel.



2 Install the pump coupler onto the pump shaftwith the set screw towards the pump. Leave a1/16 inch (1.5 mm) gap between the pumpcoupler and pump end plate.1




9-4Water Temperature and OilPressure Switches

The water temperature switch is a normally openswitch that closes at approximately 230° F(112° C). When the switch closes, the engine willshut off to prevent damage and will not start untilthe temperature drops below the switch point. Thecheck engine light will turn on. See RepairProcedure 10-5, How to Retrieve Engine FaultCodes.

Component damage hazard.Do not continue to run the enginewith the check engine light on.

The oil pressure switch is a normally closed switchthat opens at approximately 3 to 5 psi (0.21 to0.34 bar). If the oil pressure drops below the switchpoint, the switch opens and shuts off the engine toprevent damage. The check engine light will turnon. See Repair Procedure 10-5, How to RetrieveEngine Fault Codes.

Component damage hazard.Do not continue to run the enginewith the check engine light on.



How to Remove the WaterTemperature and Oil PressureSwitches


1 Open the engine side turntable cover and locatethe water temperature and oil pressureswitches.

2 Disconnect the wiring from the desired switch.

3 Remove the switch from the engine block, andthen install the new switch. Do not over tighten.

Burn hazard. Contact with hotengine fluids or components mayresult in severe burns

Always use pipe thread sealantwhen installing a switch.

Water temperature switch specifications


Hex size 13/16 inch


Oil pressure switch specifications


Hex size 1-1/16 inch

Oil pressure switch point 3-5 psi 0.21-0.34 bar

FORD LRG-425 EFI ENGINE



Ground Controls

10-1Control Relays

Relays used for single function switching are singlepole double throw (SPDT) relays.

How to Test a Single Pole DoubleThrow Relay


1 Label and then disconnect all the wiring fromthe relay to be tested.

2 Connect the leads from an ohmmeter orcontinuity tester to each terminal combinationand check for continuity. Terminals 85 and 86represent the coil and should not be tested inany other combination.

Test Desired result

terminal 85 to 86 75 to 85Ω

terminal 87 to 87a & 30 no continuity(infinite Ω)

terminal 87a to 30 continuity(zero Ω)

3 Connect 12V DC to terminal 85 and a groundwire to terminal 86, then test the followingterminal combinations.

Test Desired result

terminal 87 to 87a & 30 no continuity(infinite Ω)

terminal 87 to 30 continuity(zero Ω)

terminal no. 87a - N.C.terminal no. 85 - groundterminal no. 30 - commonterminal no. 86 - coilterminal no. 87 - N.O.

Control Relay Schematic



10-2Toggle Switches

See 1-5, Toggle Switches.

10-3Wago® Components


Wago® tools are available fromthe Genie Service PartsDepartment (Genie part number33996).

1 Label the wiring from the component to beremoved.

2 Use a small screwdriver to push in and releasethe wire from the component.

3 Locate the removal tab on the bottom or topof the component.

4 Use a small screwdriver to gently pry up on thetab of the component and remove it.

GROUND CONTROLS



GROUND CONTROLS

10-4Engine Fault Codes -Ford Models

How to Retrieve Engine FaultCodesWhen a engine malfunction is detected by theElectronic Control Module (ECM), a fault code isrecorded and the check engine light will turn ON atthe ground and platform controls. Use the followingprocedure to retrieve the engine fault code todetermine the engine malfunction.

Perform this procedure with thekey switch in the OFF position.


2 Locate the run/test toggle switch located on theleft side of the ground control box.

3 Pull out the ground controls red EmergencyStop button to the ON position.

4 Hold the run/test toggle switch to the testposition and turn the key switch to the groundcontrols 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.

Fault codes are two digits. Thecheck engine light will blink thefirst digit of a two digit code thenwill pause for 1.2 seconds andthen blink the second digit. Forexample: the check engine lightblinks 5 consecutive times thenpauses for 1.2 seconds and thenblinks 1 time. That would indicatecode 51. The ECM is able to storeup to six individual fault codes.There will be a 2.4 second pausebetween codes.

6 Refer to the Troubleshooting Section fordefinition of engine fault codes.

Once a fault code has beenretrieved and the repair has beencompleted, the ECM memory mustbe reset to clear the fault codefrom the ECM. See 10-5, How toClear Engine Fault Codes.



