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Service Manual

First Edition Second Printing Part No. 52709

Introduction

First Edition Second Printing

Important
Read, understand and obey the safety rules and operating instructions in the Genie Z-45/25 & Genie Z-45/25J Operator's Manual before attempting any maintenance or repair procedure. This service manual covers the Genie Z-45/25 & Genie Z-45/25J 2WD and 4WD models introduced in 1998. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at a Genie dealer service center. Genie Industries has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and other manuals. Please write to the technical publications team in care of Genie Industries, PO Box 97030, Redmond WA 98073-9730 U.S.A. If you have any questions, please call Genie Industries.

Contact us:
http://www.genielift.com e-mail: techpub@genieind.com

Copyright 1998 by Genie Industries First Edition: Second Printing, September 2000

"Genie" and "Z" are Registered Trademarks of Genie Industries in the USA and many other countries. These machines comply with ANSI/SIA 92.5-1992. Printed on recycled paper Printed in U.S.A.

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Section 1 Safety Rules

Safety Rules

Danger
Failure to obey the instructions and safety rules in this manual, and the Genie Z-45/25 & Genie Z-45/25J Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.

Do Not Perform Maintenance Unless:


You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturers instructions and safety rules - employers safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop.

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Section 1 Safety Rules

First Edition Second Printing

SAFETY RULES

Personal Safety
Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority.

Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Redused to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Orangeused to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Yellow without safety alert symbolused to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Greenused to indicate operation or maintenance information.

Workplace Safety
Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach.

Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage.

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

Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity.

Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time.

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

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Table of Contents
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

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TABLE OF CONTENTS

Section Four

Scheduled Maintenance Procedures Introduction ............................................................................................................... 4 - 1 Maintenance Inspection Report ................................................................................ 4 - 3 A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 Inspect the Operator's and Safety Manuals .................................................... 4 - 5 Inspect the Decals and Placards ..................................................................... 4 - 5 Inspect for Damage and Loose or Missing Parts ............................................. 4 - 6 Check the Engine Oil Level ............................................................................. 4 - 7 Check the Engine Coolant Level - Liquid Cooled Models ................................ 4 - 8 Check for Fuel Leaks ...................................................................................... 4 - 8 Check the Hydraulic Oil Level ......................................................................... 4 - 9 Check for Hydraulic Leaks ............................................................................ 4 - 10 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

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TABLE OF CONTENTS

Section Four

Scheduled Maintenance Procedures, continued B-1 B-2 B-3 B-4 B-5 B-6 B-7 B-8 B-9 Check the Battery ......................................................................................... 4 - 29 Inspect the Electrical Wiring .......................................................................... 4 - 29 Check the Radiator - Ford Models ................................................................ 4 - 30 Check the Exhaust System ........................................................................... 4 - 31 Check the Hydraulic Return Filter Condition Indicator ................................... 4 - 32 Check the Oil Cooler and Cooling Fins - Deutz Diesel Models ...................... 4 - 32 Inspect the Tires and Wheels (including lug nut torque) ................................ 4 - 33 Confirm the Proper Brake Configuration ....................................................... 4 - 34 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

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TABLE OF CONTENTS

Section Four

Scheduled Maintenance Procedures, continued 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 C-2 C-3 C-4 C-5 C-6 D-1 D-2 D-3 D-4 D-5 D-6 D-7 D-8 Check the Engine Belt- Deutz Diesel Models ................................................ 4 - 55 Replace the Engine Oil and Filter - Deutz Diesel Models .............................. 4 - 57 Check the Engine Valve Clearances - Deutz Diesel Models ......................... 4 - 57 Change or Recondition the Engine Coolant - Liquid Cooled Models ............. 4 - 58 Check the Engine Valve Clearances - Perkins Diesel Models ....................... 4 - 59 Replace the PCV Valve - Ford Models .......................................................... 4 - 60 Check the Boom Wear Pads ......................................................................... 4 - 61 Check the Turntable Rotation Bearing Bolts ................................................. 4 - 62 Check the Free-wheel Configuration ............................................................. 4 - 63 Grease the Turntable Rotation Bearing and Rotate Gear .............................. 4 - 65 Replace the Drive Hub Oil ............................................................................. 4 - 66 Replace the Drive Loop Hydraulic Filter ........................................................ 4 - 67 Check and Adjust the Air/LPG Mixture - Ford Models ................................... 4 - 68 Replace the Diesel Fuel Filter/Water Separator - Deutz Diesel Models......... 4 - 69

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Section Four

Scheduled Maintenance Procedures, continued E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 Test or Replace the Hydraulic Oil .................................................................. 4 - 70 Change or Recondition the Engine Coolant - Ford Models ........................... 4 - 72 Change the Fuel Hoses ................................................................................ 4 - 74 Check the Toothed Belt - Deutz Diesel Models ............................................. 4 - 77 Check the Engine Valve Clearance - Ford Models ........................................ 4 - 77 Check the Engine Cylinder Compression - Ford Models ............................... 4 - 77 Check the Fuel Injection Pumps and Injectors - Deutz Diesel Models ........... 4 - 77 Replace the Timing Belt - Ford Models ......................................................... 4 - 77 Grease the Steer Axle Wheel Bearings, 2WD Models .................................. 4 - 78

Section Five

Troubleshooting Flow Charts Introduction ............................................................................................................... 5 - 1 Fault Codes .............................................................................................................. 5 - 3 1 2 2A 3 4 5 6 7 8 9 10 11 Engine Will Not Crank Over ............................................................................ 5 - 6 Engine Cranks Over But Will Not Start - Ford Models ..................................... 5 - 8 Engine Runs While Cranking Then Dies ....................................................... 5 - 10 Engine Cranks Over But Will Not Start - Diesel Models ................................ 5 - 11 Engine Will Not Start On LPG, But Will Start On Gasoline - Ford Models ..... 5 - 14 Engine Will Not Start On Gasoline, But Will Start On LPG - Ford Models ..... 5 - 16 Engine High Idle Inoperative - Ford Models .................................................. 5 - 17 Engine Low Idle Inoperative - Ford Models ................................................... 5 - 18 Engine High Idle Inoperative - Diesel Models ................................................ 5 - 19 Engine Low Idle Inoperative - Diesel Models ................................................. 5 - 21 All Functions Inoperative, Engine Starts and Runs ....................................... 5 - 22 All Lift and Steer Functions Inoperative, Drive Functions Operational ........... 5 - 23

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TABLE OF CONTENTS

Section Five

Troubleshooting Flow Charts, continued 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Ground Controls Inoperative, Platform Controls Operate Normally ............... 5 - 24 Platform Controls Inoperative, Ground Controls Operate Normally ............... 5 - 25 Primary Boom Up Function Inoperative ........................................................ 5 - 26 Primary Boom Down Function Inoperative (before serial number 13099) ..... 5 - 29 Primary Boom Down Function Inoperative (after serial number 13098) ........ 5 - 32 Secondary Boom Up Function Inoperative .................................................... 5 - 35 Secondary Boom Down Function Inoperative ............................................... 5 - 38 Primary Boom Extend Function Inoperative .................................................. 5 - 41 Primary Boom Retract Function Inoperative .................................................. 5 - 43 Turntable Rotate Left Function Inoperative ................................................... 5 - 45 Turntable Rotate Right Function Inoperative ................................................. 5 - 49 All Platform Leveling Functions Inoperative .................................................. 5 - 53 Platform Level Up Function Inoperative ........................................................ 5 - 54 Platform Level Down Function Inoperative .................................................... 5 - 56 Platform Rotate Left Function Inoperative ..................................................... 5 - 58 Platform Rotate Right Function Inoperative ................................................... 5 - 61 Jib Boom Up Function Inoperative, Z-45/25J Models .................................... 5 - 64 Jib Boom Down Function Inoperative, Z-45/25J Models ............................... 5 - 66 Steer Left Function Inoperative ..................................................................... 5 - 68 Steer Right Function Inoperative ................................................................... 5 - 69 Oscillate Function Inoperative ....................................................................... 5 - 70 All Drive Functions Inoperative, All Other Functions Operate Normally ......... 5 - 71 Drive Forward Or Reverse Function Inoperative ........................................... 5 - 74 Traction Function Inoperative ........................................................................ 5 - 75 Machine Will Not Drive At Full Speed ............................................................ 5 - 76 Machine Drives At Full Speed With Platform Raised or Extended ................. 5 - 77 Drive Enable System Is Malfunctioning ......................................................... 5 - 78 Auxiliary Functions Inoperative ..................................................................... 5 - 79

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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

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TABLE OF CONTENTS

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

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TABLE OF CONTENTS

Section Six

Schematics, continued 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

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TABLE OF CONTENTS

Section Six

Schematics, continued 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 1-2 Joystick Controllers ......................................................................................... 7 - 2 Horsepower Limiter Board .............................................................................. 7 - 8

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TABLE OF CONTENTS

Section Seven

Repair Procedures, continued 1-3 1-4 Foot Switch ................................................................................................... 7 - 10 Toggle Switches ............................................................................................ 7 - 11

Platform Components 2-1 2-2 2-3 Platform ........................................................................................................ 7 - 13 Platform Leveling Slave Cylinder .................................................................. 7 - 14 Platform Rotator ............................................................................................ 7 - 15

Jib Boom Components, Z-45/25J Models 3-1 3-2 3-3 Jib Boom, Z-45/25J Models .......................................................................... 7 - 18 Jib Boom Lift Cylinder, Z-45/25J Models ....................................................... 7 - 19 Jib Boom / Platform Rotate Manifold Components, Z-45/25J Models ........... 7 - 21

Primary Boom Components 4-1 4-2 4-3 4-4 4-5 Plastic Cable Track ....................................................................................... 7 - 22 Primary Boom ............................................................................................... 7 - 27 Primary Boom Lift Cylinder ........................................................................... 7 - 30 Primary Boom Extension Cylinder ................................................................. 7 - 31 Platform Leveling Master Cylinder ................................................................ 7 - 32

Secondary Boom Components 5-1 5-2 Secondary Boom .......................................................................................... 7 - 34 Secondary Boom Lift Cylinders ..................................................................... 7 - 39

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

Deutz Engine F3L 1011F 7-1 7-2 7-3 RPM Adjustment ........................................................................................... 7 - 41 Flex Plate ...................................................................................................... 7 - 41 Oil Temperature and Oil Pressure Gauges ................................................... 7 - 42

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TABLE OF CONTENTS

Section Seven

Repair Procedures, continued Perkins 104-22 Engine 8-1 8-2 8-3 RPM Adjustment ........................................................................................... 7 - 43 Flex Plate ...................................................................................................... 7 - 43 Coolant Temperature and Oil Pressure Gauages ......................................... 7 - 44

Ford LRG-425 EFI Engine 9-1 9-2 9-3 9-4 Timing Adjustment ........................................................................................ 7 - 45 RPM Adjustment ........................................................................................... 7 - 45 Flex Plate ...................................................................................................... 7 - 45 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

Section Seven

Repair Procedures, continued 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 4WD Steering Axle Components 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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Section 2 Specifications

Specifications
Machine Specifications
Stowed dimensions Length Width Standard Base Models Narrow Base Models Height Standard Base Models Narrow Base Models Weight Standard Base Models Narrow Base Models Ground clearance Standard Base Models Narrow Base Models Operational dimensions Maximum platform height Standard Base Models Narrow Base Models Maximum horizontal reach Maximum turntable tailswing Wheelbase
1

Z-45/25 (non jib) Z-45/25J (jib) 22 ft 3 in 6.8 m 7 ft 4 in 2.2 m 5 ft 9 in 1.8 m 6 ft 10 in 2.1 m 6 ft 7 in 2.05 m 14,700 lbs 6668 kg 17,100 lbs 7756 kg 10 in 25.4 cm 7 in 17.7 cm Minimum turning radius, inside Standard Base Models Narrow Base Models 4 ft 6 in 1.4 m 5 ft 1.5 m

Z-45/25J (jib) 4 ft 6 in 1.4 m 5 ft 1.5 m 11 ft 6 in 3.5 m 11 ft 3.35 m 359 160 500 lbs 227 kg 150 lbs 68 kg

Z-45/25 (non jib) 18 ft 5.5 m 7 ft 4 in 2.2 m 5 ft 9 in 1.8 m 6 ft 10 in 2.1 m 6 ft 7 in 2.05 m 14,000 lbs 6350 kg 17,100 lbs 7756 kg 10 in 25.4 cm 7 in 17.7 cm

Minimum turning radius, outside Standard Base Models 11 ft 6 in 3.5 m Narrow Base Models 11 ft 3.35 m Turntable rotation Platform rotation Maximum capacity 6 foot platform Maximum allowable side force (ANSI and CSA) Platform dimensions Length Width 359 180 500 lbs 227 kg 150 lbs 68 kg

72 in 183 cm 30 in 76 cm

45 ft 8 in 13.9 m 45 ft 5 in 13.9 m
124 17.5

45 ft 6 in 13.8 m 45 ft 5 in 13.9 m 25 ft 3 in 7.7 m 0 in 0 cm 6 ft 8 in 2m

ft 6 in m 0 in 0 cm

6 ft 8 in 2m

Outreach specification with platform rotated 90 degrees.

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Section 2 Specifications

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SPECIFICATIONS

Tires and wheels Wheel diameter Wheel width Wheel lugs, 4WD Wheel lugs, 2WD Front Rear Lug nut torque Tire size Tire ply rating Tire contact area Overall tire diameter Tire pressure Fluid capacities Fuel tank LPG tank Hydraulic tank Hydraulic system (including tank) Drive torque hubs

Rough terrain 17.5 inches 10.5 inches 9@


5 /8

Industrial 14.5 inches 7 inches

Performance Specifications
Drive speeds, maximum Drive speed, stowed All models 4.8 mph 7.7 km/h 40 ft/5.7 sec 12.2 m/5.7 sec 0.6 mph 1 km/h 40 ft/45 sec 12.2 m/45 sec 0.36 mph 0.58 km/h 40 ft/79 sec 12.2 m/79 sec 2WD 30% 4WD 45%

-18 8 @ 5/8 -18 9 @ 5/8 -18 125 ft-lbs 169.5 Nm 9-14.5 LT Tread 8 Sidewall 6 43.5 sq in 280 sq cm 28 in 71 cm Foam filled

8 @ 5/8 -18 9 @ 5/8 -18 125 ft-lbs 169.5 Nm 14-17.5 NHS 14 59 sq in 149.9 sq cm 35.8 in 90.9 cm 45 psi 2.76 bar

Drive speed, boom raised or extended, Standard Base Models Drive speed, boom raised or extended, Narrow Base Models Gradeability Boom Stowed Position

17 gallons 64.3 liters 33.5 pounds 15.2 kg 24 gallons 91 liters 30 gallons 113.6 liters 17 fl oz 0.51 liters

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

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Section 2 Specifications

SPECIFICATIONS

Boom function speeds, maximum from platform controls Jib boom up Jib boom down Primary boom up Primary boom down Secondary boom up Secondary boom down Primary boom extend Primary boom retract Turntable rotate - 359 primary boom retracted Platform rotate - 180 Z-45/25 Models Platform rotate - 160 Z-45/25J Models Platform level up Platform level down 38 to 42 seconds 24 to 27 seconds 24 to 27 seconds 32 to 37 seconds 23 to 27 seconds 23 to 27 seconds 10 to 14 seconds 18 to 22 seconds 73 to 78 seconds 10 to 14 seconds 9 to 13 seconds 35 to 39 seconds 26 to 32 seconds

Part No. 52709

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Section 2 Specifications

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SPECIFICATIONS

Hydraulic Specifications
Hydraulic fluid Drive pump Type: bi-directional variable displacement piston pump Displacement @ 2500 rpm 0 to 30.3 gallons per minute 0 to 114.7 liters per minute Maximum drive pressure Charge pressure neutral position drive position Medium pressure filter Medium pressure filter bypass pressure Drive manifold Brake relief pressure Steer end drive motors Displacement per revolution Non-steer end drive motors Displacement per revolution, variable 4WD (2 speed motor) Displacement per revolution, variable 2WD Function pump Type: pressure balanced gear Displacement - static Displacement @ 2500 rpm Hydraulic tank circuit return line filter 0.67 cu in 11 cc 0 to 2.1 gallons per minute 0 to 7.95 liters per minute 6 micron with 25 psi (1.7 bar) bypass 0.16 to 2.8 cu in 2.62 to 45.9 cc 1.1 to 2.8 cu in 18.4 to 45.9 cc 250 psi 17.2 bar 4WD models 1.53 cu in 25 cc 3500 psi 241.3 bar 290 psi 250 psi 20 bar 17 bar 3 micron 50 psi 3.4 bar Dexron equivalent

Function manifold Function relief valve pressure Primary boom down relief valve pressure Secondary boom down relief valve pressure Steer flow regulator Auxiliary pump Type: fixed displacement gear pump Displacement Auxiliary pump relief pressure 1.75 gallons per minute 2.8 liters per minute 3200 psi 220.6 bar 3200 psi 220.6 bar 2300 psi 158.6 bar 1800 psi 124 bar 1.5 gpm 5.7 liters/min

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Section 2 Specifications

SPECIFICATIONS

Ford Engine LRG-425 EFI


Displacement Number of cylinders Bore & stroke Horsepower gross intermittent continuous horsepower @ 2500 rpm Firing order Low idle High idle Compression ratio Compression pressure (approx.) Pressure (psi) of lowest cylinder must be at least 75% of highest cylinder Valve clearances collapsed tappet Lubrication system Oil pressure (operating temp. @ 2000 rpm) Oil capacity (including filter) Oil viscosity requirements Temperature below 60F / 15.5C -10F to 90F / -23C to 32C Temperature above -10F / -23C Temperature above 20F / -6.6C 5W-30 10W-30 10W-40 to 10W-50 20W-40 or 20W-50 40 to 60 psi 2.75 to 4.1 bar 5 quarts 4.7 liters 0.035 to 0.055 in 0.889 to 1.397 mm 97 82 70 1-3-4-2 1600 rpm 2500 rpm 9.4:1 153 cu in 2.5 liters 4 3.78 x 3.4 in 96.01 x 86.36 mm

Starter motor Normal engine cranking speed Current draw, normal load Current draw, maximum load Current draw, minimum Maximum circuit voltage drop while starting (normal temperature) Brush length, new Brush length wear limit Brush spring tension Bolt torque through brush Brush mounting bolt torque Maximum commutator run-out 200 to 250 rpm 140-200A 800A 60-80A 0.5V DC 0.66 in 16.8 mm 0.25 in 6.35 mm 64 ounces 18 Newtons 45 to 84 in-lbs 5.08 to 9.5 Nm 15 to 20 ft-lbs 20 to 27 Nm 0.005 in 0.127 mm

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

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Section 2 Specifications

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SPECIFICATIONS

Battery Type Quantity Cold cranking ampere Reserve capacity @ 25A rate Electronic fuel pump Fuel pressure, static Fuel flow rate Ignition System Spark plug type Spark plug gap Engine coolant Capacity Alternator Output 95A, 14.5V 111/2 quarts 10.9 liters Motorcraft AWSF-52C 0.042 to 0.046 in 1.07 to 1.18 mm 64 psi 4.4 bar 0.58 gpm 2.18 L/min 12V, Group 34/78 1 900A 200 minutes

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Section 2 Specifications

SPECIFICATIONS

Deutz Engine F3L 1011F


Displacement Number of cylinders Bore and stroke Horsepower gross intermittent continuous horsepower @ 3000 rpm Firing order Low idle High idle Compression ratio Compression pressure Governor Valve clearance, cold Intake Exhaust Lubrication system Oil pressure Oil capacity (including filter) Oil viscosity requirements Temperature below 60F / 15.5C (synthetic) -10F to 90F / -23C to 32C Temperature above -4F / -34C 5W-30 10W-40 15W-40 26 to 87 psi 1.8 to 6 bar 6.5 quarts 6 liters 0.012 in 0.3 mm 0.020 in 0.5 mm 44 40 36 1-2-3 1400 rpm 2500 rpm 18.5:1 362 to 435 psi 25 to 30 bar centrifugal mechanical 125 cu in 2.05 liters 3 3.58 x 4.13 inches 91 x 105 mm

Injection system Injection pump make Injection pump pressure Injector opening pressure Fuel requirement Alternator output Starter motor Current draw, no load Brush length, new Brush length, minimum Battery Type Quantity Cold cranking ampere Reserve capacity @ 25A rate Fan belt deflection 12V, Group 34/78 1 900A 200 minutes
3 /8

OMAP 4351 psi 300 bar 3626 psi 250 bar diesel number 2-D 55A, 14V

90A 0.72 in 18.5 mm 0.27 in 7 mm

to 1/2 inch 9 to 12 mm

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

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Section 2 Specifications

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SPECIFICATIONS

Perkins Engine 104-22 (KR model)


Displacement Number of cylinders Bore and stroke Horsepower 135 cu in 2.2 liters 4 3.31 x 3.94 inches 84 x 100 mm

Oil viscosity requirements below 68F / 20C (synthetic) 5F to 104F / -15C to 40C above 14F / -10C 5W-20 10W-30 15W-40

Engine oil should have properties of API classification CC/SE. API classification CD/SE or CCMC D4 can be used, but is not recommended during the first 50 hours nor for light load applications. Injection system

gross intermittent continuous horsepower @ 2800 rpm Firing order Low idle High idle Compression ratio Compression pressure

50 46.9 41 1-3-4-2 1600 rpm 2500 rpm 22:1

Injection pump make Injection pressure Fuel requirement Alternator output Starter motor Current draw, no load Brush length, new Brush length, minimum Battery

Zexel 2133 psi 147 bar #2 Diesel 55A @ 13.8V

300 to 500 psi 20.7 to 34.5 bar Pressure (psi) of lowest cylinder must be 50 psi (3.45 bar) of highest cylinder centrifugal mechanical

90A 0.7480 in 19 mm 0.5 in 12.7 mm

Governor Valve clearance, cold Intake Exhaust Lubrication system Oil pressure (at 2600 rpm) Oil capacity (including filter)

0.008 in 0.2 mm 0.008 in 0.2 mm

Type Quantity Cold cranking ampere Reserve capacity @ 25A rate

12V, Group 34/78 1 900A 200 minutes


3/8 in 10 mm

41 psi 2.8 bar 8.6 quarts 8.2 liters

Fan belt deflection

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Section 2 Specifications

SPECIFICATIONS

Hydraulic Hose and Fitting Torque Specifications


Your machine is equipped with Parker Seal-Lok O-ring face seal fittings and hose ends. Machines that utilize Parker Seal-Lok O-ring face seal fittings and hose ends require that the fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.

Hydraulic Hose and Fitting Torque Specifications


SAE O-ring Boss Port - tube fitting SAE Dash Installing Size into... ft. lbs. -4 Aluminum 11 Steel 16 -6 Aluminum 23 Steel 35 -8 Aluminum 40 Steel 60 -10 Aluminum 69 Steel 105 -12 Aluminum 93 Steel 140 -16 Aluminum 139 Steel 210 -20 Aluminum 172 Steel 260 -24 Aluminum 208 Steel 315 Nm 14.9 21.7 31.2 47.5 54.2 81.3 93.6 142.4 126.1 190 188.5 284.7 233.2 352.5 282 427.1 Seal-Lok - hose end SAE Dash Size ft. lbs. -4 18 -6 27 -8 40 -10 63 -12 90 -16 120 -20 140 -24 165 Nm 24.4 36.6 54.2 85.4 122 162.7 190 223.7

Torque Procedure
1 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 or hose end has been tightened beyond finger tight. The O-rings used in the Parker Seal Lok fittings and hose ends are custom-size O-rings. They are standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 49612). 2 Lubricate the O-ring before installation. Part No. 52709 Genie Z-45/25 & Genie Z-45/25J 2-9 3 Be sure that the face seal O-ring is seated and retained properly. 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight. 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table above. 6 Operate all machine functions and inspect the hoses and fittings and related components to be sure that there are no leaks.

Section 2 Specifications

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Section 3 Theory of Operation

Theory of Operation
Power Source
The Genie Z-45/25 and Genie Z-45/25J are powered by either a gasoline/LPG engine or one of two diesel engines. The gasoline/LPG option uses a Ford LRG-425 EFI engine rated at 70 horsepower @ 2500 rpm. The diesel options include a Deutz F3L 1011F engine rated at 36 horsepower @ 3000 rpm, and a Perkins 104-22 KR engine rated at 41 horsepower @ 2800 rpm.

Electrical System
Boom/Steer functions are accomplished by moving a toggle switch or a controller, which sends voltage to the appropriate directional control valve. These directional valves determine which direction the hydraulic fluid will travel. The amount of hydraulic fluid volume is determined by a proportional valve or flow regulator valve. A proportional valve receives a variable voltage signal and delivers more hydraulic fluid as the voltage increases. A flow regulator valve is a mechanical valve and delivers a predetermined amount of hydraulic fluid. Drive forward or reverse is accomplished by pressing down the foot switch in the platform and moving the drive controller (joystick) in the appropriate direction. When activated, the drive controller completes a circuit to the electronic displacement controller (EDC). The EDC regulates drive pump displacement in direct relation to the drive controller position. A horsepower limiter printed circuit board (located in the platform control box) is provided to maintain engine RPM as drive system loads become greater. This is done by sensing engine RPM (via an AC tap on the alternator) and limiting the amount of current supplied to the drive controller/EDC, which destrokes the pump, reducing pump output.

Hydraulic System
All machine functions are performed by the hydraulic system. The hydraulic system can be divided into two groups: Boom/Steer functions and Drive functions. Boom/Steer functions are powered by a singlesection gear pump, rated at 7 gpm (26.5 L/min). When the engine is running, this pump supplies hydraulic fluid under pressure to the function manifold, where the directional and flow control valves are located. To protect from overpressurization of the Boom/Steer system, the pump is provided with a pressure relief valve, set at 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 3200 psi (220.6 bar) relief valves are used to prevent over-pressurization of the closed loop drive system. The boom lift cylinder, boom extend cylinder, platform leveling slave cylinder, platform rotator and jib boom cylinder (Z-45/25J models) incorporate counterbalance valves to prevent movement in the event of a hydraulic line failure.

Part No. 52709

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Section 3 Theory of Operation

First Edition Second Printing

THEORY OF OPERATION

Limit switches There are two types of limit switches which are found in various locations on the machine: drive speed limit switches and a drive enable limit switch. The function of a drive speed limit switch is to limit the raised or extended drive speed to 0.6 miles per hour (1 km/h) when the primary boom is raised more than 2 feet (0.6 m) OR when the primary boom is extended more than 18 inches (45.7 cm). The function of the drive enable limit switch is to limit the ability of the machine to drive when the boom is rotated beyond the non-steer wheels.

Machine Controls
The Genie Z-45/25 and Genie Z-45/25J machines are equipped with operational controls which are found in two locations: the ground controls, located on the engine side of the machine, and the platform controls, located in the platform. All lift and drive functions are available at the platform controls. Only boom functions are available at the ground controls. Ground controls are activated by holding the function enable toggle switch to either side, then moving a boom function toggle switch in the direction indicated on the control panel decal. This will determine which boom function will operate and its direction of travel. Platform controls use toggle switches and boom function controllers (joysticks) to operate the boom functions. The drive controller (joystick) regulates the drive pump displacement through the EDC in direct relation to the drive controller position. A thumb rocker switch on the top of the drive controller is used for steering. Washing electronic components is not suggested. Instead, use compressed air to remove debris.

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Section 4 Scheduled Maintenance Procedures

Scheduled Maintenance Procedures


About This Section
This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety information and step-by-step instructions.

Observe and Obey:


Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Scheduled maintenance inspections shall be completed daily, quarterly, six months, annually and every 2 years as specified on the Maintenance Inspection Report. Failure to perform each procedure as presented and scheduled may cause death, serious injury or substantial damage. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating machine. Keep records on all inspections for three years. Unless otherwise specified, perform each maintenance procedure with the machine in the following configuration: Machine parked on a flat, level surface Boom in stowed position 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

Symbols Legend Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Redused to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Orangeused to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Yellow without safety alert symbolused to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Greenused to indicate operation or maintenance information. Indicates that a specific result is expected after performing a series of steps.

Part No. 52709

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Section 4 Scheduled Maintenance Procedures

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SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.

Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily, quarterly, six months, annual, and two years. The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsectionsA, B, C, D and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection.
Inspection Daily or every 8 hours Table or Checklist A A+B A+B+C A+B+C+D A+B+C+D+E

Indicates that tools will be required to perform this procedure.

Indicates that new parts will be required to perform this procedure.

Quarterly or every 250 hours Six months or every 500 hours Annual or every 1000 hours

Indicates that a cold engine will be required to perform this procedure.

Two years or every 2000 hours

Indicates that a warm engine will be required to perform this procedure.

Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years.

Indicates that dealer service is required to perform this procedure.

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Section 4 Scheduled Maintenance Procedures

Maintenance Inspection Report


Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Instructions Make copies of both pages to use for each inspection. Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: Quarterly or 250 hour Inspection: Checklist A A-1 Manuals A-2 Decals and placards A-3 Damage and loose or missing parts A-4 Engine oil level A-5 Engine coolantLiquid 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 and ground controls A-12 Auxiliary power A-13 Tilt sensor A-14 Limit switches A-15 Check the engine beltPerkins Models A-16 Air filter A-17 Fuel filter- Ford Models A-18 Inspect the radiatorPerkins Models A-19 Perform 30 day service Perform every 100 hours: A-20 Replace oil filterFord and Perkins Models A-21 Inspect fuel filter/water separator-Diesel Models A-22 Check engine RPMPerkins Engine Models Perform every 200 hours: A-23 Check the engine beltFord Models Y N R Checklist B Y N R B-1 Check the battery B-2 Inspect electrical wiring B-3 Check the radiatorFord Models B-4 Exhaust system B-5 Hydraulic return filter condition indicator B-6 Check oil cooler and finsDeutz Models B-7 Tires and wheels B-8 Brake configuration B-9 Drive hub oil level B-10 Engine RPMFord 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 hydraulic tank return filter Perform every 400 hours: B-27 Replace fuel filter/water separator elementPerkins models B-28 Replace the fuel filter element - Perkins Models B-29 Replace spark plugsFord Models B-30 Replace engine air filter

A A+B

Six Month or 500 hour Inspection: A+B+C Annual or 1000 hours Inspection: A+B+C+D 2 Year or 2000 hour Inspection: A+B+C+D+E Place a check in the appropriate box after each inspection procedure is completed. If any inspection receives an N, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments

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Section 4 Scheduled Maintenance Procedures

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MAINTENANCE INSPECTION REPORT

Instructions Make copies of both pages to use for each inspection. Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: Quarterly or 250 hour Inspection:

A A+B

Checklist C C-1 Engine beltDeutz Models C-2 Replace engine oil and filter-Deutz Models C-3 Valves-Deutz Models C-4 Check the coolantLiquid Cooled Models C-5 Check the valve clearance-Perkins Models C-6 PCV valve-Ford Models

Y N R

Six Month or 500 hour Inspection: A+B+C Annual or 1000 hours Inspection: A+B+C+D 2 Year or 2000 hour Inspection: A+B+C+D+E Place a check in the appropriate box after each inspection procedure is completed. If any inspection receives an N, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments

Checklist D Y N R D-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 mixtureFord Models D-8 Replace the diesel fuel filter/water separatorDeutz Models

Checklist E Y N R E-1 Hydraulic oil E-2 Engine coolantFord Models E-3 Fuel hoses E-4 Check the toothed beltDeutz Models E-5 Check the engine valve clearance-Ford Models E-6 Check cylinder compression-Ford Models E-7 Check the fuel injection pump-Deutz Models E-8 Replace timing belt Ford Models E-9 Grease the steer axle wheel bearings, 2WD Models

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Section 4 Scheduled Maintenance Procedures

Table A Procedures
A-1 Inspect the Operator's and Safety Manuals
Maintaining the operators and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition. 1 Check to be sure that the storage container is present and in good condition. 2 Check to make sure that the operator's, responsibilities and safety manuals are present and complete in the storage container in the platform. 3 Examine the pages of each manual to be sure that they are legible and in good condition. 4 Always return the manuals to the storage container after use. Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed.

A-2 Inspect the Decals and Placards


Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions. 1 Refer to the Decals section in the Genie Z45/25 & Genie Z45/25J Operator's Manual and use the decal list and illustrations to determine that all decals and placards are in place. 2 Inspect all decals for legibility and damage. Replace any damaged or illegible decal immediately. Contact your authorized Genie distributor or Genie Industries if replacement decals are needed.

Part No. 52709

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Section 4 Scheduled Maintenance Procedures

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TABLE

A PROCEDURES

A-3 Inspect for Damage and Loose or Missing Parts

Check entire machine for: Cracks in welds or structural components Dents or damage to machine Battery and connections Compartment covers and latches

Daily machine condition inspections are essential to safe machine operation and good machine performance. Failure to locate and repair damage, and discover loose or missing parts may result in an unsafe operating condition. 1 Inspect the entire machine for damage and improperly 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

Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened. After you complete each inspection, be sure that all compartment covers are in place and secured.

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Section 4 Scheduled Maintenance Procedures

TABLE A PROCEDURES

A-4 Check the Engine Oil Level

Deutz Engine F3L 1011F Oil capacity (including filter) Oil viscosity requirements below 60F / 15.5C (synthetic)

6.3 quarts 6 liters

5W-30 10W-40 15W-40

Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level can damage engine components. Check the oil level with the engine 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 Oil capacity (including filter) Oil viscosity requirements below 60F / 15.5C -10 to 90F / -23 to 32C above -10F / -23C above 25F / -4C Use oils meeting API classification SH or SG. Units ship with 10-40 CC/SG. 5W-30 5W-30 5W-30 10W-30 4.5 quarts 4.3 liters

-10F to 90F / -23C to 32C above -4F / -34C

Engine oil should have properties of API classification CC/SE, CD/SE, SF/CC or SF/CD grades. Units ship with 10-40 CC/SG. Perkins Engine 104-22 Oil capacity (including filter) Oil viscosity requirements below 60F / 15.5C -10 to 90F / -23 to 32C above -10F / -23C above 25F / -4C 5W-20 10W-30 15W-40 20W-50 8.6 quarts 8.2 liters

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

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Section 4 Scheduled Maintenance Procedures

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TABLE

A PROCEDURES

A-5 Check the Engine Coolant Level Liquid Cooled Models

A-6 Check for Fuel Leaks

Maintaining the engine coolant at the proper level is essential to engine service life. Improper coolant level will affect the engine's cooling capability and damage engine components. Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems. Burn hazard. Beware of hot engine parts and coolant. Contact with hot engine parts and/or coolant may result in severe burns. 1 Check the fluid level in the coolant recovery tank. Add fluid as needed. Result: The fluid level should be at the FULL mark. Do not remove the radiator cap.

Failure to detect and correct fuel leaks will result in an unsafe condition. An explosion or fuel fire may cause death or serious injury. Explosion and fire hazard. Engine fuels are combustible. Inspect the machine in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. 1 Open the shutoff valve on the liquid petroleum gas (LPG) tank by turning it counterclockwise (if equipped). 2 Perform a visual inspection around the following areas. Ford Models: LPG tank, hoses and fittings, solenoid shutoff valve, LPG regulator and throttle body. An LPG detector may be necessary to locate LPG leaks. Fuel tank, manual shutoff valve, fuel pump, fuel filters, fuel rail and fuel injectors, hoses and fittings and throttle body.

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Section 4 Scheduled Maintenance Procedures

TABLE A PROCEDURES

Deutz and Perkins Models: Fuel tank, shutoff valve, hoses and fittings, fuel pump, fuel filter, fuel injection pumps and fuel injectors. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately.

A-7 Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic oil levels can damage hydraulic components. Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems. 1 Be sure that the boom is in the stowed position, then visually inspect the sight gauge located on the side of the hydraulic oil tank. Result: The hydraulic oil level should be within the top 2 inches (5 cm) of the sight gauge. 2 Add oil as needed.
Hydraulic oil specifications Hydraulic oil type Tank capacity Hydraulic system (including tank) 24 gallons 30 gallons Dexron equivalent 90.8 liters 113.6 liters

Part No. 52709

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Section 4 Scheduled Maintenance Procedures

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TABLE

A PROCEDURES

A-8 Check for Hydraulic Leaks

A-9 Check the Tire Pressure

Detecting hydraulic fluid leaks is essential to operational safety and good machine performance. Undiscovered leaks can develop into hazardous situations, impair machine functions and damage machine components. 1 Inspect for hydraulic oil puddles, dripping or residue on or around the following areas: Hydraulic tank fittings, hoses, auxiliary power unit, filters, and turntable surface Engine compartmenthydraulic filters, fittings, hoses, pumps, filter and turntable surface 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

Bodily injury hazard. An overinflated tire can explode and could result in death or serious injury. Tip-over hazard. Do not use temporary flat tire repair products. This procedure does not need to be performed on machines equipped with foam-filled tire. To safeguard maximum stability, achieve optimum machine handling and minimize tire wear, it is essential to maintain proper pressure in all air-filled tires. 1 Check each tire with an air pressure gauge and add air as needed.
Tire specifications 2WD Models 4WD Models

Standard base models Rough terrain tire 14-17.5 NHS 45 psi (3.1 bar) Narrow base models Industrial tire Foam Filled Only

14-17.5 NHS 45 psi (3.1 bar)

N/A

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Part No. 52709

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Section 4 Scheduled Maintenance Procedures

TABLE A PROCEDURES

A-10 Test the Oscillate Axle (if equipped)


Proper axle oscillation is essential to safe machine operation. If the axle oscillation system is not operating correctly, the stability of the machine is compromised 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 in firm contact with the ground and the chassis should 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 in firm contact with the ground and the chassis should 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 firm contact with the ground. If the chassis does not remain level during test, see Repair Procedure 12-4, How to Set Up the Directional Valve Linkage

A-11 Test the Platform and Ground Controls


Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation. An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions and shut off the engine. Each function should activate, operate smoothly and be free of hesitation, jerking and unusual noise. 1 Turn the key switch to ground control and pull out 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 either side. Attempt to activate each boom and platform function toggle switch. Result: All boom and platform functions should not operate. 4 Hold the function enable switch to either side and activate each boom and platform function toggle switch. Result: All boom and platform functions should operate through a full cycle. Descent alarm (if equipped) should sound while the boom is lowering. Machines equipped with Platform Level Control Disable Function: The platform level function will not operate when the boom is raised or extended past the drive speed limit switches.

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5 Push in the Emergency Stop button to the OFF position. Result: No function should operate, the engine should stop. Deutz and Perkins Diesel models: All functions should stop immediately. The engine will shut off after 2 to 3 seconds. 6 Start the engine from the platform controls. 7 Do not press down on the foot switch. 8 Attempt to activate each machine function. Result: All machine functions should not operate. 9 Press down on the foot switch and activate each machine function. Machines equipped with Platform Level Control Disable Function: The platform level function will not operate when the boom is raised or extended past the drive speed limit switches. Result: All machine functions should operate through a full cycle. 10 Push in the Emergency Stop button to the OFF position at the platform controls. Result: No function should operate, the engine should stop. As a safety feature, selecting and operating the ground controls will override the platform controls, including the Emergency Stop button. Deutz and Perkins Diesel models: All functions should stop immediately. The engine will shut off after 2 to 3 seconds.

A-12 Test the Auxiliary Power Operation


Detection of auxiliary power system malfunctions is essential for safe machine operation. An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss. When operating the machine on engine power, selecting auxiliary power will stop the engine immediately. Auxiliary power is designed for short term use only, and excessive use will result in battery drain and component damage. 1 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position. 2 Lift the red auxiliary power switch cover. 3 Simultaneously hold the auxiliary power switch ON and activate each boom function toggle switch.

To conserve battery power, test each function through a partial cycle. 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.

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TABLE A PROCEDURES

7 Lift the red auxiliary power switch cover. 8 Simultaneously hold the auxiliary power switch ON and activate each function control handle or toggle switch.

A-13 Test the Tilt Sensor


The tilt sensor sounds an alarm located in the platform when the incline of the turntable exceeds the rating on the serial plate. Select a level test area. The tilt alarm should not be sounding prior to the test. 1 Open the engine side turntable cover. 2 Turn the key switch to platform controls and pull out the red Emergency Stop buttons out to the ON position at both the ground and platform controls. 3 Locate the tilt sensor to the right of the hydraulic pump. 4 Press down on one side of the tilt sensor. Result: The alarm, located in the platform, should sound. Tip-over hazard. The alarm should be heard at the ground controls. If you can't hear the alarm at the ground controls, replace the alarm in the platform.

Result: All boom and steer functions should operate. Drive functions should not operate with auxiliary power. To conserve battery power, test each function through a partial cycle.

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A PROCEDURES

A-14 Test the Limit Switches

5 Locate the secondary boom drive limit switch located at the platform end of the lower secondary boom.

Drive Limit Switches Detecting limit switch malfunctions is essential to safe machine operation. The drive limit switches are used to restrict drive speed when the boom is raised or extended. An improperly functioning drive limit switch will allow the machine to operate at an unsafe drive speed. 1 Remove the hose and cable cover from the rear of the upper mid-pivot. 2 Locate the primary boom drive limit switch located on the inside of the upper mid-pivot. 3 Visually inspect primary boom drive limit switch for the following: Broken or missing roller or arm Missing fasteners Loose wiring 4 Manually activate the primary boom drive limit switch. Result: The primary boom drive limit switch arm should move freely and spring return to center. A distinct click should be felt and heard.
a a

secondary boom drive limit switch (LS3)

6 Visually inspect secondary boom drive limit switch for the following: Broken or missing roller or arm Missing fasteners Loose wiring 7 Manually activate the secondary boom drive limit switch. Result: The secondary boom drive limit switch arm should move freely and spring return to center. A distinct click should be felt and heard.

primary boom drive limit switch (LS2)

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TABLE A PROCEDURES

8 Locate the primary boom extend drive limit switch located at the pivot end of the primary boom.
a

13 Start the engine from the platform controls. 14 Move the lift/drive select switch to the lift position (if equipped). 15 Press down the foot switch. Fully retract the primary boom. 16 Move the lift/drive select switch to the drive position (if equipped). 17 Press down the foot switch and slowly move the drive control handle off center. Result: The machine should move at normal drive speeds. 18 Move the lift/drive select switch to the lift position (if equipped). 19 Press down the foot switch and raise the primary boom approximately 2 feet (61 cm). 20 Move the lift/drive select switch to the drive position (if equipped). 21 Press down the foot switch and slowly move the drive control handle off center. Result: The machine should move at a reduced drive speed. 22 Move the lift/drive select switch to the lift position (if equipped). 23 Press down the foot switch and lower the primary boom to the stowed position, then raise the secondary boom approximately 2 feet (61 cm).

primary boom extend drive limit switch (LS1)

9 Visually inspect the boom extend drive limit switch located at the pivot end of the primary boom. Inspect for the following: Broken or missing arm Missing fasteners Loose wiring 10 Start the engine from the ground controls and extend the primary boom approximately 2 feet (61 cm). 11 Turn the engine off. 12 Manually activate the boom extend drive limit switch. Result: The boom extend drive limit switch arm should move freely and spring return to center. A distinct click should be felt and heard.

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24 Move the lift/drive select switch to the drive position (if equipped). 25 Press down the foot switch and slowly move the drive control handle off center. Result: The machine should move at a reduced drive speed. 26 Move the lift/drive select switch to the lift position (if equipped). 27 Press down the foot switch and lower the secondary boom to the stowed position, then extend the primary boom approximately 2 feet (0.6 m). 28 Move the lift/drive select switch to the drive position (if equipped). 29 Press down the foot switch and slowly move the drive control handle off center. Result: The machine should move at a reduced drive speed.
Drive speed, maximum, raised or extended Drive speed, boom raised or extended, Standard Base Models 0.6 mph 1.0 km/h 40 ft/45 sec 12.2 m/45 sec 0.36 mph 0.58 km/h 40 ft/79 sec 12.2 m/79 sec

Drive Enable Limit Switch A properly functioning drive enable limit switch is essential for safe machine operation and workplace safety. The drive enable limit switch stops the drive function when the boom is rotated past a non-steer tire and alerts the operator that the machine may drive in the opposite direction that the drive and steer control handle is moved. 1 Start the engine from the ground controls and rotate the boom between the steer and non-steer tires. Turn the engine off. 2 Visually inspect the drive enable limit switch for the following: Broken or missing roller or arm Missing fasteners Loose wiring
a

Drive speed, boom raised or extended, Narrow Base Models

c a b c

b turntable drive enable limit switch (LS4) turntable rotation bearing

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3 Manually activate the drive enable limit switch. Result: The drive enable limit switch roller should move freely and spring return to center. A distinct click should be felt and heard. 4 Start the engine from the platform controls. Result: The drive enable indicator light should be on. 5 Move the lift/drive select switch to the lift position (if equipped). 6 Press down the foot switch. Then rotate the turntable until the primary boom is in between the non-steer tires. Result: The drive enable indicator light should be off. 7 Move the lift/drive select switch to the drive position (if equipped). 8 Press down the foot switch and slowly move the drive control handle off center. Result: The drive function should operate. 9 Move the lift/drive select switch to the lift position (if equipped). 10 Press down the foot switch and rotate the turntable to the left until the boom is past the left non-steer wheel. Result: The drive enable indicator light should be on. 11 Move the lift/drive select switch to the drive position (if equipped).

12 Press down the foot switch and slowly move the drive control handle off center. Result: Drive function should not operate. 13 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center. Result: Drive function should operate. 14 Move the lift/drive select switch to the lift position (if equipped). 15 Press down the foot switch and rotate the turntable to the right until the boom is past the right non-steer wheel. Result: The drive enable indicator light should be on. 16 Rotate the turntable to the left until the boom is past the left non-steer wheel. Result: The drive enable indicator light should be on. 17 Move the lift/drive select switch to the drive position (if equipped). 18 Press down the foot switch and slowly move the drive control handle off center. Result: Drive function should not operate. 19 Move and hold the drive enable toggle switch to either side and slowly move the drive control handle off center. Result: Drive function should operate.

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A-15 Check the Engine Belt Perkins Models


Maintaining the engine belt is essential to good engine performance and service life. The machine will not operate properly with a loose or defective belt and continued use may cause component damage. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 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 position and close the engine pivot plate latch. 7 Install the engine pivot plate safety pin. 8 Replace the air baffle and install the air baffle retaining fasteners.
Belt deflection
3/8 in to 1/2 in 9.5 mm to 12 mm

Engine belt - Genie part number

65537

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TABLE A PROCEDURES

A-16 Clean the Engine Air Filter Element

3 Remove the end cap from the air cleaner canister. 4 Remove the air filter retaining fastener. Remove the filter element. 5 Clean the inside of the canister and the gasket with a damp cloth.

Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage. Perform this procedure with the engine off. All Models: 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine.

6 Inspect the filter element. If needed, blow out from inside out using low pressure dry compressed air, or tap out dust taking care not to damage the element. 7 Install the end cap onto the canister. Install and tighten the retaining ring. 8 Swing the engine back to its original position and close the engine pivot plate latch. 9 Install the engine pivot plate safety pin (if equipped).

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A-17 Replace the Fuel Filters - Ford Models

1 Locate the fuel system components mounted underneath the engine pivot plate (viewed from bottom of engine pivot plate).
a b c

Replacing the gasoline fuel filter is essential to good engine performance and service life. A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Explosion and fire hazard. Engine fuels are combustible. Replace the fuel filter in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off.

a b c d e

hose from fuel pump to regulator/filter hose from fuel pre-filter to fuel pump hose from fuel tank to fuel pre-filter hose from regulator/filter to engine hose from regulator/filter to tank

2 At the pre-filter, disconnect and plug the fuel hose that goes to the fuel tank. 3 Disconnect the fuel hose from the fuel pre-filter to the fuel pump, then remove the pre-filter. 4 Install the new fuel pre-filter (Genie part number 52179) and connect the fuel hoses to the filter. 5 Clean up any fuel that may have spilled during the installation procedure.

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6 Disconnect the hoses from the pressure regulator/filter. Explosion and fire hazard. Electronic Fuel Injection (EFI) systems operate at a very high pressure. Fuel may be expelled under pressure if the hoses are removed too quickly. Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually. Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them. 7 Remove the regulator/filter mounting fasteners. Then remove the regulator/filter from the engine pivot plate. 8 Install the new regulator/filter (Genie part number 58967) onto the engine pivot plate and install the hoses to the regulator/filter. Component damage hazard. Be sure the correct regulator/filter is installed or component damage may occur. 9 Start the machine from the ground controls, then inspect the fuel filters and hoses for leaks. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately.
Fuel filters - Genie part numbers Fuel pre-filter Fuel pressure regulator/filter 52179 58967

A-18 Inspect the Radiator Perkins Models

Maintaining the radiator in good condition is essential for good engine performance. Operating a machine with a damaged or leaking radiator may result in engine damage. Also, restricting air flow through the radiator (i.e., dirt or debris) will affect the performance of the cooling system. A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Burn hazard. Beware of hot engine parts and coolant. Contact with hot engine parts and/or coolant may result in severe burns. 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine.

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3 Inspect the radiator for leaks and physical damage. 4 Clean the radiator fins of debris and foreign materials. 5 Inspect all radiator hoses and connections. 6 Swing the engine back to its original position and close the engine pivot plate latch. 7 Install the engine pivot plate safety pin.

A-19 Perform 30 Day Service

The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 50 hours of usage. After this interval, refer to the maintenance tables for continued 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

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

2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Remove the oil filler cap located on the valve cover. 4 Pull the oil drain hose out from underneath the engine. 5 Open the valve on the oil pan and allow all of the oil from the engine to drain into a suitable container. 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 filter gasket. Then install the filter and tighten it securely by hand.
Oil filters - Genie part numbers Ford LRG-425 EFI Engine Perkins 104-22 Engine

Ford and Perkins engine specifications require that this procedure be performed every 100 hours. Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation. Periodic replacement of the engine oil and filter is essential to good engine performance. Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components. A daily check of machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 100 hour interval. Perform this procedure after warming the engine to normal operating temperature. Burn hazard. Beware of hot engine parts and oil. Contact with hot engine oil and/or engine parts may result in severe burns. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

28656 65540

10 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter. 11 Fill the engine with new oil per specifications and install the filler cap. See capacity specifications. 12 Start the engine from the ground controls. Allow the engine to run for 30 seconds, then turn the engine off.

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13 Check the oil filter and the oil pan hose for leaks. 14 Swing the engine back to its original position and close the engine pivot plate latch. 15 Install the engine pivot plate safety pin (if equipped). 16 Check the engine oil level dipstick. Add oil if needed.
Ford LRG-425 EFI Engine Oil capacity (including filter) Oil viscosity requirements below 60F / 15.5C -10 to 90F / -23 to 32C above -10F / -23C above 25F / -4C Use oils meeting API classification SH or SG. Units ship with 10-40 CC/SG Perkins 104-22 Engine Oil capacity (including filter) Oil viscosity requirements below 60F / 15.5C -10F to 90F / -23C to 32C above -4F / -34C 15W-40 10W-30 15W-40 8.6 quarts 8.2 liters 5W-30 5W-30 5W-30 10W-30 4.5 quarts 4.3 liters

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

Engine specifications require that this procedure be performed every 100 hours. Proper maintenance of the fuel filter/water separator is essential for good engine performance. Failure to perform this procedure can lead to poor engine performance and component damage. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off. Perkins Models: 1 Open the engine side turntable cover and locate the fuel filter/water separator next to the hydraulic return filter on the bulkhead. 2 Inspect the filter bowl for water buildup. Result: If water is present in the filter bowl continue with steps 3 through 7 for Perkins models only.

Engine oil should have properties of API classification CF4 grade.

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TABLE A PROCEDURES

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

7 Start the engine from the ground controls and check the fuel filter/water separator and vent plug for leaks.
a

Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. Deutz Models:

c b

1 Open the engine side turntable cover and locate the fuel filter/water separator. 2 Remove the safety pin (if equipped) from the engine pivot plate latch.

Fuel a b c d

filter/water separator vent plug drain plug filter bowl separator head

The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 4 Loosen the drain plug located at the bottom of the filter. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug.

4 Loosen the drain plug located at the bottom of the bowl. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug. 5 Tighten the vent plug. If the fuel filter/water separator is completely drained, you must prime the fuel filter/water separator before starting the engine. Refer to B-27 in this section, Replace The Fuel Filter Element - Perkins Diesel Models, for instructions on how to prime the fuel filter/water separator. 6 Clean up any fuel that may have spilled.

a b

a b

fuel filter/water separator drain plug

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A PROCEDURES

4 Clean up any fuel that may have spilled. If the fuel filter is completely drained, you must prime the fuel filter/water separator before starting the engine. Refer to D-8 in this section, Replace The Diesel Fuel Filter/Water Separator Deutz Diesel Models, for instructions on how to prime the fuel filter/water separator. 5 Start the engine from the ground controls and check the fuel filter/water separator for leaks. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. 6 Swing the engine back to its original position and close the engine pivot plate latch. 7 Install the engine pivot plate safety pin (if equipped).

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

Perkins specifications require that this procedure be performed every 100 hours. Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life. The machine will not operate properly if the rpm is incorrect and continued use may cause component damage. This procedure will require two people. 1 Connect a tachometer to the engine. Start the engine from the ground controls. Result: Low idle should be 1600 rpm.

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TABLE A PROCEDURES

Skip to step 3 if the low idle rpm is correct. 2 Loosen the low idle lock nut and turn the low idle adjustment screw clockwise to increase the rpm, or counterclockwise to decrease the rpm. Tighten the low idle lock nut and confirm the rpm.

4 Loosen the yoke lock nut, then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. Be sure the solenoid fully retracts when activating high idle.
Perkins Diesel models Low idle High idle 1600 rpm 2500 rpm

b a b c d

solenoid boot high idle adjustment nut yoke low idle lock nut and adjustment screw

3 Move the function enable toggle switch to the high idle (rabbit symbol) position. Result: High idle should be 2500 rpm. If high idle rpm is correct, disregard adjustment step 4.

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A-23 Check the Engine Belt Ford Models

3 Inspect the engine belt for: Cracking Glazing Separation Breaks 4 Replace belt if any damage is found.

Engine specifications require that this procedure be performed every 200 hours. Maintaining the engine belt is essential to good engine performance and service life. The machine will not operate properly with a loose or defective belt and continued use may cause component damage. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine.

Ford LRG-425 EFI engines are equipped with a serpentine belt and incorporate a self adjusting belt tensioner. No adjustment is required. 5 Swing the engine back to its original position and close the engine pivot plate latch. 6 Install the engine pivot plate safety pin (if equipped).
Engine belt - Genie part number Ford Models

52580

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Table B Procedures
B-1 Check the Battery B-2 Inspect the Electrical Wiring

Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. 1 Put on protective clothing and eye wear. 2 Be sure that the battery cable connections are free of corrosion. 3 Be sure that the battery hold downs and cable connections are tight. The battery is a maintenance free battery and does not require the replenishing of electrolyte. Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables.

Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Open the engine side turntable cover. 2 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 4 Inspect the following areas for burnt, chafed, corroded and loose wires: Engine wiring harness Hydraulic manifold wiring

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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 and raise the boom above the turntable covers. 8 Inspect the turntable area for burnt, chafed and pinched cables. 9 Lower the boom to the stowed position and turn the 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 11 Swing the engine back to its original position and close the engine pivot plate latch. 12 Install the engine pivot plate safety pin (if equipped).

B-3 Check the Radiator Ford Models


Maintaining the radiator in good condition is essential for good engine performance. Operating a machine with a damaged or leaking radiator may result in engine damage. Also, restricting air flow through the radiator (i.e., dirt or debris) will affect the performance of the cooling system. A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Burn hazard. Beware of hot engine parts and coolant. Contact with hot engine parts and/or coolant may result in severe burns. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

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TABLE B PROCEDURES

2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Inspect the radiator for leaks and physical damage. 4 Clean the radiator fins of debris and foreign materials. 5 Inspect all radiator hoses and connections. 6 Swing the engine back to its original position and close the engine pivot plate latch. 7 Install the engine pivot plate safety pin (if equipped). 8 Replace the air baffle and install the air baffle retaining fasteners.

B-4 Check the Exhaust System


Maintaining the exhaust system is essential to good engine performance and service life. Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 1 Ford models: Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine to access the exhaust system. 3 All models: Be sure that all nuts and bolts are tight. 4 Inspect all welds for cracks. 5 Inspect for exhaust leaks; i.e., carbon buildup around seams and joints. 6 Ford models: Swing the engine back to its original position and close the engine pivot plate latch. 7 Install the engine pivot plate safety pin (if equipped).

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TABLE

B PROCEDURES

B-5 Check the Hydraulic Return Filter Condition Indicator


Maintaining the hydraulic return filter in good condition is essential to good system performance and safe machine operation. The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter. If the filter is not frequently checked and replaced, impurities will remain in the hydraulic system and cause component damage. 1 Open the engine side turntable cover. 2 Start the engine from the platform controls. 3 Move the engine RPM toggle switch to the maintained high idle position (rabbit symbol). 4 Inspect the filter condition indicator gauge. Result: The needle on the gauge should be operating in the green area. If the needle is in the red area, this indicates that the hydraulic filter is being bypassed and the filter should be replaced. The hydraulic filter condition indicator gauge is mounted to the hydraulic return filter on the engine side bulkhead.

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

Maintaining the oil cooler in good condition is essential for good engine performance. Operating a machine with a damaged oil cooler may result in engine damage. Also, restricting air flow through the oil cooler will affect the performance of the cooling system. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. Oil Cooler 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Remove the fasteners from the engine side cover, then remove the cover.

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4 Inspect the oil cooler for leaks and physical damage.


a b c

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

Maintaining the tires and wheels in good condition is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion.
a b c oil cooler cylinder head cooling fins fan blower fins

Bodily injury hazard. An overinflated tire can explode and could cause death or serious injury. Tip-over hazard. Do not use temporary 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 and cracked welds. 3 Check each lug nut for proper torque. 4 Check the pressure in each air-filled tire.
Tire specifications Tire size Inflation pressure Tire ply rating (minimum) Wheel lugs, 4WD Wheel lugs, 2WD Front Rear Lug nut torque, dry Lug nut torque, lubricated Industrial 9-14.5 LT Foam Filled 12 8 @ 5/8 -18 8 @ 5/8 -18 9 @ 5/8 -18 125 ft-lbs 169.5 Nm 94 ft-lbs 127.4 Nm Rough terrain 14-17.5 NHS 45 psi (3.1 bar) 14 9 @ 5/8 -18 8 @ 5/8 -18 9 @ 5/8 -18 125 ft-lbs 169.5 Nm 94 ft-lbs 127.4 Nm

5 Clean the oil cooler of debris and foreign material. Cooling and Fan Blower Fins 6 Inspect the fan blower fins for physical damage. 7 Clean the fan blower fins of debris and foreign material. 8 Inspect the head cooling passages and fins for physical damage or foreign material, using a flashlight. 9 Clean the cylinder head cooling passages of debris and foreign material. 10 Install the engine side cover. 11 Swing the engine back to its original position and close the engine pivot plate latch. 12 Install the engine pivot plate safety pin (if equipped).

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B-8 Confirm the Proper Brake Configuration

B-9 Check the Oil Level in the Drive Hubs

Proper brake configuration is essential to safe operation and good machine performance. Hydrostatic brakes and hydraulically-released, spring-applied individual wheel brakes can appear to operate normally when they are actually not fully operational. 1 Check each drive hub disconnect cap to be sure it is in the engaged position.
brake disengage position

Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage. Drive Hubs 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees.

brake engage position

2 Be sure the free-wheel valve on the drive pump is closed (clockwise). The free-wheel valve is located on the side of the drive pump. 2 Remove the plug located at 90 degrees and check the oil level. Result: The oil level should be even with the bottom of the plug hole.
d a c b

a b c d

drive pump free-wheel valve lift pump screwdriver

The free-wheel valve should always remain closed.

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3 If necessary, remove the top plug and add oil until the oil level is even with the bottom of the side plug hole. 4 Apply pipe thread sealant to the plug, and then install it in the drive hub. 5 Repeat this procedure for each drive hub.
Drive hub oil Capacity 17 fl oz 0.5 liters

B-10 Check and Adjust the Engine RPM - Ford and Deutz Models

Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5

Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life. The machine will not operate properly if the rpm is incorrect and continued use may cause component damage. Ford Models: The engine rpm is controlled by the ECM and can only be adjusted by re-programming the ECM. If rpm adjustment or service is required, please contact Genie Industries Service Department OR your local Ford dealer.
Ford Models Low idle High idle 1600 rpm 2500 rpm

Deutz Diesel Models: This procedure will require two people. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

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2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Connect an rpm gauge to the engine, and then start 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 low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm. Tighten the low idle lock nut and recheck the rpm.

If high idle rpm is correct, disregard adjustment step 6. 6 Loosen the yoke lock nut, then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. Be sure the solenoid fully retracts when activating high idle.
Deutz Diesel Models Low idle High idle 1400 rpm 2500 rpm

f e

a a b c d e f

solenoid boot high idle adjustment nut yoke lock nut yoke low idle adjustment screw low idle lock nut

5 Move the function enable toggle switch to the high idle (rabbit symbol) position at the ground controls. Result: High idle should be 2500 rpm.

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B-11 Test the Key Switch


Proper key switch action and response is essential to safe machine operation. The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch. Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation. 1 Pull out the Emergency Stop button to the ON position at both the ground and platform controls. 2 Turn the key switch to ground control, start the engine and then turn the key switch to platform control. 3 Check any machine function from the ground controls. Result: The machine functions should not operate. 4 Turn the key switch to ground control. 5 Check any machine function from the platform controls. Result: The machine functions should not operate. 6 Turn the key switch to the OFF position. Result: The engine should stop and no functions should operate. Deutz and Perkins Diesel models: All functions should stop immediately. The engine will shut off after 2 to 3 seconds.