How to Clear Engine Fault Codesfrom 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.

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

3 Connect the negative battery cable to thebattery.

GROUND CONTROLS



Hydraulic Pumps

11-1Lift/Steer Pump

How to Remove theLift/Steer Pump


1 Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable, then 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.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

open closed



HYDRAULIC PUMPS

11-2Drive Pump

The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electronic displacement controller(EDC), located on the pump. The only adjustmentthat can be made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorizedSundstrand-Sauer service center. Call GenieIndustries Service Department to locate your localauthorized service center.

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 connection at theelectronic displacement controller (EDC)located on the drive pump.



3 Tag and disconnect and plug the hydraulichoses from the drive and lift/steer pumps. Capthe fittings on the pumps.


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.

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a

6 Remove the drive pump from the machine.

Component damage hazard. Thehydraulic pump may becomeunbalanced and fall if it is notproperly supported.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

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.




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 Diesel models: Disconnect the enginewiring harness from the fuel solenoid at theinjector pump.

Deutz Diesel models: Hold the manual fuelshutoff valve clockwise to the CLOSED position.

a manual fuel shutoff valve

HYDRAULIC PUMPS




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 Diesel models: Connect the enginewiring harness to the fuel solenoid.

7 Start the engine from the ground controls andcheck for hydraulic leaks.

HYDRAULIC PUMPS



Manifolds

12-1Function Manifold Components

The function manifold is located next to the hydraulic tank underneath the ground controls side cover.

Index SchematicNo. Description Item Function Torque

1 Proportional solenoid valve ............... A ........... Turntable rotate left/right ................... 10-12 ft-lbs (14-16 Nm)

2 Proportional solenoid valve ............... B ........... Secondary boom up/down ................ 10-12 ft-lbs (14-16 Nm)

3 Flow regulator valve .......................... C ........... Secondary boom up/down(prevents overflowingthe proportional valve) ........................ 10-12 ft-lbs (14-6 Nm)

4 Check valve ....................................... D ........... Differential sensing circuit,secondary boom up/down ................. 11-13 ft-lbs (15-18 Nm)

5 Relief valve, 1800 psi (124 bar) ........ E ........... Secondary boom down ..................... 25-30 ft-lbs (34-41 Nm)

6 Priority flow regulator valve,1.5 gpm (5.7 L/min) ........................... F ........... Steer left/right circuit ......................... 10-12 ft-lbs (14-16 Nm)

7 Flow regulator valve .......................... G ........... Turntable rotate left/right(prevents overflowingthe proportional valve) ........................ 10-12 ft-lbs (14-6 Nm)

8 Relief valve, 3200 psi (220.6 bar) ..... H ........... System relief ..................................... 35-40 ft-lbs (47-54 Nm)

9 Flow regulator valve .......................... I ............ Primary boom up/down(prevents overflowingthe proportional valve) ........................ 10-12 ft-lbs (14-6 Nm)

This list continues. Please turn the page


Description Hex size Torque

SAE No. 2 1/8 50 in-lbs (6 Nm)

SAE No. 4 3/16 13 ft-lbs (18 Nm)

SAE No. 6 1/4 18 ft-lbs (24 Nm)



MANIFOLDS



Function Manifold Components, continued


10 Relief valve, 2300 psi (158.6 bar) ..... J ............ Primary boom down .......................... 25-30 ft-lbs (34-41 Nm)

11 Solenoid valve, 2 position 3 way ....... K ........... Primary boom retract ........................ 25-30 ft-lbs (34-41 Nm)

12 Solenoid valve, 2 position 3 way ....... L ........... Primary boom extend ........................ 25-30 ft-lbs (34-41 Nm)

13 Flow regulator valve,2 gpm (7.6 L/min) .............................. M .......... Primary boom extend/retract circuit .. 10-12 ft-lbs (14-16 Nm)

14 Flow regulator valve,1 gpm (3.8 L/min) .............................. N ........... Platform level circuit .......................... 10-12 ft-lbs (14-16 Nm)

15 Flow regulator valve,0.1 gpm (0.38 L/min) ......................... O ........... Bleeds off check valves in

differential sensing circuits to tank .... 10-12 ft-lbs (14-16 Nm)

16 Check valve ....................................... P ........... Differential sensing circuit,platform level down ........................... 11-13 ft-lbs (15-18 Nm)

17 Counterbalance valve ........................ Q ........... Platform level down .......................... 35-40 ft-lbs (47-54 Nm)

18 Counterbalance valve ........................ R ........... Platform level up ............................... 35-40 ft-lbs (47-54 Nm)

19 Solenoid valve, 3 position 4 way ....... S ........... Platform level up/down ..................... 25-30 ft-lbs (34-41 Nm)

20 Check valve ....................................... T ........... Differential sensing circuit,platform level up ............................... 11-13 ft-lbs (15-18 Nm)

21 Check valve ....................................... U ........... Differential sensing circuit,jib boom up/platform rotate left ......... 11-13 ft-lbs (15-18 Nm)

22 Check valve ....................................... V ........... Differential sensing circuit,jib boom down/platform rotate right .. 11-13 ft-lbs (15-18 Nm)

23 Check valve ....................................... W .......... Differential sensing circuit,primary boom retract ......................... 11-13 ft-lbs (15-18 Nm)

MANIFOLDS




SAE No. 4 3/16 13 ft-lbs (18 Nm)

SAE No. 6 1/4 18 ft-lbs (24 Nm)




MANIFOLDS



Function Manifold Components, continued


24 Check valve ....................................... X ........... Differential sensing circuit,primary boom extend ........................ 11-13 ft-lbs (15-18 Nm)

25 Check valve ....................................... Y ........... Differential sensing circuit,primary boom up/down ..................... 11-13 ft-lbs (15-18 Nm)

26 Check valve ....................................... Z ........... Differential sensing circuit,turntable rotate left/right .................... 11-13 ft-lbs (15-18 Nm)

27 Diagnostic nipple ............................... AA ......... Testing

28 Solenoid valve, 3 position 4 way ....... BB ......... Jib boom up/down andplatform rotate left/right ..................... 25-30 ft-lbs (34-41 Nm)

29 Flow regulator valve,0.6 gpm (2.3 L/min) ........................... CC ........ Jib boom up/down and

platform rotate left/right ..................... 25-30 ft-lbs (34-41 Nm)

30 Solenoid valve, 3 position 4 way ....... DD ........ Primary boom up/down ..................... 25-30 ft-lbs (34-41 Nm)

31 Differential sensing valve .................. EE ......... Meters flow to functions .................... 10-12 ft-lbs (14-16 Nm)

32 Solenoid valve, 3 position 4 way ....... FF ......... Turntable rotate left/right ................... 25-30 ft-lbs (34-41 Nm)

33 Solenoid valve, 3 position 4 way ....... GG ........ Steer left/right .................................... 25-30 ft-lbs (34-41 Nm)

34 Orifice, 0.040 in (1 mm) ..................... HH ........ Secondary boom circuit

35 Solenoid valve, 3 position 4 way ....... II ........... Secondary boom up/down ................ 25-30 ft-lbs (34-41 Nm)

36 Check valve ....................................... JJ .......... Secondary boom circuit .................... 10-12 ft-lbs (14-16 Nm)

37 Diagnostic nipple ............................... KK ......... Testing port

38 Proportional solenoid valve ............... LL ......... Primary boom up/down ..................... 10-12 ft-lbs (14-16 Nm)




SAE No. 4 3/16 13 ft-lbs (18 Nm)

SAE No. 6 1/4 18 ft-lbs (24 Nm)

MANIFOLDS



MANIFOLDS



12-2Valve Adjustments -Function Manifold

How to Adjust the SystemRelief Valve


1 Connect a 0 to 5000 psi (0 to 345 bar) pressuregauge to the test port (item 37) on the functionmanifold.


3 Hold the function enable switch to the HIGH IDLE

position and activate and hold the retract switchwith the boom fully retracted. Observe thepressure reading on the pressure gauge.

System relief valve specifications

Pressure 3200 psi220.6 bar

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item 8).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.

Tip-over hazard. Do not adjustthe relief valve higher thanspecified.

6 Repeat steps 2 through 5 and recheck reliefvalve pressure.

MANIFOLDS

How to Adjust the Primary BoomDown Relief Valve(before serial number 11819)





position and activate and hold the primaryboom down switch with the primary boom fullylowered. Observe the pressure reading on thepressure gauge.