B-12 Test the Emergency Stop Buttons


Properly functioning Emergency Stop buttons are essential for safe machine operation. An improperly operating Emergency Stop button will fail to shut off power and stop all machine functions, resulting in a hazardous situation for ground and platform personnel. As a safety feature, selecting and operating the ground controls will override the platform controls, including the platform Emergency Stop button. 1 Start the engine from the ground controls. 2 Push down the Emergency Stop button to the OFF position. Result: The engine should shut off and no machine functions should operate. Deutz and Perkins Diesel models: All functions should stop immediately. The engine will shut off after 2 to 3 seconds. 3 Start the engine from the platform controls. 4 Push down the Emergency Stop button to the OFF position. Result: The engine should shut off and no machine functions should operate. The ground Emergency Stop button will stop all machine operation, even if the key switch is switched to platform control.

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B-13 Test the Ground Control Override


A properly functioning ground control override is essential to safe machine operation. The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the ON or OFF position. This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position. 1 Push in the platform Emergency Stop button to the OFF position. 2 Start the engine from the ground controls. 3 At the ground controls, operate each boom function through a partial cycle. Result: All boom functions should operate.

B-14 Check the Directional Valve Linkage

Perform this test only on models equipped with a oscillating axle. Proper axle oscillation is essential to safe machine operation. If the directional valve linkage is not operating correctly, the stability of the machine is compromised and it may tip over. 1 Remove the drive chassis cover and the axle covers from the non-steer end of the drive chassis.

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2 Locate the directional valve inside of the nonsteer axle and inspect the linkage for the following: Lock nut is tight against yoke Yoke clevis pins are installed Cotter pins are installed through clevis pins Linkage is properly attached to directional valve

B-15 Test the Platform Self-leveling

Automatic platform self-leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation. The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom. A platform self-leveling failure creates an unsafe working condition for platform and ground personnel. 1 Start the engine from the ground controls and lower the boom into the stowed position.

b c d

2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch. 3 Raise and lower the primary boom through a full cycle.
a b c d directional valve clevis pin with cotter pin (hidden) yoke lock nut

Result: The platform should remain level at all times to within 5 degrees.

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B-16 Test the Horn


A functional horn is essential to safe machine operation. The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel. An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 2 Push down the horn button at the platform controls. Result: The horn should sound. If necessary, the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn.

B-17 Test the Foot Switch


A properly functioning foot switch is essential to safe machine operation. Machine functions should activate and operate smoothly as long as the foot switch is pressed down, and promptly stop when the foot switch is released. The foot switch will also shift the engine into high idle if the idle select is switched to the rabbit and foot switch symbol. An improperly functioning foot switch can cause an unsafe working condition and endanger platform and ground personnel. The engine should not start if the foot switch is pressed down. 1 Turn the key switch to platform controls and pull out the Emergency Stop button to the ON position at both the ground and platform controls. 2 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side. Result: The engine should not start. 3 Do not press down the foot switch and attempt to start the engine. Result: The engine should start. 4 Do not press down the foot switch. Check the machine functions. Result: The machine functions should not operate. 5 Press down the foot switch and operate the machine functions. Result: The machine functions should operate.

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B-18 Test the Engine Idle Select


A properly operating engine idle select switch is essential to good engine performance and safe machine operation. There are three settings. Low idle (turtle symbol) allows the operator to control individual boom functions only. Drive functions do not operate at low idle. High idle (rabbit symbol) allows the operator to control multiple boom and/or drive functions simultaneously. This setting maintains a consistent high idle and is usually selected only when the generator option is being used. Foot switch activated high idle (rabbit and foot switch symbols) should be used for normal machine operation. This selection activates high idle only when the foot switch is pressed down. 1 Pull out the Emergency Stop button to the ON position at both the ground and platform controls. 2 Start the engine from the ground controls then move the function enable toggle switch to the high idle (rabbit symbol) position and hold in the ON 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 idle control switch to high idle (rabbit symbol). Do not press down the footswitch. Result: The engine should change to high idle. 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 foot switch activated high idle (rabbit and foot switch symbol). Result: The engine should not change to high idle. 8 Press down the foot switch. Result: The engine should change to high idle.

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B-19 Test the Fuel Select Operation Ford Models


The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation. A fuel selection can be made when the engine is running or not. Switching malfunctions and/or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation. Perform this test after checking the gasoline and LPG fuel levels, and warming the engine to normal operating temperature. 1 Move the fuel select switch to gasoline and then move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). 2 Start the engine from the platform controls and allow it to run at low idle.

3 Press down the foot switch to allow the engine to run at high idle. Result: The engine should start promptly and operate smoothly in low and high idle. 4 Release the foot switch and shut the engine off by pushing the Emergency Stop button in to the OFF position. 5 Move the fuel select switch to LPG. 6 Restart the engine and allow it to run at low idle. 7 Press down the foot switch to allow the engine to run at high idle. Result: The engine should start promptly and operate smoothly in low and high idle. The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running.

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B-20 Test the Drive Enable System


Proper drive enable system operation is essential to safe machine operation. When the boom is past the non-steering wheels, drive movement is stopped and the indicator light turns on. The drive enable switch must be to either side to reactivate the drive function and should inform the operator that the machine will move in the opposite direction that the drive and steer controls are moved. An improperly functioning drive enable system may allow the machine to be moved into an unsafe position. 1 Start the engine from the platform controls. 2 Rotate the turntable to the right until the boom is past the right non-steering wheel. Result: The drive enable indicator light should turn 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 either side and slowly move the drive control handle off center.

Collsion hazard. Always use the color-coded direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel. Result: The drive function should operate. 5 Rotate the turntable to the left until the boom is past the left non-steering wheel. Result: The drive enable indicator light should come on. 6 Repeat steps 3 and 4.

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B-21 Test the Drive Brakes

5 Bring the machine to top drive speed before reaching the test line. Release the drive joystick when your reference point on the machine crosses the test line. 6 Measure the distance between the test line and your machine reference point.
Braking: paved surface Stopping distance

Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise. Hydrostatic brakes and hydraulicallyreleased individual wheel brakes can appear to operate normally when they are actually not fully operational. Collision hazard. Be sure that the machine is not in free-wheel or partial free-wheel configuration. Refer to B-8 in this section, Confirm the Proper Brake Configuration. Select a test area that is firm, level and free of obstructions. 1 Mark a test line on the ground for reference. 2 Start the engine from the platform controls. 3 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch), then lower the boom into the stowed position. 4 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the test line.

4WD 3 to 6 ft 0.9 to 1.8 m

The brakes must be able to hold the machine on any slope it is able to climb.

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B-22 Test the Drive Speed Stowed Position

5 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 6 Continue at full speed and note the time when the machine reference point crosses the finish line.

Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Select a test area that is firm, level and free of obstructions. 1 Create start and finish lines by marking two lines on the ground 40 feet (12.2 m) apart. 2 Start the engine from the platform controls. 3 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch), then lower the boom into the stowed position. 4 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines.

Drive speed, maximum stowed position All models 40 ft / 5.7 sec 12.2 m / 5.7 sec

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B-23 Test the Drive Speed Raised or Extended Position

8 Continue at full speed and note the time when the machine reference point crosses the finish line. 9 Move the lift/drive select switch to the lift position (if equipped). 10 Press down the foot switch and lower the boom to the stowed position. 11 Extend the boom 1 foot (30 cm). 12 Move the lift/drive select switch to the drive position (if equipped). 13 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 14 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 15 Continue at top speed and note the time when the machine reference point crosses the finish line.
Drive speed, boom raised or extended, Standard Base Models 0.6 mph 1 km/h 40 ft/45 sec 12.2 m/45 sec 0.36 mph 0.58 km/h 40 ft/79 sec 12.2 m/79 sec

Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Select a test area that is firm, level and free of obstructions. 1 Create start and finish lines by marking two lines on the ground 40 feet (12.2 m) apart. 2 Start the engine from the platform controls. 3 Move the lift/drive select switch to the lift position (if equipped). 4 Move the engine idle select switch to foot switch activated high idle (rabbit and foot switch). Press down the foot switch and raise the boom above horizontal. 5 Move the lift/drive select switch to the drive position (if equipped). 6 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 7 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line.

Drive speed, boom raised or extended, Narrow Base Models

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B-24 Test the Alarm Package Optional Equipment


The alarm package includes: Travel alarm Descent alarm Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion. The alarm package is installed on the turntable covers. The alarms and beacon will operate with the engine running or not running. 1 Turn the key switch to ground control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. Result: The flashing beacon should be ON and flashing. 2 Move the function enable switch to either side and activate the primary boom toggle switch in the DOWN position, hold for a moment and then release it. Result: The descent alarm should sound when the switch is held down.

3 Move the function enable switch to either side and activate the secondary boom toggle switch in the DOWN position, hold for a moment and then release it. Result: The descent alarm should sound when the 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 primary boom control handle to the DOWN position, hold for a moment and then release it. Result: The descent alarm should sound when the control handle is held down. 6 Press down the foot switch. Move the secondary boom control handle to the DOWN position, hold for a moment and then release it. Result: The descent alarm should sound when the control handle is held down. 7 Press down the foot switch. Move the drive control handle off center, hold for a moment and then release it. Move the drive control handle off center in the opposite direction, hold for a moment and then release it. Result: The travel alarm should sound when the drive control handle is moved off center in either direction.

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B-25 Perform Hydraulic Oil Analysis

B-26 Replace the Hydraulic Tank Return Filter

See E-1, Test or Replace the Hydraulic Oil. Genie requires that this procedure be performed quarterly or every 250 hours, whichever comes first. Perform this procedure more often if dusty conditions exist. Replacement of the hydraulic tank filter is essential for good machine performance and service life. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Burn hazard. Beware of hot oil. Contact with hot oil may result in severe burns. Perform this procedure with the engine off. 1 Open the engine side turntable cover and locate the 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 filter gasket. 4 Install the new filter (Genie part number 65540) and tighten it securely by hand. Clean up any oil that may have spilled during the installation procedure. 5 Start the engine from the ground controls. 6 Inspect the filter and related components to be sure that there are no leaks.

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

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

a
f

Replacing the diesel fuel filter/water separator element is essential for good engine performance and service life. A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off. 1 Open the engine side turntable cover and locate the fuel filter/water separator next to the hydraulic return filter on the bulkhead. 2 Disconnect and plug the fuel supply hose from the fuel tank to the fuel filter/water separator.

d c

Fuel a b c d e f

filter/water separator vent plug main fuel line drain plug filter bowl filter element separator head

4 Place a suitable container under the filter bowl. Loosen the drain plug located at the bottom of the bowl. Completely drain the fuel. 5 Rotate the filter bowl counterclockwise and remove it from the element. 6 Rotate the filter element counterclockwise and remove 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 filter head. Tighten the drain plug. 10 Tighten the vent plug.

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11 Clean up any diesel fuel that may have spilled during the installation procedure. 12 Install the fuel supply hose from the fuel tank to the fuel filter/water separator. Tighten the clamp. Bleed the system: 13 Loosen the vent plug on top of the fuel injection pump.

16 Operate the starter motor for intervals of 15 seconds until the engine starts. It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation. If the engine runs correctly for a short time and then stops or runs roughly, check for air in the fuel system. If there is air in the fuel system, there is probably a leak in the low pressure side of the system.

a c b

a b c

vent plug fuel injection pump fuel lift pump

14 Operate the priming lever or priming bulb (if equipped) of the fuel lift pump until fuel, free from air, comes from the vent plug. 15 Clean up any fuel that may have spilled during this procedure.

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B-28 Replace the Fuel Filter Element Perkins Diesel Models

2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Thoroughly clean the outside surfaces of the fuel filter assembly. 4 Place a suitable container under the fuel filter element. 5 Disconnect and plug the fuel line from the fuel pump to the fuel filter element. 6 Remove the fuel filter element with a filter wrench. 7 Apply a thin layer of fuel to the new fuel filter element o-ring. 8 Install the new fuel filter element (Genie part number 65542) and tighten it securely by hand. Clean up any fuel that may have spilled during the installation procedure.

Replacing the diesel fuel filter element is essential for good engine performance and service life. A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. Extremely dirty conditions may required that the filter be replaced more often. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off. 1 Remove the safety pin from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

a b c

a b c

fuel line filter head fuel filter element

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Bleed the system: 9 Loosen the vent plug on top of the fuel injection pump.

B-29 Replace the Spark Plugs Ford Models

a c b

Engine specifications requires that this procedure be performed every 400 hours. Periodic replacement of the spark plugs is essential to good engine performance and service life. Worn, loose or corroded spark plugs will cause the engine to perform poorly and may result in component damage.

a b c

vent plug fuel injection pump fuel lift pump

Perform this procedure with the engine off. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Label, then disconnect the plug wires from the spark plugs by grasping the handle on the spark plug boot. Do not pull on the plug wire.

10 Operate the priming lever or priming bulb (if equipped) of the fuel lift pump until fuel, free from air, comes from the vent plug. 11 Clean up any fuel that may have spilled during this procedure. 12 Operate the starter motor for intervals of 15 seconds until the engine starts. It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation. If the engine runs correctly for a short time and then stops or runs roughly, check for air in the fuel system. If there is air in the fuel system, there is probably a leak in the low pressure side of the system.

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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 to specifications. 8 Connect the wires. Be sure that each spark plug wire is attached to the correct spark plug. 9 Swing the engine back to its original position and close the engine pivot plate latch. 10 Install the engine pivot plate safety pin (if equipped).
Spark plug specifications Spark plug type Spark plug gap Motorcraft AWSF-52C 0.042 to 0.046 inch 1.07 to 1.18 mm

B-30 Replace the Engine Air Filter Element

Engine specifications requires that this procedure be performed every 400 hours or annually, whichever comes first. Perform this procedure more often if dusty conditions exist. Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage. Perform this procedure with the engine off. All Models:

Spark plug torque

5 to 10 ft-lbs 7 to 14 Nm

1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Open the engine side cover and remove the retaining ring from the end cap of the air filter canister.

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B PROCEDURES

4 Remove the end cap from the air cleaner canister. 5 Remove the air filter retaining fastener. Remove the filter element. 6 Clean the inside of the canister and the gasket with a damp cloth. 7 Install the new air filter element and install the mounting fastener. 8 Install the end cap onto the canister. Install and tighten the retaining ring. 9 Swing the engine back to its original position and close the engine pivot plate latch. 10 Install the engine pivot plate safety pin (if equipped).
Air filters - Genie part numbers All Models

27916

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Table C Procedures
C-1 Check the Engine Belt Deutz Diesel Models
4 Remove the front engine access cover mounting fasteners. 5 Inspect the engine belt for: Cracking Glazing Separation Engine specifications require that this procedure be performed every 500 hours. Maintaining the engine belt is essential to good engine performance and service life. The machine will not operate properly with a loose or defective belt and continued use may cause component damage. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 1 Remove the safety pin (if equipped) from the engine pivot plate latch . The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Remove the air baffle retaining fasteners. Remove the air baffle. Breaks 6 Replace belt if any damage is found. 7 Check the engine belt for proper tension. Adjust as necessary.

Deutz Diesel engine

8 Install the front engine access cover. 9 Replace the air baffle and install the air baffle retaining fasteners. 10 Swing the engine back to its original position and close the engine pivot plate latch. 11 Install the engine pivot plate safety pin (if equipped).
Belt deflection 3 /8

inch to 1/2 inch 9.5 mm to 12 mm 32698

Engine belt - Genie part number

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C PROCEDURES

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

2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Remove the oil filler cap located above the dipstick. 4 Pull the end of the oil drain hose out from under the engine. 5 Remove the plug from the drain hose and allow all of the oil from the engine to drain into a suitable 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.

Engine specifications require that this procedure be performed every 500 hours. Perform this procedure more often if dusty conditions exist or if the machine is operated in hot climates. Periodic replacement of the engine oil and filter is essential to good engine performance. Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components. A frequent check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 500 hour interval. Burn hazard. Beware of hot engine parts and oil. Contact with hot engine oil and/or engine parts may result in severe burns. Perform this procedure after warming the engine to normal operating temperature. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

c b

a b c

engine oil level dipstick fuel filter/water separator oil filter

9 Apply a thin layer of oil to the new oil filter gasket (Genie part number 49924). Install the filter and tighten it securely by hand. 10 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter.

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TABLE C PROCEDURES

11 Fill the engine with new oil per specifications and install the oil filler cap. 12 Start the engine from the ground controls. Allow the engine to run for 30 seconds then turn the engine off. 13 Check the oil filter and oil drain hose for leaks. 14 Check the engine oil level dipstick. Add oil if needed.
Deutz Engine F3L 1011F Oil capacity (including filter) Oil viscosity requirements Temperature below 60F / 15.5C (synthetic) -10F to 90F / -23C to 32C Temperature above -4F / -34C 5W-30 10W-40 15W-40 6.3 quarts 6 liters

C-3 Check the Engine Valve Clearances Deutz Diesel Models

Engine specifications require that this procedure be performed initially at 500 hours, at 1000 hours and every 1000 hours thereafter. Complete information to perform this procedure is available in the Deutz F3L 1011F Operation Manual, Deutz part number 0297 7343 (Genie part number 52883).

Engine oil should have properties of API classification CC/SE, CD/SE, CC/SF or CD/SF grades. Units shipped with 10-40 CC/SG Oil filter - Genie part number 49924

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C PROCEDURES

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

2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Put on protective clothing and eye wear. 4 Disconnect the coolant return hose at the radiator and drain the coolant return tank into a suitable container. 5 Slowly remove the radiator cap from the radiator. Bodily injury hazard. Allow any pressure to dissipate gradually before removing the radiator cap. 6 Open the drain valve on the radiator and allow all the coolant to drain into a suitable container. 7 After all the coolant has drained, close the drain valve and connect the coolant return hose to the radiator. 8 Open the drain valve on the engine block and allow the coolant to drain into a suitable container. After the fluid is drained, close the drain 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 is full. 11 Fill the coolant return tank to the NORMAL range.

Engine specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Replacing or reconditioning the engine coolant is essential to good engine performance and service life. Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage. Extremely dirty conditions may require coolant to be changed more frequently. Burn hazard. Beware of hot engine parts and coolant. Contact with hot engine parts and/or coolant may result in severe burns. Perform this procedure with the engine off and cooled. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

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TABLE C PROCEDURES

12 Clean up any coolant that may have spilled during this procedure. 13 Start the engine from the ground controls and let it run for 30 seconds. Turn the engine off and inspect for leaks. 14 Check the coolant level in the coolant return tank. Add coolant if needed. 15 Swing the engine back to its original position and close the engine pivot plate latch. 16 Install the engine pivot plate safety pin (if equipped). 17 Start the engine from the ground controls and let it run until it reaches normal operating temperature. 18 Turn the engine off. Allow the engine to cool. 19 Check the coolant level in the coolant return tank. Add coolant if needed.
Coolant capacity Ford Gasoline/LPG Engine Perkins 104-22 Engine

C-5 Check the Engine Valve Clearances Perkins Diesel Models

Engine specifications require that this procedure be performed every 600 hours. Complete information to perform this procedure is available in the Perkins Workshop Manual, Perkins part number TPD 1378 (Genie part number 72352).

11.5 quarts 6.3 quarts

10.9 liters 6 liters

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C PROCEDURES

C-6 Replace the PCV Valve Ford Models

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

Engine specifications require that this procedure be performed every 800 hours. Replacement of the PCV valve is essential to good engine performance. A malfunctioning PCV valve can impair crankcase ventilation and may cause engine damage. Perform this procedure with the engine off. 1 Open the engine side turntable cover. 2 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine.

a b

a b

PCV valve PCV valve hose

5 Remove the PCV valve from the engine. Discard the valve. 6 Thoroughly clean the inside and outside of the hose, tubes and fittings. 7 Install the new PCV valve and connect the hose. 8 Swing the engine back to its original position and close the engine pivot plate latch. 9 Install the engine pivot plate safety pin (if equipped).
PCV Valve - Genie part number 33957

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Table D Procedures
D-1 Check the Boom Wear Pads
4 Extend and retract the primary boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom. Always maintain squareness between the outer and inner boom tubes. Maintaining the boom wear pads in good condition is essential to safe machine operation. Wear pads are placed on boom tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions. If the wear pads are not worn below specification but are still within tolerence, see Repair Procedure 4-2, How to Shim the Primary Boom. 1 Start the engine from the ground controls. 2 Raise the end of the primary boom to a comfortable working height (chest high), then extend the boom 1 foot (30 cm). 3 Measure each wear pad. Replace the wear pad if it is less than 9/16 inch. If the wear pad is not less than 9/16 inch, shim as necessary to obtain zero clearance and zero drag.
Wear pad specifications All wear pads
9/16 inch 14.3 mm

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D PROCEDURES

D-2 Check the Turntable Rotation Bearing Bolts

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

Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation. Improper bolt torque could result in an unsafe operating condition and component damage. 1 Raise the secondary boom and place safety chocks on the lift cylinders rods. Carefully lower the boom onto the lift cylinders safety chocks. Crushing hazard. Keep hands away from cylinders and all moving parts when lowering the boom. The lift cylinder safety chock is available through (Genie part number 33484). 2 Turn the engine off. 3 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 4 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine.

Bolt torque sequence

6 Start the engine form the ground controls. 7 Rais the secondary boom and remove the safety chocks. 8 Lower the boom to the stowed position. 9 Remove drive chassis covers from both the steer end and the non-steer end of the machine. 10 Remove the lower chassis cover mounting fasteners from inside of the drive chassis.

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TABLE D PROCEDURES

11 Remove the lower chassis cover to access the lower turntable bearing bolts under the drive chassis. 12 Check to ensure that each lower bearing mounting bolt under the drive chassis is torqued in sequence to 210 ft-lbs (285 Nm).

D-3 Check the Free-wheel Configuration

Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing. A machine configured to free-wheel without operator knowledge may cause death or serious injury and property damage. Collision hazard. Select a work site that is firm and level. Component damage hazard. If the machine must be towed, do not exceed 2 mph (3.2 km/h).
Bolt torque sequence

Non-Steer Wheels: All Models 1 Chock the steer wheels to prevent the machine from rolling. 2 Center a lifting jack of ample capacity (20,000 lbs/10,000 kg) under the drive chassis between the non-steer tires. 3 Lift the wheels off the ground and then place jack stands under the drive chassis for support.

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D PROCEDURES

4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer wheel hub.
disengage position

Steer Wheels: 4WD Models 7 Chock the non-steer wheels to prevent the machine from rolling. 8 Center a lifting jack of ample capacity (20,000 lbs/10,000 kg) under the drive chassis between the steer tires.

engage position

9 Lift the wheels off the ground and then place jack stands under the drive chassis for support. 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub.
disengage position

5 Manually rotate each non-steering wheel. Result: Each non-steering wheel should rotate with minimum effort. 6 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the jack stands. Collision hazard. Failure to re-engage the drive hubs may cause death or serious injury and property damage.

engage position

11 Manually rotate each steer wheel. Result: Each steer wheel should rotate with minimum effort.

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TABLE D PROCEDURES

12 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel to check for engagement. Raise the machine and remove the jack stands. Collision hazard. Failure to re-engage the drive hubs may cause death or serious injury and property damage. All Models: 13 Be sure the free-wheel valve on the drive pump is closed (clockwise). The free-wheel valve is located on the side of the drive pump.

D-4 Grease the Turntable Rotation Bearing and Rotate Gear

Yearly application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life. Continued use of an improperly greased bearing and gear will result in component damage. 1 Locate the grease fitting on the front turntable cover.

d c a b

a b c d

drive pump free-wheel valve lift pump screwdriver

The free-wheel valve should always remain closed.

a b c

turntable bearing grease fitting front turntable cover power to platform plug

2 Pump grease into the turntable rotation bearing. Rotate the turntable in increments of 4 to 5 inches (10 to 13 cm) at a time and repeat this step 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

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D PROCEDURES

D-5 Replace the Drive Hub Oil

4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole. Apply pipe thread sealant to the plugs, and then install the plugs. 5 Repeat steps 1 through 4 for all the other drive hubs.
Oil capacity per hub 17 fl oz 0.5 liters

Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage. Drive Hubs: 1 Select the drive hub to be serviced. Then drive the machine until one of the two plugs is at the lowest point. 2 Remove both plugs and drain the oil. 3 Drive the machine until one plug is at the top and the other is at 90 degrees.

Type: SAE 90 multipurpose hypoid gear oil - API service classification GL5

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TABLE D PROCEDURES

D-6 Replace the Drive Loop Hydraulic Filter

3 Remove the filter element from the housing. 4 Inspect the housing seal and replace it if necessary. 5 Install the new filter (Genie part number 20880) and tighten the housing onto the filter securly head by hand. Clean up any oil that may have spilled during the installation procedure. 6 Start the engine from the ground controls. 7 Inspect the filter assembly to be sure that there are no leaks. 8 Clean up any oil that may have spilled during the installation procedure.

Replacing the drive loop hydraulic filter is essential to good machine performance and service life. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. Perform this procedure with the engine off. 1 Open the engine side turntable cover and locate the drive loop hydraulic filter mounted near the pump. 2 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing.

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D PROCEDURES

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

4 Load the system by activating the primary boom retract function, then move the function enable toggle switch to the high idle (rabbit symbol) position. 5 Adjust the high idle adjustment screw to obtain an air-to-fuel mixture ratio of 13.0:1 to 13.2:1, using an exhaust gas analyzer.

Maintaining the proper air-to-fuel mixture during LPG operation is essential to good engine performance. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. The engine should be warmed to normal operating temperature before performing this procedure. 1 Move the fuel select toggle switch to LPG fuel and start the engine from the ground controls. 2 Locate the high idle mixture adjustment screw on the throttle body elbow that attaches to the air cleaner. 3 Loosen the lock nut on the high idle mixture adjustment screw.

Preliminary setting is 1/4 inch (6.4mm) of threads showing. Measure from top of lock nut to top of adjustment screw. If an exhaust gas analyzer is not available, adjust to obtain peak or optimum rpm. 6 Hold the adjustment screw and tighten the lock nut. 7 Return the function enable toggle switch to the center position. 8 Locate the low idle mixture adjustment screw on the LPG regulator. 9 Adjust the low idle mixture adjustment screw to obtain an air-to-fuel mixture ratio of 13.0:1 to 13.2:1. Preliminary setting: turn low idle adjustment screw clockwise all the way in. Turn low idle adjustment screw counterclockwise 2 3/4 turns.

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TABLE D PROCEDURES

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

2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 At the fuel pump, disconnect and plug the fuel hose that goes to the fuel tank. 4 Remove the fuel filter with a filter wrench.

Replacing the diesel fuel filter/water separator is essential to good engine performance and service life. A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Explosion and fire hazard. Engine fuels are combustible. Replace the fuel filter in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Perform this procedure with the engine off. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

a b

a b

oil filter 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 oil or diesel fuel to the new fuel filter gasket. 6 Install the new filter and tighten it securely by hand. Clean up any diesel fuel that might have spilled during the procedure. 7 Connect the fuel hose from the tank to the fuel pump. 8 Start the engine from the ground controls, then inspect the fuel filter for leaks. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately.

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Table E Procedures
E-1 Test or Replace the Hydraulic Oil
3 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Close the valves.

Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. The machine uses Dexron equivalent hydraulic oil. Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. Perform this procedure with the boom in the stowed position. 1 Ford models: Turn the valve on the LPG tank clockwise to the OFF position. Then slowly disconnect the hose from the LPG tank. 2 Ford models: Open the clamps from the LPG tank straps and remove the LPG tank from the machine.

open

closed

Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 4 Place a suitable container underneath the hydraulic tank. 5 Remove the drain plug from the hydraulic tank. 6 Completely drain the tank into a suitable container. See capacity specifications. 7 Tag, disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves. 8 Disconnect and plug the return filter hydraulic hose at the hydraulic tank. Cap the fitting on the tank.

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TABLE E PROCEDURES

9 Disconnect and plug the supply hose for the auxiliary power unit through the access hole underneath the turntable. Cap the fitting on the hydraulic tank. 10 Remove the ground controls side turntable cover. See Repair Procedure 6-1, How to Remove a Turntable Cover. 11 Support the hydraulic tank with an appropriate lifting device. 12 Remove the hydraulic tank mounting fasteners. 13 Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank may become unbalanced and fall if it is not properly supported by the lifting device. 14 Remove the suction strainers from the tank and clean them using a mild solvent. 15 Rinse out the inside of the tank using a mild solvent. 16 Install the suction strainers using a thread sealant on the threads. 17 Install the drain plug using a thread sealant on the threads.

18 Install the hydraulic tank onto the machine. 19 Install the two suction hoses to the suction strainers. 20 Install the supply hose for the auxiliary power unit and the return filter hose. 21 Fill the tank with hydraulic oil until the level is within the top 2 inches (5 cm) of the sight gauge. Do not overfill. 22 Clean up any oil that may have spilled and open the hydraulic tank valves.

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E PROCEDURES

23 Prime the pump. See Repair Procedure 11-2, How to Prime the Pump. Component damage hazard. Be sure that the hydraulic tank shutoff valves are in the OPEN position before priming the pump. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Always use pipe thread sealant when installing the suction hose fittings and the drain plug. Use only Dexron equivalent hydraulic fluid.
Hydraulic system Hydraulic tank capacity 24 gallons 91 liters 30 gallons 114 liters Dexron equivalent

E-2 Change or Recondition the Engine Coolant Ford Models

Replacing or reconditioning the engine coolant is essential to good engine performance and service life. Old or dirty coolant may cause the engine to perform poorly and continued use may cause engine damage. Extremely dirty conditions may require coolant to be changed more frequently. Burn hazard. Beware of hot engine parts and coolant. Contact with hot engine parts and/or coolant may result in severe burns. Perform this procedure with the engine off and cooled. 1 Put on protective clothing and eye wear. 2 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine.

Hydraulic system capacity (including tank) Hydraulic fluid

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TABLE E PROCEDURES

4 Disconnect the coolant return hose at the radiator and drain the coolant return tank into a suitable container. 5 Slowly remove the radiator cap from the radiator. Bodily injury hazard. Allow any pressure to dissipate gradually before removing the radiator cap. 6 Open the drain valve on the radiator and allow all the coolant to drain into a suitable container. 7 After all the coolant has drained, close the drain valve. Connect the coolant return hose to the radiator. 8 Open the drain valve on the engine block and allow 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 and water) for your climate into the radiator until it is full. 11 Fill the radiator and then fill the coolant return tank to the NORMAL range. 12 Clean up any coolant spilled during this procedure.

13 Swing the engine back to its original position and close the engine pivot plate latch. 14 Install the engine pivot plate safety pin (if equipped). 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 fluid level in the coolant return tank. Add water if needed. 17 Start the engine from the ground controls and let it run until it reaches normal operating temperature. 18 Turn the engine off. 19 Allow engine to cool and check the fluid level in the coolant retrun tank. Add water if needed.
Coolant capacity 11.5 quarts 10.9 liters

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E-3 Change the Fuel Hoses

2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Place a suitable container underneath the engine pivot plate.

Maintaining the fuel hoses in good condition is essential to safe operation and good engine performance. Failure to detect a worn, cracked or leaking fuel hose may cause an unsafe operating condition. Explosion and fire hazard. Engine fuels are combustible. Replace the fuel hoses in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Component damage hazard. Be sure the fuel hoses are routed the same way the original hoses were. Perform this procedure with the engine off and the key switch in the OFF position. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

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

a b c d e

hose from fuel pump to regulator/filter hose from fuel pre-filter to fuel pump hose from fuel tank to fuel pre-filter hose from regulator/filter to engine hose from regulator/filter to tank

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TABLE E PROCEDURES

Deutz Diesel Models: At the fuel pump, disconnect the fuel hose to the fuel tank and drain the fuel tank into the container. 5 Remove and replace all of the fuel line hoses and clamps according to the following illustrations: Explosion and fire hazard. Fuel Injection systems operate at a very high pressure. Fuel may be expelled under pressure if the hoses are removed too quickly. Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually. Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them.

Deutz Diesel models a hose from the injector to the fuel tank b hoses connecting injectors c hose from the fuel shutoff valve to the fuel pump d hose from the fuel pump to the fuel filter e hose from the fuel filter to the injection pump f hose from the injection pump to the injectors

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E PROCEDURES

Explosion and fire hazard. Electronic Fuel Injection (EFI) systems operate at a very high pressure. Fuel may be expelled under pressure if the hoses are removed too quickly. Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually. Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them.

6 Clean up any fuel that may have spilled during this procedure. 7 Swing the engine back to its original position and close the engine pivot plate latch. 8 Install the engine pivot plate safety pin (if equipped). 9 Start the engine from the ground controls, then inspect the fuel filter and hoses for leaks. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately.

d Ford models a high pressure hose from fuel pump to regulator/filter b hose from fuel pre-filter to fuel pump c hose from fuel tank to fuel pre-filter d high pressure hose from regulator/ filter to engine e hose from regulator/filter to tank

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TABLE E PROCEDURES

E-4 Check the Toothed Belt Deutz Diesel Models

E-7 Check the Fuel Injection Pump and Injectors - Deutz Diesel Models

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

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

E-5 Check the Engine Valve Clearance - Ford Models

E-8 Replace the Timing Belt Ford Models

Complete information to perform this procedure is available in the Ford LRG-425 EFI 2.5 Liter Industrial Engine Service Manual Ford number: FPP-194-303. (Genie part number 52695).

Complete information to perform this procedure is available in the Ford LRG-425 EFI 2.5 Liter Industrial Engine Service Manual Ford part number: FPP-194-303. (Genie part number 52695).

E-6 Check the Engine Cylinder Compression - Ford Models

Complete information to perform this procedure is available in the Ford LRG-425 EFI 2.5 Liter Industrial Engine Service Manual Ford number: FPP-194-303. (Genie part number 52695).

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E PROCEDURES

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

Skip to step 10 if there is no movement. 6 Remove the dust cap from the hub, then remove the cotter pin from the castle nut. 7 Tighten the castle nut to 35 ft-lbs (47 Nm) to seat the bearings.

Maintaining the steer axle wheel bearings is essential for safe machine operation and service life. Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage. Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often. 1 Loosen the wheel lug nuts. Do not remove them. 2 Block the non-steering wheels, then center a lifting jack under the steer axle. 3 Raise the machine 6 inches (15 cm) and place blocks under the drive chassis for support. 4 Remove the lug nuts, then remove the tire and wheel assembly. 5 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down. Result: There should be no side to side or up and down movement.

8 Loosen the castle nut, then re-tighten to 8 ft-lbs (11 Nm). 9 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down. Result: If there is side to side or up and down movement, continue to step 11 and replace the wheel 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 and down movement, continue with step 11 and grease the wheel bearings. 10 Remove the dust cap from the hub, then remove the cotter pin from the castle nut. 11 Remove the castle nut. 12 Pull the hub off of the spindle. The washer and outer bearing should fall loose from the hub. 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the rear bearing.

4 - 78

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 4 Scheduled Maintenance Procedures

TABLE E PROCEDURES

14 Pack both bearings with clean, fresh grease. 15 Place the large inner bearing into the rear of the hub. 16 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush. Always replace the bearing grease seal when removing the hub. 17 Slide the hub onto the yoke spindle. Component damage hazard. Do not apply excessive force or damage to the lip of the seal may occur. 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) to seat the bearings. 21 Loosen the castle nut, then re-tighten to 8 ft-lbs (11 Nm). 22 Install a new cotter pin. Bend the cotter pin to lock it in. 23 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to 125 ft-lbs (169.5 Nm).

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

4 - 79

Section 4 Scheduled Maintenance Procedures

First Edition Second Printing

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4 - 80

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Troubleshooting Flow Charts


Before Troubleshooting:
Read, understand and obey the safety rules and operating instructions printed in the Genie Z-45/25 and Genie Z-45/25J Operators Manual.

Observe and Obey:


Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: Machine parked on a flat level surface Boom in stowed position 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

Be sure that all necessary tools and test equipment are available and ready for use. Read each appropiate flow chart thoroughly. Attempting shortcuts may produce hazardous conditions. Be aware of the following hazards and follow generally accepted safe workshop practices. Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement. Electrocution hazard. Contact with electrically charged circuits may result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Perform all troubleshooting on a firm level surface. Two persons will be required to safely perform some troubleshooting procedures.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5-1

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

TROUBLESHOOTING FLOW CHARTS

About This Section


When a malfunction is discovered, the flow charts in this section will help a service professional pinpoint the cause of the problem. To use this section, basic hand tools and certain pieces of test equipment are requiredvoltmeter, ohmmeter, pressure gauges. The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6, Schematics. Since various degrees of a particular function loss may occur, selecting the appropriate flow chart may be troublesome. When a function will not operate with the same speed or power as a machine in good working condition, refer to the flow chart which most closely describes the problem.

General Repair Process

Malfunction discovered

Identify symptoms

Troubleshoot

problem still exists

Return to service

problem solved

Inspect and test

Perform repair

Fault codes
The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle position to maintain the engine's running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum. When a sensor fails or returns signals that are outside of set parameters, the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light. See Repair Section, How to Retrieve Engine Fault Codes. Use the Fault Code Chart on the following pages to aid in identifying the fault. 5-2 Genie Z-45/25 & Genie Z-45/25J Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Fault Codes
Fault Code
11

Problem
--

Cause
--

Solution
Normal operation.

12

Throttle Position (TP) sensor low voltage. Manifold Absolute Pressure (MAP) sensor low voltage. Engine speed exceeded 4000 RPM.

Check for poor terminal Faulty TP sensor OR sensor connections or shorted wires wires shorted shorted to ground from the TP sensor to the ECM or poor terminal connection. OR replace the TP sensor. Faulty MAP sensor OR sensor wires shorted to ground or poor terminal connection. Obstruction in throttle body OR faulty ECM. The ECM senses a signal from the TP sensor that is greater than 4.9V DC OR the TP sensor wiring is shorted to ground OR there is a poor terminal connection OR the TP sensor is bad. Check for poor terminal connections OR wires shorted to ground OR replace MAP sensor. Check for obstructions in the throttle body that could cause binding of the throttle assembly OR replace ECM.

14

21

22

Throttle Position (TP) sensor high voltage.

Check for poor terminal connections or shorted wires from the TP sensor to the ECM OR replace the TP sensor.

24

Manifold Absolute Pressure (MAP) sensor high voltage.

Check for poor terminal Faulty MAP sensor OR sensor connections or shorted wires wires shorted to ground or poor from the MAP sensor to the terminal connection. ECM to ground OR replace MAP sensor. Voltage to fuel pump is greater than or equal to 2V DC below ignition voltage. Test the fuel pump relay, see the Repair Section OR check for poor terminal connection from the fuel pump relay to fuel pump OR replace the fuel pump. Check for water in the fuel, misfiring cylinder or pugged fuel filter OR check for poor terminal connections or shorted wires from the HO2 sensor to the ECM to ground OR replace HO2 sensor. Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor.

31

Fuel pump low voltage.

32

Heated Oxygen (HO2) sensor low voltage.

Water in the fuel, misfiring cylinder, plugged fuel filter OR the HO2 sensor wiring is shorted to ground OR there is a poor terminal connection OR the HO2 sensor is bad. Engine is overheating OR sensor wires shorted to ground or poor terminal connections OR ECT sensor is bad

33

Engine Coolant Temperature (ECT) sensor high voltage.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5-3

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

FAULT CODES

Fault Code

Problem

Cause
IAT sensor signal is greater than or equal to 4.93V DC for at least 3 seconds. Fuel pump is receiving voltage when the ECM is not sending the signal to the fuel pump to turn ON.

Solution
Check for poor terminal connections or shorted wires from the IAT sensor to the ECM to ground OR replace IAT sensor. Test the fuel pump relay, see the Repair Section OR check for poor terminal connections from the fuel pump relay to fuel pump OR replace the ECM.

35

Intake Air Temperature (IAT) sensor high voltage.

41

Fuel pump high voltage.

42

Heated Oxygen (HO2) sensor high voltage.

Test for a leaking or A leaking or malfunctioning fuel malfunctioning fuel injector, injector, misfiring cylinder, faulty misfiring cylinder or bad TP TP sensor or contamination sensor. Remove HO2 sensor and from fuel OR use of improper check condition of sensor for thread sealant on sensor contamination OR check for poor threads OR sensor wires terminal connections or shorted shorted to ground or poor wires from the HO2 sensor to the 2 terminal connections OR HO ECM to ground OR replace HO2 sensor is bad. sensor. ECM detects a excessively low signal voltage from the ECT sensor. Check engine coolant level OR check for shorted wires or poor terminal connections from the ECT sensor to the ECM OR replace the ECT sensor. The IAT sensor shares the same ground wire as the ECT and MAP sensors. Check for shorted wires or poor terminal connections from the IAT sensor to the ECT and MAP sensors to the ECM OR replace the IAT sensor. Check engine oil level OR check for shorted wires or poor terminal connections from the oil pressure switch to the ECM OR replace the oil pressure switch.

43

Engine Coolant Temperature (ECT) sensor low voltage.

45

Intake Air Temperature (IAT) sensor low voltage.

ECM detects a excessively low signal voltage from the IAT sensor.

51

Low oil pressure.

Bad oil pressure switch, wires shorted to ground or not enough engine oil.

5-4

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

FAULT CODES

Fault Code

Problem

Cause

Solution

52

The CKP and CMP sensors work together; if one is bad, the other one wont work correctly Crankshaft Position (CKP) and causes the ECM to detect sensor senses extra or a fault. The ECM uses the missing pulses. signal pulses from the CKP and CMP sensors to initiate sequential fuel injection. The CMP and CKP sensors work together; if one is bad, the other one wont work correctly and causes the ECM to detect a fault. The ECM uses the signal pulses from the CKP and CMP sensors to initiate sequential fuel injection. The ECM received an illegal instruction signal from one or more of the sensors and has gone into a default program and then return to normal operation. The ECM received an illegal interruption signal from one or more engine sensors and has gone into a default program and then return to normal operation. Under normal operation the ECM will store numbers into memory. If this does not happen, it will reset itself and set fault code 56.

Check for shorted wires or poor terminal connections from the CKP and CMP sensors to the ECM OR replace the CKP or CMP sensor.

53

Camshaft Position (CMP) sensor senses unknown pattern.

Check for shorted wires or poor terminal connections from the CKP and CMP sensors to the ECM OR replace the CKP or CMP sensor.

54

ECM Fault - Illegal Operation.

Replace the ECM.

55

ECM - Illegal Interuption.

Replace the ECM.

56

ECM - Computer Operating Properly (COP) failure

Replace the ECM.

61

System voltage low.

Battery supply voltage to the ECM is 8V DC or less.

Check battery and/or alternator condition OR check for shorted wires or poor terminal connections from the battery to the ECM. Check battery and/or alternator condition OR check for shorted wires or poor terminal connections from the battery to the ECM.

62

System voltage high.

Battery supply voltage to the ECM is 18V DC or more.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5-5

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 1
Engine Will Not Crank Over
Be sure the key switch is in the appropriate position. Be sure that both Emergency Stop buttons are pulled out to the ON position. Be sure the circuit breakers are not tripped. Be sure the battery is fully charged.

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5-6

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 1

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5-7

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 2
Engine Cranks Over But Will Not Start Ford Models
Be sure to check the engine oil level and fill as needed. Be sure to check fuel levels and the engine coolant level. Be sure that the radiator overflow tank is at the FULL mark. Perform following tests in gasoline mode only.

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5-8

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 2

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5-9

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 2A
Engine Runs While Cranking Then Dies
Be sure that all vacuum hoses are connected and show no signs of damage.

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5 - 10

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 3
Engine Cranks Over But Will Not Start Diesel Models
Be sure to check the engine oil level and fill as needed. Be sure to check fuel level. Be sure that the battery is fully charged.

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 11

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 3

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5 - 12

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 3

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 13

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 4
Engine Will Not Start On LPG, But Will Start On Gasoline Ford Models
Be sure fuel select switch is switched to LPG. Be sure the valve on the LPG tank is fully opened. Be sure to check LPG fuel level.
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5 - 14

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 4

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 15

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 5
Engine Will Not Start On Gasoline, But Will Start On LPG Ford Models
Be sure fuel select switch is switched to gasoline. Be sure to check gasoline fuel level.

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5 - 16

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 6
Engine High Idle Inoperative Ford Models
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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 17

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 7
Engine Low Idle Inoperative Ford Models
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5 - 18

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 8
Engine High Idle Inoperative Diesel Models
Be sure mechanical linkage is not binding or defective. Be sure 2-speed solenoid grounding wires are free of corrosion and have full continuity to ground.
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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 19

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 8

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5 - 20

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 9
Engine Low Idle Inoperative Diesel Models
Check if mechanical linkage from 2-speed solenoid to fuel injection system is binding or defective.
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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 21

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

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

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 11
All Lift and Steer Functions Inoperative, Drive Functions Operational
Be sure the hydraulic suction line shutoff valve for the lift/steer pump is in the OPEN position. Be sure all grounding wires for the hydraulic manifold valves are free of corrosion and have full continuity to ground.
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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 23

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 12
Ground Controls Inoperative, Platform Controls Operate Normally
Be sure all other functions operate normally, including the platform controls.

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5 - 24

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 13
Platform Controls Inoperative, Ground Controls Operate Normally
Be sure all cables from ground control box through the cable track are in good condition with no kinks or abrasions.

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Part No. 52709

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Genie Z-45/25 & Genie Z-45/25J

5 - 25

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 14
Primary Boom Up Function Inoperative
Be sure all other functions operate normally.

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5 - 26

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 14

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 27

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 14

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5 - 28

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 15
Primary Boom Down Function Inoperative (before serial number 13099)
Be sure all other functions operate normally.

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 29

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 15

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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5 - 30

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 15

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 31

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 16
Primary Boom Down Function Inoperative (after serial number 13098)
Be sure all other functions operate normally.

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5 - 32

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 16

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 33

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 16

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5 - 34

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 17
Secondary Boom Up Function Inoperative
Be sure all other functions operate normally.

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<UXSUXK

)UTZOT[KJUTZNKTK^Z VGMK

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 35

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 17

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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)UTZOT[KJUTZNKTK^Z VGMK

5 - 36

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 17

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 37

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 18
Secondary Boom Down Function Inoperative
Be sure all other functions operate normally.

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5 - 38

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 18

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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)UTZOT[KJUTZNKTK^Z VGMK

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 39

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 18

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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5 - 40

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 19
Primary Boom Extend Function Inoperative
Be sure all other functions operate normally.

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 41

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 19

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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5 - 42

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 20
Primary Boom Retract Function Inoperative
Be sure all other functions operate normally.

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 43

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 20

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8KVRGIK LG[RZ_ LRU] XKM[RGZUX \GR\K

5 - 44

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 21
Turntable Rotate Left Function Inoperative
Be sure all other functions operate normally.

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)UTZOT[KJUTZNKTK^Z VGMK

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 45

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 21

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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5 - 46

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 21

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RKYYZNGT 69/

)UTZOT[KJUTZNKTK^Z VGMK

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 47

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 21

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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5 - 48

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 22
Turntable Rotate Right Function Inoperative
Be sure all other functions operate normally.

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)UTZOT[KJUTZNKTK^Z VGMK

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 49

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 22

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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5 - 50

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 22

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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RKYYZNGT 69/

)UTZOT[KJUTZNKTK^Z VGMK

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 51

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 22

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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5 - 52

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 23
All Platform Leveling Functions Inoperative
Be sure all other functions operate normally.

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 53

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 24
Platform Level Up Function Inoperative
Be sure all other functions operate normally.

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5 - 54

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 24

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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UX OTLOTOZK UNSY

8KVRGIKZNKVRGZLUXS RK\KR[VJOXKIZOUTGR\GR\K IUOROZKS9

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

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 55

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 25
Platform Level Down Function Inoperative
Be sure all other functions operate normally.

=OZNZNKQK_Y]OZIN Z[XTKJZUMXU[TJ IUTZXURYGTJHUZN +SKXMKTI_9ZUVH[ZZUTY V[RRKJU[ZZUZNK54 < VUYOZOUTSU\KZNK L[TIZOUTKTGHRKZUMMRK Y]OZINZUKOZNKXYOJKGTJ GIZO\GZKZNKVRGZLUXS RK\KRZUMMRKY]OZIN:9 OTZNKJU]TJOXKIZOUT GTJINKIQZNK\URZGMKGZ UXMHRQ]OXKUTVRGZLUXS RK\KRJU]TL[TIZOUT JOXKIZOUTGR\GR\K OZKS9

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

<UXSUXK

)UTZOT[KJUTZNKTK^Z VGMK

5 - 56

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 25

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

UX *OYIUTTKIZZNK]OXKY LXUSZNKVRGZLUXSRK\KR OTLOTOZK UNSY JU]TJOXKIZOUTGR\GR\K IUOROZKS9GTJZKYZZNK XKYOYZGTIKULZNK\GR\K IUOR ZUUNSY

8KVRGIKZNKVRGZLUXS RK\KRJU]TJOXKIZOUTGR \GR\KIUOROZKS9

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

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 57

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 26
Platform Rotate Left Function Inoperative
Be sure all other functions operate normally.

=OZNZNKQK_Y]OZIN Z[XTKJZUMXU[TJ < IUTZXURYGTJHUZN +SKXMKTI_9ZUVH[ZZUTY V[RRKJU[ZZUZNK54 VUYOZOUTSU\KZNK L[TIZOUTKTGHRKZUMMRK Y]OZINZUKOZNKXYOJKGTJ GIZO\GZKZNKVRGZLUXS XUZGZKZUMMRKY]OZIN :9OTZNKRKLZJOXKIZOUT GTJINKIQ\URZGMKGZ MXT]NZ]OXKGZ:6GZ ZNKVRGZLUXSIUTZXURY < =OZNQK_Y]OZINZ[XTKJ < ZUVRGZLUXSIUTZXURYGTJ HUZN+SKXMKTI_9ZUV H[ZZUTYV[RRKJU[ZZUZNK 54VUYOZOUTGIZO\GZKLUUZ Y]OZINGTJVRGZLUXS XUZGZKZUMMRKY]OZIN:9 OTZNKRKLZJOXKIZOUTGTJ INKIQ\URZGMKGZZNKMXT ]NZ]OXKGZZNKPOHJKRG_ IGVGIOZUX

8KVGOXUVKTOTMXT]NZ ]OXKLXUS:9ZU:( ZU:658ZKYZZUMMRK Y]OZIN9KK8KVGOX 9KIZOUT

)NKIQ\URZGMKUTIKTZKX < ZKXSOTGRUL:9

8KVGOXUVKTOTXKJ VU]KX]OXKIOXI[OZ ZNXU[MNIUTZXURRKXYGTJ L[TIZOUTZUMMRKY]OZINKY ZU:9

<

=OZNQK_Y]OZINZ[XTKJ < ZUVRGZLUXSIUTZXURGTJ HUZN+SKXMKTI_9ZUV H[ZZUTYV[RRKJU[ZZUZNK 54VUYOZOUTGIZO\GZKLUUZ Y]OZINGTJVRGZLUXS XUZGZKZUMMRKY]OZIN:9 OTZNKRKLZJOXKIZOUTGTJ INKIQ\URZGMKGZ:6 < < 'IZO\GZKLUUZY]OZINGTJ < VRGZLUXSXUZGZKZUMMRK Y]OZIN:9OTZNKRKLZ JOXKIZOUTGTJINKIQ \URZGMKGZZNKMXT]NZ ]OXKUT:9 < )UTZOT[KJUTZNKTK^Z VGMK :KYZZUMMRKY]OZIN9KK 8KVGOX9KIZOUT58 XKVRGIKVRGZLUXSXUZGZK ZUMMRKY]OZIN:9

8KVGOXUVKTOTMXT]NZ ]OXKLXUS:6ZUPOH JKRG_IGVGIOZUX

8KVGOXUVKTOTMXT]NZ ]OXKLXUS:9ZU:6

5 - 58

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 26

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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

8KVRGIKZNKPOHJKRG_ IGVGIOZUX58XKVGOX UVKTOTHXU]TMXU[TJ ]OXKLXUSIGVGIOZUXZU MXU[TJ

8KVGOXUVKTOTXKJ]OXK LXUSPOHJKRG_IGVGIOZUX ZU)8

8KVRGIKXKRG_)858 XKVGOXUVKTOTVU]KX Y[VVR_LXUS6ZU)8 58XKVGOXUVKTOTHXU]T MXU[TJ]OXKZU)8

8KVGOXUVKTOTIGHRK IUTZGOTOTMXKJGTJHRGIQ ]OXKYLXUS)8ZUPOH HUUSVRGZLUXSXUZGZK YKRKIZ\GR\KY

UX OTLOTOZK UNSY

8KVRGIKLG[RZ_\GR\K IUOR

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 59

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 26

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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

5 - 60

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 27
Platform Rotate Right Function Inoperative
Be sure all other functions operate normally.

=OZNZNKQK_Y]OZIN Z[XTKJZUMXU[TJIUTZXUR < GTJHUZN+SKXMKTI_ 9ZUVH[ZZUTYV[RRKJU[Z ZUZNK54VUYOZOUTSU\K ZNKL[TIZOUTKTGHRK ZUMMRKY]OZINZUKOZNKX YOJKGTJGIZO\GZKZNK VRGZLUXSXUZGZKZUMMRK Y]OZIN:9OTZNKXOMNZ JOXKIZOUTGTJINKIQ \URZGMKGZMXT]NZ]OXK GZ:6GZZNKVRGZLUXS IUTZXURY < =OZNQK_Y]OZINZ[XTKJ < ZUVRGZLUXSIUTZXURGTJ HUZN+SKXMKTI_9ZUV H[ZZUTYV[RRKJU[ZZUZNK 54VUYOZOUTGIZO\GZKLUUZ Y]OZINGTJVRGZLUXS XUZGZKZUMMRKY]OZIN:9 OTZNKXOMNZJOXKIZOUTGTJ INKIQ\URZGMKGZZNKMXT ]NZ]OXKGZZNKPOHJKRG_ IGVGIOZUX

8KVGOXUVKTOTMXT]NZ ]OXKLXUS:9ZU:( ZU:658ZKYZZUMMRK Y]OZIN9KK8KVGOX 9KIZOUT

)NKIQ\URZGMKUTIKTZKX < ZKXSOTGRUL:9

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<

=OZNQK_Y]OZINZ[XTKJ < ZUVRGZLUXSIUTZXURGTJ HUZN+SKXMKTI_9ZUV H[ZZUTYV[RRKJU[ZZUZNK 54VUYOZOUTGIZO\GZKLUUZ Y]OZINGTJVRGZLUXS XUZGZKZUMMRKY]OZIN:9 OTZNKXOMNZJOXKIZOUTGTJ INKIQ\URZGMKGZ:6 < < 'IZO\GZKLUUZY]OZINGTJ < VRGZLUXSXUZGZKZUMMRK Y]OZIN:9OTZNKXOMNZ JOXKIZOUTGTJINKIQ \URZGMKGZZNKMXT]NZ ]OXKUT:9 < )UTZOT[KJUTZNKTK^Z VGMK :KYZZUMMRKY]OZIN9KK 8KVGOX9KIZOUT58 XKVRGIKVRGZLUXSXUZGZK ZUMMRKY]OZIN:9

8KVGOXUVKTOTMXT]NZ ]OXKLXUS:6ZUPOH JKRG_IGVGIOZUX

8KVGOXUVKTOTMXT]NZ ]OXKLXUS:9ZU:6

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 61

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 27

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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

8KVRGIKZNKPOHJKRG_ IGVGIOZUX58XKVGOX UVKTOTHXU]TMXU[TJ ]OXKLXUSIGVGIOZUXZU MXU[TJ

8KVGOXUVKTOTXKJ]OXK LXUSPOHJKRG_IGVGIOZUX ZU)8

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UX OTLOTOZK UNSY

8KVRGIKLG[RZ_\GR\K IUOR

5 - 62

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 27

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 63

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 28
Jib Boom Up Function Inoperative, Z-45/25J Models
Be sure all other functions operate normally.

=OZNZNKQK_Y]OZIN Z[XTKJZUMXU[TJIUTZXUR GTJHUZN+SKXMKTI_ < 9ZUVH[ZZUTYV[RRKJU[Z ZUZNK54VUYOZOUTSU\K ZNKL[TIZOUTKTGHRK ZUMMRKY]OZINZUKOZNKX YOJKGTJGIZO\GZKZNKPOH HUUSZUMMRKY]OZIN :9OTZNK[VJOXKIZOUT GTJINKIQ\URZGMKGZZNK MXT]OXKUTZNKPOHHUUS [VJOXKIZOUTGR\GR\K OZKS(( < =OZNZNKQK_Y]OZIN Z[XTKJZUVRGZLUXS < IUTZXURGTJHUZN +SKXMKTI_9ZUVH[ZZUTY V[RRKJU[ZZUZNK54 VUYOZOUTGIZO\GZKZNK LUUZY]OZINGTJZNKPOH HUUSZUMMRKY]OZIN:9 OTZNK[VJOXKIZOUTGTJ INKIQ\URZGMKGZ:(

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8KVGOXUVKTOTMXT]OXK LXUS:(ZUPOHHUUS [VJOXKIZOUTGR\GR\K58 XKVGOXUVKTOTHXU]T MXU[TJ]OXKIOXI[OZZU JOXKIZOUTGR\GR\K

8KVGOXUVKTOTMXT]OXK LXUS:6ZU:(

8KVGOXUVKTOTMXT]OXK LXUS:9ZU:658 XKVRGIKPOHHUUSZUMMRK Y]OZIN:9

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8KVGOXUVKTOTXKJ]OXK LXUSZKXSOTGRGUT )8ZU:958 IUTY[RZ-KTOK/TJ[YZXOKY 9KX\OIK*KVGXZSKTZ


Part No. 52709

5 - 64

Genie Z-45/25 & Genie Z-45/25J

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 28

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

'IZO\GZKLUUZY]OZINGTJ POHHUUSZUMMRKY]OZIN :9OTZNK[VJOXKIZOUT GTJINKIQ\URZGMKUT ZNKXKJGTJHRGIQ]OXKY GZZNKPOHVRGZLUXSXUZGZK YKRKIZ\GR\KYOZKS'< <

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RKYYZNGT VYO

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 65

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 29
Jib Boom Down Function Inoperative, Z-45/25J Models
Be sure all other functions operate normally.

=OZNZNKQK_Y]OZIN Z[XTKJZUMXU[TJIUTZXUR GTJHUZN+SKXMKTI_ < 9ZUVH[ZZUTYV[RRKJU[Z ZUZNK54VUYOZOUTSU\K ZNKL[TIZOUTKTGHRK ZUMMRKY]OZINZUKOZNKX YOJKGTJGIZO\GZKZNKPOH HUUSZUMMRKY]OZIN :9OTZNKJU]T JOXKIZOUTGTJINKIQ \URZGMKGZZNKMXTHRQ ]OXKUTZNKPOHHUUS JU]TJOXKIZOUTGR\GR\K OZKS(( < =OZNZNKQK_Y]OZIN Z[XTKJZUVRGZLUXS < IUTZXURGTJHUZN +SKXMKTI_9ZUVH[ZZUTY V[RRKJU[ZZUZNK54 VUYOZOUTGIZO\GZKZNK LUUZY]OZINGTJZNKPOH HUUSZUMMRKY]OZIN:9 OTZNKJU]TJOXKIZOUT GTJINKIQ\URZGMKGZ :(

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Part No. 52709

5 - 66

Genie Z-45/25 & Genie Z-45/25J

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 29

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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8KVRGIK)8

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 67

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 30
Steer Left Function Inoperative
Be sure all other functions operate normally.

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5 - 68

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 31
Steer Right Function Inoperative
Be sure all other functions operate normally.

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8KVGOXUVKTOTHR[ ]OXKIOXI[OZLXUSJXO\K IUTZXURRKX*6ZU:6 ZNKTZU:(

8KVRGIKYZKKXXOMNZ JOXKIZOUTGR\GR\KIUOR OZKS--58XKVGOX UVKTOTHXU]TMXU[TJ ]OXKZUYZKKXXOMNZ\GR\K IUOR )NKIQLUXSKINGTOIGR XKYZXOIZOUTYQKKVOTM YZKKXXOMNZL[TIZOUTLXUS UVKXGZOTM58XKVGOXUX XKVRGIKYZKKXI_ROTJKX 58XKVRGIKLRU] XKM[RGZUX\GR\KOZKS, 58IUTY[RZ-KTOK /TJ[YZXOKY9KX\OIK *KVGXZSKTZ

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 69

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 32
Oscillate Function Inoperative
Be sure all other function operate normally.

HGJ 8KSU\KZNKINGYYOY IU\KXGTJZNKG^RK IU\KXYLXUSZNKTUT YZKKXKTJULZNK SGINOTK)NKIQZNK ROTQGMKLUXJGSGMKUX OSVXUVKXROTQGMK GJP[YZSKTZ9KK8KVGOX YKIZOUT.U]ZU9KZ ;VZNK*OXKIZOUTGR<GR\K 2OTQGMK MUUJ

8KGJP[YZUXXKVRGIK ROTQGMK

/TYZGRRGZUVYO 'JP[YZZNKINGXMK ZUHGXVXKYY[XK RKYYZNGT VXKYY[XKXKROKL\GR\K MG[MKGZZNKW[OIQ 9KK8KVGOXVXUIKJ[XK JOYIUTTKIZIU[VROTMUT VYO .U]ZU'JP[YZZNK ZNKJXO\KSGTOLURJ9ZGXZ 5YIORRGZK9KW[KTIOTM ZNKKTMOTKGTJINKIQ <GR\K6XKYY[XK58 ZNKVXKYY[XK IUTY[RZ-KTOK/TJ[YZXOKY 9KX\OIK*KVGXZSKTZ VYO )UTY[RZ-KTOK/TJ[YZXOKY 9KX\OIK*KVGXZSKTZ

5 - 70

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 33
All Drive Functions Inoperative, All Other Functions Operate Normally
Be sure the rpm toggle switch is in the footswitch activated high idle position. Be sure the hydraulic tank shut off valves are in the OPEN position. Be sure machine is not in the free wheel configuration.
RKYY =OZNZNKQK_Y]OZIN ZNGT Z[XTKJZUVRGZLUXS < IUTZXURGTJHUZN +SKXMKTI_9ZUVH[ZZUTY V[RRKJU[ZZUZNK54 VUYOZOUTGIZO\GZKZNK LUUZY]OZINGTJINKIQ ZNK\URZGMKGZZKXSOTGR UTZNKJXO\KPU_YZOIQ *6 <UXSUXK 'IZO\GZKZNKLUUZY]OZIN RKYY GTJINKIQZNK\URZGMKGZ ZNGT < ZKXSOTGRUTZNK NUXYKVU]KXROSOZKX IOXI[OZHUGXJ )NKIQIUTZOT[OZ_UL 8KVGOXUVKTOTVU]KX HXU]TMXU[TJ]OXKLXUS IUTZOT[OZ_ Y[VVR_IOXI[OZLXUS:6 ZKXSOTGRUT*6ZU ZUZKXSOTGRUTJXO\K MXU[TJ PU_YZOIQ*6 TUIUTZOT[OZ_ 8KVGOXUVKTOTHXU]T MXU[TJ]OXKIOXI[OZLXUS MXU[TJZU*6

)NKIQIUTZOT[OZ_UL 8KVGOXUVKTOTVU]KX HXU]TMXU[TJ]OXKLXUS IUTZOT[OZ_ Y[VVR_IOXI[OZLXUS:6 ZKXSOTGRUTZNK ZUZKXSOTGRUTZNK NUXYKVU]KXROSOZKX NUXYKVU]KXROSOZKX IOXI[OZHUGXJZUMXU[TJ IOXI[OZHUGXJ TUIUTZOT[OZ_ 8KVGOXUVKTOTHXU]T MXU[TJ]OXKIOXI[OZLXUS MXU[TJZUZKXSOTGRUT ZNKNUXYKVU]KXROSOZKX IOXI[OZHUGXJ

<UXSUXK

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 71

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

CHART 33

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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5 - 72

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

CHART 33

)UTZOT[KJLXUSZNK VXK\OU[YVGMK

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Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 73

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 34
Drive Forward Or Reverse Function Inoperative
Be sure all other functions operate normally including drive in opposite direction of malfunction.

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5 - 74

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 35
Traction Function Inoperative
Be sure all other functions operate normally.
'T_Z_VKULZXGIZOUT VXUHRKSIUTY[RZ-KTOK /TJ[YZXOKY9KX\OIK *KVGXZSKTZ

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 75

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 36
Machine Will Not Drive At Full Speed
Be sure all other functions operate normally. Be sure the machine is not raised above or extended beyond the drive limit switches. Be sure the primary boom drive limit switch is clear of any debris and is not activated when the boom is in the stowed position. Be sure the secondary boom drive limit switch is clear of any debris and is not activated when the boom is in the stowed position. Be sure that the primary boom extend drive limit switch arm is being activated when the boom is fully retracted. Be sure the wiring to limit switches is intact and show no sign of damage or corrosion. Be sure the freewheel valve is closed on the drive pump.

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5 - 76

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 37
Machine Drives At Full Speed With Platform Raised or Extended
Be sure primary boom drive limit switch is being activated by the cam on the primary boom when the primary boom is raised. Be sure secondary boom drive limit switch is being activated by the cam on the compression link when the secondary boom is raised. Be sure that the primary boom extend drive limit switch is not being held down or being activated when the primary boom is extended. Be sure the wiring to limit switches is intact and show no sign of damage or corrosion.
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HGJ

8KVRGIKLG[RZ_ROSOZ Y]OZINIUTZGIZ58 XKVRGIKROSOZY]OZIN

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 77

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

Chart 38
Drive Enable System Is Malfunctioning
Be sure the boom is in the stowed position.

=OZNQK_Y]OZINOT VRGZLUXSVUYOZOUTGTJ HUZN+SKXMKTI_9ZUV TU H[ZZUTYV[RRKJU[ZZUZNK 54VUYOZOUTGTJZNK HUUSXUZGZKJHKZ]KKT ZNKTUTYZKKXZOXKY GIZO\GZKLUUZY]OZINGTJ JXO\KIUTZXURRKXOT LUX]GXJJOXKIZOUT=ORR [TOZJXO\K% _KY =OZNQK_Y]OZINOT VRGZLUXSVUYOZOUTGTJ HUZN+SKXMKTI_9ZUV TU H[ZZUTYV[RRKJU[ZZUZNK 54VUYOZOUTGTJZNK HUUSXUZGZKJHKZ]KKT ZNKYZKKXKTJZOXKY GIZO\GZKLUUZY]OZINGTJ JXO\KIUTZXURRKXOT LUX]GXJJOXKIZOUT=ORR [TOZJXO\K% _KY )NKIQLUXIUTZOT[OZ_ LXUS:(ZU:( TUIUTZOT[OZ_ 8KVGOXUVKTLXUS:( ZU29ZNKTLXUS29ZU :(

'IZO\GZKLUUZY]OZINGTJ < JXO\KIUTZXURRKXOT LUX]GXJJOXKIZOUTGTJ INKIQ\URZGMKGZ ZKXSOTGRUTJXO\K IUTZXURRKX*6 <UXSUXK 8KVGOXUVKTLXUS ZKXSOTGRUT*6ZU IKTZKXZKXSOTGRUT:9 58XKLKXZU)NGXZ58 IUTY[RZ-KTOK/TJ[YZXOKY 9KX\OIK*KVGXZSKTZ .URJZNKJXO\KKTGHRK Y]OZIN:9ZUKOZNKX YOJKGTJGIZO\GZKZNK LUUZY]OZINGTJJXO\K LUX]GXJL[TIZOUT=ORR [TOZJXO\K% TU 8KVGOXUVKTOTHR[]NZ ]OXKLXUSJXO\KKTGHRK ZUMMRKY]OZIN:9ZU :6ZU:(58 XKVRGIKJXO\KKTGHRK ZUMMRKY]OZIN:9

8KVGOXUVKTOTVU]KX Y[VVR_IOXI[OZLXUS :6

_KY

:NKSGINOTKOY UVKXGZOTMIUXXKIZR_/L SGINOTKJUKYTUZ UVKXGZKVXUVKXR_ IUTY[RZ-KTOK/TJ[YZXOKY 9KX\OIK*KVGXZSKTZ

IUTZOT[OZ_ 'IZO\GZKROSOZY]OZINH_ 8KVRGIKJXO\KKTGHRK IUTZOT[OZ_ ROSOZY]OZINIUTZGIZ58 NGTJGTJINKIQ IUTZOT[OZ_LXUS:(ZU XKVRGIKJXO\KKTGHRK :( ROSOZY]OZIN29 TUIUTZOT[OZ_ 6RKGYKHKMOT ZXU[HRKYNUUZOTMLXUS HKMOTTOTMULINGXZ58 IUTY[RZ-KTOK/TJ[YZXOKY 9KX\OIK*KVGXZSKTZ

5 - 78

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 5 Troubleshooting Flow Charts

Chart 39
Auxiliary Functions Inoperative
Be sure all other functions operate normally. Be sure key switch is in the appropriate position and both Emergency Stop buttons are pulled out to the ON position. Be sure engine is not running when using auxiliary power. Note: Operating auxiliary power with the engine running should immediately kill the engine.
2OLZZNKXKJG[^OROGX_ SUZUX V[SVY]OZINIU\KXOL KW[OVVKJNURJG[^OROGX_ UVKXGZKY Y]OZINGTJROYZKTLUX YU[TJULG[^OROGX_V[SV SUZUXUVKXGZOTM /TYZGRRGZUVYO ZUHGXVXKYY[XK MG[MKOTZUZNKVXKYY[XK VUXZULZNKG[^OROGX_ V[SVGTJNURJZNK G[^OROGX_VU]KXZUMMRK Y]OZINGTJTUZKZNK VXKYY[XK RKYYZNGT VYO )NKIQLUXGVUYOZO\K IUTTKIZOUTHKZ]KKT KRKIZXOISUZUXGTJZNK V[SVH_XKSU\OTMZNK V[SVLXUSZNKSUZUX H[ZRKG\KGRRZNKNUYKY IUTTKIZKJ<OY[GRR_ INKIQIU[VROTM IUTTKIZOUT HGJ 8KVRGIKZNKG[^OROGX_ VU]KX[TOZ MUUJ 8KVGOXUXXKVRGIKV[SV 58XKVRGIKXKROKL\GR\K )UTY[RZ-KTOK/TJ[YZXOKY 9KX\OIK*KVGXZSKTZ 8KIUTTKIZVXKYY[XK ROTKGTJINKIQHGZZKX_ VYO IUTJOZOUT:NKXKOY VUYYOHR_TUZKTU[MN HGZZKX_IGVGIOZ_ZU UVKXGZKHUZNG[^V[SV GTJL[TIZOUT\GR\KY

SUZUXJUKY TUZUVKXGZK

=OZNZNKQK_Y]OZIN Z[XTKJZUMXU[TJIUTZXUR GTJHUZN+SKXMKTI_ 9ZUVH[ZZUTYV[RRKJU[Z ZUZNK54VUYOZOUT GIZO\GZKZNKG[^OROGX_ V[SVZUMMRKY]OZINGTJ INKIQZNK\URZGMKUTZNK XKJIGHRKUTZNK G[^OROGX_VU]KX[TOZ

<

'IZO\GZKZNKG[^OROGX_ V[SVZUMMRKY]OZINGTJ INKIQZNK\URZGMKGZ :( < 'IZO\GZKZNKG[^OROGX_ V[SVZUMMRKY]OZINGTJ INKIQZNK\URZGMKGZZNK IKTZKXZKXSOTGRUL:9 <UXSUXK

<UX SUXK

8KVGOXUVKTLXUS:( ZU6858XKVGOXUVKT OTHXU]TMXU[TJ]OXK IOXI[OZZU6858 XKVRGIK68

<

8KVGOXUVKTOTXKJ VU]KXY[VVR_]OXKLXUS QK_Y]OZIN19ZU G[^OROGX_ZUMMRKY]OZIN :9

<

8KVGOXUVKTOTXKJ ]OXKLXUS:9ZU:( 58XKVRGIK:9

)NKIQIUTZOT[OZ_LXUS TKMGZO\KZKXSOTGRUT G[^OROGX_VU]KX[TOZZU MXU[TJ MUUJ 8KVRGIKG[^OROGX_V[SV SUZUX

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8KVRGIKTKMGZO\KIGHRK LXUSG[^OROGX_V[SVZU MXU[TJ

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

5 - 79

Section 5 Troubleshooting Flow Charts

First Edition Second Printing

This page intentionally left blank.

5 - 80

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 6 Schematics

Schematics
About This Section
There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics

Observe and Obey:


Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine.

Electrocution hazard. Contact with electrically charged circuits may result in death or serious injury. Remove all rings, watches and other jewelry. Hydraulic Schematics Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. General Repair Process

Before Troubleshooting:
Read, understand and obey the safety rules and operating instructions printed in the Genie Z-45/25 & Genie Z-45/25J Operator's Manual. Be sure that all necessary tools and test equipment are available and ready for use.

Malfunction discovered

Identify symptoms

Troubleshoot

problem still exists

Return to service

problem solved

Inspect and test

Perform repair

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6-1

Section 6 Schematics

First Edition Second Printing

Electrical Components

Item

Description

Genie Part Number

Manufacturer

Manufacturer Part Number

Qty

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 CR1,2,4,5,7,8 CR7, 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.

6-2

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 6 Schematics

ELECTRICAL COMPONENTS

Item

Description

Genie Part Number

Manufacturer

Manufacturer Part Number

Qty

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, 50 5 watt .............. 49866 ........... Dale ..................................... RH5- 50R-1% ................ 1 R2 .................. Resistor, 100 25 watt .......... 27116 ........... Dale ..................................... RH25-100R-1% ............. 1 R3 .................. Resistor, 250 5 watt ............ 27117 ........... Dale ..................................... RH5- 250R-1% .............. 1 R4, (before serial number 13099) Resistor, 15 25 watt ............ 45836 ........... Dale ..................................... RH25-15R-1% ............... 1 R4, (after serial number 13098) Resistor, 10 25 watt ............ 54516 ........... Dale ..................................... D25K10R ....................... 1 R5 .................. Resistor, 10 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 2 position momentary ............ 13480 ........... Microswitch Control Inc. ...... 2NT1-8 ........................... 2 TS2, 3, 9,13,15, 52,54 58, 59, 63 (Gas/LPG) ...... Toggle switch, SPDT 3 position momentary ............ 13037 ........... Microswitch Control Inc. ...... 1NT1-7 ........................... 9 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, DPST 2 position maintained ............ 27378 ........... Microswitch Control Inc. ...... 2NT1-3 ........................... 1 TS4 ................ Toggle switch, DPDT 3 position maintained ............ 13038 ........... Microswitch Control Inc. ...... 2NT1-1 ........................... 1 TS7, 57, 60, 61, 62, ...... Toggle switch, DPDT 3 position momentary ............ 16397 ........... Microswitch Control Inc. ...... 2NT1-7 ........................... 5

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6-3

Section 6 Schematics

First Edition Second Printing

Electrical Symbols Legend

6-4

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 6 Schematics

Abbreviation 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

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6-5

Section 6 Schematics

First Edition Second Printing

6-6

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Ford LRG-425 EFI Engine Wire Harness (before serial number 13099)

Section 6 Schematics

Service Manual

Ford LRG-425 EFI Engine Wire Harness (before serial number 13099)
A 1
THROTTLE ACTUATOR/ POSITION SENSOR FUEL INJECTOR VALVES POWER CR-FA
87A

FORD WIRING HARNESS WIRE COLOR CODE FUEL PUMP CR-FB


87A

STARTER CR-FC
87A

CODE BL

COLOR BLUE BLACK BROWN DARK BLUE DARK GREEN GREEN

CODE GY LB LG N O PK

COLOR GREY LIGHT BLUE LIGHT GREEN NATURAL ORANGE PINK

CODE P R T W Y

COLOR PURPLE RED TAN WHITE YELLOW

30

30

30

#4
WATER TEMP. SWITCH (NO)

#3

#2

#1

BK BR

87

87

86

86

87

86

85

85

85

DB DG GN

2
37CY16 361ER16 926ALB/O16 787APK/BK16 37AY12 16BR/LG18 570DBK/W18 361R12 359CGY/R18 355GY/W18 351BBR/W18 361DR14 558BR/LB18 570BK/W12 39RW20 361CR14 557BR/Y18 361JR14 264W/LB18 32R/LB16 16R/LG16 342LG/P16 32ADKBL16 361AR14 555T18 361BR14 556W18

FORD ENGINE CONTROL MODULE (ECM) QUICK DISCONNECTS (TO ECM) 95TW18 361LR18 37BY18 X1 F1 K1 F2 H1 A3 G1 H2 J1 C1 F3 Y3 Y2 W3 S3 S2 S1 T1 A2 R2 B3 C2 X2 X3 W1 W2 C3 E3 G2 G3 M1 A1 L1 H3 J2 K2 R3 K3 M2 N2 P3 L2 M3 B2 N1 N3 P1 D1 B1 D2 T2 L3 E1 R1 D3 J3 T3 P2 Y1 E2 IGNITION COIL 1 NOT USED VPWR KEEP ALIVE PWR NOT USED NOT USED CRANKSHAFT SENSOR RETURN (+) CRANKSHAFT SENSOR RETURN (-) CAMSHAFT SENSOR FEED (+) THROTTLE POSITION SENSOR INPUT FUEL PUMP MONITOR NOT USED NOT USED NOT USED FUEL INJECTOR #1 FUEL INJECTOR #2 FUEL INJECTOR #3 FUEL INJECTOR #4 VREF DRY FUEL MODULATOR NOT USED NOT USED POWER GROUND POWER GROUND POWER GROUND POWER GROUND NOT USED NOT USED NOT USED NOT USED DATA LINK DRIVE BY WIRE AUXILLARY INPUT SELF TEST INPUT GOVERNOR SELECT #1 GOVERNOR SELECT #2 MALFUNCTION INDICATOR LAMP FUEL SELECT DATA LINK CONNECTOR (+) DATA LINK CONNECTOR (-) FUEL PUMP RELAY CONTROL NOT USED NOT USED SINGLE RETURN NOT USED NOT USED NOT USED INTAKE AIR TEMP SENSOR MAP SENSOR INPUT ECT SENSOR NO USAGE STARTER LOCKOUT NOT USED IDLE AIR CONTROL DRY FUEL SENSOR OIL PRESSURE GROUND DRYFUEL LOCKOFF IGNITION COIL 2 HO2S SENSOR SIDE

MATING FACE SHOWN

A B C D E

349DB18 350GY18 282DB/O18 355GY/W18 238ADG/Y18 FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 (SEE PAGE 1) TACH LEAD RED 10awg KEEP ALIVE PWR * YELLOW 10awg KEEP ALIVE PWR * WATER TEMP. SWITCH VPWR * PINK/BLK 16awg FUEL PUMP OUTPUT VREF BLK/WHT 10awg BATT. BLK/WHT 10awg BATT. DATA LINK DRIVE BY WIRE SIGNAL INPUT AUXILARY INPUT WHT/PUR 18awg SELF TEST INPUT * TAN/LB 18awg GOV. SPD. CONT. BLK/Y 18awg GOV. SPD. CONT. PINK/LG 18awg FAULT LT. * BRN/WHT 20awg FUEL SELECT * DATA LINK CONNECTOR (+) DATA LINK CONNECTOR (-) DB/BL 16awg STARTER INPUT DRIVE BY WIRE SIGNAL RETURN RED/LB 16awg STARTER OUTPUT OIL PRESSURE SWITCH * NOTE: * SHOWS USED WIRES 2 1 8 16 9 5 31 34 42 22 14 37 18 24 25 6 7 11 3 15 33 13 26 11T/Y20 16AR/LG16 37BY18 39RW20 37Y12 767PK/BK16 351DBR/W20 570CBK/W12 570EBK/W12 107P20 151LB/BK20 198DG/O20 209W/P20 306T/LB20 307BK/Y20 658PK/LG20 674BR/W20 914T/O20 915PK/LB20 32ADKBL16 359LGY/Y20 32R/LB16 253DG/W20

555T18 556W18 557BR/Y18 558BR/LB18 351BR/W18 77DB/Y18 570BK/W18 570ABK/W18 570BBK/W18 570HBK/W18

F G H J K 1 2 3

107P20 151LB/BK20 198DG/O20 209W/P20 306T/LB20 307BK/Y20 658PK/LG20 674BR/W20 914T/O20 915PK/LB20 926ALB/O16 359FGY/R20

3 L M N P R

S T W X Y

42

743GY20 358LG/BK20 354LG/R18 342LG/P16

264W/LB18 225BK/Y20 253BDG/W20 57BK18 242DG18 96T/O18 74GY/LB18

MATING FACE SHOWN

34 354LG/R18 359DGY/Y20 74GY/LB18 89AO18 570NBK/W18 34LB/O18 658PK/LG20 570BK/W20 107P20 915PK/LB20 914T/O20 209W/P20 349DB18 350GY18 282DB/O18 359AGY/R18 743GY20 359JGY/R18 225BK/Y20 359MGY/Y20 361NR18 77DB/Y18 351CBR/W20 358LG/BK20 359KGY/Y20 253ADG/W20 96T/O18 16CR/LG16 95AT/W18 57BK18 361PR18 242DG18

MATING FACE SHOWN

OIL PRESSURE SWITCH (NC)

HEATED OXYGEN SENSOR (HO2S)

G COIL IGNITION SYSTEM CRANKSHAFT POSITION SENSOR (CKP)

ENGINE COOLANT TEMPERATURE SENSOR (ECT)

86

85

87 87A

30

CR4 (LOCATED INSIDE THE GROUND CONTROL BOX)

DIAGNOSTIC CONNECTOR

NOTES: 1. WIRES ARE LABELLED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GUAGE EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GREY WIRE WITH LIGHT BLUE STRIPE, 18 GUAGE WIRE 2. INTERNAL SPLICES ARE NOT SHOWN

MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)

INTAKE AIR TEMPERATURE SENSOR (IAT)

CAMSHAFT POSITION SENSOR (CMP)

LPG LOCKOUT RELAY AND VALVE

6-7

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Ford LRG-425 EFI Engine Wire Harness (after serial number 13098)
N M L K J I
THROTTLE ACTUATOR/ POSITION SENSOR FUEL INJECTOR VALVES

C
FORD WIRING HARNESS WIRE COLOR CODE

A 1

POWER CR-FA
87A

FUEL PUMP CR-FB


87A

STARTER CR-FC
87A

CODE BL

COLOR BLUE BLACK BROWN DARK BLUE DARK GREEN GREEN

CODE GY LB LG N O PK

COLOR GREY LIGHT BLUE LIGHT GREEN NATURAL ORANGE PINK

CODE P R T W Y

COLOR PURPLE RED TAN WHITE YELLOW

30

30

30

#4
WATER TEMP. SWITCH (NO)

#3

#2

#1

BK BR

87

87

86

85

86

87

86

85

85

DB DG GN

37CY16 361ER16 926ALB/O16 787APK/BK16

37AY12 16BR/LG18 570DBK/W18 361R12

359CGY/R18 355GY/W18 351BBR/W18

361DR14 558BR/LB18

570BK/W12 39RW20

361CR14 557BR/Y18

361JR14 264W/LB18

32R/LB16 16R/LG16 342LG/P16 32ADKBL16

361BR14 556W18

361AR14 555T18

FORD ENGINE CONTROL MODULE (ECM) QUICK DISCONNECTS (TO ECM) 95TW18 361LR18 37BY18 349DB18 350GY18 282DB/O18 355GY/W18 238ADG/Y18 X1 F1 K1 F2 H1 A3 G1 H2 J1 C1 F3 Y3 Y2 W3 S3 S2 S1 T1 A2 R2 B3 C2 X2 X3 W1 W2 C3 E3 G2 G3 M1 A1 L1 H3 J2 K2 R3 K3 M2 N2 P3 L2 M3 B2 N1 N3 P1 D1 B1 D2 T2 L3 E1 R1 D3 J3 T3 P2 Y1 E2 IGNITION COIL 1 NOT USED VPWR KEEP ALIVE PWR NOT USED NOT USED CRANKSHAFT SENSOR RETURN (+) CRANKSHAFT SENSOR RETURN (-) CAMSHAFT SENSOR FEED (+) THROTTLE POSITION SENSOR INPUT FUEL PUMP MONITOR NOT USED NOT USED NOT USED FUEL INJECTOR #1 FUEL INJECTOR #2 FUEL INJECTOR #3 FUEL INJECTOR #4 VREF DRY FUEL MODULATOR NOT USED NOT USED POWER GROUND POWER GROUND POWER GROUND POWER GROUND NOT USED NOT USED NOT USED NOT USED DATA LINK DRIVE BY WIRE AUXILLARY INPUT SELF TEST INPUT GOVERNOR SELECT #1 GOVERNOR SELECT #2 MALFUNCTION INDICATOR LAMP FUEL SELECT DATA LINK CONNECTOR (+) DATA LINK CONNECTOR (-) FUEL PUMP RELAY CONTROL NOT USED NOT USED SINGLE RETURN NOT USED NOT USED NOT USED INTAKE AIR TEMP SENSOR MAP SENSOR INPUT ECT SENSOR NO USAGE STARTER LOCKOUT NOT USED IDLE AIR CONTROL DRY FUEL SENSOR OIL PRESSURE GROUND DRY FUEL LOCKOFF IGNITION COIL 2 HO2S SENSOR SIDE

MATING FACE SHOWN

A B C D E

FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2

T/Y TACH LEAD R/GN KEEP ALIVE PWR * Y KEEP ALIVE PWR * R/W WATER TEMP. SWITCH Y VPWR * PK/BK FUEL PUMP OUTPUT * VREF BK/W BATT. - * BK/W BATT. - * P DATA LINK DB/BK DRIVE BY WIRE SIGNAL INPUT GN/O AUXILARY INPUT W/P SELF TEST INPUT * T/LB GOV. SPD. CONT. * BK/Y GOV. SPD. CONT. PK/LG FAULT LT. * Y/BK FUEL SELECT * T/O DATA LINK CONNECTOR (+) PK/LB DATA LINK CONNECTOR (-) BL STARTER INPUT GY/R DRIVE BY WIRE SIGNAL RETURN R/LB STARTER OUTPUT GN/W OIL PRESSURE SWITCH NOTE: * SHOWS USED WIRES

2 1 8 16 9 5 31 34 42 22 14 37 18 24 25 6 7 11 3 15 33 13 26

11T/Y20 16AR/LG16 37BY18 39RW20 37Y12 787PK/BK16 351DBR/W20 570CBK/W12 570EBK/W12 107P20 151LB/BK20 198DG/O20 209W/P20 306T/LB20 307BK/Y20 658PK/LG20 674Y/BK20 914T/O20 915PK/LB20 32ADKBL16 359LG/Y20 32R/LB16 253DG/W20

555T18 556W18 557BR/Y18 558BR/LB18 351BR/W18 77DB/Y18 570BK/W18 570ABK/W18 570BBK/W18 570HBK/W18

F G H J K 1 2 3

107P20 151LB/BK20 198DG/O20 209W/P20 306T/LB20 307BK/Y20 658PK/LG20 674BR/W20 914T/O20 915PK/LB20 926ALB/O16 359FGY/R20

3 L M N P R

S T W X Y

42

743GY20 358LG/BK20 354LG/R18 342LG/P16 264W/LB18 225BK/Y20 253BDG/W20 57BK18 242DG18 96T/O18 74GY/LB18

MATING FACE SHOWN

34
354LG/R18 359DGY/Y20 74GY/LB18 89AO18 570NBK/W18 34LB/O18 658PK/LG20 570BK/W20 107P20 915PK/LB20 914T/O20 209W/P20 349DB18 350GY18 282DB/O18 359AGY/R18 361NR18 77DB/Y18 225BK/Y20 359MGY/Y20 743GY20 359JGY/R18 253ADG/W20 96T/O18 16CR/LG16 95AT/W18 351CBR/W20 358LG/BK20 359KGY/Y20 57BK18 361PR18 242DG18

MATING FACE SHOWN

7
NOTES: 1. WIRES ARE LABELED WITH FORD CIRCUIT NUMBER, COLOR, AND WIRE GUAGE EXAMPLE: 74GY/LB18 MEANS CIRCUIT 74, GREY WIRE WITH LIGHT BLUE STRIPE, 18 GUAGE WIRE 2. INTERNAL SPLICES ARE NOT SHOWN

OIL PRESSURE SWITCH (NC) HEATED OXYGEN SENSOR (HO2S) G COIL CRANKSHAFT POSITION SENSOR (CKP) IGNITION SYSTEM

30

CR4 (LOCATED INSIDE THE GROUND CONTROL BOX)

DIAGNOSTIC CONNECTOR

ENGINE COOLANT TEMPERATURE SENSOR (ECT)

87

87A

MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)

LPG LOCKOUT RELAY AND VALVE

INTAKE AIR TEMPERATURE SENSOR (IAT) CAMSHAFT POSITION SENSOR (CMP)

86

85

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6-8

First Edition Second Printing

Section 6 Schematics

Ford LRG-425 EFI Engine Wire Harness (after serial number 13908)

ORG/BLK

WHT

WHT

RED RED

SELECTOR

TS50

BRN

OPTION

LIFT/DRIVE SELECTOR OPTION (REQUIRED CE MODELS)

LIFT/ DRIVE

BLK/RED-1
ENGINE SPEED TP35

TS4

LOW RPM FOOTSW. H/L HIGH RPM


TS54

LOW RPM HIGH RPM BRN/BLU


TB35
FUNCTION ENABLE

TS47

OFF GENERATOR ON GRN/WHT-1


TP45 TB45

GRN/WHT#45-E.H.#1 GENERATOR OPTION

TS3

TP39

BLU/RED-1

LP GAS
TS53

FUEL

LP
1

TB39

FB

RED/WHT#23-E.H.#1 FLASHING BEACON OPTION

TP38

L3

GAS HOUR METER BLU/WHT-1


L2

HM

FUEL WHT#21

CHECK ENGINE BLU/WHT#38 LED


TB38

CHECK ENGINE

1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

CHECK ENGINE

TP33

RUN/TEST SWITCH TEST TEST RUN

TS2

BLK-1
TS52 TS64

START START
TB33

ENGINE ENGINE BLK

CR2

POWER RELAY

PINK/LG FEH(658) PIN6


TB21 TB25

WT/PUR FEH(209) PIN18 RD/LG FEH(16A) PIN1 BR/WT FEH(674) PIN7 BRN/BLU FEH(253) PIN24 Y FEH(37B) PIN8 Y FEH(37) PIN9 (GND) BLK/WT FEH(570C) PIN34 (GND) BLK/WT FEH(570E) PIN42

CR1

FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2

CR2 NO

First Edition Second Printing

IGNITION./START RELAY

BLK#R1-E.H.#1
WHT WHT RED CR1 NO

STARTER MOTOR

TP25

TP21

TS51

RED

RED-1

TP24

PR1

AUXILIARY PUMP RED

TP27

AUXILIARY PUMP

TB27

TS1

RED#27-C.H.

AUXILIARY POWER RELAY


AUX PUMP

RED

AUXILIARY PUMP
PR1 TB28 NO

FS1 BLK

TP28

WHT WHT-2

RED/BLK-1

RED/BLK#28-C.H. RED/WHT#23-C.H.
TB23

TILT ALARM LEVEL SENSOR

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

BLK

BLK
TB22

BLK/RED-3

BLK/RED#9
CR5

TP22

HORN RELAY BLK/RED#R5-C.H.


CR5 NO

BLK-2

HORN
GRND

WHT#21-E.H.#1
TP41 TB41

RED-E.H.#1 ORG/BLK-1
RED

500 ORG/BLK#41-C.H.
RED STA. A S I

Section 6 Schematics

ALTERNATOR

15AMP.

15AMP.

CB1

CB2

FUSE

TB20

RED

RED#20-C.H.

LINK

GRD.

BAT.

REGULATOR

FLD.

12 V DC

6-9 1 2 3 4 5 6 7 8

Genie Z-45/25 & Genie Z-45/25J


BLK P3 HORN TP23 P1 RED KS1 PLAT TP9 TB9 +

P2

TP26

Part No. 52709


STARTER

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

First Edition Second Printing

BRN-2

GROUND

TP13

TB13

L1

NCHO

BLU/RED-3
BLU/RED#13-C.H.
BRN

LS4

TP30

WHT-1
WHT#30-C.H.

TB30

ORG/RED#16-C.H.

DRIVE ENABLE LIMIT SWITCH

TS15

NOHC

TB16

TP31 TP16

WHT#12-C.H.

DRIVE ENABLE
ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1

WHT/BLK#31-C.H.

DRIVE EDC

TP32

TB32

WHT/RED-1
WHT/RED#32-C.H.

BRAKE RELEASE VALVE

TRAVEL ALARM OPTION

BLU/BLK-1
BLU/BLK#37-M.H.

STEER RIGHT

BLU-1
BLU#36-M.H.

STEER LEFT

RED/WHT-1
MOTOR STROKE

RED/WHT#29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

R3

RED

BLK
100

CE MODELS ONLY

R2

Section 6 Schematics

R1

50

WHT#40-6

LS1 NCHO

BRN-6

PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

CR12

TB40

LS3 NO

ORG-1

WHT#40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

WHT#40-5
BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TS13

BLK-3
BLK/WHT-3

EXTEND

TB7

RETRACT

BOOM

TP8

BLK#7-M.H.

EXTEND

BOOM EXTEND

TS63

RETRACT

BOOM

BLK/WHT#8-M.H.

BOOM RETRACT

TP6

WHT/RED-3 WHT/BLK-3

TP5

TP4

TB4

WHT-3

TB8

WHT#4-M.H.
WHT/BLK#5-M.H.

PWM A + X

TS62

LEFT

RIGHT TURNTABLE ROTATE

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

15

TB5

R4

WHT/RED#6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED#1-M.H.

TS61

UP PRIMARY DOWN BOOM

PRIMARY BOOM UP

TB2

RED/BLK#2-M.H.

PWM A + X

PRIMARY BOOM DOWN

10

TB3

TP1

R5

RED/WHT#3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3

TB10

BLU-3

TP10

BLU
UP SECONDARY DOWN BOOM

BLU#10-M.H.

SECONDARY BOOM UP
BLU/BLK#11-M.H.

PWM A + X

TS60

BLU/BLK

BP2

SECONDARYBOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT#12-M.H.

TP14

SECONDARY BOOM FLOW CONTROL

ORG-3

TS9

ORG/BLK-3

TS59

TB14

UP PLATFORM DOWN LEVEL

CR7 NC

TP15

ORG#14-M.H.
UP PLATFORM DOWN LEVEL

PLAT LEVEL UP

ORG/BLK#15-M.H.

PLAT LEVEL DOWN

TB15

PLATFORM LEVEL

CUTOUT (CE MODELS ONLY)

TP17

GRN-3
GRN/BLK-3

TS7

LEFT

TS57

TB17

RIGHT PLAT ROTATE

TP18

GRN#17-M.H.
LEFT RIGHT PLAT ROTATE

CR8 NC

PLATFORM ROTATE LEFT


GRN/BLK#18-M.H.

PLATFORM ROTATE RIGHT

TB18

DESCENT ALARM OPTION

ORG/BLK

RED

WHT

WHT

RED

BRN

BRN

Part No. 52709

TP40

1 2 3 HORSE- 4 POWER 5 LIMITER 6 BOARD 7 8 9

10

TP7

LS2 NO

Genie Z-45/25 & Genie Z-45/25J

TP37

DP1

RED

TP36

1 2 3 4 5 6 7 8

TP29

TB29

TB36

TB37

6 - 10

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Ford Models (before serial number 13099)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Ford Models (before serial number 13099)
A 1
GROUND CONTROL BOX
GROUND CONTROL SWITCH PANEL
STACKED CONTACTS
BLK-R1#86 ORG/BLK-41A

J
LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS59 TS60 TS61 TS62 TS63 TS64
CB1 CB2 HM R4 R5 L2 CR1 CR2
BLU/WHT #38

K
DESCRIPTION

KS1
1

START RELAY

BLK-33D

M.H.

3 4

START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT

RED-27B BRN-GRD. TST. SW. RED-20C

NO

TACHOMETER

EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH
PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH

NO

5 6
7

IGN./START
MODULE
WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS
PRI. BOOM UP PRI. BOOM DOWN PRI. BOOM F.C. TURN. ROT. R TURN. ROT. L TURN. ROT. F.C. BOOM EXTEND BOOM RETRACT HORN SEC. BOOM UP SEC. BOOM DN SEC. BOOM F.C. DRV. ENA. LT. SW. PLAT. LEVEL. UP PLAT. LEVEL DN. DRV. ENA. PLAT. ROT. L. PLAT. ROT. R. JIB VALVE 12V BATT. SUPPLY IGNITION PWR. PWR. TO PLAT.
KEYSWITCH PWR.

WHT-TST. SW.

CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER TURNTABLE ROTATE SPEED LIMITING RESISTOR, 15 OHMS BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
BRN TO H.M. BLK/RED-9 BLK-22 WHT-R2 RED-CB1
CR1 CR2

EXT#6
WHT-R2#86

8
9
10

P1 NC
NO

KS1
NO

AUXILIARY PUMP

SEC.#4

3
PRIM.#5

BASE TERMINATION BLOCK

B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
41
42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BLK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5
BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-S.P OG/BK-S.P WHT#12-C.H. GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P.

RED-M.H RED/BLK-M.H R/W-M.H WHT-M.H WHT/BLK-M.H W/R-M.H BLK-M.H BLK/WHT-M.H


BLK/RED-C.H BLU-M.H BLU/BLK-M.H BLU/WHT-M.H

RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3


BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3
RED-ISM#6 BLK-2 WHT-2

NC STOP

TS51

WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2

SPLICE

L2
1 2

TS53

BLU/RED #39 RED/WHT #3


RED/BLK #2 RED #1 BLK #7 BLK/WHT #8

CR4 CR5 CR7 CR8

HOUR METER

4
WHT/PRP EH2

CHECK ENGINE LIGHT

RED

FUEL SELECT

BL/RED#13-C.H.

ORG-M.H. OR/BK-M.H. ORG/RED-CH GRN-M.H GRN/BLK-M.H


RED-C.H.

3
BLU/WHT #12

TS61
PRIMARY BOOM UP/DOWN

TS63

2
BRN ISM5
RED-EXT.#6

R4

R5
TS52

PRIMARY BOOM EXTEND/ RETRACT

TS60

WHT #4
WHT/BLK #5
BLK-R1 TO ISM#1 BLK-R1 TO E.H.#1

CR5

CR4

WHT-E.H.#1
WHT-TEST SW
BLK-TEST SW

BLK 25B WHT 23B

RD/WT-C.H.

WHT-S.P. BLK-S.P. WHT-S.P.

TS62
BLK/RED #35

WHT/RED #6
TURNTABLE ROTATE

RED-R4
WHT-21 BLK/RED-R5 GREEN-R4 WHT-40 BLK-R4

RD/GRN-EH#1

1
RED-C.H. RD/BK-C.H. RD/WT-C.H. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1
BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1
CH+EH1

OIL PRESSURE SENDER WATER TEMP. SENDER RED-S.P. AUX. PWR. TILT ALARM 2WD/4WD (DRIVE RANGE) E.D.C. E.D.C. BRAKE START GLOW PLUG BK/RD-S.P. RPM STEER RIGHT STEER LEFT TEST LIGHT L.P. (FUEL SELECT) LIMIT SWITCH SIG.
PULSE PICKUP SPARE SPARE
SPARE GEN. OPTION

START SEC. BOOM


TS54

RED-ISM#4

CB1

CB2

WHT ISM7

RUN/TEST

WHT#30-C.H. WT/BK-C.H..
WT/RD-C.H. BLK-ISM#3 BR/BLU-EH2 BLU-M.H.

TS59
BLU #10 BLU/BLK #11 RED #20 RED-R1 RED TO EH2 BLK #33

HIGH/LOW RPM

GRN/WHT #19 GRN/BLK #18 GRN #17


PLAT. LEVEL

ORG
CR7 CR8

ORG/BLK

EH2
BRN-GRD.

BLK-S.P.

TS64
WHT#40-R7 WHT-PRIM.#5

TS57 PLATFORM
ROTATE
ORG #14 ORG/BLK #15
ORG/BLK-15 ORG-14
PLATFORM LEVEL CUTOUT (CE MODLES ONLY)

BU/BK-M.H. PK/GR-EH#2 BRN/WHT-EH2 OG/BK-C.H.


BLACK-SEC.#4

BU/WT-S.P. BU/RD-S.P. WHT-SEC.#4


WHT-EXT.#6 OG/BK-ISM#2

ORG/BLK-1
ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

GRN/WHT-C.H

GROUND STUD (-12 VOLTS)

7
RED-E.H.#1 GRN-E.H.#1 BLK-E.H.#1 BLK-E.H.#1 BLK/RED-E.H.#1 ORANGE-M.H. ORG/BLK-M.H. RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8

WIRE CONNECTION ABBREVIATION KEY:

EH#1 EH#2 C.H. M.H. S.P. R or CR ISM H.M.

ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

ENGINE HARNESS # 2, FORD EFI, 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 - 25D PNK/GRN #6 - 38D BRN/WHT #7 - 39D YEL (18GA) #8 - CB2 YEL (12GA) #9 - CB2 WHT/PRP #18 - TST SW BRN/BLU #26 - 35D

6 - 11

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25 Ford Models (before serial number 13099)
N M L K J I H G F E D C B A 1
PLATFORM CONTROL BOX
LABEL P2 P3 TS1 TS2 TS3 TS7 TS10 TS13 TS11 TS12 TS9 TS50 R1 R2 R3 L1 L3 BP1 BP2 CR12 H.P.L. H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PLATFORM LEVEL SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY HORSEPOWER LIMITER BOARD TILT ALARM

WHT-24

1 2 3 4 5 6 7 8 9 10

PLAT. LVL. DN. PLAT. LVL. UP DRV. ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

GEN. (OPTION) SPARE SPARE SPARE PULSE PICKUP LIMIT SWITCH L.P. ENGINE FAULT STEER RIGHT STEER LEFT RPM GLOW PLG. OPT. START BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PWR. PWR. TO F.S. PWR. (START) PWR. (CONT.) PWR. FRM PLAT. PWR. TO PLAT. OPTION WIRE

HORN RETRACT EXTEND SWING F.C. SWING RIGHT SWING LEFT PRIMARY F.C. PRIMARY DN. PRIMARY UP

SEC.BOOM UP

JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRV. ENA.

OG/BK-41

ORG-40

HORSEPOWER LIMITER BOARD

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

RED-10

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT

GRD. STUD
CR12 50 R1

RED/BLK-28
H1 + TILT ALARM

EFI RELAY

CABLE #3

CABLE #2

CABLE #1

110

F.S.

5
BLU/WHT-38 BLU-36 BRN TO GRD. WHT-24 TO H.P.L. WHT/BLK-31 BLU/RED-39 BLK-22 BLK-26 WHT-23 BLU/RED-13 ORG/RED-16 BLK/RED-35 RED-25 BLK-33 BLU/BLK-37 WHT/RED-32 WHT-30 BLK/RED-9 ORG-14
P3

NC

NO

NC

- X

BP1
NO

TS13

NC NO

L1

NO

TS1 AUXILIARY PUMP DRIVE SPEED

100

250

ORG/BLK-15
HORN

WHT/RED-6

RED/WHT-3

GRN/WHT-19

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

TURNTABLE ROTATE

WHT/BLK-5

PLATFORM LEVEL TS9

WHT-4

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7


R2 R3

RED/BLK-2 A

RED-1

BLK-7

BLK/WHT-8
PRIMARY BOOM EXTEND/ RETRACT

GRN-17

GRN/BLK-18

BLU/WHT-12 RED-27

GEN. OPT. SEC.BOOM BP2

+
- X
R

7
DRIVE

DRV.ENA TS15 NC L3 TS2 START TS4 HIGH/LOW RPM CHECK ENGINE TS3 FUEL SELECT EMERGENCY STOP P2 NC

TS14

HIGH/LOW (2WD/4WD)

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 12

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25 Ford Models (before serial number 13099)

Section 6 Schematics

First Edition Second Printing

Electrical Schematic, Z-45/25 Ford Models (from serial number 13099 to 16303)
A 1 B C D E
SEE NOTE 1

M
SEE NOTE 2

N
ORG/BLK

TP22

P2 BLK

TP26

BLK

FS1 BLK

RED

RED

TP25 TP21

RED WHT WHT TS50

WHT

WHT LIFT/ DRIVE SELECTOR OPTION

TP24

TS1
BLK-2 WHT START AUXILIARY POWER

TS2 CHECK ENGINE L3


GAS

TS3

TS47
OFF ON

TS4
LOW RPM FOOTSW. H/L HIGH RPM

LP

2
TP41 CB1 15AMP. RED P1 RED KS1 PLAT GRND

GENERATOR

P3 HORN
BLK

FUEL

ENGINE

TB22

TP9

TP23

TP28

TP27

TP33

TP38

TP39

TP45

ENGINE SPEED TP35 RED RED

WHT-2

BLU/WHT-1

BLU/RED-1

ORG/BLK-1

BLK/RED-3

RED/BLK-1

RED-1

BLK-1

GRN/WHT-1

BLK/RED-1

TS51
START AUXILIARY POWER

TS52

TS53

TS54
LOW RPM FUNCTION ENA. HIGH RPM

GAS

LP

RED

TB39

TB45

FUEL

ENGINE

BLK

TB28
RED

TB27

TB33

TB9 TB41 CB2

TB23

TB20
RED#20-C.H.

15AMP.

RED

CR1 NO

CR1

CR2 NO TB21

CR2

1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

RED/WHT#23-E.H.#1

TB35

TAN/BLU

5
WHT#21-E.H.#1 BLK#22 BLK/RED#9 RED/WHT#23-C.H. RED/BLK#28-C.H. RED#27-C.H. BLK#R1-E.H.#1 ORG/BLK#41-C.H. RED-E.H.#1

WHT#21

WHT

FUSE LINK

ALTERNATOR BAT. GRD. STA.

TS64
PK/BLK TEST TEST RUN

CHECK ENGINE
BLU/WHT#38

L2

GRN/WHT#45-E.H.#1

FB

CR5 CR5 NO
BLK/RED#R5-C.H.

PR1 NO
WHT

PR1

TB25

500 AMP

RED

6
12 V DC +

(GND) BLK/WT FEH(570C) PIN34

(GND) BLK/WT FEH(570E) PIN42

FLD. REGULATOR

PINK/BLK FEH(787) PIN5

PINK/LG FEH(658) PIN6

Y FEH(37) PIN9

Y FEH(37B) PIN8

TAN/BLU FEH(306) PIN24

YEL/BLK FEH(674) PIN7

RD/LG FEH(16A) PIN1

WT/PUR FEH(209) PIN18

TB38

A S I

FUEL PUMP

1 HM 2 BRN
FLASHING BEACON OPTION GENERATOR OPTION HOUR METER RUN/TEST SWITCH CHECK ENGINE LED CE MODELS) LIFT/DRIVE SELECTOR OPTION (REQUIRED FOR POWER RELAY

BLK

AUX PUMP

STARTER

BLK

8
NOTE:
1) The connection to TP24 is for units without generator option. 2) 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.

6 - 13

BRN HORN RELAY AUXILIARY POWER RELAY STARTER MOTOR LEVEL SENSOR TILT ALARM IGNITION/START RELAY FUEL PUMP

Genie Z-45/25 & Genie Z-45/25J

HORN

AUXILIARY PUMP

FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2

Part No. 52709

First Edition Second Printing

Electrical Schematic, Z-45/25 Ford Models (from serial number 13099 to 16303)

BRN-2

GROUND
TB13
NCHO

TP13

L1

BLU/RED-3
BLK-7
BRN-7

LS4

TP30

WHT-1
WHT-7

TB30

RED-7
NOHC

DRIVE ENABLE LIMIT SWITCH


TB16
WHT#12-C.H.

TS15

TP31 TP16

DRIVE ENABLE ORG/RED-3


TB31

DRIVE ENABLE SWITCH

WHT/BLK-1

WHT/BLK#31-C.H.

DRIVE EDC

TP32

BRAKE RELEASE VALVE

TRAVEL ALARM OPTION


TP37
TB37

BLU/BLK-1
BLU/BLK#37-M.H.

STEER RIGHT

BLU-1
BLU#36-M.H.

STEER LEFT

RED/WHT-1
MOTOR STROKE

RED/WHT#29-C.H.

HIGH (2WD)

TS14

LOW (4WD)
DRIVE RANGE (2WD/4WD)

RED
250

R3

RED

BLK
100

CE MODELS ONLY

R2

Section 6 Schematics

R1

50

WHT#40-6

LS1 NCHO

BRN-6

PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

CR12

TB40

LS3 NO

WHT#40-5
HORSEPOWER LIMITER BOARD

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TS13

BLK-3
BLK/WHT-3
TB7

EXTEND BOOM RETRACT

TP8

BLK#7-M.H.

EXTEND

BOOM EXTEND

TS63

RETRACT

BOOM

BLK/WHT#8-M.H.

BOOM RETRACT

TP6

WHT/RED-3 WHT/BLK-3
TB5

TP5

WHT-3
TP4

TB8

WHT/BLK#5-M.H.

PWM A + X

TS62

LEFT

RIGHT TURNTABLE ROTATE

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

R4 10

WHT#4-M.H.
TB4

WHT/RED#6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED#1-M.H.
TB2

UP

PRIMARY BOOM UP

TS61

DOWN

PRIMARY BOOM

RED/BLK#2-M.H.
TB3

PWM A + X

PRIMARY BOOM DOWN

TP1

RED/WHT#3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3
TB10

BLU-3
TP10

BLU
UP SECONDARY DOWN BOOM BLU/BLK

BLU#10-M.H.

SECONDARY BOOM UP

PWM A + X

TS60

BLU/BLK#11-M.H.
TB11 TB12

BP2

SECONDARY BOOM DOWN

BLU/WHT
TP14

BLU/WHT#12-M.H.
CR7 NC

SECONDARY BOOM FLOW CONTROL

ORG-3

TS9

ORG/BLK-3
TS59 TP15

TB14

UP PLATFORM DOWN LEVEL

ORG#14-M.H.
UP PLATFORM DOWN LEVEL

PLATFORM LEVEL UP

ORG/BLK#15-M.H.
TB15

PLATFORM LEVEL DOWN


PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

TP18

GRN/BLK-3

TS7

LEFT

GRN-3
TS57

TB18

RIGHT PLATFORM ROTATE

TP17

GRN/BLK#18-M.H.
LEFT RIGHT PLATFORM ROTATE

CR8 NC

PLATFORM ROTATE RIGHT


GRN#17-M.H.
TB17

PLATFORM ROTATE LEFT

DESCENT ALARM OPTION

ORG/BLK

WHT

WHT

RED

RED

BRN

BRN

Part No. 52709

ORG-1
TP40

WHT#40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

LS2

1 2 3 4 5 6 7 8 9 10

TP7

NO

Genie Z-45/25 & Genie Z-45/25J

WHT/RED-1
WHT/RED#32-C.H.

DP1

RED

TP36

1 2 3 4 5 6 7 8

TP29

TB29

TB36

TB32

6 - 14

First Edition Second Printing

Section 6 Schematics

Electrical Schematic, Z-45/25 Ford Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Ford Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Ford Models (from serial number 13099 to 16303)
A 1
BASE CONTROL BOX BASE CONTROL SWITCH PANEL
STACKED CONTACTS KS1
BLK-R1#86 ORG/BLK-41A

J
LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS59 TS60 TS61 TS62 TS63 TS64 CB1 CB2 HM R4 L2 CR1 CR2
BLU/WHT #38 BLU/RED #39

K
DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH

NO

1 2 3 4 5 6 7 8

START RELAY

NO

TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT

BLK-33D

M.H.

RED-27B BRN-GRD. TST. SW. RED-20C WHT-TST. SW.

P1

AUXILIARY PUMP TS51 KS1


NO NO

SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

IGN./START MODULE
WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS
PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER (UNUSED) ECM KEEP ALIVE POWER (UNUSED) AUXILIARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG BK/RD-S.P. HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) LIQUID PROPANE FUEL OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

NC NC STOP

EXT#6
WHT-R2#86

9 10

SEC.#4

3
PRIM.#5

BASE TERMINATION BLOCK

B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BLK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-S.P OG/BK-S.P WHT#12-C.H. GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P.

RED-M.H RED/BLK-M.H R/W-M.H WHT-M.H WHT/BLK-M.H W/R-M.H BLK-M.H BLK/WHT-M.H BLK/RED-C.H BLU-M.H BLU/BLK-M.H BLK-ENA. ORG-M.H. OR/BK-M.H RED-ENA. GRN-M.H GRN/BLK-M.H RED-C.H.

RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-ISM#6 BLK-2 WHT-2

WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2

SPLICE

L2 1 2

LED

CR4 CR5 CR7 CR8

RED/WHT #3

TS53 FUEL SELECT

RED/BLK #2 RED #1 BLK #7 BLK/WHT #8


BRN TO H.M. BLK/RED-9 BLK-22 WHT-R2 RED-CB1 CR1 BLK-R1 TO ISM#1 BLK-R1 TO E.H.#1 CR2 CR5 CR4

4
WHT/PRP EH2 2
BRN ISM5

HOUR METER 3
BLU/WHT #12

CHECK ENGINE TS61 TS60

TS63 PRI. BOOM UP/DOWN

PRIMARY BOOM EXTEND/ RETRACT

WHT #4 WHT/BLK #5

RED-EXT.#6

WHT-E.H.#1 WHT-TEST SW BLK-TEST SW RED-ISM#4

BLK 25B WHT 23B

RD/WT-C.H. RD/GRN-EH#1

WHT-S.P. BLK-S.P. WHT-S.P.

R4 TS52 SECONDARY BOOM TS62 TURNTABLE ROTATE

WHT/RED #6

RED-R4
WHT-21 BLK/RED-R5 GREEN-R4 WHT-40 BLK-R4

1
RED-C.H. RD/BK-C.H. RD/WT-C.H. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 CH+EH1 OG/BK-C.H. ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

RED-S.P.

BLK/RED #35

START

WHT ISM7

WHT-ENA. WT/BK-C.H.. WT/RD-C.H. BLK-ISM#3 BR/BLU-EH2 BLU-M.H.

TS54

CB1

CB2

PLATFORM LEVEL TS59 TS57 PLATFORM ROTATE

RUN/TEST

GRN/WHT #19 GRN/BLK #18 GRN #17

ORG CR7 CR8

ORG/BLK

EH2
BRN-GRD.

BLK-S.P.

TS64
WHT#40-R7 WHT-PRIM.#5

HIGH/LOW RPM
BLU #10 BLU/BLK #11 RED #20 RED-R1 RED TO EH2 BLK #33

ORG #14 ORG/BLK #15


ORG/BLK-15 ORG-14 PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

BU/BK-M.H. PK/GR-EH#2 YEL/BLK-EH2

BU/WT-S.P. BU/RD-S.P. WHT-SEC.#4 WHT-EXT.#6 OG/BK-ISM#2

GRN/WHT-C.H

GROUND STUD (-12 VOLTS)

7
RED-E.H.#1 GRN-E.H.#1 BLK-E.H.#1 BLK-E.H.#1 BLK/RED-E.H.#1 ORANGE-M.H. ORG/BLK-M.H. RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8

WIRE CONNECTION ABBREVIATION KEY:

EH#1 EH#2 C.H. M.H. S.P. R or CR ISM H.M.

ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

ENGINE HARNESS # 2, FORD EFI, 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 - 25D PNK/GRN #6 - 38D YEL/BLK #7 - 39D YEL (18GA) #8 - CB2 YEL (12GA) #9 - CB2 WHT/PRP #18 - TST SW TAN/BLU #24 - 35D

6 - 15

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25 Ford Models (from serial number 13099 to 16303)
N M L K J
PLATFORM CONTROL BOX
LABEL P2 P3 TS1 TS2 TS3 TS7 TS9 TS13 TS11 TS12 TS10 TS50 R1 R2 R3 L1 L3 BP1 BP2 CR12 H.P.L. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR ( FORD AND PERKINS ONLY ) LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY HORSEPOWER LIMITER BOARD TIME DELAY ( JIB ONLY ) TILT ALARM

A 1

WHT-24

1 2 3 4 5 6 7 8 9 10

PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH L.P. GAS (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

SEC. BOOM UP

(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

ORG-40 CR12 RED-10 WHT-24 GRD. STUD R1 50 RED-10 LIMITING RELAY CABLE #3

RED/BLK-28
H1 + TILT ALARM

CABLE #2

CABLE #1

110

F.S.

WHT-23

WHT/RED-32 WHT-30

BLK-22

BLK-26

RED/BLK-2

WHT-24 TO H.P.L.

BLU-36

BRN TO GRD.

BLU/RED-13

BLU/BLK-37

ORG-14
P3

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

GRN/WHT-19

RED-1

BLK/RED-35 RED-25

RED/WHT-3

WHT/BLK-31 BLU/RED-39

WHT/BLK-5

ORG/BLK-15

GRN-17

ORG/RED-16

BLU/WHT-38

NC

NO

L1

NC

- X

BP1 NO

- X

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS1 AUXILIARY PUMP DRIVE SPEED

TS13

NC NO

NO

100

250

BLK/RED-9

BLK-33

WHT-4

WHT/RED-6

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. SEC.BOOM BP2

+
- X
R
R2 R3 DRV.ENA TS15 L3 TS14 CHECK ENGINE TS2 START TS4 HIGH/LOW RPM

DRIVE DP1

PLATFORM LEVEL TS9

NC TS3 FUEL SELECT

NC

HORN

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 16

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25 Ford Models (from serial number 13099 to 16303)

WHT

WHT

BRN

ORG/BLK

RED

RED RED

CR13

RED

BRN
JIB CUTOUT RELAY (CR13) JIB VALVE RELAY (CR-14) JIB VALVES LIFT/DRIVE SELECTOR OPTION (REQUIRED FOR
CE MODELS)

JIB CUTOUT RELAY

SEE NOTE 2

JIB VALVE RELAY


JIB VALVES

SELECTOR

TS50

OPTION

LIFT/ DRIVE

CR14 NO

CR14

BLK/RED-1

ENGINE SPEED

TP35

TS4

HIGH RPM LOW RPM FOOTSW. H/L

TS54
LOW RPM FUNCTION HIGH RPM ENABLE

BRN/BLU

TS47

OFF GENERATOR ON

TB35

GRN/WHT-1

GRN/WHT#45-E.H.#1

TP45

GENERATOR OPTION

TB45

TS3

TP39

BLU/RED-1

LP GAS FUEL

TB39

TS53

WHT

LP GAS

FB

RED/WHT#23-E.H.#1

FLASHING BEACON OPTION

TP38

HM

FUEL

L3

WHT#21

3 1 2

HOUR METER

BLU/WHT-1

L2

CHECK ENGINE

CHECK ENGINE

BLU/WHT#38
LED

1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

CHECK ENGINE

TB38

TP33

RUN/TEST SWITCH
TEST TEST RUN

TS2

BLK-1

START
START ENGINE

TS52

TB33

BLK

TS64

ENGINE

CR2

POWER RELAY

PINK/LG FEH(658) PIN6

WT/PUR FEH(209) PIN18 RD/LG FEH(16A) PIN1 BR/WT FEH(674) PIN7 BRN/BLU FEH(253) PIN24 Y FEH(37B) PIN8 Y FEH(37) PIN9

(GND) BLK/WT FEH(570C) PIN34

(GND) BLK/WT FEH(570E) PIN42

CR1

FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2

TB21

CR2 NO

TB25

First Edition Second Printing

IGNITION/START RELAY

BLK#R1-E.H.#1

SEE NOTE 1

STARTER MOTOR

TP27

RED

RED-1

TP24

PR1

AUXILIARY PUMP

AUXILIARY PUMP

TB27

TS1

RED#27-C.H.

RED

AUXILIARY POWER RELAY


AUX PUMP

RED

AUXILIARY PUMP

PR1

FS1 BLK

TP28

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

WHT

RED/BLK-1

TB28

RED/BLK#28-C.H.

NO

TILT ALARM

WHT-2

RED/WHT#23-C.H.

BLK

LEVEL SENSOR

TP23

TP26

TB23

BLK

BLK/RED-3

BLK/RED#9

TP22

TB22

CR5

HORN RELAY
BLK#22

BLK-2

BLK/RED#R5-C.H.

HORN

WHT#21-E.H.#1

TP41

TB41

RED-E.H.#1
ORG/BLK-1

500
ORG/BLK#41-C.H.

RED

RED

STA.

Section 6 Schematics

ALTERNATOR

15AMP.

15AMP.

CB1

CB2

FUSE

TB20

RED

RED#20-C.H.

LINK

GRD.

BAT.

REGULATOR

FLD.

12 V DC

6 - 17 1 2 3 4 5 6 7 8

Genie Z-45/25 & Genie Z-45/25J


BLK

P3 HORN

P2

TP9

TB9

P1 RED

GRND

KS1 PLAT

CR5 NO

Part No. 52709


CR1 NO
STARTER

WHT WHT

RED

TP25

TP21

TS51

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

First Edition Second Printing

BRN-2

GROUND

TP30 TP13

TB13

L1

NCHO

BLU/RED-3
BLU/RED#13-C.H.
BRN

LS4

WHT-1
WHT#30-C.H.

TB30

ORG/RED#16-C.H.

DRIVE ENABLE LIMIT SWITCH

TS15

NOHC

TB16

TP31 TP16

WHT#12-C.H.

DRIVE ENABLE
ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1

WHT/BLK#31-C.H.

DRIVE EDC

TP32

WHT/RED-1
WHT/RED#32-C.H.

TB32

TRAVEL ALARM OPTION

BLU/BLK-1
BLU/BLK#37-M.H.

STEER RIGHT

BLU-1
BLU#36-M.H.

STEER LEFT

RED/WHT-1
RED/WHT#29-C.H.

HIGH (2WD)

MOTOR STROKE

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

RED

BLK
100

CE MODELS ONLY

R2

Section 6 Schematics

R1

50

WHT#40-6

LS1 NCHO

BRN-6

PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

CR12

TB40

LS3 NO

WHT#40-5
BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

BLK-3
BLK/WHT-3

EXTEND BOOM

TB7

RETRACT

TP8

BLK#7-M.H.

EXTEND

BOOM EXTEND

TS63

RETRACT

BOOM

BLK/WHT#8-M.H.

BOOM RETRACT

TP6

WHT/RED-3 WHT/BLK-3

TP5

TP4

TB4

WHT-3

TB8

WHT#4-M.H.
WHT/BLK#5-M.H.

PWM A + X

TS62

RIGHT TURNTABLE LEFT ROTATE

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

15

TB5

R4

WHT/RED#6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED#1-M.H.