Primary boom down relief valve specifications








MANIFOLDS

How to Adjust the SecondaryBoom Down Relief Valve





position and activate and hold the secondaryboom down switch with the secondary boomfully lowered. Observe the pressure reading onthe pressure gauge.

Secondary boom down relief valve specifications

Pressure 1800 psi124 bar






Valve coil specifications

Proportional solenoid valve, 12V 4 to 5Ω(schematic items A, B and LL)

3 position 4 way directional valve, 10V 5 to 7Ω(schematic items S, BB, DD, FF, GG and II)

2 position 3 way solenoid valve, 10V 5 to 7Ω(schematic items K and L)



12-3Turntable Rotation Manifold ComponentsThe turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage

compartment.


1 Shuttle valve 2 position 3 way ........... MM ....... Turntable rotation brake release ...... 10-13 ft-lbs (14-18 Nm)

2 Counterbalance valve ........................ NN ........ Turntable rotate right ........................ 35-40 ft-lbs (47-54Nm)

3 Counterbalance valve ........................ OO ........ Turntable rotate left ........................... 35-40 ft-lbs (47-54Nm)




SAE No. 4 3/16 13 ft-lbs (18 Nm)

SAE No. 6 1/4 18 ft-lbs (24 Nm)

MANIFOLDS

321

MM

NN

OO



12-4Directional 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



How to Set Up the DirectionalValve Linkage

Adjustment of the directional valvelinkage is only necessary whenthe linkage 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 toperform this procedure on a levelfloor will compromise the stabilityof the machine and could result inthe machine 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 urethanesprings until they are snug. Then tighten thelocknuts.

10 Check to be sure the drive chassis iscompletely level.

11 Measure the distance between the drivechassis and the non-steer axle on both sides(from the inside 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.



MANIFOLDS







SAE No. 4 3/16 13 ft-lbs (18 Nm)

SAE No. 6 1/4 18 ft-lbs (24 Nm)

SAE No. 8 5/16 50 ft-lbs (68 Nm)

SAE No. 10 9/16 55 ft-lbs (75 Nm)

SAE No. 12 5/8 75 ft-lbs (102 Nm)

12-52WD Drive Manifold Components

The drive manifold is mounted inside the drive chassis at the non-steer end.


1 Solenoid valve, 2 position 3 way ....... PP ......... Braking ..............................................10-12 ft-lbs (14-16 Nm)

2 Relief valve, 250 psi (17.2 bar) ......... QQ ........ Charge pressure circuit .....................10-12 ft-lbs (14-16 Nm)

3 Flow divider/combiner valve .............. RR ........ Controls flow to drive motorsin forward and reverse ......................25-30 ft-lbs (34-41 Nm)

4 Orifice, 0.070 in (1.78 mm) ................ SS ......... Drive circuit

5 Check valve ....................................... TT ......... Drive circuit .......................................25-30 ft-lbs (34-41 Nm)

6 Check valve ....................................... UU ........ Drive circuit .......................................25-30 ft-lbs (34-41 Nm)

7 Shuttle valve, 3 position 3 way .......... VV ......... 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 ................................ WW....... Testing

9 Orifice, 0.030 in (0.76 mm) ................ XX ......... Brake and 2-speed circuit

10 Solenoid valve, 2 position 3 way ....... YY ......... 2-speed motor shift ...........................10-12 ft-lbs (14-16 Nm)

MANIFOLDS



2 position 3 way solenoid valve, 10V 5 to 7Ω(schematic item PP and YY)



MANIFOLDS



12-6Valve Adjustments, 2WDDrive Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi (0 to 41 bar) pressure

gauge to the test port (item 8) located on thedrive manifold.


3 Drive the machine slowly in either direction andobserve the pressure reading on the pressuregauge.

Charge Pressure Relief valve specifications


4 Turn the engine off. Hold the charge pressurerelief valve and remove the cap (item 2).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwiseto decrease the pressure. Then install thevalve cap.

6 Restart the engine. Drive the machine in eitherdirection and recheck the valve pressure.

7 Repeat steps 2 through 6 until the specifiedcharge pressure is achieved.

8 Turn the engine off, then remove thepressure gauge.

MANIFOLDS



MANIFOLDS




12-74WD Drive Manifold Components

The drive manifold is mounted inside the drive chassis at the non-steer end.