TS61

DOWN

TB2

UP PRIMARY BOOM

PRIMARY BOOM UP

RED/BLK#2-M.H.

PWM A + X

PRIMARY BOOM DOWN

10

TB3

TP1

R5

RED/WHT#3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3

TB10

BLU-3

TP10

BLU
UP SECONDARY DOWN BOOM BLU/BLK

BLU#10-M.H.

SECONDARY BOOM UP

PWM A + X

TS60

BLU/BLK#11-M.H.

BP2

SECONDARY BOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT#12-M.H.

TP14

SECONDARY BOOM FLOW CONTROL

ORG-3

TS9

ORG/BLK-3

TS59

TB14

UP PLATFORM DOWN LEVEL

CR7 NC

TP15

ORG#14-M.H.
UP PLATFORM DOWN LEVEL

PLATFORM LEVEL UP

ORG/BLK#15-M.H.

PLATFORM LEVEL DOWN

TB15

PLATFORM LEVEL

CUTOUT (CE MODELS ONLY)

CR13 NC

TP17

GRN-3
GRN/BLK-3

UP

TS8

LEFT

TS58

TB17

JIB BOOM

TP18

GRN#17-M.H.
UP

CR8 NC

LEFT

JIB BOOM

PLATFORM ROTATE LEFT/ JIB BOOM UP


GRN/BLK#18-M.H.

TS57

TS7

LEFT

RIGHT PLAT ROTATE

RIGHT LEFT

PLAT ROTATE

TB18

PLATFORM ROTATE RIGHT/ JIB BOOM DOWN

CR9 NC

DESCENT ALARM OPTION

TP19

BRN

GRN/WHT-3

TB19

ORG/BLK

WHT

WHT

RED

RED

RED

CR9

TI

BRN

BRN

Part No. 52709

ORG-1

WHT#40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

TP40

1 2 3 HORSE- 4 POWER 5 LIMITER 6 BOARD 7 8 9

10

TS13

TP7

LS2 NO

Genie Z-45/25 & Genie Z-45/25J

BRAKE RELEASE VALVE

TP37

DP1

RED

TP36

1 2 3 4 5 6 7 8

R3

TP29

TB29

TB36

TB37

6 - 18

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Ford Models (before serial number 13099)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Ford Models (before serial number 13099)
A 1
GROUND CONTROL BOX

J
LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS58 TS59 TS60 TS61 TS62 TS63 TS64

K
DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH

GROUND CONTROL SWITCH PANEL


STACKED CONTACTS

BLK-R1#86 ORG/BLK-41A

KS1
1 2 3 4 5 6 7 8 START RELAY

BLK-33D

M.H.

START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT

RED-27B BRN-GRD. TST. SW. RED-20C WHT-TST. SW.

IGN./START MODULE

NO

TACHOMETER

NO

PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER TURNTABLE ROTATE SPEED LIMITING RESISTOR, 15 OHMS BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
BRN TO H.M. BLK/RED-9 BLK-22 WHT-R2 RED-CB1 CR1 CR2 CR5 CR4

EXT#6
WHT-R2#86

9 10

3
PRIM.#5

B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BLK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-S.P OG/BK-S.P WHT#12-C.H. GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P. PRI. BOOM UP PRI. BOOM DOWN PRI. BOOM F.C. TURN. ROT. R TURN. ROT. L TURN. ROT. F.C. BOOM EXTEND BOOM RETRACT HORN SEC. BOOM UP SEC. BOOM DN SEC. BOOM F.C. DRV. ENA. LT. SW. PLAT. LEVEL. UP PLAT. LEVEL DN. DRV. ENA. PLAT. ROT. L. PLAT. ROT. R. JIB VALVE 12V BATT. SUPPLY IGNITION PWR. PWR. TO PLAT. KEYSWITCH PWR.

NO

SEC.#4

BASE TERMINATION BLOCK


RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-ISM#6 BLK-2 WHT-2

WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS

P1 NC

KS1

AUXILIARY PUMP

NC STOP SPLICE

TS51

RED-M.H RED/BLK-M.H R/W-M.H WHT-M.H WHT/BLK-M.H W/R-M.H BLK-M.H BLK/WHT-M.H BLK/RED-C.H BLU-M.H BLU/BLK-M.H BLU/WHT-M.H BL/RED#13-C.H. ORG-M.H. OR/BK-M.H. ORG/RED-CH GRN-M.H GRN/BLK-M.H RED-C.H.

WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2

BLU/WHT #38

CB1 CB2 HM R4 R5 L2 CR1 CR2 CR4 CR5 CR7 CR8

RED

L2 1 2

NO

TS53
FUEL SELECT

BLU/RED #39 RED/WHT #3 RED/BLK #2 RED #1 BLK #7 BLK/WHT #8

HOUR METER 3
BLU/WHT #12

CHECK ENGINE LIGHT

WHT/PRP EH2

TS61

TS63 PRI. BOOM UP/DOWN

R4

R5
TS52

PRIMARY BOOM EXTEND/ RETRACT

TS60

WHT #4 WHT/BLK #5
BLK-R1 TO ISM#1 BLK-R1 TO E.H.#1

BRN ISM5

RED-EXT.#6

WHT-E.H.#1 WHT-TEST SW BLK-TEST SW RED-ISM#4

BLK 25B WHT 23B

RD/WT-C.H. RD/GRN-EH#1

WHT-S.P. BLK-S.P. WHT-S.P.

TS58

TS62

WHT/RED #6

BLK/RED #35
OIL PRESSURE SENDER WATER TEMP. SENDER RED-S.P. AUX. PWR. TILT ALARM 2WD/4WD (DRIVE RANGE) E.D.C. E.D.C. BRAKE START GLOW PLUG BK/RD-S.P. RPM STEER RIGHT STEER LEFT TEST LIGHT L.P. (FUEL SELECT) LIMIT SWITCH SIG. PULSE PICKUP SPARE SPARE SPARE GEN. OPTION

START SEC. BOOM TS54 CB1 CB2 TS59 JIB

TURNTABLE ROTATE

RED-R4
WHT-21 BLK/RED-R5 GREEN-R4 WHT-40 BLK-R4

1
RED-C.H. RD/BK-C.H. RD/WT-C.H. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 CH+EH1 OG/BK-C.H. BLACK-SEC.#4 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

WHT ISM7

WHT#30-C.H. WT/BK-C.H.. WT/RD-C.H. BLK-ISM#3 BR/BLU-EH2 BLU-M.H.

BLU #10 BLU/BLK #11 RED #20 RED-R1 RED TO EH2 BLK #33

HIGH/LOW RPM PLAT. LEVEL TS57 PLATFORM ROTATE

GRN/WHT #19 GRN/BLK #18 GRN #17

ORG CR7 CR8

ORG/BLK

EH2

BLK-S.P.

BRN-GRD.

WHT#40-R7 WHT-PRIM.#5

ORG #14 ORG/BLK #15


ORG/BLK-15 ORG-14 PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

BU/BK-M.H. PK/GR-EH#2 BRN/WHT-EH2

BU/WT-S.P. BU/RD-S.P. WHT-SEC.#4 WHT-EXT.#6 OG/BK-ISM#2

GRN/WHT-C.H

GROUND STUD (-12 VOLTS)

RED-E.H.#1 GRN-E.H.#1 BLK-E.H.#1 BLK-E.H.#1 BLK/RED-E.H.#1 ORANGE-M.H. ORG/BLK-M.H.

RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8

WIRE CONNECTION ABBREVIATION KEY:

ENGINE HARNESS # 2, FORD EFI, 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 - 25D PNK/GRN #6 - 38D BRN/WHT #7 - 39D YEL (18GA) #8 - CB2 YEL (12GA) #9 - CB2 WHT/PRP #18 - TST SW BRN/BLU #26 - 35D

EH#1 EH#2 C.H. M.H. S.P. R or CR ISM H.M.

ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

6 - 19

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25J Ford Models (before serial number 13099)
N M L K J I H G F E D C B A 1
LABEL P2 P3 TS1 TS2 TS3 TS7 TS8 TS9 TS13 TS11 TS12 TS10 TS50 R1 R2 R3 L1 L3 BP1 BP2 CR12 CR13 CR14 H.P.L. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM

PLATFORM CONTROL BOX

WHT-24
1 2 3 4 5 6 7 8 9 10 PLAT. LVL. DN. PLAT. LVL. UP DRV. ENA. LT. SEC. BOOM F.C. SEC. BOOM DN. GEN. (OPTION) SPARE SPARE SPARE PULSE PICKUP LIMIT SWITCH L.P. ENGINE FAULT STEER RIGHT STEER LEFT RPM GLOW PLG. OPT. START BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PWR. PWR. TO F.S. PWR. (START) PWR. (CONT.) PWR. FRM PLAT. PWR. TO PLAT. OPTION WIRE HORN RETRACT EXTEND SWING F.C. SWING RIGHT SWING LEFT PRIMARY F.C. PRIMARY DN. PRIMARY UP SEC.BOOM UP JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRV. ENA.

OG/BK-41

ORG-40

HORSEPOWER LIMITER BOARD

RED FROM CR14

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

RED-10

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

GRD. STUD
CR12 50 R1
RED/BLK-28

EFI RELAY
WHT JIB CABLE

BLK JIB CABLE CABLE #2 CABLE #1 110 JIB CABLE F.S.

H1 + TILT _ ALARM

CABLE #3

5
RED-1 WHT-23 RED TO STOP SW RED TILT AL. RED TIM.DEL. WHT/RED-32 WHT-30 RED JUMP BLK-22 BLK-26 WHT-24 TO H.P.L. RED TO JIB CABLE BLU-36 BRN TO GRD. BLU/RED-13 BLU/BLK-37 ORG-14 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 RED-10 TO H.P.L. BLU-10 BLU/BLK-11 RED/WHT-29 GRN/WHT-19 BLK/RED-35 RED-25 WHT/BLK-31 BLU/RED-39 WHT/BLK-5 ORG/BLK-15 GRN-17 ORG/RED-16 BLU/WHT-38 BLK/RED-9 BLK-33 WHT-4 RED/BLK-2 WHT/RED-6 RED/WHT-3

NC
R

NO
A + -

NC
X

BP1
X

TS13
NO

JIB VALVE RELAY NC NO

A + -

A + -

JIB CUTOUT RELAY

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. SEC.BOOM BP2


R

CR13

CR14

L1

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 JIB


R2 R3

GRN/WHT + RED OUTPUT BRN DRIVE TIME DELAY T1

PLATFORM LEVEL P3 NO TS9

TS8 TS1 AUXILIARY PUMP DRIVE SPEED


100 250

DRV.ENA TS15 NC L3 TS2 START TS4 HIGH/LOW RPM CHECK ENGINE TS3 FUEL SELECT EMERGENCY STOP P2 NC

HORN

TS14

HIGH/LOW (2WD/4WD)

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 20

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25J Ford Models (before serial number 13099)

Section 6 Schematics

First Edition Second Printing

Electrical Schematic, Z-45/25J Ford Models (from serial number 13099 to 16303)
A 1
TP22

E
SEE NOTE 1

M
SEE NOTE 2

N
ORG/BLK

P2 BLK

TP26

BLK

FS1 BLK

RED

RED

TP25 TP21

RED WHT WHT TS50 LIFT/ DRIVE

WHT BRN WHT

TP24

TS1

TS2 CHECK ENGINE L3

TS3

TS47

TS4

SELECTOR OPTION CR13

JIB VALVES

JIB CUTOUT RELAY

JIB VALVE RELAY

BLK-2

WHT

OFF

START

ON

HIGH RPM LOW RPM FOOTSW. H/L

AUXILIARY PUMP

GAS

2
TP41 CB1 15AMP. RED P1 RED KS1 PLAT GRND

LP

RED

P3 HORN

FUEL

GENERATOR

ENGINE

RED

BLK
TB22 TP9 TP23 TP28 TP27

TP33

TP38

TP39

TP45

ENGINE SPEED TP35

CR14 NO CR14

RED RED

WHT-2

BLU/WHT-1

ORG/BLK-1

BLK/RED-3

RED/BLK-1

RED-1

BLK-1

GRN/WHT-1

BLK/RED-1

BLU/RED-1

TS51

TS52

TS53

TS54

LOW RPM FUNCTION HIGH RPM ENABLE

START

AUXILIARY PUMP
TB27

GAS

LP

RED

TB39

TB45

FUEL

ENGINE

TB28

TB33

BLK

RED
CB2 TB20 15AMP. RED

TB9 TB41

TB23

CR1 NO

CR1

CR2 NO TB21

CR2

1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

TB35

RED/WHT#23-E.H.#1

RED#20-C.H.

TAN/BLU

5
ORG/BLK#41-C.H. WHT#21-E.H.#1 BLK#22 BLK/RED#9 RED/WHT#23-C.H. RED/BLK#28-C.H. RED#27-C.H. BLK#R1-E.H.#1 RED-E.H.#1
FUSE LINK ALTERNATOR BAT. GRD. STA.

WHT#21

WHT

TS64

CHECK ENGINE

L2

GRN/WHT#45-E.H.#1

FB

BLU/WHT#38

PK/BLK

TEST TEST RUN

CR5 CR5 NO

PR1 NO

PR1

TB25

500

RED

WHT

BLK/RED#R5-C.H.

(GND) BLK/WT FEH(570C) PIN34

(GND) BLK/WT FEH(570E) PIN42

6
12 V DC +

FLD. REGULATOR A S I

Y FEH(37) PIN9

Y FEH(37B) PIN8

YEL/BLK FEH(674) PIN7

RD/LG FEH(16A) PIN1

WT/PUR FEH(209) PIN18

PINK/BLK FEH(787) PIN5

TAN/BLU FEH(306) PIN24

PINK/LG FEH(658) PIN6

TB38

FUEL PUMP

1 HM 2 BRN 3

BLK

AUX PUMP

STARTER

BLK

8
NOTE:
1) The connection to TP24 is for units without generator option. 2) 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.

6 - 21

BRN STARTER MOTOR AUXILIARY POWER RELAY

LED

FLASHING BEACON OPTION

RUN/TEST SWITCH

HOUR METER

HORN RELAY

TILT ALARM

IGNITION/START RELAY

FUEL PUMP

Genie Z-45/25 & Genie Z-45/25J

HORN

LEVEL SENSOR

CHECK ENGINE

GENERATOR OPTION

OPTION (REQUIRED FOR

JIB BOOM VALVE RELAY (CR-14)

CE MODELS)

LIFT/DRIVE SELECTOR

JIB BOOM CUTOUT RELAY (CR13)

JIB BOOM VALVES

POWER RELAY

AUXILIARY PUMP

FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2

Part No. 52709

First Edition Second Printing

Electrical Schematic, Z-45/25J Ford Models (from serial number 13099 to 16303)

BRN-2

GROUND
TB13
NCHO

TP13

L1

BLU/RED-3
BLK-7
BRN-7

LS4

TP30

WHT-1
WHT-7

TB30

RED-7
NOHC

DRIVE ENABLE LIMIT SWITCH


TB16
WHT#12-C.H.

TS15

TP31 TP16

DRIVE ENABLE ORG/RED-3


TB31

DRIVE ENABLE SWITCH

WHT/BLK-1

WHT/BLK#31-C.H.

DRIVE EDC

TP32

TB32

WHT/RED-1
WHT/RED#32-C.H.

BRAKE RELEASE VALVE

TRAVEL ALARM OPTION


TP37
TB37

BLU/BLK-1
BLU/BLK#37-M.H.

STEER RIGHT

BLU-1
BLU#36-M.H.

STEER LEFT

RED/WHT-1
MOTOR STROKE

RED/WHT#29-C.H.

HIGH (2WD)

TS14

LOW (4WD)
DRIVE RANGE (2WD/4WD)

RED

RED

BLK
100

CE MODELS ONLY

250
R2

R3

Section 6 Schematics

R1

50

WHT#40-6

LS1 NCHO

BRN-6

PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

CR12

TB40

LS3 NO

WHT#40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TS13

BLK-3
BLK/WHT-3
TB7

EXTEND BOOM RETRACT

TP8

BLK#7-M.H.

EXTEND

BOOM EXTEND

TS63

RETRACT

BOOM

BLK/WHT#8-M.H.

BOOM RETRACT

TP6

WHT/RED-3 WHT/BLK-3
TB5

TP5

WHT-3
TP4

TB8

WHT/BLK#5-M.H.

PWM A + X

TS62

LEFT

RIGHT TURNTABLE ROTATE

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

R4

WHT#4-M.H.
TB4

10

WHT/RED#6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED#1-M.H.
TB2

TS61

UP PRIMARY DOWN BOOM

PRIMARY BOOM UP

RED/BLK#2-M.H.
TB3

PWM A + X

PRIMARY BOOM DOWN

RED/WHT#3-M.H.

TP1

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3
TB10

BLU-3
TP10

BLU
UP SECONDARY DOWN BOOM BLU/BLK

BLU#10-M.H.

SECONDARY BOOM UP

PWM A

TS60

BLU/BLK#11-M.H.
TB11 TB12

BP2

SECONDARY BOOM DOWN

BLU/WHT
TP14

BLU/WHT#12-M.H.
CR7 NC

SECONDARY BOOM FLOW CONTROL

ORG-3

UP

TS9

DOWN

ORG/BLK-3
TP15 TS59

TB14

PLATFORM LEVEL

ORG#14-M.H.
UP PLATFORM DOWN LEVEL

PLATFORM LEVEL UP

ORG/BLK#15-M.H.
TB15

PLATFORM LEVEL DOWN


PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

CR13 NC

TP18

GRN/BLK-3

TS8

UP

GRN-3
TS58

TB18

DOWN JIB BOOM

TP17

GRN/BLK#18-M.H.
DOWN UP JIB BOOM

CR8 NC

PLATFORM ROTATE RIGHT / JIB DOWN


GRN#17-M.H.
TS57
TB17

PLATFORM ROTATE LEFT / JIB UP

TS7

LEFT

RIGHT PLAT ROTATE

RIGHT LEFT

PLAT ROTATE

CR9 NC

TP19

DESCENT ALARM OPTION


GRN/WHT-3
TB19
+

BRN

ORG/BLK

WHT

WHT

RED

RED

RED

CR9

TI

BRN

BRN

Part No. 52709

ORG-1
TP40

WHT#40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

LS2

1 2 3 HORSE- 4 POWER 5 LIMITER 6 BOARD 7 8 9 10

TP7

NO

Genie Z-45/25 & Genie Z-45/25J

DP1

RED

TP36

1 2 3 4 5 6 7 8

TP29

TB29

TB36

6 - 22

First Edition Second Printing

Section 6 Schematics

Electrical Schematic, Z-45/25J Ford Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Ford Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Ford Models (from serial number 13099 to 16303)
A 1
GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL
STACKED CONTACTS KS1
BLK-R1#86 ORG/BLK-41A

J
LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS58 TS59 TS60 TS61 TS62 TS63 TS64 CB1 CB2 HM R4 L2 CR1 CR2

K
DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH

2 3 4 5 6 7 8

TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT

NO

START RELAY

NO

BLK-33D

M.H.

RED-27B BRN-GRD. TST. SW. RED-20C WHT-TST. SW.

P1

AUXILIARY PUMP TS51 KS1


NO NO

IGN./START MODULE

SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY SERVICE HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
BRN TO H.M. BLK/RED-9 BLK-22 WHT-R2 RED-CB1 CR1 CR2 CR5 CR4

NC NC
WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS

EXT#6
WHT-R2#86

STOP

9 10

SEC.#4

3
PRIM.#5

BASE TERMINATION BLOCK

B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BLK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-S.P OG/BK-S.P WHT#12-C.H. GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P. PRIMARY BOOM UP

RED-M.H RED/BLK-M.H R/W-M.H WHT-M.H WHT/BLK-M.H W/R-M.H BLK-M.H BLK/WHT-M.H BLK/RED-C.H BLU-M.H BLU/BLK-M.H BLK-ENA. ORG-M.H. OR/BK-M.H RED-ENA. GRN-M.H GRN/BLK-M.H RED-C.H.

RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-ISM#6 BLK-2 WHT-2

4
WHT/PRP EH2 2
BRN ISM5

RED-EXT.#6

WHT-E.H.#1 WHT-TEST SW BLK-TEST SW RED-ISM#4

BLK 25B WHT 23B

RD/WT-C.H. RD/GRN-EH#1

WHT-S.P. BLK-S.P. WHT-S.P.

PRIMARY BOOM DOWN PRIMARY BOOM FUNTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER (UNUSED) ECM KEEP ALIVE POWER (SPARE) AUXILIARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG BK/RD-S.P. HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) LIQUID PROPANE FUEL OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2

SPLICE
BLU/WHT #38 BLU/RED #39

L2 1 2

LED

RED/WHT #3

CR4 CR5 CR7 CR8

TS53 FUEL SELECT

RED/BLK #2 RED #1 BLK #7 BLK/WHT #8

HOUR METER 3
BLU/WHT #12

CHECK ENGINE TS61 TS60

TS63 PRI. BOOM UP/DOWN TS58

PRIMARY BOOM EXTEND/ RETRACT

WHT #4 WHT/BLK #5 WHT/RED #6


BLK-R1 TO ISM#1 BLK-R1 TO E.H.#1

R4 TS52 SECONDARY BOOM

TS62

TURNTABLE ROTATE JIB


WHT-40

RED-R4
WHT-21 BLK/RED-R5 GREEN-R4 BLK-R4

1
RED-C.H. RD/BK-C.H. RD/WT-C.H. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 CH+EH1 OG/BK-C.H. ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

RED-S.P.

BLK/RED #35

START

WHT ISM7

WHT-ENA. WT/BK-C.H.. WT/RD-C.H. BLK-ISM#3 BR/BLU-EH2 BLU-M.H.

TS54

CB1

CB2 TS59 TS57 PLATFORM PLAT. LEVEL ROTATE

GRN/WHT #19 GRN/BLK #18 GRN #17

ORG CR7 CR8

ORG/BLK

RUN/TEST

EH2
BRN-GRD.

BLK-S.P.

TS64
WHT#40-R7 WHT-PRIM.#5

HIGH/LOW RPM
BLU #10 BLU/BLK #11 RED #20 RED-R1 RED TO EH2 BLK #33

ORG #14 ORG/BLK #15


ORG/BLK-15 ORG-14 PLATFORM LEVEL CUTOUT (CE VERSION ONLY)

BU/BK-M.H. PK/GR-EH#2 YEL/BLK-EH2

BU/WT-S.P. BU/RD-S.P. WHT-SEC.#4 WHT-EXT.#6 OG/BK-ISM#2

GRN/WHT-C.H

GROUND STUD (-12 VOLTS)

7
RED-E.H.#1 GRN-E.H.#1 BLK-E.H.#1 BLK-E.H.#1 BLK/RED-E.H.#1 ORANGE-M.H. ORG/BLK-M.H. RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8

WIRE CONNECTION ABBREVIATION KEY:

EH#1 EH#2 C.H. M.H. S.P. R or CR ISM H.M.

ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

ENGINE HARNESS # 2, FORD EFI, 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 - 25D PNK/GRN #6 - 38D YEL/BLK #7 - 39D YEL (18GA) #8 - CB2 YEL (12GA) #9 - CB2 WHT/PRP #18 - TST SW TAN/BLU #24 - 35D

6 - 23

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25J Ford Models (from serial number 13099 to 16303)
N M L K J
PLATFORM CONTROL BOX
LABEL P2 P3 TS1 TS2 TS3 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS50 R1 R2 R3 L1 L3 BP1 BP2 CR12 CR13 CR14 H.P.L. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH JIBBOOM UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN, TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM

A 1

WHT-24
1 2 3 4 5 6 7 8 9 10 GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH L.P. GAS (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.
(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

SEC. BOOM UP

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

RED FROM CR14

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

ORG-40

CR12
RED-10 WHT-24

GRD. STUD
R1 50 RED-10 LIMITING RELAY
RED/BLK-28

WHT JIB CABLE

BLK JIB CABLE CABLE #1 110 JIB CABLE F.S.

+ TILT _
ALARM

H1

CABLE #3

CABLE #2

WHT-23

RED TO STOP SW RED TILT AL. RED TIM.DEL.

WHT/RED-32 WHT-30

RED JUMP

BLK-22

BLK-26

RED/BLK-2

WHT-24 TO H.P.L.

RED TO JIB CABLE

BLU-36

BRN TO GRD.

BLU/RED-13

BLU/BLK-37

ORG-14

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

GRN/WHT-19

RED-1

BLK/RED-35 RED-25

RED/WHT-3

WHT/BLK-31 BLU/RED-39

WHT/BLK-5

ORG/BLK-15

GRN-17

ORG/RED-16

BLU/WHT-38

NC
R

NO
A

CR13

L1
JIB VALVE RELAY

NC
- X

BP1
NO

- X

TS13

NC NO

JIB CUTOUT RELAY

P3

NO

TS1 AUXILIARY PUMP DRIVE SPEED

100

250

BLK/RED-9

BLK-33

WHT-4

WHT/RED-6

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. SEC.BOOM BP2

CR14

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7

+
- X
R

GRN/WHT + RED OUTPUT BRN DRIVE TIME DELAY T1

PLATFORM LEVEL TS9

JIB

R2 R3

TS8

DRV.ENA TS15 NC L3 TS2 START TS4 HIGH/LOW RPM CHECK ENGINE TS3 FUEL SELECT EMERGENCY STOP P2 NC

HORN

TS14

HIGH/LOW (2WD/4WD)

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 24

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25J Ford Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

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


A 1 B C D E F G H I J K L M
ORG/BLK

LOAD SENSE OPTION (SEE DETAIL)


TP22
P2

BLK

TP26

FS1

RED-(FS)
WHT-(FS)

TP25
TP24

RED WHT

RED WHT

BLK-(FS)

WHT

TS1
WHT

TS2
CHECK ENGINE

TS3

TS47
OFF ON

TS4

L3
GAS LP

BLK-2

START

FOOTSW. H/L LOW RPM HIGH RPM

AUXILIARY PUMP

GENERATOR

2
TP41

P3 HORN
BLK

FUEL

ENGINE

CB1 15AMP. RED


P1 RED

KS1 PLAT GRND

TB22

TP9

TP23

TP28

TP27

TP33

TP38

TP39

TP45

ENGINE SPEED

TP35

RED RED

WHT-2

BLU/WHT-1

BLK/RED-1

GRN/WHT-1

BLK-1

BLU/RED-1

RED/BLK-1

RED-1

ORG/BLK-1

BLK/RED-3

TS51
START

TS52

TS53

TS54
LOW RPM FUNCTION HIGH RPM ENABLE

AUXILIARY PUMP RED

GAS

LP

TB39

TB45

FUEL

ENGINE

BLK

TB28

TB27

TB33

RED

TB9

TB41 CB2

TB23

TB20
RED#20-C.H.

15AMP.

RED

CR1 NO

CR1

CR2 NO

CR2

1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START MODULE 5 GROUND 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

TB35

RED/WHT-23-E.H.#1

TAN/BLU

TB21

5
FUSE LINK

ORG/BLK-41-C.H.

BLK-22

BLK-R1-E.H.#1

RED/BLK-28-C.H.

RED-27-C.H.

WHT-21-E.H.#1

BLK/RED-9

RED/WHT-23-C.H.

RED-E.H.#1

WHT

WHT-21

ALTERNATOR BAT. GRD.

TS64
PK/BLK

CHECK ENGINE
BLU/WHT-38

L2

GRN/WHT-45-E.H.#1

FB

TEST TEST RUN

CR5 CR5 NO
BLK/RED-R5-C.H.

PR1 NO
WHT RED

PR1

TB25

500

(GND) BLK/WT FEH(570C) PIN34

(GND) BLK/WT FEH(570E) PIN42

STA.

FLD.
12 V DC

TAN/BLU FEH(306) PIN24

PINK/LG FEH(658) PIN6

Y FEH(37) PIN9

Y FEH(37B) PIN8

YEL/BLK FEH(674) PIN7

RD/LG FEH(16A) PIN1

WT/PUR FEH(209) PIN18

REGULATOR +

TB38

PINK/BLK FEH(787) PIN5

A S I

PUMP

FUEL

AUX PUMP

STARTER

BLK

HM 2

BLK

7
LOAD SENSE OPTION
P2
BLK-26

TP22

6 - 25

BRN

BRN
CHECK ENGINE LED

STARTER MOTOR

FLASHING BEACON OPTION

FUEL PUMP

TILT ALARM

RUN/TEST SWITCH

AUXILIARY POWER RELAY

HOUR METER

IGNITION./START RELAY

HORN RELAY

HORN

LEVEL SENSOR

GENERATOR OPTION

POWER RELAY

AUXILIARY PUMP

FS1 BLK-(FS)

RED-(FS) WHT-(FS)
C B+

TP26

LOAD SENSOR BOX


GND 8

BLK-26 LOAD

WHT-LOAD

TP24

WHT-24

FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 (SEE PAGE 6)

Genie Z-45/25 & Genie Z-45/25J

ORG-LOAD

Part No. 52709

First Edition Second Printing

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

BRN-2 GROUND

TP13

TB13

L1

NCHO

BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1

TP30

TB30

LS4

TP31 TP16

WHT-12-C.H.

TS15

NOHC

TB16

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1 DRIVE EDC

WHT/BLK-31-C.H.

TP32

WHT/RED-1 WHT/RED-32-C.H.

TB32

TRAVEL ALARM OPTION

BLU/BLK-1 BLU/BLK-37-M.H. STEER RIGHT

BLU-1 BLU-36-M.H. STEER LEFT

RED/WHT-1
MOTOR STROKE

RED/WHT-29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

R3

RED

BLK
100

CE MODELS ONLY

R2

Section 6 Schematics

R1

50

WHT-40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

CR12

TB40

LS3 NO

LS1 NCHO

ORG-1

WHT-40-4 BRN-4

WHT-40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

BLK-3 BLK/WHT-3

EXTEND

TB7

RETRACT

BOOM

TP8

BLK-7-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT-8-M.H.

EXTEND

TS63

RETRACT

BOOM

TP6

WHT/RED-3 WHT/BLK-3

TP5

TP4

TB5

WHT-3 WHT/BLK-5-M.H. WHT#4-M.H. RIGHT

TB8

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

PWM A

TS62

LEFT

R4 10

TURNTABLE ROTATE

TB4

WHT/RED-6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED-1-M.H.

TS61

UP PRIMARY DOWN BOOM

PRIMARY BOOM UP PRIMARY BOOM DOWN

TB2

RED/BLK-2-M.H.

PWM A

TB3

RED/WHT-3-M.H.

TP1

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY)

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3

TP10

TB10

BLU-3 BLU UP SECONDARY DOWN BOOM BLU/BLK BLU-10-M.H.

SECONDARY BOOM UP

PWM A

TS60

BLU/BLK-11-M.H.

BP2

SECONDARY BOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT-12-M.H.

TP14

SECONDARY BOOM FLOW CONTROL

ORG-3 ORG/BLK-3

UP

TS9

DOWN

TS59

TB14

PLATFORM LEVEL

CR7 NC

TP15

ORG-14-M.H. UP PLATFORM LEVEL DOWN ORG/BLK-15-M.H.

PLATFORM LEVEL UP PLATFORM LEVEL DOWN

TB15

PLATFORM LEVEL

CUTOUT (CE MODELS ONLY)

WHT

TP18

GRN/BLK-3 GRN-3

RIGHT

TS7

LEFT

TS57

TB18

PLAT ROTATE

TP17

GRN/BLK-18-M.H. RIGHT LEFT PLAT ROTATE GRN-17-M.H.

CR8 NC

PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT

TB17

DESCENT ALARM OPTION

ORG/BLK

RED

BRN

WHT

RED

BRN

Part No. 52709

SECONDARY BOOM UP DRIVE LIMIT SWITCH

TP40

LS2

HORSEPOWER LIMITER BOARD

1 2 3 4 5 6 7 8 9 10

TS13

TP7

NO

Genie Z-45/25 & Genie Z-45/25J

BRAKE RELEASE VALVE

TP37

DP1

RED

TP36

1 2 3 4 5 6 7 8

TP29

TB29

TB36

TB37

6 - 26

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Ford Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Ford Models (after serial number 16303)
A 1
GROUND CONTROL BOX

LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS59 TS60 TS61 TS62 TS63 TS64 CB1 CB2 HM R4 L2 CR1 CR2
BLU/WHT-38 BLU/RED-39

DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

GROUND CONTROL SWITCH PANEL


STACKED CONTACTS
KS1
NO

2
M.H.

BLK-R1#86 ORG/BLK-41A BLK-33D RED-27B BRN-GRD. TST. SW. RED-20C WHT-TST. SW.

1 2 3 4 5 6 7 8

START RELAY

NO

TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT

P1

AUXILIARY PUMP TS51 KS1


NO NO

IGN./START MODULE
WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS
PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER (UNUSED) ECM KEEP ALIVE POWER (SPARE) AUXILIARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG BK/RD-S.P. HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) LIQUID PROPANE FUEL OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

NC NC STOP

EXT#6
WHT-R2#86

9 10

SEC.#4

3
PRIM.#5

BASE TERMINATION BLOCK

B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BLK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-S.P OG/BK-S.P WHT#12-C.H. GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P.

RED-M.H RED/BLK-M.H R/W-M.H WHT-M.H WHT/BLK-M.H W/R-M.H BLK-M.H BLK/WHT-M.H BLK/RED-C.H BLU-M.H BLU/BLK-M.H BLK-ENA. ORG-M.H. OR/BK-M.H RED-ENA. GRN-M.H GRN/BLK-M.H

RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-ISM#6 BLK-2 WHT-2

WHT-23 BLK-22 RED-27 BRN TO R4 BRN TO GRD WHT-21 WHT-21TO R2

SPLICE

L2 1 2

LED

CR4 CR5 CR7 CR8

RED/WHT-3

TS53
FUEL SELECT

RED/BLK-2 RED-1 BLK-7


BLK/RED-9 BLK-22 WHT-R2 RED-R1 BRN TO H.M.

HOUR METER 3
BLU/WHT-12

CHECK ENGINE TS61 TS60

WHT/PRP EH2

BLK/WHT-8

2
BRN ISM5

RED-C.H. RED-EXT.#6

PRIMARY BOOM EXTEND/ RETRACT PRIMARY BOOM UP/DOWN TS62

TS63

WHT-4 WHT/BLK-5
BLK-R1 TO ISM#1 BLK-R1 TO E.H.#1

CR1

CR2

CR5

CR4

WHT-E.H.#1 WHT-TEST SW BLK-TEST SW RED-ISM#4

BLK 25B WHT 23B

RD/WT-C.H.
RD/GRN-EH#1

WHT-S.P. BLK-S.P. WHT-S.P.

R4

TS52 SECONDARY BOOM

WHT/RED-6

TURNTABLE ROTATE
WHT-40

RED-R4
WHT-21 BLK/RED-R5 GREEN-R4 BLK-R4

5
RUN/TEST

1
RED-C.H. RD/BK-C.H. RD/WT-C.H. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 CH+EH1 OG/BK-C.H. ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

RED-S.P.

BLK/RED-35

START

WHT ISM7

GRN/WHT-19

WHT-ENA. WT/BK-C.H.. WT/RD-C.H. BLK-ISM#3 BR/BLU-EH2 BLU-M.H.

TS54

CB1

CB2 TS59 TS57 PLATFORM PLAT. LEVEL ROTATE

GRN/BLK-18 GRN-17

ORG

ORG/BLK

CR7

CR8

EH2
BRN-GRD.

BLK-S.P.
BLK/RED-35GEN

TS64
WHT#40-R7 WHT-PRIM.#5

HIGH/LOW RPM
BLU-10 BLU/BLK-11 RED-20 RED-R1 RED TO EH2 BLK-33

ORG-14 ORG/BLK-15
ORG/BLK-15 ORG-14

BU/BK-M.H. PK/GR-EH#2 YEL/BLK-EH2

BU/WT-S.P. BU/RD-S.P. WHT-SEC.#4 WHT-EXT.#6 OG/BK-ISM#2

PLATFORM LEVEL CUTOUT (CE VERSION ONLY)

GRN/WHT-C.H

BLK/RED-35GEN

GROUND STUD (-12 VOLTS)

RED-E.H.#1 GRN-E.H.#1 BLK-E.H.#1 BLK-E.H.#1 BLK/RED-E.H.#1 ORANGE-M.H. ORG/BLK-M.H.

RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8

WIRE CONNECTION ABBREVIATION KEY:

ENGINE HARNESS # 2, FORD EFI, 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 - 25D PNK/GRN #6 - 38D YEL/BLK #7 - 39D YEL (18GA) #8 - CB2 YEL (12GA) #9 - CB2 WHT/PRP #18 - TST SW TAN/BLU #24 - 35D

EH#1 EH#2 C.H. M.H. S.P. R or CR ISM H.M.

ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

6 - 27

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25 Ford Models (after serial number 16303)
N M L K J I H G F E D C B A

PLATFORM CONTROL BOX


COMPONENT INDEX
P2 P3 TS1 TS2 TS3 TS7 TS9 TS10 TS11 TS12 TS13 EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH

WHT-24

1 2 3 4 5 6 7 8 9 10

PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE (UNUSED)

PULSE PICKUP LIMIT SWITCH L.P. GAS (SPARE)

GEN. (OPTION) (SPARE) (SPARE) (SPARE)

STEER RIGHT STEER LEFT HIGH/LOW RPM

GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL.

SEC. BOOM UP HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

JIB VALVE

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT
GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

TS47 R1
R2 R3 L1 L3 BP1 BP2 CR12

GENERATOR SWITCH ( OPTION ) EFI RESISTOR


LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN ,TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1

ORG-40
CR12

RED-10 WHT-24
GRD. STUD

R1 50 RED-10 LIMITING RELAY


CABLE #3
CABLE #2 CABLE #1

RED/BLK-28

NC

NO

- X

BP1

- X

NO

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7

PLATFORM LEVEL

R2

R3

DRV.ENA TS15
NC

TS13

NC NO
SEE SIDE VIEW DP1

NC

L1

P3

NO

TS1
AUXILIARY PUMP

100

250

RED-TILT

DP1 H.P.L. H1
110

DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD


TILT ALARM

F.S.

+ TILT _
ALARM

H1

GRN/WHT-45

WHT-4

RED/BLK-2

ORG-14

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

BLU/RED-13

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

ORG/BLK-15

BLK/RED-35 RED-25

WHT/BLK-5

GRN/WHT-19

GRN-17

BLK/RED-9

RED/WHT-3

ORG/RED-16

WHT/RED-6

RED-1

BLU/WHT-38

BLK-33
GEN. OPT.

SIDE VIEW OF DP1


WHT TO PLATFORM ROTATE

BLU/BLK-37

WHT-30 WHT/BLK-31

BLU-36

WHT/RED-32

WHT-24 TO H.P.L.

BLK-26

BRN TO GRD.

BLU/RED-39

BLK-22

WHT-23

RED-TILT

PRIMARY BOOM EXTEND/ RETRACT

SEC.BOOM BP2

TS47

DP1 DRIVE

8 7 6 5 4 3 2 1

RED-GEN

+
- X R

7
NC

TS9 L3 DRIVE SPEED TS14 CHECK ENGINE TS2 START TS4


HIGH/LOW RPM

HORN

TS3
FUEL SELECT
EMERGENCY STOP P2

HIGH/LOW (2WD/4WD)

8
PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 28

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25 Ford Models (after serial number 16303)

BRN

WHT

ORG/BLK

RED

RED RED

CR13

RED

JIB CUTOUT RELAY JIB VALVE RELAY JIB BOOM VALVE RELAY (CR-14)

CR14

BRN
JIB BOOM CUTOUT RELAY (CR13) JIB BOOM VALVES BLK/RED-1

JIB VALVES

ENGINE SPEED

TP35

TS4

FOOTSW. H/L LOW RPM HIGH RPM

CR14 NO

TS54
LOW RPM FUNCTION ENA. HIGH RPM TAN/BLU

OFF GENERATOR GRN/WHT-1 GRN/WHT-45-E.H.#1 GENERATOR OPTION

WHT

RED

TS47

ON

TP45

TB45

TB35
RED/WHT-23-E.H.#1

TS3

TP39

BLU/RED-1

LP GAS FUEL

TB39

FLASHING BEACON OPTION

TS53

WHT LP GAS HOUR METER FUEL WHT-21

FB

TP38

BLU/WHT-1

L2

1 HM 3 2

L3

CHECK ENGINE BLU/WHT-38 LED

CHECK ENGINE

1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

CHECK ENGINE

TB38

TP33

RUN/TEST SWITCH TEST TEST RUN

TS2

BLK-1

START

TS52

START

ENGINE

TB33

BLK

TS64

ENGINE

CR2

POWER RELAY

PINK/LG FEH(658) PIN6

WT/PUR FEH(209) PIN18 RD/LG FEH(16A) PIN1 YEL/BLK FEH(674) PIN7 TAN/BLU FEH(306) PIN24 Y FEH(37B) PIN8 Y FEH(37) PIN9 (GND) BLK/WT FEH(570C) PIN34 (GND) BLK/WT FEH(570E) PIN42 PINK/BLK FEH(787) PIN5

CR1

PK/BLK

FUEL PUMP

BLK

First Edition Second Printing

IGNITION./START RELAY

BLK-R1-E.H.#1

STARTER MOTOR

TP25

TP24

TS51

WHT-(FS)

RED-(FS)

RED-1

PR1

AUXILIARY PUMP

TP27

AUXILIARY PUMP RED

TB27

TS1

RED-27-C.H.

AUXILIARY POWER RELAY

AUX PUMP

LOAD SENSE OPTION (SEE DETAIL)

AUXILIARY PUMP

PR1

TP28

FS1

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

WHT

RED/BLK-1 WHT-2

TB28

RED/BLK-28-C.H. RED/WHT-23-C.H.

NO

WHT RED BLK BRN

TILT ALARM LEVEL SENSOR

BLK-(FS)

TP23

TB23

BLK

BLK/RED-3

BLK/RED-9

CR5

BLK-2

BLK-22

BLK/RED-R5-C.H.

GRND

CR5 NO

P1 RED

LOAD SENSOR BOX

WHT-LOAD

KS1 PLAT

TP24

HORN

WHT-24

TP22

TB22

HORN RELAY

LOAD SENSE OPTION

WHT-21-E.H.#1

TP41

TB41

RED-(FS)

RED

WHT-(FS)

ORG/BLK-1

ORG/BLK-41-C.H.

RED

Section 6 Schematics

ALTERNATOR

REGULATOR

15AMP.

15AMP.

CB1

CB2

GRD.

FS1 BLK-(FS)

FLD.

BAT.

FUSE

TB20

LINK

RED

RED#20-C.H.

12 V DC

TP22

P2

BLK-26

TP26

BLK-26 LOAD

STA.

B+

RED-E.H.#1

500

GND

ORG-LOAD

6 - 29 1 2 3 4 5 6 7 8

Genie Z-45/25 & Genie Z-45/25J


P3 HORN TP9 TB9

P2

BLK

TP26

Part No. 52709


STARTER

FUEL PUMP

WHT

RED

CR1 NO

FORD 42 PIN QUICK DISCONNECT ENGINE HARNESS #2 (SEE PAGE 6)

TB21

CR2 NO

TB25

First Edition Second Printing

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

BRN-2 GROUND

TP13

TB13

L1

NCHO

BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1

TP30

TB30

LS4

TP31 TP16

WHT-12-C.H.

TS15

NOHC

TB16

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1 DRIVE EDC

WHT/BLK-31-C.H.

WHT/RED-1 WHT/RED-32-C.H. BRAKE RELEASE VALVE

TRAVEL ALARM OPTION

BLU/BLK-1 BLU/BLK-37-M.H. STEER RIGHT

BLU-1 BLU-36-M.H. STEER LEFT

RED/WHT-1 MOTOR STROKE

RED/WHT-29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

R3

RED

BLK 100

Section 6 Schematics

CE MODELS ONLY

R2

R1

50

WHT-40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

CR12

TB40

LS3 NO

LS1 NCHO

ORG-1

WHT-40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

WHT-40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TP7

BLK-3 BLK/WHT-3

EXTEND

TS13

TB7

RETRACT

BOOM

TP8

BLK-7-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT-8-M.H.

EXTEND

TS63

RETRACT

BOOM

TP6

WHT/RED-3 WHT/BLK-3

TP5

TB5

WHT-3

TB8

TP4

WHT/BLK-5-M.H. WHT#4-M.H.

PWM A + X

TS62

LEFT

RIGHT TURNTABLE ROTATE

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

R4 10

TB4

WHT/RED-6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED-1-M.H.

TS61

UP PRIMARY DOWN BOOM

PRIMARY BOOM UP PRIMARY BOOM DOWN

TB2

RED/BLK-2-M.H.

PWM A + X

TB3

TP1

RED/WHT-3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY)

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3

TB10

BLU-3

TP10

BLU UP DOWN SECONDARY BOOM BLU/BLK

BLU-10-M.H.

SECONDARY BOOM UP

PWM A + X

TS60

BLU/BLK-11-M.H.

BP2

SECONDARY BOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT-12-M.H.

TP14

SECONDARY BOOM FLOW CONTROL

ORG-3 ORG/BLK-3

TS9

TS59

TB14

UP PLATFORM DOWN LEVEL

CR7 NC

TP15

ORG-14-M.H. UP PLATFORM DOWN LEVEL ORG/BLK-15-M.H.

PLATFORM LEVEL UP PLATFORM LEVEL DOWN

TB15

PLATFORM LEVEL CUTOUT (CE

MODELS ONLY)

WHT

CR13 NC

TP18

GRN/BLK-3 GRN-3

TS8

TS58

TB18

DOWN JIB BOOM UP

TP17

GRN/BLK-18-M.H. DOWN UP JIB BOOM GRN-17-M.H.

CR8 NC

PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM ROTATE LEFT / JIB BOOM UP

TS57

WHT

TS7

RIGHTPLATFORM LEFT ROTATE

LEFT

RIGHT PLATFORM ROTATE

TB17

CR9 NC

TP19

DESCENT ALARM OPTION GRN/WHT-3

BRN
+

TB19

ORG/BLK

WHT

RED

RED

RED

CR9

TI

BRN

BRN

Part No. 52709

TP40

LS2

1 2 HORSE- 3 4 POWER 5 LIMITER 6 7 BOARD 8 9 10

NO

Genie Z-45/25 & Genie Z-45/25J

TP37

TP32

DP1

RED

TP36

1 2 3 4 5 6 7 8

TP29

TB29

TB36

TB37

TB32

6 - 30

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Ford Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Ford Models (after serial number 16303)
A 1
GROUND CONTROL BOX

J
LABEL P1 KS1 TS51 TS52 TS53 TS55 TS57 TS58 TS59 TS60

K
DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN

GROUND CONTROL SWITCH PANEL


STACKED CONTACTS
KS1

BLK-R1#86 ORG/BLK-41A

NO

1
2

START RELAY

NO

TACHOMETER

BLK-33D

M.H.

3 4
5 6

START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT

PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH

RED-27B BRN-GRD. TST. SW. RED-20C


WHT-TST. SW.

P1

AUXILIARY PUMP

IGN./START

NC NC
WIRING HARNESS: TO BASE CONTROL BOX CONNECTIONS

TS51

TS61 TS62

MODULE
KS1
NO NO

TS63 TS64
CB1 CB2 HM R4 L2 CR1 CR2

PRIMARY BOOM EXTEND/RETRACT SWITCH RUN/TEST SWITCH


CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS CHECK ENGINE LED IGNITION / START RELAY INGITION POWER RELAY LPG LOCKOUT RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)
BRN TO H.M. BLK/RED-9 BLK-22 WHT-R2 RED-R1

7
8

EXT#6
WHT-R2#86

STOP

SEC.#4

3
PRIM.#5

BASE TERMINATION BLOCK

10

B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BLK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P. BLU/WT-S.P. PRIMARY BOOM UP

RED-M.H RED/BLK-M.H R/W-M.H WHT-M.H WHT/BLK-M.H W/R-M.H BLK-M.H BLK/WHT-M.H

RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3

BLK/RED-C.H BLU-M.H BLU/BLK-M.H


BLK-ENA. ORG-M.H.

BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3

WHT/PRP EH2

OR/BK-M.H RED-ENA. GRN-M.H GRN/BLK-M.H RED-C.H.

ORG-S.P OG/BK-S.P WHT#12-C.H. GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P.

2
BRN ISM5
RED-EXT.#6

RED-ISM#6 BLK-2 WHT-2

WHT-E.H.#1

BLK 25B WHT 23B

RD/WT-C.H.
RD/GRN-EH#1

WHT-TEST SW

WHT-S.P. BLK-S.P. WHT-S.P.

PRIMARY BOOM DOWN PRIMARY BOOM FUNTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM

WHT-23 BLK-22 RED-27 BRN TO R4 BRN TO GRD WHT-21 WHT-21TO R2

SPLICE

BLU/WHT-38
BLU/RED-39

L2

LED

+
1 2

RED/WHT-3

TS53
FUEL SELECT

CR4 CR5 CR7 CR8

RED/BLK-2 RED-1 BLK-7 BLK/WHT-8

HOUR METER
3
BLU/WHT-12

CHECK ENGINE
TS61

TS63
PRI. BOOM UP/DOWN

TS60
R4

PRIMARY BOOM EXTEND/ RETRACT

WHT-4

CR1
BLK-R1 TO ISM#1 BLK-R1 TO E.H.#1

CR2

CR5

CR4

WHT/BLK-5

KEYSWITCH POWER (UNUSED) ECM KEEP ALIVE POWER (SPARE)

TS52
SECONDARY BOOM

TS58

TS62

WHT/RED-6

BLK-TEST SW
RED-ISM#4
RED-S.P.

TURNTABLE ROTATE
JIB
WHT-40

RED-R4
WHT-21 BLK/RED-R5 GREEN-R4 BLK-R4

5
RUN/TEST

1
RED-C.H. RD/BK-C.H. RD/WT-C.H. RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1

AUXILIARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG BK/RD-S.P. HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) LIQUID PROPANE FUEL OFF-LIMIT SPEED

BLK/RED-35

START

WHT ISM7

EH2
BRN-GRD.

WHT-ENA. WT/BK-C.H.. WT/RD-C.H. BLK-ISM#3

TS54

CB1

CB2
TS59

GRN/WHT-19 GRN/BLK-18 GRN-17

ORG

ORG/BLK

CR7

CR8

BLK-S.P.
BLK/RED-35GEN

TS64
WHT#40-R7 WHT-PRIM.#5

BR/BLU-EH2 BLU-M.H.

HIGH/LOW RPM
BLU-10 BLU/BLK-11 RED-20 RED-R1 RED TO EH2 BLK-33
PLAT. LEVEL

TS57 PLATFORM

BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1

ROTATE

ORG-14 ORG/BLK-15
ORG/BLK-15 ORG-14

BU/BK-M.H. PK/GR-EH#2 YEL/BLK-EH2

BU/WT-S.P. BU/RD-S.P. WHT-SEC.#4

CH+EH1

OG/BK-C.H.

41

WHT-EXT.#6 OG/BK-ISM#2

ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

GRN/WHT-C.H

42 43 44 45

ALTERNATOR PULSE PICKUP (SPARE) (SPARE)

PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

BLK/RED-35GEN

(SPARE) GENERATOR OPTION

GROUND STUD (-12 VOLTS)

RED-E.H.#1 GRN-E.H.#1 BLK-E.H.#1 BLK-E.H.#1 BLK/RED-E.H.#1 ORANGE-M.H. ORG/BLK-M.H.

RED-R4 GRN-R4 BLK-R4 BLK-1 BLK/RED-R5 ORG-R7 ORG/BLK-R8

WIRE CONNECTION ABBREVIATION KEY: EH#1 EH#2 C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS #1 ENGINE HARNESS #2 (FORD EFI HARNESS) CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

ENGINE HARNESS # 2, FORD EFI, 42 PIN INTERCHANGE PIN/#: TO: RED/GRN #1 - 25D PNK/GRN #6 - 38D YEL/BLK #7 - 39D YEL (18GA) #8 - CB2 YEL (12GA) #9 - CB2 WHT/PRP #18 - TST SW TAN/BLU #24 - 35D

6 - 31

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25J Ford Models (after serial number 16303)
N M L K J
PLATFORM CONTROL BOX

C
COMPONENT INDEX
P2 P3 TS1 TS2 TS3 TS7 TS8 TS9 EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH

WHT-24
1 2 3 4 5 6 7 8 9 10
(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH L.P. GAS (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

SEC. BOOM UP

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

RED FROM CR14

TS10 TS11 TS12 TS13


TS47 R1

SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH
GENERATOR SWITCH ( OPTION ) EFI RESISTOR

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

ORG-40

CR12
RED-10 WHT-24

R2 R3 L1 L3 BP1 BP2 CR12 CR13 CR14 DP1 H.P.L. T1 H1

LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN ,TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY JIB CUTOUT RELAY JIB VALVE RELAY
DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD

GRD. STUD
R1 50 RED-10 LIMITING RELAY
RED-TILT

RED/BLK-28

WHT JIB CABLE

BLK JIB CABLE CABLE #1 110 JIB CABLE F.S.

+ TILT _
ALARM

H1

CABLE #3

CABLE #2

TIME DELAY TILT ALARM

SIDE VIEW FOR DP1

WHT/BLK-5

WHT-4

RED/BLK-2

RED-1

BLK-7

BLK/WHT-8

GRN-17

GRN/BLK-18

BLU/WHT-12 RED-27

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

BLU/RED-13

ORG/RED-16

BLK/RED-35 RED-25

BLK-33

RED-STP RED-TILT RED TIM.DEL.

BLU/BLK-37

WHT/RED-32 WHT-30

RED-STP

GRN/WHT-45

NC
R

NO
A

CR13

NC
- X

- X

BP1
NO

JIB VALVE RELAY

CR14

L1

TS13

NC NO

JIB CUTOUT RELAY

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7

SEE SIDE VIEW DP1

P3

NO

TS1 AUXILIARY PUMP DRIVE SPEED

100

250

BLK/RED-9

ORG-14

ORG/BLK-15

WHT/RED-6

RED/WHT-3

GRN/WHT-19

BLU/WHT-38

RED TO JIB CABLE

RED JUMP

BLU-36

BRN TO GRD.

WHT-24 TO H.P.L.

WHT/BLK-31 BLU/RED-39

BLK-22

BLK-26

WHT-23

5
WHT TO PLATFORM ROTATE

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. TS47


RED-GEN

SEC.BOOM BP2

DP1 DRIVE

GRN/WHT + RED OUTPUT BRN TIME DELAY T1

8 7 6 5 4 3 2 1

+
- X

PLATFORM LEVEL TS9

TS8

JIB

R2 R3

DRV.ENA TS15 NC L3 TS2 START TS4 HIGH/LOW RPM CHECK ENGINE TS3 FUEL SELECT EMERGENCY STOP P2 NC

HORN

TS14

HIGH/LOW (2WD/4WD)

8
PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 32

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25J Ford Models (after serial number

ORG/BLK

WHT

WHT

RED RED

SELECTOR

BRN
LIFT/DRIVE SELECTOR OPTION (REQUIRED FOR CE MODELS) BLK/RED-1

TS50

OPTION
LOW RPM FOOTSW. H/L HIGH RPM

LIFT/ DRIVE

TP35

TS54

ENGINE SPEED

TS4

LOW RPM HIGH RPM

FUNCTION ENABLE BLK/RED


HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY BLK/RED#R4-E.H. RPM SOLENOID

TB35

CR3 NO CR3 CR4 NO

OFF GENERATOR ON

CR4

TS47

GRN/WHT-1

GRN/WHT#45-E.H.

GENERATOR OPTION

TP45

TB45

FB

RED/WHT#23-E.H. FLASHING BEACON OPTION

TP34

TB34

TS6

BLK-1

BLK/WHT#34-E.H. GLOW PLUG OPTION

TS56

GLOW PLUG GLOW PLUG BLK

L3 OIL TEMP.

WHT/RED

PR2 NO

PR2

L2 OIL PRES.

OIL TEMPERATURE LED

WHT/BLK OIL PRESSURE LED

IGN./START MODULE

TP33

TS2

BLK-1
WHT/RED#26 E.H.

GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON 10 ENG. FAULT

1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON

TB26

OTS NO

TS52

START WHT/BLK#25 E.H.

TB24

TB25

ENGINE

OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH

START

ENGINE

5 6 7 8 9

TB33

CR2

NC

BLK

OPS

POWER RELAY

TB21

FUEL SOLENOID
CR2 NO
WHT

3 HM
WHT#21

HOUR METER

First Edition Second Printing

CR1

IGNITION./START RELAY

BLK#R1-E.H.

TP25

TP21

TS51

STARTER MOTOR

TP27

RED

RED-1

TP24

PR1

AUXILIARY PUMP

AUXILIARY PUMP

TB27

TS1

RED#27-E.H.

RED

AUXILIARY POWER RELAY


AUX PUMP

RED

AUXILIARY PUMP

PR1

FS1

TP28

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

BLK

WHT

RED/BLK-1

TB28

RED/BLK#28-E.H.

NO

TILT ALARM RED/WHT#23-E.H.


LEVEL SENSOR

WHT-2
BLK TP26 TP23

BLK

BLK/RED-3

BLK/RED

HORN

TP22

TB22

RELAY
CR5 NO
BLK#22 BLK/RED#R5-E.H. HORN

BLK-2

ORG/BLK-1

ORG/BLK#41-E.H.

STA.

BAT. -

Section 6 Schematics

RED

RED

ALTERNATOR

15AMP.

15AMP.

CB2

CB1

TB20

BAT. +

REG.

RED

RED#20-E.H.
12 V DC

IND.

WHT#21-E.H.

EXCT.

6 - 33 1 2 3 4 5 6 7 8

Genie Z-45/25 & Genie Z-45/25J


TB23
P3 HORN TP9 P1 RED GRND KS1 PLAT

BLK

P2

TB9

TP41

TB41

CR5

Part No. 52709


CR1 NO
STARTER

WHT WHT

RED

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

First Edition Second Printing

BRN-2 GROUND

TP13

TB13

L1

NCHO

BLU/RED-3 BLU/RED#13-C.H. BRN ORG/RED#16-C.H. DRIVE ENABLE LIMIT SWITCH WHT#30-C.H. WHT-1

TP30

TS15

TB30

LS4

NOHC

TB16

TP31 TP16

WHT#12-C.H.

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1 DRIVE EDC

WHT/BLK#31-C.H.

TP32

WHT/RED-1 WHT/RED#32-C.H.

TB32

TRAVEL ALARM OPTION

BLU/BLK-1 BLU/BLK#37-M.H. STEER RIGHT

BLU-1 BLU#36-M.H. STEER LEFT

RED/WHT-1 MOTOR STROKE

RED/WHT#29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

RED

BLK 100

CE MODELS ONLY

R2

Section 6 Schematics

WHT#40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

TB40

LS3 NO

LS1 NCHO

WHT#40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TS13

BLK-3 BLK/WHT-3

TB7

EXTEND BOOM RETRACT

TP8

BLK#7-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT#8-M.H.

EXTEND

TS63

RETRACT

BOOM

TP6

WHT/RED-3 WHT/BLK-3

TP5

TP4

TB4

WHT-3 WHT#4-M.H. WHT/BLK#5-M.H. RIGHT TURNTABLE

TB8

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

PWM A + X

TS62

LEFT

ROTATE

15

TB5

R4

WHT/RED#6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED#1-M.H.

TS61

DOWN RED/BLK#2-M.H.

TB2

UP PRIMARY BOOM

PRIMARY BOOM UP PRIMARY BOOM DOWN

PWM A + X

10

TB3

TP1

R5

RED/WHT#3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3

TB10

BLU-3

TP10

BLU UP SECONDARY DOWN BOOM BLU/BLK

BLU#10-M.H.

SECONDARY BOOM UP

PWM A + X

TS60

BLU/BLK#11-M.H.

BP2

SECONDARYBOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT#12-M.H.

TP14

SECONDARY BOOM FLOW CONTROL

ORG-3 ORG/BLK-3

TS9

TS59

TB14

UP PLATFORM LEVEL DOWN

CR7 NC

TP15

ORG#14-M.H. UP DOWN PLATFORM LEVEL ORG/BLK#15-M.H.

PLATFORM LEVEL UP PLATFORM LEVEL DOWN

PLATFORM LEVEL

TB15

CUTOUT (CE MODELS ONLY)

TP17

GRN-3 GRN/BLK-3

TS8

LEFT

TS58

TB17

RIGHT PLATFORM ROTATE

TP18

GRN#17-M.H. LEFT RIGHT PLATFORM ROTATE GRN/BLK#18-M.H.

CR8 NC

PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT

TB18

DESCENT ALARM OPTION

ORG/BLK

RED

WHT

WHT

BRN

RED

BRN

Part No. 52709

ORG-1

WHT#40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

TP40

LS2

1 2 3 HORSE- 4 POWER 5 LIMITER 6 BOARD 7 8 9 10

TP7

NO

Genie Z-45/25 & Genie Z-45/25J

BRAKE RELEASE VALVE

TP37

DP1

RED

TP36

1 2 3 4 5 6 7 8

R3

TP29

TB29

TB36

TB37

6 - 34

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Deutz Models (before serial number 13099)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Deutz Models (before serial number 13099)
A 1
GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL
STACKED CONTACTS KS1
BLK-R1#86 ORG/BLK-41A

J
LABEL P1 KS1 TS51 TS52 TS54 TS57 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 R5 L2 L3 CR1 CR2
CR3 CR4 CR5 CR7 CR8

K
DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH

M.H.
BLK-33D RED-27B BRN-GRD. RED-R2 # 30
WHT-23A

2 3
4
5 6
7
8

TACHOMETER START INPUT

NO

START RELAY

NO

AUX. ON GROUND BATTERY


KEY PWR.
KEY BYPASS IGN./FUEL ON ENG. FAULT

IGN./START MODULE
P1 NC
NO

PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER TURNTABLE ROTATE SPEED LIMITING RESISTOR, 15 OHMS BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY
HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

SECON.4

KS1
NO

AUXILIARY

WHT-R2#86

EXT.6

9
10

WHT-24D

BASE TERMINATION BLOCK

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5
PRI. BOOM UP PRI. BOOM DOWN PRI. BOOM F.C. TURN. ROT. R TURN. ROT. L TURN. ROT. F.C. BOOM EXTEND BOOM RETRACT HORN SEC. BOOM UP SEC. BOOM DN SEC. BOOM F.C. DRV. ENA. LT. PLAT. LEVEL. UP PLAT. LEVEL DN. DRV. ENA. PLAT. ROT. L. PLAT. ROT. R. JIB VALVE 12V BATT. SUPPLY IGNITION PWR. PWR. TO PLAT.

NC
WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2

TS51

RED-4 RED/BLK-4 R/W-4

RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3

1 2 3 4 5 6 7 8 9

STOP

WHT/BLK # 25

PRIM.5

WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4

WHT/RED #26
L2
1
RED

4
3

BLU-4 BLU/BLK-4 BLU/WHT-4

RED

BLU/RED-C.H ORG-4/R7 ORG/BLK-4/R8

BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.#6 BLK-2 WHT-2

ORG/RED-C.H GRN-4 GRN/BLK-4


RED-C.H.

WHT-E.H.1
RD/WT-C.H.

WHT-ISM#10

WHT/BLK-EH.1
WT/RD-E.H.1 RED-C.H RED/BLK-C.H RED/WHT-C.H WHT-30 C.H WT/BK-E.H.1 RED-1 RED/BLK-1 R/W-1

WHT/RED-C.H BLK-ISM#3
BLK/WHT-E.H.1
BLU-M.H. BU/BK-M.H.

WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

WHT#40-R7 WHT-PRIM.#5

CH+EH1

OG/BK-E.H.1

BLK-SEC#4

GR/WT-C.H

10 11 12 13 14 15 16 17 18 19 20 21 22 WHT-S.P. 23 24 25 26 RED-ISM#4 27 28 29 30 31 32 33 34 35 BK/RD-R3#35 36 37 38 39 40 WHT-SEC#4 41 42 43 44 45

BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-SP OG/BK-SP


WHT#12-E.H.1 GRN-S.P. GR/BK-S.P.

OIL PRESS

RED/WHT #3 RED/BLK #2 RED #1 BLK #7 BLK/WHT #8


TS61
TS63

HOUR METER 3

BLK/RED#35B

BLU/WHT #12

L3 OIL TEMP.

GR/WT-S.P. RED-S.P.
WHT-S.P. BLK-S.P.
WHT-ISM#7

R4

R5
TS52

EXTEND RETRACT PRIMARY BOOM TS62 TS60

WHT-ISM#9 RED-CB1

RED-ISM#6

WHT #4 WHT/BLK #5 WHT/RED #6

CR1

CR2

CR3

CR4

BLK-ISM#1
BLK#R1-E.H
WHT#21
BLK/RED#R4-EH WHT-40B

WHT/BLK-SP WHT/RED-SP RED-S.P.

KEYSWITCH PWR. ENGINE FAULT OIL PRESSURE SENDER WATER TEMP. SENDER AUX. PWR. TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START GLOW PLUG RPM STEER RIGHT STEER LEFT TEST LIGHT L.P. LIMIT SWITCH SIG. PULSE PICKUP SPARE SPARE SPARE GEN. OPTION

BLK/RED #35

START

TURNTABLE ROTATE
SEC. BOOM

TS54

CB1

CB2
TS59

BLU #10
BLU/BLK #11

FUNCTION ENABLE
PLAT.

GRN/WHT #19 GRN/BLK #18 GRN #17


LEVEL

BLK/RED#R5-AH
ORG-4
ORG/BLK-4

CR5
BRN GRND H.M

CR7

CR8

BLK-S.P.

BK/RD-SP

RED #20 RED-R1

TS57 PLATFORM ROTATE

ORG #14 ORG/BLK #15

BLK#22 BLK/RED-9A
PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

BLK #33

WHT-EXT.#6 OG/BK-IM2

ORG/BLK-15
GRD-HOLE

ORG-14

BLK/RED-EH BLK/RED-EH BLK-E.H

BLK/RED-R4 BLK/RED-R5 BLK-R1

WIRE CONNECTION ABBREVIATION KEY: EH C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

ORG-M.H ORG/BLK-M.H

ORG-R7 ORG/BLK-R8

6 - 35

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Platform Control Box Wiring DiagramZ-45/25 Deutz Models (before serial number 13099)

First Edition Second Printing

EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG OPTION PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH

DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN, TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY

WHT-23

Section 6 Schematics

BLK-22

EMERGENCY STOP P2

BLK-26

NC

WHT/RED-32 WHT-30 WHT/BLK-31 WHT-24 TO H.P.L.

BRN TO GRD. BLU-36

BLU/BLK-37

DRIVE DP1

BLU/RED-13

RED/WHT-29 BLU/BLK-11

F.S.

BLU-10 BLU/WHT-12 RED-27 RED-10 TO H.P.L. GRN/BLK-18 GRN-17 GRN/WHT-19

PLATFORM CONTROL BOX

JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRV. ENA. PLAT. LVL. DN. PLAT. LVL. UP DRV. ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

CABLE #2

WHT-4 WHT/BLK-5

NC

1 2 3 4 5 6 7 8 9 10

CABLE #3

NO

WHT/RED-6

TURNTABLE ROTATE

HORSEPOWER LIMITER BOARD

PLATFORM LEVEL

BP1

HORN RETRACT EXTEND SWING F.C. SWING RIGHT SWING LEFT PRIMARY F.C. PRIMARY DN. PRIMARY UP

RED/WHT-3

CABLE #1

A RED/BLK-2

+
NO

- X

PRIMARY BOOM UP/DOWN

NO

PLATFORM ROTATE

TS7

SEC.BOOM UP

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

PRIMARY BOOM EXTEND/ RETRACT

110

BLK/WHT-8 BLK-7 RED-1

TS13

TS9

NC

AUXILIARY PUMP

TS1

OG/BK-41

WHT-24

RED-10

ORG-40

RED/BLK-28

GRD. STUD

ORG/BLK-15

+ TILT _

ALARM

H1

ORG-14 BLK/RED-9

P3

HORN

PLATFORM CONTROL SWITCH PANEL

SEC.BOOM BP2

HIGH/LOW (2WD/4WD)

R2

DRIVE SPEED

TS14

NC NO

100

250

- X

- X

GEN. (OPTION) SPARE SPARE SPARE PULSE PICKUP LIMIT SWITCH L.P. ENGINE FAULT STEER RIGHT STEER LEFT RPM GLOW PLG. OPT. START BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PWR. PWR. TO F.S. PWR. (START) PWR. (CONT.) PWR. FRM PLAT. PWR. TO PLAT. OPTION WIRE GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT BLK/RED-35 RED-25

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

L1

R3

DRV.ENA TS15

ORG/RED-16

TS2 START

BLK-33

GEN. OPT.

TS4

HIGH/LOW RPM

Part No. 52709

NC

Genie Z-45/25 & Genie Z-45/25J


1 2 3 4 5 6 R 7 8

HORSEPOWER LIMITER BOARD

LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR

DESCRIPTION

LABEL

H.P.L. T1 H1

R2 R3 L1 BP1 BP2 CR12

P2 P3 TS1 TS2 TS6 TS7 TS9 TS10 TS11 TS12 TS13

TS50

TIME DELAY TILT ALARM

6 - 36

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25 Deutz Models (before serial number 13099)

Section 6 Schematics

First Edition Second Printing

Electrical Schematic, Z-45/25 Deutz Models (from serial number 13099 to 16303)
A B C D
SEE NOTE 1

M
SEE NOTE 2

1
TP22 P2

ORG/BLK

BLK

TP26

BLK

FS1 BLK

RED

RED

TP25
TP21

RED WHT WHT


TS50

WHT

WHT
LIFT/ DRIVE

TP24

TS2
TS1
WHT

TS6
GLOW PLUG

TS47
OFF ON

TS4
LOW RPM FOOTSW. H/L HIGH RPM

SELECTOR OPTION

BLK-2

START

AUXILIARY PUMP

GENERATOR

P3 HORN
BLK

ENGINE

TP41

CB1 15AMP. RED


P1 RED

KS1 PLAT GRND

TB22

TP9

TP23

TP28

TP27

TP33

TP34

TP45

ENGINE SPEED

TP35

RED RED

WHT-2

BLK-1

BLK/RED-1

GRN/WHT-1

BLK-1

RED/BLK-1

RED-1

BLK/RED-3

ORG/BLK-1

TS51
START

TS52

TS56
GLOW PLUG

TS54
LOW RPM

FUNCTION HIGH RPM ENABLE

AUXILIARY PUMP

RED

TB45

ENGINE

BLK

BLK

TB28
RED

TB27

TB33
1 2 3 4 5 6 7 8 9 10

TB34
START RELAY TACHOMETER START INPUT IGN./START AUX. ON MODULE GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT

TB9

TB41

TB23

CB2

TB20
RED#20-E.H.

15AMP.

RED
CR1
CR2 N.O.
CR2

L2 OIL PRES. L3 OIL TEMP.


BLK/WHT#34-E.H.

TB35

RED/WHT#23-E.H.

BLK/RED

CR1 N.O.

TB21
WHT/RED WHT/BLK
BLK#22

CR3 N.O. CR3

BLK#R1-E.H.

RED/BLK#28-E.H.

RED#27-E.H.

BLK/RED

RED/WHT#23-E.H.

TB24

WHT

WHT#21

WHT#21-E.H.
ALTERNATOR
EXCT.

ORG/BLK#41-E.H.

CR4 .NO.

CR4

GRN/WHT#45-E.H.

FB

BLK/RED#R4-E.H.

CR5 N.O.
BLK/RED#R5-E.H.

CR5

PR1 N.O.
WHT

PR1

TB25
TB26
WHT/RED#26 E.H.

PR2 N.O.

WHT/BLK#25 E.H.

PR2

RED

6
12 V DC
BAT. +

BAT. -

6 - 37

+
REGULATOR

STA.

OPS
3

AUX PUMP

STARTER

IND.

HM 2

BLK BRN

N.C.

OIL TEMPERATURE SWITCH N.O.

BRN
GLOW PLUG

TILT ALARM

OPTION (REQUIRED FOR

CE MODELS)

LIFT/DRIVE SELECTOR

FLASHING BEACON OPTION

HIGH IDLE CUTOUT RELAY

HIGH IDLE RELAY

RPM SOLENOID

OIL PRESSURE SWITCH

OIL PRESSURE LED

OIL TEMPERATURE SWITCH

FUEL SOLENOID

OIL TEMPERATURE LED

AUXILIARY POWER RELAY

GENERATOR OPTION

POWER RELAY

HOUR METER

IGNITION./START RELAY

AUXILIARY PUMP

STARTER MOTOR

HORN RELAY

LEVEL SENSOR

Genie Z-45/25 & Genie Z-45/25J

HORN

NOTE:
1) The connection to TP24 is for units without the generator option.
2) 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.

Part No. 52709

Electrical Schematic, Z-45/25 Deutz Models (from serial number 13099 to 16303)

First Edition Second Printing

BRN-2
N.C.H.O.

GROUND
LS4

TP13

BLU/RED-3
BLK-7
BRN-7

TB13

L1

TP30

WHT-1
WHT-7

TB30

RED-7
N.O.H.C.

DRIVE ENABLE LIMIT SWITCH


TB16
WHT#12-C.H.

TS15

TP16

DRIVE ENABLE ORG/RED-3


TB31

DRIVE ENABLE SWITCH

TP31

WHT/BLK-1

WHT/BLK#31-C.H.

DRIVE EDC

TP32

WHT/RED-1
WHT/RED#32-C.H.

TB32

BRAKE RELEASE VALVE

TRAVEL ALARM OPTION


TP37
TB37

BLU/BLK-1
BLU/BLK#37-M.H.

STEER RIGHT

BLU-1
BLU#36-M.H.

STEER LEFT

RED/WHT-1
MOTOR STROKE

RED/WHT#29-C.H.

HIGH (2WD)
TS14

LOW (4WD)
DRIVE RANGE (2WD/4WD)

RED

RED

BLK
100
LS1 N.C.H.O.

CE MODELS ONLY

250
R2

WHT#40-6

BRN-6

Section 6 Schematics

PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

TB40

LS3 N.O.

ORG-1
TP40

WHT#40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

WHT#40-5
HORSEPOWER LIMITER BOARD

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

BLK-3
BLK/WHT-3
TB7

EXTEND BOOM RETRACT

TP8

BLK#7-M.H.

EXTEND

BOOM EXTEND

TS63

RETRACT

BOOM

BLK/WHT#8-M.H.

BOOM RETRACT

TP6

WHT/RED-3 WHT/BLK-3
TB5

TP5

WHT-3
TP4

TB8

WHT/BLK#5-M.H.

PWM A

TS62

LEFT

RIGHT TURNTABLE ROTATE

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

R4 10

WHT#4-M.H.
TB4

WHT/RED#6-M.H.
BP1
TB1
TB6

TURNTABLE ROTATE FLOW CONTROL

RED#1-M.H.
TB2

TS61

UP PRIMARY DOWN BOOM

PRIMARY BOOM UP

RED/BLK#2-M.H.
TB3

PWM A

PRIMARY BOOM DOWN

TP1

RED/WHT#3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3
TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3
TB10

BLU-3
TP10

TS60

BLU UP SECONDARY DOWN BOOM BLU/BLK

BLU#10-M.H.

SECONDARY BOOM UP

PWM A

BLU/BLK#11-M.H.
TB11 TB12

BP2

SECONDARY BOOM DOWN

BLU/WHT
TP14

BLU/WHT#12-M.H.
CR7 NC

SECONDARY BOOM FLOW CONTROL

ORG-3

TS9

ORG/BLK-3
TS59 TP15

TB14

UP PLATFORM DOWN LEVEL

ORG#14-M.H.
UP PLATFORM DOWN LEVEL

PLATFORM LEVEL UP

ORG/BLK#15-M.H.
TB15

PLATFORM LEVEL DOWN


PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

TP18

GRN/BLK-3

RIGHT

TS7

LEFT

GRN-3
TS57

TP17

TB18

PLAT ROTATE

GRN/BLK#18-M.H.
RIGHT LEFT PLAT ROTATE

CR8 NC

PLATFORM ROTATE RIGHT


GRN#17-M.H.
TB17

PLATFORM ROTATE LEFT

DESCENT ALARM OPTION

ORG/BLK

RED

WHT

WHT

BRN

RED

BRN

Part No. 52709

1 2 3 4 5 6 7 8 9 10

TS13

TP7

N.O.

LS2

Genie Z-45/25 & Genie Z-45/25J

DP1

RED

TP36

1 2 3 4 5 6 7 8

R3

TP29

TB29

TB36

6 - 38

First Edition Second Printing

Section 6 Schematics

Electrical Schematic, Z-45/25 Deutz Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Deutz Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Deutz Models (from serial number 13099 to 16303)
A 1
GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL
STACKED CONTACTS KS1
BLK-R1#86
1

J
LABEL P1 KS1 TS51 TS52 TS55 TS56 TS57 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4

K
DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH

START RELAY TACHOMETER START INPUT


AUX. ON GROUND BATTERY

M.H.

ORG/BLK-41A BLK-33D RED-27B BRN-GRD. RED-R2 # 30

2 3

NO

PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY

NO

5 6

WHT-23A

IGN./START MODULE
P1 NC
NO

KEY PWR.

SECON.4

KEY BYPASS IGN./FUEL ON

KS1
NO

AUXILIARY

WHT-R2#86
WHT-24D

EXT.6

BASE TERMINATION BLOCK

10

ENG. FAULT

D
PRIM.5

C
RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 1

B
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 WHT-S.P. 24 25 26 27 RED-ISM#4 28 29 30 31 32 33 34 35 BK/RD-R3#35 36 37 38 39 40 WHT-SEC#4
41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P.
BLU/WT-S.P. ORG-SP OG/BK-SP

NC
PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM
KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

TS51
WHT/BLK # 25
WHT/RED #26
LED

RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4

WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2

STOP

L2 L3 CR1 CR2 CR3 CR4 CR5 CR7 CR8

+
L2

HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY SERVICE HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

BLU-4 BLU/BLK-4
BLK-ENA. ORG-4/R7

BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3


BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3

OIL PRESS

RED/WHT #3 RED/BLK #2 RED #1 BLK #7

HOUR METER
RED

BLK/RED#35B
RED-ISM#6

3
BLU/WHT #12 BLK/WHT-34
R4
TS56

ORG/BLK-4/R8 RED-ENA. GRN-4


2

BLK/WHT #8

WHT#12-E.H.1 GRN-S.P.
GR/BK-S.P. GR/WT-S.P. RED-S.P. WHT-S.P. BLK-S.P.

L3 OIL TEMP.

TS61
PRIMARY BOOM

TS63
EXTEND RETRACT
WHT #4 WHT/BLK #5 WHT/RED #6
BLK#R1-E.H.

WHT-ISM#9 RED-CB1

GRN/BLK-4 RED-C.H.

CR1
BLK-ISM#1

CR2

CR3

CR4

5
1

TS60
TS52

WHT-E.H.1

RD/WT-C.H.
WHT-ISM#10

RED-EXT.#6 BLK-2 WHT-2

TS62

WHT-ISM#7
WHT/BLK-SP WHT/RED-SP RED-S.P.

WHT/BLK-EH.1

TURNTABLE ROTATE

WT/RD-E.H.1 RED-C.H RED/BLK-C.H RED/WHT-C.H WHT-ENA.


WT/BK-E.H.1 WHT/RED-C.H BLK-ISM#3 BLK/WHT-E.H.1 BLU-M.H. WHT#40-R7 WHT-PRIM.#5 BU/BK-M.H.

BLK/RED #35

GLOW PLUG

START

SEC. BOOM
GRN/WHT #19

WHT#21

BLK/RED#R4-EH WHT-40B

RED-1 RED/BLK-1 R/W-1 WHT-1


WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1

TS54

CB1

CB2

TS59

BLK/RED#R5-AH.
CR5

GRN/BLK #18 GRN #17

ORG-4
CR7

ORG/BLK-4
CR8

BLK-S.P. BLK/WHT-34
BK/RD-SP

BLU #10

FUNCTION ENABLE

PLAT.
LEVEL
PLAT.

TS57
ROTATE ORG #14 ORG/BLK #15

BRN GRND H.M

BLU/BLK #11
RED #20 RED-R1
BLK #33

BLK#22 BLK/RED-9A

PLATFORM LEVEL CUTOUT (CE VERSION ONLY)

WHT-EXT.#6

CH+EH1

OG/BK-E.H.1

OG/BK-IM2

GR/WT-C.H

GRN/WHT-1

ORG/BLK-15
GRD-HOLE

ORG-14

BLK/RED-EH-r.male

r.fem-BLK/RED-R4 r.male-BLK/RED-R5 r.male-BLK-R1


r.fem-ORG-R7 r.fem-ORG/BLK-R8

BLK/RED-EH-r.fem BLK-E.H-r.fem
ORG-M.H.-r.male ORG/BLK-M.H.-r.male

WIRE CONNECTION ABBREVIATION KEY: EH C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

6 - 39

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Platform Control Box Wiring DiagramZ-45/25 Deutz Models (from serial number 13099 to 16303)

First Edition Second Printing

EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR

DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN, TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN

WHT-23
EMERGENCY STOP P2

Section 6 Schematics

BLK-26 BLK-22

NC

NC

WHT/RED-32 WHT-30 WHT/BLK-31 WHT-24 TO H.P.L.

BLU-36

BLU/BLK-37
HIGH/LOW RPM

DRIVE

BRN TO GRD.

BLK/WHT-34
L1

RED/WHT-29 BLU/BLK-11
SEC.BOOM BP2 NC NO

F.S.

BLU-10 BLU/WHT-12 RED-27 RED-10 TO H.P.L. GRN/BLK-18 GRN-17 GRN/WHT-19

(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.
110

CABLE #2

WHT-4 WHT/BLK-5

NC

1 2 3 4 5 6 7 8 9 10
ORG/BLK-41

CABLE #3

NO

WHT/RED-6
ORG-40 RED-10

TURNTABLE ROTATE

HORSEPOWER LIMITER BOARD

PLATFORM LEVEL

BP1

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

RED/WHT-3
CABLE #1 PRIMARY BOOM UP/DOWN

A RED/BLK-2

+
NO

- X
NC

R
NO

PLATFORM ROTATE TS7

SEC. BOOM UP

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

PRIMARY BOOM EXTEND/ RETRACT

BLK/WHT-8 BLK-7 RED-1

TS13

TS9

WHT-24

RED/BLK-28
GRD. STUD

ORG/BLK-15

ALARM

+ TILT

H1

ORG-14 BLK/RED-9

P3

HORN

PLATFORM CONTROL SWITCH PANEL

PLATFORM CONTROL BOX

AUXILIARY PUMP

TS1

HIGH/LOW (2WD/4WD)

R2

DRIVE SPEED

TS14

100

250

- X

- X

(SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE BLU/RED-13

DRV.ENA TS15

GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT BLK/RED-35 RED-25 ORG/RED-16
R3 GLOW PLUG TS6 TS2 START

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 BLK-33

GENERATOR OPTION

TS4

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J


1 2 3 4 5 6 R 7 8

HORSEPOWER LIMITER BOARD

DESCRIPTION

LABEL

H.P.L. H1

P2 P3 TS1 TS2 TS3 TS6 TS7 TS9 TS10 TS11 TS12 TS13 TS50 R2 R3 L1 L3 BP1 BP2

TILT ALARM

6 - 40

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25 Deutz Models (from serial number 13099 to 16303)

WHT

BRN

WHT

ORG/BLK

RED

RED RED

CR13

RED

BRN
JIB BOOM CUTOUT RELAY (CR-13) JIB BOOM VALVE RELAY (CR-14) JIB BOOM VALVES LIFT/DRIVE SELECTOR OPTION (REQUIRED FOR CE MODELS) BLK/RED-1

JIB VALVES

SELECTOR

TS50

LIFT/ DRIVE

OPTION

ENGINE SPEED

TS4

LOW RPM FUNCTION


HIGH RPM ENABLE

BLK/RED
HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY BLK/RED#R4-E.H. RPM SOLENOID

TB35

CR3 NO CR3 CR4 NO

LOW RPM FOOTSW. H/L HIGH RPM

CR14 NO

CR14

TP35

TS54

OFF

TS47

ON GRN/WHT-1

GENERATOR GRN/WHT#45-E.H. GENERATOR OPTION

TP45

TB45

FB

RED/WHT#23-E.H. FLASHING BEACONS OPTION

CR4

TP34

TB34

TS6

BLK-1

BLK/WHT#34-E.H. GLOW PLUG OPTION

TS56

GLOW PLUGS GLOW PLUGS BLK

L3 OIL TEMP.

WHT/RED

PR2 NO

PR2

L2 OIL PRES.

OIL TEMPERATURE LED

WHT/BLK OIL PRESSURE LED

1 START RELAY 2 TACHOMETER 3 START INPUT IGN./START 4 AUX. ON


MODULE

TP33

GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON 10ENG. FAULT

TS2

BLK-1
WHT/RED#26 E.H.

TB26

OTS NO

TS52

START WHT/BLK#25 E.H.

TB24

TB25

ENGINE

OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH

START

ENGINE

5 6 7 8 9

TB33

CR2

NC

BLK

OPS

POWER RELAY

TB21

FUEL SOLENOID
CR2 NO
WHT

HM

WHT#21

HOUR METER

First Edition Second Printing

CR1

IGNITION./START RELAY

BLK#R1-E.H.

TP25

TP21

TS51

STARTER MOTOR

TP27

AUXILIARY

AUXILIARY PUMP RED-1

TB27

TS1

RED#27-E.H.

RED

PUMP

PR1

RED

AUXILIARY POWER RELAY


PUMP

TP24

AUX

RED

AUXILIARY PUMP

PR1

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

FS1

TP28

BLK

WHT

RED/BLK-1

TB28

RED/BLK#28-E.H.

NO

TILT ALARM RED/WHT#23-E.H.


LEVEL SENSOR

WHT-2
BLK TP26 TP23

TB23

BLK

BLK/RED-3

BLK/RED

HORN

P2

TB22

RELAY
BLK#22 BLK/RED#R5-E.H. HORN

BLK-2

ORG/BLK-1

ORG/BLK#41-E.H.

STA.

BAT. -

RED

RED

Section 6 Schematics

ALTERNATOR

15AMP.

15AMP.

CB2

CB1

TB20

BAT. +

REG.

RED

RED#20-E.H.
12 V DC

IND.

WHT#21-E.H.

EXCT.

6 - 41 1 2 3 4 5 6 7 8

Genie Z-45/25 & Genie Z-45/25J


P3 HORN TP9

BLK

TP22

TB9

P1 RED

KS1 PLAT

GRND

TP41

TB41

CR5 NO

CR5

Part No. 52709


CR1 NO
STARTER

WHT WHT

RED

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

First Edition Second Printing

BRN-2

GROUND
TB13 NCHO

TP13

BLU/RED-3

BLU/RED#13-C.H. BRN ORG/RED#16-C.H.


NOHC TB16 WHT#12-C.H.

LS4

TP30

WHT-1

TB30

WHT#30-C.H.

DRIVE ENABLE LIMIT SWITCH

TS15

TP31 TP16

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1

WHT/BLK#31-C.H. DRIVE EDC

TP32

WHT/RED-1

TB32

WHT/RED#32-C.H. BRAKE RELEASE VALVE

TRAVEL ALARM OPTION


TP37

BLU/BLK-1

BLU/BLK#37-M.H. STEER RIGHT

BLU-1

BLU#36-M.H. STEER LEFT

RED/WHT-1

RED/WHT#29-C.H. MOTOR STROKE

HIGH (2WD)
TS14

LOW (4WD)
DRIVE RANGE (2WD/4WD)

RED

RED

BLK 100

CE MODELS ONLY

250
R2

Section 6 Schematics

WHT#40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

TB40

LS3 NO

LS1 NCHO

ORG-1

WHT#40-4 BRN-4

WHT#40-5
1 2 3 HORSE- 4 POWER 5 LIMITER 6 BOARD 7 8 9 10

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

BLK-3 BLK/WHT-3
TB7

EXTEND RETRACT
TP8

BOOM BLK#7-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT#8-M.H.


TB8

EXTEND
TS63

RETRACT

BOOM

TP6

WHT/RED-3 WHT/BLK-3
TB4

TP5

WHT-3
TP4

WHT#4-M.H. WHT/BLK#5-M.H.

RIGHT
TS62

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

PWM A + X

LEFT
TB5

TURNTABLE ROTATE

15
R4

WHT/RED#6-M.H.
TB1 TB6

TURNTABLE ROTATE FLOW CONTROL

BP1

RED#1-M.H.
TB2

UP
TS61

PRIMARY BOOM UP PRIMARY BOOM DOWN

DOWN RED/BLK#2-M.H.
TB3

PRIMARY BOOM

PWM A + X

10
TP1 R5

RED/WHT#3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3
TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3
TB10

BLU-3

TS60

BLU UP SECONDARY DOWN BOOM BLU/BLK


TB11 TB12

TP10

BLU#10-M.H.

SECONDARY BOM UP

PWM A + X

BLU/BLK#11-M.H.

BP2

SECONDARY BOOM DOWN

BLU/WHT
TP14

BLU/WHT#12-M.H.
CR7 NC

SECONDARY BOOM FLOW CONTROL

ORG-3 ORG/BLK-3
TS59 TB14

TS9

UP PLATFORM DOWN LEVEL

TP15

ORG#14-M.H.
UP PLATFORM DOWN LEVEL

PLATFORM LEVEL UP ORG/BLK#15-M.H.


TB15 PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

PLATFORM LEVEL DOWN

CR13 NC

TP17

GRN/BLK-3
TB17

UP

TS8

DOWN

JIB BOOM

GRN-3
TS58 TP18
UP DOWN

GRN/BLK#18-M.H.
JIB BOOM

CR8 NC

PLATFORM ROTATE LEFT/ JIB BOOM UP GRN#17-M.H.


TS57 TB18
PLATFORM ROTATE RIGHT/ JIB BOOM DOWN
RIGHT LEFT

TS7

LEFT

RIGHT PLAT ROTATE

PLAT ROTATE

CR9 NC

TP19

DESCENT ALARM OPTION GRN/WHT-3


TB19
+

BRN

ORG/BLK

RED

WHT

WHT

RED

RED

CR9

TI

BRN

BRN

Part No. 52709

SECONDARY BOOM UP DRIVE LIMIT SWITCH

TP40

LS2

TS13

TP7

NO

Genie Z-45/25 & Genie Z-45/25J

DP1

RED

TP36

1 2 3 4 5 6 7 8

R3

TP29

TB29

TB36

TB37

6 - 42

L1

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Deutz Models (before serial number 13099)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Deutz Models (before serial number 13099)
A 1
GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL
STACKED CONTACTS KS1
BLK-R1#86
1

J
LABEL P1 KS1 TS51 TS52 TS54 TS57 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 R5 L2 L3 CR1 CR2
WHT/BLK # 25
WHT/RED #26

K
DESCRIPTION

L
EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A

START RELAY TACHOMETER START INPUT


AUX. ON GROUND BATTERY

M.H.

ORG/BLK-41A BLK-33D RED-27B BRN-GRD. RED-R2 # 30

2 3

5 6

IGN./START MODULE
P1 NC
NO

NO

NO

WHT-23A

KEY PWR.

SECON.4

KEY BYPASS IGN./FUEL ON

KS1
NO

AUXILIARY

WHT-R2#86
WHT-24D

EXT.6

BASE TERMINATION BLOCK

10

ENG. FAULT

D
PRIM.5

C
RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3
BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.#6 BLK-2 WHT-2

B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 WHT-S.P. 23 24 25 26 RED-ISM#4 27 28 29 30 31 32 33 34 35 BK/RD-R3#35 36 37 38 39 40 WHT-SEC#4
41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P.

NC
PRI. BOOM UP PRI. BOOM DOWN PRI. BOOM F.C. TURN. ROT. R TURN. ROT. L TURN. ROT. F.C. BOOM EXTEND BOOM RETRACT HORN SEC. BOOM UP SEC. BOOM DN SEC. BOOM F.C. DRV. ENA. LT. PLAT. LEVEL. UP PLAT. LEVEL DN. DRV. ENA. PLAT. ROT. L. PLAT. ROT. R. JIB VALVE 12V BATT. SUPPLY IGNITION PWR. PWR. TO PLAT.
KEYSWITCH PWR. ENGINE FAULT OIL PRESSURE SENDER WATER TEMP. SENDER AUX. PWR. TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START GLOW PLUG RPM STEER RIGHT STEER LEFT TEST LIGHT L.P. LIMIT SWITCH SIG. PULSE PICKUP SPARE SPARE SPARE GEN. OPTION

TS51

RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4


BLU-4 BLU/BLK-4 BLU/WHT-4
BLU/RED-C.H ORG-4/R7 ORG/BLK-4/R8
ORG/RED-C.H GRN-4 GRN/BLK-4

WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2

STOP

HOUR METER TURNTABLE ROTATE SPEED LIMITING RESISTOR, 15 OHMS BOOM PRIMARY AND SECONDARY SPEED LIMITING RESISTOR, 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY

4
3

L2

BK/RD-R5
BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-SP OG/BK-SP

OIL PRESS

RED/WHT #3 RED/BLK #2 RED #1 BLK #7

CR3 CR4 CR5 CR7 CR8

HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

HOUR METER
RED

RED

3
BLU/WHT #12

BLK/RED#35B
WHT-ISM#9 RED-CB1
RED-ISM#

BLK/WHT #8

WHT#12-E.H.1 GRN-S.P. GR/BK-S.P.


GR/WT-S.P. RED-S.P.

L3 OIL TEMP.

TS61

TS63
WHT #4 WHT/BLK #5 WHT/RED #6

R4

R5
TS52

RED-C.H.
WHT-E.H.1

WHT-S.P. BLK-S.P.

EXTEND PRIMARY RETRACT BOOM TS62 TS60 TS58

CR1
BLK-ISM#1

CR2

CR3

CR4

BLK#R1-E.H

RD/WT-C.H.
WHT-ISM#10
1

WHT-ISM#7
WHT/BLK-SP WHT/RED-SP RED-S.P.

BLK/RED #35

WHT/BLK-EH.1

START
SEC. BOOM

TURNTABLE ROTATE
JIB

WHT#21

BLK/RED#R4-EH WHT-40B

WT/RD-E.H.1 RED-C.H RED/BLK-C.H RED/WHT-C.H WHT-30 C.H WT/BK-E.H.1


WHT/RED-C.H

RED-1 RED/BLK-1 R/W-1


WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

TS54

CB1

CB2

GRN/WHT #19

TS59

BLK/RED#R5-AH
CR5

BLU #10

FUNCTION ENABLE

GRN/BLK #18 GRN #17

ORG-4
CR7

ORG/BLK-4
CR8

BLK-ISM#3 BLK/WHT-E.H.1 BLU-M.H. BU/BK-M.H.

BLK-S.P.
BK/RD-SP

BLU/BLK #11
RED #20 RED-R1
BLK #33

PLAT.
LEVEL

TS57 PLATFORM ROTATE

BRN GRND H.M

WHT#40-R7 WHT-PRIM.#5

ORG #14 ORG/BLK #15

BLK#22 BLK/RED-9A

PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

WHT-EXT.#6

CH+EH1

OG/BK-E.H.1
BLK-SEC#4

OG/BK-IM2

GR/WT-C.H

ORG/BLK-15
GRD-HOLE

ORG-14

BLK/RED-EH

BLK/RED-R4 BLK/RED-R5 BLK-R1


ORG-R7 ORG/BLK-R8

WIRE CONNECTION ABBREVIATION KEY: EH C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

BLK/RED-EH BLK-E.H
ORG-M.H. ORG/BLK-M.H.

6 - 43

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25J Deutz Models (before serial number 13099)
N M L K J I H G F E D C B A 1
PLATFORM CONTROL BOX
LABEL P2 P3 TS1 TS2 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS50 R2 R3 L1 BP1 BP2 CR12 CR13 CR14 H.P.L. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG OPTION PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM

WHT-24
1 2 3 4 5 6 7 8 9 10 PLAT. LVL. DN. PLAT. LVL. UP DRV. ENA. LT. SEC. BOOM F.C. SEC. BOOM DN. GEN. (OPTION) SPARE SPARE SPARE PULSE PICKUP LIMIT SWITCH L.P. ENGINE FAULT STEER RIGHT STEER LEFT RPM GLOW PLG. OPT. START BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PWR. PWR. TO F.S. PWR. (START) PWR. (CONT.) PWR. FRM PLAT. PWR. TO PLAT. OPTION WIRE HORN RETRACT EXTEND SWING F.C. SWING RIGHT SWING LEFT PRIMARY F.C. PRIMARY DN. PRIMARY UP SEC.BOOM UP JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRV. ENA.

OG/BK-41

ORG-40

HORSEPOWER LIMITER BOARD

RED FROM CR14

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

RED-10

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

GRD. STUD
RED/BLK-28

WHT JIB CABLE BLK JIB CABLE CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE F.S.

H1

+ TILT _
ALARM

5
RED-1 WHT-23 RED TO STOP SW RED TILT AL. RED TIM.DEL. WHT/RED-32 WHT-30 RED JUMP BLK-22 BLK-26 WHT-24 TO H.P.L. RED TO JIB CABLE BLU-36 BRN TO GRD. BLU/RED-13 BLU/BLK-37 ORG-14 RED-10 TO H.P.L. BLU-10 BLU/BLK-11 RED/WHT-29 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 GRN/WHT-19 BLK/RED-35 RED-25 WHT/BLK-31 WHT/BLK-5 ORG/BLK-15 GRN-17 ORG/RED-16 BLK/RED-9 BLK-33 WHT-4 RED/BLK-2 WHT/RED-6

NC
R

NO
A

CR13

NC
- X

BP1 NO

TS13

- X

JIB VALVE RELAY NC NO JIB CUTOUT RELAY

CR14

L1

RED/WHT-3

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. SEC.BOOM BP2

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 JIB TS8 TS1 AUXILIARY PUMP DRIVE SPEED R2
100

+
- X
R

DRIVE DP1 DRV.ENA TS15

GRN/WHT + RED OUTPUT BRN TIME DELAY T1

PLATFORM LEVEL P3 NO TS9

R3
250

NC TS2 START TS4

NC

HORN

TS14

HIGH/LOW (2WD/4WD)

HIGH/LOW RPM

EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 44

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25J Deutz Models (before serial number 13099)

Section 6 Schematics

First Edition Second Printing

Electrical Schematic, Z-45/25J Deutz Models (from serial number 13099 to 16303)
A B C D E
SEE NOTE 1

M
SEE NOTE 2

N
ORG/BLK

TP22

P2 BLK

TP26

BLK

FS1 BLK

RED

RED TP24

TP25 TP21

RED WHT WHT TS50

WHT

WHT LIFT/ DRIVE TS2

TS1
BLK-2 WHT START GLOW PLUG

TS6

TS47

TS4

SELECTOR OPTION

GENERATOR

AUXILIARY PUMP

2
CB1 15AMP. RED TP41 P1 RED TB22

P3 HORN
BLK

ENGINE

KS1 PLAT GRND

TP9

TP23 TP28

TP27

TP33

TP34

TP45

ENGINE SPEED

TP35 RED RED

WHT-2

BLK/RED-3

RED/BLK-1

RED-1

BLK-1

BLK-1

GRN/WHT-1

BLK/RED-1

ORG/BLK-1

TS51
START AUXILIARY PUMP

TS52

TS56
GLOW PLUG

TS54
LOW RPM HIGH RPM

RED

TB45

ENGINE

BLK

BLK

FUNCTION ENABLE

TB28
RED

TB27

TB33
1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND 6 BATTERY MODULE 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

TB34

TB9 TB41 CB2

TB23

TB20
RED#20-E.H.

15AMP.

RED CR1 CR2 NO TB21 CR2

L2 OIL PRES. L3 OIL TEMP.


BLK/WHT#34-E.H.

TB35

RED/WHT#23-E.H.

BLK/RED

CR1 NO

CR3 NO CR3 CR4 NO CR4


GRN/WHT#45-E.H.

WHT/BLK

WHT/RED

BLK#22

BLK/RED

RED/WHT#23-E.H.

RED/BLK#28-E.H.

RED#27-E.H.

BLK#R1-E.H.

TB24

WHT#21

WHT

WHT#21-E.H.
ALTERNATOR EXCT.

ORG/BLK#41-E.H.

FB

BLK/RED#R4-E.H.

CR5 NO
BLK/RED#R5-E.H.

CR5

PR1 NO
WHT

PR1

TB25 TB26
WHT/RED#26 E.H.

PR2 NO

WHT/BLK#25 E.H.

PR2

RED

12 V DC +

BAT.

BAT. -

STA.

1
REGULATOR

OPS 3 NC

AUX PUMP

STARTER

HM 2

BLK

IND.

OIL TEMPERATURE SWITCH NO BRN


FLASHING BEACON OPTION OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH OIL TEMPERATURE LED OIL PRESSURE LED CE MODELS) HIGH IDLE CUTOUT RELAY OPTION (REQUIRED FOR HIGH IDLE RELAY GENERATOR OPTION RPM SOLENOID LIFT/DRIVE SELECTOR GLOW PLUG

NOTE:
1) The connection to TP24 is for units without the generator option.

2) 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.

6 - 45

BRN STARTER MOTOR AUXILIARY POWER RELAY IGNITION/START RELAY HOUR METER POWER RELAY

HORN RELAY

TILT ALARM

FUEL SOLENOID

Genie Z-45/25 & Genie Z-45/25J

HORN

LEVEL SENSOR

AUXILIARY PUMP

Part No. 52709

Electrical Schematic, Z-45/25J Deutz Models (from serial number 13099 to 16303)

First Edition Second Printing

BRN-2 GROUND

TB30 TB13

TP13

L1

NCHO

BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1

TS15

TP30

LS4

NOHC

TB16

WHT#12-C.H.

TP16

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TP31

TB31

WHT/BLK-1 DRIVE EDC

WHT/BLK#31-C.H.

WHT/RED-1 WHT/RED#32-C.H. BRAKE RELEASE VALVE

TRAVEL ALARM OPTION

BLU/BLK-1 BLU/BLK#37-M.H. STEER RIGHT

BLU-1 BLU#36-M.H. STEER LEFT

TP29

TB29

RED/WHT-1 MOTOR STROKE

RED/WHT#29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

RED

BLK 100

Section 6 Schematics

CE MODELS ONLY

250

R2

R3

WHT#40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

LS1 NCHO

ORG-1

WHT#40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

WHT#40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

HORSEPOWER LIMITER BOARD

TS13

TP7

BLK-3 BLK/WHT-3

BOOM

TB7

RETRACT

TP8

EXTEND

BLK#7-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT#8-M.H.

EXTEND

TP6

TP4 TP5

TS63

RETRACT

WHT/RED-3 WHT/BLK-3

TB5

WHT-3 WHT/BLK#5-M.H. WHT#4-M.H.


RIGHT TURNTABLE ROTATE

TB8

BOOM

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

PWM A

TS62

LEFT

R4

10

TB4

WHT/RED#6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED#1-M.H.

TS61

UP PRIMARY DOWN BOOM

PRIMARY BOOM UP PRIMARY BOOM DOWN

TB2

RED/BLK#2-M.H.

PWM A

TB3

RED/WHT#3-M.H.

TP1

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP10 TP11

BLU/BLK-3

TB10

BLU-3 BLU

BLU#10-M.H.

PWM A

UP SECONDARY

SECONDARY BOOM UP

TS60

DOWN BOOM

BLU/BLK

BLU/BLK#11-M.H.

BP2

SECONDARY BOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT#12-M.H.

SECONDARY BOOM FLOW CONTROL

TP14

ORG-3 ORG/BLK-3

TP15

TS9

TS59

TB14

UP PLATFORM DOWN LEVEL

CR7 NC

ORG#14-M.H.
UP PLATFORM DOWN LEVEL

PLATFORM LEVEL UP ORG/BLK#15-M.H. PLATFORM LEVEL DOWN

TB15

PLATFORM LEVEL

CUTOUT (CE MODELS ONLY)

CR13 NC

TP18

GRN/BLK-3 GRN-3

TP17

TS8

UP

TS58

TB18

DOWN JIB BOOM

GRN/BLK#18-M.H.
UP DOWN JIB BOOM

CR8 NC

JIB BOOM DOWN GRN#17-M.H. JIB BOOM UP

TS57

TS7

LEFT

RIGHT PLAT ROTATE

LEFT

RIGHT PLAT ROTATE

TB17

CR9 NC

DESCENT ALARM OPTION

TP19

BRN
+

GRN/WHT-3

TB19

ORG/BLK

RED

WHT

WHT

BRN

RED

RED

CR9

TI

BRN

Part No. 52709

TB40

TP40

LS2

1 2 3 4 5 6 7 8 9 10

NO

LS3 NO

Genie Z-45/25 & Genie Z-45/25J

TP32

TP37

TP36

DP1

1 2 3 4 5 6 7 8

RED

TB36

TB37

TB32

6 - 46

First Edition Second Printing

Section 6 Schematics

Electrical Schematic, Z-45/25J Deutz Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Deutz Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Deutz Models (from serial number 13099 to 16303)
A 1
GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL
STACKED CONTACTS KS1
BLK-R1#86
M.H.

J
LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS58 TS59 TS63 TS61 TS62 TS60 CB1 CB2 HM R4 L2 CR1 CR2

K
DESCRIPTION

START RELAY TACHOMETER START INPUT


AUX. ON GROUND BATTERY

ORG/BLK-41A BLK-33D RED-27B BRN-GRD. RED-R2 # 30

2 3

IGN./START MODULE

5 6

EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED IGNITION / START RELAY POWER RELAY

WHT-23A

KEY PWR.

NO

NO

SECON.4
EXT.6

KEY BYPASS IGN./FUEL ON

P1 NC
NO

KS1
NO

AUXILIARY

WHT-R2#86
WHT-24D

3
PRIM.5

BASE TERMINATION BLOCK

10

ENG. FAULT

D
RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4
BLU-4 BLU/BLK-4
BLK-ENA. ORG-4/R7 ORG/BLK-4/R8
RED-ENA. GRN-4 GRN/BLK-4

C
RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3
BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.#6 BLK-2 WHT-2

B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5
BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-SP OG/BK-SP

NC
PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM
KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

TS51
WHT/BLK # 25
WHT/RED #26
LED

WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2

STOP

+
L2

OIL PRESS

RED/WHT #3 RED/BLK #2 RED #1 BLK #7

CR3 CR4 CR5 CR7 CR8

HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

HOUR METER 3
RED

BLK/RED#35B
RED-ISM#6

WHT#12-E.H.1 GRN-S.P. GR/BK-S.P.


GR/WT-S.P. RED-S.P.

BLU/WHT #12 BLK/WHT-34


R4
TS56

L3 OIL TEMP.

TS61
PRIMARY BOOM
TS58
EXTEND RETRACT

BLK/WHT #8

TS63
WHT #4 WHT/BLK #5 WHT/RED #6
BLK#R1-E.H.

WHT-ISM#9 RED-CB1

CR1
BLK-ISM#1

CR2

CR3

CR4

RED-C.H.
WHT-E.H.1

TS60
TS52

5
1

WHT-S.P. BLK-S.P. WHT-S.P.

RD/WT-C.H.
WHT-ISM#10

WHT-ISM#7
WHT/BLK-SP WHT/RED-SP RED-S.P.

TS62
JIB

WHT/BLK-EH.1

TURNTABLE ROTATE

WT/RD-E.H.1 RED-C.H RED/BLK-C.H RED/WHT-C.H WHT-ENA. WT/BK-E.H.1


WHT/RED-C.H BLK-ISM#3

BLK/RED #35

GLOW PLUG

START

SEC. BOOM

WHT#21

BLK/RED#R4-EH WHT-40B

RED-1 RED/BLK-1 R/W-1


WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

RED-ISM#4

TS54

CB1

CB2

TS59

GRN/WHT #19

BLK/RED#R5-AH.
CR5

GRN/BLK #18 GRN #17

ORG-4
CR7

ORG/BLK-4
CR8

6
WHT#40-R7 WHT-PRIM.#5

BLK/WHT-E.H.1

BLK-S.P. BLK/WHT-34 BK/RD-R3#35


BK/RD-SP

BLU #10

FUNCTION ENABLE

PLAT.
LEVEL

BLU/BLK #11
RED #20 RED-R1
BLK #33

TS57 PLATFORM ROTATE

BRN GRND H.M

BLU-M.H. BU/BK-M.H.

ORG #14 ORG/BLK #15

BLK#22 BLK/RED-9A

WHT-SEC#4

WHT-EXT.#6

CH+EH1

OG/BK-E.H.1

OG/BK-IM2

PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

GR/WT-C.H

ORG/BLK-15
GRD-HOLE

ORG-14

BLK/RED-EH-r.male BLK/RED-EH-r.fem

r.fem-BLK/RED-R4 r.male-BLK/RED-R5 r.male-BLK-R1


r.fem-ORG-R7 r.fem-ORG/BLK-R8

BLK-E.H-r.fem
ORG-M.H.-r.male ORG/BLK-M.H.-r.male

WIRE CONNECTION ABBREVIATION KEY: EH C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

6 - 47

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25J Deutz Models (from serial number 13099 to 16303)
N M L K J
PLATFORM CONTROL BOX
LABEL P2 P3 TS1 TS2 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS50 R2 R3 L1 BP1 BP2 CR13 CR14 H.P.L. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM

A 1

WHT-24

1 2 3 4 5 6 7 8 9 10

(SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE)

SEC. BOOM UP

(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER |BOARD

RED FROM CR14

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

RED-10

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

GRD. STUD

RED/BLK-28
H1 + TILT _ ALARM CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE F.S.

WHT JIB CABLE BLK JIB CABLE

RED-1

WHT-23

RED TO STOP SW RED TILT AL. RED TIM.DEL.

WHT/RED-32 WHT-30

RED JUMP

BLK-22

BLK-26

BLK/WHT-34

WHT-24 TO H.P.L.

RED TO JIB CABLE

BLU-36

BRN TO GRD.

BLU/RED-13

BLU/BLK-37

ORG-14
P3

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

GRN/WHT-19

BLK/RED-35 RED-25

WHT/BLK-31

WHT/BLK-5

ORG/BLK-15

GRN-17

ORG/RED-16

NC

NO

CR13

NC

- X

BP1 NO

- X

JIB VALVE RELAY NC NO JIB CUTOUT RELAY

CR14

L1

TS13

NO

TS1 AUXILIARY PUMP DRIVE SPEED

100

250

BLK/RED-9

BLK-33

WHT-4

RED/BLK-2

WHT/RED-6

RED/WHT-3

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. SEC.BOOM BP2

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7

+
- X
R
TS8 JIB R2 R3 TS6 DRV.ENA TS15 TS2 START TS14 GLOW PLUG

GRN/WHT + RED OUTPUT BRN DRIVE TIME DELAY T1

PLATFORM LEVEL TS9

NC TS4

NC

HORN

HIGH/LOW (2WD/4WD)

HIGH/LOW RPM EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 48

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25J Deutz Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring Diagram- Lift/Drive SelectOption, Z-45/25J Deutz Models (from serial number 13099 to 16303)
N M L K J
PLATFORM CONTROL BOX
LABEL P2 P3 TS1 TS2 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS50 R2 R3 L1 L3 BP1 BP2 CR13 CR14 H.P.L. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM

A 1

WHT-24

1 2 3 4 5 6 7 8 9 10

(SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE)

SEC. BOOM UP

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

RED FROM CR14

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

RED-10

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

GRD. STUD

RED/BLK-28
CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE F.S.

WHT JIB CABLE

BLK JIB CABLE

+ TILT _
ALARM

H1

RED-1

WHT-23

RED TO STOP SW RED TILT AL. RED TIM.DEL.

WHT/RED-32 WHT-30

RED JUMP

BLK-22

BLK-26

BLK/WHT-34

WHT-24 TO H.P.L.

RED TO JIB CABLE WHT-21

BLU-36

BRN TO GRD.

BLU/BLK-37

BLU/RED-13

ORG-14
P3

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

GRN/WHT-19

BLK/RED-35 RED-25

WHT/BLK-31

WHT/BLK-5

ORG/BLK-15

GRN-17

ORG/RED-16

NC

NO

CR13

NC

- X

BP1
NO

- X

JIB VALVE RELAY

CR14

L1

TS13

NC NO

JIB CUTOUT RELAY

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN


TS50

LIFT/ DRIVE SEL.

NO

TS1 AUXILIARY PUMP DRIVE SPEED

100

250

BLK/RED-9

BLK-33

WHT-4

RED/BLK-2

WHT/RED-6

RED/WHT-3

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. SEC.BOOM BP2

+
- X
R
PLATFORM ROTATE TS7 PLATFORM LEVEL TS9

GRN/WHT + RED OUTPUT BRN DRIVE TIME DELAY T1

TS8

JIB

R2

R3 TS6

DRV.ENA TS15 NC NC

GLOW PLUG

TS2 START TS4 HIGH/LOW RPM

HORN

TS14

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 49

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring Diagram- Lift/Drive Select Option, Z-45/25J Deutz Models (from serial number 13099 to 16303)

Section 6 Schematics

First Edition Second Printing

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


A B C D
LOAD SENSE OPTION (SEE DETAIL BELOW)
ORG/BLK

TP22

P2 BLK

TP26

FS1 BLK-(FS)

RED-(FS) WHT-(FS)

TP25 TP24

RED WHT WHT WHT

TS2 TS1
BLK-2 WHT GLOW PLUG START AUAXILIARY PUMP

TS6

TS47
OFF GENERATOR ON

TS4

FOOT SW H/L LOW RPM HIGH RPM

2
TP41 CB1 15AMP. RED P1 RED KS1 PLAT GRND

P3 HORN
BLK

ENGINE

TB22

TP9

TP23

TP28

TP27

TP33

TP34 TP45

ENGINE SPEED TP35 RED RED

WHT-2

BLK/RED-3

RED/BLK-1

RED-1

BLK-1

BLK-1

GRN/WHT-1

BLK/RED-1

ORG/BLK-1

TS51
START

TS52

TS56
GLOW PLUG

TS54
LOW RPM FUNCTION HIGH RPM ENABLE

AUAXILIARY PUMP RED

TB45

ENGINE

BLK

BLK

TB28

TB27

TB33
1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

TB34

RED

TB9 TB41 CB2

TB23

TB20
RED-20-E.H.

15AMP.

RED CR1 CR2 NO TB21 CR2

L2 OIL PRES. L3 OIL TEMP.


BLK/WHT-34-E.H.

TB35

RED/WHT-23-E.H.

BLK/RED

CR1 NO

CR3 NO CR3 CR4 NO CR4


GRN/WHT-45-E.H.

WHT/RED

WHT/BLK

BLK-22

BLK/RED

RED/WHT-23-E.H.

RED/BLK-28-E.H.

RED-27-E.H.

BLK-R1-E.H.

TB24

WHT

WHT-21

WHT-21-E.H.
ALTERNATOR EXCT.

ORG/BLK-41-E.H.

FB

BLK/RED-R4-E.H.

CR5 NO
BLK/RED-R5-E.H.

CR5
WHT RED

PR1 NO

PR1

TB25 TB26
WHT/RED-26 E.H.

PR2 NO

WHT/BLK-25 E.H.

PR2

12 V DC

BAT.

BAT. -

7
LOAD SENSE OPTION
TP22 P2
BLK-26 FS1 BLK-(FS) RED-(FS) WHT-(FS) BLK-26 LOAD C B+

6 - 50

+
REGULATOR

STA.

AUX PUMP

STARTER

1 HM 2 3

OPS NC

BLK

IND.

OTS NO BRN

BRN STARTER MOTOR FLASHING BEACON OPTION LEVEL SENSOR OIL PRESSURE LED

HORN RELAY

TILT ALARM

AUXILIARY POWER RELAY

FUEL SOLENOID

OIL PRESSURE SWITCH

OIL TEMPERATURE LED

HORN

OIL TEMPERATURE SWITCH

POWER RELAY

HOUR METER

IGNITION/START RELAY

HIGH IDLE RELAY

HIGH IDLE CUTOUT RELAY

GENERATOR OPTION

RPM SOLENOID

AUXILIARY PUMP

GLOW PLUG OPTION

TP26

LOAD SENSOR BOX


WHT-LOAD GND 8

TP24

WHT-24

Genie Z-45/25 & Genie Z-45/25J

ORG-LOAD

Part No. 52709

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


1

First Edition Second Printing

BRN-2 GROUND

TP13

TB13

L1

NCHO

BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1

TP30

TB30

LS4

TP31 TP16

WHT-12-C.H.

TS15

NOHC

TB16

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1 DRIVE EDC

WHT/BLK-31-C.H.

TP32

WHT/RED-1 WHT/RED-32-C.H.

TB32

TRAVEL ALARM OPTION

BLU/BLK-1 BLU/BLK-37-M.H. STEER RIGHT

BLU-1 BLU-36-M.H. STEER LEFT

RED/WHT-1 MOTOR STROKE

RED/WHT-29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

RED

BLK 100

CE MODELS ONLY

R2

Section 6 Schematics

WHT-40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

TB40

LS3 NO

LS1 NCHO

WHT-40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TS13

BLK-3 BLK/WHT-3

EXTEND

TB7

RETRACT

BOOM

TP8

BLK-7-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT-8-M.H.

EXTEND BOOM

TS63

RETRACT

TP6

WHT/RED-3 WHT/BLK-3

TP5

TB5

WHT-3

TB8

TP4

WHT/BLK-5-M.H. WHT#4-M.H.

PWM A + X

TS62

LEFT

RIGHT TURNTABL E ROTATE

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

R4 10

TB4

WHT/RED-6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED-1-M.H.

TS61

DOWN RED/BLK-2-M.H.

TB2

UP PRIMARY BOOM

PRIMARY BOOM UP PRIMARY BOOM DOWN

PWM A + X

TB3

REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY)

TP1

RED/WHT-3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3

TB10

BLU-3

TP10

BLU UP DOWN SECONDARY BOOM BLU/BLK

BLU-10-M.H.

SECONDARY BOOM UP

PWM A + X

TS60

BLU/BLK-11-M.H.

BP2

SECONDARY BOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT-12-M.H.

TP14

SECONDARY BOOM FLOW CONTROL

ORG-3 ORG/BLK-3

UP

TS9

DOWN

TS59

TB14

PLATFORM LEVEL

CR7 NC

TP15

ORG-14-M.H. UP DOWN PLATFORM LEVEL ORG/BLK-15-M.H.

PLATFORM LEVEL UP PLATFORM LEVEL DOWN

TB15

PLATFORM LEVEL

MODELS ONLY)

CUTOUT (CE

WHT

TP18

GRN/BLK-3 GRN-3

TS7

LEFT

TS57

TB18

RIGHT PLATFORM ROTATE

TP17

GRN/BLK-18-M.H. LEFT RIGHT PLATFORM ROTATE GRN-17-M.H.

CR8 NC

PLATFORM ROTATE RIGHT PLATFORM ROTATE LEFT

TB17

DESCENT ALARM OPTION

ORG/BLK

RED

BRN

WHT

RED

BRN

Part No. 52709

ORG-1

WHT-40-4 BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

TP40

LS2

1 2 HORSE- 3 4 POWER 5 LIMITER 6 BOARD 7 8 9 10

TP7

NO

Genie Z-45/25 & Genie Z-45/25J

BRAKE RELEASE VALVE

TP37

DP1

RED

TP36

1 2 3 4 5 6 7 8

R3

TP29

TB29

TB36

TB37

6 - 51

First Edition Second Printing

Section 6 Schematics

Electrical Schematic- Z-45/25 Deutz Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Deutz Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Deutz Models (after serial number 16303)
A 1
GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL
STACKED CONTACTS KS1

J
LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2
WHT/BLK-25 WHT/RED-26

K
DESCRIPTION

2
M.H.

BLK-R1-86 ORG/BLK-41A BLK-33D RED-27B BRN-GRD. RED-R2#30 WHT-23A

1 2 3 4 5 6 7 8

START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT

NO

EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY SERVICE HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

NO

IGN./START MODULE
P1 NC
NO

SECON.4 EXT.6

KS1
NO

WHT-R2#86 WHT-24D

AUXILIARY

9 10

BASE TERMINATION BLOCK

D
RED-4 RED/BLK-4 R/W-4 PRIM.5 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA. ORG-4/R7 ORG/BLK-4/R8 RED-ENA. GRN-4 GRN/BLK-4 RED-C.H. WHT-E.H.1 RD/WT-C.H. WHT-ISM-10 1 WHT/BLK-EH.1 WT/RD-E.H.1 RED-C.H RED/BLK-C.H RED/WHT-C.H WHT-ENA. WT/BK-E.H.1

C
RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.-6 BLK-2 WHT-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-SP OG/BK-SP WHT-12-E.H.1 GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P. WHT-S.P. BLK-S.P. PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

NC WHT-23 BLK-22 RED-27 BRN-(R5) BRN-(GRND) WHT-21 WHT-21 (R2) STOP

TS51

4
3

L2 1 2

LED

OIL PRESS

RED/WHT-3 RED/BLK-2 RED-1 BLK-7

CR3 CR4 CR5 CR7 CR8

HOUR METER 3
RED

BLK/RED-35B RED-R2 WHT-R2 RED-R1

BLK/WHT-8 TS61 PRIMARY BOOM TS60 TS63 EXTEND RETRACT WHT-4 WHT/BLK-5 WHT/RED-6 TS62 TURNTABLE ROTATE

BLU/WHT-12
BLK/WHT-34

L3 OIL TEMP.

R4
TS56

CR1 BLK-R1 BLK-R1-E.H. WHT-21

CR2

CR3

CR4

TS52

WHT-S.P.

WHT-ISM-7 WHT/BLK-SP WHT/RED-SP RED-S.P.

BLK/RED-35

GLOW PLUG

START

SEC. BOOM

BLK/RED-R4 WHT-40B

RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1

RED-ISM-4

TS54

CB1

CB2

TS59

6
WHT#40-R7 WHT-PRIM.#5

WHT/RED-C.H BLK-ISM-3

GRN/WHT-19 GRN/BLK-18 GRN-17 PLAT. LEVEL TS57 PLATFORM ROTATE


BRN-(GRND H.M)

BLK/RED-R5 CR5 CR7

ORG-4 CR8

ORG/BLK-4

BLK-1 BLK/WHT-E.H.1 BLK/WHT-1 BLK/RED-35GEN BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

BLK-S.P. BK/RD-R3#35 BK/RD-SP

BLU-10 BLU/BLK-11 RED-20 RED-R1 BLK-33

FUNCTION ENABLE

BLU-M.H. BU/BK-M.H.