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,0.2 gpm (0.8 L/min) ........................... AC ........ Non-steer end drive motor circuit ..... 25-30 ft-lbs (34-41 Nm)

3 Bi-directional flow control valve,2 gpm (7.6 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 thatgets 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 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 18 .... 25-30 ft-lbs (34-41 Nm)


MANIFOLDS




SAE No. 4 3/16 13 ft-lbs (18 Nm)

SAE No. 6 1/4 18 ft-lbs (24 Nm)

SAE No. 8 5/16 50 ft-lbs (68 Nm)

SAE No. 10 9/16 55 ft-lbs (75 Nm)



MANIFOLDS



4WD Drive Manifold Components, continued


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




SAE No. 4 3/16 13 ft-lbs (18 Nm)

SAE No. 6 1/4 18 ft-lbs (24 Nm)

SAE No. 8 5/16 50 ft-lbs (68 Nm)

SAE No. 10 9/16 55 ft-lbs (75 Nm)



2 position 3 way solenoid valve, 10V 5 to 7Ω(schematic items AI and AK)



MANIFOLDS



12-8Valve Adjustments, 4WDDrive Manifold

How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi (0 to 41 bar) pressure

gauge to the test port (item 5) located on thedrive manifold.


3 Drive the machine slowly in either direction andobserve the pressure reading on the pressuregauge.

Charge Pressure Relief valve specifications


4 Turn the engine off. Hold the charge pressurerelief valve and remove the cap (index 7).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwiseto decrease the pressure. Then install thevalve cap.

6 Restart the engine. Drive the machine in eitherdirection and recheck the valve pressure.

7 Repeat steps 2 through 6 until the specifiedcharge pressure is achieved.

8 Turn the engine off, then remove thepressure gauge.

MANIFOLDS



Fuel and Hydraulic Tanks

13-1Fuel Tank

How to Remove the Fuel TankExplosion and fire hazard. Enginefuels are combustible. Remove thefuel tank in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

All models:

1 Disconnect, drain and plug the supply andreturn fuel hoses. Cap the fuel return fitting onthe fuel tank.

2 Remove the mounting fasteners from the topand bottom of the fuel tank.

3 Remove the fuel tank from the machine.

13-2Hydraulic Tank

The primary functions of the hydraulic tank are tocool, clean and deaerate the hydraulic fluid duringoperation. It utilizes internal suction strainers forthe pump supply lines and has an external returnline filter mounted to the engine side bulkhead. Thehydraulic return filter incorporates a filter conditionindicator.

How to Remove theHydraulic Tank

Component damage hazard.The work area and surfaceswhere this procedure will beperformed must be clean andfree of debris that could getinto the hydraulic system.



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FUEL AND HYDRAULIC TANKS

2 Place a suitable container underneath thehydraulic tank. See capacity specificationsbelow.


3 Remove the drain plug from the hydraulic tank.

4 Completely drain the tank into a suitablecontainer. See capacity specifications below.

5 Tag, disconnect and plug the two suction hosesthat are attached to the hydraulic tankshutoff valves.

6 Disconnect and plug the return filter hydraulichose at the hydraulic tank. Cap the fitting on thetank.

7 Disconnect and plug the supply hose for theauxiliary power unit through the access holeunderneath the turntable. Cap the fitting on thehydraulic tank.

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 may become unbalanced andfall if it is not properly supportedby the lifting device.

Hydraulic Specification

Hydraulic fluid capacity 24 gallonsAll models 91 liters






2 Open the engine pivot plate latch and swing theengine out and away from the machine toaccess the turntable rotation motor.

3 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor manifold. Capthe fittings on the manifold.

Bodily injury hazard.Spraying hydraulic oil canpenetrate and burn skin. Loosenhydraulic connections very slowlyto allow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.

4 Remove the turntable rotation motor mountingfasteners, then remove the motor from thebrake.

5 Remove the turntable rotation motor from themachine.

14-1Rotation Hydraulic Motor

How to Remove the RotationHydraulic Motor


1 Secure the turntable from rotating with theturntable rotation lock pin.

Unlocked position

Locked position

Turntable Rotation Components



How to Remove the TurntableRotation Brake1 Secure the turntable from rotating with the

turntable rotation lock pin.

Unlocked position

Locked position

2 Open the engine pivot plate latch and swing theengine out and away from the machine toaccess the turntable rotation motor and brake.

TURNTABLE ROTATION COMPONENTS

3 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor manifold andthe brake. Cap the fittings on the manifold andthe brake.