ORG-14 ORG/BLK-15

BLK-22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

WHT-SEC#4

CH+EH1

OG/BK-E.H.1

WHT-EXT.#6 OG/BK-IM2

GR/WT-C.H

BLK/RED-35GEN

ORG/BLK-15
GRD-HOLE

ORG-14

BLK/RED-EH-r.male BLK/RED-EH-r.fem

r.fem-BLK/RED-R4 r.male-BLK/RED-R5 r.male-BLK-R1 r.fem-ORG-R7 r.fem-ORG/BLK-R8


WIRE CONNECTION ABBREVIATION KEY: EH C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

BLK-E.H-r.fem ORG-M.H.-r.male ORG/BLK-M.H.-r.male

6 - 52

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25 Deutz Models (after serial number 16303)
N M L K J
PLATFORM CONTROL BOX

COMPONENT INDEX
P2 P3 TS1 TS2 TS3 TS6 TS7 TS8 TS9 TS13 TS11 TS12 TS10
TS47 R1

WHT-24
1 2 3 4 5 6 7 8 9 10
TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT.

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

RED-10

EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG OPTION (DIESEL ONLY) PLATFORM ROTATE SWITCH JIB UP/DOWN (JIB OPTION ONLY) PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH
GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY )

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT.

(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

(UNUSED) (SPARE) STEER RIGHT STEER LEFT

OPTION WIRE

(SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH

START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD

HIGH/LOW RPM GLOW PLUG

SEC. BOOM F.C. SEC. BOOM DN.

SEC. BOOM UP

GEN. (OPTION)

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
WHT

RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

GRD. STUD
RED-TILT

R2 R3 L1 L3 BP1 BP2 CR12 CR13

LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY ( JIB ONLY )

RED/BLK-28

CABLE #3

CABLE #2

CABLE #1

110

F.S.

TILT ALARM

CR14 DP1 H.P.L. T1

JIB VALVE RELAY ( JIB ONLY )


DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD

TIME DELAY ( JIB ONLY ) TILT ALARM

GRN/WHT-45

SIDE VIEW DP1


WHT TO PLATFORM ROTATE

WHT-4

RED/BLK-2

GRN/WHT-19

RED/WHT-3

BLK/WHT- 34

BLU/RED-13

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

BLK/RED-35 RED-25

ORG-14

WHT/BLK-5

GRN-17

ORG/RED-16

ORG/BLK-15

BLK-33

RED-1

NC
R

NO
A

L1

- X

BP1
NO

+ - X

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7


TS1
100

TS13

NC NO

SEE SIDE VIEW DP1

P3

NO

250

BLK/RED-9

BLU-36

RED-TILT

WHT/RED-6

BLU/BLK-37

BLK-22

WHT-23

WHT/BLK-31

BRN TO GRD.

WHT-24 TO H.P.L.

BLK-26

WHT-30

WHT/RED-32

PRIMARY BOOM EXTEND/ RETRACT

SEC.BOOM BP2

GENERATOR OPTION TS47

NC

8 7 6 5 4 3 2 1

RED-GEN

+
X R

DP1 DRIVE

PLATFORM LEVEL
TS9

DRV.ENA TS15
TS6 GLOW PLUG TS2

7
NC
TS4

NC

AUXILIARY PUMP

START HIGH/LOW RPM

HORN

DRIVE SPEED

TS14

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 53

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25 Deutz Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring Diagram- Lift/Drive SelectOption, Z-45/25 Deutz Models (after serial number 16303)
N M L K J
PLATFORM CONTROL BOX

A 1

COMPONENT INDEX
P2 P3 TS1 TS2 TS6 TS7 TS9 TS10 TS11 TS12 TS13
TS47

WHT-24
1 2 3 4 5 6 7 8 9 10 (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.
(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH GENERATOR SWITCH ( OPTION ) LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD TILT ALARM

GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (UNUSED)

SEC. BOOM UP

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

RED-10

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

GRD. STUD
RED-TILT

R2 R3 L1 L3 BP1 BP2 DP1 H.P.L. H1

RED/BLK-28

H1

CABLE #3

CABLE #2

CABLE #1

110

F.S.

+ TILT ALARM

5
SIDE VIEW FOR DP1
WHT TO PLATFORM ROTATE

GRN/WHT-45

WHT-4

RED/BLK-2

BLK/WHT- 34

BLU/RED-13

ORG-14

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

GRN/WHT-19

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

RED/WHT-3

BLK/RED-35 RED-25

ORG/BLK-15

WHT/BLK-5

GRN-17

ORG/RED-16

NC
R

NO
A

L1

NC
- X

BP1
NO

+ - X

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS1 AUXILIARY PUMP DRIVE SPEED TS15 R2
100

TS13

NC NO

SEE SIDE VIEW DP1

P3

NO

250

BLK/RED-9

BLK-33

RED-1

WHT/RED-6

BLU-36

BLU/BLK-37

RED-TILT

WHT-30

BRN TO GRD.

WHT-24 TO H.P.L.

WHT/BLK-31

BLK-22

BLK-26

WHT-23

WHT/RED-32

PRIMARY BOOM EXTEND/ RETRACT

SEC.BOOM BP2

GENERATOR OPTION TS47

8 7 6 5 4 3 2 1

RED-GEN

+
X R

DP1 DRIVE

PLATFORM LEVEL TS9

R3 TS6

DRIVE ENABLE TS2 NC TS4 NC

GLOW PLUG

START HIGH/LOW RPM

HORN

TS14

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 54

First Edition Second Printing

Section 6 Schematics

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

BRN

WHT

ORG/BLK

RED

RED RED

CR13

RED

BRN
JIB BOOM CUTOUT RELAY (CR-13) JIB BOOM VALVE RELAY (CR-14) JIB BOOM VALVES

JIB CUTOUT RELAY JIB VALVE RELAY

JIB VALVES

CR14 NO

CR14

BLK/RED-1

ENGINE SPEED

LOW RPM FUNCTION HIGH RPM ENABLE

TS4

BLK/RED
HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY

TB35

CR3 NO CR3

FOOTSW. H/L LOW RPM HIGH RPM

TP35

TS54

CR4

BLK/RED-R4-E.H.

OFF GENERATOR

CR4 NO

RPM SOLENOID

TS47

ON

GRN/WHT-1

GRN/WHT-45-E.H.

GENERATOR OPTION

TP45

TB45

TB34

FB

RED/WHT-23-E.H.

FLASHING BEACON OPTION

TP34

TS6

BLK-1
GLOW PLUG OPTION

BLK/WHT-34-E.H.

TS56

GLOW PLUG GLOW PLUG


BLK

WHT/RED

PR2 NO

PR2

L2 OIL PRES.

L3 OIL TEMP.

OIL TEMPERATURE LED

WHT/BLK
OIL PRESSURE LED

TP33

1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON 5 GROUND 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

IGN./START MODULE

TS2

BLK-1
WHT/RED-26 E.H. OIL TEMPERATURE SWITCH OIL PRESSURE SWITCH

TS52

START
WHT/BLK-25 E.H.

START

ENGINE

TB24

TB25

ENGINE

TB26

TB33

BLK

CR2

OPS NC

OTS NO

POWER RELAY

TB21

FUEL SOLENOID

CR2 NO

WHT

3 HM
WHT-21

HOUR METER

CR1

IGNITION./START RELAY

First Edition Second Printing

BLK-R1-E.H.

STARTER MOTOR

TP27

AUXILIARY PUMP

RED-27-E.H.

LOAD SENSE OPTION (SEE DETAIL BELOW)

RED-1

WHT-(FS)

RED-(FS)

PR1

AUXILIARY PUMP

RED

AUXILIARY POWER RELAY

AUX PUMP

AUXILIARY PUMP

PR1

FS1

TP28

WHT

RED/BLK-1

TB28

RED/BLK-28-E.H.

NO

WHT

BLK-(FS)

TILT ALARM

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

WHT-2

RED/WHT-23-E.H.

RED

BLK

BRN

LEVEL SENSOR

BLK

TP26

TP23

TB23

TB22

TP22

CR5 NO

HORN

GRND

KS1 PLAT

LOAD SENSOR BOX

RED

WHT-LOAD

BLK-2

BLK-22

BLK/RED-R5-E.H.

TP24

BLK

BLK/RED-3

BLK/RED

HORN RELAY

P1

TP41

TB41

ORG/BLK-1

ORG/BLK-41-E.H.

LOAD SENSE OPTION

BAT. -

STA.

RED

RED

IND.

WHT-21-E.H.
ALTERNATOR

EXCT.

RED-(FS)

WHT-(FS)

15AMP.

Section 6 Schematics

CB2

15AMP.

CB1

FS1 BLK-(FS)

BAT. +

TB20

RED

RED-20-E.H.

12 V DC

TP22

P2

BLK-26

TP26

BLK-26 LOAD

REGULATOR

B+

GND

ORG-LOAD

6 - 55 1 2 3 4 5 6 7 8

Genie Z-45/25 & Genie Z-45/25J


P3 HORN
TP9

P2

TB9

WHT-24

CR5

Part No. 52709


CR1 NO
STARTER

RED

WHT WHT

TP25

TP24

TS51

TB27

TS1

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

First Edition Second Printing

BRN-2 GROUND

TP13

TB13

L1

NCHO

BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1

TP30

TB30

LS4

TP31 TP16

WHT-12-C.H.

TS15

NOHC

TB16

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1 DRIVE EDC

WHT/BLK-31-C.H.

TP32

TB32

WHT/RED-1 WHT/RED-32-C.H. BRAKE RELEASE VALVE

TRAVEL ALARM OPTION

BLU/BLK-1 BLU/BLK-37-M.H. STEER RIGHT

BLU-1 BLU-36-M.H. STEER LEFT

RED/WHT-1 MOTOR STROKE

RED/WHT-29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

R3

RED

BLK 100

Section 6 Schematics

CE MODELS ONLY

R2

WHT-40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

TB40

LS3 NO

LS1 NCHO

ORG-1

WHT-40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

WHT-40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TS13

TP7

BLK-3 BLK/WHT-3

EXTEND BOOM

TB7

RETRACT

TP8

BLK-7-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT-8-M.H.

EXTEND

TS63

RETRACT

BOOM

TP6

WHT/RED-3 WHT/BLK-3

TP5

TB5

WHT-3

TB8

TP4

WHT/BLK-5-M.H. WHT#4-M.H.

RIGHT

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

PWM A + X

TS62

LEFT

TURNTABLE ROTATE

R4 10

TB4

WHT/RED-6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED-1-M.H.

TS61

UP PRIMARY DOWN BOOM

PRIMARY BOOM UP PRIMARY BOOM DOWN

TB2

RED/BLK-2-M.H.

PWM A + X

TB3

REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY)

TP1

RED/WHT-3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3

TB10

BLU-3

TP10

BLU UP SECONDARY DOWN BOOM BLU/BLK

BLU-10-M.H.

SECONDARY BOOM UP

PWM A

TS60

BLU/BLK-11-M.H.

BP2

SECONDARY BOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT-12-M.H.

TP14

SECONDARY BOOM FLOW CONTROL

ORG-3 ORG/BLK-3

TS9

TS59

TB14

UP PLATFORM DOWN LEVEL

CR7 NC

TP15

ORG-14-M.H. UP PLATFORM DOWN LEVEL ORG/BLK-15-M.H.

PLATFORM LEVEL UP PLATFORM LEVEL DOWN

TB15

PLATFORM LEVEL

CUTOUT (CE MODELS ONLY)

WHT

CR13 NC

TP18

GRN/BLK-3 GRN-3

TS8

TS58

TB18

DOWN JIB BOOM UP

TP17

GRN/BLK-18-M.H. DOWN JIB BOOM UP GRN-17-M.H.

CR8 NC

PLATFORM ROTATE RIGHT / JIB BOOM DOWN PLATFORM ROTATE LEFT / JIB BOOM UP

TS57

WHT

TS7

LEFT

RIGHT PLAT ROTATE

RIGHT LEFT PLAT ROTATE

TB17

CR9 NC

TP19

DESCENT ALARM OPTION GRN/WHT-3

BRN

TB19

ORG/BLK

WHT

RED

RED

RED

CR9

TI

BRN

BRN

Part No. 52709

TP40

LS2

HORSEPOWER LIMITER BOARD

1 2 3 4 5 6 7 8 9 10

NO

Genie Z-45/25 & Genie Z-45/25J

TP37

DP1

RED

TP36

1 2 3 4 5 6 7 8

TP29

TB29

TB36

TB37

6 - 56

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Deutz Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Deutz Models (after serial number 16303)
A 1
GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL
STACKED CONTACTS KS1
BLK-R1-86 M.H. ORG/BLK-41A BLK-33D RED-27B BRN-GRD. RED-R2#30 WHT-23A 1 2 3 4 5 6 7 8 WHT-R2#86 WHT-24D 9 10 START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT

J
LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS58 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2 CR3 CR4 CR5 CR7 CR8
BLK/RED-35B RED-R2 WHT-R2 RED-R1

K
DESCRIPTION

NO

EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

NO

IGN./START MODULE
P1 NC
NO

SECON.4 EXT.6

KS1
NO

AUXILIARY

3
PRIM.5

BASE TERMINATION BLOCK

D
RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA. ORG-4/R7 ORG/BLK-4/R8 RED-ENA. GRN-4 GRN/BLK-4 RED-C.H. WHT-E.H.1 RD/WT-C.H.

C
RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.-6 BLK-2 WHT-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-SP OG/BK-SP WHT-12-E.H.1 GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P. WHT-S.P. BLK-S.P. PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

NC WHT-23 BLK-22 RED-27 BRN-(R5) BRN-(GRND) WHT-21 WHT-21 (R2) STOP

TS51 WHT/BLK-25 WHT/RED-26


LED

+
L2 1 2

OIL PRESS

RED/WHT-3 RED/BLK-2 RED-1 BLK-7

HOUR METER 3
RED

BLK/WHT-8 TS61 TS63 EXTEND RETRACT WHT-4 WHT/BLK-5 WHT/RED-6 TS62 TURNTABLE ROTATE

BLU/WHT-12
BLK/WHT-34

L3 OIL TEMP.

R4
TS56

TS52

PRIMARY BOOM TS60 TS58

CR1 BLK-R1 BLK-R1-E.H. WHT-21

CR2

CR3

CR4

WHT-S.P.

WHT-ISM-7 WHT/BLK-SP WHT/RED-SP RED-S.P.

WHT-ISM-10 1 WHT/BLK-EH.1 WT/RD-E.H.1 RED-C.H RED/BLK-C.H RED/WHT-C.H WHT-ENA. WT/BK-E.H.1 WHT/RED-C.H BLK-ISM-3 BLK/WHT-E.H.1 RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1

BLK/RED-35

GLOW PLUG

START

SEC. BOOM

JIB
WHT-40B

BLK/RED-R4

RED-ISM-4

TS54

CB1

CB2

TS59

GRN/WHT-19 GRN/BLK-18 GRN-17 PLAT. LEVEL TS57 PLATFORM ROTATE


BRN-(GRND H.M)

BLK/RED-R5 CR5 CR7

ORG-4 CR8

ORG/BLK-4

BLK-S.P. BK/RD-R3#35 BK/RD-SP

BLU-10 BLU/BLK-11 RED-20 RED-R1 BLK-33

FUNCTION ENABLE

WHT#40-R7 WHT-PRIM.#5

BLK/RED-35GEN BLK/RED-1 BLU-M.H. BLU-1 BU/BK-M.H. BLU/BLK-1 BLU/WHT-1 BLU/RED-1

ORG-14 ORG/BLK-15

BLK-22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

CH+EH1

OG/BK-E.H.1

ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

WHT-SEC#4

WHT-EXT.#6 OG/BK-IM2

GR/WT-C.H

BLK/RED-35GEN

ORG/BLK-15

7
BLK/RED-EH-r.male BLK/RED-EH-r.fem BLK-E.H-r.fem ORG-M.H.-r.male

GRD-HOLE

ORG-14

r.fem-BLK/RED-R4 r.male-BLK/RED-R5 r.male-BLK-R1 r.fem-ORG-R7 r.fem-ORG/BLK-R8 WIRE CONNECTION ABBREVIATION KEY:


EH C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

ORG/BLK-M.H.-r.male

6 - 57

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25J Deutz Models (after serial number 16303)
N M L K J I H G F E D C B A
1
COMPONENT INDEX
P2 P3 TS1 TS2 TS3 TS6 TS7 TS8 TS9 TS13 TS11 TS12 TS10
TS47 R1

PLATFORM CONTROL BOX


EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG OPTION (DIESEL ONLY) PLATFORM ROTATE SWITCH JIB UP/DOWN (JIB OPTION ONLY) PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH
GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY )

WHT-24
1 2 3 4 5 6 7 8 9 10
START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT.

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

(UNUSED) (SPARE) STEER RIGHT STEER LEFT

OPTION WIRE

(SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH

HIGH/LOW RPM GLOW PLUG

SEC. BOOM UP

GEN. (OPTION)

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

RED FROM CR14

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

RED-10

WHT

RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

GRD. STUD
RED-TILT

WHT JIB CABLE

BLK JIB CABLE

R2 R3 L1 L3 BP1 BP2 CR12 CR13

LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY ( JIB ONLY )

RED/BLK-28

CABLE #3

CABLE #2

CABLE #1

110

JIB CABLE

F.S.

TILT ALARM

CR14 DP1 H.P.L. T1

JIB VALVE RELAY ( JIB ONLY )


DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD

TIME DELAY ( JIB ONLY ) TILT ALARM

5
GRN/WHT-45

RED-STP RED-TILT RED TIM.DEL.

RED JUMP

RED TO JIB CABLE

WHT-4

RED/BLK-2

GRN/WHT-19

RED/WHT-3

SIDE VIEW DP1


WHT TO PLATFORM ROTATE

BLU/RED-13

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

BLK/WHT-34

BLK/RED-35 RED-25

ORG-14

WHT/BLK-5

GRN-17

ORG/BLK-15

ORG/RED-16

NC
A + - X

BP1
NO

A + - X

JIB VALVE RELAY

CR14

TS13

NC NO

JIB CUTOUT RELAY

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7

SEE SIDE VIEW DP1

P3

NO

TS1

100

250

BLK/RED-9

BLK-33

RED-1

WHT/RED-6

BLU-36

BLU/BLK-37

WHT-30 WHT/BLK-31

RED-STP

BLK-22

WHT-23

BRN TO GRD.

WHT-24 TO H.P.L.

BLK-26

WHT/RED-32

NC

NO
A + - X R

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. TS47


RED-GEN

SEC.BOOM BP2
CR13

L1

DP1 DRIVE

GRN/WHT + RED OUTPUT BRN


TIME DELAY
T1

8 7 6 5 4 3 2 1

PLATFORM LEVEL
TS9

TS8

JIB
TS6

DRV.ENA TS15

NC
GLOW PLUG

AUXILIARY PUMP

TS2 START TS4

NC

HORN

DRIVE SPEED

TS14

HIGH/LOW (2WD/4WD)

HIGH/LOW RPM

8
EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 58

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25J Deutz Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring Diagram- Lift/Drive SelectOption, Z-45/25J Deutz Models (after serial number 16303)
N M L K J
PLATFORM CONTROL BOX

1
COMPONENT INDEX
P2 P3 TS1 TS2 TS3 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13
TS47

WHT-24
1 2 3 4 5 6 7 8 9 10 (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.
(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH
GENERATOR SWITCH ( OPTION ) LOW SPEED RESISTOR LOW SPEED RESISTOR

GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (UNUSED)

SEC. BOOM UP

RED FROM CR14

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

RED-10

GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT

GRD. STUD
RED-TILT

WHT JIB CABLE

R2 R3 L1 L3 BP1 BP2 CR13 CR14 DP1 H.P.L. T1 H1

DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN,TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN JIB CUTOUT RELAY JIB VALVE RELAY
DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD

RED/BLK-28

BLK JIB CABLE CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE F.S.

H1

+ TILT ALARM

TIME DELAY TILT ALARM

SIDE VIEW FOR DP1


WHT TO PLATFORM ROTATE

GRN/WHT-45

RED-STP RED-TILT RED TIM.DEL.

WHT-4

RED/BLK-2

RED JUMP

RED TO JIB CABLE

BLU/RED-13

ORG-14

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

GRN/WHT-19

BLK/WHT-34

BLK/RED-35 RED-25

RED/WHT-3

WHT/BLK-5

ORG/BLK-15

GRN-17

ORG/RED-16

NC
R

NO
A + - X

CR13

L1

NC
A + - X

BP1
NO

A + - X

JIB VALVE RELAY

TS13

NC NO

JIB CUTOUT RELAY

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS15 TS8 JIB TS1 AUXILIARY PUMP DRIVE SPEED R2
100 250

SEE SIDE VIEW DP1

BLK/RED-9

BLK-33

RED-1

WHT/RED-6

BLU/BLK-37

WHT-30 WHT/BLK-31

BLU-36

WHT/RED-32

RED-STP

BRN TO GRD.

WHT-24 TO H.P.L.

BLK-22

BLK-26

WHT-23

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. TS47


RED-GEN

SEC.BOOM BP2

CR14

DP1 DRIVE

GRN/WHT + RED OUTPUT BRN TIME DELAY T1

8 7 6 5 4 3 2 1

PLATFORM LEVEL TS9 P3 NO

R3 TS6

DRIVE ENABLE NC NC

GLOW PLUG

TS2 START TS4 HIGH/LOW RPM

HORN

TS14

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 59

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

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


A B C D E
SEE NOTE 1

M
SEE NOTE 2

N
ORG/BLK

TP22

P2 BLK

TP26

BLK

FS1 BLK

RED

RED

TP25 TP21

RED WHT WHT TS50

WHT

WHT

TP24 LIFT/ DRIVE TS2 TS1


ENGINE BLK-2 WHT ON START

TS6

TS47
OFF ON

TS4
HIGH RPM FOOTSW. H/L LOW RPM

SELECTOR OPTION

AUXILIARY PUMP

GLOW PLUG

GENERATOR

P3 HORN
BLK

TP41 CB1 RED P1 RED KS1 PLAT GRND TB22

TP9

TP23

TP28

TP27

TP33

TP34

TP45

ENGINE SPEED

TP35
RED RED

15AMP.
ORG/BLK-1

WHT-2

BLK/RED-3

RED/BLK-1

RED-1 AUXILIARY PUMP RED

BLK-1

BLK-1

GRN/WHT-1

BLK/RED-1

TS51

TS52
ENGINE START

TS56
ON GLOW PLUG

TS54
LOW RPM HIGH RPM

TB45

BLK

BLK

FUNCTION ENABLE

4
TB28
RED

TB27

TB33
1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START MODULE 5 GROUND 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

TB34

TB9 TB41 CB2

TB23

TB20
RED#20-E.H.

15AMP.

RED CR1 CR2 NO TB21 CR2

L2 OIL PRES. L3 OIL TEMP.


BLK/WHT#34-E.H.

TB35

RED/WHT#23-E.H.

BLK/RED

CR1 NO

CR3 NO CR3 CR4 NO CR4


GRN/WHT#45-E.H.

WHT/BLK

WHT/RED

BLK#22

BLK/RED

RED/WHT#23-E.H.

RED/BLK#28-E.H.

RED#27-E.H.

BLK#R1-E.H.

TB24

WHT#21

WHT

WHT#21-E.H.

ORG/BLK#41-E.H.

FB

6
ALTERNATOR

BLK/RED#R4-E.H.

CR5 NO
BLK/RED#R5-E.H.

CR5

PR1 NO
WHT

PR1

TB25 TB26
WHT/RED#26 E.H.

PR2 NO

WHT/BLK#25 E.H.

PR2

RED

EXCT. BAT. + BAT. -

12 V DC +

STA.

7
BLK
REGULATOR

1
AUX PUMP

STARTER

HM

OIL PRESSURE SWITCH NC

IND.

OIL TEMPERATURE SWITCH NO BRN


GLOW PLUG FLASHING BEACON OPTION OIL TEMPERATURE SWITCH OIL TEMPERATURE LED OIL PRESSURE LED GENERATOR OPTION HIGH IDLE CUTOUT RELAY RPM SOLENOID LIFT/DRIVE SELECTOR HIGH IDLE RELAY OPTION (REQUIRED FOR CE MODELS)

8
NOTE:

1) The connection to TP24 is for units without the generator option 2) 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

6 - 60

BRN STARTER MOTOR AUXILIARY POWER RELAY IGNITION/START RELAY HOUR METER POWER RELAY OIL PRESSURE SWITCH

HORN RELAY

TILT ALARM

FUEL SOLENOID

Genie Z-45/25 & Genie Z-45/25J

HORN

LEVEL SENSOR

AUXILIARY PUMP

Part No. 52709

First Edition Second Printing

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

BRN-2

TP13

GROUND

TB13

L1

NCHO

BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1

TP30

TS15

TB30

LS4

NOHC

TB16

TP31 TP16

WHT#12-C.H.

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1 DRIVE EDC

WHT/BLK#31-C.H.

TP32

TB32

WHT/RED-1 WHT/RED#32-C.H. BRAKE RELEASE VALVE

TRAVEL ALARM OPTION

BLU/BLK-1 BLU/BLK#37-M.H. STEER RIGHT

BLU-1 BLU#36-M.H. STEER LEFT

RED/WHT-1 MOTOR STROKE

RED/WHT#29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

R3

RED

BLK 100

Section 6 Schematics

CE MODELS ONLY

R2

R1

WHT#40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

50

CR12

LS1 NCHO

ORG-1

WHT#40-4

BRN-4

TP40

SECONDARY BOOM UP DRIVE LIMIT SWITCH

WHT#40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TS13

TP7

BLK-3 BLK/WHT-3

EXTEND BOOM

TP8

TB7

RETRACT

BLK#7-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT#8-M.H.

EXTEND BOOM

TS63

RETRACT

TP6

WHT/RED-3 WHT/BLK-3

TP5

TP4

TB5

WHT-3 WHT/BLK#5-M.H. WHT#4-M.H.

TB8

PWM A + X

TS62

LEFT

RIGHT TURNTABLE ROTATE

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

R4

TB4

WHT/RED#6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED#1-M.H.

TS61

UP PRIMARY BOOM DOWN

PRIMARY BOOM UP PRIMARY BOOM DOWN

TB2

RED/BLK#2-M.H.

PWM A + X

TB3

RED/WHT#3-M.H.

TP1

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP10 TP11

BRN

BLU/BLK-3

TB10

BLU-3 BLU
UP SECONDARY BOOM DOWN BLU/BLK

BLU#10-M.H.

SECONDARY BOOM UP BLU/BLK#11-M.H.

PWM A + X

TS60

BP2

SECONDARY BOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT#12-M.H.

SECONDARY BOOM FLOW CONTROL

TP14

ORG-3 ORG/BLK-3

UP

TS9

DOWN

TP15

TS59

TB14

PLATFORM LEVEL

CR7 NC

ORG#14-M.H.
UP PLATFORM LEVEL DOWN

PLATFORM LEVEL UP ORG/BLK#15-M.H. PLATFORM LEVEL DOWN

TB15

PLATFORM LEVEL

CUTOUT (CE MODELS ONLY)

TP18

GRN-3 GRN/BLK-3

RIGHT

TS7

LEFT

TP17

TS57

TB18

PLATFORM ROTATE

GRN/BLK#18-M.H.
RIGHT PLATFORM ROTATE LEFT

CR8 NC

PLATFORM ROTATE RIGHT GRN#17-M.H. PLATFORM ROTATE LEFT

TB17

DESCENT ALARM (OPTION)

ORG/BLK

WHT

WHT

RED

RED

BRN

Part No. 52709

TB40

LS2

HORSEPOWER LIMITER BOARD

1 2 3 4 5 6 7 8 9 10

NO

LS3 NO

Genie Z-45/25 & Genie Z-45/25J

TP37

DP1

RED

TP36

1 2 3 4 5 6 7 8

TP29

TB29

TB36

TB37

6 - 61

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring Diagram, Z-45/25 Perkins Models (before serial number 16304)
A 1
GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL
STACKED CONTACTS KS1
BLK-R1#86 1 2 3 4 5 6 7 8 WHT-R2#86 WHT-24D 9 10 START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT ORG/BLK-41A BLK-33D RED-27B BRN-GRD. RED-R2 # 30 WHT-23A

J
LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2
WHT/BLK # 25 WHT/RED #26

K
DESCRIPTION

EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

M.H.

IGN./START MODULE

NO

NO

SECON.4 EXT.6

P1 NC

KS1

AUXILIARY

3
PRIM.5

BASE TERMINATION BLOCK

D
RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA. ORG-4/R7 ORG/BLK-4/R8 RED-ENA. GRN-4 GRN/BLK-4 RED-C.H. WHT-E.H.1

C
RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.#6 BLK-2 WHT-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-SP OG/BK-SP WHT#12-E.H.1 GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P. WHT-S.P. BLK-S.P. PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT PLATFORM ROTATE RIGHT JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

NO

NO

NC WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2 STOP

TS51

L2 1 2

LED

OIL PRESS

RED/WHT #3 RED/BLK #2 RED #1 BLK #7

CR3 CR4 CR5 CR7 CR8

HOUR METER 3

BLK/RED#35B RED-ISM#6 WHT-ISM#9 RED-CB1

RED

BLK/WHT #8 TS61 PRIMARY BOOM TS60 EXTEND RETRACT TS63 WHT #4 WHT/BLK #5 WHT/RED #6 TURNTABLE ROTATE

BLU/WHT #12 BLK/WHT-34

L3 OIL TEMP.

R4
TS56 TS52

CR1 BLK-ISM#1 BLK#R1-E.H. WHT#21

CR2

CR3

CR4

5
1

TS62

RD/WT-C.H. WHT-ISM#10 WHT/BLK-EH.1 WT/RD-E.H.1 RED-C.H RED/BLK-C.H RED/WHT-C.H WHT-ENA. WT/BK-E.H.1 WHT/RED-C.H BLK-ISM#3 BLK/WHT-E.H.1

WHT-S.P.

WHT-ISM#7 WHT/BLK-SP WHT/RED-SP RED-S.P.

BLK/RED #35

GLOW PLUG

START

SEC. BOOM TS57

BLK/RED#R4-EH WHT-40B

RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

RED-ISM#4

TS54

CB1

CB2

TS59

GRN/WHT #19 GRN/BLK #18 GRN #17 PLAT. LEVEL PLATFORM ROTATE ORG #14 ORG/BLK #15
BRN GRND H.M

BLK/RED#R5-AH. CR5 CR7

ORG-4 CR8

ORG/BLK-4

BLK-S.P. BK/RD-R3#35 BLK/WHT-34 BK/RD-SP

BLU #10 BLU/BLK #11 RED #20 RED-R1 BLK #33

FUNCTION ENABLE

6
WHT#40-R7 WHT-PRIM.#5

BLU-M.H. BU/BK-M.H.

BLK#22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE VERSION ONLY)

WHT-SEC#4

CH+EH1

OG/BK-E.H.1

WHT-EXT.#6 OG/BK-IM2

GR/WT-C.H

ORG/BLK-15
GRD-HOLE

ORG-14

BLK/RED-EH-r.male BLK/RED-EH-r.fem BLK-E.H-r.fem

r.fem-BLK/RED-R4 r.male-BLK/RED-R5 r.male-BLK-R1 r.fem-ORG-R7 r.fem-ORG/BLK-R8

WIRE CONNECTION ABBREVIATION KEY: EH C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

ORG-M.H.-r.male ORG/BLK-M.H.-r.male

6 - 62

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Platform Control Box Wiring DiagramZ-45/25 Perkins Models (before serial number 16304)
1

First Edition Second Printing

DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN, TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY HORSEPOWER LIMITER BOARD

LABEL

TS11 TS12 TS13 TS50 R2 R3 L1 BP1 BP2 CR12 H.P.L.

TS9 TS10

P2 P3 TS1 TS2 TS6 TS7

H1

WHT-23

Section 6 Schematics

BLK-22

EMERGENCY STOP P2

BLK-26

NC

WHT/RED-32 WHT-30 WHT/BLK-31 WHT-24 TO H.P.L.

BLU-36

BLU/BLK-37

DRIVE

BRN TO GRD.

RED/WHT-29 BLU/BLK-11

F.S.

BLU-10 BLU/WHT-12 RED-27 RED-10 TO H.P.L. GRN/BLK-18 GRN-17 GRN/WHT-19

(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN. GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

PRIMARY BOOM EXTEND/ RETRACT

110

BLK/WHT-8 BLK-7 RED-1 RED/WHT-3

RED-10 LIMITING RELAY

CABLE #2

WHT-4 WHT/BLK-5

NC

R1 50

ORG-40

WHT-24

RED-10

1 2 3 4 5 6 7 8 9 10

CABLE

#3

ORG/BLK-41

NO

WHT/RED-6 RED/BLK-28

TURNTABLE ROTATE

HORSEPOWER LIMITER BOARD

CR12

PLATFORM LEVEL

BP1

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

CABLE #1

A RED/BLK-2

- X
NC

PRIMARY BOOM UP/DOWN

NO

PLATFORM ROTATE TS7

SEC. BOOM UP

TS13

NO

TS9

WHT-24

ORG-40

GRD. STUD

ORG/BLK-15

ALARM

+ TILT

ORG-14

H1

BLK/RED-9

P3

HORN

PLATFORM CONTROL SWITCH PANEL

PLATFORM CONTROL BOX

SEC.BOOM BP2

AUXILIARY PUMP

TS1

HIGH/LOW (2WD/4WD)

R2

DRIVE SPEED

TS14

NC NO

100

250

- X

- X

GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE BLK/RED-35 RED-25 BLK/WHT-34

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT

L1

DRV.ENA TS15

ORG/RED-16

BLU/RED-13

R3 TS6

GLOW PLUG

TS2 START

BLK-33

GENERATOR OPTION

TS4

HIGH/LOW RPM

Part No. 52709

NC

Genie Z-45/25 & Genie Z-45/25J


1 2 3 4 5 6 R 7 8

EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH

PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH

PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH LOW SPEED RESISTOR LOW SPEED RESISTOR

DESCRIPTION

TILT ALARM

6 - 63

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25 Perkins Models (before serial number 16304)

Section 6 Schematics

First Edition Second Printing

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


A B C D E
SEE NOTE 1

M
SEE NOTE 2

N
ORG/BLK

1
TP22

P2

BLK

TP26

BLK

FS1 BLK

RED

RED

TP25
TP21

RED WHT WHT


TS50
LIFT/ DRIVE

WHT BRN WHT

TP24

TS2
TS1
WHT

TS6
GLOW PLUGS

TS47
OFF

TS4
HIGH RPM FOOTSW. H/L LOW RPM

SELECTOR OPTION

CR13

JIB CUTOUT RELAY

JIB VALVE RELAY

JIB VALVES

BLK-2

START

ON

2
TP41

RED

AUXILIARY PUMP

P3 HORN
BLK

GENERATOR

ENGINE

RED

CB1 15AMP.

RED

P1 RED

KS1 PLAT GRND

TB22

TP9

TP23

TP28

TP27

TP33

TP34

TP45

ENGINE SPEED

CR14 NO

TP35

CR14

RED RED

BLK-1

WHT-2

BLK/RED-1

GRN/WHT-1

BLK-1

RED/BLK-1

RED-1

BLK/RED-3

ORG/BLK-1

TS51
START

TS52

TS56
GLOW PLUGS

TS54
LOW RPM

FUNCTION HIGH RPM ENABLE

AUXILIARY PUMP

RED

TB45

ENGINE

BLK

BLK

TB28

TB27

TB33
1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

TB34

RED

TB9

TB41

TB23

CB2

TB20
RED#20-E.H.

15AMP.

RED
CR1
CR2 NO
CR2

L2 OIL PRES. L3 OIL TEMP.


BLK/WHT#34-E.H.

TB35

RED/WHT#23-E.H.

BLK/RED

CR1 NO

TB21
WHT/BLK WHT/RED
BLK#22

CR3 NO CR3

BLK#R1-E.H.

RED/BLK#28-E.H.

RED#27-E.H.

BLK/RED

RED/WHT#23-E.H.

TB24

WHT

WHT#21

WHT#21-E.H.
ALTERNATOR
EXCT.

ORG/BLK#41-E.H.

CR4 NO

CR4

GRN/WHT#45-E.H.

FB

BLK/RED#R4-E.H.

CR5 NO
BLK/RED#R5-E.H.

CR5

PR1
NO
WHT

PR1

TB25
TB26
WHT/RED#26 E.H.

PR2 NO

WHT/BLK#25 E.H.

PR2

RED

6
12 V DC
BAT.

BAT. -

6 - 64

+
REGULATOR

STA.

OPS
3

AUX PUMP

STARTER

HM 2

BLK

NC

IND.

OIL TEMPERATURE SWITCH NO

BRN

BRN
JIB BOOM VALVE RELAY (CR-14) JIB BOOM VALVES

FLASHING BEACON OPTION

STARTER MOTOR

TILT ALARM

CE MODELS)

JIB BOOM CUTOUT RELAY (CR-13)

OPTION (REQUIRED FOR

LIFT/DRIVE SELECTOR

OIL PRESSURE SWITCH

OIL TEMPERATURE SWITCH

OIL PRESSURE LED

HIGH IDLE CUTOUT RELAY

HIGH IDLE RELAY

RPM SOLENOID

FUEL SOLENOID

OIL TEMPERATURE LED

AUXILIARY POWER RELAY

IGNITION/START RELAY

HOUR METER

POWER RELAY

GENERATOR OPTION

HORN RELAY

LEVEL SENSOR

Genie Z-45/25 & Genie Z-45/25J

HORN

AUXILIARY PUMP

GLOW PLUGS

NOTE:
1) The connection to TP24 is for units without the generator option. 2) 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.

Part No. 52709

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

First Edition Second Printing

BRN-2 GROUND

TP13

TB30 TB13

L1

NCHO

BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1

TS15

TP30

LS4

NOHC

TB16

WHT#12-C.H.

TP16

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TP31

TB31

WHT/BLK-1 DRIVE EDC

WHT/BLK#31-C.H.

WHT/RED-1 WHT/RED#32-C.H. BRAKE RELEASE VALVE

TRAVEL ALARM OPTION

BLU/BLK-1 BLU/BLK#37-M.H. STEER RIGHT

BLU-1 BLU#36-M.H. STEER LEFT

RED/WHT-1 MOTOR STROKE

RED/WHT#29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

R3

RED

BLK 100

Section 6 Schematics

CE OPTION ONLY

R2

R1

50

WHT#40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

CR12

TP40

LS1 NCHO

ORG-1

WHT#40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

WHT#40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TS13

TP7

BLK-3 BLK/WHT-3

TB7

RETRACT

BOOM

TP8

EXTEND

BLK#7-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT#8-M.H.

TP6

TP4 TP5

TS63

RETRACT

BOOM

WHT/RED-3 WHT/BLK-3

TB5

WHT-3 WHT/BLK#5-M.H. WHT#4-M.H.


RIGHT TURNTABLE ROTATE

TB8

EXTEND

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

PWM A

TS62

LEFT

R4 10

TB4

TB6

WHT/RED#6-M.H.

TURNTABLE ROTATE FLOW CONTROL

BP1

TB1

RED#1-M.H.

TS61

UP PRIMARY DOWN BOOM

PRIMARY BOOM UP PRIMARY BOOM DOWN

TB2

RED/BLK#2-M.H.

PWM A

TB3

RED/WHT#3-M.H.

TP1

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP10 TP11

BLU/BLK-3

TB10

BLU-3 BLU
UP SECONDARY DOWN BOOM BLU/BLK

BLU#10-M.H.

SECONDARY BOOM UP

PWM A

TS60

BLU/BLK#11-M.H.

BP2

SECONDARY BOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT#12-M.H.

SECONDARY BOOM FLOW CONTROL

TP14

ORG-3 ORG/BLK-3

TS9

DOWN

TS59

TB14

PLATFORM LEVEL

TP15

UP

CR7 NC

ORG#14-M.H.
UP DOWN PLATFORM LEVEL

PLATFORM LEVEL UP ORG/BLK#15-M.H. PLATFORM LEVEL DOWN

TB15

PLATFORM LEVEL

CUTOUT (CE MODELS ONLY)

CR13 NC

TP18

GRN/BLK-3 GRN-3

TP17

TS8

UP

TS58

TB18

DOWN JIB BOOM

GRN/BLK#18-M.H.
DOWN UP JIB BOOM

CR8 NC

JIB BOOM DOWN GRN#17-M.H. JIB BOOM UP

TS57

TS7

LEFT

RIGHT PLAT ROTATE

LEFT

RIGHT PLAT ROTATE

TB17

CR9 NC

TP19

DESCENT ALARM OPTION GRN/WHT-3

BRN
+

TB19

ORG/BLK

RED

WHT

WHT

BRN

RED

RED

CR9

TI

BRN

Part No. 52709

TB40

LS2

HORSEPOWER LIMITER BOARD

1 2 3 4 5 6 7 8 9 10

NO

LS3 NO

Genie Z-45/25 & Genie Z-45/25J

TP37

TP32

DP1

1 2 3 4 5 6 7 8

RED

TP36

TP29

TB29

TB36 TB37

TB32

6 - 65

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Perkins Models (before serial number 16304)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Perkins Models (before serial number 16304)
A 1
LABEL P1 KS1 TS51 TS52 TS54
TS56 TS57 TS58 TS59

DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH
GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH

GROUND CONTROL BOX

GROUND CONTROL SWITCH PANEL


STACKED CONTACTS

2
M.H.

KS1
BLK-R1#86 ORG/BLK-41A BLK-33D RED-27B BRN-GRD. RED-R2 # 30
1

START RELAY TACHOMETER START INPUT


AUX. ON GROUND BATTERY

2 3

NO

NO

5 6

WHT-23A

IGN./START MODULE
P1 NC KS1

TS60 TS61 TS62 TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2

SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY

KEY PWR.

SECON.4
EXT.6

KEY BYPASS IGN./FUEL ON

AUXILIARY

WHT-R2#86
WHT-24D

BASE TERMINATION BLOCK

10

D
RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4
BLU-4 BLU/BLK-4
BLK-ENA. ORG-4/R7

C
RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P.

NO

ENG. FAULT

NO

NC
PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM
KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

TS51
WHT/BLK # 25
WHT/RED #26

WHT #23 BLK #22 RED #27 BRN TO R4 BRN TO GRD WHT #21 WHT#21TO R2

STOP

PRIM.5

4
3

L2

LED

+
1
2

BLK/RED-3 BLU-3 BLU/BLK-3


BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.#6 BLK-2 WHT-2

BK/RD-R5 BLU-S.P. BU/BK-S.P.


BLU/WT-S.P. ORG-SP OG/BK-SP

OIL PRESS

RED/WHT #3 RED/BLK #2 RED #1 BLK #7

CR3 CR4 CR5 CR7 CR8

HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

HOUR METER 3

BLK/RED#35B
RED-ISM#6

RED

ORG/BLK-4/R8
RED-ENA. GRN-4

BLK/WHT #8

WHT#12-E.H.1 GRN-S.P.
GR/BK-S.P. GR/WT-S.P. RED-S.P. WHT-S.P. BLK-S.P. WHT-S.P.

BLU/WHT #12 BLK/WHT-34


R4
TS56

L3 OIL TEMP.

TS61
PRIMARY BOOM TS58
EXTEND RETRACT

TS63
WHT #4 WHT/BLK #5 WHT/RED #6

WHT-ISM#9 RED-CB1

GRN/BLK-4 RED-C.H.

CR1
BLK-ISM#1

CR2

CR3

CR4

TS60
TS52

5
1

WHT-E.H.1

RD/WT-C.H.
WHT-ISM#10

TS62
BLK/RED #35
GLOW PLUG

BLK#R1-E.H.

WHT-ISM#7
WHT/BLK-SP WHT/RED-SP

WHT/BLK-EH.1

TURNTABLE ROTATE

WT/RD-E.H.1 RED-C.H RED/BLK-C.H RED/WHT-C.H WHT-ENA.


WT/BK-E.H.1 WHT/RED-C.H

START

SEC. BOOM

JIB

WHT#21

BLK/RED#R4-EH WHT-40B

RED-1 RED/BLK-1 R/W-1


WHT-1 WHT/BLK-1 WHT/RED-1 BLK-1 BLK/WHT-1 BLK/RED-1 BLU-1 BLU/BLK-1 BLU/WHT-1 BLU/RED-1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

RED-ISM#4

RED-S.P.

TS54

CB1

CB2

GRN/WHT #19

TS59

BLK/RED#R5-AH.
CR5

GRN/BLK #18 GRN #17

ORG-4
CR7

ORG/BLK-4
CR8

6
WHT#40-R7 WHT-PRIM.#5

BLK-ISM#3 BLK/WHT-E.H.1 BLU-M.H. BU/BK-M.H.

BLK-S.P. BLK/WHT-34 BK/RD-R3#35


BK/RD-SP

BLU #10

FUNCTION ENABLE

PLAT.
LEVEL

BLU/BLK #11
RED #20 RED-R1
BLK #33

TS57 PLATFORM ROTATE

BRN GRND H.M

ORG #14 ORG/BLK #15

BLK#22 BLK/RED-9A

WHT-SEC#4

WHT-EXT.#6

PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

CH+EH1

OG/BK-E.H.1

OG/BK-IM2

GR/WT-C.H

7
GRD-HOLE

ORG/BLK-15
ORG-14

BLK/RED-EH-r.male BLK/RED-EH-r.fem BLK-E.H-r.fem

r.fem-BLK/RED-R4 r.male-BLK/RED-R5 r.male-BLK-R1


r.fem-ORG-R7 r.fem-ORG/BLK-R8

WIRE CONNECTION ABBREVIATION KEY: EH C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

ORG-M.H.-r.male ORG/BLK-M.H.-r.male

6 - 66

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25J Perkins Models (before serial number 16304)
N M L K J
PLATFORM CONTROL BOX
LABEL P2 P3 TS1 TS2 TS3 TS6 TS7 TS8 TS9 TS13 TS11 TS12 TS10 TS50 R1 R2 R3 L1 L3 BP1 BP2 CR12 CR13
CR14 H.P.L. T1 H1

A 1

DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH SECONDARY BOOM UP/DOWN SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR ( FORD AND PERKINS ONLY ) LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED CHECK ENGINE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY
JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM

WHT-24
1 2 3 4 5 6 7 8 9 10

PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE (UNUSED)

PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

SEC. BOOM UP HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL.

PULSE PICKUP LIMIT SWITCH (SPARE)

GEN. (OPTION) (SPARE) (SPARE) (SPARE)

STEER RIGHT STEER LEFT HIGH/LOW RPM

PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

JIB VALVE

(SPARE)

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

RED FROM CR14

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT
GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1

ORG-40

CR12
RED-10 WHT-24
GRD. STUD

R1 50

RED/BLK-28

RED-10 LIMITING RELAY


CABLE
CABLE #2 CABLE #1

WHT JIB CABLE


BLK JIB CABLE
110

H1 + TILT _ ALARM

#3

JIB CABLE

F.S.

RED-1

RED TIM.DEL.

WHT/RED-32 WHT-30

WHT-23

BLK-22

RED JUMP

BLK-26

WHT-24 TO H.P.L.

ORG-14

BLU/BLK-37 RED TO STOP SW RED TILT AL.

RED TO JIB CABLE

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

BRN TO GRD.

BLU/RED-13

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

ORG/BLK-15

BLK/WHT-34

BLK/RED-35 RED-25

BLU-36

WHT/BLK-5

GRN/WHT-19

GRN-17

NC
R

NO
A

CR13

L1

- X

BP1

- X

NO

TS13

NC NO

JIB CUTOUT RELAY

NC

JIB VALVE RELAY

P3

NO

TS1
AUXILIARY PUMP

100

250

BLK/RED-9

WHT/BLK-31

ORG/RED-16

WHT/RED-6

BLK-33

WHT-4

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7

RED/BLK-2

RED/WHT-3

PRIMARY BOOM EXTEND/ RETRACT

GENERATOR OPTION

SEC.BOOM BP2

CR14

+
- X

DRIVE DP1 JIB

GRN/WHT + RED OUTPUT BRN

TIME DELAY

T1

PLATFORM LEVEL

TS8

R2

R3 TS6

DRV.ENA TS15
NC

TS9

NC

GLOW PLUG
DRIVE SPEED TS14

TS2 START TS4


HIGH/LOW RPM

HORN

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 67

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25J Perkins Models (before serial number 16304)

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring Diagram- Lift/Drive SelectOption, Z-45/25J Perkins Models (before serial number 16304)
N M L K J
PLATFORM CONTROL BOX
LABEL P2 P3 TS1 TS2 TS3 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13 TS50 R1 R2 R3 L1 BP1 BP2 CR12 CR13 CR14 H.P.L. T1 H1 DESCRIPTION EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH LIFT/DRIVE SELECT SWITCH EFI RESISTOR ( FORD AND PERKINS ONLY ) LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DOWN , TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY JIB VALVE RELAY HORSEPOWER LIMITER BOARD TIME DELAY TILT ALARM

A 1

WHT-24
1 2 3 4 5 6 7 8 9 10 GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN. SEC. BOOM UP (UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

RED FROM CR14

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

ORG-40 CR12 RED-10 WHT-24 GRD. STUD R1 50 RED-10 LIMITING RELAY CABLE #3
RED/BLK-28

WHT JIB CABLE BLK JIB CABLE CABLE #1 110 JIB CABLE F.S.

H1 + TILT _ ALARM

CABLE #2

5
WHT-23 RED TO STOP SW RED TILT AL. RED TIM.DEL. WHT/RED-32 WHT-30 RED JUMP BLK-22 BLK-26 BLK/WHT-34 ORG/RED-16 BLK-33 BLK/RED-35 RED-25 WHT-24 TO H.P.L. RED TO JIB CABLE WHT-21 BLU-36 BRN TO GRD. BLU/RED-13 BLU/BLK-37 GRN/WHT-19 RED-10 TO H.P.L. BLU-10 BLU/BLK-11 RED/WHT-29 BLK-7 BLK/WHT-8 GRN/BLK-18 BLU/WHT-12 RED-27 WHT/BLK-31 GRN-17

RED-1

ORG-14

ORG/BLK-15

WHT/BLK-5

NC
R

NO
A

CR13

L1 JIB VALVE RELAY CR14

NC
X

+-

BP1 NO

- X

TS13

NC NO

JIB CUTOUT RELAY

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN TS50 PLATFORM ROTATE TS7

LIFT/ DRIVE SEL.

P3

NO

TS1 AUXILIARY PUMP DRIVE SPEED

100

250

BLK/RED-9

WHT/RED-6

PLATFORM LEVEL TS9

WHT-4

RED/BLK-2

RED/WHT-3

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. SEC.BOOM BP2

+
- X R

DRIVE DP1

GRN/WHT + RED OUTPUT BRN TIME DELAY T1

TS8

JIB

R2

R3 TS6

DRV.ENA TS15 NC NC

GLOW PLUG TS14

TS2 START TS4 HIGH/LOW RPM

HORN

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 68

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

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


A B C D E F G H I J K L M N
ORG/BLK

LOAD SENSE OPTION (SEE DETAIL BELOW)

1
TP22

P2

BLK

TP26

FS1

RED-(FS)
WHT-(FS)

TP25
TP24

BLK-(FS)

RED WHT WHT


WHT

TS2
TS1
WHT

TS6

TS47
ON OFF GENERATOR

TS4

BLK-2

START

FOOTSW. H/L LOW RPM HIGH RPM

GLOW PLUGS

AUXILIARY PUMP

2
TP41

P3 HORN
BLK

ENGINE

CB1 15AMP. RED

P1 RED

KS1 PLAT GRND

TB22

TP9

TP23

TP28

TP27

TP33

TP34

TP45

ENGINE SPEED

TP35

RED RED

WHT-2

BLK-1

BLK/RED-1

GRN/WHT-1

BLK-1

RED/BLK-1

RED-1

BLK/RED-3

ORG/BLK-1

TS51
START

TS52

TS56

TS54
LOW RPM
FUNCTION HIGH RPM ENABLE

AUXILIARY PUMP RED

GLOW PLUGS

TB45

ENGINE

BLK

BLK

TB28
RED

TB27

TB33
1 START RELAY 2 TACHOMETER 3 START INPUT IGN./START 4 AUX. ON MODULE 5 GROUND 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

TB34

TB9

TB41

TB23

CB2

TB20
RED-20-E.H.

15AMP.

RED
CR1
CR2 NO
CR2

L2 OIL PRES. L3 OIL TEMP.


BLK/WHT-34-E.H.

TB35

RED/WHT-23-E.H.

BLK/RED

CR1 NO

TB21
WHT/BLK WHT/RED
BLK-22

CR3 NO CR3

BLK-R1-E.H.

RED/BLK-28-E.H.

RED-27-E.H.

BLK/RED

RED/WHT-23-E.H.

TB24

WHT

WHT-21

WHT-21-E.H.
ALTERNATOR
EXCT.

ORG/BLK-41-E.H.

CR4 NO

CR4

GRN/WHT-45-E.H.

FB

BLK/RED-R4-E.H.

CR5 NO
BLK/RED-R5-E.H.

CR5
RED WHT

PR1 NO

PR1

TB25
TB26
WHT/RED-26 E.H.

PR2 NO

WHT/BLK-25 E.H.

PR2

7
TP22
P2
BLK-26

FS1 BLK-(FS)

TP26

6 - 69

+
STA.
REGULATOR

12 V DC

BAT. +

BAT. -

AUX PUMP

STARTER

1 HM 2 3

OPS NC

BLK

IND.

OTS NO

RED-(FS) WHT-(FS) BLK-26 LOAD

BRN

BRN
STARTER MOTOR FLASHING BEACON OPTION
TILT ALARM

OIL PRESSURE SWITCH

OIL TEMPERATURE SWITCH

OIL PRESSURE LED

FUEL SOLENOID

OIL TEMPERATURE LED

AUXILIARY POWER RELAY

IGNITION/START RELAY

POWER RELAY

HOUR METER

HORN RELAY

HORN

LEVEL SENSOR

HIGH IDLE RELAY

HIGH IDLE CUTOUT RELAY

RPM SOLENOID

GENERATOR OPTION

AUXILIARY PUMP

GLOW PLUGS

LOAD SENSE OPTION


C B+

LOAD SENSOR BOX


GND 8

WHT-LOAD

TP24

WHT-24

Genie Z-45/25 & Genie Z-45/25J

ORG-LOAD

Part No. 52709

First Edition Second Printing

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

BRN-2

GROUND

TP13

TB13

L1

NCHO

BLU/RED-3
BLK-7
BRN-7

LS4

TP30

WHT-1
WHT-7

TB30

RED-7

DRIVE ENABLE LIMIT SWITCH

TP31 TP16

WHT-12-C.H.

TS15

NOHC

TB16

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1

WHT/BLK-31-C.H.

DRIVE EDC

TP32

WHT/RED-1
WHT/RED-32-C.H.

TB32

TRAVEL ALARM OPTION

BLU/BLK-1
BLU/BLK-37-M.H.

STEER RIGHT

BLU-1
BLU-36-M.H.

STEER LEFT

RED/WHT-1
MOTOR STROKE

RED/WHT-29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

RED

BLK
100

CE MODELS ONLY

R2

Section 6 Schematics

R1

50

WHT-40-6

LS1 NCHO

BRN-6

PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

CR12

TB40

LS3 NO

WHT-40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TS13

BLK-3
BLK/WHT-3

EXTEND BOOM

TB7

RETRACT

TP8

BLK-7-M.H.

EXTEND BOOM
BLK/WHT-8-M.H.

BOOM EXTEND

TS63

RETRACT

BOOM RETRACT

TP6

WHT/RED-3 WHT/BLK-3

TP5

TB5

WHT-3

TB8

TP4

WHT/BLK-5-M.H.

RIGHT

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

PWM A + X

TS62

LEFT

TURNTABLE ROTATE

R4 10

WHT#4-M.H.

TB4

WHT/RED-6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED-1-M.H.

TS61

UP PRIMARY DOWN BOOM

PRIMARY BOOM UP

TB2

RED/BLK-2-M.H.

PWM A + X

PRIMARY BOOM DOWN

TB3

REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY)

TP1

RED/WHT-3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3

TB10

BLU-3

TP10

BLU

BLU-10-M.H.

PWM A + X

UP

SECONDARY BOOM UP

TS60

DOWN

SECONDARY BOOM BLU/BLK

BLU/BLK-11-M.H.

BP2

SECONDARY BOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT-12-M.H.

TP14

SECONDARY BOOM FLOW CONTROL

ORG-3

TS9

ORG/BLK-3

TS59

TB14

UP PLATFORM DOWN LEVEL

CR7 NC

TP15

ORG-14-M.H.
UP PLATFORM DOWN LEVEL

PLATFORM LEVEL UP

ORG/BLK-15-M.H.

PLATFORM LEVEL DOWN

TB15

PLATFORM LEVEL

CUTOUT (CE MODELS ONLY)

WHT

TP18

GRN/BLK-3

RIGHT

TS7

LEFT

GRN-3

TS57

TB18

PLAT ROTATE

TP17

GRN/BLK-18-M.H.

CR8 NC

RIGHT LEFT

PLATFORM ROTATE RIGHT

PLAT ROTATE
GRN-17-M.H.

PLATFORM ROTATE LEFT

TB17

DESCENT ALARM OPTION

ORG/BLK

WHT

RED

RED

BRN

BRN

Part No. 52709

ORG-1

WHT-40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

TP40

LS2

HORSEPOWER LIMITER BOARD

1 2 3 4 5 6 7 8 9 10

TP7

NO

Genie Z-45/25 & Genie Z-45/25J

BRAKE RELEASE VALVE

TP37

DP1

RED

TP36

1 2 3 4 5 6 7 8

R3

TP29

TB29

TB36

TB37

6 - 70

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Perkins Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25 Perkins Models (after serial number 16303)
A 1
GROUND CONTROL SWITCH PANEL GROUND CONTROL BOX
STACKED CONTACTS KS1
BLK-R1-86 M.H. ORG/BLK-41A BLK-33D RED-27B BRN-GRD. RED-R2#30 WHT-23A 1 2 3 4 5 6 7 8 WHT-R2#86 WHT-24D 9 10 START RELAY

J
LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS59 TS60 TS61 TS62

TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT

NO

DESCRIPTION EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

NO

IGN./START MODULE
P1 NC
NO

SECON.4 EXT.6

KS1
NO

AUXILIARY

3
PRIM.5

BASE TERMINATION BLOCK

D
RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA. ORG-4/R7 ORG/BLK-4/R8 RED-ENA. GRN-4 GRN/BLK-4 RED-C.H. WHT-E.H.1 RD/WT-C.H.

C
RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.-6 BLK-2 WHT-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-SP OG/BK-SP WHT-12-E.H.1 GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P. WHT-S.P. BLK-S.P. PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

NC WHT-23 BLK-22 RED-27 BRN-(R5) BRN-(GRND) WHT-21 WHT-21 (R2) STOP

TS51 WHT/BLK-25 WHT/RED-26


LED

TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2 CR3 CR4 CR5 CR7 CR8

+
L2 1 2

OIL PRESS

RED/WHT-3 RED/BLK-2 RED-1 BLK-7

4
2

HOUR METER 3
RED

BLK/RED-35B RED-R2 WHT-R2 RED-R1

BLK/WHT-8 TS61 EXTEND RETRACT TS63 PRIMARY BOOM TS62 WHT-4 WHT/BLK-5 WHT/RED-6 TURNTABLE ROTATE

BLU/WHT-12
BLK/WHT-34

L3 OIL TEMP. TS60


TS56

R4
TS52

CR1 BLK-R1 BLK-R1-E.H. WHT-21

CR2

CR3

CR4

WHT-S.P.

WHT-ISM-7 WHT/BLK-SP WHT/RED-SP RED-S.P.

WHT-ISM-10 1 WHT/BLK-EH.1 WT/RD-E.H.1 RED-C.H RED/BLK-C.H RED/WHT-C.H WHT-ENA. WT/BK-E.H.1 WHT/RED-C.H BLK-ISM-3 RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1

BLK/RED-35

GLOW PLUG

START

SEC. BOOM TS57

BLK/RED-R4 WHT-40B

RED-ISM-4

TS54

CB1

CB2

TS59

GRN/WHT-19 GRN/BLK-18 GRN-17 PLAT. LEVEL PLATFORM ROTATE ORG-14 ORG/BLK-15


BRN-(GRND H.M)

BLK/RED-R5 CR5 CR7

ORG-4 CR8

ORG/BLK-4

WHT#40-R7 WHT-PRIM.#5

BLK-1 BLK/WHT-1 BLK/RED-35GEN BLK/RED-1 BLU-1 BLU-M.H. BU/BK-M.H. BLU/BLK-1 BLU/WHT-1 BLU/RED-1 BLK/WHT-E.H.1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

BLK-S.P. BK/RD-R3#35 BK/RD-SP

BLU-10 BLU/BLK-11 RED-20 RED-R1 BLK-33

FUNCTION ENABLE

BLK-22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

WHT-SEC#4

CH+EH1

OG/BK-E.H.1

WHT-EXT.#6 OG/BK-IM2

GR/WT-C.H

BLK/RED-35GEN

ORG/BLK-15

7
BLK/RED-EH-r.male BLK/RED-EH-r.fem BLK-E.H-r.fem ORG-M.H.-r.male

GRD-HOLE

ORG-14

r.fem-BLK/RED-R4 r.male-BLK/RED-R5 r.male-BLK-R1 r.fem-ORG-R7 r.fem-ORG/BLK-R8


WIRE CONNECTION ABBREVIATION KEY: EH C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

ORG/BLK-M.H.-r.male

6 - 71

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25 Perkins Models (after serial number 16303)
N M L K J
PLATFORM CONTROL BOX

COMPONENT INDEX
P2 P3 TS1 TS2 TS3 TS6 TS7 TS9 TS10 TS11 TS12 TS13
TS47 R1

WHT-24
1 2 3 4 5 6 7 8 9 10 HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.
(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG OPTION PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH
GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY )

SEC. BOOM UP

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

ORG-40 CR12 RED-10 WHT-24

GRD. STUD
R1 50 RED-10 LIMITING RELAY
RED-TILT

R2 R3 L1 BP1 BP2 CR12 DP1 H.P.L. H1

LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY UP/DOWN,TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD TILT ALARM

RED/BLK-28

+ TILT _
ALARM

H1

CABLE #3

CABLE #2

CABLE #1

110

F.S.