Bodily injury hazard.Spraying hydraulic oil canpenetrate and burn skin. Loosenhydraulic connections very slowlyto allow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.

4 Remove the turntable rotation motor mountingfasteners, then remove the motor from thebrake.

5 Remove the turntable rotation motor from themachine.

6 Remove the brake mounting bolts, and thenremove the turntable rotation brake from themachine.




3 Block the non-steering wheels, and thencenter a lifting jack of ample capacity under thesteering axle.

4 Raise the machine 6 inches (15 cm) and placeblocks under the chassis for support.

5 Remove the lug nuts. Then remove the tireand wheel assembly.

6 Remove the pin retaining fasteners from theyoke pivot pins. Do not remove the pins.

7 Support and secure the yoke/hub assembly to alifting jack.


15-1Yoke and Hub

How to Remove the Yokeand HubThe yoke installation utilizes bushings in the axleand a thrust washer that may require periodicreplacement.

1 Remove the cotter pin from the steering cylinderrod-end clevis pin and remove the cotter pinfrom the tie rod clevis pin. Remove the clevispins.

Always use a new cotter pin wheninstalling a clevis pin.

a tie rodb steer axlec yoke pivot pind yokee hubf pivot ping steering cylinder

a b

e

d

fg

c

f



8 Place a rod through the upper yoke pivot pinand twist to remove the pin, then use a softmetal drift to drive the lower yoke pivot pindown and out.

Crushing hazard. The yoke/hubassembly may becomeunbalanced and fall when the yokepivot pins are removed if it is notproperly supported and secured tothe lifting jack.

Torque specifications

Lug nut torque, dry 125 ft-lbs 169.5 Nm

Lug nut torque, lubricated 94 ft-lbs 127.4 Nm

2WD STEERING AXLE COMPONENTS

How to Remove theHub and Bearings1 Loosen the wheel lug nuts. Do not remove

them.

2 Block the non-steering wheels and place alifting jack of ample capacity under the steeringaxle.


4 Remove the lug nuts. Then remove the tireand wheel assembly.

5 Remove the dust cap, cotter pin andcastle nut.

Always use a new cotter pin wheninstalling a castle 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. Remove therear bearing.




How to Install theHub and Bearings

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.


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

10 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts to125 ft-lbs (169.5 Nm).

15-2Steering Cylinders

How to Remove aSteering CylinderThere are two identical steering cylinders thatwork in parallel. They are part of the samehydraulic circuit, but move in opposite directions.The tie rod maintains equal movement of the tires.


1 Tag, disconnect and plug the hydraulic hosesfrom the steering cylinder. Cap the fittings onthe cylinder.




2 Remove the cotter pin from the rod-end clevispin of the steer cylinder. Remove the clevis pin.

3 Remove the cotter pin from the barrel-endclevis pin of the steer cylinder then remove theclevis pin.


4 Remove the steering cylinder from the machine.


15-3Tie Rod

How to Remove the Tie Rod1 Remove the cotter pins from the clevis pins at

each end of the tie rod, then remove the clevispins.


2 Remove the tie rod.



1 Remove the cotter pin from the steering cylinderrod-end clevis pin and remove the cotter pinfrom the tie rod clevis pin. Remove the clevispins.

a oscillate cylinderb yoke pivot pinc drive hubd yokee pivot pinf steer cylinderg tie rod


3 Block the non-steering wheels, and thencenter a lifting jack of ample capacity under thesteering axle.



16-1Yoke and Hub

How to Remove the Yokeand HubThe yoke installation utilizes bushings and a thrustwasher that may require periodic replacement. Theyoke must be removed before the drive hub can beremoved.


a

b

c

defg




5 Remove the lug nuts, then remove the tire andwheel assembly.

6 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittngs on thedrive motor.


7 Remove the drive motor mounting fasteners.

8 Slide the drive motor shaft out of the drive huband then remove the drive motor from themachine.

9 Remove the pin retaining fasteners from theupper and lower yoke pivot pins. Do not removethe pins.

10 Support the yoke/drive hub assembly with alifting jack. Secure the yoke/drive hub assemblyto the lifting jack.

11 Place a rod through the upper yoke pivot pinand twist to remove the pin, then use a softmetal drift to drive the lower yoke pivot pindown and out.

Crushing hazard. The yoke/hubassembly may becomeunbalanced and fall when the yokepivot pins are removed if it is notproperly supported and secured tothe lifting jack.

12 Place the yoke/drive hub assembly on a flatsurface with the drive hub facing down.



13 Remove the drive hub mounting fasteners thatattach the yoke to the drive hub. Remove theyoke weldment from the drive hub.

Replace the thrust washer wheninstalling the yoke/drive hubassembly onto the axle.


Lug nut,dry 125 ft-lbs 169.5 Nmlubricated 94 ft-lbs 127.4 Nm

Drive hub mounting bolts,dry 120 ft-lbs 163 Nmlubricated 90 ft-lbs 122 Nm

Drive motor mounting bolts,dry 75 ft-lbs 102 Nmlubricated 56 ft-lbs 76 Nm

16-2Steering Cylinders

How to Remove aSteering CylinderThis procedure is the same as the 2WD procedure.See repair procedure 15-2,How to Remove a Steering Cylinder.

16-3Tie Rod

How to Remove the Tie RodThis procedure is the same as the 2WD procedure.See Repair Procedure 15-3,How to Remove the Tie Rod.




17-1Oscillating 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 notadjustable.

How to Remove an OscillatingAxle Cylinder

Bodily injury hazard. Thisprocedure requires specific repairskills and a suitable workshop.Attempting this procedure withoutthese skills and tools may result indeath or serious injury andsignificant component damage.Dealer service is stronglyrecommended.

Perform this procedure on a firm,level surface with the boom inthe stowed position.


Oscillating Axle Components

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 it is removed fromthe machine if it is not properlyattached to the overhead crane.

5 Remove the cylinder from the machine.



18-1Drive Motor

How to Remove a Drive MotorComponent damage hazard.Repairs to the motor should onlybe performed by an authorizedSundstrand-Sauer dealer.

Component 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 Remove the fasteners from cover on the non-steer axle. Remove the cover.

Non-steering Axle Components

2 Tag, disconnect and plug the hydraulic hosesfrom the drive motor. Cap the fittings on thedrive motor.


3 Remove the drive motor mounting fasteners.

4 Slide the drive motor shaft out of the brake andthen remove the drive motor from the machine.


Drive motor mounting bolts 75 ft-lbs 102 Nm



NON-STEERING AXLE COMPONENTS

18-2Drive Hub

How to Remove a Drive HubWhen removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section Two, HydraulicHose and Fitting TorqueSpecifications.

1 Remove the drive motor. See 18-1, How toRemove a Drive Motor.

2 Tag, disconnect and plug the hydraulic hosefrom the brake. Then remove the hydraulicfitting and the bleed valve.


4 Center a lifting jack of ample capacity under thenon-steering axle. Raise the machineapproximately 6 inches (15 cm) and placeblocks under the drive chassis for support.

5 Remove the wheel lug nuts, then the tire andwheel assembly.

6 Place a second lifting jack under the drive hubfor support and secure the drive hub to thelifting jack.

7 Remove the drive hub mounting bolts thatattach the drive hub to the non-steer axle.

8 Remove the drive hub from the non-steer axle.

Crushing hazard. The drive hubmay become unbalanced and fallif it is not properly supported andsecured to the lifting jack.


Lug nut,dry 125 ft-lbs 169.5 Nmlubricated 94 ft-lbs 127.4 Nm

Drive hub mounting bolts,dry 120 ft-lbs 163 Nmlubricated 90 ft-lbs 122 Nm

Drive motor mounting bolts,dry 75 ft-lbs 102 Nmlubricated 56 ft-lbs 76 Nm

Genie North AmericaPhone: 425 881 1800Toll Free in USA 800 536 1800Toll Free in Canada 800 426 8089Fax: 425 883 3475

Genie UK LimitedPhone: 44 1636 605030Fax: 44 1636 611090

Genie ChinaPhone: 86 21 62483040Fax: 86 21 62488180

Genie JapanPhone: 81 3 3453 6082Fax: 81 3 3453 6083

Genie Australia Pty Ltd.Phone: 61 7 3375 1660Fax: 61 7 3375 1002

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Service Manual First Edition Second Printing - Genie liftmanuals.gogenielift.com/Parts And Service Manuals/data/Service/Z... · First Edition Second Printing Part No. 52709 Service