SIDE VIEW FOR DP1


WHT TO PLATFORM ROTATE

RED-TILT

GRN/WHT-45

BLK/WHT-34

RED/WHT-3

BRN TO GRD.

WHT-24 TO H.P.L.

WHT/BLK-31

BLK-22

BLK-26

WHT-23

NC
R

NO
A + - X

TS47
5 6

L1

A + - X

BP1
NO

A + - X

TS13

NC NO

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS1 AUXILIARY PUMP DRIVE SPEED

SEE SIDE VIEW DP1

P3

NO

100

250

BLK/RED-9

ORG-14

ORG/BLK-15

WHT/RED-6

GRN/WHT-19

BLU-36

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

BLU/RED-13

ORG/RED-16

BLK/RED-35 RED-25

BLK-33

BLU/BLK-37

WHT/RED-32 WHT-30

WHT/BLK-5

PLATFORM LEVEL TS9

WHT-4

RED/BLK-2

RED-1

BLK-7

BLK/WHT-8

GRN-17

GRN/BLK-18

BLU/WHT-12 RED-27

PRIMARY BOOM EXTEND/ RETRACT

SEC.BOOM BP2

GENERATOR OPTION
RED-GEN

NC

DP1 DRIVE

8 7 6 5 4 3 2 1

7
R2 R3 TS6 DRV.ENA TS15 NC
GLOW PLUG

NC

TS2 START TS4 HIGH/LOW RPM

HORN
REMOVE FOR LIFT/ DRIVE SELECT VERSION

TS14

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 72

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25 Perkins Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring Diagram- Lift/Drive SelectOption, Z-45/25 Perkins Models (after serial number 16303)
N M L K J
PLATFORM CONTROL BOX

COMPONENT INDEX
P2 P3 TS1 TS2 TS3 TS6 TS7 TS9 TS10 TS11 TS12 TS13 TS47 R1 R2 R3 L1 BP1 BP2 CR12 DP1 H.P.L. H1 EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUEL SELECT SWITCH GLOW PLUG OPTION (DIESEL ONLY) PLATFORM ROTATE SWITCH PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY ) LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOM UP/DN,TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD TILT ALARM

WHT-24
1 2 3 4 5 6 7 8 9 10 PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN. GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE
(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

SEC. BOOM UP

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

ORG-40 CR12 RED-10 WHT-24

GRD. STUD
R1 50 RED-10 LIMITING RELAY
RED-TILT

RED/BLK-28

H1 + TILT _ ALARM

CABLE #3

CABLE #2

CABLE #1

110

F.S.

BLU/BLK-11

RED/WHT-29

BLU/RED-13

ORG/RED-16

BLK/RED-35 RED-25

BLK-33

BLU/BLK-37

WHT/RED-32 WHT-30

RED-TILT

BLK/WHT-34

GRN/WHT-45

BLU-36

BRN TO GRD.

WHT-24 TO H.P.L.

WHT/BLK-31

BLK-22

BLK-26

WHT-23

WHT/BLK-5

WHT-4

RED/BLK-2

RED-1

BLK-7

BLK/WHT-8

GRN-17

GRN/BLK-18

BLU/WHT-12 RED-27

RED-10 TO H.P.L.

BLU-10

RED/WHT-3

NC
R

NO
A + - X

NC
A + - X

TS47

L1

GENERATOR OPTION

BP1
NO

A + - X

TS13

NC NO

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7 TS1 AUXILIARY PUMP DRIVE SPEED

SEE SIDE VIEW DP1

PLATFORM LEVEL TS9 P3 NO

R2
100

R3 TS6
250

DRV.ENA TS15 NC NC

BLK/RED-9

ORG-14

ORG/BLK-15

WHT/RED-6

GRN/WHT-19

SIDE VIEW FOR DP1

5
WHT TO PLATFORM ROTATE

PRIMARY BOOM EXTEND/ RETRACT

SEC.BOOM BP2

DP1 DRIVE

8 7 6 5 4 3 2 1

RED-GEN

GLOW PLUG

TS2 START TS4 HIGH/LOW RPM

HORN

TS14

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

8
PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 73

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

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


A B C D
LOAD SENSE OPTION (SEE DETAIL BELOW)
ORG/BLK

TP22

P2

BLK

TP26

FS1

BLK-(FS)

RED-(FS)
WHT-(FS)

TP25
TP24

RED WHT WHT

BRN WHT

TS2
TS1
WHT

TS6

TS47
OFF ON

TS4
CR13
JIB CUTOUT RELAY JIB VALVE RELAY

JIB VALVES

BLK-2

FOOTSW. H/L LOW RPM HIGH RPM

START

GLOW PLUG

AUXILIARY PUMP

RED

GENERATOR

2
TP41

P3 HORN
BLK

ENGINE

RED

CB1 15AMP. RED

P1 RED

KS1 PLAT GRND

TB22

TP9

TP23

TP28

TP27

TP33

TP34

TP45

ENGINE SPEED

CR14 NO

TP35

CR14

RED RED

WHT-2

BLK-1

BLK/RED-1

GRN/WHT-1

BLK-1

RED/BLK-1

RED-1

BLK/RED-3

ORG/BLK-1

TS51
AUXILIARY PUMP
START

TS52

TS56
GLOW PLUG

TS54
LOW RPM FUNCTION HIGH RPM ENABLE

RED

TB45

ENGINE

BLK

BLK

TB28
RED

TB27

TB33
1 START RELAY 2 TACHOMETER 3 START INPUT 4 AUX. ON IGN./START 5 GROUND MODULE 6 BATTERY 7 KEY PWR. 8 KEY BYPASS 9 IGN./FUEL ON 10 ENG. FAULT

TB34

TB9

TB41

TB23

CB2

TB20
RED-20-E.H.

15AMP.

RED
CR1
CR2 NO
CR2

L2 OIL PRES. L3 OIL TEMP.


BLK/WHT-34-E.H.

TB35

RED/WHT-23-E.H.

BLK/RED

CR1 NO

TB21
WHT/RED WHT/BLK
BLK-22

CR3 NO CR3

BLK-R1-E.H.

RED/BLK-28-E.H.

RED-27-E.H.

BLK/RED

RED/WHT-23-E.H.

TB24

WHT

WHT-21

WHT-21-E.H.
ALTERNATOR
EXCT.

ORG/BLK-41-E.H.

CR4 NO

CR4

GRN/WHT-45-E.H.

FB

BLK/RED-R4-E.H.

CR5 NO
BLK/RED-R5-E.H.

CR5
RED WHT

PR1 NO

PR1

TB25
TB26
WHT/RED-26 E.H.

PR2 NO

WHT/BLK-25 E.H.

PR2

7
TP22
P2
BLK-26

6 - 74

+
REGULATOR

12 V DC

BAT. +

BAT. -

STA.

OPS
3

AUX PUMP

STARTER

HM 2

BLK

NC

IND.

OTS NO

BRN

BRN
JIB BOOM VALVE RELAY (CR-14)

STARTER MOTOR

JIB BOOM VALVES

FLASHING BEACON OPTION

TILT ALARM

OIL PRESSURE LED

OIL PRESSURE SWITCH

OIL TEMPERATURE SWITCH

FUEL SOLENOID

OIL TEMPERATURE LED

JIB BOOM CUTOUT RELAY (CR-13)

RPM SOLENOID

HIGH IDLE CUTOUT RELAY

HIGH IDLE RELAY

AUXILIARY POWER RELAY

IGNITION/START RELAY

HOUR METER

POWER RELAY

HORN RELAY

HORN

LEVEL SENSOR

GENERATOR OPTION

AUXILIARY PUMP

GLOW PLUGS

LOAD SENSE OPTION


FS1 BLK-(FS)
RED-(FS) WHT-(FS) BLK-26 LOAD
C B+

TP26

LOAD SENSOR BOX


WHT-LOAD

TP24

WHT-24

GND

Genie Z-45/25 & Genie Z-45/25J

ORG-LOAD

Part No. 52709

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

First Edition Second Printing

BRN-2 GROUND

TP13

TB13

L1

NCHO

BLU/RED-3 BLK-7 BRN-7 RED-7 DRIVE ENABLE LIMIT SWITCH WHT-7 WHT-1

TP30

TB30

LS4

TP31 TP16

WHT-12-C.H.

TS15

NOHC

TB16

DRIVE ENABLE ORG/RED-3

DRIVE ENABLE SWITCH

TB31

WHT/BLK-1 DRIVE EDC

WHT/BLK-31-C.H.

TP32

WHT/RED-1 WHT/RED-32-C.H.

TB32

TRAVEL ALARM OPTION

BLU/BLK-1 BLU/BLK-37-M.H. STEER RIGHT

BLU-1 BLU-36-M.H. STEER LEFT

RED/WHT-1 MOTOR STROKE

RED/WHT-29-C.H.

HIGH (2WD)

TS14

LOW (4WD)

RED

DRIVE RANGE (2WD/4WD)

250

RED

BLK 100

CE MODELS ONLY

R2

Section 6 Schematics

R1

50

WHT-40-6 BRN-6 PRIMARY BOOM EXTEND DRIVE LIMIT SWITCH

CR12

TB40

LS3 NO

LS1 NCHO

WHT-40-5

BRN-5 PRIMARY BOOM UP DRIVE LIMIT SWITCH

TS13

BLK-3 BLK/WHT-3

EXTEND

TB7

RETRACT

BOOM

TP8

BLK-7-M.H. BOOM EXTEND BOOM RETRACT BLK/WHT-8-M.H.

EXTEND

TS63

RETRACT

BOOM

TP6

WHT/RED-3 WHT/BLK-3

TP5

TB5

WHT-3

TB8

TP4

WHT/BLK-5-M.H. WHT#4-M.H.

PWM A + X

TS62

LEFT

RIGHT TURNTABLE ROTATE

TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT

R4 10

TB4

WHT/RED-6-M.H.

BP1

TB1

TB6

TURNTABLE ROTATE FLOW CONTROL

RED-1-M.H.

TS61

DOWN RED/BLK-2-M.H.

PRIMARY BOOM

TB2

UP

PRIMARY BOOM UP PRIMARY BOOM DOWN

REMOVE FOR LIFT/DRIVE SELECT (CE MODELS ONLY)

PWM A + X

TB3

TP1

RED/WHT-3-M.H.

PRIMARY BOOM FLOW CONTROL

RED-3

TP2

RED/BLK-3

TP3

RED/WHT-3

TP12

BLU/WHT-3

TP11

BLU/BLK-3

TB10

BLU-3

TP10

BLU UP SECONDARY DOWN BOOM BLU/BLK

BLU-10-M.H.

SECONDARY BOOM UP

PWM A + X

TS60

BLU/BLK-11-M.H.

BP2

SECONDARY BOOM DOWN

TB11

TB12

BLU/WHT

BLU/WHT-12-M.H.

TP14

SECONDARY BOOM FLOW CONTROL

ORG-3 ORG/BLK-3

TS9

TS59

TB14

UP PLATFORM DOWN LEVEL

CR7 NC

TP15

ORG-14-M.H. UP PLATFORM DOWN LEVEL ORG/BLK-15-M.H.

PLATFORM LEVEL UP PLATFORM LEVEL DOWN

TB15

PLATFORM LEVEL

CUTOUT (CE MODELS ONLY)

WHT

CR13 NC

TP18

GRN/BLK-3 GRN-3

TS8

TS58

TB18

DOWN JIB BOOM UP

TP17

GRN/BLK-18-M.H. DOWN JIB BOOM UP GRN-17-M.H.

CR8 NC

PLATFORM ROTATE RIGHT / JIBBOOM DOWN PLATFORM ROTATE LEFT / JIBBOOM UP

TS57

WHT

TS7

RIGHT PLATFORM LEFT ROTATE

LEFT

RIGHT PLATFORM ROTATE

TB17

CR9 NC

TP19

DESCENT ALARM OPTION GRN/WHT-3

BRN

TB19

ORG/BLK

WHT

RED

RED

RED

CR9

TI

BRN

BRN

Part No. 52709

ORG-1

WHT-40-4

BRN-4

SECONDARY BOOM UP DRIVE LIMIT SWITCH

TP40

LS2

HORSEPOWER LIMITER BOARD

1 2 3 4 5 6 7 8 9 10

TP7

NO

Genie Z-45/25 & Genie Z-45/25J

BRAKE RELEASE VALVE

TP37

DP1

RED

TP36

1 2 3 4 5 6 7 8

R3

TP29

TB29

TB36

TB37

6 - 75

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Perkins Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Ground Control Box Wiring DiagramZ-45/25J Perkins Models (after serial number 16303)
A 1
GROUND CONTROL BOX GROUND CONTROL SWITCH PANEL
STACKED CONTACTS KS1
BLK-R1-86 1 2 3 4 5 6 7 8 WHT-R2#86 WHT-24D 9 10 START RELAY TACHOMETER START INPUT AUX. ON GROUND BATTERY KEY PWR. KEY BYPASS IGN./FUEL ON ENG. FAULT ORG/BLK-41A BLK-33D RED-27B BRN-GRD. RED-R2#30 WHT-23A

J
LABEL P1 KS1 TS51 TS52 TS54 TS56 TS57 TS58 TS59 TS60 TS61 TS62 TS63 CB1 CB2 HM R4 L2 L3 CR1 CR2 CR3 CR4 CR5 CR7 CR8
RED-R2 WHT-R2 RED-R1

K
DESCRIPTION

M.H.

NO

EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH START ENGINE SWITCH FUNCTION ENABLE SWITCH GLOW PLUG PLATFORM ROTATE SWITCH JIB BOOM UP/DOWN (JIB OPTION ONLY) PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH CIRCUIT BREAKER, ENGINE, 15A CIRCUIT BREAKER, CONTROLS, 15A HOUR METER SPEED LIMITING VARIABLE RESISTOR 10 OHMS OIL PRESSURE LED OIL TEMPERATURE LED IGNITION / START RELAY POWER RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID RELAY HORN RELAY PLATFORM LEVEL CUTOUT RELAY- UP (CE MODELS ONLY) PLATFORM LEVEL CUTOUT RELAY - DOWN (CE MODELS ONLY)

NO

IGN./START MODULE
P1 NC KS1 AUXILIARY

SECON.4 EXT.6

3
PRIM.5

BASE TERMINATION BLOCK

D
RED-4 RED/BLK-4 R/W-4 WHT-4 WHT/BLK-4 W/R-4 BLK-4 BLK/WHT-4 BLU-4 BLU/BLK-4 BLK-ENA. ORG-4/R7 ORG/BLK-4/R8 RED-ENA. GRN-4 GRN/BLK-4 RED-C.H. WHT-E.H.1

C
RED-3 RED/BLK-3 RED/WHT-3 WHT-3 WHT/BLK-3 WHT/RED-3 BLK-3 BLK/WHT-3 BLK/RED-3 BLU-3 BLU/BLK-3 BLU/WHT-3 BLU/RED-3 ORG-3 ORG/BLK-3 ORG/RED-3 GRN-3 GRN/BLK-3 GRN/WHT-3 RED-EXT.-6 BLK-2 WHT-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

A
RED-S.P. RD/BK-S.P. RD/WT-S.P. WHT-S.P. WT/BK-S.P. WT/RD-S.P. BLK-S.P. BK/WT-S.P. BK/RD-R5 BLU-S.P. BU/BK-S.P. BLU/WT-S.P. ORG-SP OG/BK-SP WHT-12-E.H.1 GRN-S.P. GR/BK-S.P. GR/WT-S.P. RED-S.P. WHT-S.P. BLK-S.P. PRIMARY BOOM UP PRIMARY BOOM DOWN PRIMARY BOOM FUNCTION CONTROL TURNTABLE ROTATE LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE FUNCTION CTRL PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT HORN SECONDARY BOOM UP SECONDARY BOOM DOWN SECONDARY BOOM FUNCTION CTRL DRIVE ENABLE LIGHT PLATFORM LEVEL UP PLATFORM LEVEL DOWN DRIVE ENABLE RELAY COIL PLATFORM ROTATE LEFT/JIB UP PLATFORM ROTATE RIGHT/JIB DOWN JIB VALVE +12 V POWER IGNITION POWER +12 V TO PLATFORM KEYSWITCH POWER ENGINE FAULT OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH AUXILARY PUMP SELECT TILT ALARM 2WD/4WD E.D.C. E.D.C. BRAKE START ENGINE GLOW PLUG HIGH/LOW RPM STEER LEFT STEER RIGHT (SPARE) (SPARE) OFF-LIMIT SPEED ALTERNATOR PULSE PICKUP (SPARE) (SPARE) (SPARE) GENERATOR OPTION

NO

NO

NC WHT-23 BLK-22 RED-27 BRN-(R5) BRN-(GRND) WHT-21 WHT-21 (R2) STOP

TS51 WHT/BLK-25 WHT/RED-26

L2 1 2

LED

OIL PRESS

RED/WHT-3 RED/BLK-2 RED-1 BLK-7

HOUR METER 3

BLK/RED-35B

RED

BLK/WHT-8 TS61 TS63 PRIMARY BOOM TS58 TS62 EXTEND RETRACT WHT-4 WHT/BLK-5 WHT/RED-6 TURNTABLE ROTATE

BLU/WHT-12
BLK/WHT-34

L3 OIL TEMP.

R4
TS56

CR1 BLK-R1 BLK-R1-E.H. WHT-21

CR2

CR3

CR4

TS60 TS52

5
1

RD/WT-C.H. WHT-ISM-10 WHT/BLK-EH.1 WT/RD-E.H.1 RED-C.H RED/BLK-C.H RED/WHT-C.H WHT-ENA. WT/BK-E.H.1 WHT/RED-C.H BLK-ISM-3

WHT-S.P.

WHT-ISM-7 WHT/BLK-SP WHT/RED-SP RED-S.P.

BLK/RED-35

GLOW PLUG

START

SEC. BOOM

JIB

BLK/RED-R4 WHT-40B

RED-1 RED/BLK-1 R/W-1 WHT-1 WHT/BLK-1 WHT/RED-1

RED-ISM-4

TS54

CB1

CB2

TS59

GRN/WHT-19 GRN/BLK-18 GRN-17 PLAT. LEVEL TS57 PLATFORM ROTATE


BRN-(GRND H.M)

BLK/RED-R5 CR5 CR7

ORG-4 CR8

ORG/BLK-4

6
WHT#40-R7 WHT-PRIM.#5

BLK-1 BLK/WHT-E.H.1 BLK/WHT-1 BLK/RED-35GEN BLK/RED-1 BLU-1 BLU-M.H. BLU/BLK-1 BU/BK-M.H. BLU/WHT-1 BLU/RED-1 OG/BK-E.H.1 ORG-1 ORG/BLK-1 ORG/RED-1 GRN-1 GRN/BLK-1 GRN/WHT-1

BLK-S.P. BK/RD-R3#35 BK/RD-SP

BLU-10 BLU/BLK-11 RED-20 RED-R1 BLK-33

FUNCTION ENABLE

ORG-14 ORG/BLK-15

BLK-22 BLK/RED-9A PLATFORM LEVEL CUTOUT (CE MODELS ONLY)

WHT-SEC#4

CH+EH1

WHT-EXT.#6 OG/BK-IM2

GR/WT-C.H

BLK/RED-35GEN

7
GRD-HOLE

ORG/BLK-15 ORG-14

BLK/RED-EH-r.male BLK/RED-EH-r.fem BLK-E.H-r.fem

r.fem-BLK/RED-R4 r.male-BLK/RED-R5 r.male-BLK-R1 r.fem-ORG-R7 r.fem-ORG/BLK-R8

WIRE CONNECTION ABBREVIATION KEY:


EH C.H. M.H. S.P. R or CR ISM H.M. ENGINE HARNESS CHASSIS HARNESS MANIFOLD HARNESS SWITCH PANEL RELAY IGNITION/START MODULE HOUR METER

ORG-M.H.-r.male ORG/BLK-M.H.-r.male

6 - 76

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring DiagramZ-45/25J Perkins Models (after serial number 16303)
N M L K J
PLATFORM CONTROL BOX

COMPONENT INDEX
P2 P3 TS1 TS2 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13
TS47 R1

WHT-24
1 2 3 4 5 6 7 8 9 10 HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.
(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

ORG/BLK-41

ORG-40

HORSEPOWER LIMITER BOARD

EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG OPTION PLATFORM ROTATE SWITCH JIB UP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH
GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY )

SEC. BOOM UP

RED FROM CR14

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

ORG-40 CR12 RED-10 WHT-24

GRD. STUD
R1 50 RED-10 LIMITING RELAY
RED-TILT

WHT JIB CABLE

R2 R3 L1 BP1 BP2 CR12 CR13 CR14 DP1 H.P.L. T1

LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOMUP/DOWN,TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY JIB VALVE RELAY
DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD

RED/BLK-28

BLK JIB CABLE CABLE #1 110 JIB CABLE F.S.

H1

CABLE #3

CABLE #2

+ TILT ALARM

TIME DELAY TILT ALARM

RED-STP

BLK/WHT-34

GRN/WHT-45

WHT/BLK-5

WHT-4

RED/BLK-2

RED-1

BLK-7

BLK/WHT-8

GRN-17

GRN/BLK-18

BLU/WHT-12 RED-27

RED/WHT-3

BRN TO GRD.

WHT-24 TO H.P.L.

WHT/BLK-31

BLK-22

BLK-26

WHT-23

NC
R

NO
A + - X

CR13

NC
A + - X

A + - X

BP1
NO

JIB VALVE RELAY

CR14

L1

TS13

NC NO

JIB CUTOUT RELAY

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7

SEE SIDE VIEW DP1

P3

NO

TS1 AUXILIARY PUMP DRIVE SPEED

100

250

BLK/RED-9

ORG-14

ORG/BLK-15

WHT/RED-6

GRN/WHT-19

RED-STP RED-TILT RED TIM.DEL.

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

BLU/RED-13

ORG/RED-16

BLK/RED-35 RED-25

PRIMARY BOOM EXTEND/ RETRACT

SEC.BOOM BP2

GEN. OPT. TS47


RED-GEN

BLK-33

BLU/BLK-37

WHT-30

WHT/RED-32

RED TO JIB CABLE

RED JUMP

BLU-36

SIDE VIEW FOR DP1

5
WHT TO PLATFORM ROTATE

DP1 DRIVE

GRN/WHT + RED OUTPUT BRN TIME DELAY T1

8 7 6 5 4 3 2 1

PLATFORM LEVEL TS9

TS8

JIB

R2

R3 TS6

DRV.ENA TS15 NC NC

7
TS4

GLOW PLUG

TS2 START HIGH/LOW RPM

HORN
REMOVE FOR LIFT/ DRIVE SELECT VERSION

TS14

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

8
PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 77

First Edition Second Printing

Section 6 Schematics

Platform Control Box Wiring DiagramZ-45/25J Perkins Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring Diagram- Lift/Drive SelectOption, Z-45/25J Perkins Models (after serial number 16303)
N M L K J I H G F E D C B A

PLATFORM CONTROL BOX

1
COMPONENT INDEX
P2 P3 TS1 TS2 TS6 TS7 TS8 TS9 TS10 TS11 TS12 TS13
TS47 R1

WHT-24 ORG/BLK-41

EMERGENCY STOP BUTTON HORN SWITCH AUXILIARY SWITCH START ENGINE SWITCH GLOW PLUG OPTION (DIESEL ONLY) PLATFORM ROTATE SWITCH JIB BOOMUP/DOWN PLATFORM LEVEL SWITCH SECONDARY BOOM UP/DOWN SWITCH PRIMARY BOOM UP/DOWN SWITCH TURNTABLE ROTATE SWITCH PRIMARY BOOM EXTEND/RETRACT SWITCH
GENERATOR SWITCH ( OPTION ) EFI RESISTOR ( FORD AND PERKINS ONLY )

1 2 3 4 5 6 7 8 9 10

GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH (SPARE) (SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

SEC. BOOM UP

RED FROM CR14

ORG-40

HORSEPOWER LIMITER BOARD

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

ORG-40 CR12 RED-10 WHT-24

GRD. STUD
R1 50 RED-10 LIMITING RELAY
RED-TILT

WHT JIB CABLE

R2 R3 L1 BP1 BP2 CR12 CR13 CR14 DP1 H.P.L. T1 H1

LOW SPEED RESISTOR LOW SPEED RESISTOR DRIVE ENABLE LED BOOM PROPORTIONAL JOYSTICK: PRIMARY BOOMUP/DOWN,TURNTABLE ROTATE BOOM PROPORTIONAL JOYSTICK: SECONDARY BOOM UP/DOWN EFI RELAY ( FORD AND PERKINS ONLY ) JIB CUTOUT RELAY JIB VALVE RELAY
DRIVE PROPORTIONAL JOYSTICK HORSEPOWER LIMITER BOARD

RED/BLK-28

BLK JIB CABLE CABLE #1 110 JIB CABLE F.S.

H1 + TILT ALARM

CABLE #3

CABLE #2

TIME DELAY TILT ALARM

SIDE VIEW FOR DP1


WHT TO PLATFORM ROTATE

GRN/WHT-45

RED-STP RED-TILT RED TIM.DEL.

WHT-4

RED/BLK-2

BLK/WHT-34

RED JUMP

RED TO JIB CABLE

BLU/RED-13

ORG-14

RED-10 TO H.P.L.

BLU-10

BLU/BLK-11

RED/WHT-29

BLK-7

BLK/WHT-8

GRN/BLK-18

BLU/WHT-12 RED-27

GRN/WHT-19

BLK/RED-35 RED-25

RED/WHT-3

WHT/BLK-5

ORG/BLK-15

GRN-17

ORG/RED-16

NC

NO

CR13

L1

NC

BP1
NO

JIB VALVE RELAY

A +

A +

TS13

NC NO

JIB CUTOUT RELAY

TURNTABLE ROTATE

PRIMARY BOOM UP/DOWN PLATFORM ROTATE TS7

SEE SIDE VIEW DP1

P3

NO

TS1 AUXILIARY PUMP DRIVE SPEED

100

250

BLK/RED-9

BLK-33

RED-1

WHT/RED-6

BLU/BLK-37

WHT-30 WHT/BLK-31

BLU-36

WHT/RED-32

RED-STP

BRN TO GRD.

WHT-24 TO H.P.L.

BLK-22

BLK-26

WHT-23

PRIMARY BOOM EXTEND/ RETRACT

GEN. OPT. TS47


RED-GEN

SEC.BOOM BP2

CR14

DP1 DRIVE

GRN/WHT + RED OUTPUT BRN TIME DELAY T1

8 7 6 5 4 3 2 1

A +
-

X R
PLATFORM LEVEL TS9 TS8 JIB

R2

R3 TS6

DRV.ENA TS15 NC NC

GLOW PLUG

TS2 START TS4 HIGH/LOW RPM

HORN

TS14

HIGH/LOW (2WD/4WD)

EMERGENCY STOP P2

PLATFORM CONTROL SWITCH PANEL

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 78

First Edition Second Printing

Section 6 Schematics

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

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring Diagram- Load Sensor Option, All Models (after serial number 16303)

Section 6 Schematics

First Edition Second Printing

Platform Control Box Wiring Diagram- Load Sensor Option, All Models (after serial number 16303)
A 1 B C D E
PLATFORM CONTROL BOX
PART NUMBER 54904 54905 54906 54907 54908 54909 32335 48716 56765 56766

BILL OF MATERIALS
DESCRIPTION WIRE ASSY FOOTSWITCH, SERV LOOP WIRE ASSY LOADSENSE, ORANGE LED WIRE ASSY FTSWTCH/LDSENSOR, PWR WIRE ASSY, LDSENSE, LED, GROUND WIRE ASSY LDSENS/FS, WHITE JUMP WIRE ASSY LDSENSE, BROWN, GROUND LED,RED 12V LARGE DECAL, LABEL, LOAD SENSOR LOAD CELL BENDING TYPE MODULE,LOAD SENSE,1/12V RELAY
BRN-LOAD BLK-26 LOAD (P/N 54906) ORG-LOAD (P/N 54905)

(UNUSED) JIB VALVE PLAT. ROT. R. PLAT. ROT. L. DRIVE ENABLE

HORN BOOM RETRACT BOOM EXTEND TURN. ROT. F.C. TURN ROT. R. TURN ROT. L. PRIMARY F.C. PRIMARY DOWN PRIMARY UP

SEC. BOOM UP

PLAT. LEVEL DN. PLAT. LEVEL UP DRIVE ENA. LT. SEC. BOOM F.C. SEC. BOOM DN.

(SPARE) STEER RIGHT STEER LEFT HIGH/LOW RPM GLOW PLUG START ENGINE BRAKE E.D.C. E.D.C. 2WD/4WD TILT ALARM AUX. PUMP SEL. PWR. TO F.S. F.S. UP POWER PWR. (CONT.) KEYSW. PWR. +12 V TO PLAT. OPTION WIRE

GEN. (OPTION) (SPARE) (SPARE) (SPARE) PULSE PICKUP LIMIT SWITCH

HORSEPOWER LIMITER BOARD

1 2 3 4 5 6 7 8 9 10

LOAD SENSOR MODULE (COVER REMOVED) (P/N 56766)


FUSE, 500 mA
-

2
BRN-LOAD (P/N 54909)

PREALARM ADJUST (NOT USED)

N.O. N.C. C.

3
GROUND BOLT

WHT-LOAD (P/N 54908)


12 VOLTS

1 2 3 4 5 6 7 8 9

RED LED OVER LOAD YELLOW LED PREALARM (NOT USED)

RELAY OVER LOAD ADJUST

4
TILT ALARM CABLE #3 CABLE #2 CABLE #1 110 JIB CABLE F.S.

WHT-(F.S.) (P/N 54904) CABLE TO LOAD CELL (P/N 56765)

5
GENERATOR OPTION

DRIVE DP1
8

TURNTABLE ROTATE
R

NC

NO

PRIMARY BOOM UP/DOWN


A

6
- X

NC

BP1
NO

DRV.ENA

7
P3

TS15 HORN NO PLATFORM LEVEL TS9 TS7 PLATFORM ROTATE TS8 JIB AUXILIARY PUMP TS1 TS14
TS6

DRIVE SPEED
GLOW PLUG

START TS2 TS4

HIGH/LOW RPM
L4 BRN
+

BRN (P/N 54907)

TS13

- X

DRV.ENA LED

PRIMARY BOOM EXTEND/ RETRACT

SEC.BOOM BP2
R

L1

TS47
+

HIGH/LOW (2WD/4WD)

OVER LOAD LED (P/N 32335)

8
PLATFORM CONTROL SWITCH PANEL

6 - 79

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 GRN/WHT-1 GRN/BLK-1 GRN-1 ORG/RED-1 ORG/BLK-1 ORG-1 BLU/RED-1 BLU/WHT-1 BLU/BLK-1 BLU-1 BLK/RED-1 BLK/WHT-1 BLK-1 WHT/RED-1 WHT/BLK-1 WHT-1 RED/WHT-1 RED/BLK-1 RED-1 BLK (F.S.) RED (F.S.) WHT (F.S.) WHT-2 BLK-2 WHT GRN/WHT-3 GRN/BLK-3 GRN-3 ORG/RED-3 ORG/BLK-3 ORG-3 BLU/RED-3 BLU/WHT-3 BLU/BLK-3 BLU-3 BLK/RED-3 BLK/WHT-3 BLK-3 WHT/RED-3 WHT/BLK-3 WHT-3 RED/WHT-3 RED/BLK-3 RED-3

+
B V R N

WHT GRN RED BLK

ORG-LOAD (P/N 54905)

BLK-26 LOAD (P/N 54906)

BLK-26 (P/N 54906)

+
- X
R

NC

NC

EMERGENCY STOP P2

First Edition Second Printing

Section 6 Schematics

Hydraulic Symbols Legend

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 80

Section 6 Schematics

First Edition Second Printing

6 - 81

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

Section 6 Schematics

First Edition Second Printing

2WD Hydraulic Schematic


N M L K J I H G F E D C B A

JIB BOOM CYLINDER

PLATFORM ROTATE CYLINDER

TURNTABLE ROTATE

PRIMARY BOOM CYLINDER

1.5:1 3800 PSI (262 bar) semi restricted J2 J1 V2 V1

3:1 2000 PSI (137.9 bar)


OO

3:1 1500 PSI (103.4 bar)

EXTENSION CYLINDER
NN

SLAVE CYLINDER
MM
X

1.5:1 3800 PSI (262 bar) semi restricted

3:1 ATMOS. 1000 PSI (68.9 bar)

5:1 ATMOS. 1500 PSI (103.4 bar)

R2
0.030 (0.76 mm) 0.030 (0.76 mm)

S1
X

0.030 (.76 mm)

SECONDARY BOOM CYLINDERS

R1

JIB BOOM MANIFOLD

V2

V1

V2 3:1 SEMI RESTRICTIVE SEALED PILOT 3000 PSI. (206.8 bar)

V1

3
1:1 ATMOS 3000 PSI. (206.8 bar)

DRIVE MANIFOLD REAR RIGHT


RA PA

50 PSI (3.4 bar)

HIGH PRESSURE FILTER

MASTER CYLINDER OPTIONAL MOTOR/ GENERATOR

4
ST1
GG

ST2

PR1

PR2

PL1
R

PL2
Q

SW1

SW2

S1 0.040 (1 mm)
JJ HH

S2 1800 PSI (124.1 bar)


E

P1

P2

EXTEND

RETRACT

VV

RB
UU

360 PSI (24.8 bar)


KK

V BB T

4.5:1 3500 PSI (241.3 bar)

This valve was removed after serial number 12603

2300 PSI (159 bar)

P FF II
DD

0.070 (1.18 mm) LA

RR

50%

PB

GENERATOR SELECT
3500 PSI (241.3 bar)

TEST
F

C CC

50%
TT
WW
X

1.5 GPM (5.7 L/min)

5
2 GPM (7.6 L/min)
W

REAR LEFT

LB

FUNCTION PUMP
7 GPM (26.5 L/min)

PRESSURE

0.6 GPM (2.3 L/min)

1 GPM (3.8 L/min)

Z N A G D B Y LL M X

TEST

DRIVE PUMP
TANK

3200 PSI (220.6 bar)

EE

0.1 GPM (0.4 L/min)

QQ

AA T2

LIFT FUNCTION MANIFOLD OPTIONAL OSCILLATE CLYINDERS

T
XX YY PP

3200 PSI (220.6 bar) 25 PSI (1.7 bar)

2 SPEED BRAKE

0.030 (0.76 mm)

See Note #1

T2

TANK

APU

4.5:1 1000 PSI (67 bar)

STEERING CYLINDERS

OPTIONAL OSCILLATE DIRECTIONAL VALVE

NOTE #1: 250 PSI (17.2 bar) before serial number 12604 280 PSI (19.3 bar) after serial number 12603

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 82

First Edition Second Printing

Section 6 Schematics

2WD Hydraulic Schematic

Section 6 Schematics

First Edition Second Printing

4WD Hydraulic Schematic


N M L K J I H
JIB BOOM CYLINDER

G
PLATFORM ROTATE CYLINDER

D
TURNTABLE ROTATE

B
PRIMARY BOOM CYLINDER

1.5:1 3800 PSI (262 bar) semi restricted J2 J1 V2 V1

1
3:1 2000 PSI (137.9 bar)
OO

3:1 1500 PSI (103.4 bar)

EXTENSION CYLINDER
NN

SLAVE CYLINDER
MM
X

1.5:1 3800 PSI (262 bar) semi restricted

3:1 ATMOS. 1000 PSI (68.9 bar)

5:1 ATMOS. 1500 PSI (103.4 bar)

R2
0.030 (0.76 mm) 0.030 (0.76 mm)

S1
X

0.030 (.76 mm)

SECONDARY BOOM CYLINDERS

R1

JIB BOOM MANIFOLD

V2

V1

V2 3:1 SEMI RESTRICTIVE SEALED PILOT 3000 PSI. (206.8 bar)

V1

1:1 ATMOS 3000 PSI. (206.8 bar)

50 PSI (3.4 bar)

HIGH PRESSURE FILTER

MASTER CYLINDER OPTIONAL MOTOR/ GENERATOR

ST1
GG

ST2

PR1

PR2

PL1
R

PL2
Q

SW1

SW2

S1 0.040 (1 mm)
JJ HH

S2 1800 PSI (124.1 bar)


E

P1

P2

EXTEND

RETRACT

360 PSI (24.8 bar)


KK

V BB T

4.5:1 3500 PSI (241.3 bar)

This valve was removed after serial number 12603

2300 PSI (159 bar)

4
K

P S FF II C DD

GENERATOR SELECT
3500 PSI (241.3 bar)

TEST
F

L I

1.5 GPM (5.7 L/min)

CC

FUNCTION PUMP
7 GPM (26.5 L/min)

PRESSURE

0.6 GPM (2.3 L/min)

1 GPM (3.8 L/min)

Z N A G D B Y LL M X

2 GPM (7.6 L/min)

DRIVE MANIFOLD
RB
AG

DRIVE PUMP
TANK

3200 PSI (220.6 bar)

EE

0.1 GPM (0.4 L/min)

AA T2

LIFT FUNCTION MANIFOLD OPTIONAL OSCILLATE CLYINDERS

3200 PSI (220.6 bar) 25 PSI (1.7 bar) A RFB


M

6
APU
4.5:1 1000 PSI (67 bar)

REAR RIGHT
RFA RA
AS AQ

FRONT RIGHT

TANK

LFB
50%

LB

67%

AR 33%

50%

AD

AB
50% 0.2 GPM (0.76 L/min) AT 0.052 AP (1.32 mm) 50%

See Note #1

FRONT LEFT

STEERING CYLINDERS

OPTIONAL OSCILLATE DIRECTIONAL VALVE

REAR LEFT

AC

AO
0.025 (0.64 mm)

LFA
X TEST

AE AF AH

AM
AL

T2
AJ
0.030 (0.76 mm)

TANK

See Note #2

BRAKE 2 SPEED

AK

AI

NOTE #1: 2 GPM (7.6 L/min) before serial number 14775 0.8 GPM (3.02 L/min) after serial number 14774 NOTE #2: 250 PSI (17.2 bar) before serial number 12604 280 PSI (19.3 bar) after serial number 12603

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

6 - 83

First Edition Second Printing

Section 6 Schematics

4WD Hydraulic Schematic

First Edition Second Printing

Section 7 Repair Procedures

Repair Procedures
About This Section
Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

Observe and Obey:


Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine.

Perform disassembly procedures to the point where repairs can be completed. Then to re-assemble, perform the disassembly steps in reverse order. Symbols Legend Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Redused to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Orangeused to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Yellow without safety alert symbolused to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Greenused to indicate operation or maintenance information. Indicates that a specific result is expected after performing a series of steps.

Before Repairs Start:


Read, understand and obey the safety rules and operating instructions in the Genie Z-45/25 & Genie Z-45/25J Operators Manual. Be sure that all necessary tools and parts are available and ready for use. Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: Machine parked on a flat, level surface Boom in stowed position 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

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

7-1

Section 7 Repair Procedures

First Edition Second Printing

Platform Controls
1-1 Joystick Controllers
Maintaining joystick controllers at the proper settings is essential to safe machine operation. Every joystick controller should operate smoothly and provide proportional speed control over its entire range of motion.
a b

Primary Boom Up/Down Controller Adjustments


Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13.6 to 14.5V DC output. Individual trim potentiometers (trimpots) are used to adjust various output signals from the drive and boom function controllers. The trimpots will be identified 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)

Platform control box a horsepower limiter board b terminal strip c drive proportional controller d secondary boom proportional controller e primary boom proportional controller f turntable rotate proportional controller

1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. Do not start the engine.

7-2

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PLATFORM CONTROLS

2 Open the platform control box lid and locate the primary boom up/down controller.
a b c d e f g h i j

6 Set the hi range: Press down the foot switch, then move the control handle all the way to the UP position. Adjust the voltage to 6.5V DC. Turn the hi range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 7 Set the lo range: Press down the foot switch, then move the control handle all the way to the DOWN position. Adjust the voltage to 5.5V DC. Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 8 Start the engine and move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). 9 Start a timer and record how long it takes for the primary boom to fully raise. Adjust the hi range trimpot to achieve a 24 to 27 second cycle time. Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed. 10 Start a timer and record how long it takes for the boom to fully lower. Adjust the lo range trimpot to achieve an 32 to 37 second cycle time. Turn the lo range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed. If the function cycle time is not achievable, check the relief valve pressure. See 12-2, Valve Adjustments - Function Manifold. 11 Turn the engine OFF. 12 Pull out the Emergency Stop button to the ON position.

a b c d e f g h i j

ramp rate adjustable trimpot lo range adjustable trimpot terminal "R" activates hi range (not used) terminal "X" (not used) terminal "-" ground terminal "+" positive terminal "A" proportional output threshold adjustable trimpot hi range adjustable trimpot

3 Set the preliminary ramp rate: Turn the ramp rate trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click. 4 Connect the red (+) lead from a volt meter to the A terminal on the controller printed circuit board. Connect the black (-) lead to ground. 5 Set the threshold: Press down the foot switch, then slowly move the control handle off center until the moment a voltage reading appears. Adjust the voltage to 2.85V DC. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

7-3

Section 7 Repair Procedures

First Edition Second Printing

PLATFORM CONTROLS

13 Press down the foot switch and then move the control handle all the way to the UP position. Record the maximum voltage reading. 14 Start a timer and simultaneously move the control handle all the way to the UP position. Note how long it takes to reach the maximum voltage recorded in step 14. This is the ramp rate. 15 Set the ramp rate: turn the ramp rate trimpot to obtain a 3 to 4 second ramp speed. Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time.
Boom up/down specifications Threshold Primary boom up - hi range Cycle time Primary boom down - lo range Cycle time Ramp rate 2.85V DC 6.5V DC 24 to 27 seconds 5.5V DC 32 to 37 seconds 3 to 4 seconds

Secondary Boom Up/Down Controller Adjustments


Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13.6 to 14.5V DC output. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. Do not start the engine.

7-4

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PLATFORM CONTROLS

2 Open the platform control box lid and locate the secondary boom up/down controller.
a b c d e f g h i j

6 Set the hi range: Press down the foot switch, then move the control handle all the way to the UP position. Adjust the voltage to 6.5V DC. Turn the hi range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 7 Set the lo range: Press down the foot switch, then move the control handle all the way to the DOWN position. Adjust the voltageto 5.5V DC. Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 8 Start the engine and move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). 9 Start a timer and record how long it takes for the secondary boom to fully raise. Adjust the max-out trimpot to achieve a 23 to 27 second cycle time. Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed. 10 Start a timer and record how long it takes for the secondary boom to fully lower. Adjust the dual range trimpot to achieve an 23 to 27 second cycle time. Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed. If the function cycle time is not achievable, check the relief valve pressure. See 12-2, Valve Adjustments - Function Manifold. 11 Turn the engine off. 12 Pull out the Emergency Stop button to the ON position.

a b c d e f g h i j

ramp rate adjustable trimpot lo range adjustable trimpot terminal "R" activates hi range (not used) terminal "X" (not used) terminal "-" ground terminal "+" positive terminal "A" proportional output threshold adjustable trimpot hi range adjustable trimpot

3 Set the preliminary ramp rate: Turn the ramp rate trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click. 4 Connect the red (+) lead from a volt meter to the A terminal on the controller printed circuit board. Connect the black (-) lead to ground. 5 Set the threshold: Press down the foot switch, then slowly move the control handle off center until the moment a voltage reading appears. Adjust the voltage to 2.85V DC. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

7-5

Section 7 Repair Procedures

First Edition Second Printing

PLATFORM CONTROLS

13 Press down the foot switch and then move the control handle all the way to the UP position. Record the maximum voltage reading. 14 Start a timer and simultaneously move the control handle all the way to the UP position. Note how long it takes to reach the maximum voltage recorded in step 14. This is the ramp rate. 15 Set the ramp rate: turn the ramp rate trimpot to obtain a 3 to 4 second ramp speed. Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time.
Secondary boom up/down specifications Threshold Secondary boom up - hi range Cycle time Secondary boom down - lo range Cycle time Ramp rate 2.85V DC 6.5V DC 23 to 27 seconds 5.5V DC 40 seconds 3 to 4 seconds

Turntable Rotation Controller Adjustments


Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Do not adjust the joystick controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13.6 to 14.5V DC output. 1 Turn the key switch to platform control and pull out the Emergency Stop button to the ON position at both the ground and platform controls. Do not start the engine.

7-6

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PLATFORM CONTROLS

2 Open the platform control box lid and locate the turntable rotation controller. Refer to the platform control box illustration, page 7-2.
a b c d e f g h i j

6 Set the hi range: Press down the foot switch, fully retract the boom, then move the control handle all the way to the left or right. Adjust the voltage to 5.5V DC. Turn the hi range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage. 7 Start the engine and move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). Rotate the turntable to the FULL RIGHT position. 8 Start a timer and record how long it takes the turntable to rotate to the FULL LEFT position. Adjust the max-out trimpot to achieve a 73 to 78 second cycle time. Turn the hi range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed. 9 Set the ramp rate: turn the ramp rate trimpot to obtain a 3 to 4 second ramp speed. Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time.
Turntable rotation specifications Threshold Turntable rotation hi range Cycle time Ramp rate 2.85V DC

a b c d e f g h i j

ramp rate adjustable trimpot lo range adjustable trimpot terminal "R" (not used) (not used) terminal "X" (not used) terminal "-" ground terminal "+" positive terminal "A" proportional output threshold adjustable trimpot hi range adjustable trimpot

3 Set the preliminary ramp rate: Turn the ramp rate trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click. 4 Connect the red (+) lead from a volt meter to the A terminal on the controller printed circuit board. Connect the black (-) lead to ground. 5 Set the threshold: Press down the foot switch, then slowly move the control handle off center until the moment a voltage reading appears. Adjust the voltage to 2.85V DC. Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage.

5.5V DC 73 to 78 seconds 5 seconds

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

7-7

Section 7 Repair Procedures

First Edition Second Printing

PLATFORM CONTROLS

1-2 Horsepower Limiter Board


The horsepower limiter board is responsible for governing drive pump output. It senses engine rpm from the alternator. The horsepower limiter board senses drops in rpm normally due to increased drive resistance (rough terrain or incline), and decreases voltage to the drive controller which in turn decreases voltage to the drive pump, thereby reducing pump output to maintain optimum engine rpm and horsepower. Three adjustments are required for optimum performance.

1 Remove the fasteners from the platform control box lid. 2 Open the control box lid and locate the horsepower limiter board. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
a

How to Adjust the Horsepower Limiter Board


The engine rpm must be correct before performing this procedure. See Maintenance Procedure A-22, Check and Adjust the Engine RPM, for Perkins Diesel Models, OR see B-10 for Ford and Deutz Engine Models. Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC and the alternator is operating properly with 12.5 to 14.5V DC output. Ford models: Perform this procedure in gasoline mode.

Platform control box a horsepower limiter board

7-8

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PLATFORM CONTROLS

3 Connect the black (-) lead from a DC volt meter to the number 2 terminal, and the red (+) lead to the number 10 terminal.
a
12V DC or greater ground engine rpm sensor not used not used low drive speed limit switch not used not used not used output to drive controller

7 Move the engine idle control switch to low idle (turtle symbol). 8 Press down the foot switch and then adjust the "C" potentiometer to obtain a 0.1V DC to 0.5V DC voltage reading. 9 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). 10 Press down the foot switch and re-adjust the "A" potentiometer to the previous voltage setting in step 6. 11 Be sure that the boom is in the stowed position, then drive the machine and observe how the engine rpm reacts to drive control handle movement. If the engine surges or hunts, adjust the "C" potentiometer counterclockwise until surging is minimized. Under an extreme load, an excessive counterclockwise adjustment to the "C" potentiometer will cause the engine to stall. The "C" potentiometer adjustment is a compromise between engine stability (surging) and engine rpm drop. 12 Disconnect the volt meter. 13 Raise the primary boom above horizontal.

Horsepower limiter board a "A" potentiometer maximum voltage output to the controller in the stowed position "B" potentiometer maximum voltage output to the drive controller in the boom raised or extended position "C" potentiometer reaction rate or how fast the voltage output reacts to the change in engine rpm

4 Start the engine from the platform controls. 5 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol). 6 Press down the foot switch and adjust the "A" potentiometer counterclockwise to increase voltage or clockwise to decrease voltage.
"A" potentiometer specifications - all models Voltage setting 9 to 10V DC

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

7-9

Section 7 Repair Procedures

First Edition Second Printing

PLATFORM CONTROLS

14 Drive the machine for 40 feet (12 m) and record the elapsed time. Repeat this step in the opposite drive direction. 15 Adjust the "B" potentiometer to obtain the correct raised drive speed (see specifications below). Turn the "B" potentiometer counterclockwise to decrease voltage or clockwise to increase voltage. 16 Close the platform control box lid and install the fasteners.
Drive speed specifications Stowed position drive speed: All models distance: 40 ft/12.2 m 40 ft/5.7 sec 12.2 m/5.7 sec 0.6 mph 1 km/h 40 ft/45 sec 12.2 m/45 sec 0.36 mph 0.58 km/h 40 ft/79 sec 12.2 m/79 sec

1-3 Foot Switch How to Test the Foot Switch


Perform this procedure with the keyswitch in the OFF position. 1 Remove the foot switch cover plate fasteners from the platform. 2 Remove the foot switch guard mounting fasteners from the platform. 3 Remove the foot switch mounting fasteners that attach the foot switch to the foot switch guard. 4 Remove the cover plate from the bottom of the foot switch to access the foot switch wire terminals. 5 Do not press down the foot switch. Connect the leads from an ohmmeter or continuity tester to each terminal combination listed and check for continuity.

Drive speed, boom raised or extended, Standard Base Models

Drive speed, boom raised or extended, Narrow Base Models

7 - 10

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PLATFORM CONTROLS

Test N.C. to C

Desired result continuity (zero ) no continuity (infinite ) no continuity (infinite )

1-4 Toggle Switches


Toggle switches used for single function switching are single pole double throw (SPDT) switches. Dual function switching requires a double pole double throw (DPDT) switch.

N.C. to N.O.

C to N.O.

How to Test a Toggle Switch


Continuity is the equivalent of 0 to 3 ohms. A simple continuity tester may not accurately test the switch. This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches. 1 Turn the key switch to the OFF position. Tag and disconnect all wiring from the toggle switch to be tested.

6 Press down the foot switch. Connect the leads from an ohmmeter or continuity tester to each terminal combination listed below and check for continuity.
Test N.C. to C Desired result no continuity (infinite ) no continuity (infinite ) continuity (zero )

N.C. to N.O.

C to N.O.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

7 - 11

Section 7 Repair Procedures

First Edition Second Printing

PLATFORM CONTROLS

2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed to check for continuity.

Test Left position terminal 1 to 2, 3, 4, 5 & 6

Desired result

Left

Center

Right

no continuity (infinite W) continuity (zero W) no continuity (infinite W) no continuity (infinite W) no continuity (infinite W) continuity (zero W)

terminal 2 to 3 terminal 2 to 4, 5 & 6 terminal 3 to 4, 5 & 6


1 2 3 1 2 3 1 2 3

terminal 4 to 5 & 6 terminal 5 to 6

Single pole double throw (SPDT) Double pole double throw (DPDT)

1 4

2 5

3 6

1 4

2 5

3 6

1 4

2 5

3 6

Center position

There are no terminal combinations that will produce continuity (infinite W)

Right position terminal 1 to 2 terminal 1 to 3, 4, 5 & 6 terminal 2 to 3, 4, 5 & 6 terminal 3 to 4, 5 & 6 terminal 4 to 5 terminal 4 to 6 terminal 5 to 6 continuity (zero W) no continuity (infinite W) no continuity (infinite W) no continuity (infinite W) continuity (zero W) no continuity (infinite W) no continuity (infinite W)

7 - 12

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

Platform Components
2-1 Platform How to Remove the Platform
1 Remove the foot switch cover plate from the platform. 2 Remove the foot switch guard mounting fasteners from the platform. 3 Remove the footswitch and guard through the back of the platform through the access hole and set it aside. 4 Remove the platform control box mounting fasteners. Then lower the control box and set it aside. If your machine is equipped with an airline to platform option, the airline must be disconnected from the platform before removal. 5 Raise the primary boom slightly and place blocks under the platform. Then lower the primary boom until the platform is resting on the blocks just enough to support the platform. Do not rest the entire weight of the boom on the blocks.

6 Remove the platform mounting fasteners and remove the platform from the machine. Crushing hazard. The platform may become unstable and fall if it is not properly supported.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

7 - 13

Section 7 Repair Procedures

First Edition Second Printing

PLATFORM COMPONENTS

2-2 Platform Leveling Slave Cylinder


The slave cylinder and the rotator pivot are the two primary supports for the platform. The slave cylinder keeps the platform level through the entire range of boom motion. It operates in a closed-circuit hydraulic loop with the master cylinder. The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform. Do not rest the entire weight of the boom on the blocks. 4 Z-45/25J Models: Tag, disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the jib/rotate manifold and connect them together using a connector. Connect the hoses from the cylinder together using a connector. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Z-45/25 Models: Tag, disconnect and plug the hydraulic hoses from the slave cylinder and connect the hoses together using a connector. Cap the fittings on the cylinder. Then pull the slave cylinder hoses out through the primary extension boom. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Do not remove the pin. 6 Z-45/25J Models: Remove the external snap rings from the barrel-end pivot pin. Z-45/25 Models: Remove the pin retaining fastener from the slave cylinder barrel-end pivot pin. Do not remove the pin.

How to Remove the Platform Leveling Slave Cylinder


Before cylinder removal is considered, bleed the slave cylinder to be sure there is no air in the closed loop. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Z-45/25J Models: Extend the primary boom until the slave cylinder barrel-end pivot pin is accessible. 2 Raise the primary boom slightly and place blocks under the platform for support.

7 - 14

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PLATFORM COMPONENTS

7 Support the slave cylinder with a lifting device. 8 Z-45/25J Models: Support the jib boom bell crank with a suitable lifting device. 9 Use a soft metal drift to drive the rod-end pivot pin out. Crushing hazard. The jib boom bell crank may fall when the slave cylinder rod-end pivot pin is removed if it is not properly supported. Component damage hazard. The slave cylinder rod may become damaged if it is allowed to fall if it is not properly supported by the lifting device. 10 Use a soft metal drift and drive the barrel-end pin out. 11 Carefully pull the cylinder out of the primary boom.

2-3 Platform Rotator


The platform rotator is a hydraulically-activated, helical gear assembly used to rotate the platform 160 degrees.

How to Remove the Platform Rotator


Component damage hazard. Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment. The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal. If a new rotator is installed or the rotator is disassembled, proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. See 2-1, How to Remove the Platform.

How to Bleed the Slave Cylinder


Do not start the engine. Use auxiliary power for all machine functions in this procedure. 1 Raise the primary boom to a horizontal position. 2 Move the platform level switch up and down through two platform leveling cycles to remove any air that might be in the system.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

7 - 15

Section 7 Repair Procedures

First Edition Second Printing

PLATFORM COMPONENTS

2 Tag and disconnect the hydraulic hoses from the "V1" and "V2" ports on the counterbalance valve manifold located on the platform rotator and connect them together using a connector. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Support the platform mounting weldment with a lifting device, but do not apply any lifting pressure. 4 Remove the six mounting bolts from the platform mounting weldment, then remove the center bolt and slide the platform mounting weldment off of the platform rotator. Crushing hazard. The platform mounting weldment may become unbalanced and fall if it is not properly 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 jib boom and jib boom leveling arms to platform rotator pivot pins. Do not remove the pins. 7 Support the jib boom and jib boom leveling arms with a overhead crane. 8 Use a soft metal drift to drive both pins out, then remove the platform rotator from the machine. Crushing hazard. The platform rotator may become unbalanced and fall if it is not properly supported. Z-45/25 Models: 6 Support the rod end of the platform leveling slave cylinder. 7 Remove the pin retaining fasteners from the slave cylinder rod-end pivot pin and the rotator pivot pin. 8 Use a soft metal drift to drive both pins out, then remove the platform rotator from the machine. Crushing hazard. The platform rotator may become unbalanced and fall if it is not properly supported.

7 - 16

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PLATFORM COMPONENTS

How to Bleed the Platform Rotator


This procedure will require two people. Do not start the engine. Use auxiliary power for all machine functions in this procedure. 1 Move the function enable toggle switch to either side and activate the platform rotate switch to the right then the left through two platform rotation cycles, then hold the switch to the RIGHT position until the platform is fully rotated to the right. 2 Connect a clear hose to the top bleed valve. Place the other end of the hose in a container to collect any drainage. Secure the container to the boom. 3 Open the top bleed valve on the rotator, but do not remove it.
a

4 Move the function enable toggle switch to either side and hold the platform rotate switch to the LEFT position until the platform is fully rotated. Continue holding the switch until air stops coming out of the bleed valve. Then close the bleed valve. Crushing hazard. Keep clear of the platform during rotation. 5 Connect the clear hose to the bottom bleed valve and open the valve. Do not remove the bleed valve. 6 Move the function enable toggle switch to either side and hold the platform rotate switch to the RIGHT position until the platform is fully rotated. Continue holding the switch until air stops coming out of the bleed valve. Then close the bleed valve. Crushing hazard. Keep clear of the platform during rotation. 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled. 8 Rotate the platform full right then left and inspect the bleed valves for leaks.

d a b c d

c top bleed valve bottom bleed valve container clear hose

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

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Section 7 Repair Procedures

First Edition Second Printing

Jib Boom Components, Z-45/25J Models


3-1 Jib Boom, Z-45/25J Models How to Remove the Jib Boom
Perform this procedure with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. See 2-1, How to Remove the Platform. 2 Remove the platform mounting weldment and the platform rotator. See 2-3, How to Remove the Platform Rotator. 3 Remove the hose and cable cover from the side of the jib boom. 4 Attach a lifting strap from an overhead crane to the jib boom. 5 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 6 Support the barrel end of the cylinder with a suitable lifting device. 7 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. 8 Use a soft metal drift to remove the pin and let the cylinder hang down. 9 Remove the pin retaining fastener from the jib boom pivot pin. Use a soft metal drift to remove the pin, then remove the jib boom from the primary boom bellcrank. Crushing hazard. The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. 10 Remove the pin retaining fastener from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin.

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

JIB BOOM COMPONENTS, Z-45/25J MODELS

11 Slide both of the jib boom leveling arms off of the jib boom cylinder rod-end pivot pin. 12 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder. 13 Use a soft metal drift to remove the jib boom lift cylinder rod-end pivot pin, then remove the jib boom lift cylinder from the primary boom bellcrank. Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane.

3-2 Jib Boom Lift Cylinder, Z-45/25J Models How to Remove the Jib Boom Lift Cylinder
Perform this procedure with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Then lower the jib boom until the platform is resting on the blocks just enough to support the platform. Do not rest the entire weight of the boom on the blocks.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

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Section 7 Repair Procedures

First Edition Second Printing

JIB BOOM COMPONENTS, Z-45/25J MODELS

2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. 4 Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm. Do not remove the pin. 5 Support the jib boom lift cylinder with a lifting device. 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pin and let the cylinder hang down.

7 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder. 8 Use a soft metal drift to remove the jib boom lift cylinder rod-end pin. Remove the cylinder from the machine. Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane.

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

JIB BOOM COMPONENTS, Z-45/25J MODELS

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


1 2 Orifice, 0.030 inch (0.76 mm) ............ AU ........ Platform rotate circuit Solenoid valve, 2 position 3 way ...... AV ......... Platform rotate/jib boom select .......... 8-10 ft-lbs (11-14 Nm)

1 1 AU AU

AV

AV

Plug Torque Specifications


Description SAE No. 2 SAE No. 4 Hex Size
1/ 8 3/16

Valve Coil Resistance Specifications


Torque Valve coil specification

50 in-lbs / 6 Nm 13 ft-lbs / 18 Nm 2 position 3 way valve (schematic item AV) 5 to 7

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Genie Z-45/25 & Genie Z-45/25J

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Section 7 Repair Procedures

First Edition Second Printing

Primary Boom Components


4-1 Plastic Cable Track
The primary boom cable track guides the cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom. 3 Label and disconnect each wire of the cables that enter the platform control box. Eletrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 4 Pull all of the cables out of the platform control box. 5 Pull all of the electrical cables out of the plastic cable track. Do not pull out the hydraulic hoses. 6 Raise the primary boom to a horizontal position. 7 Tag, disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder. Cap the fittings on the unions. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

How to Remove the Cable Track, Z-45/25 Models


When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Locate the cables from the primary boom cable track to the platform control box. Number each cable and its entry location at the platform control box. 2 Open the platform control box.

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PRIMARY BOOM COMPONENTS

8 Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports on the counterbalance valve manifold located on the platform rotator. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 9 Tag, disconnect and plug the hydraulic hoses from the platform leveling master cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 10 Tag and disconnect the hydraulic hoses from the platform leveling slave cylinder and connect them together using a connector. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

11 Pull the four hydraulic hoses toward the platform to clear the rod end of the primary boom lift cylinder. 12 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track may become unbalanced and fall when it is removed from the machine. 13 Remove all hose and cable clamps from the underside of the primary boom. 14 Attach a strap from an overhead crane to the cable track. 15 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom. 16 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom. 17 Remove the cable track from the machine and place it on a structure capable of supporting it. Crushing hazard. The cable track may become unbalanced and fall if it is not properly attached to the overhead crane. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

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Section 7 Repair Procedures

First Edition Second Printing

PRIMARY BOOM COMPONENTS

How to Remove the Cable Track, Z-45/25J Models


When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform control box mounting fasteners. 2 Remove the foot switch access hole cover plate fasteners. Remove the cover plate. 3 Remove the foot switch mounting fasteners from the platform. 4 Remove the foot switch through the back of the platform through the access hole and set it aside. 5 Remove the platform control box and set it aside.

6 Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports on the counterbalance valve manifold located on the platform rotator. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 Tag and disconnect the hydraulic hoses from the platform leveling slave cylinder at the union and connect them together using a connector. Connect the hoses from the cylinder together using a connector. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 8 Tag, disconnect and plug the hydraulic hoses from the jib boom/platform rotate manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PRIMARY BOOM COMPONENTS

9 Tag, disconnect and plug the platform rotator hydraulic hoses at the union located above the primary boom lift cylinder. Cap the fittings on the unions. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 10 Tag, disconnect and plug the hydraulic hoses from the platform leveling master cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 11 Raise the boom to a horizontal position. 12 Remove the hose and cable cover from the side of the jib boom.

13 Remove the hose clamp on the primary boom bellcrank. 14 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track may become unbalanced and fall when it is removed from the machine. 15 Attach a lifting strap from an overhead 5 ton (4,536 kg) capacity crane to the platform end of the primary boom for support. Do not lift it. 16 Remove all hose and cable clamps from the underside of the primary boom. 17 Support the rod end of the primary boom lift cylinder with a lifting device. 18 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. Do not remove the pin. 19 Raise the primary boom slightly with the overhead crane to relieve the pressure on the primary boom lift cylinder rod-end pivot pin. 20 Use a soft metal drift to remove the primary boom lift cylinder rod-end pivot pin. Crushing hazard. The primary boom lift cylinder may become unbalanced and fall if it is not properly supported by the lifting device.

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Genie Z-45/25 & Genie Z-45/25J

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Section 7 Repair Procedures

First Edition Second Printing

PRIMARY BOOM COMPONENTS

21 Lower the rod end of the primary boom lift cylinder approximately 12 inches (30.5 cm). 22 Pull all of the hoses and cables out and away from the mounting ears for the rod end of the primary boom lift cylinder. 23 Raise the rod end of the primary boom lift cylinder back into position and install the rodend pivot pin. Then install the pin retaining fastener. 24 Attach a strap from an overhead crane to the cable track. 25 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom. 26 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom. 27 Remove the cable track from the machine and place it on a structure capable of supporting it. Crushing hazard. The cable track may become unbalanced and fall if it is not properly attached to the overhead crane. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

How to Repair the Primary Boom Cable Track


Component damage hazard. The primary boom cable track can be damaged if it is twisted. A 7 link repair section of cable track is available through the Genie Industries Service Parts Department (Genie part number 58919).

a b

link separation point lower clip

1 Use a slotted screwdriver to pry down on the lower clip. 2 To remove a single link, open the lower clip and then use a screw driver to pry the link to the side. 3 Repeat steps 1 and 2 for each link.

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PRIMARY BOOM COMPONENTS

4-2 Primary Boom How to Shim the Primary Boom


1 Extend the primary boom until the wear pads are accessible. 2 Measure each wear pad. Replace the pad if it is less than 9/16 inch (14.3 mm) thick. If the pad is more than 9/16 inch (14.3 mm) thick, shim as necessary. 3 Loosen the wear pad mounting fasteners. 4 Install the new shims under the wear pad to obtain zero clearance and zero drag. 5 Tighten the mounting fasteners. 6 Extend and retract the primary boom through an entire cycle. Check for tight spots that may cause binding or scraping of the boom. Always maintain squareness between the outer and inner boom tubes.

How to Remove the Primary Boom


Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Perform this procedure with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. See 2-1, How to Remove the Platform. 2 Remove the platform rotator and platform mounting weldment. See 2-3, How to Remove the Platform Rotator.

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Genie Z-45/25 & Genie Z-45/25J

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Section 7 Repair Procedures

First Edition Second Printing

PRIMARY BOOM COMPONENTS

3 Z-45/25 Models: Remove the platform leveling slave cylinder. See 2-2, How to Remove the Platform 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 to Remove the Cable Track. 5 Raise the primary boom to a horizontal position. 6 Remove the hose and cable cover from the upper mid-pivot. 7 Remove the pin retaining fastener from the master cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin. Then lower the cylinder and let it hang down. Component damage hazard. When lowering the master cylinder down, be sure not to damage the master cylinder hoses or fittings. 8 Locate the primary boom drive speed limit switch inside of the upper mid-pivot. 9 Remove the primary boom drive speed limit switch mounting fasteners. Do not disconnect the wiring. 10 Locate the primary boom extension drive speed limit switch inside of the extension boom. 11 Remove the primary boom extension drive speed limit switch mounting fasteners. Do not disconnect the wiring.

12 Pull the limit switch and the wiring out of the extension tube and move it out of the way. 13 Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 14 Remove the hose clamp at the pivot end of the boom. 15 Attach a 5 ton (4,536 kg) overhead crane to the center point of the primary boom. 16 Attach a similar lifting device to the primary boom lift cylinder. 17 Place support blocks under the primary boom lift cylinder. 18 Remove the pin retaining fastener from the primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The boom lift cylinder and primary boom will fall unless they are properly supported. 19 Lower the rod end of the primary boom lift cylinder onto support blocks. Protect the cylinder rod from damage. 20 Remove the pin retaining fastener from the primary boom pivot pin.

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PRIMARY BOOM COMPONENTS

21 Remove the primary boom pivot pin with a soft metal drift, then carefully remove the primary boom from the machine and place it on a structure capable of supporting it. Crushing hazard. If the overhead crane is not properly attached, the boom and may become unbalanced and fall when it is removed from the machine.

4 Remove and label the location of the wear pads from the platform end of the primary boom. Pay careful attention to the location and amount of shims used with each wear pad. 5 Support and slide the extension tube out of the boom tube. Crushing hazard. The primary boom extension tube may become unbalanced and fall when it is removed from the primary boom tube if it is not properly supported. During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. 6 Remove the external snap rings from the extension cylinder rod-end pivot pin at the platform end of the extension tube. Use a soft metal drift to remove the pin. 7 Support and slide the extension cylinder out of the base end of the extension tube. Place the extension cylinder on blocks for support. Crushing hazard. The extension cylinder may become unbalanced and fall when it is removed from primary boom extension tube if it is not properly supported. During removal, the overhead crane strap will need to be carefully adjusted for proper balancing.

How to Disassemble the Primary Boom


Complete disassembly of the boom is only necessary if the outer or inner boom tube must be replaced. The extension cylinder can be removed without completely disassembling the boom. See 4-4, How to Remove the Primary Boom Extension Cylinder. 1 Remove the primary boom. See 4-2, How to Remove the Primary Boom. 2 Place blocks under the barrel end of the primary boom extension cylinder for support. 3 Remove the pin retaining fastener from the extension cylinder barrel-end pivot pin at the pivot end of the primary boom. Use a soft metal drift to remove the pin.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

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Section 7 Repair Procedures

First Edition Second Printing

PRIMARY BOOM COMPONENTS

4-3 Primary Boom Lift Cylinder


The primary boom lift cylinder raises and lowers the primary boom. The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure.

4 Support the rod end and the barrel end of the primary boom lift cylinder with a second overhead crane or similar lifting device. 5 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 6 Remove the pin retaining fastener from the primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. The primary boom will fall if it is not properly supported when the primary boom rod-end pivot pin is removed. 7 Place a support block across both turntable covers under the primary boom lift cylinder. 8 Z-45/25J Models: Lower the lift cylinder onto the block. Protect the cylinder rod from damage. Crushing hazard. The primary boom lift cylinder may fall if it is not properly supported. 9 Remove the primary boom lift cylinder barrelend pivot pin retaining fasteners. Do not remove the pin. 10 Use a slide hammer to remove the barrel-end pivot pin. Carefully remove the primary boom lift cylinder from the machine. Crushing hazard. The lift cylinder may become unbalanced and fall if it is not properly supported and secured to the lifting device.

How to Remove the Primary Boom Lift Cylinder


Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the primary boom until the primary boom is horizontal. 2 Raise the secondary boom until the primary boom lift cylinder barrel-end pivot pin is above the turntable covers. 3 Attach a 5 ton (5000 kg) overhead crane to the primary boom for support. Do not lift the boom.

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PRIMARY BOOM COMPONENTS

4-4 Primary Boom Extension Cylinder


The primary boom extension cylinder extends and retracts the primary boom extension tube.The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

2 Extend the primary boom until the primary boom extension cylinder rod-end pivot pin is accessible in the primary boom extension tube. 3 Remove the hose and cable guard from the upper pivot. 4 Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Remove the external snap rings from the extension cylinder rod-end pivot pin (at the platform end). Use a soft metal drift to remove the pin. 6 Remove the barrel-end pivot pin retaining fasteners.

How to Remove the Primary Boom Extension Cylinder


Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the primary boom to a horizontal position.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

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Section 7 Repair Procedures

First Edition Second Printing

PRIMARY BOOM COMPONENTS

7 Place a rod through the barrel-end pivot pin and twist to remove the pin.

4-5 Platform Leveling Master Cylinder


The master cylinder acts as a pump for the slave cylinder. Its part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion. The master cylinder is located at the base of the primary boom.

8 Support and slide the extension cylinder out of the upper pivot. Crushing hazard. The extension cylinder will fall when it is removed from the extension boom if it is not properly supported. Component damage hazard. Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom. Component damage hazard. Hoses and cables can be damaged if the primary boom extension cylinder is dragged across them. Note the length of the cylinder after removal. The cylinder must be at the same length for installation.

How to Remove the Platform Leveling Master Cylinder


When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the secondary boom until both the rodend and barrel-end pivot pins on the master cylinder are accessible. 2 Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

PRIMARY BOOM COMPONENTS

3 Attach overhead crane or similar lifting device to the master cylinder. 4 Remove the pin retaining fasteners from the master cylinder barrel-end pivot pin. Do not remove the pin. 5 Place a rod through the barrel-end pivot pin and twist to remove the pin.

7 Place a rod through the rod-end pivot pin and twist to remove the pin.

8 Remove the master cylinder from the machine. Crushing hazard. The master cylinder may become unbalanced and fall if it is not properly attached to the overhead crane. 6 Remove the pin retaining fastener from the rodend pivot pin.

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Genie Z-45/25 & Genie Z-45/25J

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Section 7 Repair Procedures

First Edition Second Printing

Secondary Boom Components


a b c

i h d

e g

5-1 Secondary Boom


f

How to Disassemble the Secondary Boom


The procedures in this section require specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is required. Follow the disassembly steps to the point required to complete the repair. Then re-assemble the secondary boom by following the disassembly steps in reverse order.

Secondary Boom components a upper secondary boom (number 1 arm) b upper tension link (number 2 arm) c lower tension link (number 3 arm) d lower mid-pivot e compression link f secondary boom lift cylinder (2) g lower secondary boom (number 4 arm) h turntable pivot i boom rest j upper mid-pivot

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

SECONDARY BOOM COMPONENTS

1 Remove the platform. See 2-1, How to Remove the 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 to Remove the Primary Boom. 4 Remove the master cylinder. See 4-5, How to Remove the Master Cylinder. 5 Attach a lifting strap from an overhead crane to to the lug on the rod end of the primary boom lift cylinder. Then raise the primary boom lift cylinder with the crane, to a vertical position. 6 Tag, disconnect and plug the hydraulic hoses at the primary boom lift cylinder. 7 Remove the pin retaining fastener from the primary boom lift cylinder barrel-end pivot pin. 8 Use a slide hammer to remove the pin. Remove the primary boom lift cylinder from the machine. Crushing hazard. The primary boom lift cylinder may become unbalanced and fall if it is not properly supported by the overhead crane. 9 Tag, disconnect and plug the hydraulic hoses on both of the secondary boom lift cylinders. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

10 Remove the pin retaining fasteners from both sides of the secondary boom lift cylinder rodend pivot pin and barrel-end pivot pin. Do not remove the pins. 11 Attach a strap from an overhead crane to the lug on the rod end of one of the secondary boom lift cylinders for support. Do not apply any lifting pressure. 12 Use a soft metal drift to drive the barrel-end pivot pin half way out. Lower the barrel end of the secondary boom lift cylinder and let it hang down. 13 Use a soft metal drift to drive the rod-end pivot pin half way out. 14 Remove the secondary boom lift cylinder from the machine. 15 Repeat steps 10 through 13 for the other secondary boom lift cylinder. Crushing hazard. The secondary boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. Component damage hazard. When removing a secondary boom lift cylinder from the machine, be careful not to damage the counterbalance valve at the barrel end of the cylinder. 16 Attach a lifting strap from an overhead crane to the upper mid-pivot for support. Do not lift it. 17 Attach a lifting strap from a second overhead crane to the number 1 arm at the mid-point between the upper and lower mid-pivots.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

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Section 7 Repair Procedures

First Edition Second Printing

SECONDARY BOOM COMPONENTS

18 Remove the pin retaining fasteners from the number 1 arm pivot pins at the lower mid-pivot and the upper mid-pivot. Do not remove the pins. 19 Use a soft metal drift to drive both pins out. 20 Remove the number 1 arm from the machine. Crushing hazard. The number 1 arm may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. Crushing hazard. The upper midpivot may fall when the number 1 arm is removed from the machine if it is not properly supported by the overhead crane. 21 Using the overhead crane attached to upper mid-pivot, raise the secondary boom assembly approximately 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 boom rest. Then lower the secondary boom assembly onto the block. Crushing hazard. The secondary boom assembly may fall if it is not properly supported by the 4 x 4 x 11 inch (10.2 x 10.2 x 28cm) block. 23 Locate the 4 cables that enter the platform control box. Number each cable and its entry location at the platform control box. 24 Open the platform control box.

25 Label and disconnect each wire of the cables that enter the platform control box. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 26 Pull all of the cables out of the platform control box. 27 Pull all of the cables and hoses out through the upper mid-pivot. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 28 Remove the hose and cable covers from the top of the number 2 arm. 29 Pull all of the hoses and cables out of the upper mid-pivot and out through the lower mid-pivot. Lay the hoses and cables on the ground. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 30 Remove the pin retaining fastener from the number 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 midpivot may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane.

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

SECONDARY BOOM COMPONENTS

32 Attach the lifting strap from an overhead crane to the number 2 arm at the upper mid-pivot end. 33 Raise the number 2 arm slightly and remove the 4 x 4 x 11 inch (10.2 x 10.2 x 28 cm) block. 34 Lower the number 2 arm onto the boom rest pad. 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 the number 4 arm at the lower mid-pivot end. 36 Attach a lifting strap from the overhead crane to the lower mid-pivot for support. Do not lift it. 37 Remove the pin retaining fasteners from the number 2, 3 and 4 arm pivot pins at the lower mid-pivot. Do not remove the pins. 38 Use a soft metal drift to drive each pin out. Then remove the lower mid-pivot from the secondary boom assembly. Crushing hazard. The lower midpivot may become unbalanced and fall when it is removed from the secondary boom assembly if it is not properly supported by the overhead crane. 39 Attach the lifting strap from an overhead crane to the center point of the number 2 arm for support. Do not lift it. 40 Remove the pin retaining fasteners from both compression link pivot pins. Do not remove the pins.

41 Use a soft metal drift to remove the lower compression link pivot pin at the number 3 arm. 42 Support the compression link with an appropriate lifting device. 43 Use a soft metal drift to remove the upper compression link pivot pin from the number 2 arm. Remove the compression link from the machine. Crushing hazard. The number 2 arm may fall when the compression link is disconnected from the number 2 arm if it is not properly supported by the overhead crane. Crushing hazard. The compression link may fall if it is not properly supported when it is removed from the secondary boom assembly. 44 Remove the number 2 arm from the machine. Crushing hazard. The number 2 arm may become unbalanced and fall when it is removed from the secondary boom assembly if it is not properly supported by the overhead crane. 45 Remove the upper and lower hose and cable covers from the number 3 arm. 46 Pull all of the cables and hoses from the number 3 arm and lay them over the turntable counterweight. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

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Section 7 Repair Procedures

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SECONDARY BOOM COMPONENTS

47 Open the ground controls side turntable cover. 48 Remove the fuel tank. See 13-1, How to Remove the Fuel Tank. 49 Remove the retaining fastener from the ground control box and function manifold pivot plate. 50 Lower the ground control box and function manifold pivot plate to access the number 3 arm pivot pin. 51 Attach the lifting strap from the overhead crane to the centerpoint of the number 3 arm for support. Do not lift it. 52 Remove the mounting fasteners from the cover located in the boom storage area to access the number 3 and number 4 arm pivot pin retaining fasteners at the turntable pivot. 53 Remove the pin retaining fasteners from the number 3 arm at the turntable pivot. Do not remove the pin. 54 Use a slide hammer to remove the number 3 arm pivot pin from the turntable pivot through the access hole behind the ground control box. 55 Remove the number 3 arm from the machine. Crushing hazard. The number 3 arm may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane.

56 Remove the secondary boom drive speed limit switch mounting fasteners from the number 4 arm at the mid-pivot end. Do not disconnect the wiring. 57 Remove the pin retaining fasteners from the number 4 arm at the turntable pivot. Do not remove the pin. 58 Attach a lifting strap from the overhead crane to the center point of the number 4 arm. Do not lift it. 59 Use a slide hammer to remove the number 4 arm from the turntable pivot through the ground controls side bulkhead. 60 Remove the number 4 arm from the machine. Crushing hazard. The number 4 arm may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane.

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Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

SECONDARY BOOM COMPONENTS

5-2 Secondary Boom Lift Cylinders


There are two secondary boom lift cylinders incorporated in the structure of the secondary boom assembly. These cylinders operate in parallel and require hydraulic pressure to extend and retract. Each secondary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure.

3 Tag, disconnect and plug the hydraulic hoses on the secondary boom lift cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Remove the pin retaining fasteners from the secondary boom lift cylinder rod-end pivot pin and barrel-end pivot pin. Do not remove the pins. 5 Attach a strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder for support. Do not apply any lifting pressure. 6 Use a soft metal drift to drive the barrel-end pivot pin half way out. Lower the barrel end of the secondary boom lift cylinder and let it hang down. 7 Use a soft metal drift to drive the rod-end pivot pin half way out. 8 Remove the secondary boom lift cylinder from the machine. Crushing hazard. The secondary boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. Component damage hazard. When removing a secondary boom lift cylinder from the machine, be careful not to damage the counterbalance valve at the barrel end of the cylinder.

How to Remove a Secondary Boom Lift Cylinder


This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. 1 Lower the secondary boom to the stowed position. 2 Raise the primary boom so that it is above the secondary boom lift cylinder rod-end pivot pin.

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Section 7 Repair Procedures

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Turntable Covers
6-1 Turntable Covers How to Remove a Turntable Cover
1 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 by using carpet or padding on the crane or fork lift forks. 2 Engine side cover: Remove the upper and lower retaining clips from the gas strut. 3 Engine side cover: Gently pry the strut pivot sockets off of the ball studs and remove the strut. Protect the strut cylinder rod from damage. 4 Engine side cover: Mark the location of the hinge on the support bracket on the cover to ensure proper cover alignment during installation. Ground controls side cover: Mark the location of the hinge on the cover to ensure proper cover alignment during installation. 5 Engine side cover: Remove the cover hinge fasteners that fasten the hinge to the support bracket on the cover. Ground controls side cover: Remove the cover hinge fasteners that fasten the hinge to the cover. 6 Carefully lift and remove the cover from the machine. Crushing hazard. The turntable cover may become unbalanced and fall if it is not properly supported and secured to a appropriate lifting device. Bodily injury hazard. If a turntable cover must be replaced, be sure that all appropriate safety and instructional decals are applied to the new cover. Alignment adjustments may be necessary when a new cover is installed.

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Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

Deutz Engine F3L 1011F


7-1 RPM Adjustment
Refer to Maintenance Procedures, B-10, Check and Adjust the Engine RPM- Ford and Deutz Diesel Models.

How to Remove the Flex Plate


1 Disconnect the wiring plug at the electronic displacement controller (EDC), located on the drive pump. 2 Support the drive pump with an appropriate lifting device. Then remove all of the pump mounting plate to engine bell housing bolts. 3 Carefully pull the pump away from the engine and secure it from moving. 4 Remove the flex plate mounting fasteners, then remove the flex plate from the engine flywheel.

7-2 Flex Plate


The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the pump.
a b c d e

How to Install the Flex Plate


1 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 shaft with the set screw toward the pump. Leave a 7/16 inch (11 mm) gap between the pump coupler and pump end plate. 3 Apply Loctite removable thread sealant to the pump coupler set screw. Torque the set screw to 45 ft-lbs (61 Nm). 4 Install the pump and torque the pump mounting plate fasteners to 34 ft-lbs (46 Nm). Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged.

f a b c d e f pump pump shaft pump coupler flex plate with raised spline engine flywheel 7/16 inch gap

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DEUTZ ENGINE F3L 1011F

7-3 Oil Temperature and Oil Pressure Switches


The oil temperature switch is a normally open switch that closes at approximately 220 F (104 C). When the switch closes, the engine will shut off to prevent damage and will not start until the temperature drops below the switch point. An over-temperature indicator light at the ground controls should turn on when the switch closes. Component damage hazard. Do not crank the engine with the over-temperature light on. The oil pressure switch is a normally closed switch that opens at approximately 15 psi (1 bar). If the oil pressure drops below the switch point, the switch opens and shuts off the engine to prevent damage. A low oil pressure indicator light at the ground controls should turn on when the switch opens. Component damage hazard. Do not crank the engine with the low oil pressure light on.

2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 Oil temperature switch: Remove the fasteners from the engine side cover, then remove the cover. 4 Disconnect the wiring from the desired switch. 5 Remove the switch from the engine block, and then install the new switch. Do not over tighten. Burn hazard. Contact with hot engine fluids or components may result in severe burns Always use pipe thread sealant when installing a switch.
Oil temperature switch specifications Torque Hex size Temperature switch point Oil pressure switch specifications Torque Hex size Oil pressure switch point 15 psi 8-18 ft-lbs 11-24 Nm 1-1/16 inch 1 bar 8-18 ft-lbs 11-24 Nm
13/16

inch

220 F (104 C)

How to Remove the Oil Temperature and Oil Pressure Switches


Perform this procedure with the engine off. 1 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

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Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

Perkins 104-22 Engine


8-1 RPM Adjustment
Refer to Maintenance Procedures, A-22, Check and Adjust the Engine RPM.

How to Remove the Flex Plate


1 Disconnect the wiring plug at the electronic displacement controller (EDC), located on the drive pump. 2 Support the drive pump with an appropriate lifting device. Then remove all of the pump mounting plate to engine bell housing bolts. 3 Carefully pull the pump away from the engine and secure it from moving. 4 Remove the flex plate mounting fasteners, then remove the flex plate from the engine flywheel.

8-2 Flex Plate


The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the pump.
a b c d e

How to Install the Flex Plate


1 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 shaft with the set screw toward the pump. Leave a 1/16 inch (1.5 mm) gap between the pump coupler and pump end plate. 3 Apply Loctite removable thread sealant to the pump coupler set screw. Torque the set screw to 45 ft-lbs (61 Nm). 4 Install the pump and torque the pump mounting plate fasteners to 34 ft-lbs (46 Nm). Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged.

a b c d e f

pump pump shaft coupler flex plate with raised spline flywheel 1/16 inch (1.5 mm) gap

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PERKINS 104-22 ENGINE

8-3 Coolant Temperature and Oil Pressure Gauges


The engine coolant temperature gauge is an electrical gauge. The engine coolant temperature sending unit has limit contacts that are factory set. The contacts will close at approximately 221o F (105o C). When the contacts close, the engine will shut off to prevent damage and will not start until the temperature drops below the contact point. Engine coolant temperature will be indicated on the gauge when the key is ON and the Emergency Stop Button is pulled out to the ON position. Component damage hazard. Do not crank the engine with the over-temperature light on. The engine oil pressure gauge is an electrical gauge. The engine oil presure sending unit has limit contacts that are factory set. The contacts will close at approximately 4.2 psi (0.3 bar). When the contacts close, the engine will shut off to prevent damage. Engine oil pressure will be indicated on the gauge when the engine is running. Component damage hazard. Do not crank the engine with the low oil pressure light on.

How to Remove the Coolant Temperature and Oil Pressure Gauge Sending Units
Perform this procedure with the engine off. 1 Tag and disconnect the wiring from the desired sending unit. Remove the sending unit from the engine block. 2 Install the new sending unit. Do not over tighten. 3 Connect the wires to the new sending unit. Burn hazard. Contact with hot engine fluids or components may result in severe burns. Always use pipe thread sealant when installing a sending unit.
Water temperature sending unit specifications Torque Hex size Temperature switch point 8-18 ft-lbs 11-24 Nm
7 /8

inch

221 F (105 C)

Oil pressure sending unit specifications Torque Hex size Oil pressure switch point 4.2 psi 8-18 ft-lbs 11-24 Nm
7 /8

inch

0.3 bar

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Part No. 52709

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Section 7 Repair Procedures

Ford LRG-425 EFI Engine


9-1 Timing Adjustment
The ignition timing is controlled by the ECM and can only be adjusted by re-programming the ECM. If timing adjustment or service is required, please contact Genie Industries Service Department OR your local Ford dealer.

9-3 Flex Plate


The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the pump.
a b c d e

9-2 RPM Adjustment


Refer to Maintenance Procedures, B-10, Check and Adjust the Engine RPM- Ford and Deutz Diesel Models.
a b c d e f

pump pump shaft pump coupler flex plate with raised spline engine flywheel 1/16 inch (1.5 mm) gap

Flex Plate Removal


1 Disconnect the wiring plug at the electronic displacement controller (EDC), located on the drive pump. 2 Support the drive pump with an appropriate lifting device. Then remove all of the pump mounting plate to engine bell housing bolts.

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FORD LRG-425 EFI ENGINE

3 Carefully pull the pump away from the engine and secure it from moving. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 4 Remove the flex plate mounting fasteners, then remove the flex plate from the engine fly wheel.

9-4 Water Temperature and Oil Pressure Switches


The water temperature switch is a normally open switch that closes at approximately 230 F (112 C). When the switch closes, the engine will shut off to prevent damage and will not start until the temperature drops below the switch point. The check engine light will turn on. See Repair Procedure 10-5, How to Retrieve Engine Fault Codes. Component damage hazard. Do not continue to run the engine with the check engine light on. The oil pressure switch is a normally closed switch that opens at approximately 3 to 5 psi (0.21 to 0.34 bar). If the oil pressure drops below the switch point, the switch opens and shuts off the engine to prevent damage. The check engine light will turn on. See Repair Procedure 10-5, How to Retrieve Engine Fault Codes. Component damage hazard. Do not continue to run the engine with the check engine light on.

How to Install the Flex Plate


1 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 shaft with the set screw towards the pump. Leave a 1/16 inch (1.5 mm) gap between the pump coupler and pump end plate.1 3 Apply Loctite removable thread sealant to the pump coupler set screw. Torque the set screw to 45 ft-lbs (61 Nm). 4 Install the pump and torque the pump mounting plate fasteners to 34 ft-lbs (46 Nm). Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged.

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Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

FORD LRG-425 EFI ENGINE

How to Remove the Water Temperature and Oil Pressure Switches


Perform this procedure with the engine off. 1 Open the engine side turntable cover and locate the water temperature and oil pressure switches. 2 Disconnect the wiring from the desired switch. 3 Remove the switch from the engine block, and then install the new switch. Do not over tighten. Burn hazard. Contact with hot engine fluids or components may result in severe burns Always use pipe thread sealant when installing a switch.
Water temperature switch specifications Torque Hex size Temperature switch point Oil pressure switch specifications Torque Hex size Oil pressure switch point 3-5 psi 8-18 ft-lbs 11-24 Nm 1-1/16 inch 0.21-0.34 bar 8-18 ft-lbs 11-24 Nm
13/16

inch

230 F (112 C)

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Ground Controls
10-1 Control Relays
Relays used for single function switching are single pole double throw (SPDT) relays. 3 Connect 12V DC to terminal 85 and a ground wire to terminal 86, then test the following terminal combinations.
Test terminal 87 to 87a & 30 Desired result no continuity (infinite ) continuity (zero )

How to Test a Single Pole Double Throw Relay


Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Label and then disconnect all the wiring from the relay to be tested. 2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity. Terminals 85 and 86 represent the coil and should not be tested in any other combination.
Test terminal 85 to 86 terminal 87 to 87a & 30 Desired result 75 to 85 no continuity (infinite ) continuity (zero )

terminal 87 to 30

terminal no. 87a - N.C. terminal no. 85 - ground terminal no. 30 - common terminal no. 86 - coil terminal no. 87 - N.O.

Control Relay Schematic

terminal 87a to 30

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Section 7 Repair Procedures

GROUND CONTROLS

10-2 Toggle Switches


See 1-5, Toggle Switches.

10-3 Wago Components


Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Wago tools are available from the Genie Service Parts Department (Genie part number 33996). 1 Label the wiring from the component to be removed. 2 Use a small screwdriver to push in and release the wire from the component. 3 Locate the removal tab on the bottom or top of the component. 4 Use a small screwdriver to gently pry up on the tab of the component and remove it.

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GROUND CONTROLS

10-4 Engine Fault Codes Ford Models How to Retrieve Engine Fault Codes
When a engine malfunction is detected by the Electronic Control Module (ECM), a fault code is recorded and the check engine light will turn ON at the ground and platform controls. Use the following procedure to retrieve the engine fault code to determine the engine malfunction. Perform this procedure with the key switch in the OFF position. 1 Open the ground controls side turntable cover. 2 Locate the run/test toggle switch located on the left side of the ground control box. 3 Pull out the ground controls red Emergency Stop button to the ON position.

4 Hold the run/test toggle switch to the test position and turn the key switch to the ground controls 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 the test position and count the blinks. Fault codes are two digits. The check engine light will blink the first digit of a two digit code then will pause for 1.2 seconds and then blink the second digit. For example: the check engine light blinks 5 consecutive times then pauses for 1.2 seconds and then blinks 1 time. That would indicate code 51. The ECM is able to store up to six individual fault codes. There will be a 2.4 second pause between codes. 6 Refer to the Troubleshooting Section for definition of engine fault codes. Once a fault code has been retrieved and the repair has been completed, the ECM memory must be reset to clear the fault code from the ECM. See 10-5, How to Clear Engine Fault Codes.

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Section 7 Repair Procedures

GROUND CONTROLS

How to Clear Engine Fault Codes from the ECM


Perform this procedure with the engine off and the key switch in the OFF position. 1 Open the engine side turntable cover and locate the battery. 2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes. Electrocution hazard. Contact with electrically charged circuits could cause death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery.

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Hydraulic Pumps
11-1 Lift/Steer Pump How to Remove the Lift/Steer Pump
When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable, then close the valves. 2 Tag, disconnect and plug the lift/steer pump hydraulic hoses. Cap the fittings on the pump. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Remove the pump mounting bolts. Carefully remove the pump. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump.

open

closed

Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition.

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First Edition Second Printing

Section 7 Repair Procedures

HYDRAULIC PUMPS

11-2 Drive Pump


The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump. The only adjustment that can be made to the pump is the neutral or null adjustment. Any internal service to the pump should only be performed at an authorized Sundstrand-Sauer service center. Call Genie Industries Service Department to locate your local authorized service center.

2 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable, then close the valves.

open

closed

How to Remove the Drive Pump


Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Disconnect the electrical connection at the electronic displacement controller (EDC) located on the drive pump.

Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 3 Tag and disconnect and plug the hydraulic hoses from the drive and lift/steer pumps. Cap the fittings on the pumps. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Support the pump with a lifting device and remove the two drive pump mounting fasteners. 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate.

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HYDRAULIC PUMPS

6 Remove the drive pump from the machine. Component damage hazard. The hydraulic pump may become unbalanced and fall if it is not properly supported. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump.

3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 4 Ford models: Close the valve on the LPG tank then disconnect the hose from the tank. Then move the fuel select switch to the LPG position. Perkins Diesel models: Disconnect the engine wiring harness from the fuel solenoid at the injector pump. Deutz Diesel models: Hold the manual fuel shutoff valve clockwise to the CLOSED position.

How to Prime the Pump


1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to the test port on the drive pump. 2 Remove the safety pin (if equipped) from the engine pivot plate latch. The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

manual fuel shutoff valve

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Section 7 Repair Procedures

HYDRAULIC PUMPS

5 Have another person crank the engine with the starter motor for 15 seconds, wait 15 seconds, then crank the engine an additional 15 seconds or until the pressure reaches 320 psi (22 bar). 6 Ford models: Connect the LPG hose to the LPG tank and open the valve on the tank. Perkins Diesel models: Connect the engine wiring harness to the fuel solenoid. 7 Start the engine from the ground controls and check for hydraulic leaks.

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Manifolds
12-1 Function Manifold Components
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index No. 1 2 3 Description Schematic Item Function Torque

Proportional solenoid valve ............... A ........... Turntable rotate left/right ................... 10-12 ft-lbs (14-16 Nm) Proportional solenoid valve ............... B ........... Secondary boom up/down ................ 10-12 ft-lbs (14-16 Nm) Flow regulator valve .......................... C ........... Secondary boom up/down (prevents overflowing the proportional valve) ........................ 10-12 ft-lbs (14-6 Nm) Check valve ....................................... D ........... Differential sensing circuit, secondary boom up/down ................. 11-13 ft-lbs (15-18 Nm) Relief valve, 1800 psi (124 bar) ........ E ........... Secondary boom down ..................... 25-30 ft-lbs (34-41 Nm) Priority flow regulator valve, 1.5 gpm (5.7 L/min) ........................... F ........... Steer left/right circuit ......................... 10-12 ft-lbs (14-16 Nm) Flow regulator valve .......................... G ........... Turntable rotate left/right (prevents overflowing the proportional valve) ........................ 10-12 ft-lbs (14-6 Nm) Relief valve, 3200 psi (220.6 bar) ..... H ........... System relief ..................................... 35-40 ft-lbs (47-54 Nm) Flow regulator valve .......................... I ............ Primary boom up/down (prevents overflowing the proportional valve) ........................ 10-12 ft-lbs (14-6 Nm)

4 5 6 7

8 9

This list continues. Please turn the page

Plug Torque Specifications


Description SAE No. 2 Hex size
1/8

Torque 50 in-lbs (6 Nm)

SAE No. 4 SAE No. 6

3/16 1/4

13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm)

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Section 7 Repair Procedures

MANIFOLDS

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MANIFOLDS

Function Manifold Components, continued


Index No. 10 11 12 13 14 15 Description Schematic Item Function Torque

Relief valve, 2300 psi (158.6 bar) ..... J ............ Primary boom down .......................... 25-30 ft-lbs (34-41 Nm) Solenoid valve, 2 position 3 way ....... K ........... Primary boom retract ........................ 25-30 ft-lbs (34-41 Nm) Solenoid valve, 2 position 3 way ....... L ........... Primary boom extend ........................ 25-30 ft-lbs (34-41 Nm) Flow regulator valve, 2 gpm (7.6 L/min) .............................. M .......... Primary boom extend/retract circuit .. 10-12 ft-lbs (14-16 Nm) Flow regulator valve, 1 gpm (3.8 L/min) .............................. N ........... Platform level circuit .......................... 10-12 ft-lbs (14-16 Nm) 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) Check valve ....................................... P ........... Differential sensing circuit, platform level down ........................... 11-13 ft-lbs (15-18 Nm) Counterbalance valve ........................ Q ........... Platform level down .......................... 35-40 ft-lbs (47-54 Nm) Counterbalance valve ........................ R ........... Platform level up ............................... 35-40 ft-lbs (47-54 Nm) Solenoid valve, 3 position 4 way ....... S ........... Platform level up/down ..................... 25-30 ft-lbs (34-41 Nm) Check valve ....................................... T ........... Differential sensing circuit, platform level up ............................... 11-13 ft-lbs (15-18 Nm) Check valve ....................................... U ........... Differential sensing circuit, jib boom up/platform rotate left ......... 11-13 ft-lbs (15-18 Nm) Check valve ....................................... V ........... Differential sensing circuit, jib boom down/platform rotate right .. 11-13 ft-lbs (15-18 Nm) Check valve ....................................... W .......... Differential sensing circuit, primary boom retract ......................... 11-13 ft-lbs (15-18 Nm)

16 17 18 19 20 21 22 23

This list continues. Please turn the page

Plug Torque Specifications


Description SAE No. 2 Hex size
1/8

Torque 50 in-lbs (6 Nm)

SAE No. 4 SAE No. 6

3/16 1/4

13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm)

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Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

MANIFOLDS

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MANIFOLDS

Function Manifold Components, continued


Index No. 24 25 26 27 28 29 Description Schematic Item Function Torque

Check valve ....................................... X ........... Differential sensing circuit, primary boom extend ........................ 11-13 ft-lbs (15-18 Nm) Check valve ....................................... Y ........... Differential sensing circuit, primary boom up/down ..................... 11-13 ft-lbs (15-18 Nm) Check valve ....................................... Z ........... Differential sensing circuit, turntable rotate left/right .................... 11-13 ft-lbs (15-18 Nm) Diagnostic nipple ............................... AA ......... Testing Solenoid valve, 3 position 4 way ....... BB ......... Jib boom up/down and platform rotate left/right ..................... 25-30 ft-lbs (34-41 Nm) 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) Solenoid valve, 3 position 4 way ....... DD ........ Primary boom up/down ..................... 25-30 ft-lbs (34-41 Nm) Differential sensing valve .................. EE ......... Meters flow to functions .................... 10-12 ft-lbs (14-16 Nm) Solenoid valve, 3 position 4 way ....... FF ......... Turntable rotate left/right ................... 25-30 ft-lbs (34-41 Nm) Solenoid valve, 3 position 4 way ....... GG ........ Steer left/right .................................... 25-30 ft-lbs (34-41 Nm) Orifice, 0.040 in (1 mm) ..................... HH ........ Secondary boom circuit Solenoid valve, 3 position 4 way ....... II ........... Secondary boom up/down ................ 25-30 ft-lbs (34-41 Nm) Check valve ....................................... JJ .......... Secondary boom circuit .................... 10-12 ft-lbs (14-16 Nm) Diagnostic nipple ............................... KK ......... Testing port Proportional solenoid valve ............... LL ......... Primary boom up/down ..................... 10-12 ft-lbs (14-16 Nm)

30 31 32 33 34 35 36 37 38

Plug Torque Specifications


Description SAE No. 2 Hex size
1/8

Torque 50 in-lbs (6 Nm)

SAE No. 4 SAE No. 6

3/16 1/4

13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm)

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Section 7 Repair Procedures

MANIFOLDS

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MANIFOLDS

12-2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve
Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure gauge to the test port (item 37) on the function manifold. 2 Start the engine from the ground controls. 3 Hold the function enable switch to the HIGH IDLE position and activate and hold the retract switch with the boom fully retracted. Observe the pressure reading on the pressure gauge.
System relief valve specifications Pressure 3200 psi 220.6 bar

How to Adjust the Primary Boom Down Relief Valve (before serial number 11819)
Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure gauge to the test port (item 37) on the function manifold. 2 Start the engine from the ground controls. 3 Hold the function enable switch to the HIGH IDLE position and activate and hold the primary boom down switch with the primary boom fully lowered. Observe the pressure reading on the pressure gauge.
Primary boom down relief valve specifications Pressure 2300 psi 158.6 bar

4 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item 10). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 through 5 and recheck relief valve pressure.

4 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item 8). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 through 5 and recheck relief valve pressure.

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Section 7 Repair Procedures

MANIFOLDS

How to Adjust the Secondary Boom Down Relief Valve


Perform this procedure with the boom in the stowed position. 1 Connect a 0 to 5000 psi (0 to 345 bar) pressure gauge to the test port (item 37) on the function manifold. 2 Start the engine from the ground controls. 3 Hold the function enable switch to the HIGH IDLE position and activate and hold the secondary boom down switch with the secondary boom fully lowered. Observe the pressure reading on the pressure gauge.
Secondary boom down relief valve specifications Pressure 1800 psi 124 bar

Valve Coil Resistance Specifications


Valve coil specifications Proportional solenoid valve, 12V (schematic items A, B and LL) 3 position 4 way directional valve, 10V (schematic items S, BB, DD, FF, GG and II) 2 position 3 way solenoid valve, 10V (schematic items K and L) 4 to 5 5 to 7 5 to 7

4 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item 5). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the relief valve cap. Tip-over hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 2 through 5 and recheck relief valve pressure.

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MANIFOLDS

12-3 Turntable Rotation Manifold Components


The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment.
Index No. 1 2 3 Schematic Item

Description

Function

Torque

Shuttle valve 2 position 3 way ........... MM ....... Turntable rotation brake release ...... 10-13 ft-lbs (14-18 Nm) Counterbalance valve ........................ NN ........ Turntable rotate right ........................ 35-40 ft-lbs (47-54Nm) Counterbalance valve ........................ OO ........ Turntable rotate left ........................... 35-40 ft-lbs (47-54Nm)

NN

OO

MM

Plug Torque Specifications


Description SAE No. 2 SAE No. 4 SAE No. 6 Hex size
1/8 3/16 1/4

Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm)

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MANIFOLDS

12-4 Directional Valve Manifold Components


The directional valve manifold is mounted inside the drive chassis at the non-steer end. Index No.
1 2

Description

Function

Torque

Cap ................................................................... Breather ........................................... 20-25 ft-lbs (27-33 Nm) Spool valve ....................................................... Directional control

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MANIFOLDS

How to Set Up the Directional Valve Linkage


Adjustment of the directional valve linkage is only necessary when the linkage or valve has been replaced. 1 Lower the boom to the stowed position. 2 Use a "bubble type" level to be sure the floor is completely level. Tip-over hazard. Failure to perform this procedure on a level floor will compromise the stability of the machine and could result in the machine tipping over. 3 Check the tire pressure in all four tires and add air if needed to meet specification. 4 Remove the drive chassis cover and the nonsteer axle covers. 5 Place a "bubble type" level across the drive chassis non-steer end. Check to be sure the drive chassis is completely level. 6 To level the drive chassis, start the engine and loosen the lock nuts on both sides of the urethane cushions. 7 Push up or pull down on the threaded rod until the machine is completely level.

8 Verify that the ground and drive chassis are completely level. 9 Tighten the nuts on both sides of the urethane springs until they are snug. Then tighten the locknuts. 10 Check to be sure the drive chassis is completely level. 11 Measure the distance between the drive chassis and the non-steer axle on both sides (from the inside of the drive chassis). If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level, repeat steps 6 through 10 OR consult Genie Industries Service Department.

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MANIFOLDS

12-5 2WD Drive Manifold Components


The drive manifold is mounted inside the drive chassis at the non-steer end. Index No.
1 2 3 4 5 6 7

Description

Schematic Item

Function

Torque

Solenoid valve, 2 position 3 way ....... PP ......... Braking .............................................. 10-12 ft-lbs (14-16 Nm) Relief valve, 250 psi (17.2 bar) ......... QQ ........ Charge pressure circuit ..................... 10-12 ft-lbs (14-16 Nm) Flow divider/combiner valve .............. RR ........ Controls flow to drive motors in forward and reverse ...................... 25-30 ft-lbs (34-41 Nm) Orifice, 0.070 in (1.78 mm) ................ SS ......... Drive circuit Check valve ....................................... TT ......... Drive circuit ....................................... 25-30 ft-lbs (34-41 Nm) Check valve ....................................... UU ........ Drive circuit ....................................... 25-30 ft-lbs (34-41 Nm) Shuttle valve, 3 position 3 way .......... VV ......... Charge pressure circuit that directs hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2-speed motor shift ......................................... 15-18 ft-lbs (20-24 Nm) Diagnostic fitting ................................ WW ....... Testing Orifice, 0.030 in (0.76 mm) ................ XX ......... Brake and 2-speed circuit Solenoid valve, 2 position 3 way ....... YY ......... 2-speed motor shift ........................... 10-12 ft-lbs (14-16 Nm)

8 9 10

Plug Torque Specifications


Description SAE No. 2 SAE No. 4 SAE No. 6 SAE No. 8 SAE No. 10 SAE No. 12 Hex size
1/8 3/16 1/4 5/16 9/16 5/8

Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm) 50 ft-lbs (68 Nm) Valve coil specifications 55 ft-lbs (75 Nm) 75 ft-lbs (102 Nm) 2 position 3 way solenoid valve, 10V (schematic item PP and YY) 5 to 7

Valve Coil Resistance Specifications

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MANIFOLDS

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MANIFOLDS

12-6 Valve Adjustments, 2WD Drive Manifold How to Adjust the Charge Pressure Relief Valve
1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to the test port (item 8) located on the drive manifold. 2 Start the engine from the platform controls. 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge.
Charge Pressure Relief valve specifications Pressure 250 psi 17.2 bar

4 Turn the engine off. Hold the charge pressure relief valve and remove the cap (item 2). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the valve cap. 6 Restart the engine. Drive the machine in either direction and recheck the valve pressure. 7 Repeat steps 2 through 6 until the specified charge pressure is achieved. 8 Turn the engine off, then remove the pressure gauge.

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MANIFOLDS

12-7 4WD Drive Manifold Components


The drive manifold is mounted inside the drive chassis at the non-steer end. Index No.
1

Description

Schematic Item

Function

Torque

Flow divider/combiner valve .............. AB ......... Controls flow to non-steer end drive motors in forward and reverse ...................................... 25-30 ft-lbs (34-41 Nm) 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) Bi-directional flow control valve, 2 gpm (7.6 L/min) .............................. AD ........ Steer end drive motor circuit ............ 25-30 ft-lbs (34-41 Nm) Directional control valve .................... AE ......... 2 speed motor shift circuit/ High speed bypass .......................... 10-12 ft-lbs (14-16 Nm) Diagnostic fitting ................................ AF ......... Testing Shuttle valve, 3 position 3 way .......... AG ........ Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2-speed motor shift ......................................... 15-18 ft-lbs (20-24 Nm) Relief valve, 250 psi (17.2 bar) ......... AH ........ Charge pressure circuit .................... 10-12 ft-lbs (14-16 Nm) Solenoid valve, 2 position 3 way ....... AI .......... 2-speed motor shift ........................... 10-12 ft-lbs (14-16 Nm) Orifice, 0.030 inch (0.76 mm) ............ AJ ......... Brake and 2-speed circuit Solenoid valve, 2 position 3 way ....... AK ......... Braking .............................................. 10-12 ft-lbs (14-16 Nm) Check valve ....................................... AL ......... 2 speed motor shift circuit ................. 10-12 ft-lbs (14-16 Nm) Orifice, 0.025 inch (0.64 mm) ............ AM ........ 2 speed motor shift circuit Flow divider/combiner valve .............. AN ........ Controls flow to flow divider/combiner valves 1 and 18 .... 25-30 ft-lbs (34-41 Nm)

2 3 4 5 6

7 8 9 10 11 12 13

This list continues. Please turn the page

Plug Torque Specifications


Description SAE No. 2 SAE No. 4 Hex size
1/8 3/16

Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm)

SAE No. 6 SAE No. 8 SAE No. 10

1/4 5/16 9/16

18 ft-lbs (24 Nm) 50 ft-lbs (68 Nm) 55 ft-lbs (75 Nm)

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MANIFOLDS

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MANIFOLDS

4WD Drive Manifold Components, continued


Index No.
14 15 16 17

Description

Schematic Item

Function

Torque

Check valve ....................................... AO ........ Steer end drive motor circuit ............. 10-12 ft-lbs (14-16 Nm) Orifice, 0.052 in (1.32 mm) ................ AP ......... Drive circuit Check valve ....................................... AQ ........ Steer end drive motor circuit ............. 10-12 ft-lbs (14-16 Nm) Flow divider/combiner valve .............. AR ........ Controls flow to steer end drive motors in forward and reverse ...................................... 25-30 ft-lbs (34-41 Nm) Check valve ....................................... AS ......... Non-steer end drive motor circuit ...... 10-12 ft-lbs (14-16 Nm) Check valve ....................................... AT ......... Non-steer end drive motor circuit ...... 10-12 ft-lbs (14-16 Nm)

18 19

Plug Torque Specifications


Description SAE No. 2 SAE No. 4 SAE No. 6 SAE No. 8 SAE No. 10 Hex size
1/8 3/16 1/4 5/16 9/16

Torque 50 in-lbs (6 Nm) 13 ft-lbs (18 Nm) 18 ft-lbs (24 Nm) Valve coil specifications 50 ft-lbs (68 Nm) 55 ft-lbs (75 Nm) 2 position 3 way solenoid valve, 10V (schematic items AI and AK) 5 to 7

Valve Coil Resistance Specifications

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MANIFOLDS

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MANIFOLDS

12-8 Valve Adjustments, 4WD Drive Manifold How to Adjust the Charge Pressure Relief Valve
1 Connect a 0 to 600 psi (0 to 41 bar) pressure gauge to the test port (item 5) located on the drive manifold. 2 Start the engine from the platform controls. 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge.
Charge Pressure Relief valve specifications Pressure 250 psi 17.2 bar

4 Turn the engine off. Hold the charge pressure relief valve and remove the cap (index 7). 5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Then install the valve cap. 6 Restart the engine. Drive the machine in either direction and recheck the valve pressure. 7 Repeat steps 2 through 6 until the specified charge pressure is achieved. 8 Turn the engine off, then remove the pressure gauge.

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Fuel and Hydraulic Tanks


13-1 Fuel Tank How to Remove the Fuel Tank
Explosion and fire hazard. Engine fuels are combustible. Remove the fuel tank in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Explosion and fire hazard. When transferring fuel, connect a grounding wire between the machine and pump or container. All models: 1 Disconnect, drain and plug the supply and return fuel hoses. Cap the fuel return fitting on the fuel tank. 2 Remove the mounting fasteners from the top and bottom of the fuel tank. 3 Remove the fuel tank from the machine.

13-2 Hydraulic Tank


The primary functions of the hydraulic tank are to cool, clean and deaerate the hydraulic fluid during operation. It utilizes internal suction strainers for the pump supply lines and has an external return line filter mounted to the engine side bulkhead. The hydraulic return filter incorporates a filter condition indicator.

How to Remove the Hydraulic Tank


Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable, then close the valves.

open

closed

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FUEL AND HYDRAULIC TANKS

2 Place a suitable container underneath the hydraulic tank. See capacity specifications below. Component damage hazard. The engine must not be started with the hydraulic tank shutoff valves in the CLOSED position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 3 Remove the drain plug from the hydraulic tank. 4 Completely drain the tank into a suitable container. See capacity specifications below. 5 Tag, disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves. 6 Disconnect and plug the return filter hydraulic hose at the hydraulic tank. Cap the fitting on the tank.

7 Disconnect and plug the supply hose for the auxiliary power unit through the access hole underneath the turntable. Cap the fitting on the hydraulic tank. 8 Support the hydraulic tank with an appropriate lifting device. 9 Remove the hydraulic tank mounting fasteners. 10 Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank may become unbalanced and fall if it is not properly supported by the lifting device.
Hydraulic Specification Hydraulic fluid capacity All models 24 gallons 91 liters

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Turntable Rotation Components


14-1 Rotation Hydraulic Motor How to Remove the Rotation Hydraulic Motor
When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Secure the turntable from rotating with the turntable rotation lock pin. 2 Open the engine pivot plate latch and swing the engine out and away from the machine to access the turntable rotation motor. 3 Tag, disconnect and plug the hydraulic hoses from the turntable rotation motor manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Remove the turntable rotation motor mounting fasteners, then remove the motor from the brake. 5 Remove the turntable rotation motor from the machine.

Unlocked position

Locked position

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Section 7 Repair Procedures

TURNTABLE ROTATION COMPONENTS

How to Remove the Turntable Rotation Brake


1 Secure the turntable from rotating with the turntable rotation lock pin.

3 Tag, disconnect and plug the hydraulic hoses from the turntable rotation motor manifold and the brake. Cap the fittings on the manifold and the brake. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Remove the turntable rotation motor mounting fasteners, then remove the motor from the brake. 5 Remove the turntable rotation motor from the machine. 6 Remove the brake mounting bolts, and then remove the turntable rotation brake from the machine.

Unlocked position

Locked position

2 Open the engine pivot plate latch and swing the engine out and away from the machine to access the turntable rotation motor and brake.

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2WD Steering Axle Components


15-1 Yoke and Hub How to Remove the Yoke and Hub
The yoke installation utilizes bushings in the axle and a thrust washer that may require periodic replacement. 1 Remove the cotter pin from the steering cylinder rod-end clevis pin and remove the cotter pin from the tie rod clevis pin. Remove the clevis pins. Always use a new cotter pin when installing a clevis pin.
a b c d

2 Loosen the wheel lug nuts. Do not remove them. 3 Block the non-steering wheels, and then center a lifting jack of ample capacity under the steering axle. 4 Raise the machine 6 inches (15 cm) and place blocks under the chassis for support. 5 Remove the lug nuts. Then remove the tire and wheel assembly. 6 Remove the pin retaining fasteners from the yoke pivot pins. Do not remove the pins. 7 Support and secure the yoke/hub assembly to a lifting jack.

g a b c d e f g

tie rod steer axle yoke pivot pin yoke hub pivot pin steering cylinder

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Section 7 Repair Procedures

2WD STEERING AXLE COMPONENTS

8 Place a rod through the upper yoke pivot pin and twist to remove the pin, then use a soft metal drift to drive the lower yoke pivot pin down and out.

How to Remove the Hub and Bearings


1 Loosen the wheel lug nuts. Do not remove them. 2 Block the non-steering wheels and place a lifting jack of ample capacity under the steering axle. 3 Raise the machine 6 inches (15 cm) and place blocks under the chassis for support. 4 Remove the lug nuts. Then remove the tire and wheel assembly.

Crushing hazard. The yoke/hub assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly supported and secured to the lifting jack.
Torque specifications Lug nut torque, dry Lug nut torque, lubricated 125 ft-lbs 94 ft-lbs 169.5 Nm 127.4 Nm

5 Remove the dust cap, cotter pin and castle nut. Always use a new cotter pin when installing a castle nut. 6 Pull the hub off the spindle. The washer and outer bearing should fall loose from the hub. 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub. Remove the rear bearing.

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2WD STEERING AXLE COMPONENTS

How to Install the Hub and Bearings


When replacing a wheel bearing, both the inner and outer bearings including the pressed-in races must be replaced. 1 Be sure that both bearings are packed with clean, fresh grease. 2 Place the large inner bearing into the rear of the hub. 3 Press the bearing seal evenly into the hub until it is flush. 4 Slide the hub onto the yoke spindle. Component damage. Do not apply excessive force or damage to 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) to seat the bearing. 8 Loosen the castle nut, then re-tighten to 8 ft-lbs (11 Nm). 9 Install a new cotter pin. Bend the cotter pin to lock it in. 10 Install the dust cap, then the tire and wheel assembly. Torque the wheel lug nuts to 125 ft-lbs (169.5 Nm).

15-2 Steering Cylinders How to Remove a Steering Cylinder


There are two identical steering cylinders that work in parallel. They are part of the same hydraulic circuit, but move in opposite directions. The tie rod maintains equal movement of the tires. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Tag, disconnect and plug the hydraulic hoses from the steering cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

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Section 7 Repair Procedures

2WD STEERING AXLE COMPONENTS

2 Remove the cotter pin from the rod-end clevis pin of the steer cylinder. Remove the clevis pin. 3 Remove the cotter pin from the barrel-end clevis pin of the steer cylinder then remove the clevis pin. Always use a new cotter pin when installing a clevis pin. 4 Remove the steering cylinder from the machine.

15-3 Tie Rod How to Remove the Tie Rod


1 Remove the cotter pins from the clevis pins at each end of the tie rod, then remove the clevis pins. Always use a new cotter pin when installing a clevis pin. 2 Remove the tie rod.

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4WD Steering Axle Components


16-1 Yoke and Hub How to Remove the Yoke and Hub
The yoke installation utilizes bushings and a thrust washer that may require periodic replacement. The yoke must be removed before the drive hub can be removed. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the cotter pin from the steering cylinder rod-end clevis pin and remove the cotter pin from the tie rod clevis pin. Remove the clevis pins.
a

f a b c d e f g

oscillate cylinder yoke pivot pin drive hub yoke pivot pin steer cylinder tie rod

2 Loosen the wheel lug nuts. Do not remove them. 3 Block the non-steering wheels, and then center a lifting jack of ample capacity under the steering axle. 4 Raise the machine 6 inches (15 cm) and place blocks under the chassis for support.

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4WD STEERING AXLE COMPONENTS

5 Remove the lug nuts, then remove the tire and wheel assembly. 6 Tag, disconnect and plug the hydraulic hoses from the drive motor. Cap the fittngs on the drive motor. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 Remove the drive motor mounting fasteners. 8 Slide the drive motor shaft out of the drive hub and then remove the drive motor from the machine. 9 Remove the pin retaining fasteners from the upper and lower yoke pivot pins. Do not remove the pins. 10 Support the yoke/drive hub assembly with a lifting jack. Secure the yoke/drive hub assembly to the lifting jack.

11 Place a rod through the upper yoke pivot pin and twist to remove the pin, then use a soft metal drift to drive the lower yoke pivot pin down and out.

Crushing hazard. The yoke/hub assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly supported and secured to the lifting jack. 12 Place the yoke/drive hub assembly on a flat surface with the drive hub facing down.

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4WD STEERING AXLE COMPONENTS

13 Remove the drive hub mounting fasteners that attach the yoke to the drive hub. Remove the yoke weldment from the drive hub. Replace the thrust washer when installing the yoke/drive hub assembly onto the axle.
Torque specifications Lug nut, dry lubricated Drive hub mounting bolts, dry lubricated Drive motor mounting bolts, dry lubricated

16-2 Steering Cylinders How to Remove a Steering Cylinder


This procedure is the same as the 2WD procedure. See repair procedure 15-2, How to Remove a Steering Cylinder.

125 ft-lbs 94 ft-lbs

169.5 Nm 127.4 Nm

120 ft-lbs 90 ft-lbs

163 Nm 122 Nm

16-3 Tie Rod How to Remove the Tie Rod

75 ft-lbs 56 ft-lbs

102 Nm 76 Nm

This procedure is the same as the 2WD procedure. See Repair Procedure 15-3, How to Remove the Tie Rod.

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Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

Oscillating Axle Components


17-1 Oscillating Axle Lock-out Cylinders
The oscillating axle cylinders extend and retract between the drive chassis and the oscillating axle. The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. The valves are not adjustable. 1 Tag, disconnect and plug the oscillating axle cylinder hydraulic hoses. Cap the fittings on the oscillate cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 2 Remove the pin retaining fasteners from the rod-end pivot pin. Use a soft metal drift to remove the pin. 3 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder. 4 Remove the pin retaining fasteners from the barrel-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The oscillate cylinder may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane. 5 Remove the cylinder from the machine.

How to Remove an Oscillating Axle Cylinder


Bodily injury hazard. This procedure requires specific repair skills and a suitable workshop. Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage. Dealer service is strongly recommended. Perform this procedure on a firm, level surface with the boom in the stowed position. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications.

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

7 - 89

Section 7 Repair Procedures

First Edition Second Printing

Non-steering Axle Components


18-1 Drive Motor How to Remove a Drive Motor
Component damage hazard. Repairs to the motor should only be performed by an authorized Sundstrand-Sauer dealer. Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended. When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the fasteners from cover on the nonsteer axle. Remove the cover. 2 Tag, disconnect and plug the hydraulic hoses from the drive motor. Cap the fittings on the drive motor. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Remove the drive motor mounting fasteners. 4 Slide the drive motor shaft out of the brake and then remove the drive motor from the machine.
Torque specifications Drive motor mounting bolts 75 ft-lbs 102 Nm

7 - 90

Genie Z-45/25 & Genie Z-45/25J

Part No. 52709

First Edition Second Printing

Section 7 Repair Procedures

NON-STEERING AXLE COMPONENTS

18-2 Drive Hub How to Remove a Drive Hub


When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the drive motor. See 18-1, How to Remove a Drive Motor. 2 Tag, disconnect and plug the hydraulic hose from the brake. Then remove the hydraulic fitting and the bleed valve. 3 Loosen the wheel lug nuts. Do not remove them. 4 Center a lifting jack of ample capacity under the non-steering axle. Raise the machine approximately 6 inches (15 cm) and place blocks under the drive chassis for support. 5 Remove the wheel lug nuts, then the tire and wheel assembly.

6 Place a second lifting jack under the drive hub for support and secure the drive hub to the lifting jack. 7 Remove the drive hub mounting bolts that attach the drive hub to the non-steer axle. 8 Remove the drive hub from the non-steer axle. Crushing hazard. The drive hub may become unbalanced and fall if it is not properly supported and secured to the lifting jack.
Torque specifications Lug nut, dry lubricated Drive hub mounting bolts, dry lubricated Drive motor mounting bolts, dry lubricated

125 ft-lbs 94 ft-lbs

169.5 Nm 127.4 Nm

120 ft-lbs 90 ft-lbs

163 Nm 122 Nm

75 ft-lbs 56 ft-lbs

102 Nm 76 Nm

Part No. 52709

Genie Z-45/25 & Genie Z-45/25J

7 - 91

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